NickKovalcik

Industrial facilities are complex environments where machinery, processes, and personnel must operate in harmony to achieve efficiency, safety, and reliability. Over time, systems can become outdated, workflows may need optimization, and infrastructure may require reinforcement. Strategic upgrades and evaluations are essential to maintaining performance, reducing operational risk, and ensuring compliance with evolving safety standards. Facilities that invest in proactive assessments and improvements protect their personnel, assets, and long-term operational capabilities. 

Why Industrial Facility Upgrades Are Critical 

Upgrades are not merely maintenance; they are a structured approach to sustaining operational excellence. Industrial systems are subject to wear, changes in production demand, and evolving regulatory requirements. Without targeted upgrades, facilities face increased risk of equipment failure, unplanned downtime, or compliance violations. 

Regular evaluations and upgrades allow facility operators to: 

• Maintain continuous and reliable operations. 
• Reduce exposure to hazards for employees and contractors. 
• Enhance efficiency by streamlining processes and integrating modern technologies. 
• Ensure compliance with safety, environmental, and operational standards. 

By approaching upgrades strategically, companies protect both operational performance and long-term investment. 

Key Components of Effective Facility Upgrades 

Successful industrial upgrades require expertise across multiple engineering disciplines. Coordinated cross-disciplinary efforts reduce risk and ensure upgrades are executed correctly the first time. Core areas include: 

1. Process Engineering – Optimizing workflows and integrating upgrades without disrupting ongoing operations. This ensures productivity remains high while improvements are implemented. 
2. Mechanical Engineering – Maintaining the reliability of machinery, piping, and equipment under updated conditions. Upgrades in this area strengthen operational integrity and longevity. 
3. Electrical and Instrumentation – Implementing controls, monitoring systems, and interlocks to maintain process stability and support safe operation. 
4. Civil and Structural Engineering – Reinforcing physical infrastructure to accommodate modifications safely and efficiently, including structural support for new equipment or layouts. 
5. Safety and Compliance Integration – Conducting hazard analyses, interlock procedures, and risk mitigation strategies throughout the upgrade process. This ensures upgrades meet both regulatory standards and internal safety expectations. 

Each of these areas contributes to a holistic approach, combining technical rigor with practical execution to maximize reliability and minimize risk. 

Coordinating Upgrades Across Multiple Projects 

Industrial facilities often manage upgrades across multiple sites simultaneously. Coordinating these efforts requires standardized evaluation methods, careful scheduling, and integrated project management. A systematic approach allows teams to: 

• Conduct thorough facility evaluations, such as front-end engineering (FEL 0) assessments and process safety management interlock reviews. 
• Prioritize upgrades to minimize operational downtime while addressing the most critical needs first. 
• Maintain consistency and regulatory compliance across multiple facilities and projects. 

By aligning engineering expertise with structured planning, operators can implement upgrades efficiently while maintaining operational continuity. 

Real-World Example: Wastewater System Improvement Project 

The Wastewater System Improvement project demonstrates the value of structured upgrades. The initiative provided additional wastewater storage capacity while allowing for the removal of an existing tank during a critical operational outage. Careful sequencing ensured that operations were not disrupted. 

High-resolution laser scanning technology reduced the need for repeated site visits, improved the accuracy of preliminary designs, and streamlined the transition into detailed engineering. The project highlights how proactive planning, cross-disciplinary collaboration, and technology integration allow industrial facilities to complete upgrades safely and efficiently while maintaining reliability and meeting industry standards. 

The Impact of Structured Upgrades 

Industrial upgrades are investments in resilience. By combining rigorous evaluations with cross-disciplinary engineering expertise, facilities reduce operational risk, improve safety, and enhance overall performance. Systematic upgrades ensure that facilities operate reliably, protect personnel and assets, and remain prepared for evolving production demands and regulatory expectations. 

Facilities that adopt this approach create a sustainable foundation for ongoing operations, demonstrating that strategic planning and expert execution are essential to long-term industrial success. 

As demand for artificial intelligence, cloud computing, and data storage accelerates, data centers are becoming some of the most energy- and infrastructure-intensive facilities ever built. But before the racks are installed and the servers come online, data centers rely on something far more foundational: engineered infrastructure that connects the site to the energy, utilities, and systems that power it. 

At Allied Engineering + Design (AED), we focus on the systems outside the building that make continuous data center operation possible. Our multidisciplinary teams support project development from feasibility through execution, designing and managing the pipelines, substations, site utilities, and construction support services that underlie digital infrastructure. 

What It Takes to Power a Data Center 

According to the International Energy Agency, data centers accounted for 460 terawatt-hours (TWh) of electricity use globally in 2022, and that figure could double by 2026 due to AI workloads. This exponential growth places enormous pressure not just on the facilities themselves, but on the infrastructure that powers them. 

To operate reliably, data centers require: 

• Secure energy delivery systems like natural gas pipelines 
• Integrated electrical substations and grid interconnects 
• Precise site development to support modular or phased builds 
• QA/QC protocols, scanning, and field support during installation and commissioning 

These are the systems AED is built to support. 

Site-Focused Engineering for Data Center Development 

Our engineering and construction teams provide services designed to streamline site development, reduce rework, and accelerate timelines for large-scale digital infrastructure. 

Core areas of expertise include: 

• Pipeline Engineering: Design and integration of gas delivery systems and compression stations that power onsite generation 
• Electrical Support Infrastructure: Engineering and field services for substations, feeders, and distribution systems 
• Laser Scanning & Existing Conditions Modeling: Terrestrial and aerial LiDAR to support accurate design and layout 
• Procurement & Construction Support: Streamlined RFQ, bid clarification, QA/QC inspection, and documentation support 
• Site-Based Services: Field walkdowns, RFI resolution, safety oversight, and project coordination 

We support these capabilities with a strong safety culture and a focus on operational outcomes, not just design. 

Designing for Scale, Safety, and Speed 

Modern data centers must come online faster than ever and scale without compromising reliability. AED approaches every project with this reality in mind. 

Our solutions are built to: 

• Support fast-track construction schedules 
• Integrate clean energy and backup systems 
• Enable safe operations with minimal onsite disruption 
• Meet regional permitting, interconnection, and compliance requirements 

We don't just produce drawings. We engineer infrastructure that can be built safely, maintained efficiently, and expanded intelligently. 

Infrastructure That Supports What’s Next 

While much of the attention in data center development focuses on IT, mechanical systems, and uptime, the infrastructure that makes these facilities viable is just as critical. 

Whether it’s a greenfield build in a remote region or an expansion project requiring utility coordination and scanning, AED delivers the engineering expertise and execution support needed to keep the project moving and the power flowing. 

If you’re developing or supporting a new data center project, AED is ready to help you engineer the infrastructure that makes digital operations possible. 

Any facility with electrical systems—whether new construction or existing infrastructure—requires an arc flash study. It’s not a new concept, but as industrial operations become more automated and electrically complex, the importance of getting it right has never been greater. Modern arc flash studies aren’t just about compliance—they’re about ensuring safety, system reliability, and informed decision-making across your facility.  

Among electrical hazards, arc flashes remain one of the most dangerous risks — capable of causing severe injuries, extensive equipment damage, and costly operational downtime. 

Arc flash studies form the cornerstone of managing these risks effectively. At AED, we view them as much more than regulatory checkboxes — they’re critical tools that protect people, infrastructure, and business continuity. 

What Is an Arc Flash and Why Conduct a Study? 

An arc flash is a sudden electrical explosion that occurs when an electric current arcs through air between conductors or from a conductor to ground. This event releases an intense burst of heat, light, and pressure. 

The consequences can be devastating: 

• Severe burns 
• Blindness 
• Fatal injuries 
• Equipment destruction 
• Extended downtime 

An arc flash study is a detailed engineering analysis designed to identify and quantify these hazards. Using specialized software like SKM Power*Tools or SIL hazard analysis programs, the study: 

• Pinpoints locations and potential severity of arc flash events in your electrical system
• Calculates incident energy (thermal energy exposure) at critical points
• Determines the required Personal Protective Equipment (PPE) levels
• Defines safe working boundaries and safe procedures to minimize risk 

Why Arc Flash Studies Matter for Your Facility 

Worker Safety is the Priority 

Arc flash studies deliver precise hazard assessments, empowering your workforce with knowledge of exactly how to protect themselves. Knowing the right PPE to wear and the safe work practices to follow reduces injury risk significantly. 

Regulatory Compliance Made Practical 

Our engineers ensure your studies comply with key standards like NFPA 70E and OSHA. Staying compliant helps you avoid costly fines and insurance complications while demonstrating commitment to workplace safety. 

Minimize Equipment Damage and Downtime 

Arc flash incidents can destroy switchgear, control panels, and vital electrical assets. Accurate studies inform protection schemes that limit fault duration and energy release — preserving equipment and reducing costly outages. 

Proactive Risk Management and Operational Excellence 

Beyond meeting minimum regulations, our team integrates arc flash hazard analysis early in electrical system design, upgrades, and maintenance planning. Using advanced design tools such as AutoCAD 3D and Bluebeam, we coordinate seamlessly with project teams to embed safety into every phase. 

When Should You Update or Conduct an Arc Flash Study? 

You should initiate or update arc flash studies in the following situations: 

• Installation of new electrical systems 
• Major modifications, upgrades, or changes to protective devices 
• At least every 3 to 5 years, as industry standards recommend 
• When equipment operates at or above 50 volts 

AED’s Comprehensive Arc Flash Study Process 

Our proven process includes: 

1. Field Survey: Detailed data collection on electrical equipment, wiring, and protective devices 
2. Short Circuit and Coordination Studies: Advanced software analyzes fault currents and sequences protective device operation 
3. Incident Energy Analysis: Thermal energy exposure levels are calculated throughout your electrical system 
4. Labeling and Documentation: We provide clear, compliant warning labels and detailed reports for operations and safety teams 
5. Collaboration and Integration: We work across engineering, construction, and operations teams to embed safety into every stage of the project 

Beyond the Study: Embedding Arc Flash Safety into Your Operations 

At AED, arc flash studies are living documents, integrated into ongoing operations through: 

• Maintenance strategies and safety training programs 
• Control system upgrades and automation improvements 
• Continuous hazard analysis including SIL and process hazard assessments 
• Construction support and quality assurance 

Our E&I engineers combine technical rigor with practical field experience, ensuring your systems operate safely and reliably in today’s demanding industrial environments. 

The Bottom Line 

Arc flash studies are far more than regulatory necessities — they’re essential components of operational resilience, safety culture, and asset protection. 

At AED, we leverage cutting-edge tools, deep industry knowledge, and a collaborative approach to help you build safer, smarter electrical systems. 

Because great facilities don’t just meet safety standards — they set them.

In today’s energy and industrial markets, project success hinges not only on smart planning and engineering but on the strength of what happens in the field. Field execution determines outcomes. That’s why embedding a capable, connected site team is a competitive advantage. 

Site teams that are aligned with project objectives, deeply integrated with design efforts, and empowered to make decisions in real time can drastically reduce risk, improve safety, and keep work on schedule. They become an extension of the owner’s project vision, safeguarding both technical integrity and delivery. 

Why Site Team Support Matters 

Owners and operators are under increasing pressure to manage risk, deliver on aggressive schedules, and close skill gaps in the field. When complexity rises and the stakes are high, having the right people embedded on site—who fully understand the project’s scope and objectives—can be the difference between success and costly setbacks. 

Effective site team support enhances: 

• Communication between design, engineering, and field execution 
• Agility in responding to evolving site conditions 
• Control over safety, quality, and contractor performance 
• Continuity from early planning to final commissioning 

It’s not about placing bodies in the field. It’s about deploying knowledgeable leaders who bring ownership, clarity, and alignment to day-to-day operations. 

What Effective Site Support Looks Like 

Strong site support is proactive, not reactive. It integrates with the full project lifecycle and is tailored to the unique demands of the work. A capable site team is embedded early, scales appropriately, and remains aligned with the owner’s core goals throughout. 

Some hallmarks of effective site support include: 

• Integrated presence on site, not just periodic visits 
• Direct accountability to project performance metrics 
• Close collaboration with engineering and project leadership 
• Strong situational awareness and problem-solving capabilities 

When these traits are in place, the site team becomes a strategic asset—delivering insight and control at the point where projects are most vulnerable. 

The Role of the Site Manager 

A strong site manager acts as a bridge between planning and execution, ensuring that what was designed on paper translates effectively into field performance. They maintain alignment between the owner, contractors, and engineering teams while driving progress with a focus on safety and quality. 

A high-performing site manager: 

• Leads with a safety-first mindset 
• An excellent communicator 
• Coordinates field activity with the overall execution strategy 
• Manages contractors, inspectors, and field engineers 
• Manages project budgets and identify opportunities for cost savings 
• Identifies potential risks and prevents schedule-impacting issues 
• Facilitates collaboration and clear communication across all stakeholders 

With the right leadership in place, site managers become a force multiplier for the entire project team. 

Lifecycle Support and Workforce Continuity 

Strong site team support doesn’t start when construction begins—and it doesn’t end when the last bolt is tightened. From front-end planning and constructability reviews to startup and commissioning, field teams should support every phase. 

Lifecycle support provides: 

• Fewer delays and less rework, thanks to early involvement 
• Faster decision-making, through real-time field and engineering collaboration 
• Greater consistency, as the same personnel support multiple phases 

For long-term programs or portfolio-wide improvements, continuity is especially critical. That’s why strong site support includes: 

• Safe, qualified labor pools with experience in the facility type and standards 
• Clear handoff planning between project phases and personnel 
• Retained institutional knowledge, bridging capital projects and operations 

These factors reduce ramp-up time and improve outcomes across the board. 

Scalable Collaboration and Technical Depth 

For projects that require specialized expertise or additional capacity during peak execution, a scalable model is essential. Effective site support means being able to grow the team while maintaining the same high standards of performance and safety. 

In some models, this is accomplished through partnerships with trusted technical staffing or inspection firms. These relationships ensure: 

• Quality remains consistent even when headcount increases 
• Field needs are met quickly, avoiding delays due to workforce shortages 
• Specialized skills are available on demand, without sacrificing oversight 

When site teams are supported by strong partnerships, owners gain confidence that even the most complex challenges will be met with competence. 

Continuous Improvement and Field Innovation 

Site teams don’t just execute the work—they refine how it’s done. Embedded field teams have a unique vantage point to propose new solutions, while having a close tie to facility operations. Supporting this mindset of continuous improvement creates lasting value. 

Modern site teams use tools such as: 

• 3D scanning and digital twin technology to validate field conditions 
• Streamlined reporting platforms to improve transparency 
• Real-time collaboration tools to align field and engineering workflows 

These innovations support a feedback loop between planning and execution—and help drive safer, more productive outcomes. 

Conclusion 

In today’s industrial and energy sectors, field execution is where projects succeed or fail. Owners and operators are resource constrained; therefore, those who invest in capable, empowered site teams gain not only control over day-to-day activity but a strategic advantage that improves every project outcome. 

It’s about elevating the project with insight, continuity, and leadership right where it matters most: in the field.

In industries like manufacturing, chemical processing, and steel production, cooling towers play a critical role in maintaining operational efficiency. However, as systems age and environmental or regulatory constraints increase, facilities often face inefficiencies, rising maintenance costs, and unexpected downtime. This article explores practical ways to optimize your cooling towers to enhance performance, minimize operational disruptions, and reduce long-term costs. Whether your facility is scaling up production or working with aging infrastructure, the strategies outlined here can help you address these challenges and ensure long-term sustainability. 

With years of experience delivering engineering solutions across diverse industries, Allied Engineering + Design (AED) provides insights into optimizing cooling tower systems to benefit not only operational efficiency, but broader facility needs—ultimately supporting growth and enhancing reliability. 

The Challenge: Aging Systems and Rising Demands 

Cooling towers are essential for heat dissipation, temperature regulation, and ensuring smooth operations. However, as equipment ages or regulations change, cooling towers can become misaligned with facility needs. This mismatch can lead to reduced production efficiency, increased maintenance needs, and unplanned downtime. In many cases, the root cause may lie not in the towers themselves, but in supporting systems—such as outdated or poorly designed piping—which can cause energy losses and compromise overall system performance. 

For example, we recently worked with a facility facing new regulatory requirements to reduce its reliance on river water from the Delaware River. The existing cooling tower, originally designed for a specific service, remained adequate for that purpose. However, the facility needed to shift additional load from an open-loop (river water) system to the closed-loop (cooling tower) system. Although the capacity increase required was nominal—approximately 8.6%—the closed-loop system was not sufficient to meet the updated duty requirements. By redesigning and optimizing both the cooling tower and its associated systems, we enabled the client to achieve their environmental goals without major operational disruptions. 

At AED, we understand these challenges firsthand. While we have experience with cooling tower upgrades across a range of facilities, this project marked our first implementation of a custom "stick built" cooling tower design—distinct from more typical packaged units. The unique design and construction requirements presented key differences that demanded a highly tailored engineering approach. 

Optimizing Cooling Tower Efficiency: Proven Strategies

1. Upgrading to Modular Cooling Systems

One of the most effective ways to optimize cooling tower performance is upgrading to modular cooling systems. Modular units offer flexibility, scalability, and increased capacity, allowing your system to grow in line with your production needs. Replacing older, undersized towers with larger, more efficient modular systems can significantly reduce energy consumption while improving cooling capacity. 

For instance, we helped a steel production facility replace two outdated cooling towers with a single, larger modular unit. The result? Improved cooling efficiency, simplified maintenance, and long-term savings. Modular systems can also be expanded as production requirements grow, making them ideal for businesses looking to future-proof their facilities. 

2. Addressing Water Distribution and Structural Weaknesses

Inefficient water distribution and structural issues can waste energy, cause excessive wear on equipment, and disrupt performance. These inefficiencies can be corrected through careful inspection and targeted improvements. 

For one client in the refining industry, we reinforced the structure of their two-cell cooling tower and optimized the water distribution system. This led to improved flow, better system reliability, and reduced energy costs. Addressing foundational issues ensures that your cooling system performs at its best and minimizes the risk of unexpected failures. 

3. Advanced Piping and System Integration

Optimizing cooling tower systems isn’t just about upgrading the towers themselves; it’s also about integrating the entire system, including water treatment plants and associated piping. Proper system integration reduces friction, lowers energy consumption, and minimizes maintenance needs. 

We recently designed a new water treatment and cooling distribution system for a large manufacturing facility. By ensuring all components were properly sized and seamlessly integrated, we enhanced cooling efficiency and set the stage for long-term sustainability. A well-integrated system not only improves cooling tower performance but also boosts the overall efficiency of the entire facility. For example, the streamlined piping reduced pump head pressure requirements, which in turn decreased energy consumption. Improved balance across cooling loops led to more consistent heat rejection and lower operational stress on equipment. These gains allowed the facility to run more efficiently and with fewer interruptions, delivering not just energy savings, but improved throughput and reduced maintenance intervals across multiple units. 

4. Optimizing Cooling Tower Operations for Long-Term Efficiency

Efficient cooling tower operations are vital for maintaining the performance and reliability of industrial facilities. It’s not just about replacing old equipment—it’s about understanding the unique challenges each facility faces and applying tailored solutions. Whether scaling systems for growth or enhancing performance in aging infrastructure, the key lies in optimizing design and functionality to ensure long-term reliability and efficiency. 

For instance, when we replaced two outdated cooling towers at a steel manufacturing plant with a single, larger modular unit, it resulted in significant reductions in energy consumption and improved overall performance. Similarly, at a chemical plant, we implemented a closed-loop system that minimized the need for frequent maintenance, yielding both cost savings and more consistent production. These examples highlight how a strategic approach to cooling tower design can address both immediate operational needs and long-term efficiency. 

Preparing for Future Demands in Cooling Tower Systems

Beyond immediate optimizations, the future of cooling tower systems lies in scalability and flexibility. As facilities grow and production demands increase, cooling towers must be adaptable to these changes. The goal is to design systems that not only meet today’s needs but can easily accommodate future expansions without costly overhauls. 

In a recent project for a refining facility, we upgraded a cooling tower to handle an expanding production line. By taking a forward-thinking approach, we ensured the new system could meet future demands without requiring significant additional investments. This type of long-term planning ensures that facilities can scale their operations without encountering inefficiencies or excessive costs. 

Strategic Cooling Tower Optimization for Long-Term Efficiency and Scalability

Optimizing cooling towers requires a tailored approach to address the unique needs of each facility. Whether improving heat dissipation efficiency, enhancing water treatment processes, or increasing system capacity, the goal is to improve thermal efficiency, reduce water consumption, and lower maintenance costs. 

At AED, we apply our expertise in modular cooling tower design, advanced control systems, and integrated water treatment to ensure systems are optimized for both today’s operational demands and scalable for future growth. Our solutions focus on maximizing cooling efficiency, extending the life of the tower, and reducing energy consumption—helping businesses adapt to evolving industry standards and ensure long-term sustainability.