In 1998, Parke-Davis began preparation for a $300,000,000 expansion program at their Ann Arbor facility. The Parke-Davis complex is a 1M square foot campus of research and testing labs, administrative offices, and support facilities with 3000 employees in sixteen buildings. Many of the labs are 24-hr., 7-day operations. Prior to beginning the expansion, the underground utilities required relocation and increased capacity.
The project consisted of electrical and communication ductbanks, adding 15KV switchgear to the existing 15KV primary electrical service line-up, 15KV cable, outdoor 15KV switching units and the redistribution of the existing 15KV loads. Safety and coordination were major issues as primary cables were pulled into existing manholes and vaults containing energized primary cables.
Cutting over existing 15KV loads required error-free planning and coordination. Over 60 primary cables were successfully spliced during the final phase. Most splices were executed in manholes and other very restricted working quarters. The project was completed on time and on budget.
New switchgear was added to an existing line-up with no downtime to existing critical operations
15KV Primary cables were reworked in existing cable vaults. Over 60 primary cables were spliced in the course of cutting over to the new distribution system.
The Rouge River Wet Weather Combined Sewer Overflow Basin Demonstration Project/City of Inkster Retention Basin was the first of a multiple of similar basin projects across SE Michigan in the 90's. Its purpose was to curb overflows of storm/sewage into the Rouge River by intercepting the storm drains and diverting the waste- water through a pumping, disinfecting, and storage facility. The project consisted of screening, pumping, and a 3.3 million gallon underground storage basin. The facility was designed with basketball courts/restrooms over the basins for public benefit. The facility's process control, security, fire alarm, and electrical systems are completely automated and are operated/monitored from an off-site central office.
The service under construction consisted of a double- ended substation with one end fed via Detroit Edison 13.2kv and the other via 2 transfer switches fed from 2-2000kw diesel generators in an outdoor courtyard.The substation is automated for electrically-operated transfer between mains/ties/and feeder positions.Feeders include those to 6-600hp pumps.
Installation of an “Accusonics” 10-path flowmeter in the twelve foot tall influent channel feeding the wet well of the CSO Basin.The influent, wet well, and effluent chambers’ electrical installations are installed per N.E.C. Article 510 Hazardous/Classified locations.
The project consisted of building a new water treatment plant for the Marion, Howell, Oceola, and Genoa Sewer & Water Authority (MHOG). The major components of the project were:
Site improvements.
Underground utilities.
Pumps.
Sand filtration equipment.
Lime storage & transport.
Carbon Dioxide storage & dissolution equipment.
Power distribution equipment, Lighting, Stand-by diesel generator, Instrumentation, & SCADA system utilizing Allen Bradley PLC's.
Laboratories
Offices
No Problems with lay down areas for the construction of the MHOG Water Treatment plant. The plant was built on what used to be a large cornfield.
The maze of embedded conduits feeding feeding equipment with power, control and instrumentation is made easy with detailed working drawings engineered by Shaw's project management team.
This state-funded project is part of the phase I Combined Sewer Overflow (CSO) elimination program. The successful completion of this project will help prevent storm water mixed with sewage from being dumped into the Clinton River during extreme storm conditions. The 480 volt, 2000 KW generator will parallel the plants existing Detroit Edison service and provide them with enough power to run the entire facility during a power outage.
One of the difficulties in the installation of this project was tying into the existing switchgear. The project required a stainless steel enclosure for housing a new main breaker, automatic transfer switch and a bypass switch. This enclosure, designed by Shaw Electric Co., is 8.5 feet high by 7 feet deep by 12.5 feet wide. Limited access and 24-#600KCMIL cables run in parallel through this enclosure made for a challenging installation.
A 2 Megawatt motor generator arrives on site. Today's work assignment is pretty clear.
Installation of large gensets requires a great deal of pre-planning to make it look this easy. Pad layouts, anchor positions, underground conduits, and more must be laid out in advance for a smooth install.
The project consisted of implementing a department wide supervisory controls & data acquisition system. This system was integrated to the departments existing distributed control system at the Mount Clemens Waste Water Treatment Plant. Moscad Motorola SCADA Remote Terminal Units were used. Major Components of the job included:
Installation of RTU/Radio's
Installation of Antennas & Coaxial Cable for RTU's
Rebuilding of and adding pump control panels
Rewiring & reprogramming of distributed control system at WWTP
Programming of RTU's
Checkout & testing of system
The installation of New Moscad Motorola SCADA Remote Terminal units at existing underground pump station.
Mounting of new RTU and antenna on existing utility pole in line of site of Repeater tower.
This storm water pump station was constructed as part of the Wayne County pollution control program. Huron Valley Pump Station 1A is a critical part of Wayne County’s overall plan to reduce storm water run off into the Rouge River. The project included new Detroit Edison primary feeds that had to be brought in from the D.E.CO substation and a new 1500KW Caterpillar Diesel generator with automatic transfer switching. New power distribution equipment was installed, including a primary transformer and a switchgear lineup. The MCC included soft starters for five-150 horsepower motors. A full SCADA system was a part of this project, integrating the outfall RTU for Detroit Water & Sewerage Department with Wayne County’s system monitoring control room at their Henry Ruff facility.
The pump station building was constructed over the top of the 12 feet division chamber and the wet well which made for a challenging installation of underground conduits.
The storm water pump station construction included the installation of a 1500KW standby generator.
The project consisted of a large renovation to the existing Northfield Twp. Waste Water Treatment Plant. The major componets of the project were connection and installation of:
Final settling tank.
Aeration tank.
Primary settling tank.
Automatic backwash filter.
Coarse bubbler diffusion equipment.
Digester, Boiler.
New filter building.
New screenings facility.
New MCC's.
New Lighting.
Instrumentation, Bubbler system, Magnetic flow meters.
Connection of new equipment to plants existing SCADA system
A crowded construction site and the obstacle of not interrupting operations of the plant made proper scheduling of construction critical to the success of this project.
Installation of PVC-coated RGS conduit & fittings for use in Class I, Div. I, Group C & D environments. Was used to power up and control the new screenings equipment in this
facility.
The 1994 upgrade of DWSD's Oakwood Pumping Station entailed the complete renovation of the electrical and instrumentation systems as well as architectural and mechanical modifications. Originally constructed in 1928, the facility consists of switchgear building with 1920's vintage switchgear and a pumping station with (8) high voltage pumps ranging from 150 to 450 horsepower.
The original bid schedule called for the replacement of half of the high-voltage switchgear and half of the high-voltage pump starters in one phase and the balance in the second phase. Due to the critical nature of the station's operation, only two pumps could be out of service at any time.
Shaw's foreman, Tony Goddeeris, proposed an alternative installation method in which the switchgear building was temporarily isolated from the Edison service. This innovative plan maintained the pump station operation, reduced the overall project duration by six months, and provided a safer work environment during construction around the 4800 volt open bus. For his effort and proactive planning Tony Goddeeris was nominated for the Walbridge Aldinger Quality Achiever Award in 1996.
Installation of new switchgear in cramped quarters would have been even more difficult if Shaw had not proposed bypassing the switchgear building with temporary prior to demolition.
Much of the existing cable vault had not been upgraded since the pumping station was originally built in 1928
This project consisted of constructing a 2.8 Million gallon reinforced concrete combined sewage overflow detention facility within Eliza-Howell park. Approximately 4000-feet of 12-feet diameter influent sewer was constructed extending from Puritan Avenue to the new basin. Major Components of the job included:
2.8 Million Ga. Concrete Basin.
4,000' of 12' Diameter Sewer.
550' of Dewatering Sewer.
Control Building.
Process piping including in basin flushing system, Odor control system, Dry weather & dewatering pumps, Chemical system & mixers, Bar screens & conveyors.
Electrical Switchgear, MCC's Stand-by diesel generator, Lighting, A real time distributed control system, Main control panel, Fire Alarm, & Security systems .
Tennis Courts & New Playground.
Unique in design the control building is constructed over the top of the 12-foot diameter influent tunnel. Switchgear, MCC’s, a DCS and a Stand-by Diesel Generator requiring underground conduit penetration made for a challenging installation.
This below grade utility service tunnel was constructed in phases. It required the use of Class I, Div. I Group C & D Explosion Proof Equipment & Raceways
This project was a joint venture effort between Chapel Electric of Dayton, OH and Shaw Electric Co. The building is a six-story facility with one additional level below grade comprising 130,000 sq. ft. of office and laboratory space.
Power to the facility is from two Detroit Edison 4800 volt feeds to 3,200 amp. switchgear. Two 900 KW emergency generators provide emergency backup.
The 1st, 2nd, 4th, and 5th floors are primarily labs and research work areas. The 3rd floor contains office areas and classrooms. The 6th level is a full floor penthouse containing extensive air-handling equipment required to maintain the clean, controlled atmosphere in the research areas. The facility also includes a linear accelerator in the lower level and two Level 3 Bio-Safety Labs. The construction of these two labs was very exacting due to the intended usage. They operate under negative air pressure and utilize airlocks for entry and exit.
The Research building had restricted access on three sides of the facility, requiring close coordination of all trades when moving materials into the building.
The Research building contains state of the art equipment commensurate with a world class facility.
In 1997, William Beaumont Hospital found itself in critical need of additional mechanical and electrical services. Beaumont decided to expand their powerhouse, add a third 15KV electrical service from Detroit Edison, and make provisions for a future fourth service. The project also included a third 15KV primary switchgear line-up, high-voltage bus duct ties between the two existing 15KV primary switchgear line-ups and the new switchgear, an automatic throw-over control scheme, and balancing the existing loads over the three line-ups. Shaw Electric Co. was assigned the task of installing the ductbanks, 15KV switchgear and 15KV cable for the new services as well providing the electrical installation the expansion of the powerhouse.
Shaw Electric worked under a very demanding schedule on this project. The electrical installation had to be completed before Detroit Edison completed the third service and prior to completion of the new Heart Center. Of even greater concern was the redistribution of all existing loads over the now-energized three services without shutting down critical operations. There were approximately 45 primary cables that were relocated, spliced or had new cables pulled in as replacements. 42 cable splices and 90 stress cones were installed without a failure.
Key to the success of this extremely complex project was the planning and coordination effort of the entire construction team: Beaumont Hospital, Harley Ellington Design, Detroit Edison, Centex Aim, and Shaw. Shaw's foreman, Mr. Tony Goddeeris, worked closely with the owner to determine phasing and cutover schedules for the load redistribution work. It was through these efforts that this project was completed on schedule.
Some of the 20,000 feet of underground PVC and rigid steel conduit installed for the primary system upgrade.
Over 35,00 feet of
primary cable installed, fireproofed, and terminated on schedule
Shaw was the electrical contractor of choice on the expansion of the Macomb Hospital Center in Warren, MI. The project is comprised of an 85,000 square foot, three story building addition and related peripheral work. This infrastructure will support an additional 2 stories in the future.
The lower level consists of mechanical spaces/equipment, labs, sterilizers, decontamination rooms and other support facilities. A new double ended substation, transfer switches, distribution panels, and motor control centers were installed to distribute normal, critical, and life safety power.
The first floor contains 43 pre-op/recovery cubicles, 9 operating rooms, sterile cores, nurse stations, waiting areas and operating support areas.
The existing electrical plant was also upgraded by adding a single ended substation, chiller, cooling tower, and related supporting pumps.
Upon completion of the original expansion project, Shaw was selected as the electrical contractor for the fit-up of the second floor, consisting of 17 ICU rooms, 12 step-down rooms, nurse stations, family waiting, and support areas
The Surgery Addition added nine operating rooms complete with state of the art equipment, isolation power, and systems.
The project includes a new main entrance canopy and revolving doors. The parking lots were expanded and new lighting installed by Shaw. This project was selected as Year 2000 feature projects by CAM Magazine as 1 of 12 most unique/complex projects.
Henningson,
Durham, Richardson Inc.
Omaha Nebraska
Prime Contractor:
Walbridge
Aldinger Co.
Contract
Value:
$4,165,000
Project
Manager:
Randy
Block
Project
Foreman:
Tony
Goddeeris
Completed:
October,
1999
The new Cancer Center houses 4 Angioplasty/Heart Catheterization labs.
A sample of one of four radiology labs which shaw installed the x-ray duct in-wall, in-floor, above ceiling, and below floor per each piece of medical equipment's particular configuration.
This project was one of Shaw Electric Co.'s "Most Difficult" Projects. In the summer of 1998, Walbridge Aldinger awarded Shaw the electrical contract for Oakwood Hospital's main campus "Facility Upgrade" project in Dearborn, MI. This 3 year, 36 phase/work area project consisted of selective renovations to 100,000sq. ft. over 3 floors. It included a new Emergency Dept., new Cancer Center, and new OT/PT Dept., in addition to the renovations.
The project's A/E was stationed out-of-state without on-site representation. The design documents were developed from sketchy as-built information from past projects. Dimensions and conditions could not be verified until demolition of an area revealed the concealed conditions.
Each and every phase included relocating staff. Shaw worked a variety of shifts in each of 36 phases/work areas to minimize any disruption to the owner's continual operation. Contractor site offices were located North of Oakwood Blvd. and no on-site parking was allowed. All equipment was stored off-site at Shaw's Livonia warehouse and shipped to site
J.I.T.
Shaw furnished and installed:
15 exam lights with engineered structural supports.
33 X-ray film illuminators averaging 4' x 4'.
2,300 light fixtures.
An existing single ended substation was double-ended. The new
switchgear had to be completely disassembled to transport it to its location in the lower level.
Variable frequency drives for existing AHU's.
One non-designed scope addition to the project occurred when the authorities having jurisdiction mandated the owner upgrade their fire alarm/life safety system in each renovated area to measure up to BOCA prescribed dB levels for audible/visual signaling devices. Head end equipment could not support this expansion, so Shaw worked closely with Seimens/Cerberus to design and install enhancements against time to catch the phases up to codes and not delay owner occupancies.
Another scope addition was to retain Shaw Electric Co. to 'fit-out' each new medical
lab for the pre-purchased/owner selected medical equipment vendor. This included extensive x-ray wiring ducts, conduits, wiring, grounding, feeders, and final connections to the specialty equipment. A list of labs installed by Shaw include:
2 - G.E.M.S. Adv 100/LFX Cath Labs in the new Cancer Center.
2 - Philips Integris H5000F Cath Labs in the new Cancer Center.
Shaw was selected as the GMP/Design Assist electrical contractor for St. Johns New Cancer Center. Shaw participated in the development of construction specifications and drawings from a design narrative to completion, incorporating proven electrical construction techniques, materials, and methods to the design/construction documents.
The state-of-the art facility offers the public alternative medicine, spiritual healing, and traditional oncology-related care. The facility holds 2 linear accelerators, 2 CT Simulators, 1 High-dose Radiation Vault, 2 Radiographic Rooms, 2 Mammography Rooms, and 52 Exam/Infusion/Treatment Rooms. A Boutique, Healing Garden, and Life-Enhancement Center offers staff trained in special diets, acupuncture, therapy, herbology, hypnosis, pain management, massage, etc. for holistic assessments.
Shaw Electric Co. coordinated closely with the owner's multitude of medical equipment vendors in installing the specialty electrical for their equipment. The facility includes an extensive occupancy sensor system for energy management of the lighting system.
The 70,000 SQ FT., 3 story addition is connected to an existing occupied commercial building on Mack Avenue.
The Project includes many specialized procedure rooms dedicated to providing leading edge treatment to cancer patients.
Fast track design and construction was critical on this project. When the building slabs were being poured the electrical drawings were only preliminary, yet there were several conduits required for each MG set that had to be in the slab. Conduits were sized and placed only hours before slabs were poured. Despite the pace, virtually no rework was required.
The entire project, from groundbreaking to full operation, was completed in less than five months. This project was one of the early projects by an IPP (Independent Power Producer) in the Detroit Edison service area. The electrical power generated is sold to Detroit Edison.
One of ten 1 Megawatt generating units installed at the City Sand site. Each unit runs on the filtered and dried methane gas produced by the City Sand landfill.
External fan-cooling radiators for the ten 1MW motor generators