Client: Tinker Air Force Base
Contractor: Honeywell Building Solutions
Year: 2017 – Present
Status: Active
Location: Oklahoma City, OK
Industry: Aerospace & Defense
Description: Providing Honeywell Building Solutions (Honeywell) with design-build services to address multiple Energy Conservation Measures (ECM). Services include the design, build, installation, and commissioning of new automation and control systems, motorized tank covers, and ventilation system modifications for various surface finishing, cleaning and stripping process lines, paint booths, and thermal spray booths throughout Tinker AFB’s Buildings 9001 and 3001 manufacturing facilities. All the ECMs involve management of equipment operating modes (Inactive, Standby, and Active) to reduce ventilation requirements and energy usage. ECM One (1.2) includes the addition of tank covers on Miscellaneous Process Tanks and installation of electric heaters in select tanks as part of a program to phase out steam heating in Buildings 3001 and 9001. ECM Two (16.7) includes modifications to three (3) major Paint and Surface Preparation Booth exhaust systems, makeup air units (MAUs), and lighting systems to reduce energy usage and improve booth reliability. ECM Three (16.8) includes modifications to Thermal Spray Booth exhaust system controls to reduce ventilation energy usage. ECM Four (16.19) includes the addition of innovative ventilation system controls, on an existing automated Chemical Cleaning Line, to reduce energy consumption and enhance environmental conditions. The control system varies ventilation rates with the use of automated dampers on process tank ventilation hoods by monitoring operating conditions (operating temperature and agitation) based on variable air hazard ratings as a function of changing conditions. ECM Five (16.21) includes the addition of automation and control systems and replacement of existing ventilation systems on the Building 9001 Phosphoric Acid Anodizing (PAA) Line. ECM Six (16.22) includes changing existing process tank ventilation systems to push-pull and the addition of automated dampers to control ventilation rates on another automated Chemical Cleaning Line.
Keywords: Design-Build, Paint and Surface Preparation System Upgrades, PAA Process Line Upgrades, Industrial Ventilation Optimization, Energy Use Reduction, Energy Savings Performance Contracts
Client: Rock Island Arsenal – Joint Manufacturing Technology Center
Contractor: Honeywell Building Solutions
Year: 2014-2017
Status: Complete
Location: Rock Island, IL
Industry: Aerospace & Defense
Description: Provided design-build services for multi-phase renovation and modernization of the Rock Island Arsenal (RIA) Joint Manufacturing & Technology Center (JMTC), Building 212 Surface Finishing Plant, in Rock Island, IL under an Energy Savings Performance Contract (ESPC). The project required development of a master plan for phased demolition and construction with no lost production. The project resulted in reduction of ventilation from 500,000 cfm to < 40,000 cfm while also adding new processing capabilities. The savings were realized by (1) right sizing and vertical orientation of equipment; (2) integration of an innovative ventilation system, which included automated tank covers and ventilation dampers with priority-based constraints that limit the number of covers that could be opened concurrently; and (3) automated management of equipment operating modes (Inactive, Standby, and Active) to reduce ventilation requirements and energy usage. ITI’s work scope included project planning, engineering and design, equipment fabrication and FAT, installation, functional and process commissioning, and training. The manufacturing capabilities of the JMTC include a plating department, which applies surface finishes to its products. This area can process components from the very small to up to 20 feet in length. Surface finishing process capabilities now include: cadmium, chromium, copper, nickel, lead alloy, and zinc electroplating; Type I, II, and III anodizing; light and heavy zinc and manganese phosphate coatings, black oxide; conversion coating for aluminum, cadmium and zinc substrates; titanium and aluminum etching; and stainless-steel descaling and passivation.
Keywords: Design-Build, Pre-Paint System Construction, Surface Finishing Process Lines, Process Optimization, Industrial Ventilation Optimization, Energy Use Reduction, Energy Savings Performance Contracts
Client: Carpenter Technology Corporation
Contractor: N/A
Year: 2014
Status: Complete
Location: Reading, PA
Industry: General Manufacturing
Description: Provided engineering design services, equipment fabrication, commissioning, construction management, and training for a new Acid Pickling Process Line at their facility located in Reading, PA. This new line replaced the existing Acid Pickling Process Line, which was a manually operated batch process, installed in the 1940’s. The new pickling line is fully-automated, continuously operating, and in a new, approximately 20,000 square ft. building specifically constructed for this project. The main components for the new line are a crane system, control software, salt bath furnace (provided by Carpenter), process tanks, ventilation system, and ancillary process support systems. The new line will pickle and coat wire coils of stainless steel (nickel and cobalt based alloys). Coil sizing can vary greatly with coil diameters up to 65” and load weights up to 6,500 pounds. The new line is designed for continuous operation, 24 hours per day, 7 days per week, and 365 days per year.
Keywords: Surface Finishing Process Lines
Client: NORDAM Group
Contractor: N/A
Year: 2014
Status: Complete
Location: Tulsa, OK
Industry: Aerospace & Defense
Description: Provided engineering design services, equipment fabrication, installation, commissioning, and training for a new Phosphoric Acid Anodizing and FPL Etch Process Line at NORDAM’s facility located in Tulsa, OK. ITI designed and built this new fully-automated and continuously operating line in a new building area that was specifically constructed for this project. This wet process line is integrated with a power & free conveyor system feeding paint and curing operations with automatic transfer between systems. The main components for the process line are an automatic crane-hoist system, control software, process tanks, ventilation system, and ancillary process support systems. ITI also provided a deck grating system to be constructed over the secondary containment pit around the process line. This new line enables NORDAM to process aluminum sheets with an individual load weight up to 1500 pounds per flight bar with the capacity to simultaneously process up to five flight bars.
Keywords: Surface Finishing Process Lines
Client: Moen
Contractor: N/A
Year: 2013
Status: Complete
Location: Sanford, NC
Industry: Appliances
Description: Provided process control improvements for a return-type automatic plating line with an integrated powered conveyor controlled by a ControlLogix PLC. These control improvements included the addition of FlexTime PC-based software and configuration for automatic control, data logging, alarming, and integration with a total of four new HMIs. The system was designed to read and identify specific racks equipped with RFID tags as they were loaded on the line.
Keywords: Data Acquisition System
Client: Lancer
Contractor: N/A
Year: 2012
Status: Complete
Location: San Antonio, TX
Industry: General Manufacturing
Description: Provided turn-key Stainless Descale and Passivation Process Systems at the LancerMex manufacturing facility. In addition to the state-of-the-art process systems, ITI provided ventilation and scrubber systems and water and wastewater treatment systems to support the Stainless Steel Descale and Passivation Process Lines.
Keywords: Surface Finishing Process Lines
Client: OKAY Industries, Inc.
Contractor: N/A
Year: 2011-2012
Status: Complete
Location: New Britain, CT
Industry: General Manufacturing
Description: Provided an Evaporation System for the Electropolish Line, which was designed and fabricated as a pre-assembled module and accessory waste minimization components, which were then installed by OKAY.
Keywords: Environmental Systems
Client: Snap-On Tools
Contractor: N/A
Year: 2011
Status: Complete
Location: Elizabethton, TN
Industry: General Manufacturing
Description: Provided the design and fabrication of the equipment needed for automated, chemical makeup system.
Keywords: Process Control Systems
Client: OKAY Industries, Inc.
Contractor: N/A
Year: 2010-2011
Status: Complete
Location: New Britain, CT
Industry: General Manufacturing
Description: Provided a temporary Electropolish Line, which was designed and fabricated as a pre-assembled module and accessory waste minimization components, which were then installed by OKAY.
Keywords: Surface Finishing Process Lines
Client: OKAY Industries, Inc.
Contractor: N/A
Year: 2010
Status: Complete
Location: New Britain, CT
Industry: General Manufacturing
Description: Provided turnkey, design-build services, which involved electropolishing system process improvements and water use reduction. These improvements consisted of a new aqueous cleaning and rinse system installed prior to the electropolish process, a new rinse system installed after the electropolishing, and enhancements to existing wastewater evaporation systems.
Keywords: Surface Finishing Process Lines
Client: Sikorsky Aircraft Corporation
Contractor: N/A
Year: 2009
Status: Complete
Location: Stratford, CT
Industry: Aerospace & Defense
Description: Provided a turnkey self-contained water dip tank for air leakage inspection of helicopter blade components.
Keywords: Test Systems
Client: Sikorsky Aircraft Corporation
Contractor: N/A
Year: 2008
Status: Complete
Location: Shelton, CT
Industry: Aerospace & Defense
Description: Designed, fabricated, and installed a turnkey self-contained cleaning station with rinse water recycling systems. The station is used for overhaul and repair of helicopter components.
Keywords: Process Cleaning Systems
Client: GE Water
Contractor: N/A
Year: 2008
Status: Complete
Location: Marlborough, MA
Industry: General Manufacturing
Description: Provided engineering services for the design and fabrication of a turnkey control system for water testing of membranes.
Keywords: Test Systems
Client: Goodrich Sensors and Integrated Systems
Contractor: N/A
Year: 2008
Status: Complete
Location: Vergennes, VT
Industry: Aerospace & Defense
Description: Provided engineering service for the design and manufacture of a data acquisition and monitoring system for the surface finishing of aerospace parts. The data acquisition and monitoring systems were required to meet the Nadcap accreditation standards.
Keywords: Data Acquisition System; Process Control Systems
Client: Lytron
Contractor: N/A
Year: 2008
Status: Complete
Location: Woburn, MA
Industry: General Manufacturing
Description: Provided engineering services for the design and fabrication of a control system for water testing of production parts in a water recirculation system.
Keywords: Test Systems
Client: Hubbell Die Casting
Contractor: N/A
Year: 2007
Status: Complete
Location: Moultrie, GA
Industry: General Manufacturing
Description: Design, fabricated, and installed a turnkey wastewater evaporation system and vibratory recycling system.
Keywords: Environmental Systems
Client: Astroseal Products Mfg. Corp
Contractor: N/A
Year: 2006 – 2011
Status: Complete
Location: Chester, CT
Industry: Aerospace & Defense
Description: Designed and constructed a closed-loop chromate conversion coating process for aerospace composite conducting materials, including copper and aluminum. The process system included an integrated DI water and vacuum evaporation recycling system without a drain connection to a POTW.
Keywords: Surface Finishing Process Lines, Approaching Zero Discharge (AZD)
Client: REM Chemical
Contractor: N/A
Year: 2009
Status: Complete
Location: Southington, CT
Industry: General Manufacturing
Description: Provided engineering services for the design and fabrication of a rust preventative station and transfer tanks.
Keywords: Process Control Systems
