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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Mini Compack
Electric Steam Boiler

This manual must be available to the boiler operator at all times. MINI-IOMM-2016-6
Fulton Ltd

Page II MINI-IOMM-2016-6
Fulton Ltd TABLE OF CONTENTS
SECTION 1 - INTRODUCTION SECTION 4 - MAINTENANCE
1.1 General 1 4.1 Visual Checks 21

1.2 Technical Data 1 4.2 Water Level and Low Water Safety Controls 22

1.3 Product Overview 1 4.2.1 Feedwater Pump Test 22

4.2.2 Low Water Level Checks 23


SECTION 2 - INSTALLATION 4.2.3 Evaporation Check 23
2.1 General 5 4.3 Blowdown Procedures 24
2.2 Pre-Installation 5 4.3.1 Main Boiler Blowdown 24
2.2.1 Siting 6 4.4 Element Care and Protection 25
2.3 Boiler Connections 6 4.4.1 Element Removal 26
2.3.1 Steam Safety Valves 7 4.5 Boiler Internal Inspection 26
2.4 Water Supply 8 4.5.1 Feedwater Tank Internal Inspection 27
2.5 Electrical Requirements 8 4.6 Cleaning Water Level Probes 27
2.6 Commissioning the Boiler 10 4.7 Schedule of Operator Tests and Checks 28

4.7.1 Daily 29
SECTION 3 - OPERATION
4.7.2 Weekly-in addition 29
3.1 General 13
4.7.3 Monthly-in addition 29
3.2 Controls 13
4.7.4 Three Monthly-in addition 30
3.2.1 Boiler Control Panel 14
4.8 Maintenance Record Keeping 31
3.2.2 Steam Pressure Controls 15
4.9.1 Troubleshooting-boiler 32
3.2.2.1 Setting Steam Pressure Controls 15
4.9.2 Troubleshooting-feedwater pump 33
3.3 Filling The Boiler 16

3.4 Draining the Boiler 17 APPENDIX A - TI SHEETS


3.5 Boiler Start-Up (from cold)-all models 18 MINI Dimensions & Specification 36
3.5.1 Boiler Start-Up Following short term Shut-Down 18 MINI Probe Lengths 38
3.6 Boiler Shut-Down 19 Recommended Water Conditions 39
3.6.1 Short Term Shut-Down (hours) 19 Water Level Probes 40
3.6.2 Long Term Shut-Down (weeks) 19 Auto TDS Blowdown Systems 42
Auto TDS Blowdown System Install Guide 44

Electrical diagrams supplied separately

MINI-IOMM-2016-6 Page III


WARNINGS Fulton Ltd

! CAUTION
In case of emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.

If such a condition should occur during commissioning or during subsequent operation of this product,
regardless of the cause, then the electrical supply to the boiler should be isolated immediately, until the fault
has been investigated by a competent person and rectified.

For your safety!


The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.

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

! WARNING
Steam boilers are a potential hazard, possibly fatal if not properly maintained.

! CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry
out the routine maintenance checks could result in a drastic reduction in the life expectancy of the
system and increase the possibility of fire, explosion, property damage, personal injury or loss of life.

The Pressure System Safety Regulations 2000

Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.

For further information contact:

(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.

(b) Health and Safety Executive local office.

(c) Your Competent Person.

Page IV MINI-IOMM-2016-6
Fulton Ltd WARNINGS
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the heater and serious personal injury.

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

Non-approved modifications can cause injury and


damage. Contact your Fulton dealer before modifying
the boiler.

Only qualified persons should be allowed to


operate and maintain the boiler and its equipment.
Boilers should always be drained through an approved
blowdown vessel.

Prior to the commencement of any work requiring the


removal of cover plates and the opening of control panel
box, the electrical supply to the boiler must be isolated.

Steam boilers have high temperature surfaces, that if


touched may cause serious burns. Only competent and
qualified personnel should work on or in the locality of
a steam boiler and ancillary equipment. Always ensure
the working area and floor are clear of potential hazards,
work slowly and methodically.
Do NOT store inflammable materials near the boiler.

The importance of correct boiler water and feedwater


cannot be over emphasised, see the relevant section in
this manual.

MINI-IOMM-2016-6 Page V
Fulton Ltd

Page VI MINI-IOMM-2016-6
Fulton Ltd INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

The Fulton Mini Compack electric steam boiler service manual is a generic publication, providing
information on standard boiler operation and maintenance.

Every care has been taken in the manufacture of the boiler to ensure that quality and reliability
standards are maintained. Satisfactory performance can only be ensured if the installation
recommendations, operating routines and maintenance schedules laid out in this manual are
adhered to.

Particular attention should be paid to electrical installation and water treatment.

1.2 TECHNICAL DATA

For a full specification refer to Appendix A - TI-112-MINI Dimensions & Specification.

1.3 PRODUCT OVERVIEW

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

CONTINUED ON NEXT PAGE

MINI-IOMM-2016-6 Page 1
INTRODUCTION - 1 Fulton Ltd

5 6

3
2
1

9
18

10

12

11

13
14

19

20

Figure. 1 - General Arrangement

Page 2 MINI-IOMM-2016-6
Fulton Ltd INTRODUCTION - 1

10

15

17

8
16

Figure. 2 - General Arrangement Top

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

MINI-IOMM-2016-6 Page 3
Fulton Ltd

Page 4 MINI-IOMM-2016-6
Fulton Ltd INSTALLATION - 2

SECTION 2 - INSTALLATION

2.1 GENERAL

The installation of the Fulton Mini Compack electric steam boiler should be carried out by
competent personnel in accordance with all relevant safety regulations. It is the responsibility of
the installer to ensure that these regulations are complied with.

2.2 PRE-INSTALLATION

Prior to delivery of the boiler, consideration should be given to the following:


(Planning regulations may call for more consents than those listed below, always check with your
Local Planning Authority).

A. Local Planning consents where appropriate.

B. Consideration given to access for delivery and positioning of the boiler.

C. Preparation of a suitable base, which must be able to support the total weight of the system
under operating conditions.

The locations of services to the site required for the system, under operating conditions.

D. Electricity supply, check the loading required/available.

E. Drainage system, check the suitability of the drainage system.

F. L
ocal regulations for discharge into existing drains.

G. Suitable access for delivery and off-loading.

H. Safe access to the plant when installation is complete.

MINI-IOMM-2016-6 Page 5
INSTALLATION - 2 Fulton Ltd

2.2.1 SITING

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

Reference should be made to Appendix A - TI-112-MINI Dimensions & Specification to


ascertain the relevant dimensions and weights, special note should be taken of the required
clearance for maintenance. Allow sufficient room at the rear and to the right-hand side of the
boiler to allow for the connection of all services.

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

2.3 BOILER CONNECTIONS

All connections for services are mounted at the rear and on the right-hand side of the boiler.
For connection sizes, refer to Appendix A - TI-112-MINI Dimensions & Specification.

1. Feedwater Inlet (feedwater tank)


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

2. Steam Safety Valve Discharge


The outlet from this valve should be piped to a safe discharge point and the piping should be
so arranged that condensate trapped in the discharge pipe is drained away from the valve.

! CAUTION
Unless otherwise specified the steam safety valve supplied with the boiler is pre-set at 90 p.s.i.g.
(6.2 bar). This valve is provided as a safety device for the boiler and should not be used as the sole
protection for other equipment using steam from the boiler.

3. Steam Outlet Valve

4. Overflow from feedwater tank


The overflow should be piped to a drainage point.

5. Boiler Blowdown Valve


The blowdown valve supplied with the boiler should be fitted as close as possible to the boiler in a
readily accessible position.
Connection must be made from the Blowdown valve to a blowdown receptacle of approved
design. Regulations exist covering such items and care must be taken to ensure compliance with
these regulations. If in any doubt regarding blowdown arrangements consult Fulton Ltd.

6. Feedwater pump feed

7. Feedwater tank drain

Page 6 MINI-IOMM-2016-6
Fulton Ltd INSTALLATION - 2

1
3

1
4

6
7
5

Figure. 3 - Boiler Connection Points

2.3.1 STEAM SAFETY VALVES

Safety valves are factory fitted and pre-set, they MUST NOT be adjusted. The discharge outlet
should be piped to a safe discharge point and the piping so arranged that any condensate
trapped in the pipework will drain away from the valve.

Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806
clause 4.9.7. / BSEN 134801-1:2002

a) The lift pressure is indicated on the safety valve (do not adjust).
b) The safety valve fitted to the boiler is designed to prevent the boiler exceeding its design
pressure.
c) Any system connected to the boiler not capable of accepting boiler pressure must be protected
by a separate safety valve set to the required pressure.

! WARNING
Factory fitted safety valves are pre-set to protect the boiler only and must not be used to protect any
other items not capable of accepting boiler pressure.

MINI-IOMM-2016-6 Page 7
INSTALLATION - 2 Fulton Ltd

2.4 WATER SUPPLY

! CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical treatment plants
CAN BE SUPPLIED by Fulton.
It is the responsibility of the operator to ensure adequate supplies of chemical are available
at all times (including commissioning).
Costly repairs could be required should the plant operate without chemicals or the wrong
dosage of chemicals.

The quality of the water used in the boiler will affect the life and performance of the boiler and
elements.
Feedwater contains solids and dissolved gases, these may promote encrustations of scale;
foaming, priming, surging; corrosion and pitting; or caustic embrittlement. To prevent this
happening it is strongly recommended that a reputable water treatment concern is consulted prior
to commissioning the boiler.

Note: See Appendix A - TI-139-Recommended Water Conditions.

Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. Should chemical
dosage of the boiler feedwater be required a connection point and a water sampling point are provided at the rear
of the boiler.

2.5 ELECTRICAL REQUIREMENTS

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

The power ratings and requirements are given in Appendix A - TI-112-MINI Dimensions &
Specification.

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

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

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

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

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

Page 8 MINI-IOMM-2016-6
Fulton Ltd INSTALLATION - 2

NOT FULTON SUPPLY

MAINS SUPPLY
E N L1 L2 L3

CONTACTOR

ELEMENT PUMP
MCB MCB

Fulton Control Panel


DOOR
MICROSWITCH

Figure. 4 - Recommended External Wiring

Connection Audible alarm


to water level
probes
Door microswitch

LC relays Element and


pump contactors
Element and
pump overload

Boiler heating
element

Figure. 5 - Electrical Panel

MINI-IOMM-2016-6 Page 9
INSTALLATION - 2 Fulton Ltd

2.6 COMMISSIONING THE BOILER

These procedures should be carried out by a competent person.

Although every care is taken to ensure that the boiler has been despatched from the factory
fully tested, it is possible that during transportation and installation, pipework and electrical
connections may be loosened or broken. On completion of the installation and prior to switching
on the boiler it is advisable to carry out the following checks:

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

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

1. Isolate boiler (mains supply)

2. Open front access door


Remove access cover on the top of the boiler

3. Check all electrical connections for tightness

4. Insulation test (IR) the elements

5. Set the steam operating pressure control to 80 psi maximum

6. Ensure Boiler switch is in the OFF position


Connect to the mains electrical supply

7. Close boiler blowdown valve


Close main steam valve

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

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

10. Close front access door


Refit access cover on the top of the boiler

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

Page 10 MINI-IOMM-2016-6
Fulton Ltd INSTALLATION - 2
11. Switch main isolator ON
Check the Power On light illuminates

12. Open the main steam valve

13. Switch the boiler On/Off switch to the ON position


Check:
a) Low Water light illuminates
b) Feedwater pump starts
c) Alarm sounds

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

14. Check rotation of the feedwater pump (correct rotation shown by arrow on the pump, usually
clockwise from front of boiler)

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

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

16. Switch the element energised switch to the ON position


The element energised switch should illuminate

17. Close the main steam stop valve

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

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

19. Check for leaks


Turn Boiler switch OFF
Turn element energised switch OFF
Turn main electrical isolator OFF
Open access cover on the top of boiler and front access door
Check for steam/water leaks
Close access cover on the top of boiler and close front access door
Slowly open the steam valve to release pressure from the boiler
Check for steam leaks in connecting pipework

Turn main isolator ON


Turn element energised switch ON

The boiler is now ready for placing into full operation.

MINI-IOMM-2016-6 Page 11
Fulton Ltd

Page 12 MINI-IOMM-2016-6
Fulton Ltd OPERATION - 3

SECTION 3 - OPERATION

! CAUTION
The following instructions are given for the guidance of the operator in the use of the Fulton steam
boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.

3.1 GENERAL

The following instructions are given for the guidance of the operator in the use of the Mini
Compack electric steam boiler and to provide adequate information to ensure that when the boiler
is put into use it will be done safely and without risk to health. Where original equipment service
manuals are supplied, they must be read and understood in conjunction with this manual.
All warnings and cautions must be observed.

3.2 CONTROLS

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

MINI-IOMM-2016-6 Page 13
OPERATION - 3 Fulton Ltd

3.2.1 BOILER CONTROL PANEL

The control panel contains a range of indicator lights to assist with the starting and testing
procedures, in addition the panel contains warning and fault indicators. Should a warning or fault
be indicated, the boiler must be isolated and the cause investigated by a competent person.

3. 1.

4. 2.

Figure. 6 - Controls and Indicators

1. Power On
Indicates that power is being supplied to the boiler control circuit and that the control panel is
live. This lamp should be illuminated immediately when the main isolator is switched ON and
should remain on until the main isolator is switched OFF.

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

3. Boiler On/Off
The switch is illuminated when in the ON position and indicates that the boiler is in a fully
operational state.
The switch should remain illuminated until switched to the OFF position.

4. Elements Energised
The lamp is illuminated when in the ON position and the element is energised. The switch is
extinguished when the element is de-energised during the normal on/off cycle of operation or
low water condition.

Page 14 MINI-IOMM-2016-6
Fulton Ltd OPERATION - 3

3.2.2 STEAM PRESSURE CONTROLS

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

Operating Pressure Control Switch (On/Off)


Controls the ON/OFF cycle of the element, switching the element off when the desired steam
pressure is reached and switching it on when steam pressure falls.

Operating pressure
controller

Figure. 8 - Steam Pressure Controller

3.2.2.1 SETTING STEAM PRESSURE CONTROLS

Adjust the steam pressure controls to suit the boiler application.

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

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

Operating Pressure Control Switch (On/Off)

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

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

A B

Figure. 7 - Setting Pressure Controllers

MINI-IOMM-2016-6 Page 15
OPERATION - 3 Fulton Ltd

3.3 FILLING THE BOILER

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

2. Ensure Boiler and element switches are both in the OFF position

3. Ensure the following valves are OPEN:

a) All valves in the line to the feedwater tank

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

4. Ensure the following valves are SHUT:

a) Steam outlet valve

b) Main blowdown valve

! CAUTION
The feed pump seals are water cooled.
The pump must never be allowed to run whilst dry, irreparable damage may result.
Ensure the pump is fully primed before energising the motor.

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

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

7. Switch the Boiler Switch to the ON position

8. Check:

a) Boiler Low Water indicator illuminates

b) Audible alarm sounds

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

Note: If the boiler has not been used for some time, it is possible that the boiler will be either air-locked or under
vacuum, it may be necessary to let air into the system to allow the boiler to fill.

9. Check:

a) Boiler Low Water indicator extinguishes

b) Audible alarm silences

Page 16 MINI-IOMM-2016-6
Fulton Ltd OPERATION - 3

3.4 DRAINING THE BOILER

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

Boilers with manual blowdown valves

1. Ensure the boiler is cold.

2. Ensure Boiler and element switches are both in the OFF position

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

4. Open the main steam valve.

5. Open the boiler blowdown valve.

6. Open all valves in the drain lines.

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

Boilers with automatic blowdown systems

1. The boiler should not be under pressure.


The boiler should be cold.

2. Open the main blowdown valve.

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

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

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

Automatic blowdown valve

A Blowdown bypass valve

Main blowdown valve

Figure. 9 - Automatic Blowdown Valve

MINI-IOMM-2016-6 Page 17
OPERATION - 3 Fulton Ltd

3.5 BOILER START-UP (FROM COLD) ALL MODELS

Do not attempt to start the boiler until this section has been read and fully understood.
Carry out the following procedure on every occasion when restarting the boiler after a shut-down.

1. Fill the boiler (see Section 3.3 - Filling The Boiler). Ensure the feedwater pump is primed.

2. Ensure the main steam isolating valve is SHUT.

3. Check the steam pressure controls are set correctly (see Section 3.2.2.1 - Setting Steam
Pressure Controls)

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

The steam pressure control will control the on/off sequence of the element once the boiler is
operating. The low water relays automatically maintain the level of water in the boiler and
will immediately shut-off the power to the element should the water fall to an unsafe level.

4. When the boiler has achieved the required (set) pressure, the main steam isolating valve
should be slowly opened allowing steam to enter the system distribution pipework.

! CAUTION
The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock
and water hammer.

This can be achieved by one of two methods:

a) Partially open the main steam valve and allow the system to heat up slowly (minimum
15 minutes) before fully opening the main steam valve.

b) Open the main steam valve when starting the boiler, allowing the boiler and system to heat
up together.

Note: This can lead to water logging of the steam lines until full pressure is achieved.
If fitted, TDS Panel Mounted Controllers (BC3150) must be reset after any break in electrical supply to the unit.

Note: Before leaving the boiler unattended, the daily operating tests (see Section 4.7.1) should be carried out to
check the functions of all the safety interlocks.

3.5.1 BOILER START-UP FOLLOWING SHORT TERM SHUT-DOWN

If the boiler has been shut-down short term (see Section 3.6.1 - Short Term Shut-Down), the
boiler can be simply switched ON and then left to reach working temperature/pressure.

Page 18 MINI-IOMM-2016-6
Fulton Ltd OPERATION - 3

3.6 BOILER SHUT-DOWN

3.6.1 SHORT TERM SHUT-DOWN (HOURS)

1. Turn Boiler switch OFF


Turn Element switch OFF
The element will de-energise.

2. Close the steam outlet valve

3.6.2 LONG TERM SHUT-DOWN (WEEKS)

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

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

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

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

MINI-IOMM-2016-6 Page 19
Fulton Ltd

Page 20 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

SECTION 4 - MAINTENANCE

! CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to.
Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic
reduction in the life expectancy of the boiler.

Tests should be carried out by a competent person trained to perform such tests. If any test shows that the
equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used.

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

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

4.1 VISUAL CHECKS

Inspect the steam and feedwater pipework, valves, fittings and elements for signs of leakage.
If leaks are suspected, shut down and evacuate the system to atmospheric pressure before
attempting any repairs.

Note: Ensure that the water level is maintained during the pressure build-up. If any part of the equipment is not
operating correctly, the fault should be investigated before the boiler is used. Ensure that all blowdown pipework
is safe and discharged to a blowdown receptacle.

MINI-IOMM-2016-6 Page 21
MAINTENANCE - 4 Fulton Ltd

4.2 WATER LEVEL AND LOW WATER SAFETY CONTROLS

The following procedures ensure the correct functioning of the water level controls and the low
water safety controls.

4.2.1 FEEDWATER PUMP TEST

a) If the boiler is not heating and not under steam pressure, lower the water level using the main
blowdown valve:

If the pump is running:

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

If the pump is not running:

1. Lower the water level by opening the main boiler blowdown valve.

2. Verify that the pump starts to run when the water level reaches the Pump On level.

3. CLOSE the main boiler blowdown valve.

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

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

If the pump is running:

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

If the pump is not running:

1. The water level will lower through natural evaporation.

2. Verify that the pump starts to run when the water level reaches the Pump On level.

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

Page 22 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

4.2.2 LOW WATER LEVEL CHECKS

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

2. Switch the Boiler switch to the OFF position.

3. Drain the boiler below the Low Water level.

4. Switch the Boiler switch to the ON position.

5. Check

a) Low Water lamp illuminates

b) Audible alarm sounds

c) Element Energised switch does not illuminate.

d) Feedwater pump starts

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

6. When Pump Off level is reached, Check:

a) Feedwater pump switches off

b) Low Water Lamp de-energises

c) Audible alarm stops

d) Element Energised Switch illuminates

4.2.3 EVAPORATION CHECK

This check may be required by your insurance inspector as part of the annual inspection.

To perform the evaporation check, follow the procedure in Section 4.2.2 - Low Water Level
checks allowing water to lower by natural evaporation and not by manual blowdown.

MINI-IOMM-2016-6 Page 23
MAINTENANCE - 4 Fulton Ltd

4.3 BLOWDOWN PROCEDURES

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

Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service
Department regarding the appropriate blowdown procedure.

Note: Boilers fitted with auto-timed main blowdown systems still require the water level controls to be tested, this
may be done by operating the auto blowdown bypass valve.

Note: A safe blowdown receptacle must be used.

4.3.1 MAIN BOILER BLOWDOWN

1. Start the boiler and generate 10 psi of steam pressure (see Section 3.5 Boiler Start-Up).

2. Switch Boiler and Element switches OFF.

3. Fully OPEN the boiler blowdown valve for not more than 5 seconds, or as recommended by
the water treatment specialist.

4. CLOSE the blowdown valve.

5. Resume normal operation by switching Boiler and Element switches ON.

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

Page 24 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 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 Appendix A -
TI-139-Recommended Water Conditions.

The dangers of scale to the life of the element cannot be overstressed. Scale possesses excellent
insulating qualities and its formation on the element prevents the heat generated by the element
being transferred to the water, causing the element to overheat and burn out. Loose, powdery
formations can be removed with a wire brush. Hard scale may be removed using a chemical
cleaning agent.

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

Element and
pump contactors

Boiler heating
element

Figure. 10 - Boiler Elements

MINI-IOMM-2016-6 Page 25
MAINTENANCE - 4 Fulton Ltd

4.4.1 ELEMENT REMOVAL

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

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

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

Element
mounting flange

Boiler heating
element

Element power
supply terminals

Figure. 11 - Boiler Element Removal

4.5 BOILER INTERNAL INSPECTION

The boiler elements should be removed (see Section 4.4.1 Element Removal) after one month
of operation and the interior of the boiler thoroughly examined. If scale or sludge build-up is
observed, it should be removed and the water treatment supplier advised.

New gaskets must be fitted every time an element is removed. Subsequent interior examinations
should be carried out on a regular basis until satisfactory conditions are observed. Thereafter,
inspections should be carried out at three monthly intervals.

Boiler heating
element removed to
reveal inspection hole

Figure. 12 - Boiler Inspection Hole

Page 26 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

4.5.1 FEEDWATER TANK INTERNAL INSPECTION

Isolate the boiler and remove the boiler top access panel.
Check the tank is clean and clear of obstruction.
Drain the tank and clean as necessary.

Top access to tank


(panel removed)

Figure. 14 - Feedwater Tank Inspection Panel

4.6 CLEANING WATER LEVEL PROBES

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

Remove and clean the boiler level probes taking note of probe lead positions.

For more information on the water level probes see Appendix A - TI-103-Water Level Probes.

Low water Pump on Pump off


(red cable) (yellow cable) (black cable)

Figure. 13 - Boiler Water Level Probes


MINI-IOMM-2016-6 Page 27
MAINTENANCE - 4 Fulton Ltd

4.7 SCHEDULE OF OPERATOR TESTS AND CHECKS

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

Maintenance must be carried out by competent, trained personnel

If any fault is found during these operations, contact your Fulton representative.

! WARNING
Prior to the commencement of any work requiring the removal of access panels, the electrical supply
to the boiler must be isolated.

Ensure any residual pressure within the boiler is completely vented before working on the pressure
vessel.

! CAUTION
It is essential that regular checks are made to ensure that scale build-up is not taking place within the
boiler. Such checks will ensure that water treatment being applied to the boiler feedwater is effective.

Make sure that lifting equipment complies with all local regulations and is suitable for the job.
You can be injured if you use faulty lifting equipment.
Make sure the lifting equipment is in good condition.

! IMPORTANT
If any fault is found during these procedures, shut down the
boiler immediately and consult Fulton Ltd.

The following procedures are designed to prevent the build-up of scale, silt or sludge in the
bottom of the boiler and on the elements. Personnel involved in doing this work must have
received the appropriate training in all aspects of maintenance and safety procedures.

In addition to these procedures, the advice of a water treatment specialist should be sought and
followed.

Page 28 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

4.7.1 DAILY

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

a) Steam and feedwater pipework

b) Valves and fittings

2. Low water level check (see Section 4.2.2 - Low Water Level Checks).

3. Blowdown the boiler (see Section 4.3.1 –Main Boiler Blowdown).

4.7.2 WEEKLY IN ADDITION

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

Note: Isolate the electrical supply to the boiler and set the selector switch to OFF.

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

a) Steam and feedwater pipework

b) Valves and fittings

c) Elements

! WARNING
Ensure the fittings around the steam safety valve(s) are secure.
The safety valve will be very hot, do not operate the safety valve without protection.

5. Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe
blowdown point.

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

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

4.7.3 MONTHLY IN ADDITION

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

MINI-IOMM-2016-6 Page 29
MAINTENANCE - 4 Fulton Ltd

4.7.4 THREE MONTHLY IN ADDITION

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

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

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

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

13. Check and clean the feedwater strainer.

14. Check all electrical connections for tightness.

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

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

16. Return all valves to normal working position.

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

Page 30 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

4.8 MAINTENANCE RECORD KEEPING

Boiler log sheets should be completed on a regular basis, this provides invaluable information in
the subsequent investigation of the boiler history. Maintenance log sheets can be found in the
Fulton boiler Log Books provided by Fulton.

To Purchase a Fulton Boiler Log Book, please contact training@fulton.co.uk.

Model:

E
Electric Steam Boiler - Daily and Weekly Tests Boiler Number:

DAILY TESTS 1 2 3 4 5 6 7

L
Date
1. Visual Inspection of casing exterior pipework and fittings for signs of leakage Y-N Y-N Y-N Y-N Y-N Y-N Y-N
2. Low Water Level Check - low water indicator illuminate, alarm sound, feedwater pump stops/

P
Y-N Y-N Y-N Y-N Y-N Y-N Y-N
starts and elements de-energise/energise.
Duration seconds.
3. Blowdown, Boiler
Test Time.
Duration seconds.

M
4. Blowdown, Water Column
Test Time.
Duration seconds.
5. Blowdown, Water Level Gauge
Test Time.

A
6. Pressure gauge reading for blowdown tests.
Boiler water and water treatment values must be within known tolerances of the datum.
datum value. TDS. reading

X
7. Boiler Water.
datum value. PH reading
8. Oxygen Scavenger Concentration datum value. reading
9. Brine level correct Y-N Y-N Y-N Y-N Y-N Y-N Y-N

E
WEEKLY TESTS 7+
10. Visual Inspection of casing interior pipework, fittings and elements for signs of leakage Y-N
11. Feedwater Pump Test - Feedwater pump, start/stop Y-N
12. Safety valve outlet pipe to safe blowdown point and free of damage Y-N

Test results and actions taken


Day 1. sig. Day 5. sig.

2. sig. 6. sig.

3. sig. 7. sig.

4. sig. 7+. sig.

Log examined by: Date:

E
MAINTENANCE LOG
Date Time Operation Performed Remarks Operators Initials

P L
A M
E X
MINI-IOMM-2016-6 Page 31
MAINTENANCE - 4 Fulton Ltd

4.9.1 TROUBLESHOOTING BOILER

Problem Cause Remedy


Power On indicator 1. Mains supply failure. External circuit MCB requires resetting.
not illuminated 2. Door interlock microswitch Fuses need replacing.
not made. Indicator lamp needs replacing.
Low Water lamp 1. Insufficient water in the Check that the feedwater supply line valves are
illuminated and boiler. open. Check that the ball valve in the tank is
Audible alarm sounds operating correctly by removing the inspection cover
on the tank.
2. Obstruction in the feedwater Check that the shut-off valve below the tank is open.
line to the pump. Remove and clean the filter in the strainer. Check
that the non-return valve is operating correctly.
3. Air lock in the pump. Bleed the pump at the point provided.
4. Feedwater pump impeller
worn.
5. Incorrect connections to Check connections to water level probes.
water level probes.
6. Faulty water level relay. Check that each relay is pressed firmly home on its
base.

Page 32 MINI-IOMM-2016-6
Fulton Ltd MAINTENANCE - 4

4.9.2 TROUBLESHOOTING FEEDWATER PUMP

Problem Cause Remedy


FEEDWATER PUMP 1. Supply failure. Connect the electricity supply.
Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers.
3. Motor contactor overload has Reactivate the motor protection.
tripped out.
4. Contactors not making Check, the coil is faulty or wiring loose.
5. Control circuit is defective. Repair the control circuit.
6. Motor is defective. Replace the motor.
Motor starter overload, 1. One fuse/automatic circuit breaker is Replace the fuse, reset the circuit
trips out immediately blown. breaker.
when supply is 2. Contacts in motor contactor overload Replace motor starter contacts.
switched on. are faulty.
3. Cable connection is loose or faulty. Tighten or replace the cable connection.
4. Motor winding is defective. Replace the motor.
5. Pump blocked. Remove the blockage.
6. Overload setting too low. Set the motor starter correctly.
Motor contactor 1. Overload setting is too low. Set the overload correctly.
overload trips out 2. Low voltage at peak times. Check the electricity supply.
occasionally.
Motor contactor has Check:
not tripped out but the Motor does not run when started:
pump does not run. items: 1, 2, 4, 5, 6,
Pump capacity not 1. Pump inlet pressure is too low Check the suction conditions.
constant. (cavitation).
2. Suction pipe/pump partly blocked. Clean the pump or suction pipe.
3. Pump draws in air. Check the suction conditions.
Pump runs but gives 1. Suction pipe/pump blocked. Clean the pump or suction pipe.
no water. 2. Foot or non-return valve blocked in Repair the foot or non-return valve.
closed position.
3. Leakage in suction pipe. Repair the suction pipe.
4. Air in suction pipe or pump. Check the suction conditions.
5. Pump rotates in the wrong direction. Change the direction of rotation of the
motor.
6. Boiler feedwater non-return valve Check and clean boiler feedwater
letting water passed the valve seat, non-return valve, ensure it is seating
(normally and not allowing water passed.
accompanied by banging in the feedwater
tank).

CONTINUED ON NEXT PAGE

MINI-IOMM-2016-6 Page 33
MAINTENANCE - 4 Fulton Ltd

4.9.2 TROUBLESHOOTING FEEDWATER PUMP

Problem Cause Remedy


Pump runs 1. Leakage in suction pipe. Repair the suction pipe.
backwards when 2. Foot or non-return valve is Repair the foot or non-return valve.
switched off. defective.
Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal.
Noise. 1. Cavitation occurs in the Check the suction conditions.
pump.
2. Pump does not rotate Adjust the pump shaft.
freely (frictional resistance
because of incorrect pump
shaft position.
3. Frequency converter See Grundfos manual.
operation.
4. Boiler feedwater non-return Check and clean boiler feedwater non-return valve,
valve letting water passed ensure it is seating and not allowing water passed.
the valve seat, (normally
accompanied by banging
in the feedwater tank).
Water pump will 1. Scale on probes. Check and clean probes, replace as necessary.
not come on at 2. Faulty pump contactor Check the contactor has power. Check the contactor
times. is pulling in.
Replace if necessary.
3. Faulty pump motor. Check the pump has power.
If the pump has power but is not running, replace it.
4. Faulty Level Control Relay Check the relay has power and is secure on it’s
base. Replace if faulty.
Boiler flooding 1. Pump does not shut off. Dirty probes. Clean or replace as necessary.
2. Relay failed. Ensure the relay is secure on its base.
If so replace the water level relay.
3. Earth connection. Clean and tighten as required.
4. Vacuum created with boiler As the boiler cools, it pulls water from the system
off. piping. To prevent this, add a check valve on the
steam gauge assembly piping, which closes under
pressure and opens under vacuum.

Page 34 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

APPENDIX A - TI SHEETS

The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in
this Appendix.

Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To
check you have the most up to date TI sheet, please check the downloads section on the Fulton website
(www.fulton.co.uk/support/downloads) or consult Fulton Ltd.

MINI-IOMM-2016-6 Page 35
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 112 Issue 6

Mini Compack
Dimensions & Specification

Dimensions

A C
B E

D
F J
G
H
L

M
K
N

MODEL: MINI COMPACK CP9, CP12 ,CP15, CP18


A Minimum Clearance* 500
B Overall Width 600
C Overall Depth 915
D Overall Height 750
E Boiler Depth 760
F Safety Valve Discharge Height 570
G Steam Outlet Height 495
H Electrical Supply Inlet Height 465
J Feedwater Inlet Height 510
K Feedwater Tank Drain 135
L Feedwater Tank Overflow 450
M Pump Feed Inlet Height 200
N Main Boiler Blowdown Height 45
* Required in front of the boiler for maintenance and element removal.

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

Page 1 of 2

Page 36 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

Specification TI-112-MINI-DS-2016-6

MODEL: MINI COMPACK UNIT CP9 CP12 CP15 CP18


Designed and manufactured to British Standard BS1894 1992 Class 2 and PED/97/23/EC.

General
Steam Output F & A 100 °C kg/h 14 19 24 29
kW Rating kW 9 12 15 17.5
Operating Pressure barg 5.8 5.8 5.8 5.8
Number of Elements 1 1 1 1
Weight
Shipping Weight kg 120 120 120 120
Operational Weight kg 162 162 162 162
Water Content L 28 28 28 28
Feed Tank Volume L 14 14 14 14
Electrical Requirements
FLC 400 V 3 ph 50 Hz** A/ph 16 20 24.5 29
FLC 230 V 1 ph 50 Hz*** A 44 57 70 80
Connection Sizes All threads BSP
Steam Outlet DN 15 15 15 15
Safety Valve Discharge DN 25 25 25 25
Feedwater Inlet DN 15 15 15 15
Blowdown, Boiler DN 15 15 15 15
Tank Drain DN 15 15 15 15
Tank Overflow DN 25 25 25 25
** 3 A/ph for feedwater pump & standard control circuit, included.
*** 5 A for feedwater pump & standard control circuit, included.

Note: Isolator, mains contactor and fusing not included.


Note: Not suitable for condensate return-cold water make-up only.
Note: Electrical enclosures are rated IP20

Page 2 of 2

Telephone: +44 (0) 117 972 3322


Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: sales@fulton.co.uk
BS5 7FG. England. Website: www.fulton.co.uk 003
FMFM28400
28400

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

MINI-IOMM-2016-6 Page 37
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 147 Issue 1

Mini & Midi Compack


Probe Lengths

1 Branch Mini Compack


Low Water
Pump On
Pump Off

PROBE LENGTHS - 1 BRANCH MINI


Pump OFF (black) 127 mm
Pump ON (yellow) 152 mm
Low Water (red) 184 mm

Note: Dimensions mm
Note: Measurement taken from under the hexigon.
Note: Dimensions taken from drawing: FL080018

2 Branch Midi Compack


Low Water

Pump On
Pump Off

PROBE LENGTHS - 2 BRANCH MIDI


Pump OFF (black) 152 mm
Pump ON (yellow) 178 mm
Low Water (red) 216 mm

Note: Dimensions mm
Note: Measurement taken from under the hexigon.
Note: Dimensions taken from drawing: FL080018

Telephone: +44 (0) 117 972 3322


Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: sales@fulton.co.uk
BS5 7FG. England. Website: www.fulton.co.uk 003
FMFM28400
28400

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Page 38 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

Technical Information
Sheet No. 139 Issue 2

J Series & Electric Steam Boilers


Recommended Water Conditions

! IMPORTANT

It is very important that a strict water management program is followed to ensure trouble free boiler
operation.

The following are recommended for feedwater and for boiler water

FEEDWATER (water entering boiler)


pH Value 8.5 to 9.5 tested at room temperature.
Hardness Less than 2.0 mg/kg in the form of CaCO3.
Suspended Solids None
Chloride Less than 50 mg/kg.
Organic Matter Less than 5 mg/kg.
Oil None
Minimum Temperature 85 °C
BOILER WATER (water inside boiler)
pH Value 9.5 to 11.5 tested at room temperature.
Hardness Not detectable.
Suspended Solids Less than 100 mg/kg.
Chloride Less than 500 mg/kg.
Oxygen Scavenger, Sodium Sulphite or Tannin 20 to 50 mg/kg.
Phosphate Less than 50 mg/kg, in the form of PO4.
Total Alkalinity Less than 1000 mg/kg.
Caustic Alkalinity Minimum 300 mg/kg as CaCO3.
Total Dissolved Solids (TDS) Less than 2000ppm.
Iron Less than 1 mg/kg.
Silica Less than 150 mg/kg, in the form of SiO2.
Dissolved Oxygen None

KEY
mg/kg = Milligrams per Kilogram It is critical that the boiler water pH be
CaCO3 = Calcium Carbonate alkaline in the range 9.5 - 11.5.

PO4 = Phosphate Daily boiler blowdown is essential to


SiO2 = Silicon Dioxide help prevent formation of deposits
and reduce Total Dissolved Solids
PPM = Parts Per Million (TDS).

1 Grain hardness = 17.118 ppm Consult your water treatment specialist


to establish the frequency and duration
therefore 70 ppm = 4.10 grains hardness
of blowdown required to achieve the
required conditions.
For practical
= ppm
purposes mg/kg

Telephone: +44 (0) 117 972 3322


Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: sales@fulton.co.uk
BS5 7FG. England. Website: www.fulton.co.uk 003
FMFM28400
28400

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

MINI-IOMM-2016-6 Page 39
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 103 Issue 3

Water Level Probes


Replacement

Standard Probes (brass)


Probes are supplied in a standard length and should be cut to the length required, (the length of the probe being
replaced) ensuring measurements are taken from the underside of the probe hexagonal nut, remove any burrs
caused by cutting.

! IMPORTANT
Terminal and securing nuts must not be adjusted.

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

The Terminal & Securing Nuts are tightened to a specified torque during manufacture which causes the PTFE
Insulation to seal against the probe body. Therefore these nuts must not be adjusted because the seal will be
broken which may cause the probe to leak (see Figure. 1).

Angle Rajah ONLY must be used to connect wire to the probes because they clip directly to the Terminal Nut.
Spade Connectors must NOT be used because the Terminal Nut would require adjustment and therefore cause the
probe to leak (see Figure. 2).

N.B. The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture, meaning the probe is
ready to be installed without any adjustment.

The ONLY instance a spanner should be used, is to turn the Probe Body in order to remove or reinstall the entire
probe.

Terminal nut
Securing nuts

Probe wire

Probe body
Angle rajah

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

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

Page 1 of 2

Page 40 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

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

The probe is supplied in two parts, the head and the tip. The tip should be screwed onto the head aligning the slot
in the top of the tip with the hole in the screwed shaft of the head.

Locate the pin provided into the slot/hole and secure with the lock nut.

Using the measurement from the old probe, cut the new probe to length and de-burr. Ensure both measurements
are taken from the underside of the hex. nut on the probe head.

Ensure measurements are


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

Locknut Locate the pin in the hole/slot


and secure with the locknut.

Figure. 3 - High Integrity Water Level Probe

Page 2 of 2

Telephone: +44 (0) 117 972 3322


Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: sales@fulton.co.uk
BS5 7FG. England. Website: www.fulton.co.uk 003
FMFM28400
28400

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

MINI-IOMM-2016-6 Page 41
Fulton Ltd

Technical Information
Sheet No. 30 Issue 3

Automatic TDS Blowdown Systems

The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS level
within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be used to
control suspended solids, and prevent the build-up of sludge in the bottom of the boiler. The daily testing of boiler
water level controls is a mandatory requirement as defined in the Health & Safety Executive Guidance Note BG01,
Arrangement 3.

The method of operation is to take a sample of the boiler water at pre-set timed intervals, pass the sample over an
electrode which measures water conductivity (which is proportional to TDS for a given water chemistry), and then
compares the result with the control value (normally 2000 ppm), which is set when the unit is commissioned.

If the sample value is higher than the control value, the blowdown solenoid valve opens in a series of pulses until
the measured value corresponds to, or is lower than, the set value. When this is achieved, blowdown finishes until
the next timed sample is taken when the process is repeated. Should the sample value be lower than the set value,
blowdown is deferred until the next timed sample.

For the system to function reliably, the control must be calibrated to a typical water sample that is representative
of the water conditions that are likely to prevail during normal running of the boiler and system. Conductivity and
as a consequence TDS, can vary significantly with water chemistry. Changes in condensate return rates, alkalinity,
chemical dosage, and suspended solids can all affect the performance of an Automatic TDS Blowdown System.

Condensate return rates that vary greatly on a day to day basis can severely disrupt the reliability of the
conductivity measurement.

Feed water TDS at varying


condensate return rates
500

400
Feed water TDS (ppm)

300

200

100

0
0 10 20 30 40 50 60 70 80 90 100
Condensate return(%)

Raw water TDS (ppm)


50 100 150 200 250

300 350 400 450 500

Figure. 1 - TDS Graph 1

e.g. A boiler with a 50% condensate return and a raw water TDS of 400 will have a boiler feed water TDS of 200 ppm.

Page 1 of 2

Page 42 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

TI-30-AutoTDSBlowdown-2015-3

Systems that return for example very little condensate during the day, but a high proportion at night, are almost
impossible to control with any real accuracy. At best a compromise calibration will be achieved, where too much
blowdown at times may be the penalty.

When installing and commissioning a new Automatic TDS Control Blowdown System, it must be accepted that the
calibration will be a reiterative process, requiring continual sampling, testing, and re-calibration until stable system
operating conditions are achieved.

When purchasing an Automatic TDS Control Blowdown System from Fulton, the equipment would normally
be supplied with the controller wired and fitted to the boiler control panel, with all the other parts supplied
loose for piping and wiring on site by others, unless agreed otherwise in our order acknowledgement.

The purchase price of the system supplied fully or part fitted includes for one single visit to commission the system
once installed. Part of the commissioning process will be the initial calibration of the TDS sensor to the water
conditions prevailing at the time.
Further re-calibration will be required until the water treatment regime has been established, and “typical” water
conditions have been achieved. Routine calibration checks will be required as part of the site maintenance and
water treatment monitoring.

The equipment and staff training required to carry out TDS sampling and calibration can be provided by Fulton. In
order to achieve the maximum benefit from the installation of an Automatic TDS Blowdown System, it is strongly
recommended that site personnel be provided with the necessary equipment, and training in order for them to fully
understand the function of the system, and the possible consequences of their actions.

Note: Where Automatic TDS Blowdown systems are provided as part of a skid mounted or packaged plantroom
system, they will be fully installed piped and wired.

For further details on the installation of Automatic TDS Controlled Blowdown Systems consult the Fulton Ltd
Technical Information Sheet 35. Automatic TDS Control Blowdown System Installation Guide.

30
(as a percentage of boiler output in kg/h)

25

20
Blowdown

15

10

0
0 100 200 300 400 500
Feed water TDS (ppm)
From Fig. 1.
% Blowdown required to maintain a boiler TDS
of 2000ppm against feed water TDS

Figure. 2 - TDS Graph 2


e.g. Hourly blowdown rate required to maintain a boiler TDS of 2000 with a feedwater TDS of 200 = 12%

For a 1000 kg/h boiler 125 kg/h (125 l/h) of blowdown is required.

Page 2 of 2

Telephone: +44 (0) 117 972 3322


Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: sales@fulton.co.uk
BS5 7FG. England. Website: www.fulton.co.uk 003
FMFM28400
28400

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

MINI-IOMM-2016-6 Page 43
APPENDIX - A Fulton Ltd

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

The Automatic Total Dissolved Solids Control Blowdown System supplied by Fulton Ltd is an intermittant
type. It consists of an electrical TDS Control Unit, valves (including a solenoid valve) and fittings, TDS
sensor, strainer and non return valve (See fig 1).

In most cases the TDS control box will be supplied mounted in the boiler control panel, with the remaining
items supplied loose for piping and wiring on site by the installer/site contractor.

All new Fulton vertical steam boilers are provided with a connection to facilitate the fitting of a vertical
15mm NB. dip pipe through the top of the boiler shell, terminating inside the boiler approximately 150mm
below the boiler normal working water level, where the maximum concentration of TDS is found.

The 15mm NB. discharge pipework from the dip pipe should incorporate the TDS blowdown system as
illustrated. For practical reasons, and to minimise the length of cable runs, the solenoid valve and sensor
should be installed as close to the boiler as is practicable. For maintenance purposes the pipework should
incorporate unions, and be routed such that access to the boiler flue cover plates, hand hole doors, and
blowdown valves are not obstructed.

The site wiring required is one twin core screened cable for the TDS sensor, and one twin core and earth
supply to the solenoid valve. The screened cable terminates within the TDS control unit, the twin core and
earth cable terminates on terminals in the control panel.

Note:- The screen on the sensor cable should be earthed at the controller end only.
For electrical connection details consult the data sheets supplied with the equipment.

The discharge from TDS blowdown systems should be connected to a certified blowdown vessel. For
single boiler installations the discharge can be connected into a common boiler ancillary blowdown line,
which may be connected to the main blowdown line. For multiple boiler installations the ancillary blowdown,
and main blowdown lines must be separated. For recommended pipework installation see the Fulton
Typical System Schematic Diagram (SD1V0402).

Full details of these requirements are given in the HSE Guidance Note PM60.

Where TDS blowdown systems are used, it is possible that the frequent discharge into the blowdown vessel
will not allow sufficient time for the blowdown vessel contents to cool between successive blowdowns,
resulting in discharge temperatures to the drains that are unacceptably high.

The limit set by the Public Health Act 1936 section 27(1)b for the maximum temperature of waste steam
or liquids discharged into the public sewers is 43°C. A further practical consideration is that many
modern drainage systems employ plastic pipes with mastic joints, which could be seriously damaged by
temperatures which under fault conditions could reach 100°C.

Page 1

Page 44 MINI-IOMM-2016-6
Fulton Ltd APPENDIX - A

TI35 ISSUE 2

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

Aftercooling can be achieved by using direct acting controls that do not require any power supply, or by
electrically controlled and activated systems which are marginally cheaper, but require site wiring, and
more maintenance after prolonged use.

Aftercooling systems are available from Fulton Boiler Works (Great Britain) Ltd.
Technical Information Sheet No 40, Blowdown After Cooling Systems, covering this topic is also available.

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

Strainer
Fig 12
Blowdown Valve
BCV1
Ball Valve
M10

Plug Tail
PT2
Check Valve
LCV1
Sensor
CP10
Sensor Chamber
S10
Ball Valve
M10
Blowdown to heat
recovery system

Fig. 1 Typical Automatic TDS Blowdown Pipework Assembly

Note:- Regular testing of the boiler water is essential for the correct operation of the boiler in terms of
the water treatment programme, but also for the routine re-calibration of the TDS sensor. The 1/4in. BSP
tapping at the bottom of the S10 sensor chamber can be used as the connection for a boiler water sample.

In order to take a boiler water sample safely it is important that a Water Sample Cooler made specifically
for the purpose is used. Water sample coolers are available from Fulton Boiler Works (Great Britain) Ltd.

Telephone: +44 (0) 117 972 3322


Fax: +44 (0) 117 972 3358
Fulton Ltd E-mail: sales@fulton.co.uk
5 Fernhurst Road, Fishponds, Bristol, BS5 7FG, England. Website: www.fulton.co.uk
Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.
TI35 12 13 ISSUE 2

Page 2

MINI-IOMM-2016-6 Page 45
APPENDIX - A Fulton Ltd

Page 46 MINI-IOMM-2016-6
Fulton Ltd

Material & Workmanship Guarantee

5 Year
GUARANTEE

D
FU
LT
ON L

T
On the Fulton Boiler Pressure Vessel
Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within five (5)
years of the date of delivery is found to be defective in workmanship, or material, provided this
equipment is operated and maintained by the buyer for the purpose for which it was designed and
in accordance with the manufacturer’s handbook. This guarantee does not cover damage or
failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions.
This guarantee is good only in the United Kingdom of Great Britain and Northern Ireland.
This guarantee does not include labour or delivery charges of any kind.

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

MINI-IOMM-2016-6 Page 47
www.fulton.co.uk

MINI-IOMM-2016-6

Fulton Ltd
5 Fernhurst Road
Fishponds
Bristol BS5 7FG
England

Telephone: +44 (0) 117 972 3322


Fax: +44 (0) 117 972 3358
Email: sales@fulton.co.uk 003
FM 28400