A major research and technology facility required a robust, pre-engineered Process Cooling Water (PCW) system to support laboratory infrastructure and equipment cooling operations. The system had to deliver reliable flow and pressure performance, precise temperature control, and full integration with the site’s building management system (BMS). Burt Process was selected to engineer and deliver a fully integrated, skid-mounted PCW system, designed for plug-and-play installation, high reliability, and precise monitoring of critical process variables.
Industry
Research & Technology
Challenge
Reliable, integrated cooling
Solution
Challenges
- Delivering and maintaining 300 GPM at 100 PSI to meet varying cooling load demands
- Ensuring system-level visibility and communication with the BMS via BACnet/IP
- Achieving reliable air removal, pressure stability, and chilled water temperature control
- Minimizing on-site installation work while providing a factory-tested, single-skid solution
- Grundfos CR-64 vertical multistage pump, 30 HP motor controlled by ABB ACH580 VFD in a NEMA 12 enclosure
- Integrated pump discharge monitoring with swing check valves, isolation valves, PTFE flex connectors, and pressure gauges
- Air separator (Vortex Type SS) with full bypass and pressure monitoring to remove entrained air and maintain flow consistencyQ0055817 DPS SUNY Poly …
Temperature Management & Heat Rejection
- Plate-and-frame heat exchanger designed for 10°F temperature reduction using 40% glycol
- Includes 304SS plates, EPDM gaskets, isolation valves, and shrouded carbon steel chilled water connections
- Temperature sensors and pressure indicators on both hot and cold sides for precise thermal management
Filtration, Expansion & Chemical Conditioning
- 304SS multi-bag filter housing, 4-bag configuration, rated for 300 GPM
- 120-gallon ASME-rated expansion tank with pressure switch and 34-gallon receiver
- Chemical pot feeder (2” 304SS) on the slip stream line for loop conditioning additives
- Paddlewheel and pressure sensors installed on process and chilled water loops for continuous feedback
Control System Integration
- Allen-Bradley CompactLogix PLC with 7” PanelView+ HMI and full BACnet/IP compatibility
- Includes temperature, pressure, and flow instrumentation; chilled water control valve; and all low-voltage components
- Electrical conduit (PVC rigid and flexible PolyTuff), all control elements mounted and pre-wired to a powder-coated steel skid
- A fully modular and prewired design, reducing field installation time and complexity
- Built-in redundancy and control logic for flow, pressure, and air removal
- Precision cooling with inline temperature control and isolated chilled water circuit
- Seamless communication with the site’s BMS through BACnet protocol
Following a Factory Acceptance Test (FAT), the system was shipped and installed with support from Burt Process field engineers. The result is a high-efficiency utility cooling system that delivers stable operation, precise thermal control, and centralized digital oversight.
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