Upgraded Booster Sets For A Leading Poultry Producer
The Challenge
One of our customers who processes chickens and their by-products had an issue with their booster set supply into the factory. There were two issues with their existing pump booster sets.
The first issue was the fact that the booster set was below ground and therefore difficult to maintain and repair. Secondly, if the level control went into fault the water tank next to the booster set would overflow and flood the underground room that the booster set was in. This not only cost a lot to repair the booster set, but cost thousands in downtime for the factory.
The challenge Dura Pump was presented with was to come up with a way of relocating the booster set to above the ground with minimal downtime to the factory. Also, the customer wanted to use the existing pumps as they had not long been repaired.
The Solution
Our solution was to fabricate manifolds and pipework in an above ground kiosk directly above the existing tank. We connected pipework into the tank and connected it to the existing ring main. We also installed all the non-return and isolation valves onto the manifold, mounted the controls and ran the cabling to the correct position.
Once complete, we swapped one pump at a time onto the new booster set in their correct positions. We made all mechanical and electrical connections and tested each pump before the next was swapped over. This process was repeated for the third pump.
Once all three pumps were in position, we carried out the final commissioning which then allowed us to decommission the rest of the old booster set, ensuring the pipework and the electrical installation was isolated correctly. Also, on the control panel we added controls for all the sumps in the underground tank room. Finally, we upgraded the level control in the tank to radar to stop flooding in the future.
The Outcome
As a result, our client now has a reliable water supply for processing their chickens with minimal interruption during the installation. The other benefits from this were it enabled easier maintenance, eliminated the need for confined space working, therefore reducing health and safety risks.
With the new level control, the risk of flooding was massively reduced, saving thousands of litres of water and reducing headaches for the maintenance team.
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