Latest News
UK Coal fired Power Plant ESP E&C replacements
One of the largest UK power stations recognised that the Precipitator control panels and associated feeder panels plus rapping panels were of such an age that it was no longer possible to continue to maintain the equipment due to obsolescence. The power station approached Castlet to design, build and install the complete package.
The upgrade equipment included a dual redundant 1200A incoming switchboard connected to a fixed pattern MCC. The MCC houses the feeders for 12 precipitator HT cubicles, the supply to three rapping MCC’s as well as associated small power feeders. The form rating for the total supply included Form 1, 3b and 4b
The HV Cubicles – custom built to the same original footprint, (avoiding replacing of the original imperial Aluminium power conductors) - together with the new controller MCSIII + Colour-touch HMI, was manufactured with an increased current capability above the original design to allow the option of installing larger TR units in the future. The panels were fitted with Castlet latest generation controller the MCSIII along with the new colour touch HMI.
The dual redundant 1200A incomer switchboards were supplied with a manual interlocked bus coupler. The original equipment had a considerable distance between the two sets of incoming cables and we had to design the switchboard layout to match with these dimensions. This meant a non standard type of layout, but it ensured that the feeder cables were of suitable length to be terminated without requiring to be extended.
The three rapper panel MCC units were considerably smaller than the existing equipment. However as they were moved closer to the incomer switchboard, all that was required was to shorten the feeder cables.
Castlet aiming to further upgrade facilities
Castlet is currently reviewing proposals to upgrade it facilities at No16 Crofton Drive. The new enhancements will provide improvements to the manufacturing area and an interactive product display and potentially additional office space.
UK Coal Fired Power plant LV MCC retrofits
A major UK power plant had been having problems with large motors as the MCC protection equipment, although regularly maintained, was not providing sufficient protection due to its age (40 years installed). Castlet together with support from the Siemens EFIE team (Castlet are a Siemens Solutions Partner), analysed the requirements and developed a scheme to refurbish and modernise the MCCs. By refurbishing rather than replacing, there was no major installation works or replacements of cabling. The ‘prototype’ starter compartment components, and door with its components, was removed and replaced with a designed and factory assembled gear tray and component chassis. This installation has been successful, and the aim is to assist the plant with retrofitting high risk or problematic starter circuits, in a pre-budgeted roll out program over the next few years.
Single licensee/agent for Brazil - Klaus Essen
Castlet have moved forward in the Brazilan market by selecting Klaus Essen as the single licensee/agent for the region, following many successful projects including new ESP power supply equipment and retrofits with the former Likstrom company. We consider this gives clear direction in this market and gives clients in Brazil the single point of contact to secure Castlet ESP TR Units and HV controllers
Electrochlorination Package High Current Power Supply
Castlet has completed a design and build project for a single electrochlorination package.The requirement was for the design of a unit to directly replace a 15 year old system installed on an offshore platform. There were several design limitations to meet which included the physical size, weight and electrical connection points. The enclosure contained a single water /air cooled transformer rectifier assemblies . The equipment was installed on an offshore platforms in the North Sea. The equipment was designed for installation in a hazardous zone 2 area, with an ambient of 40deg C. The unit was rated at 60V @ 1415A.
Castlet wins new contract for MoD to supply new equipments
Castlet has won a contract against stiff competition to produce a new type of equipment for the Armed Forces. Details of which cannot be released at this time. This equipment will be used to make safer operations for Army personnel.
Coal Fired power plant Korea
Castlet supplied the original MCS1 controllers for this power plant in the early 1990’s. The controllers have performed well over the past 20 years but it was agreed with the plant they needed to replace with the latest technology, to ensure future performance requirements are met, as 20 year old technology begins to fatigue. Castlet, together with our S Korean agent Dong Yang, secured the order with this end client
Coal fired power plant in Greece
Castlet supplied new TR Units and MCS1 controller for a new generating unit at a major coal fired power plant in Greece in 1994. After successful running for 17 years, we agreed with the client to upgrade a proportion of the controllers to the latest version, MCSIII, to ensure there were no operational problems in future years, as controllers begin to fatigue. The 1st two fields of each gas pass were retrofitted on site, totalling 16, including upgrades on the communication network. After we completed the installation our engineers optimised the system and noticeable improvements to the emissions achieved.
Castlet delivers new Digital Battery Capacity Tester
Castlet has designed and produced a new Digital, microprocessor controlled Battery Capacity Tester primarily used on Aircraft Batteries, direct for the UK MoD. These units have now been delivered in full and are already in use by the customer. Field trials were also completed at a local forces base, to ensure the design would meet the customer requirements in full.
Belgium Biomass Conversion
With a tendancy to migrate towards Biomass usage, Castlet were awarded the contract to provide new ESP TR Units and HV controllers for a plant converting from coal to firing 100% biomass using wood pellets. This 180MW plant is the largest conversion of its kind and Castlet controllers will be key to ensuring emission targets are achieved.
Electrochlorination packages Zone 1 Classification
Castlet has completed a design and build project for five electrochlorination packages. Each enclosure contained three independent water /air cooled transformer rectifier assemblies . The equipment was installed on various offshore platforms operated by an Indian Oil and Natural Gas company. The equipment was designed for installation in a hazardous zone 1 area, with an ambient of 55deg C. The units were typically rated at 90V @ 500A DC per section ( three sections per enclosure).
Diesel Engine Power plant
Castlet have concluded an order for a Diesel engine power plant in Costa Rica. With stringent emission regulations, it has become necessary to provide particulate collection via Electrostatic precipitators. To reduce civil construction costs, the project also included a 40’ containerised switchroom in place of a switchroom, containing all electrical and control equipment required for the turnkey electrical solution for the ESPs. This construction contained our HV power supply control panels, MCCs, PLC system, and SCADA. The TR units were situated on the ESP roof
Coal – Biomass Co-Firing
Castlet have recently completed a total power and control system for a co-firing facility at a major UK coal fired power station. As the plant was alongside the main facilities, the plant allowed a ‘wardrobe’ style MCC (Form 1) hence avoiding the expense of a traditional MCC. This equipment incorporated the PLC control system within the same enclosure.
Support Equipment for Norwegian Navy delivered on time in full
Castlet has recently delivered simulation equipments to the Prime Contractor for onward shipment to the Norwegian Navy. These equipments support the Sting Ray Torpedo for training and validation of the system infrastructure.
Saudi Arabia Refinery Catalytic Cracker
Castlet have completed an ESP turnkey E&C project for a new refinery in KSA. With it being a refinery, the requirement was to provide the solution to ATEX regulations, for Zone 2 Gas classification. The project included containerised switchrooms. This equipment was fully certified to ATEX standards, and included dual redundant ATEX air conditioning units, and a ATEX purge / pressurised system, maintaining positive air pressure for safety, including when personnel access doors open via a high power blower. The container included ESP HV Control panels, and Motor Control Centres. The TR units were situated on the ESP roof.
Castlet does it again! UKTI East Midlands IBA’s
Following on from last year’s success at the UK Trade and Invest East Midlands International Business Awards, where Castlet scooped the top prize; this year saw another accolade as a group of managers led by Mark Field, Castlet Ltd’s Sales Director, went up to the podium to collect the East Midlands World Wide Exporter of the Year Award on behalf of the Company. Once again this award recognises the outstanding partnership and dedication of all Castlet staff, both at the headquarters in Lincoln, and Shanghai Resistor Factory Limited, in China.
City Firm Set to Benefit from £370M MoD Deal
The following is an extract from an article which appeared in the Lincolnshire Echo on Wednesday 19 August 2009 “Castlet has been awarded a slice of a £370m pot to maintain and develop torpedoes for the Royal Navy and Royal Air Force. They are one of 19 contractors nationwide to be selected, and the 10 year programme of work will help sustain the current workforce. “It is brilliant news for the company” says Aerospace Engineering Manager Tom Cooney; “we are very pleased our bid to work on this project has been accepted. It will be a good feather in our cap as well as a very interesting thing to work on.” Under the new contract Castlet will be responsible for developing a training simulator used to test Sting Ray torpedoes. The guidance missile bombs are carried on Merlin helicopters and the RAF Waddington and RAF Kinloss based Nimrod aircraft. Crews will hook the kit on to the bottom of the aircraft to simulate dropping bombs so they can perfect the technique.
Castlet (India) pvt Ltd – Pune India
Castlet with its JV partner have completed registration with the plan to set up a manufacturing facility for Electrostatic Precipitator TR units and control panels, using state-of-the-art Castlet surface mount microprocessor controllers with key algorithms including Regupulse, (automatic prf for high resistivity coals and in built energy management). Castlet India’s aims is to be a leading supplier to both the power and industrial markets throughout India.
6 x 500MW Coal fired power plant Kazakhstan
Castlet were awarded a major multi-million GBP project for 6 x 500MW refurbishment of ESPs via a long term ESP customer. This included, per each of the 6 units, TR Units, HV Control panels and MCCS, integrated via ASTA rated busbars, PLCs, SCADA, UPS and remote I/O field boxes. The project is to be completed over a 5 year period and maximises the use of our specialist controls for high resistivity coals, to ensure maximum collection efficiency of the ESPs
Electrochrorination – On shore high current power supplies
Castlet has completed a design and build project for three Transformer Rectifiers units for the production of Hypochloride. The equipment was installed at an Electrochlorination plant in the UAE. The equipment was designed for installation in a safe area with an ambient of 55deg C and had an output of 160V @ 8000A DC
Castlet Limited - East Midlands International Business of the Year 2008.
Now in it’s third year, the UK Trade and Investment East Midlands International Business Awards took place at the Leicester Marriott Hotel on 27 November, 2008.The awards are to recognise and reward companies who have excelled and embraced the challenge of exporting; demonstrating the importance of internal trade for business growth and sustainability.Against very stiff competition, it was the unanimous decision of the judges that the top award of the night, namely East Midlands International Business of the Year 2008 be awarded to Castlet. We are extremely proud to have won this prestigious award which acknowledges the tremendous hard work, commitment, and team effort given by each and every member of our workforce.
Dong Yang Mundra India
Via one of our key licenscees, Castlet were awarded a major project for a new power plant in India, the largest single location privately owned power plant in the world, to generate 4,620MW. The project requires over 100 state of the art ESP HV controllers for large Electrostatic Precipitators. This order is significant, as the Indian power plant market, with its low sulphur, high ash coals, needs sophisticated control systems to ensure ESPs operate and collect within the national ESP emission limits. Castlet intend to increase market share in the Indian market by setting up a manufacturing facility in Pune
1st Major Ash Handling Control System – Petacalco Mexico
With major success in the electrostatic precipitator (ESP) power supply and controls market, Castlet has been making progress expanding into new areas. Ash Handling systems, predominantly in coal fired power plants, made good sense for Castlet as every ESP is connected to an Ash Handling system to remove the collected fly ash. Hence the end users are the same as for our existing customers. Castlet were awarded the Ash Handling control system in February 2008, by the OEM Clyde Bergemann Materials Handling, a company located in Doncaster, UK, who are also a world leader in their field. This equipment was successfully pre-commissioned in our works in May 2008, leading to another order from the same company for a power plant in Spain. Castlet will continue to evolve into this market and continued success is expected.
Major Upgrade to Larger New Clean Room Production Facility
A larger new 85m2 clean room was officially opened on the 4th April by Dennis Strydom MD, of Castlet South Africa Pty Ltd. The new clean room further extends the company’s facilities at the Lincoln site for the qualification, manufacture and test of electronics hardware being delivered to defense, aerospace and industrial markets. This will enable the Company to continue to deliver and to expand this business sector, manufacturing state of the art products from a quality purpose built facility
Battery Charger Analyser for Eurofighter Typhoon
Castlet has shipped the first batch of series production equipment for ground support on the Typhoon Aircraft. This is the Battery Charger Analyser (BCA), a complex design requirement having taken several years of development. These equipments are being supplied through BAe Systems for Tranche 1 and Tranche 2 Aircraft.
Shuaibah IWPP Saudi Arabia
A new order was completed, for Hamon Environmental in Belgium, (one of Castlets key customers), for the Shuaibah stage III IWPP 3 x 300MW crude oil fired power/water plant. Castlet shipped complete integrated purpose built transportable rooms, which were constructed from modified shipping containers. These containers included lighting, power, fire detection, interconnecting cables and air conditioning. Actual equipment supplied inside the containers included a sophisticated UPS, Distribution switchgear, Motor Control centres, and the key precipitator HV power supply cubicles, state of the art MCSII controls and computerised SCADA systems. The benefit for the end client is to receive pre-commissioned containerised equipment, thus reducing costly site installation, cabling and commissioning on site in Saudi Arabia
Remote network Laziska
At Laziska power plant in Poland, Castlet successfully installed a remote link via VPN to Castlet office, - for monitoring and trouble shooting, via a Castlet supplied Siemens PLC system connected to the ESP controllers. Castlet equipment is installed on all 4 units of the power plant, which were installed from the late 1990
NBC Ventilator Respirators for Eurofighter Typhoon
Update: Series production of the Ventilator Supply Package (VSP) for the Eurofighter Typhoon is scheduled to complete in 2012 for Tranche 1 & 2 Aircraft. Castlet have now been asked to support the Eurofighter programme until 2018.
Major Upgrade to Clean Room Facility Planned
In early 2006 a new 45m² clean room facility was created at the Crofton Drive site. This extended the company’s facilities for the qualification, manufacture and test of electronics hardware being delivered to defence, aerospace and industrial markets.
Castlet is to build on the success of this facility in 2007 by creating a new 80m² Clean Room Production and Test Facility within 400m² of newly acquired warehouse facilities on the Crofton Drive Site. This will enable the Company to continue to deliver its state of the art products from quality purpose built accommodation.
NBC Ventilator Respirators for Joint Strike Fighter F-35 Lightning II
Castlet was has been awarded a contract through Honeywell Life Support Systems for the design, prototype development and manufacture of flight equipment in support of the Lockheed Martin F-35 Lightning II (Joint Strike Fighter) aircraft. The equipment consists of sophisticated integrated high speed fan blowers with electronic speed control and supervisory systems to be used as part of the ventilation supply package to provide decontaminated air to the aircrew. These units benefit from Castlets proven track record in the design and manufacture of this type of equipment. Over the years Castlets engineering expertise in this area has provided similar units of which have supported platforms such as Jaguar, Harrier, Tornado and more recently, Typhoon.
Typhoon Eurofighter.
Castlet has shipped the first batch of series production equipment for the Ventilator Supply Package (VSP) on the Typhoon Aircraft. Around 500 of these flight-qualified equipments are being supplied through BAe Systems for Tranche 1 and Tranche 2 Aircraft, and the monthly delivery programme is scheduled to complete in 2012.
New Clean Room Production Facility
A new 45m2 clean room facility has now been installed and commissioned at the Crofton Drive site. This extends the Company’s facilities for the qualification, manufacture and test of electronics hardware being delivered to defence, aerospace and industrial markets.
