Case study: Aerospace
- YEAR:
This leading supplier to the aviation industry chose a shell of a building from which to create its new production facility. Planning staff called in R&S to design and develop a modern, efficient, high-spec facility.
This client is a leading global provider of parts and services for ‘legacy aircraft’. It manufactures and services a range of aerospace component parts for more than 3,000 customers worldwide.
The challenge
In 2011 the company needed to relocate and consolidate a number of its manufacturing and repair processes to a single location: they were, at the time, spread across a number of locations, some of which were owned by their competitors. The nature of its activities and the requirements placed on it by its clientele mean the company’s operations have to be flexible and adaptable to meet changing demands. The new facility needed to meet very specific requirements for tasks including handling aviation fuel – and be adaptable and easily modified to suit constant changes in processes and work activities
The biggest challenge, perhaps, was to complete the work while achieving zero unplanned manufacturing downtime.
For a variety of reasons its executives chose to refurbish and modernise an existing steel-framed building in Cheltenham, Gloucestershire, to create a 6,000 square metre manufacturing, repair and overhaul facility.
Our solution
We worked with the client to design and develop plans for comprehensive mechanical and electrical services installations.
Our client had the foresight to involve us from the outset, enabling us to provide concept designs and venture guidance costs before agreeing a fixed price contract and defining the scope of works.
- three Carrier 500 kW R410A air-source heat pump chillers located on the external plant area at low level, with the ability to add a further chiller for future resilience;
- rationalisation of existing 400V / 415V LV power to release three 400V supplied for the new pumps;
- retention of existing single operational Dunham Bush chiller while we commissioned the new plant;
- the buildings are cooled by operating the air source heat pump chillers in "cooling mode" with a chilled water supply temperature of 6°C at an energy efficiency ratio of approximately 2.8;
- pre-heat is supplied by operating the air-source heat pumps in "heating mode" with a water supply temperature of 35°C and a coefficient of performance at approximately 2.5;
- "stage 1" heat recovery with refrigerant de-super-heaters at approximately 50°C when the machines are operating in a "cooling" or "heating mode";
- a facility for a future ("stage 2") heat recovery to further reduce energy consumption and carbon emissions when investment funds are available.
The project took 12 months to complete, including R&S assisting the client with their relocations and post-move analysis to ensure maximum production efficiency.
The result
The benefits of applying air source heat pump chillers with “stage 1” heat recovery include:
Delivered on time, on budget
Together, we completed this project on time, on budget and with zero unplanned manufacturing downtime
We continue cooperation
The initial mechanical and electrical services contract value was in excess of £2.3 million. Following this project our client relocated its oxygen cylinder refurbishment service facilities from Slough, calling in R&S to assist and involving us in the design and construction of the new facility, in Cheltenham
Full technical support
R&S now provides a comprehensive planned preventative maintenance package with full technical support
TESTIMONIALS
What our clients say
The total cost of ownership over a 25-year period has the potential to save over £1 million and 2,500 tonnes of CO 2
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