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FULTON BOILER

FB-S SERIES INSTALLATION, OPERATION & MAINTENANCE MANUAL

Fulton Boiler FBS Series

1 FBS 01/05

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.

These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.

The requirements and instructions contained in this section generally relate to the standard Fulton boiler model FBS. When installing a packaged unit, this entire section should be read to ensure that the installation work is carried out correctly.

Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing: a) Material inspections. b) Manufacturing process inspections c) ASME welding inspection. d) ASME hydrostatic test inspection. e) Electrical components inspection. f) Operating test. g) Final engineering inspection. h) Crating inspection.

NOTE The installation of the Fulton Boiler should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association. All state and jurisdictional codes beyond the scope of the applicable ASME boiler and pressure vessel codes, for its corresponding classification, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation. All units are crated for fork lift transport. Once uncrated, all units can be transported with a forklift. Under no circumstances should weight be allowed to bear on the jacket., control panel, or fan housing of any Fulton Boiler. The customer should examine the boiler for any damage, especially the refractories. Rigging your boiler into position should be handled by a competent rigger experienced in handing heavy equipment.


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CONTENT

1 Safety Warnings & Precautions

2 Description & Introductions General Specifications & Dimensions

3 Installation Locating the Boiler Boiler room ventilation Flue and chimney requirements Water supply Valves Electrical Requirements Gas Supply Oil Supply Installation check points Cleaning Boil-out of new unit

4 Controls & Burner Boiler Control panel Burner

5 Operation Fitting the boiler Starting the burner Daily operating test Bolwdown procedure To shutdown the burner Evaporation test Fault finding

6 Maintenance General

Weekly Six monthly Annually Fitting new gasket

7 Warranty


3 FBS 01/05

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 personal. 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, CUATIONS, and NOTES by which hazards are to be reduced or eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.

WARNING Do not operate, service, or repair this equipment unless you fully understand all applicable sections of this manual. Do not allow others to operate, service, or repair this equipment unless they fully understand all application sections of this manual. Failure to follow all applicable warnings and instructions may result in severe personal injury or death.


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Section 2 Description & Introductions

General Fulton boiler standard FB-S model is a three-pass, wet 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; Though 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 stack and vents out. Corrugated furnace highly increases the heat exchange area, heat transfer efficiency and reduces the possible damage to the boiler durability caused by heat expansion and cold contraction. Boiler is designed and manufactured to comply with BS code and Chinese Boiler Standard, with maximum working pressure of 1.0MPa (150PSI) or 1.25MPa (180PSI). The fully packaged boiler has passed the strict test before it is delivered to the customer. The equipment will give long life and excellent service on the job if proper operating and maintenance instructions are followed. FB-S boiler is a cylindrical vessel, with horizontal tubes passing through and connected to the front and rear tube sheets. The vessel contains the water and absorbs the energy generated from the flame. The front door and rear door provide the seal to contain the hot combustion gasses. Baffles designed into the doors serve to redirect the combustion gasses through the various firetube passages. The flame originates in the furnace. As the combustion gasses travel down the furnace and through the various firetube channels, heat from the flame and combustion gasses is transferred to the water. Transferred energy develops into the required steam or hot water. The front door and rear door make it is easy to clean the combustion chamber. The pressure vessel can be inspected and repaired by the manhole on the top and handholes on the side or bottom. The general information in this manual applies directly to boilers in sizes ranging from 1 ton/hr through 6 ton/hr steam output boiler for the following fuels: Gas No.2-6 Oil No.2 Oil and Gas Boiler equipped with fully automatic burner for two-stage operation, the fully modulating burner can be supplied on customer’s requirement.


5 FBS 01/05

Specifications & Dimensions

Specifications

Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25

Nominal steam output�T/h � 1.0 1.5 2.0 3.0 4.0 4.0 6.0

Operating pressure�MPa � 1.0 1.0 1.0 1.0 1.0 1.25 1.25

Operating steam temperature�� 184 184 184 184 184 194 194

Inlet water temperature �� 20 20 20 20 20 20 20

Water pump electric power (Kw) 2.2 2.2 2.2 3.0 3.0 4.0 5.5

Maximum fuel consumption

Light oil (Kg/h) 60.9 91.4 121.8 182.7 243.6 244.4 365.6

Heavy oil (Kg/h) 62.2 93.3 124.4 186.6 248.8 249.7 374

Natural gas (m3/h) 76.6 114.9 153.2 229.8 306.4 315.3 445

Town gas (m3/h) 189.4 284.1 378.8 568.2 757.6 778.7 1099.1

Note: 1) All steam output (kg/hr) ratings from 0 MPa at 100 , fuel consumption based on light oil 1,1200 Kcal/kg, heavy oil �

10,960 kcal/kg, nature gas 8,900 kcal/m3, town gas 3600kcal/m3.

2) Specification and dimensions are approximate, the Fulton Companied reserve the right to change specifications or

dimensions.

Connection

Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25

Main steam valve DN50 DN65 DN65 DN100 DN100 DN100 DN125

Safety valve DN40 DN40 DN40 DN50 DN50 DN50 DN80

Water inlet valve DN40 DN40 DN40 DN40 DN40 DN40 DN50

Drain valve DN40 DN40 DN40 DN50 DN50 DN50 DN50

Flue diameter (mm) 300 350 400 450 500 500 600

Water gauge outlet DN15 DN15 DN15 DN15 DN15 DN15 DN15

Note: 1) The connections of steam valve, safety valve and blow-down valve are all flange connections.

2) If the burners and /or pumps are different, the boiler electrical usages are also different, please based on the finally

drawings.

3) Specifications and dimensions are approximate. The Fulton Companies reserve the right to change specifications

and dimensions.


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Section 3 Installation

General

NOTE It is essential that the installing shall be undertaken only by suitably qualified and experienced personnel. And it should comply with appropriate Codes and Standards.

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. Check location for ease of water supply and electrical connections.

B) Place the boiler on a non-combustible floor with clearances to unprotected combustible materials, including plaster or combustible supports.

C) It is necessary to have enough clearance from the floor to the ceiling for removing of the burner and have the following clearance from boiler for servicing:

Dimensions of the boiler and the necessary clearance

Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25

Total length(mm) 3324 3624 4072 4772 4956 4956 5540 Total width(mm) 1705 1785 2100 2196 2170 2170 2700 Total height(mm) 1955 2040 2335 2490 2542 2546 3000 For pipe changing(mm) 3300 3300 4300 4500 4700 4700 5300 Front of boiler(mm) 3000 3000 3000 3000 3000 3200 3200 Two sides of boiler(mm) 1500 1500 1500 1500 1500 2000 2000 Back of boiler(mm) 1500 1500 1500 1500 1500 2000 2000

Boiler Room Ventilation A) It is most important to provide free access of air to the boiler. To burner fuel properly, it

requires one square inch opening of fresh air for every 3,000 BTU input of fuel. (6.4cm2 for every 56 Kcal).

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.

C) The following openings are the recommended for each size boiler:


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Recommended minimum opening

Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25 Minimum area (m2) 0.7 1.0 1.5 2.1 3.0 3.2 4.5

Be sure total BHP= proper make up air opening size. For instance if you have three 300 BHP boilers, it is a total BHP of 900, and the 900 BHP make up air opening size is recommended.

NOTE These measurements are subject to state and local regulations. The installation of exhaust fans in a boiler room is not recommended. An exhaust fan can create down draft in the stack or restrict the burner’s air supply which will result in poor combustion. It is essential that only fresh air is allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint, in the combustion system can create hazardous conditions. Flue and Chimney Requirements A) The flue from the appliance and the joint between this flue and the chimney are sealed to prevent

leakage of combustion products. B) The top of the flue or chimney shall be higher than any roof within a radius of 10 meters. C) Checks are made to ensure that the chimney is suitable for burner and that the proposed

installation complies with the local authority and other regulations covering such installations. D) If more than one appliance is connected to a common flue or chimney the cross-section 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 have a angle more than 15 degrees for the horizontal run. Reducing the resistance of the combustion products and avoid rusting by accumulating condensation in flue.

F) The installer should check the draft with a meter at -.02-.04” W.C. pressure (-0.508 to -1.016mm) with the burner off. If the pressure is too low, a balancing damper should be located close to the flue outlet to regulating the pressure of the draft.

Water Supply A. General

The operator should be familiar with this part before attempting to place the unit into operation.

Although it is of prime importance, the subject of water supply and treatment cannot adequately be covered in this manual. For specific information or assistance with your water treatment requirements, contact your boiler service and parts representative.

Feed water equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and receivers are installed in accordance with prevailing codes and practices.

Water requirements for steam boilers are essential to boiler life and length of service. It is vital that care be taken in placing the pressure vessel into initial service. The waterside of new boilers and new or remodeled steam or hot water systems may contain oil, grease or other foreign matter. A method of boiling out the vessel to remove the accumulations is described later in this part.

Boilers, as a part of a hot water system, require proper water circulation. The system must be operated as intended by its designer in order to avoid thermal shock or severe, possibly damaging, stresses from occurring to the pressure vessel. B. water treatment Feed water contains solids and dissolved gases. These may promote incrustation of scale; foaming, priming, surging, and solids in steam; corrosion and pitting; or caustic embrittlement. To prevent this, feedwater must be studied individually and treated accordingly by reputable professionals specializing in this field. It is strongly recommended that a competent water treatment company be


FBS 01/05 8

consulted prior to the installation of the boiler. The purpose of this treatment should be to provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized. Dissolved oxygen, high chloride levels and low PH can all be major causes of corrosion. Untreated hardness is the major cause of deposits. Poor quality feedwater requires increased blow off and increased chemical treatment cost to prevent boiler corrosion and scaling. The Fulton warranty does not cover damage or failure that can be attributed to corrosion, scale or dirt accumulations. Oxygen is a corrosive. See the warranty section of this manual for full details. Following are recommendations for feed water and boiler water. Contract your local water treatment professional for testing and treatment recommendations. It is very important that a strict water treatment program be followed. Feed water Total dissolved solids …………………….. � 5 mg/l Hardness .………………………………… � 0.03mmol/l PH Valve……………………………………. � 7 (25 � ) Dissolved Oxygen………………………… � 0.1 mg/l Oil …………………………………………… � 2 mg/l Boiler water Total Alkalinity ……………………………..6-26 mmol/l PH Valve…………………………………….10-12 (25 � ) Dissolved Oxygen………………………….none

Properly treated boiler feed water, coupled with good engineering and operating practices, lead to maximum effectiveness and long trouble-free life of pressure vessels, at the lowest operating cost. Contact your local authorized boiler representative for information on how to prevent the presence of unwanted solids and corrosive gases.

Accomplishment of the above objectives generally requires proper feed-water treatment before and after introduction of the water into the boiler. The selection of pre-treatment processes depends upon the water source, its chemical characteristics, amount of makeup water needed, plant operating practices, etc. Treating methods filtering, softening, de-mineralizing, deaerating, and preheating. After-treatment involves chemical treatment of the boiler water.

Because of the variables involved, no single boiler compound can be considered a “cure-all” nor is it advisable to experiment with homemade treating methods. Should recommendations and their employment should be augmented by a periodic analysis of the feed-water, boiler water, and condensate.

The internal or waterside surfaces of the pressure vessel should be inspected with enough frequency to determine the presence of any contamination, accumulations of foreign matter, or corrosion, and/or pitting. If any of the conditions are detected, contact your local authorized boiler representative for advice on corrective action.

A properly sized water meter should be installed in the raw water make-up line in order to accurately determine the amount of raw water admitted to the boiler (steam or hot water) and to aid in maintaining proper waterside conditions.

Valves

A) Pressure gauge

The Pressure gauge is above the panel box which installed on the right hand of the boiler. A three-way valve is fitted with the pressure gauge, to assist drain off regularly.


9 FBS 01/05

B) Main steam valve

The main steam valve is installed on the top of the boiler. It will be connected with the steam pipework to all kinds of equipments which consume steam. There should be enough outlet for drain off and flush in the pipework.

C) Safety valve

The safety valve is installed on the top of the boiler. Its setting was finished by the manufacturer before delivery; do not attempt to change the setting without permission of Fulton or authority. The function of the safety valve is avoid the pressure in the boiler exceed the design value. Any equipment connect with the boiler should can run under the boiler pressure. If not, another safety valve must be used for protecting it.

CAUTION

The safety valve supplied by manufacturer can only protect the boiler, it can not protect any other equipments in the system.

D) Water level gauge

Two plate water level gauges are equipped to Fulton boiler FB-S model. Boiler operator can see the water level in side the boiler from these gauges. Both of them are connected to a 1/4” copper pipe which drain water can flow through to assistant pipework. Electrical Requirements� A) Connect wiring as shown in the wiring diagram which is furnished inside the electrical control

panel box. B) Electrical power available is usually 230/460 volt, 3 phase, 60 HZ or 380 volt, 3 phases, 50 HZ. Gas Supply Natural gas is the standard gas for the gas boiler. Special requirements on request- i.e. liquid petroleum gas, town gas. Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and furnace while running at full input. This pressure is different from the kinds of the burner used for the boiler. On FB-S1-1.0 to FB-S3-1.0, the pressure of supply gas is 50-100 mbar.; on FB-S4-1.0 to FB-S6-1.25, the pressure of supply gas is 100-130 mbar, the pressure must be checked and make sure it is high enough. If it is too low, a gas booster must be used in the gas supply system. When a gas booster is used, the gas pressure at the booster inlet must not fall below 100 mbar. The booster should be installed as near to the burner as possible. It should be positioned on a firm, flat, horizontal surface using anti-vibration mountings. All connecting pipework should be well supported and accurately positioned in order to avoid stressing the booster casting. The use of flexible connections, which reduce both pipework stresses 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 pressure and flow are available. The gas supply pipework 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.

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 bruner control train in order to avoid any restriction in gas flow.


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WARNING It is essential that the installation of the gas pipework must be undertaken only by suitably qualified and experienced personnel and in compliance with appropriate Codes and Standards. Fulton Companies can accept no responsibility for consequential loss, damage or personal injury which results from a failure to follow the manual. Oil Supply The oil supply pipework 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 oil flow rate anticipated. Galvanized steel pipe should not be used. The supply pipework should include an appropriate filter. A) A two-pipe system must be used between 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 from the storage tank to the burner. A oil filter must be installed before the oil circulating pump, recommend less than 60 Mesh.

B) The final connection to the oil pump inlet should be made using the flexible pipes supplied with

the burner. C) One gate valve should installed to the inlet and outlet of the circulating pump separately. A

pressure gauge (0-60psi) is needed also to the outlet. D) It is important to ensure that the return pipe is not obstructed as this may result in damage to the

pump. E) In the case of heavy oil (No.4, No.5, and No.6 oil) the pipework and oil storage tank should be

insulated trace heated and thermostatically controlled. Refer to the details in the BURNER section Installation Check Points A) Make sure that all piping connections are complete and tight. B) Make sure the pressure controls are adjusted properly. C) Make sure all electrical connections in the control box, the water column, and elsewhere are

secure. D) Make sure the door in the boiler room is closed. Combustion air contaminates can cause damage

to the boiler jacket and stack. Before operating pumps, metering heads and compressors, make certain that reservoirs are properly filled with the specific lubricant. Open all necessary oil shut-off valves. Do not run compressors, pumps, or metering units without oil. Before connecting electrical current to any component, be sure the supply voltage is the same as that specified on the component nameplates. 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


11 FBS 01/05

Cleaning

A�STEAM PIPING

Steam and water piping systems connected to the boiler may contain oil, grease, or foreign matter. The impurities must be removed in order to prevent damage to pressure vessel heating surfaces. On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities. During the period that condensate is wasted, attention must be given to the treatment of the raw water used as make-up so that an accumulation of unwanted materials or corrosion does not occur. For more information, contact your local authorized boiler representative.

On a hot water system, chemical cleaning is generally necessary and the entire system should be drained after treatment. Consult your local authorized boiler representative for recommendations, cleaning compounds, and application procedures.

B�PRESSURE VESSEL

The waterside of the pressure vessel must be kept clean from grease, sludge, and foreign material. Such deposits, if present, will shorten the life of the pressure vessel, will interferer with efficient operation and functioning of control, of safety devices, and quite possibly cause unnecessary and expensive re-work, repairs, and down-time.

The installation and operating conditions that the boiler will be subjected to should be considered and cleaning of the waterside of the pressure vessel should be provided during the course of initial start-up.

The pressure vessel and the steam and return lines or hot water piping represent, in effect, a closed system. Although the steam and return (condensate) lines or hot water piping system may have been previously cleaned, it is possible that:

(1) Cleaning has been inadequate.

(2) Partial or total old system is involved.

(3) Conditions may prevent adequate cleaning of piping.

The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal true 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. The frequency of further periodic inspections will depend upon the internal conditions found.

If any unwanted conditions are observed, contact your local authorized boiler representative for recommendations.

Any sludge, mud or sediment found will need to be flushed out. If excessive mud or sludge is noticed during the blowdown the scheduling or frequency of blowdown may need to be revised. The need for periodic draining or washout will also be indicated.

Any oil or grease present on the heating surfaces should be removed promptly by a boil-out with an alkaline detergent solution.

NOTE

Temperature of initial fill of water for hydrostatic tests, Boil-out, or for normal operation should be as stated in the ASME Boiler Code.


FBS 01/05 12

Boil-out of New Unit

The internal surfaces of a newly installed boiler may have oil, grease or other protective coatings used in manufacturing. Such coatings must be removed 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 face mask, 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. Failure to follow these instructions could result in serious personal injury or death.

Your local authorized boiler representative will be able to recommend a cleaning or boil-out procedure. In the event such service is unavailable or is yet unscheduled, the following information may be of assistance.

There are several chemicals suitable for boil-out. One combination often used is soda ash (sodium carbonate) and caustic soda (sodium hydroxide) at the rate of 3 to 5 pounds each per 1.000 pounds of water, along with a small amount of laundry detergent added as a wetting agent.

The suggested general procedure for cleaning a boiler is as follows:

(1) Have sufficient cleaning material on hand to complete the job.

(2) When dissolving chemicals, the following procedure is suggested. Warm water should be put into a suitable container. Slowly introduce the dry chemical into the water, stirring it at all times until the chemical is completely dissolved. Add the chemical slowly and in small amounts to prevent excessive heat and turbulence.

(3) An over-flow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge. A safety valve tapping is usually used.

(4) Water relief valves and steam safety valves must be removed before adding the boil-out solution so that neither it nor the grease which it may carry will contaminate the valves. Use care in removing and reinstalling the valves.

(5) All valves in the piping leading to or from the system must be closed to prevent the cleaning solution from getting into the system.

(6) Fill the pressure vessel with clean water until the top of the tubes are covered. Add the cleaning solution and then fill to the top. The temperature of the water used in the initial fill should be at ambient temperature.

(7) The boiler should then be fired intermittently at a low rate sufficient to hold solution just at the boiling point. Boil the water for at least five hours. Do not produce steam pressure.

(8) Allow a small amount of fresh water to enter the boiler to create a slight overflow that will carry off surface impurities.

(9) Continue the boil and overflow process until the water clears. Shut the burner down.

(10) Let the boiler cool to 120 � or less. 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.

(11) Remove hand-hole plates and wash the waterside surfaces thoroughly using a high pressure water stream.

(12) Inspect the surfaces. If they are not clean, repeat the boil out.

(13) After closing the hand-holes and reinstalling the safety or relief valves, fill the boiler and fire it


13 FBS 01/05

until the water is heated to at least 180 � to drive off any dissolved gases, which might otherwise corrode the metal.

The above procedure may be omitted in the case of a unit previously used or known to be internally clean. However, consideration must be given to the possibility of contaminating materials entering the boiler from the system.

On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities. During the period that condensate is wasted, be sure make-up water is treated to prevent an accumulation of unwanted materials or corrosion. Washing Out

No later than three months after initially placing the boiler into operation and starting service, and thereafter as conditions warrant, the pressure vessel should be drained after being properly cooled to near ambient temperature. Hand-hole covers should be removed and waterside surfaces should be inspected for corrosion, pitting, or formation of deposits.

Flushing of Pressure Vessel Interior

Upon completion of the inspection, the pressure vessel interior should be flushed out, as required, with a high pressure hose. If deposits are not fully removed by flushing, a consultation may be required with your local authorized boiler representative. In extreme cases, it may be necessary to resort to acid cleaning. Professional advice is recommended if acid cleaning is required.

The inspections will indicate the effectiveness of the feed-water treatment. The effectiveness of treatment, the water conditions, and the amount of fresh water make-up required are all factors to be considered in establishing frequency of future pressure vessel washouts. Contact your local authorized boiler representative for more information.


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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 Boiler controls and indicators are housed in a control panel mounted on the side of the boil. One-phase 220v/50HZ power is available. These controls are as follows: Power Isolator Switch. Control panel power supply ON/OFF switch, mounted on the panel door. Power On Indicator. Indicates that the door isolator is in the ON position and the panel is electrically live.

WARNING The power on the indicator is derived from on phase. It is possible for that the Power On Indicator supply phase to be down, leaving the other two phases live. Always isolate the supply before working on the panel. 1st Low Water Indicator. This lamp will be illuminated and an alarm sounded when the water level in the boiler 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 and alarm on 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 (when fitted). This lamp will illuminate and alarm sound when the water level reaches a pre-determined high level. The feed pump will stop. When the water level falls to the normal working level, the indicator lamp will extinguish and the alarm cancel. 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 requirement of the AOTC and gas supply standards that when the control system is first energized, or re-energized (power restoration), it must go to a fail-safe shutdown position, sound and alarm and require manual resetting to cancel the alarm. The alarm condition, when activated, is cancelled in both position by pressing the 2nd Low Water Alarm and High Pressure Alarm reset switches. PUMP ONLY Position. This position should only be selected to fill the boiler. The normal functions of the level alarm system are overridden to prevent a continuous alarm while the boiler is being filled. The pump off level will function normally and switch the pump off once the correct water level is reached.

NOTE 1) The burner mounted Burner ON/OFF/Reset switch should be in the OFF position during

the filling process. 2) The Pump On/Pump off Switch should be in the PUMP ON position. 3) The power restoration alarms will only sound if the burner mounted Burner On/Off/Reset

switch is left in the 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, feed 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.


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NOTE 1. When selecting this position from either PUMP ONLY or OFF, the power restoration alarms

will be activated. The alarms can be cancelled by pressing the High Pressure Alarm and 2nd Low Water Alarm/Reset switches.

2. 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 feed water pump to restore the water level to the normal working level (approximately mid-way up the sight glass) and the reset the alarm.

Low Water Safety Relays and Feedwater Pump Relays. These 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. The probes are located in two, 100mm diameter standpipes mounted on either side of the boiler centre line towards the front of the boiler. A standard boiler is fitted with Feedwater pump On/Off, 1st Low Water and 2nd Low Water probes. Steam Pressure Controls. Three steam pressure controls are mounted on the side of the control panel. These are as follows: a) Control Pressure On/Off Switch. Controls the on/off cycle of the boiler, 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 pre-set limit causing the High Limit Switch (set a least 0.5 bar 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. Switches the burner from high to low flame and vice-versa. Burner Programmer. Is located in the centre 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. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to ‘lock-out’ and both main and pilot gas/oil valves will shut to isolate the fuel line to the burner. Sequence Manual/Auto Switch (when fitted). 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. Flame Failure Indicator. Indicates the burner combustion control relay, detects a flame failure condition. Hand Indicator (when fitted). This 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 Indicator (when fitted). This lamp will illuminate when the hand/auto switch mounted inside the panel is the auto position. High Pressure Indicator (when fitted). This lamp is not wired when high steam pressure alarm/lamp is provided in the boiler control panel. 2. Burner Fulton boiler FB-S model can mounted with gas burner, oil burner or dual fuel burner on customer’s requests.

OIL BURNER The fuel for the oil burner is from No.2 to No.6 oil. The standard light oil burner for Fulton boiler is No.2 oil. The heavy oil burner can be used for No.4 to No.6 oil. 1) Air Pressure Switch. 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.

2) Air Damper Servomotor. The combustion air control system including air damper and a servomotor. 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


FBS 01/05 16

controls the combustion air entering the burner on the requirement of the boiler heating during operating. The standard servomotor of the oil burner is Landis & Staefa STM6 with 5 cam motor. A fully closed position is provided to prevent air flowing through the appliance when the burner is not in operation.

3) The Inner Assembly. Consist of flame tube, diffuse, oil nozzle, ignition electrode and so on. 4) Oil Nozzle. The oil nozzles are held in a nozzle block located within the flame tube. The nozzles

are pre-sized by the manufacture according with the heat inputs required and the available operating pressure. When replace 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, the following should be taken into account:: Nozzles are marked for capacity and calibrated at an oil pressure of 7 bar/100psi. the correction factor to be used to establish the nozzle sizes is as follow: Nozzle marking 1.66 Imperial Gallons at 27.6 bar-400 PSI Nozzle marking 7.16 = Kg/h at 27.6 bar-400 PSI 5) Oil Preheater Tank( for heavy oil burners). 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. GAS BURNER 1) Air Pressure Switch. Each of the gas burners is mounted

a Air Pressure Switch on the burner scroll. Lack of combustion air, or insufficient air pressure, will stop the switch completing the circuit, preventing the burner from operating.

2) Air Control The 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 operating. The standard servomotor of the oil burner is Landis & Staefa STM30 with 3 cam motor. The servomotor has

been adjusted by manufacture before the boiler delivery, so normally customer needn’t to set it again. 3) Gas Train Assembly. Consist of pilot and main supply line, each line having a manual cock, a governor, solenoid operated valves and two air pressure switch (high and low). The governors maintain a constant pressure of fuel entering the burner and are adjustable. The solenoid valves are electronically controlled by the burner programmer. For specific details, consult the burner manufacture’s instruction Manual.

Three thermostats on the preheater tank


17 FBS 01/05

4) Valve Proving System. A valve proving system, as show schematically below, is standard on the

boilers from FB-S3-1.0 to FB-S6-1.25 model. 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) 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 crease 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.

5) Flame Monitor. An ultraviolet cell is fitted as standard on all burners. It monitors the status of the flame, any failure will course the burner shut down.


FBS 01/05 18

BURNER OPERATING SEQUENCE The burner operating sequence begins with a pre-purge period on full air. Fuel is then supplied to the burner at start rate and ignition initiated. Start flame proving is followed by establishment of the main flame. Consult the following timing chart.


19 FBS 01/05

Section 5 Operating 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. Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down. 1. FILLING THE BOILER

A) Ensure the following valves are OPEN. i) Main steam valve ii) Steam pressure gauge isolating valve. iii) All valves in the water feed line. iv) Water gauge isolating valves. v) Air release valve.

B) Ensure the following valves are SHUT. i) Main blowdown valve ii) Water gauge blowdown valves. iii) All valves in the gas/oil train to the burner.

C) Ensure that the Burner On/Off/Reset Switch is set to OFF. D) Ensure that the Pump On/Off Switch is in the PUMP OFF position, and that the Manual/Off/Auto

Switch is in the Off position. E) Turn the door isolator to the ON position. F) Place the Pump On/Off Switch to the PUMP ON position. G) Place the Pump Only/Off/Burner & Pump Switch to the PUMP ONLY position. H) The feed pump should start and fill the boiler to the pump off level and then switch off.

NOTE

If the 2nd 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 STARTING PROCEDURE (a) Fill the boiler as described in Section 5.1. (b) SHUT the main steam valve. (c) Open all the valves in the gas train/oil supply. It is assured 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 position. (e) Switch the 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 3.3-Pump Only/Off/Pump & Burner On switch description).

(f) Reset the alarm by pressing both switches. If the 2nd Low Water alarm cannot be cancelled, check the water level in the sight glass.

(g) The burner motor will start and, after going through post purge/ pre purge interlock checks, should fire after approximately 45 seconds.


FBS 01/05 20

NOTE

Before leaving the boiler unattended, the daily operating tests 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 manufacture’s Operation and Maintenance instructions. PRACTICAL CONSIDERATIONS When starting up the boiler, it is prudent to minimize the thermal and mechanical stress caused by differential expansion of various parts of the boiler as they reach working temperature. The temperature of the shell is determined by the contained water/steam 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. 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 the boiler progressively by firing the boiler on low fire for a few minutes and leaving it to ‘soak’ (e.g. allowing the temperatures in the boiler and water to even out by diffusion) for 20 to 30 minutes, blowing down the boiler, firing the boiler again for a little longer and soaking for less, and so on. If the boiler has been fired the day before, the large thermal mass in the boiler will maintain the internal temperature to a point that the boiler can be simple switched on (preferably on low fire) and then left to reach working temperature/pressure. The life expectancy of the boiler and door insulation, ignoring other factors, is proportional to the number of the 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 that is constantly heated and cooled. Service Inspection of Weld Joints. The frequency of the safety 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 inspected at five year intervals and the longditudinal seam every ten years. Boilers that are continually heated and cooled require more frequent inspection. The purpose of the in-service weld inspections ins 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 testing these tests may be waived at the discretion of the ‘competent person’.

B. Cracks propagating from region of the toe of the fillet weld on the shell to the tube plate weld, resulting from fatigue or corrosion fatigue cracking. These cracks would no 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 3. The importance of correct water treatment cannot be over emphasized.

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.


21 FBS 01/05

3. DAILY OPERATING TESTS CAUTION

If any of the following tests fail to function as described, shut down the boiler immediately and consult the factory. With the burner firing, carry out the following tests:

NOTE Ensure the correct water level is maintained during pressure build up. If any part of the equipment is not operating correctly, the fault should be investigated before the boiler is used. Ensure all blowdown pipework is safe and discharged to a blowdown receptacle. Flame Sensor (UV Photo Cell) Check. Remove the burner UV photocell from its plug-in connection (on the side of the burner) and cover the detection window to exclude all light. The burner control should immediately (2-3 seconds gas, 5 seconds oil) go to a lockout/flame failure condition and will require manual resetting. Clean the UV photocell with soft cloth before replacing it. Pump Check. (a) Lower the water level in the boiler, either by evaporation or by opening the main blowdown valve

with the key provided. (b) Observe the water level in the water level gauges and, as the water level falls, check that the

feedwater pump starts. (c) SHUT the main blowdown valve if opened, and ensure that the feedwater pump continues to fill

the boiler to the correct level then switch off. 1st Low Water Check. (a) Turn the Pump On/Off Switch on the boiler control panel to the PUMP OFF position. (b) Lower the water level in the boiler, either by evaporation or by opening the main blowdown valve

with the key provided. (c) Observe the water level in the water level gauges and check that, as the water level reached the

low water position: The 1st Low Water alarm sounds. The 1st Low Water indicator lamp illuminates. The burner stops firing.

(d) SHUT the main blowdown valve if opened, and turn the Pump On/ Off Switch to the PUMP ON position, Check that: The feedwater pump starts. The water level in the boiler is restored to the normal working position. The 1st Low Water indicator lamp extinguishes and the alarm cancels. The burner automatic start sequence commences.

2nd Low Water Check. (a) Repeat the procedure described in above section but allow the water level to continue to fall,

either by evaporation or maintaining the main blowdown valve open. Before the level falls below the level of the water level gauge, check that the 2nd Low Water Alarm/Reset Switch illuminates, the alarm sounds and the burner shuts down.

(b) SHUT the main blowdwon valve (if opened). (c) Set the Pump On/ Off Switch to the PUMP ON position. (d) Check that:

The feedwater pump starts, restores the water level to a safe working level, then stops. The 1st Low Water alarm cancels. The 1st Low Water indicator lamp extinguishes but the burner does not start. The 2nd Low Water alarm continues to sound. The 2nd Low Water Alarm/Reset Switch remains illuminated.

(e) Press the 2nd Low Water Level Alarm/Reset switch. (f) Check that:

The 2nd Low Water alarm cancels. The 2nd Low Water Alarm/Reset Switch extinguishes. The automatic burner firing sequence commences.


FBS 01/05 22

To reduce the possible down time and loss of pressure to steam, load the tests detailed can be accomplished by isolating the feed pump using the pump ON/OFF switch on the boiler control panel. Allowing the water level to fall by evaporating steam to the system. Once the 1st Low Water Level Alarm is activated the water level can be lowered to the 2nd Low Water Level by using the main blowdown valve. When the 2nd Low Water Alarm sounds CLOSE the blowdown valve, turn the feedwater Pump On/Off switch to PUMP ON. Once the 1st Low Water Level cancels the burner should remain off, but the 2nd Low Water Alarm should continue to sound, reset the 2nd Low Water Alarm. The burner should start and the pump restore the water level to normal and stop.

NOTE This procedure requires a longer attendance time by the boiler operator, but reduces the pressure loss to the system.

4. BLOWNDOWN PROCEDURE In order to keep the boiler and water level guage pipework clear and free from sludge and scale build-up, regular blowdown should be carried out.

Boiler Blowdown (a) Fully OPEN the main blowdown valve, using the key provided, for a minimum of 10 seconds, see

note. (b) SHUT the main blowdown valve.

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. In order to establish the required blowdown rate, consult your water treatment specialist who will recommend a water treatment program in terms of appropriate chemicals and the required blowdown rate which takes these factors into account. WATER LEVEL GAUGE BLOWDOWN (A) Blowdown the water level gauge set by opening the gauge blowdown valve A and closing the top

and bottom gauge valves B and C in sequence. (B) On completion of the blowdown procedures, ensure all isolation valves are open, and all

blowdown valves are SHUT, (all handles vertical). 5. TO SHUT DOWN THE BURNER

Short Term (Hours)

Turn the Burner On/Off/Reset Switch on the Control Panel to OFF.

The burner will stop firing, post-purge and then stop.

Medium Term (Days)

(a) Turn the Burner On/Off/Reset Switch on the Burner Control Panel to OFF.

The burner will stop firing, post-purge and then stop.

(b) SHUT the main steam valve.

(c) SHUT the water feed valve.

(d) 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 the specified limits.

Long Term (Weeks)

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

(a) Fully flood the boiler to exclude a much air as possible.

(b) Drain the boiler completely.


23 FBS 01/05

Remove all hand hole and man hole doors.

Open all gas/oil-side access doors (refer to the maintenance section).

(c) As (b) but also introduce a form of convection heating to the gas/oil and water side. A very

effective solution is to install a string of outdoor-type waterproof light bulbs distributed throughout the

boiler.

6. EVAPORATION TEST

This test may be required by your insurance inspector as part of the annual inspection.

(a) With the burner running, switch off the boiler feedpump and allow the water level in the boiler to

lower by evaporation.

(b) When the water level reaches the 1st Low Water position an alarm will sound, the 1st Low Water

indicator lamp will illuminate and the burner will stop.

(c) Allow the evaporation process to continue until the 2nd Low Water alarm sounds and the 2nd Low

Water Alarm/Switch illuminate.

(d) Switch the feed pump to the PUMP & BURNER ON position.

(e) The water level will be restored to normal working level, the 1st Low Water indicator lamp will

extinguish and the alarm will cancel.

(f) Press the 2nd Low Water Alarm/Reset switch.

(g) The 2nd Low Water Alarm/Reset switch will extinguish, the alarm will cancel and the burner will

start.

NOTE

Because the burner shuts down during this test it is possible that the steam load will rapidly

decrease the pressure in the boiler causing a premature 2nd 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 (oil and dual fuel burners). (c) Oil storage tank contains an adequate level of fuel. (d) Oil filter(s) are not blocked. (e) Water feed line from feed 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. (i) Thermal overload on the pump motor is not tripped. (j) Thermal overload on the burner motor is not tripped. (k) Normal water level is visible in the water level gauges. (l) Feed pump is primed and not air locked. (m) Front door proof of closure microswitch is closed. 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) The model and type of burner fitted.


FBS 01/05 24

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 draw in water in an attempt to equalize the pressure. The appearance in the water level gauges is the same if they are empty or fully flooded. If the sight glasses 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 drop the water to the normal operating level. FAULT FINDING TABLE Problem Solution

Burner does not start

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 circuit not completed- no voltage at end

of limit circuit program relay terminal. a. Pressure or temperature is above setting of

operation control. b. Water below required level. c. Fuel pressure must be within setting of low

pressure and light pressure switch. d. Check burner air proving switch and high

fire limit switch. e. Heavy oil fired unit-oil temperature below

minimum setting. 4. Fuel valve interlock circuit not completed.

No ignition

1. Lack of spark a) Electrode grounded or porcelain creaked. b) Improve electrode setting. c) Loose terminal on ignition cable. d) Inoperative ignition transformer. e) Insufficient at pilot ignition circuit terminal.

2. Spark but not flame a. Lack of fuel- no gas pressure, closed valve,

empty tank etc. 3. Low fire switch open in low fire proving circuit. Damper motor not closed, defective switch. 4. Running interlock circuit not completed. a. Combustion or atomizing air proving

switched defective or not properly set. b. Motor starter interlock contact not closed.

5. Flame detector defective, sight tube obstructed, or lens dirty.

6. Check the programmer controller. Pilot flame, no main flame

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. 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.


25 FBS 01/05

Pilot flame, no main flame

4. Flame detector defective, sight tube obstructed or lens dirty.

5. Insufficient or no voltage at main fuel valve circuit terminal.

Burner stays in low fire

1.Pressure or temperature above modulating control setting.

2.Manual-automatic switch in wrong position. 3. Inoperative modulating motor.

Shutdown occurs during firing

1. Loss or stoppage of fuel supply. 2. Defective fuel valve; loose electrical

connection. 3. Flame detector weak or defective. 4. Scanner lens dirty or sight tube obstructed. 5. If the programmer lockout switch has not

tripped, check the limit circuit for an opened safety control.

6. If the programmer lockout switch has tripped.

a. Check fuel lines and valves. b. Check flame detector. c. Check for open circuit in running interlock

circuit. d. The flame failure light is energized by

ignition failure, main flame failure, inadequate flame signal, or open control in the running interlock circuit.

7. Interlock device inoperative or defective. 8. Air in the oil lines. Bleed lines.

Boiler will not maintain pressure

1. Check oil supply in the supply tank. Check for clogged nozzle. clean or replace it. Check oil filter and replace if necessary.

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.

Water pump does not Start or stop normally

1. Check the connection of water probe. 2. Check and clean the water probe. 3. Check the water level relay, if necessary

replace it.

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

1. check for tightness and clean the connections

2. clean or replace the dirty probes 3. Replace the water level relay

Check the tightness of the earth connection

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

1. Boiler is completely filled with water, blown down the boiler to normal water level.

2. On/Off pressure switch has failed, check the reading on the pressure gauge.


FBS 01/05 26

Section 6 Maintenance GENERAL 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 Fulton China LLC.

NOTE It is essential that regular checks are made to ensure scale build-up is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler water feed is effective. The lower hand hole doors should be removed after one month and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, a water treatment specialist should be consulted. Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are obtained. Thereafter, inspections should be carried out at six monthly intervals. IMPORTANT New gaskets must be fitted every time a hand hole door is removed, refer to Section 4.5 for fitting procedures. WEEKLY

WARNING All steam pipework, 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. Check for signs of leaks on all valves and fittings and take the appropriate action. Test all the boiler water level functions by evaporation, e.g. switch off the boiler feed pump-see Starting the Burner. Carry out routine maintenance checks on the burner as recommended by the manufacturer’s Installation and Maintenance instructions. Check the flame failure controls by removing the burner flame sensor from its plug-in connection on the side of the burner and covering the detection window to exclude all light. The burner control should immediately go to a lockout flame failure condition and will require manual resetting. Clean the flame sensor before replacing it. SIX MONTHLY

WARNING The boiler must be completely cold before carrying out any of the following procedures. (a) Ensure that the following valves are SHUT:

The main steam stop valve The feedwater isolating valve 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. (c) Empty the boiler. It will be necessary to allow air into the boiler before it will drain via the main

blowdown valve. (d) 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


27 FBS 01/05

consulted. Ensure there are no accumulated deposits of sludge in the bottom of the boiler. (e) Remove the feedwater disperser inspect and clean. (f) Replace the man hole and hand hole door gaskets, refer to Section � FITTING NEW GASKET �

for fitting procedures. (g) Open the boiler front access door with the burner mounted on it as described below. It will be

necessary to disconnect the gas supply from the gas train and oil supply from the oil lines to allow the door to swing open.

(h) Where retarders are fitted they should be removed-some burning of the retarders at the inlet end is normal.

(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 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 Boiler Works.

(m) Clean out the rear smoke boxes to remove the deposits brushed through from the tubes.

IMPORTANT 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. (p) Inspect the door seal for signs of wear and replace if necessary. The first indication of a worn door

seal would be evident by signs of leakage around the external periphery of the door. WARNING

When handling ceramic fibre always follow the local regulations regarding such materials, including the use of breathing apparatus, suitable body protection and protective gloves. (q) Examine the internal surface of the door lining for defects. Small repairs may be carried out by

cutting out the defective area and replacing with new fibre, ensure the correct adhesive is used. (r) 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 irregular flame patterns.

(s) Inspect the rear smoke box door seals for deterioration and replace if necessary. (t) Close the hinged front access door by reversing the opening procedure. (u) Re-connect the gas/oil connections. (v) Drain and flush the feedwater/ hotwell tank, clean any filters and the strainer in the feedline before

the pump. (w) Drain and flush out the blowdown separator. (x) 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. ANNUALLY It is a requirement of the Factories Act and Pressure Systems Regulations that the boiler is internally inspected and re-certified at not more than 14 month intervals. 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 Boiler Works can offer this service if required. The engineering surveyor may require the removal of the ceramic fibre insulation around the periphery of the front tube plate to facilitate inspection of the shell to tube plate weld. The standard Fulton service kit includes replacement ceramic fibre log material 50*50*150 mm which must be glued in place with the adhesive supplied. It is vital the material is fitted ensuring the ends of the fibre face into the centre of the boiler.


FBS 01/05 28

FITTING NEW GASKET General

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 adhere 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. Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degredation 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 minimize 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 gaskets leaks after fitting this is almost certainly due to incorrect seating or alignment. As such gaskets are very reduce the life of the gasket and cause problems later. Under stress can be avoided by tightening just sufficiently to stop any leakage when fitting cold and before firing the boiler. Fire the boiler and then gradually warm the boiler up, allowing the increasing steam pressure to take over and complete the seal. The will allow the gasket material to contract naturally and follow the topography of the mating surfaces. The securing nut can then broken when the boiler is cold and under negative pressure. Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber ‘cures to shape’. If the rubber post-cures, the elastic memory will be destroyed and any initial over-tightening will cause the gasket to become hardened and embrittled, leading to cracks and eventual failure. Fitting Instructions Blowdown the boiler completely and examine all inspection holes in the boiler. If any leakage is evident, proceed as follow: (a) Disassembly the crabs 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. (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 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. Set the crabs further quarter of the turn using a spanner. DO NOT OVERTIGHTERN.

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. (d) Gradually warm up the boiler, allowing steam pressure to make the seal. If the gasket leaks

during pressure build up, tighten the securing nuts sufficiently only to stop the leakage. It is important to keep the nuts correctly tightened thereafter, this prevents the vacuum developed by cooling on shutdown from feeding and draining the boiler.

NOTE New gasket fitted to inspection holes located along the bottom of the boiler are more difficult to install without leaking. Small particles of the 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. (e) Clean and inspect each water gauge sight glass. If any water leakage is evident, renew the sight

glass gasket.

3Year (36 Month) Conditional Warranty On the Fulton Boiler Pressure Vessel

Fulton China LLC will repair or replace F.B factory any Fulton pressure which, within 3 years of the date of shipment from factory, is found of

be defective in workmanship or material, provided this equipment is installed, operated and maintained by the buyer in accordance with the

Fulton instruction manual and approved practices, and that the +water quality used in the system has been regularly checked to meet the

standards for ideal and proper boiler feedwater during the warranty period. ++This warranty does not cover damage or failure that can be

attributed to corrosion, (including oxygen pitting) scale or dirt accumulations, or to low water conditions. The warranty does not include labor

charges of any kind. In the event a failure reported. Fulton will require an analysis of the boiler feedwater to determine that acceptable water

conditions are present at the installation site as well as documentation on the feedwater treatment employed since the installation of the boiler.

The boiler will be required to be shipped freight prepaid to the Fulton factory of inspection after a failure is reported. The customer may witness

the inspection and verification at the factory.

+Consult Fulton China LLC for analysis of acceptable water conditions.

++Feedwater treatment and proper daily blowdown procedures are very important in keeping your boiler heating surface free of scale

formation, pitting, oxygen corrosion and foaming or bouncing water. Professional feedwater treatment consultants should be contacted when

the boiler is installed. They will recommend the proper treatment required for prolonging boiler life. A thorough boiler inspection should take

place during the first six months of operation to access the effectiveness of boiler water treatment techniques, including analysis of potential

oxygen pitting.

It is the owner’s responsibility to assure sate operation of the boiler. To avoid corrosion, scale or dirt accumulations, it is recommended that a

daily blow down procedure be instituted. The boiler power should be left on during daily blow down so that correct operation in the low water

relay may be checked. While blow down the boiler, the pressure will drop significantly. While blowing boiler down with power on, it is normal to

hear the boiler feed pump come on. The burner should no turn on. If the burner does come on, turn the boiler off and contact the local service

representative or our factory immediately. Detailed blow down procedures are in the boiler instruction manual shipped with your boiler.

Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler. It is the owner’s responsibility to have the

boiler room periodically tested to assure these damaging chemicals are not present.

1 Year (12 Month) Standard Warranty A

Fulton China LLC will repair or replace F.B. factory any other part which within twelve months of the date of shipment from factory is found to

be defective in workship or material, provided the equipment has been installed, commissioned, operated and maintained by the buyer in

accordance with the operating instruction manual provided with the equipment and generally accepted approved practices, and on the

provision that the buyer gives proper notification in writing as soon as the defect becomes apparent, and that he has properly filled out and

returned his warranty card. This warranty does not include labor charges of any kind. Follow maintenance instructions as listed in the

“Instruction Book”.

This warranty is exclusive and in lieu of all other warranties, express or implied, including but not limited to the implied warranties of

merchantability and fitness for particular purpose. Fulton China LLC shall in no event be liable for a consequential or incidental damages

arising in any way, including but not limited to any loss of profits or loss of business, even if Fulton China LLC has been advised of the

possibility of such damages.

B Controls, motors, feed water pumps, auxiliaries, accessories, and parts manufactured by others may be warrantied by them, but Fulton China

LLC does not provide any warranty for parts manufactured by others. We endeavor to use nationally known controls of the highest quality and

most of the manufacturers of these controls maintain exchange or repair offices in the principal cities in the United States and foreign countries,

expressly for the exchange, service, and repair of their products. Therefore, we request that our distributors and owners of our Fulton Boilers

utilize the nearest offices of the individual manufacturers, for the exchange, service, and/ or repair of these items. We will be glad to furnish the

address of the manufacturers nearest office. If it is more convenient for our distributors or owners of our Fulton Boilers, The effective item may

be returned to our factory. The manufacturer’s sole judgment shall determine the extent of allowance for or replacement of such parts claimed

defective.

C Pleased do not request the replacement of parts on a no-charge basis that are not within the warranty period. No personnel of Fulton China

LLC has the authorization to grant such a request. We will no honor labor charges of any kind unless authorized in writing by our company.

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