Need Ideas! Improving existing 3 Hot Water Heater Setup

hotelplumb

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First post here, but long time lurker!

I have an 80 room hotel which I operate & I like to do my own research to develop ideas/plan prior to engaging a plumber given I’ve seen the ‘easy route’ taken far too often. I also enjoy making informed decision which make sense in the long run.

With all said, I am in process of getting my entire hot water system at this hotel overhauled. While doing this I’d like to make improvements in respect to flow, efficiency & longevity.

I have attached a sketch of my Mech. Room & photos to supplement.

Going from (3) Rheem GN100-200 to (2) new Rheem GHE100SU-200 & (1) Rheem GN100-200 (reusing 1 old one)

Questions:

1) How much sense it would make for me to increase the 1.5” pipes (from the hold/cold trunks to water heaters) to 2”? How much GPM & Pressure increase should I expect?

2) Based on how the recirculating pumps are plumbed, should the hot lines be plumbed in a ‘Reverse Return’ configuration? Basically First In, Last Out? Currently the system is piped to be FIFO & I am going through tanks every 6 or so years. Not sure if this is why?

3) Should the return lines be tied into a different area of this system or leave as is?

4) This is my first time seeing 2 return lines. Could someone tell me what “setup” I may have so I can research more on this?
 

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