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7.4. ICESR 04-08-2014 City of Elk Request for Action ever To Item Number Ice Arena Commission 7.4 Agenda Section Meeting Date Prepared by Arena Manager's April 8,2014 Rich Czech,Arena Manager Update Item Description Reviewed by R22 Refrigeration Phase out/ Mighty Ducks Michael Hecker, Parks and Recreation Director Funding Reviewed by Cal Portner, City Administrator Action Requested None required,Information on phase out of R-22 and State Grant Funding Background/Discussion In 2020 the Phase out of the R22 Refrigeration will be completed and production will end. While R22 will still be available, the cost of the refrigerant is still in question. Another item of concern is getting parts for the R22 systems which will become obsolete as newer systems replace them. Both Ice Arena ice plants use approximately 5,500 pounds of R22 each to make ice. Legislation was introduced in the State Senate and the House of Representatives to again fund the Mighty Ducks Grant Program assist with replacement of obsolete R22 systems. Grants will be awarded for new construction,with a maximum of$250,000. Existing Direct R22 Systems could get up to $200,000 for upgrades, and $50,000 for indirect systems. In the bill's current format up to $5 million in bonds will be issued per year. It is unclear how many years the program will last. That is the good news,however there are 187 ice rinks in Minnesota, 120 need to convert from the R22 refrigerant,40 of them are direct systems. Financial Impact • Projected costs to replace the ice plants are $1.8 —2 million Attachments • State Legislation from the House and Senate • Stevens Engineering Study P' UM € AEU 0V Ali ' M9 as introduced-$8th Legislature(2013-2014) 3110114 2-,47 PM Minneso ta State Legislature Minnesota Douse of Representatives EY: = removed, old language. underscored = added, new language. �rSiflFt Lst Authors aLi �St t s .urrent Version- as introduced i A bill for an act relating to capital investment; appropriating money for Mighty Ducks grants; 3 authorizing the sale and issuance of state bonds;arnending Minnesota Statutes 2012, section 240A.09. 3 BE IT ENACTED BY THE LEGISLATURE OF THE STATE OF MINNESOTA- i Section 1. MIGHT-Y AIR HANDLING v' �a Q00,000 is appropriated from the bond_ noc�_-_pds� fund t a t s Commission for grants o 1.0cal governingat 't a i h or-(k), to install. renov r 0 i `c r t' i whD0_tcg_r_esurfacing and ice edging e nt ot powered by electricity ig ordpr 2 L12 iml2rQmg d t o c r i a 3 nitrogen d' Tbg new or s o ate I vend€ Lino and air co di=io i s� to include 4 may ti o electronic t' f ho 5 ve iE -o vste ms whgn t e concehtLation of on inonoxide €r nitm-gen dioxide-waches 6 a oredetermingd level or install renovate ice-maklag systems that I - 7 Sub d. 2. Bond s.saa J© 12rMide -1be tY1ongy appmpriated ig this_seLtifla from the 8 b Q6d proc&ds fund. thg commissiOner of managierneilt an u shall Il a d issue 9 bL)nds gf tbc state ja au s oun o $5,000,00D in the nner uipon the terros, ad i h 0 the ct prescribed sgta Statutes, seg;tfons 16A..631 to 16A.675, and by the 1 minnesot•a Constitution, article XI, sections 4 t 2 EFEECTIVE DATEJbis sectioa-is g-Mictive the day following fr al en ctme t. Sec. 2. Minnesota Statutes 2012, section 240A.09, is amended to read: 240A.09 PLAN DEVELOPMENT; CRITERIA. The Minnesota Amateur Sports Commission shall develop a plan to promGte the development of proposals for new statewide public ice facilities including proposals for ice centers and snatching grants based can the criteria in this section. (a) For ice center proposals, the commission will give priority to proposals that come from more than one local government unit. Institutions of higher education are not eligible to receive a grant. (b) In the metropolitan area as defined in section 473.121, subdivision 2, the J commission is encouraged to give priority to the following proposals: P=_Qsalsf_QrrenovatlQn indoo iL quality- ve t an e2jisting indgor ice arena or r 1 i-or renava loo of-ice-umking s Ste s that meplace Freon -22 3 } proposals for construction of two or more ice sheets in a single new facility, fR-�_W proposals for construction of an additional sheet of ice at an existing ice center; ' f3�_W proposals for construction of a new, single sheet of ice as part of a sports i complex with multiple sports facilities; and f4l}_(5_� proposals for construction of a new, single sheet of ice that will be expanded t to a two-sheet facility in the future. ► (c) The commission shall administer a site selection process for the ice centers. The i commission shall invite proposals from cities or counties or consortia of cities. A nr000sal 1/www.revisor.mn.gov/billsftext.phVn ember=HF0868&session-Is8m version=latest&sessionn urn ber-0&sessionjear=2413 Page 1 of 2 368 as introduced—88th Legislature(2013—2014) 3110114 247 PM 21 for an ice center must include matching contributions including in-kind contributions of 22 land, access roadways and access roadway improvements, and necessary utility services, 23 landscaping, and parking. 24 (d) Proposals for ice centers and matching grants must provide for meeting the 25 demand for ice time for female groups by offering up to 50 percent of prime ice time, as 26 needed, to female groups. For purposes of this section, prime Ice time means the hours Z7 of 4:00 p.m. to 10:00 p.m. Monday to Friday and 9:00 a.m. to 8:00 p.m. on Saturdays 2a and Sundays. 29 (e) The location for all proposed facilities must be in areas of maximum 30 demonstrated interest and must maximize accessibility to an arterial highway. 31 (f) To the extent passible, all proposed facilities must be dispersed equitably, must 32 be located to maximize potential for full utilization and profitable operation, and must 33 accommodate noncompetitive family and community skating for all ages. 34 (g) The commission may also use the money to upgrade current facilities, purchase 35 girls` ice time, or conduct amateur women's hockey and other ice sport tournaments, 1 (h) To the extent possible, 50 percent of all grants must be awarded to communities in greater Minnesota. (i) To the extent passible, technical assistance shall be provided to Minnesota l communities by the commission on Ice arena planning, design, redesign, installation. renovatign of heatfria. ventilating, and r ogd1tioning systgffls, and operation, including > the marketing of ice time. (7) A grant for new facilities may not exceed $250,000. (k) The commission may make grants for rehabilitation and renovation. A rehabilitation or renovation grant for air qualdy may not exceed�� 2D0.00D and 0 a mbabilitalion 1 cooling not d $200,000 for e o } e s. Priority must be 2 given to grant applications for indoor air quality Improvements, Including zero emission 3 ice resurfacing equipment and thg uparading of heatLngv!2jijjjatinO,,..and &9120ditioninCl., dgMiCes; and priority mu5t be 5 gixg= 6 (1) Grant money may be used for Ice center's designed for sports other than hockey. 7 (m) Grant money may be used to upgrade existing facilities to comply with the 8 bleacher safety requirements of section 3266.112. 9 T o ct /www.reviror.mn.govibills/text.pbp?number=HF0868&sessfon=ls88&version=latest&session_number=0&session year=2013 Page 2 of 2 736 as introduced-88th Legislature(2013-2014) 3110/14 2:45 IM Minnesota Scat e Legislature Minnesota Senate (EY: striek-en = removed, old language. underscored added, new language. jersior,t List Authors and Status A bill for an act relating to capital investment, appropriating money for Mighty Ducks grants; .3 authorizing the sale and issuance of state bonds amending Minnesota Statutes .4 2012, section 240A.09. .5 BE IT ENACTED BY THE LEGISLATURE OF THE STATE OF MINNESOTA: .6 Section 1. MTGHTY.QUCM GRANTS; AIR HANDLING SYSTEMS. .7 Subdivision 1. Approprintion. $5,000,000 is appropriated from the boK)d proceeds .8 fund to the Minnesota-Amateur Sports Commission for grants to local Qovernfoent units .9 unde-r-Minagsgta Statutes, section 240A.09, paragraph (a) or (k), to install, renovate, or .10 replace heating, Mentilating, and air conditioning systems in existing indoor ice arenas_ .11 whose ice resurfacing and jo edging equipment are not powered by electricb in order .12 to improve indoor air quality by reducing concentratJoas of carbon monoxide and .13 nitrocien dioxide. The new o r ren gy@ted heating, ventilating, gnd air conditioning Z Ste ms .14 m-ayia-cluo-e-continuous electronic air monitoring devices to automatics y actlyate the .15 ventilation systgais when thg Goncgntration of carbon monoxide or nilmgen dioxide reaches .16 a predetermined level or lri5tall and renovate ice-Making systems that replace Freon R-22. .17 Su d. 2. Bond sale. To provide the mane y appropriated in this section from the .18 bond proceeds and the co!Mrnissioner of management and budget shall sell and issue '19 bonds of the state in an amQunt up to t5,000.000jn the manner, upon the terms, and with .20 the-effect prescribed by Minnesota Statutes. sections 16A.631 to 16A.675, and by the .21 Minnesota Constitution, article XI, sections 4 to 7. 12 EffEC-T-1-YE DATE.Thi5 section is effective the day following final enactment. Sec. 2. Minnesota Statutes 2012, section 240A.09, is amended to read. .2 240A.09 PLAN DEVELOPMENT; CRITERIA. .3 The Minnesota Amateur Sports Commission shall develop a plan to promote the .4 development of proposals for new statewide public ice facilities including proposals for .5 ice centers and matching grants based on the criteria in this section. .6 (a) For ice center proposals, the commission will give priority to proposals that 7 come from more than one local government unit. Institutions of higher education are not 8 eligible to receive a grant. 9 (b) In the metropolitan area as defined in section 473.121, subdivision 2, the 10 commission is encouraged to give priority to the following proposals: 11 (1) proposals for renovation and indoor air quality improvements at an existing 12 "indoor ice arena or proposals for renovation of..ice-makin g systems that re lace Freon R-22, 13 f4- W proposals for construction of two or more ice sheets in a single new facility; 14 �A-31 proposals for construction of an additional sheet of ice at an existing ice center; 15 f-3�-U4 proposals for construction of a new, single sheet of ice as part of a sports 16 complex with multiple sports facilities; and 17 f4 -LSD proposals for construction of a new, single sheet of ice that will be expanded 18 to a two-sheet facility in the future. 19 (c) The commission shall administer a site selection process for the ice centers. The 20 commission shall invite proposals from cities or counties or consortia of cities. A proposal 21 for an ice center must include matching contributions including in-kind contributions of 22 land, access roadways and access roadway improvements, and necessary utility services, s://www.revisor.mn.gov/bills/text.php?number-SF73G&versforL=o&sessiork_year=2013&session-numbet--o Page 1 oft F 736 as introduced—88th legislature(2013—2014) 3110114 2:45 PM 2.23 landscaping, and parking. 2.24 (d) Proposals for ice centers and matching grants must provide for meeting the 2.25 demand for ice time for female groups by offering up to 50 percent of prime ice time, as 2.26 needed, to female groups. For purposes of this section, prime ice time means the hours 2.27 of 4:00 p.m. to 10:00 p.m. Monday to Friday and 9:00 a.m. to 8:00 p.m. on Saturdays 2.28 and Sundays. 2.29 (e) The location for all proposed facilities must be in areas of maximum 2.30 demonstrated interest and must maximize.accessibility to an arterial highway. 2.31 (f) To the extent possible, all proposed facilities must be dispersed equitably, must 2.32 be located to maximize potential for full utilization and profitable operation, and must 2.33 accommodate noncompetitive family and community skating for all ages. 1.34 (g) The commission may also use the money to upgrade current facilities, purchase 1.35 girls' ice time, or conduct amateur women's hockey and other ice sport tournaments. 3.1 (h) To the extent possible, 50 percent of all grants must be awarded to communities 3.2 in greater Minnesota. 3.3 ({) To the extent possible, technical assistance shall be provided to Minnesota �.4 communities by the commission on ice arena planning, design, redesign, installation, immation of heatino, ventilatina., 'r conditioning st s and operation, including 1.6 the marketing of ice time 13 (j) A grant for new facilitles may not exceed $250,000. s.8 (k) The commission may make grants for rehabilitation and renovation. A 1.9 rehabilitation or renovation grant for u it may not exceed 99f9BQ-$2DD 00Q and %10 a rehgbilitation grant for Ereon R-22 e o exceed 0 00 for indirect 1.11 c li e ms and may nL)t-gxF,,ggd-$2QQ,0QQ for direct cooling systems. Priority must be 12 given to grant applications for indoor air quality improvements, including.zero emission .13 ice resurfacing equipment and the upgrading of'heatina, ventilating, and aircor ditionina .14 systeMs w include e p i o[gir mQgILodag aevim and priority t be 15 giyen to c i k' e Fr-eoji R-22. .16 (l) Grant money may be used for ice centers designed for sports other than hockey. .17 (m) Grant money may be used to upgrade existing facilities to comply with the .18 bleacher safety requirements of section 326B.112. .19 EFFECTIVE p effactive the day following final gnactme //www.revisor.mn.gov/hifis/text.php7nuMber=5F736&version=O&$esslnn_year=2013&session—number-0 Page 2 of 2 Ice System Evaluation and Recommendations Elk River Ice Arena For: City of Elk River, Minnesota 13065 Orono Pkwy NW Elk River, Minnesota 55330-5600 April17, 2012 Submitted By: Stevens 2211 O'Neil Road Hudson,WI 54016 800.822.7670 RStevens File No.900.12.159 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Table of Contents SECTION TOPIC PAGE 1 Project Information........................................................................................ 1 2 Project Overview................................................................................................. 4 3 Ice Systems........................................................................................................... 8 4 Alternative Energy Sources.............................................................................. 26 5 Project Schedule................................................................................................ 29 6 Financial Assistance Programs........................................................................... 31 1 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 1 Project Information 1 2 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Contact Information Facility Address: Elk River Ice Arem) 1000 School Street N.W. Elk River, MN 55330 Facility Manager: Rich Czech P. 703,035.,1 41 ... (........cJ.elk rivermn.us .................................................................................................... Consulting Engineering Firms: Stevens 2211 O'Neil Ro�)d 11 ludson, WIl 54016 P. 6 5 1.,4 3 6.,2 0 7 5 F. 715.,386.,587 Scott A., W)rd, P.E. D.5 !2.gineers.corn ........................................................................ Electric Utility: Xcel Energy, 1518 Chestnut Avenue, 1" Floor, Minne�)polis, MN 55403 Account No, Meter No, Account M�)m)ger, Gas Utility: Certification I hereby certify that this report was prepared by me or under my direct supervision and that I am a duly registered Professional Engineer under the laws of the State of Minnesota. 40921 4.17.12 Scott A.Ward,P.E. Registration Number Date STEVENS 961tevens 3 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 2 Project Overview 4 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS PROJECT OVERVIEW Background The Elk River Ice Arena consists of two (2) ice arenas where both ice rinks are served by individual Holmsten direct R-22 refrigeration systems. The refrigeration system serving the original rink(Rink 1 or"The Barn") has a capacity of 80 tons and the system for the new rink (Rink 2) has capacity of 135 tons. The ice rink floor and dasher board systems were replaced in Rink 1 in 2004. Due to the age of the Rink 1, the City is interested in completing an evaluation of ice system (rink floor and refrigeration system) to determine the condition and to identify and recommend improvements and/or replacement options to assist in future planning for the facility. The evaluation includes improvement recommendations and estimated project costs for the improvements. To plan long term, it was also necessary to include discussion on the future of Rink 2's ice system. The HVAC, electrical, lighting and building systems were not part of our scope of services and are being evaluated by other consultants. Purpose As part of a continued effort to: improve operation and efficiency of Elk River Arena; to plan for future improvements to the facility; and to continue to provide high quality ice for its user groups; Stevens was retained by the City to prepare an evaluation of Rink 1(The Barn). The primary objectives of this evaluation are as follows: • To evaluate the ice system for Rink 1 and provide recommendations for improvements. • To provide accurate cost estimates to assist the City in making informed decisions on future projects. • To recommend improvements that maximize energy efficiency while incorporating sustainable design practices that reduce the use of fossil fuels, the production of greenhouse gas emissions and reduce total energy use. It is recommended that the findings presented in this report be used to improve the operations and maintenance of the facility and to assist in planning and budgeting of the recommended improvements. 5 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Scope of Services and Approach The Scope of the ice system evaluation includes an overall evaluation of the physical conditions and improvement options for the following systems: • Ice systems in Rinks 1 • Related waste heat recovery systems Investigation Methods and Documents Various methods were used to evaluate the existing facility including: Visual Observations: A site visit was conducted on April 3, 2012 to observe the operation of the facility and its ice systems. Interviews: During the on-site visit, an in-depth discussion was conducted with the facility's management staff to document existing issues with the facility and discussed historical problems with the ice systems. Research: Where applicable, additional research was conducted to provide accurate and detailed information regarding improvements or systems recommendations. Documents: The following documents were received and reviewed for the evaluation: • None PIStevens 6 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Estimated Project Costs The proposed cost estimates presented throughout this report were developed by estimating the probable construction costs based on similar types of construction projects and work performed and bid in 2008-2012 and updated for 2013 costs unless otherwise noted. The estimated costs include all materials and labor for a complete installation unless otherwise noted. Costs will vary depending on the time of year the projects are bid, the current economic climate and the size of project. In addition to the probable construction costs of the proposed work, other associated project costs are included to provide a total estimate cost for the project. The Estimate, Design and Construction Contingency line item in each cost table is included during the evaluation phase of projects since the exact scope of the project has not yet been determined. This percentage is typically reduced from 15% to 5% during the final design phase of the project. The Engineering, Legal and Administrative line item in each cost table is provided to cover all work performed by the design team and all legal and administrative work required by the City for projects of this type. Applicable Codes and Standards The following codes were considered during the evaluation: • Minnesota State Building Code, 2007, including Chapter 1341 Accessibility Code • International Building Code, 2006 • 2007 Minnesota State Fire Code (International Fire Code, 2006) • International Mechanical Code, 2006 • 2009 Minnesota State Mechanical Code • NFPA 70(NEC), 2008 • Department of Labor & Industry— High Pressure Piping and Code for Power Piping Systems, Chapters 326 (MN Statues 1999) and Chapter 5230 (MN Rules 2001) • ANSI/ASHRAE Standard 15-2007 • The City's CODE OF ORDINANCES were not reviewed or referenced for this evaluation. ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 3 Ice Systems PIStevens 8 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS ICE SYSTEMS General The facility is served by two separate ice systems (including refrigeration system and ice rink floor), one for each rink. The ice systems for both Rink 1 and Rink 2 are direct refrigeration type systems and were installed with the construction of the buildings they serve, 1981 and 1997 respectively. This report will discuss another common type refrigeration system used in the ice industry; indirect type systems. The options for replacing the direct ice systems, including replacing them with indirect systems, are discussed in this section. Definitions for each type of system are provided below: Indirect System: In an indirect system the primary refrigerant (R-22 for example) remains in the refrigeration room. Heat is removed from the ice rink floor through a secondary refrigerant (glycol/water solution for example) that is circulated in the floor. The heat exchange between the primary and secondary refrigerants takes place in the refrigeration room. Direct System: A direct refrigeration system circulates the primary refrigerant (R-22 in this case) directly through the ice rink floor and refrigeration system. There is no secondary refrigerant and therefore, no secondary heat exchange process. Overall, both systems have been very well maintained by the facility's operational and maintenance personnel. PIStevens 9 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Observations of Existing Conditions We toured the ice systems for both Rink 1 and Rink 2 with the facility's management and operating and maintenance staff and have the following observations and comments. Rink 1 (The Barn): • The operational season typically runs from the middle of September through middle of April. • Rink 1 is served by a direct refrigeration system manufactured by Holmsten Ice Rinks. The major of the components include two (2) 4 cylinder York compressors, one (1) low pressure receiver, two (2) pumper drum vessels and one (1) motor control center. The 31-year old refrigeration system has exceeded its expected life of 25-30 years. However, since this system only operates 6 months per year, the life span of the equipment is likely to be greater than 30 years. The system is in fair condition for its age, but, it's becoming more difficult to maintain with its outdated electrical and control systems, discontinued compressors units, etc. Some improvements have been performed on the refrigeration package over the years and include rebuilding compressors, new valves and insulation, new fill solenoids, float switches, top ends on compressors, dryer cores, replaced relief valves, and new ASME certified oil separator. • The existing evaporative condensing tower, was replaced in 2010 and is manufactured by Baltimore Aircoil (BAC). This system uses air and water to dissipate heat for the refrigeration processes. • There are no waste heat recovery systems on this refrigeration system. The existing snowmelt pit that is dedicated to Rink 1 is only used as a back-up and uses a boiler system to heat the water and melt the ice shavings. The primary pit is a common pit with Rink 2. There is no subfloor heating system beneath the rink floor. All waste heat is dissipated to the atmosphere, through the condensing tower. PIStevens 10 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS • The ice rink floor was replaced in 2004 with a new direct refrigeration ice rink floor of similar design to the original floor. The floor, which measures 85 feet x 185 feet, is slightly smaller than the standard NHL size of 85 feet x 200 feet. The 8-year old rink floor consists of: 3-4 inches of floor insulation; % inch steel tubing installed at 4 inches on- center with welded connections; and a 5 inch of reinforced concrete. It was very typical for the rink floors, in a Holmsten Rink System, to be the first components to fail. There are no reported problems with the existing rink floor or with ice quality at this time. • The existing dasher board system was installed new in 2004. It is a steel framed system with a supported tempered glass system. The system is in very condition and should have life expectancy of approximately 20-25 years. • The existing refrigeration room for Rink 1 is very small. The room is not equipped with mechanical ventilation and refrigerant leak detection systems and there does not appear to be an emergency stop switch or ventilation switch near the exterior door as is required by code. These systems are addressed in the mechanical system review. Rink 2: • The operational season is typically year round. Approximately every other year the rink is taken down for one month to perform maintenance on the ice rink floor and system. • Rink 2 is also served by a direct refrigeration system manufactured by Holmsten Ice Rinks. The major of the components include two (2) 8-cylinder York compressors, one (1) low pressure receiver, three (3) pumper drum vessels and one (1) motor control center. The refrigeration was purchased used 15-years ago and is believed to be 28- 30-years old exceeding its expected life of 25-30 years. The system is in fair condition. As with the Rink 1 Holmsten Ice Rink system, it's becoming more difficult to maintain with its outdated electrical and control systems, discontinued compressors units, etc. There have also been some on- going, fairly significant, problems with the system such as: oil return problems which relates to ice quality concerns; compressor shaft seal problems; R-22 leaks in the refrigeration system; vent line damage; etc. PIStevens 11 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS American Engineering Testing performed ultra sound testing on the low pressure receiver to investigate the effect of visible corrosion on the vessel. The test reportedly showed no loss of vessel wall thickness. • The existing evaporative condensing tower was replaced 5 years ago and is in good condition. It is manufactured by Balitimore Aircoil Company (BAC). A variable frequency drive was installed on the system when the new condenser was installed.. This system uses air and water to dissipate heat for the refrigeration processes. • Waste heat is recovered and used for serving the snow melt pit and the subfloor heating system beneath the rink floor. The existing snow melt pit in the in-ground type which does not work very well in terms of both allowing snow into the pit and quickly heating and melting the snow. The remainder of the heat is dissipated to the atmosphere, through the condensing tower. • The ice rink floor is a direct refrigeration ice rink floor. The floor, which measures 100 feet x 200 feet, is larger than the standard NHL size of 85 feet x 200 feet. The 15-year old rink floor is likely constructed to the standard design: 3-4 inches of floor insulation; % inch steel tubing installed at 4 inches on-center with welded connections; and a 5 inch of reinforced concrete. The only reported problem with the existing rink floor is that oil gets trapped in several of the tubes causing streaks and sometimes poor ice quality in those locations. • The existing dasher board system was installed new in 1997. It is a steel framed system with a supported tempered glass system. The system is in very condition and should have life expectancy of approximately 20-25 years. • The existing refrigeration room for Rink 2 is fairly large at 576 square feet. The room is equipped with mechanical ventilation and refrigerant leak detection systems. It was not verified whether an emergency stop switch or ventilation switch was located near the exterior door as is required by code. PIStevens 12 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Recommendations The main focus of this report is to evaluate the 31-year old ice system in Rink 1 and provide recommendations to assist the City in its planning and budgeting for its replacement. Given that: the rink floor was replaced fairly recently in 2004; the system is a direct system; and that the options for refrigerants and systems in the ice rink industry are changing with the phase-out of R-22 refrigerant; there isn't a clear, single replacement option. This section outlines not only the options for replacement, but for improvements to the existing ice system as well. It is also prudent to consider the eventual replacement of the ice system in Rink 2 and how combining systems could maximize energy savings. Cost estimates are provided for each option in the table at this end of section. The following options will be discussed in this section: Option 1: Do nothing. Continue to maintain existing systems. Option 2: Make improvements to the existing direct system. Option 3: Convert to an indirect, industrial grade, R-22 or other HFC refrigerant based system using the existing refrigeration equipment. Option 4: New indirect, industrial grade, HFC refrigerant based system. Option 5: New indirect, industrial grade, ammonia based system. Option 6: Same as option 6 but includes future connection to Rink 2. Option 7: New carbon dioxide (CO2) based system. Option 8: Alternate energy source system. See Section 6. PIStevens 13 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Before the system options are discussed in more detail, a general discussions of six (6) major factors or considerations that Stevens feels are most important to consider when evaluating ice system options is presented below. A general understanding of these factors, we believe, will aid the City in making the best possible selection for improving or replacing the existing ice system. In a historically slowly-changing industry; recent breakthroughs in new technology and cutting-edge design applications, and changing environmental regulations have generated a laundry list of design considerations for the City to evaluate when renovating or replacing its direct ice systems. In general, this list includes: • Type of Refrigerant: R-22 has been the most popular refrigerant, used in ice rink applications, in recent history. However, with the signing of the Montreal Protocol, the United States Environmental Protection Agency implemented the final rule of Section 604 of the Clean Air Act, in July 1992 limiting the production and consumption of a set of chemicals known to deplete the stratospheric ozone layer as measured by their ozone depleting potential (ODP). R-22 refrigerant, a hydrochlorofluorocarbon or HCFC, is the next refrigerant on the list to be phased out. Starting this year, R-22 can no longer be produced and imported in to new packaged type refrigeration equipment and will be banned from installing in existing equipment in 2020. The EPA is also proposing to significantly reduce allowances to produce and/or import R-22 in the U.S. ranging from 11-17% per year from 2012-2014. These regulations are certainly affecting the price of R-22 as it has risen from $7 per pound to $13 per pound since mid March. Replacement or "drop-in" refrigerants for R-22 are starting to be manufactured and currently cost around $15 per pound. 14 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS There is now pressure to consider phasing out refrigerants that contribute to global warming as measured by their global warming potential (GWP), in addition to those affecting the ozone. This affects mainly hydrofluorocarbons (HFCs) like those used in blended refrigerants such as R- 507A and R-404A. Europe has been on the leading edge of this change. The European Parliament passed legislation called the F Gas Directive that became effective in 2007, that requires very strict inspection of systems for leakage, rigorous record keeping and mandatory training and certification on systems using HFCs. With the changing of environmental regulations, careful consideration of all refrigerant options should be made. The new refrigerants and replacements for R-22 are "blended" HFC refrigerants meaning they are a mixture of several different, individual refrigerants. Since refrigerants have different properties, each one reacts differently to changes in its properties such as pressure and velocity. When a leak occurs, varying amounts of each refrigerant may leak out, throwing the original mixture out of balance. Ammonia refrigerant is making a comeback from when it was pushed aside in the early 1970's for R-22. Ammonia's low cost, high efficiency and zero ozone depleting and global warming potential make it a very attractive option. Large global companies, such as Coke Cola, are leading the charge to ban HFCs and use natural refrigerants such as CO2, hydrocarbons and ammonia. Many ice skating facilities in Europe have switched over to CO2-based systems. The first CO2-based ice system in North America recently opened in Les Coteaux, Quebec, Canada. • Quality of Materials and Equipment: Balancing the initial cost of materials and equipment with energy savings can be difficult during the budgeting process of the project. For example, the phrases "commercial grade" and "industrial grade" systems, used throughout the report, refer to quality and operational efficiency differences in the refrigeration system. Commercial grade systems are similar to supermarket type refrigeration systems, built on a rack package, and have a lower life expectancy (15-20 years). These systems typically use copper and PVC pipe in place of steel, disposable type compressors in place of rebuildable ones, direct expansion type heat exchangers in place of flooded type systems, etc. Industrial grade systems are typically stick built on site, have a longer life expectancy (25-35 years), and are generally more efficient to operate. 15 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS • System Design: The design of the system is critical to maximizing its efficiency. For example, lowering the condensing temperature of the refrigeration system increases its efficiency but decreases the amount of waste heat that is generated. Finding the balance between these system elements is key to a successful and efficient design. • Energy Source: As energy costs rise, alternative sources of energy, such as geothermal, natural gas, or co-generation, may look more attractive. Electricity still remains the most practical energy source for these types of systems. • Waste Heat Recovery: Refrigeration systems generate a large amount of heat that is typically wasted into the atmosphere. A refrigeration system for a single ice sheet can typically generate enough waste heat to serve the subfloor heating system, snowmelt pit, the dehumidification system, and potentially preheat domestic water source or in-coming air. Historically, ice rink facilities have only captured and reused approximately 25% of the waste heat generated. It has now become normal design practice to capture 100% of the waste heat and reuse this "free energy"throughout the facility. • Sustainability: Sustainability goes hand-in-hand with all the items in this list of considerations. Energy savings, through smart design practices, translates directly into the reduction of green house gas emissions such as carbon dioxide. PIStevens 16 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Option 1: Do Nothing—Maintain Existing Rink 1 Ice System With a relatively new ice rink floor (8-years old) and no current major problems with the 31-year old refrigeration system, the City may elect to keep operating the existing system in the near future and plan long term for its replacement. The existing direct refrigeration ice systems in both Rinks 1 and 2, manufactured and installed by Holmsten Ice Rinks; were commonly installed in arenas during the 1970's and 80's. The design of this direct ice system is unique and has proven to perform very well and be very efficiently. However, the system is outdated and numerous concerns with the standard system design and current code regulations have prompted facilities to convert or change to indirect ice systems. These concerns include: • Aging equipment: Major improvements to the existing refrigeration system will soon be required to extend its safe and useful life. • Safety: The direct ice system circulates R-22 refrigerant in the ice rink floor, which is located in the occupied space of the facility, potentially exposing spectators, skaters and workers to leaking refrigerant as the floor system ages. • Environmental: The existing system uses a large volume of R-22 refrigerant (approximately 4,000 Ibs) with a high global warming potential (GWP) rating. R-22 refrigerant is scheduled to be phased out of production in the near future. • Cost and future availability: As the phase-out date for R-22 approaches, the cost will continue to increase. Since 2005, the cost of R-22 refrigerant has risen 850%. Because of these concerns, we do not recommend replacing the existing direct refrigeration system with a new direct refrigeration system even though the rink floor is only 8-years old. Replacing the rink floor in 2004 with the same system was a good option at the time given the high operating efficiency and performance of the Holmsten direct system and the quality of construction of the refrigeration system. Unfortunately, the phase-out of R-22 refrigerant started to accelerate shortly after construction of the new floor was completed. PIStevens 17 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Some of the potential downsides, or risks, involved in continuing to operate the existing direct systems for too much longer are as follows: • Continued Equipment Costs: The equipment and parts on the refrigeration system will continue to require replacement in the near term. It's similar to driving a vehicle with high miles; the longer it runs, the more costly it becomes to repair and the lower the return on investment. Parts for the existing York compressors are no longer manufactured and becoming extremely difficult to find and costly to purchase. Some valve manufacturers (like Sporlan) no longer manufacture some of the valves used on the system. • Risk of a Refrigerant Release: As the system ages, the risk of a major release of refrigerant increases. The existing direct systems contain approximately 4,000 pounds of R-22 refrigerant in Rink 1 and approximately 6,000 pounds for R-22 in Rink 2. Depending on the availability of R-22 when this occurs, the City may be forced to install a new blended refrigerant which will require additional modifications to the system. • Dependability: The risk of problems occurring with the refrigeration system, and therefore, the risk of losing the ice sheet, increases as the system ages. Option 2 — Make Improvements to the Existing Rink 1 Ice System: Holmsten Ice Rinks provided good quality vessels (e.g. high pressure receiver, pumper drums, etc.) with their systems. This opens up the option of renovating the existing refrigeration system to extend its useful, dependable, and safe life. This has successfully been performed at several facilities such as Gustavus Adolphus College, University of Minnesota-Duluth and others. If the existing refrigeration system is going to remain in place, whether in its current operation as a direct system, or converted into an indirect ice system, we recommend the following improvements be performed on the existing refrigeration system. 18 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Recommended minimum improvements include: • Investigate the integrity of the existing steel vessels and piping systems: The refrigeration system was re-insulated and therefore the condition of the steel vessels and piping systems could not be inspected. Corrosion along the bottom of the low pressure receiver is common in these systems. The extent of any corrosion cannot be determined without removing the insulation. The recommended repair includes: removing several sections of the existing insulation on the system; conducting a visual inspection of the vessels and piping; and conducting a non- destructive ultra sound tests of the steel. If high levels of corrosion are found, the entire insulation system should be removed; the surface of the vessels and piping should be sanded, primed, painted; and then the entire system should be re-insulated. If the steel vessels and piping systems are found to be in good shape, this system could last another 15 or more years with the other recommended improvements completed and with continued proper maintenance. If extensive corrosion is found, the vessels should be repaired and recertified and/or replace and piping should be replaced before reinsulating. Poor insulation can aid in pre-mature corrosion and loss of efficiency. • Replace vent solenoids on each pumper with some materials: Inspect and replace the existing valve (typically a Sporlan MA50) with same model. This valve cannot be replaced with a higher quality valve as manufactured by Hanson due to the inadequate space. Table 2. Option 2—Minimum Improvements to Existing Rink 1 System Item" Gast,,, Investigate Integrity of vessels and piping systems $3,000 Replace vent solenoid valves(2 total) $2,000 Subtotal of estimated construction costs $5,000 Estimate,design and constr.contingency(20%)1 $1,000 Total estimated construction costs $6,000 Engineering, legal,and administrative(18%)1 $1,000 Total estimated project costs $7,000 1. See explanation in Section 2 of this report. 961tevens 19 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Other recommended improvements to the existing refrigeration system include: • Replace compressors: Parts for the existing York compressor can be difficult to find since they are no longer in production. These compressors can be rebuilt and reused for well over 30 years. However, the existing 42-year old compressors are reportedly showing wear on the main casting which would require replacement in the near future. The compressors should be replaced by compressors that can be used in a future refrigeration system. Table 3. Option 2—Other Improvements to Existing System fit,,,,,, Replace compressors and motors $75,000 1. See explanation in Section 2 of this report. 2. Costs also include contingency,engineering,legal,and administrative. Option 3: Convert existing Rink 1 system to an indirect industrial grade system Only recently has this option proven feasible for converting i Holmsten refrigeration packages from direct to indirect systems i while using the existing refrigeration equipment. The option includes converting the existing refrigeration system to an indirect system by installing a new heat exchanger and rink pumps. This option includes reusing the existing low Photo P-1: The 2010 conversion of pressure receiver, pumper drums and piping, and main motor University of Minnesota-Duluth's ice on-campus ice rink system has proven control center. The existing system would be updated as very successful. See Option 3. recommended in Option 1. The existing ice rink floor would require replacement under this option. The existing ice equipment room would likely require expansion for the additional equipment This option will reduce the charge of R-22 in the system from approximately 4,000 pounds to 1,000 pounds. The City could store the extra R-22 refrigerant for future use. A reduction from 4,000 pounds of R-22 to 1,000 pounds of R-22 will noticeably reduce the facility's carbon footprint. 961tevens 20 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Option 4: —New indirect industrial grade system: Ills This option includes replacing the entire refrigeration system and concrete ice rink floor with an industrial grade flooded chiller, new blended HFC refrigerant, reciprocating compressors, pumps, and concrete rink floor. Option 5: Same as Option 4 but replace Freon with ammonia. This option is the same as Option 4 but replaces the use of a PhotoP-2: An example ofa"stick-built" new blended HFC type refrigerant with ammonia refrigerant. industrial grade,hydrocarbon, refrigeration system for a single ice This option also includes installing a new mechanical ventilation sheet,Andover,MN.See Option 5. system to meet the current ventilation code requirements for ammonia refrigerant and installing an exterior door for egress. or z ° rim Option 6. Carbon Dioxide (CO2) Refrigeration System ; Continuing the discussion from the refrigerant discussion earlier r in the report, the use of CO2 refrigerant will likely be the next substantial "innovation" in the ice rink industry. Currently European countries are using CO2 as a secondary refrigerant in ice rink applications. One rink in Canada just recently installed a �t r primary CO2 system. CO2 applications in the U.S are increasing Photo P-3: An example of a"skid package", especially in the supermarket industry. However the selection industrial grade,ammonia refrigeration of equipment is limited and the regulatory codes are still under system for a single ice sheet,Scottsdale,AZ. See Option 6. development. The cost information provide in the table at the end of this section is very preliminary. Because this is a new technology and application, there is fairly limited information on the systems. The cost estimates should be updated as the desired project date approaches. It is recommended that a CO2 refrigerant based ice system be seriously considered, as a replacement option for the current system, especially if the replacement of the West Arena's ice system will be more than two years from now. Option 7. Combined Refrigeration Systems using Ammonia This system option was included to provide an option for long term planning, including the replacement of the 15-year old refrigeration system in Rink 2. A common refrigeration system that serves both Rinks 1 and 2 offers advantages such as lower life cycle costs, higher efficiency, and lower operation and maintenance costs compared to two separate single ice systems. 961tevens 21 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS The one disadvantage of a common system is that if a major problem occurs with the refrigeration system, both ice sheets �,, are down. However, most equipment and systems have %����� � backups, minimizing the chance that a total system failure will occu r. ' A common ice system could be installed in phases as described below: I Phase 1 includes the replaced of the existing ice rink floor and Photo P-4: The City of Alexandria insta I I ed a new industrial grade common refrigeration refrigeration system in the Rink 2 since the existing refrigeration system(for 2 rinks)in 2009 as discussed in room is likely large enough for the common system. At that Option 7. The system currently operates time the refrigeration system would be designed and installed one ice rink but is designed to connect a second ice rink in the future. with the capacity and accommodations to connect to Rink 2 at some point in the future. The existing ice rink floor in Rink 2 would be replaced with a concrete rink floor of the same size. A new mechanical ventilation system and refrigerant leak detection system would be installed to meet code requirements. The R-22 refrigerant that is salvaged from Rink 2 can be used in the refrigeration system for Rink 1 alleviating some concerns for an R-22 shortage in the future. Phase 2 includes installing the final compressor(s), pump(s), piping and controls to serve Rink 1, replacing the existing ice rink floor with a concrete rink floor, and change over the snow melt system to use waste heat from the refrigeration system. The cost estimates presented in the following table for Option 8 are shown in two phases as described above and include the complete replacement of both ice systems including refrigeration systems and ice rink floors. The cost estimates do not include the following items: • Building a new refrigeration room for a common refrigeration system to serve both rinks. • Improvements to the Rink 2 refrigeration system to keep it operating. • Expanding the length of the ice rink floor in Rink 1 from 185'to 200'. This would require a building expansion. • Reducing the size of the ice rink floor in Rink 2 from Olympic to NHL size and expanding the bleachers. 22 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Summary of Ice System Replacement Options: Table 4. Ice System Options-Cost Estimate Summary Gosh 1ce'` rn Ian Go.rfba nw�d ytem 4 to Conu�rsiof IU v� „ IU ti „ than �,,, I�Frase 2,,, Ex. R-22,,,, ,., New HFC Ammonia,,, ,, ,,,CO2,,,,,,, ,,,,,,,,,, Refrigerant type Ammonia Ammonia Grade of System Industrial Industrial Industrial Commercial Industrial Industrial Removal&reinstall $30,000 $30,000 $30,000 $30,000 $30,000 $30,000 existing dasher boards Demolition of existing $10,000 $25,000 $25,000 $25,000 $25,000 $15,000 refrigeration system Demolition of existing $60,000 $60,000 $60,000 $60,000 $20,000 $60,000 conc. ice rink floor Replace mechanical N/A N/A $25,000 $25,000 $30,000 N/A ventilation system New exterior door and N/A N/A $20,000 $20,000 N/A N/A concrete stoop Repairs to Ex.System $5,000 N/A N/A N/A N/A N/A (From Table 2) Other repairs to existing Not included N/A N/A N/A N/A N/A system(Table3) See Table 3 Expand refrigeration $70,000 $70,000 $70,000 $70,000 N/A N/A room approx.200 SF New refrigeration $225,000 $475,000 $575,000 $725,000 $775,000 $180,000 system or equipment New concrete Ice rink N/A $350,000 $350,000 $475,000 $420,000 $338,000 floor&subfloor New snow melt pit heat N/A N/A N/A N/A $75,000 N/A recovery system Size of future Additional heat reclaim Not included Not included Not included Not included Not included Not included systems See Table 3 See Table 3 See Table 3 See Table 3 See Table 3 See Table 3 Subtotal of estimated $400,000 $1,010,000 $1,155,000 $1,430,000 $1,375,000 $623,000 construction costs Estimate,design and $60,000 $151,500 $173,000 $214,500 $206,300 $93,500 constr.Contingency (15%)1 Total estimated $460,000 $1,161,500 $1,328,000 $1,644,500 $1,581,300 $716,500 construction costs Engineering, legal,and $55,200 $139,500 $159,400 $197,500 $189,800 $86,000 administrative(12%)1 Total estimated project $515,200 $1,301,000 $1,487,400 $1,842,000 $1,771,100 $802,500 cost Expected Useful Life- 15-25 25-30 25-30 TBD 25-30 25-30 Refrig System(yrs) Expected Useful Life- 40-50 40-50 40-50 TBD 40-50 40-50 Rink Floor(yrs) 1. See explanation in Section 2 of this report. PIStevens 23 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 4 Alternative Energy Sources PIStevens 26 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS ALTERNATIVE ENERGY SOURCES General Ice arena facilities use large amounts of energy. With high energy use come opportunities to apply new technologies that may reduce energy use and the opportunity to explore technologies that focus on sustainable and/or renewable energy sources. This section briefly discusses several alternative energy sources that the City may want to consider when the facility is renovated. Greenhouse Gas Reduction Greenhouse Gas (GHG) emissions are increasingly being considered when choosing between facility/process alternatives. Although there is not currently a cost associated with greenhouse gas emissions, there is the potential that there will be. Alternatives with lower GHG emissions therefore have the potential to have lower on-going costs. At the New Hope Arena, the primary sources of GHG emissions are natural gas combustion and electricity use. In addition, there are GHG emissions associated with the manufacture and use of the refrigerant R-22. Geothermal Geothermal exchange systems offer numerous opportunities for energy savings in an ice arena application. Geothermal systems are considered a renewable energy source and have been the focus of a recent wave of funding opportunities from the Federal Government. A detailed analysis should be performed when considering incorporating geothermal systems with the ice system improvements. Construction of several geothermal type ice systems have recently been completed using traditional well type systems Photo P-31: Well drilling rig for a (e.g. Burnsville Ice Center in 2010) and non-traditional geothermal system. geothermal systems (e.g. Brooklyn Park in 2010). The Brooklyn Park Arena project used the City's well water source as a geothermal sink in place of the traditional well field, saving over $200,000 in construction costs and increasing the energy savings. As these projects "season" or are "fine tuned", extremely valuable information will be available on lowering energy use and GHG emissions to apply to the next generation of ice rink systems. The City will benefit from the information collected on these projects. 27 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS The cost to add a geothermal sink to the ice system improvements options listed in Table 4 of this report could add anywhere from $200,000 to $600,000 to the project costs. Further investigation and analysis will be required to determine if this is a feasible option for the City of Elk River. PIStevens 28 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 5 Project Schedule 29 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS PROJECT SCHEDULE General The improvements should be planned well in advance of the desired construction time so equipment and materials can be ordered and delivered to the site. Minimizing disruption to the facility's busy event schedule and user groups will be a key element to the success of this project. We understand the City will use the information in this study to determine the scope of the project(s). Once the project scope and funding sources have been identified, a detailed schedule can be developed. 30 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Section 6 Financial Assistance Programs 31 ELK RIVER ICE ARENA—ICE SYSTEM EVALUATION AND RECOMMENDATIONS FINACIAL ASSISTANCE PROGRAMS There are several financial programs that Xcel Energy has available that the City may wish it take advantage of. They include: 1. Engineering Assistance Study Program. The purpose of this program is to provide the City with the necessary business case justification to implement energy-saving opportunities. This evaluation report can be expanded to identify energy conservation opportunities, energy modeling, etc. to meet the programs requirements. Xcel Energy will reimburse the City up to fund up to 75%of the cost of this study. One example where the City would benefit from this additional energy analysis is in selecting a refrigerant (ammonia, CO2, etc.) or refrigeration system to replacing the existing R-22 refrigerant or system. It is required that the program be pre-approved by Xcel Energy prior to starting any work on the study. 2. Rebate Programs. Rebate programs are available through Xcel Energy for many energy improvement measures that can be performed such as lighting replacement, motor replacement, installation of variable frequency drives, improving insulation systems, etc. Custom rebate programs are also available and may apply to the refrigeration system replacement depending on the type of system selected. Xcel Energy should be contacted to identify possible rebates prior to starting any improvement project relating to energy savings. Some rebates require preapproval prior to purchasing and installation. State Appropriation Board Programs should be reviewed for potential funding opportunities. Sports Commission Programs should be reviewed for potential funding opportunities. American Recovery and Reinvestment Act The initial program deadlines have pasted. However, new programs continue to develop so this program along with other Federal grant programs should be monitored for funding opportunities. There may be other grants or cost-sharing programs available. 32 ELK RIVER ICE ARENA-ICE SYSTEM EVALUATION AND RECOMMENDATIONS Alternate Project Delivery Method Another delivery and funding option the City may consider for this project is through guaranteed-savings contracts. Stevens has teamed with several Energy Service Organizations to successfully complete ice rink projects for the City of Brooklyn Park, Northfield and Eden Prairie. We are currently working with the City of New Hope on a guaranteed-savings contract project at the New Hope Arena. If the City is interested in learning more about this delivery method we would be happy to discuss it in more detail with you. 33