PWE takes a look at how Babcock Wanson’s Navinergy is changing the way boiler rooms are managed, providing users with advanced tools to improve efficiency and maintain regulatory compliance

Industrial process heating equipment and solutions specialist Babcock Wanson has completed a turnkey project to supply steam, via its BWD30 fire tube boiler, to cookers at IRC Cucina’s new Trafford Park centralised kitchen. PWE reports

At a time when national electrical grids are under extreme pressure, unexpected outages can prove to be a considerable challenge. When a power plant in Germany experienced the sudden failure of a boiler feed pump, output dropped by more than 40%, which affected both the local grid and company profits. Needing to resolve this situation urgently, Sulzer was called in to repair the asset and investigate to secure the reliability of the power station. PWE reports.

Carl Knight – managing director of process steam and heat transfer specialist Fulton – looks at the advantages of electric steam boilers versus their traditional fuel-fired counterparts.

The University of East Anglia (UEA) has used steam boilers from Fulton for many years, but even the University was surprised at how efficient the installation of new VSRT boilers proved to be when it replaced ageing plant. PWE reports.

In these days of pushing the boundaries on energy efficiency it’s very easy to connect a lower working temperature in a boiler to a lower flue gas temperature and therefore higher efficiency but is that really the case? The Combustion Engineering Association (CEA) explains further.

Etienne Fourie, Technical Sales Manager, Babcock Wanson, looks at the drive towards energy efficient, decarbonised technology.

Kieran Bennett explains how to select the right valve for steam temperature control.

Michael Hyde, Northern Europe Business Development Manager, Spirax Sarco, provides insight into what can be done today to optimise your steam system.

PWE looks at the installation of VSRT steam boilers at a food processing facility, which is expected to cut costs by a significant 21%, while also reducing carbon emissions by almost 25% and nitrous oxide (NOx) levels by 75%.

In 2015, with business improving but original process equipment reaching end-of-life, Rebellion Beer Company bucked the trend and, with impartial advice from heat transfer specialist Fulton, replaced its ageing steam boiler for a thermal fluid system. Now, six years on, Rebellion’s Mark Gloyens explains how brewery life has coped with the switch. PWE reports.

Clive Jones* explains the importance of proactive boiler maintenance and offers advice on best practice

Matt Watson* explores potential solutions as to how organisations might mitigate current demand and bridge the gap between old technology and new.

Luke Worrall* explains why the Government’s planned end to the Non-Domestic Renewable Heat Incentive (NDRHI) could harm the UK’s efforts to reach net zero carbon emissions by 2050 unless policy gaps are addressed.

As the government makes moves to open businesses and get the country’s workforce off of furlough and back into the work environment, there are many companies for whom the rest of the year – and beyond – will be challenging.

PWE spoke to Phil Kemp, general manager at SAACKE Combustion Services Ltd, which is celebrating its 60th year of business in the UK, to discuss the importance of low NOx combustion, the future of Hydrogen Boilers within UK manufacturing, and the importance of servicing combustion equipment.

Having moved from a facility that was too small and would have been uneconomical to upgrade, the overriding requirements for Elis’ new, state-of-the-art Southampton-based facility were to increase and future-proof throughput by increasing capacity as and when required. Protecting their investment was also paramount, so manufacturer-backed aftercare solutions were also key to the long-term plan.

Garret Haegelin, HICoat Division Superintendent at Sulzer, looks at the features and processes used when applying high-quality coatings and how attention to detail is essential for optimum performance.

Since the inception of the Industrial Gas Accreditation Scheme commonly referred to as I-GAS, accredited by the Combustion Engineering Association (CEA) in 2015 there has been a steady increase in its recognition. Nick Evans reports.

The CEA strongly recommends a daily log of all activities in every boilerhouse and kept up to date on a daily/ shift basis. This assists all staff in understanding what has and has not been done that day and what is still required to do in order to ensure all checks and tests are carried out.

The introduction of tighter regulations around carbon emissions for thermal combustion plants is encouraging industrial businesses to explore cleaner fuel options. Oliver Knight, Industry sales manager, at Calor discusses the options for off-grid manufacturers and explains how one dairy producer has already cut its energy costs by nearly 29% per year.

Many will know that the Medium Combustion Plant Directive (MCPD) was published by the EU back in November 2015. It then took until January 2018 to be transposed into legislation for England and Wales (Environmental Permitting (E&W)(Amendment) Regs 2018), with a compliance date of 19th December 2018 for ‘new’ combustion plants. Other UK countries laid their own versions of this legislation. MCPD – good for the environment, good for business, or a missed opportunity? Paul Whitehead on behalf of the Combustion Engineering Association (CEA) reports.

Heiko Doppler, a Bosch customer service engineer, and Thomas Steffes, project leader at Kramer & Best, have recently handed over a new steam boiler system to André Ködel, master brewer of Park & Bellheimer's brewery in Pirmasens, south-west Germany. PWE reports.

You can be forgiven for not realising that the Medium Combustion Plant Directive (MCPD) was transposed into UK legislation around the beginning of the year, and the implementation date is just around the corner. Emissions to atmosphere are a hot topic at present, and this legislation is designed to help the fight against excessive amounts of NOx, SOx and dust in the air we breathe. PWE reports.

This year’s Air Quality & Emissions Show, AQE 2018, will focus heavily on the Medium Combustion Plant Directive (MCPD), which will come into force on 20th December 2018. AQE Organiser Marcus Pattison says: “This new regulation will affect an enormous number of processes, so it is vitally important that they are fully aware of the requirements and how to implement them.

In the run-up to the heating season, start-up dangers are a serious problem for many heating systems using steam as a source of heat, largely due to the fact that they have been lying dormant over the summer.

The CEA has launched a new two-day training course aimed at water testing. 

Fulton has supplied an oil-fired, skid-mounted steam boiler system to Neal’s Yard Remedies, a UK-based manufacturer of natural, organic health and beauty products including essential oils, moisturisers, shower gels and soaps. The 60J oil-fired boiler was supplied with the necessary ancillary items including hot-well, water softening, chemical dosing and blowdown vessels. PWE reports.

While Combined Heat and Power (CHP) systems continue to grow in popularity, aftercare all too often remains an afterthought. Carl Main, business development manager – Commercial and Industrial After Sales at Bosch Commercial and Industrial, explains the importance of servicing and maintenance in order to protect what often is a sizable investment.

Just three-and-a-half-years after their introduction, Fulton is celebrating having welcomed its 1000th trainee onto its City & Guilds Accredited training course. PWE reports.

As part of a £11m investment in its Preston plant, corrugated sheet board manufacturer Board24 has installed a Babcock Wanson BWD60 fire tube boiler, which is being used to provide steam for a new bespoke volume corrugator.

Byworth Boiler Hire has been supporting Hospitals throughout the country for many years providing both steam and LTHW hire boilers for ad hoc hire and to cover annual inspections or peak seasonal loading.

Recycling firm Ward Recycling Ltd (WRL) approached EOGB to provide an improved and more cost-efficient process heating solution at its glass beneficiation plant in Middlesbrough.

Mike Griffin, Emerging & Innovation Technology Manager Northern Europe at Spirax Sarco, outlines the problems with conventional heat transfer design, and explains how technology is providing a solution that is both innovative and has the potential to pay for itself in double-quick time.

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

You will be amazed to know how waste heat recovery units can be used in so many industrial applications says Matthew Crewe, managing director of Green’s (pictured).

PWE takes a look at the launch of the Combustion Engineering Association’s “I-GAS” - a new qualification for maintenance and gas fitters working in industry.

In any workplace, managers have a duty to evaluate the risks associated with that setting and, if there is a boiler installation on site, they are legally bound to keep it working correctly and safely at all times. Chris Coleman, marketing product manager, condensate handling & customer training at Spirax Sarco, looks at some of the key requirements of a boiler house risk assessment and explains how training plays a vital role.

Failure of existing temperature control plant, steam and hot water systems can have disastrous consequences including downtime, closure of facilities, financial penalties, loss of revenue and a failure to provide a duty of care.

Steve O’Neill, Technical specifications engineer at EOGB Energy Products Ltd, focuses on energy efficiency in non-domestic buildings and how forced draught burners still play a role in reducing emissions.

The UK’s high energy costs continue to present a major obstacle hindering the country’s manufacturing performance. A 2014 survey by the EEF highlighted the cost of energy as a major concern for UK manufacturers, with many identifying it a key factor impacting on their profitability and competitiveness. On sites where steam and hot water is used, significant cost savings can often be found in the boilerhouse and steam distribution system. Alan Hunt of ABB Measurement & Analytics offers advice on the best ways to optimise the efficiency of your steam boilers.

With fluctuations in steam pressure having the potential to affect energy savings, environmental credentials, and wear and tear to boiler components, it is vital that the steam boiler operates to the correct design pressure at all times. Matt Walton, contracts manager at Bosch Commercial and Industrial, explains how this is best achieved.

Steve O’Neill, technical specifications engineer at EOGB Energy Products Ltd, looks at how the implementation of new heating technology can have a significant effect on the efficiency of industrial heating systems.

What do a golf ball, a hamburger and a bucket of paint have in common? Not much at first sight. But delve deeper into how they’re made and you might find your answer. Thermal fluid systems are commonly used in manufacturing food and beverage, pharmaceutical, textile and plastic products of all kinds, including golf balls, hamburgers and paint. Clive Jones, managing director of thermal fluid specialist Global Heat Transfer, explains how boiler maintenance can make or break a thermal fluid system and ultimately, a manufacturing line.

A London distillery has decided to switch from an electrically-heated process to one using a steam boiler. PWE reports.

The Combustion Engineering Association’s (CEA) activities continue to expand and grow, and for over 82 years the CEA has been providing information and education on how to improve the understanding and development of the combustion industry. The forthcoming conference on 17th November, explaining the Medium Combustion Plant Directive (MCPD), is just one example of the numerous education programmes it organises. PWE takes a closer look at this important industry association.

Given the expected life expectancy of an industrial boiler, it can be difficult to find justifiable reasons to invest in modernising or even replacing entire systems during their life cycle 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 and discusses some of the upgrade options available.

Martin Cooke, technical manager at EOGB Energy Products Ltd, looks at the steps that need to be taken to ensure a successful commissioning process.

Detecting the presence of a flame in a combustion process is often more complex than might be first imagined. Mick Barstow of LAMTEC UK reports.

Martin Cooke, technicalmManager at EOGB Energy Products Ltd, discusses the critical considerations to bear in mind when selecting a replacement industrial heating system.

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