News

Enersol Flomar

Read more...

New website live!

Read more...

Thanks to Square Daisy

Read more...

SAACKE and Harveys Brewery

Read more...

Cochran Record Order Book 2013

Read more...

MCL Energy introduce hand writing recognition pen to service operations

Read more...

Fulton Boilers at the Heart of Domestic & General's Process

Read more...

Fulton electric boiler provides a cure for Prysmian Group

Read more...

MCL Energy appoint Jason Perry to General Manager

Read more...

MCL Energy seal the deal with world class adhesives manufacturer

Read more...

Enersol Flomar

Enersol Flomar has been successful in being awarded a 5 year care package at Smurfit Kappa Weston Super Mare. Enersol Flomar Win 5 Year Care Package at Smurfit Weston Super Mare

The package won, it is to look after the steam raising plant and all of the auxiliary systems and equipment within the boiler house.

The package also includes;

  • Testing of all steam traps, (boiler house and plant)
  • Identifying any energy efficiency improvements within the boiler house and plant
  • Providing quotations, with return of investments (ROI), on any of the above
  • Providing ‘Turnkey’ installations of any of the improvements.

After being awarded the contract, the first thing that Enersol Flomar did was to upgrade the two existing 15,000lb/hr. boilers in line with BG01 Arrangement 3 recommendations. Remote operation was removed and a local control panel to allow for boiler start up and an automatic system warm up valve have now been installed.

Our sister company, M&M Training then had to provide training to 20 of their engineers. This training was not only carried out at M&M in Fleckney, (Leicestershire), but also continued development training which was then carried out on site, this ensured that their engineers were competent in operating the boilers and systems with confidence rather than fear. 

Both boilers have now been through their annual inspection, and the burners, to ensure maximum efficiency, are checked every 3 months. Flomar also supply all boiler chemicals and these are closely monitored and kept within the correct set parameters.

The boilers, after the BG01 upgrade are now operating more smoothly, automatic side TDS and bottom blow down valves have been fitted to each boiler. Enersol Flomar have also fully surveyed the insulation on the plant and within the boiler house and are currently in the process of supplying and installing all of the necessary pipe insulation and valve and flange jackets.

Enersol Flomar have also conducted a full trap survey, the failed traps have been replaced.

The Managing Director of Enersol Flomar, Mr Paul Bough’s initial aims after winning the care package was;

To upgrade the boiler house to BG01 Recommendations

To maintain the boiler house and plant to a high level

To minimise down time and maintenance

To maximise the efficiency of the boiler house and plant

To get a better understanding of the sites efficiency and to check ROI on any of the work that has been approved, a steam meter was installed at the earliest opportunity. This has allowed a bench mark to be set, calculations were then carried out to analyse the steam to gas ratio, the amount of make-up water and chemicals used and the amount of condensate returned.

The improvements in efficiency and reliability can already be seen, however, Enersol Flomar’s main aim, is to raise Smurfit Kappa Weston Super Mare as high as possible within their group energy efficiency table, whilst providing a safe and reliable workplace. This in turn will help Enersol Flomar to win the next 5 year care package.

 

Permalink

New website live!

The CEA opened the tender for their new website in September 2012 and after a range of companies offered their services to complete the works, the successful contractor was named as Square Daisy, a small creative agency based in London.

The full project involved renewing the CEA branding, designing and building a future-proof website and creating a video to promote the benefits of membership to a wider audience and ensure that existing members were getting the most from their own membership.

The process involved creating a number of logo treatments and presenting them to a newly formed Sales and Marketing working group who were overseeing the project on behalf of the CEA.  The new logo, which now adorns all of our literature, was almost unanimously agreed upon by the wider council and was a very popular choice.  The branding element did not just include the logo, but also stationary, templates, brand guidelines and documents.  This is now being employed across the Association and is being very well received by all members, new and old!

The website process involved looking at what the website needed to offer our members in terms of information and updates and building it in such a way that made the user experience enjoyable and easy, and also to ensure that we gave a very professional image to the outside world. Through wireframes the structure of the site was agreed and the design phase began.  Once we were happy with the designs and functionality, the site was built and pushed live.

Whilst the site was being built, the video was being produced for upload which is what you will have seen on the home page.  We believe this can help people understand more clearly what the CEA does and how it can help, and by attracting more members we will have a stronger voice and achieve more together.  We encourage members to share the link to the new site amongst their networks and spread the word far and wide that the CEA is rejuvinated and ready for the next stage of its growth.

Permalink

Thanks to Square Daisy

Square Daisy were the successful agency who were contracted to work with the CEA to develop the brand, website and video and we would like to not only thank them for their work, but also to encourage other members to consider them for any similar work they may be considering.

Jovan Maric, Managing Director of Square Daisy said:

"Working with the CEA was a real pleasure.  Not only was the input and insight from David and Julie invaluable to the success of this project but the support and guidance from the wider membership, actively taking an interest from the outset as if it was their own business.  This always helps with a project like this to gather as much insight as possible and deliver the best results we can for the membership" 

Dave Kilpatrick, Director of the CEA said:

"It's been an eye opening experience to re-brand an organisation in the first year of being employed as Director, launch a new website and commission a video so the help and support that the Square Daisy team gave to us was vital.  I am very confident that we have laid the foundations for a long relationship with Square Daisy and hope that they become more integral to the work we do at the CEA"

For more information on Square Daisy visit www.squaredaisy.com

 

MAIN_SQD_LOGO.jpg

Permalink

SAACKE and Harveys Brewery

Harveys Brewery 

When your product, reputation and future prosperity depend on the quality of steam, then you make absolutely sure that you find the very best solution.  And that’s exactly what Harveys of Lewes did when they called on SAACKE to improve the operation of their boiler plant. 

Harveys Brewery in Lewes is the oldest brewery in Sussex, dating back to 1790. Its rich heritage is passionately carried through to the present day.  It brews using only local hops and barley, while it draws water from an artesian well 60ft below its site, known locally as Lewes Cathedral.

As with all breweries the use of steam is a vitally important process and the quality of the steam is imperative, the temperature of the hops being the key to the taste of the beer.

So when Harveys invested in a reconditioned boiler fitted with a pressure jet burner suitable for firing natural gas and diesel and encountered issues with the quality of steam and the frequency of burner firing, Richard Spiller, Chief Engineer, immediately turned to SAACKE for help 

The brewing process requires a large variation in steam demand, a case of all or nothing.  The small turndown of the burner on the new boiler meant that to maintain the boiler at its required level the burner would start and stop every few minutes which significantly reduced plant efficiency.  After spending some time studying the boiler, SAACKE recommended fitting a burner with a superior turndown, thus allowing the boiler to match the site’s steam demand.

The new burner uses a low pressure gas register for the main fuel, and Rotary Cup atomisation for the standby diesel fuel.  Alongside this SAACKE fitted a new control system; a combined burner management and air/fuel ratio controller, the SAACKE SCanView. 

Once commissioned, it was very clear right from the start that the change in burner was giving the Brewery greater boiler control, providing easier and more accurate boiler operation and yielding substantial fuel and energy savings.

With the burner operation now vastly improved, the hunt was on for ways to further improve the efficiency of the boiler plant.  SAACKE quickly identified the original Feed Water System as an area for improvement.

The original system was based on an on/off system with the feed water pump, much like the original burner, constantly stopping and starting.  This constant cycling of the Feed Water Pump introduced cooler water into the boiler and caused unnecessary wear on the pump motor. 

SAACKE’s challenge was to find a way to control the flow of water from the pump, delivering only the required water quantity into the boiler.  If they could achieve this, as well as matching the water added to the boiler steam demand, the wear and tear on the pump motor would be reduced and the energy use of the pump minimised.

The SAACKE solution was to fit the SCanView Boiler Water Control (BWC) module.  This expansion to the SCanView system allows control of the boiler feed water system through the 10.4” Touchscreen of the SCanView.

By installing the SCanView burner management control and Boiler Water Control in one control system, SAACKE helped Harveys save energy, improve control and increase efficiency.

Most critical of all, SAACKE helped Harveys to improve the safety of their boiler operating system by virtue of the unique SCanView Controller Safety Test System which is designed to assist the operator through the statutory boiler and burner tests.  Alarm logs, fault and event histories are available on the 10.4” touchscreen.

So lovers of Harveys’ Sussex Best Bitter, the Champion Best Bitter at the Great British Beer Festival for consecutive years, can rest assured that the winner of the many awards, including regular World Beer Award titles, will continue to produce wonderful ales, with just a little help from SAACKE.

 

 

 

                       

 

Permalink

Cochran Record Order Book 2013

images.jpeg

Record Order Book for Cochran Ltd

Cochran has had an excellent first half in 2013 and currently has a record order book. Orders for new boiler projects for 2013 are 70% higher than for 2012.  In order to keep up with current and forecast demand we have been actively recruiting new staff, both for the factory floor, field service team and engineering design support. 13 new staff have been recruited this year and in the summer 6 new apprentices will be added to the 14 we are currently training.

We are still seeing strong orders for turnkey projects from theUKwhilst our export markets remain strong. We have continued to have a strong export business with significant orders currently in the factory for projects in Russia,China,Bangladesh,Singaporeand Dubai and overall our order book is approximately £5m ahead of this time last year.

The order book reflects Cochran’s international presence and the capability to design, manufacture and supply a solution to any industrial boiler requirement. Our project engineering and service support team has enabled us to secure a number of large blue chip projects both in UKand overseas. The Annan factory renewed its ASME accreditation in June 2013. This, along with our Chinese and Russian government accreditation, not to mention Royal Warrant from HM The Queen enables Cochran to manufacture for most of the world.

Tom Ritchie, Managing Director, commented “2013 has, so far, exceeded our expectations. It is extremely satisfying to be in a position where we are creating skilled jobs in UK heavy engineering and training apprentices. We are very proud of the fact that apprentices now make up 10% of our workforce and, as someone who started my career as a Cochran apprentice, I fully appreciate the importance to the business of giving young people such opportunity. The record order book is a testament to the hard work and skills of the staff within our business”

 

Permalink

MCL Energy introduce hand writing recognition pen to service operations

The Introduction of Digital paperwork during the next 3-months should assist in the speedy transfer of paperwork both internally and to our Client base.

The system is based on laser technologies provided by Digital Field Solutions to transcribe engineering job sheets that once completed are transmitted via Bluetooth technology to the operations help desk for dispatch to clients for validation and record keeping.

The software also has built in hand writing recognition conversion. Initially the system will be piloted in summer with roll out across engineering personnel during autumn 2013.

For more details on our service solutions please call MCL Energy on 01623 741940 or visit www.mclenergy.co.uk

Permalink

Fulton Boilers at the Heart of Domestic & General's Process

Fulton Limited, a leading British manufacturer of steam, hot water and thermal fluid solutions, has supplied three dual-fuel-fired, skid-mounted boiler systems – a 30J and two 40J – to cavity wall insulation specialist Domestic & General Insulation (DGI) and its wholly-owned processing subsidiary Thermabead.

Formed in 1986, DGI is one of the largest insulation specialists in the UK and has, since 2005, been manufacturing its own cavity wall bead at its Worcester-based Thermabead facility, where the first Fulton skid-mounted steam boiler system – the 30J model - was installed.

With business growing rapidly thanks to government improvement grants for energy-saving home insulation and DGI winning support to promote the only programme able to offer a 20% more efficient carbon-saver bead, the company quickly expanded its installer and processing divisions and now has a manufacturing plant in Manchester (using the first of the 40J-based boiler systems), with a third facility – known as ‘Project X’ – currently in the planning stages. Steam from the Fulton boilers is at the heart of the operation, playing a critical role in the Thermabead production process which, without it, would simply stop. So, while specifying and installing a reliable boiler system was critical, the decision to use Fulton boilers was an easy one, as DGI’s Mark Aston explains: “I have dealt with a number of boiler manufacturers, and over the years have learned to trus tFulton implicitly. The combination of ‘second-to-none’ products and the Fulton service offering means there’s just no need to go anywhere else. Put simply, we can’t operate without Fulton!”

DGI is in the process of establishing a third production facility, which will feature the second 40J skid-mounted boiler system and, as well as a service contract plans to take advantage of Fulton’s recently introduced City & Guilds certified Operator Routines & Maintenance course, which will train its engineers on the boilers they will be operating on a day-to-day basis.

“Fulton has always reacted positively to any issues, even attending call-outs at weekends. The boiler systems are tremendously reliable, simple in operation and easy to understand.Fulton even offers our engineers training at the point of installation.” says Mark.

Much of DGI’s growth, and its success, has been attributed to the effectiveness of its surveying and the quality of the cavity wall product, which is unique and has been developed through a partnership between its processing subsidiary Thermabead, and BASF. Mark Aston says the result – the ‘Diamondbead’ polymeric insulation product – is the most advanced and efficient bead available and is acknowledged by many in the industry as the best. He says traditional polystyrene-based cavity wall products use round ‘tumble’ beads of different sizes that don’t properly interlock or provide enough air space, which is vital for insulation performance. Diamondbead is more uniform in its shape, which means it locks together to provide a better insulation value inside the cavity.

In its raw state, ‘Diamondbead’ looks like a grain of salt, so indirect steam from Fulton boilers is used to heat the polymeric bead to make it more malleable. Heat is also used to raise the temperature of the blowing agent (pentane gas), which forms polymer chains within the bead to make it ‘puff up’ (expand?) to the required densities.

In a typical week, 110 tonnes of the base polymeric beads are processed to produce approximately 103 tonnes of Diamondbead, the difference in weight being attributed to the loss of the pentane blowing agent. This volume is enough to insulate the cavity walls of up to 7,000 properties per week (a mix of housing association, local authority housing stock and private housing). Sixty percent of installations are carried out by DGI’s own installer network, with the additional 40% by the company’s customers.

The decision to specify skid-mounted systems for the Thermabead facilities was based on Fulton’s ability to respond to DGI extremely short lead-times and the need to move into each facility within a week! For this reason,Fulton’s specification and design also included flanged connections for the pipe work to enable the systems to be easily installed. In addition, the Series J boilers, which deliver proven reliability and performance, are built in Britain to BS2790 1992 Class 1 and are covered by a five-year warranty on the pressure vessel.

Dual-fuel boilers were specified initially as the gas supply at both Worcester and Manchester sites was insufficient. The problem is being addressed and Fulton is currently working to prepare the necessary pipe work. When the required gas supply is available, modulating burners will be retro-fitted to help reduce energy costs. However, even without modulating burners Fulton’s boilers are proving easy to control and linear in their steam output.

Fulton’s modulating burners feature a linkageless burner management system to operate two modulating actuators, one of which regulates the flow of gas; the other adjusts air flow to ensure optimum combustion across the boiler’s full firing range. To optimise combustion and output, each valve can be adjusted by as little as 0.1º. Thanks to the modulation burners the boiler is also more efficient, as a more consistent steam pressure is maintained.

Summarising for DGI, Mark Aston says: “A great deal of technology has been built into our Manchester and Project X facilities, making them the most advanced of their kind. In a very competitive market, this level of investment and the installation of Fulton boiler technology make us more efficient and ensures that our Diamondbead insulation sets new standards in the industry.”

For further information on its steam boiler ranges, call Fulton on 0117 972 3322 or email uk.sales.office@fulton.com

Permalink

Fulton electric boiler provides a cure for Prysmian Group

Bristol-based heat transfer specialist Fulton has supplied Prysmian Group’s Bishopstoke facility a skid-mounted electric boiler and ancillaries, steam from which is being used to cure the insulation applied to the company’s electric cables.

Commenting on the process, Prysmian’s Nicolas Chevaux explains that curing is used to strengthen and increase the heat resistance of the insulation. “Without the process, the insulation would have a lower temperature resistance and hence the cable would have a lower current rating.”

Following manufacture, batches of up to 16 drums are placed into a container where steam from Fulton’s EP100 Electropack boiler system is injected to start a curing process that can take up to twelve hours at 80°C.

The cable that uses this particular curing process is Prysmian’s 6491b low fire-hazard wiring cable – a BS7211 BASEC approved single-core conduit cable for wiring applications in buildings such as stadia, hospitals, cinemas/theatres, etc. Unlike PVC-based thermoplastic insulation found on standard 6491x cable, Prysmian’s 6491b cable uses a thermosetting low-smoke material that doesn’t generate dense acidic fumes when burnt.

Commenting on the reasons for specifying Fulton, Nicolas says that experience was the main consideration as the technology has proved itself in a Prysmian Group site in South Wales, which is using the same unit for a similar curing process.

He goes onto say that an electrically-heated boiler was specified as it can be applied as a point-of-use steam source without the need for a separate plant room typical associated with gas- or oil-fired systems. This option also makes the electric boiler system much quicker, easier and cheaper to install.

Fulton’s electric range combines traditional engineering in a number of versatile modern packages and the Electropack is the company’s seven-model range designed for steam loads between 29 and 160kg/h. It is fully packaged in an attractive modern case and all services are connected at the rear for easy installation.

The Electropack offers unrivalled flexibility and mobility in a compact unit that occupies minimal floor space. It is easily moved to provide point-of-use steam wherever required and the heating elements are individually switched to allow the boiler to respond quickly and efficiently to variable steam demands.

For further information on Fulton’s range of electric boilers, including the Electropack, call Fulton on 0117 972 3322, email uk.sales.office@fulton.com or visit www.fulton.co.uk

 

Permalink

MCL Energy appoint Jason Perry to General Manager

Leading independent technical energy management specialist MCL Energy recently appointed long standing senior manager Jason Perry to General Manager.

For the past ten years Jason has worked for the Company in business development and more recently as Sales Director which saw him drive the growth of the business primarily through the process and commercial customer base.

Jason will be responsible for the overall strategic development of the service proposition and day-to-day management.

For more details on our service solutions please call MCL Energy on 01623 741940 or visit www.mclenergy.co.uk

Permalink

MCL Energy seal the deal with world class adhesives manufacturer

MCL Energy has been successfully working with UK process sectors for over 30 years, providing customers with bespoke energy and technical solutions.

A recent project for Huntsman Advanced Materials UK, who is a leading global supplier of structural adhesives for joining composite materials comprises the Design, Build, Finance & Operate of a new boiler house with civil works, building, steam plant, reverse osmosis, plant provision of project capital and long term inclusive O&M support service. In the first six months full operation over 30% energy savings has been achieved.

Process service solutions include Contract Energy Management, Design, Build, Finance & Operate, Building Services, Utilities Services & Maintenance, and Energy and related plant installation. For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

Permalink

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.