MEP Roundtable

ENGINEERING INSIGHTS

MEP ROUNDTABLE

Designing safe laboratories and research facilities Engineers working on laboratory and research projects are tasked with balancing state-of-the-art systems, budgetary concerns, occupant safety, sustainable performance, and other factors.

CSE: What’s the biggest trend you see today in laboratory and research facility projects?

Scott A. Bilan: Recent trends include taking the user’s spirits into account. Several studies have shown that happy employees are more productive, resulting in companies having higher retention rates.

Simple yet effective measures include rich color themes, windows to outdoors, open offices, high-end break rooms, etc.

Gordon Handziuk: Energy efficiency and sustainability continue to trend, both as part of overall building systems and as part of laboratory equipment selection.

Off-hour or unoccupied setbacks through

the building automation system (BAS) are becoming generally accepted as systems prove to maintain directional airflow or if pressure cascade is required. Our client base is seeing great value when combined with, for example, variable flow fume hoods. Most of our clients are looking to seasonal commissioning to prove and benchmark performance over the full range of laboratory operations.

Rick Hombsch: We’re noticing three things: t "DBEFNJD SFTFBSDI MBCT XIJDI GFBUVSF interdisciplinary/multidisciplinary research mixing many kinds of research activity within a single building, floor, or individual laboratory.

t $PSQPSBUF SFTFBSDI BOE EFWFMPQNFOU biopharma, where we’re seeing integration of automation/robotics into the laboratory workflow, and big data and computational science into the overall research effort. t 5FBDIJOH MBCT XIJDI BSF NBLFS TQBDFT where students can learn hands-on, sometimes with only minimal guidance from instructors.

Kent Locke: A big trend is upgrades.

For example, a system was removed from a project during value engineering and is now being installed; a lab has more new equipment to support experiments and the room is too hot, cluttered, or there is no available space; or systems are just beyond their useful life and need replacement. New areas need to be developed/expanded for new opportunities/funding.

Christian Matthews: 5IF WBTU NBKPSity of our upcoming laboratory facility projects are partially or fully occupied renovations rather than new construction. We believe that this is a result of how rapidly science is advancing. Facility owners are more likely to act quickly with a renovation project to meet the current or future need through a renovation than a much longer and costly new construction project.

Figure 1: Kerry’s new Global Technology & Innovation Centre consolidates product research and development operations from several Asia Pacific satellite locations for the company’s ingredients and flavors division. This centralization serves to improve recruitment and increase resource sharing. Courtesy: CI&A Photography

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Scott A. Bilan, PE

John C. Palasz: One of the biggest

trends in laboratory and research facility projects that I have noticed is a flexible design approach using modular furniture design along with collaboration spaces.

Also, the lab layout and style are geared to attract perspective scientists with larger and more open work areas and other architectural features.

Aaron Saggars: Operational efficiency is one of the biggest trends we have been programming into new facilities.

The placement of lab functions and their support spaces in a new facility so end users can better use the space with reallife data metrics. This has proven to get the attention of the executive group when you are saving them one to two full-time equivalents while still achieving production or research goals.

Jim Sharpe: We are continuing to see the integration of previously siloed research groups. In the university setting, combining biology, chemistry, physics, and computational analytics is common.

Machine learning is also playing an enhanced part in helping researchers target drug development more efficiently on promising cures. In the private sector, we see research and manufacturing of clinical trial drugs moving into the same facility.

CSE: What trends are on the horizon for such projects?

Handziuk: We’re going to see higher-efficiency heat recovery. Many of our project types, academic and biological laboratories, consider separation of airflow critical, as in no air-to-air heat exchangers. Several recovery-loop arrangements are coming to market where the coils are pumped at high velocity/turbulent flow, and with multiple-pass, extended tube runs. The net result is recovery rates in the 70% to 85% range (sensible). We are also seeing clients interested in eliminating the bypass element on high-plume fans while operating with variable speed fans.

The challenge is to continue to manage the plume height in conjunction with the overall system dilution rate.

Bilan: Energy use from lab buildings is among the highest per square foot for most types of buildings. Safety is paramount for lab facilities. However, we’re seeing more interest in more sustainable design with reduced operating cost.

In addition, ASHRAE is becoming more stringent and requiring such measures as www.csemag.com

energy recovery on most sizes of systems.

Saggars: In addition to improving the overall operational efficiency, our clients are looking for lowest first cost without giving up all the bells and whistles. We are constantly looking for opportunities to use standard offerings from our vendors.

We are often creating custom solutions for our projects, but applying competitive alternatives helps keep the overall project budgets down. Our vendors are continuing to innovate products for the designers to apply and use.

Matthews: Most of the renovations include a significant shift toward automation in laboratories, which has elevated the design requirements on the existing facility infrastructure and has added complexity to the traditional design approach.

We have responded to this industry shift with enhanced methods of coordination during design as well as teaming directly with the automated laboratory equipment vendors as part of our holistic lab design approach.

Palasz: For the HVAC designs to accommodate the trends, the system type must also be flexible. This often leads to a traditional air-cooled variable air volume (VAV) system or an active or passive chilled-beam design solution that can be adjusted and expanded to suit future lab modifications.

Hombsch: Automation and computational processes are shrinking the “wet lab” area. Computational research demands much larger and more integrated office, collaboration, and social spaces.

CSE: Are you noticing an increase in the building of new projects, versus retrofitting existing buildings?

Bilan: Yes, many labs are looking at greenfield sites for development. This is due to two main advantages: One is cost. Often, it is less expensive to build new facilities as opposed to renovating an existing building. Second, there’s less downtime. A new building can be constructed and have a “smart” shutdown.

This allows users and existing equipment to move over the course of a week or two, which decreases the months of potential shutdowns or decreased productivity.

Sharpe: The San Francisco Bay area is booming, so we are seeing many new projects than retrofits. The life science developers are building new facilities that CONSULTING-SPECIFYING ENGINEER

Principal Peter Basso Associates Troy, Mich.

Matt Edwards, PE, LEED AP BD+C Mechanical Associate ME Engineers Golden, Colo.

Gordon Handziuk, PE, PEng Vice President WSP Atlanta

Rick Hombsch, PE, LEED AP Principal, Energy and Infrastructure Group HGA Architects and Engineers Milwaukee,

Kent Locke, PE, NCEES Associate Principal Bailey Edward Fox River Grove, Ill.

Christian Matthews, PE, PMP, CEM, LEED AP Associate; Client Manager Dewberry Raleigh, N.C.

John C. Palasz, PE, HFDP Mechanical Engineer Primera Engineers Ltd. Chicago

Aaron Saggars, PE, LEED AP Core Team Leader CRB USA Kansas City, Mo.

Jim Sharpe, PE, LEED AP Principal Affiliated Engineers Inc. San Francisco

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MEP ROUNDTABLE

Figure 2: The Health and Science Center cadaver laboratory at the College of DuPage, located in Illinois, recently was upgraded to fit the needs of the school’s nursing, physical therapy, and pre-med students. Features include interactive audio/video components, four new cadaver stations, upgraded offices, and upgrades to other areas.

Courtesy: Bailey Edward

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are millions of square feet. Developer lab-vacancy rates are unprecedently low; as a result, demand for new space is high. At this point in the market cycle, the mantra is, “Build it quickly because we can lease it as fast as it’s built.”

Saggars: In recent years, we really haven’t seen a swing either way. We have been involved in several projects where the client was assuming a renovation but ended up with a greenfield project.

It depends on the client and situation.

Locke: Remodeling or additions are the projects we are working on—deferred maintenance upgrades, laboratory reorganization/upgrades, elevator additions, greenhouse additions, and remodeling.

Handziuk: I’ve seen a similar trend over the past 10 to 15 years.

Renovating versus starting a new construction project seems to relate to the structure, floor plate, and floor-to-floor. The question is essentially deciding whether the updates can be accommodated within the existing structure. Renovated high-bay space easily accommodates renovations. Structures with acceptable floor-tofloor heights that have adequate duct, pipe, and cabling tend to be reused.

CSE: How are engineers designing such facilities to keep initial costs down while also offering appealing features, complying with relevant codes, and meeting client needs?

Saggars: I believe our previous experiences help us to continuously improve our approach to our clients’ problems. What we use tomorrow may not be applicable next year. I think knowledge and experience of knowing when to add or detract from the program requirements is critical. Does this client have a robust maintenance program to keep up with an extremely efficient system?

Every project is unique, but using what you have learned from the previous 20 projects and understanding when a client might benefit from that knowledge is critical to having the project meet everyone’s expectations.

Handziuk: CVRL employed an autoscan-type HEPA housing.

The housing is smaller in size, therefore less stainless steel (SS); however, the mobile scan unit is a cost, so the number of housings is a factor. The mechanical space above the lab was existing and limited, and the smaller housings were more easily located near the penetration, resulting in less welded stainless-steel containment ductwork. The shorter SS runs, of course, benefit decontamination routines, but the biggest benefit is the reduced time frame associated with filter recertification. The reduced recertification time is expected to result in 2 weeks per year of additional operational time.

Palasz: Keeping costs down is always a challenge. If first costs are a concern, then a more traditional HVAC system may be feasible with constant-volume airflow and energy-recovery devices as needed to comply with energy code. But if lifecycle costs are analyzed, then often a chilled-water solution using active or passive chilled beams can be a better design approach, especially if the lab has high sensible loads and goals for improved occupant comfort.

CSE: When a lab or research building is associated with a college/university, are there unusual engineering challenges?

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Locke: We have worked in several buildings that the government uses on campuses. The utilities are still provided through underground, campus-owned and -operated systems. Coordination with the university’s facilities department is required to obtain the specifics of those utilities as well as their standards.

Bilan: The most common challenge is the standards may be different between the lab facilities group and campus facilities group. Having discussions with both groups early in the project to determine which standard will be followed is the key to success.

Hombsch: Yes, a particular challenge in academic lab settings is that many of the lab users are graduates and sometimes undergraduate students. This creates a variety of problems: varying skill levels, challenges with safety awareness, irregular work hours, lack of “ownership” over space, high user turnover, etc. In response, many colleges and universities are very risk-averse and favor solutions with proven track records.

Matt Edwards: Most universities have specific design standards that meet the operational preference of university staff while maintaining a reasonable first cost for construction projects. The challenge for the design team is to work within these constraints to deliver a project that meets additional goals, such as sustainability and performance. Often, we must challenge existing standards to ensure that projects meet current building codes and sustainability programs.

lab cooling load increases, the effectiveness of the cooling inherently increases, so this system design approach is more forgiving to the lab designer and allows for flexibility in that capacity. The active chilled-beam design approach also often maintains a very uniform temperature in the space, which leads to improved occupant comfort.

Edwards: In our area of the country, altitude is a significant factor in the design of HVAC systems and often has the effect of requiring larger equipment.

Most HVAC equipment is designed with elevations of 2,000 ft. above sea level in mind, so it’s imperative that equipment be sized appropriately to account for thinner air. System types at higher altitudes are very similar to their sea-level counterparts, but often the equipment (burners, motors, compressors, etc.) is sized larger to account for the effects of altitude.

Saggars: We designed the environmental control system at the University of Kansas, where the university archives its museum specimens. The facility is

historic, and through this process, CRB assisted the researchers with a new space that maintained tight temperature and humidity requirements. We used a dedicated outdoor-air system (DOAS) with a variable refrigerant flow heating and cooling system. The new system is considerably more efficient, but more important, it has stabilized the historic specimens that are used in research and to display at the university.

Sharpe: What was once unique but is now standard design for our San Francisco office—but is still unique to most of the industry—is the use of compressor-less “free” heat recovery. The way this works is we turn off the chillers and heatrecovery chillers when outdoor-air temperatures are below about 55˚F. We then circulate chilled water to fan coil units serving telecom rooms, electrical rooms, freezer farms, and anywhere else with year-round cooling needs. The coolingcoil valves on 100% outside AHUs are modulated so heat is transferred from the year-round cooling rooms and into Continued on page 63

CSE: What unique heating and cooling systems have you specified into such projects? Describe a difficult climate in which you designed an HVAC system.

Palasz: Although it varies by lab, a lab with a high sensible load may lead to an active chilled-beam design. Because the active chilled beam can be very energy efficient, and is typically constantvolume airflow, the lab HVAC system is able to maintain minimum air-change rates and can maintain differential pressures between specific rooms with fewer control costs and higher reliability. This also has the benefit of being a good heating and cooling method due to the radiant cooling effects, and as the

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MEP ROUNDTABLE

Continued from page 61 the outdoor airstream of the air handling units (AHUs). This provides “free� heat recovery with only minor pumping energy required. No additional equipment is needed, only control software programming.

Hombsch: Cold climates pose unique challenges to prevent freezing of coils, etc.

However, cold climates can provide good opportunities for free cooling to serve base-cooling and process-cooling loads.

Another unique challenge in cold climates is confirming the building thermal envelope is suitable for handling humidified spaces without condensing issues.

CSE: What best practices should be followed to ensure an efficient HVAC system is designed for this type of building?

Sharpe: Performing a wind tunnel study is critical for these building types where dangerous chemicals can www.csemag.com

be emitted from fume-exhaust stacks and entrained into building outside-air intakes. A wind tunnel study in the schematic phase will inform the design for placement of AHU intakes and fumeexhaust stacks and determining minimum fume-exhaust stack velocities.

Another best practice is do not exhaust fume hoods individually or by groups.

Instead, combine the fume hood exhaust with the laboratory’s general exhaust into a large central exhaust system. Do this so any chemicals are diluted within the ductwork airstream (often avoiding expensive stainless steel fume-exhaust ductwork).

This also allows flexibility when a fume hood needs to be added in place of the room’s general exhaust. There are numerous other best practices, like reducing room air-change rates, diffuser placement to avoid turbulence at the fume hood face, VAV fume hoods, and ceiling-space zoning of MEP systems to avoid congestion.

Edwards: A best practice would be to stay engaged with the owner to

understand the facility requirements.

Most laboratory buildings share requirements, but each facility has a unique twist that needs attention in the design of the HVAC system. To achieve an efficient HVAC system, it’s necessary to look beyond what was done on the last project to find what is better for the new project.

Hombsch: A comprehensive understanding of the program requirements, user/owner expectations, project goals, and project budget. cse

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