News

SAACKE and Harveys Brewery

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Cochran Record Order Book 2013

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MCL Energy introduce hand writing recognition pen to service operations

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

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Fulton electric boiler provides a cure for Prysmian Group

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MCL Energy appoint Jason Perry to General Manager

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MCL Energy seal the deal with world class adhesives manufacturer

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MCL Energy seal the deal with Akcros Chemicals

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MCL Energy 'linked' with New Energy Centre for World Class Adhesives Manufacturer

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Fulton's move to new Bristol-based facility

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Brexit and The Machinery Directive - 'Game of Change'

Warren Spiers, Managing Director at Spiers Engineering Safety, looks at the possible changes that may come, following our exit from the EU.

Synopsis: 

The machine safety industry should be watching the Brexit process with baited breath. Nobody truly knows what the outcome will be. In fact, all we know is that our relationship with the EU will never be the same again and in this 'game of change' nobody knows the outcomes for sure. The purpose of this article is to explore the changes that could occur to the Machinery Directive and the machinery safety industry. 

As a professional in machine safety and as a machine safety consultancy business owner responsible for the livelihood not just of my own family, but also of the families of our employees, I am keenly focussed on what contingencies I might want to put in place to protect us all from the effects of the Brexit process.

To read the full article click here.

Warren Spiers will be delivering a one-day machine safety workshop at Cannock on Tuesday 21st March 2017. 

To view all of Spiers  Engineering Safety conferences and workshops for 2017 please click here.

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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.

 

 

 

                       

 

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Cochran Record Order Book 2013

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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”

 

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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

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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

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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

 

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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

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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

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MCL Energy seal the deal with Akcros Chemicals

Technical energy management specialist MCL Energy was recently awarded a prestigious operation & maintenance boiler house contract by the leading global additives supplier Akcros Chemicals.

Akcros Chemicals is the leading chemical additive suppliers into the PVC and polymers industries and is expanding its range to cover a wider variety of additives in the coatings, rubber, silicones and sealants markets. Eccles represents the principle manufacturing and research site for their global operations.

The term contract comprises all routine maintenance and combustion support to maximise plant reliability and optimise cycle efficiencies to reduce gas consumption in the steam generation process. MCL Energy will monitor plant, back up for remote access, provide callout and service all the steam boiler plant and associated systems.

Ian Benbow, Site Engineering HSE Manager stated “We decided to award the term contract to MCL Energy based on MCL’s expertise in this specialist field, competitive cost base and capability to ensure our site receives reliable, economic steam supplies for our production process”

For more details on our industrial process portfolio and site energy services please contact Business Development on 01302 738000 or visit www.mclenergy.co.uk

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MCL Energy 'linked' with New Energy Centre for World Class Adhesives Manufacturer

Established Technical Energy Services Provider MCL Energy Was Awarded A Prestigious Long Term Contract To Design, Build, Finance And Operate A New Energy Centre For Leading Structural Adhesives Manufacturer Huntsman Advanced Materials (UK) Ltd.

Huntsman Advanced Materials is a leading global supplier of structural adhesives for joining composite materials with a primary global manufacturing and distribution site based at Duxford.

The installation includes project management, Construction Design and Management (CDM) regulations, natural gas site infrastructure, and steam and condensate connection.  The energy centre build incorporates civils, portal building, two 4000kg/hr steam boilers, a 1000kg skid mounted boiler and ancillary systems.

Following successful completion, the operation and support contract includes plant performance, efficiency guarantees, daily operation, planned preventative maintenance, 24/7 callout and remote plant monitoring.

Jason Perry, Sales Director said “We are looking forward to working together with Huntsman Advanced Materials and providing a first class Energy Centre. This long term solution enables Huntsman to move forward, assured that their new Energy Centre will provide efficient process steam for manufacturing.”

For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

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Fulton's move to new Bristol-based facility

Fulton's move to new Bristol-based facility will see pressure vessel manufacturing return to the UK

Heat transfer specialist Fulton Limited is moving to a new 43,000 sq. ft. Bristol-basedheadquarters on Monday, 3 June 2013.

The Fulton name has been synonymous with steam since 1949 when the company introduced the vertical tubeless steam boiler in the USA. The UK company, which was founded in Bristol in 1966, is now established as a leading manufacturer of thermal heat transfer systems for applications such as water heating, steam sterilisation and processing.

Announcing the move, managing director Paul Richards says: “The move to the new facility, also in Bristol, will help us manage current demand, and plan for the future. The increased space will also allow us to introduce the latest, state-of-the-art manufacturing processes and the technologies that will enable Fulton to create the energy saving systems of the future.

He goes onto say that, as a result of the move, the manufacture of larger boiler pressure vessels for UK and Export markets will return to Bristol from Fulton’s facilities in China.

The new UK headquarters, which creates a centre of excellence for the company’s heat transfer products, will provide comprehensive customer support, from applications advice and sales processing, through to delivery. Experienced teams are available to help with enquiries for the company’s range of thermal fluid, fuel-fired and electric steam boilers, hot water boilers and ancillary products.

The site will also accommodate a new training and seminar facility created to enable qualified staff to keep customers up-to-date with the latest products and applications; and host the company’s recently announced City & Guild certified training courses, which offer a mix of theoretical and practical operational assignments.

The new Fulton facility is located at 5 Fernhurst Road, Bristol, BS5 7FG. Telephone/fax numbers and email addresses are not affected by the move. 

For further information call Fulton on +44 (0)117 972 3322, email uk.sales.office@fulton.com.

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