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Horizontal Boiler
FB-S Series
100-800 Hp
Installation, Operation and Maintenance Manual
Serial # __________________________
Model # __________________________
Sold To __________________________
Date __________________________
This operating manual presents information that will help to properly operate and care for the equipment.
Study its contents carefully. The unit will provide good service and continued operation if proper operating
and maintenance instructions are followed. No attempt should be made to operate the unit until the
principles of operation and all of the components are thoroughly understood. Failure to follow all
applicable instructions and warnings may result in severe personal injury or death.
These instructions must not be considered as a complete code of practice, nor should they replace
existing codes or standards which may be applicable.
The requirements and instructions contained in this section generally relate to the Fulton model FBS.
When installing a packaged unit, this entire section should be read to ensure that the installation work is
carried out correctly.
Prior to shipment, the following tests are made to assure the customer the highest standards of
manufacturing.
a) Material inspections
b) Manufacturing process inspections
c) ASME welding inspection
d) ASME hydrostatic test inspection
e) Electrical components inspection
f) Operating test
g) Final engineering inspection
h) Crating inspection
Note
The installation of the boiler should be carried out by competent personnel in accordance with the
standards of the National Fire Protection Association. All state and jurisdictional codes beyond
the scope of the applicable ASME boiler and pressure vessel codes, for its corresponding
classification, should be followed in all cases. Jurisdictional authorities must be consulted prior
to installation.
The customer should examine the boiler for any damage, especially the refractories around the burner.
Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy
equipment.
Steam Outlet
Sight Glass Pressure Controls
Safety Valve
Connection
Manway
Pressure Gauge
Control Panel
Burner
Stack Connection
Rigging Point
(each side) Gas Train
*Lifting eyes on top
may be used also* ASME Stamping
Rigging Point
(each side)
*Lifting eyes on top
may be used also*
The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual.
They are repeated on these safety summary pages as an example and for emphasis.
WARNING
Do not operate, service or repair this equipment unless you fully understand all applicable
sections of this manual.
Prior to commencing any internal work on any control panel or electrical junction box, the
power must be disconnected.
Do not allow others to operate, service or repair this equipment unless they fully
understand all application sections of this manual, and are qualified to operate/maintain
the equipment.
Gauge glass valves need to be fully open during boiler operation to prevent boiler water
damage in case of gauge glass failure.
o
Boiler blowdown water must be cooled to <140 F prior to discharge to a drain. Failure to
use an approved blow off vessel with adequate cooling could cause personnel/equipment
damage.
A warm boiler will have very hot metal exposed. Care should be taken not to touch these
open across without protective clothing.
The water chemistry in the boiler must be kept within limits outlined in this manual. Failure
to do so will likely cause premature boiler pressure vessel failure and poor steam quality.
o
Boiler feed water temperature must be 140 F or greater to prevent corrosion fatigue
cracking at the feed water nozzle.
The bolts that connect the boiler shell to the rails need to be loosened slightly before the
boiler is warmed up to allow thermal expansion of the pressure vessel. Failure to do so
will create unwanted pressure vessel stress.
NOTES
After installation is complete and prior to operation the pressure vessel should be cleaned
or boiled out per instructions included in this manual.
The normal water level is approximately the center of the water gauge glass.
To ensure that your Fulton Steam Boiler is kept operating safely and efficiently, follow the
maintenance procedures set forth in this manual.
It is normal for the boiler safety relief valve to weep water if the boiler is operated above
90% of the valve setpoint (i.e. weep will occur for a 100 psig valve if boiler is >90 psig).
To ensure the continued safety and efficiency of the boiler, the schedule of maintenance
outlined in this section should be adhered to.
The boiler blow off operation should be done a minimum of once during the day when the
boiler is at 10 PSIG or less.
After a new Fulton Boiler has been in operation for several months, pieces of burned metal
will be found in the space at the bottom of the boiler. These pieces of metal are the
remains of a light gauge metal form which was used during manufacture for forming the
All secondary low water trips, flame failure trips or high steam pressure trips will require,
by code, a manual reset at the boiler.
1. General
a) Fulton model FB-S is a three-pass, water back and corrugated furnace design
steam boiler. In the first pass, the flame and high temperature flue gas flows from
the front to the back of the furnace. Through the second pass pipes, high
temperature flue gas flows from the combustion furnace to the front chamber. In
the third pass, the flue gas passes through the third pass pipes to the back of the
boiler and vents out. Corrugated furnace highly increases the heat exchange
area, heat transfer efficiency and reduces the possible damage to the boiler
durability cased by heat expansion and cold contraction.
b) Boiler is designed and manufactured to comply with ASME Code, with maximum
working pressure of 1.0MPa (150 PSI).
c) The fully packaged boiler has passed the strict test before it is delivered to the
customer. The equipment will give long life and excellent service on the job if
proper operating and maintenance instructions are followed.
d) FB-S boiler is a cylindrical vessel, with horizontal tubes passing through and
connected to the front and rear tube sheets. The vessel contains the water and
absorbs the energy generated from the flame. The front door and rear door
provide the seal to contain the hot combustion gasses. Baffles designed into the
doors serve to redirect the combustion gasses through the various firetube
passages. The flame originates in the furnace. As the combustion gasses travel
down the furnace and through the various firetube channels, heat from the flame
and combustion gasses is transferred to the water. Transferred energy develops
into the required steam or hot water.
e) The front door and rear door make it easy to clean the combustion chamber. The
pressure vessel can be inspected and repaired by the manhole on the top and
handholes on the side or bottom. The general information in this manual applies
directly to boilers in sizes ranging from 1 ton/hr through 6 ton/hr steam output
boiler for the following fuels: gas, No.2-6 Oil, No2 Oil and Gas.
f) The boiler is equipped with an automatic burner for fully modulating output.
Specifications
Model FB-S 100 125 150 200 250 300 400 500 650 800
Nominal steam output
3450 4312 5175 6900 8625 10350 13800 17250 22425 27600
(lbs/h) (1)
Design pressure (psig) 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150 15/150
Water Volume (gallons) 779 924 924 1294 1585 1849 3594 4650 4677 5265
Maximum fuel consumption (2)
Light Oil (gp/h) 29 36 43 58 73 88 117 146 189 234
Heavy Oil (gp/h) 27 34 41 54 68 82 108 136 177 216
Natural Gas (ft3/h) 4156 5196 6235 8313 10,392 12,470 16,626 20,784 27,019 33,252
Note:
(1) All steam output lbs/hr ratings from 0 psig at 212F.
3
(2) Fuel consumption based on light oil 1, 40,000 BTU/gal, natural gas 1000 BTU/ft , heavy oil 160,000
BTU/gal.
Connection
Model FB-S 100 125 150 200 250 300 400 500 650 800
Main steam valve (150 psig)
2.5 3 3 4 4 4 6 6 6 8
Flange
Safety valve connections
2 1.5 (2) 1.5 (2) 2 (2) 2 (2) 2.5 (2) 2.5 (2) 4 4 (2) 4 (2)
(150 psig) (in)
Main steam valve (15 psig) (in) Consult Factory
Safety valve (15 psig) (in) Consult Factory
Feed Water inlet line (in) 1.0 1.25 1.25 1.25 1.25 1.5 1.5 2 2 2
Blowdown line (in) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 1.5 (2) 2 (2) 2 (2) 2 (2)
Flue diameter (in) 14 16 16 18 20 20 22 22 26 26
Note: Specifications and dimensions are approximate. Fulton reserves the right to change specifications and
dimensions.
General
Note
It is essential that the installing shall be undertaken only by suitably qualified and
experienced personnel. Installation should comply with appropriate local and state codes
and standards.
36” Min
36” Min
Clearance
48” Min
36” Min
d) Be sure the total BHP= proper make up air opening size. For instance, if you
have three 300 BHP boilers, it is a total BHP of 900, and the 900 BHP make up
air size is recommended.
Note
These measurements are subject to state and local regulations. The
installation of exhaust fans in a boiler room is not recommended. An
exhaust fan can create down draft in the stack or restrict the burner’s air
supply which will result in poor combustion. 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.
Carbon Steel
Parameter Feedwater Horizontal Boiler/SteamPac Water
pH 7.5-9.5 8.5-10.5
Feedwater 140F* ---
Temperature
Hardness as < 2ppm < 15 ppm
CaCO3
Chlorides --- ---
Total Alkalinity --- < 500 ppm
Total Dissolved --- < 3000 ppm
Solids
Suspended No visual turbidity** No visual turbidity**
Solids
Total Organic No sheen No foam + No sheen No foam +
Carbon
Iron Colorless liquid++ Colorless liquid++
Dissolved <1 ppm* ND
Oxygen
Visual Oil ND ND
Conductivity --- < 4477
µS/cm)
(µ
NOTES:
*Feedwater temperatures below 200oF will require an oxygen scavenger
** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.
++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red
or orange tinge.
CAUTION
The safety valve supplied by the manufacturer can only protect the boiler;
it cannot protect any other equipment in the system.
d) Water Level Gauge: the water level gauge is equipped to monitor the boiler water
level. The boiler operator can see the water level inside the boiler from these
gauges. Both of them are connected to a drain line for periodic flushing.
8. Electrical Requirements
a) Connect wiring as shown in the wiring diagram, which is furnished
inside the electrical control panel box.
b) Electrical power available is usually 230/460 volt, 3 phase, 60 HZ (in
USA), 3 phases, 50 HZ (outside USA).
9. Gas Supply
a) Natural gas is the standard gas for the gas boiler. Special
requirements on request- i.e. liquid petroleum gas, town gas.
b) Gas must be supplied at a pressure high enough to overcome the
pressure loss in the burner gas train and furnace while running at full
input. This pressure is different based on the burner used. The
pressure must be checked to make sure it is high enough. If it is too
low, a gas booster must be used in the gas supply system.
Note
It is essential that a manual isolation valve is fitted upstream of the gas
control train to allow the burner to be isolated for maintenance. The size of
this valve should not be less than that of the burner control train in order to
avoid any restriction in gas flow.
Warning
It is essential that the installation of the gas piping must be undertaken
only by suitably qualified and experienced personnel and in compliance
with appropriate Codes and Standards. The Fulton Companies can accept
no responsibility for consequential loss, damage or personal injury, which
results from a failure to follow the manual.
Note
The pressure vessel must be cleaned before running the boiler after
installation.
12. Cleaning
Steam Piping
a) Steam and water piping systems connected to the boiler may contain
oil, grease, or foreign matter. The impurities must be removed in order
to prevent damage to pressure vessel heating surfaces. On a steam
system, the condensate should be wasted until tests show the
elimination of undesirable impurities. During the period that
condensate is wasted, attention must be given to the treatment of the
raw water used as make-up so that an accumulation of unwanted
materials or corrosion does not occur. For more information, contact
your local authorized boiler representative.
Pressure Vessel
a) The waterside of the pressure vessel must be kept clean from grease, sludge, and
foreign material. Such deposits, if present, will shorten the life of the pressure
vessel, will interfere with efficient operation and functioning of control, of safety
devices, and possibly cause unnecessary and expensive re-work, repairs, and
down-time.
b) The installation and operating conditions that the boiler will be subjected
to should be considered, and cleaning of the waterside of the
pressure vessel should be provided during the course of initial start-
up.
c) The pressure vessel and the steam and return lines, in effect, represent
a closed system. Although the steam and return (condensate) lines
system may have been previously cleaned, it is possible that:
Note
Temperatures of initial fill of water for hydrostatic tests, Boil-out, or for
normal operation should be as stated in the ASME Boiler Code.
Caution
Do not store halogenated hydrocarbons in or near the boiler room. In general,
ensure that the boiler area is in conformance with established boiler room
requirements. Review national and local codes.
Warning
The following brief description of the fittings and controls used on the FB-S boiler is intended
to provide the operator with a basic understanding of the operating principles, which is essential for
the continued efficient use of the boiler.
Various Relays
Motor Fuses
Flame Programmer
Warning
The power on the indicator is derived from one phase. It is possible for
that the Power On Indicator supply phase to be down, leaving the other
two phases live. Always isolate the supply before working on the panel.
Note
The Burner ON/OFF/Reset switch should be in the OFF
position during the filling process.
nd
The 2 Low Water Alarm can only be cancelled if the boiler water level is
nd
above the 2 Low Water Level. If the alarm cannot be cancelled, allow the
feed water pump to restore the water level to the normal working level
(approximately mid-way up the sight glass) and the reset the alarm.
st
1 LWCO
nd
2 LWCO
Pump Off
Pump On
High Water
Note
If the Level Control System is a float type or pressure differential transmitter,
then refer to specific spec sheets located in this manual.
Operating Limit
Modulating Control
Note
Boiler may be supplied with PID type pressure controls in lieu of on/off and
high/low pressure switches.
g) Burner Programmer
i. Is located in the center of the control panel. Acts in conjunction with a
sensing device to ‘supervise’ the ignition sequence, prove the flame is
satisfactory and finally ‘monitor’ 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/oil valves will shut to isolate the fuel line
to the burner. Lockouts include high steam pressure, low water, high/low
gas pressure and flame failure.
h) Flame Failure Indicator
i. Indicates the burner combustion control relay, detects a flame failure
condition.
2. Burner
Fulton Boiler FB-S model can mount with gas burner, oil burner or dual fuel burner
on customer’s request. See specific Burner Manual fro details.
Oil Burner
The fuel for the oil burner is from No.2 to No. 6 oil. The standard light oil burner for
a Fulton boiler is No.2 oil. The heavy oil burner can be used for No.4 to No.6
oil.
Note
When fitting nozzles to the heavy oil burners the nozzle filters must be
removed.
In calculating the correct size of nozzles to be fitted, refer to the specific
burner manual.
Check with local authorities where approval for start-up is required. In some
localities, final inspection of services may be required.
In general, ensure that the boiler area is in conformance with established boiler
room requirement. Review national and local codes.
Carry out the following procedure on the initial start up of the boiler and on every
subsequent occasion when restarting the boiler after a shut down.
d) Ensure that the Pump On/Off switch is in the PUMP OFF position, and that the
Hand/Off/Auto Switch is in the Off position.
e) Place the Pump On/Off Switch to the PUMP ON position, or Hand/Off/Auto in the
Auto position.
f) The feed pump should start and fill the boiler to the pump off level and then switch
off.
Note
It may be necessary to vent the feed water pump by bleeding air from the
plug mounted in the top casting below the pump motor to pump body
connection
Note
Before leaving the boiler unattended, the daily operating tests should be
carried out to check the functions of all the safety interlocks. For more
detailed information on the burner firing sequence consult the burner
manufacture’s Operation and Maintenance instructions.
Practical Considerations
When starting up the boiler, it is prudent to minimize the thermal and mechanical stress
caused by differential expansion of various parts of the boiler as they reach working
temperature. The temperature of the shell is determined by the contained water/steam
The frequency of the safety requirement for in service inspection of the main welded joints
of the boiler is calculated by the number of cycles since the last inspection. Boilers running
twenty four hours a day require the shell and furnace end plate welds to be inspected at
intervals specified by local boiler codes. Boilers that are continually heated and cooled
require more frequent inspection. The purpose of the in-service weld inspections is to check
for:
i. Buried defects during manufacture that are outside acceptable limits.
Because the boiler was 100% tested during manufacture none should be
found, and upon proof of 100% manufacturer testing these tests may be
waived at the discretion of the ‘competent person’.
ii. Cracks propagating from region of the toe of the fillet weld on the shell to
the tube plate weld, resulting from fatigue or corrosion fatigue cracking.
Note
Ensure the correct water level is maintained during pressure build up. If
any part of the equipment is not operating correctly, the fault should be
investigated before the boiler is used. Ensure all blowdown piping is safe and
discharged to a blowdown receptacle.
The Low Water Cutoff tests can be accomplished by isolating the feed pump using the
pump ON/OFF switch on the boiler control panel while the boiler is operating. Allow the
water level to fall by evaporating steam to the system.
st nd
Once the 1 Low Water Level Alarm is activated the water level can be lowered to the 2
Low Water Level by using the main blowdown valve.
nd
When the 2 Low Water Alarm sounds CLOSE the blowdown valve, turn the feed water
Pump On/Off switch to PUMP ON.
st nd
Once the 1 Low Water Level cancels the burner should remain off, but the 2 Low Water
nd
Alarm should continue to sound, reset the 2 Low Water Alarm. The burner should start
and the pump restores the water level to normal and stop.
4. Blowdown Procedure
In order to keep the boiler and water level gauge pipe work clear and free from sludge and
scale build-up, regular blowdown should be carried out.
Boiler Blowdown
a) Fully OPEN the fast opening blowdown valve, for a minimum of 5-10 seconds, see
note.
b) Regulate the blowdown flow using the common slow opening Y-type valve.
Flame Programmer
6. Evaporation Test
This test may be required by your insurance inspector as part of the annual inspection.
a) With the burner running, switch off the boiler feed pump and allow the water level in
the boiler to lower by evaporation.
st st
b) When the water level reaches the 1 Low Water position an alarm will sound, the 1
Low Water indicator lamp will illuminate and the burner will stop.
c) Allow the evaporation process to continue until the 2nd Low Water alarm sounds
nd
and the 2 Low Water Alarm/Switch illuminate.
d) Switch the feed pump to the PUMP & BURNER ON position.
st
e) The water level will be restored to normal working level, the 1 Low Water
indicator lamp will extinguish and the alarm will cancel.
nd
f) Press the 2 Low Water Alarm/Reset switch.
nd
g) The 2 Low Water Alarm/Reset switch will extinguish, the alarm will cancel and the
burner will start.
Note
Because the burner shuts down during this test it is possible that the steam
nd
load will rapidly decrease the pressure in the boiler causing a premature 2
7. Fault Finding
Before calling the Fulton Service Department, check the following:
a) Gas isolating valve(s) OPEN (gas and dual fuel burners).
b) Oil isolating valve(s) OPEN (gas and dual fuel burners).
c) Oil storage tank contains an adequate level of fuel.
d) Oil filer(s) are not blocked.
e) Water feed line from feed tank/hotwell is OPEN.
f) Water feed isolating valve on boiler is OPEN.
g) All blowdown valves are SHUT.
h) Fuses or MCBs in the main supply are not tripped.
i) Thermal overload on the pump motor is not tripped.
j) Thermal overload on the burner motor is not tripped.
k) Normal water level is visible in the water level gauges.
l) Feed pump is primed and not air locked.
m) Front door proof of closure microswitch is closed.
Before calling the Fulton Service Department, have the following information available:
a) The model and size of the boiler.
b) The boiler serial number.
c) The model and type of burner fitted.
Note
A very common problem is that when a boiler cools down, the steam in
the steam space condenses and gradually forms a vacuum. If the feed water
line is open, the boiler will draw in water in an attempt to equalize the
pressure. The appearance in the water level gauges is the same if they are
empty or fully flooded. If the sight glasses appear empty, but the water level
control alarm(s) have not sounded, it is highly probable that the boiler is
flooded. Allow air into the system and drop the water to the normal operating
level by opening a blowdown valve. Installing a vacuum breaker on the boiler
or steam header will not allow a vacuum condition to occur as a boiler cools
down.
IMPORTANT: If any fault is found during these procedures, shut down the
boiler immediately and consult The Fulton Companies.
Note
It is essential that regular checks are made to ensure scale build-up is not
taking place within the boiler. Such checks will ensure that water treatment
being applied to the boiler water feed is effective.
The lower hand hole doors should be removed after one month and the
interior of the boiler thoroughly examined. If scale or sludge build-up is
observed, a water treatment specialist should be consulted.
IMPORTANT: New gaskets must be fitted every time a hand hole door is
removed, refer to Section 5 for fitting procedures.
Check the hand holes and man holes for signs of leakage. This is particularly
important when the boiler is started from new or when gaskets have been
replaced (refer to the Section for fitting procedures for new gaskets). Corrective
action taken as soon as a leak occurs can prevent costly repairs later.
Check for signs of leaks on all valves and fittings and take the appropriate action.
Test all the boiler water level functions by evaporation, e.g. switch off the
boiler feed pump-see Starting the Burner.
Check the flame failure controls by removing the burner flame sensor from its
plug-in connection on the side of the burner and covering the detection window
to exclude all light. The burner control should immediately go to a lockout flame
failure condition and will require manual resetting. Clean the flame sensor before
replacing it.
Caution
The boiler and attaching parts will retain heat long after the boiler has been
shut down. Always use protective clothes and extreme caution when
working on a hot boiler.
c) Empty the boiler. It will be necessary to allow air into the boiler before it will drain via
the main blowdown valve.
d) Remove the hand hole and manhole doors and thoroughly inspect the internal
surfaces of the boiler, paying particular attention to the junction of the tubes
with the front tube plate and the tubes for signs of pitting. Any deposits should
be removed and your water treatment specialist consulted. Ensure there are no
accumulated deposits of sludge in the bottom of the boiler.
e) Remove the feed water dispenser, inspect and clean.
f) Replace the man hole and hand hole door gaskets, refer to Section FITTING
NEW GASKET for fitting procedures
g) Open the boiler front access door with the burner mounted on it as described
below. It will be necessary to disconnect the gas supply from the gas train and oil
supply from the oil lines to allow the door to swing open.
h) Remove water column plug at cross section and clean nipple to boiler.
n) Inspect the door seal for signs of wear and replace if necessary. The first indication
of a worn door seal would be evident by signs of leakage around the external
periphery of the door.
Warning
When handling ceramic fiber always follow the local regulations regarding
such materials, including the use of breathing apparatus, suitable body
protection and protective gloves.
o) Examine the internal surface of the door lining for defects. Small repairs may be
carried out by cutting out the defective area and replacing with new fiber, ensure
the correct adhesive is used.
p) Examine the end of the burner blast tube where it extends through the door into the
furnace. Clean off any deposits, paying particular attention to the internal lip where
deposits can cause irregular flame patterns.
q) Inspect the rear smoke box door seals for deterioration and replace if necessary.
r) Close the hinged front access door by reversing the opening procedure.
s) Re-connect the gas/oil connections.
t) ) Drain and flush the feed water/ hotwell tank, clean any filters and the strainer in
the feedline before the pump.
u) Drain and flush out the blowdown separator.
Note
Depending upon the mode of operation, it may be found that the six
monthly interval can be extended, possibly to an annual service. It is
strongly recommended, however, that the interval should be 6 months
from initial start up until such times as a ‘pattern of use’ and the condition of
the boiler after a typical 6 months can be established.
4. Annual Maintenance
It is normal practice to carry out an annual service during which your insurance
surveyor would attend to carry out the statutory inspection. The scope of a full
insurance strip-down is such that it should only be attempted by persons
competent to do so who have had the necessary training, and have the
required test equipment. Fulton Boiler Works can offer this service if required.
The engineering surveyor may require the removal of the ceramic fiber
insulation around the periphery of the front tube plate to facilitate inspection of
the shell to tube plate weld. The standard Fulton service kit includes
replacement ceramic fiber log material which must be glued in place with the
adhesive supplied. It is vital the material is fitted ensuring the ends of the fiber face
into the centre of the boiler.
Incorrect
(Overtightened)
Correct
Installation
Water treatment and oxygen attack can be combated by ensuring that the gasket is
aligned correctly so that only the extreme edges of the gasket are exposed. If a
new gasket leaks after fitting this is almost certainly due to incorrect sealing or
alignment. Incorrect sealing or misalignment will reduce the life of the gasket and
cause problems later.
Under stress can be avoided by tightening just sufficiently to stop any leakage
when fitting cold and before firing the boiler. Fire the boiler and then gradually
warm the boiler up, allowing the increasing steam pressure to take over and
complete the seal. The will allow the gasket material to contract naturally and
follow the topography of the mating surfaces. The securing nut can then broken
when the boiler is cold and under negative pressure.
Gentle warming of the boiler on initial firing after maintenance will also help to
ensure that the rubber ‘cures to shape’. If the rubber post-cures, the elastic
memory will be destroyed and any initial over-tightening will cause the gasket
to become hardened and embrittled, leading to cracks and eventual failure.
Fitting Instructions
Blowdown the boiler completely and examine all inspection holes in the boiler. If
any leakage is evident, proceed as follows:
a) Remove the old gasket and thoroughly clean the mating faces of the cover plate
and boiler ring.
Note
Ensure the gasket is aligned correctly so that only the extreme edges are
exposed to water treatment or oxygen attack. If the gasket is misaligned,
over tightening to seal a leak will not prevent subsequent leakage at a later
date.
d) Gradually warm up the boiler, allowing steam pressure to make the seal. If the
gasket leaks during pressure build up, tighten the securing nuts sufficiently
only to stop the leakage. It is important to keep the nuts correctly tightened
thereafter, this prevents the vacuum developed by cooling on shutdown from
feeding and draining the boiler.
Note
New gasket fitted to inspection holes located along the bottom of the boiler
are more difficult to install without leaking. Small particles of the scale or
sand tend to run down on the mating surfaces after cleaning but prior to
assembling. This condition is likely to have occurred if excess tightening
is required to stop a leak before warming the boiler. In this event, the best
course of action is to drain the boiler and repeat the gasket fitting procedure.
Failure to do so will severely reduce the life of the gasket.
e) Clean and inspect each water gauge sight glass. If any water leakage is evident,
renew the sight glass gasket.
Parts Warranty
Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is
found to be defective in workmanship or material within one (1) year of shipment from the factory
provided this equipment has been installed, operated and maintained by the buyer in accordance
with the Installation, Operation & Maintenance Manual and the component manufacturers’
instructions and the commissioning agency has successfully completed and returned the
equipment Installation and Operation Checklists to Fulton’s Quality Assurance department.
General
Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does
not include freight, handling or labor charges of any kind.
These warranties are contingent upon the proper sizing, installation, operation and maintenance
of the boiler and peripheral components and equipment. Warranties valid only if the boiler is
installed, operated, and maintained as outlined in the Fulton Installation, Operation &
Maintenance Manual.
No Sales Manager or other representative of Fulton other than the Quality Manager or an officer
of the company has warranty authority. Fulton will not pay any charges that were not pre-
approved, in writing, by the Fulton Quality Manager.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but
not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton
shall in no event be liable for any consequential or incidental damages arising in any way,
including but not limited to any loss of profits or business, even if the Fulton Companies has been
advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid
for the original equipment found to be defective.
To activate the warranty for this product, the appropriate commissioning sheets must be
completed and returned to the Fulton Quality Assurance department for review and approval.
12/2/09
The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system.
Generally, this system MUST include ALL of the following equipment in order for the warranty to apply.
Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation,
Operation and Maintenance Manual
There is a $1,000 labor allowance for any failed pressure vessel that is covered under the above warranty.
Parts Warranty
Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in
workmanship or material within twelve (12) months of shipment from the factory provided this equipment has been
installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by
both Fulton and the component manufacturers.
General
Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight,
handling or labor charges of any kind.
No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has
warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality
Manager.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose. Fulton shall in no event by liable for any consequential
or incidental damages arising in any way, including but not limited to any loss of profits or business, even if Fulton has
been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original
equipment found to be defective.
Conditions of Warranty
Warranties are only valid if the boiler is installed, operated and maintained as outlined in the Installation, Operation and
Maintenance Manual. Fulton shall accept no responsibility if the equipment has been improperly installed, operated or
maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the equipment. The
use of replacement parts not manufactured or authorized by Fulton will void any warranty express or implied.
Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a
factory certified technician. The commissioning agency must successfully complete and return the equipment Installation
and Operation Checklist to Fulton’s Service department.
The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports
must be produced for warranty consideration.
The warranty is valid for the original installation only in the U.S.A and Canada.
Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton
Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.