Control System for Military-Grade Heat Exchanger System

When Caltherm, a supplier to the UK’s defence sector, needed a control system for a high-security military facility, they turned to T-T for a solution they could trust. The facility in question stores and assembles jet-fighter defence flares—an environment where precision, reliability, and full compliance aren’t just desirable, they’re essential.

T-T was commissioned to design and build a bespoke control system. The system involved the integration of four water dosing pumps, four discharge lines, and four fan heaters, all working together to maintain a constant temperature across four specialised rooms. T-T undertook full assembly of pipework, wiring of pumps and instrumentation, and construction of the control panel on a skid unit, culminating in a factory acceptance test (FAT) witnessed by the client and their engineering team.

The Challenge

As a new client to T-T, Caltherm approached us following a recommendation from an experienced freelance design engineer familiar with our technical competence and commitment to compliance. Previously, the client had procured similar systems elsewhere, but those lacked both build quality and the technical documentation necessary for critical military applications.

The challenge was not only to deliver a robust, compliant, and fully traceable system, but also to instil confidence in a first-time client responsible for equipment supporting national defence infrastructure.

Our Solution

We hosted Caltherm’s Managing Director at our production facility, giving him a detailed walkthrough of our assembly capabilities, quality standards, and handling procedures. He observed firsthand:

• Our ISO 9001:2015 accredited Quality Management System
• Full traceability in build procedures
• Crimp and tooling trace logs with calibration certificates
• Stringent in-house test procedures
• Comprehensive build documentation, including Declaration of Conformity

Additionally, our engineering team conducted a site visit to better understand the client's broader operational needs and how T-T could support future projects, such as multi-stage booster pump sets and additional custom control panel builds.

What We Delivered

• Custom Control Panel Manufacture
  A fully integrated PLC system with ATEX-rated components, emergency stop and safety circuits, thyristor-based temperature control, and advanced monitoring and logging features.
• Mechanical & Electrical Integration
  We handled complete on-site pipework fabrication, assembly to comply with the client‘s drawing, which was finished with a full pressure test and a coat of Hi-Temp paint, pump wiring, instrumentation setup, and loop testing. Everything was built onto a skid frame to ensure straightforward installation at the client’s facility.
• Factory Acceptance Test (FAT)
  The system underwent full simulation and live testing in the presence of Caltherm’s engineering team, benchmarked against a comprehensive technical and compliance checklist.

Compliance & Standards

Every aspect of the system was built to meet stringent regulatory and quality standards. We ensured full compliance with BS EN ISO 9001:2015 (Quality Management), the Electrical Equipment (Safety) Regulations 2016 / Low Voltage Directive 2014/35/EU, and the Electromagnetic Compatibility Regulations 2016 / EMC Directive 2014/30/EU. This gave Caltherm the confidence and assurance they needed to support their work in critical defence applications.

If you have high-stakes applications that demand precision, compliance, and proven performance, get in touch with T-T today on 01630 647200 or email response@ttpumps.com to see how our bespoke engineering solutions can support your next project.