Boilers & Burners

Industrial process heating equipment and solutions specialist Babcock Wanson has launched the FM Pack range of Steam Water Tube Boilers, for steam outputs from 4.5 to 80 t/h. 

Suitable for applications requiring high steam output, high pressure steam or superheated steam, the FM Pack range provides high quality steam, from dry saturated to high temperature superheated and, due to the heat exchanger design, have the ability to provide very high operating pressures, from 10 to 95 barg. 

Babcock Wanson has designed these latest Steam Water Tube Boilers for optimum efficiency, durability and longevity. The casing is pressurised to maintain the flue gas outlet temperature, avoiding corrosion risk due to condensation, plus there is a complete separation between tubes and casing and minimal refractory components. All parts of the boiler have been designed for easy access for maintenance.

For applications where poor types of fuel gases are used, the FM Pack boiler is available in a specially constructed variant, making it suitable for use in locations around the world.

This flexible approach can also be seen in FM Pack’s adaptability to different types of burners to ensure the boiler can work with different fuels in compliance with emissions regulations such as the Medium Combustion Plant Directive.

For maximum efficiency, FM Pack boilers can be connected to an external economiser.

The FM Pack boilers join Babcock Wanson’s existing range of water tube boilers, which includes boilers designed for operation at 150 barg at outputs of up to 150 tonnes per hour, plus Standard Fasel water tube boilers, following the acquisition of this renowned specialist in boiler technology and burner technology. 

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions. The company aims to help optimise customer’s energy production with high quality products and efficient service.

For more information, please contact Babcock Wanson on 020 8953 7111 or This email address is being protected from spambots. You need JavaScript enabled to view it. or go to https://www.babcock-wanson.com/products/steam-boilers/water-tube-boilers/

Kings have over 80 years’ experience in supplying boilers for all types of commercial and industrial applications, offering businesses a full range of services.

Steam Boiler Hire

Our fleet of temporary steam boilers range from 340kg/hr (750lb/hr) to 15,800 kg/hr (35,000lb/hr) comprisingtrailerised, containerised or staticboilers that are oil, gas or dual fuel with pressures up to 12 bar.  Available nationwide.

Hot Water Boiler Hire

Our fleet of temporary hot water boilers range from 94kW (320,000 btu) to 8,000 kW (27,000,000 btu) and include a range of containerised or static low-pressure units, with oil, gas or dual fuel. Available nationwide.

Steam and Hot Water Boilers for Purchase

Kings have boilers for sale for any size project with fast, nationwide delivery.We have an unrivalled choice of modern steam and hot water boilers in stock, ranging from 340kg/hr to 16,000kg/hr steam and 150kW to 7,500kW hot water with working pressures from 7bar to 18 bar. Our fully re-furbished boilers save businesses time and money over new.

In-house expert engineers

Kingsteam of in-house engineershave extensive knowledge and expertise in boiler installation, replacement, servicing and maintenance. Our highlyexperienced burner and combustion engineers carry out all aspects of servicing and repair to all popular makes and models of Oil, Gas & LPG fired commercial burners.

Long-standing relationships

Kings have relationships with many customers which span decades. We are extremely proud of our long-term relationships which are testament to the excellent service, great quality and value for money we provide.  Over the summer we provided boiler plant for Scotland's continually growing brewery and distillery industry, hiring a fully refurbished containerised boiler house with steam boiler unit comprising a 1,362 KG, 10 bar for a client of 20 years.

Kings help to ensure essential services continue to run

Kings’engineers recently installed two temporary boilersto provide hot water and heating to a community centre whilst essential repair works are carried out, in Suffolk.

The project initially involved providing hot water to taps for direct hot water, however, due to winter weather coming our dedicated team of engineers ensured heating was supplied to enable the community centre to continue running throughout the cold winter months. 

The community centre, formerly an old middle school, now the hive of the town, offers essential facilities for local residents including a nursery, indoor sports facilities, meeting room space, work areas and NHS facilities.  

Kings are proud to help ensure essential services like these continue to run throughout the UK.   If your business needs to hire or to purchase boiler plant, please contact us today.

Contact us today:

+44 (0)1992 451629                www.kingsboilerhire.com

This article also featured in the December/Jan issue below

Corrosion and Erosion are major concerns for all Waste-to-Energy and Biomass facilities. Highly corrosive operating environments present maintenance challenges which, if left untreated, can lead to costly asset failures and unplanned outages.

WtEBoiler Corrosion Mechanisms

Most corrosion protection mechanisms consist of generating a corrosion barrier on the base metal by forming an oxide layer. The challenge inside WtE boilers is that this layer is quickly eroded forcing the formation of another layer and consequently leading to the erosion-corrosion phenomenon. Erosion-corrosion thinning can happen quickly when harsh conditions are combined with soft or poor erosion resistance materials.

WtE Boiler Corrosion and Erosion Protection

Refractory protection is the first defense against corrosive flue gases and can also have excellent erosion properties but has limited heat exchange properties as the thermal efficiency is low. Refractory alloys can be used, but due to the excessive material costs and limited erosion resistance, the implementation of the surface protection layer is often a more cost-effective solution.

The use of thin ceramic coatings seems like an attractive approach; however, the thermal expansion mismatch and the fragility of such coatings make this solution unreliable. The coatings tend to crack, and corrosion can develop underneath the protective layer which can then peel off.

Corrosion-resistant HVTS Metal Spray Coatings

Integrated Global Services (IGS) has successfully developed a High Velocity Thermal Spray (HVTS) coating which has provided protection in boiler corrosion applications for decades. HVTS has been designed to apply a metal layer with very low porosity and sealability to better protect the base metal in high corrosion environments. This technology allows the use of solid or cored wire, enabling easy material modification compared to technologies depending on the market available solid wire. Since the process does not generate any dilution with the base metal, the quality of the coating remains uncompromised.

In boiler applications, HVTS has been successfully applied under refractory tiles to protect boiler tubes from leaks and asset failure. 

Case Study #1: HVTS Cladding Under Refractory Protects Boiler Tubes from Corrosionat Waste-to-Energy Plant

Introduction

A Waste-to-Energy (WtE) plant in Italy consists of two 35.7 MW combustion lines, that can supply nominal electric power of 22.25 MW and thermal power of 43.5 MW.

The plant was suffering from corrosion and erosion behind the refractory tiles which was causing damage to the boiler tubes. HVTS was chosen to prevent costly unexpected leaks in the boiler.

The Solution

In September 2021, HVTS was applied to the first pass (behind the refractory) of the boiler. The total area that was cladded was approximately 100m2 with a nominal cladding thickness of 500μm. The application was completed within just four days and without any technical concessions or deviations. The project was also completed in accordance with ISO: 8503-1 (preparation of steel substrates before application of paints and related products).

HVTS was chosen as it is a proven technology which stops corrosion of the base metal. Thus, refractory contacts the tube sheet and is cooled as designed. Functioning to design conditions, fouling build-up on the refractory is mitigated.

The Inspection

An inspection took place in September 2022. The results showed that the coated areas were in excellent condition and do not have anomalies or any other visible damage 13 months after the installation of HVTS. There was also no accumulation of slag or ash on the affected area.

The condition of the overlying tiles was also evaluated and showed that the refractory was totally intact and in good condition which is an indication that the underlying cladding and the coated pegs are still in good condition.

The HVTS thickness values were recorded with an elcometer and were found to comply with IGS specifications.

The report states, “the refractory and HVTS are in perfect condition and have no major defects”.

Case Study #2: HVTS Cladding and New Refractory Protects Boiler Tubes at Biomass Plant

Introduction

A biomass plant in southern Italy converts wine residue and other greener locally sourced deposits to steam to produce electricity. The plant operates a large boiler and refractory tiles regularly fall off during operation, exposing the boiler tubes. When boiler tubes are exposed, they are susceptible to corrosion which eventually leads to tube leaks and asset failure, which can be costly.

The Solution - Cladding and Refractory

HVTS Metal Alloy Cladding

Integrated Global Services (IGS) High Velocity Thermal Spray (HVTS) metal alloy cladding was applied behind the tiles to protect the tubes if the refractory became damaged allowing flue gas to enter the boiler tubes. 

A two-meter band at the top of the refractory area was removed in the boiler’s first pass. New hangers were then welded before the application of the HVTS cladding. As a result, IGS’ HVTS protects both the tubes and the tile hangers, with the latter commonly being the source of refractory failure. 

IGS worked in conjunction with COREF Engineering, which then installed the new refractory. The cladding is half a millimeter thick with a smooth surface which meant that the same tiles could be installed without any design modifications or other challenges.

The Inspection

After two years in service, a visual inspection of the cladding and refractory was performed. The IGS HVTS cladding was found to be in very good condition and is expected to greatly extend the life of the boiler.

 This article also featured in the December/Jan issue below

Riello RS and RLS 310 to 610 ranges of burners with electronic cam control are proving increasingly popular with specifiers and end users that want to improve efficiency and reduce environmental impact.

Precise positioning of the servomotors afforded by electronic cam control improves air fuel ratio control and reduces heat loss through the flue. Additionally, improved control of boiler temperature with integrated PID (Proportional Integral Derivative) reduces boiler stop/starts, saving energy from purge losses, and maximises the potential for improved burner turndown ratio. Thermal stresses on the boiler are minimised by safe start-up of the plant from cold.

A further advantage of electronic cam control is that it avoids the wear and tear that occurs with mechanical cams and linkages over time, thereby improving reliability and avoiding hysteresis. 

These Riello burner ranges are available for use with gas (RS) and dual fuel (RLS)and enable lower boiler NOx emission. In RLS models, electronic cam control enables separate fuel profiles for both fuels so that, for example, adjustments to the gas firing curve will not affect the oil firing curve.

Additional features on Riello electronic cam burners include variable speed drives (offering up to 35% electrical energy saving), oxygen trim combustion control, external flue gas recirculation to reduce NOx emissions and remote control/monitoring.

Ends

For further information visit www.rielloburners.co.uk

This article was also featured in the December/jan issue below

The move affects boiler systems with more than one applianceand is a bid to ensure end user safety

17 October 2022 – Bosch Commercial & Industrial have announced that anyone installing their boiler systems using cascade flues, where there is more than one appliance, will be required to include a carbon monoxide (CO) detector. 

Given CO detectors that incorporate boiler shut down are more readily available, the company now considers them state-of-the-art and an essential way of ensuring CO incidents are identified and dealt with almost immediately, protecting the end user.

The requirement covers cascade flues as they have a naturallyhigher level of risk than a single boiler and will only be for new installations, not a retrospective requirement. This will affect the manufacturer’s Condens 7000 WP, 7000 F and FP range, GB402 and Condens 8000 F boilers.

Pete Mills, Commercial Technical Operations Manager, commented; “It may seem like a no-brainer that CO detectors should be included on cascade boiler systems to protect end users from CO, however there is no national mandate for them to be included”.

“We hope that by taking the first step we can encourage the rest of the industry to follow suit, after all it is our duty to ensure that the public are able to access warmth and power without risk to their safety.”

For more information on what this means for upcoming commissions or installs please contact Bosch Commercial & Industrial onThis email address is being protected from spambots. You need JavaScript enabled to view it./

This article also featured in the December/Jan issue below

Unattended boiler operating systems have been in use for over 20 years, traditionally by organisations whose operational hours extend beyond the standard and may not have a full gamut ofboiler house staff on site during these times.  Recent years have seen a considerable acceleration in both the popularity of these systems (our customers now ask for it as standard) and the length of time they are able to safely operate unattended, going from the usual three days up to seven.  But what is driving the growth of unattended boiler operating systems?

From our experience, the answer appears to be a combination of necessity, a greater awareness of the wide ranging benefits to be had from these systems, and clear guidance on how they are to besafely deployed.  Necessity stems from the lack of qualified, experienced staff to operate steam plant, which was amplified by Brexit and now, more recently, by the covid pandemic. Awareness of the benefits includes an understanding of theimproved safety and cost effectiveness that these systems can bring to bear.  The guidance comes in the form of BG01 Guidance on Safe Operation of Boilers.

But before we look at these aspects in more detail, let’s recap.

What is an unattended boiler operating system?

An unattended boiler operating system, such as the Babcock Wanson BW3DAYS, permits uninterrupted operation for a set period (usually of up to six months) and unattended boiler operation, most commonly for up to three days.

The system can be set at commissioning for daily or three day checks depending on a risk assessment of the customer’s steam process and their degree of monitoring of the water treatment system employed - all in accordance with the latest BG01 Guidance on Safe Operation of Boilers.  

It's important that these systems at the very least meet BG01 Typical Arrangement 2, which outlines the minimum equipment required for a boiler with critical alarms monitored on-site by a remote panel located in a manned area such as a gatehouse.  Ideally, they should also meet BG01 Typical Arrangement 3, which is aimed at the lowest degree of supervision, where no boiler operators could be on-site for up to 72 hours, and with status monitoring and boiler safety shutdown by a remote location/telemetry system.  

Once set up for unattended operation, all the user needs to do is monitor for any operational alarms and undertake a very simple check every three days, which is completed without interfering with boiler operation and is acknowledged to the boiler control system, thereby ensuring the tests are completed to the operating schedule.  

Virtually all steam boilers can be adapted to work with unattended boiler operating systems and nearly all manufacturers supply such systems.  However, there are occasions when the introduction of such a system is not feasible or may not be considered necessary.  Very old equipment - 40 or more years – would involve changing so many components to make it compliant with BG01 that ultimately the expense and complexity of doing so would actually make buying a new system a better option.  And, of course, sites that operate 24/7 where staff are always present are unlikely to adopt an unattended boiler operating system (although even here there are benefits to be had!).

Unexpectedbenefits

Apart from the obvious cost and convenience of being able to run a boiler without operator attendance, unattended boiler operating systems have a number of benefits that you may not have factored in.

Top of this list is a lower boiler operation cost.  This is achieved through the replacement of daily boiler water level control checks by a simple 15 minute test every three days.  The test can be undertaken without stopping the boiler thereby avoiding interference with normal production requirements.  Furthermore, the mandatory daily/weekly boiler water level control evaporation test is replaced with a six monthly test, thereby reducing overall manning and operational costs.  Overall energy savings are achieved when boilers are controlled by an unattended boiler operating system, along with reduced emissions.

Obviously, any savings made have to be offset against the annual cost of the system, but this is a fraction of the cost when compared to the labour savings made, especially if staff are being paid extra to work at weekends, evenings etc.

Next in line in driving the popularity of these systems, is the ease of operation.  Self-checking burner controls, for example, enableuninterrupted, unattended burner operation.  

Improved safety and conformance with current and future UK & EU legislation is also a key benefit and one that even 24/7 operational sites that are fully staffed are increasingly attracted to.  Unattended boiler operating systems have to meet Safety Integrity Level (SIL) 2; SIL being a measurement of performance required for a safety instrumented function (SIF). Based on the IEC 61508 standard, four SILs are defined, with SIL 4 the most dependable and SIL 1 the least. Many manually operated systems are at the lowest SIL level 1.

What makes for a good system?

Virtually all manufacturers offer unattended boiler operating systems to accompany their steam generators and boilers, but as you might expect they are not all equal (although they do all have to meet BG01).  One of the key differentiators between manufacturer’s systems is the interface with HMI, controls and operation.  A good system should have in-built data logging of activities and details of HMIs.  Generally, they have a wider range of functions, making them more valuable.

Taking unattended operation to the next level

Three day unattended boiler operating systems (essentially covering a weekend) are the standard and are written in to BG01 Guidance on Safe Operation of Boilers, the revised version of which was released in 2020.  But, with the introduction of seven day unattended boiler operating systems, those guidelines are already behind the curve.  

A relative newcomer to the market, seven day systems operate with the same principle as three day systems but have many additional benefits including extensive data logging, providing the user with valuable information.  Ideally seven day systems should meet BG01 Typical Arrangement 3 with a boiler house risk assessment on both the boiler feed water and returning condensate conditions.  Further water analysis equipment may need to be fitted, along with further boiler house protection systems such as fire detection to meet this high level of unattended operation, but the benefits are considerable.

Babcock Wanson’s BW7DAYS system, which comes with automatic Total Dissolved Solids Control, is the first seven day unattended boiler operating system to market and has proven highly popular.  It features the unique and innovative NAVinergy remote monitoring system which integrates all of the components necessary for the supervision and management of the boiler room: control, regulation, recording, visualisation and communication.  It enables organisations to monitor their boiler room from any device, anywhere in the world.  All relevant data - including regular tests - is recorded, saved and stored on a compact flash type memory which also records normal boiler operating data; all of which can be easily downloaded to a standard PC for record keeping.  The cost to upgrade from a three to a seven day system is negligible, which makes it all the more appealing.

Unattended boiler operating systems fills a gap

In 2021, the IET reported an estimated shortfall of over 173,000 workers in the STEM sector, which equates to an average of ten unfilled roles per business in the UK. Its recent Skills Survey shows that half of engineering businesses are experiencing difficulties in recruiting skilled staff.  These staff are in such short supply that more and more businesses are having to look at other solutions, primarily automation of plant.  Unattended boiler operating systems that provide seven day cover will only become more prevalent in the UK to meet this skills gap.

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs.  

02089537111 

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www.babcock-wanson.com

US-based surface protection solutions provider, Integrated Global Services (IGS), has been accredited with the esteemed ISO 9001 standard after an extensive two-day audit.

Following an ISO audit, Integrated Global Services (IGS) has been certified with the new ISO 9001:2015 standard for its Quality Management System (QMS). The certification recognises the company’s dedication to meeting customer requirements and maintaining its documentation, demonstrating to clients that its products and services meet all international quality standards.

Headquartered in Virginia, USA, IGS provides essential surface protection solutions for mission-critical equipment in a variety of industrial environments, all of which help to prevent equipment failure and drastically extend service life. A detailed audit of its Quality Management System (QMS) led accreditors to recognise the company as being worthy of the widely sought-after ISO 9001 standard. 

The team at IGS’ Tech Solutions is responsible for more than 100 pieces of performance qualification equipment, which are all operated through a complex management system. This system was highly praised by the auditor, whose report highlighted IGS’ ‘very thorough QMS that covers [the company’s] unique processes’. 

Iain Hall, Chief Technology Officer at Integrated Global Services, said; “We’re thrilled to have been accredited with the ISO 9001 certification. The auditor communicated that most companies take a template and try to squeeze their widget manufacturing into the same QMS. Our team was congratulated for taking the time to write our own, comprehensive QMS.”

“One aspect of the audit that was particularly commended was the traceability of our manufacturing materials. Random samples were tested, and supplier certifications were traceable to source to a level beyond the required standard and expectations.”

“I’m very proud of our team for their consistent efforts in ensuring quality for our clients, which has now been formally recognised by ISO. We will continue developing our QMS to deliver innovative and customised solutions to our customers”.

IGS' in-house state-of-the-art laboratory and research center provides their customers with the most accurate forecast of the performance of any field application.Watch a short video showcasing some of its capabilities.

www.integratedglobal.com

Industrial process heating equipment and solutions specialist Babcock Wanson has launched two new electric boiler ranges: the VAP EL 400V three-phase, 50Hz electric steam boiler, with models from 16 to 360 kW; and the e-Pack industrial electric boiler, with models from 500 to 17,000 KG/H.

As with all electric steam boilers, VAP EL and e-Pack use electrical energy to boil water and produce steam for process heating. Unlike many others though, they are configured for high efficiency approaching 100% with only minor standing losses. The boilers start quickly on demand – ideal for locations where grid power fluctuates - and react well to change of load.  Steam can be produced in a matter of minutes depending on the capacity of the boiler.  

Precise control of steam pressure – 4.5, 7 or 8.5 barg as standard, with higher pressures available on demand – has been built into the VAP EL, with multi stage and fully modulating input of power. With e-Pack boilers, the NAViNERGY operating system allows both on site and remote monitoring of operating parameters, for maximum convenience.

In addition to their high efficiency, VAP EL and e-Pack electric boilers have a number of further benefits, including simple installation. As the boilers do not consume fossil fuel, there is no requirement for chimneys, fuel storage or complicated gas piping. In the case of VAP EL, its compact size also means it requires minimum space for installation. All models are fully integrated and come with a Babcock Wanson factory tested control system for simple and reliable operation and are fully certified by Babcock Wanson in accordance with the PED for operation throughout Europe. They are delivered ready to operate, with just the connection to the electricity, feed water and the steam users required. Commissioning is controlled and repeatable.

Being powered by electricity, VAP EL and e-Pack boilers offer substantial environmental advantages as they produce no waste combustion gases and have very low overall emissions. From an operational perspective, this has the added benefit of removing the need for periodic monitoring of atmospheric emissions. Furthermore, they are quiet in operation and their robust construction ensures safe operation and long life, which adds to their environmental credentials.

VAP EL and e-Pack can be used in diverse process industries, such as food processing, drying, chemical, cosmetic and pharmaceutical, but are best suited to locations where electricity is a readily available and low-cost resource, or where it is not feasible to install a fossil fuel fired traditional boiler.

A full range of ancillary equipment, including feed water tanks and pressurised and atmospheric thermal deaerators, plus pressure reducing stations and steam control valves are available with VAP EL and e-Pack.

The VAP EL and e-Pack series of electric steam boilers are the latest addition to Babcock Wanson’s range of products and services for boiler houses and other process heating needs, including steam generators, thermal fluid heaters, hot water boilers, VOC and odour treatment by thermal oxidation, water treatment and process air heating solutions. The company aims to help optimise customer’s energy production with high quality products and efficient service.

For information on Babcock Wanson, go to www.babcock-wanson.com

Process gas burner specialists, Lanemark Combustion Engineering Ltd., has completed the development of a new in-house testing facility which is set to enhance services to its customers.  The Nuneaton-based organisation, which supplies burner systems for applications ranging from brewing and metal treatment to automotive manufacturing and, through an associated division, the petrochemical industry, says the new resource will enable larger, more detailed equipment analysis to take place while also helping to optimise customers’ emission controls.

“Our range is based on process tank, oven and duct heating systems through, respectively, our TX, FD, FDB and DB series,” says Jeff Foster, Lanemark’s Sales Director.  “In all cases, our success is centred on supplying the optimum configuration for each customer’s needs, so it is vital that our equipment undergoes the most rigorous testing and analysis procedures – both during product development and pre-installation phases.  This new facility will make a major contribution in this context.”

The announcement now of the company’s enhanced capability in this area will build on the role played by Lanemark’s longstanding testing installation.  Jeff Foster is keen to highlight key areas in which the new installation will help optimise this important element of production.

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“We can now test a greater range of both tank and oven burners in terms of size and output with specified configurations to match precise operating conditions,” he says.  He  points out that this now includes the company’s largest tank heating burner design, the TX80, using an 8” N.B. submersed tube heat exchanger.

“A wider range of emissions can also be monitored including NOx, SO2, CO2, CO and O2 as a result of the new facility incorporating a Horiba PG-350 flue gas analyser,” Jeff Foster explains.

The new test furnace now offers a volume measuring six metres in length and 2.5 metres in diameter.  No less than 25 viewing ports are available, each fitted with thermocouples to monitor temperatures of up to 1350°C, and pressure transmitters that can accommodate a range from -5 to +70 mbar.  Alongside this, the TX test installation provides improved flue gas testing accuracy and is able to address common issues such as condensation.

“Both the FD and TX test facilities are fully fitted with duct work and dampers to accurately reflect precise operating conditions,” adds Jeff Foster.  He explains that extensive plc control helps to optimise both set up and monitoring processes.

“We have always believed in working closely with our customers to ensure that the equipment we supply provides them with optimised usage in terms of performance, fuel consumption and emissions, and our investment in this new testing facility underlines this commitment,” concludes Jeff Foster.  “With the new service now up and running, we believe even greater benefits from our burner technology can be realised by users across our range of marketplaces.” 

Fulton is delighted to announce the appointment of Stephen Finch as applications engineer. Stephen joined the leading steam boiler and heat transfer specialist just as the UK government announced its lockdown measures to combat Covid-19, but that hasn’t prevented Stephen, who has a degree in mechanical engineering and background in design engineering, from absorbing himself in his new role.

Commenting for Fulton, managing director Carl Knight says: “As we continue to innovate and look at new heat transfer solutions, like the multi-award-winning VSRT steam boiler, Stephen will play an essential role in product development. He will also be assisting the quality department in ensuring compliance for the company’s latest range of heat transfer equipment, including our fuel-fired and electric steam boilers; and providing engineering support for customers requiring bespoke skid-mounted boiler solutions featuring ancillaries including water treatment, chemical dosing and blowdown.”