Construction and Design Consulting

Grafton Hospital – Central Chiller Upgrade

Grafton Hospital – Central Chiller Upgrade Slide 1
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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. 

Parnell Manufacturing Facility Upgrade

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.

Sewerage Pumping Station, Pressure Main and Receiving Gravity Sewer

Sewerage Pumping Station SP1197, Pressure Main and Receiving Gravity Sewer Slide 1
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Sewerage Pumping Station SP1197, Pressure Main and Receiving Gravity Sewer

Mechanical, Civil and Structural Detailed Design

EPES were engaged by Zinfra as Sydney Waters D&C contractor for the design and construction of SP1197 sewerage pumping station, pressure main and receiving gravity sewer at Emerald Hills in the South West Growth Centre, Leppington NSW.

Design package included:

​1. 71L/s Sewage pumping station consisting of two sets of submersible pumps, precast wet well, valve chamber, inlet maintenance hole, outdoor electrical kiosk, bypass pumping arrangement, emergency storage tank, chemical dosing unit and associated works

2. Pressure main consisting of 1,130m of DN315 HDPE pipe including scours, jetting points and associated works

Project Information

Location: South West Growth Centre, Leppington, New South Wales, Australia
Client: Zinfra c/o Sydney Water
Engagement: Detailed Design Consultant
Sectors: Industrial, Water and Waste Water
Services: Construction and Design Consulting, Digital Engineering, Infrastructure Engineering, Piping Engineering, Water and Waste Water
Year: 2015-2017

3. Receiving gravity sewer consisting of 1,770m of DN355 HDPE pipe draining to the receiving maintenance hole

The scope of the works included all mechanical, civil and structural design elements including development of various approval documentation including Design Management Plans, Safety in Design, CHAIR, FMECA and various design reviews with Sydney Water management and operations teams.

Design deliverables were prepared following tendered Concept Design through 30% and 80% Detailed Design, Workshop Coordination and Works-as-Constructed (as Approved by Sydney Water). Site inspections during construction.

The Problem

Several challenges were identified during the design delivery effort, such as:

We were also tasked with ensuring that the information we produced was coherent, organised and in a suitable format to be integrated into AFMOnline.

Analysis and Implementation

Ongoing and regular communication with stakeholders enabled issues to be raised as early as possible, with an agreed path to resolution. Identifying key concerns and risks in the design enabled the design to take a pragmatic approach with buy-in.

Outcome

The project has been operational since 2017 with no technical issues identified.

Using experienced technical staff and ensuring that communication channels are always open presents an opportunity to deliver a challenging project with final acceptance. Long term reliable operation follows diligent design.

Nepean Blue Mountain LHD – Asset Data and Life Cycling

Nepean Blue Mountain LHD – Asset Data and Life Cycling Slide 1
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Nepean Blue Mountain LHD – Asset Data and Life Cycling

Asset Data Capture and Life Cycle Assessment

As part of NSW Health’s implementation of Asset and Facilities Management System (AFMOnline), EPES were engaged by NBMLHD to undertake a district wide audit of maintainable assets and prepare a database of plant and equipment to enable population of data into the new system.

The scope EPES undertook was significant and hands-on:

​1. Assessment of age and condition, estimate of remaining service life

2. Assign unique Asset number

3. Collation of available technical data associated with each piece of equipment

4. Image log for each piece of equipment

Project Information

Location:  Penrith, New South Wales, Australia
Client: Nepean Blue Mountains Local Health District (NBMLHD)
Engagement: Engineering Consultant
Sectors: Buildings, Hospitals and Healthcare
Services: Asset Management, Building Services, Construction and Design Consulting, Independent Reviews and Audits
Year: 2018

​5. Inspection of mechanical, electrical and hydraulic assets at Nepean Hospital, Blue Mountains Hospital, Lithgow Hospital, Portland and Springwood Hospitals

In our planning for this project, we identified a need to develop an electronic Data Collection System and developed a customised EPES Asset Management Register with VBA Microsoft Excel. This enabled EPES personnel to undertake the data collection using Tablets, avoiding double handling and simplifying reporting.  

The Problem

There were several logistical challenges associated with the works, that included:

We were also tasked with ensuring that the information we produced was coherent, organised and in a suitable format to be integrated into AFMOnline.

Analysis and Implementation

We recognised early that to compile high quality, repeatable and consistent data we needed to constrain the way the information was collected. We developed the EPES Asset Management System with limited customisable fields, and otherwise standardised data entry fields (e.g. drop-down lists & scales). This would be crucial to the quality the end-product.

We also understood that we needed to break down the communication barriers and liaise directly with on-the-ground maintenance staff who would be able to short circuit the information gathering processes. Given the significant practical experience of our technical staff, we easily build rapport with maintenance and trade staff gaining access to information and assistance in finding where assets were in the absence of as-built drawings and data. 

Finally, as consistency was fundamental, we ensured that teams working on the different sites attended regular briefings during the work with other teams to ensure alignment in the recording process, consistency in the evaluation of asset condition and assumptions used in estimating remaining service life.

Outcome

Because of the extent of planning and control, and the development of a consistent data collection system we were able to provide NBMLHD with a register of maintainable assets that was consistent across the district. It also gave them visibility of which assets were approaching the end of service life to enable budget forecasting and ARRP planning to be initiated in a proactive manner.  

Where complex tasks and challenging outcomes are required, the best investment is to plan both the outcome of the works and the method of execution. From this understanding, a robust and accelerable plan is defined.

Kenya Water Treatment Plant – Brine Discharge Pipeline

Kenya Water Treatment Plant – Brine Discharge Pipeline Slide 1
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Kenya Water Treatment Plant – Brine Discharge Pipeline

Engineering Design

The Kenya Water Treatment Plant is located outside of Chinchilla in Queensland and treats by-product water from coal seam gas operations. Following the reverse osmosis (RO) process, reject is further concentrated in brine concentrators.

High temperature brine is discharged from the brine concentrators and is transferred via a pipeline to a storage pond. Various performance issues were related to the original design due to the elevated temperatures and corrosivity of the fluid.

EPES were engaged to design a replacement brine discharge pipeline to address the performance issues being experienced with the line. The objective of the design process was to ensure performance of the pipeline during discharge of elevated temperature brine discharge to the storage pond without impacting operation of the water treatment plant. Our scope included:

Project Information

Location: 35km from Chinchilla, Queensland, Australia
Client: Laing O’Rourke
Engagement: Design Consultant
Sectors: Industrial, Oil and Gas, Water and Waste Water
Services: Construction and Design Consulting, Digital Engineering, Independent Reviews and Audits, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2016

The Problem

Several technical challenges exist with high temperature fluids in pipelines, particularly fluids with high chloride concentrations such as brine discharge. Non-metallic materials are typically unsuitable and metallic materials need to be carefully considered with respect to corrosion and durability of materials.

Pipeline leakage or rupture is not acceptable recognising the environmental risks.

Analysis and Implementation

Pipelines subject to elevated temperatures are designed in accordance with pressure piping standards to account for thermal expansion (temperature difference between non-operating and operating cases) as well as other static and dynamic load cases.

Once design loads cases are defined, the pipeline is subject to pipe stress analysis to ascertain both compliance of the pipeline allowable stresses, and primary support loadings to be used in the structural design of the secondary support system.  

Typical design considerations including liaison with stakeholders, safety in design, risk assessment and constructability reviews were incorporated into the design process. 

Outcome

The outcome for the project was a pipeline suitable for the intended duty offering users a robust and reliable transfer pipeline for delivery of concentrated brine to the storage pond. With careful consideration of the design requirements, durability issues, performance requirements and constructability, the pipeline offered a low impact construction with a superior outcome for the project.

Taking the time to properly understand the technical and construction constraints ensures that the project can be delivered within the stakeholder expectations in a reliable, practical and robust way.

Aimeliik Cargoline Replacement Project

Aimeliik Cargoline Replacement Project Slide 1
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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:

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).

Dyno 3 Mechanical Ventilation

Dyno 3 Mechanical Ventilation Slide 1
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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.

Gosford and Wyong Hospital – Isolation Room Testing

Gosford and Wyong Hospital – Isolation Room Testing Slide 1
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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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