Background Colin Taylor - Director 30+ years in Building Services industry - 10 years design/installation of heat networks Background in BMS & energy networks, ESCo’s & Facility Management Richard Johnson - Director 25+ years construction & civil engineering industry with major UK contractor 8 years management/design/installation of heat networks Original Objectives in December 2012 Establish credible UK Design and Installation Contractor • • Become a Benchmark for Quality Capitalise on the Opportunity within UK market • • Increase Powerpipe UK Market Share • Offer a non-operator “Turnkey Solution”
Established 1986, Sweden’s largest manufacturer of pre-insulated • pipes • Annual Production of: • 25,000 Pipes – Single & Twin (300Km) • 10,000 Fittings & Joints • Products confirm to BS EN Standards EN BS 253, 489 • Verified by Euroheat & Power 2015 Powerpipe’s UK sales £2M – 30% •
Design/Technical Support High Quality Installation Pipe Supply Business Development Product Risk Management Training UK based operation Sub Suppliers Contractors • Directly employed & highly trained technical installation operatives • Technical and design capability – supported by Powerpipe 13/14 Turnover: £1.6m Design Install 14/15 Turnover: £2.5m Maintain 15/16 Turnover: £3.5m UK District Heating Network Market
Capabilities • Pre-insulated pipe design – routing, expansion, feasibility studies & coordination • Pre-insulated pipe supply, install & commission • Civil engineering works associated with the installation of pre-insulated pipe • Maintenance of pre-insulated pipe heating and cooling networks, including water quality • Energy Services Company (ESCo) consultancy – financial and technical modelling • Stockist
Quality • “Once Only” Policy - Raise the bar in terms of UK DH installation • Employed competent trained and certified staff “Best in Class” installation processes and • procedures developed from Swedish standards • Accurate records and data from installation process - GPS • Accreditations:
Heat Network Design • Heat mapping, high level routing & load assessments • Detailed design to BS EN13941– expansion, maximise temperature differential & heat loss calculations • CIBSE Heat Networks – Code of Practice Network sizing, diversity, form of terminations, heat substations, • future expansion • Service coordination – Ground Penetrating Radar, Trial Pits etc. Accurate utility information, reduces project risk, delays & costs • • Installation depth – cost critical Cap/Op ex Wayleaves, possessions, NRSWA, parking suspensions – optimised • practical routing • Construction phased implementation coordination • Testing allowances – NDT, Air Tightness, Hydraulic • Live before all installed – Temporary Energy Centre • Flushing and testing considerations • Operation, Maintenance & Warranty
DH in the UK - Practicalities • Construction/installation generally not considered – time & cost • National Joint Utilities Group - DH not recognised • Utility/general contractors - life cycle risk and conditions required for install of DH • UK Construction Environment – Adversarial • Contracts – Civils & Mechanical • Health & Safety • Time & Programme Constraints Site Coordination & Logistics – 12m lengths • • Cold Lay “the norm” in the UK • Warranty • Contractors Warranty – 12 months • Product Warranty– 12 months, 5yr, 10yr, more… Specialist Contractor Warranty – contract specific durations •
Heat Network – Costs Civil Work- Excavate and Reinstate Composite Rates Mechanical F&R - • Typical split 50:50 Civils and Mechanical Mechanical Mechanical Supply and Install, Excavation in Soft Excavation in Hard Soft per M Hard per M • Central London 60:40 or even 70:30 Inc. prelims per M Surface per M Surface per M Pipe/Casing • Considerations to factor feasibility rates DN 20/110 £ 268.00 £ 140.00 £ 310.00 £ 408.00 £ 578.00 • Environment DN100/225 £ 392.00 £ 156.00 £ 328.00 £ 548.00 £ 720.00 • Access DN150/280 £ 454.00 £ 164.00 £ 344.00 £ 618.00 £ 798.00 DN300/500 £ 860.00 £ 190.00 £ 478.00 £ 1,050.00 £ 1,338.00 • Programme Note: No Allowance for hand excavation/services • Season/Weather • Services • Excavation – hard/soft • Reinstatement materials Possessions – parking bays, road, network rail • • Contractor Risk • Operational costs also critical in overall commercial model • Eneteq can assist with development of site specific budgets for cap-ex and op-ex
Heat Network - Project Risk Risk Management & Allocation Nr Risk Description Impact High Med Low Control Measure Cost Resultant Risk • Design 1 Desired pipe route obstructed Trench diversion and Hold additional pipe offsite or £6,691.97 by additional unkown services alterations that result in the onsite if space and security (£133,839.35 x 5%) • Routing, Expansion, Heat Loss, Sizing requiement for additional pipe, permits Yes - - Low standard and bespoke fittings, joints and assocaited labour, • Installation plant and prelims Hold additional standard £12,549.43 fittings offsite or onsite if space (£83,662.88 x 15%) Low • Services, Programme (3m day in London), and security permits Hold additional joint casings £62,454.71 Pipe 12m, Delay and foam packs offsite or Based upon an addional 102 Low onsite if space and security joints permits • Operation 2 Excavation/Install rate slower Non-productive working Addional civils labour and plant Increased excavtion labour and • Water Quality, Leak Detection, Annual than anticipated at Tender resulting in increased project to maintain tender programme plant costs to be provided by Yes - - Unknown duration, staff and prelims rates others Cycles costs Additional prelims and labour £26,788.00 costs estimated to be 4-weeks or £8,188.00 per week Medium • Controls in duration 3 Logisitcs and materials Unloading area(s) in or around Budget for additional 4-number £5,038.00 • Framework Agreement distribution not as planned Bart's Square not available, HIAB days and associated or £1,259.50 per day resulting in increased time for labour Shared Risk Register • deliveries and/or additional Yes - - Low HIAB days to bring pipe and • Documented Test & Inspection Processes materials from the offsite compound. • Quality Procedures Items not onsite or at the Hold additional materials offsite As detailed above offsite compound will result in - Yes - Low increased programme periods, • As Installed Drawings & Records - GPS prelims etc. • Turnkey Solutions – Supply & Install • Defects Liability & Warranty
Leak Detection What is it? • A pair of wires embedded in throughout the pipe insulation during manufacture • Alarm, Surveillance & Fault Location • Passive or Active Systems Available • Monitors Water Egress & Ingress What does it Cost? • Typically <3% of Contract Value What does it Offer? • Long term monitoring, performance analysis • Early fault location – (1mtr in 1,000mtr) • Minimise & reduce cost of repairs • Reduce OPEX
Heat Loss Conditions • Ground/Ambient Temperature – 10DegC • Conductivity – 1.5W/mK • Cover - 600mm Flow Return Differential Series-1 Series-2 Series-3 Series-4 Unit 95 75 20 352.8 295.8 257.5 226.9 W/mK 75 45 30 235.2 197.2 171.7 151.3 W/mK Reduction in Losses 117.6 98.6 85.8 75.6 W/mK Reduction from Series-1 n/a 155.6 181.1 201.5 W/mK
Innovation Hybrid Systems • Main Transition Mains - Pre-insulated Steel • House/Plot Connections – Flexible Pipes • PEX-A 85DegC 6bar (Higher temps & pressure reduce life expectancy) • Alu-PEX 95DegC 10bar • CuFlex 95DegC+ 16bar • Single, Double & different sizes • High levels of insulation – 0.0216W/mK • Press fittings Steel Press Fitting • HAELOK AG – Swiss manufacturer • Steel Pipe sizes - 6mm – 168mm (6”) • High Temperature, High Pressure no welding • Being assessed by the Danish District Heating Association
Summary Good Design • Compliant with EN13941, CIBSE Code of Practice • Correctly sized carrier pipe, diversified to meet the predicted load • Shortest route, considers construction & site constraints • Maximum differential temperature, minimum heat loss • Active leak detection Good Implementation & Maintenance • Quality Installation that provides accurate records (GPS) Leak detection & System monitoring • • Water quality, “steady” operating conditions Minimises Total Cost of Ownership • CAPEX & OPEX
Case Study: Bristol City Council • Initial appointment for detail design, supply and installation of preinsulated pipe suspended below a new bridge crossing the River Avon • Appointed under a framework agreement for design and procurement of City wide DH network including GPR Surveys, Civils & Supply and Installation • Current Contract Value circa £750k (anticipated £4-5M over 5-years)
Recommend
More recommend
