INSTALLATION, OPERATION & MAINTENANCE MANUAL

Transcription

1 Fulton Ltd INSTALLATION, OPERATION & MAINTENANCE MANUAL EFS Electric Flash Steam Boiler (Optional 9 Kw Heated Tank) This Manual must be available to the boiler operator at all times. EFS Optional heated tank Manual ISSUE 1

2 ! 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, whatever 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 boiler. 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.

3 LIST OF CONTENTS INTRODUCTION 1 General 1.1 Technical Data 1.2 INSTALLATION 2 General 2.1 Siting 2.2 Water Supply (see also section 5.3) 2.3 Connections (no tank) Connections (optional tank fitted) Electrical Requirements 2.5 Steam Pressure Control 2.6 Commissioning 2.7 Electrical General GENERAL DATA 5 Boiler Dimensions 5.1 Boiler Specification 5.2 Recommended Water Conditions 5.3 Gloassary of Terms 5.4 Electrical Diagrams (Supplied Separately) OPERATION 3 Control Panel 3.1 Controls and Fault Indicators Feedwater Tank Controls Starting the Boiler 3.2 MAINTENANCE 4 Visual Checks 4.1 Water Level and Safety Controls 4.2 Pump Test st Low Water Level Check nd Low Water Level Check Blowdown Procedure 4.3 Element Care and Protection 4.4 Internal Inspection 4.5 Removal Replacement Schedule of Operator Tests and Checks 4.6 Daily Weekly Three Monthly Troubleshooting 4.7 Boiler Controls Test Log 4.8

4 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 boiler and serious personal injury.! WARNING Do not try to do repairs or any other maintenance work you do not understand. Obtain a Service Manual from Fulton Ltd. or call a Fulton Service Engineer.! WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner.! WARNING Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and or damage.! WARNING 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.! CAUTION Obey all laws and local regulations which affect you and your boiler.! WARNING 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.! WARNING 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.! WARNING Non-approved modifications can cause injury and damage. Contact your Fulton dealer before modifying the boiler.! WARNING 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.! WARNING DANGER FROM HOT SURFACES 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.! WARNING The importance of correct boiler water and feedwater cannot be over emphasised, see the relevant section in this manual.! CAUTION 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 Fulton Ltd.! CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by Fulton Ltd. 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.! CAUTION 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. WARNING 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.

5 LIST OF ILLUSTRATIONS TITLE FIG. NO. EFS Boiler 1 General Arrangment (Heated Tank) 2 Boiler Connection Points (No Tank) 3a Boiler Connection Points (Optional Tank Fitted) 3b Electrical Connections (Unheated/No Tank) 4a Electrical Connections (Heated Tank) 4b Pressure Controllers 5 Feedwater Pump 6 Control Panel 7 Heating Elements 8 Hand Hole Assembly 9 Boiler Dimensions 10

6 Electrical Control Panel Pressure Gauge FIG. 1 EFS Boiler Page 6

7 SECTION 1 - INTRODUCTION GENERAL The Fulton EFS Electric Flash Steam Boiler is a compact, fully automatic, self-contained steam raising unit, specifically designed to meet the requirements of applications requiring a short period high demand steam supply. A heated feedwater tank is available as an option, the purpose of which is to reduce the level of non-condensable gases (NCG s) in the steam as required by HTM* 2010 and to limit the temperature and pressure drop within the boiler when feedwater is introduced. 1.2 TECHNICAL DATA For a full specification refer to Section 5. Note: *Glossary of Terms Section 5.4 Page 1

8 Audible Alarm Electrical Control Panel Delay Timer Door Isolator Switch Pump Contactor Cooling Fan Feedwater Pump Boiler Feedwater Pressure Controllers Heating Elements Feedwater Isolation Valve Chemical Dosing Point FIG. 2 GENERAL ARRANGMENT (Heated Tank) Page 2

9 SECTION 2 - INSTALLATION GENERAL The installation of the Fulton EFS Electric Flash 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.! WARNING At all stages of operation the boiler will generate high temperatures, which will be transferred to the boiler and the boiler fittings. Great care must be taken to avoid any chance of receiving burns when working on or near the boiler. The Fulton Electric Flash Steam Boilers are designed to provide short term peak steam loads up to three times the boiler steady state output. This is achieved by providing the boiler with a very large pressure vessel, which acts as a combined boiler and steam accumulator. As is the case with all accumulator applications the peak load must be followed by a dwell/low load period to allow the accumulator to recharge back up to full pressure. When a peak load which exceeds the normal output occurs, the boiler pressure falls releasing energy in the form of flash steam to satisfy the peak load. Note: To enable this to happen it is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of barg. 2.2 siting The boiler should be sited in dry surroundings on a level base as close as possible to the steam using equipment. Take note of the dimensions given in Section 5 and ensure there is sufficient room around the boiler to allow for the connection of all services and to enable the maintenance engineer to gain access to all parts of the boiler. 2.3 WATER SUPPLY The quality of the water used in the boiler will affect the life of the elements and it is strongly recommended that a competent water treatment supplier be consulted prior to the installation of the boiler. Water should be treated to obtain the values quoted in Section 5.3 Recommended Water Conditions. Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. In order to take a boiler water sample safely it is advisable to fit a Water Sample Cooler which is not supplied as standard.! CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by Fulton Ltd. 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. Page 3

10 2 Safety valve Steam stop valve Water sample point (valve not fitted as standard) Boiler blowdown Water feed FIG. 3A BOILER CONNECTION POINTS (No Tank) Page 4

11 CONNECTIONS (NO tank) All connections for services are located at the rear of the boiler, and should be made as follows: a) Feedwater Inlet, DN20 (3/4 in. BSP) 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. The feedwater tank is not suitable for condensate return. b) Safety Valve DN25 (1 in. BSP) 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 safety valve and contains a weep/tell-tale leakage pipe.! CAUTION Unless otherwise specified the steam safety valve supplied with the boiler is preset and must not be adjusted. 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. c) Main Steam Valve DN40 (1 1/2 in. BSP) It is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of barg. d) Boiler Blowdown Connection DN20 (3/4 in. BSP) 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 After Sales Department. e) Water Sample Outlet DN15 (1/2 in. BSP) If the water sample point is used the valve should be fitted as close as possible to the boiler. Page 5

12 2 Condensate Return DN15 (1/2in. BSP) Feed Tank Overflow and Vent DN25 (1in.BSP) Feedwater Inlet DN20 (3/4in.BSP) Safety Valve DN25 (1in.BSP) Steam Stop Valve DN40 (1 1/2in.BSP) Boiler Water Sample Point DN15 (1/2in.BSP) Tank Drain DN15 (1/2in.BSP) Feed Water Check Valve Boiler Blowdown DN20 (3/4in.BSP) Feedwater Isolation Valve FIG. 3b BOILER CONNECTION POINTS (Optional Tank Fitted) Boiler layout may vary from the photograph. Page 6

13 CONNECTIONS (optional tank fitted) All connections for services are located at the rear of the boiler, and should be made as follows: a) Combined Overflow and Vent pipe DN25 (1 in. BSP) The overflow should be piped to a suitable drainage point. The vent should be piped to a safe discharge point, avoiding any possibility of condensation problems. b) Feedwater Inlet (Solenoid Valve) DN20 (3/4 in. BSP) 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. c) Connection for Condensate Return Line DN15 (1/2 in. BSP) d) Safety Valve Outlet DN32 (1 1/4 in. BSP) 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 safety valve and contains a weep/tell-tale leakage pipe.! CAUTION Unless otherwise specified the steam safety valve supplied with the boiler is preset and must not be adjusted. 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. e) Main Steam Valve DN40 (1 1/2 in. BSP) It is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of barg. f) Boiler Blowdown Connection DN20 (3/4 in. BSP) 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. g) Water Sample Outlet DN15 (1/2 in. BSP) If the water sample point is used the valve should be fitted as close as possible to the boiler. h) Chemical Dosage Point (If required) is provided in the feedwater pump pipework. (See Fig 2) Page 7

14 2 Pump overload protection Element MCBs Pump contactor Element contactors Door isolation switch Controls MCB FIG. 4a ELECTRICAL CONNECTIONS (Unheated/No Tank) Pump overload protection Tank Element Tank Element Contactor Controls MCB Pump contactor Element MCBs Door isolation switch Element contactors Note: Water level relays are behind the facial panel. FIG. 4b ELECTRICAL CONNECTIONS (Heated Tank) Page 8

15 2 2.5 ELECTRICAL REQUIREMENTS Power ratings are given in Section 5.2, EFS Specification. The boiler contains all necessary electrical protection. An electrical isolator should be fitted on the wall as close as possible to the boiler, and connections made to the terminals on the Residual Current Device mounted on the electrical panel inside the boiler. A Three Phase and Neutral supply is required and care should be taken to ensure that the wire used is the size given in Section 5.2, EFS Specification.! 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.! WARNING Isolate the electrical supply before removing the feedwater tank heating element cover. 2.6 steam pressure control Adjust the steam pressure controls to barg. (see Section 2.1). Setting the pressure controllers High Limit Controller 1. Set the controller range scale to 5 psi below the safety valve setting. Set the differential scale to zero. Operating (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). A valve is fitted in the pressure supply line to allow the testing of the boiler pressures and the controllers. A B FIG. 5 PRESSURE CONTROLLERS Page 9

16 2 2.7 COMMISSIONING 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 ELECTRICAL 1. Remove the front and right hand access panels. 2. Check that all electrical connections are tight. 3. Megger* test the elements in accordance with the notes in Section Element Care and Protection. (Including heated tank element if fitted) 4. Set the High Limit and Operating (On/Off) steam pressure controllers to the pressures required. 5. Set the tank thermostat to 85 C. (Heated tank only) general IN addition 6. Ensure that the element switches are in the off position, and that the Pump On/Off switch is in the pump off position. Turn the Boiler On/Off switch to the on position. 7. Open all the valves in the water feed line and allow the water storage tank to fill. Check for leaks. The water level controls will close the solenoid when the water level reaches the normal working level. 8. Open the feedwater pump inlet isolating valve, prime/bleed the pump by releasing air from the bleed nipple. 9. Close the boiler blowdown valve and the main steam valve. 10. Ensure that the Boiler On/Off switch mounted on the boiler control panel is switched to the OFF position. Feedwater Pump Bleed Nipple Note: *Glossary of Terms Section 5.4 FIG. 6 Feedwater PUMP Page 10

17 2! WARNING Use extreme caution. Live element terminals. 11. Switch on the electrical supply at the isolator. Manually override the front panel interlock microswitch. 12. Turn the Boiler On/Off switch on. The boiler Low Water alarm light should light up. If it does not do so, refer to the list of fault indications. Turn the feedwater Pump On/Off switch to on.! WARNING Do not make contact or place anything in touch with the moving parts of the pump drive. The cover is removed only for the visual checking of the pump rotation. 13. Check for correct rotation of the feedwater pump by removing the cover to expose the pump drive shaft coupling. 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. Check that the pump rotation is now correct. 14. Turn the Boiler and Pump selector switches to the off position. Release the front panel interlock microswitch. 15. Replace the front panel.! WARNING The front panel must be replaced when the elements are live. 16. Switch the element switches to the on position. 17. Turn the Boiler and Pump switches to the on position. 18. Allow steam pressure to build up, check the reading on the steam pressure gauge, until it reaches the high limit cut-off point as set on the on/off steam pressure control. Re-adjust this control as necessary. 19. 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. 20. Test the high limit contoller by changing the high limit on the On/Off contoller to a value above the value set on the high limit contoller, allow the boiler to build-up steam pressure until the high limit controller value is reached, the boiler should cutout. Reset the On/Off controller to its original setting. 21. Turn the Boiler and Pump switches to the off position. Isolate the boiler at the main isolator and remove the front and right hand panels to check for steam or water leakage. 22. Replace the panels and slowly open the steam valve to release the pressure in the boiler. Check for steam leaks in all new pipework. Reset the High Pressure Reset button. 23. The boiler is now ready for placing into full operation. Page 11

18 Low Water Reset Pump Fault Element Fault Boiler On/Off Tank Low Water If Fitted High Pressure Reset Low Water Circuit Live Element switches Pump On/Off Audible alarm FIG. 7 CONTROL PANEL Page 12

19 SECTION 3 - OPERATION 3! WARNING The following instructions are given for the guidance of the operator in the use of the Fulton electric steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored. 3.1 control panel The control panel contains a range of indicator lights to assist with the starting and testing procedures described in Sections 3.2 and 4.2, 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 CONTROLS AND FAULT INDICATORS! 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. Circuit Live Indicates that power is being supplied to the boiler control circuit and that the control panel is live. This light should be illuminated immediately the main isolator is switched on and should remain on until the main isolator is switched off. 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 alarm will cancel and the boiler will restart when the normal working water level is restored. Low Water Reset Indicates that a 2nd 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 depresseed. Pump Fault This light will illuminate if there is an electrical fault with the feedwater pump. Boiler Indicator/ Boiler On/Off Switch 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. Element Switches and Element Indicators The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised during normal on/off cycle of operation.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. Page 13

20 3 High Pressure Reset 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 the reason for the high pressure condition. Pump On/Off In the off position the feedwater pump control circuits are isolated. In the on position the On/Off switch will illuminate and the feedwater pump will be controlled by the boiler water level controls feedwater tank controls WARNING Isolate the electrical supply before removing the feedwater tank heating element cover. Tank Low Water This light will illuminate if there is a low water condition in the feedwater tank. The boiler feed pump will be inhibited until the water level in the tank is restored. Element On/Off If fitted. The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised. Element Fault 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. Tank Thermostat The tank thermostat will allow the tank heating element to heat the water in the tank to the set temperature, normally 85 C, and maintain that temperature. Should the Element On/Off indicator not illuminate on start up from cold it may indicate a fault in the thermostat. Page 14

21 3 3.2 starting the boiler 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 shutdown. 1. Open the steam valve. 2. Open all the valves in the water feed line. Ensure the feedwater pump is primed. 3. Switch the isolator switch to the on position. 4. With the Boiler selector switch 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 selector switches should extinguish. 5. Close the blowdown valve. 6. 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. 7. Press the low water level reset button. The light should extinguish and the audible alarm should cease. The elements should re-energise, the element selector switches should illuminate. The boiler is now ready for use. a) The on/off steam pressure controller will control the on/off cycle of the elements once the boiler is operating. b) The low water relays automatically maintain the level of water in the boiler and will immediately shut off the power to the elements should the water level fall to an unsafe level. c) The element switches situated on the control panel enable elements to be switched on or off independently to meet steam requirements. Page 15

22 Page 16

23 SECTION 4 - MAINTENANCE 4 Fulton recommends that these tests and checks are carried out on a regular basis to ensure that the boiler is operating safely. 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. The Boiler Controls Test Log supplied in Section 4.8 should be copied and used to maintain a record of the daily and weekly procedures carried out. Any rectification or repairs should be carried out by trained, competent service personnel.! WARNING The electrical supply to the boiler must be isolated prior to the opening of the casing doors. 4.1 VISUAL Checks Inspect the steam and feedwater pipework, valves and fittings for signs of leakage. If leaks are suspected, shut the system 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. 4.2 water level and safety controls The following procedures ensure the correct functioning of the water level controls and the low water safety controls and should be carried out with the boiler turned on 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. Page 17

24 4 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 st low water level check 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 Interrupt/Pump Run switch. 3. Allow the water level to lower by natural evaporation below the 1st Low Water level. 4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burner stops firing. 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 Interrupt/Pump Run switch. 6. Verify that the pump runs and refills the boiler. When the water level rises above the 1st Low Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silences and the burner fire sequence starts. 7. Verify that the pump continues to run until the Pump Off level is reached and then switches off. Page 18

25 nd low water level check 1. Ensure that the boiler is heating, the feedwater pump is not running and that the water level is between Pump On and Pump Off. 2. Switch off the pump. 3. Allow the water level to lower by natural evaporation to the 1st 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. Allow the water level to lower further by natural evaporation below the 2nd Low Water level. 6. Verify that the Low Water Reset switch illuminates. If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used. 7. Switch on the pump using the Pump Interrupt/Pump Run switch. 8. Verify that the pump runs and refills the boiler. When the water level rises above the1st Low Water level, verify that the 1st Low Water lamp extinguishes but the elements do not energise. 9. Press the Low Water Reset switch- Verify that the 2nd Low Water lamp and audible alarm extinguishes and the elements energise. 10. Verify that the pump continues to run until the Pump Off level is reached and then switches off. 4.3 blowdown procedure Keep the boiler free from sludge and scale buildup by blowing down in the following manner: Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure. 1. Start the boiler and generate not more than 1 barg of steam. 2. Shut off both the elements and the pump. Boiler Blowdown 1. Fully OPEN the boiler main blowdown valve for not more than 5 seconds, or as recommended by the water treatment specialist. 2. CLOSE the valve. Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required. Page 19

26 4 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 the notes on water treatment. The dangers of scale to the life of the element cannot be over stressed. Scale possesses excellent insulative 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 megger test* elements prior to fitting or starting up, following prolonged shut down. If the reading is low (below 1 megaohm), heating in an oven at 300 C for three hours should restore the element FIG 8. HEATING ELEMENTS Page 20

27 4 4.5 INTERNAL INSPECTION The lower hand hole doors should be removed 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 a hand hole door 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. Switch off the boiler and allow to cool before removing the hand hole cover removal 1. Using the special tee handle wrench provided remove the hand hole plate retaining nut. 2. Remove the complete assembly. 3. Remove the old gasket and thoroughly clean the mating surfaces of the hand hole plate and the boiler replacement 4. Locate the new gasket on the hand hole access plate, ensure it is seated correctly. DO NOT use any grease, lubricant or adhesive. 5. Position the plate inside the boiler and lightly secure in position with the crab, check the plate is located correctly in the boiler and tighten the retaining nut, (do not over tighten). 6. Using the tee wrench tighten the retaining nut a further quarter turn. DO NOT over tighten. 7. Check for leaks as the boiler pressure increases, Should a leak occur, tighten the retaining nut only sufficiently to stop the leak. Hand hole Hand Hole Cover Plate Gasket Crab FIG. 9 HAND HOLE ASSEMBLY Page 21

28 4 4.6 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 warranty. The Controls Test Log supplied in Section 4.7 should be copied and used to maintain a record of the daily and weekly procedures carried out., 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 cover plates and the opening of control panel box, the electrical supply to the boiler must be isolated.! WARNING 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 buildup is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler feedwater is effective.! CAUTION 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 buildup of scale, silt or sludge in the bottom of the boiler, 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 DAILY WARNING The electrical supply to the boiler must be isolated prior to the opening of the casing doors. 1. Check that the water level controls are working correctly. Perform the Water Level Test and Pump Test (See Section 4.2). 2. Blowdown the boiler (See Section Blowdown Procedure). Page 22

29 weekly IN addition 1. Check that the water storage tank is clean and free from obstructions. 2. Remove the front access panels and check for signs of leakage from the steam fittings and elements (See Section Visual Checks). 3. Check the element and pump contactors are free and operating correctly by manually depressing them. 4. Check all fittings for signs of leakage (See Section Visual Checks). WARNING The safety valve may be very hot, take precautions to avoid burns three monthly IN addition Note: Isolate the electrical supply to the boiler and set the selector switch to off. 1. With the main steam valve open, close the boiler feedwater supply valve, located at the side of the boiler. Isolate and completely drain the boiler by opening the boiler blowdown valve and allowing the boiler to drain. 2. Remove each element and check for excessive scale build up or corrosion. Clean as required and replace, always use a new gasket (see Section Element Care and Protection). 3. Prior to refitting the elements, examine the interior of the boiler for deposits of scale and sludge. Clean the boiler if necessary. 4. Check and clean the feedwater strainer. 5. Check all electrical connections for tightness. 6. Note the probe lead positions, remove and clean both the boiler and feedwater tank probes. Note: Ensure caps are reconnected to the correct probes. 7. Return all valves to the normal working position. Restore the boiler water level and reconnect the electrical supply. Page 23

30 4 4.7 troubleshooting Problem Cause Remedy CIRCUIT LIVE 1. Mains supply failure. Check fuse, replace as required. indicator not 2. Lower door interlock Check transformer. illuminated. microswitch not made Check control circuit. Low Water Indicated Insufficient water in the boiler PUMP FAULT indicated. ELEMENT FAULT. 3. Earth Leak Detector (RCD*) has tripped, indicating an earth leakage in the boiler s electrical circuit. 1. No water in the feedwater tank. 2. Obstruction in the water feed line to the pump This fault can only be traced by a qualified person with correct electrical test equipment. Check that water supply line valves are open. Check that the ball valve in the tank is operating correctly. Check that the pump isolation 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. Feed water 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. 1. Electrical fault in the M.C.B.* requires re-setting. feedwater pump circuit Thermal overload fitted to the pump motor contactor requires re-setting. Check that the unit has been set to the correct amperage and adjust if necessary. If the fault continues after the controls have been reset, a major fault exists which can only be corrected by a qualified person with correct electrical test equipment. Check M.C.B. setting. If the fault persists the element and the circuit must be fully checked by a qualified person. Note: Unless a faulty element is allowing steam or water to cape, it is safe to operate the boiler with the faulty element fitted, provided that the element selector switch has been switched off. Page 24

31 4 4.8 controls test LOG Electric Boiler Controls Test Log Model: Boiler Number: The following tests are to be performed in accordance with the maintenance schedule in the Fulton Service Manual. Daily Test Weekly Test Date Date Water Level Control Test by lowering water level Boiler low water indicator Y - N Y - N Y - N Y - N Y - N Y - N Y - N Low water reset indicator and alarm sounded Y - N Y - N Y - N Y - N Y - N Y - N Y - N Feed pump, start/stop Y - N Y - N Y - N Y - N Y - N Y - N Y - N Main Boiler Blowdown duration/seconds Time test carried out Pressure gauge reading Boiler water test TDS ph Water treatment Softened water Y - N Y - N Y - N Y - N Y - N Y - N Y - N Brine level correct Y - N Y - N Y - N Y - N Y - N Y - N Y - N Operator Signature: Log examined by: Date: Page 25

32 Page 26

33 SECTION 5 - GENERAL DATA boiler DIMENSIONS B E C A D F FIG. 10 BOILER dimensions Model: efs , 72 A Minimum Clearance * B Overall Width C Overall Depth D Overall Height E Boiler Depth F Safety Valve Discharge Height G Steam Outlet Height H Feedwater Inlet Height K Feedwater Tank Drain L Feedwater Tank Overflow M Condensate Return Height N Main Boiler Blowdown P Water Sample Point Height Note: * Required for maintenance and element removal. Dimensions mm Dimensions are approximate and only intended as a guide to aid installation. Information from TI 114 Issue 4 Page 27

34 5 5.2 boiler SPECIFICATION Model: E.F.S. Unit Designed and manufactured to BS EN 13445:2009 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 F= Female, M=Male Steam Outlet DN Safety Valve Discharge DN Feedwater Inlet DN Blowdown, Boiler DN Tank Drain DN Tank Overflow DN Water Sample Outlet DN Note: Instantaneous outputs are up to 300 kg/h. Information from TI 114 Issue 4 Page 28

35 5 5.3 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 feed water 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. BOILER WATER (water inside boiler) ph Value , 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 50mg/kg. Phosphate Less than 50 mg/kg, in the form of PO 4. Total Alkalinity Less than 1000 mg/kg. Caustic Alkalinity Less than 300 mg/kg as CaCO 3. Total Dissolved Solids (TDS) Less than 2000 ppm. Iron Less than 1 mg/kg. Silica Less than 150 mg/kg, in the form of SiO 2. Dissolved Oxygen None. mg/kg = Milligrams per Kilogram CaCO 3 = Calcium Carbonate PO 4 = Phosphate SiO 2 = Silicon Dioxide 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. Page 29

36 5 5.4 Glossary of TERMS WORD Megger Test M.C.B NCG HTM BSP RCD MEANING (Electrical Engineering) an instrument that generates a high voltage in order to test the resistance of insulation. (Electronics) Miniature Circuit Breaker; a small trip switch operated by an overload and used to protect an electric circuit Non Condensible Gases - incapable of being liquified at normal temperatures Health Technical Memorandum British Standard Pipe Residual Current Device, is a life-saving device which is designed to prevent you from getting a fatal electric shock if you touch something live, such as a bare wire. Page 30

37 Material & Workmanship Warranty 5 Year Warranty On the Fulton Boiler Pressure Vessel Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within five (5) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the Manufacturer s Handbook. This Warranty does not cover damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions. This Warranty is good only in the United Kingdom of Great Britain and Northern Ireland. This Warranty does not include labour or delivery charges of any kind. Fulton Ltd General Warranty The Fulton general Guarantee is given in lieu of and in exclusion of any warranty expressed or implied, statutory or otherwise, as to the state, condition, performance, quality or fitness of the goods. Save thereunder we shall be under no obligation or liability of any kind to you in regard to the goods. In the case of new goods manufactured and supplied by us we will make good any defect developing therein under proper use within 12 months of delivery, provided that after investigation in our sole discretion we are satisfied that the defect arose from faulty design, materials or workmanship and from no other cause whatsoever. Defective goods or parts must be returned to us as soon as possible after discovery of the defect, Costs of carriage and of detaching and incorporating parts will be borne by you..ln all cases at the termination of such 12 months all liability on our part will cease. No liability whatsoever is to be incurred by us in respect of gauge or sight-glasses, packing glands or electric motors orany goods or accessories not of our manufacture. But so far as we are able, we shall let you have the benefit of any guarantee or warranty given to us in respect thereof.

38 Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk