FULTON VSRT Series Installation, Operation And Maintenance Manual
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FULTON VSRT Series Installation, Operation And Maintenance Manual

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

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Summary of Contents for FULTON VSRT Series

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

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Fulton Ltd SECTION 5 - OPERATION Warnings & Cautions Explained Warnings & Cautions In Manual General Regulations Controls 5.2.1 Boiler Controls SECTION 1 - INTRODUCTION 5.2.2 Control Panel General 5.2.3 Steam Pressure Controls Technical Data 5.2.3.1 Setting Steam Pressure Controls Product Overview 5.2.3.2 Testing Steam Pressure Controls...
  • Page 3 TABLE OF CONTENTS Fulton Ltd SECTION 7 - INSPECTION Inspection SECTION 8 - TROUBLESHOOTING Troubleshooting - Gas Boiler Troubleshooting - Feed Water Pump APPENDIX A - TI SHEETS VSRT Dimensions & Specification Recommended Water Conditions High Integrity Water Limiters Auto TDS Blowdown Systems Material &...

  • Page 4: Iwarnings & Cautions Explained

    SAFETY PRECAUTIONS Fulton Ltd WARNINGS & CAUTIONS EXPLAINED For your safety! The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual. It is the responsibility and duty of all personnel involved • WARNINGS must be observed to prevent serious in the operation and maintenance of this equipment injury or death to personnel.
  • Page 5 DANGER FROM INCOMPLETE COMBUSTION you do not understand. Obtain a service manual from The importance of correct burner adjustment to achieve Fulton Ltd or call a Fulton service engineer. low emissions, safe, clean and efficient combustion is paramount. Poor combustion, where unburnt gas...
  • Page 6 Return the maximum amount of condensate and if necessary preheat the Should you suspect that the boiler’s flue passage feedwater. If in doubt consult Fulton Ltd. ways have become blocked, stop the boiler immediately and contact the Fulton office.

  • Page 7: Regulations

    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.
  • Page 8 Fulton Ltd Page VIII VSRT-IOMM-2019-1...

  • Page 9: Section 1 - Introduction

    • Packing, inspection and final check This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the staff responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable.
  • Page 10 INTRODUCTION - 1 Fulton Ltd Table 1 – VSRT Customer Connections (See Figs. 1-4) 10/15BPH 20/30 BPH 40/50/60 BPH Description Size Type Size Type Size Type A. Feed Water Inlet 1” B.S.P.T. 1” B.S.P.T. 1” B.S.P.T. B. Blowdown Outlet 1¼”...
  • Page 11 INTRODUCTION - 1 Fulton Ltd Figure 1 – Model VSRT-60 Dimensions – Front View VSRT-IOMM-2019-1 Page 3...
  • Page 12 Figure 2 – Model VSRT-60 Dimensions VSRT-IOMM-2019-1 Page 4...
  • Page 13 INTRODUCTION - 1 Fulton Ltd Figure 3 – Model VSRT-60 Dimensions – Top Side View VSRT-IOMM-2019-1 Page 5...
  • Page 14 Figure 4 – Model VSRT-60 Dimensions – Rear Side View VSRT-IOMM-2019-1 Page 6...

  • Page 15: Section 2 - Installation

    INSTALLATION - 2 Fulton Ltd GENERAL The installation of a VSRT fuel fired 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.

  • Page 16: Receiving Inspection

    INSTALLATION - 2 Fulton Ltd 2.2.1 RECEIVING INSPECTION The customer should examine the equipment for any damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are fitted in a correct and safe manner.

  • Page 17: Siting

    INSTALLATION - 2 Fulton Ltd 2.2.2 SITING ! WARNING Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist. (Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication 1676, and in particular to Section 5, Location of Appliances).
  • Page 18 INSTALLATION - 2 Fulton Ltd It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances in the combustion system can create hazardous conditions. Particulate matter like lint, combustible volatiles, dust, smog or chemicals (example, perchloroethylene, halogenated compounds) in the combustion air supply to the equipment will cause damage or failure of the burner and is not covered under warranty.

  • Page 19: Connections

    INSTALLATION - 2 Fulton Ltd CONNECTIONS 2.4.1 FLUE OUTLET The height and type of flue will be subject to local planning regulations and approvals. The following information is only intended to provide assistance for the installation of a simple flue. Where multi-boiler flues or difficulties are experienced, specialist advice should be obtained.
  • Page 20 INSTALLATION - 2 Fulton Ltd ! WARNING To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the section of the chimney duct within the building should be insulated. CAUTION Concentration levels of only a few ppm of chlorine containing compounds in combustion air can produce serious corrosion of the flue over long periods of time.

  • Page 21: Blowdown Valves

    Each connection must be connected 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 doubt regarding blowdown arrangements, consult Fulton Ltd or CEA Guidance Note Document BG03, which covers blowdown vessels and associated systems.
  • Page 22 INSTALLATION - 2 Fulton Ltd d) Ensure pipes and connections are clean and free of any foreign material. e) Install the valve vertically with no unnecessary intervening piping between the boiler and the valve. f) Do not cap or plug the weep hole on the side of the safety valve.
  • Page 23 INSTALLATION - 2 Fulton Ltd VSRT-IOMM-2019-1 Page 15...
  • Page 24 VSRT-IOMM-2019-1 Page 16...

  • Page 25: Main Steam Valve

    INSTALLATION - 2 Fulton Ltd 2.4.4 MAIN STEAM VALVE It is recommended to have a minimum of five pipe diameters of vertical rise out of the steam outlet. This is considered good piping practice and will allow for proper operation.

  • Page 26: Gas Supply

    INSTALLATION - 2 Fulton Ltd GAS SUPPLY ! WARNING Do not change the boiler fuel without consulting the boiler manufacturer. A qualified installer, service agency or the gas supplier must perform installation and service on the fuel delivery system. Do not use naked flames or other sources of ignition to check for gas leaks.

  • Page 27: Gas Valve With Pilot Gas Line

    INSTALLATION - 2 Fulton Ltd 2.5.1 GAS VALVE WITH PILOT GAS LINE The main gas valve is fitted with a bypass system (internal or external depending on the model) the bypass allows pilot pressure to be maintained whilst the flame is verified.

  • Page 28: Multi Bloc Gas Valves

    INSTALLATION - 2 Fulton Ltd 2.5.2 MULTI BLOC GAS VALVES Note: See attached manufacturers leaflets. Output pressure controller adjusting screw Operating indicator Hydraulic Brake Adjustable pressure Main gas flow adjustment switch Test point connection Test point connection downstream of Valve 1...

  • Page 29: Electrical Requirements

    INSTALLATION - 2 Fulton Ltd ELECTRICAL REQUIREMENTS CAUTION Any electrical work should be undertaken by a qualified electrician to current local regulations. ! WARNING Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment.
  • Page 30 INSTALLATION - 2 Fulton Ltd Bottom Blowdown Valve. Connect the Bottom Blowdown valve per the electrical drawing. A controller in the control panel will then allow automatic bottom blowdown to occur on a time basis. The contact gives feedback to the controller that the blowdown valve has opened and closed as required (Valve supply Max.
  • Page 31 This page is intentionally left blank VSRT-IOMM-2019-1 Page 23...

  • Page 32: Water Supply

    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.

  • Page 33: Glossary Of Water Supply Terms

    INSTALLATION - 2 Fulton Ltd 2.7.1 GLOSSARY OF WATER SUPPLY TERMS Dissolved Oxygen: Oxygen that is dissolved in Alkalinity: Alkalinity is the capacity of a water to the feedwater will cause the steel in the boiler and neutralize acids. Common water alkalinities consist of...

  • Page 34: Piping Specifications

    INSTALLATION - 2 Fulton Ltd Chlorides: If chloride levels are high enough to In all cases the water hardness should be tested cause severe corrosion, they can be controlled by periodically and prior to starting the generator to limiting the cycles of concentration and increasing ensure efficient operation of the softener.

  • Page 35: Insulation

    INSTALLATION - 2 Fulton Ltd 2. Valves are used in piping systems to stop and start the flow of fluids, to regulate flow, to prevent back flow, and to relieve excessive pressure build-up in the piping. Consideration should be given to the appropriate location and orientation of valves necessary for safe operation and isolation of the piping.
  • Page 36 Fulton Ltd VSRT-IOMM-2019-1 Page 28...

  • Page 37: Section 3 - Post Installation

    POST INSTALLATION - 3 Fulton Ltd GAS PURGE ! WARNING Gas purging by qualified persons only. A purge of the gas lines must be carried out to remove air (oxygen) from the pipework and to ensure the pipework is flooded with gas.
  • Page 38 POST INSTALLATION - 3 Fulton Ltd VSRT-IOMM-2019-1 Page 30...

  • Page 39: Section 4 - Commissioning

    Commissioning by qualified persons only. COMMISSIONING THE BOILER It is essential that the commissioning procedures listed below are carried out by a Fulton service engineer who will have the necessary experience and testing equipment to ensure that the installation is not only correct but is operating safely and at optimum efficiency.
  • Page 40 COMMISSIONING - 4 Fulton Ltd 6. Set up the load controller, see service information sheet SI012sheet. 7. Set the air pressure switch to its minimum setting. The gas pressure switch should be set at 10 mbar. The gas pressure switch is located on the gas train and the air pressure switch is located on the fan casing.
  • Page 41 COMMISSIONING - 4 Fulton Ltd Press enter and navigate to parameter 641, press enter and edit value to 1, press enter again to save. The LMV should now run speed standardisation procedure and the display should go back to. Once speed standardisation is complete the value of parameter 641 should become 0 again if the standardisation was successful, navigate back to parameter 641 to confirm this.
  • Page 42 COMMISSIONING - 4 Fulton Ltd Close any gas isolation valves. Once Pre-purging is complete the system will pause in phase 36, the ignition position phase. Ratio values for P0 will be displayed and ignition will commence if the plus arrow is pressed. DO NOT IGNITE THE BURNER BY PRESSING “+”...
  • Page 43 COMMISSIONING - 4 Fulton Ltd The gas pressure switch may be set by using the mono-meter and attaching it to the pressure tap on the gas line into the gas train. The low inlet gas pressure switch should be set to around 3 mbar lower than the normal working gas pressure (Minimum mandatory setting is 10mar).
  • Page 44 COMMISSIONING - 4 Fulton Ltd This step may need repeating a few times to purge any air trapped in the pilot line and valve assembly, if this is the case press and hold enter for 2 seconds to reset the LMV and restart this step.
  • Page 45 COMMISSIONING - 4 Fulton Ltd Use the + key to ramp the burner up through P1-P9 allowing the burner to stop at each set point long enough for the flame to settle to confirm stability. If the flame fails at any setpoint, reset the burner and return to the “cold” settings as described in step 14 and increase the fuel damper valve opening by 1°...
  • Page 46 99999999h *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 47 1=activated *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 48 *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 49 65535 *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 50 Error flags *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.

  • Page 51: Adjustment Of The Yokogawa Ut-32A Operating Controller

    COMMISSIONING - 4 Fulton Ltd Once the commissioner is satisfied that the flue gas contains O across setpoints P1-P9 at a boiler pressure of 10bar use the+ key to quickly ramp the burner up to P9, once at P9 use the - key to quickly ramp the burner down to P1 to confirm the flame is stable under transient load conditions.
  • Page 52 COMMISSIONING - 4 Fulton Ltd (1) DISP key used to switch the Operation Displays. Press the key in the Menu Display or Parameter Setting Display to return to the Operation Display. (2) PARA key hold down the key for 3 seconds to move to the Operation Parameter Setting display. Hold down the key and the left arrow key simultaneously for 3 seconds to move to the Setup Parameter Setting Display.
  • Page 53 The smaller the number, the faster the controller reacts. If it reacts too fast, it will oscillate. Integral setting allows the boiler to reach the set point Fulton standard Integral time setting is “minutes/ seconds per repeat” “D” – Derivative Band Proportional does the heavy lifting getting the temperature close to the set point and Integral gradually removes error.

  • Page 54: Section 5 - Operation

    OPERATION - 5 Fulton Ltd 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. GENERAL The following instructions are given for the guidance of the competent operator in the use of the VSRT fuel fired 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.

  • Page 55: Control Panel

    OPERATION - 5 Fulton Ltd Air Pressure Switch Mounted on the burner fan, this switch is operated by the pressure of air entering the burner through the fan. Lack of air, or insufficient pressure, will prevent the switch completing the circuit thus preventing the burner from operating.
  • Page 56 OPERATION - 5 Fulton Ltd Low Water Limiter 1 This light will energise when the boiler water is below low limiter 1. The light will illuminate, a continuous alarm will sound and the burner will go to lockout. Once the water in the boiler has been restored to a safe operating level, pressing the Common Alarm Reset button will reset the controls and allow the burner start sequence to initiate.

  • Page 57: Steam Pressure Controls

    OPERATION - 5 Fulton Ltd 5.2.3 STEAM PRESSURE CONTROLS Pressure controls are mounted on a bracket above the control panel. Pressure controls are as follows: Operating pressure transducer Provides an analogue signal to the boiler controller to control the pressure levels to maintain a set pressure.4 - 20 mA signal scaled to 0-16 bar.

  • Page 58: Setting Steam Pressure Controls

    OPERATION - 5 Fulton Ltd 5.2.3.1 SETTING STEAM PRESSURE CONTROLS 1. Set the boiler controller to the maximum pressure required (system pressure). Do not exceed the boiler operating pressure 5.2.3.2 TESTING STEAM PRESSURE CONTROLS 1. Start the boiler. 2. SHUT the main steam valve.

  • Page 59: Water Level Control Probes

    OPERATION - 5 Fulton Ltd 5.2.4 WATER LEVEL CONTROL PROBES Level 1 2 standard level probes fitted Level 2 and 3 1 x Vegaswing 66 vibrating level switch. 1 x Vegaflex 86 TDR sensor for continuous level and interface measurement.

  • Page 60: Draining The Boiler

    OPERATION - 5 Fulton Ltd DRAINING THE BOILER CAUTION Your local regulations could state boiler water above 43 °C must not be discharged into the drain. ALWAYS check your local regulations. Boilers with manual blowdown valves A low-level drain point is required in the blowdown pipework between the boiler and the Blow Down Vessel for both manual and automatic blowdown systems.

  • Page 61: Boiler Start-Up (From Cold) All Models

    OPERATION - 5 Fulton Ltd BOILER START-UP (FROM COLD) ALL MODELS 1. Fill the boiler (see Section 5.3 - Filling the Boiler). 2. Ensure the main steam isolating valve is SHUT. 3. Open all the valves in the gas train. It is assumed that the fuel supply lines have been purged prior to attempting to start the boiler/burner.

  • Page 62: Boiler Shut-Down

    OPERATION - 5 Fulton Ltd BOILER SHUT-DOWN 5.6.1 SHORT TERM SHUT-DOWN(HOURS) Switch OFF burner and pump. The burner will stop firing, post-purge and then stop. 5.6.2 MEDIUM TERM SHUT-DOWN(DAYS) 1. Shut the main steam valve. 2. Leave Pump switch ON.
  • Page 63 VSRT-IOMM-2019-1 Page 55...
  • Page 64 Fulton Ltd VSRT-IOMM-2019-1 Page 56...

  • Page 65: Section 6 - Maintenance

    MAINTENANCE - 6 Fulton Ltd 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.

  • Page 66: Burner Flame Sensor Test

    MAINTENANCE - 6 Fulton Ltd BURNER FLAME SENSOR TEST This test checks the operation of the flame safeguard sensor. 1. Ensure that the burner is firing. 2. Remove the flame sensor from its plug-in connection on the top of the burner.

  • Page 67: Water Level And Low Water Safety Control Procedures

    MAINTENANCE - 6 Fulton Ltd WATER LEVEL AND LOW WATER SAFETY CONTROL PROCEDURES The following procedures ensure the correct functioning of the water level controls and the low water safety controls. 6.4.1 FEEDWATER PUMP TEST a) If the boiler is not firing and not under steam pressure, lower the water level using...

  • Page 68: Low Water Level Check

    MAINTENANCE - 6 Fulton Ltd 6.4.2 LOW WATER LEVEL CHECK 1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off. 2. Switch the Pump switch to the OFF position.

  • Page 69: Evaporation Check

    Keep the boiler, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by blowing down in the following manner: Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.

  • Page 70: Water Level Gauge (Sight Glass) Blowdown

    If the valve is in any other position, the ball will not seat. Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure...

  • Page 71: Boiler Internal Inspection

    MAINTENANCE - 6 Fulton Ltd BOILER INTERNAL INSPECTION The lower hand hole doors should be Hand Hole Cover Plate removed after one month of operation and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, it should be removed and the water treatment supplier advised.

  • Page 72: Fitting Procedure

    MAINTENANCE - 6 Fulton Ltd 6.7.2 FITTING PROCEDURE Blowdown the boiler completely (see Section 6.5.1 - Main Boiler Blowdown) and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows: 1. Disassemble the crab and cover plate and remove the inspection hole assembly.

  • Page 73: Schedule Of Operator Tests And Checks

    Fulton Ltd SCHEDULE OF OPERATOR TESTS AND CHECKS The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler is installed in. Failure to maintain the boiler adequately may void the Fulton guarantee.

  • Page 74: Daily

    MAINTENANCE - 6 Fulton Ltd 6.8.1 DAILY ! WARNING All steam pipework, valves and fittings will be very hot. 1. Visually inspect for signs of leakage: a) Steam and feedwater pipework. b) Valves and fittings. c) Handholes If leakage is evident, the gasket needs replacing.

  • Page 75: Monthly-In Addition

    11. Clean any water traps and strainers fitted in the feedwater line. Check feedwater and boiler water quality against the values given in Appendix A - TI-139- Recommended Water Conditions. Note: Use only genuine Fulton replacement parts. VSRT-IOMM-2019-1 Page 67...

  • Page 76: Six Monthly Gas Safe Engineer Only

    With the flue capped and a smoke generator inserted into the flue, there should be no smoke visible. If either of these tests fail, shut down the boiler and contact Fulton Ltd immediately. 17. Check the burner combustion to ensure that excess air and carbon monoxide values are within normal limits (see combustion values in Appendix A-TI-151-VSRT Dimensions &...

  • Page 77: After All Repairs & Maintenance - In Addition

    MAINTENANCE - 6 Fulton Ltd Inspection/Cleaning Of The Burner Assembly Most of the particulate matter in the combustion air stream should be caught by a pre-filter or cyclone. However it is necessary to pull the burner head once a year, and inspect and clean it Remove Burner •...

  • Page 78: Maintenance Record Keeping

    Boiler log sheets should be completed on a regular basis, this provides invaluable information in the subsequent investigation of the boiler history. Maintenance log sheets can be found in the Fulton boiler Log Books provided by Fulton. To Purchase a Fulton Boiler Log Book, please contact training@fulton.co.uk. Model: Boiler Number:...

  • Page 79: Section 7 - Inspection

    INSPECTION - 7 Fulton Ltd INSPECTION 1. Provide annual inspection by a qualified boiler inspector, as required by local codes. VSRT-IOMM-2019-1 Page 71...
  • Page 80 Fulton Ltd VSRT-IOMM-2019-1 Page 72...

  • Page 81: Section 8 - Troubleshooting

    TROUBLESHOOTING - 8 Fulton Ltd TROUBLESHOOTING GAS BOILER Problem Cause Remedy 1. Gas supply Check for gas pressure and intermittent supply problems. 1. Ignition Failure 2. Power Supply Check fuse or circuit breaker. Reset or Replace as required. 3. Ignition Electrodes Check for cracks in porcelain, if found replace the electrode.
  • Page 82 TROUBLESHOOTING - 8 Fulton Ltd TROUBLESHOOTING GAS BOILER Problem Cause Remedy 1. Power Supply Check fuse or circuit, reset or replace as necessary. 3. Flame Failure During Normal Run 2. Gas Supply Check gas pressure coming into the gas train, if low contact the gas supplier.
  • Page 83 TROUBLESHOOTING - 8 Fulton Ltd TROUBLESHOOTING GAS BOILER Problem Cause Remedy 6. Poor Combustion 1. Main Air Adjustment Check air and gas servo motors and check CO2 and O2 combustion levels. 2. Draft Check draft with a gauge. Draft should be -.05 to -.10 mbar with the burner off, or -.10 to -.15 mbar when operating.
  • Page 84 3. Scale build-up or lime deposits. Consult Fulton or call a water treatment specialist. 4. Too much compound (water Dump contents of the return tank and flush the system. treatment over dose).

  • Page 85: Troubleshooting - Feed Water Pump

    TROUBLESHOOTING - 8 Fulton Ltd TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 1. Supply failure. Connect the electricity supply. 1. FEEDWATER PUMP Pump will not run 2. Fuses/Circuit Breakers are Replace fuses/Circuit Breakers. blown. 3. Motor contactor overload has Reactivate the motor protection.
  • Page 86 TROUBLESHOOTING - 8 Fulton Ltd TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 8. Noise. 1. Cavitation occurs in the pump. Check the suction conditions and the feed water temperature into the pump is not exceeding 90°C.” 2. Pump does not rotate freely Adjust the pump shaft.

  • Page 87: Vsrt Dimensions & Specification

    Fulton Ltd The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in this Appendix. Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To check you have the most up to date TI sheet, please check the downloads section on the Fulton website (www.fulton.co.uk/support/downloads) or consult Fulton Ltd.
  • Page 88 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 89 APPENDIX - A Fulton Ltd VSRT Model VSRT-10 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-10 Fuel Usage at Rated Input 10.7 (Natural Gas)* Fuel Usage at Rated Input (Propane Gas)**...
  • Page 90 APPENDIX - A Fulton Ltd VSRT Model VSRT-10 Open Flued (Type Boiler Room Ventilation for Combustion (free area) Low Level Inlet Boiler Room Ventilation for Combustion (free area) High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate VSRT Model...
  • Page 91 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 92 APPENDIX - A Fulton Ltd VSRT Model VSRT-15 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-15 Fuel Usage at Rated Input 16.1 (Natural Gas)* Fuel Usage at Rated Input (Propane Gas)**...
  • Page 93 APPENDIX - A Fulton Ltd VSRT Model VSRT-15 Open Flued (Type Boiler Room Ventilation for Combustion (free area) Low Level Inlet Boiler Room Ventilation for Combustion (free area) High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate VSRT Model...
  • Page 94 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 95 APPENDIX - A Fulton Ltd VSRT Model VSRT-20 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-20 Fuel Usage at Rated Input 21.5 (Natural Gas)* Fuel Usage at Rated Input (Propane Gas)**...
  • Page 96 APPENDIX - A Fulton Ltd VSRT Model VSRT-20 Open Flued (Type Boiler Room Ventilation for Combustion (free area) Low Level Inlet Boiler Room Ventilation for Combustion (free area) High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate VSRT Model...
  • Page 97 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 98 APPENDIX - A Fulton Ltd VSRT Model VSRT-30 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-30 Fuel Usage at Rated Input 32.3 (Natural Gas)* Fuel Usage at Rated Input 13.8 (Propane Gas)**...
  • Page 99 APPENDIX - A Fulton Ltd VSRT Model VSRT-30 Open Flued (Type Boiler Room Ventilation for Combustion (free area) 1285 Low Level Inlet Boiler Room Ventilation for Combustion (free area) High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate VSRT Model...
  • Page 100 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 101 APPENDIX - A Fulton Ltd VSRT Model VSRT-40 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-40 Fuel Usage at Rated Input (Natural Gas)* Fuel Usage at Rated Input 18.3 (Propane Gas)**...
  • Page 102 APPENDIX - A Fulton Ltd VSRT Model VSRT-40 Open Flued (Type Boiler Room Ventilation for Combustion (free area) 1714 Low Level Inlet Boiler Room Ventilation for Combustion (free area) High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate VSRT Model...
  • Page 103 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 104 APPENDIX - A Fulton Ltd VSRT Model VSRT-50 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-50 Fuel Usage at Rated Input 53.9 (Natural Gas)* Fuel Usage at Rated Input (Propane Gas)**...
  • Page 105 APPENDIX - A Fulton Ltd VSRT Model VSRT-50 Open Flued (Type Boiler Room Ventilation for Combustion (free area) 2142 Low Level Inlet Boiler Room Ventilation for Combustion (free area) 1071 High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate...
  • Page 106 § Cyclonic air filter Information provided in this document is based on standard boiler configurations. Alternate or custom configurations may result in deviations. Fulton practices continuous product improvement and reserves the right to change specifications and/or dimensions without notice. VSRT-IOMM-2019-1...
  • Page 107 APPENDIX - A Fulton Ltd VSRT Model VSRT-60 Rated Input at High Fire Minimum Input at Low Fire Boiler Rated Output kg/hr VSRT Model VSRT-60 Fuel Usage at Rated Input 64.7 (Natural Gas)* Fuel Usage at Rated Input 27.6 (Propane Gas)**...
  • Page 108 APPENDIX - A Fulton Ltd VSRT Model VSRT-60 Open Flued (Type Boiler Room Ventilation for Combustion (free area) 2574 Low Level Inlet Boiler Room Ventilation for Combustion (free area) 1287 High Level Outlet Typical Combustion M3/hr Air Intake Flow Rate...

  • Page 109: Recommended Water Conditions

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 139 Issue 4 VSRT, J Series & Electric Steam Boilers Recommended Water Conditions IMPORTANT It is very important that a strict water management program is followed to ensure trouble free boiler operation.
  • Page 110 APPENDIX - A Fulton Ltd VSRT-IOMM-2019-1 Page 102...
  • Page 111 APPENDIX - A Fulton Ltd VSRT-IOMM-2019-1 Page 103...

  • Page 112: High Integrity Water Limiters

    This allows the device to operate in boiler water with very low or varying conductivity such as RO or De-mineralised water. No polarising electrical connection is made through the probe so scale build-up is significantly reduced. Integrity The GWR unit that Fulton supplies is certified to provide SIL2 level of protection against low water level. VSRT-IOMM-2019-1 Page 104...
  • Page 113 This allows the device to operate in boiler water with very low or varying conductivity such as RO or De-mineralised water. Integrity The Vibrating Fork unit that Fulton supplies is certified to provide SIL2 level of protection against low water level. VSRT-IOMM-2019-1 Page 105...
  • Page 114 APPENDIX - A Fulton Ltd TI-149-High Integrity Water Limiters-2017-2 Pros Cons • Works with RO and DeMin Water • Probe lengths need to be ordered to • SIL2 low water limiter function size within a range • Doesn’t mistake foam for water...

  • Page 115: Auto Tds Blowdown Systems

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 30 Issue 4 Automatic TDS Blowdown Systems The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS level within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be used to control suspended solids, and prevent the build-up of sludge in the bottom of the boiler.
  • Page 116 The equipment and staff training required to carry out TDS sampling and calibration can be provided by Fulton. In order to achieve the maximum benefit from the installation of an Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the necessary equipment, and training in order for them to fully understand the function of the system, and the possible consequences of their actions.

  • Page 117: Material & Workmanship Guarantee

    On the Fulton Boiler Pressure Vessel Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within ten (10) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the manufacturer’s handbook.
  • Page 118 VSRT-IOMM-2019-1 Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 Email: BS EN ISO 9001:2015 Company Registration 855790 England...

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