Remeha off-site fabricated cascade system provides rapid solution for Council

WOKINGHAM, U.K. - March 6, 2019 - PRLog -- Medway Council has installed five Remeha Gas 220 Ace floor-standing condensing boilers on an off-site fabricated cascade system at Gun Wharf, its main council offices, to achieve more reliable heating with minimum disruption.

Replacing ageing or inefficient boiler plant with high efficiency condensing boilers is a cost-effective solution to significant environmental and operational savings. Improving the reliability and effectiveness of the heating provision also helps generate a more comfortable – and more productive – building environment for its occupants.

So when the existing boilers came to the end of their serviceable life, the Council were quick to appoint contractors TSS Facilities to replace the dated boiler plant.

TSS Facilities recommended installing five Remeha Gas 220 Ace boilers with a plate heat exchanger (PHE) on an off-site fabricated cascade system to meet the project requirements.

Mark Basset, Mechanical Installations and Asset Manager at TSS Facilities, said:

"We've fitted Remeha boilers for many years and are impressed with the operational efficiencies and performance of their products, which is matched by the great service we receive."

The Gas 220 Ace boilers were selected partly due to their small footprint and width, and also because of the Remeha off-site fabricated cascade options that facilitate faster, smoother installation.

To overcome the plantroom space restrictions at Gun Wharf, Remeha worked with TSS Facilities to design and manufacture off-site a bespoke pipework arrangement that would ensure a space and time-saving boiler cascade configuration and integrate a PHE into the design. PHEs are increasingly applied to refurbishment projects to achieve hydraulic separation between the boiler circuit and the heating circuit and so optimise boiler performance and longevity.

Off-site fabrication techniques achieve rapid, high-quality heating solutions, as Remeha's Product Manager, Paul Arnold, explained: "Off-site fabrication offers huge benefits for end-users and contractors as the unique requirements of the project and the site can be factored in from the outset.

"This cascade arrangement for Gun Wharf not only accommodated the space constraints but was designed to be easily connected to the existing system, to save TSS Facilities on-site time and labour and achieve the most effective use of the space available. This solution also reduces on-site hot works, improving site safety. And as the cascade is produced under factory conditions, it brings the added benefit of factory quality assurance and pre-release testing."

Working with TSS Facilities, Remeha prepared 3D drawings to enable early visualisation of the layout before producing the pipework assembly in sections off site. These drawings then formed part of a comprehensive documentation pack for the client.

To overcome the plantroom space restrictions, the design called for the PHE and the pump to be positioned behind the boilers. The pipework was then configured so that the system connection faced upwards, as required by TSS Facilities.

Mark continued: "Having the option to design the position of the PHE and pump ahead of installation meant that we could improve access. And while the pipework was being configured off-site, we were able to work on the system pipework, which sped up the installation process."

Once the equipment was delivered to site, TSS Facilities bolted together the boilers, pipework connection components and the PHE, on its wheeled frame, and connected them to the existing system. It was a seamless process, as Mark explained:

"The project went well from start to finish. Having the Gas 220 Ace boilers delivered in an off-site fabricated system made our lives so much easier. It allowed us to schedule the project and team more accurately, increasing our productivity. At the same time, it saved downtime and installation time. Ultimately, the customer benefits too, with reduced costs and disruption at the installation stage, and easier servicing in the future."

Applying this heating solution smoothed the heating upgrade process, as Consultant John Richardson, working on behalf of the Council, explained:

"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 fabricated off site," he said. "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."

On projects like this, off-site fabricated equipment can bring advantages for the entire supply chain. Medway Council is benefitting from more efficient, more reliable heating following minimal disruption. The Consultant can be assured that the specification and customer requirements have been met. And TSS Facilities have benefitted from improved site productivity and reduced installation time.

Available in a wide range of outputs, the Gas 220 Ace series delivers higher than average gross efficiencies of up to 98% with ultra-low NOx emissions and is supplied with total in-built control as standard.

-ENDS-

remeha.co.uk – T: 0118 978 3434 – E: info@remeha.co.uk

About Remeha (http://www.remeha.co.uk)

Remeha has been reliably engineering high-performance and high efficiency heating solutions since 1935, providing the most energy-efficient, sustainable and economical heating solution for every commercial requirement. At the heart of its comprehensive product portfolio is the class-leading, fully modulating, low NOx Remeha condensing boiler range. Built around a single design concept, these boilers can be combined with Remeha's complementary high-performance renewable and low carbon heating solutions to create the low carbon plant room. This includes its combined heat and power (CHP) range spanning 5.5kWe to 150kWe, HIUs and gas absorption heat pumps.