Posts Tagged ‘Mechanical engineering’

Then and Now: Advancements in Egan’s Project Approach

Wednesday, October 23rd, 2024

Hospital and healthcare facilities are common projects for Egan’s 12 specialty trades. So much so, in fact, that a recently discovered article from Egan’s archives depicts just that: a new Shriners Children’s Hospital being erected in Minneapolis, with Egan’s (then called Egan & Sons) Mechanical team playing an integral role in the plumbing, heating, cooling, and medical gas systems within the building. 

While the story itself may seem typical at first glance, in the more than 30 years since the hospital was built and the article was written, many things have changed in the cities in which we work, and the way in which we build them. 

THEN AND NOW: WHAT’S DIFFERENT? 

Egan continues to work on many different healthcare facilities, from new construction and renovations to electrical service calls and everything in between. What’s different, however, is the way teams approach the work. 

The most obvious difference in the way the industry has evolved is in the shift from hand-drawn project plans to digitized versions. This has enabled increased collaboration among project teams, reduced risk for human error, and more efficient operating costs and timelines for projects. 

The historical article depicts the old ways of coordinating project drawings: 

Egan Air is also responsible for coordinating drawings for all of the trades. Gary Hunt, their draftsman, produced the drawings on Egan Air’s new computer aided drafting machine. Joel Bohach, Egan & Sons, then overlays the heating and cooling piping so that only minimal interferences are encountered by the men in the field. Some of the areas in this two story hospital are so congested, that without this coordination most people would wonder if the project would ever be completed on time.

Egan Pipeline 1989

Today, a single modeler or a team of drafts personnel can work on project drawings and modeling without any need for hand-drawn coordination or overlays from other trades. By working exclusively with 3D modeling and computer aided drafting, Egan can collaborate with trades professionals and even other contractors to ensure the schematics are accurate and available to everyone on the project. 

SURPRISING SIMILARITIES

Comparing the Shriners Hospital to a modern project such as M Health Fairview in Minneapolis, Minn. reveals many similarities between the two. Since the building of Shriners in Minneapolis, Egan has worked on dozens of hospitals and healthcare facilities throughout Minnesota, including Essentia in Duluth and Mayo Clinic in Rochester. The project scopes of these jobs are very similar, as hospitals continue to build and upgrade their facilities, using much of the same equipment now as they did back then to meet patient needs.

Prefabrication in the construction industry has been around for decades, and Egan has been leveraging our prefab shops on nearly every project to promote accuracy, quality, and safety. The article is a testament to Egan’s longstanding commitment to innovation, quality, and safety as the featured project utilized prefabrication for the chiller room piping.

Today, Egan’s fabrication efforts have expanded greatly, resulting in a new prefabrication facility currently under construction in Kasson, Minn. As was the case three and a half decades ago, prefabrication saves time and money on projects, while increasing safety and quality.  

ALWAYS IMPROVING

A lot can change in 30 years. Since the project in 1989, Shriners Children’s Hospital has moved to a new state-of-the-art facility in Woodbury, Minn., while the original building is now used by the University of Minnesota. Technological advancements, increased safety standards, and new business groups have all arisen within Egan in the last four decades. What hasn’t changed in that time, however, are the high standards Egan brings to every project.

Whether it’s through prefabrication or the implementation of new technology, Egan’s goal is to find ways to deliver projects more efficiently, at a higher quality, and with no injuries. For the last 80 years, Egan has been able to deliver on our promises by doing so, and we remain committed to our customers’ success for the next 80 years and more. 

Fire Impact Requires Rapid Response from Egan Trades

Monday, December 28th, 2020

For over 75 years, Egan Company has committed to providing exceptional service and keeping our promises to our customers, no matter the time of day nor the severity of the need. When a fire destroyed part of Burnett Dairy Cooperative’s Grantsburg, Wisc. plant this summer, Egan was consulted immediately to develop a plan to get the plant fully operational as soon as possible. 

UNDER AN ‘AS SOON AS POSSIBLE’ DEADLINE

Known for producing award-winning, high-quality cheese products for over 120 years, and with customers waiting for products in their stores, the need to get the plant fully operational as soon as possible was of utmost importance. Working around the clock, multiple Egan crews comprised of six different trades partnered with Burnett Dairy and additional contractors to demolish and rebuild the infrastructure that was damaged in order to get the production lines back up running.

“We’ve worked with Burnett Dairy for the past few years and have formed a strong relationship,” said Dan Reintjes, Egan Company Project Manager. “When the call came in that we were needed to help after the fire, we were there as fast as possible to get the infrastructure and  production lines in perfect working order again.” 

The fire is believed to have started in the boiler building, which will require a complete rebuild. In the meantime, a temporary operation was conceived and constructed to ensure cheese production and assembly continued.  Egan’s process controls team worked late into the first night getting power to three of the plant’s electrical services and started a complete demolition of the fourth 2000 amp 5-section service gear which was then designed, built, installed and operational in nine days. The ammonia compressors were also powered up with generators on the first day in order to get Burnett Dairy’s warehouse coolers running to save all the products that were  already produced. Egan’s Mechanical team worked to make damaged piping safe and get temporary water piping installed as well as planning for a temporary boiler installation.

Egan was one of the contractors that was onsite within 18 hours of the fire trucks leaving the scene and didn’t leave until the plant was fully operational,” said Dave Gaiser, Burnett Dairy Cooperative CEO.  “With their help, Burnett was able to get our retail store back open within a few days so we were able to open for the weekend after the fire.  Within seven days, they assisted with getting one of our packaging lines operating so we could package cheese from other manufacturers and begin shipping to our customers. Egan worked 24/7 coordinating with other contractors to get Burnett running within two months of a fire impacting all utilities servicing the plant.

Beyond the initial scope of work that was completed to get the plant operational, additional projects were finished in order to restore complete operation to the plant. Egan engineers designed and programmed a new control system for the milk transfer and CIP systems that were lost in the fire, and additional electricians were tasked with installing new power distribution panels and feeders as well as installing the new milk transfer and CIP control panels and interconnect wiring.

Working alongside the controls electricians, Egan’s Mechanical trades were tasked with setting up the temporary, 900 horsepower self-contained boiler.  The team was also responsible for hydro testing and repairing all existing piping to ensure functionality and safety due to the fire.

BACK UP AND OPERATIONAL

The plant was back up and operational in 62 days, processing milk from 150 farms, and bringing 300 people back to work.

Burnett Dairy is currently operating with a temporary boiler trailer in place and due to the work of many contractors working within a tight timeline. Next steps for the plant include the design, engineering, and construction of the new boiler building; Egan’s full-time maintenance presence at the plant will continue, and any additional help the site needs as it starts the process of rebuilding from the fire.  

“Egan is a valuable business partner and the accomplishments of the past couple of months would not have been possible without them,” said Gaiser.

MULTI-TRADE PROJECT TEAM

  • 35 Egan onsite electricians
  • 15 Egan controls and mechanical engineers contributed to the needed design and engineering
  • 31 Egan plumbers, pipefitters, and sheet metal workers were onsite
  • 5 limited energy technicians delivered network installations with all new data cabinets and cabling for the plant
  • 10 control panel technicians built eight U.L. 508A control panels on a tight turnaround

Highly Specialized Project Completed in Crunch Time

Friday, September 14th, 2018

High-rise buildings are the distinguishing trademark of cities around the world. And, being the 16th largest metropolitan area in the country, Minneapolis and St. Paul are no different.

As a specialty contractor, Egan has played a role in helping to build, remodel, and maintain many of these high-rise buildings that help shape the Twin Cities’ skyline. While these projects have included scopes of all sizes, this past spring brought forth a very unique high-rise venture.

Egan’s team was utilized for a highly-specialized project in downtown St. Paul, Minn. The scope included the replacement of four massive cooling towers located on the rooftop of Galtier Tower – a staggering 31 stories from the ground.

Galtier Tower is one of two high-rise towers that make up the city block called Cray Plaza. The plaza also includes two other commercial buildings. Together, the block boasts hundreds of apartments and luxury condominiums, a small preparatory school, YMCA facility, and an assortment of other retail space – all of which fully rely on these cooling towers to air condition their buildings.

Overall, the project would require the tallest crane in Minnesota, in-house design and prefabrication, and even more pre-planning and coordination to complete the job within the compressed schedule.

Navigating a Tight Schedule

The project was officially awarded to Egan by Bigos Management in late March. From the start, Egan’s team knew the new cooling towers would need to be “flown” up to the top of the building. To do the “flying”, Egan began coordinating and pre-planning with a local crane company, Vic’s Crane and Heavy Haul.

An in-depth, engineered lift (or often called “pick”) plan was created while Egan’s team began designing the piping and support systems for the towers. A structural engineer was also hired to design the steel platforms for beneath each cooling tower based on the drawings provided by Egan.

Vic’s crane, standing at 410 feet tall, was tasked to hoist these four new cooling towers onto Galtier. However, driving a monster crane into a heavily populated urban city isn’t the most practical of tasks.

In the weeks prior to setting up the crane downtown, the city of St. Paul removed a light pole, cut down a tree, and approved and coordinated road closures. Vic’s also obtained multiple permits, clearances, and police support. Once complete, the crane took 12 hours to set-up on the street.

Another unique aspect of this project was that the new piping system for the cooling towers utilized Aquatherm – a fairly new type of system that is an environmentally friendly alternative to metal. Though extremely lightweight (and vibrantly colored!), Aquatherm pipe is one of the longest-lasting and most chemically inert piping material available.

Egan’s fabrication shop prefabricated all of the Aquatherm piping system for this job. It was also specifically designed so it could fit into the 7’7” elevator and transported to the rooftop of Galtier.

The Race to the Top

Although there was two feet of snow on the ground when the project started, Minnesota’s infamously, unpredictable spring weather found itself over 85 degrees just a few weeks later. With the previous cooling towers entirely off the building, the countdown was on to get the first new cooling tower operational in order to start cooling all of the buildings within the city block.

At the top of Galtier, Egan’s team worked with a subcontractor to set up an extensive amount of scaffolding so the team of pipefitters, electricians, and controls electricians could safely access the work. All of the prefabricated Aquatherm and structural steel platforms were also set before the crane could “fly” the cooling towers to the roof.

The first weekend of May, less than six weeks after being awarded the project, Egan’s team, alongside Vic’s, successfully lifted and installed all four cooling towers onto Galtier. The compressed schedule… accomplished.

Egan installed a majority of the piping after the cooling towers were set and officially completed the project in July.

Core Project Team: Bigos Management, Vic’s Crane and Heavy Haul

Services Provided: Cooling towers replacement, pipe fabrication, pipefitting, electrical controls, electrical installation