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Combustion Engineering Association

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SAACKE

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We're on Twitter!

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Enersol Flomar

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New website live!

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Thanks to Square Daisy

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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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The Five Levels of Manning

 

Fully manned

  • A competent boiler operator in the boilerhouse whilst the boilers are operating.

Local manning

  • A competent boiler operator on site whilst the boilers are operating.
  • Must be within earshot of alarms and able to attend within 7 minutes.

Unmanned (level 1)

  • A competent boiler operator must attend the boilers on a daily basis.
  • A trained person must be able to attend an alarm in the absence of a competent boiler operator to ensure that the boiler/boilers are shut down safely and be able to summon a competent boiler operator if required.

Unmanned (level 2)

  • Automation on the boilers must follow guidance and be such that the boilers shut themselves down safely in the event of an incident.
  • A competent boiler operator must attend the boilers on a daily basis.
  • The boilers must be monitored from a remote monitoring centre all the time the boilers are operating and who has the ability to summon a competent boiler operator in the event of failure.

Unmanned (level 3)

  • Automation on the boilers must follow guidance and be such that the boilers shut themselves down safely in the event of an incident.
  • A competent boiler operator must attend the boilers at least every 72 hours.
  • Increased monitoring must be incorporated and monitored from a remote monitoring centre all the time the boilers are operating and who has the ability to summon a competent boiler operator in the event of failure.
 
 
 
To download a PDF version click here.


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Combustion Engineering Association

 

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CEA Conference’s grow from strength to strength

Industrial Guidance PM5 and PSG2 have both been replaced for automatic boiler operation.

The Health and Safety Executive published a new guidance document INDG436 (Industrial Guidance 436), and the HSE in partnership with SAFed and the CEA have produced the supporting document BG01 to put the flesh on the bones, and help “Owners” and “Operators” of boiler plant understand what this new guidance means to them.

Since the launch of INDG436 and BG01 in October 2011 the CEA have held nine conferences around the United Kingdom in Warwick, Selby, Warrington, Belfast, Bristol, Hatfield, Perth, Sutton Coldfied and Crawley, with record numbers of delegates and Exhibitors attending at Sutton Coldfield and Crawley. We were also fortunate to have Ige Adebayo HSE speakers at several of these conferences, followed by David Bosworth Head of the Safety Unit speaking at Bristol, and Phil Strickland speaking at Crawley explaining the HSE view on the guidance and their expectations from it.

Due to the demand it is likely that there will be two more of these conferences early in 2014 with dates and venues still to be confirmed, should you wish to attend please contact us and we will put you on a list, so you receive the information when we send out further details.

 

David Kilpatrick

 

Director - CEA

 

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SAACKE

 

Carl Büttner Shipmanagement will be using innovative exhaust gas purification technology from SAACKE

Carl Büttner Shipmanagement GmbH & Co. KG in Bremen, specializing in the operation of oil and chemical tankers, has selected SAACKE GmbH for the implementation of an innovative exhaust gas purification system. Since October this year, the SAACKE LMB Scrubber will be installed in the four-year-old 140 meter long tanker MT Levana. Completion is scheduled for November 2013. The new plant will pay for itself after about 2 years. The increasingly demanding exhaust gas emissions standards for sea travel make the refitting mandatory for the tanker company. The scrubber is a more economical alternative to a fuel switchover. The unique characteristic of the SAACKE solution is the upstream soot separation, which avoids the usual production of sludge, which is difficult to process.

Starting 2015, fuel will be subject to limit values of 0.1 percent sulphur on the North Sea and theBaltic Sea. The limit will gradually be lowered across the globe down to 0.5 percent by 2020. The majority of ships currently in operation are driven by heavy oil with a high portion of sulphur. In addition, the fuel on board is also used to create warm water or steam. Both processes create exhaust gases that contain soot and sulphur oxides and are harmful to the environment. Refitting existing ships to run on alternative fuels is either impossible or extremely difficult, which is a sizeable problem. "In contrast, due to the compact design of the LMB Scrubber from SAACKE, most ships can be easily refitted and the system significantly undercuts the required limit values", explains Gerhard Heißenbüttel, Head of Maritime Competence Centre at SAACKE.

Soot separation using a dry process and 99 percent sulphur reduction

The SAACKE solution uses a patented ventilator unit, the so-called VentSep, as well as a desulfurizer and a special filter unit. By separating the soot using a dry process, 80 percent of the fine particles are separated. The majority of the soot produced – which is up to 200 kilograms per day – thus doesn’t make it into the spray nozzle filter and is therefore not mixed in with the sludge, but instead collected in a dry way and disposed of or processed on shore. 99 percent of the sulphur particles in the exhaust gas are filtered by a spray nozzle scrubber using an atomized water spray and a water cascade. There is now a 1-MW test plant for the scrubber at the Viktor Lenac shipyard inCroatiawhich can be used for crew training or viewed by interested clients after consultation with SAACKE.

SAACKE GmbH was founded in 1931 as CSÖ Carl SAACKE Ölfeuerungsgesellschaft mbH. The company introduced its first burner for marine use to the market in 1934. The company is now one of the leading specialists for combustion engineering and complete plant systems. Annual sales were in 2011 around EUR 184 million. The company employs about 1,100 staff worldwide, including 300 engineers. The head office inBremen is home to both the production facilities and the development centre.

Please contact us for further information and visual material:

 www.dialog-pr. www.saacke.com

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We're on Twitter!

Well we've finally taken the plunge and joined the world of social networking!  We have set up a Twitter page and would like for you guys to come and follow us so you can keep up to date with all of the news and events from the CEA.

As part of the new website we worked very closely with Square Daisy who helped us to understand new media in general and how we can utilise it to help our members stay in touch with what is going on.  We recongnise that everyone is busy and may not have time to check the CEA website every day (although we would really like you too!) so we need to find a way to make it easier to let you know about things that are going on that fits into your daily lives.  We've set up the Twitter account to push over information on new events, functions, news stories and resources so when something interests you, click on the link and have a look.  

Everything we do is for the benefit of our members and we think this is a great way to keep you informed in a way that suits you.  We'd love to get some feedback and as we're very new at this, any tips, hints or advice would be warmly welcomed....as we're sure some of you out there are Twitter experts and could help us a great deal!

Remember to follow us - our handle is @CombEngAss - and please, please retweet our posts if you think your followers would benefit from reading the content on the site!  You can also use Twitter to contact us, but as we say, we're new at this so if you need a prompt response...it may be safer to pick up the phone!

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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.

 

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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.

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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

 

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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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