Innovative Solutions for Modern Infrastructure
Modernising High Pressure Steam Infrastructure at Ipswich Hospital.
A critical infrastructure upgrade was undertaken at Ipswich Hospital to replace
an outdated steam system. This complex project involved the design and installation
of a new external steam equalisation header to enhance the efficiency and reliability
of the hospital’s boiler house.
The Challenge: Outdated Infrastructure and Complex Logistics
The existing steam infrastructure at the hospital was outdated, leading to inefficiencies in the boiler system. The primary objective was to install a new equalisation header, a modern solution designed to maintain consistent pressure and resistance across all boilers. This ensures that whether one or all four boilers are operational, the steam output remains stable and predictable, eliminating performance differentials.
The project’s scope presented significant logistical challenges. Key tasks included:
- Installing extensive large-bore pipework, with much of it positioned on the exterior of the building.
- Utilising a boom crane for lifting heavy pipe sections into place.
- Erecting comprehensive scaffolding, which remained in place for over three months to ensure safe access for all stages of the installation.
The entire process was meticulously planned with pre-booked, scheduled stages and executed according to a detailed CAD design with extremely tight tolerances and all of the local partners involved from our very own Ross, suppliers, stakeholders and the commissioning department at the hospital.
The Solution: Precision Engineering and Expert Installation
The successful execution of this project relied on a combination of off-site fabrication and expert on-site installation. A significant portion of the pipework was fabricated in a controlled workshop environment to ensure precision. However, the nature of connecting to an existing system required numerous positional welds on-site within the active boiler house and these can be seen in the images.
Our installation team made a crucial engineering decision to minimise the use of flange joints wherever possible. By prioritising welded connections, we significantly reduce the long-term risk of steam leaks or “weeps” that can develop at flanged connections over time, ensuring a more robust and durable system for the hospital.
The largest pipework installed was 300mm (12-inch) Schedule 40 steel pipe, equiring specialist handling and welding expertise.
The project was phased over five months, incorporating four planned shutdowns for critical connection work. These shutdowns were strategically scheduled for Saturdays and out-of-hours periods to minimise disruption to the hospital’s essential operations.
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Collaborative Design and Execution
A Collaborative Effort
While the initial system was designed by JSNH, our team’s extensive experience
was vital in translating the design into a functional reality. There is no standard
manual for retrofitting a system of this scale into an existing building; it requires
practical knowledge and problem-solving from every team member.
Chris Chapman quotes, “We have to use our experience and expertise to get this
fitted in right. There’s no how-to manual with it. There’s a lot of consideration in the
experience of not just the office team and the design, but also the fitters and
installers, the welders and fabricators, to know how things go together and at what
stage what has to go in so that it all fits.”
The boom crane was hired in and both staff from the crane team joined in as part of
the overall operation.
This collaborative expertise, from the project managers to the on-site fitters, ensured that each component was installed in the correct sequence to guarantee a perfect fit and a successful outcome. The project is currently in its final stages, with the team focused on completing and testing the external sections before moving inside to finalise the internal connections.
