Qepi Project Profiles - Quality and Process Engineering
| Location: |
Franklin, Indiana |
| Time Frame: |
March 2002 - April 2003 |
Qepi was contracted by Mitsubishi Heavy Industries Climate Control, Inc. located in Franklin, IN to assist with the implementation of an ISO 14001 Environmental Management System for the company's locations in Franklin and Greenwood, Indiana.
The facility had in place an effective QS-9000 Quality Management System.
Qepi utilized elements from the QS-9000 system and developed new procedures necessary for the ISO 14001 system to create an integrated quality and environmental management system for the company.
Qepi assisted the company in the design of the ISO 14001 system, including:
- Identification and evaluation of the facility's aspects and impacts
- Development of objectives and targets for improvement of the facility's environmental performance
- Development and implementation of necessary standard operating procedures (SOPs) and work instructions
- Development of a program for communicating necessary SOPs and work instructions to suppliers and contractors
- Development of an employee awareness training program
- Training of internal auditors
As part of the activities involved with the implementation of the ISO 14001 system, it was necessary for the facility to complete an environmental compliance audit and perform health and safety training for selected employees of the facility.
With inside knowledge of the facility's operations, gained though the development of the Environmental Management System, Qepi was able to efficiently respond to the company's needs and quickly complete the audit and training.
The facility successfully completed implementation of the ISO 14001 Environmental Management System and was recommended for registration to the ISO 14001 standard on its initial registration audit.
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| Client: |
BICC Cables |
| Time Frame: |
2001 - 2003 |
| Services Provided: |
Quality Optimization of Process Systems (QOPS) |
Phase I – Partial Wastewater Recirculation Project
Qepi completed a partial wastewater recirculation project that reduced the average daily wastewater discharge via the facility’s NPDES permit from approximately 200,000 gallons per day to approximately 80,000 gallons per day. This reduction provided annualized savings in water consumption of approximately $72,000.
The partial wastewater recirculation project was accomplished in the following manner:
- Rerouted all but one of its permitted NPDES outfalls to the facilities main cooling tower with a holding capacity of 125,000 gallons.
- Installed two (2) 600 gallons per minute pumps and associated piping to recirculate the cooled water from the main cooling tower to the facility for use as contact and non-contact process water.
- Installed three (3) 1,000 gallon holding tanks on three separate processes that utilize a large quantity of water. The water was recirculated through the process until a temperature-activated thermocouple is activated to add more water to the holding tank. Any overflow from the holding tanks is sent back to the main cooling tower to be recirculated.
The approximate return on capital was two years for this project.
Phase II – Zero Discharge Recirculation Project
Qepi completed a wastewater minimization analysis that will allow the facility to reach zero discharge and recirculate nearly all of its water requirements. This project included the evaluation that included the following:
- Evaluation of particulate filtration system.
- Evaluation of ultraviolet sterilization for the treatment of biological contamination.
- Evaluation for the installation of a larger, more efficient cooling tower with a holding capacity of 200,000 gallons.
- Evaluation of chillers for specific processes to reduce the recirculated water requirements.
The estimated annualized savings is expected to be $70,000 with an estimated return on capital from three to five years.
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