Independent Reviews and Audits

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.

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.

MONA Pharos – Mechanical System Assessment

MONA Pharos – Mechanical System Assessment Slide 1
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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.

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.

Smithfield – Precision Oxy Cut

Smithfield – Precision Oxy Cut Slide 1
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Smithfield Precision Oxy Cut

Mechanical Ventilation Design

EPES were engaged by Sell and Parker to prepare a compliant ventilation solution to address poor internal air quality due to plasma and oxy cutting processes.

Our scope for this project included:

​1. Assessment of ventilation issues within the Plasma and Oxy Cutting Areas

2. Identification of constraints for installation of ventilation plant and equipment

3. Prepare contract design drawings and technical specifications for the recommended solution

Project Information

Location: Sydney, New South Wales, Australia
Client: Sell and Parker
Engagement: Design Consultant
Sectors: Buildings, Industrial
Services: Building Services, Construction and Design Consulting, Independent Reviews and Audits, Specialist Analysis
Year: 2014-2019

4. Ventilation calculations, equipment selections and controls

Sell and Parker required better ventilation for occupants of the space.

The Problem

The source of contaminants (smoke) was associated with plasma and oxy cutting, and existing ventilation provisions were inadequate. Significantly greater air quantities were required to maintain acceptable internal air quality. Generally, the ventilation system was subject to the requirements of Australian Standards.

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

Compliant ventilation system custom designed for the space and the cutting processes being used, whilst minimising impact to current operations. 

Port Macquarie Base Hospital – PACS and Renal Redevelopment

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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.

WestConnex – M4-M5 Link

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WestConnex - M4-M5 Link

Pressurised Services and Dewatering Concept Strategy

The M4-M5 link is part of the WestConnex project in Sydney and involves the construction of twin 7.5km tunnels to link the new M4 at Haberfield and the new M5 at St Peters. EPES were engaged by LSBJV to perform conceptual design methodology for installation of pressurised temporary services for use during construction.

​1. Dewatering systems

2. Compressed air

3. Industrial water

The works include the determination of installation, testing, inspection and maintenance requirements for the pressurised services systems, as well as nominating pumps, piping and valving requirements.

Project Information

Location: Sydney, New South Wales, Australia
Client: Lend Lease, Samsung, Bouygues Joint Venture (LSBJV)
Engagement: Temporary Works Design Engineer
Sectors: Industrial, Road Infrastructure (Tunnels)
Services: Construction and Design Consulting, Independent Reviews and Audits, Infrastructure Engineering, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2019

The Problem

Pressurised services are complex on large construction projects and can be high risk in the event of a failure. They can also be highly problematic for construction works if they do not perform as required by the demands of the construction process.

Recognising the size and complexity of this project, as well as a need to ensure consistency across the various construction fronts, the objective of this design was to collate and coordinate all of the variable pieces of information and perspectives and achieve a common approach to pressurised services installation.  

Analysis and Implementation

Several meetings with stakeholders in design, project management, construction and procurement were undertaken to collate the different ideas and information associated with the works. Design documents were developed, along with robust and practical engineering design to ensure consistency, standardisation and a clear path toward compliance with standards.

Outcome

Through this process significant commercial advantages were achieved through standardisation and sharing of plant and equipment, enabling early ordering of piping and valves and exploiting the opportunities of economies of scale. 

Undertaking early planning and design concept development, as well as opening communication with various stakeholders early in the project life cycle there are significant commercial benefits as well as reduced level of risk.

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