Industrial Equipment Replacement

Air House & Regenerative Thermo Oxidizer (RTO) Replacement Project

Background

• Customer/Location: Paint facility located in West Michigan
• This paint facility is primarily an automotive-based tier 1 supplier and was facing a dilemma. The dilemma was knowing that replacement of their aging HVAC & RTO system was badly needed, but downtime available was very limited due to an extremely high production demand.
• Throughout the budgeting and design process, production continued to ramp up, which meant the allowable downtime continued to shrink.
• The original downtime shrank from 3 months, to 2 months, to 2 weeks, and finally to just 9 days.
• Due to the above time constraints, a total re-design was incorporated to perform the following:
  • Install a single structure/stand next to the plant
  • Install a mechanical room at the base of the new structure
  • Demolition of existing regenerative thermal oxidizer (RTO)
  • Install a new RTO
  • Installation of (6) new Air Houses
  • Demolition of existing Air Houses
  • MEP installation inside mechanical room
  • Energy Management Controls
  • Replacement of roof-mounted exhaust fans and stacks
  • Duct across the roof
  • Plumbing of mechanical room and mechanical room equipment
  • Nine day change over to new system including the demolition of existing

Objective

Upgrade the system to meet the new design parameters of 70°F at 70% Relative Humidity for all units and zones, including as basis for Humidification for 100% Outdoor Air units.

Equipment

• Recirculating Air House:
  • Booth #1 › 60,000 CFM Design basis
  • Booth #2 › 60,000 CFM Design basis
  • Booth #3 › 40,000 CFM Design basis
• 100% Outdoor Air House
  • Booth #1 › 30,000 CFM Design basis
  • Booth #2 › 30,000 CFM Design basis
  • Booth #3 › 40,000 CFM Design basis
• 340 Ton Heat Reclaim Chiller
• 390 Ton VFD Screw Chiller
• 150 H.P. Humidification Boiler
• RTO
• RTO Heat Reclaim Coil
• 13 Pumps with VFD's
• Energy Management Controls
• Cooling Tower

Results

• Completed the project in 8 days!
• Product First Time Thru (FTT) rate improved on day one
• Elimination of Boiler System previously required for heating
• Increased quality of product
• Greatly improved system control
• And much more!