Boiler Room Retrofit - State Office Complex
Conversion from high-temp to efficient low-temp variable flow system with zero interruption to government operations
CLIENT
State Government Agency
LOCATION
Government Office Complex
PROJECT TYPE
Boiler System Retrofit and Modernization
FACILITY TYPE
Large Government Office Complex
The Situation
This large government facility had a centralized hot-temp water system which was scheduled for decommissioning. The old system included an aging two pipe changeover heating and chilled water piping system, which included high-temp hot water heat exchangers from their previous integration project. This is a very busy government complex which could not afford to interrupt their daily operations.
Our Approach
We designed a comprehensive retrofit that converted the existing high-temperature system to a modern, efficient low-temperature variable flow system. The new design provided improved efficiency while maintaining the ability to serve the existing building infrastructure.
The Work
- Conversion from high-temp to low-temp variable flow hot water system
- Installation of three 500 MBH high-efficiency condensing boilers
- Complete heat exchanger replacement and integration
- Pump system upgrades with variable speed drives
- Extensive piping modifications and control system upgrades
- Integration with existing building automation systems
Special Coordination Requirements
Several factors complicated this project. First, the boiler flue needed to be installed within an existing masonry chimney which extended from the basement to the roof of a stories above. The boiler plant was located in the existing mechanical equipment room in the parking garage. Our team designed a plan which would complete all work while enabling this facility to remain operational during the upgrade.
Key Challenges
- Decommissioning of aging high-temperature water system
- Conversion from two-pipe changeover to modern system
- Zero tolerance for interruption of government operations
- Integration with existing building infrastructure
- Budget and timeline constraints for government project
Our Solution
- Converted aging high-temp system to efficient low-temp variable flow design
- Installed three new 500 MBH high-efficiency Cleaver Brooks condensing boilers
- Integrated new heat exchangers, pumps, and piping modifications
- Implemented advanced control systems for optimal performance
- Maintained continuous temperature control throughout project duration
The Results
This project was a huge success, since we completed the full project on-time and within budget and this resulted in high customer satisfaction. Our customer appreciated the substantial energy savings, improved comfort and efficiency of their new condensing boilers. Our customer was also pleased that they saved for our help with another project to achieve similar additional energy and cost savings.
