Story

Mechanical piped services represent a significant proportion of the total build cost in today’s modern buildings. During the design and tender stage of large construction projects, spanning one or two years how much cost can be built into the supply chain to protect against inflationary costs whilst maintaining that competitive edge? The contractor is often left to absorb these unforeseen increases and is at the mercy of the markets which are at best unpredictable! In recent times we have all felt the effects of large % increases in the cost of commodity items such as steel, copper, zinc and oil based plastics, outside of our direct control.

Increasingly, contractors have had to become innovative in their approach to manage and minimse the elements of cost that are within their own direct control. The UK piping market for Building Services, Industrial and Process systems utilises largely screwed, flanged or welded jointing but in light of escalating material and labour costs, coupled with increased concern for operator health and safety and a diminishing skills base, there is a significant uptake in the use of Grinnell’s Grooved Piping System which is now used in many major UK construction projects and offers contractors the opportunity to greatly reduce installation times and therefore recoup a significant portion of their costs when compared to traditional methods:

• Installation times of individual fittings can be 1/10th those of welding
• No hot works
• No maintenance
• Compliments off-site manufacture
• Simple to install

The speed and simplicity of the Grinnell grooved piping system provides a Safer Working Environment, eliminates the requirement for Hot Working, optimises available Labour and operator Skills and compliments other innovative jointing systems being used in smaller sizes. The benefits of a Grooved pipework system can be realised in modular prefabrication techniques as well as in on-site installations.

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Lodge Cottrell use Micronics PF330 Portable clamp-on Flow Meter to substantially reduce commissioning time and fixed installation costs on large scale pollution control plant for coal fired boilers.

Lodge Cottrell is a world-leading supplier of large-scale industrial air pollution control equipment. On a project carried out during 2010 they had a requirement to process the ash extracted from their boiler flue gas treatment system by mixing this with water to form slurry suitable for disposal.

The ash is extracted from the flue gas using an Electrostatic Precipitator with the ash collecting in hoppers, which have varying fill rates determined by the extraction process. These hoppers then feed through to mixers where a specific water flow rate is required to achieve the target slurry consistency from the plant. The plant has 32 water lines with pipe sizes ranging from 18 to 1 inch diameter pipe and the Micronics Portaflo meters were used to accurately measure the water flow rate for the set-up of each mixer section.

The alternative to using the portable meter would have been 32 fixed metering points and as a consequence the use of the portable, clamp-on solution generated substantial benefits in terms of reduced commissioning time – labour and fixed metering point costs, plus the added advantage that the PF330 can be utilised again on other sites with similar requirements.

Having considered various suppliers Lodge Cottrell selected the Micronics – Portaflo PF330 – Time of Flight – portable flow instrument. Portable clamp-on Ultrasonic flow measurement has clear advantages for commissioning/set-up work and Micronics were selected as the supplier due to a combination of their long-term experience with non-invasive, clamp-on technology, product performance and best value.

Project Manager Nigel Dolphin says “The Portaflo PF330 has proved to be a valuable tool for commissioning of the plant water flow lines with considerable time and cost benefits over alternative fixed in-line metering points. The PF330 was simple to set-up/use and the flow measurement performance was good. The product has worked well and the customer service and technical support from Micronics has also been good.”

The potential for re-use by Lodge Cottrell on other plant installations with similar requirements is significant and the project has demonstrated the clear benefits available from using portable, clamp-on, ultrasonic flow metering for temporary flow measurement requirements such as commissioning and set-up of water flow lines. For further information call Micronics on 01628 810456, email sales@micronicsltd.co.uk or visit www.micronicsflowmeters.com. For information about air pollution control systems visit www.lodgecottrell.com.

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As SME manufacturers go global, ERP can help them respond quickly to changes in local market demand, improve business processes and benefit from economies of scale. James Flood of Exact examines why smaller manufacturers must match investment in new plants and sites with investment in enterprise business systems

A growing number of medium-sized manufacturers are benefiting from the opportunities afforded by globalisation. Having been adversely affected by the 2008-9 financial and economic crisis, which saw substantial closures and rationalisations, manufacturing SMEs now have the opportunity to drive a return to pre-crisis employment and output levels in the recovery period.

However, globalisation presents many operational challenges, such as a growing patchwork of IT systems, different cultures and business practices, multiple languages, and complex laws in different jurisdictions, to name but a few. Its also important for those with an international presence to be able to respond quickly and uniformly to changes in local market demand. Whereas service-led firms are able to overcome many of the barriers to international business via electronic means, manufacturers face the considerable task of coordinating the movement of physical goods and resources – whether personnel, raw materials or finished products – between sites, across borders and time zones in a timely manner.

And as they take in new sites, SME manufacturers will have to be just as effective as their larger counterparts in consolidating and exploiting their operations as a single global resource. This ensures their ability to pool capacities to meet orders, rationalise stock and supply across sites, and benefit from economies of scale when bidding for new business and negotiating contracts with suppliers. At the same time, smaller players must operate within the constraints of available budget.

There is general consensus that as the global recession eases, there will be a significant increase in ERP project activity as organisations reactivate postponed technology investment programmes and position themselves to take advantage of the economic upturn. Those getting a firm grasp of international operations, being responsive to changes in international markets and responsive to emerging markets as they crop up will be best placed to benefit from the ongoing process of globalisation.

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• Exact Software

Story

Market-leading loading and unloading equipment specialists Thorworld Industries Ltd has achieved the prestigious SAFEcontractor accreditation in recognition of its high standards of health and safety practices.

Under the independent SAFEcontractor scheme, businesses undergo a vetting process which examines their health and safety procedures and track record for safe practice.

Only those companies that meet the very highest standards are accepted into the scheme. Accredited contractors are then included on a database enabling member organisations to vet potential contractors before they even set foot on-site. What’s more, these users agree that they will only engage those contractors who have received accreditation.

The SAFEcontractor scheme has been running since 1999 and a wealth of well-known names have signed up to use the scheme to vet contractors, including Nestle, Kellogg, Debenhams and Virgin to name but a few. Thorworld managing director John Meale said: “Health and safety is vitally important to us, in everything we do – it’s a fundamental keystone of our business from initial product design and development through to manufacturing and installation.

“SAFEcontractor accreditation allows us to further demonstrate our positive commitment to health and safety, confirming to prospective customers that we have all the right systems and procedures firmly in place.”

Thorworld is firmly established as one of the foremost designers, manufacturers and suppliers to the loading bay and materials handling sectors and is recognised as both a market leader and innovator in the supply of quality engineered equipment.

BSI registered with ISO 9002 accreditation since 1992, it was one of the first companies in the industry to achieve the latest international quality management ISO 9001 (2008) standard, and now has an extensive list of prestige customers across a wide range of industries and business types, including distribution, logistics, transport, retail, food, drink, manufacturing, industry, waste management and recycling and the service sector.

Thorworld provides a one-stop, single source for the UK’s widest range of high quality loading bay and materials handling equipment, safety aids and accessories, including dock seals and shelters, dock levellers, modular loading docks, dock plates and boards, dock and vehicle bumpers, wheel chocks, vehicle restraints, traffic lights, dock lights, wheel guides and alignment curbs, access ramps, trailer safety jacks and mobile yardramps – (yardramps are available for purchase or rental on a sale or return basis through the company’s RentARamp division) – together with the Truckloada mobile yardlift and the Dockloada scissor lift platform.

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It’s taken a long time and a lot of hard work but we have done it. PTS have launched what is probably the most comprehensive online Stainless Steel Fastener webshop available. Offering our full range of Metric and Unified threaded fastener in both A2 and A4 material. Customers will be able to log on and use the full customer portal to view activity and retrieve documents, they can even place order and repeat previous orders. Full technical data and specifications are available to view online. Why not take a look www.stainlesssteelfasteners.biz

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Tesco DCs

An innovative hi-tech management reporting and safety system designed to prevent the premature departure of vehicles from the loading bay is set to be installed at the Goods In section of every one of Tesco’s distribution centres across the UK.

The supermarket is investing in the Dock Management System, which was jointly developed by UK firms Easilift Loading Systems and Traka, after it impressed during a pilot scheme at Tesco’s distribution centre in Hinckley, Leicestershire.

The system combines Easilift's dock door and associated control equipment with Traka's electronic key control system and was tailored to complement Tesco's existing safety processes, creating a high-tech solution to the problem of vehicle drive-off accidents.

The Dock Management System works by using electronic keys – known as iFobs –each containing a unique electronic chip, which is individually programmed to open or close one specific door when inserted into a control panel.

At Hinckley, the system is now an integral part of a robust protocol whereby drivers are required to hand in their ignition keys when they arrive at the Goods In office. The keys are clipped to an iFob, which is inserted into the main Traka control panel, allowing a corresponding iFob to be removed and handed to the driver.

Only then is it possible to open the bay door, when an authorised operative inserts their personal iFob into a secondary control panel located adjacent to each door.

Once loading or unloading is complete, the operative closes the door. This sends a message to the Goods In control box, permitting the removal of the driver’s keys – but only after the deposit iFob is inserted back into the box.

Tesco trialled the Dock Management System at 26 Goods In loading bays at the Hinckley depot. The bays are used by between 300 and 400 vehicles each day, many of which arrive from overseas, representing a stern test for the new Easilift system.

“We have an excellent safety record at Hinckley, but worker safety is paramount and there is always room for improvement,” said Joe Carthy, distribution health and safety manager for Tesco UK and Ireland.

“It was important therefore that the system was tested in the Goods In section, where we deal with a high volume of drivers, many of whom will be unfamiliar with the layout.

“If the system worked there, we knew that it would be able to achieve our objectives at other loading bays too.”

Fitting the system involved surface-mounting cabling on the inside of the exterior walls and linking 26 individual boxes stationed next to each loading bay door with the control panel in the Goods In office.

“The Easilift Dock Management System was attractive to us because by using control boxes and indicator lights, it lessens the chance of human error,” said Joe.

“This was a limited trial, but the results were fantastic. The system was easy to operate and to understand, and it took a huge amount of human element out of the process. Importantly, it made people feel safe and put them at ease.”

Although the system was developed with a health and safety angle in mind, it has a whole range of other benefits. The system minimises the amount of time the door is open – which can save money and reduce carbon footprints for chilled distribution centres – and, furthermore, can provide an audit trail, logging who used what door and for how long.

This can not only improve efficiency and assist companies in tracking down any missing stock, but can also help with servicing costs. By using the information recorded within the system and the reports generated, a company can devise a servicing programme which takes into account how much the door is used over a set period of time.

The Dock Management System can be easily retro-fitted to virtually any loading bay door and will now be installed in all of Tesco's distribution centres, representing what David Whyatt, sales director at Easilift Loading Systems, described as an excellent way to launch the product onto the market.

He added: “We are thrilled that Tesco has agreed to roll out the Dock Management System UK-wide and by doing so has shown great foresight by investing in a solution which has the potential to cut out serious accidents.

“There could have been no tougher test for the system than to trial it at Hinckley, which is an extremely busy depot where any shortcomings in the system would have been very quickly highlighted.

“It is testament to the technology and expertise at Easilift Loading Systems and Traka that the system proved itself to be watertight and demonstrated that it goes further than any other system on the market to offer peace of mind.”

With 35 years’ experience in the design, manufacture, installation and maintenance of high quality loading bay equipment and industrial doors, Easilift Loading Systems is the UK’s leading specialist supplier of total loading bay solutions to some of the biggest names in retailing, manufacturing, logistics, distribution, warehousing, building, construction and the service sector.

In addition to its unique new Dock Management – Anti Drive-Off System, the company provides a complete range of loading bay equipment, including dock levellers, dock shelters & seals, industrial & high speed doors, and lifting platforms, together with a wide selection of safety aids & accessories such as dock plates, dock bumpers, dock & traffic lights, wheel guides & vehicle restraints, and integrated control systems. Easilift also provides comprehensive service and maintenance programmes for all makes and types of loading bay equipment – irrespective of the manufacturer.

Easilift was also one of the pioneers in the design and installation of dock pod systems, which are complete stand-alone loading bay enclosures that can be installed directly onto the external face of a building. Suitable for new buildings, extensions and refurbishments, they can be quickly and easily re-positioned, if required, and are ideal for use with the increasingly popular and highly cost-effective double deck trailer units.

As the UK’s leading loading bay specialist, Easilift was one of the first in its sector to achieve the prestigious SAFEcontractor accreditation in recognition of its excellent health & safety record and competence, confirming to prospective customers that effective policies and systems are in place.

Easilift is a member of the Loading Systems International Group, one of Europe’s foremost manufacturers of loading bay equipment. The Group has over 450 employees across Europe and a total turnover in excess of 60 million Euros.

An active member of the Association of Loading & Elevating Equipment Manufacturers (ALEM) and the Confederation of Construction Specialists, Easilift operates to the International ISO 9001:2008 Quality Management Standard. The company has Investors In People Bronze status accreditation and is a participant in the Construction Skills Certification Scheme (CSCS), with all its engineers fully qualified under the CITB Site Supervisory Training Scheme.

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Story

ELGA Process Water is helping Veolia Environmental Services
maximise boiler efficiency at a major energy recovery facility

When Veolia Environmental Services required a specialist conditioning chemical supplier for the boiler water at its Tyseley Energy Recovery Facility it turned to ELGA Process Water for help. The Tyseley plant incinerates 350,000 tonnes of Birmingham’s non-recyclable rubbish each year and exports 25MW of electricity to the National Grid, suitable to power over 41,000 homes. The facility has two 45bar 400°C water tube boilers delivering 67 tonnes per hour of steam to the high pressure turbines. It also has a 10bar waste heat shell boiler fuelled by a clinical waste incinerator, and this supplies steam to a low pressure turbine.

In order to maximise boiler efficiency, the quality of the water fed to the boilers has to be carefully controlled. Tyseley produces high purity deionised water on site and adds chemicals to scavenge oxygen and adjust the pH to prevent corrosion. The combination of two types of boiler with common feed water and condensate systems means that controlling the boiler water chemistry at Tyseley requires a specialist solution.

ELGA Process Water, a Veolia Water Solutions & Technologies company, carried out a detailed site survey with technical support from their Boiler Competence Centre. A solution was developed, which included the appropriate chemicals from their Hydrex range to provide protection of the boilers, turbines and condensate system, as well as recommendations for regular service support to maintain ongoing boiler efficiency and optimal performance.

Andy Bullock, Operations Manager for the Tyseley facility is pleased with the result: “ELGA Process Water worked closely with us to achieve the appropriate boiler water quality and we’ve been particularly impressed with the technical support from the Boiler team and their readiness to formulate bespoke conditioning chemicals for our system.”

About the company:

ELGA Process Water is part of Veolia Water Solutions & Technologies (VWS), a subsidiary of Veolia Water. VWS is a leading design & build company and a specialised provider of technological solutions in water treatment. With over 9,500 employees in 57 countries, Veolia Water Solutions & Technologies recorded revenue of ?2.5 billion Euros in 2009.

Veolia Water, the water division of Veolia Environnement, is the world leader in water and wastewater services. Specialized in outsourcing services for municipal authorities, as well as industrial and service companies, Veolia Water provides water service to 95 million people and wastewater service to 66 million. With 95,789 employees in 66 countries, its 2009 revenue amounted to ?12.5 billion.

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Precision Technology Supplies Ltd have consistently increased the range and depth of stock it hold for Metric Stainless Steel Fasteners. With the range starting at M1 and covering up to M24 we now offer more than ever before. Also big increase in the depth of stock in our Unified(American) Threaded Fastener range starting from 0un and up to 1” diameter in stock. For full details visit our website www.pts-uk.com

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The results of a seven month trial just published by Mitsubishi Electric have demonstrated an average Coefficient of Performance (COP) of 6.27 for a ground source heat pump air conditioning system and an impressive COP of 7.14 when the efficiency is maximised through heat recovery during the months when there is a mixed demand for heating and cooling.

The ground source system was designed to provide heating and cooling to the Hoddesdon headquarters of civil engineering and building contractor, VolkerFitzpatrick. It was installed by sustainable energy solutions provider, Cool Planet in conjunction with VolkerFitzpatrick and incorporates seven Mitsubishi Electric City Multi WR2 condensing units in conjunction with a closed loop ground array of 36 bore holes. These were arranged at a spacing of 5.5 metres and at a depth of 100 metres.

VolkerFitzpatrick designed its new building to replace outdated facilities, enhance the company’s corporate identity and showcase its sustainable credentials. The company’s Building Division carried out the design and build of the new office space, with the equipment installed to provide 100% of the heating and cooling demand for the building. VolkerFitzpatrick’s in-house building services department specified a range of energy efficient solutions to suit the overall building design.

A ground source heat recovery system was installed in conjunction with other technologies including PQFY heat pump boilers, solar thermal hot water preheating, an Ecodan® hot water generator, ground air technology, low energy light fittings, daylight saving lighting controls and photo-voltaic brise soleil.

Cool Planet was contracted by VolkerFitzpatrick to design and install a closed loop geothermal system to provide 100% of the heating and cooling load for its new corporate headquarters building. The location on the outskirts of Hoddesdon in Hertfordshire and the amount of surrounding land made it ideal for a ground source heat pump solution.

“First we carried out a feasibility study to determine the scale of the ground works required based on indicative peak heating and cooling loads,” explained Cool Planet’s Steve Gray. “We also carried out a thermal model of the building to ensure the correct sizing of the system to minimise energy consumption and capital costs.”

Both trench and vertical closed loop boreholes were considered, with boreholes preferred because they could be confined to particular areas of the site and in comparison to their trench counterparts impinged less on the construction works. In addition, there is a more consistent COP due to more stable ground temperatures.

“This was the regeneration of a brownfield plant compound and VolkerFitzpatrick’s plan was to use realistic and practical low energy design to reduce carbon emissions, both in construction and in use,” added Gray. “The pioneering three-storey office design had to utilise current best practice and sensible sustainable solutions with the company aiming to achieve a BREEAM Excellent rating.”

From the seven months of analysis it is clear that the ground source system was highly efficient and capable of dealing with the building’s heating and cooling requirements in an environmentally friendly way. It is also clear that system efficiency is maximised when heat recovery takes place during months when there was a mixed demand for heating and cooling. However, even when heat recovery was not being used, the ground source system was still able to produce very high COP’s.

“When we compare the results with alternative technologies and contrast expected efficiencies we estimated a 46% reduction in running costs compared to a chiller and gas boiler system as well as a 53% reduction in CO2 emissions,” added Gray. “Taking this a step further, the cost per m2 to heat and cool the building using the ground source system over the 7 months was £1.29/m2.

From the results it is clear that the building is actually performing better than envisaged at design stage, highlighting the efficiency of the Mitsubishi Electric ground source units and therefore enabling VolkerFitzpatrick to heat and cool their building in a highly environmentally friendly manner.

“We had anticipated monthly COP’s of between 4.0 and 6.0 at the design stage and the resulting 5.54 and 7.14 are a significant improvement which demonstrates the advantages of a heat recovery system,” said Gray.

For more details on the comprehensive design and installation services provided by Cool Planet, call 0870 850 9493 or visit www.cool-planet.co.uk.

For further information on the City Multi WR2 ground source system call 01707 282880 or visit www.mitsubishielectric.co.uk/aircon.

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Precision Technology Supplies Ltd, are pleased to announce we have extended our stock range of American Threaded Stainless Steel fasteners. Our stock range start at just 0un and goes up to 1” diameter. From Bolts and Nuts to Machine screws and Socket screw and all fastener types in between. Full details of the range are available in our handbook which is available to download at www.pts-uk.com/downloads.html.

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