During the design phase, the entire design-build construction project was modeled in 3-D computer simulation. This allowed for the assembly of detailed fabrication isometrics in less than half the normal detailing time.
Much of the fabricated piping was preassembled into a large module, complete with a catwalk modular hanger system. This was then installed in the compressor room as a single assembly—saving significant time and labor due to the elimination of the extensive, field installed, piping assemblies normally required for this type of room.
In order to meet the enormous production demand that resulted from a large US Military order, AmeriQual needed to expand an ammonia refrigeration system for a large –55°F warehouse, two dock areas, and two –10°F freezer spaces.
Scope of Services
Shambaugh designed and installed a centralized, single stage, ammonia refrigeration system which centered around two liquid recirculation packages each mated to a single stage compressor.
One package handled the high temperature rooms (warehouse/docks), and the other was dedicated to the –10°F freezers. Evaporators located in each of these areas were fed with pumped liquid from the re-circulators.
High temperature evaporators were added to the production rooms to augment the capacity of the existing air handlers in the “old” Evansville building. Finally, a new state-of-the-art ammonia refrigeration PLC control system complete with a graphical interface and trending capabilities was installed to operate the system.
In addition, Shambaugh & Son installed:
- A new centralized ammonia refrigeration system design and installation to support ingredient and final product storage
- Extensive use of 3-D Computer Modeling Software for the assembly of fabrication drawings
- Assembly of a Modular Hanger System to minimize field installation of the engine room piping
This particular construction project was challenging due to the plant remaining operational during the expansion. Additionally, the construction project schedule was compressed to meet the owner’s stringent delivery requirements. In order to address these challenges, Shambaugh relied upon its mechanical fabrication facility in Fort Wayne, Indiana for all of the prefabrication and modular construction services.
AmeriQual Foods, LLC, a major food processor for the US Military and other private companies, found itself in need of expanded cold storage and warehouse space after the military ordered a large amount of MREs (Meals Ready to Eat).