Issue 11 2014
Innovative Solutions for a Greener Tomorrow
Why selecting the right tank can equal anaerobic digestion success
EU reports lowest greenhouse gas emissions on record
The technology behind the UK’s largest energy from waste facility
E N V I R O N M E N TA L - E N E R G Y - W AT E R - W A S T E
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Innovative Solutions for a Greener Tomorrow Issue 11 - 2014
Cover Story - Page 10
CONTENTs Industry News
4
AD & Biogas
10
Environmental
16
Energy - Renewables
25
Energy - Monitoring
28
Efficiency & Cost Reduction
31
Fire & Safety
36
Sustainable Development
38
Water Treatment
42
Waste Management
46
Landia’s GasMix At Cory’s First AD Plant - Page 15
Vattenfall announces two contract wins for Pen y Cymoedd - Page 26
Emily Seymour Editor
emily@sustainableengineeruk.com
Martin Richardson Sales Manager
sales@sustainableengineeruk.com
Dan Humphrys Publishing Director
dan@sustainableengineeruk.com
Martin Holmes Publishing Director
martin@sustainableengineeruk.com
UK’s largest energy from waste facility - Page 46 Published by Sustainable Engineer Ltd 9 Upchurch Walk, Margate Kent CT9 3NT TEL: + 44 (0) 20 3289 4075 www.sustainableengineeruk.com
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INDUSTRY NEWS New test facility will help marine energy ride the tide to success The trade association representing the wind, wave and tidal energy industries, RenewableUK, is hailing the opening today of a new marine energy test centre at the University of Edinburgh as another positive example of the progress being made by the sector. The new £9.5m FloWave Ocean Energy Research facility will have the capability to recreate scale version equivalents of waves reaching 28 metres in height and fast-moving currents of up to 14 knots which are typical off coastlines around the UK and Europe. The opening of this new state-of-the-art site, based at the University of Edinburgh’s science campus, marks another step towards the commercial development of wave and tidal energy at a potentially lower cost. The centrepiece is a circular pool, 2m deep by 25m across. By allowing developers to test devices in a range of sea conditions, on demand, the time in which they can see demonstrable results in their work could be significantly shortened. Similar tests in open waters may take months or years, Issue 11 - Page - 4
while the new site can achieve these in days or weeks. It is expected that the facility will be used to test full-scale devices such as wave and tidal energy converters, but it can also be utilised to develop floating offshore wind platforms and refine vessels needed to install offshore wind projects. RenewableUK’s Wave and Tidal Development Manager, Dee Nunn, said: “The opening of Flowave adds a string to the bow of the UK’s suite of test facilities for marine energy and will contribute to maintaining the worldleading position of the UK in this sector. The facility will help improve reliability and reduce costs and the results could provide additional confidence to investors as we move towards the first commercial arrays. The scale of opportunity for wave and tidal is huge with the potential to supply around 20% of the UK’s current electricity demand and we hope this will encourage more investors to get their feet wet”.
Ricardo-AEA to propose 2030 renewable energy targets for Scotland Scotland, and the UK as a whole, has legally binding targets to reduce carbon emissions by 80 percent by the year 2050. Renewable energy will deliver a major part of these reductions and Scotland is already committed to meet 30 percent of the country’s total energy consumption from renewable sources by 2020. Scotland has also set out an ambition to secure 100 percent of its electricity demand from renewable energy by 2020. With excellent progress made towards the 2020 targets, a key policy issue is the need to assess the potential for renewable energy in 2030. The Ricardo-AEA project will include an assessment of Scotland’s current renewable energy provision and its existing aspirations, together with its corresponding emissions targets. UCL’s contribution to this is offered through its world-leading Energy Institute in combination with UCL Consultants Ltd. The UK MARKAL model – a multi-time period linear optimization model developed extensively by UCL Energy Institute and Ricardo-AEA, portraying the entire UK energy system
from imports and domestic production resources through to energy service demands – will then be used to develop renewable energy scenarios covering heat, electricity and transport in 2030. The work will provide a robust evidence base to help support decision-making on renewable energy issues in Scotland. “The recent IPCC reports confirmed the degree of change in energy supply that is needed to mitigate dangerous climate change,” said RicardoAEA renewables knowledge leader Colin McNaught. “Scotland has already made great strides towards its renewables target for electricity and is rich in renewable energy potential. As the need to decarbonize the power sector has been widely recognized, much attention has been paid to how this would be done. Our project will therefore also focus on the increasing importance of renewable energy for the heat and transport sectors. We’re excited to have won this important project which should help Scotland to move towards a broadly supported 2030 renewable energy target.”
German solar breaks three records within two weeks • • • • •
Over 50 percent of total demand met with solar for the first time New solar peak power production record set Weekly total solar power output hits new high Sales of solar power storage systems set to skyrocket in Germany Renewables experts from Germany Trade & Invest at Energy Storage China
“German solar demonstrated just what it is capable of in the first two weeks of June,” says Tobias Rothacher, expert for renewable energies at Germany Trade & Invest, the country’s economic development agency.
The latest analysis from the Fraunhofer ISE solar energy research institute shows that photovoltaic systems generated a record 24.24 GW between 1 and 2 pm on Friday, June 6 and a total of 1.26 TWh over the entire week. On June 9, which was a national holiday in Germany, solar power production peaked at
Onshore wind is vital to help UK reach 2020 renewable energy target RenewableUK has said that if the UK is to meet its legally-binding target of generating 15% of all energy from renewable sources by 2020, more onshore wind may be needed to make up for a possible shortfall in other parts of the energy mix. The warning follows comments by the Chairman of the Committee on Climate Change, Lord Deben, in The Times, in which he stated: “I’m happy that we have already got enough onshore wind to
2020 to meet that part of the portfolio”. RenewableUK points out that not all the onshore wind projects which have been approved will actually get built - about 10% will drop away for financial and other reasons between now and 2020. This means the UK could lose more than 450 megawatts of onshore wind capacity – enough to power nearly a quarter of a million British homes. So the pipeline of approvals will need to be extended to make up for this.
23.1 GW, which equaled 50.6 percent of total electricity demand – setting another milestone. “The large amounts of solar electricity being generated demonstrate clearly that Germany will need more energy storage capacity in the future. Already, the more than 1.4 million
As well as generating renewable electricity from wind and other clean sources, the UK has committed to produce a significantly higher proportion of heat, and fuel for transport, from renewables. According to the latest available Government figures, the UK is only a third of the way towards its target for transport fuel, and just a fifth of the way towards its target for renewable heat. To make up for a shortfall in these other areas, the Government could increase the amount of clean electricity to hit the overall target, as the UK is already over half way towards generating 30% of its electricity from renewables - more than half of which is being provided by wind.
photovoltaic systems are producing a surplus, especially on sunny days around midday,” Rothacher says. “From now on, every new solar system that is installed in Germany increases the need for electricity storage solutions. The cost of storage systems is forecast to drop in the coming years and this means that storage is not only becoming more necessary – it is becoming more attractive from a financial point of view as well.” Experts from GTAI will be at Energy Storage China from June 23-24 in Beijing to advise international investors about relevant opportunities in the German market.
RenewableUK is also calling on the CCC Chairman Lord Deben to support the case for wind energy in the 2020s. In The Times interview, he stated “It is likely that onshore wind will continue to play a part in our renewables after 2020, but it is not a decision we have to make now, and there are circumstances in which it might not. The public will decide what the balance is.” The CCC’s 4th Carbon Budget, currently being considered by the Government, envisages 25 gigawatts of onshore wind by 2030, 12 gigawatts above what the Government says we should have installed by 2020. The CCC has also acknowledged that onshore wind is one of the cheapest technologies to achieve this.
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First Solar Connect Three Utility-Scale Solar Power Plants to UK Grid The plants will generate 33.9 million kWh of energy per year, sufficient to power over 10,000 homes
which is equivalent to planting about 3,260,000 trees or removing over 4,300 cars from Britain’s roads.
First Solar, Inc. (Nasdaq: FSLR) and BELECTRIC GmbH have announced the grid connection of three utility-scale power plants in the United Kingdom. Together, the projects - all powered by First Solar’s advanced thin film modules - will produce approximately 33,900,000 kilowatt-hours (kWh) of electricity per year, which is sufficient to supply the energy needs of an estimated 10,200 average homes.
The plants have been designed to have a minimal impact on the communities and ecosystems they are located in. For instance, Holton Solar Farm has been constructed on an abandoned World War Two-era airfield, RAF Halesworth, with the full approval of the local community. The site will feature a biodiversity enhancement program to further mitigate its impact on local ecosystems. Similarly, Marsh Solar Farm was also built on a decommissioned airfield, while the Weston Longville Solar Farm features a habitat management initiative.
The largest of the three facilities, the 14MWAC Marsh Solar Farm in Wiltshire, is owned by, German asset management group KGAL’s ESPF 3 renewable energy fund for institutional investors. The 10.5MWAC Weston Longville Solar Farm in Norfolk and the 10MWAC Holton Solar Farm in Suffolk are owned by the BBIP infrastructure fund. Together, the projects will displace approximately 11,800 tonnes of carbon dioxide per year,
“The United Kingdom is a fast growing photovoltaic market and these plants are an important demonstration of our combined ability to effectively deliver clean, reliable solar energy in the United Kingdom,” said Martin Zembsch, Chief Business Development Officer of BELECTRIC. “The
Green Investment Bank’s £1 billion offshore wind fund will secure jobs for the future RenewableUK says today’s announcement by the Green Investment Bank (GIB) that it plans to raise £1 billion for a fund to invest in offshore wind projects will help to boost the sector’s rapid growth.
the past year in 18 clean energy schemes with an additional £1.9 billion raised from private money, which in total contributed £2.5bn of new investment in the UK’s green economy in 2013/2014.
The bank has already invested in 5 large offshore wind farms since its inception in 2012, such as London Array, currently the largest project of its kind in the world. The bank has invested £668m over
The 18 projects are estimated to save 3.5 million tonnes of carbon dioxide a year once completed, and produce enough clean energy to power three million homes.
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plants were completed and grid-connected on schedule and on budget, in keeping with BELECTRIC’s quality-based philosophy. We’re proud to have partnered with First Solar, whose advanced thin-film modules are powering all three plants.” BELECTRIC and First Solar share a longstanding partnership that spans over a decade: the two groups entered into a joint venture in 2013 and also collaborated on the development of the 128MWAC Templin solar power plant in Germany, the largest deployment of First Solar modules in Europe. An estimated 80% of the 1,400MW of solar electricity generation capacity installed by BELECTRIC, is powered by First Solar modules. “As the United Kingdom embraces the potential of clean and affordable solar electricity, these projects represent a new milestone in the country’s development of a sustainable solar energy portfolio,” said Stefan Degener, Managing Director, First Solar GmbH. “The projects also represent the latest success in First Solar’s longstanding partnership with BELECTRIC, demonstrating how our companies are capable of bringing together industry-leading capabilities and technologies to deliver reliable solar energy in virtually any market.” Commenting on the fund’s announcement, RenewableUK’s Director of External Affairs, Jennifer Webber, said: “The GIB’s offshore wind fund will provide a significant boost to the UK’s offshore wind industry, at a time when it’s expanding by leaps and bounds. It will create a virtuous cycle by encouraging more private investors to come forward – this will in turn enable offshore wind farm developers to invest in further projects. More than 13,000 people are already employed full time in the UK’s world-leading offshore wind industry – and that’s set to grow to 45,000 jobs by 2023. The establishment of this fund by the GIB helps to secure those jobs for the future”.
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Germany tops world energy efficiency ranking German (energy) efficiency combatting climate change Berlin (gtai) Germany has knocked the UK off the top spot to take first place in the 2014 International Energy Efficiency Scorecard, the American Council for an EnergyEfficient Economy (ACEEE) revealed today. The only report of its kind identifies best practices across 31 key metrics in the world’s
largest economies. China tied with France for fourth place, the UK and Japan tied for sixth, and the USA came thirteenth. The study praised Germany’s comprehensive energy strategy and awarded the country maximum points for its building codes, retrofit policies, and tax credit and loan programs. “Germany’s commitment to creating a framework that encourages investment in energy efficiency has made it a world-leading market in the field,” says Henning Ellermann, energy efficiency industry expert at Germany Trade & Invest. For example, Germany’s state development bank’s building renovation loan program stimulated private investments of over EUR 34 billion (USD 46 billion) in 2013, government figures show. Germany also offers SMEs subsidies of up to 30% for improvements to the
efficiency of their manufacturing processes made by upgrading technology and equipment. The ACEEE report lauded Germany’s target of a 20% reduction in primary energy consumption by 2020 and 50% by 2050, compared to 2008 levels, and awarded the country first place for energy efficiency in the industrial sector. “We are doing well but there are still a lot of untapped business opportunities in the German energy efficiency sector that make great economic sense even without subsidies,” says Ellermann, who assists companies looking to establish a presence in Germany. The report comes just days after Fraunhofer ISE reported that Germany produced around 31 percent of its electricity from renewables in the first half of 2014.
Chinook Sciences Continues Winning Streak with Prestigious National Recycling Award The Company Follows Up Three Previous Award Wins This Year by Taking Top Honours in the Best Energy from Waste Initiative Category Nottingham, UK –– Leading cleantech group, Chinook Sciences, won top honours in the Best Energy From Waste Initiative category of this year’s Materials Recycling World (MRW) National Recycling Awards. The company received the award in recognition of the importance of its Issue 11 - Page - 8
latest facility, an advanced thermal treatment plant being commissioned at Oldbury in the West Midlands, in defining the standard for what the Circular Economy can achieve for resource efficiency in the automotive and metal recycling industries. The plant will recover unprecedented amounts of recyclable metal and renewable energy from waste, using Chinook’s patented EndStage Recycling® technology. It is the world’s largest industrial waste gasification plant, and has been developed in partnership with
Warrington-based European Metal Recycling (EMR), the leading global metal recycling company. Chinook was described by the judges as ‘standing head and shoulders above the competition.’ In addition, Robin Latchem, the editor of MRW, praised the company and said, ‘This is a very innovative and impressive technology that has been demonstrated and can be applied to a wide range of waste streams including automotive and household waste. ‘
Energy Harvesting and Hybrid Power Storage Achieving efficient energy storage has been and remains the “Holy Grail “of many Industries. From F1 cars to vast wind and solar installations, capturing and storing energy for use at the appropriate time of need is a major engineering challenge…..until now. Cardiff based Rentalspec Products Ltd have been working in collaboration with Fitcraft Energy, a Czech renewable energy company to develop an advanced 1.5kWh Lithium Iron Phosphate energy storage cell which is now at the heart of our energy storage systems. One of the unique features of the system lies in the patented Battery Management System (BMS) that overcomes many of the limiting issues associated with traditional heavy battery cells that use nasty chemicals. Our lighter energy efficient cells can achieve 100% Depth of Discharge and they are designed to be easily repaired, refreshed or recycled after 5000 charge /discharge cycles ,after they have completed their first life cycle of around seven years. Even the best generators are often inefficient, costly to run and burn many litres of diesel per hour as they are left idling in order to provide electricity on demand. In addition to the fuel costs, burning diesel causes noise, co2 emission & pollution issues. By combining 16 of these 1.5kWh cells the result is a hybrid 24kWh
power storage system that can deliver power on demand with minimum energy loss by controlling the charging source whether it be from renewables like wind and solar or diesel generators . The unit shown below works automatically with our chosen generator supplier ranging from 10kVA to 100kVA and is available as a complete unit for hire or for sale.
The system can also be configured to work manually with other generators that do not have suitable electronic interface which allows our system to
multiple ‘daisy chaining’ provide potential to scale systems for any amount of power storage requirement. In addition using advanced telemetry units can provide monitoring and control to help manage the power being used. One of the most versatile systems we produce is the 3kWh Solar Charging station, which is light and easy to assemble. Utilised as grid free water pumping station application it can
work in sensitive conservation areas where the use of diesel could cause environmental problems. Details of hire or sale please contact 0044 (0) 2920 450128 or sales@rentalspec.com www.rentalspec.com
talk to and control the generator. Features such as simultaneous charging and discharge as well as
GENERATE IT… STORE IT USE IT Issue 11 - Page - 9
Why selecting the right tank can equal anaerobic digestion success
Digestion and Biogas Association (ADBA) asked Dr Les Gornall, Process Consultant for ADBA member PROjEN, to take a look at the various types of AD tanks available including their suitability for different businesses incorporating AD. “As the largest and often most Issue 11 - Page - 10
expensive part of an AD plant, selecting the right tank for your project is crucial to its success. But with so many variations on the market, it can be difficult to know where to begin, particularly for firsttime AD developers. The UK AD industry is building
hundreds of tanks a year, each one defined by process needs and often limited by planning permission and soil strength. Containing thousands of cubic metres of organic materials, structural integrity is paramount; tanks support technical equipment and can have as many as 30 penetrations and nozzles fitted.
There are three main types of tank available; above ground, underground and semi-submerged. Above ground tanks are usually the cheapest to erect – leaks are easy to detect and fixing nozzles for instruments is simple. However, planners may insist on a visual bund or shelter belt and could also limit the tank’s height. The walls and roof can be constructed from concrete, steel or plastic, although the roof can also be made from fibreglass or constructed as a textile double skin inflatable gas dome.
Concrete tanks can be constructed as follows: •
Precast panels wrapped with cables that are tensioned after erection
•
Cast with single pour moving mould Shuttered with bolted shuttering
•
ü sealing concrete flat roof structures is not easy in practice if the gas content is under pressure, so ensure the tank manufacturer provides an adequate guarantee that includes gas tight tops as well as hydraulic integrity. Steel tanks can be constructed as follows:
Top tips
•
ü Always double check the steel reinforcement calculations.
•
ü If air is found in a concrete wall when the moulds are removed, break out the affected area the same day before the concrete cures to full strength. ü Cutting holes through the post-tensioned cables of precast tanks reduces the strength of the tank considerably.
• •
Epoxy or glass coated steel plates (bolted) Triple glass coated steel (bolted) for maximum chemical resistance Pre-coated steel fabricated onsite using lip sealing machine Black (mild) steel, painted and insulated
Top tips üGlass coated steel tanks are generally thicker, heavier and more expensive than epoxy painted tanks – more aggressive chemicals may benefit from triple glass coated steel. Issue 11 - Page - 11
What are the key topics? • ü All steel tanks collapse easily with negative pressure that may be created by sealing all the tank instrument ports with blank flanges in the daytime and cooling the sealed tank at night. ü Mild steel anaerobic insulated tanks have been very successful in Danish digesters. Underground tanks minimise visual impact and can be easier to maintain. However, consideration must be given to access into underground tanks and safe systems of work put in place. Top tips ü The Environment Agency (EA) may require a method of catching underground seeps and leaks, and of monitoring the quality and quantity of any leaks.
ü The land area required is normally larger than for vertical above ground tanks. ü Empty underground tanks will bounce out of the ground if emptied in soil with a high water table. Semi-submerged tanks benefit from the heat insulation from the soil and can be finished with a glass reinforced plastic top with an external gas bag, or constructed with a textile gas bag top.” So, no matter what kind of AD project you’re planning, its financial and operational success will substantially depend on selecting the right tank technology and it’s worth spending some extra time talking to suppliers to source the right tank for you. You can meet over 250 tank suppliers, technology providers and consultants at ADBA’s. www.adbiogas.co.uk
•
The political outlook for the UK and EU – Chris Huhne, Strategic Advisor, ADBA How AD fits into the circular economy – Ken Webster, Head of Innovation, Ellen MacArthur Foundation
•
GIB – new market report – Partha Vasudev, Vice President Waste & Bioenergy, Green Investment Bank
•
Adapting to degression of financial incentives – how to make up for it – Julian O’Neill, Chief Executive, Biogen
•
Unlocking finance for AD – seminar chaired by Bruce Nelson, Director, Compass Renewables
•
Profiting from biomethane – one-to-one advice clinic with Green Gas Trading Ltd
Find out more at UK AD & Biogas 2014 You can find out more about AD technology, designing and operating an AD plant at UK AD & Biogas 2014 (2-3 July, NEC, Birmingham) which offers: • • • • • • •
250 exhibitors Free two day conference 22 free seminars Free one-to-one advice clinics New R&D Hub AD site tour The third UK AD & Biogas Industry Awards
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Bioenergy plant design - material decisions for tanks
Lipp spiral seam tank construction Over the years, Lipp has applied its in-depth knowledge of anaerobic digestion to create more efficient processes and ultimately better gas yields from a variety of substrates. Development of the mixing tank included the creation of a number of horizontal and vertical stirring systems, to account for the individual substrate characteristics. The smooth internal surface of the base tank combined with the most efficient height-width ratio, ensures a very effective circulation with reduced energy consumption. The use of a highly advanced hydrolysis process prior to the digestion process can improve the overall
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output of the plant. The Lipp hydrolysis tank pre-heats the substrate which results in the splitting up and pre-acidification of the long-chain carbohydrates, fats and proteins. This reduces the retention time in the digester and achieves a higher methane yield. In the UK market, Lipp Systems is responsible for the design, construction and commissioning of the Lipp products. Andy Shedden, Sales Director, comments: “Interest in the UK market for AD plants is really accelerating now but it is important that anyone planning to make the investment takes the time to consider
all of the options available. Overall efficiency, reliability and lifetime costs are very important factors that can make or break such a project. “At the moment in the UK, this industry lacks any specific standards for the design and construction of bulk storage tanks outside of the petroleum industry, but, we have considerable experience in meeting the standards of many other countries such as TUV in Germany. Fortunately, BSI are currently working on a new national standard (BS 17800) covering the design and construction of anaerobic digestion plants, which is a very positive move.�
Landia’s GasMix at Cory’s first AD plant Cory Environmental, who with over 40 sites
are one of the UK’s leading recycling, waste management and energy recovery companies, has unveiled its first anaerobic digestion facility, with Landia’s acclaimed GasMix system at the heart of the process. Generating up to 500kw of energy per hour for on-site use and export to the National Grid, Cory’s inaugural digester at Weston-super-Mare has the capacity to handle 12,000 tonnes of food waste pa. Around 7,500 tonnes of this is part of a seven year waste treatment contract with North Somerset Council. Alistair Holl, Cory’s Director of Resource Management, said:
“We are very proud of our first AD facility, for which our team were main contractors, as well as plant and site designers, achieving energy production just 18 months after planning consent was gained. This includes us recognising the importance of a highly effective and ultra-reliable mixing system, which is why we’ve chosen Landia’s GasMix. It mixes the digester throughout at a consistent temperature, which will optimise our gas generation”.
He added: “GasMix is mounted externally on the digester so routine maintenance can be carried out with no interruptions, and from our past experience with Landia, we also have peace of mind in the back up service that they provide”. For over a decade, Landia’s Chopper Pumps have been installed at other Cory sites – and at Weston-super-Mare, they are also in use in eight other process and storage tanks, where they perform a combination of process mixing and transfer functions.
Paul Davies, Landia’s UK & Eire Sales Manager commented: “Our relationship with Cory has grown steadily over the years as we’ve worked together to adapt the best possible pumping and aeration solutions for their wastewater needs. We are very pleased to see the faith placed in us and our equipment, with our GasMix system set to play a long-term role in the success of this impressive new facility”. Alistair Holl continued: “Initially, we’ll be producing enough energy to power around 1,000 homes, and will soon be working towards the second phase of the development, which will see an upgrade of the plant to a minimum of 1MW. This will double the volume of our green energy generation at Westonsuper-Mare” Comprising three 18.5kW chopper pumps and a self-aspirating system that reduces solids to produce more methane in a much shorter time period, Landia’s GasMix (designed specifically for AD/ biogas) has no mechanical equipment inside the digester. Simple to regulate, GasMix also offers significant energy savings because it only has to run for a maximum of 30 per cent of the installed capacity. Landia info@landia.co.uk +44 (0) 1948 661 200 www.landia.co.uk Issue 11 - Page - 15
EU reports lowest greenhouse gas emissions on record The European Union’s greenhouse gas emissions continued to fall in 2012, as a 1.3 % decrease cut emissions to 19.2 % below 1990 levels, according to official data from the European Environment Agency (EEA). This puts the EU within reach of its 20 % reduction target, with eight years to go until the 2020 deadline. The findings come from final EU greenhouse gas emissions for 2012, reported to the United Nations. Emissions have decreased by 1 082 Mt in the EU since 1990, which is more than the combined 2012 emissions of Italy and the United Kingdom. As a result, the EU was already very close to reaching its 2020 Climate and Energy Package target through domestic measures alone. The first 15 EU Member States are also joint signatories to the Kyoto Protocol, with a collective target of 8 % average reduction over the period Issue 11 - Page - 16
2008-2012. This group of countries have reduced emission by an average of 11.8 % during 2008-2012 compared to base year without counting ‘sinks’ or credits from Kyoto Protocol flexible mechanisms. The emission reduction from 2008 to 2012 in the EU15 was in absolute terms greater than Spain’s total emissions in 2012.
Why did emissions fall in the EU in 2012? Emissions fell by 1.3 % between 2011 and 2012, largely due to reductions in transport and industry and a growing proportion of energy from renewable sources. Italy alone accounted for 45 % of the total EU net reduction in emissions in 2012, largely due to lower emissions from transport and industry. The second largest reduction, in Poland, was mainly due to a substantial decrease in solid fuel consumption. In contrast to their overall decreasing emission trend since 1990, the United Kingdom and Germany increased emissions in 2012 because
of increased use of solid fuels.
Greenhouse gas emissions and changes in GDP The EEA technical analysis of emission trends shows that changes in GDP, for example growth or recession, can explain up to one third of the change in total greenhouse gas emissions since 1990. During periods experiencing recession (including in the 20082012 period), changes in GDP can explain less than 50 % of observed emission reductions for the EU as a whole. Other factors and policies have played at least as important a role in reducing emissions, including the sustained and strong growth in renewable energy and improvements in energy efficiency. Although GDP is a significant factor behind changes in greenhouse gas emissions on an annual basis, GDP and greenhouse gas emissions show an absolute ‘decoupling’ when compared to 1990, according to the EEA analysis. While GDP has increased 45 % since 1990, emissions have fallen 19 %, halving
EU’s ‘emission intensity’, the volume of emissions generated for each euro of GDP. In addition, Member States’ emission intensities have been converging. Per capita greenhouse gas emissions in the EU have decreased by almost a quarter since 1990, from 12 to nine tonnes. Hans Bruyninckx, EEA Executive Director, said: “The EU has demonstrated that there is no conflict between a growing economy and reducing greenhouse gas emissions. Policies have been at the heart of this success. We need to go even further, but this will depend on countries implementing policies which already map a path towards a low carbon, energy secure society.” The downward emission trajectory seems to have continued in 2013, according to emissions data from EU Emissions Trading System and early estimates based on energy statistics from Eurostat. In the autumn the EEA and DG CLIMA will publish official estimates for total EU greenhouse gas emissions for 2013.
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For information visit www.jee.co.uk/training Call +44 1732 371 371 to request a brochure or contact your local Business Development Manager Issue 11 - Page - 17
Using Recycled CO , Nike Unveil The ColorDry polo Using DyeCoo’s technology 2
It is a bright new day in apparel land where Nike unveiled the ColorDry polo -the first consumer product available using clean ColorDry technology, the water free dyeing process developed by DyeCoo. Instead of using water, DyeCoo’s technology uses recycled CO2, saving up to 30 litres of clean water per dyed T-shirt. The technology not only provides huge environmental benefits, it also ensures intense saturated colour, saves energy and eliminates the need for added chemicals in the fabric dyeing process. DyeCoo is very proud to see Nike launch its first ColorDry consumer line, making the technology a reality. “Creating this game-changing technology has been a long process on which we have been working for over ten years. To now see DyeCoo’s technology brought to the market, and not just by any brand, but by Nike, makes all our hard work worthwhile” said Mats Blacker, DyeCoo’s CEO. “We see this as an important step towards revolutionizing the textile dyeing industry. This product line proves that our technology is economical viable and suitable to scale, while hugely decreasing environmental impact”. Of course Nike would not be Nike if the new product line did not incorporate more state of the art textile technology. The polos use Nike Dri-FIT technology to draw sweat away from the body through the fabric; it has a sleek design and clean seams, increasing comfort and performance. To add to the sustainable character the polos are made from 100% recycled polyester. ColorDry polos will be available in six different colours from June the 12th on Nike.com and in select Nike retail stores. More information on Nikeinc.com About DyeCoo DyeCoo is a spin-off from the Dutch company FeyeCon, the global leader in carbon dioxide technology (www.feyecon.com). DyeCoo provides the sustainable water free dyeing alternative -providing a process that uses zero water, less chemicals and less energy. The process is not only sustainable but reduces processing costs as well. For more information DyeCoo.nl or DyeCoo.YouTube Issue 11 - Page - 18
Issue 11 - Page - 18
REMOTE LEVEL MONITORING SOLUTIONS
offers level sensors and remote level monitoring solutions for urban sewers, river levels, diesel tanks and silo farms. SolidAT sensors span a wide measurement range (0.15m to 40m), a variety of outputs (GPRS, 4-20mA, HART, Modbus, RS485 and Relays) and are certified ATEX / IECEx for explosive applications. SolidAT IP68 solution for sewer level monitoring is deployed in tens of cities and towns. The system reports critical overflow alerts and long-term trends for planning. Recent enhancements include over-the-air programming, flow measurement based on Manning formula and Modbus-TCP interface for third party software.
TWI Accreditation for all Niplast Welders The skills of all Niplast’s qualified welders have been recognised with The Welding Institute’s (TWI) accreditation. Simpson Thomson Filtration Ltd, manufacturers of Niplast Tanks, was approached by TWI to review how the recognised qualification could offer new business opportunities, particularly in the offshore wind industry sector. Fabrication Technicians, Lee Dervan and Mark Richardson successfully completed the assessment following a two-day hot gas and extrusion welding qualification programme to BS EN 13067, for welding polypropylene and polyethylene. The team’s acknowledged skills in welding thermoplastic sheet and pipe offer customers guaranteed quality assurance and further confidence in the manufacture of Niplast Storage Tanks.
Visit SolidAT website: www.solidAT.com
www.niplast.com
A range of ultrasonic leak detectors
Fully Relocatable 100% Steel Buildings from Quickway Buildings Ltd. Due to the unique pre clad B.S. 5950 design, Quickway buildings can be easily extended or relocated, and have the added advantage of achieving a good resale value due to the durability of the 100% steel construction. These characteristics also underline the capacity for long life and recycling. A recent request from a client to extend a 10 year old building by an additional 52 square metres was completed on site in two days, complete with an electrically operated roller shutter door and an additional steel pedestrian access door Nationwide Service available www.quickway-wingham.co.uk
that will detect compressed air, gas and vacuum leaks quickly easily and efficiently. Powered by a pp3 battery with sensitivity adjustment, bar graph display, hard hat compatible Koss headphones and a touch probe for checking steam traps, process valves and condition monitoring bearings. The unit comes complete with a manual in a hard shell case and no future calibration will be required. Regular leak detection of compressed air lines alone will help with gaining and retaining iso 14001, Co2 emissions will be reduced and energy savings are guaranteed, as leaks are cured and your compressor on load time is reduced. www.leak-detector.co.uk www.pneumaticsnorthern.co.uk rbaker41@msn.com
World’s first vertical resist stripping line installed Photofabrication Limited, the Cambridgeshire based chemical etching company has today announced the installation of the world’s first vertical resist stripping line at its St Neots manufacturing facility. During the fabrication of metal components through a wet process, resist stripping is the final procedure where photoresist films are removed from a substrate without leaving residues. The new stripping line draws upon innovative technology to dry a sheet of either ferrous or non ferrous metal without staining: The benefit of which is a superior clean surface. Being automated, process control and chemical maintenance is improved as variability is eliminated with the removal of human intervention. www.photofab.co.uk
Issue 11 - Page - 19
Issue 11 - Page - 20
Landfill community funding helps to give nature a home at RSPB reserve Woodlarks, tree pipits and butterflies have flourished at an RSPB East Sussex nature reserve thanks to £135,000 worth of funding from the Landfill Communities Fund The £120,000 donated by the SITA Trust has funded a wide variety of work at Broadwater Warren, including the removal of 57acres of non-native conifer trees and the restoration of 91 acres of original Heathland. Ibstock Cory Environmental Trust also contributed £15,000, which funded the restoration of a decoy pond and the planting of 350 native trees. An Amber Status grey wagtail is thought to be nesting on the restored pond island. Visitors are voting with their feet and coming to the reserve in greater numbers. The amount of adults and children visiting has more than doubled over the three years of funding. The land at Broadwater Warren was planted with timber crops which do not support native species and restoring the habitat which existed for hundreds of years previously will help to encourage them to return and breed on the reserve. The woodlarks have come back after a decade of absence and the tree pipits have increased in numbers and are enjoying a record year. Native butterfly species such as the Brimstone have really benefitted from the Heathland restoration and are being found in increasing numbers where the conifers have been removed.
The signs are already looking hopeful for other native Heathland butterflies such as Small Heath, Small Copper, and some of the blues. Broadwater Warren is also beginning to be mentioned in the Sussex branch of the Butterfly Conservation’s reports due to the reserve’s site records.
“The landfill community funding has helped us to achieve a huge amount for wildlife and for visitors at Broadwater Warren,” said reserve assistant warden Chloe Ryder. “The results have been quick and fascinating to see. Areas of impenetrable conifer that the funding allowed us to clear in 2011 are already blooming with heather and buzzing with bees.”
Kissing gates have been installed which help families to experience different areas of the reserve as it changes, and two large areas have been fenced off, which has helped management of the six Exmoor ponies who graze the reserve in summer. The ponies are a draw for visitors who enjoy seeing the semi-wild native species against the backdrop of the Wealden landscape. The money has also funded the monitoring of bats, lizards, snakes and dormice, and the findings inform the reserve’s conservation work.
www.rspb.org.uk
Angela Haymonds, Secretary of ICET said: “Trustees were delighted to fund this important project to encourage native British wildlife to flourish. The RSPB have created a valuable habitat that encourages the return of native species and we were very pleased that grey wagtails are already nesting.” Sixty reserve volunteers have been equipped with gloves, tools and other equipment thanks to the trusts’ funding. Issue 11 - Page - 21
Crowd Funding for Community Energy Projects
Abundance, however, has slightly modified the loan based funding structure by offering debentures, all of which are unsecured, with a 20 – 25 year life that pay a cash return twice a year. Unlike shares in a company, the debentures should not attract stamp duty on transfer, but equally there is a limited secondary market should an investor wish to realise their investment.
What is a platform? Websites have been established to provide access to investors and these platforms will advertise each opportunity and forward any investment funds received to the project owner. In return, the platform will typically charge the project owner an upfront fee (ranging from 0.5% to 2.5% of funds raised), together with an ongoing monitoring fee.
Crowd funding, a growing global
The investor might also be charged per
phenomenon, allows entrepreneurs,
transaction or to join the platform, along
business-owners, social enterprises,
with an exit fee should they decide to
charities and even film-makers to raise
realise or transfer their investment.
substantial sums of money. When the opportunity is structured correctly and
What are the benefits of crowd funding?
marketed on the right online platform,
For community projects, crowd funding
crowd funding can be an efficient and reliable way of getting projects off the
What is crowd funding?
provides an alternate source of finance
ground. But equally, the failure rate for
Crowd funding allows organisations or
crowd funding projects is high and it can
individuals to directly obtain funding
the investment, the project may avoid
be very expensive if things go wrong.
for a wide range of projects, via an
Earlier this year DECC announced that crowd funding was one of three measures it was considering to tackle
online platform. Typically there are four categories: • Equity funding – investors
and depending on the structure of needing to give security over its assets (a prerequisite for banks). It might also avoid a heavy dilution in the equity share capital which one might expect from a third party private equity/venture capital
the financial barriers which many
contribute in return for shares/
investor.
community energy projects were
an equity stake in the project.
Crowd funding allows investors an
encountering.
• Loan based funding (peer to
It is clear there is an appetite from
peer) – investors loan monies
the public investor to get involved in
direct to the project.
relatively small-scale and medium-sized community energy projects. Abundance Generation for example, was launched in 2011 and has since raised over £6 million from around 1,300 investors for various projects including solar and wind. So, if you are a community project, struggling to raise the necessary finance, or if you are an investor seeking renewable/energy efficiency investment opportunities, what should you consider
• Reward funding – investors receive a specific reward (i.e. for film-makers it might be a mention in the credits, access to the premiere and a free copy of the film). • Donation funding – usually associated with charities, where the investor receives nothing in return for their contribution.
opportunity to diversify their investment portfolio. Platform fees tend to be lower than investing through a managed fund and the investor enjoys a more hands-on feel to transactions, particularly if the structure is peer-to-peer. Crowd funding also offers easier access to projects that are often restricted to professional investors (either through a restriction to the type of investor or a high minimum). In certain circumstances, it is possible to wrap the investment tax efficiently, perhaps through the Enterprise Investment Scheme/Seed Enterprise Investment Scheme or SIPP.
before getting involved? Issue 11 - Page - 22
What are the risks? The risks are high, particularly for the investor. The Financial Conduct Authority (FCA) which regulates the crowd funding sector, suggests investors should understand what level of due diligence has been undertaken, understand the
Finally, depending on the platform and the structure of the crowd funding, investors may have no right of complaint to the Financial Ombudsman Service and may not be eligible to apply to the Financial Services Compensation Scheme (FSCS).
As a result, the FCA aims to ensure that investors understand the risks and requires platforms to have safety nets in place in case they run into financial difficulty. Loan based and equity based crowd funding will be regulated by requiring platform operators to apply for
level of risk and understand the value
The risks for projects raising capital
full FCA authorisation.
for money offered, after charges, taxes
through a crowd funding platform are
and potential defaults before making a
relatively low, unless it fails to raise the
Further regulation is expected to be
decision.
minimum investment amount, when it will
Crowd funding projects tend to be relatively small-scale and may not
suffer the cost of using the platform and preparing the offering documentation.
What are the legal and personnel in place to deliver the proposed regulatory considerations? necessarily have the infrastructure or
returns. However, as with most community energy projects, if the opportunity has guaranteed government backed incentives such as FITs, ROCs or RHI, risk can be somewhat offset.
As crowd funding has become popular, platforms are increasingly seeking access to more investors, in particular retail investors. This commercial aspiration raises difficult questions of
Another risk is time. Even if the project is
policy; is this sort of investment suitable
only seeking to raise £25,000, this may
for the ‘general public’ and how can the
take months to raise and whilst investors
sector be adequately regulated without
will ordinarily have their investment
stifling it?
introduced, ensuring platforms have the necessary capital to protect against financial shocks, but currently, although equity funding will be covered by the FSCS, investors will not have recourse to the FSCS should the platform run into trouble. There are wrinkles in the process to be ironed out as the legal and regulatory frameworks try to catch up, so whether you’re looking to invest or raise money through a platform, the advice remains the same; seek appropriate legal, financial and regulatory advice.
returned if the target is not achieved, this will not include interest that may otherwise have accrued. Issue 11 - Page - 23
Altec Laser System Takes The Pressure Out Of Welding ALTEC Engineering’s latest production automation system, used for the manufacture of Tyre Pressure Sensors, combines the company’s expertise in the design and build of bespoke machines, with Laser technology from Rofin-Baasel to create a highly efficient plastic welding cell. This latest machine from Bowburn based ALTEC Engineering has the capability to produce a range of sensor variants using quick-change tooling. The sensor component parts are manufactured from Polyamide material and the application requires the welding of a clear cover to a coloured base of the same material to create a hermetically sealed joint.
(Quasi-simultaneous welding is achieved using a Galvo scanning head in conjunction with the Diode laser) Welding is achieved using a DILAS 200 Watt average power diode laser with a 200 micron fibre-optic. This in turn delivers the laser beam to a Galvo Scanning Head, which allows quasi-simultaneous welding, ensuring the whole weld seam reaches the melting temperature and collapses uniformly. Consistent clamping pressure is essential to produce consistent and reliable welding and in this instance this is achieved using a pneumatically operated system which incorporates force and distance monitoring. The machine concept was developed by ALTEC and a Class 1 enclosure ensures operator safety. Overall machine control, and set up for different part variants, is achieved via an intuitive menu driven system displayed to the operator on an HMI.
(Altec’s Machine produces a range of Tyre Pressure Sensors using quick-change tooling)
Issue 11 - Page - 24
ALTEC Engineering Limited took turnkey responsibility for this project, drawing upon the comprehensive skill base which the company retains in-house including: machine, control and software design, machine building and development and project management. In the 36 years since the company was founded, Altec has grown
to become a highly successful and dynamic company offering a comprehensive range of services including Mechanical & Electrical Engineering, CNC Precision Machining and Special Purpose Machine Design & Build. The company operates within the Oil & Gas, Automotive, Aerospace & Space-Science, Medical Science and Nuclear & Renewables sectors. For more information, please contact:Mr Nick Batey Director Altec Engineering Limited Unit , Bowburn North Industrial Estate Durham, DH6 5PF Telephone - +44(0)191 377 0555 E-Mail – altec@alteceng.co.uk Web – www.alteceng.co.uk
DNV approves ABB’s REA arc flash protection relays for ship and offshore electrical systems The leading marine certification body has lent its approval to safety product designed to reduce arcing times to prevent major hazards and minimize equipment damage ABB, the leading power and automation technology group, has won the approval of DNV GL - the world’s largest ship and offshore type approval organization - for its REA 10 arc flash monitoring systems for installation on board ship and offshore units. Designed to protect new and existing medium and low voltage electrical switchgear, the REA modules use fibre optic detectors to monitor and protect against electrical arcs. Arc flash is particularly important in the oil and gas sector, where growing demand for power is twinned with the highest health and safety standards. It is not a new phenomenon but interest and concern about the dangers associated with arc flash events have increased dramatically in recent years in response to new guidelines and standards put forward by various international trade and safety bodies such as the Institute of Electrical and Electronic Engineers (IEEE), the US Occupational Safety and Health Administration (OSHA) and Lloyds Register. Reducing the arcing time through faster detection is the most practical means of lowering incident energy levels and improving workplace
safety. The energy released in an arc flash incident is directly proportional to arcing time and even a few milliseconds improvement may shift hazard levels and PPE requirements to lower categories. For arcing times of 40 ms or less there is typically no personal injury or switchgear damage, while arcing times of 500 ms or more will cause serious personal injury and major damage to switchgear. ABB’s REA arc flash protection relays deliver ultra-fast detection by using a long unclad fibre-optic sensor that can absorb the light from an arc flash throughout its length. This offers the benefits of simpler installation and better coverage than individual light sensors, as well as the ability to retrofit in existing installations and self-checking. In normal operation, both intense light and over-current must be present simultaneously for tripping to occur, with the relay signaling the circuit to break within a miniscule 2.5 ms. Offshore operators are now required to carry out studies to identify arc flash risks and put in place measures to protect operatives and equipment, with an approach being to supply and renew specialist PPE on an annual basis. Operators could instead install ABB’s REA arc flash detection system, which eliminates a significant portion of the risk by reducing tripping times.
Ian Hodkinson, Head of ABB’s Distribution Automation business in the UK said: “Winning type approval from DNV is a major endorsement for ABB’s REA Arc Flash Detection System. A typical substation might only experience a single incidence of arc flash protection in its lifetime but the impact of such an incident is significant in terms of risk to life and limb, serious damage to electrical hardware and lost production time.” To achieve DNV’s approval, ABB’s equipment was type tested by DNV in accordance with the standard set out by IEC 60255 and environmental tests were carried out according to DNV’s Standard for Certification (low temperature, dry heat, damp heat, salt mist and vibration) in accordance with the EMC directive and IEC 60255 series. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 150,000 people.
Tel: 01785 825050 www.abb.com Issue 11 - Page - 25
Vattenfall announces two contract wins for Pen y Cymoedd Wales-based companies to work on major onshore wind farm Renewable energy developer Vattenfall has announced two new multi-million pound contracts for work on its £400m Pen y Cymoedd wind energy project in south Wales. The successful companies are Neath- based Express Reinforcements and the Wrexham manufacturing facility of Prysmian Cables & Systems Ltd. The announcements coincide with the laying of the first foundations for the 76 turbines at the Pen y CyIssue 11 - Page - 26
moedd project site in the county boroughs of Neath Port Talbot and Rhondda Cynon Taf. Prysmian Cables & Systems, which employs 350 people at its Wrexham site, will produce the high-technology power cables to interconnect the two high voltage substations that ABB, the principal contractor, is constructing to connect the wind farm to the National Grid. Express Reinforcements, which has a workforce of 181, is sub-contracted by the 50:50 joint venture between Jones Bros and Balfour Beatty to work on the bases of the turbines. Each of the 76 turbines at
Pen y Cymoedd will have 3MW capacity. When operational, in 2016/17, Pen y Cymoedd will annually generate power for the equivalent of 140,000 homes – enough to meet the domestic demands of Neath Port Talbot and Rhondda Cynon Taf county boroughs. Since planning of the project began Vattenfall has worked to encourage as many local firms as possible to bid for contracts and sub contracts. After 12-months of a four-year construction £45m of contracts have been placed with Walesbased businesses. So far, more than 50 companies and more than 600 jobs in Wales have been supported by the project. The project will be worth up to £1 billion to the Welsh economy over its 25 year life time.
The Secretary of State for Energy & Climate Change, Edward Davey, commented on the development and the local economic benefits it is delivering. He said: “This onshore wind project will be the largest in England and Wales and will send a clear signal about this Government’s commitment to the industry. It will add to our energy mix that is tackling climate change and boosting energy security through moves to increase ‘homegrown’ sources. “The project is fantastic news for the local economy not just in terms of investment but for local growth and green jobs. Businesses in Wales have already received contracts worth £45m over the last year for the Pen y Cymoedd project and Vattenfall are commit-
ted to recruiting as many local people as possible. The area will also benefit from the annual £1.8m benefit fund for local community projects. “All in all PyC is good news for the economy, for consumers and for the environment. It is just the latest example of the benefits that onshore wind is bringing to the UK.” Vattenfall’s Director of Onshore Wind Development in the UK and UK Country Manager, Piers Guy, said: “This project is forging ahead after tremendous support from Government at UK, Wales and local authority levels, as well as Natural Resources Wales. From the outset Vattenfall has been determined to ensure that it is developed sensitively and will deliver tangible benefits in terms
of contracts for local firms, new jobs and increasing prosperity.
“Vattenfall is delighted that so much work is going to firms with bases here in Wales. Every contract has been won on merit and it demonstrates that we have the enthusiasm, skills and supply chain capability here in Wales to help deliver the UK’s onshore wind potential.” Express Reinforcements managing director Andy Lodge said: “We’re delighted to have been contracted to supply steel for such a significant project so close to our home base.
“Furthermore, in line with the values of the Pen y Cymoedd wind energy project as a whole, our raw materials have been sourced from within the UK and the steel itself is being made in Cardiff.” Speaking on behalf of the joint venture, Huw Jones, managing director of Jones Bros, said: “The joint venture itself is working hard to engage the skills and resources available in the area. “This includes employing local plant operators and apprenticeship opportunities, as well as contracts for companies like Express Reinforcements.” HV Systems, Business Director of Prysmian Cables & Systems, Darrel Cook added: “Prysmian is ideally suited to this type of con-
tract. With complete local control over manufacturing and testing of the entire system we can be sure of both the quality and timely delivery to our customer. We are delighted to be involved in this project as it represents another step forward in the move towards renewable energy generation in the UK.” Stephen Trotter, Managing Director ABB Power Systems UK and Ireland, added: “The Pen y Cymoedd grid connection project is a perfect example of ABB’s proven capability to undertake large turnkey substation projects anywhere in the UK thanks to our philosophy that integrates sophisticated engineering design skills and advanced technology with cost-effective delivery through the local supply chain.”
Realtime Energy Building Displays The Complete Energy Monitoring Solution from Elcomponent...
MeterRing RT presents your organisation’s energy and carbon performance, and renewables contribution in a high quality display designed to both captivate and inform through the use of hi-resolution internet-based graphics.
www.elcomponent.co.uk
Elcomponent Ltd, Unit 5 Southmill Trading Centre, Bishop’s Stortford, Hertfordshire CM23 3DY
tel. 01279 503173
Issue 11 - Page - 27
Practical and Effective Energy Monitoring Effective monitoring not only assists with reducing energy consumption and costs, but is relevant for organisations aiming to achieve or maintain the ISO 14001 environmental standard. ISO 14001 states that objectives and targets shall be measurable, where practicable, and that an organisation should regularly monitor and measure the key characteristics of its operations that can have a significant environmental impact – of which electricity consumption can be one. It is often easier to look at logger readings than attempt to decipher electricity bills (which are often estimated) or meter readings! The Energy Logger uses non-invasive flexible coils to monitor the current in each phase of a three phase supply, while voltage information may be obtained via a standard 13A wall socket. Safe and easy to use, the logger records data which is downloaded to a PC. The unit also records ‘Power Factor’ (PF) data, a measure of power transmission efficiency: this can be significant because power companies typically charge a higher rate for industrial or commercial customers with a low PF.
Issue 11 - Page - 28
The Tinytag Energy Logger from Gemini Data Loggers provides an effective means of power usage monitoring for high consumers of electricity
Energy monitoring can sometimes lead to very direct savings. For example, in Gemini’s own production facility, recorded data revealed that one of the space heaters was coming on unnecessarily during the night. ‘Before and after’ monitoring can help in the evaluation of, for example, replacement LED lighting or Building Environmental
Management Systems. Gemini Data Loggers has been manufacturing Tinytag data loggers in the UK since 1992 and trades globally with a network of over 40 distributors. Other Tinytags in the range monitor parameters such as temperature, humidity and CO2 and are used for a variety of energy efficiency applications. The Energy Logger costs £795 +VAT.
Visit Gemini at The Energy Event, NEC, 16-17 September, Stand B51 Gemini Data Loggers (UK) Ltd Scientific House Terminus Road Chichester PO19 8UJ +44 (0)1243 813000 info@tinytag.info www.tinytag.info
Tinytag Data Loggers:
Robust Environmental Monitoring Solutions temperature
»
humidity
»
power usage
»
co2
»
Manufactured in the UK
count
»
voltage
»
current
Tinytag data loggers include discreet units for indoor monitoring and robust loggers for the harshest environments. • Rugged and compact • Easy to use • Dust, splash or waterproof • Data downloaded to PC • Cost-effective Accompanying probes are available for measuring extremes of temperature, and for monitoring awkward to reach areas such as pipework. Data loggers with displays are also available. For larger sites, the Tinytag radio data logging system uses wireless communications to automatically gather data for viewing at the user’s own desk.
tinytag Ultra 2
tinytag plus 2
energy Logger
Rugged outdoor/industrial temperature/RH logger
Single & three phase power monitoring
from £95 +vat
£795 +vat
tinytag co2
radio data logging system
Indoor temperature/RH logger
Discreet indoor monitoring
from £69 +vat
from £325 +vat
Ideal for larger or remote sites
poa See
oUr
fULL
proDUct
ranGe
at
the
enerGy
event,
nec,
16-17
Sept,
StanD
B51
Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info Issue 11 - Page - 29
Rugged, reliable SMA fibre-optic devices from OMC transmit digital signals with ease
High launch power, sensitivity and precision ensure reliable data transmission in industrial applications OMC, the pioneer in optoelectronics and one of the world’s longestestablished manufacturers of standard and bespoke industrial fibre-optic components, has launched the H22R6850G, a rugged, reliable receiver for multimode glass and polymer fibre systems and its corresponding transmitter, H22E6850G, both in the widelypreferred SMA package. The high-sensitivity H22R6850G is optimised for use with 850nm transmitters and provides a direct 0-5V digital output, allowing direct connection to digital circuitry. It can also be used with 660nm transmitters making it ideal for use with polymer fibre systems as well as multimode glass. The device features a precision-machined all-metal body and incorporates a rugged screw-mounting mechanical connection to the circuit board, providing unparalleled consistency and ruggedness and ensuring that it can withstand the challenges of the Issue 11 - Page - 30
industrial environment. When used with OMC’s matching H22E6850G high-output 850nm SMA transmitter, which incorporates the same high-reliability features, along with OMC’s high-performance optical terminations, an exceptionally long life, consistent optical link can be achieved. Comments OMC’s Commercial Director, William Heath: “The metal SMA connector system has a number of unique features that make it ideal for industrial applications. Unlike systems that rely on a latching mechanism or spring to locate the ferrule and hold it in place, the SMA system’s connector nut holds the ferrule much more firmly, ensuring exceptionally longlasting, secure coupling between the diode and the fibre face. This provides a truly fit-and-forget solution which has the potential to last for many decades without the need for maintenance. We have customers using our SMA devices alongside our high performance optical terminations who justifiably expect the optical links to perform for twenty, thirty or even forty years. The devices provide excellent launch power and sensitivity, and should
the application demand it we can use our proprietary Active Alignment technology to produce the devices to specific electro-optical performance windows.” OMC offers a wide range of transmitter/receiver parts as standard products, and can house diodes in a variety of housings and connector systems to provide the most appropriate solution for each application. The company also specialises in re-engineering obsolete transmitter, receiver and connectors to support legacy systems requiring maintenance or refurbishment.
For further information: William Heath – Commercial Director, OMC Tel: +44-1209-215424 Email: Heathw@omc-uk.com www.omc-uk.com
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Issue 11 - Page - 31
Document management company Synertec saves 80% on lighting energy costs thanks to MHA. A LEADING document management company has reduced its lighting energy consumption by 80% thanks to a new LED solution from MHA Lighting. Synertec, with sites in Warrington, St Albans and Bristol, is one of the first organisations within the UK to have installed the revolutionary new LightStar LED luminaire from MHA. Thanks to their ruthlessly efficient new LED technology, MHA was able to reduce overall lighting energy consumption by 80% across all three sites – a staggering lifetime saving of £509,000 and a 1,921Tonne reduction in Co2. At the same time Lux levels in all areas of each facility were improved, with the LightStar product delivering 500 lux to Synertec’s machines, 400 lux to the floor and 200 lux to the shelves. Issue 11 - Page - 32
MHA Lighting MD Tom Harrison said: “Our new LightStar luminaire is undoubtedly one of the most ruthlessly efficient products on the market. “We believe it is unrivalled in light quality and distribution and energy efficiency. It is also incredibly versatile – allowing the client to select from a range of wattages (15 to 121w) to deliver between 100 to 123 lumens per circuit watt and providing a total lumen output of between 1845 and 12100. “Combining this high performance with un-rivalled light distribution from the luminaire enables us to install fewer fittings too, creating a multiplier effect in terms of energy savings and payback periods for clients like Synertec. “We are delighted that this has been such a successful project. It has been a pleasure to work alongside the
Synertec Team in devising a ‘made-tomeasure’ lighting scheme that really matches Synertec’s requirements. “To see such fantastic results from the LightStar fitting is incredibly rewarding and that coupled with the results for Synertec means that this has been a victory for all parties.” The LightStar 204 and 205 luminaires replaced 142 400w (without ballast) Metal Halides. The LightStar 204 specified at Synertec is just 85w (inclusive of ballast) and the LightStar 205 is just 120w (including ballast). Both light engines can be driven however at a range of wattages to increase or decrease light levels. The fitting’s 66,000 hour minimum life span means that there is no need for regular maintenance and this lifespan can further be increased to a minimum of 109,000 hours if the driver is replaced at 66,000 hour point.
Tom Baldock, Synertec’s project and facilities manager, said that switching to LED lighting was part of the forward-thinking company’s strategy to improve light levels across their sites whilst ultimately reducing associated energy costs and Co2. Tom added:
“We are very happy with the lighting. It has cut our costs dramatically whilst also increasing the quality of the light we have in all three of our production sites - all of our staff are extremely pleased with the results”
“MHA handled the proposal and installation process with great detail and efficiency. As promised we have had no maintenance issues, which is a vast improvement on the previous luminaires, saving further money in maintenance costs.” For more information Visit: www.mhalighting.com Email: sales@mhalighting.com
“We reviewed several luminaires and the MHA product came out on top with the fastest payback and the best long term savings, whilst also not being over the top on capital cost.
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The UK is increasingly becoming an energy-efficient nation, having a low-carbon economy that is steadily gaining significant traction. With government legislations already in place (carbon reduction targets, CRC, CCL, ECO’s, DECC, ESOS etc.), now is the optimum time for businesses to invest in cleaner proven technologies, and promote environmentally-friendly behaviours. Whether you are looking to start a new project or develop your existing energy management strategy, financial support is essential. Despite the long term financial benefits of these, there are often reactive maintenance demands on capital and OPEX projects that
can often take priority over energy saving projects. e-fficient Energy Systems Ltd are a bespoke energy solutions provider, specialising in the energy audit process, identifying which areas in a company could benefit from energy efficient upgrades, and implementing these projects with an engineering focused team in a customer-driven environment. e-fficient Energy offer tailored expertise, industry knowledge, and a unique ‘ESaaS’ Energy Savings as a Service contracts package. This enables organisations to reduce energy costs and increase profit by adopting low carbon proven
technologies from a diverse portfolio. Energy legislation will enhance the need for both public and private sector organisations to become increasingly energy efficient. Questions still centre on the methods of adopting the correct technologies, the best companies to work with, and the funding to accommodate these projects. e-fficient Energy offer the full turnkey solution, Design, Finance, Deliver. They ascertain the best energy strategy for each site, have the capacity to install products using in-house teams or approved subcontractors, and adopt a rigorous approach to project management; ensuring high quality work and excellent customer service remain uncompromised. e-fficient Energy has a streamlined and hassle-free approach to energy efficiency, shown in 4 stages: 1. The Energy Audit: A full energy analysis is conducted on each site to establish the best equipment to maximise savings potential. 2. The business case and our proposal: highlighting cost savings and anticipated ROI demonstrates the benefits of investing in energy efficiency. 3. The sourcing of equipment: The proven technologies are chosen from our portfolio, and all high quality products are sourced from approved manufacturers and suppliers. Our range of products include eVO+R voltage optimisation units, eVSD’s, UPS, BeMS, PFC, eM&T and Lighting upgrades. 4. Pay for the project with the cash savings: Flexible and affordable ESaaS; Helping clients avoid all upfront cap-ex costs, and maximise their sustained energy cost savings. The ESaaS service contract is a self-funding solution, energy and carbon savings remain the same for the client. To find out more, visit the website: www.e-fficientenergy.co.uk Call the team on 01909 569 016 or email info@e-fficientenergy.co.uk
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A.E.Oscroft install sustainable energy technology A.E.Oscroft is a third-generation, family run presswork engineering company with more than 70 years experience. We manufacture quality metal pressings, welded assemblies and tooling as well as prototype projects in a diverse range of materials. As part of our expansion plans, last year we moved to a 56,000 sq. ft. property which was three times the size of our previous premises. We operate a LEAN policy and recognised that as part of this process we could reduce our dependence on fossil fuels, thereby control our energy costs and gain a competitive edge. As a result we decided to install sustainable energy technology. Having considered the sustainable energy options, we took the decision to install solar panels with extra space to increase yield and fitted a dual state of the art biomass heating system and introduced low-energy lighting within the facility thereby reducing our carbon footprint and
minimising our impact and dependence on fossil fuels. The company’s aim is to run the business as sustainable and eco-friendly as possible. Whilst offering manufacturing solutions that exceed our customers expectations. Quality Assured Quality is of paramount importance to A. E. Oscroft & Sons Limited - it is the foundation that our business and reputation are built upon. A. E. Oscroft & Sons Limited recognise that genuine commitment and investment in quality is essential, our accreditations to Quality Management Systems ISO 9001/2000, TS 16949 & ISO 14001 is testimony to this.
It is the policy and overall business objective of A. E. Oscroft Limited to provide services of the highest quality and in compliance with our customers specified requirements.
We have a long established reputation within our industry for constantly providing excellent components and assemblies of the highest quality, continued investment in our quality assurance programme manifests our total commitment to. Tel: 01527 502203 Email: info@aeoscroft.co.uk Web: www.aeoscroft.co.uk Issue 11 - Page - 35
Evacuator last resort from burning skyscraper LONDEN/NETHERLANDS – Residents and workers in skyscrapers and other tall buildings are often trapped in case of a fire, 9/11 has demonstrated. The newly developed Evacuator offers a last resort, allowing them to slowly and safely descend on a steel cable at the outside of the building. Worldwide the device can save thousands of lives, from residents in tall buildings to mechanics in wind turbines.
Dutch inventors Eugene Verstegen and Joris Veeger came up with the idea when they saw people fall to their death from the Twin Towers in New York. ,,If you are living or working on this height, you must be able to get out at all times. We can put people on the moon. Why is there no simple solution for evacuations from great heights?,” they wondered.
Together with a professional engineering company they developed a fireproof steel winch, which is guaranteed to work at all times, even when electricity is down. The device allows four persons at the same time to descend 50, 140 or 300 meters. They automatically descend in a safety harness on a steel cable, at a speed of 1 meter per second. The Evacuator is people’s last resort if elevators are switched
off, emergency exits are filled with smoke and firemen can’t reach them. ,,What the airbag is for cars, the Evacuator is for tall buildings. With this technology we can save lives in 99 percent of all tall buildings in the world,” Verstegen states. They were invited to the London conference by host professor Ed Galea, founding director of the Fire Safety Engineering Group (FSEG) at the University of Greenwich. Verstegen: ,,After we had shown him the Evacuator, he got so excited that he invited us to come demonstrate the device.” The Evacuator has been developed, tested and produced in the Netherlands, approved by the German inspection institute DEKRA and awarded with the EN341 certification for 33 European countries.
More information: www.evacuator.com Issue 11 - Page - 36
Evac+Chair International announce new division – Sigma Fire & Security Birmingham based Evac+Chair International, leading manufacturer of emergency equipment, has announced they will be launching Sigma Fire & Security; a new part of the Emergency Solutions products and services, which will be headed up by Ges Wallace who has over 30 years’ experience within the industry. Evac+Chair International is the original manufacturer of the evacuation chair, a universal solution that delivers smooth stairway descent for the mobility impaired during an emergency evacuation. The business has recently expanded its product portfolio to offer a wider range of emergency products and solutions including training and aftersales servicing.
SIGMA FIRE & SECURITY
INTERNATIONAL
Ges Wallace, Divisional Director at Sigma Fire & Security said: ‘Using my knowledge and experience within the industry, together with Evac+Chair’s infrastructure and extensive skills, we have formed SIGMA Fire & Security which will be a specialist fire & security, product manufacturing and distribution division under the umbrella of Evac+Chair International. Mark Wallace, Managing Director at Evac+Chair International said: ‘The launch of Sigma Fire & Security is designed to enhance our existing product range and it will also enter us in to a new market sector that will provide us with new opportunities. We are in the process of securing exclusive distribution agreements for a number of
exciting new products. Over the coming months Sigma will continue to expand its product offering by designing new and innovative products, targeted specifically for the fire, safety and security markets. Exciting times are ahead with the introduction of Sigma Fire and Security and we welcome Ges on board with his wealth of experience and knowledge of the industry’.
INTERNATIONAL
Tel 0121 765 5543 www.evacchair.co.uk
Global Leader in Explosion and Pressure Safety Solutions Launches Revolutionary Dust Detection System A global fire, explosion and pressure relief solutions company has introduced a revolutionary product that will assist in the prevention of dust explosions and as such eliminate the risk of potentially devastating disasters occurring in the workplace.
Fike UK, based in Kent has enhanced its already extensive range of high quality, safety driven products with the introduction of the Fike Dust Detection System (FDDS). The FDDS functions by signalling the presence of unusually high airborne dust particles enabling the prevention of explosion devastating the workplace.
Keith Avila, General Manager of Fike UK said of the new product launch: “A dust explosion can be potentially catastrophic. We are very proud to be the first in the industry to introduce such ground breaking technology and be at the forefront of providing safety solutions like this which prevent devastating and irreversible effects.”
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Fike has almost 70 years’ experience advising on fire explosion and pressure relief solutions with a team of in-house engineers, application specialists, and combustion researchers specialising to companies across the food, power, wood and pharmaceutical/chemical industries.
Featuring unique technology the FDDS - a processor based device - can identify levels of dust that can cause explosive hazards whilst also having the ability to validate the protection of non-zoned areas. The advanced technology is installed in ducts and will alert a business to any early warning signs of potential contamination caused by nuisance dusts. The system works by detecting the normal amount of dust particles passing by with an easy ‘traffic-light’ notification system indicating the levels of dust concentration within the duct. Commenting on the benefits of the new product Keith said: “As well as detection, it comes with an additional layer of protection which removes any potential hazardous dust zones, whilst also being able to detect leaking filter bags. One of the key benefits of the FDDS for our customers is it requires little or no maintenance – a feature that really appeals to them in terms of cost efficiency and resourcing.” The use of innovative Inductive Electrification technology sets the product ahead of other optical or tribo-electric devices by determining the background acceptable level of dust during normal process operation and triggering alarms at different pre-set dust concentration levels when these are attained. Issue 11 - Page - 38
This is coupled with running advanced filtering algorithms that can detect the smallest of dust concentration variations and provide the most accurate dust measurement signalling. Dust is a serious health and safety consideration with a wide range of materials capable of causing a dust explosion. These include anything from agricultural products and metals, through to chemicals, wood and many more raw materials. Dusts can be caused through various means including transporting, handling, processing, and polishing; through to abrasive blasting, cutting and mixing. The dust explosion is caused by a sudden ignition of a mixture of air and a high concentration of suspended combustible dust particles.
Keith added: “In our industry, Fike has unprecedented expertise and is committed to providing quality safety products that are fully explosion tested. The FDDS has been developed over a considerably long period of time and carry the highest industry standards to ensure our customers have the safest potentially life-saving product.” Fike is a globally recognised company supplying products and services which protect people and critical assets from fire, explosion and over/underpressurisation. A leader within the industry, Fike manufacture solutions for a diverse range of process industries, providing products ranging from bursting discs and explosion protection systems to energetic oil and gas products for the offshore markets. Other UK branches of Fike also provide fire suppression systems, fire detection devices and alarm panels. Tel: +44 (0)1622 677081 Fax: +44 (0)1622 685737 Email: sales@fike.co.uk www.fike.co.uk
ECS & Waterfront help to deliver new flood defence scheme As the Environment Agency (EA) continues its work to improve flood defences around the country, in the Northern region, it has chosen to install a new hydraulic, multi-turn actuator as part of a new penstock control system, which will make the flood defences at Market Weighton, in East Yorkshire, compliant with the 1975 Reservoirs Act. The project, which was installed by ECS Engineering Services, saw a new penstock and actuator being installed along with a new control kiosk, which was located on higher ground. Mill Beck flows into Market Weighton through an area called the Monkey Run, which is normally used as a general amenity area and includes a football pitch. During periods of heavy rainfall however, the flood water is held back in this area, which is classed as a flood storage reservoir. The EA has a responsibility to ensure that as the water level in Mill Beck subsides, the flood water is allowed to return to the river under controlled conditions, without any erosion to the embankment. Therefore, as part of a ÂŁ3 million scheme the EA appointed Jackson as the main civil engineering contractor to design and construct a weir, spillway and a stilling basin at the site together with a new inlet structure on the culvert. A new cast iron penstock will replace the old penstock and will be controlled by a hydraulically powered, multi-turn actuator from Centork, which was acquired by Rotork in 2011. ECS was responsible for the installation of the penstock and the new control kiosk, which is located on higher ground to avoid the flood water.
The Environment Agency has chosen to install a new hydraulic, multi-turn actuator as part of a new penstock control system
A hydraulic actuator is powered by pressurised oil and provides a 4-20mA position signal back to the control panel
The actuator will be used to control the new cast iron penstock, which was supplied by Waterfront Fluid Controls
A hydraulic actuator is powered by pressurised oil and provides a 4-20mA position signal back to the control panel, which is located in the kiosk along with the hydraulic power pack. This design was chosen because of the location of the penstock, which could become submerged during periods of especially heavy rainfall, making a more common, electrically powered actuator unfeasible. The actuator will be used to control the new cast iron penstock, which was supplied by Waterfront Fluid Controls, which has an agreement with ECS as its distributor and installer for both standard and bespoke water control products. The design has been made as simple as possible so as to ensure complete reliability and thus providing the residents of Market Weighton with improved flood defences. In the event of heavy rainfall, the improved containment system will collect the flood water and then release it back into Mill Beck under the control of the penstock. This can be controlled from a central control point via the telemetry station located in the control kiosk. This allows an engineer to adjust the position of the penstock remotely, allowing a much quicker and safer response which can start to allow the flood water to dissipate at the earliest opportunity. Jamie Wesley, Commercial Manager - Water Control Division at ECS comments: “This is an important project for the local area and it is vital that we install a reliable system with the minimum of impact on the surrounding area. This new actuator, the design of which allows it to operate while submerged, combined with the Waterfront penstock provides an excellent solution.�
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Flagship Village style housing development for Surrey A new housing development in Walton, Surrey, aims to set new standards for sustainable development and village style living. A primary school, 1,000 new homes and a riverside park would be built on the site of a former quarry. Proposals for the site which is currently used for commercial storage and grazing horses, have been unveiled by developer Bonnar Allan. Of the 1,000 homes on Drake Park, half would be affordable and the remainder sold privately. The homes, set within 147 acres of landscaped parkland, would be a range of one and two-bedroom flats, three and four-bedroom townhouses, three and four-bedroom semidetached houses and four and fivebedroom detached houses. The proposed village creates a Issue 11 - Page - 40
pleasant, open environment for all, with a continuing habitat for wildlife, and is designed where one can safely walk or cycle, catch the bus or train minimising the use of the motorcar. It also includes a riverside walkway, open grasslands habitat and picnic facilities The proposed development uses the full spectrum of sustainable design techniques to achieve low carbon living, providing low energy costs to future residents and enhancing the local environment. The project team’s consulting engineers, The Stilwell Partnership, are responsible for bringing together all the technical elements to ensure the development achieves its sustainable aspirations. This includes dealing with Ecology, the Geotechnical issues, Highway
Engineering, Sustainable Drainage, and Renewable & Low Carbon Energy The overall design aims to enhance the local environment through the provision of green spaces, wildlife habitats and biodiversity features, and the improvement of the river corridor. As the lake, river and copse remain unchanged, there will be no negative impact on the indigenous or migratory wildlife. The roads and housing are designed to minimise on-road parking and keep the roads free and safe. The highway engineers have integrated sustainable transport principles into the infrastructure design to cater for all road users; pedestrians, cyclists, public transport users, car owners and service vehicles. The location benefits from the existing bus and train transport networks and the design
and location of new civic amenities means that within the village most people can access shopping, education, medical, recreation and leisure amenities on foot. Charging units will be provided for electric cars in parking areas. In addition, sustainable urban drainage techniques have been incorporated to contain the surface water run-off on the site and not disturb the hydrology of the surrounding area. The construction of the buildings shall aspire to achieve Level 5 of the Code for Sustainable Homes and include Lifetime Homes, exceeding that usually required by the Planning Authorities or Building Regulations. These codes set wide-ranging standards including consideration of energy efficiency, water conservation, use of sustainable and recycled construction materials, and local ecology. The CO2 emissions arising from the development’s energy use will be significantly reduced by a range of measures. The highly insulated buildings, incorporating the latest energy efficiency measures and A++ appliances fitted as standard will all contribute towards reducing the carbon impact of the site. This will be further reduced by the application of low carbon and renewable energy technologies, such as combined heat and power, biomass, hydro, PV and solar panels. The adopted sustainable energy solution for the site will incorporate the technologies that achieve maximum utilisation and CO2 savings performance. Satellite House 2 Nexus Park Ash Vale, Guildford GU12 5QE UNITED KINGDOM www.stilwell-ltd.co.uk Tel +44 (0) 1276 700 400
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DETECTRONIC INFORMS GLOBAL WATER INDUSTRY Representatives from the UK, European and International water industry have attended an open day hosted by Detectronic, specialists in preventing flooding and reducing pollution. Attendees were treated to seminars led by guest speakers from the Environment Agency, the Met Office and the University of Exeter and were able to take part in workshops from Detectronic’s engineers, data analysts and site crews. Explains Steve Woods, managing director at Detectronic: “Following our move to new premises in Colne, Lancashire earlier this year, we wanted to invite our current and prospective water industry customers to see, first hand, exactly what we have to offer, meet the team and relevant industry experts and network. “Ian Hodkin from the Environment Agency gave an in-depth overview of emergency planning and flood risk management and gave a fascinating insight into the organisation’s role in last December’s floods. Coping with a record 25 flood warnings in one day and protecting 78,500 homes
on the East coast from flooding were just two of Ian’s talking points!” Continues Steve: “William Wheeler who worked at the Met Office for over 40 years then gave an entertaining talk on building the National Weather Radar Network, its advantages for water companies in predicting rainfall and taught us all there’s much more to rain than meets the eye. “Finally, Dr Michele Romano from the University of Exeter shared his work on how water companies can prevent leaks and bursts using a methodology – Smart Monitoring of Pipe Networks – he has developed to deliver timely detection. Over 3,300 million litres of water are lost every day in the UK water industry due to leaks and bursts so prevention offers substantial operational savings and customer benefits for water companies.” Following a hog roast lunch, guests
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took part in various workshops led by Detectronic personnel. These included a discussion of the advantages and disadvantages of ultrasonic level sensors, new innovation in product design and an introduction to Detec DataPro, Detectronic’s data analysis and reporting system that enables water companies to monitor their networks in real-time and prevent incidents from occurring. Concludes Steve: “By sharing best practice and working together in partnership with water companies, it’s our aim to help prevent flooding, reduce pollution and improve rivers and bathing water. The open day enabled us to discuss these objectives with our existing and potential customers and, most importantly, demonstrate how we do this and how they, and their customers, can benefit - it was a huge success.”
OIL RECOVERY SUCCESS FOR CSG After a year in full operation, waste managers Cleansing Service Group (CSG) have evaluated the savings made following a £200,000 upgrade of the emulsified oil treatment processing facility at its Coventry treatment plant.
process, as well as producing better grade oil which is more useable as a fuel.
The upgrade was designed to provide environmental benefits by reducing the amount of fuel used and heat wasted during the recovery
CSG has six oil treatment plants – all ISO 14001 accredited - processing thousands of tonnes of oily wastes each year delivered by the
Plant managers have reported that over 240 tonnes of CO2 has been saved as well as 1,000 cubic metres of mains water, made possible by eliminating the need to use steam to heat water during the process of recovery.
company’s fleet of specialised tankers following the emptying of interceptors, tanks and drainage systems at commercial and industrial facilities. CSG operate a nationwide network of specialist treatment facilities for solid and liquid wastes as well as what is believed to be the UK’s largest hazardous waste treatment and recovery facility at Cadishead, Manchester. Tel: 0800 048 0622 Web: www.csg.co.uk Email: technicalsales@csg.co.uk
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Dee Valley Water’s £17m flagship water treatment works at Llwyn Onn, North Wales, is controlled from inlet-to-outlet by a Mitsubishi Electric system redundant, Q series modular PLC solution.
Mitsubishi Electric solution controls new £17m showpiece Llwyn Onn water treatment works from inlet-to-outlet The Dee Valley Water (DVW) project to build a new water treatment works at its flagship site, Llwyn Onn in North Wales, has now been completed. The £17M project was officially opened in March 2014 by the Minister for Natural Resources and Food, Alun Davies and is controlled by a Mitsubishi Electric system redundant, Q series modular PLC solution. The new works has been operational since August 2013. The new works provides DVW with the capacity to produce 47,000m3 of drinking water per day for Wrexham and the surrounding area. In addition to the standard treatment processes, Llwyn Onn also includes an automated processing system for removing manganese, a mineral that occurs naturally in the surface water of the DVW area. With so many people depending on a continued supply of clean water the process for selecting a reliable automation control system for the entire works was particularly stringent. In all, four automation providers, including Mitsubishi, submitted proposals which were scrutinised by DVW and the main Issue 11 - Page - 44
project contractor Black &Veatch, before the preferred Mitsubishi solution was chosen. The majority of the subcontract supply chain for this project has been sourced from the north Wales area, including the system integrator, Tycon Automation Ltd. Tycon has an extensive knowledge of the Mitsubishi product range, having used components to complete several large water control projects in the past. Investing in the development of a large library of field proven application specific software modules meant that Tycon was perfectly positioned to provide the integration for what is a large and complex site control solution.
Process optimisation at Llwyn Onn The water treatment process consists of dissolved air flotation (DAF) clarification, granular activated carbon (GAC) filtration followed by rapid gravity filtration (RGF) and a chlorine contact tank before being pumped to a storage tank - from where it is fed into the distribution network. Although this is not the conventional process order, it is an arrangement that has been designed to work in this area, which has the additional issue of manganese to deal with. A crucial aspect to the control system was the use of a full dual redundant PLC system. Complete with its own CPU, the secondary
system is fully wired-in and tested, increasing the system reliability by mirroring the primary CPU so that in the unlikely event of a failure of the main CPU, power supply or base unit, the secondary system can take over within 21 milliseconds from the same control point. Andrew Robertson, Technical Director at Tycon, ‘There were elements in the contract specification which in our opinion meant it suited the Mitsubishi hardware. Historically I believe this was a Rockwell site but Dee Valley Water were flexible in their approach and were looking for a fully redundant system. They could see that we had achieved this before with a very reliable fully redundant architecture on a larger system installed on the Isle of Man, which we arranged for them to visit, it meant that we could meet both the performance targets and the price point set for this project. Realising control with 1000+ I/O ‘We spoke to Dee Valley Water at length about their preferences and reliability was of paramount concern. The Mitsubishi QnPRH PLCs are designed to work in a redundant set-up and therefore met the specification from the outset. The system was designed with two processor racks and three I/O racks in the main MCC, with 1/3 of the plant on each I/O rack. The system lent itself to being designed this way as the process contains three DAF lanes, six carbon filters and six rapid gravity filters which give an inherent amount of redundancy in the process; we matched with the control system design to provide the most robust engineering solution. ‘The pump motors are mostly controlled by variable speed drives (VSDs) which are connected using a Profibus network. We used separate Profibus networks within the MCC, with separate networks going out into the field to simplify design and increase robustness. We employed Mitsubishi Slice I/O with Profibus interfaces to manage the I/O locally in the field, which reduces cabling and installation costs and works well with the Mitsubishi PLC which will accept most fieldbus network protocols with a plug-in comms module.
The Mitsubishi QnPRH PLCs are designed to work in a redundant set-up. The system was designed with two processor racks and three I/O racks in the main MCC, with 1/3 of the plant on each I/O rack.
‘Speed wise, and because there is a lot of digital and 4-20mA I/O (over a thousand I/O points) including flow meters, level instruments and quality instruments we segmented the Profibus networks to provide maximum redundancy and system resilience. The response time of the PLC however is far beyond what we would need for this application. PID control loops for flow control valves etc are well within the processing capability of the CPU, with the control loops for the chemical dosing system being the most critical. For this application we are talking seconds, rather than milliseconds, which we often work with in other more dynamic higher-speed applications. ‘The Mitsubishi GX Works II software is a nice environment for us to work in, it is easy to find your way around and easy to use. We were able to use function blocks previously developed for water treatment applications by Tycon Automation Ltd, which made the job simpler to realise and enabled us to add value to the project. The flexibility of the programming environment meant that the system architecture could be broken down into function blocks representing all parts of the plant. A remote access VPN link into the site means we can access the SCADA layer and therefore the PLC in real time and can easily interrogate the system to see what the raw code is doing and carry out any fault finding activities. It is important with such a large program to have a logical structure which makes it easy to interrogate.’
Mitsubishi Electric QnPRH Series PLC architecture The QnPRH is Mitsubishi’s most sophisticated control solution and represents the top end of the Q Series Automation Platform. It offers a high level of system redundancy which insures complete immunity to process interruptions caused by power or system failures. This is achieved by using a fully redundant architecture that duplicates processors and network links. Hot-swap capability provides an operational level of redundancy. The solution was developed specifically for use in applications where downtime cannot be tolerated for reasons of equipment damage, interruption of service, penalties, or regulatory compliance. The dual redundant CPUs (control and standby) mean that any failure of the control CPU causes immediate transfer of control to the back-up, preventing system failure or interruption. Synchronization of up to 100,000 words of process data is possible between CPUs per scan. Switchover time is typically around 20-40ms, ensuring a “bumpless” transfer. Because the CPUs reside on physically separate racks, the control CPU can be replaced while back-up maintains system operation. Most parts are interchangeable with standard Q Series systems which controls both purchase cost and total cost of ownership.
Web: gb3a.mitsubishielectric.com Email: automation@meuk.mee.com Issue 11 - Page - 45
UK’s largest energy from waste facility - Riverside Resource Recovery - is using Metso DNA automation system The Riverside Resource Recovery Energy from Waste Facility is situated on the bank of the River Thames, in the London Borough of Bexley. It is currently the largest such facility in the UK, and process control is achieved using Metso DNA automation system. Municipal household waste from six London boroughs is taken to Riverside by barge – the most cost-effective and environmentally friendly way of transporting around 10,000 tonnes of waste each week. Riverside also accepts waste by road from its local borough, Bexley. It is expected to manage an average of 585,000 tonnes of waste per
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year, with a capacity of 670,000 tonnes. The plant produces around 478,000 MWh of electricity, which is the amount you would get by burning 191,000 tonnes of coal or 95,000,000 m3 of gas. On arrival at the Riverside facility, the barges are unloaded at a purpose built jetty by two goliath cranes and the waste is taken to the main plant building by dock tractor trailer units. The waste is tipped into a storage bunker through one of 12 tipping bays. Infrared cameras monitor the waste in the bunker for hot spots allowing an automatic fire control system to
operate if temperature limits are exceeded. Combustion air for the process is drawn from above the bunker thus minimising odours and dust in the bunker and tipping area. Two overhead grabbing cranes are used to charge each of the three boilers with waste, up to a throughput of 30 tonnes per hour each. Waste enters the combustion chamber via a vertical feed chute and is pushed by hydraulic rams from the feeder table onto a sloping stoker grate consisting of alternate rows of fixed and moving cast steel bars, carrying a moving bed of burning waste. Complete combustion is achieved by the use of primary air nozzles in the grate bars and secondary air nozzles above the waste bed and varying the speed of the grate and the temperature and flow of air. The heat value of the waste can vary considerably even after mixing in the waste bunker and does not have a standard heating value like most carbon based liquid solid or gas fuels. Controlling the combustion process therefore requires many variable inputs to ensure a stable output together with a combustion process that continuously operates safely and within acceptable environmental limits. The combustion
control system has an interface with the Metso DNA system to allow total control of the process. Steam is generated through heat transfer from the combustion process into water filled boiler tubes. Superheated steam from the boilers is used to operate the 72 Mega Watt turbo generating unit, which is connected to the National Grid. The Metso system monitors and controls water levels, steam flows, steam temperatures and pressures. There are inevitably some residues from the process as the waste contains some materials that do not burn. At the lowest point of the grate where burning has ceased the ash produced in the combustion process and any noncombustibles fall into a quench bath and are conveyed into a Bottom Ash storage bunker. The ash and scrap metals are sorted at a plant in Tilbury Docks. Metals are recycled as scrap and ash is recycled for use as aggregate. Flue gases are drawn through the various stages of the process by large fan units and exit the plant at the stack . Sensors capture the composition of the gases throughout the process, and this information is fed back to Metso DNA for careful monitoring. The levels of nitrous oxide are reduced by injecting ammonia
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into the system, the acid gases that result from burning plastic are neutralised using hydrated lime, and active carbon captures heavy metals. Finally, the gas passes through a fabric filtration system before being released through the chimney stack. What does Metso DNA do? Metso DNA is a single integrated automation and information platform for process control, high speed machine control, batch control and SIL certified safety controls. It offers advanced optimisation, mechanical condition monitoring and process performance monitoring. At the Riverside Energy from Waste Plant, Metso DNA gathers information from a large number of sensors – everything from the initial waste handling process to the composition of the emission gasses at the stack to the pressure of the steam at the turbine and the conditions in the various auxiliary systems. Any readings captured by other systems are carefully integrated with the data captured by Metso DNA’s own field interface network and are displayed together, providing operators with the information they need. All of the gathered information is relayed back to the main plant control room and is suitably displayed on screens with system views set up by the operations team, visual and audible indications of parameters that move outside normal operating ranges allow manual intervention . Operators can easily view both live and previous data simultaneously thus enabling them to identify trends, and to take any necessary remedial action as soon as possible. Likewise this information can be displayed and easily accessed in read-only format by managers or engineers, and is used to provide user friendly management and operational reports. The sheer quantity of information available could be overwhelming, but Metso DNA displays it in such a
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way that only those areas requiring attention are highlighted while still making all information visible. Not only can operators see what is happening as it is happening, they can do something about it. Metso DNA enables them, for example, to open and close valves to adjust pressures or to inject lime (the quantity calculated automatically) to neutralise acidity in the emission gases. Finally, in addition to the on-screen information available, Metso DNA can be configured to send alarm notifications to designated people automatically when certain conditions are met. Day-to-day operations Teams of three – a Shift Team Leader, a Plant Operator and an Assistant Plant Operator – control the process on a day-to-day basis using Metso DNA. The control room houses several control stations, each consisting of a PC with three screens, enabling the entire plant to be monitored. “Keeping the operator in control from the control room.” Richard Gledhill, Operations Manager. The visual display has been designed to enable the operators to concentrate on what’s important. Although more elements are being measured and monitored than ever before, they are only highlighted when they need attention. Trends can be seen instantly – for example, is an increase in temperature an isolated incident, or has it gradually been creeping up over the last few hours? The team leader can investigate issues and take appropriate action without interfering in the continued monitoring of other parts of the plant. Gradual drifts can be identified and corrected before they become serious. “You think about what system data you want to see and it is generally available incidentally there is not much that isn’t..” Quentin Gillett, Plant Manager.
A wide range of adjustments can be made and parameters monitored electronically from the operator’s position. These would traditionally, in many cases, have needed someone to physically go to adjust a valve or check a reading. This facet of the system is important with a small operating team on shift. Routine maintenance Lee Alford, the engineering manager, and Matthew Bourner, the Control & Instrument Engineer (C &IE) who manages the Metso system, use Metso DNA to plan and manage routine maintenance and repairs and to generate reports. Lee Alford also uses the information system to generate and view relevant reports on his PC. Many faults are identified by the operators before they become serious issues, and information about these is passed to the maintenance department, who may either investigate further using the remote access facility or who may discuss the issues with an operator. All the required information is available regardless of how it is accessed. Diagnostic information is good – the operators can see details that previously Matthew had to provide, which has enabled him to concentrate on other aspects of his job, dealing with the issues that the operators cannot manage for themselves. Historical data is also easy to access, and a read-only version of the monitoring system enables more detailed analysis when this is required. “A high level of diagnostic information is available remotely.” Richard Gledhill, Operations Manager. Small changes to operating parameters can be made easily from the control room. Online changes to equipment have also been carried out successfully and safely, minimising disruption to the routine operation of the plant.
Information from the system Quentin Gillett is the Plant Manager. He has been working in the Energy from Waste industry since 1992, and appreciates the management information he is able to access. The reports enable him to see exactly what he needs, without having to interface with other systems, and simplify the process of providing management reports. Flexible reports can be designed, generated and automatically emailed on a daily basis. Monthly forecasting reports can be produced and sent to the facility owners. All without interfering in the routine operation of the plant. Lee Alford, the engineering manager
The Information Management system is available for as many people as need access to it. The remote interface enables managers to access real-time read-only information from their desks – there is no need to enter the control room and interrupt normal operations to obtain it. Detailed historical information is stored in a database, enabling comparison and forecast reports to be produced quickly and easily. “We all have the ability to use the DNA system, even the financial controller. We’ve all got access on our PCs.” Quentin Gillett, Plant Manager, talking about the information management system
Quentin Gillett is the Plant Manger
The flexible nature of the reports means that the information required can be extracted, filtered and displayed in the way that is most useful and meaningful. Training on the information management system is enabling the managers and engineers to obtain all of the information they require, and as their knowledge of the system increases, they are obtaining more benefit from it. “We’re scratching the surface at the moment but enjoying scratching. the full potential is yet to be seen.” Quentin Gillett, Plant Manager, talking about the information management system
More info: Neil Buckland Sales Director, Automation neil.buckland@metso.com Richard Gledhill, Operations Manager
www.metso.com Issue 11 - Page - 49
FANS HELP IN LANDMARK PROJECT TO GENERATE ENERGY FROM WASTE
A total of 23 axial fans supplied by Elta have been installed throughout the first large Energy from Waste (EfW) facility to be built in the Lincoln area. The recently completed project on land off Paving Way, North Hykeham is a low cost facility that dramatically reduces the amount of non-recyclable waste that Lincolnshire County Council sends to various landfill sites. The fan manufacturer supplied: six SRECU heat recovery units; three aluminium long cased SmokeVent fans; five Revolution long cased fans; two backward curved, inline units; two aluminium and one GRP long cased fans and one carbon filled ATEX fan all from the company’s factory in Kingswinford near Dudley in the West Midlands. Elta Fans’ SRECU heat recovery units are designed to create healthy air quality and comfort within buildings by providing a constant supply of warm, fresh air. Issue 11 - Page - 50
Each unit incorporates a plate heat exchanger capable of recovering up to 65% of the heat from the air being expelled through the building’s ventilation system. This cuts down on heat loss and thereby reduces the cost of heating. The outgoing air is passed over aluminium plates within the heat exchanger. This warms the plates which, in turn, transfer the heat to the fresh incoming air. The design of the heat exchanger keeps the incoming and outgoing air supplies separate, eliminating the possibility of any contamination of the fresh, incoming air by the expelled air. With low profile, robust casings of double skin, galvanised sheet steel and fire-resistant mineral wool infill for quiet performance, SRECU heat recovery units are directly driven by an AC external rotor motor. Efficient, easy to mount and maintain, they are designed and manufactured with procedures as defined in
All the Elta units were delivered to site where they were installed by electrical contractor, N.G.Bailey, the engineering, IT and facilities services company. Main contractor for the overall project in North Hykeham was Clugston Construction Ltd. and lead civil works consultant was Arup. Run by the FCC Environment (formerly the Waste Recycling Group), the landmark EfW project came about as a result of the company securing a contract to dispose of Lincolnshire County Council’s residual waste over the next 25 years. The facility is fed from a series of new waste transfer stations (WTS) strategically located throughout Lincolnshire in Grantham, Sleaford, Boston and Gainsborough. These stations have replaced landfill sites for disposal of local waste and are in addition to the similar station in Louth, in the Lincolnshire Wolds. Household waste is collected at these WTS, sorted and then sent to the EfW plant. There, the non-recyclable waste is stored within a large underground bunker before being used as fuel to power a hot water boiler. The resulting steam, in turn, drives a turbine capable of generating 11 megawatts of electricity. The facility was designed to treat approximately 150,000 tonnes of residual household and commercial waste a year on behalf of Lincolnshire County Council and now exports the renewable electricity generated from burning the waste for sale to the National Grid. The amount of power created is sufficient to supply between 10,000 and 15,000 homes.
www.eltafans.com
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RAISING THE BAR IN REDUCING YOUR WAREHOUSING COSTS With class-leading residual capacities, high efficiency and superior ergonomics, the new Cat® NR14-25N2 range achieves the next level in performance and operation. And with eleven models to choose from including high performance, compact and straddle versions, you’ll be spoilt for choice. Whatever materials handling equipment you need, we can provide the level of service to match your expectations. From a wide choice of quality, durable products, to flexible finance packages, comprehensive after sales service and maintenance, we pride ourselves on making it easy for you to put the right truck into the right application.
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