- Cooling & Heating Asset Management Program (CHAMP)
Our team is executing the Cooling & Heating Asset Management Program (CHAMP) to address HVAC modernization issues to meet mission requirements and reduce deferred maintenance growth across the National Nuclear Security Administration (NNSA) complex. We initially executed the CHAMP pilot and are working on the enterprisewide program.
We are partnered with Lawrence Livermore National Security LLC. (LLNS) to assist in execution of cooling and heating upgrade projects across the eight NNSA sites. We provide detailed design (Title I and Title II) and engineering during construction (Title III) including architectural, structural, mechanical, electrical, civil and fire protection. As construction manager for the design-build program, we provide scoping, build effort competitive procurement and subcontract award, management and lower-tier build subcontractors oversight and administration. Projects are completed to provide deferred maintenance reduction; modernization of facilities in support of science mission; reduction of energy consumption, as verified through measurement and verification; regulatory requirement compliance; and decreased operational costs.
The program demonstrates our ability to:
- Analyze a prioritized list of HVAC system projects provided by NNSA Office of Infrastructure, Safety and Operations (NA-50)
- Assess the HVAC needs/problems at the proposed sites
- Recommend an engineering solution to the problems/needs
- Provide construction cost estimates, AACE Class I
- Provide engineering drawings, specifications and design documents for construction bidding
- Integrate 10 CFR 851 ES&H into planning and execution at multiple sites
- Obtain multiple construction bids, select the best value providers and coordinate construction at sites while managing multiple subconsultants
- Report on the potential cost saving/energy efficiencies gained through the work at each site
- Engineering assessments
- Measurement and verification
Architecture responsibilities include building modifications to remove existing and install new mechanical systems. Structural design includes support for mechanical systems and removal modifications; existing structure review for efficient demolition and installation; fall protection systems required for construction and permanent installation; new lifting plans and rigging systems for on-going maintenance, construction, demolition and removal of existing systems. Mechanical design includes HVAC systems and piping; equipment sizing and selection; sequence of operation and controls (pneumatic, direct digital control, and programmable logic control); flow diagrams; piping and instrumentation diagrams; system appurtenances sizing and selection; makeup water systems; makeup air systems; coil sizing and selection; dehumidification and humidification systems; boiler sizing and selection; natural gas and/or fuel-oil system sizing; system sizing for optimal operation such as N+1 redundancy and low-load conditions. Additionally, we provide modeling of mechanical and architectural systems (including building envelope) to determine life cycle cost and energy consumption for comparison.
Electrical system design include sizing and distribution, arc-flash and short circuit calculations, and breaker coordination studies to support installation of new equipment and demolition of existing systems; standby generator designs; and lighting systems design. Civil design includes site drainage; site lay-down yard designation; construction traffic support and paving; geotechnical reports and surveys; and utilities.
Since this program is comprised of a variety of design-build projects, one of the key aspects is to assemble a list of program-level and project-level lessons learned. Project-level lessons learned are shared with the individual stakeholders during design and construction kickoff and program-level lessons learned are shared with program leadership. A few examples include:
- Thorough safety job hazard analysis development in advance of construction activities allows for initiating construction activities as planned.
- Phone interview with knowledgeable facility personnel, remote advance data gathering, preliminary data evaluation followed by on-site kickoff for field reconnaissance is advantageous for efficient field reconnaissance.
- Field reconnaissance using personnel with DOE Q-Clearances during assessments and design is efficient.
- Maintaining the same site lead and technical lead from assessment through construction is beneficial.
- Each task order schedule should be collaboratively developed between program manager, project team and LLNS for concurrence and appropriate scheduling between milestones.
During the design process on a CHAMP Pilot HVAC project at NNSS, our design team conducted an evaluation of the site’s design requirements and worked with the site to identify cost savings prior to construction procurement. During the design process, we reduced the number of outside condensing units needed; utilized existing HVAC capacity previously installed on a recent project; and modified an exterior unit to be added in a manner that allowed for a 67 percent reduction in the number of new exterior units to be installed. Additionally, as part of an enhanced procurement process, we increased competition by working with an additional qualified subcontractor to compete for the project. The result was a cost savings of $300,000 on a $2,500,000 project.