Project: Acomb Primary School

Business Need

Frogmech Ltd were requested to provide a quotation for Boiler replacement at Acomb Primary School. When we looked through the original specification provided we found areas in which we felt the specification didn’t correctly meet the schools needs and wasn’t the best option for the school to take. At short notice with the project due to commence in the summer holidays 2018 and receiving the spec 3 weeks before, we arranged a site meeting with the client to discuss their requirements and put forward our recommendations.

The school heating consisted mainly of underfloor heating circuits, CT (constant temp) circuits supplying fan convectors within gym area, VT (variable temp) circuit supplying radiators in reception area and a primary hot water circuit supplying hot water calorifier.

Our Role

We wanted to utilise the rare opportunity of such a vast area been underfloor heating circuits to install 3x Hoval Ultragas high efficiency gas boilers, taking full advantage off there unique low temp return connections. This would ensure full condensation throughout high demands of all 3 units therefore providing unrivalled efficiencies for the school.

We knew we were connecting to a system 20 years + of age so the steel shell boilers would cope with any debris that will have accumulated over the years. With additional magnetic filters installed on both high and low temp return pipework we knew we had system filtration covered.

We Explained to the customer installing 5x wall hung boilers with no filtration and minimal pipework alterations, as originally specified was the cheapest option but wouldn’t offer the guaranteed life expectancy and efficiencies that we could offer them. With very limited access to the plant room the client had doubts about removing and installing shell boilers as we were proposing. And with the time scales becoming very tight we knew they had reservations.

Immediately after our meeting we set about measuring and designing our proposals to provide the client with reasurances that we could deliver. We provided them with drawings, crane lift plans, schedules of work and detailed quotations. The Client where impressed with the speed, detail and efficiency in which we provided them with the information.
The quotation was higher than other prices from original spec, however with the huge improvement on life expectancy, system filtration, huge efficiency increases and fuel savings not to mention our 5 year guarantee periods the client decided to offer us the project.

With a week before summer holidays, we provided the client with full risk assessment and method statements and swiftly began ordering the materials and equipment needed to complete the works. Our engineers and coded welders fabricated most of the pipework off site to save on installation time on site.

First job was the decommissioning and removal of old appliances. Then with a complicated crane lift we removed the old appliances and lifted in the new prefab pipework and boilers. For the next 4 weeks or mechanical and electrical engineers installed all pipework, field wiring and containment and made alterations to existing BMS control panel and software. All pipework was installed in steel (threaded and welded) to ensure maximum longevity of heating system.

The Outcome

On completion our engineers fully tested and commissioned both mechanical and electrical installations. Pipework was fully insulated and all gas safe and electrical certification was issued. We provide the client with as fitted drawings and o&m manuals and took time to fully explain the new system to them.

The project was completed on time and on budget with no distribution to the schools services and was fully commissioned and working for the childrens return to school. The Client is now seeing a massive reduction in fuel costs and unrivaled efficiencies.
They also have piece of mind that everything within the installation is now covered by Frogmech Ltds 5 year warranty period.