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Dissatisfied with the energy consumption of the two gas-fired 60J steam boilers at its bioscience areas, Cardiff University began reviewing ways to reduce energy consumption and improve its carbon footprint.

Following conversations with Fulton, the university allowed the company to conduct trials with the prototype of new modulating burners to replace the boilers’ standard on/off burners.

The Fulton boilers (one running 24/7 the other operating on-demand) are used to raise steam for autoclave sterilisation services and supply-air humidification for the University’s research facilities, where ambient humidity must remain constant regardless of external air conditions.

Before the modulating burners were installed, the energy graphs produced by the university’s building energy management system (BEMS) would show typical peaks and troughs associated with on/off burners due to the boilers firing when steam pressure falls to 7 bar and continuing to fire until the required 10 bar pressure is met.

Key benefits of product application

  • The modulating burner operates two modulating actuators — one to regulate the flow of gas, the other to adjust airflow, to ensure that optimum combustion is always possible
  • After 12 months the trial installation had proved successful — energy graphs no longer showed peaks and troughs, but instead an oscillating wave
  • A more consistent rate of steam pressure made the boiler more efficient and the steam easier to control
  • Humidification and sterilisation processes were improved, reducing maintenance requirements

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 Ltd is an important design and manufacturing base in Fulton’s global network that also includes production facilities in the US and China. The company’s UK facility makes it possible to manufacture products more efficiently and to 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 on 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 co-ordinated 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 to 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.

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