Recent Projects Archives - Page 2 of 3

Gas Line Installation – Global Online Retailer

19th November 2022/in Recent Projects

Christmas is around the corner and as one might imagine, retailers are operating in sales overdrive; so when we were commissioned to install a gas line to an existing Lennox Air Handling Unit (AHU) for a global online retailer, the team at CG Systems was prepared to work out of hours so as not to disrupt operations (never a problem for us!).

The work comprised the installation of 80 meters of 76mm Geberit Stainless Gas pipework and fittings, which took place at an ‘above level’ working height that required the operation of scissor lifts to give us access to the gas line. We opted to use the Novopress ACO203XL pressing tool as this meant we did not have any trailing power leads (created by the height at which we were working) and this managed to avoid any potential Health & Safety safety issues.

See below for images of the installation in process:

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Gas Fired Warm Air Unit – Global Internet Retailer

19th November 2022/in Recent Projects

The life expectancy of a boiler depends very much upon the type of boiler in question but, on average, a traditional gas boiler should last between 10 and 15 years. When it comes to the end if its serviceable life, it’ll need to be replaced – as was the case when we were called to check out some issues a client (global internet retailer) was having with their current heating system at a warehouse in Croydon.

The team at CH Systems discovered that the older gas fired Reznor units had fulfilled their life expectancy and a decision was made to replace the current units with 6no new Reznor UDSA-100 units.

With the roof of the warehouse being 13 meters off the slab, the work had to be carried out on Mobile Elevating Work Platforms (MEWPs) – this was no problem as all of our engineers hold current IPAF Certified Training For Working Height certificates, which enabled us to carry out the work in a much more timely fashion (saving the time and effort of scaffold towers etc). See pics below:

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Plant Room Installation and Pipework – Royal Chelsea Hospital

15th November 2022/in Recent Projects

Having carried out the enabling works for both the East and West Plant Rooms at the Royal Chelsea Hospital, the CG team moved on to carry out the installation of three Worcester GB162 boilers, supplied with frames and low loss headers to each plant room.

Due to the age of the existing system and a need to prolong the life of the new boilers, a decision was made to install a Plate Heat Exchanger, which offers hydraulic separation between the new and old system whilst allowing the necessary heat transfer to take place.

The team was also tasked with finding a suitable location for the associated Vessels and Pressurisation Units within some very compact/tight spaces. Looking at the images below, you’ll be able to see that usable space is at a premium; as such, a great deal of time was spent in consultation with the client over what would be the best and most acceptable use of the space we had.

This was by no means the largest project we have undertaken but the space constraints proved challenging – the team worked efficiently to get the job done and we are pleased with the end result.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Freezing and Enabling Work – Royal Chelsea Hospital

9th November 2022/in Recent Projects

The team at CH Systems is currently on contract at the Royal Chelsea Hospital – one of our most prestigious projects to date. We won a tender that commissioned the following:

1.Freezing and Enabling work
2.Plant room installation and pipework
3.Below ground pipe gas pipework

The work includes the creation of two small boiler rooms (within existing plant rooms), which are required to supplement the existing heating system during periods of high load. As one might imagine, this is extremely important within the context of a hospital environment.

As part of the ‘enabling’ that had to be carried out prior to commencing work on the boilers, we had to cut into the existing primary pipework within the plant rooms in order to make our connections to the existing system. With a building of this size, draining down the pipework is not an option due to the length of downtime and inconvenience this might cause to hospital guests, so we froze the pipework in the West and East plant rooms (with the help of an expert Pipe Freezing Service) and used liquid nitrogen to stop the flow of water thus enabling work to take place with as little downtime possible.

Because we were under pressure to get the system up and running as soon as possible, we opted for a number of prefabricated sections of 3-inch and 4-inch pipework (on which our welders did an excellent job) that we joined to the existing system without issue. Not being able to thread pipework or weld anything into place, we used the Viega Megapress system, with support from Paul Burkett (this being our first instance of using the megapress), enabling us to press onto medium and heavy weight pipe thus dramatically speeding up the entire process.

We’re still in the midst of completing the project but check out the pics below to get an idea of the the work explained above…and watch this space for further project updates.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Small Space Boiler Installation – MRM Worldwide

26th October 2022/in Recent Projects

Sometimes, the installation process is like a puzzle – figuring out how to make the best use of the available space in order to ensure a system that is as cost-effective, safe and efficient as possible. The team at CG Systems was recently commissioned for a boiler installation by MRM Worldwide, which turned out to be an interesting challenge.

The work took place in a ‘package plant room’ that was built and assembled off site then craned up into place and essentially “plugged in”. The seven Keston boilers populating this very tight space had reached the end of their serviceable life and needed replacing but due compact nature of this plant room, our only option was to fit four Keston Heat 55 Boilers in the space left when we removed six of the original Keston 170 Boilers.

Keston’s Heat 55 Boiler was the perfect option for this type condensed space as it has been designed to be light weight and offer flexible installation solutions. Every component within the Heat 55 has been carefully selected to ensure maximum reliability and longevity. With simplicity in mind the boiler features a large back lit screen and simple button controls, allowing the user to get the most from their new boiler installation.

Also included in the installation was a compact, fully integrated Flamco Pressurisation unit – again, perfect for a small are. Have a look at the pics below to get a sense of the space we were working with:

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Aldi RDC – Isle of Sheppey

25th September 2022/in Recent Projects

CG Systems secured the pipework installation contract on the new Aldi Regional Distribution Centre (RDC) in June 2017. The new £50m RDC has created around 400 new jobs and measures more than 40,000 square foot. Have a look at the below pics for an idea of the scale of the project:

Our scope of work included:

136no Fan coil units on a 4 pipe system
all the LTHW & CHW pipework on this system which was Geberit stainless steel mapress
3no Plant rooms incorporating the 2no Viessmann boilers
2no Beta Echos chillers and 2no Barkell air handling units
Over 500meters of welded gas pipe serving 9no Reznor warm air unit heaters
2no Vaillant air source heat pumps
1no GRP water tank and pumps.

All of the Domestic water services pipework was installed in Geberit Copper Mapress with all the valves on the project manufactured by Crane.

Once again we received fantastic support from our suppliers and the engineers involved in the project proved why they are an invaluable part of our team.

We recently achieved Prime Cost (PC) on this project, which makes it the longest running and largest project we have carried out to date.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

AAH Ruislip

1st September 2018/in Recent Projects

The ‘Ruislip project’ is a great example of the lateral thinking that is often required in the type of contract work that the team at CG Systems is recruited to do. In this instance, an existing building on the site in question was to be demolished and all the service pipework for 3 Sanyo Gas Fired Heat Pumps was fixed to this building. Our team was contracted to run three new refrigerant circuits as well as a new natural gas line to feed each unit. Have a look:

The team carried out some very tidy welding on the 4-inch branch that we tied in to the existing 6-inch gas line with the remainder of the natural gas pipework being run in Geberit stainless steel pipework and fittings. The final connection was carried out by hot-tapping the service as this ensured the least amount of down time possible, which was critical on this project due to £27m’s worth of stock in the warehouse (and all the product temperature critical).

The Air Handling Unit served by the GHPs is housed on the first floor of the warehouse, which made running the refrigerant pipework an interesting challenge, but nothing that our capable team couldn’t figure out.

These GHPs are fantastic units as they give customers the option to introduce additional cooling capacity into a property where the electrical capacity has already been utilised for other applications.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

BBC Allis Studio

29th August 2018/in Recent Projects

CG Systems worked alongside Soho House and ATS on a project that entailed the mechanical fit out of the Allis Bar, as part of an overall revamp of the BBC’s Television Centre. The project was time sensitive, with a definitive date for the opening the Bar (that was set in stone), which meant late nights and long shifts to get the work done.

Our scope of work included the piping up of ten fan coils all in Geberit Mapress copper. These units run on the “Chilled Water” and “Low Temperature Heating Water” systems, giving the option to heat and cool this vibrant space.

There are also two bar and toilet areas that required hot and cold domestic services as well as soil and waste connections.

The finish in the bar area (featured below) is of a high standard, even down to the choice of sanitary-ware and brassware.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Major Supermarket Ashford

5th May 2018/in Recent Projects

A major supermarket commissioned CG Systems for a pipework installation to two air handling units in its Ashford branch. The project involved up-sizing the heating pipework to two of the roof mounted AHUs. The coils on the AHUs were replaced and the units themselves were overhauled at the same time that the pipework was being installed.

All the heating in this store is generated by air-source and ground source pumps.

All the pipework on this site was Geberit Mapress and because of the project location, we carried out all the crimping with a Novopress XL pressing tool, which is cordless and enabled us to carry out the installation timorously.

We’re really proud of how this project turned out. If you have any questions, please do contact us directly.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.

Louthus Romford

22nd April 2018/in Recent Projects

One of the most challenging projects the CGS team has worked on was an assist on a block of apartments directly above a parade of shops, with the plant room above the stair well.

The district heating scheme providing low temperature hot water (LTHW) to he heat interface units in each flat is served by a Valliant Buffer, which is in turn served by a pair of Vaillant boilers. The primary pipework required modification from the boilers to the buffer vessel as there was not sufficient flow. The secondary pipework also required modifications to ensure we got the required flow rates. Tough stuff.

Our team managed to complete all the work in one day and with little disruption.

The primary pipework required modification from the boilers to the buffer vessel as there was not sufficient flow. The secondary pipework also required modifications to ensure we got the required flow rates.

Our team managed to complete all the works with only one day of down time to the tenants and with little disruption.

If you’d like further information on our involvement in this project, feel free to contact the CG Systems team on info@cgsystems.cc.