Installation Background of HVAC system
The equipment to cool the church was originally installed in the late 1950’s to very early 1960’s.

• this equipment includes:
  1. 2 chillers -Westinghouse unit 
     • One has not been in operation since 2007.
  2. Trane unit replaced a non-operational Westinghouse unit and was installed in 2007.
     • the Trane chiller has been operating continually without backup.
  3. 2 fan coil units for the nave of the church (behind the organ)
  4. 1 air handler unit used to cool sanctuary and transept of the church.
     • Removed due to poor operating condition
     • currently, there is no cooled or conditioned air provided in the sanctuary or transept area of the church building.
  5. cooling tower installed/replaced in 2006

Operation of HVAC Unit
     HVAC system equipment needed to cool the church utilizes 2 high pressure chillers that work together to chill water used to cool the interior of the church, 3 air handler units, and a cooling tower.
Current Situation of HVAC System
Because of long term deferred maintenance for the equipment associated with the HVAC system, various components were either:

• non-operational
• working intermittently
•  below normal operating parameters, i.e., not cooling efficiently.

While it was necessary to get all of the equipment working to provide cooling to the church, each piece of equipment was identified and individually surveyed on how to repair or replace the item.  
 Repair and Replacement- HVAC system components

• Cooling Tower
  1. replacement of individual components not operating efficiently:
     • main fan motor
     • water inlet valves and float controllers
     • cleaning of interior of scale and grime
     • replacement of filters.
  2. equipment required deferred maintenance to allow for proper and efficient operation 
  3. working properly without requiring replacement.
  4. system is being routinely tested for Legionella, all tests negative.
• Chiller #1, Trane equipment
  1. unit working constantly since 2007 installation without backup.
     • during heating season, when cooling was not required, the equipment was disassembled, components cleaned, gaskets replaced and tested for proper operation.
     • unit was tested and operating parameters were adjusted for use in the cooling season
     • the equipment is currently being maintained
  2. the cost to rebuild and repair the Trane chiller and conduct performance testing was $5,472.76.
     • Potential cost if replaced: $114,483
• Chiller #2, Westinghouse equipment
  1. unit not operational since 2007.
  2. the equipment was in poor condition:
     • control panel open with broken components
     • control wiring exposed and some wires not connected
     • isolation water valves were inoperable 
  3. due to the poor condition of the Westinghouse chiller and its operating controls and other components, it was decided to replace it.
     • as with the replacement cost of the Trane chiller the cost to replace the Westinghouse chiller was $114,483.00 with a lead time of 6-9 months.
  4. It is important to have this Chiller replaced since it will be needed as a backup should the Trane chiller fail at some point, which would leave the church without air conditioning.
  5. because of the high expenses associated with replacing the Westinghouse chiller #2, certain tests were performed on the equipment to see if it would operate.
     • a complete in-depth diagnosis of the chiller was made, and it was determined there was a chance the chiller could be repaired and made operational.
       • technicians were able to ‘jump start’ the chiller and maintain a pressurized operating condition for 15 minutes.
       • although there were still many other problems with the equipment that had to be addressed, being able to run the chiller provided enough technical information it could be rebuilt rather than replaced.

currently, the Westinghouse chiller #2 is being rebuilt and when the work is finished will work alternately with the Trane chiller.

1. The cost to rebuild the Westinghouse chiller, replace the controls, and isolation valves is $16,592.80. 
   • Potential cost of replacement was $114.483.00.
   • the cost to conduct the performance testing is $2,627.00.
   • the effective lifespan of the rebuilt equipment has been extended approximately 10-15 years.

• Sanctuary/Transept Air Handler
  1. installed approximately 1960 but has been removed for the following reasons:
     • extremely poor operating condition.
       • as with other mechanical components of the building, there was no routine maintenance on this piece of equipment.
       • cooling coils constantly leaked
       • enclosure rusted, cooled air leaked.
       • asbestos insulation (properly removed)
     • location of this equipment was in space designated for new commercial kitchen.
  2. Cannot be rebuilt, requires total replacement.
     • the cost to replace this equipment is $128,482.71.
     • there is no conditioned air provided in the sanctuary or transept areas of the church without this Air Handler
• Nave Air Handlers #2&3
  1. these 2 units are located behind the great organ and provide conditioned air to the nave by supply grilles running along the upper part of the church.
     • these units were originally customized to fit behind the organ loft and it would be very difficult and extremely costly to replace them.
  2. until recently, these units were not properly maintained and in very poor condition.
  3. the coils of these units were found to be clogged
     • recently cleaned so the equipment could provide a better source of cool air to the nave.
  4. the cost for this maintenance was $2,167.00
     • a proposal to completely rebuilt these units was requested.
       • this work would replace all of the interior mechanical and electrical components within the existing enclosures:
         1. new blower assembly
         2. new chilled water coils and connections
         3. control wiring and controls
         4. refurbish all other components
     • the cost to rebuild both nave Air Handlers #2&3: $85,400.00

Chemical Treatment

1. the HVAC (and boiler) systems are being chemically treated to provide optimum operating performance, as well as protection against corrosion.