FULTON VSRT Series - User Manual

VSRT Series
Gas Fired Steam Boiler
This manual must be available to the boiler operator at all times.
VSRT-IOMM-2019-1

Summary

Safety Precautions

Understanding Safety Information

Defines WARNINGS, CAUTIONS, and NOTES for safe operation.

General Hazard Warnings

Alerts to potential hazards of steam boilers, gas, and flue gas leaks.

Combustion Safety and Environmental Hazards

Warnings about incomplete combustion, CO, and air quality hazards.

Operational Safety and Equipment Warnings

Cautions on handling pressurized fluids, hot surfaces, and equipment limits.

Regulatory Compliance and Emergency Procedures

Outlines legal regulations and emergency actions for hazardous conditions.

Section 1 - Introduction

1.1 General

Explains pre-shipment inspections and the purpose of the manual.

1.2 Technical Data

Refers to Appendix A for specifications.

1.3 Product Overview

Describes the VSRT fuel fired steam boiler and its technology.

Section 2 - Installation

2.1 General

States installation must be by competent personnel according to regulations.

2.2 Pre-Installation

Lists considerations before boiler delivery, including planning and access.

2.2.1 Receiving Inspection

Customer should examine equipment for damage; installer ensures correct fitting.

2.2.2 Siting

Warnings about access for maintenance and safe siting requirements.

2.3 Ventilation

Importance of adequate fresh, clean air for combustion and ventilation requirements.

2.4 Connections

Details various connections to the boiler system.

2.4.1 Flue Outlet

Guidance on flue type, size, installation, material, condensate drain, and draft.

2.4.2 Blowdown Valves

Types of blowdown connections and requirements for blowdown receptacles.

2.4.3 Steam Safety Valve

Warnings about factory-set safety valves and discharge piping requirements.

2.4.4 Main Steam Valve

Recommendations for steam outlet piping rise, sizing, and condensate drainage.

2.4.5 Steam Pressure Gauge

Assembly of the steam pressure gauge and connection requirements.

2.5 Gas Supply

Warnings and cautions regarding gas supply, installation, and leak testing.

2.5.1 Gas Valve with Pilot Gas Line

Explains the gas valve bypass system and components.

2.5.2 Multi Bloc Gas Valves

Refers to manufacturer leaflets and illustrates gas valves and actuators.

2.6 Electrical Requirements

Cautions and warnings about electrical work, supply voltage, and wiring.

2.7 Water Supply

Cautions regarding water softeners, chemical treatment, and warranty.

2.12 Piping Specifications

Basic considerations for piping, including arrangement, material, and supports.

2.13 Insulation

Warnings about insulating hot pipework and vessels, and recommendations for covers.

Section 3 - Post Installation

3.1 Gas Purge

Warning about gas purging being for qualified persons only.

3.2 Pipework Leak;Pressure Tests

Procedures for soundness and leak detection fluid tests.

3.3 Electrical Installation Testing

Specifies earth bond test and terminal tightening.

3.4 Final Installation Inspection

Lists checks for ventilation, gas supply, flue system, and pipework.

Section 4 - Commissioning

4.1 Commissioning the Boiler

Emphasizes commissioning by qualified persons and outlines flue commissioning.

4.1.2 Boiler Inspection and Initial Firing Gas Burner

Steps for boiler inspection, water analysis, wiring, and feedwater pump checks.

4.1.3 Adjustment of the Yokogawa UT-32 A Operating Controller

Explains controller keys and procedures for adjusting set points and PID parameters.

Section 5 - Operation

5.1 General

Instructions for competent operator use, safety, and understanding controls.

5.2 Controls

Overview of controls for efficient boiler operation.

5.2.1 Boiler Controls

Explains limiters, feedwater pump, high water controller, and burner programmer.

5.2.2 Control Panel

Explains indicator lights on the control panel and their meanings.

5.2.3 Steam Pressure Controls

Describes operating pressure transducer and high pressure limiter.

5.2.4 Water Level Control Probes

Describes types of water level probes for high integrity monitoring.

5.3 Filling the Boiler All Models

Step-by-step instructions for filling the boiler safely.

5.4 Draining the Boiler

Cautions regarding boiler water discharge and procedures for manual/automatic blowdown.

5.5 Boiler Start-Up (From Cold) All Models

Step-by-step guide for cold start-up, including safety checks and pressure build-up.

5.6 Boiler Shut-Down

Procedures for short, medium, and long-term boiler shutdown.

Section 6 - Maintenance

6.1 Boiler Platform (If Fitted)

Recommendations for mobile platforms for easy access and site risk assessment.

6.2 Visual Checks

Inspecting pipework, fittings, and handholes for leaks.

6.3 Burner Flame Sensor Test

Procedure to test the flame safeguard sensor's operation.

6.4 Water Level and Low Water Safety Control Procedures

Procedures to ensure correct functioning of water level and low water safety controls.

6.5 Blowdown Procedures

Importance of blowdown for removing sludge and scale.

6.5.1 Main Boiler Blowdown (Manual)

Step-by-step guide for manual boiler blowdown.

6.5.2 Water Level Gauge (Sight Glass) Blowdown

Procedure for blowdown of the water level gauge sight glass.

6.6 Boiler Internal Inspection

Procedure for inspecting the boiler interior for scale or sludge build-up.

6.7 Fitting New Gaskets to Boiler Inspection Holes

Important information regarding fitting new gaskets.

6.8 Schedule of Operator Tests and Checks

Advice on test frequencies, maintenance of gas parts, and fault reporting.

6.8.1 Daily

Daily inspection and checks for leakage, low water level, and blowdown.

6.8.2 Weekly in Addition

Weekly checks including safety valve security, pump test, evaporation check, flame failure.

6.8.3 Monthly in Addition

Monthly checks including internal water space inspection and feedwater line cleaning.

6.8.4 Six Monthly Gas Safe Engineer Only

Procedures for gas safe engineers including feedwater tank flush, flue test, combustion check.

6.8.5 Annually Gas Safe Engineer Only

Annual inspection of the pilot assembly.

6.8.6 After All Repairs & Maintenance - In Addition

Post-repair checks including safety checks, firing, and combustion analysis.

6.9 Maintenance Record Keeping

Importance of boiler log sheets for history and maintenance.

Section 7 - Inspection

7.1 Inspection

Requirement for annual inspection by a qualified boiler inspector.

Section 8 - Troubleshooting

8.1 Troubleshooting Gas Boiler

Lists common problems like ignition failure, flame failure, and poor combustion.

8.2 Troubleshooting Feedwater Pump

Lists problems with the feedwater pump not running, overload, capacity, or noise.

Appendix A

VSRT-10 Specifications and Features

Details VSRT-10 model features, controls, listings, and trim kit items.

VSRT-15 Specifications and Features

Details VSRT-15 model features, controls, listings, and trim kit items.

VSRT-20 Specifications and Features

Details VSRT-20 model features, controls, listings, and trim kit items.

VSRT-30 Specifications and Features

Details VSRT-30 model features, controls, listings, and trim kit items.

VSRT-40 Specifications and Features

Details VSRT-40 model features, controls, listings, and trim kit items.

VSRT-50 Specifications and Features

Details VSRT-50 model features, controls, listings, and trim kit items.

VSRT-60 Specifications and Features

Details VSRT-60 model features, controls, listings, and trim kit items.

Technical Information: Recommended Water Conditions

Recommended water quality parameters for feedwater and boiler water.

TI-149: High Integrity Water Limiters

Details on Guided Wave Radar, Vibrating Fork, and conductive water level limiters.

TI-30: Automatic TDS Blowdown Systems

Explains the operation and calibration of Automatic TDS control blowdown systems.

Material & Workmanship Guarantee

General Guarantee

Details the general guarantee terms for Fulton products.

On the Fulton Boiler Pressure Vessel

Specific guarantee terms for the boiler pressure vessel.

FULTON VSRT Series Specifications