Fulton Heating Solutions Inc. - Experts & Thought Leaders

St. Vincent Fishers Hospital in Fishers, Indiana is part of the largest Catholic, a not-for-profit healthcare system in the United States of America. It serves its community, not only by providing the utmost in compassionate care, but also by implementing excellence in environmental stewardship, by obtaining LEED certification, under the healthcare rating system, and by being the first hospital in Indiana to do so. This explains why, in 2013, when St. Vincent Fishers Hospital needed to expand its emergency care clinic, to a full-service in-patient care hospital, it adopted its vision statement - ‘Expansion with the environment in mind.’ And why, when it came to its heating, humidification, and sterilization needs, St. Vincent Fishers Hospital chose to install Fulton boiler equipment. Fulton boilers Acting on the advice of Kevin McNutt of BSA LifeStructures, consulting engineer on the project, and working with Fulton representative and product specialist Byron Koch, President of A.B Young Company, St. Vincent Fishers Hospital installed: Three dual-fuel Fulton Vantage (VTG-2000DF) high-efficiency condensing hydronic heating boilers, and Two Fulton Classic (ICS-20) vertical tubeless steam boilers. In 2015, the ICS-20s, used for humidification only, were upgraded to two (bigger) Fulton Vertical Multi-Port (VMP-50), low-emissions, dual-fuel steam boilers. These boilers back-fed the existing surgery suite for sterilization and then, re-fed St. Vincent Fishers Hospital’s need for humidification, serving a much greater overall load. Vantage hydronic boilers installed The Vantage boilers are dual-fuel optimized for both, natural gas and No. 2 fuel oil The three installed Fulton Vantage hydronic boilers, as fully condensing boilers, achieve higher thermal efficiencies, of up to 99%, by recovering the latent heat of condensation from their own exhaust gases. The Vantage boilers are dual-fuel optimized for both, natural gas and No. 2 fuel oil. In fact, Vantage is the world’s first condensing boiler to offer full-time operation on No. 2 oil as a secondary fuel. Featuring Fulton ModSync controller The Vantage boilers were also installed with a Fulton ModSync controller, to offer outdoor reset and BACnet communication, to maximize system efficiencies, based on seasonal temperatures and integration with building software systems. Senior Mechanical Engineer at BSA LifeStructures, Kevin McNutt said, “Our firm has incorporated Fulton Vantages for hospital boiler plants, for at least the past 10 years, because of their ability to drop the heat and hot water temperature, so that we could get the condensing out of them, for energy savings. Also, there is a dual-fuel feature that we need for healthcare.” Dual-fuel on a condensing boiler Kevin McNutt adds, “We arrived at Fulton, because it’s a quality product, number one and number two, because you (Fulton) were the only ones who would provide dual-fuel on a condensing boiler, for a long time. Fulton products were used to generate cost savings, to generate more LEED points, to be more sustainable with hot-water heating systems.” I like how easily accessible the Vantage is for routine maintenance and safety checks" Matt Todd, Power Plant Specialist at St. Vincent Fishers, said “When it comes to the day-to-day operation of the Vantage boilers, I like how easily accessible the Vantage is for routine maintenance and safety checks.” Matt Todd adds, “In the two years, since I have been here, I haven’t had enough issues (with the Vantages) that I can be specific enough about, to complain about. The squeaky wheel gets the oil, as they say, but (the Vantages) haven’t made much noise at all. They have been wonderful boilers.” Vertical Multi-Port boilers (VMP-50s) While the Vantage hydronic condensing boilers were standalone boilers, the two Vertical Multi-Port boilers (VMP-50s) were shipped and installed, as part of a fully-skidded system. This system included a boiler feed unit, a 304 stainless steel tank and blow down separator, and a ModSync controller, in addition to the VMP’s dual-fuel and low-NOx capabilities. Kevin McNutt stated, “The first set (of ICS-20s) was ordered from Fulton in a three-skid arrangement, and those were installed without issue. What’s compelling about this story is that, a year down the road, when we decided that we needed to replace these boilers, to address long-term sterilization use, we replaced them with Fulton VMPs that were able to pass through standard door-sized openings, so that they could be easily installed on-site.” Byron Koch commented, “The very tight space of the boiler room presented an installation concern, but luckily the VMP system shipped as multiple units that broke down into sections. Moreover, the only way we could get the boilers installed in the limited space we had, was because of the vertical design of the boilers, which allowed them to fit, where other types of boilers, like horizontal fire tube and water tube, would not.” VMP boilers perform critical hospital functions Energy savings and installation is easy, as the VMP boilers at St. Vincent Fishers perform critical hospital functions Energy savings and installation is easy, as the VMP boilers at St. Vincent Fishers perform critical hospital functions, such as controlling the temperature and humidity in the surgery rooms, which helps maintain infection control. This can literally mean the difference between life and death. In fact, so critical is the function of boilers in helping maintain infection control in hospitals that the 2013 edition of the American Society of Heating, Refrigerating and Air-Conditioning Engineers’ (ASHRAE) HVAC Design Manual for Hospitals and Clinics devotes an entire chapter to it. In addition, they acknowledge the importance of installing boilers in hospitals that are low- maintenance, energy-efficient, and reliable. energy-efficient heating solutions Matt Todd stated, “In addition to sterilization and comfort needs, we feed our hospital humidifiers, with our Fulton Vertical Multi-Port (VMP) boilers and they, in turn, feed our operating room, which has to be in the range of certain specs, usually 30 to 60% (humidity).” He adds, “If out of range there, you have downtime in Surgery and the ER. So humidification plays a big role in it too and that includes our Labor and Delivery C-section room that also has the same strict humidification requirements.” Matt Todd concludes, “At St. Vincent, patients are always the number one priority, but number two is the power plant and the boilers that are installed in there. They (the boilers) heat the building, humidify our air and also sterilize our equipment. They are critical to patient care. We have to have them and Fulton has done a great job in helping us fulfill that need.”

As a 22-year veteran of the dry-cleaning industry that has successfully opened several dry-cleaning facilities, Piyush Bhula knows a thing or two about operating a business that delivers an amazing dry-cleaning experience. That’s why, when he needed to replace his boiler at his Majik Touch Cleaners in Sawanee, Georgia, he contacted Gulf States Laundry Machinery, a pioneer in the distribution of dry-cleaning and commercial laundry equipment in the Atlanta area. Dry-Cleaning market At Gulf States, Piyush spoke to Ben Prema, Head of Dry-Cleaning Equipment Sales, who recommended Fulton as the company to buy from. (Fulton has been a premier provider of high-pressure steam boilers for the dry-cleaning and industrial- laundry markets for over sixty years.) Ben recommended Fulton’s revolutionary new Vertical Spiral Rib Tubeless (VSRT) Steam Boiler Moreover, Ben recommended Fulton’s revolutionary new Vertical Spiral Rib Tubeless (VSRT) Steam Boiler, a 30- HP model, for what would be its first installation in the Atlanta laundry and dry-cleaning market. The VSRT-30 was installed by Ben Prema with help from Kyle Petrie, Fulton Service Technician, and Mike McLean, Fulton Sales Manager. Turndown ratio burner “Ben started setting it up before Mike and Kyle came in, and Mike and Kyle came in the afternoon and helped set it up and were here all day,” said Piyush, adding, “I have never seen service as good as this with any other company. Set up time was just a few hours.” Commented Ben Prema from Gulf States, “It was very easy to install through a 36” door. The new VSRT-30 boiler is smaller and installs easier than previous 30-HP boilers. It’s also easier to connect to the gas, electrical and steam output lines – they are all very easily accessible.” Piyush purchased the VSRT-30 to replace a boiler that was larger in size though lesser in HP (20 HP). Because the VSRT-30 has a modulated 6:1 turndown ratio burner, it was able to meet Piyush’s actual (lower, as needed) steam demands throughout the day by automatically adjusting its air and gas intake. Monthly fuel bill It’s a 30-HP machine, but doesn’t look like a 30 HP. It’s too small, which is great!" This resulted in Piyush saving $300 on his first monthly fuel bill even though his new boiler has greater HP capacity. Said Piyush, “It’s a 30-HP machine, but doesn’t look like a 30 HP. It’s too small, which is great! It just doesn’t look like a boiler; it looks like a smart robot, like a dry cleaning machine with all of its relays and everything. And when Mike and Kyle were here and they tested, it was turning on at less than 15 HP, which is also great; it’s much more energy-efficient.” Continued Piyush, “I track my utility bills from previous years and from month to month, and in the three short months that it’s been installed, it’s already shown a significant savings on utilities, not just on the gas but on electric as well in the way the boiler runs, maintains, idles, then the way it cuts off and turns back on. I would say that I am saving at least 20% on my utilities. So it’s paying me at this point.” Dry-Cleaning machines “The only problem, which is a good problem, is that it’s too quiet. I’m used to yelling over the noise of the [previous] boiler. In the past, when I didn’t hear that roaring sound, it meant the boiler was not on. So literally, for the first two weeks, I had to go to the back of my store to check to see if the boiler was running or not because it’s so quiet.” In the past, when I didn’t hear that roaring sound, it meant the boiler was not on" “[The VSRT-30] Is able to make steam much faster; it takes half the time to end up at full PSI. Literally, I can run my dry-cleaning machines at 30 PSI because at 30 PSI it’s full steam, and it’s dry steam . . . very dry . . . I’m sure I will have a lot less issues with my traps because it’s so dry. Later, I operate at full pressure (100 PSI) with other equipment.” Producing less noise “Before, when I’d turn my boiler on, it would take 45 minutes to get to full PSI. With the old boiler, at a higher set pressure, I barely had any usable steam for my plant; while the VSRT takes half the time to end up at full PSI, and even at 30 PSI with the VSRT you can start your steam collections.” Said Ben Prema, “It’s a better boiler than a regular boiler, a competitor’s boiler, than any other boilers of its size. Compared to other boiler companies, it’s very easy to install. It automatically adjusts the air/gas mixture, produces less noise, takes up less room, produces faster steam. It’s more reliable. Longer lasting,” added Piyush, “[It’s] absolutely a better boiler than anything I’ve ever had . . . only good and nothing bad with it.”

Living far enough north to experience temperatures of -30 °F during the winter months, the people of Alexandria, MN know a thing or two about the importance of installing high-performance heating systems. That’s why, in June of 2009, when their school district decided to build Woodland Elementary School, it chose to install some of the most energy-efficient, environmentally clean, and cost-effective heating systems available: Condensing boilers; and Geothermal heat pumps Why Fulton’s Endura+? A geothermal (or ground-source) heat pump uses ground temperature, which stays about 55 °F year-round, as a heat source in the winter and a heat sink in the summer. While a heat pump’s major advantage is the reduction of energy use, it can sometimes malfunction altogether, creating an emergency heating need. Due to the high turn-down ratio of ENDURA+ boiler, it can supplement the heat pump heat in warmer and winter months" This is what occurred with the heat pumps installed at Woodland Elementary, says Jerry Bitzan, District Buildings and Grounds Supervisor for the Alexandria School District. Says Jerry, “The heat pumps failed. So when we decided we needed to re-do the heat pumps, we added Fulton’s ENDURA+ boiler. So in case, the heat pumps failed again, we would have the redundancy needed to heat the building adequately.” “We are also using the ENDURA+ boiler for warm-ups on super-cold mornings. Because of the high turn-down ratio of the ENDURA+ boiler, we are using the boiler to supplement the heat pump heat in warmer as well as our coldest winter months.” Selecting Fulton The purchase of Fulton’s ENDURA+ boiler came with strong recommendations. Bryan Petricka, the Sales Engineer at Ryan Company Inc., had shared the information with the consulting engineer on the project, Randy Christenson. Randy had previously recommended Fulton boilers, so Randy endorsed the purchase. All that was left was to make sure the boiler would work with the geothermal system and that the size of the boiler would match the demand load (3.0MM BTU/hr). This would ensure that the single boiler could handle the entire heating load for the school in the event of a complete failure of the geothermal system. Durability and Quality Said Randy, “We’ve had great success with Fulton. There’s always maintenance to do every year, but the durability and the quality of materials used is the outstanding thing. The other important factor is the high turn-down ratio so that we can run this boiler at low flows and low temperatures to save energy.” Randy complimented Fulton's ability to provide controls that can integrate hybrid heating systems and still use one control Randy also emphasized the importance of the integration of controls. He complimented Fulton on its ability to provide controls that can integrate hybrid heating systems like this one, or multiple boilers, and still use only one boiler control. He further praised the important energy savings provided by the condensing technology of the ENDURA+, “the fact that they could reuse valuable heat energy rather than just sending it up the flue.” Simplified Installation Just as complimentary, Robert Maxfield, service technician and installing contractor with L&M Boiler Systems, Inc. in Austin, MN commented, “The installation access of that boiler was superb. The piping was easy. The flanges on the back of the boiler were easily accessed, and we had lots of room to install it.” “That’s a 3.0MM BTU boiler that we put in through a doorway, which is a huge deal as I don’t know of any other 3.0MM BTU condensing style boiler that can do this.” It was additionally important that the ENDURA+ could be installed with variable primary flow piping. This is the simplified piping method wherein the hydronic heating loop flows directly through the boiler to enhance temperature control and efficiency. Service Excellence Fulton makes sure there is enough time to make sure the boiler is operating at the right parameters" The people involved in setting up the ENDURA+ were also a big part of its success. Factory-authorized service personnel came out for the installation to perform start-up procedures, and to make sure the boiler was operational in all aspects. Said Randy, “I think that’s one thing that Fulton does very well, as does Ryan Company. They make sure there is enough time and enough visits for service people to come out and make sure the boiler is operating at the right parameters.” Application Flexibility Once fully operational, the ENDURA+ demonstrated its ability to automatically maintain heating water comfort levels. Since the boiler, as a redundant heat source, connects to the backside of the geothermal heat pump system, it had to adjust to the constant change of flow through the heat pumps. This required the ENDURA+ to go to low flow (sometimes only 80 GPM), which it did without any worry of low-flow cutoff. “We could easily match the [boiler] firing rate to the flow,” said Randy. Increased energy savings The ENDURA+, as part of a geothermal system, also required the hot water on its geothermal side to be operated at only 120 °F. But this was no problem for the ENDURA+ because it could easily match this temperature while achieving peak condensing efficiencies. The low-temperature, the geothermal heating loop was a perfect fit for maximizing the energy savings (96.3% AHRI Certified Thermal Efficiency) that the ENDURA+ was designed for. O2 Compensation Key ENDURA+ also demonstrated its ability to boost combustion efficiency across all modulation rates The ENDURA+ also demonstrated its ability to boost combustion efficiency across all modulation rates by automatically tuning the air/fuel ratio in real-time—what is also known as O2 trim control or O2 compensation. This was especially important due to the wide swings in local outdoor temperature. Commented Randy, “In Alexandria, Minnesota, we see outdoor air temperatures from minus 25 °F to 95 °F. For re-heat, the system can operate up to an outside air temperature of 65 °F. So the boiler needs to operate under many varying conditions.” Highly Recommended The ENDURA+ was not Alexandria School District’s first experience with Fulton, as they have Fulton boilers at Lincoln Elementary as well as Discovery Middle School. “And both of those systems have worked great since day one,” says Jerry. “We’ve only had a few issues that were corrected right away.” So the deciding factor for purchasing the ENDURA+ was as much the quality of the Fulton brand as it was a chance to try out a new and highly efficient boiler. Adds Jerry, “I would recommend Fulton boiler equipment. The Fulton reps are great to work with. They’re good people, always wanting to please you. We’ve already gone through a winter with the ENDURA+, and we noticed some savings on our heating bill.”