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Northside Hospital

Maneuvers made the day

THE GIST:

Atlanta’s Northside Hospital needed to replace a trio of aging boilers as well as a deaerator tank inside the central energy plant. Space was the challenge: The footprint wouldn’t hold the new systems built as-is, and expanding the square footage wasn’t in the budget. B&K consulted the manufacturer of the equipment and made a series of modifications to the boilers and deaerator, then orchestrated step-by-step maneuvers to get the new water system up and running.

Maneuvers made the day

“If everyone is moving forward together, then success takes care of itself.” — Henry Ford

Ford was talking about mass assembly, which he pioneered more than a century ago.

But his words hold true for building and installing mechanical and process systems – and one of our projects with Northside Hospital is evidence of that.

A trio of 45-year-old steam boilers provided all of the hospital’s domestic and heating hot water, sterilization and humidification capacity. The boilers had lived a good life, but it was time for them to go.

The problem was, newer technology is configured differently these days. For Northside, that meant you couldn’t just take three boilers out and put three new ones in. The footprint wouldn’t hold the replacements, and all kinds of piping and duct work were packed in tightly overhead. Expanding the space wasn’t in the budget, either.

So, how do you make it all fit and work? The answer is you lean on your team.

In the chess game of replacing system components, the deaerator was the first move. It had to be assembled in the field while a standby tank kept the system functioning.

Northside_Photo_2

In the chess game of replacing system components, the deaerator was the first move. It had to be assembled in the field while a standby tank kept the system functioning.

“We had so many steps in this project, large and small, that had to be followed in exactly the right order,” says David Burns, who served as project manager. “They were steps that involved not just our team, but suppliers, partners, the property owners – everybody. Their input was needed, so we asked and listened.”

Step one was to cut a good-sized hole in an exterior wall to get equipment in and out of the central energy plant space. And before any boilers were going anywhere, we had to install a new deaerator tank, as the existing one was aging. “The tank was in a place you couldn’t get to easily, so that had to go in first,” Burns says.

To get the boilers to a size that fit the space, we contacted the manufacturer, Cleaver Brooks. They worked out a way to modify some of the height and width to take off a few inches here and there. “We knew there were certain things they could do inside the factory to play with it a little bit,” Burns says, “so we started there.”

Then we sent all three boilers to our partners at T&D Rigging to trim them down further. They took off the outer casing and removed the gas train and other accessories – all to get them down to a size small enough to be maneuvered into place.

But with the network of pipes and systems overhead, it still wasn’t enough. So, we devised a series of repeatable steps that involved temporarily moving fuel lines, adding valves to piping, installing Victaulic couplings and other tactics.

With that series of moves – kind of like a chess game or Rubik’s cube – we could then demo and remove a boiler, install a new one, add back the boiler components we’d removed and adjust the overhead pipes and systems. We then repeated the whole process in different configurations for the other two boilers.

THE PROJECT INVOLVED...

  • Replacing three 400-HP boilers supplying heating and domestic hot water
  • Replacing 840-gallon deaerator tank with four 10HP boiler feed pumps
  • Maintaining 24/7 supply of water without interrupting hospital operations
  • Developing shop drawings to detail installation of piping
  • Project timeline: 5 months

THE PROJECT INVOLVED...

  • Replacing three 400-HP boilers supplying heating and domestic hot water
  • Replacing 840-gallon deaerator tank with four 10HP boiler feed pumps
  • Maintaining 24/7 supply of water without interrupting hospital operations
  • Developing shop drawings to detail installation of piping
  • Project timeline: 5 months

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