Chiller System Replacement at a Corporate Headquarters

About This Project

Challenge

A customer’s headquarters, located in Northbrook, IL was operating with a 20-year-old chiller system that had reached the end of its useful life and needed to be replaced. Kroeschell was selected to perform the multi-million dollar plan and specification project to install a new system.

Solution

Kroeschell performed a chilled water system replacement that included the installation of:

  • Two (2) new 1100 ton Trane chillers
  • Two (2) new medium voltage VFDs
  • Six (6) pumps
  • One (1) combination ventilation and refrigerant evacuation exhaust system
  • Control panel for a 450 ton Trane chiller

At the onset of the project, Kroeschell discovered that the new chillers’ compressors and VFDs would be expelling more heat than the old units, creating an extremely uncomfortable mechanical room. An allowance was provided to Kroeschell to complete the installation of a new 7.5 ton Trane AHU. However, when Kroeschell received the engineering plans, it was discovered that the design would cost upwards of $55,000. The design engineering firm looked to Kroeschell for a solution, and the team delivered by value engineering a new system that yielded 33% cost savings to the customer. Design modifications included the installation of a different type of unit, paring down the control system, relocating the unit, installation of an alternate piping system and removing unnecessary ductwork and insulation.

While the project was slated to begin on the 19th of October, it did not actually commence until the 23rd of November. With a completion date of March 1st, Kroeschell worked to compress the project timetable from 19 weeks to 14 weeks. Although the schedule was shortened, the team put in over 7,000 man hours and completed the project on time.

Over the course of 14 weeks, Kroeschell self-performed all pipe fitting and plumbing and took on the general contractor role, managing multiple third party contractors including sheet metal, electrical, test and balance, temperature controls, demolition, machine movers, fire sprinkler system, chemical treatment, refrigerant removal and a general trades contractor.

Results

Kroeschell completed the chilled water system replacement in a compressed timetable, did so with minimal disturbance to the customer’s operations and produced an extremely clean mechanical equipment room. Additionally, Kroeschell value engineered a new AHU that delivered 33% cost savings to the customer.

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Customer Profile

Our customer is the largest publicly held personal lines property and casualty insurer in America, serving more than 16 million households nationwide. The company has its headquarters in Northfield Township, Illinois, near Northbrook. As of year-end 2015, they had nearly $104.7 billion in total assets.

Category

Commercial, MEP Design-Build Engineering