Fulton Electric Steam Boiler User Manual

Installation Operation And

Fulton Electric Boilers

Maintenance Manual

(Steam Models)

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ProductBulletin

Product Bulletin

2010-001PB

The Fulton Companies
972 Centerville Road
Pulaski, N.Y. 13142

Date: January 22, 2010

Subject: Water Chemistry Requirements for Fulton Steam Products

Products: ICS/ICX, FB-A, FB-F, FB-S, VMP, PVLP, PHP, Electric Steam

Boilers and Unfired Steam Generators

Please note that the water chemistry is different for carbon steel vs. stainless steel
pressure vessels and vertical vs. horizontal orientation.

Effective immediately, please use the limits below. Should you have any questions,
please do not hesitate to contact Fulton at 315-298-5121.

Water Chemistry Requirements for Fulton Steam Products (to 300 psig MAWP)

NOTES:

*This is a minimum temperature. Feedwater temperatures below 200F will require an oxygen scavenger.

** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.

+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible.

++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or

orange tinge.

ND: None Detected.

Parameter

Carbon Steel Stainless Steel

Feedwater Vertical

Boiler/Steam

Pac Water

Horizontal

Boiler/Steam

Pac Water

Feedwater Vertical

Boiler/Steam

Pac Water

Horizontal

Boiler/Steam

Pac Water

pH 7.5-9.5 8.5-10.5 8.5-10.5 6.0-9.5 8.5-10.5 8.5-10.5

Feedwater
Temperature

140F* --- --- 140F* --- ---

Hardness as
CaCO

3

<2ppm <10 ppm <15 ppm <2 ppm <10 ppm <15 ppm

Chlorides --- --- --- --- 50 ppm 50 ppm

Tota l
Alkalinity

--- <300 ppm <500 ppm --- <300 ppm <500 ppm

Tota l
Dissolved
Solids

--- <2000 ppm <3000 ppm --- <2000 ppm <3000 ppm

Suspended
Solids

No visual
turbidity**

No visual
turbidity**

No visual
turbidity**

No visual
turbidity**

No visual
turbidity**

No visual

turbidity**

Total Organic
Carbon

No sheen
No foam+

No sheen
No foam+

No sheen

No foam+

No sheen
No foam+

No sheen
No foam+

No sheen
No foam+

Iron Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Dissolved
Oxygen

<1ppm* ND ND <5ppm ND ND

Visual Oil ND ND ND ND ND ND

Conducivity
(uS/cm)

--- <2985 <4477 --- <2985 <4477



Contents

Section

4

Maintenance

5

Parts and
Warranty

3

Operation

2

Installation

1

Safety Warnings
and Precautions

PAGE 7

PAGE 3

PAGE 23

PAGE 19

PAGE 31

1

Electric IOM

Electric IOM

2

Section

Safety Warnings
and Precautions

4
5

3

2

1

3

Electric IOM

Safety Warnings and Precautions

This manual is provided as a guide to the correct operation and
maintenance of your Fulton Electric Steam Boiler, and should be
permanently available to the staff responsible for the operation of
the electric boiler.

These instructions must not be considered as a complete code of
practice, nor should they replace existing codes or standards which
may be applicable.

The requirements and instructions contained in this section
generally relate to the standard Fulton Electric Steam Boiler. When
installing a packaged unit, this entire section should be read to
ensure that the in stallation work is carried out correctly.
Prior to shipment the following tests were made to assure the
customer the highest standards of manufacturing:

a) Material inspections.
b) Manufacturing process inspections.
c) ASME welding inspections.
d) ASME hydrostatic test inspection.
e) Electrical components inspection.
f) Operating test. (panel powered up)
g) Final Engineering Inspection
h) Crating inspection.

All units are crated for fork lift transport. Once uncrated, all units can
be transported with a forklift. Under no circumstances should weight
be allowed to bear on the jacket, control panel, or fan housing of any
Fulton Boiler.

Rigging your boiler into position should be handled by a competent
rigger experienced in handling heavy equipment.

NOTE

The installation of the Fulton Electric Steam Boiler should be
carried out by competent personnel in accordance with all
relevant safety regulations. A complete list of all safety
precautions may be found in the safety summary at the
conclusion of Section 1. It is the responsibility of the installer
to ensure that the installation is in compliance with these
regulations.

N OTE

If it is necessary to store the boiler for a prolonged period of
time prior to installation, the boiler should be stored at a
minimum 40 degree F in an atmosphere in which excessive
moisture cannot damage the controls or the steel casing. If the
storage is to be over sixty days, one element should be
removed. Place several bags of dry dessicant inside the boiler.
Bolt a blank flange over the element mounting plate to seal the
boiler. If handholes are provided, these can be used to provide
an opening versus an element to place the dessicant.

For Your Safety

The following WARNINGS, CAUTIONS, and NOTES appear in various sections of this manual.

They are repeated on these safety summary pages as an example and for emphasis.

WARNINGS must be observed to prevent serious injury, or death to personnel.
CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness.
NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the
WARNINGS, CAUTIONS, and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects
of safety and equipment prior to operation or maintenance of the equipment.

WARNING

Improper installation or maintenance of gauge glass and
connections can cause immediate or delayed breakage
resulting in bodily injury and/or property damage.

WARNING

When stopping the boiler for any extensive repairs, shut off
main power switch and pull main disconnect switches on both
the boiler side as well as the feed water side.

WARNING

Prior to the commencement of any work requiring the removal
of cover plates and the opening of the control panel box, the
electrical supply to the boiler must be disconnected.

WARNING

Prior to powering the boiler up, all electrical contacts shall be
re-torqued to the individial components manufacturers
recommendations.

CAUTION

Do not downsize piping below safety valve size.

CAUTION

Unless otherwise specified, the steam safety valve supplied
with the boiler is pre-set. This valve is provided as a safety
device for the boiler and should not be used as the sole
protection for other equipment using steam from the boiler. Do
not tamper with the setting (It could accidentally be set at a
pressure higher than the design pressure of the boiler and,
therefore ,create a hazardous condition.

CAUTION

Do not exceed pressure rating on boiler.

CAUTION

In general, ensure that the boiler area is in conformance with
established boiler room requirements. Review national and
local codes.

4

Electric IOM

CAUTION

Do not tamper with the safety features of the low water safety
cut out.

CAUTION

Keep boiler area clear and free from combustible materials,
gasoline, and other flammable vapors and liquids.

CAUTION

Do not use harsh compounds that will injure the feed water
pump or elements.

CAUTION

Do not clean the gauge or gauge glass while pressurized or in
operation.

CAUTION

Prior to performing the “try lever” test, be certain to take
precautions as a loud noise and high velocity steam will
discharge freely from discharge port and through drain hole
provided in the side of the valve body.

NOTE

Where a condensate return tank is to be fitted, this should:

a) Be vented and
b) Have a capacity sufficient to satisfy boiler consumption

(normally 10 minutes worth of storage minumum) as well
as maintain proper return tank temperature and

c) Vent pipe should not be down-sized (This may cause

pressure build up in the condensate tank.)

NOTE

Care should be taken to ensure that the blow off receptacle
used meets the regulations covering such items. If in doubt,
consult a Fulton Representative for advice.

NOTE

Only properly trained personnel should install and maintain
water gauge glass and connections. Wear safety glasses
during installation. Before installing, make sure all parts of free
of chips and debris.

NOTE

Keep gauge glass in original packaging until ready to install.

NOTE

After Installation is complete and prior to operation, the
pressure vessel should be cleaned.

NOTE

Check with local authorities where approval for start-up is
required. In some localities, final inspection of services may
be required.

NOTE

To ensure that your Fulton Steam Boiler is kept operating
safely and efficiently follow the maintenance procedures set
forth in this manual.

NOTE

The policy of Fulton Boiler Works, Inc. is one of continuous
improvement, and therefore, we reserve the right to change
prices, specifications, and equipment without notice.

Safety Warnings and Precautions

5

Electric IOM

6

Electric IOM

Section

2

Installation

4
5

3

1

7

Electric IOM

Installation

Water Bottle
for Models
30-100 BHP

Steam

Outlet
Valv e

Safety

Valv e

Shut-Off

Valv e

Electric

Steam Boiler

Fast Opening

Valv e

Blowdown

Valv e

Check

Valv e

Check

Valv e

Electric
Control

Panel

Water Column
or Water Bottle

Blowdown
Valv e

Basic Boiler,
Condensate Tank,
and Blow off Separator
Piping Diagram

8

Electric IOM

Installation

NOTE

Where a condensate return tank is to be
fitted, this should:

1. Be vented and

2. Have a capacity sufficient to satisfy
boiler consumption as well as maintain
proper return tank temperature.

codes. The water gauge blow off valve
should be connected to the main blow off
line.

NOTE

Care should be taken to ensure that
the blow off receptacle used meets the
regulations covering such vessels. If
in doubt consult a Fulton
Representative for advice.

Locating the Boiler

The boiler should be located in dry
surroundings on a level base, as close as
possible to the steam using machinery.
See right hand page for minimum
clearances to ensure that there is sufficient
room around the boiler to enable the
operator and maintenance engineer to gain
access to all parts of the boiler. Check
location for ease of water supply and
electrical connections.

3. Vent pipe should not be down-sized
(This may cause pressure build up in
the condensate tank.

There are two blow off valves on the boiler;
the main valve at the rear of the boiler and
the water gauge glass blow off valve. The
boiler blow off valve supplied with the boiler
should be screwed to the blow off pipe at
the rear of the boiler and connected to a
blow off receptacle of approved design
piping. All these procedures should be
done in accordance with state and/or local

Cold Water
Supply

Ven t

Ven t

Return

Sight

Glass

Temperature

Control

Valv e

Thermometer

Blowdown

Separator

Return

Condensation

Tank

Union

Union

Drain

Pump / Strainer

Check

Valv e

Cold Water

Inlet

Outlet

9

Electric IOM

1. Pressure Vessel Is Built to ASME Code
5 Year Warranty

2. Electrical Control Panel Box

3. Electric Heating Elements

4. Low Water Cut Off Probe

5. Second (auxiliary) Low Water Cut Off

Probe

6. Pump “On” Probe

7. Pump “Off” Probe

8. Sight Glass Assembly

9. Operating pressure control

10. High Limit Pressure Control w/ manual

reset

11. Steam Outlet

12. Safety Valve

13. Steam Guage Assembly

14. Steam Pressure Guage

15. High Temperature Insulation Surrounds

The Pressure Vessel

16. Large (3” x 4”) Easy Access Handholes

17. Feedwater Shut Off Valve

18. Blowdown Valve

19. Water Bottle Assembly for 300 to 1000

kW Only

NOTE:

All Fulton Electric Steam Boilers have a
second (auxiliary) low water cut-off
probe

Electric IOM

Installation

10

Component Locations of the Fulton 12 to 1000 kW
(1.2 to 100BHP) Steam Boilers

3

11

12 to 36 kW (1.2 to 3.6 BHP)

Element(s) are horizontally mounted at the
bottom of the pressure vessel. All probes
are located in the top of the boiler.

50 to 200 kW (5 to 20 BHP)

Elements are vertically mounted. All probes
are located in the top of the boiler.

12

14

11

3

4

6

7

8

13

5

15

16

17

10

18

2

9

1