Boiler Plant Upgrade - Mather High School

EOS Mechanical executed a comprehensive boiler plant modernization at Stephen Tyng Mather High School for Chicago Public Schools—replacing aging infrastructure with high-efficiency systems while maintaining operations for this vital North Side educational facility.

About the Facility

Stephen Tyng Mather High School, serving Chicago’s North Side since 1959, provides comprehensive education to students throughout the community. The school’s extensive facilities include academic classrooms, science laboratories, athletic facilities, and a natatorium requiring year-round climate control and specialized dehumidification.

The aging boiler plant, original to the building, had become increasingly unreliable and inefficient, threatening comfort for students and staff while driving up operational costs. Chicago Public Schools prioritized this upgrade as part of their ongoing infrastructure modernization program, recognizing that reliable heating systems are fundamental to educational success.

EOS Mechanical Scope

EOS Mechanical provided complete mechanical system replacement and modernization, handling all phases from demolition through commissioning while coordinating with active school operations.

Heating Plant Equipment

• Three high-efficiency condensing boilers - Replacing original atmospheric units with modern sealed-combustion technology
• Primary and secondary pumping systems - Variable speed drives for optimal flow control
• Expansion tanks - Properly sized for system volume and temperature variations
• Glycol fill station - Enabling freeze protection for outdoor components
• Air separation and dirt removal systems - Ensuring long-term system health

Pool Dehumidification System

• New pool dehumidification unit - Sized for natatorium moisture loads
• Supply and return ductwork - Stainless steel construction in corrosive environment
• Integrated controls - Maintaining precise humidity levels for comfort and building protection
• Energy recovery ventilation - Capturing energy from exhaust air stream

Water Treatment & Filtration

• Magnetic filtration system - Removing ferrous particles from decades-old piping
• Side-stream filtration - Continuous cleaning of system water
• Chemical treatment stations - Maintaining proper water chemistry
• Isolation valves and bypasses - Enabling maintenance without system shutdown

Combustion Air & Venting

• Reconfigured intake and exhaust flues - Accommodating condensing boiler requirements
• Stainless steel vent piping - Resisting condensate corrosion
• Combustion air louvers - Properly sized for new equipment demands
• Condensate neutralization systems - Protecting drainage infrastructure

Construction Challenges & Solutions

Challenge: Water Quality in Existing System

The existing hydronic piping, serving the school for decades, contained significant accumulations of magnetite, rust, and debris. Installing new high-efficiency boilers without addressing water quality would risk immediate fouling of heat exchangers, reducing efficiency and potentially causing premature failure.

Our Solution

EOS Mechanical implemented a comprehensive water treatment strategy centered on magnetic filtration technology:

1. Pre-Installation Cleaning - System flush and chemical cleaning before new equipment connection
2. Magnetic Filter Installation - Industrial-grade magnetic separators capturing ferrous particles
3. Continuous Filtration - Side-stream filtration removing non-magnetic contaminants
4. Water Chemistry Management - Proper inhibitor levels preventing future corrosion

The magnetic filter’s powerful rare-earth magnets create an intense magnetic field, capturing even the smallest particles. This protection is critical for maintaining the tight tolerances in modern high-efficiency heat exchangers.

Challenge: Maintaining Operations During Construction

The project timeline extended through the school year, requiring heating for classrooms and continuous pool dehumidification to prevent structural damage.

Our Solution

We developed a detailed phasing plan with CPS facilities management:

• Phase 1: Install new boilers alongside existing units during summer break
• Phase 2: Sequential boiler replacement maintaining sufficient heating capacity
• Phase 3: Pool dehumidification replacement during winter break
• Phase 4: Final commissioning and optimization during spring break

This approach ensured uninterrupted heating and dehumidification throughout construction.

Energy Efficiency & Sustainability

The new high-efficiency condensing boilers achieve significantly higher efficiency ratings compared to the original atmospheric boilers. Combined with variable speed pumping and optimized controls, the upgrade delivers:

• Substantial reduction in natural gas consumption - Verified through utility billing analysis
• Reduced carbon emissions - Significant environmental impact reduction
• Lower maintenance costs - Modern equipment requires less frequent service
• Extended equipment life - Water treatment protects investment long-term

Results

The completed boiler plant modernization provides:

• Reliable heating for students and staff in Chicago’s variable climate
• Precise humidity control protecting the natatorium structure and ensuring swimmer comfort
• Dramatically reduced energy costs freeing budget for educational programs
• Quiet operation eliminating classroom disruptions from mechanical equipment
• Remote monitoring capabilities enabling proactive maintenance

This project exemplifies EOS Mechanical’s ability to execute complex mechanical retrofits in occupied educational facilities while maintaining critical building operations. Our water treatment expertise ensures these systems will serve Chicago Public Schools efficiently for decades to come.