Manual Calderas

Fulton Steam Horizontal Boiler

FB-S Series 100-800 Hp

Installation, Operation and Maintenance Manual Serial #

__________________________

Model #

__________________________

Fulton Order #

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Sold To

__________________________

Job Name

__________________________

Date

__________________________

The Fulton Companies 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com

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Table of Contents 13. Boil-out of new unit

Introduction Section 1 – Safety Warnings &

Section 4 – Controls & Burner 1. Boiler control panel

Precautions

2. Burner

Section 2 – Description & Section 5 – Operation

Introductions

1. Fitting the boiler

1. General 2. Specifications & Dimensions

2. Starting the burner 3. Daily operating test

Section 3 – Installation 1. Locating the boiler 2. Boiler room ventilation

4. Blowdown procedure 5. To shutdown the burner 6. Evaporation test 7. Fault finding

3. Flue & chimney requirements 4. Recommended Water Conditions 5. Water Supply 6. Glossary of Water Terms

Section 6 – Maintenance 1. General 2. Weekly

7. Valves 8. Electrical requirements 9. Gas supply

3. Six monthly 4. Annually 5. Fitting new gasket

10. Oil supply 11. Installation check points 12. Cleaning

Section 7 - Warranty

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Introduction This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.

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

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

Prior to shipment, the following tests are made to assure the customer the highest standards of manufacturing.

a) Material inspections b) Manufacturing process inspections c) ASME welding inspection d) ASME hydrostatic test inspection e) Electrical components inspection f)

Operating test

g) Final engineering inspection h) Crating inspection

Note

The installation of the boiler should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association. All state and jurisdictional codes beyond the scope of the applicable ASME boiler and pressure vessel codes, for its corresponding classification, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

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All units are crated for crane lift transport. Under no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of the boiler.

The customer should examine the boiler for any damage, especially the refractories around the burner.

Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy equipment. Steam Outlet Safety Valve Connection

Sight Glass

Pressure Controls

Manway

Pressure Gauge Control Panel Burner

Stack Connection

Rigging Point (each side)

Gas Train

*Lifting eyes on top may be used also*

ASME Stamping Rigging Point (each side) *Lifting eyes on top may be used also*

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Section 1

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Section 1 – Safety Warnings & Precautions The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis. •

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

•

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

•

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

WARNING Do not operate, service or repair this equipment unless you fully understand all applicable sections of this manual.

Prior to commencing any internal work on any control panel or electrical junction box, the power must be disconnected.

Do not allow others to operate, service or repair this equipment unless they fully understand all application sections of this manual, and are qualified to operate/maintain the equipment.

Gauge glass valves need to be fully open during boiler operation to prevent boiler water damage in case of gauge glass failure.

Never tamper with low water cutoff sensors or circuitry. o

Boiler blowdown water must be cooled to 90 psig).

To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to.

The boiler blow off operation should be done a minimum of once during the day when the boiler is at 10 PSIG or less.

After a new Fulton Boiler has been in operation for several months, pieces of burned metal will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the

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boiler insulation. This is a normal condition and does not affect the efficiency or the life of the boiler in any way.

All secondary low water trips, flame failure trips or high steam pressure trips will require, by code, a manual reset at the boiler.

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Section 2

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Section 2 – Description & Introductions 1. General a) Fulton model FB-S is a three-pass, water back and corrugated furnace design steam boiler. In the first pass, the flame and high temperature flue gas flows from the front to the back of the furnace. Through the second pass pipes, high temperature flue gas flows from the combustion furnace to the front chamber. In the third pass, the flue gas passes through the third pass pipes to the back of the boiler and vents out. Corrugated furnace highly increases the heat exchange area, heat transfer efficiency and reduces the possible damage to the boiler durability cased by heat expansion and cold contraction. b) Boiler is designed and manufactured to comply with ASME Code, with maximum working pressure of 1.0MPa (150 PSI). c) The fully packaged boiler has passed the strict test before it is delivered to the customer. The equipment will give long life and excellent service on the job if proper operating and maintenance instructions are followed. d) FB-S boiler is a cylindrical vessel, with horizontal tubes passing through and connected to the front and rear tube sheets. The vessel contains the water and absorbs the energy generated from the flame. The front door and rear door provide the seal to contain the hot combustion gasses. Baffles designed into the doors serve to redirect the combustion gasses through the various firetube passages. The flame originates in the furnace. As the combustion gasses travel down the furnace and through the various firetube channels, heat from the flame and combustion gasses is transferred to the water. Transferred energy develops into the required steam or hot water. e) The front door and rear door make it easy to clean the combustion chamber. The pressure vessel can be inspected and repaired by the manhole on the top and handholes on the side or bottom. The general information in this manual applies directly to boilers in sizes ranging from 1 ton/hr through 6 ton/hr steam output boiler for the following fuels: gas, No.2-6 Oil, No2 Oil and Gas. f)

The boiler is equipped with an automatic burner for fully modulating output.

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2. Specifications and Dimensions Specifications Model FB-S

100

125

150

200

250

300

400

500

650

800

3450

4312

5175

6900

8625

10350

13800

17250

22425

27600

Design pressure (psig)

15/150

15/150

15/150

15/150

15/150

15/150

15/150

15/150

15/150

15/150

Water Volume (gallons)

779

924

924

1294

1585

1849

3594

4650

4677

5265

Nominal steam output (lbs/h) (1)

Maximum fuel consumption (2) Light Oil (gp/h)

29

36

43

58

73

88

117

146

189

234

Heavy Oil (gp/h)

27

34

41

54

68

82

108

136

177

216

4156

5196

6235

8313

10,392

12,470

16,626

20,784

27,019

33,252

Natural Gas (ft3/h)

Note: (1) All steam output lbs/hr ratings from 0 psig at 212F. 3

(2) Fuel consumption based on light oil 1, 40,000 BTU/gal, natural gas 1000 BTU/ft , heavy oil 160,000 BTU/gal.

Connection Model FB-S Main steam valve (150 psig) Flange Safety valve connections (150 psig) (in)

100

125

150

200

250

300

400

500

650

800

2.5

3

3

4

4

4

6

6

6

8

2

1.5 (2)

1.5 (2)

2 (2)

2 (2)

2.5 (2)

2.5 (2)

4

4 (2)

4 (2)

Main steam valve (15 psig) (in)

Consult Factory

Safety valve (15 psig) (in)

Consult Factory

Feed Water inlet line (in)

1.0

1.25

1.25

1.25

1.25

1.5

1.5

2

2

2

Blowdown line (in)

1.5 (2)

1.5 (2)

1.5 (2)

1.5 (2)

1.5 (2)

1.5 (2)

1.5 (2)

2 (2)

2 (2)

2 (2)

Flue diameter (in)

14

16

16

18

20

20

22

22

26

26

Note: Specifications and dimensions are approximate. Fulton reserves the right to change specifications and dimensions.

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Section 3

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Section 3 – Installation General Note It is essential that the installing shall be undertaken only by suitably qualified and experienced personnel. Installation should comply with appropriate local and state codes and standards.

1. Locating the Boiler a) The boiler should be closed in dry surroundings on a level base, making sure that there is sufficient room around the boiler to enable the operator and/or the maintenance engineer to gain access to all parts of the boiler. Check location for ease of water supply and electrical connections. b) Place the boiler on a non-combustible floor with clearances to unprotected combustible materials, including plaster or combustible supports. c) It is necessary to have enough clearance from the floor to the ceiling for removing of the burner and have the following clearance from boiler for servicing:

36” Min

36” Min Clearance

36” Min

48” Min

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2. Boiler Room Ventilation a) It is most important to provide free access of air to the boiler. To burn fuel properly, it requires one square inch opening of fresh air for every 3, 000 BTU input of fuel. b) Proper ventilation of the boiler room is essential for good combustion. Install two make up air openings, one at a low level (24” or 610mm from floor) and one at a higher level in the boiler room wall. This will provide a flow of air to exhaust the hot air from the boiler room. c) The following openings are recommended for each size boiler:

Recommended Minimum Makeup Air Openings Model FB-S

100

125

150

200

250

300

400

500

650

800

Minimum area (in2)

1437

1797

2156

2875

3593

4312

5750

7187

9343

11,500

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

Note These measurements are subject to state and local regulations. The installation of exhaust fans in a boiler room is not recommended. An exhaust fan can create down draft in the stack or restrict the burner’s air supply which will result in poor combustion. It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint, in the combustion system can create hazardous conditions.

3. Flue and Chimney Requirements a) The flue from the appliance and the joint between this flue and the chimney are sealed to prevent leakage of combustion products. b) The top of the flue or chimney shall be higher than any roof within a radius of 10 meters. c) Checks are made to ensure that the chimney is suitable for burner and that the proposed installation complies with the local authority and other regulations covering such installations.

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900

d) If more than one appliance is connected to a common flue or chimney the crosssection of the chimney should be adequate for the total volume of combustion products from the appliances. e) The total horizontal run of the boiler flue should not exceed 25% of the total vertical rise. There should be an angle more than 15 degrees for the horizontal run reducing the resistance of the combustion products and avoid rusting by accumulating condensation in the flue. f)

The installer should check the draft with a meter at 0 to 0.15” W.C pressure with the burner off. If the pressure is too low, a balancing damper may be used close to the flue outlet to regulating the pressure of the draft.

4. Recommended Water Conditions 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 water chemistry 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

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

Feedwater 7.5-9.5 140F*

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

< 2ppm

< 15 ppm

-------

--< 500 ppm < 3000 ppm

No visual turbidity**

No visual turbidity**

No sheen No foam +

No sheen No foam +

Colorless liquid++