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Central Utilities Upgrade for Life Sciences Manufacturing Plant

New Chiller Installation to Meet Corporate Energy Saving Directives

Deliverables: Engineering Design, Construction Administration

A leading manufacturer of pharmaceutical drug administration systems and components, this client needed engineering design expertise for a new chiller system to satisfy a company directive to become more energy efficient. To help reduce the energy footprint, DME recommended a new central system design along with new water-cooled chillers to replace old, inefficient ones. The facility had very limited expansion space, posing a unique design challenge. DME’s engineering team devised the perfect solution—a compact multi-story chiller plant providing 1800 tons of cooling capacity.

DME’s innovative chiller plant was designed as engineering design expertisea three-story facility. This accommodates three 600-ton chillers, as well as primary and secondary chilled water pumps on level one. The mezzanine houses the primary condenser water pumps, chemical treatment systems, and a new electrical transformer and switchboard. On the top level and above the roof, three 600-ton cooling towers reside on a platform, which is accessible to maintenance staff from a new stair tower. The design also incorporated a new central chilled water distribution loop throughout the manufacturing facility, supporting all existing cleanroom HVAC and providing expansion capacity for process cooling loads.

The result: improved chilled water capacity; increased reliability (through built-in redundancy); and superior energy efficiency in accordance with the client’s energy savings initiatives. The construction manager on the project commented that DME “commits to a project regardless of distractions. The DME team is very responsive—rarely taking more than half a day to return emails and phone calls.” 

Of Special Interest: In addition to the new design, the DME team had to accommodate a no-shutdown mandate. To comply with this requirement, DME designed a distribution system to provide phased system tie-ins to minimize the impact on operations during construction. This project received an “Award of Excellence” 1st place from the 2014 ABC Builder’s Council.

DME Headquarters
7540 Windsor Drive, Suite 311
Allentown, PA 18195
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Phone: (610) 366-1744