Fulton Vertical Tubeless (FT-A) Thermal Fluid (hot oil) Heater - Manual (Page 3)

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FTA-IOM-2013-0227
TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Placement & Rigging ........................................................................................... 2-2
Clearances & Serviceability .................................................................................. 2-3
Environment, Ventilation and Combustion Air Requirements ............................ 2-3
Utilities ................................................................................................................. 2-7
THE GAS SUPPLY ..........................................................................................................................2-7
THE OIL SUPPLY ...........................................................................................................................2-7
Instrument Air ...................................................................................................... 2-8
Electrical Supply ................................................................................................... 2-8
Thermal Fluids .................................................................................................... 2-10
THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................2-10
SELECTING A THERMAL FLUID ..................................................................................................2-11
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2-12
THERMAL FLUID BREAKDOWN .................................................................................................2-12
Piping Specifi cations .......................................................................................... 2-14
Insulation ........................................................................................................... 2-20
System Interfaces ............................................................................................... 2-20
HEATER CONNECTIONS ..............................................................................................................2-20
THERMAL FLUID CIRCULATING PUMP .....................................................................................2-20
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2-22
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................2-22
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2-22
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................2-23
PRESSURIZED SYSTEMS ............................................................................................................2-23
VENT CONNECTIONS ..................................................................................................................2-26
CATCH TANK ...............................................................................................................................2-27
DRAIN/FILL CONNECTION .........................................................................................................2-27
PRESSURE GAUGES ...................................................................................................................2-27
THERMOMETERS .......................................................................................................................2-27
VALVES .......................................................................................................................................2-28
AUTOMATIC FLUID CONTROL VALVES .......................................................................................2-29
BY-PASS VALVES ........................................................................................................................2-29
Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-30
Stack and Flue .................................................................................................... 2-31
Testing ................................................................................................................ 2-32
Operation 3-1
Start-Up Preparation & Installation Review ........................................................ 3-2
Fill the System ...................................................................................................... 3-2
FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................3-3
FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................3-3
Circulating Pump .................................................................................................. 3-4
PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................3-5
PUMP WITH PACKED SEAL ..........................................................................................................3-6
Start-Up Service ................................................................................................... 3-6
Initial Start-Up ..................................................................................................... 3-6
COLD CIRCULATION......................................................................................................................3-6
FILTERING THE SYSTEM ...............................................................................................................3-7
BOILOUT .......................................................................................................................................3-8
COMBUSTION ...............................................................................................................................3-9
Flame Programmers .......................................................................................... 3-12
Operating Controls ............................................................................................. 3-12
LIQUID LEVEL SWITCH - WHEN COMBINATION TANK IS SUPPLIED ........................................3-12
AIR SAFETY SWITCH ..................................................................................................................3-12
BLOWER MOTOR STARTER .........................................................................................................3-13
PUMP MOTOR STARTER .............................................................................................................3-13
DIFFERENTIAL PRESSURE SWITCH ...........................................................................................3-13
HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3-14
GAS PRESSURE SWITCH ............................................................................................................3-15
OPERATING TEMPERATURE CONTROLS ....................................................................................3-15
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................3-16
OPERATING LIMIT CONTROLLER ...............................................................................................3-17
ON/OFF CONTROLS ....................................................................................................................3-17
MODULATING CONTROLS ..........................................................................................................3-17
PRESSURE GAUGES ....................................................................................................................3-17
TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................3-18
CYCLE TESTING ...........................................................................................................................3-18
Required Pressure Drop Across the Heater ......................................................... 3-18
Procedure for First Shutdown ............................................................................ 3-19
Daily Start-Up ..................................................................................................... 3-19
Daily Shutdown .................................................................................................. 3-20
Before Leaving the Installation .......................................................................... 3-20
Maintenance 4-1
Required Equipment ............................................................................................ 4-2
Required Maintenance at First Shutdown ........................................................... 4-2
Daily Maintenance Schedule ................................................................................ 4-2
Weekly Maintenance Schedule ............................................................................ 4-3
Monthly Maintenance Schedule .......................................................................... 4-3
Semi-Annual Maintenance Schedule .................................................................. 4-4
Annual Maintenance Schedule ........................................................................... 4-4
General Maintenance Procedures ....................................................................... 4-5
LUBRICATION ...............................................................................................................................4-5
SOOT CLEANING ..........................................................................................................................4-5
Safety Check Procedures ..................................................................................... 4-5
LIQUID LEVEL SWITCH ................................................................................................................4-5