Warehouse MEP Design & Build Project

How BTU Delivered a Full MEP Design & Build Project in Record Time for Chrysels

We recently had the opportunity to deliver a complete Design & Build MEP solution for Chrysels’ new facility in Production City, Dubai. The project involved transforming a warehouse consisting of Ground and Mezzanine floors into a centralized hub, consolidating Chrysels’ operations from three different facilities in Al Quoz into a single, efficient location.

Understanding the Scope

The warehouse was initially equipped with a 400 kW connected load—spread across the Ground, Mezzanine, and warehouse. However, upon receiving the proposed architectural layout, we initiated a series of detailed coordination meetings with the client to assess their equipment and operational needs. It quickly became evident to both parties that the existing 400 kW would not suffice, especially with the addition of new equipment to the already extensive existing setup.

Upgrading to 800 kW: A Strategic Load Distribution

With the finalized equipment list and architectural layout in hand, We first applied for additional load to DEWA. We upgraded the connected load to 800 kW. The original load was distributed through 2 Main Distribution Boards (MDBs), each carrying 200 kW. To accommodate the increased load, we added 2 more MDBs, maintaining a similar capacity per board. 

Prior to additional load approval the primary focus during the initial phase was to maintain the continuity of power supply for all existing systems, while making necessary adjustments to improve and support future needs in MDB 1 and MDB 2. To accommodate the client's immediate operational needs, areas requiring urgent operation were temporarily supplied with generator power & existing MDBs, ensuring that critical functions continued smoothly. Once the additional power allocation was approved, the required modifications were again made to the existing MDB 1 & MDB 2 to accommodate the new MDB 3 & MDB 4. 

To ensure clarity, safety, and compliance with DEWA regulations, we segregated the facility into power zones as follows:

• MDB 1 – Supplies Ground Floor (Grid 1 to 5)

• MDB 2 – Supplies Mezzanine (Grid 1 to 5)

• MDB 3 – Supplies Warehouse Area (Grid 5 to 9)

• MDB 4 – Supplies Warehouse Area (Grid 9 to 12)

This zoning strategy not only simplifies maintenance and troubleshooting but also complies with DEWA’s policy, which prohibits supplying the same area with multiple SMDBs or MDBs. MDB 4 supplies power to equipment over 80 meters away, which can lead to voltage drop—a reduction in voltage as electricity travels through long cables. This can impact equipment performance, causing inefficiency or potential damage. To prevent this, we performed detailed voltage drop calculations and selected suitable cable sizes to ensure stable power delivery. This approach meets DEWA’s safety and performance standards while maintaining system reliability and efficiency over long distances.

In this project, all equipment requiring 6 kW or more is directly connected to the Main Distribution Board (MDB) or Sub Main Distribution Board (SMDB). This ensures that high-power equipment is not connected to the same circuits as lighting or power sockets, which could cause the entire circuit or distribution board (DB) to trip due to fault or leak in one of the equipment. This approach reduces the risk of disruptions, ensures smooth operation, and makes future maintenance and upgrades easier.

The electrical system in this MEP project meets all DEWA standards and was designed to use power efficiently, ensure safety, and allow easy maintenance or upgrades—all without affecting the existing lighting and power systems.

In this project , we have 4 sets of VRF systems. Each set has multiple outdoor units. For example,  VRF 1 has 3 outdoor units, VRF 2 has 2 outdoor units and both VRF 3 & 4 have 2 outdoor units each, totalling 9 outdoor units. Each of these 9 outdoor units will  have a separate power connection and isolator connected to respective dedicated AC - DB’s.

Efficient Cooling with Toshiba VRF

For air conditioning, we proposed a Toshiba VRF system, well-suited for industrial applications with an emphasis on cost efficiency without compromising in cooling and controls. Instead of traditional ducted units throughout, we used cassette-type indoor units in most areas, eliminating ducting and air outlet costs.

However, for reception, meeting rooms, and the MD’s office, we provided ductable AC units to maintain aesthetic and functional comfort.

We segmented the cooling into 4 distinct zones—two per floor (Ground and Mezzanine)—with each zone managed by an individual VRF system. This setup allows precise temperature control and energy efficiency, giving the client the flexibility to manage different spaces independently.

In this project we used  a  total of four sets of VRF systems. Two VRF sets were installed on the ground floor and Two VRF sets were installed on the Mezzanine floor. On the mezzanine floor VRF 1 is the first section and VRF 2 is the second section. On the ground floor VRF 3 is the first section and VRF 4 is the second section.

We completed the installation of 13 machines out of the 20 machines. For 7 machines, due to their height issues, we needed a scissor lift, which wasn’t available at that time. So, we held off on those 7 machines.

According to the guidance from the Toshiba  team, we modified the pipe routing and added a valve. We closed the valve and proceeded with the pressure testing, vacuuming and complete commissioning for the remaining 13 machines, and we started them up.

After the client arranged for the scissor lift, we completed the installation of the 7 machines and conducted separate pressure tests, vacuuming, and commissioning for them before starting them up. This project was a great learning experience for our team as well. 

A Perfect Collaboration

One of the standout aspects of this project was the client’s dedication to coordination. They deployed a full-time on-site engineer, Mr. Jojo Vargheese, available daily from 9:00 AM to 10:00 PM, which significantly streamlined decision-making and reduced turnaround time for approvals. This close coordination between client representative & our engineering team Mr. Faizal (Project Engineer) and Mrs. Gayathri (Electrical Engineer) played a crucial role in enabling us to complete the entire MEP works in just 3 months—a timeline that would typically demand 5 to 6 months under standard conditions.

At BTU Electromechanical Works LLC, we believe every successful project is built on trust, transparency, and teamwork. The Chrysels Production City facility is a great example of how collaborative execution, strategic engineering, and smart design decisions can lead to outstanding results—delivered on time and within budget.