Spotlight Issue 2 – 2017 For owners and operators of heat generating plants in the UK and Ireland NEW - Boiler Operations System Supervisor (BOSS) No remote alarm system installed? The new SAACKE BOSS panel can be fitted to a current operating system to enhance safety levels and with conformity to recommended alarm response times. It can be installed with any brand of burner/control equipment. Find out more on page 4. What’s inside this issue 02 A new chapter at SAACKE UK Looking forward to a bright future 05 SAACKE Boiler-house Technical Risk Assessment What’s it all about? 06 SAACKE Marine Systems - EGCS-HM scrubber On a mission to reduce sulphur emissions 08 SAACKE UK team snippets We say some goodbyes and welcome some new faces Hot tips SAACKE don’t just look after SAACKE equipment! We offer Aftersales support for burners manufactured by other companies and boilers too. Read more on page 3. We have had some excellent feedback from our CPD accredited 2017 ‘E4U Elite’ conference programme that is well underway. You can still join us in September – please visit www.conferences.saacke.co.uk for more information and to book. Find out more on page 3. SAACKE Service Contract customers will receive their next SAACKE Boiler-house log book in November in preparation for the new year. If you don’t have a Service Contract with us or you wish to order further copies, please get in touch. The log book costs £75 including VAT, postage and packing. SAACKE Combustion Services Ltd Telephone: +44 (0) 23 92 333900 Email: [email protected]
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Spotlight issue 2 – 2017 1Spotlight Issue 2 – 2017 For owners and operators of heat generating plants in the UK and Ireland
NEW - Boiler Operations System Supervisor (BOSS)No remote alarm system installed?
The new SAACKE BOSS panel can be fitted to a current operating system to enhance safety levels and with conformity to recommended alarm response times. It can be installed with any brand of burner/control equipment. Find out more on page 4.
What’s inside this issue02
A new chapter at SAACKE UK Looking forward to a bright future
05 SAACKE Boiler-house Technical Risk Assessment What’s it all about?
06 SAACKE Marine Systems - EGCS-HM scrubber On a mission to reduce sulphur emissions
08 SAACKE UK team snippets We say some goodbyes and welcome some new faces
Hot tipsSAACKE don’t just look after SAACKE equipment! We offer Aftersales support for burners manufactured by other companies and boilers too. Read more on page 3.
We have had some excellent feedback from our CPD accredited 2017 ‘E4U Elite’ conference programme that is well underway. You can still join us in September – please visit www.conferences.saacke.co.uk for more information and to book. Find out more on page 3.
SAACKE Service Contract customers will receive their next SAACKE Boiler-house log book in November in preparation for the new year. If you don’t have a Service Contract with us or you wish to order further copies, please get in touch. The log book costs £75 including VAT, postage and packing.
The end of an eraOn 17th May, we said farewell to our Managing Director, Malcolm Cook as he retired from SAACKE after over 37 years of service.
Joined by colleagues from our Head Office in Bremen, Germany including Henning Saacke as well as Malcolm’s family, we enjoyed some tea/coffee and delicious cake with Malcolm before saying our goodbyes. We wish him all the very best for a long and happy retirement. Apparently his wife has a long job list at home for him to get started on and he is also going to do some baby-sitting for his grandchildren as well as develop some hobbies so he will have plenty to keep him busy for a while yet!
And the beginning of a new chapterSo now we look to the bright future with some new roles in the management team.
We are delighted to welcome Kristian Sumfleth as the new Managing Director of SAACKE Combustion Services Ltd. Kristian joined the SAACKE Group in 2012 as Global Service Manager having previously worked in the paper converting and wind turbine industries. Service development incorporating manpower, material and information logistics from a customer perspective is a real passion of his.
Kristian says, “I look forward to continuing the successful development of SAACKE Combustion Services Ltd with a great team in place. The team spirit and a focus on customer demands are key. Creating long-term partnerships with our customers will be the solid basis for us.” Kristian is also in charge of the worldwide service strategy for the SAACKE Group (Industrial Solutions).
Phil Kemp, previously Aftersales Manager, now has a new role within the company as General Manager. Phil comments, “I am really looking forward to the new challenges at SAACKE Combustion Services Ltd. Along with our new Managing Director, Kristian Sumfleth, we are here to support you.”
Adam Hartin is the new Aftersales Manager and adds, “Working at SAACKE for the past 11 years as a Service Technician and then a Senior Service Technician in the UK and overseas followed by a period of assisting the Service department from Head Office, I have seen how both challenging and rewarding the Aftersales market can be. With Kristian and Phil, together with dedicated and knowledgeable trainers, service technicians and a strong back-up team at Havant, I am confident that we can continue to meet our customers’ requirements with the high quality products and service that SAACKE is known for.”
Pictured left to right: Adam Hartin, Kristian Sumfleth, Phil Kemp
Spotlight issue 2 – 2017 03
We support all brands of equipmentThe Aftersales support for customers whether they have SAACKE equipment or equipment manufactured by other companies is a major priority for us.
We offer Service Contracts with varying levels of complexity to suit all combustion plant.The benefits are there for all:
Lower downtime costs and service savings Targeted measures to increase efficiency Reduced fuel/energy consumption Increased reliability Reduced emissions Structured maintenance processes
So for Servicing of all types of burners and boilers, Spares, Training, Boiler-house Technical Risk Assessments, Modernisations, New Plant and Emission Testing, we are able to offer you the technology of the future.
Last chance for conferences in 2017!The E4U Elite conferences programme began in March and there are now just two remaining dates for 2017.
We will be in Coventry on Tuesday 12th September and Brentwood on Thursday 14th September. To find out more and to book, please visit www.conferences.saacke.co.ukWe have had some excellent feedback from delegates such as:
The event has been accredited by The CPD Standards Office. On completion of the event and submission of feedback, a CPD Certificate will be issued enabling delegates to claim CPD hours or points.
Get your tickets while you can!
“ Exhibition content excellent and staffed by helpful people”
“ I found the event very beneficial and will be passing on my recommendation to colleagues who I think should attend future events”
“ SAACKE take superb initiative in hosting this event”
04 SAACKE UK
Boiler Operations System Supervisor (BOSS)The SAACKE BOSS (Boiler Operations System Supervisor) has been designed for use on sites that have no remote alarms present and can also be fitted into installations where older traditional set-ups are still operating.
The BOSS panel is a stand-alone control panel that is fitted inside the Boiler-house and contains contacts for three boilers that are hardwired to the respective boiler control panel’s lockout relay. In the event of a critical lockout (Low water, Extra Low water or Excess pressure/Temperature) the contacts in the BOSS panel will activate a logic controller and start a countdown timer. This timer will be set to fall in-line with the standard alarm response times for boiler alarms in the UK (7-12 minutes).
If the operative has not been able to attend to the alarm condition within that time, the BOSS panel will double lock out the boiler and show a flashing beacon and fault lamp. The boiler will now be double-locked out and the Trained Boiler Operator will need to reset the burner/boiler and the BOSS panel before it can be placed back into operation.
Blowdown system interlockAnother useful function of the BOSS panel is the provision of a blowdown system interlock included as standard. Automatic bottom blowdown valve control in the UK and Ireland is becoming more common as controls and systems are upgraded or retrofitted.
Above: Our new product to enhance current safety levels
Guidance Note BG03 lists a requirement to have the bottom blowdown valves interlocked so that simultaneous blowdown cannot occur unless the system has been designed to do so. In addition to the safety alarm response time, the BOSS panel can take the timed interlock function of the bottom blowdown into account through one simple auxiliary panel.As with all safety related modifications and improvements, SAACKE Combustion Services Ltd recommends that a full Boiler-house Technical Risk Assessment is completed to assess the needs of the plant.
The BOSS panel is not intended to replace external Emergency Stop buttons or locations, but to enhance current safety levels and benefit safe operation.
Advantages at a glance Conformity to recommended alarm
response times
Blowdown interlocks can be run through the same panel
System can be used in tandem with pre-existing remote alarm system to improve safety
Can be installed with any brand of burner/control equipment
No need to run lengthy flying leads to remote locations from the Boiler-house
Assists Trained Boiler Operators in maintaining a safe plant when they are not in attendance
Simple operation, basic overview and demonstration of the new panel is all that is required
To find out more, please call us on +44 (0) 23 92 333900.
General panel arrangement
Spotlight issue 2 – 2017 05
Boiler-house Technical Risk AssessmentSAACKE Combustion Services Ltd offer a consultancy-based service to assist customers in producing an in depth site specific Boiler-house Technical Risk Assessment in line with all current regulations and good practice standards.
The Boiler-house Technical Risk Assessment needs to take into account numerous documents and standards. It must also focus on several different disciplines within the plant area, but must not be solely focused on the plant area itself.
SAACKE are able to undertake the full Boiler-house Technical Risk Assessment process on your behalf and produce a formal written report in line with HSE standards.
We can also produce all gas supply line schematics and plant layout drawings utilising computer aided design. We will then retain copies on file for future amendments as the site develops or changes. This will make future modifications simpler and aid you in producing an up-to-date document for examination by competent persons whenever required.
In order to do this effectively, we will attend site to complete a full survey of all of the available equipment and any supporting paperwork that may exist already such as written schemes of examination or previous risk assessments.
In the majority of cases, we are able to assist with remedial action to improve the situation where requested.
For further information on the Boiler-house Technical Risk Assessment and training enquiries, please contact Paul Nolan, Training Manager, via [email protected]
Above: Example of a written report which will be supplied to you printed and smartly bound
Above: Example of a schematic layout drawing which will be supplied to you on A0 sized foam backed board
A
1615
C
B
1413
D
F
E
1211109
THIRD ANGLE PROJECTION
G
J
H
K
SHEET
MCONTRACT REF:
15
R
DRG SIZE: A1
REVISION
L
PRODUCT REF:
1413
DRAWN:
DATE:
1211109
8765
DO NOT SCALE - IF IN DOUBT ASK
4321
A
C
B
D
F
E
8765
DIMENSIONS IN mm UNLESSOTHERWISE STATED ON DRAWING
Langstone Technology Park, Havant,Hampshire PO9 1SA Great BritainTel: +44 (0)23 9233 3900Fax: +44 (0)23 9233 3901E-mail: [email protected]: www.saacke.com
A1 DRG sheet rev 1.0 - SE ST4 2D
REVISIONSREV. DATE BY MODIFICATION
SOLIDEDGE 2D
PDN-RA-20
PDN-RA-20
PI PI PI
F F F
M M M
PI
PI
PI
N
E
S
W
M F
GAS BOOSTER AND LPG IGNITIONLAYOUT DETAIL
12 DEG. NORTH
BLOWDOWN VESSELPM60 (BG03)
MAIN CHIMNEY (WITH FLUE LINERS)FLUES TO BOILERS NOT SHOWN FOR CLARITY
WORKSHOP AREA
DUPLEX OIL PUMPING STATION
LPG IGNITION GAS STORAGE(EXTERNAL)
CENTRAL CONTROL PANELCOMBINED STEAM HEADERAND ACCUMULATOR(AT HIGH LEVEL)
SAACKE DDCCCONTROL PANEL
MAIN STEAM TRAP-SET
MAIN STEAM TRAP-SETSAACKE GTM-1 GAS TRAIN
CALORIFIER/PUMPING ROOM
STANDARD CALORIFIERFEEDWATER PUMPSFOR BOILERS AND DE-AERATOR
CONSTANT TEMPERATURE
MANUAL GAS ISOLATION
EMERGENCY FUEL ISOLATION VALVE 6"O LOW LEVEL
SINK AND WASH AREAWITH FIRST AID
EASI-TREAT 35
EASI-TREAT C35WATER MAKE-UP
BASE EXCAHNGE
REVERSE-OSMOSISPLANT
EASI-TREAT 3F
MODULATINGFEEDWATER CONTROL VALVE
CHECK-VALVE 2"O
PRESSURE REGULATINGVALVE (FEEDS BACK TO DE-AERATOR ON THE FIRST FLOOR)
5% ECONOMISER 5% ECONOMISER 5% ECONOMISER
BOILER No.3 BOILER No.2 BOILER No.1
FROM HOTWELL(AT HIGH LEVEL)
THREE-WAY-VALVE
LPG IN 37 MBAR
NATURAL GAS IN
RE-SET GAS PRESSURE SWITCH4" WG (10 MBAR)
FLEXIBLECONNECTION
CHECK VALVE
FILTER
METER
GOVERNOR
GAS SOLENOIDVALVE (SKP TYPE)
DUAL IGNITION MEDIUMTO BURNER
NATURAL GAS TO BURNER
GAS CONTROL VALVE(MK3 GCV)
23106
1424
8
2057 2047
721
677
690
617
5719
7208
OPEN VENTS
STEAM TO HOSPITAL
SCHEMATIC LEGEND
NATURAL GAS
DIESEL OIL (35SR1)
STEAM
BLOWDOWN
LPG (PROPANE) IGNITION MEDIUM
SPARGE TO DE-AERATOR
FEEDWATER SUPPLY
What’s included? A full day on site to survey the current
installation and take detailed measurements
Completion of a site survey form detailing all items required for the final report
An A0 sized foam board colour drawing showing the current site layout and critical services in line with current Gas Regulations and best practice standards (example shown below) which will be produced and sent to site at a later date together with a copy of the report itself
Some of the items covered are:
A review of the current operations in line with Guidance Note BG01
BG01, BG03 and BG04 review and compliance recommendations based on survey results
Confirmation of the current site arrangement detail under Guidance Note BG01 (Typical arrangement 1, 2, 3 or 4 for hot water installations)
BS 7671 Wiring Regulations (17th Edition)
BS EN 676: 2009 Automatic Forced Draught Burners for Gaseous Fuels
BS EN 298: 2012 Automatic Gas Burner Control Systems
IGEM UP/10 Installation of Flued Gas Appliances in Industrial and Commercial Premises
BS 5410 PT1 Code of Practice for Firing Installations
06 SAACKE UK
Helping to reduce sulphur emissionsAround the world, the overwhelming majority of ships run on engines and boilers powered by heavy fuel oil. The resulting combustion exhaust gases that are emitted contain soot and sulphur oxides that pollute the environment.
The International Maritime Organization (IMO) has ordered the gradual reduction of the sulphur content in exhaust gases. Accordingly, these limit values have been reduced to 0.1% in the emission control areas (ECA), including the North and Baltic Seas, since the start of 2015. This upper limit has already applied in ports in the EU since 2010. Around the world, the limit outside the ECAs will be reduced to 0.5% from the year 2020.
The gradual reduction of limit values is now creating a need for action amongst shipping and charter companies. In new ships, gas-powered or dual fuel solutions are playing an increasingly important role – but a gas-based propulsion system is expensive and the fuel is subject to significant price fluctuations. Ports around the world also currently lack the necessary infrastructure to bunker fuel gas.
There is also the question of usability over long distances and, ultimately, conversion to dual fuel is also a complex and expensive challenge.
Alternatively, an exhaust gas wash tower can be installed instead of using low-sulphur fuel. One solution is the SAACKE EGCS-HM scrubber.
The SAACKE EGCS-HM scrubber is a more efficient and sustainable alternative for retrofits as well as the construction of new ships. This exhaust gas cleaning system ensures the continued use of heavy fuel oil while safely complying with the required emission limit values and enabling a lower-cost operation.
The scrubber achieves removal rates of up to 99% for SOx and fully satisfies all of the requirements imposed by the IMO MEPC.259(68) regulation. The SAACKE multistream exhaust
gas cleaning system can be connected to main and auxiliary engines as well as boilers. Two fans, connected in parallel, bring the exhaust gas flow from the emitters together and conduct this into the wash tower.
Currently, relatively few ships are equipped with a scrubber but intelligent solutions relating to the purification of exhaust gases will gain more and more importance in the shipping industry. The SAACKE EGCS-HM scrubber meets the strictest emission regulations using a unique combination of efficiency and sustainability - for retrofitting or for newly constructed ships. The system is ideal for all ship applications.
Improvements in air quality particularly around ports will be seen as a result of EGCS technology, bringing health benefits to all.
For all marine enquiries, please contact Stuart Rielly, UK Marine Sales Manager, via [email protected]
Above: A SAACKE scrubber is installed on the back of the stack on a crude oil tanker, image is prior to it being enclosed.
Spotlight issue 2 – 2017 07
Creating value – combining steam and electricitySAACKE deliver highly efficient combined heat and power (CHP) systems including turbine exhaust gas burner and control technology.
The company Interquell GmbH, located in the south of Germany, requires process steam to produce food, such as baby food and cereals. To increase efficiency and save costs, the food producer decided to install a SAACKE Micro-CHP system mounted by the plant engineering company Lausser. The combination of micro gas turbine, turbine exhaust gas burner and steam boiler was selected, because CHP systems with a gas engine cannot guarantee the requirements.
A micro gas turbine was installed upstream from the SAACKE DDZG-GTM turbine exhaust gas burner, which produces 1,460 MWh of electrical energy at the location per year. The use of the hot exhaust gas of the turbine as combustion air in the turbine exhaust gas burner increases overall efficiency up to 97%. The additional use of a flue gas calorific value exchanger significantly increases the overall energy efficiency. The challenges of this highly efficient solution included effective time management and comprehensive service. Downtimes had to be kept to a minimum to ensure that continuous operation was not interrupted.
The delivered DDZG-GTM can be supplied as a dual fuel burner for natural gas and light fuel oil (LFO). No additional atomising medium is required for LFO. Fresh air operation, a turbine exhaust gas (TEG) operation and waste heat operation (holding operation) is available on the burner side – always in combination with the lowest emission values. The burner can be safely and reliably operated with a high
or a low amount of excess air (lambda 2.1 to 1.1). The micro gas turbine can either be provided by the customer or delivered by SAACKE.
The comprehensive scope of supply for Interquell GmbH included the delivery of the burner, the fuel supply for natural gas and LFO, the fan for fresh and secondary air, the installation of measuring and monitoring equipment and the electric control unit. The SAACKE service included installation, commissioning and trial operation as well as a 24 hour on-call service.
The combination of the micro gas turbine and the SAACKE DDZG-GTM turbine exhaust gas burner is the key to the success of the SAACKE Micro-CHP system. A high level of overall efficiency, the generation of electrical energy and the efficient and low emission combustion of turbine exhaust gases help save costs and efficiently generate process steam. This has also been tested and certified by external experts.
“ The innovative SAACKE solution not only proved itself in active operation – the plant also received the LEW Innovation Prize 2013.”Georg Müller, CEO, Interquell GmbH
“ Very happy with the work carried out. Work carried out to a high standard. Good communication with staff. Always at the end of the phone for advice.”
“ I receive an outstanding response at all times.”
“ Good service as usual. Keep up the good work.”
“Excellent service. Arrived on site when they said they would. Had problem diagnosed and repaired in a timely manner.”
Customer comments
08 SAACKE UK
WelcomeWe are pleased to welcome:
Graham Woolven Service Technician, South
Daniel Foy Trainee Service Technician, North
Stephen Milakovic-Jackson Service Technician, Midlands
Michael Kinnaird Service Technician, Scotland
Dale Camplin Regional Sales Manager, North
CongratulationsCongratulations to the following employees:
Kenny Marshall who becomes Regional Service & Sales Manager (Scotland) following Mike Brawley’s retirement. Good luck, Mike!
Jim Hutchinson (Service Technician, North) Paul Nolan (Training Manager) who have both recently celebrated 10 years
David Golden (GmbH Key Account Director) who has recently celebrated 25 years with SAACKE UK companies.
UK team snippets
Happy RetirementTerry Hibbard (Service Co-Ordinator, Havant) retired on 24th March after over 35 years with SAACKE in the UK. Terry is planning on spending much more time at his allotment!
New arrivalGuy Harper (Service Technician, North) and his partner Nina celebrated the birth of their son, Spencer, on 5th April.
FarewellJanet Albien from Bremen in Germany has been working with us in Havant since April and returns home at the end of June. Janet says: “I really like the work that I’m doing and the insight that I’m getting in to such an international company. I feel very welcomed here.” When Janet is back in Bremen, she starts her clerical apprenticeship for a global company.
DistinctionAlex Atteman’s (Engineering Apprentice, Havant) project open day at South Downs College, where Alex is currently studying, took place on 3rd May and was attended by Phil Kemp (General Manager) and Adam Hartin (Aftersales Manager). The project is part of his Level 3 Engineering Diploma. Alex created a 3D printed boiler for educational purposes, scaled down to 1/10th of its size. Although he had some challenges along the way, Alex’s hard work paid off as he has been awarded a ‘Distinction’ grade for this project.
