Baltimore Convention Center
Plant 1 Chiller Replacement
PROJECT DETAILS
Project Location:
Baltimore Convention Center
Baltimore, Maryland
Owner:
Veolia Energy, NE (Vicinity Energy)
Schedule:
October, 2016 - May 2017
Engineer of Record:
Burns & McDonnell
5521 Research Park Dr
Suite 120
Catonsville, MD 212281228
Contract Value:
$5,700,000.00
Despite a new total plant capacity of only 5,400 tons, the P-1 Chiller Plant Renovation and Capacity Upgrades at the Baltimore Convention Center ranks among one of the most complicated projects completed by Green Contracting to date.
This was a high profile, fast paced, large scale chilled water plant replacement and capacity upgrade project located at the Baltimore Convention Center in Baltimore, Maryland. Chilled Water Plant 1 is one of three plants that support Veolia’s district chilled water loop. It is the largest and most critical plant on the loop which serves a multitude of buildings in Baltimore City, including the Stadiums. This complete plant renovation and capacity upgrade project had to be completed on a very compressed schedule commencing on 10/10/16 and substantially completed (producing dependable chilled water) no later than April 1, 2017 (173 calendar days). Complicating an already tight schedule was the coordination of work with the active convention center events and neighboring Baltimore Ravens and Orioles home games. Adding to the complexity, the proximity of Plant 1 is centrally oriented in a penthouse on the roof of the Convention Center, located on the corner of Light Street and 395 which is a major thoroughfare into and out of the City and Stadium Complex’s. After a complete gut demolition phase, major structural reinforcements and architectural modifications were completed to accept the new mechanical equipment; electrical services were upgraded, and all new piping and controls were installed. The project was a huge success story and Green was highly recognized by all the stake holders for its performance on the job.
PROJECT OVERVIEW
A complete remodel and upgrade project, the entire mechanical space was demolished back to the building shell to include the removal of the existing evaporators and condenser barrels, compressors, pumps, all associated piping, electrical conduits, and gear. Due to the increased sizes and weights of the new equipment and existing vibration issues, major structural upgrades were performed. Structural work included reinforcement of the existing building beams and columns, structural support framing for the chillers and cooling towers, a pop-up roof structure, and miscellaneous steel platforms and handrail, all totaling 90 plus tons of steel.
The major equipment included three (3) new 1800-ton Trane chillers coupled with nine (9) 600-Ton BAC cross flow cooling towers and four (4) 3700 GPM Armstrong in-line condenser water pumps, all set on significant vibration isolation components. Three major crane lifts were performed. The first and second lift utilized a 600-ton unit to remove the existing cooling towers and to set the new BAC units. The third utilized a 900-ton machine to set the three fully assembled chillers. 30” Condenser Water piping connected the cooling towers and chiller equipment with branch piping ranging from 18” to 8” pipe. The 24” Chilled Water mains feeding the loop were connected by 16” pipe.
The associated electrical scope included new 4160 volt feeders from the 15KV switchgear and substation to the chillers, a new transformer, and a 480-volt MCC panel which feeds the pumps, towers, and other associated building services. Architectural work comprised of new aluminum storefronts with double doors installed for maintenance access, new roofing and siding on the pop-up structure, epoxy flooring, and extensive cutting and patching of finishes were required.
SCOPE OF WORK
THE CHALLENGES - TIME & SPACE
As mentioned in the overview, the schedule was a major challenge driven by three major criterions: seasonal demand, owner operations and use, and impact to the visitors of Baltimore City and its events.
Seasonal Demand – As a utility provider Veolia is required to provide steam and chilled water to its users. While its satellite plants can maintain cooling demand in the winter, Plant 1 is essential to meeting the increasing demand and peak loads generated in the swing and summer seasons. This dictated the overall construction schedule with construction starting October 10, and ending with the owner’s beneficial use (reliable production of chilled water) on April 1, just 173 calendar days later.
Owner Operations – The Convention Center is owned and operated by the Baltimore Stadium Authority and is also a customer of Veolia. Maintaining convention center operations and limiting impacts to their events was a contractual requirement; no noise impacts or any other signs of construction for the exhibitors and their patrons. This dramatically affected allowable construction activity during said events which typically run for several days and through many weekends.
Schedule:
This project was impacted by space constraints in nearly every aspect of the work. The size of the physical plant and tower enclosure, the egress path and loading zones, and the streets and sidewalks surrounding the building, all presented challenges for the construction team.
Physical Plant – While it wasn’t evident until well into the final layout and coordination phases, the BIM model revealed relatively zero free space between the walls and all the equipment. Once minimum clearances for code and maintenance requirements were considered, there was less than 1” combined overall float in the east-west dimensions of the Plant. Similarly, the final clearance between the 30” condenser water main and the wall of the CT enclosure was less than 1” in the north-south plane, after every possible space saving idea was implemented.
Egress Path - The established egress path to the plant was a major factor when planning the possible means and methods for material handling and delivery to the project site. Starting with the low ceilings in the congested loading dock, to the size and capacity of freight elevators, and finally, the narrow personnel hallway and mandoor leading into the plant, it was obvious no large equipment or materials were going to travel this path to site.
The mechanical scope included total demolition of all existing piping and mechanical equipment including the chillers, cooling towers, pumps, and all associated supports and appurtenances. Etc.
Space Constraints: