1-2 broadgate final project report

1-2 BROADGATE PROJECT REVIEW

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We have extensive experience of undertaking complex projects where we have worked with occupiers to develop their requirements and used our substantial project management expertise to deliver their expectations, resulting in buildings that positively enhance their business.

Many of our projects are undertaken in occupation and we are adept at reviewing the strategy to advise on the phasing of work to minimise disruption to the occupiers while reducing costs and maintaining business continuity.Peter Bicknell, Client Services Director (Head of Technical Services)

Peter Bicknell, Client Services Director (Head of Technical Services)

Paul J Warrington, Engineering Manager

Foreword

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1.0 Introduction 41.2 Project summary .................................................................................................................................................................. 6

2.0 Phase 1 82.1 N+1 resilience system ......................................................................................................................................................... 9

2.2 Sixth floor chillers ............................................................................................................................................................... 10

2.3 Ground to second floor chillers ......................................................................................................................................... 11

2.4 Pumps ................................................................................................................................................................................. 12

2.5 Sprinkler heads ................................................................................................................................................................... 13

2.6 Cooling towers ................................................................................................................................................................... 14

2.7 Miscellaneous works .......................................................................................................................................................... 16

3.0 Phase 2 183.1 Generators ......................................................................................................................................................................... 19

3.2 LV switchgear ..................................................................................................................................................................... 20

3.3 Loadbank ............................................................................................................................................................................ 21

3.4 Building works ..................................................................................................................................................................... 22

3.5 Sprinkler systems ............................................................................................................................................................... 23

3.6 Pumps ................................................................................................................................................................................. 24

3.7 Chillers ................................................................................................................................................................................ 25

3.8 Cooling towers ................................................................................................................................................................... 27

4.0 Phase 3 284.1 Pumps ................................................................................................................................................................................. 29

4.2 Chillers ................................................................................................................................................................................ 30

4.3 Cooling towers ................................................................................................................................................................... 31

5.0 Conclusion 32

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1.0 Introduction

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1-2 Broadgate consists of 305,272ft2 of floor area spread across six levels occupied by a range of businesses including ICAP, Royal Mail, KBW, Regus, Precise Media, Brookfield Multiplex, ETX and GF Securities.

A four year comprehensive refurbishment programme was carried out at the property restoring key elements of the mechanical and electrical building infrastructure with the aim of extending life to 2019. A key aim of the project was to give confidence to the occupiers ensuring their needs will be fulfilled in the future so they can re-gear their lease and extend the duration of their stay in the property.

The works were completed in three phases between 2012 and 2015, whilst the building was fully occupied.

Prior to the programme, the majority of systems and equipment in the property had not undergone significant upgrades from the systems installed during the initial development of the property in 1986. An exception being the transformation of the chilled water air conditioning system in 2005 from a centralised system to a quadrant chiller system with dedicated chillers and AHUs housed on each floor. However the majority of equipment in the building was approaching the end of its serviceable life at the time of the programme.

In order to initiate the refurbishment project, Broadgate Estates were invited by the landlord to summarise and advise on the engineering systems within the property with respect to suitability, reliability and obsolescence of the equipment. Additionally any major equipment or systems which had exceeded or were nearing their service life were identified for replacement to ensure the needs of the occupiers can be fulfilled until 2019.

A key aspect of the project initiation process was the risk assessments carried out by Broadgate Estates on all 386 engineering systems and assets in the building. The assessments resulted in risk ratings being given for the potential failure of all equipment and systems. This was based on multiple factors such as condition, compliance and service impact upon failure. Based on the risk scores, equipment were prioritised within the four year programme which resulted in the equipment that was likely to pose the highest potential risk to the occupiers’ business being addressed within the early phases of the programme.

In order to transform these findings into specific work items, Broadgate Estates commissioned several specialists engineering service providers to propose technical recommendations for the work required. These proposals were utilised as guidance to produce a detailed version of the phased refurbishment plan spanning the four year period.

1.1 General

1.2 Project summary

The most significant and critical parts of the refurbishment works were completed during phase 1 over an 18-month period. The most notable of these works was the replacement of the two dedicated chillers and cooling tower which provide cooling to the occupiers’ UPS facility on an N+1 configuration.

Further replacements were carried out of two chillers located on the sixth floor whilst the floor was fully occupied. Broadgate Estates ensured that occupiers’ cooling needs were continually satisfied by installing and managing similar sized temporary chillers on the roof for the duration of the works.

A complete refurbishment of the rest of the cooling system in the building was undertaken during the three phases. This included replacement or refurbishment of 78 primary and secondary chilled water and condenser pumps, 22 chillers and 12 cooling towers in the building.

All of these works involved the contribution of multiple contractors who worked on site simultaneously as planned and coordinated by Broadgate Estates. This ensured efficient and timely completion of work packages with minimal downtime of systems.

Through meticulous planning and careful co-ordination between the multiple parties, the cooling system refurbishment works were completed without interruption to occupiers’ air conditioning services.

The fire protection systems in the building were subjected to overhaul to ensure these critical systems can continue to perform at their optimum level. Key aspects of these works were the change of all fire phones, sprinkler heads and tanks and refurbishment of the main sprinkler pumps in the building.

A number of important electrical upgrades formed a substantial share of the phase 2 works in which the two occupiers’ life safety generators were replaced in their entirety and the four landlords’ generators were fully reconditioned. Temporary generators were installed and operated by Broadgate Estates to maintain the level of backup power to occupiers operations throughout the works.

Replacements to LV switchgear were undertaken where ACBs (Air Circuit Breakers) had become obsolete and unsupported with spare parts. Broadgate Estates also managed the installation of a new load bank connection facility as part of these works.

A number of temporary and permanent modifications to the building were completed to enable the electrical upgrades and to provide safe access routes for occupiers during the works.

Several other restoration works were accomplished within the programme including the replacement of all dry riser landing valves and the refurbishment of passenger and goods lifts and the two main AHUs. Upgrades were made to the LTHW boiler system to transform the boiler burners to flame controlled burners resulting in improved efficiency.

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1.3 Project governance

The responsibility of overall project delivery was held by an incumbent Project Lead who also provided immediate client oversight. A Project Engineering Director and a Project Client Director was also appointed to provide engineering oversight and client oversight respectively and to be jointly responsible for approving works and contracts. Any significant variations to costs and timescales were scrutinised and approved by the Project Directors. In the occurrence of considerable technical variations, the Project Engineering Director was responsible for approving the changes.

Systems upgrades and IT and fabric related works were managed by three appointed project managers from the respective departments within Broadgate Estates. The project team also included a Manager who ensured compliance of the programme with CDM (Construction, Design and Management) regulation.

A clear communication plan was vital in carrying out works within timescales and budgets with minimal interruption to the multiple client operations in the property. A building management meeting and an occupiers’ meeting held on a weekly basis and a landlord’s meeting held every month were crucial elements of the communication plan. A six weekly programme which was updated on a monthly basis was presented by Broadgate Estates to stakeholders during these three types of meetings.

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WEEKLY MEETINGS MONTHLY MEETINGS

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2.0 Phase 1

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The most significant part of Phase 1 was to refurbish the N+1 resilience cooling system which provides cooling to the occupiers’ UPS facilities.

The refurbishment of this critical system was carried out with the collaboration of three specialist contractors working simultaneously whilst the building was fully occupied.

The UPS cooling system consists of a Carrier 30HXC230 Chiller located within the basement and a ground floor chiller which provides N+1 resilience. The system works in conjunction with a dedicated cooling tower.

The most critical aspect of the works was the replacement of the carrier chiller. Additionally the ground floor chiller and the cooling tower were fully refurbished in order to extend their service life.

Broadgate Estates ensured the work did not compromise the cooling requirements and cooling system resilience of the UPS system by installing and operating an equally sized temporary AC plant with air cooled chillers housed in the loading bay.

Furthermore the fan control strategy for the cooling tower was upgraded from two speed control to fully modulating control resulting in increased efficiency.

Changes were also made to the BMS to increase the frequency of flushing to protect the tower should the system not run for the preceding 12 hours.

Previous to the change, condenser flushing was accommodated in a single time zone each day.

The set point temperature to enable the cooling tower fan was also decreased from 24ºC to 18.5ºC.

2.1 N+1 resilience system

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A complete replacement of the two chillers supplying the sixth floor was carried out whilst the floor remained fully occupied.

The new chillers were assembled on site within the plant rooms whilst full cooling to the floor was maintained using temporary chillers.

The temporary chillers were lifted by crane on to the roof of the building and placed on a purpose built steel structure for the duration of the works. These were connected to the primary CHW circuit by temporary flexible pipework which were fed through the roof and seventh floor slabs.

Upon installation, the temporary system was tested and commissioned before work started on the sixth floor chillers.

One of the main challenges was the transportation of the new chillers to the sixth floor plant rooms, which was carried out by dismantling the units to manageable sections and using the goods lift for transportation between floors.

The old chillers were also transported from the sixth floor to the ground floor using the same process.

The work was carefully co-ordinated and managed with the contractor and the site M and E team to eliminate the possibility of any disruption to the occupiers.

2.2 Sixth floor chillers

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A phased refurbishment programme was carried out for all ten essential chillers on ground to second floor. This included the replacement of all electronic monitoring equipment, electronic switches, oil pumps and oil filters.

Furthermore the refrigerant volume and flow of the systems were confirmed and the heat exchanger internals were chemically cleaned using a flushing rig.

2.3 Ground to second floor chillersThe refurbishment process for each unit was concluded by a comprehensive testing and commissioning process. The chillers were refurbished to a carefully planned schedule to ensure the cooling needs of the occupiers were satisfied throughout the programme.

Broadgate Estates managed the refurbishment or replacement of all 78 main pumps during the four-year programme to ensure the units can perform effectively until 2019.

The pumps relate to all primary and secondary chilled water and condenser pumps within the building. Each floor consists of two primary chilled water pumps, eight condenser pumps and eight secondary chilled water pumps.

Phase 1 addressed pumps on floors one to six with a particular focus on third, fourth and fifth floors.

Some pumps were replaced in their entirety, whereas the majority of pumps were refurbished.

Complete replacements were carried out for pumps that were obsolete and unsupported by spares.

The pumps relating to refurbishment were initially assessed to determine any components that required replacement. Refurbishment consisted of replacement of seals, bearings, O-rings, gaskets, motors and inverter drives.

Recognising the significant efficiency improvements that can be realised, a number of bigger condenser pumps were upgraded to inverter drives during the programme.

In order to minimise disruption and risk to the cooling systems, the pump refurbishment programme was carefully planned to match the cooling towers and chiller refurbishment programmes that ran simultaneously.

Working in conjunction with the onsite M and E team, the works were carried out successfully without any disruption to the occupiers’ business.

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2.4 Pumps

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2.5 Sprinkler heads

A substantial element of the renewal of the fire protection systems was the replacement of all sprinkler heads in the property during the first 18 months of the programme. The key challenge was undertaking the work in a property that was occupied with a number of floors housing critical operations to occupiers’ businesses such as various trading floors in the building.

Sprinkler replacements on occupied floors were carried out between 06.00pm and 03.00am to ensure no disruptions occurred and sufficient time was available to prepare the floors ready for the morning. An important aspect of the planning process was ensuring all precautions were taken to eliminate the possibility of any impact on occupiers’ property including highly sensitive and costly equipment. The successful completion of the sprinkler replacement works required careful planning and coordination and sound communication between the site M&E team and cleaning and fabric teams.

During the planning stage, each floor was divided into four quadrants with work in each quadrant split further into multiple stages. Each stage involved the replacement of around 30 sprinkler heads which was typically completed within a single night shift.

Phase 1 of the programme incorporated the replacement of all 2,700 sprinkler heads from third floor to sixth floor which were fully occupied during the works.

As Phase 1 was in progressions, the tenancy of ground, first and second floors ended, which provided an opportunity to replace all the sprinkler heads on these levels towards the latter part of phase 1.

Although not part of the initial plan for the programme, these works were successfully incorporated to phase 1 works which resulted in the renewal of all sprinkler heads in the building.

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A key part for the refurbishment programme of the cooling system was the reconditioning of all cooling towers.

Broadgate Estates also utilised this programme to upgrade the fan motors to IP65 inverter driven motors. The 12 cooling towers in the building feeding the quadrant condenser system were reconditioned over three phases to an equal standard.

This resulted in prolonging life, improving efficiency and ensuring protection against waterborne pathogens.

The SE1, NE1 and NW3 cooling towers were fully refurbished during Phase 1.

A complete restoration of the fan sections was undertaken which included the replacement of fan motors, wheels, shafts, bearings and couplings.

The infrastructure was also modified to support the new control strategy where new pumps and brominators were fitted and an IQ enclosure for monitoring and fault finding was manufactured and installed.

New wiring infrastructure including new screened power supply, control wiring and network wiring were also installed for each cooling tower.

As part of the programme, components such as drive sets and belts, drift eliminator media, fill packs, access door gaskets and float valve assemblies were also replaced for all cooling towers.

Electrical aspects of refurbishment included renewing of local isolators and flange boxes and other localised lagging repairs.

The work was carried out during normal working hours, without any compromise on occupiers’ cooling needs. This was achieved by refurbishing one cooling tower from each quadrant condenser system at a time; ensuring two units were always online to fulfil cooling needs of the occupiers.

In addition to the phased mechanical and electrical works, various other works were undertaken as detailed below.

2.6 Cooling towers

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2.7 Miscellaneous works

In addition to the phased mechanical and electrical works, various other works were undertaken as detailed below:

2.7.1 Boiler BurnersIn order to replace the obsolete burners for the two LTHW boilers that provide underfloor heating for the main atriums, the old burners were replaced in their entirety with high efficiency flame controlled burners.

This was successfully carried out by the onsite M and E maintenance team during the summer months to avoid disruptions to occupiers’ heating.

2.7.2 AHUsThe on-site M and E service provider at 1-2 Broadgate carried out full refurbishment of the two main AHUs located on the roof as part of phase 1 of the programme to extend their life to 2019.

Works carried out on units include the overhaul of fans and fan drives, replacement of filters, sensors, cleaning and lubrication of components and treatment of corroded areas in the AHUs. A number of door hinges, locks and seals were also renewed.

Units were then tested and commissioned and set back into operation.

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2.7.3 Dry Riser ValvesIn order to ensure the dry riser valves are in their optimum condition to support the fire services in an event of a fire, all 32 dry riser landing valves in the building were fully replaced. Additionally four inlet breeching valves and four air release valves were also replaced.

2.7.4 Passenger and Goods LiftsBroadgate Estates incorporated the refurbishment of the lift motors and gearboxes of the four passenger lifts and two goods lifts as part of the building infrastructure works in Phase 2.

The lift motors in the passenger and goods lifts were replaced due to their age which resulted in an extension of life for the motors by 20 years.

Replacement of the gearboxes was a particularly challenging aspect of these works as the original and replacement gearbox assemblies had to be disassembled for transport between floors due to their size. The new gearboxes were reassembled and commissioned in the lift plant rooms on the roof. Arrangements were made by Broadgate Estates to utilise a gearbox specialist from Germany to carry out assembly and disassembly of gearbox units for each lift.

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3.0 Phase 2

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The generator project aimed to renew and refurbish the generator units to increase service life to 2019 and to realise additional benefits of improved resilience, reliability and maintainability.

The most significant part of the project was the replacement of two life safety generators in their entirety and the reconditioning of four occupiers’ generators.

These works also included a pressure test of the occupiers’ generator flues and a full function test.

In order to increase the life of the generator switch panels to 2019, generator sync panels, switch panels and switchboard components in a number of generator and LV rooms were replaced.

Additionally BMS devices, software, hardware and graphics were also upgraded to support the new and refurbished generators.

Careful co-ordination and planning was required between Broadgate Estates, the site maintenance team and the contractor who carried out the work, in order to minimise disruption or loss of backup power to occupiers and to ensure N+1 resilience of the generator systems was always maintained.

Broadgate Estates also ensured the building works programme was planned to have the necessary walls demolished to create access to remove the old generators and deliver the new generators.

3.1 Generators

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Refurbishment of the LV switchgear included the replacement of all Air circuit Breakers (ACBs) and Moulded Case circuit Breakers (MCCBs) within the old generator switch boards.

The ACB and the MCCB ranges within the old generator switch boards had become obsolete and therefore replacements of these units were carried out to ensure the availability of spares beyond 2019.

Due to a number of incompatibilities between the old and the new ACB ranges, modification had to be made to the old busbar connections to accommodate the new units.

In order to eliminate any disruption to occupiers’ operations, the ACB replacement and load bank installation were completed during weekend shutdowns.

3.2 LV switchgear

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A load bank connection facility was installed to facilitate individual testing of the landlord’s generators. This panel provides simulated loads to allow the landlord to test each generator at any one time. In the event of a mains failure during such a test, the load bank automatically switches off to allow the generators to provide backup power to the property.

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The services of a specialist building works company was needed to undertake temporary and permanent modifications to the building structure to satisfy access requirements for the electrical works.

A number of walls and doorways of generator rooms were demolished to remove old generators from the building and to deliver the new units.

Temporary walls and doorways were put up to ensure access was permitted to hazardous areas and safe walkways were available for occupiers.

Additionally cladding was installed on Finsbury Avenue which was painted and illuminated to safely store the temporary generators and load bank testing equipment.

Upon completion of the electrical upgrades, all walls and doorways were rebuilt and the four generator rooms were redecorated including restoring walkways and floor markings.

Permanent changes to the building include the holes formed through blockwork to feed the loadbank busbar and cables, modifications to the mesh cages to house the new loadbank connection panels and installation of fire cladding to all openings of busbar and cables.

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3.5 Sprinkler systems

3.5.1 Sprinkler PumpsThe two main sprinkler pumps and the associated jockey pumps serving the building were subjected to a full refurbishment programme with the aim to ensure this critical system is able to perform at its optimum level.

3.5.2 Sprinkler TanksAs part of the phase 1 works, all the sprinkler tanks storing water in the basement were relined.

3.5.3 Fire PhonesAll fire phones within the building were replaced with new units in Phase 1. It was crucial to carefully plan and manage this element of the programme to ensure the large quantity of fire phones located throughout the building were renewed using an efficient and methodical approach.

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On continuation of the pump replacement and refurbishment works, eighteen secondary chilled water and condenser pumps on the ground to 5th floors were addressed during phase 2.

The work done for each pump varied depending on their condition.

Complete replacement was carried out for eight pumps that were unsupported with spares with the rest being refurbished.

New inverters were fitted for five of the refurbished pumps and the remaining pumps were fitted with new seals, gaskets and bearings. All pumps refurbished were fitted with new motors.




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During phase 2, four more chillers were subjected to refurbishment.

This included the replacement of all electronic monitoring equipment, electronic switches, oil pumps and oil filters.


The refurbishment process for each unit was concluded by a comprehensive testing and commissioning process. The chillers were refurbished to a carefully planned schedule to ensure the cooling needs of the occupiers were satisfied throughout the programme.

3.7 Chillers

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The refurbishment works for the cooling towers were continued during phase 2 to fully restore three cooling towers (i.e. SW1, NW1 & NE3).


The infrastructure was also modified to support the new control strategy where new pumps and brominators were fitted.

New wiring infrastructure including new screened power supply, control wiring and network wiring were also installed for the cooling towers.

As part of the programme, components such as drive sets and belts, drift eliminator media, fill packs, access door gaskets and float valve assemblies were also replaced.



3.8 Cooling towers

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4.0 Phase 3

The pump replacement and refurbishment works were completed during phase 3.

A similar approach to phase 1 and 2 was taken, whereby each pump was assessed for replacement requirements before replacing the required components.

Eight twinhead pumps on levels two, four and five were addressed on this phase. Six of these pumps were replaced and two were fitted with new seals and O-rings. All pumps were fitted with new motors.





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In order to conclude the chiller refurbishment works, the eight remaining chillers in the building were refurbished using the same process used in the first two phases.

This included the replacement of all electronic monitoring equipment, electronic switches, oil pumps and oil filters.



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The final phase also involved the completion of the cooling tower refurbishment works.

Six cooling towers (i.e. NE2, NW2, SW2, SW3, SE2 and SE3) were fully refurbished in this phase.


The infrastructure was also modified to support the new control strategy where new pumps and brominators were fitted.

New wiring infrastructure including new screened power supply, control wiring and network wiring were also installed for the cooling towers.

As part of the programme, components such as drive sets and belts, drift eliminator media, fill packs, access door gaskets and float valve assemblies were also replaced.



Completion of these works ensured all the cooling towers at 1 and 2 Broadgate are at an equal standard with increased life, efficiency and protection against waterborne pathogens.

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5.0 Conclusion

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Under the management of Broadgate Estates, the refurbishment program of 1-2 Broadgate was delivered before the scheduled completion date, significantly under budget and without the occurrence of any safety incidents.

Though careful planning, coordination and a highly client focussed approach, Broadgate Estates ensured all building services to occupiers were maintained throughout the program, without any compromise on standards and resilience.

5.0 Conclusion

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1-2 broadgate final project report

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