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Industrial Heating System Modernization

Complete rehabilitation of the heat distribution infrastructure for an industrial platform in Baia Mare.

Technical Challenge

The existing heating system, over 25 years old, presented major thermal losses (estimated at 22%), inconsistent network pressure, and frequent failure points that affected the continuity of production processes.

  • Reduce thermal energy losses below 8%.
  • Ensure stable pressure in all network branches.
  • Integrate a centralized monitoring and control system.
  • Maintain heat supply to production units during the works.

Approach and Design

We adopted a phased intervention strategy, based on a digital twin model of the existing network. The project was structured into three main engineering stages:

1

3D Diagnostics and Modeling

Laser scanning of all pipelines and critical nodes to create an accurate map of the physical state and insulation.

2

Hydraulic and Thermal Simulation

CFD analysis to optimize pipe diameters, pump positioning, and balancing valves.

3

Detailed Executive Design

Development of assembly plans, material lists, and switching procedures for each sub-network.

Implementation and Results

The works were executed on an aggressive 9-month schedule, using high-efficiency equipment and preformed calcium silicate insulation.

Final Performance Indicators

7.2%
Thermal losses
1420 m
New pipelines
24/7
Monitoring
18%
Energy savings

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