CEA Yearbook 2016 17

CEA Yearbook 2016/2017 2016/2017 The Association The Combustion Combustion Engineering Engineering Association

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CEA Yearbook 2016/2017

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Contents Message from the Chairman Message from the Director About the CEA

page 4 pages 6-8 page 9

Medium Combustion Plant Directive (MCPD)

pages 10-14

What you need to know about emissions

pages 15-16

Continued development of the CEA website

page 17

A new chapter in energy efficiency

page 19

David Gunn Memorial Lecture and Lord Ezra Awards: Prestigious awards and fascinating lectures mark key CEA events

pages 20-24

Training: Engineering Your Future

pages 26-27

Training: The I-GAS initiative is helping improve industrial gas safety

page 28

Training: It pays to put the right skills in place

page 30

Training: Directory of training providers

page 33

Energy Savings Opportunities Scheme: Countdown to ESOS

page 34

Energy Savings Opportunities Scheme: ESOS and reformed energy efficiency taxes

page 35

Energy Savings Opportunities Scheme: O is for Opportunity: Why ESOS is more than just form filling

pages 37-38

Boilers and Burners: COe Control – Closed Loop Burner Efficiency & Enhanced Safety

pages 41-42

Boilers and Burners: Let’s start with the basics!

pages 44-45

Boilers and Burners: Industrial boilers: upgrade or replace?

For further information about the CEA please contact David Kilpatrick on: Tel: 01740 625538 Email: info@cea.org.uk Web: www.cea.org.uk or write to: The Combustion Engineering Association NETPark Thomas Wright Way Sedgefield Co. Durham TS21 3FD

The CEA Yearbook 2016/2017 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

armitagecommunications CONTENT

page 46

IN

CONTEXT

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Boilers and Burners: Thermal fluid or steam – a case for both

pages 47-48

Boilers and Burners: Burning questions

pages 50-51

Biomass: Oat husk - a viable alternative to wood for biomass Biomass: Lessons in safe biomass design Steam generator transplant for Guys & St Thomas Hospital

page 52 pages 53-56 page 59

ROCs and syngas testing – Do you really know how to prove it?

pages 61-62

Control intelligence reduces boiler operating costs

pages 64-65

University Teaching Hospital goes green

pages 66-67

Boilerhouse risk assessments deliver real value CEA Members guide

Paper Cover printed onto 300 gsm Claro Silk Text pages onto 150 gsm Claro Silk 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.

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Copyright © CEA 2016

page 68 pages 70-75

DID YOU KNOW In 2015 two members were recognised for their long term support of the CEA with honorary life membership, they are Martin Fletcher of Flomar and M&M Training and Jim Findlay of Heatsol, congratulations to them both.

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CEA Yearbook 2016/2017

3

Message from the CEA Chairman

T

he last 12 months have seen a great deal of activity within the CEA. So much in fact that in the last eighteen months the Sedgefield team has gone from two part-time employees to two full-time, plus one part-time and an apprentice. In addition we have increased the paid member activity with the introduction of a Certification Officer and a Lead Member focused on the Large and Medium Combustion Plant Directives. All this is due mainly to the drive and dedication of the Sedgefield team. Backing the Sedgefield team up is a significant and growing number of members who are extremely generous with their time and more importantly with their innovative ideas, along with a passion for the industry.

Our membership has grown – in 2013 we had 90 members, we now have 124; our membership has now grown 96% in just four years. In 2013 two new categories of membership were created for Universities and Hospitals. Last year, and in line with our status as an educational charity we opened a free student membership, to encourage young engineers who wish to follow a career in combustion engineering. We were delighted to welcome three of the first student members to the David Gunn Memorial Lecture at the House of Lords in October 2014.

In 2013 at the David Gunn Memorial Lecture we gave an award to the 1000th BOAS candidate. To get to this point had taken us nine years. Just nine months later we had passed 2,000 successful candidates, it was at this point we realised that the BOAS courses and assessments are now recognised as the only viable training accreditation for boiler operators and managers.

It has been recognised for many years that there has been a grey area in the field of gas safety. Gas Safe Registration is, at the moment, the only way a gas technician/engineer can prove his/ her competence when working on gas systems. However this registration is based around the Gas Safety (Installation and Use) Regulations 1998, which are mainly focused on the domestic and small commercial areas of the market. Factories and generating facilities fall outside these regulations and this is where the majority of our members operate. With this in mind it was decided some three years ago to introduce the ‘Industrial Gas Accreditation Scheme’. I am pleased to announce that this scheme has gone live with the first two course having taken place in June and July 2015.

We are fortunate in the CEA to have a membership that includes some of the top experts in many differing fields, such as boiler and burner construction, water treatment, steam systems, gas and liquid fuels, to name but a few. It was with this in mind that one of our members, Sam Thiara, promoted the idea of an ‘Experts Academy’. This will allow members and non-members to have confidence, that if they approach the CEA with a problem or a question, they will get expert, up to date advice.

We are also extremely grateful to our President Dr Pete Waterman for his continued support, and in return we, as an organisation fully support his Railway Exchange Training Academy taking young people through to traditional technician level engineers.

2016/17 looks to be as busy and challenging as previous years.

We are facing changes in legislation driven from Europe, economic challenges in UK markets, initiatives to provide our growing membership with guidance and value for money. The CEA has the ability to rise to these challenges, we have a strong and focused team at Sedgefield, tremendous support from Lord Chidgey and Lord O’Neill at Westminster, a stable financial base to work from and above all, an active and committed membership.

Mr Derry Carr Chairman of Council, Industrial Boilerhouse Safety

DID YOU KNOW

?

CEA is creating an accreditation for Industrial Gas, (I-GAS) because Gas Safe does not apply to people working on industrial gas installations and there needs to be a way that they can prove their competence.

The CEA enjoys the continued support and active involvement of its President Dr Pete Waterman, seen here talking at the 2015 David Gunn Memorial and Lord Ezra awards event at the House of Lords

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CEA Yearbook 2016/2017

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Message from the Director Patron: The Lord Ezra President: Dr Pete Waterman, OBE, DL Director: David Kilpatrick

L

ate 2014 and throughout 2015 has been another very busy time for the CEA with many activities such as LCPD & MCPD, I-GAS, BOAS, Biomass, Risk Assessment and others, all of which require significant support from CEA members and CEA staff alike. I would like to thank all of those who have freely given so much of their time and effort.

The membership continues to grow steadily and attendance at our events has also grown, which is fantastic news.

Chairman Derry Carr continues to steer the CEA on its current course, the AGM in March was very well attended with all seats taken, the Members and Partners dinner had good attendance especially when you consider it was a Friday night of a bank holiday weekend.

The CEA’s David Gunn Memorial Lecture in October 2015 had Dr Stephen Payne OBE as the guest speaker; he is the principal designer and project engineer for the magnificent ocean liner Queen Mary 2. This is one of the three latest ships of the Cunard line, Queen Elizabeth 2, Queen Mary 2 and Queen Victoria which were recently on a world tour celebrating the 175th anniversary of the Cunard shipping line which Stephen has been closely involved with.

Two conference workshops late in 2014 and a further three in 2015 were all well attended by new delegates and exhibitors alike.

2015 saw three, two-day technical boilerhouse risk assessment conference workshops on compliance with BG01, with some 300 delegates attending.

The October 2014 David Gunn Memorial Lecture in the House of Lords featured “Energy in the Sugar Industry” as the topic by David Gent, past CEA chairman and engineering manager at AB Sugar, Accompanied by placement student Jamie Lam AB Sugar

Meanwhile a CEA biomass conference proved timely in 2015 after considering the impact of several serious incidents in the UK and Europe. CEA was contacted through one of its members by an organisation that had suffered a serious explosion incident. Luckily nobody was injured and we were asked if we could help resolve the cause of a totally unexpected explosion on a brand new plant.

Ali Nicol of Element Consultants was approached by CEA to help and then acted as investigator into the cause of the accident. As a result of his help the organisation have been able to understand why it happened, put in place a plan to resolve any on-going risks associated with the plant design, and satisfy the HSE that they have taken on-board all of the advice they were given. This organisation has since joined CEA as a new member.

CEA were then asked if we could do some training on biomass, we said yes and organised this with Ali. As a result CEA have been involved throughout August 2015 helping with Health Safety and Awareness training for some 60 staff that are, or could be, involved with biomass boilers, some of which are in containerised units.

The CEA team also organised and ran two conference workshops over a three days period in August. In an attempt to spread the word about the Health and Safety issues associated with biomass boilers, CEA hosted a Biomass conference workshop at the Beardmore hotel Glasgow with Ali Nicol chairing the day. The feedback was excellent but more needs to be done to ensure safe operation of these biomass boiler plants. Luckily to date nobody has been killed in the UK that we are aware of, but it would appear that poor training and a lack of knowledge by the operators is the main cause of several of these incidents. Better training by the manufacturers and installers is what’s needed.

Left to right - Stuart Walker and Lee Hopkins of Bentley Motors, CEA Chairman Derry Carr, Lord O’Neill of Clackmannan and Sharon Kuligowski Dunphy Combustion presenting the 2000th BOAS accreditation certificate Continued on page 8

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CEA Yearbook 2016/2017

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CEA Yearbook 2016/2017

7

Message from the Director (continued)

CEA can help if they were involved from the design phase of new systems through to operation. By using its members and by offering bespoke training on the Health Safety and Awareness aspects of running biomass boiler plant, we can hopefully make biomass a safer option.

A bespoke BOAS training programme for managers, covering their specific responsibilities has also been introduced. This would include the basics of using and checking a daily activity logbook, risk assessments, internal audits, safety issues, traceability, emissions, environmental and other aspects which will all be included in the course, to help ensure total safety.

The Medium Combustion Plant Directive (MCPD) is gathering momentum and will start to take effect in 2017; Paul Whitehead continues leading on this project and is the CEA representative with Defra and the Environment Agency (EA). November 2015 saw the first conference in Daventry to start and make the UK aware of what it needs to do to achieve compliance, once the directive is passed into UK law. Defra and the EA also explained the issues from the regulator’s point of view. The MCPD will be a change to how the UK addresses emissions to atmosphere from industry; it will affect anybody using boilers, burners and engines for any process above 1MW thermal input.

Consider this scenario: During a boilerhouse or biomass incident, a major steam leak or at worst an explosion, the boilerhouse would fill with smoke or steam very quickly, it happens in seconds.

People may be trapped in the boilerhouse and not necessarily at ground level. How would they find their way out? How do they find the emergency exits to escape from the boilerhouse?

Have you carried out risk assessments? Do you have all of your emergency procedures in place according to the PSSR (regulation 11.1.b the action to be taken in the event of an emergency)?

Since the last edition of the yearbook the CEA has awarded the “Malcolm Dunphy Award” to the 2000th BOAS candidate who gained accreditation, this was Lee Hopkins from Bentley Motors. Lee and his manager Stuart Walker also attended the 2014 David Gunn lecture to be presented with the award. Currently CEA have some 2,500 people accredited under the BOAS scheme as either operator, manager or in some cases a joint operator and manager award.

Industrial Gas Accreditation Scheme (I-GAS) is on its way, but it is often believed that Gas Safe covers all gas installations, yes it does for domestic and light commercial activity, but it does not cover industrial sites. This is why CEA have created I-GAS which has been developed and is ready for launch to industry: there are five levels that can be achieved by anybody working on gas equipment in industry if they are suitably skilled. I-GAS will allow the candidate to prove their competence on industrial gas equipment.

As the review of BOAS continued throughout 2014-15 it became clear that there was a need for a Certification Officer to check and ensure the paperwork required for BOAS applications and accreditation is complete and accurate, Past Chairman David Gent has taken on this role. Further work reviewing BOAS has led to the three distinct categories which have now been defined, Cat 1 is for Hot Water boilers, Cat 2 is Shell Steam boilers and Cat 3 is Water Tube boilers. Applicants can apply for one or more of these categories and will be assessed accordingly.

On the terrace at the House of Lords, Derry Carr, Lee Hopkins, Stuart Walker, Julie Kilpatrick

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CEA Yearbook 2016/2017

CEA are also writing a number of new documents including BG02 Risk Assessment, BG03 to replace PM60 Boiler Blowdown, and BG04 Boiler Water Treatment in partnership with ICOM. David Kilpatrick Director of the CEA

As ever, the House of Lords provided a special setting for the CEA’s October event that recognizes excellence in the combustion engineering industry

About the CEA

T

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 Council Members 2015-2016

Honorary Patron The Lord Ezra

Honorary President Dr Pete Waterman

Honorary Vice Presidents The Lord Chidgey

The Lord O’Neill of Clackmannan

Mr Kenneth Fergusson

Prof Bill Kaye

Mr David Arnold

Executive Committee

Chairman of Council Mr Derry Carr Industrial Boilerhouse Safety

Vice Chairmen Mr Jim Findlay Heatsol Technology Ltd

Prof Bill Kaye Kaye and Associate Limited

Mr Adrian Rhodes Byworth Boilers

Immediate Past Chairman Mr David Gent AB Sugar

Treasurer Mr Nick Wilson ISIS Fluid Control Ltd

Trustees Mr Derry Carr Industrial Boilerhouse Safety

Mr David Gent AB Sugar

Mr Nick Wilson ISIS Fluid Control Ltd Important Note: The offices of Hon Patron, President and Vice President are honorary posts and do not carry any automatic right to representation on Council. Trustees are automatically members of Council.

Council Members 2015-2016

Mr Derry Carr Mr David Gent Prof Bill Kaye Mr Jim Findlay Mr Adrian Rhodes Mr Malcolm Cook Mr Sam Thiara Mrs Sharon Kuligowski Mr Andy Rout Mr Kim Stopher

Mr Paul Bough Mr Paul Whitehead Mr John Bashall Mr Barrie Church Mr Paul Mayoh Mr Bernard Fox Mr David Branch Mr Matthew Walton Mr Chris Coleman Mr Carl Knight Mr Ian Sutherland Mr Nick Wilson Mr Ali Nicol Ms Zenaida D’Sa

Industrial Boilerhouse Safety

AB Sugar

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Co-opted to Council 2015 /16 Mr Mark Crowther Kiwa GASTEC at CRE Mr Martin Fletcher M&M Training

CEA Yearbook 2016/2017

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Medium Combustion Plant Directive – update on progress Paul Whitehead brings us up to date with the proposed Medium Combustion Plant Directive requirements, progress on bringing it into UK law and some of the issues that remain to be resolved.

M

any readers will be aware that the CEA has been actively following and contributing to the proposed Medium Combustion Plant Directive over the last 18 months or so. Defra has provided much of the background information for this article, but as I write this (August 2015) the legislation is in its final throes of negotiation in the EU, and things may change.

Equally, some issues that look like a potential problem today may have been discussed and decided by the time this article is published, so do please look out for the latest updates on the CEA and other web sites.

Defra is only able to comment on the implementation of the Directive for operators in England. They are talking to the authorities in other parts of the UK and will be aiming for a consistent delivery of the directive across the UK, but it is for the other UK jurisdictions to set final rules for their regions.

The Medium Combustion Plant Directive applies to all combustion plants rated above 1MW net thermal input (and less than 50MWth)

Scope of the proposed directive The directive applies to all combustion plants rated above 1MW net thermal input (and less than 50MWth). In broad terms, this applies to every steam boiler rated at around 1.25 tonnes per hour and above, and every diesel or gas fuelled engine rated around 450kVA and above. These are not large plants by industrial standards, so many users of combustion plants not currently affected by environmental legislation will have to comply with the new directive; there are at least an estimated 15,000 such plants in the UK. There is an upper limit of 50MWth from where

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CEA Yearbook 2016/2017

the relevant legislation is the Large Combustion Plant Directive; operators of multiple combustion plants each rated greater than 15MWth and totalling over 50MW on one site will have to comply with LCPD. The directive seeks to control the emissions of NOx, SOx, dust and CO to atmosphere. CO will be measured but will not yet have limits applied; the remaining pollutants will have Emission Limit Values (ELV) applied according to the type of fuel burned. All fuels are included in the ELVs. The main points of the directive are as follows: • New plant will need to be registered and comply with ELVs from late 2018 (transposition must be completed two years after the MCPD comes into force (presumed to be November 2015), and new plant must be registered and comply with ELVs one year after transposition).

•E xisting plant (not new plant) will need to comply with ELVs from 2025 if they are 5-50MWth and by 2030 if they are 1-5MWth. Deadline extensions for compliance with ELVs are only for specific sectors (biomass, district heating, plant driving gas compressors in the National Grid) and not beyond 2030.

Operators must register existing plant at least one year before the deadlines for compliance with ELVs. •O perators will need to monitor plant emissions to ensure compliance with applicable ELVs, and also monitor carbon monoxide. Monitoring is required every 3 years for 1-20MW plant and every year for 20-50MW plant. Emissions must be first monitored within four months of start of operation or registration.

• New plant discharging waste gases through a common stack, or which could, in the judgement of the competent authority, discharge waste gases through a common stack, will have their thermal input aggregated for the purpose of the Directive – with possible implications for applicable ELVs and monitoring frequency.

• All plants can be exempted from emission limit compliance if they operate up to 500 hours (as a five year rolling average for existing and as a three year rolling average for new); for existing plant, an extension to 1000h is proposed for connected offshore islands and heat production in exceptionally cold weather.

• Operating hours exclude start up and shut down and compliance with ELVs during these periods is not required. Start up and shut down have yet to be fully defined, especially for strategies such as banking boilers and no load running of turbines and engines.

• Member States will need to assess the case for applying stricter ELVs to plant located in zones not compliant with the Air Quality Directive. This will be informed by a report to be prepared by the Commission setting out the ELVs achievable using best available techniques and their costs.

• Certain types of plant are exempted, including those covered

by Chapters III and IV of the Industrial Emissions Directive, gas turbines and gas and diesel engines used on offshore platforms, combustion plants firing refinery fuels alone or with other fuels for the production of energy within mineral oil and gas

refineries, recovery boilers in installations for the production of pulp, and plants used for R&D. There are other exemptions, but the MCPD ELVs will apply to plant with emission controls under Chapter II of the Industrial Emissions Directive unless those emission controls are stricter than the MCPD ELVs. • Competent Authorities must hold, and make available to the public, a register with information about the combustion plant.

The actual ELVs are being finalised in the current legal drafting of the final proposal.

MCPD Timescale The main points of the proposed Directive were agreed by the 28 Member States (MS) of the EU during the summer of 2015 following a lengthy period of discussion in each MS and working through various committees of the EU. The official text is now being translated into all the EU languages, and legal definitions and corrections are being applied.

It is expected that the final text will be published in the Official Journal (OJ) of the EU in October or November 2015 and this will make the directive legally binding on MS from 20 days after publication. The expected timetable is therefore as follows: November 2015 Directive comes into force one month after publication in the OJ. November 2017 Transposition deadline. Member States (MS) to lay National legislation which provides appropriate penalties for non-compliance and notify Commission.

November 2017 New plant must be registered from this date or have a permit issued before being put into operation (New plant is plant put into operation later than one year after the date of transposition or for which a permit was granted after the date of transposition).

November 2018 New plant must comply with Emission Limit Values. First measurements must be made no later than 4 months after permit/registration.

1 Jan 2020 Commission will review progress in energy efficiency and assess the benefits of setting minimum energy efficiency standards in line with best available techniques.

1 Jan 2023 Commission to assess whether there is a need to regulate carbon monoxide emissions.

1 Jan 2024 Existing plant above 5MW must be registered (plant put into operation before the date of transposition or for which a permit was granted before date of transposition and put into operation no later than 1 year after transposition).

1 May 2024 First measurement of emissions for existing plant above 5MW must be made before this date.

1 Jan 2025 Existing plant above 5MW must comply with ELVS. October 2026 Member States to report to the Commission:

a) an estimate of total annual emissions of

pollutants from MCP grouped by plant type, fuel type and capacity class

b) quantitative and qualitative information on the implementation of the Directive, any action taken to verify compliance and details of any enforcement activities.

1 Jan 2029 Existing plant 5MW and below must be registered/permitted.

1 May 2029 First measurements of emissions for existing plant 5MW and below must be made before this date.

1 Jan 2030 Existing plant 5MW and below must comply with ELVs. October 2031 Second MS report on emissions and compliance.

1 Jan 2033 Commission to conduct a review and assess whether it is appropriate to set stricter ELVs in particular for new installations.

The timetable above is reasonably fixed, especially after 2020.

If an MCP Operator wants a plant to be classified as an existing plant it needs to be able to demonstrate that the plant was put into operation no later than one year after transposition, i.e. before November 2018.

Otherwise it is a new plant, and that means compliance from the date of first putting into operation.

The directive seeks to control the emissions of NOx, SOx, dust and CO to atmosphere

Operator obligations Operators will have to follow certain obligations under the MCPD. The Annexes to the directive set out specific details, but in summary, operators must: a) Operate plant only if registered or permitted (which requires submitting the data set out in Annex I to the competent authority at the relevant time)

CEA Yearbook 2016/2017

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Medium Combustion Plant Directive – update on progress (continued)

b) Submit a declaration of intention to operate less than 500h per annum (rolling average) if wishing make use of available exemption from ELV compliance, for plant operating limited hours c) Ensure plants comply with ELVs applicable by given dates and anniversaries (which may require upgrades to the plant or abatement techniques) d) For MCPs applying secondary abatement equipment, keep a record of information proving the effective continuous operation of that equipment e) Carry out emissions monitoring at set intervals and record results in such a way as to enable verification of compliance with ELVs according to rules set out in Annex IV f ) Take necessary measures to ensure non-compliance is rectified within shortest possible time - without prejudice to measures required under Art 7 g) Record information regarding operation of the plant (fuels used, operating hours, records of non-compliance and action taken to address it), retain for six years and make the information available to the competent authority when requested h) Report events of non-compliance where required by the competent authority; i) Report upgrades to plant which would affect applicable ELVs j) Assist representatives of the competent authority to carry out inspections to ensure compliance with the MCPD (data and sample collection and checks of records) k) Keep periods of start up or shut down as short as possible

Issues to be resolved Some of the issues that need to be resolved are as follows:

Competent Authority – views on who should be the CA: The Environment Agency in England and their devolved partners elsewhere in the UK have the expertise and systems to register and permit combustion installations. They would provide a consistent approach and be able to extend the scope of the work they already do in many combustion related fields. However, Local Authorities are currently responsible for managing and improving the air quality in their localities, and they already contribute to relevant planning applications and local transport related air quality issues. Some LAs have already introduced pollution control rules and targets that meet or exceed the proposals in the MCPD, and the directive gives MS the opportunity to impose stricter limits if appropriate. Defra have not yet decided how this will work, but a split responsibility seems likely, probably based on size of plant.

Definitions – is the list of definitions in the Directive comprehensive enough? Are other definitions needed in guidance or domestic legislation? Are there any definitions of concern?

Discussions around precise definitions of key terms are essential for a clear and unambiguous directive. Some definitions are stated and agreed, but there are still some that require development.

Further work is required, for example, on the definitions for ‘Start up and shut down’, when an existing plant that is modified or

changed becomes a new plant, who is responsible for emissions from temporary or hired plant, etc.

Exemptions – need to determine what is covered by the exemption for direct gas-fired heating; which plant using refinery fuels might be outside the scope of the exemption; whether guidance/conditions are needed to clarify what should be included in R&D definition.

As with similar directives, there are many exemptions that allow operators of certain types of combustion plant to be allowed to avoid certain parts of the directive without penalty. For direct gas fired heating (of spaces or products) the issue is that it is usually impossible to measure emissions. For R&D, the issue is whether this includes Factory acceptance tests, on-site commissioning tests, using test plant instead of ‘normal’ registered plant to provide a service, and whether testing includes testing different fuels as well as different techniques.

Aggregation – views on guidance needed (when to apply it and how to carry out emissions testing when applied) The Aggregation clause only applies to new plant. This means that all new plant >1MWth per unit on a site that does or could exhaust up the same stack is added together for the purposes of the directive. If this means 3 gas fired boilers then the aggregation is fairly meaningless as the NOx levels to be attained are the same (aggregated or not) and the only issue is whether the total plant installation is now >20MW in which case it has to be measured annually and not every three years. If, however, the aggregation covers different fuel types and different plant types (such as oil and biomass boilers and CHP engines all on one site), how are all the different ELVs to be measured, and if plants do exhaust up the same stack, how do you measure the contribution from each (presumably by turning all the others off, which may be impossible on a factory site)?

Registration/permitting – views on process for registration/ permitting? How will operators prove when plant commenced operation? Would it be a large additional burden for operators to report monitoring results? How will they record operating hours and report them to the Competent Authority?

Apart from finding all the 1MWth combustion plants that will be hidden away in sheds and under buildings, there will be some significant issues for the Competent Authority to resolve in the registration process. Registration implies filling in a form and sending it to someone; this will probably not be sufficient for the level of detail that is required for MCPD, so is permitting an option?

Permitting implies a scrutiny of the application and a considered response, possibly a site visit, and maybe technical meetings or submissions. Is this too much regulation for the environmental benefit? The process has to be proportionate to the risk and the potential for environmental harm, and must not be seen as a deterrent by SMEs who may face significant regulatory costs.

Continued on page 14

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CEA Yearbook 2016/2017

MCLENERGY Energy & Technical Services

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CEA Yearbook 2016/2017

13

Medium Combustion Plant Directive – update on progress (continued)

Non-compliances - What non-compliances should have to be reported to the Competent Authority? What is a good model to determine risk and frequency of compliance inspections?

of compliance and the service engineer can keep the burners correctly tuned all in the one visit.

Summary A wide ranging discussion is required to determine appropriate penalties for operators failing to meet the requirements of the directive. If an operator fails to register a plant, or fails to send in the annual monitoring results, or fails to meet the ELVs set for his plant, what should the response be? It will not be possible or practicable to tell a hospital that they must shut down their boilers because they are emitting too much NOx, so how will this be handled? And if the monitoring of the plant is only carried out once every three years, how will the operator know they are not performing to the required levels? A proportionate response related to the environmental harm caused by the non-compliance is required.

Monitoring - What are reasonable requirements for monitoring (technique, certification)?

It is important to set realistic monitoring and measurement strategies for the MCPD. Using a fully certified MCERTS approach would seem too onerous, but there must be confidence that the measurements are reliable, validated and taken using calibrated instruments, otherwise they are worthless and the process fails.

A proportionate response is required, hopefully using existing instruments, techniques and operatives as far as possible. If boiler and burner makers can be allowed to continue and expand on their current regimes of servicing and adjusting burners, probably on an annual basis, then MCP Operators will have the confidence

The MCPD will require operators to run plant only if registered or permitted

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CEA Yearbook 2016/2017

CEA has been in regular contact with Defra regarding the details of implementation for this directive. Defra is now looking to engage with stakeholders very closely over the coming months, realising that many of the affected installations are operated by organisations who have no knowledge of environmental permitting and the rigorous processes related to permitting combustion installations and measuring emissions.

CEA members and other interested parties are strongly encouraged to look out for events such as workshops and conferences that will be organised for operators and other stakeholders. Defra recognise that this will not be a simple directive to transpose, and they will be seeking stakeholder involvement at every opportunity.

Eventually it is envisaged that there will be statutory public consultation and a parliamentary debate, so there is much to do over the implementation period.

This is your opportunity to influence that way a significant part of our industry will be regulated over the coming years. It is not far off – a new combustion plant will have to comply with all the new requirements from November 2018, and if an operator wants to order and install a plant before the MCPD deadline and register it as an existing plant they have even less time.

There are opportunities for all CEA members here – get involved and make the most of them!

Rigorous processes related to permitting combustion installations and measuring emissions will be applied

What you need to know about emissions When we refer to emissions, we are referring to the passing of matter (gases, particulates) or energy (radiation, heat, noise) into the environment. This is something which has to be minimised or eliminated altogether. Weishaupt explains how to reduce emissions

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eishaupt develops efficient technologies that conserve resources in order to ensure that the environment is always protected as much as possible. For example, the company’s multiflam® technology (up to 23 MW) has enabled its burners to be used in countries with the most stringent of emission limits.

Defra is only able to comment on the implementation of the Directive for operators in England. They are talking to the authorities in other parts of the UK and will be aiming for a consistent delivery of the directive across the UK, but it is for the other UK jurisdictions to set final rules for their regions.

Carbon monoxide and soot There are different factors that influence the formation of carbon monoxide and soot.

− Carbon monoxide is a combustible component that is not being utilised

The best known of these factors is sub-stoichiometric combustion, where there is insufficient air present for complete combustion and the flame is starved of oxygen. Pure hydrogen, hydrogen from the CH compounds, and sulphur in the fuel, have a higher affinity than carbon, and are oxidised to form water vapour and sulphur oxides. Due to the lack of oxygen, the carbon from the CH compounds cannot completely oxidise. This leads to the formation of carbon monoxide (carbon that has not been completely combusted) and soot.

Nitrogen oxide

A second influencing factor is non-homogeneous mixing. Under these conditions, despite combustion taking place with excess air, there are low-oxygen zones within the flame. Once again, this leads to the formation of CO and soot.

The size of the combustion chamber is also an important factor.

If it is too small then there is flame impingement, which prevents complete combustion from taking place and if it is too large then the flame undergoes too much cooling, which also leads to CO and soot formation.

CO and soot in the flue gases present serious disadvantages: • Contamination of the environment with carbon monoxide (colourless, odourless, poisonous gas) • Risk of explosion due to uncontrolled through-ignitions • Poor energy yields: − Soot is an excellent heat insulator (a 1-mm layer of soot can reduce efficiency by about 4 %)

NOx is a collective term for nitrogen monoxide, NO, and nitrogen dioxide, NO2.

Oxides of nitrogen are a product of combustion. The chemical reaction takes place at high temperatures, which lead to the formation of numerous other compounds in addition to NO. Nitrogen monoxide (NO) is an unstable compound. It reacts in the atmosphere to form nitrogen dioxide.

During combustion, depending on the type of burner, 90–97 % of NOx will be in the form of NO and 3–10 % in the form of NO2.

NO is a colourless, poisonous, and extremely reactive gas. It reacts with free oxygen to form the equally harmful NO2. Oxides of nitrogen, along with oxides of sulphur, are responsible for “acid rain”, as they contribute to the formation of the extremely aggressive nitric acid, HNO3.

A further pollutant that should not be overlooked is ozone. It is formed near ground level under the influence of UV radiation.

NO2 separates into NO and O. The free oxygen atom combines with a molecule of oxygen, thereby forming ozone (O + O2 = O3), which is harmful both to people and the environment.

Methods of thermal NOx reduction Latest developments in the design of burner mixing assemblies can effectively contribute to the reduction in the formation of thermal NOx within the combustion process.

CEA Yearbook 2016/2017

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Design options include: Fuel distribution with NR burners - Reduced flame root temperature Gas distribution and swirling with swirlflame VSF/3SF burners - A high rotational speed allows the flame geometry to be controlled Recirculation with LN burners - Reduced dwell time Fuel distribution and recirculation with multiflam® 3LN burners Reduction of the flame root temperature creates a “cooler” flame and thus a greater reduction in NOx emissions.

• A special fuel distribution design creates a primary and secondary flame • The primary flame ensures flame stability and the creation of the secondary flame

Latest designs of burner mixing assemblies can effectively reduce the formation of thermal NOx within the combustion process

Sound emission: The sound energy that continually radiates from an acoustic source is referred to as a sound emission. The term sound power refers to the rate at which sound energy is transmitted per unit time.

Sound power level: Sound power, measured in accordance with EN ISO 9614-2, is a theoretical quantity that cannot be measured directly. It is derived from a measurement of intensity on an envelope (designated volume around the burner). The result can be expressed in two different units, as the sound power, which is measured in watts, or as a sound power level (LWA), which is measured in decibels. Sound power is independent of spatial and distance considerations. The sound power of an acoustic source causes sound pressure variations in the air, whereas the sound pressure of an acoustic source is the resultant, distancedependent effect.

Sound pressure level: The reference point for airborne sound was defined at the beginning of the 20th century to be p0 = 20 µPa. This sound pressure was considered to be the threshold level of human hearing at a frequency of 1 kHz. It is measured at a distance of 1 metre from the acoustic source (burner). Project specifications and local regulations mostly stipulate sound pressure levels.

Sound level reduction on WM series burners External measures Mixing flue gases with the regular combustion air reduces the oxygen concentration and thus also the oxygen supply in the hot reaction zone. It also increases the flow speed, thereby reducing dwell time in the reaction zone for the nitrogen and oxygen. This system, which is designed for use with gaseous fuels, enables extremely low NOx emissions to be achieved.

The FGR/CO version of the Weishaupt W-FM 200 combustion manager that is used with this system has special software, which ensures reliable cold-start behaviour and a high degree of operational reliability.

Sound power level and sound pressure level

Sound power level, LWA, and sound pressure level, LpA are two different quantities that are both measured in decibels (dB(A)).

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CEA Yearbook 2016/2017

Sound-attenuated air inlet: The burner’s aerodynamic air housing with its sound-attenuated inlet ensures that the burner has a very low sound pressure level as standard. Compared to older burner models, the air inlet silencer reduces the noise level by approximately 25%, given the same operating conditions and burner rating.

Variable speed drive: The sound pressure level of the burner at intermediate and partial load can be considerably reduced if its motor is equipped for variable speed drive (VSD). Taking the WM-G20/3-A gas burner as an example, at 20 % load the burner’s sound pressure level is reduced by approximately 14 dB(A).

Sound absorber shroud: Should extremely low sound emissions be specified, they can be achieved using optionally available sound absorber shrouds. Weishaupt offers two different versions for WM-series burners. The W-SH15 shroud reduces burner sound emissions by 10–15 dB(A), while the W-SH20 shroud reduces burner sound emissions by 20–25 dB(A).

Continued development of the CEA website Phase 2 development of the CEA website is well underway, aiming to offer a new level of expertise to the sector

credibility on the site. The CEA will act as the go between, policing fair use and ensuring that experts are not bombarded with requests and that those looking for support get what they need.

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The Academy of Experts marks a step-change in the way that the CEA supports its members and offers value for the membership.

During the initial re-branding of the CEA the video produced featured a line which suggested that the organisation aspired to be more than just sending out a quarterly newsletters and having an annual conference like many other not-for-profit entities. The Academy of Experts initiative proves the innovative approach to support that the CEA is looking to offer its members and the sector as a whole.

The initial phase was to deliver a modern and functional website that allowed the organisation to engage existing and potential members in the online world. Looking at what the purpose of the CEA was and revisiting those founding principles, the project was designed to make the association the ‘go-to’ place for anything to do with industry information, knowledge, training and safety, becoming the aggregator of information for members to have rapid and easy access to the things that they needed to know.

The CEA Academy of Experts is launched in January 2016 and will be promoted amongst the members via a number of methods when live. Should any of our members wish to become ‘Founder Experts’ please contact Dave or Julie at info@cea.org.uk

hree years ago the CEA undertook a substantial re-branding of the organisation under the guidance of the new Director, David Kilpatrick but with tremendous input from the council and the marketing working group led by Sam Thiara and supported by Jovan Maric of Square Daisy. This re-branding exercise was not only a revision of the logo to bring it more up to date and the launch of a new website, it was about changing the very fabric of the CEA to make it so much more for its members.

High visitor numbers To ensure that the content that featured on the website was up to date and of the highest integrity, the membership were instrumental in delivering a constant flow of information to a central administrative function that pushed it out for all to see.

Positioning the CEA in this way and approaching a strategy of being the nerve centre for everything combustion related has generated visitor numbers to the site in the high thousands, which has in turn benefitted many individuals and businesses in the sector.

There is an appetite to build on this and in mid-2015 planning started on a phase two element of the website which will propel the CEA into a new category of support agency. The Academy of Experts is due to go live in early 2016 and will be a knowledge centre on highly specific topics, delivered by ‘experts’ who are signed up by the CEA to support the initiative, generating a new level of information to the sector.

The initiative is designed to get those with advanced knowledge in different areas of combustion engineering to put themselves forward as a resource for others in the industry, needing support to be contacted about working as an expert for the organisation that requires the assistance. The expert will offer a small amount of time at no cost and should additional support be required, this can be delivered on a paid for basis agreed between the two parties.

A step-change in support To feature as an expert and showcase their credentials as such, each expert will be required to submit a series of articles over the year that pertain to their area of specialism, allowing them to gain

CEA Yearbook 2016/2017

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TEXTILE DRYING

STEAM GENERATION INCINERATORS & WASTE

HEATING AND HOT WATER

PLANT MODERNISATION

FOOD PRODUCTION

WOOD DRYING ENGINEERING

ASPHALT & BUILDING

CHEMICAL PLANTS

WASTE OIL

AGRICULTURE

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CEA Yearbook 2016/2017

www.ecoflam.co.uk

Burners Division of Ariston Thermo Group

A new chapter in energy efficiency Mark Bingley, Operations Manager for the UK and Ireland for Ecoflam, looks at changes in legislation and what the future holds for the burner industry.

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s part of the European Union’s commitment to reduce carbon emissions, the introduction of the Energy-Related Products (ErP) Directive in September 2015 has ensured all energy consuming products now have to adhere to a new set of minimum requirements – sending the heating and energy sector into a new era.

Essentially, the Directive consists of two areas – Energy Labelling and, more significantly for the burner sector, Eco-Design (2009/125/CE). Both directives are frameworks defining the rules for setting product-specific requirements and legislation. It is the combined effect of both measures which ensures a dynamic improvement of the market.

Eco-Design sets the minimum energy performance and environmental criteria for energy-related products sold in the European Economic Area. One of the biggest impacts of the new legislation has been on fossil fuel (gas and oil) boilers and water heaters (including heat pumps) with outputs up to 400kW. Heavy industrial projects with outputs over 400kW won’t fall under the ErP requirements, but will be affected by other initiatives such as the Medium Combustion Plant (MCP) Directive, currently scheduled for 2020.

Plant upgrades are likely The Eco-Design Directive has prescribed significant improvements in boiler efficiency, so it effectively rules out non-condensing models. So, for any replacements required in the next few years, it is highly likely that an upgrade of plant will be required.

Furthermore, EU member states will review the legislation in 2017, which will shape Eco-Design requirements in the future.

years? Well, regardless of the fuel type, ensuring complete combustion is essential, which requires an adequate supply of oxygen and the provision for this should be confirmed on every inspection, with any restrictions or debris removed from the plant room. In addition, the flue should be checked to ensure it is adequately supported and evacuating gases effectively. Further checks include correcting the operating pressures and gas rate/ heat input of the burner, as well as the overall safe function of the plant.

A long-term approach A long term approach to maintenance will ensure the burner/ boiler continues to run efficiently, plus minimise environmental impact and running costs. This will become more of an issue in years to come for any burner related systems, especially as the cost of energy inevitably increases and running costs are put under the spotlight.

Unfortunately, regardless of how effective a service and maintenance programme is, components will eventually reach the end of their lifecycle. At this point, it is important to evaluate whether a like for like replacement is possible, which depending on the age of the unit, might not be achievable due to legislative changes – such as the recent ErP Directive. At this stage, it’s important to consider manufacturers, such as Ecoflam UK, which has a broad range of products for all applications, and can offer the highest efficiencies along with market leading emissions levels.

The next few years are sure to create some challenges for the sector, with further rounds of legislation in the form of reduced NOx emissions and stricter targets for larger sized heating equipment. With this in mind, choosing products from manufacturers that are continually developing their product ranges will help beat efficiency targets for years to come.

Of course, many systems and products in use today are already specified to a high standard and will not need replacing in the immediate future. However, it then becomes more important than ever for such systems to be maintained regularly and ensure they perform efficiently for their entire lifetime. This approach to servicing is vitally important in commercial buildings, where continuity of supply is essential and any fault could have a substantial impact on productivity and finances.

To reduce faults or breakdowns, building managers need to ensure that servicing schedules are thorough and regular. This approach is perfect for spotting the early signs of any problems developing, while reducing the potential cost and added inconvenience of a breakdown.

So, as far as burners are concerned, what elements need to be incorporated into a regular maintenance plan over the forthcoming

Running a regular maintenance plan will help building managers to spot the early signs of problems arising and help avoid costly breakdowns

CEA Yearbook 2016/2017

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DAV ID GU N N M E MO RIAL LEC TU RE AN D LOR D EZR A AWA R DS

Prestigious awards and fascinating lectures mark key CEA events On the 22nd October 2015, The CEA held its most prestigious annual event at the House of Lords in London – the David Gunn Memorial Lecture and the Lord Ezra Awards at the House of Lords in London, hosted by Lord Chidgey.

In this special feature we report on who won what and give an insight into a personal story behind the building of the Queen Mary 2. We also look back to 2014’s event.

Byworth wins award for Unity project The Lord Derek Ezra Award 2015 for achievement in areas of higher efficiency, safety and lower emissions in industrial combustion was won by Byworth Boilers for its Unity control system.

The award recognises Byworth’s contribution to enhancing safety and efficiency in the boiler house. Despite its high-tech nature, Unity strikes a chord with the humble roots and entrepreneurial spirit of Byworth founder, Dennis Baldwin.

Much of Dennis’ working life was as a user of steam, rather than a steam engineer. He became frustrated with the limited functionality and features of the boilers on the market at the time and after failing to find a single boiler that met his requirements he decided to create his own.

Unity was touted as an idea in 2007 to existing controls manufacturers; but after years of getting nowhere trying to persuade them to take on the development, Byworth felt so strongly that the industry was missing the key technological advancement, it appointed one of its own staff to develop the idea into the finished product. Unity was born after a two-year development project.

Pete Waterman OBE (second from left), the Association’s President presented the award to Byworth which was accepted by the system’s creator, Jason Atkinson, Control Systems Engineer (left) and Technical Director, Adrian Rhodes (second from right). Derry Carr, Chairman of the CEA announced the winner

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CEA Yearbook 2016/2017

Dennis Baldwin, Founder of Byworth Boilers. Dennis used steam in his process to grow Chrysanthemums

Armstrong International receives new commendation A new award for 2015 is the highly Commended award, which Derry Carr announced as being Armstrong International, who had submitted an “excellent entry” that was “a master class in improving efficiency of steam and condensate systems”.

Pete Waterman OBE, the Association’s President, presented the award to Armstrong International. From left to right: Ian Sutherland UK Operations Director, Pete Waterman OBE, Sean Martin UK Marketing Manager and Derry Carr, Chairman of the CEA

Lowest emissions, highest efficiency – combustion technologies made by SAACKE SSB burner From flexible standard models to customised systems, we plan, develop and manufacture combustion technologies for thermal processes – for the industrial sector as well as for ship and offshore installations.

Whether the integration of burners and boilers, retrofit applications and additional management tools, or a turnkey solution – our services and products are always focussed on our four core competencies: SAFETY, ENERGY, EFFICIENCY and EMISSIONS.

Gasification of household waste In Lahti (Finland), for example, we won over general contractor Metso Power with our highly efficient combustion technology. Now the first large-scale pilot project for household waste gasification with combined heat and power generation is located there. The SAACKE SSB burner ensures stable combustion at the lowest possible calorific values and high volume flows.

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Calorific value of natural gas and gasification gas

CO < 50 NOX< 300

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Gasification gas emission values in mg/Nm3

Natural gas emission values in mg/Nm3

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DAV ID GU N N M E MO RIAL LEC TU RE AN D LOR D EZR A AWA R DS

Building the Queen Mary 2: David Gunn Memorial lecture 2015 The David Gunn Memorial lecture 2015 was delivered by Dr Stephen Payne OBE, the chief naval architect of the Queen Mary 2 (QM2) - Cunard’s flagship ocean liner, which entered service in 2004. This fascinating presentation reflected on the challenges of becoming a naval architect and the inspiration given by a school teacher.

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ne of the UK’s most prominent engineering figures, Dr Stephen Payne OBE, delivered a highly memorable lecture peppered with entertaining anecdotes reflecting on the challenges in becoming a naval architect and his single-minded determination to achieve a boyhood dream – to build a liner that would be reminiscent of the Queen Elizabeth 2.

Stephen was presented with the David Gunn Memorial Medal and a plaque in the colours of the Queen Mary 2, commemorating his presentation by sponsor in the House, Lord David Chidgey. Lord O’Neill also attended as did Lord Renwick and Lord Howie, long term supporters of the CEA. Closing the day at the 2015 event, Pete Waterman, President of the CEA gave an impromptu speech about skills in the UK and the quality of its Engineers, complementing the winners of the awards, especially Dr Payne on his achievement and determination in achieving his lifelong ambition to build the magnificent QM2 Ocean Liner, taking only two years to construct her 150,000 ton majesty.

Particularly inspiring was his memories of a supportive physics teacher Justin Johnson. Johnson persuaded Stephen to ‘follow his dreams’ which led him down his successful path. They stayed in touch throughout Stephen’s career, although unfortunately Johnson passed away just before the QM2 first set sail.

A touching end to the story came when Dr Payne explained there was a plaque dedicated to his teacher hidden on the QM2 and he hopes one day it will be found and the inspirational story will be exposed.

Atlantic storms? No problem!

The QM2 has made more than 250 Atlantic crossings since her maiden voyage in 2004 to Fort Lauderdale in Florida.

Dr Payne said: “During a westbound crossing from Southampton to New York in August 2008, the ship encountered an Atlantic storm that had a 600 mile front. With force 12 seas and with winds over 120 knots, Queen Mary 2 continued on her way to New York at 24 knots with little discomfort on board. Other ships were heaved to on the Atlantic that day and the bridge officers said they had been called by some of the ships asking how they were able to maintain such speed in the prevailing conditions”. The Queen Mary 2’s reply “because we can!”.

The design and project management of Cunard Line’s flagship Queen Mary 2 was a huge achievement for Dr Payne. Evaluating market trends and the business model led to an epoch breaking design that has proven to be eminently successful in service.

Dr Payne managed the project throughout, leading contract and specification negotiations with the shipyard in the pre-contract phase, monitoring construction and finally accepting delivery of the ship on behalf of Cunard upon her completion. In recognition of the success of the project he was awarded the title Officer of the Order of the British Empire (OBE) by Her Majesty the Queen and was awarded a Special Achievement Award by the Royal Academy of Engineering.

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CEA Yearbook 2016/2017

Stephen Payne commands the attention of the audience with his entertaining lecture

Life as a naval architect: Dr Stephen Payne OBE Royal Designer of Industry Stephen Michael Payne was engaged with Carnival Corporation for over 26 years culminating with the position of Vice President Chief Naval Architect. Dr Payne was instrumental in the design and construction of more than 40 passenger ships between January 1985 and December 2010.

Between July 2007 and July 2010 he was the President of the Royal Institution of Naval Architects and in July 2008 he was elected a Fellow of the Royal Academy of Engineering. In 2010 he was appointed one of the eight trustees of the City of Southampton Cultural Trust.

Stephen graduated from the University of Southampton in 1984 with an Honours Degree in Ship Science. During his time at Southampton Dr Payne was a member of the University Royal Naval Unit (URNU), part of the RNR. He is a Governor of Quilley School of Engineering (Eastleigh) and is a founding member of “Future Engineers”, an ongoing programme to promote awareness of careers in engineering to youth. In July 2010 he was awarded the title of “Amazing Person 2010” by Solent Education Business Partnership for his work in promoting engineering careers to young people.

DAVID G UNN MEMOR IA L LECTUR E A ND LOR D EZR A AWA R D S

Combustion and the sugar industry: David Gunn Memorial lecture, October 2014 David Gent and Jamie Lam gave a fascinating presentation covering all the various aspects of combustion in the sugar industry.

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avid is the Engineering Manager at AB Sugar and a long standing member of the CEA, he has only recently stood down after his two year term as Chairman, some of which he had to do from overseas as his job took him to sugar factories in Africa and China. In the audience were Carolyn, David’s wife and also David’s mother Maureen both proudly listening to his presentation.

After the David Gunn Lecture several of the guests commented on just how surprised they are to see the diversity of products that are produced from sugar beet in the UK, and how large the volumes are. The tomatoes alone use 115 million litres of water annually harvested over an area the equivalent of 18 football pitches. 8500 bumble bees pollinate the tomato plants at this one site alone.

Under David’s watchful eye and careful guidance and with the consensus of the CEA’s Executive and Council he has moved the CEA forward at a tremendous pace. He has worked with the Director to help re-shape who and what CEA are, and what else we can offer the existing members of the Association for added value. He also has an eye on the wider engineering world for those who may wish to join the Association, and he never misses an opportunity to tell people about CEA. Alongside David for this presentation was Jamie Lam, a placement student from Loughborough University benefitting from David’s steady guidance. This is the fourth student David has supported in the last four years giving them unique exposure to the CEA and engaging the students in CEA activities, from executive level meetings through to helping at conferences. Two of these students won the Bill Kaye Young Researcher prize in 2012 and 2013.

David and Jamie’s presentation to 90 guests which included CEA’s new Honorary Vice President Lord O’Neill was very well received, they told us of all the products that come from the process of making sugar whether it is from sugar cane or sugar beet.

There are many by products from 1.3 million tons of sugar production such as Top Soil, Stones from the beet washing, Animal Feed, Lime, Sugar Products, Betaine, Bioethanol, Rafinate, Vinasse, liquid CO2, Tomatoes and Electricity.

Lord O’Neill presented David with the David Gunn Memorial Medal and certificate commenting on the excellent presentation by both David and Jamie and commemorating today’s event, Jamie was also awarded with an engraved glass flame and a CEA certificate

CEA Yearbook 2016/2017

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DAV ID GU N N M E MO RIAL LEC TU RE AN D LOR D EZR A AWA R DS

Highlights from October 2014 Three long standing members of the Association, Professor Bill Kaye, Barrie Church and Paul Whitehead, were awarded honorary life membership.

Lord O’Neill and Chairman Derry Carr present the Malcolm Dunphy award certificate to the 2000th BOAS candidate Lee Hopkin from Bentley Motors. Left to right are: Stuart Walker and Lee Hopkin of Bentley Motors, Chairman Derry Carr, Lord O’Neill and Sharon Kuligowski, MD of Dunphy Combustion

Prof Bill Kaye – Kaye and Associates Limited Bill had also been honoured earlier in the year at the AGM with a lifetime achievement award for his long standing support of the CEA

Diageo Roseisle Distillery with Veolia won the Lord Ezra award for their submission

Barrie Church – Global Energy

Ben Ievins won the Bill Kaye Young Research Engineer prize

Paul Whitehead – Energy and Environmental Solutions

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CEA Yearbook 2016/2017

TR A IN I N G

Engineering Your Future The Academy of experts is a CEA initiative to help showcase talent within the combustion industry and through the ‘Engineering Your Future Blueprint’ offers a step by step ‘Personal Brand Accelerator’ programme to help engineers become recognised as experts, promote their technical authority and begin to take their position as industry leaders. Sam Thiara explains more.

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eing a professional in the Science, Technology, Engineering and Manufacturing (STEM) sector means you hold a significant position in the economy. Without engineers and talented engineers, for that matter, some of the most important advances in history would never have transpired. We should congratulate and recognise engineers as Industry’s ‘rock stars’ and here begins the theme for this blog.

To hold the pedal to the floor and accelerate our careers and businesses we keep educating and learning how best to serve our customers by creating breakthroughs in technologies, solutions and services and with that burgeoning talent begins a drive your build credibility, reputation and as a result opening up a world of opportunity. Your journey to becoming a technical authority and your rightful position as an expert has begun.

As industry increasingly looks towards experts to help them solve complex problems many are turning to the Internet for help.

The decision-making process now includes Google who helps to identify not only the company but increasingly the expert in that company to help them.

be loyal to their discipline and by staying true to their craft or ‘calling’ they embody some of the qualities we all know engineers possess as trusted advisors.

So how do you determine a great engineer from a good engineer?

You’re online personal brand is increasingly being taught to career professionals, subject matter experts, business owners and entrepreneurs at schools, colleges, universities and within organisations.

Are you Google friendly?

A ‘troubled’ customer will often seek advice from their trusted inner circle, but will establish for themselves the credentials required to help them eliminate risk when it comes to engaging the right technical specialist. So where do they go?

Their journey starts online When you next have the chance to look back through your career and ponder over how you have grown and evolved into the person you are today recognise what changes have gone on around you, especially with the online world, easy to use apps, social media and the list goes on. Make the internet your friend and use the available platforms to make yourself Google friendly.

We see this with platforms like Linkedin.com, a community of professionals but ask yourself a question ‘Do I really use the power of this platform to position myself in my niche and be recognised as the go to person in my industry?

Engineers, in whatever field or industry they come from tend to

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CEA Yearbook 2016/2017

Herein then lies a challenge With a natural tendency to be slightly introverted and conservative in nature, although this may not be true for every engineer, means you move around the company and industry without too much pomp and circumstance. Longevity in one’s career is built on capability and expertise and although that expertise is of high value to both your employer and your customers, it remains known to relatively few people, often only to those in your inner circle.

The world is changing much faster now than at any other time.

From the earliest days of the industrial revolution to the present time; geography kept many people apart, travel was much slower, more costly and limited to those who could afford it, economic migration was mild compared to today’s environment, business models were pretty much defined but that all changed significantly. Recent times have shown that irrespective of one’s expertise and standing a volatile economy can lead to drastic cuts

TR A I N I N G

or changes in a workforce and often with little or no notice as companies look to become leaner to survive and prosper.

In all that mix engineers keep doing what they keep doing and providing their expertise to the task at hand. This focused approach often means that they miss opportunities to help themselves and improve their circumstances.

Online search is not going away so being ‘positioned’ to be found online, be able to demonstrate your unique talents, skills and expertise is becoming a mainstay of personal, career and business development. For many engineers, doing anything more is a distraction and even more so if the ‘thing’ you need to do is often a world away from your core expertise, capabilities or desires and personal or ‘self’ promotion is as far away from most engineers’ comfort zones as you can get.

Traditional barriers have come down, opportunities have opened up to the masses, we are all connected 24/7 and in this often turbulent, exciting and invigorating environment you cannot leave anything to chance, when competition once so far away is now on your doorstep.

In respect to career development and longevity, promoting your expertise to those outside of your inner circle requires ‘marketing’. Engineers are generally not predisposed to this as it generally works against their natural inclination to ‘shout from the rooftops’ about their successes. The subtle art of soft marketing can overcome this and a strategy that can help engineers to communicate their projects, ideas, IP and capabilities and skills to help them raise their visibility. You can see this happening in all industries but only a small fraction of engineers take the opportunity to consider how to proactively market their personal

profile or ‘brand’ as it is increasingly being referred to.

Personal branding is often a term reserved for celebrities and high profile business people but it is equally applicable in our industry, even more so now considering the flux in the economy and the need to be at the front of any queue when it comes to seeking new opportunities for career progression or to gain new customers.

Although widely discussed in terms of career development personal branding is not mainstream in the STEM sector and much of this has to do with the engineer’s psychology in taking this initiative, its real value to them and the impression it gives of branding being self-serving. Nothing could be further from reality and I come across examples of this every day. Just go visit Amazon or your industry bookstore to see how many engineers and consultants are marketing themselves. I would go even further to say look at the journals, white papers, blogs, books, video etc. that you read, listen to and watch every day and you will see that engineers in your field are already branding themselves.

For all those engineers out there, take the opportunity to help yourself to become an authority in your chosen field and share your expertise ‘online’ amongst your colleagues, customers and industry so that you and your organisation can benefit from the tremendous opportunity that can buffer a change in a constantly changing world.

Career professionals and subject matter experts are beginning to see the potential of personal branding to keep ahead of the game and offer them a differentiator as they move their careers and businesses to another level.

Find out more at www.engineeringyourfutureblueprint.com

A long and successful career in industry will increasingly demand engineers to create and promote their personal brand of skills and capabilities

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T R A IN I N G

The I-GAS initiative is helping improve industrial gas safety CEA Chairman, Derry Carr introduces the CEA’s Industrial Gas Accreditation Scheme (I-GAS) that focus on improving gas safety in industry.

T

he CEA is actively driving a new gas qualification to encompass gas in the industrial environment. Many people will ask why we should want to do such a thing when there is already a qualification that ‘should’ be more than adequate to prove the competence of personnel working in the gas sector, namely ‘Gas Safe Registration’.

Gas Safe Registration is a formal and excellent qualification that has over many years, along with its predecessor Corgi Registration, ensured that personnel working on gas are competent to do so. The backbone of this qualification is the Gas Safety (Installation and Use) Regulations 1998 (GSIUR). Gas Safe Registration is predominately aimed at the domestic and small commercial sectors, and quite rightly so. There are millions of gas appliances in homes and offices across the country and ensuring the general public’s safety is paramount. However, when it comes to the industrial sectors things get a little confusing. For a start they are not covered by the GSIUR as can be seen from the extract below.

(4) Save for regulations 37, 38 and 41 and subject to regulation 3(8), these Regulations shall not apply in relation to the supply of gas to, or anything done in respect of a gas fitting at, the following premises, that is to say—

Industrial-sized gas systems need appropriately qualified engineers

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CEA Yearbook 2016/2017

a. factory within the meaning of the Factories Act 1961(4) or any place to which any provisions of the said Act apply by virtue of sections 123 to 126 of that Act;

Working on big gas plant Although the Industrial sector accepts the quality of the GSIUR and follows it as much as it can, there are many areas where it is not fit for the industrial environment. The CEA recognised this grey area and decided to take steps to improve gas safety in industry. Bringing together some of the top industrial gas specialists in the country and with the support of the Institute of Gas Engineers and Managers, the Industrial Gas Accreditation Scheme (I-GAS) was born. It encompasses such things as large diameter pipework, high gas pressures and some of the less common gases such as biogas and furnace gas.

The main difference however is the size of the equipment, the average domestic boiler is less than 20kW and 15mm pipe diameter, whereas the average industrial boiler is 10MW and anything from 150mm diameter upwards with many installations having a thermal input way in excess of 50MW. There is plenty of anecdotal evidence of personnel working on these large systems that have only previously worked on domestic/commercial systems and even worse, where they have had no formal gas training at all.

The bottom line is, if you are going to allow personnel to work on your gas system, make sure they are competent to do so.

A Gas Safe Registered plumber is not competent to work on a 25 bar g gas turbine gas train, just as an I-GAS accredited technician is not competent to work on your boiler at home, they are very different.

Bringing training to life.

Hands on learning at Spirax Sarcoâ&#x20AC;&#x2122;s UK Steam Technology Centre

Take advantage of our extensive training facilities in Cheltenham, with a fully working boiler house, demonstration and practical areas.

Book on one of our many training courses today â&#x20AC;&#x201C; including BOAS, BOAS Renewal, Steam Boiler Plant Fundamentals and Steam Plant Maintenance (City & Guilds Module 13).

For course information and dates: www.spiraxsarco.com/global/uk/Training/Pages/home.aspx

Why not take a tour around our training centre? bit.ly/UKSTCVIDEO

01242 535211 training@uk.spiraxsarco.com

@Spirax_Sarco_UK

SpiraxSarcoUK

spiraxsarcouk.blogspot.co.uk

T R A IN I N G

It pays to put the right skills in place Outsourcing training is a key way for companies to tackle the skills gap.

Spirax Sarco is helping a wide range of companies to reap the rewards of steam and condensate system training.

T

he advantages of outsourcing training to an expert supplier are long-proven. Specialised facilities, professionally structured courses and highly-qualified instructors help to ensure that trainees get in-depth tuition that is delivered uniformly every time. Such consistency is something that steam-using organisations can find hard to achieve with their own internal training, especially when providing students with practical fault-finding experience, which is often not possible in a production environment.

Spirax Sarco is a leading provider of training in this field. The company’s UK Steam Technology Centre in Cheltenham delivers over 90 courses and has trained more than 1,000 delegates in the past year. Many of these courses are supported by practical training facilities in the shape of specialised rigs, a fully functioning boiler and demonstration areas. In addition, the company also provides correspondence courses and on-site training to support specific training needs.

In fact a recent survey1 found that more than 77% of its customers only use Spirax Sarco for steam training.

Courses to suit all needs Spirax Sarco’s courses fall into four categories: • New to Steam – for those needing an underpinning knowledge and introduction to steam and boilers • Boiler House – covering all aspects of boiler house, safety and efficiency

• Maintenance – comprehensive training to cut costs and improve steam system efficiency • Specialist – specialist courses aimed at improving efficiency and cost savings The courses range from an introductory level to the more advanced. Working alongside the CEA, City & Guilds and CIBSE to provide accredited courses, Spirax Sarco has developed a structured boiler training path to highlight progression routes through the courses available, including BOAS (Boiler Operation Accreditation Scheme).

Long-term commitment to training Spirax Sarco has invested substantially in its training services for many years, with the UK Steam Technology Centre spearheading its capabilities and commitment. As the leading manufacturer and supplier of thermal energy and steam system control solutions, why does the company place such a sharp focus on this aspect of its business?

“Our commitment does not end with the delivery of equipment and solutions,” explains Sally O’Connell, UK Steam Technology Centre Manager at Spirax Sarco. “The advanced technology used in today’s steam systems requires skilled engineers to operate and maintain, to ensure it delivers maximum performance and value. Training is an integral part of how we help our customers to improve their business performance.”

That’s a sentiment echoed by the CBI in a recent report2 that stated: “Raising employees’ skill levels represents a win–win for businesses and their workforces. Firms perform better, while individuals can benefit from higher pay as their productivity increases.”

So if you’re asking whether your company can afford to invest in training, you’re asking the wrong question. The real question is whether you can afford not to.

Skill shortages impact business • According to the Institution of Engineering and Technology (IET), the ‘skills gap’ has worsened for the ninth year in a row.

• The 2015 CBI education and skills survey3, reveals that 52% of businesses see a shortfall in experienced staff, with STEM (Science, Technology, Engineering and Mathematics) skills particularly lacking.

• In a recent survey of British firms that employ engineers and IT staff by the IET, more than half reported they could not find the employees they were looking for and 59% said the shortage would be “a threat to their business in the UK”.

Survey of more than 500 customers, April 2015 http://news.cbi.org.uk/news/skills-shortages-fuel-productivity-problem/ 3) http://news.cbi.org.uk/reports/education-and-skills-survey-2015/ 1)

2)

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CEA Yearbook 2016/2017

BOILER OPERATOR TRAINING COURSES

“The practical boiler-house work was excellent.”

- Richard Warren, Cofely

FOR THOSE NEW TO STEAM ■ Steam Awareness ■ Boiler Operation Fundamentals FOR EXPERIENCED ENGINEERS ■ Design of Steam and Condensate Systems ■ Boiler Operation Accreditation Scheme (BOAS) FOR PLANT & PROCESS MANAGERS ■ BOAS Boiler Manager Course ■ A Risk Based Approach to Steam Design

www.byworth.co.uk

01535 665225

The Harris Pye Group is a global leader in the offshore oil and gas, industrial and marine industries. With a worldwide operation on a 24/7 basis, we offer services in maintenance, retrofit, conversion work and cost effective repair.

Excellent track record of turnkey gas conversions in the marine and land industry.

• Low Emission Oil / Gas Burners • Auxiliary Low Emission Systems FGR/OFA/Steam Injection Systems • BMS / Combustion Control Systems • Fuel Handling Skids • Boiler Fuel Changover Mass Flow/Eficiency and Lifetime Studies • Boiler Refurbishment • Installation Teams • Commissioning Teams • After Sales and Service Teams

Combustion Systems Harris Pye United Kingdom Ltd Combustion Systems Division Office 218 Golden Cross House 8 Duncannon Street WC2 N4JF, London Tel: +44 (0) 20748 8625

www.harrispye.com

Global Excellence

Project Delivery Safety • Performance • Quality

TR A I N I N G

Directory of training providers Byworth Boilers Parkwood Boiler Works, Parkwood Street Keighley, West Yorkshire BD12 4NW Tel: +44 (0) 1535 665225 Fax: +44 (0) 1535 680997 Email: sales@byworth.co.uk Web: www.byworth.co.uk Chris Newton Steam Services Geraint Cottage Geraint, Llangollen LL20 8AA Tel: +44 (0) 1978 860578 Email: chrisnewtonsteamservices@fsmail.net Web: www.chrisnewtonsteamservices.co.uk Cochran Ltd Newbie Works Annan, Dumfries & Galloway DG12 5QU Tel: +44 (0) 1461 202111 Fax: +44 (0) 1461 205511 Email: info@cochran.co.uk Web: www.cochran.co.uk

Spirax Sarco Ltd Charlton House Cirencester Road Cheltenham, Gloucestershire GL53 8ER Tel: +44 (0) 1242 535211 Fax: +44 (0) 1242 535578 Email: training@uk.spiraxsarco.com Web: www.spiraxsarco.com/uk Newcastle City Council Byker District Heating Office Raby Street, Byker Newcastle upon Tyne NE6 2BY Mobile: +44 (0) 7966 583094 Web: www.newcastle.gov.uk SAACKE Combustion Services Ltd Langstone Technology Park Langstone Road Havant, Hampshire PO9 1SA Tel: +44 (0) 23 9251 8200 Web: www.saacke.com

Dunphy Combustion Queensway Rochdale, Lancashire OL11 2SL

Geof f Castles Boiler Services Ltd 97A Belfast Road Carrickfergus BT38 8BX

Tel: +44 (0)1706 649217 Email: sharon.kuligowski@dunphy.co.uk Web: www.dunphy.co.uk

Tel: +44 (028) 9336 8949 Web: www.geoffcastles.co.uk

EMK Education & Environmental Services Ltd Tel: +44 (0) 1244 641 606 Email: info@emk-ltd.co.uk Web: www.emk-ltd.co.uk M&M Training Ltd Fletcher House, Marlsborough Drive Fleckney, Leicestershire LE8 8UR Tel: +44 (0) 116 240 3430 Email: mmtraining@enersolcorp.com Web: www.enersolflomar.com JBC Industrial Services Ltd Howley Park Road East Morley, Leeds LS27 0SW

DID YOU KNOW

?

From the start of BOAS in 2004/05 CEA accredited 1,000 people up to October 2013, by July 2014 a further 1,000 people were accredited and a further 500 have been accredited in 2015.

Tel: +44 (0) 113 220 3830 Fax: +44 (0) 113 252 1407 Email: info@jbcmail.co.uk Web: www.jbcindserv.co.uk Neil Riches IEng; MIPlantE; MSOE; GCGI Little Orchard 40 Mount Road, Penn, Wolverhampton WV4 5SW Tel: +44 (0) 01902 345233 Mobile: +44 (0) 7710 444842 Email: neil.riches@btinternet.com

CEA Yearbook 2016/2017

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EN ERGY S AV I N GS O PPO RTU NITIES S CHEME

Countdown to ESOS Kiwa takes a look at the Energy Savings Opportunities Scheme and what it means

E

SOS (Energy Savings Opportunity Scheme) is a mandatory assessment scheme for UK-based organisations meeting specific criteria: If an organisation either employs 250 or more people, or has an annual turnover of 50 million euros as well as an annual balance sheet total exceeding 43 million euros, it has to comply with ESOS. ESOS looks at the total energy consumption of a company, examines how efficiently that energy is used, and identifies energy saving measures. If you fall under the ESOS Scheme, you must be inspected every 4 years by an approved assessor.

ESOS compliance can be achieved through a number of routes: having an ESOS assessment, obtaining a Display Energy Certificate, having a Green Deal assessment, or by being ISO50001 certified.

Whichever approach you take, with the exception of ISO150001 certification, at the end of the day an accredited ESOS Assessor

will have to provide documentation showing your organisation’s total energy consumption as well as a report on energy saving opportunities. The Assessor is also obliged to report their findings to the Environment Agency.

ESOS Assessors are not accredited lightly. They must be members of an approved register, and will have in depth expertise and knowledge on energy assessments. They will also have industry experience and it’s beneficial to appoint an Assessor who has knowledge of your particular industry.

Depending on the scale of operation and carbon dioxide emissions at your site(s), you may also need EU ETS verification.

Potential benefits • An ESOS assessment provides an overview of energy consumption and identifies activities in which most energy is used • The ESOS Assessor will provide cost-effective recommendations on how to reduce energy consumption • ESOS assessment demonstrates commitment to sustainability • Compliance with ESOS will avoid penalties by the Environment Agency

Specialist Training and Assessment Kiwa and the CEA working together to provide training and assessment for BOAS and IGAS courses.

•

IGAS Assessments (Industrial Gas Accreditation Scheme)

•

BOAS Assessments (Boiler Operation Accrediation Scheme)

•

ESOS Assessments (Energy Savings Opportunities Scheme)

Kiwa House | Malvern View Business Park | Stella Way | Bishops Cleeve | Cheltenham | GL52 7DQ Tel: +44 (0) 1242 677877

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CEA Yearbook 2016/2017

www.kiwa.co.uk

Email: training@kiwa.co.uk

ENERGY SAV INGS OP P ORTUNITIES S CH E M E

ESOS and reformed energy efficiency taxes The Government is looking to rationalise overlapping energy regulations and ESOS is set to play a key role in shaping the proposals. Independent consultant Chris Duckworth, MEI, an ESOS Lead Assessor, gives an insight.

A

s we go to press, the Government’s consultation period for reviewing business energy taxes is closing, and we await the outcome in the Summer Budget 2016. A clue as to current business energy tax complexity is seen in that the Treasury, Department of Energy & Climate Change (DECC), HM Revenue and Customs (HMRC) and the Department for Business, Innovation and Skills (BIS) are all sharing the consultation responses.

The review does not include those taxes paid by electricity generators (Renewables Obligation etc.) but “only” the Climate Change Levy (CCL), Carbon Reduction Commitment Energy Efficiency Scheme (CRC), Climate Change Agreements (CCA), mandatory greenhouse gas (GHG) reporting, Enhanced Capital Allowances (ECAs), the Electricity Demand Reduction (EDR) pilot and the Energy Saving Opportunity Scheme (ESOS).

Energy management fundamentals The ESOS assessment approach identifies if a company has covered the fundamentals of energy management. The guidance document runs through planning the whole process and requires certain standards of energy audit. The use of consumption profiles in analysing energy use is mandatory (although it is flexible in defining the analysis) and this is often an eye opener to some companies that have never applied any sort of analysis.

The guidance recommends the use of life cycle cost analysis (LCCA) instead of simple payback period (SPP). LCCA models are simple to set up in conjunction with the finance department and modelling real increases in future energy costs, recognising maintenance savings and avoided asset replacement costs are all working in the right direction to gain sufficient return on investment to get the go-ahead.

Motivation is key to changing behaviour. ESOS is an energy savings opportunity scheme and implementing ESOS recommendations is not mandatory. Perhaps another possible element of the new CCL tax will help when the changes take effect sometime in 2017 – potentially those companies that are seen to implement their ESOS recommendations will receive CCL exemptions.

The prism of ESOS Putting to one side the slow submission of completed ESOS assessments, shortage of Lead Assessors and general under estimation of the compliance requirements of data collection; ESOS contains some very sensible constructs. In the consultation document the government states that it is minded to design the framework for the new reporting scheme “through the prism of the ESOS”. They like that the ESOS delivers focussed recommendations and ESOS’s mandatory board level reporting.

They also like GHG reporting, providing information on energy and carbon consumption to investors and other stakeholders; both “inform investment decisions” and “create a reputational driver to incentivise decarbonisation”.

On the tax side the main revenues are split about equally from CRC and CCL at around £900 million each per annum. Key consultation points centre on scrapping the taxation element of CRC (retaining some reporting elements) and transferring this across to CCL. Current sector rebates under CCAs will be reviewed but exemptions for energy intensive industries are likely to remain.

Combustion engineers’ interest stirs when the Government proposes to shift the carbon tax towards gas. Whilst the current weighting reflects the carbon intensity of electricity and gas, there continues to be continuing progress in decarbonising electricity and some parties consider that investment in improving heat efficiency has not been so strongly incentivised.

Audit methods and Life Cycle Cost Analysis are recommended by ESOS guidance

CEA Yearbook 2016/2017

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ENERGY SAV INGS OP P ORTUNITIES S CH E M E

O is for Opportunity: Why ESOS is more than just form filling While it’s still early days to see the results of ESOS – the Government’s Energy Saving Opportunity Scheme – what is clear is its focus on understanding energy use as a first step in reducing consumption, says Spirax Sarco.

E

SOS is a mandatory energy assessment scheme that applies to large UK undertakings and their corporate groups. Under ESOS, eligible organisations must undertake energy assessments that cover at least 90% of energy use across buildings, transport and industry activities at least every four years.

The reasoning behind ESOS is solid – by auditing energy use in buildings, industrial processes and transport, companies will be in a much better position to identify cost-effective, energysaving measures. The goal is to help drive the take-up of such measures by participants, benefiting their competitiveness and contributing to the wider growth agenda.

Organisations are not currently required by ESOS to achieve a specific energy saving. Instead they must decide how much energy they can save and put strategies in place to enable them to do so. Similarly, no deadline has been given for fulfilling their energyreducing commitments. The idea is that the size of the potential prize – estimated to be around £3bn in energy savings by 2030 – will be enough of an inducement that companies will want to put into place the energy efficiencies identified in the audit phase.

Whatever individual organisations’ energy-saving targets, it’s important to recognise that ESOS is not a short-term ‘quick fix’ to the issue of energy efficiency. Instead, it can be considered as the start of a long-term energy-saving journey that will ultimately improve energy efficiency, cut costs and improve productivity across all aspects of operations.

ESOS points the way to more efficient steam plants By following the ESOS philosophy, steam-using organisations can improve the energy efficiency of their steam systems and enjoy substantial cuts in their energy bills for relatively minor investments. Steam is the most energy efficient and flexible way to transfer heat within many industrial operations providing process heating, hot water, space heating and sterilisation.

Steam systems are also incredibly reliable, working day in and day out for many years to deliver steam in the right quantities to keep production going.

Like any industrial plant, steam systems need regular maintenance to keep them at their most energy efficient, but their dependability means this can often be overlooked.

Companies can find it hard to apply the necessary time and resources for regular maintenance programmes, while some lack

the skills needed to service specialised steam plant.

The upshot is that drops in performance can go unrecognised.

Productivity is unaffected but unseen problems, such as damaged insulation or a blocked steam trap, can result in reduced energy efficiency.

Regular energy audits will flag up opportunities for improvement, helping to save energy and cut costs, which is exactly the theory behind ESOS.

Surveys identify thousands in savings Audits identify achievable energy savings with calculated return on investment, highlight health and safety shortfalls, detect water treatment issues such as corrosion and scaling, identify productivity improvements and advise on good engineering practice.

There are multiple ways that audits reveal energy-saving opportunities in steam systems, one of the most effective being a steam trap survey. As Paul Mayoh, Technical Manager, Spirax Sarco explains: “Surveys typically achieve a payback of between two and six months, mainly from reduced energy costs. Our analysis shows that on average each survey identifies about £28,000 of cost savings that could be achieved.”

Energy audits can reveal potential efficiency improvements in many other areas too. Replacing conventional hot water calorifiers with compact steam-to-hot-water on demand systems can achieve significant gains, for example.

Maximising the return of hot condensate to the boiler feedtank is another. Condensate contains up to 20% of the useful energy in the original steam and recovering it saves energy, reduces water charges and chemical treatment costs and brings down effluent charges. Typical payback for new condensate recovery systems are between one and two years, while most existing systems can be improved to achieve substantial energy savings.

Meanwhile huge opportunities to save on annual fuel and water costs, estimated to range from £17,000 for a small system to £160,000 for larger systems, are possible by implementing a closed-loop, pressurised recovery system that allows virtually all the energy from condensate and its flash steam to be used.

It is clear that there is an opportunity to save thousands of tonnes of emissions per year through the application of new technology and enhanced maintenance strategies – and ESOS is designed to focus organisations’ sights on setting and achieving energy-saving targets.

Saving energy throughout the steam and condensate loop Spirax Sarco products and services are helping organisations across multiple industries to cut energy consumption and contribute to their long-term energy saving targets.

Continued on page 38 CEA Yearbook 2016/2017

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EN ERGY S AV I N GS O PPO RTU NITIES S CHEME

O is for Opportunity: Why ESOS is more than just form filling (continued)

Upgrading the heating and hot water supply in ten plant rooms to Spirax Sarco’s EasiHeat™ steam-to-hotwater solutions is forecast to save Blackpool Victoria Hospital more than £240,000 per annum (p.a.) in energy costs plus an additional £34,000 p.a. in maintenance costs.plication. Replacing the controls with equipment from Spirax Sarco solved the problem.

Effective condensate removal has reduced tablet drying times on steamheated ovens at Piramal Healthcare’s pharmaceutical production site in Morpeth, Northumberland, resulting in energy savings. Automatic pump traps (APTs) from Spirax Sarco have improved the temperature control on the ovens from ±5°C to ±0.5°C, reducing drying time and thereby cutting energy consumption.

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CEA Yearbook 2016/2017

Westons Cider has cut its annual fuel costs by £44,000 per annum and has significantly reduced water consumption following the installation of a Spirax Sarco Reverse Osmosis (RO) water treatment system.

Spirax Sarco helped a water supplier to halve the energy used to raise steam at an anaerobic digestion plant.

The energy-saving project centred on solving an issue with two boilers where a low-water alarm would come into operation, even though there was plenty of water in the system. Low-water alarms made the boilers cut out, reducing the time that the boilers were in action.

Spirax Sarco engineers quickly spotted that the existing level probes and controllers were not suitable for the application. Replacing the controls with equipment from Spirax Sarco solved the problem.

Biomar Grangemouth has sliced between 9 and 10% off its annual gas bill with the help of a system to recover energy from flash steam that would otherwise be lost to atmosphere. The aquaculture manufacturer says that the energy savings alone mean that the Flash Recovery Energy Management Equipment (FREME) engineered system from Spirax Sarco has paid for itself around 10 times in the four years since installation.

Recycle today Resource tomorrow Paperback are processors and suppliers of Bio Mass and Waste Derived Fuels to the UK Combined Heat and Power Industry.

PAPERBACK For information on our services visit www.paperbackrecyling.co.uk or call us on: 01244 833370 Paperback Recycling Ltd, Unit 1-2 Zone 2, Parkway, Deeside Ind. Estate, Deeside, Flintshire CH5 2NS

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CEA Yearbook 2016/2017

BOILER S A ND BU R N E R S

COe Control – Closed Loop Burner Efficiency & Enhanced Safety Mick Barstow, Regional Sales Manager at LAMTEC, explains how COe Control can be used to optimise combustion control to deliver maximum cost and emissions reductions.

O

xygen Trim (O2 trim) is widely acknowledged as an essential element of burner control that allows boiler operators to reduce both energy costs and associated harmful emissions. Over the past two decades O2 trim has evolved from basic systems that adjusted mechanical linkages using Bowden cables through to today’s sophisticated microprocessorcontrolled electronic linkageless burner management systems that employ highly accurate and repeatable servo motors to position air dampers and fuel drives.

The concept of O2 trim was the result of the development of in-situ zirconia-based flue gas measuring technology. Efficient and safe combustion requires a precise mixture of fuel and air. Too much air results in energy being wasted up the flue; too little air results in incomplete combustion. Incomplete combustion is particularly undesirable and results in the formation of Carbon Monoxide (CO), Hydrocarbons (HC) and Hydrogen in the form of H2.

To combat the chances of incomplete combustion, burners are always commissioned with an element of ‘excess air’. Combustion is complex and there are many variables such as air temperature, humidity, barometric pressure and fuel quality that affect the whole process. Excess air ensures that, even if the combustion variables change detrimentally, the combustion process remains safe.

O2 sensors allow combustion systems to become ‘closed loop’.

This means that any changes in combustion variables are detected and can be corrected accordingly.

So, how does O2 trim work? The answer is fairly simple in that it adds or reduces either fuel or air to compensate for changes in these combustion variables. For each point on the combustion profile there is an O2 setpoint. If the O2 reading for any point increases, then air is reduced, or fuel added, to bring the process variable back to the setpoint. If the O2 decreases the opposite happens. Most systems work by adding or subtracting air as this has less effect on the power output. Decreasing air will reduce costs whilst adding air will increase costs. However in the latter case systems will ensure the combustion process remains safe and CO/H2 is not produced.

In an ideal world, combustion, without excess air, would result in the best efficiency possible; this is called stoichiometric combustion and is a theoretical state where exactly the right amount of oxygen molecules reacts with fuel molecules to complete the combustion reaction. In simple terms, e.g. for methane:

CH4 + 2O2 = CO2 + 2H2O + Heat COe Control takes a more empirical approach that allows combustion systems to get closer to stoichiometric conditions, whilst remaining safe. COe sensors use a modified version of zirconia O2 sensors that enable them to detect the products of incomplete combustion. These include CO, H2 and HC. This is why the term COe is used instead of CO; COe is effectively a CO equivalent.

The LT3-F Failsafe Combined O2 /COe Analyser and Probe Continued on page 42 CEA Yearbook 2016/2017

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B OI L E RS AN D BU RNERS

COe Control – Closed Loop Burner Efficiency & Enhanced Safety (continued)

COe Control produces savings over that of O2 trim by enabling the burner to operate a fuel/air mixture on the edge of stoichiometric conditions. One important aspect that allows this level of control is the rapid response of the COe sensor to the detection of the products of incomplete combustion. COe Control is a self-adapting algorithm that ‘learns’ each point on the programmed combustion curve by reducing air to the point where COe is detected and then ‘backing-off’’ to a safe setpoint. After the learning process has been completed, if at any time incombustibles are detected, the system simply readapts by ‘backing off’’ to the next safe position. Each ’learned’ point has a lifetime of eight hours after which it is ‘learned’ again. This ensures that if external conditions have improved then the COe Control will readapt to compensate for this and increase efficiency. It is not uncommon for systems employing COe Control to run at 1% O2.

In order to ensure systems employing COe Control remain safe, a failsafe oxygen sensor is required. An oxygen level of about 0.4% is typically set as a safety threshold and if the flue gas oxygen level reaches this level then the COe Control is switched off and an alarm produced.

The KS1D is the latest version of LAMTEC’s combination zirconiabased probe that detects both O2 and COe. By using the KS1D with the latest LT3-F failsafe transmitter, COe control can be implemented using a single probe located in the flue. The LT3-F uses two separate processors to cross-check the zirconia cell’s signal reading.

Quantifying cost savings when employing O2 trim and COe Control is always difficult as the starting point, i.e. the base profile set by the commissioning engineer, is somewhat subjective. However, as

Efficient and safe combustion requires a precise mixture of fuel and air. COe Control enables the burner to operate a fuel/air mixture on the edge of stoichiometric combustion in which exactly the right amount of oxygen molecules reacts with fuel molecules to complete the combustion reaction

a rule of thumb, COe Control can generate an additional saving of up to 50% over conventional O2 trim systems.

COe Control has been widely adopted in Europe but its benefits have not yet been recognised in the UK. LAMTEC has extensive experience of COe Control and introduced the first systems back in 2004. Since then, over 2,500 systems have been installed. COe Control is available as an option on all of LAMTEC combustion control systems from the new BT300 through to the wellestablished Etamatic and FMS/VMS. What about the Enhanced Safety?

One of the inherent problems with O2 trim is that if ingress air ‘leaks’ into the system then the oxygen level in the flue or exhaust will increase; the response of an O2 trim system is to reduce the air, which has a negative effect on the combustion process and causes incomplete combustion, and the resultant COe. COe Control is a much safer option as it is not affected by ingress air; incomplete combustion is the only source of COe so if it is detected then the operator can be sure there is a problem.

CO & O2 curves with cost saving area highlighted between the two

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CEA Yearbook 2016/2017

For further details contact: Mick Barstow – Regional Sales Manager, LAMTEC UK Email: mick.barstow@lamtec.de Tel: +44 (0)1732 445001

CEA Yearbook 2016/2017

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B OI L E RS AN D BU RNERS

Let’s start with the basics!

Before any treatment, any doctor worthy of their profession has to diagnose the illness.

The same applies to burners and boilers.

What ailment is afflicting the control sys­tem? Why is there steam coming out of the manhole cover behind the boiler house? How many restarts does the burner do in a day? Only when the diagnosis and analysis is complete can the right medicine be pre­scribed. However, to do this, you have to know how the plant works and how high its level of efficiency could be says Saacke.

T

he key word “efficiency” is the basis for all improvement and optimisation mea­sures, so it is worth having a closer look at what efficiency really means.

Energy balance Frustratingly, there isn’t just one way of measuring efficiency, but at least five possi­bilities. Three are standard and important. To tell them apart, we need another defi­nition: energy balance. Just like a pair of scales, on one side you place what goes into the heat generator and on the other side, what you get out of it. The difference between the two is what you lose. These losses are bad for the energy balance, com­promise the effectiveness of the plant and make it inefficient.

Fuel efficiency This efficiency ratio gives us a useable basis not only to evaluate boiler house “hard­ware” but also how this plant is controlled.

Ultimately there’s a difference between an insensitive output control which constant­ly turns the burner on, modulates to full load and shuts it off again. Compare this to a control system which rarely restarts the burner and sensibly maintains it within an optimum load range. With the same hard­ware and producing identical amounts of steam, a plant with wildly fluctuating loads will use more fuel and be less efficient. This can only be measured properly by applying this fuel efficiency.

Recording measurements In order to determine fuel efficiency you will need at least one data logger which can continuously record numerous plant para­ meters and ideally be smart enough to eva­luate what it records.

If it also has a display, it can compute the data as it goes along and shows the fuel efficiency ratio for the last three hours, for example. If combustion during this period was doing no more than just keeping the boiler warm, a quick glance at the screen won’t put a smile on your face – all you’ll see is a zero.

The SAACKE se@vis Efficiency Monitor is the simplest way to track down thirsty inefficient plant. It interprets readings in real time and can for example calculate the more complicated fuel ef­ficiency ratio for various periods of time. When fitted with a display, such a device doesn’t just log data but processes and displays it.

The monitoring equipment has to be programmed with the parameters of the plant. What is the power output rating of the burner? What fuel is used? At what pressure does the

Combustion efficiency When it comes to efficiency what as­pect of the firing process should you place in those scales? If you only measure flue gas losses when calculating the actual power output, you arrive at the combustion efficiency. This only tells you one thing: the amount of loss the burner/boiler system has at maximum power rating through the stack. Losses through radiation or blowdown are unfor­tunately omitted by this calculation. Boiler efficiency takes radiation losses as well as combustion efficiency into account and is therefore never quite as good. Boiler efficiency is also measured during a “sta­tic” procedure – at a given power output.

Losses at very low or zero loads are conve­niently ignored.

Plant efficiency In the case of plant efficiency (or total sys­tem efficiency), you have to look at all parts of the process from the fuel right up to your finished pro­duct. This also includes water treatment, the condensate system and the deep­fat fryer as well as bypass equipment and the condenser.

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In the last three hours, this plant has only converted 85 % of the fuel used into steam. Such an instantaneous display of data is really not more than a gimmick.

What is much more important, however, are the diagrams and graphs depicting trends (see examples on adjacent page) and the interface to export data

BOILER S A ND BU R N E R S boiler operate? Is an economiser fitted? How hot is the flue gas temperature? Since this “static” information already says a lot about the plant, a simple “burner is off ” – or “burner is on” signal can provide an awful lot about the efficiency or waste­fulness of the combustion process.

In the last three hours, this plant has only converted 85 % of the fuel used into steam. Such an instanta­neous display of data is really not more than a gimmick. What is much more important, however, are the diagrams and graphs depicting trends (see examples on adjacent page) and the interface to export data.

Independent of the implemented solu­tion, simply recording data sheds a lot of light on the combustion process – and shows us exactly what the plant gets up to during the night shift or over the week­end. A monitor system is ideal, it can quantify blowdown

losses for example and if you input the current gas price it can even calculate costs per day or per hour! An operating profile established in this way doesn’t just show all losses, but also the plant’s potential – with the help of a simulation: How would it behave with an economiser? What gains would a speed controller provide with this profile? The answers given by the monitoring system are always based on the actual combustion process, this data is – above all – incorruptible.

For an analysis of your plant contact SAACKE Combustion Services Ltd, the experts in all the E’s – Energy, Efficiency, Emissions, together with EU compliant combustion, boiler plant and heat recovery systems plus the highest quality of aftersales support with Employee friendly Boiler-house log book, BG01/BOAS/I-GAS Training, Risk Assessments and MCPD compliance.

Recording trends

Distribution graph

Daily tasks for monitoring equipment include the simple chore of recording trends. Here, various input and output signals, calculated values for given time periods can be displayed.

This is an ideal and universal method to identify unfavourable control settings or abnormal plant behaviour at a glance.

This diagram shows how hard the burner and boiler actually work. Ideally burner load should be in the region of 40 80 %. If however it only reaches 30 %, the burner is often just crawling along on low load or “OFF” (purging losses).

Whereas if the burner constantly runs at full load, flue gas losses increase. Provides persuasive arguments for measures to reduce the maximum power rating or for the provision of a bigger burner.

Burner starts per day

Fuel efficiency

The number of burner starts per day (or per hour) provides valuable information about incorrect con­troller settings or indicates that the burner is simply too big for the job at hand.

The adjacent diagram indicates that a reduction of steam pressure during the weekends would minimise purging losses.

When the logger has sufficient data, the efficiency ratio can be displayed in “dashboard” style. This takes into consideration in equal measure flue gas, radiation, water and purging losses.

Depending on the time period under observation, the needle reacts in a laid back manner or with the frenetic activity of a whirling Dervish when the plant is operated inefficiently.

CEA Yearbook 2016/2017

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Industrial boilers: upgrade or replace?

Given the life expectancy of an industrial boiler, it can be difficult to find justifiable reasons to upgrade or even replace entire systems mid-lifecycle to enhance energy efficiency. Rob Brown, Technical Manager for Industrial Boilers at Bosch Commercial and Industrial Heating, emphasises the importance of a detailed site survey before any decisions are taken.

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System (BMS), which in turn has significant cost saving benefits.

Not only is it possible for the boiler to be controlled remotely, but it is also possible for the boiler to monitor its own performance to ensure it is operating correctly.

There will become a point at which the best option may be to combine multiple technologies, working together to cater for the entire heating, hot water and process heating requirements.

Using a steam boiler alongside a CHP module for example, a system would effectively be capable of delivering free steam, domestic heating and hot water, and secondary heat – not to mention electricity.

he investment in an industrial boiler plant will never be one that can be made without an in-depth analysis of performance and, more significantly, the payback period.

As with any energy system, including industrial plant rooms, there is no such thing as ‘one solution fits all’. It is important to remember that the system in place today may not just require a like-for-like swap, and it is vitally important to consider wider implications, such as whether the system requirements have changed since the initial installation, or if modern technologies can be implemented to enhance the performance of the system.

Ultimately, the key to maximising the boiler performance on a given site – whether for hot water or process heating – is to conduct a thorough site survey before any work takes place. It is vitally important to understand the requirements of the people and processes on site before any decisions are made on product selection.

Taking a low temperature system for example, it may be that a Combined Heat & Power (CHP) module can be installed, which essentially gives a boiler plant free heat alongside electricity generation. Regardless of the circumstances, it’s important to look at the full plant requirements, as well as whether or not the site has the potential for a packaged boiler house. For example, it may lend itself to small de-centralisation and or point of use steam generation which can be achieved with a containerised solution.

Follow Bosch Commercial and Industrial Heating on Twitter (@BoschHeating_UK) and LinkedIn (Bosch Commercial and Industrial Heating UK).

For more information on Bosch Commercial & industrial Heating and its product portfolio, visit www.bosch-industrial.co.uk or call 0330 123 3004.

A pre-packaged solution In the event a site does require a new boiler, it is very rare that the investor will want to construct a brand new building to house the system, so investing in a boiler housed in a container often proves to be the favoured option.

The convenience of the containerised solution is that the investor can have a boiler delivered and installed in an appropriate location on site for point of use, close to the process application requiring the heat or steam output.

There is no such thing as a ‘one solution fits all’ when it comes to boiler systems

There are a number of different reasons for stakeholders opting for a containerised solution. It may be that they only have one boiler on site and need another to cater for additional output following a change of requirements. Alternatively, in the case of a steam boiler, it may be that the requirement for a statutory shutdown makes it more practical to have a containerised solution.

Taking control When it comes to controlling modern systems, boilers can be turned both on and off remotely through a Building Management

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Regardless of the circumstances, it’s important to look at the full plant requirements

BOILER S A ND BU R N E R S

Thermal fluid or steam – a case for both Fulton now offers a range of thermal fluid heaters and multi-fuel-fired steam boilers, making it well placed to offer an unbiased review of their heat transfer requirements.

and effective operation; and the thermal fluid should be checked regularly to verify that it has retained its heat transfer properties.

Thermal Fluid: The Facts

The choice between adopting steam or thermal systems is determined by the requirements of the process and its temperature range. In general, if the process requires a temperature below 180°C, steam is usually the first choice.

However, if the required process temperature is above 180°C, thermal fluid is often the better solution.

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ater and steam are typically used as heat carriers in heating systems, but at high temperatures, both require a corresponding high operating pressure. For industrial heating systems, a high temperature is often a great advantage, but establishing this with water and steam can be controversial and expensive.

Thermal fluid heaters use specialist oils as heat carriers and operate at atmospheric pressures up to 300°C. To gain a similar operating temperature from traditional water- or steam-based systems would require a pressure of 85 bar. Thermal fluid heaters are therefore an ideal source of heat for industrial processes where high process temperatures are required and there are circumstances, especially where low running costs is a requirement, where they are more suitable for heat transfer than steam systems.

A properly designed, installed and maintained thermal system that uses the correct thermal fluid for the application’s operating conditions should give 20 to 30 years of reliable service. However, as with water and steam systems, maintenance is essential for safe

Thermal Fluid vs. Steam But at what point does thermal or steam become the best or most cost-effective solution for a process?

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

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

The choice between adopting steam or thermal systems is determined by the requirements of the process and its temperature range Continued on page 48 CEA Yearbook 2016/2017

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Thermal fluid or steam – a case for both (continued)

Thermal Heaters With a range of thermal oil systems Fulton is now considered a major provider of thermal fluid solutions. Its thermal fluid heaters feature a four-pass, high-efficiency design that pre-heats the combustion air. Their compact construction can, like many Fulton systems, be skid-mounted with ancillary equipment and their layout designed to suit the customer’s requirements. The range includes models with heat outputs to 3500kW and standard operating temperatures of 345°C (400°C is also available with optional heater enhancements and suitable thermal fluids).

Fulton’s FT-N features a compact, vertical design with the capacity to operate at temperatures up to 340°C and with heat outputs from 22 to 504kW. The FT-C offers outputs from 235kW to an impressive 4.1mW and its largest heater, the horizontal FT-HC, provides heat outputs from 0.7 to 5.9mW.

Fuel-fired Steam Boilers Fulton has been designing and manufacturing high quality steam boilers since 1949. The eight models in the vertical ‘J’ Series range covers outputs from 96 to 960kg/h and can quickly raise full steam output in just 20 minutes. Three JFS models offers peakrate outputs between 300 and 680kg/h and are manufactured with larger pressure vessels to allow a much greater flash reserve to be stored. The seven-model VMP combines high output and efficiency with a small footprint and low maintenance; and covers outputs ranging from 626 to 2348kg/h and with a maximum fuel-to-steam operating efficiency of 85%. Fulton’s nine model horizontal RB provides outputs from 1150 to 4787kg/h and can be specified with matched multi-stage oil, modulating gas or dual-fuel burners as standard. The largest boiler from Fulton is the eight model FB, which has outputs from 4,699 to 25,000kg/h at 10.34 barg and can be configured for gas, oil or dual-fuel installations and for either steam or hot water applications.

Electric Steam Boilers Fulton’s compact electric boilers cater for a wide range of applications and combine traditional engineering in a number of versatile modern packages with outputs ranging from the 14kg/h (9kW) Mini Compack to the 2393kg/h (1500kW) FB-L. The sevenmodel Electropack, is designed for steam loads between 29 and 160kg/h and is ideal for ‘clean environments’; and the four-model EFS range, which has been designed specifically to deliver the short period/high demand steam loads at a steady pressure (typically 3 barg).

Packaged and Skid Mounted Systems Fulton manufactures a range of modular or bespoke plant rooms and skid-mounted systems. All are designed to be delivered to site and installed on a prepared concrete base and final installation is made easier by connecting to pre-installed termination points.

Single or multiple skid-mounted systems are available complete with all necessary ancillary plant for a range of applications.

After Sales Service And finally, Fulton’s service doesn’t just stop when a boiler or

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system has been sold. Its one-day training courses (Operator Routines & Maintenance and Knowledge of Steam Systems) are certified by City & Guilds and offer a mix of theoretical and practical operational assignments which, Fulton claims, bridges the gap between the more expensive courses – that can cost many thousands of pounds per employee – and straightforward ‘toolbox’ training.

Additionally, the company’s nationwide Service and Installation team is available to deal with the requirements for steam boiler installations and retrofitting of additional ancillaries where customers that don’t have access to an installation service can draw on Fulton’s extensive experience. Water treatment service packages and a commitment to provide a comprehensive stock of spare parts available for next day delivery as standard, completes the total solution packages available from Fulton.

Technology in Action Specialising in the manufacture of precast masonry blocks, Interfuse’s plants are amongst the most advanced facilities of their kind in the UK and are capable of producing around 21 million dense and lightweight blocks per year.

The manufacturing process for the concrete and lightweight building blocks uses a press to precast the products and a series of kilns to provide heat for rapid curing and, at its Gainsborough site, Interfuse replaced a live steam system that was proving too expensive to operate, with a Fulton FT-C vertical coil thermal fluid heater.

Commenting on the installation, Interfuse works manager Len Parks says: “Using live steam for the curing process at Gainsborough was costing the company in the region of £20,000 per month in fuel costs alone, so while the change to the Fulton FT-C thermal fluid boiler proved to be a significant investment, the thermal fluid system’s operating costs are about a tenth of those for the steam system, so we are expecting to achieve payback in three to four years.”

Whilst the decision to change to thermal fluid was based on the company’s positive experience over a number of years with a German-manufacturer boiler at its Syston facility, Interfuse decided that UK-based service and support was essential for the new boiler. “Fulton’s UK base was a big incentive when choosing the replacement.” says Len. Highlighting other significant reasons for the change, Len confirms that thermal fluid is much cleaner than the original steam installation and the maintenance costs are significantly lower because no annual strip-down is required. In addition, there are no associated costs for mains water, water softeners or chemicals to run the system, nor are there pressure regulations to adhere to.

For further information on its heat transfer solutions, call Fulton on +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

We have the power to cut your client’s off-grid energy bill If you have off-grid clients in industries that consume significant amounts of energy then why not recommend gas.

By linking up with Calor we can reduce their energy costs and carbon output in the process.

The benefits of Calor gas are clear: • Lower pence per kilowatt prices than kerosene • Lower CO₂ emissions – up to 20% lower • Substantially lower SOx and NOx than fuel oils • Returns on capital employed within 1-2 years

For your next client consultation call our industrial energy expert: Kev Houlden on 0800 121 4519 Quoting Gen-Industrial or visit calor.co.uk/Business

B OI L E RS AN D BU RNERS

Burning questions Alain Grangeret of AG Gas London looks at the working principals of the dual gas burner design, which is widely used in many conventional firing furnaces.

The outer jet discharges gas at a lower speed below 100 m/s and this is because of its larger cross section and lower pressure inlet.

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The fully developed core of the gas flow mixes downstream with the furnace combustion air. With the same burner, it is possible to have different velocity profiles in the jet near field regions for the same gas flow rate (Fig 1).

ithin the glass industry there are only a few suppliers of gas burners. Therefore, prior to purchasing burner technology, the supplier market can be easily researched and assessed.

The manner in which the gas is injected results in the formation of a combustible mixture of air and ring-jet gas.

Since the late 1990s, the general trend is to use dual impulse gas burners for conventional air-fuel regenerative furnaces. The related burner is commonly called a pipe in pipe burner and is a technology that originated from trials carried out in the 1970s.

The single jet principles are similar for double concentric jet flames. There is a relationship between the injector design and the downstream flow profile up to the fully- developed region.

Thereafter, little can influence the flame development and this is the end of the relationship with the physical injector design.

The claims for energy saving and NOx abatement by using this technology in the glass industry differs from one supplier to the other. These claims should be associated with the specific details of the operational furnaces, however, it is found this is not always the case.

Soot production occurs in a fuel-rich flame and oxidation/ destruction occurs in a fuel-lean region. The ring-jet gas boundary is the condition for the formation of soot and this happens at the root of the flame, which can be referred to as the initial and transitional regions.

The current burner technology has many advantages including low momentum, good flame luminosity, flame control coverage and relatively good NOx results. When using this type of burner, it is important that the working principles of the dual impulse design are clearly understood.

The heat emission of a flame is not only related in the formation of soot but its action is combined with the mixing factor. It is easy to reduce the NOx level by operating the furnace with a higher CO content level at the furnace port exit.

How does the burner work?

The gas tubes supply the natural gas, dividing it into two jets, an inner and outer jet.

However, this is not always taken into consideration when producing low iron clear glass and also the lifespan of the regenerator materials.

Port design and the consequences with air/fuel mixing The inner jet discharges gas at high speed, a speed of a few hundred metres per second depending on the pressure supply.

A turbulent diffusion flame is controlled by the mixing (or diffusion) processes of the fuel and its oxidant. Therefore, the

Fig 1. A gas injector design

Fig 2. Thermal image

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BOILER S A ND BU R N E R S

furnace port design, the burner location and their respective distances between the glass surface to the crown have a major effect on the flame and furnace thermal behaviour.

Dual Impulse gas burner – Is it a good burner?

Yes – the equivalent burner diameter based on the velocity profiles can be changed by varying the high pressure and low pressure gas supplies. This can influence the heat flux profile (rear and front crown temperature are important furnace indicators) and the visible flame length. This type of burner can offer flexibility to the furnace operators.

Does the outer and central jet arrangement influence NOX levels?

As explained, the double concentric jet arrangement with the correct velocity profiles are the key factors for soot creation at the root of the flame.

Beware of disappointment – the burner will not necessarily reduce the NOx level by much because the furnace combustion space design must be configured adequately. There is a combination with the inlet ports and the furnace design for optimising results, however other factors which intervene in the heat transfer to the glass have to be considered.

These control valves allow for the implementation of burner control management, which adds a complementary function to the furnace supervision. This gives the advantage of changing the settings for various pull rates without adjusting the mechanical setup. The burner support should be light and versatile to use, however, many burner support designs are bulky and do not allow for the furnace operator to adjust the burner easily within a hot location.

The burner refractory block should be designed to limit the proportion of induced flow of furnace gases and dust back to the burner tips. The reason for this is that batch particles stick within the burner block and may compromise the dual impulse flame.

The burner tips can be cooled with soft water (water jacket nozzle) or with external airflow. Both of these solutions should offer a design opportunity to seal the burner face against the burner block.

The last consideration is to use the ‘cooling’ air for the internal burner parts when it is not firing. The purpose of this is not to cool the parts but to counteract the furnace pressure to avoid a hot reverse flow within the burner. Then it is not necessary to have a high flow rate of ‘cooling’ air (Fig 2).

Reference Are there any other requirements?

The correct use of the dual impulse gas burner is based on implementing an adequate fuel gas control system.

Rogier, J. – Report GN 6 of Groupe d’Etudes des Flammes de Gaz Naturel, Toulouse, Oct. 1972 Published by Glass International - Jul/Aug 2015 www.glass-international.com

Attention must be given to adjusting the high and low gas pressure input combinations. This can be done mechanically with a specific burner design and/or with the help of additional pressure control valves.

DID YOU KNOW In 2014 we honoured Professor Bill Kaye with a life time achievement award at the David Gunn Memorial Lecture for the long and outstanding service he has given to the CEA.

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The burner block design must be appropriate if the burner face is sealing against the block. If the design is inappropriate, it causes internal recirculation of batch/hot gases products causing trouble to the flame development

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B I OM AS S

Oat husk - a viable alternative to wood for biomass Whitfuel oat husk pellets provide high calorific value, minimal ash and low volume

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oultry and arable farmer, Ed Warner of Great Ness in Shrewsbury is constantly trying new things experimenting with different types of fuels in the Lin-ka Biomass Boilers installed on his farm heating his poultry sheds.

more and more attractive against wood - as they maintain quick returns on investment and ongoing revenues.

Whitfuel is a trading name of A1 Biomass Fuels Ltd - producers of Oat Husk Pellets, Wood Pellets, Wood Chip and Agri-Fuels.

Contact 01772 805995 or www.whitfuel.com.

When asked about Oat Husk Pellets supplied by Whitfuel, Warner says: “The pellets have a very high calorific value, typically just under 5% less than the industry standard wood pellets, but at a significantly lower cost. The pellets take up very little room compared to wood chip, Miscanthus and straw, which means fewer deliveries. They go through the boiler perfectly and there is also less ash compared to Straw and Miscanthus.”

The Linka boilers have the capacity to burn many fuels from wood chip and wood pellets to agri-fuels such as Miscanthus, Straw and other Agricultural residues. As the tariff’ for the Government’s Renewable Heat Incentive are reduced due to increased uptake of the scheme, alternative fuels are becoming

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Poultry and arable farmer, Ed Warner uses oat husk pellets in his biomass system

BI OM A SS

Lessons in safe biomass design Alastair Nicol and Matjaz Ciglar reflect on their experience of design and the most recent of Biomass explosions in the UK. Alastair provides Biomass Health and Safety training on behalf of the CEA. Matjaz is an experienced design and controls engineer with over 15 years of design and experience in commissioning biomass and waste burning systems ranging from 0.5 – 25 MWt.

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he raft of health and safety legislation in the UK places onerous duties of care on equipment manufacturers, those integrating assemblies of equipment (installers who have conducted design) and specifically Consultants advising installers. These duties of care require formal consideration of the foreseeable use and importantly, misuse of equipment placed on and sold into the UK market.

A safe system of work is arguably one in which unsafe operating conditions are prevented from occurring, when foreseeable use or misuse of the system has taken place. But is it foreseeable that a boiler operator will not always conduct checks? Is it then acceptable that a boiler will present an explosion risk if the boiler operator did not carry out checks? Well, not in my opinion.

To fulfil the letter and indeed the intent of health and safety legislation in the UK (Indeed European law) the system must incorporate fail-safe mechanisms.

There have been at least three serious and potentially fatal biomass boiler explosions recently. The nature, location and the exact mechanisms of failure must currently remain confidential, but in the interests of safety and the promulgation of good practice the basic facts are explored here.

The causes of these explosions were smoke deflagrations (see foot note). These explosions (very rapid transit of a flame front with allied pressure wave) represented three interesting scenarios, an overbed explosion, a fuel supply system explosion, and a flue explosion. The extent of explosion in the cases cited was sufficiently forceful to project heavy boiler system components some distance.

What lessons can we learn from recent biomass plant incidents?

The explosions had certain combinations of factors that would make an explosion almost inevitable, namely: – Syngas smoke side explosions – Conditions arising after hot start (or effective hot start) – Inadequately considered control strategies – Inadequate physical protection – Inadequate training – Inappropriate (but foreseeable) operator intervention or lack of intervention by the operator.

Luckily, no fatalities

Smoke explosion requires the prerequisite mixture of carbon monoxide (primarily), other products of pyrolysis, and air at some point within the upper and Lower Explosive Limits (LEL) of that mixture (Note that while the LEL of CO maybe 12.5% the measured concentration of CO may be a third of this and the conditions for explosion depend on the interaction of moisture content and other products of pyrolysis) and an ignition source or the attainment of an auto ignition temperature.

The release of energy was destructive and in all cases caused the projection of heavy boiler, flue or fuel system components (In one case weighing hundreds of kg) with secondary damage. In two of the cases there was the potential for a fatality had personnel been present, in one case personnel were actually present and whilst there was the potential for a fatal outcome - the staff present were extremely lucky.

There are at least two scenarios that could give rise to a difficult but foreseeable situation. A grate fired biomass boiler is operated at high fire but suddenly or rapidly reduced to low fire for extended period with significant fuel already charged (arguably a control strategy failure) - this will result in the evolution of syngas in the boiler and flue system.

Continued on page 54 CEA Yearbook 2016/2017

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Lessons in safe biomass design (continued)

If the boiler is started from hot and there is fuel charged to the grate and where there is pre-existing incandescent material or excessive heat but no ignition of the syngas that will be evolved - then there also exists the potential to generate large quantities of explosive syngas without necessarily the flame front required to burn this in a controlled manner.

The control of gas air mixture and the physical establishment of ignition are of paramount importance under these circumstances and the control systems must manage these scenarios safely.

The syngas eventually fills the flue system. The consistency of mixture, e.g. the ratio of carbon monoxide to air, is not necessarily the same throughout the flue system. However if at some point a flame front travels through the mixture it will transit zones of varying stoichiometry and the flame speed will eventually reach a point where the mixture is not capable of combustion and where the shockwave ahead of the flame front is dissipated.

This gas is predominantly carbon monoxide but potentially hydrogen and other products of pyrolysis including tars and hydrocarbon vapours and water vapour. The LEL of Carbon monoxide is approximately 12.2% for these conditions but the vapour/gas mixture could have a significantly lower LEL exacerbated by the temperature which will reduce the LEL. The presence of water vapour in the flue gas will act as an accelerant in the case specifically of carbon monoxide at low concentrations because the water vapour supplies OH and H atoms required for combustion. The moisture content of the fuel may be instrumental in determining the LEL and UEL and the rate of flame propagation at lower concentrations of CO but it is not the primary cause of explosion. A minimum oxygen concentration of 5% (4% according to TRD) in the total flue gas mix is required but this is relatively low compared with most fuels.

It is probably worth pointing out that if the pyrolysis/gasification process has produced a range of tar vapours and intermediates at temperature, then the LEL might fall well below 12.5% and the minimum oxygen content for the mixture drop to a few % with elevated temperature. In summary, the risk from explosion is present unless there is controlled combustion on the grate and management of the flue contents. These are smoke explosions and not simply a carbon monoxide explosion.

In one case, the operator had evolved a new procedure to overcome inappropriate design after explosion. Both the original and revised procedures retain severe risk for the operators in my opinion. The problem was perhaps a simple failure on the part of the manufacturer and the seller to consider and integrate safe procedure.

What can be learned?

Well inspection for first use under the PSSR should consider

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control but might not necessarily have considered the risk from a smoke side explosion.

In purchasing a boiler plant from a manufacturer or perhaps particularly from the systems integrator (who may have consultants designing for them) it is imperative that they comprehend the provisions of law governing design and that foreseeable use and misuse are adequately addressed in a formal design Hazard Identification Process with the risk being managed thereafter. A simple reliance on operator intervention is not going to stand much scrutiny. Human nature is what it is.

Interlocked safeguards (Physical control measures) have to be used where practical to prevent these foreseeable circumstances from occurring or to manage the circumstances so that safe intervention can be made.

Unsafe circumstances should be avoided by ensuring that well considered operating practice is evolved. Operating procedures need to be evolved based on safety and not around optimal commercial practice which are subsequently window dressed.

Element Consultants are an experienced multi-disciplinary energy consultancy who can advise and project manage for you across a range of energy related sectors: RECENT LEGISLATION Biomass/Combustion plants MCPD (Medium Combustion Plant Directive): Expert advice on impending legislation which will affect you if you have any combustion plant between 1 and 50 MW PUWER and CE Marking The importance of full plant CE mark certification Energy Efficiency ESOS (Energy Savings Opportunity Scheme) : Lead energy assessor to major clients. Mandatory energy regulations for larger companies. Are you complying?

Renewable Energy Let us advise you on the best way to deploy new technology while understanding the changeable funding environment OTHER SERVICES WE PROVIDE: Lead Assessor, Expert witness, Project Management, Energy Audits, Plant Design, Waste & Water solutions

Email: info@elementconsultants.co.uk www.elementconsultants.co.uk Tel: +44 28 93340311 Alastair Nicol is a CEA council member and regularly lectures for the CEA

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B I OM AS S

Lessons in safe biomass design (continued)

Control strategies Fuel feed must be inhibited on the basis of combustion space temperature, rate of rise of temperature, physical flame detection – or combinations of these, to supplement the inhibition of fuel charge on falling oxygen level (where fitted). Charging other than that required for ignition should not be permitted until a sufficiently high operational temperature is detected.

Restart and hot start should be enabled only after a predetermined purge period and with auto ignition. The flue gas content/condition must be determined because the purge action or natural draft may actually result in continued pyrolysis/ gasification on the grate. Effective purging will only be achieved with the operation of an ID fan. Confirmation of the purged condition must be assured because unlike gas where the fuel air mix can categorically be stopped during purge – purging may exacerbate the evolution of combustible products.

Reliance on an oxygen reading from an O2 probe to determine the likelihood of explosive mixture is not a reliable test where, for example, fuel is being pyrolysed as opposed to gasified. This is because an explosive mixture of syngas could be generated with very low equivalent CO threshold. On the other hand, using O2 readings to determine a trend toward combustion conditions that may give rise to combustion conditions that may be “rich“ and thus prone to the attainment of LEL is useful. As a minimum, a combination of temperature and O2 measurement must be used.

– The system must be purged (at least 5 x the whole combustion, boiler, filters, ducts volume) before start up burner/Ignition is operated. The effective subsequent duration of the purge period must be established or else repeated.

– The ID fan should remain operative at all times (at least while all remaining fuel is burned out under worst possible conditions to allow for the maximum amount of fuel with minimal or virtually no combustion air) regardless of boiler status although, only with minimum required draft – There must be a CO detector in the flue gas system (in old TRD 604 Sheet 2 annex 1 –Safeguarding against unacceptable gas concentrations in the flue gas O2 :4% by volume, or CH4+CO+H2 :5% by volume, however CH4+CmHn :2% by volume) (CO sensor is also useful for increasing combustion efficiency).

– The minimum auto ignition temperature in the furnace should be determined according to fuel type (usually 500°C is fine for most of the fuels) and introduced as a safety control value – before fuel charging is automated (BS EN 12952/12953).

Interlocking – Simple logical interlocking should be adopted to prevent the sequence of incorrect operator intervention. The logic of the interlocking should be tested by formal documented HAZID, Risk Assessment (RA) and the preparation of control measures.

– In the event of a failed start where temperature has not been achieved, then the boiler should lock out and operate fail safe performance until safe a clearance purge can be assured. (see above) – In the event of a failed start with ignition bypassed, the fuel feed should be inhibited unless furnace temperature is reached (Temperature to be determined and agreed).

– In the event of an incorrect shutdown a restart must not be possible until the boiler condition is determined as safe.

– The auto ignition heater should self-test and report, and failure to detect impedance will result in lockout of the starting procedure.

– The SCADA control systems must provide intelligent control and prevent foreseeable operator interventions as well as response to measured parameters.

Blast relief Flue duct blast relief is routinely incorporated into the flue systems of CHP, Coal fired boiler and others, indeed some manufacturers incorporate blast relief into the smoke box of their biomass boilers.

– Identify the hazards – Design the hazards out – Control the risk from hazard – Mitigate against the effects of hazard being realised

Boiler plant manufacturers and systems integrators need to comprehend the provisions of law governing design and that foreseeable use and misuse are adequately addressed by a design Hazard Identification Process

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Steam generator transplant for Guys & St Thomas Hospital How CERTUSS tackled a complex installation in the heart of London Case study

I

n July 2013 CERTUSS UK Ltd was invited to tender for a project by specialist Mechanical Electrical installer CFES Ltd. The request was to visit Guys & St Thomas Hospital London, to view the potential replacement of 3 x Stones Steam Generators.

Prior to the invite to site, CERTUSS was informed that a Boiler company had previously been invited to site, however they were unable to come up with a solution for the changeover of the equipment, due to the complexity of the task.

The equipment was located on the 6th floor of the hospital, which is situated between London Bridge, Tower Bridge and next to the Shard building, therefore making the logistics for the project extremely difficult both from an external and an internal point of view.

After viewing the site, CERTUSS offered a proposal, which was accepted by CFES as a very viable option. The proposal was forwarded to the Hospital trust and Engineers for review. In September 2013 CERTUSS was then approached by Northmoore Associates, appointed by the Hospital Trust to act as its Consultant and Design team for the project.

Tender details were issued to various Mechanical Electrical installers to submit their proposal for the works, which was to include CERTUSS Steam Generators and Package Plant Modules.

The equipment was to be supplied as N+1 to serve a Sterilization system with a peak load of 1586kg/hr @ 8 barG and Frost coils with a peak load of 2847kg/hr. The system will be operated as Duty during winter times. Steam production would be required 24 hours a day, 7 days a week.

With the requested delivery achieved, the equipment was lifted up onto the 6th floor with the use of a specialist crane company.

Prior to the lift taking place, a temporary platform was built to accommodate the introduction of the new equipment into the building and removal of 1 x Stones Generator and associated equipment.

Phase 1 installation works was carried out by CFES, with commissioning of 2 x CERTUSS Generators and 1 x Package Plant taking place April 2014. After successful commissioning of Phase 1 equipment, the works for Phase 2 were complete and final commissioning of the equipment was carried out September 2014.

CERTUSS included for 2 x phased formal training programmes to be carried out with the site Engineers. To date CERTUSS carries out the annual servicing of the plant, with a full service/ breakdown contract in place. CERTUSS also arranged for the water treatment programme to be carried out on an agreed service contract by Western Environmental, the recommended water treatment specialists for CERTUSS UK Ltd. This site is also available for any potential CERTUSS UK customers to visit to see the equipment in a working environment, where they can speak to an independent Engineer for an unbiased opinion (to arrange any appointments please contact CERTUSS UK).

After evaluation of the requirements, CERTUSS UK offered a tender for the following equipment: • 4 x 2000kg/hr Gas Fired CERTUSS TC Steam Generators (Duty/ stand-by) • 2 x CERTUSS Package Plant Module (Each tank sized for 2 x 2000 Generator) • Automatic Operation • CERTUSS Interface facility • Delivery to site • Commissioning In January 2014 CERTUSS received an order from CFES Ltd, the selected Mechanical Electrical installer, for the supply of the equipment.

Due to the logistics for the project, detailed planning and liaison was required for all concerned. CFES issued a programme of works for the project, with installation works being carried out over 2 x phases and which also required the equipment to be delivered in March 2014 on a specified day and at a specific time.

CERTUSS provided a package of products and services for Guys & St Thomas Hospital London

CEA Yearbook 2016/2017

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CEA Yearbook 2016/2017 ©Zeeco, Inc. 2015

ROCs and syngas testing – Do you really know how to prove it?

Everyone knows everything about the theory behind Renewable Obligation Certificates (or ROCs), and yet few know how to prove and claim them in practice.

Dr. Alen Sarlah, director of Enervis d.o.o. shares some personal experiences with sampling and analysing syngas in gasification plants

T

he Renewable Obligation Certificate (ROC) scheme, which encourages electricity generation from eligible renewable sources in the UK, has been in force since 2002 (England, Wales and Scotland) and 2005 (Northern Ireland). It is set

by DECC (in England) and DETI (in Northern Ireland), but administered by Ofgem. In 2009 Ofgem introduced the banding scheme which provided differing levels of support to various technologies based on their market-readiness, development and market costs, and associated risk. This banding scheme paved the way for incentivising technologies in the early stages of development – one such technology is gasification.

In 2014, the UK government announced a proposal for wideranging reforms to replace the RO scheme with contract for difference (CfD) in 2017/2018. Although this is a major change in the subsidizing scheme of renewable technologies, the technical requirements of the gasification technologies have stayed more or less the same.

Technical requirements for generating stations Technical requirements set by Ofgem and imposed on a generating station operating as a gasifier have been revised several times (for technical, commercial as well as administrative changes), but in essence has remained similar, i.e. every generating station operating as a gasifier or a pyrolysis plant and processing waste fuels must prove to be either a “standard” or an “advanced” gasification/pyrolysis plant. The latest document by Ofgem on RO, that is “Renewables Obligation: Guidance for Generators – Guidance” published in April 2015 states that the generator must measure the gross calorific value (GCV) of the syngas that is used to generate electricity and must show that it has a minimum GCV of 2MJ/m3 (for standard gasification) or minimum of 4MJ/m3 (for advanced gasification).

This is where the certainty ends, because everything else is up to each generator to define, whereas the authority/regulator has the power to approve or reject it. Sampling and analysing location and equipment/instruments, methodology, sampling protocol, data analysing and statistics, reporting, all this must be defined by the client and approved by Ofgem before the plant can operate commercially.

or cleaning the syngas are: • hazardous gases posing health risks • high concentration of tars which condense at lower temperatures and can block system components • moisture condensing inside the sampling/analysing components • corrosive gases causing damage to the components • particulate matter blocking filters and components • volatile gases that can lead to explosions or self-ignition.

Filtration of such compound gases is not straightforward, but a rather complicated set of filtration stages during which all potentially problematic components are removed preferably without affecting the GCV of syngas (or at least with a minimal effect).

There are a number of sophisticated and tested solutions on the market. However, their longer-term availability, reliability and efficiency are yet to be confirmed as many are newcomers.

During our syngas sampling/measuring experiments we were constantly confronted with problems and issues that were not even known to the equipment suppliers. Calibration curves; corrections for pressure, temperature, moisture and more; the effect of various external conditions on the reliability of the measurement - these are only a few points worthy of close attention.

From our experience we can say that syngas cleaning/ scrubbing is the single most important part of the sampling/ analysing procedure, which determines the overall availability of the equipment – most of the measurement outages that we have experienced were due to sampling and gas conditioning (sampling probe failure, blockages, filter failures, etc.).

Sampling methodology and protocol Ofgem’s guidance document “Renewables Obligation: Fuel Measurement and Sampling” states that “the operator must measure the GCV of the gaseous fuel that is used to generate electricity, at the inlet to the generating station, each month”.

This is also the only guidance available about the methods that need to be used and implemented in a gasification system for sampling and analysing syngas GCV. Ofgem wants each operator to design and implement their own syngas sampling/measuring method and system, but it reserves the right to approve or reject it through the FMS (Fuel Measurement and Sampling) review process.

This consequently means that each operator has to carry a full burden of the complete fuel and syngas sampling/measuring process without any forward guidance from the regulator. This is where the hard part begins, i.e. the uncertainty about the acceptance of the proposed protocol.

Sampling and analysing equipment Syngas generated from gasification plant waste is a complex mixture that is hard to deal with. The problems of dealing with

Following is a list of only few steps/decisions that operator must successfully take before it can achieve ROC (pre)accreditation: Continued on page 62 CEA Yearbook 2016/2017

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ROCs and syngas testing – Do you really know how to prove it? (continued)

– Definition of the exact sampling location that enables representative sampling within the gasifier (single- or multi-point) – nonintrusive equipment used for sampling syngas (such that does not affect the GCV of the syngas yet still enables representative sample extraction) – suitable filtration and conditioning of the syngas prior to the analyser (that does not significantly impact the GCV reading and is reliable enough for continuous operation) – analyser and its method of determining syngas GCV (direct or indirect methods: gas chromatography, catalytic oxidation, calorimetry, gas-component analyser,…)

– data processing (sampling rate, corrections according to Ofgem requirements) – correct statistical evaluation (averaging according to Ofgem requirements), – suitable reporting

Data analysing and statistics Every analyser has its own inherent method of determining the syngas GCV value and as such it requires careful data analysing/ processing and correct statistical representation. The result obtained by the analyser may not be the correct final value – it often (if not always) needs to be corrected at least for pressure and temperature according to the Ofgem requirements: it must be measured and reported at 25°C and 0.1MPa. Syngas guidance document also requires that the GCV of syngas is reported for the gas as it is used in the final conversion (steam boiler, gas engine, etc…), which means that it must be corrected for any significant syngas changes during the sampling or filtration/scrubbing process. For example: if during syngas filtration step moisture is removed from the sample but it isn’t

removed in the gasifier before its final conversion (to steam or electricity), then the final GCV measurement needs to be corrected for the “removed” moisture. Same goes for tars and particulate matter if they have a significant impact on the final GCV value.

Reporting Ofgem does not explicitly prescribe, but usually does require that the operator implements continuous syngas analysing (with the sampling rate at a minute level) and that it reports the average GCV value of the syngas for every month. This inevitably means that the operator must prepare and use a reliable and correct statistical method for analysing a large amount of monthly data, calculating the correct averages, and proper reporting to the regulator.

Summary Syngas sampling/measuring is only one, but an unavoidable step, in the process if an operator of a gasification plant wants to claim ROCs (subsidised power generation). Other steps, which are technically less complex but still equally important, involve fuel sampling/analysing, fuel biogenic content analysis and ash sampling/analysing.

Together they form a complete set of requirements that were prescribed by DECC and are implemented/controlled by the Ofgem. A lot was written and discussed in the WtE market about the whole syngas sampling/analysing process in theory, but we have seen very limited reports of the actual syngas tests or experiments. This confirms our suspicion that not all operators are fully aware of the requirements and consequences. Or as James Russell Lowell said: “One thorn of experience is worth a whole wilderness of warning”.

These figures reveal the problems of experimental syngas measurements. They show good and bad correlation of results, periods of time when external influences had an impact on the final result, outages of an analyser and also variations in syngas quality. These results were obtained on a plant not optimized for gasification.

Figure 1: An example of the syngas measuring results showing continuous 5-sec readings from two independent analysers (gas component analyser and calorimeter) for a period of 12 hours (7am – 7pm), and two bag sample results (lab result).

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Figure 2: An example of the syngas measuring results showing continuous 5-sec readings from two independent analysers (gas component analyser and calorimeter) for a period of 12 hours (9am – 9pm), and two bag sample results (lab results).

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Control intelligence reduces boiler operating costs Controls 4 Steam looks at the issue of water treatment for steam boilers and explains why a more intelligent approach is needed to protect against corrosion and improve energy efficiency

I

mproving boiler energy efficiency through water treatment is the title of ‘Good Practice Guide 221’ (BPG221) first published in 1998 by the Department of Environment under the ‘Energy Efficiency Best Practice Programme’. The aim was to provide guidance on how to achieve energy savings through the application of good water treatment.

It highlighted the problems associated with scale and sludge which impede the operation of the level controls, cause overheating and reduce boiler efficiency. With high fuel prices and increasingly compelling research about Climate Change it has more relevance in 2016 than it had when it was first published.

Correct feedwater treatment plays a significant role in the efficient operation and safety of boilers; reducing the risk of failure whilst saving energy, reducing fuel, water and maintenance costs.

Yet, despite the evidence to the contrary, the perception appears to be that providing chemicals are added to the feedwater and boilers are blown down to limit the solids content then all will be well.

History paints a different picture Extensive studies of boiler feedwater systems have shown that the present method of manually setting the stroke length and pulse rate of a dosing pump, ‘Open Loop’, allowing chemicals to be added does not prevent scaling or corrosion of the heat transfer surfaces nor does it meet the current requirements of HSE INDG436, BS EN 12953-10:2003 or CEA/SAFed BG01. There is no intelligence that allows the dosing pump(s) to change the injection rate in response to changing water quality or temperature.

Without feedback there is no control Whether steam is used as part of a manufacturing process or to provide heating and hot water in hospitals, steam demand varies hour to hour and with it the condensate and make-up water volumes: having a direct effect on the temperature and chemical composition of the stored water. Changes in the water temperature or quality will affect the pH, conductivity and oxygen content.

Changes that cannot be recorded with a manual daily water test.

Incorrect oxygen treatment causes corrosion (oxygen pitting) of the boiler tubes and steam distribution system. Scale formation reduces efficiency conservative estimates (BGP221) are between 2% and 5% of the fuel bill.

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Internal water treatment Involves adding chemicals to the boiler water and is covered by British Standard BS 2486:1997 & BS EN 12953-10:2003 which supersedes it. With improvements in control systems, manning levels have reduced and the importance of water treatment as part of the safe and efficient operation of steam boilers has been largely overlooked.

The maximum steam output and fuel efficiency of a boiler at any given pressure is governed by the rate at which heat can be supplied and transferred in the boiler. Impurities in the feedwater cause scale or chemical deposits to form and reduce the rate of heat transfer from the tube walls to the water, overheating the metal surfaces whilst reducing the steam output.

Boiler efficiency falls and the possibility of failure increases.

The treatment should be monitored and adjusted relative to the actual steam evaporation rate throughout the course of each day.

Oxygen Control The most common source of corrosion in boiler systems is the amount of dissolved oxygen that remains in the boiler feedwater after treatment. Dissolved oxygen reacts with the iron in the boiler system to form oxides and so must be removed.

This is achieved by adding oxygen scavenging chemicals to the stored feedwater. The problem is that the whole ethos is based on a fixed feedwater temperature. Rarely if ever is the boiler feed tank temperature constant, with a fixed chemical feed rate there will be times when the water is under or over dosed.

Under dosing leads to corrosion attack: even small concentrations of dissolved oxygen can cause serious corrosion problems. Over dosing increases the Total Dissolved Solids (TDS) level resulting in higher blowdown rates and wasting energy.

Unfortunately oxygen corrosion is not uniform across the entire metal surface, it is identified by well-defined pits or a very pockmarked surface; the pits vary in shape but have very sharp edges at the surface.

An active oxygen pit has a cap of red/brown oxide which when removed reveals black iron oxide within the pit. Because the pits penetrate very deep within the metal, oxygen corrosion can result in rapid boiler failure.

The correct dosing of oxygen treatment based on actual requirements eliminates pitting due to oxygen attack, eliminates excessive chemical usage and reduces surface blowdown.

pH Control For effective, economic boiler operation, close control of the boiler water pH is a necessity. The safe, recommended, pH range for steam boilers is between 10.5pH and 12.0pH. Boiler water with pH

Extract from Good Practice Guide 221 4.0

70

3.5

Ca lci

50 40

um

i Calc

30 20

2.5

te lpha

Su

2.0

hate hosp P m u esi xide Magn Iron o te phospha Calcium

1.5

Efficiency loss (%)

3.0

um

60

Ca rbo na te

80

Silic ate

Increase in Metal Temp. Deg C

Improving boiler energy efficiency through water treatment

1.0 0.5

10

0

0 0

0.25

0.5

0.75

Deposit Thickness (mm) Graphical Representation of the effects of scale on boiler efficiency Chemical constituents of boiler scale can be any one or a combination of all of the above

of 10.5 contributes 12.6mg/l towards the boiler TDS, whilst at a pH of 12.0 it increases to 400mg/l and at 12.5pH the value is 1264.9 mg/l a 100 fold increase.

Take a 5T boiler, containing approximately 8,200 litres of water, the amount of caustic required to maintain a pH of 10.5 would be 0.7 litres whilst at 12.5pH that rises to 69.1 litres of caustic contributing 1264.9mg/l towards the boiler TDS level.

Controlling the pH towards the bottom end of the safe range significantly reduces the quantity of chemicals used and the effect the pH has on the boiler blowdown rate.

Stable pH levels are a prerequisite for accurate TDS control: pH maintenance of the feed, boiler and condensate system is essential for corrosion control.

Dissolved Solids (TDS) Control Even though we add chemicals to the feedwater to protect the boiler from scale and corrosion, they do add to the ‘Total Dissolved Solids’ (TDS) content. As steam is evaporated the concentration of TDS increases in the boiler water. If the TDS concentration is allowed to get too high then carryover of boiler water will occur. This carryover can cause serious damage to the steam and condensate systems through corrosion and deposition on heat transfer surfaces.

In order to limit the TDS concentration it is normal to drain off, (or “blowdown”) boiler water and replace it with relatively low TDS feedwater. Excessive blowdown is very costly in terms of lost energy and water treatment chemicals.

Automatic TDS control ensures that the boiler water is maintained at the optimum level. For every 1% reduction in boiler blowdown approximately 0.19% reduction in fuel is achievable depending on feedwater temperature and boiler operating pressure.

The conductivity of water is temperature dependent: every 1°C temperature variation introduces a 2% error in the measured value. For accurate control temperature compensated measurements are imperative.

Condensate Monitoring Is now part of the unmanned boiler operation requirement as stated in CEA/SAFed BG01.

Oxygen and carbon dioxide are absorbed by the cooling condensate causing it to become acidic. In order to ensure the effectiveness of feedwater treatment and safeguard the condensate system from corrosive attack the pH and conductivity of the returning condensate should be monitored.

Given that in protecting the boiler from corrosion and scale we adversely affect the dissolved and suspended solids, it is in the interest of the operator to ensure that feedwater quality is correct throughout the system; from the incoming cold feed to the returning condensate. In so doing we ensure the cleanliness of the heat transfer surfaces and the overall efficiency of the boiler.

Minimising the Risk of Boiler failure, reducing the environmental impact; saving energy and lowering chemical costs.

Find out more by contacting Controls 4 Steam. Tel: 01254 841769 Email: sales@controls4steam.co.uk www.controls4steam.co.uk

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University Teaching Hospital goes green UHSM reaps benefits of RHI

U

niversity Hospital of South Manchester NHS Foundation Trust (UHSM) is a major acute teaching hospital trust providing services for adults and children at Wythenshawe Hospital and Withington Community Hospital, as well as community services. As a major University Teaching Hospital, UHSM provides many specialist services for patients across Greater Manchester and beyond. Wythenshawe was the first NHS hospital to install biomass boilers; their capacity to reduce carbon emissions by 3,400 tonnes each year is one of the reasons why UHSM has staked a claim to the title ‘Britain’s Greenest Hospital’.

“The guidance, advice and support from Endress+Hauser was instrumental in the success of this scheme.”

Mark Foden, Energy & Environment Manager, UHSM

The challenge In 2010, in an effort to reduce carbon emissions and improve sustainability, UHSM’s Wythenshawe Hospital replaced a 4.2 MW gas boiler with two 2.2 MW capacity biomass boilers. The boilers burn 20 tonnes of wood chip a day, all sustainably sourced from within a 60-mile radius of the hospital. Utilising biomass allowed the hospital to reduce its carbon emissions in line with the Carbon Reduction Commitment (since replaced by the CRC Energy Efficiency Scheme), a mandatory

Consult the experts in energy metering For all matters concerning steam and energy metering, turn to Endress+Hauser. Whether you need help to determine the fuel-to-steam efficiency of your current system, heat metering to meet Renewable Heat Incentive (RHI) accreditation or even help with a new RHI application, we have the right solution for you. With a wealth of experience in providing compliant metering, consultancy services and reporting solutions, you’re in expert hands.

Endress+Hauser Ltd Floats Road Manchester M23 9NF

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CEA Yearbook 2016/2017

Tel: 0161 286 5000 Fax: 0161 998 1841 info@uk.endress.com www.uk.endress.com

RHI-compliant steam metering system

RHI-compliant condensate metering system

carbon emissions reduction scheme for large energy-intensive organisations in the public and private sectors.

Endress+Hauser helped UHSM develop a plan to locate and install the necessary metering, including five RHI-compliant steam heat metering systems and three condensate heat metering systems. A series of controlled shutdowns took place on Friday and Saturday nights to clear asbestos from the steam pipework with minimal disruption to patients and hospital staff.

After all the work was completed, UHSM was awarded RHI accreditation in February 2015.

The installation of the biomass boilers was prompted by the introduction of the Renewable Heat Incentive (RHI). Officially launched in November 2011 by the UK’s gas and electricity regulator Ofgem, the RHI aims to further encourage businesses and public sector organisations to generate heat from renewable technologies. The RHI pays participants of the scheme for generating renewable heat and using it in their buildings and processes. But proving that your organisation meets the requirements of the RHI can be difficult, as eligible heat output has to be determined and verified. “We’ve got quite a complicated site that has developed over the last 100 years or so, resulting in a whole maze of steam pipework delivering heat,” explains UHSM’s Energy and Environment Manager, Mark Foden. “After our eligibility for the scheme was confirmed I spoke to quite a few people to try to determine how to meet the RHI requirements but nobody could give me a definitive answer or really much support. They all just wanted to sell me their meters and lots of them – but they couldn’t necessarily demonstrate how that would meet Ofgem’s requirements and release the payments.”

Endress+Hauser also supplied a data collection panel and a cloud-based data management software solution which tracks eligible heat output every 15 minutes, removing the need for monthly or quarterly manual readings. Automatic loss of data alarms can also generate warnings of possible equipment fault.

“It’s really important for us to be able to see what proportion of our heat is being supplied by biomass,” confirms Mark Foden.

“The software helps me demonstrate how we can increase efficiency and predict payments.”

The benefits

The solution

As well as the obvious benefits to the environment, receiving payments from the RHI scheme has had a huge financial impact for the hospital; it’s expected that over a 20 year period the subsidy will be worth in excess of £6 million for the Trust, which will be reinvested.

Two main criteria have to be fulfilled in order to successfully gain RHI accreditation and receive tariff payments for steam boilers. The first is that eligible heat output has to be determined using RHI-compliant metering. Secondly, applicants need to commission an Independent Report on Metering Arrangements (IRMA), in order to verify to Ofgem that they have eligible metering arrangements in place, such as appropriately located and installed meters. Endress+Hauser was able to carry out this consultancy on UHSM’s behalf, even accompanying them to a meeting with Ofgem to make their case for accreditation.

“Endress+Hauser’s energy efficiency manager, Wes Allen, and I put in a lot of work ahead of that meeting,” explains Mark Foden. “When Wes came to site he was much more proactive in working out what it was we needed and not just what he could sell me; it was a breath of fresh air.”

The hospital is now receiving 2p/kWh produced, after the government doubled the tariff for large-scale biomass in April 2014. It now plans to add wood chip biomass consumption and gas meters to the data collection and reporting solution to monitor the cost of steam to individual building and parts of the hospital. Fuel cost analysis and comparisons can then be determined for wood chip and natural gas fuels. Endress+Hauser is also helping UHSM to determine the fuel economy and fuelto-steam efficiency of the biomass boilers by adding additional parameters to the data collection system. “The guidance, advice and support from Endress+Hauser was instrumental in the success of this scheme,” says Mark Foden. “Their knowledge of the RHI scheme and how to interpret the regulations made the whole process much more straightforward.”

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Boilerhouse risk assessments deliver real value Far from being a pointless exercise, a Boilerhouse Technical Risk Assessment should be seen as an opportunity to look closely at your boilerhouse to ensure it is being operated safely, efficiently and reliably, writes Derry Carr, Chairman of Council, CEA.

W

hen risk assessments are mentioned, the common response from many engineers in industry is, eyes going skywards and mumbled expletives. It is often seen as extra paperwork, and of little point. In fact it does have a point, for the following reasons taken from HSE guidance: A risk assessment is a systematic examination of a task, job or process that you carry out at work for the purpose of: • Identifying the significant hazards that are present (a hazard is something that has the potential to cause someone harm or ill health).

• Deciding if what you have already done reduces the risk of someone being harmed to an acceptable level, and if not • Deciding what further control measures you must take to reduce the risk to an acceptable level.

Risk Assessments should also be carried out to satisfy the requirements of legislation but above all to ensure the Health & Safety of employees.

So, as it quite clearly states, it is a legal requirement!

its own BTRA. The HSE has no problem with this, provided recommendations are acted upon.

Frequently there is a positive outcome to the BTRA, and not just legal compliance. When a boilerhouse is scrutinised during a BTRA, common practices are looked at in detail. Some may be a risk to the operation. An example of this may well be erratic steam demand, causing the boiler to cycle from low loads to high loads at short notice. This could be reduced by educating process workers to bring steam equipment on line slowly as opposed to just swinging the steam valve open. The result of this could be: a) The boiler does not struggle to keep up with production demand b) The chances of water carry over are reduced and potentially eradicated c) The chances of water hammer in the steam system are reduced and potentially eradicated d) There is likely to be a reduction in fuel cost As most engineers know the boilerhouse is often overlooked, and if as is so often the case you are challenged by the hierarchy as to why you need to spend money on the BTRA and its outcomes, the following is always a good reply: • Efficiency goes straight to the bottom line – fuel is expensive!

• Reliability – downtime costs money!

• Safety, accidents are very expensive and comes straight from the bottom line!

The cheapest and safest way to run any boilerhouse is to build and run it properly.

Health and Safety professionals often think they are responsible for all risk assessments, however, in the case of a Boilerhouse Technical Risk Assessment (BTRA) it is most likely they will not be qualified for the task.

The best BTRAs are carried out by teams, drawing knowledge from different aspects of the operation. It is a good idea to include somebody not involved with boiler operations who may well see things differently. It is also advisable to consult with manufacturers to ensure that various items of equipment are: a) Right for the job b) Correspond with the existing or desired manning levels c) Are being operated correctly It is quite common to employ an external consultant to carry out the BTRA or to assist and guide the assessment team in writing

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Boilerhouse technical risk assessments can reveal surprising ways to improve energy efficiency and productivity

Low NOx, combustion Low NOx,high highefficiency efficiency combustion Biomass Biomass

Biogas Biogas

Liquid Biofuels Liquid Biofuels

Fossil FuelsFuels Fossil

Dunphy axialflow air flow burners deliver Dunphy axial air burners deliver consistently reliable combustion with high consistently reliable combustion with high efficiency and ultra low NOx levels which efficiency and ultra NOx with levels are fullylow compliant the which are fully compliant with the requirements of the Large Combustion requirements of the Combustion PlantLarge Directive.

Plant Directive.

Digitally managed simultaneous firing safely controls the combustion of traditional fuels Digitally managed simultaneous safely supplemented by fuels withfiring fluctuating controls the combustion of traditional fuels volumes and CVs.

supplemented by fuels with fluctuating volumes Dunphy singleand andCVs. multi fuel burners

efficiently combust gas, oils, B5 to B100 biodiesel, pure and waste vegetable oils, Dunphy single and multi fuel burners biomass and liquid biofuels.

Our burners are specified for all types of heat, steam, CHP, district heating, Our to burners for all types of waste energy are andspecified WWT processes.

efficiently combust gas, oils, B5 to B100 heat, steam, CHP, district heating, biodiesel, pure and waste vegetable oils, For further information, contact sharon.kuligowski@dunphy.co.uk waste to energy and WWT processes. biomass and liquid biofuels. www.dunphy.co.uk

01706 649217

For further information, contact sharon.kuligowski@dunphy.co.uk www.dunphy.co.uk 01706 649217

AQUAnet™

Unattended, Reduced Cost. Revolutionary AQUAnet™ is an automatic monitoring & chemical dosing system revolutionising the steam industry. AQUAnet™ enables you to achieve compliance with BS EN 12953-10:2003 and SAFed/CEA BG01 for unattended boiler operation, reducing the cost of steam generation.

AQUAnet™

     

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Continuous monitoring and control Correct chemical application Constant system performance monitoring Automatic corrective actions Economic use of chemicals and water Performance history

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Improve boiler water and steam quality Minimise surface blowdown Reduce waste and maintenance costs Save energy Reduce fuel costs

AQUAnet™

Controlling the Key Elements of Boiler Feedwater

Contact Us

Feel free to get in touch, anytime. We are here to help.

Phone: +44 (0) 1254 841769 Email: info@controls4steam.co.uk Web: www.controls4steam.co.uk

CEA Yearbook 2016/2017

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CEA Members guide Autoflame Engineering Ltd Unit 1-2, Concorde Business Centre Airport Ind Est, Wireless Road Biggin Hill, Kent, TN16 3YN

A1 Biomass Fuels Limited Whitfire Yard, Church Lane Farington Moss, Preston, PR26 6RD Tel: +44 (0)1772 805995 Email: bill@whitfuel.com Web: www.whitfuel.com

Tel: +44 (0)845 8722002 Email: zdsa@autoflame.com Web: www.autoflame.com

A S Technical Solutions Ltd Unit 12C Old Bridge Way Shefford Industrial Estate, Sheffield Bedford, SG17 5HQ

Aylan Associates Netherclose, 15 Langwith Road Collingham, Wetherby, LS22 5DH Tel: +44 (0)1937 579805 Email: aylanassociates@aol.com

Tel: +44 (0)1462 414255 Email: andy@astech-ltd.com Web: www.ecomproducts.co.uk

Blue Flame Associates Unit 8 High Carr Network Centre, Millennium Way, High Carr Business Park, Newcastle Under Lyme, Staffordshire, ST5 7XE

AB Mauri Products Sugar Way, Peterborough, PE2 9AY Tel: + 44 (0)1733 871 500 Email: steve.bargate@abmauri.com Web: www.abmauri.com

Tel: +44 (0)1782 576810 Email: training@blueflameassociates.com Web: www.blueflameassociates.com / www.trainingassessment.com

AB Sugar Plc Sugar Way, Peterborough, PE2 9AY

Bosch Commercial & Industrial Heating Cotswold Way, Worcester, WR4 9SW

Tel: +â&#x20AC;¨44 (0)1733 563171 Email: david.gent@absugar.com Web: www.britishsugar.co.uk

Tel: +44 (0)330 123 3004 Email: commercial.enquiry@uk.bosch.com Web: www.bosch-industrial.co.uk

AG Gas London Alain Grangeret MEI CEng Chartered Energy Engineer 76 Middleham Road London, N18 2SD Tel: +44 (0)203 287 3701 Email: aggaslondon@gmail.com Darren Collins Tel: +44 (0)7714 637308 Email: Darren.collins@aig.com Air and Water Consultants Limited Tel: +44 (0)7973 891196 Email: airandwater@orange.net Airedale Training Tel: +44 (0)7539 829069 Email: airedaletraining@aol.co.uk Web: airedaletraining@aol.co.uk American Embassy 24 Grosvenor Square London, W1K 6AH Tel: +44 (0)20 7499 9000 Web: www.london.usembassy.gov Andrew Bidston Tel: +44 (0)7933 038666 Email: andrew.bidston@icloud.com Aquanet International Limited Unit 7 & 8, The Galloway Centre Hambridge Lane, Newbury, RG14 5TL Tel: +44 (0)1635 580680 Email: clive@aquanetint.com Web: www.aquanetint.com

British Industrial Furnace Constructors Association (BIFCA) National Metalforming Centre, 47 Birmingham Road West Bromwich, West Midlands, B70 6PY No. 565189

Tel: +44 (0) 121 601 6350 Email: enquiry@bifca.org.uk Web: www.bifca.org.uk British Sugar Plc Sugar Way, Peterborough, PE2 9AY Tel: +44 (0)1733 563171 Web: www.britishsugar.co.uk Brocklesby Ltd Estate office, Brocklesby Park, Grimsby North East Lincolnshire, DN41 8PN Tel: +44 (0)1469 560214 Web: www.brocklesby.co.uk Byker District Heating Newcastle City Council 142a Raby Street, Newcastle upon Tyne NE6 2BY Tel: +44 (0)191 278 8600 Email: duncan.robson@newcastle.gov.uk Web: www.yhn.org.uk Byworth Boilers Ltd Parkwood Boiler Works Parkwood Street, Keighley West Yorkshire, BD21 4NW Tel: +44 (0)1535 665225 Email: sales@byworth.co.uk Web: www.byworth.co.uk

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

Calor Gas Limited Athena House, Athena Drive Tachbrook Park, Warwick CV34 6RL

Tel: +44 (0)161 2662279 Email: isutherland@armstronginternational.eu Web: www.armstronginternational.com

Tel: +44 (0)1926 318764 Email: khoulden@calor.co.uk Web: www.calor.co.uk

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CEA Members guide CB Cranshaw

Derry Carr Industrial Boiler House Safety

Charles Cruttenden

Tel: +44 (0)7774 150607 Email: derrycarr53@outlook.com

Certuss UK Ltd Unit 45, Gravelly Industrial Park Birmingham, B24 8TG

Duncan Moncrief fe Tel: +44 (0)7855 426017 Email: duncan.moncrieffe@imtech.co.uk

Tel: +44 (0)121 3275362 Email: nick.wilson@certuss.co.uk Web: www.certuss.co.uk

Dunphy Combustion Queensway Rochdale, Lancashire, OL11 2SL

Chris Newton Steam Services Geraint Cottage Geraint, Llangollen, LL20 8AA

Tel: +44 (0)1706 649217 Email: sharon.kuligowski@dunphy.co.uk Web: www.dunphy.co.uk

Tel: +44 (0)1978 860578 Email: chrisnewtonsteamservices@fsmail.net Web: www.chrisnewtonseamservices.co.uk

Ecoflam UK Suite 3, The Crown House, Blackpole East, Blackpole Road, Worcester, WR3 8SG

Cochran Ltd Newbie works Annan, Dumfries & Galloway, DG12 5QU

Tel: 01905 788010 Email: m.bingley@ecoflam.co.uk Web: www.ecoflam-burners.com and www.ecoflam.co.uk

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

Element Consultants Ltd 45 Breckenhill Road Ballyclare, County Antrim, BT39 0TB

Combustion Technology Limited Tel: +44 (0)78500 853222 Email: clivetchamberlain@aol.com

Tel: +44 (0)28 93340311 Email: alinicol@elementsconsultants.co.uk Web: www.elementsconsultants.co.uk

Confederation of Paper Industries (CPI) 1 Rivenhall Road Swindon, Wiltshire, SN5 7BD

Emerson Process Management Ltd Meridian East, Leicester LE19 1UX

Tel: +44 (0)1793 889632 Email: dmorgan@paper.org.uk Web: www.paper.org.uk

Tel: +44 (0)116 282 2822 Email: sam.thiara@emerson.com Web: www.emersonprocess.com

Controls 4 Steam UK Ltd Suite 1, Blackburn Rovers Enterprise Centre Ewood Park, Blackburn, Lancashire, BB2 4JF

EMK Education & Environmental Services Ltd Tel: +44 (0) 1244 641 606 Email: emkennedy@tiscali.co.uk Web: www.emk-ltd.co.uk

Tel: +44 (0)1254 841769 Email: chris.reid@controls4steam.co.uk Web: www.controls4steam.co.uk Danstoker (UK) Ltd 2 Studio Court, Queensway Bletchley, Milton Keynes, MK2 2DG Tel: +44 (0)7966 099124 Email: ac@danstoker.com Web: www.danstoker.com

Emvertec Ltd Millenium Works Valletta Street, Hull, HU9 5NP Tel: +44 (0)1386 831582 Email: j.vernon@emvertec.co.uk Web: www.emvertec.co.uk Endress+Hauser Ltd Floats Road, Manchester, M23 9NF

David Graham 30 Ballaquark Walk Douglas, Isle of Man, IM2 2EZ

Tel: +44 (0)161 286 5000 Email: info@uk.endress.com Web: www.uk.endress.com

Tel: +44 (0)1624 614742 Email: david.graham@manx.net

Energy & Environmental Solutions Nithsdale, Broadway Road Windlesham, GU20 6DA

Deep Water Blue Ltd Business & Technology Centre Bessemer Drive, Stevenage, Herts, SG1 2DX

Mob: +44 (0)7860 600477 Email: paulw2000@btinternet.com

Tel: +44 (0)870 460 2780 Email: info@deepwaterblue.co.uk Web: www.deepwaterblue.co.uk

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

Dermot Hogan Consultant Engineer Core Mechanical

Tel: +44 (0)1273 480667 Email: csnook@energytechnologycontrol.com Web: www.energytechnologycontrol.com

Tel: +44 (0)1832 272858 Email: dermotchogan@yahoo.com

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CEA Members guide Enersol Flomar Fletcher House, Marlsborough Drive Fleckney, Leicestershire, LE8 8UR Tel: +44 (0)116 240 3430 Email: leigh.ridlington@enersolcorp.com Web: www.enersolflomar.com Enspec Engineering (UK) Ltd Hamilton House, 11 Dawpool Drive Bromborough, Wirral, Merseyside, CH62 6DE Tel: +44 (0)151 334 3821 Email: helpdesk@enspectechnology.com Web: www.enspectechnology.com Envirocare St Blaise House, Vaughan Street, Bradford BD1 2LL Tel: +44 (0)1274 738668 Email: info@envirocare.org Web: www.enirocare.com EOGB Energy Products Ltd 5 Howard Road, Eaton Socon St Neots, Cambs, PE19 8ET Tel: +44 (0)1480 477066 Email: martin.cooke@eogb.co.uk Web: www.eogb.co.uk ES Pipelines Ltd Hazeldean, Station Road Leatherhead, Surrey, KT22 7AA Tel: +44 (0)1372 227560 Email: nickc@espipelines.com Web: www.espipelines.com

Gas & Environmental Services Ltd Tel: +44 (0)1707 373751 Email: kevin@gesuk.com Web: www.gesuk.com Gas Solutions Tel: +44 (0)7500 555 535 Email: info@gas-solutions.co.uk Gavin Hoole Kennington Road Lambeth, London, SE11 6BY Tel: +44 (0)20 7498 9734 Email: gavin_hoole@hotmail.com GEMchem Ltd 1 John Street, Bristol, BS1 2HR Tel: +44 (0)117 922 5544 Email: david.green@gemchem.co.uk Web: www.gemchem.co.uk Geof f Castles Boiler Services Ltd 97a Belfast Road Carrickfergus, Co Antrim, BT38 8BX Tel: +44 (0)2893 368949 Email: michael@geoffcastles.co.uk Web: www.geoffcastles.co.uk Geof frey Robinson Ltd Macklin Avenue, Cowpen Industrial Estate Billingham, TS223 4ET Tel: +44 (0)1642 370500 Email: gr@geoffreyrobinson.co.uk Web: www.geoffreyrobinson.co.uk

Facultatieve Technologies Ltd Moor Road Leeds, West Yorkshire, LS10 2DD

Global Energy Associates Ltd Gardeners House, South End Great Rollright, Chipping Norton Oxon, OX7 5RR

Tel: +44 (0)113 276 8888 Email: andrew.mallalieu@facultatieve-technologies.co.uk Web: www.facultatieve-technologies.co.uk

Tel: +44 (0)1608 730878 Email: richard.marrow@globalenergy.co.uk Web: www.globalenergy.co.uk

Fans and Blowers Ltd Commerce Way, Walrow Industrial Estate Highbridge, Somerset, TA9 4AG

Guernsey Electricity Electricity House, PO Box 4 North Side View, Guernsey Channel Islands, GY1 3AD

Tel: +44 (0)1278 784004 Email: sally@fansandblowers.com Web: www.fansandblowers.com Flowserve Gestra GB Ltd Gestra - Power Division Euro House, Abex Road Newbury, Berkshire, RG14 5EY Tel: +44 (0)1635 46999 Email: jchavda@flowserve.com Web: www.flowserve.com Fulton Boiler Works (GB) Ltd 5 Fernhurst Road Fishponds, Bristol, BS5 7FG Tel: +44 (0)117 972 3322 Email: sales@fulton.co.uk Web: www.uk.sales.office@fulton.com

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CEA Yearbook 2016/2017

Tel: +44 (0)7781 411281 Email: sam.hubbard@electricity.gg Web: www.electricity.org Hamworthy Combustion Engineering Ltd Fleets Corner, Poole, Dorset, BH17 0LA Tel: +44 (0)1202 662700 Email: info@hamworthy-combustion.com Web: www.johnzinkhamworthy.com Harris Pye Engineering Ltd Hangers 5+6, Bona Road, Llandow South Wales, CF71 7PB Tel: +44 (0)1446 720066 Email: hpuk@harrispye.com Web: www.harrispye.com

Engineering operations

CEA Members guide Heart of England NHS Trust Web: www.heartofengland.nhs.uk HeatSol Technology Ltd HeatSol House, 28 High Street Droitwich Spa, Worcestershire, WR9 8ES Tel: +44 (0)1905 773377 Email: jim.findlay@heatsol.co.uk Web: www.heatsol.co.uk ICS Cool Energy Ltd ICS Cool Energy House, Calmore Industrial Estate Southampton, SO40 3RY Tel: +44 (0)800 774 7403 Email: info@icscoolenergy.com Web: www.icscechillerhire.co.uk

Kiwa GASTEC Kiwa House, Malvern View Business Park Stella Way, Bishops Cleeve, Cheltenham, GL52 7DQ Tel: +44 (0)1242 677877 Email: enquiries@kiwa.co.uk Web: www.kiwa.co.uk LAMTEC GmbH & Co. KG UK Office 10 Quarry Bank, Tonbridge Kent, TN9 2QZ Tel: +44 (0)1732 445001 Mob: +44 (0)7415 327038 Email: mick.barstow@lamtec.de Web: www.lamtec.de

IHEEM 2 Abingdon House, Cumberland Business Centre Northumberland Road, Portsmouth, PO5 1DS

Limpsfield Combustion Unit 7 Concorde Business Centre Airport Industrial Estate, Main Road Biggin Hill, Kent, TN16 3YN

Tel: +44 (0)23 9282 3186 Email: chris.parker@iheem.org.uk Web: www.iheem.org.uk

Tel: +44 (0)1959 576633 Email: sales@limpsfield.co.uk Web: www.limpsfield.co.uk

INCINER8 International Unit 2, Canning Road Industrial Estate Canning Road, Southport, PR9 7SN

Lubron UK Ltd Lubron House, 8 Challenge Way Hythe Hill, Colchester, CO1 2LY

Tel: +44 (0)1704 532900 Email: claire@inciner8.com Web: www.inciner8.com

Tel: +44 (0)1206 866444 Email: info@lubron.co.uk Web: www.lubron.co.uk

ISIS Fluid Control Ltd Station Yard, The Leys Chipping Norton, Oxon, OX7 5HZ

Machinery Safety Compliance Services Ltd 15 Bentley Court, Paterson Road Wellingborough, Northants, NN8 4BC

Tel: +44 (0)1608 645755 Web: www.isissteam.com

Tel: +44 (0)7795 152422 Email: info@puwer.co.uk Web: www.puwer.co.uk

J & S Engineers (EUR) Ltd 35 Barrington Road Sutton, Surrey, SM3 9PR Tel: +44 (0)20 8641 2217 Email: js.engineers@btconnect.com Jason Roberts Email: jason.roberts@westons-cider.co.uk JBC Industrial Services Ltd Howley Park Road East Morley, Leeds, LS27 0SW Tel: +44 (0)113 220 3830 Email: info@jbcmail.co.uk Web: www.jbcindserv.co.uk

MWA Technology Ltd Wharton Street Industrial Estate Birmingham, West Midlands, B7 5TR Tel: +44 (0)121 327 7771 Email: martin.wardell@btclick.com Web: www.mwatechnology.com M&M Training Fletcher House, Marlborough Drive Fleckney, Leicestershire, LE8 8UR Tel: +44 (0)116 240 3430 Email: mmtraining@enersolcorp.com Web: www.enersolflomar.com

Mr John Wealthy Email: jawbkk@aol.com

MCL Energy Ltd Metcalfe House, Park View Langwith, Nottinghamshire, NG20 9DE

Johnsons Apparelmaster Pittman Way, Fulwood, Preston Lancashire, PR2 9ZD

Tel: +44 (0)1623 741940 Email: enquiry@mclenergy.co.uk Web: www.mclenergy.co.uk

Tel: + 44 (0)1455 232398 Email: davejackson@johnsonplc.com Web: www.apparelmaster.co.uk

M K Mechanical Services Ltd 10 St Hildaâ&#x20AC;&#x2122;s Terrace Whitby, North Yorkshire, YO21 3AE

Kaye & Associates Ltd Albion Mills House, 5 Marlborough Close Charlton Kings, Cheltenham, Glos, GL53 7RY

Tel: +44 (0)1947 600677 Email: info@mkmechanical.co.uk Web: www.mkmechanical.co.uk

Tel: +44 (0)1242 513747 Email: kaye777@btinternet.com

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CEA Members guide Museum of Science & Industry Web: www.mosi.org.uk MWW Engineering Inspections Ltd Penniche Pentwyn Parc, Penaullt Monmouth, NP25 4SP Tel: +44 (0)7737 986617 Email: mike@mww-inspect.com Web: www.mww-inspect.com Neil Riches IEng; MIPlantE; MSOE; GCGI Little Orchard, 40 Mount Road Penn, Wolverhampton, WV4 5SW Tel: +44 (0)1902 345233 Mob: +44 (0)7710 444842 Email: neil.riches@btinternet.com NHS Grampian Estates and Facilities Office Aberdeen Royal Infirmary, Foresterhill Aberdeen, AB25 2ZB Tel: +44 (0)1224 552418 Email: graham.mutch@nhs.net Web: www.nhsgrampian.org

Peter Pearson Tel: +44 (0)7717 200916 Email: peter@twock.com Pillinger of Ireland Unit 13, Westlink Business Park Doughcloyne Industrial Estate Sarsfield Road, Cork Tel: +44 (0)21 434 8950/51 Email: info@pillinger.ie Web: www.pillinger.ie RG Combustion Ltd Unit 12, Newport Business Park Barry Way, Newport, Isle of Wight, PO30 5GY Tel: +44 (0)1983 526111 Email: info@rgcombustions.co.uk Web: www.rgcombustions.com Richard Harling Email: richardharling1@gmail.com Riello Ltd The Ermine Centre, Ermine Business Park Huntingdon, Cambs, PE29 6WZ

NHS Highland Web: www.nhshighland.scot.nhs.uk

Tel: +44 (0)1480 432144 Email: info@rielloburners.co.uk Web: www.rielloburners.co.uk

Nu-way (Enertech Ltd) Ten Acres, Berry Hill Industrial Estate Droitwich, Worcestershire, WR9 9AQ

Robertson Robertson House Castle Business Park, Stirling, FK9 4TZ

Tel: +44 (0)1905 794331 Email: info@nu-way.co.uk Web: www.nu-way.co.uk

Tel: +44 (0)1786 431600 Web: www.robertson.co.uk

OIC Valve Covers Ltd Unit 9, Oakfield Industrial Estate, Eynsham, Oxon, OX29 4TH Tel: +44 (0)1865 882881 Web: www.oicvalvecovers.co.uk

Robey Boiler Supplies and Services Ltd Tel: +44 (0)121 543 0000 Robinson Biomass UK Email: simon@robinsons-uk.co.uk

Orbital Gas Systems Ltd Cold Meece, Swynnerton Nr Stone, Staffordshire, ST15 0NQ

Rural Energy Unit 21 Burrough Court Burrough-on-the-Hill Melton Mowbray, LE14 2QS

Tel: +44 (0)1785 857000 Email: enquiries@orbital-gas.com Web: www.orbital-uk.com

Tel: +44 (0)203 189 0676 Email: paul.clark@ruralenergy.co.uk Web: www.ruralenergy.co.uk

Palm Paper Limited Poplar Avenue Saddlebow Industrial Estate, Kingâ&#x20AC;&#x2122;s Lynn Norfolk, PE34 3AL

SAACKE Combustion Services Ltd Langstone Technology Park Langstone Road, Havant, Hamps, PO9 1SA

Tel: +44 (0)1553 782222 Email: enquiries@palmpaper.co.uk Web: www.palmpaper.co.uk Paperback Recycling Ltd Unit 1-2 Parkway Zone 2 Deeside Industrial Estate Deeside, Flintshire, CH5 2NS Tel: +44 (0)1244 833370 Email: info@paperbackrecycling.co.uk Web: www.paperbackrecycling.co.uk

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Tel: +44 (0)23 9233 3813 Email: p.kemp@saacke.com Web: www.saacke.com Sembcorp Utilities (UK) Ltd PO Box 1985, Wilton International Middlesbrough, TS90 8WS Tel: +44 (0)1642 212798 Email: scott.taylor@sembcorp.com Web: www.sembcorp.co.uk

CEA Members guide Society of Operations Engineers (SOE) City Hall Building, 64 Victoria Street 8th floor, London, SW1E 6QP

TLV Euro Engineering UK Ltd Star Lodge, Montpellier Drive Cheltenham, Gloucester, GL50 1TY

Tel: +44 (0) 20 7630 1111 Email: soe@soe.org.uk Web: www.soe.org.uk

Tel: + 44 (0)1242 227223 Email: sales@tlv.co.uk Web: www.tlv.com/global/UK/

Suez Recycling and Recovery UK Diamond Street, Huddersfield, West Yorkshire, HD1 6BZ

Tomatin Distillery Co Ltd Inverness-shire Scotland, IV13 7YT

Tel: +44 (0)7969 618066 Email: robin.walsh@sita.co.uk Web: www.sita.co.uk

Tel: +44 (0)1463 248148 Email: info@tomatin.co.uk Web: www.tomatin.com

SMC Pneumatics (UK) Ltd Vincent Avenue, Crownhill Milton Keynes, Buckinghamshire, MK8 0AN

Torque Engineering Limited Torque Engineering Unit 10, Stirlin Court Saxilby Enterprise Park Lincoln, LN1 2LR

Tel: +44 (0)1908 555170 Email: tshannon@smcpneumatics.co.uk Web: www.smcpneumatics.co.uk Spiers Engineering Safety Web: www.spierssafety.co.uk Spirax Sarco Ltd Charlton House, Cirencester Road Cheltenham, Gloucestershire, GL53 8ER Tel: +44 (0)1242 521361 Email: chris.coleman@uk.spiraxsarco.com Web: www.spiraxsarco.com/uk Stopher Associates Ltd 34 Ickwell Road, Northill Biggleswade, Bedfordshire, SG18 9AB Tel: +44 (0) 1767 626330 Email: info@stopherassociates.co.uk Web: www.stopherassociates.co.uk Stream Engineering Solutions Ltd 3 The Wiend, Port Sunlight Wirral, Cheshire, CH63 7RG Tel: +44 (0)7808 141318 Email: john.wahlers@ntlworld.com Web: www.streames.co.uk Swan Analytical UK Ltd Unit 3, The Steading, Copthill Farm Uffington, Stamford, Lincs, PE9 4TD Tel: +44 (0)1780 755500 Fax: +44 (0)1780 755508 Email: sales@swan-analytical.co.uk Web: www.swan-analytical.co.uk SWFT NHS Trust Lakin Road Warwick, CV34 5BW Tel: +44 (0)1926 495321 Email: Mark.Wise@swft.nhs.uk Web: www.swft.nhs.uk Tata Steel UK Ltd PO Box 1, Brigg Road Scunthorpe, North Lincs, DN16 1BP Tel: +44 (0)1724 404040 Email: richard.jackson@tatasteel.com Web: www.tatasteel.com

Tel: +44 (0)1522 702234 Email: jeremylee@torqueengineering.co.uk Web: www.torqueengineering.co.uk University of Dundee Nethergate, Dundee Scotland, DD1 4HN Tel: +44 (0)1382 384066 Email: g.x.smith@dundee.ac.uk Web: www.dundee.ac.uk Vital Energi Century House, Roman Road Blackburn, Lancashire, BB1 2LD Tel: +44 (0)1254 296000 Email: sarah.lowe@vitalenergi.co.uk Web: www.vitalenergi.co.uk Vulcan Burners Unit 3B, Loves Hill, Castledawson Magherafelt, Northern Ireland, BT45 8DP Tel: +44 (0)2879 469501 Email: karen.mcerlean@burnerservices.net Web: www.burnerservices.net Watkins Hire Ltd Ward Industrial Estate, Church Road Lydney, Gloucestershire, GL15 5EL Tel: +44 (0)1594 840025 Email: katie@watkinshire.co.uk Web: www.watkinshire.co.uk Weishaupt (UK) Ltd Neachells Lane, Willenhall West Midlands, WV13 3RG Tel: +44 (0)1902 609841 Email: info@weishaupt.co.uk Web: www.weishaupt.co.uk Zeeco Europe Ltd The Woolfox Building Great North Road, Rutland, LE15 7QT Tel: +44 (0)1780 765077 Email: stephanie@zeeco.com Web: www.zeeco.com

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GEMchem

Kiwa ESOS Assessment

Water treatment

•

Registered ESOS Assessors

•

Competitively priced

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Decades of experience in the energy industry

•

We can also assist with certification to ISO9001/ISO14000 and EU-ETS verification

T : 01242 677877 E : enquiries@kiwa.co.uk

www.kiwa.co.uk/esos

Experts in Energy Efficient Solutions for Steam Boilers

T: 0117 922 5544

www.GEMchem.co.uk

1 John Street | Bristol | BS1 2HR

info@GEMchem.co.uk

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 for you to take control of your energy use and assist your business in saving energy for the future. Saving the environment and money in the process. Introductions to operation of boilers and orientation.

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 DipBOM, MIPlantE, TAQA, PTTLS CertEd. Mechanical

“Helping Engineers & Consultants Promote their Technical Expertise Online” E: info@EngineeringYourFutureBlueprint.com www.EngineeringYourFutureBlueprint.com Tel: +44 (0) 796 388 3662

foreman. CEA member.

Engineering operations

Tel – 07813375196

Engineering operations

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, municipal waste and wet bio-mass.

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CEA Yearbook 2016/2017

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8 3 1 5 8 2

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Reduce emissions

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SAACKE Combustion Services Ltd.

For all your burner, boiler, heat recovery and control equipment needs – new, upgrades and repairs. Expert aftersales service and support for the lifetime of your plant.

Products, services, guidance and local support for

Safety – Energy – Efficiency – Emissions SAACKE Combustion Services Ltd. Langstone Technology Park, Langstone Road, Havant, Hampshire, PO9 1SA., Tel. 02392-333900

www.saacke.com

135 years of world-beating energy solutions

Cochran are the internationally acknowledged experts in the provision of packaged steam, hot water generation and heat transfer systems, combustion and ancillary technology. Every product is constructed to meet stringent UK, European and international standards.

Over a century leading the field Unrivalled durability and quality Total turnkey energy solutions Steam and hot water boilers Combustion and control systems Bespoke heat recovery boilers Short and long-term boiler hire Servicing and emergency repair Global reach sales and assistance In-house/on-site client training Spares - all makes, models, ages

+44(0) 1461 202 111 www.cochran.co.uk Cochran Ltd, Newbie Works, Annan, Dumfries & Galloway, UK DG12 5QU.