Salem-Keizer School District South Salem High School Chilled Water System Repairs Design

When South Salem High School began experiencing persistent issues with its new chilled water system after an extensive renovation and expansion, the Salem-Keizer School District knew it needed more than a routine repair; it needed clarity. Systems West Engineers recognized that the real challenge lay beneath the surface: Understanding and correcting the underlying causes of system failure.

Understanding the Problem

The new chilled water system, a closed-loop network designed to circulate treated water through the school’s mechanical infrastructure, had been compromised due to improper sealing of underground piping connections. Fresh water was being inadvertently introduced into the system, accelerating corrosion and raising concerns about long-term reliability, while thousands of gallons of water and antifreeze solution had leaked into the ground.

Systems West approached the District directly with a better question: What problem are we really trying to solve? By reframing the scope, the team earned the opportunity to assess the true condition of the system and develop a tailored, sustainable repair strategy.

Evaluation and Collaboration

Systems West led the effort to identify failed piping sections and redesign an improved distribution route. Hydro-Temp and Daikin provided a preconstruction analysis that informed equipment condition and design adjustments, and the original building architect was reengaged to assist with finish repairs after excavation. Partnering with SoniTech, a Denver-based specialist in non-destructive testing, the team used ultrasonic methods to evaluate pipe wall thickness and determine the extent of corrosion. This analysis provided reassurance to the District that, while some service life had been lost, the system could still perform reliably for decades with proper maintenance.

Collaboration played a key role throughout the project. During construction of designed corrective actions, Systems West worked alongside Otak, the Owner’s representative, and C.J. Hansen, the mechanical contractor, to coordinate field investigations and corrective work.

Challenges and Innovative Solutions

The project demanded creative problem-solving. Since school operations depended on a tight summer construction window, design and bidding had to occur rapidly to complete repairs before the academic year began. During implementation, the contractor identified routing conflicts that prompted an in-field redesign, rerouting piping overhead through a classroom, complete with a drip pan and liquid sensing system for added protection. This flexible, solution-oriented collaboration exemplified the project’s adaptive spirit.

Additional improvements were integrated to enhance the school’s operations and maintenance capabilities, including proper air separation, water flow and makeup meters, and filtration systems. These measures ensure future leaks can be detected quickly and that water quality remains stable over time.

Outcome and Impact

Despite encountering unforeseen issues, including the failure of a counterpart pipe that had initially passed multiple pressure tests, the team responded quickly to restore system function and confidence. In the end, South Salem High School regained a fully operational chilled water system, improved monitoring capabilities, and a longer-term path to reliability.

The project marked Systems West Engineers’ first design engagement with the Salem-Keizer School District and set a precedent for future K–12 facility collaborations. Through careful investigation, teamwork, and technical insight, the team delivered not just repairs, but a renewed foundation for building performance.

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