Launched in 2018, Fulton’s VSRT steam boiler is unlike anything the industry has seen before. And because of its radical, world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard, it’s also catching the eye of those judging product and innovation awards.
At the recent Institute of Gas Engineers and Managers’ (IGEM) Gas Industry Awards 2019 at the London Hilton on Park Lane, Fulton’s VSRT continued its winning streak by claiming the Product of the Year award, the vertical steam boiler’s third award in six months.
Commenting for Fulton, managing director Carl Knight says: “The double-award-winning VSRT becomes a multi-award-winning steam boiler and we couldn’t be more delighted with this Product of the Year award. It was up against some stiff competition, which we hope proves just how impressive this next-generation boiler is and how much hard work has gone into developing the VSRT.”.
With over 15 patents pending in three continents, the VSRT’s spiral-rib heat exchanger is a world first. It attains industry-leading heat transfer rates thanks to its unique spiral design, which achieves low stack temperatures by passing the flue gases through a spiral-wound heat exchanger that is fully immersed in water.
“The PURE Technology approach adopted for the VSRT aims to enhance heat transfer, provide class-leading efficiencies, improve steam quality and reduce NOx emissions.” says Carl. “Rather than simply try to improve existing products to achieve these goals, PURE Technology challenges the industry status quo on conventional boiler design by engineering solutions that are fit-for-purpose and fully-optimised for all applications.”.
Fulton is delighted to confirm that its VSRT Steam Boiler Operation & Maintenance course has been certified by the CPD Certification Service as conforming to the continuing professional development principles.
The news follows the company’s announcement in late-2018 that it had achieved similar CPD Certification status, but for its Vertical Steam Boiler Operation & Maintenance course.
Commenting for Fulton, aftercare and business development manager Jeff Byrne says: “You could be forgiven for thinking that achieving certified status for the VSRT course was easy as we had recently achieved similar for our vertical steam boiler course. However, given the radical design of our double-award-winning VSRT steam boiler and the fact that it was only launched in early-2018, it took months of extra assessments to achieve. We are therefore delighted to have gained certification for the training course so quickly.”
Designed for boiler operators, the one-day VSRT Steam Boiler Operation & Maintenance course covers basic monitoring and day-to-day operation of steam boilers to provide employees with the knowledge required to ensure boilers are running safely and efficiently. It also focuses on the VSRT’s use of state-of-the-art controls and technology, looks in-depth at its patented spiral heat exchanger and includes training in operational procedures, daily blowdowns and the checking of water levels, alarms, etc. Finally, it examines the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections.
Further information on Fulton’s training courses can be found on their website, by calling +44 (0)117 972 3322 or emailing training@fulton.co.uk.
The claims made by vertical steam boiler manufacturers are easy to get excited about, especially at a time when stringent industry and environmental standards – such as the MCPD and London’s Air Quality Strategy – are making the headlines. Fulton’s Carl Knight takes a closer look.
We’ve all read the claims, “class-leading”, “energy efficient”, “superior steam quality”, “low maintenance”, the list goes on. But do these claims really stack up?
There are really only two vertical tubeless steam boiler solutions available in the UK. One is based on decades-old technology and the other is Fulton’s all-new, award-winning VSRT, a ground-up, clean-slate design approach that combines new people with new skills that have brought a new approach to the design and optimisation of heat transfer solutions.
And yes, Fulton has its own claims to make: that the VSRT is the most radical change to vertical steam boiler design since they pioneered the vertical tubeless boiler in 1949.
But let’s look at some of these claims in more detail and base the findings on Fulton’s VSRT-60 compared to equivalent 60HP vertical tubeless steam boiler models available in the UK.
Energy Efficiency
With full operating performance curves available throughout the full range of output – and at various operating pressures – Fulton’s VSRT provides exceptionally high operating efficiencies (84% gross thermal efficiency compared to approximately 80% from equivalent models), which result in lower operating costs.
These operating efficiencies are achieved thanks to the VSRT’s long heat transfer path and double-wall annular spiral rib heat exchanger that are fully-water-backed. This means that heat is transferred in two directions to double the heat transfer area in a fixed volume. The fully-water-backed design of the VSRT also allows low jacket loses which, combined with low flue gas temperatures, provides the highest thermal efficiencies.
Its combustion technology – featuring a Fulton-designed modulating burner and furnace that have been designed as a single component and fully-matched with the VSRT in mind – has also helped Fulton to achieve ultra-low NOx emissions of less than 20ppm and up to 10:1 turndown capability. Additionally, when correctly sized for applications, the exceptionally high turndown of the VSRT will result in savings above and beyond those gained from the stated efficiencies.
Steam Output & Quality
At 1,306 litres, the water volume of the VSRT-60 is almost 120% greater than equivalent 60HP vertical tubeless steam boilers yet, despite the increased volume, the VSRT still boasts a start-up time of 10-15 minutes and its installed footprint is up to 25% smaller. At 8 bar, the VSRT also achieves a 99.75% steam quality, a figure most manufacturers are unwilling to publish.
Durability & Warranty
Thanks to its down-firing burner alignment – that eliminates flame impingement on the pressure vessel – and the VSRT’s patented spiral-rib heat exchanger design that virtually eliminates thermal stress, Fulton has created a longer-lasting boiler that not only improves boiler efficiency, but one that the company believes will beat the competition in every category of durability. This is why all VSRT models come with the assurance of a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.
Maintenance
With features including a tubeless design, no internal refractory and a revolutionary air filtration system as standard, the VSRT is extremely easy to maintain. For applications where contaminated air can reduce boiler uptime, the VSRT’s standard-fit cyclonic air filter effectively separates debris and damaging particles from the combustion air and, because it won’t clog over time, eliminates the need for replacement filters.
Compared to other tubeless vertical steam boilers, maintenance is further improved thanks to the VSRT’s industrial control platform and easy access to the pressure vessel.
In Summary
All the advanced, energy-saving and environmentally-beneficial features mentioned above are standard across the VSRT range, which is currently available with outputs from 160 to 960 kg/h. Fulton is also developing a much larger VSRT-250 model – planned for early 2019 – with a steam output of approximately 4,000 kg/h, similar to that offered by manufacturers of horizontal steam boilers.
Compared to equivalent 60HP vertical tubeless steam boilers, the VSRT is a more durable, compact boiler that is energy-efficient, produces an increased volume of higher quality steam, is easy to maintain and backed by an unparalleled warranty. Additionally, the VSRT complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED.
So, before committing to a tubeless vertical steam boiler for your next heat transfer project, consider the “class-leading” claims about energy efficiency, performance, reliability and maintenance and instead look at the figures that speak for themselves!
For further information on the VSRT, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.
The VSRT from Fulton – the company’s all-new vertical spiral-rib tubeless steam boiler – already boasts ultra-low NOx emissions and high efficiencies, but now comes with a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.
Commenting for Fulton, sales and marketing manager Leigh Bryan says: “The unique spiral-rib design of the VSRT creates a longer-lasting boiler that we believe will beat the competition in every category of durability so, to put our money where our mouth is, we have decided to include a 10-year warranty on the pressure vessel as standard!”
The patented spiral-rib heat exchanger design – a result of the company’s ‘Pure Technology’ approach to systems engineering – not only allows Fulton to improve boiler efficiency but, with virtually zero thermal stress and a thick-walled construction featuring vertical tubeless design architecture, the VSRT is one of the most durable steam boilers available.
The VSRT is available with outputs from 160 to 960 kg/h and boasts ultra-low NOx emissions of less than 20ppm that are achieved thanks to its purposely-designed combustion technology. This has helped Fulton to achieve up to 10:1 turndown capabilities, an industry-leading performance of >82.5% gross thermal efficiency and 99.75% steam quality at 8 bar. It also complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED.
Having recently rationalised its product range to ensure its solutions meet the requirements of the MCPD, Fulton announced that production of its horizontal reverse-flame boilers has ceased. However, the company can confirm that a much larger VSRT model with a steam output of approximately 4,000 kg/h – similar to those of its legacy RB horizontal steam boilers – is planned for early 2019 and will benefit from the same 10-year warranty on the pressure vessel.
For further information on the VSRT Series, call Fulton on +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.
Having introduced its City & Guilds accredited training courses four-and-a-half years ago, Fulton is delighted to announce that, following months of hard work and assessments, its Vertical Tubeless Boiler Operation & Maintenance training course has been certified by the CPD Certification Service as conforming to the continuing professional development principles.
Commenting for Fulton, aftercare and business development manager Jeff Byrne says: "Fulton has always enjoyed promoting the benefits of operator training to its customers and this CPD Certification adds real value to our course offering.”
Having achieved CPD status for its Vertical Steam Boiler Operation & Maintenance course, Fulton is now working towards certification for its VSRT Boiler Operation & Maintenance course which, given the radical design of the boiler, focuses on the VSRT’s use of state-of-the-art controls and technology and looks in-depth at its patented spiral heat exchanger. This all-new boiler design has emerged from Fulton’s adoption and implementation of its Pure Technology approach, an initiative that resulted in a world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard.
The Vertical Steam Boiler Operation & Maintenance course is designed for boiler operators and covers basic day-to-day operation and monitoring of steam boilers. It provides employees with the knowledge required to monitor boilers and ensure they are running efficiently and safely. The course also includes training in operational procedures, daily blowdowns and the checking of water levels, alarms, etc; as well as examining the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections.
Training is also proven as being invaluable to employers and gives operators the knowledge and ability to handle more of their own maintenance and repairs and avoid call-outs to ‘boiler breakdowns’ that require no more than the simple flick of a switch to resolve. Real examples like this prove that a Fulton one-day Operator Routines & Maintenance course could potentially save the cost of many expensive and unwanted engineers’ visits.
Further information on Fulton’s training courses can be found on their website, by calling +44 (0)117 972 3322 or emailing training@fulton.co.uk.
Fulton will be using Stand X291 at Foodex to showcase the VSRT, the company’s all-new range of gas-fired, vertical spiral-rib tubeless steam boilers.
The VSRT is the first range to emerge from the company’s new ‘PURE Technology’ approach, an initiative that has resulted in a world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard.
Commenting for Fulton, sales and marketing manager Leigh Bryan says: “Our products are already proving themselves in food processing applications in the UK and around the world; and we’re really looking forward to promoting the VSRT and its benefits to other companies at Foodex.”
He goes on to say that Fulton’s PURE Technology approach aims to enhance heat transfer, provide class-leading efficiencies, improve steam quality and reduce NOx emissions.
“Rather than further-improve products like our renowned J Series to achieve these goals, PURE Technology – the culmination of Fulton’s clean slate approach to design – challenges the industry status quo on conventional boiler design by engineering solutions that are fit-for-purpose and fully-optimised for all applications.” says Leigh.
With over 15 patents pending in three continents, the VSRT’s attains industry-leading heat transfer rates thanks to a unique spiral-rib heat exchanger, which achieves low stack temperatures by passing the flue gases through a spiral-wound heat exchanger that is fully immersed in water.
The VSRT’s combustion technology achieves ultra-low NOx emissions of <20ppm and features a fully-matched modulating burner and furnace that have been purposely-designed as a single component. This helps to achieve up to 10:1 turndown capabilities and industry-leading performance of up to 82.5% gross thermal efficiency with 99.75% steam quality. At launch, the VSRT is available with outputs from 160 to 960 kg/h and its pressure vessel and burner are backed by a five-year guarantee as standard.
For applications where contaminated air can reduce boiler uptime the VSRT’s cyclonic air filter effectively separates debris and damaging particles from the combustion air and, because it won’t clog over time, eliminates the need for replacement filters.
The all-new gas-fired, vertical spiral-rib tubeless steam boiler from Fulton, the VSRT, is the first range to emerge from the company’s new ‘PURE Technology’ approach, an initiative that has resulted in a world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard.
By adopting a systems-engineering approach to design and implementing PURE Technology – the result of a clean-slate design approach that combines new people with new skills bringing a new approach to the design and optimisation of heat transfer solutions – Fulton’s VSRT radically challenges the heat transfer and mechanical design principles of traditional steam boilers. It is also claimed by the company to be the most radical change to vertical steam boiler design since Fulton pioneered the vertical tubeless boiler in 1949 and, for the right application, a worthy successor to the company’s renowned J Series.
Commenting for Fulton, sales and marketing manager Leigh Bryan says: “To meet ever-more stringent industry and environmental standards, our PURE Technology approach looks to enhance heat transfer, provide class-leading efficiencies, improve steam quality and reduce NOx emissions. So rather than improve existing products to achieve these goals, PURE Technology radically challenges conventional boiler design by engineering solutions that are fit-for-purpose and applications.”
With over 15 patents pending in three continents, the VSRT’s spiral-rib heat exchanger is a world first. It attains industry-leading heat transfer rates thanks to its unique spiral design, which achieves low stack temperatures by passing the flue gases through a spiral-wound heat exchanger that is fully immersed in water.
“This all-new spiral-rib design benefits from an extended heat transfer path and dual-direction heat flow, with the spiral annulus designed and optimised to create high heat transfer rates.” says Leigh. “This optimises heat transfer to create a longer-lasting boiler that we believe will beat the competition in every category of durability!”
The ground-breaking spiral rib heat exchanger design not only allows Fulton to improve boiler efficiency but, with virtually zero thermal stress, a thick walled construction and featuring vertical tubeless design architecture, the VSRT is one of the most durable steam boilers available.
It features a fully water-backed pressure vessel, which is wrapped in high-density insulation to achieve minimal thermal losses and low outer surface temperatures. The tubeless design has also enabled Fulton to create a compact boiler with minimal footprint. No refractory also means significantly lower weight (compared to traditional vertical steam boilers) for ease of installation.
Ultra-low NOx emissions of less than 20ppm are achieved thanks to the VSRT’s combustion technology, which 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. When correctly sized for applications, the exceptionally high turndown will result in savings above and beyond those gained from the stated efficiencies.
With features including a tubeless design, no internal refractory and revolutionary cyclonic air filtration, the VSRT is extremely easy to maintain and operate. For applications where contaminated air can reduce boiler uptime – such as laundry and dry cleaning – the VSRT’s cyclonic air filter effectively separates debris and damaging particles from the combustion air and, because it won’t clog over time, eliminates the need for replacement filters. Maintenance is further improved compared to other vertical boilers thanks to the VSRT’s industrial control platform and easy access to the pressure vessel.
The VSRT is currently available with outputs from 160 to 960 kg/h, complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED. Its pressure vessel and burner are backed by a five year guarantee as standard.
For further information on the VSRT Series, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.
Fulton Limited, the leading heat transfer specialist, has appointed Leigh Bryan as sales and marketing manager.
Commenting on the appointment, managing director Carl Knight says: “Leigh’s appointment is a real benefit for the company and he joins Fulton with considerable knowledge of process steam, hot water and thermal fluid applications. His technical experience as a time-served combustion and steam boiler engineer has proved beneficial in his managerial and directorial roles in the industry, for companies including Watkins Hire, Robey-Wellman and Nu-Way.”
Leigh adds that he intends to continue placing great emphasis in providing sales and application advice to existing customers and a growing customer base in hospital and healthcare facilities, food and beverage processing, laundries and other applications.
“As identified by the recent launch of the ground-breaking VSRT steam boiler, our product range is evolving, making these exciting times for Fulton and a great time to join the company.” says Leigh.
For further information from Fulton, call +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.
Fulton Limited – the leading heat transfer specialist – has supplied an oil-fired, skid-mounted steam boiler system to Neal’s Yard Remedies, a UK-based manufacturer of natural, organic health and beauty products including essential oils, moisturisers, shower gels and soaps. The 60J oil-fired boiler was supplied with the necessary ancillary items including hot-well, water softening, chemical dosing and blowdown vessels.
Commenting for Neal’s Yard, a spokesperson says: “The Fulton boiler was suited to the processes demanded from Neal’s Yard Remedies and was of a style and type that was ideal for the location of the company’s new plant room, which is situated on a mezzanine floor.”
This is Neal’s Yard’s first steam boiler installation and it replaces an old electric element heating process, which used de-ionised water – an important ingredient in most products – introduced into small mixing vessels and heated using electric elements to produce a steam jacket. The new process line uses steam from the Fulton boiler to provide indirect heat – in excess of 90 degrees – to a heating pot containing products such as coconut oil. Two larger mixing vessels on the same line are also indirectly heated and contain only naturally-occurring products, blended to produce cosmetics including hand lotions, shampoos, face polishes, etc.
While the new process line features a much larger heating pot and mixing vessels, Fulton’s boiler system quickly raises steam and bring the vessels up to temperature, making it a very efficient way for the company to produce the indirect heat required for its processes.
The skid-mounted Fulton system has been designed to future-proof the Neal’s Yard operation and allow for the addition of a second boiler, which will be used during maintenance and shutdown periods and to cope with increased demands in throughput.
“The combination of larger vessels and a move to a steam-based process has enabled us to more than doubled the potential throughput of the new line.” says the Neal’s Yard spokesperson.
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. Today, Fulton is still one of the world’s leading manufacturers, producing an unrivalled range of heat transfer solutions, including steam and thermal fluid systems, but increasingly these are ordered by customers as part of bespoke turnkey systems designed to meet exacting specifications.
Fulton’s renowned ‘J’ Series vertical gas- and oil-fired steam boilers includes eight models covering outputs from 96 to 960 kg/h. Its tubeless design, invented by Fulton, eliminates the coils and tubes traditionally used in steam raising plant and enables the Series ‘J’ to raise its full steam output in just 20 minutes. The simple design and robust construction from top quality materials make them ideal for arduous applications in a wide range of industries.
Fulton’s heat transfer solutions can be delivered as fully-prefabricated plant rooms or complete skid-mounted units, built to fit a prepared location and connect direct to pre-installed 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.
Further information on the products and services available from Fulton can be found at www.fulton.co.uk, by emailing sales@fulton.co.uk or by calling +44 (0)117 972 3322.
Just three-and-a-half-years after their introduction, Fulton Limited – the leading heat transfer specialist – is celebrating having welcomed its 1,000th trainee onto its City & Guilds Accredited training course.
The City & Guilds-certified, one-day training course was introduced by Fulton in 2013 and offers a mix of theoretical and practical operational assignments which, the company claims, bridges the gap between the more expensive courses (that can cost many thousands of pounds per employee), and cheaper, straightforward ‘toolbox’ training.
Commenting for Fulton, customer services manager Jeff Byrne says: "This is a real milestone for the company. We are delighted to have welcomed Muhammad Ateeb Farooq, our 1,000th trainee, who successfully completed the course and gained the City & Guilds certificate. We operate the courses throughout the UK and Republic of Ireland and at our Bristol-based manufacturing facility, which has a dedicated training room.”
He goes on to say that with no two boiler systems being the same, Fulton prefers to run its training courses at customers’ own facilities, so technicians and engineers learn on the equipment they will be monitoring day-to-day. However, Fulton’s in-house facility can accommodate training for its range of electric, gas, oil and dual-fuel-fired vertical and horizontal steam boiler systems.
City & Guilds certification adds value to the training courses and supports both the Safe Management of Industrial Steam and Hot water boilers Guidelines BG01 (SAFed) and INDG-436 (HSE) regarding operation and training.
The Fulton Operator Routines & Maintenance course is designed for boiler operators and covers basic day-to-day operation and monitoring; and provides employees with the knowledge required to monitor a boiler and ensure it is running efficiently and safely. It also includes training in operational procedures, daily blowdowns, and checking of water levels, alarms, etc. the course also examines the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections.
“We have always promoted the benefits of operator training to our customers and enjoy seeing technicians and engineers grow in confidence as they improve their knowledge.” says Jeff.
Fulton’s training has proven to be invaluable to employers, with operators managing more of their own maintenance and repairs and avoiding costly call-outs that require no more than the simple flick of a switch to resolve.
“Real examples like this prove that a Fulton one-day Operator Routines & Maintenance course could potentially save the cost of many expensive and unwanted engineers’ visits.” says Jeff.
For further information on Fulton’s City & Guilds Accredited training programme, call 0117 972 3322, or email jeff.byrne@fulton.co.uk.
