Turbochyll - Recent Projects

Project #10 – ECM Fan Arrays

Wed, 08 Apr 2026 00:11:31 GMT

Project #10 – ECM Fan Arrays

Scope of Work:

The Challenge: Upgrade Fan System - With Minimal Business Disruption

The client notified TurboChyll that the existing fan assembly required replacement due to frequent mechanical failures, escalating maintenance expenses, and increasing operating costs. The project also needed to be executed while keeping facility operations running with minimal disruption.

Declining efficiency and higher operating costs
High maintenance and unreliable

Our team recently completed the installation of high-efficiency ECM fan arrays for a major global telecommunications company, upgrading their air handling system to improve reliability, efficiency, and airflow control.

Delivered Results & Impact

C ompleted in under 24 hours with minimal business disruption
Significant improvements in efficiency, performance, and reliability
Lower energy use reduced operating costs while also shrinking environmental impact and carbon footprint

Project Photos

Project #9 – Chiller Replacement

Fri, 27 Mar 2026 00:09:43 GMT

Project #9 – Chiller Replacement

Scope of Work:

The Challenge: Aging Chiller Plant Replacement

An aging chiller plant built around four Multistack modular chillers had reached the end of service life. The system presented multiple challenges:

Declining efficiency and higher operating costs
Limited flexibility for future system controls and optimization
Aging electrical and piping infrastructure

TurboChyll delivered a turnkey modular chiller replacement, upgrading four legacy Multistack units to four new 30-ton Aermec modular chillers. The scope included engineering and design coordination, turnkey installation, electrical, insulation and piping upgrades, and preparation for future building management system (BMS) integration. A Phase 2 planned to add new condenser and chilled water pumps with VFDs to improve efficiency.

Delivered Results & Impact

Modernized, high-efficiency modular chiller plant
Lower risk of downtime and emergency repairs
Infrastructure aligned with modern standards and future controls
Scalable design supporting VFD upgrades and BMS integration
Clear path to ongoing energy savings and performance gains

Project Photos

Project #8 – Return Fan Replacement

Thu, 26 Mar 2026 23:57:36 GMT

Project #8 – Return Fan Replacement

Scope of Work:

The Challenge: Return Fan Compromising HVAC Reliability

The 20th floor return air system relied on an outdated tubular inline fan assembly that no longer provided reliable airflow or efficient operation. The existing unit required full disconnection, demolition, and disposal, as it could not meet the building’s airflow, static pressure, control, or integration requirements.

Restore reliable and consistent airflow
Better system control & visibility
Improve energy efficiency
Reduce operating costs
Enhance comfort with less noise inside
Reduce vibration to minimize equipment wear
Decrease frequent maintenance & repairs
Extends lief of HVAC connected equipment

TurboChyll provided a turnkey replacement of the system including:

Removal and disposal of the existing tubular inline fan.
Supplied and installed a new 12,000 CFM, 7.5 HP tubular inline direct-drive fan with premium-efficiency TEFC motor.
Installed VFD controller featuring BACnet touchscreen integration.
Added airflow monitoring and pre-wired 25' EC whips (230/3 voltage).
Installed the new fan and completed all wiring and system start-up.
Trained engineering staff on fan operation and controls.
Customer support with a 1 year TurboGuard Plus parts & labor warranty.

Delivered Results & Value

The new fan will restore stable airflow, improve energy efficiency with VFD and BACnet controls, and decrease maintenance through its direct-drive design. Engineering staff received training for system operation, and the one year TurboGuard Plus warranty will ensure reliability and peace of mind.

Project Photos

Project #7 - Plate & Frame Heat Exchanger Cleaning

Thu, 26 Mar 2026 23:43:40 GMT

Project #7 - Plate & Frame Heat Exchanger Cleaning / Regasketing / Dye Penetrant Testing / Close Up

Scope of Work:

The Challenge: Extend life of 25-year-old plate & frame heat exchanger

A critical healthcare facility was operating a 25-year-old plate and frame heat exchanger that had never been dye-penetrant tested, creating risk from unknown plate integrity, obsolete components, and potential internal leaks. With chiller reliability at stake and minimal allowable downtime, the facility needed to extend the unit’s life without triggering a costly full replacement.

Detect hidden plate cracks before failure
Extends life of aging, obsolete equipment
Restores heat-transfer efficiency
Eliminates fouling & flow restrictions
Identifies internal cross-leaks
Replaces degraded gaskets to stop seepage

TurboChyll executed a coordinated labor plus materials program to fully restore integrity & performance of the heat exchanger:

Onsite coordination: isolated and drained exchanger with facility staff
Plate removal: opened frame and removed plates
Cleaning and testing: cleaned plates and performed dye-penetrant testing
Regasketing: installed new OEM gaskets
Reassembly: rebuilt plate pack and torqued to OEM specifications
System restart: pressurized and leak-tested
Documented: system performance of chiller, condenser, and heat exchange r

Delivered Results & Value

This project transformed an aging, high-risk heat exchanger into a stabilized, documented, and leak-free system, preventing failure, extending the life of a 1999 asset, and avoiding costly replacement. Coordinated execution minimized downtime, established a 15% failure benchmark for future planning, and ensured uninterrupted hospital chiller and condenser performance while delivering measurable lifecycle value.

Project Photos

Project #6 - VRF Design

tom@psdigitalli.com (Tom Donohue) — Mon, 05 May 2025 00:12:55 GMT

Project #6 - VRF Design

Scope of Work:

Equipment to Be Furnished and Installed

(2) 4-Ton LG Condensing Units
(4) 2-Ton LG Ceiling Cassette Air Handlers

Condensing Unit Installation

Mount (2) 4-ton condensing units on the rooftop.
Includes furnishing and installing roof rails for secure mounting.

Indoor Unit Installation

Ceiling-mount (4) 2-ton ceiling cassette air handlers within the apartment area.

Refrigerant Piping

Furnish and install all required refrigerant piping, fittings, and insulation as needed for a complete and operational system.
All piping to comply with manufacturer specifications and local code requirements.

Before & On-Going Project Photos

Completed Project Photos

Projected Finished Project Photos

Project #5 - 10 Ton Unit–Supplemental Cooling

tom@psdigitalli.com (Tom Donohue) — Mon, 05 May 2025 00:05:32 GMT

Project #5 - 10 Ton Unit–Supplemental Cooling

Scope of Work:

Disassemble and remove existing 10 Ton Main for Rack Room Chilled Water Air handling unit and properly dispose of.
Furnish and Install (1) Custom Indoor MLRa Supplemental 10 Ton AHU to include the following:
- 2” Double Wall Construction
- Custom stand/base to allow bottom intake
- Filters (2” MERV8)
- “A” style chilled water coil
- Fan & a humidifier shipped loose to be installed in duct
- The approx. dimensions are: 64” High (12” stand) x 62” Wide x 36” Deep
Includes Packaged Controls:
- Touchscreen Sensor
- Chilled Water Valve (24V)
- Programming
Reconnect existing piping as required. Re-Insulate existing piping if required.
Furnish and Install Ductwork to connect to existing.

Completed Project Photos

Design:

Project #4 - AHU Life Extension Project

tom@psdigitalli.com (Tom Donohue) — Mon, 05 May 2025 00:05:28 GMT

Project #4 - AHU Life Extension Project

Scope of Work:

Completed Pre-Demolition Testing:

Provide labor to perform a total air flow traverse of SU-1.
Record baseline airflow measurements prior to any demolition or modification work.

Demolition and Disposal:

Disconnect and remove the existing fan section from SU-1.
Properly dispose of all removed components in accordance with local regulations and jobsite protocols.

Equipment Procurement:

Supply and deliver the specified ECM Fan Array as detailed in the Equipment List.

Installation of New EC Fan Assembly:

Provide all labor and materials to install the new EC fan assembly into the existing SU-1 air handling unit.
Ensure proper mechanical integration and alignment with existing ductwork and structural supports.

Controls Installation:

Furnish and install premium control system compatible with EC fan operation.
Provide and install EC whips and control dampers as required for full system functionality and integration.

On-Going Project Photos

Completed Projects Photos

Project #3 - VRF System

tom@psdigitalli.com (Tom Donohue) — Mon, 05 May 2025 00:00:29 GMT

Project #3 - VRF System

Scope of Work:

The client informed TurboChyll of the necessity for additional cooling in their upscale night club, which features an expansive hot tub. In response, TurboChyll implemented a VRF system to regulate humidity levels.

(2) 16Ton Heat Pump Condensers
(10) 36k Wall mounted Air Handlers

Before & After Photos of VRF System Installed

Project #2 - Cooling Tower Replacement

tom@psdigitalli.com (Tom Donohue) — Sun, 04 May 2025 23:55:22 GMT

Project #2 - Cooling Tower Replacement

Scope of Work:

Client advised TurboChyll that the Fan Motor Shaft had final broke and it was time to replace the Cooling Tower entirely.

TurboChyll hired an Engineer and Structural Engineer to develop Drawings and Plans to provide the client a price on.

Once awarded the project, TurboChyll worked to Remove the Existing Cooling Tower and properly Dispose of.

Install New Steel according to Structural Engineers Drawings.

Furnish and Install / New Cooling Tower onto New Steel with New VFD’s, New Spring Isolators, New Electrical Panels, and New Chilled Water Piping/Insulation.

After Photos of New Tower Install – Including New Steel / Piping / VFD’s

Project #1 B - ECM Fan Wall Arrays

tom@psdigitalli.com (Tom Donohue) — Sun, 04 May 2025 23:51:21 GMT

Project #1 B - ECM Fan Wall Arrays

Schedule:

6-8 Weeks Lead Time
Install 2-3 Weeks
New Fans in 10-11 Weeks

Cost / ROI:

Improved operating efficiency by operating at the fan's best efficiency point and using speed control
Improved reliability through fan redundancy
Reduced installation costs through modular design
Improves acoustic performance

Project #1 A - ECM Fan Wall Arrays

Thu, 01 May 2025 18:05:01 GMT

Project #1 A - ECM Fan Wall Arrays

ECM Wind Wall Retrofits on 108 Data Aire Units

Details of Project:

Quantity of Units: 88 total – DACD-0734/0934

Design of Unit: To cool the Data Rooms

Cost Savings:

Dollar amount saved in Kwh saved in 1 year is $178,834.48

16,380.3 Kwh - (Minus) New Fan 3,679 Kwh
Total =12,701.3 Kwh saved per year = $2,032.21 saved per unit
$2,032.21 x 88 units = $178,834.48

Data Aire Maintenance Details = $56,320.00

$160 hr x 1 hours(Maintenance) x 4 times per year x 88 fans = $56,320.00
Savings in 1 year - $235,154.00

All of these Savings Reduced Carbon footprint in this Building with The New LL-97 Regulations as shown below up to 782 metric tons of Co2

After Photos of DACD Wind Wall Installed (0734 Model)

After Photos of DACD Wind Wall Installed (2234 Model)

Turbochyll - Recent Projects

Project #10 – ECM Fan Arrays

Project #10 – ECM Fan Arrays

Project #9 – Chiller Replacement

Project #9 – Chiller Replacement

Project #8 – Return Fan Replacement

Project #8 – Return Fan Replacement

Project #7 - Plate & Frame Heat Exchanger Cleaning

Project #7 - Plate & Frame Heat Exchanger Cleaning / Regasketing / Dye Penetrant Testing / Close Up

Project #6 - VRF Design

Project #6 - VRF Design

Project #5 - 10 Ton Unit–Supplemental Cooling

Project #5 - 10 Ton Unit–Supplemental Cooling ﻿

Project #4 - AHU Life Extension Project

Project #4 - AHU Life Extension Project

Project #3 - VRF System

Project #3 - VRF System

Project #2 - Cooling Tower Replacement

Project #2 - Cooling Tower Replacement

Project #1 B - ECM Fan Wall Arrays

Project #1 B - ECM Fan Wall Arrays

Project #1 A - ECM Fan Wall Arrays

Project #1 A - ECM Fan Wall Arrays

Project #5 - 10 Ton Unit–Supplemental Cooling