Steam measurement provides opportunity for Fulton

When Bristol-based Fulton Boilers was asked to size a boiler for a customer that was unable to give an accurate reading of maximum steam flow, it needed accurate flow measurement tools.

Bristol-based Fulton Boilers has been manufacturing steam boilers since 1949, and is renowned both for its products and its ability to provide solutions for every type of industrial application.

Recently, when asked to size a boiler for a customer that was unable to give an accurate reading of maximum steam flow, Fulton called on Solartron Mobrey and its industry-leading flow measurement tools to help solve the problem.

Steam was being delivered to the customer via a 100mm pipe, but the existing steam meter - which had not been calibrated for several years - was not providing reliable readings.

This left the customer unable to measure maximum steam flow at any given time during a 24-hour period - data that are essential when planning any new system, especially one such as this where the new boiler would need to cope with an extremely variable load with short-term peak values.

Fulton, in need of a reliable, easy-to-use and short-term method of measuring the steam, decided to implement Solarton Mobrey's KB Series self-averaging pitot tube flow sensor.

A flowmeter with a unique 1% accuracy of flow, it has the ability to provide an immediate reading of any liquid gas or steam flow.

The KB Series can be installed with ease into any pipe with a diameter between 12mm and 2.5m - an important feature for scenarios such as this where there is no major structural welding.

And unlike the alternative method of measurement that involves an orifice plate, variable orifice and shedding vortex meters, no pipe need be removed or welded - dramatically reducing down time.

Using a smart, multivariable, differential pressure transducer, the mass flow of steam is determined direct from the cell.

The unit measures flow and line pressure from the single pipe connection - then calculates steam density and mass flow.

To complete the application a Solartron Mobrey datalogger is attached to site to collect the data from the steam flow meter and then downloads it to a portable computer via an inbuilt modem connected to a dedicated telephone line.

The equipment, set up by Fulton, was at the site for four weeks, during which time the meter proved that the maximum flow was significantly greater during a short period than the client predicted.

As a result, the calculation of the replacement boiler and equipment was able to incorporate realistic site conditions and allow for a 20% predicted increase in demand, to cope with site expansion.

Fulton was so impressed with the precision and ease of the KB Series that it decided to launch a new steam flow monitoring service to its clients, and has purchased KBs for 50, 75 and 150mm pipe sizes.

This service will minimise on-site disruption and negate any unnecessary costs associated with new or updated boiler facilities.

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