Confidential Manufacturing Client, Athens, GA
Facilities Automation Systems & HVAC Retrofit Services
AIRCOND VALUE DELIVERED
More reliable plant processes, greater productivity, less downtime, more consistent product quality, increased business continuity protection, improved competitiveness through integrated facilities management services and automation systems.
HVAC RETROFIT SERVICE OBJECTIVES
Have EMCOR Services Aircond provide HVAC retrofit services to improve an undependable and inefficient chilled water loop system.
MECHANICAL & FACILITIES SERVICES SOLUTIONS
The problems? Operating inconsistencies and expensive production downtime. The cause? A chilled water loop system that couldn't respond quickly and efficiently enough to variations in the type of products being manufactured, production speeds and the number of machines in operation. Periodic component breakdowns only added to these problems. The client asked EMCOR Services Aircond to help.
Aircond's mechanical construction solution included HVAC equipment upgrades, improved process control and greater system redundancy. The company began by replacing three large indoor process solution tanks, six pumps, and process piping, with properly sized components to match the production load. The new heating and air conditioning system included one solution tank mounted outdoors (increasing plant floor space), a primary variable speed pump with stand-by capabilities and a variable speed process loop pump with stand-by pumping. Aircond also installed a new air-cooled chiller, piping and controls in addition to the current four chillers in order to provide redundancy, reliability and better chilled water control. The company also modified the electrical power systems, expanded the outdoor cooling plant's concrete platform and added security fencing. Finally, Aircond reworked the piping, valves, and controls, so the chilled water supply and return temperatures could be mixed more efficiently, improving management of the production machines' cooling load.
The result is an integrated facilities automation system that effectively coordinates chiller capacity with the process load in the three bays with multiple process lines, even when each line has different requirements. A customized control sequence combines individual chillers in configurations that handle each bay's load with maximum energy efficiency. The sequence also adapts to load changes and mechanical failures by maintaining process water conditions, while alerting plant personnel early to potential emergencies. At the same time, the load and equipment redundancies now built into the building control system minimize the production impact of component breakdowns.
In addition to providing proper chiller sequencing, the facility automation system improves control of the cooling load by modulating valves to maintain system pressure and stabilize process water conditions. This means fewer fluctuations and more consistent product quality.
When the commercial HVAC retrofit project was completed, the client praised the Aircond team for maintaining a courteous, friendly, businesslike attitude throughout the project, while ensuring the client's complete satisfaction with the project's progress and quality. The client also cited the mechanical construction project manager for creating an atmosphere of respect, saying "…in my opinion, a happy crew is a productive crew that maintains pride in its work. Well done. Nice team effort."
MANUFACTURING FACILITIES BACKGROUND
With manufacturing and corporate facilities around the world, our client manufactures various types of container closures. This manufacturing facility in Athens, Georgia includes three large production bays of highly precise equipment that produces high quality closures at a rapid rate of speed.