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Warm Air Heating Solutions
Recent works by Harry Taylor of Ashton

Warm Air Heating / Case Study 1 / GKN Aerospace:

In 2010 GKN Aerospace Transparency Systems Ltd of Luton Bedfordshire had a centralised steam boiler system which was nearing the end of its life. This consisted of 4 steam boilers.

The project we were given was to produce a decentralised heating system for the factory allowing individual control of the many distinct areas within the factory. The Client's objective was to shut down the steam boilers with efficiencies possibly as low as 50% and replace them with warm air heaters on the Energy Technology List with efficiencies greater than 91% providing individual control of the many distinct areas within the factory significantly reducing the Carbon Footprint of the Factory by reducing the gas consumption on the site.

GKN wanted to use Energy Efficient Equipment and as our web site shows that we try to always specify products on the Energy Technology List they were keen to see what we would propose.

The buildings that we were charged to heat covered an area of approximately 6,060 square metres. As we were working in an existing building it was important that we did not affect business continuity within the premises. The premises are a collection of buildings of varying age and fabric. The main building which houses the offices and part of the production is of brick fabric. There are also a selection of buildings of mainly brick construction with a variety of roofs some with cladding and others with flat bitumen roofs. Within these areas are closed control areas that we were not responsible for as they had their own HVAC systems. We were concerned with the general working areas. Each building was carefully measured and heat losses calculated taking account of building fabric.

We also looked at efficiency measures specifying destratification fans where appropriate. All heaters were to be fitted with optimised controllers. Not only do these optimise heater use they also can be set to meter use of each heater. As members of HVCA and BESCA we are able to self certify our works as far as Building Regulations are concerned.

We used Benson VRA room sealed heaters and Reznor UDSA room sealed heaters which were at that time both on the Energy Technology List. Each heater was controlled using an optimised controller giving zoned control of each area. The customer has monitored the performance of the system and they have been able to achieve weekly savings of approximately 12.95 Tonnes of Carbon per week.

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Warm Air Heating / Case Study 2 / Bryce & Wood Ltd
In January 2011 Harry Taylor of Ashton Ltd was approached by a property development company working on behalf of Bryce & Wood Ltd of Blyth near Newcastle looking for a heating solution for a new building, 1,500 sqm and 8.5m high.

The building had not been built and planning permission had yet to be obtained. The structure would have low traffic as it is to be used for the storage of archived data with a minimum internal temperature requirement of 10 deg C. when -5 deg C outside. The client had originally intended to heat the space with electric heating but because of the size of the structure we advised against this due to running cost reasons especially when Natural Gas was available on the site.

When designing the system we were faced with quite a few problems. The building was large and tall and the heating load low in relation to the space at only 90 kW. These factors would produce severe heat distribution and stratification problems which would be further aggravated because around 70% of the space was to be racked out to roof level. It was imperative that the temperature around the building was constant to provide temperature protection for the building contents but equally important was fuel economy and hence carbon saving. A normal system using warm air heaters and destratification fans would not allow thermal equilibrium because of the low temperature requirements in the building and the density of racking. Such a system could also cause discomfort problems and be both expensive to install and maintain. After careful consideration it was decided that the best solution would be the use of an Air Rotation system. Air Rotation systems comprise a small number of units strategically placed within the premises they are to heat. These operate by circulating large volumes of air at low velocities and temperatures thereby maintaining constant air circulation in the building. This system reduces stratification and provides a uniformity of heat that is difficult to match. They are best used in buildings that operate 24 hours per day and because of this no allowance is required for pre heat meaning that a lower heat input is required. In short we were able to reduce the scheme to one floor mounted air rotation heater with no destratification requirements and was ideal for this application.

Planning permission was achieved and site construction commenced in March 2011. The heating system consisted of one Nordair Niche IDF5V Vertical Air Rotation unit which was commissioned by the Manufacturers on the 6th December 2011. The system works very effectively.

The unit is 91% efficient and is listed on the Enhanced Capital Allowance scheme and is rated for an output of 100 kW. Because the unit uses parts readily available in standard unit heaters and all serviceable components are at low level (burner, heat exchanger, fan etc) maintenance is simple without the need for access equipment. The value of the project was £15,700 + VAT.

Life costs should be very good, the system has been reduced to one piece of equipment and all parts are at low level, therefore maintenance and service costs are kept to a minimum. The heater itself has a low leaving air temperature and a continual air flow and therefore will be under stressed which should allow for a very long life span.
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Warm air heating / Case study 3 / Taylor made
When Clive Bew of Adidas Salomon Taylormade was given the task of moving the warehousing and bespoke golf club productions to their new premises, he searched for suitable companies on the web and found Harry Taylor. One problem with their 23,000 sq ft warehouse was the potential loss of heat through the roller shutter doors.

Harry Taylor's solution was the installation of 5 Modine PDE warm air heaters controlled by programme stats and located in positions which ensured that the whole building was adequately heated, including the susceptible area around the roller shutter doors. In addition the heaters were complimented by 5 Eliturbo destratification fans, which help to keep running costs down - an important factor with a building of this size.

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Warm air heating / Case study 4 / Dhamecha
The Dhamecha Group currently serves London and the South East from 7 locations - Wembley, Barking, Enfield, Croydon, Hayes and Watford and the new seventh branch in Lewisham which opened in October 2012. Harry Taylor was first asked to redesign the heating system at the Dhamecha premises in Barking. An existing radiant heating system had to be adapted to suit Dhamecha's store layout. The existing radiant tube heaters were perfect to heat the checkout area of the store, but these units only produced localised heat. In order to provide full coverage an uneconomical number of additional radiant heaters would have been needed. Harry Taylor's solution was to install a number of the largest Modine gas fired unit heaters at strategic points around the store to create welcome pools of warmth for the benefit of customers and staff alike.

This solution worked well for Dhamecha so when the group decided to open their Croydon, Enfield, Hayes, Watford & now Lewisham Cash and Carry stores they asked Harry Taylor of Ashton to produce systems based on the Barking formula with radiant heaters for the checkout area & Modine warm air heaters to provide background heating throughout the rest of the store. They even replaced the heaters at their original Wembley branch.
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Dont forget to check out our other case studies sections:-
Radiant heating case studies
Evaporative cooling case studies
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