The Brief
Buildings 5 and 6 at Leavesden Park in Hertfordshire were experiencing recurring problems due to outdated boilers that frequently malfunctioned. To resolve this, we recommended installing new, modern boilers capable of meeting the heating demands of both buildings. After multiple maintenance issues, Heathlands conducted a comprehensive site survey and designed a suitable heating system to replace the old MHS Regency 4 Modulek atmospheric boilers, ensuring the new system could be retrofitted into the existing plant infrastructure.
The Solution
The assessment began by determining the best method and equipment for replacing the existing MHS Regency 4 Modulek atmospheric boilers. Given the significant power consumption of these two boilers, we opted for a new system comprising three Viessmann Vitodens 200-W 150KW boilers to meet the building’s needs.
As we were incorporating three boilers instead of two, we redesigned the system to reconfigure the existing pipework. This required identifying sections of pipework to be removed and preparing isolation valves for the new connections.
Once isolation procedures were in place, we dismantled the boilers and cut the internal sections for removal. The old boiler components and stripped-back pipework were cut into manageable sizes to facilitate removal. All control cabling from the BMS system was isolated and labeled, and the electrical supplies were locked off for reconfiguration.
The addition of a third boiler meant that the existing base lacked the necessary space for the new equipment. We calculated the required area and extended the base to accommodate all new components.
Since the site remained operational with staff present, we ensured that water services stayed active, with only heating being shut down. We arranged material deliveries in advance of the boiler shutdown and sectioned off an area for deliveries and a skip, ensuring the site remained tidy.
Installation of the new boilers began, with the units mounted on frame kits with a pre-set manifold. Once secured, we hung the boilers and started the pipework installation.
A plate heat exchanger was integrated into the system to protect the new boilers from the existing system, allowing the heat demand to be met without mixing water. Isolation valves were installed on either side of the heat exchanger for easier maintenance without draining the entire system.
Finally, the boilers were connected to the Vitotronic 300 controller, which efficiently manages all three units. This controller was also integrated with the BMS system for fault detection and monitoring.
The Result
After completing the installation of all pipework and electrical systems, we conducted thorough testing and system commissioning. This included checking all hot and cold water services to ensure the new system was leak-free. The gas services were purged, tested, and approved before activating any equipment. We also inspected all connections to the existing system. Once these verifications were done, the boilers were fired up, and we began testing the heating demand. The system performed efficiently, meeting the required temperatures. After the full commissioning process, all pipework was insulated, labeled, and the O&M manuals were issued.
The Gallery
