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Fulton Dragon User manual

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This manual must be available to the boiler operator at all times. DRAGON-IOMM-2016-5
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Dragon
Electric Steam Boiler
DRAGON-IOMM-2016-5
Fulton Ltd
Page II
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Fulton Ltd
Page III
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Technical Data 1
1.3 Product Overview 1
SECTION 2 - INSTALLATION
2.1 General 5
2.2 Pre-Installation 5
2.2.1 Siting 6
2.3 Boiler Connections 6
2.3.1 Steam Safety Valves 7
2.4 Water Supply 8
2.5 Electrical Requirements 8
2.6 Commissioning the Boiler 10
SECTION 3 - OPERATION
3.1 General 13
3.2 Controls 13
3.2.1 Boiler Control Panel 14
3.2.2 Steam Pressure Controls 16
3.2.2.1 Setting Steam Pressure Controls 16
3.3 Filling The Boiler 17
3.4 Draining the Boiler 18
3.5 Boiler Start-Up (from cold)-all models 19
3.5.1 Boiler Start-Up Following short term Shut-Down 19
3.6 Boiler Shut-Down 20
3.6.1 Short Term Shut-Down (hours) 20
3.6.2 Long Term Shut-Down (weeks) 20
Electrical diagrams supplied separately
SECTION 4 - MAINTENANCE
4.1 Visual Checks 21
4.2 Water Level and Low Water Safety Controls 22
4.2.1 Feedwater Pump Test 22
4.2.2 Low Water Level Checks 23
4.2.3 Evaporation Check 23
4.3 Blowdown Procedures 24
4.3.1 Main Boiler Blowdown 24
4.3.2 Water Level Gauge (Sight Glass) Blowdown 24
4.4 Element Care and Protection 25
4.4.1 Element Removal 26
4.5 Boiler Internal Inspection 26
4.5.1 Feedwater Tank Internal Inspection 27
4.6 Cleaning Water Level Probes 27
4.7 Schedule of Operator Tests and Checks 28
4.7.1 Daily 29
4.7.2 Weekly-in addition 29
4.7.3 Monthly-in addition 29
4.7.4 Three Monthly-in addition 30
4.8 Maintenance Record Keeping 31
4.9.1 Troubleshooting-boiler 32
4.9.2 Troubleshooting-feedwater pump 33
APPENDIX A - TI SHEETS
 DragonDimensions&Specication 36
Dragon Probe Lengths 38
Recommended Water Conditions 39
Water Level Probes 40
Auto TDS Blowdown Systems 42
Auto TDS Blowdown System Install Guide 44
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WARNINGS
The Pressure System Safety Regulations 2000
Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.
For further information contact:
(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) HealthandSafetyExecutivelocalofce.
(c) Your Competent Person.
For your safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
• WARNINGS must be observed to prevent serious
injury or death to personnel.
• CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
effectiveness.
• Notes: must be observed for essential and
effective operating procedures, conditions and as
a statement to be highlighted.
It is the responsibility and duty of all personnel involved
in the operation and maintenance of this equipment
to fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.
CAUTION
In case of emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.
If such a condition should occur during commissioning or during subsequent operation of this product,
regardless of the cause, then the electrical supply to the boiler should be isolated immediately, until the fault
hasbeeninvestigatedbyacompetentpersonandrectied.
!
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 routine maintenance checks could result in a drastic reduction in the life expectancy of the
systemandincreasethepossibilityofre,explosion,propertydamage,personalinjuryorlossoflife.
!
!
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WARNINGS
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the heater and serious personal injury.
WARNING
Do not try to do repairs or any other maintenance work
you do not understand. Obtain a service manual from
Fulton Ltd or call a Fulton service engineer.
It is the responsibility of the installer to ensure all parts
suppliedwiththeboilerarettedinacorrectandsafe
manner.
Understand the electrical circuit before connecting
or disconnecting an electrical component. A wrong
connection can cause injury and or damage.
A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing
parts. Make sure that all maintenance procedures are
completed before using the boiler.
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local
regulations and is suitable for the job. You can be injured
if you use faulty lifting equipment. Make sure the lifting
equipment is in good condition.
Operating the boiler beyond its design limits can damage
the boiler, it can also be dangerous. Do not operate the
boiler outside its limits. Do not try to upgrade the boiler
performancebyunapprovedmodications.
Non-approvedmodicationscancauseinjuryand
damage. Contact your Fulton dealer before modifying
the boiler.
Onlyqualiedpersonsshouldbeallowedto
operate and maintain the boiler and its equipment.
Boilers should always be drained through an approved
blowdown vessel.
Prior to the commencement of any work requiring the
removal of cover plates and the opening of control panel
box, the electrical supply to the boiler must be isolated.
Steam boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent and
qualiedpersonnelshouldworkonorinthelocalityof
a steam boiler and ancillary equipment. Always ensure
theworkingareaandoorareclearofpotentialhazards,
work slowly and methodically.
DoNOTstoreinammablematerialsneartheboiler.
The importance of correct boiler water and feedwater
cannot be over emphasised, see the relevant section in
this manual.
!
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary preheat the
feedwater. If in doubt consult Fulton Ltd.
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners
and chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
It is the responsibility of the operator to ensure adequate
supplies of chemical are available at all times
(including commissioning). Costly repairs could be
required should the plant operate without chemicals or
the wrong dosage of chemicals.
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and
is normally only required by engineering surveyors /
inspectors. In order to ensure the material/ pressure
vessel does not suffer from brittle fracture, hydraulic
testing should not be carried out below 7 °C.
!
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Page 1
INTRODUCTION - 1
SECTION 1 - INTRODUCTION
1.1 GENERAL
1.2 TECHNICAL DATA
ForafullspecicationrefertoAppendixA-TI-113-DRAGONDimensions&Specication.
The Fulton Dragon electric steam boiler service manual is a generic publication, providing
information on standard boiler operation and maintenance.
Every care has been taken in the manufacture of the boiler to ensure that quality and reliability
standards are maintained. Satisfactory performance can only be ensured if the installation
recommendations, operating routines and maintenance schedules laid out in this manual are
adhered to.
Particular attention should be paid to electrical installation and water treatment.
1.3 PRODUCT OVERVIEW
CONTINUED ON NEXT PAGE
TheFultonDragonelectricsteamboilerisacompactandhighlyefcientunitdesignedtomeet
the requirements of the lower demand steam user.
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INTRODUCTION - 1
Figure. 1 - General Arrangement
1
4
3
2
5
1
9
17
15
18
13
12
8
10
14
11
16
19
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INTRODUCTION - 1
Figure. 2 - General Arrangement Top
1. Boiler control panel
2. Steam pressure gauge
3. Front access door
4. Access door lock
5. Top access panel
6. Electrical control panel
7. Operating pressure controller
8. Boiler steam safety valve
9. Main steam stop valve
10. Boiler blowdown valve
11. Water sample point
12. Feedwater pump
13. Boiler feedwater check valve
14. Boiler feedwater stop valve
15. Feedwater tank mounted (optional)
16. Feedwatertankoverow
17. Feedwater tank water inlet
18. Feedwater pump feed
19. Feedwater tank drain
20. Pressure vessel
21. Boiler water level probes
Key
20
21
6
7
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INSTALLATION - 2
2.1 GENERAL
SECTION 2 - INSTALLATION
2.2 PRE-INSTALLATION
Prior to delivery of the boiler, consideration should be given to the following:
(Planning regulations may call for more consents than those listed below, always check with your
Local Planning Authority).
A. Local Planning consents where appropriate.
B. Consideration given to access for delivery and positioning of the boiler.
C. Preparation of a suitable base, which must be able to support the total weight of the system
under operating conditions.
The locations of services to the site required for the system, under operating conditions.
D. Electricity supply, check the loading required/available.
E. Drainage system, check the suitability of the drainage system.
F. Local regulations for discharge into existing drains.
G. Suitable access for delivery and off-loading.
H. Safe access to the plant when installation is complete.
The installation of the Fulton Dragon electric steam boiler should be carried out by competent
personnel in accordance with all relevant safety regulations. It is the responsibility of the installer
to ensure that these regulations are complied with.
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INSTALLATION - 2
2.2.1 SITING
Theboilerhouseshouldbesufcientlysizedtoalloweasyandsafeaccesstoallpartsofthe
boiler for operational and maintenance purposes.
Reference should be made to AppendixA-TI-113-DRAGONDimensions&Specication
to ascertain the relevant dimensions and weights, special note should be taken of the required
clearanceformaintenance.Allowsufcientroomattherearoftheboilertoallowforthe
connection of all services.
Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto
support the boiler.
All connections for services are mounted at the rear of the boiler.
For connection sizes, refer to AppendixA-TI-113-DRAGONDimensions&Specication.
1. Feedwater Inlet
Itisadvisabletotastopvalveascloseaspossibletothisconnectionpoint.
2. Steam Safety Valve Discharge
The outlet from this valve should be piped to a safe discharge point and the piping should be
so arranged that condensate trapped in the discharge pipe is drained away from the valve.
3. Steam Outlet Valve
4. Boiler Blowdown Valve
Connection must be made from the Blowdown valve to a blowdown receptacle of approved
design. Regulations exist covering such items and care must be taken to ensure compliance with
these regulations. If in any doubt regarding blowdown arrangements consult Fulton Ltd.
5. Water Sample Outlet
This is to be connected to a sample cooler to take safe boiler water samples.
NON STANDARD FITTING CONNECTIONS
6. Water Level Gauge (sight glass) Blowdown
It is recommended the blowdown connection is made with a short (6 in.) length of soft copper
tube connected to steel tube running to the blowdown receiver. The copper tube will relieve any
stresses on the water level gauge set caused by the steel blowdown line.
7.Feedwatertankoverow
Theoverowshouldbepipedtoadrainagepoint.
8. Feedwater pump feed
9. Feedwater tank drain
10. Feedwater tank water inlet
CAUTION
Unlessotherwisespeciedthesteamsafetyvalvesuppliedwiththeboilerispre-set.Thisvalveis
provided as a safety device for the boiler and should not be used as the sole protection for other
equipment using steam from the boiler.
!
2.3 BOILER CONNECTIONS
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INSTALLATION - 2
Figure. 3 - Boiler Connection Points
2.3.1 STEAM SAFETY VALVES
Safetyvalvesarefactoryttedandpre-set,theyMUSTNOTbeadjusted.Thedischargeoutlet
should be piped to a safe discharge point and the piping so arranged that any condensate
trapped in the pipework will drain away from the valve.
Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806
clause 4.9.7. / BSEN 134801-1:2002
a) The lift pressure is indicated on the safety valve (donotadjust).
b) Thesafetyvalvettedtotheboilerisdesignedtopreventtheboilerexceedingitsdesign
pressure.
c) Any system connected to the boiler not capable of accepting boiler pressure must be protected
by a separate safety valve set to the required pressure.
WARNING
Factoryttedsafetyvalvesarepre-settoprotecttheboileronlyandmustnotbeusedtoprotectany
other items not capable of accepting boiler pressure.
!
1
2
3
8
7
10
4
59
6
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INSTALLATION - 2
2.5 ELECTRICAL REQUIREMENTS
The quality of the water used in the boiler will affect the life and performance of the boiler and
elements.
Feedwater contains solids and dissolved gases, these may promote encrustations of scale;
foaming, priming, surging; corrosion and pitting; or caustic embrittlement. To prevent this
happening it is strongly recommended that a reputable water treatment concern is consulted prior
to commissioning the boiler.
Note: See Appendix A - TI-139-Recommended Water Conditions.
Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. Should chemical
dosage of the boiler feedwater be required a connection point and a water sampling point are provided at the rear
of the boiler.
2.4 WATER SUPPLY
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical treatment plants
CAN BE SUPPLIED by Fulton.
It is the responsibility of the operator to ensure adequate supplies of chemical are available
at all times (including commissioning).
Costly repairs could be required should the plant operate without chemicals or the wrong
dosage of chemicals.
!
An individual wiring diagram for the boiler is located with the control panel. When referring to the
electricalspecicationoftheboiler,thewiringdiagramnumbershouldbequoted.
The power ratings and requirements are given in Appendix A - TI-113-Dragon Dimensions &
Specication.
A suitable 3-phase, neutral and earth isolated and fused supply is required external to the boiler
and must be connected in accordance with local electrical regulations.
CAUTION
Theboilerfrontaccessdooristtedwithasafetymicroswitch.Thisswitchautomaticallyisolates
theboilerelectricallywhenthefrontdoorisopen,andmustbeconnectedtoacontactorttedinthe
external mains supply distribution system.
!
It is essential that the electrical installation of the boiler is designed to protect both element and
pump circuits from excess current. See Figure. 4 for recommended external wiring.
Anelectricalisolatorshouldbesecurelyttedascloseaspossibletotheboiler.
Note: Any electrical work should be undertaken by a qualied installer, to current I.E.E regulations.
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INSTALLATION - 2
Figure. 4 - Recommended External Wiring
Figure. 5 - Electrical Panel
LC relays
Element and
pump overload
Audible alarm
Element and
pump contactors
MCB
MAIN
ISOLATOR
L1
3 PHASE FUSED AND ISOLATED SUPPLY
N
L3 L2
E
NOT FULTON SUPPLY
MCB MCB MCB
External Wiring Box
CONTACTOR
ELEMENT 1
CONTACTOR
ELEMENT 2
CONTACTOR
ELEMENT 3
CONTACTOR
FEED PUMP
External
Supply
Wiring
Panel
Wiring
Main Terminal Rail
Connections
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INSTALLATION - 2
WARNING
The Power On indicator is derived from one phase. It is possible for the Power On indicator supply
phase to be down, leaving the other two phases live. Always isolate the supply before working on the
panel.
!
CONTINUED ON NEXT PAGE
2.6 COMMISSIONING THE BOILER
These procedures should be carried out by a competent person.
Although every care is taken to ensure that the boiler has been despatched from the factory
fully tested, it is possible that during transportation and installation, pipework and electrical
connections may be loosened or broken. On completion of the installation and prior to switching
on the boiler it is advisable to carry out the following checks:
WARNING
The boiler electrical circuit must be isolated prior to doing the following tests.
!
1. Isolate boiler (mains supply)
2. Open front access door
Remove access cover on the top of the boiler
3. Check all electrical connections for tightness
4. Insulation test (IR) the elements
5. Set the steam operating pressure control to maximum pressure required
6. Ensure Mains switch Circuit live switch is in the OFF position
Connect to the mains electrical supply
7. Close boiler blowdown valve
Close main steam valve
8. Open all valves in the feedwater line and pump supply line
Allowfeedwatertanktoll
Check for leaks
9. Loosen the air release valve on the pump until water emerges from the plug and then re-
tighten
10. Close front access door
Retaccesscoveronthetopoftheboiler
WARNING
With the door open and the electrics overridden it is possible for the elements to be LIVE.
Extreme caution must be observed when working under these conditions.
!
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INSTALLATION - 2
11. Switch main isolator ON
Check the Circuit Live light illuminates
12. Open the main steam valve
13. Switch the Mains On/Off switch to the ON position
Check:
a) Low Water lights illuminate
b) Feedwater pump starts
c) Alarm sounds
CAUTION
The feedwater pump impeller blades can be damaged by incorrect rotation.
!
14. Check rotation of the feedwater pump (correct rotation shown by arrow on the pump)
Note: If the rotation is incorrect, switch the Mains On/Off switch to the OFF position, isolate the boiler and alter
the phase connections between the pump contactor overload and the pump. Check that the pump rotation is now
correct.
15. Check the feedwater pump runs until correct water level is achieved.
When water level is at normal working level (NWL) the Low Water lights will extinguish
16. Switch the element switches to the ON position
The element switches should illuminate
17. Close the main steam stop valve
18. Observing the steam pressure gauge, allow the boiler to build-up steam pressure until it
reaches the set limit on the operating pressure control switch and de-energises the elements.
Adjust the control switch as necessary
19. Check for leaks:
Turn Mains switch OFF
Turn element switches OFF
Turn main electrical isolator OFF
Open access cover on the top of boiler and front access door
Check for steam/water leaks
Close access cover on the top of boiler and close front access door
Check for steam leaks in connecting pipework
Turn main electrical isolator ON
Turn Mains switch ON
Turn element switches ON
Slowly open the steam valve to release pressure from the boiler until it reaches the set limit on
the operating pressure control switch and re-energises the elements
The boiler is now ready for placing into full operation.
WARNING
The boiler electrical circuit must be isolated prior to doing the following tests.
!
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OPERATION - 3
CAUTION
The following instructions are given for the guidance of the operator in the use of the Fulton steam
boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.
!
3.1 GENERAL
The following instructions are given for the guidance of the operator in the use of the Dragon
electric steam 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.
SECTION 3 - OPERATION
3.2 CONTROLS
The following brief description of the controls used on the Dragon steam boiler is intended to
provide the operator with a basic understanding of the operating principles, which is essential for
thecontinuedefcientoperationoftheboiler.
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OPERATION - 3
Figure. 6 - Controls and Indicators
The control panel contains a range of rocker switch lights to assist with the starting and testing
procedures, in addition the panel contains warning and fault indicators. Should a warning or fault
be indicated, the boiler must be isolated and the cause investigated by a competent person.
3.2.1 BOILER CONTROL PANEL
1.
2.
3.
4.
3.
3.
4.
5.
7.
6.
8.
/