CASE-069 · Workstream overview

Steam and Boiler System Modernization

An overview of the related projects, technical interfaces and outcomes within this workstream.

Why the Work Mattered

Purpose and Operating Need

Project scope and individual work packages are presented separately; project totals are not additive to their component values.

Engineering Approach

Led engineering and implementation coordination for the 350 HP boiler, economizer and feedwater skid, condensate-return rebuild, PRV-manifold redesign and pasteurizer-controls upgrade. Completed engineering study and design development for steam delivery manifold rebuild from the 4 in PRV inlet to tank steam jackets, including P&ID updates, line sizing, equipment specifications, and installation scopes. Coordinated lessons from prior condensate upgrade testing, including replacement of a 3 in condensate return and mechanical pumps with 1/2 in to 1 in return lines and 1 to 2 HP pumps. Evaluated steam supply sizing and operating pressure strategy to meet jacket demand and reduce the need for additional PRV stations.

Outcome & Engineering Context

Outcome and Context

The workstream includes boiler and steam-control repairs, electrical and controls coordination, and an AFE-ready warehouse ventilation design.

Workstream Results & Impact

Increased available steam capacity by about 25 percent and stabilized jacket pressure to support production uptime.

Avoided approximately $15,000 per month in rental-boiler expense during peak periods by restoring in-house generation. The peak-period benefit is reported monthly.

Reduced fuel consumption through heat recovery and improved process safety by restoring automated temperature control and dependable low-pressure steam regulation.

Defined boiler-room exhaust, electrical disconnect and maintenance-access provisions to remove heat from the building and reduce the heat load in the shipping warehouse.

Reduced batch-loss and rework exposure through reliable steam control, tight isolation and temperature feedback.

Measures & Operating Detail

Engineering scope and design basis

Workstream covering steam and boiler system modernization across its named projects, with project-level engineering scope, capital values and operating context.

Increased available steam capacity by about 25 percent and stabilized jacket pressure to improve line uptime; The boiler business case projected approximately $15K/month in rental avoidance during peak periods through restored in-house generation; Included heat recovery with reported performance references and separate modeled energy benefits; Defined an AFE-ready ventilation scope to expel boiler-room heat to the exterior and reduce heat load within the shipping warehouse; Included forced exhaust capacity and electrical disconnect provisions to support safe operation and maintenance; Improved process safety and controllability by restoring automated temperature control and eliminating manual steam throttling on degraded piping.

Workstream Cost: 16297 K.

Bottling & Packaging Systems, Steam & Boiler Systems; Industrial Ventilation, Ductwork and Exhaust Fans, Electrical Power Feeds and Disconnects; Steam distribution and control, batch temperature control, instrumentation, insulation systems, commissioning and startup

Capital Project Lifecycle Management, Multidisciplinary Coordination; Scope Development, Contractor Coordination, AFE Development; Scope development, contractor and vendor coordination, controls coordination, safety and risk reduction, commissioning planning

Capabilities Demonstrated

Coordinate Construction Discipline Interfaces

Actions, Methods & Controls

ACTIVITIES IN CONTEXT