Blog

The air in the office is buzzing with more than just morning coffee today – it's electric with the excitement of new beginnings! We're thrilled to officially announce that the refurbishment of our newly consolidated United House office building has kicked off! This marks a significant milestone for us as we bring together our team under one roof. By sharing one building we can reduce overheads, invest in new facilities and maintain our valued location right here in Cheadle, Manchester. This amalgamation isn't just about combining physical spaces; it's about weaving together our collective talents, fostering closer team working, and building an even more vibrant and unified company culture.  So, let the transformation begin! We're incredibly excited about this new chapter and look forward to sharing the journey with all of you. Stay tuned for more updates as our new, united office takes shape!

Presenting at Energy Storage & Hydrogen Solutions Last month, our Head of Consultancy, Clare Dunkerley, was invited to speak at an event in Cyprus, hosted by Ideopsis and the British High Commission Nicosia. The Energy Storage & Solutions Conference brought together leading experts, policymakers, and industry players, with the aim of to fostering dialogue, sharing expertise, and catalysing action towards a more sustainable, resilient, and low-carbon future. The conference attracted some esteemed speakers, including introductory addresses from the Deputy High Commissioner, Adam Sandbrook and the Minister of Energy, Commerce and Industry, George Papanastasiou. The programme was split into 2 sessions with the first highlighting the future of energy storage, moderated by Dr Alexandros Charalambides from the Cyprus University of Technology. Staveros Stavrinos, the Executive Director of the Transmission System Operator Cyprus, explained the issues the Cyprus Energy Transmission System faced, concentrating on curtailment of renewable solar power. Michael Toumbas, of EV power Ltd, shared innovative thinking around an AI enabled electric vehicle local grid power sharing mechanism. There were also great presentations from smart grid expert Dr Andreas Procopiou and the Cyprus Energy Regulatory Authority. The second session concentrated on hydrogen solutions. Dr Andreas Poullikkas delivered on future energy systems while Charles Purkiss updated us on the latest developments at ITM Power. Jeremy Bowman, from Hypermotive Ltd, discussed hydrogen technology for transport and Philippa Oldham shared some work from the Advanced Propulsion Centre. An interesting Q&A session was chaired by Dr Nestor Fylaktos of the Cyprus Institute. Clare presented ‘A Safe Hydrogen Future’, addressing the importance of public perception and the imperative for no major incidents. Clare shared her experience from working on hydrogen projects and provided an insight in how to use the current UK regulatory framework in conjunction with industry codes and standards to demonstrate that risks in hydrogen projects were acceptable to all concerned.  It was a fascinating conference providing a fantastic insight to the current and future energy situation in Cyprus, with plenty of time for networking and discussing hydrogen solutions and projects with all the attendees. Our thanks go to Ideopsis and the British High Commission in Nicosia for the invitation and opportunity to participate in the discussions.

Taking Safety Seriously at Otto Simon We’re proud to celebrate the achievement of our Head of Construction and Commissioning, Hugh Doble, who has recently earned his NEBOSH Certificate in Health and Safety Management for Construction. Hugh has been instrumental in the successful delivery of multiple EPC and EPCm contracts across various sectors nationwide. Our continued commitment to excellence and safety underscores the core values we uphold at Otto Simon — ensuring the wellbeing of our people and partners on every project. Congratulations Hugh! To learn more about how Otto Simon can support your Construction and Commissioning needs, get in touch with us at eng@ottosimon.co.uk .

Standards Development: PAS 4445:2025 for Hydrogen-Fired Equipment The future of energy is undeniably leaning towards hydrogen, a clean and versatile fuel poised to revolutionise industrial and commercial operations, which is required to take place within 25 years to meet the country’s net zero targets. Today, we are proud to celebrate both our contribution to, and the publication of, Publicly Available Specification (PAS) 4445:2025, hydrogen-fired equipment. The publication is a significant step forward in ensuring the safe and effective integration of hydrogen-fired equipment into industrial and commercial applications. This standard will play a crucial role in fostering confidence and driving innovation. Otto Simon’s Support: In early 2024, BSI invited Otto Simon Ltd. to provide expert technical representation on the Steering Group for the development of the fifth publication in the PAS series concerning hydrogen appliance/equipment fuel gas. This initiative builds upon the four preceding publications, which focused on the transition to hydrogen as a replacement for natural gas within the UK's domestic and small business sectors. The fifth publication, PAS 4445:2025, expands the scope to address the implementation of hydrogen in larger, more complex industrial applications, necessitating significant deviations from established domestic installation practices.  Mike Wray, Principal Mechanical Engineer at Otto Simon, joined the Steering Group, contributing alongside technical representatives from diverse industrial equipment suppliers, end-users, and the Department for Energy Security and Net Zero (DESNZ). Throughout the second half of 2024, the group convened to provide technical guidance and input into the publication's development. Mike Wray's expertise, gained from his involvement in the Keele University HyDeploy project plus numerous industrial fuel switching trials as part of the HyNet North West UK Hydrogen network and CCUS projects, proved to be invaluable. Under the proficient leadership of Beverley Goodchild (BSI), who effectively managed group discussions and maintained focus on achieving a successful outcome, the Steering Group finalized PAS 4445:2025, "Hydrogen fired equipment for use in industrial and commercial (non-domestic) settings – Code of Practice." This publication, released in late March 2025, aims to establish a robust technical framework for fuel gas users and equipment suppliers transitioning to low or zero-carbon fuel utilisation in their operational processes and system designs. Why PAS 4445:2025 is Significant: The use of hydrogen, while promising, requires meticulous handling and infrastructure. PAS 4445:2025 provides a comprehensive framework to: · Prioritise Safety: Establishing stringent safety protocols for the design, installation, operation, and maintenance of hydrogen-fired equipment. · Optimise Efficiency: Promoting best practices to maximise the performance of hydrogen utilisation · Minimise Risks: Addressing potential hazards associated with hydrogen storage, handling, and combustion. · Standardise Practices: Providing clear and consistent guidelines for organisations across the hydrogen equipment value chain. · Enable Industry Growth: Fostering confidence and accelerating the adoption of hydrogen technologies. Who Will Benefit from PAS 4445:2025? This PAS is vital for a wide range of stakeholders, including: · Manufacturers of hydrogen-fired equipment. · Industrial and commercial users of hydrogen technologies. · Engineering and construction firms. · Safety and regulatory bodies. · Hydrogen infrastructure developers. · Insurance providers. By developing the guidelines in PAS 4445:2025, Otto Simon has further demonstrated its commitment to safety, its technical understanding and continuing contribution to the hydrogen economy.

At times it may feel as though there are far too many obstacles and barriers to overcome whilst attempting to get the most out of a tight capex budget. Increases in overheads, increased energy prices, changes in compliance requirements can all contribute to the headache that comes with providing effective engineering solutions in tough times. The margins achieved from selling your products could be the only thing which is decreasing. There’s no doubt that today more than ever it is imperative to get the best value for your money. Whilst it may be tempting to call in the big engineering contractors who can provide a one-stop-shop, convenience shopping is an expensive way of doing projects. Project success depends on getting things right. Everybody gets so easily engrossed in the day-to-day activities that they often do not invest enough time and effort into the fundamentals that will make or break a project’s success. Skimping at the concept stage and investing insufficient development into the scope, deliverables and stage gate estimates, are just some of the things that will usually result in ballooning costs and even bigger headaches . Otto Simon can help guide you to a successful conclusion. We can work with you to take the your concept through to a FEED, providing you with much needed cost certainty. No chemical manufacturer worth their salts wants to keep going back to their board asking for more money to complete what was a fully budgeted and financed project. Why Otto Simon? We have an unrivalled level of expertise and experience in eliminating unnecessary inefficiencies and superfluous costs by working with you using a skilled small team to develop your concept. This will save you money, and give you options about who or how or when the installation should be implemented. If you want to ease the pinch, please get in touch.

Otto Simon is proud to be able to report the successful trialling of hydrogen as a substitute fuel to natural gas at Novelis's Aluminium Recycling facility in Warrington. As part of the Industrial Fuel Switching programme, Otto Simon designed the hydrogen supply infrastructure and integrated this into the existing furnace working alongside Novelis's supply chain and the hydrogen supplier. Otto Simon managed the installation and commissioning of the facility and assisted the site team during the trials, another step along the road for industrial decarbonisation in the Northwest. This project builds upon Otto Simon's track record of hydrogen projects which includes trials in Glass Manufacture, Food and Ceramics as well as the pioneering HyDeploy project at Keele University.

 Otto Simon has a unique selling point in comparison with the multitude of engineering contractors plying their trade to the chemical manufacturers in the North West of England. The North West chemical industry is of great importance to Otto Simon and we are dedicated in the provision of service and support to our chemical clients. Our USP? Otto Simon’s engineers have extensive experience of working on site and being in the ‘thick of it’. We know what the issues are, we understand the challenges, whether these arise from getting products to market on time, increasing manufacturing capacity or improving energy efficiency and being compliant with safety and emissions legislation. We can help. The North West is strong in chemical manufacture and accounts for 25.3% of the UK Chemical Sector GVA employing some 27,325 people, exports amount to £7.9bn and the data available from the CIA goes into greater depth to underline how our region is a significant strategic UK asset.

Otto Simon attended the two-day H2 Conference in Liverpool on the 5th and 6th of February at the Titanic Hotel.  There was cautious optimism on the part of the attendees in respect of the UK H2 developments as the economy currently has sluggish growth forecasts and the HAR 1 Contracts between the H2 producers and the Government are slowly reaching conclusion. HyNet is moving forward but at a pedestrian pace. Interest in hydrogen is high and there are more potential off-takers of H2 than there is projected supply over the next five years, but this imbalance is being addressed. Questions were raised about the current funding model, which if maintained, could add up to £200- £300 per year to the average domestic consumer’s household bill. It was suggested that just burning H2 as a natural gas replacement was a futile exercise, whereas using it to create energy from powering turbines and developing H2 storage would be a more economically effective use of H2. Apparently, Air Products is the world’s biggest global H2 producer with some 9,000 tonnes per day and they intend to grow this business. The EU has a plan to produce 1,000 tonnes per day and is on track to achieve this. The UK has some catching up to do. There were altruistic comments calling for greater collaboration in the sharing of innovative ideas and how to tackle emergent issues together which have arisen from the numerous H2 projects involving the H2 community. However, whilst this notion was tepidly received, the companies concerned, often in competition with each other to get awarded H2 projects, will remain naturally protective of their technologies, their IP and their commercial aspirations therefore co-operation will be somewhat limited and transactional. Cadent and others highlighted the planning issues associated with developing the intended H2 cross- county pipelines and urged the local authorities to work together. Modular Nuclear Generation was discussed. At the present there are only five sites in the UK where these can be legally located. The manufacturers stressed the safety case for considering locating reactors in areas where there are greater densities of population to supply energy closer to intended H2 facilities. A promising idea in principle?