APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-061 · Engineering case
Built a repair option study to restore Line 1 pasteurizer steam shutoff, thermal control, and reliability.
The selected scope needed to address the root failure mode, not only the cheapest visible component, because an FCV-only rebuild or bypass loop could leave repeat overheating risk in place.
Preferred Option 1 is full valve replacement and system coordination with coordinated cost planning; Alternatives were FCV rebuild only and bypass loop; Scope includes three valves, two Class VI shutoff valves and one Class IV FCV, piping rework, UDC coordination, commissioning, and verification of steam shutdown logic.
Compared repair alternatives and selected a valve-replacement and system-integration approach to restore steam shutoff and thermal control.
Workstream Portfolio Rollup
28,095,000 USD
Production and Packaging Modernization
Recorded workstream portfolio reference. This is the workstream-level value and is not a project expenditure or a new total of reassigned projects.
| Measure | Value | Type & meaning | Attribution & operating context |
|---|---|---|---|
| Stated Contingency Rate | 4 percent | Estimate Draft estimate rate | Applies to: Line 1 Pasteurizer Repair Option Study 2025 repair AFE — The draft labels its $1,800 allowance as 4%; component arithmetic is not silently recomputed. |
Defined the selected repair scope to address overheating risk, recurring pump/seal failures, manual intervention, energy waste, unplanned downtime, equipment-damage exposure, and lost-production exposure.
Selected a pasteurizer repair approach intended to reduce overheating and failure risk, using a $40,000-$50,000 preferred scope and the stated $20K+ equipment-damage and $100Kannual lost-production exposures, with full valve replacement, controls coordination, and commissioning preferred over partial repair options.
preferred option; equipment-damage exposure; annual lost-production exposure.
Completed the option study and selected full repair; the scope specified replacement of steam control/shutoff valves, UDC control coordination, commissioning, and verification of steam shutdown logic. The sustainability rationale was to reduce energy waste, CO2 impact, and repeated pump/seal replacement waste through tighter steam control.
Food and Beverage Manufacturer
Owned the full project lifecycle, from capital planning through commissioning and post-startup support. Unreliable steam shutoff can overheat product even when the rest of a pasteurizer is operating normally.
TSK-000140 · Technical context
Line 1 Pasteurizer Repair
TSK-000835 · Action
Line 1 Pasteurizer Repair
TSK-000836 · Action
Line 1 Pasteurizer Repair
TSK-000837 · Action
Line 1 Pasteurizer Repair
Action
Applies capabilities
ACTIVITIES IN CONTEXT
TSK-000133 · Action
Line 1 Pasteurizer Repair Option Study
TSK-000134 · Method
Line 1 Pasteurizer Repair Option Study
TSK-000135 · Method
Line 1 Pasteurizer Repair Option Study
Full lifecycle project ownership
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Preferred Option 1 is full valve replacement and system coordination with coordinated cost planning.
Alternatives were FCV rebuild only and bypass loop.
Option 1: full valve replacement and system reintegration using two Class VI shutoff valves, one Class IV flow-control valve, piping, UDC integration, commissioning, and steam-shutdown logic.
Option 1 expected to prevent pump/seal failures and downtime, avoid an estimated $20,000 or more in damage and $100,000 or more in lost production annually, eliminate manual overnight steam shutoff, and improve stability; risk characterized as moderate.
Option 2: rebuild failed FCV only, swap spare, and retune UDC; characterized as quick but high risk if the FCV was not the root cause.
Option 3: bypass loop with secondary isolation valve and logic; characterized as moderate-high risk because the exchanger might still overheat and system complexity would increase.
Hot Water Loop Mechanical, mechanical contractor.
Steam Line Mechanical, mechanical contractor.
Rush valve shipping, controls integrator.
Startup/commissioning, controls integrator.
PM and engineering, controls integrator.
Contingency 4 percent.
Existing TCV rebuild/spare, controls integrator.
Condensate shutoff valve.
Steam shutoff valve.
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Investigated valve alternatives, defined the repair boundary with operations and maintenance, and led the steam-control repair. Commissioning checks included steam shutdown behavior, connecting valve selection and control response to dependable pasteurizer operation.
