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Twin Pump Horizontal Booster Set Replacement

The Background:

This booster set replacement was carried out in the centre of Manchester in November 2017. The existing booster set was down to a single pump, running constantly and barely delivering pressure. This was largely due to the dilapidated state of the set due to a lack of repairs when necessary over the years. For the last 4 years we have been servicing this set and keeping it together so the residents did not lose water.

The unit was beyond economical repair for the budget of the site, therefore, this    installation was made possible due to the switch from fixed to variable speed pumps, which will provide significant energy savings and offset the cost of the new booster unit.

The Installation:

The main issue with this installation was logistics, the new set had to brought in through the buildings lobby, carried down 2 flights of stairs and lifted over a brick bund. Please see picture of access below:

In this scenario our primary concern is creating as little disruption to the property as we bring in the new unit through their main entrance and remove the old unit. We successfully managed this with ease and used lifting equipment to aid the transference of the unit into the bund. Please see before and after pictures of the job:

Original set:                            New set:

As is often the case when retrofitting, space was very limited and the access to the original unit wasn’t ideal. Therefore, we had to go for a horizontal pump set in this scenario, to fit into the space available but also to allow room at the front and behind for future service and maintenance. The original unit had multiple single points of failure, the new twin pump Lowara unit comes complete with individual accumulator vessels, individual isolation and drain valves and individual pressure transducers. Given the importance of the set for the residents, this fail safe operation is imperative.

If you have an ageing set and you would like a quotation for a modern equivalent, please don’t hesitate to get in touch and we can organise a site survey. Alternatively, if you are interested in service and maintenance of your existing plant, please get in touch for a quotation!

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Replacement and repair of 6″ Pressure Regulating Valve

We are always looking at ways to provide more cost effective service for the customer. This job was carried out at a prestige site in Manchester, they had two 6″ pressure regulating valves that fed cold water to the entire building (20 plus floors), they were desperately in need of repair. Site could not afford any downtime at all, therefore, the most cost effective solution for them was to buy one new valve, repair the current two valves and then keep the second repaired valve as an emergency spare. Over the course of two visits we were able to remove the first valve and replace with new, while taking that valve away to our workshop to carry out repairs and a deep clean. Please see pictures below:

1st visit:

Original configuration:                         New valve installed:

Once we took the valve away for cleaning and repair, we gained a true realisation of the build up of deposits in the valve, thus causing the valve to seize in the first place:

Clean and Repair:

This is a natural occurrence as time goes on, however, in this instance it had caused the valve to fail. Please see pictures of valve fully cleaned:

Once this valve was fully cleaned, we reassembled and recommissioned, installing new pilot PRV in the process. The valve was then ready for reinstallation.

2nd visit:

Repaired valve reinstalled:                       Final configuration:

On the second visit to site, we removed the bottom valve for  repair and reinstalled the valve we had cleaned and repaired. Please see picture above of repaired valve reinstalled. Final configuration also in pictures.

This site now has two fully functioning PRV’s with a backup critical spare in the future. As you can see from the pictures, these repairs were carried out with minimal down time and disruption to the client, while also assuring them peace of mind in the future.

We can work to specific confines and come up with multiple cost effective solutions to suit you and your site. Please fill out a ‘quick enquiry’ form today should you require any advice or a site visit. Alternatively, contact us on 0161 798 5872 to discuss anything further.

 

 

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Importance of Pressure and Booster Unit Maintenance

Our mission:

Here at PressBoost our primary concern is to provide comprehensive quality service and repair to all makes and types of Pressurisation and Booster equipment. Servicing of Pressure and Booster equipment is absolutely pivotal to the longevity of your plant. The majority of manufacturers will only guarantee the gas charge of a pressure vessel for 6 months. If a vessel is not serviced every 6-12 months by a competent individual this can compromise the integrity of the vessel. As a result, we recommend as a minimum a bi-annual or annual service visit for all of your pressure and booster equipment.

How do you know if your equipment is being maintained?

On a standard service visit we will always test the full operation of the unit, monitor any/all pumps and drain down and recharge the pressure vessel/s. Once serviced we will affix one of our service labels:  

As well as this, any pressure vessel that we maintain we will affix one of our company stickers, so that in the event of any issue or if you want to arrange a service visit, you have our emergency contact details: 

In the event that your equipment has been manufactured by ourselves, we will always affix one of our manufacturer labels with a serial number so that you can always quote that number to us when contacting us for any reason:  

Anybody working on or maintaining your plant should affix similar signage to highlight that your equipment is being maintained. If your equipment is not being maintained, please fill out a ‘quick enquiry’ today or alternatively call us and we can quote for a service visit. We operate nationwide and offer price packages for sites with multiple units on site.

Compliance:

Recently, we have had some customers enquiring about written schemes of examination. Unfortunately, the guidance can be quite difficult to decipher in this area. However, we are able to specifically tell these clients which pressure vessels do and which pressure vessels do not fall under the scheme. In addition, all of our service reports have a section that explains whether a written scheme of operation is required for that specific unit:

If we maintain your equipment we will advise you as a matter of course if your pressure vessel falls under the written scheme, in terms of the guidance we operate on the following proviso:

A written scheme of examination is required under the “Pressure Systems Safety Regulations 2000” when a pressure vessel exceeds the 250 Bar/Litre rule. This rule stipulates that if the volume of the vessel multiplied by the charge of the relevant fluid (in this case the compressed air/nitrogen) exceeds 250 Bar/Ltrs then this vessel shall be subject to an additional test/examination. This test is separate to the Statutory maintenance which must be carried out by a ‘Competent’ engineer on an annual/Bi-annual basis.

This examination is normally carried out by a representative of the insurance company who provide the cover for the equipment at any particular site. It may or may not include Ultrasonic thickness testing, Pressure drop testing and/or in some cases internal inspection of the pressure vessel and its protective devices.

Pressboost regularly provides support engineering to these inspections to facilitate the testing that is required, please don’t hesitate to give us a call or fill out a ‘quick enquiry’ if you want to talk further.

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Control Panel Modifications

The job:

One of the many aspects of works we carry out here at PressBoost is control modifications. All of our engineers are control specialists and highly experienced working in control panels. Recently at a site in Bury we replaced 4 x contactors and overloads feeding the supply and extract fans to the building. Two of the contactors had burnt out and were consistently tripping the MCBs. One of the problems here and reason for the contactors being burnt out was that the overloads were not sized properly on the original install. We sized the correct overloads and correct Kw rated contactors. We also installed a higher standard of part to increase the longevity of the equipment and attended site the very next day to carry out the remdial due to the vital nature of the plant.

The pictures:

Before…                                               After…

  

The benefits:

We are able to size, replace and modify all existing and new control circuits on request. Additionally, we can carry out these works with a very short turnaround to site specifications and as you can see from the pictures, the retrofit looks better than the original install. These problems are picked up on service visits which again highlights the importance of service and maintenance of your plant. If you are interested in a price for servicing of your Pressure and Booster equipment please fill out a ‘quick enquiry’ form today or email adam@pressboost.co.uk.

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RPZ Valve Servicing

The Legal Requirement:

One of the most important services we offer at PressBoost is servicing of RPZ (backflow prevention) devices.  Quick filling loops which used to be installed to most pressurised heating systems are no longer satisfactory, as LTHW & CHW pressurised systems are now in the main classified as Fluid Category 4 and therefore require an RPZ valve to be installed rather than a quick fill loop.

These valves must be tested and certified as a minimum on an annual basis by Approved Water Regulations Advisory Scheme Testers as listed in the WRAS Guide. Here at PressBoost we have multiple testers accredited, if you have any RPZ valves on your site, please fill out a ‘quick enquiry’ form today and we can advise you further.

 

During service:                                   After Service:

 

RPZ valves must also be installed to fall within strict guidelines in terms of access and configuration. If you have any quick filling loops which you would like removing and replacing with an RPZ valve, again please don’t hesitate to contact us and we can arrange a site visit.

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3 x Pressurisation Unit Installations

The background:

These jobs were carried out at 3 different hotels in Bournemouth. All 3 units were u/s and in need of replacement. As a result, PressBoost installed all 3 units in a 2 day trip, thus, by combining the 3 jobs into such a small time frame we managed to save on labour and travelling expenses for the customer.

As you can see from the pictures below, the original installations were ageing and/or piston pumps. PressBoost installed 1 x floor mounted Presfix Beta MKII and 2 x wall mounted Mini Presfix, these both benefit from digital controls and peripheral turbine pumps and the ease of access for maintenance is excellent.

The Before and After:

The logistics:

As you can see from the pictures above, the access to install these units was challenging, however, we are able to fully retrofit all replacement units to suit the requirements of site. We have a variety of unit options to suit the requirements of site as well of a variety of sizes. Additionally, although we are based in Manchester, we operate nationwide so please do not hesitate to get in contact if you have any queries!

 

 

 

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Fixed Speed to Variable Speed Booster Replacement

The Justification:

Here at PressBoost something we take seriously is energy savings, the conversion from fixed speed to variable speed pumps typically results in 30-50% energy savings (one large hotel in Daresbury saw savings of 53%). The larger the motor, typically the larger the saving. Fixed speed pumps often run on timer and if the accumulator vessels are not regularly serviced and maintained, one small draw off from a tap will cause the pump to run on timer even if the requirement is very small. Variable speed pumps will ramp up and down depending on the demand on the system, thus, resulting in significant power reduction.

The Installation:

This install at a site in Leeds was replacing the existing twin pump fixed speed booster due to the fact pump 1 had failed and the unit had obsolete controls. We have installed a twin pump variable Lowara GHV booster complete with the new generation of hydrovar inverters. These inverters have a much sharper and accessible display and have an increased amount of features, furthermore, they can be modified and adapted to any standard pump with a wired motor box.

The Pics!

Before:                                              After:

We can size any make and model of Booster Unit, if you have any issues with your pressure or booster equipment call us now on 0161 798 5872 or alternatively fill in a ‘quick enquiry’ form today. Furthermore, if you have a fixed speed booster and are interested in the variable speed option, we have multiple options available and can quickly carry out an energy savings calculation for you with just a small amount of information from you.

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Wall Mounted Pressurisation Unit Replacement

The Install:

PressBoost carried out this installation recently replacing a U/S wall mounted Pressurisation Unit with a Lowara Mini Presfix. The existing wall mounted unit had 2 U/S piston pumps which were not suitable for the size of the system, the Mini Presfix benefits from having two peripheral turbine pumps. Additionally, the expansion vessel supporting the system had been piped incorrectly (into the flow and return header which created constant circulation between them), therefore, we modified the pipework accordingly and the system is now working appropriately. Please see pictures below of our install:

Before:                                      After:

The new unit is conveniently located in the same space as the old unit and as you can see from the pictures, the new unit is quite a bit bigger, facilitating future service and maintenance to aid the longevity of the plant. Here at PressBoost we offer a wide range of floor and wall mounted pressurisation units in a number of outputs. Once again, if you have and questions at all, please do not hesitate to get into contact today by filling out a ‘quick enquiry’.

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PressBoost New Headquarters Renovation

Background:

In August 2016 we managed to secure our new, larger premises that will be our home for the foreseeable future. We are still conveniently located in Prestwich, just off the M60 motorway. The building dates back to 1892, over the years it has been a Co-op building, a butchers and slaughterhouse (with a path connecting the cellar to Heaton Park), a sewing factory and most recently a plumbers merchants.

The pictures below give a snapshot of the condition of the building at the start of our works:

Renovation:

The renovation was a lengthy process that included taking down and rebuilding the gable end, roof works, extending the building at the back to provide a loading bay, full rewire, plumbing throughout, steel work, new windows throughout and so on. The pictures below demonstrate just some of the steps along the way!

Before:                                  After:

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What this means for PressBoost:

This new headquarters will provide the base for PressBoost as we continue to grow and develop as a company. At c.4000 sq/ft it is more than big enough to sustain us as we continue to offer quality service and repair to all makes of pressure and booster equipment across the country.

Also, this now provides us with enough workshop space for PressBoost at the new site, whilst our sister company PumpCare Ltd have moved into our previous premises.

                        

32-34 bailey Street                                       Unit 14 The Old Co-op Yard

Prestwich                                                       Prestwich

Manchester                                                   Manchester

M25 1HQ                                                       M25 3Hb

 

The FINISHED product!

In January 2017 we completed the long awaited move in, over time we have gradually added the finishing touches and kitted out the workshop. The end product is something we are all very proud of and we hope to enjoy many years here. We are committed to never standing still and striving to improve the quality of the service we provide, this is one big step along the way!

 

 

 

 

 

Home Booster Replacement

The Installation:

Here at PressBoost we offer service and maintenance to domestic booster units as well as commercial. Recently we replaced a home booster unit at a school in Liverpool. The existing Grundfos unit had obsolete controls and a failed control board, therefore, the only suitable alternative was replacement. We replaced the unit with a Lowara modern equivalent designed for site. The new set is variable speed making it 30-50% more efficient and much quieter. In this instance noise control was very important to site due to the unit being palced in a Science classroom. Additionally, this unit has the required air gap so it can safely feed the lab taps and comply with regulations. See pictures below of our install.

Before:                                              After:

We can size and install equipment to suit all of your specific needs and requirements, should you have any specific questions please get in touch, we are happy to help. Alternatively, if you are interested in the benefits of variable speed over fixed speed, fill out a ‘quick enquiry’ form today and we will contact you.

 

 

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