Fulton Vertical Tubeless User Manual

INSTALLATION AND

OPERATION MANUAL

Vertical Tubeless Design

Thermal Fluid Heaters

Model FT-A

Serial/National Board #

Model

Fulton Order

Sold To

Job Name

Date

FTA-IOM-2013-0227

FTA-IOM-2013-0227 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 .................................................................................................................2-7

THE GAS SUPPLY ..........................................................................................................................27

THE OIL SUPPLY ...........................................................................................................................27

Instrument Air ......................................................................................................2-8

Electrical Supply ................................................................................................... 2-8

Thermal Fluids .................................................................................................... 2-10

THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................210

SELECTING A THERMAL FLUID ..................................................................................................211

ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................212

THERMAL FLUID BREAKDOWN .................................................................................................212

Piping Speci cations .......................................................................................... 2-14

Insulation ........................................................................................................... 2-20

System Interfaces ............................................................................................... 2-20

HEATER CONNECTIONS ..............................................................................................................220

THERMAL FLUID CIRCULATING PUMP .....................................................................................220

REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................222

REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................222

COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................222

SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................223

PRESSURIZED SYSTEMS ............................................................................................................223

VENT CONNECTIONS ..................................................................................................................226

CATCH TANK ...............................................................................................................................227

DRAIN/FILL CONNECTION .........................................................................................................227

PRESSURE GAUGES ...................................................................................................................227

THERMOMETERS .......................................................................................................................227

VALVES .......................................................................................................................................228

AUTOMATIC FLUID CONTROL VALVES .......................................................................................229

BYPASS VALVES ........................................................................................................................229

Assembly of Fulton Multi-Skid Engineered Systems .........................................2-30

Stack and Flue ....................................................................................................2-31

Testing ................................................................................................................ 2-32

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

COLD CIRCULATION......................................................................................................................36

FILTERING THE SYSTEM ...............................................................................................................37

BOILOUT .......................................................................................................................................38

COMBUSTION ...............................................................................................................................39

Flame Programmers ..........................................................................................3-12

Operating Controls .............................................................................................3-12

LIQUID LEVEL SWITCH  WHEN COMBINATION TANK IS SUPPLIED ........................................312

AIR SAFETY SWITCH ..................................................................................................................312

BLOWER MOTOR STARTER .........................................................................................................313

PUMP MOTOR STARTER .............................................................................................................313

DIFFERENTIAL PRESSURE SWITCH ...........................................................................................313

HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................314

GAS PRESSURE SWITCH ............................................................................................................315

OPERATING TEMPERATURE CONTROLS ....................................................................................315

HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................316

OPERATING LIMIT CONTROLLER ...............................................................................................317

ON/OFF CONTROLS ....................................................................................................................317

MODULATING CONTROLS ..........................................................................................................317

PRESSURE GAUGES ....................................................................................................................317

TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................318

CYCLE TESTING ...........................................................................................................................318

Required Pressure Drop Across the Heater .........................................................3-18

Procedure for First Shutdown ............................................................................3-19

Daily Start-Up ..................................................................................................... 3-19

Daily Shutdown ..................................................................................................3-20

Before Leaving the Installation .......................................................................... 3-20

Maintenance 4-1

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

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

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

Weekly Maintenance Schedule ............................................................................4-3

Monthly Maintenance Schedule .......................................................................... 4-3

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

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

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

LUBRICATION ...............................................................................................................................45

SOOT CLEANING ..........................................................................................................................45

Safety Check Procedures ..................................................................................... 4-5

LIQUID LEVEL SWITCH ................................................................................................................45

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

0-1

TABLE OF CONTENTS FTA-IOM-2013-0227

STACK LIMIT .................................................................................................................................45

DIFFERENTIAL PRESSURE SWITCH .............................................................................................46

LOW INLET PRESSURE SWITCH ...................................................................................................46

HIGH OUTLET PRESSURE SWITCH ...............................................................................................46

AIR SWITCH ..................................................................................................................................47

AIR FILTER BOX SWITCH IF EQUIPPED .....................................................................................47

TEMPERATURE LIMITS ..............................................................................................................47

HIGH/LOW GAS PRESSURE SWITCH ...........................................................................................47

Troubleshooting ...................................................................................................4-7

Warranty & Parts 5-1

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

Parts ..................................................................................................................... 5-4

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 Product-IOM-2011-0216 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. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

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 I or Section VIII, Div. 1.

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 FTA-IOM-2013-0227 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.

§ 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 FTA-IOM-2013-0227 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)

§ Heater top (for burner removal) 36” (1 m)

NOTE: ´ Burners may weigh up to 250 lbs (113 kg) depending on the type and

con guration.

! 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.

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.

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.

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.

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

2-3

INSTALLATION FTA-IOM-2013-0227 SECTION 2

Legend

A Top Mounted Burner B Electrical Control Panel C Convection Fins D High Density, High Temperature Insulation

Notes

The top-mounted down  red burner delivers a spinning  ame down the length of the furnace. As the  ame swirls downward in a controlled  ow pattern, the  uid spirals upward in the pressure vessel. Hot gases from the  ame are carried up the outside of the vessel in the secondary  ue passage convection area. Convection  ns welded along the full length of the vessel transmit the remaining heat through the outer side of the  uid vessel and into the  uid. The result is even heating of thermal  uids

for optimal thermal e ciency.

FIGURE 1 COMPONENT VIEW OF THE FTA THERMAL FLUID HEATER

2-4

FIGURE 2  DIMENSIONS REFER TO TABLE 2

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

TABLE 1  SPECIFICATIONS  VERTICAL TUBELESS THERMAL FLUID HEATER

Model FTA 0200 0380 0520 0690 1050 1740

Heat Output

1000 BTU/HR

1000 KCAL/HR

Thermal Fluid Content

GAL

LITERS

Recommended Flow Rate

GPM

M3/HR

Typical Circulating Pump

Motor

Typical Burner Motor

Fuel Consumption @ Full

Output No.2 Oil

GPH

LITER/HR

Natural Gas

FT3/HR

M3/HR

Notes:

Speci cations and Dimensions are approximate. Consult factory for model speci c electrical requirements. We reserve the

right to change speci cations and/or dimensions without notice.

207

7.5

.33

.248

2.2

8.3

259

7.2

348

144

7.5

.33

.248

3.2

11.9

435

12.2

519

131

170

125

11.2

.33

.248

4.7

17.8

649

18.4

693

175

246

125

11.2

.75

.56

6.7

25.4

866

24.2

1052

265

371

150

11.2

.75

.56

9.4

35.6

1315

36.8

1736

437

117

443

200

14.9

1.5

1.1

15.8

2170

60.8

TABLE 2  DIMENSIONSVERTICAL TUBELESS THERMAL FLUID HEATER SEE FIGURE 2

Model FTA 0200 0380 0520 0690 1050 1740

Heater Inlet/ Outlet Connections

(A) Overall Height

(B) Overall Width

(D) Flue Outlet Diameter

Approximate Dry Weight

1.5

1752

737

1092

152

1850

840

1.5

1905

787

45.5

1156

152

2,100

955

2159

838

1168

203

2300

1045

2185

965

1432

254

3400

1540

2185

1168

1626

305

4400

1995

2.5

110

2794

1168

1626

305

7200

3275

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

2-5

INSTALLATION FTA-IOM-2013-0227 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.

TABLE 3 APPROXIMATE FLOOR LOADING*

Model Free Standing Skid Mounted

FT-0200-A 400 250

FT-0380-A 400 250

FT-0520-A 400 200

FT-0690-A 400 250

FT-1050-A 400 300

FT-1740-A 600 400

*All weights are lbs/ft2

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

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

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.

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.

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

TABLE 4  MINIMUM MAKEUP AIR REQUIREMENTS AND RECOMMENDED AREA OF

OPENING FOR VENTS

Model Minimum Make-

Up Air (SCFM)*

FT-0200-A 50 115 40

FT-0380-A 95 195 65

FT-0520-A 130 290 100

FT-0690-A 175 385 130

FT-1050-A 265 585 195

FT-1740-A 435 965 325

*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

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).

2-6

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

Utilities

¡ The Gas Supply

Adhere to the following for gas supply (Figure 3) 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 piping.

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

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.

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

#2 Less

than 31.9 Seconds Redwood

#1 at 100 F (38 C)

0.824 to 0.852 at 59 F (15 C)

Sulfur Content

Less than 0.40% by weight

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 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 with the model of heater. The requirements for FT-A natural gas- red models are 7 to 11 in. w.c.

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

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.

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 85 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

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

2-7

INSTALLATION FTA-IOM-2013-0227 SECTION 2

1” Gas Connection

Manual Gas Valve

Gas Pressure Regulator

Diaphragm Gas Valves

Butterfly Valve

Pilot Gas Valve

Pilot Gas Regulator

Manual Ball Valve

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

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).

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.

2-8

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

0-400 PSIG

TO LOW PRESSURE OIL

SWITCH ON CONTROL PANEL

RETURN TO TANK

PUMP INLET

BURNER

3/8" COPPER TUBING

OIL S.S.O.V.

MOUNTED

TO SKID

MOUNTED TO TOP OF UNIT

1/4" COPPER TUBING

SUPPLY

NC OIL VALVE

PRESSURE INDICATOR

FUEL

OIL PUMP

INLET

RETURN

3/8" COPPER TUBING

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

FIGURE 4  TYPICAL NO. 2 OIL FIRED FUEL TRAIN

2-9

INSTALLATION FTA-IOM-2013-0227 SECTION 2

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

! WARNING

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.

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 Z2231-1991 or latest addenda. In Canada, gas installations must be in accordance with the current CAN/CGA B149.1 and 2 and/or local codes.

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

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

8. 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 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.

Thermal Fluids

2-10

¡ 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 600 F (316 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

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

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.

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 Thermal Corporation or the  uid manufacturer.

Consider the following for selection:

1. The Fulton vertical tubeless thermal  uid heater is a  red heat exchanger and the safe control and monitoring of the thermal  uid temperature is of paramount importance.

! WARNING

4 CAUTION

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

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.

§ AMOCO Transfer Oil 4199

§ CHEVRON

§ DOW G

§ EXXON 43

§ MOBIL

§ MONSANTO

§ MULTITHERM

§ PARATHERM

§ PETROCANADA T

§ SHELL

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

2-11

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

If a  re does occur, extinguish using CO2 foam or dry chemical. DO NOT USE WATER.

4 CAUTION

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 information.

§ 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 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

2-12

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

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 5. 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. See Figure 6. Refer to Maintenance section of this manual for troubleshooting activities.

! WARNING

FIGURE 5  PRESSURE SWITCHES

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

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INSTALLATION FTA-IOM-2013-0227 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.

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.

FIGURE 6  TEMPERATURE LIMIT DISPLAY

Adhere to the following for piping installation (see Figure 7):

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

2-14

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

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

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. See Figure 8.

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.

! 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.

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

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.

14. 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.

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 9 and Tables 5-8 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”

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

2-15

INSTALLATION FTA-IOM-2013-0227 SECTION 2

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.

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, expansion tank, vent)

16. Valve

17. Strainer

18. 3/4” System Fill Connection

19. Flexible Connection

2-16

FIGURE 7  TYPICAL THERMAL PIPING SCHEMATIC

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

Pump

Pipe Must Be Diameter of Pump Intake

From Outlet of Deaerator

First Fitting

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

6 - 10 Pipe Diameters

FIGURE 8  TYPICAL PUMP PIPING

FIGURE 9  BOLTING SEQUENCE FOR 4 AND 8 BOLT FLANGES

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

2-17

INSTALLATION FTA-IOM-2013-0227 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 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)

TABLE 6 - 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)

2-18

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

TABLE 7 - 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

TABLE 8 - RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 300# GASKETS SAE

Number of Bolts Diameter of Bolts

(in.)

GRADE 5 BOLTS OR EQUAL

Preferred Torque

Req. Per Bolt (ft-lb)

! 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 (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)

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

2-19

INSTALLATION FTA-IOM-2013-0227 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.

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.

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:

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.

¡ 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

2-20

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Fulton Vertical Tubeless User Manual

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User Manual