Plant Upgrade & Equipment Integration

  • Year: 2016-2022
  • Client: Intel
  • Project Type: Plant Upgrade & Equipment Integration | Semiconductor

About The Project 

Installation of high purity pipes and low purity pipes inside clean rooms and Sub-Fab for more than 500 tools using many pipeline types.

We completed more than 20k of welds to complete the installation of more than 11 KM Piping for Intel company.

The purpose of this project is to improve the technology of intel’s computer chips.

 

Project Description

The tool installation process is very organized and is done in adherence to Intel specifications. To Provide excellent service to our customer, the collaboration between manufacturing, procurement, planning, safety, and quality assurance departments is required. Designing in 3D each tool is an essential and important operation, which lets each tool component be checked. After a 3D design is prepared, the planning department provides material demands to the procurement department, purchasing the material based on project schedule and lead. Based on the 3D model, the manufacturing department produces spools and racks off the field to optimize installation time. Furthermore, welding is done in our workshop, and at the end of the procedure, analytical tests are performed to ensure no defects were found. Our expert team completed more than 20K of welds.
During installation, authorised team, work in Sub-Fab, and Clean Room must be aware of the rules and work according to specs. To ensure this, the quality assurance team is supervising and confirming that installation is being done based on specs. As tool installation end, quality assurance is doing various tests such as pressure test for high purity and low purity, analytical test for high purity piping, and visual test.

Challenges

This enormous project to improve Intel technology cope with various obstacles. Starting from field condition, Safety Protocols meet project schedules by our customer needs up to lack of human resources such as orbital welders.
Routing development action is an important step to get excellent results and to prevent malfunctions during piping installation. Our expert routing development team examines and measures the area to generate a 3D model as accurately as possible. This action occurred six months before tool installation. Planning each tool in a 3D model has a lot of advantages. One of them is saving time by using the BIM program. Through this program, we can export files with all data needed to the manufacturing and procurement department.
Installing tools is a challenging  environment that requires each employee to regularly take part in safety training. Safety protocols apply to all employees in the field, and each worker is obliged to meet field rules. Our top priority is to follow protocols to get a high-quality result and keep our employees safe.

Solution 

We utilize historical data sheets collected and use a data-driven approach to predict the exact material needed for the job non-dependent to design/layout, combined with our modular Interface connectors that can significantly reduce commissioning costs, reduce time in project installations, reduce our clients’ headcount on-site, and eliminate project bottlenecks

Results

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Reduction in construction timelines

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Decreased onsite welding

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Head count reduction