FULTON VSRT Series Manuel utilisateur

VSRT Series

Gas Fired Steam Boiler

This manual must be available to the boiler operator at all times. VSRT-IOMM-2019-1

Page II

VSRT-IOMM-2019-1

TABLE OF CONTENTS

Fulton Ltd

I Warnings & Cautions Explained IV

II Warnings & Cautions In Manual IV

III Regulations VII

SECTION 1 - INTRODUCTION

1.1 General 1

1.2 Technical Data 1

1.3 Product Overview 1

SECTION 2 - INSTALLATION

2.1 General 7

2.2 Pre-Installation 7

2.2.1 Receiving Inspection 8

2.2.2 Siting 9

2.3 Ventilation 9

2.4 Connections 11

2.4.1 Flue Outlet 11

2.4.2 Blowdown Valves 13

2.4.2.2 Water Level Gauge (sight glass) 13

2.4.3 Steam Safety Valve 13

2.4.4 Main Steam Valve 17

2.4.5 Steam Pressure Gauge 17

2.5 Gas Supply 18

2.5.1 Gas Valve with Pilot Gas line 19

2.5.2 Multi Bloc Gas Valves 20

2.6 Electrical Requirements 21

2.6.1 Electrical Customer Connections 21

2.7 Water Supply 24

2.7.1 Glossary of Water Supply Terms 25

2.12 Piping Specifications 26

2.13 Insulation 27

SECTION 3 - POST INSTALLATION

3.1 29

3.2 29

3.3

Gas Purge

Pipework Leak/Pressure Tests

Electrical Installation Testing

Final Installation Inspection

SECTION 4 - COMMISSIONING

4.1 Commissioning the Boiler 31

4.1.2 Boiler Inspection and Initial Firing - Gas Burner 31

SECTION 5 - OPERATION

5.1 General 46

5.2 Controls 46

5.2.1 Boiler Controls 46

5.2.2 Control Panel 47

5.2.3 Steam Pressure Controls 49

5.2.3.1 Setting Steam Pressure Controls 50

5.2.3.2 Testing Steam Pressure Controls 50

5.2.4 51

5.3 51

5.4 52

5.5

Water level control probes

Filling the Boiler - all models

Draining the Boiler

Boiler Start-Up (from cold) - all models 53

5.5.1 Boiler Start-Up Following Short Term Shut-Down 53

5.6 Boiler Shut-Down 54

5.6.1 Short Term Shut-Down (hours) 54

5.6.2 Medium Term Shut-Down (days) 54

5.6.3 Long Term Shut-Down (weeks) 54

SECTION 6 - MAINTENANCE

6.1 Boiler Platform (if fitted) 57

6.2 Visual Checks 57

6.3 Burner Flame Sensor Test 58

6.4 Water Level and Low Water Safety Control Procedures 59

6.4.1 Feedwater Pump Test 59

6.4.2 Low Water Level Check

6.4.3 Evaporation Check

6.5 Blowdown Procedures

6.5.1 Main Boiler Blowdown (Manual)

6.5.2 Water Level Gauge (Sight Glass) Blowdown

6.6 Boiler Internal Inspection

6.7 Fitting New Gaskets To Boiler Inspection Holes

6.7.1 Important Information

6.7.2 Fitting Procedure

6.8 Schedule of Operator Tests and Checks

6.8.1 Daily

6.8.2 Weekly-in addition

6.8.3 Monthly-in addition

6.8.4

6.8.5

Six Monthly - Gas Safe Engineer Only

6.8.6

Annually - Gas Safe Engineer Only

6.9

After All Repairs & Maintenance - In Addition

Maintenance Record Keeping

3.4 29

4.1.3 Adjustment of the Yokogawa UT-32A Operating

Controller 43

Page III

VSRT-IOMM-2019-1

Fulton Ltd TABLE OF CONTENTS

SECTION 7 - INSPECTION

7.1 Inspection 71

SECTION 8 - TROUBLESHOOTING

8.1 73

8.2 77

Troubleshooting - Gas Boiler

Troubleshooting - Feed Water Pump

APPENDIX A - TI SHEETS

VSRT Dimensions & Specification 79

Recommended Water Conditions 101

High Integrity Water Limiters 104

Auto TDS Blowdown Systems 107

109

Material & Workmanship Guarantee

Page IV

VSRT-IOMM-2019-1

SAFETY PRECAUTIONS

Fulton Ltd

I WARNINGS & CAUTIONS EXPLAINED

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.

II WARNINGS & CAUTIONS IN MANUAL

! 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.

Escaping gas can lead to explosions which may result in serious injury.

WHAT TO DO IF YOU SMELL GAS:

•

Do not use matches, candles, flame or other sources of ignition to check for gas leaks.

•

Do not try to light the appliance.

•

Do not touch any electrical switch; do not use any phone in your building.

•

Immediately call your gas supplier from a safe location.

•

Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department.

Flue Gas can lead to life threatening poisoning.

WHAT TO DO IF YOU HAVE A FLUE GAS LEAK:

•

Shut down the heating system.

•

Ventilate the boiler room.

•

Close all doors leading to the space.

SAFETY

The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in

damage to the boiler and serious personal injury.

Page V

VSRT-IOMM-2019-1

SAFETY PRECAUTIONS

Fulton Ltd

! 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.

Do not change the boiler fuel without consulting the

boiler manufacturer.

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.

The installation of gas appliances including the flue

system should only be carried out by Gas Safe

registered engineers.

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 flammable materials near the boiler.

The importance of correct boiler water and feedwater

cannot be over emphasized, see the relevant section in

this manual.

! WARNING

DANGER FROM INCOMPLETE COMBUSTION

The importance of correct burner adjustment to achieve

low emissions, safe, clean and efficient combustion

is paramount. Poor combustion, where unburnt gas

forms carbon monoxide is both a health hazard, and

the potential risk to the boiler from overheating, caused

by re-burning of the unburnt gas in the secondary flue

passes.

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.

Boilers should always be drained through an approved

blowdown vessel.

This boiler is equipped with an ignition device, which

automatically lights the burner. Do not try to light the

burner by hand.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation.

Never attempt to operate equipment that has failed to

pass all the safety checks.

Follow proper lockout procedures for the electrical, gas

and water connections.

If any “Manual Reset” limit device trips, DO NOT reset

without determining and correcting the cause. (Manual

Reset Limits may include: flame safeguard, high or low

gas pressure, high pressure limit.)

Never tamper with low water (liquid level) cut-off

sensors or circuitry.

Before commissioning the equipment, verify with

authorized personnel that gas lines have been purged

and certified.

Check daily that the equipment area is free and clear

of any combustible materials, including flammable

vapours & liquids.

Do not store or use gasoline or other flammable

vapours and liquids or corrosive materials in the vicinity

of this or any other appliances. Cements for plastic pipe

should be kept away from all sources of ignition.

Proper ventilation should be maintained to reduce the

hazard and to minimize breathing of cement vapours.

No shut-off of any kind shall be placed between

the safety relief valve and the equipment or in

the discharge pipe between such valve and the

atmosphere. Doing so can cause an accidental

explosion from overpressure.

Page VI

VSRT-IOMM-2019-1

SAFETY PRECAUTIONS

Fulton Ltd

! WARNING

The discharge from the safety relief valve shall be

so arranged that there will be no danger of scalding

personnel or damage to equipment. Provisions should

be made to properly drain safety relief valve discharge

piping.

Fluids under pressure may cause injury to personnel or

damage to equipment when released. Be sure to shut

off all incoming and outgoing fluid shut-off valves and

carefully decrease all trapped pressures to zero before

performing any maintenance.

Do not attempt to start the equipment for any testing

prior to filling and purging the vessel. A dry fire will

seriously damage the equipment and may result in

property damage or personnel injury and is not covered

by warranty. In case of a dry firing event, shut off

the fuel supply and allow the vessel to cool to room

temperature before fluid is reintroduced to the pressure

vessel. The boiler should be inspected by a qualified

individual prior to commissioning the unit.

When opening any drains on the equipment or piping

system, steps should be taken to avoid scalding/

burning of personnel due to hot fluids. Whenever

possible, the system should be cooled prior to opening

any drains.

Hot surfaces (over 49 °C) should be insulated or

shielded for safety where practicable. See

installation section.

Should overheating occur or the gas supply fails to shut

off, manually shut off the gas supply external to the

equipment.

Improper installation or maintenance of gauge glass

and connections can cause immediate or delayed

breakage resulting in bodily injury and/or property

damage. Only trained personnel should install and

maintain gauge glass connections. Wear suitable

safety eye-wear during installation. Be sure all parts

are free of chips and debris.

! CAUTION

WATER SOFTENER, SALT & 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.

The stack arrangement and draft conditions should be

in accordance with the information in this manual for

proper performance of the equipment.

Use appropriate leak-detection fluid. Clean all piping

thoroughly after completing the leak check.

A temperature exceeding 32 °C* in the boiler room

may cause premature failure of electrical components.

Provisions should be made to maintain an ambient

temperature of 32 °C* or less (the panel box interior

should not exceed 32 °C*.

*Pumps, Programmable Logic Controllers (PLC)

or sequence panels may require lower ambient

temperatures or additional cooling.

Particulate matter or chemicals (example: per

chloroethylene, chlorine, or halogenated compounds)

in the combustion air supply to the boiler will cause

damage or failure to the burner and is not covered

under warranty. High-risk situations for particulate

matter to be in the air include construction and

maintenance activities.

For all systems containing boilers or unfired steam

generators, the water chemistry in the boiler must be

kept within the limits outlined in this manual. Failure to

do so may cause premature pressure vessel failure and

poor steam quality and will void the warranty.

Do not run the pump dry. Irreparable damage to the

seal can result. Prime the pump in accordance with the

manufacturer’s instructions. Never operate the pump

with a closed discharge valve.

Should you suspect that the boiler’s flue passage

ways have become blocked, stop the boiler

immediately and contact the Fulton office.

! 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.

Page VII

VSRT-IOMM-2019-1

SAFETY PRECAUTIONS

Fulton Ltd

III REGULATIONS

Observe the following when working on this system:

•

Work on gas equipment must only be carried out by a qualified gas engineer.

•

Work on electrical equipment must only be carried out by a qualified electrician.

•

All legal instructions regarding the prevention of accidents,

•

All legal instructions regarding environmental protection,

•

The Code of Practice of relevant trade associations,

•

All current safety regulations as defined by PED, DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable

standards,

•

Gas Safety (Installation & Use) Regulations

The appropriate Building Regulation either the Building regulations, the Building Regulation (Scotland) or

Building Regulations (Northern Ireland).

The Water Fittings Regulation or Water Bylaws in Scotland,

The current I.E.T. Wiring Regulations.

! CAUTION

In case of emergency

This boiler has been designed and constructed to meet all of the essential requirements of the applicable

European Directives and subject to proper maintenance should not give occasion to any hazardous

conditions.

If such a condition should occur during commissioning or during subsequent operation of this product,

whatever the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been

investigated by a competent person and rectified.

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 VIII

VSRT-IOMM-2019-1

Fulton Ltd

INTRODUCTION - 1

Fulton Ltd

1.1 GENERAL

Prior to shipment, the following inspections and tests are made to ensure the highest standards of

manufacturing for our customers:

•

Material inspections

•

Manufacturing process inspections

•

Hydrostatic test inspection

•

Electrical components inspection

•

Documented Fire and Test (FaT)

•

Packing, inspection and final check

This manual is provided as a guide to the correct operation and maintenance of your Fulton

equipment, and should be read in its entirety and be made permanently available to the staff

responsible for the operation of the boiler. It should not, however, be considered as a complete

code of practice, nor should it replace existing codes or standards which may be applicable.

Fulton reserves the right to change any part of this installation, operation and maintenance

manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained,

qualified installers and service personnel. Trained personnel are responsible for the installation,

operation, and maintenance of this product, and for the safety assurance of installation, operation,

and maintenance processes. Do not install, operate, service or repair any component of this

equipment unless you are qualified and fully understand all requirements and procedures.

1.2 TECHNICAL DATA

For a specification, refer to Appendix A - VSRT Data Sheets

1.3 PRODUCT OVERVIEW

The VSRT fuel fired steam boiler is a vertical two-pass boiler of efficient design and construction.

The VSRT uses Fulton’s PURE technology to achieve higher efficiency and lower NOx levels with

a smaller footprint than its Fulton J series equivalent.

VSRT connections and specifications are listed in Tables 1 and 2 and shown in Figures 1, 2, 3

and 4.

CONTINUED ON NEXT PAGE

VSRT-IOMM-2019-1

Page 1

INTRODUCTION - 1

Fulton Ltd

Table 1 – VSRT Customer Connections (See Figs. 1-4)

Table 2 – VSRT Specifications

Unit Size (BHP)

Maximum allowable working pressure (barg)

10.34 barg

Boiler input

120 kw

179 kw

239 kw

359 kw

478 kw

598 kw

718 kw

Boiler input (Natural gas); m3/hour

10.7 m3/hr

16.1 m3/hr

21.5 m3/hr

32.3 m3/hr

43 m3/hr

53.9 m3/hr

64.7 m3/hr

Boiler input (Propane); m3/hour

4.6 m3/hr

6.9 m3/hr

9.2 m3/hr

13.8 m3/hr

18.3 m3/hr

23 m3/hr

27.6 m3/hr

RATINGS* (Sea level to 914.4m)

Boiler Output

98 kw

147 kw

196 kw

294 kw

392 kw

490 kw

589 kw

Steam Output - Minimum Service Capacity; kg/hr

156 kg/hr

235 kg/hr

313 kg/hr

470 kg/hr

626 kg/hr

782 kg/hr

939 kg/hr

Net Effective Heating Service (m2)

5.06 m2

6.04 m2

10.77 m2

Water Capacity (Operating)

356 litres

424 litres

1,306 litres

Burner Turndown

4:1

6:1

4:1

6:1

8:1

10:1

Minimum Draft Requirement

-0.25” W.C.

Minimum Incoming Gas Pressure

19 mbar

Weights (Approximate)

Dry Weight; kg

876 kg

1,284 kg

2,654 kg

Operating Weight; kg

1,232 kg

1,707 kg

3,959 kg

Shipping Weight; kg

1,134 kg

1,542 kg

2,800 kg

Flooded Weight; kg

1,364 kg

1,841 kg

4,228 kg

Electric Power Requirements

Voltage

400/50/3

Operating FLA (refers to boilers rated draw at high fire)

14.8 AMPS

21.6 AMPS

10/15BPH

20/30 BPH

40/50/60 BPH

Description

Size

Type

Size

Type

Size

Type

Feed Water Inlet

1”

B.S.P.T.

1”

B.S.P.T.

1”

B.S.P.T.

Blowdown Outlet

1¼”

B.S.P.T.

1¼”

B.S.P.T.

1½”

B.S.P.T.

Steam Outlet

1¼”

DN32

1½”

DN32

2”

B.S.P.T.

Flue

152.4

------

202

------

254

------

Auxiliary Water Column

1”

B.S.P.T.

1”

N.P.T.

1”

N.P.T.

Fuel Inlet

1”

B.S.P.T.

1¼”

B.S.P.T.

1½”

B.S.P.T.

Water Column

1”

B.S.P.T.

1”

B.S.P.T.

1”

B.S.P.T.

Surface Blowdown

¾”

B.S.P.T.

¾”

B.S.P.T.

¾”

B.S.P.T.

Combustion Air Inlet

101.6

-----

152.4

------

152.4

------

Safety Relief Valve

¾”

B.S.P.T.

¾”

B.S.P.T.

1”

B.S.P.T.

Steam Gauge Port

¼”

B.S.P.T.

¼”

B.S.P.T.

1/42

B.S.P.T.

Inspection Port

-----

82.55

150#

N. Inspection Opening

-----

50.8

N.P.T.

VSRT-IOMM-2019-1

Page 2

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