Fulton Midi Compack Manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

This manual must be available to the boiler operator at all times.

Midi Compack

Electric Steam Boiler

MIDI-IOMM-2016-5

Fulton Ltd

Page II MIDI-IOMM-2016-5

Fulton Ltd

SECTION 1 - INTRODUCTION

1.1 General

1.2 Technical Data

1.3 Product Overview

SECTION 2 - INSTALLATION

2.1 General

2.2 Pre-Installation

2.2.1 Siting

2.3 Boiler Connections

2.3.1 Steam Safety Valves

2.4 Water Supply

2.5 Electrical Requirements

2.6 Commissioning the Boiler

SECTION 3 - OPERATION

3.1 General

3.2 Controls

3.2.1 Boiler Control Panel

3.2.2 Steam Pressure Controls

3.2.2.1 Setting Steam Pressure Controls

3.3 Filling The Boiler

3.4 Draining the Boiler

3.5 Boiler Start-Up (from cold)-all models

3.5.1 Boiler Start-Up Following short term Shut-Down

3.6 Boiler Shut-Down

3.6.1 Short Term Shut-Down (hours)

3.6.2 Long Term Shut-Down (weeks)

TABLE OF CONTENTS

SECTION 4 - MAINTENANCE

4.1 Visual Checks

4.2 Water Level and Low Water Safety Controls

4.2.1 Feedwater Pump Test

4.2.2 Low Water Level Checks

4.2.3 Evaporation Check

4.3 Blowdown Procedures

4.3.1 Main Boiler Blowdown

4.4 Element Care and Protection

4.4.1 Element Removal

4.5 Boiler Internal Inspection

4.5.1 Feedwater Tank Internal Inspection

4.6 Cleaning Water Level Probes

4.7 Schedule of Operator Tests and Checks

4.7.1 Daily

4.7.2 Weekly-in addition

4.7.3 Monthly-in addition

4.7.4 Three Monthly-in addition

4.8 Maintenance Record Keeping

4.9.1 Troubleshooting-boiler

4.9.2 Troubleshooting-feedwater pump

APPENDIX A - TI SHEETS

Midi Dimensions & Specification

Midi Probe Lengths

Recommended Water Conditions

Water Level Probes

Auto TDS Blowdown Systems

Auto TDS Blowdown System Install Guide

Electrical diagrams supplied separately

MIDI-IOMM-2016-5 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 injury or death to personnel.

• CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness.

• Notes: must be observed for essential and effective operating procedures, conditions and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the

WARNINGS, CAUTIONS and

NOTES by which hazards are to be eliminated or reduced.

Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.

WARNING

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

CAUTION

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

The Pressure System Safety Regulations 2000

Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.

Regular inspections are therefore required by a competent person

The scope of the examination and the actual intervals between examinations is at the discretion of the competent person.

It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which a defect may give rise to danger.

Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover periodic statutory inspections.

For further information contact:

(a) SAFed

SAFETY ASSESSMENT FEDERATION Limited.

Nutmeg House,

60 Gainsford Street,

Butlers Wharf,

London, SE1 2NY.

(b) Health and Safety Executive local office.

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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

Do not try to do repairs or any other maintenance work you do not understand. Obtain a service manual from

Fulton Ltd or call a Fulton service engineer.

It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner.

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and or damage.

A defective boiler can injure you or others. Do not operate a boiler which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the boiler.

LIFTING EQUIPMENT

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

Operating the boiler beyond its design limits can damage the boiler, it can also be dangerous. Do not operate the boiler outside its limits. Do not try to upgrade the boiler performance by unapproved modifications.

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.

CAUTION

Obey all laws and local regulations which affect you and your boiler.

LOW FEEDWATER TEMPERATURE

Low feedwater temperature can result in thermal shock to the boiler pressure vessel. Return the maximum amount of condensate and if necessary preheat the feedwater. If in doubt consult Fulton Ltd.

WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and chemical treatment plants

CAN BE SUPPLIED by

Fulton Ltd.

It is the responsibility of the operator to ensure adequate supplies of chemical are available at all times

(including commissioning). Costly repairs could be required should the plant operate without chemicals or the wrong dosage of chemicals.

HYDRAULIC TEST - RISK OF BRITTLE FRACTURE

Hydraulic testing requires specialist equipment and is normally only required by engineering surveyors / inspectors. In order to ensure the material/ pressure vessel does not suffer from brittle fracture, hydraulic testing should not be carried out below 7 °C.

MIDI-IOMM-2016-5 Page V

Fulton Ltd

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INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1

1.2

1.3 GENERAL

The Fulton Midi 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.

TECHNICAL DATA

For a full specification refer to Appendix A - TI-121-MIDI Dimensions & Specification.

PRODUCT OVERVIEW

The Fulton Midi 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

MIDI-IOMM-2016-5 Page 1

INTRODUCTION - 1

Fulton Ltd

Page 2

Figure. 1 - General Arrangement

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Fulton Ltd

Figure. 2 - General Arrangement Top

Key

1. Boiler control panel

2. Access door lock

3. Front access door

4. Steam pressure gauge

5. Top access panel

6. Boiler steam safety valve

7. Main steam stop valve

8. Operating pressure controller

9. Feedwater tank water inlet

10. Feedwater tank mounted (optional)

11. Feedwater pump feed

12. Boiler feedwater check valve

13. Feedwater pump

14. Boiler blowdown valve

15. Pressure vessel

16. Electrical control panel

17. Water level probes

18. Boiler feedwater stop valve

19. Feedwater strainer

20. Feedwater tank condensate return

21. Feedwater tank overflow

INTRODUCTION - 1

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INSTALLATION - 2

SECTION 2 - INSTALLATION

2.1

2.2 GENERAL

The installation of the Fulton Midi 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.

PRE-INSTALLATION

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

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

Local Planning Authority).

A. Local Planning consents where appropriate.

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

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

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

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

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

F. Local regulations for discharge into existing drains.

G. Suitable access for delivery and off-loading.

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

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INSTALLATION - 2

2.2.1

2.3

Fulton Ltd

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-121-MIDI 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.

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-121-MIDI 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

8. Condensate return inlet

9. Feedwater tank vent

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INSTALLATION - 2

1 & 8

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.

MIDI-IOMM-2016-5 Page 7

INSTALLATION - 2

2.4 WATER SUPPLY

Fulton Ltd

CAUTION

WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and chemical treatment plants

CAN BE SUPPLIED by Fulton.

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-121-Midi 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.

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Connection to water level probes

LC relays

INSTALLATION - 2

NOT FULTON SUPPLY

MAINS SUPPLY

N L1 L2 L3

CONTACTOR

ELEMENT

MCB

Fulton Control Panel

PUMP

MCB

DOOR

MICROSWITCH

Figure. 4 - Recommended External Wiring

Audible alarm

Door microswitch

Element and pump contactors

Element and pump overload

Boiler heating elements

Figure. 5 - Electrical Panel

MIDI-IOMM-2016-5 Page 9

INSTALLATION - 2

2.6

Fulton Ltd

COMMISSIONING THE BOILER

These procedures should be carried out by a competent person.

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

WARNING

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

WARNING

With the door open and the electrics overridden it is possible for the elements to be LIVE.

Extreme caution must be observed when working under these conditions.

1. Isolate boiler (mains supply)

2. Open front access door

Remove access cover on the top of the boiler

3. Check all electrical connections for tightness

4. Insulation test (IR) the elements

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

6. Ensure Boiler switch is in the OFF position

Connect to the mains electrical supply

7. Close boiler blowdown valve

Close main steam valve

8. Open all valves in the feedwater line and pump supply line

Allow feedwater tank to fill

Check for leaks

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

10. Close front access door

Refit access cover on the top of the boiler

WARNING

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

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CONTINUED ON NEXT PAGE

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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.

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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

3.2 GENERAL

The following instructions are given for the guidance of the operator in the use of the Midi

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.

CONTROLS

The following brief description of the controls used on the Midi 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.

MIDI-IOMM-2016-5 Page 13

OPERATION - 3

3.2.1

Fulton Ltd

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.

Page 14

Figure. 6 - Controls and Indicators

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.

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.

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.

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.

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3.2.2

OPERATION - 3

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 elements, switching the elements 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 elements being de-energised (switched off) and energised (switched on).

A B

MIDI-IOMM-2016-5

Figure. 7 - Setting Pressure Controllers

Page 15

OPERATION - 3

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

Fulton Ltd

CAUTION

The feed pump seals are water cooled.

The pump must never be allowed to run whilst dry, irreparable damage may result.

Ensure the pump is fully primed before energising the motor.

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

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

7. Switch the Boiler Switch to the ON position

8. Check: a) Boiler Low Water indicator illuminates b) Audible alarm sounds c) The feedwater pump starts and fills the boiler to the correct working level and then switches

OFF.

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

9. Check: a) Boiler Low Water indicator extinguishes b) Audible alarm silences

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3.4 DRAINING THE BOILER

OPERATION - 3

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

MIDI-IOMM-2016-5

Blowdown bypass valve

Main blowdown valve

Figure. 9 - Automatic Blowdown Valve

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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 elements 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 elements 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.

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3.6 BOILER SHUT-DOWN

OPERATION - 3

3.6.1

3.6.2 SHORT TERM SHUT-DOWN (HOURS)

1. Turn Boiler switch OFF

Turn Element switch OFF

The element will de-energise.

2. Close the steam outlet valve

LONG TERM SHUT-DOWN (WEEKS)

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

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

2. Drain the boiler completely (see

Section 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.

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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.

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MAINTENANCE - 4

4.2

4.2.1

Fulton Ltd

WATER LEVEL AND LOW WATER SAFETY CONTROLS

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

FEEDWATER PUMP TEST

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

If the pump is running:

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

If the pump is not running:

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

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

3. CLOSE the main boiler blowdown valve.

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

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

If the pump is running:

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

If the pump is not running:

1. The water level will lower through natural evaporation.

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

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

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4.2.2

4.2.3

MAINTENANCE - 4

LOW WATER LEVEL CHECKS

1. Ensure that the Element Energised switch is in the ON position and is illuminated to indicate elements are energised.

Ensure the feedwater pump is not running and that the water level is between Pump On and

Pump Off.

2. Switch the Boiler switch to the OFF position.

3. Drain the boiler below the Low Water level.

4. Switch the Boiler switch to the ON position.

5. Check a) Low Water lamp illuminates b) Audible alarm sounds c) Element Energised switch does not illuminate.

d) Feedwater pump starts

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

6. When Pump Off level is reached, Check: a) Feedwater pump switches off b) Low Water Lamp de-energises c) Audible alarm stops d) Element Energised Switch illuminates

EVAPORATION CHECK

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

To perform the evaporation check, follow the procedure in

Section 4.2.2 - Low Water Level checks

allowing water to lower by natural evaporation and not

by manual blowdown.

MIDI-IOMM-2016-5 Page 23

MAINTENANCE - 4

Fulton Ltd

4.3 BLOWDOWN PROCEDURES

Keep the boiler, elements 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 MIDI-IOMM-2016-5

Fulton Ltd

4.4

MAINTENANCE - 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

MIDI-IOMM-2016-5 Page 25

MAINTENANCE - 4

4.4.1

Fulton Ltd

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

4.5

Figure. 11 - Boiler Element Removal

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 MIDI-IOMM-2016-5

Fulton Ltd

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.

MAINTENANCE - 4

Top access to tank

(panel removed)

4.6

Figure. 14 - Feedwater Tank Inspection Door

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.

Pump off

(black cable)

Low water

(red cable)

Pump on

(yellow cable)

Figure. 13 - Boiler Water Level Probes

MIDI-IOMM-2016-5 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 MIDI-IOMM-2016-5

Fulton Ltd

4.7.1

4.7.2

MAINTENANCE - 4

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

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

4.7.3

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

MONTHLY IN ADDITION

8. Check the element and pump contactors are working correctly by manually depressing them

(see

Figure. 5 on page 9

MIDI-IOMM-2016-5 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 elements (see

Section 4.4.1 - Element Removal

11. Visually inspect the internal water space of the pressure vessel (see

Section 4.5 - Boiler

Internal Inspection

12. Visually inspect the elements 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 MIDI-IOMM-2016-5

Fulton Ltd

4.8

MAINTENANCE - 4

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 [email protected].

Date

Model:

Boiler Number:

Electric Steam Boiler - Daily and Weekly Tests

DAILY TESTS 1 2 3 4 5 6

Y - N

Date

1. Visual Inspection

of casing exterior pipework and fittings for signs of leakage

2. Low Water Level Check

low water indicator illuminate, alarm sound, feedwater pump stops/ starts and elements de-energise/energise.

Duration seconds.

3. Blowdown, Boiler

Test Time.

4. Blowdown, Water Column

5. Blowdown, Water Level Gauge

Duration seconds.

Test Time.

Duration seconds.

Test Time.

6. Pressure gauge

reading for blowdown tests.

Boiler water and water treatment values must be within known tolerances of the datum.

7. Boiler Water.

datum value.

TDS.

8. Oxygen Scavenger Concentration datum value.

reading reading reading

Day 1.

Log examined by:

WEEKLY TESTS

10. Visual Inspection

of casing interior pipework, fittings and elements for signs of leakage

11. Feedwater Pump Test

- Feedwater pump, start/stop

12. Safety valve outlet pipe

to safe blowdown point and free of damage sig.

sig.

Y - N

Day 5.

7+.

Y - N

Test results and actions taken

Date:

Y - N Y - N Y - N sig.

sig.

Y - N

9. Brine level correct

EXAMPLE

Y - N

MAINTENANCE LOG

Time Operation Performed Remarks Operators Initials

MIDI-IOMM-2016-5

EXAMPLE

Page 31

MAINTENANCE - 4

4.9.1

Fulton Ltd

TROUBLESHOOTING BOILER

Problem

Power On indicator not illuminated

Low Water lamp illuminated and

Audible alarm sounds

Cause

1. Mains supply failure.

2. Door interlock microswitch not made.

1. Insufficient water in the boiler.

2. Obstruction in the feedwater line to the pump.

3. Air lock in the pump.

4. Feedwater pump impeller worn.

5. Incorrect connections to water level probes.

6. Faulty water level relay.

Remedy

External circuit MCB requires resetting.

Fuses need replacing.

Indicator lamp needs replacing.

Check that the feedwater supply line valves are open. Check that the ball valve in the tank is operating correctly by removing the inspection cover on the tank.

Check that the shut-off valve below the tank is open.

Remove and clean the filter in the strainer. Check that the non-return valve is operating correctly.

Bleed the pump at the point provided.

Check connections to water level probes.

Check that each relay is pressed base.

firmly home on its

Page 32 MIDI-IOMM-2016-5

Fulton Ltd

4.9.2 TROUBLESHOOTING

MAINTENANCE - 4

FEEDWATER PUMP

Problem

FEEDWATER PUMP

Pump will not run

Motor starter overload, trips out immediately when supply is switched on.

Motor contactor overload trips out occasionally.

Cause

1. Supply failure.

2. Fuses/Circuit Breakers are blown.

3. Motor contactor overload has tripped out.

4. Contactors not making

5. Control circuit is defective.

6. Motor is defective.

1. One fuse/automatic circuit breaker is

blown.

2. Contacts in motor contactor overload

are faulty.

3. Cable connection is loose or faulty.

4. Motor winding is defective.

5. Pump blocked.

6. Overload setting too low.

1. Overload setting is too low.

2. Low voltage at peak times.

Motor contactor has not tripped out but the pump does not run.

Pump capacity not constant.

Pump runs but gives no water.

Remedy

Connect the electricity supply.

Replace fuses/Circuit Breakers.

Reactivate the motor protection.

Check, the coil is faulty or wiring loose.

Repair the control circuit.

Replace the motor.

Replace the fuse, reset the circuit breaker.

Replace motor starter contacts.

Tighten or replace the cable connection.

Replace the motor.

Remove the blockage.

Set the motor starter correctly.

Set the overload correctly.

Check the electricity supply.

1. Pump inlet pressure is too low

(cavitation).

2. Suction pipe/pump partly blocked.

3. Pump draws in air.

1. Suction pipe/pump blocked.

2. Foot or non-return valve blocked in closed position.

Check:

Motor does not run when started: items: 1, 2, 4, 5, 6,

Check the suction conditions.

Clean the pump or suction pipe.

Check the suction conditions.

Clean the pump or suction pipe.

Repair the foot or non-return valve.

3. Leakage in suction pipe.

4. Air in suction pipe or pump.

Repair the suction pipe.

Check the suction conditions.

5. Pump rotates in the wrong direction. Change the direction of rotation of the motor.

6. Boiler feedwater non-return valve letting water passed the valve seat,

Check and clean boiler feedwater non-return valve, ensure it is seating

(normally and not allowing water passed. accompanied by banging in the feedwater tank).

CONTINUED ON NEXT PAGE

MIDI-IOMM-2016-5 Page 33

MAINTENANCE - 4

4.9.2 TROUBLESHOOTING

Fulton Ltd

FEEDWATER PUMP

Problem Cause Remedy

Pump runs backwards when switched off.

1. Leakage in suction pipe.

2. Foot or non-return valve is

defective.

Leakage in shaft seal.

1. Shaft seal is defective.

Noise.

1. Cavitation occurs in the

pump.

2. Pump does not rotate

freely (frictional resistance

because of incorrect pump

shaft position.

3. Frequency converter

operation.

Water pump will not come on at times.

Boiler flooding

Repair the suction pipe.

Repair the foot or non-return valve.

Replace the shaft seal.

Check the suction conditions.

Adjust the pump shaft.

See Grundfos manual.

4. Boiler feedwater non-return

valve letting water passed

the valve seat, (normally

accompanied by banging

in the feedwater tank).

1. Scale on probes.

2. Faulty pump contactor

3. Faulty pump motor.

Check and clean boiler feedwater non-return valve, ensure it is seating and not allowing water passed.

Check and clean probes, replace as necessary.

Check the contactor has power. Check the contactor is pulling in.

Replace if necessary.

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.

1. Pump does not shut off. Dirty probes. Clean or replace as necessary.

2. Relay failed.

3. Earth connection.

4. Vacuum created with boiler

off.

Ensure the relay is secure on its base.

If so replace the water level relay.

Clean and tighten as required.

As the boiler cools, it pulls water from the system piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes under pressure and opens under vacuum.

Page 34 MIDI-IOMM-2016-5

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.

MIDI-IOMM-2016-5 Page 35

APPENDIX - A

Fulton Ltd

Technical Information

Sheet No. 121 Issue 5

Midi Compack

Dimensions & Specification

Dimensions

MODEL: MIDI COMPACK

A Minimum Clearance*

B Overall Width

C Overall Depth

D Overall Height

E Boiler Depth

F Safety Valve Discharge Height

G Steam Outlet Height

H Electrical Supply Inlet Height

J Feedwater Inlet Height

K Feedwater Tank Vent

L Feedwater Tank Drain

M Feedwater Tank Overflow

N Pump Feed Inlet Height

P Condensate Return Height

Q Main Boiler Blowdown Height

* 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.

24, 36, 48

560

630

520

155

555

500

760

1030

820

780

640

580

465

Page 36

Page 1 of 2

MIDI-IOMM-2016-5

Fulton Ltd

APPENDIX - A

Specification

TI-121-MIDI-DS-2016-5

MODEL: MIDI COMPACK UNIT 24 36

Designed and manufactured to BS EN 13445:2009 and PED 2014/68/EU for operating pressure

150 psi (10.34 barg).

General

Steam Output F & A 100 °C kW Rating

Operating Pressure

Number of Elements

Weight

Shipping Weight

Operational Weight

Water Content

Feed Tank Volume

Electrical Requirements

FLC 400 V 3 ph 50 Hz**

FLC 230 V 1 ph 50 Hz***

Connection Sizes

Steam Outlet

Condensate Return

Safety Valve Discharge

Feedwater Inlet

Feedwater Pump Inlet

Blowdown, Boiler

Tank Drain

Tank Overflow

Tank Vent kg/h kW barg kg kg

A/ph

All threads BSP

** 5 A/ph for feedwater pump & standard control circuit, included.

*** 6.5 A for feedwater pump & standard control circuit, included.

10.34

180

270

111

10.34

180

270

163

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

10.34

180

270

215

Page 2 of 2

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol.

BS5 7FG. England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

www.fulton.co.uk

003

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.

MIDI-IOMM-2016-5 Page 37

APPENDIX - A

Mini & Midi Compack

Probe Lengths

1 Branch Mini Compack

Fulton Ltd

Technical Information

Sheet No. 147 Issue 1

PROBE LENGTHS - 1 BRANCH MINI

Pump OFF (black) 127 mm

Pump ON (yellow)

Low Water (red)

152 mm

184 mm

Note: Dimensions mm

Note: Measurement taken from under the hexigon.

Note: Dimensions taken from drawing: FL080018

2 Branch Midi Compack

PROBE LENGTHS - 2 BRANCH MIDI

Pump OFF (black)

Pump ON (yellow)

152 mm

178 mm

Low Water (red) 216 mm

Page 38

Note: Dimensions mm

Note: Measurement taken from under the hexigon.

Note: Dimensions taken from drawing: FL080018

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol.

BS5 7FG. England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

www.fulton.co.uk

003

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.

MIDI-IOMM-2016-5

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 pH Value

Hardness

Suspended Solids

Chloride

Organic Matter

Oil

Minimum Temperature

FEEDWATER (water entering boiler)

8.5 to 9.5 tested at room temperature.

Less than 2.0 mg/kg in the form of CaCO

None

Less than 50 mg/kg.

Less than 5 mg/kg.

None

85 ° C

BOILER WATER (water inside boiler)

9.5 to 11.5 tested at room temperature.

pH Value

Hardness

Suspended Solids

Chloride

Oxygen Scavenger, Sodium Sulphite or Tannin

Phosphate

Total Alkalinity

Caustic Alkalinity

Total Dissolved Solids (TDS)

Iron

Silica

Dissolved Oxygen

Not detectable.

Less than 100 mg/kg.

Less than 500 mg/kg.

20 to 50 mg/kg.

Less than 50 mg/kg, in the form of PO

Less than 1000 mg/kg.

Minimum 300 mg/kg as CaCO

Less than 2000ppm.

Less than 1 mg/kg.

Less than 150 mg/kg, in the form of SiO

None mg/kg

CaCO

SiO

PPM

KEY

= Milligrams per Kilogram

= Calcium Carbonate

= Phosphate

= Silicon Dioxide

= Parts Per Million

1 Grain hardness = 17.118 ppm therefore 70 ppm = 4.10 grains hardness

It is critical that the boiler water pH be alkaline in the range 9.5 - 11.5.

Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids

(TDS).

Consult your water treatment specialist to establish the frequency and duration of blowdown required to achieve the required conditions.

For practical purposes mg/kg

= ppm

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol.

BS5 7FG. England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

www.fulton.co.uk

003

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.

MIDI-IOMM-2016-5 Page 39

APPENDIX - A

Fulton Ltd

Page 40

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 rod lock nut Probe rod

Figure. 1 - Water Level Probe Components

Probe body

Figure. 2 - Angle Rajah Fitted to Probe

Page 1 of 2

MIDI-IOMM-2016-5

Fulton Ltd

High Integrity Probes (stainless steel)

APPENDIX - A

TI-103-WaterLevelProbes-2015-3

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

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

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

Ensure measurements are taken from the underside of the hex. nut on the probe head.

Align the hole in the probe head with the bottom of the slot in the probe tip.

Hold the probe head secure whilst fitting the probe tip.

Locknut Locate the pin in the hole/slot and secure with the locknut.

Figure. 3 - High Integrity Water Level Probe

Page 2 of 2

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol.

BS5 7FG. England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

www.fulton.co.uk

003

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.

MIDI-IOMM-2016-5 Page 41

Fulton Ltd

Technical Information

Sheet No. 30 Issue 3

Automatic TDS Blowdown Systems

Page 42

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

300

200

100

0 10 20

300

30 40 50

Condensate return(%)

Raw water TDS (ppm)

100 150 200

350 400 450

250

500

80 90 100

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

MIDI-IOMM-2016-5

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.

0 100 400 500 200 300

Feed water TDS (ppm)

From Fig. 1.

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

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol.

BS5 7FG. England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

www.fulton.co.uk

003

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.

MIDI-IOMM-2016-5 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 44

Page 1

MIDI-IOMM-2016-5

Fulton Ltd

TI35 ISSUE 2

APPENDIX - A

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

Ball Valve

M10

Blowdown Valve

BCV1

Plug Tail

PT2

Sensor

CP10

Check Valve

LCV1

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.

Fulton Ltd

5 Fernhurst Road, Fishponds, Bristol, BS5 7FG, England.

Telephone:

Fax:

E-mail:

Website:

+44 (0) 117 972 3322

+44 (0) 117 972 3358 [email protected]

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

MIDI-IOMM-2016-5 Page 45

Fulton Ltd

Page 46 MIDI-IOMM-2016-5

Fulton Ltd

Material & Workmanship Guarantee

5 Year

G U A R A N T E E

LTON LT

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

MIDI-IOMM-2016-5

www.fulton.co.uk

MIDI-IOMM-2016-5

Fulton Ltd

5 Fernhurst Road

Fishponds

Bristol BS5 7FG

England

Telephone:

Fax:

Email:

+44 (0) 117 972 3322

+44 (0) 117 972 3358

[email protected]

FM 28400

003

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