Boutique Hotel – Ground Loop Geothermal

Boutique Hotel - Geothermal Ground Heating

Completed Entryway After First Snowfall

Through innovation in engineering Rohde collaborated with a full-service boutique to install a $10 million snow melt system to enhance their guest experience and to protect their parking structure. The design-build rehabilitation included engineering, steam fitting, plumbing and HVAC work.

The system was one of the most aggressive design solutions ever done for such a large and varied area of an outdoor structure,” said Rick Nierzwicki, CG Schmidt Managing Director. According to Nierzwicki, “I don’t believe the project would have been successful without the attention to detail by the Rohde team and their commitment to meet an extremely aggressive construction schedule.

Rick Nierzwicki

Managing Director, CG Schmidt

Customized Solution:

Design and installation of a 70,000 square foot in-slab snow melt system for the entire parking structure, including the parking deck, drives, sidewalks, stairwells and ramps. It included 25 zones and over 22 miles of buried PEX tubing.

Furnish and install steam to hot water heat exchangers, pumps, hydronic equipment, hot water piping in-slab tubing and controls for the entire snow melt system.

Major equipment supplied included a 3-stage high pressure steam reducing station, two steam to hot water heat exchangers, hot water pumps, expansion tank, glycol fill system and snow melt controls.

Addition and modification of storm water drainge for the parking deck.

Replacement of parking structure ventilation equipment with new fans along with controls to maintain ventilation rate to prevent carbon monoxide buildup.

Mercury Marine

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Gold-N-Plump Foods

Waste Heat Recovery - Gold N Plump Poultry

Custom-Heat-Pump-Uses-Waste-Heat

“As we look forward to this cost savings over time we realized that we would have gone in the same expensive wasteful direction if we had not met with Rohde Brothers, Inc. The solution that they provided in two of our locations is exactly what we’d hoped for, and that is pretty challenging to come by in today’s business environment.

Anonymous

Senior Facilities Engineer

The Rohde team fully engineered the mechanical and electrical systems to recover waste heat being generated from the ammonia cooling system for use in heating water for production sanitation needs.

Customized Solution:

  • A custom designed heat pump that is 8 times larger than what is traditionally available

  • Directly recovering heat from an ammonia refrigeration system

  • Integration of hot water heating system controls with the ammonia refrigeration controls

  • Remote monitoring and data collection

  • Rohde designed, engineered and implemented the system within 6 months, typically during scheduled plant shutdowns. Working closely with Gold’n Plump’s team, Rohde ensured integration of the new system with minimal disturbance to the existing facility and processes in place

  • Rohde engineers scaled an existing heat recovery design to accommodate the plant’s daily use of 1,000,000 gallons of 140°F water for production and sanitation

  • This is the largest heat pump heat recovery unit in Wisconsin

  • Saved Gold’n Plump $178,000 per year in energy costs

Mercury Marine

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Energy Conservation – Grande Cheese – Multiple locations

Energy Conservation - Grande Cheese

Evaporative-Cooling-Towers-w-award

“As we look forward to this cost savings over time we realized that we would have gone in the same expensive wasteful direction if we had not met with Rohde Brothers, Inc. The solution that they provided in two of our locations is exactly what we’d hoped for, and that is pretty challenging to come by in today’s business environment.

Anonymous

Senior Facilities Engineer

In just 7 ½ months, Rohde redesigned, engineered and implemented an ammonia refrigeration system expansion, with integrated controls, using the existing infrastructure. The plan was to save the client’s capital in installing a much more efficient system that not only uses less energy, but requires much less maintenance to operate between service oriented repairs. The design needed to be changed to reduce the amount of ammonia in the system while still providing the proper cooling needed for their cold storage facility. The benefit of lower pressure operations were felt by keeping the system out of the threshold of the EPA’s PSM Program, saving $30k in consulting fees.

Customized Solution:

  • Rohde’s redesign eliminated the high-pressure receiver and significantly reduced the ammonia charge required in the system. Rohde’s design reduced it to 7,000 lbs. from the initial base bid of 14,000 lbs.

  • Variable frequency drives on all components including the two new 150 HP compressors.

  • Low discharge pressure design that allowed the system to run at much lower pressure in the cooler months.

  • Redesign of all the expansion devices such that high pressure liquid was not required to get the liquid into the various evaporator coils.

  • Eliminated the need to change relief valves every five years by redesigning to remove surge drums.

  • Coil circuiting designed to carry oil back to the recirculation vessel to drain at a single point in the ammonia room rather than several points on the roof.

  • Saved the client over 38% in electrical costs and significantly reduced maintenance and operating costs.

  • Gas costs reduced by 5-10% with significant reduced maintenance costs.

  • · Eliminated the need for a full Process Safety Management program (PSM) and $30,000 in consulting fees by reducing charge holds below EPA and OSHA thresholds.

Mercury Marine

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Mercury Marine – Utility Piping Retrofit

Mercury Marine Utility Piping

Filter installation 2020-05-19

“We (Mercury Marine) are continuously modifying and adding to our operations to accommodate new engine programs. Rohde Brothers, Inc. has provided design, engineering support and installation for many of these projects in our manufacturing and design facilities. In sever of the recent addition, Rohde Brothers, Inc…to provide entire mechanical systems integration packages and added their own value engineering to reduce installed cost and operating cost while enhancing our original performance expectations,”

Stephen Mlinaz

Senior Facilities Engineer, Mercury Marine

Mercury Marine utilizes a central recirculated cooling water system for cooling components in their die casting plant. Without cooling water, components and equipment begin to overheat within minutes.  As Mercury prepared for long-term growth of the die casting operations, the need for upgrading the recirculated cooling water system became critical.  The cooling towers were maintained well by Mercury Marine, but were operating many years beyond their rated life, and were showing signs of their age.  The original system was expanded multiple times through the decades, with multiple supply and return lines in each of the utility tunnels.  Rohde worked closely with Mercury Marine to upgrade the system over a three year period with new cooling towers, pumps, controls, piping, and filtration equipment processing up to 2,330 gallons of water per minute. Changes in die casting technology required improved filtration to prevent plugging of die cavities and ineffective part cooling, which resulted in significant downtime, loss of productivity, and defective parts.

The Rohde team completed a sequenced rebuild of a plant-wide recirculated water cooling system for their aluminum die-casting operations, with no disruption to plant production. Water flow rates were reduced to allow for lower pumping energy costs and improved water quality, leading to reduced maintenance costs.  The phased upgrade of the system started with replacement of one cooling tower in a temporary location.  Sequential replacement of the entire network of supply and return piping for the system was started after the first cooling tower was replaced.  Installing new piping while maintaining flow of water to the plant with highly congested utility tunnels required careful layout and review off every piping system within the plant.  With the piping replaced and new cooling towers in place, planning for the permanent system installation started.  The final phase of the project included replacement of the pumps and controls along with relocation of the cooling towers to a permanent location on the roof of the plant.

The Rohde Customized Solution:
  • Replaced cooling towers sequentially first in temporary location and then final location to maintain plant operations

  • Replaced recirculated cooling water piping in the tunnels serving more than 30 die cast machines

  • Added and upgraded piping at die cast machines as individual cells were added or reconfigured

  • Replaced the original side stream strainer with two full flow multi-bag filtration units.

  • Allen-Bradley Micrologix control system integrated with the plant Factory Talk SCADA system

  • Careful planning and coordination with plant operations to complete the installation without disruption of plant operations

  • Ongoing monitoring and maintenance of the complete system to ensure peak efficiency and performance

Mercury Marine

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Johnsonville, LLC

Johnsonville USA - Ongoing Partnership

Since the construction of the Johnsonville plant in the early 1970’s, Rohde Brothers has worked with Johnsonville Sausage’s engineering department to support small and large projects throughout their multi-plant meat processing campus.

Rohde Brothers has embraced this partnership as an opportunity to bring value to the table and provide ingenuity in all solutions presented whether it be as small as a control program change of the corporate office HVAC systems, to process and waste water treatment plant installation and maintenance projects.

The Meadowside Plant Expansion is a great example of this partnership. Rohde completed the HVAC work for the 81,600 square foot expansion that included ventilation, controls and steam piping for new custom cook equipment.

Rohde maintains a presence with Johnsonville as a valued partner in their operations and maintenance programs. 

The Rohde Customized Solution:
  • Identified engineering and detailed application issues while maintaining effective communication and coordination with trades

  • Created unique solutions that work as planned for custom cook equipment ventilation, installation of process ventilation, steam, and gas service to new production dual-spiral cook oven

  • Executed work under tight deadlines, all while remaining ever-mindful of customer’s large scale plant shutdowns

  • Installation of HVAC, electric controls (DDC hybrid), and high pressure steam piping for industrial process areas

  • Installation of HVAC for engine room and hot water heater room additions

  • Installation of stainless steel flues for CIP water heaters

  • Installation of source capture carbon dioxide gas exhaust system for process blender equipment

  • Ductwork in food production areas is all heli-arc welded stainless steel

  • Design assistance, fabrication, and installation of process utilities to cook oven including high pressure steam service to spiral oven and freezer, natural gas service, flue gas piping to eight (8) industrial burners, and three (3) gravity stacks on the spiral oven, and combustion air ducting to spiral oven

Johnsonville

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