Challenge
A confidential life science client operating a 24/7 cGMP manufacturing facility had experienced years of growth, which placed increasing demand on its aging chilled water infrastructure. Multiple independent chilled water systems had been installed over time, creating operational complexity and maintenance challenges.
The facility required a modernized system that could consolidate cooling capacity into a single, reliable solution capable of supporting heavy process loads while maintaining continuous operation. The project also presented several logistical challenges, including tight building space constraints, complex permitting issues related to site boundaries and wetlands, and the need to maintain ongoing facility operations throughout the renovation. Additionally, the project needed to accommodate phased implementation while complying with evolving Massachusetts energy code requirements.
Solution
Hallam-ICS designed a new central chilled water plant to replace and consolidate the facility’s existing cooling infrastructure. The design introduced a single 820-ton air-cooled chilled water system with 410 tons of free cooling capacity to accommodate the facility’s heavy process loads.
To address space limitations within the building, outdoor pump houses were incorporated into the design. The team conducted a detailed analysis of BMS trend data to accurately assess total building demand and optimize pumping strategies for improved chiller performance and system controllability. The system was converted to a primary-secondary loop configuration, supported by new pumps to manage flow and enhance operational flexibility.
The project was executed in multiple phases to maintain continuous facility operation. Existing chillers remained operational during installation while temporary equipment was removed in stages. The design also included updates to the chilled water plant control scheme to improve system performance and reliability.
A unique challenge arose when both chillers were purchased in Phase 1 but the second chiller was not scheduled for installation until Phase 2 the following year. During that time, Massachusetts state energy codes changed, requiring the project team to collaborate closely with the vendor to modify the second chiller to meet stricter performance standards.
