Asphalt Load Rack Upgrade

In addition to safety improvements, SSOE’s upgrades also improved product distribution and reduced downtime.

SSOE completed multiple projects for the Marathon Load Rack Program. This program was charged with improving safety and optimizing truck loading across their facilities by eliminating potential fall hazards. The Detroit Load Rack was one of the larger projects completed due to the extent of piping and electrical changes implemented.

The scope included the design of new platforms, gangways, stairs, safety cages, load arms, and piping. The safety-enhanced version of Marathon’s load rack included improved controls and safety interlocks, as well as improved lighting. The operator interface was redesigned to assure that safety interlocks and protocol for loading are satisfied prior to the start of loading. To ensure safety and ergonomics, many of the hand-operated valves were replaced with actuated valves. SSOE also integrated the control of the hydraulic gangway as part of the load rack controls. Hydraulically actuated gangways were installed to prevent injuries related to strain and poor ergonomics. In some areas, SSOE added stairs or extended platforms to create an optimal distance between the operator and the fill point.

SSOE’s experience with asphalt piping and electrical systems extends far beyond addressing safety issues, providing the added benefit of increased efficiency at this facility. Redesigned piping at loading stations improved product distribution. Reconfigured controls ensured that only affected lane(s) would shut down in the event of a problem, resulting in less downtime. The features integrated were part of a standard used throughout Marathon’s facilities so that workers can now safely operate equipment at any location.

Nuclear Regulatory Agency New Campus

SSOE’s efforts, along with other design consultants, will save $100 million a year through sustainable features.

When the National Nuclear Security Administration (NNSA) decided to develop a new site with multiple facilities, SSOE was enlisted to lead design efforts for all Mechanical, Electrical, Pluming (MEP) and structural systems. With a large multidisciplined team in place and innovative use of 3D BIM design, SSOE played an integral role to the success of the project.

Mandated by Kansas City’s Responsive Infrastructure, Manufacturing and Sourcing (KCRIMS) transformation plan, the project was implemented to protect some of the nation’s most premier security assets. The new complex incorporates five buildings, featuring manufacturing spaces, laboratories, office spaces, and warehouses. SSOE led all MEP and structural design efforts for the campus buildings and provided structural and MEP design for a central utility plant, which included a chilled water system, cooling tower system, hot water boiler system, and a compressed air system. SSOE’s scope also included the electrical design of medium and low voltage power, lighting, auxiliary, grounding, and outbuilding systems.

The new campus, which manufactures non-nuclear mechanical, electronic and engineered materials for national defense systems, was developed to replace outdated facilities. SSOE’s efforts enabled the client to upgrade from an outdated complex into a 21st century Nuclear Security Enterprise.

SSOE followed sustainable design principles in an effort to reduce environmental waste, maintenance and energy costs. The efforts from the design team and their consultants will result in saving the client more than $100 million each year and qualified the project for LEED® Gold certification.

A/E Services for Facilities Master Planning

SSOE was awarded a nationwide, five-year IDIQ contract for A/E services related to master planning for over 12 million SF of the EPA’s environmental and analytical laboratory and support facilities. This included coordination with EPA program and regional offices to incorporate their missions and strategic goals into specific master plans.

SSOE has completed the following tasks for the EPA:

Research Triangle Park (RTP), North Carolina
The RTP EPA Research and Administration Facility consists of approximately 1.4 million SF of laboratory, vivarium, office, and special use space.

SSOE has performed the following tasks at this site:

  • Facility master plan
  • Programming and planning to relocate the EPA Division now located off-site into the RTP facility
  • Energy reduction strategies
  • Evaluation of sustainability opportunities

Chapel Hill, North Carolina
SSOE completed an engineering study to provide recommendations for energy reduction strategies and HVAC improvements.

Narragansett, Rhode Island; Athens, Georgia; and Corvallis, Oregon
SSOE provided master planning services to address the renovation of the existing 40 year-old laboratory buildings, strategies to meet/exceed EPAct and EISA criteria, and a “green” strategy for restructuring the site.

Las Vegas, Nevada
SSOE developed a POR and Design Intent documents for a new two-story, 40,000 SF leased laboratory / office building. This building will house the offices and laboratories of the EPA’s Radiation and Indoor Environments National Laboratory currently located at the University of Las Vegas.

Houston, Texas
SSOE developed the POR for a new EPA Region 6 build-to-suit 10 acre campus, including a 90,000 SF laboratory building and support facilities.

Edison, New Jersey
SSOE developed a POR for a new 400,000 SF, state-of-the-art Environmental Science Center. The new facility consolidates the Edison EPA’s program into one building, replacing the aging, inadequate existing facilities.

Fort Meade, Maryland
SSOE completed a conceptual design for modifications of the EPA Environmental Science Center to allow for chemical warfare agents testing as requested by the Department of Homeland Security.

Pipeline and Meter Station Replacement

Tight coordination of the procurement process prevented potential schedule delays and cost increases due to a scarcity of available parts.

Increasing demand for gas in areas served by an obsolete pipeline prompted Consumers Energy to engage SSOE’s engineering and procurement services to upgrade and replace the line. The project included developing multiple iterations of the routing plan to avoid  recreational areas. SSOE assisted in obtaining permits from the township and various other agencies. The approved route added two miles to the line, making the 24-inch pipe 11 miles in length. SSOE also designed a temporary bypass to maintain gas service while the 2.5-year project was completed.

The project also involved significant changes to the existing metering stations. One station was demolished and replaced, while the other was upgraded and remodeled. A separation wall was installed to provide safety in the event of a gas leak. SSOE developed renderings of the stations and designed landscaping to create a residential character to these buildings, allowing them to blend into their surroundings.

Procurement proved to be challenging due to the extent of supplies and materials that had to be pre-purchased and the difficulty of obtaining the needed parts. SSOE responded to the challenge with careful tracking and tight coordination of the procurement process.

Blast Resistant Central Control Facility

SSOE applied significant value engineering to the preliminary schematic project design. Through design innovations, utilization of specialists in blast resistant design, and other ideas, Husky realized more than $7 million in savings.

In an effort to improve safety and communication at their Lima Refinery, Husky embarked on a plan to relocate all non-essential personnel away from blast risk zones to a centralized location outside the battery limits of the production facility. They called upon SSOE’s extensive refinery expertise and familiarity with blast resistant structures to design their new control building. SSOE provided full architecture and engineering for the 250,000 SF, two-story structure, which consists of a central control room, laboratory, warehouse, maintenance shops, vehicle repair center, and unit personnel housing.

Due to it’s proximity to plant production operations, the facility was designed to resist a substantial blast over-pressure while maintaining an open and architecturally appealing structure. SSOE collaborated with the owner, specialized design consultants, constructors, and material systems providers to provide a functioning structure that is fully code compliant, protects its occupants from hazards, and allows for the operation and controlled shutdown of systems should an event occur. This collaboration and the application of specific design techniques resulted in a $3 million reduction in the cost of the structural frame alone.

As part of the project, SSOE customized the fire alarm, access control, data cabling, and raceway systems including the specialized protection needs of potentially hazardous operations. SSOE’s Data, Fire, and Security (DFS) team also designed an electronically secure enclosed area featuring anti-passback technology within the access control system.

Ethanol Facility Expansion

Reduced engineering schedule by 30%, saving GLE $60,000 a day.

Glacial Lakes Energy (GLE), a manufacturer of corn-based ethanol, underwent a capacity increase to more than double their existing capability. SSOE provided full engineering, design, procurement, fabrication, erection, and commissioning support. We coordinated with GLE, the contractor, and the process provider to successfully complete a fast-track, turnkey project which increased GLE’s existing ethanol production to 100 million gallons per year.

SSOE utilized staff in its Shanghai, China office to provide 24-hour project support, which reduced the engineering schedule by 30% and helped bring the facility to full production capacity in just 11 months. Also, as a result of the accelerated schedule, the client recognized a sizable profit. GLE saved $60,000 per day, which equaled approximately $1.8 million in profit per month.