Replacing equipment without stopping the line.
Five aging units across two production areas, tied into an existing central system, on a schedule set by the plant rather than by the contractor.
Download the one-page PDFThe problem
A packaging and production operation needed five aging fan coil and make-up air units replaced across two production areas, with the new equipment tied into an existing central rack. Production could not absorb an extended shutdown, so every outage had to be planned around the schedule.
The solution
We scheduled shutdowns with the plant team, recovered and disconnected the old units, and installed five new medium-temperature unit coolers. We ran the copper and condensate piping, tied the system into the rack, then pressure tested, evacuated, charged and started it up with full operating readings and equipment verification.
| Item | Detail |
|---|---|
| Center-mount unit coolers | 2 units, 214,020 BTUH each |
| Warehouse unit coolers | 3 units, 322,222 BTUH each |
| Combined capacity | ~1.4 million BTUH |
| Piping | ~1,600 ft copper liquid and suction lines; ~300 ft condensate |
| System tie-in | Existing central rack, with solenoid and isolation valves |
- 01Recover refrigerant
- 02Install and tie in
- 03Pressure test and evacuate
- 04Charge R507
- 05Start up and verify
Scope of work
- Recovered and disconnected five existing units
- Installed five new unit coolers
- Ran copper piping with solenoid and isolation valves
- Installed condensate piping
- Pressure tested, evacuated and charged the system
- Full start-up, operating readings and verification
Planning a replacement in a facility that cannot go down?
Email sales@rabinemechanical.com or call 815.331.1035. Our own crews cover northern Illinois and southern Wisconsin; qualified service partners cover all other markets.