FULTON J Series, Installation, Operation And Maintenance Manual, Page: 3 / 72

JGASUK-IOMM-2015-2
Fulton Ltd
Page III
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Technical Data 1
SECTION 2 - INSTALLATION
2.1 General 3
2.2 Siting 3
2.3 Ventilation 4
2.4 Flue Outlet 4
2.5 Water Supply 6
2.6 Blowdown Valve 7
2.7 Main Steam Valve 8
2.8 Steam Safety Valves 8
2.9 Water Level Gauge Set (sight glass) 8
2.10 Gas Supply 8
2.10.1 Gas Valve with Pilot Gas Line 9
2.11 Electrical Requirements 9
2.12 Steam Pressure Gauge 9
2.13 Commissioning the Boiler 11
2.13.1 Boiler Inspection and Initial Firing 11
2.13.2 Setting Burner Controls-low/high fire (40J-60J) 14
2.13.3 Setting Burner Controls-fully modulating (30J-60J) 14
2.14 Multi Bloc Gas Valves 15
2.15 Cleaning Steam Lines and Pressure Vessels 18
SECTION 3 - OPERATION
3.1 General 19
3.2 Boiler Controls 19
3.3 Indicator Lights 21
3.4 Filling the Boiler-all models 22
3.5 Starting the Burner-all models 23
SECTION 4 - MAINTENANCE
4.1 Visual Checks 25
4.2 Water Level and Low Water Safety Controls 25
4.2.1 Pump Test 25
4.2.2 1st Low Water Level Check 26
4.2.3 2nd Low Water Level Check 27
4.3 Main Blowdown 28
4.4 Water Column Blowdown 28
4.5 Water Level Gauge Blowdown 29
4.6 Evaporation Checks 30
4.7 Flame Sensor Test 30
4.8 Draining the Boiler 31
4.9 Long Term Shut Down 32
4.10 Internal Inspection 32
4.11 Schedule of Operator Tests and Checks 33
4.11.1 Daily 34
4.11.2 Weekly-in addition 34
4.11.3 Monthly-in addition 34
4.11.4 Three Monthly-in addition 35
4.11.5 Six Monthly-in addition 35
4.11.6 Annually-in addition 37
4.12.1 Troubleshooting-boiler 38
4.12.2 Troubleshooting-feedwater pump 41
4.12.3 Troubleshooting-burner control unit-LFL1 43
4.13 Maintenance Log 45
APPENDIX A - TI SHEETS
APPENDIX B - WATER LEVEL PROBE INFO
APPENDIX C - MOTORISED HIGH/LOW CONTROL
1.1 General 57
1.2 Operation 57
1.3 Additional Controls 58
1.4 Commissioning 58
1.4.1 Fuel Input Rates 58
1.4.2 Air Damper Motor - Factory Cam Settings 58
1.4.3 Setup Procedure 59
1.5 Spare Parts 59
APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL
CONTROLS
1.1 Daily Tests 61
1.1.1 1st Low Water-daily 61
1.1.2 2nd Low Water-daily 61
1.2 Weekly Test-in addition 62
1.2.1 1st Low Water-weekly in addition 62
1.2.2 2nd Low Water-weekly in addition 62
APPENDIX E - AUTOMATIC TDS BLOWDOWN
SYSTEM
1.1 General 63
Electrical diagrams supplied separately