Book Your Place at PM5 Replaced – CEA Conference 2013

PM5 Replaced – HSE Guidance for Steam and Hot Water Boilerplant

Walmley, Sutton Coldfield, Wednesday 20th November 2013

Crawley, Gatwick, Wednesday 4th December 2013

This conference introduces the most significant development in the steam industry for over a decade and is therefore essential for operators, managers and owners to ensure the safe operation and management of steam and hot water boiler plant.

The Agenda includes:

HSE – The Safe Operation of Boilers
The CEA Boiler Operator Accreditation Scheme and Approved Training Courses
Legal Requirements for Boiler and Systems Inspection
Control Systems v Manning? What is the Optimum?
Why Boiler Water Quality Matters
How to Manage a Steam Boilerplant under the New HSE Guidelines

Don’t miss our Presentation! We will be presenting at 11:50 – 12:30.

Our presentation: Risk Assessment and Risk Management – Boilerhouses and Steam Systems will cover factors to be considered when designing and operating Boilerhouses and steam systems from a risk assessment perspective.

PLUS… for your chance to win a FREE place on our Boiler Operator Training course, simply quote BY when booking your place at the CEA conference and you will automatically be entered into our prize draw.

New Challenge Steaming Ahead

Powered by an innovative new boiler from Byworth, the historically famous steam tugboat ‘Challenge’ is going better than ever and drawing plenty of admiration on its travels over UK waters.

Having first found fame as an important participant in the 1940 Dunkirk rescue missions, the tug had needed a new boiler following the severe corrosion of its original coal-fired ‘Scotch’ type, due to sea water ingress.

As part of a £1million heritage lottery fund restoration project, Byworth designed a bespoke replacement, state-of-the-art triple pass boiler, producing a maximum continuous rating of 6,800 kg/h and operating up to 13.8 bar/g.

It incorporates twin furnaces and digitally controlled pressure jet dual fuel burners, which utilise both low sulphur gas oil and low sulphur intermediate fuel, for optimum performance.

Despite being smaller in size than the previous boiler, the new system achieves impressive standards of efficiency, heat transfer and turbulence – reducing costs and preventing deposits, making cleaning a less frequent requirement.

Byworth’s Phil Carr highlighted the reason for the company’s selection to contribute to such an exciting and prestigious project:

‘Space in the boiler house of Challenge was extremely confined, so our challenge was to produce a boiler to fit this restricted space that would also be arranged in such a manner that tubes could be replaced by withdrawing through the very narrow passageway from engine to boiler room.’

‘Working on the new boiler was an extremely interesting and diverse project, demanding the expertise and skill of experienced engineers from both boiler and combustion design disciplines, fortunately areas in which we boast considerable experience.’

Following the completion of the renovation, Challenge has returned to fully operational service as an educational resource and public reminder of the thousands of similar vessels that were once seen throughout the ports and harbour of Britain.

It has already welcomed on board many interested visitors of all ages, including some parties to keen to learn more about the creators of the boiler that helped the Challenge set sail once more.

For further details on the restoration of the steam tug, please visit stchallenge.org 

Best for Breweries – The MX Boiler

Smaller breweries throughout the UK are raising a glass to Byworth’s modestly sized but high-performance boiler house hero, the incomparable MX range – now available with a number of flexible leasing options.

Recently selected by York Brewery as their boiler of choice, the MX is a proven cost-effective and efficient answer for applications where light-to-medium steam load is required.

Key features of the MX include:

  • Achievable Low NOx Emissions
  • High-quality Dry Steam
  • Output Easily Achieved
  • Good Steam Volume
  • Generous Sized Shell and Furnace
  • Reliability and Long Lifespan

Of course, the obvious appeal of the MX range doesn’t just suit breweries – its qualities are also in demand with laundries, cleaning companies, food producers and pharmaceutical manufacturers.

Click here for more info on flexible leasing options, or contact our engineers for further information on dimensions, applications, technical specs and prices, or to arrange a site visit.

Byworth Boiler Hire Lets Off 24 Tonnes Of Steam

In late 2011 Byworth Boiler Hire received an enquiry to provide over 20,000kg/hr of steam to ensure the smooth decommissioning of a large industrial site in the Midlands. Following the initial quotation prepared by Sales Engineer, Michael Rutter, and a number of meetings an order was placed for Byworth to provide five dual fuel trailerised hire boilers coupled with operator training and 24 hour call out cover.

The final contract was based on adhering to rigorous site operation restrictions and Environment Agency emission constraints. The five packaged boilers that were supplied comprised a range of Byworth’s highly efficient Yorkshireman and Yorkshireman2 boilers, all of which were prepared to meet the latest HSE INDG 436 and CEA BG01 guidance notes for the safe operation of boilers.

Prior to delivery and installation Byworth Boiler Hire prepared the five dual fuel boilers and compiled a consignment stock of spares large enough to ensure smooth running and minimal down time due to minor component faults.

Following delivery the boilers were connected up to the newly designed and installed manifold supporting all services and were up and running in December. Initially the process demand required all five boilers to complete the remaining processes which ran to the end of March. At that point two boilers were de-commissioned leaving three boilers on site for the remaining period of the contract.

Byworth Boilers is the UK’s leading independent manufacturers of steam and hot water boilers and pioneered the hiring out of trailerised industrial boilers. Today the company has a fleet of over 100 trailer mounted, static and containerised boilers available for short or long term hire.

Raising the bar for steam boiler efficiency

Byworth Boilers are yet again raising the bar for steam boiler efficiency with the addition of an air to air heat exchanger to pre-heat the combustion air.

This, together with other fuel saving design features gives a predicted net efficiency of 94.3% for these new boilers which are currently being installed in Surrey.

Byworth’s Managing Director Peter Baldwin commented, “We have placed a great deal of importance on R&D in the past few years, the goal being reduced energy costs for our customers.   As an independent boiler maker, with all production taking place here in the UK and having our own expert design team, developing new concepts is perhaps relatively easy for us.”

The two Yorkshireman2 boilers are each 3500 kg/hr output and have a working pressure of 17 bar g.  The basic design of the Yorkshireman boiler is in itself important for efficient operation.  The three pas wetback boiler range is designed with generous shell and furnace dimensions.  A plentiful steam space is important for good quality dry steam and to reduce the risk of priming and “carry over”. The furnace length and diameter ratio, which is critical to reduce NOx formation, and the heating surface for optimum efficiency are all important features of the boiler design.    As a most efficient and reliable boiler range, the Yorkshireman has featured predominantly in Byworth’s R&D.  Peter believes, “If you want to push the boundaries of efficiency it is obvious to start with the best available boiler and add energy saving features to that basic design”.

Raising the bar for steam boiler efficiency Industrial BoilersThe inclusion of special X-ID fire tubes in the Yorkshireman2 boiler range gives a significant increase in efficiency.  The internal helical ribbing of these special tubes not only increases surface area, but creates a complex boundary layer attachment/reattachment phenomenon.  This reattachment vastly increases heat transfer from the tubes, up to 85% greater than for a plain tube.  The overall boiler efficiency for these 3500kg/hr boilers is increased by around 2%, and with a modest premium paid for this feature, payback is literally achieved in a few weeks.  Maintenance is the same as for plain tubes, and X-ID can be used with great results on fuel, even heavy oil.

Flue gas economisers are a proven concept and can improve boiler efficiency by up to 5%.  The heat in flue gases, which would otherwise be lost up the stack, is utilised in an air to water heat exchanger to preheat the feed water to the boiler.  The Byworth economiser seen here in the photo is a drawer type for ease of maintenance and located above the rear smoke box.

Even after the flue gases have passed through the economiser there is still usable heat.  The air to air heat exchanger shown here above the economiser draws clean air past banks of tubes in which the flue gases pass en route to the stack.  The combustion air then travels through specially designed ducting incorporating a bypass section for use should preheating not be required.  Air pre-heaters can be used without an economiser providing very cost effective fuel saving on all fuels.