San Antonio, Texas

Construction Management, General Contracting

Phillips Semiconductors needed to expand their manufacturing capacity as well as upgrade their facilities systems for new, larger 200mm wafer manufacturing equipment. The CPI Group served as the CM/GC on the project providing construction oversight, quality assurance, cost control and scheduling. This fast-track project included a number of complex industrial systems:

• Addition of new 650 gpm Process Cooling Water system
• Addition of new 365 gpm Rinse Water Recycle system
• Upgrade of Solvent Exhaust abatement system to new 45,000 cfm system
• Addition of new 34,000 cfm Ammonia Exhaust system
• Addition of new 1,000 kva emergency generator and synchronizing gear
• Addition of vacuum assist and upgrade of Clean Dry Air system
• Upgrade of Reheat Water system
• Installation of SCADA factory monitoring system and conversion of existing data
• Addition of new 1,250 ton chiller and cooling tower

Every utility system in the plant was affected by the project – either through direct upgrade or by associated maintenance activities during the planned shutdowns. Several innovative solutions were developed including a new rinse water recycling system that saved Phillips millions of gallons of water per year and a new VOC Regenerative Thermal Oxidizer built over the existing loading dock.

As part of the larger utility upgrade, CPI finished out two additional cleanroom spaces, a Class 3 manufacturing space and a Class 5 sort-test space. A new 36,000 square foot office space was also constructed allowing for additional personnel needed for the expanded operation.

• 1,200 sf of class-1 cleanroom
• 3,000 sf of class-100 cleanroom
• 10 associated process utility systems
• 36,000 sf of office space
• $28 million project