instlltion, oertion nd mintennce mnul · the fulton electropack 100 kw electric steam boiler is a...

This manual must be available to the boiler operator at all times. EP100-IOMM-2016-10

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Electropack 100 kWElectric Steam Boiler

(Step Controlled)

EP100-IOMM-2016-10

Fulton Ltd

Page II

EP100-IOMM-2016-10

Fulton Ltd

Page III

TABLE OF CONTENTS

SECTION 1 - INTRODUCTION1.1 General 1

1.2 Technical Data 1

1.3 Product Overview 1

SECTION 2 - INSTALLATION2.1 General 5

2.2 Pre-Installation 5

2.2.1 Siting 6

2.3 Boiler Connections 6

2.3.1 Steam Safety Valves 7

2.4 Water Supply 8

2.5 Electrical Requirements 8

2.6 Commissioning the Boiler 10

2.7 Cleaning Steam Lines and Pressure Vessels 13

SECTION 3 - OPERATION3.1 General 15

3.2 Controls 15

3.2.1 Boiler Control Panel 16

3.2.2 Steam Pressure Controls 18

3.2.2.1 Setting Steam Pressure Controls 19

3.2.2.2 Step Controller 20

3.2.2.3 Step Controller Indicator Lights 21

3.3 Filling The Boiler 22

3.4 Draining the Boiler 23

3.5 Boiler Start-Up (from cold)-all models 24

3.6.1 Boiler Start-Up Following short term Shut-Down 24

3.6 Boiler Shut-Down 25

3.6.1 Short Term Shut-Down (hours) 25

3.6.2 Long Term Shut-Down (weeks) 25

Electrical diagrams supplied separately

SECTION 4 - MAINTENANCE4.1 Visual Checks 27

4.2 Water Level and Low Water Safety Controls 28

4.2.1 Feedwater Pump Test 28

4.2.2 Low Water Level Checks 29

4.2.3 Evaporation Check 29

4.3 Blowdown Procedures 30

4.3.1 Main Boiler Blowdown 30

4.3.2 Water Level Gauge (Sight Glass) Blowdown 30

4.4 Boiler Internal Inspection 31

4.5 Fitting New Gaskets To Boiler Inspection Holes 32

4.5.1 Important Information 32

4.5.2 Fitting Procedure 33

4.6 Element Care and Protection 34

4.6.1 Element Removal 35

4.7 Cleaning Water Level Probes 36

4.8 Schedule of Operator Tests and Checks 37

4.8.1 Daily 38

4.8.2 Weekly-in addition 38

4.8.3 Monthly-in addition 38

4.8.4 Three Monthly-in addition 39

4.9 Maintenance Record Keeping 40

4.10.1 Troubleshooting-boiler 41

4.10.2 Troubleshooting-feedwater pump 42

4.10.2 Troubleshooting-feedwater pump 43

APPENDIX A - TI SHEETS EP100Dimensions&Specification 46

EP Probe Lengths 48

Recommended Water Conditions 50

High Integrity Water Level Controls 51

Water Level Probes 52

Auto TDS Blowdown Systems 54

Auto TDS Blowdown System Install Guide 56

Auto Timed Blowdown System 58

EP100-IOMM-2016-10

Fulton Ltd

Page IV

WARNINGS

The Pressure System Safety Regulations 2000

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

For further information contact:

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

(b) HealthandSafetyExecutivelocaloffice.

(c) Your Competent Person.

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

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

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

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

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

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

CAUTION

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

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

hasbeeninvestigatedbyacompetentpersonandrectified.

!

WARNING

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

CAUTION

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

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

!

!

EP100-IOMM-2016-10

Fulton Ltd

Page V

WARNINGS

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

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

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

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

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

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

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

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

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

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

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

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

! CAUTIONObey all laws and local regulations which affect you and your boiler.

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

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

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

!

EP100-IOMM-2016-10

Fulton Ltd

Page VI

EP100-IOMM-2016-10

Fulton Ltd

Page 1

INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

1.2 TECHNICAL DATA

ForafullspecificationrefertoAppendix A - TI-130-EP100 Dimensions & Specification.

The Fulton Electropack electric steam boiler service manual is a generic publication, providing information on standard boiler operation and maintenance.

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

Particular attention should be paid to electrical installation and water treatment.

1.3 PRODUCT OVERVIEW

TheFultonElectropack100kWelectricsteamboilerisahighlyefficientunitdesignedtomeettherequirements of the lower demand steam user.

The Electropack 100 kW contains a pressure vessel, feedwater pump and system controls including a step controller to automatically switch elements on and off with steam demand to create a fully contained steam raising unit with easy access removable cabinet panels

The Electropack 100 kW is similar to the Electropack 18-72 kW range with differences such as a larger pressure vessel and elements entering from the top of the boiler instead of the front. The 100 kW does not have a self contained feedwater tank like the 18-72 kW range due to the larger pressure vessel. Feedwater and condensate return tanks can be supplied separately.

CONTINUED ON NEXT PAGE

EP100-IOMM-2016-10

Fulton Ltd

Page 2

INTRODUCTION - 1

Figure. 1 - General Arrangement

17

1

2

3

7

8

9

10

11

12

13

14

15

16

EP100-IOMM-2016-10

Fulton Ltd

Page 3

INTRODUCTION - 1

1. Boiler control panel2. Control panel lock3. Boiler door isolator switch4. Feedwater pump5. Operating pressure control switch6. High limit pressure control switch7. Water level gauge (optional)8. Water level gauge blowdown valve9. Steam pressure gauge10. Side access panel11. Front access panel12. Main steam stop valve13. Boiler steam safety valve14. Boiler water sample point15. Feedwater check and isolating valves

16. Main boiler blowdown valve17. Feedwater inlet18. Water level probes19. Boiler elements20. Pressure vessel

Key

4

5

6

19

18

20

Figure. 2 - General Arrangement Inside

EP100-IOMM-2016-10

Fulton Ltd

Page 4

EP100-IOMM-2016-10

Fulton Ltd

Page 5

INSTALLATION - 2

2.1 GENERAL

SECTION 2 - INSTALLATION

2.2 PRE-INSTALLATION

Prior to delivery of the boiler, consideration should be given to the following:(Planning regulations may call for more consents than those listed below, always check with your Local Planning Authority).

A. Local Planning consents where appropriate.

B. Consideration given to access for delivery and positioning of the boiler.

C. Preparation of a suitable base, which must be able to support the total weight of the system under operating conditions.

The locations of services to the site required for the system, under operating conditions.

D. Electricity supply, check the loading required/available.

E. Drainage system, check the suitability of the drainage system.

F. Local regulations for discharge into existing drains.

G. Suitable access for delivery and off-loading.

H. Safe access to the plant when installation is complete.

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

EP100-IOMM-2016-10

Fulton Ltd

Page 6

INSTALLATION - 2

2.2.1 SITING

Theboilerhouseshouldbesufficientlysizedtoalloweasyandsafeaccesstoallpartsoftheboiler for operational and maintenance purposes.

Reference should be made to Appendix A - TI-130-EP100 Dimensions & Specification to ascertain the relevant dimensions and weights, special note should be taken of the required clearance for maintenance.

Theflooringmustbelevel,laidinanon-combustiblematerialandbeofsufficientstrengthtosupport the boiler.

All connections for services are mounted at the rear of the boiler. For connection sizes, refer to Appendix A - TI-130-EP100 Dimensions & Specification.

1. Feedwater InletAnisolatingvalveanddisctypenon-returnvalvearesuppliedfittedtotheboiler.Thisshouldbeconnected to the feedwater pump discharge which is mounted inside the cabinet.

2. Steam Safety Valve DischargeThe outlet from this valve should be piped to a safe discharge point and the piping should be so arranged that condensate trapped in the discharge pipe is drained away from the valve.

3. Steam Outlet Valve

4. Boiler Blowdown ValveConnection must be made from the Blowdown valve to a blowdown receptacle of approved design. Regulations exist covering such items and care must be taken to ensure compliance with these regulations. If in any doubt regarding blowdown arrangements consult Fulton Ltd.

5. Water Sample OutletIfthewatersampleoutletisused,thevalveshouldbefittedascloseaspossibletotheboiler.Totake a sample safely, a water sample cooler (not supplied as standard) should be installed.

6. Water Level Gauge Blowdown Valve (if fitted))The water level gauge blowdown cock should be connected to the auxiliary blowdown line from the blowdown valve by 3/8 in. soft copper tubing.

CAUTION

Unless otherwise specified the steam safety valve supplied with the boiler is pre-set and should not be altered. This valve is provided as a safety device for the boiler and should not be used as the sole

protection for other equipment using steam from the boiler.

!

2.3 BOILER CONNECTIONS

EP100-IOMM-2016-10

Fulton Ltd

Page 7

INSTALLATION - 2

Figure. 3 - Boiler Connection Points

2.3.1 STEAM SAFETY VALVES

Safetyvalvesarefactoryfittedandpre-set,theyMUSTNOTbeadjusted.Thedischargeoutletshould be piped to a safe discharge point and the piping so arranged that any condensate trapped in the pipework will drain away from the valve.

Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806 clause 4.9.7. / BSEN 134801-1:2002

a) The lift pressure is indicated on the safety valve (do not adjust).b) Thesafetyvalvefittedtotheboilerisdesignedtopreventtheboilerexceedingitsdesign

pressure.c) Any system connected to the boiler not capable of accepting boiler pressure must be protected

by a separate safety valve set to the required pressure.

WARNING

Factory fitted safety valves are pre-set to protect the boiler only and must not be used to protect any other items not capable of accepting boiler pressure.

!

1

23

4

5

6

EP100-IOMM-2016-10

Fulton Ltd

Page 8

INSTALLATION - 2

2.5 ELECTRICAL REQUIREMENTS

The quality of the water used in the boiler will affect the life and performance of the boiler and elements. Feedwater contains solids and dissolved gases, these may promote encrustations of scale; foaming, priming, surging; corrosion and pitting; or caustic embrittlement. To prevent this happening it is strongly recommended that a reputable water treatment concern is consulted prior to commissioning the boiler.

Note: See Appendix A - TI-139-Recommended Water Conditions.

Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. Should chemical dosage of the boiler feedwater be required a connection point and a water sampling point are provided at the rear of the boiler.

2.4 WATER SUPPLY

CAUTION

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

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

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

dosage of chemicals.

!

An individual wiring diagram for the boiler is located with the control panel. When referring to the electricalspecificationoftheboiler,thewiringdiagramnumbershouldbequoted.

The power ratings and requirements are given in Appendix A - TI-130-EP100 Dimensions & Specification. The boiler contains all necessary electrical protection.

A suitable 3-phase, neutral and earth isolated and fused supply is required and must be connected in accordance with local electrical regulations.

Anelectricalisolatorshouldbesecurelyfittedascloseaspossibletotheboiler.

It is recommended that the electrical supply cable to the boiler is located through the rear of the unit in the bottom left corner. Ensure the cable is not rubbing against areas capable of damaging it.Thecableshouldberoutedfromthispointandsecuredinaglandnut(notsupplied)fittedthebulkhead at the base of the electrical panel.

Care should be taken to ensure the supply cable is the correct size and installed in accordance with local regulations.

EP100-IOMM-2016-10

Fulton Ltd

Page 9

INSTALLATION - 2

3

2

10

5

4

1

6

9

7

8

Figure. 4 - Electrical Panel

1. Miniature relays2. MCB3. Door electrical isolator (supply cable connection point) 4. LC relays5. Element circuit breakers6. Cooling fan7. Fuse terminal8. Step controller9. Pump circuit breakers10. Element contactors 11. Pump contactor12. Pump overload13. Supplycableaccesshole(fitwithglandnutsuitablefortheelectricalsupplycableused)

Key

11

12

13

EP100-IOMM-2016-10

Fulton Ltd

Page 10

INSTALLATION - 2

2.6 COMMISSIONING THE BOILER

1. Isolate boiler (door isolator and mains supply)

2. Remove front access panelRemove right side access panel

3. Check all electrical connections for tightness

4. Insulation test the elements

5. Set the steam pressure controls (see Section 3.2.2.1 - Setting Steam Pressure Controls)

6. Ensure Boiler switch is in the OFF positionConnect to the mains electrical supply

7. Close boiler blowdown valveClose main steam valve

8. Open all valves in the feedwater lineCheck for leaks

9. Ensure Boiler switch is in the OFF positionEnsure Pump switch is in the OFF position

10. Ensure master step controller Block one - Switch 3 is in the ON position

11. Replace front access panelReplace right side access panel

12. Switch main isolator ONTurn boiler door isolator ON

13. Fill the feedwater pumpClose the isolating valve on the discharge side of the feedwater pump (at rear of boiler). Removetheprimingplugfromthepumpheadandslowlyfillthepumpwithwater.Replacethepriming plug and tighten securely.

These procedures should be carried out by a competent person.

Although every care is taken to ensure that the boiler has been despatched from the factory fully tested, it is possible that during transportation and installation, pipework and electrical connections may be loosened or broken. On completion of the installation and prior to switching on the boiler it is advisable to carry out the following checks:

WARNING

The boiler electrical circuit must be isolated prior to doing the following tests.

!


EP100-IOMM-2016-10

Fulton Ltd

Page 11

INSTALLATION - 2

14. Feedwater pump checksBleed the feedwater pump (see Figure. 5)Remove the feedwater pump cover to expose the pump drive shaft coupling (see Figure. 5)Turn Pump switch ONCheck the rotation of the feedwater pump. Correct rotation is anti-clockwise when viewed from the top of the pump.Turn Pump switch OFF and wait until the drive shaft stops rotating before replacing the cover.

Note: The pump impeller blades can be damaged by incorrect rotation. If the rotation is incorrect turn the selector switch to the OFF position. Isolate the boiler and alter the phase connections between the pump contactor overload and the pump. Re-check the pump rotation.

WARNING

Do not make contact or place anything in touch with the moving parts of the pump drive. The cover is removed for a visual inspection of the pump rotation. Stop the pump to replace the cover.

!

15. Fill the boilerOpen the isolating valve on the discharge side of the feedwater pump (at rear of boiler) Turn Pump switch ONLow water light and low water reset button will illuminateAudible alarm soundsAllowfeedwaterpumptofilltheboilerCheck feedwater pump stops when correct water level is reachedPress low water reset button to cancel alarm and Low water warning lights

16. Elements automatic on/off check with Low waterPut the step controller into Commissioning mode (master unit, block 1, DIP switch 3 OFF) Turn Boiler switch ONTurn Pump switch OFFEnsure Element Switches are in the ON positionElements should energise indicated by the Element Switch lights

Figure. 5 - Feedwater Pump

Feedwater pump bleed nipple

Removable cover to check pump rotation


EP100-IOMM-2016-10

Fulton Ltd

Page 12

INSTALLATION - 2

WARNING

The boiler electrical circuit must be isolated prior to doing the following tests.

!

Turn Boiler switch OFFTurn Pump switch OFFTurn boiler door isolator OFFRemove access panelsCheck for steam/water leaksPut step controller into Operation Mode (master unit, block 1, DIP switch 3 ON)Replace access panelsSlowly open the steam valve to release pressure from the boiler to below high pressure set pointCheck for steam leaks in connecting pipework

Turn boiler door isolator ON Turn Boiler switch ONTurn Pump switch ON

Press High Pressure Reset button to cancel alarm and energise the elements

The boiler is now ready for placing into full operation.

Open Boiler Blowdown valve and drain water from the boiler until:a) Low water light illuminatesb) Low water reset button illuminatesc) Audible alarm sounds

Close Boiler Blowdown valveCheck that the elements de-energise and Element lights switch off in Low water conditionTurn Pump switch ONCheckfeedwaterpumpstartsandfillstheboilertothecorrectwaterlevelPress low water reset button to cancel alarm and Low water warning lightsCheck that the elements energise and element lights illuminate when correct water level is restored

17. Elements automatic on/off check with High pressureSet the Steam Pressure Control to its maximumSet the High Limit Pressure Control to 0.5 barg below the safety valve settingWith the Boiler switch ON, the boiler will slowly raise steam pressureCheck that the elements de-energise when the set high limit pressure is reached. The High Pressure Reset button will illuminate and an audible alarm will soundCheck that the pressure reading on the pressure gauge at boiler cut-out corresponds with the High Pressure Controller settingReset the Steam Pressure Control to the required working pressure

EP100-IOMM-2016-10

Fulton Ltd

Page 13

INSTALLATION - 2

2.7 CLEANING STEAM LINES AND PRESSURE VESSELS

Duringthefirstweekofboileroperation,cleanalloilanddirtfromtheboiler,thesteamlineandcondensate return line.

1. Disconnect the condensate return pipe adjacent to the condensate return tank.

2. Directthereturnstoafloordrainorothersafedischargepointandmakesafe.

3. Leaveinthispositionforoneweektoallowallimpuritiestoflushthrough.

4. Drain the boiler completely each day.

5. Aftertheweekiscompleted,drainandflushthecondensatereturntank,removingallinstallation sediment. Reconnect the condensate return pipe to the condensate return tank.

EP100-IOMM-2016-10

Fulton Ltd

Page 14

EP100-IOMM-2016-10

Fulton Ltd

Page 15

OPERATION - 3

CAUTION

The following instructions are given for the guidance of the operator in the use of the Fulton steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.

!

3.1 GENERAL

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

SECTION 3 - OPERATION

3.2 CONTROLS

The following brief description of the controls used on the Electropack steam boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for thecontinuedefficientoperationoftheboiler.

EP100-IOMM-2016-10

Fulton Ltd

Page 16

OPERATION - 3

Figure. 6 - Controls and Indicators

The control panel contains a range of indicator lights to assist with the starting and testing procedures, in addition the panel contains warning and fault indicators. Should a warning or fault be indicated, the boiler must be isolated and the cause investigated by a competent person.

3.2.1 BOILER CONTROL PANEL

1. High Pressure Reset ButtonThe high pressure reset button will illuminate when the steam high limit controller is tripped. Resetthecontrolbydepressingthepushbutton,havingfirstascertainedandcorrectedthereason for the high pressure condition.

2. Low Water Reset ButtonIndicates that a low water condition exists and the boiler has shut down. An audible alarm will continue to sound and the elements will remain de-energised until the normal working water level is restored and the reset button is depressed.

3. Boiler Element Fault IndicatorEach element has its own M.C.B. which will activate the indicator and shut down the electrical supply to the element. It is safe to operate the boiler with the faulty element switched off providing the faulty element is not allowing steam or water to escape.

4. Pump Fault IndicatorThis light will illuminate if there is an electrical fault with the feedwater pump.

5. Boiler Low Water IndicatorIndicates that a low water condition exists in the boiler and that the boiler has shut down. Operates in conjunction with an audible alarm.

6. Circuit Live IndicatorIndicates that power is being supplied to the boiler control circuit and that the control panel is live. This light should be illuminate immediately when the door isolator is switched on and should remain on until the door isolator is switched off.

7. Boiler IndicatorIndicates that the selector switch has been switched to the on position and that the boiler is in a fully operational position. This light should remain on until the selector switch is turned to the off position.

1. 5. 6. 8. 10. 11.

2. 4. 3. 7. 9.

EP100-IOMM-2016-10

Fulton Ltd

Page 17

OPERATION - 3

8. Boiler Element Switches The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised during and Element normal on/off cycle of operation.

9. Boiler On/Off Switch

10. Pump On/Off SwitchIn the off position the feedwater pump control circuits are isolated.

11. Audible Alarm

EP100-IOMM-2016-10

Fulton Ltd

Page 18

OPERATION - 3

3.2.2 STEAM PRESSURE CONTROLS

Pressure controls are mounted on the side of the control box.

Pressure controls are as follows:

Operating Pressure Control Switch (On/Off) Controls the ON/OFF cycle of the elements, switching the elements off when the desired steam pressure is reached and switching it on when steam pressure falls. The 0 - 135 ohms resistance from the controller is converted by a transducer to a 0 - 10 V signal for use by the step controller.

High Limit Pressure Control Switch Should the operating Pressure Control Switch fail, the steam pressure will raise above the pre-set limit causing the High Limit Switch (set at least 0.5 barg higher than the Operating Pressure Control Switch and 5 psi below the safety valve setting) to switch off and de-energise the elements.

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

Should this happen, switch the boiler to Boiler Off and wait until the steam pressure is discharged. Check the connection to the pressure switch, replace as required.

Figure. 7 - Steam Pressure Controllers

High pressurecontroller

Operating pressurecontroller

Pressure test valve

EP100-IOMM-2016-10

Fulton Ltd

Page 19

OPERATION - 3

Adjust the steam pressure controls to suit the boiler application.

Itshouldbenotedthatboilersaredesignedtooperatemostefficientlyattheirmaximumoperatingpressure.

Where steam is required below a pressure of 60 psi (4 bar), consideration should be given to the fittingofapressurereducingset.

Setting the pressure controllers

High Limit Controller

1. Set the controller range scale to 5 psi below the safety valve setting.

2. Set the differential scale to zero.

Operating Pressure Control Switch (On/Off)

1. Set the Range Scale to the maximum pressure required.

2. Set the Differential Scale to give the required pressure differential between the boiler heating elements being de-energised (switched off) and energised (switched on).

Valve Cisfittedinthepressuresupplylinetoallowthetestingoftheboilerpressuresandthecontrollers.

High pressure controller

A B

C

Figure. 8 - Setting Pressure Controllers

3.2.2.1 SETTING STEAM PRESSURE CONTROLS

EP100-IOMM-2016-10

Fulton Ltd

Page 20

OPERATION - 3

3.2.2.2 STEP CONTROLLER

Boilers with up to six elements will have one step controller. Boilers with more than six elements will have two step controllers (master and slave).

The step controller/s operate/s on a 0 - 10 V signal received from the Operating pressure controller via a transducer. The signal is used to switch the elements ON and OFF in sequential steps, this maintains a constant boiler pressure as the steam load varies. Commissioning Mode During Commissioning and Fault Finding the unit should be in commissioning mode (master unit, block 1, DIP switch 3 OFF), this will switch the elements ON and OFF in sequence.

100 kW - (1,2,3,4 - 4,3,2,1,)

A time delay on energising prevents the elements from hunting.

Operation Mode

In operation mode (master unit, block 1, DIP switch 3 ON), the unit will monitor the ON time of each element and subsequently operate the element relays to give an even ON time between elements.

Figure. 9 - Step Controller

Block 1 Block 2

Master step controller

EP100-IOMM-2016-10

Fulton Ltd

Page 21

OPERATION - 3

The step controls have a range of indicator lamps located on the front panels:-

Relay OutputSix red LEDs of which only four are used on this model, illuminated lights indicate activated relays.

RelayOne yellow LED indicates 0 - 10 V DC output selected.

Power OnOne green LED illuminates when power is supplied to the unit and indicates power ON, or when flashing,itindicatesanincorrectDIPswitchfunctionhasbeenselected.

STEP CONTROLLER - DIP SWITCH SETTINGSBLOCK 1 BLOCK 2

Boiler Model: 1 2 3 4 5 6 1 2 3 4 5 6100 kW OFF OFF ON OFF OFF OFF OFF OFF ON OFF OFF OFF

Figure. 10 - Step Controller Blocks

3.2.2.3 STEP CONTROLLER INDICATOR LIGHTS

WARNING

The step controller indicator lamps are located inside the control panel. To view the lights, the control panel door isolator must be set to ‘ON’ with the door open. This must only be done by a qualified

electrician, using extreme caution.

!

Figure. 11 - Step Controller Indicator Lights

Note: Dip switch settings shown are for Operation Mode

EP100-IOMM-2016-10

Fulton Ltd

Page 22

OPERATION - 3

3.3 FILLING THE BOILER

CAUTION

The feed pump seals are water cooled. The pump must never be allowed to run whilst dry, irreparable damage may result.

Ensure the pump is fully primed before energising the motor.

!

1. Ensurethefeedwatertankhasbeenfilled(wherefittedtosystem)

2. Ensure Boiler and Pump switches are both in the OFF position

3. Ensure the following valves are OPEN:

a) All valves in the feedwater line to the boiler

b) Waterlevelgauge(sightglass)isolatingvalves(wherefitted)

4. Ensure the following valves are SHUT:

a) Steam outlet valve

b) Main blowdown valve

c) Waterlevelgaugeblowdownvalves(iffitted)

5. Switch the Pump Switch to the ON position

6. Switch the Boiler Switch to the ON position

7. Check:

a) Boiler Low Water indicator illuminates

b) Audible alarm sounds

c) Thefeedwaterpumpstartsandfillstheboilertothecorrectworkinglevelandthenswitches OFF.

8. Press the Reset Low Water button.

9. Check:

a) Boiler Low Water indicator extinguishes

b) Audible alarm silences

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

EP100-IOMM-2016-10

Fulton Ltd

Page 23

OPERATION - 3

CAUTION

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

!

Figure. 12 - Automatic Blowdown Valve

Boilers with manual blowdown valves

1. Ensure the boiler is cold.

2. Isolate the boiler electrics at the isolator on the front access panel.

3. Isolatethefeedwatertank(wherefitted)andthefeedwaterpump.

4. Open the main steam valve.

5. Open the boiler blowdown valve.

6. Open all valves in the drain lines.

Note: Skid units and plant rooms have internal drainage systems which require the same procedures.

Boilers with automatic blowdown systems

1. The boiler should not be under pressure. The boiler should be cold.

2. Open the main blowdown valve.

3. Usingtheblowdownbypassvalvetothrottletheflow,draintheboiler.

Note: Skid units and plant rooms have internal drainage systems which require the same procedures.

Ifablowdownbypassvalveisnotfittedthenyoucanmanuallyblowdowntheboilerbyusing aflat-headscrewdriver.Locatemanualblowdownbutton(labelledasAinFigure.12),pushthe Manual Blowdown Button up and make a quarter turn clockwise, this will lock the button in position and open the blowdown valve.

A

Main blowdown valve

Automatic blowdown valve

Blowdown bypass valve

3.4 DRAINING THE BOILER

EP100-IOMM-2016-10

Fulton Ltd

Page 24

OPERATION - 3

3.5 BOILER START-UP (FROM COLD) ALL MODELS

Do not attempt to start the boiler until this section has been read and fully understood. Carry out the following procedure on every occasion when restarting the boiler after a shut-down.

1. Fill the boiler (see Section 3.3 - Filling The Boiler). Ensure the feedwater pump is primed.

2. Ensure the main steam isolating valve is SHUT.

3. Check the steam pressure controllers are set correctly (see Section 3.2.2 - Steam Pressure Controls)

4. Switch the door isolator switch to the ON position, the Circuit Live light will illuminate.

Note: If the boiler has not been used for some time it is possible that the boiler will be either air-locked or under vacuum. It may, therefore, be necessary to allow air into the boiler to allow the water to drain.

6. Turn the Boiler switch to the ON position. The boiler is now fully operational and will be controlled as follows: The steam pressure control and step controller will control the on/off sequence of the elements once the boiler is operating. The low water relays automatically maintain the level of water in the boiler and will immediately shut-off the power to the elements should the water fall to an unsafe level.

5. When the boiler has achieved the required (set) pressure, the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework.

CAUTION

The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer.

!

This can be achieved by one of two methods:

a) Partially open the main steam valve and allow the system to heat up slowly (minimum 15 minutes) before fully opening the main steam valve.

b) Open the main steam valve when starting the boiler, allowing the boiler and system to heat up together.

Note: This can lead to water logging of the steam lines until full pressure is achieved.If fitted, TDS Panel Mounted Controllers (BC3150) must be reset after any break in electrical supply to the unit.

Note: Before leaving the boiler unattended, the daily operating tests (see Section 4.8.1) should be carried out to check the functions of all the safety interlocks.

3.5.1 BOILER START-UP FOLLOWING SHORT TERM SHUT-DOWN

If the boiler has been shut-down short term (see Section 3.6.1 - Short Term Shut-Down), the boiler can be simply switched ON and then left to reach working temperature/pressure.

EP100-IOMM-2016-10

Fulton Ltd

Page 25

OPERATION - 3

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

1. Fullyfloodtheboilertoexcludeasmuchairaspossible.

2. Drain the boiler completely (see Section 3.4 - Draining the Boiler). Remove all hand holes and boiler elements (see Section 4.6.1 - Element Removal).

3. Same as 2. but also introduce a form of convection heating into the boiler.

3.6 BOILER SHUT-DOWN

3.6.2 LONG TERM SHUT-DOWN (WEEKS)

3.6.1 SHORT TERM SHUT-DOWN (HOURS)

1. Turn Boiler switch OFFTurn Pump switch OFFThe elements will de-energise.

2. Close the steam outlet vale

EP100-IOMM-2016-10

Fulton Ltd

Page 26

EP100-IOMM-2016-10

Fulton Ltd

Page 27

MAINTENANCE - 4

4.1 VISUAL CHECKS

CAUTION

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

reduction in the life expectancy of the boiler.

!

Inspectthesteamandfeedwaterpipework,valves,fittingsandelementsforsignsofleakage.If leaks are suspected, shut down and evacuate the system to atmospheric pressure before attempting any repairs.

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

SECTION 4 - MAINTENANCE

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

Anyrectificationorrepairsshouldbecarriedoutbytrained,competentservicepersonnel.

CAUTION

The electrical supply to the boiler must be isolated prior to the opening of the access panels.

!

EP100-IOMM-2016-10

Fulton Ltd

Page 28

MAINTENANCE - 4

4.2.1 FEEDWATER PUMP TEST

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

If the pump is running:

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

If the pump is not running:

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

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

3. CLOSE the main boiler blowdown valve.


b) If the boiler is heating and under load, lower the water level by evaporation, observing a pump cycle:

If the pump is running:


If the pump is not running:

1. The water level will lower through natural evaporation.

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


4.2 WATER LEVEL AND LOW WATER SAFETY CONTROLS

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

EP100-IOMM-2016-10

Fulton Ltd

Page 29

MAINTENANCE - 4

4.2.2 LOW WATER LEVEL CHECKS

1. Ensure that the boiler elements are energised, the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch OFF the feedwater pump using the Pump On/Off switch.

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

4. Verify that the Low Water lamp illuminates, the Low Water reset button illuminates, the audible alarm sounds and that the boiler elements de-energise.

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

5. Switch ON the feedwater pump using the Pump On/Off switch.

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

7. Press the Low water reset button.

8. Check that the Low Water lamp extinguishes, the Low Water audible alarm silences and the elements energise.

4.2.3 EVAPORATION CHECK

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

To perform the evaporation check, follow the procedure in Section 4.2.2 - Low Water Level checks allowing water to lower by natural evaporation and not by manual blowdown.

EP100-IOMM-2016-10

Fulton Ltd

Page 30

MAINTENANCE - 4

4.3.1 MAIN BOILER BLOWDOWN

1. Start the boiler and generate 10 psi of steam pressure (see Section 3.5 Boiler Start-up).

2. Switch Pump and Element switches OFF.

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

4. CLOSE the blowdown valve.

5. Resume normal operation by switching Pump and Element switches ON.

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

4.3 BLOWDOWN PROCEDURES

Keep the boiler, elements, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by following these blowdown procedures.

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

Note: Boilers fitted with auto-timed main blowdown systems still require the water level controls to be tested, this may be done by operating the auto blowdown bypass valve.

4.3.2 WATER LEVEL GAUGE (SIGHT GLASS) BLOWDOWN

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

1. Open the water level gauge glass blowdown valve A

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

3. Open valve B

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

5. Open valve C

6. Close valve A

WORKINGPOSITION

STEAMBLOWDOWN

WATERBLOWDOWN

AAA

BBB

CCC

Operating Positions

Figure. 13 - Water Level Gauge Operating Positions

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 31

MAINTENANCE - 4

4.4 BOILER INTERNAL INSPECTION

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

Newgasketsmustbefittedeverytimea hand hole door is removed (see Section 4.5 - Fitting New Gaskets To Boiler Inspection Holes).

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

Hand Hole Cover Plate

Gasket

Crab

Figure. 14 - Hand Hole

EP100-IOMM-2016-10

Fulton Ltd

Page 32

MAINTENANCE - 4

4.5 FITTING NEW GASKETS TO BOILER INSPECTION HOLES

4.5.1 IMPORTANT INFORMATION

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

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

Water treatment and oxygen attack can be minimised by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fittingthisisalmostcertainlyduetoincorrectseatingoralignment.Assuchgasketsareveryflexibleitispossibletocuretheleakbyexcessivetightening,butsuchanactionwillseriouslyreduce the life of the gasket and cause problems later. Unduestresscanbeavoidedbytighteningjustsufficientlytostopanyleakagewhenfittingcoldandbeforefiringtheboiler.Starttheboilerandgraduallybringituptoworkingtemperature,allowing the increasing steam pressure to take over and complete the seal. This will allow the gasket material to contract naturally and follow the topography of the mating surfaces. The securing nut can then be tightened gently by approximately a quarter of a turn, to ensure a ‘snug’ fitandpreventthesealfrombeingbrokenwhentheboileriscoldandundernegativepressure. Gentlewarmingoftheboileroninitialfiringaftermaintenancewillalsohelptoensurethattherubber ‘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.

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.

!

EP100-IOMM-2016-10

Fulton Ltd

Page 33

MAINTENANCE - 4

4.5.2 FITTING PROCEDURE

Blowdown the boiler completely (see Section 4.3.1 - Main Boiler Blowdown) and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows:

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

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

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

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

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

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

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

the water level gauge gasket.

COVER PLATE ANDGASKET IN PLACE

CORRECTPLACEMENT

DO NOT OVER-COMPRESS

GASKET

COVER PLATENOT IN CENTRE

Figure. 15 - Fitting a New Topog-E Gasket

EP100-IOMM-2016-10

Fulton Ltd

Page 34

MAINTENANCE - 4

4.6 ELEMENT CARE AND PROTECTION

To protect the element and prolong its life, it is essential that regular inspections are carried out. The most common causes of element failure are excessive build-up of scale and corrosive attack. Both causes are due to adverse water conditions and reference should be made to Appendix A - TI-139-Recommended Water Conditions.

The dangers of scale to the life of the element cannot be overstressed. Scale possesses excellent insulating qualities and its formation on the element prevents the heat generated by the element being transferred to the water, causing the element to overheat and burn out. Loose, powdery formations can be removed with a wire brush. Hard scale may be removed using a chemical cleaning agent.

Elements,ifstoredcorrectly,haveanindefiniteshelflife.However,problemswillariseiftheyarestored in damp or humid conditions. Moisture can be absorbed by the insulation as the elements arefittedwithabreathingseal.Itis,therefore,ausefulprecautiontoperformanelectricalinsulationtestontheelementspriortofittingorstartingup,followingprolongedshut-down.Ifthereading is low (below 1 megohm), heating in an oven at 300 °C for three hours should restore the element.

Figure. 16 - Boiler Elements

Boiler heatingelements

EP100-IOMM-2016-10

Fulton Ltd

Page 35

MAINTENANCE - 4

4.6.1 ELEMENT REMOVAL

Figure. 17 - Boiler Element Removal

Isolate and completely drain the boiler (see Section 3.4 - Draining the Boiler) before removing the boiler heating elements.

Removethefourelementsecuringnutsfromtheelementmountingflange.Elementisnowloosefor removal from the boiler.

The elements will need removing to complete element checks mentioned in Section 4.6 - Element Care and Protection.

Boiler heatingelement

Element power supply terminals

Element mountingflange

Element securing nut

EP100-IOMM-2016-10

Fulton Ltd

Page 36

MAINTENANCE - 4

4.7 CLEANING WATER LEVEL PROBES

Figure. 18 - Boiler Water Level Probes

BoilerIsolate the boiler electrics at the isolator on the front access panel and remove the boiler side access panels.

Remove and clean the boiler level probes taking note of probe lead positions.

For more information on the water level probes see Appendix A - TI-103-Water Level Probes.

Low water(red cable)

Low water(brown cable)

Pump on(yellow cable)

Pump off(black cable)

EP100-IOMM-2016-10

Fulton Ltd

Page 37

MAINTENANCE - 4

WARNING

Prior to the commencement of any work requiring the removal of access panels, the electrical supply to the boiler must be isolated.

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

!

CAUTION

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

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

!

IMPORTANT

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

!

4.8 SCHEDULE OF OPERATOR TESTS AND CHECKS

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

Maintenance must be carried out by competent, trained personnel

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

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 38

MAINTENANCE - 4

1. Visually inspect boiler casing exterior for signs of leakage (see Section 4.1 - Visual Checks):

a) Steam and feedwater pipework

b) Valvesandfittings

2. Low water level check (see Section 4.2.2 - Low Water Level Checks).

3. Blowdown the boiler (see Section 4.3.1 –Main Boiler Blowdown).

Note: Isolate the electrical supply to the boiler and set the selector switch to OFF.

4. Visually inspect boiler casing interior for signs of leakage (see Section 4.1 - Visual Checks):

a) Steam and feedwater pipework

b) Valvesandfittings

c) Elements

4.8.1 DAILY

4.8.2 WEEKLY IN ADDITION

WARNING

Ensure the main electrical supply is isolated before starting work.

!

WARNING

Ensure the fittings around the steam safety valve(s) are secure.The safety valve will be very hot, do not operate the safety valve without protection.

!

5. Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point.

6. Pump test (see Section 4.2.1 - Feedwater Pump Test).

4.8.3 MONTHLY IN ADDITION

7. Check the element and pump contactors are working correctly by manually depressing them (see ”Figure. 4 - Electrical Panel” on page 9).

EP100-IOMM-2016-10

Fulton Ltd

Page 39

MAINTENANCE - 4

4.8.4 THREE MONTHLY IN ADDITION

8. Drain the boiler (see Section 3.4 - Draining The Boiler).

9. Remove boiler elements (see Section 4.6.1 - Element Removal).

10. Visually inspect the internal water space of the pressure vessel (see Section 4.4 - Boiler Internal Inspection).

11. Visually inspect each element and check for excessive scale build-up or corrosion. Clean as required and replace, always use a new gasket (see Section 4.6 Element Care and Protection).

12. Check and clean the feedwater strainer.

13. Check all electrical connections for tightness.

14. Remove and clean the boiler water level probes (see Section 4.7 - Cleaning Water Level Probes).

Note: Ensure probe caps are reconnected to the correct probes.

15. Return all valves to normal working position.

16. Reconnect the electrical supply and restore the boiler water level.

EP100-IOMM-2016-10

Fulton Ltd

Page 40

MAINTENANCE - 4

MAINTENANCE LOGDate Time Operation Performed Remarks Operators Initials

4.9 MAINTENANCE RECORD KEEPING

Boiler log sheets should be completed on a regular basis, this provides invaluable information in the subsequent investigation of the boiler history. Maintenance log sheets can be found in theFulton boiler Log Books provided by Fulton.

To Purchase a Fulton Boiler Log Book, please contact [email protected].

EXAMPLE

EXAMPLE

DAILY TESTS 1 2 3 4 5 6 7Date

1. Visual Inspectionofcasingexteriorpipeworkandfittingsforsignsofleakage Y - N Y - N Y - N Y - N Y - N Y - N Y - N

2. Low Water Level Check - low water indicator illuminate, alarm sound, feedwater pump stops/starts and elements de-energise/energise. Y - N Y - N Y - N Y - N Y - N Y - N Y - N

3. Blowdown, BoilerDuration seconds.

Test Time.

4. Blowdown, Water ColumnDuration seconds.

Test Time.

5. Blowdown, Water Level GaugeDuration seconds.

Test Time.

6. Pressure gauge reading for blowdown tests.

Boiler water and water treatment values must be within known tolerances of the datum.

7. Boiler Water.datum value. TDS. reading

datum value. PH reading

8. Oxygen Scavenger Concentration datum value. reading

9. Brine level correct Y - N Y - N Y - N Y - N Y - N Y - N Y - N

WEEKLY TESTS 7+10. Visual Inspectionofcasinginteriorpipework,fittingsandelementsforsignsofleakage Y - N

11. Feedwater Pump Test - Feedwater pump, start/stop Y - N

12. Safety valve outlet pipe to safe blowdown point and free of damage Y - N

Test results and actions takenDay 1. sig. Day 5. sig.

2. sig. 6. sig.

3. sig. 7. sig.

4. sig. 7+. sig.

Log examined by: Date:

Electric Steam Boiler - Daily and Weekly Tests

Model:

Boiler Number:

EP100-IOMM-2016-10

Fulton Ltd

Page 41

MAINTENANCE - 4

4.10.1 TROUBLESHOOTING BOILER

Problem Cause RemedyCircuit Live indicator not illuminated

1. Mains supply failure. External circuit MCB requires resetting.Fuses need replacing.Indicator lamp needs replacing.

2. Door interlock microswitch not made.

Boiler Low Water lamp illuminated andAudible alarm sounds

1. Insufficientwaterintheboiler.

Check that the feedwater supply line valves are open. Check that the ball valve in the tank is operating correctly by removing the inspection cover on the tank.

2. Obstruction in the feedwater line to the pump.

Check that the shut-off valve below the tank is open. Remove andcleanthefilterinthestrainer.Checkthat the non-return valve is operating correctly.

3. Air lock in the pump. Bleed the pump at the point provided. 4. Feedwater pump impeller

worn. 5. Incorrect connections to

water level probes.Check connections to water level probes.

6. Faulty water level relay. Check that each relay is pressed firmlyhomeonitsbase.

High Pressure Audible alarm sounds

1. On/Off Pressure Control failure.

2. High pressure controller set too close to on/off control setting.

Pump Fault indicated 1. Electrical fault in the feedwater pump circuit.

Check the circuit fuse, replace as required.

2. Thermal overloadfittedtothe pump motor contactor requires re-setting.

Check that the unit has been set to the correct amperage and adjust if necessary. If the fault continues after the controls have been reset, a major fault exists which can only be corrected by a competent person with correct electrical test equipment.

3. Faulty pump overload.Element Fault 1. MCB requires re-setting. If the fault persists the element and the circuit must

be fully checked by a competent person.

Note: Unless a faulty element is allowing steam or water to escape it is safe to operate the boiler with the faulty element fitted.

Note: Open circuit element faults will not be detected by the element fault detection system.

EP100-IOMM-2016-10

Fulton Ltd

Page 42

MAINTENANCE - 4

Problem Cause RemedyFEEDWATER PUMPPump will not run

1. Supply failure. Connect the electricity supply.2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers.3. Motor contactor overload has

tripped out. Reactivate the motor protection.

4. Contactors not making Check, the coil is faulty or wiring loose.5. Control circuit is defective. Repair the control circuit.6. Motor is defective. Replace the motor.

Motor starter overload, trips out immediately when supply is switched on.

1. One fuse/automatic circuit breaker is blown.

Replace the fuse, reset the circuit breaker.

2. Contacts in motor contactor overload are faulty.

Replace motor starter contacts.

3. Cable connection is loose or faulty. Tighten or replace the cable connection.4. Motor winding is defective. Replace the motor.5. Pump blocked. Remove the blockage.6. Overload setting too low. Set the motor starter correctly.

Motor contactor overload trips out occasionally.

1. Overload setting is too low. Set the overload correctly.2. Low voltage at peak times. Check the electricity supply.

Motor contactor has not tripped out but the pump does not run.

Check:Motor does not run when started:items: 1, 2, 4, 5, 6,

Pump capacity not constant.

1. Pump inlet pressure is too low (cavitation).

Check the suction conditions.

2. Suction pipe/pump partly blocked. Clean the pump or suction pipe.3. Pump draws in air. Check the suction conditions.

Pump runs but gives no water.

1. Suction pipe/pump blocked. Clean the pump or suction pipe.2. Foot or non-return valve blocked in

closed position. Repair the foot or non-return valve.

3. Leakage in suction pipe. Repair the suction pipe.4. Air in suction pipe or pump. Check the suction conditions.5. Pump rotates in the wrong direction. Change the direction of rotation of the

motor.6. Boiler feedwater non-return valve

letting water passed the valve seat, Check and clean boiler feedwaternon-return valve, ensure it is seating(normally and not allowing water passed. accompanied by banging in the feedwater tank).

4.10.2 TROUBLESHOOTING FEEDWATER PUMP


EP100-IOMM-2016-10

Fulton Ltd

Page 43

MAINTENANCE - 4

Problem Cause RemedyPump runs backwards when switched off.

1. Leakage in suction pipe. Repair the suction pipe.2. Foot or non-return valve is defective.

Repair the foot or non-return valve.

Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal.Noise. 1. Cavitation occurs in the

pump. Check the suction conditions.

2. Pump does not rotate freely (frictional resistance because of incorrect pump shaft position.

Adjust the pump shaft.

3. Frequency converter operation.

See Grundfos manual.

4. Boiler feedwater non-return valve letting water passed the valve seat, (normally accompanied by banging in the feedwater tank).

Check and clean boiler feedwater non-return valve, ensure it is seating and not allowing water passed.

Water pump will not come on at times.

1. Scale on probes. Check and clean probes, replace as necessary.2. Faulty pump contactor Check the contactor has power. Check the contactor

is pulling in.Replace if necessary.

3. Faulty pump motor. Check the pump has power.If the pump has power but is not running, replace it.

4. Faulty Level Control Relay Check the relay has power and is secure on it’s base. Replace if faulty.

Boiler flooding 1. Pump does not shut off. Dirty probes. Clean or replace as necessary.2. Relay failed. Ensure the relay is secure on its base.

If so replace the water level relay.3. Earth connection. Clean and tighten as required.4. Vacuum created with boiler off.

As the boiler cools, it pulls water from the system piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes underpressure and opens under vacuum.

4.10.2 TROUBLESHOOTING FEEDWATER PUMP

EP100-IOMM-2016-10

Fulton Ltd

Page 44

EP100-IOMM-2016-10

Fulton Ltd

Page 45

APPENDIX - A

APPENDIX A - TI SHEETS

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 46

APPENDIX - A

Electropack 100 kWDimensions & Specification

Technical InformationSheet No. 130 Issue 4

Dimensions

Page 1 of 2

* Required for maintenance and element removal. Once installed, a minimum clearance of 600 mm is required all around the unit.

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

MODEL: ELECTROPACK EP100A Minimum Clearance* 2845B Overall Width 760C Overall Depth 1160D Overall Height 1950E Boiler Depth 965F Safety Valve Discharge Height 1545G Steam Outlet Height 1585H Feedwater Inlet Height 415J Main Boiler Blowdown Height 330K Water Sample Point Height 740

AD

B EC

F

HK

G

J

65

135

EP100-IOMM-2016-10

Fulton Ltd

Page 47

APPENDIX - A

Specification TI-130-EP100-DS-2015-4

Page 2 of 2

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

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: [email protected] Website: www.fulton.co.uk

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

FM 28400

003

FM 28400

MODEL: ELECTROPACK UNIT EP100Designed and manufactured to European Standard BS EN 13445: 2009.

GeneralSteam Output F & A 100 °C kg/h 153kW Rating kW 100Operating Pressure barg 10.34Number of Elements 4WeightShipping Weight kg 430Operational Weight kg 580Water Content L 150Electrical RequirementsFLC 400 V 3 ph 50 Hz A/ph 150FLC 230 V 1 ph 50 Hz A 443Connection Sizes All threads BSP Steam Outlet DN 20Safety Valve Discharge DN 25Feedwater Inlet DN 25Blowdown, Boiler DN 20Water Sample Outlet DN 15

EP100-IOMM-2016-10

Fulton Ltd

Page 48

APPENDIX - A

EP, EU & DragonProbe Lengths


Page 1 of 2

Note: Dimensions mmNote: Measurement taken from under the hexigon.

1, 2 & 3 Branch Electropack and Dragon

Low

Wat

er 1

300

186.

510

830

40

45

6464

Pum

p O

ff

Pum

p O

n

Low

Wat

er 1

Pum

p O

ff

Pum

p O

n

Pum

p O

ff

Pum

p O

n

64

1 Branch

2 Branch

3 Branch

300

186.

510

830

3535

4530

018

6.5

108

3030

45

Low

Wat

er 2

Low

Wat

er 2

Low

Wat

er 1

Low

Wat

er 2

PROBE LENGTHS 1 BRANCHPump OFF 185 mm

Pump ON 215 mm

Low Water Limiter 1 270 mm



Pump ON 215 mm




Pump ON 215 mm



EP100-IOMM-2016-10

Fulton Ltd

Page 49

APPENDIX - A

TI-62-EP-EU-DR-ProbeLengths-2016-5

Page 2 of 2




FM 28400

003

FM 28400

500

- E

lem

ent D

ead

Sec

tion

350

= M

odel

‘350

’ Sig

ht G

lass

264

- Vi

ewab

le in

Sig

ht G

lass

405

- 2nd

Low

Wat

er P

robe

405

- 1st

Low

Wat

er P

robe

330

- Pum

p O

n P

robe

300

- Pum

p O

ff P

robe

51

75

30

108

1

150

175

42

PROBE LENGTHS - EU & 100KW BOILERS IN BOTTLEPump OFF 300 mm 204 mm

Pump ON 330 mm 234 mm

1st. Low Water 405 mm N/A

2nd. Low Water 405 mm N/A

PROBE LENGTHS - E.F.SPump OFF 380 mm

Pump ON 405 mm

1st. Low Water 635 mm

2nd. Low Water 635 mm

Europacks and 100 kW

E.F.S

EP100-IOMM-2016-10

Fulton Ltd

Page 50

APPENDIX - A

J Series & Electric Steam Boilers Recommended Water Conditions





FM 28400

003

FM 28400

IMPORTANT

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

The following are recommended for feedwater and for boiler water

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

BOILER WATER (water inside boiler)pH Value 9.5 to 11.5 tested at room temperature.Hardness Not detectable.Suspended Solids Less than 100 mg/kg.Chloride Less than 500 mg/kg.Oxygen Scavenger, Sodium Sulphite or Tannin 20 to 50 mg/kg.Phosphate Less than 50 mg/kg, in the form of PO4.Total Alkalinity Less than 1000 mg/kg.Caustic Alkalinity Minimum 300 mg/kg as CaCO3.Total Dissolved Solids (TDS) Less than 2000ppm.Iron Less than 1 mg/kg.Silica Less than 150 mg/kg, in the form of SiO2.Dissolved Oxygen None

!

KEYmg/kg = Milligrams per Kilogram

CaCO3 = Calcium Carbonate

PO4 = Phosphate

SiO2 = Silicon Dioxide

PPM = Parts Per Million

1 Grain hardness = 17.118 ppm

therefore 70 ppm = 4.10 grains hardness

For practical purposes mg/kg = ppm

It is critical that the boiler water pH be alkaline in the range 9.5 - 11.5.

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 51

APPENDIX - A

High Integrity Water Level Controls





FM 28400

003

FM 28400

Probes located in the boiler shell will detect low water conditions, the 1st low water level will be indicated by an illuminated indicator lamp, the 2nd low water will activate an indicator and an audible alarm, and switch off the heating elements/burner.

The controls are self monitoring and will indicate an alarm if scale or dirt builds up or if moisture enters the probe body. The control also operates a cyclic self test, checking the integrity of the probe, probe cable and electric circuitry every few seconds. If a fault is found, it will sound an alarm and shut down the elements/burner.

The system meets Health & Safety Executive Guidance Note BG01, Arrangements 2 and 3 for level alarms requiring only weekly testing.

Note: For water level probe replacement see Technical Information sheet TI-103-WaterLevelProbes-2015-3.

High integrity level probes (stainless steel)

High Integrity Water Level Controllers (LC3050)

High Integrity Water Level Probes

Standard level probes (brass)

Note: For operation and maintenance information, please refer to original manufacturers OEM literature supplied.

EP100-IOMM-2016-10

Fulton Ltd

Page 52

APPENDIX - A

Water Level Probes Replacement


Page 1 of 2

Standard Probes (brass)

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

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

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

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

IMPORTANT

Terminal and securing nuts must not be adjusted.

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

!

Terminal nut

Probe body

Probe rod

Securing nuts

PTFEInsulation

Probe rodgrub screw

Probe rodlock nut

Terminal nut

Angle rajah

Probe body

Probe wire

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 53

APPENDIX - A

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

Page 2 of 2




FM 28400

003

FM 28400

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

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

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

Figure. 3 - High Integrity Water Level Probe

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

head.

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

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

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

EP100-IOMM-2016-10

Fulton Ltd

Page 54

APPENDIX - A

Automatic TDS Blowdown Systems


Page 1 of 2

The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS level within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be used to control suspended solids, and prevent the build-up of sludge in the bottom of the boiler. The daily testing of boiler water level controls is a mandatory requirement as defined in the Health & Safety Executive Guidance Note BG01, Arrangement 3.

The method of operation is to take a sample of the boiler water at pre-set timed intervals, pass the sample over an electrode which measures water conductivity (which is proportional to TDS for a given water chemistry), and then compares the result with the control value (normally 2000 ppm), which is set when the unit is commissioned.

If the sample value is higher than the control value, the blowdown solenoid valve opens in a series of pulses until the measured value corresponds to, or is lower than, the set value. When this is achieved, blowdown finishes until the next timed sample is taken when the process is repeated. Should the sample value be lower than the set value, blowdown is deferred until the next timed sample.

For the system to function reliably, the control must be calibrated to a typical water sample that is representative of the water conditions that are likely to prevail during normal running of the boiler and system. Conductivity and as a consequence TDS, can vary significantly with water chemistry. Changes in condensate return rates, alkalinity, chemical dosage, and suspended solids can all affect the performance of an Automatic TDS Blowdown System.

Condensate return rates that vary greatly on a day to day basis can severely disrupt the reliability of the conductivity measurement.

500

400

300

200

100

00 10 20 30 40 50 60 70 80 90 100

Feed water TDS at varying condensate return rates

Condensate return(%)

Raw water TDS (ppm)

50

300

100

350

150

400

200

450

250

500

Feed

wat

er T

DS

(ppm

)

e.g. A boiler with a 50% condensate return and a raw water TDS of 400 will have a boiler feed water TDS of 200 ppm.

Figure. 1 - TDS Graph 1

EP100-IOMM-2016-10

Fulton Ltd

Page 55

APPENDIX - A

TI-30-AutoTDSBlowdown-2015-3

Page 2 of 2




FM 28400

003

FM 28400

e.g. Hourly blowdown rate required to maintain a boiler TDS of 2000 with a feedwater TDS of 200 = 12%

For a 1000 kg/h boiler 125 kg/h (125 l/h) of blowdown is required.

Figure. 2 - TDS Graph 2

30

25

20

15

10

5

00 100 200 300 400 500

% Blowdown required to maintain a boiler TDS of 2000ppm against feed water TDS

Feed water TDS (ppm)From Fig. 1.

Blow

dow

n(a

s a

perc

enta

ge o

f boi

ler o

utpu

t in

kg/h

)

Systems that return for example very little condensate during the day, but a high proportion at night, are almost impossible to control with any real accuracy. At best a compromise calibration will be achieved, where too much blowdown at times may be the penalty.

When installing and commissioning a new Automatic TDS Control Blowdown System, it must be accepted that the calibration will be a reiterative process, requiring continual sampling, testing, and re-calibration until stable system operating conditions are achieved.

When purchasing an Automatic TDS Control Blowdown System from Fulton, the equipment would normally be supplied with the controller wired and fitted to the boiler control panel, with all the other parts supplied loose for piping and wiring on site by others, unless agreed otherwise in our order acknowledgement.

The purchase price of the system supplied fully or part fitted includes for one single visit to commission the system once installed. Part of the commissioning process will be the initial calibration of the TDS sensor to the water conditions prevailing at the time. Further re-calibration will be required until the water treatment regime has been established, and “typical” water conditions have been achieved. Routine calibration checks will be required as part of the site maintenance and water treatment monitoring.

The equipment and staff training required to carry out TDS sampling and calibration can be provided by Fulton. In order to achieve the maximum benefit from the installation of an Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the necessary equipment, and training in order for them to fully understand the function of the system, and the possible consequences of their actions.

Note: Where Automatic TDS Blowdown systems are provided as part of a skid mounted or packaged plantroom system, they will be fully installed piped and wired.

For further details on the installation of Automatic TDS Controlled Blowdown Systems consult the Fulton Ltd Technical Information Sheet 35. Automatic TDS Control Blowdown System Installation Guide.

EP100-IOMM-2016-10

Fulton Ltd

Page 56

APPENDIX - A

Automatic TDS Controlled Blowdown System Installation Guide

Fulton LtdTechnical Information

Sheet No. 35 Issue 2

Page 1

The Automatic Total Dissolved Solids Control Blowdown System supplied by Fulton Ltd is an intermittant type. It consists of an electrical TDS Control Unit, valves (including a solenoid valve) and fittings, TDS sensor, strainer and non return valve (See fig 1).

In most cases the TDS control box will be supplied mounted in the boiler control panel, with the remaining items supplied loose for piping and wiring on site by the installer/site contractor.

All new Fulton vertical steam boilers are provided with a connection to facilitate the fitting of a vertical 15mm NB. dip pipe through the top of the boiler shell, terminating inside the boiler approximately 150mm below the boiler normal working water level, where the maximum concentration of TDS is found.

The 15mm NB. discharge pipework from the dip pipe should incorporate the TDS blowdown system as illustrated. For practical reasons, and to minimise the length of cable runs, the solenoid valve and sensor should be installed as close to the boiler as is practicable. For maintenance purposes the pipework should incorporate unions, and be routed such that access to the boiler flue cover plates, hand hole doors, and blowdown valves are not obstructed.

The site wiring required is one twin core screened cable for the TDS sensor, and one twin core and earth supply to the solenoid valve. The screened cable terminates within the TDS control unit, the twin core and earth cable terminates on terminals in the control panel.

Note:- The screen on the sensor cable should be earthed at the controller end only. For electrical connection details consult the data sheets supplied with the equipment.

The discharge from TDS blowdown systems should be connected to a certified blowdown vessel. For single boiler installations the discharge can be connected into a common boiler ancillary blowdown line, which may be connected to the main blowdown line. For multiple boiler installations the ancillary blowdown, and main blowdown lines must be separated. For recommended pipework installation see the Fulton Typical System Schematic Diagram (SD1V0402).

Full details of these requirements are given in the HSE Guidance Note PM60.

Where TDS blowdown systems are used, it is possible that the frequent discharge into the blowdown vessel will not allow sufficient time for the blowdown vessel contents to cool between successive blowdowns, resulting in discharge temperatures to the drains that are unacceptably high.

The limit set by the Public Health Act 1936 section 27(1)b for the maximum temperature of waste steam or liquids discharged into the public sewers is 43°C. A further practical consideration is that many modern drainage systems employ plastic pipes with mastic joints, which could be seriously damaged by temperatures which under fault conditions could reach 100°C.

EP100-IOMM-2016-10

Fulton Ltd

Page 57

APPENDIX - A

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: [email protected]: www.fulton.co.uk

TI35 ISSUE 2

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice. TI35 12 13 ISSUE 2

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

Page 2

Blowdown fromBoiler

Plug 1/4in. BSP (for sample valve via sample cooler)

Strainer Fig 12

Blowdown Valve BCV1Ball Valve

M10

Plug Tail PT2 Check Valve

LCV1 Sensor

CP10 Sensor Chamber S10

Blowdown to heat recovery system

Ball Valve M10

A solution is to fit a blowdown after cooling system, which automatically mixes cold water with the blowdown discharge.

Aftercooling can be achieved by using direct acting controls that do not require any power supply, or by electrically controlled and activated systems which are marginally cheaper, but require site wiring, and more maintenance after prolonged use.

Aftercooling systems are available from Fulton Boiler Works (Great Britain) Ltd. Technical Information Sheet No 40, Blowdown After Cooling Systems, covering this topic is also available.

Fig. 1 Typical Automatic TDS Blowdown Pipework Assembly

Note:- Regular testing of the boiler water is essential for the correct operation of the boiler in terms of the water treatment programme, but also for the routine re-calibration of the TDS sensor. The 1/4in. BSP tapping at the bottom of the S10 sensor chamber can be used as the connection for a boiler water sample.

In order to take a boiler water sample safely it is important that a Water Sample Cooler made specifically for the purpose is used. Water sample coolers are available from Fulton Boiler Works (Great Britain) Ltd.

EP100-IOMM-2016-10

Fulton Ltd

Page 58

APPENDIX - A

Automatic Timed Boiler Blowdown System





FM 28400

003

FM 28400

A purpose designed cyclic timer used in conjunction with an air actuated ball valve and switch box for the control of blowdown intervals and their duration. The timer can be wired to a switch box on the blowdown valve actuator to monitor valve operation and release an alarm relay if the blowdown valve fails to close fully within a certain period.

The timer front panel has a four digit LED display and push buttons to select functions and set parameters. In RUN mode the control will show a continuous display of the time to the next programmed blowdown in hours and minutes with a decimal point flashing at two second intervals.

For multiple boiler installations, up to nine boilers can be linked, preventing more than one boiler blowing down at a time. A time delay can be programmed to prevent different boilers blowing down in rapid succession and overloading the blowdown vessel.

Controls for boiler blowdown can be fitted to the boiler control panel; BC3150 blowdown controller & BT1050 boiler blowdown timer. Please refer to the relevent Spirax Sarco OEM literature.

An air compressor can be fitted to the system to open/close the automatic timed blowdown valve using compressed air.

Compressed air line in

Air set

Blowdown valve

Auto blowdown valve Open/Closed indicator

Solenoid valve

Auto Blowdown ValveAuto Blowdown Controls

Note: For operation and maintenance information, please refer to original manufacturers OEM literature supplied.

EP100-IOMM-2016-10

Fulton Ltd

Page 59Page 59

Material & Workmanship Guarantee

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

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

On the Fulton Boiler Pressure Vessel

Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within five (5) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the manufacturer’s handbook. This guarantee does not cover damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions.

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

FU LT O N LT D

5 YearG U A R A N T E E

www.fulton.co.uk

Fulton Ltd5 Fernhurst RoadFishpondsBristol BS5 7FGEngland

Telephone: +44 (0) 117 972 3322Fax: +44 (0) 117 972 3358Email: [email protected]

FM 28400

003

EP100-IOMM-2016-10

instlltion, oertion nd mintennce mnul · the fulton electropack 100 kw electric steam boiler is a...

Documents