Fulton SteamPac Unfired Steam Generators Installation, Operation and Maintenance Manual Serial # __________________________ Model # __________________________ Fulton Order # __________________________ Sold To __________________________ Job Name __________________________ Date __________________________ Fulton Thermal Corp. 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com Fulton Thermal Corp.
Fulton Thermal Corp.
Table of Contents Section 1 – Safety Warnings & Precautions 28. The Feed Water Piping 29. The Steam Supply 30. The Steam Safety Valve 31. The Steam Pressure Gauge Assembly Section 2 – Installation 1. Introduction 2. Placement 3. Transport 4. Location 5. Access 6. Clearance 7. Installation Check Points 8. Ventilation 9. Feedwater 10. Recommended Water Conditions 11. Water Supply 12. Glossary of Water Supply Terms 32. Electrical Supply 33. Frost Protection Section 3 – Operation 1.
Fulton Thermal Corp.
Section 1 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 1 – Safety Warnings & Precautions This manual is provided as a guide to the correct operation and maintenance of your Fulton SteamPac Unfired Steam Generator, and should be permanently available to the staff responsible for the operation of the SteamPac. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.
Rigging your heater into position should be handled by a competent rigger experienced in handling heavy equipment. The customer should examine the unit for any damage. Note All factory piping flanges should have bolts re-torqued before filling of system as bolts may loosen in shipping. Note All unions on piping should be tightened prior to operation. For Your Safety The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual.
3. Vent pipe should not be downsized (This may cause pressure build up in the condensate tank.) 4. Return pipes must not be insulated. This can cause overheating the return system, causing a vapor lock in the pump. 5. See return system instruction manual for detailed instructions. Note Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton Representative for advice.
Warning Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected. When stopping the SteamPac for any extensive repairs, shut off main disconnect switches on both the boiler side as well as the feed water side. Note To ensure the continued safety and efficiency of the SteamPac, the schedule of maintenance outlined in this manual should be adhered to.
Section 2 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 2 – Installation 1. Introduction a) This manual is provided as a guide to the correct operation and maintenance of your unfired steam generator, and should be permanently available to the staff responsible for the operation and maintenance of the unfired steam generator. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards that may be applicable.
Pipes should not be run within 10” of any control cabinets or combustible material. All SteamPacs will also require a minimum clearance overhead for personnel access. In cases where available height is insufficient, a roof or ceiling trap might be considered. 6. Clearance a) Front/Vertical: TBD-Consult the end assembly drawing for the tube bundle removal length specific to the model purchased. b) Sides: 18” (0.5m) c) Rear: 18” (0.5m) 7.
d) Make sure two check valves are installed between the SteamPac and feedwater pump. e) An end of the line trap should be installed in the SteamPac steam header. f) There are three valves on the SteamPac: the main blowdown valve, the gauge glass drain valve, and the water column drain valve. The SteamPac blow off valve supplied with the SteamPac should be installed on the blow off pipe and connected to a blow off receptacle of approved design.
2. The high limit pressure control must be manually reset by depressing the plunger located on top of the control. 8. Ventilation a) Ventilation in the room must be sufficient to maintain a building temperature of 100°F or less. 9. Feedwater a) In its readily available form, water is a corrosive chemical solution having dissolved and suspended solids and it is therefore, essential that feed water for any steam generating plant be conditioned prior to use.
Parameter 7.5-9.5 140F* Carbon Steel Vertical Horizontal Boiler/ Boiler/SteamPac SteamPac Water Water 8.5-10.5 8.5-10.5 ----- < 2ppm < 10 ppm ----- Feedwater pH Feedwater Temperature Hardness as CaCO3 Chlorides Total Alkalinity Total Dissolved Solids Suspended Solids Total Organic Carbon Iron Dissolved Oxygen Visual Oil Conductivity (μS/cm) Feedwater Stainless Steel Vertical Horizontal Boiler/SteamPac Boiler/SteamPac Water Water 6.0-9.5 140F* 8.5-10.5 --- 8.5-10.
c) One way to lower the amount of dissolved gases in the boiler feed water is to preheat the feedwater. This option injects live steam into the feedwater to increase the water temperature to 180 degrees F or higher which removes oxygen and carbon dioxide from the water. d) RO/DIWater: Reverse Osmosis / Deionized water is water that all dissolved solids have been removed. Osmosis is a process that uses a semi-permeable membrane, under pressure, to reject dissolved salts and allow water to pass through.
slightly more than enough sodium sulfite to consume all of the dissolved oxygen that slips through the deareating equipment. Sulfite as a treatment represents the second line of defense against oxygen corrosion. Primary protection against this type of attack requires adequate facilities for mechanical deareation of the feed-water plus a vigorous maintenance program to safe guard against oxygen leakage into the pre-boiler system.
result. Often oil in boiler water will originate in the condensate. This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken. h) Iron (oxides): Iron in any of its oxide or complex forms is undesirable in boiler water. Iron in its various forms can originate in the raw water makeup, condensate return water, or form directly in the boiler as a result of corrosion.
maximum of 110% of the generator steam capacity where no condensate return is expected. Warning Under no circumstances should the water softener water flow limit be exceeded. q) In all cases the water hardness should be tested periodically and prior to starting the generator to ensure efficient operation of the softener. In no event must unsoftened water be allowed to enter the steam generator. 13.
glass outlet is pointing at five o’clock (about 1/8 turn from its final downward vertical position). e) Install the bottom gauge fitting (the fitting with a drain valve) until it is snug and the glass outlet is pointing directly upward. Verify top and bottom fittings are threaded into the tappings the same number of turns (distance A = f) distance B). Remove glass packing nut, friction washer and glass packing from the fittings, and place them, in the same order, on to both ends of the gauge glass.
f) During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system. 17. Thermal Fluid Pipework a) The thermal fluid pipework and main body of the generator should be lagged. Leave the lower flange of the generator free so that the heat exchanger may be removed periodically if required. b) All pipework should be constructed from seamless mild steel pipe, conforming to ASME SA 106B or SA 53A schedule 40 or equal.
7. Tighten all bolts to 40% final torque specification following a “star” pattern. 8. Tighten all bolts to 60% final torque specification following a “star” pattern. 9. Tighten all bolts to 80% final torque specification following a “star” pattern. 10. Tighten all bolts to 100% final torque specification following a “star” pattern. 11. Following a sequential pattern, ensure that all bolts are tightened to 100% final torque specification. 12.
Standard gaskets supplied by Fulton are JM Clipper Elastograph for operating temperatures up to 650oF. Recommended Loads for JM Clipper elastograph 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 Number of Bolts Diameter of Bolts Inches Preferred Torque Required per Bolt Ft-Lbs.
Standard gaskets supplied by Fulton for operating temperatures above 650oF are Flexitallic Spiral Wound. Recommended Loads for Flexitallic Spiral Wound Class 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 Number of Bolts Diameter of Bolts Inches Preferred Torque Required per Bolt Ft-Lbs.
18. Bolting Sequence for 4 and 8 Bolt Flanges a) High point bleeds are to be installed at all high points in the system piping. 1/2” x 12” nipples welded in the top of the piping with ball valves & plugs attached are to be used. b) It will save a considerable amount of time during the cold filtration if the thermal system piping is cleaned prior to assembly.
b) When ordering valves, the maximum possible service temperature and type of fluid must be indicated on the order. c) A partial list of manufacturers known to market valves of acceptable quality follows: 1. Jenkins Brothers 2. Lunkenheimer Company 3. Nibco Incorporated 4. Stockham Valves and Fittings Company 5. Velan 6. Vogt Machine Company 7. Worcester Valve Company d) Automatic Fluid Control Valves 1.
c) Hot oil pipe insulation should be a minimum of 2” thick, high temperature, laminated, foamglass cellular glass insulation as manufactured by Pittsburgh Corning Corporation, or equal. 23. Thermal Fluids Thermal Fluids at Elevated Temperatures a) Plant engineers must be familiar with the nature of potential hazards when working with thermal fluids at operating temperatures.
temperature. A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater systems, however, your final selection should be made in conjunction with Fulton Thermal Corporation or the fluid manufacturer. 3. The safe maximum bulk temperature of the fluid must be strictly adhered to. The safe maximum temperature of the fluid varies, but a typical maximum for many types of mineral oil based fluids is 600°F (320°C). 4.
9. The thermal fluid manufacturer must guarantee the characteristics of the product, and verify that the fluid bulk temperature limitation exceeds the expected operating temperature. 10. After a fluid is selected, refer to the manufacturer’s recommendations, published in compliance with OSHA. 11. If the fluid expansion volume from 50o F to 600°F exceeds 20% of the initial fluid volume, consult Fulton Thermal Corporation.
condition. A low flow rate through the heater will result in high film temperatures leading to breakdown of the thermal fluid. 3. Multiple pressure switches and a differential pressure switch are used to prevent this condition from occurring. These safeties must not be bypassed at any time. 4. Exceeding the maximum operating temperature of the thermal fluid will also result in thermal fluid breakdown.
Caution It is imperative that an adequate vent to atmosphere is provided on all such covered or enclosed vessels which may receive steam. c) Special care is to be taken to ensure that blowdown lines are properly secured so no movement (other than expansion) can be caused by the action of steam discharge from that pipe. d) Care must always be taken to comply with water board or other authority requirements to avoid damage to PVC main drains due to the discharge of hot effluent.
e) Allowance must be made for expansion of both the pipework and the generator; especially if the pipework is rigidly fixed in any place other than adjacent to the safety valve. f) All open ended pipes are to be suitable secured to ensure that no movement (other than expansion) can be caused by the action of steam discharge from that pipe. g) In cases where multiple generators are to be installed, a header incorporating a steam trap must be provided.
30. The Steam Safety Valve a) Before installing, be sure that all pipes and connects have been blown clean. Pipe compound or dope is used on external threads only. Be sure inlet of valve is free of any foreign material. b) Do not use a pipe wrench on flange bolts/nuts! When making installation, use proper type and size wrench. c) The valve can be installed in any position (the upright position is preferred) in the connection provided on the top left side of the boiler with no unnecessary intervening pipe.
d) Make sure the information on the electrical drawings corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over or under voltage exceeding 10% of the nominal value. e) In all cases, connections to a ground point must be made with correctly sized wire. 32. Frost Protection a) When the unfired steam generator is installed in an unheated area, frost could cause serious damage to the generator and also to the water softener (when supplied).
Section 3 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 3 – Operation 1. Unit Description and Application a) The basic system consists of a fully automatic oil or gas fired Fulton Thermal Fluid Heater with circulation pump and expansion tank which delivers high temperature thermal fluid to the independent unfired steam generator (as well as to other heat exchange equipment). b) The steam generator, can, therefore be sited where the steam is required thus avoiding long runs of distribution pipework.
3. Steam Pressure Controls a) The basic controls consist of a thermal fluid control valve which varies the rate of flow of hot fluid through the heat exchanger. This valve may be modulating type and be either electric motorized, pneumatic, or solenoid operated. It is this valve’s operations that controls the steaming rate of the generator. It is operated by means of a steam pressure switch or control mounted on the control panel which monitors steam pressure.
a) The steam pressure inside the generator is monitored by a small pressure gauge mounted at the top. 8. Overload Protection a) The feed pump motor is protected by thermal relays in case of excessive current caused by voltage variation or malfunction of the feed pump. If the overload operates it must be manually rest after ascertaining the cause. 9. Control Switch a) The generator is switched on and off by means of a three-way position selector switch on the control panel Position 1 is “off”.
Fulton Thermal Corp.
Section 4 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 4 – Maintenance Warning Prior to commencement of any work requiring the removal of cover plates at the opening of the control panel box, the electrical supply to the SteamPac must be disconnected. The unit should be off and cool before performing work on any piping or components. 1. Recommended Water Conditions a) Following are the recommendations for feedwater and boiler water. Contact your local water treatment professional for testing and treatment recommendations.
d) It is critical that the SteamPac pH be alkaline (9-11) whenever water is in the vessel. Solids that enter in with the water concentrate in the SteamPac. Daily blowdown is recommended to help prevent the formation of deposits. 2. Maintenance Schedule Daily a) The following procedures should be carried out daily. They are designed to prevent the build up of scale, silt or sludge in the SteamPac. In addition to these procedures, the advice of a water treatment specialist should be sought and followed.
3. Safety Relief Valves a) When the valves leave the factory, they have been carefully set and tested to ensure that the seating surfaces are perfect. However, in service, and when the pressure in the vessel is neat to the set pressure of the valve, the clamping force between the seating surfaces is very light and any foreign matter lodged between the two surfaces will cause the valve to leak.
Warning When dissolved, the solution is a severe irritant and must be treated in the same manner as all strong acids. If any of the solution comes into contact with eyes or skin, flush immediately with a large volume of water. If the eyes are affected, seek immediate medical attention. 5. Cleaning the Water Probes a) Clean the probes in the water column. Make sure there is no pressure on the SteamPac during the removal of the probes.
9. Troubleshooting a) The following troubleshooting guide will assist in the diagnosis and correction of minor field problems. In any case requiring additional assistance, contact your local authorized Fulton Representative. b) Feedwater Pump 1. Problem: Pump rotates freely but does not pump. Check: 1. Excessive feed water temperature (normal maximum 180°F) will result in flashing at pump inlet. This is usually caused by leaky check valve between pump and boiler or failure of steam traps to close tightly.
deposits occur, have the water analyzed and treated by a reliable chemical treatment company. Remove any mineral deposits from pump parts. 4. Worn bearings. Replace. 5. Pump cavitation. High water temperatures or a suction line restriction, such as a clogged strainer, will cause cavitation. Any restriction must be corrected immediately or severe pump damage will result. 3. Problem: Receiver overflows constantly. Check: 1. Make-up valve seat worn, not sealing tight. Replace valve. 2.
1. Reset and inspect pump and motor for proper operation. 6. Problem: Motor fails to start. Check: 1. Make certain boiler level switch is functioning properly. 2. Check control circuit for continuity. 7. Problem: Preheat kit solenoid valve does not open. Check: 1. Check wiring to the solenoid valve and aquastat. 2. If faulty, replace solenoid and/or aquastat. Fulton Thermal Corp.
Fulton Thermal Corp.
Section 5 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 5 – Parts & Warranty Part Description Number Approx. Weight lbs. kgs. Pressure Switches & Transducers 2-40-000233 Pressuretrol L404C1162-M/R 1.96 .89 2-40-000663 Pressuretrol L404B1320 1.96 .89 2-40-000662 6NNK54FIA SOR Pressuretrol-NEMA 4 1.62 .73 2-40-000661 6R3-D5-SOR Pressuretrol-M/R-NEMA 4 2.1 .
2-12-000535 ¾” float valve disc .01 0.0 2-30-000332 300# steam gauge .5 .23 Water Column 2-11-000106 Fulton water column bottle casting – 4-100hp 20.0 9.09 5-20-000023 Fulton water column bottle casting – w/tri-cock tappings 20.0 9.09 4-21-000010 Water column electrode basket & cover .5 .23 2-21-000021 Water column probe cover – 4” .05 .02 2-21-000013 Water column probe cover – 4” 1.0 .
2-20-000057 Auburn plug – WCC-1112KH – 151 to 451 psi .2 .09 2-20-000016 16” brass rod – cut to length .1 .04 2-40-000227 Pressuretrol L404A1354 – 2-15psi 1.7 .77 2-40-000228 Pressuretrol L404A1370 5-50psi 2.0 .91 2-40-000229 Pressuretrol L404A1396 10-150psi 2.0 .91 2-30-000230 Pressuretrol L404A1404 20-300psi 2.7 1.23 2-40-000231 Pressuretrol L404C1147 2-15psi 2.0 .91 2-40-000232 Pressuretrol L404C1154 5-50psi 2.0 .91 2-40-000233 Pressuretrol L404C1162 10-150psi 2.0 .
2-30-000788 1” gate valve – 150# 2.0 .91 2-30-000789 1-1/4” gate valve – 150# 3.2 1.28 2-30-000790 1-1/2” gate valve – 150# 4.9 2.23 2-30-000791 2” gate valve – 150# 6.8 3.09 2-30-000793 3” gate valve – NPT, OS&Y 12.0 4.8 2-30-000391 1” Y type blowdown valve – 225UT- 200# 4.0 1.82 2-30-000392 1-1/4” Y type blowdown valve – 225UT – 200# 5.5 2.5 2-30-000393 1-1/2” Y type blowdown valve – 225UT – 200# 8.4 3.82 2-30-000394 2” Y type blowdown valve – 225UT – 200# 13.5 6.
2-30-000071 ¾” - 200# safety valve - 19KEDA200 5.1 2.23 2-30-000073 ¾” - 300# safety valve - 19KEDA300 2.35 1.07 2-30-000074 1” - 15# safety valve - 13-202-08 1.1 .5 2-30-000075 1” - 75# safety valve - 19FEA75 4.0 1.82 2-30-000076 1” - 100# safety valve - 19FEA100 4.1 1.86 2-30-000077 1” - 125# safety valve - 19FEA125 4.1 1.86 2-30-000078 1” - 150# safety valve - 19FEA150 4.1 1.86 2-30-000079 1” - 200# safety valve - 19FEA200 4.0 1.82 2-30-000081 1” - 300# safety valve 5.
2-12-000025 Teflon disc for 1” Y valve .2 .09 2-11-000015 Brass seat for 1” Y valve .1 .05 2-12-000026 Teflon disc for 1-1/4” Y valve .5 .23 2-11-000016 Brass seat for 1-1/4” Y valve .1 .05 2-12-000027 Teflon disc for 1-1/2” Y valve .2 .09 2-11-000017 Brass seat for 1-1/2” Y valve .1 .05 2-11-000018 Brass seat for 2” Y valve .1 .05 2-30-001062 PRV ½” 7-25# 7.0 3.18 2-30-001064 PRV ¾” 7-25# 7.0 3.18 2-30-001061 PRV 1” 50-140# 7.0 3.18 2-30-001065 PRV 1” 7-15# 7.0 3.
7-75-000112 24 x 48 Horiz. Tank & Stand - HT60 255.0 115.91 7-75-000114 28 x 48 Horiz. Tank & Stand - HT80 275.0 125.0 7-75-000116 30 x 48 Horiz. Tank & Stand - HT100 305.0 138.64 7-75-000118 30 x 72 Horiz. Tank & Stand - HT150-200 380.0 172.73 7-75-000119 36 x 72 Horiz. Tank & Stand - HT250-300 405.0 184.09 7-75-000120 42 x 72 Horiz. Tank & Stand - HT350-400 440.0 200.0 7-75-000035 Horiz. Stand only for 18 x 20 25.0 11.36 7-75-000021 Horiz. Stand only for 18 x 30 25.0 11.
4-50-000078 F-10 Cooling kit – 220v 12.0 5.45 4-50-00075 F20 – 150 Cooling kit – 120v 12.0 5.45 4-50-000079 F20 – 150 Cooling kit – 220v 12.0 5.45 4-50-000076 F10 Cooling kit – self actuated – 120v 20.0 9.09 4-50-000077 F20-150 Cooling kit – self actuated – 120v 20.0 9.09 2-30-000551 Liquid level HG-34 SqD 4.3 1.95 7-21-000035 Venturi steam injector (sparge tube) 7.0 3.18 2-30-001410 Self-actuated preheat valve w/sensor 6.5 2.
4-75-000502 ¾” trim kit 50-100HP 4.0 1.82 4-75-000054 1” float valve assembly (HT-200) 2.1 .95 2-30-000029 ½” float valve only .6 .27 2-30-000028 ¾” float valve only .8 .36 2-30-000142 1” float valve only 1.2 .55 2-12-000534 ½” float valve disc .01 0.0 2-12-000535 ¾” float valve disc .01 0.0 2-12-000536 1” float valve disc .01 0.0 2-30-000124 Float ball only .6 .27 2-11-000000 ¼” rod for float valve assembly – short .15 .
2-60-000108 Smoke tester – oil 2.0 .91 2-60-000110 Fisher gauge – 50 PZ 1.0 .45 2-30-000123 Hot water thermometer 1.0 .45 2-60-000112 Flue cleanout brush – 1” .8 .36 2-60-000155 Flue cleanout brush – 5/8” Edge .8 .36 2-60-000247 Flue brush – pipetype – 2-1/2” – 80 & 100HP 1.0 .45 2-60-000248 Flue brush – pipetype – 2” – 40/50/60HP VMP (80 oldstyle) 1.0 .45 5-10-000397 Tee handle wrench – 1-1/4” 2.7 1.23 8-00-000043 Fan puller – 5/8” hub 2.0 .
Standard Warranty for Fulton Thermal Fluid Heaters Warranty Valid for Models FT-A, FT-C, FT-S, FT-N, FT-HC One (1) Year (12 Month) Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of one (1) year from the date of shipment from the factory. Fulton will repair or replace F.O.B.
Fulton Thermal Corp.
Section 6 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 6 –Product Specs & Data Fulton SteamPac Packaged Heat Exchanger Systems 1. General Description a) Contractor shall furnish and install a_____HP thermal fluid to steam heat exchanger package. The entire system shall be “Fulton” as manufactured by Fulton Thermal Corporation, Pulaski, New York.
a) Houses probes for electronic water level controller b) Sight glass incorporated into water bottle for visual inspection of water level c) Cast construction as per ASME Code Section I 6. Instrumentation & Controls a) The following instrumentation/controls/safety devices shall be supplied as a minimum requirement: 1. Pressure Gauge – Fulton 2. Operating Pressure Control - Yokogawa UT-350 w/ pressure transducer 3. High Limit Pressure Control – Danfoss 4. Water Level Control - Fulton 5.
Specifications and Dimensions Horizontal SteamPacs Specifications – Fulton Horizontal SteamPacs from 70 to 350 HP Models FT 070XH 100XH 150XH 180XH 200XH 250XH 300XH 350XH LB/HR 2,415 3,450 5,175 6,210 6,900 8,625 10,350 12,075 KG/HR 1,096 1.
Specifications and Dimensions Vertical SteamPacs Specifications – Fulton Vertical SteamPacs from 10 to 100 HP Models FT 010X 015X 020X 030X 040X 050X 075X 100X Steam Output* LB/HR 345 517 690 1,035 1,380 1,725 2,587 3,450 KG/HR 157 235 313 470 626 783 1,174 1,565 BTU/HR (1000) 335 502 669 1,017 1,339 1,674 2,678 3,347 KCAL/HR (1000) 84 126 169 256 337 422 675 843 GPM 23 35 46 69 92 114 171 228 M3/HR 5.2 8 10.
Fulton Thermal Corp.
Fulton Thermal Corp.
Fulton Thermal Corp.
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. For more of the following patents apply to this unit: U.S. Patent Numbers 4856558, 4884963, 4926789, 4951706 and 5, 145, 345. Swiss Registration Numbers 119122 and 119243. Swedish Registration Numbers 51873 and 51874. German Patent Number M9104923.7. Benelux Registration Numbers 21548-01/02, 03/04 and 21548-05/06.
