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Our latest

2016-03-06 19:38:44

 

electric installation projects

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MandM Direct

MandM Direct Ltd new warehouse project 2015.

In early 2015 Melcon won the contract to provide the electrical installation for MandM Direct Ltd at their new warehouse on the Moreton Business Park. The new warehousing facility is needed to help the company with its continued growth, to provide extra storage space and help deal with returned items. The new warehouse is the end unit of one of the site’s existing buildings and measures roughly 100m wide by 150m long.

An extensive refurbishment of the structure was carried out. An amenities block was built within the warehouse, with male, female, and disabled toilets and a canteen for employees along with two stand alone office blocks for staff.

The first job was to install a new 18 way distribution panel and 70mm tails to connect it to the existing main switch. The job had to be done on a Saturday, to reduce disruption, as the electrical supply in the neighbouring unit is fed from the panel we were changing. The neighbouring company asked us to provide a generator to keep their power on throughout the day. At Melcon, we have our own 16kW generator so this was not a problem.

Our engineers then started installing the extensive cable containment around the building to allow the 9 sub mains to be wired back to the main distribution panel, all in all the Melcon engineers installed in excess of 500m of ladder rack. We installed a mixture of 450mm, 300mm and 150mmwide ladder rack depending on the amount of cables to be carried on a particular section, whilst leaving some free space for future use.

Next was the sizeable task of installing the sub main cables, of which there were 9, the longest being approximately 170m. These sub-mains were to feed local distribution boards which intern fed local circuits ranging from 13a socket outlets and conveyor control panels, to rows of lighting trunking and outside lighting.

The distribution boards installed were the ‘Schneider Acti9 Isobar Distribution Board’. There were 2specifically for the warehouse lighting, 3 located within the offices and the amenities block, 1 solely for supplying the battery chargers for the forklift trucks, and a further 3 for general power such as sockets and the roller shutter door supplies. Above the 2 lighting distribution boards the Melcon engineers installed extension boxes to house contractors to allow emergency lights on multiple lighting trunking rows to be tested with the operation of a single rotary key switch.

A total of 16 rows of Zucchini 40A 3 phase lighting trunking was installed. 12 were located centrally to each row of storage racking, and 4 were spaced evenly above the other portion of the warehouse left open for returned goods and general storage. In total the Melcon engineers installed 2400m of Zucchini lighting trunking. Thats a massive 800 individual 3m lengths. The lighting trunking was suspended from the steel roof frame using Gripple, 100 were used per row of trunking, meaning by the end of the job we had used 1600 Gripple’s.

To the newly installed lighting trunking our engineers installed a total of 554 NVC florescent fittings,and a further 228 Cooper Lighting dedicated emergency LED fittings. The T5 florescent fittings installed all have their own programmable PIR (passive infrared) sensor which monitors 2parameters, movement and ambient light, to determine whether to turn the light on. Using this technology dramatically reduces the energy consumption of the warehouse.

Once the offices and amenities blocks had been built, the Melcon engineers had to wire the lighting and ring main socket circuits. The lighting circuits were again controlled by PIR sensors, in a bid to reduce energy consumption.

The new facility is now fully operational, helping to increase the capacity of this growing company, MandM Direct. Melcon and MandM Direct have forged a strong working relationship over the years that we have supplied our services to them. They know that we are on call 24/7, 365 days of the year if a problem were to arise at either of their sites in Moreton or Leominster.

This is what they have said about our service:

“We have used Melcon for the past 20 years which in itself should speak volumes. We use Melcon for all cases ranging from replacing broken plug sockets through to full, new build, warehouse installations. We have always found them to be courteous, responsive to needs, efficient and safe contractors. They listen to our requirements and advise on the best options to take in our interests. We have no hesitation in continuing the relationship and would happily recommend their services”.

Rob Arnold - Safety, Health, Environmental and Facilities Manager - MandM Direct

Hereford Left Bank

Most people from Herefordshire will have heard of the Hereford Left Bank, with its stunning views across the south of Hereford, not to mention its position on the bank of the River Wye. In 2014 the venue was purchased by Mr Joe Lively, then subsequently leased to the Waring Family, who also operate the successful Lyde Court. The building was in bad condition and in need of some care and attention. Melcon were initially hired by Mr Lively to restore a basic electrical service to the building, after it had been vandalised and cables supplying distribution boards on all 4 floors had been cut. A daunting prospect, but not for Melcon. Our engineers worked methodically through the building restoring power to each floor, installing a new 18 way distribution panel in the basement, to bring the building back to life.

At this point, Mr Waring approached Melcon to help him realise his dream of producing a high quality electrical installation that a venue of the stature of the Left Bank deserves. This included;new lighting throughout the building, including external lighting and emergency lighting, a completely new addressable fire alarm system, and a new kitchen on each of its 3 usable floors.

It was always vital to keep it mind that costs on a renovation project like this one can spiral out of control. The Melcon engineers always kept this in mind, reusing existing cable containment and wiring wherever possible. But always making sure that what was reused met the requirements of BS7671.

The final product of months of hard work, proudly sits once again upon the bank of the River Wye,and can be seen lit up at night in all its glory.

The Left Bank is now fully operational and Melcon provide an ongoing service as Mr and Mrs Waring continually look to improve and evolve the venue.

Here is what Mr Waring said about our service:

“Melcon Hereford Ltd have helped us with a major project. We have undertaken the renovation and repair of the Hereford Left Bank. The original wiring had been subject to considerable deliberate damage. The task of rewiring was not an easy one, Melcon methodically worked through the building using the old systems were possible. Melcon developed a knowledge for the systems both new and old, and it appears that anything becomes possible with a little thought. The building is up and running, and Melcon are on 24 hour call in case of a problem. They are a great company to work with and we highly recommend their services and aftercare.”

Another successful job completed by the team at Melcon.

Kingspan Insulation Ltd

1.5 megawatt Boimass Boiler.

At Melcon, we have been providing our service to Kingspan Insulation at their UK head office in Pembridge for in excess of 30 years. Kingspan are a keen adopter of eco friendly technologies, so when they had the green light to go ahead with a new 1.5 Megawatt Biomass Boiler project, to provide heating to their vast warehouses, they had to look no further than Melcon to provide the electrical installation to power the new machinery.

We were initially approached by Kingspan to provide the sub main distribution, power and lighting along with a fire alarm system in the new purpose built structure to house the new equipment. Eventually, this evolved into issuing a quote and ultimately being asked by Wood Energy (who installed the machinery) to provide the electrical installation for the power supplies and control wiring for the Biomass Boiler itself on a sub-contract basis.

The electrical works commenced in late February 2016, starting with the installation of the lighting and power in the warehouse, all circuits were wired in SWA cable and clipped to cable tray and ladder rack which we had installed. The lighting in the warehouse is controlled by individual PIR (passive infrared) sensors at each light fitting; these monitor ambient light and movement to determine whether to turn the light on. The new circuits were connected into a new distribution board for the building.

Next up was the task of installing the 100m of sub main cable. This was to provide power to the new building; the supply had to be taken from a distribution panel located in the adjacent factory building. The work had to be carried out on a Saturday, as to minimise disruption in the busy factory from which the supply had to be taken from. The job also required the use of two scissor lifts and two boom lifts, as the cable was to be installed on some existing cable containment approximately 6 metres above the ground. With a gang of three electricians and three apprentices, the cable was installed, clipped to the existing containment and connected at each end in a matter of a few hours.

After the installation had been tested and energised we were approached by Wood Energy to provide the electrical installation for the boiler itself. The main cable runs consisted of two compartment galvanised cable trunking with one compartment used for low voltage cables, supplying mainly motors and other items operating at 230 volts and the other compartment used for extra low voltage cables, mainly used for the various number of sensors located around the boiler. Galvanised conduit was used to carry cables from the main routes of trunking to their final location and some flexible conduit was used insituations where it was impractical to use galvanised conduit.

The final result is one which Melcon and Kingspan themselves are very proud of, with the project being completed on time and to an extremely high standard. The long standing partnership between the two companies is testimony to the quality of service and workmanship we provide.

2016-03-06 19:39:13

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