South Main Church of Christ

Proven Results: Our HVAC Project at South Main Church of Christ

BEFORE: Critical System Failures & Safety Risks

When we arrived at this location, the HVAC system was experiencing a range of mechanical, electrical, and performance issues that impacted reliability, safety, and efficiency. Key problems included:

System Reliability & Performance Challenges

The unit frequently tripped on high pressure during hot weather due to an underperforming cooling tower and system imbalance.
The compressor was pulling dangerously high amps on one power leg, risking failure.
Oil return was poor, with signs of system contamination and disconnected safety controls.
The refrigerant system was low, with visible leaks, broken valve cores, and degraded insulation on sensing bulbs.
Superheat and subcooling values were unstable, reducing system efficiency and compressor protection.
The old condenser water pump could not move enough flow for the system, which also contributed to issues in the system.

Mechanical & Structural Deficiencies

Valve caps and cores were leaking throughout the system, and service valves on both the suction and discharge valves were compromised.
The discharge line was improperly routed, contributing to excessive vibration and was cracking and releasing the charge up to several times a year.
Compressor was rigid-mounted to a steel plate which is fine, but due to the issues found, our mechanical engineer (Deborah Blackall www.gagliardigroup.com) did a vibration study on the machine to determine what course of action would need to be taken.
Overflow piping and water lines were damaged or incorrectly installed, requiring complete replacement and reconfiguration.

Electrical & Control System Issues

Safeties were bypassed or non-functional, including a disconnected oil pressure safety switch.
The grounding was unsafe, with trace voltage found on ground wires and shocks reported by technicians.
Electrical terminals were loose, and motor starters were improperly set, sized, and wired.
The control wiring was disorganized and had been spliced many times over the years contributing to ongoing troubleshooting issues and operator confusion.

Cooling Tower & Water System Issues

Tower nozzles were clogged with scale, reducing cooling efficiency.
Improper bonding and grounding posed safety hazards for service personnel.
The customer lacked proper water treatment and chemical management procedures.

Air Distribution & Comfort Concerns

Inside the building, airflow design flaws were evident—air handler operation caused light fixtures in the sanctuary to sway.
There were visible signs of poor air balancing, and no structured monitoring or building automation was in place to track performance or issues.

AFTER: Comprehensive HVAC System Upgrade

Following a full system evaluation, we performed a complete overhaul of the existing HVAC equipment and controls to improve performance, reliability, and energy efficiency. Key upgrades and improvements included:

Mechanical Improvements

Removed damaged compressor components and refrigerant/condenser water lines.
Installed spring isolators under the compressor and stand to reduce vibration.
Re-piped and properly sized suction and discharge lines with vibration absorbers, ball valves, flanges, and a discharge muffler.
Replaced compressor suction and discharge service valves.
Added new liquid line sight glasses, solenoid valves, TXVs (35-ton balance port), and dryer cores.
Installed a suction accumulator.
Installed new safeties: high pressure switch, low pressure switch, oil pressure switch, and relief valve.

Electrical & Control Upgrades

Installed new VFDs (Variable Frequency Drives) for the evaporator fan, cooling tower fan, and condenser water pump.
Replaced the two improperly sized 90-amp motor starters with one new 250-amp motor starter and cleaned up control wiring for optimal function.
Integrated a fully customized Automated Logic Building Management System (BMS) with Shane Aldrich at Logical Solutions (lsicontrols.com) for full monitoring and proper control of the unit (monitoring points available upon request).
Installed a new flow switch to prevent compressor operation without proper water flow.

Water System Enhancements

Installed a new condenser water pump and coordinated with a chemical treatment company to treat tower water properly.
Replaced and cleaned clogged cooling tower nozzles.
Reworked piping between the condenser barrel and 3” existing condenser water lines, added drain valves to reduce winter water retention.

Service, Clean-Up & Commissioning

Removed all unused conduit, wiring, and outdated controls.
Cleaned the evaporator coil and air handler with coil cleaner and bacteriostat spray.

Results:

The upgraded system now operates within optimal performance ranges, offering improved reliability, efficiency, and control. This comprehensive overhaul prepares the facility for long-term operation with a significantly reduced risk of future breakdowns. A Preventative Maintenance contract will be in place to ensure the system continues to run at peak performance, allowing us to proactively alert the customer when repairs or upgrades are recommended.