FULTON VMP40 Installation, Operation And Maintenance Manual page 45

Furnace Refractory
Replacement Procedure
1. Remove the burner plate and top plate
assembly up and out of the air to air
heat exchanger.
2. Remove the stainless steel combustion
ring from the furnace .
3. Remove the clean-out plugs from the
bottom sides of the boiler. The boiler has
two clean out plugs, one is located at the
bottom of the boiler to the right hand
side of the panel box. The second one is
180 degrees on the opposite side of the
boiler.
4. Break off the top holding clips that were
used to keep the refractory in position
during shipping. The boiler has welded
flat bars beneath the top refractory.
These bars will have to be cut to change
the lower refractory. Rewelding of the
bars will be required prior to installation
of the top refractory. For the lower
refractory you will also need to break off
the top holding clips that were used to
keep the refractory in position during
shipment.
5. Break up the top and/or bottom
refractories and remove the pieces from
the boiler through the clean-out plugs.
NOTE
If only the top refractory is to be
changed, the bottom refractory need not
be broken.
6. Round and bevel the outer edges of the
new refractories.
7. The bottom refractory has the largest
hole, while the top refractory has the
smallest.
8. Lower the bottom refractory down
the furnace with wire fastened around
the refractory in three positions. When
the refractory is close to position, it can
be tipped by maneuvering the wire to
drop it flat on the holding clips. If the
refractory will not tip, it may have to be
removed and again rounded and
beveled.
9. Install the top refractory in the same
manner as the bottom refractory. When
installed the outer edges must be
sealed with insulcrete - a castable
refractory mix available from the Fulton
factory. It is not necessary to reinstall the
shipping clips.
9. Install the stainless steel combustion ring,
burner assembly, and clean out plug.
10.Normal operation can be resumed
immediately.
Stainless Steel
Combustion
Chamber Ring
Top Castable
Refractory
Turbulator
Bottom
Castable
Refractory
Handhole
Maintenance
Gas Train Assembly
Air Deflector
Artwork Revision 2017-0927
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VMP IOM