Overview: Electrical Installation for Aluminum Recycling Machinery
FTI was contracted by Aluminum Dynamics to install electrical systems for 16 pieces of aluminum recycling machinery designed to dry aluminum. These machines melt recycled aluminum in preparation for casting and filter airborne dirt before clean air is released into the atmosphere. The electrical installation for this project included multiple 480-volt, three-phase variable frequency drive motors, motor control centers, remote input/output panels and control panels and devices.
Challenges: Accelerated Schedule and Complex Equipment Integration
The customer shortened the construction schedule, requiring field resources to be doubled to meet deadlines so the end user could begin production. Installation fell behind schedule due to numerous material delays and logistical challenges related to geography, resulting in trade stacking and re-touches. The project also posed a challenge with the number of devices and moving parts with heat-related destruction risks per square foot, as it was three times larger than in previous installations.
Additionally, FTI encountered four pieces of aluminum melting machinery that were unfamiliar and required extensive planning and communication to successfully install safely and effectively.
Solutions: Strategic Planning and Resource Optimization
The logistical challenges related to geography were resolved using bulk buyouts and vendor-directed inventory material management systems. A split-shift installation plan was created to eliminate trade stacking, allowing the mechanical contractor and electrical team to work in the same areas simultaneously and meet all customer deadlines. Electrical components were pre-gathered, and control panels were constructed onsite to ease pressure on the electrical engineering team and keep construction moving in a forward direction.
