Fulton Hopkins (HPN) Horizontal Coil Thermal Fluid (hot oil) Heater - Manual (Page 3)

Questions? Call (315) 298-5121, or visit us online at www.fulton.com
HPN-IOM-2014-0416
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 ...................................................................................................... 2-7
Electrical Supply ................................................................................................... 2-7
Thermal Fluids ...................................................................................................... 2-8
THERMAL FLUIDS AT ELEVATED TEMPERATURES ......................................................................2-8
SELECTING A THERMAL FLUID ....................................................................................................2-9
ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................2-10
THERMAL FLUID BREAKDOWN .................................................................................................2-10
Piping Specifi cations .......................................................................................... 2-11
Insulation ........................................................................................................... 2-15
System Interfaces ............................................................................................... 2-15
HEATER CONNECTIONS ..............................................................................................................2-16
THERMAL FLUID CIRCULATING PUMP .....................................................................................2-16
REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................2-17
REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................2-17
COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................2-17
SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................2-18
TWO-PIPE EXPANSION TANK ....................................................................................................2-18
PRESSURIZED SYSTEMS ............................................................................................................2-18
VENT CONNECTIONS ..................................................................................................................2-18
CATCH TANK ...............................................................................................................................2-20
DRAIN/FILL CONNECTION .........................................................................................................2-20
PRESSURE GAUGES ...................................................................................................................2-22
THERMOMETERS .......................................................................................................................2-22
VALVES .......................................................................................................................................2-23
AUTOMATIC FLUID CONTROL VALVES .......................................................................................2-23
BY-PASS VALVES ........................................................................................................................2-23
Assembly of Fulton Multi-Skid Engineered Systems ......................................... 2-23
Stack and Flue .................................................................................................... 2-24
Testing ................................................................................................................ 2-25
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 .......................................................................................... 3-13
FIREYE LINKAGE MODULATION, YB110/E110 ..........................................................................3-13
SIEMENS LINKAGELESS MODULATION, LMV 51 ......................................................................3-14
Operating Controls ............................................................................................. 3-18
LIQUID LEVEL SWITCH - WHEN COMBINATION TANK IS SUPPLIED ........................................3-19
AIR SAFETY SWITCH ..................................................................................................................3-19
BLOWER MOTOR STARTER .........................................................................................................3-19
PUMP MOTOR STARTER .............................................................................................................3-19
DIFFERENTIAL PRESSURE SWITCH ...........................................................................................3-20
HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3-20
GAS PRESSURE SWITCH ............................................................................................................3-21
OPERATING TEMPERATURE CONTROLS ....................................................................................3-22
HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................3-22
HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................3-22
OPERATING LIMIT CONTROLLER ...............................................................................................3-23
MODULATING CONTROLS ..........................................................................................................3-24
PRESSURE GAUGES ....................................................................................................................3-24
TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................3-24
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
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