Controls Integration and RSSB Fabrication 

The upgrade began with the in-house design and build of a stainless steel RSSB suited to the ammonia plant environment. Controls were engineered around an RDM Intuitive controller to manage pumps, valves, and alarms. Logic and interfaces were aligned with the site’s control philosophy so operators kept familiar screens while gaining tighter temperature control and faster pull-down. 

Skid Installation and Tie-Ins 

A new chilled water and glycol pump skid was installed and connected into existing services to add capacity without removing proven equipment. Pipework, supports, and penetrations were coordinated with site services to maintain access and hygiene. Cable routes were set cleanly, terminations were tight, and labelling was clear for future maintenance. 

Maintaining Production 

All works were sequenced around live production windows. Staged changeovers and short outage slots kept the plant online while tie-ins were completed. Day-to-day operations continued without impact. 

Testing and Commissioning 

Once installation was complete, MECS carried out a full suite of checks including: 

• Continuity and insulation testing of power and control circuits 

• Point-to-point verification for pumps, valves, and interlocks 

• Functional I/O checks and alarm confirmation 

• On-load commissioning under real production conditions 

• Programming adjustments and optimisation of setpoints 

• Handover with updated drawings, schedules, and setpoint records 

Project Challenges and Solutions 

Live Production Environment 

Working in a food manufacturing facility required strict controls on hygiene, access, and timing. MECS minimised disruption by sequencing tie-ins after hours, using controlled work zones, and coordinating closely with the client’s production team. 

Tight Program 

With limited windows to work, the team relied on parallel workshop build and site preparation, staged shutdowns, and clearly marked changeover packs to keep the schedule on track. 

Integration Risk 

Bringing new equipment into legacy controls and services can introduce faults if not managed well. MECS reduced risk through pre-mapping of cables and terminations, factory verification of the RSSB, and witnessed functional tests with the client’s maintenance crew. 

Client Response 

The client praised MECS for delivering added cooling capacity quickly and without operational downtime. The system now achieves faster pull-down, steadier temperature bands, and improved efficiency on equipment the operators already know. Built right, tested right, and ready to work.