Clean Steam Generator Replacement in an Active Laboratory
Updated: Sep 7
Location: West Virginia
Industry: Research & Laboratory
Service: Infrastructure & Utility Modernization
The Situation
An active research and laboratory facility needed a complete clean steam generator replacement involving two aging unfired units and their supporting water-conditioning equipment. Clean steam served essential facility processes, so replacing both generators under a full-system shutdown was not an acceptable option.
The project required a phased approach that would keep one generator operating while the other was isolated, removed, replaced, connected, tested, and returned to service.
The Challenge
Each generator was integrated into several existing systems. Replacement required reconnection to the source steam supply, pressure-reducing arrangement, steam condensate return, clean steam distribution, softened-water supply, pressure-relief piping, and electrical service.
Existing dimensions, equipment access, rigging routes, adjacent systems, and connection points had to be field-verified before removal began. Shutdowns also required coordinated lockout/tagout procedures, isolation of the active steam system, and controlled release of residual pressure.
The supporting infrastructure expanded beyond the generators themselves. Two flash tanks were required to receive condensate from the generator traps and transfer recovered energy through the existing heat-recovery system. Their installation required modified support legs, precisely coordinated elevations, condensate piping, outlet connections, vent piping, and insulation.
The existing water softeners also had to be replaced with units sized to support the full clean-steam demand of the new system.
How We Worked
JBrennon managed the work as a phased design-build equipment replacement. The team first verified field dimensions, existing connections, equipment access, and the rigging path needed to remove the existing generators and position the new units within the mechanical space.
The first generator was isolated using coordinated lockout/tagout procedures. After residual pressure was relieved, the existing unit and associated components were disconnected, rigged out, and removed. The replacement generator was then positioned and connected to the existing source steam, pressure-reducing, condensate, clean steam, softened-water, pressure-relief, and electrical systems.
New isolation valves, fittings, and piping appurtenances were installed as required for a complete operating connection. The generator was insulated, started, tested, and returned to operation before work shifted to the second unit. The same controlled sequence was then repeated, allowing one generator to remain online during each replacement phase.
JBrennon also removed and replaced the water softeners serving the clean steam system. The new equipment was sized to support the operating capacity of both generators and connected to the existing water infrastructure.
Two flash tanks were installed as part of the completed system. Their support legs were extended to establish the required elevation above the energy-recovery heat exchanger inlet. New piping connected the generator steam traps to the flash tanks, the flash tank outlets to the heat exchanger, and the tank vents to the existing main vent system.
Fiberglass insulation was installed on the flash tanks and new piping. Insulation disturbed during demolition and reconnection was repaired or replaced to restore continuity throughout the mechanical system.
Following installation, both generators and flash tanks underwent startup and operational checks to confirm that the complete clean steam system was functioning as intended.
The Outcome
JBrennon delivered a modernized and fully integrated clean steam generation system while preserving clean steam availability during construction. The facility received two new unfired generators, two flash tanks, replacement water softeners, reconfigured piping, renewed insulation, and completed electrical connections.
Two unfired clean steam generators replaced through phased shutdowns
One generator maintained in operation while the other was replaced
Source steam, condensate, clean steam, softened-water, relief, and electrical connections completed
Two flash tanks installed and connected to the energy-recovery system
Water softeners replaced with units sized for the new system capacity
New piping and equipment insulated following installation
Startup, testing, and operational verification completed for the integrated system