INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Transcription

1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Mini Compack Electric Steam Boiler This manual must be available to the boiler operator at all times.

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3 SECTION 1 - INTRODUCTION 1.1 General Technical Data Product Overview 1 SECTION 2 - INSTALLATION 2.1 General Pre-Installation Siting Boiler Connections Steam Safety Valves Water Supply Electrical Requirements Commissioning the Boiler 10 SECTION 3 - OPERATION 3.1 General Controls Boiler Control Panel Steam Pressure Controls Setting Steam Pressure Controls Filling The Boiler Draining the Boiler Boiler Start-Up (from cold)-all models Boiler Start-Up Following short term Shut-Down Boiler Shut-Down Short Term Shut-Down (hours) Long Term Shut-Down (weeks) 19 TABLE OF CONTENTS SECTION 4 - MAINTENANCE 4.1 Visual Checks Water Level and Low Water Safety Controls Feedwater Pump Test Low Water Level Checks Evaporation Check Blowdown Procedures Main Boiler Blowdown Element Care and Protection Element Removal Boiler Internal Inspection Feedwater Tank Internal Inspection Cleaning Water Level Probes Schedule of Operator Tests and Checks Daily Weekly-in addition Monthly-in addition Three Monthly-in addition Maintenance Record Keeping Troubleshooting-boiler Troubleshooting-feedwater pump 33 APPENDIX A - TI SHEETS MINI Dimensions & Specification 36 MINI Probe Lengths 38 Recommended Water Conditions 39 Water Level Probes 40 Auto TDS Blowdown Systems 42 Auto TDS Blowdown System Install Guide 44 Electrical diagrams supplied separately Page III

4 WARNINGS! 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 injury or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. Notes: must be observed for essential and effective operating procedures, conditions and as a statement to be highlighted. It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.! 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) (b) (c) SAFed SAFETY ASSESSMENT FEDERATION Limited. Nutmeg House, 60 Gainsford Street, Butlers Wharf, London, SE1 2NY. Health and Safety Executive local office. Your Competent Person. Page IV

5 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 you do not understand. Obtain a service manual from or call a Fulton service engineer. It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner. Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and or damage. A defective boiler can injure you or others. Do not operate a boiler which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the boiler. LIFTING EQUIPMENT 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. Operating the boiler beyond its design limits can damage the boiler, it can also be dangerous. Do not operate the boiler outside its limits. Do not try to upgrade the boiler performance by unapproved modifications. Obey all laws and local regulations which affect you and your boiler. LOW FEEDWATER TEMPERATURE Low feedwater temperature can result in thermal shock to the boiler pressure vessel. Return the maximum amount of condensate and if necessary preheat the feedwater. If in doubt consult. WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by. 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. HYDRAULIC TEST - RISK OF BRITTLE FRACTURE Hydraulic testing requires specialist equipment and is normally only required by engineering surveyors / inspectors. In order to ensure the material/ pressure vessel does not suffer from brittle fracture, hydraulic testing should not be carried out below 7 C. 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. Page V

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7 INTRODUCTION - 1 SECTION 1 - INTRODUCTION 1.1 GENERAL The Fulton Mini Compack 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-112-MINI Dimensions & Specification. 1.3 PRODUCT OVERVIEW The Fulton Mini Compack electric steam boiler is a compact and highly efficient unit designed to meet the requirements of the lower demand steam user. CONTINUED ON NEXT PAGE Page 1

8 INTRODUCTION Figure. 1 - General Arrangement Page 2

9 INTRODUCTION Figure. 2 - General Arrangement Top Key 1. Boiler control panel 2. Access door lock 3. Front access door 4. Steam pressure gauge 5. Top access panel 6. Boiler steam safety valve 7. Main steam stop valve 8. Operating pressure controller 9. Feedwater tank inlet 10. Feedwater tank mounted (optional) 11. Feedwater pump feed 12. Boiler feedwater check valve 13. Feedwater pump 14. Boiler blowdown valve 15. Pressure vessel 16. Electrical control panel 17. Water level probes 18. Pressure reducing set (optional) 19. Boiler feedwater stop valve 20. Feedwater strainer Page 3

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11 INSTALLATION - 2 SECTION 2 - INSTALLATION 2.1 GENERAL The installation of the Fulton Mini Compack 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. Page 5

12 INSTALLATION 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-112-MINI 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 and to the right-hand side 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 and on the right-hand side of the boiler. For connection sizes, refer to Appendix A - TI-112-MINI Dimensions & Specification. 1. Feedwater Inlet (feedwater tank) 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 at 90 p.s.i.g. (6.2 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. 3. Steam Outlet Valve 4. Overflow from feedwater tank The overflow should be piped to a drainage point. 5. Boiler Blowdown Valve The blowdown valve supplied with the boiler should be fitted as close as possible to the boiler in a readily accessible position. 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. 6. Feedwater pump feed 7. Feedwater tank drain Page 6

13 INSTALLATION Figure. 3 - Boiler Connection Points 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 / BSEN :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 7

14 INSTALLATION 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-112-MINI 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. Page 8

15 INSTALLATION - 2 NOT FULTON SUPPLY E MAINS SUPPLY N L1 L2 L3 CONTACTOR ELEMENT MCB PUMP MCB Fulton Control Panel DOOR MICROSWITCH Figure. 4 - Recommended External Wiring Connection to water level probes LC relays Audible alarm Door microswitch Element and pump contactors Element and pump overload Boiler heating element Figure. 5 - Electrical Panel Page 9

16 INSTALLATION 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 80 psi maximum 6. Ensure Boiler 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 retighten 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. Page 10

17 INSTALLATION Switch main isolator ON Check the Power On light illuminates 12. Open the main steam valve 13. Switch the boiler On/Off switch to the ON position Check: a) Low Water light illuminates 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, usually clockwise from front of boiler) Note: If the rotation is incorrect, switch the boiler 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 light will extinguish. 16. Switch the element energised switch to the ON position The element energised switch 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 Boiler switch OFF Turn element energised switch 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 Slowly open the steam valve to release pressure from the boiler Check for steam leaks in connecting pipework Turn main isolator ON Turn element energised switch ON The boiler is now ready for placing into full operation. Page 11

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19 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 if these instructions are ignored. 3.1 GENERAL The following instructions are given for the guidance of the operator in the use of the Mini Compack 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 Mini Compack 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. Page 13

20 OPERATION BOILER CONTROL PANEL 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 Figure. 6 - Controls and Indicators 1. Power On Indicates that power is being supplied to the boiler control circuit and that the control panel is live. This lamp should be illuminated immediately when the main isolator is switched ON and should remain on until the main isolator is switched OFF. 2. 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. 3. Boiler On/Off The switch is illuminated when in the ON position and indicates that the boiler is in a fully operational state. The switch should remain illuminated until switched to the OFF position. 4. Elements Energised The lamp is illuminated when in the ON position and the element is energised. The switch is extinguished when the element is de-energised during the normal on/off cycle of operation or low water condition. Page 14

21 OPERATION STEAM PRESSURE CONTROLS Pressure controls are mounted to the back of the electrical panel and can be accessed by removing the top access panel. Operating Pressure Control Switch (On/Off) Controls the ON/OFF cycle of the element, switching the element off when the desired steam pressure is reached and switching it on when steam pressure falls. Operating pressure controller Figure. 8 - Steam Pressure Controller 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 element being de-energised (switched off) and energised (switched on). A B Figure. 7 - Setting Pressure Controllers Page 15

22 OPERATION FILLING THE BOILER 1. Ensure the feedwater tank has been filled (where fitted to system) 2. Ensure Boiler and element switches are both 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 retighten 6. Ensure all valves in the feedwater line to the boiler are OPEN 7. Switch the Boiler Switch to the ON position 8. 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. 9. Check: a) Boiler Low Water indicator extinguishes b) Audible alarm silences Page 16

23 OPERATION 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 Boiler and element switches are both 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 Page 17

24 OPERATION 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 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 Setting Steam Pressure Controls) 6. Turn the Boiler 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 element 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 element 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 BOILER START-UP FOLLOWING SHORT TERM SHUT-DOWN If the boiler has been shut-down short term (see Section Short Term Shut-Down), the boiler can be simply switched ON and then left to reach working temperature/pressure. Page 18

25 OPERATION BOILER SHUT-DOWN 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 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 Draining the Boiler). Remove all hand holes and boiler elements (see Section Element Removal). 3. Same as 2. but also introduce a form of convection heating into the boiler. Page 19

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27 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. Page 21

28 MAINTENANCE 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 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 22

29 MAINTENANCE LOW WATER LEVEL CHECKS 1. Ensure that the Element Energised switch is in the ON position and is 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 Boiler switch to the OFF position. 3. Drain the boiler below the Low Water level. 4. Switch the Boiler switch to the ON position. 5. Check a) Low Water lamp illuminates b) Audible alarm sounds c) Element Energised switch 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 Lamp de-energises c) Audible alarm stops d) Element Energised Switch illuminates 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 Low Water Level checks allowing water to lower by natural evaporation and not by manual blowdown. Page 23

30 MAINTENANCE BLOWDOWN PROCEDURES Keep the boiler, element 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 MAIN BOILER BLOWDOWN 1. Start the boiler and generate 10 psi of steam pressure (see Section 3.5 Boiler Start-Up). 2. Switch Boiler 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 Boiler and Element switches ON. Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required. Page 24

31 MAINTENANCE 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. Element and pump contactors Boiler heating element Figure Boiler Elements Page 25

32 MAINTENANCE ELEMENT REMOVAL Isolate and completely drain the boiler (see Section 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 Element Care and Protection. Element mounting flange Boiler heating element Element power supply terminals Figure Boiler Element Removal 4.5 BOILER INTERNAL INSPECTION The boiler elements should be removed (see Section 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 Boiler Inspection Hole Page 26

33 MAINTENANCE FEEDWATER TANK INTERNAL INSPECTION Isolate the boiler and remove the boiler top access panel. Check the tank is clean and clear of obstruction. Drain the tank and clean as necessary. Top access to tank (panel removed) Figure Feedwater Tank Inspection Panel 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. Low water (red cable) Pump on (yellow cable) Pump off (black cable) Figure Boiler Water Level Probes Page 27

34 MAINTENANCE SCHEDULE OF OPERATOR TESTS AND CHECKS The following schedule is the advice of. 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. 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

35 MAINTENANCE DAILY 1. Visually inspect boiler casing exterior for signs of leakage (see Section Visual Checks): a) Steam and feedwater pipework b) Valves and fittings 2. Low water level check (see Section Low Water Level Checks). 3. Blowdown the boiler (see Section Main Boiler Blowdown) 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 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 Feedwater Pump Test). 7. Externally mounted feedwater tanks should be checked to ensure they are clean and not obstructed (see Section Feedwater Tank Internal Inspection) MONTHLY IN ADDITION 8. Check the element and pump contactors are working correctly by manually depressing them (see Figure. 5 on page 9). Page 29

36 MAINTENANCE THREE MONTHLY IN ADDITION 9. Drain the boiler (see Section Draining The Boiler). 10. Remove boiler element (see Section Element Removal). 11. Visually inspect the internal water space of the pressure vessel (see Section Boiler Internal Inspection). 12. Visually inspect the 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 water level probes (see Section 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

37 MAINTENANCE 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 training@fulton.co.uk. Electric Steam Boiler - Daily and Weekly Tests DAILY TESTS 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/ starts and elements de-energise/energise. 3. Blowdown, Boiler 4. Blowdown, Water Column 5. Blowdown, Water Level Gauge 6. Pressure gauge reading for blowdown tests. Duration seconds. Test Time. Duration seconds. Test Time. Duration seconds. Test Time. Boiler water and water treatment values must be within known tolerances of the datum. 7. Boiler Water. datum value. TDS. reading datum value. PH reading 8. Oxygen Scavenger Concentration datum value. reading Y - N Y - N Y - N Y - N Y - N Y - N Y - N 9. Brine level correct Y - N Y - N Y - N Y - N Y - N Y - N Y - N WEEKLY TESTS Visual Inspection of casing interior pipework, fittings and elements for signs of leakage Y - N EXAMPLE 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. Model: Boiler Number: Log examined by: Date: MAINTENANCE LOG Date Time Operation Performed Remarks Operators Initials EXAMPLE Page 31

38 MAINTENANCE TROUBLESHOOTING BOILER Problem Cause Remedy Power On indicator not illuminated Low Water lamp illuminated and Audible alarm sounds 1. Mains supply failure. External circuit MCB requires resetting. 2. Door interlock microswitch Fuses need replacing. not made. Indicator lamp needs replacing. 1. Insufficient water in the boiler. 2. Obstruction in the feedwater line to the pump. Check that the feedwater supply line valves are open. Check that the ball valve in the tank is operating correctly by removing the inspection cover on the tank. Check that the shut-off valve below the tank is open. 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. Page 32

39 MAINTENANCE TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy FEEDWATER PUMP Pump will not run Motor starter overload, trips out immediately when supply is switched on. Motor contactor overload trips out occasionally. Motor contactor has not tripped out but the pump does not run. Pump capacity not constant. Pump runs but gives no water. 1. Supply failure. Connect the electricity supply. 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. 1. One fuse/automatic circuit breaker is blown. 2. Contacts in motor contactor overload are faulty. Replace the fuse, reset the circuit breaker. Replace motor starter contacts. 3. Cable connection is loose or faulty. Tighten or replace the cable connection. 4. Motor winding is defective. Replace the motor. 5. Pump blocked. Remove the blockage. 6. Overload setting too low. Set the motor starter correctly. 1. Overload setting is too low. Set the overload correctly. 2. Low voltage at peak times. Check the electricity supply. 1. Pump inlet pressure is too low (cavitation). Check: Motor does not run when started: items: 1, 2, 4, 5, 6, Check the suction conditions. 2. Suction pipe/pump partly blocked. Clean the pump or suction pipe. 3. Pump draws in air. Check the suction conditions. 1. Suction pipe/pump blocked. Clean the pump or suction pipe. 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 letting water passed the valve seat, Check and clean boiler feedwater 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 33

40 MAINTENANCE 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 switched off. defective. Repair the foot or non-return valve. Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal. Noise. 1. Cavitation occurs in the 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 operation. See Grundfos manual. 4. Boiler feedwater non-return valve letting water passed the valve seat, (normally accompanied by banging in the feedwater tank). Check and clean boiler feedwater non-return valve, ensure it is seating and not allowing water passed. Water pump will 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 off. As the boiler cools, it pulls water from the system piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes under pressure and opens under vacuum. Page 34

41 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 ( or consult. Page 35

42 APPENDIX - A Mini Compack Dimensions & Specification Technical Information Sheet No. 112 Issue 6 Dimensions B A C E F D H L J G M N K MODEL: MINI COMPACK CP9, CP12,CP15, CP18 A Minimum Clearance* 500 B Overall Width 600 C Overall Depth 915 D Overall Height 750 E Boiler Depth 760 F Safety Valve Discharge Height 570 G Steam Outlet Height 495 H Electrical Supply Inlet Height 465 J Feedwater Inlet Height 510 K Feedwater Tank Drain 135 L Feedwater Tank Overflow 450 M Pump Feed Inlet Height 200 N Main Boiler Blowdown Height 45 * Required in front of the boiler for maintenance and element removal. Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation. Page 1 of 2 Page 36

43 APPENDIX - A Specification TI-112-MINI-DS MODEL: MINI COMPACK UNIT CP9 CP12 CP15 CP18 Designed and manufactured to British Standard BS Class 2 and PED/97/23/EC. General Steam Output F & A 100 C kg/h kw Rating kw Operating Pressure barg Number of Elements Weight Shipping Weight kg Operational Weight kg Water Content L Feed Tank Volume L Electrical Requirements FLC 400 V 3 ph 50 Hz** A/ph FLC 230 V 1 ph 50 Hz*** A Connection Sizes All threads BSP Steam Outlet DN Safety Valve Discharge DN Feedwater Inlet DN Blowdown, Boiler DN Tank Drain DN Tank Overflow DN ** 3 A/ph for feedwater pump & standard control circuit, included. *** 5 A for feedwater pump & standard control circuit, included. Note: Isolator, mains contactor and fusing not included. Note: Not suitable for condensate return-cold water make-up only. Note: Electrical enclosures are rated IP20 Page 2 of 2 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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. FM FM Page 37

44 APPENDIX - A Mini & Midi Compack Probe Lengths Technical Information Sheet No. 147 Issue 1 1 Branch Mini Compack Pump Off Pump On Low Water PROBE LENGTHS - 1 BRANCH MINI Pump OFF (black) 127 mm Pump ON (yellow) 152 mm Low Water (red) 184 mm Note: Dimensions mm Note: Measurement taken from under the hexigon. Note: Dimensions taken from drawing: FL Branch Midi Compack Pump Off Low Water Pump On PROBE LENGTHS - 2 BRANCH MIDI Pump OFF (black) 152 mm Pump ON (yellow) 178 mm Low Water (red) 216 mm Note: Dimensions mm Note: Measurement taken from under the hexigon. Note: Dimensions taken from drawing: FL Telephone: +44 (0) Fax: +44 (0) Fernhurst Road, Fishponds, Bristol. sales@fulton.co.uk BS5 7FG. England. Website: FM FM 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 38

45 APPENDIX - A J Series & Electric Steam Boilers Recommended Water Conditions Technical Information Sheet No. 139 Issue 2! IMPORTANT It is very important that a strict water management program is followed to ensure trouble free boiler operation. The following are recommended for feedwater and for boiler water FEEDWATER (water entering boiler) ph Value 8.5 to 9.5 tested at room temperature. Hardness Less than 2.0 mg/kg in the form of CaCO 3. Suspended Solids None Chloride Less than 50 mg/kg. Organic Matter Less than 5 mg/kg. Oil None Minimum Temperature 85 C BOILER WATER (water inside boiler) ph Value 9.5 to 11.5 tested at room temperature. Hardness Not detectable. Suspended Solids Less than 100 mg/kg. Chloride Less than 500 mg/kg. Oxygen Scavenger, Sodium Sulphite or Tannin 20 to 50 mg/kg. Phosphate Less than 50 mg/kg, in the form of PO 4. Total Alkalinity Less than 1000 mg/kg. Caustic Alkalinity Minimum 300 mg/kg as CaCO 3. Total Dissolved Solids (TDS) Less than 2000ppm. Iron Less than 1 mg/kg. Silica Less than 150 mg/kg, in the form of SiO 2. Dissolved Oxygen None KEY mg/kg = Milligrams per Kilogram CaCO 3 = Calcium Carbonate PO 4 = Phosphate SiO 2 = Silicon Dioxide PPM = Parts Per Million 1 Grain hardness = ppm therefore 70 ppm = 4.10 grains hardness For practical purposes mg/kg = ppm It is critical that the boiler water ph be alkaline in the range Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids (TDS). Consult your water treatment specialist to establish the frequency and duration of blowdown required to achieve the required conditions. 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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. FM FM Page 39

46 APPENDIX - A Water Level Probes Replacement Technical Information Sheet No. 103 Issue 3 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 PTFE Insulation Probe rod Probe rod grub screw Probe rod lock nut Terminal nut Probe body Figure. 1 - Water Level Probe Components Figure. 2 - Angle Rajah Fitted to Probe Page 1 of 2 Page 40

47 APPENDIX - A High Integrity Probes (stainless steel) TI-103-WaterLevelProbes 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 the hex. nut on the probe head. Align the hole in the probe head with the bottom of the slot in the probe tip. Hold the probe head secure whilst fitting the probe tip. Locknut Locate the pin in the hole/slot and secure with the locknut. Figure. 3 - High Integrity Water Level Probe Page 2 of 2 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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. FM FM Page 41