Fulton Vertical Coil User Manual

INSTALLATION AND

OPERATION MANUAL

Vertical Coil Design

Thermal Fluid Heaters

Models FT-C and FT-S

Serial / National Board Number

Model

Fulton Order

Sold To

Job Name

Date

FTCS-IOM-2013-1114

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE PARTS & WARRANTY

3 4 5

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

1-1

INTRODUCTION FTCS-IOM-2013-1114 SECTION 1

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 installers and 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 Z2231/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 VIII, Div. 1 or Section I. It is the responsibility of the customer to ensure equipment conforms to requirements and codes.

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

FTCS-IOM-2013-1114 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 ............................ 2-4

Utilities ................................................................................................................. 2-7

THE GAS SUPPLY ..........................................................................................................................2 7

THE OIL SUPPLY .........................................................................................................................210

Instrument Air .................................................................................................... 2-10

Electrical Supply ................................................................................................ 2-11

Thermal Fluids .................................................................................................... 2-12

THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................212

SELECTING A THERMAL FLUID ..................................................................................................212

ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2 14

THERMAL FLUID BREAKDOWN .................................................................................................214

Piping Speci cations .......................................................................................... 2-15

Insulation ........................................................................................................... 2-21

System Interfaces ............................................................................................... 2-21

HEATER CONNECTIONS ..............................................................................................................2 21

THERMAL FLUID CIRCULATING PUMP .....................................................................................222

REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2 23

REQUIREMENTS FOR WATER COOLED PUMPS ......................................................................... 223

COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2 24

SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................226

PRESSURIZED SYSTEMS ............................................................................................................227

VENT CONNECTIONS ..................................................................................................................228

CATCH TANK ............................................................................................................................... 229

DRAIN/FILL CONNECTION .........................................................................................................229

PRESSURE GAUGES ...................................................................................................................229

THERMOMETERS .......................................................................................................................230

VALVES .......................................................................................................................................230

AUTOMATIC FLUID CONTROL VALVES .......................................................................................231

BYPASS VALVES ........................................................................................................................ 231

Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-31

Stack and Flue .................................................................................................... 2-32

Testing ................................................................................................................ 2-34

Operation 3-1

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

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

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

FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................34

Circulating Pump .................................................................................................. 3-5

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

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

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

Initial Start-Up ..................................................................................................... 3-7

COLD CIRCULATION......................................................................................................................37

FILTERING THE SYSTEM ...............................................................................................................3 8

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

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

Flame Programmers .......................................................................................... 3-14

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

Operating Controls ............................................................................................. 3-19

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20

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

HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3 21

GAS PRESSURE SWITCH ............................................................................................................322

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

HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................323

OPERATING LIMIT CONTROLLER ...............................................................................................324

ON/OFF CONTROLS ....................................................................................................................324

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

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

TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................325

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

Required Pressure Drop Across the Heater ......................................................... 3-26

Procedure for First Shutdown ............................................................................ 3-27

Daily Start-Up ..................................................................................................... 3-27

Daily Shutdown .................................................................................................. 3-28

Before Leaving the Installation .......................................................................... 3-28

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

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

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

0-1

TABLE OF CONTENTS FTCS-IOM-2013-1114

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

Parts and Warranty 5-2

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

0-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE PARTS & WARRANTY

3 4 5

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

2-1

INSTALLATION FTCS-IOM-2013-1114 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 Figures 1 and 2, and Tables 1 and 2) 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 3 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 shipped upright and crated for forklift transport. Once

uncrated, all units can be transported with a forklift with the exception of freestanding models FT-0080C, FT-0120C, FT-0160C and FT-0240C. These four models can only be lifted for unloading and moving by means of lifting lugs at the top of the heaters. All skidded units can be moved with forklifts.

 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 FTCS-IOM-2013-1114 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)

 Heater Sides 18” (0.5 m)

 Heater Rear 18” (0.5 m)

 Flue Pipe 18” (0.5 m)

 Minimum clearances for personnel access and burner removal: refer to

Table 4.

» In cases where the available height is insu cient, a roof or ceiling

trap must be considered. Fulton Vertical Coil design units need su cient headroom for burner maintenance. Larger models of the vertical coil design unit (FT-0320C and above) require an access ladder/gantry to be provided by the customer to allow clear access to the top of the heater for maintenance purposes. Fulton Thermal Corporation will advise on the suitability of the access provided and will provide assistance that may be required in this respect.

» Access provision should avoid possible contact with hot

pipework,  ues etc.

! WARNING

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate personal protective equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including personal protective equipment recommendations.

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.

NOTE:  Burners may weigh up to 550 lbs (249 kg) depending on the type and

con guration.

NOTE:  For UL listed units, see the speci cation plate on the Fulton Thermal Fluid

Heater for these clearances.

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.

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

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

2-3

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

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:

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.

FIGURE 1 COMPONENT VIEW OF THE FTC / FTS THERMAL FLUID HEATER

Legend

A - Fluid Outlet B - Fluid Inlet C - Top Mounted Burner D - Control Panel E - Fan Inlet

Notes

1. Thermal  uid heater is of four-pass combustion design.

2. First pass (radiant): combustion air enters burner fan and travels upward between inner and outer jacket before it enters top-mounted burner.

3. Second pass (convection): Gases travel back across the inner row of coils.

4. Third pass (convection): Gases continue back down between inner and outer coil.

5. Fourth pass: Upward between the outer coil and inner jacket to the  ue outlet.

2-4

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

TABLE 1  SPECIFICATIONS  COIL DESIGN THERMAL FLUID HEATER

Model FT-C 0080 0120 0160 0240 0320 0400 0600 0800 1000 1200 1400

Heat Output

Thermal Fluid Content

Recommended Flow Rate

Typical Circulating Pump Motor

Typical Burner Motor*

Fuel Consumption @ Full Output No.2 Oil

Natural Gas

1000 BTU/HR

1000 KCAL/HR

GAL

LITERS

GPM

M3/HR

GPH

LITER/HR

FT3/HR

M3/HR

800 200

11.4

7.5

1.5

1.1

7.1

998

38.3

1,200

300

10 38

7.5

2.2

10.7

40.6

1,498

42.4

1,600

400

21 80

75 17

100

22.7

11.2

2.2

14.3

54.1

1,998

56.5

2,400

600

19 72

116

150

11.2

2.2

21.4

2,999

84.9

3,200

800

258

250

56.8

14.9

3.7

108.8

4,000

113.2

4,000 1,000

288

250

56.8

14.9

3.7

35.3 136

4,997

141.5

6,000 1,500

132 498

375

85.2

22.5

201

7,498

212.3

7.5

5.6

8,000 2,000

113.6

29.5

11.2

69.3

263.7

9,997

171 648

500

283

10,000

2,500

290

1,097

615 139

37.3

87.1

329.6

12,496

353.8

12,000

3,000

1,448

37.3

20 15

104.5

395.5

14,998

424.6

383

730 167

20 15

14,000

3,500

460

1,741

800 182

60 45

20 15

122

461.5

17,500

495.5

* Std burner, single fuel applications.

Notes: Voltage 3 Phase for Burner and Pump - Each unit has an incorporated stepdown transformer. Fuel up to No. 6 Oil Available for Large Units (FT-0600-C and larger). E ciency up to 80% Minimum Based on High Heating Value of the Fuel (No. 2 Oil @ 140,000 BTU/GHHV; Natural Gas @ 1000 BTU/ft3HHV. Modulation 3 to 1 Turn Down Ratio (5 to 1 for 320). Optional on FT-0080, 0120, and 0160-Standard on all others. Circulating pump motor sizes based on standard pressure (55 PSIG) and viscosity 1 cs, speci c gravity 0.7, with 25-37 PSID available head for installation.

TABLE 2  DIMENSIONSCOIL DESIGN THERMAL FLUID HEATER SEE FIGURE 2

Model FT-C 0080 0120 0160 0240 0320 0400 0600 0800 1000 1200 1400

Heater Inlet/ Outlet Connections

(A) Overall Height

(B) Overall Width

(D) Flue Outlet Diameter

Recommended Vertical Stack Diameter

Approximate Dry Weight

LBS

1.25

73.7

1,872

31.6 803

46.2

1,173

254

1,500

700

1.5 38

80.7

2,050

34.4 873

60.6

1,540

254

304

2,100

950

80.6

2,046

45.9

1,165

60.6

1,540

254

304

2,550 1,150

2.5 64

89.7

2,278

50.1

1,273

66.6

1,691

305

356

3,400 1,550

76.3

100.6 2,556

49.3

1,252

80.6

2,046

356

457

5,300 2,400

112.4 2,856

49.3

1,252

80.6

2,046

356

457

5,300 2,400

102

143.6 3,648

63.4

1,611

88.1

2,237

457

558

8,250

3.750

102

143

3,632

70.5

1,791

107.75 2,736

508

609

11,450

5,200

152

146.5 3,721

2,413

135.1 3,432

508

609

19,250

8,750

152

146.4 3,718

108.4 2,753

152.9 3,882

559

661

21,700

9,850

152

163.1 4,144

108.4 2,753

152.9 3,882

559

661

23,000 10,455

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

2-5

INSTALLATION FTCS-IOM-2013-1114 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.

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

4. See Table 5 for minimum make-up air required and the recommended area of each opening for each model.

TABLE 3 APPROXIMATE FLOOR LOADING

Model Heater Only*

FT-0080C 500

FT-0120C 400

FT-0160C 450

FT-0240C 450

FT-0320C 450

FT-0400C 450

FT-0600C 550

FT-0800C 500

FT-1000C 500

FT-1200C 400

FT-1400C 450

FT-0400S 675

FT-0600S 675

FT-0800S 525

*All weights are lbs/ft

TABLE 4  RECOMMENDED MINIMUM CLEARANCES FOR PERSONNEL ACCESS/BURNER

REMOVAL

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.

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.

Model Inches (Meters)

FT-0080C 109 (2.8)

FT-0120C 115 (3.0)

FT-0160C 119 (3.1)

FT-0240C 125 (3.2)

FT-0320C 133 (3.4)

FT-0400C 145 (3.7)

FT-0600C 171 (4.4)

FT-0800C 172 (4.4)

FT-1000C 173 (4.4)

FT-1200C 172 (4.4)

FT-1400C 188 (4.8)

FT-0400S 162 (4.2)

FT-0600S 170 (4.4)

FT-0800S 171 (4.4)

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

2-6

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

combustion or nuisance failures.

TABLE 5 MINIMUM MAKEUP AIR REQUIREMENTS AND

RECOMMENDED AREA OF OPENING FOR VENTS

Model Minimum

Make-Up

Air (SCFM)*

FT-0080C 200 400 135

FT-0120C 300 600 205

FT-0160C 400 800 270

FT-0240C 600 1200 400

FT-0320C 800 1600 535

FT-0400C 1000 2000 670

FT-0600C 1500 3000 1000

FT-0800C 2000 4000 1335

FT-1000C 2500 5000 1670

FT-1200C 3000 6000 2000

FT-1400C 3500 7000 2335

FT-0400S 1000 2000 670

FT-0600S 1500 3000 1000

FT-0800S 2500 4000 1335

*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

Ven t

Opening

Area (in2)

Upper Vent

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.

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. See Figure 4.

FIGURE 2  DIMENSIONS REFER TO TABLE 2

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

2-7

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

2” N.P.T. Gas Connection

Main Gas

Regulator

Manual Gas

Valv e

Gas Safety

Shuto Valve

Pilot Gas

Valv e

Pilot Gas

Regulator

Buttery

Valv e

FIGURE 3  TYPICAL GASFIRED MODULATED CSD1 FUEL TRAIN

Pilot Gas

Valves

HI / LOW

Gas Pressure Switch

Manual Gas

Valv e

2” N.P.T. Gas Connection

Manual Gas Regulator

Manual Gas Valve

Vent Valve

Pilot Gas

Regulator

Gas Safety Shutoff Valve

HI/LOW

Gas Pressure Switch

Manual Gas Valve

2-8

Butterfly Valve

FIGURE 4  TYPICAL GASFIRED MODULATED NFPA FUEL TRAIN

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

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 nonstacking, 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 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

TO LOW PRESSURE OIL

SWITCH ON CONTROL PANEL

PUMP

INLET

1/4" COPPER TUBING

0400 PSIG

SUPPLY

with the model of heater. The requirements for natural gas- red coil design models are as follows:

 Models FT-0080-C to FT-0400-C 14”w.c.

 Models FT-0600-C to FT-0800-C 60”w.c.

 Models FT-1000-C to FT-1400-C 120”w.c.

NOTE:  Note: Low emissions burners for all models

require 5 psi.

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

pressure must never exceed these values.

NOTE:  When operating, the supply pressure must not drop

below these limits: Not less than 11 “ w.c. where 14” w.c is required. Not less than 50” w.c. where 60” w.c. is required. Not less than 100” w.c. where 120” w.c. is required.

OIL S.S.O.V.

BURNER

3/8” COPPER TUBING OR ½” SCHEDULE 40 CARBON STEEL PIPING

RETURN

TO TANK

MODULATING

OIL VALVE

IF APPLICABLE

MOUNTED

TO SKID

INLET

RETURN

FUEL OIL PUMP

MOUNTED TO TOP OF UNIT

RETURN

PI 0200 PSIG

PRESSURE INDICATOR

BURNER

CHECK VALV E

MODULATING OIL VALVE

1/4" NPT

CHECK VALVE

3/8” COPPER TUBING OR ½” SCHEDULE 40 CARBON STEEL PIPING

NC OIL VALVE

FIGURE 5  TYPICAL NO. 2 OIL FIRED FUEL TRAIN

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

MOUNTING BRACKET

2-9

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

! 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.

4 CAUTION

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

11. 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

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)

*Notes: Propane gas pilot required. Oil must be delivered to the Fulton equipment at 160°F, 3 psi. Fulton equipment will then preheat the oil from 160°F to 230°F. All fuel train components to be rated for the temperature and pressure. Fuel train to be heat traced and insulated.

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. See Figure 5.

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/national requirements. In addition, if a two pipe system is employed, a check valve must be  tted into the return pipe.

0.824 to 0.852 at 59°F (15°C) less than 0.40% by weight

0.90 to 0.93 at 59°F (15°C) less than 1.6% by weight

0.95 to 0.98 at 59°F (15°C) less than 2.12% by weight

4. Meet the maximum pressure allowed at 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 supply with a dew point of -40°F (-40°C).

2-10

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

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 come down for shipping, the wire will be left at the end of the conduit where possible and wired in the  eld (by others). When the system has multiple skids that are adjoining, the conduit will be installed to break at the skid joints. The wire for the conduit running between the skids will be shipped loose to prevent damage when the skids are put back together. These wires will need to be run by the installing contractor in the  eld and wired to proper locations. If there is wiring between skids that are not adjoining, then this will need to be done by quali ed personnel.

! WARNING

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

NOTE:  If the unit is not skid-mounted at the factory, the client/contractor is

required to wire the circulating / feed water pump starter.

NOTE:  If the circulating pump motor is not supplied by Fulton, the motor starter

will not be supplied.

6. Locate electrical schematic diagram, a copy of which is inside of the panel box.

7. Ensure the information on the electrical drawing corresponds to your voltage and frequency. Adhere to the following:

 Typical 120 VAC controls allow for a +10% and -15% voltage  uctuation.

 Motors are designed to operate within the following limits at the motor

terminals: AC power supplied is within +/- 10% of the motor rated voltage with the rated frequency applied; or AC power supplied is within +/- 5% of the rated frequency and with the rated voltage; or a combined variation in voltage and frequency of +/- 10% (sum of absolute values) of rated values provided the frequency variation does not exceed +/-5% of rated

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

2-11

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

! WARNING

If a  re does occur, extinguish using

, foam or dry chemical. DO NOT

USE WATER.

4 CAUTION

Some plastics can be dissolved by thermal  uid.

frequency.

 For 3-phase motors, the line to line full load voltage must be balanced

within 1% of the rated motor voltage. If the motor is rated 208-230V, the voltage deviations must be calculated from 230V. Operation outside of these limits will degrade motor performance. 575V rated motors cannot be operated at voltages above 600V. Depending on the motor manufacturer, a 208V rated motor may not be able to run below the design voltage.

 Electric elements will have an increase n watt density if the applied voltage

is higher than the element design voltage. Therefore, electric elements have a 0% tolerance for operation over design voltage. Electric elements can tolerate a lower than design voltage but the kW must be derated accordingly.

 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.

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.

 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.

2-12

Heat transfer  uids of both mineral and synthetic origin have been specially

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

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 Thermal Corporation or the  uid manufacturer.

Consider the following for 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

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

 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 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

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

2-13

INSTALLATION FTCS-IOM-2013-1114 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.

4 CAUTION

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

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

product, and verify that the  uid bulk temperature limitation exceeds the expected operating temperature

7. After a  uid is selected, refer to the manufacturer’s recommendations, published in compliance with the Occupational Safety and Health Administration (OSHA).

8. 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 Thermal Corporation.

 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 Thermal Corporation 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.

 THERMAL FLUID BREAKDOWN PREVENTION

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

prevent this condition from occurring. See Figure 6. These safeties must not be bypassed at any time.

2-14

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

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

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. See Figure 7. Refer to Maintenance section of this manual for troubleshooting activities.

FIGURE 6  PRESSURE SWITCHES

! WARNING

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 damage as a result of expansion, contraction, vibration, or other movements.

FIGURE 6  PRESSURE SWITCHES

FIGURE 7  TEMPERATURE LIMIT DISPLAY

Piping Speciﬁ cations

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

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.

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

2-15

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

Adhere to the following for piping installation (see Figure 8):

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.

Legend

1. Thermal Fluid Heater

2. Thermal Fluid Circulating Pump

3. Safety Relief Valve

4. Thermometer

5. Pressure Gauge

6. Thermal Fluid Heated Equipment

7. Bypass Valve

8. Expansion Joints

9. Anchor and Pipe Guides

10. Expansion Tank

11. Vent Piping

12. Deaerator Tank

13. Deaerator Tank Inlet (must be highest point of piping)

14. Thermal Bu er Tank

15. Catch tank (for drain of pressure relief valve, cold seal, expnasion tank, vent)

16. Valve

17. Strainer

18. 3/4” System Fill Connection

19. Flexible Connection

20. Isolating Valve

21. Manual Low Level Test Line

22. Manual High Level Test Line

23. Bu er Drain

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, Schedule 80, or equal, based on design temperature and pressure of the system.

2-16

Vent to atmosphere in safe location

FIGURE 8  TYPICAL THERMAL PIPING SCHEMATIC

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

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 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 @ 100°F temperature rise (1mm per meter over 100 C rise).

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. See Figure 9.

11. 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.

12. 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.

13. 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.

10. Provide properly designed supports and anchors for all

Pipe Must Be Diameter of Pump Intake

Pump

14. Cut screw threads carefully and accurately. If possible,

From Outlet of Deaerator

First Fitting

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

FIGURE 9  TYPICAL PUMP PIPING

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

6 - 10 Pipe Diameters

2-17

INSTALLATION FTCS-IOM-2013-1114 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.

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.

15. 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 Figure 10 and Tables 6-9 for guidelines.

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

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

16. 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.)

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

FIGURE 10  BOLTING SEQUENCE FOR 4 AND 8 BOLT FLANGES

2-18

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

TABLE 6  RECOMMENDED GASKET LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 150#

GASKETS SAE GRADE 5 BOLTS OR EQUAL

Nominal Flange Size

(inches)

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

(inches)

Preferred Torque Req.

Per Bolt (ft-lb)

TABLE 7  RECOMMENDED LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 300# GASKETS

SAE GRADE 5 BOLTS OR EQUAL

! 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.

Nominal Flange Size

(inches)

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

(inches)

Preferred Torque Req.

Per Bolt (ft-lb)

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

2-19

INSTALLATION FTCS-IOM-2013-1114 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 8  RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 150# GASKETS SAE

GRADE 5 BOLTS OR EQUAL

Nominal Flange Size

(inches)

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

(inches)

Preferred Torque Req.

Per Bolt (ft-lb)

TABLE 9  RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 300# GASKETS SAE

GRADE 5 BOLTS OR EQUAL

Nominal Flange Size

(inches)

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

(inches)

Preferred Torque Req.

Per Bolt (ft-lb)

2-20

SECTION 2 FTCS-IOM-2013-1114 INSTALLATION

! WARNING

Insulation

All information in this manual is for

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:

reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

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.

5. For heaters equipped with  ue gas recirculation (FGR) on the burner, the ducting must be insulated to prevent personnel injury.

System Interfaces

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

 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.

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.

No shuto of any kind may be placed between the safety relief valve and the equipment, or in the discharge pipe between such valve and the atmosphere. Doing so may cause accidental explosion from overpressure.

Discharge from safety relief valve must be con gured so that there is no danger of scalding personnel or causing equipment damage. Provisions must be made to properly drain safety relief valve discharge piping.

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.

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

Failure to insulate ducting on equipment with Flue Gas Recirculation on the burner may result in personnel injury.

2-21

INSTALLATION FTCS-IOM-2013-1114 SECTION 2

 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 (see Figure 9):

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.

GREASE FITTING

1/4” X 1/8”

KEYWAY

2-22

3/8” NPT BARRIER OIL

FILLMECH. SEAL ONLY

1/8” NPT

3/8” NPT BEARING GREASE

RELIEF AND LIP SEAL

FAILURE DETECTION

DISCHARGE

1/8” NPT VENT

1/2” NPT DISCHARGE

GAUGE CONNECTION

WHEN SPECIFIED

PUMPAGE

LEAK DETECTION

MECH. SEAL ONLY

SUCTION

1/2” NPT CASING DRAIN

WHEN SPECIFIED

FIGURE 11  TYPICAL AIR COOLED PUMP

+ 64 hidden pages

Fulton Vertical Coil User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual