college –heating hot water engineering feasibility · pdf fileoption 1 – retain...

Fullerton College – Heating Hot Water Master Planning Engineering Feasibility Study

Fullerton College

FinalNovember 3rd , 2017

North Orange County Community College District

Designing Your Sustainable Future

North Orange County Community College District – Fullerton College Heating Hot Water Master Planning Engineering Feasibility Study November 3, 2017 Final Page 1

Table of Contents 1 EXECUTIVE SUMMARY ...................................................................................................................... 2

2 EXISTING CONDITIONS ...................................................................................................................... 6

2.1 Building 1200 Steam Plant ......................................................................................................... 6

2.2 Wilshire Heating Hot Water Plant ............................................................................................. 9

3 ANTICIPATED CAMPUS GROWTH AND MODERNIZATION ............................................................ 11

3.1 Option 1 – Retain Existing Steam Plant & Add Decentralized Boilers at New Buildings ......... 12

3.2 Option 2 – Decentralize the Boilers Down to the Building Level ............................................. 13

3.3 Option 3 – Centralized Heating Hot Water Plant with a Campus Distribution Loop ............... 16

3.3.1 Phase I – Heating Hot Water Central Plant & Campus Loop to Building 100 .................. 17

3.3.2 Phase II – Heating Hot Water Campus Loop from Building 100 to Building 1000 ........... 20

3.3.3 Phase III – Heating Hot Water Campus Loop from Building 1000 Back to Central Plant 21

4 ENGINEERING COST ESTIMATES ..................................................................................................... 23

4.1 Engineers Opinion of Cost ....................................................................................................... 23

4.1.1 Option 1 Costs – Retain Existing Steam Plant & Add Decentralized Boilers .................... 23

4.1.2 Option 2 Costs – Decentralize the Boilers Down to the Building Level ........................... 24

4.1.3 Option 3 Costs – Centralized Heating Hot Water Plant with a Campus Loop ................. 29

5 CONCLUSIONS & RECOMMENDATIONS ......................................................................................... 31

6 APPENDIX A ..................................................................................................................................... 32



1 EXECUTIVE SUMMARY BSE Engineering has been retained by Fullerton College to conduct a heating hot water master planning engineering feasibility study. In order to determine the best solution for addressing the heating hot water requirements of the master planned buildings and major retrofit projects, the following three possible options were studied:

Option 1 – Retain the existing steam plant & add decentralized heating hot water boilers at the new buildings and major retrofits as needed.

Option 2 – Decentralize the boilers down to the building level – provide building level heating hot water boiler plants.

Option 3 – Provide a new centralized heating hot water boiler plant with a distribution loop around the campus.

Figure 1 ‐ Fullerton College Facilities Master Plan



The engineer’s opinion of cost associated with the proposed three options are:

Option 1 ‐ $1,159,058

Option 2 ‐ $2,795,457

Option 3 ‐ $4,915,447

There are a total of nineteen (19) existing buildings on campus that are being analyzed in this study as shown in Table 1. Per the Campus Master Plan, five (5) proposed future buildings will be added to the campus as listed in Table 2.

Table 1 ‐ Existing Buildings

Building Number Building Name Heating Load1

[MBH] Boiler Plants

100 Administration 882 1200 Steam Plant

200 College Center / Food

Services 600 1200 Steam Plant

300 Business & Computer Info 282 1200 Steam Plant

400 South Science 2,500 1200 Steam Plant

500 Applied Arts / Humanities 800 1200 Steam Plant

600 North Science 1,128 1200 Steam Plant

700 Technology & Engineering 3,030 1200 Steam Plant

800 Library Learning Resource

Center 700 1200 Steam Plant

900 Technology & Engineering 315 1200 Steam Plant

1000 Fine Arts / Art Gallery 802 1200 Steam Plant

1100 Music 875 1200 Steam Plant

1200 Physical Education 4,587 1200 Steam Plant

1300 Theater Arts 1,155 1200 Steam Plant

1400 Classroom Office Building 785 1400 HHW Plant

2000 Student Services / TV 1,688 2100 HHW Plant

2100 Wilshire Auditorium 676 2100 HHW Plant

W100 Wilshire Continuing Ed 390 2100 HHW Plant



Total: 22,195 Footnotes:

1. Existing data based on research of available engineering drawings and site investigations.



Table 2 – Planned Future Buildings

Future Building Name Planned Square

Footage [ASF]

Estimated Heating Load1 [MBH]

Instructional Building 47,900 1054

Maintenance and Operation Building 13,200 290

Welcome Center 29,470 648

Performing Arts Complex 25,658 564

Instructional Building South of Chapman 35,200 744

Total: 151,428 3,331 Footnotes:

1. Estimated Heating Load based on 22 BTU per square foot.

RECOMMENDATIONS:

Based on our findings, the existing steam boiler plant does not have adequate spare capacity

to serve the needs of the new proposed buildings. The existing plant is very inefficient and

the existing distribution piping has reached the end of its useful life. Old systems pose

unnecessary risk to the campus in terms of potential failures with the added costs due to high

maintenance and operation. This means Option 1 is not a viable option and our office

recommends against it.

Further, when comparing Options 2 (decentralized) versus Option 3 (centralized), BSE

Engineering recommends Option 2 for the following reasons:

1. Option 2 is $2,119,990 less expensive than Option 3 ‐ $2,795,457 vs. $4,915,447

2. Option 2 is more efficient than Option 3 – Even though the boiler equipment

efficiencies between the two options would be similar, Option 3 will have additional

pumping operational costs due to longer pipe runs associated with increased pipe

friction. Also Option 3 would also have higher piping heat losses due to longer pipe

runs.

3. Option 2 is easier to implement in phases with minimal impact to the campus

operations.

Other Comments:

The northern portion of campus at the Horticulture buildings are all currently served by direct

expansion (DX) equipment as the primary source of heating and cooling. Given the relatively

remote location, it is recommended to maintain those buildings on DX equipment.



The Wilshire buildings are served by a satellite heating hot water boiler plant located in the

basement of building 2100. Based on our calculations, the existing heating hot water plant

has adequate capacity to handle the replacement of building 2000 with the new anticipated

Performing Arts Complex.

Building 1400 has a newer existing decentralized heating hot water boiler plant. It is

recommended to retain this decentralized plant until the plant has reached the end of its

useful life and Boiler Plant #9 is installed capable of addressing Building 1400 loads.

The anticipated new Instructional building (adjacent to building 1400) is recommended to be

provided with a temporary decentralized heating hot water boiler plant until when the Boiler

Plant #9 is installed capable of addressing the Instruction Building loads.



2 EXISTING CONDITIONS Heating for the Fullerton Campus is currently provided using one of the following three (3) systems:

1. Centralized Steam Boilers in Building 1200 – Serving the majority of the campus

2. Decentralized Heating Hot Water Boiler Plants – One serving the Wilshire Complex and another serving Building 1400

3. Direct Expansion (DX) Equipment – Serve areas not covered by the above.

The primary source of heating for the campus is generated by the central steam boiler heating plant located at building 1200. A satellite heating hot water boiler plant is located south of Chapman Avenue serving the Wilshire buildings, building 1400 consists of a decentralized heating hot water boiler and the remaining campus consists of DX equipment.

Refer to “Appendix A”, exhibit “M1.0 EXISTING CAMPUS STEAM & HHW PIPING DISTRIBUTION PLAN” for a map of the existing Fullerton College campus steam and heating hot water piping distribution plan and breakdown of heating systems.

2.1 Building 1200 Steam Plant The 1200 building central steam boiler plant consists of two 9,846 MBH steam boilers, with a total capacity of 19,692 MBH. The steam plant provides steam for comfort heating as well as some limited domestic hot water (DHW). Table 3 below provides a breakdown of each buildings heating load and domestic hot water load.



Table 3 ‐ Existing Building 1200 Steam Plant

Building Number

Building Name Area [ASF]

Heating Load1

[MBH]

DHW Load On Steam [MBH]

Heating Load BTU/SF

100 Partial 100 Building 1,986 82 0 41

100 Administration 16,624 800 0 48


Services 28,292 600 0 21

300 Business & Computer

Info 14,612 282 0 19

400 South Science 39,176 2,500 400 64

500 Applied Arts / Humanities

22,228 800 0 36

600 North Science 16,051 1,128 0 70

700 Technology & Engineering

53,539 3,030 221 57

800 Library Learning Resource Center

54,630 700 0 13

900 Technology & Engineering

22,886 315 0 14

1000 Fine Arts / Art Gallery 28,656 802 0 28

1100 Music 20,278 875 0 43

1200 Physical Education 61,802 4,587 3,300 74

1300 Theater Arts 25,658 1,155 0 45

Total: 406,418 17,656 3,921 43 Footnotes:


The steam is distributed through underground service tunnels to the basement of each building. At the building, the steam is converted to heating hot water and domestic hot water via shell and tube heat exchangers. Condensate is collected and then pumped back through the underground service tunnels to building 1200 central plant to be returned to the steam boilers. Refer to Figure 2 for existing steam distribution to main campus.



Figure 2 ‐ Existing 1200 Central Plant Steam Distribution

Based on the building 1200 steam boiler plant total capacity of 19,692 MBH and the buildings total combined heating load and domestic hot water load of 21,577 MBH (from Table 3), the existing plant does not have adequate capacity to serve any increased future loads. Additionally, based on our field observations, there is no available space within the existing steam boiler plant to add additional boilers in order to provide adequate capacity for the future loads.



In the current configuration only three (3) buildings (Buildings 400, 700, & 1200) are using the existing steam plant to generate domestic hot water. However, there is evidence that as many as eight buildings (400, 500, 700, 800, 1000, 1100, 1200, & 1300) have at one point or another generated domestic hot water with a shell and tube heat exchanger using the steam central plant. The other buildings have disconnected and abandoned the heat exchangers. These buildings are now producing domestic hot water with back‐up electric water heaters.

2.2 Wilshire Heating Hot Water Plant The Wilshire heating hot water boiler plant consists of two 1,260 MBH boilers, with a total capacity of 2,520 MBH. The boiler plant is located in the basement of building 2100 and provides heating hot water for comfort heating. Table 4 below provides a breakdown of each building heating loads.

Table 4 ‐ Existing Wilshire Heating Hot Water Plant

Building Number


Heating Load1

[MBH] Heating Load

BTU/SF

2000 Student Services / TV 25,139 1,688 67

2100 Wilshire Auditorium 8,804 676 77

W100 Wilshire Continuing Ed 6,000 390 65



Total: 54,583 3,754 69 Footnotes:


The heating hot water distribution is buried underground. Figure 3 show the approximate distribution of the existing heating hot water supply and return to each building. The heating hot water is distributed to building W100 from the roof of building W200.



Figure 3 ‐ Wilshire Heating Hot Water Distribution

Based on the Wilshire heating hot water boiler plant total capacity of 2,520 MBH and the buildings total combined heating load of 3,754 MBH (from Table 4), the existing plant does not have adequate capacity to serve any increased future loads. However, the existing heating hot water boiler plant has space available to add additional boilers or replace existing boilers with larger boilers in order to provide adequate capacity for the future loads.



3 ANTICIPATED CAMPUS GROWTH AND MODERNIZATION Based on the Facility Master Plan outlining anticipated projects, improvements, buildings scheduled for demolition, and the campus future needs, an estimated 151,428 square feet of conditioned floor area is projected to be added to the campus’s heating plants (Table 5), while an estimated 73,061 square feet of conditioned floor area is to be removed from campus (Table 6).

Three key options have been considered in this study to address the future campus growth impact on the campus heating plants:

Option 1 – Retain the existing steam plant & add decentralized heating hot water boilers on the new buildings and major retrofits as needed.

Option 2 – Decentralize the boilers down to the building level – provide building level heating hot water boiler plants.

Option 3 – Provide a centralized heating hot water plant with a looped around the campus piping configuration.

Refer to “Appendix A” for Fullerton College campus steam and heating hot water piping distribution plans.

Table 5 ‐ Future Campus Growth

Future Building Name Planned Square Footage

[ASF] Estimated Heating Load1

[MBH]

Instructional Building 47,900 1054

Maintenance and Operation Building 13,200 290

Welcome Center 29,470 648

Performing Arts Complex 25,658 564

Instructional Building South of Chapman 35,200 744

Total: 151,428 3,331 Footnotes:

1. Estimated Heating Load based on 22 BTU per square foot.



Table 6 ‐ Estimated Building Loads Removed

Building Number


Heating Load1

[MBH] Heating Load

BTU/SF

100 Partial 100 Building ‐1,986 ‐82 41

1100 Music ‐20,278 ‐875 43

1300 Theater Arts ‐25,658 ‐1,155 45

2000 Student Services / TV ‐25,139 ‐1,688 67

Total: ‐73,061 ‐3,800 52 Footnotes:


3.1 Option 1 – Retain Existing Steam Plant & Add Decentralized Boilers at New

Buildings The existing underground utility tunnels used for steam distribution are original to the campus and were constructed at the same time as the first buildings on campus were constructed, which was around 1936. There are no more recent records indicating the age and condition of the steam distribution piping in the utility tunnels. Campus facilities have indicated that there has been occasional small maintenance, replacement, and repair projects related to the steam distribution system. The original steam plant was relocated from the West side of campus to building 1200 in 2002, which makes the existing steam plant fifteen years old. Generating steam for heating hot water and domestic hot water in a Southern California warm climate is very inefficient. Additionally, there are no processes on campus where steam is actually required or necessary to have.

If the existing steam was to be continued to be used, decentralized heating hot water boiler plants would have to be added to address the increased loads associated with the addition of the proposed future buildings. These buildings include the proposed new Operations & Maintenance building, the Instructional building, and the new Welcome Center building.

The addition of decentralized boiler plants for the new proposed buildings would have an impact on the gas infrastructure and a detailed gas load analysis and coordination with the local gas utility company, Southern California Gas (SCG), would be required.

The Wilshire campus south of Chapman Avenue has an existing satellite heating hot water boiler plant located in the basement of building 2100. Existing building 2000 (Student Services / TV) is planned to be removed and replaced with a new proposed Performing Arts Complex. Based on our calculations, the difference between what is being removed and added are about even, which mean the existing heating plant can be used to serve the new Performing Arts Complex provided that its current location can be preserved.

The follow is list of pros and cons for retaining the steam plant and adding decentralized boiler plants to serve the new proposed buildings:



Pros:

There is no large impact on campus operations & infrastructure

Redundancies can be provided in decentralized boiler plants at new proposed buildings

Cons:

On‐going maintenance costs to repair, replace and maintain the old steam distribution piping system

On‐going maintenance costs associated with the maintenance and operation of the existing steam boiler plant

Emergency repairs are very expensive and impossible to plan

There is no existing redundancy in the existing steam plant if plant fails or pipe repairs are required

Cost to repair/maintain existing condensate reservoirs and pumps

Age and condition of existing steam piping is unknown, risk of costly steam pipe leak

Operating this steam plant is expensive and inefficient especially when a plant is also serving some domestic hot water loads

3.2 Option 2 – Decentralize the Boilers Down to the Building Level BSE had previously studied and presented two options of decentralizing the existing steam heating plant into building level heating hot water boiler plants. The “Fullerton College Decentralization of Existing Steam Heating Plant Engineering Study” was finalized and released in February of 2017.

To summarize, BSE had considered two options of the decentralization of the existing steam plant. Option A proposed to decentralize heating hot water into nine new heating plants as seen in Figure 4. Option B proposed to decentralize heating hot water into six new heating plants as in Figure 5. BSE had concluded that both options were viable with Option A being slightly more favorable.

The benefits of a decentralized heating hot water plant are as follows:

Allows the campus to move away from steam heating

Lower initial cost



Allows phasing and flexibility of implementation

Simpler system operations and easy maintenance

Smaller equipment is more readily available by multiple vendors

Figure 4 ‐ Option A ‐ Nine New Heating Plants



Figure 5 ‐ Option B ‐ Six New Heating Plants

The previous report did not take into account the Campus Master Plan, which now includes adding additional buildings to the campus. As seen on the “M1.1 FUTURE CAMPUS HHW PIPING DISTRIBUTION PLAN – OPTION 2” in “Appendix A”, Option 2 now includes a total of eleven (11) new decentralized heating hot water boiler plants in lieu of the originally anticipated nine (9) decentralized plants as presented in Figure 4.

The additional two (2) decentralized heating hot water boiler plants are for the future proposed M&O building (Boiler Plant #10) and Instructional Building, south of Chapman (Boiler Plant #11). The final location of the decentralized boiler plants shall be determined during the design of those buildings.

The future proposed Instructional building adjacent to building 1200 is scheduled to be designed and constructed in the near future. To allow for phasing of the decentralized boiler plants, it is recommended to add a temporary heating hot water boiler plant on the roof of the new Instructional building with provisions to connect the building to the decentralized boiler plant #9 in the future. To allow for this future connect, piping stub‐outs in concrete vaults needs to be provided during the design of the Instructional building.



Figure 6 ‐ Proposed Decentralized Boiler Plant #9

3.3 Option 3 – Centralized Heating Hot Water Plant with a Campus Distribution

Loop This option requires a phasing plan to develop a centralized heating hot water plant and campus distribution loop. Based on the future master plan, buildings 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1200, proposed New Welcome Center and Maintenance & Operations buildings are included in the centralized plant option. Buildings 1100 and 1300 are planned to be demolished based on the campus master plan.

The buildings not included in the centralized heating hot water plant are buildings 1400, 2000, 2100, W100, W200, W300, and the planned new Instructional buildings (Instructional Building and Instructional Building south of Chapman).

The benefits of a central heating hot water plant are as follows:

Air quality management from boiler equipment is easier to manage than individual plants



Larger centralized equipment can lower the maintenance and operation cost

Higher thermal efficiency can be achieved

Higher reliability and redundancy

A central plant can easily be expanded based on campus growth

Easier noise mitigation

Option 3 can be implemented in three phases. The phasing of the proposed plan has been coordinated, in campus, with the previously proposed chilled water plant expansion project and the associated piping expansion/loop. The following is a general overview of the proposed phases:

Phase I – As part of the chiller plant expansion in the existing “Mini Lot 3” add a new central heating hot water boiler plant. Install heating hot water piping in the same trench as the chilled water loop up to building 100.

Phase II – As the chilled water loop expands, also expand the heating hot water piping. Install heating hot water piping from building 100 to building 1000.

Phase III – Finish the heating hot water loop. Install heating hot water piping in the existing tunnel from building 200 back to the new central plant located in parking lot 3.

Refer to “1.2 FUTURE CAMPUS HHW PIPING DISTRIBUTION PLAN ‐ OPTION 3” in “Appendix A” for proposed piping distribution and phasing.

3.3.1 Phase I – Heating Hot Water Central Plant & Campus Loop to Building 100

Phase I of developing a centralized heating hot water central plant is to address the immediate needs of the campus growth, which includes the addition of the Maintenance & Operations building and major retrofit projects for buildings 300 and 500. The buildings associated with phase I are buildings 100, 300, 500, 700, 1100, 1300, new Welcome Center, and new Maintenance & Operation building. Once buildings 1100 and 1300 are demolished, the new Welcome Center will come online.

The new central heating hot water plant would be built in lot 3 in parallel with the expansion of “Mini Lot 3” chilled water central plant. Additionally, the heating hot water piping is to be installed at the same time and share the trench as the chilled water loop. This will save time and cost. Refer to Figure 7 below for proposed location of central plant and routing of heating hot water piping.



For Phase I, the central boiler plant should be sized and consist of two 6,000 MBH boilers at a total capacity of 12,000 MBH. This will provide almost 100 percent redundancy at the plant and will allow additional buildings to come online as the heating hot water piping distribution loop is expanded. Table 7 below shows the estimated loads associated with Phase I of the central plant.

Table 7 ‐ Phase I: Centralized HHW Plant Building Loads

Building Number


Heating Load

[MBH] Heating Load

BTU/SF

100 Administration 16,624 8001 48

300 Business & Computer Info 14,612 2821 19

500 Applied Arts / Humanities 22,228 8001 36

700 Technology & Engineering 53,539 30301 57

Welcome Center 29,470 6482 22

New Maintenance & Operation Building

13,200 2902 22


1. Existing data based on research of available engineering drawings and site investigations. 2. Estimated Heating Load based on 22 BTU per square foot.



Figure 7 ‐ Phase I: Centralized HHW Plant

Phase I

proposed new

HHW routing

in red (share

trench with

CHW piping)



3.3.2 Phase II – Heating Hot Water Campus Loop from Building 100 to Building 1000

Phase II of developing a centralized heating hot water central plant is to add buildings 200 and 1000 to the new central heating hot water boiler plant. This phase shall follow the phasing of the chilled water loop piping, which will extend the piping from building 100 to 1000. Refer to Figure 8 for Phase II distribution.

The new central heating hot water plant has adequate capacity to address the addition of buildings 200 and 1000 heating loads. The central plant will maintain 60 percent redundancy. Refer to Table 8 for total building load for the new central boiler plant during Phase II.

Table 8 ‐ Phase II: Centralized HHW Plant Building Loads

Building Number


Heating Load

[MBH] Heating Load

BTU/SF



Services 28,292 6001 21




1000 Fine Arts / Art Gallery 28,656 8021 28


New Maintenance and Operation Building

13,200 2902 22



Figure 8 ‐ Phase II: Centralized HHW Plant

Phase II proposed

new HHW in green

(share trench with

CHW piping)



3.3.3 Phase III – Heating Hot Water Campus Loop from Building 1000 Back to Central Plant

Phase III of developing a centralized heating hot water central plant is finishing the heating hot water loop. This includes adding buildings 400, 600, 800, 900, and 1200 to the new central heating hot water central plant.

The new central heating hot water plant no longer has adequate capacity to address the additional building heating loads. An additional two 6,000 MBH boiler are to be added to the central plant. Only one 6,000 MBH boiler is required to meet the building loads, as see in Table 9 below, however, the fourth boiler will provide N+1 redundancy.

The final stretch of the heating hot water piping loop will utilize the existing tunnel from building 200 to building 900. From building 900, approximately 350‐ft of trenching is required in order to connect the loop to the central plant. Refer to Figure 9 for heating hot water routing.

Table 9 ‐ Phase III: Centralized HW Plant Building Loads

Building Number


Heating Load

[MBH] Heating Load

BTU/SF



Services 28,292 6001 21


400 South Science 39,176 2,5001 64


600 South Science 16,051 1,1281 70

700 Technology & Engineering 53,539 3,0301 57

800 Library Learning Resource

Center 54,630 7001 13


1000 Fine Arts / Art Gallery 28,656 8021 28

1200 Physical Education 61,802 4,5871 74


New Maintenance and Operation Building

13,200 2902 22





Figure 9 ‐ Phase III: Centralized HHW Plant

Phase III proposed

new HHW in orange

(route piping in

existing tunnel)

Trenching is

required from

building 900 to

Phase I piping



4 ENGINEERING COST ESTIMATES

4.1 Engineers Opinion of Cost For the purpose of this study, pricing was estimated based on published pricing data from the Mechanical & Electrical Estimating books by RS‐Means and good engineering practice and judgment.

The goal of this cost estimate was to develop a rough order of magnitude applied across the three options presented in this study. The estimates are provided in current 2017 $USD.

The following are the estimated engineer’s opinion of cost associated with the three options presented in this study:

Option 1 ‐ $1,159,058

Option 2 ‐ $2,795,457

Option 3 ‐ $4,915,447

This cost estimate does not include annual maintain cost associated with each option. Option 1 will have the highest maintenance cost due to the age and condition of the existing steam system and the due to the higher number of equipment, such as the heat exchangers and steam traps, that required to be maintained. Option 2 will have the second highest maintenance costs due to the fact that there will be more decentralized boilers to maintain. Lastly, Option 3 will have the lowest maintains cost because all boilers will be located in a central location and there will be no need for heat exchangers or steam traps at each building.

4.1.1 Option 1 Costs – Retain Existing Steam Plant & Add Decentralized Boilers

The costs associated with Option 1 are providing decentralized heating hot water boilers, pumps, controls, and gas service at the three new buildings (Welcome Center, Maintenance & Operations, and Instructional Building). Additional costs are included for removal and replacement of the existing heating hot water building pumps, steam‐to‐water heat exchangers and associated condensate return pumps and receivers at buildings 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, and 1200.



4.1.2 Option 2 Costs – Decentralize the Boilers Down to the Building Level

BSE had previously studied and presented two options (A & B) of decentralizing the existing steam heating plant into building level heating hot water boiler plants. The “Fullerton College Decentralization of Existing Steam Heating Plant Engineering Study” was finalized and released in February of 2017. See Table 11 for the cost summary of Options A from the previous report.

The previous report did not provide engineers opinion of cost for the additional two (2) heating hot water boiler plants at the future proposed M&O building and Instructional building south of Chapman Avenue. Additionally, boiler plant #9 did not include the extra cost for adding additional heating capacity to include the heating load for the Instructional building adjacent to building 1200.

The total estimated engineer’s opinion of cost for adding the additional boiler plants and buildings to address the Campus Master Plan is seen in Table 10.

PROJECT LOCATION DATE PREPARED

Fullerton College 08/23/17

ESTIMATED BY

BSE ENGINEERING, INC.

NUMBER UNIT UNIT COST TOTAL UNIT COST TOTAL UNIT COST TOTAL

DIVISION 2 THRU 9 12,500$ DIVISION 23 MECHANICAL 648,800$ DIVISION 26 ELECTRICAL 35,250$ TAX (7.5%) 28,586$ OVERHEAD & PROFIT (20%) 145,027$ SUBTOTAL (BEFORE DESIGN & CONTINGENCY) 870,164$

A/E DESIGN (11%) 95,718$ CONTINGENCY (20%) 193,176$

TOTAL CONSTRUCTION COST 1,159,058$ DIVISION 2 THRU 9

MISC Demolition 1 LS -$ -$ 6,500.00$ 6,500.00$ 6,500.00$ 6,500$

Patching and Clean Up (Mechanical) 1 LS 2,000.00$ 2,000.00$ 4,000.00$ 4,000.00$ 6,000.00$ 6,000$

DIVISION 2 THRU 9 TOTAL 12,500$

DIVISION 23 - MECHANICALGas Fired 650 MBH Hot Water Boiler (Welcome Center) 1 EA 30,100.00$ 15,600.00$ 14,500.00$ 14,500.00$ 44,600.00$ 44,600$

Gas Fired 300 MBH Hot Water Boiler (M&O Bldg) 1 EA 10,700.00$ 15,600.00$ 7,175.00$ 7,175.00$ 17,875.00$ 17,875$

Gas Fired 1088 MBH Hot Water Boiler (Instructional Bldg) 1 EA 32,200.00$ 15,600.00$ 16,600.00$ 16,600.00$ 48,800.00$ 48,800$

Pumps W/VFD (New Buildings) 3 EA 7,700.00$ 23,100.00$ 7,500.00$ 22,500.00$ 15,200.00$ 45,600$

Gas Piping to Welcome Center 600 LF 7.00$ 4,200.00$ 6.50$ 3,900.00$ 13.50$ 8,100$

Gas Piping to M&O Bldg 1,000 LF 7.00$ 7,000.00$ 6.50$ 6,500.00$ 13.50$ 13,500$

Gas Piping to Instuctional Bldg 400 LF 7.00$ 2,800.00$ 6.50$ 2,600.00$ 13.50$ 5,400$

TAB Work 1 LS -$ 6,750.00$ 6,750.00$ 6,750.00$ 6,750$

Controls and Integration 1 LS 7,500.00$ 7,500.00$ 12,000.00$ 12,000.00$ 19,500.00$ 19,500$

Start-up and Commissioning 1 LS -$ 30,000.00$ 30,000.00$ 30,000.00$ 30,000$

Heat Exchanger Remov al (Existing Buildings) 14 EA -$ 560.00$ 7,840.00$ 560.00$ 7,840$

New Heat Exchangers (Existing Buildings) 14 EA 5,375.00$ 75,250.00$ 179.00$ 2,506.00$ 5,554.00$ 77,756$

HHW Pump Remov al (Existing Buildings) 16 EA -$ 149.00$ 2,384.00$ 149.00$ 2,384$

HHW Pump (Existing Buildings) 16 EA 7,700.00$ 123,200.00$ 7,500.00$ 120,000.00$ 15,200.00$ 243,200$ Condensate Return Pump Replacement 11 Ea 6,550.00$ 72,050.00$ 495.00$ 5,445.00$ 7,045.00$ 77,495$

DIVISION 23 TOTAL 648,800$

DIVISION 26 - ELECTRICALElectrical equipment, conduits, wiring 1 LS 17,250.00$ 17,250.00$ 18,000.00$ 18,000.00$ 35,250.00$ 35,250$


COST SUMMARY

COST ESTIMATE - Option 1

QUANTITY MATERIAL COST LABOR COST ENGINEERING ESTIMATE

ITEM DESCRIPTION



Table 10 ‐ Option 2 Total Engineer's Opinion of Cost

Engineer’s Opinion of Cost

M&O Building (Boiler Plant #10) $220,241

Instructional Building south of Chapman Avenue (Boiler Plant #11) $252,660

Instructional Building added to Boiler Plant #9 $63,551

Decentralization of Existing Steam Heating Plant Engineering Study (Option A)

$2,259,005

Total: $2,795,457

Table 11 ‐ Decentralization of Existing Steam Heating Plant Engineering Study Opinion of Cost Summary

Building #Building Heating MBH for Planning

New Heating PlantEngineering Cost Estimate - $ USD

100 560 Plant #6 at Bldg 500300 455 1,670 MBH 316,331$ 500 655 On Roof200 1,050 Plant #7 -1,050 MBH 231,111$ 400 1,950 Plant #5 - 1,950 MBH 252,484$ 600 475 Plant #4 - 475 MBH 206,122$ 700 1,855 Plant #1 - 1,855 MBH 242,821$ 800 1,355 Plant #2 - 1,355 MBH 242,254$ 900 635 Plant #3 - 635 MBH 220,241$ 1000 790 Plant #9 - 2,790 MBH1200 2,000 Temporary on Roof 294,983$ 1100 655 Plant #8 - 1,655 MBH1300 1,000 On Roof 252,660$

Option A Total: 2,259,005$



DATE PREPARED

ESTIMATED BY


DIVISION 2 THRU 9 (Coring, platform, roofing, wall repair) Lot 12000 12,000$ DIVISION 23 MECHANICAL 111,960$ DIVISION 26 ELECTRICAL 23,500$ TAX (8.0%) 5,485$ OVERHEAD & PROFIT (20%) 30,589$ SUBTOTAL (BEFORE DESIGN & CONTINGENCY) 183,534$

CONTINGENCY (10%) 36,707$

TOTAL CONSTRUCTION COST 220,241$

DIVISION 23 - MECHANICAL Boilers, integral pumps and controls for cold start 2 EA 8,680.00$ 17,360.00$ 10,500.00$ 10,500.00$ 27,860$

Pumps w/VFD 2 LS 5,500.00$ 11,000.00$ 7,500.00$ 7,500.00$ 18,500$

Expansion tank, air separator, v alv es, etc. 1 LS 7,100.00$ 7,100.00$ 4,900.00$ 4,900.00$ 12,000$

Natural gas piping to plant 300 LF 7.00$ 2,100.00$ 3,500.00$ 3,500.00$ 5,600$

Cranes and Lifts 1 EA 5,000.00$ 5,000.00$ 5,000$

HHW piping w/ Insulation at plant 80 LF 25.00$ 2,000.00$ 4,000.00$ 4,000.00$ 6,000$

HHW piping w/insulation down to mech room 300 LF 25.00$ 7,500.00$ 10,000.00$ 10,000.00$ 17,500$

TAB work 1 LS -$ 4,500.00$ 4,500.00$ 4,500$

Controls and Integration 1 LS 5,000.00$ 5,000.00$ 8,000.00$ 8,000.00$ 13,000$

Start-up and commissioning 1 LS -$ 2,000.00$ 2,000.00$ 2,000$




ITEM DESCRIPTION

COST SUMMARY

COST ESTIMATE - FULLERTON COLLEGE

Heating Hot Water System forMaintenance & Operation Building

09/14/17




DATE PREPARED

ESTIMATED BY






Pumps w/VFD 2 LS 7,800.00$ 15,600.00$ 7,500.00$ 7,500.00$ 23,100$


Natural gas piping to roof 600 LF 7.00$ 4,200.00$ 4,000.00$ 4,000.00$ 8,200$


HHW piping w/ Insulation on roof of 1100 110 LF 25.00$ 2,750.00$ 4,000.00$ 4,000.00$ 6,750$

HHW piping w/insulation between buildings 400 LF 25.00$ 10,000.00$ 9,000.00$ 9,000.00$ 19,000$

TAB work 1 LS -$ 4,500.00$ 4,500.00$ 4,500$






ITEM DESCRIPTION

COST SUMMARY


Heating Hot Water System forInstructional Building South of Chapman

09/14/17




DATE PREPARED

ESTIMATED BY






Pumps w/VFD 2 LS 7,700.00$ 15,400.00$ 7,500.00$ 7,500.00$ 22,900$


Natural gas piping to roof 75 LF 7.00$ 525.00$ 1,200.00$ 1,200.00$ 1,725$



HHW piping w/insulation between buildings 850 LF 25.00$ 21,250.00$ 18,000.00$ 18,000.00$ 39,250$

TAB work 1 LS -$ 4,500.00$ 4,500.00$ 4,500$






ITEM DESCRIPTION

COST SUMMARY


Heating Hot Water System forBuildings 1000, 1200, and Instructional Bldg

09/14/17




4.1.3 Option 3 Costs – Centralized Heating Hot Water Plant with a Campus Loop

The costs associated with Option 3 include adding heating hot water boilers at the central plant in Lot 3, circulation pumps, underground steel piping with insulation and PVC casing for the heating hot water loop, and building heating hot water pumps.

Trenching for the heating hot water piping loop and central plant enclosure were not included in the cost estimate because they are included in the chilled water study. There will be cost savings by installing the heating hot water central plant with the chilled water plant, as well as, installing the heating hot water campus loop at the same time and in the same trench as the chilled water campus loop.

DATE PREPARED

ESTIMATED BY






Pumps w/VFD 2 LS 5,500.00$ 11,000.00$ 7,500.00$ 7,500.00$ 18,500$


Natural gas piping to roof 200 LF 7.00$ 1,400.00$ 2,200.00$ 2,200.00$ 3,600$



HHW piping w/insulation to mech room 600 LF 25.00$ 15,000.00$ 13,000.00$ 13,000.00$ 28,000$

TAB work 1 LS -$ 4,500.00$ 4,500.00$ 4,500$






ITEM DESCRIPTION

COST SUMMARY


Temporary Heating Hot Water System forInstruction Building

09/14/17




PROJECT LOCATION DATE PREPARED

Fullerton College 08/23/17

ESTIMATED BY

BSE ENGINEERING, INC.


DIVISION 2 THRU 9 33,500$ DIVISION 23 MECHANICAL 2,834,610$ DIVISION 26 ELECTRICAL 43,000$ TAX (7.5%) 164,120$ OVERHEAD & PROFIT (20%) 615,046$ SUBTOTAL (BEFORE DESIGN & CONTINGENCY) 3,690,275$

A/E DESIGN (11%) 405,930$ CONTINGENCY (20%) 819,241$

TOTAL CONSTRUCTION COST 4,915,447$ DIVISION 2 THRU 9

MISC Demolition 1 LS -$ -$ 6,500.00$ 6,500.00$ 6,500.00$ 6,500$

Patching and Clean Up (Mechanical) 1 LS 2,000.00$ 2,000.00$ 4,000.00$ 4,000.00$ 6,000.00$ 6,000$

Trenching & Backfill 350 LF 25.00$ 8,750.00$ 35.00$ 12,250.00$ 60.00$ 21,000$

DIVISION 2 THRU 9 TOTAL 33,500$

DIVISION 23 - MECHANICALGas Fired 6,000 MBH Hot Water Boiler 4 EA 153,000.00$ 612,000.00$ 40,900.00$ 163,600.00$ 193,900.00$ 775,600$

End Suction Circulating Pump 4 EA 16,300.00$ 65,200.00$ 5,300.00$ 21,200.00$ 21,600.00$ 86,400$

Gas Piping to Boilers 1,000 LF 7.00$ 7,000.00$ 6.50$ 6,500.00$ 13.50$ 13,500$

Misc Fittings, hangers, v alv es, strainers, etc. 80 EA 150.00$ 12,000.00$ 35.00$ 2,800.00$ 185.00$ 14,800$

Control points 100 EA 200.00$ 20,000.00$ 200.00$ 20,000.00$ 400.00$ 40,000$

HHW Preinsulated Black Steel Pipe (2" Polyurethane) 5,400 LF 246.00$ 1,328,400.00$ 60.50$ 326,700.00$ 306.50$ 1,655,100$

PVC Carrier and Casing 5,400 LF 15.65$ 84,510.00$ 30.50$ 164,700.00$ 46.15$ 249,210$

In-Line Centrifugal Building Pump 12 EA 1,700.00$ 20,400.00$ 223.00$ 2,676.00$ 1,923.00$ 23,076$

DIVISION 23 TOTAL 2,834,610$

DIVISION 26 - ELECTRICALBoiler Electrical 4 EA 6,000.00$ 24,000.00$ 3,000.00$ 12,000.00$ 9,000.00$ 36,000$

Pump Electrical 4 EA 1,000.00$ 4,000.00$ 750.00$ 3,000.00$ 1,750.00$ 7,000$


COST SUMMARY

COST ESTIMATE - Option 3


ITEM DESCRIPTION



5 CONCLUSIONS & RECOMMENDATIONS Based on our findings, the existing steam boiler plant does not have adequate spare capacity

to serve the needs of the new proposed buildings. The existing plant is very inefficient and

the existing distribution piping has reached the end of its useful life. Old systems pose

unnecessary risk to the campus in terms of potential failures with the added costs due to high

maintenance and operation. This means Option 1 is not a viable option and our office

recommends against it.

Further, when comparing Options 2 (decentralized) versus Option 3 (centralized), BSE

Engineering recommends Option 2 for the following reasons:

4. Option 2 is $2,119,990 less expensive than Option 3 ‐ $2,795,457 vs. $4,915,447

5. Option 2 is more efficient than Option 3 – Even though the boiler equipment

efficiencies between the two options would be similar, Option 3 will have additional

pumping operational costs due to longer pipe runs associated with increased pipe

friction. Also Option 3 would also have higher piping heat losses due to longer pipe

runs.

6. Option 2 is easier to implement in phases with minimal impact to the campus

operations.

Other Comments:

The northern portion of campus at the Horticulture buildings are all currently served by direct

expansion (DX) equipment as the primary source of heating and cooling. Given the relatively

remote location, it is recommended to maintain those buildings on DX equipment.

The Wilshire buildings are served by a satellite heating hot water boiler plant located in the

basement of building 2100. Based on our calculations, the existing heating hot water plant

has adequate capacity to handle the replacement of building 2000 with the new anticipated

Performing Arts Complex.

Building 1400 has a newer existing decentralized heating hot water boiler plant. It is

recommended to retain this decentralized plant until the plant has reached the end of its

useful life and Boiler Plant #9 is installed capable of addressing Building 1400 loads.

The anticipated new Instructional building (adjacent to building 1400) is recommended to be

provided with a temporary decentralized heating hot water boiler plant until when the Boiler

Plant #9 is installed capable of addressing the Instruction Building loads.



6 APPENDIX A

M1.0 ‐ EXISTING CAMPUS STEAM & HHW PIPING DISTRIBUTION PLAN

M1.1 ‐ FUTURE CAMPUS HHW PIPING DISTRIBUTION PLAN ‐ OPTION 2 (Recommended Option)

M1.2 ‐ FUTURE CAMPUS HHW PIPING DISTRIBUTION PLAN ‐ OPTION 3

BSE ENGINEERING, INC.C

FULL

ERTO

N C

OLL

EGE

BSE Project No.: 615-007

321

E. C

HAPM

AN

AV

EFU

LLER

TION

, CA

928

32

HEA

TING

HO

T W

ATE

R M

AST

ER P

LAN

NIN

G F

EASI

LITY

STU

DY

DescriptionNum Date

XX XX/XX/XX1

NOT FOR CONSTRUCTION

EXISTING CAMPUSSTEAM & HHWPIPING DISTRIBUTIONPLAN

M1.0


FULL

ERTO

N C

OLL

EGE


321

E. C

HAPM

AN

AV

EFU

LLER

TION

, CA

928

32

HEA

TING

HO

T W

ATE

R M

AST

ER P

LAN

NIN

G F

EASI

LITY

STU

DY

DescriptionNum Date

XX XX/XX/XX1


FUTURE CAMPUSHHW PIPINGDISTRIBUTION PLAN -OPTION 2

M1.1


FULL

ERTO

N C

OLL

EGE


321

E. C

HAPM

AN

AV

EFU

LLER

TION

, CA

928

32

HEA

TING

HO

T W

ATE

R M

AST

ER P

LAN

NIN

G F

EASI

LITY

STU

DY

DescriptionNum Date

XX XX/XX/XX1


FUTURE CAMPUSHHW PIPINGDISTRIBUTION PLAN -OPTION 3

M1.2

college –heating hot water engineering feasibility · pdf fileoption 1 – retain...

Documents