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Installation

The installation on this project began on April 5, 2007 and was scheduled to be completed on June 15, 2007 based on the Astorino layout. The installation was completed on August 31, 2007 due to the delay of the Automatic Transfer Switch and Soft Load Controller. The major components to the installation include:

  • Site Preparation: Pouring Pads, Coring, and Demolition
  • Placing of Equipment: Engine-Generator and Steam Generator
  • Piping: Fuel Supply Line, Vents, Steam, and Hot Water
  • Electrical: High Voltage AC from Generator, Controls and Instrumentation Wiring

Site Preparation

Site preparation took about two weeks which included clearing out the site of debris, demolition of the existing duct work, door, and lighting, and coring holes through the ceiling and exterior walls for all the necessary piping. This process happened in parallel with placing the equipment and piping. 

Placing Equipment

Placing the equipment for this project was a significant undertaking because the installation site is three levels below grade, which required a crane to lower the large equipment down an exterior stair well and swing it through a set of double doors. Then the equipment had to be moved down a hall using a pallet jack and maneuvered between large columns. 

Next, the equipment had to be lifted onto the poured concrete pads by driving hooks into the concrete ceiling above and using chains to lift the equipment into place. Upon placing the equipment in the proper location it was bolted onto the pad.

The necessary equipment for the entire system is shown in the Components & Supplier diagram

Piping

The piping for this project is extensive as it has all the necessary piping for a small power plant. The steam lines must travel out of the steam generator, down a hallway, then outside the building, and then rise seven stories on the exterior of the building to tie into the steam driven absorption chiller sitting on the Intelligent Workplace (IW) southeast platform. In addition to the steam line going outside the building, another steam line goes to a steam-hot water converter on flight up in the second basement and ties into the IW hot water grid. Also, a condensate line runs down the side of the building allowing the consumed steam to return to the steam generator. The condensate from the converter goes into the campus condensate grid which the steam generator is also tied to.

Additional piping includes coolant lines from the engine to the radiator sitting outside and and one floor up, and the coolant heat exchanger in the same room. Two sets of fuels lines run to the outside, one for petrol-diesel and one for biodiesel. Finally, several vent lines are required from the fuel tanks (storage and day) as well as the steam and condensate equipment. All the lines that had to go outside (vents, fuel, steam) required coring through the ceiling of the installation site and the outside walls. 

Electrical

Two sets of electrical work were completed, first the high voltage work that includes tying the generator output to the building-campus grid connection. This work is being completed by Hoffmann Electric of Pittsburgh. Electrical work began on April 30th, 2007 and is expected to be completed on June 15th, 2007. The long lead item for this work is the ASCO 7000 Series Transfer Switch, which takes about twelve weeks to deliver upon purchae. However, due to supplier issues, the delivery time was 19 weeks. 

The second set of electrical work includes the controls and instrumentation wiring, which was completed by Logical Automation of Pittsburgh. Included in this work are several automatic valves as well as dozens of sensors. See the instrumentation diagram for detailed information. 

Construction Log