Top marks for Fulton's modulating burner at Cardiff trials 09 September 2011

Cardiff University is reporting improved boiler efficiency, better consistency of steam delivery and reduced maintenance on its Fulton boilers, following a 12-month trial of the firm's prototype modulating burners.

In 2003, Fulton installed two gas-fired 60J steam boilers for Cardiff University's bio-science areas and, at the point of installation and commissioning, each boiler was fitted with a standard on/off burner.

Eight years on, and with energy costs reaching unprecedented levels, the University was reviewing ways to reduce energy consumption and improve its carbon footprint. And hence the burner trial.

Senior plant attendant John Blakemore says that the boilers – one running 24/7, the other operating on-demand – are used to raise steam for autoclave sterilisation and to supply constant and consistent air humidification for the university's research facilities.

"If it is damp or raining, external humidity levels are high, so steam demand for the supply-air humidification is reduced. Under these conditions, the BEMS [building energy management system] will usually only operate one of the two boilers," explains Blakemore.

"Conversely, if external air conditions are dry, the demand for humidification is high and both 60J boilers will be operating," he adds.

Before installation of the modulating burners, energy graphs produced by the BEMS showed peaks and troughs associated with on/off burners, due to the boilers firing when steam pressure falls to 7bar and continuing to fire until the required 10bar pressure is met.

Blakemore says this rise and fall meant that peak demands were difficult to achieve, especially when pressure was approaching 7bar. It also meant that condensate would build up in the steam, making it wetter than required for the humidification and sterilisation processes – so placing a greater reliance on steam traps.

Fulton installed its prototype linkage-less modulating burner – which is based on a twin independent modulating actuator system regulating the flow of gas and air – on the primary 60J boiler, and improvements were almost immediate, according to Bob Duckett university estates officer for controls.

"We were no longer seeing peaks and troughs, but were instead seeing an oscillating wave. In addition, because steam pressure is kept at a more consistent rate, the boiler was more efficient and wasn't working as hard to achieve peak demand," he says.

"This was therefore giving us better control of the steam, which meant that steam delivery and condition had improved," he continues. And that, in turn, improved the humidification and sterilisation processes and also resulted in "additional benefits, as it reduced maintenance issues by reducing stress on the steam system and associated equipment".

Brian Tinham

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