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MCL Energy introduce hand writing recognition pen to service operations

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Fulton Boilers at the Heart of Domestic & General's Process

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Fulton electric boiler provides a cure for Prysmian Group

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MCL Energy appoint Jason Perry to General Manager

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MCL Energy seal the deal with world class adhesives manufacturer

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MCL Energy seal the deal with Akcros Chemicals

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MCL Energy 'linked' with New Energy Centre for World Class Adhesives Manufacturer

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Fulton's move to new Bristol-based facility

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Scottish CEA Conference is Success for Byworth

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Vital Energi spreads the CHP word in Hampshire

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MCL Energy introduce hand writing recognition pen to service operations

The Introduction of Digital paperwork during the next 3-months should assist in the speedy transfer of paperwork both internally and to our Client base.

The system is based on laser technologies provided by Digital Field Solutions to transcribe engineering job sheets that once completed are transmitted via Bluetooth technology to the operations help desk for dispatch to clients for validation and record keeping.

The software also has built in hand writing recognition conversion. Initially the system will be piloted in summer with roll out across engineering personnel during autumn 2013.

For more details on our service solutions please call MCL Energy on 01623 741940 or visit www.mclenergy.co.uk

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Fulton Boilers at the Heart of Domestic & General's Process

Fulton Limited, a leading British manufacturer of steam, hot water and thermal fluid solutions, has supplied three dual-fuel-fired, skid-mounted boiler systems – a 30J and two 40J – to cavity wall insulation specialist Domestic & General Insulation (DGI) and its wholly-owned processing subsidiary Thermabead.

Formed in 1986, DGI is one of the largest insulation specialists in the UK and has, since 2005, been manufacturing its own cavity wall bead at its Worcester-based Thermabead facility, where the first Fulton skid-mounted steam boiler system – the 30J model - was installed.

With business growing rapidly thanks to government improvement grants for energy-saving home insulation and DGI winning support to promote the only programme able to offer a 20% more efficient carbon-saver bead, the company quickly expanded its installer and processing divisions and now has a manufacturing plant in Manchester (using the first of the 40J-based boiler systems), with a third facility – known as ‘Project X’ – currently in the planning stages. Steam from the Fulton boilers is at the heart of the operation, playing a critical role in the Thermabead production process which, without it, would simply stop. So, while specifying and installing a reliable boiler system was critical, the decision to use Fulton boilers was an easy one, as DGI’s Mark Aston explains: “I have dealt with a number of boiler manufacturers, and over the years have learned to trus tFulton implicitly. The combination of ‘second-to-none’ products and the Fulton service offering means there’s just no need to go anywhere else. Put simply, we can’t operate without Fulton!”

DGI is in the process of establishing a third production facility, which will feature the second 40J skid-mounted boiler system and, as well as a service contract plans to take advantage of Fulton’s recently introduced City & Guilds certified Operator Routines & Maintenance course, which will train its engineers on the boilers they will be operating on a day-to-day basis.

“Fulton has always reacted positively to any issues, even attending call-outs at weekends. The boiler systems are tremendously reliable, simple in operation and easy to understand.Fulton even offers our engineers training at the point of installation.” says Mark.

Much of DGI’s growth, and its success, has been attributed to the effectiveness of its surveying and the quality of the cavity wall product, which is unique and has been developed through a partnership between its processing subsidiary Thermabead, and BASF. Mark Aston says the result – the ‘Diamondbead’ polymeric insulation product – is the most advanced and efficient bead available and is acknowledged by many in the industry as the best. He says traditional polystyrene-based cavity wall products use round ‘tumble’ beads of different sizes that don’t properly interlock or provide enough air space, which is vital for insulation performance. Diamondbead is more uniform in its shape, which means it locks together to provide a better insulation value inside the cavity.

In its raw state, ‘Diamondbead’ looks like a grain of salt, so indirect steam from Fulton boilers is used to heat the polymeric bead to make it more malleable. Heat is also used to raise the temperature of the blowing agent (pentane gas), which forms polymer chains within the bead to make it ‘puff up’ (expand?) to the required densities.

In a typical week, 110 tonnes of the base polymeric beads are processed to produce approximately 103 tonnes of Diamondbead, the difference in weight being attributed to the loss of the pentane blowing agent. This volume is enough to insulate the cavity walls of up to 7,000 properties per week (a mix of housing association, local authority housing stock and private housing). Sixty percent of installations are carried out by DGI’s own installer network, with the additional 40% by the company’s customers.

The decision to specify skid-mounted systems for the Thermabead facilities was based on Fulton’s ability to respond to DGI extremely short lead-times and the need to move into each facility within a week! For this reason,Fulton’s specification and design also included flanged connections for the pipe work to enable the systems to be easily installed. In addition, the Series J boilers, which deliver proven reliability and performance, are built in Britain to BS2790 1992 Class 1 and are covered by a five-year warranty on the pressure vessel.

Dual-fuel boilers were specified initially as the gas supply at both Worcester and Manchester sites was insufficient. The problem is being addressed and Fulton is currently working to prepare the necessary pipe work. When the required gas supply is available, modulating burners will be retro-fitted to help reduce energy costs. However, even without modulating burners Fulton’s boilers are proving easy to control and linear in their steam output.

Fulton’s modulating burners feature a linkageless burner management system to operate two modulating actuators, one of which regulates the flow of gas; the other adjusts air flow to ensure optimum combustion across the boiler’s full firing range. To optimise combustion and output, each valve can be adjusted by as little as 0.1º. Thanks to the modulation burners the boiler is also more efficient, as a more consistent steam pressure is maintained.

Summarising for DGI, Mark Aston says: “A great deal of technology has been built into our Manchester and Project X facilities, making them the most advanced of their kind. In a very competitive market, this level of investment and the installation of Fulton boiler technology make us more efficient and ensures that our Diamondbead insulation sets new standards in the industry.”

For further information on its steam boiler ranges, call Fulton on 0117 972 3322 or email uk.sales.office@fulton.com

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Fulton electric boiler provides a cure for Prysmian Group

Bristol-based heat transfer specialist Fulton has supplied Prysmian Group’s Bishopstoke facility a skid-mounted electric boiler and ancillaries, steam from which is being used to cure the insulation applied to the company’s electric cables.

Commenting on the process, Prysmian’s Nicolas Chevaux explains that curing is used to strengthen and increase the heat resistance of the insulation. “Without the process, the insulation would have a lower temperature resistance and hence the cable would have a lower current rating.”

Following manufacture, batches of up to 16 drums are placed into a container where steam from Fulton’s EP100 Electropack boiler system is injected to start a curing process that can take up to twelve hours at 80°C.

The cable that uses this particular curing process is Prysmian’s 6491b low fire-hazard wiring cable – a BS7211 BASEC approved single-core conduit cable for wiring applications in buildings such as stadia, hospitals, cinemas/theatres, etc. Unlike PVC-based thermoplastic insulation found on standard 6491x cable, Prysmian’s 6491b cable uses a thermosetting low-smoke material that doesn’t generate dense acidic fumes when burnt.

Commenting on the reasons for specifying Fulton, Nicolas says that experience was the main consideration as the technology has proved itself in a Prysmian Group site in South Wales, which is using the same unit for a similar curing process.

He goes onto say that an electrically-heated boiler was specified as it can be applied as a point-of-use steam source without the need for a separate plant room typical associated with gas- or oil-fired systems. This option also makes the electric boiler system much quicker, easier and cheaper to install.

Fulton’s electric range combines traditional engineering in a number of versatile modern packages and the Electropack is the company’s seven-model range designed for steam loads between 29 and 160kg/h. It is fully packaged in an attractive modern case and all services are connected at the rear for easy installation.

The Electropack offers unrivalled flexibility and mobility in a compact unit that occupies minimal floor space. It is easily moved to provide point-of-use steam wherever required and the heating elements are individually switched to allow the boiler to respond quickly and efficiently to variable steam demands.

For further information on Fulton’s range of electric boilers, including the Electropack, call Fulton on 0117 972 3322, email uk.sales.office@fulton.com or visit www.fulton.co.uk

 

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MCL Energy appoint Jason Perry to General Manager

Leading independent technical energy management specialist MCL Energy recently appointed long standing senior manager Jason Perry to General Manager.

For the past ten years Jason has worked for the Company in business development and more recently as Sales Director which saw him drive the growth of the business primarily through the process and commercial customer base.

Jason will be responsible for the overall strategic development of the service proposition and day-to-day management.

For more details on our service solutions please call MCL Energy on 01623 741940 or visit www.mclenergy.co.uk

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MCL Energy seal the deal with world class adhesives manufacturer

MCL Energy has been successfully working with UK process sectors for over 30 years, providing customers with bespoke energy and technical solutions.

A recent project for Huntsman Advanced Materials UK, who is a leading global supplier of structural adhesives for joining composite materials comprises the Design, Build, Finance & Operate of a new boiler house with civil works, building, steam plant, reverse osmosis, plant provision of project capital and long term inclusive O&M support service. In the first six months full operation over 30% energy savings has been achieved.

Process service solutions include Contract Energy Management, Design, Build, Finance & Operate, Building Services, Utilities Services & Maintenance, and Energy and related plant installation. For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

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MCL Energy seal the deal with Akcros Chemicals

Technical energy management specialist MCL Energy was recently awarded a prestigious operation & maintenance boiler house contract by the leading global additives supplier Akcros Chemicals.

Akcros Chemicals is the leading chemical additive suppliers into the PVC and polymers industries and is expanding its range to cover a wider variety of additives in the coatings, rubber, silicones and sealants markets. Eccles represents the principle manufacturing and research site for their global operations.

The term contract comprises all routine maintenance and combustion support to maximise plant reliability and optimise cycle efficiencies to reduce gas consumption in the steam generation process. MCL Energy will monitor plant, back up for remote access, provide callout and service all the steam boiler plant and associated systems.

Ian Benbow, Site Engineering HSE Manager stated “We decided to award the term contract to MCL Energy based on MCL’s expertise in this specialist field, competitive cost base and capability to ensure our site receives reliable, economic steam supplies for our production process”

For more details on our industrial process portfolio and site energy services please contact Business Development on 01302 738000 or visit www.mclenergy.co.uk

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MCL Energy 'linked' with New Energy Centre for World Class Adhesives Manufacturer

Established Technical Energy Services Provider MCL Energy Was Awarded A Prestigious Long Term Contract To Design, Build, Finance And Operate A New Energy Centre For Leading Structural Adhesives Manufacturer Huntsman Advanced Materials (UK) Ltd.

Huntsman Advanced Materials is a leading global supplier of structural adhesives for joining composite materials with a primary global manufacturing and distribution site based at Duxford.

The installation includes project management, Construction Design and Management (CDM) regulations, natural gas site infrastructure, and steam and condensate connection.  The energy centre build incorporates civils, portal building, two 4000kg/hr steam boilers, a 1000kg skid mounted boiler and ancillary systems.

Following successful completion, the operation and support contract includes plant performance, efficiency guarantees, daily operation, planned preventative maintenance, 24/7 callout and remote plant monitoring.

Jason Perry, Sales Director said “We are looking forward to working together with Huntsman Advanced Materials and providing a first class Energy Centre. This long term solution enables Huntsman to move forward, assured that their new Energy Centre will provide efficient process steam for manufacturing.”

For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

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Fulton's move to new Bristol-based facility

Fulton's move to new Bristol-based facility will see pressure vessel manufacturing return to the UK

Heat transfer specialist Fulton Limited is moving to a new 43,000 sq. ft. Bristol-basedheadquarters on Monday, 3 June 2013.

The Fulton name has been synonymous with steam since 1949 when the company introduced the vertical tubeless steam boiler in the USA. The UK company, which was founded in Bristol in 1966, is now established as a leading manufacturer of thermal heat transfer systems for applications such as water heating, steam sterilisation and processing.

Announcing the move, managing director Paul Richards says: “The move to the new facility, also in Bristol, will help us manage current demand, and plan for the future. The increased space will also allow us to introduce the latest, state-of-the-art manufacturing processes and the technologies that will enable Fulton to create the energy saving systems of the future.

He goes onto say that, as a result of the move, the manufacture of larger boiler pressure vessels for UK and Export markets will return to Bristol from Fulton’s facilities in China.

The new UK headquarters, which creates a centre of excellence for the company’s heat transfer products, will provide comprehensive customer support, from applications advice and sales processing, through to delivery. Experienced teams are available to help with enquiries for the company’s range of thermal fluid, fuel-fired and electric steam boilers, hot water boilers and ancillary products.

The site will also accommodate a new training and seminar facility created to enable qualified staff to keep customers up-to-date with the latest products and applications; and host the company’s recently announced City & Guild certified training courses, which offer a mix of theoretical and practical operational assignments.

The new Fulton facility is located at 5 Fernhurst Road, Bristol, BS5 7FG. Telephone/fax numbers and email addresses are not affected by the move. 

For further information call Fulton on +44 (0)117 972 3322, email uk.sales.office@fulton.com.

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Scottish CEA Conference is Success for Byworth

The seventh in the series of successful CEA (Combustion Engineering Association) Conferences was held in Perth, Scotland at the end of April. Visitors to the Byworth Boilers stand were brought up to speed with the new BG01 Health & Safety Executive guidelines for steam and hot water boiler plant as well as being shown the importance of the correct training.

The Health & Safety at Work Act specifies that employees must be provided with adequate training following the introduction of new procedures, systems or technology and that training must be refreshed on a regular basis. In addition PUWER-Use and maintenance of equipment states that everyone who uses and maintains work equipment needs to be adequately trained if new technology or new equipment is introduced.

For insurance purposes employers must ensure all operators are adequately trained and must be able to show evidence of that training. From a health and safety point of view it is essential all operators are trained to a competent standard in the event of any involvement of the Health & Safety Executive.

As part of the programme of workshops, held throughout the day, Byworth’s Ian Roberts, spoke on Risk Assessment and Risk Management relating to Boiler House and Steam Systems. In his talk he stressed the factors to be considered when designing and operating boiler houses and steam systems from a risk assessment perspective.

Commenting on the success of the conference Tony Green said “The whole event was extremely well organised by David and Julie Kilpatrick and well attended by representatives from a good cross section of relevant industries, many of whom had a need for the training facilities we provide.”

Gordon Smith, from The University of Dundee, won a place on a Byworth Boiler Operator Training Course in a special business card free draw.

Byworth offers a choice of training courses for both new and experienced boiler operators. The Certified Industrial Boiler Operator Course for example is the only national boiler operator qualification and has been developed by the CEA in conjunction with the Health & Safety Executive and the Insurance Industry. It also has the backing of the Carbon Trust.

For further information on all Byworth’s training course options please phone the Training Sales Team on 01535 665225 or email  training@byworth.co.uk

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Vital Energi spreads the CHP word in Hampshire

Sustainable energy specialists from Vital Energi provided industry insight into the issues currently affecting the development of Combined Heat and Power (CHP) in the UK during a presentation at an event organised by Hampshire County Council in April.

The event, which took place on Monday 15th April 2013 at Ashburton Hall, Hampshire County Council, QEII Building, Southampton SO23 8UJ, is part of the Ecotec21 project which seeks to improve energy efficiency by promoting Combined Heat and Power (CHP) from many fuels including biomass.

Vital Energi’s Mark Howell and Howard Roche gave a presentation at the event on the ‘Use of Biomass in Combined Heat and Power District Energy Schemes’. They demonstrated the cost, technology and legislative barriers for biomass CHP, in the UK, and covered the challenges and opportunities presented by government incentives.

The aim of the Hampshire County Council’s event was to bring together local authorities, universities, research institutions, government funded organisations, energy and facility managers, architects and elected members to explore how delegates from the UK and France can collaborate and compare the methods and practicalities of establishing CHP district energy schemes in their respective regions.

Ian Whitelock, joint managing director of Vital Energi, commented: "Vital Energi is always happy to give our time and expertise to educational events, like this conference, that demonstrate the benefits of using renewable CHP as a technology in district heating schemes.

"As a market leader in sustainable energy we understand the importance of sharing our expertise with public and private sector organisations and providing the guidance that is fundamental to the successful delivery of their community energy schemes."

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