Sunil Pradkhan

Results-driven Mechanical Engineer II specializing in HVAC optimization, industrial ventilation, and MEP integration for large-scale facilities. Evaluates and re-engineers legacy systems to reduce energy consumption and enhance reliability. Knowledgeable in ASHRAE 62.1, airflow analysis, hydronic systems, and load modeling. Delivers engineering solutions from analysis through field validation and commissioning.

Industrial HVAC Recommissioning & ACH Optimization

• Led engineering evaluation of a high-bay welding facility (2 bays, ~3.76M ft³) operating at an excessive 5 ACH baseline
• Quantified over-ventilation relative to ASHRAE 62.1 (~0.3 ACH), identifying >15× deviation from required outdoor air
• Re-engineered system concept by separating envelope ventilation (S-units) from process ventilation (M-units)
• Performed ACH conversions, airflow validation, and ventilation heat loss calculations using Q = 1.08 × CFM × ΔT
• Developed staged ventilation strategy (1.1–5 ACH) aligned with operational demand and welding intensity
• Modeled fan energy using affinity laws (HP ∝ flow³) to evaluate electrical impact of airflow reduction

Results:

• Identified 30–50% reduction in heating demand under typical operation
• Demonstrated 60–70% fan energy savings potential
• Established IH-informed minimum ventilation framework, shifting from rule-of-thumb to performance-based design

HVAC Energy Modeling & System Load Reduction

• Developed full ventilation-driven heating load model across multiple airflow scenarios.
• Confirmed ventilation accounted for >90% of total heating load, not conduction
• Built engineering analysis tools:
• Load vs ACH curves
• Energy vs baseline comparisons
• System staging vs airflow demand
• Modeled annual heating energy (MMBtu/therms) to quantify operational impact

Results:

• Reduced modeled load from ~32,000 → ~22,000 MMBtu/year per bay
• Provided data-backed justification for operational optimization without capital investment

Ventilation Compliance & IAQ Engineering (ASHRAE 62.1 + ACGIH)

• Performed Ventilation Rate Procedure (VRP) calculations and converted results into equivalent ACH
• Identified mismatch between IAQ requirement (~0.3 ACH) and existing operation (5 ACH)
• Integrated ACGIH industrial ventilation principles to evaluate dilution vs source capture effectiveness
• Developed framework linking Industrial Hygiene (IH) sampling to HVAC operating conditions

Results:

• Delivered defensible, code-compliant ACH reduction strategy
• Enabled transition to performance-based ventilation design approach

HVAC Air Distribution Optimization & System Rebalancing

• Performed room-by-room load analysis (30+ zones) including sensible and latent loads
• Calculated required airflow using CFM = Q / (1.08 × ΔT) and normalized against system capacity (~13,000+ CFM)
• Identified major imbalance driven by single dominant zone (~50% load)
• Rebalanced system using existing dampers and VAV controls (no capital investment)
• Implemented pressurization strategy and corrected ventilation distribution

Results:

• Achieved airflow balance within ±10% across all zones
• Eliminated thermal discomfort and airflow instability
• Improved IAQ in high-occupancy zones

HVAC & Plumbing System Modernization – Multi-Floor Facility

• Led coordination of full HVAC and hydronic system renovation, including demolition and new system integration
• Managed execution across penthouse systems, hydronic risers, VAV distribution, and kitchen exhaust systems
• Identified and mitigated critical interconnection risks (B-520/B-522 variable flow systems)
• Supported commissioning including TAB, BAS integration, and functional testing

Results:

• Delivered stable, fully integrated mechanical systems
• Reduced risk of flow instability and system incompatibility
• Enabled controlled transition from legacy infrastructure

Domestic Water System Replacement & Hydraulic Optimization

• Led replacement of galvanized domestic piping with PVC system
• Redesigned piping layout to improve hydraulic performance and reduce pressure losses
• Eliminated corrosion-related degradation and failure risks
• Improved system accessibility and maintenance strategy

Results:

• Increased system reliability and reduced failure potential
• Reduced long-term maintenance burden
• Extended infrastructure lifecycle

HVAC & Industrial Ventilation Assessment

• Led joint site evaluation with Merrick Engineering, Facility Engineering, and production teams
• Standardized engineering assumptions for pickling tanks and welding operations
• Evaluated source-capture ventilation systems at welding stations
• Developed airflow verification and validation strategy

Results:

• Streamlined engineering analysis for ongoing study
• Confirmed effectiveness of localized exhaust systems over dilution reliance
• Defined next steps for system performance validation