User manual FULTON 40E

[. . . ] R Fulton Boiler Works (Great Britain) Ltd. OPERATOR, SERVICE & PARTS MANUAL SERIES 'E' - GAS FIRED STEAM BOILERS (6E - 60E) GFSE-Std-0202 WARNING Steam Boilers are a potential hazard possibly fatal if not properly maintained. CAUTION It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy of the boiler. NOTE The Pressure system and Transportable Gas Containers Regulations 1989 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme and Section 40 of the Health and Safety at Work Act, 1974. Regular inspections are therefore required by a 'Competent Person' at intervals not exceeding 14 months. The scope of the examination and the actual intervals between examinations is at the discretion of the competent person. [. . . ] PILOT BALL VALVE GAS PILOT ORIFICE TUBE GOVERNOR GAS START VALVE GAS STOP VALVE MAIN GAS FIG. GAS TRAIN MONOBLOC ADJUSTMENTS LPG Boilers (MBZRDLE 405/412 BO1) A F E B D C ADJUSTMENTS A Main Gas Governor. B First and second stage initial lift adjuster, main gas valve. C Main gas throughput D E F Gas supply test point Boiler side test point High gas pressure switch ACTION Turn clockwise to increase gas pressure. Range 4 - 50 mbar. Slacken locking screw, turn fluted knob anticlockwise to increase, clockwise to decrease. GFSE-Std-0499 16 3 3 MODULAR GAS UNIT STEAM PRESSURE GAUGE GAS COCK MAIN STEAM VALVE WATER LEVEL PROBES AIR SAFETY SWITCH WATER GAUGE CHECK VALVE STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN VALVE FIG. 11 BOILER OPERATION 17 GFSE-Std-0499 3 3 OPERATION SECTION 3 3. 1 GENERAL The following instructions are given for the guidance of the operator in the use of the Series 'E' gas fired boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health. Where original equipment Service Manuals are supplied, they must be read and understood in conjunction with this manual. All Warnings and Cautions must be observed. 3. 2 BOILER CONTROLS The following brief description of the controls used on the Series E gas fired boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient operation of the boiler. Note: All the controls are of the `fail-safe' type and are wired in series; failure of any one will automatically shut down the boiler. Low Water Relays and Feedwater Pump Relays. These relays operate in conjunction with probes suspended in the boiler and water column to automatically maintain the level of water in the boiler and to cut-off the burner should the water level fall to an unsafe level. Located on the control panel box and connected to the steam pressure gauge assembly by copper tube, the pressure regulator controls the on/off cycle of the burner, shutting the burner off when maximum pressure is reached and switching it on when the steam pressure falls. This is the main control in the panel box. The programmer in conjunction with a sensing device `supervises' the ignition sequence, proves the flame is satisfactory and finally `monitors' the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to `lock-out' and both main and pilot gas valves will be closed. Mounted on the burner scroll, this switch is operated by the pressure of air entering the burner through the throat of the scroll. Lack of air, or insufficient pressure, will prevent the switch completing the circuit thus preventing the burner from operating. Consists of pilot and main gas supply lines, each line having a manual gas cock, a governor and electrically powered gas valves. The governors maintain a constant pressure of gas entering the burner and are adjustable. The electrically powered gas valves are controlled by the burner programmer. GFSE-Std-0499 18 3 3 MODULAR GAS UNIT STEAM PRESSURE GAUGE GAS COCK MAIN STEAM VALVE WATER LEVEL PROBES AIR SAFETY SWITCH WATER GAUGE CHECK VALVE STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN VALVE FIG. 11 BOILER OPERATION 19 GFSE-Std-0499 3 3. 3 INDICATOR LIGHTS Indicator lights are fitted to the control panel as an additional aid to the operator. The meaning and operating sequence of these lights is as follows: 3 Start/Low Water Reset This switch is used to start the boiler and to reset the low water alarm. When the switch is pressed to initiate the start-up sequence, the low water alarm lamp also illuminates and the low water audible alarm sounds. [. . . ] Main Steam Valve Steam Safety Valve Steam Pressure Gauge Assembly Boiler Blowdown Valve Water Level Gauge Set Feedwater Check Valve Feedwater Stop Valve Flue Spigot Audible Alarm Flue Brush Tee Handle Wrench Quantity 1 1 1 1 2 1 1 1 1 or 2* 1 1 Items marked * vary according to boiler specification. BOILER TRIM Steam Safety Valve (Discharge side) (DN) Steam Outlet Valve Feed Water Stop Valves Feed Water Check Valve Boiler Blowdown Valves Water Column Blowdown Valves Sight Glass Blowdown Valve 6E 8E 10E 15E 20E 30E 40E 50E 60E 32 32 32 32 32 32 32 32 32 (DN) 20 20 25 32 32 40 50 50 50 (DN) 25 25 25 25 25 25 25 25 25 (DN) 25 25 25 25 25 25 25 25 25 (DN) 20 20 20 20 25 25 25 25 25 (DN) 20 20 20 20 20 20 20 20 20 (DN) 6 6 6 6 6 6 6 6 6 GFSE-Std-0499 33 5 5 MAINS SENSING INTERNAL SCHEMATIC INTERNAL BASE WIRING Note: A common base is supplied for type A & B controller bases. 21 TYPE LC1 LEVEL CONTROLLER GFSE-Std-0499 34 IMPORTANT Recommended Water Conditions It is very important that a strict water management program is followed to ensure trouble free boiler operation. The following are recommended for feedwater and for boiler water. FEEDWATER pH Value 8. 5 to 9. 5 Hardness less than 2. 0mg/kg Oil Suspended Solids Organic Matter Chloride Tested at room temperature. In the form of CACO3 None None Less than 5 ppm Less than 50 ppm BOILER WATER Oxygen Scavenger, Sodium Sulphide or Tannin Phosphate Total Alkalinity Caustic Alkalinity Chloride pH Value Total Dissolved Solids Iron Silica Hardness Dissolved Oxygen Suspended Solids 20 to 50 mg/kg Maximum 0 to 50 mg/kg, in the form of PO4 1000 mg/kg Maximum Less than 300 mg/kg as CACO3 Less than 500 mg/kg 9. 5 - 11. 5, tested at room temperature 2000 ppm Maximum 1 mg/kg Maximum 180 mg/kg Maximum, in the form of SiO2 Not detectable None 100 mg/kg Maximum mg/kg = Milligrams per Kilogram CACO3 = Calcium Carbonate PO4 = Phosphate SiO2 = Silicon Dioxide 1 Grain hardness = 17. 118 ppm therefore 70 ppm = 4. 10 grains hardness. [. . . ]