ORIGINAL INSTRUCTIONS
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Electropack 18 kW - 72 kW Electric Steam Boiler
This manual must be available to the boiler operator at all times. EP18-72-IOMM-9 Fulton Ltd
Page II Original Instructions EP18-72-IOMM-9 Fulton Ltd TABLE OF CONTENTS
SECTION 1 - INTRODUCTION SECTION 4 - MAINTENANCE 1.1 General 1 4.1 Visual Checks 23 1.2 Product Overview 1 4.2 Water Level and Low Water Safety Controls 24 1.3 Technical Data 1 4.2.1 Feedwater Pump Test 24 4.2.2 Low Water Level Checks 25 SECTION 2 - INSTALLATION 4.2.3 Evaporation Check 25 2.1 General 3 4.3 Blowdown Procedures 26 2.2 Pre-Installation 3 4.3.1 Main Boiler Blowdown 26 2.2.1 Siting 3 4.3.2 Water Level Gauge (Sight Glass) Blowdown 27 2.3 Major Components 4 4.4 Element Care and Protection 28 2.3.1 Steam Safety Valves 4 4.4.1 Element Removal 29 2.4 Boiler Connections 6 4.5 Boiler Internal Inspection 30 2.5 Water Supply 8 4.5.1 Feedwater Tank Internal Inspection 30 2.6 Electrical Requirements 8 4.6 Cleaning Water Level Probes 31 2.7 Steam Pressure Control 10 4.7 Schedule of Operator Tests and Checks 32 2.8 Commissioning the Boiler 11 4.7.1 Daily 33 2.9 Cleaning Steam Lines and Pressure Vessels 14 4.7.2 Weekly in addition 33 4.7.3 Monthly in addition 33 SECTION 3 - OPERATION 4.7.4 Three Monthly in addition 34 3.1 General 15 4.8.1 Troubleshooting boiler 35 3.2 Controls and Indicators 15 4.8.2 Troubleshooting feedwater pump 36 3.3 Filling The Feedwater Tank 17 4.8.2 Troubleshooting feedwater pump 37 3.4 Filling The Boiler 18
3.5 Draining the Boiler 19 APPENDIX A - TI SHEETS 3.6 Draining the Feedwater Tank 20 EP 18 - 72 Dimensions & Specification 42 3.7 Boiler Start-Up 20 EP Probe Lengths 44 3.7.1 Boiler Start-Up Following short term Shut-Down 20 Recommended Water Conditions 46 3.8 Boiler Shut-Down 21 Water Level Probes 47 3.8.1 Short Term Shut-Down (hours) 21 3.8.2 Long Term Shut-Down (weeks) 21 Electrical diagrams supplied separately
EP18-72-IOMM-9 Original Instructions 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.
(c) Your Competent Person.
Page IV Original Instructions EP18-72-IOMM-9 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.
EP18-72-IOMM-9 Original Instructions Page V Fulton Ltd
Top access panel
Boiler control panel
Boiler isolator switch
Pressure gauge
Front access panel
Figure. 1 - Electropack Electric Steam Boiler
Page VI Original Instructions EP18-72-IOMM-9 Fulton Ltd INTRODUCTION - 1
SECTION 1 - INTRODUCTION
1.1 GENERAL
The Fulton Electropack electric steam boiler service manual is a generic publication, providing information on standard boiler operation and maintenance.
Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained. Satisfactory performance can only be ensured if the installation recommendations, operating routines and maintenance schedules laid out in this manual are adhered to.
Particular attention should be paid to electrical installation and water treatment.
1.2 PRODUCT OVERVIEW
The Electropack electric steam boiler is a compact and highly efficient unit designed to meet the requirements of the lower demand steam user.
The Electropack 18-72 contains a feedwater tank, pressure vessel, feedwater pump and system controls to create a fully contained steam raising unit with easy access removable cabinet panels
There is the option to heat the feedwater tank with the purpose of reducing the level of Non-Condensable Gases (NCG’s) in the steam as required by HTM2010 and to limit the temperature and pressure drop within the boiler when feedwater is introduced.
1.3 TECHNICAL DATA
For a full specification refer to Appendix A - TI-115-EP-18-72 Dimensions & Specification.
EP18-72-IOMM-9 Original Instructions Page 1 Fulton Ltd
Page 2 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
SECTION 2 - INSTALLATION
2.1 GENERAL
The installation of the Fulton Electropack electric steam boiler should be carried out by competent personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these regulations are complied with.
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.
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-115-EP-18-72 Dimensions & Specification to ascertain the relevant dimensions and weights, special note should be taken of the required vertical clearance required for maintenance.
The flooring must be level, laid in a non-combustible material and be of sufficient strength to support the boiler.
EP18-72-IOMM-9 Original Instructions Page 3 INSTALLATION - 2 Fulton Ltd
2.3 MAJOR COMPONENTS
Boiler/Pressure vessel. Mounted inside the cabinet in the lower half.
Feedwater and condensate return tank. Mounted inside the cabinet in the upper half.
Operator control panel. Mounted inside the cabinet behind the front access panel and accessible with the access panel attached..
Electrical control panel. Mounted inside the cabinet in the upper half behind the front access panel. Panel must be removed for access.
Operating pressure controls
Boiler feedwater pump (Grundfos). 1 x Grundfos feedwater pump is provided for the boiler feedwater mounted to the base of the cabinet. For more information on the feedwater pump, please refer to the Grundfos OEM literature.
Steam pressure gauge. Fitted to the cabinet frame and visible from the front with the access panel attached.
Steam outlet valve. Steam outlet stop valve fitted centrally to the rear of the cabinet.
Safety valve. Fitted to the rear of the cabinet.
Main boiler blowdown valve. Fitted centrally to the rear of the cabinet at the bottom.
Water level gauge set (sight glasses) (optional). Fitted to the side of the cabinet.
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.
Page 4 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
Operator control panel Feedwater tank
Data plate (at rear) Electrical control panel
Pressure gauge Boiler/Pressure vessel
Operating pressure controls
Feedwater pump Boiler elements
Note: For connection points at rear of the boiler, see Figure. 3.
Figure. 2 - General Arrangement
EP18-72-IOMM-9 Original Instructions Page 5 INSTALLATION - 2 Fulton Ltd
2.4 BOILER CONNECTIONS
All connections for services are mounted at the rear of the boiler. For connection sizes, refer to Appendix A - TI-115-EP-18-72 Dimensions & Specification.
Feedwater Inlet (Solenoid Valve) It is advisable to fit a stop valve as close as possible to this connection point. Local Water Authority bylaws may require the fitting of a break (interpose) tank between the mains water supply and the cold water inlet connection on the boiler.
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 at 162 p.s.i.g. (11.2 bar). 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.
Steam Outlet Valve
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.
Water Sample Outlet If the water sample outlet is used, the valve should be fitted as close as possible to the boiler.
Chemical Dosing Inlet point (inside the cabinet on all models)
Combined Overflow and Vent (Heated Tanks Only)
Condensate Return
Feedwater Tank Vent This should be piped to a safe discharge point to avoid any possibility of condensation problems.
Feedwater Tank Overflow The overflow should be piped to a suitable drainage point.
Feedwater Tank Drain
Page 6 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
Feedwater inlet
Feedwater tank vent Condensate return Feedwater tank overflow
Steam outlet valve Safety valve
Water sample outlet
Boiler blowdown valve Feedwater tank drain
Recommended entry area for mains electrical cable
Pump inlet isolating valve
Chemical dosing point
Strainer
Figure. 3 - Boiler Connection Points EP18-72-IOMM-9 Original Instructions Page 7 INSTALLATION - 2 Fulton Ltd
2.5 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.
2.6 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-115-EP-18-72 Dimensions & Specification. The boiler contains all necessary electrical protection.
An electrical isolator should be fitted on a wall as close as possible to the boiler.
It is recommended that the electrical supply to the boiler is located through the rear of the unit below the boiler blowdown valve as shown in Figure. 3 (ensure the cable is not rubbing against areas capable of damaging it). The cable should be routed from this point and secured in a gland nut (not supplied) fitted in the bulkhead at the base of the electrical panel.
Care should be taken to ensure the supply cable is the correct size and installed in accordance with local regulations.
! WARNING The control circuit live light is derived from a single phase. It is possible that with the control phase down or a defective bulb the other phase could be live. Always isolate the supply before investigating any fault.
Page 8 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
Door electrical isolator (supply cable connection point)
Supply cable access hole (fit with a gland nut suitable for the electrical supply cable used)
Figure. 4 - Electrical Supply Cable Location
N.B. Control Panel frame is unbolted on right hand side to allow complete access to the main electrical panel
LC relays Miniature relays
Circuit breakers Transformer
Fuse holders / MCB’s Pump contactor Element contactors Pump overload Door electrical isolator switch
Cooling fan Electrical supply access hole
Figure. 5 - Electrical Connections
EP18-72-IOMM-9 Original Instructions Page 9 INSTALLATION - 2 Fulton Ltd
2.7 STEAM PRESSURE CONTROL
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.
Setting the pressure controllers
High Limit Controller
1. Set the controller range scale to 5 psi below the safety valve setting.
2. Set the differential scale to zero.
On/Off Controller
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).
Valve C is fitted in the pressure supply line to allow the testing of the boiler pressures and the controllers.
A B
High limit controller
On/Off controller
C
Figure. 6 - Pressure Controllers
Page 10 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
2.8 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.
1. Remove cabinet access panels.
2. Check all electrical connections for tightness.
3. Insulation test the elements (see Section 4.4 - Element Care and Protection).
4. Set the steam pressure controllers (High Limit and On/Off) to the pressures required (see Section 2.7 - Steam Pressure Control).
5. Set the tank thermostat to 85 °C (when heated tank fitted).
6. Ensure all element switches are in the OFF position, and connect to the mains electrical supply.
7. Switch the supply main isolator and door isolator to the ON position. Switch the 2A MCB’s to the ON position. The circuit live indicator will illuminate. Override the door micro switches. The fan should run.
8. Fill the Feedwater Tank Turn the water supply ON. Switch the pump switch ON, the Tank Low Water indicator will illuminate. The tank will fill. When working level is reached the Tank Low Water lamp will de-energise.
9. Feedwater Pump checks Bleed the Pump (see Figure. 7). Remove the feedwater pump cover to expose the pump drive shaft coupling (see Figure. 7).
! WARNING Do not make contact or place anything in touch with the moving parts of the pump drive. The cover is removed for a visual inspection of the pump rotation. Stop the pump to replace the cover.
CONTINUED ON NEXT PAGE
EP18-72-IOMM-9 Original Instructions Page 11 INSTALLATION - 2 Fulton Ltd
Removable cover to check pump rotation Feedwater pump bleed nipple
Figure. 7 - Feedwater Pump
Switch the pump MCB ON. Check the rotation of the feedwater pump. Correct rotation is anti-clockwise when viewed from the top of the pump. Switch the pump OFF and wait until the drive shaft stops rotating before replacing the cover.
Note: The pump impeller blades can be damaged by incorrect rotation. If the rotation is incorrect turn the selector switch to the OFF position. Isolate the boiler and alter the phase connections between the pump contactor overload and the pump. Re-check the pump rotation.
With the pump running (pump switch ON), turn the water supply OFF and OPEN the boiler blowdown valve. Check the Tank Low Water indicator, when the indicator illuminates the feedwater should stop.
10. Refill the Feedwater Tank and Boiler CLOSE the blowdown valve. Switch the boiler ON, the Boiler Low Water indicator will illuminate and the alarm will sound. With the mains water ON, the tank will fill and the Tank Low Water indicator will extinguish, the feedwater pump will restart and fill the boiler to normal working level (NWL).
11. Fault indicators and switches checks (see Figure. 8) When the Boiler Low Water Level indicator extinguishes, press the Low Water reset button. Switch OFF the pump MCB, the Pump and Element Fault indicators illuminate, Switch ON the Element Switches. Check Element Fault indicators stay illuminated. Switch ON the element MCB’s, the Element Fault indicators will de-energise and the element switches illuminate.
12. Elements automatic on/off check OPEN the blowdown valve and allow water to drain from the boiler, the Low Water Reset will illuminate and an audible alarm sound, the elements will switch OFF. CLOSE the blowdown valve and switch the Pump MCB to ON, the pump will start to fill the boiler. With the pump filling the boiler, the Low Water indicator will extinguish (when NWL is reached). Press the Low Water Reset switch in order to silence the alarm. When NWL is restored the Element Switches will illuminate. Check the element switch delay is set at 5 seconds (if fitted). CONTINUED ON NEXT PAGE
Page 12 Original Instructions EP18-72-IOMM-9 Fulton Ltd INSTALLATION - 2
13. Pump on/off check When the pump switches OFF, the boiler is at NWL, OPEN the blowdown valve until the pump switches ON, CLOSE the blowdown valve the pump will start to replace the blowdown losses and then stop, SHUT the steam valve.
14. On/off pressure controller check Allow the boiler to gain working pressure, when normal working pressure is reached the boiler will switch off. SLOWLY OPEN the main steam valve and allow the steam pressure to fall until the lower limit on the on/off pressure controller is reached, the boiler should restart. Re-adjust this control as necessary.
15. High limit controller check Test the high limit controller by changing the high limit on the on/off controller to a value above the value set on the high limit controller, allow the boiler to build-up steam pressure until the high limit controller value is reached, the boiler should cut out. Reset the On/Off controller to its original setting. Allow the steam pressure to fall below the set point of the high limit pressure controller. The elements should not energise until the High Pressure Reset is pressed.
16. Check boiler interior for signs of leakage Turn the boiler and feedwater pump switches to the OFF position. Isolate the boiler at the door isolator and check inside the cabinet for steam or water leakage.
17. Check boiler external pipework for signs of leakage Replace the cabinet access panels, SLOWLY OPEN the steam valve to release the pressure in the boiler. Check for steam leaks in all new pipework. Press the High Pressure Reset button.
The boiler is now ready for placing into full operation.
2. 4. 3. 7. 9. 12.
1. 5. 6. 8. 10. 11. 13. 14.
Key 1. High pressure reset button 9. Boiler on/off switch 2. Low water reset button 10. Pump on/off switch 3. Element fault indicator 11. Audible alarm 4. Pump fault indicator 12. Feedwater tank low water indicator 5. Boiler low water indicator 6. Circuit live Indicator Heated tanks only 7. Boiler indicator 13. Tank element On/Off 8. Boiler element switches 14. Tank element fault indicator
Figure. 8 - Control Panel Indicators and Switches
EP18-72-IOMM-9 Original Instructions Page 13 Fulton Ltd
2.9 CLEANING STEAM LINES AND PRESSURE VESSELS
During the first week of boiler operation, clean all oil and dirt from the boiler, the steam line and condensate return line.
1. Disconnect the condensate return pipe adjacent to the condensate return tank.
2. Direct the returns to a floor drain or other safe discharge point and make safe.
3. Leave in this position for one week to allow all impurities to flush through.
4. Drain the boiler completely each day.
5. After the week is completed, drain and flush the condensate return tank, removing all installation sediment. Reconnect the condensate return pipe to the condensate return tank.
Page 14 Original Instructions EP18-72-IOMM-9 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 Electropack electric steam boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health. Where original equipment service manuals are supplied, they must be read and understood in conjunction with this manual. All warnings and cautions must be observed.
3.2 CONTROLS AND INDICATORS
The control panel contains a range of indicator lights to assist with the starting and testing procedures, in addition the panel contains warning and fault indicators. Should a warning or fault be indicated, the boiler must be isolated and the cause investigated by a competent person.
! CAUTION The control circuit live light is derived from a single phase. It is possible that with the control phase down or a defective bulb the other phase could be live. Always isolate the supply before investigating any fault.
CONTINUED ON NEXT PAGE
EP18-72-IOMM-9 Original Instructions Page 15 OPERATION - 3 Fulton Ltd
2. 4. 3. 7. 9. 12.
1. 5. 6. 8. 10. 11. 13. 14.
Figure. 9 - Controls and Indicators
1. High Pressure Reset Button The high pressure reset button will illuminate when the steam high limit controller is tripped. Reset the control by depressing the push button, having first ascertained and corrected the reason for the high pressure condition.
2. Low Water Reset Button Indicates that a low water condition exists and the boiler has shut down. An audible alarm will continue to sound and the elements will remain de-energised until the normal working water level is restored and the reset button is depressed.
3. Boiler Element Fault Indicator Each element has its own M.C.B. which will activate the indicator and shut down the electrical supply to the element. It is safe to operate the boiler with the faulty element switched off providing the faulty element is not allowing steam or water to escape.
4. Pump Fault Indicator This light will illuminate if there is an electrical fault with the feedwater pump.
5. Boiler Low Water Indicator Indicates that a low water condition exists in the boiler and that the boiler has shut down. Operates in conjunction with an audible alarm.
6. Circuit Live Indicator Indicates that power is being supplied to the boiler control circuit and that the control panel is live. This light should be illuminated immediately the door isolator is switched on and should remain on until the door isolator is switched off.
7. Boiler Indicator Indicates that the selector switch has been switched to the on position and that the boiler is in a fully operational position. This light should remain on until the selector switch is turned to the off position.
8. Boiler Element Switches The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised during and Element normal on/off cycle of operation.
CONTINUED ON NEXT PAGE
Page 16 Original Instructions EP18-72-IOMM-9 Fulton Ltd OPERATION - 3
9. Boiler On/Off Switch
10. Pump On/Off Switch In the off position the feedwater pump control circuits are isolated.
11. Audible Alarm
12. Feedwater Tank Low Water Indicator This light will illuminate if there is a low water condition in the feedwater tank. The boiler feedwater pump will be inhibited until the water level in the tank is restored.
13. Feedwater Tank Element On/Of Switch (if fitted) If fitted. The switch is illuminated in the on position and the element is energised. The switch is not illuminated when element is de-energised.
14. Feedwater Tank Element Fault Indicator (if fitted) The feedwater tank element has its own M.C.B. which will activate the indicator and shut down the electrical supply to the element. It is safe to operate the boiler with the faulty element switched off providing the faulty element is not allowing water to escape.
3.3 FILLING THE FEEDWATER TANK
1. Isolate the boiler for initial tank fill to prevent the boiler from draining the tank
2. Ensure the tank drain valve is SHUT
3. Ensure Boiler and Pump switches are both in the OFF position
4. Switch the supply main isolator and door isolator to the ON position
5. Check:
a) Circuit live indicator illuminates.
b) Tank Low Water indicator illuminates
c) The fan runs
6. Turn the water supply ON
7. Check:
a) The tank fills.
b) When working level is reached the Tank Low Water lamp extinguishes
EP18-72-IOMM-9 Original Instructions Page 17 OPERATION - 3 Fulton Ltd
3.4 FILLING THE BOILER
1. Ensure the feedwater tank has been filled (see Section 3.3 - Filling the Feedwater Tank)
2. Ensure Boiler and Pump switches are both in the OFF position
3. Ensure the following valves are OPEN:
a) All valves in the feedwater line to the boiler
b) Water level gauge (sight glass) isolating valves (where fitted)
4. Ensure the following valves are SHUT:
a) Steam outlet valve
b) Main blowdown valve
c) Water level gauge blowdown valves (where fitted)
5. Switch the Pump Switch to the ON position
6. Switch the Boiler Switch to the ON position
7. Check:
a) Boiler Low Water indicator illuminates
b) Audible alarm sounds
c) The feedwater pump starts and fills the boiler to the correct working level and then switches OFF.
8. Press the Reset Low Water button.
9. Check:
a) Boiler Low Water indicator extinguishes
b) Audible alarm silences
Note: It may be necessary to vent the feedwater pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection.
Page 18 Original Instructions EP18-72-IOMM-9 Fulton Ltd OPERATION - 3
3.5 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. Isolate the boiler electrics at the isolator on the front access panel.
3. Close the boiler feedwater stop valve.
4. Open the main steam valve and the feedwater tank drain valve.
5. Open the boiler blowdown valve.
6. Open all valves in the drain lines.
Boilers with automatic blowdown systems
1. The boiler should not be under pressure.
2. The boiler should be cold.
3. Close the blowdown isolation valve.
4. Using a flat-head screwdriver, locate manual blowdown button (labelled as A in Figure. 10), push the Manual Blowdown Button up and make a quarter turn clockwise, this will lock the button in position and open the blowdown valve.
5. Using the blowdown isolation valve to throttle the flow, drain the boiler.
Note: Skid systems and plantrooms have internal drainage systems which require the same procedures.
A
Figure. 10 - Automatic Blowdown Valve
EP18-72-IOMM-9 Original Instructions Page 19 OPERATION - 3 Fulton Ltd
3.6 DRAINING THE FEEDWATER TANK
1. Ensure the tank is cold (heated tanks only).
2. Isolate the boiler electrics at the isolator on the front access panel.
3. Turn off the water supply to the tank.
4. Open the feedwater tank drain valve.
5. Open all valves in the drain lines.
3.7 BOILER START-UP
Do not attempt to start the boiler until this section has been read and fully understood. Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut-down.
1. OPEN the steam valve.
2. OPEN all the valves in the feedwater line. Ensure the feedwater pump is primed.
3. Switch the door isolator switch to the ON position.
4. With the boiler selector switch ON and the boiler and tank elements (when fitted) ON. Turn the Feedwater Pump On/Off switch to the OFF position. Open the boiler blowdown valve and lower the water level in the boiler until the Low Water Alarm Reset button is illuminated and the alarm sounds.
Note: When the Low Water Level alarm sounds, elements that are energised should de-energise and the Element Switches should extinguish.
5. CLOSE the blowdown valve. Turn the Feedwater Pump On/Off switch to the ON position. The feedwater pump should start and restore the water level to the normal position and stop.
6. Press the Low Water Level Reset button. The light should extinguish and the audible alarm should cease. The elements should re-energise, the Element Switches should illuminate.
The boiler is now ready for use.
The on/off steam pressure controller will control the on/off cycle of the elements once the boiler is operating. The low water relays automatically maintain the level of water in the boiler (and tank if fitted) and will immediately shut off the power to the elements should the water level fall to an unsafe level. The Element Switches situated on the control panel enable elements to be switched on or off independently to meet steam requirements.
3.7.1 BOILER START-UP FOLLOWING SHORT TERM SHUT-DOWN
If the boiler has been shut-down short term (see Section 3.8.1 - Short Term Shut-Down), the boiler can be simply switched ON and then left to reach working temperature/pressure.
Page 20 Original Instructions EP18-72-IOMM-9 Fulton Ltd OPERATION - 3
3.8 BOILER SHUT-DOWN
3.8.1 SHORT TERM SHUT-DOWN (HOURS)
1. Select Boiler OFF on the operators control panel switch. The elements will de-energise.
2. Close the steam outlet vale
3.8.2 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 and tank completely (see Section 3.5 - 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.
EP18-72-IOMM-9 Original Instructions Page 21 Fulton Ltd
Page 22 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
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.
EP18-72-IOMM-9 Original Instructions Page 23 MAINTENANCE - 4 Fulton Ltd
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.
Page 24 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.2.2 LOW WATER LEVEL CHECKS
1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off.
2. Switch OFF the pump using the Pump On/Off switch.
3. Allow the water level to lower by natural evaporation below the Low Water level.
4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the boiler stops heating.
If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.
5. Switch ON the pump using the Pump On/Off switch.
6. Verify that the pump runs and refills the boiler. When the water level rises above the Low Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silences and the elements start heating.
7. Verify that the pump continues to run until the Pump Off level is reached and then switches off.
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.
EP18-72-IOMM-9 Original Instructions Page 25 MAINTENANCE - 4 Fulton Ltd
4.3 BLOWDOWN PROCEDURES
Keep the boiler, elements, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by following these blowdown procedures.
Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.
4.3.1 MAIN BOILER BLOWDOWN
1. Start the boiler and generate not more than 10 psi of steam (see Section 3.3 Starting the Boiler).
2. Switch Pump and Element switches OFF.
3. Fully OPEN the boiler blowdown valve for not more than 5 seconds, or as recommended by the water treatment specialist.
4. CLOSE the blowdown valve.
5. Resume normal operation by switching Pump and Element switches ON.
Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required.
Boiler feedwater Feedwater stop valve non-return valve
Boiler blowdown valve
Figure. 11 - Blowdown Valve
Page 26 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.3.2 WATER LEVEL GAUGE (SIGHT GLASS) BLOWDOWN
Blowdown the water level gauge (sight glass) set 1.
1. Open the water level gauge glass blowdown valve A
2. Close (for approx. 3 seconds) the top gauge valve B
3. Open valve B
4. Close (for approx. 3 seconds) the bottom gauge valve C
5. Open valve C
6. Close valve A
Repeat for gauge set 2
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.
WORKING STEAM WATER POSITION BLOWDOWN BLOWDOWN
B B B
C C C
A A A
Operating Positions Figure. 12 - Water Level Gauge Operating Positions
EP18-72-IOMM-9 Original Instructions Page 27 MAINTENANCE - 4 Fulton Ltd
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 elements
Figure. 13 - Boiler Elements
Page 28 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.4.1 ELEMENT REMOVAL
Isolate and completely drain the boiler (see Section 3.5 - 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 securing nut Element mounting flange
Boiler heating element
Element power supply terminals
Figure. 14 - Boiler Element Removal
EP18-72-IOMM-9 Original Instructions Page 29 MAINTENANCE - 4 Fulton Ltd
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
Boiler heating element
Figure. 15 - Boiler Inspection Hole
4.5.1 FEEDWATER TANK INTERNAL INSPECTION
Isolate the boiler electrics at the isolator on the front access panel and remove the boiler top access panel. Open the feedwater tank access door and check the tank is clean and clear of obstruction. Drain the tank and clean as necessary (see Section 3.6 - Draining the Feedwater Tank).
Boiler water level Feedwater tank probes access door
Figure. 16 - Feedwater Tank Inspection Door
Page 30 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.6 CLEANING WATER LEVEL PROBES
Feedwater Tank Isolate the boiler electrics at the isolator on the front access panel and remove the boiler top access panel.
Remove and clean the feedwater tank level probes taking note of probe lead positions.
For more information on the water level probes see Appendix A - TI-103-Water Level Probes.
Solenoid Solenoid valve valve closed open Low water (black cable) (yellow cable) (red cable)
Figure. 17 - Feedwater Tank Water Level Probes
Boiler Isolate the boiler electrics at the isolator on the front access panel and remove the boiler right side access panel.
Remove and clean the boiler level probes taking note of probe lead positions.
Pump off Pump on Low water Low water (black cable) (yellow cable) (brown cable) (red cable)
Figure. 18 - Boiler Water Level Probes
EP18-72-IOMM-9 Original Instructions Page 31 MAINTENANCE - 4 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 32 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
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 Check).
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. Pump test (see Section 4.2.1 - Feedwater Pump Test).
4.7.3 MONTHLY IN ADDITION
7. Visually inspect the feedwater tank interior (see Section 4.5.1 - Feedwater Tank Internal Inspection).
8. Check the element and pump contactors are working correctly by manually depressing them (see Figure. 5 Electrical Connections).
EP18-72-IOMM-9 Original Instructions Page 33 MAINTENANCE - 4 Fulton Ltd
4.7.4 THREE MONTHLY IN ADDITION
9. Drain the boiler (see Section 3.5 - 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 each element 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 and feedwater tank 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. Restore the boiler water level and reconnect the electrical supply.
Page 34 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.8.1 TROUBLESHOOTING BOILER
Problem Cause Remedy Circuit Live indicator 1. Mains supply failure. External circuit MCB requires resetting. not illuminated 2. Door interlock microswitch Fuses need replacing. not made. Indicator lamp needs replacing. Boiler Low Water 1. Insufficient water in the Check that the feedwater supply line valves are lamp illuminated and boiler. open. Check that the ball valve in the tank is Audible alarm sounds operating correctly by removing the inspection cover 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. High Pressure 1. On/Off Pressure Control Audible alarm sounds failure. 2. High pressure controller set too close to on/off control setting. Feed Water Tank Low 1. Low Water. Check that water supply line valves are open. Check water indicated the feedwater solenoid valve is opening. 2. Faulty water level relay. Check that the feedwater relay is pressed firmly home on its base. Pump Fault indicated 1. Electrical fault in the Check the circuit fuse, replace as required. feedwater pump circuit. 2. Thermal overload fitted to Check that the unit has been set to the correct the pump motor contactor amperage and adjust if necessary. If the fault requires re-setting. continues after the controls have been reset, a major fault exists which can only be corrected by a competent person with correct electrical test equipment. 3. Faulty pump overload. Element Fault 1. MCB requires re-setting. If the fault persists the element and the circuit must be fully checked by a competent person. Tank Low Water 1. Insufficient water in the tank Check the valves in the feedwater supply line indicated are open. Check the feedwater solenoid valve is opening. Incorrect connections to the tank water level probes. Faulty water level relay, check that each relay is pressed firmly on to its base.
Note: Unless a faulty element is allowing steam or water to escape it is safe to operate the boiler with the faulty element fitted provided that the element selector switch has been switched off.
Note: Open circuit element faults will not be detected by the element fault detection system.
EP18-72-IOMM-9 Original Instructions Page 35 MAINTENANCE - 4 Fulton Ltd
4.8.2 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
Page 36 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4
4.8.2 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.
EP18-72-IOMM-9 Original Instructions Page 37 MAINTENANCE - 4 Fulton Ltd 7 7+ Y - N Y - N Y - N Y - N Y - N Y - N 6 Y - N Y - N Y - N sig. sig. sig. sig. 5 Y - N Y - N Y - N 4 Y - N Y - N Y - N Model: 3 Y - N Y - N Y - N Boiler Number: 2 Y - N Y - N Y - N 5. 6. 7. 7+. Date: Day 1 Y - N Y - N Y - N Test results and actions taken Test Date reading reading reading sig. sig. sig. sig. TDS. PH Duration seconds. Time. Test DAILY TESTS DAILY WEEKLY TESTS WEEKLY datum value. datum value. datum value. 2. 3. 4. 1. Blowdown, Boiler Boiler Water. Low Water Level Check - low water indicator illuminates, alarm sounds and feedwater pump Low Water stops/starts. Visual Inspection of casing interior pipework, fittings and elements for signs leakage Visual Visual Inspection of casing exterior pipework and fittings for signs leakage Visual Pressure gauge reading for blowdown tests. Oxygen Scavenger Concentration Brine level correct - Feedwater pump, start/stop Pump Test Safety valve outlet pipe to safe blowdown point and free of damage Day Log examined by: 3. 4. Boiler water and treatment values must be within known tolerances of the datum. 5. 2. 8. 1. 6. 7. 9. 10. Electric Steam Boiler - Daily and Weekly Tests Electric Steam Boiler - Daily and Weekly
Page 38 Original Instructions EP18-72-IOMM-9 Fulton Ltd MAINTENANCE - 4 Operators Initials Remarks MAINTENANCE LOG Operation Performed Time Date
EP18-72-IOMM-9 Original Instructions Page 39 Fulton Ltd
Page 40 Original Instructions EP18-72-IOMM-9 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.
EP18-72-IOMM-9 Original Instructions Page 41 APPENDIX - A Fulton Ltd
Technical Information Sheet No. 115 Issue 10 Electropack 18 kW - 72 kW Dimensions & Specification
Dimensions
C B E
H M
A D J L G F P N1 N2 K N3
MODEL: ELECTROPACK 18, 24, 36, 48, 54, 72 A Minimum Clearance* 2230 B Overall Width 760 C Overall Depth 1100 D Overall Height 1931 E Boiler Depth 965 F Safety Valve Discharge Height 1085 G Steam Outlet Height 1125 H Feedwater Inlet Height 1760 J Feedwater Tank Vent 1770 K Feedwater Tank Drain 210 L Feedwater Tank Overflow 1705 M Condensate Return Height 1757 N1 Main Boiler Blowdown (1 Element Vessel) 630 N2 Main Boiler Blowdown (2 Element Vessel) 495 N3 Main Boiler Blowdown (3 Element Vessel) 330 P Water Sample Point Height 780 * Required for maintenance and element removal. Once installed, a minimum clearance of 600 mm is required all around the unit.
Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation.
Page 1 of 2
Page 42 Original Instructions EP18-72-IOMM-9 Fulton Ltd APPENDIX - A
Specification TI-115-EP18-72-DS-2017-10
MODEL: ELECTROPACK UNIT EP18 EP24 EP36 EP48 EP54 EP72 Designed and manufactured to BS EN 13445:2009 and PED 2014/68/EU.
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 390 390 390 390 390 390 Operational Weight kg 560 560 560 560 560 560 Boiler working water volume L 38 38 61 61 84 84 Feed Tank Volume L 77 77 77 77 77 77 Electrical Requirements FLC 400 V 3 ph 50 Hz** A/ph 32 40 58 75 84 110 FLC 230 V 1 ph 50 Hz*** A 86 112 164 216 242 320 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 Condensate Return DN 15 15 15 15 15 15 Feedwater Inlet DN 20 20 20 20 20 20 Feedwater Pump Inlet DN 25 25 25 25 25 25 Blowdown, Boiler DN 20 20 20 20 20 20 Blowdown, Water Level Gauge DN 15 15 15 15 15 15 (Sight Glass) - where fitted Feedwater Tank Vent DN 40 40 40 40 40 40 Feedwater Tank Drain DN 15 15 15 15 15 15 Feedwater Tank Overflow DN 25 25 25 25 25 25 Water Sample Outlet DN 15 15 15 15 15 15 ** 6 A/ph for feedwater pump & standard control circuit, included. *** 7.5 A 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
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.
EP18-72-IOMM-9 Original Instructions Page 43 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 44 Original Instructions EP18-72-IOMM-9 Fulton Ltd APPENDIX - A
Europacks and 100 kW TI-62-EP-EU-DR-ProbeLengths-2017-6 1 150 300 - Pump Off Probe 300 - Pump Off 330 - Pump On Probe Probe 405 - 1st Low Water Probe 405 - 2nd Low Water 42 175 108 30 75 500 - Element Dead Section Sight Glass 350 = Model ‘350’ in Sight Glass 264 - Viewable 51
PV PROBE LENGTHS - EU & EP100 IN BOTTLE Pump OFF 300 mm 204 mm Pump ON 330 mm 234 mm 1st. Low Water 405 mm N/A 2nd. Low Water 405 mm N/A
E.F.S
PV PROBE LENGTHS - E.F.S Pump OFF 380 mm Pump ON 405 mm 1st. Low Water 635 mm 2nd. Low Water 635 mm
Page 2 of 2
Telephone: +44 (0) 117 972 3322 Fulton Ltd Fax: +44 (0) 117 972 3358 E-mail: [email protected] 5 Fernhurst Road, Fishponds, Bristol. 003 BS5 7FG. England. Website: www.fulton.co.uk 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.
EP18-72-IOMM-9 Original Instructions Page 45 APPENDIX - A Fulton Ltd
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
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.
Page 46 Original Instructions EP18-72-IOMM-9 Fulton Ltd APPENDIX - A
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
EP18-72-IOMM-9 Original Instructions Page 47 APPENDIX - A Fulton Ltd
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
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.
Page 48 Original Instructions EP18-72-IOMM-9 Fulton Ltd Material & Workmanship Guarantee
5 Year GUARANTEE F U D L T T O N L
n the Fulton Boiler Pressure essel
Fulton td will repair or replace E W factor an Fulton pressure essel which within fi e (5) ears of the date of deli er is found to be defecti e in workmanship, or material, pro ided this e uipment is operated and maintained b the bu er for the purpose for which it was designed and in accordance with the manufacturer s handbook. This guarantee does not co er damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions. This guarantee is good onl in the nited ingdom of Great Britain and orthern reland. This guarantee does not include labour or deli er charges of an 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.
EP18-72-IOMM-9 Original Instructions Page 49 www.fulton.co.uk
EP18-72-IOMM-9
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