News

I-GAS a new qualification for maintenance & gas fitters

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Reducing boiler pressure saves energy – myth or fact?

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A new guide to water treatment for Industrial Boiler plant (BG04)

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C&D Foods saves over £50,000 and more than halves carbon emissions with LPG switch

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LNG from Calor powers Cochran’s new R&D centre

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IHEEM WALES 2016 Regional Conference and Exhibition

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CEA Launches I-GAS

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ICOM’s 2016 Annual Lunch focuses on energy (Jun 2016)

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The Medium Combustion Plant Directive (MCPD) is on it's way and will be transposed into UK law by December 2017

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Brewery rebels as Fulton’s thermal fluid installation is one of only a handful in the UK

Read more...

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

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I-GAS a new qualification for maintenance & gas fitters

 

Plant & Works Magazine have recently published an article about the introduction to the CEA's new I-GAS Course.

The CEA’s Industrial Gas Operations Accreditation Scheme (I-GAS) qualification has been devised to fill this gap, in collaboration with industrial gas training providers, manufacturers of combustion equipment, and employers.  It is the only formal training and accreditation scheme currently available that is specifically designed for maintenance staff and technicians working with gas in industrial premises.

 

To see the article please click here

 

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Reducing boiler pressure saves energy – myth or fact?

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Environmental sustainability has never been so important and this pressure is leading many plant engineers to explore ways they can reduce boiler house energy consumption. A common idea is to reduce boiler pressure to save energy, but does it work? Chris Coleman, Marketing Product Manager at Spirax Sarco, explains how steam system pressure and fuel economy are interlinked. 

The pressure for companies to reduce their environmental impact is growing daily. Consumers, investors, governmental bodies, the media and many other groups are all increasingly focused on the need to lower emissions. This is leading many boiler operators to review their boiler house energy consumption with a view to reducing total carbon emissions and saving energy costs. 

One question we’re often asked is whether it’s a good idea to run a steam boiler at lower than its design pressure to save energy.

The answer is not always a simple yes or no; there may be bigger issues to consider other than relatively minor adjustments to boiler pressure. In particular, it’s vital to ensure that all condensate and flash steam is recovered and its heat re-used efficiently.

Ultimately, what really counts is ensuring that the steam distribution system is as energy efficient as possible.

Higher distribution pressure is more efficient

Generating steam at a higher pressure will require more fuel. However, at its simplest level, the same amount of energy is used whether the boiler raises steam at 4 bar g or 10 bar g. This is because it’s the connected load and not the boiler output that determines the overall energy consumption of a building or industrial plant.

We have to also consider losses around the system. Within the boiler itself these losses depend on the boiler’s combustion efficiency, the heat transfer efficiency of its combustion chamber and fire tubes, and flue losses, which are likely to be higher at higher boiler pressures. However, these rises are marginal when compared to the benefits of distributing steam at a higher pressure.

The most efficient way to run steam plant is to operate the boiler at higher pressures, with pressure reducing equipment to lower the system pressure at the point of use. Using higher pressures increases the boiler’s thermal storage capacity, helping it to cope more efficiently with fluctuating loads and minimising the risk of wet and dirty steam being carried over into the distribution system. It also cuts the cost of materials, insulation and labour, since smaller bore steam mains can be used.

Consider all losses

There will also be losses from the steam distribution system, including heat loss from pipework and fittings to the surrounding atmosphere, as well as steam leaks. Again, all of these losses will be greater at higher distribution pressures.

Potentially though, the most significant losses occur after the steam-using process, whether space heating for a building, or process heating in an industrial plant. Once the steam gives up the amount of heat that the process demands, condensate is released. In most cases, flash steam is also produced.

Now it gets interesting. If the condensate system is effective in recovering all or most of the heat in the condensate, and the flash steam is used by another process or fed to a recovery system, then losses will be minimal. In this case, the boiler operating pressure will not have much impact on the overall losses, and any efficiency gains may be offset by other considerations, such as the risk of wet and dirty steam being carried into the process.

On the other hand, if the hot condensate is not recovered effectively, or the flash steam escapes, then the losses will be large. In this case a lower operating pressure will produce lower losses. However, this would be an inefficient steam system and, rather than adjusting the boiler pressure, much greater savings could be made by improving the plant’s energy performance.

Achieving optimum steam distribution pressure

The optimum pressure within a system varies from plant to plant and depends on the maximum safe working pressure of the boiler as well as the minimum pressure required by steam-using equipment around the site.

Deciding on the optimum initial distribution pressure can be complex, taking in to consideration the application, equipment and safety issues. Allowances must also be made for steam pressure loss as the steam passes through the pipework to ensure the minimum pressure is met at the point of use. So it’s important that the pressure is not altered in a misguided attempt to reduce fuel consumption.

There are other considerations too, such as whether the existing control valves and heat exchangers are adequately sized if the pressure is dropped.

It can take a degree of expertise and experience to successfully balance conflicting factors and arrive at the optimum pressure for a steam system. That’s why many boiler operators would be better off getting advice from a steam system specialist.

Other ways to reduce fuel consumption

There are many effective ways to save fuel. It is estimated that industries could save up to 30% of the fuel feeding its boilers by combining established good practice with improved technologies.

Recover all condensate

Condensate can contain up to 20% of the energy in the steam from which it came. Returning water to the boiler feedtank typically recovers about half this energy, while the rest can be recovered by installing a flash steam vessel or pressurised condensate return system.

The benefits of condensate recovery do not end with energy savings, though. It also saves water and treatment chemical costs, and even effluent charges may be reduced because less water is discharged to drain.

Install automatic boiler blowdown

All boilers need to be periodically purged by blowdown, the key to which is removing only enough water to maintain contamination at an acceptable level. Dumping any more than this is a waste of energy and treated water.

Many boiler houses use blowdown valves that are manually opened at regular intervals and dump water down the drain. An automatic TDS (Total Dissolved Solids) blowdown controller is a better option. By continuously monitoring TDS build-up in the boiler, the controller opens the blowdown valve only as required. It is often cost effective to recover the heat from the necessary boiler blowdown using a simple flash vessel and heat exchanger system.

Creating the right boiler feedtank conditions will also reduce the amount of fuel needed to produce steam from hot feedwater. Using returned condensate, for example, to raise the feedwater temperature by 6°C gives a fuel saving of 1%. Ideally, feedwater should be maintained at 90°C.

Taking the next step

These are just a few of the factors that can determine whether a steam system operator is paying over the odds by running their plant below its optimum efficiency. A full energy audit can identify where energy is being wasted and suggest ways to win significant savings, however we know that some companies don’t have the necessary steam system expertise in-house. Therefore calling in an external provider like Spirax Sarco is often the best option. You can get in touch on ukenquiries@spiraxsarco.com

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A new guide to water treatment for Industrial Boiler plant (BG04)

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For information on our new Steam Boiler Water Treatment Training Course Click Here

The ICOM Energy Association and the Combustion Engineering Association (CEA) have joined forces to produce a new Industrial Water Treatment Guide, an easy-to-follow guide to water treatment for steam and hot water boiler systems. As such, it is designed for use by non-specialists through the use of straightforward, everyday language.

Designated ‘BG04’, the new Guide was launched at the CEA’s conference in July to an audience of primarily plant managers and engineers. It was well-received and acknowledged as providing an invaluable insight into the responsibilities of managing commercial and industrial boiler plant.

Industrial Water Treatment Guide BG04 will now become an integral component of the training courses run by the CEA for operators and managers of industrial and commercial boiler plant.

ICOM Director Ross Anderson noted: “Correct water treatment is essential in ensuring the reliable and efficient operation of steam and hot water boilers but until now there has been no definitive guide for commercial and industrial boilers. BG04 fills this gap in documented best practice and will play a key role in preventing corrosion and scaling.”

CEA Director David Kilpatrick added: “We recognise that many of the people responsible for the day-to-day management of such plant are not chemists or water treatment specialists. BG04 has therefore been written as a simple guide to setting up and treating these systems to ensure long, reliable life.”

The guide has been written for the layperson who does not have 'O' level chemistry but who is responsible on site for boilers and boiler water treatment, either directly or subcontracting it to a third party.

CEA hosted a very successful seminar at the Cambridge Belfry on Thursday 14th July 2016 explaining: 

  • Boiler Water Treatment (BG04) launched. 
  • Industrial Gas Accreditation Scheme (I-GAS) launched. 
  • Medium Combustion Plant Directive (MCPD) updates.  

Ideally we would like you to attend the next seminars where a hard copy will be included as part of the delegate pack, dates and locations for these seminars are currently being confirmed for the remainder of 2016 (3 are being arranged). However, if you wish to purchase your copy of BG04 for £75.00 plus £2 p&p please contact the CEA office on 01740 625538 or email info@cea.org.uk.

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About This Guide

This comprehensive guide deals with all aspects of water treatment for steam boilers, steam generators and hot water boilers. This document applies to industrial and commercial steam and hot water boiler plant including steam generators, operating at a working pressure of between 0.5 and 60bar gauge (except where stated)  and a working temperature between 110oc and 400oc. We trust that by studying the contents and following the freely given advice your boiler plant will operate safely and more efficiently, and provide you with a trouble-free system.

Having considered who is responsible for looking after steam boilers, steam generators and hot water boilers and also who is responsible for managing the safe operation of this type of equipment, the Combustion Engineering Association (CEA) and ICOM Energy Association agreed to write this guide, with the help of our respective Members.

It is aimed as a document that can be read and understood by boiler operators, engineers and personnel with limited or no knowledge of water treatment chemistry. It is also intended to help them understand what effect any water and its subsequent treatment will have on their boiler plant.

 

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C&D Foods saves over £50,000 and more than halves carbon emissions with LPG switch

18th July 2016

A premium dry pet food manufacturer has saved in excess of £50,000 and more than halved its CO2 emissions since converting its boiler fuel from oil to liquefied petroleum gas (LPG) from Calor.

A strong partnership

C&D Foods’ site in Larkshall, Norfolk, produces approximately 20,000 tonnes of dry pet food every year, requiring a significant amount of fuel to power its manufacturing processes. Situated off the mains gas grid, the company has partnered with Calor for the last 20 years, using LPG to fuel a collection of large on-site industrial dryers that reduce the moisture content of the dry pet food once it has been extruded.

Having established a strong relationship as C&D Foods’ fuel partner of choice, Calor then approached the business in the summer of 2014 with a plan to dramatically improve its existing oil boiler efficiency and lower its carbon output.

Working with Calor

Ian Harridge, General Manager at C&D Foods, explains: “Calor removed the existing large oil tanks and installed six 4,000 litre LPG tanks, as well as a vaporiser that can give us extra power when needed. Calor then supplied and installed a packaged gas burner to allow us to modify the boiler from its original oil burner.”

The ability to install a packaged gas burner meant the entire boiler system did not have to be replaced, which would have incurred substantial costs.

“We chose Calor based on two reasons,” Ian continues. “First, they’re the market leader, with the best coverage for off-mains sites. Second, the proposal that they put forward to assist with the installation of the new equipment was excellent, minimising any downtime or additional costs. Calor worked around times when the plant did not need to run, which included some weekend work. The installation went through with no real interruption to the business.”

The key benefits of LPG

LPG’s reduced CO2 impact compared to oil was a critical reason behind the site’s decision to fully embrace gas for its processes, as the site continues to work towards the Carbon Trust Standard. LPG is currently the lowest off-mains carbon emitting fuel available on the market, emitting 20 per cent less CO2 per kWh than oil.1 Since switching to LPG, C&D Foods has reduced its CO2 emissions by 52 per cent.

The reduced overhead costs and improved operational efficiencies achieved with LPG was also a key driver for C&D Foods, resulting in financial savings of more than £50,000.

Each LPG tank is also fitted with Calor’s intelligent automatic top-up technology, alerting the supplier when a tank is low on fuel. This ensures C&D Foods has a constant supply of fuel, guaranteeing a tank never runs short.

First class service

“The service provided by Calor has been second-to-none,” adds Ian. “They managed the whole project for us, from fitting the new foundations for the new equipment to connecting the boiler and commissioning.

“Based on the experiences we’ve had, I would have no hesitation in recommending Calor to other businesses.”

 

– Ends –

 

1 LPG’s Carbon Footprint Relative to Other Fuels – A Scientific Review, page 6 https://www.calor.co.uk/media/wysiwyg/PDF/atlantic_consulting_scientific_review_carbon_footprint_ed._2009.pdf

 

For further press information please contact:

James Montgomery, Richard Jansen-Parkes

or Jane Woods                                                                      

Edson Evers Public Relations            james.montgomery@edsonevers.com

120 Newport Road                             richard.jansen-parkes@edsonevers.com

Stafford, ST16 1BY                             jane.woods@edsonevers.com

01785 255146


About Calor Gas

Calor is the UK’s leading supplier of liquefied petroleum gas (LPG), bringing clean, efficient and modern energy to rural Britain. The company provides gas to some of the two million homes and 350,000 commercial premises located off the mains gas grid, distributed via the UK's largest LPG delivery fleet.

Calor has continued to invest in its offering to ensure it provides the best service for its customers, including supply of LPG to homes and businesses and a wide range of products and appliances from boiler installations to portable heaters.

Please visit www.calor.co.uk or call 0800 121 7827 for more information.

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LNG from Calor powers Cochran’s new R&D centre

A leading manufacturer of industrial steam and hot water boilers is switching to liquefied natural gas (LNG) from Calor, reducing its CO2 output by 169 tonnes. LNG will power the next stage of the company’s development as it creates a new research and development (R&D) centre.

Located off the mains gas grid next to the River Annan in Newbie, Scotland, LNG will fuel a new on-site R&D centre for boiler manufacturer Cochran, helping to train more than 500 employees and commercial customers every year. LNG will also provide space heating for the company’s factory during the colder winter months.

Previously fuelled by oil, LNG’s green credentials are a key driver for the switch, reducing the site’s CO2 emissions by 28 per cent.

David Branch, Business Development Manager at Cochran, explains: “We have been looking to make the switch for a long time. The majority of boilers we manufacture are fuelled by gas and, coupled with the environmental benefits and reduced costs when compared to oil, it made commercial sense for us to introduce LNG as our fuel partner of choice.

“LNG will be used in our new R&D centre, powering the boilers we test as we facilitate product development. In addition, it will enable us to deliver vital training to our employees and customers, including the Combustion Engineering Association’s BOAS (Boiler Operation Accreditation Scheme) and I-GAS (Industrial Gas Operations Accreditation Scheme) programmes.

“Furthermore, we anticipate savings of between £10,000 to £12,000 a year. We have been delighted with the service offered from Calor so far and the proposal they put forward to fuel our site with LNG. We look forward to working together in future.”

Kevin Houlden, Business Development Manager at Calor, adds: “LNG offers an environmentally superior and cost-efficient alternative to oil. We will be supplying a 20,000-litre LNG unit, supported by a number of vaporisers that can offer extra power when demand increases.

“A highly efficient fuel, LNG achieves a greater calorific value than even propane gas, offering an impressive output of 15.2 kWh per kg.Depending on the application, LNG emits up to a third less carbon dioxide than diesel or oil based products, with Cochran predicted to reduce its CO2 emissions by 28 per cent.”

It is expected that Cochran will have fully converted to LNG by September, with the installation assisted by Calor’s sister company, PrimaLNG.

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– Ends –

 

For further press information please contact:

 

James Montgomery, Richard Jansen-Parkes

or Jane Woods                                                                      

Edson Evers Public Relations            james.montgomery@edsonevers.com

120 Newport Road                             richard.jansen-parkes@edsonevers.com

Stafford, ST16 1BY                             jane.woods@edsonevers.com

01785 255146

 

About Calor Gas

Calor is the UK’s leading supplier of liquefied petroleum gas (LPG), bringing clean, efficient and modern energy to rural Britain. The company provides gas to some of the two million homes and 350,000 commercial premises located off the mains gas grid, distributed via the UK's largest LPG delivery fleet.

Calor has continued to invest in its offering to ensure it provides the best service for its customers, including supply of LPG to homes and businesses and a wide range of products and appliances from boiler installations to portable heaters.

Please visit www.calor.co.uk or call 0800 121 7827 for more information.

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IHEEM WALES 2016 Regional Conference and Exhibition

New to the IHEEM events calendar this summer

This one-day Regional Conference and Exhibition is being held at the Village Hotel Cardiff on Thursday 8 September and will be open to delegates from both the public and private sector.

The conference raises the question: ‘How Safe Is My Hospital?’ - challenging attendees to look at their hospital with renewed vigour.

Every day healthcare estates are under attack in one form or another from both internal and external sources affecting patient safety and the patient environment. Is your hospital safe from government and public scrutiny? Do you keep up to date with legislation as it continues to be revised and are able to demonstrate compliance? How safe is your water supply? In addition to this, the threats to hospital security systems is rising. With information being an essential asset within the hospitals, sensitive or critically important data can be lost in a number of ways - including system failure, data theft, inappropriate usage, unauthorised access and cyber-attacks using computer viruses.

In response to these questions, a plethora of expert speakers from across the healthcare estates sector will be leading discussions on key themes: Water Safety, Governance and Compliance, Hospital Resilience and Hospital Security of IT Systems.

Confirmed speakers include:

  • Mike Simmons - Consultant Microbiologist, Public Health Wales  

  • Phil Ashcroft - Principal Buildings & Facilities Management Services Engineer, Department of Health  

  • Dr Jimmy Walker - Scientific Leader for Water and Decontamination Biosafety, Air and Water Microbiology Group      

  • Chris Northey - Associate Director, Chapman BDSP and IHEEM President

  • Geoff Walsh - Assistant Director of Planning, Capital, Estates and Operational Services, Cardiff and Vale University Health Board

  • Greg Markham - Technical Director, EMCOR UK and IHEEM Past President 

  • Eugene Conroy - Managing Director, ETA Projects LTD 

  • Graham Marsh - Governance and Compliance Technical Platform Chair and Chair of the South West Branch, IHEEM

  • Julian Amey - Chief Executive, IHEEM

  

Download the full Conference programme

 

IHEEM WALES 2016 is a joint venture between IHEEM and the IHEEM Wales Branch who have been working closely to produce an innovative event, that shares best practice and technical knowledge.

This regional event will feature a variety of expert speakers from across the UK presenting sessions that will have a universal appeal for attendees from across the UK.

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CEA Launches I-GAS

The Combustion Engineering Association launches “I-GAS”

a new qualification for maintenance and gas fitters working in industry

 

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  • Do you or any of your team work on industrial gas systems? Have you been formally trained and can you prove competence?
  • Do you or your team organise or carry out any maintenance or installation work on industrial gas systems?
  • Do you employ contractors to do this work?
  • Do you check contractor’s qualifications and competency?

There are many activities routinely occurring in industrial premises that might require breaking into a gasway for maintenance or repairs. Currently, available training and certification for gas fitters and engineers working on domestic and commercial appliances is not often appropriate for the types of gas equipment commonly found in industry, increasingly including premises where electricity is generated using gas.

Large numbers of maintenance technicians, gas operatives and contractors working in factories may have no formal training in the safe use of gas in industry.  Gas is widely used in bakeries and other food processes, breweries, laundries, metals processing, energy centres, chemical works, hospitals, pharmaceutical, and lots of other manufacturing across a wide range of industrial users and sites.  Most people know of GasSafe qualifications, and that it is a legal requirement in domestic situations to have the appropriate GasSafe accreditation for the appliance being worked on.  However, these qualifications are not required in factories and the associated training will not be relevant for the types of equipment and sizes of plant involved, the only requirement is to be able to prove competence.

Regulation 3 of the ‘Gas Safety (Installation and Use) Regulations 1998’ (GSIUR) says:

 “Gas work for those working at premises that fall outside the scope of the Regulations should only be undertaken by a person who has successfully completed an appropriate full training course followed by assessment of competence”.

The CEA’s Industrial Gas Operations Accreditation Scheme (I-GAS) qualification has therefore been devised to fill this gap, in collaboration with industrial gas training providers, manufacturers of combustion equipment, and employers.  It is the only formal training and accreditation scheme currently available that is specifically designed for maintenance staff and technicians working with gas in industrial premises.

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Candidates for I-GAS qualifications are expected to already be working as mechanical fitters or installers, maintenance technicians or in other associated industrial activities where they are working around gas fired systems and equipment.  They may already have domestic gas qualifications and need to enhance these with an industrial gas qualification, or they may have no formal gas training at all.

Whilst everything is done correctly by suitably qualified and experienced personnel, then all is well - but: Below - the devastation caused by an untrained operative adjusting the gas valve to the boiler.

The first boiler exploded in 2013 - Its sister boiler exploded in 2014, all because the operator and the company had not learnt its lesson from the first explosion.

No Formal training and no company procedures were in place either before or after the first explosion.

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2013 (NB. The sister boiler in the background)| 2014 (both boilers now lay in ruins)    

In order to prepare candidates for I-GAS accreditation a number of independent and competing organisations offer suitable training courses approved by the CEA. 

These courses are intended to supplement and confirm existing knowledge and prepare suitable candidates for the various levels of qualification afforded by I-GAS.  All courses are a mix of practical assessments and written examinations assessed by independent gas Assessors.

I-GAS Accreditation of itself is not a legal requirement, but it is a test of a person’s competence in relation to their current knowledge and experience at the time their assessment is completed.  It is only one possible component that may help an organisation to demonstrate their corporate responsibility to provide suitable training for employees under the Health and Safety at Work Act.

I-GAS is not a substitute for GasSafe qualifications which are still needed for work on gas installations in a wide variety of domestic and commercial premises and other publicly accessible locations such as hospitals.

The CEA is the independent Certification Body responsible for the scope, syllabus and administration of the scheme, and the selection and appointment of Training Providers and Assessors.

There are five levels that can be achieved under the I-GAS accreditation scheme and suitably skilled entrants can join at the appropriate level in line with their knowledge and skills, these are:-

  • Level 1 - Entry portfolio

New entrants, possibly with limited gas experience.

Off line course and home study to familiarise candidates with gas industry standards, legislation and procedures.  Not accredited to work on gas systems.

  • Level 2 - Industrial Gas Maintenance

Safe procedures for gas work, breaking into gas ways, repairing or replacing gas line components ‘like-for-like’, strength testing, tightness testing, purging & relighting end of line equipment.  Knowledgeable to supervise gas contractors.

  • Level 3 - Industrial Gas Technician

Work on gas pipework; understand combustion principles and combustion equipment.  Combustion analysis and emissions.  Setting regulators.

  • Level 4 - Industrial Gas Engineer

Pipework design, strength testing, Pipeline replacement and modifications to installations (incl. “component change” procedures), and gas system commissioning.

  • Level 5 - Industrial Gas Designer
 

Contact details for further information:

David Kilpatrick – Director:  The Combustion Engineering Association

NET Park, Thomas Wright Way, Sedgefield, Co. Durham, TS21 3FD

Tel: 01740 625538 - Fax: 01740 625251 - Mobile: 07866 764716 - Email: info@cea.org.uk

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ICOM’s 2016 Annual Lunch focuses on energy (Jun 2016)

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Members of ICOM and their guests gathered recently at the RAF Club in London for the Association’s 2016 annual lunch, bringing together over 100 of the commercial and industrial heating sector’s key decision makers.

Highlights of the event, which were sponsored by Bosch and Nortek, included a fascinating overview of global energy markets by BBC Science Editor David Shukman and the presentation of the third ICOM Apprentice of the Year award.

Proceedings were opened by honorary life member Phil Brompton, who introduced the Association’s new chairman Simon Parker. In response, Mr Parker welcomed the recent growth in the commercial boiler, warm air and radiant markets though he was less sanguine about the renewable energy sector. The government’s modifications to the Renewable Heat Incentive, he suggested, will have serious implications for biomass and solar thermal potential – whilst on a more positive note flagging up the opportunities for green gases, CHP and heat pumps.

He also made reference to the hard work by ICOM members on implementing the latest ErP regulations with a warning that there is still a lot more to come. The Gas Appliance Regulations in particular were cited as having a significant impact on members.

In this respect, Mr Parker noted how the growing ICOM membership, covering market sectors that have not been included before, is giving the organisation a more holistic approach to the industry that will stand it in good stead for meeting future challenges.

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L­R: Simon Parker (General Manager Europe) Nortek HVAC Ltd; David Shukman (BBC Science Editor); ICOM Keynote Speaker, Ross Anderson (Director) ICOM

 

Policy and reality

Guest speaker David Shukman also made energy the theme of his address, with a focus on the relationship between public policy pronouncements and reality, using the Paris Agreement 2015 – and its commitment to reducing global temperatures by 2°C – as an example. Whilst many governments are reluctant to invest in mitigating climate change, he noted that progress will be reviewed every five years as politicians do not like to be embarrassed by unachieved targets.

In this respect, Mr Shukman observed that public pressure can also be effective in other ways. For instance, there is now considerable social pressure in China around the issue of air quality and this is helping to shift emphasis away from coal to wind farms and solar. This has a knock­on effect for the rest of the world as it is serving to drive down the cost of turbines and solar panels ­ helping to bring us closer to the key target of making renewables cheaper than fossil fuels.

Corporate engagement was also cited as another key driver in tackling climate change, with a number of big companies committing to carbon neutrality as part of their overall corporate social responsibility.

Nevertheless, he warned, switching to renewables must be seen as a long­term objective because of our continued dependence on liquid fossil fuels – especially for transportation. He noted that it took around two centuries for the internal combustion engine to become dominant over steam.

Best practice for water treatment

Speaking on behalf of the guests, David Kilpatrick, Director of the Combustion Engineering Association (CEA), explained to the audience how ICOM and the CEA are now working closely together in a number of areas, including the publication of guidance documents.

By way of illustration, he observed that around 90% of incidents involving boilers or burners were due to poor water treatment, so that a key focus for the two Associations has been the development of a new water treatment best practice guide, designated BG04. Due for publication in July 2016, this is designed to be a simple guide for people who are not engineers but have responsibility for managing or maintaining boiler plant.

Apprentice of the Year

The proceedings were concluded with a presentation of the Apprentice of the Year Award, which this year went to Andrew Bell of Cochran; with Kyle Dean of Lochinvar and Phillip Roberts of Nortek Global (HVAC) as runners­up.

ICOM Director Ross Anderson spoke eloquently about the importance of apprenticeships in replacing the skills of those older people in the industry who are close to retirement. He was particularly pleased that so many ICOM members employ apprentices, noting that this puts the industry in a strong position to encourage more emphasis on engineering by the skills councils.

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L­R: David Young (Chief Engineer) Cochran; Andrew Bell (winning apprentice) Cochran, Ross Anderson (Director) ICOM

 

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The Medium Combustion Plant Directive (MCPD) is on it's way and will be transposed into UK law by December 2017

If your company runs any combustion plant from 1MW thermal Input up to 50 MWth you will fall into the MCPD. The emission limits have already been set for the European Union and a number of staging dates set for the various sizes and types of industrial plant. 

Having seen on the news the smog in certain Chinease cities, reminisent of 1950's London smogs here is some information that may indicate the direction of travel in terms of NOx reduction globally. 

The CEA are running an MCPD Awareness Seminar on Thursday 14th July 2016 at the Cambridge Belfry - Click here for details

SAACKE LONOX UCC System already complies with future Chinese emission limits

Nitrogen oxide emissions < 30 mg/m³ based on 3.0% dry O2 certified by the German TÜV

From 2017, particularly strict emission guidelines will apply in selected urban areas in China, such as Beijing. New heat generation plants and power stations will then be subject to a NOx limit value of a maximum of 30 mg/m³ based on 3.0% dry O2, while the regulation enters into force in five years for existing plants. The optimized SAACKE LONOX UCC (Ultra Clean Combustion) System, based on burner technology that has proven its worth over decades, already complies with the future guideline values in all areas – without expensive additives or secondary measures. This was verified by the German TÜV (Technical Inspection Authority) in January 2016, based on measurements at a test facility at the SAACKE research and development location in Bremen.

The new statutory regulations are the Chinese government’s response to rising air pollution and smog formation, especially in urban areas. These are the result of released nitrogen oxides, which are unwanted by-products of combustion processes that use high temperatures in many sectors of industry or are also released by motor vehicles in traffic. “We want to use our technology to contribute to a better climate and better living circumstances for the inhabitants”, says Dr. Norbert Schopf, Director Business Development at SAACKE. “The guidelines for new plants may only enter into force from 2017, but they also affect power stations that supply heat. The goal is to be able to commission the first SAACKE Low NOx burners at the start of the 2016/2017 heating period.” Plants that are already in operation can also be fitted with the technology, so that they can continue to be used.

 

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Cost-effective and efficient compliance with limit values

The reduction of nitrogen oxides in industrial processes is generally achieved by cooling the flame temperature in the burner, such as by installing cooling fins or water injection. NOx reduction measures of many SAACKE competitors often lead to a high amount of excess O2 or a high level of CO. Significant reductions in the released nitrogen oxide can often only be achieved using expensive, catalytic (SCR) or non-catalytic (SNCR) processes. However, all of these options increase fuel consumption, material costs and the use of necessary additives at the operator’s expense. By contrast, the SAACKE LONOX UCC System is based on an internally developed technology, whose core elements are a swirled and particularly stable spherical flame as well as a specially-engineered flame control. “This function has proven itself in practice over many years and has undergone constant optimization”, explains Dr. Norbert Schopf. The SAACKE burner fires all gaseous fuels cost-effectively and efficiently in compliance with the limit values of 30 mg/m³ NOx based on 3.0% dry O2 – with a low flue gas recirculation rate of < 30%. Specifically, measurements by the TÜV Nord, under low, partial and full load, resulted in NOx values (averaged over half an hour) of < 19 mg/m³ at an output of 1 MW, < 28 mg/m³ at 4 MW and < 24 mg/m³ at 8 MW. The CO value is below 100 mg/m³. The SAACKE LONOX UCC System does not require any external measures for NOx or CO, and has a capacity range of 8 to 64 MW, making it suitable for plants with shell boilers or water-tube boilers with capacity ranges between 10 and 80 tons per hour. The burner solution is also ideal for extremely short furnaces due to the special flame geometry.

The SAACKE LONOX UCC System can be customized to customer requirements and the local infrastructure. Besides the test plant at the research and development location in Bremen, a 32 MW demonstration plant is also in planning at SAACKE's Chinese site in Qingdao.

 

 

News: 2016/05

Managing Director: Malcolm J. Cook

SAACKE Combustion Services Ltd. │Registered in England No. 7184556 │VAT Number is GB 989  1797 35

 

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Brewery rebels as Fulton’s thermal fluid installation is one of only a handful in the UK

Steam is often seen as a traditional source of indirect heat for brewing and distilling processes but, with the recent explosion in micro-breweries and resurgence in craft brewing, the regulations and additional ongoing investment required for running a pressure-based system often adds too much cost when considering steam as a heat transfer solution. So when Rebellion Beer Company was looking to replace its ageing steam boiler system, they turned to two of the UK’s major thermal fluid specialists for help.

Established in 1993 by two school friends from Marlow, Rebellion Beer Company is a medium-sized micro-brewery that uses traditional brewing methods and natural ingredients to produce four million pints of beer from its Chiltern Hills-based brewery every year.

Having secured a new 20-year lease on its premises, and as part of a three-stage development plan for the business, Rebellion’s Mark Gloyens decided that an upgrade to some of the company’s original brewing equipment was required and, with its steam boiler reaching the end of its operational life, he started looking at options for new heat transfer equipment.

“This was the first time we had approached thermal fluid system specialists for a project of this sort and, having met with two of the UK’s main suppliers to discuss the project, we were impressed with Fulton’s enthusiasm and interest in getting involved with what turns out to be one of only a handful of brewery-based thermal fluid heat transfer projects in the UK.” says Mark.

Explaining the potential energy savings, Mark says that Fulton’s new FT-C 240 vertical coil thermal system should save money on the company’s energy bills as it is possible to easily turn the heater on and off as required, and with minimal heat-up time. In contrast, the old steam-based system needed to be turned on at the beginning of the day and left running regardless of the demand for steam.

The new system also provided value-for-money, as thermal fluid heaters are non-pressurised systems and therefore not subject to the costs of running a system under the pressure regulations. For example, thermal fluid heaters use specialist oils as heat carriers and operate, at atmospheric pressures, up to 300°C. To gain a similar operating temperature from traditional water- or steam-based systems would require a pressure of 85 bar. And while Rebellion Beer Company prefers to operate its thermal system at lower temperatures of around 135°C to ensure a quality product, for many processes where high process temperatures are required, thermal fluid heaters are an ideal source of heat.

For Rebellion, the system is also much simpler than a steam solution and was therefore less expensive to set-up and maintain. Additionally, Fulton’s FT-C thermal fluid system is more compact than the original steam-based system, which has freed up much needed space for other valuable process equipment.

Commenting for Fulton, Doug Howarth explains that unlike steam, thermal systems provide useable temperature with very little pressure and a variety of cost savings should therefore be expected. The additional control provided by thermal systems also allows multiple, easy and accurate temperatures throughout a single system that can also include cooling. There are also no freezing hazards, they provide rapid start up and shutdown with minimal heat losses and there’s no requirement for blow down or condensate losses.

“The whole life costs for thermal systems can also be cheaper because they require fewer insurance inspections, which minimises production downtime and shut down periods. There’s also no requirement for water treatment or chemical dosing, which leads to zero waste disposal and minimal maintenance costs.” says Doug.

Fulton’s thermal fluid heat transfer solution is now used throughout Rebellion’s brewing process. From the brewhouse, where liquor (water) is heated to 66 degrees for the mashing-in process and wort is boiled with hops for 90 minutes; to heating the brewhouse and fermentation tank CIP system.

Fulton’s highly-efficient FT-C thermal fluid boiler offers a compact, fuel-fired, 4-pass heater design capable of operating at temperatures up to 345°C. The system is designed to provide high-fluid velocities and low-film temperatures for improved longevity. The system’s compact footprint also means it could be skid-mounted, accommodating ancillaries such as circulating pump, expansion tank and related pipework, to minimise the floor space required for installation.

Summarising, Doug Howarth says that whilst the company is known as a reliable source of multi-fuel-fired steam boilers, Fulton is also synonymous with heat transfer solutions and produces an unrivalled range of thermal oil and hot water solutions. And because Fulton offers a complete range, they are well placed to offer customers an unbiased review of their heat transfer requirements.

For further information on its thermal fluid systems, including the FT-C vertical coil, FT-N vertical electric and FT-HC horizontal coil heaters, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit Fulton’s new-look website at www.fulton.co.uk.

Ends

Editors Notes
With manufacturing facilities in the United States, Great Britain and China, Fulton is a global manufacturer of steam, hydronic and thermal fluid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer solutions. For additional information about Fulton, please visit www.fulton.co.uk.

For further information contact Doug Howarth
Fulton Limited, Fernhurst Road, Bristol, BS5 7FG
Tel: 0117 972 3322 Fax: 0117 972 3358
E-mail: doug.howarth@fulton.co.uk Web: www.fulton.co.uk

For press information contact Simon Cantillion,
Cantillion King Advertising, 16 The Cornhill, Stroud, Gloucestershire, GL5 2JT
Tel: 01453 755551 Fax: 01453 751525
E-mail: simon@cka.co.uk Web: www.cka.co.uk

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