Details
Project Details
Location
Weybridge, Surrey
Client
ISS / DEFRA / APHA
Completion
February 2026
Project Value
£250,000+
Sector
Government / Public Sector / Special Projects
Duration
12 Weeks
Environment
Secure operational science estate
Overview
Project Overview
KPS was appointed to deliver a lifecycle upgrade at the DEFRA / APHA Science Estate in Weybridge, Surrey, working in partnership with supply partner ISS.
The project involved the replacement of four steam calorifiers across two plant rooms, supporting both process and water heating for laboratory spaces within a secure and operational science estate.
Challenges
The Challenge
Several of the assets on the estate had reached the end of their operational lifespan and required full replacement to maintain resilience for the scientific work being carried out on site.
Because the laboratory operations could not be easily stopped, the project required a robust delivery plan, staggered replacement works and temporary services to ensure continuity throughout the programme.
Refurbishment
Scope of Works
The scheme involved the replacement of four steam calorifiers across two plant rooms, alongside associated valves, pipework, electrical and BMS coordination.
Key Works Included
Replacement of four steam calorifiers
Works across two plant rooms
Installation of new stainless steel 1100 litre calorifier vessels
Installation of new Spirax steam valves
Stainless steel pipework installation
Temporary services to maintain continuity
Coordination with BMS and electrical works
Weekend changeover and isolation works
Testing, certification and client witnessing
Installation
Working Within a Secure Science Estate
The APHA Weybridge estate is a secure operational environment, which required additional control and coordination throughout the project.
Works were managed by an on-site CTC cleared KPS Site Manager, who was responsible for health and safety, permits, operative escorting and the planning of weekend changeover and isolation works. This ensured that services were available at the beginning of each week and that disruption to scientific operations was minimised.
Coordination
Adding Value During Delivery
During the project, KPS identified additional works linked to previous installations and equipment that sat outside the original scope, but would have been impacted by the planned upgrade.
By incorporating these items into the wider package, KPS helped provide better value for the client, reducing downtime, preliminaries and additional labour costs. This allowed more lifecycle works to be completed within the same overall timescale.
Result
The Result
The project was completed with a full regime of testing and certification, carried out alongside the client witnessing team. All documentation was provided in line with current regulations and guidance.
Through careful planning, staggered replacement and strong site management, KPS delivered the calorifier upgrade while maintaining operational resilience across the laboratory environment.
CALL TO ACTION
Planning Works Within a Secure or Operational Environment?
If you are planning plant room upgrades, lifecycle replacement works or specialist projects within a secure or live environment, KPS can provide the planning, coordination and control required.