APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIP

CASE-078 · Workstream overview

Cooling and Utility Reliability Modernization

An overview of the related projects, technical interfaces and outcomes within this workstream.

Conceptual engineering visualization: Cooling and Utility Reliability Modernization
Conceptual engineering visualization · AI generated

Why the Work Mattered

Purpose and Operating Need

Project scope and individual work packages are presented separately; project totals are not additive to their component values.

Engineering Approach

Engineering Approach

Coordinated the 250-ton standby-chiller installation, equipment removal, pump package, cooling-tower-loop tie-ins and mechanical/electrical startup interfaces. Developed the cooling-tower, chiller, injection-well, BAS/PLC and VFD-pump retrofit design. The cooling workstream also includes completed production-chiller upgrades, ozone-treatment integration, BAS monitoring and electrical interfaces.

Outcome & Engineering Context

Outcome and Context

The workstream includes production and standby cooling upgrades, a retrofit, and cooling-alarm and utility-design work.

Workstream Results & Impact

Added standby cooling capacity and improved utility resilience through chiller installation, piping tie-ins and coordinated controls.

Eliminated catastrophic compressor-failure risk and restored reliability across critical acetator and fermenter cooling operations. Reduced operating expense by approximately $118,000 annually through replacement of failed chillers.

Closed an approximately 78-ton cooling deficit through recirculation and loop redesign.

Integrated ozone treatment with projected savings of $26,500 per year and a 10-year payback. Together with the documented cooling operating-expense reduction, the annual benefit basis is $144,500, including the projected treatment component.

Developed the tower, chiller-loop and variable-speed pump design to restore cooling capacity and reduce energy use per ton.

Measures & Operating Detail

Engineering scope and design basis

Workstream covering cooling and utility reliability modernization across its named projects, with project-level engineering scope, capital values and operating context.

Added standby cooling capacity and improved cooling system resiliency for facility operations through a dedicated chiller installation and tie-in; Reduced compressor-failure exposure and improved cooling reliability for critical acetator and fermenter operations; Reduced OPEX by ~$118K annually through replacement of failed chiller supplier units; Closed ~78-ton cooling deficit via recirculation and loop redesign; Delivered sustainability benefits with ozone injection retrofit, projected $26.5K/year savings and 10-year payback; Designed tower-chiller loop modernization and VFD control to restore cooling capacity and reduce kWh per ton.

Workstream Cost: 14998 K.

Chiller coordination, pump package and piping tie-ins, cooling tower loop interfacing, field installation coordination; Chiller & Cooling Systems, BAS & Controls Coordination, Ozone Water Treatment, Electrical Power Distribution; Chiller & Cooling Systems, PLC & HMI Programming, VFDs & Drive Coordination

Chiller and utility coordination, installation sequencing, mechanical and electrical coordination, startup and commissioning readiness; Capital Project Lifecycle Management, AFE Development & Budget Modeling, Multidisciplinary Coordination, Sustainability Engineering; Capital Project Lifecycle Management, Multidisciplinary Coordination

Actions, Methods & Controls

ACTIVITIES IN CONTEXT

Additional Technical Detail

Roles & contributions

  • Project Ownership

    Full lifecycle project ownership

    Project Leadership

    Coordinated production and standby cooling projects, utilities and startup interfaces; developed the tower/chiller/well retrofit and related controls scope.

    Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Workstream context
Cooling and Utility Reliability Modernization ↗
Additional technical detail
Explore 1 detail record
  • Workstream installation reference

    The cooling-workstream rollup references an East/West-building installation with two160-ton chiller manufacturer chillers and one250-ton unit, followed by a truncated Cold Water tie-in sentence. The separately corrected production/backup cases retain their own equipment counts.

All portfolio connections
All portfolio connections (31)
Related analysis and application artifacts

WHAT COMES NEXT

Complex Challenge?
Let’s Work Through It.

Engineering leadership, capital projects, and independent consulting.

Start a conversation ↗