St Barnabas Hospital



St. Barnabas Hospital is a 461-bed, not-for-profit acute care community Hospital and Level I Trauma Center. The campus encompasses 5 buildings totaling approximately 650,000 SF and includes a 199-bed nursing home. There are three (3) operating steam pressures utilized throughout the Hospital campus; 125 psig, 60 psig and low pressure.

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An underground high pressure steam distribution system serves each of the buildings from the existing central plant (chilled water is also distributed from a central location). The steam generation system was antiquated and had far exceeded its normal life expectancy. It was beyond any reasonable capitalized maintenance program.

K&L Group was retained to prepare a Feasibility Study in order to assess the actual steam load requirements, conceive the various design schemes, determine the options for the quantity / size / types of boilers for consideration, establish budget cost estimates for construction and determine approximate energy savings (over the pre-existing plant).

Following the study, we provided design to replace the existing high-pressure steam plant with a new 22 million fully redundant plant utilizing 100% back-up (N+1).

The new stand-alone plant building consisted of three (3) “D” type water tube high-pressure steam boilers, each producing 22,000 lbs./hr. It houses the new boiler plant and includes support spaces such as a control room, Plant Operator’s offices, a bathroom, emergency eye wash stations, storage and an extensive network of mezzanines connected to the main floor with stairs. A dedicated emergency standby generator was provided in the new building to serve both the new heating plant and a portion of the existing Hospital. The #6 fuel oil heating system was de-commissioned and the pre-existing #6 fuel oil tanks were cleaned and reused for use with #2 fuel oil. A new high-pressure Con Edison natural gas service was brought to the plant as well, thereby providing a dual fuel source for the new boilers. A new 125 foot tall, engineered steel stack was constructed on the south side of the new plant building. The 48” diameter boiler stack is surrounded by a 7 foot diameter outer stack enclosure, which also houses a 21” diameter stainless steel stack to be used for a future cogeneration unit.

In fact, after touring this plant at the completion of construction, Robert Daly, former Boiler Director of the NYC Department of Buildings stated, “This is the finest boiler plant I’ve ever seen, and I’ve seen many. I want to have every one of our inspectors come here to see how a high-pressure steam plant is supposed to be designed and built, and I love those access platforms!”

Project completed by K&L Group, A Division of MG Engineering