|Client:||European Paint Manufacturer|
|Project:||New 100,000 square metre paint manufacturing facility in UK.|
Its cutting edge design was the first of its kind in the UK and utilised Siemens PCS7 architecture to control nine automated paint filling lines, each featuring an advanced robotic stacking system to service over 200 sizes of tin using barcode identification.
The factory reduces the energy consumption per litre of paint through cutting edge manufacturing technology and the latest innovations in building design, whilst placing a strong emphasis on sustainability through the introduction of: biomass, solar energy, rainwater harvesting and intelligent lighting, to name but a few technologies adopted.
Our early design obligations were primarily to provide detailed design to both the client and the Boulting construction team to facilitate the E&I Installation works. We were further requested to provide assistance and carry out front end design for subsequent packages for both E&I and Mechanical works. We provided a suite of designers (peaking at over 15 designers) over a 3 year period, proving integral to the successful progression of a very complex project.
After an initial award of three E&I packages, further packages were issued once the design was developed. The scope of work included main LV feeds, Power & Control Cabling, Profibus & Instrumentation Cabling, Installation of AFD’s, Valve Couplers, Instrumentation junction boxes and cabling, Instrument Tubing & Manifolds, lighting, Fibre Optic & Data Networks, all fully tested with handover documentation provided for all.
In total, in excess of 250,000m of cabling on new Cable Ladder Rack and Traywork was installed.
We were initially engaged mechanically to complete Filling and Packing Hall pipework which included a mix of Hygenic Stainless Steel Pipework and Screwed Carbon Pipework. With the clients emphasis on quality and aesthetics, our installation stands out as the show piece to this plant to demonstrate its automation capability.
Effective solutions provided to substantial challenges
Much of the original piping (completed by others) had been installed using temporary supports, typically constructed of Unistrut and hangers. Following a stress analysis of the systems it became evident that these supports would not be suitable and therefore they would need replacing. In summary, over 45km of pipework was surveyed and fitted with new permanent supports where necessary. Each support was referenced, added and identified via a tracker after which it was designed, fabricated and installed.
Finally, to ensure the overall completeness and integrity of all the systems we hydrostatic tested all pipework, providing full handover documentation, including associated test certs for each system.
Our system integration team completed a predesign check of the Profibus system, as well as set up and test rigs for each of the 5000 plus devices. In an extensive programme every single device interface was designed, tested and documented.
In addition, the existing corporate, site-wide, fibre optic infrastructure was evaluated. This was to facilitate six autonomous, resilient, Ethernet networks to 68 additional locations. Following the evaluation, we were further engaged to performed detailed design, implementation and network performance testing
Boulting achieved the key handover dates with an excellent health and safety performance.
Collaboration from concept to construction
Read our take on the benefits of integrated project delivery (IPD) and the collaborative culture it produces.
Engineering standards and the importance of professional registration
Here, Glyn Shawcross, Boulting Design Manager, explores the importance of working with accredited contractors who invest in training for employees.