The data centre, which will become the largest of its kind for HSBC, required a superior fuel system to provide fuel oil to the back-up power generators in the case of an emergency.

Electrical & Mechanical engineering contractors ASEE Ltd was tasked with supplying and fitting the data centre with a pipework system that would effectively transport fuel to the back up generators in order keep the data centre processes active should a power failure occur.

The pipework was to be installed underground and so ASEE Ltd needed a system that would ensure fuel did not leak out into the ground, causing damage to the environment. As a result, PLX in sizes 50mm#63mm – 90#160mm was installed to safely transport fuel oil from the 30,000L holding tank to the eight bulk tanks which in turn would supply the day tanks, which feed the generators should there be a power failure.

The PLX secondary contained systems are specialist pipework solutions designed to convey a variety of fuel blends, and are manufactured in a robust polyethylene material that provides excellent resistance to long term stress cracking. Additionally, the product’s impressive durability gives it a design life of 30 years – making these systems ideal for use in emergency power applications, where it is imperative to install a system that does not have to be regularly maintained or replaced.

Commenting on the installation, Stuart Davies from ASEE Ltd said: “The product material characteristics, and specifically the pipe-in-pipe aspect of the pipework as it could be monitored with a leak detection system above ground, was the deciding factor for us, as we needed to be confident we would not be accountable for fuel leaking out into the ground.”

“The added cost savings that were possible through using Durapipe PLX was also a major factor for us; the long term durability of the product made it a very cost effective solution for this project.”

The Durapipe PLX portfolio offers complete flexibility as it is available in both Close-Fit and Pipe-In-Pipe secondary contained pipework systems in sizes 32mm – 315mm. With an easy to use electrofusion jointing system, Durapipe PLX also has a wide range of fittings and transition fittings to suit these systems.

The high-tech data centre in Newport is a new development that required a superior fuel system to provide fuel to the back up power generators in the case of an emergency. Leading electrics company Power Electrics was tasked with supplying and fitting the data centre with a pipework system that would effectively transport fuel to the back up generators in order keep the data centre processes active should a power failure occur.

Power Electrics opted to use high performing pipework system Durapipe PLX as the system has an enviable 30 design fuel life and its anti corrosion properties made it the choice product ahead of metal competitors such as steel. The PLX pipe-in-pipe system was specified in 32mm # 63mm to safely transport fuel from an above ground fuel tank that feeds six smaller fuel tanks to power different areas of the data centre.

The PLX system is a specialist pipework solution that is designed to cater for a variety of fuel blends, and is manufactured in a robust polyethylene material that provides excellent resistance to long term stress cracking. Additionally, its impressive durability gives it a design life of 30 years – making it ideal for use in emergency power applications, where it is imperative to install a system that does not have to be regularly maintained or replaced.

Power Electrics project manager for the development, Leon Shackleton, comments: “With the NGD data centre development, we needed a pipework solution that would perform well over a long period of time as well being cost effective for our project budget. Plastic pipework system PLX was the ideal choice for us as it could overcome traditional steel materials, both in performance and long term durability – something that other competitors just could not promise.”

The Durapipe PLX portfolio offers complete flexibility as it is available in both Close-Fit and Pipe-In-Pipe secondary contained pipework systems in sizes 32mm – 315mm. With an easy to use electrofusion system, Durapipe PLX also has a wide range of fittings and transition fittings to suit these systems.

The four year £170 million redevelopment project, led by Skanska, has seen outdated buildings replaced to bring together the majority of clinical services under one roof in state-of-the-art facilities that will benefit both patients and hospital staff.

The vast pipework requirements of the project has seen both Durapipe PLX and Durapipe SuperFLO installed within the hospital after being specified by sub-contractors Hilton Building Services.

Durapipe PLX was specified, in sizes 32#63 and 50#90, to transfer diesel from the energy centre at the side of the hospital to the day tank generators installed on the roof of the building.

Durapipe PLX is manufactured in a robust polyethylene material, which provides exceptional resistance to rapid crack propagation and long term stress cracking. A visible protective liner allows increased resistance to all types of fuel blends, ensuring there is no permeation of fuel through to the atmosphere showing itself to be highly effective in the transportation of fuel above and below ground.

SuperFLO, in sizes up to 150mm, has been installed to cater for the boosted cold water and chilled water requirements throughout the hospital. The pipework was installed onto pre-fabricated modules, which were constructed off-site by Skanska Fabrications, and then positioned on the roof of the hospital.

SuperFLO was specified based on its exceptional installation properties. The lightweight nature of SuperFLO makes it easy to handle on site and, combined with the easy solvent welding jointing technique, which eliminates the need for any hot works, offers significant time and cost savings during the installation stage.

Commenting on the pipework selection, Steve Baguley from Hilton Building Services said: “There was a very specific timescale mapped out at the beginning of this project with no room for movement. With such a time critical project it was crucial that we selected products which would aid us in completing our installations on time and the solutions offered by Durapipe UK were ideal.

“The speed and ease of installation of both PLX and SuperFLO was the deciding factor for this project and we were not disappointed; it saved us a significant amount of time, compared with metal alternatives. Selecting two different systems from the same manufacturer also made the process smoother.”

Now open, Walsall Manor Hospital boasts many new services including a new Diagnostic and Treatment centre, a Family Health and Diagnostics Centre (previously women’s and children’s), the Outpatient and Day Case Centre and the Manor Learning and Conference Centre.

The Durapipe UK portfolio of products can cater for all above ground pipework requirements within a hospital from chilled water applications through to chemical drainage and the transportation of fuel.

The new build depot will service the trains running on the London over-ground lines and will provide an automated high powered cleaning service for the trains.

To provide the industrial cleaning of the trains, a pipework system was needed to fuel the boiler unit that would provide the hot water for the washing facilities. Emico Ltd was the mechanical engineering installers tasked with fitting the new boiler and pipework system that was specified by leading consulting engineers, Pentangle.

Having successfully used the PLX system within previous developments, Pentangle was keen to specify it again within this project. It found the plastic system particularly suitable for this application as the DC power system that the trains run on, does not work well with traditional steel pipework systems, causing them to corrode at a faster pace than normal. As a result, the corrosion resistant properties of PLX make it the ideal pipework system for this application.

Secondary contained close-fit PLX pipework was specified in sizes 32mm#40mm. The pipework is used to transport diesel from the underground storage tank, into the heavy-wash room, where it provides the fuel power to the water boiler that provides hot water for the train washing unit.

Matthew Anderson, undergraduate engineer (electrical) at Pentangle comments: “It is extremely important in industrial projects that we can be confident of product performance under pressure and across a long period of time and this is why we specified the PLX system. We have used the system within previous developments and found it to be the ideal system both in terms of performance and durability and will continue to specify it for similar projects we are working on.”

Durapipe PLX is a high performing pipework system for fuel transportation; its visible inner liner allows increased resistance to all types of fuel blends, ensuring there is no permeation of fuel through to the atmosphere. Furthermore, its robust Polyethylene material provides exceptional resistance to rapid crack propagation and long term stress cracking.

The major development has transformed inpatient care and has seen the state-of-the-art hospital become the most modern and innovative mental health hospital in the UK.

As part of the project, Gartnavel Royal Hospital was carrying out extensive modernisations to its psychiatric care unit and specifically to the emergency power supply generator and pipework systems. Tasked with updating the system and developing an effective replacement system was generator specialist Progress Group, which supplies and installs generators worldwide.

Progress Group installed a new 500 KVA generator, but needed a reliable pipework solution that would transport fuel from the existing fuel tank, above and below ground, and then onto the generator to power it. The Progress Group has specified steel systems in the past, but was keen to find an alternative as it had concerns over steel corrosion, especially as some of the pipework run would be installed below ground.

Lindsay Crockett from Pipe Center comments: “When faced with the challenge, from The Progress Group, of recommending a system to suit the needs of the client for this important installation, there was no question of using any other pipework solution other than PLX. We knew that, based on the experience and knowledgeable backup from Durapipe, we would be able to provide the solution that The Progress Group were looking for.”

PLX was chosen as the ideal high performing system that Progress Group was looking for. The pipework has been specified in close-fit sizes 32mm # 40mm for the 50m of pipework that ran below ground, and pipe-in-pipe sizes 32mm # 63mm for the 150m pipework that was installed aboveground. The pipework is being used to transport fuel to the power generator to power this area of the hospital should the main power system fail.

Commenting on the pipework choice, Hughie McRobbie, Northern Business Development Manager of Progress Group, comments: “We specified Durapipe PLX pipework as it presented a reliable system that would perform well against corrosion, the 30 year design life reflects the long term solution the pipework offers. Additionally, it proved extremely easy to handle and install on site and the on-going customer support we received from the Durapipe team reinforced the high quality brand and products we were dealing with.”

Durapipe PLX is a high performing pipework system for fuel transportation; its visible protective liner allows increased resistance to all types of fuel blends, ensuring there is no permeation of fuel through to the atmosphere. Furthermore, its robust Polyethylene material provides exceptional resistance to rapid crack propagation and long term stress cracking.

The £338 million construction project is the largest single investment in healthcare undertaken in the community since the National Health Service was formed. The project encompasses the building of two new hospitals; St Helens Hospital and Whiston Hospital sites to provide modern healthcare facilities in world class hospitals for the local communities.

As with any healthcare facility, the efficient running of medical equipment and apparatus is imperative to the treatment and recovery process for patients. A power failure could be extremely dangerous for patients as medical equipment needs to be fully operational at all times to ensure the continued treatment and safety of patients.

As a result, the selection of equipment to work with the emergency fuel powered back-up generators at the new Whiston Hospital was an important process. A reliable pipework system was needed to safely transport the fuel from the fuel storage tanks to the main hospital generators and Durapipe PLX was specified as it met the specific criteria demanded of the project.

Durapipe PLX secondary contained pipe-in-pipe system in sizes 110mm # 160mm, 90mm # 160mm and 63mm # 110mm was used to safely transfer the fuel from the storage tanks to the generators, whilst single wall 90mm Durapipe PLX was used for the fill lines for filling the fuel storage tanks.

Durapipe PLX was selected due to its high performance properties; a visible Polyamide liner allows increased resistance to all types of fuel blends, ensuring there is no permeation of fuel through to the atmosphere and its robust Polyethylene material provides exceptional resistance to rapid crack propagation and long term stress cracking.

The six storey, new Whiston Hospital contains over 800 beds, state-of-the-art operating theatre suites, along with the very latest diagnostic facilities in radiology and cardiology, a regional specialist burns and plastic surgery unit and the full range of acute in-patient, emergency and out-patient healthcare services.

Furthermore, the refuelling process is such an important part of the overall efficiency of these modes of transport it is vital that reliable products are specified to carry out this job.

As a result, it is essential that reliable and durable systems are in place to successfully refuel vehicles to ensure that unnecessary technical faults do not cause time wasting and delays in transportation. The pipework that carries the fuel is an integral part of the system and within the bulk refuelling market, traditionally stainless steel pipe-in-pipe systems have been specified by contractors for conveying fuel however these systems do not always provide a cost effective pipework solution. In an economy where budgets are increasingly tight, contractors should be looking to ensure that every penny of their budget is being spent on the best performing and most cost effective products that will provide benefits across the lifetime of the system.

When dealing with the transportation of fuel, and particularly in large volumes, it is becoming increasingly consistent for contractors to use secondary contained (pipe-in-pipe) systems due to the potential safety hazards caused if fuel was to leak into the atmosphere. Secondary contained pipe systems, are becoming compulsory for many pipework applications, and are the specified solution for fuel conveyance. However, Durapipe UK is keen to stress that not all secondary contained pipe systems are the same and they all offer different performance and installation capabilities.

For bulk refuelling installations, performance capabilities over a long period are essential due to the volume of fuel being transported on a regular basis for the vital operations within the transport sector. This reiterates the requirement for reliable and durable systems that can ensure they will continue to operate and provide a reliable transportation process for the fuel.

A consistent flow rate of fuel is essential to keep the bulk refuelling process in operation and to avoid costly delays. As the fuels for these modes of transport can vary in composite and blend, clogging and corrosion, which can occur with steel pipe systems, are issues that contractors need to consider in relation to flow rates. Clogging and corrosion have the potential to reduce fuel flow rates, stop it altogether or potentially contaminate the fuel it is carrying. These issues highlight just how important it is that careful consideration is given to the type of pipework system that is specified for bulk refuelling applications.

Although Stainless Steel has been widely used in many applications, its lifespan can be questioned when conveying aggressive liquids such as fuel. This provides concerns for bulk refuelling applications; contractors need to be aware that with an estimated fuel carrying lifespan of just over five years, steel is a solution that cannot guarantee performance capabilities over a long period of time, and would need frequent maintenance and replacement work to ensure it is continuing to perform to the required standards.

In some stainless steel pipework systems, the build up of particles in the inner bore can contaminate the fuel it is carrying which has potentially hazardous consequences for the vehicle. For instance, contaminated fuel can result in damage to the engine it is powering and in certain cases can result in the fuel tank within systems needing to be replaced incurring additional costs to the running of these means of transportation. These issues highlight the need and importance for rigorous and frequent quality control checks on pipework systems that cannot convey fuel to all transportation vehicles.

In terms of the installation process, this can be lengthy with traditional metal systems such as stainless steel. Whether these systems run above or belowground, it requires skilled installers to fit the pipework. In the case of installing underground pipework systems, hot works permits are needed, and extra wrapping has to be added to the outside of these pipes, which can result in an extremely complicated and timely installation process. Considering these issues, sparks the question of why innovative materials, such as plastic, are not being readily used by contractors and specifiers.

Plastic is an example of a reliable alternative material that can be used to provide pipework solutions for bulk refuelling applications. Lightweight and easy to install by nature, plastic pipework eradicates the complex installation properties associated with metal alternatives. Plastic pipework systems simplify the installation process for contractors, as they do not need a skilled welder to install the system due to the innovative electrofusion jointing system. What is more, they do not require the use of hot works permits when being installed, which greatly speeds up the installation time as well as significantly reducing labour time and costs. These sorts of economic savings can be extremely beneficial for contractors in a time when project timings and budgets are continuing to be ever narrower.

Leading plastic pipework system, PLX from Durapipe UK, is an example of a viable pipework alternative that can be used for bulk refuelling applications. Manufactured in a robust polyethylene material, the secondary contained (pipe-in-pipe) system, which has been extensively used in the forecourt market for over 15 years, provides excellent resistance to long term stress cracking and is ideal to carry a wide variety of fuel based liquids. Additionally, its impressive durability gives it a design life of 30years making it ideal for use in applications such as bulk refuelling, where it is imperative to install a system that does not have to be regularly maintained or replaced.

Alternative pipework solutions that build on the performance quality of traditional materials whilst addressing its limitations are available to contractors and need to be more readily explored in the initial specification process. In an industry that is continually looking for higher performing and more reliable products, it calls for a reassessment of just how well traditional materials, such as stainless steel, are working within the bulk refuelling market and why alternatives are not being explored at the outset of projects.

Note: – This article appeared in the June edition of Bulk Distributor magazine

Ricardo’s is a renowned engineering solution consultancy to the world’s automotive, transport and energy industries. Its UK manufacturing facility, based in Shoreham-by-Sea in Sussex, houses over 50 engine assessment facilities that test a variety of industrial products and systems for a host of international clients.

The automotive division of the company is involved in testing combustion engines on behalf of clients, though monitoring the engines capabilities when using a variety of fuel blends. Ricardo’s was looking for a pipework solution that would safely transport the different fuel types to the combustion engines in the test centre, allowing the engine performance to be closely monitored and assessed.

Due to the underperformance of the existing steel pipework system, it was imperative that the new system could cope with a variety of fuel types, and is durable over a long period of time. Ricardo’s looked to specialist fuel pipework system PLX to replace the old pipework; specified due to its high corrosion resistance and proven quality performance, the pipework system was the ideal choice to meet the needs of Ricardo’s manufacturing site.

Durapipe PLX secondary contained pipe-in-pipe was specified in sizes 50#90mm and is used to transport diesel, gasoline, bio-fuel and other fuel blends from the main on-site fuel farm, through the site, and onto the test centre to activate the combustion engines. The fuel farm has a storage capacity of 0.5 million litres and is used to house all fuel types that are used as part of the testing process.

Durapipe PLX is a high performing pipework system for fuel transportation; its visible Polyamide liner allows increased resistance to all types of fuel blends, ensuring there is no permeation of fuel through to the atmosphere. Furthermore, its robust Polyethylene material provides exceptional resistance to rapid crack propagation and long term stress cracking.

Commenting on the installation, Alan Platt plant supervisor said: “When it comes to the transportation of fuel, safety was always our main priority and we found the PLX secondary contained system to be the best performing solution for us. Due to problems with the old system we were looking for a pipework solution that would perform over a long time period and the 30 year design life of the PLX system made it the ideal solution.”

The provision of fuel powered generators is an integral part of the construction of modern buildings such as hospitals, data centres, prisons, banks and modern schools and academies. They rely on this emergency fuel supply in the event of a power failure, to ensure they can continue to operate vital systems. Yet despite this, these systems are often not given enough consideration at the outset of a project.

In a culture where electrical power is fundamental for day to day living, power cuts have shown how, within a modern day society, we are left utterly helpless and vulnerable when denied electrical power. Power failures have the potential to cause widespread catastrophes and as a result, the need for a high performing emergency power supply is absolutely essential.

Unfortunately, whilst we enjoy the benefits of extensive technological advancement in the 21st century, we are still very much reactionary when it comes to problems that occur. For instance, we often hear after an incident that it could easily have been prevented should a certain measure have been taken beforehand. What is more, we frequently see that whilst the problem may have been a technical failing our own legal or health and safety regulations were not what they should have been leading up to the problem.

Power cuts are by their very nature unexpected, meaning that emergency power systems need to be regularly checked and updated to ensure that they will perform to the required standards, should they be called upon in an emergency. As a result, it is essential that the utmost thought is given to the specification of these systems at the outset of a project, as they have the potential to prevent large scale problems in the event of a power cut.

However, due to careless installation or low performing systems, emergency power generators themselves have also been known to fail leaving buildings without a back up plan and in potentially serious danger. One incident occurred in a Los Angeles hospital in 2008: due to the faults with the emergency power supply, 200 patients were left without power for nearly four hours. This included 24 patients who had been reliant on ventilators, some of the patients being new born babies. Although the situation was eventually resolved, the situation would not have reached the worrying heights it did, had a suitably performing emergency power system been in place.

Fuel powered generators are popular systems to use to provide power if the main power source fails. They function through a pipework system transporting fuel to a emergency generator, which will then provide a temporary power supply whilst the main system is repaired or replaced. There are two typical pipework systems that are used to provide the fuel supply, underground pipework systems or imperative fuel flow systems.

For fuel supply applications, it is important that contractors specify secondary containment (pipe-in-pipe) systems due to the potential safety hazards caused if fuel was to leak into the atmosphere. Secondary containment pipe systems are becoming compulsory for many pipework applications, and are the preferred solution for fuel conveyance. However, Durapipe is keen to stress that not all secondary containment pipe systems are the same and they all offer different performance and installation capabilities.

Traditionally, steel pipework has been specified as the preferred pipework solution to provide the generators with the fuel they need to function, although frustratingly, these pipework solutions are also known to sometimes fail. A common cause of flawed systems can be fuel not reaching the emergency generator, meaning it has no way of functioning. This can occur for several reasons, including, complete corrosion of the pipework, where the fuel or the environment has penetrated the pipe or there is clogging of the pipe bore, resulting in fuel not flowing at a consistent rate.

In some steel pipework systems, ‘clogging’ in the inner bore can contaminate the fuel which will then result in long term damage to the generator itself. These issues highlight the need for rigorous and frequent quality control checks, on pipework systems that cannot offer a long term product performance.

The difficulty with steel, is that although it has been felt to be a durable pipework solution for certain applications, the lifespan of this durability is limited and has shown no signs of improvement. This provides concerns for emergency fuel solutions, as although the hope is that it will never be called upon, if it is, it needs to perform. Contractors need to be aware that with an estimated fuel carrying lifespan of just over five years steel is a solution that cannot guarantee performance capabilities over a long period of time, and corrosion may prevent it from performing when it needs to.

In terms of the installation process, this can be lengthy with traditional metal systems such as steel. Whether these systems run under, or over ground, it requires skilled installers to fit the pipework. In the case of installing underground pipework systems, hot works permits are needed, which can result in an extremely complicated and timely installation process. Considering these issues, sparks the question of why innovative materials, such as plastic, are not being readily exploited by contractors and specifiers.

Plastic, is an example of a reliable alternative material that can be used to provide pipework solutions for emergency fuel supply. Lightweight and easy to install by nature, plastic pipework eradicates the complex installation properties associated with metal competitors. Plastic systems simplify the installation process for contractors, as they do not need a skilled welder to install the system due to the innovative electrofusion jointing system. What is more, they do not require the use of hot works permits when being installed, which greatly speeds up the installation time as well as saving contractors money on labour costs significantly. These sorts of economic savings can be extremely beneficial for contractors in a time when project timings and budgets are continuing to be ever narrower.

Leading plastic pipework system, PLX from Durapipe UK, is an example of a viable pipework alternative that can be used for emergency fuel applications. Manufactured in a robust polyethylene material, the secondary containment (pipe-in-pipe) system provides excellent resistance to long term stress cracking and is ideal to carry a wide variety of fuel based liquids. Additionally, its impressive durability gives it a design life of 30 years making it ideal for use for applications such as emergency fuel supply, where it is imperative to install a system that does not have to be regularly maintained or replaced.

Alternative pipework solutions that build on the performance quality of steel whilst addressing its limitations are available to contractors and need to be more readily explored in the initial specification process. In an industry that is continually looking for higher performing and more reliable products, it calls for a reassessment of just how well traditional materials such as steel, are working within the emergency power generation sector and why alternatives are not being explored at the outset of projects.
(This article was published in April 2010 in Electrical Review magazine).

Dennis joined the company back in 1978 as a Technical Sales Engineer following stints firstly in the Merchant Navy and working for the family engineering business.

During his time at Durapipe, Dennis has been a true pioneer in developing a vast array of different polyethylene based pipework systems, including the innovative Durapipe PLX system that is now widely used across the World in both forecourt and many other industrial applications.

Dennis was also responsible for introduction of Protecta-line, a specialist pipework system to preserve water quality in contaminated ground.

During his retirement, Dennis intends to spend time with his wife & family whilst further engaging his passion for motor cycles, travel & home cooking.