The University of East Anglia (UEA) is no stranger to steam boilers from Fulton having been using the heat transfer specialist’s solutions for many years. But having replaced their ageing plant with new VSRT boilers, even they were surprised at just how efficient the installation would prove!
With steam being essential to the University and used extensively for humidification purposes – to ensure that the appropriate environmental conditions of 55% to 65% RH are maintained – and for the autoclaving of equipment and waste, any installation needed a form of redundancy in place from the outset.
Installed in 2004 and handed over to the facilities team in 2005, the University’s original installation therefore featured three J Series boilers, allowing for two to cope with daily requirement and the third as a standby for when steam demand was high or during servicing and maintenance schedules on the other boilers.
Commenting for UEA, Estates Project Lead Philip Page says: “Even during the original planning phases for the boiler plant room we knew that floorspace, headroom and access was going to be limited. With horizontal firetubes out of the question and many vertical boilers at the time requiring almost double the height of the boiler itself for maintenance purposes, Fulton’s J Series was the perfect solution.
“Fast forward to when we started the replacement programme for the J Series a review revealed that things, in the most part, hadn’t changed in the boiler market and no other boiler that could fit within the plant room was as capable or efficient. We therefore put the programme on hold.”
Thankfully for the University, when the time did come to complete the replacement programme, a market review in 2019 revealed that Fulton had just launched its all-new VSRT, the most radical change to vertical steam boiler design since the company pioneered the vertical tubeless boiler back in 1949; and the world’s first fully-wetted, refractory-free vertical tubeless boiler. The compact footprint of the VSRT also meant it was a perfect fit for the existing plant room.
Available with outputs from 160 to 960 kg/h, the VSRT boasts ultra-low NOx emissions of less than 20ppm, achieved thanks to the VSRT's combustion technology that features a modulating burner and furnace that have been purposely-designed as a single component and fully-matched with the VSRT in mind. This has helped Fulton to achieve up to 10:1 turndown capabilities and industry-leading performance of >82.5% gross thermal efficiency and 99.75% steam quality at 8 bar.
Having been in constant use for over 14 years, the University replaced all three Fulton J Series steam boilers with an all-new heat transfer system featuring three VSRT-50 boilers complete with all necessary ancillary plant including water treatment, chemical dosing, blowdown vessel and feedwater tank.
Because of the plant room’s situation – located in the middle of the building on the second floor – a temporary steam main was installed and piped to an external boiler plant solution that was hired so the facility’s steam supply could be maintained. A crash desk was then built two floors up, the end wall of the building removed, and the J Series boilers removed and replaced with the VSRTs. In total, the entire replacement process took six weeks to complete.
Two years after the VSRT installation was commissioned and handed over to the University’s estates team, a review of energy savings was commissioned to compared the old and new installations, with the results proving significant.
“The sustainability team compared the last 12 months usage of the three VSRTs to that of the three J Series boilers’ pre-Covid usage in 2019 and has reported a reduction in gas consumption of nearly 28% and over 57% for water.” says Philip. “Even if you don’t to take into account the recent cost increases in gas, these savings are significant and really impressive!”.
In addition to the gas and water savings, the sustainability report also identified an 85-tonne reduction in CO2 annually, savings that can be credited towards the University’s net zero goals. The University is also seeing an approximate 40% reduction in NOx emissions throughout the burner firing range.
As part of the new VSRT package, Fulton’s SCOPE boiler sequencing system was also specified which, as Philip Page explains, the University sees as being vital to the installation’s longevity.
“We operate an N+1 strategy at the University and most of the time two of the three boilers are firing to meet demand. The autoclaves are not always in use and during these times only one of the boilers is needed. However, we’re keen on maintaining equal operating hours across all three boilers and balancing water treatment across them too, so Fulton’s new SCOPE system enables us to automate weekly boiler changeovers to vary the lead boiler.
And while Philip can’t attribute the savings achieved from the boiler installation to the SCOPE itself, he is confident that the sequencing system will help to reduce maintenance costs by balancing operating times across the three boilers.
Beyond the impressive savings achieved, the University’s Estates team has also noted that compared to the J Series installation, the VSRTs are noticeably quiet in operation thanks in part to the fully-modulating burners running at lower levels when steam demand is low.
Summarising, Philip Page says that in the years that the University had Fulton boilers they really do tick all boxes. “We can’t fault their operation, and we can’t fault the Fulton service or customer support.”.
Steam specialist TLV Euro Engineering has launched the FJ32, a range of free-float steam traps designed for process applications including jacketed pans, heat exchangers and vulcanisers that, while adopting the universal QuickTrap® connection, can be regularly, safely and easily removed, repaired and reused.
Commenting for TLV Euro Engineering, General Manager Michael Povey says: “The new FJ32 steam traps really are exceptional! The FJ32 is a maintainable process steam trap with QuickTrap connections that, when used in conjunction with TLV’s recently-launched QuickStation™ QS10 steam trap station, can be safely isolated, the system blown down, existing trap removed and new trap installed and reopened for getting the process back up and running quickly. The FJ32 can then be maintained and put back into stock for future use.”
A reliable and durable stainless-steel steam trap for use on steam mains and process equipment, the two models in the FJ32 range – FJ32-X and FJ32-B – feature a two-bolt universal QuickTrap connector that facilitates inline steam trap replacement in either vertical or horizontal piping. This significantly reduces the time required for installation, removal, repair and maintenance; with removal of the old and installation of the new traps undertaken in a matter of minutes. This connection also allows traps to be positioned correctly regardless of pipeline configuration.
Utilising TLV’s Free Float technology, the trap quickly adjusts to changes in the condensate load, with the three-point seating ensuring a steam tight seal even under low load conditions. The precision ground float provides an infinite number of contact surfaces with the orifice, ensuring negligible wear.
The high temperature (max. 350ºC) FJ32-B and low temperature (max. 240ºC) FJ32-X models come with different air venting methodologies to minimise start-up time. This, coupled with the maximum operating pressure of 32barG, offers a versatile trap suitable for a variety of applications.”
For further information, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
Industrial safety engineering specialist Euchner will use its stand at this year’s PPMA exhibition to launch two new and exciting products – the Industry 4.0 Ready CTS safety switch and CKS2 coded key system – and showcase its extensive range of guard locking products available for common fieldbus connections.
The all-new, one-fits-all CTS is Euchner’s first FlexFunction device and expands the company’s product range by sitting between the all-round CTP and specialist CTM safety switch solutions, by combining the best of both worlds in a single switch while offering maximum flexibility. A key innovation of the compact CTS – which is IO-Link compatible and Industry 4.0 ready – is the company’s new FlexFunction feature that, by using the transponder-coded actuator to determine the switch’s function, allows a single device to perform a wide variety of functions that would otherwise require several switch variants. Its compact dimensions, high locking force of 3,900N and suitability to mount in three orientations ensures the CTS is suitable for use across numerous safety engineering applications.
Combined with highly-coded, transponder-based keys, the new CKS2 from Euchner forms a safe system that meets the highest safety requirements for machine and installation lockout and starting. Thanks to the integrated evaluation electronics and depending on the key used, various safety engineering tasks are possible with the compact CKS2 key system. Additionally, combining it with Euchner’s IO-Link Gateways expands its applications and enables comprehensive diagnostic and communication functions.
Unlike the CKS, the CKS2 can be integrated as a module within Euchner’s Multifunction Gate Box MGB2, expanding the functionality of the simple door interlocking solution to a small control terminal with access control.
Commenting, Euchner’s UK&I Country Manager David Dearden says: “The combination of MGB2 and CKS2 can be used across multiple sectors and for numerous applications to ensure process efficiency, create access rights flexibility, increase personnel and process safety, safeguard product quality and create transparency and traceability.”
The MGB2 is a unique interlocking or guard locking system for the protection of safety doors on machines and systems that, thanks to its modular approach, is more than simply a safety switch or bolt and offers a vast array of safety functionality. By incorporating additional safety modules to the MGB2, machine builders can include numerous functions, including guard locking, escape release, start/stop, emergency stop, etc. Its modular design also means the MGB2 can remove the additional need for a separate operator panel. And with networking opportunities available, it also reduces wiring and installation time.
The MGB2, CKS2 and CTS are just three examples of the safety devices available from Euchner. For further information on these and other machinery safety solutions, the company’s technical and product support team will be on stand E68 at PPMA 2022 from 27th to 29th September.
Curtiss-Wright’s Industrial Division has today confirmed its continued commitment to its long-term strategy of advancing the electrification market with the extension of its traction inverter product portfolio. These latest CWTIs offer the most highly efficient and innovative design for use in hybrid and pure-electric applications for on-highway and off-highway commercial vehicles.
Commenting, Jason Watkins, GM Curtiss-Wright Industrial Division says: “Having successfully logged over two billion on-road kilometers since launching the first production units, these second generation CWTI models have been engineered to be the very best performing and most efficient IGBT inverters on the market today, using state-of-the-art technology to design and ensure end users receive peak performance from a CW engineered solution.”
The advanced motor control software within a CWTI ensures adaptive tuning works to create the highest efficiency between the inverter and motor, delivering a system that is both powerful and superior in performance. Results from extensive testing on some of the world’s most powerful and efficient electric motors have demonstrated improvements of up to 38% on peak torque and power. Furthermore, using the CWTI can improve the efficiency of the drive system (motor plus inverter) by 2% resulting in an increase of up to 14% in vehicle range from a single battery charge.
The latest CWTI models launch as 420kW vehicle-grade traction inverters for single (CWTI-S420) or dual (CWTI-D420) motor applications. To provide ultimate flexibility, the enhanced functionality of both models operates with multiple motor technologies, including AC induction, permanent-magnet synchronous (PMS) and interior permanent-magnet (IPM) types, to ensure improved range, longer battery life and lower running costs.
CWTIs offer unrivalled full fault protection and a high level of self-protection with both current and temperature measured directly on the IGBTs. These accurate temperature measurements deliver higher power from the motor, while current measurements offer superior short circuit protection to the system.
A pressure reducing valve from steam specialist TLV Euro Engineering has been installed at King’s College Hospital in London and operating on a daily basis for nearly 14 years without an overhaul or spares fitted.
The COSPECT pressure reducing valve was originally specified by TLV Euro Engineering and installed by a contractor in 2008 for the King’s College Hospital NHS Foundation Trust’s Ruskin Wing, the tallest building in the Denmark Hill campus and one housing many of the hospital’s neurological departments. Originally installed outside between two buildings at the site, the COSPECT valve has since been enclosed by further building works at the hospital campus.
Installed to reduce pressure in the main steam line from 8 bar to 2 bar, indirect steam is used for the hospital’s heating batteries and domestic hot water purposes, so the COSPECT valve is operating 24 hours a day, 365 days a year.
It is estimated that the valve has achieved an average throughput of 950kg/h over its 14-year life, equivalent to 117,000 tonnes of steam. And in that time, the pressure reducing valve has never had any spares fitted, never been overhauled and has only occasionally had the operating pressures adjusted by the end user.
Commenting for TLV Euro Engineering, general manager Michael Povey says: “We were approached by Joji Abraham, the hospital’s estate officer, who was so impressed with the durability and longevity of the valve that he had no hesitation in contacting us when seeking a quote for a new plate heat exchanger system for the refurbishment of the Trust’s bone marrow ward.
“The age of the COSPECT was subsequently confirmed by our regional sales engineer during an initial site audit for the planned ward refurbishment project, with the programme since being fully commissioned and featuring two new plate heat exchangers from TLV Euro Engineering.”
When the COSPECT was first introduced in 1985, TLV had been manufacturing steam traps and related steam products for over 30 years and was well aware of the limitations and inadequacies its customers were experiencing with conventional PRV’s. Based on this feedback, TLV applied its fluid control technology to solve the many associated problems including fluctuations in primary and secondary pressures and valve hunting and vibration.
The renowned COSPECT, which many believe to be the ultimate pressure reducing valve (PRV), uniquely combines three components in a single valve – a piston-operated pressure reducing valve, a cyclonical effects separator and a free-float steam trap. This innovation not only saves space but also simplifies system layout, piping and maintenance. The COSPECT also ensures that dry saturated steam is provided at constant pressure and temperature, which helps to improve product quality.
COSPECT’s separator achieves 98% condensate separation efficiency and the strainer removes any remaining rust or scale. In addition, the condensate that is separated out is quickly removed through the built-in free float trap. All of which produces a noticeable improvement in the quality of the steam, and its heat conductivity. This can lead to increased valve life as well as increasing the service life and performance downstream equipment.
Maintenance is also simplified thanks to the COSPECT’s modular construction and use of PTFE gaskets, which makes the unit quick and easy to remove, or to maintain inline.
For further information, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
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.
