In 2023 we were commissioned by Integral Projects to provide a new hotwell tank for the Rolls Royce Estate in Barnoldswick, Lancashire.
Their existing system included a mild steel tank that had reached the end of its life cycle, with leaks beginning to appear. We formulated a multi-phase approach that would allow the new tank to be installed without necessitating any unscheduled downtime in plant operations whilst ensuring full compatibility with existing infrastructure.
Hotwell Tank Systems
A hotwell tank system is a crucial component in steam boiler plants, used to store a large body of boiler feed water and collect condensed steam from various processes. Its primary function is to remove impurities from the water, ensuring that only clean water circulates back into the boiler for reuse.
These systems provide improved energy efficiency, reduced water treatment costs, enhanced equipment longevity, effective removal of impurities, optimal water chemistry maintenance, continuous water level control, and operational flexibility. Overall they contribute to a more sustainable, cost-effective, and reliable operation of the steam boiler plant.
Phase One - System Design
The project began with the design process. A new building was designed and installed by Integral adjacent to the existing boilerhouse so that the new Hotwell Tank could be integrated with the plant in full operation.
This design phase featured some crucial considerations and calculations to ensure that the tank was fit for purpose and fitted the space exactly as required and that the pipework and connectivity were in the correct positions. Any failure within the configuration could have a catastrophic effect on the boiler’s ability to function so precise calculations were paramount.
The final design included a 20m3 stainless tank, along with a purpose-built platform and ladder to provide superb access for routine operation and maintenance tasks.
Phase Two - Tank Manufacture
With the final designs approved, we commenced manufacturing of the tank at our boiler works. Some components were laser cut from our CAD designs, and the tank was fabricated by our skilled engineers.
Insulating Rockwool slabs and neat cladding completed the tank build, along with the access platform and ladder. The whole assembly was then hauled to the site where it was lifted into position in the new building.
Phase Three - Installation & Integration
Having lifted the tank into place, we were then able to precisely design the pipework, manufacturing it off-site to speed up the process. The complete installation was then finalised in time for the plant’s Christmas shutdown.
During this period we were able to integrate the system with the existing infrastructure and install double block and bleed arrangements - a redundant safety measure ensuring proper isolation of sections for maintenance, repairs, or pressure testing while providing a means to vent or drain trapped fluids for safety purposes. We then fully tested the completed system and the boiler plant was fully operational again by the time the site was back to work in the new year.
