Gas pulse combustion hydronic heating boilers (94 pages)
Summary of Contents for FULTON RB Series
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL RB / RBC Series Gas / Oil / Dual Fuel Horizontal Steam Boilers This manual must be available to the boiler operator at all times. RB-RBC-IOMM-2015-1...
TABLE OF CONTENTS Fulton Ltd SECTION 1 - INTRODUCTION SECTION 4 - MAINTENANCE General 4.1 Boiler Platform (if fitted) Product Overview Visual Checks Technical Data Burner Flame Sensor Test Water Level and Low Water Safety Control Procedures SECTION 2 - INSTALLATION 4.4.1 Feedwater Pump Test General 4.4.2...
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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.
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DANGER FROM INCOMPLETE COMBUSTION you do not understand. Obtain a service manual from The importance of correct burner adjustment to achieve Fulton Ltd or call a Fulton service engineer. low emissions, safe, clean and efficient combustion is paramount. Poor combustion, where unburnt gas forms carbon monoxide is both a health hazard, and...
INTRODUCTION - 1 Fulton Ltd SECTION 1 - INTRODUCTION GENERAL The Fulton RB and RBC Series fuel fired steam boiler service manual is a generic publication, providing information on standard boiler operation and maintenance. Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained. Satisfactory performance can only be ensured if the installation recommendations, operating routines and maintenance schedules laid out in this manual are adhered to.
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Fulton Ltd Pressure Top exit gauge and flue (rear pressure Steam exit flue Steam Boiler vent Main steam controller pressure optional) safety valve valve valve connection gauge Boiler water Feedwater Feedwater Water level Boiler Boiler Burner sample pump inlet gauge set blowdown...
INSTALLATION - 2 Fulton Ltd SECTION 2 - INSTALLATION GENERAL The installation of an RB/RBC series fuel fired steam boiler should be carried out by competent personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these regulations are complied with. PRE-INSTALLATION Prior to delivery of the boiler, consideration should be given to the following: (Planning regulations may call for more consents than those listed below, always check with your Local Planning Authority).
INSTALLATION - 2 Fulton Ltd 2.2.1 SITING (Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication 1676, and in particular to Section 5, Location of Appliances). The boiler house should be sufficiently sized to allow easy and safe access to all parts of the boiler for operational and maintenance purposes. Reference should be made to Appendix A - TI-135-RB Dimensions & Specification &...
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Fulton Ltd Cowl Standard boiler trim supplied with boiler Note: Ball float or solid state water level controls available. D = Diameter of flue Condensate return (no flex) H = 1.5 X D Pipe safety Make-up feedwater valve to a...
INSTALLATION - 2 Fulton Ltd MAJOR COMPONENTS Main steam valve. Steam outlet stop valve fitted centrally on the top centre line of the boiler. Steam vent valve. Fitted to the rear, on the top centre line of the boiler. Safety valve. Fitted to the rear, on the top centre line of the boiler. Boiler control box Steam pressure gauge.
INSTALLATION - 2 Fulton Ltd FLUE OUTLET The height and type of flue will be subject to local planning regulations and approvals, and to the requirements of the Clean Air Act or similar local regulations. Note: Before erecting a flue, Public Health Authority and Planning permission must be obtained. The following information is intended to provide assistance where the installation of a simple flue is required. Where multi-boiler flues are necessary, or difficulties could be experienced, specialist advice must be obtained. Boilers are fitted with a flanged flue outlet. The flue manufacturer/installer must be consulted at an early stage to ensure a correct mating component for flue connection (see Figure. 3).
Regulations exist covering such items and care must be taken to ensure compliance with these regulations. If in doubt regarding blowdown arrangements, consult Fulton Ltd or Health and Safety Executive Guidance Note PM60 which covers blowdown tanks and associated pipework installation.
INSTALLATION - 2 Fulton Ltd 2.6.2 WATER LEVEL GAUGE SET (SIGHT GLASS) All RB/RBC series boilers are fitted with two, ‘Clifton’ type (unless otherwise specified) reflex water level gauges. The water level gauge blowdown valves should be connected to the auxiliary blowdown line; final connection to the blowdown valves being via soft copper tubing. The valve fittings are 6 mm. Figure. 5 - Water Level Gauges MAIN STEAM VALVE Distribution pipework should be run...
INSTALLATION - 2 Fulton Ltd STEAM SAFETY VALVE WARNING Factory fitted safety valves are pre-set to protect the boiler only and must not be used to protect any other items not capable of accepting boiler pressure. Safety valves are factory fitted and pre-set, they MUST NOT be adjusted. The discharge outlet should be piped to a safe discharge point and the piping so arranged that any condensate trapped in the pipework will drain away from the valve.
The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by Fulton. 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.
If the site gas pressure is too low, it will be necessary to fit a gas booster system. Consult Fulton Ltd if in doubt. To minimise pressure drops, eliminate all unnecessary bends and elbows in the pipework between the gas meter and the inlet to the gas train.
INSTALLATION - 2 Fulton Ltd 2.10.3 DUAL FUEL SUPPLY Figure. 11 - Dual Fuel Burner Installation Note: Installation will change with the type of burner fitted. 2.11 ELECTRICAL REQUIREMENTS CAUTION Any electrical work should be undertaken by a qualified electrician to current local regulations. An individual wiring diagram for the boiler is located on the inside cover of the control box.
INSTALLATION - 2 Fulton Ltd 2.12 CLEANING STEAM LINES AND PRESSURE VESSELS During the first week of boiler operation, clean all oil and dirt from the boiler, the steam line and condensate return line. 1. Disconnect the condensate return pipe adjacent to the condensate return tank. 2. Direct the returns to a floor drain or other safe discharge point and make safe. 3. Leave in this position for one week to allow all impurities to flush through. 4. Drain the boiler completely each day. 5. After the week is completed, drain and flush the condensate return tank, removing all installation sediment.
Fulton Ltd SECTION 3 - OPERATION CAUTION The following instructions are given for the guidance of the operator in the use of the Fulton steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored. GENERAL...
OPERATION - 3 Fulton Ltd Burner Programmer Is located in the burner mounted control panel. Acts in conjunction with a sensing device to ‘supervise’ the ignition sequence, prove the flame is satisfactory and finally ‘monitor’ the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to ‘lock-out’ and both main and pilot gas/oil valves will shut to isolate the fuel lines to the burner. Air Pressure Switch (Gas and Dual Fuel Burners only) Mounted on the burner, this switch is operated by the pressure of air entering the burner through the throat of the scroll. Lack of combustion air, or insufficient air pressure, will stop the switch...
OPERATION - 3 Fulton Ltd 3.2.3 BOILER CONTROL PANEL Pressure gauge LC3050 level limiters LC2250 level (if fitted) controller (if fitted) PM5 test Pump on/off Low fire hold Pump & burner/ Flame failure reset pump only Pump select Audible alarms Modulating pressure transducer 2nd low water reset...
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OPERATION - 3 Fulton Ltd Boiler controls and indicators are housed in a control panel mounted on the side of the boiler. These are as follows: Power Isolator Switch Control panel power supply ON/OFF switch, mounted on the panel door.
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OPERATION - 3 Fulton Ltd Sequence manual/auto switch (if fitted) Used to select either manual or automatic sequence step control. In the manual position the burner will operate under the direct control of the master pressure controller, mounted in the steam header/distribution pipework. The boiler mounted high pressure and on/off pressure switches are still functional.
OPERATION - 3 Fulton Ltd 3.2.4 BURNER CONTROL PANEL Note: A gas burner is illustrated, for specific details consult the burner manual supplied with the boiler. Figure. 15 - Burner Control Panel Burner controls and indicators are mounted on the burner. The following controls are typical for a dual fuel burner, but reference should be made to the burner manufacturer’s Operating Manual...
OPERATION - 3 Fulton Ltd FILLING THE BOILER ALL MODELS 1. Ensure the following valves are OPEN: a) Steam pressure gauge isolating valve. b) All valves in the feedwater line. c) Water level gauge (sight glass) isolating valves. d) Air release valve.
OPERATION - 3 Fulton Ltd DRAINING THE BOILER CAUTION Your local regulations could state boiler water above 43 °C must not be discharged into the drain. ALWAYS check your local regulations. Boilers with manual blowdown valves 1. Ensure the boiler is cold.
OPERATION - 3 Fulton Ltd BOILER START-UP (FROM COLD) ALL MODELS CAUTION The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer. When starting up the boiler, it is prudent to minimise the thermal and mechanical stress caused by differential expansion of various parts of the boiler as they reach working temperature.
OPERATION - 3 Fulton Ltd Note: If the 2nd Low Water and High Pressure Alarm/Reset switches illuminate and the alarms sound, check that the burner mounted Burner On/Off/Reset Switch is in the OFF position, and then reset both alarms by pressing the switches.
OPERATION - 3 Fulton Ltd INTERNAL ECONOMISER (IF FITTED) Feedwater from a constantly running modulating pump is passed through the economiser before entering the boiler. Heat is extracted from the boiler exhaust gases by the economiser which in turn heats the feedwater to temperatures that can exceed 100 °C.
MAINTENANCE - 4 Fulton Ltd SECTION 4 - MAINTENANCE CAUTION It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy of the boiler.
MAINTENANCE - 4 Fulton Ltd VISUAL CHECKS Inspect the steam and feedwater pipework, valves and fittings for signs of leakage. If leaks are suspected, shut-down and evacuate the system to atmospheric pressure before attempting any repairs. Note: Ensure that the water level is maintained during the pressure build-up. If any part of the equipment is not operating correctly, the fault should be investigated before the boiler is used.
MAINTENANCE - 4 Fulton Ltd WATER LEVEL AND LOW WATER SAFETY CONTROL PROCEDURES The following procedures ensure the correct functioning of the water level controls and the low water safety controls. 4.4.1 FEEDWATER PUMP TEST a) If the boiler is not firing and not under steam pressure, lower the water level using the main...
MAINTENANCE - 4 Fulton Ltd 4.4.2 1ST LOW WATER LEVEL CHECK 1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off. 2. Switch off the pump using the Pump on/off switch. 3. Allow the water level to lower by natural evaporation below the 1st Low Water level.
MAINTENANCE - 4 Fulton Ltd 4.4.3 2ND LOW WATER LEVEL CHECK 1. Complete steps 1 to 4 of the 1st Low Water Level Check. 2. Allow the water level to lower by natural evaporation or manual blowdown below the 2nd Low Water level.
Keep the boiler, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by following these blowdown procedures. Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.
On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are CLOSED. Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure.
MAINTENANCE - 4 Fulton Ltd BOILER INTERNAL INSPECTION Drain and isolate the boiler before carrying out an internal inspection of the boiler. The lower hand hole and man hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined, paying particular attention to the junction with the front tube plate and tubes for signs of pitting.
MAINTENANCE - 4 Fulton Ltd FITTING NEW GASKETS TO BOILER INSPECTION HOLES 4.7.1 IMPORTANT INFORMATION CAUTION TOPOG-E gasket have a finite life after installation and must be renewed annually. It is important that the instructions given in this section are adhered to.
MAINTENANCE - 4 Fulton Ltd 4.7.2 FITTING PROCEDURE Blowdown the boiler completely (see Section 4.5.1 - Main Boiler Blowdown) and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows: 1. Disassemble the bridge and cover plate and remove the inspection hole assembly.
MAINTENANCE - 4 Fulton Ltd FRONT ACCESS DOOR 4.8.1 FRONT ACCESS DOOR ADJUSTMENT AND SEAL WARNING When handling ceramic fibre always follow the local regulations regarding such materials, including the use of breathing apparatus, suitable body protection and protective gloves.
MAINTENANCE - 4 Fulton Ltd 4.8.2 FRONT ACCESS DOOR INSULATION WARNING When handling ceramic fibre always follow the local regulations regarding such materials, including the use of breathing apparatus, suitable body protection and protective gloves. The front access door is lined with end-on ceramic fibre leaving an air gap between the fibre and the boiler tube face plate.
MAINTENANCE - 4 Fulton Ltd FEEDWATER DISPERSER CAUTION DO NOT use unheated or untreated feedwater which can result in premature tube failure by oxygen corrosion. RB Boilers are fitted with a feedwater disperser, removable for cleaning. The holes in the disperser are sized to give an exit velocity sufficient to ensure rapid mixing of the boiler water and the cooler feedwater, reducing temperature gradients within the water to a minimum. In order to reduce oxygen corrosion to the tubes and prevent thermal shock, it is imperative that feedwater entering the boiler is heated to 80 °C - 85 °C.
MAINTENANCE - 4 Fulton Ltd 4.10 SERVICE INSPECTION OF WELDED JOINTS (UK ONLY) The requirement for in-service inspection of the main welded joints of the boiler is calculated by the number of cycles since the last inspection. Boilers running twenty four hours a day require the shell and furnace end plate welds to be inspected at five year intervals and the longitudinal seam every ten years.
4.11 SCHEDULE OF OPERATOR TESTS AND CHECKS The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler is installed in. Failure to maintain the boiler adequately may void the Fulton guarantee.
MAINTENANCE - 4 Fulton Ltd 4.11.1 DAILY WARNING All steam pipework, valves and fittings will be very hot. 1. Visually inspect for signs of leakage (see Section 4.2 - Visual Checks): a) Steam and feedwater pipework b) V alves and fittings c) Hand holes and man holes - If leak is detected shut down and replace the gasket.
MAINTENANCE - 4 Fulton Ltd 4.11.3 THREE MONTHLY IN ADDITION WARNING The boiler should be completely cold before carrying out any of the following procedures. 11. Visually inspect the boiler interior (see Section 4.6 - Boiler Internal Inspection). 4.11.4 SIX MONTHLY IN ADDITION 12.
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22. Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas reburning in the tube ends as a result of poor combustion, e.g. carbon monoxide carry-over. If the tube ends exhibit these signs, consult Fulton Ltd. IMPORTANT Ensure that the rear smoke box drain connections are clean and free from deposits.
The scope of a full insurance strip-down is such that it should only be attempted by persons competent to do so who have had the necessary training, and have the required test equipment. Fulton Ltd can offer this service if required. The engineering surveyor may require the removal of the ceramic fibre insulation around the periphery of the front tube plate to facilitate inspection of the shell to tube plate weld.
MAINTENANCE - 4 Fulton Ltd 4.12.1 TROUBLESHOOTING BOILER Problem Cause Remedy Power supply Check fuses or circuit breaker. Starting Gas supply Check for gas pressure. Check main gas cock is open. Low water probe Check low water probes. Loose wire connection Check connections to all components.
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MAINTENANCE - 4 Fulton Ltd 4.12.1 TROUBLESHOOTING BOILER Problem Cause Remedy Too much boiler treatment chemical Dump return tank, flush system or stop Wet steam, boiler primes treatment for a week. Steam traps See previous page. Earth connection Check for tightness and clean. Pump will not cut off Probes connections Check for tightness and clean.
MAINTENANCE - 4 Fulton Ltd 4.12.2 TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 1. Supply failure. Connect the electricity supply. FEEDWATER PUMP Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers. 3. Motor contactor overload has Reactivate the motor protection.
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MAINTENANCE - 4 Fulton Ltd 4.12.2 TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 1. Leakage in suction pipe. Repair the suction pipe. Pump runs backwards when 2. Foot or non-return valve is Repair the foot or non-return valve. switched off. defective.
Fulton Ltd APPENDIX A - TI SHEETS The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in this Appendix. Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To check you have the most up to date TI sheet, please check the downloads section on the Fulton website (www.fulton.co.uk/support/downloads) or consult Fulton Ltd.
APPENDIX - A Fulton Ltd Technical Information Sheet No. 136 Issue 1 Fulton Probe Lengths - RB Series 2nd. Low Water 1st. Low Water Pump On High Water Pump Off Normal Working 30mm Level (NWL) minimum 20mm 180mm 15mm 70mm...
APPENDIX - A Fulton Ltd Technical Information Probe Lengths - RBC Series TI63 2nd. Low Water 1st. Low Water Pump On High Water Pump Off Normal Working 30mm Level (NWL) minimum 25mm 209mm 25mm 80mm WARNING The 2nd. Low Water at 30mm in the sight glass must not be changed.
APPENDIX - A Fulton Ltd Technical Information Sheet No. 140 Issue 1 Horizontal Steam Boilers Recommended Water Conditions IMPORTANT It is very important that a strict water management program is followed to ensure trouble free boiler operation. The following are recommended for feedwater and for boiler water...
In order to ensure the safe, efficient and economical running of boiler plant, it is imperative the boiler water is sampled for analysis at frequent and regular intervals. The Fulton water sample cooler has been designed and manufactured to facilitate the safe monitoring of the boiler water.
APPENDIX - A Fulton Ltd Technical Information Sheet No. 103 Issue 3 Water Level Probes Replacement Standard Probes (brass) Probes are supplied in a standard length and should be cut to the length required, (the length of the probe being replaced) ensuring measurements are taken from the underside of the probe hexagonal nut, remove any burrs caused by cutting.
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APPENDIX - A Fulton Ltd TI-103-WaterLevelProbes-2015-3 High Integrity Probes (stainless steel) The probe is supplied in two parts, the head and the tip. The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head.
APPENDIX - A Fulton Ltd Technical Information Sheet No. 30 Issue 3 Automatic TDS Blowdown Systems The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS level within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be used to control suspended solids, and prevent the build-up of sludge in the bottom of the boiler.
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The equipment and staff training required to carry out TDS sampling and calibration can be provided by Fulton. In order to achieve the maximum benefit from the installation of an Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the necessary equipment, and training in order for them to fully understand the function of the system, and the possible consequences of their actions.
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G U A R A N T E E On the Fulton Boiler Pressure Vessel Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within three (3) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the manufacturer’s handbook.