Fulton Steam: FB-S Series

Fulton Steam
Horizontal Boiler
FB-S Series
100-800 Hp
Installation, Operation and Maintenance Manual

Serial # Model # Fulton Order # Sold To Job Name Date __________________________ __________________________ __________________________ __________________________ __________________________ __________________________
The Fulton Companies 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com
The Fulton Companies*FB-S Series Manual*Version 2010-0820 Page 1
Table of Contents
Introduction Section 1 Safety Warnings & Precautions Section 2 Description & Introductions
1. General 2. Specifications & Dimensions 13. Boil-out of new unit
Section 4 Controls & Burner

1. Boiler control panel 2. Burner
Section 5 Operation
1. Fitting the boiler 2. Starting the burner 3. Daily operating test
Section 3 Installation
1. Locating the boiler 2. Boiler room ventilation 3. Flue & chimney requirements 4. Recommended Water Conditions 5. Water Supply 6. Glossary of Water Terms 7. Valves 8. Electrical requirements 9. Gas supply 10. Oil supply 11. Installation check points 12. Cleaning
4. Blowdown procedure 5. To shutdown the burner 6. Evaporation test 7. Fault finding
Section 6 Maintenance
1. General 2. Weekly 3. Six monthly 4. Annually 5. Fitting new gasket
Section 7 - Warranty
Introduction
This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.
These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.
The requirements and instructions contained in this section generally relate to the Fulton model FBS. When installing a packaged unit, this entire section should be read to ensure that the installation work is carried out correctly.
Prior to shipment, the following tests are made to assure the customer the highest standards of manufacturing.
a) Material inspections b) Manufacturing process inspections c) ASME welding inspection d) ASME hydrostatic test inspection e) Electrical components inspection f) Operating test
g) Final engineering inspection h) Crating inspection
Note
The installation of the boiler should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association. All state and jurisdictional codes beyond the scope of the applicable ASME boiler and pressure vessel codes, for its corresponding classification, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.
All units are crated for crane lift transport. Under no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of the boiler.
The customer should examine the boiler for any damage, especially the refractories around the burner.
Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy equipment. Steam Outlet Safety Valve Connection Sight Glass Pressure Controls
Manway
Pressure Gauge Control Panel Burner
Stack Connection
Rigging Point (each side)

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

*Lifting eyes on top may be used also*
Section 1
Section 1 Safety Warnings & Precautions

The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis.
WARNINGS must be observed to prevent serious injury or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted.
WARNING Do not operate, service or repair this equipment unless you fully understand all applicable sections of this manual.
Prior to commencing any internal work on any control panel or electrical junction box, the power must be disconnected.
Do not allow others to operate, service or repair this equipment unless they fully understand all application sections of this manual, and are qualified to operate/maintain the equipment.
Gauge glass valves need to be fully open during boiler operation to prevent boiler water damage in case of gauge glass failure.
Never tamper with low water cutoff sensors or circuitry. Boiler blowdown water must be cooled to <140oF prior to discharge to a drain. Failure to use an approved blow off vessel with adequate cooling could cause personnel/equipment damage.
A warm boiler will have very hot metal exposed. Care should be taken not to touch these open across without protective clothing.
CAUTIONS A temperature exceeding 100o F in the boiler room may cause premature failure of electrical components on the boiler control panel.
The water chemistry in the boiler must be kept within limits outlined in this manual. Failure to do so will likely cause premature boiler pressure vessel failure and poor steam quality. Boiler feed water temperature must be 140o F or greater to prevent corrosion fatigue cracking at the feed water nozzle.
The bolts that connect the boiler shell to the rails need to be loosened slightly before the boiler is warmed up to allow thermal expansion of the pressure vessel. Failure to do so will create unwanted pressure vessel stress.
NOTES
After installation is complete and prior to operation the pressure vessel should be cleaned or boiled out per instructions included in this manual.
The normal water level is approximately the center of the water gauge glass.
To ensure that your Fulton Steam Boiler is kept operating safely and efficiently, follow the maintenance procedures set forth in this manual.
It is normal for the boiler safety relief valve to weep water if the boiler is operated above 90% of the valve setpoint (i.e. weep will occur for a 100 psig valve if boiler is >90 psig).
To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to.
The boiler blow off operation should be done a minimum of once during the day when the boiler is at 10 PSIG or less.
After a new Fulton Boiler has been in operation for several months, pieces of burned metal will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the
boiler insulation. This is a normal condition and does not affect the efficiency or the life of the boiler in any way.
All secondary low water trips, flame failure trips or high steam pressure trips will require, by code, a manual reset at the boiler.
Section 2
Section 2 Description & Introductions

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

Model FB-S
Nominal steam output (lbs/h) (1) Design pressure (psig) Water Volume (gallons) 100 3450 15/150 779 125 4312 15/150 924 150 5175 15/150 924 200 6900 15/150 1294 250 8625 15/150 1585 300 10350 15/150 1849 400 13800 15/150 3594 500 17250 15/150 4650 650 22425 15/150 4677 800 27600 15/150 5265
Maximum fuel consumption (2)

Light Oil (gp/h) Heavy Oil (gp/h) Natural Gas (ft /h)
3
29 27 4156
36 34 5196
43 41 6235
58 54 8313
73 68 10,392
88 82 12,470
117 108 16,626
146 136 20,784
189 177 27,019
234 216 33,252
Note: (1) All steam output lbs/hr ratings from 0 psig at 212F.
3 (2) Fuel consumption based on light oil 1, 40,000 BTU/gal, natural gas 1000 BTU/ft , heavy oil 160,000
BTU/gal.
Connection
Model FB-S
Main steam valve (150 psig) Flange Safety valve connections (150 psig) (in) Main steam valve (15 psig) (in) Safety valve (15 psig) (in) Feed Water inlet line (in) Blowdown line (in) Flue diameter (in) 1.0 1.5 (2) 14 1.25 1.5 (2) 16 1.25 1.5 (2) 16 1.25 1.5 (2) 18
100
2.5
125
3
150
3
200
4
250
4
300
4
400
6
500
6
650
6
800
8
1.5 (2)
1.5 (2)
2 (2)
2 (2)
2.5 (2)
2.5 (2)
4 (2)
4 (2)
Consult Factory Consult Factory 1.25 1.5 (2) 20 1.5 1.5 (2) 20 1.5 1.5 (2) 22 2 2 (2) 22 2 2 (2) 26 2 2 (2) 26
Note: Specifications and dimensions are approximate. Fulton reserves the right to change specifications and dimensions.
Section 3
Section 3 Installation
General Note It is essential that the installing shall be undertaken only by suitably qualified and experienced personnel. Installation should comply with appropriate local and state codes and standards.
1. Locating the Boiler

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

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

Model FB-S Minimum area (in )
2
100 1437
125 1797
150 2156
200 2875
250 3593
300 4312
400 5750
500 7187
650 9343
800 11,500
900
d) Be sure the total BHP= proper make up air opening size. For instance, if you have three 300 BHP boilers, it is a total BHP of 900, and the 900 BHP make up air size is recommended.
Note These measurements are subject to state and local regulations. The installation of exhaust fans in a boiler room is not recommended. An exhaust fan can create down draft in the stack or restrict the burners air supply which will result in poor combustion. It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint, in the combustion system can create hazardous conditions.
3. Flue and Chimney Requirements

a) The flue from the appliance and the joint between this flue and the chimney are sealed to prevent leakage of combustion products. b) The top of the flue or chimney shall be higher than any roof within a radius of 10 meters. c) Checks are made to ensure that the chimney is suitable for burner and that the proposed installation complies with the local authority and other regulations covering such installations.
d) If more than one appliance is connected to a common flue or chimney the crosssection of the chimney should be adequate for the total volume of combustion products from the appliances. e) The total horizontal run of the boiler flue should not exceed 25% of the total vertical rise. There should be an angle more than 15 degrees for the horizontal run reducing the resistance of the combustion products and avoid rusting by accumulating condensation in the flue. f) The installer should check the draft with a meter at -.02-.04 W.C pressure (-.508 to 1.016mm) with the burner off. If the pressure is too low, a balancing damper may be used close to the flue outlet to regulating the pressure of the draft.
4. Recommended Water Conditions

a) Following are recommendations for feed water and boiler water. Contact your local water treatment professional for testing and treatment recommendations. It is very important that a strict water treatment program be followed. b) It is critical that the boiler pH water chemistry follow the attached schedule whenever water is in the boiler. Solids that enter in with the feed water will concentrate in the boiler. A regular schedule of boiler blowdown must be maintained to prevent high solid concentrations from corroding the vessel or forming deposits
Parameter pH Feedwater Temperature Hardness as CaCO3 Chlorides Total Alkalinity Total Dissolved Solids Suspended Solids Total Organic Carbon Iron Dissolved Oxygen Visual Oil Conductivity (S/cm)
Feedwater 7.5-9.5 140F* < 2ppm ------No visual turbidity** No sheen No foam + Colorless liquid++ <1 ppm* ND ---
Carbon Steel Horizontal Boiler/SteamPac Water 8.5-10.5 --< 15 ppm --< 500 ppm < 3000 ppm No visual turbidity** No sheen No foam + Colorless liquid++ ND ND < 4477
NOTES: o *Feedwater temperatures below 200 F will require an oxygen scavenger ** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.
+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible. ++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or orange tinge. ND: None Detected.
5. Water Supply
a) The quality of the water used in the boiler will affect the life of the elements and pressure vessel and it is strongly recommended that a competent water treatment company be consulted prior to the installation of the boiler. PV damaged due to adverse water conditions will not be replaced under warranty. b) Natural feedwater supplies contain solids and dissolved gases. These may promote scale, foaming, corrosion, and/or poor steam quality. To prevent this, feedwater must be studied individually and treated accordingly. The treatment should provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized. Thermal cycling, dissolved oxygen, high or low pH can all be major causes of corrosion. Untreated hardness is the major cause of scale deposits. Poor quality feedwater requires increased blowdown and increased chemical treatment costs to prevent boiler corrosion and scaling. c) One way to lower the amount of dissolved gases in the boiler feed water is to preheat the feedwater. This option injects live steam into the feedwater to increase the water temperature to 180 degrees F or higher which removes oxygen and carbon dioxide from the water. d) RO/DIWater: Reverse Osmosis / Deionized water is water that all dissolved solids have been removed. Very high purity steam quality can be obtained with RO/DI water. RO/DI water has no buffering capacity and a pH of <6.5. It is corrosive to carbon steel, however, not to stainless steel. Therefore, anytime RO/DI water is used in a carbon steel vessel, pH neutralization is required to bring the pH up to the required level. e) The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or fouling.
6. Glossary of Water Supply Terms

a) Dissolved Oxygen: Oxygen that is dissolved in the feedwater will cause the steel in the boiler and the feedwater system to be attacked by the water in a manner described as pitting. The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide. Once pitting starts, it may be extremely hard to arrest. Pitting can proceed at a surprisingly rapid rate and can occur not
only in the boiler proper, but also in pre-boiler equipment such as ecomomizers, feedwater tanks, and feedwater lines. b) Sodium Sulfite: Its purpose is to chemically remove the dissolved oxygen left in the feedwater after the feedwater has been mechanically deareated. Sodium Sulfite reacts chemically with dissolved oxygen, producing sodium sulfate. Since it is desirable to remove dissolved oxygen from the feedwater before it reaches a boiler. Sodium sulfite is best introduced continuously at some suitable point in the feedwater system (the storage section of the feedwater heater or deareator, six inches below the water line). Chemical residual control is based on the maintenance of a specific excess of sodium sulfite in the boiler water. The essential requirement being to maintain in the feedwater at all times slightly more than enough sodium sulfite to consume all of the dissolved oxygen that slips through the deareating equipment. Sulfite as a treatment represents the second line of defense against oxygen corrosion. Primary protection against this type of attack requires adequate facilities for mechanical deareation of the feed-water plus a vigorous maintenance program to safe guard against oxygen leakage into the pre-boiler system. c) Suspended Solids: Suspended solids are the undissolved matter in water, including dirt, silt, vegetation, iron oxides, and any other insoluble matter. Normally suspended solids are expressed in terms of turbidity. Suspended solids may also deposit in low velocity areas and create fouling. In line filters, or various types of pretreatment can be used to lower the suspended solids level. Various polymers assist in holding solids in suspension. Periodic blowdowns will eliminate suspended solids. d) Alkalinity: Alkalinity is the capacity of a water to neutralize acids. Common water alkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, and silicate. These alkalinities, especially bicarbonates and carbonates, break down to form carbon dioxide in steam, which is a major factor in the corrosion on condensate lines. High alkalinity also causes foaming and carry over in boilers. Both foaming and carry over cause erratic boiler operation. When foaming occurs an antifoam should be added or increased. The reason for the high alkalinity should be determined. It may result from lack of sufficient blow off. Quite often the source of alkalinity is an overdose of alkaline internal water treatment chemical. e) pH: pH is a measure of the degree of acid or base of solution. pH ranges of 8.010.5 will have little influence on the corrosion rate of carbon steel. A low pH can result in corrosion of metals, while a high pH can result in scale formation or
caustic embrittlement. In order to control boilers and equipment used for the external treatment of make up water, it is essential that reliable pH measurements be made. RO/DI water will have a pH of 6.0 - 6.5 and will require neutralization if used in a carbon steel vessel. f) Chlorides: If chloride levels are high enough to cause severe corrosion, they can be controlled by limiting the cycles of concentration and increasing boiler blowdowns. Corrosion from chlorides can also be controlled by increasing the amount of corrosion inhibitor or changing to a more effective inhibitor. Reverse osmosis is another method of pretreatment to reduce chlorides. Chlorides are a major concern in a stainless steel vessel. g) Oil: Oil is not a natural constituent of boiler water; still it can frequently enter a system through leaks in a condenser or other heat exchanger. Oil can also enter a system through the lubrication of steam driven reciprocating equipment. Whatever the source, the presence of oil in boiler water is undesirable. Oil can act as a binder to form scale. In high heat-transfer areas oil can carbonize and further contribute to the formation of scale and low pH. Foaming is one indication of oil in boiler water. Its presence can also be confirmed by first shaking a bottle containing boiler water. If oil is present foam will result. Often oil in boiler water will originate in the condensate. This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken. h) Iron (oxides): Iron in any of its oxide or complex forms is undesirable in boiler water. Iron in its various forms can originate in the raw water makeup, condensate return water, or form directly in the boiler as a result of corrosion. It can concentrate in the boiler and it tends to collect in stagnant areas. If a boiler is using raw water makeup, iron is almost certain to be a major component of developing scale or create fouling. i) Water Hardness: Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents. Water hardness is a primary source of scale in boiler equipment. Hardness is removed by softening. j) Feedwater: Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler. k) Condensate: Condensate is condensed steam that is normally low in dissolved solids. Hence, it does not contribute to the dissolved solid content of the feedwater. In addition, condensate is very expensive to waste. It's been chemically treated, heated, pumped, converted to steam, and condensed. This costs money and when condensate is returned to the boiler, money is saved.
7. Valves
a) Pressure Gauge: the pressure gauge is above the panel box, which is installed on the right hand of the boiler. A three-way valve is fitted with the pressure gauge, to assist drain off regularly. b) Main Steam Valve: the main steam valve is installed on the top of the boiler. It will be connected with the steam pipe work to all kinds of equipment, which consume steam. There should be enough outlet for drain off and flush in the pipe work. c) Safety Valve: the safety valve is installed on the top of the boiler. Its setting was finished by the manufacturer before delivery; do not attempt to change the setting. The function of the safety valve is to avoid pressure in the boiler from exceeding the design valve. Any equipment connected with the boiler can run under the boiler pressure. If not, another safety valve must be used to protect it.
CAUTION The safety valve supplied by the manufacturer can only protect the boiler; it cannot protect any other equipment in the system.
d) Water Level Gauge: the water level gauge is equipped to monitor the boiler water level. The boiler operator can see the water level inside the boiler from these gauges. Both of them are connected to a drain line for periodic flushing.
8. Electrical Requirements
a) Connect wiring as shown in the wiring diagram, which is furnished inside the electrical control panel box. b) Electrical power available is usually 230/460 volt, 3 phase, 60 HZ (in USA), 3 phases, 50 HZ (outside USA).
9. Gas Supply
a) Natural gas is the standard gas for the gas boiler. Special requirements on request- i.e. liquid petroleum gas, town gas. b) Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and furnace while running at full input. This pressure is different based on the burner used. The pressure must be checked to make sure it is high enough. If it is too low, a gas booster must be used in the gas supply system.
c) The gas supply piping to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriate Codes and Standards. It should be of sufficient size to satisfy the pressure and volume flow requirements of the burner under all firing conditions. Checks should be made to ensure that all meters and other components are appropriately rated for the maximum gas flow rate anticipated.
Note It is essential that a manual isolation valve is fitted upstream of the gas control train to allow the burner to be isolated for maintenance. The size of this valve should not be less than that of the burner control train in order to avoid any restriction in gas flow.
Warning It is essential that the installation of the gas piping must be undertaken only by suitably qualified and experienced personnel and in compliance with appropriate Codes and Standards. The Fulton Companies can accept no responsibility for consequential loss, damage or personal injury, which results from a failure to follow the manual.
Gas Line Sizing Chart

*There is a more exact formula, but you can round off the conversion of CF to BTU by using 1=1000 (for example 174 CF on the chart would be equal to 174,000 BTU). This will give a more conservative total estimate.
Pipe Size Inches 1 1 1 2 2 3 10 174 363 684 1404 2103 4050 6455 11,412 20 119 249 470 955 1445 2784 4437 7843 30 96 200 377 775 1161 2235 3503 6299
Length of Pipe in Feet
40 82 171 323 663 993 1913 3049 5391
50 73 152 286 588 880 1696 2703 4778
60 66 135 259 532 795 1538 2449 4329
70 61 127 239 490 734 1413 2253 3983
80 56 118 222 456 688 1315 2096 3705
90 53 111 206 428 641 1234 1966 3476
100 50 104 197 404 605 1165 1857 3284
Example: From the chart we can see that a line that is 80 in length can supply 118,000 BTU/hr.
10. Oil Supply

a) The oil supply piping to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriate Codes and Standards. It should be of sufficient size to satisfy the pressure and volume flow requirements of the burner under all firing conditions. Checks should be made to ensure that all meters and other components are appropriately rated for the maximum oil flow rate anticipated. Galvanized steel pipe should not be used. The supply piping should include an appropriate filter. b) A two-pipe system must be used between oil storage tank and the burner. One for oil supply and one for oil return. A circulating oil pump is required to deliver fuel oil at 1-3 psig from the storage tank to the burner. A oil filter must be installed before the oil-circulating pump, recommend less than 60 Mesh. c) The final connection to the oil pump inlet should be made using the flexible pipes supplied with the burner. d) One gate valve should be installed to the inlet and outlet of the circulating pump separately. A pressure gauge (0-60psi) should be added to the outlet. e) It is important to ensure that the return pipe is not obstructed as this may result in damage to the pump. f) In the case of heavy oil (No.4, No.5, and No.6 oil) the piping and oil storage tank should be insulated, trace heated and thermostatically controlled.
11. Installation Check Points-Refer to the details in the BURNER section

a) Make sure that all piping connections are complete and tight. b) Make sure the pressure controls are adjusted properly. c) Make sure all electrical connections in the control box, the water column, and elsewhere are secure. d) Make sure there is adequate boiler room ventilation. Combustion air contaminates can cause damage to the boiler jacket and burner. e) Before operating pumps, metering heads and compressors, make certain that reservoirs are properly filled with the specific lubricant.
Open all necessary oil shut-off valves. Do not run compressors, pumps, or metering units without oil. f) Before connecting electrical current to any component, be sure the supply voltage is the same as that specified on the component nameplates. g) Make certain that the operator in charge is properly instructed in the operation and maintenance procedures.
Note The pressure vessel must be cleaned before running the boiler after installation.
12. Cleaning
Steam Piping a) Steam and water piping systems connected to the boiler may contain oil, grease, or foreign matter. The impurities must be removed in order to prevent damage to pressure vessel heating surfaces. On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities. During the period that condensate is wasted, attention must be given to the treatment of the raw water used as make-up so that an accumulation of unwanted materials or corrosion does not occur. For more information, contact your local authorized boiler representative. Pressure Vessel a) The waterside of the pressure vessel must be kept clean from grease, sludge, and foreign material. Such deposits, if present, will shorten the life of the pressure vessel, will interfere with efficient operation and functioning of control, of safety devices, and possibly cause unnecessary and expensive re-work, repairs, and down-time. b) The installation and operating conditions that the boiler will be subjected to should be considered, and cleaning of the waterside of the pressure vessel should be provided during the course of initial startup. c) The pressure vessel and the steam and return lines, in effect, represent a closed system. Although the steam and return (condensate) lines system may have been previously cleaned, it is possible that:
1. Cleaning has been inadequate. 2. Partial or total old system is involved. 3. Conditions may prevent adequate clearing of piping. d) The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal internal conditions and serve as a check against conditions indicated by chemical analysis of the boiler water. Inspection should be made three months after initial starting and at regular 6-, 9-, or 12-month intervals thereafter. The frequency of further periodic inspections will depend upon the internal conditions found. e) If any unwanted conditions are observed, contact your local authorized boiler representative for recommendations. f) Any sludge, mud or sediment found will need to be flushed out. If excessive mud or sludge is noticed during the blowdown the scheduling or frequency of blowdown may need to be revised. The need for periodic draining or washout will also be indicated. g) Any oil or grease present on the heating surfaces should be removed promptly by a boil-out with an alkaline detergent solution.
Note Temperatures of initial fill of water for hydrostatic tests, Boil-out, or for normal operation should be as stated in the ASME Boiler Code.
Caution Do not store halogenated hydrocarbons in or near the boiler room. In general, ensure that the boiler area is in conformance with established boiler room requirements. Review national and local codes.
h) As a final checkpoint, again...Water Treatment! We cannot emphasize enough the importance of proper water treatment: Water analysis should be made by a competent water treatment professional and their recommendations should be followed.
13. Boil-out of New Unit

a) The internal surfaces of a newly installed boiler may have oil, grease or other protective coatings used in manufacturing. Such coatings must be removed
because they lower the heat transfer rate and could cause over-heating of a tube. Before boiling out procedures may begin, the burner should be ready for firing. The operator must be familiar with the procedure outlined under burner operation.
Warning Use of a suitable facemask, goggles, rubber gloves, and protective garments is strongly recommended when handing or mixing caustic chemicals. Do not permit the dry material or the concentrated solution to come in contact with skin or clothing. Failure to follow these instructions could result in serious personal injury or death. b) The suggested general procedure for clearing a boiler is as follows: i. ii. Have sufficient cleaning material on hand to complete the job. When dissolving chemicals, the following procedure is suggested. Warm water should be put into a suitable container. Slowly introduce the dry chemical into the water, stirring it at all times until the chemical is completely dissolved. Add the chemical slowly and in small amounts to prevent excessive heat and turbulence. iii. Isolate the boiler from the system by shutting off the main steam valve. iv. v. Remove the steam safety valve. Water relief valves and steam safety valves must be removed before adding the boil-out solution so that neither it nor the grease which it may carry will contaminate the valves. Use care in removing and reinstalling the valves. vi. All valves in the piping leading to or from the system must be closed to prevent the cleaning solution from getting into the system vii. We have found a popular laundry detergent called OxiClean is an excellent boilout agent. Mix 8 oz. for every 10 BHP (i.e. 40 HP will require 32 oz.) and enough water to allow addition to the boiler. viii. ix. Replace the steam safety valve. Fill the boiler with water. Water level is about center in the water gauge glass. x. Generate 5 PSI (1.054 kg/cm2) of steam and shut off the boiler. Allow this hot solution to remain in the boiler for 10 minutes. xi. Allow the boiler to cool to <140F.
xii. xiii.
Drain and flush the boiler twice with fresh water. To remove all the oil and dirt from the main steam and the condensate return lines, allow the returns to go into a floor drain or a safe discharge point for the first few days of operation.
Warning Be sure to drain the hot water to a safe point of discharge to avoid scalding. Failure to follow these instructions could result in serious personal injury or death.
xiv. Remove hand-hole plates. xv. Inspect the surfaces. If they are not clean, repeat the boil out. xvi. After closing the hand-holes and reinstalling the safety or relief valves, fill the boiler and fire it until the water is heated to at least 180oF to drive off any dissolved gases, which might otherwise corrode the material. xvii. The above procedure may be omitted in the case of a unit previously used or known to be internally clean. However, consideration must be given to the possibility of contaminating materials entering the boiler from the system. xviii. On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities. During the period that condensate is wasted, be sure make-up water is treated to prevent an accumulation of unwanted materials or corrosion.
Section 4
Section 4 Controls & Burner

The following brief description of the fittings and controls used on the FB-S boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient use of the boiler.
1. Boiler Control Panel

a) Boiler controls and indicators are housed in a control panel mounted on the side of the boiler. These controls are as follows: i. Power Isolator Switch- control panel power supply ON/OFF switch, mounted on the panel door. ii. Power On Indicator- indicates that the door isolator is in the ON position and the panel is electrically live.
Various Relays
Flame Programmer
Motor Fuses
Fan Motor Starter
Water Level Relays
Warning The power on the indicator is derived from one phase. It is possible for that the Power On Indicator supply phase to be down, leaving the other two phases live. Always isolate the supply before working on the panel.
b) Low Water Indicator i. This lamp will be illuminated and an alarm sounded when the water level, as sensed by an internal probe, in the boiler falls to the 1st low water level. The burner will shut down and the alarm will continue to sound until the water level is restored to a safe working level. The alarm will then cancel, the indicator lamp will extinguish and the burner will automatically restart. c) Low Water Alarm/Reset Switch i. Sounds and alarm on switch on, press to reset. If the level of water in the boiler falls below the second pre-set limit, as sensed by a second low water internal probe, during boiler operation. The 2nd Low Water Alarm/Reset Switch will illuminate, the alarm will sound and the burner will shut down. The water level must be restored before the alarm can be cancelled by pressing the switch.
d) High Water Indicator i. This lamp will illuminate and alarm sound when the water level reaches a pre-determined high level, as sensed by an internal probe. The feed pump will stop. When the water level falls to the normal working level, the indicator lamp will extinguish and the alarm cancel.
Note The Burner ON/OFF/Reset switch should be in the OFF position during the filling process. The Pump Hand/Off/Auto Switch should be in the PUMP Auto position, except when manually filling the boiler (Hand position). The 2nd Low Water Alarm can only be cancelled if the boiler water level is above the 2nd Low Water Level. If the alarm cannot be cancelled, allow the feed water pump to restore the water level to the normal working level (approximately mid-way up the sight glass) and the reset the alarm.
e) Low Water Safety Relays and Feedwater Pump Relays i. These relays operate in conjunction with probes suspended in the boiler shell (or externally mounted floater pressure differential transmitters) to automatically maintain the water level in the boiler between set limits. If the water should fall to an unsafe level, the burner is cut out and an alarm is sounded. The probes are located in two,
100mm diameter standpipes mounted on top of the boiler center line towards the front of the boiler. A standard boiler is fitted with Feedwater pump On/Off, 1st Low Water, 2nd Low Water and High Water probes. 1st LWCO 2nd LWCO Pump Off Pump On High Water
Note If the Level Control System is a float type or pressure differential transmitter, then refer to specific spec sheets located in this manual.
f)
Steam Pressure Controls i. Three steam pressure controls are mounted on the side of the boiler near the control panel. These are as follows: a. Operating Control Pressure On/Off Switch. Controls the on/off cycle of the boiler, switching the burner off when the desired steam pressure is reached and switching it on when steam pressure falls. b. High Limit Switch. Should the Control Pressure Switch fail, the steam pressure will raise above the pre-set limit causing the High Limit Switch (set a least 0.5 {3-4 psig} bar higher than the Control Pressure Switch) to switch off and lock out the burner. A High Limit Indicator will illuminate and an alarm will sound. c. Modulating Pressure Switch. Switches the burner from high to low flame and vice-versa as steam pressure/water temp increases or decreases from setpoint.
High Limit w/ Manual Reset
Operating Limit Modulating Control
Note Boiler may be supplied with PID type pressure controls in lieu of on/off and high/low pressure switches.
g) Burner Programmer i. Is located in the center of the control panel. Acts in conjunction with a sensing device to supervise the ignition sequence, prove the flame is satisfactory and finally monitor the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to lock-out and both main and pilot gas/oil valves will shut to isolate the fuel line to the burner. Lockouts include high steam pressure, low water, high/low gas pressure and flame failure. h) Flame Failure Indicator i. Indicates the burner combustion control relay, detects a flame failure condition.
2. Burner
Fulton Boiler FB-S model can mount with gas burner, oil burner or dual fuel burner on customers request. See specific Burner Manual fro details. Oil Burner The fuel for the oil burner is from No.2 to No. 6 oil. The standard light oil burner for a Fulton boiler is No.2 oil. The heavy oil burner can be used for No.4 to No.6 oil.
Possible Burner Options for FBS
a) Air Pressure Switch i. Mounted on the burner, this switch is operated by the pressure of air entering the burner though the throat of the scroll. Lack of combustion air, or insufficient air pressure, will stop the switch completing the circuit, preventing the burner from operating. b) Air Damper Servomotor i. The combustion air control system including air damper and a servomotor. The servomotor is mounted on the burner and directly coupled to the air damper blade. this system monitors and controls the combustion air entering the burner on the requirement of the boiler heating during operating. A fully closed position is provided to prevent air flowing through the appliance when the burner is not in operation. c) The Inner Assembly i. Consist of flame tube, diffuse, oil nozzle, ignition electrode and so on. d) Oil Nozzle i. The oil nozzles are held in a nozzle block located within the flame tube. The nozzles are pre-sized by the manufacture according with the heat inputs required and the available operating pressure. When replacing the nozzles, they must be the same capacity as the original.
Note When fitting nozzles to the heavy oil burners the nozzle filters must be removed. In calculating the correct size of nozzles to be fitted, refer to the specific burner manual.
e) Oil Pre-heater Tank (for heavy oil burners) i. The oil preheater tank is mounted on the heavy oil burner ahead of the fan housing. Its function is to preheat the oil to correct temperature. The unit is equipped with three thermostats, low temperature operating and limit. A thermometer and hot oil filter are mounted together as one unit on the top left-hand side of the preheater tank viewed from the rear of the burner.
f)
Air Pressure Switch i. Each of the gas burners is mounted on an Air Pressure Switch on the burner scroll. Lack of combustion air, or insufficient air pressure, will stop the switch completing the circuit, preventing the burner from operating.
g) Air Control i. The Air Control System of the gas burners is similar to that of the oil burners. The servomotor is mounted on the rear of the air inlet of the burner and directly coupled to the air damper blade. This system monitors and controls the combustion air entering the burner on the requirement of the boiler heating during operating. The servomotor has been adjusted by the manufacturer before the boiler delivery, so normally the customer neednt set it again. h) Gas Train Assembly i. Consist of pilot and main supply line, each line having a manual cock, a governor, solenoid operated valves and two-air pressure switch (high and low). The governors maintain a constant pressure of fuel entering the burner and are adjustable. The solenoid valves are electronically controlled by the burner programmer. For specific details, consult the burner manufacturers instruction manual.
i)
Valve Proving System i. A valve proving system, as show schematically below, is standard on the FB-S Boilers. When the boiler operating sequence is initiated, the burner control box energizes the proving system, which then carries out the following checks.
a. Valves V1, V2 and V3 are initially closed. The proving system then opens V3 and then closes it after 2 seconds. b. V1, V2 and V3 remain closed for 23 seconds while the minimum side of the gas pressure switch (PS) checks for an increase in pressure. If no crease occurs there is no leakage past V1 and the sequence continues. c. V1 is opened for 2 seconds and then closed. V1, V2 and V3 again remain closed for 23 seconds while the maximum side of the gas pressure switch checks for a decrease in pressure. If no decrease occurs there is no leakage past V2 or V3 and the burner operating sequence will continue. j) Flame Monitor i. An ultraviolet cell is fitted as standard on all burners. It monitors the status of the flame, any failure will cause the burner to shut down.
Section 5
Section 5 Operation
Boiler starting STOP! Make sure you have read any followed all previous safety information. Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required.
In general, ensure that the boiler area is in conformance with established boiler room requirement. Review national and local codes.
Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down.
1. Filling the Boiler

a) Ensure the following valves are OPEN i. ii. iii. iv. v. Main Steam Valve Steam pressure gauge isolating valve All valves in the water feed line Water gauge isolating valves Air release valves
b) Ensure the following valves are SHUT i. ii. iii. Surface and bottom blowdown valves Water gauge blowdown valves All valves in the gas/oil train to the burner
c) Ensure that the Burner On/Off/Reset Switch is set to OFF d) Ensure that the Pump On/Off switch is in the PUMP OFF position, and that the Hand/Off/Auto Switch is in the Off position. e) Place the Pump On/Off Switch to the PUMP ON position, or Hand/Off/Auto in the Auto position. f) The feed pump should start and fill the boiler to the pump off level and then switch off.
Note If the 2nd Low Water and High Pressure Alarm/Reset switch illuminate and the alarms sound, check that the burner mounted Burner On/Off/Reset Switch is in the OFF position, and then reset both alarms by pressing the switches
Note It may be necessary to vent the feed water pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection
2. Starting the Burner From Cold

a) Fill the boiler as described in Section 1. b) SHUT the main steam valve. c) Open all the valves in the gas train/oil supply. It is assured that the fuel supply lines have been purged prior to attempting to start the boiler/burner. d) Switch the Burner On/Off/Reset Switch to the ON position. The 2nd Low Water and High Pressure Alarm/Reset switches will illuminate and alarms will sound due to the power restoration interlock. e) Reset the alarm by pressing both switches. If the 2nd Low Water alarm cannot be cancelled, check the water level in the sight glass. f) The burner motor will start and, after going through post purge/ pre purge interlock checks, should fire after approximately 45 seconds.
Note Before leaving the boiler unattended, the daily operating tests should be carried out to check the functions of all the safety interlocks. For more detailed information on the burner firing sequence consult the burner manufactures Operation and Maintenance instructions.
Practical Considerations
When starting up the boiler, it is prudent to minimize the thermal and mechanical stress caused by differential expansion of various parts of the boiler as they reach working temperature. The temperature of the shell is determined by the contained water/steam
temperature and by the heat transfer rate and gas temperature. The tube temperature lies between the shell and furnace temperature, but is nearer the shell temperature. Since all these components are virtually the same length, they expend longitudinally by different amounts causing mechanical and thermal stress. Whilst this is catered for in mechanical design of the pressure vessel, the life expectancy of the boiler can be affected if the boiler is frequently heated to quickly from cold. When starting from cold the furnace approaches its design temperature shortly after start-up, whereas the tube and shell temperatures are delayed by the time taken to bring the contained water up to temperature. As a result, the thermal expansion is at its greatest. Additionally, the temperature gradient which exists between the bottom and the top of the boiler is exaggerated. This can be reduced by blowing the boiler down during the heat-up period. In practical terms, the ideal solution would be to gradually raise the temperature and pressure in the boiler progressively by firing the boiler on low fire for a few minutes and leaving it to soak (e.g. allowing the temperatures in the boiler and water to even out by diffusion) for 20 to 30 minutes, blowing down the boiler, firing the boiler again for a little longer and soaking for less, and so on. If the boiler has been fired the day before, the large thermal mass in the boiler will maintain the internal temperature to a point that the boiler can be simple switched on (preferably on low fire) and then left to reach working temperature/pressure. The life expectancy of the boiler and door insulation, ignoring other factors, is proportional to the number of the thermal/mechanical cycles that the boiler undergoes from cold/zero pressure to working temperature and pressure. A boiler that is continually maintained at working pressure will last longer than one that is constantly heated and cooled.
Service Inspection of Weld Joints
The frequency of the safety requirement for in service inspection of the main welded joints of the boiler is calculated by the number of cycles since the last inspection. Boilers running twenty four hours a day require the shell and furnace end plate welds to be inspected at intervals specified by local boiler codes. Boilers that are continually heated and cooled require more frequent inspection. The purpose of the in-service weld inspections is to check for: i. Buried defects during manufacture that are outside acceptable limits. Because the boiler was 100% tested during manufacture none should be found, and upon proof of 100% manufacturer testing these tests may be waived at the discretion of the competent person. ii. Cracks propagating from region of the toe of the fillet weld on the shell to the tube plate weld, resulting from fatigue or corrosion fatigue cracking.
These cracks would not be there after manufacture but can develop in service, they are caused by stress due to a combination of pressure loads, differential expansion, local temperature gradients, oxygen impurities in the boiler water/steam and inadequate PH (water chemistry) control. Differential thermal expansion and local temperature gradients all result from continuous pressure/temperature cycling and heating from cold too quickly. Water treatment and in particular oxygen corrosion are covered in Section 3. The importance of correct water treatment cannot be over emphasized.
To Achieve Long Trouble-Free Boiler Life: i. Maintain the boiler at working pressure as long as possible, minimize cycling. ii. When heating from cold do so slowly.
iii. Maintain water treatment within the prescribed limits at all times, blowdown frequently.
3. Daily Operating Tests

Caution If any of the following tests fail to function as described, shut down the boiler immediately and consult the factory.
With the burner firing, carry out the following tests:
Note Ensure the correct water level is maintained during pressure build up. If any part of the equipment is not operating correctly, the fault should be investigated before the boiler is used. Ensure all blowdown piping is safe and discharged to a blowdown receptacle.
a) Flame Sensor (UV Photo Cell) Check i. Remove the burner UV photocell from its plug-in connection (on the side of the burner) and cover the detection window to exclude all light. The burner control should immediately (2-3 seconds gas, 5 seconds oil) go to a lockout/flame failure condition and will require manual resetting. Clean the UV photocell with soft cloth before replacing it.
b) Pump Check i. Lower the water level in the boiler, either by evaporation or by opening the main blowdown valve with the key provided. ii. Observe the water level in the water level gauges and, as the water level falls, check that the feed water pump starts. iii. SHUT the main blowdown valve if opened, and ensure that the feed water pump continues to fill the boiler to the correct level then switch off. c) 1 Low Water Check i. Turn the Pump On/Off Switch on the boiler control panel to the PUMP OFF position. ii. Lower the water level in the boiler, either by evaporation or by opening the main blowdown valve with the key provided. iii. Observe the water level in the water level gauges and check that, as the water level reached the low water position: a. The 1st Low Water alarm sounds b. The 1st Low Water indicator lamp illuminates c. The burner stops firing
st
iv. SHUT the main blowdown valve if opened, and turn the Pump On/ Off Switch to the PUMP ON position, Check that: a. The feed water pump starts b. The water level in the boiler is restored to the normal working position c. The 1st Low Water indicator lamp extinguishes and the alarm cancels d. The burner automatic start sequence commences d) 2 Low Water Check i. Repeat the procedure described in above section but allow the water level to continue to fall, either by evaporation or maintaining the main blowdown valve open. Before the level falls below the level of the water level gauge, check that the 2nd Low Water Alarm/Reset Switch illuminates, the alarm sounds and the burner shuts down. ii. SHUT the main blowdown valve (if opened).
nd
iii. Set the Pump On/ Off Switch to the PUMP ON position. iv. Check that: a. The feed water pump starts, restores the water level to a safe working level, then stops
b. The 1st Low Water alarm cancels c. The 1st Low Water indicator lamp extinguishes but the burner does not start d. The 2nd Low Water alarm continues to sound e. The 2nd Low Water Alarm/Reset Switch remains illuminated v. Press the 2 Low Water Level Alarm/Reset Switch. a. The 2nd Low Water alarm cancels b. The 2nd Low Water Alarm/Reset Switch extinguishes c. The automatic burner firing sequence commences
nd
vi. Check that:
The Low Water Cutoff tests can be accomplished by isolating the feed pump using the pump ON/OFF switch on the boiler control panel while the boiler is operating. Allow the water level to fall by evaporating steam to the system. Once the 1st Low Water Level Alarm is activated the water level can be lowered to the 2nd Low Water Level by using the main blowdown valve. When the 2nd Low Water Alarm sounds CLOSE the blowdown valve, turn the feed water Pump On/Off switch to PUMP ON. Once the 1st Low Water Level cancels the burner should remain off, but the 2nd Low Water Alarm should continue to sound, reset the 2nd Low Water Alarm. The burner should start and the pump restores the water level to normal and stop.
4. Blowdown Procedure
In order to keep the boiler and water level gauge pipe work clear and free from sludge and scale build-up, regular blowdown should be carried out.
Boiler Blowdown a) Fully OPEN the fast opening blowdown valve, for a minimum of 5-10 seconds, see note. b) Regulate the blowdown flow using the common slow opening Y-type valve.
Note As well as removing sludge from the boiler, a second and equally important function is to maintain the TDS (totally dissolved solids) level to within the required limits. The amount of blowdown, and hence time required, it dependent on the amount of TDS in the raw water supply, the percentage condensate return, water treatment chemicals added and the number of the hours a day operation. In order to establish the required blowdown rate, consult your water treatment specialist who will recommend a water treatment program in terms of appropriate chemicals and the required blowdown rate, which takes these factors into account.
Water Level Gauge Blowdown a) Blowdown the water level gauge set by opening the gauge blowdown valve A and closing the top and bottom gauge valves B and C in sequence. b) On completion of the blowdown procedures, ensure all isolation valves are open, and all blowdown valves are SHUT (all handles vertical).
Pressure Controller
Pressure Switches Level Probes
Steam Stop Valve Surface Blowdown Connection
Flame Programmer
Level Controller
Feedwater Connection
5. To Shut Down the Burner

Short Term (hours) a) Turn the burner On/Off/Reset Switch on the Burner Control Panel to OFF. b) The burner will stop firing, post-purge and then stop.
Medium Term (days) a) Turn the Burner On/Off/Reset Switch on the Burner Control Panel to OFF. b) The burner will stop firing, post-purge and then stop. c) SHUT the main steam valve. d) SHUT the water feed valve. e) Turn the power isolator On/Off switch on the Boiler Control Panel to OFF. Note: Ensure the boiler water treatment levels for dissolved oxygen are within specified limits.
Long Term (weeks) To store the boiler in a corrosion-free situation there are three practical solutions as follows: a) Fully flood the boiler to exclude as much air as possible. b) Drain the boiler completely. c) Remove all hand hole and manhole doors. d) Open all gas/oil-side access doors (refer to the maintenance section) e) As (b) but also introduce a form of convection heating to the gas/oil and water side. A very effective solution is to install a string of outdoor-type waterproof light bulbs distributed throughout the boiler.
6. Evaporation Test
This test may be required by your insurance inspector as part of the annual inspection. a) With the burner running, switch off the boiler feed pump and allow the water level in the boiler to lower by evaporation. b) When the water level reaches the 1st Low Water position an alarm will sound, the 1st Low Water indicator lamp will illuminate and the burner will stop. c) Allow the evaporation process to continue until the 2nd Low Water alarm sounds and the 2nd Low Water Alarm/Switch illuminate. d) Switch the feed pump to the PUMP & BURNER ON position. e) The water level will be restored to normal working level, the 1st Low Water indicator lamp will extinguish and the alarm will cancel. f) Press the 2nd Low Water Alarm/Reset switch. g) The 2nd Low Water Alarm/Reset switch will extinguish, the alarm will cancel and the burner will start.
Note Because the burner shuts down during this test it is possible that the steam load will rapidly decrease the pressure in the boiler causing a premature 2nd
Low Water alarm. This is normal and typical of priming where a boiler tries to maintain an overload condition resulting in unstable water conditions.
7. Fault Finding
Before calling the Fulton Service Department, check the following: a) Gas isolating valve(s) OPEN (gas and dual fuel burners). b) Oil isolating valve(s) OPEN (gas and dual fuel burners). c) Oil storage tank contains an adequate level of fuel. d) Oil filer(s) are not blocked. e) Water feed line from feed tank/hotwell is OPEN. f) Water feed isolating valve on boiler is OPEN.
g) All blowdown valves are SHUT. h) Fuses or MCBs in the main supply are not tripped. i) j) Thermal overload on the pump motor is not tripped. Thermal overload on the burner motor is not tripped.
k) Normal water level is visible in the water level gauges. l) Feed pump is primed and not air locked.
m) Front door proof of closure microswitch is closed.
Before calling the Fulton Service Department, have the following information available: a) The model and size of the boiler. b) The boiler serial number. c) The model and type of burner fitted.
Note A very common problem is that when a boiler cools down, the steam in the steam space condenses and gradually forms a vacuum. If the feed water line is open, the boiler will draw in water in an attempt to equalize the pressure. The appearance in the water level gauges is the same if they are empty or fully flooded. If the sight glasses appear empty, but the water level control alarm(s) have not sounded, it is highly probable that the boiler is flooded. Allow air into the system and drop the water to the normal operating level by opening a blowdown valve. Installing a vacuum breaker on the boiler or steam header will not allow a vacuum condition to occur as a boiler cools down.
Fault Finding Table Problem

a) b) c)
Solution
1. No voltage at program relay power input terminals. Main disconnect switch open. Blown control circuit fuse. Loose or broken electrical connection.
2. Program relay safety switch requires resetting. 3. Limit of circuit not completed-no voltage at end of limit circuit program relay terminal. a) Burner does not start b) c) Pressure of temperature is above setting of operation control. Water below required level. Fuel pressure must be within setting of low pressure and light pressure switch. d) Check burner air proving switch and high fire limit switch. e) Heavy oil fired unit-oil temperature below minimum setting. 4. Fuel valve interlock circuit not completed. 1. Lack of spark a) b) c) d) e) Electrode grounded or porcelain cracked. Improve electrode setting. Loose terminal on ignition cable. Inoperative ignition transformer Insufficient at pilot ignition circuit terminal.
2. Spark but not flame a) Lack of fuel-no gas pressure, closed valve, empty tank, etc. No Ignition 3. Low fire switch open in low fire proving circuit. Damper motor not closed, defective switch. 4. Running interlock circuit not completed. a) Combustion or atomizing air proving switch defective or not properly set. b) Motor starter interlock contact not closed.
5. Flame detector defective, sight tube obstructed or lens dirty. 6. Check the programmer controller.
1. Insufficient pilot flame. 2. Gas fired unit a) b) c) Manual gas cock closed. Main gas valve inoperative. Gas pressure regulator inoperative.
3. Oil fired unit a) Pilot flame, no main flame Oil supply cut off by obstruction, closed valve, or loss of suction. b) c) d) e) Supply pump inoperative. No fuel. Main oil valve inoperative. Check oil nozzle, gun and lines.
4. Flame detector defective, sight tube obstructed or lens dirty. 5. Insufficient or no voltage at main fuel valve circuit terminal. 1. Pressure or temperature above modulating control Burner stays in low fire setting. 2. Manual-automatic switch in wrong position. 3. Inoperative modulating motor. 1. Loss or stoppage of fuel supply. 2. Defective fuel valve; loose electrical connection. 3. Flame detector weak or defective. 4. Scanner lens dirty or sight tube obstructed. 5. If the programmer lockout switch has not tripped, check the limit circuit for an opened safety control. 6. If the programmer lockout switch has been tripped; a) Shutdown occurs during firing b) c) Check fuel lines and valves. Check flame detector. Check for open circuit in running interlock circuit. d) The flame failure light is energized by ignition failure, main flame failure, inadequate flame signal, or open control in the running interlock circuit. 7. Interlock device inoperative or defective. 8. Air in the oil lines. Bleed lines.
1. Check oil supply in the supply tank. Check for clogged nozzle. Clean or replace it. Check oil filter and replace if necessary. Boiler will not maintain pressure 2. Check gas supply. 3. The flue is too dirty. Clean it. 4. Check the steam pressure switch, reset it if necessary. 5. Steam is overloaded, reduce it. 1. Check the connection of water probe. Water pump does not start or stop manually 2. Check and clean the water probe. 3. Check the water level relay, if necessary replace it. 1. Check for tightness and clean the connections. Low water alarm/burner shut off will not act in time 2. Clean or replace the dirty probes. 3. Replace the water level relay. 4. Check the tightness of the earth connection. 1. Boiler is completely filled with water, blow down the Starting the boiler, the high limit steam pressure limit is illuminated and the burner stops boiler to normal water level. 2. On/Off pressure switch has failed; check the reading on the pressure gauge.
Section 6
Section 6 Maintenance
1. General Maintenance
To ensure the continuing efficiency of the boiler, regularly carry out regular routine maintenance procedures as detailed below.
IMPORTANT: If any fault is found during these procedures, shut down the boiler immediately and consult The Fulton Companies.
Note It is essential that regular checks are made to ensure scale build-up is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler water feed is effective.
The lower hand hole doors should be removed after one month and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, a water treatment specialist should be consulted.
Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are obtained. Thereafter, inspections should be carried out at six monthly intervals.
IMPORTANT: New gaskets must be fitted every time a hand hole door is removed, refer to Section 5 for fitting procedures.
2. Weekly Maintenance
Warning All steam pipe work, valves and fittings will be very hot. Do not operate the safety valve without protection.
Check the hand holes and man holes for signs of leakage. This is particularly important when the boiler is started from new or when gaskets have been replaced (refer to the Section for fitting procedures for new gaskets). Corrective action taken as soon as a leak occurs can prevent costly repairs later.
Check for signs of leaks on all valves and fittings and take the appropriate action.
Test all the boiler water level functions by evaporation, e.g. switch off the boiler feed pump-see Starting the Burner.
Carry out routine maintenance checks on the burner as recommended by the manufacturers Installation and Maintenance instructions.
Check the flame failure controls by removing the burner flame sensor from its plug-in connection on the side of the burner and covering the detection window to exclude all light. The burner control should immediately go to a lockout flame failure condition and will require manual resetting. Clean the flame sensor before replacing it.
3. Six Month Maintenance

Warning The boiler must be completely cold before carrying out any of the following procedures. a) Ensure that the following valves are SHUT: i. ii. iii. The main steam stop valve The feed water isolating valve The fuel (gas/oil) valves
b) Ensure that the power supply to the boiler is switched OFF.
Caution The boiler and attaching parts will retain heat long after the boiler has been shut down. Always use protective clothes and extreme caution when working on a hot boiler.
c) Empty the boiler. It will be necessary to allow air into the boiler before it will drain via the main blowdown valve. d) Remove the hand hole and manhole doors and thoroughly inspect the internal surfaces of the boiler, paying particular attention to the junction of the tubes with the front tube plate and the tubes for signs of pitting. Any deposits should be removed and your water treatment specialist consulted. Ensure there are no accumulated deposits of sludge in the bottom of the boiler. e) Remove the feed water dispenser, inspect and clean. f) Replace the man hole and hand hole door gaskets, refer to Section FITTING NEW GASKET for fitting procedures g) Open the boiler front access door with the burner mounted on it as described below. It will be necessary to disconnect the gas supply from the gas train and oil supply from the oil lines to allow the door to swing open. h) Remove water column plug at cross section and clean nipple to boiler.
i) j)
Remove the rear smoke box access doors. Brush through the tubes to remove any deposits from the products of combustion.
k) Using a wire brush, clean the internal surfaces of the furnace and the face of the front tube plate. Pay particular attention to the tube ligaments (the spaces between adjacent tubes). l) Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas re-burning in the tube ends as a result of poor combustion, e.g. carbon monoxide carry-over. If the tube ends exhibit these signs, consult the Fulton Service Department. m) Clean out the rear smoke boxes to remove the deposits brushed through from the tubes. Important Ensure that the rear smoke box drain connections are clean and free from deposits. This is particularly important on oil fired boilers because of the acidic nature of the condensate formed.
n) Inspect the door seal for signs of wear and replace if necessary. The first indication of a worn door seal would be evident by signs of leakage around the external periphery of the door.
Warning When handling ceramic fiber always follow the local regulations regarding such materials, including the use of breathing apparatus, suitable body protection and protective gloves.
o) Examine the internal surface of the door lining for defects. Small repairs may be carried out by cutting out the defective area and replacing with new fiber, ensure the correct adhesive is used. p) Examine the end of the burner blast tube where it extends through the door into the furnace. Clean off any deposits, paying particular attention to the internal lip where deposits can cause irregular flame patterns. q) Inspect the rear smoke box door seals for deterioration and replace if necessary. r) Close the hinged front access door by reversing the opening procedure.
s) Re-connect the gas/oil connections. t) ) Drain and flush the feed water/ hotwell tank, clean any filters and the strainer in the feedline before the pump. u) Drain and flush out the blowdown separator.
v) Carry out routine maintenances to the burner as detailed in the manufacturers installation and maintenance instructions.
Note Depending upon the mode of operation, it may be found that the six monthly interval can be extended, possibly to an annual service. It is strongly recommended, however, that the interval should be 6 months from initial start up until such times as a pattern of use and the condition of the boiler after a typical 6 months can be established.
4. Annual Maintenance
It is normal practice to carry out an annual service during which your insurance surveyor would attend to carry out the statutory inspection. The scope of a full insurance strip-down is such that it should only be attempted by persons competent to do so who have had the necessary training, and have the required test equipment. Fulton Boiler Works can offer this service if required. The engineering surveyor may require the removal of the ceramic fiber insulation around the periphery of the front tube plate to facilitate inspection of the shell to tube plate weld. The standard Fulton service kit includes replacement ceramic fiber log material which must be glued in place with the adhesive supplied. It is vital the material is fitted ensuring the ends of the fiber face into the centre of the boiler.
5. Fitting New Gasket

General
Incorrect (Overtightened)
Correct Installation
Caution TOPOG-E gasket have a finite life after installation and must be renewed annually. It is important that the instructions given in this section are adhered to. The boilers are fitted with TOPOG-E gaskets in all the inspection holes of the boiler. These gaskets work very well and millions have been safely used over the last 30 years, however, it is absolutely essential to observe a few simple rules in order to get the best performance from your installation. Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation from many sources including heat, oxygen, stress, and overdosing from certain types of water treatment. This takes the form of material oxidation, hardening/embrittlement and cracking which may result in gasket failure. Steps must be taken to minimize the effects of such attacks.
Water treatment and oxygen attack can be combated by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fitting this is almost certainly due to incorrect sealing or alignment. Incorrect sealing or misalignment will reduce the life of the gasket and cause problems later.
Under stress can be avoided by tightening just sufficiently to stop any leakage when fitting cold and before firing the boiler. Fire the boiler and then gradually warm the boiler up, allowing the increasing steam pressure to take over and complete the seal. The will allow the gasket material to contract naturally and follow the topography of the mating surfaces. The securing nut can then broken when the boiler is cold and under negative pressure.
Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber cures to shape. If the rubber post-cures, the elastic memory will be destroyed and any initial over-tightening will cause the gasket to become hardened and embrittled, leading to cracks and eventual failure.
Fitting Instructions Blowdown the boiler completely and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows: a) Remove the old gasket and thoroughly clean the mating faces of the cover plate and boiler ring.
b) Pace the new Topog-E gasket on the cover plate, ensure the gasket is the correct size and is seating flat against the plate. Do not use any grease, lubricant or adhesive. If the new gasket is not seated properly before the plate is tightened, the gasket may be pinched causing a failure when the pressure builds up. c) Position the cover plate in the boiler ring, ensuring that the plate is correctly centered. An off-centre cover plate can concentrate forces on the gasket and cut it in two. The cover plate may also drag on the boiler hole ring and fail to seal as the pressure rises. Set the crabs further quarter of the turn using a spanner. DO NOT OVERTIGHTEN.
Note Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack. If the gasket is misaligned, over tightening to seal a leak will not prevent subsequent leakage at a later date.
d) Gradually warm up the boiler, allowing steam pressure to make the seal. If the gasket leaks during pressure build up, tighten the securing nuts sufficiently only to stop the leakage. It is important to keep the nuts correctly tightened thereafter, this prevents the vacuum developed by cooling on shutdown from feeding and draining the boiler.
Note New gasket fitted to inspection holes located along the bottom of the boiler are more difficult to install without leaking. Small particles of the scale or sand tend to run down on the mating surfaces after cleaning but prior to assembling. This condition is likely to have occurred if excess tightening is required to stop a leak before warming the boiler. In this event, the best course of action is to drain the boiler and repeat the gasket fitting procedure. Failure to do so will severely reduce the life of the gasket.
e) Clean and inspect each water gauge sight glass. If any water leakage is evident, renew the sight glass gasket.
Section 7
Standard Warranty for Fulton Boilers

Warranty Valid for Models FB-S, FB-C, FB-D
Three (3) Year (36 Months) Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of three (3) years from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained by the buyer in accordance with the Installation, Operation & Maintenance Manual. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fultons Quality Assurance department. This warranty does not cover any failure caused by waterside corrosion or scaling. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Fulton Installation, Operation & Maintenance Manual, approved practices and recommendations made by Fulton. Parts Warranty Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with the Installation, Operation & Maintenance Manual and the component manufacturers instructions and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fultons Quality Assurance department. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if the boiler is installed, operated, and maintained as outlined in the Fulton Installation, Operation & Maintenance Manual. No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges that were not preapproved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if the Fulton Companies has been advised of the possibility of such damages. Fultons liability shall never exceed the amount paid for the original equipment found to be defective. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.
12/2/09
Extended Warranty for Fulton Skid Mounted Steam Boilers

Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S
Ten (10) Year Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of ten (10) years from the date of shipment from the factory. Fulton will repair or replace at our option, F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained in accordance with the Installation, Operation and Maintenance Manual. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklist to Fultons Service Department. This warranty covers any failure caused by defective material or workmanship, however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation, Operation and Maintenance Manual. The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system. Generally, this system MUST include ALL of the following equipment in order for the warranty to apply. 1. 2. 3. 4. 5. 6. Fulton boiler with model number as listed above. Fulton DA or condensate return system with preheat kit. Fulton blowdown tank/separator Water softener Chemical feed system Automatic surface or bottom blowdown, which must operate to maintain TDS levels as specified in the Installation, Operation and Maintenance Manual.
Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation, Operation and Maintenance Manual There is a $1,000 labor allowance for any failed pressure vessel that is covered under the above warranty. Parts Warranty Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve (12) months of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event by liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if Fulton has been advised of the possibility of such damages. Fultons liability shall never exceed the amount paid for the original equipment found to be defective. Conditions of Warranty Warranties are only valid if the boiler is installed, operated and maintained as outlined in the Installation, Operation and Maintenance Manual. Fulton shall accept no responsibility if the equipment has been improperly installed, operated or maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the equipment. The use of replacement parts not manufactured or authorized by Fulton will void any warranty express or implied. Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a factory certified technician. The commissioning agency must successfully complete and return the equipment Installation and Operation Checklist to Fultons Service department. The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports must be produced for warranty consideration. The warranty is valid for the original installation only in the U.S.A and Canada.
08/20/10
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies.
Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.

Fulton Steam: FB-S Series

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Fulton Steam

Installation, Operation and Maintenance Manual

The Fulton Companies*FB-S Series Manual*Version 2010-0820 Page 1

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Section 4 Controls & Burner

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

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g) Final engineering inspection h) Crating inspection

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Pressure Gauge Control Panel Burner

Rigging Point (each side)

Gas Train ASME Stamping Rigging Point (each side)

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Section 1 Safety Warnings & Precautions

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Section 2 Description & Introductions

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2. Specifications and Dimensions Specifications

Maximum fuel consumption (2)

117 108 16,626

146 136 20,784

189 177 27,019

234 216 33,252

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1. Locating the Boiler

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2. Boiler Room Ventilation

Recommended Minimum Makeup Air Openings

3. Flue and Chimney Requirements

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4. Recommended Water Conditions

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6. Glossary of Water Supply Terms

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Gas Line Sizing Chart

Length of Pipe in Feet

40 82 171 323 663 993 1913 3049 5391

50 73 152 286 588 880 1696 2703 4778

60 66 135 259 532 795 1538 2449 4329

70 61 127 239 490 734 1413 2253 3983

80 56 118 222 456 688 1315 2096 3705

90 53 111 206 428 641 1234 1966 3476

100 50 104 197 404 605 1165 1857 3284

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10. Oil Supply

11. Installation Check Points-Refer to the details in the BURNER section

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13. Boil-out of New Unit

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