To install more than 1km of mainly 350/630mm pre-insulated pipe at a university campus during term time. Not only did we have to connect six large buildings, the connection had to be completed with less than eight hours of downtime.
Due to the large size of the pipes and limited space, Health and Safety was a critical part of the project with the site being based at the centre of a live campus. PPSL worked closely with our client FES Group to coordinate the route and all the services, producing detailed 2D and 3D drawings. We also produced installation plans, combined with detailed risk planning, to ensure the project was delivered safely.
In addition, to the buried pre-insulated pipework, PPSL also had to produce designs for 400mm OD (Outside Diameter) pipes to be above ground, producing a further 3D model of the connections and routes to coordinates, as well as bracket and expansion designs.
Once flushed and commissioned, the tie-in works were planned on a night shift to prevent disruption to the university buildings. Three welders, two managers and one jointing team worked through the night, undertaking the welds required with the pipes frozen using liquid nitrogen to minimise the time needed to bring the system live again and prevent a refill being required. Doing this in one night shift meant there was no disruption to the university.
The project was delivered on time with the detailed designs implemented as planned. Trenches and install in some areas went as deep as almost 2.5m, requiring additional measures to overcome expansion challenges at these depths. Excellent communication between all parties ensured all demands were met and a successful project was delivered.
I found the PPSL team to be first class in the way in which they approached the project. They provided good input into our proposed methodology as this was critical to maintaining access to campus. PPSL provides clear and concise site-specific RAMS as well as imparting a huge amount of knowledge and expertise on how we approached the more complex tasks. The regular visits by their senior managers and in-house SHEQ advisor were also welcome and helped the site team focus. With regards to the commercial aspects of the project these were particularly challenging due to the level of design development and changes instigated by the client. I found PPSL to be fair and reasonable at each stage of the process. I have no doubt in my mind that in numerous circumstances PPSL could have really leveraged an advantage, however, they were open and keener to build a longer-term relationship, which was refreshing. The site team and senior management were always keen to drive the program we had agreed. The work was resourced adequately and, in all honesty, when required PPSL gave the necessary push to progress the works, assigning additional teams and on one occasion dispatching a specialist operative overnight to assist the project. In summary I could not fault the level of commitment to the project from PPSL. I have already put PPSL forward to other contractors and designers.
Gary Wilson
Senior Project Manager at FES Group
