Pre-Installation View of Building
Aerofoam Turnkey Project
Aerofoam Turnkey Project: Overview
The Aerofoam turnkey project is a key event for Hira Industries new facility in Abbeville, SC. Its creation this past year is meant to solidify their ability to meet U.S. demand for the insulating products they manufacture. Their new facilities’ team involves JDI with planning the logistics, manpower, and the commissioning of the facility to succeed at their goals.
Our millwrights began the first phase, then we involve the electricians and mechanical teams, and lastly, we give the facility the ability to startup. Once operational, the begin to create their products for the market.
To understand all that JDI did to make the new production plant operational, read on below.
Phase I - Millwrights on Deck
Firstly, this project begins with the millwright phase. JDI’s millwrights, experts in lifting and rigging for projects like this one at Aerofoam, take on the task of rigging over 20 pieces of major manufacturing machinery.
The millwrights, superintendent, and the project manager align the logistics and schedule to be able to meet demand. The largest equipment piece weighs over 60,000 lbs. with a pick and set over 100 ft. from the truck. The team have to figure the load, reach necessary for crane, before the pick can take place.
Once it is set on the skates, we pull it in with a Doosan 12K forklift. The team sets this piece, as well as over 20 others that range from 5,000 lbs. and up, into their operational positions. This requires a dance between setting some pieces in place, then waiting for others to come in before a final set and alignment is made.
The millwrights anchor each piece into the ground once the alignment procedure is done. This allows the mechanical and electrical team to start the mechanical portion of the commissioning process.
Phase II - Mechanical & Electrical Installations
Secondly, we begin to get into the mechanical and electrical phase. This phase concurrently happens as the machines load into the facility. JDI’s industrial electricians run conduit and drops to the electrical breaker systems, main feeds, and near the machinery. Our mechanical contracting team also simultaneously begins to prep and layout the duct work, airlines, and foundations for chiller equipment.
Sequentially, the electricians connect the wiring, install each breaker, and perform their startup tests. In total, our electricians wire 20 panels. Power and distribution, as well as control panels total up to 20 installations. Ran 3 1/2″ conduit, feeders, 2″ and 12″ cable trays, in addition to grounding and troubleshooting.
Ultimately, our industrial electricians brought the facility to NEC code compliancy.
Once testing is complete, thereafter the electricians LOTO the distributions for the equipment as they are not ready to operate yet. The electrical distribution system is complete, which wraps up this side of the mechanical commissioning. Next, the mechanical contracting team will finish the mechanical piping and systems side.
The mechanical teams work with the millwrights to align the two chiller units and mechanical equipment. The team create two concrete foundations, place it, and set a chimney stack and FuMax on one, and Trane chiller unit on the other. This Fumax ESP and chimney system effectively draws out fumes and scrubs them, purifying the exhaust.
Phase III - Commissioning
Once all mechanical and electrical components are complete, system commissioning can begin, where all the electrical and mechanical equipment works together as a system for the first time.
Auxiliary systems are brought online followed by major apparatus, and interfaces are verified for all equipment. Hereafter, all the systems are available and ready for startup of the plant processes.
Mechanical processes slowly start for the initial operating scenarios. Flows start and are monitored to ensure correct operation.
JDI’s crews make sure electrical interfaces are verifiable and power slowly ramps up to operating levels. Automation executes and fault scenarios are ran as well. The equipment undergoes analysis at each stage to ensure the plant process is operating correctly.
The Owner reps, Sandeep Patil and Thomas Cloarec, are present to verify correct operation of the plant process. The Aerofoam plant is now up and running and functioning to produce their products.
Tasks Included
- Move and Install 20+ Machines
- 280 Feet of Duct Work Installation
- 300 Feet of Copper Airlines and Aluminum Prevost
- 30+ Electrical Panel Installations
- Scrubber & Chimney Installation
- 500 feet of CPVC chill water lines
- Foundation and Setup of Jib Crane
- Install Power to Warehouse Outlets and Scale, Miscellaneous
- Connect Airlines and Power to Lab Room
- Perform Utility Connection of 1″ and 3/4″ City Water Lines
Results
Without a doubt, the Aerofoam USA facility will now be able to produce the foam insulation products that the U.S. markets are demanding. With this turnkey project complete, the facility now produces thousands of feet of foam products per day.
The commercial, residential, and industrial markets that need HVAC insulation now have another U.S.-based supplier. JDI’s mechanical contracting team is proud to enable Hira Industries to better serve their customers.
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