Fulton Hopkins Horizontal Coil Thermal Fluid Heater User Manual

INSTALLATION AND

OPERATION MANUAL

Hopkins

Horizontal Coil Design

Thermal Fluid Heaters

HPN-IOM-2014-0416

Serial/ National Board Number

Model

Fulton Order

Sold To

Job Name

Date

HPN-IOM-2014-0416 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................ 1-2

Disclaimers and Local Codes ................................................................................ 1-2

Installation 2-1

Placement & Rigging ........................................................................................... 2-2

Clearances & Serviceability .................................................................................. 2-3

Environment, Ventilation and Combustion Air Requirements ............................ 2-3

Utilities ................................................................................................................. 2-6

THE GAS SUPPLY ..........................................................................................................................2 6

THE OIL SUPPLY ...........................................................................................................................27

Instrument Air ...................................................................................................... 2-7

Electrical Supply ................................................................................................... 2-7

Thermal Fluids ...................................................................................................... 2-8

THERMAL FLUIDS AT ELEVATED TEMPERATURES ......................................................................28

SELECTING A THERMAL FLUID ....................................................................................................29

ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2 10

THERMAL FLUID BREAKDOWN .................................................................................................210

Piping Speci cations .......................................................................................... 2-11

Insulation ........................................................................................................... 2-15

System Interfaces ............................................................................................... 2-15

HEATER CONNECTIONS ..............................................................................................................2 16

THERMAL FLUID CIRCULATING PUMP .....................................................................................216

REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2 17

REQUIREMENTS FOR WATER COOLED PUMPS ......................................................................... 217

COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2 17

SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................218

TWOPIPE EXPANSION TANK ....................................................................................................218

PRESSURIZED SYSTEMS ............................................................................................................218

VENT CONNECTIONS ..................................................................................................................218

CATCH TANK ............................................................................................................................... 220

DRAIN/FILL CONNECTION .........................................................................................................220

PRESSURE GAUGES ...................................................................................................................222

THERMOMETERS .......................................................................................................................222

VALVES .......................................................................................................................................223

AUTOMATIC FLUID CONTROL VALVES .......................................................................................223

BYPASS VALVES ........................................................................................................................ 223

Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-23

Stack and Flue .................................................................................................... 2-24

Testing ................................................................................................................ 2-25

Operation 3-1

Start-Up Preparation & Installation Review ........................................................ 3-2

Fill the System ...................................................................................................... 3-2

FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................33

FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................33

CIRCULATING PUMP ....................................................................................................................34

PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................35

PUMP WITH PACKED SEAL ..........................................................................................................36

Start-Up Service ................................................................................................... 3-6

Initial Start-Up ..................................................................................................... 3-6

Filtering the System ............................................................................................. 3-7

BOILOUT .......................................................................................................................................38

COMBUSTION ............................................................................................................................... 39

Flame Programmers .......................................................................................... 3-13

FIREYE LINKAGE MODULATION, YB110/E110 ..........................................................................313

SIEMENS LINKAGELESS MODULATION, LMV 51 ...................................................................... 314

Operating Controls ............................................................................................. 3-18

LIQUID LEVEL SWITCH  WHEN COMBINATION TANK IS SUPPLIED ........................................3 19

AIR SAFETY SWITCH ..................................................................................................................319

BLOWER M OTOR STARTER .........................................................................................................319

PUMP M OTOR S TARTE R .............................................................................................................319

DIFFERENTIAL PRESSURE SWITCH ...........................................................................................3 20

HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3 20

GAS PRESSURE SWITCH ............................................................................................................321

OPERATING TEMPERATURE CONTROLS ....................................................................................322

HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................322

HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3 22

OPERATING LIMIT CONTROLLER ...............................................................................................323

MODULATING CONTROLS ..........................................................................................................3 24

PRESSURE GAUGES .................................................................................................................... 324

TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................324

CYCLE TESTING ...........................................................................................................................325

Required Pressure Drop Across the Heater ......................................................... 3-25

Procedure for First Shutdown ............................................................................ 3-26

Daily Start-Up ..................................................................................................... 3-26

Daily Shutdown .................................................................................................. 3-27

Before Leaving the Installation .......................................................................... 3-27

Maintenance 4-1

Required Equipment ............................................................................................ 4-2

Required Maintenance at First Shutdown ........................................................... 4-2

Daily Maintenance Schedule ................................................................................ 4-2

Weekly Maintenance Schedule ............................................................................ 4-4

Monthly Maintenance Schedule .......................................................................... 4-4

Semi-Annual Maintenance Schedule .................................................................. 4-5

Annual Maintenance Schedule ........................................................................... 4-5

General Maintenance Procedures ....................................................................... 4-5

LUBRICATION ...............................................................................................................................45

SOOT CLEANING ..........................................................................................................................46

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

0-1

TABLE OF CONTENTS HPN-IOM-2014-0416

Safety Check Procedures ..................................................................................... 4-6

LIQUID LEVEL SWITCH ................................................................................................................46

STACK LIMIT .................................................................................................................................46

DIFFERENTIAL PRESSURE SWITCH ............................................................................................. 47

LOW INLET PRESSURE SWITCH ...................................................................................................4 7

HIGH INLET PRESSURE SWITCH ..................................................................................................47

HIGH OUTLET PRESSURE SWITCH ...............................................................................................4 7

AIR SWITCH .................................................................................................................................. 48

AIR FILTER BOX SWITCH ..............................................................................................................48

TEMPERATURE LIMITS ..............................................................................................................48

HIGH/LOW GAS PRESSURE SWITCH ...........................................................................................48

Troubleshooting ................................................................................................... 4-9

FLOW CIRCUIT/ CIRCULATING PUMPS ..................................................................................... 49

Warranty & Parts 5-1

Parts ..................................................................................................................... 5-2

Standard Warranty for Fulton Thermal Fluid Heaters .......................................... 5-3

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315)298-5121, or visit us online at www.fulton.com

1-1

INTRODUCTION HPN-IOM-2014-0416 SECTION 3

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

 Material inspections

 Manufacturing process inspections

 American Society of Mechanical Engineers (ASME)

welding inspection

 ASME hydrostatic test inspection

 Electrical components inspection

 Operating test

 Final engineering inspection

 Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the heater. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installersand service personnel. In order to meet Fulton warranty requirements, this unit must be commissioned by a Fulton Factory Technician. Trained personnel are responsible for the operation and maintenance of this product, and for the safety assurance of operation and maintenance processes.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

 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 e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z223.1/NFPA 54 latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section I or Section VIII, Div. 1.

Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jursidictional authorities prior to installation.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-1

INSTALLATION HPN-IOM-2014-0416 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Unless otherwise noted, this heater is certi ed for indoor installation only.

A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.

The equipment must be installed on a non-combustible surface.

Ensure all labels on the heater are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

Placement & Rigging

Proper placement of your Fulton Product (see Figure 2, and Table 1) is essential. Attention paid to the following points will save a great deal of di culty in the future. Correct placement is the  rst step to trouble-free installation, operation and maintenance.

Adhere to the following for equipment placement and rigging:

1. Consult authorities with jurisdiction over any national or local codes (including but not limited to National Fire Protection Agency (NFPA), American National Standards Institute (ANSI), Underwriters Laboratories (UL), SCA, and ASME, which might be applicable to heater applications before beginning.

2. Make appropriate determinations for placement, based on the following:

 Check building speci cations and Table 2 for permissible  oor loading.

 Ensure the equipment is to be placed on a non-combustible level base

with adequate clearances from combustible materials. See Clearances

& Serviceability section.

 Locate heater as close as possible to the place where the heat will be

used in order to keep pipe work costs to a minimum.

 Ensure that there is adequate clearance around the unit to provide

access for operators and maintenance personnel to all parts of the equipment. Ensure also that clearance provides for component removal for maintenance. See Clearances & Serviceability section. The equipment should be placed in a suitable heater house or well ventilated separate room through which personnel do not normally pass. The layout should eliminate tra c in potentially hazardous areas. For instance, the service engineer or the operator should not have to pass exposed, hot pipe work to make adjustments to the heater controls.

4 CAUTION

Do not allow weight to bear on equipment components to prevent damage.

2-2

 Ensure the equipment is to be placed in such a way that the electrical

components are protected from exposure to water or excessive humidity.

3. Determine rigging procedure, based on the following:

 Units are crated for forklift or crane transport. Once uncrated, all units

can be transported with a forklift or crane. All skidded units can be moved with forklifts. Some stand-alone heaters are supplied with lifting lugs.

 If means of lifting are not available, place rollers beneath the frame of the

equipment for guidance to the position of where it is to be installed.

 Under no circumstances allow weight to bear on the jacket, control

panel, burner, fuel train or fan housing of any Fulton heater.

4. Install a 4 inch (102 mm) curb completely around the unit. In the event of a large spill, this will help contain the  uid.

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

Clearances & Serviceability

Adhere to the following for equipment clearances and serviceability:

1. Ensure appropriate front, back, sides and top clearances are met. This will allow access around the equipment to facilitate maintenance and a safe work environment, and ensure technicians will commission the unit. Technicians will not commence commissioning if hazardous conditions exist.

2. Place heater with clearances to unprotected combustible materials, including plaster or combustible supports, not less than the following:

 Heater Front 36” (1m) or more, depending on burner requirements

 Heater Sides 18” (0.5 m), 36” (1 m) on side where panel located

 Heater Rear: enough room for coil to be pulled

 Flue Pipe 18” (0.5 m)

3. Pipes must not be run within 10” (254 mm) of any control cabinets or combustible material.

4. Verify that all clearances are acceptable with the local ordinances.

! WARNING

Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

Environment, Ventilation and Combustion Air Requirements

Ventilation must be su cient to maintain a building temperature of 120°F (49°C) or less. Consistent proper ventilation of the equipment room is essential for good combustion.

NOTE:  When calculating ventilation requirements, heat losses from the Fulton

equipment (and other equipment) should be considered.

Adhere to the following to meet ventilation and combustion air requirements, if installed indoors:

1. Install two fresh air openings, one at a low level, 24” (610 mm) from the  oor, and one at a higher level on the equipment room wall. This will provide a  ow of air to exhaust the hot air from the equipment room.

2. Ensure the burner has an adequate supply of air. Based on NBIC recommendations, unobstructed air openings must be sized on the basis of 0.5 square inch of free area per 1,000 BTU/hr input maximum fuel input of the combined burners in the equipment room or as speci ed by applicable codes.

3. Ensure the equipment room air supply openings are kept clear at all times.

4. See Table 3 for minimum make-up air required and the recommended area of each opening for each model.

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-3

INSTALLATION HPN-IOM-2014-0416 SECTION 2

TABLE 1  SPECIFICATIONS AND DIMENSIONS

Speci cations MODEL 100S 200S 350S 600S 800S 1000S 1200S 1400S 1600S 2000S 2400S 3000S 4000S

Heat Output Million BTU/hr 1 2 3.5 6 8 10 12 14 16 20 24 30 40 Flow Rate-Standard *1 GPM 75 150 265 425 600 725 900 1050 1200 1500 1800 2250 3000 Flow Rate-Low Flow *2 GPM 40 75 135 225 300 375 450 525 600 750 900 1125 1500 Circulating Pump Motor - STD HP 7.5 15 20 30 40 50 60 75 100 100 125 150 200 Circulating Pump Motor - LF HP 7.5 7.5 15 20 30 30 40 30 40 50 60 75 100 Blower Motor HP 1/3 1 2 7.5 10 10 5 7.5 7.5 15 20 25 30 Light Oil (approx. fuel usage)*3 GPH 8.8 17.5 30.6 52.5 70 87.5 104.9 122.4 139.9 174.9 209.8 262.3 349.7 Natural Gas (approx. fuel usage)*3 FT3/hr 1,334 2,667 4,667 8,000 10,667 13,334 16,000 18,667 21,334 26,667 32,000 40,000 53,334 Pressure Drop - STD PSI 10 23 11 16 16 13 16 10 15 14 15 9 21 Pressure Drop - LF PSI 15 19 11 14 15 18 14 11 15 20 14 12 17

Dimensions MODEL 100S 200S 350S 600S 800S 1000S 1200S 1400S 1600S 2000S 2400S 3000S 4000S

(A) Overall Height (w/o Stack) IN 51 60 62 82 82 105 105 106 106 125 133 133 142 (B) Overall Width IN 42 50 50 74 93 87 103 110 110 123 130 130 142 (C) Overall Length IN 115 152 211 231 302 311 360 408 444 450 550 575 64 8 Inlet/Outlet Connections IN23346688810121212 Thermal Liquid Volume GAL 45 86 168 426 661 724 853 1168 1400 1721 2322 3180 4626 Approx. Dry Weight LBS 3,936 6,800 9,052 14,350 18,500 23,100 26,800 30,500 32,600 41,400 68,000 74,000 80,000 Ap pr ox . F lo od ed We ig ht LB S 4, 310 7, 514 1 0,4 47 17, 88 6 2 3, 98 7 29,11 0 3 3, 88 0 4 0, 195 4 4, 220 5 5, 68 5 8 7,2 73 10 0, 39 4 118 ,3 96 Floor Loading LB/FT3 129 143 143 151 123 155 132 129 131 145 176 194 186

Note: All dimensions are approximate. Please consult factory for your job speci c drawings with dimensions.

2-4

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

TABLE 2  APPROXIMATE FLOOR LOADING

BASED ON OPERATING WEIGHT

Model Heater Only

(lbs/ft2)

100 129

200 143

350 143

600 151

800 123

1000 155

1200 132

1400 129

1600 131

2000 145

2400 176

3000 194

4000 190

FIGURE 2  DIMENSIONS

TABLE 3 MINIMUM MAKEUP AIR REQUIREMENTS AND RECOMMENDED AREA OF OPENING

FOR VENTS

Model Minimum Make-Up

Air (SCFM)*

100 300 600 200

200 600 1200 400

350 1000 2000 667

600 1800 3600 1200

800 2300 4600 1534

1000 2900 5800 1934

1200 3500 7000 2334

1400 4000 8000 2667

1600 4600 9200 3067

2000 5800 11600 3867

2400 6900 13800 4600

3000 8600 17200 5734

4000 11500 23000 7667

* Minimum make-up air requirements are based on 25% excess air at high  re.

** Opening areas are calculated based input of a single heater and do not

account for the ventilation needs of the equipment room. These measurements

are subject to state and local regulations.

Opening Area (in2)**

Lower Vent

Opening Area (in2)

Upper Vent

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-5

INSTALLATION HPN-IOM-2014-0416 SECTION 2

! WARNING

A quali ed installer, service agency or the gas supplier must perform installation and service on the fuel delivery system.

Do not use matches, candles,  ame or other sources of ignition to check for gas leaks.

What to do if you smell gas: Do not try to light the appliance. Do not touch any electrical switch. Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the  re department.

When making gas piping joints, maintain proper ventilation to reduce breathing hazards.

An exhaust fan may draw products of combustion into the work environment creating a possible hazard to personnel.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment.

5. If positive forced ventilation is adopted, ensure that there will be no appreciable pressure variation in the equipment room.

6. Avoid ventilation which creates a negative pressure in the building as it will seriously a ect combustion and proper operation of the stack. Please note that exhaust fans or similar equipment can create a down draft in the chimney or starve the burner’s air supply. Either case may result in poor combustion or nuisance failures. A properly designed make-up air system in the equipment room will preclude these possibilities and is required to maintain proper combustion.

NOTE:  A properly designed make-up air system in the equipment room will

preclude these possibilities and is required to maintain proper combustion.

7. Eliminate potential for high risk situations for particulate matter to be in the combustion air supply (e.g., as a result of construction and maintenance activities).

Utilities

 The Gas Supply

Adhere to the following for gas supply installation:

1. Install gas piping in accordance with all applicable codes.

2. Ensure pipe and  ttings used are new and free of dirt or other deposits.

3. Ensure piping is of the proper size for adequate gas supply to the gas head assembly. Consult your gas company for speci c recommendations.

4. When making gas piping joints, use a sealing compound resistant to the action of lique ed petroleum gases. Do not use Te on tape on gas line heads.

4 CAUTION

It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the combustion air inlet must be piped to an outside location. Failure to do so will void the warranty.

To avoid failures due to poor combustion, ensure make-up air system is properly designed.

2-6

5. Ensure no piping stresses are transmitted to the equipment. The equipment shall not be used as a pipe anchor.

6. Ensure all vent connections on diaphragms, gas valves, pressure regulators, and pressure switches (gas- red units) are vented per local code.

7. On gas- red units with NFPA valve trains, ensure the vent valve is piped to atmosphere per local code.

8. During any pressure testing of the system at pressures in excess of 1/2 psig (14 inch W.C.)., disconnect the heater at the heater manual shuto valve (located at the end of the supplied gas train) from the gas supply piping system.

9. Ensure the supply pressure is regulated by a non-stacking, tight, shut-o regulator.

10. Arrange gas piping so that it does not interfere with any cover or burner, inhibit service or maintenance, or prevent access between unit and walls

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

or another unit.The burner assembly and gas controls terminate at a manual stop valve to which the gas supply should be connected. Piping must be sized for a gas  ow consistent with the required BTU/Hr input. Large pressure drops must be avoided. Fulton recommends that the supply piping between the pressure regulator and the inlet to the heater be kept to a minimum. The minimum required gas pressure at the stop valve varies with the model of heater.

NOTE:  Even when the unit is shut down, the gas supply

pressure must never exceed these values.

11. Some fuel train con gurations are require a safety relief valve which must be piped to a safe area in accordance with local codes.

12. After gas piping is completed and before wiring installation is started, carefully check all piping connections, (factory and  eld), for gas leaks. Use a soap and water solution.

 The Oil Supply

the fuel oil pump inlet per the National Fire Protection Association (NFPA).

NOTE:  If for some reason the pressure of the fuel supply will

exceed NFPA maximum,  tting a regulator to the fuel line must be considered, e.g. when there is a tank situated with an oil level eight feet (2.4 m) or more above the pump.

5. On units  tted with NFPA controls, ignition is obtained by means of a gas pilot. A natural gas or LP supply is required for these units. The required gas supply pressure is 7” w.c. If a guaranteed supply of natural gas is not available, then a supply of bottled gas at 11“w.c. is required. For details contact a local liquid propane dealer.

Instrument Air

Instrument air provision for pneumatically actuated control devices should meet the minimum and maximum  ow rate and delivery pressures speci ed by the individual equipment. Additionally, it should be a dry, dust-free,water-free, and oilfree supply with a dew point of -40°F (-40°C).

Fuel Oil Viscosity Speci c Gravity Sulfur Content

#2 Less than

31.9 Seconds

Redwood #1 at

100°F (38°C)

#4 Less than

81 Seconds

Redwood #1 at

100°F (38°C)

#6 Less than 3000

Seconds Redwood #1 at 100°F (38°C)

0.824 to 0.852 at

59 C (15°C)

0.90 to 0.93 at 59

C (15°C)

0.95 to 0.98 at 59°F (15°C)

less than 0.40%

by weight

less than 0.1.6%

by weight

less than 2.12% by weight

Adhere to the following for installation:

1. Fuel pipes must be of approved materials and of a diameter suitable for the quantity of oil being delivered to the burner and the static head available.

2. Make fuel connection in accordance with the details on the enclosed fuel pump cut sheet.

3. Ensure fuel oil piping is in accordance with local and/or national requirements. In addition, if a two pipe system is employed, a check valve must be  tted into the return pipe.

4. Do not exceed the 3 psi maximum pressure allowed at

Electrical Supply

Adhere to the following for electrical supply installation:

1. Install wiring and ground in equipment in accordance with authority having jurisdiction or in absence of such requirements the National Electrical Code, ANSI/NFPA 70.

2. Provide a wall-mounted, fused disconnect sized for the unit. This must be  tted by the client/contractor if disconnect is not supplied on the panel.

3. Size fuses according to motor name plates and local electrical codes.

4. Connect power to the terminal strip as supplied on the inside of the panel box.

NOTE:  Single skid systems are generally shipped completely

prewired.

NOTE:  The liquid level switch on the expansion tank, when

supplied, will be shipped in the parts box and must be installed in the  eld.

5. Determine multiple skid systems wiring requirements (between the skids). Fulton will run conduit and wire the devices on each skid. For the devices that have to

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-7

INSTALLATION HPN-IOM-2014-0416 SECTION 2

2” NPT Gas Connection

Manual Gas Valve

Pilot Gas Valve

HI/LOW Gas Pressure Switch

Main Gas Regulator

Gas Safety Shutoff Valve

FIGURE 3  TYPICAL GASFIRED FUEL TRAIN

come down for shipping, the wire will be left at the end Locate electrical schematic diagram, a copy of which is inside of the panel box. Ensure the information on the electrical drawing corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over-or under-voltage exceeding 10% of the nominal value.

NOTE:  Normal supply will be 460 volts, 3 phase, 60 Hz, AC

unless otherwise speci ed.

Thermal Fluids

 Thermal Fluids at Elevated Temperatures

Personnel must be familiar with the nature of potential hazards when working with thermal  uids at operating temperatures. Unlike steam or high-pressure water systems, thermal  uid attains extremely high temperatures without a corresponding increase in pressure.

Manual Gas Valve

Adhere to the following:

1. Be aware that certain types of thermal  uid may have operating temperatures reaching 650°F (345°C) and above, so all exposed pipework is hazardous and should be insulated.

2. Check that  anged joints are tight during and after the  rst warming up of the system. Turn burner and pump o before  ttings are tightened. After these checks, exposed hot  anges, pumps, valves and  ttings should be  tted with some sort of shield.

3. Remember that there is pressure generated in the system by the circulating pump. Care should be exercised when opening any drain or vent valves in the system. This is especially important during commissioning, when any air trapped in the system is vented at high points, and when water, which will  ash into steam, is either expelled from the deaerator vent or drained o at low points.

2-8

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

 Selecting a Thermal Fluid

The selection of the thermal  uid most suited to your application is very important. Factors to be considered include e ciency, thermal stability, adaptability to various systems, and physical properties, including vapor pressure, freezing point, and  ash and  re points.

Heat transfer  uids of both mineral and synthetic origin have been specially developed to give thermal stability over a very wide range of temperature. A wide variety of thermal  uids have been used successfully in Fulton Thermal Fluid Heater systems, however, your  nal selection should be made in conjunction with recommendations from Fulton or the  uid manufacturer.

Consider the following for thermal  uid selection:

1. The Fulton coil design heater is a  red heat exchanger and the safe control and monitoring of the thermal  uid temperature is of paramount importance.

2. The safe maximum bulk temperature of the  uid must be strictly adhered to. The safe maximum temperature of the  uid varies.

3. Special care must be taken when consulting  uid manufacturers’ literature, as maximum  uid temperatures quoted are the actual limit to which any of the  uids may be subjected. It is important to remember that in any  red heater there exists a “ lm temperature” which is higher than the temperature of the “bulk” of the  uid. It is the BULK  uid temperature and NOT the FILM temperature that is indicated by the instruments.

4. As a general guide, the following list of  uids that have given satisfactory service over many years is provided. This is by no means a complete list. Any  uid speci cally designed for heat transfer use may be considered; multipurpose oils are not acceptable.

! WARNING

The vent line connection on the gas pressure regulator must be piped to outdoor air by the installer in accordance with National Fuel Gas Code, ANSI Z223-1-1991 or latest addenda. In Canada, gas installations must be in accordance with the current CAN/CGA B149.1 and 2 and/or local codes.

If a  re does occur, extinguish using CO2 foam or dry chemical. Do not use water.

4 CAUTION

Proper selection of thermal  uid is critical to system performance.

 AMOCO Transfer Oil 4199

 CHEVRON

 DOW G

 EXXON 43

 MOBIL

 MONSANTO

 MULTITHERM

 PARATHERM

 PETROCANADA T

 SHELL

 TEXACO

5. Any  uid speci cally designed for heat transfer use must also exhibit these characteristics:

 Be a stable and homogenous liquid to a temperature of at least 100°F

(38°C) over and above the maximum intended temperature of utilization, compatible with metals used in the installation, and tolerating contact

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-9

INSTALLATION HPN-IOM-2014-0416 SECTION 2

! WARNING

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

Some plastics can be dissolved by thermal  uid.

If excessive amounts of thermal  uid are vented from the system, additional thermal  uid may be required in the system. Contact Fulton for further assistance.

with atmospheric air.

 No solid matter in suspension.

 Non-toxic in the case of leakage.

 Su cient lubricity, i.e. not likely to cause seizure.

6. The thermal  uid manufacturer must guarantee the characteristics of the product, and verify that the  uid bulk temperature limitation exceeds the expected operating temperature. After a  uid is selected, refer to the manufacturer’s recommendations, published in compliance with the Occupational Safety and Health Administration (OSHA).

7. If the  uid expansion volume from 50°F to 600°F (10°C to 316°C) exceeds 20% of the initial  uid volume, consult Fulton.

 Routine Analysis of Heat Transfer Fluid

Nearly all leading manufacturers of heat transfer  uids provide an after sales service to monitor the condition of the  uid in operation and make recommendations when replacement becomes necessary.

Each  uid manufacturer has procedures for regular testing and analysis of the  uid. These usually allow for a sample to be taken and analyzed at least once a year, although actual frequency will depend on operating temperature, number of hours operated weekly, and the results of tests made during the  rst weeks of system operation.

Fulton recommends that the thermal  uid in your system be analyzed within the  rst two months after startup and annually thereafter.

During the  rst few months of operation, sampling may be carried out at frequent intervals to con rm that system performance has been predicted correctly.

If the supplier of your thermal  uid does not contact you within four weeks of commissioning, contact the supplier and make certain that the “ ll” is registered for routine analysis.

 Thermal Fluid Breakdown

The possibilities of thermal  uid breakdown are very slim in a typical closed loop thermal  uid system. Fulton’s combination expansion/deaerator/thermal bu er tank creates a “cold seal” of  uid that is slightly above ambient temperature. This prevents oxidation that will otherwise happen when high temperature  uid contacts air.

Oxidation of the  uid will also occur when hot thermal  uid contacts air at a leak in the system piping. Oxidized thermal  uid becomes acidic and will damage the thermal  uid system. Thermal  uid breakdown can occur in sections of piping where there is a low  ow condition. A low  ow rate through the heater will result in high  lm temperatures leading to breakdown of the thermal  uid.

2-10

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

 THERMAL FLUID BREAKDOWN PREVENTION

 Multiple pressure switches and a di erential pressure switch are used to

prevent this condition from occurring. These safeties must not be bypassed at any time.

 Exceeding the maximum operating temperature of the thermal  uid will

also result in thermal  uid breakdown. Fulton heaters are equipped with a temperature limit switch (located on the front of the panel box) to prevent this from occurring.

 A high temperature limit switch is an over temperature safety device.

If the high temperature limit shuts down the unit, the manual reset button on the limit switch must be pressed. The reset button on the  ame programmer must also be pressed to reset the unit before it can be restarted. Refer to Maintenance section of this manual for troubleshooting activities.

Piping Speciﬁ cations

For piping, the basic considerations are: the design temperature, the pressure retained by the pipe, the  uid in the pipe, the load resulting from thermal expansion or contraction, impact or shock loads imparted such as water hammer, external loads, wind loads and vibration from equipment.

! WARNING

Fulton is not responsible for any injury or damage caused by the use of inadequate  uid.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

Adhere to the following for piping installation:

1. Ensure the arrangement of the piping and its appurtenances takes into consideration the location of other structures and equipment adjacent to the piping, which may result in freezing interference and/or damage as a result of expansion, contraction, vibration, or other movements.

2. Consider the appropriate location and orientation of valves necessary for safe operation and isolation of the piping. Valves are used in piping systems to stop and start the  ow of  uids, to regulate  ow, to prevent the back  ow, and to relieve excessive pressure build up in the piping.

3. Ensure all piping and piping components are suitable for the design temperatures, pressure and  uid used in the system.

4. Ensure all components exposed to thermal  uid  ow, including pipe, valves, and screens, are not copper, copper alloys, bronze, brass, aluminum, or cast iron. Cast iron is porous to thermal  uids, and copper and aluminum act as catalysts in the degradation of some thermal  uids. Carbon or stainless steel, or ductile iron, are recommended.

5. Ensure all pipework is constructed from seamless mild steel pipe, conforming to ASME SA 106B or SA 53B, Schedule 40 or Schedule 80 or equal, as required based on the design temperature and pressure of the system.

6. If an isolating valve is completely closed, the pressure in the system will rise to the deadhead pressure of the pump. Suitably sized pipe will enable the system to withstand the total head generated by the circulating

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-11

INSTALLATION SECTION 2

! WARNING

If a  re does occur, extinguish using

, foam or dry chemical. DO NOT

USE WATER.

4 CAUTION

Some plastics may be dissolved by thermal  uid.

pump, should this occur. In applications where it is desirable to design to pressures lower than 100 psig, an alternative safeguard is to install appropriately sized safety valves.

7. Where secondary circulating pumps are installed, ensure the system is suitable for the aggregate head, against a closed valve, of both pumps.

8. During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system.

9. Consider expansion joints or pipe loops to accommodate thermal expansion. Design should be per latest edition of ASHRAE Systems and Equipment Handbook to prevent detrimental forces and stresses at connected equipment. Thermal expansion should be calculated using the maximum possible utilization  uid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will grow axially and can be expected to expand approximately 1” over 100ft @ 100dg°F temperature rise (1mm per meter over 100 C rise).

10. Provide properly designed supports and anchors for all piping where necessary to prevent undue stress from being imparted on equipment such as pumps, valves and the heater. Care should be taken as end reactions transmitted to rotating equipment, such as pumps, may deform the equipment. Therefore equipment manufacturers’ recommendations on allowable forces and movements should be followed. Ensure all pipe joints are of either welded or  anged construction. Screwed joints must be avoided where possible. In no instance should screwed joints be used in the  ow circuit. All  anges should be welded to the pipe and not screwed. Depending on the size,  anges should be 150# or 300# raised face  anges, SA105. See Figure 4.

11. Ensure heaters that are skid mounted with pumps and tanks are equipped with a y-strainer, a  ex connector and a valve in the inlet run between the pump and the combination tank. Piping between the discharge of the pump and the inlet of the heater will include a  ex connector and a valve.

12. If screwed connections have to be made, e.g., to items of control equipment, use a thread sealant suitable for use with  uids at elevated temperature. Te on tape, standard pipe sealant, or hemp and paste are not acceptable.

13. Cut screw threads carefully and accurately. If possible, new tools should be used. Threaded connections larger than 1” are not to be used. It is recommended that GR5 or higher tensile steel bolts be used for all  anged joints.

14. Use gaskets to make all  anged connections. Gasketing material must be suitable for use with the pressure, temperatures and  uids in the system. Flexible graphite gaskets are suited for most applications. Recommended gasket thickness is 1/10 - 1/8 inch. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. Refer to Tables 4 - 7 and Figure 5 for guidelines.

2-12

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

NOTE:  Typical gaskets used by Fulton include JM Clipper Elastograph gaskets and

Flexitallic gaskets. Adhere to installation instructions and torque requirements for these gaskets.

15. Install high point bleeds at all high points in the system piping. 1/2” x 12” nipples welded in the top of the piping with ball valves and plugs attached are to be used.

NOTE:  It will save a considerable amount of time during the cold  ltration if the

system piping is cleaned prior to assembly. The mill scale (the results of oxidation) on the inside of the piping as well as construction debris can foul the  uid and cause the need for the  lters (strainers) to be cleaned more than need be. This can range from simply using a rag to ordering pickled pipe. (“Pickling” is a process where the piping is  rst soaked in an acid bath, then soaked in a neutralizing bath, then given a protective oil coating.)

16. Install all pipes with a pitch to facilitate draining and venting.

TABLE 4  RECOMMENDED GASKET LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 150#

GASKETS SAE GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 45

3/4 4 1/2 45

1 4 1/2 45

1 1/4 4 1/2 45

1 1/2 4 1/2 45

2 4 5/8 90

2 1/2 4 5/8 90

3 4 5/8 90

3 1/2 8 5/8 90

4 8 5/8 90

5 8 3/4 150

6 8 3/4 150

8 8 3/4 150

10 12 7/8 240

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

! WARNING

Fulton is not responsible for any injury or damage caused by the use of inadequate  uid.

4 CAUTION

The weight of all piping must be properly supported. Failure to support piping may result in equipment damage and/or system leakage.

Piping must take into consideration potential for freezing interference and/ or damage as a result of expansion, contraction, vibration, or other movements.

Dirt, water, and/or other debris in the piping system after welding may result in equipment failure.

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-13

INSTALLATION HPN-IOM-2014-0416 SECTION 2

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

TABLE 5  RECOMMENDED LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 300# GASKETS

SAE GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 45

3/4 4 5/8 90

1 4 5/8 90

1 1/4 4 5/8 90

1 1/2 4 3/4 150

2 8 5/8 90

2 1/2 8 3/4 150

3 8 3/4 150

3 1/2 8 3/4 150

4 8 3/4 150

5 8 3/4 150

6 12 3/4 150

8 12 7/8 240

10 16 1 368

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

TABLE 6  RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 150# GASKETS SAE

GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 30

3/4 4 1/2 30

1 4 1/2 30

1 1/4 4 1/2 30

1 1/2 4 1/2 30

2 4 5/8 60

2 1/2 4 5/8 60

3 4 5/8 60

4 8 5/8 60

5 8 3/4 100

6 8 3/4 100

8 8 3/4 100

10 12 7/8 160

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

2-14

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

TABLE 7  RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 300# GASKETS SAE

GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 30

3/4 4 5/8 60

1 4 5/8 60

1 1/4 4 5/8 60

1 1/2 4 3/4 100

2 8 5/8 60

2 1/2 8 3/4 100

3 8 3/4 100

4 8 3/4 100

5 8 3/4 100

6 12 3/4 160

8 12 7/8 245

10 16 1 160

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

Insulation

After the appropriate system tests have been satisfactorily completed (see Testing section of this manual), all hot pipework and vessels must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury.

Adhere to the following for insulation installation:

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the section of the chimney duct within the building should be insulated.

Due to extremely high operating temperatures of the thermal  uid, all exposed pipework should be insulated, and exposed hot  anges, pump, valve, and  ttings should be shielded. Refer to Insulation section of this manual for details.

1. For inspection and maintenance purposes, leave pumps,  anges, valves and  ttings uninsulated but suitably shielded for safety.

2. Insulate the deaerator section of the combination tank.

3. Do not insulate the thermal bu er and expansion sections of the combination tank. On units operated with inert gas blankets above the  uid in the expansion tank, the entire combination tank, including the expansion and thermal bu er sections, may be insulated but it is not necessary.

4. Ensure hot oil pipe insulation is a minimum of 2” (51 mm) thick, high temperature, laminated, foamglass cellular glass insulation as manufactured by Pittsburgh Corning Corporation or equal.

System Interfaces

Proper selection and installation of the components in the hot oil system will ensure proper and safe operation of the heater.

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-15

INSTALLATION HPN-IOM-2014-0416 SECTION 2

 Heater Connections

Adhere to the following for heater connections:

1. Connect the outlet of the pump directly to the inlet of the heater via an isolating valve (preferably a throttling valve) and pump  exible connector.

2. Pipe heater outlets directly to the system via an isolating valve.

3. A safety relief valve may be shipped in the parts box accompanying the fuel- red heater, and must be installed in the outlet manifold. On all units, the outlet must be piped to a safe discharge area. The piping from the outlet of the safety valve must be piped to a catch tank. The discharge  ow must not be restricted, i.e. no valve should be installed. The weight of the piping must be properly supported in order to prevent damage to the safety valve. If the valve body becomes warped, leakage may result.

 Thermal Fluid Circulating Pump

Installing the pump in accordance with the manufacturer’s speci cations and these instructions will prolong the life of the pump and contribute signi cantly to the successful operation of your Fulton heater system. The pump manufacturer’s installation and operation instructions can be obtained from the manufacturer.

Adhere to the following for pump installation:

1. Locate pump adjacent to the heater. Its base must be  rm, level (preferably concrete), and free from vibration.

2. Route pump per the manufacturer’s requirements. It should be equipped with  exible connections at the suction and discharge sides. The primary function of these connections are to prevent stresses due to pipe expansion from being placed on the pump and to isolate pump vibrations from the pipe work and the heater. They also allow for expansion and de ection of the pipe work. These connections should be rated for high temperature since they are considered part of the piping system.

3. Connect suction pipe work directly to the deaerator section via a vertical run with as few elbows as possible. It should contain the strainer and an isolating valve. The discharge pipe work must be connected directly to the heater inlet, and should contain an isolating valve. See that pipe work connections match up accurately with pump  anges. Refer to the pump manufacturer’s recommendations for the speci c pump inlet piping

requirements. Typically these requirements are that:

 It be a straight run of pipe.

 The straight run from the pump inlet to the  rst

 tting, valve, or  ex connector be a minimum of 6-10 pipe diameters in length.

 The pipe used should be the same size as the inlet of

the pump.

 The piping in the immediate vicinity of the pump

must not be supported by the pump. The pump is not designed to bear the weight of the piping, and weight on any part of the pump will throw it out of alignment.

 Proper alignment directly a ects bearing, coupling,

and seal life expectancy. The pump is properly aligned before it leaves the factory. Because the system expands in operation, pump must be realigned when the system is at operating temperature.

 The coupling alignment of the pump and driver must

be carefully checked for angular and axial alignment. Check pump manufacturers instructions for these speci cations. The use of a dial indicator to check the axial and angular alignment is recommended.

 An air cooled pump does not have an oiler. This type

of pump has a sleeve bearing which is, like the seals, lubricated by thermal  uid. An air cooled pump has a grease nipple located at the drive end of the pump near the coupling connection. This comes pre-greased, and should be greased at intervals as recommended by the manufacturer.

 An oiler is shipped with each water cooled pump and

it should be  lled with a lubricating oil recommended by the manufacturer. The suggested lubricant is usually SAE-30 non-detergent oil.

 Thermal  uid is not su cient lubrication for bearings.

 All seals on air cooled pumps are lubricated by

thermal  uid, therefore the pump must never be run dry, i.e., without thermal  uid in it.

 Filling a pump equipped with either a Grafoil packed

or mechanical seal with thermal  uid will ensure lubrication. However, in order to be certain that all seals on an air cooled pump are coated with thermal  uid, the pump must be bled.

 Grafoil packings require a run-in procedure. Typically,

pumps with these seals are shipped with four or

2-16

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

Pipe Must Be Diameter of Pump Intake

Pump

Pipe Support Must Be Provided (Not To Be Welded On Both Ends)

6 - 10 Pipe Diameters

FIGURE 4  TYPICAL PUMP PIPING

From Outlet of Deaerator

 ve rings installed and several rings loose. These extra rings must be on hand for the initial run-in procedure. See manufacturer’s instruction manual for this procedure.

First Fitting

FIGURE 5  BOLTING SEQUENCE FOR 4 AND 8 BOLT FLANGES

2. Check local codes regarding disposal of hot water.

 Combination Deaerator/Thermal Buﬀ er/

Expansion Tank

 Requirements for Air Cooled Pumps

Adhere to the following for air cooled pumps (See Figure

6):

1. Allow for free air  ow around the entire pump casing at all times.

2. Maximum room temperature should be 100°F (38°C).

3. In no case should any part of the drive side of the pump be insulated.

4. Maximum operating temperature for air cooled pumps varies by manufacturer. Consult instruction manual to verify.

 Requirements for Water Cooled Pumps

Adhere to the following for water cooled pumps (See Figure 7):

1. Requirements for water cooled pumps will vary with manufacturer. Consult manufacturer’s instructions for  ow rate and temperature requirements.

Fulton’s e cient design combines the operation of the expansion, deaerator, and thermal bu er tanks. Installation is considerably simpli ed by virtue of this arrangement.

The expansion section is vital to the thermal  uid system. From ambient to operating temperature, the thermal  uid in the system will typically expand in the range of 25% to 50%, and a vessel capable of handling this expansion is mandatory. The customer should con rm the expansion rate of the chosen  uid and system volume.

At start up, the primary purpose of the deaerator section is to remove all volatiles from the system to avoid pump cavitation. The deaerator section also allows air to be vented from the system on a continuous basis during operation to avoid oxidation of the thermal  uid, and removes other volatile particles generated by the  uid itself during system operation. This section of the tank must be insulated.

A system of interconnecting pipe work in the thermal bu er tank section prevents the movement of any oil that has not cooled su ciently into the expansion section. This avoids contact of very high thermal  uid temperature with oxygen contained in the atmosphere, which causes  uid breakdown. DO NOT insulate this section.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-17

INSTALLATION HPN-IOM-2014-0416 SECTION 2

 Sizing The Expansion Tank For The System

Expansion tank capacity is the total volume of the tank (see Figures 8 and 9). It is necessary to have some air space available at the top of the tank to avoid spillage or over ow. At initial  ll (for system volume calculations) the deaerator and cold seal sections must be  lled completely and the expansion section must be  lled to a level of 4 inches (102 mm) to “make” the liquid level switch.

The volume between the initial  ll level and the safe “full” level is the amount available for expansion. That volume is used to decide which tank is suitable for the system expansion.

 SIZING EXAMPLE

A system contains 175 gallons, including the heater, but not the tank. You select the FT-200-L, so you add 25 gallons to 175 for a total of 200 gallons.

You look up the expansion rate for the thermal  uid. (Assuming it is 25%), 200 gal. x 1.25 = 250 gallons, 250-200 = 50 gallon expansion.

may be used at start-up to remove air and water from the system, and then valved appropriately during operation to provide expansion capacity for the system.

 Pressurized Systems

Nitrogen pressurization may be used if the total system content is very large, or in a system operating near or above the vapor pressure of the  uid employed, or if the inlet of the DA tank is not the highest point in the piping system, or at any time to further protect the  uid from oxidation.

In conjunction with this system, adhere to the following:

1. An automatic venting device must be  tted to the system expansion tank. Consult Fulton for further details.

2. The location for the liquid level switch (Figure 10) is a 2-1/2” NPT connection on the same end of the tank as the inlet. The liquid level switch is supplied and shipped with the unit, and must be installed by the customer and then wired to the control panel.

The FT-200-L has only 46 gallons available for expansion, so the correct selection is the FT-500-L.

Adhere to the following for installation:

1. Install tank in accordance with Fulton’s speci cations.

2. Unless the system is pressurized, the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping.

3. Take into account the head required at the circulation pump suction inlet to avoid the possibility of pump cavitation.

4. In systems operating close to maximum  uid temperature, ensure the tank is elevated enough, possibly well above the highest point in the system, to prevent pump cavitation by increasing the static head. An inert pressurizing blanket may be considered as an alternative. See Pressurized Systems section of this manual.

5. Provide supports for tank mounting. These should be suited for supporting the tank by the side rails. The eyelets  tted to the tank are for lifting only.

3. If the tank is located outdoors, nitrogen is required.

 Vent Connections

Adhere to the following for vent connections:

1. Make vent connection in a manner that will prevent penetration of water or foreign bodies into the tank. This connection must always terminate in a safe, well ventilated area and has to be free of obstruction, open to atmosphere, and arranged in such a manner that, in the event of discharge from the system, thermal  uid could drain into a catch tank without danger to personnel or property.

2. Make the vent run the same size as the tank outlet. It should run pitch down from the outlet of the tank to the catch tank.

3. If nitrogen is used on the system, the vent can be reduced to 2” (51 mm) and should be piped with a positive closing valve at the catch tank.

4. Ensure the connection between the tank outlet and the horizontal pump inlet is as close to a vertical drop as possible. It should have the minimum bends and length of pipe.

 Two-Pipe Expansion Tank

An alternate con guration is the 2-pipe expansion tank. This

2-18

5. Ensure the inlet to the deaerator is higher than or equal to the highest point in the system, or a pressurized

SECTION 2 HPN-IOM-2014-0416 INSTALLATION

1/8” NPT

GREASE FITTING

1/4” X 1/8”

KEYWAY

3/8” NPT BEARING GREASE

3/8” NPT BARRIER OIL

FILLMECH. SEAL ONLY

RELIEF AND LIP SEAL FAILURE DETECTION

1/8” NPT VENT

PUMPAGE

LEAK DETECTION

MECH. SEAL ONLY

DISCHARGE

1/2” NPT CASING DRAIN

WHEN SPECIFIED

FIGURE 6  TYPICAL AIR COOLED PUMP

1/2” NPT DISCHARGE

GAUGE CONNECTION

WHEN SPECIFIED

SUCTION

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 7  TYPICAL WATER COOLED PUMP

system must be used.

6. Field-install the liquid level switch (supplied and shipped with the unit). This must be wired to the control panel.

7. Ensure test connections are accurate. The high and low level test connections are 1/2” NPT, and are located on the end of the tank opposite the inlet. The low level is on the center line of the expansion tank, the high level is next to it, slightly o center. The high level rises up from the bottom of the tank and ends 4” (102 mm) below the top; the low level rises 2” (51 mm) from the bottom of the tank.

8. Both the high and low level connections should be piped to a safe catchment. Valves should be installed in these lines at the catch tank. Installation of the valves should be accomplished in such a manner that any  ow will be visible when the valves are open.

9. Flow from the high level test connection indicates a tank that is too full; no  ow from the low level test connection indicates too little  uid.

10. There is a 300 #, raised face,  anged drain on the bottom of the thermal bu er section, for the purpose of draining the tank when necessary. This should be piped with a valve in the line, to a safe catchment. The valve speci cations outlined above apply to this valve as well.

Questions? Call (315)298-5121, or visit us online at www.fulton.com

2-19

INSTALLATION HPN-IOM-2014-0416 SECTION 2

11. An inspection opening is located at the highest point on the tank. Access to this port is recommended but not required.

12. Refer to the maintenance schedule for recommendations on draining the bu er tank. For positioning of all connections on tank, see Figure 9.

 Catch Tank

Adhere to the following for the catch tank:

1. Ensure the heater safety relief valve outlet and connections on the DA tank are piped to a safe catch tank. The catch tank must be appropriately sized based on the system volume and con guration.

2. Under normal operating conditions, the catch tank should be empty. Fluid that is expelled into the tank should not be reintroduced into the system.

3. Ensure the vent from the catch tank is located and installed in such a manner as to protect personnel and property from discharge of steam, water, and thermal  uid. Vent outlet should be positioned in a safe location outside the heater room.

 Drain/Fill Connection

The system is usually  lled from the lowest point, with the aid of a pump. On skid-mounted units, a drain and  ll connection is provided in the inlet piping to the pump. See Figure 11.

Vent for Piping

to Safe Catchment

Expansion

Tank

Expansion

Volume

Liquid

Level

Switch

Model Capacity (gallons) Initial Fill (gallons) Available for

FT-200-L 52 25 46 184

FT-500-L 132 40 121 525

FT-1000-L 264 80 232 1000

FT-1500-L 397 90 380 1400

FT-2000-L 528 145 444 1700

FT-3000-L 793 215 717 2600

FT-5000-L 1310 300 1168 4600

Fluid In

Deaerator

Section

Fluid Out

FIGURE 8  EXPANSION TANK DETAILS

Drain

Expansion (gallons)

Thermal Buffer Section

Hot Fluid

Medium Fluid

Cool Fluid

Gases (Steam)

Max System

Volume

2-20

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Fulton Hopkins Horizontal Coil Thermal Fluid Heater User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual