Fulton installation at University of Sheffield is a real Diamond

Tue, Sep 20, 2016

Fulton's EFS electric steam boiler is installed at the University of Sheffield's £81m Diamond building

Opened in September 2015, the £81m Diamond building is the University of Sheffield’s largest ever investment in learning and teaching. It is home to students from its Faculty of Engineering and over its six floors, provides teaching facilities, library and IT services and state-of-the-art specialist engineering laboratories, including a clean room, a virtual reality suite and a project workshop.

The Diamond is a multi-disciplinary engineering teaching space, utilised by all seven departments and three interdisciplinary programme areas. Of the many disciplines taught at The Diamond – from materials science and aerospace to traditional mechanical engineering – the University’s bio-engineering degree is an innovative and technology-driven subject that uses engineering techniques to analyse and solve some of the most important questions in biology and medicine today.

For this undertaking, the bio-engineering department required a source of low- and high-pressure steam and, having looked at numerous solutions and manufacturers from the UK and Europe, approached Fulton for advice and a solution.

Low and high pressure steam is used by the department for process control in the laboratory-scale Solaris bio fermenters. These are used to produce a variety of single-cell organisms that are used to break down cells, extract DNA and look at protein extraction and expression. High pressure steam is used for vessel sterilisation to ensure that both the vessels are bacteria-free and ready for the next broth batch.

Commenting for the University of Sheffield, The Diamond’s technical operations manager, Dr Stephen Mason says: “A method of raising steam wasn’t considered as part of the building’s original specification so we started looking at laboratory steam generators, but couldn’t find a solution to provide the mass flow rate required for the faculty. It therefore became obvious that we needed some fairly serious steam-raising equipment and started looking at alternative boiler systems.”

Having dismissed steam generators, Stephen and his team looked at fuel-fired steam boilers but, with their requirement for ancillary equipment, these ‘traditional’ systems would have taken up too much of the laboratory’s valuable space and also weren’t deemed compatible with the building’s existing infrastructure. Additionally, with steam load only being required during teaching sessions, it was essential that a system could be powered-up and operational with 30 minutes and shut down again within just a few hours.

So, the University’s operations team started looking at numerous alternatives from manufacturers in the UK and Europe and eventually opted for a bespoke, skid-mounted EFS electric steam boiler system from Bristol-based Fulton Limited.

“With the search for a suitable source of steam for the bio-engineering laboratory having taken longer than we had hoped, our principal performance requirement had moved from output and size, to lead time.” says Stephen. “And having opened discussions with manufacturers in early December, Fulton was the only supplier able to survey, design, deliver and install a bespoke system within the three-month timescale required of the University.”

To make The Diamond an integral part of the city centre and allow visitors to watch students studying, a large proportion of the building façade is glass and the plant room (pilot plant) within it also surrounded by a glass partition. Because the Fulton EFS electric flash steam boiler was placed within the laboratory and therefore on display to students and visitors alike, the system was skid-mounted with a blowdown vessel that was housed in an identical cabinet to the boiler. The system was then delivered to site and installed within the self-contained, glass-fronted pilot plant, which also housed the Solaris fermenter.

With the boiler system installed on the ground floor and located almost at the point-of-use for the laboratory, all safety and planning aspects were discussed with, and solved by Fulton, with excess steam from the system being vented to roof-level via convoluted risers.

Having successfully resolved the planning and health and safety aspects of the installation, Fulton was also tasked with discussing the fermenter’s requirements for process steam with Solaris, the Italian manufacturer.

“Having no first-hand knowledge of fermenters or steam raising equipment, the University was delighted when Fulton took the lead on discussing its conceptual and detailed designs with Solaris, as the two companies were able to ensure that its systems worked seamlessly together.” says Stephen.

Fulton’s four-model EFS range has been designed specifically to deliver the short period/high demand steam loads that are typical of laboratory applications. The fully-automatic and self-contained steam boiler range incorporates an integrated feed water tank and feed water pump and provides short duration steam pulses at steady pressures. The EFS is able to meet fluctuations in steam loads and meets short-term peak flow rates of a typical steriliser cycle.

EFS boilers are designed to reduce entrainment of water droplets to a minimum and, as a result, produce high quality, contaminant-free steam. They are also quiet, clean and efficient and are protected with a fail-safe control system to ensure trouble-free operation in medical environments.

Working from a 400V 3ph 50Hz electrical supply, the University of Sheffield’s boiler system was designed by Fulton to BS1894 Class 2 and PED EC/97/23/EC and included an EFS54 automatic carbon steel electric flash steam boiler, rated at 86kg/h (F&A 100°C). This was skid-mounted with a Fulton model BDV2 blowdown vessel was constructed and certified to BS5500 Cat. 3.

Share and subscribe

MEDIA

Show all Media

Quotes

“It therefore became obvious that we needed some fairly serious steam-raising equipment.” (Dr Stephen Mason, University of Sheffield)
“Fulton was the only supplier able to survey, design, deliver and install a bespoke system within the three-month timescale required of the University.” (Dr Stephen Mason, University of Sheffield)
"...the University was delighted when Fulton took the lead on discussing its conceptual and detailed designs..." (Dr Stephen Mason, University of Sheffield)

External Links

About Us

Advanced Insulation (www.aisplc.com)

Since its formation in 2007, Advanced Insulation has become a single source provider for insulation and fire protection systems to the oil and gas industry, and represents one of the most respected and progressive names in topside and subsea insulation worldwide.

Advanced Insulation offers a wide range of products to meet the growing demand for fire protection and thermal insulation systems adaptable for elevated service temperatures and pressures.

AL-KO Kober (www.al-ko-co.uk)

Since 1931, AL-KO Kober has been manufacturing premium, high quality components used in the Automotive, Commercial and Leisure industry.

The extensive range of chassis components, premium accessories and spare parts are engineered to last, ensuring whatever product you have purchased, you will benefit from the generations of development and enjoy a lifetime of service.

Arc Energy Resources (www.arcenergy.co.uk)

Arc Energy Resources is one of the UK’s leading specialists in weld overlay cladding and fabrication for the oil & gas industry. The company’s expertise provides protection against corrosion and wear for a variety of process and pipeline equipment for use in any hostile environment.

The company recently made a major investment in two new Rotating Head welding machines costing £500,000. This has increased productivity and extended the size and scope of work it can handle, which now includes complicated component geometries for the full or partial cladding and fabrication of a huge range of component sizes weighing up to 15 tonnes. The company’s in-house designed cladding workstations feature state-of-the-art control systems developed to suit its customer’s specialised engineering requirements, and can clad bores up to four metres diameter and areas of restricted access within bores as small as 20mm diameter. Arc Energy also offers in-house test weld, heat treatment, PMI and NDT facilities.

Industry certifications include ISO 9001:2008 quality management, ISO 3834-2 fusion welding of metallic materials, and the internationally renowned ASME U and R Stamps, as well as ISO 14001:2004 environment management, Investors in People and OHSAS 18001:2007 Health & Safety management system.

Curtiss-Wright Industrial Group, which includes the legacy brands of Arens Controls, Penny & Giles, PG Drives Technology and Williams Controls, is a recognized leader in providing components and sub-systems which enable customer specific solutions for on- and off-highway vehicles. These include medium- and heavy-duty trucks, buses and motor coaches, construction and agricultural vehicles, materials handling, and other specialty vehicles, as well as sophisticated wheelchairs and scooters for medical mobility.

We are a leading provider of electronic throttle controls, transmission shifters and sensors for commercial off-highway equipment and heavy trucks, so helping to address the long-term trend towards attaining higher fuel efficiency and lower emissions. We also supply operator controls and advanced motor controllers for hybrid and electric vehicles, such as buses, forklift trucks, pallet stackers, wheelchairs and rehabilitation chairs.

With a proud legacy spanning more than 85 years, Curtiss-Wright is a global innovative company that delivers highly-engineered, critical-function products and services to the commercial, industrial, defense and energy markets. Building on the heritage of Glenn Curtiss and the Wright brothers, we have a long tradition of providing reliable solutions through trusted customer relationships.

Further information is available from the Curtiss-Wright Industrial website (www.cw-industrialgroup.com) or by calling +44 (0)1202 034000.

Euchner (UK) Limited (www.euchner.co.uk)

Safety for people, machines and products has been the maxim of this family-owned company since 1953. Stefan Euchner is the third generation to take the helm.

As specialists in industrial safety engineering, Euchner develops and manufactures products and solutions tailored to the requirements of customers from a wide range of sectors. Using its guards on machines and installations helps to minimise hazards and risks, which in turn protects people and processes. For its 800 employees around the world, safety is the watchword.

Further information is available from the Euchner (UK) Limited website (www.euchner.co.uk) or by calling +44 (0)114 256 0123.

Industry Superstore (www.industrysuperstore.co.uk)

Industry Superstore is a one-stop-shop for a wealth of budget-friendly, high-quality products tailored to industry!

Further information is available from the Industry Superstore website (www.industrysuperstore.co.uk) or by calling +44 (0)1892 664499.

Exmac Automation Limited has many years experience in the design, manufacture, and installation of unit conveyors, conveyor systems and associated materials handling equipment for most industry sectors.

Exmac Automation is part of the MacDonald Humfrey group of companies and are market leaders in the supply of automated materials handling equipment to the automotive, aerospace, white goods, warehouse & distribution, nuclear, pharmaceutical and food & beverage industries.

The group supplies to most industry sectors and have over 250 employees with many years experience in the design, manufacture and installation of unit conveyors, conveyor systems and associated materials handling equipment.

Projects have ranged from individual standard conveyors and bespoke handling applications, through to complete turnkey contracts involving conceptual and process design, installation and commissioning.

We are ISO 9001 accredited and constantly strive to achieve continuous improvements in the overall quality of our products and service.

Exmac Automation has has established a reputation for supplying high quality, robust systems at competitive prices.

In-house resources enable us to provide clients with a single source for complete systems integration including simulation, engineering, machining, fabrication, assembly, controls, installation & commissioning and after sales service.

Our 70,000 sq ft facility in Worcester has extensive design, manufacturing and assembly resources. Our skilled team of customer focussed automation professionals offers a broad base of knowledge and experience in a wide variety of industries.

A large workshop enables us to carry out comprehensive pre-installation assembly and factory acceptance tests on all projects.

Fulton Limited (www.fulton.co.uk)

The Fulton name has been synonymous with steam since the company first introduced the vertical tubeless steam boiler in 1949 and Fulton was established in Bristol in 1966. Fulton is still one of the world’s leading manufacturers, producing an unrivalled range of multi-fuel steam boilers. But increasingly these are ordered by customers as part of bespoke turnkey systems designed to meet exacting specifications.

Today Fulton Limited is an important design and manufacturing base in Fulton’s global network that also includes production facilities in the USA and China. The company’s UK facility makes it possible to manufacture products more efficiently and assemble completed units for whenever and wherever they are needed throughout the UK and in export markets.

Once just a steam boiler manufacturer, Fulton now specialises in ready-to-ship skid mounted and fully packaged boiler plant rooms to meet the current demand for off-site fabrication. The company puts great emphasis in providing sales and application advice and a full commissioning and after sales service to a growing customer base in hospital and healthcare facilities, food and beverage processing, laundries and other applications.

Design and manufacturing resources are shared and coordinated around the world, but no matter where your product originates, it will always be produced to the highest quality in a facility that is wholly owned and managed by the Fulton Group, which remains a privately owned family business.

Fulton’s heating and hot water systems can be delivered as fully prefabricated plant rooms or complete skid-mounted units, built to fit a prepared location and connect direct to your services.

Using the latest CAD equipment its design team can accommodate the most sophisticated engineering specifications in surprisingly compact spaces, locating components in the best possible position to suit the installation.

In every sense, today’s Fulton boiler systems are solutions that fit the requirements of the modern age of steam.

Gast Group (www.gastmfg.com / www.jun-air.com)

Since 1921, Gast Manufacturing, Inc. has been designing and manufacturing quality air-moving products. Our vacuum pumps, compressors, air motors, gear motors, vacuum generators, regenerative blowers and Smart Air technology meet the many challenging applications of OEMs and end-users worldwide.

For industrial manufacturing, health care lab, or environmental cleanup applications, Gast provides a full range of ideally suited and cost-effective solutions to any pneumatic problem.

Monodraught (www.monodraught.com)

In the current climate of soaring energy prices and the fear of global warming, increasing attention is being focused on Monodraught’s range of energy-free products.

Monodraught has always sought to invent, explore and develop innovative technologies that harness the wind and sun. Products include Windcatchers, Sunpipes, Suncatchers, Sola-vents, Sola-boosts and Cool-phase.

Nexen Lift Trucks (www.nexenlifttrucks.com)

Disillusioned with the ever-increasing complexity of new forklift trucks and the failure of the major manufacturers to provide a high level of support to their dealer networks, the decision was taken to develop its own range of forklifts.

In 2003 Nexen Lift Trucks was established with the vision to design and manufacture its own range with a combined 70 years experience of the lift truck rental industry. Nexen's ultimate goal is to build worldwide brand recognition based on its product's design and build quality as well as outstanding reliability at competitive prices.

In 2007 Nexen completed the purchase of the second largest lift truck manufacturer in Taiwan, creating the Nexen Motor Corporation. Initially the existing models were improved whilst a European based design team was established to develop a completely new range of trucks from the ground up to meet Nexen's standards.

Q8Oils (www.Q8Oils.co.uk / @Q8OilsUK)

Q8Oils has become a major player in the global lubricants market. Our success is founded on significant corporate resources, a commitment to product development and uncompromising standards of quality and service.

Q8Oils has a unique and innovative approach producing some of the world´s finest quality lubricants. Manufactured in its state of the art plant at Leeds, West Yorkshire, Q8Oils represent the very best and latest in lubricant technology. With over 1000 grades of finished lubricants, base oils, process oils, extracts and waxes.

We are dedicated to serving the needs of our customers by striving to understand, anticipate and satisfy their needs faster and better than our competitors. To achieve this our objective is to develop and supply products and services which reflect customer demands in each of our market sectors.

TLV Euro Engineering (www.tlv.co.uk)

TLV Euro Engineering UK is part of TLV, an internationally-established designer, manufacturer and provider of steam traps, condensate recovery pumps, pressure reducing valves and other specialist steam solutions. The company plays a leading role in the promotion of efficient energy systems and increased environmental conservation on a worldwide scale through its products and consulting and engineering services.

Rockatek (www.rockatek.com)

Cheltenham-based Rockatek Ltd is an engineering consultancy that offers design, analysis and physical testing services that set it apart from others. Its directors have over 40 years’ experience in complex engineering product optimisation and development; and its engineers specialise in engineering solutions for harsh environments and value improving reliability and performance.

Verco (www.ver.co.uk)

Founded in 1965, Verco quickly built a reputation for supplying quality refrigerated glass door and open chill cabinets to supermarkets, convenience and forecourt stores. Verco is now a leading supplier of retail refrigeration and the largest UK manufacturer of glass door cabinets.