Abtec Building Technologies (Abtec BT) has recently completed a project to install a connected lighting system at a newly constructed brick factory in the East Midlands. Ibstock Brick, an Ibstock PLC company, has built a new factory capable of producing 100 million bricks a year, helping to address the UK’s housing shortage. With lighting such a fundamental part of any manufacturing facility, the company wanted to install the latest technologies to help save on costs, energy consumption and CO2 emissions.
Ibstock Brick is the UK’s market leader in brick manufacture with 20 factories across the country and a total annual capacity in excess of 750 million bricks. In addition, the firm employs almost 1400 people, with a substantial number in the local Ibstock and Ellistown areas in Leicestershire.
Despite the impressive output figures, the UK as a whole is suffering from a housing shortage that is not helped by a lack of bricks. To address the shortfall, it is estimated that a further 400 million bricks will be required annually; a demand that is currently met by imports from continental Europe.
In response, Ibstock Brick is increasing its output by constructing one of the most modern brick factories in the world. In fact, the company estimates that the new £54 million facility will increase its production capacity by a further 100 million bricks per annum.
All modern factories call for connectivity, and this includes services such as lighting, for which the company was keen to ensure the latest technologies were utilised.
“We were introduced to the project by Siemens as we are a solutions partner for their building technologies division,” explains Dave Watkins, director of Abtec BT, a specialist in bringing cost-saving intelligence to buildings. “After an initial chat with Ibstock, at which we had the opportunity to put forward our ideas, we were asked to tender formally for the project, which we duly won.”
The solution proposed by Abtec BT was based on a number of class-leading technologies, including LED sources, open platform functionality, sustainability and, of course, connectivity. This proposal contrasted notably to the original brief, which was based on fluorescent lighting.
“We had to justify the technology and why Ibstock should go for it,” states Mr Watkins. “However, the advantages of the proposal were pretty apparent and the company soon placed the order.”
Abtec BT’s alternative to traditional lighting and controls facilitated the potential to build an energy-efficient building management system. Significant payback on the proposed solution was demonstrated, along with CO2 savings to match.
In terms of the actual choice of lighting, the nature of the environment within the factory made this task especially challenging. Specialist conditions meant that the system not only had to be energy efficient, but had to be installed to a very specific standard, a factor that called for careful thought in the design of the concept, as well as consideration for future maintenance requirements.
“We proposed DALi light fittings, which were rated to a high IP (ingress protection) with no metal exposed,” explains Mr Watkins. “This is important as a combination of brick dust and moisture in the atmosphere can cause incorrectly specified light fittings to corrode. In addition to their suitability for the operating environment, the use of DALi lighting would also provide the control and feedback needed at the management graphics end of the system.”
In total, Abtec BT calculated the need for 300 light fittings above the 295 x 86m factory floor in order to maintain the necessary lux levels. Contamination from the brickmaking process will of course affect lux levels over time, but the nature of the connected lighting solution proposed by Abtec BT means it is possible to account for this eventuality.
“At installation, new lights can be dimmed to counter the fact that they will probably emit lux levels that are too high,” says Mr Watkins. “However, as time passes and the lights get contaminated from factory production processes, so we can dim up accordingly. Having a high understanding of issues such as these helped us to secure the Ibstock contract.”
The installation undertaken by Abtec of the electrical elements such as the busbar also had to be carefully selected and installed. Due to the challenging height of the building (over 17m), the sensors used and the location required close scrutiny.
Abtec BT’s system has all the elements necessary to provide effective energy management, including presence detection from sensors mounted throughout the factory, automated function and duration testing of emergency lighting, constant daylight control and some scene setting.
“Constant light control means that we monitor natural light levels across the whole factory and adjust the DALi lighting accordingly,” says Mr Watkins. “For instance, if the sun comes out and natural light levels improve we can slowly dim the lights [not noticeable by the naked eye], thus generating savings.”
In total, energy savings of around 50% are anticipated in comparison with a traditional lighting install, along with an annual CO2 reduction of 170,041 kg. When coupled with the automated emergency testing, further savings are expected, leading to an estimated project payback of less than two years.
“The system installed is open in its approach to technology; KNX has been used for the field based sensors, BACnet for integration to heating and ventilation, and MODBUS to bring in the metering data,” explains Mr Watkins.
Importantly, the entire system links to Abtec’s integrated building energy management system, HYDRA, which allows users to easily navigate and visualise logged events. Built on the latest vector graphics platform (HTML5), HYDRA helps users zoom in to the information they need, whether on a PC, laptop, tablet or smartphone.
The HYDRA system, with its supervisor control and data acquisition functions, is a window into the heart of a building, as well as a proactive tool giving information to managers so they can make informed business decisions.
HYDRA supports OPC, ModBus and BACnet, and allows integration with third-party systems. Data aggregation pulls information from many different sources, while historical analysis gives side-by-side trend comparisons.
In the next phase of the project at Ibstock, the Abtec-designed system will link to further services such as heating, cooling and process water, making it an exemplar of intelligent building management.
“When finished, our sister company Abtec Network Systems will continue acting as a bureau moving forward, in effect offering lighting as a service,” concludes Mr Watkins.
The connected lighting project at Ibstock was bestowed with a Highly Commended accolade by the Electrical Contractors Association (ECA) at its recent annual awards.
Abtec Building Technologies has scooped an honour at this year’s ECA Industry Awards, held on Friday 8 June at the London Hilton Bankside Hotel.
The ECA Industry Awards recognise key achievements of the finest talent in the sector, providing a great opportunity for contractors and wider industry associates to showcase exceptional work.
Abtec’s team won a highly commended award in the Best Energy Solutions Project, for a recent project with Ibstock Brick. The project, which delivers energy efficient and intelligent lighting for Ibstock Brick’s new factory, will save 170,000kg of CO2 per year.
The ECA Industry Awards judges were impressed with Abtec’s demonstration of significant CO2 savings, anticipated energy savings of 50% and a project payback time of less than two years.
Commenting on the commendation by the ECA, Site Engineering Manager John Grew said:
“What we have achieved with the team from Abtec BT is the coming-together of the key elements of energy management. This includes lighting that is controlled by presence detection, automated emergency lighting testing, constant daylight control, as well as scene-setting. All of this is integrated within a wider, site-wide building management solution. The result is a 50% saving when it is compared with the cost of a traditional lighting solution – thus saving 170,041 kg CO2 per year, when coupled with the automated emergency testing further savings that are expected. These numbers are very significant indeed make a major contribution to our overall energy efficiency goals.”
Ibstock Brick’s engineering team is now working with Abtec to fully integrate the building services on the new site and the wider estate to provide even greater energy management.
Safecontractor is a leading third party accreditation scheme which recognises very high standards in health and safety management amongst UK contractors.
Abtec is principally involved in the building services sector, specialising in reducing the energy used by large buildings with the implementation of ‘smart’ building technology. Last year saw a record turnover for the company with a number of high profile projects, including; Northumbria Specialist Emergency Care Hospital, F1’s Red Bull Racing factory, and Damien Hirst’s new London gallery.
Dave Watkins, commercial director at Abtec Building Technologies, comments; “We are continuing to see lots of growth and this accreditation will enable us to deliver that growth safely.”
John Kinge, technical director of Safecontractor said, “More companies need to understand the importance of adopting good risk management in the way that Abtec has done. The firm’s high standard has set an example which hopefully will be followed by other companies within the sector.”
Under the Safecontractor scheme, businesses undergo a vetting process which examines health and safety procedures and their track record for safe practice. Those companies meeting the high standard are included on a database, which is accessible to registered users only via a website.
Abtec designed, configured and deployed the hospital’s extensive KNX and DALI networks. As well as controlling standard devices, such as heating and cooling, there are novel uses for the protocol too. Theatre anaesthetic gas volumes are monitored, with alarms triggered if they breech set points. Critical blood bank refrigerators’ temperatures are monitored to ensure the safe storage of bloods. Water temperatures are kept to a rigid monitoring regime too, to mitigate the threat of legionella.
The hospital’s entire lighting uses DALI over KNX to deliver sophisticated, interactive lighting control. The lighting design complies with CIBSE Lighting Design Guide L2 specification, and emergency lighting testing and reporting is now a scheduled automated process.
Abtec’s KNX engineers created several areas of integration with other building control protocols. The building’s third party access control system now integrates with lighting and climate control. Access cards no longer just open doors they also trigger lighting and heating in certain rooms.
Dave Watkins, Commercial Director Abtec Building Technologies, notes “This is another great example of KNX going beyond room and building control. The open standard is now being used to monitor critical resources in the building”.
Northumbria Healthcare NHS Foundation Trust’s Northumbria Specialist Emergency Care Hospital opened on 16th June 2015 and is the first purpose-built hospital in England to have emergency care consultants in a broad range of conditions on site 24/7. The new emergency care hospital will treat seriously ill and injured patients from across Northumberland and North Tyneside and is part of Northumbria Healthcare’s new model of emergency care which will help save more lives and improve clinical outcomes for more patients.
Over the last two years we’ve seen an increase in the number of attacks against automated buildings. Many of these attacks, including the ones that have made the headlines, have occurred because of the lack of security added to the BMS when installed.
Knowing what security measures to take and, more importantly, how to implement them is a challenge. This is where we can help. Our sister organisation, Abtec Network Systems, has specialist knowledge to help secure BMS and head ends. It has helped many BMS and energy specialists harden their network connections and add appropriate security to projects.
It’s worth talking to the client about security from the early stages of the project as this will help identify what kind of security is appropriate. Most of the BMS security measures we discuss in the article are low cost and fairly simple to implement. Some of your larger projects will warrant additional security measures, for example if the project includes building access control, and again we can help here too. We can work on your behalf, identifying the best security measures to take, with your client.
Call us on 01858 438 550 to discuss how we’ve helped other specialists like you secure their clients’ projects.
Don’t forget we’ve also created a free training session that looks at securing building automation projects. You can book onto this here:CPD Training
Also, our white paper looking at the best way to provide remote connections to BMS can be found here, it’s well worth a read.White paper
In our latest article for KNX Today, the leading online KNX journal, we explore some of the steps to take to protect KNX projects from cyber attack. You can read the article here.
Attacking industrial control protocols and building management systems (BMS) is nothing new. Over the last 18 months however, the number of reported attacks on such systems appears to be growing. The common thread between some of the more notable cases is Internet Protocol (IP) networks. The trend in deploying building control projects over IP networks has the potential to make those systems less secure – if you don’t exercise appropriate IP security.
The article highlights some of the simple steps to take to secure KNX projects delivered over IP networks. It’s part of a series of articles that addresses the changing deployment methods of BMS systems. Historically these systems have been deployed on their own self-contained network. It’s now popular to deliver KNX and BMS projects over IP networks. The articles focus on protecting these projects from cyber attack.
For more information about how to deploy KNX and BMS projects over IP sign up for our free trainingCPD Training
or download our white paper “Providing Remote Access Connections for Building Services Projects”White Paper
The challenge is that many of us are using standard internet access to make those remote connections. This, together with the fact that many popular BMS and building control systems don’t have the strongest built in security, can create vulnerabilities for your clients.
This white paper explores what other options are available for consultants and engineers. It highlights the variety of connectivity technologies and suggests what would be best to use when. The paper recommends using private, secure networks rather than the internet to access client sites remotely, and gives clear recommendations to help identify the right network provider for your projects. The great this is that the cost of private, secure connections that avoid the internet is about the same as standard internet connectivity.
Download the white paper here.Download
And don’t forget if you need help with IP networks we’ve developed a free, accredited training session that can be delivered at your premises. Find out more here.CPD Training
It will be interesting to compare this event to the Light and Build 2014 exhibition we visited earlier this year. One of the biggest take away points here was the idea of connected devices. Most of the new products we saw were connected, at some point, to a network. The interesting point was just how little the manufactures of those connected devises had thought about network security. Many were flummoxed by simple questions around security.
This is exactly what our CPD offers, a guide to how to protect your projects from cyber security threats when delivering projects over IP networks.
You can book onto the CIBSE accredited course when you arrive at the exhibition.
The IP networks CPD training, which has been approved by the Charted Institute of Building Services Engineers (CIBSE), is free and can be run on your site. It can be run over a lunch-hour with plenty of time for questions and answers.
As more building building controls and building management systems are deployed over IP networks the training delivers the following:
Download our brochure about the course.
This iconic, East London building was opened to the public on 29th September. “It’s fantastic to see Abtec’s cost and energy reduction expertise in use in this landmark building” says Dave Watkins, MD of Abtec Building Technologies. Read all about it in this new case study.
The uniquely shaped, glass-clad structure is London’s newest landmark and encompasses an area of more than 6,300 square metres. Inside is the world’s largest exhibition on the future of cities covering 2,000 square metres. The high-tech exhibition is fully interactive with two immersive film theatres and more than 50 screens with a host of games and experiences that help visitors explore the cities of the future.
Abtec’s role in this historic building included:
“Our technology has helped Siemens take complete control of the building. It will be integral as the building aims to be one of the greenest in the world” adds Dave.