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PROCESS SAFETY
Top of this list is a lower boiler operation cost. This is achieved through the replacement of daily boiler water level control checks by a simple 15 minute test every three days. The test can be undertaken without stopping the boiler thereby avoiding interference with normal production requirements. Furthermore, the mandatory daily/weekly boiler water level control evaporation test is replaced with a six monthly test, thereby reducing overall manning and operational costs. Overall energy savings are achieved when boilers are controlled by an unattended boiler operating system, along with reduced emissions. Obviously, any savings made have to be offset against the annual cost of the system, but this is a fraction of the cost when compared to the labour savings made, especially if staff are being paid extra to work at weekends, evenings etc. Next in line in driving the popularity of these systems, is the ease of operation. Self- checking burner controls, for example, enable uninterrupted, unattended burner operation. Improved safety and conformance with current and future UK and EU legislation is also a key benefit and one that even 24/7 operational sites that are fully staffed are increasingly attracted to. Unattended boiler operating systems have to meet Safety Integrity Level (SIL) 2; SIL being a measurement of performance required for a safety instrumented function (SIF). Based on the IEC 61508 standard, four SILs are defined, with SIL 4 the most dependable and SIL 1 the least. Many manually operated systems are at the lowest SIL level 1.
WHAT MAKES FOR A GOOD SYSTEM? Virtually all manufacturers offer unattended boiler operating systems to accompany their steam generators and boilers, but as you might expect they are not all equal (although they do all have to meet BG01). One of the key differentiators between manufacturer’s systems
is the interface with HMI, controls and operation. A good system should have in-built data logging of activities and details of HMIs. Generally, they have a wider range of functions, making them more valuable.
TAKING UNATTENDED OPERATION TO THE NEXT LEVEL
Three day unattended boiler operating systems (essentially covering a weekend) are the standard and are written in to BG01 Guidance on Safe Operation of Boilers, the revised version of which was released in 2020. But, with the introduction of seven day unattended boiler operating systems, those guidelines are already behind the curve.
A relative newcomer to the market, seven day systems operate with the same principle as three day systems but have many additional benefits including extensive data logging, providing the user with valuable information. Ideally seven day systems should
meet BG01 Typical Arrangement 3 with a boiler house risk assessment on both the boiler feed water and returning condensate conditions. Further water analysis equipment may need to be fitted, along with further boiler house protection systems such as fire detection to meet this high level of unattended operation, but the benefits are considerable. Babcock Wanson’s BW7DAYS system, which comes with automatic Total Dissolved Solids Control, is the first seven day unattended boiler operating system to market and has proven highly popular. It features the unique and innovative NAVinergy remote monitoring system which integrates all of the components necessary for the supervision and management of the boiler room: control, regulation, recording, visualisation and communication. It enables organisations to monitor their boiler room from any device, anywhere in the world. All relevant data - including regular tests - is recorded, saved and stored on a compact flash type memory which also records normal boiler operating data; all of which can be easily downloaded to a standard PC for record keeping. The cost to upgrade from a three to a seven day system is negligible, which makes it all the more appealing.
UNATTENDED BOILER OPERATING SYSTEMS FILLS A GAP
In 2021, the IET reported an estimated shortfall of over 173,000 workers in the STEM sector, which equates to an average of ten unfilled roles per business in the UK. Its recent Skills Survey shows that half of engineering businesses are experiencing difficulties in recruiting skilled staff. These staff are in such short supply that more and more businesses are having to look at other solutions, primarily automation of plant. Unattended boiler operating systems that provide seven day cover will only become more prevalent in the UK to meet this skills gap. .
Babcock Wanson
www.babcock-wanson.com
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