Kallen & Lemelson initially prepared a condition assessment report, an analysis of various operational problems and a feasibility study to consider the possibility of increasing the plant capacity to 2,400-tons in order to satisfy the existing and future loads. A system of three (3) separate engine emissions systems were added (one for each of the existing engine drives). The systems were designed to reduce the total plant NOx to under 25 tons per year as per EPA guidelines for such sever attainment areas. The system contained catalytic converters, silencers, chemical emissions sensors and a microprocessor based control system.
The plant originally contained three (3) 700-ton gas engine driven centrifugal chillers operating on R-12 (CFC) refrigerant. The new chillers were 800-ton gas engine driven chillers having R-134A (HFC) refrigerant. Our design included a new plant-wide refrigerant leak detection system having multi-refrigerant sensors and sensing tubes / ports, digital alphanumeric display panel, alarm and control panel and chiller interlocking capability. Self-contained breathing apparatus (SCBA) were located at all entrances to the MER. A new emergency refrigerant purge exhaust system was added and included a rooftop exhaust fan, exhaust ductwork, air intake louvers and automatic and manual controls. The system automatically evacuates air from the MER in the event of a system alarm condition, as well as if manually initiated.
Work also included the following:
– A new cooling tower sized to serve three (3) 800-ton engine driven chillers
– Three (3) new condenser water pumps
– Three (3) automated digital control valves installed in the condenser water piping
– A new system of chemical treatment and filtration for the CW system
– A new Direct Digital Control (DDC) system with local controls, venturi flow meters and automatic valves to facilitate the remote control and monitoring capability through the Building Automation System (BAS)
– Modifications to the existing chilled water piping to enable the interconnection with the new chiller plant
