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Solvay Group, Wales

Solvay Group, Wales

    • CLIENT:
    • Solvay Group
    • MAIN CONTRACTOR:
    • Fluor
    • CONSULTANT:
    • Fluor
    • PROJECT:
    • Project ACE: Adhesive Capacity Expansion
    • VALUE:
    • £13m
    • SECTOR:
    • Industrial Manufacturing / Aerospace
    • LOCATION:
    • Wrexham, UK

PROJECT DESCRIPTION

Kirby delivered full Mechanical, Electrical and Instrumentation and Process Piping services for a new purpose-built Adhesive manufacturing facility and had a significant involvement from project initiation right through to handover stage.

Kirby worked closely with Fluor in bringing the principal M&E design from IFT stage to construction. This involved engaging with Fluor in design workshops to develop mechanical P+ID’s to ensure that coordination of all services, operator safety, and future maintenance access were incorporated as an integral part of the design process.

By successfully applying Lean construction principles, Kirby designed, manufactured and installed a fully loaded pipe bridge, which contained approximately 1,200m of pipework which was installed at the same time as the building steelwork was installed over three weekends. This pipe bridge was prefabricated off-site and delivered in modular sections which were joined on site post installation, without the need for spool pieces. This early activity greatly assisted with front loading the schedule, thereby reducing on site construction hours, ensuring maximum efficiency and optimising the build schedule.

With manpower peaking at 110 trades, a significant project achievement from a safety perspective was delivering 100,000 hours without a lost time incident.

SCOPE OF WORK

The electrical systems installed by Kirby included:

• LV Distribution
• UPS
• General & Emergency Lighting
• General Service Power
• Mechanical Plant Service Power
• Fire Detection & Alarm
• Access Control, Intruder & CCTV
• Earthing & Bonding
• Voice & Data Distribution
• Lightning Protection
• EMS
• SCS
• Profibus
• Profinet

The mechanical systems installed by Kirby included:

• Chilled Water
• Low Temperature Hot Water
• Supply & Extract Ventilation Distribution
• DWS
• Leak Detection
• BMS
• Server Room Air Conditioning
• Clean In Place (CIP)
• Humidification Water
• Process Chilled Water
• Solvent / Solvent Waste
• Compressed Air
• Instrument Air
• Hot Oil
• Natural Gas
• Process Waste
• Soils & Waste
• Domestic Water Services
• Plastic Exhaust
• Stainless Exhaust

Installed plant items included AHUs, Chillers, Compressors, LV Distribution Boards, Boilers, Humidifers, Reactor Vessels, Nitrogen Skids and all Ancillary Process Equipment.

The total project meterage consisted of 115,000m of cable, 23,000m of containment, 900 number of instruments and 1,100 loops, 900 calibrations, 3,600m of impulse piping, 1,100 number of I/O points; 8,200m of black utilities pipework, 150m of plastic pipework, 30m of copper pipework, 1,260m of clean utilities pipework and 6,100m² of ductwork.