Clark center

Project Overview

The Clark Center facility in Monett, Missouri underwent a comprehensive HVAC and Building Automation System (BAS) upgrade to address rising energy costs, excessive maintenance requirements, and limited operational control caused by aging steam-based infrastructure. The project focused on modernizing the central heating plant, improving system efficiency, and providing operators with a clear, intuitive control platform.

Existing Conditions & Challenges – Heating System

The facility was served by an oversized 150 HP steam boiler that provided both building heating and domestic hot water through heat exchangers. The system was difficult to maintain, required frequent service, and resulted in large year-round natural gas bills to accommodate domestic hot water heating. Annual maintenance costs were high due to the age, complexity, and operating requirements of the steam system.

Existing Conditions & Challenges – Building Automation System

The existing building automation system was outdated and difficult to understand, providing limited visibility and control of the central heating and cooling plants. Inefficient control sequences contributed to unnecessary energy usage and increased operating costs.

Project Goals

• Improve system reliability and maintainability
• Reduce natural gas and electrical energy consumption
• Separate hydronic heating and domestic hot water systems
• Modernize system controls for improved building-level visibility
• Achieve long-term operational savings with a reasonable payback period

New Heating & Building Automation System – System Configuration

The project separated the hydronic heating and domestic hot water systems into two dedicated systems, improving control, efficiency, and redundancy.

Domestic Hot Water System Upgrades

Three (3) 199 MBH high-efficiency natural gas-fired water heaters were installed to provide dedicated domestic hot water production, eliminating the need for year-round boiler operation.

Hydronic Heating System Upgrades

Three (3) 750 MBH high-efficiency condensing boilers were installed in a modular configuration, allowing staged operation to match building heating demand.

Pumping and Air Handling Improvements

Four (4) variable frequency drives (VFDs) were installed on heating and cooling pumps, and one (1) VFD was installed on a constant volume air handling unit to reduce energy consumption during partial-load conditions.

Building Automation System Upgrades

A new BAS was implemented to provide centralized control of the hydronic heating plant, central cooling plant, and air handling unit. The system delivers improved visibility, simplified operation, and enhanced energy management capabilities.

Results & Performance Outcomes

The upgraded systems are easier to maintain and significantly reduce annual maintenance costs. Dedicated heating and domestic hot water systems provide improved building control and reliability.

Energy and Cost Savings

• Average natural gas cost reduction of $6,000 per year due to high-efficiency heating and water heating equipment
• Average electrical cost reduction of $4,000 per year from variable speed pumping and improved system control

Financial Performance

The combined energy savings result in an estimated simple payback period of approximately seven (7) years.

Project Impact

The Clark Center Monett HVAC upgrade transformed an aging steam-based system into a modern, efficient hydronic and domestic hot water plant with intuitive building controls. The project delivered measurable energy savings, improved reliability, reduced maintenance costs, and positioned the facility for long-term operational success.