Boilers/Burners

Lodge Cottrell use Micronics PF330 Portable clamp-on Flow Meter to substantially reduce commissioning time and fixed installation costs on large scale pollution control plant for coal fired boilers.

 

Lodge Cottrell is a world-leading supplier of large-scale industrial air pollution control equipment. On a project carried out during 2010 they had a requirement to process the ash extracted from their boiler flue gas treatment system by mixing this with water to form slurry suitable for disposal.

Cochran Ltd have recently handed over complete turnkey installation of two high efficiency Thermax steam package boilers to Billerud Beetham, Milnthorpe, Cumbria.

 

Billerud Beetham who specialise in producing different types of packaging and paper for industrial use including grease-resistant paper for fast-food industry and paper that can be sterilised for medical applications were looking into replacing three 40 year old boilers with two new steam boilers capable of integrating with an additional Cochran Thermax and Ruston Thermax boiler choose Cochran Ltd to provide total turnkey installation.

David Young, Cochran General Manager, recently took a call from a boiler insurance inspector based in South Africa. He was trying to trace design and manufacturing records for two vertical Cochran boilers still installed and operating in Calitzdorp, South Africa.

Impressively we were able to supply the required records for the boilers built in 1939 and 1945 and more impressively the boilers passed their inspection and continue to deliver.

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At the Milch-Union Hocheifel eG in Pronsfeld they are proud of over 40 years experience in milk processing. More than 700 employees refine more than one billion kilograms of raw milk annually into delicious milk products.

 

With more than 2700 farms of the Hocheifel region and the nearby regions of Belgium and Luxemburg and a sympathic registered trade mark, well-known in Germany and wide parts of Europe, MUH stands for highest quality in accordance with producers and customers.

 

To guarantee the high standards of quality for the future, a twodigit millions amount is annually invested in the Pronsfeld facility. In 2010 for example the steam generation centre was extended by a further boiler.

The experienced plant constructor HSK Rohrleitungsbau was the client for dreizler® ordering 2 x marathon®M10001.2oxygenplus. These two high efficient burners heat a new double fire tube boiler of LOOS with a capacity of 28 to and 20 bar pressure.

With the World concentrating on cutting carbon emissions for sound ecological reasons and Industry working hard to save money by reducing energy bills, it is rare to find a simple and proven technology that readily meets both criteria.

Thermal Fluid Systems from Babcock Wanson have regularly shown energy savings over conventional Steam process heating of between 30-50% with reduced maintenance needs and fully automatic operation.
To learn how this technology could help your business why not request a copy of The Practical Application of Thermal Fluid Heating.

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The latest addition to its FD oven burner range – which is designed to maximise performance and energy efficiency – is being introduced by process gas burner specialist, Lanemark International Ltd. The FD-C (GA) packaged burner provides flexible, high turn-down control of both gas and air and utilises the latest ‘air pressure lead’ (APL) monobloc gas valve technology. 

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At the beginning of September 2008 we were approached by two companies regarding the rental of an O&G unit for a small platform in the North Sea called Varg A. The generator was to run the Fire Pump onboard for any emergency situations, so it is basically a standby unit. We offered a budget rate for renting one of our new Oil & Gas units.

After several discussions and clarifications Teekay Norway took over the project at the beginning of 2009, and the ball really started rolling. We not only had to place our Oil & Gas unit on the platform, it also needed some modifications. Together with our Technical Manager, Kjell Olsen Øen, Teekay decided that they needed some very special arrangements onboard the platform. This meant that we had to rebuild certain parts of the unit, and also install an extra long piping construction for the air intake and also for removal of the exhaust gases. See pictures. The container also needed overpressure, because of the danger of gas.

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Even on a rough sea, a crane has to be able to lower loads of up to 120 tons into the water, accurate to the tenth of a metre

She was ready earlier this year: the Seven Atlantic, an ultra modern support vessel for divers in the North Sea. Responsible for the electrical wiring is Croon-Bakker Sliedrecht, who during the test phase could rely on the services of Energyst CAT ® Rental Power.

The recent delivery of the Seven Atlantic Subsea 7 to its owner meant the next step in a truly epic project for IHC Merwede Shipyard in Hardinxveld-Giessendam. In a relatively short time the company has produced two so-called pipe laying vessels – the Seven Oceans and the Seven Seas - and has completed project number three with the transfer of the Seven Atlantic. They are currently already working on the fourth ship, which as of yet remains nameless. Starting this year, the ships will perform their duties in the deep oil fields in the North Sea.

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http://www.engineeringmaintenance.info/images/stories/Energyst%20PR1.jpgThe collaboration between Degussa and Energyst is very varied in its nature. Within the framework of the expansion of the public utilities, linked with the construction of the new Methionine factory in Antwerp, Energyst offers support by means of temporary heating and cooling equipment.

In consultation with the central energy unit, and their German colleagues, Energyst supplied several back-up central heating boilers during the expansion work carried out within the gas supply system.

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Flu AceThermal Energy International Inc., which recently acquired the Bristol based steam trap manufacturer GEM Ltd, is launching its highly acclaimed FLU-ACE technology to the UK and European market.  Greatly improving the fuel efficiency of boiler operations, FLU-ACE provides a significant return on investment, and reduces environmental emissions.

FLU-ACE effectively converts an Industrial boiler into a condensing boiler and, in so doing, effectively recovers up to 90% of the heat normally lost. This is possible because FLU-ACE

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Fire-Tube BoilerThe company Huilerie de Tahiti in Papeete recently inaugurated its new coconut oil-fired boiler house in the presence of Oscar T

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Dual Gas Fired BoilerQueensway based Dunphy Combustion Ltd has recently completed a state of the art, carbon neutral, energy installation for a major dairy and cheese making factory in Wels, Austria. Landfrisch Molkerei GmbH approached Dunphy

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HydroflowAn Indonesian garment producer has reduced its fuel consumption by a third, simply by improving the water supply to its boiler.

The Cathay Murni Garment Factory has been using a 20-year-old steam boiler to supply hot water for washing and steam for ironing.  The factory draws its water supply from a bore hole, but the water has a hardness of 200 parts per million. In an attempt to prevent limescale build-up on the boiler

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Wellman BoilerAnnual maintenance and strip downs happen every year and planning is the key, working out when you can fit in that all-important service, is a vital part of maintaining a healthy boiler house, but can you really afford to have the downtime?

Novartis vaccines and diagnostic plant at Speke in Liverpool relies heavily on its three boiler houses, accommodating various sizes and makes of boiler. When your prime business is manufacturing vaccines to prevent and cure diseases, ease suffering and enhance quality of life, you need steam, you need quality steam, and you need it running. So how do you plan for that all essential maintenance?

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Steam BoilerKING depots in the UK hold vast stocks of pre-owned steam boilers of varied manufacture from 250lb/hr

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ImageBIB Cochran provides hot water solutions for both process and heating applications. BIB Cochran hot water plant is the trusted preference of many industries, ranging from hotel chains, bottling plants, food processing factories and a wide range of public buildings.

BIB Cochran hot water generating solutions employ high efficiency boiler designs from the Calpac, Clansman and Thermax HW ranges, plus advanced control options to ensure optimum efficiency throughout the boiler life.

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ImageBABCOCK WANSON are specialists in industrial coil boilers offering a range of steam generators from 150 to 8000 Kg/h with operational pressures from 5 to 50 bar. The water volume is low and flows directly proportional to the desired steam output using a positive displacement water feed pump. In the high pressure HPVAP Series 100 bar is possible in a closed loop thermosyphon pumpless design offering very high overall plant efficiency without pressure vessels and suitable for a range of batch and variable process flow applications particularly in edible oil processing.

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COAL POWER magazine :: Operations & Maintenance >> 
Biomass has many advantages as a fuel for boilers: It’s inexpensive, readily available in many regions, CO2 neutral, and its use warrants government subsidies. The fuel also presents unique concerns to the designers, owners, and operators of biomass plants, especially in the design of the control system....

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COAL POWER magazine :: Operations & Maintenance >> 
The Energy Information Administraion has predicted that, as the economy gathers steam this year, rising demand for gasoline, crude oil, coal, and natural gas is expected to push up energy prices, aided by a projected boost in crude oil production....

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COAL POWER magazine :: Operations & Maintenance >> 
Operating a boiler is not difficult, but operating a boiler safely and efficiently requires skill and proper training. Following boiler operation best practices will keep your equipment in like-new condition for years to come. This game plan includes a compendium of best practices, with web links to a number of additional key resources you should be famililar with....

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COAL POWER magazine :: Operations & Maintenance >> 
There are four approaches to measuring fly ash content and, therefore, the quality of fuel combustion in a boiler. Before choosing one, you should understand their relative levels of complexity and accuracy....

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COAL POWER magazine :: Operations & Maintenance >> 
The decision to retube a heat exchanger or condenser begins with understanding why tubes are failing. Only when the “why” is understood can the economic replacement tube material be selected. We explore the most common tube material failure mechanisms and then illustrate how to perform a proper life-cycle analysis for that new set of condenser tubes your plant so desperately needs. In sum, there are many reasons to consider getting the copper out of your condenser....

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COAL POWER magazine :: Operations & Maintenance >> 
Every power engineer must have a firm grasp of the rudiments of how fuel is processed to produce electricity in a power generation facility. With this article, we continue our three-part series on the essentials of recovering heat from flue gas to dry and process coal, with the goal of improving overall plant operating efficiency....

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COAL POWER magazine :: Operations & Maintenance >> 
Many claim that wind generation is beneficial because it reduces pollution emissions and does not emit carbon dioxide. This isn’t necessarily the case. When wind is introduced into a generation system that uses carbon technologies to back up the wind, it actually reduces the energy efficiency of the carbon technologies....

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COAL POWER magazine :: Operations & Maintenance >> 
If you want the most accurate test results, it's worth the extra effort to take isokinetic coal samples from coal pipes when collecting fuel and air measurements. Together, the data collected will allow more accurate balancing of coal pipes, measure fuel fineness, and improve the combustion efficiency of your steam generator....

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COAL POWER magazine :: Operations & Maintenance >> 
Combustion flue gas analysis has been used to optimize the boiler air/fuel ratio for decades. Measuring the amount of excess oxygen and/or carbon monoxide in combustion flue gases gives an indication of boiler efficiency and, thereby, plant operating economics. New sensors make those measurements simple and accurate....

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COAL POWER magazine :: Operations & Maintenance >> 
Efficient boiler operation requires boiler auxiliary equipment to operate in harmony. The air preheater, for example, though it has few moving parts, is vital to maintaining efficient boiler performance. In this second installment of our Power 101 series, we examine performance degradation caused by corrosion and fouling of the air preheater that results from the combustion of coal plus the effects of ammonia and sodium bisulfite injection for SO3 mitigation....

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COAL POWER magazine :: Operations & Maintenance >> 
Because refractory is out of sight inside the gas flow path of a steam generator and its auxiliaries, it's also often out of mind. That is, until the refractory fails and causes a forced outage....

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COAL POWER magazine :: Operations & Maintenance >> 
One of the largest returns on investment a plant can achieve is the improved condenser performance that results from an effective condenser tube cleaning. Perhaps it is time to reevaluate your choice of cleaning technologies, establish an optimal cleaning schedule, and add routine air and water in-leakage surveys to your plant's maintenance schedule....

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COAL POWER magazine :: Operations & Maintenance >> 
Why should utilities consider converting existing coal-fired plants to burn gas? We explore the rationale for fuel switching, some of the options available for the conversion of coal-fired units, technical considerations related to conversion, and some of the financial considerations that will impact the final decision....

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COAL POWER magazine :: Operations & Maintenance >> 
Utilizing engineering ingenuity and today’s developing computational fluid dynamics tools, a new classifier design is now available that significantly improves fineness from pulverizers without the heavy costs associated with dynamic classification or any downsides on pulverizer capacities, maintenance, and parasitic power.  Instead, operational flexibility and improved emission control options are enhanced....

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COAL POWER magazine :: Operations & Maintenance >> 
Pulverizers prepare the raw fuel by grinding it to a desired fineness and mixing it with the just the right amount of air before sending the mixture to boiler burners for combustion. In Part I of this three-part report, we examined the essentials of pulverizer design and performance.  In the second part, we discuss the importance of fuel fineness. In the final article, we will discuss the importance of air and fuel measurement....

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COAL POWER magazine :: Operations & Maintenance >> 
When sootblower operation frequency is too high, a plant risks losing power generation from tube leaks; but when sootblower frequency is too low, there is a risk of boiler pluggage. Intelligent sootblowing finds the right balance between tube erosion and plant economic operation....

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Spirax Sarco shows its continued commitment to world-class training with the opening of its UK Steam Technology Centre. The centre is the only training facility in the UK to offer a fully-operational steam system with SCADA control. This enables it to enhance the quality of training across Spirax Sarco’s array of steam engineering courses, as well as supporting live technology demonstrations.

 

The revamped centre offers a variety of training courses to help steam system operators address key issues, such as improving energy efficiency and carbon emissions, reducing downtime and operating costs and ensuring safe operation.

We have recently supplied and commissioned a new Borderer reverse flame steam boiler for Spirax Sarco’s Training and Steam Technology Centre in Cheltenham.

When Spirax Sarco were considering to extensively refurbish their training Centre they selected the Borderer steam boiler manufactured in Annan, Dumfries & Galloway by Cochran Ltd, the UK’s  leading manufacturer of industrial steam and hot waters boilers.

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With the burner types marathon® M/MC10003.6 up to 10003.8 dreizler® presents the consequent development of the CE type tested DUObloc burner series for gaseous and liquid fuels. With combustion capacities from 25 up to max. 44 MW per burner these powerhouses can optimally be applied to water tube boilers, thermal oil heaters, ignition and auxiliary burner application in power stations and as process burners of all kinds.

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A major addition is being made to the range of process gas burner systems available from industry leader Lanemark International Ltd. that is set to enhance the choice of application opportunities for its customers.  The company has announced an agency agreement with American manufacturer, Midco International Inc – covering the UK and other key international markets – which complements Lanemark’s highly successful TX tank heating and FD air heating product ranges.

Midco burners are widely known for the benefits they offer to a number of industries, most notably where make up or replacement air requirements need to be met – an example being paint spraybooth air replenishment.  High turn-down and controllability are key features as are low emission levels, flame stability and a modular design.  This latter characteristic allows any number of individual six-inch sections to be connected to meet precise application needs in terms of dimensions and heat requirement.  This versatility is further enhanced with the ability to use either natural or propane gas on a standard burner head.

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Twin Industries International (TII), with over 30 years experience in the Boiler Industry, knows the importance of purchasing the right boiler for the job and are leading Brokers, not only for new industrial boilers but also for the purchase and sale of reconditioned boiler plant and allied equipment, and the hire of boilers.
 
Being completely independent and therefore able to provide totally unbiased information on all Industrial Boilers, whether Steam, Hot Water, Thermal Fluid or CHP Units, TII does its utmost to ensure potential customers end up with the very best option for their business.

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Wellman Robey “Combination” Boilers have become an integral part of two Combined Heat and Power installations for the N.H.S Foundation Trust.
The principle of the “Combination” Boiler is to take the  exhaust gases from the C.H.P electricity generator engine and use the heat from it to raise steam or hot water. A completely independent section within the boiler (with it’s own furnace and oil or gas fired burner) guarantees that the unit will be able to provide its required output at all times regardless of the supply of waste gases available by firing the boiler in the conventional way as well as (or instead of) using the waste heat recovery section.

The two N.H.S Trust Foundations that have recently taken delivery of the Wellman Robey Combination Boilers are Countess of Chester and Aintree University (Liverpool) hospitals.

Countess of Chester has 580 beds on a single site and provides a range of medical services for over 400,000 patients a year for Western Cheshire, the Wirral and North Wales. The Robey- Loos boiler supplied is a UL-S IE Composite Boiler designed for an output of 3945kg/hr at 5barG that will provide steam and hot-water for the total requirement of the hospital complex.

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ems front cover oct 09
The October edition of EMS magazine is now available to read online in page turning digital format or PDF format. This edition contains articles on achieving best practice in condition monitoring and plant maintenance as well as the latest products, news and case studies.

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thrust monitoringOne of the challenges facing plant instrumentation engineers today is the effective and reliable monitoring of thrust bearing wear in critical pump applications.  Typically pumps of this type are in continuous use and operational downtime is normally only permitted during planned outages.  Predicting the wear and hence requirement to replace the thrust pads, is essential to fit in with this regime.

 With rotational speeds between 3000 and 7000 RPM, protection against potential pump damage is also key, as excessive thrust wear can not only damage the bearing assembly but also the impeller, resulting in the plant potentially being out of action for 6 months or more.
 

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Ratiotronic TM 6000 digital burner/boiler management systemDunphy has launched their new, in-house designed touchscreen for the Ratiotronic TM 6000 digital burner/boiler management system. The panel has all the functionality of a standard PC including IP addressable web access.

The touchscreen offers building services engineers the facility for multiple set points as well as a unique timer features which enable burners to fire at specific temperatures and pressures preset for any time of the day or night.

The Windows style interface makes the system easy to navigate. On screen documentation is also available for datasheets and manuals of all system components. This advanced digital combustion management system provides engineers with one central point of control for monitoring all operational aspects of burners, boilers and related peripheral equipment.It has a large, easy to read 19 inch screen with 1080 x 1280 resolution and 65,000 colours.

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Yorkshireman 2Earlier in 2007, Byworth Boilers announced the launch of their new fuel efficient steam boiler.  It was claimed that the Byworth Yorkshireman2 steam boiler is the most fuel efficient boiler of its type due not only to unique XiD boiler tube, but by the quality and integrity of design and engineering.  Fuel savings will vary according to the efficiency of the existing boilers, but can be between 2 and 20%.

With Gas prices predicted to rise yet again during 2008, many forward thinking companies have averted the impact of this increase by investing in this latest boiler technology.  A leading mushroom producer in Lancashire, Drinkwater Mushrooms, not only purchased his sixth Byworth boiler to keep up with spiralling expansion, but purchased the first Yorkshireman2. So impressed were they by the significant reduction in fuel oil usage and the rear end temperature (over 40degC lower than similar boilers) that discussions are taking place regarding a second installation.

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The Yorkshireman 2Byworth Boilers are aware that boiler users are increasingly suffering from rising fuel bills, and with this in mind the boiler manufacturer embarked on a 2 year project in conjunction with Leeds University.  The brief was, by rigorous testing, to ascertain and prove the optimum configuration of shell, furnace, and tubes for maximum boiler efficiency and low emissions. 

The project almost came to an early close when on testing the existing Byworth Yorkshireman range of boilers, it was found that efficiency results for this range were actually higher than previously claimed and better than similar boilers available.  However, rather than resting on laurels, the company persevered with the research which has culminated in the launch of the Yorkshireman2 boiler range.

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Thermal Oil HeaterBABCOCK WANSON is leader in the field of the design and the installation of thermal oil heaters TPC and EPC (high outputs, service contracts on demand, compliance with environmental standards).

User advantages :
reliability and rugged long life construction ;
guarantee on both the burner and the boiler ;
efficiency, which can be higher than 92% over the operating range ;
investments and maintenance costs reduced ;
optimised heat balance, associates the high output of the boiler with very low thermal losses on the distribution system which means very high overall plant efficiency ;
very short response time, low inertia ;
optimisation of the thermal coefficient of transfer of the boundary layers ;
low pressure of operation normally no more than total system resistance (10 bar max) for high temperature

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ImageWellman Robey supply boilers and pressure vessels to a worldwide marketplace and provide CHP schemes, ultra low nox high efficiency boilers, steam and hot water boilers, pressure vessels and specialised solutions, as well as offering extensive aftercare relationships to our clients. We have achieved a reputation for providing quality products which meet future demands of economy, ecology and performance.

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COAL POWER magazine :: Operations & Maintenance >> 
Every power engineer must have a firm grasp of the rudiments of how fuel is processed to produce electricity in a power generation facility. With this article, we begin a series of Power 101 tutorials that present these fundamentals in a clear and concise way. First up are the essentials of recovering heat from flue gas....

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COAL POWER magazine :: Operations & Maintenance >> 
One of the primary challenges of reliably burning coal is managing the corrosion experienced by the furnace heat transfer surfaces. Fireside corrosion remains a leading cause of failure in superheater and reheater tubes. Three case studies examine the different failure modes experienced by tubes located throughout the furnace....

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COAL POWER magazine :: Operations & Maintenance >> 
The loading and discharge of conveyor belts is the area where many, if not most, of the problems in solids conveying occur. Fortunately, a new technology provides chutes to accomplish conveyor loading and discharge without blockages while minimizing the dust generated: engineered-flow transfer chutes....

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COAL POWER magazine :: Operations & Maintenance >> 
When the Łagisza power plant began commercial operation in late June 2009, it marked the beginning of a new era in the evolution of circulating fluidized bed (CFB) technology. At the heart of this 460-MW plant is the world’s largest CFB boiler, which is also the world’s first once-through unit supercritical CFB boiler....

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COAL POWER magazine :: Operations & Maintenance >> 
Erosion can significantly reduce the operational life of boiler components. Abrasion-resistant ceramic parts can be a sound alternative to expensive metallic parts when replacing boiler components....

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COAL POWER magazine :: Operations & Maintenance >> 
One of the primary challenges of reliably burning coal is managing the corrosion experienced by the furnace heat transfer surfaces. Fireside corrosion remains a leading cause of failure in superheater and reheater tubes. In Part I, we examined three case studies of different failure modes experienced by tubes located throughout the furnace. In Part II, we conclude with two additional boiler tube failure case studies....

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COAL POWER magazine :: Operations & Maintenance >> 
Progress Energy has incorporated online combustion optimization/tuning to eliminate furnace reducing atmospheres at its Asheville Plant. The optimization project utilized individual burner airflow measurement and continuous burner coal flow measurement to adjust burner air/fuel ratios. The result: significantly improved boiler combustion....

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COAL POWER magazine :: Operations & Maintenance >> 
Every power engineer must have a firm grasp of the rudiments of how fuel is processed to produce electricity in a power generation facility. With this article, we conclude our three-part series on the essentials of recovering heat from flue gas to dry and process coal, with the goal of improving overall plant operating efficiency....

Read more...

COAL POWER magazine :: Operations & Maintenance >> 
Boiler auxiliary equipment often receives no respect for the role it plays in maintaining efficient boiler performance. In this second installment of our Power 101 series, we examine the design and performance of the air preheater....

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COAL POWER magazine :: Operations & Maintenance >> 
An unintended consequence of employing selective catalytic reduction and wet flue gas desulfurization to reduce nitrogen oxide and sulfur dioxide levels at coal-fired power plants has been unwanted sulfur trioxide (SO3) emissions. Picking the right sorbent in the right amount can eliminate that problem....

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COAL POWER magazine :: Operations & Maintenance >> 
San Miguel Electric Cooperative selected and installed an automatic sootblowing system for its Unit 1 to minimize clinkers in the boiler that caused semi-annual unscheduled outages. New boiler surface-cleaning equipment and intelligent cleaning software eliminated these expensive outages....

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COAL POWER magazine :: Operations & Maintenance >> 
Efficient boiler operation requires boiler auxiliary equipment to operate in harmony. In this third and last installment of our Power 101 series, we examine ways to decrease the auxiliary power requirements of boiler auxiliaries....

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COAL POWER magazine :: Operations & Maintenance >> 
Pulverizers prepare raw fuel by grinding it to a desired fineness and mixing it with the just the right amount of air before sending the mixture to boiler burners for combustion. In Part I of three parts, we'll examine the essentials of pulverizer capacity, what should be done after a coal pulverizer fire or other incident, and how to tune up pulverizer performance. In future articles we'll discuss measuring pulverizer performance and performance optimization....

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COAL POWER magazine :: Operations & Maintenance >> 
The international policy framework regulating the emissions of greenhouse gases from industrial and utility boilers is in flux. Meanwhile, most boiler owners are evaluating potential strategies for when, not if, more stringent emissions reduction regulations are put in place. One of the most attractive compliance options is the cofiring of biomass in existing coal-fired boilers....

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COAL POWER magazine :: Operations & Maintenance >> 
Several states have already instituted mercury emission limits in expectation of tightening mercury emission rules that will require reductions of up to 91%. Coal-fired plants searching for an economical way to meet the new limits may need to look no further than replacing their baghouse filter elements....

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COAL POWER magazine :: Operations & Maintenance >> 
Pulverizers prepare raw fuel for burning by grinding it to a desired fineness and mixing it with the just the right amount of air before sending the mixture to boiler burners for combustion. Part I of this three-part report examined the essentials of pulverizer design and performance; Part II discussed the importance of fuel fineness. This final article discusses the importance of air and fuel measurement....

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COAL POWER magazine :: Operations & Maintenance >> 
A Romanian lignite-fired power station wanted to minimize the operating cost of the flue gas desulfurization (FGD) system by placing the booster fans in the "wet position," between the wet FGD scrubber and the wet stack, where they would consume significantly less power. A number of combined environmental effects must be considered in this design....

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