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Projects and Case Studies

The demands placed on today's facilities have never been greater. Modern buildings must be flexible and reach new levels of energy efficiency. They require attentive cost-control practices in all stages of initial construction and modernization, as well as in daily operation. Those charged with building construction and management must rely on technologies and the people behind them to meet their facility-related responsibilities. For 40 years, KMC Controls has been designing, building, and, through our distribution partners, delivering innovative control solutions. We are committed to being the provider of choice for HVAC controls and building automation.

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Commercial Office

Kuwait Oil Company Headquarters
(Al Ahmadi, Kuwait) – Kuwait Oil Company (KOC), a subsidiary of state-owned Kuwait Petroleum Corporation, is universally recognized as one of the world’s top oil energy producing enterpris...
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Wachovia Bank Building
(Tampa, Florida) - The 22-story, 387,000 sq. ft. high rise at 100 South Ashley Drive is known as one of the friendliest and most e...
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Intel - IDC 9
(Haifa, Israel) – Computer hardware giant, Intel Corporation, has received LEED® Gold certification, the internationally recognized stamp of approval from the U.S. Gre...
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100 North Tampa Building
(Tampa, Florida) – Located downtown, the 100 North Tampa building is a prominent piece of architecture in the city’s skyline. It is the tallest building in Tampa wit...
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Forsyth Center
(St. Louis, Missouri) - In the St. Louis suburb of Clayton, MDR Properties has added a second 14-story class A office complex imme...
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SouthTrust Plaza
(Tampa, Florida) – With the exception of some geographic variability, commercial office space remains amply available to the buying/leasing community. As a result, many ow...
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Energen Headquarters
(Birmingham, Alabama) - Located in the foot-hills of the Appalachian Mountains, Birmingham, Alabama is home to over 240,000 residents w...
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Nationwide Insurance Company
(Gainesville, Florida) – What does an insurance provider do to insure the continued comfort of their own staff? For Nationwide, one of the largest insurance and financial ...
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LEED & ENERGY STAR

Greenway Middle School
(Phoenix, Arizona) - Greenway Middle School has a proud history dating back to 1912. What began as a one room schoolhouse in northeast Phoenix has evolved int...
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Intel - IDC 9

(Haifa, Israel) – Computer hardware giant, Intel Corporation, has received LEED® Gold certification, the internationally recognized stamp of approval from the U.S...

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Goshen College, Rieth Village
(Goshen, Indiana) - When Luke Gascho, Goshen College’s Merry Lea Building Executive Director, interviewed contractors and architects for a new collegiat...
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Wachovia Bank Building
(Tampa, Florida) - The 22-story, 387,000 sq. ft. high rise at 100 South Ashley Drive is known as one of the friendliest and most easily...
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Schools (K-12)

Franklin School District
(Franklin, Massachusetts) - The city of Franklin is located in Norfolk County, one of the original four counties of the Colony of Massa...
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Nantucket Public Schools
(Nantucket, Massachusetts) Nantucket, a place of charm and beauty, is located thirty miles from the mainland of Massachusetts on...
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Greenway Middle School
(Phoenix, Arizona) - Greenway Middle School has a proud history dating back to 1912. What began as a one room schoolhouse in northeast Phoenix has evolved int...
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Clay Community Schools
(Clay County, Indiana) - The rural county is located in west-central Indiana approximately 15 miles east of Terra Haute. The small...
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Colleges/Universities

TDK's Headway Technologies

(Milpitas, CA) - Continuous Improvement.  When there's a great deal of low-hanging fruit to gather, it's an easy concept to...

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University of Guelph
(Guelph, Canada) - With approximately 16,000 undergraduate and graduate students, the University of Guelph (U of G) is a leading educat...
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Goshen College, Rieth Village
(Goshen, Indiana) When Luke Gascho, Goshen College’s Merry Lea Building Executive Director, interviewed contractors and architects for a new coll...
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Saint John's University
(Collegeville, Minnesota) Saint John’s University is an all men’s school of approximately 1,900 students. The Univer...
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Retail

Brandon Town Center
(Brandon, Florida) – Setting on a beautifully landscaped 262-acre lot just 8 miles east of downtown Tampa, Florida lies the Brandon Town Center mall. This 1.2 million squa...
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Hospitality

The Westin Michigan Avenue Chicago
(Chicago, Illinois) - A landmark on Chicago’s famed “Magnificent Mile” the Westin Michigan Avenue is rich in history ...
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Essenhaus
(Middlebury, Indiana) - Located in the center of a predominant Amish community, the Essenhaus attracts many visitors every year. The fa...
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TPC at Deere Run
(Silvis, Illinois) – The annual John Deere Classic golf tournament is held at TPC at Deere Run in this Illinois town near the Davenport, Iowa border. According to D.A. Wei...
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Government/Public

Royal Saudi Naval Force
(Riyadh, KSA) – In the Kingdom of Saudi Arabia (KSA), the Royal Saudi Naval Force (RSNF) is the naval branch of the armed forces. Founded in 1960, the RSNF was developed largely as a defensive f...
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Kuwait Oil Company Headquarters
(Al Ahmadi, Kuwait) – Kuwait Oil Company (KOC), a subsidiary of state-owned Kuwait Petroleum Corporation, is universally recognized as one of the world’s top oil energy producing enterpris...
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Indiana State Museum
(Indianapolis, Indiana) – Located in White River State Park in the heart of Indiana’s capital city, the Indiana State Museum is a world-class institution where India...
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Government Palace
(Brasilia, Brazil) – The Brazilian government’s recently completed headquarters required the newest technology and control systems. ISAI Controles of San Pablo, Braz...
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Glenmont House
(West Orange, New Jersey) - Llewellyn Park, located in West Orange, New Jersey, was the first planned residential community in the United States. Developed in...
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Federal Police Building
(San Pablo, Brazil)  Brazilian-based Federal Police now have a new building with plenty of offices and jail space. The...
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Jefferson City Correctional Center
(Jefferson City, Missouri) - The new Jefferson City Correctional Center is now open for inmate occupancy. The facility is capable of ho...
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Department of Defense Computer Facility
(Ogden, Utah) – The Defense Department’s Enterprise Computing Center (DECC) is a facility with complex environmental control system requirements. When it came time t...
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Industrial

Seattle Life Sciences Building
(Seattle, Washington) – Seattle is home to numerous firms in the life sciences arena.  The buildings that house them are often described as mixed use with office, laboratory, and research s...
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OPTODEV Inc.
(Manila, Philippines) – Since 1998, OPTODEV, Inc., a subsidiary of Essilor International, one of the leading global players in health care, has been a producer of high-index ophthalmic lens...
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Midwest Laboratories
(Omaha, Nebraska) - Founded in 1975, Midwest Laboratories analyzes the components of many different items—from soil, to plant tis...
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Molex
(Lincoln, Nebraska) - One of the fastest growing companies, Molex, stands as number two in the electronics molded connectors industry. ...
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Healthcare

OPTODEV Inc.
(Manila, Philippines) – Since 1998, OPTODEV, Inc., a subsidiary of Essilor International, one of the leading global players in health care, has been a producer of high-index ophthalmic lens...
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Bellin Health System
(Green Bay, Wisconsin) – Bellin Health System is an integrated healthcare delivery system based in Green Bay, Wisconsin, serving 450,000 people in northeastern Wisconsin and the Upper Peninsula ...
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HEALTHSOUTH Lakeshore Rehabilitation Hospital
(Birmingham, Alabama) - HEALTHSOUTH Lakeshore Rehabilitation Hospital is a top-tier healthcare facility serving north central and centr...
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St Edwards Mercy Medical Center
(Ft. Smith, Arkansas) – Product reliability and customer service are important, but not always common currency among products and companies. When St. Edwards Mercy Medical...
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Pinellas County's Forensic and Medical Examiners Center
(Largo, Florida) – In recent times forensic science has garnered quite a following in the popular culture scene. Though the associated control system may never be featured...
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OPTODEV Inc.
(Manila, Philippines) – Since 1998, OPTODEV, Inc., a subsidiary of Essilor International, one of the leading global players in health care, has been a producer of high-index ophthalmic lenses for the medical sector. Their plant in Laguna, Philippines is considered a "Center of Manufacturing Excellence" and mass produces a number of Essilor’s more notable brands.

To meet strict product-quality standards and to address environmental safety and health compliance requirements, OPTODEV's manufacturing facility demands precise control over the temperature and relative humidity while maintaining 100% outside air. This also serves to ensure a comfortable and safe workplace for its employees. 

 

Such sophisticated requirements can be very energy-intensive on the facility and taxing on personnel. To eliminate settling of particulates and to dilute possible clean room contamination to an acceptable level, the air must be properly conditioned and ventilated at a minimum of 10 changes per hour. This caused the building’s old electromechanical, manually-operated HVAC system to use a substantial amount of energy. Further, the company had, for many years, manually monitored their clean environments with traditional chart recorders. These systems and processes were highly inefficient and lacked any sort of alarm mechanism to alert personnel to out-of-specification building conditions. 

In search of ways to significantly reduce both energy costs and time spent manually monitoring environmental conditions of the building, OPTODEV turned to energy management contractor, Asyst Power Technologies. The challenge? Develop a retrofit master plan (four phases) to replace individual, antiquated systems with a fully-open, interconnected BACnet building automation system (BAS). Representing, at the time, Siemens Industry, Inc., Asyst chose the APOGEE BACnet BAS suite for Phase I and began by retrofitting the manually-operated HVAC system with a fully automated DDC system flexible enough to address all specific requirements of system equipment (AHUs, boilers, chillers, etc.).

Initial operating costs savings were estimated at 20% annually, with actual measured costs metrics for the first year showing closer to 25% savings.

While pleased with the initial phase of the retrofit, dissatisfaction with on-going manufacturer support in the Philippines, and the customer’s desire for increased energy savings caused Asyst to switch their offering to another BACnet manufacturer—KMC Controls. "We chose to switch our offering to KMC Controls due to their highly interoperable and reliable BACnet product line, and also for their renowned product support," commented Liberato Donato, VP of Operations at Asyst. He went on to say, "Our customer wanted more energy savings, but we had squeezed all we could out of the original system. We needed a more capable solution."

Asyst initiated Phase II of the project, which expanded the overall building system and seamlessly integrated the original system with the more capable KMC BACnet system. Through the installation of a number of BTL-listed, KMC BACnet Building Controllers (B-BC), expansion modules, electronic actuators, and sensors, as well as, the improved customization of control sequences, Asyst was able to better optimize and fully automate complex control functions of the entire building management system. The system more closely monitors and controls the conditioning and use of outside air and better detects and adjusts air-handling devices based on predetermined setpoints and other occupancy conditions. Because the facility runs around the clock, the system’s responsiveness is vital to overall performance and energy efficiency.

All of Phase II process and control upgrades were accomplished while the plant remained at full capacity without any interruption in production and plant cooling. Preliminary savings projections were estimated at an additional 10–15% in operating costs, with initial results indicating savings more in the 15–20% range. The plant has expanded capacity by over 20% in last two years, while measured energy cost metric (KWH/GL) has dropped by over 20%. Also, due to systems automation, air-conditioning start-ups can now be performed by only one technician enabling other plant technicians to focus on more technical tasks.

The flexibility provided by KMC’s building automation and control solutions was exactly what was needed at OPTODEV, Inc. "Our highest priority was to find a local systems integrator who could provide reliable hardware and flexible software to meet the needs of our complex sequence of operation, as well as our monitoring and alarming needs," commented Herman Robles, Head of Energy Conservation Projects at OPTODEV Inc. "KMC Controls and Asyst Power Technologies have met all of these challenges, and provided us an intuitive, simple to understand GUI," he added. By creating an open and sustainable BACnet building automation system, KMC and Asyst have provided for a modern-day level of data input, reduced overall operating costs and have laid the groundwork for future upgrades.

Future plans (Phases III–IV, to be completed by Y/E 2012), include the construction of a new 90,000+ sq. ft. facility to expand OPTODEV’s manufacturing space. Further BACnet control via KMC building controllers will be required in the chilled water plant to manage the 400-ton York and 300-ton Carrier machines, associated pumps, cooling towers, and other process water equipment. A KMC Modbus/BACnet gateway is planned to integrate over 30 submeters into the system for monitoring and plant power control purposes.

Also in Phase III, the KMC TotalControl web-based workstation will replace the existing operator workstation, allowing for improved data-handling capabilities, trending analysis, and automated alarm notifications to facility engineers. TotalControl will also make it possible to record and produce reports denoting exact compliance with, and deviation from, the specified room conditions (e.g., pressure, temperature, and humidity).

In the final analysis, more than 2,000 data points will allow operators to have access to and receive information from all integrated systems.




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