Eliminating Generator Dependence and Reducing Electrical Costs by 35%
Electrical Engineering & Power Distribution Optimization
Executive Summary
A commercial facility relying on both utility power and generators to support their HVAC operations, resulting in increased monthly operating expenses. Dellew conducted an electrical capacity analysis and reconfigured the facility's power distribution system. This process involved: eliminating generator dependence and reducing monthly electrical costs by approximately 35%.
Client Background
The facility operated with a 400-amp electrical service and required multiple three-phase HVAC units to maintain building operations. Due to perceived electrical limitations, portions of the cooling system had been connected to generators rather than the primary utility feed.
The Challenge
The client faced several challenges:
-
Ongoing fuel and maintenance expenses associated with generators
-
Dual utility and generator operating costs
-
Risk of electrical overloads and system interruptions
-
Potential equipment damage from power surges and overloaded circuits
Additionally, industry best practices recommend operating electrical systems at no more than 80% capacity to maintain reliability and prevent nuisance tripping
The Solution
Dellew's engineering team performed a comprehensive power assessment to determine:
-
Existing electrical demand
-
Available capacity within the system
-
Opportunities for load redistribution
After completing the analysis, the team:
-
Reconfigured Electrical Panels: Redistributed electrical loads to maximize available transformer capacity while maintaining safe operating margins.
-
Upgraded Distribution Infrastructure: Completed approximately $14,000 in electrical modifications to redirect power from the existing transformer to critical HVAC equipment.
-
Conducted Multi-Stage Testing: Performed extensive testing under both light and full-load conditions to verify system stability and reliability before full implementation.
Key Takeaway
Engineering decisions should be based on current operational data rather than historical assumptions. By conducting a detailed load analysis, Dellew identified a solution that delivered significant cost savings while avoiding unnecessary capital expenditures.