The Mission: Carry out a full service on a CHP unit for Bourne Leisure, resolving a pipe leak and replacing worn components to keep the system running safely.
For a busy holiday site, power systems must perform reliably at all times, particularly during periods of peak demand. For Bourne Leisure, making sure their CHP unit was in full operating order was key to keeping the park running smoothly, especially heading into peak season. That’s where Canning came in, to give the unit a good look over and inspection and correct some remedial issues before they caused bigger problems.
The Solution
Our engineers were called in to tackle a few concerns around the CHP unit’s performance – most notably a leak from a condensate pipe on the flue. This was causing products of combustion (POC) to seep into the plant room, which presented a significant safety concern. On top of that, the unit was due a 40-hour service, and Bourne Leisure wanted to make sure everything was operating to specification.
Full Service
Our engineers commenced with a scheduled 40-hour service on the CHP unit. That meant replacing all the key components to keep the engine in top condition, including the oil filter, fine oil filter, spark plugs, sump oil, HT connectors, air filter, and rocker cover gasket. These checks aren’t just routine, they’re vital for performance and efficiency.
During the service, the team also identified a critical issue: a leaking condensate pipe on the flue was causing POC (products of combustion) to creep into the plant room. This required immediate rectification to maintain safety and compliance. We made it a priority to deal with it during the job, making the whole area safer.
“To stop the leak at the source, we capped off the additional condensate pipe, eliminating the risk of combustion residue escaping into the room.”
Fixing the Flute
To stop the leak at the source, we capped off the additional condensate pipe, eliminating the risk of combustion residue escaping into the room. Once resolved, we moved onto more detailed checks. We examined the valve clearances, which didn’t need adjustment – a good sign that the unit had been running as expected.
From there, we recorded a series of readings including crankcase pressure, working gas pressure, and exhaust backpressure. These figures give a clear view of how the CHP unit is performing, making sure everything is operating within the right range and flagging anything that might cause issues later.
Peace of Mind
Each project is only complete once the site has been fully cleaned and reinstated. We gave the bund a full wipe-out and left the plant room returned to its original condition, with the CHP system restored to improved performance.
By the time we signed out and closed off the job, the unit was back to running reliably and efficiently, with no leaks, no outstanding issues, and a full operational clearance. Bourne Leisure now have a power setup they can depend on, prepared to meet the demands of the busy season.
Conclusion
Bourne Leisure now have a CHP unit that’s performing exactly as it should be – clean, serviced, and reliable. The flue issue was fully resolved, and thanks to the thorough checks and servicing, the unit is set for a long, trouble-free run.
This outcome reflects our core expertise: maintaining system reliability, addressing issues proactively, and providing clients with confidence in their power resilience.
