Eastern Florida State College Health Sciences Building

CDE recently helped Eastern Florida State College design a next generation education facility that will focus on Health Sciences.  CDE was tasked to design the entire mechanical, electrical, and plumbing systems design for this new two story, 61,000 sq. ft. teaching facility.   The new building design was integrated into available space of the existing Melbourne campus and tapped into the existing campus cooling loop.  The new facility is the focal point of the campus entrance on Wickham Road.   The Health Science building provides offices, classrooms, and patient simulation areas that focus on teaching surgical, respiratory, radiography, diagnostic medical sonography, occupational therapy as well as physical therapy programs for the Nursing and Health Sciences department at the college.

The building is unique in that it incorporates Hospital equipment and services for hands on training programs such as an actual ambulance entrance to working critical care stations. The facility incorporates medical gases such as oxygen, nitrogen, and carbon dioxide, as well as a vacuum system into its infrastructure for teaching purposes.  Alarms connected to a central nursing station can provide failure response training.  Operating room and x-ray tech room with operating x-ray machine were also included.

CDE is proud to say that the construction of this facility was completed in early 2017 and the building currently in use helping train the next wave of heath care professionals.

UCF Wayne Densch Expansion Building

This project involves the design of a new 40,000 sq. ft building located between the existing Wayne Densch Athletic Offices and the Nicholson Field House. The building will be two stories and include training, classroom, locker rooms, and offices.

The project is designed to be constructed in multiple phases. The First Phase, or “shell building” will include first and second floors, exterior walls without interior finishes, but including windows, doors and storefront systems and roof.  Interior, fire-rated corridors will provide egress from the Wayne Densch Center to the exterior on the first floor and similar corridors leading to the egress stairs on the second floor.   Future phases will be incorporated as funding permits through budgeting and donations.

The “Shell Building” has been customized through design charrette with the Athletics and facilities department to ensure the program desired for the buildout can be accommodated. Close coordination was also required to address budget constraints and University Design standards.

Design/Build NASA Generator RICE-NESHAP Compliance Projects

Cape Design Engineering provided full Design/Build services for a time critical project to bring three power generation sites into compliance with RICE-NESHAP regulations (five generators at the C-5 substation, two generators at the CD & SC Facility, and two generators at the Press Site launch observation site). These generators are critical since they serve the the Vehicle Assembly Building and surrounding areas of NASA. CDE processed a Construction Air Permit from the Florida Department of Environmental Protection (FDEP) for making modifications to the 9 generators currently covered under an active air permit. This effort was coordinated with the KSC Environmental Assurance Branch (EAB). The permit was obtained from FDEP ahead of the schedule due in part to the thorough, clear and concise permit application.

CDE’s design service included structural, electrical and controls engineering for all three sites. Structural provided design to support the new silencer/catalysts. This effort included some finite element modeling of existing steel support towers and their modifications to support the new silencer/catalysts. Electrical design included power, Lightning protection, primary power distribution and controls. The controls tied new catalyst metering and monitoring devices into the existing power distribution.

After completing the mechanical modifications on the generators, CDE conducted comprehensive testing to ensure all generators complied with the EPA Reference Test Method requirements. This testing was coordinated with the state of Florida and local environmental jurisdictions as required by RICE-NESHAP, FDEP rules, and the Title V operating permit. The Compliance testing verified acceptable CO reduction was achieved.

CDE’s design and construction effort met the RICE-NESHAP requirements of reducing CO concentration by 70% when comparing measurements before and after the oxidation catalyst. CDE’s design and scheduling ensured that each site maintained the ability to provide standby power for their part of the NASA KSC power distribution system safely.

Design/Build Fuel Skid System

Cape Design Engineering was responsible for a turnkey design, fabrication and installation of a new semi-automated, high pressure fuel skid system (FSS) and installation of new stainless steel supply distribution piping in the south section of building 795, Fleet Readiness Center Southeast (FRCSE) Jacksonville, Florida. The FSS is capable of delivering 400 gallons of calibration fluid (MIL-C-7024 Type II) per minute (GPM) at a line pressure of 1650 PSIG to eight test stands operating at full capacity with no interruptions. The new stainless steel supply distribution piping with test stand connection points were installed prior to the installation of the pump systems to negate operational down time. The FSS incorporated state-of-the-art electronic PLC controls that are easily supportable for the next 15 years and provide intuitive capacity management and control. CDE performed non-destructive X-Ray testing of all pipe welds. CDE provided complete training of system operations. A fuel/water separator was incorporated in the open loop return line to ensure water free calibration fluid. The calibration fluid has a flash point of 104°F, therefore, the pump skid was rated as a Class 1 Division 2 hazardous environment. All electrical components complied with the appropriate NEC requirements for a Class 1 Division 2 environment. Complete chilled water cooling system (47 °F water), 100 PSIG shop air pneumatic system, and 408 volt electrical distribution from MCC to power these systems were designed by CDE.

The benfits of the design include a highly reliable, fully automated, least maintenance cost fuel skid with the following features: Appropriate vibration dampening was employed to reduce stress on hardware. Commercial-Off-the-Shelf components were used in all instances. Pump, filter, valve placement, and orientation were geared toward ease of maintenance support and accessibility. Ensuring successful purge cycles during each start up was a challenge. CDE developed a sequence of operations, tested each one, and commissioned the systems to ensure that the purge cycle is successful without any damage to the system each time. A rupture disc rated to burst at 2000 PSI and a pressure relief valve were installed in each branch supply pipe and vented back to the open loop return pipe for additional safety. The FSS control system was configured to operate as a stand-alone system with fully redundant manual controls. The PLC manages the use of the available pumps to satisfy the instantaneous flow demand of the connected test stands.

Daytona State College Thermal Energy Storage System

In 2012, CDE was tasked to study a thermal storage system (TES) for the Daytona campus of Daytona State College. TES is a system that makes ice of chilled water using a lower electric rate, often during off-peak demand hours for electricity. The ice or chilled water is then used during peak hours to cool buildings. CDE reviewed the options of providing ice storage and chilled water storage system. Based on the energy cost savings review and lifecycle cost analysis, CDE recommended a 2.5-million gallon chilled water storage tank which could have a payback in less than nine years.

Daytona State College secured funding for the $3 million that CDE estimated for this project, and in 2013 started the design and construction effort. CDE was hired to act as the owner’s rep and commissioning agent. Throughout the project’s successful execution, CDE provided valuable constructive comments and analyzed the best plant operating scenarios, doing so along with Florida Power & Light.

In the summer of 2014, CDE successfully commissioned this project, ensuring that the savings predicted would reach fruition. Toward that end, this project annually saves Daytona State College over $200,000 in energy costs, which resulted in FPL providing more than $1.1 million in incentives. On November 20, CDE proudly attended the ribbon-cutting ceremony.

All in all, it was another successful TES installation. Kudos to the architect, Pond and company, who designed the 80-foot tank’s exterior appearance to merge with Daytona State’s campus exterior building aesthetics.

NASA’s SSPF Science Annex

The SSPF Science Annex is a new building located adjacent to the Space Shuttle Processing Facility. It serves as a science laboratory which supports manned space missions. The SSPF Science Annex is located at Kennedy Space Center.

CDE’s design team performed, complete design including site civil, architectural, structural, electrical, mechanical, plumbing, process piping, controls, fire detection and protection as well as data system. This building is designed with 100% redundancy in system operation without single point failure. CDE’s construction team completed the construction of this facility and it was commissioned by a third party. The entire building and systems were modeled using BIM.

CDE’s design team also had the difficult task of maintaining precise temperature and humidity control in each of the spaces over a wider range than that of a normal building. The other, bigger challenge was to accommodate all the mechanical systems with redundancy in less than a 500-square-foot space. Because the site was so limiting, CDE had to add a mezzanine to accommodate extensive systems. CDE also had to fit two steam boilers, five humidifiers, three hot water heaters, water treatment, a deionized water generator, DI water storage tank and an exhaust fan system within this 500 ft.² space. In addition, the fire protection riser had to be installed within the same space with code required clearances. The architectural aspects of construction came with several challenges. The building had to be airtight and moisture-proofed. The surfaces were required to be resistant to repeated cleaning cycles.
Another challenge was a design that allowed pressure relationships to be maintained over a wide range of air flow rates to the individual spaces. Additionally, the commissioning of the building was a huge challenge because of several possible system/control failure scenarios. These systems were rigorously tested and validated for each of those scenarios.
This building utilizes every possible utility, such as chilled water, compressed air, DI water, high and low temperature hot water, steam, condensate, and natural gas. This project was completed on time and within budget.

There are several ECMs incorporated for energy savings for this facility compared to a standard facility and this building has been designed for LEED Silver Certification. The energy conservation features included the following: Chilled water system was provided for this 5,700 sq.ft conditioned spaces. In addition, VFD control for air handlers and exhaust fans, Occupancy sensors, Demand-controlled ventilation based on mode of operation, High-efficiency steam boilers and hot water heaters, SCR controls for every heater in the facility for precise temperature control, Supply air temperature reset control, a complete direct digital control system for monitoring, measurement and verification were provided. Since it is a lab building, there were unique requirements for precise temperature and humidity range controls for each of the spaces. Modulation of supply and exhaust with VFDs to maintain positive pressure in the building was provided. The building saves 35% more energy compared to a conventional building design.

Belle Glades Technical Education Facility and Chiller Plant

This two story 33,982 square foot building is the first LEED Platinum Certified Project constructed at Palm Beach State College. The new Technical Education Center (TEC) was designed to consolidate instructional training and certification for a variety of vocational programs. CDE provided MEP design services, LEED documentation, site mechanical and electrical distribution and commissioning support for the plant. This building houses facilities for vocational classrooms and labs, administrative offices, student support services, and ancillary functions as well as auxiliary facilities for equipment and material storage. The building accommodates programs in Welding, Construction Trades, Law Enforcement, and Cosmetology. The new building was designed for a future addition of approximately 8,700 S.F. to accommodate new programs in Heavy Duty Truck and Bus Mechanics, and an expansion of the Welding program.

CDE designed Plumbing and fire protection systems for this building as well. A grey water system was designed to collect rain water from the building and existing building and condensate from air handling units. All the collected rain water and condensate drains were designed to be pumped to flush water closets and for cooling tower make-up. Wet pipe fire protection system was designed for this building.

CDE designed the entire electrical distribution for the campus, electrical system design for the building including fire alarm system and PV power for renewable energy source. CDE modeled the energy use for the entire campus and M&V proved that the model was very accurate.

CDE also designed the upgrades for the entire Belle Glades campus chiller plant. The chiller plant modifications consisted of replacing two existing chillers with 300 ton rotary screw chillers. The existing chilled water and condenser water pumps were also replaced. The cooling towers were also replaced with new cooling towers.

Based on all of the modifications, the campus energy use significantly reduced. Even after the TEC building addition, the campus energy use was lower than the previous years due to primary variable chilled water flow modifications, high efficiency chiller operation and dual-path AC system design for the new building.

Renovation of Building 614

CDE was tasked with the complete interior renovation of Building 614 (the NAS Jacksonville gymnasium) with all new wall, floor, and ceiling finishes, new lighting, new HVAC equipment, and refinishing two racquetball court floors and a basketball court floor. The building was originally built in 1945 and is a two-story, 12,000 square foot facility with workout room, locker rooms, saunas, office space, and a massage therapy room. The current HVAC system uses chiller water as the cooling medium but the system is not balanced and cannot meet the demand. Many of the ceiling tiles were sagging because of the high humidity in the facility.

The new HVAC design incorporates a heat recovery variable flow mini-split refrigerant based system with minimal ductwork. Soffits were designed to hide the refrigerant and condensate piping as several of the rooms do not have drop or gypsum ceilings. All of the showers and restrooms have been redesigned to remove and replace all partitions and fixtures. The steam rooms have been damaged due to the use of coarse and abrasive cleaning techniques on the tile and have moisture behind the tile. The new design repairs the damaged walls and replaces all the ceramic tile on the walls, floors and ceiling of the steam rooms.

In addition to the HVAC effort of the project, some of the additions and enhancements to the gym are a new open but covered outside training facility, refinished sauna/stream rooms, new equipment such as flat screen TVs, refinished gym floor with striping and new floor finishes.

Energy conservation was a critical part of this project. Some of the conservation measures incorporated with design includes:

  • Low e- windows throughout the building.
  • Separate VRF system for the first floor (exercise room area) and the second floor (locker rooms). These units are zoned ductless systems that meet the designated areas specific demands.
  • Zoned ductless variable flow refrigerant system (18 fan coil units with two condensers).
  • All exercise room units are ceiling suspended with target cooling sensors.
  • Occupancy sensors for lighting control throughout the facility.
  • OA control based on occupancy profile and to maintain building pressure during all occupied hours.
  • T-8 lights installed throughout the facility to improve lighting and lighting efficiency.
  • New controls allow for variable set points on supply air temperature for the outside air conditioning unit during summer and winter months to maximize energy savings.
  • A well ventilated and tempered laundry facility with its envelope isolated from the rest of the facility.
  • The new condensers have variable speed compressors with (18.1 IEER for first floor unit and 20.8 IEER for the second floor unit).
  • Individual room temperature control for the offices/lobby for improved comfort and energy savings.

Design of the Mori Hosseini Center at Daytona State College

The 66,000 square foot Mori Hosseini Center was designed by the team of Cape Design Engineering and Florida Architects. The facility is home of the Southeast Museum of Photography, complete with large presentation galleries and exhibit area. Additionally, the facility contains three commercial kitchens, a dining lab, a 500 person banquet facility, hotel rooms, and teaching classrooms for Daytona State College’s Culinary & Hospitality Management programs.

Cape Design Engineering was responsible for the complete structural, mechanical, electrical, plumbing, and fire protection design of this new facility. Cape Design Engineering also provided construction administration and support services during the construction phase of the project.