BMC hired ESI to develop a multi-year energy conservation master plan for their 2.3 million square foot campus located in Boston MA.The main objective of the plan was to reduce the campus carbon footprint and energy consumption by 25% by the year 2018. ESI began this work by surveying the entire campus to identify energy conservation measures. This initial survey resulted in a list of HVAC and electrical energy conservation measures that were prioritized based on payback and infrastructure need. This list included measures such as HVAC unoccupied setback/airflow reduction, kitchen variable volume exhaust control, chiller plant optimization, winter free cooling, retro-commissioning, fan power reduction measures, DX to chilled water cooling conversions, power cogeneration, high efficiency boiler plant and other mechanical measures. ESI then prepared construction documents for bidding and oversaw the necessary construction for measure implementation.
ESI is currently designing a new boiler plant for BMC so that the hospital can produce steam instead of purchasing from the city district steam supplier. ESI is also designing a 2 megawatt cogen plant for the campus. In only two years, BMC has reduced their carbon footprint by 15% and are on track to exceed their goal of 25%. To help BMC fund the work, ESI completed the necessary analysis so that BMC could acquire energy conservation incentives from the local utility companies. Over the past two years, BMC and ESI have won two awards for this energy conservation effort from the Association of Energy Engineers. ESI is proud to be BMC’s energy conservation engineer.
ESI was retained by Partners Healthcare System Inc. to provide engineering services for the evaluation, design, and construction administration services for the phased replacement of an existing 2000 KW diesel fired CHP and emergency power system with a new diesel fired Emergency Power System (dual 820 KW gensets with paralleling gear in custom outdoor enclosure) and new dual engine CHP plant (1640 KW total) with HRSG and hot water heat recovery and paralleling gear.ESI assisted with filing an Interconnect Application with the utility NSTAR and coordination of paralleling gear requirements to permit parallel operation of the CHP with NSTAR.
ESI also is designing replacement HPS boilers for process steam and replacement of an old steam absorption chiller system. The design for this project is nearly complete, scheduled for bid documents by November 15, 2014. Budget cost for the construction is estimated at $10-12 million.
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ESI developed bid documents to replace MEEI’s cooling tower system that had reached its useful life and which had never worked correctly due to poor piping design. MEEI requires chilled water cooling year-round for critical radiology equipment and laboratories and therefore could not tolerate a shutdown of the tower system to facilitate replacement. ESI developed a plan that allowed one existing cooling tower to remain in operation while all original condenser water piping, pumps and cooling towers were removed to make room for an entire new 3,600-ton cooling tower system with N+1 redundancy. The new system is also equipped with a winter free cooling heat exchanger, which significantly decreased the operating cost of the system. ESI also negotiated a substantial utility rebate for the Owner that reduced the first cost of the system. This project was completed on time with no cost overruns and the system is working great.
ESI developed bid documents to replace six operating room, lab and patient care AHUs that were at the end of their useful life. These AHUs operate continuously and MEEI could not tolerate downtime to allow one-to-one replacement of the systems. ESI’s devised a scheme to install one large custom AHU in a tight machine room by reconfiguring the existing mechanical system. Once installed, cutover of the six units could begin to gain mechanical space for two more large custom AHUs. The six air handling units were replaced with three custom air handling units with a total capacity of 105,000 CFM. This project was completed on time with no cost overruns.
Since 1998, ESI has worked closely with MGH Facilities Engineering Department to develop a Master Plan for upgrade of the Main campus chilled water plants, with phasing based on capital availability and system downtime constraints. As part of this phased implementation process, 6000 tons of rooftop cooling towers were replaced as well as all of the chillers, pumps, Electric switchgear and transformers. The Building Automation System was upgraded and sequences modified. This was done over multiple years, with very little impact on the delivery of cooling throughout the Main campus or interruption of patient services.
This lab facility in Charlestown is one of the country’s largest laboratory facilities consisting of over 1,000,000 sf of labs and support spaces. The Mechanical/Electrical Infrastructure for these Labs was installed in the early 1970s and at the end of its useful life. The fume hood exhaust system consisted of individual roof fans for each hood, with short stacks and no heat recovery. ESI, working in collaboration with Thompson Consultants Inc., designed a new custom rooftop ventilation system which converted the exhaust systems to a Centralized header system with Enthalpy Wheel Heat Recovery units (320,000 CFM) and large Induced Draft Exhaust Fans (520,000 CFM capacity). This custom system was completed in 2008 & operation thus far has permitted elimination of multiple indoor AHUs freeing up valuable space for Lab expansion.
Upgraded the CNY 149 steam and hot water boiler plant by integrating a new 570 KW gas-fired Cogeneration unit into the building heating and power systems. Took the lead on design of the 570 KW Gas-fired Cogeneration plant on the roof of the Lab Building in collaboration with Southworth Milton Cat. The unit, on line since 2005, operates at a nearly continuous 500 KW load with all of the waste heat utilized year round by the building reheat systems, via new heat exchangers and pumps.
ESI provided Electrical Engineering Design and Construction Administration Services for the phased upgrade/replacement of Normal and Emergency Power Services to the high rise in-patient White Building. This critical project design included the layout of new distribution equipment in new Emergency and Normal Electrical Rooms on the fourth floor (former CSR unit), new Normal and Emergency Electric risers to all floors in an abandoned elevator shaft, and the development of a carefully phased design and cutover plan to permit this work to take place in an occupied inpatient building with minimum shutdowns impacting patient care. ESI also worked with MGH to design related upgrades of the fire alarm system. The infrastructure portion of this project cost approximately $7 million dollars and was substantially completed in October 2014.
ESI was retained by the Hospital to determine the best way to increase cooling capacity and to design the new system to support the Hospital’s expansion, which includes a new Emergency Department, Cancer Center, Operating Rooms and additional In-Patient Space. ESI determined that 1,500 tons of additional cooling capacity was required to support the hospital expansion. However, the mechanical room that housed the hospital’s existing 2,200 ton chiller plant did not have the floor space to accommodate new chillers and related pumps. ESI developed a premium efficient chiller plant expansion plan and design that placed two new 750 ton chillers and related pumps in an adjacent building penthouse with cross connect piping installed on a six story bridge spanning two buildings. The cross-connect piping allowed the existing chiller plant and new chillers to operate as one single chiller plant providing optimum performance and N+1 redundancy. Because this system was so efficient, NSTAR electric awarded the hospital with a $250,000 rebate.
When Newton Wellesley Hospital decided to build a state-of-the-art Cancer Center, they called in ESI to help them determine the best way to install new air handling system in their existing 80-year-old South Building. After extensive field survey and collaboration with the Owner, ESI recommended that the hospital install two side-by-side 60,000 CFM air handling units on the roof to serve the new cancer center as well as the remainder of the building which is equipped with older system that didn’t comply with DPH requirements. The new custom air handling system will provide 75% redundancy in the event that one air handling units fails or is taken down for maintenance.
ESI was hired by the hospital to prepare construction documents and to oversee construction of a new central utility plant to replace the hospital’s 50-year-old plant that was located in the front of the campus. What made this project especially challenging was that the plant had to be relocated to the opposite side of the campus to make room for a new ED and inpatient building tower which ESI is designing currently. After extensive field work and collaboration with the owner, ESI developed a plan to install a new 1,500 BHP boiler plant, 800 KW cogeneration plant, new 15kV switchgear for the entire campus and emergency power plant for the Davenport building within a new utility building at the rear of the campus. ESI’s creative approach allowed for the construction of the $30 million plant at the rear of the campus without significant disruption to the hospital’s normal business of caring for patients. The project was successfully completed under budget in the Fall of 2014.