HALLORAN ICE ICE RINK AND RINK REFRIGERATION SKATING RINK SYSTEM EVALUATION

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Final Report – October 14, 2016 Existing Systems Observations and Conditions Assessment In response to the City of Cleveland request for an evaluation of the Halloran Ice Skating Rink, in particular, the rink refrigerating system, CJL Engineering, in partnership with Osborn Engineering visited the site on Thursday, September 15, 2016. In attendance at this initial site visit were: Sam Gissentaner: Commissioner; Department of Public Works Thomas Nagel: Commissioner; Department of Public Works Richard Seitz: Chief Architect: Mayor’s Office of Capital Projects Steve Shipp: Mr. Spronz: Director Dan Galli: Osborn Engineering Jim Vizzini: CJL Engineering John Burley: Everything Ice Ian Bennett: Everything Ice The following is an outline of observations, early phase recommendations and long term upgrade recommended actions: Based on the received drawings, the existing cold slab ice floor was installed in 1987 / 1988. The existing cold slab utilizes what is commonly referred to in the industry as a “flooded refrigerant” or “Holmsten” system. The term “Holmsten” comes from the name of the company that developed the “flooded refrigerant” approach to cooling an ice slab. The term “flooded refrigerant” more accurately describes the installation/design in that cold refrigerant is pumped through all the in-slab tubing to generate an ice surface. Systems such as this have historically been abandoned due to the mass of refrigerant required, the phase out of R-22 refrigerant, replacement refrigerant cost and the “not as advertised” energy efficiencies when compared to the now common pumped glycol systems. The rink refrigeration system consists of the following main components which all date to 1987 / 1988.

R-22 chiller, manufactured by Holmsten, dual compressors, 128 tons cooling capacity.

Chiller is functional, but utilizes a phased out refrigerant and is not as efficient as the newer families of available chillers.

Evaporative condenser, manufactured by Baltimore Air Coil (BAC), 128 tons heat rejection capacity utilizing R-22 refrigerant.

Condenser has failed. Refrigerant leak last year cost the City approximately $50,000 to top off the leak. Given the priority need for the ice sheet for use by Thanksgiving, an emergency upgrade project has already been put in place. Refer to 9/12/16 Phase-I report and design documents attached.

Evaporative condenser sump tank (BAC) Evaporative condenser water supply pump, 2HP

The rink floor does not have a sub-floor heating system. These are now standard with rink floor design and are used to prevent permafrost heaving of the cold slab. Heaving was observed at the near header trench area between the mechanical room and the cold slab ice sheet. The ice slab is detailed at 9” thick. This includes two layers (4” total) of insulation and a 5” concrete cold slab. 2” supply and 4” return refrigerant pipe headers are detailed as is the 5/8” O.D. refrigerant tubing

HALLORAN ICE ICE RINK AND RINK REFRIGERATION SKATING RINK SYSTEM EVALUATION

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throughout the entire slab. Tubing is noted to be spaced on 5” centers and made of steel (0.035” wall thickness). It is surmised that last year’s refrigerant leak and its subsequent costly replacement was the result of the failed evaporative condenser. There is however justifiable concern that a similar leak event, should it occur in the floor tubing could put the rink (City) in a very similar and undesired position. Given that fact that this system in its entirety holds over 6,000 pounds of the discontinued R-22 refrigerant, plans should be made for the eventual changeover of this rink to a more conventional and more efficient type. Lighting is mercury vapor high bay type fixtures and consideration should be given to conversion to a much more efficient LED system. The dasherboard system is in very poor condition, having been exposed to the weather for many continuous years. We recommend full replacement of the dasherboard system. Recommendations:

1. Replace existing failed evaporative condenser. This is ongoing as previously referenced.

2. Remove existing chiller, piping, rink slab and dasherboards.

3. Install a new rink refrigeration system to include the following:

Chiller Glycol piping mains and headers Sub-floor heating (permafrost prevention) Insulation Cold slab (thickness to be confirmed based on anticipated “non-ice” events) Sub-floor and cold slab piping shall be polyethylene tubing Dasherboards

Estimated Probable Cost of Construction Recent rink rebuild projects have been referenced and to rebuild the existing floor/piping and refrigeration system as described is roughly estimated as follows: Chiller and Mechanical Room Piping: $300,000 New Ice Slab Construction: $650,000 Dasherboards: $195,000 Controls: $40,000 Sub-Total: $1,185,000 Contingency: (Design, Escalation to 2017, etc.) $59,000 Engineering Design and Construction Administration Fee: $75,000 Estimated Project Total: $1,319,000 If a project of this comprehensive magnitude is undertaken, it would additionally be recommended to upgrade the lighting to more efficient and much longer lasting LED type. A project to relight the rink is estimated to cost $62,000. Improved efficiency and daylight controls are estimated to save approximately $7,000-$9,000 /year in lighting power costs. This does not figure in the additional savings due to the longer life of the fixtures and the costly lamp replacement associated with the existing mercury vapor (and their disposal).

HALLORAN ICE ICE RINK AND RINK REFRIGERATION SKATING RINK SYSTEM EVALUATION

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Schedule This time of year is the appropriate time to plan/ design a potential rink upgrade project due to the anticipated start of construction being as soon as the ice sheet is taken down in the spring. To assist the City in planning, a tentative timeline schedule is hereby attached.

Proposed Halloran Ice Rink Renovations

7 14 21 28 5 12 19 26 2 9 16 23 30 6 13 20 27 6 13 20 27 3 10 17 24 1 8 15 22 29 5 12 19 26 3 10 17 24 31Description Start Date End Date

DesignDesign Development 12/19/2016 1/13/2017Construction Documents 1/16/2017 2/10/2017Bid/Review/Award 2/17/2017 3/10/2017Construction 4/3/2016 7/7/2017

2016 - 2017November December MarchJanuary February JulyJune April May

Pittsburgh 1555 Coraopolis Heights Road, Suite 4200, Moon Township, PA 15108 P: 412.262.1220 F: 412.262.2972

Johnstown 232 Horner Street, Johnstown, PA 15902 P: 814.536.1651 F: 814.536.5732

Youngstown 1044 N. Meridian Road, Suite B, Youngstown, OH 44509 P: 330.746.1360 F: 330.746.7000

cjl@cjlengineering.com www.cjlengineering.com

September 12, 2016 Daniel M. Galli Manager of Construction Engineering Osborn Engineering 1100 Superior Avenue, Suite 300 Cleveland, OH 44114 REFERENCE: Halloran Park Ice Skating Rink Improvements CJL Project No. 16-0543 Dan, It was a pleasure to meet up with you and the rest of the City representatives on Wednesday, September 7, 2016. Based upon our initial walk through, and with an understanding that Tom Nagel needs an ice sheet by Thanksgiving, we would recommend a two phased approach as outlined below. Phase I: Replace the damaged evaporative condenser. Notes:

Existing condenser is 28 years old, long past an ASHRAE defined life cycle, and in very poor condition. (See photos attached)

Any attempts to repair would most likely be a waste of money given the unit’s condition and age.

A new unit can be used with both the existing flooded refrigerant rink refrigeration chiller system and a future glycol floor refrigeration chiller system.

New evaporative condenser to be purchased by the City. Schedule, specifications and sketch attached with this cover.

Installation will be procured by the City thru their list of approved mechanical contractors.

Estimated cost of the new evaporative condenser: $25,000 Estimated cost of the installation: $9,000

Phase II: Eventual replacement of the balance of the rink refrigeration system. Notes:

Replace Chiller. Remove existing dasherboards, floor and piping. Install a new sub-floor heating system to prevent permafrost heaving. Install a new rink floor utilizing polyethylene (PEX) tubing and a glycol piping system. Install new dasherboards A project of this scope is estimated to cost in the range of $1,000,000.

The additional details and outline of work scope to accommodate the Phase I project are hereby outlined in Appendix items “A” thru “F”.

We would normally provide a report outlining all the pieces/parts of the existing system including comments on condition expected life, retrofit options, etc. Given the compressed time frame that the City presented to us on Wednesday, we made the judgement call to present the data in a different format to better support the immediate needs of the City of Cleveland. Should anyone require a more conventional report, we will be glad to follow up in due course. Should you or representatives of the City have any questions or require additional information, please do not hesitate to contact us. Regards,

James M. Vizzini, P.E. Managing Partner LEED Accredited Professional JMV/tek

Attachments (Appendix “A” thru “F”)

APPENDIX “A”

DESCRIPTION OF PHASE - I WORK

1. Valve off / isolate refrigerant from the existing evaporative condenser.

2. Reclaim refrigerant from evaporative condenser.

3. Disconnect existing refrigerant and condenser water piping to allow for removal of existing evaporative condenser and installation of new.

4. Sand, prime and paint existing condenser post and rail structural frame in preparation for setting the new evaporative condenser.

5. Accept new evaporative condenser (purchased by the City) and set on existing structural support frame. Installing contractor shall provide and install vibration isolators. Coordinate with condenser manufacturer.

6. Repipe as shown on sketches included in Appendix “E”.

7. Change out existing RTD floor temperature senor and replace with thermocouple (existing control wiring can remain). Thermocouple temperature controller shall be model ETC-111000 as manufactured be Ranco or equivalent.

APPENDIX “C”

Halloran Park Ice Rink 236333 - 1

SECTION 236333 – EVAPORATIVE CONDENSER

PART 1 - GENERAL

1.1 GENERAL

A. General: Furnish one factory assembled evaporative condenser of counterflow blow-through design, with single side entry, conforming in all aspects to the specifications and schedule as shown on the plans. Installation shall be by a yet to be signed mechanical contractor.

1.2 CAPACITY

A. Capacity: The evaporative condenser shall be warranted by the manufacturer to have condensing capacity of 96 tons heat rejection, operating with R-22 refrigerant and 105ºF condensing temperature and 76ºF entering wet-bulb temperature.

1.3 WARRANTY

A. Warranty: The manufacturer’s standard equipment warranty shall be for a period of one year from the date of startup. The manufacturer shall, in addition, provide a 5-year mechanical drive warranty covering the fans, fan shafts, bearings, sheaves, supports, and fan motors.

1.4 FACTORY TESTING

A. Factory Testing: Equipment manufacturer shall be capable of testing the operation of the condenser in the manufacturer’s own test facility. Test facilities shall be capable of simulating design conditions, including but not limited to design wet-bulb, airflow, refrigerant mass flow rate, refrigerant condensing temperature, and total heat rejection.

1.5 QUALITY ASSURANCE

A. Quality Assurance: The manufacture shall have a Management System certified by an accredited registrar as complying with the requirements of ISO-9001 to ensure consistent quality of products and services. Manufacturers that are not ISO-9001 certified shall provide an additional one-year warranty to the customer at no additional cost.

PART 2 - PARTS

2.1 EVAPORATIVE CONDENSER MATERIALS AND COMPONENTS

A. General: All steel panels and structural elements shall be constructed from heavy-gauge, G-235 (Z700 metric) hot-dip galvanized steel, with cut edges given a protective coating of zinc-rich compound.

2.2 COIL CASING ASSEMBLY (SPLIT CIRCUIT)

A. The evaporative condenser shall include a coil casing section consisting of a split circuit refrigerant condensing coil, a spray water distribution system, and drift eliminators as indicated by the manufacturer.

1. The split circuit refrigerant condensing coil shall be fabricated of all prime surface steel at the manufacturer’s own facility, and hot-dip galvanized after fabrication.

APPENDIX “C”

Halloran Park Ice Rink 236333 - 2

a. The split circuit refrigerant condensing coil shall be tested at 375 psig (2,687 kPa) air pressure under water.

b. The split circuit refrigerant condensing coil shall be designed for low pressure drop with sloping tubes for free drainage of liquid refrigerant.

c. The split circuit refrigerant condensing coil shall be ASME B31.5 compliant and coils shipping into Canada shall be supplied with a CRN.

2. Water shall be distributed evenly over the coil at a minimum flow rate of 4.5 gpm/ft2 (3.1 lps/m2) to ensure complete wetting of the coil at all times by large-diameter, non-clog, 360° plastic distribution nozzles spaced across the coil face area in Schedule 40 PVC spray branches. Nozzles shall utilize a two-stage diffusion pattern to provide overlapping, umbrella spray patterns that create multiple intersection points with adjacent nozzles.

a. Directional nozzles shall not be acceptable. b. Spray branches and nozzles shall be held in place by snap-in rubber grommets,

allowing quick removal of individual nozzles or complete branches for cleaning or flushing.

c. Nozzles shall have a minimum of 0.25” (6.35 mm) protrusion inside the spray branches to ensure unimpeded water flow between regular cleanings of the water distribution system.

3. Removable PVC drift eliminators shall be positioned to prevent moisture from leaving the evaporative condenser and incorporate a minimum of three (3) changes in air direction.

2.3 BASIN ASSEMBLY

A. The evaporative condenser shall be modified to accommodate the use of an independent sump and pump for recirculating water (existing to remain)

1. The recirculating water pump, steel strainer, make-up valve, and integral bleed line assemblies shall be omitted from the evaporative condenser scope of supply.

2. The evaporative condenser shall be supplied with a cold water basin outlet sized and located as indicated on the drawings for gravity drain to the remote sump.

3. The water distribution system shall have an operating pressure of 2 psig (115 kPa) at the evaporative condenser spray water inlet connection.

B. Air shall enter the evaporative condenser through the centrifugal fan assemblies and integral air plenum.

1. Fans and motors shall be located in the dry entering air stream to provide greater reliability and ease of maintenance.

2. Fan housings shall have curved inlet rings for efficient air entry and rectangular discharge cowls that extend into the pan to increase fan efficiency and prevent water from entering the fans.

3. Fan housings on units more than 8’ wide shall be split to facilitate the removal of the fan shaft.

4. Fan(s) shall be heavy-duty, centrifugal flow type mounted on a steel shaft with heavy-duty, self-aligning, relubricatable bearings with cast iron housings, designed for a minimum L10 life of 40,000 hours (280,000 hours average life).

5. Fan motor(s) shall be totally enclosed fan cooled (TEFC) type, premium efficiency/VFD ready with a 1.15 service factor, suitable for 460 V, 3 phase, 60 Hz electrical service and shall be mounted on an easily adjusted, heavy-duty motor base. Fan motors shall comply with NEMA Standard MG 31, Section IV, Part 31.

END OF SECTION 236333

APPENDIX “D”

LIST OF SUPPLIERS Baltimore Air Coil: FES-Ohio Inc. 4030 Mount Carmel Tobasco Road, Suite 227 Cincinnati, OH 45255 Phone: (513) 772-8566 Contact: Joe Rubino Email: Jrubino@fesohio.com Evapco: Pier Associated Inc. 2317 Manchester Road Akron, OH 44314 Phone: (800) 627-PIER Contact: Jim Pier Jr. Email: jpier@pierhvac.com Marley: AERO Sales 26313 Clemmens Road, Suite 2-J Westlake, OH 44145 Phone: (440) 250-9940 Contact: Joel Weissinger Email: info@aerosalesinc.com

APPENDIX “F”

Heaving at header trench Evaporative condenser - top view

Evaporative condenser - near endRink - Lengthwise

Chiller Evaporative condenser - far end

APPENDIX “F”

Evaporative condenser - top view Heaving at header trench

ChillerChiller

Remote water sump Remote water sump

APPENDIX “F”

Floor temperature controller Chiller log

Chiller logChiller equipment tag

Evaporative condenser equipment tag