Problem
Our customer, a large national retailer, was operating an old Distribution Center which was initially commissioned in the late 1960’s. Due to the age of this facility and equipment, the company was struggling with high repair costs and significant downtime. They needed a complete redesign of their chilled water cooling and hot water heating systems.
Solution
Mallory and Evans designed a custom solution for this facility, which achieved their goals of reducing downtime while providing the redundancy and greater efficiency their company expected. In addition, our solution enabled this distribution center to remain in operation during the project.
The Situation
Our team needed to replace the primary chilled water, condenser water, and hot water heating pumps with new variable speed pumps. The solution also required replacement of the existing 600-ton crossflow cooling tower with a new 850-ton counterflow cooling tower. Our design included variable speed fans capable of supporting both chillers operating at the same time.
The Work
The project included a redesign of the hot water heating piping to allow for the installation of three (3) new 4000 MBH high efficiency boilers configured in a primary / secondary loop, plus the removal and replacement of a 600-ton variable speed primary chiller and a 250-ton variable speed pony chiller.
The Results
First, our team designed a project which enabled the ongoing operation of this facility while we made the necessary upgrades. Our plan met all the customer’s objectives for the central plant upgrade. We achieved their necessary heating and cooling requirements while maintaining the project’s timeline and budget, to the great satisfaction of our customer.
