CASE STUDY

Replacement of outdated gas meter for Innovia Films

Stark’s expertise and timely execution ensures smooth transition to modern high-pressure metering installation.

Innovia films logo

Background

Innovia Films is a global manufacturer and supplier of biaxially-oriented polypropylene (BOPP) films for speciality packaging, labelling, tobacco overwrap, security films and industrial products. The company’s UK headquarters, and manufacturing facility is based at a large site in Wigton, Cumbria.

The brief

Innovia approached Stark Works to replace an existing gas meter that was reaching the end of its asset life cycle. Demand for gas at its Wigton HQ is high, and the site required security of supply. The existing High Pressure (HP) gas meter installation on site did not adhere to modern IGEM gas standards. The business needed a new high-pressure metering installation in the most time-efficient manner, to prevent disruption to its manufacturing capabilities.

Innovia also requested integration of Stark’s data services on all its installations, to help the business reduce its energy usage and fulfil reporting requirements across all its gas and electricity meters.

gas pipes

5

deadline for main gas supply restoration

3

replacement duration

40

years. Existing gas meter lifespan

The project

Innovia appointed Stark Works after being impressed with the company’s extensive gas metering experience and all-in-one service offering – not only was Stark Works able to offer the engineering solutions required for the installation, it was able to provide ongoing energy data and analytics through Stark.

Initial discussions with the client revealed its current meter installation was over 40 years old and no longer complied with some of the current standards and regulations; it would need to be completely replaced. The existing asset had also suffered from the Joules-Thompson effect, a phenomenon which occurs when cutting gas pressure results in a temperature drop. In this case, the gas pressure regulator was reducing pressure from 19 bar to two bar, which had caused the temperature to drop dramatically, resulting in freezing around the regulators.
Stark Works proposed replacing the old metering installation with a new high pressure twin stream module, with a pre-heating element to mitigate the temperature drop and subsequent freezing and potential damage.

gas pipes on crane

As one of only around c.100 high pressure meter installations across the whole of the UK, the work was significant and complex, not least due to the nature of the site. An essential requirement of the client was that the work was carried out as efficiently as possible, to ensure minimal disruption to product manufacturing. Innovia operates bi-annual shutdowns to allow for any required maintenance work to be carried out at its site. Stark Works worked closely with the client to coordinate the exchange to take place during this period – ensuring the business did not lose any manufacturing time outside of what was already planned. For Stark Works, this meant it had just five days to restore the main gas supply.

Alongside the tight deadline, there were additional challenges posed by the nature of an HP meter installation. The meter module was 11m long (split into sections) and required a crane to lift into place. Due to the additional safety risks that come with this type of installation, the work had to be carried out in line with the Pressure Systems Safety Regulations and Stark Works’ competent body, DNV, also needed to be on site to oversee the main aspects of the project.

Subsequently, the project’s success relied on the planning, attention to detail and efficiency of the Stark Works team, who not only rose to the occasion but were able to beat their deadline, completing the replacement in just three days, to the delight of the client.

Client testimonials

Liam WalkerCHP and Site Services Supervisor, Innovia Films

This was a complex project, which required detailed planning and the work to be carried out efficiently to meet the required deadline. From the beginning, we were impressed with Stark Works' solutions to the challenges posed, and the level of experience and expertise within the team. The service we received was exceptional, and meant the work was delivered well ahead of the required timeframe, ensuring we didn’t incur any delays restarting our plant.

Kirstin McEvoySustainability & Corporate Social Values Manager

Just by measuring and viewing data on Stark you automatically see how to improve. Look at the data as often as possible. The more detail you look at, the better.

Kirstin McEvoySustainability & Corporate Social Values Manager

The more people involved on the ground, engaged and implementing energy best practices the better.

Ian RentonManaging Director of The Jockey Club West Region

With increasing energy costs, the focus on data and monitoring is more important than ever. We know this, so implementing KPIs around effective best practice, with sites recognised for their efforts, is a priority. We need Stark to achieve this.

Stark can help you with replacing your gas meter and optimising your energy usage too. Call us on 01293 776 747 or drop up a message by completing our contact form.