Customized Solution:

• Rohde used 3D building information and shop prefabrication to the fullest extent possible in order to reduce field manpower requirements, increase the speed of project delivery, and to ensure space was allocated to fit everything required by all contractors including plumbing and electrical contractors
• Allen-Bradley programmable logic control system was employed at the facility to continuously monitor and control the entire system to ensure safe and energy efficient operation
• Rohde fabricated a variety of system components in our shop including ductwork, piping, and control panels
• Rohde built subassemblies as large as practical considering trucking and material handling requirements. Building components before space on site was available helped us maintain the demanding project schedule
• Rohde installed all components for the freezer including:

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.

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

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.

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