The Client

The client on this LEV installation project was one the of the UK’s leading independent engineering and services businesses who had been specified to construct a maintenance depot on London’s Crossrail (also known as the Elizabeth Line) project in Plumstead on behalf of another construction company, on behalf of TfL (Transport for London).

The facility was built to maintain the infrastructure maintenance rail vehicles, to ensure that the upkeep of the tracks and other infrastructure in the tunnels below London. Facilities in the main facility included:

  • Three non-electrified sidings for the stabling, formation, loading and unloading of dedicated infrastructure maintenance rail vehicles.
  • Refuelling facilities for the infrastructure maintenance rail vehicles.
  • A building for maintaining the infrastructure maintenance rail vehicles.
  • Lay down space for the storage of infrastructure maintenance components when they are not installed on a rail vehicle.
  • A facility for the manual jet washing of the infrastructure maintenance rail vehicles.
  • Storage facilities for infrastructure maintenance equipment and consumables.
  • Parking for approximately 20 maintenance vans and trucks and approximately 100 staff vehicles.
  • A two-storey accommodation and mess facility to support up to 100 infrastructure maintenance personnel and train crew staff.


The Challenge

Auto Extract Systems were tasked with proposing and installing a comprehensive LEV (local exhaust ventilation) system in one of Crossrail’s locomotive workshops to safely capture and remove the diesel fumes that were being emitted into the workplace. The LEV system was installed as part of a project to ensure the site meets stringent operational requirements and to work strictly in accordance with HSE’s ‘HSG258: Controlling Airborne Contaminants at Work – A Guide to Local Exhaust Ventilation (LEV)’ guidance.

Consideration also had to be taken into account to ensure that the supply and distribution of the necessary parts met strict approval at a specific time. To ensure we met the stringent requirements of getting our supplier’s goods necessary for the installation to the site, we arranged for all the specialist equipment required for the installations to be delivered to our premises so we could arrange our own approved dedicated FORS accredited distributor to get the equipment onsite and on time.

Another challenge we faced was working on behalf of a subcontractor for the main client. This is a common occurrence for Auto Extract Systems but proved to be challenging when we communicating the LEV system’s design and functionality for approval and we communicated our LEV system’s design and functionality with detailed CAD drawings.


The Solution

The solution was proposed and agreed to supply and install 2 new specialist comprehensive LEV systems to capture and safely remove locomotive diesel fumes at-source.

The two systems were identical and comprised of the supply and installation of 3 extraction points. Each point was designed to be held above the train line on a swinging cantilever boom arm, which had a maximum working radius of 8.5 meters (in straight length) and featured a triple hinge for maximum radius articulation of up to 17 meters.

Each point featured a bespoke capture nozzle to suit the train’s double exhaust system and was connected to a 4-meter-long, 160mm diameter, 400oC exhaust extraction hose (for expected higher temperatures) hanging section. The high-temperature hose was connected to galvanized steel ducting and ran the length of the cantilever section and back to correctly specified centrifugal extraction fans. Each fan was housed within acoustic boxes to reduce the excess noise.

The two fans specified for the two LEV systems exceed the E.U Directive 2009/125/EC ErP, which is aimed at reducing CO² emissions by 20% by using energy-efficient motors in conjunction with industry-leading blade design.

The LEV system’s fan outlet was ducted to atmosphere via the nearest wall, where it was upwards to be vented to atmosphere through high-velocity cowls, as per HSE guidance. LEV systems were designed to fully compliant with the latest HSE guidance and 100% utilisation, so all points have the capacity to be open at once).


Have You got a Similar Problem? We Can Help…

We’re accustomed to helping workshops solve their diesel fume problems. We can provide a multitude of different local exhaust ventilation (LEV) solutions – Get in touch today to arrange a FREE site assessment and provide a no-obligation quotation.

To book a free FREE site assessment, please click here or call 01942 267444.