Big win for Wembley Stadium
Wembley Stadium upgraded its boiler plant rooms with advanced BMS and innovative, high-efficiency technology. Billy Huggett director of Autoflame Service & Support details how this upgrade led to significant cost and emissions reductions, with ROI achieved in under 12 months.
The journey to net zero is a marathon, not a sprint. While the end goal is crucial, it’s equally important to focus on the measures that can be taken today to significantly reduce energy consumption and emissions from the point of install. A recent project at Wembley Stadium perfectly illustrates this principle. Upgrading existing boilers with new burners and precise controls that include advanced Boiler Management System (BMS) functionality delivered 52% energy savings and a return on investment in under 12 months.
Wembley Stadium, national treasure and iconic venue synonymous with world-class sporting and entertainment events, faced a challenge familiar to many large facilities. Their existing boiler plant equipment was nearing the end of its operational life, leading to inefficiency, unreliability, and increasing operating costs. The stadium’s management team recognised the need for a solution that would not only improve reliability but also address rising energy prices and reduce their environmental impact.
Autoflame Service & Support, who has been servicing Wembley’s boiler rooms for many years, undertook a comprehensive energy audit and emissions report to assess the existing equipment. The findings highlighted the potential for increased operational efficiency through more precise, intelligent combustion. Working closely with the Football Association and Wembley Stadium, five boilers across two boiler rooms were upgraded with high-efficiency, low NOx Limpsfield burners and precise Autoflame Mk8 MM controls.
Intelligent control
A key element of this upgrade was the enhanced BMS functionality provided by the Autoflame Mk8 MM. Autoflame’s modern Intelligent Boiler Sequencing function (IBS) goes far beyond basic on/off control. In Wembley’s case, the Mk8 incorporates full fuel-flow metering and works in collaboration with Autoflame sensors to match heat flow to the stadium’s precise demands. This precise control is crucial in minimising boiler cycling, a major source of energy waste in traditional systems.
Boiler cycling occurs when a boiler repeatedly turns on and off to maintain a set temperature. Each start-up requires additional energy to bring the boiler up to operating temperature, leading to increased fuel consumption and emissions. By accurately matching heat output to demand, the Autoflame Mk8 significantly reduces these start-up cycles, thereby maximising energy efficiency.
Efficiency, safety, support
The upgrade also included the installation of Autoflame Exhaust Gas Analysers (EGA) in both boiler rooms. This multi-award-winning technology continuously measures up to six exhaust gases and stores a three-year history, ensuring both safety and compliance with environmental regulations. Driving efficient combustion further, the EGA constantly communicates the data to the Mk8 MM for precise fuel/air adjustments.
The final piece of the system is the Autoflame Data Transfer Interface (DTI) which collects data from all five boilers, providing a comprehensive overview of the entire boiler plant. The service team can remotely access this data which facilitates troubleshooting and ensures rapid response times, minimising downtime. This is a key element for the iconic venue, which would face large fines if games were postponed due to heating failures.
Tangible results
The results of the upgrade speak for themselves. Wembley Stadium has achieved a remarkable 52% reduction in annual gas consumption. This translated to a return on investment in under one year. Moreover, emissions have also been reduced by 52%, contributing to the stadium’s sustainability goals.
John Stirrup, technical manager at Wembley Stadium, says: “In 2023, we upgraded our heating systems with high-efficiency Limpsfield burners and Autoflame controls, reducing annual energy usage by 52% and achieving a return on investment in under 12 months. Despite rising post-Covid energy prices, our fuel bill remains below pre-Covid levels due to reduced gas usage and optimal combustion and burner sequencing, thanks to Autoflame Service & Support’s outstanding technology and service.”
Sustainable step forward
The Wembley Stadium project demonstrates that significant energy savings and emissions reductions are achievable today through strategic upgrades to existing boiler plants. By focusing on enhanced IBS functionality to minimise boiler cycling, facilities can make substantial strides towards their sustainability targets while also improving operational efficiency and reducing costs.
Furthermore, the newly installed equipment’s ability to fire all liquid or gaseous fuels, including being 100% hydrogen approved, adds another layer of future-proofing and emissions reduction potential. This fuel flexibility ensures that whatever fuel might be required or available in the future, the system can fire it, further contributing to reduced emissions.
As we move towards a net-zero future, it is important to recognise that every step counts. Upgrading existing systems with intelligent controls, accurate emissions monitoring, and future-ready fuel capabilities is a crucial step in that journey, delivering tangible benefits for both the environment and the bottom line from the point of commissioning.
