Fulton Steam Horizontal Boiler FB-S Series 100-800 Hp Installation, Operation and Maintenance Manual Serial # __________________________ Model # __________________________ Fulton Order # __________________________ Sold To __________________________ Job Name __________________________ Date __________________________ The Fulton Companies 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Table of Contents 13. Boil-out of new unit Introduction Section 1 – Safety Warnings & Section 4 – Controls & Burner 1. Boiler control panel Precautions 2. Burner Section 2 – Description & Section 5 – Operation Introductions 1. Fitting the boiler 1. General 2. Specifications & Dimensions 2. Starting the burner 3. Daily operating test Section 3 – Installation 1. Locating the boiler 2. Boiler room ventilation 4. Blowdown procedure 5. To shutdown the burner 6. Evaporation test 7. Fault finding 3.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Introduction This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.
All units are crated for crane lift transport. Under no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of the boiler. The customer should examine the boiler for any damage, especially the refractories around the burner. Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy equipment.
Section 1 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 1 – Safety Warnings & Precautions The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis. • 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.
CAUTIONS o A temperature exceeding 100 F in the boiler room may cause premature failure of electrical components on the boiler control panel. The water chemistry in the boiler must be kept within limits outlined in this manual. Failure to do so will likely cause premature boiler pressure vessel failure and poor steam quality. o Boiler feed water temperature must be 140 F or greater to prevent corrosion fatigue cracking at the feed water nozzle.
boiler insulation. This is a normal condition and does not affect the efficiency or the life of the boiler in any way. All secondary low water trips, flame failure trips or high steam pressure trips will require, by code, a manual reset at the boiler. The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 2 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 2 – Description & Introductions 1. General a) Fulton model FB-S is a three-pass, water back and corrugated furnace design steam boiler. In the first pass, the flame and high temperature flue gas flows from the front to the back of the furnace. Through the second pass pipes, high temperature flue gas flows from the combustion furnace to the front chamber. In the third pass, the flue gas passes through the third pass pipes to the back of the boiler and vents out.
2.
Section 3 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 3 – Installation General Note It is essential that the installing shall be undertaken only by suitably qualified and experienced personnel. Installation should comply with appropriate local and state codes and standards. 1. Locating the Boiler a) The boiler should be closed in dry surroundings on a level base, making sure that there is sufficient room around the boiler to enable the operator and/or the maintenance engineer to gain access to all parts of the boiler.
2. Boiler Room Ventilation a) It is most important to provide free access of air to the boiler. To burn fuel properly, it requires one square inch opening of fresh air for every 3, 000 BTU input of fuel. b) Proper ventilation of the boiler room is essential for good combustion. Install two make up air openings, one at a low level (24” or 610mm from floor) and one at a higher level in the boiler room wall. This will provide a flow of air to exhaust the hot air from the boiler room.
d) If more than one appliance is connected to a common flue or chimney the crosssection of the chimney should be adequate for the total volume of combustion products from the appliances. e) The total horizontal run of the boiler flue should not exceed 25% of the total vertical rise. There should be an angle more than 15 degrees for the horizontal run reducing the resistance of the combustion products and avoid rusting by accumulating condensation in the flue.
+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible. ++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or orange tinge. ND: None Detected. 5.
only in the boiler proper, but also in pre-boiler equipment such as ecomomizers, feedwater tanks, and feedwater lines. b) Sodium Sulfite: Its purpose is to chemically remove the dissolved oxygen left in the feedwater after the feedwater has been mechanically deareated. Sodium Sulfite reacts chemically with dissolved oxygen, producing sodium sulfate. Since it is desirable to remove dissolved oxygen from the feedwater before it reaches a boiler.
caustic embrittlement. In order to control boilers and equipment used for the external treatment of make up water, it is essential that reliable pH measurements be made. RO/DI water will have a pH of 6.0 - 6.5 and will require neutralization if used in a carbon steel vessel. f) Chlorides: If chloride levels are high enough to cause severe corrosion, they can be controlled by limiting the cycles of concentration and increasing boiler blowdowns.
7. Valves a) Pressure Gauge: the pressure gauge is above the panel box, which is installed on the right hand of the boiler. A three-way valve is fitted with the pressure gauge, to assist drain off regularly. b) Main Steam Valve: the main steam valve is installed on the top of the boiler. It will be connected with the steam pipe work to all kinds of equipment, which consume steam. There should be enough outlet for drain off and flush in the pipe work.
c) The gas supply piping to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriate Codes and Standards. It should be of sufficient size to satisfy the pressure and volume flow requirements of the burner under all firing conditions. Checks should be made to ensure that all meters and other components are appropriately rated for the maximum gas flow rate anticipated.
Example: From the chart we can see that a ¾” line that is 80’ in length can supply 118,000 BTU/hr. 10. 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 appropriate Codes and Standards. It should be of sufficient size to satisfy the pressure and volume flow requirements of the burner under all firing conditions.
Open all necessary oil shut-off valves. Do not run compressors, pumps, or metering units without oil. f) Before connecting electrical current to any component, be sure the supply voltage is the same as that specified on the component nameplates. g) Make certain that the operator in charge is properly instructed in the operation and maintenance procedures. Note The pressure vessel must be cleaned before running the boiler after installation. 12.
1. Cleaning has been inadequate. 2. Partial or total old system is involved. 3. Conditions may prevent adequate clearing of piping. d) The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal internal conditions and serve as a check against conditions indicated by chemical analysis of the boiler water. Inspection should be made three months after initial starting and at regular 6-, 9-, or 12-month intervals thereafter.
because they lower the heat transfer rate and could cause over-heating of a tube. Before boiling out procedures may begin, the burner should be ready for firing. The operator must be familiar with the procedure outlined under burner operation. Warning Use of a suitable facemask, goggles, rubber gloves, and protective garments is strongly recommended when handing or mixing caustic chemicals. Do not permit the dry material or the concentrated solution to come in contact with skin or clothing.
Warning Be sure to drain the hot water to a safe point of discharge to avoid scalding. Failure to follow these instructions could result in serious personal injury or death. xiii. Remove hand-hole plates. xiv. Inspect the surfaces. If they are not clean, repeat the boil out. xv. After closing the hand-holes and reinstalling the safety or relief valves, fill the boiler and fire it until the water is heated to at least o 180 F to drive off any dissolved gases, which might otherwise corrode the material.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 4 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 4 – Controls & Burner The following brief description of the fittings and controls used on the FB-S boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient use of the boiler. 1. Boiler Control Panel a) Boiler controls and indicators are housed in a control panel mounted on the side of the boiler. These controls are as follows: i.
b) Low Water Indicator i. This lamp will be illuminated and an alarm sounded when the water level, st as sensed by an internal probe, in the boiler falls to the 1 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. c) Low Water Alarm/Reset Switch i. Sounds and alarm on switch on, press to reset.
100mm diameter standpipes mounted on top of the boiler center line towards the front of the boiler. A standard boiler is fitted with Feedwater st nd pump On/Off, 1 Low Water, 2 Low Water and High Water probes. st 1 LWCO 2 nd LWCO Pump Off Pump On High Water Note If the Level Control System is a float type or pressure differential transmitter, then refer to specific spec sheets located in this manual. f) Steam Pressure Controls i.
High Limit w/ Manual Reset Operating Limit Modulating Control Note Boiler may be supplied with PID type pressure controls in lieu of on/off and high/low pressure switches. g) Burner Programmer i. Is located in the center of the control panel. Acts in conjunction with a sensing device to ‘supervise’ the ignition sequence, prove the flame is satisfactory and finally ‘monitor’ the established flame.
Possible Burner Options for FBS a) Air Pressure Switch i. Mounted on the burner, this switch is operated by the pressure of air entering the burner though the throat of the scroll. Lack of combustion air, or insufficient air pressure, will stop the switch completing the circuit, preventing the burner from operating. b) Air Damper Servomotor i. The combustion air control system including air damper and a servomotor. The servomotor is mounted on the burner and directly coupled to the air damper blade.
e) Oil Pre-heater Tank (for heavy oil burners) i. The oil preheater tank is mounted on the heavy oil burner ahead of the fan housing. Its function is to preheat the oil to correct temperature. The unit is equipped with three thermostats, ‘low temperature’ ‘operating’ and ‘limit’. A thermometer and hot oil filter are mounted together as one unit on the top left-hand side of the preheater tank viewed from the rear of the burner. f) Air Pressure Switch i.
i) Valve Proving System i. A valve proving system, as show schematically below, is standard on the FB-S Boilers. When the boiler operating sequence is initiated, the burner control box energizes 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.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 5 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 5 – Operation Boiler starting STOP! Make sure you have read any followed all previous safety information. Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required. In general, ensure that the boiler area is in conformance with established boiler room requirement. Review national and local codes.
Note nd If the 2 Low Water and High Pressure Alarm/Reset switch 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 feed water pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection 2. Starting the Burner From Cold a) Fill the boiler as described in Section 1. b) SHUT the main steam valve.
temperature and by the heat transfer rate and gas temperature. The tube temperature lies between the shell and furnace temperature, but is nearer the shell temperature. Since all these components are virtually the same length, they expend longitudinally by different amounts causing mechanical and thermal stress. Whilst this is catered for in mechanical design of the pressure vessel, the life expectancy of the boiler can be affected if the boiler is frequently heated to quickly from cold.
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.
b) Pump Check i. Lower the water level in the boiler, either by evaporation or by opening the main blowdown valve with the key provided. ii. Observe the water level in the water level gauges and, as the water level falls, check that the feed water pump starts. iii. SHUT the main blowdown valve if opened, and ensure that the feed water pump continues to fill the boiler to the correct level then switch off. st c) 1 Low Water Check i.
st b. The 1 Low Water alarm cancels c. st The 1 Low Water indicator lamp extinguishes but the burner does not start d. The 2nd Low Water alarm continues to sound nd e. The 2 Low Water Alarm/Reset Switch remains illuminated v. Press the 2 nd Low Water Level Alarm/Reset Switch. vi. Check that: nd a. The 2 Low Water alarm cancels b. The 2nd Low Water Alarm/Reset Switch extinguishes c.
Note As well as removing sludge 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, it dependent on the amount of TDS in the raw water supply, the percentage condensate return, water treatment chemicals added and the number of the hours a day operation.
Medium Term (days) a) Turn the Burner On/Off/Reset Switch on the Burner Control Panel to OFF. b) The burner will stop firing, post-purge and then stop. c) SHUT the main steam valve. d) SHUT the water feed valve. e) Turn the power isolator On/Off switch on the Boiler Control Panel to OFF. Note: Ensure the boiler water treatment levels for dissolved oxygen are within specified limits.
Low Water alarm. This is normal and typical of ‘priming’ where a boiler tries to maintain an overload condition resulting in unstable water conditions. 7. Fault Finding Before calling the Fulton Service Department, check the following: a) Gas isolating valve(s) OPEN (gas and dual fuel burners). b) Oil isolating valve(s) OPEN (gas and dual fuel burners). c) Oil storage tank contains an adequate level of fuel. d) Oil filer(s) are not blocked. e) Water feed line from feed tank/hotwell is OPEN.
Fault Finding Table Problem Solution 1. No voltage at program relay power input terminals. a) Main disconnect switch open. b) Blown control circuit fuse. c) Loose or broken electrical connection. 2. Program relay safety switch requires resetting. 3. Limit of circuit not completed-no voltage at end of limit circuit program relay terminal. a) Burner does not start Pressure of temperature is above setting of operation control. b) Water below required level.
1. Insufficient pilot flame. 2. Gas fired unit a) Manual gas cock closed. b) Main gas valve inoperative. c) Gas pressure regulator inoperative. 3. Oil fired unit a) Pilot flame, no main flame Oil supply cut off by obstruction, closed valve, or loss of suction. b) Supply pump inoperative. c) No fuel. d) Main oil valve inoperative. e) Check oil nozzle, gun and lines. 4. Flame detector defective, sight tube obstructed or lens dirty. 5.
1. Check oil supply in the supply tank. Check for clogged nozzle. Clean or replace it. Check oil filter and replace if necessary. Boiler will not maintain pressure 2. Check gas supply. 3. The flue is too dirty. Clean it. 4. Check the steam pressure switch, reset it if necessary. 5. Steam is overloaded, reduce it. 1. Check the connection of water probe. Water pump does not start or stop manually 2. Check and clean the water probe. 3. Check the water level relay, if necessary replace it. 1.
Section 6 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 6 – Maintenance 1. General Maintenance To ensure the continuing efficiency of the boiler, regularly carry out regular routine maintenance procedures as detailed below. IMPORTANT: If any fault is found during these procedures, shut down the boiler immediately and consult The Fulton Companies. Note It is essential that regular checks are made to ensure scale build-up is not taking place within the boiler.
2. Weekly Maintenance Warning All steam pipe work, valves and fittings will be very hot. Do not operate the safety valve without protection. Check 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 the Section for fitting procedures for new gaskets). Corrective action taken as soon as a leak occurs can prevent costly repairs later.
3. Six Month Maintenance Warning The boiler must be completely cold before carrying out any of the following procedures. a) Ensure that the following valves are SHUT: i. The main steam stop valve ii. The feed water isolating valve iii. The fuel (gas/oil) valves b) Ensure that the power supply to the boiler is switched OFF. 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.
i) Remove the rear smoke box access doors. j) Brush through the tubes to remove any deposits from the products of combustion. k) 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). l) Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas re-burning in the tube ends as a result of poor combustion, e.g. carbon monoxide carry-over.
v) Carry out routine maintenances 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. 4.
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. The boilers are fitted with TOPOG-E gaskets in all the inspection holes of the boiler. 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.
b) Pace the new Topog-E gasket on the cover plate, ensure the gasket is the correct size and is seating flat against the plate. Do not use any grease, lubricant or adhesive. If the new gasket is not seated properly before the plate is tightened, the gasket may be pinched causing a failure when the pressure builds up. c) Position the cover plate in the boiler ring, ensuring that the plate is correctly centered. An off-centre cover plate can concentrate forces on the gasket and cut it in two.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Section 7 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Standard Warranty for Fulton Boilers Warranty Valid for Models FB-S, FB-C, FB-D Three (3) Year (36 Months) Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of three (3) years from the date of shipment from the factory. Fulton will repair or replace F.O.B.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
Extended Warranty for Fulton Skid Mounted Steam Boilers Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S Ten (10) Year Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of ten (10) years from the date of shipment from the factory. Fulton will repair or replace at our option, F.O.B.
08/20/10 The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems. The Fulton Companies*FB-S Series Manual*Version 2010-0820 rev.
