GOLD COAST Hospital Review - Mechanical-27441175€¦ · Design Life of mechanical equipment: Major...

GOLD COAST Hospital – CONDITION REPORT – MECHANICAL

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GOLD COAST Hospital – CONDITION REPORT - MECHANICAL

(a) SUMMARY

Overall Details:

• The age of the buildings range between 12 and 30 years. The age of the main services range up to 20 years, with a major refurbishment occurring about 9 years ago.

Some services have been installed or replaced within the lower side of this age range – such as cold rooms and plant, chillers, boilers, CSSD sterilisers, etc. Some services are now aged – such as medical gases and suction plant, building water supply pump(s), HWS calorifiers, ducts to lower floors, O.T. sterilisers, etc.

• A Strategic Direction is required to be determined for the proposed life of this facility.

• The functional design of the Air Handling Units (AHUs) serving the Operating Theatres is wrong, and consumes excessive energy. The AHUs themselves are now 13 years old and are still operational, but should be replaced.

• The strategic direction being taken with the chillers is endorsed (provide 5th chiller in the Mental Health block, retire the existing chiller there, and interconnect the systems).

• We recommend that the chilled water main system should be interconnected around the main buildings with a ‘ring main’ system (depending on the determination of the Strategic Direction recommended above) for future reliability and security of supply in case of service and/or breakdown of plant. This has not been included in the costings.

• We recommend specialist testing and reporting on critical items such as chilled and condenser water piping (especially the headers), ductwork cleanliness (particularly in the older areas), etc.

• The digital control system should be expanded – - extend the extent of the controls monitoring and control - extend the capability to deliver ‘on-line’ energy information to enable

savings in energy consumption (and hence costs).

Recommendations:

Mechanical refurbishments totalling $750,000 have been identified as being high priority items which are required to be carried out to raise these services to a satisfactory standard commensurate with the operations presently carried out in the facility.

A further $490,000 has been estimated for medium priority items which have been identified as required for continued operation of this facility.

Mechanical items are listed (refer Recommendations schedule on page 14), and are detailed in the body of the report.

RTI Folio No. 1

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(b) INTRODUCTION

History –

The existing Block A (multi-storey building) was built in the late 1970s, and at that time was largely not air conditioned.

The stage 2 extension (Blocks B & C) were built in 1985, and were partially air conditioned (eg. operating theatre suites and support areas, and partially on the lower floors), while the rest was ventilated (ducted air with heating). The chilled water system at that time used Carrier 19H centrifugal units.

In 1992, the Psychiatric Unit building was constructed south of blocks B&C, and it was fully air conditioned using stand-alone TRANE chiller plant.

The operating theatres were relocated and new air conditioning plant provided in 1994-5.

In 1998-9 the hospital underwent an extensive refurbishment of most areas, which included fully air conditioning the whole facility, upgrading medical gases, and communications. A new central chiller station was installed in the basement of Block A, with cooling towers on the roof. The new chillers then installed were CFC friendly York centrifugal units using refrigerant R-123. A new digital control system by TAC was instigated.

A new Rehabilitation building was constructed in 2001 (named Block D), which was fully air conditioned using chilled water from the existing central chiller plant.

Normal support services (medical gases, central kitchen area, stand-by generators, etc.) are incorporated into the buildings. There are a number of small stand-alone buildings on the site, with some reticulated services, and some stand-alone services. There are over a hundred minor air conditioners (room and split type) spread throughout these buildings.

Life of this Facility –

The major high rise block (part A) is about 30 years old and the part B extension is about 22 years old, but the entire block was refurbished about 10 years ago. It is rated as a 470 bed facility now, with current building works to increase this by 30 beds. It is understood the management is looking to increase the capacity by another 70 beds in this facility. There are many support and complementary health functions which are located in minor buildings on this site.

However it has been announced that a major new 750 bed hospital facility is to be constructed for the Gold Coast, to be located about 4km west of this existing facility, and is currently scheduled for commissioning in 2014.

Consequently the short term life of this facility appears to be 7 years in its present form.

Strategic Direction –

The existing chiller station is at one end of the site (under Block A), while there are chilled water loads in the Mental Health Block and the Rehabilitation Block. There are also over a hundred small separate DX room and split units over the site. It is understood the additional chiller will be installed in the existing Mental Health Block.

An overall strategic direction is required to assist in design decisions on how the chilled water reticulation may be upgraded and/or extended to maximise long term reliability, economy and flexibility to the site.

RTI Folio No. 2

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Design Life of mechanical equipment:

Major mechanical equipment is usually assigned a 15–20 year life, and buildings a 30-50 year life before it should be budgeted for replacement and/or refurbishment. While the original building on this site (the 10 level hospital block A) was constructed in the late 1970s, and so is about 30 years old, a major refurbishment was carried out in 1998-9. At this time the major items of plant were replaced, and so are only about 9 years old. However a number of items of equipment and ductwork were installed with the building, and so have reached the limit of their operational life (because of corrosion, dilapidation, etc.) and so will need to be replaced.

Functional Design of Systems:

The original design of the hospital was based on-

• Central chilled water cooling plant • Floor-by-floor multi-zone Air Handling Units (AHUs) • Operating Theatres functioning in pairs • Fire mode - operate AHUs by shut down A/C to the affected area, and exhaust. operate the AHUs on floors above and below with positive pressure. air pressurisation of the fire stairs.

The Operating Theatre units show a hangover from the original D&C philosophy popular at the time under which the hospital was built – to minimise capital cost at the expense of future running costs. The hospital has been paying the additional energy cost for 25 years of re-heating air conditioned air in these theatres.

For instance it was observed that theatre 1 had a set point of 24.1°C (attaining 22.9°C with 85% reheat) while the other theatre (no.2) supplied from this A/C unit was set at 19.7°C (attaining 19.5°C). The AHU was working hard to cool the air for theatre 2, then re-heating the cooled air for theatre 1.

Chilled Water System:

When the Psychiatric Block was constructed in 1992, a stand-alone chiller system was provided, with space for a second chiller system adjacent. In the refurbishment of 1998/99, the new chiller station was installed in the basement of Block A. This new chiller plant was not interconnected to the original Psychiatric Block plant. When Block D (Rehab block) was constructed, the decision was made to use the “spare” capacity in the main chiller plant, so no new chiller was installed.

The situation now is that – • The main chiller plant capacity is about 10% overloaded for the current peak

summer demand, • The mental health plant is adequate in capacity, but has become aged. It has no

back-up for plant failure, and is not interconnected to the main plant, • Growth in demand and additional services will further erode system capability, • There is no spare capacity to allow for unit failure, or shut down for servicing.

RTI Folio No. 3

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Current System Initiatives:

The chiller system capacity was investigated and reported upon in 2005 by Sinclair Knight Merz (consulting engineers), who recommended:

1) Provide connections for a rental chiller facility (for breakdowns) – completed,

2) Interconnect chillers between Mental Health and Tower Blocks – under way,

3) Provide new chiller 860 kWR capacity – under way.

We endorse these recommendations, and point out that the modern centrifugal chillers to the tower block are significantly more efficient to operate than old reciprocating units, and will generate significant savings in running cost. The existing chillers to the Mental Health block should be used as a last resort (eg. in breakdown situations).

These initiatives are now under way or completed. We support this action.

It is understood that the increased chiller capacity will be provided by a new 1380kWR centrifugal chiller in the Mental Health plant room (possibly a Power-Pax oil free type), located adjacent to the old TRANE reciprocating unit, and with the TRANE unit retired to emergency stand-by status. The new cooling tower for this chiller should be located on the roof to Block C (using the existing condenser water risers).

Provided the chillers are interconnected (recommendation 2 above), it would then be possible to isolate the chiller and tower (for service) without disrupting air conditioning to the Mental Health building.

The new chiller plant should be fully integrated into the site DDC controls and BMS, in order to take advantage of the energy economies possible with an integrated plant system.

RTI Folio No. 4

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(c) CHILLER PLANT

Main Chiller Plant:

In the refurbishment of 1998/99, a new chiller station was set up in the basement (Lower Ground level) of Block A. This consists of:

Chiller #1 YORK centrifugal 1,380 kWR model YTH3J3B25CMG Chiller #2 YORK centrifugal 1,380 kWR model YTH1C1E15CKJ Chiller #3 YORK centrifugal 1,380 kWR ” Chiller #4 YORK screw 650 kWR (light load screw unit, on stand-

by generator power)

Chillers 2, 3 and 4 are 9years old and are in good condition. Chiller #4 is a light load chiller, and is connected to the stand-by generator for operation in case of power failure. All units operate on refrigerant R-134.

The original Chiller #1 failed a few years ago, and was replaced about 2 years ago with a new YORK unit nominally the same capacity. The new unit is significantly more efficient than units 2 and 3 (on full load it draws about 450 amps, against 500 amps for the other 2 chillers).

At the time of the failure Kim Fetter was very concerned at the ability of the remaining chillers to meet the cooling load. One of the current system initiatives is to provide space and connections for a rental chiller facility (for breakdowns) – this has been completed.

Main Chillers (chiller #4 on right)

RTI Folio No. 5

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Mental Health Unit Chiller Plant: (Previously referred to as the Psychiatric Block)

Chiller #1 TRANE reciprocating 500 kWR model C60D135D

The original chiller comprises an assembly with dual reciprocating compressors. It was installed in this building when it was constructed in 1992. This unit is about 15 years old, and while still operating satisfactorily, suffers from some shortcomings.

(1) Unit is approaching its economic life and is to be expected that reliability problems will increase.

(2) The system to this building is not interconnected to the main plant, so has no backup in case of failure.

(3) Energy running costs for this plant would be significantly above costs for operating on the centrifugal chillers.

(4) Unit uses refrigerant R-22, which is approaching its phase-out date.

TRANE Chiller in Mental Health Block

We would recommend that the practicability and cost of interconnection with the main plant be investigated, and that the TRANE chiller be replaced with a new high efficiency chiller (or dual chillers if interconnection could not be achieved).

One of the current system initiatives is to interconnect the chillers between Mental Health and Tower Blocks – this action is under way.

Another of the current system initiatives is to increase chiller capacity. It is understood that a new centrifugal chiller to be installed in the Mental Health plant room , and with the TRANE unit retired to emergency stand-by status. The new cooling tower for this chiller should be located on the roof to Block C (using the existing condenser water risers).

The new chiller plant should be fully integrated into the site DDC controls and BMS, in order to take advantage of the energy economies possible with an integrated plant system.

RTI Folio No. 6

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Main Cooling Towers:

Cooling Towers 1, 2 and 3 are AQUACOOL model MSS275. The fans are fitted with VSD control on the fan motors to minimise energy usage. The towers are about 9years old and are in relatively good condition.

In common with all cooling towers in these days of restricted water supply, it is required that the maximum use is made of the water. This requires high quality water treatment and monitoring controls, with (preferably) monitoring from the DDC control system.

It is recommended these water controls be upgraded to Aquarius or similar systems able to achieve control with 5 concentrations of TDS, and with external monitoring.

Mental Health Cooling Tower:

The Cooling Tower for the Mental Health Block is located on the roof of Block C. It is a BAC steel unit and has reached the end of its economic life. It should be replaced with a new fibreglass tower similar to the Main Cooling Towers.

The base pan has corroded, so there is now a leak from one of the seams. Similarly the end louvers need replacing, and the fill is the original as originally installed. The tower is a single unit which is required to operate continuously, so there is little chance of regular maintenance. The water treatment control and monitoring facilities are not modern high performance type, nor is there an energy saving VSD on the fan motor.

BAC Tower (note water leak to roof below)

RTI Folio No. 7

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Chilled and Condenser Water Piping:

The Tower Block chilled water piping system is generally as originally installed, in 1997. The chilled water system consists of a primary pumping system, with modern VSD drives fitted to both the chilled water and condenser water pumps. Each chiller has its own matching chilled water and condenser water pump. The Psychiatric Block chilled water piping system is as originally installed, in 1992. The chilled water system consists of a primary pumping system, with oversize condenser water line rising to the Cooling Tower on the level 9 roof. There are no energy saving VSDs to the pump motors (both chilled water and condenser water systems). The condition of the reticulation would be subject to a detailed assessment, which is beyond the scope of this investigation. It is noted the condenser water reticulation is in spiral welded stainless steel, however the chilled water lines are not accessible to view. It is recommended that ultrasonic (or similar) testing be carried out to the major trunk piping, and in particular the chilled water and condenser water headers. Also we recommend that the major isolating valves be tested, to ensure that they actually seal off correctly

RTI Folio No. 8

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(d) MAIN AIR CONDITIONING and VENTILATION UNITS

Air Handling Units – Typical Tower Floors:

• Restricted by plant space allocations • Floor by floor systems – generally 2 AHUs per floor • Multi-zone systems – high maintenance to face & bypass dampers • Difficult to get to O.A. grilles for service and cleaning (both Block A and Block

B/C units). • Motorised dampers inspected appear well maintained and operational. These are

high maintenance items.

Air Handling Units – Operating Theatres (in plant rooms levels 1 and 2):

• Operating Theatre units are connected in pairs (refer “Functional design of Systems” above). This is energy intensive and is a significant design shortcoming.

We recommend that new Air Handling Units be provided, eight in total (in place of the existing 4), one for each Operating Theatre.

• Existing Operating Theatre units are 100% fresh air units, with exhausts discharging above the 9th floor roof. This is very energy intensive (particularly when they are in “stand-by” mode).

We recommend that new AHUs be designed using recirculation of a portion of the air (through HEPA filters), with provision left so that the AHUs can be operated as all fresh air when required.

Air Handling Units – Level 1 Plant Room:

• These are the oldest units in service in this hospital, being over 20 years old. The two larger units are at present being replaced by new AHUs.

• The two units serving O.T.s 5 – 8 are recommended to be replaced (refer above).

• The other 4 AHUs in the plant room should be scheduled for replacement in the next few years. Similarly the AHU C-1G serving the Recovery area should be scheduled for replacement.

Air Handling Units – Lower Ground Plant Room:

• The two major units serving the ground floor were installed in 1985, and are over 20 years old.

• The units are still functional, but are showing their age. They are showing depreciation and corrosion typical of their age, the dampers are prone to jamming and breakdown, and they are generally now a high maintenance item.

We recommend that new Air Handling Units be provided, one for each of the existing functional areas.

RTI Folio No. 9

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Ductwork and Air Outlets:

• The ducts to the lower tower floors date from the mid-1980s and include internal insulation. The hospital engineers advise they have an ongoing program (as funds permit) to seal this insulation with anti-mould FOSTER 40-20. This program should be accelerated to cover all of the existing internal insulation.

• The other (not internally insulated) ducts should have a thorough cleaning carried out.

We recommend that an internal inspection be made of the ducts by a specialist duct cleaning company (using remotely controlled camera), and quote be obtained for the complete cleaning and anti-mould treatment of the existing ductwork.

Fire Mode Operation:

• Generally the tower block operates in “sandwich” pressurisation mode. The affected floor has the AHU shut down on fire alarm and the floor is exhausted through a floor exhaust fan. The floors above, below and at the other end of the floor all run on all outside air mode – producing a positive pressure differential with the fire alarmed area.

• Tower block areas A, B and C are all fire isolated from each other on each level.

• Fire stairs – stair pressurisation systems to 3 sets of stairs of Tower Block.

We recommend that a NEBB certified company be engaged to carry out a complete check of the operation of all motorised dampers, check the correct operation of the fire mode systems, and check the operation of the stair pressurisation systems.

(e) CONTROLS

• TAC digital controls have been installed to blocks A, B, and C, and Block D.

• These controls include the basic functions to control the plant and report correct operation, alarms and malfunctions.

• The system does have extended energy monitoring capability, such as monitoring energy use as it happens, and operating the plant to inbuilt algorithms designed to minimise energy consumption. However the points required to monitor the water metering and energy sub-meters should be upgraded to “intelligent” type to give live readings of energy and water use as it happens and when action can be taken to improve or correct system operation. The associated software to monitor and display are also required. These capabilities should be extended.

• The TAC control system has not been extended to cover the Mental Health building. At present this building is not covered by the site wide TAC reporting functionality. It is recommended this functionality should be extended to the Mental Health building.

RTI Folio No. 10

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(f) BOILERS and STEAM SUPPLY

Boilers:

• 2 x MaxiTherm gas fired boilers each rated at 1MW (installed in 1998 refurb).

• Units are in good condition, but are under-utilised. It is recommended they be left as is.

Units serve – Sterilisers (3 pre-vac in CSSD + 4 instrument in Op.Th’s.) Domestic Hot Water Calorifiers (2 – when both are operational) Kitchen (3 kettle boilers, D/washer, etc) Humidifiers to 4 Op.Th. AHUs.

The boilers were originally sized to include heating to the AHU air heater coils – these have now been converted to electric element heating.

One of gas fired MAXITHERM boilers

RTI Folio No. 11

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(g) OTHER SERVICES

Sterilizers:

• CSSD in block 3B – 3 x Getinge pre-vacuum sterilisers – units OK.

• Operating Theatres – 4 x instrument sterilisers – units OLD.

Medical Gases and Suction Plant:

• New bulk LOX plant installed 1996, plus existing bulk tank.

• The medical air plant consists of 2 Ingersol-Rand horizontal reciprocating units, model ESH-1-NL-2, and associated refrigerated dryers. The date on the nameplate is 1985.

• Suction plant consists of two systems, each with 3 suction motor/pump units (ROTOMIL B300), each with 2 Compare ultra filters. The date on the nameplate is 1987.

Units are in fair condition for their age, and can be retained, but they will require increasing service and maintenance to prolong their life.

Medical air plant

Hot Water service

• 2 x steam Calorifiers are installed with Block A (so are about 30 years old). These are used for provision of “domestic” hot water.

• Both have had tube bundles repaired/replaced. However one has corrosion leaks in the pressure shells, and is unserviceable. This leaves one serviceable unit at present. These units are at the end of their useful life.

Because of the size of the gas fired steam boilers and the requirement to keep them loaded, it is recommended that the steam calorifiers be replaced with new steam heated units.

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Hot water Calorifiers (one on left is out of service)

Cold Rooms

• All the cold rooms and freezers (4 cool rooms, 1 freezer and 1 ante-room) to the kitchen have been re-built recently.

• The refrigeration units were changed from air cooled type to condenser water cooled type in the refurbishment of 1998.

• Condition is considered satisfactory.

Domestic Water Pump and Storage

• The existing pump for pumping to the level 10 storage tanks is obsolete and requires replacing with new dual (duty plus stand-by) units.

• The water pressure on levels 9 and 8 is not good, since the water storage tanks are only 1 level above. (This precludes some functions on these floors, eg dialysis). It is suggested that a second storage tank is provided located higher in the building to give adequate supply head pressure to these floors only.

• Alternatively a pump booster system could be used for the top 2 floors, however this is wasteful of operating energy.

Room Air Conditioners

• The various buildings have a multitude of minor room air conditioners of various styles (room unitary, splits, ceiling cassettes, etc). The hospital engineers have an asset listing of:

34 units in tower block 117 units in various other buildings on the site.

We have not attempted to investigate these in this report.

RTI Folio No. 13

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(h) GOLD COAST HOSPITAL - RECOMMENDATIONS Item Description Priority Status Estimate

1 Provide connections for a rental chiller facility (for breakdowns completed 2 Interconnect chillers between Mental Health and Tower Blocks under way

3 Provide new chiller 860 kWR capacity see 3(a)

3(a) Provide new high efficiency chiller 1400kWR capacity, and retire TRANE unit. under way

4 Controls - Integrate new chiller plant into the site DDC controls and BMS High incl in 3(a)

Controls - Integrate Mental Health plant into TAC system

- Additional control to Op Th systems $80,000$40,000

5 - Water and electrical energy metering, and 'live' energy reporting

software High $50,000

6 Provide new high performance Cooling Tower water controls (Aquarius or similar system) to existing Cooling Towers High $20,000

7 Replace BAC cooling Tower (to Mental Health) with a new fibreglass tower similar to the Main Cooling Towers. under way see 3(a)

8 Include high performance Cooling Tower water controls (Aquarius or similar system) to new tower to Mental Health High $20,000

9 Carry out ultrasonic (or similar) testing to the major chilled water and condenser water piping, and in particular the water headers High $20,000

10 Test the major chilled and condenser water isolating valves to ensure that they actually seal off correctly Medium $8,000

11

Provide eight new Operating Theatre (OT) AHUs (in place of the existing 4), one for each Theatre. Design new AHUs to O.T.s using recirculation of a portion of the air (through HEPA filters), but with capability to be converted to all fresh air operation when required. High $400,000

12 Schedule 4 AHUs in the 1st floor plant room for replacement in the next few years, similarly the AHU serving the Recovery area Medium $220,000

13 Schedule 2 new AHUs be provided in LG plant room, one for each of the existing functional areas. Medium $150,000

14

Arrange for an internal inspection of the ducts by a specialist duct cleaning company (using remotely controlled camera), and obtain quote for complete cleaning and anti-mould treatment High $25,000

15 Budget for duct cleaning and anti-mould treatment Medium $100,000

16

Engage a NEBB certified company to carry out a complete check of the operation of all motorised dampers, check the correct operation of the fire mode systems, and check the operation of the stair pressurisation systems High $20,000

17 Provide two new steam heated hot water calorifiers High $50,000

18 Provide 2 new potable water pumps (duty plus stand-by) to the existing level 10 storage tanks. High $25,000

19 Provide a second potable water storage tank located higher in the building to give adequate supply head pressure to floors 8 and 9 Low $12,000

High Priority (excl GST): $750,000

Medium Priority (excl GST): $490,000

Items 1, 2, 3(a), 4 and 7 are under way as a result of the recommendations of a report by consulting engineers SKM. We endorse these actions as a necessary first step in any upgrade.

RTI Folio No. 14

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RTI Folio No. 15

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GOLD COAST Hospital Review - Mechanical-27441175€¦ · Design Life of mechanical equipment: Major...

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