Juicer plant upgrades to an Italtherm condensing boiler

The Limery boiler upgrade

Based in Wairoa, Northern Hawkes Bay, The Limery grows and processes whole lime fruit and juices. The plant needed a newer more reliable boiler with an increased output.

“We are super happy with the Italtherm condensing boiler which has made a huge difference in the time it now takes to pasteurise our juice products.  Safe instant constant heat when we require it.”

– Dianne Downey, The Limery

Our Waikato based team removed the old atmospheric boiler and pipes and installed an Italtherm Time Power 115 kW and LPG adapter. Older conventional atmospheric boilers have only 55 – 78% efficiency with 30% of the heat wasted.

The Italtherm condensing boiler was chosen for its compactness, high-efficiency of up to 99% and newer smart technology for optimizing performance. Reducing your carbon footprint along with reduced fuel bills make condensing boilers the best choice.

The technicians also installed a new gas line with Europress, connecting the boiler to the new LPG cylinders recently supplied to the customer. All piping is stainless steel food grade standard for gas and hot water systems. A 25 litre reflex expansion tank was also installed to ensure equal pressure throughout the heating system.

Italtherm time power 115kW condensing boiler
Reflex expansion tank and pipework

Thermal Oil Heater Recommendation

A thermal oil heater, also known as a thermal oil boiler, thermal fluid system, hot oil heater and thermic fluid heater, is a closed loop liquid phase heat transfer system.

A thermal fluid heating system has five key advantages:

  • A standard thermal oil heater can operate at low pressures while still reaching high temperatures, up to 343⁰C
  • Can be installed outdoors due to the closed loop system and as an indirect heating system they can be located remotely
  • Reduced maintenance requirements as there are less susceptible elements in a centralized system
  • Can be run as an unattended system because there is no exposed heating element
  • A central heating system when combined with a steam boiler for manufacturing plants

As an authorised distributor for PIROBLOC, Tubman Heating Limited recommend PIROBLOC Thermal Oil Heaters for processes that require a medium to high temperature range up to 400⁰C, such as food manufacturing, storage tanks, drying processes, solar energy, timber processing and the aviation industry.  With over 40 years in the industrial heating system industry PIROBLOC are the experts in the design and manufacture of thermal fluid boilers, with a commitment to safety, reliability, and efficiency.

  • Bitumen Storage
  • Solar energy
  • Storage tanks
  • Drying processes
  • Aviation industry
  • Chemical industry
  • Timber processing
  • Food manufacturing
Play Video about Tubman Heating recommends PIROBLOC thermal oil heaters

PIROBLOC Thermal Oil Heater specifications:

  • Power range: From 0,1 to 15 MW
  • Admissible maximum pressure: 40 bar
  • Test pressure: 60 bar
  • Service maximum pressure: 25 bar
  • Service temperature: till 400ºC
  • Design temperature: 400ºC
  • Two coils, three smoke passes
  • Fluids content: thermal fluids. Group 1
  • Surveillance system: Indirect
  • Control interval: till 24 hours

PIROBLOC Thermal Oil Heater standard components:

  • KSB thermal oil pump
  • Unigas CIB burner
  • Allan-Bradley PLC and touch screen
  • Wika pressure transmitters
  • Ari valves

PIROBLOC thermal oil heaters are fully customisable to suit the customer’s needs including horizontal or vertical placement according to the space available. There is no operational difference between the two placement settings of the boiler. The use of a thermal oil heater increases fuel savings up to 20%, due to the closed circuit which ensures minimal energy releases. Temperature consistency also increases your heating systems efficiency.

For more information on the PIROBLOC thermal oil heaters contact our Sales and Design Engineer, Dave Teesdale on 021 771 130 or Head Office on 09 444 5076.

Health and Safety Training Part 2 – Incident Reporting

Welcome back to Tubman Heating’s Health and Safety training. Part 2 of our H&S series discusses incident reporting, it’s purpose and outcomes.

Play Video about Health & Safety Trainingg video Part 2 - Incident Reporting

What is an incident?

An incident is an unplanned event which:

  • Injures someone (including death)
  • Could have injured someone (near miss/near hit)
  • Damaged property
  • Could have damaged property (near miss/near hit)
  • A environmental release
  • Anything which could bring the company into disrepute

 

What is an incident report?

An incident report must provide the following information:

  • Date and time of the incident
  • Clear description of what happened
  • Supporting evidence if needed (photos of injury, environment or damage)
  • What was the outcome (scope of injury or damage to property)
  • Who has been informed
  • Any other relevant information

 

The incident report must be submitted to your manager, the Safety and Compliance Officer, the Chief Executive Officer, and the customer if on site. Serious incidents where injury or property damage required emergency services to be called or an environmental release that leaks into waterways need to be reported immediately. WorkSafe incidents must be reported as soon as possible on 0800 030 040. All other incidents to be reported by days end.

Incident reporting allows the Health, Safety and Compliance Officer to analyse and if needed investigate the event to determine the cause and what actions can be taken to reduce the risk of it happening again. Incidents reports can also be used to disclose future risks and hazards on a site. Reporting near misses and observations will keep employees, management, and customers aware and will help prevent major incidences in the future.

 

Tubman Heating Limited remain committed to providing a safe work environment and ensuring safe working practices for our employees and customers. If you have an incident or observation to report please contact our Health, Safety and Compliance Officer Kevin Prosser on 021 993 159.

Heat Source Fuel Series: Natural Gas

As one of New Zealand’s leading boiler and burner specialists, Tubman Heating Limited takes you through the various fuel types used to power your heating system. Different industries and processes will have various requirements and regulations pertaining to their specific needs.

Tubman Heating Industry Experts

Natural Gas

A heat source uses a fuel substance that is heated up, from which the heat can be extracted or absorbed. These fuels, along with your heating system, generate energy in the form of power, steam, hot air, hot water and more. Natural Gas is a fossil fuel energy source formed deep beneath earth’s surface, over millions of years and extracted either vertically or horizontally through a production well. All natural gas in New Zealand is sourced from 15 fields within the Taranaki region, both onshore and offshore. Natural gas is only transmitted and distributed across the North Island.

A heating device such as a burner requires a fuel source (Natural Gas), an ignition source and oxygen to create combustion. The gas and oxygen ratio needs to be calculated based on the consumption rate of the boiler and the expected usage of the heating system. Synthetic methane, biomethane, and hydrogen and gas blend are currently compliant with NZS 5442. Natural gas is used in the petrochemical sector, fertiliser manufacturing, steel manufacturing, wood processing and dairy plants. Commercially natural gas is used in hotels, greenhouses and in food manufacturing.

natural gas pie chart sectors

The NZ Government’s 2050 target of net-zero and low emissions aims to replace natural gas with hydrogen and existing gas pipelines will be repurposed for hydrogen and biogas, most modern boiler systems will be able to continue use with biogas options, with only a burner modification or upgrade required. While in this transition phase, natural gas remains a reliable and affordable fuel source for our customers. Natural gas use in a boiler heating system offers more precise control and monitoring capabilities, including remote access.  Compared to other fossil fuels, natural gas produces the least amount of CO2 when heated, and only half as much as coal. Clean combustion, due to no particulate emissions reduces the wear on the burner and boiler.

For advice on fuel options and heating system requirements, please contact your local branch on

Auckland 09 444 5076

Hamilton 07 838 3080

Wellington 04 939 4334

*Sources

Gas and Liquid Fuel Boiler Systems SNZ PAS 5312:2021

Gas Industry Co. www.gasindustry.co.nz

Starship Children’s Hospital Donation on behalf of THL staff

Starship is New Zealand’s national children’s hospital who receive over 140, 000 patient visits each year. Donations made to the Starship Foundation are used to invest in Starship Child Health and the Starships’s National Air Ambulance Service. This brings change to the lives of all New Zealand’s children that need it.

Our children. Better Health. Brighter Futures.

COVID-19 and red traffic light settings saw us postpone the Tubman Heating Limited Annual Christmas Function for our staff. With case numbers soaring and our teams located across the North Island, it was decided to cancel the year-end function and a number of staff members and their partners chose to donate in lieu of the Christmas Function.

Tubman Heating Limited are honoured to donate $7500.00 to Starship on behalf of our staff.

Learn how to make your own donation here.

Health and Safety Training Part 1 – Noise

Welcome to Tubman Heating’s Health and Safety training. Our Health, Safety and Compliance Officer Kevin Prosser will be taking us through the health and safety training that ensures our workplace policies and procedures are up-to-date keeping our staff, customer’s and the environment safe.

Play Video about Health & Safety Training Part 1 - Noise

What is noise?

Noise is generally unwanted background sound that can affect you in any of the following ways:

  • Psychological – scare, startle, annoy or disrupt concentration
  • Physiological – can cause pain and hearing loss
  • Communication – interference with communication can affect the job and safety

Noise levels are measured in decibels

  • 30 – 40 quiet pleasant sounds, birds chirping
  • 40 – 50 quiet normal office sounds
  • 50 – 60 normal conversation
  • 70 – 90 heavy machinery and electric motors
  • 100 – 120 jack hammers, power saws, motorcycle
  • 140+ jet engines

Sounds 85dB and higher cause hearing loss and hearing protection must be worn from this noise decibel level. You can search your app store for a sound meter to measure the noise level of your environment. The rule of thumb is; if you need to shout to be heard then you must be wearing hearing protection. There are two types of hearing protection options, earplugs and earmuffs. NZ Safety Blackwoods stocks various options and are available throughout New Zealand. Tubman Heating staff are supplied the correct hearing protection and any other PPE that is needed to conduct work safely.

Hearing loss is permanent, if you think you have hearing damage you should get it tested at your local hearing clinic and speak to your manager and compliance officer. Bay Audiology offer free online hearing assessments and have clinics throughout New Zealand. Hearing damage can also include constant ringing in the ears and ongoing pain. For questions and more information, please contact Kevin Prosser on 021 993 159.

Burner and Control Panel Upgrade for a Steam Boiler

During a site visit to Koppers Performance Chemicals NZ Tubman Heating Limited identified the steam boiler as critical to the plants operation. Investigation of the burner and control panel found that both pieces of this essential equipment were outdated and in need of upgrading. Tubman Heating suggested that a new fully modulating burner with a built-in modulating pressure controller will provide better performance in both the control of the burn for the boiler and energy use, with increased efficiency.  

New CIB E205A burner

Outdated burner at the end of it’s design life

New CIB Unigas E205A fully modulating burner

A CIB E205A was fitted to replace the 24 year old burner that had reached the end of it’s design life along with a new control panel that included a back end temperature limit controller. The E205A burner is equipped with a high performance combustion head that is designed to achieve maximum efficiency when working on natural gas. A by-passing nozzle can reach a turndown ratio of 1:3 with a pressure regulator.

“Thank you for the fantastic job you and your team did over the Christmas / New Year break getting the new burner and control system installed and other required testing all sorted for our boiler. Really appreciate the great job you did and being able to do it during a period when we didn’t need to be operating the boiler so we had no lost production time.”

 – Steve Crimp, General Manager of Koppers Performance Chemicals New Zealand

Steam Boiler Recommendation

Unical AG S.p.A. was established in 1972 to design and produce civil and industrial heating units and now boasts one of the most extensive catalogues in the industry. Unical R & D has a team of over 30 employees who continuously work on projects such as co-generation, revolutionary condensing heat exchangers and highly compact and modular applications to maintain the highest quality standards.

Steam is a fundamental and process for many industrial sectors including pharmaceutical, food, chemical, paper and many more production facilities, as well as for sterilisation and large scale energy production. A steam boiler is a pressure vessel that converts water to hot steam through a combustion reaction between fuel and air, which ignites a flame into tubes submerged in water. The heat contained in the steam is used for whichever heating process is required.

Tubman Heating has a long and respected relationship with Unical and we have installed a number of their steam boilers in New Zealand, including a recent Unical Bahr 3000. Our steam boiler recommendations as shown in the video below can be found on our steam boiler page.

Play Video about THL Steam Boiler Recommendation
Contact our Auckland or Wellington branch for more information.

Steam Boiler Replacement Case Study

The customer’s brief required replacement of a 1974 Anderson Steam Boiler due to age, as the average life span of a steam boiler is 20 to 30 years, and to increase maximum capacity since installing additional steam operated equipment such as a pasteuriser and CIP (Clean in Place) system.  

Tubman Heating replaced the old boiler with a Unical Bahr 3000 fitted with a Prolec Control Panel, for unattended use. This steam boiler will provide a reliable supply of steam to the production facility. The Prolec control panel allows for customization and increased safety controls, to suit New Zealand requirements. The customer is sent a notification via text or email if there is a fault.

Unical Steam Boiler installed by Tubman Heating Limited

The Unical Bahr 3000 steam boiler is connected to a new pasteuriser and existing waste water treatment station with a new 80 mm steam line that runs through the production area. This process was made complicated by the pipe running through the roof structure, but with scaffolding and strict health and safety measures our team completed the task and, in some areas, even on their hands and knees.

An economiser has been fitted to the boiler to capture waste heat from the flue gases to pre-heat the boiler feedwater. The boiler coupled with the economiser provides up to 95% efficiency compared to the previous boiler that operated at ~80% efficiency.

Season’s Greetings and our closing dates for 2021-2022

As we look back at the past year, we would like to acknowledge those who have helped us shape our business. To our customers for their continued support and understanding during lockdown’s and the delays they may have caused. To our suppliers for their service and assistance during these challenging times. Our CEO and Director’s are also grateful to the THL team for their hard work over the past year.  

Tubman Heating Limited wishes our customers, suppliers and staff a wonderful and festive summer break. Our Auckland and Hamilton offices will be closed from Friday December 24th  2021 until reopening on Wednesday January 5th 2022.   After hours emergency break down assistance will continue over this period. Our Wellington branch will be closed for statutory holidays only.

We look forward to creating more heat with you in 2022.