Their challenge

Our client wanted to expand production at one of their facilities, which required an increase in their refrigeration capacity. Prior to expansion, their system was already under-performing to meet the existing demand of 3,000 tons of refrigeration (TR), and our client required an additional 500 TR to increase production. The four existing chillers had been installed in the 1990’s and modified throughout the years to support new product lines.

Our solution

Salas O’Brien provided a thorough analysis of the system, revealing that two of the aging chillers were operating at less than the original capacity and one of the chilled water pumps was operating below its original curve. The analysis also revealed flaws in the piping configuration and cooling tower location. We provided detailed recommendations and estimates to modify and correct the chillers, piping, and pumping and identified an operating sequence that could be automated that would improve cooling capability and efficiency.