User guide
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FTCS-IOM-2013-1114 TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Placement & Rigging ........................................................................................... 2-2
Clearances & Serviceability .................................................................................. 2-3
Environment, Ventilation and Combustion Air Requirements ............................ 2-4
Utilities ................................................................................................................. 2-7
THE GAS SUPPLY ..........................................................................................................................27
THE OIL SUPPLY .........................................................................................................................210
Instrument Air .................................................................................................... 2-10
Electrical Supply ................................................................................................ 2-11
Thermal Fluids .................................................................................................... 2-12
THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................212
SELECTING A THERMAL FLUID ..................................................................................................212
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................214
THERMAL FLUID BREAKDOWN .................................................................................................214
Piping Speci cations .......................................................................................... 2-15
Insulation ........................................................................................................... 2-21
System Interfaces ............................................................................................... 2-21
HEATER CONNECTIONS ..............................................................................................................221
THERMAL FLUID CIRCULATING PUMP .....................................................................................222
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................223
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................223
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................224
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................226
PRESSURIZED SYSTEMS ............................................................................................................227
VENT CONNECTIONS ..................................................................................................................228
CATCH TANK ...............................................................................................................................229
DRAIN/FILL CONNECTION .........................................................................................................229
PRESSURE GAUGES ...................................................................................................................229
THERMOMETERS .......................................................................................................................230
VALVES .......................................................................................................................................230
AUTOMATIC FLUID CONTROL VALVES .......................................................................................231
BYPASS VALVES ........................................................................................................................231
Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-31
Stack and Flue .................................................................................................... 2-32
Testing ................................................................................................................ 2-34
Operation 3-1
Start-Up Preparation & Installation Review ........................................................ 3-2
Fill the System ...................................................................................................... 3-3
FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................33
FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................34
Circulating Pump .................................................................................................. 3-5
PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................35
PUMP WITH PACKED SEAL ..........................................................................................................36
Start-Up Service ................................................................................................... 3-6
Initial Start-Up ..................................................................................................... 3-7
COLD CIRCULATION......................................................................................................................37
FILTERING THE SYSTEM ...............................................................................................................38
BOILOUT .......................................................................................................................................38
COMBUSTION ...............................................................................................................................39
Flame Programmers .......................................................................................... 3-14
SIEMENS LINKAGELESS MODULATION, LMV 51 ......................................................................314
Operating Controls ............................................................................................. 3-19
LIQUID LEVEL SWITCH WHEN COMBINATION TANK IS SUPPLIED ........................................319
AIR SAFETY SWITCH ..................................................................................................................319
BLOWER MOTOR STARTER .........................................................................................................319
PUMP MOTOR STARTER .............................................................................................................320
DIFFERENTIAL PRESSURE SWITCH ...........................................................................................320
HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................321
GAS PRESSURE SWITCH ............................................................................................................322
OPERATING TEMPERATURE CONTROLS ....................................................................................322
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................323
OPERATING LIMIT CONTROLLER ...............................................................................................324
ON/OFF CONTROLS ....................................................................................................................324
MODULATING CONTROLS ..........................................................................................................324
PRESSURE GAUGES ....................................................................................................................324
TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................325
CYCLE TESTING ...........................................................................................................................325
Required Pressure Drop Across the Heater ......................................................... 3-26
Procedure for First Shutdown ............................................................................ 3-27
Daily Start-Up ..................................................................................................... 3-27
Daily Shutdown .................................................................................................. 3-28
Before Leaving the Installation .......................................................................... 3-28
Maintenance 4-1
Required Equipment ............................................................................................ 4-2
Required Maintenance at First Shutdown ........................................................... 4-2
Daily Maintenance Schedule ................................................................................ 4-2
Weekly Maintenance Schedule ............................................................................ 4-4
Monthly Maintenance Schedule .......................................................................... 4-4
Semi-Annual Maintenance Schedule .................................................................. 4-5
Annual Maintenance Schedule ........................................................................... 4-5
General Maintenance Procedures ....................................................................... 4-5
LUBRICATION ...............................................................................................................................45
SOOT CLEANING ..........................................................................................................................46
Safety Check Procedures ..................................................................................... 4-6