Industrial / Renovation
Project: Industrial plant in South Carolina
Building Size: 1,000,000 sq ft
Building Type: Industrial Manufacturing Plant
Overall Project Budget: $3,000,000
General Description of Project: This project involved the replacement of twelve large air handling units serving the main manufacturing floor of the plant. The project also included adding one new chiller, condenser water pump, two new cooling towers and up-grading the building automation system. The intent of the project is to increase product quality by providing better temperature and humidity control to the manufacturing areas. All balancing work was performed during normal operation of the plant.
The supply air distribution design presented considerable challenges to accurately measure and balance the airflow. However, innovative solutions were provided by the TAB personnel that were proven to be repeatable and met the accuracy required by the design engineer. All supply, return, outside, and exhaust airflows were balanced to design quantities. The new exhaust air recirculation systems were tested and balanced to the required airflow values. All hydronic pumps, chillers, and cooling towers were balanced to required values. The TAB personnel also assisted with the calibration and problem resolution of the up-dated building automation system.
Systems Balanced Are:
- Twelve large air handling units (each unit 30K CFM or greater)
- 300 supply air outlets
- 16 return air inlets
- 4 large exhaust fans (each unit 30K CFM or greater)
Tasks Included:
- Development of the Project Plan
- Scheduling of all Testing
- Updating of as Built Drawings
- Coordination with the Design Engineer on Existing HVAC Issues
- Balancing of all Supply, Return and Exhaust Airflows
- Calibration of Airflow Stations Serving the Supply, Return and Outside Air
- Final Testing and Adjustment of the Air Handling Units
- Final Testing and Adjustment of the Chilled and Condenser Water Pump Flows
Special Challenges and Accomplishments:
All work on the unit was performed during plant operation. Balancing of the supply, return and exhaust air distribution was performed during normal hours by coordinating all work with the production staff and maintenance manager. During the project it was discovered that the existing building mechanical prints were not accurate, the prints were up-dated to reflect the actual installed condition. The TAB personnel then worked with the design engineer to produce new balancing criteria at no additional cost to the owner.