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Allied Bakeries Case Study - INSTALLATION PROJECTS

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Allied Bakeries Case Study - ENERGY & TECHNICAL

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Allied Bakeries Case Study - OPERATION & MAINTENANCE

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The safe operation of boilers - who's responsible?

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Optimizing Energy Usage in Multi-Fuel Boilers

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A First Step in Reducing Power and Utility Costs and Emissions

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Solutions to complex Burner Management System (BMS) applications

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How to avoid energy over consumption in your manufacturing process

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The Lord Ezra Award

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What is going on inside a Steam and Condensate System?

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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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Allied Bakeries Case Study - INSTALLATION PROJECTS

Installation Objectives

  • Guaranteed Energy Savings
  • Low Carbon Footprint
  • Reliable Steam Supplies

Installation Benefits

  • Realise lower emissions and energy cost savings
  • Realise economic project capital payback
  • Plant configured steam load for maximum efficiency
  • Long term site plant reliability
  • Access Project teams with proven track records
  • Explore project feasibility options such as biomass

Renolit Cramlington, a leading decorative surfacing materials manufacturer commissioned MCL Energy to Design, Build, & Operate their new boiler house.

The Energy Centre installation comprises two new steam boilers with integral economisers, chimney stack & associated works and site gas infrastructure.

The operation and support contract includes boiler operation, planned preventative maintenance, warranty and 24-hour emergency callout.

Renolit benefit from improved steam supply reliability, better plant efficiencies and good capital payback terms.

Recent installation clients include Huntsman Advanced Materials with energy savings of 30.5% or 1998 MWh in the first six months full operations.

 If you need to improve plant performance and reduce carbon footprint please email Business Development enquiry@mclenergy.co.uk or visit www.mclenergy.co.uk

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Allied Bakeries Case Study - ENERGY & TECHNICAL

ENERGY & TECHNICAL OBJECTIVES

  • Guaranteed Energy Savings
  • Low Carbon Footprint
  • High Efficiency Steam Supplies
  • Capital Provision To Fund Project

ENERGY & TECHNICAL BENEFITS  

  • Realise lower emissions and energy cost savings
  • Access project capital amortised over contract term
  • Guaranteed fixed costs for the next decade
  • Plant configured steam load for maximum efficiency
  • Long term site plant reliability
  • Access to free technical advice

Huntsman Advanced Materials (UK), a leading global supplier of structural adhesives for joining composite materials commissioned MCL Energy to Design, Build, Finance & Operate their new boiler house.

The Energy Centre installation includes project management, Construction Design & Management (CDM) regulations, natural gas site infrastructure, steam and condensate connection, civil works, building, steam plant, reverse osmosis and plant project capital.

Following successful completion an operation and support contract was awarded comprising plant performance, daily operation, planned preventative maintenance, emergency callout and remote plant monitoring.

Huntsman Advanced Materials has realised 30.5% energy savings or 1998 MWh in the first six months full operation. Recent Energy & Technical clients include Renolit Cramlington & SCA Hygiene Products.

If you need to improve plant performance and reduce carbon footprint please email Business Development enquiry@mclenergy.co.uk or visit www.mclenergy.co.uk

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Allied Bakeries Case Study - OPERATION & MAINTENANCE

Service Objectives

  • Competitive & Value-For-Money
  • Accurately Budget Maintenance Costs
  • Reduce Running Costs

Service Benefits

  • Accurately budget energy and heating plant costs
  • Optimise maintenance regimes and plant life cycle
  • Prevention focus to minimise reactive maintenance
  • Flexible service agreements to suit business needs
  • Access multi skilled engineering team

A leading UK manufacturer Allied Bakeries commissioned MCL Energy to Operate & Maintain their Stevenage site. Allied Bakeries produce the Kingsmill™ bread, one of the UK’s Top 10 grocery brands. Sub-brands Great Everyday White, 50/50, Tasty Wholemeal and Crusts Away are all manufactured at the site.

A flexible service approach enables Allied Bakeries to outsource specific energy and heating plant activities through the Service Level Agreement (SLA). The operation and maintenance comprises daily maintenance, combustion support, planned preventative maintenance, ad hoc asset replacement, water treatment and 24/7 inclusive callout.

Other Operation & Maintenance clients include Arriva Group, Dunlop Oil & Marine, Ribble Packaging, SAICA Packaging, SCA Hygiene Products and Synthomer Chemicals.

If you need to make energy cost savings, improve plant performance and budget accurately please email Business Development enquiry@mclenergy.co.uk or visit www.mclenergy.co.uk

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The safe operation of boilers - who's responsible?

Recently, our Chairman - Derry Carr - has had an article published in Plant & Works Engineering Magazine:

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If you are reading this, then the likelihood is you're an engineer with responsibility of the boiler plant in your organisation. Now that could be a factory, a hospital, a chemical plant, a prison or in fact anywhere with a boiler.

So, is the boiler plant your responsibility? Yes; you say, it is my responsibility.

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The fact is, the over-riding responsibility for the safe operation of the boilers within your organisation sits with the head of your organisation. It may be the MD or the CEO or some other such title but for this exercise we will call him/her the MD. The chances are, they're not from an engineering background and possibly don't even know where the boilerhouse is, but they cannot get away from it, in law, they are responsible.

So what are their responsibilities?

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Optimizing Energy Usage in Multi-Fuel Boilers

Steam is a critical part of many process manufacturing processes and the energy to produce it can be a significant source of operational costs. Jim Cahill recently caught up with process automation hall-of-fame member Greg McMillan and Emerson’s Scott Pettigrew at the Emerson Exchange conference in Austin.

Read full article here

Greg and Stan Weiner had recently interviewed Scott in a ControlGlobal.com article, Boilers as fast as can be.

controlglobal-boiler-responTo highlight just a sampling of their wisdom shared with the readers; read the entire article. Greg opened noting:

Steam header pressure controllers can be properly tuned for fast response, and use feedforward signals and half decouplers to minimize disruptions in a header and between headers from large changes in steam usage and generation by production units.

He asked Scott about ways to minimise purchased fuel usage on multi-fuel boilers. Scott explained:

We can use boilers running on waste fuel to take all the swings in the plant steam demand within minutes. The starting point is good flow measurements and computations on a mass flow basis.

Coriolis flowmeters are great in terms of providing the most accurate mass flow measurement with the greatest rangeability, as well as density measurement with incredible precision. However, for solid fuels, very large lines or other applications where Coriolis flowmeters are not practical, strategies can provide the missing information as long as the flow measurements are relatively repeatable.

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A First Step in Reducing Power and Utility Costs and Emissions

Industrial power and utility operations are amongst the biggest users of fuel, and greatest generators of emissions. With escalating fuel costs and challenging environmental regulations, it is important that these facilities operate at their best.

Efficiency must be maximised across the entire operation, waste and low-cost fuels need to be leveraged to the highest degree possible, and the electric tie-line must be managed, all while being responsive to changing demands for steam and other utilities. 

Industrial boilers represent the largest single source of energy transformation in an industrial utility. For facilities generating steam and electricity for subsequent use on-site, the effective operation and control of fired equipment plays a major role in tackling energy efficiency. 

Read full article here

A First Step in Reducing Power and Utility Costs and Emissions

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Solutions to complex Burner Management System (BMS) applications

Providing solutions to complex Burner Management System (BMS)applications requires a combination of process knowledge, regulatory awareness, robust components, and an intuitive interface all applied with industry experience to ensure that life, equipment, and revenue are well-protected.

A BMS is truly the last line of defense in preventing the catastrophic failure of a boiler, fired heater or other industrial heating systems involving the combustion of a fossil fuel. Safety is always the number one priority.

Industrial Energy processes involve large equipment and machinery, combustion, some hazardous materi­als, and other potentially dangerous aspects. Proper safety practices and procedures must always be in place and used. The end user must therefore be confi­dent that the BMS supplier has a firm understanding in several key areas.

Read full article here

Solutions to complex Burner Management System (BMS) applications

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How to avoid energy over consumption in your manufacturing process

When Manufacturers look at minimising operating costs it's no surprise that energy efficiency comes to mind. Plant equipment operators are often blind to losses that can and do occur on a real-time basis as they focus on the productivity demands of the business.

So how does a business keep on track of energy consumption and importantly energy over consumption that so many plants experience?

Read the full article here

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The Lord Ezra Award

About Lord Derek Ezra, MBE 

The Lord Derek Ezra had been associated with energy and combustion for over 60 years. For more than 20 years, The Combustion Engineering Association (CEA) were privileged to work with Lord Ezra, first as President of the CEA and latterly as Patron of the Association.

In mid-2015 he expressed his pleasure at hearing of the activity and progress within CEA and wished us all well for the future, sadly he passed away on the 22nd December 2015 at age 96.

 Lord Ezra was an Honorary Fellow of Magdalene College, Cambridge, and Liberal Democrat Life Peer having joined the Liberals in 1936. He worked in the UK coal industry for 35 years, the last 11 years as Chairman of the National Coal Board. During that time he was instrumental in the early forming of today's European Union.

Lord Ezra was the Liberal Democrat’s spokesperson for Economic Affairs, Trade & Industry (Energy) (1998-2005) and latterly spokesperson on Energy Matters and had been Honorary President of the Coalfield Communities Group since 2006.

In recent political times, Lord Ezra had concentrated on the environmental impacts of energy/clean coal technology and the problem of fuel poverty. More recently Lord Ezra had formed a private company promoting small-scale electricity generation.

The Lord Ezra Award 

Lord Ezra was very keen that CEA should continue to support the industry through education and training. He wanted to add his own personal support and commitment to that end by offering a prize to encourage new entrants to the industry and new innovation where possible. Thus, in 1995, the Lord Ezra Award was initiated and presented each year.

The Combustion Engineering Association, on behalf of Lord Ezra, is proud to present the award and invites entries from a person or group of persons in combustion engineering who have created or facilitated a benefit to that industry, especially through a new, innovative or novel idea.

The award is open to a large field and entrants who are asked to submit competitively based schemes in order to qualify and actually win. The winning entrant or entrants receive the award in October at the House of Lords, and the award presentation will follow the CEA David Gunn Memorial Lecture 20th October 2016. 

The competition is open to all Members of the CEA at any level within a Member company or organisation submitting an entry/s that meet the terms of reference

To submit an entry for this award please click here   

 

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What is going on inside a Steam and Condensate System?

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Nowadays, knowledge is the most important non-material asset of an enterprise. The quality and speed of which knowledge is transmitted contribute considerably to determining success and failure. With this in mind, Flowserve has created the GESTRA Academy to actively support companies by providing personalized consulting, training programs, comprehensive technical literature and project management.

They have developed movies to allow people to explore and get to grips with the inner workings of processes that you can never see in real life!

Watch GESTRA’s various exciting movies – all shot in Bremen at the world's only full scale glass model – to find out more about what is actually going on inside a steam and condensate system Here

DEAERATION

This video demonstrates the thermal dearation of feedwater for steam boilers. To explain the process of dearation, with the glass model.

STEAM GENERATION

This video shows the thermal processes taking place during the generation of saturated steam in a glass steam boiler. This is demonstrated with the aid of the glass evaporator.

STEAM TRAP UNA 16

Steam Trap UNA16: This video looks at condensate discharge using the ball float trap, type UNA 16, as demonstrated in the glass steam system.

STEAM TRAP MK45

Steam Trap MK45: This video looks at condensate discharge by means of the thermostatic steam trap with membrane regulator, type MK 45, as demonstrated in the glass steam system.

WATERHAMMER

In this film clip, the origin and effect of thermal pressure pulses, generally known as waterhammer, will be demonstrated.

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