OPTIMUM OPERATING FACILITY

INDUSTRIAL

At Engineered Air Balance, our team is specifically trained, equipped, and technically astute to the unique needs of the Industrial industry. Our experience has spanned from petrochemical facilities to nuclear power plants to manufacturing facilities to pharmaceutical operations and technology production. 

Our past projects include nuclear weapons production cleanrooms, industrial hydronic process control, industrial ventilation and even cooling systems for nuclear power facilities.  

In addition to our technical experience, our team understands the unique regulatory, safety, and security requirements that are present in these facilities. 

Texas Instruments RFAB2Texas Instruments RFAB2

EAB was honored to be a part of Texas Instruments’ newest project, RFAB2. Spanning an impressive 630,000 square feet, this 300-millimeter wafer fabrication facility strengthens the future growth of semiconductor manufacturing. The Texas Instruments RFAB2 facility achieved the LEED v4 Gold certification from the U.S. Green Building Council. According to Texas Instruments, “It’s the first semiconductor factory in the United States and fourth in the world to achieve this certification.”

Located in Richardson, Texas, the RFAB2 facility’s intricacies demanded meticulous attention to detail. EAB took on the challenge of testing and balancing the mechanical air and water systems, including vital components like the Deionization (DI) and Reverse Osmosis (RO) systems. This mission was essential to create the ideal environment for semiconductor production.

The facility is divided into three levels: the Sub-fab, Wafer-fab, and Truss. The Sub-fab contains critical tools and equipment to support ISO 5 wafer-fab processes, while the Truss level houses essential fan filter units and cooling coils. The facility’s rooftop boasts two decks, one for scrubbers to purify process exhaust and another for make-up air units that maintain a constant 47°F supply air dewpoint temperature, ensuring precise operation of the sensible cooling coils. The two large central utility plants (CUP), located at the north and south ends of the fab, serve two distinct yet equally important roles. The north CUP is equipped with chillers, pumps, cooling towers, and heat exchangers, which help to maintain the required temperature conditions. Meanwhile, the south CUP features DI and RO skids that ensure the facility meets its process water requirements.

During construction, EAB was instrumental in ensuring the Sub-fab exhaust systems maintained the required pressures for tool installation while adhering to a tight project schedule. EAB’s expertise was crucial in testing and balancing the General Exhaust (GENX), Acid Exhaust (ACIDX), Caustic Exhaust (CAUSX), and VOC Exhaust (VOCX) systems. In an effort to keep Texas Instruments’ production on schedule, tools were installed before the HVAC building automation system (BAS) was brought online. To protect the integrity of the production environment and equipment, EAB continuously balanced the air systems as each tool was installed, until the BAS was operating.

EAB skillfully proportioned three massive manual water balance systems to meet Texas Instruments’ construction and production schedules. The 54°F CHW system, with over 650 coils and 43,000 GPM, posed a significant challenge. EAB’s team collaborated closely with mechanical contractors and worked tirelessly to complete the balance before the facility became fully operational.

Texas Instruments could feel the difference on this project due to our team’s unwavering commitment to collaboration, communication, and precision. EAB maintained close communication with Texas Instruments’ System Owners to keep the team updated with all current data. In an environment where change was the only constant, EAB’s consistency and adaptability were invaluable. We provided Texas Instruments with essential test data to provide peace of mind that each space of the RFAB2 consistently met pressurization requirements.

Texas Instruments RFAB2

Texas Instruments RFAB2EAB was honored to be a part of Texas Instruments’ newest project, RFAB2. Spanning an impressive 630,000 square feet, this 300-millimeter wafer fabrication facility strengthens the future growth of semiconductor manufacturing. The Texas Instruments RFAB2 facility achieved the LEED v4 Gold certification from the U.S. Green Building Council. According to Texas Instruments, “It’s the first semiconductor factory in the United States and fourth in the world to achieve this certification.”

Located in Richardson, Texas, the RFAB2 facility’s intricacies demanded meticulous attention to detail. EAB took on the challenge of testing and balancing the mechanical air and water systems, including vital components like the Deionization (DI) and Reverse Osmosis (RO) systems. This mission was essential to create the ideal environment for semiconductor production.

The facility is divided into three levels: the Sub-fab, Wafer-fab, and Truss. The Sub-fab contains critical tools and equipment to support ISO 5 wafer-fab processes, while the Truss level houses essential fan filter units and cooling coils. The facility’s rooftop boasts two decks, one for scrubbers to purify process exhaust and another for make-up air units that maintain a constant 47°F supply air dewpoint temperature, ensuring precise operation of the sensible cooling coils. The two large central utility plants (CUP), located at the north and south ends of the fab, serve two distinct yet equally important roles. The north CUP is equipped with chillers, pumps, cooling towers, and heat exchangers, which help to maintain the required temperature conditions. Meanwhile, the south CUP features DI and RO skids that ensure the facility meets its process water requirements.

During construction, EAB was instrumental in ensuring the Sub-fab exhaust systems maintained the required pressures for tool installation while adhering to a tight project schedule. EAB’s expertise was crucial in testing and balancing the General Exhaust (GENX), Acid Exhaust (ACIDX), Caustic Exhaust (CAUSX), and VOC Exhaust (VOCX) systems. In an effort to keep Texas Instruments’ production on schedule, tools were installed before the HVAC building automation system (BAS) was brought online. To protect the integrity of the production environment and equipment, EAB continuously balanced the air systems as each tool was installed, until the BAS was operating.

EAB skillfully proportioned three massive manual water balance systems to meet Texas Instruments’ construction and production schedules. The 54°F CHW system, with over 650 coils and 43,000 GPM, posed a significant challenge. EAB’s team collaborated closely with mechanical contractors and worked tirelessly to complete the balance before the facility became fully operational.

Texas Instruments could feel the difference on this project due to our team’s unwavering commitment to collaboration, communication, and precision. EAB maintained close communication with Texas Instruments’ System Owners to keep the team updated with all current data. In an environment where change was the only constant, EAB’s consistency and adaptability were invaluable. We provided Texas Instruments with essential test data to provide peace of mind that each space of the RFAB2 consistently met pressurization requirements.

Alcon Laboratories – William C. Conner Research Center & North Manufacturing Building

Alcon LaboratoriesEAB has had the pleasure of serving and supporting Alcon Laboratories Inc. as a long-term client at their ophthalmic research lab facility in Fort Worth, Texas. As a trusted partner, our team was once again hired to provide our services for two renovation projects: The William C. Conner Research Center, and North Manufacturing Building.

The William C. Conner Research Center project consisted of Testing and Balancing, point and sensor calibration verification, control sequence verification, as well as room pressure and air change verification during the multi-year renovation and addition of the animal husbandry research building and vivarium. In addition to an already complex laboratory control design, special software was developed by the controls contractor to monitor the Phoenix air valves beyond what the manufacturer provided, which resulted in additional and unique verification requirements for EAB. The vivarium also had very sophisticated room pressure requirements and pressure cascades. As experts in our field, our team was able to meet the unique requirements by listening to our client’s needs and using our consistent approach to deliver an optimum operating facility.

The North Manufacturing Building scope included Testing and Balancing, Building Commissioning, and Critical Environment Certification services. Our TAB team reviewed the construction documents, submittal for balanceability, construction observations, site testing, and witnessing AHU pressure testing. Then, our team performed testing and balancing on all HVAC equipment. Finally, our team performed all local BAS point verification and control sequence verification in preparation for functional testing by our commissioning team. Our Cx team assisted with the commissioning plan, site observations and support, commissioning meetings, and creation of all system verification checklists for the HVAC systems, review of proper equipment installation, HVAC Functional Performance Test development, facilitating all Functional Performance Testing on the HVAC systems. Our team also provided Critical Environment Certification services by supporting and performing the integrity testing and cleanroom certification of various areas in the facility. This accounted for approximately 250 HEPA filters in thirty plus rooms. The project was successful because of our effective communication, our technical expertise, and our ability to work together as a team to deliver an optimum operating facility. For more details about this project, view the full story here.

Alcon Laboratories – William C. Conner Research Center & North Manufacturing BuildingAlcon Laboratories – William C. Conner Research Center & North Manufacturing Building

EAB has had the pleasure of serving and supporting Alcon Laboratories Inc. as a long-term client at their ophthalmic research lab facility in Fort Worth, Texas. As a trusted partner, our team was once again hired to provide our services for two renovation projects: The William C. Conner Research Center, and North Manufacturing Building.

The William C. Conner Research Center project consisted of Testing and Balancing, point and sensor calibration verification, control sequence verification, as well as room pressure and air change verification during the multi-year renovation and addition of the animal husbandry research building and vivarium. In addition to an already complex laboratory control design, special software was developed by the controls contractor to monitor the Phoenix air valves beyond what the manufacturer provided, which resulted in additional and unique verification requirements for EAB. The vivarium also had very sophisticated room pressure requirements and pressure cascades. As experts in our field, our team was able to meet the unique requirements by listening to our client’s needs and using our consistent approach to deliver an optimum operating facility.

The North Manufacturing Building scope included Testing and Balancing, Building Commissioning, and Critical Environment Certification services. Our TAB team reviewed the construction documents, submittal for balanceability, construction observations, site testing, and witnessing AHU pressure testing. Then, our team performed testing and balancing on all HVAC equipment. Finally, our team performed all local BAS point verification and control sequence verification in preparation for functional testing by our commissioning team. Our Cx team assisted with the commissioning plan, site observations and support, commissioning meetings, and creation of all system verification checklists for the HVAC systems, review of proper equipment installation, HVAC Functional Performance Test development, facilitating all Functional Performance Testing on the HVAC systems. Our team also provided Critical Environment Certification services by supporting and performing the integrity testing and cleanroom certification of various areas in the facility. This accounted for approximately 250 HEPA filters in thirty plus rooms. The project was successful because of our effective communication, our technical expertise, and our ability to work together as a team to deliver an optimum operating facility. For more details about this project, view the full story here.

MEGlobal Plant Support Building

EAB provided Testing and Balancing services and facilitated Building Commissioning duties on the MEGlobal Plant Support Building, a two-story, 53,000 square foot refinery support building with a control area, maintenance bay, and a research lab. 

During construction, we tested and balanced the HVAC systems, verified HVAC control point and sensor calibration, developed, and performed HVAC control sequence verification, while working closely with the control contractor to refine the laboratory sequence and functionality. Our highly organized team of experts succeeded in turning tested systems over in a timely manner to meet construction deadlines.

The Total Building Commissioning scope of the mechanical, electrical and plumbing systems included management of the commissioning process. Unique to this project, we assisted the construction team by providing schedule development feedback and in-depth coordination of construction activities to meet a rigorous turnover schedule for the owner. In addition, we also created and reviewed all system verification checklists, developed and facilitated all Functional Performance Testing and Integrated Systems Testing for the entire facility. Our team reviewed the owner’s training process, as well as, all O&M documentation for compliance with the project requirements.    

Due to the location of the facility and the surrounding chemical plants, our team verified the gas detection system, and its interaction with the HVAC systems. This was a special condition for this industrial project, that helped them achieve an optimum operating facility.

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