Case Study
Restoring Peak Efficiency Through a
Full-System Cooling Tower Refurbishment
| Client | Major Facilities Management Firm |
| Facility | Northern California Government Building |
| Asset | BAC Model PT2-1009A Cooling Tower |
| Service | WSC Performance Restoration |
The Challenge
A Failing Asset and Soaring Energy Costs
A major facilities management firm, operating a critical government building, was facing a cascade of problems with an aging cooling tower. Years of use had led to severe calcium buildup on the packing media and significant basin corrosion.
This wasn’t just a maintenance issue; it was a financial drain.
The fouled tower was choking the entire HVAC system, forcing the chillers to work harder to meet the building’s cooling demand. This performance gap meant the client was facing two disastrous choices:
- Rising OpEx: Pay a massive, escalating energy bill every month.
- Sudden CapEx: Face a catastrophic failure and an unbudgeted, $500,000+ replacement.
The Solution
The WSC Performance Restoration
A simple “cleaning” would not solve this problem. The asset required a full-system overhaul to restore its original design performance. Our team was brought in to execute a complete “Performance Restoration.”
This high-value service included:
- Full Media Replacement: Complete removal of the scaled-out, original fill and installation of new, high-efficiency PVC packing material.
- Basin Refurbishment: Mechanical sanding and grinding of all interior surfaces to remove all corrosion and failed coating.
- Marine-Grade Epoxy Coating: Application of a high-performance, corrosion-resistant epoxy lining to create a durable, new surface and extend the asset’s life for years.
The Results
A Documented 10x Return on Investment
The outcome was immediate, measurable, and confirmed directly by the client’s engineering team.
- RESULT #1: A 10°F TEMPERATURE DROP The client’s own feedback was the most powerful metric. The performance restoration resulted in the supply water being “8 to 10 degrees cooler” than before the service, confirming a massive gain in thermal efficiency.
- RESULT #2: A $38,753 ANNUAL SAVINGS A 10°F temperature drop directly translates to a ~25% gain in chiller efficiency. For this 271-ton tower, this performance gain delivered an estimated $38,753 in annual energy savings – a return that paid for the project many times over.Here is the simple math behind that saving:
- Asset: 1 x BAC PT2-1009A (271-ton capacity)
- Performance Gain: 10°F drop = 25% Chiller Efficiency Gain (at 2.5%/°F)
- Baseline Cost: 271 tons * 0.65 kW/ton * 4,000 hours/yr * $0.22/kWh = $155,012 / year
- Annual Savings: $155,012 (Baseline Cost) x 25% (Gain) = $38,753
- RESULT #3: A $500,000 CAPEX DEFERRAL By refurbishing the tower and lining it with a marine-grade epoxy, we extended the asset’s operational life by 7-10 years. This allowed the client and the building owner to defer a $500,000+ capital expenditure for a full tower replacement.
Why It Matters
This project illustrates how a comprehensive refurbishment can breathe new life into aging equipment.
Rather than performing isolated repairs or temporary fixes, WaterSystems focuses on end-to-end restoration — addressing both mechanical and structural issues to deliver measurable, lasting results.
Our experienced team ensures every project meets the highest standards of safety, efficiency, and compliance, giving facility managers confidence that their systems are built to perform.
Key Outcomes
8–10°F improvement in supply water temperature
25% gain in chiller efficiency
$39,000 estimated annual energy savings
1-week project completion
Extended equipment life and reduced maintenance costs
Restore Your System’s Peak Performance
a full-system refurbishment can restore performance and deliver significant energy savings.
