300 HP Cleaver-Brooks Boiler, Advanced Controls and New Deaerator Installed Within Existing Footprint
When a Delaware industrial manufacturer needed to replace its 50-year-old steam boiler system, the project presented several challenges: aging infrastructure, limited installation space and a short window for downtime.
The facility, which manufactures gas filtration membranes, relies on steam to support its manufacturing operations. Maintaining a reliable steam supply was an important consideration throughout the replacement process.
Delval Equipment, working alongside its trusted contracting partners, delivered a comprehensive, two-phase turnkey solution that included a new Cleaver-Brooks CBLE boiler, deaerator, steam headers, advanced controls and temporary rental boiler equipment.
The result was a modernized steam plant installed within the footprint of the original system.
The Challenge: Replacing 50-Year-Old Equipment With Limited Downtime
Replacing an aging boiler plant is rarely as simple as removing old equipment and installing new machinery. For this Delaware manufacturer, the project required careful coordination to accommodate a short downtime window while working within the constraints of the existing boiler room.
The scope extended beyond the boiler itself. The existing deaerator, steam headers and associated piping also needed to be replaced, requiring a coordinated approach to equipment removal, installation and system integration.
To address these challenges, Delval Equipment and its contracting partners developed a two-phase installation plan that incorporated temporary rental boiler equipment to help maintain steam availability during the transition.
The Solution: A Complete Turnkey Boiler Plant Replacement
Delval coordinated the equipment and resources needed to replace the aging steam system, from temporary steam generation through final startup and commissioning.
The new installation includes:
- 300 HP Cleaver-Brooks CBLE Steam Boiler: A new firetube boiler equipped with a 30 ppm NOx emissions specification.
- Cleaver-Brooks HAWK 4000 Controls: Advanced boiler controls featuring a new touchscreen interface for operational monitoring, trending and communication.
- SM15 Deaerator: A new deaerator equipped with advanced ADAC controls to support feedwater system operation.
- New Steam Headers and Piping: Replacement components to integrate the new equipment with the facility’s existing steam distribution system.
- Temporary Rental Boiler Room: A temporary steam solution to help support facility operations during the replacement.
- Integrated Plant Controls: Communication between the boiler system and the facility’s building management system (BMS).
By managing the project in two phases, the team was able to coordinate the removal of existing equipment and installation of the new system around the facility’s limited downtime requirements.
Advanced Controls Provide Greater Operational Visibility
A significant component of the modernization was the integration of advanced boiler and deaerator controls.
The new Cleaver-Brooks CBLE firetube boiler features the HAWK 4000 control system with an advanced touchscreen interface, providing operators with access to boiler operating information, system trending and communication capabilities.
Gas flow and steam flow data will be communicated through the HAWK 4000 system to the facility’s building management system, providing greater visibility into steam generation and fuel consumption.
The new SM15 deaerator incorporates advanced ADAC controls, further modernizing the plant’s feedwater management capabilities.
Together, these technologies provide the facility with improved access to operating data and a foundation for monitoring system performance over time.
Turnkey Execution Within a Tight Downtime Window
One of the most demanding aspects of the project was completing the replacement within a short downtime window.
With a 50-year-old boiler system to remove, new equipment to install and multiple system components requiring integration, successful execution depended on detailed planning and close coordination among Delval Equipment and its contracting partners.
The project included temporary boiler support, equipment removal, new steam header installation, boiler and deaerator replacement, controls integration, startup and commissioning.
Despite the scope of the modernization, the new equipment was installed within the existing boiler plant footprint, eliminating the need to expand the boiler room.
The Result: Modern Steam Generation for a Specialized Manufacturing Facility
The completed project replaced a half-century-old steam system with modern boiler equipment, advanced controls and updated steam distribution components.
The facility now has a 300 HP Cleaver-Brooks CBLE boiler, a new SM15 deaerator and integrated monitoring capabilities designed to support its ongoing manufacturing requirements.
Beyond the equipment replacement, the project demonstrates the value of a coordinated turnkey approach when facilities face aging infrastructure, space constraints and limited downtime.
From temporary rental boilers to complete plant replacements, Delval Equipment brings together the equipment, technical expertise and trusted contracting partners needed to execute complex industrial steam system projects.
Planning a boiler plant replacement? Contact Delval Equipment to discuss your facility’s steam requirements, modernization opportunities and turnkey installation options.
