Starbank Panel Products Ltd is the Premier Panels Manufacturer in the UK, specialising in high pressure laminates, wood, commercial and industrial plastics. Solarcrown Commercial were invited to tender a full Electrical Installation package for Starbank Panel Products new facility. Starbank had secured a new property for their existing manufacturing facility to move into that allowed for future expansion. We were successful in securing the complete installation package competing against 2 other Electrical Contractors. The project included the following installations:
250KwP Solar PV System
The installation of an 250 kWp Solar PV System, comprised of 960 x Risen 260W Solar PV panels mounted on 5 of the south facing roof pitches, in conjunction with 10 x Samil 25,000TL Inverters. The system is designed to ensure that all of the inverters would be mounted inside the electrical plant room adjacent to the Eaton G59 Relay Panel Board. The Eaton G59 Panel board then links the solar panels directly to the LV Board within the same plant room.
Cost of Installation: £233,785.35
System Size: 249.6 kWp
Savings in Year One: £40,749.25
Payback Period including Energy
Increase: 4.8 years
Savings Over Lifetime: £447,806.31
LV Panel and Associated Equipment
Working alongside Starbank, Solarcrown Commercial designed a LV Panel to suit Starbanks requirements. In addition to the LV panel we supplied and installed a 200 KVAR Detuned Power Factor Correction Unit and a 2000A Back Up Generator Point.
Power Distribution – Eaton 630W Busbar System
Solarcrown installed a future proof infrastructure of 6 x 630A Aluminum BUS Bars running down gridline A, C and E to feed all of the factories machinery. This systems gives maximum flexibility for any additional machine installations in the future. The installation of various Section Boards power the facilities compressors, extraction and Biomass Boiler. Distribution boards around the factory were also installed to allow for small power and sub circuits.
Containment Network
We installed a network of containment running down and centrally across all 6 bays. The containment consists of 2 x 100mm Heavy Duty Tray and 1 x 300mm Heavy Duty perforated Basket, providing containment for the data, fire and LV with room for future expansion.
Internal, Emergency and Additional Lighting
Solarcrown Commercial installed a fully programmable energy efficient LED lighting system across the 6 identical bays. There are 4 zones per bay, with fully programmable Sensor in each zone allowing us to set up lighting systems to operate in whichever way required for each zone. We can also change the operation of the lighting system in the future when required. The installation resulted in 24 High Output Dimmable LED High Bays with 4 sensors and 12 emergency light being installed within each bay. A bank of switching is located close to the office, consisting of 24 switches, one for each zone. We also provided an exercise to show the overall lifetime cost of the LED Lighting system that we installed against a fluorescent T5 Lighting installation without controls.
All of our lighting installed meets CIBSE Design guide levels and has been designed to emit 200lux average across each
bay. We designed an Emergency Exit Lighting System to meet an extended viewing distance for the vast size of the factory,
which ensures that wherever a person is within the factory they will be able to see a minimum of 2 emergency exits.
Additional LED Lighting was installed into the Plant Room, Compressor Room, Lean Too Area, Biomass Room and externally. The External Lighting has various types of controls to allow the lighting to operate as per Starbanks requirements. A mixture of Lux Level Controls and PIR Detectors have been used around the factory, with override switches to allow lighting in the goods area to switch on when needed in hours of darkness.
Fire and Intruder Alarms
Solarcrown supplied, installed and commissioned a Digital Fire Alarm System to the Starbank Panel Products new manufacturing and office premises to meet a category L1 system for the production and warehousing facility.
The Fire Alarm System was designed and modified for automatic detection within the production and warehousing area, providing aspirating smoke detection using a Xtralis VESDA Laser Compact c/w PSU system. Automatic detection has been provided as standard by Generation 6 Smoke/Heat Detectors installed within the facility.
We also installed a G3 Galaxy Dimension Intruder Alarm System. The dimension range of panels supersedes the G3 Galaxy and has the advantage of being a combined Access Control System with the 96 zone variant having the capacity to monitor 32 Doors during non-operation hours.
External CCTV System
The revised HD IP static CCTV system provides coverage to all of the building perimeters. In addition we provided CCTV overlooking the car parking area. All external cameras include data/image storage at 15 FPS with RAID 5 capabilities. Future expansion and development is essential to the CCTV strategy requested by Starbank Panel Products as well as full control of the systems operation by Starbanks operatives.
Data Network
We installed a full Data Network throughout the production facility, consisting of 3 fibre linked data cabinets that feed 7 gridlines with 12 double data point per gridline. The new Data Network has a total of 84 Double Data Points evenly distributed across the facility, giving room for any future expansion on the system.
Heating Controls and Lightening Protection to Biomass Chimney
Solarcrown Commercial supplied and installed the required power infrastructure and the facilities heating controls and fans supplied by a third party that connect to the Starbank Biomass Boiler System. We carried out the appraisal to install the system comprising of 2 bonds to the base of the chimney steelwork. Each bond utilises a Gunmetal ‘B’ clamp, which is drilled and tapped to the base of the chimney via an M10 bolt. From the bonding connection, a length of 25 x 3mm PVC sheathed copper tape runs directly to a Copper Bond earth electrode, housed within a GRP lockable inspection zone.
Cost of LED Lighting System: £105,287.28
Annual Costs of LED Lighting System: £8,264.95
Lifetime Cost including Installation: £209,242.99
Saving Over Lifetime: £140,351.00
Cost of T5 Lighting System: £77,709.82
Annual Costs of LED Lighting System: £21,616.04
Lifetime Cost including Installation: £349,593.99