BOILERS, PUMPS & VALVES FEATURE


THE RISE OF prefabrication


I


n recent times, the government has underlined the importance of


prioritising the energy efficiency of our buildings. Energy efficiency is also a key pillar in the UK’s approach to achieve its 2050 net zero target. And, as over a third of UK emissions come from heat, this sector is a clear target for improvement. Certainly, given that many


Production only takes place once the design is clearly identified


buildings still rely on old or inefficient boiler plant for their heating, there is huge scope for efficiency savings. In today’s circumstances, a relatively straightforward and cost-effective plant upgrade may be the most pragmatic solution for energy managers to cut energy consumption, running costs and associated emissions in their buildings. The challenge, however, is to combine minimised disruption and quality installation with COVID-19 safety guidance.


OFF-SITE BENEFITS Using prefabrication techniques can achieve all three goals. The opportunity to use turnkey prefabricated rig or cascade systems for wall-hung or floor-standing boilers on boiler replacement projects, for example, results in faster project completion and minimal disruption. Carrying out most of the manufacturing offsite, using specialist machinery in a quality-controlled factory environment, reduces waste and leads to better build quality through improved control procedures. At the same time this method reduces on-site time, labour and headcount, enabling physical distancing requirements to be more easily met.


OPTIMISING EFFICIENCY Where prefabricated heating systems are designed bespoke to the project, all requirements – from space and access limitations to water quality, project-specific controls and optimal pipework for connection to the system – can be addressed in advance at the design stage.


Tom Murray, specification director at Baxi Heating, looks at the growing use of


bespoke prefabricated heating solutions to provide a safe, quality, non-disruptive solution to high efficiency heating


The boiler


configuration maximises efficient use of energy with the option to integrate customised controls, housed within a comprehensive


panel, to deliver optimised operation at all times. Additionally, hydraulic separation can be


achieved using either a specially sized plate heat exchanger or low loss header to ensure high boiler and system performance. Importantly, the design also addresses lifetime boiler performance as individual units can easily be taken off-line for servicing as required, with minimal disruption or impact on system performance. Selection of associated components such


as boiler pumps, controls and plate heat exchanger or low loss header, is carried out by the prefabricated solution provider, ensuring that the resulting package delivers the specified performance as a combined system.


EARLY VISUALISATION As production only takes place once the design is clearly identified, energy and facilities managers have the opportunity to provide input at the early stages and the assurance of a quality outcome. Once the rig has been manufactured and tested off-site in a specialist, quality-controlled factory environment, it is delivered to the plant room on a wheeled frame, with insulated pipework set, ready for easy connection. With zero on-site fabrication related to the


boiler assembly and no need for the associated hot works, on-site safety is increased and disruption to building occupants avoided. System downtime is also minimised as rapid, ‘plug and play’ prefabricated rig systems, will reduce installation and commissioning down from weeks to days.


MINIMISING DISRUPTION So how and where are these solutions being used? One example is at Gun Wharf, Medway Council’s main offices. When planning to replace the old boilers, disruption was a major concern for the Council. TSS Facilities recommended installing five Remeha Gas 220 Ace boilers with a plate heat exchanger in a Remeha prefabricated heating system to meet the project requirements. Consultant John Richardson, working on behalf


For Medway Council’s main offices, TSS Facilities recommended five


Remeha Gas 220 Ace boilers in a prefabricated heating system


of Medway Council, said: “By using the Remeha Gas 220 boilers, the contractor was able to strip out the old plant and carry out pipework modifications while the boiler sets were being


/ DESIGNSOLUTIONS


fabricated off site. This installation technique enabled the Council to control the shutdown period required to complete the contract. The fully modulating Remeha boiler plant, in conjunction with upgraded controls, have greatly enhanced the building’s efficiency and the Council’s carbon footprint.”


MEETING TIGHT SCHEDULES Prefabricated heating solutions like these are frequently specified to meet tight project deadlines due to the rapid installation. When Nottinghamshire Police began a three-month programme to refurbish the heating systems at a series of its police stations, the tight schedule was a critical challenge. As all the police stations were to be kept operational during the works, there could be no disruption to the hot water service. Additionally, all systems needed to be fully operational by the start of the heating season. Working with


consultants CJR Midlands and M&E contractor ASBN, Remeha provided prefabricated cascade arrangements for its Gas 220 Ace floor-standing range to enable rapid product completion. “Nottinghamshire


Police are pleased with the end result, especially as the collaborative approach enabled the team to deliver on time and on budget,” commented David Griffiths, regional director at CJR Midlands.


A prefabricated cascade arrangement was provided for Nottinghamshire police


QUALITY SOLUTION As energy managers strive to reduce energy usage in their buildings, addressing the efficiency of the heating system is a natural starting point. Examples like these illustrate how using manufacturer prefabricated heating systems provides a practical means of resolving any obstacles at the outset, achieving rapid, safe, non-disruptive, quality solutions for optimum results and efficiency savings. The UK is seeing a bigger push for use of


prefabrication than ever before. Given the numerous benefits, it’s easy to understand why.


Baxi Heating remeha.co.uk


ENERGY MANAGEMENT | AUTUMN 2020 23


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