News

Maxecon Boilers - NDT Inspection Issue

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Testimonial from Durham Conference

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The Vital Importance of Good Water Treatment for Steam Boilers/Generators and Systems

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BetteRSAfe Newsletter

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BIFCA Training Courses

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EMK - The first Dedicated Managers BOAS Training Course.

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MatchTech are looking for a BOAS Qualified Operator

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Zeeco Europe Ltd Searching for Technical Sales Manager

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CEA on Plant & Works Front Cover

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CEA featured in the Industrial Process News

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Maxecon Boilers - NDT Inspection Issue

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Please note that this is to let you know of an issue that has recently come to light. We don’t know the size of the installed population of this type of boiler so cannot judge this in any statistical sense.

NB. One of our members who run Maxecon Boilers has failed its NDT SBG01 examination.

Defects were found between the end plate and the furnace tubes, and on subsequent inspection a crack at the toe of the weld was found on the fillet weld of the end plate to shell. The crack starts at the 4 O’clock position and finishes at the 8 O’clock positions. In some places it is 10mm deep (the parent metal thickness is 20mm) and is a finger nail thickness crack.

According to an Insurance inspector, this is the 3rd Maxecon Boiler in three years that has failed the NDT in exactly the same way. All of these boilers were built in the early 70’s so have been in service for a significant length of time, often used as auxiliary boilers.

It was commented that it is good that this has been found now (2015), as it was not found at the last inspection in 2010. Their other Maxecon Boiler failed in 2010 with defects in the furnace tube. 

We would just like to make other owners of Maxecon Boilers aware of this possible problem and to specifically look for this at the next NDT inspection.

It is alway difficult to be sure where the crack originates from and how long it has been there, but the usual NDT on the shell to end plate would be 6 O’clock, 12 O’clock and 2 other position to a total of 20% of the total circumference.

The Furnace mouth is 100% checked every 5 years so the defect in this location had occurred after the previous NDT and within the last five years, this could be as a result of a more cyclic loading than previous boiler operations.

 

 

 

 16-07-2015                                                                                                                   End

 

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Testimonial from Durham Conference

I would like to thank the CEA for hosting such a useful conference on Boiler House Technical Risk Assessments. The 2 days provided exceptional input from industrial experts and allowed opportunity to practice the theory with delegates from similar backgrounds. The class of exhibitors was also a bonus as they provided a broad spectrum of products that can enhance boiler house safety/efficiency without a pushy sales pitch. The event has acted as a driver to raise awareness of the risks of boiler systems within our business and ensure compliance with aging assets.


Matthew Schofield

Utilities Engineer


Dr. Reddy's Laboratories Ltd

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The Vital Importance of Good Water Treatment for Steam Boilers/Generators and Systems

Does any of the following sound familiar to you?

Boiler tubes failed due to corrosion?
Steam generator coil failed due to corrosion?
Boiler or Steam Generator scaled/hotspot failure?
Feedwater pump seals failed/split?
Tube thinning leading to rupture?
Hotwell leaking?
Blocked or failed steam traps?
Steam header or condensate system leaking?
Blocked pipework and plant?
Loss of system efficiency?
Not enough available steam out to process?
Dirty loads or product taint/contamination?
Product “spotting”?
Paying unexpectedly for a hire boiler?

If they do...

It’s very likely then, that you have been unfortunate enough to have experienced poor water treatment and control, leading to poor waterside conditions and subsequently (very expensive) equipment failure and loss of production.
It’s also very likely that before you’ve experienced this unfortunate equipment failure, that your running costs have risen and your system efficiencies have dropped off.
This will have increased your normal running cost considerably.
Eventually you will suffer unplanned breakdowns/shutdowns that will be costing you significant amounts of money in both downtime and lost production.

So… let’s be absolutely clear

It’s comparatively rare for a steam boiler or generator to suffer a failure due to a manufacturing defect or similar.

However…

It is a well-known fact that in excess of 90% of all boiler failures are water treatment related and not mechanically related.
To be clear here, in order for a boiler or steam generator to undergo a water treatment related failure, the existing water treatment control program cannot have been suitable and sufficient to arrest all known failure mechanisms.
Hence water treatment and its control and interpretation is the single most important thing that you need to get right, when running any steam system.

The bottom line is...

If your water treatment application and control is not correct your boiler or steam generator will definitely fail at some point.
On the way to failure, it will have cost you a lot more to run your system.
There is also a requirement to log your test data/training records and service/inspection records.
vSteam®-The state of the art web based monitoring system for steam.

At Deep Water Blue Limited we don’t sell boilers, we don’t sell valves and we don’t sell boiler ancillaries.
We do sell high quality technical water treatment for steam systems.
Contact Mick Casey - 0870 460 2980.

 

Examples of failure mechanisms;

Pitting Corrosion Attack Due to Oxygen

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Pipe Blockage due to Precipitation and Deposition

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Scale Formation

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©Deep Water Blue Limited - all rights reserved.

By Mick Casey - Deep Water Blue Limited
Chartered Chemist/Chartered Scientist
Fellow of The Royal Society of Chemistry

Deep Water Blue Limited
Business & Technology Centre
Bessemer Drive, Stevenage
Herts SG1 2DX

http://www.deepwaterblue.co.uk/

Tel: 0870 460 2980
Fax: 0870 460 2988
Email: info@deepwaterblue.co.uk 

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BetteRSAfe Newsletter

The BetteRSAfe newsletter from RSA helps to keep up to date with health and safety issues, especially those related to our Engineering Inspection & Consultancy services.

In Issue 13 the CEA thought that the articles included would be of some interest to our members and colleagues.

To read the Newsletter click here or follow this link http://www.rsainspection.co.uk/News/pr-news-bettersafe-issue13.html

The titles included are:

Pressure System Failure Leads to the Largest Ever Corporate Manslaughter Fine
A South Yorkshire waste firm has been fined £500,000 after being found guilty of corporate manslaughter following an explosion in January 2011 which caused the death of a 42-year-old employee

Proposed Increase in Sentences for Health & Safety Offences
The Sentencing Council has published draft guidelines to assist sentencers dealing with corporate manslaughter, health & safety offences and food safety and hygiene offences.

HSE Publish Latest Annual Health and Safety Statistics
The HSE has published the latest annual statistics on work-related health and safety in Great Britain.

Newer PUWER!
The HSE has published a new version of its Approved Code of Practice (ACOP) and guidance on the Provision and Use of Work Equipment Regulations 1998 (also known as PUWER).

Updated Guidance on Pressure Systems
The HSE has also published an updated version of its ACOP and guidance on the Pressure Systems Safety Regulations 2000 (PSSR).

Firm Sentenced after Pressure System Fatality
A horticultural company has been fined after a 67-year-old worker died and three others were seriously injured in an explosion while emptying a pressurised tank used to heat greenhouses.

Veterinary Firm Punished for Fume Cupboard Failings
A Bedfordshire veterinary firm has been fined after workers were potentially exposed to harmful substances found in animal chemotherapy drugs prepared at the practice over a four year period.

Company to pay £125,000 following Crane Collision Death
An Oldham manufacturer has been ordered to pay £125,000 in fines and costs after an employee died when he was struck by a three-tonne piece of steel being lifted by an overhead crane.

Defective Dumper Truck Caused Worker’s Death
A 20-year-old man died on his first day at work for a new company when the four-tonne dumper he was driving toppled over a bank and crushed him. The HSE investigated the incident and prosecuted the company at Exeter Crown Court.

Man Killed on First Day at Work in Forklift Truck Accident
The worker, 29, was using a forklift truck at a glass recycling plant when it overturned and fatally crushed him.  

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BIFCA Training Courses

The British Industrial Furnace Constructors Association offer a range of courses designed to help companies educate and inform employees of the skills and knowledge needed to oversee the efficient running of furnace equipment and processes.

Furnace & Burner Controls:

This very popular BIFCA course offers an Introduction to the principles and application of Control Technologies, when applied to air flow, gas flow and ultimately temperature control. The course looks at the different types of control systems used, from the basic hand valve, through butterfly valves and ratio regulators to full PID Controls examining the selection and usage of appropriate controls to increase overall efficiency.

Burner Technology:

This is an ideal course for delegates new to the furnace industry or for those looking to update their knowledge. This popular course is an Introduction to the principles of combustion technology; it looks at maintaining plant efficiency and the latest developments in minimising combustion emissions, with the main focus on high temperature processes the course will cover a wide range of applications.

Introduction to Induction Hardening:

The course has been designed to provide professionals with an understanding of the basic principles of Induction heating and its application to the hardening of ferrous materials. Devised in association with industry experts, this course aims to support and offer guidance to all furnace users who are using or are considering using induction processes.

Industrial Furnace Technology:

This is a two day course and benefits from the academic knowledge and hands on industry experience of its two presenters. This is an ideal course if you have delegates who are new to the industry, or you want to update knowledge and enhance the skills of your workforce.

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For more information on BIFCA and these courses go to: www.bifca.org.uk

Or you can email BIFCA at: enquiry@bifca.org.uk

 

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EMK - The first Dedicated Managers BOAS Training Course.

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The first Dedicated Managers BOAS Training Course.

CEA approved training providers deliver pre-assessment training for the Boiler Operation Accreditation Scheme (BOAS) to a standard syllabus; Kiwa Gastec then carry out an independent assessment of the candidate and their test papers and CEA provide the certification and ID card for those that have achieved the required standard.

Many CEA members will know that the BOAS Working Group has been reshaping the BOAS offering which has been streamlined to meet industry’s needs.  Specific categories for the various types of boilers have been redefined along with the test papers that apply to each category:

Category 1. Hot Water Boilers.

Category 2. Shell Boilers (Steam).

Category 3. Water Tube Boilers.

BOAS was originally designed for the Operator to be trained and accredited, with the Manager accreditation being added at a later date.  Within the scheme there is now opportunity for both Operators and Managers to achieve the accreditation.  Managers who are responsible for overseeing the running of boilers, but who don’t actually do the day to day hands on activities, need to know and understand more about the overall operation of the plant than the Operators do. There may be Environmental permits to implement, emission regulations to understand and implement, insurance inspections to organise, repairs and maintenance, Written Schemes of Examination, Risk assessments and PSSR (Pressure Systems Safety Regulation) etc. to manage along with all the other day to day tasks of the Manager.

Mike Cogan, Head of Engineering Training at EMK, (Educational and Environmental Services Ltd) became concerned that Managers who had been trained with operators as part of the same course may not get the opportunity to gain as much knowledge and advice as they otherwise might; there is much more the Manager needs to know about boilerhouse management processes than can be covered during a standard course.

In developing an approach to a dedicated BOAS Managers Course after a few telephone conversations and some brief discussions at assessments, both Mike and assessor David Graham got together for a one-day workshop. They were able to thrash out what was needed to give these very vulnerable Managers what they needed to help them with their responsibilities when managing boiler plant.

EMK held their first dedicated Managers BOAS training course in January 2015.  Though the full CEA BOAS syllabus was covered, Mike has added a lot more pertinent information to his training course dedicated to training boiler house Managers.

During previous courses Mike had discussed the Manager issue with David as well as with other BOAS assessors.  David had commented that many of the newer Manager candidates he assessed found it difficult to assimilate, in detail, all aspects their job.  When involved in pressure plant such as boilers there is a great deal to know.  David said “It soon becomes evident during the Manager Interview that when going over their paper work submitted as evidence you can find numerous anomalies and so many areas that need to be addressed”. He continued “examining Standard Operating Procedures (SOPs), for example, has proved to be beneficial; just reading them tells you they do not work, and that’s without going into the individual person’s boilerhouse.  BOAS is only part of the training they require but it has a great opportunity to help improve Managers’ knowledge and understanding. It must be designed to give the Managers exactly what they need: Knowledge and Understanding of the Processes”.  Which is why this bespoke course is now a part of the BOAS product range for EMK.

 

Feedback from the candidates both during and after the dedicated management course indicated that there were two different stages in the training.  The trainees were mostly experienced Managers and were particularly keen to improve their technical and operational knowledge of the boilerhouse, so that they could more effectively oversee and manage the running of the plant.  They were quite open about their lack of nuts, bolts and valves knowledge and clearly enjoyed learning this part of the BOAS syllabus and said so.

Throughout Mike’s many years of delivering boilerhouse training courses to groups of Operators, their Managers have often taken part.  Mike had never attempted to train the Manager to manage his boilerhouse but the Manager’s presence always helped make for a successful course; there are many good reasons for this.

He gets to carry out a first-hand quality control job on the training he is paying for and he can make sure he gets value for money.

  • His presence ensures his Operators take the course that much more seriously.
  • He experiences an unusual, almost informal forum with his Operators, which is to the Manager’s benefit.
  • The Manager is able to give valuable input due to his knowledge and experience.
  • And finally, he really enjoys the course for its technical and operational content; he re-learns a lot of useful old lessons and goes over a lot of material which he finds tremendously interesting.

One disadvantage is that because the Manager enjoyed the Operator course he felt that it was a benefit to him.  In some ways it was, but did it benefit him in those managerial aspects where he might be vulnerable and need more relevant and more focused training?

The BOAS Manager delegate often thinks he has been trained fully in boilerhouse management but he has only got a part of the overall puzzle.  It has been said by Manager Candidates: “We don’t know what we don’t know”.

As this bespoke course progressed it became very clear that the candidates were not doing their jobs correctly and they knew it. A part of the management section of the course was to review operating procedures as a group activity. The activity took on a life of its own and the group members burst into furious activity and actually wrote up several procedures which were in need of review together with the necessary risk assessments.  On Thursday morning the atmosphere was almost euphoric; the candidates were on a high.  They were actually learning something very important.  They also undertook a very critical review of their management systems in general.  In short Mike said “they got stuck into their job during the course once they learned what it was”. One trainee’s comment was “This has really opened my eyes”. David commented after his assessment of the trainees that “They tore their own management systems apart”.

This was the first dedicated management course delivered by EMK. There is clearly much to be done in developing the course to deliver that which the Managers need to protect their Operators, their plant, the public and themselves.  Mike and David are currently working on developing materials and training strategies which will meet the management trainees’ overall requirements.

Mike put the following question to the CEA BOAS Working Group:

“Should the current BOAS syllabus be modified to produce a special syllabus for Managers?”  Mike’s view is: probably but not just yet.  Many Managers still need to learn about nuts, bolts and valves up to a point, and also the technical essentials of the boilerhouse procedures.  The existing BOAS syllabus does this quite well.  The syllabus also mentions all the important aspects of boiler plant management; the core of the issue is: does boiler plant management need to be taught as a special case scenario?

For now Mike feels we need to deliver more dedicated BOAS Managers’ courses and obtain more feedback and experience to help create a more bespoke Managers course. As mentioned earlier, BOAS is only a part of that puzzle. “We don’t know what we don’t know”. 

David would like to see a more advanced course for Managers only, many of whom would enjoy the challenge and have already put their names forward, but it has to test them to the maximum in responding to questions from the Judge if the worst happens.

When the Judge says “Can you demonstrate what actions you have taken to have prevented this?”  a Manager could be asked: Under the PSSR 2000 Regulation 11 Operation (1) (b) did you provide adequate and suitable instructions for the action to be taken in the event of ANY emergency!!  It’s very open but still needs to be identified and dealt with.  David has seen some great attempts from major companies in addressing this issue and even they realise they may not have covered everything but at least they made a good attempt at addressing it.

David Kilpatrick Director of the CEA  thanked Mike and David for taking this action from a previous BOAS working group meeting, creating this very comprehensive look at the need for bespoke boilerhouse Managers training.  This has clearly been a great success.

Should anybody reading this article feel they would like to take a closer look at this training please contact David Kilpatrick directly.

Tel CEA on 01740 625538

or email Info@cea.org.uk

 

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MatchTech are looking for a BOAS Qualified Operator

Matchtech.jpgare looking for a BOAS Qualified Operator

Job Description:

  • Work on manually operated steam boiler
  • 1-2 months work, possibility of a contract extension
  • Based in Dartford
  • Rate £250 Ltd, per day
  • Shift Work, likely to be 12 hour shifts, TBC

For more information please contact:

Steve Carter

Contract Consultant

Water & Environment

t: 01489 898215
f: 01489 898290
e: steve.carter@matchtech.com

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Zeeco Europe Ltd Searching for Technical Sales Manager

PRESS RELEASE

March 27, 2015

Zeeco Europe Ltd Now Searching for

Technical Sales Manager

Zeeco, the world leader in advanced combustion and environmental systems, has announced it is actively recruiting for a Technical Sales Manager to join Zeeco Europe in the company’s Power Burner Department. Zeeco, whose product lines include ultra-low NOx burners, flaring systems, incinerators, flare gas recovery systems and vapour control systems, continues to report impressive growth as the world’s energy industries build and update existing plants to operate more energy efficiently. Zeeco Europe, based in Rutland, UK, has recently embarked upon a multi-million pound expansion of its facility and now operates an ISO 9001:2008 accredited manufacturing facility and research and testing facility. Do you want to be part of their success?

Responsibilities for the position include:

  • Implementing a sales strategy and driving it to successful completion
  • Meeting and delivering agreed targets through proactive new business development
  • Growing the existing customer base
  • Establishing and executing a budget and technical marketing strategy that focuses on the oil and gas and petrochemical industries
  • Analysing enquiries and optimising offers in coordination with Applications Managers
  • Building relationships with suppliers and service groups to assist our customers and grow business through strategic partnerships
  • Ensuring Zeeco is on the vendor’s list for all Zeeco products
  • Maintaining and improving the Zeeco Quality System whilst adhering to ISO 9001:2008 requirements

The ideal candidate will possess the following:

  • A degree in engineering
  • Proven technical selling and business development experience
  • International and European sales experience and must enjoy regular international travel
  • Strong plant experience
  • Good interpersonal skills, strong organisation, detail orientated

For more information on career opportunities within Zeeco Europe, visit www.zeeco.com or contact Clare Scott, Resourcing Officer at hr_europe@zeeco.com

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CEA on Plant & Works Front Cover

The CEA has been featured on the front cover of Plant & Works Engineering Magazine in their March 2015 Edition, Issue no. 393. To view the entire magazine please click here.

This advertises our Technical Boilerhouse Risk Assessment Conference on 29th & 30th April 2015 at The Hallmark Hotel, Manchester.

We also have another Technical Boilerhouse Risk Assessment Conference being held at the Radisson Blu Hotel, Durham on 1st & 2nd July 2015.

Both conferences are ran over 2 days, with a practical workshop on the 2nd day. The CEA received lots of very positive feedback about the technical content and quality of the conference, from the first event ran in 2014 at Crawley, Gatwick. 

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Delegate_Booking_Form_-_Durham.pdf

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CEA featured in the Industrial Process News

The CEA is featuring in the Industrial Process News next week (March 23rd 2015), this is our article:

To book or view more information about our conferences and events please click here

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Request for Membership Details

Membership is available in several categories. Please fill in the form below and full details of membership and costs will be forwarded to you.