Fulton Vertical Coil (FT-C_S) Thermal Fluid (hot oil) Heater - Manual (Page 5)

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FTCS-IOM-2013-1114
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 ............................ 2-4
Utilities ................................................................................................................. 2-7
THE GAS SUPPLY ..........................................................................................................................2-7
THE OIL SUPPLY .........................................................................................................................2-10
Instrument Air .................................................................................................... 2-10
Electrical Supply ................................................................................................ 2-11
Thermal Fluids .................................................................................................... 2-12
THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................2-12
SELECTING A THERMAL FLUID ..................................................................................................2-12
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2-14
THERMAL FLUID BREAKDOWN .................................................................................................2-14
Piping Specifi cations .......................................................................................... 2-15
Insulation ........................................................................................................... 2-21
System Interfaces ............................................................................................... 2-21
HEATER CONNECTIONS ..............................................................................................................2-21
THERMAL FLUID CIRCULATING PUMP .....................................................................................2-22
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2-23
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................2-23
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2-24
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................2-26
PRESSURIZED SYSTEMS ............................................................................................................2-27
VENT CONNECTIONS ..................................................................................................................2-28
CATCH TANK ...............................................................................................................................2-29
DRAIN/FILL CONNECTION .........................................................................................................2-29
PRESSURE GAUGES ...................................................................................................................2-29
THERMOMETERS .......................................................................................................................2-30
VALVES .......................................................................................................................................2-30
AUTOMATIC FLUID CONTROL VALVES .......................................................................................2-31
BY-PASS VALVES ........................................................................................................................2-31
Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-31
Stack and Flue .................................................................................................... 2-32
Testing ................................................................................................................ 2-34
Operation 3-1
Start-Up Preparation & Installation Review ........................................................ 3-2
Fill the System ...................................................................................................... 3-3
FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................3-3
FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................3-4
Circulating Pump .................................................................................................. 3-5
PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................3-5
PUMP WITH PACKED SEAL ..........................................................................................................3-6
Start-Up Service ................................................................................................... 3-6
Initial Start-Up ..................................................................................................... 3-7
COLD CIRCULATION......................................................................................................................3-7
FILTERING THE SYSTEM ...............................................................................................................3-8
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 ............................................................................................................3-22
OPERATING TEMPERATURE CONTROLS ....................................................................................3-22
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................3-23
OPERATING LIMIT CONTROLLER ...............................................................................................3-24
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 ......................................................... 3-26
Procedure for First Shutdown ............................................................................ 3-27
Daily Start-Up ..................................................................................................... 3-27
Daily Shutdown .................................................................................................. 3-28
Before Leaving the Installation .......................................................................... 3-28
Maintenance 4-1
Required Equipment ............................................................................................ 4-2
Required Maintenance at First Shutdown ........................................................... 4-2
Daily Maintenance Schedule ................................................................................ 4-2
Weekly Maintenance Schedule ............................................................................ 4-4
Monthly Maintenance Schedule .......................................................................... 4-4
Semi-Annual Maintenance Schedule .................................................................. 4-5
Annual Maintenance Schedule ........................................................................... 4-5
General Maintenance Procedures ....................................................................... 4-5
LUBRICATION ...............................................................................................................................4-5
SOOT CLEANING ..........................................................................................................................4-6
Safety Check Procedures ..................................................................................... 4-6