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Jefferson Lab

UIM Process Cooling Towers 12000 Jefferson Avenue | Newport News | VA 23606 Basis of Design Report OWNER CONTRACT NUMBER: JSA 10-C0503010 (TASK ORDER NO. 19) EWINGCOLE PROJECT NUMBER: 20140386 March 18, 2014

Federal Reserve Bank Building, 100 North 6th Street, Philadelphia, PA 19106 TEL 215.923.2020 FAX 215.574.9163 ewingcole.com

CONTENTS EXECUTIVE SUMMARY Tab 1 1.1 Goals and Objectives 1.2 Next Steps/Path Forward GENERAL Tab 2 2.1 Design Drawings 2.2 Applicable Codes and Standards MECHANICAL Tab 3 3.1 Project Overview 3.2 Design Criteria 3.3 North Access Cooling Towers 3.4 End Station (Building 92) Cooling Towers 3.5 South Access Cooling Towers 3.6 Component Description 3.7 Energy Conservation Strategies 3.8 Calculations 3.9 Energy Analysis 3.10 Cooling Tower Selections ELECTRICAL Tab 4 4.1 Applicable Codes and Standards 4.2 North Access Building #67 4.3 South Access Building #38 4.4 End Station (Building #92) Cooling Towers 4.5 ESR End Station (Building #102) Cooling Towers 4.6 Electrical Cabling and Equipment Standards 4.7 Building and Electrical System Grounding 4.8 Lighting Standards 4.9 Security system 4.10 Telecommunications System STRUCTURAL TAB 5 5.1 Project Overview 5.2 Design Criteria 5.3 Geotechnical and Foundation Information 5.4 Structural Systems 5.5 End Station Cooling Towers Scope (Phase 1) 5.7 North Access Cooling Towers Scope (Phase 2) 5.8 South Access Cooling Towers Scope (Phase 3)

EWINGCOLE | JEFFERSON LAB TASK ORDER NO. 19 PROJECT NUMBER 20140386 | © EWINGCOLE 2014

EXECUTIVE SUMMARY 1.1 GOALS AND OBJECTIVES The UIM Process Cooling Upgrades include the replacement of three (3) primary cooling

tower systems located on the accelerator site including:

• North and South Access Building Cooling Towers • End Station Refrigerator and 4kW End Station Refrigerator Cooling Towers • Building 92 Cooling Towers

Existing cooling towers serving process cooling loads at the North and South Access Buildings will be demolished and replaced with larger cooling tower cells to match the existing 12 GeV Cooling Towers. One new additional cell will be provided at the North Access (Building 67) and South Access (Building 38) locations on the existing dunnage platform provided as part of the 12 GeV Project. Piping headers from the new UIM Process Cooling Towers will be extended to the 12 GeV Cooling Tower piping distribution to provide centralized cooling towers at both North Access and South Access Building. Condenser water piping will be extended from the North Access Cooling Tower to serve the End Station Refrigerator (ESR) Building 102 and 4kW End Station Refrigerator Building 104. The existing ESR cooling towers will be demolished. Cooling towers at the End Station Building 92 will be demolished and replaced with new. The scope of the work will include electrical modifications to support the mechanical equipment, new dunnage platforms and foundations, and new concrete pads for associated cooling tower pumps. The project will be performed in two phases. The scope of Phase 1 will include:

• End Station Cooling Tower Replacement • North Access Building

o Piping tie-ins to allow demolition of existing towers o One (1) cooling tower cell to be located on existing 12 GeV tower platform

• South Access Building o Piping tie-ins to allow demolition of existing towers o One (1) cooling tower cell to be located on existing 12 GeV tower platform

The scope of Phase 2 will include:

• North Access Building o Removal of existing cooling towers and associated pumps, piping and dunnage o Installation of new three (3) cell cooling tower, associated pumps, piping and

steel platform • South Access Building

o Removal of existing cooling towers and associated pumps, piping and dunnage o Installation of new one (1) cell cooling tower, associated pumps, piping, and

steel platform • ESR Cooling Tower Demolition

EWINGCOLE | JEFFERSON LAB TASK ORDER NO. 19 20140386 | © EWINGCOLE 2014 PAGE 1-1

EXECUTIVE SUMMARY

o Extension of new condenser water piping from North Access cooling towers to serve the ESR and 4 kW Building

o Removal of existing ESR cooling towers, associated pumps, piping, dunnage and chemical treatment system

1.2 NEXT STEPS/PATH FORWARD This Basis of Design Report is to provide the documentation required to be prepared for CD-2

and CD-3 approval followed by bidding, award and construction.


GENERAL 2.1 DESIGN DRAWINGS

SHEET NO. SHEET TITLECS COVER SHEETG-1 INDEX SHEETEX-1 EXISTING CONDITIONS TOPOGRAPHIC SURVEYC-1 PROCESS COOLING SITE PIPELINE PLANC-2 PROCESS COOLING SITE PIPELINE PROFILEC-3 PROCESS COOLING SITE DETAILSC-4 PROCESS COOLING SITE DETAILSC-5 PROCESS COOLING SITE NOTESC-6 PROCESS COOLING SITE EROSION AND SEDIMENT CONTROL PLANC-7 PROCESS COOLING EROSION CONTROL DETAILSSG.1 PHASE 1 & PHASE 2 GENERAL NOTESS2.1 PHASE 1 - END STATION DEMOLITION, FOUNDATION AND FRAMING PLANSS2.2 PHASE 2 - NORTH AND SOUTH ACCESS FOUNDATION PLANS & FRAMING PLANSS3.1 PHASE 1 & PHASE 2 SECTIONS & TYPICAL DETAILSM-G HVAC INDEX SHEETM-1-1 END STATION COOLING TOWER SITE PLAN - PHASE 1 DEMOLITIONM-1-2 NORTH ACCESS COOLING TOWER SITE PLAN - PHASE 1 DEMOLITIONM-1-3 SOUTH ACCESS COOLINGTOWER SITE PLAN - PHASE 1 DEMOLITIONM-1-4 END STATION COOLING TOWER SITE PLAN - PHASE 1 NEW WORKM-1-5 NORTH ACCESS COOLING TOWER SITE PLAN - PHASE 1 NEW WORKM-1-6 SOUTH ACCESS COOLING TOWER SITE PLAN - PHASE 1 NEW WORKM-2-1 NORTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 DEMOLITIONM-2-2 SOUTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 DEMOLITIONM-2-3 NORTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 NEW WORKM-2-4 NORTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 NEW WORKM-2-5 SOUTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 NEW WORKM-2-6 SOUTH ACCESS COOLING TOWER SITE PLAN - PHASE 2 NEW WORKM-2-7 EST COOLING TOWER SITE PLAN - PHASE 2 DEMOLITIONM-3-1 END STATION COOLING TOWER FLOW DIAGRAMM-3-2 NORTH ACCESS COOLING TOWER FLOW DIAGRAMM-3-3 SOUTH ACCESS COOLING TOWER FLOW DIAGRAMM-4-1 HVAC SCHEDULESM-5-1 SECTIONSM-7-1 END STATION COOLING TOWERS CONTROL DIAGRAMM-7-2 END STATION COOLING TOWERS POINTS LIST AND SEQUENCE OF OPERATIONSM-7-3 NORTH ACCESS COOLING TOWERS CONTROL DIAGRAMM-7-4 NORTH ACCESS COOLING TOWERS POINTS LIST AND SEQUENCE OF OPERATIONSM-7-5 SOUTH ACCESS COOLING TOWERS CONTROL DIAGRAMM-7-6 SOUTH ACCESS COOLING TOWERS POINTS LIST AND SEQUENCE OF OPERATIONSE-1 ELECTRICAL COVER SHEET ABBREV. AND MOUNTING HEIGHTSE-2 ELECTRICAL COVER SHEET SYMBOLS LISTE-3-1 NORTH ACCESS BUILDING - ONE-LINE DIAGRAM - NEW WORKE-3-2 NORTH ACCESS BUILDING - ONE-LINE DIAGRAM - DEMOLITIONE-3-3 NORTH ACCESS BUILDING - ONE-LINE DIAGRAM - NEW WORKE-3-4 NORTH ACCESS BUILDING - ELECTRICAL SITE PLAN - EXISTING COND AND DEMOE-3-5 NORTH ACCESS BUILDING - ELECTRICAL SITE PLAN - EXISTING COND AND NEW WORKE-3-6 NORTH ACCESS BUILDING - ELECTRICAL SITE PLAN - LIGHTNING PROTECTION SYSTEME-4-1 SOUTH ACCESS BUILDING - ONE-LINE DIAGRAM - NEW WORKE-4-2 SOUTH ACCESS BUILDING - ONE-LINE DIAGRAM - DEMOLITIONE-4-3 SOUTH ACCESS BUILDING - ONE-LINE DIAGRAM - NEW WORKE-4-4 SOUTH ACCESS BUILDING - ELECTRICAL SITE PLAN - EXISTING COND AND DEMOE-4-5 SOUTH ACCESS BUILDING - ELECTRICAL SITE PLAN - EXISTING COND AND NEW WORKE-4-6 SOUTH ACCESS BUILDING - ELECTRICAL SITE PLAN - LIGHTNING PROTECTION SYSTEME-5-1 END STATION BUILDING #92 - ONE-LINE DIAGRAM-DEMOLITIONE-5-2 END STATION BUILDING #92 - ONE-LINE DIAGRAM-NEW WORKE-5-3 END STATION BUILDING #92 - ELECTRICAL SITE PLAN - EXISTING COND AND DEMOE-5-4 END STATION BUILDING #92 - ELECTRICAL SITE PLAN - EXISTING COND AND NEW WORKE-5-5 END STATION BUILDING #92 - ELECTRICAL SITE PLAN - LIGHTNING PROTECTION SYSTEME-6-1 ESR SERVICE BUILDING #102 - ONE-LINE DIAGRAM - DEMOLITIONE-6-2 ESR SERVICE BUILDING #102 - ELECTRICAL SITE PLAN - EXISTING COND AND DEMOE-7-1 MECHANICAL EQUIPMENT COORDINATION SCHEDULEE-7-2 ELECTRICAL DETAILSE-7-3 PANELBOARD SCHEDULESE-7-4 MISCELLANEOUS DETAILS


GENERAL 2.2 APPLICABLE CODES AND STANDARDS

• Virginia Construction Code 2009, (based on the 2009 edition of the International Building Code)

• Virginia Rehabilitation Code 2009 (based on the 2009 edition of the International Existing Building Code)

• Virginia Plumbing Code 2009 (based on the 2009 edition of the International Plumbing Code)

• Virginia Mechanical Code 2009 (based on the 2009 edition of the International Mechanical Code)

• Virginia Fuel Gas Code 2009 (based on the 2009 edition of the International Fuel Gas Code)

• Virginia Energy Conservation Code 2009 (based on the 2009 edition of the International Energy Conservation Code)

• Virginia Statewide Fire Prevention Code 2009, (based on the 2009 International Fire Code) • Virginia Industrialized Building Safety Regulations 2009 • ASHRAE Standard 90.1-2007: Energy Efficient Design of New Buildings Except Low-Rise

Residential Buildings • NFPA 101®, The Life Safety Code®, 2009 edition (LSC) • DOE STD-1066-99 Fire Protection Design Criteria • Factory Mutual Loss Prevention Data Sheets –as referenced by DOE STD-1066-99


MECHANICAL 3 PROCESS COOLING TOWERS 3.1 PROJECT OVERVIEW There are fifteen (15) cooling towers located throughout the accelerator site that

provide process cooling at each building. Several existing cooling towers, essential for continued operations of the accelerator site, are aging and in need of replacement:

• North Access Cooling Towers (3 cooling tower cells) • South Access Cooling Towers (3 cooling tower cells) • End Station Refrigerator (ESR) Cooling Towers (2 cooling tower cells) • End Station Cooling Towers (3 cooling tower cells)

The goals of the UIM Process Cooling Upgrades Project were to improve reliability

and reduce ongoing maintenance and operation costs. The scope outlined below was established with these objectives in mind.

Cooling tower plants will be located in three different locations. A new three cell

tower will be located at the North Access (Building 67), a two cell tower will be located at the South Access (Building 38) and a three cell tower will be located at the End Station (Building 92). One new additional cell will be provided at the North Access (Building 67) and South Access (Building 38) locations on the existing dunnage platform provided as part of the 12 GeV Project. The new North Access cooling tower cells will be cross connected to the cells provided as part of the 12 GeV Project to provide condenser water to serve process cooling loads for 12 GeV, the existing loads at the North Access (Building 67), ESR (Building 102), and the 4kW Refrigerator Unit. The South Access tower will be cross connected to the cells provided as part of the 12 GeV Project to provide condenser water to serve process cooling loads for 12 GeV, and the existing loads at the South Access (Building 38). The new cooling tower located at Building 92 will replace the existing cooling towers that currently serve the End Station process cooling loads.

The project will be performed in two phases as described herein. 3.2 DESIGN CRITERIA Climactic Location: Newport News, Virginia Wet Bulb (Evaporative): 81°F Source: ASHRAE 0.4% Annual Evaporation Design Conditions +1°F Cooling Tower Selection Criteria (North and South Access): Entering Condenser Water Temperature - 100°F Leaving Condenser Water Temperature - 85°F Cooling Tower Selection Criteria (End Station): Entering Condenser Water Temperature - 95°F Leaving Condenser Water Temperature - 85°F


MECHANICAL 3.3 NORTH ACCESS COOLING TOWERS The North Access Cooling Tower Plant will consist of (2) three cell towers for a total

of six cells. Five cells will be sized to provide the total required load of 4050 Tons of process cooling water; the sixth cell will be redundant. The North Access Cooling Tower Plant will be located adjacent to Building 67 in the area of the existing towers. New concrete foundations and steel dunnage will be provided to support the new tower arrangement. The dunnage will include a four foot access platform around the perimeter of the cooling towers.

Six condenser water pumps will be provided (one for each cooling tower) to

distribute condenser water, one pump will be redundant. Pumps will be located on a concrete pad adjacent to the cooling towers. The condenser water to/from the towers will be configured to allow operation of any pump with any operating cooling tower and common distribution to each building.

Two cooling tower cells and three condenser water pumps were installed as part of

the 12 GeV Cooling Tower Project. The scope of this Process Cooling Upgrade Project includes removal of existing cooling towers, installation of four additional cooling tower cells and three condenser water pumps. This project will have two phases.

Phase 1 Scope Description: One cooling tower cell will be added to the existing dunnage platform installed as

part of the 12 GeV Cooling Tower Project. Piping connections will be extended to the new cell from the existing piping mains.

Equalizer connections will be added to the two existing cooling tower cell basins. The existing condenser water 3-way bypass valve electric actuators will be replaced

with pneumatic actuators. New valves and taps will be installed to connect a rental cooling tower system;

providing supplemental cooling to facilitate operation of the accelerator during Phase 2.

New condenser water supply and return will be extended from the mains installed

as part of the 12 GeV Cooling Tower Project to serve the existing loads in North Access (Building 67) and allow demolition of the existing North Access Cooling Towers. The distribution piping serving the existing loads will be run above grade. New fibercast piping will be extended from the existing piping distribution below grade to connect to new steel piping distribution above grade via flanged connection.

Phase 2 Scope Description: Phase 2 includes the demolition of the existing North Access and ESR Cooling

Towers, installation of a new three cell cooling tower and extension of condenser


MECHANICAL

water piping to serve existing loads at ESR (Building 102) and the 4kW Refrigerator Building.

Demolition scope includes the following:

• Removal of the (3) 625 Ton Cells;(2) 2000 GPM condenser water pumps at the North Access (Building 67)

• Removal of dunnage and concrete pads at North Access (Building 67) • Removal of piping and accessories between cooling towers and the North Access

(Building 67) • Removal of the (2) 835 Ton Cells;(2) 1000 GPM condenser water pumps at the

ESR (Building 102) • Removal of dunnage and concrete pads at ESR (Building 102) • Removal of piping and accessories between cooling towers and the ESR

(Building 102) • Demolition of chemical treatment within ESR (Building 102)

The second three cell cooling tower will be installed with the associated condenser

water pumps required and connected to the mains installed as part of the 12 GeV Cooling Tower Project. One cooling tower cell will be included as an Add/Alternate to the Phase 2 scope of work.

Direct Buried Condenser water piping will be extended from the condenser water

connections provided in the main distribution piping as part of the 12 GeV Cooling Tower Project to ESR (Building 102) and the 4kW Refrigerator Building. Some demolition at ESR (Building 102) will have to take place during the shutdown to facilitate the connection of the new condenser water piping to the existing distribution. After the connection of the new condenser water distribution, the ESR towers can be removed.

3.4 END STATION (BUILDING 92) COOLING TOWERS All of the work at the End Station (Building 92) will be provided as part of Phase 1. A new three cell cooling tower will be provided to replace the existing towers. Two

cells will be sized to provide the total required process cooling water load of 1365 Tons; the third tower will be redundant. The End Station Cooling Tower Plant will be located in the same location as the existing towers, adjacent to Building 92. The existing dunnage will be replaced with new. Three new condenser water pumps will be provided, one pump will be redundant. The piping distribution will be removed and replaced with new.

Demolition scope includes the following:

• Removal of the (3) 600 Ton Cells;(3) 1425 GPM condenser water pumps at the End Station (Building 92)

• Removal of (2)abandoned 640 gpm pumps • Removal of dunnage and concrete pads at the End Station (Building 92) • Removal of piping and accessories between cooling towers and the End Station

(Building 92)


MECHANICAL During the demolition and new work a temporary cooling tower system will provide

supplemental cooling to facilitate operation of the accelerator during construction. 3.5 SOUTH ACCESS COOLING TOWERS The South Access Cooling Tower Plant consists of a (1) two cell cooling tower and

(1) two cell tower for a total of four cells. Three cells will be sized to provide the total required process cooling water load of 2820 Tons, the fourth cell will be redundant. The South Access Cooling Tower Plant will be located adjacent to Building 38 in the area of the existing towers. New concrete foundations and dunnage will be provided to support the new tower arrangement. The dunnage will include a four foot access platform around the perimeter of the cooling towers.

Four condenser water pumps will be provided (one for each cooling tower) to

distribute condenser water, one pump will be redundant. Pumps will be located on a concrete pad adjacent to the cooling towers. The condenser water to/from the towers will be configured to allow operation of any pump with any operating cooling tower and common distribution to each building.

One cooling tower cell and two condenser water pumps were installed as part of the

12 GeV Cooling Tower Project. The scope of this Process Cooling Upgrade Project includes removal of existing cooling towers, installation of three additional cooling tower cells and two condenser water pumps. This project will have two phases.

Phase 1 Scope Description: One cooling tower cell will be added to the existing dunnage platform installed as

part of the 12 GeV Cooling Tower Project. Piping connections will be extended to the new cell from the existing piping mains.

Equalizer connections will be added to the two existing cooling tower cell basins. The existing condenser water 3-way bypass valve electric actuators will be replaced

with pneumatic actuators. New valves and taps will be installed to connect a rental cooling tower system;

providing supplemental cooling to facilitate operation of the accelerator during Phase 2.

New condenser water supply and return will be extended from the mains installed

as part of the 12 GeV Cooling Tower Project to serve the existing loads in South Access (Building 38) and allow demolition of the existing South Access Cooling Towers. The distribution piping serving the existing loads will be run above grade. New fibercast piping will be extended from the existing piping distribution below grade to connect to new steel piping distribution above grade via flanged connection.

Phase 2 Scope Description: Phase 2 includes the demolition of the existing South Access Cooling Towers,

installation of a new two cell cooling tower.


MECHANICAL Demolition scope includes the following:

• Removal of the (3) 625 Ton Cells;(2) 2000 GPM condenser water pumps at the South Access (Building 38)

• Removal of dunnage and concrete pads at South Access (Building 38) • Removal of piping and accessories between cooling towers and the South Access

(Building 38) The second two cell cooling tower will be installed with the associated condenser

water pumps required and connected to the mains installed as part of the 12 GeV Cooling Tower Project. One cooling tower cell will be included as an Add/Alternate to the Phase 2 scope of work.

3.6 COMPONENT DESCRIPTION Cooling Tower Description: Cooling towers shall be forced draft counterflow, factory assembled. Standard

construction will be specified for the steel panels and structural elements. Hardware and basin heater construction will be stainless steel. Spray nozzles shall be capable of operating at 50% flow. Fan motors will be equipped with variable speed drives. Stair and handrails will be provided in accordance with OSHA requirements. Isolation valves will be provided on the inlets and outlets of each cell. Each cell will be equipped with single inlet connections on the bottom of the units. An equalizer will be provided for each tower arrangement. Bypass and equalizer connections will be provided at each cell.

Condenser Water Piping: Underground condenser water piping will be direct buried, ductile iron. All above ground condenser water piping will be Carbon Steel, Schedule 40. Joints

will be welded. 3.7 ENERGY CONSERVATION STRATEGIES Larger cooling towers were selected with the lowest horsepower available to

decrease operating costs. Premium efficiency motors with variable frequency dives are specified for cooling towers fans to optimize cooling tower efficiencies.

Condenser water pumps have been specified with premium efficiency motors. 3.8 CALCULATIONS See Condenser Water Load Summary 3.9 ENERGY ANALYSIS See Energy Analysis – Cooling Tower Spreadsheet


MECHANICAL 3.10 COOLING TOWER SELECTIONS North Access Full Buildout – Selection North Access Full Buildout – Drawing

South Access Full Buildout – Selection South Access Full Buildout – Drawing

End Station Full Buildout – Selection End Station Full Buildout – Drawing


Jefferson Lab National Accelerator FacilityProcess Cooling Upgrade - Task Order 10

Cells Operating Backup

GPM (Each Cell)

GPM (Operating) ∆T

Total Load (Operating)

North Access (12 Gev) Building 67 2 1 1550 3100 12 18600000North Access (Existing Loads) Building 67 2 1 1000 2000 15 15000000ESR Building 102 1 1 1000 1000 20 100000004kW Refrigerator 1000 10 5000000

7100 13.69 48600000

Cells Operating Backup

GPM (Each Cell)

GPM (Operating) ∆T

Load (Operating)

End Station Building 92 1 1 3275 3275 10 163750003275 10.00 16375000

Cells BackupGPM

(Each Cell)GPM

(Operating) ∆TLoad

(Operating)South Access (12 Gev) Building 38 2 1 900 1800 12 10800000South Access (Existing Loads) Building 38 2 1 1000 2000 15 15000000General Purpose Building Building 36 200 10 1000000FEL (New LCW System) Building 18 932 15 6990000

4932 13.70 33790000

Area Served

Totals

Building 92 Cooling TowersLoad Summary

Area Served

Totals

South Access Cooling TowersLoad Summary

Area Served

Totals

North Access Cooling TowersLoad Summary

Jefferson Lab National Accelerator FacilityProcess Cooling Upgrade - Task Order 10

Plant Areas Served Cells Backup GPM

(Each Cell)GPM

(Operating) ∆TLoad

Operating (Tons)

Load Backup (Tons)

Total Load

Cooling Tower

(Fan HP)

CT Fan Qty bhp

Tower Fan % Hours

Operationalbhp kW Operating

hrs Fan kwh Pump (HP) Pump Qty bhp

kWOperating

hrs Pump kwh Total kwhBuilding 67 5 1 1420 7100 15 4438 887.5 5325.0 30 5 0.85 52% 25.5 19.02 4555.2 433094 60 5 50 37 8760 1633083 206617712 Gev 0Building 102 04kW Refrig. 0Building 38 4 1 1235 4940 15 3088 771.9 3859.4 30 4 0.85 72% 25.5 19.02 6307.2 479734 60 4 47.6 35 8760 1243756 172349012 Gev 0Building 36 0Building 18 0Building 92 1 1 3275 3275 10 1365 1364.6 2729.2 30 2 0.85 42% 25.5 19.02 3679.2 139923 60 2 52 39 8760 679363 819285

000

15315 8890 3024 11914 1,052,751 3556202 4,608,952

Assumptions<40 HP Motors: 85% Efficiency (Cooling Tower)>40 HP Motors: 92% Efficiency (Cooling Tower)Tower Fan % Hours Operation taken from Fan Annual Operational Hours from Jlab

Totals

Load Summary Pumping Energy AnalysisEnergy Analysis - Cooling Tower Replacement

Fan Energy Analysis

End Station

South Access Plant

North Access Plant

Baltimore Aircoil Company, Inc.Cooling Tower Selection ProgramVersion: 8.1.4 NAProduct data correct as of: February 07, 2014

Project Name: Jefferson Lab UIM Process Cooling UpgradesSelection Name: End Station Cooling Towers-Full LoadProject State/Province: VirginiaProject Country: United StatesDate: March 18, 2014

Model Information Design ConditionsProduct Line: New Series 3000 Flow Rate: 3,275.00 USGPMModel: XES3E-1222-12O Hot Water Temp.: 95.00 °FNumber of Units: 2 Cold Water Temp.: 85.00 °FFan Type: Standard Fan Wet Bulb Temp.: 81.00 °FFan Motor: Full Speed, 30.00 BHP Tower Pumping Head: 7.86 psiTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit Reserve Capability: 5.66%Intake Option: NoneInternal Option: NoneDischarge Option: None

Engineering Data, per UnitUnit Length: 11' 9.75" Minimum Distance Required

Unit Width: 21' 6.50" From Solid Wall: 6 ft.

Unit Height: 19' 1.00" From 50% Open Wall: 3 ft.

Air Flow: 176,300 CFM Energy Rating:

Approximate Shipping Weight: 16,120 pounds 88.27 per ASHRAE 90.1, ASHRAE 189 and CA Title 24.

Heaviest Section: 8,980 pounds This XE model is an extremely efficient model, with a

Approximate Operating Weight: 36,110 pounds base energy rating that meets or exceeds 2x the

minimum ASHRAE 90.1 energy rating.

Note: These unit dimensions do not account for any options/accessories. Please contact your local BAC sales

representative for dimensions of units with options/accessories.

Warning1. One or more selection parameters are outside of CTI Certification limits.

Page 1/3



Model & Fan Motor Model AccessoriesProduct Line: New Series 3000 Intake Option: NoneModel: XES3E-1222-12O Internal Option: NoneNumber of Units: 2 Discharge Option: NoneFan Motor: Full Speed, 30.00 BHP Fan Type: Standard FanTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit

Design Conditions @ Standard Total Fan Motor Power per Unit (30.00 HP)Flow Rate: 3,275.00 USGPMHot Water Temp.: 95.00 °FCold Water Temp.: 85.00 °FWet Bulb Temp.: 81.00 °F

Predicted PerformanceFan Motor Alternative = Full Speed, 30.00 BHP

Flow Rate = 3275.00 USGPM (100.00% of Design)

These performance curves are based on constant fan power.

Applies to Applies toWarning Design Off Design

Conditions Conditions1. One or more selection parameters are outside of CTI Certification limits. Yes Yes

Page 2/3



Model InformationProduct Line: New Series 3000 Intake Option: NoneModel: XES3E-1222-12O Internal Option: NoneNumber of Units: 2 Discharge Option: NoneFan Type: Standard FanFan Motor: Full Speed, 30.00 BHP/UnitTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit

Octave band and A-weighted sound pressure levels (Lp) are expressed in decibels (dB)reference 0.0002 microbar. Sound power levels (Lw) are expressed in decibels (dB)reference one picowatt. Octave band 1 has a center frequency of 63 Hertz.

TopSound Pressure (dB)

Octave DistanceBand 5 ft. 50 ft.

1 88 782 88 783 87 774 84 715 81 676 75 627 71 588 69 55

A-wgtd 86 74

Air InletSound Pressure (dB)


1 83 722 85 713 84 744 77 705 71 656 65 567 59 508 56 47

A-wgtd 79 71

EndSound Pressure (dB)


1 81 762 82 703 79 724 72 665 68 616 60 527 53 478 51 43

A-wgtd 75 68



1 81 762 82 703 79 724 72 665 68 616 60 527 53 478 51 43

A-wgtd 75 68



1 83 722 85 713 84 744 77 705 71 656 65 567 59 508 56 47

A-wgtd 79 71Sound Power (dB)Octave Center FrequencyBand (Hertz) Lw

1 63 1072 125 1053 250 1064 500 1015 1000 966 2000 897 4000 858 8000 82

Note: The use of frequency inverters (variable frequency drives) can increase sound levels.

Page 3/3


Project Name: Jefferson Lab UIM Process Cooling UpgradesSelection Name: North Acces Cooling Towers-Full LoadProject State/Province: VirginiaProject Country: United StatesDate: March 18, 2014

Model Information Design ConditionsProduct Line: New Series 3000 Flow Rate: 7,100.00 USGPMModel: XES3E-1222-12O Hot Water Temp.: 100.00 °FNumber of Units: 5 Cold Water Temp.: 85.00 °FFan Type: Standard Fan Wet Bulb Temp.: 81.00 °FFan Motor: Full Speed, 30.00 BHP Tower Pumping Head: 7.86 psiTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit Reserve Capability: 3.20%Intake Option: NoneInternal Option: NoneDischarge Option: None






Heaviest Section: 8,980 pounds This XE model is an extremely efficient model, with a

Approximate Operating Weight: 36,110 pounds base energy rating that meets or exceeds 2x the

minimum ASHRAE 90.1 energy rating.




Page 1/3



Model & Fan Motor Model AccessoriesProduct Line: New Series 3000 Intake Option: NoneModel: XES3E-1222-12O Internal Option: NoneNumber of Units: 5 Discharge Option: NoneFan Motor: Full Speed, 30.00 BHP Fan Type: Standard FanTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit







Page 2/3



Model InformationProduct Line: New Series 3000 Intake Option: NoneModel: XES3E-1222-12O Internal Option: NoneNumber of Units: 5 Discharge Option: NoneFan Type: Standard FanFan Motor: Full Speed, 30.00 BHP/UnitTotal Standard Fan Power: (1) 30.00 = 30.00 HP/Unit




1 89 802 89 803 88 794 85 735 82 696 76 647 72 608 70 57

A-wgtd 87 76



1 84 742 86 733 85 764 78 725 72 676 66 587 60 528 57 49

A-wgtd 80 73



1 81 782 82 723 79 744 72 685 68 636 60 547 53 498 51 45

A-wgtd 75 70



1 81 782 82 723 79 744 72 685 68 636 60 547 53 498 51 45

A-wgtd 75 70



1 84 742 86 733 85 764 78 725 72 676 66 587 60 528 57 49


1 63 1092 125 1073 250 1084 500 1035 1000 986 2000 917 4000 878 8000 84


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Project Name: Jefferson Lab UIM Process Cooling UpgradesSelection Name: South Access Cooling Towers-Full LoadProject State/Province: VirginiaProject Country: United StatesDate: March 18, 2014

Model Information Design ConditionsProduct Line: New Series 3000 Flow Rate: 5,000.00 USGPMModel: S3E-1222-14P Hot Water Temp.: 100.00 °FNumber of Units: 3 Cold Water Temp.: 85.00 °FFan Type: Standard Fan Wet Bulb Temp.: 81.00 °FFan Motor: Full Speed, 40.00 BHP Tower Pumping Head: 9.02 psiTotal Standard Fan Power: (1) 40.00 = 40.00 HP/Unit Reserve Capability: 4.34%Intake Option: NoneInternal Option: NoneDischarge Option: None






Heaviest Section: 9,600 pounds

Approximate Operating Weight: 37,590 pounds




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Model & Fan Motor Model AccessoriesProduct Line: New Series 3000 Intake Option: NoneModel: S3E-1222-14P Internal Option: NoneNumber of Units: 3 Discharge Option: NoneFan Motor: Full Speed, 40.00 BHP Fan Type: Standard FanTotal Standard Fan Power: (1) 40.00 = 40.00 HP/Unit







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Model InformationProduct Line: New Series 3000 Intake Option: NoneModel: S3E-1222-14P Internal Option: NoneNumber of Units: 3 Discharge Option: NoneFan Type: Standard FanFan Motor: Full Speed, 40.00 BHP/UnitTotal Standard Fan Power: (1) 40.00 = 40.00 HP/Unit




1 88 782 89 793 88 784 84 725 81 686 76 637 71 588 70 55

A-wgtd 86 75



1 84 732 85 723 84 744 77 715 71 666 65 577 60 518 57 48

A-wgtd 79 72



1 81 772 82 713 79 734 72 675 68 636 60 547 53 488 51 44

A-wgtd 75 69



1 81 772 82 713 79 734 72 675 68 636 60 547 53 488 51 44

A-wgtd 75 69



1 84 732 85 723 84 744 77 715 71 666 65 577 60 518 57 48


1 63 1082 125 1063 250 1074 500 1025 1000 986 2000 907 4000 858 8000 82


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ELECTRICAL 4 PROCESS COOLING TOWERS 4.1 APPLICABLE CODES AND STANDARDS

Reference Standards and Applicable Codes for this section: • National Electrical Code (NEC), NFPA 70, latest edition • National Electrical Safety Code, ANSI C2 • Emergency and Standby Power Systems Standard, NFPA 110 • Life Safety Code, NFPA 101, latest edition • International Building Code (IBC), 2009 edition • Underwriter’s Laboratories, Inc. (UL) • National Electrical Manufacturer’s Association (NEMA) • American National Standards Institute (ANSI) • Factory Mutual, Inc. (FM) • Telecommunications Industry Associations/Electronic Industry Association

Standards (TIA/EIA) • International Telecommunication Association (BICSI) Reference Manuals • Basic National Fire Prevention Code, latest edition

4.2 NORTH ACCESS BUILDING #67 The existing North Access Building #67 is served from the north accelerator primary

12.47 kV service loop feeders #7 and #9 originating at the CEBAF 12.5 kV master substation located in the center of the Linear Accelerator site. These feeders serve existing pad mount primary master loop feed switches #1082 and #1083 which, in turn, serves existing Unit Substations W5 and W6. These substations are contained within a NEMA 3R weatherproof enclosures located on an existing exterior equipment pad to the southeast of the existing building.

Substations W5 and W6 are rated for 1,500 kVA capacity with a primary voltage of

12.47 kV and a secondary distribution voltage of 480Y/277 volt, three-phase. Each substation has a co-located switchboard with two (2) feeder circuit breakers. The circuit breakers located in Switchboard W5 serve distribution panel NA2 located in Building #67 and distribution panel MDP located in the Injector Building. The circuit breakers located in Switchboard W6 serve distribution panel NA1 located in Building #67 and the normal side of an automatic transfer switch which provides emergency power to the linear accelerator loop.

Existing switchboard NA2 distributes secondary voltage to an existing motor control

center, the existing main LCW pumps, lighting panel and multiple appliance panels via step-down transformers. The existing motor control center provides power to additional LCW pumps, condenser water pumps and the existing three (3) cooling tower cells. Existing switchboard NA1 provide secondary power to multiple Linac power supply modules as well as a welding receptacle, appliance panel and distribution panel MDP located in building W5. Based on the preliminary load calculations, the replacement of the LCW pumps and the removal of the Linac power supplies, these existing panels appear to have sufficient capacity to serve the proposed cooling tower additions and replacement.


ELECTRICAL In order to maintain operation of the linear accelerator, the expansion and

replacement of the existing cooling towers at this building will occur under the scope of both the 12 GeV upgrade and UIM projects. Under the scope of 12 GeV Upgrades, three (3) cooling tower and associated pumps were installed and commissioned while maintaining the existing cooling towers and pumps in operation. In addition, the existing low conductivity water (LCW) pumps were replaced with larger pumps. Under the scope of the UIM project, the existing cooling towers and pumps will be removed and replaced with three (3) additional towers and pumps. The work will have to be completed with sufficient time allowed for commissioning of the systems by Jefferson Lab.

Service to the 12 GeV cooling towers and associated pumps provided under a

previous project phase consisted of a secondary 480 volt, three-phase feeder that originates from switchboard NA-1-A and serve a motor control center. At the completion of this phase, two (2) towers, three (3) pumps, two (2) sets of pan heaters and all associated heat trace circuits were completed. In addition, the motor control center has provisions for expansion to the standby tower and pan heaters provided under the scope of this project. Thus, under the phase 1 scope of work, the standby tower and associated pan heater will be incorporated into the existing tower arrangement.

Under the scope of the UIM project, replacement of the existing three (3) cooling

towers presently serving the North Access Building will require modifications to the existing motor control center due to the increase in fan horsepower, the additional condenser water pump and the use of variable frequency drives (VFD) in lieu of two-speed starters for control of the cooling tower fans. Existing combination starter/disconnect units will be used to serve the proposed condenser water pumps as these existing units are appropriately sized for the new pump horsepower. The existing two-speed combinations starter/disconnects will be removed and replaced with feeder circuit breaker for power to the cooling tower fan VFDs.

The replacement of the existing cooling towers will occur in project phase 2 and

add/alternate phase 2. Two (2) of the three (3) proposed towers and associated pan heaters will be provided under the base project phase 2 scope of work. In addition, all three (3) proposed condenser water pumps will be provided under the base phase 2 project scope. As an add/alternate to the project scope for phase 2, the additional cooling tower and associated pan heaters will be provided. Refer to the scope of work notes provided on the contract documents.

4.3 SOUTH ACCESS BUILDING #38 The existing South Access Building #38 is served from the south accelerator

primary 12.47kV service loop feeders #5 and #6 originating at the CEBAF 12.5kV master substation located in the center of the Linear Accelerator site. These feeders serve existing pad mount primary master loop feed switch #1064 which, in turn, serves existing Unit Substation E6. This substation is contained within a NEMA 3R weatherproof enclosures located on an existing exterior equipment pad to the northwest of the existing building.

Substation E6 is rated for 1,500 kVA capacity with a primary voltage of 12.47 kV

and a secondary distribution voltage of 480Y/277 volt, three-phase. The substation


ELECTRICAL

has a co-located switchboard with two (2) feeder circuit breakers. These circuit breakers serve distribution panels SA1 and SA2 located in Building #38.

Existing switchboard SA2 distributes secondary voltage to an existing motor control

center, the existing main LCW pumps, lighting panel and multiple appliance panels via step-down transformers. The existing motor control center provide power to additional LCW pumps, condenser water pumps and the existing three (3) cooling tower cells. Existing switchboard SA1 provide secondary power to multiple Linac power supply modules as well as a welding receptacle, appliance panel and distribution panel MDP located in building E5. Based on the preliminary load calculations including the removal of the Linac power supplies and incorporation of the new LCW pumps, these existing panels appear to have sufficient capacity to serve the proposed cooling tower additions, proposed LCW pumps and replacement cooling towers.

In order to maintain operation of the linear accelerator, the expansion and

replacement of the existing cooling towers at this building will occur under the scope of both the 12 GeV upgrade and UIM projects. Under the scope of 12 GeV project, two (2) cooling towers and associated pumps were installed and commissioned while maintaining the existing cooling towers and pumps in operation. In addition, the existing low conductivity water (LCW) pumps were replaced with larger pumps. Under the scope of the UIM project, the existing cooling towers and pumps will be removed and replaced with three (3) additional towers and pumps. The work will have to be completed with sufficient time allowed for commissioning of the systems by Jefferson Lab.

Service to the 12 GeV cooling towers and associated pumps provided under a

previous project phase consisted of a secondary 480 volt, three-phase feeder that originates from switchboard SA-1-A and serves a motor control center. At the completion of this phase, one (1) tower, two (2) pumps, one (1) set of pan heaters and all associated heat trace circuits were completed. In addition, the motor control center has provisions for expansion to the standby tower and pan heaters provided under the scope of this project. Thus, under the phase 1 scope of work, the standby tower and associated pan heater will be incorporated into the existing tower arrangement.

Under the scope of the UIM project, replacement of the existing two (2) cooling

towers presently serving the South Access Building will require modifications to the existing motor control center due to the increase in fan horsepower, the additional condenser water pump and the use of variable frequency drives (VFD) in lieu of two-speed starters for control of the cooling tower fans. Existing combination starter/disconnect units will be used to serve the proposed condenser water pumps as these existing units are appropriately sized for the new pump horsepower. The existing two-speed combinations starter/disconnects will be removed and replaced with feeder circuit breaker for power to the cooling tower fan VFDs.

The replacement of the existing cooling towers will occur in project phase 2 and

add/alternate phase 2. One (1) of the two (2) proposed towers and associated pan heaters will be provided under the base project phase 2 scope of work. In addition, both of the proposed condenser water pumps will be provided under the base phase 2 project scope. As an add/alternate to the project scope for phase 2, the


ELECTRICAL

additional cooling tower and associated pan heaters will be provided. Refer to the scope of work notes provided on the contract documents.

4.4 END STATION (BUILDING #92) COOLING TOWERS

The three (3) existing cooling towers and associated condenser water pumps will be

replaced with (3) three new cell cooling towers. The existing dunnage will be removed and new will be provided to support the new cooling tower cells. The existing condenser water pumps will be replaced.

The existing End Station Building #92 is served from the end station primary

12.47kV service loop feeders #1 and #2 originating at the CEBAF 12.5kV master substation located in the center of the Linear Accelerator site. These feeders serve existing pad mount primary master loop feed switches #1015 and #1016 which, in turn, serves existing Unit Substations T5 and T6. These substations are contained within a NEMA 3R weatherproof enclosures located on an existing exterior equipment pad to the southeast of the existing building.

Substations T5 and T6 are rated for 1,500 kVA capacity with a primary voltage of

12.47 kV and a secondary distribution voltage of 480Y/277 volt, three-phase. Each substation has a co-located switchboard with integral feeder circuit breakers. The circuit breaker in located in Switchboard T5 serve distribution panel SB ESB located in End Station B. The circuit breakers located in Switchboard T6 serve distribution panel SB B1 located in Building #92 and distribution panel MDP TB located in End Station B.

Existing switchboard SB B1 distributes secondary voltage to an existing motor

control center, lighting panel and multiple appliance panels via step-down transformers. The existing motor control center provide power to LCW pumps, condenser water pumps and the existing three (3) cooling tower cells. Based on the preliminary load calculations, the existing panel and motor control center appears to have sufficient capacity to serve the proposed cooling tower replacement.

Based on site survey information, the existing condenser water pumps are rated for

50 horsepower and the proposed replacement pumps will be rated for 60 horsepower. Therefore, it is proposed that the existing motor circuit protectors (MCP) “buckets” located in the motor control center serving the existing pumps will be revised as required to provide the proper NEMA size starter (Size 4) and overcurrent protection (150 ampere) for the increased capacity motors.

The proposed cooling tower fans will be rated for 30 horsepower and be controlled

via integral variable frequency drives. The existing cooling tower fans are presently two-speed motors and controlled via two-speed starters located in the motor control center. It is proposed that the existing combination circuit breaker/two-speed starter “buckets” be revised as required to provide new overcurrent protection to serve the new tower fans. It is anticipated that the existing feeders will be reused and the existing routing be modified to serve the new fans.

The existing branch circuit serving the existing cooling tower pan heaters will be demolished. The existing feeder circuit breaker will be reused to serve the proposed distribution equipment for service to the new pan heaters.


ELECTRICAL The complete demolition and new work will be required to be completed during the

shutdown of the accelerator site. The work will have to be completed with sufficient time allowed for commissioning of the systems by Jefferson Lab.

4.5 ESR END STATION (BUILDING #102) COOLING TOWERS

The two (2) existing cooling towers and associated condenser water pumps will be

demolished in their entirety. The existing above ground condenser water piping will be modified in accordance with the HVAC system designs.

The existing ESR End Station Building #102 is served from the end station primary

12.47kV service loop feeders #1 and #2 originating at the CEBAF 12.5kV master substation located in the center of the Linear Accelerator site. These feeders serve existing pad mount primary master loop feed switches #1012, #1013 and #1014 which, in turn, serves existing Unit Substations T-7, T-9 and T-8, respectively. These substations are contained within a NEMA 3R weatherproof enclosures located on an existing exterior equipment pad to the southeast of the existing building.

Each of these substations are rated for 1,500 kVA capacity with a primary voltage

of 12.47 kV and a secondary distribution voltage of 480Y/277 volt, three-phase. Each substation has a co-located switchboard with integral feeder circuit breakers. Substations T-7 and T-9 are existing to remain and not involved under the scope of this project. One of the circuit breakers in located in Switchboard T-8 serve distribution panel SB B2 located in ESR End Station #102.

Existing switchboard SB B2 distributes secondary voltage to an existing exterior

motor control center, lighting panel and multiple appliance panels via step-down transformers. The existing motor control center is co-located with the cooling towers and provides power to condenser water pumps and the existing two (2) cooling tower cells.

Under the scope of this UIM project, the existing cooling towers, condenser water

pumps and dunnage will be removed. In addition, the existing exterior, pad-mounted motor control center will also be removed including the existing feeder back to switchboard SB B2. The existing branch circuits that provide power to the existing condenser water piping heat tracing will be maintained.

The complete demolition will be required to be completed during the shutdown of

the accelerator site. The work will have to be completed with sufficient time allowed for commissioning of the systems by Jefferson Lab.

4.6 ELECTRICAL CABLING AND EQUIPMENT STANDARDS

Based on the environment within this process building, it is proposed that all feeder and branch circuit wiring will be run in metallic pathways to provide physical protection. Electric metallic tubing (EMT) will be used from the panel to the end device or equipment for the installation of the line voltage power conductors. Final connections to fixed motor loads and luminaires will be accomplished via liquidtite flexible metallic tubing (Sealtite) in lengths not to exceed 6 feet. Final connections to luminaires will be accomplished via metal-clad, type MC, cable lengths not to exceed 6 feet. Where installed in damp, wet or exterior locations Rigid Steel will be used.


ELECTRICAL Branch circuit and feeder conductors will consist of 600 volt single solid copper

THHN type conductors. Conductors sized #10 AWG and smaller shall be solid copper conductors. An insulated equipment ground conductor will be installed with all feeder and branch circuits. An insulated equipment ground conductor sized in accordance with NEC will be installed with all feeders and branch circuits. The conduit system will not be used as the sole grounding pathway.

In general, all appliances and equipment branch circuits will have dedicated

neutrals. Branch circuit conductors will be sized as required to minimize the voltage drop to

maximum 3%. Feeder conductors will be sized to limit the voltage drop in both feeder and branch circuits to maximum 3%.

Receptacles and switches will be UL listed, “heavy-duty” type. Device faceplates

will be 302-type stainless steel with a No. 4 finish in finished areas and galvanized steel in unfinished spaces. Receptacles will have an ivory yoke. Ground Fault Circuit Interrupters (GFCI) receptacles will be provided in accordance with the NEC and when installed within 6 feet of a water source (i.e. sink). All branch circuit devices will be permanently labeled with panelboard name and branch circuit number.

All motors one-half horsepower and greater will be 460 volt rated, three phase and

specified as premium efficiency motors. All motors controlled by variable frequency drives will be inverter duty rated motors with ceramic bearings and higher insulation characteristics as specified by the mechanical engineer.

Standard, non-VFD motor control will be controlled by combination starters with integral motor circuit protectors (MCP) with solid-state electronic overloads installed in existing motor control centers as noted on the drawings. Variable frequency drives and associated filters will be furnished by the mechanical contractor and installed and wired by electrical contractor.

Variable Frequency Drives (VFD) will be provided for motors as noted on the

preliminary single line diagrams. Motors rated for 30 horsepower and larger controlled via VFD units will use 12-pulse type drives. Motors rated less than 30 horsepower will use 6-pulse drives with filtering as noted herein. To mitigate harmonics generated by variable frequency drives, the 6-pulse drives will be provided with AC line reactors and DC link reactors or with a combination AC reactors and DC link reactors and trap filters as required by IEEE 519. Therefore, the electrical contractor will also install and wire the associated line reactors, broadband and output filters typically associated with the VFD.


ELECTRICAL

4.7 BUILDING AND ELECTRICAL SYSTEM GROUNDING

The existing electrode ground system will be extended to the new equipment in accordance with the requirements of the National Electrical Code (NEC). UFER grounds will be installed in all new pads.

4.8 LIGHTING STANDARDS

Based on the current scope of renovations to the existing ESR, north, south and end station buildings, there is anticipated no lighting scope of work. The existing exterior and interior building lighting will remain.

4.9 SECURITY SYSTEM

The existing security system will remain in these buildings as presently installed.

4.10 TELECOMMUNICATIONS SYSTEM

Based on the current scope of renovations to the existing ESR, north, south and end station buildings, there is no anticipated telecommunications scope of work. The existing telecommunications system will remain.


STRUCTURAL 5.1 PROJECT OVERVIEW The Process Cooling Upgrade Project consists of three locations of construction within the

campus that will be carried out in two primary phases. Phase 1 will consist of three new cooling tower cells that will replace the End Station cooling towers supported on a new dunnage platform located adjacent to Building 92. Phase 2 will address the North Access and South Access locations. The North Access Cooling Tower Plant, located adjacent to Building 67, will consist of a dunnage platform capable of supporting up to three cooling tower cells. Finally, located adjacent to Building 38, the South Access Cooling Tower Plant will consist of a dunnage platform capable of supporting up to two cooling tower cells.

5.2 DESIGN CRITERIA The following sections describe the general design criteria to be used in analyzing and

designing the Process Cooling Tower Upgrade. 5.2.1 Reference Codes and Standards

• IBC 2009 International Building Code • ASCE 7-05 Minimum Design Loads for Buildings and Other Structures • ACI 318-05 Building Code Requirements for Structural Concrete • ACI 530-5 Specifications for Masonry Structures • AISC 360-05 Manual of Steel Construction – 13th Edition • AWS D1.1-04 Structural Welding Code for Steel • ASTM American Society for Testing and Materials

5.2.2 Design Dead and Live Loads

Design dead loads for the purpose of structural design shall be the actual weight of construction material and fixed equipment, but shall not be less than the unit dead loads prescribed in ASCE 7.

Design Live Loads to be supported shall be as follows: First Floor 250 psf (Slab on grade) Platform Live Load 60 psf

5.2.3 Snow Load Criteria

Ground Snow Load (Pg) 15 psf Snow Importance Factor (IS) 1.0

5.2.4 Wind Load Criteria

Type of Structure Open Basic Wind Speed 110 mph Exposure “B” Wind Importance Factor 1.0


STRUCTURAL 5.2.5 Seismic Load Criteria

Occupancy Category II 1.0 Second Spectral Response Acceleration S1 = 5.0% 0.2 Second Spectral Response Acceleration SS = 12.7% Soil Site Classification D Seismic Importance Factor (IE) 1.0 Seismic Design Category B Response Modification Factor, R 3

5.3 GEOTECHNICAL AND FOUNDATION INFORMATION A specific site geotechnical investigation has not been carried out for the cooling tower sites

at this time. An extensive Geotechnical Investigation was conducted for the TEDF project by GeoConcepts dated June 25th, 2009. Due to the close proximity of this site to the TEDF project site, EwingCole followed the same recommendations for the basis of design of this project.

5.4 STRUCTURAL SYSTEMS The allowable bearing capacity for the design of the foundation systems shall be 2000 psf. All

concrete used for foundations, slabs on grade and retaining walls shall have a minimum 28-day compressive strength of 4500 psi. All slabs on grade will be poured on a four inch crushed stone sub base and 15 mil vapor barrier. Rebar to conform to ASTM A615 – Grade 60. Wire mesh reinforcing to conform to ASTM A185.

All structural steel wide flange members shall be ASTM A992 – Grade 50. All structural steel

base plates and moment plates shall be ASTM A572 – Grade 50. All structural steel angles, channels and other plates shall be ASTM A36. All structural steel directly exposed to the weather shall be hot dipped galvanized and touched up with ZRC.

5.5 END STATION COOLING TOWERS SCOPE (PHASE 1) A new dunnage platform consisting of steel wide flange beams and posts will be provided to

support three new cooling towers cells with a four-foot access platform around the perimeter of the cooling towers. Shallow spread footings will be provided under the dunnage posts.

A new concrete pad will be provided for the condenser water pumps associated with each

cooling tower cell. Turned down slab construction will be provided along the perimeter of the pad for frost protection.

An existing steel dunnage platform and associated foundations, as well as an existing

concrete pad and an existing retaining wall structure will be demolished in order to provide space for the construction of the new dunnage platform.

5.6 NORTH ACCESS COOLING TOWERS SCOPE (PHASE 2) The scope for the North Access Cooling Towers will include a new dunnage platform and

foundations to support a three cell cooling tower, as well as new concrete pads for condenser water pumps associated with each cooling tower cell.


STRUCTURAL An existing steel dunnage platform and associated foundations, as well as an existing

concrete pad, will be demolished in order to provide space for the construction of a three cell cooling tower dunnage platform.

The new dunnage platform will be provided to support three new cooling tower cells with a

four-foot access platform around the perimeter of the cooling towers. Two cells will be installed as part of this scope of work and the third cooling tower cell will be an additive bid item. Shallow spread footings will be provided under the dunnage posts.


cooling tower. Turned down slab construction will be provided along the perimeter of the pad for frost protection.

5.7 SOUTH ACCESS COOLING TOWERS SCOPE (PHASE 2) The scope for the South Access Cooling Towers will include a new dunnage platform and

foundations to support a two cell cooling tower, as well as new concrete pads for condenser water pumps associated with each cooling tower cell.

An existing steel dunnage platform and associated foundations, as well as an existing

concrete pad, will be demolished in order to provide space for the construction of a two cell cooling tower dunnage platform.

The new dunnage platform will be provided to support two new cooling tower cells with a

four-foot access platform around the perimeter of the cooling towers. One cell will be installed as part of this scope of work and the second cooling tower cell will be an additive bid item. Shallow spread footings will be provided under the dunnage posts.


cooling tower. Turned down slab construction will be provided along the perimeter of the pad for frost protection.


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