Grampian Country Pork

Case Study Grampian Country Pork, E Yorkshire

Being in the food preparation business, Grampian Country Pork requires large quantities of constant hot water as well as power. If the hot water supply shuts down, the factory is unable to operate. The company approached Heat & Power Services with a view to increasing plant availability, improving heat recovery and boosting efficiency.

The engine we took over was so poorly maintained that it required new pistons, valves or turbochargers, once a month. The heat recovery processes were producing sufficient high-pressure steam but inadequate amounts of hot water and low-pressure steam. With no heat rejection system in place, the engine would malfunction whenever the client was unable to make use of all the generated heat. This had the effect of further increasing the unit’s maintenance requirements and reducing its cost effectiveness.

Following a thorough assessment, Heat & Power Services proposed a significant redesign of the system which was accepted. This included an urgent rebuild of the Caterpillar engine (pistons, liners, big ends, turbos, cylinder head, etc), converting the engine to run at lower temperatures, changing from LP steam to hot water (eliminating a substantial part of the ongoing overheating problems). We also replaced the Toshiba programmable logic controller (PLC) with one manufactured by Fenook, and added an up-to-date, versatile monitoring system with remote access options.

We further added a heat recovery system to increase heat recovery from the jacket and from the oil cooler and after-cooler circuits. We also installed heat rejection equipment so that the unit could run continuously without overheating. Subsequent maintenance now features the use of our quality and innovative parts (incl. oil type and spark plug designs) aligned to intensive 24h system monitoring innovations link. The cost of this conversion was met by Heat & Power Services to be recovered over time through the agreed maintenance service contract with written performance guarantees.

Plant availability ‘link to formula’ has gone up from 60% to 96%, increasing dramatically the savings in fuel of the company by 60%.