Industrial, Chemical, Manufacturing
(Metric) Conversion Project
CLIENT: GAF/ELK Materials Corporation
LOCATION: Maryland
OBJECTIVE: Convert line to metric size laminated shingles; Increase plant capacity; Upgrade utility infrastructure
PROJECT SIZE: $20 million 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 43 different components such as belt conveyors, lug conveyors, bundle squaring wheels, unwind stand, paper knife, corner conveyors, kicker conveyors, and gravity roller conveyors.
Silica Plant Expansion
CLIENT: W.R. Grace
LOCATION: Maryland
PROJECT: Silica Plant Expansion
OBJECTIVE:
Increase Plant Capacity; Enable Production of New Products; Upgrade Utility Infrastructure
PROJECT SIZE: $10 Million 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 cut plant production costs and expanded the capacity of the client’s existing Silica Gel plant. The intent of the new process was also to institute elements of GMP in the manufacturing of silica gel for their toothpaste manufacturing clientele. This project included the conversion of three (3) existing silica gel wash tanks from a bulk wash system to a recirculation wash system. Additionally, the conversion included the change from drying silica gel in tubs to a continuous drying system. This featured the installation of a Carrier Dewatering Feeder, Dryer, hot waste water recovery system, storage hoppers, dense phase transport system, dust collector, pumps, filters, heat exchangers, storage silos, truck loading facility, GMP compliant packaging system, extensive modification to the plant electrical distribution & control systems and a new transformer station. This project included significant piping and conduit relocation and design. These changes required the installation of over 1,000 feet of pneumatic transfer piping and over 1,000 feet of process piping of various diameters. To support the mechanical system changes, extensive changes to the plant electrical distribution and control systems were also accomplished, which included the installation of a new transformer station, new motor control center, and over two hundred (200) electrical/control loops.
Magnapore Plant Expansion
CLIENT: W.R. Grace
LOCATION: Maryland
OBJECTIVE: Increase Plant Capacity; Upgrade Utility Infrastructure
PROJECT SIZE: $6 million 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 the capacity of the customer’s existing Magnapore plant. This project included the addition of a new 2,000 gallon glass-lined reactor, new bucket elevators, conveyors, screeners, wash pots, material storage tanks and product baggers. Substantial upgrades to the plant control system infrastructure and power distribution system were required to support the project. The process engineering effort included mass balance and PFD development. The mechanical and electrical engineering effort included P&ID development and equipment and instrument specification. The design effort included equipment supports and access platforms, a tank farm expansion, piping and ductwork details, and finally all conduit, cable and wiring details. The project budget was met and the production increase far exceeded the client’s expectations.
Polyolefin Plant Expansion
CLIENT: W.R. Grace
LOCATION: Maryland
PROJECT: Polyolefin Plant Expansion
OBJECTIVE: Increase Plant Capacity; Upgrade Utility Infrastructure
Project Size: $8 million 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 the capacity of the customer’s existing Polyolefin plant. This included the expansion of their existing process in an 80 year old adjoining warehouse. Polyolefin is a catalyst compound produced by the customer and sold to manufacturers to use in the production of high density polyethylene. This project started with completing fully developed flow diagrams and piping and instrumentation diagrams, and then continued through inspection of the contractors work and assisting with start-up. Other tasks included foundations, vessel design, numerous platforms up to the roof (80ft), layout of all the equipment, structurally support collectors on the roof, design of a spray dryer, new motor control room, and the total design of all the electrical and instrumentation work. The engineering was completed on a fast-track basis and the project was brought in significantly under budget and within schedule.
Alloy Vacuum Melt Building Expansion
CLIENT: Alcoa
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: $20 Million 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
CLIENT: Covidien
LOCATION: New Jersey
OBJECTIVE: Install RTO and Cryogenic; Upgrade Utility Infrastructure
PROJECT SIZE: $25 Million 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. J&W’s construction management team has responsibility for all construction-related activities.
Belt Dryer Installation
CLIENT: WR Grace
LOCATION: Maryland
OBJECTIVE: Replacement of an existing steam-heated dryer with a new direct gas-fired dryer. Special consideration was given to flammable vapors exhausted from the dryer.
PROJECT SIZE: $1.6 million
SERVICES:
1. Project Scoping and Estimating
2. Code Review and Permit Preparation
3. Process Engineering and Design
4. MEP Engineering and Design
5. Burner Management System Design
6. On-site Project and Construction Management
HIGHLIGHTS: The highlights of this project included the demolition of the existing dryer and the assembly and startup of the new dryer, which were accomplished during a seven day shutdown.
The design activities included an analysis of the flammable vapors which evolved from the drying process. This analysis ultimately determined the electrical classification of the dryer and the surrounding area.
The control system for the dryer included a PLC-Based burner management system. The hardware and software for the PLC and HMI’s were designed, programmed, and tested by J&W’s Controls Team. The PLC also interfaced with the plant DCS Control System.
HF Storage Tank Replacement
CLIENT: Cabot SuperMetals
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: $500,000
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.
Railcare & Truck Ore
Loading System
CLIENT: Alcoa Eastalco Works
LOCATION: Maryland
PROJECT: Railcar and Truck Ore Loading
OBJECTIVE: To modify and upgrade an existing hopper unloading mechanism.
PROJECT SIZE: $250,000
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
CLIENT: DuPont
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: $4 Million
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
Axcelis
Process & DI Cooling Water Project
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
CLIENT: CertainTeed
LOCATION: Kansas
OBJECTIVE: Capacity Increase
PROJECT SIZE: $6.5 Million
SERVICES:
1. Project Scoping and Estimating
2. Mechanical Engineering and Design
3. Electrical Engineering and Design
5. Civil/Structural Engineering and Design
HIGHLIGHTS: The intent of the project was to design certain portions of CertainTeed’s 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.
DuPont
Pressure Relief Device Documentation Project
Engineering, Field survey, process evaluation and documentation of various pressure relief devices throughout the plant, necessitated by OSHA and PSM requirements.
Alcoa
Plantwide Fall Protection Survey and Upgrade
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.
Pharmaceutical & Biotechnology
PM Job Plan
CLIENT: Merck
LOCATION: Pennsylvania
PROJECT: Preventive Maintenance Job Plan Upgrade and Development Project (in Response to a Regulatory Compliance Commitment)
OBJECTIVE: Provide engineering support in the upgrade and development of over twenty thousand (20,000) preventive maintenance job plans for various types of process equipment, HVAC equipment and instrumentation, in order to meet a Regulatory Compliance Commitment.
HIGHLIGHTS: This effort took place over a seven month period with a team of multi-disciplined engineers. Existing Job Plans were updated and new Job Plans were written with the goal of standardization and technical correctness. Collaboration and coordination with maintenance, reliability and operations personnel was a key to the project success. The Regulatory Compliance Commitment was met within budget and on schedule.
Compressed Gas Filter
CLIENT: Merck
LOCATION: Pennsylvania
PROJECT: Compressed Gas Filter Inventory and Assessment Project (in Response to a Regulatory Compliance Commitment)
OBJECTIVE: Provide engineering support in the inventory and assessment of compressed gas filters in order to meet a Regulatory Compliance Commitment.
HIGHLIGHTS: This was a Plantwide initiative that involved the survey of over a dozen process buildings/areas. This effort took place with a team of mechanical and process engineers. Information was gathered from field verifications. Once the data was assembled, it was assessed against the clients’ Principles of Filter Function and Integrity Testing. Once areas of non-compliance were identified, remediation actions were formulated, and then taken.
Wetted Path Elastomer
CLIENT: Merck
LOCATION: Pennsylvania
PROJECT: Wetted Path Elastomer Inventory and Preventive Maintenance Job Plan Development Project (in Response to a Regulatory Compliance Commitment)
OBJECTIVE: Provide engineering support in the upgrade and development of preventive maintenance job plans for the wetted path elastomers in diaphragm valves, clamps and hoses in order to meet a Regulatory Compliance Commitment.
HIGHLIGHTS: This was a Plantwide initiative that looked at non-sterile product contact components in process lines, clean utilities such as clean steam, water for injection (WFI) systems and clean-in-place (CIP) systems. This effort took place with a team of mechanical and process engineers. Information was gathered and assembled from the review of over seven hundred (700) P&ID’s, and then field verified. Existing Job Plans were updated and new Job Plans were written with the goal of standardization and technical correctness. Collaboration and coordination with maintenance, reliability and operations personnel was a key to the project success.
Corridor Renovation
CLIENT: Merck
LOCATION: Pennsylvania
PROJECT: Chemistry/Research Lab Renovation
OBJECTIVE: Renovate existing labs and associated infrastructure within a state of the art research and development laboratory facility.
PROJECT SIZE: 16,000 sq. ft.
SERVICES:
1. MEP and Structural Engineering
2. Architectural Services
3. Construction Management
HIGHLIGHTS: The complete renovation of the HVAC, power, communication and data distribution systems within the building based on the new layout and the requirements of the labs.
The equipment and casework was also designed and specified to be mobile and allow the lab owners the flexibility of changing the layout based on their needs.
Design included a CV supply and exhaust air system with high purity gases for HPLC’s and Biosafety Cabinets.
Containment Laboratory
CLIENT: Bristol Myers Squibb
LOCATION: New Jersey
OBJECTIVE: Renovate an existing cGMP lab suite and associated infrastructure to provide adequate containment for the handling of potent compounds.
PROJECT SIZE: $600,000
SERVICES:
1. MEP and Structural Engineering
2. Architectural Services
3. Construction Management
HIGHLIGHTS: included the complete renovation of the existing space to include the design of anterooms, clean and dirty areas and provisions for cGMP requirements.
This included modifications to the existing HVAC system controls in order to provide a system which could track the CFM’s being supplied to the various rooms in order to validate the design.
The controls for the HVAC system were tied into the building automation system. This design also included architectural changes to the rooms, the addition of anti rooms and changing rooms for the lab owners.
This also required modifications to the power, communication and data distribution systems within the building based on the new layout.
Lab Renovation
CLIENT: Merck
LOCATION: Pennyslvania
PROJECT: B75 Laboratory Renovation
OBJECTIVE: Renovate existing labs and associated infrastructure to allow the installation of multiple new fume hoods and mass spectrometers in an existing lab building.
PROJECT SIZE: $1,400,000
SERVICES:
1. MEP
2. Architectural Services
3. Construction Assistance
HIGHLIGHTS: The highlights of this project included the complete renovation of the existing lab areas to accommodate the installation of eight new fume hoods, a robotic enclosure and six new mass spectrometer units in a suite of laboratories.
This required the redesign of the existing overall HVAC system, duct work, individual exhaust systems, lab gas utilities, power distribution, emergency power, communication and data distribution systems within the building based on the new layout and the requirements of the labs.
A high purity nitrogen distribution system was also installed for the equipment.
Cage Wash System
CLIENT: Bristol Myers Squibb
LOCATION: New Jersey
PROJECT: Cage Wash System Upgrade
OBJECTIVE: Provide the engineering and design package to modify the existing exhaust system in the cage wash room to improve the overall performance of the installation.
PROJECT SIZE: $400,000
SERVICES:
1. MEP and Structural Engineering
2. Architectural Services
3. Construction Assistance
HIGHLIGHTS: The highlights of this project included the investigation and design to improve the operation of an existing cage wash machine for a vivarium.
The existing ceiling was replaced with a new high performance system to minimize leaks and corrosion.
The existing HVAC and area exhaust systems were also redesigned in order to improve the overall system.
Baxter
Vaccine Suite Upgrade
Provided the engineering and design services for a Vaccine Suite Upgrade project at the Beltsville Maryland site. The intent of this project was to convert two existing rooms into rooms which could handle flammable liquids. We also evaluated options for storing and dispensing these liquids for the site.
MedImmune
Engineering Support for Validation
For a vaccine manufacturing facility, we provided engineering support to the client’s validation department to validate various process and utilities systems for a cGMP cell culture production expansion project. We sent a validation project team to develop and implement IQ, OQ and PQ protocols followed by final execution reports over a six-month period. The process, equipment, and utility systems validated for this project included RODI, process water, chilled glycol, hot WFI, cold WFI, CIP, SIP, plant steam, bulk oil and compressed air systems.
Johnson & Johnson
Engineering & Design package for ANESI Lab Renovation
Provided the engineering and design package to renovate the existing ANESI Lab. This project included renovations to existing labs, office areas and infrastructure to a state of the art facility comprised of: Chemical Stockroom, Hydrogenation Room, new office/administrative area, Dry Ice room and break area. The highlights of this project included the complete renovation of the existing space to provide a new testing, research and development area. This project required the redesign of the existing HVAC, power, communication and data distribution systems within the building
Merck
Installation of fume hoods and bio safety cabinets
We provided the engineering and design package to install additional fume hoods and bio safety cabinets in the existing chemistry and analytical lab. This included reviewing and verifying the capacity of the existing HVAC system for the building.
Merck
Site Pressure Relief Devices
Completed a detailed plant survey to verify the installation of pressure relief devices throughout the facility. This included preparing PRD calculation packages for all of the devices based on various failure scenarios. As part of this project we prepared and updated the associated P&ID’s for the systems and the devices included in the project.
Merck
DI Water Installation
MEP and Structural Engineering/Construction Assistance
Provide the design to install a new DI Water System in an existing building.
Merck
Equine Barn
MEP and Structural Engineering/Construction Assistance
Design and construct an Equine Barn and Riding Area for the care of horses used in the production of Anti-venom.
Commissioning Services (multiple projects)
CLIENT:Bristol-Myers Squibb
LOCATION:Hopewell, NJ
OBJECTIVE:
- Provide commissioning agent to monitor and report on design compliance during construction.
- Write and execute the commissioning documentation for the projects.
HIGHLIGHTS: Javan Engineering has provided commissioning services on many GMP and non-GMP projects for Bristol-Myers Squibb. In addition to creating Commissioning Master Plans, IC/OC/PC documents, and Final Commissioning Reports for each project, Javan provides more value to the construction team by providing an experienced Commissioning Agent. Our commissioning agents are experienced in multi-disciple construction practices and are able to observe and report on compliance to the design during construction. This client support function has proven to reduce construction errors, inspection issues, and time consuming deviations during start-up and commissioning execution. Our commissioning agents also assist with Project Closeout Documentation, and they developed the standard template used by the BMS site.
Healthcare & Universities
Bone Lab Design
CLIENT: Thomas Jefferson University
LOCATION: Pennsylvania
PROJECT: Bone Lab Design Project
OBJECTIVE: Renovate an existing lab to provide a new teaching lab for surgical techniques on the human skull.
PROJECT SIZE: 1,000 sq. ft.
SERVICES:
1. MEP and Structural Engineering
2. Construction Assistance
HIGHLIGHTS: The highlights of this project included the complete renovation of the HVAC, power, communication and data distribution systems within the building based on the new layout and the requirements of the labs.
A new air compressor system was also installed which included the design of a CA distribution loop and drops for each teaching station in the lab.
Laser Chiller Installation
CLIENT: University of Pennsylvania
LOCATION: Pennsylvania
OBJECTIVE: Provide the engineering design package to install a new laser chiller system in an existing research lab.
PROJECT SIZE: 400 sq. ft.
SERVICES:
1. MEP Engineering
2. Construction Assistance
HIGHLIGHTS: The highlights of this project included the engineering and design required to install a new laser chiller system in an existing research lab.
The equipment had already been purchased by the University and needed to be modified in order to install the equipment in the area/room selected.
The existing HVAC and electrical systems needed to be redesigned for this new equipment.
Biological Research Room
CLIENT: University of Pennsylvania
LOCATION: Pennyslvania
PROJECT: Confocal Microscope Room
OBJECTIVE: Renovate existing office area for the installation of a new Confocal microscope.
PROJECT SIZE: 250 sq. ft.
SERVICES:
1. MEP Engineering
2. Construction Assistance
HIGHLIGHTS: The highlights of this project included the complete renovation of the HVAC, power and lighting system to support the installation of the new confocal microscope.
The ventilation system was also modified to provide adequate ventilation to the microscope based on the vendor requirements.
Operating Room Renovation
CLIENT: Thomas Jefferson University
LOCATION: Pennsylvania
OBJECTIVE: Provide the design to renovate an existing procedure room into a new operating room.
PROJECT SIZE: 500 sq. ft.
SERVICES:
1. MEP Engineering
2. Construction Assistance
HIGHLIGHTS: The highlights of this project included the engineering and design to modify the existing HVAC system to ensure proper air flow and to design the new med gas lines for the operating room.
Thomas Jefferson University
Administration Area Renovation Project
MEP and Structural Engineering/Construction Assistance
Provide the design to renovate the existing area and provide new offices, meeting rooms and concession area for the admissions office.
Thomas Jefferson University
Lighting Suite/Dark Room Design
Detail Design/MEP and Structural Engineering/Construction Assistance
Provide the design to construct a testing suite to observe the affects of lighting on people.
Thomas Jefferson University
Clean Room Design
Detail Design/MEP Engineering/Construction Assistance
Provide the design to renovate an existing office area to create a new clean room space for drug dispensing based on USP 797 guidelines.
Thomas Jefferson University
Dish Washer Installation Project
Detail Design/MEP Engineering/Construction Assistance
Provide the design to replace an existing industrial size dish washing machine and install a new dish washing machine with conveyor line for the university and hospital.
University of Pennsylvania
Anatomy/Chemistry Room
B22 Cryo Facility
MEP Engineering/Construction Assistance
Renovate the existing office/storage room into a new cryogenic filling and storage area.
University of Pennsylvania
Engineering Projects –
Expense Work
MEP and Structural Engineering/Construction Assistance
Provide support for a variety of smaller engineering and design projects for the building owners.