The Mission: Keep both CHP units running consistently to avoid downtime on a busy Devon holiday site.
When you’re running a busy holiday site, you need systems that work as hard as you do. For Bourne Leisure, keeping their CHP (Combined Heat and Power) units running smoothly means guests can enjoy hot showers, warm lodges, and a stress-free break – all without worrying about what’s going on behind the scenes. But when their CHP system started playing up at a Devon holiday site, they gave us a call. Low water levels, inconsistent performance, and poor run times were all getting in the way, so we stepped in to sort it.
The Solution
Bourne Leisure were facing a double problem: Unit 1 had started to misbehave with inconsistent run times and unstable load, while Unit 2 was dealing with low water levels and a persistent leak. Together, these issues risked disrupting operations across the site. With holidaymakers on-site and no time for downtime, getting to the bottom of the faults (and fast) was a top priority.
Unit 1: Stabilising the Run Time
The first priority was Unit 1, which was struggling to maintain a steady run. It was hunting on and off load – a classic sign of a control issue – making it unreliable for sustained operation. Our engineers began with a full diagnostic sweep, ruling out common issues by checking gas pressures, load demands and engine performance. We also carried out a series of component swaps to isolate the problem.
After a deep dive into the system, we traced the fault to an incorrectly configured throttle PID (Proportional-Integral-Derivative). This control setting plays a critical role in balancing engine response to load changes. Once we recalibrated the PID to the correct parameters, the hunting stopped, the engine settled into a smooth run, and reliability was restored.
“Our engineers began with a full diagnostic sweep, ruling out common issues by checking gas pressures, load demands and engine performance.”
Unit 2: Fixing the Leak
With Unit 1 steady, attention turned to Unit 2, where a persistent drop in water levels was affecting system pressure and efficiency. A careful inspection of the pipework between the pump and the Plate Heat Exchanger (PHEX) revealed the issue – a perished sealing washer that had started to deteriorate, allowing coolant to escape.
We replaced the faulty washer with a dowty seal, offering a more durable and leak-proof solution. Once the leak was resolved, we topped up the coolant, tested the strength (reading -40 for resilience), and closely monitored the system to make sure pressure held and there were no signs of further loss.
Final Checks
To wrap up, we gave both units a full once-over. Valve clearances were checked and found to be within tolerance, and we took detailed readings across crankcase pressure, working gas pressure, and exhaust backpressure – all critical for understanding long-term health. With the throttle PID corrected and the coolant leak sealed, both CHP units were running at optimal efficiency. As always, we left the site tidy and the system ready to do its job. Job done, the right way.
Conclusion
Two faults, one thorough fix. By stabilising the engine load on Unit 1 and stopping the coolant leak in Unit 2, we made sure Bourne Leisure’s CHP system was back to running correctly, and ready to do its job without any more unexpected issues. Our no-nonsense approach and careful monitoring meant the park could carry on without worrying about power or performance. That’s what we’re here for.
