Project Overview
Project Overview
Vardhaman Infra undertook the complete electrical panel upgrade, LED lighting retrofit, and replacement of aging centralised HVAC systems with high-efficiency VRF units for a 1.2 lakh sq.ft. shopping mall in Kota city centre. This retrofit project was particularly challenging because the mall remained fully operational throughout the renovation, requiring all work to be executed without disrupting retail operations or customer experience.
The mall’s original MEP systems, installed over a decade earlier, had become energy-inefficient and increasingly unreliable. Rising electricity costs and frequent HVAC breakdowns were impacting tenant satisfaction and occupancy rates. The mall management engaged Vardhaman Infra to modernise the entire electrical and HVAC infrastructure while achieving a minimum 30% reduction in energy consumption.
Scope of Work
- Electrical Panel Upgrade: Replacement of the main LT panel (3,200A bus capacity) and 28 sub-distribution boards across all floors. Installation of new APFC (Automatic Power Factor Correction) panel to improve power factor from 0.82 to 0.98, and integration of a building energy management system (BEMS) for real-time energy monitoring.
- LED Lighting Retrofit: Replacement of over 2,800 conventional fluorescent and metal halide fixtures with LED equivalents across retail corridors, parking areas, food court, and external facade. Installation of motion-sensor controls in washrooms and staircases, and daylight harvesting sensors in atrium areas.
- HVAC System Replacement: Removal of the existing 400-TR centralised chiller plant and AHU-based cooling system, and replacement with a distributed VRF (Variable Refrigerant Flow) system comprising 12 outdoor units and 180 indoor units, providing individual zone control for each retail tenant.
- Electrical Safety Upgrades: Installation of surge protection devices, earth leakage circuit breakers, and arc fault detection on critical circuits to bring the installation up to current IS 732 and NBC standards.
Technical Challenges and Solutions
The defining challenge of this project was executing a full MEP retrofit in a live commercial environment. The mall operated 12 hours daily with peak footfall during weekends and evenings. Vardhaman Infra developed a detailed phased execution plan where all noisy and disruptive work — demolition of old ductwork, panel replacement, cable pulling — was scheduled between 11 PM and 6 AM. Daytime hours were reserved for quiet finishing work such as sensor installation, cable termination, and system programming.
Replacing the centralised chiller system with VRF required a completely new refrigerant piping network throughout the building. Routing new copper piping through an existing structure with limited ceiling void space demanded creative solutions. Our team utilised 3D laser scanning of the existing ceiling voids to plan piping routes precisely, avoiding existing utilities and structural elements. This eliminated the trial-and-error approach typical of retrofit projects and significantly reduced installation time.
Maintaining cooling during the HVAC changeover was non-negotiable — tenants could not operate without air conditioning in Kota’s extreme summer heat. We devised a zone-by-zone switchover strategy, commissioning new VRF zones while keeping the old chiller running for the remaining areas, then progressively decommissioning the old system as each new zone came online. At no point did any occupied area lose cooling for more than 4 hours.
Materials and Methods
The VRF system was Daikin VRV-X series, selected for its high energy efficiency (ISEER rating above 4.5) and capability to operate efficiently in Kota’s extreme ambient temperatures exceeding 47°C in summer. LED fixtures were sourced from Philips and Wipro, with a minimum efficacy of 120 lumens per watt. The new LT panel was manufactured by Schneider Electric with type-tested assemblies conforming to IS 61439. All refrigerant piping used dehydrated and nitrogen-purged copper tubes with brazed joints.
Timeline, Team, and Execution
The retrofit was completed in 10 months, with a team of 60 technicians working primarily in night shifts. A dedicated client liaison coordinator from Vardhaman Infra managed daily communication with the mall management and individual tenants, providing advance notice of any scheduled disruptions. The night-shift model, while challenging for workforce management, proved highly effective in maintaining mall operations and was completed two weeks ahead of the contracted schedule.
Results and Client Satisfaction
The energy performance results exceeded expectations. Post-retrofit energy audits showed a 38% reduction in total electricity consumption — surpassing the 30% target. The HVAC energy consumption alone dropped by 45% due to the VRF system’s inverter-driven compressors and elimination of the energy-intensive chilled water pumping system. The improved power factor from the APFC panel reduced the mall’s electricity bill by an additional 8% through elimination of power factor penalties. The mall management estimated a full payback period of under 3 years for the entire retrofit investment.
Key Takeaways
This project showcased Vardhaman Infra’s expertise in live-environment retrofits — a growing segment as India’s commercial building stock ages and energy costs rise. The night-shift execution model, 3D laser scanning for route planning, and zone-by-zone HVAC switchover strategy have since become standard practices in our retrofit project playbook. The City Mall project is frequently cited in our proposals as evidence of our ability to deliver complex upgrades without operational disruption.