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A Welcombe boiler replacement
The Welcombe in William Shakespeare’s birthplace Stratford-upon-Avon is one of Hallmark’s many
prestigious hotels in the UK. Like many hotels, the Welcombe was facing the issue of old boilers becoming unreliable, nearing the end of their serviceable life, with spare parts being difficult to source.
This led to a two-year process to replace the boilers, gas fired water heaters and calorifiers in the hotel, spa and golf club from Hamworthy’s range
D
anny Bulch, director at Cedar Green Projects Ltd, chose the equipment thanks to its ability
to suit a range of applications and overcome the main challenges of the project: refurbishing a hotel during peak heat requirements in winter, overcoming access issues to the plant room and accommodating different fuel options.
Replacing the spa boilers
The Welcombe’s spa offers guests an indoor and outdoor pool, luxury treatments and a fully equipped gym. Five large cast iron boilers with a combined output of approximately 500kW supplied heating and hot water to the spa. As the sections of the boilers kept splitting and were becoming unreliable, a replacement was needed. Danny chose three Hamworthy Purewell VariHeat cast iron floor standing condensing boilers with a combined output of 540kW to substitute the five old boilers. They are the only ErP-compliant cast iron
S14 September 2018
condensing boilers in the UK. He commented: “Hamworthy’s
Purewells are compact and sturdy cast iron boilers with large waterways; we use them in our temporary boiler rooms for this very reason. Looking at the requirements of the spa, there wasn’t a moment of hesitation in choosing these boilers as we know them so well.” To accommodate the hot water
requirements, PS200 and PS500 Powerstock calorifiers were chosen. These glass-lined indirectly heated water heaters provide a combined hot water output of up to 2,149 litres per hour at 50 degrees differential temperature. They also benefit from a recovery time of only 20 and 18 minutes respectively.
Finding boilers to fit requirements
Two large atmospheric boilers on a fan dilution system previously delivered heating and hot water to the main building of the hotel. One of the
boilers suffered from a split heat exchanger which meant the second boiler was the only one left working. Danny opted for Hamworthy’s Wessex ModuMax mk3 196/588V, a small modular condensing boiler with stainless steel heat exchanger that has a 10-year warranty, to replace the old boilers. The chosen model can deliver an output up to 588kW from less than a square metre of footprint and consists of three individual boiler modules which can be flexibly stacked on top of each other to suit difficult plant room layouts. The boiler can efficiently match the heat load from 39kW incrementally all the way up to 588kW. This is possible thanks to the 5 to 1 turndown ratio per module. Combined in a three-high stack, it then becomes 15 to 1. The higher the number of modules, the higher the turndown ratio of the system. Danny said: “We chose the Wessex
because it delivers a high output from a small footprint and it’s a tried and tested product with stainless steel heat exchanger. I’ve been working with
Hamworthy for a long time and I like their products because they are reliable. We’ve installed a large number of Wessex ModuMax which means we’re very familiar with the product. Thanks to its compact size, the Wessex fitted onto the footprint of only one of the old boilers, so we’ve effectively halved the space needed for the heating equipment.”
Replacing boilers without disruption
The replacement was undertaken during winter while the hotel stayed open, with high heating and hot water requirements which made it more challenging. According to Danny: “The remaining old working boiler kept the hotel running while we were installing the Wessex ModuMax on the footprint of the second, failed boiler.” When atmospheric boilers are
replaced with condensing models, changes to the flues are required to deal with the acidic condensate. In this
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