Wheildon’s installed the plumbing and heating for this private client undertaking their first barn conversion. During this project, Wheildons were commissioned to install an oil fired central heating system, underfloor heating to two floors, solar panels and a solar cylinder for hot water with associated plant and pipe work, plumbing for first and second fix for a family bathroom, two en-suite shower rooms, downstairs shower-room, kitchen and utility room.

As with any barn conversion there are challenges, in this case our challenge was to future proof the conversion yet keep it cost effective. The location of the barn ruled out mains gas. The options available were the installation of a heat pump for either ground or air source, LPG or Oil fired central heating.

At the time, ground source heating was a relatively new and expensive technology to install. The choice to install the horizontal coil or vertical bore hole method was simply not an option at this time. However, Wheildon’s wanted the installation to be future proofed should the client decide to install this technology at a later date.

The decision to install an air source heat pump was over ruled because of the low electricity supply at the barn and the cost to install an additional transformer to increase supply proved very expensive.

The decision was made to install oil fired central heating, underfloor heating, solar (hot water) panels and a Solar Cylinder. This ensured that during the summer months the solar panels would supply enough hot water for the property and the oil boiler and underfloor heating could be turned off, thus reducing running costs. Electric heated towel rails were installed by the electrician in the bathrooms to ensure towels were always dry and bathrooms were warm during the cooler summer months.

This has been an exciting yet challenging project and not without its difficulties. One of the biggest challenges was lifting the oil from the oil tank to the boiler located in the house. The challenge presented itself as a 25m downhill gradient. The solution was the installation of a mechanism called an Oil Lifter, its role was to simply help the oil boiler lift the oil up through the oil line to the boiler. Simple solution, we thought.

The battle between Wheildon engineers and oil lifters began. It took several attempts involving the installation of three oil lifters, a new pump house and the re-location of the oil lifter onto the patio. Eventually, the problem of noise, air locks and continuous oil flow were finally overcome. We can’t wait for our next challenge!

October 2012: What began as an enquiry from the website from Foyle Food Group has now seen the development of a three phase project at the groups Melton Mowbray site. Foyle Foods acquired the site with a view to cutting running costs. The aim of the project is to decommission the currently hired and expensive steam generator which currently supplies all the hot water for the steam plant at the abattoir. The challenge for this project is the guarantee of a continuous rate of hot water at 85 degrees. The hot water requirements for the site are as follows:

• 85 Degrees for the Gut Room.
• 60 Degrees for washing down.
• 45 Degrees for showers and Taps.

Phase 1: November 2012, Wheildons installed two commercial ACV units to provide the continuous hot flow rates as above. Temperatures of 60 and 45 degrees were achieved for the washing down, showers and taps. However, the demand for a continuous flow of hot water at 85 degrees, were not being achieved.

It was soon apparent that the two ACV units that were commissioned to do this, based on their statistics to deliver this rate of hot water could not keep up with the current demand for continuous hot water at 85 degrees. Troubleshooting meetings between the parties were arranged to overcome this obstacle. The outcomes were discussed:

• The Installation of 2 ACV units would not produce the desired 85 degrees continuous flow, in fact it would require 4 ACV units.
• Water flow restrictors to be installed to reduce the amount of water currently being used and reduce water wastage.
• The installation of a tripe machine and its requirements need to be considered.
• The current return rate of hot water around the plant was too slow due to small pipework, this meant that the temp of the water returning to the ACV units were lower than the required temp return rate to produce a continuous flow rate of 85 degrees.
• The pipe work in the abattoir needs to be increased in size to accommodate this and the pipework also needs to be insulated.
• A ‘tank in tank’ hot water storage tank is to be installed to utilize the currently wasted energy generated from the re-fridgeration units. The hot water storage will form a pre-heat that will supply the ACV units. This will make the plant more efficient.
• The work needs to be carried out with minimal disruption to the site and downtime kept to a minimum.
• The allocation of budgets restricted the amount of work that could be done and when.

Following this meeting in February 2013, Wheildons were commissioned to carry out the installation of a further two ACV units. Increase the size of the pipework in the abattoir to aid a quicker return rate of hot water, implement the use of water flow restrictors at key points to reduce the amount of water currently being used until the new sterilization equipment is installed and install the hot water storage tank.

Foyle Foods are going to replace the roof at the abattoir in March, this will require a shut down period of one week, during this time the pipe work will be upgraded. Foyle will supply the hot water storage tank and insulate the pipe work themselves to reduce costs.

This work would be carried out in a further two phases, scheduled for February and March 2013.

Phase 2: 12th February 2013: This week Wheildons are back in Melton Mowbray for the Foyle Group. Wheildons will be installing two more ACV units & plant, thus completing phase two of the project.

Phase 3: March 2013: Factory will be shut down for the replacement roof and pipework increase.

To be continued.

Clients: Graham & Debbie Atkinson
Location: Carus Lodge, Arkholme.
Duration: June – Sept 2012

Project: House Renovation: Complete Plumbing and Heating Upgrade, Main Bathroom Refurbishment, Creation and Installation of new En-suite Bathroom, Installation of Wood Burning Stove.

Heating: Remove old boiler, radiators, pipe work and header tanks from loft space. Install new boiler, flue, weather compensator, radiator pipework, manifolds and new radiatiors. Run pipes to loft space in case of future renovation.

Main Bathroom: Plasterboard and plaster outside wall & side of newly formed cupboard. Plumb washing machine into cupboard. Remove old sanitary ware, 1st & 2nd fix soil (new stack) & waste pipes, 1st & 2nd fix sanitary ware. Hard backer & tile bathroom floor, tile bath area, half tile toilet area.

En-suite: Bench out external manhole, lift section of concrete path, dig external trench, lift floorboards in bedroom 1 & excavate internal hole, lift floorboards in bedroom 3 and excavate external hole. Install underground soil pipe from bedroom 1 to manhole. Make good holes and concrete above drain outside. Knock Out nib in bedroom wall, form en-suite bathroom. Re-enforce joists under shower tray. 1st & 2nd fix bathroom. Tile the floor, shower area, toilet wall, above the toilet framework and above the sink.

Kitchen: Run pipe work to new sink location, plumb sink and dishwasher. Drill hole in kitchen worktop & install kitchen tap. Install outside tap.

Lounge: Install flue, Install Wood Burner & Connect to Flue. Install Spinner cowl to flue.

Testimonial:

I am writing to say how pleased we are with the work done by your company on our property. We are pleased with the very professional finish both the bathroom and en-suite look lovely and function well and the heating system installed is super. However, we were also very impressed with the way the work was carried out with all the different staff being very friendly helpful and patient – with Mick deserving a special mention!

In addition to which your staff always came when they said they would and always did their utmost to keep our rather lengthy job moving. From Mick’s first visit to finishing off I had confidence in the company and wasn’t disappointed.

Regards
Debbie

In Progress Photos