mike carroll mechanical option · mike carroll’s capstone design project report executive summary...

H. J. Heinz Distribution FacilityH. J. Heinz Distribution Facility

Pittsburgh, PAPittsburgh, PA

Penn State Architectural Engineering Penn State Architectural Engineering

Spring 2004 Capstone ProjectSpring 2004 Capstone Project

Mechanical OptionMechanical OptionMike CarrollMike Carroll

H. J. Heinz Distribution FacilityH. J. Heinz Distribution Facility

Pittsburgh, PAPittsburgh, PA

Mike CarrollMike Carroll

Mechanical OptionMechanical Option

MechanicalMechanical-- Packaged Terminal Heat PumpsPackaged Terminal Heat Pumps

-- Gas Fired Heating UnitsGas Fired Heating Units

-- Electric Wall HeatersElectric Wall Heaters

--120/480 V Exhaust Fans120/480 V Exhaust Fans

-- Variable Speed Ventilation and Centrifugal Variable Speed Ventilation and Centrifugal Supply Air FansSupply Air Fans

Lighting / ElectricalLighting / Electrical-- 400 Watt Suspended Metal Halide Fixture 400 Watt Suspended Metal Halide Fixture

Task Lighting in Warehouse.Task Lighting in Warehouse.

-- 120V 120V -- 2’x4’ Fluorescent Luminaires in Office 2’x4’ Fluorescent Luminaires in Office SpacesSpaces

-- Main Distribution Panel : 480 Volts, 3 Phase, Main Distribution Panel : 480 Volts, 3 Phase, 400 Watts.400 Watts.

StructuralStructural-- Steel Framed Columns and Trusses on AugerSteel Framed Columns and Trusses on Auger--

Driven PilesDriven Piles

-- Insulated Metal Siding enclosing WarehouseInsulated Metal Siding enclosing Warehouse

-- CMU Block on Steel Frame enclosing OfficesCMU Block on Steel Frame enclosing Offices

Project TeamProject Team-- Architect / Engineer: LLI TechnologiesArchitect / Engineer: LLI Technologies

-- Site / Civil Consultant: CEC, INC.Site / Civil Consultant: CEC, INC.

-- Landscape Architect: Klavon Design Associates, Inc.Landscape Architect: Klavon Design Associates, Inc.

-- Railroad Consultant: SSOERailroad Consultant: SSOE

CPEP: CPEP: http://www.arche.psu.edu/thesis/2004/mjc315/http://www.arche.psu.edu/thesis/2004/mjc315/

150,000 Square Foot 150,000 Square Foot

Warehouse and Distribution FacilityWarehouse and Distribution Facility

Mike Carroll Mechanical Option H. J. Heinz Distribution Facility AE Capstone Thesis Report Pittsburgh, PA April 5, 2004 Primary Faculty Advisor: Dr. Bahnfleth

Page 1

Table Of Contents

Executive Summary Page 2

Building Synopsis Page 4

Client Concerns Page 7

Mechanical System Design Page 10

Daylighting Design Page 23

Structural Design Page 28

Overall Conclusions 1

Accolades Page 34

Appendices Page 36

References Page 47


Page 2

Mike Carroll’s Capstone Design Project Report

Executive Summary


Page 3


Executive Summary

This report is the written form of Mike Carroll’s fifth year Architectural Engineering design

thesis. As a student having a mechanical emphasis, Mike reviewed the existing mechanical

systems, building materials, and conformation with national standards. For this design project, he

also evaluated some aspects of the structural, electrical, and construction characteristics of the

facility.

The H. J. Heinz Distribution Facility is a 150,000 ft2 warehouse and office building located

adjacent to the Allegheny River in Pittsburgh, Pennsylvania. The facility’s main function is to store

pallets of canned food delivered from the processing plant that are awaiting to be picked up by

trucks that will take them to their final destination. The warehouse space is 140,000ft2 and includes

a conveyer system that brings in the cans from the processing plant. The two separate remaining

areas are utilized for three offices, two break rooms, two sets of restrooms, and a second-floor bay

for the electrical distribution panels.

Heinz originally hoped the facility would be state-of-the-art and be able to decrease the need

for running forklifts around the warehouse. Due to budget concerns, there were multiple cutbacks

from the original plan. Because of these cutbacks, the employees have had some reserves with

numerous entities of the facility since the building was completed in August, 2001.

The ultimate goal of this design project was to redesign the facility to supply better

conditions for the employees, while still serving the purpose of storing canned food. The major

aspects of this design are better conditioning of the air utilizing water source heat pumps, and

supplying natural daylight to the warehouse floor via clerestories. The addition of the two

clerestories require a redesign of the roof’s structural system. Overall, the new design will be more

economical, more comfortable and more aesthetic for the employees of Heinz.


Page 4


Building Synopsis


Page 5

Building Synopsis

H. J. Heinz built an second distribution and storage warehouse in 2001. The original desires

of the company were to have a state-of-the-art facility where they could use large racking machines

to sort through the pallets of cans and bring them directly to the garage doors at the east end of the

warehouse. This idea was to reduce the need to run forklifts throughout the warehouse. Originally,

the owners desired a fully conditioned facility that was both aesthetically appealing to both the

employees, and any civilians who viewed the building from outside.

Due to budget constraints, there were numerous cutbacks in the final design of the facility.

The large racking machines were removed, garage doors were located at both ends of the

warehouse, cooling of the warehouse was deleted, and the only concern about the exterior was a

screen wall installed at the east end of the site to decrease the amount of noise perceived by a

neighboring residential area on Washington’s Landing in the Allegheny River.

The extent of air conditioning for the entire facility are terminal through-wall heat pumps

located in the offices and break rooms; three gas-fired heating units for heating the warehouse and

conveyor hallway; and draw-through fans for ventilation of the warehouse. Following construction

completion, during the cold winter months, the warmest the warehouse reaches is the mid 50’s (oF),

and additional space heaters are utilized throughout the offices and break rooms. Employees have

complained of cold conditions throughout the building. The large air-intake louvers along the south

wall have also caused freezing problems for the canned food stored next to the louvers. The

original heating design calls for a positive pressurization of the entire warehouse and conveyor

hallway. This is not the case; there is a displacement of the heated air meant for the warehouse

through the conveyor to the preceding warehouse, and the replacement of this air via infiltration

increases the need for overall space conditioning for the warehouse and conveyor hallway.

Lighting in the office and break rooms are fluorescent 2’x4’ and 1’x4’ fixtures. The lighting

scheme of the warehouse consists of 190 metal halide suspended luminaries, and 140 fluorescent

eight –foot T-8 luminaries. There are no windows to allow daylight into the warehouse. The only

daylight that enters is through semi-opaque plastic screens located on the top of the south wall

which is actually meant for some interior florescent lighting directed outwards for a nighttime

architectural feature.


Page 6

The floor slab was poured upon a foundation set upon almost two thousand auger piles

driven to bedrock (some as deep as 62 feet). The structural system around the warehouse (as well

as over the west set of offices, restrooms and break room) was a contractor-designed wide flange

steel girder and truss system with steel cladding. The walls of the warehouse are mostly steel

cladding. The particular walls on the west and east sides that contain the garage doors are built with

concrete masonry units (CMU) to the height of the garage doors. Above the CMU walls is more

steel cladding. The office and break areas on both the interior and exterior sides of the warehouse

are also framed with CMUs. The west-side office and break room are built under the warehouse’s

steel framing and cladding, with the electrical distribution panels positioned above. The east-side

office and break area are built outside the warehouse with CMU framing, and topped with steel

cladding and roofing much the same as the warehouse.

Fig. 1 – East side office area and truck parking lot

Fig. 2 – West side truck parking lot


Page 7


Client Concerns


Page 8

Client Concerns

In 2000 Heinz wanted to build a new state-of-the-art warehouse facility that could simplify

the process in which they transport, store, label, and deliver their canned food products. They

planned to install large mechanically powered racking systems to cycle through their pallets of cans.

This would make the organizational structure of the warehouse easier to find cans, and transport the

pallets into trucks. Unfortunately, due to budget constraints, these racks were not installed, and

many of the original idealistic plans were cut back.

When value engineering is required in many architectural projects, the mechanical systems

are usually the first to be scaled back. This was the case with the Heinz distribution center as well.

Not only were the pallet racks removed, typical requirements for air conditioning were reduced as

well. The extent of cooling is only provided in the offices and break rooms through terminal

through-wall heat pump units. Residential electric space heaters are used in the offices and break

rooms during the heating months to add to the need for heat where the through-wall heat pumps

lack. Duct heaters were provided on the east and west walls above the garage door walls, as well as

on the north wall above the conveyor system. Accompanying the duct heater on the high side of the

north wall are exhaust fans. The exhaust fans are intended to aid in the intake of outdoor air that

enters via air louvers on the bottom of the south wall.

The entire warehouse was designed to have a positive pressurization to decrease infiltration.

The true case is in fact that air of the warehouse is actually exfiltrating into the prior warehouse

through the conveyor belt hallway. A major source of the infiltrating air are the intake louvers in

the south wall. Since building completion in August 2001, Heinz discovered that the canned food

adjacent to the intake louvers was freezing in the cold winter months. During this cold period

(which is quite a long duration in Pittsburgh) Heinz attempts to gasket closed the louvers with rigid

insulation. With this insulation, the majority of infiltration through the louvers is reduced (to the

satisfaction of Heinz), but there is still a large amount of cold air infiltrating through the open

garage doors.

The garage doors provide more conditioning concerns than just infiltration. The Heinz

employees do not utilize the provided system of heated air curtains to retard the amount of cold air

insulation. Whether they find the air curtains to be uncomfortable, or ineffective due to stack effect,


Page 9

the air curtains are not presently used. If there were a solid barrier, for instance a plastic curtain, or

some heating system that utilized stack effect instead of working against it, the employees would be

more likely to work with the cold air barrier.

The only lighting provided to the employees in the warehouse are suspended metal halide

and 8 foot fluorescent luminaries. The architect did provide semi-opaque plastic panels on the top

of the South wall that allows some daylight into the warehouse (a minimal amount), but the main

function of the panels is to provide an aesthetic look from interior lighting to the outside façade at

night. Each of the offices and break room on the eastern side have windows in them. Overall, there

is very little capability for any daylight to enter the facility. Any entrance of daylight will provide

better lighting on the warehouse floor where the majority of work is done, will create a better

ambiance on the interior for the employees, and will provide a cutback on the electrical costs for

Heinz.

The overall aim of this redesign is not to improve upon the existing design, but rather to

provide a mechanical system that is economical and efficient for Heinz year-round, and to provide

an environment that is better for the employees on a year-round basis.

Fig. 3 – Northern aisle near conveyor belt taken from second story electrical distribution area


Page 10


Mechanical System Design


Page 11

Mechanical System Design

Original Cooling System The original mechanical system for the entire facility was sufficient for the essential

requirements of the space, canned food storage, and few people utilizing the office and break room

spaces. However, due to the large fluctuation of outdoor conditions in the Pittsburgh climate, the

system should be redesigned to focus on the extreme design days. Should Heinz or another

company (Del Monte Foods presently works out of the warehouse also) wish to change the use of

the facility; the mechanical system is hardly capable of conditioning the spaces for anything other

than soup cans, and a few occupants.

Under the original mechanical design, there are only five rooms that had any cooling

systems in them, the three offices and two break rooms. The cooling done in these spaces

(indicated by the yellow hatching in Figure 4 below) are with the terminal air-to-air heat pumps.

The heat pumps are GE Zoneline nominally sized at 10.7 MBH and 8.8 MBH on the east and west

sides, respectively. According to the cooling loads performed by Trane Trace (see Appendix A,

Table 4), the sizes of these units is incorrect. The east side heat pumps are oversized, the west side

offices are oversized, and the west side break room is undersized.

There are employees working in other parts of the building as well. Throughout the

warehouse and conveyor hallway, employees are working with heavy machinery, and receive no

cooling throughout the entire year.

Fig. 4 – Original Cooling Areas


Page 12

Original Heating System The original design had limited area of heating as well. The specific areas where heating

was supplied can be seen with the orange hatching on the plan in Figure 5 below. Specifically,

these heating units are the same GE units with a 0.92 MBH heating to cooling ratio in the offices

and break rooms. The bathrooms have 3.4 kW electric wall heaters in them. The conveyor hallway

has two 156 MBH duct furnaces that heat the air from 1,900 CFM centrifugal fan into 130-foot

long, 14-inch round duct socks. Positioned centrally on the west, north, and east walls of the

warehouse are 1,104 MBH gas fired heating units.

It is important to note that there are no heating sources on the south wall where 8-foot by 8-

foot air intake louvers are located. This is a major concern now because cold air that enters the

louvers is never heated before as it spreads throughout the southern half of the warehouse. The

lack of heating on the southern wall is why Heinz has problems with cans that are located along this

wall freezing.

Fig. 5 – Original Heating Areas


Page 13

New Mechanical Design Utilizing the nearby Allegheny River and the temperate constant volume of ground water

around the Heinz site, and considering the requirement for both heating and cooling throughout the

unstable seasons of Pittsburgh, a new design utilizing large heat pumps was performed. The

varying types of heat pumps that were considered are Geothermal Ground-Coupled Heat

Exchangers (GCHP), Ground Water Source (GWHP), and Surface-Water Source (SWHP). All

three versions of heat pumps utilized a different loop of water for the heat rejection or heat

extraction for air conditioning. The size of the interior loop of water to each zonal heat pump is

able to be designed the same for each, even though the source of the water for the interior loop

differs. The design loads for heating and cooling for the entire facility were calculated using Trane

Trace, and are summarized in the Table 4 in Appendix A.

According to the calculated loads, the required units are fourteen 25-ton heat pumps for the

warehouse, two 10-ton heat pumps for the conveyor hallway, one 2-ton unit for the east office area,

and one 1-ton unit for the west office area. A summary of the costs for this equipment can be found

in Table 9 in Appendix A. Table 1 below describes sizes and zones for each of the heat pump units.

The layout of the new heat pumps can be seen below in Figures 6, 9 and 10 (the red units). Also, in

Figure 9, the location of a proposed plate-and-frame heat exchange can also be viewed.

Pipe sizing for all three systems was based on a 3 gpm/ton standard, and to protect the pipe

from condensation and possible damage, a ½ “ jacket insulation was installed around the water loop

on the interior of the building.

Fig. 6 - New Heat Pump Location Plan


Page 14

Zone Rooms Design Load Unit Size Quantity of UnitsZone 1 East Office Area 1 Ton 1 Ton 1Zone 2 West Office Area 2 Tons 2 Tons 1Zone 3 Conveyor Hallway 20 Tons 10 Tons 2Zone 4 Warehouse 336 Tons 25 Tons 14

Zonal Heat Pump Sizes and Quantities

Table 1 - Zonal Heat Pump Sizes and Quantities

McQuay makes a typical large-load vertical heat pump that can supply 25 tons of cooling. A

picture of the unit is Figure 7, and the design schedule for it is Figure 8.

Fig. 7 – Image of McQuay’s Example of a Large Vertical Heat Pump

Fig. 8 – McQuay’s Large Heat Pump Schedule


Page 15

These are the partial plans of the east and west office area to show the location of their heat pump

unit, and the location of the plate and frame heat exchanger for the facility in Figure 9.

Fig. 9 – West Office Area New Heat Pump Plan

Fig. 10 – East Office Area New Heat Pump Plan


Page 16

Ground Water Heat Pumps - GWHP The original Civil Engineer on the Project, A&A Consultants, Inc. performed a soil and site

analysis using 20 bores to determine soil types and water table heights. The depth of the water table

varied from a value of 7 feet deep to 29 feet deep over the entire site. The original design called for

a well to be drilled on the southwest end of the facility, which is the southeast corner of the truck

loading lot. The bore that supplied the depth of this well gave the distance to the water table to be

23 feet. This provided to be a convenient location for a well so that it could be accessible, and at

the same time, out of the way of any trucks that may enter the loading lot. The location of the

production and injection wells can be seen in Figure 11 below. The design of a ground water

source heat pump (GWHP) requires the pumping of ground water from one well, into the interior of

the building where it exchanges heat with the interior water loop of the building, and finally back

out to a second well. (A schematic of a GWHP is located in Figure 12.)

The ground water is provided to the building with the use of a end-suction pump that cycles

ground water from the production well to the interior heat pump loop, and then expunges the used

water to a second pump to return the water to an injection well which returns to the natural

temperature of the ground water. This temperature of ground water in Pittsburgh is a fairly constant

52oF year-round. The design entering water temperature of the heat pump units is 76oF for cooling,

and 44oF for heating. Applying the need to reject 4,306 MBH from the building to the heat

exchanger (and then to the ground water), this provides that a maximum 108 gallons per minute of

cooler ground water must be pumped to the heat exchanger in order to cool the building.

(Conversely, a maximum of 87 GPM of warm water must be pumped to the heat exchanger in

which to heat the building 1,493 MBH in the winter.) See Appendix A, Table 7 for the table of

calculations of these values.


Page 17

Fig. 11 – Plan Showing Ground Water Wells

Fig. 12 –Schematic of Ground Water Source Heat Pump


Page 18

Surface-Water Source Heat Pumps - SWHP The bank of the Allegheny River is located approximately 150 feet from the south side of

the Heinz distribution facility. Since it is located so closely, the possibility of utilizing this

constantly flowing water as a heat exchanger was viewed. The use of this system negates the

necessity of a heat exchanger inside the building, since the heat exchanger is literally the spools of

polyethylene pipe located in the river water.

ASHRAE (ASHRAE, 1995) design recommends a length of 300 ft/ton, which will provide

an entering water temperature of 35oF during the winter into the hump loop and 59oF during the

summer months. Using the 300ft/ton recommendation, the total number of spools required is 360.

These spools are placed at a depth of 22 feet in the river so that any ice or boats on the surface of

the river will never come into contact with the heat exchanger spools. These 360 five-foot diameter

spools of 300-foot long pipe are aligned in a square pattern of 19x19. The spools are piped to a

single run out of pipe that enters the building on the southwest corner of the building, and then

flows to each of the internal heat pumps units. The location of the spools can be seen below in

Figure 13. A schematic of the SWHP and heat exchanger piping is Figure 14.

The table (Table 2) below supplies the heat transferred from the interior loop to the river

during heating (orange) and cooling (blue) conditions. The pipe must therefore be sized for the

cooling flow rate, 9.16 gpm with a 4’/100’ pressure drop. This pipe size is 1¼” polyethylene, and

will require 1½” jacket insulation around the interior of the building.

Q = 1,492,900 4,306,700 BTU / Hrρ = 62 62 lbs / ft3

v. = 2589.14 4110.23 ft3 / hrCp = 1 1 BTU / lb-oFT1 = 44.3 75.9 oFT2 = 35 59 oF

v. = 346.14 549.50 gal / hrv. = 5.77 9.16 gal /min

Heat Exchanger Loop Flow RateQ = ρ*v.*Cp*∆T

Table 2 – Heat Transfer and Flow Rates for Surface Water Heat Exchanger


Page 19

Fig. 13 – Water Source Heat Exchanger Spool Plan

Fig. 14 – Schematic of a (Lake) Water Source Heat Pump


Page 20

Geothermal Ground-Coupled Heat Pumps - GCHP The extensive amount of ground water around the site can also be utilized as a heat sink or a

heat source without the necessity of pumping water out of the ground. A geothermal heat pump

utilizes the constant temperature of the soil and groundwater under the site as the heat exchanger.

Polyethylene piping is fed into 250-foot bores and a 30% glycol-water solution is pumped through

each of the bores into the building where it’s fed to the heat pump units much the same as a water

source heat pump system.

A length of 38,043 feet of heat exchanging pipe is required to reject the 4,307 MBH of heat

that the distribution facility supplies during cooling conditions. Organizing each of the pipes in a

“u-tube” configuration, requires 77 bores of 250 feet. With a distance of 15 feet provided between

each bore, and configuring seven run outs of eleven bores each, a space of 150’x90’ is required in

which to create bore holes for the piping. There is ample space for this size configuration in the

west truck lot between the two adjacent warehouses. A plan of this location is depicted below in

Figure 15, and a schematic of vertical bored geothermal heat exchange piping is depicted in Figure

16.


Page 21

Fig. 15 – Geothermal Heat Exchanger Boring Plan

Fig. 16 –Schematic of Ground Coupled Heat Pump


Page 22

Preferred Heat Pump Selection The variance in prices to install the three different heat pump systems was calculated using

R. S. Means 2000 (a summary of these costs is located in Appendix A, Table 9). Since a water

source heat exchanger requires 360 three-hundred foot spools of piping in the river, its cost is by far

the highest; on the magnitude of 2.5 times that of the other two systems. There is also concern of

scaling and possible damage to the piping due to wildlife or boating in the river, so there are too

many concerns on the upkeep of the heat exchangers of the SWHP system to consider it economical

for Heinz.

The cost of the geothermal system versus the ground water source system is slightly higher

(1.2 times) due to the large quantity of piping and drilling required for the heat exchanger piping.

The best location of the piping bores is under the truck lot on the west side of the site. Should

maintenance ever be required on the piping, it is impossible to access without digging up the

concrete of the parking lot (and interrupting Heinz’s delivery progress).

Taking cost and maintenance into account, the obvious choice of heat pump system is a

groundwater source heat pump. Even though it requires the use of a plate-and-frame heat

exchanger inside the building, there is far less piping required than the other two systems, so the

cost of the heat exchange is justified at purchase.

The implementation of a groundwater heat pump system is the best decision economically

for Heinz. There will be less stress on pumps from the geothermal loop side than there will be with

surface water, and with vertical boring. The first cost of the system (as seen in Appendix A, Table

9) is certainly higher than the originally designed system, but there will be less stress on the

mechanical systems, and the entire facility will be conditioned throughout the course of the year.


Page 23


Daylighting Design


Page 24

Daylighting Design

Addition of Clerestories The original lighting system in the warehouse consists of 190 suspended metal halide and 90

eight-foot T-8 fluorescent luminaries. The extent of any sunlight that is allowed to enter the

warehouse is through a small semi-opaque plastic screen that is at the top of the south wall. The

main function of this screen is to allow florescent light outside at night, not to allow sunlight into

the warehouse during the day. Allowance of sunlight into the warehouse can increase the amount of

natural light that shines on the task surfaces of the floor and the lower portion of the racks of cans

where the labels are located. Entrance of daylight also creates a better environment for the

employees who work within the warehouse.

Daylighting can easily be achieved with the installation of clerestories over each of the main

aisles of the warehouse. Assuming a visible transmittance of 50% (an average number for

commercial glazing), and using a rule-of-thumb (Ander 2003) for maximizing the amount of

daylight on a task plane of

0.18 = VT x WWR

where VT is the visible transmittance (0.5), and WWR is the window-to-wall ratio (0.36), it was

determined that the area of south-facing windows should be 6,633 ft2. Splitting this new glazing

into two clerestories and windows on the south wall, and running each for the entire length of the

warehouse (737 feet), a glazing height of 3 feet is required. A rendering of the warehouse with the

new windows and clerestories can be seen in Figures 17 and 18 below.


Page 25

Fig. 17 – Rendering of Warehouse with Clerestories

Fig.18 - Elevation of Clerestory Framing


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Electrical Savings The newly added daylight now reduces the need for the high-energy metal halide fixtures.

Using AGI 32 daylighting software, it was shown that providing daylight on a clear summer day

provides approximately 275 foot-candles (Fc) on the floor, and approximately 130 Fc on the side of

the cans. Addition of daylight on an overcast winter day supplies approximately 50 Fc on the floor,

and 20 Fc on the sides of the cans.

Using the Lumen Method presented in the IESNA Lighting Handbook, the original lighting

design provided an illuminance value of 30 Fc for the task plane on the warehouse floor. Keeping

this 30 Fc rating, and including the use of daylight onto the task plane, it was determined that up to

160 (selectively chosen) metal halide luminaries could be turned off during a clear day in the

summer and still provide an adequate amount of lighting. (The illuminance rendering from AGI 32

for a clear summer day can be viewed on the next page in Figure 19). Likewise, on an overcast day

in the winter, up to 64 (again, selectively chosen) luminaries could be turned off and provide a

comparable amount of illuminance (the rendering for an overcast winter afternoon is on the next

page, Figure 20).

Through the use of daylight during the condition of a clear summer day, and turning off 160

of the 400-watt luminaries produces a savings of 64 kilowatts. On an overcast winter day, the

savings of 64 400-watt luminaires produces a savings of 25.6 kW. The table of energy demand

charges for Allegheny Power is located in Appendix B, Table 11 showing that Heinz is charged

$0.165 per “additional demanded kWh”. Assuming that the power supplied to the lighting can be

reduced from the original charge, the power savings attributes to a monetary savings of $186.41

during the summer months and $74.56 in the winter months.


Page 27

Fig. 19 - Summer with Clear Sky Conditions Illuminance Diagram

Fig. 20 - Winter with Overcast Sky Conditions Illuminance Diagram


Page 28


Structural Design


Page 29

Structural Design Clerestory Joist Design

Addition of the two clerestories on the roof alters the loading placed upon each of the roof

trusses. This new roof design must be able to support the weight of the clerestories, as well as a

dead load of load at 21 pounds-per-square-foot (psf), and a wind speed of 70 mph which is

equivalent to 15 psf. The original size of the roof trusses and joist-girders were not able to be

determined from the design documents, so a new structural roof-framing system was designed using

RAM structural software. The original spacing of the roof trusses was 5-feet on center (o.c.)

spanning west-to-east.

The same spacing was continued, but this time the steel members are open-web joists. Two

entire rows of joists need to be removed from this design to allow space for the clerestories, and to

not block any of the entering daylight. The specific joists that now support the clerestories are

white in Figure 21 below. The locations of the clerestories are ten feet north of each of the rows of

interior columns (which support the yellow joists in Figure 21). A load schedule of the new joists

can be seen in Appendix C, Table 12. All of the trusses that support the roof could be calculated

using RAM. These are all of the west-east spanning joists in green and blue joists in Figure 21.

Fig .21 - Partial New Structural Plan


Page 30

RAM will not provide truss sizing for members that do not have equal loads throughout. The

sizing of the girders that span north-to south need to be done with a fashion other than a computer.

Doing load calculations for the distributed load upon each truss that sits upon these girders is able to

determine the loads required for sizing these girder trusses. For the two rows of girders that

include the clerestories, a load had to be divided from three 5-ft o.c. trusses to two 10-ft o.c. trusses.

These new girders were calculated and drawn by hand to show a contractor what the design should

be to comply with the snow and wind loads, and to help support the new weight of the clerestories.

A design schematic of those particular trusses is shown below in Figure 22.

Fig., 22 - Schematic of New Joist Girders

Each of the new joist members and their locations in the warehouse framing are listed in the

following table:

Joist Size Location 24K7 North and South Exterior Walls

32LH06 Roof Framing Throughout (excluding Clerestories) 36LH13 Roof Framing Supporting Clerestories

60G12N13.4K Joist Girder on Interior with No Clerestories 60G12N6.7K Joist Girder on West/East Exterior Walls with No Clerestories

Modified 60G12N13.4K Joist Girder on Interior with Clerestories Modified 60G12N6.7K Joist Girder on West/East Exterior with Clerestories

Table 3 – Location of the various Open Web Joists


Page 31


Overall Conclusions


Page 32

Overall Conclusions

Mechanically A review of the heating and cooling loads upon the facility as built revealed a required peak

design load of 360 tons, taking the peaks over summer and winter into account. Considering the

vast changes of season in Pittsburgh, using a heat pump conditioning system was an obvious choice.

The site location enabled the opportunity to use each of geothermal heat exchanger, groundwater

source, and surface water source heat pumps. Performing calculations for the sizes of pumps, pipes,

and heat exchanger for each system, it was determined that the implementation of the surface water

heat exchanger was entirely too expensive compared to the other two. Taking into account future

maintenance and location convenience, a selection of a groundwater source heat pump instead of a

geothermal heat exchanger was made.

Lighting The original facility lacked any direct sunlight into any of the spaces with the exception of

two offices and one break room. The space in which the most employees spend most of their time

is the warehouse. There was no direct sunlight in the warehouse under the previous design. Using

AGI software, the illuminance values for daylighitng were obtained. These values of illuminance

were compared to those of the original lighting design using the lumen method, and calculations to

determine the unnecessary luminaires was found to be as many as 75% of the total metal halide

fixtures from the previous design. The addition of two clerestories over the main working aisles in

the warehouse creates a more aesthetic atmosphere for the employees, and can save Heinz up to

$186 a month.


Page 33

Structural Adding the two clerestories creates a change in the original snow and wind loads upon the

roof and the roof framing members. Using the same design loads for snow and wind (21 psf and 15

psf, respectively), the sizes of the new roof framing members were calculated using RAM software.

RAM has its fallacies, however. The open-web joists that are the girders for the roof supports were

not fully able to be designed in RAM, because there needs to be a gap between two of the joists for

the clerestories. These members were calculated by hand, and a design schematic was created to

show the appropriate sizes and loadings for the new girders.


Page 34


Accolades


Page 35

Accolades

Professional

LLI Technologies

James White; Mechanical Department Head

Marjorie Conrad; Executive Secretary

Chuck Boyle; Structural Engineer

Mosites Construction Company

Tom Edwards

Star Electric

Bob Kalan

Educational

Architectural Engineering Faculty

Dr. William Bahnfleth

Dr. James Freihaut

Dr. Moses Ling

Dr. M. Kevin Parfitt

Architectural Engineering Colleagues

Dan Rusnack

Ben Hagan

Geoff Measel

Brian Genduso

Nick Maffeo

Darren Bruce

Sam Snyder


Page 36


Appendices


Page 37

Appendix A – Mechanical Schedules

Heating and Cooling Load Schedule:

Space

Sensible Cooling (Btu/h)

Total Cooling (Btu/h)

Total Cooling (Tons)

Cooling Coil CFM

Total Heating

Load (Btu/h)

Total Heating

Load (Tons)

Heating Coil CFM

Break 107 3,300 5,600 0.47 90 8,100 0.68 90Janitor 106 300 300 0.03 8 100 0.01 8Men 105 300 300 0.03 8 100 0.01 8Women 104 300 300 0.03 8 100 0.01 8Office 108 2,700 3,500 0.29 90 4,000 0.33 90ZONE 1 6,900 10,000 0.83 204 12,400 1.03 204Break 116 7,300 11,300 0.94 215 10,200 0.85 215Janitor 115 400 400 0.03 12 200 0.02 12Men 113 1,900 1,900 0.16 60 600 0.05 60Women 114 1,900 1,900 0.16 60 600 0.05 60Office 111 3,500 4,300 0.36 115 4,700 0.39 115Office 112 3,500 4,300 0.36 115 4,700 0.39 115ZONE 2 18,500 24,100 2.01 577 21,000 1.75 577Conveyor 181,300 233,600 19.47 6,398 219,000 18.25 6,398ZONE 3 181,300 233,600 19.47 6,398 219,000 18.25 6,398Warehouse 2,805,700 4,039,400 336.62 100,823 1,240,600 103.38 100,823ZONE 4 2,805,700 4,039,400 336.62 100,823 1,240,600 103.38 100,823

Space Heating and Cooling Loads (provided by Trane Trace)

Table 4 – Heating and Cooling Design Loads

After systematically dividing the spaces into zones, the higher amount of Btu/h required for

heating or cooling for each zone was chosen. Cooling was dominant in the warehouse, in the

conveyor hallway, and the east side office area. The west office area was heating dominated.

Tonnage of the higher loads governed the size of each of the heat pump units for each zone.

The size of the units for each zone is organized below in Table 5.

Zone Rooms Design Load Unit Size Quantity of UnitsZone 1 East Office Area 1 Ton 1 Ton 1Zone 2 West Office Area 2 Tons 2 Tons 1Zone 3 Conveyor Hallway 20 Tons 10 Tons 2Zone 4 Warehouse 336 Tons 25 Tons 14

Zonal Heat Pump Sizes and Quantities

Table 5 - Zonal Heat Pump Sizes and Quantities


Page 38

Geothermal Heat Pump Heat Exchanger Calculations:

Cooling HeatingHeat Rejected Heat Extracted

4,306,700 Btu/h 1,492,900 Btu/h

Mean Ground Water Temperature 52 oF

Heat Pump Entering Water TempMinimum 34 oF Q = 1,492,900 4,306,700 BTU / HrMaximum 88 oF ρ = 62 62 lbs / ft3

v. = 668.86 3859.05 ft3 / hrTmax-Tmean = 36 oF Cp = 1 1 BTU / lb-oFTmean-Tmin = 18 oF T1 = 88 52

oF

T2 = 52 34 oFQ / ∆T = 120 * 318 = 38,043 feet of HX pipeQ / ∆T = 83 * 343 = 28,448 feet of HX pipe v. = 89.42 515.92 gal / Hr

v. = 1.49 8.60 gal /minLarger Pipe Length : 38,043 feet of HX pipe

38,043 feet of HX pipe / 2 = 19,021 feet of bores

At 250 foot depth per bore = 76 Bores

Vertical Heat Exchanger Pumping / Closed Loop Geothermal Heat Pump

Internal Loop Flow RateQ = ρ*v.*Cp*∆T

Table 6 – Geothermal Heat Exchanger Pipe Calculations

The following calculations were used for the above table:

To determine the length of the Heat Exchanger in Cooling conditions, the formula

HX Length = mean

R

TTQ

−×

max

318

and the following chart from the ASHRAE Commercial heat pump design guide were used:

Fig. 23 – Vertical circuit pipe heating length vs. energy rejected


Page 39

To determine the length of the Heat Exchanger in Cooling conditions, the formula

HX Length = min

343TTQ

mean

R

−×

and the following chart from the ASHRAE Commercial heat pump design guide were used:

Fig. 24 – Vertical circuit pipe heating length vs. energy extracted


Page 40

Ground Water Heat Pump Heat Exchanger Calculations:

Mean Ground Water Temperature 52 oFGround Water ∆T = 5 oF

Leaving Liquid TemperatureTmean + 5 = 57

oF

Tmean - 5 = 47 oF

Cooling HeatingHeat Rejected Heat Extracted Q = 1,492,900 4,306,700 BTU / Hr

4,306,700 Btu/h 1,492,900 Btu/h ρ = 62 62 lbs / ft3

v. = 3009.88 2894.29 ft3 / hrSpeficic Heat for 30% Propylene Glycol / Water Antifreeze Solution (CF)= 0.94 Cp = 1 1 BTU / lb-oF

T1 = 52 76oF

∆Twl = QR / (500*GPMwl*CF) T2 = 44 52oF

GPMwl = 150v. = 402.39 386.94 gal / hr

Entering Liquid Temp = 76 oF v. = 6.71 6.45 gal /minEntering Liquid Temp = 44 oF

∆Twl = 61 oF ∆Twl = 21 oFELTwl = 137 oF ELTwl = 23 oFLLTgw = 132 oF LLTgw = 18 oF∆Tgw = 80 oF ∆Tgw = 34 oF

GPMgw = 108 GPMgw = 87

Use 108 GPM to size Heat Exchanger

Internal Loop Flow RateQ = ρ*v.*Cp*∆T

Plate / Frame Heat Exchanger / Open Loop Ground Water Heat Pump

Water Loop CalculationsCooling Heating

Table 7 – Ground Water Source Heat Exchanger Calculations

The following calculations were used for the above table:

CFDFRQT

wl

Rwl ××

=∆500

Where: QR = Design Heat Rejected DFRwl = Design water loop flow rate CF = Correction Factor to account for antifreeze in the loop

( )( )water

antifreeze

heatspecificdensityheatspecificdensityCF ×

×=

wlwlwl TLLTELT ∆+=

Where: ELTwl = Entering Liquid Temperature of Water Loop LLTwl = Water Temperature entering Heat Pumps

gwgwgw ELTgLLTT −=∆

Where: ELTgl = Maximum Liquid Temperature of Groundwater

gw

Rgw T

QDFR∆×

=500

Where: QR = Design Heat Rejected DFRgw = Design groundwater loop flow rate

(In order to perform the process for the heating system, change QR to QE, and reverse the ELT’s and LLT’s.)


Page 41

Previous Mechanical Equipment Schedule:

H. J. Heinz Distribution Facility Existing Mechanical Equipment

Packaged Terminal Heat Pump Schedule

Label CFM OA

CFM E.E.R. Cool MBH Heat kW Elec. Data Description Quantity

A 330 70 10.7 10.7 2.01 208-1φ-60 GE Zoneline Series 5200 2

B 310 70 11.3 8.8 2.01 208-1φ-60 GE Zoneline Series 5201 2

C 280 70 12 8.8 2.01 208-1φ-60 GE Zoneline Series 5202 2

Gas Fired Heating Unit Schedule

Label CFM MBH, in MBH, out Elec HP Elec V/φ Description

Quantity

HV-1 6,625 1,200 1,104 5 460/3 Cambridge, S-1200 3

DF-1 2,500 200 156 Powered Aire HED-200 2

Electric Wall Heater Schedule

Label CFM kW Amps Elec Data Height Depth Description Quantity

EWH-1 65 3.4 8.4 120-1φ-60 14-7/8" 4-11/16" QMark - CWH Series 2000 4

EWH-2 100 13.6 19.5 208-1φ-60 19-3/16" 5-1/4" QMark - CWH Series 3000 2


Page 42

Fan Schedule Label CFM SP

(wg) RPM Motor HP Motor Elec. Sones Type Quantity Description

EF-1 220 0.375 1,050 130 W 120-1φ 2.9 Centrifugal 2 Penn Ventilator Zephyr TD-8H

EF-2 200 0.375 1,050 131 W 120-1φ 3.3 Centrifugal 1 Penn Ventilator

Zephyr RA-Z8H

EF-3 250 0.375 1,050 153 W 120-1φ 4.6 Centrifugal 1 Penn Ventilator

Zephyr TD-Z101S

EF-4 23,000 0.375 500 7.5 480−3φ 38 Propeller 12 Penn Ventilator Zephyr BHH-

54

EF-5 12,000 0.375 915 3 480−3φ 23.9 Propeller 1 Penn Ventilator Zephyr BHH-

30B

Ventilating Fan Schedule

Label Blade Sweep

Elec. FLA Elec V/φ RPM Control Description Type Quantity

VF-1 56" 1.0 120-1φ 265 Dial On-Off

Variable Speed

Leading Edge Model 5600-ILC

Ceiling Paddle Fan 12

Supply Fan Schedule

Label CFM SP (wg) RPM Motor HP Motor Elec. Sones Type Description Quantity

SF-1 1,900 0.2 1,190 0.33 120-1φ 8.8 Centrifugal GE Zoneline Series 5200 2

Water Heater Schedule

Label Gallons Watts Elec. Data Recovery Temperature Set point Description Quantity

A 15 2,500 208-1φ-60 10 GPH @ 100o Rise 135oF

A.O. Smith Model #DEL-

15 2

Table 8 – Previous Design Mechanical Equipment Schedule


Page 43

New Mechanical Heat Pump Pricing Schedule:

Unit Quantity Material Installation Unit Total Total25 Ton Heat Pump 14 $14,500.00 $6,425.00 $20,925.00 $292,950.001 Ton Heat Pump 1 $1,325.00 $1,100.00 $2,425.00 $2,425.002 Ton Heat Pump 1 $1,925.00 $1,350.00 $3,275.00 $3,275.0010 Ton Heat Pump 2 $9,200.00 $2,800.00 $12,000.00 $24,000.00110 GPM Plate & Frame Heat Exchanger 1 $7,360.00 $590.00 $7,950.00 $7,950.003 HP - 150 GPM End-Suction Pump (each) 2 $4,340.54 $2,336.88 $6,677.42 $13,354.842-1/2" Sch. 40 Steel Pipe (LF) 360 $5.05 $9.60 $14.65 $5,274.001-1/4" Polyethelene HX Pipe (in Linear Feet) 39,219 $0.61 $2.03 $2.64 $103,538.161-1/4" Polyethelene HX Pipe (in Linear Feet) 109,885 $2.37 $4.03 $6.40 $703,264.001" Copper H2O Pipe (in Linear Feet) 1,875 $2.37 $4.03 $6.40 $12,000.001-1/2" Fiberglass with Jacket Insulaton (LF) 1,875 $1.04 $1.94 $2.98 $5,587.50

Total Costs = Ground Water HP $366,816.34 = Geothermal HP $443,775.66 = Water Source HP $1,043,501.50= All Systems --------------------

Heat Pump Equipment Pricing

Table 9 – New Mechanical Design Equipment Pricing Schedule

These numbers were obtained from R.S. Means Mechanical Cost Data from the year 2000.


Page 44

Appendix B – Daylighting Calculations

Illumiance Calculations:

Lighting Illuminance Values

hcc (feet) = 2 CCR = 0.0662 hrc (feet) = 20 RCR = 0.6620

hcc (feet) = 4 FCR = 0.1324

Length (ft) = 737 Width (ft) = 190

Luminaire

F01 (metal halide)

F02 (fluorescent)

F10 (fluorescent) ------------

F01 (metal halide)

F01 (metal halide)

Luminaires 190 50 90 ------------ 126 30 Lumens = 36,000 5,950 9,200 ------------ 36,000 36,000 CU = 0.87 0.87 0.80 ------------ 0.87 0.87 ------------

RSDD = 0.96 ------------ LLD = 0.85 0.91 0.91 ------------ 0.85 0.85

BF = 0.90 0.98 0.98 ------------ 0.90 0.90 LDD = 0.82 ------------

------------ LFF = 0.60 0.70 0.70 ------------ 0.60 0.60

------------ ------------ Illuminance (fc) = 25.60 1.30 3.32 ------------ 16.98 4.04 ------------ Total Illuminance (fc) = 30.22 ------------ 21.59 8.66

Table 10 – Illuminance Calculations Table


Page 45

Distribution Charge Transmission Charge Generation Charge Total Charge

First 5,000 kW of demand: $9,074.96 $2,150.00 $48,748.48 $59,973.44

($ per kW) ($ per kW) ($ per kW) ($ per kW)

Next 10,000 kW of Demand $1.46 $0.43 $7.73 $9.62

Next 25,000 kW of Demand $1.42 $0.43 $7.50 $9.35

Additional kW of Demand $1.38 $0.43 $7.30 $9.11

Distribution Charge Transmission Charge Generation Charge Total Charge(cents per kW) (cents per kW) (cents per kW) (cents per kW)

First 750,000 kWh plus 400 kWh per kW of Demand 0.4375 0.1188 2.3332 2.8895Next 150 kWh per kW of Demand 0.2797 0.1188 1.4424 1.8409

Additional kWh 0.2517 0.1188 1.2844 1.6549

Demand Charges

Energy Charges

Allegheny Power Distribution Charges

Table 11 – Allegheny Power Discharge Pricing


Page 46

Appendix C – Structural Schedules

Open Web Joist Schedule:

Design Design Allowable AllowableBeam Joist Size W/L (lbs/ft) Length (ft) Load (kips) W/L Load (kips) Quantity

1 24K7 145.14 46 6.68 191.00 8.79 342 32LH06 278.53 46 12.81 363.36 16.71 4933 36LH13 809.73 46 37.25 871.73 40.10 694 60G12N13.4K 63.333 10.44 0.00 165 60G12N6.7K 63.333 5.22 0.00 26 mod. 60G12N13.4K 63.333 0.00 0.00 327 mod. 60G12N6.7K 63.333 0.00 0.00 4

Structural Joist Design Schedule

Table 12 – Open Web Joist Schedule


Page 47


References


Page 48

References

Books Heat Pumps / HVAC Applications

Commercial/Institutional Ground-Source Heat Pump Engineering Manual, The American Society

of Heating, Refrigerating and Air-Conditioning Engineers, Inc; 1995

Mechanical and Electrical Equipment for Buildings, 9th edition; Benjamin Stein and John S.

Reynolds. John Wiley & Sons, Inc; 2000

Heating, Ventilating, and Air Conditioning, Analysis and Design, 5th edition; Faye C. McQuiston,

Jerald D. Parker, Jeffery D. Spitler. John Wiley & Sons, Inc; 2000

ASHRAE Handbook of Fundamentals; The American Society of Heating, Refrigerating and Air-

Conditioning Engineers, Inc; 2001

ASHRAE Handbook of Systems; The American Society of Heating, Refrigerating and Air-


ASHRAE Handbook of Applications; The American Society of Heating, Refrigerating and Air-


Ground Water for Air-Conditioning in Pittsburgh; D. W. Van Tuyl; Topographical and Geological

Survey, Bulletin W. O., 1961

R. M. Means Mechanical Cost Data, 2000; R. S. Means Company, Inc.


Page 49

Daylighting

Daylighting; Performance and Design, 2nd edition; Gregg D. Ander. John Wiley & Sons, Inc;

2003

IESNA Lighting Handbook, 9th edition; IES, the Illuminating Engineering Society of North

America, 2000

Steel Design

American Institute of Steel Construction, Manual of Steel Construction, 3rd Edition, American

Institute of Steel Construction, Inc., 2001

Vulcraft Steel Joists and Joist Girders Design Guide, 2001

Websites

HVAC Applications

American Society of Heating, Refrigeration, and Air-Conditioning Engineers Website:

http://www.ashrae.org

U.S Department of Energy, Office of Energy Efficiency and Renewable Energy Website:

http://www.eere.energy.gov/buildings/highperformance/

U.S Department of Energy, Building Technologies Program Website:

http://www.eere.energy.gov/buildings/design/integratedbuilding/passivedaylighting.cfm


Page 50

Articles

Heat Pumps

Geothermal Heat Pumps, Four Plus Decades of Experience; R. Gordon Bloomquist, PhD.,

Washington State University Energy Program, GHC Bulletin, December 1999

1998 Standard for Ground-Water Source Heat Pumps; Standard 325; Air-Conditioning and

Refrigeration Institute

Energy and Demand Study of Heating and Cooling Equipment; Air-Conditioners, Furnaces, Air

Heat Pumps, and Ground Source Heat Pumps; Steve Kavanaugh, The University of Alabama

Software Cooling Load Analysis

Carrier’s Hourly Analysis Program (HAP), Version 4.20 Software

Trane Trace 700, Version 4.1.1 Air Conditioning Load Software

Daylighting Analysis

AGI32-EDU, Version 1.66 Software

Structural Load Analysis

RAM Manager, Version 1.03 Software

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