Industrial Project Profiles
- Allison Transmission, Inc. Fire Loop Phases I and II and Pump House #6
- Citizens Thermal Illinois Street Satellite Chilled Water Plant
- Eli Lilly and Company, Fire Panel Replacement
- Eli Lilly and Company, Utility Service Expansion
- Eli Lilly and Company, Compressed Air Upgrades
- Knauf Insulation, Corporate Office Building Addition
- Knauf Insulation, Plant 1 Expansion
- Praxair Surface Technologies, Process Building Addition
- Delphi Delco Electronics, Short Circuit, Coordination and Arc Flash Hazard Study
- Cummins Inc., Replacement of Control Room
- Cummins Inc., New Engine Test Cell
Allison Transmission, Inc.
Fire Loop Phases I and II and Pump House #6
Allison Transmission’s Plant 3 in Indianapolis is replacing its aging
campus fire loop in seven phases. The first two phases of the project
replaced the oldest portion of the fire loop and provided a new fire pump
house so that an existing pump house could be demolished.
Applied utilized hydraulic modeling software to study water pressures at
existing building fire risers under various system conditions. The software
calculation results provided a basis for equipment and pipe sizing. Modeling
was also used to predict the impact of the new pump house operation on the
city water system which fed the new fire pumps.
Applied reviewed code issues with Allison Transmission’s fire chief, safety
and environmental representatives. Applied also communicated with Allison
Transmission’s insurance provider and city officials to ensure that the fire
loop changes would meet applicable standards and requirements.
The first two phases included the replacement of approximately 3,650 lineal
feet of 12” fire loop piping. The design of tie-ins to the existing system
minimized downtime for fire risers. One portion of the loop piping was
located under a new traffic island included in this project. Another section
of piping included relocation of existing site perimeter fencing to enhance
traffic logistics as well as site security. Applied coordinated with
locating services to identify as many existing underground utility locations
as possible prior to issuing design documents.
The new fire pumps provided 2,500 gpm of water at 155 psi to the campus loop
and were housed in a pre-engineered pump house. The pump house also
contained all controls and monitoring systems for the pumps. A 4160V to 480V
transformer was installed outside the pump house to serve the new fire
pumps.
During construction, poor soil conditions were encountered under existing
pavement. The project was expanded to include replacement of sub-standard
soil with appropriate fill. Applied contracted a geotechnical engineering
firm to oversee the soil removal and backfill.
The first two phases of the project have an estimated construction cost of
$4,700,000. Subsequent design and construction phases are expected to
follow.
Citizens Energy Group
Citizens Thermal
Illinois Street Satellite Chilled Water Plant
Applied Engineering was retained by Citizens Thermal, a division of
Citizens Energy Group, to provide engineering design for the
construction of a plant expansion at their satellite chiller plant,
located at 817 N. Illinois Street. The need for new capacity originated
from customer growth associated with the expansions of IUPUI and Clarian Hospital. At the time of
the design, the original satellite plant consisted of three 2,000-ton
chillers housed in a block building. The design work incorporated the
long-term plan for the site to ultimately house 20,000 tons of capacity. The
initial expansion of the plant included the installation of a 2,500-ton
chiller, with space for two additional 2,500-ton units. In addition, the
original cooling towers were demolished to allow room for expansion on the
site, and the replacement cooling towers were installed on the roof of the
new building. The new building was constructed at the sidewalk line of
Illinois Street; therefore it had to meet special neighborhood design
guidelines, including the installation of screens to hide the cooling towers
from street-level view, and the addition of storefront windows with awnings
on the wall facing the sidewalk. Other features included designing a
chemical bulk storage facility with a chemical feed system for each cooling
tower loop, and the installation of a new 480V transformer to support the
plant expansion auxiliary equipment.
The expansion at the Illinois Street satellite plant was designed so that it
could be remotely operated from the original facility, located at 350 S.
West Street. This was made possible by the installation of a fiber optic
communication link from the West Street plant to the Illinois Street plant,
and an extension of the plant control system in the Illinois Street plant.
In addition, a security system with cameras was installed for remote
observation of the satellite plant.
The project design documents were divided into multiple bid packages to
allow scheduled phases for completion for the building, mechanical and
electrical contracts to improve delivery time. Design efforts for the
initial construction began in August 2007 and the last construction set
was issued to contractors in January 2008. The plant expansion framework
and existing chiller system cooling towers were placed into service in
July 2008. The new chiller was placed into service in September 2008.
Eli Lilly and Company
Lilly Corporate Center and Lilly Technology Center
Fire Panel Replacement
Applied Engineering Services was contracted to design a new fire alarm system network at Lilly Corporate Center (LCC) and Lilly Technology Center (LTC) to eliminate the dependence on a voice evacuation system and to replace existing fire alarm systems that were not documented with up-to-date drawings. Additionally, many of the existing fire alarm systems were not supported by the manufacturer due to the age of the system.
Phase I of the project included designing and constructing three fire alarm systems in three different types of buildings (administrative, lab and manufacturing). This approach was selected to assist in the cost estimating process of replacing approximately 150 fire alarm panels in 81 buildings. The scope also included replacing all fire alarm strobes in buildings that already had a new Simplex 4100U fire alarm panel with horn/strobes. A fire alarm network (IMS) was also installed to connect all new fire alarm panels together which allows Lilly security staff and the Fire Security Systems group (FSS) to monitor all panels at LCC and LTC as well as at some remote sites such as the Plainfield Distribution Center, MQLC and E Street Child Care Center.
Phase II of the project involved designing 44 fire alarm systems for the remaining 78 buildings. Many security input and output points were relocated to the Lilly security system which separated the fire alarm system function from the security system function. This will allow the fire alarm systems to monitor and control only the fire alarm system points and the security systems to monitor and control only security points. All designs and testing meet the minimum requirements specified by the applicable versions of NFPA 72 and the International Building Code. Applied provided preliminary engineering and final design through the completion of construction documents and construction support.
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Eli Lilly and Company
Utility Service Expansion Design, Lilly Technology Center North
The utility master planning process (Phase 1) performed by Applied yielded an initial site expansion project consisting of the demolition of one existing building and the design/construction of three new buildings on site (Phase 2). The new buildings are a 105,000-square-foot administration building, a 220,000-square-foot laboratory building, and a 485,000-square-foot development building. The administration and laboratory buildings were completed in early 2005, and the development building was completed in late 2006.
Applied provided engineering services to design the site utility infrastructure to support the three new buildings. Highlights of Applied’s scope of work are as follows:
- New 1,010-foot-long precast, walk-through utility tunnel
- New 220,000 pph steam PRV station and distribution to the new buildings
- Condensate cooling and draining
- New 1,600 gpm variable speed city water booster pump station
- New 1,250 gpm and 600 gpm sanitary lift stations
- Rerouting of existing utilities from former city street including:
- Storm and sanitary sewers
- City water
- Fire protection
- Telecommunications
- Extension of new utility services including:
- Chilled water (24-inch mains)
- Steam — 450 psi and 250 psi services
- Compressed air — low and high pressure services
- Purified water
- Dewatering well discharge water
- Fire protection water
- Electrical power — two 5-inch conduits with three 750 MCM, 15 kV cables each
- Telecommunications — fiber and copper for telecom, CCTV, Ethernet, and voice cable
- O2 and N2 piping
- Commissioning, qualification and validation of selected critical utility system installations
Construction of the site utility work is complete, and final commissioning and qualification was completed at the end of 2005. The total estimated cost of the site utility support work was $25 million.
Eli Lilly and Company
Lilly Technology Center North
Compressed Air Upgrades
Applied Engineering Services prepared design drawings, project scheduling and construction administration for a $7 million central air compressor upgrade project for Eli Lilly and Company’s LTCN campus. The project replaced two Ingersoll-Rand 1,250 cfm reciprocating air compressors and an AIR-TEK 4,000 SCFM blower purge heat regenerative desiccant air dryer with two Cooper three stage 1,250 SCFM centrifugal air compressors and two Pneumatech duplex 2,600 SCFM blower purge heat regenerative desiccant air dryers. In addition, the existing three stage Joy 1,200 SCFM centrifugal air compressor received a controls retrofit. All of the compressors are controlled via Cooper’s Vantage control system for optimized efficiency and performance logging. A new 4” compressed air main was installed from building K358 to the K329 central air compressor building to allow the two 800 SCFM Atlas Copco screw air compressors in K358 to be fully utilized as needed. The construction cost was $3,200,000 and the project was completed in March 2008.
Knauf Insulation
Knauf Corporate Office Building Addition
Applied Engineering provided the mechanical engineering, electrical engineering, and commissioning for a new 20,000-square-foot, two-story addition to the corporate headquarters for Knauf Insulation in Shelbyville, Indiana. This building was designed in partnership with Browning Day Mullins Dierdorf Architects and Fink Roberts & Petrie Structural Engineers. The project includes offices, open office areas and an academy for training activities. The building was designed to achieve Gold rating by the U.S. Green Building Council under its Leadership in Energy and Environmental Design (LEED) rating system. Energy efficiency is maximized through building orientation, construction and systems design. The design team paid careful attention to materials and construction techniques used in order to minimize the environmental impact.
The HVAC system consists of variable air volume (VAV) air handling units with direct expansion refrigeration cooling and electric heat. Carbon dioxide (CO2) monitoring devices, in conjunction with air flow measuring stations, measure and maintain proper levels of fresh air. The plumbing systems are designed for efficient use of fresh water by utilizing waterless and low flow fixtures with automatic valves. Instantaneous water heaters minimize energy usage. The electrical system achieves energy efficiency through active lighting controls and daylight harvesting. Light wells and open interior spaces maximize daylight admittance while external shading and high performance window coatings minimize solar heat gain and glare. Light monitoring devices adjust interior lighting levels, and high efficiency fixtures minimize energy usage. The fire protection work included a new main and sprinklers throughout the building.
Project construction began in January 2008, and the project was completed in the fall of 2008. Estimated construction cost: $4,500,000.
This project received an Honor Award from ACEC Indiana in its
2009 Engineering Excellence Awards competition.
Knauf Insulation
Plant 1 Expansion
The Applied team (consisting of Applied Engineering, Fink Roberts & Petrie, and Browning Day Mullins Dierdorf Architects) was selected by Knauf Insulation GmbH to perform the design work for a $240 million expansion of their manufacturing operations in Shelbyville, Indiana. The new plant produces commercial and industrial insulations for the U.S. market.
The project included a new 374,000-square-foot warehouse, new production facilities, and the associated utility and raw material support systems/structures. The project required a high-voltage electrical substation; a chemical compounding plant; a utility building; a batch house for glass-making raw materials; and new production lines with associated support processes.
Applied's work included all of the architectural, civil, foundation, and the majority of the mechanical and electrical design. Selection and design of the batch house, wet electrostatic precipitator, regenerative thermal oxidizers, the production equipment, and packaging equipment was performed by Knauf with several OEMs that specialize in fiberglass manufacturing equipment. The Applied team was responsible for many of the support structures and the utility hookups for this OEM equipment. Applied was also responsible for overall site planning and development, including access roads, parking lots, utility relocation/improvements, fire protection, and landscaping.
The design work began in August 2004. Construction began in February of 2005. The project was designed and built in seven phases, with final construction completed in 2008.
This project received the Grand Prize Award from ACEC Indiana in its 2008 Engineering Excellence Awards competition.
Praxair Surface Technologies
Process Building Addition
This project included engineering for a 22,000-square-foot, two-story addition to an existing process building to house a new piece of part coating equipment that is used in the manufacturing process for aircraft engine turbine blades. Applied Engineering completed the MEP design, working directly for the Owner, in conjunction with Fink, Roberts, and Petrie who completed the architectural and structural design.
The HVAC design included four rooftop air handling units, one of which presented the primary engineering challenge of achieving stringent humidity control for process operations while avoiding the use of desiccant technology, at the Owner’s request. Plumbing design was complicated by design constraints requiring the design of an indoor lift station. Existing process gases were extended into the addition. Fire protection requirements were specified, and a new water service main was provided for the building addition. Utilities were modified in a transitional bay of the existing building to accommodate structural modifications.
The electrical design included the engineering design of new 480V unit substation for the building expansion. In addition, the design included lighting and electrical service throughout the new building, as well as the specification of telecommunications outlets.
The estimated mechanical and electrical cost was $2.5 million. The project was completed in August 2007.
Delphi Delco Electronics
Short Circuit, Coordination and Arc Flash Hazard Study
The purpose of this project was to perform a power study that included short circuit, coordination and arc flash hazard assessment analyses for the Delphi Delco Electronics Systems facility in Kokomo, Indiana. This study was driven by an OSHA requirement to label all electrical equipment with a rating for arc flash hazard potential that will determine the equipment and classification of clothing that an electrician will need to work on the equipment. The study was performed using SKM PowerTools software, and drawings
were completed in Microstation.
The study included: data collection assistance; creation of one-line diagrams; short circuit – ANSI standard; protective device coordination; arc flash hazard evaluation; and documentation. This work is was completed in 2006.
At the completion of the project, a report was written and presented to the client. The report included a narrative and tabulated results from the PowerTools analysis. Arc flash hazard warning labels were provided to the client to be placed on all electrical equipment affected by the study.
Cummins Inc.
Replacement of Control Room
The existing control room in Cummins’ large engine test cell facility was
destroyed in a flood during the weekend of June 7th and 8th, 2008. The test cell
facility housed major mechanical and electrical equipment. There were eleven
control panels in the control room serving fuel safety shutdown, sprinkler
systems, oil storage and combustion air, boilers, chillers, cooling towers,
pumps and fire alarm system. The control panels were over 20 years old and
needed to be replaced complete with underground conduits, wiring and pneumatic
tube systems.
Applied Engineering Services completed a study and cost opinion that compared
the cost of rebuilding the control room “As Was” (central location) or “Virtual”
(distributed locations). The study required extensive field surveys of the
existing equipment, wiring, conduits, controls, and fuel pump house equipment.
Applied utilized Johnson Controls to provide cost opinions for the Metasys
system using the latest technology to facilitate enhanced energy management,
monitoring capabilities, future expansion capabilities, data collection and
improve facility management. The study which included detailed cost estimates
for “As Was” and “Virtual” was presented to Cummins; Cummins elected to proceed
with the “Virtual” option.
Applied was then awarded the turnkey project to rebuild the control room in a
“Virtual” fashion. The project design and construction was broken into a number
of defined phases so that construction could begin right away on the most
critical portion while design was still being completed on less critical phases.
An Applied engineer was placed at the plant site during all construction
activities providing coordination and field engineering services to Cummins.
Applied utilized the services of Johnson Controls, ERMCO, Forester Electrical
Services, and Dunlap & Company as subcontractors to perform the mechanical,
electrical, controls, programming, sheet metal, civil, and structural work for
the project.
The project began in June 2009 and was completed in September 2010. The total cost
of the project was approximately $2.4 million.
New Engine Test Cell
Cummins wished to build a new engine test cell where a previous
test cell once existed. Applied was retained to evaluate how best to
accomplish this work and then to prepare the design, drawings and
specifications for bidding and construction. All of the HVAC, power,
fuel supply, etc. serving the previous test cell had been removed.
This meant all new ancillary services and equipment would need to be
installed. This was a difficult task as space for new equipment was
scarce as equipment for other building uses had been installed in
most of the area previously utilized for test cell ancillary
services.
The solutions consisted of the following:
- A custom-built roof-mounted air handling unit with a glycol heating coil providing the ventilation air to the test cell was provided.
- A roof-mounted exhaust fan was installed.
- Existing duct work, piping and electrical conduits were relocated to make room for new duct work and piping.
- A control system and variable frequency drives for the supply fan and exhaust fan were provided to automatically maintain negative pressure in the test cell.
- The engine test controls system was provided to meet the Owner’s requirement and specification.
- Structural work included installation of a platform on the roof for the air handling unit and cutting holes in the floor slabs and roof for the supply and exhaust work.
The project was completed in 2009, and the estimated construction
cost was $350,000.
