Steam Pressure Control System Upgrade for Brewing Facility

Valveforce partnered with a leading brewing and drinks manufacturer to deliver a robust upgrade to their steam pressure control system. Acting as a trusted engineering specialist, Valveforce brought deep expertise in steam and industrial applications to resolve critical reliability and safety concerns impacting production.

What Was the Problem?

The site was experiencing persistent failures with a series of standard pilot-operated pressure reducing valves (PRVs) . These valves were subject to excessive wear, leading to:

Inconsistent pressure control
Inability to maintain critical process temperatures
Frequent and problematic safety valve lifts
Increased maintenance requirements and operational disruption

Multiple PRVs across the system were affected, indicating a systemic issue rather than isolated component failure.

How Did Valveforce Help?

The Solution

Valveforce engineered a complete redesign of the steam pressure control system to improve durability, stability, and overall performance.

At the core of the solution was the introduction of a centralised steam chest arrangement, where all downstream steam take-offs were supplied from a common header. This header was designed to handle the total combined steam load of the system.

To manage this demand, a single high-capacity control valve was installed:

Valve Type: ARCA ECOTROL cage-controlled globe valve
Trim: Hardened perforated cage
Seat: Stellited for enhanced wear resistance and longevity

This design significantly reduced the number of pressure-reducing points, eliminating the root cause of repeated valve failures.

Control & Automation

A modern pressure control loop was implemented to ensure precise and reliable operation:

Pressure Measurement: High-accuracy pressure transducer
Control System: Siemens HMI and micro-PLC
Communication Protocol: MODBUS TCP/IP integration with the site’s SCADA system
User Interface: HMI with a full system mimic for real-time monitoring and interrogation

System Design Features

The complete pressure control loop incorporated several key components to ensure reliability and maintainability:

Double block and bleed valve arrangements
High-performance butterfly isolation valves
Inline strainers for system protection
Effective condensate removal to maintain steam quality

The Result

The upgraded system delivered a step change in reliability and performance. By eliminating multiple failure points and introducing a robust, centralised control approach, the client achieved stable pressure control, improved temperature consistency, and a significant reduction in maintenance requirements.

Operational disruptions were minimised, and overall system safety was greatly enhanced.

Client Feedback

“Valveforce provided a practical and highly effective solution to a long-standing issue. Their engineering expertise and understanding of steam systems delivered a result that has improved both reliability and operational confidence across the site.” (Process Control Engineer)

Valveforce Are Here to Help

Whether your project requires fast turnaround, specialist valve selection, or technical support for complex applications, Valveforce has the expertise to deliver.

Get in touch with Valveforce to discuss your next Stream Pressure Control System Upgrade project and discover how we can support your success.