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INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL 'J' SERIES - OIL FIRED STEAM BOILERS (6J - 60J) This Manual must be available to the boiler operator at all times. J OIL-E-10 2008...
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Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the boiler. Continual improvement in boiler design and fittings may result in some of the components used being different to those in this manual, if in any doubt about individual components or their operation, contact Fulton Service Department. NOTE The Pressure System Safety Regulations 2000 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme.
LIST OF CONTENTS TITLE SECTION INTRODUCTION General Technical Data INSTALLATION General Siting Ventilation Flue Outlet Water Supply Blowdown Valves Main Steam Valve Steam Safety Valve Water Level Gauge Set Oil Supply 2.10 Electrical Requirements 2.11 Steam Pressure Gauge 2.12 Commissioning the Boiler 2.16 Cleaning Steam Lines and Pressure Vessels 2.17...
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Do not change the boiler fuel without consulting the Do not try to do repairs or any other maintenance boiler manufacturer. work you do not understand. Obtain a Service Manual from Fulton or call a Fulton Service Engineer WARNINg Non-approved modifications can cause injury and WARNINg damage.
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Optional Variations (where fitted) Appendix Spirax High Integrity Level Controls LIST OF ILLUSTRATIONS TITLE FIg. NO. Oil Fired Steam Boiler Boiler Top View Typical Installation Boiler Flue Connection Boiler Feedwater Arrangements Boiler Blowdown (20-60) Boiler Blowdown (6-15) Water Column Sequencing Valve Boiler Top Components Steam Pressure Gauge Nozzle and Ignition Assembly...
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Air Intake Manifold Feed Water to Boiler Steam Supply Valve Pump Water Column Strainer Probes Water Column Feed / Return Lines Boiler Control Panel Cleanout Door Handhole (flue passes and (Pressure Vessel flame turn around) Inspection) FIg.1 OIL FIRED STEAM BOILER J OIL-E-08 2008...
INTRODUCTION SECTION 1 general The Fulton Series J Oil Fired Steam Boiler is a vertical two-pass boiler of simple and efficient design and construction. 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.
INSTALLATION SECTION 2 gENERAL The installation of a Series J Oil 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. SITINg The boiler house should be sufficiently large to allow easy and safe access to all parts of the boiler for installation, operation and maintenance purposes.
FLUE OUTLET The boiler is supplied with a stainless steel flue spigot that should be inserted into the flue outlet in the back of the boiler and secured with the three angle clips supplied loose in the trim box. The height and type of flue will generally be subject to local planning regulations and approvals. The following information is intended to provide assistance where the installation of a simple flue is required. Where multi- b oiler flues or difficulties are experienced, specialist advice should be obtained.
Care should be taken to ensure the pipework is properly aligned and not placing any strain upon the feed water pump. Note: The boiler feed water pump may contain an inhibitor and this should be flushed from the pump prior to fitting the pump to the boiler. Failure to do so may result in water bounce or foaming due to the inhibitor forming a seal in the boiler. If the boiler is to be operated with little or no condensate return, consideration should be given to pre-heating the feed water. If in doubt consult Fulton Boiler Works. The Feed water inlet connection on some boilers is located on the left hand side of the boiler below the sight glass assembly. Feed Water Check Feed Water Stop Valve Valve Dip Pipe...
2.6. BLOWDOWN VALVE FIg. 6 BOILER BLOWDOWN (models 20-60) FIg. 6A BOILER BLOWDOWN (models 6 - 15) 2.6.1 BLOWDOWN VALVE - Water Column (Australian boilers only). The valve is a three position isolation valve, each position is indicated on a backing plate mounted with the valve, (the valve is shown in the blowdown position).
MAIN STEAM VALVE The main steam stop valve should be inserted in the steam line approximately 12in. (305 mm) from the top of the boiler. STEAM SAFETy VALVES Safety Valves are factory fitted and preset, 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.
2.16 COMMISSIONINg THE BOILER It is essential that the commissioning procedures listed below are carried out by a Fulton Service Engineer who will have the necessary experience and testing equipment to ensure that the installation is not only correct, but is operating safely and at optimum efficiency.
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2.16 COMMISSIONINg THE BOILER - continued INSPECTION Ensure the boiler has been washed out after installation. Conduct a water analysis before operating the boiler. Examine the probes in the water column and the boiler shell. Replace any damaged probes. Remove the burner and check the electrodes have not been damaged and that their settings are correct. If the burner is fitted with a photocell, remove it and check for damage.
Feed Water Oil Supply Pipes Line Main Steam Valve Main Air Intake Oil Strainer Boiler Data Plate Water Level Sight Gauges Flow / Sight Gauge Return Blowdown Pipes Valves Engineers Test Water Column Button (PM5) Blowdown Valve Control Box Isolator Switch Cleanout Handhole Cleanout Door FIg.
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2.16 COMMISSIONINg THE BOILER - continued (e) A barometric type draught stabiliser (if fitted in the flue) should be set for a draught of - 0.01in. to - 0.02in. (- 0.025mb to - 0.050 mb) of water column pressure with the burner off. Open all the valves in the water feed line. Open all the valves in the feed water line. FEED PUMP Close the isolating valve on the discharge side of the pump.
2.16 COMMISSIONINg THE BOILER - continued Adjust the steam pressure control to suit the boiler application. It should be borne in mind that boiler are designed to operate most efficiently at their maximum operating temperature. When boilers are to be operated below a pressure of 80 psi (5.5 bar) consideration should be given to the fitting of a pressure reducing set (see Section 2.8 - Steam Safety Valves).
OPERATION SECTION 3 gENERAL The following instructions are given for the guidance of the operator in the use of the J Series gas fired boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health. Where original equipment Service Manuals are supplied, they must be read and understood in conjunction with this manual.
BOILER CONTROLS continued. Fuel Pump Mounted on the burner scroll and driven by the burner motor, the fuel pump delivers oil to the burner nozzles at the correct pressure to allow complete atomisation and therefore combustion. PUMP CONTROL Pump Interrupt/Pump Run Switch. Fitted on the left side of the control panel, used to override (switch off) the pump controls during evaporation tests.
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INDICATOR LIgHTS Indicator lights are fitted to the control panel as an additional aid to the operator. The meaning and operating sequence of these lights is as follows: Start / Low Water Reset This switch is used to start the boiler and to reset the low water alarm. When the switch is pressed to initiate the start-up sequence, the low water alarm lamp also illuminates and the low water audible alarm sounds.
FILLINg THE BOILER - ALL MODELS Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down: Ensure that the main steam stop valve is OPEN. Ensure that the steam pressure gauge isolating valve is OPEN.
STARTINg THE BURNER - continued. When the boiler has achieved the required (set) pressure, the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework. WARNINg The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer.
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3.6.5 2nd. (Overriding) Low Water Check (for boilers fitted with Spirax High Integrity Level Controls, see Appendix 'C') Ensure the following: The burner is firing. The water level is correct in the boiler. The water pump is not running. Switch the pump OFF at the pump override switch. OPEN the main blowdown valve. When the water level nears the bottom of the water level gauge sight glass, the LOW WATER ALARM lamp should illuminate, the low water audible alarm should sound and the burner should stop firing.
Keep the boiler, water gauge, water column and interconnecting pipework free from sludge and scale buildup by blowing down in the following manner: Note: Where a boiler is operating continuously at steam pressure, advice should be sort from Fulton regarding the appropriate blowdown procedure.
On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves CLOSED. Note: Where a Boiler is operating continuously at steam pressure, advice should be taken from a Fulton agent as to the appropriate blowdown procedure. STEAM WORKING...
DRAININg THE BOILER, Boilers with manual blowdown valves CAUTION Your local regulations could state boiler water above 43 C must not be discharged into the drain. ALWAYS check your local regulations. Ensure the boiler is cold. Isolate the boiler electrics at the isolator on the control box door. Isolate the feed water tank and the feed water pump.
3.11 TROUBLESHOOTINg Problem Cause Remedy Ignition Failure 1. Oil tank empty Refill the oil tank. A slight delay in the re-priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily. 2. Power Supply Check fuse or Circuit breaker. Reset or replace as required. 3.
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3.11 TROUBLESHOOTINg - continued. Problem Cause Remedy Boiler Fails to Start 1. No Power Check fuse or circuit breaker. Reset or replace as necessary. 2. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. connect an ohmmeter between the switch terminals.
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3.11 TROUBLESHOOTINg - continued. Problem Cause Remedy Poor Combustion 1. Refractory Bricks Check the bricks are not plugged with soot or broken into pieces. Clean and replace as required. 2. Stainless Steel Ring Check to ensure the ring is present and fits securely against the furnace wall. 3. Main Air Adjustment Check air adjustment. Open main air until fire brushes the furnace wall.
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Raise the set point and recheck, switch should break. If the controller operates improperly, replace it. 7. Scale buildup in boiler Consult Fulton. 8. Refractory Bricks Check the bricks are not plugged with soot, cracked or broken into pieces. Clean and replace as required.
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3.11 TROUBLESHOOTINg - continued. Problem Cause Remedy Boiler is Surging 1. Steam Traps Check traps, clean or replace as required. blowing through. 2. Scale buildup or Call water treatment company and consult lime deposits. the factory. 3. Too much water Dump the return tank and flush the system. treatment. Test the water treatment.
Boiler Ignition Flame Burner Boiler Poor Burner Fault will not Cutoff Failure Failure Combustion Back will not Maintain Fires Maintain Cause Pressure Water Supply Oil Supply Refractories S.S. Ring Ignition Electrodes Oil Nozzle Main Air Adjustment Oil Valves Oil Pump Photoelectric Cell Low Water Probes Low Water Control...
SECTION 4 gENERAL To ensure the efficiency of the boiler, carry out the regular maintenance instructions detailed below. If any fault is found during these operations contact your Fulton representative. CAUTION It is essential that regular checks are made to ensure that scale buildup is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler feed water is effective.
The following procedures are designed to prevent the buildup of scale, silt or sludge in the bottom of the boiler, water gauge and water column pipework. In addition to these procedures, the advice of a water treatment specialist should be sought and followed. Note: for boilers fitted with Spirax High Integrity Level Controls see Appendix 'C'.
Ensure the main electrical supply is isolated before starting work. Inspect the hand holes in the boiler. If any leakage is evident proceed as follows: Note: Use only genuine Fulton replacement parts. Using the special tee handle wrench, remove the handhole assembly.
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Handhole Cover Plate Gasket Crab FIg. 18 HANDHOLE Ignition Burner Plate Screws Ignition Leads Transformer Burner Burner Motor Scroll Photocell Air Gate Electrodes Oil Feed Pipe Air Damper Burner Plate Burner Top Plate Oil Line Rubber Spider Coupling Electrode Nozzle Holder Deflector Fuel Pump...
SIx MONTHLy (including three monthly) It should be noted that after a Fulton boiler has been in operation for several months, pieces of burned metal will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation.
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Appendix ‘C’ Spirax High Integrity Level Controls The daily testing of boiler water level controls is a mandatory requirement as defined in the Health & Safety Executive Guidance Note PM5. The level of supervision is dependent upon the type of level controls (limiters) fitted. Boilers fitted with self monitoring high integrity controls (limiters) should be tested daily by a qualified boiler at- tendant, but may be supervised during the silent hours and weekends by a Competent Person trained to re- spond to an alarm. Daily testing of the controls is required which can be by simulation, with a weekly test by interrupting the feed water pump and lowering the water by evaporation.
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Spirax High Integrity Level Controls, continued. Weekly Test (Daily test plus) 1st. Low Water 1. With the burner firing 2. Switch the pump interrupt switch to the pump interrupt position. 3. By evaporation lower the water level in the boiler until the first low water alarm sounds and the low water indicator lamp illuminates, and the burner shuts down 4.
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WARNINg It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted to the boiler in a correct and safe manner. Connection Sizes (DN) (F=female, M=male) All connections BSP Model 1. Steam Outlet 2. Feed Water 3.
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IMPORTANT Recommended Water Conditions 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 boiler water. FEEDWATER (water entering boiler) pH Value 8.5 to 9.5 tested at room temperature, Hardness less than 2.0 mg/kg in the form of CaCO Suspended Solids...
SPARE PARTS SECTION 6 In order to ensure spare parts are correct, please complete the details below and have them at hand when ordering parts or making enquires regarding the boiler. Boiler number Boiler type Type of fuel used Wiring Diagram No. Commissioning Date WARNINg The type, size and lift pressure of the safety valve fitted to a boiler is specific to that boiler.
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5 year Warranty On the Fulton Boiler Pressure Vessel Fulton Boiler Works (Great Britain) Ltd. will repair or replace FoB factory any Fulton pressure vessel which within five (5) 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.
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Fulton Boiler Works (Great Britain) Ltd. Broomhill Road, Bristol, BS4 4TU, England. Telephone 0117 972 3322 Fax: 0117 972 3358 e -mail: uk-info@fulton.com web site: www.fulton.com FM 28400...