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Spirax Safebloc Double Block and Bleed valves have helped SCA Hygiene in Prudhoe, Northumberland, to eliminate unscheduled boiler shutdowns costing up to GBP20,000 each in lost production.

SCA Hygiene runs a 24/7 process, producing branded tissue.

It is the company’s practice to only carry out maintenance work on a live-steam system behind double block-and-bleed isolation.

The company frequently suffered minor problems with blocked level-gauge glasses on its boilers.

However, because only single isolation valves were fitted to the gauge glasses, the boiler had to be shut down and depressurised to enable maintenance engineers to fix the problem safely, halving production output for up to 10 hours.

SCA Hygiene decided to replace the existing single isolation valves with four Safebloc valves on each of its boilers, so that any future maintenance work on its gauge levels could be done without having to shut down a boiler.

Previously, a boiler shutdown could cost the company up to GBP20,000 in production downtime, meaning the last four valves paid for themselves three times over within the first six months.

Double block and bleed (DBB) is the industry’s best practice for double isolation for safe maintenance without having to shut down the entire system.

Double isolation is achieved by closing two isolation valves, with the intermediate bleed valve being left open to provide a sealing integrity check to ensure the downstream pipeline remains safely isolated during maintenance work.

The patented design of Spirax Safebloc incorporates two isolation valves and a bleed port in a compact assembly, making it easy to install into the space left by an existing single isolation valve.

According to the company, it had never have been able to install a DBB system in the past as other designs take up too much space, often sticking two to three feet out from the boiler.

An added advantage of Spirax Safebloc is that a retrofit can be undertaken quickly, eliminating the time-consuming and expensive pipe cutting, welding and pressure testing needed to engineer a conventional double block and bleed arrangement from separate isolation and bleed valves.

This UK-manufactured and easy-to-fit unit is robust enough for industrial environments.

It uses proven technology from the Spirax Sarco range of bellows-sealed globe valves that offer zero gland leakage, while ensuring tight shut-off conforming to DIN 3230 BO1 and ISO 5208 Rate A specifications.

Spirax Sarco benefits built on knowledge. Spirax Sarco has all the products, services and expertise needed to make the best investments in building and maintaining a steam or industrial fluid plant.

A complete and flexible range of services is available to cover any need from supplying an individual steam trap, to a complete new plant and everything in between. Spirax Sarco Services can help identify, improve and sustain steam system efficiency at every point in the steam and condensate loop.

In addition, custom-built solutions can be created to take a project from design and build to commissioning, support and scheduled maintenance on time and on budget. Pioneers in steam, Spirax Sarco has developed longstanding relationships with customers across a wide range of industries, including hospitals; food & beverage; pharmaceutical; oil and petrochemical; and waste and waste water. Forward thinking to keep you one step ahead As the market leader in steam systems, Spirax Sarco has the market presence and resources to keep abreast of the latest legislative and technological developments.

At the forefront of training Well-trained personnel are essential to achieving the best plant performance.

Spirax Sarco can provide all the training that your staff requires, either on-site or at the Cheltenham-based training centre, for nationally recognised qualifications including BTEC, City & Guilds and the Boiler Operative Accreditation Scheme (BOAS).

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