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“We had proposed more traditional efficiency boilers, which is what the state had requested. However, during the design phase, the entire team worked with the state in exploring more energy efficient solutions, which resulted in using the high-efficiency boilers. That created a fast-track boiler plant design, construction, and start-up. It was a benefit for the owner,” says Justin Apprill, chief procurement officer for U.S. Engineering.

Maintaining overall campus security was an important aspect of the work on this project. One feature that affected the HVAC design was the buildings' roof areas, which are designed with little to no roof equipment to reduce clutter and minimize areas where individuals could hide. The design of the campus utility water distribution loop posed particular challenges, which included incorporating piping access, minimizing piping losses, and determining location to the buildings.

KAI designed the central utility loop 12- to 16-ft. above grade, rather than underground, which allowed for identifying any problems quickly and easing access for repairs. The design also uses building structures at the entrances and exits of the buildings to help support the loop.

Outstanding Indoor Air Quality

The comfort conditions for each building and area within the complex are defined by the occupancy for that area. Comfort conditions for all areas were met, according to state correctional facility requirements. The indoor air quality (IAQ) for the complex is based on the number of air changes and the quality of the outside air. IAQ at the prison meets or exceeds state requirements for comparable facilities.

“From a mechanical systems standpoint, the state has been trying to encourage energy efficiency in all their projects,” Kumar says. “So we were looking at what we wanted to do in terms of energy efficiency from the very start. We think we designed a great system for this facility, and we did it within a very tight time frame.

“The state is a good customer of ours, and they asked if we could bring the facility to completion in 16 months rather than their initial requirement of 24. When a good customer asks, you do your best to deliver.”

Inmates at the Chillicothe Correctional Center can appreciate the difference between 16 months and 24. Although no one may necessarily wish to be there, the team from KAI Design & Build, in cooperation with the project's other engineers and contractors, ensured that the facility would be as comfortable as possible for the inmates, and as energy efficient as possible for the state.

Winners at a Glance:

COMPANIES:

KAI Design & Build,
St. Louis, MO; U.S. Engineering, Kansas
City, MO; DLR Group, Overland Park, KS;
J.E. Dunn, Kansas City, MO

PROJECT NAME/LOCATION:

Chillicothe Correctional Center, Chillicothe, MO

TOTAL COST: $20 million

PRODUCTS KEY TO SUCCESS:

• 9 AERCO natural gas/propane boilers
• 9 AERCO boiler management system with combination control panel
• 3 Carrier XRV chillers
• 3 Marley cooling towers
• 3 Armstrong primary chilled water pumps, two secondary chilled water pumps, three condenser water pumps and two hot water primary pumps
• 2 Cemline domestic water heater/storage tanks
• 2 Bell and Gossett water-to-water brazed heat exchangers