Jefferson Laboratories Technology, Engineering Development Facility

Addition to existing building: Jefferson Laboratories Technology and Engineering Development Facility; EwingCole

08/09/2012


Rendered shot of the Jefferson Laboratories Technology and Engineering Development Facility, which is estimated to be finished at the end of 2012. Courtesy: EwingCole (Click to enlarge)Project name: Jefferson Laboratories Technology and Engineering Development Facility

Location: Newport News, Va.

Firm name: EwingCole

Project type, building type: Addition to existing building, research/lab/high-tech

Project duration: 4 years

Project completion date: Dec. 1, 2012

Project budget for mechanical, electrical, plumbing, fire protection engineering only: $950,000

Engineering challenges

Jefferson Lab (JLab) selected EwingCole through a nationwide competition to provide full architectural and engineering design services for the Technology and Engineering Development Facility (TEDF) project. The $51M project included the renovation of the 88,900 sq ft of existing Test Lab Building 58, a 30,000-sq-ft addition to Building 58, and a new 70,000-sq-ft Technology and Engineering Development (TED) building. The Test Lab Building 58 was originally built by NASA in 1965 for radiation effects research and has been modified to accommodate activities now performed by the SRF (Superconductor Radio Frequency) group. Programmatically, the design includes small parts fabrication, etching, cleaning, and assembly in the new addition and the high-bay crane handling activities occurring in the existing Building 58. A new high-bay area with a 10-ton crane houses welding shops and room for various experimental assemblies for cryofab, vacuum, electrical, and physics. New ISO 4 and 5 clean rooms are also part of the project. As part of this project, EwingCole performed a facility conditions assessment including a careful reevaluation and confirmation study of JLab operational requirements and the prior master plan basis for design. EwingCole organized collaborative, interactive workshops to understand workflow processing and production. The design improves upon the prior master plan and basis for design, and achieves the scientific user goals of this project to create a unified, team-oriented working environment by optimizing and standardizing the process flow of people, products, waste, supplies, and information through the facility. Jefferson Lab credits EwingCole for significantly improving the previous master planning through this early reevaluation and confirmation process.

Solutions

Due to the combination of new and existing facilities with renovation pieces as part of the project, two separate HVAC systems were proposed for the addition of the TEDF. A hybrid geothermal system will be provided to generate chilled water and heating hot water for the TED building central air-handling units. The existing chiller and boiler plants within Building 58 will be utilized to provide chilled and hot water to the systems serving the Building 58 expansion and renovations. 

The concept for the new HVAC systems serving the new and renovated areas address prior concerns in the existing facility related to operational flexibility, service, and maintenance of mechanical equipment and energy efficiency. The final design and scope of work consolidates and centralizes mechanical equipment to reduce overall maintenance. The cooling and heating water for the Building 58 high-bay and support spaces will be provided from the Building 58 chiller and boiler plants. Chilled water and heating water will be extended from existing mains within Building 58. The estimated cooling load for the existing Building 58 renovation is 126 tons. The cooling and heating for the Building 58 office renovation will be served from the TED building geothermal condenser water system. Condenser water piping will extend across the corridor link from the second-floor mechanical room located in the TED building. The estimated load for the Building 58 office renovation is 85 tons excluding the effect of heat recovery. 

Integrated power distribution centers consisting of low-voltage distribution panels and step-down transformers are incorporated throughout the laboratory and high-bay spaces to maximize efficient space usage for electrical distribution equipment. The use of wireless access points is incorporated throughout the buildings in order to maximize connectivity to the campus networks. The electrical distribution systems have been design to be energy efficient and contain sufficient capacity for future expansion. The transformers are Energy Star compliant, meeting TP-1 energy compliant guidelines for efficient operation. The TED building was located adjacent, and attached, to the test lab building to enhance communication among cross-functional product teams and to accommodate continued operation during construction. 

The new TED building can also be used temporarily to house functions that will be interrupted during the renovation of the test lab building. This will enable cryomodule production to continue during the second phase of construction when the current high-bay area in Building 58 is being renovated. This location also provides an improved image to the campus by screening existing concrete warehouse buildings with a dynamic new structure, and maintains more of the existing wooded area and wetland, which contributes to the project’s goal of U.S. Green Building Council (USGBC) LEED Gold certification. Interestingly, the project is on track for two LEED Gold ratings: one for the TED building and one for the Building 58 renovation due to the differing USGBC requirements of new and renovation projects. Major sustainable design features include a ground source hybrid geothermal well field, solar heating of domestic hot water, a dedicated outdoor air energy recovery unit, and demand control ventilation. 



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Leaders Under 40 program features outstanding young people who are making a difference in manufacturing. View the 2013 Leaders here.
The new control room: It's got all the bells and whistles - and alarms, too; Remote maintenance; Specifying VFDs
2014 forecast issue: To serve and to manufacture - Veterans will bring skill and discipline to the plant floor if we can find a way to get them there.
2013 Top Plant: Lincoln Electric Company, Cleveland, Ohio
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Bring focus to PLC programming: 5 things to avoid in putting your system together; Managing the DCS upgrade; PLM upgrade: a step-by-step approach
Balancing the bagging triangle; PID tuning improves process efficiency; Standardizing control room HMIs
Commissioning electrical systems in mission critical facilities; Anticipating the Smart Grid; Mitigating arc flash hazards in medium-voltage switchgear; Comparing generator sizing software

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.