BAE Systems – a global defense, aerospace and security company — was moving its production line from a 1940s-era building into a new, world-class aviation electronics manufacturing and office center.
Enter Wiegmann Associates, one of the mechanical industry’s premiere national Design/Build mechanical contractors and experts in value engineering. Wiegmann Associates has focused on innovative, energy saving and cost-effective HVAC solutions since 1995, when Gerry Wiegmann founded the company.
As often is the case with production-based businesses, BAE needed to maintain its production lines while moving equipment and operations from an old, inefficient plant to the new facility with state-of-the-art equipment and systems. The project involved tight phasing and strict scheduling to minimize down time and avoid loss of production. In response, Wiegmann ensured that all necessary HVAC equipment, including chilled water and process piping systems, were in place on schedule to allow BAE to maintain production throughout the move.
Wiegmann designed and installed the $4.3 million design/build HVAC, process piping and controls systems solution with strict temperature/humidity controls in just 20 months, with no interruption in plant production.
The 334,000 sq.ft. building includes a nearly 50,000 sq.ft. office/support area and a 285,000 sq.ft. manufacturing production floor with complex process piping: gaseous nitrogen, compressed air, hot exhaust air and chemical exhaust air. The manufacturing processes require cooling water to keep production equipment operating within temperature tolerances.
The nearly 50,000 sq.ft. office and support space is conditioned by a rooftop unit system serving VAVs and FTUs in the space.
The manufacturing facility processes require cooling water to keep production equipment operating within temperature tolerances. Process control loops include chemical and hot exhaust ductwork, process chilled water (75F), vacuum, low-pressure compressed air (120psi), high-pressure compressed air (generated and stored at 5,000 psi and regulated to the plant at 1,500psi) and nitrogen.
The facility is served by Trane packaged 50-ton RTU’s and AbsolutAire make up air units with evaporative cooling, to maintain humidity during the winter months. The plant’s process chilled water loop is cooled via a Marley SPX cooling tower and a Sondex plate-and-frame heat exchanger. During the warm summer months, the loop is cooled by Trane split condenser chillers.
BAE Systems needed ultimate flexibility on the production floor to be able to rearrange equipment as needed for future product demand. Wiegmann Associates collaborated with the owner to design a solution that would be cost-effective without compromising the HVAC and piping systems.
Wiegmann’s solution was to install a main trunk run of duct and piping down the center of the production floor with perpendicular branches across the plant, so that equipment would never be far from a connection. Wiegmann was careful not to overdesign while still providing efficient systems.
BAE’s customers demand precise temperature and humidity controls on the production floor, with air temperature in the 72-75F range and relative humidity between 30% to 60% year-round. Rather than install humidifiers on each of multiple RTUs, Wiegmann went back to the drawing board multiple times to develop a system that would maintain consistent humidity across the production floor while minimizing equipment. They kept it simple and cost-effective by using make-up air units with evaporative cooling media, reducing the overall project cost.
Wiegmann met ASHRAE standards 62.1 for proper ventilation.
BAE needed to maintain its production lines while moving equipment and operations from an old, inefficient plant to the new facility with state-of-the-art equipment and systems. The project involved tight phasing and strict scheduling to minimize down time and avoid loss of production. Wiegmann ensured that all necessary HVAC equipment including chilled water and process piping systems were in place on schedule to allow BAE to maintain production throughout the move.
As often is the case with production-based businesses BAE needed to maintain its production lines while moving equipment and operations from an old, inefficient plant to the new facility with state-of-the-art equipment and systems.
BAE Systems, Fort Wayne, Ind.
Building automation controls:
Wiegmann installed a Delta Controls custom building management system with a VYKON JACE to allow web access. Includes Niagara customized graphics.
Product Keys to Success:
Sales – Steve Pearce, Gerry Wiegmann
Engineers – Todd Jacks, Steve Pearce
Project Manager – Bryan Kenkel
Controls Tech – Bob Phillips
Commissioning – Chad Wiegmann
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