Case Study: Replacement of Commercial Boiler at Large Manor House in Canterbury
Client: Private Manor House.
Location: Canterbury, Kent.
Project Type: Boiler replacement and plant room upgrade.
Background
The manor house in Canterbury had been relying on an outdated cast iron sectional boiler that had reached the end of its service life. The original boiler system was inefficient and suddenly broke down all together. The client required an upgrade to a more efficient and modern heating solution, while maintaining the bespoke design of the plant room and ensuring minimal disruption to the operation of the house.
Project Requirements
The project involved the removal of the existing cast iron sectional boiler and the installation of three modern Grant Vortex 46-70 oil boilers. The system was designed to meet the client`s specific heating requirements, incorporating a range of advanced components for efficiency, reliability and longevity. The work had to be completed in a manner that would integrate seamlessly into the existing plant room, with all necessary modifications made to accommodate the new equipment.
Scope of Works
Dismantling & Removal of Old Boiler
The first step of the project was the safe and efficient dismantling of the old cast iron sectional boiler. This was a challenging task, requiring careful planning to avoid any damage to the plant room or surrounding equipment. Once dismantled, the old boiler was removed from site.
Design & Installation of New System
A bespoke reinforced concrete plinth was designed and constructed to support the new Grant Vortex 45-70 oil boilers. The design of the plant room was modified to accommodate the new system, with careful attention to space utilisation and ensuring compliance with safety and operational standards.
Installation of New Boilers
Three Grant Vortex 46-70 oil boilers were installed on the newly constructed plinth. These highly efficient condensing boilers were chosen for their reliability, energy efficiency and ease of operation. A Grant sequence controller was installed to ensure that the boilers communicated effectively and operated in a synchronised manner.
Supporting Infrastructure
A low loss header was installed to ensure efficient heat distribution across the system. A pressurisation unit, magnetic filters and an air/dirt separator were installed to improve the longevity and efficiency of the system by maintaining optimal water quality. A plate heat exchanger was incorporated to facilitate the transfer of heat between the primary and secondary circuits.
Pipework & Drilling
The boiler room walls are 1000mm thick in places which required drilling to accommodate the installation of fire valves, sensors and wiring as well as the condense and oil lines.
New swing check valves, outdoor sensors and a 10 meter flue system with a top fan for ventilation were installed to ensure safe and efficient operation of the new system.
Pipework Support & Insulation
The pipework throughout the plant room was supported using Unistrut bracketry, ensuring stability and ease of maintenance. To prevent heat loss and protect the system, the pipework was lagged, taped and carefully labelled.
Commissioning
Once all the components were installed, the system was thoroughly tested and commissioned.
This involved checking all connections, verifying the functionality of the sequence controller, and ensuring the correct operation of the low loss header, pressurisation unit and other components.
Challenges
Space constraints, the bespoke design of the plant room meant that careful planning was required to ensure that the new system could be integrated without compromising the layout or safety of the room.
Drilling through 1000mm thick walls, this was a complex task and required specialised equipment to ensure precision and safety.
Co-ordinating multiple systems, the integration of the Grant sequence controller, along with the other heating components required a high level of coordination to ensure all systems operated harmoniously.
Result
The client was extremely satisfied with the outcome noting the improved efficiency, reliability and overall performance of the new heating system. The bespoke design of the plant room was maintained and all new components were seamlessly integrated into the existing infrastructure.
The new system has significantly reduced the manor house`s heating costs and environmental impact, providing a sustainable for the long term. The installation also ensures that the estates heating requirements will be met reliably, even during peak demand periods.
Conclusion
This project demonstrates the successful replacement of an outdated heating system with modern, efficient equipment. The installation of the Grant Vortex oil boilers, along with the bespoke modifications to the plant room, ensures that the manor house in Canterbury now benefits from a reliable and energy-efficient heating system. The project was a collaborative effort that combined technical expertise, careful planning and attention to detail, resulting in a highly successful outcome for the client.
