Burt Process Equipment engineered and delivered a fully integrated Process Cooling Water (PCW) skid system to support facility-wide thermal management at a research and technology campus. Designed to provide 500 GPM flow at 200 TDH, the system was built for high efficiency, operational redundancy, and seamless integration into the facility’s building management system (BMS).
Industry
Research & Technology Facilities
Challenge
High-Capacity Thermal Control
Solution
Customer Profile
The customer, a world-renowned engineering consultancy overseeing a major science and technology campus, required a turnkey PCW system as part of the campus infrastructure upgrade. The system had to deliver precise temperature and flow control for critical equipment, with robust monitoring, control, and safety features—all within a factory-assembled, skid-mounted package.
Challenge
The facility needed a high-capacity, highly reliable process cooling system that would meet precise flow and temperature specifications, support integration into a facility-wide BMS, and be easy to install and commission. The system had to include major components like pumps, heat exchangers, air separators, and VFDs, and be delivered on a compact, modular skid.
Solution
Burt Process delivered a factory-assembled, pre-piped, and pre-wired PCW skid.
Features:
Pump Assembly:
- 2 Grundfos CRI-120 pumps rated for 500 GPM @ 200 TDH
- 50 HP motors with ABB ACH580 VFDs
- Bray butterfly valves, swing check valves, PTFE flex connectors
- Pressure gauges upstream and downstream
- Pressure relief valve for downstream protection
Variable Frequency Drives (VFDs):
- 2 ABB ACH580 50 HP drives
- NEMA 12 enclosures with disconnects and bypass
- Bluetooth-enabled keypad displays with HOA (Hand-Off-Auto)
- Built-in support for BACnet, N2, and Modbus protocols
- Programmable digital and analog I/O, fireman’s override, and damper control
Air Separator:
- ASME vortex-style air separator with stainless steel internals
- Isolation butterfly valves and bypass
- Pressure gauges before and after the unit
Heat Exchangers:
- 2 Plate-and-frame heat exchangers S-PCW-HX-01 & 02
- 316SS plates with EPDM gaskets
- Designed to cool water by 10°F using 48°F chilled water
- Less than 10 psi pressure drop on both hot and cold sides
- Carbon steel chilled water and stainless-steel process water fittings
- Shroud and butterfly isolation valves included
Piping and Enclosure:
- All piping: Schedule 10 304SS, except carbon steel on heat exchanger chilled water side
- Electrical: PVC rigid conduit and PolyTuff flexible conduit (Hubbell)
- Epoxy-coated structural steel skid for long-term durability
Key System Features:
- 100% skid-mounted and factory-tested prior to shipment
- Designed for plug-and-play utility connections
- Supports remote monitoring and integration with building automation systems
- All components isolated with valves for ease of maintenance
Outcome
The skid-mounted PCW system delivered by Burt Process provided:
- Immediate deployment capability with minimal on-site labor
- Consistent cooling capacity to support lab and process equipment
- System redundancy and ease of service through dual-pump and dual-heat exchanger design
- Compatibility with advanced building management systems
Conclusion
Burt Process Equipment successfully met the demanding cooling requirements of a high-tech research institution by delivering a fully integrated PCW system. With robust construction, advanced control compatibility, and pretested reliability, the system ensures long-term operational performance and facility uptime in mission-critical environments.
Do you have a similar application?