FULTON VMP40 Installation, Operation And Maintenance Manual page 56

PROBLEM CAUSE
Boiler will not 1. Gas Supply
maintain pressure 2. Dirty Flue
3. Pressuretrol
4. Scale Built up in boiler
5. Refractories
6. Steam traps blowing through
7. Boiler size
Boiler is Surging 1. Steam traps blowing through
2. High organic in boiler
3. High boiler TDS
4. Too much water akalinity
5. High sudden steam load
6. High level of water
Boiler Rumbles and 1. Draft problem
Pulsates
Boiler pushing water 1. Steam Traps
with the steam 2. High boiler TDS
(carryover)
3. High level of water
Pump will not cut off 1. Dirty Probes
2. Relay failed
3. Ground Connection
4. Probes not sensitive enough
Pump runs but does 1. Vapor locking of pump
not put water into boiler
2. Impeller Adjustment
3. Pump suction plugged
4. Plugged feed water nipple
5. Pump undersized/worn
Water pump will not 1. Scale on probes
come on at times 2. Bad Pump Contactor
3. Bad Pump Motor
Low Fuel pressure 1. Gas pressure regulator
Boiler Flooding 1. Pump does not shut off
2. Relay failed
3. Ground Connection
4. Vacuum created with boiler off
(i.e. Perc or oil)
(high PH)
treatment chemicals
treatment chemicals
(RO/DI Water)
REMEDY
Check gas pressure coming into gas train. If low, contact gas company.
Check flue for carbon buildup or blockage. Clean flue passages with brush.
Disconnect all power to the controller. Disconnect the wires from the
controller. Put an OHM meter between the switch terminals. Lower the
set point and recheck with OHM meter. Switch should break. If the
controller operates improperly, replace it.
Refer to Section 2 "Pressure Vessel Cleaning".
Check refractories to see if they are cracked or broken in pieces.
Replace as necessary.
Check traps to see if they are clean or replace as necessary.
Boiler may be undersized.
Check traps to see if they are clean or replace as necessary.
Drain and clean boiler with washing soda per instruction manual.
Drain boiler and flush system. Refill and increase blow-down
rate/frequency.
Have water tested by water treatment company, lower boiler alkalinity
to recommended level.
Check total equipment horsepower required against horsepower of
boiler being used. Decrease amount of equipment being used at one
time, or reduce the steam flow by partially closing the steam stop valve.
Consult water treatment expert and adjust levels to boiler
recommended levels.
Check draft with a gauge. Draft should be a -.02" to -.04" W.C. with
burner off or -.04" to -.06" when operating. May need to install a
barometric damper.
Check traps. Clean or replace as necessary.
Drain boiler and flush system. Refill and increase blow-down
rate/frequency.
Consult water treatment expert and adjust to boiler
recommended levels.
Clean or replace as necessary.
Make sure relay is plugged in tightly. If so, replace water level relay.
Check for tightness and clean.
Replace probes and relays with extra sensitive ones.
Allow system to cool down, check steam traps and check temp. If it is
to be sure return lines are not insulated.
Check return tank above 180°F (82°C) vapor locking of pump may occur.
Inspect check valves. Clean and replace as needed.
Replace pump with multistage centrifugal good for 250°F (121°C).
Check for impeller wear and adjust per component information in
instruction manual (Burks only).
Remove/clean inlet strainer.
Check and clean or replace as necessary.
Replace with appropriate pump.
Check and clean or replace as necessary.
Check to see if contactor is being powered.
Check to see if contactor coil is pulling in. Replace if necessary.
Check the incoming power to the pump to be sure it is receiving power.
If power is present but motor does not run, replace it.
Check and replace.
Dirty probes. Clean or replace as necessary.
Make sure relay is plugged in tightly. If so, replace water level relay.
Check for tightness and clean.
As the boiler cools off, it pulls water from the system piping. To prevent
1
this, add a / " check valve on the steam gauge assembly piping,
4
which closes under pressure and opens under vacuum.
Maintenance
45
VMP IOM