Location: John J. Foley Building – Yaphank, NY
Contractor: Commercial Instrumentation Services, Inc.
The Challenge: Outdated Heating in Vacant Five-Story Building
Once a skilled nursing facility, the John J. Foley Building in Yaphank, NY, stood empty since 2012 until Suffolk County renovated this five-story structure to consolidate multiple government departments under the Department of Public Works (DPW). The original 1993 boiler plant featured two large cast iron gas-fired hot water boilers with a total input of 20 million BTU, which were inefficient and oversized for modern needs.
ATI collaborated with contractor Commercial Instrumentation Services, Inc. to engineer a downsized, high-efficiency system matching the building’s heating and domestic hot water demands.
The Solution: Fulton Boilers with Integrated Support Systems
ATI supplied all equipment after assessing the spacious boiler room, which allowed straightforward installation via a large freight elevator.
Fulton starred as the core of this upgrade with five EDR+3000 condensing boilers for building heat and two EDR-1000 units for domestic hot water. These advanced systems provided unmatched reliability and performance in a demanding public facility.
The Equipment: Fulton Excellence Supported by Key Partners
Fulton boilers took center stage, delivering superior condensing technology that transformed the outdated plant:
- Five Fulton EDR+3000 Ultra-High Efficiency Condensing Boilers (building heat): These firetube boilers feature patent-pending Stress Reliever technology with precisely engineered wall thickness gradients that absorb thermal stresses, preventing cracks and extending service life far beyond traditional designs. They offer up to 15:1 modulation turndown for precise load matching, low-NOx emissions under 20 ppm, and efficiencies up to 96% in condensing mode. Ideal for variable primary flow systems, their compact footprint and simple waterside maintenance made them perfect for the Foley Building’s needs.
- Two Fulton EDR-1000 Ultra-High Efficiency Condensing Boilers (domestic hot water): Compact yet powerful, these boilers boast a rugged pressure vessel with innovative tube-in-tube heat exchangers for rapid response and high steam quality. They achieve 15:1 turndown, operate with ultra-low emissions, and include user-friendly controls for easy integration. Paired seamlessly with supporting equipment, they ensure endless domestic hot water supply.
Complementing Fulton’s lead role were:
- Two Armstrong Design Envelope Sensorless 4200H End Suction Pumps (25 HP Each): Intelligent sensorless controls deliver up to 75% energy savings.
- Two Thermal Leverage Packaged Plate and Frame Water Heaters: Efficiently paired with EDR-1000 boilers.
- One Armstrong Domestic Water Triplex Booster System 6800G: Provides reliable pressure boosting.
- Additional Items: Smaller pumps, storage tanks, four Armstrong expansion tanks, and boiler room accessories.
This Fulton-centric package unified heating, domestic water, and plumbing.
The Results: 15% Efficiency Gain and Cost Savings
The Fulton boilers improved heating efficiency by about 15% and cut total BTU input by 25%, maintaining full redundancy. Customers benefit from lower gas and electricity costs in this critical county facility. ATI’s expertise ensured a smooth retrofit into the aging structure with no major constraints.
Building Systems You Can Trust
ATI specializes in modernizing institutional facilities like government buildings, delivering reliable, efficient solutions that cut costs and ensure redundancy, which allows for continuous operation if one unit fails, preventing downtime for critical public works. With decades of experience in engineering, supply, and integration, we handle complex renovations without disruption.
Contact ATI today to upgrade your heating and hot water systems with Fulton excellence.