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Completed boiler replacement

Case study

LTI Metaltech, Milton Park

A twin-boiler installation designed to fit the plant room while the offices stayed open

Completed twin Vaillant commercial boiler cascade at LTI Metaltech, Milton Park

Commercial boiler replacement

Project brief

LTI Metaltech’s facilities manager approached the Oxyplumb Commercial team directly to replace the existing floor-standing boilers and flue at the company’s Milton Park premises.

Designed around the plant room

Space constraints ruled out a standard arrangement. The Oxyplumb Commercial team built a custom cascade frame for two Vaillant ecoTEC Plus 64 kW commercial boilers.

  • Reverse-return configuration for optimum performance.
  • Plate heat exchanger for hydraulic separation from the existing heating system.
  • Cascaded flue routed through the existing flue opening, avoiding new roof work or a new roof penetration.

Installation and commissioning

The team completed the necessary wiring alterations. The existing heating system was flushed and dosed with inhibitor before the completed installation was fully tested.

Live office coordination

The offices remained operational throughout. The Oxyplumb Commercial team worked around LTI Metaltech’s schedule, kept work areas clean and tidy, and maintained safe access routes.

Completed result

The finished installation is a compact, purpose-built cascade combining two 64 kW Vaillant boilers, the custom support frame, reverse-return pipework, hydraulic separation and the cascaded flue through the existing opening.

Project photographs

Before

Existing floor-standing boilers and their flues at LTI Metaltech before removal
The original floor-standing boilers and flue arrangement.

Installation and testing

Twin Vaillant commercial boilers on the custom cascade frame with the new flue under construction
Twin boilers on the custom frame with the cascaded flue taking shape.
Combustion analyser connected to the open Vaillant commercial boiler cascade during testing
Testing and commissioning the complete twin-boiler installation.

Completed views

Completed twin Vaillant ecoTEC Plus boiler cascade with shared flue at LTI Metaltech
Completed twin Vaillant cascade and shared flue within the constrained plant room.
Twin Vaillant ecoTEC Plus commercial boilers above the insulated reverse-return pipework
The two 64 kW boilers with the completed insulated reverse-return arrangement.
Completed insulated boiler connections, valves and supporting pipework at LTI Metaltech
Completed boiler connections and compact pipework beneath the cascade.

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