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FULTON FT-C - User Manual

FULTON FT-C
91 pages
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-lon
INSTALLION AND
OPERATION MANUAL
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Summary

Introduction

Overview

Provides a general overview of the manual's purpose and the equipment.

Warnings & Cautions

Highlights critical safety information that must be observed to prevent injury or damage.

Disclaimers and Local Codes

Outlines installation compliance with codes and disclaims responsibility for non-compliance.

Installation

Placement & Rigging

Details essential steps for correctly placing and rigging the heater for safe installation.

Clearances & Serviceability

Specifies required clearances around the equipment for maintenance and safe operation.

Environment, Ventilation and Combustion Air Requirements

Outlines ventilation needs for proper combustion and maintaining a safe operating environment.

Utilities

Covers essential utility connections like gas, oil, and instrument air.

The Gas Supply

Provides instructions for the proper installation of the gas supply system.

The Oil Supply

Details installation requirements for the oil supply system.

Instrument Air

Specifies requirements for instrument air supply for pneumatic controls.

Electrical Supply

Details requirements for proper electrical supply installation and wiring.

Thermal Fluids

Discusses thermal fluids, their properties, and selection criteria.

Thermal Fluids at Elevated Temperatures

Warns about hazards and precautions when working with hot thermal fluids.

Selecting a Thermal Fluid

Guides on choosing the appropriate thermal fluid based on system needs.

Routine Analysis of Heat Transfer Fluid

Explains the importance and procedure for regularly analyzing the heat transfer fluid.

Thermal Fluid Breakdown

Discusses causes of thermal fluid breakdown and prevention methods.

Piping Specifications

Outlines considerations for selecting and installing piping for the system.

Piping Installation

Provides detailed instructions on how to install piping systems correctly.

Insulation

Details requirements for insulating hot pipework and vessels for safety and efficiency.

System Interfaces

Covers the proper connection and installation of system components.

Heater Connections

Specifies how to connect the heater to the system's piping.

Thermal Fluid Circulating Pump

Details installation procedures for the circulating pump.

Requirements for Air Cooled Pumps

Outlines specific installation requirements for air-cooled pumps.

Requirements for Water Cooled Pumps

Outlines specific installation requirements for water-cooled pumps.

Combination Deaerator;Thermal Buffer;Expansion Tank

Describes the function and installation of the integrated tank system.

Sizing The Expansion Tank For The System

Explains how to determine the correct size for the expansion tank.

Pressurized Systems

Discusses the use and installation of pressurized systems, including nitrogen blanketing.

Vent Connections

Provides instructions for making proper vent connections to prevent hazards.

Catch Tank

Details requirements for the catch tank and its connection to safety relief systems.

Drain;Fill Connection

Describes the location and use of the drain and fill connection.

Pressure Gauges

Explains the selection and installation of pressure gauges.

Thermometers

Guides on selecting and installing thermometers.

Valves

Provides installation guidelines for various types of valves.

Automatic Fluid Control Valves

Discusses selection and requirements for automatic control valves.

By-Pass Valves

Explains when and why to install a bypass valve.

Assembly of Fulton Multi-Skid Engineered Systems

Provides instructions for assembling multi-skid systems.

Stack and Flue

Details requirements for proper stack and flue installation for efficient combustion.

Testing

Outlines the necessary tests to perform after installation before operation.

Operation

Start-Up Preparation & Installation Review

A crucial step before initial start-up, reviewing all installation aspects.

Fill the System

Details the procedure for filling the system with thermal fluid.

Filling Procedure for Systems Open to Atmosphere

Specific steps for filling systems open to atmosphere.

Filling Procedure for Systems Equipped with Inert Blankets

Steps for filling systems that use an inert blanket.

Circulating Pump

Instructions related to the circulating pump's operation.

Pump With Mechanical;Air Cooled Seal

Specific operational procedures for pumps with mechanical/air-cooled seals.

Pump with Packed Seal

Operational notes for pumps with packed seals.

Start-Up Service

Information regarding factory start-up services.

Initial Start-Up

Comprehensive steps for starting the unit for the first time or after a shutdown.

Cold Circulation

Procedure for initial pump operation without heating.

Filtering the System

Describes the process of filtering the thermal fluid.

Boilout

Procedure for boiling out the system to remove impurities.

Combustion

Details the operation of the burner system.

SEQUENCE OF OPERATION FOR GAS FIRED BURNERS

Step-by-step sequence for gas-fired burner operation.

SEQUENCE OF OPERATION FOR ON;OFF BURNER

Sequence for on/off burner operation.

MODULATING BURNER

Details for modulating burner operation.

OIL FIRED BURNER

Describes the operation of oil-fired burners.

Flame Programmers

Information on operating flame programmers.

Siemens Linkageless Modulation, LMV 51

Operating procedures for the Siemens LMV 51 linkage-less modulation system.

Operating Controls

Overview of the various operating controls.

Liquid Level Switch - When Combination Tank is Supplied

Describes the function and testing of the liquid level switch.

Air Safety Switch

Explains the air safety switch function and testing.

Blower Motor Starter

Information on the blower motor starter.

Pump Motor Starter

Information on the pump motor starter.

Differential Pressure Switch

Details the differential pressure switch function and testing.

High and Low Fluid Pressure Switches

Explains high/low fluid pressure switches and their testing.

Gas Pressure Switch

Details gas pressure switches for gas-fired units.

Operating Temperature Controls

Describes temperature controls for regulating heater operation.

High Temperature Limit Switches Safety

Explains the function and setting of high temperature limit switches.

Operating Limit Controller

Information on the operating limit controller.

On;Off Controls

Describes on/off control operation.

Modulating Controls

Describes modulating control operation.

Pressure Gauges

Details pressure gauges used for monitoring.

Test of Ignition Safety System Shutoff

Critical procedure for testing ignition safety.

Cycle Testing

Verifies proper operation through multiple cycles.

Required Pressure Drop Across the Heater

Important parameter for heater performance.

Procedure for First Shutdown

Steps for safely shutting down the heater for the first time.

Daily Start-Up

Routine procedure for starting the heater daily.

Daily Shutdown

Routine procedure for shutting down the heater daily.

Before Leaving the Installation

Final checks before leaving an installation site.

Maintenance

Required Equipment

Lists necessary equipment for maintenance tasks.

Required Maintenance at First Shutdown

Essential maintenance after initial shutdown for warranty.

Daily Maintenance Schedule

Routine daily checks and tasks.

Weekly Maintenance Schedule

Tasks to be performed weekly.

Monthly Maintenance Schedule

Tasks to be performed monthly.

Semi-Annual Maintenance Schedule

Tasks to be performed every six months.

Annual Maintenance Schedule

Tasks to be performed annually.

General Maintenance Procedures

General maintenance guidelines.

Lubrication

Instructions for lubricating system components.

Soot Cleaning

Procedure for cleaning soot from the heater.

Safety Check Procedures

Procedures for verifying safety systems.

Liquid Level Switch

Testing the liquid level switch.

Stack Limit

Testing the stack limit switch.

Differential Pressure Switch

Testing the differential pressure switch.

Low Inlet Pressure Switch

Testing the low inlet pressure switch.

High Inlet Pressure Switch

Testing the high inlet pressure switch.

High Outlet Pressure Switch

Testing the high outlet pressure switch.

Air Switch

Testing the air switch.

Air Filter Box Switch

Testing the air filter box switch.

Temperature Limit(s)

Testing temperature limit controls.

High;Low Gas Pressure Switch

Testing high/low gas pressure switches.

Troubleshooting

Section dedicated to diagnosing and resolving issues.

Flow Circuit;Circulating Pump(s)

Troubleshooting issues related to flow and the circulating pump.

LOW INLET PRESSURE SWITCH

Troubleshooting specific to the low inlet pressure switch.

HIGH OUTLET PRESSURE SWITCH

Troubleshooting specific to the high outlet pressure switch.

FLOW SWITCHES

Troubleshooting flow switches.

HIGH INLET PRESSURE SWITCH

Troubleshooting specific to the high inlet pressure switch.

DIFFERENTIAL PRESSURE SWITCH

Troubleshooting specific to the differential pressure switch.

CALL FOR HEAT;BURNER INTERLOCK

Troubleshooting the call for heat and burner interlock circuits.

AIR SWITCH

Troubleshooting the air switch.

Parts & Warranty

Parts

Information on ordering spare and replacement parts.

Standard Warranty for Fulton Thermal Fluid Heaters

Details the warranty terms and conditions.

FULTON FT-C Specifications

General IconGeneral
BrandFULTON
ModelFT-C
CategoryHeater
LanguageEnglish

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