Dry Well Ventilation Electrical Installation

ATS were appointed to deliver both the Mechanical & Electrical aspects for Central London dry well ventilation solution.

Initial Engagement

Following the engagement with our client, assessing the existing dehumidification system within the dry well, it was deemed the system was non-operational.

The end user’s standards were not consulted previously, therefore ATS had to come up with a solution in which constraints were already in place.

The existing system was housed within a small GRP kiosk and no additional civil penetrations could be made apart from the existing for the supply and exhaust that were positioned either side of the dry well.

Our Solution

From this we provided a mechanical supply system compromising of 2 no. inline axial fans in a duty/standby arrangement, a range of uPVC/GRP ductwork and 1 no. passive exhaust system.

This system aimed to remove potential H2S contaminates from the dry well, providing a safe working environment for operatives when assessing the lower levels.

Electrical Requirements

As well as being awarded the mechanical ventilation package we were also asked to provide the ventilation control panel along with the power and controls installation.

Following our recent engagement with the end user, we were able to provide our own inhouse built form 2 non-framework control panel, by providing the guarantee that our control panel would be designed and built-in accordance with framework specifications.

Installation

As we were responsible for developing the full ventilation solution, we were able to have a full understanding of the new system and how it operates This resulted in a smooth mechanical and electrical design sign off without issue or delay.

Upon design approval the team worked hard to ensure programme dates were met by building, FAT, and delivering the control panel to site within 5 working days.

In addition, due to the area being near to the coast this brought about the requirement for C4 protection. This can usually be overcome by utilising plastic equipment; however, this can result in a high price tag.

Solution

To manage client expectations and budget we were able to abet the solution of cladding the ventilation system instead thus provided the required C4 protection alongside keeping within budget.

In aid of our programme dates and ensure a superior installation process, the panel and equipment was assembled at our workshop as a modular package.

As the fans and instrumentation were local to the position of the control panel, we were able to pre-install, contain, wire, connect and test part of the installation before delivery to site.

We installed our custom-built isolators containing motor power connections, auxiliary early break contacts, heater, and thermistor controls along with flow monitoring instrument connections to the modular frame. We delivered this to site and bolted into position ready for final connection to the fan motors and instrumentation.

Result

This was a successfully completed project, on time and to a high standard, resulting in a well-ventilated environment in the dry well for personnel to complete any tasks, knowing that they are safe and protected by a high quality, high specification, tested and proven ventilation system.

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Dunstable Temperature & Humidity Control

The scope of project was to provide tight temperature and humidity control to a processed printing site in Dunstable.

Client – RSR Ltd

Offering a full solution from construction to completion with Air Technology Systems, with both Mechanical design & Installation support.

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Project Scope

The scope of project was to provide tight temperature and humidity controlled to a processed printing site.

This site was for a world-renowned global distribution company to enable them to print books to ensure ink for text and glue for book spine was at suitable conditions.

Our Services:

• Ventilation services with heat recovery, humidification, heating coil, cooling coil and air filtration. Supply & Extract ventilation totalling 37m3/s of air.
• Heating services via duty/assist/assist LPHW pumped services exceeding 330kW
• Cooling services via duty/standby chilled water pumped services exceeding 680kW’s
• Gas humidifiers with reverse osmosis and brine treated water, offering over 540kg/hr of steam introduction
• Full site integrated BMS in Tridium software
• Medium pressure gas around 70mBar in the space
• Exhaust ventilation for COSHH due to printer works and gluing process

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Challenges

• Meeting tight control in the space of +/- 1.5 degrees C & +/- 5% RH
• Tight programme of circa 16 weeks for all services supplied and installed
• Integration of various services such as Ventilation & Water services in a tight area.
• Installation of ductwork on a mezzanine roof that could not be installed onto suspension from over 8m’s up.

Solution

To design the solution from bottom up with all bespoke equipment and ductwork to suit the client’s needs.

The tight programme dates posed as a challenge for the project, we therefore had to increase the delivery team to overcome this. We employed skilled and qualified engineers, due to the bespoke nature of project, to upskill and train current ATS staff.

Our Systems

Result

A quality installation on each level and service to provide the client will full autonomous Industrial Temperature & Humidity control. It can adjust to all conditions in the space to all deliveries, changes in printing whilst maintaining the set design conditions.

The result was a happy client, with a full production zone, causing no delays to any works.

Distribution Centre – Dirft

Air Technology Systems Ltd were commissioned to complete the warehouse Industrial Climate Control System at the prestigious Royal Mail Dirft site.

Client – Phase Mechanical Projects (PMP) for Royal Mail

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Project Stats

• >4000m of Ductwork
• 90m³/s of Air Movement
• 9 bespoke Air Handling Units & associated direct expansion Air Cooled Condensing Units
• 9 bespoke HVAC Control Panels
• >4000m of Sensor Wiring
• 528 Air Induction Nozzles
• 1765kW of Heating Demand
• 1621kW of Cooling Demand

Project Scope

Air Technology Systems Ltd were instructed by our valued client PMP to complete the design, installation, and commissioning of the industrial climate control systems for the Warehouse at Royal Mail Dirft, which included:

• Bespoke air handling units
• Direct expansion air cooled condensing units
• Return air inline axial fans
• Supply air and Return air ductwork in galvanised mild steel to DW144.
• Integration with Solar Wall Technology

Electrical Scope

In addition to the above, our mechanical team enlisted the specialist services of our Controls & Electrical department to design, manufacture, and install of the 9no. bespoke Trend PLC Control Panels. This required the efficient control and operation of the individual zoned systems, including:

• All internal AHU controls wiring and instrumentation
• All fire damper controls wiring
• All field sensor wiring and all field return air axial fan controls wiring.

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Objectives

The primary objective for this project was to provide an Industrial Climate Control Solution to meet demands of the client’s performance specification. The focus on being able to meet the heating demand during peak wintertime conditions, whilst providing an element of cooling during summer months.

The South Zone System also incorporated a Solar Wall® system, provided as part of the main building cladding structure. This is a proprietary building cladding system designed specifically for the collection of free heat energy given off by the suns radiation. In winter this heat energy is collected via Air Technology System’s packaged systems, which pre-heats the internal space conditions, thus lowering the operational cost and required duty of combined heating output.

Challenges

• Client preferred the design of duct routes and AHU positions in North plant deck, this created access issues throughout the plant deck due to space limitations.
• Working at a fast pace to be out of handover areas on time, enabling the client to build mezzanine decks throughout warehouse area.
• Coordination between trades daily to keep segregation between work areas and plant decks
• Distribution of 1621kW of Cooling & 1725kW of Heating
• Mechanical Handling Equipment (MHE) heat loads
• Pressurisation of adjoining warehouse in free cooling mode

Our Industrial Climate Control System

Solution

This was a challenging project from the offset, due to the physical size of the building and the logistics involved with the delivery and installation. The solution required a turnkey approach from design to project management, involving delivery techniques that needed to be adapted and developed to suit the construction line.

Our Technology

Our solution incorporated our very own proprietary High Velocity Industrial Climate Control System together with 9no. high efficiency electric-gas hybrid Air Handling Units and high efficiency air cooled direct expansion condensing units. This combination of advanced technology enabled our design team to provide a solution that provided the client with the most effective solution in Warehouse Climate Control.

The system is designed to provide horizontal and vertical temperature control throughout the space, making it ideal for densely packed areas, mezzanines, and tall warehouse buildings. Distribution ductwork is routed at high level within the pitch of the roof, limiting the impact the HVAC services have on space comparative to conventional systems.

System Design

The treated supply air is distributed into the space via a series of self-balancing High Velocity Nozzle Outlets. These outlets are designed and selected such that no mechanical balancing aids are required resulting in a maintenance-free high-level system. This is a key design characteristic of this Industrial Climate Control System, providing maximum performance and efficiency, delivered via a method which is significantly smaller than like-for-like conventional HVAC and or Displacement Systems.

The completed systems are fully automated, designed and programmed to optimise system performance, based on meeting the needs of the internal space condition against the external ambient conditions. This was all down to our inhouse Controls & Electrical department who designed and manufactured the control panels and integrated the intelligent programmable logic controllers.

Result

The project was completed on time and within budget, meeting with the client’s required practical completion dates and successfully handing over the fully commissioned system to the client’s consultant.

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White City House, West London

Laid back luxury members’ club occupies iconic BBC Television Centre building. ATS Commercial complete significant mechanical and electrical project at White City House, Wood Lane, West London.

Client – White City House

Project Scope

The sophisticated four-floor complex offers stunning facilities to its members including a basement pool, spa, 24,000 Sq. ft gym. It bodes numerous restaurant and dining areas, screening rooms and a dazzling rooftop pool.

Elegant Destination within Hospitality Sector

Working in partnership with the international private members’ club operator, Soho House & Co, ATS managed the entire mechanical, electrical and HVAC requirements.

White City House is the latest addition to Soho House’s exclusive property portfolio and part of a major White City local regeneration.

Private member club accommodation and entertainment includes forty-five superior designed hotel rooms and suites, restaurants, bars, and a luxurious waiter service three-screen cinema.

Taking challenges in our stride

The eight-month, £6.8m project encountered daily logistical challenges due to the nature of the urban site. To mitigate risk and delay, ATS appointed a logistics manager to coordinate a real-time online delivery system, materials distribution and personnel.

ATS collaborated with Mace Group Ltd London, utility service providers and partner construction companies. Proactive communication between 100s of individuals within the design, project management and subcontractor teams ensured an agile approach and minimal disruption.

Significant changes to the design brief during the third stage of the project necessitated personnel reorganisation at the highest level, which in turn, impacted the redistribution of on-site resources, equipment and labour. Despite this, the project was still completed within the agreed timescale – a huge achievement by all.

Remarkable quality and classic furnishings

Equipment such as grilles, controls and access panels were hidden to enhance aesthetic appeal. Bespoke plating and surface finishing was applied to sockets, switches and controllers to match the exclusive décor.

The entire installation was fitted with reliable and dimmable ultra low energy LED lighting including custom-made components to create the Soho House trademark ambience.

Seriously Cool Environment – Whatever the Weather

Behind the scenes, all M&E and HVAC equipment was housed within five plant rooms monitored by a comprehensive building management system with automatic testing and fault reporting.

Sensors operate climate control throughout the building and programmable lighting with pre-set scenes eliminates user error and has the ability to track natural light and adjust accordingly.

Odour Control and Lighting Wastewater Treatment Site

ATS Electrical were required to Design & CDM Project Manage the Installation of both a Form 4 Control Panel and the lighting for this Wastewater Project.

Client – Wastewater Treatment Site

Project Scope & Objectives

The design and installation of a Form 4 control panel and electrical installation to WIMES and specific water industry specifications. It needed to control a new odour control system, comprising of 2no. biological filter units, 1no. droplet eliminator, 2no. duty stand-by centrifugal exhaust fans with emergency stop, heat extraction, thermistors, flow switches and motor heaters, 3no. carbon filter units, 2no. pressure transmitters, motorised water supply valves, trace heating and panel heaters and flow and limit switches.

Additionally, Air Technology Systems took on the Construction Design Management (CDM) role for this project, completing the removal of redundant PLC code and HMI mimics relating to old plant and new SCADA signals to be integrated with existing site wide system.

Air Technology Systems were also awarded the design, supply and installation of emergency and task lighting to cover the extent of the new installation.

Challenges

Due to this site being a live site, with a fully working process area and the works involving the replacement of an old system, we needed to utilise and change some of the, already in-place, wiring ducts. This needed to be a fast-paced project delivery to reduce “downtime” of the old system, to reduce odours affecting nearby public areas.

It was essential for us to interface with the clients controls system and their external specialists, to adapt the existing feeders and SCADA system for utilisation and commissioning.

Whilst designing the project, we were also required to install a new Form 4 panel in the new Kiosk, due to increased size and capabilities.

We had to ensure WIMES and specific water industry specification to be met with the panel build and full electrical installation, while large amount of Interfacing with new mechanical odour control plant and existing infrastructure was essential to ensure a smooth all round project delivery.

Solution

We created new wiring routes with the use of existing wiring ducts and above-ground, heavy duty, post-dipped galvanised tray work to serve all items of kit. This enabled a fast-paced project delivery, while we increased the size of our installation team to reduce overall programme duration.

Due to the complex nature of this project, we positioned on-site, non-working supervisors to assist with smooth CDM project management.

With the new size of Form 4 panel needed, we installed and positioned a new kiosk (4.5m x 2.5m) to house the controls and distribution. To meet with project deadlines, the kiosk was lifted into position after the installation of the control panel, with a temporary waterproof marquee installed to facilitate full installation.

We used our in-house labour team to carry out this project, who have a wealth of experience relating to WIMES and numerous water body specifications, along with our internal Electrical and Mechanical Design teams worked closely to ensure a seamless functional design was provided

Result

As a result of firm teamwork, value engineering and client support; we ensured a fully functional Odour Control and emergency lighting systems were designed, installed, and commissioned to high specification-compliant standards.

We guaranteed both internal and client collaborations, throughout the course of the project, resulting in programme deadlines being met in good time, without any changes to quality or philosophy.  At the end of this successful project, all new plant and controls were seamlessly integrated and commissioned alongside local site PLC/HMI and regional SCADA, the emergency lighting installation was installed to a high standard as per design calculations and layout; and tested without issue.

Mining Controls Package

ATS Electrical were required to provide a new Mining Facility Winder building and Hoist House Ventilation Controls Package

Client – Mining Industry

Project Scope & Objectives

ATS Electrical were awarded this project, to install both the electrical and control system for the ventilation services to the winder building and hoist house on a new mining facility. The Winder building ventilation was controlled by four separate AHU’s and the Hoist House via 6no. extract & supply fans, wired back to a central control panel

Challenges

The biggest challenge faced by the team was due to the sheer height of the high bay area alongside the tight deadline and relatively short time frame given: 6 weeks. This meant work on the project needed to be fast-paced throughout and included careful coordination with other trades to ensure the project was completed to a high quality, in-line with the client specification and on time.

At over 40m high, the biggest requirement of the frost protection system was to ensure a constant and even temperature distribution, both horizontally and vertically, throughout the high bay area. A large percentage of the works had to be carried out at the 40m roof-level height, therefore specialist equipment was required on site to gain full access. This was not a problem for ATS, as all our staff who are required to work at heights are IPAF (International Power Access Federation), PASMA (Prefabricated Access Suppliers Manufacturers Association), and harness trained; this is a basic requirement to operate any MEWP (Mechanical Elevating Work Platform) on site.

ATS, having been in the industry for over 30 years, had the right temperature control expertise, knowledge, and training to be able to take on a unique and challenging project such as this one.

Solution

As our Temperature Control specialist sales team took the time to gain an in-depth knowledge and understanding of what the client required, it meant that our dedicated team designed an air induction system utilising our warehouse heating technology with 3 specialist air handling units (AHU’s).

To achieve an even temperature distribution throughout the areas, especially the 40m high bay area, the design team had to meticulously select ductwork routes, sizes and the appropriate equipment in order to meet the temperature requirements.

A total of 750KW of heating was supplied to the warehouse and over 1000m of ductwork was installed within the short time frame given. One ahu was dedicated to heating the mezzanine area, another AHU was dedicated to serve one side of the high and low bay areas, and the third AHU was dedicated to serve the other half of the high and low bay areas, resulting in even warehouse temperature distribution.

Result

The hard work and dedication given by the onsite project management team meant the warehouse heating goals were met within the project deadline and to the high exacting standard that ATS continuously provide.

Our warehouse heating system maintained a constant air temperature of 5°C, providing frost protection, throughout the high bay and low bay areas, as well as heating the mezzanine area.
Our specialist temperature control engineers worked around the clock to provide our client with a successfully installed, high specification warehouse heating system, designed for one of the UK’s largest high bay areas.

The project was completed within the time frame and within budget, and the best result of all was a happy client.