Explore Projects

Redirection of Inbound (RIC) Conveyor

Western was chosen as the first turnkey engineering, fabrication, and installation contractor for the Redirection of Inbound Conveyors Program in 2006. Since then, Western has successfully completed eight RIC-type projects at multiple facilities throughout the United States. The program consisted of adding new Western-designed and -fabricated conveyors and pivoting deflectors for the purpose of redirecting the inbound mail directly to the secondary sorters. Two revised direct-to-secondary paths were added — one from the north inbound conveyors and one from the south inbound conveyors. The most challenging part of the program was installing the new conveyor systems over operating equipment. This required customized scaffolding, work platforms, and rigging paths to install the equipment. Upon completion, inbound mail was fed directly to the existing accumulation and surge conveyors in order to feed the secondary induction platforms and singulators.

Composite Sorter Upgrades

Western was awarded the first “full” composite upgrade and I/O relocation project in 2004 at the Des Moines NDC. Since 2004, Western has successfully completed 34 overhauls of secondary and sack sorters in 17 facilities across the United States. The projects include: - Mechanical demolition of the existing sorter components - Refurbishment of the existing bull gear shaft, coupling, and bearings - Electrical fabrication of new sorter panels - Electrical demolition and relocation of existing sorter I/O wiring - Installation of ControlNet Cards for upgrade to a ControlNet Network - Installation of new steel support structure - Installation of new polyurimide composite sorter components - Controls engineering to create new I/O wiring drawings to assist with the on-site I/O wiring relocation - Mechanical fabrication of new exit-track slip joints, tray straighteners, and bull gear components - Creation of acceptance test documentation - Associated training and start-up support for the customer Each overhaul was completed in a 21-day outage window utilizing 24-hour, around-the-clock field installation and engineering support.

Network Distribution Center (NDC) Consolidations

Western was awarded the first Network Distribution Center (NDC) Consolidation project in 2009 at the Philadelphia NDC, which consisted of removing 5,000 linear feet of sorting machines, 14,000 linear feet of bulk mail conveyor, 20,000 square feet of concrete mezzanines and induction platforms, and the installation of nearly 1,000 linear feet of new conveyor. The removal effort returned over 4 million pounds of structural steel for scrap, yielding a credit of nearly $450,000 back to our customer. Since then, Western has continued this ongoing program at several facilities, consisting of surgical demolition of equipment in operating facilities to allow for the design, fabrication, and installation of state-of-the-art mail handling and sortation equipment. These projects range from the full demolition of primary sorters, sack sorters, and all related feed and takeaway mechanization equipment to strategic re-routes of existing equipment to accommodate current inbound and outbound parcel mail flow.

Ventilation Filtration System

To provide additional security for employees and to the general public, the United States Postal Service developed and installed hazardous material detection systems (the “Ventilation Filtration System”) at more than than 280 postal facilities across the United States. Western was the installation contractor on this project and was able to meet the project’s schedule by simultaneously deploying six installation teams across the nation with specialized tooling and equipment.

Coal-Fired Power Plant Turnaround

Western successfully supported a coal-fired power plant turnaround in 2012. Our scope included replacing the feed water heater, repairing a coal silo, modifying the economizer dry flight conveyor, and performing preventative maintenance tasks on the condenser, cooling tower, coal pipes, and pyrite pipes. This turnaround engaged the total capability of Western to include engineering, fabrication, and multi-trade field operations (millwrights, boilermakers, pipefitters, carpenters, electricians, and laborers). To save our customer money, Western’s engineering department developed an alternative approach to repairing the coal silo, which resulted in a savings of approximately $150,000.

Warranty Maintenance

Western provided 12 months of warranty maintenance support on a new power generation unit at a coal-fired power plant in Arizona. Our on-site crew ranged in size from two to more than 100 skilled workers, including millwrights, pipefitters, boilermakers, carpenters, laborers, operating engineers, and supervisors. Tasks ranged from simple belt replacements to extending complex concrete foundations used to support heavy rotating machinery.

Coal Mill Rebuilds

Since 2008, Western has safely completed more than 100 emergency and scheduled coal mill rebuilds in power plants throughout the United States. Over this time frame, Western has also serviced pulverizers, exhausters, and feeder conveyors on CE Raymond, Riley, Foster Wheeler, and Babcock & Wilcox (B&W) coal mills. To continually improve our quality and capabilities, Western has invested in specialized, 45-foot tool semi-trailers to support the efficient response to emergency service calls. In addition, Western has developed an inspection/maintenance procedure and project record book for our customers and site superintendents.

Ethanol Plant Upgrade

Western supported a joint venture research and development project to develop a new process for converting sugar cane into ethanol. In addition to supporting the overall design of the plant, Western’s role included the design, fabrication, and installation of process piping systems, maintenance platforms, and a biomass-weighing conveyor.

System Maintenance

Western provided four years of onsite maintenance support at a Chondroitin production facility. Western’s on-site manager was responsible for scheduling and assembling teams to perform the preventative maintenance, repair, replacement, and alignment of all equipment. Western provided this support on a 24/7 basis with a response time of less than four hours on emergency maintenance calls.

Palletizer Upgrade Project

In support of a major brewery capital improvement project, Western rebuilt several palletizers to include adding new sprockets, fences, chains and other ancillary parts to allow the machines to accommodate varying package sizes. Western also removed obsolete shrink-wrap machines and installed new, higher-speed machines to work with the rebuilt palletizers. Once complete, the new system met all customer performance requirements.