SCF Steam Deaerator Replacement

SEC designed the replacement of the high-pressure steam system deaerator at Sterling Correctional Facility with minimal service outages. The construction cost was $1,000,000, with Mr. Orrin Fryer serving as Project Manager.

A temporary docking station was designed to connect a truck-mounted deaerator prior to removing the existing unit, ensuring continuous operation. The existing single transfer pump was upgraded to a redundant pump design. Three constant-volume feedwater pumps were replaced with three variable speed pumps with pressure controls that stage and modulate the correct pump quantity to maintain feedwater pressure, providing significant energy conservation.

PLC controls optimize deaerator operation and energy consumption, fully integrated into the building automation system. An automatic blow down separator was added per code requirements to cool boiler blow down water. A new mechanical combustion air system with VFD fan was installed to replace the previous system that suffered from freezing issues. The project was divided into pre-purchase and installation bid packages.