Table of Contents
Section 1: Safety & Warnings ...................................................................................................................1-1
Introduction .............................................................................................................................................................................................1-2
Receiving Inspection ............................................................................................................................................................................1-2
General Warnings, Cautions and Notes .....................................................................................................................................1-2
Steam Boiler Systems Warnings and Cautions .......................................................................................................................1-6
Section 2: Installation ...........................................................................................................................2-1
Product Overview ..................................................................................................................................................................................2-2
Massachusetts Installations ..............................................................................................................................................................2-2
Placement & Rigging............................................................................................................................................................................2-2
Clearances & Serviceability ...............................................................................................................................................................2-2
Equipment Ventilation & Combustion Air Requirements ................................................................................................2-16
Utilities.......................................................................................................................................................................................................2-17
Electrical Supply ...................................................................................................................................................................................2-18
Water Chemistry ...................................................................................................................................................................................2-18
Steam Outlet ..........................................................................................................................................................................................2-19
Water Supply ..........................................................................................................................................................................................2-19
Piping Specifications ..........................................................................................................................................................................2-21
Insulation .................................................................................................................................................................................................2-25
System Interfaces .................................................................................................................................................................................2-25
Assembly of Fulton Multi-Skid Engineered Systems ..........................................................................................................2-28
Stack & Flue Connections ................................................................................................................................................................2-28
Venting Terminations .........................................................................................................................................................................2-30
System Piping Testing ........................................................................................................................................................................2-31
Before Leaving the Installation ....................................................................................................................................... 2-31
Section 3: Operation .............................................................................................................................3-1
Start-Up Preparation & Installation Review...............................................................................................................................3-2
Start-Up Service ......................................................................................................................................................................................3-2
Prepare for Initial Start-Up..................................................................................................................................................................3-2
Perform Boil-Out ....................................................................................................................................................................................3-2
Sequence of Operation: Gas Fired Burners ...............................................................................................................................3-3
Flame Programmers .............................................................................................................................................................................3-4
Siemens Linkageless Modulation...................................................................................................................................................3-4
Commissioning the Unit....................................... .............................................................................................................................3-5
Operating Controls ...............................................................................................................................................................................3-7
Burner Settings .......................................................................................................................................................................................3-7
Pressure Modulation Controller ......................................................................................................................................................3-7
Cycle Testing ...........................................................................................................................................................................................3-11
Daily Start-Up ........................................................................................................................................................................ ..3-11
Daily Shutdown.....................................................................................................................................................................3-11
Section 4: Maintenance & Troubleshooting ...................................................................................4-1
Procedure for Cleaning Water Probes ..........................................................................................................................................4-2
Flame Scanner Adjustments for Fulton Gas Fired Steam Boilers ...................................................................................4-2
Recommended Daily Maintenance Schedule .........................................................................................................................4-3
Recommended Weekly Maintenance Schedule ....................................................................................................................4-4
Recommended Monthly Maintenance Schedule .................................................................................................................4-4
Recommended Semi-Annual Maintenance Schedule........................................................................................................4-5
Recommended Annual Maintenance Schedule ....................................................................................................................4-8
After All Repairs or Maintenence ...................................................................................................................................................4-8
Assembly Drawings and BOMs .......................................................................................................................................................4-8
Troubleshooting
..................................................................................................................................................................................4-22