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SSE & SAACKE – new partnershipWe are delighted that SSE, one of the leading energy suppliers in the UK and Ireland, has recently chosen to partner with SAACKE to bring substantial savings to local markets by using SAACKE’s proven micro gas turbine CHP and gas turbine flue gas burner technology - find out more at the 2016 Energy & Combustion conferences (see page 4).

Plant been running flat out over the winter period? Is it time for the burner to have its bi-annual service? Call yourSAACKE Regional Service Office to arrange for one of our Technicians to give the burner a new lease of life andensure it is running to optimum efficiency.

Not under contract and interested in our Bronze, Silver or Gold Service Contracts? Give us a call and we can quote the same day. Barbara is awaiting your enquiry on 023 92 333830 or via b.diplock@saacke.com

“A comprehensive maintenance programme can result in annual savings of 25% to 35% in most applications.”

What’s inside this issue

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Spotlight Issue 1 - 2016For boiler and heating plant users in the UK and Ireland

Bernie’s hot tips

New legislation is comingFind out how this affects you

2016 Energy & combustion conferencesEnergy, Efficiency, Emissions, Expertise

Dunlop Oil & Marine chooses SAACKENew boiler installed and commissioned

Regional Service Manager updateJohn Heneghan is appointed in the South

SAACKE UK team snippetsWelcome, good luck and congratulations!

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If you have a firing appliance, whether it be boiler, furnace, turbine or engine, having a rated thermal input equal to or greater than 1MW and less than 50MW, you have a ‘Medium Combustion Plant’ and you will need to be prepared for the introduction of new legislation.

The EU Directive 2015/2193 “on the limitation of emissions of certain pollutants into the air from medium combustion plants” will become law in the UK on the 19th December 2017. The Directive plugs the gap in legislation between the Industrial Emissions Directive 2010/75/EU which covers larger plant in excess of 50MW, and the ‘Eco Design’ Directive 2009/125/EC which covers smaller appliances.

Each individual appliance will be required to meet the Emission Limit Values (ELV’s) laid down for emission of Nitrogen Oxide (NOx), Sulphur Oxide (SO2) and Dust (particulates) which are the main contributors to ‘Acid Rain’. Furthermore it will be necessary to test and submit this data by prescribed dates including Carbon Monoxide (CO) emissions although currently no CO limit is specified in the Directive. Compliance with the ELV’s differ in timescale for new and existing plants, as well as for different combinations of plant size, plant type and fuel type.

MCPD timeline – key dates:

19 Dec 2017 - Transposition completed in Member States

20 Dec 2018 - New plant must be registered, test emissions and comply with ELV’s

01/01/2024 – Existing plant above 5MW must be registered and test emissions within 4 months of registration

01/01/2025 – Existing plant above 5MW must comply with ELV’s

01/01/2029 – Existing plant 5MW and below must be registered and test emissions within 4 months of registration

01/01/2030 – Existing plant 5MW and below must comply with ELV’s

Defra (Department for the Environment, Food and Rural Affairs) are currently holding workshops with stakeholders and industry specialists to discuss the current wide range of uncertainties regarding the implementation of the Directive. These include who might be the Regulating body – the Environment Authority or Local Authorities, the registration system, data management, penalties for non-compliance, how/who/where appliances are tested, and costs to operators. Final public consultation and refinement of the statutory instrument is expected in the spring of 2017. If you would like to be involved, contact Control.Pollution@defra.gsi.gov.uk

Main obligations for Plant Operators:

Register each appliance/obtain permit and update as required

Ensure plant meets ELV’s and monitor regularly

Take measures to ensure non-compliance is kept to a minimum

Record information regarding plant operation

Keep information proving the effective continuous operation of secondary abatement if fitted

Report changes or upgrades to plant which would affect applicable ELV’s

Assist Regulators during inspections to ensure compliance with the MCPD

Keep periods of start-up and shut down periods as short as possible

New regulations! More compliance! More tests and records! Extra costs!

Costs for implementing the Directive, regulating and controlling the data will be considerable. Initial indications from Defra are that costs will be passed to the polluter! Blunt we know, but that’s what their words say. It is suggested that an annual administration charge of £90 to £120 will apply with a maximum of £800 for the minority of higher risk plants.

In addition a one-off permitting/registration charge will apply of circa £200 (up to £1600 for the minority of higher risk plants). Plant operators should also be aware of potential increased costs for training, testing and data storage.

It is expected that the impact of the Directive will be considerable in that no plant currently burning heavy oil is expected to be able to meet the ELV’s. The change to natural gas as the primary fuel with gas oil as back-up/standby fuel is therefore expected to continue. Closures of coal fired power stations have been announced (LCPD impact) and considerable costs for solid fuel firing plant are anticipated for secondary abatement to achieve compliance.

We recommend that you start to plan for the introduction of the Directive and to future proof your plant. We suggest you review your fuel policy and consider a change away from high sulphur liquid fuel and solid fuels, obtain frequent fuel analyses from your fuel provider, collate emission test data for each plant to determine if it will be compliant, and consider combustion optimisation by the combustion equipment manufacturer.

Remember that it may be possible to modify the burner head or to fit an exhaust gas recirculation system to achieve compliance. Prior to ordering new burners, boilers or other plant, check for MCPD compliance but bear in mind that a boiler cannot be compliant – it is the burner type and design coupled with the fuel and combustion air (both having organically bound nitrogen) which with a given furnace size will dictate the plant emissions performance.

SAACKE have combustion equipment on both new and existing boilers that are performing well within the ELV’s for natural gas and gas oil fuels.

To carry out a site survey and check whether your existing plant will comply or for complete compliant new boiler plant give us a call on +44 (0) 23 92 333900

Or, to learn more and hear the latest information on this fast moving topic book to attend one of SAACKE’s regional Energy & Combustion conferences by visiting www.ukcombustionseminar.co.uk

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If you are reading this newsletter but don’t receive your own personal copy and would like to be sent one directly, please contact Susie Bell via s.bell@saacke.com or on 023 92 333831

Supported by

EliteConference programme Energy, Efficiency, Emissions, Expertise

Benefits of attending

Access to a range of advisory, consultancy and technical information to ensure that you keep boiler plant and heat generating equipment operating at optimum efficiency and with compliant emissions

Ensure your compliance with Health & Safety legislation

Keep abreast of developments in the energy and heat generating market

See the SAACKE Boiler-house Log Book that ensures you are recording mandatory tests to ‘best practice’, BG01 and Health & Safety requirements

Learn how to generate electrical power for your site and utilise the exhaust gases in your steam/hot water boiler plant – increase overall plant efficiency and save money

Learn of leading edge strategies for increased efficiency and reduction of energy costs

The opportunity to rub shoulders with and learn from leading industrial figures

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The first 2016 conferences took place in April, followed by Haydock Park and Daventry in May. It’s not too late to join us though! The remaining dates and venues are:

Tuesday 13th September – Dublin: Castleknock Hotel & Country Club

Thursday 15th September – Cork: Radisson BLU Hotel & Spa

Tuesday 4th October – Perth: Murrayshall House Hotel

Thursday 6th October – Bradford: Cedar Court Hotel

Presentations include:

Combustion Engineering Association and what it can do for you

Health & Safety legislation

BG01 – Guidance for the Safe Operation of Boilers

Boiler-house Technical Risk Assessment

Emissions legislation and potential impact of the ‘Medium Combustion

Plant Directive’

Energy losses in boiler plant operation and how to improve efficiency

SAACKE Micro-CHP System – boosting plant efficiency into the high 90%’s

SSE – The turnkey solution for Micro-CHP systems

Practical exercise and guidance to enable you to carry out a Boiler-house Technical Risk Assessment

Benefits

Each delegate attending the Conference will receive a copy of ‘A Better Use of Energy – A Practical Handbook for Combustion’. In addition you will receive a USB containing all of the presentations from the event, including copies of CEA Guidance on Safe Operation of Boilers Ref. BG01, HSE Safe management of industrial steam and hot water boilers Ref. INDG436, and the MCPD EU Directive.

More information

For further details on the conferences, please contact Susie Bell via s.bell@saacke.com or on+44 (0) 23 92 333831. You can also visit www.ukcombustionseminar.co.uk to find out moreand apply for tickets.

The 2016 Energy & combustion conference programme

Dunlop Oil & Marine chooses SAACKE for boiler project Dunlop Oil & Marine Limited, part of Continental AG, has an unrivalled track record in the design, manufacture and supply of oil and marine hoses to the global oil and gas industry.

Dunlop Oil & Marine approached SAACKE when they realised that one of their two steam boilers at their Grimsby site was in need of replacement. They had SAACKE burners fitted to the two existing boilers, had used SAACKE to Service the plant for 25 years and approximately 8 months earlier had employed SAACKE to upgrade the newer of the two boilers. This upgrade included electronic fuel/air ratio control to the burner and an economiser fitted to the boiler to improve plant efficiency and reduce fuel costs.

They asked SAACKE for advice on how to move forward. Rather than replace the boiler for a like for like size, SAACKE recommended a steam survey be completed. This entailed taking steam meter readings over an extended period of time to get a peak steam requirement. This survey was completed over a number of weeks to run in line with the site’s production needs. As well as running the site’s normal production process the system was also pushed by running an over capacity production. This was to ensure any revision in steam loadcould cope with any future expansion in the site’s steam demand.

The survey found a peak demand of approximately 5,000kg/h of steam would be required. From this information Dunlop Oil & Marine were able to put a specification together to replace the boiler, which included the details of work to be completed by the successful contractor and in-house. The in-house works included refurbishing the boilerhouse once the old boiler was removed. The specification for the boiler included DDCC SCanView burner management controls, complete with the integrated Boiler Water Controls (BWC), fitted to a SAACKE burner. This is to allow communication between the new boiler and the boiler converted 18 months earlier.

As part of their standard purchasing procedure, Dunlop Oil & Marine tendered the project to a minimum of three separate companies to supply, install and commission a boiler package to match the specification. After various meetings and negotiations the order for the complete package was awarded to SAACKE Combustion Services Limited who used Torque Engineering, an approved contractor, for the installation of the boiler and the client selected a Cochran Boiler.

The old boiler in place on site

The old boiler arriving in 1969

The old boiler coming out after 46 years The new boiler going in

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Once the order was placed, SAACKE provided a programme of works for the delivery of the equipment, installation of the plant and finally commissioning of the complete package. With an approximate 16 week delivery programme, 4 weeks installation and 1 week’s commissioning, the client and SAACKE agreed a completion date.

The old boiler was taken out of the boilerhouse and removed from site by S Lyon & Son (Haulage) Limited, a specialist in heavy plant haulage, approximately 4 weeks prior to the delivery of the new boiler to allow the site team sufficient time to refurbish the boilerhouse and to lay a new floor. S Lyon had also been contracted to deliver and position the new boiler.

During this period an additional order was placed on SAACKE to modify the gas pipework within the boilerhouse, to enable easier isolation of each of the boilers and for the installation of a gas meter into each boiler incoming line.

Other preparation work was completed pre boiler delivery. Although the boiler was delivered slightly behind schedule, the preparation work that had been done in advance ensured the installation schedule was maintained. With minor modifications to existing services the new boiler was connected to the existing stack, fuel and feed water pipework and steam main.

A combination of the Torque Engineering team completing the mechanical installation and members of the SAACKE Midlands Service Team carrying out the electrical installation, the project time schedule was maintained to ensure the commissioning and on-site boiler inspection could be completed to the agreed schedule.

Post-handover, SAACKE maintained close contact with the client and a number of snagging items that occurred were reported and dealt with in good time.

With the necessary accumulation tests and equipment commissioning complete, the boiler installation was signed off by the client’s inspection authority. The project had been completed and handed over to the client within the pre-contract agreed time schedule.

We are pleased to announce that John Heneghan has been appointed as the new Regional Service Manager for the Southern region and we wish him all the very best in his new role. We would also like to thank Paul Nolan for all his efforts during his time as Acting Regional Service Manager. Paul will now revert to his Training Manager role working out of the Crawley Office, although he is of course on hand to help as John settles in! Wendy Scott continues to provide administrative support to the Southern office.

John’s contact details are:SAACKE Combustion Services Limited, Unit 6, Southpoint,Old Brighton Road, Lowfield Heath, Crawley, RH11 0PR

Tel: +44 (0) 1293 853953Fax: +44 (0) 1293 543442 Email: j.heneghan@saacke.com

New Regional Service Manager – South

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Paul Nolan John Heneghan Wendy Scott

The new boiler almost ready for use!

“On my behalf can you please thank everyone at SAACKE who was involved in the installation and commissioning of the new replacement boiler here at Dunlop Oil & Marine Ltd. The project went very well and I would have no hesitation in using SAACKE again.”

Phil Pattison - Mechanical Project Engineer, CAPEX Team Dunlop Oil & Marine Ltd

Derek Partington (third from right) enjoyed a farewell lunch with some of his SAACKE colleagues during his last week at work. We wish him a long and happy retirement.

Welcome to the world Halle Palmer Hartin who was born on 9th January 2016 at 8.09AM weighing 7lb to proud parents Adam Hartin (Aftersales Engineer, Havant) and his partner, Hollie. Big sisters Phoebe-Rae and Ferne Harper are even more proud!

Barbara Diplock (Service Administrator, Havant) performed in ‘Sweeny Todd: The Demon Barber of Fleet Street’ in November 2015.

The production involved a 24 piece orchestra and a working barber’s chair with an exit into a pit below. Lots of people had fun testing out the chair!

Barbara loved performing in this show. There was a full house most nights which made the 4 months of rehearsing all worthwhile. They even had to find some extra chairs for the last night!

The next production of the comedy ‘Lend Me a Tenor’ will be in June. Good luck, Barbara!

Sarah Elkington (Service and Spares Financial Administrator, Havant) took up pole dancing less than a year ago and is already at Intermediate Level (Level 3).

Sarah says, “My body strength and tone have increased significantly since I’ve been doing it, and I get a great sense of achievement from it – far more than I would from just going to the gym. There is no way of learning to do the moves, you just have to keep trying until you get it. I like to try and master a new move every week. There are so many clichés surrounding this form of dance, when in fact it is something that takes a lot of focus and dedication, and is currently producing some world class athletes.”

We are pleased to welcome:

Peter Furmage Service Technician, Midlands

Josh Rendle Apprentice, Havant

Adam Goodson Service Technician, Midlands

Nick Readings Service Technician, South

Jonny Bates Service Technician, Midlands

Derek Partington (Service Technician, Midlands) who retired on 31st January 2016 after 23 years with SAACKE.

To John Heneghan (Regional Service Manager - South) who has recently celebrated 10 years with SAACKE UK Companies.

Well done as well to Matthew Walker (Service Technician, Midlands) who has gained his Higher National Certificate (HNC) with Merit in Electrical and Electronic Engineering and also to Stephen Howells (Business Development Manager) who has achieved Fellowship status of the Chartered Management Institute.

Welcome

Good luck

Congratulations

UK team snippets

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SAACKE Combustion Services Ltd.Langstone Technology Park,Langstone Road, Havant,Hampshire, PO9 1SA. England

Telephone: +44 (0) 23 92 333900Website: www.saacke.com