2010-0201-iom-steampac

Fulton SteamPac Unfired Steam Generators Installation, Operation and Maintenance Manual Serial #

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Model #

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Fulton Order #

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Sold To

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Job Name

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Date

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Fulton Thermal Corp. 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 1

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Table of Contents Section 1 – Safety Warnings & Precautions

28. The Feed Water Piping 29. The Steam Supply 30. The Steam Safety Valve 31. The Steam Pressure Gauge Assembly

Section 2 – Installation 1.

Introduction

2.

Placement

3.

Transport

4.

Location

5.

Access

6.

Clearance

7.

Installation Check Points

8.

Ventilation

9.

Feedwater

10. Recommended Water Conditions 11. Water Supply 12. Glossary of Water Supply Terms

32. Electrical Supply 33. Frost Protection

Section 3 – Operation 1.

Unit Description and Application

2.

Basic Operation

3.

Steam Pressure Controls

4.

Feed Pump Control

5.

High Steam Pressure Control

6.

Steam Safety Valve

7.

Steam Pressure Gauge

8.

Overload Protection

9.

Control Switch

13. Chemical Dosing 14. The Water Column 15. Water Gauge & Gauge Glass

Section 4 – Maintenance 1.

Recommended Water Conditions

16. General

2.

Maintenance Schedule

17. Thermal Fluid Pipework

3.

Safety Relief Valves

18. Bolting Sequence

4.

De-scaling

19. System Connections

5.

Cleaning the Water Probes

20. Valves

6.

Feed Pump

21. Testing

7.

Electrical Controls

22. Insulation

8.

Miscellaneous

23. Thermal Fluids

9.

Troubleshooting

Installation Instructions

24. Return Tank and Connecting Pipework 25. Connection to Drains

Section 5 – Parts & Warranty

26. Steam Pipework 27. The Blow-Off Valve

Section 6 – Product Specs & Data

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Section 1

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Section 1 – Safety Warnings & Precautions This manual is provided as a guide to the correct operation and maintenance of your Fulton SteamPac Unfired Steam Generator, and should be permanently available to the staff responsible for the operation of the SteamPac.

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 SteamPac Unfired Steam Generator. 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 Fulton SteamPac Unfired Steam Generators should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association, National or Canadian Electrical Code. 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 equipment.

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Rigging your heater into position should be handled by a competent rigger experienced in handling heavy equipment.

The customer should examine the unit for any damage.

Note All factory piping flanges should have bolts re-torqued before filling of system as bolts may loosen in shipping.

Note All unions on piping should be tightened prior to operation.

For Your Safety The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis. •

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

•

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

•

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 operating 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 of safety and equipment prior to operation or maintenance of the equipment.

Caution Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly with clean water after leak check has been completed.

Note Where a condensate return tank is to be fitted, this should: 1. Be vented 2. Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature.

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3. Vent pipe should not be downsized (This may cause pressure build up in the condensate tank.) 4. Return pipes must not be insulated. This can cause overheating the return system, causing a vapor lock in the pump. 5. See return system instruction manual for detailed instructions.

Note Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton Representative for advice.

Only properly trained personnel should install and maintain water gauge glass and connections. Wear safety glasses during installation. Before installing, make sure all parts are free of chips and debris.

Keep gauge glass in original packaging until ready to install. Never operate with lucite gauge glass guard removed or without brass rods for gauge glass protection kit.

Warning Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and/or property damage.

Warning Under no circumstances should the water softener water flow limit be exceeded.

Note After installation is complete and prior to operation the pressure vessel should be cleaned. Note a) The non-fused disconnect switch on the control panel that controls the feed water pump should be kept in the “on” position at all times during the boiler operation as well as during the nonoperating period of the boiler.

b) This switch should be turned “off” only when repairs or adjustments should be made.

The pump will continue to operate until the water reaches the correct level in the SteamPac. This level is approximately the center of the water gauge glass.

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

When stopping the SteamPac for any extensive repairs, shut off main disconnect switches on both the boiler side as well as the feed water side.

Note To ensure the continued safety and efficiency of the SteamPac, the schedule of maintenance outlined in this manual should be adhered to.

Note Fulton recommends that the feedwater treatment should be added between the pump and the SteamPac.

Warning Make sure main power switch is off before starting work.

Caution Do not clean the gauge or glass while pressurized or in operation.

Note All of the above maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-7148 or your local Fulton Thermal Representative.

Note o

Room temperature not to exceed 100 F.

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Section 2

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Section 2 – Installation 1. Introduction a) This manual is provided as a guide to the correct operation and maintenance of your unfired steam generator, and should be permanently available to the staff responsible for the operation and maintenance of the unfired steam generator. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards that may be applicable. b) In the event that you require after sales service, Fulton Thermal Corporation has a complete staff of field service technicians, and spare parts are available direct from the factory. Should you require additional information or assistance on the operation and maintenance of your unfired steam generator, please contact the Fulton service department at (315) 298-7148 or contact your local Fulton Representative.

2. Placement a) Proper placement of your unfired steam generator is essential. Attention paid to the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble free installation, operation and maintenance.

3. Transport a) Fulton SteamPacs are skid mounted. Rollers should be placed beneath the frame of the skid or the fork lift holes in the bottom of the skid may be utilized for positioning in the installation area.

4. Location 1. Authorities with jurisdiction over any national, local or insurance codes should be consulted prior to installation to assure compliance. 2. The unfired steam generator should be located as close as possible to the steam users in order to keep condensation & pressure drop to a minimum. 3. A level, hard surface of non-combustible material is required as a suitable base for mounting the unit. It is suggested that a 4” containment curb be installed completely around the unit. In the event of a spill of thermal fluid, the curb will help contain the fluid.

5. Access 1. Access around the unfired steam generator should be provided to facilitate maintenance. Place the SteamPac with clearances to unprotected combustible materials including plaster or combustible supports not less than the clearances listed in the table below.

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Pipes should not be run within 10” of any control cabinets or combustible material. All SteamPacs will also require a minimum clearance overhead for personnel access. In cases where available height is insufficient, a roof or ceiling trap might be considered.

6. Clearance a) Front/Vertical: TBD-Consult the end assembly drawing for the tube bundle removal length specific to the model purchased. b) Sides:

18” (0.5m)

c) Rear:

18” (0.5m)

7. Installation Check Points a) Make sure 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 panel box, the water column, and elsewhere are secure.

Note After installation is complete and prior to operation the pressure vessel should be cleaned.

In general, ensure that the SteamPac area is in conformance with established boiler room requirements. Review national and local codes.

Note Where a condensate return tank is to be fitted, this should: 1. Be vented to a safe location 2. Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature. 3. Vent pipe should not be downsized (this may cause pressure build up in the condensate tank). 4. Return pipes should not be insulated. This can cause overheating the return system, causing a vapor lock in the pump.

5. See Return System Instruction Manual for detailed instructions.

Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton Representative for advice.

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d) Make sure two check valves are installed between the SteamPac and feedwater pump. e) An end of the line trap should be installed in the SteamPac steam header. f)

There are three valves on the SteamPac: the main blowdown valve, the gauge glass drain valve, and the water column drain valve. The SteamPac blow off valve supplied with the SteamPac should be installed on the blow off pipe and connected to a blow off receptacle of approved design.

g) With a pressure transducer, this control sends out a 4 – 20 ma signal to modulate the thermal fluid valve. The controller also sends out a 120V signal to energize an air solenoid on the modulating valve. In the event the steam pressure exceeds the set point by (X) PSI, the valve will de-energize sending the modulating valve to its fail position. h) All these procedures should be done in accordance with state and/or local codes. The water column blow off valve and the gauge glass blow off valve should be connected to the main blow off line.

Caution Do not tamper with the safety features of the low water safety cut out.

i)

Pressure Relief Valve 1. Limits maximum operating pressure of the SteamPac.

j)

Operating Seam Pressure Control 1. Located at the control panel box is a digital process control. The pressure control regulates the thermal fluid control valve, diverting the flow of fluid when maximum pressure is reached and opening the valve when the steam pressure falls below a predetermined level.

k) Sight Glass Isolation Valves 1. The brass sight glass isolation valves are equipped with an internal ball check. In the event that a sight glass should break, the ball will seat, preventing the discharge of steam and water. The brass valve stem must be opened fully to enable this feature. If the valve is in any other position than full open, the ball will not seat. For added safety all Fulton boilers are equipped with gauge glass protectors. l)

High Limit Pressure Control 1. Located at the control panel box and connected to the steam pressure gauge assembly by means of a copper tube. The pressure is usually set 10 to 15 PSI (.703 – 1.054 kg/cm2) above the operating pressure, but below the maximum pressure of the pressure relief valve. If the pressure exceeds the high limit pressure control setting, the SteamPac will automatically shut off.

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2. The high limit pressure control must be manually reset by depressing the plunger located on top of the control.

8. Ventilation a) Ventilation in the room must be sufficient to maintain a building temperature of 100°F or less.

9. Feedwater a) In its readily available form, water is a corrosive chemical solution having dissolved and suspended solids and it is therefore, essential that feed water for any steam generating plant be conditioned prior to use. Specialists in water treatment should always be consulted. b) Just with any other type of steam boiler, the generator must be fed with clean soft water free from calcium and magnesium salts, organic compounds and corrosive reagents. See the table below for upper limits of water characteristics for the steam generator use.

10. Recommended Water Conditions for Boilers/Unfired Steam Generators a) Following are recommendations for feed water and boiler water. Contact your local water treatment professional for testing and treatment recommendations. It is very important that a strict water treatment program be followed. b) It is critical that the boiler pH follow the attached schedule whenever water is in the boiler. Solids that enter in with the feed water will concentrate in the boiler. A regular schedule of boiler blowdown must be maintained to prevent high solid concentrations from corroding the vessel or forming deposits.

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Parameter

7.5-9.5 140F*

Carbon Steel Vertical Horizontal Boiler/ Boiler/SteamPac SteamPac Water Water 8.5-10.5 8.5-10.5 -----

< 2ppm

< 10 ppm

-----

Feedwater

pH Feedwater Temperature Hardness as CaCO3 Chlorides Total Alkalinity Total Dissolved Solids Suspended Solids Total Organic Carbon Iron Dissolved Oxygen Visual Oil Conductivity (μS/cm)

Feedwater

Stainless Steel Vertical Horizontal Boiler/SteamPac Boiler/SteamPac Water Water

6.0-9.5 140F*

8.5-10.5 ---

8.5-10.5 ---

< 15 ppm

< 2ppm

< 10 ppm

< 15 ppm

--< 300 ppm

--< 500 ppm

-----

50 ppm < 300 ppm

50 ppm < 500 ppm

---

< 2000 ppm

< 3000 ppm

---

< 2000 ppm

< 3000 ppm

No visual turbidity** No sheen No foam +

No visual turbidity** No sheen No foam +

No visual turbidity** No sheen No foam +

No visual turbidity** No sheen No foam +

No visual turbidity** No sheen No foam +

No visual turbidity** No sheen No foam +

Colorless liquid++