News

Medium Combustion Plant Directive News

Read more...

Testimonial - Ford Motor Company

Read more...

Use of Filming Amines and Reverse Osmosis in boiler water treatment

Read more...

Reducing Boiler Operating Pressure

Read more...

Copper Pitting in Boilers

Read more...

NEW: Steam Boiler Water Treatment Training Course

Read more...

The Five Levels of Manning

Read more...

Triumph Of Coal - Free Day

Read more...

Technical Director becomes Chairman of the Combustion Engineering Association (CEA)

Read more...

Acquisition of Gestra for £160 million

Read more...

Medium Combustion Plant Directive News

Now that the recent election is over Defra are able to re-engage with Stakeholders on current projects, the most pressing being MCPD.

A number of matters have arisen over the last few weeks:

Consultation

The Government’s consultation on the implementation of the MCPD ran between 16 November 2016 and 8 February 2017, and the results were published at the end of June.

Of the 112 responses received, the largest number of responses were from the Energy sector, followed by Industry, Local Authorities and Regulators.

Implementation Summary

MCP Timetable

AQMAs

One clearly overriding factor in these discussions is the scope and importance of Air Quality Management Areas.  The Directive (Art 6:9) allows the Regulator to impose stricter controls on emissions for AQMA and it is likely with current public pressure and interest that this will be done.

EA Guidance

NOTE – this is a short form of the document discussed at the stakeholder working group and further detail (especially for diesel generator rules) is available on request to the CEA.

See the full News article Here

Permalink

Medium Combustion Plant Directive News

Now that the recent election is over Defra are able to re-engage with Stakeholders on current projects, the most pressing being MCPD.

A number of matters have arisen over the last few weeks:

Consultation

The Government’s consultation on the implementation of the MCPD ran between 16 November 2016 and 8 February 2017, and the results were published at the end of June.

Of the 112 responses received, the largest number of responses were from the Energy sector, followed by Industry, Local Authorities and Regulators.

Implementation Summary

MCP Timetable

AQMAs

One clearly overriding factor in these discussions is the scope and importance of Air Quality Management Areas.  The Directive (Art 6:9) allows the Regulator to impose stricter controls on emissions for AQMA and it is likely with current public pressure and interest that this will be done.

EA Guidance

NOTE – this is a short form of the document discussed at the stakeholder working group and further detail (especially for diesel generator rules) is available on request to the CEA.

See the full News article Here

Permalink

Testimonial - Ford Motor Company

I am very pleased to provide this testimonial on behalf of Ford Motor Company.

My role is Engineering Manager responsible for the Boiler House & estate maintenance for the Ford plant at Dagenham, Essex.

I contacted the CEA for advice on training after the completion of our new boiler house in 2015 on the recommendation of the boiler manufacturer.

I was contacted by David Kilpatrick who recommended the BOAS accreditation for Managers, Supervisors, & Operators, which we completed.

I found the course very informative giving us an excellent understanding of BG01, with the benefit of having it delivered on our own premises.

My team have all given positive feedback on what they received.

I have since attended the Technical Boiler House Risk Assessment conference which has been very useful in giving me the tools to enable implementing my own technical Risk Assessments.

The CEA are always on hand for advice and networking in other areas, on the recommendation of David Kilpatrick I have since started my team on an industrial gas qualification I-GAS, which is going well so far.

As a customer I have found the whole experience excellent and would most definitely recommend the CEA. Well done.

 

Dean Sheldrake,

Superintendent
Utility & Estate Services
Ford Motor Company Limited

Permalink

Use of Filming Amines and Reverse Osmosis in boiler water treatment

 

clean.jpg

 The Camberley plant is a large commercial laundry part of the CLEAN group of laundries. This plant processes up to one million pieces of linen per week on a two shift/7 day per week operation.

For Clean Camberly, the use of and RO plant and injection of amine is very successful.  The boilers have stayed in good condition with minimal scaling in the boiler. TDS stays low and constant so blowdowns are minimised with a good saving in energy.  They have little or no problems with the other parts of the steam system either.

L. Armitstead

Engineering Manager, Clean Camberley

June 2017

Please Note - This article is a personal view by the author based on their results of their steam boiler and system.

Also note - David Kilpatrick director of the CEA would like to point readers to the CEA guidance document BG04 which talks in detail about all aspects of Steam and Boiler Water Treatment. Pages 22 and 23 offer words of caution on when and where Amine can be used, as it may suit this closed loop process but please check with a steam boiler water treatment expert that it is suitable for your process. Because steam boiler water treatment is a complex subject CEA do not endorse any technical aspect of this article and it is highly recommended that the reader carries out a thorough risk assessment in accordance with BG04 to ensure the correct boiler water treatment is applied to your individual application. 

Click Here to view Full Article

Permalink

Reducing Boiler Operating Pressure

What Are the Implications of De-rating Boiler Pressure Below that of Boiler Design Pressure

Is it appropriate on your plant to reduce the boiler operating pressure with a view to saving money on fuel costs, when you consider both the effects on the plant and equipment and the associated risks of making the necessary changes?

In these days of pushing the boundaries on energy efficiency it’s very easy to connect a lower working temperature in a boiler to a lower flue gas temperature and therefore higher efficiency; but is that really the case?  While it’s true that a 15°C reduction in flue gas temperature will save most steam users 1% of the boiler running cost, it isn’t quite that simple when it comes to looking at the effect on the system as whole.

Click here to read the article.

Adrian Rhodes - CEA Vice Chairman

boilers & Gauge.jpg

Permalink

Copper Pitting in Boilers

It’s quite common in boilers with base-exchange water softeners, the effects are worsened by having hard water and/or high make-up rates.

copper deposit.png

If you have a base-exchange softener the scale forming calcium is taken out but the carbonate remains, this doesn’t harm the boiler but instead breaks down to form CO2.  This CO2 leaves the boiler with the steam, and then dissolves in the condensate to form carbonic acid which erodes the condensate pipework forming a metal salt (Iron carbonate, copper carbonate, etc.).  The carbonate returns to the boiler via the feed system where it once again breaks down to form CO2 and the cycle begins again.

Copper and zinc are a particular problem as the metal ion left over from the dissociation plates-out on the steel boiler surfaces; as the steel and the copper are dissimilar, a galvanic cell is formed and, as steel acts as the anode, the steel is eroded rapidly local to the copper deposit.

There are a number of possible solutions depending on how deep your pockets are:

  • Remove the copper pipework (remember – it is corroding right now so you will have to do this at some point anyway) and;
  • Replace with steel (this won’t stop the corrosion of the condensate lines but it will stop the galvanic corrosion in the boiler) or;
  • Replace with stainless steel (this will stop both the damage to the boiler AND the condensate lines).

Soluble copper usually results from carbon dioxide, oxygen or ammonia in the condensate system.

copper hole.pngIn order to deal with these problems, the common solution is to eliminate or neutralise the sources of these gases.

With all steam systems, it is recommended that you carry out a boiler water treatment risk assessment in accordance with BG04, considering the suitability of introducing chemical product(s), in order to boost pH and reduce free CO2 (and therefore reduce the damage to the condensate line). This boiler water treatment risk assessment should consider the destination of the steam and what it might contact.

It should also consider the suitability of the pre-treatment plant currently in operation.

From the conclusions of the boiler water treatment risk assessment, carried out in accordance with BG04, you can then consider your pre-treatment options.

Usually, there are at least two options;

Install a reverse osmosis unit after your existing base-exchange softener, which will not only remove carbonates but almost everything else too, producing ultra-pure water.

Alternatively, install a dealkalisation plant, which will remove the carbonates only. Both systems will have the potential added benefit of removing make-up water dissolved solids, thereby consequentially reducing blowdown and energy costs.

 

You will need to talk to a water treatment company, proficient in boiler water treatment, about these options and they should be able to then put an economic case together for you, to put to management.

It is very important when dealing with copper pitting in boilers that the whole steam system is sampled and considered, since there are other routes to copper corrosion, which are very specialist and as such are not considered here.

We would suggest contacting a specialist in steam boiler water chemistry, for further advice with respect to this.

BG04.png

The boiler maker however, will no doubt refer to BG04 Boiler water treatment guidance for shell boilers, coil boilers, steam generators and hot water boilers or BS 2486 Recommendations for treatment of water for steam boilers and water heaters in their technical documentation. Both will recommend keeping the alkalinity below 25mg/kg in the feed water to keep the amount of CO2 released in the boiler to a minimum.

Permalink

NEW: Steam Boiler Water Treatment Training Course

Do you really know if your boilerhouse and steam systems are safe? 

You may have BOAS accreditation which touches on Steam Boiler Water Treatment (SBWT) within the BOAS assessment. But this SBWT course is a Full Bolt On addition to your accreditation covering all the things you need to know...

CEA are trying to help you and your industry understand the hidden potential risks when operating steam boilers - GSK have suffered as a result of the boiler explosion on one of their sites that killed a 24-year-old technician, All the facts have not emerged yet, but please take a look at this link and decide if  this could be you.
 Do you really know - What would be the impact on your business?
  • It is common knowledge in the industry that there are more boiler explosions in the UK than are reported to the HSE under RIDDOR. Luckily so far no recent fatalities in the UK.
  • The PSSR (Pressure Systems Safety Regulations) ACOP also highlights this issue of boiler water treatment and training for staff - The law
  • 95% of all boiler related accidents and incidents are as a result of poor management of boiler water treatment.
  • This is often because people are unaware of what needs to be done, why it needs to be done and what the results are telling you.  
  • The job of managing boiler water treatment is often left to contractors to do on a once a month basis, which is not adequate.
  • The water chemistry inside your boiler can change very quickly if something goes wrong therefore a minimum of daily testing is a must. A recent explosion at a site in Immingham highlighted this point.
  • People often glaze over when trying to understand the chemistry involved.
  • Designed for people who ARE NOT CHEMISTS and don't have any qualifications in boiler water treatment.
  • But are you responsible for operating or managing your sites boilers. See article - Who's responsible?

The CEA have launched a new two-day training course aimed at water testing and training:
 Certified by CEA to sit alongside BOAS as a Full Bolt On Addition. 
 Independent training by our team of CEA Experts.


Next Training Course to be advised

For more information on the Boiler Water Treatment Course please contact the CEA office, 01740 625538 

Click here for an introduction to BG04 Water Treatment Guide

Permalink

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.


Permalink

Triumph Of Coal - Free Day

The announcement by the National Grid that no coal-fired power was produced in Britain yesterday has been widely covered in today's national news. BBC TV showed the National Grid "meter" with coal at zero. This has been seen as a triumphant step on the way to meeting our climate change obligations. 

What has NOT been highlighted in this coverage is that, at the same time as using no coal, the weather has been largely windless and cloudy. This morning, wind generation was contributing about 4% of our requirements and solar about 5%. At the same time, we were importing 10% of our needs on the interconnectors from the continent. The backbone of our electricity supply was from gas, almost half of the total.

Nuclear power accounts for a fifth of our generation and it is a tragedy that the next generation of nuclear stations is mired in so much uncertainty, most recently the financial problems of Toshiba putting at risk the project in Cumbria. It is of fundamental national importance that we secure an ongoing nuclear generation baseload. 

In talking up the achievements of Britain in building renewable generation, we MUST recognise that its variability is inescapable. Secure and affordable gas supplies are vital. Importing gas is less beneficial than domestic output. It really IS time for the public to be educated in the whole story and to consider the well-regulated development of shale gas as a national priority. For too long, opponents have been allowed to promulgate scare stories and whip up opposition to exploration and development of shale gas. 

Permalink

Technical Director becomes Chairman of the Combustion Engineering Association (CEA)

After 3 years acting as Vice Chairman for the CEA, Adrian Rhodes becomes the official Chairman. 

ARhodes.pngTaking place at the association's AGM on Thursday 16th March 2017 which is held in the House of Lords, Adrian's predecessor, Derry Carr stepped down from his role as Chairman and fondly reminisced about his last three years in the position. 

Derry remains an active member of the Combustion Engineering Association as the Immediate Past Chairman. The CEA have conferences throughout the year where both Adrian and Derry are keynote speakers, along with other very experienced presenters from all across this sector.

After the initial proceedings, and during the prestigious dinner served in the House of Lords, Adrian unconventionally sparked a discussion amongst the members. His technical knowledge has earnt him the authority of a recognised expert within the industry, but Adrian wanted to raise a matter that's often overlooked yet one he feels strongly about. "Awareness".  

To read the full article click here. 

Permalink

Acquisition of Gestra for £160 million

RNS.png

Spirax-Sarco Engineering plc (Spirax Sarco), which specialises in the control and efficient use of steam, and in peristaltic pumping and associated fluid path technologies, announces that it has signed a conditional sale and purchase agreement to acquire Gestra AG and associated businesses (Gestra) from Flowserve Corporation for a cash-free, debt-free consideration of €186 million (£160 million). 

Gestra, which has its headquarters in Bremen, Germany, is a technology leader in advanced industrial boiler control systems and specialises in the design and production of valves and control systems for steam and fluid process control.

In 2016, Gestra recorded revenues of €92.5 million (£79.7 million), EBITDA of €16.6 million (£14.3 million) and EBIT of €15.2 million (£13.1 million).  Approximately 80% of the company's revenues are in Europe with the balance spread roughly evenly between the Americas and Asia Pacific. 

To read the full article click here. 

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.