Challenge/Solution Case Study:

Designing a Custom Cooling System for Large Electric Motor

Result

EFI Group designed, specified, purchased and supplied all materials for an outdoor, stand-alone, ventilation system to deliver ambient cooling to an 115,000 HP electric motor.

The EFI Group team managed the entire project, including contributions by outside vendors, which minimized freight charges and field installation costs and achieved on-time delivery and performance in excess of client expectations. The client experienced full ROI after just one year.

Challenge

EFI Group’s OEM client needed a complete, outdoor, stand-alone ventilation system robust enough to operate problem-free at an unmanned station that was subject to drifting snow and airborne debris from adjacent farmlands.

The scope included the design engineering, specification, purchase and supply of all cooling equipment, instruments and fabricated sheet metal and structural steel parts.

All components had to be completely preassembled, with equipment mounted and shipped in as few pieces as possible for efficient field assembly.

The ductwork was installed into an existing building with tight space constraints, and was required to hold a minimum outdoor footprint.

Solution

EFI Group decided to approach the project in three phases:

  1. Research/Fieldwork: EFI Group collected enough solid field data for all the design work from a single jobsite visit. Fieldwork included: obtaining relevant building drawings; taking extensive, accurate, as-built field measurements; and photographically documenting the work area.
  2. Design Configuration Options: This phase included the submission of several viable ductwork routing options for client review. From the client’s selection, a full system general arrangement (GA) was developed and approved by all interfacing disciplines. EFI Group minimized field installation costs by utilizing bolted structural connections and minimized freight charges by designing for standard flatbed consolidation.
  3. Final Design: Based on the approved GA, EFI Group developed detailed design drawings consisting of: all subsystems and fabricated components and design calculations for structural supports, system pressure drop, thermal expansion, accumulative tolerances and design conformity. EFI Group guaranteed integrity during fabrication by attaining design/approval of shop drawings for each piece, performing frequent inspections and ensuring adherence to effective quality control practices and documentation.

Deliverables

  • General arrangement and field assembly drawings.
  • Complete fabricated system: inspected, pre-assembled, match-marked, with step-by-step assembly instructions and all assembly parts required.
  • Process description narrative and operation manuals for all equipment and instruments.

Read more about EFI Group’s Core Competencies
Read additional EFI Group Case Studies

We hired EFI Group to help us figure out a project and scope it, and I felt confident they would keep a keen eye on it. They had to deliver quickly and they did it well. They are especially good at project management when you don’t have the resources to do it internally. Reliability is the word I would use to describe EFI Group.
— Coatings Industry Professional
EFI Group is timely. We’ve had a lot of situations when we’ve been in a time crunch and they’ve responded very quickly. They are detail oriented and efficient. They’re a good group of people who also have a lot of strength in pre-engineering — the thought process to get to preliminary design and making sure we’ve investigated all the potential asks of a project to ensure we didn’t miss anything. They have great attention to detail up front which is very important to any project because having that detail-oriented deep dive into the pre-engineering phase sets the stage for the success of the rest of the project, making the process smoother and making it much easier to keep the project on schedule and on budget.
— Mike Quigley, Engineering & Maintenance Manager, Food Industry
I’ve worked with EFI Group for a while, so I know they have a good, knowledgeable staff. We know we’re going to get the results from them we expect. From my interactions with all the different EFI team members I’ve worked with, I know they have knowledge across many industries. Equally, I never have to follow up with EFI Group and, in some cases, they keep me on track.
— Ryan Fredsall, General Manager, Pacer Minerals LLC
We view EFI Group as a team that can dimensionalize our capability to execute projects. We can articulate what it is we want to do and they can take that input and run with it without much intervention from us. They’re able to move a project along independently and only engage us when it’s time to bring us up to speed or get more input to drive a project to conclusion. That’s one of the reasons I view them as an excellent contractor.
— Environmental Engineering Industry Professional
EFI Group has good engineers and good customer service. We know when we get an EFI engineer on a project, we’re going to a get a good job from them and it’s been a productive relationship for both of us — I genuinely like the people.
— Corporate Director, Project Management in Food & Flavors Industry
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