Projects: Chemical, Industrial & Manufacturing

Wyssmont Dryer Installation (Structural, Architectural, Mechanical/Piping, Electrical & Controls)

CLIENT/LOCATION: Chemical Facility/Maryland
OBJECTIVE: The objective of the project was to provide civil/structural, architectural, mechanical, electrical design & construction administration for a new state-of-the-art dryer system, including selective demolition with temporary supports of existing infrastructure components.
PROJECT SIZE:  Approximately $11M


New Dual Coating Project  (Structural, Mechanical/Piping, Electrical & Controls)

CLIENT/LOCATION: Manufacturing Facility/Georgia
OBJECTIVE: The objective of the project was to provide civil/structural, mechanical, piping, electrical, and controls design for a new state-of-the-art dual coating system including selected modifications to the existing equipment, piping and infrastructure.
PROJECT SIZE:  Approximately $8M


Fiber Prep Reconfiguration

CLIENT/LOCATION:  General Manufacturing/Pennsylvania
OBJECTIVE: Provided automation of converting/consolidating six (6) batch pulp processing systems into two (2) continuous pulp processing systems supplying feed stock for entire plant.
PROJECT SIZE: Approximately $ 3.6M


Pressure Relief Devices (PRD) Calculations & Certifications

CLIENT/LOCATION: API Manufacturing/Pennsylvania
OBJECTIVE: The objective of this project was to review, design & prepare PRD basis sizing calculations for numerous PRDs for existing process utility applications.
PROJECT SIZE: Approximately $ 2.2M


HVAC/Boiler System Upgrade

CLIENT/LOCATION: API Manufacturing/Pennsylvania
OBJECTIVE: The primary objective of this project was to assess the existing building HVAC, steam heat and chilled water systems and provide improvements/recommendations to either/repair and or replace, including engineering and design for the new systems. Also, provided engineering design support to replace an existing 1960’s vintage steam boiler with new a boiler system at their central utility plant. Additionally, provided engineering design support for the replacement of an existing site emergency generator system.
PROJECT SIZE: Approximately 2.1M


Various Plant Optimizations/Expansions Projects

CLIENT/LOCATION: Chemical manufacturing/Maryland
OBJECTIVE: The objective of the project was to convert an area, previously occupied by an old dryer to house a new production line while staying in full production. The Project consisted of relocation of one Wash Box Tub Dumper and the demolition of another, relocation & demolishing of various electrical conduits, piping, tanks, various mechanical equipment and structural members. Reconfigure & redesign equipment for best optimization and use of the said limited real estate.
PROJECT SIZE: Approximately $1.6M


Lab 47 Reactors Control Upgrade (Electrical/Controls)

CLIENT/LOCATION: Chemical manufacturing R&D Lab/New Jersey.
OBJECTIVE: The objective of the project included design for a control cabinet for the three (3) reactors in Lab facility.
PROJECT SIZE: Approximately $1.4M


New Maintenance Building (Structural, Architectural, Mechanical, Electrical)

CLIENT/LOCATION: Chemical Facility/New Jersey
OBJECTIVE: The objective of the project was to provide civil/structural and architectural design for a pre-engineered building, including MEP design.
PROJECT SIZE: Approximately $1.2M


DI Water Tank Replacement Project

CLIENT/LOCATION: API Manufacturing/Pennsylvania
OBJECTIVE: Client needed to replace the existing square stainless steel DI Water Tank in a basement with only man door access. Provided conceptual options for the replacement of this tank in the Impact Modifiers Building. Once a path forward was determined, created a tank fabrication drawing for the replacement of this tank.
PROJECT SIZE: Approximately $1M


Short Circuit Coordination and Arc Flash Hazard Studies

CLIENT/LOCATION: Chemical Manufacturing/Pennsylvania
OBJECTIVE: The objective of the project was to perform the electrical engineering and design activities for the Short Circuit Coordination and Arc Flash Hazard Studies including updating the existing site Single-Line drawings. Also, developed three (3) different options to upgrade or reuse the existing I/O Wiring between the plant DCS system and the existing field instrumentation of the Kynar System.  These options addressed the code compliance issues in the existing installation.
PROJECT SIZE:  Approximately $650K


Boiler Relocation Project (Mechanical)

CLIENT/LOCATION: Chemical Manufacturing/Pennsylvania
OBJECTIVE: The objective of the project was to relocate and convert one (1) of the two (2) temporary Power House Cleaver Brooks Steam Boilers to a permanent installation.
PROJECT SIZE:  Approximately $400K


Arc Flash and Short Circuit Coordination Study Project (Electrical)

CLIENT/LOCATION: Chemical Manufacturing/Tennessee
OBJECTIVE: The objective of the project was to perform the electrical engineering and design activities for the Short Circuit Coordination and Arc Flash Hazard Studies Project.
PROJECT SIZE:  Approximately $320K


Pilot Plant Fluoromonomer Feed System Project

CLIENT/LOCATION: Manufacturing Facility/Kentucky
OBJECTIVE: The objective of this project was to finalize project P&IDs, equipment specifications, and process control strategy for the installation of a new Flouromonomer Feed System for a Kynar Reactor.
PROJECT SIZE:  Approximately $210K


Resin Plant Control Room HVAC Pressurization System

CLIENT/LOCATION: Manufacturing Facility/Kentucky
OBJECTIVE: The objective of this project was to evaluate the existing HVAC pressurization system for the resin’s plant control room, and provide a report containing a code review analysis and corrective actions recommendations.
PROJECT SIZE:  Approximately $140K


Silicate Recirculation Header

CLIENT/LOCATION: Chemical Manufacturing/Ohio
OBJECTIVE: The objective of this project was to install a recirculation header from a Heat Exchanger back to a congested area Tank.  The new line needed to be heat traced and required installation of two (2) automated valves, to divert the flow from one Tank to another which ran over 200 feet weaving through an existing process area and then to an existing tank farm.
PROJECT SIZE:  Approximately $800K


(Metric) Conversion Project

LOCATION: Maryland
OBJECTIVE: Convert line to metric size laminated shingles; Increase plant capacity; Upgrade utility infrastructure
PROJECT SIZE: $20M Plus
SERVICES:

  1. Project Management
  2. Mechanical Engineering and Design
  3. Civil/Structural Engineering and Design
  4. Electrical Engineering and Design
  5. On-site Project Scheduler and Construction Management

HIGHLIGHTS: Project converted plant laminated shingle size to metric and increased capacity. Our scope included new power runs, grounding, and lighting/receptacles. Structurally was documenting existing plant columns/ trenching layouts, truss repairs, moving columns, E-House Support, and wall modifications. Mechanically documented existing Raw Material piping, and modifying all production for metric size laminated shingles upstream and down from RDI’s scope. This also included modifications to the Coater, Tape Applicator, Blender, Sand System, and Wrappers that consisted of forty-three (43) different components such as belt conveyors, lug conveyors, bundle squaring wheels, unwind stand, paper knife, corner conveyors, kicker conveyors, and gravity roller conveyors.


Alloy Vacuum Melt Building Expansion

LOCATION: New Jersey
PROJECT: Alloy Vacuum Melt Building Expansion and Vacuum Induction Melt Furnace Installation Project
OBJECTIVE: Increase Plant Capacity; Upgrade Utility Infrastructure
PROJECT SIZE: $20M Plus

SERVICES:

  1. Project Scoping and Estimating
  2. Process/Mechanical Engineering and Design
  3. Civil/Structural Engineering and Design
  4. Electrical/Controls Engineering and Design
  5. On-Site Project and Construction Management

HIGHLIGHTS: Project expanded an existing building and installed a new Vacuum Induction Melt Furnace at the customer’s existing plant. Specifically, this included General Demolition, Civil Site work, Underground Utilities, Concrete Foundations – Main Building, Concrete Foundations -Cooling Tower, Concrete slabs, Structural-Building Framing and Siding, Overhead Cranes, Miscellaneous Platforms, Cooling tower Support Steel, Cooling Tower Pump House, Major Equipment Installation, Interior Piping, Cooling Tower Equipment Installation, Cooling Tower Piping, Heating and Ventilation, Lighting, Electrical Power Distribution and Utilities, and finally Grounding and Lightning Protection. Also provided assistance in permit preparation and acquisition.


MON Project Utilities Supply and Upgrade

LOCATION: New Jersey
OBJECTIVE: Install RTO and Cryogenic; Upgrade Utility Infrastructure
PROJECT SIZE: $25M Plus
SERVICES:

  1. Project Scoping and Estimating
  2. Mechanical Engineering and Design
  3. Civil/Structural Engineering and Design
  4. Electrical Engineering and Design
  5. On-Site Project and Construction Management

HIGHLIGHTS: Project installs a new Regenerative Thermal Oxidizer (RTO) and Cryogenic Unit at the customer’s existing plant. Specifically, this design/build project provided utilities consisting of the following services: natural gas, compressed air, well water that served as process water, potable water, connection to an on-site chemical drain, electrical service, and fire protection. The electrical upgrade portion of the project included a new Unit Substation with a walk-in enclosure. The unit sub consisted of an electrically operated primary means of disconnect, a transformer, and a secondary distribution.


HF Storage Tank Replacement

LOCATION: Pennsylvania
PROJECT: HF Storage Tank Replacement
OBJECTIVE: The replacement of an existing HF Storage Tank. Special consideration was given to the handling of contaminated equipment and materials.
PROJECT SIZE: Approximately $500K

SERVICES:

  1. Project Scoping and Estimating
  2. Civil/Structural Engineering and Design
  3. MEP Engineering and Design
  4. On-site Construction Management

HIGHLIGHTS: The highlights of this project included the re-routing of several HF and MIBK pipe lines which allowed for the removal of the existing HF storage tank. Once the new tank was in position, a new structural platform was installed to provide access to the valving and instrumentation on the top of the tank.

The project also included electrical tie-ins for new instrumentation, along with an update to the electrical area classification documents.


Railcar & Truck Ore Loading System

LOCATION: Maryland
PROJECT: Railcar and Truck Ore Loading
OBJECTIVE: To modify and upgrade an existing hopper unloading mechanism.
PROJECT SIZE: Approximately $250K
SERVICES:

  1. Project Scoping and Estimating
  2. Mechanical Engineering and Design
  3. Electrical Engineering and Design

HIGHLIGHTS: The highlights of this project included the installation of a retractable fill spout which conveyed material from an existing ore hopper to railcars or trucks below. The design included structural modifications to the access platforms and equipment supports. The control system was designed such that the operators could initiate the transfers from a remote (safe) location.


Edge Trim Removal & Flake Cutter

LOCATION: Virginia
PROJECT: Edge Trim Removal & Flake Cutter
OBJECTIVE: This project enabled the client to gain total control of one product at this local facility. This product line was outsourced in the past.

PROJECT SIZE: Approximately $4M

SERVICES:

  1. Project Scoping and Estimating
  2. Mechanical and Electrical design
  3. On-Site Project and Construction Management

HIGHLIGHTS: The highlights of this project included the installation of a film edge trim slitting station based on rotary burst blade technology with a driven female back up roll. The system includes a vacuum nozzle and flex duct integrated with the positioning system of the knife station, which has motorized positioning based on operator or recipe input and read out of its position.

COMPONENTS:

  1. Eductor / Draft Blower System
  2. Silencer
  3. Flake Receiver
  4. Static Neutralizer
  5. Flake Cutter
  6. Convey Fan
  7. Convey Ductwork
  8. Acoustical Enclosure

Process & DI Cooling Water Project

LOCATION: Pennsylvania

HIGHLIGHTS: Engineering/Design/Build — A retrofit to an existing process and DI water storage and distribution system, which included new cooling towers, chillers and distribution piping throughout the facility. Design included civil/structural and utility piping. Additional services included construction management and start-up support. The project value was $1.5 million and was completed on-time and under budget. The client achieved energy savings that exceeded original expectation.


Furnace Piping and Controls Project

LOCATION: Kansas
OBJECTIVE: Capacity Increase
PROJECT SIZE: Approximately $6.5M
SERVICES:

  1. Project Scoping and Estimating
  2. Mechanical Engineering and Design
  3. Electrical Engineering and Design
  4. Civil/Structural Engineering and Design

HIGHLIGHTS: The intent of the project was to design certain portions of a K-22 Line Expansion for the Kansas City plant. Forehearth Piping that consisted of control stations for the conditioning zones and bushing stations, tie-ins to the existing combustion air and gas train systems, a compressed air bubbler system, and emergency/start-up gas. Fiberizer Piping that consisted of mixing stations for the Fiberizers, combustion air, tie-ins to the natural gas train system, compressed air, and cooling water. Design a water conveying flume and separator to handle cullet that consisted of a water conveyor, cullet pumps, piping, separator, and a housing over the cullet bunker for the separator.


Pressure Relief Device Documentation Project

LOCATION: Pennsylvania

HIGHLIGHTS: Engineering, Field Survey, Process Evaluation and documentation of various pressure relief devices throughout the plant, necessitated by OSHA and PSM requirements.


Plantwide Fall Protection Survey and Upgrade

LOCATION: Pennsylvania

HIGHLIGHTS: Engineering/Design — Field survey, evaluation and design of fall protection systems throughout various plant sites, necessitated by OSHA requirements. Fall prevention and fall arrest system designs included access platforms, lifelines and anchor points.