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FEATURE INDUSTRIAL BUILDINGS True as steel integrated FM solution


When Outokumpu sought an experienced facilities management team to manage its state-of-the-art production facility in Sheffield, it turned to Clugston FM for an effective solution. Lesley Grace from Clugston FM, highlights how the company overcame the practical challenges of implementing integrated facilities management on site


T


he trials inherent with managing today’s industrial premises – from


heavy manufacturing facilities producing steel, to more high-tech sites generating petrochemicals and fuel – are often as varied and complex as the facilities themselves. With wide- ranging and more specialised process, plant and machinery in place, each with their own individual requirements, the challenges of ensuring smooth day-to- day operation are substantially increased for industrial premises. For Outokumpu’s modern four mile


premises, with heavy industrial production utilising 200 tonne cranes lifting molten steel for process, as well as a building housing a specialist melting shop, continuous casting and bar finishing facilities on the same site, each operational 24 hours a day, seven days a week, this was certainly the case.


EFFICIENT SERVICE The size, nature and complexity of processes in place at the organisation’s modern production facility, which produces some 300,000 tonnes of steel annually, demands an effective and efficient facilities management service to ensure production runs smoothly at all times and any unnecessary downtime is avoided. The consequences of any unplanned stoppages would be significant on costs, productivity and reputation. A stoppage on critical plant equipment or inside the control room, for instance, could lead to substantial manufacturing back-ups which not only impact the production process, but also on customer lead-times. Keen to avoid such stoppages, the stainless-steel manufacturer turned to Clugston FM, which was able to provide a fully comprehensive integrated facilities management service for the facility. The


16 MAY 2018 | FACTORY EQUIPMENT


FM service delivered on site includes a range of traditional hard and soft FM services, additional specialist-technical services including ESOS compliance, installation and commissioning, the supply of specialist material handling fleet, as well as major shut down and lifecycle planning and management.


VALUE FOR MONEY By using a full time, on-site support and contract management team, the leading manufacturer can ensure effective planned maintenance is undertaken, while a condition-based monitoring stategy ensures asset optimisation, delivery of greater efficiency and value for money. Working proactively with Outokumpu,


Clugston FM has analysed trends, non- core processes and support services, recommending adoption of an incremental year-round approach to dust control in the melting shop. This approach has enabled the Outokumpu subcontractors to focus on essential plant maintenance – optimising resource, timescales and costs. Critical plant, assets in the server rooms,


process cooling equipment, control room, crane cab and x-ray spectro facilities are all centrally planned and controlled via a state-of-the-art computer-aided facility management (CAFM) system and maintained by the sites based team. Clugston FM also provide immediate reactive breakdown responses to critical areas, limiting any plant downtime and maintaining efficiency.


SAFETY DURING HOT WORKS As with any industrial site, issues can arise that necessitate a more reactive approach to facilities management. So, naturally, when an external Du-Pont management audit on safety during hot works raised concerns over employee safety, Clugston FM’s experienced team were on hand to provide an effective solution.


Working with long term partners, Lynx


AC, the FM team designed a fully comprehensive Variable Refrigerant Flow (VRF) system which formed part of an extensive HVAC upgrade across the site. The VRF system encompasses the entire production office management building within Outokumptu’s Stainless Melting and Continuous Casting (SMACC) building. Additional split VRF systems for critical areas, including server rooms, were also required. Building on its experience of completing


a similar live site scenario at Outokumpu Steels Sheffield between January and May 2017, Clugston FM was able to deliver a VRF system – comprising some 22 indoor units and nine split systems – that met all operational requirements. Outsourcing facilities management services has enabled Outokumptu to focus on core operations.


A UNIQUE CHALLENGE The trials of providing premises management are substantially increased for industrial premises. Organisations must balance reactive and planned maintenance, emergency repairs, systems upgrades and planned lifecycle replacements just to keep facilities in operation. Given the breadth of processes in operation in any industrial environment – from HVAC and lighting systems, to heavy machinery and critical plant equipment – and the many potential points of failure on any given day, the value of a capable and knowledgable FM team cannot be underestimated. Add the regulatory compliance requirements associated with large industrial sites and the challenge becomes even greater for today’s facilities management professionals.


Clugston FM www.clugston.co.uk/facilities- management T: 07425 622826


/ FACTORYEQUIPMENT


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