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The Challenge:

The Heat, Light, and Power Team at St. Marys Hospital Medical Center knew that it was time to upgrade the outdated Bailey pneumatic control systems on their three boilers when devices started to fail and their supply of replacement parts began to dwindle.

“The controls were easily 35- to 40-years old and replacement parts were unavailable from Bailey. We have over 300 beds and run 24/7 so we were not about to wait for something catastrophic to happen before we took action,” says Clarence Day, the Supervisor for Heat, Light, and Power. “We wanted to be proactive.”

The Team’s action steps involved doing some initial research, which included speaking with the facilities personnel at Beloit Memorial Hospital (Beloit, Wisconsin) who had recently done a burner controls upgrade project with Industrial Controls.

“We knew about Industrial Controls having bought parts from them over the years,” recalls Day. “We checked out a number of control schemes that we were interested in pursuing, and invited them and one other burner management systems company in for interviews. The Team also wanted a “walk-through” of a similar, completed project. Industrial Controls took us to see what they had done for Beloit Memorial.”

“After making sure that the proposed engineering specifications were precisely what we wanted and needed at St. Marys, we decided as a team to go with Industrial Controls,” says Day.

The Solution:

The three electronic burner management systems provided by Industrial Controls included Honeywell Leaderline Multiloop Controllers for steam pressure and drum level control, Fireye Flame-Monitors™ with expanded annunciation for burner management, and Maxon Micro-Ratio® valves for precise fuel/ratio control.

Working closely with Day and his team, including Bill Miller, their in-house electrician, Industrial Controls did the engineering, prepared the schematics, and built the burner control panels. Once the panels were delivered, a local contractor did the turnkey pipefitting and welding, and Miller, with assistance from the plant staff, removed the old controls, set the new pre-wired boiler control panel, and did all the electrical wiring on the controls side. The new, smaller panels and intuitive layout not only made servicing easy but saved a significant amount of space in the boiler room.

According to Day, “The drawings were excellent. The engineers at Industrial Controls were extremely knowledgeable about burner control and management schemes.”

“What we wanted was simplicity of operation, a reliable, user-friendly system, and local support when needed,” concludes Day. “We’ve even realized labor savings since the system pretty much runs itself. We got all that by working with Industrial Controls.”

“I would strongly recommend Industrial Controls to other hospitals or health care facilities looking to upgrade their burner/boiler control systems.”

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