Commissioning Assistance

Grafton Hospital – Central Chiller Upgrade

03/02/2020 By EpesEditor

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Grafton Hospital - Central Chiller Upgrade

Mechanical Engineering

EPES were engaged by NNSWLHD to investigate performance issues with existing chillers and prepare contract design documentation for the upgrade of central chilled water system. Central chilled water systems serving critical care areas such as operating theatres, sterile store and reprocessing areas.

Our role in the works was from initial investigations, concept development through to detailed engineering design, tendering assistance, construction supervision and thorough witness testing during commissioning.

Scope included mechanical, electrical and BMS.

The Problem

Project Information

Location: Grafton, New South Wales, Australia
Client: Northern NSW Local Health District (NNSWLHD)
Engagement: Design Consultant
Sectors: Buildings, Hospitals and Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Independent Reviews and Audits
Year: 2015

As hospitals are refurbished and extended to, there is a tendency for the hydraulics of the chilled water system to vary from the original design. This is particularly important when modern technology and design thinking is introduced into legacy systems.

Differences in thinking around variable flow versus constant flow, system configurations (primary versus primary/secondary) necessitate critical thinking and taking the time to understand the original design intent and how new design thinking will influence performance and reliability. Modern equipment is much more sensitive to changes in flow and temperature.

The main challenges in this project was to understand the legacy system and the changes that have been introduced since it was initially commissioned.

Analysis and Implementation

EPES spent considerable time in the investigation stages to gain a thorough understanding of the following:

EPES also liaised extensively with various stakeholders including clinical staff, project managers and Contractors involved in the original works as well BMS controls technicians and site-based maintenance engineers.

Once the various pieces of the puzzle had been determined, a contract design was prepared which included replacement of a legacy chiller, modifications to chilled water piping and reprogramming of BMS controls functions.

Outcome

The resulting chilled water system has provided the hospital with reliable chilled water production and reticulation throughout the field. Controls functions have been rigorously tested, including staging and failure controls functions to ensure that critical areas are always provided with cooling and dehumidification.

Integrating new technologies into legacy systems must be subjected to a high degree of diligence and investigation to ensure compatibility. Taking the time to understand the root cause of performance problems enables long term reliable solutions to be identified economically and with minimised disruption to availability.

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Parnell Manufacturing Facility Upgrade

03/02/2020 By EpesEditor

Parnell Manufacturing Facility Upgrade Slide 1

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Parnell Manufacturing Facility Upgrade

Rectification of Humidity Control Systems, Stability Rooms and Central Cooling and Heating Systems

Parnell are manufacturers of veterinary pharmaceuticals with FDA and EMA accredited sterile manufacturing facilities in Alexandria NSW. Parnell produces products for animals such as dogs, dairy and beef cows, and horses.

EPES were engaged by Parnell to investigate and resolve long running humidity control issues within product stability rooms, humidity control, central heating and cooling systems and central Building Management System controls.

It was recognised that there were problems with the performance of the mechanical systems, however our involvement was required to develop a methodology and contract design for resolution.

Project Information

Location: Alexandria, New South Wales, Australia
Client: Parnell Veterinary Pharmaceuticals
Engagement: Design Consultant
Sectors: Buildings, Pharmaceuticals
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Independent Reviews and Audits, Specialist Analysis
Year: 2016

The Problem

Unreliable system controls and mechanical services performance made demonstrating compliance challenging for the various critical certifications that the facility holds. Of primary concern were stability rooms which are required to control within tight limits for long durations of product testing, as well as the reliability of central heating and cooling systems in delivering humidity control to the various sterile rooms.

Analysis and Implementation

EPES studied and tested the existing system to ascertain the shortcomings in system configuration versus what space conditions control was required for the certification process. Performance issues were identified, and design documentation prepared to enable rectifications works to be undertaken with supplementary equipment for humidification, greater reliability in controls and modifications to central heating hydraulics to improve flow circulation and availability.

EPES assisted the client in tendering the works, reviewing tender submissions and supervising the construction works with witness testing of the commissioning process for validation of performance in accordance with the design.

Outcome

The client achieved a predictable and reliable system performance following the works and greater control over the space conditions throughout the facility.

Taking time at the start of the project to study and test the existing systems enabled greater clarity in defining the rectification solution as well as ensuring that the contracted scope that was tendered was tight, mitigating cost escalation risks.

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Aimeliik Cargoline Replacement Project

03/02/2020 By EpesEditor

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Aimeliik Cargoline Replacement Project

Engineering Design

EPES in partnership with Endeavour Inspection Services (based in Guam), undertook the detailed survey and engineering design for replacement of the replacement of the existing 12” cargo pipeline enabling diesel fuel transfer from the jetty to the Power Plant tank farm in Aimeliik, Republic of Palau. The existing pipeline was showing signs of excessive corrosion and undermining of supports.

Scope of the technical services included:

Civil and structural design works for new sea retaining wall and pipeline supports
Detailed engineering design to ASME piping codes for the replacement of the existing transfer pipeline and waste oil pipeline
Detailed survey of the existing transfer pipeline between the Jetty and the storage tank nozzles within the Tank Farm
Replacement of spill booms, hose reels and interfaced valving arrangements

Project Information

Location: Aimeliik, Republic of Palau
Client: Palau Public Utilities Corporation
Engagement: Detailed Design Consultant
Sectors: Industrial, Oil and Gas
Services: Commissioning Assistance, Construction and Design Consulting, Digital Engineering, Petroleum Engineering, Piping Engineering, Specialist Analysis
Year: 2017

The Problem

The existing pipeline was commissioned in 1983 from bare carbon steel piping and was showing extensive evidence of severe corrosion from exposure to seawater both internally and externally. Due to its exposed coastal location, significant undermining of supports from wave action was also evident.

Given the age and location of the existing facility, very little documentation was available to understand the design of the existing pipeline. Quality control of procurement and construction works is also a challenge in this region.

Analysis and Implementation

EPES with EIS undertook significant surveying works of the existing pipeline, geotechnical conditions and ground levels along the pipeline alignment. This was necessary due to the absence of original design documentation.

We then undertook detailed engineering design with a key focus on simplifying the construction process and addressing further risk of corrosion by specifying coating technologies suitable for the exposed environment.

Design documentation including 3D model, plan drawings and Technical Specifications were prepared in combined SI/Imperial units to aid in communication with local Contractors and Clients. EPES also offered technical advice in maintaining quality control and supervision of the procurement and construction works.

Outcome

EPES were able to deliver a high quality and detailed set of design deliverables that assisted the Client in tendering and controlling the Procurement and Construction works. The Client can rely on high quality documentation with an emphasis on ensuring that construction works is completed with a high degree of commercial control.

Good quality documentation and diligent preparation of design in brownfield environments offers a high level of commercial control (i.e. de-risking).

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Dyno 3 Mechanical Ventilation

03/02/2020 By EpesEditor

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Dyno 3 Mechanical Ventilation

Mechanical Engineering

EPES were engaged to undertake engineering design for the design of a ventilation system for a new exhaust hood in Dyno 3, which includes:

1. New custom design retracting hood configuration designed especially for the side loading engine dynamometer

2. Required to remove high volumes of fumes and heat during testing

The Problem

The engines tested in Dyno 3 produce extremely high volumes of heat and fumes during dynamometer testing in the facility. The current arrangement in use at the facility is not effective and inefficient.

Project Information

Location: Rockhampton, Queensland, Australia
Client: Hastings Deering Rockhampton
Engagement: Engineering Consultant
Sectors: Buildings, Industrial
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Digital Engineering, Specialist Analysis
Year: 2017-2019

Analysis and Implementation

EPES analysed that a retractable hood arrangement was the preferred solution to enable the engine under test to install and removed easily, making the changeover process more efficient.

The ventilation system consisted of Two (2) exhaust fans at 35,000L/s each, and one (1) supply air fan at 30,000L/s as well as natural ventilation openings for removal of heat and exhaust fumes during testing. Large exhaust duct was reticulated within the constraints of the adjacent building structures.

Outcome

The resulting design was a robust ventilation system design that offered flexibility or engine change overs and included bypass air to overcome high temperature issues with mechanical equipment. Recognising the operational challenges was crucial to the success of this design, our engineers have previous experience working with dyno test facilities and were able to prepare a practical and functional design solution for a unique problem.

Unique and complex problems are best resolved by engineers with experience.

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Gosford and Wyong Hospital – Isolation Room Testing

31/01/2020 By EpesEditor

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Gosford and Wyong Hospital Isolation Room Testing

Testing, Inspection and Upgrade Works

EPES performed comprehensive isolation room pressure testing and functional performance verification of 49 isolation rooms commissioned between 1989 and 2006.

Generally, the works included:

1. Alarms

2. Functional controls

3. HEPA certifications

4. Inspection of rooms and sealing

5. Validation of room pressures and air flow directions

6. Verification against current compliance requirements

Project Information

Location: Gosford, New South Wales, Australia
Client: Central Coast Local Health District
Engagement: Engineering Consultant
Sectors: Buildings, Hospitals and Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Independent Reviews and Auditing
Year: 2019

Subsequently, EPES developed Contract Design documentation for upgrade works associated with the findings of the testing and validation. The upgrade works were associated with ongoing due diligence.

The Problem

Health Facility Guidelines are subjected to change as better approaches and advancement in isolation room design are identified. Changes have occurred in how isolation rooms are designed and controlled, as well as the way in which modern controls technologies have enabled safer more robust approaches to infectious and protective isolation room design.

Analysis and Implementation

EPES undertook a baseline compliance review to identify the compliance requirements at the time each isolation room was commissioned, that includes:

We assessed how subsequent changes effected the installed systems. Where measurable improvements were identified, contract design documents were prepared to enabled upgrade works to be undertaken.

Outcome

Requirements within health facilities frequently undergo change, it is important to understand how these changes may affect legacy systems as well as how upgrades may significantly improve safety and reliability.

It is preferred to ensure that design and construction is controlled in such a way that performance related issues are either avoided or addressed during the commissioning stages. This relies on using experienced engineers throughout the process.

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MONA Pharos – Mechanical System Assessment

31/01/2020 By EpesEditor

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MONA Pharos – Mechanical System Assessment

Mechanical Engineering

The Pharos extension to MONA in Hobart was commissioned is 2018, however staff raised ongoing concerns about the performance of the mechanical services systems.

EPES was engaged by MONA to undertake an assessment of the mechanical services design and installation with a view to identifying and providing recommendations for rectification of the identified issues. Our scope included assessing:

1. Air distribution and air flows

2. Building envelope issues and impact to space conditions

3. Building management system

4. Chilled and heating water systems and configurations

5. Commissioning records and processes

6. Exhaust systems

Project Information

Location: Hobart, Tasmania, Australia
Client: Museum of Old and New Art, MONA
Engagement: Engineering Consultant
Sectors: Buildings
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Independent Reviews and Audits
Year: 2018

EPES subsequently provided set of recommendations with technical details for the rectification of the identified issues.

The Problem

EPES reviewed in detail the issues identified and the performance of mechanical and air handling systems within the spaces. The objective of the review was to identify practical rectification works which could be undertaken with minimal impact to the existing facility.

Analysis and Implementation

Ventilation air quantity calculations were performed based on a required air change rate for the space volume and process. Ventilation equipment and ductwork was designed to maximise pick up and minimise additional noise whilst moving the additional quantity of ventilation air. Intake air was positioned to ensure clean air was drawn into the building.

Outcome

EPES provided recommendations such as rectification of installation defects, pipework modifications to chilled and heating water circuits, and addressing building related issues such as sealing of plenums and culverts. Rectification works needed to be undertaken retrospectively with the building operational.

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Inverell Hospital – Redevelopment Stage 1B

31/01/2020 By EpesEditor

Inverell Hospital – Redevelopment Stage 1B Slide 1

Inverell Hospital – Redevelopment Stage 1B Slide 2

Inverell Hospital Redevelopment Stage 1B

Parts 1 – 9 Concept Design, Design Development, Contract Documents and Construction Services

This project involved the major refurbishment of the original hospital building which was built in the 1930’s served by a wide variety of air conditioning and heating systems or varying age and condition.

The refurbished facility will include Oral Health, Ambulatory Care, Women’s & Children and Office areas or Education and Telehealth.

Our role in this project is to develop a practical and robust solution to the ongoing provision of heating, cooling and ventilation for the changed building usage and maintain consistency with Stage 1A design.

Project Information

Location: Inverell, New South Wales, Australia
Client: Health Infrastructure
Engagement: Mechanical Services and Medical Gases
Sectors: Buildings, Hospitals & Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Digital Engineering
Year: 2019

Additionally, we were engaged as the Watching Brief consultant for Stage 1A ($30m budget) which includes a new Clinical Services Building with Emergency Department, Paediatric and Maternity Facilities, Palliative Care, medical Imaging, Operating Theatres, Day Surgery and new main entry.

The Problem

The existing building has various systems installed throughout the life of the hospital for heating, cooling and ventilation with poor levels of compliance with current standards and guidelines.

Several challenges were identified:

1. Complex building geometry and constraints

2. Gaps between current day standards and what was existing

3. No documentation for existing systems

4. Significant redundant equipment left in place

5. Very little consistency of types of systems

Analysis and Implementation

With a brownfield site such as this, there is very little choice other than detailed survey works to properly understand what systems and equipment are in place, what is redundant, what is working and its condition, maintenance history and compliance.

We commenced our work with extensive surveys of existing equipment, recording existing systems and the areas they served. Additionally, we discussed the performance of existing systems with staff and maintenance personnel to get a picture of how the existing systems were performing.

Through our engagement on Stage 1A, we were also able to align our design decisions with the technology and approach used in the new building further simplifying the maintenance tasks for local staff. This approach offers many benefits to the LHD by enabling consistent maintenance contracts across both stages of the project.

We opted to introduce a chilled water plant, consistent in technology and controls to that of Stage 1A and to interconnect with existing hot water boilers exploiting a surplus in heating capacity. Existing medical gas recirculation were able to be repurposed for the new usage.

Outcome

Simple design solution tailored to the long-term use of the building:

Better temperature control and heating performance in cold winter conditions
Capitalise on surplus existing heating capacity reducing new equipment
Consistent equipment and controls across the site, reduced maintenance costs
Ease of maintenance
Long term solution, 25 years to major upgrade/replacement

Take the time to study existing systems and understand the constraints of users in rural or remote areas. Consistency and simplicity is key to successful outcomes.

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Port Macquarie Base Hospital – PACS and Renal Redevelopment

31/01/2020 By EpesEditor

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Port Macquarie Base Hospital – PACS and Renal Redevelopment

Mechanical Services

The project consisted of the completed refurbishment of existing redundant theatre precinct and renal dialysis unit to provide new PACS (Patient Admissions Centre) and new Renal Dialysis unit (RDU) at Port Macquarie Base Hospital.

The Problem

Due to the significant change in usage (existing theatre precinct) and the age of the original installation works (circa 1992) there was a significant step in the design process to gain a detailed understanding of the existing systems and how they operated.

We spent considerable time studying ventilation and smoke control standards which applied in 1992 to develop a strategy for the mechanical services design.

Project Information

Location: Port Macquarie, New South Wales, Australia
Client: Mid North Coast Local Health District
Engagement: Consultant
Sectors: Buildings, Hospitals and Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Independent Reviews and Audits
Year: 2016

There were several issues identified during this analysis that required an integrated approach with the rest of the hospital, including ensuring that adjacent zones were not affected.

Existing systems serving the spaces were circa 25 years old and in poor condition.

Analysis and Implementation

We evaluated the suitability of existing systems for repurposing however decided that given the age of the existing systems and the likely time before the area would be accessible again, that the existing air handling plant and ductwork should be replaced with new. It was decided that new plant should be located for ease of maintenance consistent with existing maintenance practices already in place.

Existing capacity from central chillers, boilers and pumps were adequate given the change in usage being a lower load intensity than previously.

New systems would be introduced which satisfy current AusHFG requirements.

Outcome

EPES designed new mechanical systems for the new spaces with as much consistency and integration with existing central services as possible, as well as connectivity with BMS systems already in place at the site.

New air handling plant and smoke control systems were installed matching existing maintenance and operational practices at the site with minimal impact.

Taking time during design to understand the site, existing processes and the personnel responsible for managing assets allows design to closely consider the end user.

Systems serving healthcare facilities are required to be reliable, ensuring that design properly considers the end user greatly assists in achieving reliability.

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Commissioning Assistance

Grafton Hospital - Central Chiller Upgrade

Mechanical Engineering

The Problem

Analysis and Implementation

Outcome

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Parnell Manufacturing Facility Upgrade

Rectification of Humidity Control Systems, Stability Rooms and Central Cooling and Heating Systems

The Problem

Analysis and Implementation

Outcome

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Aimeliik Cargoline Replacement Project

Engineering Design

The Problem

Analysis and Implementation

Outcome

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Dyno 3 Mechanical Ventilation

Mechanical Engineering

The Problem

Analysis and Implementation

Outcome

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Gosford and Wyong Hospital Isolation Room Testing

Testing, Inspection and Upgrade Works

The Problem

Analysis and Implementation

Outcome

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MONA Pharos – Mechanical System Assessment

Mechanical Engineering

The Problem

Analysis and Implementation

Outcome

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Inverell Hospital Redevelopment Stage 1B

Parts 1 – 9 Concept Design, Design Development, Contract Documents and Construction Services

The Problem

Analysis and Implementation

Outcome

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Port Macquarie Base Hospital – PACS and Renal Redevelopment

Mechanical Services

The Problem

Analysis and Implementation

Outcome

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