JERSEY CITY USPS

Main Office Facility

Occupied since 1913, this USPS facility is the primary delivery office in Jersey City, NJ. This facility has 95,000 square feet of floor space comprised of administrative offices, service counters, local mail sorting, mail delivery and delivery loading docks. The existing historic building consists of masonry block with a monumental stone façade and a copper metal seam roof. CA was responsible to inspect and upgrade the broken heating,cooling, ventilation and controls system.

CLIENT: USPS
LOCATION: JERSEY CITY, NJ
COMPLETION YEAR: 2018
DISCIPLINE: GOVERNMENT FACILITY
SIZE: 95,000 SQ. FT

 

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PROJECT BRIEF

Crane Associated was tasked with a multi-phased project to address key issues required to redesign the USPS existing broken boiler plant. The machinery needed to be replaced quickly and construction needed to be coordinated specifically to remediate hazardous asbestos and lead from the premises. The plant also needed to be operational in time for the heating season.

At the time of inspection, the building chillers were broken and temporary cooling needed to be established; the air handling units were failing and controls did not meet today’s energy requirements. and the boiler plant would not start in time for the heating season. The Crane team designed and oversaw the construction of an emergency replacement boiler plant including three new boilers, four new pumps, controls and all building upgrades to integrate the new system with the existing HVAC system. The team then designed a new cooling system and building controls system before the next cooling season. The new system will replace four large hot water and cold water air handling units, two large roof mounted air cooled chillers and an aging building automation system.

 

BOILER PLANT (PHASE 1)

Due to the failing state of the boiler plant, immediate replacement was crucial. The pumps, boilers, expansion tanks and piping also needed replacing. The new plant was sized to handle the updated HVAC system loads and the AHU heating coils were removed from the heating load. The downsized boiler plant would handle the perimeter heating load including baseboard, convectors, and unit heaters. This system would heat the building while the AHUs and Chillers were replaced as part of phase 2. The new boiler plant would also be tied into the new HVAC system.

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CHILLER PLANT, BUILDING AUTOMATION SYSTEM & AIR-HANDLING UNITS (PHASE 2)

The chiller plant also needed immediate replacement. The temporary cooling units were removed during the winter and the new HVAC units installed prior to the next cooling season. The pumps, air cooled chillers, VFDs and piping were removed and replaced with a new HVAC system sized to handle current building loads.

The Air-handling units were replaced with a new air distribution system according to USPS standards. Recommendations to replace AHUs and chiller plant with packaged rooftop units (RTU) with DX cooling coils and gas fired heating burners have been incorporated into the new design. The existing chilled water pipes were removed from the roof and new packaged RTUs were installed on the existing steel dunnage. 

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The Crane team recommended a 100% design for the chillers and AHU replacement analysis and design. This will include a 30% life cycle cost analysis review to determine if it is better to replace the HVAC system in kind or to replace with packaged RTUs.

The building automation system unit controllers were removed in addition to existing HVAC equipment. The front end system was also replaced at this point in the project. The new BAS system integrates the updated HVAC and boiler plant equipment to meet the current USPS design criteria, and connects to the USPS EEMS (Enterprise Energy Management System).


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