CEA 2012 Yearbook by Tim Haines

CEA 80th Anniversary Edition 1933-2013

The Combustion Engineering Association

Experts in industrial and marine boiler repair

CEA Yearbook 2012/13

Contents

Message from the President

page 5

Message from the Director

page 6

About the CEA

page 8

PM5 Replaced - Conference

page 9

Energy policy - 10 years older and wiser

pages 10-11

On a mission to deliver process steam generation systems

page 14

Zero-cost investment in biomass heating with Energy Efficiency Financing scheme

page 16

Condensate recovery system upgrades that boost steam system centre efficiency

pages 18-20

The impact of the new Industrial Emissions Directive

page 23

CEA moves to NETPark

page 25

Byworth a complete boiler service pages 27-29 The Lord Ezra award: Sustainable energy for Northern Ireland pages 33-35 The Lord Ezra award: Looking into Diesel optical engines

pages 35-36

Thoughts on three decades of water treatment for package boilers

pages 39-40

Reducing NOx production while keeping fuel costs and carbon emissions down

pages 42-44

Our contribution to our and future generationsâ&#x20AC;&#x2122; quality of life A look at hazardous areas for flammable gas systems

or write to: The Combustion Engineering Association NETPark Thomas Wright Way Sedgefield Co. Durham TS21 3FD

The CEA Yearbook 2012/2013 is published by Armitage Communications Mill House Wandle Road Beddington Croydon Surrey CR0 4SD Tel: 020 8667 9660 Fax: 020 8667 9426 enquiries@armitage-comms.co.uk www.armitage-comms.co.uk

Printed by

page 47 pages 48-49

Using alternative fuels to reduce energy costs and reduce emissions

page 50

A global presence in combustion engineering

page 51

CEA Members guide

For further information about the CEA please contact David Kilpatrick on: Tel: 01740 625538 Email: info@cea.org.uk Web: www.cea.org.uk

Colourset Litho Limited 3-5 Swan Close Croydon CR0 2DZ Tel: 020 8689 2200 Paper Cover printed onto 300 gsm Claro Silk Text pages onto 150 gsm Claro Silk

pages 52-55

The pulp used in the paper process has not been bleached with chlorine gas therefore all the papers are ECF (Elemental Chlorine Free). The finished paper is 100% recyclable. All pulp purchased and produced is sourced from managed sustainable forests.

CEA Yearbook 2012/13

COME AND MEET THE

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CEA Yearbook 2012/13

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Message from the President

A very warm welcome to the Combustion Energy Association’s 2012/2013 Yearbook, the 69th edition of the Yearbook since the CEA’s inception in 1933.

rail vehicle maintenance specialists. He is also the founder of the Waterman Railway Heritage Trust, which owns several steam and diesel locomotives.

We are delighted that the yearbook includes a message from our President Pete Waterman who, well known for his huge success as a pop impresario, is probably not quite so well known as a leading advocate for the restoration of steam engines, railways and the preservation of their important heritage.

Pete has a keen interest in model railways and started the model railway business ‘Just Like the Real Thing’ regularly appearing on the company’s stand at exhibitions and shows. He has written several books and many articles on the subject.

Dr Pete Waterman OBE, DL is the Chairman of the LNWR Heritage Company which, at its Crew Heritage Centre, has become one of Europe’s largest restorers of steam boilers and

t was a privilege and an honour for me to give the Gunn Memorial Lecture at the House of Lords in October 2011 – something I never, ever dreamed that I would be invited to do and I am very grateful to have been given that opportunity. We live in very interesting times and it is with some incredulity that I listen to politicians now extolling the virtues of manufacturing. What we take as a given i.e. that the manufacturing industry in the UK is of critical importance to the health of the nation, seems only now to have filtered through to the powers that be. This was evident at the Tory Party Conference last year when it was stated de facto by the Prime Minister in his speech that the only way to drag the country out of recession was to rebuild our skills’ base and our manufacturing industry. With respect, I am prompted to say that this is something anyone in The Combustion Engineering Association could have told him in return for a decent pint in the local pub any time he wished! I believe that now more than ever, our Association is well placed to help provide the demands of industry for the next 50 years. Industrial units will now need to look at the way they use and burn fuel. Health and Safety has always been a critical factor here

He has an extensive private collection of railway models and railway layouts and recently completed the building of a scale model of Leamington Spa station set in the 1950s.

but it is now essential that industry looks at the environmental issues and is sensitive to this. We are fortunate in our Association to have members who are hugely experienced in these and other areas. Areas which are important to the future industries where we can offer them a wealth of experience. We are all very aware of the European Union and some of its edicts but what I’ve learned over the last few years from our members, is that it’s never quite as easy as the experts would have us believe. Those experts who inevitably, in difficult economic climates, are the people voicing strong opinions and selling their solutions. All too often a ‘one size fits all’ type of solution! I believe the time is right to recruit more members and to offer them the same facilities as existing members already enjoy. As some members (and I count myself in this group) are already at, or indeed past, retirement age, we can proudly say that we are the quintessential fountain of knowledge. Let us then convince like-minded bodies that they should be part of the Association and that they can dip freely into the fountain contained therein. Hard times call for effective solutions. We have some retiring members who have worked long and hard to bring our Association forward so let us take it to the next phase and look forward with anticipation! Dr. Pete Waterman OBE, DL President of the CEA

CEA Yearbook 2012/13

Message from the Director 2011 and 2012 have been extremely busy with a number of significant changes. Firstly, the long awaited changes to PM5, which has been replaced by the HSE guidance document INDG436 and supported by BG01 written by the CEA in conjunction with SAFed and the HSE in October 2011. The documents’ publication in turn started a flurry of activity and conferences to help the industry understand the changes. Then there was my appointment as Director in July 2011 and that of Julie as the new office administrator in January 2012, which was also a significant change with David Arnold and Carolyn taking up retirement again. From a standing start it’s been non-stop since we opened our new office. We started with a very well-attended CEA Launch event at NETPark in February; several PM5/BG01 and Biomass conferences across the country; the AGM at the House of Lords in March with the appointment of CEA’s new Chairman David Gent of British Sugar; and the Members and Partners dinner in May at the House of Lords. Having Lord Chidgey as our host and Lord Renwick and Lord Howie and their wives and partners attend the dinner was a great honour and recognition of the CEA’s activity. The dinner was followed by the David Gunn Memorial Lecture and Lord Ezra Award at the House of Lords in mid-October. With the agreement of Chairman Malcolm Dunphy and the Council, the CEA offices relocated from Cardiff to NETPark (North East Technology Park) in Sedgefield, County Durham in January 2012. See page 25 for a look at our new offices. BOAS continues to go from strength to strength with the imminent 1,000th candidate to gain their first accreditation and some 400 reassessments after having held accreditation for five years. CEA is also reviewing the scheme and improving the qualification to ensure it is as well respected as it has always been and to take into account changes across the relevant sectors. The Industrial Emissions Directive (IED) is actively looking at emissions from industry in general, and the CEA is focussing on the large combustion plant above 50MWth input. CEA members have come together as a team, looking at the impact this will have on UK industry and advising Defra of its views. CEA also has one of five seats on the Commission’s Technical Working Group rewriting the combustion BREF (Best Practice Reference) Document. It must also be noted that the Commission has also carried out a survey, looking at the emissions from 1MWth input through to 50MWth input to identify where the major CO2 reductions could be made, this identifies 5 – 20 MWth input as the major areas for CO2 savings. Recently CEA held the Council weekend at Stratford-Upon-Avon and had a very pleasant evening on the River Avon with dinner on the Countess of Evesham river boat.

CEA Yearbook 2012/13

CEA has been approached to support the creation of a local Universities Technical College (UTC) in the area, in collaboration with Bishop Auckland College, The University of Sunderland and industrial partner Hitachi trains. Currently there are 34 UTCs that have been approved by Government with an initial investment of £10m per UTC. To find out more, please see the Baker Dearing Report (Lord Kenneth Baker ex-conservative cabinet minister). CEA Executive and Council have agreed to offer a letter of support to the local UTC being led by Bishop Auckland College. I would also like to say a very big thank you to all Executive and Council members for the help, support and friendship you have shown to both Julie and I as we endeavour to deliver the aims and objectives of the CEA. I hope we are able to continue to give you the service that the Association requires. At the CEA, we like to think we are easy to talk to and easy to deal with, so should you have any reason to contact us please feel free to do so. Finally, I would like to say that should you as a member need access to facilities at NETPark, please contact us and we will make the necessary arrangements. David Kilpatrick Director of the CEA

Process waste to process energy Many manufacturing processes generate waste streams, co-products or residues which can be converted into biogas, liquid biofuels or biomass to supplement fossil fuels used in combustion. These â&#x20AC;&#x2DC;own makeâ&#x20AC;&#x2122; bio-fuels reduce supply risks associated with external fuel supplies and contribute to lower overall energy costs.

Dunphy triple fuel burner which simultaneously fires natural gas and biogas derived from brewing residues and which has the additional capacity to co-fire biogas and gasoil.

Dunphy has wide international experience in designing, manufacturing, installing and maintaining multi-fuel combustion plant for food and dairy producers, brewers and distillers, industrial manufacturing, municipal waste to energy and wastewater utilities.

Multi fuel combustion requires safe and simple fuel changeover processes. Dunphy control touchscreens provide combustion management and fuel changeover functions via a 17 inch monitor - with fingertip control of all boiler and burner operations. Totalised fuel, electricity and water consumption data as well as quantified steam outputs are all immediately available. Information can be transferred remotely to BM systems or via Dunphy software to all standard computers.

For more information, contact sharon.kuligowski@dunphy.co.uk www.dunphy.co.uk

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CEA Yearbook 2012/13

About the CEA

he CEA is an educational charity originally formed to promote the science of combustion engineering and today embraces the study of efficient energy use, the exchange of new technology information, the training of industry professionals, the development of standards and good practices and the provision of services for its ever growing membership. Members include; • Boiler, burner and equipment manufacturers • Steam equipment manufacturers and suppliers • End users, installers and energy suppliers

• Facilities management and maintenance providers • Industrial, environmental and design consultants Core activities also include the organisation of conferences and seminars, managing the CEA’s involvement in trade exhibitions, hosting an annual Memorial Lecture and the presentation of an Award for Innovation. In addition to the Yearbook, the CEA works closely with other organisations in the publication of guides and best practice information and plays an active role in the formulation and development of British and European Standards and Directives.

Officers and Members of Council as at May 2012

Honorary Patron Honorary President Honorary Vice Presidents Executive Committee Chairman of Council Vice Chairmen Immediate Past Chairman Treasurer Support Director Trustees

The Lord Ezra, MBE Dr Pete Waterman, OBE, DL The Lord Chidgey Prof Bill Kaye - Kaye & Associates Limited Prof Ian Fells Mr Kenneth Fergusson Mr David Arnold Mr David Gent AB Sugar Ltd Mr Jim Findlay Heatsol Technology Ltd Mr Paul Richards Fulton Boiler Works (GB) Ltd Mr Malcolm Dunphy Dunphy Combustion Ltd Mr Chris Coleman Spirax-Sarco Ltd Prof Bill Kaye Kaye and Associates Ltd Mr David Kilpatrick CEA Mr Jim Findlay Mr David Gent Mr Chris Coleman

Important Note: The offices of Patron, President and Vice Presidents, are Honorary posts and do not carry any automatic right to representation on Council. Trustees are automatically Members of Council.

Council Members 2012-2013

Derry Carr Sam Thiara Paul Balmer Paul Whitehead Kim Stopher Peter Pearson Adrian Rhodes John Bashall Jamie Bashall Dr Clive Chamberlain Barrie Church Martin Fletcher Prof Bill Kaye Paul Mayoh Alistair Nicol Andrew Mallalieu Bernard Fox Andy Rout David Arnold David Kilpatrick

CEA Yearbook 2012/13

Dalkia Emerson GasTec at CRE Independent Consultant Independent Consultant Independent Consultant Byworth Boilers JBC Industrial Services Ltd JBC Industrial Services Ltd Combustion Technology Consultants Global Energy Associates Enersol Flomar Kaye & Associates Limited Spirax-Sarco Ltd Independent Consultant Facultatieve Technologies Ltd Weishaupt UK Ltd TLV Engineering Ltd Retired Director CEA

PM5 Replaced â&#x20AC;&#x201C;

New HSE Guidance for Steam and Hot Water Boiler Plant

The most significant in the steam industry for over a decade

Coffee Break and Exhibition

boilerhouses and steam systems from

EXHIBITING

spiraxsarco.com/uk

When & where:

Wednesday 31st October 2012 Engineers House,The Promenade, Bristol, Avon BS8 3NB

spiraxsarco.com/uk

}

Extra Seminar Biomass Conference Workshop running on same day!

Wednesday 21st November 2012 Mercure Hatfield Oak Hotel, Roehyde Way, Hatfield AL10 9AF

Registration commences for both conferences at 9:30, event starts at 10:00, event concludes at 15.40 â&#x20AC;&#x201C; lunch provided. Tel: 01740 669022 Email: info@cea.org.uk

Energy policy – 10 years older and wiser? Kenneth Fergusson, hon. Vice President, CEA, gives his view of the state of energy policy in the UK 10 years have gone by since I was elected President of CEA in 2002. I began my message for the 2002/3 yearbook with: “One way or another, CEA members are all in the energy business.” That year, national energy policy was centre-stage, with the government preparing the Energy White Paper.

Gas price and availability Oil has always been a traded commodity with price volatility. Gas, once it became possible to transport it internationally, first by pipeline, and then by LNG tanker, began to mirror the oil price. In the last 3 – 4 years, this link has been broken in the US by the huge rush to produce domestic resources of shale gas, which has halved the gas price in the US. This could also happen in UK, which would undermine the huge investment in LNG terminals, but will encourage the construction of more gas-fired power stations.

Coal supply My President’s message for the 2003/4 Yearbook was an analysis of the White Paper and its impact on CEA members. For power generation, the thrust was on gas (to provide 80% of UK demand in 20 years’ time) and renewables (20% by 2020) while “keeping the nuclear and clean coal options open”. Secure, affordable, sustainable energy supplies were the objective. The world was assessed as having plentiful gas supplies. Generators were to be bound by a “Renewables Obligation”, to generate 3% of their output from renewables initially, 10% by 2010, and 20% by 2020.

Domestic production has dwindled to a few million tons per year and 80 % of our requirements are now imported. Until the 1990s, international coal prices were more-or-less the cost of mining and transportation, with some reflection of fluctuating international shipping rates. But more and more, coal became a traded commodity, reflecting oil price movements. Together with the high cost of meeting greenhouse gas (CO2) capture costs, this has put a stop to almost all new coal-fired power projects in Britain. Some based on coal gasification may continue.

So, almost a decade into the plot of the UK energy policy, where are we now? It’s a huge subject, but the following are key points.

Underground coal gasification

CEA Yearbook 2012/13

There are still massive coal occurrences in Britain, which cannot be

economically mined, but are amenable to in-situ gasification. The UCG process is being developed commercially in many countries; 13 sites in Britain have been licensed. When it does finally arrive, UCG will reinforce the case for gas-fired power generation.

Nuclear Eventually, the “nuclear option” was supported in Britain by the formation of two consortia, one French-led, the other German, to construct eight reactors, the first by 2017. Fukushima dealt this a blow, when the German consortium was saddled with huge costs at home, by the German government’s decision to abandon nuclear power. They have pulled out of UK projects and maybe Chinese or Russians will take these over; there’s a thought! The EDF/Centrica consortium is still proceeding, and the election of Francois Hollande does not seem to have impacted on EDF financing (yet?), but there are still unresolved issues on the ultimate liability for long-term power prices and the decommissioning costs and waste disposal. At best, the date for a first new station will be at least three years later than planned.

Renewables Effectively, renewable = wind, and it has been favoured by large subsidies and many other tactics. The voices of technical and economic reason have been ignored. Onshore wind costs double the generation cost from clean gas or nuclear; offshore wind costs

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treble that. The additional true cost of standby generation to cover the variability of wind, and the cost of connection and losses from remote locations, have been fudged. Now the Chancellor, recognising the political effect of rising domestic bills, is proposing to cut the subsidies for wind by 25%; as a result, a Danish company has cancelled plans to build a turbine factory in the UK, and some projected wind farms are in doubt. One thing is for sure – we won’t generate 20% of our power from wind by 2020, if ever.

Emissions trading This was keenly anticipated by traders in the City, but so far, fraudsters have been the most accomplished beneficiaries. Setting a carbon floor price has been a political hot potato; without it, carbon capture and storage projects will be stillborn. But the risk of it is a threat to carbon-intensive industries. In the last two years, for example, the two major aluminium smelters in Britain have closed. 10 years older? That’s for sure! Wiser? I wish I knew... There are many issues still to be resolved and many areas of development, such as biomass, tidal power, energy storage, geothermal, micro-generation, which can have a significant positive impact. Others, such as solar and wave power, are hard to foresee other than on the periphery. But I think I am wise enough not to risk making any more predictions!

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CEA Yearbook 2012/13

TURNKEY SPECIALISTS IN THE DELIVERY OF STEAM AND HOTWATER BOILERHOUSE SYSTEMS Part of the Global Torishima Corporation, with a turnover of over $630 million a year, Torishima (Europe) Projects Ltd has an outstanding track record in renewable energy engineering and a client portfolio to match. DESIGN, MANUFACTURE & INSTALLATION – WE PROVIDE THE TOTAL SOLUTION With over 20 years’ experience TEP has been involved in some of the most high-profile and demanding projects in the water/waste/renewables, food, health and process sectors and has a fully developed supply chain which has proved its competitiveness over recent awards. REDUCING FUEL COSTS AND CARBON FOOTPRINT Alongside proven expertise in conventional boilerhouse design and delivery, we have a particular specialism in biogas utilisation systems and offer unique control and heat recovery systems to deliver efficient and ‘best in class’ assets for our clients.

TWICE VOTED ‘COMPANY OF THE YEAR’ IN 2012 www.torishimaprojects.co.uk

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Torishima House, Brook Lane, Westbury, Wiltshire, BA13 4ES. UK. Tel: +44 (0)1373 858143 or email guyforrest-hay@torishima.co.uk 12

CEA Yearbook 2012/13

INDUSTRIAL BOILER TECHNOLOGY AT ITS BEST ABOUT ICI CALDAIE ICI Caldaie is one of the largest manufacturers of commercial and industrial boilers in Europe, producing up to 12,000 units per year for the global market.

OUR RANGE Steam boilers with duties up to 25,000kg/hr and 20 bar operating pressure. We also offer a range of coil type generators, Thermal fluid heaters and LTHW/MTHW boilers including condensing, from 57kW up to 20MW

NO IFS, NO T-BUTTS The absence of T Butt weld joints between the furnace and tube plate eliminates any potential failure mechanisms common to many other boiler designs.

MAX PERFORMANCE â&#x20AC;&#x201C; FOR LIFE ICI Caldaie use the highest quality materials available. Our state of the art fabrication techniques ensure that the safety and service life of our products is always at the forefront of our design. We are so confident about the quality of our designs and manufacturing that we offer a standard THREE-YEAR WARRANTY across our entire range.

FUTURE-PROOFING THE ENVIRONMENT Our range of products are designed to meet the highest efficiency levels in the industry, whilst at the same time reducing harmful Nox and Co2 gas emissions into the atmosphere.

www.icicaldaie.co.uk Torishima House, Brook Lane, Westbury, Wiltshire, BA13 4ES. UK. Tel: +44 (0)1373 825563 or email sales@icicaldaie.co.uk CEA Yearbook 2012/13

On a mission to deliver process steam generation systems Torishima (Europe) Projects delivers fully integrated process steam generation systems across the industrial sector – here’s how

he time-served, proven team now fully established as Torishima (Europe) Projects [TEP] was formed to meet current market demands for a company that can provide high quality, turnkey engineering solutions. Our unique offering is the ability to design, install and commission complete steam and hot water systems to the highest standard. Combine that with the application of high quality equipment and materials - delivered by acknowledged industry specialists - and we feel we can add significant value to a client’s project. TEP are on a mission is to provide ‘best in class’ fully integrated process steam generation systems across the industrial sector. The company prides itself on being at the forefront of technology and continuously strives to offer competitive solutions that enable its customers to reduce their fuel costs; improve their environmental performance and reduce their carbon emissions.

Based UK-wide With bases in Wiltshire, Essex, Somerset, Manchester and Scotland, TEP continue to expand its offerings to the marketplace. The recently mobilised Torishima House in Westbury, 20 miles south-east of Bath, will be a ‘centre of excellence’ for training – delivering the BOAS and DipBOM training courses amongst others with live hands-on systems – and house a significant stock holding of leading brand boiler house equipment and ancillaries to ensure a fast response to clients’ needs. Torishima House will also be the HQ for a significant R&D programme, which is well underway and will deliver an advanced, intelligent complete boiler house control system. The intelligent control system can be retrofitted to any boiler and will represent a significant step-forward compared to other offerings in the

CEA Yearbook 2012/13

marketplace. Work is also at an advanced stage to further drive up boiler efficiencies to the ‘holy-grail’ of just below 100% through the application of innovative condensing technologies.

Range of capabilities TEP are fast developing a reputation for delivering excellence in: • The supply of complete packaged steam and hot water generation systems, including biomass. • The provision of high energy efficiency boilers to reduce fuel bills and carbon dioxide emissions • Expertise in utilising waste heat, biogas and alternative fuels (TEP were awarded ‘Renewable Energy Company of the Year – Best Practice’ (Midlands) • Operating as a sole-entity supplier to simplify process interfaces and ensure robust and optimised asset delivery. • Application of expertise and know-how on steam generation

Double awards As well as developing a high profile client base - including major water utilities and a leading soft drinks company - the progress and contribution of TEP has been externally recognised with two ‘Company of the Year’ awards in 2012. Assistant Editor of Business & Industry Today, Thomas Gill, said: “We presented Torishima with the ‘Company of the Year Award’ due to their innovative approach to delivering complete turnkey solutions and for high quality steam energy and biomass systems. In such a rapidly declining economy, saving time and money is regarded as essential, and Torishima deliver both on efficiency and quality within an impressive lead time of typically 15weeks.

Our Guarantee • Strong, in-house, proceduralised design capability based on 20+ years of experience in boilerhouse design, installation, integration and optimisation. • Backing of a significant player in the Global marketplace, employing over 1,000 people, with a turnover in excess of US$ 630M and an annual growth rate of 15%. TEP offer peace of mind in terms of financial security, accreditations, assurances/ guarantees and business administration. • Unique turnkey offering with a reputation for excellence in all aspects of Project Management. • A track record for delivering technical and engineering excellence at a competitive price. • Strategic alliance with ‘Best in Class’ boiler supplier and fully developed supply chain. • Guarantees on safety, reliability and quality of supply from boiler supplier, ICI Caldaie – with a leading market position and international reputation - producing over 9,000 boilers per annum, designed to the latest standards and required efficiency performance. • A proven team with a real passion for delivery of a fully integrated system which is right first time. • Fully developed supply chain for all mechanical and boiler ancillary equipment ensuring a fast response and turnaround in the unlikely event of any equipment issues.

A4 Cochran Ad:Layout 1 02/08/2012 15:53 Page 1

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CEA Yearbook 2012/13

Zero-cost investment in biomass heating with Energy Efficiency Financing scheme The Energy Efficiency Financing scheme (EEF) provides finance for organisations acquiring energy-efficient equipment, with affordable monthly payments, explains Darren Riva, Head of Green Financing, Energy Efficiency Financing Scheme

Energy Efficiency Financing scheme (EEF). It is designed to provide finance for organisations acquiring energy-efficient equipment, with affordable monthly payments designed to match - and be offset by - the average monthly savings on energy bills, effectively meaning the equipment pays for itself. In some cases, the savings can be greater than the monthly costs, allowing the end customer to be cash positive from day one.

Suppliers of biomass heating technologies can also apply to become a recognised supplier of the scheme, which will allow them to integrate the financing offer into their overall sales proposition. This removes the obstacle of large up-front capital investment for customers, and helps suppliers to close more deals as efforts can be focused on providing the best solution, rather than being constrained by customer perceptions of capital budget restrictions.

iomass heating is playing an increasingly important role in decarbonising the UK, with research showing that carbon savings of up to 20 million tonnes of CO2 per year could be achieved using UK biomass resources alone.1 Currently, heat in all its forms accounts for nearly half of the UK’s carbon emissions. Given that the UK has a legal requirement to reduce carbon emissions by at least 26% by 2020 and 80% by 2050 (against a 1990 baseline) under the Climate Change Act, there is a strong requirement to shift away from fossil fuel heating systems to lower carbon forms of heating. In June 2008, the Government’s Renewable Energy Strategy consultation proposed that under one possible scenario 14% of the UK’s heating may need to come from renewable sources by 2020 for the country to meet its renewable heating target identified under the EU’s Directives.2 As less than 1% of UK heat demand is met by renewable sources at present, the supply of heat is likely to undergo a dramatic and rapid transformation over the next decade. According to the EU, the use of biomass will double over the next few years, and will be responsible for around half of the total effort in reaching its 20% renewable energy target by 2020.3 The market for biomass heating is already relatively well established in some European countries. In Sweden, 38% of overall heat demand was provided by heat from biomass sources. In the UK, biomass supplies less than 0.6% of the country’s overall heat demand.4 There remains significant potential for a greater proportion of the UK’s heat to be derived from biomass.

Affording biomass heating systems Nowadays, organisations increasingly recognise the merits of biomass heating, including operational cost savings and reduced carbon footprint. Restricted access to credit in recent years, however, has discouraged many businesses from implementing biomass heating solutions. Reports from the Bank of England show that the annual rate of growth in the stock of lending to UK businesses was negative and fell by around £3 billion in the second quarter of 2012. This contraction was also reflected in the stock of lending to SMEs, with tight lending criteria showing little sign of abatement.5 To help companies overcome the financial barrier, the Carbon Trust and Siemens Financial Services Limited (SFS) have initiated the

CEA Yearbook 2012/13

Corrimony, a working family farm in Inverness-shire, Scotland, has already made use of the affordable and flexible terms of the EEF scheme to invest in biomass heating at what is effectively zero net cost. The farm house and three cottages used to be heated by old fashioned oil and wood fire heating systems which were inefficient and expensive. The specialist financing from EEF has enabled the farm to invest £180,000 in a centralised wood chip biomass boiler. It supplies heating and domestic hot water to the farm house and cottages as well as a neighbouring property and removes reliance on expensive oil fired heating, with the seasoned logs sourced from the plentiful wood on the estate. Annual savings are expected to be about £36,000, with a return on investment in less than 7 years.

Conclusion To encourage businesses to install renewable heat technologies, the government has already launched the Renewable Heat Incentive (RHI). By allowing organisations to earn a fixed income for every kilowatt hour of heat they generate, this stimulus is a welcome boost to the biomass heating market in the UK. With the financial obstacle to investment now removed by the EEF scheme, in addition to policy inducement, businesses wishing to reduce energy costs and minimise their environmental impact are able to seize the opportunity to realise their investment ambitions at zero net cost. For more information, please visit www.energyefficiencyfinancing. co.uk or call 01753 434476 1

The Carbon Trust, Biomass heating, A practical guide for potential users ibid 3 Process Engineering, Burning matters, 14 Sept 202 4 The Carbon Trust, Biomass heating, A practical guide for potential users 5 Bank of England, Trends in lending, July 2012 2

Opportunity NOx.

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CEA Yearbook 2012/13

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©Zeeco, Inc. 2012

Condensate recovery system upgrades that boost steam system centre efficiency Condensate contains about a quarter of the energy of the steam from which it came. That’s a significant amount of heat available to a steam system. Ensuring that existing condensate recovery systems are as efficient as possible is, therefore, vital for reducing steam system costs. Paul Mayoh, Product Manager at Spirax Sarco, looks at ways to ensure as much condensate as possible is re-used.

n today’s straitened economic climate with capital budgets being squeezed, the focus of many energy managers has shifted away from significant capital expenditure projects. Instead, relatively low cost and easy to implement upgrades and enhancements to existing installations are in the spotlight, especially ones that can improve steam system efficiency. Making the most of existing plant is the order of the day. For many steam using operators, the boiler house is a major source of operational costs and any improvements here can quickly repay themselves. In particular, it’s vital that steam systems run at optimum efficiency. Condensate recovery is a juicy target for upgrades because although steam systems will almost all have condensate recovery systems in place, often they can be improved relatively easily to achieve rapid payback. Condensate is the hot, treated water produced as steam releases its heat energy. It’s a valuable resource that contains around 25% of the useful energy in the original steam. It makes sense to return it to the boiler, instead of dumping it to drain. It may be impractical to return all the condensate to the boiler for various reasons, but in most applications a goal of 75-80% condensate return is reasonable. Condensate recovery offers several benefits. It reduces fuel costs and saves energy, reduces water charges and chemical treatment costs and brings down effluent charges.

The latest steam trapping station technology allows energy-saving, hassle-free steam trap operations

Smaller fuel bills: Returning hot condensate to the boiler feedtank can save thousands of pounds per year in energy alone. Using condensate to heat the boiler feedwater leaves the boiler with less to do to convert water to steam. In other words, less fuel is needed to produce steam from hot water rather than cold water. Using returned condensate to raise boiler feedwater temperature by 6°C gives a fuel saving of 1%. Energy saving: Condensate is distilled water with little total dissolved solids (TDS). Condensate returned to the feedtank reduces the need for boiler blowdown, which reduces the concentration of dissolved solids in the boiler. This therefore reduces the energy lost from the boiler during the blowdown process. Reduced water charges: Any condensate that is not returned and re-used must be replaced by fresh water, incurring additional water charges. Lower chemical treatment chemical costs: Re-using as much condensate as possible minimises the amount of costly chemicals to treat raw water. Reduced effluent costs: In the UK, water above 43°C cannot be returned to the public sewer because it is detrimental to the environment and may damage earthenware pipes. Condensate above this temperature must be cooled if discharged, which could incur extra costs. Similar restrictions apply in most countries and effluent charges and fines may be imposed by water suppliers for non-compliance.

Condensate contains around 25% of the useful energy in the original steam

CEA Yearbook 2012/13

Eliminated steam plumes: Steam systems that allow condensate to flash to steam can create visible plumes, potentially presenting a poor image to the outside world of an organisation that is not environmentally friendly.

A professional steam trap survey will identify where improvements could be achieved and give an estimate of the potential financial gains through upgrades

Rapid payback often possible Each steam system is different and only a technical assessment and cost saving calculation can determine the payback of a particular enhancement project. However, itâ&#x20AC;&#x2122;s typically between one and two years, making it an attractive proposition for healthcare organizations. At sites where the payback is longer than two years, it may still be a worthwhile project offering substantial cost savings in the longer term. However, many healthcare organisations may find it difficult to invest upfront in these projects, even though they could be saving them money. Help is at hand with the rising availability of rental options that can enable organisations to carry out projects sooner and reap the benefits of eliminating wasted energy immediately. The resulting savings effectively make many projects self-funding. There are several essential steps in effective condensate recovery.

The role of steam traps In order to recover and re-use condensate it is first necessary to remove it from the steam system. The steam trap is the most important link in the condensate loop because it connects steam usage with condensate return by retaining steam within the process for maximum utilisation of heat, while releasing condensate and incondensable gases at the appropriate time. Steam condenses as it gives up its heat. The resulting condensate must be purged from the system or it will lead to poor heat transfer and possible problems with waterhammer. Waterhammer is a risk in a poorly drained steam main, where condensate collects and forms a slug of water. This water is incompressible unlike steam - and can cause damage when carried along by the high-speed steam. Air and other non-condensable gases must also be purged or they can lead to poor heat transfer and corrosion problems. A question sometimes asked is why are there several different types of steam trap? The answer is that steam application has its own requirements and it is impossible to meet all needs with just one type of steam trap. The major steam trap types include:

Thermostatic steam traps, which do not open until the condensate temperature has dropped below steam saturation temperature. These traps are widely used in applications where it is acceptable to use some of the sensible heat in the condensate and reduce flash steam losses, such as non-critical tracing. Mechanical steam traps, which discharge condensate at steam temperature. This makes them the first choice for applications where the rate of heat transfer is high for a given heat transfer area, such as heat exchanger applications. Thermodynamic steam traps, which are compact, simple, lightweight and not affected by waterhammer or vibration. Thermodynamic traps discharge condensate close to steam saturation temperature. This makes them the first choice for steam mains drainage and critical tracing.

Commission a steam trap survey A good start point in any project to improve condensate recovery and one of the most cost effective measures is to commission a professional steam trap survey to identify where improvements could be achieved. Such a survey will also give an estimate of the potential financial gains through upgrades â&#x20AC;&#x201C; providing information to help justify maintenance expenditure. A steam trap survey will help to keep a system running smoothly and will almost certainly reveal impressive savings through reduced fuel consumption, fuel emissions, water and effluent charges. For example, an analysis of 50 Spirax Sarco steam trap surveys revealed potential annual energy savings of ÂŁ28,400 per survey on average. The average payback time on each survey, including the cost of replacement products and their installation, is about two months, when all upgrade work is completed.

Automatic pump traps maintain heat exchanger efficiency Conventional steam traps need an upstream steam pressure that is higher than the downstream pressure to enable them to remove condensate from pipelines and heating equipment. Yet in plate heat exchangers commonly used in heating and hot water

CEA Yearbook 2012/13

water, vapour and energy can be lost and just as importantly, air will be admitted, which could lead to corrosion of the boiler and steam plant. Oxygen in feedwater can be dispersed by heating and absorbed by chemical treatment. By heating the feedwater, typically to 85°C to remove the bulk of the oxygen, the amount of scavenging chemicals required can be reduced by up to 75%. Heating and deaeration is most efficiently achieved by using a deaerator head, which mixes returned condensate, flash steam and cold make up water as they are fed into the feedwater tank. The deaerator head mixes the cold feedtank make-up water with its high oxygen content with the flash steam from the condensate and blowdown heat recovery.

Survey the system It is important to ‘walk the plant’, looking for tell-tale signs of escaping flash steam and checking that the condensate recovery system is working properly. It is best to engage a steam system expert to do this initial inspection as experience goes a long way in identifying opportunities for improvement. Automatic pump traps act as conventional steam traps under normal operating conditions, but in conditions where back pressure would cause a normal trap to stall and flood the system, pump traps automatically switch to pumping mode to ensure condensate is removed

applications, when demand falls, so does the upstream pressure, and steam traps can fail to clear condensate. The consequences can be a slowing of the heating process, a drop in energy efficiency, noise and vibration within the heat exchanger, burst pipes, higher maintenance requirements and even a totally stalled exchanger. The most effective way to clear condensate from heat exchangers in this situation, as well as in other applications where there is insufficient pressure to clear condensate, is to fit an automatic pump trap. Under normal operating conditions, these act as conventional steam traps. But in conditions where back pressure would cause a normal trap to stall and flood the system, pump traps automatically switch to pumping mode to ensure condensate is removed. Like mechanical condensate pumps, automatic pump traps are self-contained and use plant steam to provide the motive power to pump out condensate, even under vacuum. In operation, condensate enters the trapping chamber through the inlet. Normally, the condensate flows freely through the chamber into the condensate return system. However, if back pressure prevents the condensate from leaving normally, the pump trap’s condensate outlet closes. Condensate continues to flow into and fill the chamber and is then pumped out using the same principle as a conventional mechanical condensate pump.

Feedtank heating and deaeration Once the condensate is returned to the boiler feedtank, it needs to be mixed with the existing feedwater to raise the temperature. However, simply feeding condensate into the top of the feedwater tank can be inefficient. As it falls through the space above the

CEA Yearbook 2012/13

From here it is possible to put together a detailed project proposal with full costings to identify payback periods and energy savings. As well as a full range of condensate recovery and management products, Spirax Sarco offers technical support, knowledge and services, and works with healthcare organisations to identify, design and implement improvements to their steam systems, and then help to maintain the resulting system efficiency gains. Surveys cover a wide range of equipment including steam traps, high limit control equipment and condensate pumps. The most popular survey is the steam trap survey. Once the survey is complete and the steam trap population is brought up to peak operating efficiency, Spirax Sarco’s steam trap management service can save money and effort by taking responsibility for keeping steam traps running at maximum efficiency year after year.

spiraxsarco.com/uk

Join the 500+ engineers who’ve gained BOAS accreditation with us

www.spiraxsarco.com/uk

Practical training that complements the UK’s widest steam product and services portfolio Since Spirax Sarco became the first accredited Boiler Operation Accreditation Scheme (BOAS) trainer in 2005, more than 500 engineers have achieved their BOAS certification with us. That’s more than any other BOAS training provider can say by a long chalk. Enjoy our state-of-the-art training facilities in our recently revamped UK Steam Technology Centre - the only UK training facility with a fully-operational steam system with SCADA control. Training delegates receive a ‘hands-on’ experience that provides ‘real-world’ training, leading to formally recognised qualifications. We don’t just offer excellent training. We have the products, solutions and services to help you reduce energy costs, increase efficiency and improve productivity. Want to find out more? Email uk.enquiries@uk.spiraxsarco.com, ref: ‘CEA’.

Help yourself to delicious food from our new Bistro during your training – on us, of course!

CEA Yearbook 2012/13

Steam Boiler Energy Savings patented dreizler marathon burners (15kW to 44MW)

10% to 20% Energy Savings in Gas Consumption and Electrical Power are available with burner retrofit installations

High Quality Engineering For more information contact:

HeatSol Technology Ltd Tel: 0800 313 4643 22

HeatSol House, 28 High Street, Droitwich Spa, Worcestershire WR9 8ES

CEA Yearbook 2012/13

Email: info@heatsol.co.uk

The impact of the new Industrial Emissions Directive The Industrial Emissions Directive, or IED, will impose new emissions limits on large combustion plant. The CEA is representing the industry’s interests. The combustion industry is increasingly being driven to develop low emissions systems and technological solutions. This current push comes from the introduction of the Industrial Emissions Directive, or IED. For large combustion plant, the IED implements a number of special provisions and these come into effect from January 1st 2016, forcing industry to take one of three options with their 50 MW thermal boilers. Boilers could be replaced or retrofitted to comply with the new lower emission limits, employing technologies such as SCR (Selective Catalytic Reduction), low NOx burners or use of different fuels. The emission limits are expressed in mg/Nm3 and categorised according to many different factors, including size (by thermal input), fuel classification and type of combustion equipment. These limits can be found in Annex V of the IED.

Options for transition A plant could also choose to take one of two transitional options available within the IED, which allow the plant to delay compliance with the emissions limits, easing the strain on industry to comply. A ‘Limited Life Derogation’ (LLD) allows a plant 17,500 hours of running time at the current LCPD (Large Combustion Plant Directive) emission limits from January 1st 2016 before being shutdown. This option is available throughout the EU and is likely to be taken up by utility plants wanting to extend the life of their coal fired power station asset base.

The other arrangement available is the Transitional National Plan (TNP). Member States have the option to implement a TNP and the UK has indicated it will do so. , This option allocates tonnage ‘allowances’ for plant based on actual emissions over a 10 year baseline period (2001 to 2010), which reduce linearly over a 4 year period to zero by 2020. Surplus allowances are tradable, creating some flexibility and a financial opportunity for some.

CEA speaks for the industry In the past the CEA has made significant contributions to the implementation of the Large Combustion Plants Directive in the UK, lobbying for the National Emissions Reduction Plan (NERP) transposition in order to help UK industry comply. Collaboration on the IED arrangements and the Emission Limit Values (ELVs) going forward is continuously being carried out and the CEA Large Combustion Plant Working Group continues to engage with this process, speaking for the combustion industry to ensure the legislation is steered to account for industry sized boiler plant in the UK. The IED could be opened up to affect even more plant in the future, with a review of the 50 MW threshold underway, a decision is expected before the end of the year which could mean plant as small as 1 MWth input could be included. This, along with the aggregation rules stating boilers must be ‘combined’ when considering the threshold, means that even more of industry could become affected by the IED. This increased drive for low emission equipment highlights the importance of the CEA’s work to keep abreast of developments and be the voice of the industry when collaborating with legislative bodies on the IED.

CEA Yearbook 2012/13

Valves Industrial Electronics Automation Special Equipment and Vessels for Heat Recovery Services

Flowserve GB Ltd. · Gestra - Power Division · Euro House · Abex Road · Newbury · Berkshire · RG14 5EY · United Kingdom Telephone: +44 (0)1635 46999 · Fax: +44 (0)1635 36034 · gestraukinfo@flowserve.com · www.flowserve.com 24

CEA Yearbook 2012/13

CEA moves to NETPark In February 2012, the CEA moved into new offices at NETPark, the North East Technology Park, which is claimed to be the UKâ&#x20AC;&#x2122;s fastest growing Science Park. The park focuses on supporting companies that are developing technology and products in the physical sciences, particularly printable electronics, microelectronics, photonics and nanotechnology, and their application in the fields of energy, defence, and medical-related technologies. The facilities at NETPark are exceptional and are available for use by CEA members by prior arrangement. The Combustion Engineering Association, NETPark, Thomas Wright Way, Sedgefield, Co. Durham, TS21 3FD.

CEA Yearbook 2012/13

renewab e energy... ...now there’s a bright idea!

As the leading supplier of utilities and services to the Wilton International manufacturing site we take our environmental responsibilities seriously. This is why we have invested millions of pounds in our Biomass Power Station, to create 30 MW of renewable energy from wood and to help combat global warming. If you wish to understand more about Sembcorp and our new Biomass Power Station please visit our website: www.sembcorp.co.uk

Sembcorp Utilities (UK) Limited, PO Box 1985, Wilton International, Middlesbrough, TS90 8WS. Phone: 01642 212229 Web: www.sembcorp.co.uk

Flame of a multiflam® gas burner

The art of making fire For decades, Weishaupt has been honing and perfecting the precise art of combustion technology. A prime example is Weishaupt’s multiflam® technology, which reduces emissions from gas, oil and dual-fuel burners to an extremely low level. From 12 kW to 22 000 kW, for fossil or biogenic fuels, every Weishaupt burner employs cutting edge digital technology and embodies the expertise that comes only from experience. Weishaupt (UK) Limited, Neachells Lane, Willenhall, West Midlands, WV13 3RG. Tel.: 01902 609841, www.weishaupt.co.uk

That’s reliability. W Burners

CEA Yearbook 2012/13

WM Burners

WK Burners

Byworth a complete boiler service Yorkshire based Byworth Boilers is the country’s leading independent steam and hot water boiler manufacturer and has been producing quality boilers in Yorkshire since 1968. In our Keighley factory the latest manufacturing techniques are combined with time-honoured boiler making skills to ensure quality control of the very highest standards

yworth’s success is based on a passion for steam and we are dedicated to working in partnership with our customers to ensure individual requirements are met in full. Byworth provides a complete boiler solution whether it be custom built plant for purchase or lease, long or short term hire, servicing, repairs, replacement parts and training.

Byworth manufactures a comprehensive range of boilers, each with many options and variations. The Yorkshireman range is a conventional three-pass wetback design of up to 18000 kgs/ hour and is a time proven robust boiler suitable for arduous workloads. The MX reverse flame range suits small and medium sized applications from 125 to 5000 kgs/hour and is a compact, reliable yet affordable boiler. The Dalesman is a traditional threepass wetback shell hot water boiler built to withstand the rigours and continual heavy workload. Dalesman boilers are available with output up to 10,000 kW and working pressure up to 20 bar. The Fellsman is a reverse flame wetback hot water boiler. It is compact and highly efficient with output options up to 3000 kW and working pressure up to 15 bar. Byworth’s Waste Heat boilers can operate in a range of applications using heat which is produced as a by-product of another process or from CHP engines. Individually designed by our specialist design team they are available either as steam or hot water boilers with outputs up to 16,000 kgs/hour or 9,600 kW.

Byworth’s Pre-Heat Boiler showing the flue gas economiser and air-to-air heat exchange

CEA Yearbook 2012/13

UK's leading

boiler hire service from the manufacturer of the UK's most fuel efficient boilers • UK's most reliable and efficient rental boilers • Modern, fuel efficient boilers with latest technology

• Plant for long term projects can be built to specification

• Service back up second to none • Speedy emergency hire service • Steam boilers from 500 to 16000 kgs/hr • Hot water boilers from 250 to 5500 kW/hr • Multiple boilers installed for larger demand • Full installation, commissioning and training available

UK’S LEADING

BOILER MANUFACTURER 28

CEA Yearbook 2012/13

We promise to beat any comparable quote - just give us a call

Tel: 01535 665225 Email: hire@byworth.co.uk Web: www.byworth.co.uk

We also manufacture a range of Combination boilers which are special gas or oil fired boilers with a waste heat section built into the same boiler shell. The waste section usually supplies the base load with the burner modulating to provide the full steam demand. In today’s competitive industrial climate efficiency is of the paramount importance. Combustion equipment from simple high-low burners to highly sophisticated electronically controlled management systems combine with boiler design features to achieve low NOx emissions, fuel and energy efficiency, minimum noise levels and ease of maintenance.

Design Byworth responded quickly to the need for energy efficiency, with new boiler designs shifting the emphasis from low purchase prices to low running costs and emissions. Boiler shells and furnaces should both now be generously sized, not minimized to save on steel costs. A steam space which is too small causes priming and “carry over” of water in the steam system resulting in wet steam, dissolved solids in the process, scaling and water hammer.

Byworth Waste Heat Combination Boiler

In order to reduce NOx emissions, the furnace length to diameter ratio should ideally be 3.5 to 1: the lower volumetric heat release rate in the furnace reduces the flame temperature and less thermal NOx is formed. For sites which require “ultra-low” NOx levels, Byworth will design bespoke furnaces to match the particular requirements of the preferred burner supplier.

Add-on Technology

X-ID Tubes The quest to improve efficiency has led to a number of groundbreaking innovations such as X-ID tubes. These unique tubes with internal helical ribs increase the heat transfer rate from the exhaust gases to the tube by over 80%. This is achieved not only due to the larger surface area but, moreover, due to a boundary layer detachment / re-attachment phenomenon. The hot gases leave the boiler at dramatically lower temperatures than from plain tubes, with much less heat wasted in flue gases. Installations of boilers in the UK with X-ID tubes are now entering their fifth year, providing ongoing fuel savings without compromising reliability. X-ID tubing is suitable for all fuels. The increased turbulence in the tube helps to keep the tubes clean and therefore offers reduced downtime, which is particularly useful for users of heavy fuel oil and solid fuels.

Pre-heating Combustion Air The latest development in steam boiler technology has seen the introduction of the pre-heated combustion air boiler. This recovers otherwise wasted heat from the exhaust gases using a recuperator. When combined with X-ID tubes, tests have shown efficiency gains of up to 7% when benchmarked against Byworth’s already efficient Yorkshireman 3-pass boiler. Advantages of pre-heated combustion air are that it is completely synchronous with the burner operation and that it maintains a high efficiency gain with turndown, 5% at one third firing.

Flue Gas Economisers Flue gas economisers are a proven concept and can improve boiler efficiency by up to 5%. The heat in flue gases, which would otherwise be lost up the stack, is utilised in an air to water heat exchanger to pre-heat the feed water to the boiler. The economiser illustrated is a drawer type for ease of maintenance and located

above the rear smoke box. Even after the flue gases have passed through the economiser there is still usable heat that can be recovered in a recuperator to pre-heat the combustion air.

To support the increased efficiency of the boilers themselves there have been significant technological advances in burners and boiler controls. Burners with electronic air and fuel control give better efficiency right across the turn down range and also reduce NOx emissions. Variable speed drives on burners and feed water pumps will greatly reduce electrical consumption whilst automatic blowdown and TDS control systems also increase efficiency and reduce risks associated with sludge build up and foaming. When it comes to finance, Byworth also offers a choice of options to make payment as easy and painless as possible and our highly experienced sales team can advise on the latest information on leasing or long term hire agreements. To avoid loss of production whilst a boiler undergoes essential work a Byworth mobile hire boiler will hook up seamlessly to existing services. Whether it be a sudden breakdown or a planned long term requirement Byworth has a fleet of over 100 modern boilers for short or long term hire to ensure minimum disruption. Production continuity and reliability is vital to steam users. Byworth understands that prolonged downtime can be disastrous and that is why we offer a complete boiler service from in-house design to full installation plus boiler hire and lease, maintenance, repair and replacement parts service. The service division provides a maintenance contract package to give reassurance that help is only a phone call away. An experienced team of engineers, based throughout the UK take care of annual insurance inspections, servicing, repairs and emergency call outs. As the leading British boiler maker Byworth is a CEA accredited trainer for the Boiler Operator Accreditation Scheme and offers boiler operators a unique training experience that combines expert theoretical knowledge with practical hands on experience on a fully operational boiler. The courses can be completed at our new training facility in Keighley or on site at client`s premises and tailored to suit individual needs.

CEA Yearbook 2012/13

ANALYTICAL INSTRUMENTS

Monitor AMI Deltacon Power On-line Monitor for Conductivity and Calculated pH in Feedwater, Steam and Condensate. Automatic and continuous direct conductivity measurement before and after cation exchanger. Calculation of the sample pH value and ppm alkaliser. Cation exchanger with automatic deaeration for quick start-ups. Second cation exchanger as pre-rinse setup for easy maintenance and fast resin replacement.

kr o w e fre r a l am e u t s r Reg e at w r o n f shops trumentatio ns cycle i K Of fices. U at our ontact for ec Pleas etails. d r e h t r fu www.swan-analytical.co.uk www.swan-analytical.co.uk · SWAN ANALYTICAL UK LIMITED · Unit 3 The Steading · Copthill Farm Deeping Road · Stamford PE9 4TD · sales@swan-analytical.co.uk · Phone 01780 755 500

CEA Yearbook 2012/13

The Lord Ezra Award: Sustainable energy for Northern Ireland A pioneering project is using waste wood in a biomass plant to power almost 3,000 Northern Irish homes. The project’s innovative approach has won the Lord Ezra Award for 2012, presented on 18th October 2012 at the House of Lords, London

ne of the most pioneering biomass projects in the UK, in Artigarvan, Northern Ireland and owned by Tyrone Energy, is heralds a new era of sustainable power generation for Northern Ireland. The plant will burn approximately 25,000 tonnes of waste wood every year to generate enough electricity to power almost 3,000 Northern Irish homes, simultaneously solving a waste problem and displacing more than 11,000 tonnes of CO2 emissions. This provides a stable and consistent contribution to grid power, incorporating SCADA operated voltage and power factor regulation to support and maintain local grid power quality. Consultation and support from NIE has resulted in the development of a system designed to work harmoniously with the national electrical distribution system. The waste wood fuel is diverted from the NI waste chain and would otherwise have been landfilled. Landfill is an increasing problem across Europe and the damaging environmental effects of landfill are often overlooked or misunderstood. Utilising waste wood reduces the reliance of new forest and timber harvest, reduces pollution and ground contamination.

From wood to steam Waste wood is collected locally and separated from the waste chain by specialist recyclers e.g. Irish Recycling Services, and the wood that cannot be recovered and reutilised is processed to fuel. The fuel is tested to ensure quality and suitability despite the plants operational tolerance and flexibility. Steam is generated at high pressure and supplied via three stages of super-heater to the steam turbine. The two stage steam turbine has been selected to allow steam extraction for future process and district heating use. The turbine supplied by Siemens, has been designed to accommodate maximum power and/or heat generation. The combustion plant incorporates the robust and reliable step grate technology, which provides continuous partial pyrolysis and gasification prior to a WID compliant 850o°C and 2-second residence full combustion. This design arrangement is used safely and reliably across Europe and was provided by KIV d.d. the Slovenian based technology supplier.

Controlling NOx emissions NOx production is managed with a combination of Flue Gas Recirculation (FGR) and Selective Non Catalytic Reduction (SNCR) –

addressing the problems associated with the NOx formation from both fuel and combustion air related Nitrogen sources. The water cooled condensing plant incorporates environmentally neutral treatment systems and provides condenser operation at sub atmospheric pressures and relatively low temperatures for maximum turbine output when required. The custom water treatment solution ensures that the water quality for the plant is maintained to the very highest standards required for the turbine. The combination of dry scrubbing media and fine bag filtration ensure that the plant can meet emissions standards, way beyond those imposed by European Legislation. Tyrone Energy has worked closely with The Northern Irish Environment agency and the plant has no adverse impact on local rivers or watercourses and represents an exemplary step forward in sustainable, manageable and small scale, local solution for waste and energy.

Providing local employment During the year-long construction phase, the plant has generated employment for nearly 50 staff from a number of local Irish companies including the “One Industrial Group1 ” – a consortia of local Northern Irish companies that now have developed track record of power project construction. The same group is set to build a slightly larger plant later in 2012. Once commissioned and operational the plant will also provide permanent local employment for up to eight staff – a welcome boost in the current economic climate – and an insight into the other ways that sustainable energy projects will support local economies. The UK design team headed by Alastair Nicol (Element Consultants2) and Dr Alen Sarlah (KIV3) have developed the project over a three year period with support from INI, DETI and the Carbon Trust Northern Ireland.

CEA Yearbook 2012/13

New TC Model • 500 - 2000kg/hr • Touch control screen • Full modulation feature 50-100% firing • Natural Gas, Light Oil, LPG and Bio Fuel • Automatic facility option • PM5 Facility option • Pressure range up to 32 barG • >98% Efficiency * • Remote compatible with Profibus/ CANbus etc. • Steam in 3 minutes • Compact construction • Lightweight • Suitable for mezzanine floors • Factory tested prior to dispatch to site • NOx Gas reduction option • Dual fuel option

Junior Range • 80 - 400kg/hr • Natural Gas, Light Oil, LPG and Bio Fuel • Automatic facility option • PM5 Facility option • Pressure range up to 32 barG • >98% Efﬁciency * • Steam in 3 minutes • Compact construction • Lightweight • Suitable for mezzanine ﬂoors • Factory tested prior to dispatch to site • NOx Gas reduction option

Electrical Range • Compact • 8 - 160kg/hr Steam output • Modulating ouput • Skid mountable • Steam in 3 minutes • Automatic facility option

CERTUSS (UK) Limited Unit 45 Gravelly Industrial Park Tyburn Road Birmingham B24 8TG

CEA Yearbook 2012/13

Tel: 0121 327 5362 Fax: 0121 328 2934 sales@certuss.co.uk www.certuss.co.uk

Duty Standby with CVE Package Plant

CVE Package Plant • compact • Pre-pied, Pre-Wired • Skid mounted • Fully factory tested • Lightweight • Easily maintained

Containerised Plant • Easily relocated • Self contained plant room • Full lighting and heating • Fast site connection

Alastair Nicol, Element Consultants, concludes: “We face an increasingly challenging economic environment and the need for energy source diversification has never been greater – this project demonstrates that small sustainable designs servicing a local need, are key to our energy, environmental and employment futures. Energy from waste is vital to our energy future in the UK - burning trees for power generation is fundamentally wrong and simply unsustainable. We must reduce, recycle, re-use and turn waste into power.

“The engineering team that designed and built this CHP plant has overcome the widest range of technical and regulatory challenge to succeed in building a facility that will set the highest standards for the UK.” The one Industrial Group is a team developed and mentored by Invest Northern Ireland. 2 For more information contact Alastair J Nicol (alinicol@elementconsultants.co.uk) 1

KIV d.d (www.kiv.si)

About the Lord Ezra award Lord Derek Ezra has been connected with energy and combustion for over 60 years. For the last 20 years, The Combustion Engineering Association has been privileged to work with Lord Ezra—first as President of the CEA and latterly as Patron of the Association. Lord Ezra is 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 has been Honorary President of the Coalfield Communities Group since 2006. In recent political times, Lord Ezra has concentrated on the environmental impacts of energy/clean coal technology and the problem of fuel poverty. Recently Lord Ezra formed a private company promoting small-scale electricity generation. 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. By way of further encouragement and equitability, the Award is open to a large field and entrants are asked to submit competitively based schemes in order to actually win the award. The meritorious entrant or entrants receive the Award every October in the House of Lords. Combustion Engineering Association, on behalf of Lord Ezra, is proud to present the Award and each year 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 nature.

Looking into Diesel optical engines A special prize for research, donated by Professor Bill Kaye, past CEA Chairman, has been won by Ben Myatt as part of the Lord Ezra awards for a project looking at the design of a new Diesel optical engine. Here, Ben describes his work

missions legislation regulating diesel engines within member countries of the European Union is becoming tighter and tighter with each new stage that is implemented. The permissible emission limits for nitrogen oxides (NOx) and particulate matter (PM) will soon become so low that the focus of engine research will shift from reducing NOx and PM emissions to reducing carbon dioxide (CO2) emissions and increasing the efficiency of the engine.

Figure 1: Optically Accessible Single Cylinder Research Engine with Extended Bowditch Piston1

CEA Yearbook 2012/13

The aim of this project was to design the critical components of a fully fired, optically accessible diesel engine using stress and thermal computational analysis. The purpose of this new engine will be to investigate in-cylinder flows and the combustion mechanisms inside the combustion chamber of a diesel engine, in an effort to understand ways of increasing the efficiency and decreasing the emissions of future diesel engines. The engine design centres on the use of a Bowditch piston, an extended, hollow piston with a longitudinal cut-out allowing viewing of the combustion chamber through a window in the top of the piston, via a mirror held at 45Â° within the cut-out. The Bowditch piston reciprocates within a cylinder liner manufactured from an optical glass to allow combustion imaging and optical diagnostics from the side of the engine. Stress analysis was carried out for a range of high specific strength materials, and two different Bowditch piston designs were simulated using a finite element analysis package. The finite element analysis simulations conducted found that one of the Bowditch piston designs manufactured from a titanium 10-2-3 alloy would be able to safely operate in the new optical diesel engine to the significant peak cylinder pressure considered in this project. This piston design compromised on the level of optical access that could be achieved at such a high peak cylinder pressure. A second piston design was considered that allowed viewing of the combustion chamber via the Bowditch piston for the entire stroke of the piston. The maximum safe operational peak cylinder pressures for this piston design, and the materials considered in this report were also determined.

The author Ben Myatt is currently in his fifth year of reading a Masters in Mechanical Engineering at Loughborough University. In 2010/11, he Ben Myatt winner of the Lord Ezra special research completed an prize being presented by Lord Chidgey Honorary Vice industrial President of CEA placement year working for AB Sugar in Peterborough, in the Group Technology Department where he gained a Diploma in Industrial Studies. Ben will be returning to British Sugar plc in September 2013 to join the Graduate Training Scheme. During his fourth year, Ben completed an individual project titled â&#x20AC;&#x2DC;The Design of a New Diesel Optical engineâ&#x20AC;&#x2122; Fused silica cylinder liners were found to be insufficiently strong enough for the peak cylinder pressures considered in this project whilst maintaining a good level of optical access through the liner. A range of sapphire glass cylinder liners of varying thickness were found to be suitably strong enough and safe. The thickness of these liners was noted to be similar to that of cylinder liners of current optically accessible engines and therefore suitable for optical access. The feasibility of manufacturing a fully optical piston crown/bowl was investigated with an optical glassware company to enable more accurate replication of the in-cylinder geometry in the optical diesel engine. Early indications suggested that this could be possible and highly successful. The feasibility of manufacturing a carbon fibre Bowditch piston was also investigated. This showed significant promise as an area of future work, allowing notably lighter, and therefore lower inertia piston designs, whilst still maintaining the strength required for high peak cylinder pressures.

Figure 2: Stress Simulation Result - Titanium Max Pressure Bowditch Piston, 250 Bar Applied Pressure, 80 mm Mirror Bore

Figure 3: Overall Displacement Simulation Result - Aluminium Full View Bowditch Piston Assembly, 250 Bar Applied Pressure, 90 mm Mirror Bore

CEA Yearbook 2012/13

http://www.forbrf.lth.se/english/research/applications_in_combustion_devices/ internal_combustion_engines/

Figure 4: Cylinder Liner and Bowditch Piston Assembly

The UK's leading industrial maintenance magazine Plant & Works Engineering supporting the Combustion Engineering Association and celebrating its 80th Anniversary. Featuring Boilers, Burners & Controls in the January, May, July and October issues. For more information contact: Tel: 01732 370340 Email: pwe@dfamedia.co.uk

Jan 11 - Dec 11 Average circulation 10,007 100% individually requested

www.pwemag.co.uk CEA Yearbook 2012/13

CEA Yearbook 2012/13

Thoughts on three decades of water treatment for package boilers Andy Perkins, Field Sales Manager, Lubron Water Technologies, provides a personal insight into how water treatment has changed over the years

he water treatment industry has traditionally been a very competitive market, and as such sometimes the lowest common denominator of ensuring that the boiler water feed system is nominally compliant with BS 2486:1998 or EN BS 12953 Pt10 takes precedence over the medium to long term view of what is really best for a system. The medium to long term view being: • Lowest possible energy and water costs • Total system protection • Ease of maintenance • Chemical usage We should always take into account local site towns mains or private water supply water quality and the rate of condensate return. In general, if you are in Wales, Scotland or Northern Ireland and the boiler is supplied with a water of TDS 50 ppm and has between 0 and 95% condensate return, the supply of anything other than a softener would be debatable. However, if the same boiler is installed in most parts of England (and in some other locations as well) then a softener plus RO may well be the solution to both boiler and system protection against scale and corrosive attack of the steam system. Of course there will always be exceptions to this rule.

If we take chemical dosing, we must on a new installation always assume that the whole system has been well designed and that the hotwell and feed line are manufactured from stainless steel and operated at 85-95 deg C depending on feed pump specifications.

Feedwater options There are a variety of ways to feed water to boilers: 1. Straight on/off control 2. Modulating feed valve with spill back to hotwell 3. Inverter driven pump system operating on a pressure transducer/water meter Option 1 can lead to very simple dosing based on taking a level switch signal to a central control box and that allows a degree of proportionality to steam load or even a simple in line water/ steam meter. Option 2 can be interesting as the water normally spills back to the hotwell which means using a water meter can give erroneous readings, so taking a 4-20mA signal from the modulating valve could be the answer. Always have the return pipework engineered to be below the minimum working water level within the hotwell to avoid entrainment of air. Option 3 fits if no spills back line and this can be controlled like option 1. Alternatively there are a series of options open to you for example: a. Take the boiler treated water make up signal if condensate return is steady b. Measure the make-up vs. steam demand and rate of condensate return if available, integrate all the readings via

CEA Yearbook 2012/13

the BMS and feed the 4-20mA signal to the new smart dosing pump ranges that are available.

A choice of dosing There are a variety of dosing locations depending on several factors: i) Do you want to give each boiler independence of dosing so that you get directly proportional dosing of chemical and the ability to dose idle boilers? If so, inject the alkalinity builder as far back in the feed line as possible after the individual feed line split. Inject the oxygen scavenger about 200 mm towards the boiler after any feed line split, but as far back as possible. This needs more dosing pumps but gives you more control. You can dose the boiler shell directly, but this requires much more highly specified dosing equipment. Consider dosing the sludge conditioner into the boiler hotwell itself.

ii) If centralised dosing is required then put the caustic and phosphate sludge conditioner in the main body of water in the hotwell and the oxygen scavenger as close to the de-aerated exit of the hotwell as possible, or if a stainless steel feed line, dose into the feed line itself. iii) If you have a mild steel economiser you must try to deoxygenate the feed water prior to the unit, but you need enough residence/contact time for this to happen, which is normally about 6 - 8 metres and you must have a minimum pH of 8.2. For longevity you must always specify a stainless steel economiser.

An example of an actual enquiry and the response A boiler plant in the south west of England: Duty Working pressure Economiser Hotwell Tank temperature injection) Softened Towns water Operation Condensate return

15,880kg/hr steam 10.34 Barg Yes (boiler mounted) 850C (maintained by steam Yes 12-16 hrs a day, 7 days a week 0

Q. Is an oxygen scavenger required? A. Correct and if a food factory, will normally be a USFDA approved chemical, at this pressure and temperature it will be a catalysed sulphite Q. Is phosphate or a scale control agent required?

boiler the Economisers ceased to ‘fur-up’? A. Economisers are notorious with regard to corrosion if constructed out of mild steel and only stainless steel units would be recommended by us. We have filtration equipment installed on a system in Scotland where we constantly “polish out” the corrosion product but the system is continuously corroding. If they are furring up, this would suggest that there is some hardness in the water or high levels of corrosion product that is reacting with the phosphate due to the high heat fluxes and low flow that you may experience in an economiser. Q. Can you also advise what is needed if there was no softened water? A. We interpret this as to mean hard water breakthrough, please advise if you mean other types of pre-treatment.

A. Yes, coupled with a food grade polymer to condition sludge Q. Is caustic required? A. With very low rates of condensate return in this geography this may only need to be a small amount to raise the pH in the feed to >8.2 to protect any steel pipework. With this water, natural caustic will be formed by decomposition of sodium bicarbonate under temperature and pressure on a softened high alkalinity water as experienced at this location. The potential for high rates of condensate line corrosion are very high due to the high levels of carbonic acid that will be produced. We would recommend the supply of an RO plant for both blowdown and corrosion reasons. Q. Can you please advise exactly what chemical is required and where best to inject it, bearing in mind that a couple of years ago, some problems were encountered with chemicals building up inside the tubes of some economisers where the chemicals were injected prior to the economisers and after the feed water pumps. When they were moved to the line directly into the

CEA Yearbook 2012/13

Short term, lower the TDS to 2,000 and dose extra caustic to raise alkalinity to minimum level recommended in the BS to help precipitate the hardness in a manageable manner. Add additional phosphate polymer to aid precipitation. Q. A block type drawing would be useful if you had such a thing, or even a sketch copied to a pdf, I feel sure it would also be better for you in the long run if we actually asked you for equipment that is correct rather than 2 of those and 1 of those etc etc

Making you more competitive

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can give you the solution.

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CEA Yearbook 2012/13

Reducing NOx production while keeping fuel costs and carbon emissions down In this article, Autoflame looks at the issues surrounding the need to meet low emissions legislation, particularly ultra-low NOx output

s regulations regarding emissions become more stringent in the boiler industry, particularly those concerning NOx levels, it is essential to maintain high combustion efficiency levels to keep carbon emissions to a minimum and fuel costs as low as possible. Current regulations on emissions are focused around single digit NOx levels, typically 9ppm. This trend towards lower NOx requirements looks set to continue and before long it is possible that sub-5ppm NOx will become a reality in certain parts of the US.

from 2% to 7.5%). An existing EPA document: â&#x20AC;&#x2DC;Guide to Industrial Assessments for Pollution Prevention and Energy Efficiencyâ&#x20AC;&#x2122; states that the optimal quantity of excess air to guarantee complete combustion for natural gas is 10% (2% O2). In reality, this amount of excess air is not maintained in the majority of applications. Increasing the excess air levels causes several issues: firstly, the combustion efficiency levels are reduced dramatically by higher excess air due to high O2 levels and elevated stack temperatures (increasing the amount of excess air causes the combustion gases to be pushed through the boiler tubes at higher velocities, leading to reduced heat transfer time and greater heat loss up the stack; this means that more fuel must be burnt in order to achieve the same output). Secondly, by introducing excess air and lowering the chances of complete combustion in the primary mix, there is a tendency to produce carbon monoxide.

As is well documented, low NOx combustion can be obtained from many different burner designs, whether through adapting the existing burner, fuel and/or air staging, flue gas recirculation (FGR) or a specialist burner head design, of which several are currently available on the market.

This in turn can lead to carbon build-up in the tubes leading to increased maintenance requirements, but also reducing the heat transfer to the medium. Again, this will reduce the overall efficiency of the system.

Increasing the excess air levels

Flue gas recirculation is commonly used to achieve lower NOx levels. Typically 15-30% flue gases are re-introduced into the mixing process. The effect is to lower the production of thermal NOx by reducing the flame temperature and amount of O2 available for combustion. There are obvious limitations to how much FGR can be introduced based on the burner design. Higher percentages of FGR can lead to major stability issues with flame retention, causing nuisance failures, but also dangerous combustion characteristics; this can also lead to boiler vibration, excess noise and tube impingement.

On many applications, lower instantaneous NOx levels are achieved by increasing the amount of excess air, typically from 10% to 50% (this is equivalent of an increase in the oxygen in the emissions

Recirculating flue gases

Whilst it is certainly important to examine ways of reducing NOx levels in the combustion process itself, particularly in light of regulatory requirements, it is crucial to ensure that this is not achieved at the expense of excessive carbon production, which is also to be regulated. As technology advances, low NOx burner techniques will improve and higher efficiency levels will be maintained (particularly at lower firing rates), with burners also offering reasonable turndown (minimum 5:1 on natural gas) and reliability. Rapid technological improvements are currently being made in this area. Another method of reducing NOx after the combustion process is to use a Selective Catalytic Reduction (SCR) system; typical NOx emissions are reduced by over 70% and often over 90% for a gas-fired boiler application. This methodology uses a single-reactor unit complete with a catalyst and reducing agent delivery system (typically anhydrous ammonia). The unit passes the combustion gases through a grid system in which the reducing agent is added to the combustion gases and is absorbed by the catalyst to remove the NOx; the reaction of the NOx (NO or NO2) and NH3 (ammonia) produces a by-product of nitrogen and water vapour. Typical performance of such units will see NOx levels reduced from 30ppm to sub-5ppm.

CEA Yearbook 2012/13

Monitoring and auditing the emissions The majority of analysers used in the package boiler market measure oxygen and stack temperature, offering a calculated carbon dioxide value and corresponding efficiency. Further to this, carbon monoxide can be an additional option for safety and monitoring clean combustion. In order to measure the NOx emissions, an additional analyser will typically be required. With low NOx burner technology it is essential that further parameters of combustion are measured. The latest Autoflame analyser has been specifically designed in light of current regulations on emissions monitoring; the Mk.7 CEMS Exhaust Gas Analyser (E.G.A.) offers all of the requirements for the boiler industry firing on both gaseous and liquid fuels. As standard, this analyser measures oxygen, carbon dioxide, carbon monoxide and nitrogen oxide, with the option to include nitrogen dioxide and sulphur dioxide. Three of these parameters (oxygen, carbon dioxide and carbon monoxide) are used for the patented trim process, enabling tight combustion control especially with high performance burners. It is also possible to use limits of combustion on all measured parameters to inform the client when certain conditions exceed performance guidelines or state or federal regulations, i.e. NOx level exceeded. All measured parameters offer an instantaneous analysis of the combustion gases (%, ppm, ft3/hr and lbs/hr); additionally, a 10.4” full colour touch screen HMI allows the user to view a totalised analysis of all of the emissions updating the data every second and logging up to two years of data. This data can be manipulated to review a monthly emissions total for all of the measured parameters, but particularly the NOx and carbon emissions (ft3, lbs or tonnes).

Incorporated into the Mk.7 CEMS E.G.A. is the ability to input the fuel composition data, the fuel flow (via an input signal) and also the fuel cost per unit. This allows the E.G.A. to calculate not only the total fuel input and average combustion efficiency over the designated period, but also the fuel costs for each fuel. All of this data is displayed in tabular and graphical format and can be exported for client analysis. All of the data recorded and analysed by the Mk.7 CEMS E.G.A. can be monitored via the latest Autoflame Mk.7 Data Transfer Interface (D.T.I.) unit. This allows up to ten boilers to be monitored and logged through any single D.T.I. unit, and this information can then be accessed via any EtherNet connection. The capabilities of this technology will allow the client to bring individual boiler room control to a higher management level, allowing immediate access to all emissions and operational data from each boiler located globally.

A recent solution and case study In 2005, a leading healthcare company in California decided to expand their steam capacity by 50%. A new 1,000 horsepower 4-pass steam boiler was specified and selected for the expansion, along with a sub-9ppm low NOx burner and control system. By the end of 2006, the new boiler was installed and the sub9ppm low NOx target had been achieved. However, the residual oxygen levels were in the range of 8 – 8.5%. In addition, maintaining this low NOx level was causing many problems: excessive vibration from the 125 hp blower motor running at 3,600 rpm, flame failures, material and refractory failures. Reliability was a serious issue with the existing system, and

The boiling issue Harris Pye explains the benefits of its new Remnant Life Inspection

arris Pye is a world leading specialist in the repair and maintenance of marine and industrial boilers. Over the past decade, the company has developed its services to include in situ repair, upgrade and conversion of ships, tankers, rigs (including mobile offshore drill units), jack-ups and semisubmersibles, FPSOs (Floating Production, Storage and Offloading vessels), FSOs (Floating Storage and Offloading vessels), FSUs (Floating Storage Units) and FSRUs (Floating Storage and Re-gasification Units). Although it’s now globally renowned for its success in these areas, boiler repair and maintenance remains a core strength and service offering. Having taken on a senior metallurgist, Dr David Mumford, and invested significantly in state-of-the-art inspection equipment, Harris Pye now offers a new, unique type of Survey - a comprehensive Remnant Life Inspection. “This service has the potential to save considerable costs, as it’s able to identify how to effectively and safely extend the life of boiler plant,” says Dr Mumford. “Plus by dint of methodology, it ascertains future repair work so that operators can be fully in control of costs and schedules. By comparison,

usually repairs or renewals are a reaction to a problem rather than a pro-active response.” When one considers that the majority of equipment, particularly steam raising plant, in use today on offshore facilities such as FPSOs and FSOs are 30 to 40 years old, the potential for this life-extending service becomes clear. The plant on these vessels would have been designed for a useful working life of around 20 years (100,000 hours), so operators either have to increasingly spend on repairs, or else purchase new plant. “What makes our Remnant Life Inspection so different and beneficial, is that it includes every part of the plant and is of a much greater depth than traditional surveys,” comments Dr Mumford. The Inspection is even able to identify microscopic creep and fatigue failures. At the end of the inspection, the team is able to present an in-depth report with recommendations on how to extend the life of the plant. “The cost benefits of this are substantial, and we believe that we’re unique in offering it to the marine and offshore market – that no one else offers this boiler service apart from Harris Pye.”

CEA Yearbook 2012/13

further to this the boiler could not reach the rated steam capacity. In 2010, a Steam Reliability Study was conducted on site and commissioned by the Autoflame Technology Centre in this region, One Source Engineering, Inc. It was decided at this time that reliability was a priority given the existing conditions and, therefore, replacing the burner and offering a Selective Catalytic Reduction (SCR) system was the best long term solution for the client. This would not only offer the client improved functionality and reliability, but also a high efficiency burner complete with low NOx and low carbon production. There were several requirements that any potential new burner had to meet: the selected burner had to be robust incorporating a standard low NOx design (sub-30 ppm), as well as being able to perform with a reasonable turndown ratio (5:1). The dampers and bearing assembly, combustion air system, burner head and igniter system all needed to demonstrate high quality engineering and craftsmanship. It was important to the client that the entire burner package had the appearance and design of a quality engineered product. After reviewing the available burners on the market today, One Source Engineering chose Limpsfield Combustion Engineering Ltd to supply the burner, as theirs was a package that met all of these customer specific requirements and would guarantee the necessary efficiency levels. The next stage was to review the SCR system. Again, One Source Engineering chose a supplier that had vast experience in this technology, including many installations and successful case

studies, and was also a local manufacturer. The Nationwide Environmental Solutions CataStakTM system was chosen.

System Performance Installation of the specified equipment began in November 2011. The Limpsfield burner was commissioned in January 2012, achieving a 5:1 turndown, sub-30 ppm NOx, corrected to 3% O2, CO was zero throughout the firing range, and the O2 level was 2-3% from low to high fire. The split head design manufactured by Limpsfield mixes the fuel and air in the high pressure zone in the burner head offering superb stability and flame retention, which is essential for this type of application. Boiler capacity was also achieved for the first time ever. In February 2012, the SCR was commissioned and the NOx was reduced from sub-30 ppm to 1 ppm throughout the firing range. The contractual NOx emission guarantee to the client was sub-5 ppm and below the required air permit level of sub-9 ppm NOx. Over time, the NOx will be adjusted to approximately 4-5 ppm, corrected to 3% O2, by reducing the ammonia flow. The installation has been a great success and since commissioning the new Limpsfield LCN123 burner and CataStakTM SCR system have been operating without issue, i.e. no faults, lockouts or problems that were inherent before the upgrade. Most importantly, the system has retained its commissioned values operating at high efficiency, low excess air levels, low carbon production and ultra-low NOx.

MCL Energy ‘linked’ with new energy centre for world class adhesives manufacturer Technical energy services provider MCL Energy was awarded a prestigious long term contract to design, build, finance and operate a new energy centre for leading structural adhesives manufacturer Huntsman Advanced Materials (UK) Ltd.

untsman Advanced Materials is a leading global supplier of structural adhesives for joining composite materials with a primary global manufacturing and distribution site based at Duxford. The installation includes project management, Construction Design and Management (CDM) regulations, natural gas site infrastructure, and steam and condensate connection. The energy centre build incorporates civils, portal building, two 4,000 kg/hr steam boilers, a 1,000 kg skid mounted boiler and ancillary systems. Following successful completion, the operation and support contract includes plant performance, efficiency guarantees, daily operation, planned preventative maintenance, 24/7 callout and remote plant monitoring. Jason Perry, Sales Director said: “We are looking forward to

CEA Yearbook 2012/13

working together with Huntsman Advanced Materials and providing a first class Energy Centre. This long term solution enables Huntsman to move forward, assured that their new Energy Centre will provide efficient process steam for manufacturing.” Impressive first six monthly site gas consumption figures for the energy centre indicate energy cost savings in the region of 30% or 1998 MWh. For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

CEA Yearbook 2012/13

Our contribution to our and future generations’ quality of life SAACKE says its vision is: We are committed to the ‘transformation of energy’ through innovative, resource-saving, energy-efficient and eco-friendly technologies.

s we go forward into another year our on-going investment in research and development continues to introduce vision related products and enhancements, and to expand our international growth through approved products, technologies and the highest quality of local customer support. We can advise on effective energy utilisation and offer solutions to optimise plant performance thus reducing fuel bills and minimising emissions. Our technicians are able to commission, service and upgrade combustion equipment and associated plant, including those supplied by other manufacturers.

SAACKE Combustion Services Limited The SAACKE Group was established in 1931 as a family enterprise. Today, SAACKE ranks among the world’s leading specialists in combustion and environmental technology as well as marine and land-based plant engineering. The Saacke family as shareholder regards our corporate values as a basis for continued growth and to be regarded as an attractive choice for employees, customers and business partners.

SAACKE offers tailored operator training courses for both combustion and boiler plant. All this is here to provide you with an exceptional service. U.K. Head Office: Langstone Technology Park, Langstone Road, Havant, Hampshire, PO9 1SA, U.K. Tel: +44 (0)23 9251 8200. Fax: +44 (0)23 9251 8201. E-mail: ukadmin@saacke.com Website: www.saacke.com

Chris Newton Steam Services Ltd Boiler Operation and Maintenance Training

B.O.A.S. Training and Assessment ON YOUR SITE

Also available at our Llangollen training facility centre One and two day INDG 436 safety and maintenance certificated courses available on your site Tel 01978 860578 Mb 07533619277

www.chrisnewtonsteamservices.co.uk

CEA Yearbook 2012/13

A look at hazardous areas for flammable gas systems Barrie Church, Director Global Energy Associates Ltd, provides practical advice on dealing with hazardous areas They say ignorance of the law is no defence, but even eight years after the initial enactment of the Dangerous Systems and Explosive Atmospheres Regulatio ns (DSEAR) in 2003 we find a large proportion of British industrial and commercial companies, designers and installers are unaware of the implications of DSEAR. What is particularly unusual is that they are retrospective for all natural gas and LPG installations in factories, hospitals, shopping centres, shops and central plant in domestic blocks of flats. They do not however apply to pipework within domestic occupation and CE marked gas appliances. However, even CE marked appliances in the relevant premises would require a risk assessment. Each installation will need to be considered for the likelihood of a gas leak occurring and for this gas leak to then lead to an incident that may cause harm or injury. It is a legal duty upon site occupiers to consider the risks and the control measures that are put into place to mitigate against such leakage. Such a risk assessment will need to consider the initial design specification, the construction standards, local ventilation provisions, the testing procedures and finally the on-going maintenance procedures.

Figure 1: Hazardous Zones

Any ignition source inside this volume has to be classified for use in a hazardous area with Zone 2 being the lowest risk, Zone 1 being a higher risk such as in a coal mine and Zone 0 in a very high risk area such as continuous blowing gas vent. Such equipment is often called Explosion Proof and is always more expensive than normal electrical equipment. It will normally be marked with something like EEx n IIB T2 as well as the Ex hexagonal logo.

Zone 2 Pressure switch and lighting

Much of this is covered in outline within the Institution of Gas Engineers and Managers procedures: â&#x20AC;˘ IGE/UP/1 Strength & tightness testing & purging of industrial & commercial gas installations, â&#x20AC;˘ IGE/UP/2 Installation of pipework on industrial & commercial premises â&#x20AC;˘ IGE/UP/10 Installation of flued gas appliances in industrial & commercial premises. What is new is IGEM UP/16 (Hazardous area classification for Natural Gas installations downstream of primary meter installations), which now provides the latest information and guidance to systems with an operating pressure not exceeding 2 bar. Most gas installations operate at low gas pressures below 100 mbar and it is a simple process for a competent person to ensure compliance within the design.

What does Zoning mean? Electrical components and other ignition sources such as hot surfaces on furnaces and exhausts all provide a means of igniting a leakage of flammable gas. Of course the bigger the leak, the bigger the problem (fire or explosion)! Test work in the UK has determined what are reasonable leakage potentials, what sort of ventilation is needed to dilute them to a safe level and how far away the ignition sources must be kept from potential leakages for them NOT to ignite. These distances are referred to as Hazardous Zones and are the volumes contained within the hatched area, see figure 1.

CEA Yearbook 2012/13

The leakage size determined for typical pipework systems not exceeding 100 mbar operating pressure will normally generate a Zone 2 classification but because the leak is so small and it is in an occupied space it will be detected quite quickly. This means that it can be designated as Zone 2 Negligible Extent (NE) where the use of special electrical components is not necessary. However if the same leak was in a space that was not visited more than twice a year or it was never maintained or there was poor ventilation, then Zone 2 electrical equipment might be required.

UP/16 Scope and Implications The Standard covers all natural gas (and methane based lighter than air bio-gas) installations downstream of the primary meter

with an operating pressure not exceeding 2 bar that are not located in dwelling places. It does not cover Liquefied Petroleum Gas (LPG) installations for which at this time there seems to be no similar definitive guidance. Compliance with UP/16 should however provide a better level of safety than doing nothing. The implications are widespread and will require updates to most installation standards and particularly UP/2 and UP/10. Ideally new systems should be designed from the onset to take account of DSEAR and this can save much heartache and ÂŁ1000â&#x20AC;&#x2122;s in subsequent remedial works! In existing installations, engineering judgement will be essential. Global Energy Associates Ltd saved one client ÂŁ6M which they would have spent to follow the advice of their consultant! Whilst for others it is possible to propose solutions that can be easy to apply within existing operating budgets. Simply; it is a requirement that pipework installations be properly designed and installed to UP/2, tested to UP/1, located in ventilated locations and maintained to prevent corrosion, damage and subsequent leakage that might lead to danger.

How does UP/16 define Zoning? The initial design of the complete gas system downstream of the Emergency Control Valve (ECV) will need to be such that it can be classified as Zone 2 NE (Negligible Extent). Where this is not possible it will be necessary to consider the Zonal classification which in turn will require the use of flameproof equipment. To achieve Zone 2 NE, adequate local ventilation around every joint (not welded, soldered or brazed joints) or potential gas leakage source has to be provided. Local congestion will normally restrict the availability of ventilation and may preclude the possibility of achieving a Zone 2 NE classification unless other measures are taken, for example, by the use of lower gas pressures, increased local ventilation or more frequent inspections. A Negligible Extent Zone is similar to but not the same as a Safe Area, even though neither requires action with regard to ignition sources. Changes should not be made to any pipework installation or the nearby environment that may adversely affect the assessment as Zone 2 NE. This would include changes to pipework, reducing ventilation, addition of more equipment producing increased congestion or changes to the building layout where the change may affect the flow of diluting air flows.

So what practical issues and solutions are there? DSEAR requires a risk assessment be completed of the various parts of the downstream gas installation. Examples are given in the Appendices to UP/16. The smaller leak rate for below 100mbar systems should always be able to achieve Zone 2 NE classification provided they are designed and installed to meet UP/2, tested to UP/1, located in a ventilated environment with air changes normally above 0.5 per hour and most importantly have a maintenance programme. Equally importantly is that any change in the pipework which increases congestion, the locality of nearby surfaces or restriction in ventilation could invalidate the Zone 2 NE classification.

2 around any joints behind and to the left of the boiler. Boilers/ gas appliances cannot be classified for Zone 2 areas so something MUST change. The options are to all weld the pipework system or to move the pipework away from the confined space behind or to the side of the boiler as shown with ochre pipes. UP/16 also gives more detail on the ventilation requirements for ducts and ceiling spaces. Ventilation of spaces in general requires the space to be ventilated such that air movement takes place. This in turns ensures that any leaks are diluted safely. Equally all appliance compartments MUST be ventilated despite what domestic boiler manufacturers might say! The best way to get air movement is vents on 4 outside walls and as high and as low as practicable. UP/16 also considers the issue of pipework in loft spaces, here most will or should have soffit ventilation which in itself should ensure more than 0.5 air changes per hour. But high level ventilation will still be required and UP/16 gives advice of the size of the ventilator opening which is dependent upon the height between the soffit vents and the high level vent itself. There will also be a restriction on the operating pressure of such systems. There are similar issues with basements. Again most should have adequate ventilation but provision will need to be made for high level ventilation back into the building. Where this falls foul of the Fire Compartment requirements in the Building Regulations, there will be a need for additional safety measures such as the use of automatic fire dampers within the high level ventilators or more regular inspection visits. For mechanical ventilation the design issues are the same but here inlet ventilation must be ducted or blown to low level and extract ventilation as high as possible. If the extract fans cannot be at high level, permanent natural ventilation grilles will also be needed at high level.

For gas pipework the first design issue is that there must not be 3 surfaces within 1m of the pipe joints. In the sketch taken from UP/16, the yellow pipe would generate the requirement for a zone

CEA Yearbook 2012/13

Using alternative fuels to reduce energy costs and reduce emissions As fuel prices rise and emissions regulations become tougher, companies must adopt new methods to remain profitable and sometimes just to survive.

ndustrial production sites face many challenges, but for power and utility operations several challenges are especially acute, as increasing populations and per-capita energy use drive an inexorable rise in long term energy prices. To survive, companies must adapt by addressing power and utility energy costs; they must improve efficiencies, utilize cheaper fuels and eliminate waste. At the same time emissions control requirements are becoming more stringent and difficult to achieve. This presents significant challenges for industry, yet it also presents an enormous opportunity. According to the International Energy Agency, the industrial sector has only realized 50 percent of the potential system/life cycle improvements in energy. Consider that energy is typically the largest controllable cost of manufacturing that can be affected locally at a site, and energy savings go directly to the bottom line. Depending on the size of a company’s operations, a 2 percent improvement in power and utility efficiency can bring £1 million benefit annually, Potentially even more significant is substituting 20 percent of traditional

fossil fuel consumption with low cost/alternate fuel sources. This could bring an additional £2-3 million in annual return. Such improvement programs can be self funding at the start, and then yield a profit via sustained benefits — with additional advantage coming through improved maintenance and the avoidance of fines and shutdowns. Penalties or taxes for CO2 production are already in place in some parts of the world and are likely to be more widespread in the future.

Fuel BTU variation But optimizing a combustion process in the boiler house to maximize efficiency and utilize low cost fuels at all times is difficult, especially when attempting to operate highly reliably and responsively. Changing load in the industrial boiler house is a challenge, and an even larger challenge is fuel variability. Natural gas is considered a stable and consistent fuel, but even this conventional fuel can vary in BTU per volume by ±10% over time. Combustion control systems must manage even this level of variability in order to optimize energy cost results. In an effort to restrain costs, a large percentage of industrial boilers make use of both conventional and unconventional fuels. Most often, these unconventional fuels are being produced as byproducts of the main site production operations. Examples include off-gases in chemical plants and refineries, coke oven gas and blast furnace gas in steel mills, waste wood in a pulp and paper mill, or biogas at a food plant. These sources are often essentially a free source of energy for power and utility operations, but they are not typically available with consistent supply and they usually vary considerably in energy content per volume over time. Off-gas or waste liquids from a refinery or chemical plant can change dramatically as feedstock’s and product mix change. This inconsistency is not conducive to running combustion processes in a stable manner, and therefore the use of unconventional fuel sources has traditionally been restricted. Low cost fuels have most typically been used in a base load manner, with traditional fossil fuels being used to achieve stability and follow load. This has often resulted in cases where off-gas is being flared while natural gas is being used to produce steam for production needs. A recent installation at a UK Steel Manufacturer’s 85MW boiler house using Multi-Fuel Combustion Control from Emerson showed significant benefits in alternative fuel management.

Sam Thiara (MEng) Global Industrial Energy Solutions Group, Emerson Process Management Sam.Thiara@Emerson.com

CEA Yearbook 2012/13

A global presence in combustion engineering Zeeco, trusted worldwide for the design and manufacturing of combustion and environmental solutions for the refining, petrochemical, production, power and pharmaceutical industries since 1979. Beginning as a small operation, Zeeco focused on the ideas of expertise, innovation, and reliability that today are the company’s foundation of success.

EECO® product lines include ultra-low emission burners, gas and liquid flaring systems and hazardous and non-hazardous waste incineration. Zeeco has supplied some of the world’s largest combustion systems. These include the largest enclosed ground flare, acid gas thermal oxidizer, enclosed flare and elevated flare. We also have developed the industry’s best performing ultra-low NOx burner. With over decades of industry experience, we have developed a reputation for excellence in engineering, reliability, and integrity in the combustion industry worldwide. Over thirty-three years and nine expansions later, Zeeco employs over 500 people in its Broken Arrow, Oklahoma, USA corporate headquarters alone and has offices and staff in 11 countries. International manufacturing capabilities and local experts make Zeeco a trusted name by customers worldwide. Privately owned, our company remains focused solely on the combustion industry by engineering reliable, world-leading combustion equipment to meet the strictest emission requirements and survive some of the harshest operating environments. With our better by design philosophy, Zeeco’s product development continues to change the combustion industry. Due to continuous demand in Europe and the Middle East, Zeeco Europe Ltd, an affiliate of Zeeco, Inc., has recently expanded to nearly 3,500 square meters of additional office

and manufacturing space near Stamford, UK, providing shorter response times for UK and other European customers. Zeeco Europe now manufactures a wide-variety of combustion equipment and proprietary products, allowing us to quickly and competitively respond to customer needs across the globe. From Aftermarket products and services to equipment inspections and maintenance, Zeeco Europe has the experience and capabilities to meet your needs and exceed your expectations from any location. At Zeeco, we believe in treating every customer with the same responsiveness and respect. We work closely with our suppliers to provide our customers with heroic turnaround times when you need them most. Zeeco’s Power Division exemplifies this commitment with the experience and continued success needed in transforming the industry with technological innovations. We have the market leading burner technology for your emissions reduction projects for all types of utility boilers. From Ultra-Low NOx burners to Over-fire Air systems, our cost effective and energy saving solutions will help to mitigate your capital and operating costs. We can assist with fuel switching or opportunity fuels projects improving efficiency and lowering your fuels costs and minimizing CO2 footprint. Zeeco retrofits lower total costs by using little to no Flue Gas Recirculation (FGR), and have virtually no impact on your boiler and convective heat transfer surfaces. Our applicability spans across all boiler types including wall-fired, T-fired, and fluid bed designs. Zeeco has the industry leading burner technology for your NOx reduction or fuel switching project. Our robust designs lead the market in maintenance free operation and allow your staff to work on other projects while our burners operate without issue. Our Ultra-Low NOx designs to simple maintenance and operational improvements, Zeeco is the one to call for all combustion services. From wall-fired boilers to stoker boiler conversions, we have the technology that will work for you. Call or e-mail us today to learn more about Zeeco’s innovative combustion systems and let us put our experience to work for you.

CEA Yearbook 2012/13

CEA Members guide Airpac Bukom Oilfield Services Mugiemoss Road, Bucksburn Aberdeen, AB21 9NP

Cochran Ltd Newbie Works, Annan, Dumfries & Galloway Scotland, DG12 5QU

Tel: +44 (0)1224 715008 Fax: +44 (0)1224 714290 Email: airpac.rentals@vpplc.com Web: www.airpackbukom.com

Tel: +44 (0)1461 202111 Fax: +44 (0)1461 205511 Email: enquiries@cochran.co.uk Web: www.cochran.co.uk

Armstrong International SA Manchester Business Park 3000 Aviator Way, Manchester, M22 5TG

Dalkia plc Elizabeth House, 56-60 London Road Staines, Middlesex, TW18 4BQ

Tel: +44 (0)161 266 2279 Fax: +44 ()161 266 1001 Email: b.allsopp@armstronginternational.eu Web: www.armstronginternational.com

Tel: +44 (0)1784 496200 Fax: +44 (0)1784 496222 Email: staines.reception@dalkia.co.uk Web: www.dalkia.co.uk

Autoflame Engineering Ltd Unit 1-2 Concorde Business Centre Airport Industrial Estate Wireless Road, Biggin Hill Kent, TN16 3YN

Danstoker UK Ltd 2 Studio Court, Queensway Bletchley, Milton Keynes, MK2 2DG

Tel: +44 (0)845 872 2002 Fax: +44 (0)845 872 2036 Email: service@autoflame.com Web: www.autoflame.co.uk Aylan Associates Netherclose, 15 Langwith Road Collingham, Wetherby, LF22 5DH Tel: +44 (0)7887 621796 Email: aylanassociates@aol.com

British Sugar plc Sugar Way, Peterborough, PE2 9AY Tel: +44 (0)1733 563171 Fax: +44 (0)1733 563068 Email: David.Gent@absugar.com Web: www.britishsugar.co.uk Byworth Boilers Parkwood Boiler Works, Parkwood Street Keighley, West Yorkshire, BD21 4NW Tel: +44 (0)1535 665225 Fax: +44 (0)1535 680997 Email: sales@byworth.co.uk Web: www.byworth.co.uk Certuss Steam Generators Unit 5, Gravelly Industrial Park Birmingham, B24 8TG Tel: +44 (0)121 327 5362 Fax: +44 (0)121 328 2934 Email: sales@certuss.co.uk Web: www.certuss.co.uk Chris Newton Steam Services Llwyn CelynTyâ&#x20AC;&#x2122;n, Dwr Road, Llangollen Tel: +44 (0)1978 860578 Mobile: +44 (0)7533 619277 Email: chrisnewtonsteamservices@fsmail.net Web: www.chrisnewtonsteamservices.co.uk

Tel: +44 (0)7966 099124 Email: ac@danstoker.com Website: www.danstoker.com David Graham 30 Ballaquark Walk, Douglas Isle of Man, IM2 2EZ Tel: +44 (0)1624 614742 Email: david_graham@manx.net DS Smith Paper Ltd Wansborough Paper Mill, Watchet Somerset, TA23 0AY Tel: +44 (0)1984 631456 Web: www.dssmithpaper.com

Dunphy Combustion Ltd Queensway, Rochdale, Lancashire, OL11 2SL Tel: +44 (0)1706 649217 Fax: +44 (0)1706 655512 Email: sharon.kuligowski@dunphy.co.uk Web: www.dunphy.co.uk Duomo (UK) Ltd Units 5 & 6, Judge Court, North Bank Berry Hill Industrial Estate, Droitwich Worcestershire, WR9 9AU Tel: +44 (0)1905 797989 Fax: +44 (0)1905 774296 Email: sales@duomo.co.uk Web: www.duomo.co.uk Element Consultants Ltd 48 Straid Road, Ballycastle Co Antrim, BT54 6NP Tel: +44 (0)282 076 1240 Fax: +44 (0)870 460 1630 Email: info@elementsconsultants.co.uk Web: www.elementconsultants.co.uk Emerson Process Management Ltd Meridian East, Leicester, LE19 1UX Tel: +44 (0)116 282 2822 Fax: +44 (0)116 282 2730 Email: uksales@emersonprocess.com Web: www.emersonprocess.com

CEA Yearbook 2012/13

CEA Members guide EMK Educational & Environmental Services Ltd Somerville House, 20-22 Harbourne Road Birmingham, B15 3AA

Gavin Hoole 3 Dayley Thompson Way, South Lambeth London, SW8 3DA

Tel: +44 (0)800 083 2088 Email: info@emk-ltd.co.uk Web: www.emk-ltd.co.uk

Tel: +44 (0)781337519 / +44 (0)20 7498 9734 Email: gavin_hoole@hotmail.com

Emvertec Ltd Millenium Works, Valletta Street Hull, HU9 5NP

Geof frey Robinson Limited Macklin Avenue, Cowpen Industrial Estate Billingham, TS23 4ET

Tel: +44 (0)1386 831582 Email: j.vernon@emvertec.co.uk Web: www.emvertec.co.uk

Tel: +44 (0)1642 370500 Fax: +44 (0)1642 370600 Email: enquiries@geoffreyrobinson.ltd.uk Web: www.geoffreyrobinson.co.uk www.Gr4renewable-energy.com

Endress & Hauser Ltd Floats Road, Manchester, M23 9NF

Gestra – Flowserve GB Ltd Gestra – Power Division, Euro House Abex Road, Newbury, Berkshire, RG14 5EY

Tel: +44 (0)161 286 5000 Fax: +44 (0)161 998 1841 Email: info@uk.endress.com Web: www.ukendress.com Energy and Environmental Solutions Nithsdale, Broadway Road Windlesham, GU20 6DA Tel: +44 (0)1276 472354 Mob: +44 (0)7860 600477 Email: Paulw2000@btinertnet.com Energy Technology & Control Ltd 25 North Street, Lewes, East Sussex, BN7 2PE Tel: +44 (0)1273 480667 Fax: +44 (0)1273 480652 Email: sales@energytechnologycontrol.com Web: www.energytechnologycontrol.com Enersol Flomar Fletcher House, Marlborough Drive Fleckney, Leicestershire, LE8 8UR Tel: +44 (0)116 240 3430 Web: www.enersolflomar.com

ES Pipelines Ltd Hazeldean, Station Road, Leatherhead Surrey, KT22 7AA Tel: +44 (0)1372 227560 Fax: +44 (0)1372 377996 Email: info@espipelines.com Web: www.espipelines.com Facultatieve Technologies Ltd Moor Road, Leeds West Yorkshire, LS10 2DD Tel: +44 (0)113 276 8888 Fax: +44 (0)113 271 8188 Email: info@facultatieve-technologies.co.uk Web: www.facultieve-technologies.com Fulton Boiler Works (GB) Ltd 210 Broomhill Road, Brislington Bristol, BS4 4TU Tel: +44 (0)117 972 3322 Fax: +44 (0)117 972 3358 Email: uk.sales.office@fulton.com Web: www.fulton.co.uk

Engineering operations

Tel: +44 (0)1635 46999 Fax: +44 (0)1635 36034 Email: gestraukinfo@flowserve.com Web: www.flowserve.com Global Energy Associates Ltd Dr Richard Marrow, Gardeners House, South End, Great Rollright Chipping Norton, Oxon, OX7 5RR Tel: +44 (0)1608 730878 Email: admin@globalenergy.co.uk Web: www.globalenergy.co.uk Guernsey Electricity Electricity House, PO Box 4, North Side Vale, Guernsey, Channel Islands, GY1 3AD Tel: +44 (0)1481 200700 Web: www.electricity.org

Hamworthy Combustion Engineering Ltd Fleets Corner, Poole, Dorset, BH17 0LA Tel: +44 (0)1202 662700 Fax: +44 (0)1202 665333 Email: info@hamworthy-combustion.com Web: www.hamworthy-combustion.com Harris Pye Marine Ltd David Davies Road, No. 2 Barry Docks Barry, Vale of Glamorgan, CF63 4AB Tel: +44 (0)1446 720066 Fax: +44 (0)1446 700801 Email: hpuk@harrispye.com HeatSol Technology Ltd HeatSol House, 28 High Street Droitwich Spa, Worcestershire, WR9 8ES Tel: +44 (0)1905 773377 Fax: +44 (0)1905 773399 Web: www.heatsol.co.uk Ian Fells Associates 29 Rectory Close, Newcastle upon Tyne Tyne & Wear, NE3 1YB Tel: +44 (0)8703 211661 Email: info@fellsassociates.com Web: www.fellsassociates.com

CEA Yearbook 2012/13

CEA Members guide Inciner8 Ltd INCINER8 House, Balmoral Drive Southport, PR9 8PZ

Mobrey Horsfield Way, Bredbury, Stockport Cheshire, SK6 2SU

Tel: +44 (0)1704 506506 Fax: +44 (0)1704 506666 Email: claire@inciner8.com Web: www.inciner8.com

Tel: +44 (0)870 240 1978 Fax: +44 (0)800 966 181 Email: mobrey.enquiries@emersonprocess.com Web: www.mobrey.com

J&S Engineers (EUR) Ltd 35 Barrington Road, Sutton Surrey, SM3 9PR

M. W. A Technology Ltd 2 Wharton Street Industrial Estate Birmingham, West Midlands, B7 5TR

Tel: +44 (0)20 8641 2217 Fax: +44 (0)20 8644 1703 Email: jsengineers@btconnect.com

Tel: +44 (0)121 327 7771 Fax: +44 (0)121 327 1117 Email: info@mwatechnology.com Web: www.mwatechnology.com

JBC Industrial Services Ltd Howley Park Road East, Morley Leeds, LS27 0SW.

Neil Riches Little Orchard, 40 Mount Road, Penn Wolverhampton, WV4 5SW

Tel: +44 (0)113 220 3830 Fax: +44 (0)113 252 1407 Email: info@jbcmail.co.uk Web: www.jbcindserv.co.uk

Tel: +44 (0)1902 345233 Mob: +44 (0)7710 444842 Email: neil.riches@btinternet.com

Johnson Apparelmaster Pittman Way, Eastway, Fulwood Preston, Lancashire, PR2 9ZD Tel: +44 (0)1772 662555 Fax: +44 (0)800 393837 Email: jaminfo@jsg.com Kaye & Associates Ltd Albion Mills House, 5 Marlborough Close Charlton Kings, Cheltenham Gloucestershire, GL53 7RY Tel: +44 (0)1242 513747 Email: kaye777@btinternet.com Kiwa GASTEC at CRE Ltd Orchard Business Centre, Stoke Orchard Cheltenham, Gloucestershire, GL52 7RZ Tel: +44 (0)1242 677977 Fax: +44 (0)1242 676506 Web: www.kiwa.co.uk Lubron Water Technologies Lubron House, 8 Challenge Way Hythe Hill, Colchester, CO1 2LY Tel: +44 (0)1206 866444 Fax: +44 (0)1206 866800 Email: info@lubron.co.uk Web: www.lubron.co.uk MCL Energy 1 Derwent House, Richmond Business Park Siding Court, Doncaster, DN4 5NL Tel: +44 (0)1302 738000 Fax: +44 (0)1302 384300 Email: enquiry@mclenergy.co.uk Web: www.mclenergy.co.uk MK Mechanical Services Ivanhoe, 160 Hinckley Road Leicester Forest East, Leicester Leicestershire, LE3 3JT Tel: +44 (0)116 239 0220 Fax: +44 (0)116 239 0220 Email: info@mkmechanical.co.uk Web: www.mkmechanical.co.uk

CEA Yearbook 2012/13

Novartis Vaccines and Diagnostics Site 4, Renaissance Way, Liverpool L24 9JW Tel: +44 (0)151 705 5000 Fax: +44 (0)151 705 5018 Web: www.novartis.co.uk Orbital Gas Systems Ltd Cold Meece, Swynnerton, Nr Stone Staffordshire, ST15 0NQ Tel: +44 (0)1785 857000 Fax: +44 (0)1785 857001 Email: enquiries@orbital-uk.com Web: www.orbital-uk.com Peter Pearson Binhams, Tuckers Lane, Ubley Bristol, Avon, B40 6PB

R G Combustion Ltd Unit 12 Newport Business Park Barry Way, Newport, Isle of Wight Hants, PO30 5GY Tel: +44 (0)1983 526111 Email: info@rgcombustions.co.uk Web: www.rgcombustions.com Reach Power 15 Ridgeway, Acomb York, YO26 5DA Tel:+44 (0)1904 795743 Mob: +44 (0)7553 066667 Email: chrishstockton@hotmail.com

CEA Members guide SAACKE Combustion Services Ltd Langstone Technology Park Langstone Road, Havant Hampshire, PO9 1SA Tel: +44 (0)23 9251 8200 Fax: +44 (0)23 9251 8201 Email: ukadmin@saacke.com Web: www.saacke.com Sembcorp Utilities (UK) Ltd PO Box 1985, Wilton International Middlesbrough, Cleveland, TS90 8WS Tel: +44 (0)1642 212229 Fax: +44 (0)1642 212690 Web: www.sembcorp.co.uk SMC Espana SA International Training Division Zuazobidea 14, Poligono Industrial Jundiz E-01015 Vitoria, Spain Tel: +44 (0)7846 691136 Fax: +945 184 126 Email: mbevan@smctraining.com Web: www.smc.eu Spirax-Sarco Ltd Charlton House, Cirencester Road Cheltenham, Gloucestershire, GL53 8ER Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342 Email: enquiries@uk.spiraxsarco.com Web: www.spiraxsarco.com/uk Stream Engineering Solutions Ltd 3 The Wiend, Port Sunlight, Wirral Cheshire, CH63 7RG Web: www.streames.co.uk

TLV Euro Engineering UK Ltd Star Lodge, Montpellier Drive Cheltenham, Gloucester, GL50 1TY Tel: +44 (0)1242 227223 Fax: +44 (0)1242 223077 Email: sales@tlv.co.uk Web: www.tlv.com Tomatin Distillery Co Ltd Tomatin, Invernessshire, Scotland IV13 7YT Tel: +44 (0)1463 248148 Fax: +44 (0)1463 248149 Email: info@tomatin.co.uk Web: www.tomatin.com Torishima (Europe) Projects Ltd Torishima House, Brook Lane, Westbury, Wiltshire, BA13 4ES Tel: +44 (0)1373 858143 Email: guyforrest-hay@torishima.co.uk Web: www.torishimaprojects.co.uk Unilever Deutschland GmbH Unilever Deutschland GmbH Dammtorwall 15, 20355 Hamburg, Germany Tel: +49 40 34932417 Fax: + 49 40 35547072417 Email: ulf.jornitz@unilever.com Web: www.unilever.com Weishaupt (UK) Ltd Neachells Lane, Willenhall West Midlands, WV13 3RG Tel: +44 (0)1902 609841 Fax: +44 (0)1902 633343 Email: info@weishaupt.co.uk Web: www.weishaupt.co.uk

Stopher Associates Ltd 34 Ickwell Road, Northill Biggleswade, Bedfordshire, SG18 9AB

Wellman Thermal Services Ltd Newfield Road, Oldbury West Midlands, B69 3ET

Tel: +44 (0)1767 626330 Mob: +44 (0)7582 733930 Web: www.stopherassociates.co.uk

Tel: +44 (0)121 543 0000 Fax: +44 (0)121 543 0101 Email: info@wellman-thermal.com Web: www.wellman-group.com

Swan Analytical UK Ltd Unit 3, The Steading, Copthill Farm Uffington, Stamford, Lincs, PE9 4TD

Zeeco Europe Ltd The Woolfox Building, Great North Road Rutland, LE15 7QT

Tel: +44 (0)1780 755500 Fax: +44 (0)1780 755508 Email: sales@swan-analytical.co.uk Web: www.swan-analytical.co.uk

Tel: +44 (0)1780 765077 Fax: +44 (0)1780 757121 Email: zeeco_europe@zeeco.com Web: www.zeeco.com

Tata Steel UK Ltd PO Box 1, Brigg Road, Scunthorpe North Lincs, DN16 1BP Tel: +44 (0)1724 404040 Email: construction@tatasteel.com Web: www.tatasteel.com

CEA Yearbook 2012/13

ES Pipelines is proud to sponsor the CEA Yearbook ES Pipelines congratulates the CEA on its 80th anniversary and wishes it continued success in the coming years ES Pipelines Hazeldean, Station Road, Leatherhead KT22 7AA Tel: 01372 227560 www.espipelines.com

TLV EURO ENGINEERING – A STEAM SPECIALIST COMPANY Founded over 60 years ago, TLV Euro Engineering is a recognised global leader in steam engineering. From its UK headquarters in Cheltenham, TLV offers a wide range of products supported by services including consulting, site inspections and seminar training. TLV has always strived to manufacture innovative, high-quality products and systems and an early success – the A3 steam trap – was awarded no less than seven patents and offered an incredible 10 times the durability of previous products. Other innovative products include the award-winning CV-COS, an electro-pneumatic PRV with convenient control function; and the Vacuumizer, a vacuum pressure steam heating and cooling system. TLV has also revolutionised fluid control technology with its patented ‘Free Float’ steam traps which, with only one moving part, guarantee long life and reliability. TLV also offers steam training seminars covering the efficient use of process steam which, in holding Level 3 BTEC Advanced Award status, offer a nationally recognised qualification. The three-day seminars at TLV’s state-of-the-art European headquarters in Germany, aim to develop the knowledge of those in the steam industry whose job it is to increase steam efficiency, reduce maintenance costs and/or improve the design/performance of steam systems. Further help is also available from TLV’s recently launched iPhone App. TLV ToolBox is based on the company’s SE-1 software and is available as a free download from Apple’s App Store. Features include standard unit conversions; steam tables; steam pipe sizing; velocity and flow rates through a pipe; condensate pipe sizing; direct/indirect

CEA Yearbook 2012/13

heat loads; continual/batch heat loads; a KV calculator, and flow rates through orifice or valve. A version for Google’s Android mobile operating system will also be available soon.

For further information call 01242 227223, email sales@tlv.co.uk or visit http://www.tlv.com.

CEECON® Condensing Economisers

Proven technology for unlocking the last drop of energy from flue-gases. Emvertec has been producing CEECON® condensing economisers since 1986. Emvertec CEECON® technology is suitable for use with the combustion products from a variety of fuels, including natural gas and wet bio-mass.

w w w. e m v e r t e c . c o . u k +44(0)1386 831582

The Second Age of Steam Boilers Kiwa Ltd – a new name but the same reliable GASTEC at CRE team doing BOAS assessments just like we’ve always done. There are two flavours of BOAS course – BOAS (O) for existing boiler operators and BOAS (M) for managers of boiler operators. Training is carried out by a number of training providers over the country, but the examination and candidate interviews are all carried out by Kiwa Ltd. We are a low carbon consultancy, training and product testing company. As a Notified Body (0558) under the Boiler Efficiency Directive, we know a thing or two about boilers of all kinds. Since the publication of the CEA’s paper ‘Guidance on Safe Operation of Boilers,’ (BG01) there has been a big increase in the number of boiler operators enrolling on BOAS courses.

For more information or to book your course, please call us on (01242) 677877 or email: gastecenquiries@kiwa.co.uk

Kiwa GASTEC at CRE, The Orchard Business Centre, Stoke Orchard, Cheltenham, GL52 7RZ Tel: +44 (0)1242 677877 Fax: +44 (0)1242 676506 Email: gastecenquiries@kiwa.co.uk www.kiwa.co.uk

CEA Yearbook 2012/13

Our Mechanical fitter/Supervisor will visit your business and talk you through all of your options, as well as giving you Support on how you could improve your Business energy efficiency and introduce you to the latest technologies. We can provide support to you to take control of your energy use and assist your Business into saving energy for the future. Saving the environment and money in the process. Professional holiday cover and operational support. London Based Engineer. Experienced mechanical fitter and foreman in Steam and HVAC operations and CHP operations. HVAC/Steam plant operations.

Gavin Hoole—gavin_hoole@hotmail.com

Dip Bom. Mechanical foreman. CEA member.

Tel—07813375196 / 02074989734

Engineering operations

DAVID GRAHAM CONSULTANCY BA MISM Training Assessor for; Gas, Oil, Water, and Steam Cat 1, 2 and 3 DED Government Approved Consultant for Quality Systems, Environmental Solutions, Email: david_graham@manx.net Phone: 01624 614742 Mobile: 07624 495882 Company Established 2005 Registration No 018878B

zeeco_europe@zeeco.com ZEECO Europe Ltd. • +44 (0)1780 765077

Energy Efﬁcient Combustion Control For

INDUSTRIAL BOILERS

Internal Auditor for: ISO 9001: 2008, ISO 14001: 2006, OHSAS 18001: 2007 Review: Boiler House Management Systems, Audit Metrics Corrective and Preventive Actions, Setting Objectives Training Needs Analysis Audit: Management Procedures, Legal and Regulatory

Emerson Process Management Ltd Emerson’s Global Industrial Energy Group offers comprehensive automation solutions for boiler house operations; Packaged Boiler, Multi-Fuel Combustion Control, Burner Management, Economic Dispatch, Steam Header and Energy Management. Together with consulting expertise to support site audits, safety, reliability, control & instrumentation assessments and functional design expertise Emerson Process Management offers a single source of expertise worldwide.

Sam Thiara, Marketing & Sales Manager, Global Industrial Energy Solutions Group Email: Sam.Thiara@Emerson.com Tel: +44 (0) 7825 862 808 Website: www.emersonprocess.com

Reduce fuel costs and emissions by up to 10% Biofuel options with variable ratio combined ﬁring Boiler water level controls

Armitage Communications is proud to be selected as publisher of the CEA Yearbook 2012/13

ATEX options for Zone 1 & Zone 2 OEM customisation and bespoke software solutions Complies with worldwide standards including EN61508 to S.I.L.3

The ETC6000 Series of Burner Controls INTEGRATED CONTROLS

SERVOS & SENSORS

TOUCHSCREEN INTERFACES

FUEL:AIR RATIO CONTROLS

T: +44 (0)1273 480667 F: +44 (0)1273 480652 E-mail: sales@energytechnologycontrol.co m Web: www.energytechnologycontrol.com

Leaders in Combustion Control

CEA Yearbook 2012/13

• Advertising • Brochures • Contract publishing • Databases

• Direct mail • Email marketing • Graphic design • Media relations

• Social media • Video and animations • Websites • White papers

To find out how to get winning results from your marketing, please contact us at:

Energy Technology & Control Ltd. 25 North Street, Lewes, East Sussex, BN7 2PE, UK

A wide range of public relations services for the engineering sector:



Armitage Communications Ltd, Mill House, Wandle Road, Beddington, Surrey, CR0 4SD

Tel: 020 8667 9660 Email: enquiries@armitage-comms.co.uk Web: www.armitage-comms.co.uk

BOAS:

Boiler Training BG01 - Do your operatives comply?

JBC training provides a range of courses including the five day BOAS course (Boiler Operation Accreditation Scheme) recommended by BG01 to ensure compliance with best practice for all boiler managers and operators.

Who should attend?

• Plant Manager • Shift Operative • Staff involved in boiler operations... these courses are relevant to you!

Gain • • • •

Compliance with BG01 Boilerhouse procedures Burner sequencing Overall boilerhouse operations

To enhance your boilerplant knowledge, learn more about BG01 and how you are could be affected, please email our training department: enquiries@jbcboilertraining.co.uk

Boiler Operation Accreditation Scheme 5 day course

MOB:

Maintenance & Operation of Boiler 2 day course

BOSH:

Boiler Operative Safety & Health 1 day course

SOBA: Safe Operation & Boiler Awareness 1 day course Bespoke on-site training and workshop based options

Visit: www.jbcindserv.co.uk | www.jbcboilertraining.co.uk | www.ecosafe.co.uk

Call: 0113 220 3830

JBC Industrial Services Ltd, Howley Park Road East, Leeds LS27 0SW

CEA Yearbook 2012/13

Reduce both your costs and emissions with Ecosafe digital combustion control. JBC specialise in industrial steam boilers and combustion. Our Ecosafe product range is designed to retrofit current and superseded burner applications. Ecosafe delivers the benefits of digital combustion management at a fraction of the price of a new burner.

Improve your boilerplant efficiency... • ROI within 12 months • Reduce fuel consumption • Improve emissions • Reduce costly downtime • Save energy • Save fuel costs

Ecosafe finance options available, offering: • Easy regular payments • Cash preservation • Tax advantages • Flexibility to upgrade

Call today for more help and information, and also take advantage of our Free Energy Audit service

0113 220 3836 enquiries@ecosafe.co.uk

www.ecosafe.co.uk | www.jbcboilertraining.co.uk | www.jbcindserv.co.uk JBC Industrial Services Limited Howley Park Road East Leeds LS27 0SW