Boiler House & Utility Piping — Manufacturing Plant

Project overview

A Ruiru manufacturer's utility costs and boiler-house incidents traced back to its distribution network: uninsulated steam runs, failed traps, water hammer and compressed-air leaks that kept two compressors running for one compressor's load.

Ventron redesigned the utility distribution as an integrated package — steam and condensate first, then water and air — with metering that let the plant finally allocate energy costs per line.

Client challenge

Fuel bills rising while production stayed flat, plus recurring water hammer events that threatened the boiler house. The plant needed lower losses and safer operation without a production shutdown longer than a weekend.

Ventron solution

Thermal imaging and flow logging quantified every loss before design began, so each recommendation carried a payback. Steam headers were resized and re-trapped, condensate recovery restored, air leaks surveyed and repaired under a managed programme, and supports and expansion provisions corrected throughout. Fuel consumption per tonne of output fell measurably within the first quarter.

Scope of work

• Utility loss survey with thermal imaging and logging
• Steam, condensate, water and air network redesign
• Trap, insulation and support specification
• Weekend-window installation supervision

Engineering deliverables

• Loss survey and payback-ranked recommendations
• Utility P&IDs and isometrics
• Equipment and trap schedules
• Metering plan and commissioning records