When a nationwide paper and cardboard manufacturer asked us to undertake a Boilerhouse audit, to assess the potential for energy savings, we quickly identified a significant opportunity for heat recovery from the returning condensate.
To prevent this waste in energy, which was due to condensate being flashed off and vented to atmosphere, we completely redesigned the condensate return system.
Once designed, we manufactured and installed the new heat recovery system, including a bespoke deaerator head, to return the total energy in the condensate to the feed tank. As a result, the feed tank temperature has now increased from 70°C to 90°C, which in turn could lead to over £14,000 worth of energy savings per year and provide a return on investment in only 14 months.
NEED MORE INFO? Find out how much energy you could be saving by contacting us today and asking about our energy audits.
Having met us at the Maintec Exhibition, a leading pharmaceutical company asked if we could look at solving the problems they were experiencing with their large steam let down station.
With oversized, non-responsive pressure control valves leading to poor building controls for a critical environment, they needed steam knowledge, control valve expertise, process controls and M&E installation as a turnkey offering.
As the many valve and control system companies they had previously contacted being unable to offer them a complete resolution to their problems, they were delighted when we offered a comprehensive solution.
Working closely with the project engineers, we produced all risk assessment and method statements, asbestos and other necessary surveys, full design scope and specified a DN250 duplex pressure control train with a detailed HMI PLC based process control package. In order to work around a critical weekend shutdown timescale we undertook weekend installation and pre-fabricated the pipework and valve assemblies.
As an independent specialist provider, we were able to ensure that the new plant design specification offered the very best balance of quality of equipment and equipment costs. This included pressure control valves, bellow sealed isolation valves and strainers, duel plate non-return valves, pneumatic control valves with feedback position and a stainless-steel condensate pump-set, with mod bus control panel.
The newly installed turnkey package, now fully commissioned, accurately controls the system within the tight tolerances required. Much tighter temperature and humidity controls have now been achieved for the critical environment and the system is far more efficient and responsive for our client.
Together with a cost effective specification, our internal project managers, now valued as an integral member of the project team, worked closely with the contractors to ensure timely project delivery under extremely tight lead times.
If you are experiencing problems with your steam process, please get in touch. You can rely on our knowledge and expertise to deliver solutions where others may fall short.
As self-confessed valve geeks we love nothing better than a good chat about all things valve and steam related, so we really were in our element at the recent Maintec show.
As the UK’s leading show for maintenance engineers, there were plenty of people looking for our help and expertise and it was great to share our technical knowledge with both new and existing customers.
With a focus on helping businesses to access the latest technology, benefit from cost-cutting solutions, increase productivity and enjoy a higher return on investment, the show perfectly mirrors what we do for our clients every day and we look forward to returning next year.
Thanks to everyone who visited our stand, we hope you found it useful and we look forward to working together in the future.