This manual must be available to the boiler operator at all times. FB-IOMM-2015-1

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FB Series Gas/Oil/Dual Fuel Fired Horizontal Steam Boiler

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TABLE OF CONTENTS

SECTION 1 - INTRODUCTION1.1 General 1

1.2 Technical Data 1

SECTION 2 - INSTALLATION2.1 General 3

2.2 Siting 3

2.3 Ventilation 3

2.4 Flue Outlet 4

2.5 Water Supply 5

2.6 Blowdown Valve 6

2.7 Main Steam Valve 6

2.8 Steam Safety Valve 7

2.9 Water Level Gauge Set (sight glass) 7

2.10 Water Sample Valve (Surface Blowdown) 8

2.11 Feedwater Valve/Check Valve 8

2.12 Gas Supply 9

2.13 Oil Supply 10

2.14 Electrical Requirements 11

2.15 Installation Check Points 11

SECTION 3 - OPERATION3.1 General 13

3.2 Boiler Fittings 13

3.2.1 Steam Pressure Controls 14

3.3 Typical Burner Fittings 15

3.4 Boiler Control Panel 17

3.5 Burner Mounted Control Panel 20

3.6 Filling the Boiler 21

3.7 Starting the Burner From Cold 22

3.7.1 Practical Considerations 22

3.7.2 Starting Procedure 23

3.8 Burner Operation 23

3.8.1 Burner 23

3.8.2 Firing Preparations for Gas Burners 24

SECTION 4 - MAINTENANCE4.1 Visual Checks 25

4.2 Water Level and Low Water Safety Controls 25

4.2.1 Pump Test 25

4.2.2 1st Low Water Level Check 26

4.2.3 2nd Low Water Level Check 27

4.3 Main Blowdown 28

4.4 Water Level Gauge Blowdown 29

4.5 Evaporation Checks 30

4.6 Flame Sensor Test 30

4.7 Draining the Boiler 31

4.8 Burner Shut Down 32

4.8.1 Short Term (Hours) 32

4.8.2 Medium Term (Days) 32

4.8.3 Long Term (Weeks) 32

4.9 Internal Inspection 33

4.9.1 Fitting New Gaskets 33

4.9.2 Fitting Instructions 34

4.10 Steam Pressure Switch Adjustment 35

4.10.1 Controls 35

4.10.2 Adjusting the Pressure Switches 36

4.11 Feedwater Disperser 37

4.12 Service Inspection of Welded Joints 38

4.13 Schedule of Operator Tests and Checks 39

4.13.1 Daily 40

4.13.2 Weekly-in addition 40

4.13.3 Six Monthly-in addition 41

4.13.4 Annually-in addition 43

4.14 Troubleshooting 44

APPENDIX A - TI SHEETS FBDimensions&Specification 50

FB Probe Lengths 52

Recommended Water Conditions 53

Water Level Probes 54

Electrical diagrams supplied separately

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WARNINGS

The Pressure System Safety Regulations 2000

Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.Regular inspections are therefore required by a competent person.The scope of the examination and the actual intervals between examinations is at the discretion of the competent person.It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which a defect may give rise to danger.Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover periodic statutory inspections.

For further information contact:

(a) SAFed SAFETY ASSESSMENT FEDERATION Limited. Nutmeg House, 60 Gainsford Street, Butlers Wharf, London, SE1 2NY.

(b) HealthandSafetyExecutivelocaloffice.

(c) Your Competent Person.

For your safety!The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.

• WARNINGS must be observed to prevent serious injury or death to personnel.

• CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness.

• Notes: must be observed for essential and effective operating procedures, conditions and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced.

Personnel must become familiar with all aspects ofsafety and equipment prior to operation ormaintenance of the equipment.

CAUTION

In case of emergencyThis boiler has been designed and constructed to meet all of the essential requirements of the applicable European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.

If such a condition should occur during commissioning or during subsequent operation of this product, whatever the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been

investigatedbyacompetentpersonandrectified.

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WARNING

Steam boilers are a potential hazard, possibly fatal if not properly maintained.

CAUTION

It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the

system and increase the possibility of fire, explosion, property damage, personal injury or loss of life.

!

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WARNINGS

SAFETYThe instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in damage to the heater and serious personal injury.

!WARNINGDo not try to do repairs or any other maintenance work you do not understand. Obtain a service manual from Fulton Ltd or call a Fulton service engineer.

It is the responsibility of the installer to ensure all parts suppliedwiththeboilerarefittedinacorrectandsafemanner.

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and or damage.

A defective boiler can injure you or others. Do not operate a boiler which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the boiler.

Do not change the boiler fuel without consulting the boiler manufacturer.

LIFTING EQUIPMENTMake sure that lifting equipment complies with all local regulations and is suitable for the job. You can be injured if you use faulty lifting equipment. Make sure the lifting equipment is in good condition.

Operating the boiler beyond its design limits can damage the boiler, it can also be dangerous. Do not operate the boiler outside its limits. Do not try to upgrade the boiler performancebyunapprovedmodifications.

Non-approvedmodificationscancauseinjuryanddamage. Contact your Fulton dealer before modifying the boiler.

Only qualified persons should be allowed to operate and maintain the boiler and its equipment. Boilers should always be drained through an approved blowdown vessel.

The installation of gas appliances including the fluesystemshouldonlybecarriedoutbyGasSaferegistered engineers.

Steam boilers have high temperature surfaces, that if touched may cause serious burns. Only competent and qualifiedpersonnelshouldworkonorinthelocalityofa steam boiler and ancillary equipment. Always ensure theworkingareaandfloorareclearofpotentialhazards,work slowly and methodically.DoNOTstoreinflammablematerialsneartheboiler.

The importance of correct boiler water and feedwater cannot be over emphasised, see the relevant section in this manual.

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CAUTIONObey all laws and local regulations which affect you andyour boiler.

LOW FEEDWATER TEMPERATURELow feedwater temperature can result in thermal shock to the boiler pressure vessel. Return the maximum amount of condensate and if necessary preheat the feedwater. If in doubt consult Fulton Ltd.

WATER SOFTENER and CHEMICAL TREATMENTThe chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by Fulton Ltd.It is the responsibility of the operator to ensure adequatesupplies of chemical are available at all times (including commissioning). Costly repairs could be required should the plant operate without chemicals or the wrong dosage of chemicals.

HYDRAULIC TEST - RISK OF BRITTLE FRACTUREHydraulic testing requires specialist equipment and is normally only required by engineering surveyors / inspectors. In order to ensure the material/ pressure vessel does not suffer from brittle fracture, hydraulic testing should not be carried out below 7 °C.

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WARNINGDANGER FROM INCOMPLETE COMBUSTIONThe importance of correct burner adjustment to achieve lowemissions,safe,cleanandefficientcombustionis paramount. Poor combustion, where unburnt gas forms carbon monoxide is both a health hazard, and the potential risk to the boiler from overheating, caused byre-burningoftheunburntgasinthesecondaryfluepasses.

Prior to the commencement of any work requiring the removal of cover plates and the opening of control panel box, the electrical supply to the boiler must be isolated.

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Figure. 1 - Typical FB Steam Boiler

* Burner will vary depending on the specification of the boiler.

Note: Component locations may vary from that shown.

Burner *

Front access doors Front access doors

Control panel

Water level gauges

(sight glasses)

Burner *

Control panel

Feedwater pump

Safety valve (optional 2nd)

Boiler vent (usedwhenfillingoremptying the boiler)

Topflue(rearflueand

economiser optional) Steam

pressure gauge

Inspection Hole

Oil pump (iffitted)

Feedwater Inlet

Inspection Hole

Boiler blowdown

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INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

The Fulton FB Series comprises of the FB-S and the FB-C range of horizontal, three-pass, wet-back boilers, constructed in accordance with BS EN 2790 and ASME. The packaged boiler consists of pressure vessel, burner, burner controls and appropriate boiler trims.

Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained. Satisfactory performance can only be ensured if the installation recommendations, operating routines and maintenance schedules laid out in this manual are adhered to.

Smoke boxes are mounted at the front and rear of the boiler for convenience of cleaning the combustion chamber. There is a manhole on the top of boiler, while hand holes are located at side bottom, front and rear of the boiler for PV (pressure vessel) check.

Astandardcomplementofvalvesandmountingsarefittedasfollows:Alternative/additionalvalves/mountingsmaybefittedaccordingtospecificrequirements.

1.2 TECHNICAL DATA

ForafullspecificationrefertoAppendix A - TI-129-FB Series Dimensions & Specification.

CAUTION

WATER SOFTENER and CHEMICAL TREATMENTThe chemicals required to operate the water softeners and chemical treatment plants

CAN BE SUPPLIED by Fulton.It is the responsibility of the operator to ensure adequate supplies of chemical are available

at all times (including commissioning).Costly repairs could be required should the plant operate without chemicals or the wrong

dosage of chemicals.

!

Theburnerwillvaryduetothespecificationofeachindividualboilerbutboilercombustionistypicallyprovidedbygas,oilordualfuelfiredburnersdesignedforhigh/lowflameoperation.Combustionairisnormallycontrolledbyamotorisedbutterflydamperincorporatingaproofofclosure interlock. Burnercontrolsandafuelpumpunit(oil-firedmodelsonly)aretypicallymountedontheburner.

Note: Consult burner manufacturer’s Operation and Maintenance instructions for more details.

a) Main Steam Valve b) Steam Pressure Gauge Assemblyc) Safety Valve d) Feedwater Valve and Check Valvee) Blowdown Valve f) Water Level and Steam Pressure Controls g) Water Level Gauge Set (Sight Glasses)

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INSTALLATION - 2

2.1 GENERAL

The installation of the FB Series steam boiler should be carried out by competent personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these regulations are complied with.

2.2 SITING

(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication 1676, and in particular to Section 5, Location of Appliances).

Theboilerhouseshouldbesufficientlysizedtoalloweasyandsafeaccesstoallpartsoftheboiler for operational and maintenance purposes.

Reference should be made to Appendix A - TI-129-FB Series Dimensions & Specification to ascertain the relevant dimensions and weights, special note should be taken of the required vertical clearance required for maintenance.

Theflooringmustbelevel,laidinanon-combustiblematerialandbeofsufficientstrengthtosupport the boiler.

WARNING

Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job.

You can be injured if you use faulty lifting equipment. Make sure the lifting equipment is in good condition.

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SECTION 2 - INSTALLATION

2.3 VENTILATION

Adequatefresh,cleanairisnecessaryforsafeandefficientcombustion,andshouldbeprovidedat high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.

Note: Ensure that there is adequate ventilation in the boiler room. Lack of ventilation will create a high temperature and cause control lockout. There is a minimum ventilation requirement to supply the air for combustion.

Note: Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the necessary boiler draught.

Note: Do not store chemicals such as perclorethylene in the boiler house, the fumes may damage the boiler and flue and cause the burner to lock out on flame failure.

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INSTALLATION - 2

2.4 FLUE OUTLET

Figure. 2 - Flue Flange

A B

C

12 mm

FB Flue Connection Holes 15mm dia. equi-spacedMaterial mild steel

Theheightandtypeoffluewillbesubjecttolocalplanningregulationsandapprovals,andtotherequirements of the Clean Air Act.

Note: Before erecting a flue, Public Health Authority and Planning permission must be obtained.

The flue should be designed to withstand a minimum temperature of 350 °C.

Thefollowinginformationisintendedtoprovideassistancewheretheinstallationofasimpleflueis required.Wheremulti-boilerfluesarenecessary,ordifficultiescouldbeexperienced,specialistadvice must be obtained.

Boilersarefittedwithaflangedflueoutlet.Thefluemanufacturer/installermustbeconsultedatanearlystagetoensureacorrectmatingcomponentforflueconnection.

Thefluediametermustbethesameorlargerthantheboilerflueoutlet.Areductioninfluediameter will cause additional resistance which could have an adverse effect on combustion.

Avoidfitting90°shortradiuselbows,90°teesandlonghorizontalrunswhereverpossible.Allhorizontalfluerunsshouldhavearisingpitchof15°minimumtopreventcondensatebuild-upand subsequent corrosion. Oil-firedboilerinstallationsaregenerallymorecriticalbecauseofthesulphurcontentinthefueland the higher dew-point temperature.Specialistadviceshouldbeobtainedonfluematerialandinsulation.

ModelFB-S FB-C

200 300 400 500 650 800 1000 1300 1650A 570 TBC TBC 670 TBC TBC TBC TBC TBCB 450 TBC TBC 560 TBC TBC TBC TBC TBCC (PCD) 520 TBC TBC 620 TBC TBC TBC TBC TBCHoles 8 TBC TBC 12 TBC TBC TBC TBC TBC

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INSTALLATION - 2

Note: See Appendix A - TI-140-Recommended Water Conditions.

The quality of the feedwater will affect the life and performance of a steam boiler. Steam is produced by heat transfer from the heat source into the water contained within the boiler’s cylindrical shell, by the passage of hot gases through the furnace and tubes. It should be noted that solids entering the boiler with the feedwater can rapidly concentrate in areas of high heat transfer. Such deposits can restrict heat transfer and consequently raise mean metal temperature, which can cause corrosion and reduce safety margins possibly to the point of failure. It is therefore strongly recommended that a reputable water treatment specialist is consulted prior to putting the boiler into service. WatercharacteristicsaregenerallyasspecifiedinBS24861997“TreatmentofWaterforSteamBoilers and Water Heaters”, Table 2.

Boilers operating in areas with high residual hardness, high levels of Bicarbonate (temporary) hardnessandlowcondensatereturnrates,willhavedifficultyinmaintainingTotalandCausticAlkalinity(TDS)figures,withinthespecifiedlimitswhenbaseexchangesofteningisused.This will result in a tendency of the boiler water to foam causing unstable water level conditions possibly leading to priming and carry over. In these instances particular care should be taken to establish a suitable water treatment programme and blowdown schedule in consultation with your water treatment specialist.

Cold feedwater contains high levels of dissolved oxygen which is highly corrosive when released within a steam boiler. The dissolved oxygen can cause corrosion in boiler plate and water supply system, with many pits. These little pits gradually change into larger ones and usually covered by ferric oxide. Once the corrosion sets forth, the speed will be rapid without reverse. Always pre-heat the feedwater to 80 °C - 85 °C to reduce dissolved oxygen to a minimum and prevent thermal shock. Water treatment chemicals should be used to remove the remainder of the dissolved oxygen. It is recommended to install oxygen removing equipment.

Failure to do so will result in premature failure of the boiler tubes which will not be covered by warranty. The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or dirt accumulations

2.5 WATER SUPPLY

WARNING

DO NOT use unheated or untreated feedwater which can result in premature tube failure by oxygen corrosion

!

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INSTALLATION - 2

2.6 BLOWDOWN VALVE

Figure. 3 - Automatic Boiler Blowdown (if fitted)

2.7 MAIN STEAM VALVE

Distribution pipework should be run from the main steam valve on top of the boiler to the steam or hot water delivery point(s).

Care should be taken to ensure that adequate condensate drainage and expansion facilities are provided within the pipework run(s).

To prevent excessive loads being imposed on the main steam isolating valve, the pipework should be secured near the boiler,ensuringadequateflexibilityexistsin the pipework between the steam valve and the securing point, to minimise any loads imposed on the valve.

Theboilerisfittedwithfourblowdownvalves;oneateachwaterlevelgauge(sightglass) assembly and each of the main boiler blowdown valves at the front and rear of the boiler. The pipework from these blowdown valves must be connected to a receptacle of approved design, following local regulations. If in doubt, consult Fulton Ltd or Health and Safety Executive Guidance Note PM60 which covers blowdown tanks and associated pipework installation.

WARNING

Never discharge blowdown from the boiler directly to a drain. Where a high level of blowdown or automatic blowdown systems are installed, serious consideration should be given to fitting a

Blowdown After Cooling System.

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Boiler blowdown isolation valve

Automatic boiler blowdown valve

Pneumatic actuator

Main Steam Valve

Steam Distribution Flange

Figure. 4 - Main Steam Valve

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INSTALLATION - 2

2.8 STEAM SAFETY VALVE

Thesafetyvalveisfactoryfittedatthetopoftheboilerandpre-set;itMUSTNOTbeadjusted. The discharge pipe should be capable of strength bearing, and as short as possible. The discharge outlet should be piped to a safe discharge point and the pipework so arranged that any trapped condensate will drain away from the valve. a) The lift pressure is indicated on the

safety valve (DO NOT adjust).

b) The safety valve is designed to prevent the boiler from exceeding its design pressure.

c) Any system connected to the boiler which is not capable of accepting boiler pressure must be protected by a separate safety valve set to the required pressure.

Note: Safety valve outlet connections should be piped two sizes larger than the inlet connection size, this will ensure there are no accumulation issues.

2.9 WATER LEVEL GAUGE SET (SIGHT GLASS)

AllFBboilersarefittedwithtwo,‘Clifton’type(unlessotherwisespecified)reflexwater level gauges.

The water level gauges are equipped to monitor the boiler water level. The boiler operator can see the water level inside the boiler from these gauges.

The water level gauge blowdown valves should be connected to the auxiliary blowdownline;finalconnectiontotheblowdown valves being via 1/4 in. soft copper tubing.

Thevalvefittingsare6mm.For operating details refer to Section 3 - Operation.

WARNING

The factory-fitted safety valve is designed to protect only the boiler. This valve must not be used to protect other items.

!

Figure. 5 - Safety Valve

Figure. 6 - Water Level Gauges

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INSTALLATION - 2

Thestandardfittingisatthesideoftheboiler.Sample coolers are used to take a sample of the water in the pressure vessel of the boiler. They pass the sample through a water cooled coil to reduce it to a safe temperature.

Taking samples of boiler water is essential to ensuring the boiler feedwater is correctly maintained. Regular readings should be taken, to allow the correct management of Total Dissolved Solids (TDS) in the boiler water. Other tests can be done to ensure that the water is kept to the correct PH levels and hardness.

Please consult a water treatment specialist who will advise you on the best chemicals and water treatment to use for your process and location.

When taking a sample allow standing water from the previous sample to clear the line before taking the sample.

For more information on the water sample cooler, please contact Fulton Ltd.

2.10 WATER SAMPLE VALVE (SURFACE BLOWDOWN)

CAUTION

Sample boiler water could cause scalding, always use protective gloves and eye protection when obtaining a boiler water sample.

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Feedwater Inlet Check Valve

Feedwater Inlet Valve

The feedwater valve is connected to the water inlet which is on the middle right side of boiler. A checkvalveisfitteddirectlybeforethefeedwatervalvetopreventboilerwaterreturningtothefeedwater tank.

2.11 FEEDWATER VALVE/CHECK VALVE

Figure. 7 - Feedwater Valve

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INSTALLATION - 2

The gas/pressure requirement varies according to the burner size and the gas train selected. Verifythatthetypeandpressureofthegasavailableonthesiteissuitablefortheburnerfitted.Ifthesitegaspressureistoolow,itwillbenecessarytofitagasboostersystem.Consult Fulton Ltd if in doubt. When a gas booster is used, the gas pressure at the booster inlet must not fall below 10 mbar. The booster should be installed as near as possible to the burner.Itshouldbepositionedonafirm,flat,horizontalsurfaceusinganti-vibrationmountings.All connecting pipework should be well supported and accurately positioned in order to avoid stressingtheboostercasting.Theuseofflexibleconnections,whichreducebothpipeworkstresses and transmitted noise, is strongly recommended. The gas supplier should be asked to recommend the size of pipework between the meter and the booster to ensure that the required pressureandflowareavailable.

To minimise pressure drops, eliminate all unnecessary bends and elbows in the pipework between the gas meter and the inlet to the gas train. Ensure that a gas cock of the correct size is installed as close as possible to the gas train.

Onebutterflygasstopvalvewithinterlockswitchismountedonthedualburner.Theswitchshould be connected to the interlock terminal inside the control panel.

Allgaspipeworkmustbeappropriatetolocalconditionsandmustbeinstalledby‘CompetentPersons’ in accordance with the gas regulations.

Note: It is essential that a manual isolation valve is fitted upstream of the gas control train to allow the burner to be isolated for maintenance. The size of this valve should not be less than that of the burner control train in order to avoid any restriction in gas flow.

2.12 GAS SUPPLY

WARNING

It is essential that the installation of the gas pipework must be undertaken only by suitably qualified personnel and in compliance with appropriate Codes and Standards.

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INSTALLATION - 2

2.13 OIL SUPPLY

a) The oil supply piping to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriateCodesandStandards.Itshouldbeofsufficientsizetosatisfythepressureandvolumeflow requirementsoftheburnerunderallfiringconditions.Checksshouldbemadetoensurethatallmetersandothercomponentsareappropriatelyratedforthemaximumoilflowrateanticipated. Galvanized steel pipe should not be used. The supply piping should include an appropriate filter.

b) A two-pipe system must be used between the oil storage tank and the burner. One for oil supply and one for oil return. A circulating oil pump is required to deliver fuel oil at 69 - 207 mbar from the storage tank to the burner. Anoilfiltermustbeinstalledbeforetheoil-circulatingpump,lessthan60Meshisrecommended.

c) Thefinalconnectiontotheoilpumpinletshouldbemadeusingtheflexiblepipessuppliedwiththe burner.

d) One gate valve should be installed to the inlet and outlet of the circulating pump separately. A pressure gauge 0 - 4137 mbar should be added to the outlet.

e) It is important to ensure that the return pipe is not obstructed as this may result in damage to the pump.

f) In the case of heavy oil (No.4, No.5, and No.6 oil) the piping and oil storage tank should be insulated, trace heated and thermostatically controlled.

Figure. 8 - Oil Burner Installation

Note: Installation will change with the type of burner fitted.

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INSTALLATION - 2

The boiler wiring diagram is located on the inside of the boiler control panel. A3-phase,neutralandearthisolatedsupplyisrequired;thisshouldbeconnectedtothesupplyterminals of the main isolator in the boiler control panel. Details of power ratings to be provided at time of order.

a) Check all pipework connections, remove dirt in pipework and check for leakage.

b) Check pressure control.

c) Check control panel and all other circuit connections. Impurity among combustion air would damagethesteeljacketandfiretubesifthedoorofboilerroomisclosed.

Note: After completing the installation, clean the pressure vessel prior to operation.

CAUTION

Any electrical work should be undertaken by a qualified electrician to current local regulations.

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2.14 ELECTRICAL REQUIREMENTS

2.15 INSTALLATION CHECK POINTS

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OPERATION - 3

CAUTION

Before putting the boiler into operation it must be fully commissioned. In order to ensure safety, the commissioning must be carried out by a Fulton engineer. The commissioning of the boiler by any other

person without the specific written authority from Fulton Ltd will invalidate the warranty.

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3.1 GENERAL

The following instructions are given for the guidance of the operator in the use of the FB Series steam boiler and to provide adequate information to ensure that when the boiler is put into use, it will be done safely and without risk to health. Where original equipment service manuals are supplied, they must be read and understood in conjunction with this manual. All warnings and cautions must be observed.

SECTION 3 - OPERATION

3.2 BOILER FITTINGS

CONTINUED ON NEXT PAGE

ThefollowingbriefdescriptionofthefittingsandcontrolsusedontheFBrangeofboilersisintended to provide the operator with a basic understanding of the operating principles, which is essentialforthecontinuedefficientuseoftheboiler.

Main Steam ValveSteamoutletstopvalvefittedcentrallyonthetopcentrelineoftheboiler.

Safety Relief ValveFitted to the rear, on the top centre line of the boiler.

Air Vent ValveFitted to the rear, on the top centre line of the boiler.

Steam Pressure GaugeFitted to the control box mounting plate on the side of the boiler.

Blowdown ValvesFourblowdownvalvesarefittedonthepipework.Thetwomainblowdownvalvesarefittedatthesideofthefrontandtherearoftheboilerandoneblowdownvalveisfittedforeachwaterlevelgauge set.

Feedwater ValveWater supply inlet stop valve mounted on the side of the boiler.

Feedwater Non-return (Check) ValveWater supply NRV mounted on the side of the boiler directly under the main feedwater inlet valve.

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OPERATION - 3

Figure. 9 - Steam Pressure Controls

Pressure controls are mounted on the side of the control box. These are as follows: a) Control Pressure On/Off Switch

Controls the ON/OFF cycle of the burner, switching the burner off when the desired steam pressure is reached and switching it on when steam pressure falls.

b) High Limit Switch Should the Control Pressure Switch fail, the steam pressure will raise above the preset limit causing the High Limit Switch (set at least 0.5 barg higher than the Control Pressure Switch) to switch off and lock out the burner.

A High Limit Indicator will illuminate and an alarm will sound.

c) High/Low Pressure Switch

1. Air pressure transducer for fully modulated burners switches the burner from high to low flameandvice-versa.

2. Provides a proportional control signal to the burner combustion control.

Water Level Gauge Set (Sight Glasses) Two‘Clifton’typereflexwaterlevelgaugesaremountedonthesideoftheboiler.

Boiler Water Sample ValveFitted behind the feedwater inlet on the side of the boiler.

Low Water Safety Relays and Feedwater Pump RelaysThese relays operate in conjunction with probes suspended in the boiler shell to automatically maintain the water level in the boiler between set limits. If the water should fall to an unsafe level, the burner is cut out and an alarm is sounded. Theprobesarelocatedintwo,100mmdiameterstandpipeflangesmountedoneithersideoftheboiler centre line towards the front of the boiler. AstandardboilerisfittedwithFeedwaterPumpOn/Off,1stLowWaterand2ndLowWaterprobes.A20mmTDS(surface)Blowdownconnectionissupplied,fittedwithablankflange.

IfaTDSmonitoredsystemisfitteditshouldbeinterlockedsuchthatthevalvewillnotopenwhenthe feedwater pump is running.

3.2.1 STEAM PRESSURE CONTROLS

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OPERATION - 3

3.3 TYPICAL BURNER FITTINGS

Note: Fittings will vary depending on the burner that is fitted on the boiler.

Burner ProgrammerIs located in the burner mounted control panel. Acts in conjunction with a sensing device to‘supervise’theignitionsequence,provetheflameissatisfactoryandfinally‘monitor’theestablishedflame.Shouldanyfaultoccur,eitherduringtheignitionsequenceorduringnormalrunning,theprogrammerwillimmediatelygoto‘lockout’andbothmainandpilotgas/oilvalveswill shut to isolate the fuel lines to the burner. Lockouts include high steam pressure, low water, high/lowgaspressureandflamefailure.

Air Damper ServomotorThe combustion air control system which includes an air damper and a servomotor. The servomotor is mounted on the burner and directly coupled to the air damper blade. This system monitors and controls the combustion air entering the burner on the requirement of the boiler heatingduringoperation.Afullyclosedpositionisprovidedtopreventairflowingthroughtheappliance when the burner is not in operation.

The Inner AssemblyConsistsofflametube,diffuse,oilnozzleandignitionelectrode.

Oil NozzleTheoilnozzlesareheldinanozzleblocklocatedwithintheflametube.Thenozzlesarepre-sizedby the manufacturer according to the heat inputs required and the available operating pressure. When replacing the nozzles, they must be the same capacity as the original.

Note: When fitting nozzles to the heavy oil burners the nozzle filters must be removed. In calculating the correct size of nozzles to be fitted, refer to the specific burner manual.

Oil Pre-heater Tank (for heavy oil burners)The oil pre-heater tank is mounted on the heavy oil burner ahead of the fan housing. Its function istopreheattheoiltothecorrecttemperature.Theunitisequippedwiththreethermostats,‘lowtemperature’‘operating’and‘limit’.Athermometerandhotoilfilteraremountedtogetherasoneunit on the top left-hand side of the pre-heater tank viewed from the rear of the burner.

Air Pressure Switch. (Gas and Dual Fuel Burners only) Mounted on the burner, this switch is operated by the pressure of air entering the burner through thethroatofthescroll.Lackofcombustionair,orinsufficientairpressure,willstoptheswitchcompleting the circuit, preventing the burner from operating.

Air ControlThe Air Control System of the gas burners is similar to that of the oil burners. The servomotor is mounted on the rear of the air inlet of the burner and directly coupled to the air damper blade. This system monitors and controls the combustion air entering the burner on the requirement of the boiler heating during operation. The servomotor has been adjusted by the manufacturer before the boiler delivery, so normally the customer needn’t set it again.

Gas Train AssemblyConsists of pilot and main supply lines, each line having a manual cock, a governor and solenoid operated valves. The governors maintain a consistent pressure of fuel entering the burner and are adjustable. The solenoid valves are electronically controlled by the burner programmer. For specificdetails,consulttheburnermanufacturersinstructionmanual.

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V1V2

V3

Valve Proving SystemA valve proving system, as shown schematically below, is standard on the FB range of boilers. When the boiler operating sequence is initiated, the burner control box energises the proving system, which then carries out the following checks.

a) Valves V1, V2 and V3 are initially closed. The proving system then opens V3 and then closes it after 2 seconds.

b) V1, V2 and V3 remain closed for 23 seconds while the minimum side of the gas pressure switch (PS) checks for an increase in pressure. If no increase occurs there is no leakage past V1 and the sequence continues.

c) V1 is opened for 2 seconds and then closed. V1, V2 and V3 again remain closed for 23 seconds while the maximum side of the gas pressure switch checks for a decrease in pressure. If no decrease occurs there is no leakage past V2 or V3 and the burner operating sequence will continue.

Figure. 10 - Valve Proving System

Flame MonitorAnultravioletcellisfittedasstandardonallburners.Itmonitorsthestatusoftheflame,anyfailure will cause the burner to shut down.

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3.4 BOILER CONTROL PANEL

Boiler controls and indicators are housed in a control panel mounted on the side of the boiler.

These are as follows:

Power Isolator Switch. Control panel power supply ON/OFF switch, mounted on the panel door.

Power On Indicator. Indicatesthatthedoormounted‘poweron’isolatorisintheONpositionandthatthepaneliselectrically live.

WARNING

The Power On indicator is derived from one phase. It is possible for the Power On indicator supply phase to be down, leaving the other two phases live.

Always isolate the supply before working on the panel.

!

Pump Only/Off/Pump & Burner On. This rocker switch has three separate functions. In the PUMP ONLY and PUMP & BURNER ON positions, the power supply is switched through to the control system. It is a mandatory requirementoftheAOTCandGasSupplyStandardsthatwhenthecontrolsystemisfirstenergised, or re-energised (power restoration), it must go to a fail-safe shut-down position, sound an alarm and require manual resetting to cancel the alarm. The alarm condition, when activated, is cancelled by resetting the 2nd low water reset switch.

PUMP ONLY Position. Thispositionshouldonlybeselectedtofilltheboiler.Thenormalfunctionsof the level control alarmsystemareoverriddentopreventacontinuousalarmwhiletheboilerisbeingfilled.Thepump off level control will function normally and switch the pump off once the correct water level is reached.

Note: The burner mounted Burner On/Off/Reset Switch should be in the OFF position during the filling process.

Note: The Pump On/Pump Off Switch should be in the PUMP ON position. Both alarms will be cancelled when pressing the reset switches irrespective of the water level in the boiler.

OFF Position. In this position the burner, feedwater pump and control system are off.

PUMP & BURNER ON Position. In this position, both burner and pump will run under automatic control providing that the burner mounted Burner On/Off/Reset Switch is in the ON position, and the Pump On/Pump Off Switch is in the PUMP ON position.

Note: When selecting this position from either PUMP ONLY or OFF, the power restoration alarms will be activated. The alarm can be cancelled by pressing the 2nd Low Water Alarm/Reset switch.

Note: The 2nd Low Water alarm can only be cancelled if the boiler water level is above the 2nd low water level. If the alarm cannot be cancelled, allow the feedwater pump to restore the water level to the normal working level (approximately midway up the sight glass) and then reset the alarm.

Pump Off/On switch This switch is only used for evaporation and low water tests. It interrupts the power supply to the feed pump contactor coil.

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Sequence manual/auto switch(iffitted)Used to select either manual or automatic sequence step control. In the manual position the burner will operate under the direct control of the master pressure controller, mounted in the steam header/distribution pipework. The boiler mounted high pressure and on/off pressure switches are still functional.

1st Low Water Indicator. This lamp will be illuminated and an alarm sounded when the water level in the burner falls to the 1st low water level. The burner will shut down and the alarm will continue to sound until the water level is restored to a safe working level. The alarm will then cancel, the indicator lamp will extinguish and the burner will automatically restart.

2nd Low Water Alarm/Reset Switch. Sounds an alarm during switch on, press to reset. If the level of water in the boiler falls below the second pre-set limit during boiler operation, the 2nd Low Water Alarm/Reset Switch will illuminate, the alarm will sound and the burner will shut down. The water level must be restored before the alarm can be cancelled by pressing the switch.

High Water Indicator(iffitted).This lamp will illuminate and an alarm sound when the water level reaches a pre-determined high level. The feedwater pump will stop. When the water level falls to the normal working level, the indicator lamp will extinguish and the alarm will cancel.

Burner Run Indicator. Indicates that the burner is operating in the normal run position.

High Steam Pressure Alarm/Reset Switch. This switch will Illuminate and an alarm sound when the high limit pressure switch is tripped. The switch/alarm must be manually reset after the pressure has reduced to a safe level.

Flame Failure Indicator. Indicatestheburnercombustioncontrolrelay,detectsaflamefailurecondition.

Night Set Back Switch(iffitted).The‘SetBackSwitch’needstobesettothe‘On’positionattheendoftheworkingshift.Thismeanstheburnerwillonlyfireiftheboilerpressurefallsbelowasetstand-bypressure.Thisthereforereducesstart-upleadtimeatthebeginningofthenextshift,whenthe‘SetBackSwitch’should be set to the off position to enable the boiler to reach normal operating pressure.

WARNING

Before resetting this control, ascertain the reason for the alarm, and rectify.

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Note: Components and their location on the control box will vary with boiler specification.

Figure. 11 - Boiler Control Panel

Pressure gauge

Pump on/off

Pump only & pump & burner on

Audible alarms

2nd low water reset

High pressure alarm reset

Burner on

Power on

1st low water

Flame failure

LC3050 Level Limiters (iffitted)

BC3150 blowdown controller (iffitted)

BT1050 boiler blowdown timer

(iffitted)

Engineers test button

Power on isolator switch

BurnerAutoflame

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3.5 BURNER MOUNTED CONTROL PANEL

(Consultthespecificburnermanualascontrolswillvarydependingontheburnerfittedtotheboiler.)

Burner controls and indicators are mounted on the burner. The following controls are typical for a dual fuel burner, but reference should be made to the burner manufacturer’s operating manual for the particular type used.

Burner On/Off/Reset SwitchThree-position switch used to switch on/off and/or reset the burner.

Lockout IndicatorIndicatestheburnercombustioncontrolrelaydetectsaflamefailurecondition.The burner controller can be reset by setting the Burner On/Off/Reset Switch to the RESET position.

Hand IndicatorThis lamp will illuminate when the hand/auto switch mounted inside the burner control panel is in the hand position, normally used for commissioning only.

Auto IndicatorThis lamp will illuminate when the hand/auto switch mounted inside the panel is in the auto position.

High Pressure IndicatorThis lamp is not wired when a high steam pressure alarm/lamp is provided in the boiler control panel.

Modulating ControllerControlsthefiringoftheburnerwithinthepressurebandselected.

Burner Control Panel

Figure. 12 - Burner Control Panel

Note: A oil burner is illustrated, for specific details consult the burner manual supplied with the boiler.

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3.6 FILLING THE BOILER

1. Ensure the following valves are OPEN: a) Steam pressure gauge isolating valve.b) All valves in the water feed line.c) Water level gauge isolating valves. d) Air release valve.

2. Ensure the following valves are SHUT: a) Main steam valve.b) Main blowdown valves.c) Water gauge blowdown valves.d) All valves in the gas/oil train to the burner.

3. Ensure that the Burner On/Off/Reset Switch is set to OFF.

4. Ensure that the Pump On/Pump Off Switch is in the PUMP OFF position, and that the Pump Only/Off/Pump & Burner On Switch is in the OFF position.

5. Turn the door isolator to the ON position.

6. Place the Pump On/Pump Off Switch to the PUMP ON position.

7. Vent the pump.

8. Place the Pump Only/Off/Pump & Burner On switch to the PUMP ONLY position.

9. Thefeedwaterpumpshouldstart,(checkthepumpdirectionofrotation)andfilltheboilertothe correct working level and then switch OFF.

Note: If the 2nd Low Water and High Pressure Alarm/Reset switches illuminate and the alarms sound, check that the burner mounted Burner On/Off/Reset Switch is in the OFF position, and then reset both alarms by pressing the switches.

Note: It may be necessary to vent the feedwater pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection.

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When starting up the boiler, it is prudent to minimise the thermal and mechanical stress caused by differential expansion of various parts of the boiler as they reach working temperature.The shell temperature is determined by the contained water/steam temperature. The furnace temperature which is higher is determined by the heat transfer/furnace wall loading and gas temperature. The tube temperature lies between the shell and furnace temperatures, but is nearer the shell temperature. Since all these components are virtually the same length, they expand longitudinally by different amounts causing mechanical and thermal stress. Whilst this is catered for in the mechanical design of the pressure vessel, the life expectancy of the boiler can be affected if the boiler is frequently heated too quickly from cold .

When starting from cold the furnace approaches its design temperature shortly after start-up, whereas the tube and shell temperatures are delayed by the time taken to bring the contained water up to temperature. As a result, the thermal expansion is at its greatest. Additionally, the temperature gradient which exists between the bottom and the top of the boiler is exaggerated. This can be reduced by blowing the boiler down during the heat-up period.

In practical terms, the ideal solution would be to gradually raise the temperature and pressure in theboilerprogressivelybyfiringtheboileronlowfireforafewminutesandleavingitto‘soak’(e.g. allowing the temperatures in the boiler and water to even out by diffusion) for 20 to 30 minutes,blowingdowntheboiler,firingtheboileragainforalittlelongerandsoakingforless,andso on. Iftheboilerhasbeenfiredthedaybefore,thelargethermalmassintheboilerwillmaintaintheinternal temperaturetoapointthattheboilercanbesimplyswitchedon(preferablyonlowfire)and then left to reach working temperature/pressure.

The life expectancy of the boiler, ignoring other factors, is proportional to the number of thermal/mechanical cycles that the boiler undergoes from cold/zero pressure to working temperature and pressure. A boiler that is continually maintained at working pressure will last longer than one that is constantly heated and cooled.

3.7 STARTING THE BURNER FROM COLD

3.7.1 PRACTICAL CONSIDERATIONS

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3.7.2 STARTING PROCEDURE

Note: When starting from cold Section 3.7.1 must be read and understood, if in doubt consult Fulton Ltd.

a) Fill the boiler as described in Section 3.6.

b) Ensure the main steam valve is SHUT.

c) Open all the valves in the gas train/oil supply. It is assumed that the fuel supply lines have been purged prior to attempting to start the boiler/burner.

d) Turn the Pump Only/Off/Pump & Burner On Switch to the PUMP & BURNER ON positions.

e) Switch the burner mounted Burner On/Off/Reset Switch to the ON position. The 2nd Low Water and High Pressure Alarm/Reset switches will illuminate and alarms will sound due to the power restoration interlock, (refer to Section 3.4 - Pump Only/Off/Pump & Burner On switch description).

Note: If the 2nd Low Water and High Pressure Alarm/Reset switches illuminate and the alarms sound, check that the burner mounted Burner On/Off/Reset Switch is in the OFF position, and then reset both alarms by pressing the switches.

f) The burner motor will start and, after going through the post purge/pre purge interlock checks, shouldfireafterapproximately45seconds.

Note: Before leaving the boiler unattended, the daily operating tests (see Section 4.13.1) should be carried out to check the functions of all the safety interlocks. For more detailed information on the burner firing sequence consult the burner manufacturer’s Operation and Maintenance instructions.

3.8 BURNER OPERATION

3.8.1 BURNER

1. Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit.

2. Check the direction or rotation of the motors.

3. Open the housing to check the electrode setting. Check the gas pilot pressure at the pilot regulator.Normalsetting:7.5-15mbar(Dseries);44.8-50mbar(Sseries).

4. Check control linkage for proper movement of the air volume damper and fuel metering components. This can be done by loosening the linkage at the actuator level and manipulating by hand.

5. Checktheshutterandadjustlowfiresetting.

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3.8.2 FIRING PREPARATIONS FOR GAS BURNERS

1. A representative of the gas utility should turn on the gas.

2. Determinebyatestgaugeupstreamoftheburnerregulatorthatsufficientpressureexistsatthe entrance to the gas train. The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded.

3. On combination fuel models, set the selector switch to gas. On initial start-up it is recommended that the main gas shut-off cock remain closed until the programmer has cycled through pre-purge and pilot sequences to deter.

4. Check for leaks and determine there is adequate gas pressure available at the burner for operating at full capacity. Check with the local utility if necessary.

5. Check gas pressure at the pilot and the main burner.

6. Close the manual gas valve.

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4.1 VISUAL CHECKS

CAUTION

It is vitally important that the instructions given in this manual are strictly adhered to.Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic

reduction in the life expectancy of the boiler.

!

Inspectthesteamandfeedwaterpipework,valvesandfittingsforsignsofleakage.Ifleaksaresuspected, shut down the system and evacuate the system to atmospheric pressure before attempting any repairs.

Note: Ensure that the water level is maintained during the pressure build-up. If any part of the equipment is not operating correctly, the fault should be investigated before the boiler is used. Ensure that all blowdown pipework is safe and discharged to a blowdown receptacle.

4.2 WATER LEVEL AND LOW WATER SAFETY CONTROLS

The following procedures ensure the correct functioning of the water level controls and the low water safety controls.

SECTION 4 - MAINTENANCE

Tests should be carried out by a competent person trained to perform such tests. If any test shows that the equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used.

Anyrectificationorrepairsshouldbecarriedoutbytrained,competentservicepersonnel.

4.2.1 PUMP TEST

a) If the boiler is not firing and not under steam pressure, lower the water level using the main blowdown valve:

If the pump is running:

1. Observe the water level in the water level gauge (sight glass).

2. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. Check that the water level in the water level gauge is between Pump On and Pump Off levels.

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2. Lower the water level by opening the main boiler blowdown valve.

3. Verify that the pump starts to run when the water level reaches the Pump On level.

4. Close the main boiler blowdown valve.

5. Continue to observe the water level in the water level gauge and verify that the pump continues to run until the Pump Off level is reached and then switches off.

b) If the boiler is firing and under load, lower the water level by evaporation, observing a

pump cycle:

If the pump is running:

1. Observe the water level in the water level gauge.

2. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. Check that the water level in the water level gauge is between Pump On and Pump Off levels.

2. The water level will lower through natural evaporation.

3. Verify that the pump starts to run when the water level reaches the Pump On level.

4. Continue to observe the water level in the water level gauge and verify that the pump continues to run until the Pump Off level is reached and then switches off.

4.2.2 1ST LOW WATER LEVEL CHECK

1. Ensurethattheboilerisfiring,thefeedwaterpumpisnotrunningandthatthewaterlevelis between Pump On and Pump Off.

2. Switch off the pump using the Pump Interrupt/Pump Run switch.

3. Allow the water level to lower by natural evaporation below the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burnerstopsfiring.Donotallowthewaterleveltodropbelowthebottomofthewaterlevelgauge (sight glass).

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Switch on the pump using the Pump Interrupt/Pump Run switch.

6. Verifythatthepumprunsandrefillstheboiler.Whenthewaterlevelrisesabovethe1stLow Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silencesandtheburnerfiresequencestarts.

7. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

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4.2.3 2ND LOW WATER LEVEL CHECK

1. Ensurethattheboilerisfiring,thefeedwaterpumpisnotrunningandthatthewaterlevelisbetween Pump On and Pump Off.

2. Switch off the pump using the Pump Interrupt/Pump Run switch.

3. Allow the water level to lower by natural evaporation to the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burnerstopsfiring.Donotallowthewaterleveltodropbelowthebottomofthewaterlevelgauge (sight glass).

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Allow the water level to lower further by natural evaporation below the 2nd Low Water level. Do not allow the water level to drop below the bottom of the water level gauge.

6. Verify that the Low Water Reset switch illuminates.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

7. Switch on the pump using the Pump Interrupt/Pump Run switch.

8. Verifythatthepumprunsandrefillstheboiler.Whenthewaterlevelrisesabovethe 1stLowWaterlevel,verifythatthe1stLowWaterlampextinguishesbuttheburnerfire sequence does not start.

9. Press the Low Water Reset switch- Verify that the 2nd Low Water lamp and audible alarm extinguishes and the burner starts.

10. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

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4.3 MAIN BLOWDOWN

Keep the boiler, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by blowing down in the following manner:

Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.

1. Start the boiler and generate not more than 10 psi of steam (see note).

2. Shut off both the burner and the pump.

Boiler Blowdown

1. Fully OPEN the boiler main blowdown valve for not more than 5 seconds, or as recommended by the water treatment specialist.

2. CLOSE the valve.

Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required.

Auto Blowdown/Draining

The boiler may be drained by opening the boiler blowdown isolation valve, having mechanically opened the auto blowdown valve.

Note: As well as removing sludge (suspended solids) from the boiler, a second and equally important function is to maintain the TDS (totally dissolved solids) level to within the required limits. The amount of blowdown, and hence time required, is dependent on the amount of TDS in the raw water supply, the percentage condensate return, water treatment chemicals added and the number of hours a day operation. In order to establish the required blowdown rate, consult your water treatment specialist who will recommend a water treatment programme in terms of appropriate chemicals and the required blowdown rate which takes these factors into account.

Figure. 13 - Main Boiler Blowdown Valve (automatic)

Note: The boiler blowdown shown is an automatic installation, manual blowdown is also available.

Boiler blowdown/drain isolation valve

Boiler auto blowdown valve

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4.4 WATER LEVEL GAUGE BLOWDOWN

Blowdown the water level gauge (sight glass), set 1.

1. Open the water level gauge glass blowdown valve A

2. Close (for approx. 3 seconds) the top gauge valve B

3. Open valve B

4. Close (for approx. 3 seconds) the bottom gauge valve C

5. Open valve C

6. Close valve A

Repeat for gauge set 2

On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are CLOSED.

Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure.

Figure. 14 - Water Level Gauge Operating Positions Figure. 15 - Water Level Gauges (sight glasses)

WORKING POSITION

STEAM BLOWDOWN

WATER BLOWDOWN

B B

C

B

C C

A A A

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4.5 EVAPORATION CHECKS

With the boiler running under normal load conditions, and the pump stopped having just completedarefillcycle:

a) Ensure that the boiler water level is correct.

b) Switch the pump OFF at the pump interrupt/pump run switch.

The water level in the boiler will lower through natural evaporation. When the level nears the bottomofthewaterlevelgauge(sightglass),thefirstlowwateralarmwillsound,thelowwateralarm lamp will illuminate and the burner will shut down. If it is required to check the second low water alarm, wait a further period for the LOW WATER RESET switch to illuminate.

When the check is complete, proceed as follows:

c) Switch the pump ON at the pump interrupt/pump run switch.

d) Pressthelowwaterresetswitch.Thepumpwillstarttorefilltheboiler.

If the pump starts to run at any time during the test then the test must be abandoned and restarted from the beginning.

4.6 FLAME SENSOR TEST

This test checks the operation of the flamesafeguardsensor.

1. Ensurethattheburnerisfiring.

2. Removetheflamesensorfromitsplug in connection on the side of the burner.

3. Cover the sensor glass to exclude all light.

4. The burner control should immediately (2-3 sec gas, 5 sec oil) gotolockout/flamefailureconditionand will require manual resetting.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Clean the UV photocell before replacing it.

6. Fire the burner to ensure correct operation.

Figure. 16 - Flame Sensor Removal

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4.7 DRAINING THE BOILER

CAUTION

Your local regulations could state boiler water above 43 °C must not be discharged into the drain. ALWAYS check your local regulations.

!

A

Figure. 17 - Automatic Blowdown Valve

Boilers with manual blowdown valves

1. Ensure the boiler is cold.

2. Isolate the boiler electrics at the isolator on the control box door.

3. Isolate the feedwater tank and the feedwater pump.

4. Open the main steam valve and the boiler drain valve.

5. Open the drain valve on the blowdown vessel.

6. Open all valves in the drain lines.

Boilers with automatic blowdown systems

1. The boiler should not be under pressure.

2. The boiler should be cold.

3. Either:

1. Usetheblowdownbypassvalvetothrottletheflowtodraintheboiler.

Or:

1. Close the blowdown isolation valve.

2. Usingascrewdriverlocatedasshown‘A’,pushupandmakeaquarterturn,thiswilllockthe button in position and open the blowdown valve.

3. Usingtheblowdownisolationvalvetothrottletheflow,draintheboiler.

Note: Skid systems and plantrooms have internal drainage systems which require the same procedures.

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4.8.3 LONG TERM (WEEKS)

To store the boiler in a corrosion-free situation there are three practical solutions:

1. Fullyfloodtheboilertoexcludeasmuchairaspossible.

2. Drain the boiler completely. Remove all hand hole and manhole doors. Open all gas/oil side access doors.

3. As (2) but also introduce a form of convection heating to the gas/oil and water side.

4.8 BURNER SHUT DOWN

4.8.1 SHORT TERM (HOURS)

4.8.2 MEDIUM TERM (DAYS)

Select OFF on the burner control panel switch. Theburnerwillstopfiring,post-purgeandthenstop.

1. Turn Boiler On/Off on the burner or boiler control panel to OFF. Theburnerwillstopfiring,post-purgeandthenstop.Shut the main steam valve.

2. Select pump only on the boiler control panel.

3. Shut the water feed valve

4. Shut the fuel valve

5. Turn the power switch on the boiler control panel to OFF.

Note: Ensure the boiler water treatment levels for dissolved oxygen are within the specified limits.

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4.9 INTERNAL INSPECTION

The lower hand hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, it should be removed and the water treatment supplier advised.

Newgasketsmustbefittedeverytimeahandholedoorisremoved.Subsequentinteriorexaminations should be carried out on a regular basis until satisfactory conditions are observed. Thereafter, inspections should be carried out at three monthly intervals.

Figure. 18 - Hand Hole

Hand Hole Cover Plate

Gasket

Bridge

4.9.1 FITTING NEW GASKETS

CAUTION

TOPOG-E gasket have a finite life after installation and must be renewed annually. It is important that the instructions given in this section are adhered to.

!

TheFBseriesofboilersarefittedwithTOPOG-Egasketsinalltheinspectionholesoftheboiler.These gaskets work very well and millions have been safely used over the last 30 years, however, it is absolutely essential to observe a few simple rules in order to get the best performance from your installation.

Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation from many sources including heat, oxygen, stress, and overdosing from certain types of water treatment. This takes the form of material oxidation, hardening/embrittlement and cracking which may result in gasket failure. Steps must be taken to minimise the effects of such attacks.

Water treatment and oxygen attack can be combated by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fittingthisisalmostcertainlyduetoincorrectseatingoralignment.Assuchgasketsareveryflexibleitispossibletocuretheleakbyexcessivetightening,butsuchanactionwillseriouslyreduce the life of the gasket and cause problems later. Unduestresscanbeavoidedbytighteningjustsufficientlytostopanyleakagewhenfittingcoldandbeforefiringtheboiler.Firetheboilerandthengraduallywarmtheboilerup,allowingtheincreasing steam pressure to take over and complete the seal. This will allow the gasket material to contract naturally and follow the topography of the mating surfaces. The securing nut can then betightenedgentlybyapproximatelyaquarterofaturn,toensurea‘snug’fitandpreventthe

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COVER PLATE ANDGASKET IN PLACE

CORRECTPLACEMENT

DO NOT OVER-COMPRESS

GASKET

COVER PLATENOT IN CENTRE

seal from being broken when the boiler is cold and under negative pressure. Gentlewarmingoftheboileroninitialfiringaftermaintenancewillalsohelptoensurethattherubber ‘curestoshape’.Iftherubberpost-cures,theelasticmemorywillbedestroyedandanyinitial over tightening will cause the gasket to become hardened and brittle, leading to cracks and eventual failure.

4.9.2 FITTING INSTRUCTIONS

Blowdown the boiler completely (see Section 4.3) and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows:

1. Disassemble the crab(s) and cover plate and remove the inspection hole assembly. Remove the old gasket and thoroughly clean the mating faces of the cover plate and boiler ring.

2. Place the new Topog-E gasket on the cover plate, ensure the gasket is the correct size and is seatingflatagainsttheplate.Donotuseanygrease,lubricantoradhesive.Ifthenewgasketis not seated properly before the plate is tightened, the gasket may be pinched causing a failure when the pressure builds up.

3. Position the cover plate in the boiler ring, ensuring that the plate is correctly centred. An off-centre cover plate can concentrate forces on the gasket and cut it in two. The cover plate may also drag on the boiler hole ring and fail to seal as the pressure rises. Setthecrab(s)andhand-tightenthesecuringnut(s)sufficientlytoprovideasnugfit. Tighten the nuts a further quarter of a turn using a spanner. DO NOT OVER TIGHTEN.

Note: Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack. If the gasket is misaligned, over-tightening to seal a leak will not prevent subsequent leakage at a later date.

4. Gradually warm up the boiler, allowing steam pressure to make the seal. If the gasket leaks duringpressurebuildup,tightenthesecuringnut(s)sufficientlyonlytostoptheleakage.Itisimportant to keep the nuts correctly tightened thereafter, this prevents the vacuum developed by cooling on shut down from feeding and draining the boiler.

Note: New gaskets fitted to inspection holes located along the bottom of the boiler are more difficult to install without leaking. Small particles of scale or sand tend to run down on the mating surfaces after cleaning but prior to assembling. This condition is likely to have occurred if excess tightening is required to stop a leak before warming the boiler. In this event, the best course of action is to drain the boiler and repeat the gasket fitting procedure. Failure to do so will severely reduce the life of the gasket.

5. Clean and inspect each water level gauge (sight glass). If any water leakage is evident, renew

the water level gauge gasket.

Figure. 19 - Fitting a New Topog-E Gasket

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MAINTENANCE - 4

4.10 STEAM PRESSURE SWITCH ADJUSTMENT

Control Pressure Switch

Pressure limiter

Pressure Transducer

Figure. 20 - Pressure Switch Locations Non-Modulating

Figure. 21 - Pressure Switch Locations Modulating

4.10.1 CONTROLS

Thestandardboilerisfittedwithsteampressureswitchesasfollows:

a) HighLimitPressureSwitch(proportional,non-adjustable)whenfitted.b) High/Low Pressure Switch c) Control Pressure Switch

They are located on the control box together with a syphon pipe, pressure test point and steam pressure gauge.

The Control Pressure Switch controls the on/off cycle of the burner, switching the burner off when the desired steam pressure is reached, and switching it on when the steam pressure falls.

The High Limit Pressure Switch is a maximum steam pressure switch which has to be set to operate at least 0.5 barg higher than the Control Pressure Switch. Normally the High Limit Switch does not operate, but if the Control Pressure Switch fails and steam pressure rises above the adjusted steam pressure, the High Limit Switch should switch off, lock out the burner, illuminate the High Limit Pressure lamp and sound the alarm. Should this happen, switch the boiler to pump only and wait until the steam pressure is discharged. Check the connection to the pressure switch, replace as required. TheHigh/LowPressureSwitchswitchestheburnerbetweenhighandlowfire.

High/Low Pressure Switch

Pressure limiter

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MAINTENANCE - 4

4.10.2 ADJUSTING THE PRESSURE SWITCHES

1. Start the boiler.

2. SHUT the main steam valve.

3. Set the control pressure switch to its maximum.

4. Set the high limit pressure switch to 0.5 barg below the safety valve setting.

5. Allow the steam pressure to rise until the high limit pressure switch trips. On the steam pressure gauge, check that the pressure is not less than 0.5 barg below the safety valve lift pressure.

If the pressure is incorrect, repeat steps 2, 4 and 5.

6. OPEN the main steam valve to lower the steam pressure.

7. Reset the control pressure switch to the required working pressure and the high/low pressure switch to 0.3 barg - 0.5 barg below the control pressure switch setting.

8. SHUT the main steam valve.

9. Reset the high limit pressure switch and allow the steam pressure to rise until the high/low pressure switchreducestheburnertolowfire,andthentheburnershutsdownunderthecontrol pressure switch.

10. Readjust if necessary to achieve the required settings.

Note: The requirement for a difference between the control and high limit pressure switches is to prevent unnecessary high limit steam pressure faults tripping the burner at no load conditions. The residual heat in the furnace, the flue pipes and the door refractory is capable of raising steam pressure slightly, causing the high limit pressure switch to trip out.

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MAINTENANCE - 4

Feedwater Valve

Disperser Holes

Feedwater Mounting Flange

4.11 FEEDWATER DISPERSER

CAUTION

DO NOT use unheated or untreated feedwater which can result in premature tube failure by oxygen corrosion.

!

FBboilersarefittedwithafeedwaterdisperser,removableforcleaning.Theholesinthedisperseraresizedtogiveanexitvelocitysufficienttoensurerapidmixingoftheboilerwaterandthe cooler feedwater, reducing temperature gradients within the water to a minimum.

In order to reduce oxygen corrosion to the tubes and prevent thermal shock, it is imperative that feedwater entering the boiler is heated to 80 °C - 85 °C. (The solubility of oxygen in water reduces substantially at 85 °C), on initial start-up this may not be possible.

As part of the water treatment programme chemicals will be dosed into the boiler feedwater line and/or the boiler feedwater tank. The nature of many of these chemicals is that they react when there is a rapid rise in temperature such that dissolved solids are precipitated and fall out of solution as a sludge. Thefirstmajorchangeintemperaturetothefeedwaterisasitentersthefeedwaterdisperser,asa result some solids will be precipitated within the disperser, the majority will be washed through, however some may remain as deposits. The disperser should therefore be removed, inspected and cleaned at each inspection interval i.e. 6monthlyorbeforeifthefeedwaterpumphasdifficultyinmaintainingtheboilerwaterlevel.To reduce the problems of possible disperser blockage, chemical dosage should always be applied as a slug into the feedwater pipe rather than into the feedwater tank. By chemical slug method, precipitation of solids only takes place from the water either side and mixed with the dose.

By dosing the feedwater tank all of the feedwater becomes saturated with chemical causing all of the feedwater entering the boiler to release precipitates/sludge. The exceptions are Sulphite compounds used for oxygen scavenging which can be dosed directly into the feedwater tank.

Figure. 22 - Feedwater Disperser

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MAINTENANCE - 4

4.12 SERVICE INSPECTION OF WELDED JOINTS

The requirement for in-service inspection of the main welded joints of the boiler is calculated by the number of cycles since the last inspection. Boilers running twenty four hours a day require the shell and furnace end plate welds to be inspectedatfiveyearintervalsandthelongitudinalseameverytenyears.

Boilers that are continually heated and cooled require more frequent inspection. During manufacture the major longitudinal and circumferential weld seams are subject to non-destructive testing by X-ray and/or Ultrasonic testing. TheboilerconstructionstandardBS27901992class1,specifiesaminimumleveloftesting,inordertoreducedowntimeduringtesting.FBboilersarefittedwithremovablecladdingstripslocated above the main shell horizontal and circumferential weld seams. The purpose of the in-service weld inspections is to check for:-

a) Buried defects during manufacture that are outside acceptable limits. Because the boiler was 100% tested during manufacture none should be found, and upon proof of 100% manufacture testingthesetestsmaybewaivedatthediscretionofthe‘competentperson’.

b) Crackspropagatingfromtheregionofthetoeofthefilletweldontheshelltothetubeplateweld, resulting from fatigue or corrosion fatigue cracking. These cracks would not be there after manufacture but can develop in service, they are caused by stress due to a combination of pressure loads, differential expansion, local temperature gradients, oxygen impurities in the boiler water/steam and inadequate pH (water chemistry) control.

Differential thermal expansion and local temperature gradients all result from continuous pressure/temperature cycling and heating from cold too quickly. Water treatment and in particular oxygen corrosion are covered in Section 2.5. The importance of correct water treatment cannot be overemphasised.

To achieve long trouble free boiler life :-

1. Maintain the boiler at working pressure as long as possible.

2. When heating from cold do so slowly.

3. Maintain water treatment within the prescribed limits at all times.

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MAINTENANCE - 4

WARNING

Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be isolated.

Ensure any residual pressure within the boiler is completely vented before working on the pressure vessel.

!

CAUTION

It is essential that regular checks are made to ensure that scale build-up is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler feedwater is effective.

Make sure that lifting equipment complies with all local regulations and is suitable for the job.You can be injured if you use faulty lifting equipment.Make sure the lifting equipment is in good condition.

!

IMPORTANT

If any fault is found during these procedures, shut down theboiler immediately and consult Fulton Ltd.

!

4.13 SCHEDULE OF OPERATOR TESTS AND CHECKS

The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary accordingtositeriskassessmentand/orspecificrequirementsofthecountry/territorythattheboiler is installed in. Failure to maintain the boiler adequately may void the Fulton guarantee.

Maintenance on gas related parts of a boiler must be carried out by competent, trained personnel who are GAS SAFE/ACS registered, and who have the necessary equipment to check combustion.

If any fault is found during these operations, contact your Fulton representative.

The following procedures are designed to prevent the build-up of scale, silt or sludge in the bottom of the boiler, water level gauge (sight glass) and water column pipework. Personnel involved in doing this work must have received the appropriate training in all aspects of maintenance and safety procedures.

In addition to these procedures, the advice of a water treatment specialist should be sought and followed.

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MAINTENANCE - 4

4.13.1 DAILY

4.13.2 WEEKLY IN ADDITION

WARNING

All steam pipework, valves and fittings will be very hot. Do not operate the safety valve without protection.

!

8. Visually inspect the hand holes and man holes for signs of leakage. This is particularly important when the boiler is started from new or when gaskets have been replaced (refer to Section4.6forfittingproceduresfornewgaskets).Correctiveactiontakenassoonasaleakoccurs can prevent costly repairs later.

9. Test all the boiler water level functions by evaporation, e.g. switch off the boiler feedwater pump - see Starting the Burner, Section 3.8.

10. Carry out routine maintenance checks on the burner as recommended by the manufacturer’s Installation and Maintenance instructions.

1. Visuallyinspectthesteamandfeedwaterpipework,valvesandfittingsforsignsofleakage. If leaks are suspected, shut the system down and evacuate the system to atmospheric pressure before attempting to repair the leaks.

2. Flame Sensor Test (see Section 4.6).

3. Pump Test (see Section 4.2.1).

4. 1st Low Water Level Check (see Section 4.2.2).

5. 2nd Low Water Level Check (see Section 4.2.3).

6. Blowdown the Boiler (see Section 4.3).

Note: If the boiler is being operated automatically on a time clock, the blowdown may be done once during the workingdayandonceattheendofthedaywhengenerating10psigorless,providingthisissufficientto control the TDS level within limits.

7. Blowdown the Water Level Gauge (sight glass), (see Section 4.4).

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MAINTENANCE - 4

4.13.3 SIX MONTHLY IN ADDITION

CONTINUED ON NEXT PAGE

11. Ensure that the following valves are SHUT.

12. The main steam stop valve

13. The feedwater isolating valve

14. The fuel (gas/oil) valves

15. Ensure that the power supply to the boiler is switched OFF.

16. Empty the boiler by allowing air into the boiler via the boiler vent valve, and draining through the boiler blowdown valve.

17. Remove the hand hole and manhole doors and thoroughly inspect the internal surfaces of the boiler, paying particular attention to the junction of the tubes with the front tube plate and the tubes for signs of pitting. Any deposits should be removed and your water treatment specialist consulted. Ensure there are no accumulated deposits of sludge in the bottom of the boiler.

18. Remove the feedwater disperser, inspect and clean.

19. Replace the man hole and hand hole door gaskets, refer to Section 4.6.2 forfitting procedures.

20. Open the boiler front access door with the burner mounted on it as described below. Undotheretainingnuts.Openthedoorsufficientlytoallowfullaccesstothetubeends.

21. Removetheaccesspanelfromtheeconomiser(wherefitted),checkforcloggingorblockingofthefinnedtubes,shouldthetubesneedtobecleanedextremecareshouldbetakennottodamageordistortthefins.Maintenanceinstructionsforcontrolandsafetydevicesfittedtotheeconomiser system should be fully observed.

22. Refittheeconomiseraccesspanel.

WARNING

The boiler must be completely cold before carrying out any of the following procedures.

!

WARNING

Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job.

You can be injured if you use faulty lifting equipment. Make sure the lifting equipment is in good condition.

!

CAUTION

The boiler and attaching parts will retain heat long after the boiler has been shut down.Always use protective clothes and extreme caution when working on a hot boiler.

!

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MAINTENANCE - 4

23. Remove the rear smoke box access doors.

24. Brush through the tubes to remove any deposits from the products of combustion.

25. Using a wire brush, clean the internal surfaces of the furnace and the face of the front tube plate. Pay particular attention to the tube ligaments (the spaces between adjacent tubes).

26. Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas reburning in the tube ends as a result of poor combustion, e.g. carbon monoxide carry-over. If the tube ends exhibit these signs, consult Fulton Ltd.

27. Clean out the rear smoke boxes to remove the deposits brushed through from the tubes.

28. Whenfitted,inspectthefinnedtubesoftheeconomiserforcloggingorblocking,cleanasrequired.

29. Examine the internal surface of the door lining for defects. Small repairs may be carried out bycuttingoutthedefectiveareaandreplacingwithnewfibre,ensurethecorrectadhesiveisused.

30. Examine the end of the burner blast tube where it extends through the door into the furnace. Clean off any deposits, paying particular attention to the internal lip where deposits can cause irregularflamepatterns.

31. Inspect the rear smoke box door seals for deterioration and replace if necessary.

32. Close the hinged front access door by reversing the opening procedure.

33. Reconnect the gas/oil connections.

34. Drainandflushthefeedwater/hotwelltank,cleananyfiltersandthestrainerinthefeedlinebefore the pump.

35. Drainandflushouttheblowdownseparator.

36. Carry out routine maintenance to the burner as detailed in the manufacturers Installation and Maintenance instructions.

Note: Depending upon the mode of operation, it may be found that the six monthly interval can be extended, possibly to an annual service. It is strongly recommended, however, that the interval should be 6 months from initial start up until such times as a ‘pattern of use’ and the condition of the boiler after a typical 6 months can be established.

IMPORTANT

When handling ceramic fibre always follow the local regulations regarding such materials, including the use of breathing apparatus, suitable body protection and protective gloves.

!

WARNING

Ensure that the rear smoke box drain connections are clean and free from deposits. This is particularly important on oil fired boilers because of the acidic nature of the condensate formed.

!

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MAINTENANCE - 4

4.13.4 ANNUALLY IN ADDITION

It is a requirement of the Factories Act and Pressure Systems Regulations that the boiler is internallyinspectedandre-certifiedatnotmorethan14monthintervals. It is normal practice to carry out an annual service during which your insurance surveyor would attend to carry out the statutory inspection. The scope of a full insurance strip-down is such that it should only be attempted by persons competent to do so who have had the necessary training, and have the required test equipment. Fulton Ltd can offer this service if required. Theengineeringsurveyormayrequiretheremovaloftheceramicfibreinsulationaroundtheperiphery of the front tube plate to facilitate inspection of the shell to tube plate weld. ThestandardFultonservicekitincludesreplacementceramicfibrematerialwhichmustbegluedinplacewiththeadhesivesupplied.Itisvitalthematerialisfittedensuringtheendsofthefibreface into the centre of the boiler.

For burner maintenance, refer to the burner manufacturer’s Installation and Maintenance instructions.

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MAINTENANCE - 4

4.14 TROUBLESHOOTING

Before calling the Fulton Service Department, check the following:

a) Gas isolating valve(s) are OPEN (gas and dual fuel burners).

b) Oil isolating valve(s) are OPEN (oil and dual fuel burners).

c) Oil storage tank contains an adequate level of fuel.

d) Oilfilter(s)arenotblocked.

e) Water feed line from feedwater tank/hotwell is OPEN.

f) Water feed isolating valve on boiler is OPEN.

g) All blowdown valves are SHUT.

h) Fuses or MCBs in the mains supply are not tripped

j) Thermal overload on the pump motor is not tripped.

k) Thermal overload on the burner motor is not tripped.

l) Normal water level is visible in the water level gauges (sight glasses).

m) Feedwater pump is primed and not air locked.

Before contacting the Fulton Service Department, have the following information available:

a) The model and size of the boiler.

b) The boiler serial no.

c) Themodelandtypeofburnerfitted.

Note: A very common problem is that when a boiler cools down, the steam in the steam space condenses and gradually forms a vacuum. If the feedwater line is open, the boiler will syphon water in, attempting to equalise the pressure. The appearance in the water level gauges (sight glasses) is the same if they are empty or fully flooded. If the water level gauges appear empty, but the water level control alarm(s) have not sounded, it is highly probable that the boiler is flooded. Allow air into the system and lower the water to the normal operating level.

CONTINUED ON NEXT PAGE

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MAINTENANCE - 4

4.14 TROUBLESHOOTING

Problem Cause RemedyStarting Power supply Check fuses or circuit breaker.

Gas supply Check for gas pressure. Check main gas cock is open.

Control circuit dead Door interlock microswitch.Gas burner will not start

Gas supply Check for gas pressure. Gas pressure switch(s) Reset gas pressure switch. Air pressure switch Check air pressure switch.

Check fan and thermal overload switch. Oil burner will not start

Oil supply Check for oil in storage tank. Check oil feed line is open. Check oil solenoid valves

Fuel pump Check oil pump is de-aerated.Check oil strainer.

Burner will not start Burner control locked Reset. Ignition Check ignition electrode and readjust or clean.

Check transformer.Flame failure Flame sensor Clean or replace.

Burner programmer Check functions or replace.Poor combustion Fuelflow Check fuel pressure.

Check fuel valves. Check fuel nozzle.

Air adjustment Readjust.Check air inlet. Check fan and thermal overload switch

Offcentreflame Check diffuser alignment in the blast tube. Flue Checkflueforblockage.

Boiler will not maintain pressure

Gas supply See above. Oil supply See above.Steam pressure switch Check steam pressure switch, readjust or replace. Scale build up in boiler Check Water Treatment advisor. Steam traps Check steam traps and replace as necessary. Dirtyflue Cleanfluesideofboiler.Steam overload Reduce.

CONTINUED ON NEXT PAGE

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MAINTENANCE - 4

Note: For more detailed fault finding on the burner consult the burner manufacturers Installation and Maintenance instructions.

Problem Cause RemedyWet steam, boiler primes

Too much boiler treatment chemical

Dumpreturntank,flushsystemorstoptreatmentfora week.

Steam traps See previous page. Pump will not cut off Earth connection Check for tightness and clean.

Probes connections Check for tightness and clean.Dirty probes Clean or replace. Water level relay Replace.

Feedwater pump runs but does not put water into boiler

Air/steam lock in pump Check for bad steam traps.Check for check valve in water feed line. Reduce temperature of the feedwater tank.

Blocked water feed line Check and clean if necessary. Impellers damaged Replace pump.

Feedwater pump will not start in time

Probe connections Check for tightness and clean the connections.Dirty probes Clean or replace.Water level relay Replace.Earth connection Check for tightness and clean.

Low water alarm/burner shut-off will not act in time

Probe connections Check for tightness and clean the connections.Dirty probes Clean or replace. Water level relay Replace. Earth connection Check for tightness and clean.

Starting the boiler, the high limit steam pressure limit is illuminated and the burner stops

Boileriscompletelyfilledwithwater.

Blowdown the boiler to a normal water level.

On/off pressure switch has failed.

Check pressure switch replace as required.

4.14 TROUBLESHOOTING

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MAINTENANCE - 4M

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MAINTENANCE - 4Ho

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APPENDIX - A

APPENDIX A - TI SHEETS

The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in this Appendix.

Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To check you have the most up to date TI sheet, please check the downloads section on the Fulton website (www.fulton.co.uk/support/downloads) or consult Fulton Ltd.

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APPENDIX - A

FB SeriesDimensions & Specification

Technical InformationSheet No. 129 Issue 3

Dimensions

Page 1 of 2

MODEL: FB SERIES FB-S FB-C200 300 400 500 650 800 1000 1300 1650

A Minimum Clearance* 3320 TBC TBC 3930 TBC TBC TBC TBC TBCB Overall Width 1820 2352 2403 3037 3068 3058 3520 3620 3770C Overall Length (with burner) Dependant on burner selectionD Overall Height 2370 2470 2711 3264 3146 3144 3516 3916 4015E Boiler Length (without burner) 4650 6541 6250 6714 7100 7850 7205 8560 8560F Base Frame Width 1465 1566 1816 2150 1976 1976 2180 2230 2450G Pipe/Tube Withdrawal Distance 4000 5316 5026 4916 6026 6776 6200 7210 7210H Rear Door Opening N/A N/A N/A 1350 1380 1455 1560 1660 1735

* Recommended height for service & maintenanceNote: Dimensions mmNote: Dimensions are approximate and only intended as a guide to aid installation.

C

D

A

B

E

F

G H

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APPENDIX - A

Specification TI-129-FB-DS-2015-3

Page 2 of 2

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: sales@fulton.co.uk Website: www.fulton.co.uk

Fulton Ltd5 Fernhurst Road, Fishponds, Bristol.BS5 7FG. England.

FM 28400

003

FM 28400

MODEL: FB SERIES UNITFB-S FB-C

200 300 400 500 650 800 1000 1300 1650CE marked to PED and designed to BS EN 2790GeneralSteam Output F & A 100 °C kg/h 3133 4699 6266 7810 10 000 12 000 15 000 20 000 25 000kW Rating kW 2000 3000 4000 5000 6500 8000 10 000 13 000 16 500Operating Pressure barg 12.8 12.8 12.8 10.34 10.34 10.34 10.34 10.34 10.34WeightShipping Weight* kg 9200 15 200 17 800 23 000 25 000 30 000 40 000 48 000 52 000Operational Weight kg 14 100 22 400 26 100 40 700 42 800 50 000 63 000 77 000 82 000Water Content L 4900 7200 8300 17 700 17 800 20 000 23 000 29 000 30 000Gas PressuresMin. Natural Gas Modulating mbar Dependant on burner selectionMin. Natural Gas On/Off mbar Dependant on burner selectionMax. Natural Gas mbar Dependant on burner selectionMin. LPG mbar Dependant on burner selectionMax. LPG mbar Dependant on burner selectionFiring RateNatural Gas m3/h 236 371.1 436.1 557 695 838 1050 1400 1777LPG/Propane m3/h TBC 149 175 223 278 336 420 560 711Light Oil L/h 221 260 346.6 443 553 665 834 1113 1412Heavy Oil L/h TBC 265.5 354.2 453 565 680 853 1137 1443Ventilation Requirements for Combustion Purposes (Free Area)Low Level inlet cm2 10270 21 100 24 800 31 500 39 200 47 800 59 200 78 800 100 000High Level Outlet cm2 5135 10 550 12 400 15 750 19 600 23 900 29 600 39 400 50 000Electrical Requirements**FLC 400 V 3 ph 50 Hz A/ph 13.6 TBC TBC 44 TBC TBC TBC TBC TBCFLC 230 V 1 ph 50 Hz A TBC TBC TBC 16 TBC TBC TBC TBC TBCConnection Sizes All threads BSP F= Female, M=MaleSteam Outlet DN 100 100 150 150 150 200 200 200 250

Safety Valve Discharge DN 80 x 2 65 x 2 65 x 2 100 x 2 100 x 2 50,65 x 2 80 x 3 100 x 2 125,100

Feedwater Inlet DN 32 40 40 50 50 50 65 80 80Feedwater Pump Inlet DN 32 40 40 50 50 50 65 80 80Blowdown, Boiler DN 40 x 2 40 x 2 40 x 2 40 x 2 50 x 2 50 x 2 50 x 2 50 x 2 50 x 2Blowdown, Water Level Gauge (Sight Glass) DN 8 8 8 8 8 8 8 8 8

Blowdown, TDS DN 25 25 25 25 25 25 25 25 25Flue Outlet DN 450 500 560 560 650 650 750 850 900Gas Inlet DN TBC 65 65 80 80 100 100 125 125

* Shipping weight does not include the burner system ** Electric requirement is based on the standard fittings

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APPENDIX - A

FB Series Probe Lengths

Technical InformationSheet No. 141 Issue 1

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: sales@fulton.co.uk Website: www.fulton.co.uk

Fulton Ltd5 Fernhurst Road, Fishponds, Bristol.BS5 7FG. England.

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Note: Dimensions in mm.Note: Dimensions are approximate and only intended as a guide to aid installation.

Note: Water levels and probe lengths should be noted on commissioning and recorded with the boiler. Probe lengths are nominal and must be checked against the requirements of each individual boiler to achieve 30 mm of water visible in the water level gauge (sight glass) at 2nd. Low Water.

Note: All probe lengths are measured from the underside of the hex. nut.Replacement probes are supplied at a standard length and should be cut to the same length as the probe being replaced.

MODEL: FB SERIES 200 500Pump OFF 390 500

Pump ON 440 550

1st. Low Water 470 600

2nd. Low Water 485 615

High Water 320 430

WARNING

The 2nd. Low water at 30 mm in the water level gauge (sight glass) must not be changed.

!

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APPENDIX - A

Horizontal Steam Boilers Recommended Water Conditions

Technical InformationSheet No. 140 Issue 1

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: sales@fulton.co.uk Website: www.fulton.co.uk

Fulton Ltd5 Fernhurst Road, Fishponds, Bristol.BS5 7FG. England.

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IMPORTANT

It is very important that a strict water management program is followed to ensure trouble free boiler operation.

The following are recommended for feedwater and for boiler water

FEEDWATER (water entering boiler)pH Value 8.5 to 9.5 tested at room temperature.Hardness Less than 2.0 mg/kg in the form of CaCO3.Suspended Solids NoneChloride Less than 50 mg/kg.Organic Matter Less than 5 mg/kg.Oil NoneMinimum Temperature 85 °C

BOILER WATER (water inside boiler)pH Value 10.5 - 12.0, tested at room temperature.Hardness Not detectable.Suspended Solids Less than 200 mg/kg.Chloride Less than 500 mg/kg.Oxygen Scavenger, Sodium Sulphite or Tannin 30 to 70 mg/kg.Phosphate Less than 50 mg/kg, in the form of PO4.Total Alkalinity Less than 1000 mg/kg.Caustic Alkalinity Minimum 300 mg/kg as CaCO3.Total Dissolved Solids (TDS) Less than 3500ppm.Iron Less than 1 mg/kg.Silica Less than 150 mg/kg, in the form of SiO2.Dissolved Oxygen None

KEYmg/kg = Milligrams per Kilogram

CaCO3 = Calcium Carbonate

PO4 = Phosphate

SiO2 = Silicon Dioxide

PPM = Parts Per Million

1 Grain hardness = 17.118 ppm

therefore 70 ppm = 4.10 grains hardness

For practical purposes mg/kg = ppm

It is critical that the boiler water pH be alkaline in the range 10.5 - 12.0.

Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids (TDS).

Consult your water treatment specialist to establish the frequency and duration of blowdown required to achieve the required conditions.

!

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Page 54

APPENDIX - A

Water Level Probes Replacement

Technical InformationSheet No. 103 Issue 3

Page 1 of 2

Standard Probes (brass)

The Terminal & Securing Nuts are tightened to a specified torque during manufacture which causes the PTFE Insulation to seal against the probe body. Therefore these nuts must not be adjusted because the seal will be broken which may cause the probe to leak (see Figure. 1).

Angle Rajah ONLY must be used to connect wire to the probes because they clip directly to the Terminal Nut. Spade Connectors must NOT be used because the Terminal Nut would require adjustment and therefore cause the probe to leak (see Figure. 2).

N.B. The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture, meaning the probe is ready to be installed without any adjustment.

The ONLY instance a spanner should be used, is to turn the Probe Body in order to remove or reinstall the entire probe.

IMPORTANT

Terminal and securing nuts must not be adjusted.

Only Angle Rajah are to be used to connect wire to the probes.

!

Terminal nut

Probe body

Probe rod

Securing nuts

PTFEInsulation

Probe rodgrub screw

Probe rodlock nut

Terminal nut

Angle rajah

Probe body

Probe wire

Probes are supplied in a standard length and should be cut to the length required, (the length of the probe being replaced) ensuring measurements are taken from the underside of the probe hexagonal nut, remove any burrs caused by cutting.

Figure. 1 - Water Level Probe Components Figure. 2 - Angle Rajah Fitted to Probe

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APPENDIX - A

High Integrity Probes (stainless steel) TI-103-WaterLevelProbes-2015-3

Page 2 of 2

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: sales@fulton.co.uk Website: www.fulton.co.uk

Fulton Ltd5 Fernhurst Road, Fishponds, Bristol.BS5 7FG. England.

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The probe is supplied in two parts, the head and the tip. The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head.

Locate the pin provided into the slot/hole and secure with the lock nut.

Using the measurement from the old probe, cut the new probe to length and de-burr. Ensure both measurements are taken from the underside of the hex. nut on the probe head.

Figure. 3 - High Integrity Water Level Probe

Ensure measurements are taken from the underside of the hex. nut on the probe

head.

Align the hole in the probe head with the bottom of the

slot in the probe tip. Hold the probe head secure whilst fitting the probe tip.

Locknut Locate the pin in the hole/slot and secure with the locknut.

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Page 57Page 57

Material & Workmanship Guarantee

General GuaranteeThe Fulton general guarantee is given in lieu of and in exclusion of any warranty expressed or implied, statutory or otherwise, as to the state, condition, performance, quality or fitness ofthe goods. Save thereunder we shall be under no obligation or liability of any kind to you in regard to the goods. In the case of new goods manufactured and supplied by us we will make good any defect developing therein under proper use within 12 months of delivery, provided that after investigation in our sole discretion we are satisfiedthatthedefectarosefromfaultydesign,materials or workmanship and from no other

cause whatsoever. Defective goods or parts must be returned to us as soon as possible after discovery of the defect. Costs of carriage and of detaching and incorporating parts will be borne by you. In all cases at the termination of such 12 months all liability on our part will cease. No liability whatsoever is to be incurred by us in respect of gauge or sight glasses, packing glands or electric motors or any goods or accessories not of our manufacture. But so far as we are able, we shall let you have the benefitofanyguaranteeorwarrantygiventousin respect thereof.

On the Fulton Boiler Pressure Vessel

Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within three (3) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the manufacturer’s handbook. This guarantee does not cover damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions.

This guarantee is good only in the United Kingdom of Great Britain and Northern Ireland. This guarantee does not include labour or delivery charges of any kind.

FU LT O N LT D

3 YearG U A R A N T E E

www.fulton.co.uk

Fulton Ltd5 Fernhurst RoadFishpondsBristol BS5 7FGEngland

Telephone: +44 (0) 117 972 3322Fax: +44 (0) 117 972 3358Email: sales@fulton.co.uk

FM 28400

003

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