Challenge
Due to regulatory changes coming in the near future regarding emissions testing on automotive vehicles, our client had an immediate need to move swiftly to ensure that their test facilities met these new regulatory requirements. Having recently completed a high profile and demanding project for this client in recent years, Picow were identified very earlier as a key partner to deliver on what was a highly technical performance specification from a HVAC perspective in particular! Picow were appointed PD, PC and preferred design and installation contractor to deliver a turnkey solution, involving construction, mechanical and electrical services.
Solution
Our final solution included the initial strip-out of all existing plant and equipment associated with four existing test cells in the plantroom area to make way for the new HVAC systems. We then completed a full remodelling and refurbishment of two of the existing test cells to bring them up to current standards and the remaining two cells were converted into an instrument room and a welfare area. Each test cell is capable of 16 No of tests. Test conditions vary between -10°C at 0.2g/kg to 45°C at 14.3g/kg. Depending on the test type, some temperature tolerances were to be kept within +/- 1.0°C and moisture levels within +/-0.71g/kg. To achieve this each cell is served with dedicated HVAC plant equipment, consisting of fresh air handling units incorporating dehumidification and humidification plant, recirculation air handling unit, tail pipe exhaust fan and a pit extract fan.
Solution
Heating to all air handling equipment is provided by the existing MTHW system, whilst cooling was provided by extending an existing 2°C / 8°C chilled water system and a new 25°C / minus 20°C chilled water system. New dedicated sub-zero chillers and distribution system were installed to serve the air handling equipment. Large mechanical elements of the project were prefabricated off site and brought in on a ‘just in time’ basis. A new dedicated building management system was installed to control all HVAC plant and equipment. Picow were also responsible for the full electrical infrastructure associated with new Dyno power as well and general LV distribution boards, small power and lighting. Associated life safety services were also installed to meet cell safety matrix requirements.
Outcome
On a completion of a very demanding test cell commissioning process, the results showed our HVAC system could provide very tight control over temperature and humidity within each test cell. Regulatory requirements state that a tolerance of +/- 3 degrees from a set temperature is allowed during testing, whilst the performance engineering specification of our clients stated that this tolerance be no more than +/- 1 degree across all 16 tests between -10 to 45 degrees Celsius with a vehicle load running within the cell. We managed to achieve the engineering requirement across all 16 tests, with some tests almost flatlining at the base temperature requirement. The BIM model process did play a significant role in achieving a highly technical solution in what was an existing and extremely tight space in the plantroom to work with. In general this is a project we are all extremely proud to have delivered.
