Industrial Project Profiles
- Delphi Delco Electronics
- International Truck and Engine Corporation, Engine Group
- Eli Lilly and Company, Utility Service Expansion
- Eli Lilly and Company, Site Utilities Expansion
- Knauf Fiber Glass
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 will be 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 ongoing, with completion anticipated in mid-2005.
At the completion of the project, a report is to be written and presented to the client. The report will include a narrative and tabulated results from the PowerTools analysis. Arc flash hazard warning labels will be provided to the client to be placed on all electrical equipment affected by the study.
International Truck & Engine Corporation, Engine Group
Building 34/35 HVAC Renovation
This project included engineering and design for a new renovated HVAC system for the new engine line being installed in approximately 270,000 square feet of existing manufacturing space. The project included two new 1,000-ton chillers, two new 50,000 cfm rooftop HVAC units, rebuild of 14 existing 50,000 cfm units, installation of new ductwork in a portion of the plant, and new 480-volt substation. The project was designed, bid and constructed in essentially three phases, in order to complete the work in conjunction with the new engine production equipment. In addition, the owner purchased the long-lead equipment using purchase specifications developed by Applied. The project was completed in early 2003. The estimated construction cost for the project was $4.5 million.
Eli Lilly and Company
Utility Service Expansion Design, Lilly Technology Center North
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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. All three buildings are under construction, with the administration and laboratory buildings slated for completion in early 2005 and the development building 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, with final commissioning and qualification completion scheduled for mid-2005. The total estimated cost of the site utility support work is $25 million.
Eli Lilly and Company
Site Utilities Expansion, Lilly Greenfield Laboratories
This project involved study and design for a major expansion of site utilities at Lilly’s Greenfield Laboratories. The study phase included a short-term projection of growth at the site (through 2006), allowance for new buildings already in the design or construction phase, and evaluation of current system loads. The design phase implemented findings of the study with development of detailed construction drawings and specifications.
The Lilly complex is located approximately 20 miles east of downtown Indianapolis on Route 40 in Greenfield. The site has 42 buildings totaling approximately 950,000 square feet dedicated to laboratory research, development, production, administration, and utility generation.
Five new building projects slated for completion between spring of 2002 and 2003 required an increase and/or modification to Lilly’s generation and distribution systems.
The site utility work included development of a new 2,200-foot-long utility trench with the following services:
- 24-inch chilled water supply and return
- 16-inch 125 psig steam
- 4-inch steam condensate
- 4-inch 100 psig compressed air
- 8-inch city water
- 3-inch de-ionized water
- Fire protection water
- 48-inch storm sewer
- 24-inch sanitary sewer
- Electrical duct bank
- Telecom duct bank for voice, fiber optics, and broadband
The utility generation improvements included these main components:
- Removal of an existing 1,000-ton chiller and installation of a 2,500-ton chiller
- Replacement of:
- Four cooling tower pumps
- Two chilled water pumps
- One 4,160-volt switchgear
- One 480-volt motor control center
- Refurbishment and reinstallation of two 500 scfm, 100 psig air compressors
This project was awarded an Honor Award from ACEC Indiana for its 2003 Engineering Excellence Awards competition.
Knauf Fiber Glass
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 $218 million expansion of their manufacturing operations in Shelbyville, Indiana. The new plant will produce commercial and industrial insulations for the U.S. market.
The project will include 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 is 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 is being designed and built in seven phases, with final construction complete in 2008.