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case, a FuranFlex flue liner was applied to the inside of the old chimney which was running through a brick stack to the boiler room. New twin wall flue components were then used to connect back to the new boiler from the liner. Working with Cedar Green Projects, Midtherm Engineering were employed to design, supply and install a new flue system and boiler room air supply and extract system at the historic hotel in Warwickshire. “Whilst we installed the boilers, Midtherm were able to set up the flue using the FuranFlex flue liner. Once finished, our team of coded welders undertook some complex positional welds whilst the hotel remained open for business as usual. Within only a few hours, the hotel was running on the new Wessex boiler, a virtually seamless changeover with no noticeable loss of heating or hot water.”
While the ventilation was relatively
simple, the flue installation was not without its challenges. Ian Ford, flue division manager at Midtherm Engineering, commented: “First of all, we erected a scaffold tower from the ground to above roof level with the help of our partners Perry Scaffolding. This included a platform built around three sides of the chimney stack to provide safe access to carry out a camera survey of the six flues within the chimney. In keeping with a building of this age, the routes of the flues from the chimney top were complex, and in some cases blocked. Ultimately, it was found that there was only one flueway which linked the boiler room to atmosphere, with others serving fireplaces in the rooms in that area of the hotel. The problem was that the path from the boiler room’s chimney breast to the top of the chimney had multiple offsets, and the cross-section was rectangular. This meant traditional stainless steel flue liners were not practical, and because of the condensation and pressure created in the flue by the Wessex ModuMax boilers, we needed a proven and reliable flue liner which could negotiate the awkward route, as well as changing in shape to match the rectangular flueway in the chimney.” He elaborated: “FuranFlex liner was our clear favourite for this application, delivering the much-needed flexibility. FuranFlex is a glass fibre reinforced thermosetting resin flue liner. Essentially, the liner arrives on site in uncured condition. Resembling one leg of a pair of trousers, the soft form allows the liner to be passed through
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Three Hamworthy Purewell VariHeat cast iron floor standing condensing boilers
The Welcombe’s spa
Lastly, we just had to connect the liner to the boiler and install the new mechanical input ventilation system to complete the installation and make it safe and efficient.”
The whole installation was subsequently tested and commissioned by Hamworthy. Danny commented: “We chose commissioning from Hamworthy, as it extends the standard warranty terms. Since the installation, the hotel has been benefiting from the Wessex’s fuel efficiency and reliability.”
a complicated flue route before being suspended from the scaffolding, once positioned. Then, the liner is inflated using fast blowers. When complete, a camera survey is carried out to ensure it is free from twists and damage. A bank of steam generators is then
connected to the plastic inner sleeve of the liner to slowly cure it under heat, turning it into a hard and smooth material which resembles carbon fibre in appearance.
The Welcombe’s golf club plant room
Access issues to golf club plant room
The hotel’s clubhouse with function rooms and sports bar was the last part of the refurbishment project at the Welcombe. The old boilers were installed in a loft space plant room with awkward access. Danny elaborated: “We wanted a
Hamworthy’s Wessex ModuMax mk3 196/588V, a small modular condensing boiler with stainless steel heat exchanger was chosen for the main building
Hamworthy product which is wall hung and made of stainless steel. LPG was required as there is no mains gas to this part of the estate. We opted for two boilers, as these are smaller and lighter than a big model and provide back up for servicing and maintenance. Making use of multiple boilers means we can benefit from better load matching thanks to the combined higher turndown ratio.” The chosen new boilers were two
Stratton mk2 S2-70 stainless steel wall hung condensing boilers with 5- year warranty and 154kW total output. Additionally, the two boilers have a combined turndown ratio of 10 to 1 for flexible load matching from as little as 15.4kW up to its full output of 154kW.
September 2018
S15
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