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Bespoke off-site fabricated rig system provides school with top class heating

22nd May 2018
Remeha Quinta Pro boilers

Four Remeha Quinta Pro 115 boilers have been installed on two bespoke-designed, off-site fabricated Remeha rig systems at Glebe Primary School in Rayleigh, Essex, to provide a rapid, quality solution to high performance heating.

Now part of the Rayleigh Schools Trust, Glebe Primary School formerly came under the local authority of Essex County Council. Following a routine condition survey, Essex County Council recommended replacing the sectional cast-iron boilers serving the Infant and Junior School buildings with high efficiency condensing boilers.

Reliability was a key requirement for the school together with ease and speed of installation, as the refurbishment project was scheduled to be completed within a tight, fixed timeframe.

Spyros Sergiou of Triglyph Engineering Services was the M&E consultant on the project, working alongside heating contractor Balm and Davies Ltd and principal contractor Mitie.

Spyros recommended installing four energy-saving Remeha Quinta Pro 115 boilers on two bespoke-designed rig systems to meet the requirements.

“We are familiar with Remeha boilers and have also used Remeha’s bespoke rig service on several projects,” said Spyros. “Installing multiple condensing boilers rather than one larger output unit will help maximise system efficiency and reliability for the school as well as ensuring easier future maintenance. Installing them on Remeha’s bespoke rig system meant that the unique requirements of the project and the site could be factored in from the outset.”

Using a bespoke design enabled all the space and access restrictions relating to the plant room at Glebe Primary School to be addressed from the outset. This resulted in a more compact design, enabling faster installation and reduced on-site labour and costs.

“The boilers needed to pass through a double set of doors to enter the plant room,” continued Spyros. “This was accounted for in the design, so that when the boilers were delivered into the plant room in the pre-assembled wheeled unit, they fitted in neatly and just needed to be plugged in. It couldn’t have been more straightforward.”

A further advantage of the detailed forward planning process was that the cost, size and specification were all fixed and in place before the bespoke rig was built. This helped keep the project on time and on budget.

When installing condensing boilers onto old systems, it is important to consider the quality of the water as this can affect boiler operation and longevity. This aspect can be accommodated in the bespoke rig unit, as Spyros explained:

“The heating system at the school is around 20 years old. To achieve hydraulic separation and so ensure good condition water, we integrated a plate heat exchanger and air and dirt separators into the rig design.”

A prefabricated heating solution like the bespoke rig system reduces the intensity of skills required on-site. For schools this means added flexibility as the safer conditions, combined with the rapid changeover, enable boiler replacements to be carried out outside the holiday period.

As part of the refurbishment at Glebe Primary School, a new Building Management System has been fitted to enable accurate control and operation of the boilers. The design also uses a variable temperature circuit to maintain low flow and return temperatures, further maximising boiler and system efficiency.

The off-site fabricated bespoke heating solution has achieved an excellent outcome for all.

Improving the reliability and control of the heating provision will help generate a more comfortable, productive learning environment, benefiting children and staff. With higher heating efficiencies and easier future maintenance, the school can anticipate lower operating costs. At the same time, the cleaner operation of the Remeha boilers, with their ultra-low NOx emissions, will help reduce the school’s environmental impact.

Contractors Balm and Davies Ltd commented: “Remeha products are high quality and always first choice for installers. The prefabricated rig system enabled us to schedule the project and team more accurately and so increase site productivity, saving downtime, installation time and, ultimately, costs for the customer.”

Spyros added: “For us as designers, the bespoke nature of the rig and the ability to ‘frontload’ the design means that we can be assured that the specification is met. And at the end of the day, that makes everyone a winner.”