Fulton Alliance (FT-HC) Horizontal Coil Thermal Fluid (hot oil) Heater - Manual (Page 3)

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FTHC-IOM-2012-1001
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 ................................................................................................................. 2-6
THE GAS SUPPLY ..........................................................................................................................2-6
THE OIL SUPPLY ...........................................................................................................................2-7
Instrument Air ...................................................................................................... 2-8
Electrical Supply ................................................................................................... 2-8
Thermal Fluids ...................................................................................................... 2-9
THERMAL FLUIDS AT ELEVATED TEMPERATURES ......................................................................2-9
SELECTING A THERMAL FLUID ..................................................................................................2-10
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2-11
THERMAL FLUID BREAKDOWN .................................................................................................2-11
Piping Specifi cations .......................................................................................... 2-13
Insulation ........................................................................................................... 2-16
System Interfaces ............................................................................................... 2-16
HEATER CONNECTIONS ..............................................................................................................2-16
THERMAL FLUID CIRCULATING PUMP .....................................................................................2-18
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2-19
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................2-19
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2-20
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................2-20
PRESSURIZED SYSTEMS ............................................................................................................2-21
VENT CONNECTIONS ..................................................................................................................2-21
CATCH TANK ...............................................................................................................................2-24
DRAIN/FILL CONNECTION .........................................................................................................2-24
PRESSURE GAUGES ...................................................................................................................2-25
THERMOMETERS .......................................................................................................................2-26
VALVES .......................................................................................................................................2-26
AUTOMATIC FLUID CONTROL VALVES .......................................................................................2-26
BY-PASS VALVES ........................................................................................................................2-27
Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-27
Stack and Flue .................................................................................................... 2-28
Testing ................................................................................................................ 2-29
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
FILTERING THE SYSTEM ...............................................................................................................3-7
BOILOUT .......................................................................................................................................3-8
COMBUSTION ...............................................................................................................................3-9
Flame Programmers .......................................................................................... 3-14
SIEMENS LINKAGELESS MODULATION, LMV 51 ......................................................................3-14
Operating Controls ............................................................................................. 3-19
LIQUID LEVEL SWITCH - WHEN COMBINATION TANK IS SUPPLIED ........................................3-19
AIR SAFETY SWITCH ..................................................................................................................3-19
BLOWER MOTOR STARTER .........................................................................................................3-19
PUMP MOTOR STARTER .............................................................................................................3-20
DIFFERENTIAL PRESSURE SWITCH ...........................................................................................3-20
HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3-21
GAS PRESSURE SWITCH ............................................................................................................3-21
OPERATING TEMPERATURE CONTROLS ....................................................................................3-22
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................3-23
OPERATING LIMIT CONTROLLER ...............................................................................................3-23
ON/OFF CONTROLS ....................................................................................................................3-24
MODULATING CONTROLS ..........................................................................................................3-24
PRESSURE GAUGES ....................................................................................................................3-24
TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................3-25
CYCLE TESTING ...........................................................................................................................3-25
Required Pressure Drop Across the Heater ......................................................... 3-25
Procedure for First Shutdown ............................................................................ 3-26
Daily Start-Up ..................................................................................................... 3-26
Daily Shutdown .................................................................................................. 3-27
Before Leaving the Installation .......................................................................... 3-27
CONTINUED ON NEXT PAGE