Electric Steam Boiler

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Dragon Electric Steam Boiler

This manual must be available to the boiler operator at all times. DRAGON-IOMM-2016-5 Fulton Ltd

Page II DRAGON-IOMM-2016-5 Fulton Ltd TABLE OF CONTENTS

SECTION 1 - INTRODUCTION SECTION 4 - MAINTENANCE 1.1 General 1 4.1 Visual Checks 21 1.2 Technical Data 1 4.2 Water Level and Low Water Safety Controls 22 1.3 Product Overview 1 4.2.1 Feedwater Pump Test 22 4.2.2 Low Water Level Checks 23 SECTION 2 - INSTALLATION 4.2.3 Evaporation Check 23 2.1 General 5 4.3 Blowdown Procedures 24 2.2 Pre-Installation 5 4.3.1 Main Boiler Blowdown 24 2.2.1 Siting 6 4.3.2 Water Level Gauge (Sight Glass) Blowdown 24 2.3 Boiler Connections 6 4.4 Element Care and Protection 25 2.3.1 Steam Safety Valves 7 4.4.1 Element Removal 26 2.4 Water Supply 8 4.5 Boiler Internal Inspection 26 2.5 Electrical Requirements 8 4.5.1 Feedwater Tank Internal Inspection 27 2.6 Commissioning the Boiler 10 4.6 Cleaning Water Level Probes 27 4.7 Schedule of Operator Tests and Checks 28 SECTION 3 - OPERATION 4.7.1 Daily 29 3.1 General 13 4.7.2 Weekly-in addition 29 3.2 Controls 13 4.7.3 Monthly-in addition 29 3.2.1 Boiler Control Panel 14 4.7.4 Three Monthly-in addition 30 3.2.2 Steam Pressure Controls 16 4.8 Maintenance Record Keeping 31 3.2.2.1 Setting Steam Pressure Controls 16 4.9.1 Troubleshooting-boiler 32 3.3 Filling The Boiler 17 4.9.2 Troubleshooting-feedwater pump 33 3.4 Draining the Boiler 18

3.5 Boiler Start-Up (from cold)-all models 19 APPENDIX A - TI SHEETS 3.5.1 Boiler Start-Up Following short term Shut-Down 19 Dragon Dimensions & Specification 36 3.6 Boiler Shut-Down 20 Dragon Probe Lengths 38 3.6.1 Short Term Shut-Down (hours) 20 Recommended Water Conditions 39 3.6.2 Long Term Shut-Down (weeks) 20 Water Level Probes 40 Auto TDS Blowdown Systems 42 Auto TDS Blowdown System Install Guide 44

Electrical diagrams supplied separately

DRAGON-IOMM-2016-5 Page III WARNINGS Fulton Ltd

! CAUTION In case of emergency This 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 has been investigated by a competent person and rectified.

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

• WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel involved injury or death to personnel. in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and • CAUTIONS must be observed to prevent damage NOTES by which hazards are to be eliminated or or destruction of equipment or loss of operating reduced. effectiveness. Personnel must become familiar with all aspects of • Notes: must be observed for essential and safety and equipment prior to operation or effective operating procedures, conditions and as maintenance of the equipment. a statement to be highlighted.

! 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.

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) Health and Safety Executive local office.

Page IV DRAGON-IOMM-2016-5 Fulton Ltd WARNINGS

SAFETY The 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.

! WARNING ! CAUTION Do not try to do repairs or any other maintenance work Obey all laws and local regulations which affect you and you do not understand. Obtain a service manual from your boiler. Fulton Ltd or call a Fulton service engineer. LOW FEEDWATER TEMPERATURE It is the responsibility of the installer to ensure all parts Low feedwater temperature can result in thermal shock supplied with the boiler are fitted in a correct and safe to the boiler pressure vessel. Return the maximum manner. amount of condensate and if necessary preheat the feedwater. If in doubt consult Fulton Ltd. Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong WATER SOFTENER and CHEMICAL TREATMENT connection can cause injury and or damage. The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by A defective boiler can injure you or others. Do not Fulton Ltd. operate a boiler which is defective or has missing It is the responsibility of the operator to ensure adequate parts. Make sure that all maintenance procedures are supplies of chemical are available at all times completed before using the boiler. (including commissioning). Costly repairs could be required should the plant operate without chemicals or LIFTING EQUIPMENT the wrong dosage of chemicals. Make sure that lifting equipment complies with all local regulations and is suitable for the job. You can be injured HYDRAULIC TEST - RISK OF BRITTLE FRACTURE if you use faulty lifting equipment. Make sure the lifting Hydraulic testing requires specialist equipment and equipment is in good condition. is normally only required by engineering surveyors / inspectors. In order to ensure the material/ pressure Operating the boiler beyond its design limits can damage vessel does not suffer from brittle fracture, hydraulic the boiler, it can also be dangerous. Do not operate the testing should not be carried out below 7 °C. boiler outside its limits. Do not try to upgrade the boiler performance by unapproved modifications.

Non-approved modifications can cause injury and damage. 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 qualified personnel should work on or in the locality of a steam boiler and ancillary equipment. Always ensure the working area and floor are clear of potential hazards, work slowly and methodically. Do NOT store inflammable materials near the boiler.

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

DRAGON-IOMM-2016-5 Page V Fulton Ltd

Page VI DRAGON-IOMM-2016-5 Fulton Ltd INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 General

The Fulton Dragon 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.

1.2 Technical Data

For a full specification refer to Appendix A - TI-113-DRAGON Dimensions & Specification.

1.3 Product Overview

The Fulton Dragon electric steam boiler is a compact and highly efficient unit designed to meet the requirements of the lower demand steam user.

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DRAGON-IOMM-2016-5 Page 1 INTRODUCTION - 1 Fulton Ltd

1 3

1 4

9 16 8 17 15

12 18 19 11

Figure. 1 - General Arrangement

Page 2 DRAGON-IOMM-2016-5 Fulton Ltd INTRODUCTION - 1

20 6

Figure. 2 - General Arrangement Top

Key 1. Boiler control panel 12. Feedwater pump 2. Steam pressure gauge 13. Boiler feedwater check valve 3. Front access door 14. Boiler feedwater stop valve 4. Access door lock 15. Feedwater tank mounted (optional) 5. Top access panel 16. Feedwater tank overflow 6. Electrical control panel 17. Feedwater tank water inlet 7. Operating pressure controller 18. Feedwater pump feed 8. Boiler steam safety valve 19. Feedwater tank drain 9. Main steam stop valve 20. Pressure vessel 10. Boiler blowdown valve 21. Boiler water level probes 11. Water sample point

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Page 4 DRAGON-IOMM-2016-5 Fulton Ltd INSTALLATION - 2

SECTION 2 - INSTALLATION

2.1 General

The installation of the Fulton Dragon 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.

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.

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2.2.1 Siting

The boiler house should be sufficiently sized to allow easy and safe access to all parts of the boiler for operational and maintenance purposes.

Reference should be made to Appendix A - TI-113-DRAGON Dimensions & Specification to ascertain the relevant dimensions and weights, special note should be taken of the required clearance for maintenance. Allow sufficient room at the rear of the boiler to allow for the connection of all services.

The flooring must be level, laid in a non-combustible material and be of sufficient strength to support the boiler.

2.3 Boiler Connections

All connections for services are mounted at the rear of the boiler. For connection sizes, refer to Appendix A - TI-113-DRAGON Dimensions & Specification.

1. Feedwater Inlet It is advisable to fit a stop valve as close as possible to this connection point.

2. Steam Safety Valve Discharge The 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.

! CAUTION Unless otherwise specified the steam safety valve supplied with the boiler is pre-set. 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.

3. Steam Outlet Valve

4. Boiler Blowdown Valve Connection 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 Outlet This is to be connected to a sample cooler to take safe boiler water samples.

Non standard fitting connections

6. Water Level Gauge (sight glass) Blowdown It is recommended the blowdown connection is made with a short (6 in.) length of soft copper tube connected to steel tube running to the blowdown receiver. The copper tube will relieve any stresses on the water level gauge set caused by the steel blowdown line.

7. Feedwater tank overflow The overflow should be piped to a drainage point.

8. Feedwater pump feed

9. Feedwater tank drain

10. Feedwater tank water inlet

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7 2 10

5 9

Figure. 3 - Boiler Connection Points

2.3.1 Steam Safety Valves

Safety valves are factory fitted and pre-set, they MUST NOT be adjusted. The discharge outlet should 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) The safety valve fitted to the boiler is designed to prevent the boiler exceeding its design 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.

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2.4 Water Supply

! CAUTION WATER SOFTENER and CHEMICAL TREATMENT The 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.

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.

2.5 Electrical Requirements

An individual wiring diagram for the boiler is located with the control panel. When referring to the electrical specification of the boiler, the wiring diagram number should be quoted.

The power ratings and requirements are given in Appendix A - TI-113-Dragon Dimensions & Specification.

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

! CAUTION The boiler front access door is fitted with a safety microswitch. This switch automatically isolates the boiler electrically when the front door is open, and must be connected to a contactor fitted in the external mains supply distribution system.

It is essential that the electrical installation of the boiler is designed to protect both element and pump circuits from excess current. See Figure. 4 for recommended external wiring.

An electrical isolator should be securely fitted as close as possible to the boiler.

Note: Any electrical work should be undertaken by a qualified installer, to current I.E.E regulations.

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NOT FULTON SUPPLY

3 PHASE FUSED AND ISOLATED SUPPLY

L1 L2 L3 External Wiring Box

N E MAIN ISOLATOR

MCB MCB MCB MCB External Supply Wiring

Main Terminal Rail Panel Connections Wiring

CONTACTOR CONTACTOR CONTACTOR CONTACTOR ELEMENT 1 ELEMENT 2 ELEMENT 3 FEED PUMP

Figure. 4 - Recommended External Wiring

LC relays

Element and pump contactors Element and pump overload Audible alarm

Figure. 5 - Electrical Panel

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2.6 Commissioning the Boiler

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.

! WARNING With the door open and the electrics overridden it is possible for the elements to be LIVE. Extreme caution must be observed when working under these conditions.

1. Isolate boiler (mains supply)

2. Open front access door Remove access cover on the top of the boiler

3. Check all electrical connections for tightness

4. Insulation test (IR) the elements

5. Set the steam operating pressure control to maximum pressure required

6. Ensure Mains switch Circuit live switch is in the OFF position Connect to the mains electrical supply

7. Close boiler blowdown valve Close main steam valve

8. Open all valves in the feedwater line and pump supply line Allow feedwater tank to fill Check for leaks

9. Loosen the air release valve on the pump until water emerges from the plug and then re- tighten

10. Close front access door Refit access cover on the top of the boiler

! WARNING The Power On indicator is derived from one phase. It is possible for the Power On indicator supply phase to be down, leaving the other two phases live. Always isolate the supply before working on the panel.

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Page 10 DRAGON-IOMM-2016-5 Fulton Ltd INSTALLATION - 2

11. Switch main isolator ON Check the Circuit Live light illuminates

12. Open the main steam valve

13. Switch the Mains On/Off switch to the ON position Check: a) Low Water lights illuminate b) Feedwater pump starts c) Alarm sounds

! CAUTION The feedwater pump impeller blades can be damaged by incorrect rotation.

14. Check rotation of the feedwater pump (correct rotation shown by arrow on the pump)

Note: If the rotation is incorrect, switch the Mains On/Off switch to the OFF position, isolate the boiler and alter the phase connections between the pump contactor overload and the pump. Check that the pump rotation is now correct.

15. Check the feedwater pump runs until correct water level is achieved. When water level is at normal working level (NWL) the Low Water lights will extinguish

16. Switch the element switches to the ON position The element switches should illuminate

17. Close the main steam stop valve

18. Observing the steam pressure gauge, allow the boiler to build-up steam pressure until it reaches the set limit on the operating pressure control switch and de-energises the elements. Adjust the control switch as necessary

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

19. Check for leaks: Turn Mains switch OFF Turn element switches OFF Turn main electrical isolator OFF Open access cover on the top of boiler and front access door Check for steam/water leaks Close access cover on the top of boiler and close front access door Check for steam leaks in connecting pipework

Turn main electrical isolator ON Turn Mains switch ON Turn element switches ON Slowly open the steam valve to release pressure from the boiler until it reaches the set limit on the operating pressure control switch and re-energises the elements

The boiler is now ready for placing into full operation.

DRAGON-IOMM-2016-5 Page 11 Fulton Ltd

Page 12 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

SECTION 3 - OPERATION

! 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 Dragon 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.

3.2 Controls

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

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3.2.1 Boiler Control Panel

The control panel contains a range of rocker switch 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.

1. 3.

7. 8.

5. 6.

4. 4.

Figure. 6 - Controls and Indicators

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1. Circuit live Indicates that power is being supplied to the boiler control circuit and that the control panel is live. This light should be illuminated immediately when the main isolator is switched on and should remain on until the main isolator is switched off.

2. Mains This is an illuminated switch and will be lit when the switch is in the ON position only. The switch controls all power to the boiler control system.

3. Element Switches These are illuminated switches, each switch controls one element. The switches are illuminated when in the ON position and the elements are energised. The switch is extinguished when the elements are de-energised during the normal on/off cycle of operation

4. Low Water Indicates that a low water condition exists in the boiler and that the boiler has shut down. Operates in conjunction with an audible alarm. The boiler cannot be restarted until the fault has been rectified.

5. Pump Running This light will be illuminated when the feedwater pump circuit is energised.

6. Max Water Level This light will be illuminated once the water level in the boiler is at a satisfactory level. It will be extinguished when the water level drops to the point where the feedwater pump is energised.

7. Boiler Heating This light operates in conjunction with the steam operating pressure controller. At start-up it indicates that it is safe to switch the elements ON. During the normal running cycle it indicates whether the elements are energised or not.

8. Max Pressure This light will be illuminated only when the boiler has reached its maximum operating pressure.

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3.2.2 Steam Pressure Controls

Pressure controls are mounted to the back of the electrical panel and can be accessed by removing the top access panel and RH side panel.

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.

Operating pressure controller

Figure. 8 - Steam Pressure Controller

3.2.2.1 Setting Steam Pressure Controls

Adjust the steam pressure controls to suit the boiler application.

It should be noted that boilers are designed to operate most efficiently at their maximum operating pressure.

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

Operating Pressure Control Switch (On/Off)

1. Set the Range Scale (A) to the maximum pressure required.

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

A B

Figure. 7 - Setting Pressure Controllers

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3.3 Filling The Boiler

1. Ensure the feedwater tank has been filled (where fitted to system)

2. Ensure Mains and Element switches are in the OFF position

3. Ensure the following valves are Open:

a) All valves in the line to the feedwater tank

b) All valves in the feedwater line to the feedwater pump

4. Ensure the following valves are Shut:

a) Steam outlet valve

b) Main blowdown valve

! 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.

5. Loosen the air release valve on the pump until water emerges from the plug and then re- tighten

6. Ensure all valves in the feedwater line to the boiler are OPEN

7. Open the main steam out valve

8. Switch the Boiler Switch to the On position

9. Check:

a) Boiler Low Water indicator illuminates

b) Audible alarm sounds

c) The feedwater pump starts and fills the boiler to the correct working level and then switches Off.

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 be necessary to let air into the system to allow the boiler to fill.

10. Check:

a) Boiler Low Water indicators extinguish

b) Audible alarm silences

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3.4 Draining the Boiler

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

Boilers with manual blowdown valves

1. Ensure the boiler is cold.

2. Ensure Mains switch and Element switches are in the OFF position

3. Isolate the feedwater tank (where fitted) and the feedwater pump (close valves).

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. Using the blowdown bypass valve to throttle the flow, drain the boiler.

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

If a blowdown bypass valve is not fitted then you can manually blowdown the boiler by using a flat-head screwdriver. Locate manual blowdown button (labelled as A in Figure. 9), push the Manual Blowdown Button up and make a quarter turn clockwise, this will lock the button in position and open the blowdown valve.

Automatic blowdown valve

A Blowdown bypass valve

Main blowdown valve

Figure. 9 - Automatic Blowdown Valve

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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 controls are set correctly (see Section 3.2.2.1 - Setting Steam Pressure Controls)

6. Turn the Mains switch and Element switches to the ON position. The boiler is now fully operational and will be controlled as follows:

The steam pressure control 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.

4. 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 4.7.1) 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.

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3.6 Boiler Shut-Down

3.6.1 Short Term Shut-Down (hours)

1. Turn Boiler switch OFF Turn Element switch OFF The element will de-energise.

2. Close the steam outlet valve

3.6.2 Long Term Shut-Down (weeks)

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

1. Fully flood the boiler to exclude as much air as possible.

2. Drain the boiler completely (see Section 3.4 - Draining the Boiler). Remove all hand holes and boiler elements (see Section 4.4.1 - Element Removal).

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

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SECTION 4 - MAINTENANCE

! 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.

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.

Any rectification or repairs should be carried out by trained, competent service personnel.

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

4.1 Visual Checks

Inspect the steam and feedwater pipework, valves, fittings and elements for signs of leakage. 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.

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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.

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.

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

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

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. 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.

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

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4.2.2 Low Water Level Checks

1. Ensure that the Element Switches are in the ON position and are illuminated to indicate elements are energised. Ensure the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch the Mains switch to the OFF position to stop the pump from starting

3. Drain the boiler below the Low Water level

4. Switch the Mains switch to the ON position

5. Check

a) Low Water lights illuminate

b) Audible alarm sounds

c) Boiler Heating light does not illuminate

d) Feedwater pump starts

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

6. When Pump Off level is reached, Check:

a) Feedwater pump switches off

b) Low Water Light de-energises

c) Audible alarm stops

d) Boiler Heating light illuminates

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.

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4.3 Blowdown Procedures

Keep the boiler, elements and interconnecting pipework free from sludge and scale build-up by following this blowdown procedure.

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.

Note: A safe blowdown receptacle must be used.

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 Mains 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 Mains and Element switches ON.

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

4.3.2 Water Level Gauge (Sight Glass) Blowdown

Blowdown the water level gauge (sight WORKING STEAM WATER glass) set 1. POSITION BLOWDOWN BLOWDOWN

1. Open the water level gauge glass B blowdown valve A B B

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

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

5. Open valve C Operating Positions Figure. 10 - Water Level Gauge Operating Positions 6. Close valve A

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.

Page 24 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

4.4 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, if stored correctly, have an indefinite shelf life. However, problems will arise if they are stored in damp or humid conditions. Moisture can be absorbed by the insulation as the elements are fitted with a breathing seal. It is, therefore, a useful precaution to perform an electrical insulation test on the elements prior to fitting or starting up, following prolonged shut down. If the reading is low (below 1 megohm), heating in an oven at 300 °C for three hours should restore the element.

Boiler heating element

Figure. 11 - Boiler Elements

DRAGON-IOMM-2016-5 Page 25 OPERATION - 3 Fulton Ltd

4.4.1 Element Removal

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

Remove the four element securing nuts from the element mounting flange. Element is now loose for removal from the boiler.

The elements will need removing to carry out internal inspections of the boiler and to complete element checks mentioned in Section 4.4 - Element Care and Protection.

Element mounting flange

Boiler heating element

Element power supply terminals

Figure. 12 - Boiler Element Removal

4.5 Boiler Internal Inspection

The boiler elements should be removed (see Section 4.4.1 Element Removal) 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.

New gaskets must be fitted every time an element is removed. 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.

Boiler heating element removed to reveal inspection hole

Figure. 13 - Boiler Inspection Hole

Page 26 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

4.5.1 Feedwater Tank Internal Inspection

Isolate the boiler and remove the tank top access panel.

Check the tank is clean and clear of obstruction.

Drain the tank and clean as necessary.

4.6 Cleaning Water Level Probes

Boiler Isolate the boiler electrics at the main isolator and remove the boiler top access panel.

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.

Water level probes

Figure. 14 - Boiler Water Level Probes

DRAGON-IOMM-2016-5 Page 27 OPERATION - 3 Fulton Ltd

4.7 Schedule of Operator Tests and Checks

The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler 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.

! 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 the boiler immediately and consult Fulton Ltd.

The following procedures are designed to prevent the build-up of scale, silt or sludge in the bottom of the boiler 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.

Page 28 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

4.7.1 Daily

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

a) Steam and feedwater pipework

b) Valves and fittings

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).

4.7.2 Weekly in addition

! WARNING Ensure the main electrical supply is isolated before starting work.

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) Valves and fittings

c) Elements

! 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. Feedwater pump test (see Section 4.2.1 - Feedwater Pump Test).

7. Externally mounted feedwater tanks should be checked to ensure they are clean and not obstructed (see Section 4.5.1 - Feedwater Tank Internal Inspection).

4.7.3 Monthly in addition

8. Check the element and pump contactors are working correctly by manually depressing them (see Figure. 5 on page 9).

DRAGON-IOMM-2016-5 Page 29 OPERATION - 3 Fulton Ltd

4.7.4 Three Monthly in addition

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

10. Remove boiler elements (see Section 4.4.1 - Element Removal).

11. Visually inspect the internal water space of the pressure vessel (see Section 4.5 - Boiler Internal Inspection).

12. Visually inspect the elements and check for excessive scale build-up or corrosion. Clean as required and replace, always use a new gasket (see Section 4.4 Element Care and Protection).

13. Check and clean the feedwater strainer.

14. Check all electrical connections for tightness.

15. Remove and clean the boiler water level probes (see Section 4.6 - Cleaning Water Level Probes).

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

16. Return all valves to normal working position.

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

Page 30 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

4.8 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 the Fulton boiler Log Books provided by Fulton.

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

Model:

Electric Steam Boiler - Daily and Weekly Tests Boiler Number:

DAILY TESTS 1 2 3 4 5 6 7 Date 1. Visual Inspection of casing exterior pipework and fittings for signs of leakage 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/ Y - N Y - N Y - N Y - N Y - N Y - N Y - N starts and elements de-energise/energise. Duration seconds. 3. Blowdown, Boiler Test Time. Duration seconds. 4. Blowdown, Water Column Test Time. Duration seconds. 5. Blowdown, Water Level Gauge Test Time.

6. Pressure gauge reading for blowdown tests. Boiler water and water treatment values must be within known tolerances of the datum. datum value. TDS. reading 7. Boiler Water. 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 Inspection of casing interior pipework, fittings and elements for signs of leakage 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 taken Day 1. sig. Day 5. sig.

2. sig. 6. sig.

3. sig. 7. sig.

4. sig. 7+. sig. Log examinedEXAMPLE by: Date:

MAINTENANCE LOG Date Time Operation Performed Remarks Operators Initials

EXAMPLE DRAGON-IOMM-2016-5 Page 31 OPERATION - 3 Fulton Ltd

4.9.1 Troubleshooting boiler

Problem Cause Remedy Circuit Live indicator 1. Mains supply failure. External circuit MCB requires resetting. not illuminated. 2. Mains fuse failure Fuses need replacing. Indicator lamp needs replacing. 3. Mains isolator switch not switched on. Low Water lamp 1. Insufficient water in the Check that the feedwater supply line valves are illuminated. feedwater tank. open. Check that the ball valve in the tank is Audible alarm operating correctly by removing the inspection cover sounds. on the tank. 2. Obstruction in the feedwater Check that the shut-off valve below the tank is open. line to the pump. Remove and clean the filter in the strainer. Check that 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 Check connections to water level probes. water level probes. 6. Faulty water level relay. Check that each relay is pressed firmly home on its base. Lack of steam 1. All elements are not pressure switched on. 2. Faulty element contactor. Check contactor points and coil. 3. Faulty element. Megger test each leg of the element.

Note: It is safe to operate a boiler with a faulty element provided that the faulty element is switched OFF and it is not leaking either steam or water.

Page 32 DRAGON-IOMM-2016-5 Fulton Ltd OPERATION - 3

4.9.2 Troubleshooting feedwater pump

Problem Cause Remedy FEEDWATER PUMP 1. Supply failure. Connect the electricity supply. Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers. 3. Motor contactor overload has Reactivate the motor protection. tripped out. 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, 1. One fuse/automatic circuit breaker is Replace the fuse, reset the circuit trips out immediately blown. breaker. when supply is 2. Contacts in motor contactor overload Replace motor starter contacts. switched on. are faulty. 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 1. Overload setting is too low. Set the overload correctly. overload trips out 2. Low voltage at peak times. Check the electricity supply. occasionally. Motor contactor has Check: not tripped out but the Motor does not run when started: pump does not run. items: 1, 2, 4, 5, 6, Pump capacity not 1. Pump inlet pressure is too low Check the suction conditions. constant. (cavitation). 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 1. Suction pipe/pump blocked. Clean the pump or suction pipe. no water. 2. Foot or non-return valve blocked in Repair the foot or non-return valve. closed position. 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 Check and clean boiler feedwater letting water passed the valve seat, non-return valve, ensure it is seating (normally and not allowing water passed. accompanied by banging in the feedwater tank).

CONTINUED ON NEXT PAGE

DRAGON-IOMM-2016-5 Page 33 OPERATION - 3 Fulton Ltd

4.9.2 Troubleshooting feedwater pump

Problem Cause Remedy Pump runs 1. Leakage in suction pipe. Repair the suction pipe. backwards when 2. Foot or non-return valve is Repair the foot or non-return valve. switched off. defective. Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal. Noise. 1. Cavitation occurs in the Check the suction conditions. pump. 2. Pump does not rotate Adjust the pump shaft. freely (frictional resistance because of incorrect pump shaft position. 3. Frequency converter See Grundfos manual. operation. 4. Boiler feedwater non-return Check and clean boiler feedwater non-return valve, valve letting water passed ensure it is seating and not allowing water passed. the valve seat, (normally accompanied by banging in the feedwater tank). Water pump will 1. Scale on probes. Check and clean probes, replace as necessary. not come on at 2. Faulty pump contactor Check the contactor has power. Check the contactor times. 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 As the boiler cools, it pulls water from the system off. piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes under pressure and opens under vacuum.

Page 34 DRAGON-IOMM-2016-5 Fulton Ltd 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.

DRAGON-IOMM-2016-5 Page 35 APPENDIX - A Fulton Ltd

Technical Information Sheet No. 113 Issue 4 Dragon Dimensions & Specification

Dimensions

C B A E

G F L H K

MODEL: DRAGON 18, 24 36, 48 54, 72 A Minimum Clearance* 600 600 600 B Overall Width 565 565 565 C Overall Depth 840 840 840 D Overall Height 950 950 1100 E Boiler Depth 695 695 695 F Safety Valve Discharge Height 650 785 955 G Steam Outlet Height 695 825 995 H Feedwater Inlet Height 355 355 355 K Main Boiler Blowdown Height 200 200 200 L Water Sample Point Height 655 655 655 * Recommended height for service & maintenance

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

Page 1 of 2

Page 36 DRAGON-IOMM-2016-5 Fulton Ltd APPENDIX - A

Specification TI-113-DRAGON-DS-2016-4

MODEL: DRAGON UNIT 18 24 36 48 54 72 Designed and manufactured to BS EN 13445:2009 and PED 97/23/EC for operating pressure 150 psi (10.34 barg). General Steam Output F & A 100 °C kg/h 29 38 57 77 86 115 kW Rating kW 18 24 36 48 54 72 Operating Pressure barg 10.34 10.34 10.34 10.34 10.34 10.34 Number of Elements 1 1 2 2 3 3 Weight Shipping Weight kg 236 236 240 240 280 305 Operational Weight kg 226 226 230 230 270 270 Water Content L 41 41 66 66 91 91 Electrical Requirements FLC 400 V 3 ph 50 Hz** A/ph 32 40 58 75 84 110 Connection Sizes All threads BSP F= Female, M=Male Steam Outlet DN 20 20 20 20 20 20 Safety Valve Discharge DN 25 25 25 25 25 25 Boiler Feedwater Inlet DN 15 15 15 15 15 15 Blowdown, Boiler DN 20 20 20 20 20 20 Blowdown, Water Level Gauge DN 8 8 8 8 8 8 (Sight Glass) - where fitted Tank Overflow DN 25 25 25 25 25 25 Tank Inlet DN 30 30 30 30 30 30 Water Sample Outlet DN 15 15 15 15 15 15 ** 6 A/ph for feedwater pump & standard control circuit, included.

Note: Electrical enclosures are rated IP20

Page 2 of 2

Telephone: +44 (0) 117 972 3322 Fulton Ltd Fax: +44 (0) 117 972 3358 5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected] BS5 7FG. England. Website: www.fulton.co.uk 003 FMFM 28400 28400 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.

DRAGON-IOMM-2016-5 Page 37

APPENDIX - A Fulton Ltd

Technical Information Sheet No. 62 Issue 6 EP, EU & Dragon Probe Lengths

1, 2 & 3 Branch Electropack and Dragon 1 Branch 1 Branch 1 Branch PV PROBE LENGTHS 1 BRANCH 45

Pump OFF 185 mm 45 45 186.5

Pump ON 215 mm 108 Pump Off Pump On Low Water 1 Low Water 2 Low Water 186.5 108 186.5 Pump Off Pump On Low Water 1 Low Water 2 Low Water 108 300 30 Pump Off Low Water Limiter 1 270 mm Pump On Low Water 1 Low Water 2 Low Water 300 30 300 Low Water Limiter 2 270 mm 30 40 64 40 64 40

Note: Dimensions mm 64 Note: Measurement taken from under the hexigon.

2 Branch 2 Branch 2 Branch

PV PROBE LENGTHS 2 BRANCH 45 45 Pump OFF 185 mm 45 186.5 108 Pump Off Pump On Low Water 1 Low Water 2 Low Water

Pump ON 215 mm 186.5 108 Pump Off Pump On 186.5 Low Water 1 Low Water 2 Low Water 108 Pump Off 300 Pump On 30 Low Water 2 Low Water Low Water 1 Low Water 300 Low Water Limiter 1 275 mm 30 300 30 35

Low Water Limiter 2 275 mm 64 35 64 35 64

3 Branch 3 Branch 3 Branch 45

PV PROBE LENGTHS 3 BRANCH 45 45 Pump OFF 185 mm 186.5 108 Pump Off Pump On Low Water 1 Low Water 2 Low Water 186.5 108 Pump Off Pump On 186.5 Low Water 1 Low Water 2 Low Water 108

Pump ON 215 mm 300 Pump Off Pump On 30 Low Water 2 Low Water Low Water 1 Low Water 300 30 300 Low Water Limiter 1 280 mm 30 30 64

Low Water Limiter 2 280 mm 30 30 64 64

FEEDWATER TANK EP 18-72 PROBE LENGTHS (1-3 BRANCH) Low Water 400 mm Solenoid Valve Open 215 mm Solenoid Valve Close 185 mm

Page 1 of 2

Page 38 DRAGON-IOMM-2016-5 Fulton Ltd APPENDIX - A

Technical Information Sheet No. 139 Issue 3 J Series & Electric Steam Boilers Recommended Water Conditions

! 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 ppm in the form of CaCO3. Suspended Solids None Chloride Less than 50 ppm. Organic Matter Less than 5 ppm. Oil None Minimum Temperature 85 °C BOILER WATER (water inside boiler) pH Value 10.0 to 12.0 tested at room temperature. Hardness Not detectable. Suspended Solids Less than 100 ppm. Chloride Less than 500 ppm. Oxygen Scavenger, Sodium Sulphite 30 to 70 ppm. Tannin 30 to 70 ppm

Phosphate 30 to 70 ppm, in the form of PO4. Total Alkalinity Less than 1000 ppm.

Caustic Alkalinity Minimum 300 ppm as CaCO3. Total Dissolved Solids (TDS) Less than 2000 ppm. Iron Less than 1 ppm.

Silica Less than 150 ppm, in the form of SiO2. Dissolved Oxygen None

KEY mg/kg = Milligrams per Kilogram It is critical that the boiler water pH be alkaline in the range 10.0 - 12.0. CaCO3 = Calcium Carbonate = Phosphate PO4 Daily boiler blowdown is essential to help prevent formation of deposits SiO2 = Silicon Dioxide and reduce Total Dissolved Solids PPM = Parts Per Million (TDS).

1 Grain hardness = 17.118 ppm Consult your water treatment specialist therefore 70 ppm = 4.10 grains hardness to establish the frequency and duration of blowdown required to achieve the For practical required conditions. = mg/kg purposes ppm

DRAGON-IOMM-2016-5 Page 39 APPENDIX - A Fulton Ltd

Technical Information Sheet No. 103 Issue 3 Water Level Probes Replacement

Standard Probes (brass)

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.

! IMPORTANT Terminal and securing nuts must not be adjusted.

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

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.

Terminal nut Securing nuts

Probe wire

Probe body Angle rajah

Terminal nut PTFE Insulation Probe rod grub screw Probe body Probe rod Probe rod lock nut

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

Page 1 of 2

Page 40 DRAGON-IOMM-2016-5 Fulton Ltd APPENDIX - A

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

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.

Ensure measurements are taken from the underside of Align the hole in the probe the hex. nut on the probe head with the bottom of the Hold the probe head secure head. slot in the probe tip. whilst fitting the probe tip.

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

Figure. 3 - High Integrity Water Level Probe

Page 2 of 2

DRAGON-IOMM-2016-5 Page 41 APPENDIX - A Fulton Ltd

Technical Information Sheet No. 30 Issue 3 Automatic TDS Blowdown Systems

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.

Feed water TDS at varying condensate return rates 500

400

300

200

100 Feed water TDS (ppm)

0 0 10 20 30 40 50 60 70 80 90 100 Condensate return(%) Raw water TDS (ppm) 50 100 150 200 250

300 350 400 450 500

Figure. 1 - TDS Graph 1

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.

Page 1 of 2

Page 42 DRAGON-IOMM-2016-5 Fulton Ltd APPENDIX - A

TI-30-AutoTDSBlowdown-2015-3

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.

15 Blowdown 10

5 (as a percentage of boiler output in kg/h) 0 0 100 200 300 400 500 Feed water TDS (ppm) From Fig. 1. % Blowdown required to maintain a boiler TDS of 2000ppm against feed water TDS

Figure. 2 - TDS Graph 2 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.

Page 2 of 2

DRAGON-IOMM-2016-5 Page 43 APPENDIX - A Fulton Ltd

Technical Information Fulton Ltd Sheet No. 35 Issue 2 Automatic TDS Controlled Blowdown System Installation Guide

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.

Page 1

Page 44 DRAGON-IOMM-2016-5 Fulton Ltd APPENDIX - A

TI35 ISSUE 2

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

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

Strainer Fig 12 Blowdown Valve BCV1 Ball Valve M10

Plug Tail PT2 Check Valve

LCV1 Sensor CP10 Sensor Chamber S10 Ball Valve M10 Blowdown to heat recovery system

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.

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 E-mail: [email protected] Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol, BS5 7FG, England. Website: www.fulton.co.uk 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 Page 2

DRAGON-IOMM-2016-5 Page 45 Fulton Ltd

Page 46 DRAGON-IOMM-2016-5 Fulton Ltd Material & Workmanship Guarantee

5 Year GUARANTEE F U D L T T O N L

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.

General Guarantee

The Fulton general guarantee is given in lieu of cause whatsoever. Defective goods or parts and in exclusion of any warranty expressed or must be returned to us as soon as possible implied, statutory or otherwise, as to the state, after discovery of the defect. Costs of carriage condition, performance, quality or fitness of and of detaching and incorporating parts will the goods. Save thereunder we shall be under be borne by you. In all cases at the termination no obligation or liability of any kind to you in of such 12 months all liability on our part will regard to the goods. In the case of new goods cease. No liability whatsoever is to be incurred manufactured and supplied by us we will make by us in respect of gauge or sight glasses, good any defect developing therein under proper packing glands or electric motors or any goods use within 12 months of delivery, provided that or accessories not of our manufacture. But so after investigation in our sole discretion we are far as we are able, we shall let you have the satisfied that the defect arose from faulty design, benefit of any guarantee or warranty given to us materials or workmanship and from no other in respect thereof.

DRAGON-IOMM-2016-5 Page 47 www.fulton.co.uk

DRAGON-IOMM-2016-5

Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 Email: [email protected] 003 FM 28400