Six months in Erbe: a direct site between tight space and UK safety rules

Not every industrial project starts from an empty building.

At MEG UK, in England, InTech delivered a turnkey piping project within an existing, fully operational industrial plant. An assignment that required technical expertise, careful coordination and the ability to adapt installation activities to a complex production environment.

The project was completed in two main phases, involving approximately six months of on-site activities.

The first phase, Blending, took place between November and December, followed by electrical testing and initial energisation in early January.

The second phase, City Water, ran from April to June and focused on external piping installations connecting the storage tanks to the water treatment area, including insulation and associated finishing works.

The Project: Integrating New Piping into an Existing Plant

The relationship with MEG UK developed from previous activities carried out at the same facility in collaboration with Sidel on the bottling lines.

During those activities, one of InTech's site managers, specialising in piping installations, had been extensively involved in weld inspections across the plant. This established technical familiarity with the facility and contributed to the development of a direct relationship with the client.

When MEG UK required additional piping works associated with a new water treatment system supplied by Sidel Water System, InTech was entrusted with the execution of the project.

The scope included the fabrication and installation of piping connecting the client's storage tanks to the water treatment system, modifications to existing pipework and the installation of new valve assemblies with pneumatic and electrical actuation systems.

The electrical team was responsible for the associated cabling, connections and energisation activities.

A complete installation package, independently managed by InTech.

While the engineering design was provided by the client, InTech took responsibility for site organisation, resource coordination, installation and execution, managing the technical and operational challenges throughout the project.

InTech's Role: Mechanical, Piping and Electrical Expertise

The project brought together different technical disciplines under a coordinated site organisation.

During both phases, the core mechanical team consisted of four to five specialised pipefitters and welders, supported by a dedicated site supervisor.

The supervisor coordinated daily activities, managed technical priorities and maintained direct communication with the client's representatives.

An additional team of three electrical specialists handled the electrical installations and related testing activities.

The project also required particular attention to site safety, including dedicated supervision for certain activities at height and compliance with stringent site-specific procedures.

Continuous communication between InTech, the client and the teams on site was essential to keeping the project aligned with technical requirements and operational priorities.

The Challenge: Working Within a Live Industrial Environment

Unlike a greenfield installation, where equipment can be positioned and assembled in an open space, this project required working around existing machinery, pipework and infrastructure while the plant remained operational.

Restricted access, limited working areas and the need to protect ongoing operations added significant complexity to everyday installation activities.

Tasks that would normally be straightforward required additional planning, specialised equipment and careful coordination.

Even activities such as orbital pipe cutting demanded strict control of workpiece positioning, equipment stability and personal protective measures.

The site's rigorous safety procedures introduced additional operational constraints, requiring more time for certain activities than would typically be necessary in an unrestricted installation environment.

Technical documentation and site procedures also required careful review to ensure full alignment with the client's standards.

Throughout the project, InTech maintained a proactive approach to resource planning, reinforcing the team when necessary and addressing potential issues before they could affect project execution.

The greatest challenge was not simply fabricating and assembling the piping components, but successfully integrating them into an existing industrial environment where space, accessibility and operational continuity had to be considered at every stage.

From Engineering Drawings to Site Reality

One of the most important aspects of working on existing industrial plants is the ability to translate engineering designs into practical installation solutions.

Drawings provide the technical framework, but actual site conditions may reveal dimensional constraints, interferences or access limitations that are difficult to anticipate during the design phase.

InTech's approach begins well before installation, with a preliminary review of technical documentation, identification of potential constraints and coordination meetings with the project stakeholders.

Once on site, the team verifies the actual conditions and, where necessary, works with the client to identify and agree on practical adjustments.

This combination of preparation and field experience allows technical challenges to be addressed efficiently while maintaining the integrity of the original project requirements.

At MEG UK, activities were organised according to individual specialisations, with dedicated resources working on valve assemblies, piping fabrication and welding.

Where possible, components were prepared in advance to minimise the amount of work required in the most restricted areas of the plant.

The objective was not simply to follow the drawings, but to transform the design into a reliable, functional installation adapted to real operating conditions.

People, Coordination and Safety

The successful execution of the project depended on the coordination and commitment of everyone involved.

Working inside an operational facility requires more than technical competence. It demands discipline, flexibility and a consistent focus on safety.

The presence of the client's safety representatives, the strict control of work activities and the need to coordinate multiple disciplines required continuous attention throughout the installation.

InTech's teams responded by adapting their working methods, maintaining close communication and addressing technical challenges directly on site.

The experience also reinforced the importance of selecting the right equipment and allocating resources specifically for brownfield installations, where access limitations and unexpected constraints can significantly influence the execution strategy.

A Milestone in InTech's Piping Capabilities

The MEG UK project represents an important milestone in the continued development of InTech's piping activities.

Building on its established experience in industrial installation, mechanical assembly and electrical works, InTech is progressively expanding its capabilities in piping projects and integrated plant modifications.

This assignment also demonstrated the company's ability to manage a complete installation package directly for an industrial client, taking responsibility for operational planning, multidisciplinary coordination and on-site execution.

More importantly, it reinforced an approach that defines InTech's work across different industrial sectors:

Understand the client's requirements, assess the real operating conditions and develop practical solutions to overcome technical challenges.

From the initial assessment to the completion of installation activities, the MEG UK project demonstrated how technical expertise, field experience and effective coordination can come together to deliver complex industrial works.

Because successful installation is not just about executing a design. It is about making that design work in the real world.