Fulton SteamPac Unfired Steam Generators

Installation, Operation and Maintenance Manual
Serial # Model # Fulton Order # Sold To Job Name Date __________________________ __________________________ __________________________ __________________________ __________________________ __________________________

Fulton Thermal Corp. 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com
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Table of Contents
Section 1 – Safety Warnings & Precautions Section 2 – Installation
1. 2. 3. 4. 5. 6. 7. 8. 9. Introduction Placement Transport Location Access Clearance Installation Check Points Ventilation Feedwater 28. The Feed Water Piping 29. The Steam Supply 30. The Steam Safety Valve 31. The Steam Pressure Gauge Assembly 32. Electrical Supply 33. Frost Protection

Section 3 – Operation
1. 2. 3. 4. 5. 6. 7. 8. 9. Unit Description and Application Basic Operation Steam Pressure Controls Feed Pump Control High Steam Pressure Control Steam Safety Valve Steam Pressure Gauge Overload Protection Control Switch

10. Recommended Water Conditions 11. Water Supply 12. Glossary of Water Supply Terms 13. Chemical Dosing 14. The Water Column 15. Water Gauge & Gauge Glass Installation Instructions 16. General 17. Thermal Fluid Pipework 18. Bolting Sequence 19. System Connections 20. Valves 21. Testing 22. Insulation 23. Thermal Fluids 24. Return Tank and Connecting Pipework 25. Connection to Drains 26. Steam Pipework 27. The Blow-Off Valve

Section 4 – Maintenance
1. 2. 3. 4. 5. 6. 7. 8. 9. Recommended Water Conditions Maintenance Schedule Safety Relief Valves De-scaling Cleaning the Water Probes Feed Pump Electrical Controls Miscellaneous Troubleshooting

Section 5 – Parts & Warranty

Section 6 – Product Specs & Data

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Section 1

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Section 1 – Safety Warnings & Precautions
This manual is provided as a guide to the correct operation and maintenance of your Fulton SteamPac Unfired Steam Generator, and should be permanently available to the staff responsible for the operation of the SteamPac.

These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.

The requirements and instructions contained in this section generally relate to the standard Fulton SteamPac Unfired Steam Generator. When installing a packaged unit, this entire section should be read to ensure that the installation work is carried out correctly.

Prior to shipment, the following tests are made to assure the customer the highest standards of manufacturing:

a) Material inspections b) Manufacturing process inspections c) ASME welding inspection d) ASME hydrostatic test inspection e) Electrical components inspection f) Operating test

g) Final engineering inspection h) Crating inspection

Note The installation of Fulton SteamPac Unfired Steam Generators should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association, National or Canadian Electrical Code. All state and jurisdictional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classification, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

All units are crated for fork lift transport. Once uncrated, all units can be transported with a forklift. Under no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of any Fulton equipment.

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Rigging your heater into position should be handled by a competent rigger experienced in handling heavy equipment.

The customer should examine the unit for any damage.

Note All factory piping flanges should have bolts re-torqued before filling of system as bolts may loosen in shipping.

Note All unions on piping should be tightened prior to operation.

For Your Safety
The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are repeated on these safety summary pages as an example and for emphasis. • • •

WARNINGS must be observed to prevent serious injury or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.

Caution Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly with clean water after leak check has been completed.

Note Where a condensate return tank is to be fitted, this should: 1. Be vented 2. Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature.

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3. Vent pipe should not be downsized (This may cause pressure build up in the condensate tank.) 4. Return pipes must not be insulated. This can cause overheating the return system, causing a vapor lock in the pump. 5. See return system instruction manual for detailed instructions.

Note Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton Representative for advice.

Only properly trained personnel should install and maintain water gauge glass and connections. Wear safety glasses during installation. Before installing, make sure all parts are free of chips and debris.

Keep gauge glass in original packaging until ready to install. Never operate with lucite gauge glass guard removed or without brass rods for gauge glass protection kit.

Warning Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and/or property damage.

Warning Under no circumstances should the water softener water flow limit be exceeded.

Note After installation is complete and prior to operation the pressure vessel should be cleaned. Note a) The non-fused disconnect switch on the control panel that controls the feed water pump should be kept in the “on” position at all times during the boiler operation as well as during the nonoperating period of the boiler.

b) This switch should be turned “off” only when repairs or adjustments should be made.

The pump will continue to operate until the water reaches the correct level in the SteamPac. This level is approximately the center of the water gauge glass.

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Warning Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.

When stopping the SteamPac for any extensive repairs, shut off main disconnect switches on both the boiler side as well as the feed water side.

Note To ensure the continued safety and efficiency of the SteamPac, the schedule of maintenance outlined in this manual should be adhered to.

Note Fulton recommends that the feedwater treatment should be added between the pump and the SteamPac.

Warning Make sure main power switch is off before starting work.

Caution Do not clean the gauge or glass while pressurized or in operation.

Note All of the above maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-7148 or your local Fulton Thermal Representative.

Note Room temperature not to exceed 100 F.
o

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Section 2

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Section 2 – Installation
1. Introduction a) This manual is provided as a guide to the correct operation and maintenance of your unfired steam generator, and should be permanently available to the staff responsible for the operation and maintenance of the unfired steam generator. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards that may be applicable. b) In the event that you require after sales service, Fulton Thermal Corporation has a complete staff of field service technicians, and spare parts are available direct from the factory. Should you require additional information or assistance on the operation and maintenance of your unfired steam generator, please contact the Fulton service department at (315) 298-7148 or contact your local Fulton Representative.

2. Placement
a) Proper placement of your unfired steam generator is essential. Attention paid to the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble free installation, operation and maintenance.

3. Transport
a) Fulton SteamPacs are skid mounted. Rollers should be placed beneath the frame of the skid or the fork lift holes in the bottom of the skid may be utilized for positioning in the installation area.

4. Location
1. Authorities with jurisdiction over any national, local or insurance codes should be consulted prior to installation to assure compliance. 2. The unfired steam generator should be located as close as possible to the steam users in order to keep condensation & pressure drop to a minimum. 3. A level, hard surface of non-combustible material is required as a suitable base for mounting the unit. It is suggested that a 4” containment curb be installed completely around the unit. In the event of a spill of thermal fluid, the curb will help contain the fluid.

5. Access
1. Access around the unfired steam generator should be provided to facilitate maintenance. Place the SteamPac with clearances to unprotected combustible materials including plaster or combustible supports not less than the clearances listed in the table below.

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Pipes should not be run within 10” of any control cabinets or combustible material. All SteamPacs will also require a minimum clearance overhead for personnel access. In cases where available height is insufficient, a roof or ceiling trap might be considered.

6. Clearance
a) Front/Vertical: TBD-Consult the end assembly drawing for the tube bundle removal length specific to the model purchased. b) Sides: c) Rear: 18” (0.5m) 18” (0.5m)

7. Installation Check Points
a) Make sure all piping connections are complete and tight. b) Make sure the pressure controls are adjusted properly. c) Make sure all electrical connections in the control panel box, the water column, and elsewhere are secure.

Note After installation is complete and prior to operation the pressure vessel should be cleaned.

In general, ensure that the SteamPac area is in conformance with established boiler room requirements. Review national and local codes.

Note Where a condensate return tank is to be fitted, this should: 1. Be vented to a safe location 2. Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature. 3. Vent pipe should not be downsized (this may cause pressure build up in the condensate tank). 4. Return pipes should not be insulated. This can cause overheating the return system, causing a vapor lock in the pump.

5. See Return System Instruction Manual for detailed instructions.

Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton Representative for advice.

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d) Make sure two check valves are installed between the SteamPac and feedwater pump. e) An end of the line trap should be installed in the SteamPac steam header. f) There are three valves on the SteamPac: the main blowdown valve, the gauge glass drain valve, and the water column drain valve. The SteamPac blow off valve supplied with the SteamPac should be installed on the blow off pipe and connected to a blow off receptacle of approved design. g) With a pressure transducer, this control sends out a 4 – 20 ma signal to modulate the thermal fluid valve. The controller also sends out a 120V signal to energize an air solenoid on the modulating valve. In the event the steam pressure exceeds the set point by (X) PSI, the valve will de-energize sending the modulating valve to its fail position. h) All these procedures should be done in accordance with state and/or local codes. The water column blow off valve and the gauge glass blow off valve should be connected to the main blow off line.

Caution Do not tamper with the safety features of the low water safety cut out.

i)

Pressure Relief Valve 1. Limits maximum operating pressure of the SteamPac.

j)

Operating Seam Pressure Control 1. Located at the control panel box is a digital process control. The pressure control regulates the thermal fluid control valve, diverting the flow of fluid when maximum pressure is reached and opening the valve when the steam pressure falls below a predetermined level.

k) Sight Glass Isolation Valves 1. The brass sight glass isolation valves are equipped with an internal ball check. In the event that a sight glass should break, the ball will seat, preventing the discharge of steam and water. The brass valve stem must be opened fully to enable this feature. If the valve is in any other position than full open, the ball will not seat. For added safety all Fulton boilers are equipped with gauge glass protectors. l) High Limit Pressure Control 1. Located at the control panel box and connected to the steam pressure gauge assembly by means of a copper tube. The pressure is usually set 10 to 15 PSI (.703 – 1.054 kg/cm2) above the operating pressure, but below the maximum pressure of the pressure relief valve. If the pressure exceeds the high limit pressure control setting, the SteamPac will automatically shut off.

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2. The high limit pressure control must be manually reset by depressing the plunger located on top of the control.

8. Ventilation
a) Ventilation in the room must be sufficient to maintain a building temperature of 100°F or less.

9. Feedwater
a) In its readily available form, water is a corrosive chemical solution having dissolved and suspended solids and it is therefore, essential that feed water for any steam generating plant be conditioned prior to use. Specialists in water treatment should always be consulted. b) Just with any other type of steam boiler, the generator must be fed with clean soft water free from calcium and magnesium salts, organic compounds and corrosive reagents. See the table below for upper limits of water characteristics for the steam generator use.

10. Recommended Water Conditions for Boilers/Unfired Steam Generators
a) Following are recommendations for feed water and boiler water. Contact your local water treatment professional for testing and treatment recommendations. It is very important that a strict water treatment program be followed. b) It is critical that the boiler pH follow the attached schedule whenever water is in the boiler. Solids that enter in with the feed water will concentrate in the boiler. A regular schedule of boiler blowdown must be maintained to prevent high solid concentrations from corroding the vessel or forming deposits.

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Parameter

Feedwater

pH Feedwater Temperature Hardness as CaCO3 Chlorides Total Alkalinity Total Dissolved Solids Suspended Solids Total Organic Carbon Iron Dissolved Oxygen Visual Oil Conductivity (μS/cm)

7.5-9.5 140F* < 2ppm -------

Carbon Steel Vertical Horizontal Boiler/ Boiler/SteamPac SteamPac Water Water 8.5-10.5 8.5-10.5 ----< 10 ppm --< 300 ppm < 2000 ppm No visual turbidity** No sheen No foam + Colorless liquid++ ND ND < 2985 < 15 ppm --< 500 ppm < 3000 ppm

Feedwater

Stainless Steel Vertical Horizontal Boiler/SteamPac Boiler/SteamPac Water Water 8.5-10.5 --< 10 ppm 50 ppm < 300 ppm < 2000 ppm 8.5-10.5 --< 15 ppm 50 ppm < 500 ppm < 3000 ppm

6.0-9.5 140F* < 2ppm -------

No visual turbidity** No sheen No foam + Colorless liquid++ <1 ppm* ND ---

No visual turbidity** No sheen No foam + Colorless liquid++ ND ND < 4477

No visual turbidity** No sheen No foam + Colorless liquid++ < 5 ppm ND ---

No visual turbidity** No sheen No foam + Colorless liquid++ ND ND < 2985

No visual turbidity** No sheen No foam + Colorless liquid++ ND ND < 4477

NOTES: o *Feedwater temperatures below 200 F will require an oxygen scavenger ** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible. + Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible. ++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or orange tinge. ND: None Detected.

11. Water Supply
a) The quality of the water used in the boiler will affect the life of the elements and pressure vessel and it is strongly recommended that a competent water treatment company be consulted prior to the installation of the boiler. Elements/PV damaged due to adverse water conditions will not be replaced under warranty. b) Natural feedwater supplies contain solids and dissolved gases. These may promote scale, foaming, corrosion, and/or poor steam quality. To prevent this, feedwater must be studied individually and treated accordingly. The treatment should provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized. Thermal cycling, dissolved oxygen, high or low pH can all be major causes of corrosion. Untreated hardness is the major cause of scale deposits. Poor quality feedwater requires increased blowdown and increased chemical treatment costs to prevent boiler corrosion and scaling.
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c) One way to lower the amount of dissolved gases in the boiler feed water is to preheat the feedwater. This option injects live steam into the feedwater to increase the water temperature to 180 degrees F or higher which removes oxygen and carbon dioxide from the water. d) RO/DIWater: Reverse Osmosis / Deionized water is water that all dissolved solids have been removed. Osmosis is a process that uses a semi-permeable membrane, under pressure, to reject dissolved salts and allow water to pass through. When a solution of salt and water is separated by a membrane, the osmotic pressure forces the water through the membrane, diluting the salt solution. When pressure greater than osmotic pressure is applied to the salt solution, the membrane allows the water from the salt solution to pass into the water solution and rejects the dissolved salts. The osmotic process is reversed, hence, reverse osmosis. RO/DI water has no buffering capacity and a pH of <6.5. It is corrosive to carbon steel, however, not to stainless steel. Very high purity steam quality can be obtained with RO/DI water. e) Electric boiler and unfired steam generators’ pressure vessels made from carbon steel that use RO/DI water for the supply water will require pH neutralization for vessel longevity. Electric boilers and unfired steam generators with stainless steel pressure vessels do not require pH neutralization. ASME Code allows electric boilers to be manufactured with stainless steel pressure vessels provided RO/DI water is used as the water supply. f) The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or fouling.

12. Glossary of Water Supply Terms
a) Dissolved Oxygen: Oxygen that is dissolved in the feedwater will cause the steel in the boiler and the feedwater system to be attacked by the water in a manner described as “pitting”. The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide. Once pitting starts, it may be extremely hard to arrest. Pitting can proceed at a surprisingly rapid rate and can occur not only in the boiler proper, but also in pre-boiler equipment such as ecomomizers, feedwater tanks, and feedwater lines. b) Sodium Sulfite: Its purpose is to chemically remove the dissolved oxygen left in the feedwater after the feedwater has been mechanically deareated. Sodium Sulfite reacts chemically with dissolved oxygen, producing sodium sulfate. Since it is desirable to remove dissolved oxygen from the feedwater before it reaches a boiler. Sodium sulfite is best introduced continuously at some suitable point in the feedwater system (the storage section of the feedwater heater or deareator, six inches below the water line). Chemical residual control is based on the maintenance of a specific excess of sodium sulfite in the boiler water. The essential requirement being to maintain in the feedwater at all times
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slightly more than enough sodium sulfite to consume all of the dissolved oxygen that slips through the deareating equipment. Sulfite as a treatment represents the second line of defense against oxygen corrosion. Primary protection against this type of attack requires adequate facilities for mechanical deareation of the feed-water plus a vigorous maintenance program to safe guard against oxygen leakage into the pre-boiler system. c) Suspended Solids: Suspended solids are the undissolved matter in water, inc-luding dirt, silt, vegetation, iron oxides, and any other insoluble matter. Normally suspended solids are expressed in terms of turbidity. Suspended solids may also deposit in low velocity areas and create fouling. In line filters, or various types of pretreatment can be used to lower the suspended solids level. Various polymers assist in holding solids in suspension. Periodic blowdowns will eliminate suspended solids. d) Alkalinity: Alkalinity is the capacity of a water to neutralize acids. Common water alkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, and silicate. These alkalinities, especially bicarbonates and carbonates, break down to form carbon dioxide in steam, which is a major factor in the corrosion on condensate lines. High alkalinity also causes foaming and carry over in boilers. Both foaming and carry over cause erratic boiler operation. When foaming occurs an antifoam should be added or increased. The reason for the high alkalinity should be determined. It may result from lack of sufficient blow off. Quite often the source of alkalinity is an overdose of alkaline internal water treatment chemical. e) pH: pH is a measure of the degree of acid or base of solution. pH ranges of 8.0-10.5 will have little influence on the corrosion rate of carbon steel. A low pH can result in corrosion of metals, while a high pH can result in scale formation or caustic embrittlement. In order to control boilers and equipment used for the external treatment of make up water, it is essential that reliable pH measurements be made. RO/DI water will have a pH of 6.0 6.5 and will require neutralization if used in a carbon steel vessel. f) Chlorides: If chloride levels are high enough to cause severe corrosion, they can be controlled by limiting the cycles of concentration and increasing boiler blowdowns. Corrosion from chlorides can also be controlled by increasing the amount of corrosion inhibitor or changing to a more effective inhibitor. Reverse osmosis is another method of pretreatment to reduce chlorides. Chlorides are a major concern in a stainless steel vessel. g) Oil: Oil is not a natural constituent of boiler water; still it can frequently enter a system through leaks in a condenser or other heat exchanger. Oil can also enter a system through the lubrication of steam driven reciprocating equipment. Whatever the source, the presence of oil in boiler water is undesirable. Oil can act as a binder to form scale. In high heat-transfer areas oil can carbonize and further contribute to the formation of scale and low pH. Foaming is one indication of oil in boiler water. Its presence can also be confirmed by first shaking a bottle containing boiler water. If oil is present foam will

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result. Often oil in boiler water will originate in the condensate. This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken. h) Iron (oxides): Iron in any of its oxide or complex forms is undesirable in boiler water. Iron in its various forms can originate in the raw water makeup, condensate return water, or form directly in the boiler as a result of corrosion. It can concentrate in the boiler and it tends to collect in stagnant areas. If a boiler is using raw water makeup, iron is almost certain to be a major component of developing scale or create fouling. i) Water Hardness: Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents. Water hardness is a primary source of scale in boiler equipment. Hardness is removed by softening. j) Feedwater: Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler. k) Condensate: Condensate is condensed steam that is normally low in dissolved solids. Hence, it does not contribute to the dissolved solid content of the feedwater. In addition, condensate is very expensive to waste. It's been chemically treated, heated, pumped, converted to steam, and condensed. This costs money and when condensate is returned to the boiler, money is saved.

Warning Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and/or property damage.

l)

It is critical that the SteamPac pH be alkaline (9-11) whenever water is in the SteamPac. Solids that enter in with the water concentrate in the vessel. Daily boiler blowdown is recommended to help prevent the formation of deposits. Consult instruction manual for proper blowdown procedure.

m) The most common method of water softening is by base or ion exchange, and softeners of this type are readily available from a number of manufacturers. n) Periodically, the ion exchange resin bed requires regeneration by flushing through with a brine solution followed by rising with fresh water. o) The interval between regeneration is dependent upon the raw water hardness and flow rate. Softeners can usually be set to initiate the regeneration cycle during periods when the generator is off line. If this is not possible, it is essential either to install a duplex softener arrangement or select a return tank of sufficient capacity to provide constant full water supply during the regeneration period. p) Peak flow rates should be taken into consideration when selecting a softener. The hourly raw water throughput will depend on the system condensate return but can be taken at a

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maximum of 110% of the generator steam capacity where no condensate return is expected. Warning Under no circumstances should the water softener water flow limit be exceeded.

q) In all cases the water hardness should be tested periodically and prior to starting the generator to ensure efficient operation of the softener. In no event must unsoftened water be allowed to enter the steam generator.

13. Chemical Dosing
a) In addition to softening the feedwater, it is also important to consider other factors such as dissolved oxygen and acidity. Depending on the results of an analysis, it may be necessary to inject appropriate amounts of corrective chemical into the feedwater system. This is usually achieved by means of a chemical compound solution and variable output metering pump mounted at the storage vessel. It is important that the chemicals and quantities are correct and it is advisable to contact a water treatment company to arrange a feedwater analysis.

14. The Water Column
a) Install the piping from the water column and water gauge glass to a safe blow-off point.

15. Water Gauge & Gauge Glass Installation Instructions

Note Only properly trained personnel should install and maintain water gauge glass and connections. Wear safety glasses during installation. Before installing, make sure all parts are free of chips and debris.

Keep gauge glass in original packaging until ready to install.

a) Verify the proper gauge has been supplied. b) Examine the gauge glass and packings carefully for damage before installation. Do not use the glass if it contains any scratches, chips, or any other visible signs of damage. c) Do not subject the gauge glass to bending or torsional stresses. d) Apply teflon tape or pipe dope to pipe threads. Install top gauge fitting (fitting without a drain valve) into the uppermost tapping. Wrench tighten the fitting until it is snug and the

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glass outlet is pointing at five o’clock (about 1/8 turn from its final downward vertical position). e) Install the bottom gauge fitting (the fitting with a drain valve) until it is snug and the glass outlet is pointing directly upward. Verify top and bottom fittings are threaded into the tappings the same number of turns (distance A = f) distance B).

Remove glass packing nut, friction washer and glass packing from the fittings, and place them, in the same order, on to both ends of the gauge glass. Push both packings about an inch up the gauge glass.

g) Gently insert one end of the glass into

the top gauge fitting. Keeping the glass inside

the top fitting, gently rotate to the top gauge fitting clockwise until vertically aligned with the bottom gauge fitting, then inset glass into bottom fitting until glass bottoms out on the shoulder inside the bottom fitting. h) Carefully raise glass about 1/16” and slide lower glass packing down until the glass packing contacts the lower gauge fitting. DO NOT allow the glass to remain in contact with any metal! i) j) Carefully slide upper glass packing up as far as possible. Hand tighten both glass packing nuts, then tighten 1/2 turn more by wrench. Tighten only enough to prevent leakage. DO NOT OVER TIGHTEN! If any leakage should occur, tighten slightly, a quarter turn at a time, checking for leakage after each turn. k) Install the protective guard, and utilize automatic ball checks where necessary to help prevent injury in case of glass breakage.

16. General
a) All components exposed to thermal fluid flow, including pipe, valves, and screens, must not be made out of copper, copper alloys, aluminum, or cast iron. Cast iron is porous to thermal fluids, and copper and aluminum act as catalysts in the degradation of some thermal fluids. Carbon or stainless steel, or ductile iron, are recommended. b) For standard applications, all components must be rated to 650°F unless otherwise stipulated. c) All pipework, valves, and user equipment must be suited to the maximum operating pressure of the heater. Consult the nameplate on the heater for this rating. d) If an isolating valve is completely closed, the pressure in the system will rise to the deadhead pressure of the pump. Suitably sized pipe will enable the system to withstand the total head generated by the circulating pump, should this occur. In applications where it is desirable to design to pressures lower than the safety relief valve setpoint, an alternative safeguard is to install additional appropriately sized safety valves. e) Where secondary circulating pumps are installed, the system must be suitable for the aggregate head, against a closed valve, of both pumps.

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f)

During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system.

17. Thermal Fluid Pipework
a) The thermal fluid pipework and main body of the generator should be lagged. Leave the lower flange of the generator free so that the heat exchanger may be removed periodically if required. b) All pipework should be constructed from seamless mild steel pipe, conforming to ASME SA 106B or SA 53A schedule 40 or equal. c) Expansion joints or properly designed and sited loops should be provided to accommodate thermal expansion. Thermal expansion should be calculated using the maximum possible utilization fluid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will expand approximately 1” per 100’ over a 100°F temperature rise (1 mm per meter over 100°C rise). d) Supports and anchors must be provided for all pipes where necessary to prevent undue stresses from being placed on items of equipment, including pumps, valves and the SteamPac. Supports and anchors which will not interfere with thermal expansion should be chosen. e) All pipe joints should be either welded or flanged construction. Screwed joints must be avoided where possible. In no instance should screwed joints be used in the flow circuit. f) All flanges should be welded to the pipe and not screwed. Flanges should be 150# of 300# raised face flanges, SA105. g) Gasketing material suitable for use with thermal fluids at high temperatures should be used to make all flanged joints. Flexible graphite gaskets are suited for most thermal fluids. Recommended gasket thickness is 1/10 – 1/8 inch. h) Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. i) Gasket Installation Instructions 1. Lubricate nuts, bolts and washers with a graphite/oil mixture. 2. Assure that the flange surfaces are clean and free from damage. 3. Center gasket properly over flange. In retrofit, use pry bar to spread flange apart enough that then gasket will not be damaged when sliding in place. 4. Install all flange nuts and bolts. 5. Hand tighten. 6. Utilizing a torque wrench, tighten all bolts to 20% final torque specification following a “star” pattern. (This means do not tighten bolts in the order of a clock. This will result in a poor seal between 12 o’clock and 1 o’clock).
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7. Tighten all bolts to 40% final torque specification following a “star” pattern. 8. Tighten all bolts to 60% final torque specification following a “star” pattern. 9. Tighten all bolts to 80% final torque specification following a “star” pattern. 10. Tighten all bolts to 100% final torque specification following a “star” pattern. 11. Following a sequential pattern, ensure that all bolts are tightened to 100% final torque specification. 12. It is important that all bolts are checked and retorqued after flanges have been heated and cooled down for the first time.

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Standard gaskets supplied by Fulton are JM Clipper Elastograph for operating temperatures up to 650oF.
Recommended Loads for JM Clipper elastograph 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Preferred Torque Required per Bolt Ft-Lbs.
30 30 30 30 30 60 60 60 60 100 100 100 160

Nominal Flange Size Inches
1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10

Number of Bolts
4 4 4 4 4 4 4 4 8 8 8 8 12

Diameter of Bolts Inches
1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 3/4 3/4 7/8

Recommended Loads for JM Clipper elastograph 300# Gaskets SAE Grade 5 Bolts (typical) or Equal Preferred Torque Required per Bolt Ft-Lbs.
30 60 60 60 100 60 100 100 100 100 160 245 160

Nominal Flange Size Inches
1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10

Number of Bolts
4 4 4 4 4 8 8 8 8 8 12 12 16

Diameter of Bolts Inches
1/2 5/8 5/8 5/8 3/4 5/8 3/4 3/4 3/4 3/4 3/4 7/8 1

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Standard gaskets supplied by Fulton for operating temperatures above 650oF are Flexitallic Spiral Wound.
Recommended Loads for Flexitallic Spiral Wound Class 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches
1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10

Number of Bolts
4 4 4 4 4 4 4 4 8 8 8 8 8 12

Diameter of Bolts Inches
1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 3/4 3/4 3/4 7/8

Preferred Torque Required per Bolt Ft-Lbs.
45 45 45 45 45 90 90 90 90 90 150 150 150 240

Recommended Loads for Flexitallic Spiral Wound Class 300# Gaskets SAE Grade 5 Bolts (typical) or Equal Preferred Torque Required per Bolt Ft-Lbs.
45 90 90 90 150 90 150 150 150 150 150 150 240 368

Nominal Flange Size Inches
1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10

Number of Bolts
4 4 4 4 4 8 8 8 8 8 8 12 12 16

Diameter of Bolts Inches
1/2 5/8 5/8 5/8 3/4 5/8 3/4 3/4 3/4 3/4 3/4 3/4 7/8 1

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18. Bolting Sequence for 4 and 8 Bolt Flanges

a) High point bleeds are to be installed at all high points in the system piping. 1/2” x 12” nipples welded in the top of the piping with ball valves & plugs attached are to be used. b) It will save a considerable amount of time during the cold filtration if the thermal system piping is cleaned prior to assembly. c) The mill scale (the results of oxidation) on the inside of the piping as well as construction debris can foul the oil and cause the need for the filters to be cleaned more than need be. This can range from simply using a rag to ordering pickled pipe. (“Pickling” is a process where the piping is first soaked in an acid bath, then soaked in a neutralizing bath, then given a protective oil coating.) d) All pipes should be installed with a pitch to facilitate draining and venting.

19. System Connections
a) If screwed connections have to be made, e.g. to items of control equipment, then a thread sealant suitable for use with fluids at elevated temperature must be used. Teflon tape, standard pipe dope, or hemp and paste are not acceptable. b) Screw threads must be carefully and accurately cut. If possible, new tools should be used. Threaded connections larger than 1” are not to be used. It is recommended that GR5 or better tensile steel bolts be used for all flanged joints.

20. Valves
a) Manual control and isolating valves should be the flanged or weld type, manufactured from cast or forged steel or ductile iron, with internals and gland seals made from materials suitable for use with high temperature fluids.

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b) When ordering valves, the maximum possible service temperature and type of fluid must be indicated on the order. c) A partial list of manufacturers known to market valves of acceptable quality follows: 1. Jenkins Brothers 2. Lunkenheimer Company 3. Nibco Incorporated 4. Stockham Valves and Fittings Company 5. Velan 6. Vogt Machine Company 7. Worcester Valve Company d) Automatic Fluid Control Valves 1. Because of the widely varied thermal systems, it is not possible to set down specific rules for the selection of automatic fluid control valves. Generally, these valves must satisfy the materials and construction requirements described above. 2. The type of operation and design of porting are governed by the degree of control required as well as the particular application.

21. Testing
a) Upon completion of the installation, a pneumatic test not exceeding 15 psig should be conducted. Soap tests should be made at all welds and joints to ensure that the system is free from leaks. b) Under no circumstances should the system be filled with water. Make sure that the air supply is as free from moisture as possible. c) The most satisfactory method of testing is to introduce bottled nitrogen through a pressure control valve. Check pressure ratings on all the equipment in the system to make sure that it is capable of withstanding the pressure involved. d) The time needed to be spent during boilout directly corresponds to the amount of moisture in the system. Boilout can take anywhere from two to three days to complete. Pressure testing on the system should be done by means of an inert gas, such as nitrogen, or by an air compressor producing dry air (air with a dewpoint of 50o F or less). Never perform a hydrostatic test on the system.

22. Insulation
a) After the appropriate system tests have been satisfactorily completed, all hot pipework, including manifolds on the heater, must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury. b) It is recommended that for inspection and maintenance, pumps, flanges, valves, and fittings be left un-insulated but suitably shielded for safety.
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c) Hot oil pipe insulation should be a minimum of 2” thick, high temperature, laminated, foamglass cellular glass insulation as manufactured by Pittsburgh Corning Corporation, or equal.

23. Thermal Fluids
Thermal Fluids at Elevated Temperatures a) Plant engineers must be familiar with the nature of potential hazards when working with thermal fluids at operating temperatures. b) Unlike steam or high-pressure water systems, thermal fluid attains extremely high temperatures without a corresponding increase in pressure. While this lack of high pressure in the system yields many advantages, a false sense of security should not be allowed to develop on account of this alone. c) Certain types of thermal fluid may have operating temperatures reaching 650°F (345°C) and above, so all exposed pipework is hazardous and should be insulated, as indicated in the preceding sections. d) Flanged joints must be checked for tightness during and after the first warming up of the system. After these checks, exposed hot flanges, pumps, valves and fittings should be fitted with some sort of shield. e) It is important to remember that there is pressure generated in the system by the circulating pump. Great care should be exercised when opening any drain or vent valves in the system. d) This is especially important during commissioning, when any air trapped in the system is vented at high points, and when water, which will flash into steam, is either expelled from the deaerator vent or drained off at low points.

Caution During operation, any leaks are usually detected by a small amount of vapor. Leaks should be attended to as soon as possible because under certain circumstances, such as saturated insulation, thermal fluid can ignite when exposed to air and heat.

e) If a fire does occur, extinguish using CO2, foam or dry chemical. DO NOT USE WATER. f) Selecting a Thermal Fluid 1. The selection of the thermal fluid most suited to your application is very important. Factors to be considered include efficiency, thermal stability, adaptability to various systems, and physical properties, including vapor pressure, freezing point, and flash and fire points. 2. Heat transfer fluids of both mineral and synthetic origin have been specially developed to give thermal stability over a very wide range of
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temperature. A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater systems, however, your final selection should be made in conjunction with Fulton Thermal Corporation or the fluid manufacturer. 3. The safe maximum bulk temperature of the fluid must be strictly adhered to. The safe maximum temperature of the fluid varies, but a typical maximum for many types of mineral oil based fluids is 600°F (320°C). 4. Special care must be taken when consulting fluid manufacturers’ literature, as maximum fluid temperatures quoted are the actual limit to which any of the fluids may be subjected. It is important to remember that in any fired heater there exists a “film temperature” which is higher than the temperature of the “bulk” of the fluid. 5. It is the BULK fluid temperature and NOT the FILM temperature that is indicated by the instruments. 6. As a general guide, the following list of fluids that have given satisfactory service over many years is provided. 7. This is by no means a complete list. Any fluid specifically designed for heat transfer use may be considered; multipurpose oils are not acceptable.
a. b. c. d. e. f. g. h. i. j. k. AMOCO CHEVRON DOW EXXON MOBIL MONSANTO MULTITHERM PARATHERM PETROCANADA SHELL TEXACO Transfer Oil 4199 Teknifax Dowtherm A or G Caloria HT 43 Mobiltherm 603 or 605 Therminol PG1, IG4, IG1 Paratherm NF or HE CalFlo, AF, Purity FG, CalFlo LT Thermia 23 Texatherm

8. Any fluid specifically designed for heat transfer use must also exhibit these characteristics: a. Be a stable and homogenous liquid to a temperature of at least 100°F over and above the maximum intended temperature of utilization, compatible with metals used in the installation, and tolerating contact with atmospheric air. b. The absence of any solid matter in suspension. c. Non-toxic in the case of leakage.

d. Sufficient lubricity, i.e. not likely to cause seizure.

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9. The thermal fluid manufacturer must guarantee the characteristics of the product, and verify that the fluid bulk temperature limitation exceeds the expected operating temperature. 10. After a fluid is selected, refer to the manufacturer’s recommendations, published in compliance with OSHA. 11. If the fluid expansion volume from 50o F to 600°F exceeds 20% of the initial fluid volume, consult Fulton Thermal Corporation.

Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid.

g) Routine Analysis of Heat Transfer Fluid 1. Nearly all leading manufacturers of heat transfer fluids provide an after sales service to monitor the condition of the fluid in operation and make recommendations when replacement becomes necessary. 2. Each fluid manufacturer has procedures for regular testing and analysis of the fluid. These usually allow for a sample to be taken and analyzed at least once a year, although actual frequency will depend on operating temperature, number of hours operated weekly, and the results of tests made during the first weeks of system operation. 3. Fulton Thermal Corporation recommends that the thermal fluid in your system be analyzed within the first two months after start-up. 4. During the first few months of operation, sampling may be carried out at frequent intervals to confirm that system performance has been predicted correctly. 5. If the supplier of your thermal fluid does not contact you within four weeks of commissioning, contact the supplier and make certain that the “fill” is registered for routine analysis. h) Thermal Fluid Breakdown 1. The possibilities of thermal fluid breakdown are very slim in a typical closed loop thermal fluid system. Fulton’s D/A tank creates a “cold seal” of fluid that is slightly above ambient temperature. This prevents oxidation that will happen when high temperature fluid contacts air. 2. This will also occur when hot thermal fluid contacts air at a leak in the system piping. Oxidized thermal fluid becomes acidic and will damage the thermal fluid system. Thermal fluid breakdown can occur in sections of piping where there is a low flow

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condition. A low flow rate through the heater will result in high film temperatures leading to breakdown of the thermal fluid. 3. Multiple pressure switches and a differential pressure switch are used to prevent this condition from occurring. These safeties must not be bypassed at any time. 4. Exceeding the maximum operating temperature of the thermal fluid will also result in thermal fluid breakdown. Fulton heaters are equipped with a temperature limit switch (located on the front of the panel box) to prevent this from occurring. 5. A high temperature limit switch acts as an over temperature safety device. If the high temperature limit shuts down the unit, the manual reset button on the limit switch must be pressed. The reset button on the flame programmer must also be pressed to reset the unit before it can be restarted.

24. Return Tank and Connecting Pipework
a) Typically Fulton SteamPacs are sold as a completely skidded packaged units which include: a safety relief valve, steam separator (vertical models only), pressure gauge, return system complete with feedwater pump plus controls, a blow-off separator, automatic control valve and accessories similar to those found on a boiler. b) The return tank is pre-piped on the skid except for the condensate return connection, the vent connection, the overflow opening and the cold water make up. c) The feedwater for our standard package should be maintained in a temperature range of 180°F. If higher temperatures are required, contact the factory for proper pump selection. d) Where there is insufficient condensate return to maintain this temperature, it is sometimes necessary to provide some alternative method of preheating such as steam injection. This can be controlled using a thermostat and steam inlet solenoid valve. e) The vent pipe must rise continuously so there are no low points where condensate could accumulate and cause an obstruction. It must always terminate open to atmosphere outside the building and be arranged in a manner which eliminates danger to personnel or property in the event of a steam discharge. f) Local water authority requirements must also be met where applicable.

25. Connection to Drains
a) Water softener finishing pipes and return tank overflows may be connected to drains in accordance with water softener manufacturer’s instructions. b) Blowdown pipe work must run to a suitable catch pit or receiver vessel to be cooled before connection to the main drains. The blowdown separator may also be equipped with a cooling kit.
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Caution It is imperative that an adequate vent to atmosphere is provided on all such covered or enclosed vessels which may receive steam.

c) Special care is to be taken to ensure that blowdown lines are properly secured so no movement (other than expansion) can be caused by the action of steam discharge from that pipe. d) Care must always be taken to comply with water board or other authority requirements to avoid damage to PVC main drains due to the discharge of hot effluent. If cold water is blended with the effluent to assist cooling, this should usually come from a separate tank or directly from the main supply.

Note A deaerator may be supplied in lieu of a return tank. Please consult the manufacturers manual for installation and operation of the deaerator.

26. Steam Pipework
a) All pipework and equipment to be fed with steam must either be designed to withstand the generator safety relief valve setting, or alternatively, an additional safety valve or valves should be inserted in the service line adjacent to the equipment to be protected. All steam pipework should comply with all Federal, State and Local Codes. b) Steam pipework to the plant must be sized to suit the steam flow and pressure. The correct diameter for interconnecting pipework to the steam generator is at least equal to the diameter of the main steam outlet valve above the generator. c) All safety relief valves must be connected to a discharge line of a diameter at least equal to the discharge port. These lines should be piped directly to outside the building and terminate in such a way that steam discharge does not create a danger to personnel or property. Extra care must be exercised when this pipework cannot be of minimal length, and, if necessary a larger diameter pipe employed to reduce resistance to flow. d) Discharge pipework is to be installed such that no water can accumulate and a small drain provided close to the relief valve(s) and piped to a safe place.

Warning No undue load is to be imposed on the safety relief valve body by this pipework.

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e) Allowance must be made for expansion of both the pipework and the generator; especially if the pipework is rigidly fixed in any place other than adjacent to the safety valve. f) All open ended pipes are to be suitable secured to ensure that no movement (other than expansion) can be caused by the action of steam discharge from that pipe. g) In cases where multiple generators are to be installed, a header incorporating a steam trap must be provided. In all instances where generators are connected in parallel with another steam boiler, it is the responsibility of the customer to comply with Local Authority, Insurance Company, Factory Act and Health & Safety at Work Act requirements. These requirements are concerned mainly with maximum pressure, water contents, safety valves, piping sizes etc.

27. The Blow-Off Valve
a) There are two blow off valves on the Steampac: The main valve and the water gauge glass blow off valve. The SteamPac blow off valve supplied with the boiler should be screwed to the blow off pipe and connected to a blow off receptacle of approved design. This should be done in accordance with state and local codes.

28. The Feed Water Piping
a) Provisions must be made for adequate water supply and properly sized piping. Piping must be done in compliance with all local codes. b) When feeding the SteamPac using a return system, the city water pressure should not exceed 40 PSI. A pressure reducing valve should be installed a head of the return tank when above this pressure. c) It is important that all piping be lined up and not forced into place. It is recommended that you begin piping at the pump. If the lines are ended at the pump, particularly if the last piece is cut too short or too long, the pump will be forced to meet the pipe and strain or distortion will result. d) Do not use the pump as a piping support. It is critical that the pipe be independently supported near the pump so no strain will be transmitted to the unit. e) Connect the feed water stop valve to the feed water pipe and pipe it to the return system.

29. The Steam Supply
a) Pipe the steam supply line from the steam outlet.

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30. The Steam Safety Valve
a) Before installing, be sure that all pipes and connects have been blown clean. Pipe compound or dope is used on external threads only. Be sure inlet of valve is free of any foreign material. b) Do not use a pipe wrench on flange bolts/nuts! When making installation, use proper type and size wrench. c) The valve can be installed in any position (the upright position is preferred) in the connection provided on the top left side of the boiler with no unnecessary intervening pipe. Under no circumstances should there be a shut off valve or restriction of any kind between the safety valve and the connection provided. d) Do not cap or plug drain hole in the side of valve body. e) Since the purpose of this safety valve is to protect against an overpressure situation, it will loudly discharge hot steam in doing so. Therefore, it is recommended that a discharge pipe be securely installed and run to a safe point of disposal. f) When a discharge pipe is used, it must be of a pipe size equal to or greater than that of the valve outlet. Use schedule 40 discharge pipe only. Do not use schedule 80, extra strong or double extra strong discharge pipe or connections. It must be as short and straight as possible and so arranged as to avoid undue stress on the valve. It must have ample provision for draining condensate at or near the valve outlet. It must terminate freely to atmosphere with no intervening valve of any description and it must be securely anchored and supported.

31. The Steam Pressure Gauge Assembly
a) The gauge should be facing towards the panel box and/or operator of the boiler. b) Except as noted, each assembly or any of its component parts may be oriented, other than as shown to provide improved operating clearances and/or view of gauge. Before installing steam gauge on the siphon, add a small amount of water to the siphon to create a water seal to buffer the gauge element. This must be done to prevent inaccurate pressure readings and/or premature failure of the gauge. Install the steam gauge into the siphon on the water column.

32. Electrical Supply
a) A wall mounted, fused disconnect sized for the unit must be provided and fitted by the customer/contractor if a disconnect is not supplied on the panel. b) Fuses must be sized according to motor name plates, element ratings, NEC and local electrical codes. c) Normal supply will be 460 volts, 3 phase, 60 Hz AC unless otherwise specified. Consult electrical drawing for specifics relating to your equipment.

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d) Make sure the information on the electrical drawings corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over or under voltage exceeding 10% of the nominal value. e) In all cases, connections to a ground point must be made with correctly sized wire.

32. Frost Protection
a) When the unfired steam generator is installed in an unheated area, frost could cause serious damage to the generator and also to the water softener (when supplied). The resin bed will be destroyed when the temperature drops below 32°F. b) It is therefore, advisable to install protective electrical heating with thermostatic control switching on the protection as soon as temperature becomes too close to 32°F. Should this have to be done in a very large building it would be preferable to create a small cubicle around the generator to reduce the volume to be protected. c) Should, however, frost protection be totally unpractical, the heat exchanger shell and the water feed pump must be drained as do the water softener, chemical feed, and positioner on modulating thermal fluid valve.

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Section 3

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Section 3 – Operation
1. Unit Description and Application
a) The basic system consists of a fully automatic oil or gas fired Fulton Thermal Fluid Heater with circulation pump and expansion tank which delivers high temperature thermal fluid to the independent unfired steam generator (as well as to other heat exchange equipment). b) The steam generator, can, therefore be sited where the steam is required thus avoiding long runs of distribution pipework. c) The vertical steam generator basically consists of a small diameter cylindrical shell, inside which is the single or multiple tube heat exchanger, containing the hot thermal fluid. Water is fed into the bottom of the shell and is turned into steam by means of the exchange of heat from the thermal fluid. The steam is discharged from the top into a steam separator immediately above. Dry steam is thus produced. The steam output can be widely varied with great rapidity. Output is varied by controlling the rate of circulation of the thermal fluid through the unit by means of a control valve. d) Since the shell diameter is small, the liquid content is minimal giving very safe operation. The unit is very compact although relatively tall. e) It includes various accessories such as safety valve, feed pump, control panel box, pressure gauge, pressure switches, 3-way fluid control valve feed tank and pipework. f) The unit thus gives rapid steam raising, with widely varying load and, if required, at reasonably high pressures due to the small shell diameter. It is fully automatic once put into operation.

2. Basic Operation
a) In the main heat exchanger hot thermal fluid (refer to the original specification/quotation for minimum required thermal fluid temperature) passes through the tube bundle and is controlled by the quick acting two or three way control valve. Water is fed into the shell side of the exchanger from the treated return tank via the boiler and feed pump and feed check valve(s). b) Vertical units: The wet steam produced in the heat exchanger passes through into the steam separator above. Water from the separator returns under gravity to the bottom of the heat exchanger via feedwater piping. Dry steam flows to the users from the final stop valve above the separator for vertical units, steam outlet connection for horizontal models. c) Horizontal units: Horizontal steampacs consist of custom designed single or multiple to be heat exchanger, containing the hot thermal fluid, mounted in a large horizontal shell. Steam is produced in this vessel, passes over the internal baffling and exits through the steam outlet.
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3. Steam Pressure Controls
a) The basic controls consist of a thermal fluid control valve which varies the rate of flow of hot fluid through the heat exchanger. This valve may be modulating type and be either electric motorized, pneumatic, or solenoid operated. It is this valve’s operations that controls the steaming rate of the generator. It is operated by means of a steam pressure switch or control mounted on the control panel which monitors steam pressure. b) The pressure control, if of the modulating type, will have a set point which it will try to maintain via an analog output to a three-way control valve (or 2-way modulating valve). c) When the desired steam pressure has been reached, the pressure switch contacts open to de-energize the control valve which stops the thermal fluid flow into the generator. Note Pneumatic control valves are operated by controlling the air supply to the valve diaphragm by means of a solenoid valve integral to the actuator body. These valves have a spring return and will shut off thermal fluid flow in case of control circuit failure. Minimum 80 PSIG clean, dry instrument air is required. Consult valve O&M manual for SCFH of air required.

4. Feed Pump Control
a) Water is fed into the base of the steam generator by the feed pump. This pumps a preset quantity of water into the generator. The quantity is usually just in excess of the steaming rate to avoid superheat, afford control, and to carry dissolved solids. b) The feed pump is controlled by means of a high water level probe or float device located in the water bottle attached to the side of the steam separator (or steampac).

5. High Steam Pressure Control
a) The unit is fitted with an excess steam pressure switch which will shut down both thermal fluid flow. This is a manual reset switch and must be reset before operation of the unit will resume.

6. Steam Safety Valve
a) The steam safety valve is fitted to the top of the steam generator shell to prevent excess steam pressure if the controls were to malfunction. It is set at the maximum design pressure for the generator. When modifying the operating pressure, do not alter the safety valve setting.

7. Steam Pressure Gauge
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a) The steam pressure inside the generator is monitored by a small pressure gauge mounted at the top.

8. Overload Protection
a) The feed pump motor is protected by thermal relays in case of excessive current caused by voltage variation or malfunction of the feed pump. If the overload operates it must be manually rest after ascertaining the cause.

9. Control Switch
a) The generator is switched on and off by means of a three-way position selector switch on the control panel Position 1 is “off”. Position 2 is to enable the feed pump only to be selected in order to fill the unit before start-up. Position 3 is to enable the three-way control valve to start steam generator.

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Section 4

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Section 4 – Maintenance
Warning Prior to commencement of any work requiring the removal of cover plates at the opening of the control panel box, the electrical supply to the SteamPac must be disconnected. The unit should be off and cool before performing work on any piping or components.

1. Recommended Water Conditions
a) Following are the recommendations for feedwater and boiler water. Contact your local water treatment professional for testing and treatment recommendations. It is very important that a strict water management program be maintained. b) Feedwater
1. 2. 3. Dissolved Oxygen pH Value *Hardness less than 0.005 ppm 9 to 11 (tested at room temperature) less than 50 ppm in the form of CaCO 4. 5. 6. 7. 8. 9. Oil Suspended Solids Organic Matter Chloride Total Dissolved Solids Iron None None None less than 50 ppm less than 300 ppm 2 ppm max.
3

c) Boiler Water
1. 2. Phosphate Alkalinity 30 to 50 ppm in the form of PO
3 4

less than 300 ppm in the form of CaCO

3. 4. 5. 6. 7.

Chloride pH Value Total Dissolved Solids Iron Silica

less than 50 ppm 9 to 11 (tested at room temperature) 400 – 2,000 ppm 1 ppm max. 180 ppm max. in the form of SiO2

8. 9.

Hardness Dissolved Oxygen

less than 50 ppm None 15 ppm None

10. Suspended Solids 11. Oil

ppm = parts per million; CaCO3 = Calcium Carbonate; PO4 = Phosphate; SiO2 = Silicon Dioxide *1 Grain Hardness = 17.118 ppm; therefore: 70 ppm = 4.10 grains hardness

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d) It is critical that the SteamPac pH be alkaline (9-11) whenever water is in the vessel. Solids that enter in with the water concentrate in the SteamPac. Daily blowdown is recommended to help prevent the formation of deposits.

2. Maintenance Schedule
Daily a) The following procedures should be carried out daily. They are designed to prevent the build up of scale, silt or sludge in the SteamPac. In addition to these procedures, the advice of a water treatment specialist should be sought and followed. An ASME Section VIII blow off receptacle must be provided for the appropriate pressure. b) Blow down the SteamPac each morning from the bottom blow down connection by starting the SteamPac and generating not more that 10 psi of steam. c) Blowdown the water column each morning for 5 seconds at 10 psi or less d) Drain gauge glass each morning for 1 second at 5 psi or less. e) Ensure that chemical treatment/water softener is operating properly. f) Ensure that the feedwater pump is operating properly.

g) Observe at least 1 cycle of operation to ensure proper operation. Monthly a) Clean the water column gauge glass. b) Clean the water pump strainers. c) Check motor starter contacts for pitting or burns. d) Check operation of all steam traps on condensate return system. e) Check tightness of all joints or flanges on the water, steam and thermal fluid piping. Tighten or replace any leaking valve packing. f) Check operation of pressure switches/controllers. When the unit is in operation, reduce the setting of the pressure switches to a value well below that of which they

normally operate. The steam pressure control should shut the fluid control valve. Semi-Annually a) Clean water level and pump probes with light sandpaper or emory cloth. For float type water level controllers check float & float housing for unrestricted movement. b) Drain and flush condensate return tank. Annually a) Remove hand hole covers and inspect the inside of the pressure vessel. Check for scale, sludge or pitting. Check tube bundle for fouling. Any of these conditions indicate improper water management.

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3. Safety Relief Valves
a) When the valves leave the factory, they have been carefully set and tested to ensure that the seating surfaces are perfect. However, in service, and when the pressure in the vessel is neat to the set pressure of the valve, the clamping force between the seating surfaces is very light and any foreign matter lodged between the two surfaces will cause the valve to leak. b) Particles lodged on the seating surfaces are, therefore, the first things to look for in the case of a leaking valve and it is usually sufficient to flush the seating surfaces. If however, the seating surfaces have been damaged, it will be necessary to replace the valve.

4. De-scaling
a) The need to de-scale the steam generator is indicated when steam generation becomes slower and more difficult. Operation of the unit may become erratic. b) De-scaling is normally carried out chemically by preparing a solution of proprietary chemical such as “Scale Kleen”, and pouring it into the top of the generator. (Remove the pressure gauge and use its connection). The pump is run so that the generator is filled. If possible, some heat is added to warm the solution slightly. Note: It is the responsibility of the customer to insure that during the descaling of the tube bundle, the tubes are not chemically attacked and form leaks or cracks. c) There are two basic ways of ensuring the scale dissolving process continues. Either keep filling the generator with new solution and drain off the used solution, or use suitable circulating pump, rubber piping and bucket to continuously circulate the chemical through the exchanger. Usually the solution changes color, as an indication that the acid is spent. If necessary, add more solution. Scale cleaning is only completed when no further color change of new solution takes place. Finally, flush through with an alkali, such as soda ash (1 oz. Per 250 pounds of nominal steaming rate of the unit) in solution. If desired, remove the heat exchanger tube bundle and visually inspect the interior. d) During the cleaning process, the equipment must be vented and no unshielded lights allowed in the vicinity.

Warning Follow all safety instructions provided by the manufacturer of the de-scaling chemical. Read the MSDS sheets that are provided. Disposal of spent solution must be done in accordance with local regulations.

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Warning When dissolved, the solution is a severe irritant and must be treated in the same manner as all strong acids. If any of the solution comes into contact with eyes or skin, flush immediately with a large volume of water. If the eyes are affected, seek immediate medical attention.

5. Cleaning the Water Probes
a) Clean the probes in the water column. Make sure there is no pressure on the SteamPac during the removal of the probes. Remove one probe (using 7/8” socket) clean with a very fine emory cloth and replace it before removing another probe to assure no probe mix-ups that would change the control functions.

6. Feed Pump
a) The better the pump is maintained, the longer its working life will be. b) In many cases it is not possible to install the pumps in places where they are protected against frost (especially when used in conjunction with steam generators.) c) Please follow these special instructions to prevent damage. d) As soon as the boiler has been shut down, the pumps must be carefully drained. e) Before the pump is returned to service, the pump should be primed with hot water and turned several times by hand. Only then should the equipment be started up.

7. Electrical Controls
a) Monthly – Check that connection screws have not become loose. Clean electrical contacts on relays etc. inside the panel with a small brush. b) Check operation of the controlling pressure switches. c) When the unit is in operation, reduce the setting of the pressure switches to a value well below that of which they normally operate. d) The steam pressure control should shut the fluid control valve. e) The excess steam pressure switch should shut the fluid control valve.

8. Miscellaneous
a) Check tightness of all joints or flanges on the water, steam, and thermal fluid piping. Tighten or replace any leaking valve packing. Note: Shut off and cool the system prior to replacing valve packing.

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 48

9. Troubleshooting
a) The following troubleshooting guide will assist in the diagnosis and correction of minor field problems. In any case requiring additional assistance, contact your local authorized Fulton Representative. b) Feedwater Pump 1. Problem: Pump rotates freely but does not pump.

Check: 1. Excessive feed water temperature (normal maximum 180°F) will result in flashing at pump inlet. This is usually caused by leaky check valve between pump and boiler or failure of steam traps to close tightly. Repair or replace defective equipment at once before causing damage to pump. 2. Obstruction in suction line. This can be determined by a visual check or installing a compound gauge (reading vacuum and pressure) in the pump suction line close to the pump. An unrestricted line will produce a pressure reading on the gauge of approximately 1 PSIG while the pump is running. A vacuum reading on the gauge indicates an obstruction, which must be eliminated. Be sure to remove strainer basket, scrub clean and reinstall. 3. Motor not up to rated speed. Check speed with tachometer. 4. Wrong direction of rotation. Check arrow on pump casing. 5. Broken pump shaft. Check shaft at both ends.

2. Problem:

Pump vibrates or is very noisy.

Check: 1. Misalignment of pump and motor. Check coupling and piping strain. 2. Bent or broken shaft. 3. Pump impeller binding. Check for foreign matter in pump, bent impeller, or mineral deposits on impeller, channel ring or spacer. If mineral
Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 49

deposits occur, have the water analyzed and treated by a reliable chemical treatment company. Remove any mineral deposits from pump parts. 4. Worn bearings. Replace. 5. Pump cavitation. High water temperatures or a suction line restriction, such as a clogged strainer, will cause cavitation. Any restriction must be corrected immediately or severe pump damage will result.

3. Problem:

Receiver overflows constantly.

Check: 1. Make-up valve seat worn, not sealing tight. Replace valve. 2. Make-up valve float waterlogged or disconnected. Replace. 3. Lower the level of make-up water to allow more tank volume for condensate.

4. Problem:

Some Common Causes of Motor Failure.

Check: 1. Tripped starter overload. Reset and check motor and pump for proper operation. 2. Improper power supply. Check voltage and motor nameplate data. 3. Incorrect connections. Check wiring diagram. 4. Mechanical failure. Check for free rotation and examine bearings. 5. Short-circuited windings. Indicated by blown fuse or failure to start. Motor must be replaced. 6. Overload. Check pump for proper operation and free rotation. 7. One phase open in three-phase circuit. Check power supply lines.

5. Problem:

Starter overload tripped.

Check:

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 50

1. Reset and inspect pump and motor for proper operation.

6. Problem:

Motor fails to start.

Check: 1. Make certain boiler level switch is functioning properly. 2. Check control circuit for continuity.

7. Problem:

Preheat kit solenoid valve does not open.

Check: 1. Check wiring to the solenoid valve and aquastat. 2. If faulty, replace solenoid and/or aquastat.

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 51

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 52

Section 5

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 53

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 54

Section 5 – Parts & Warranty
Part Number
Pressure Switches & Transducers 2-40-000233 2-40-000663 2-40-000662 2-40-000661 2-40-000999 2-40-000994 2-40-000998 Pressuretrol L404C1162-M/R Pressuretrol L404B1320 6NNK54FIA SOR Pressuretrol-NEMA 4 6R3-D5-SOR Pressuretrol-M/R-NEMA 4 Pressure transducer – 0-100psi Pressure transducer – 0-200psi Pressure transducer – 0-15psi 1.96 1.96 1.62 2.1 .89 .89 .73 .95

Description

Approx. lbs.

Weight kgs.

Temperature Controls/Limits/Thermocouples 2-40-000861 2-40-000862 O&M Manuals 5-60-000121 Unfired steam generator manual UT 350 Yokogawa UT 350L Yokogawa 1.2 1.16 .55 .55

SteamPac Components 2-40-000420 2-40-000422 2-40-000403 2-40-000202 2-40-000421 2-40-000423 2-40-000229 2-40-000960 Miscpart 2-30-000139 2-12-000004 2-12-000007 2-12-000019 2-12-000020 2-30-000149 2-30-000047 2-20-000017 2-20-000010 2-20-000012 2-30-000029 2-30-000028 2-30-000124 2-12-000534 Fulton pump relay – 120v Base for Fulton relay (8pin) IDIDO Relay Motor starter R4243 – 30amp 120V water level relay Base for 120V water level relay (11 pin) Pressuretrol L404A1396 Model 2705 masonilian press control Bourdon tube-ss for masonilian Fairchild reg mod 10 - 2-way Handhole gasket 5/8” x 9-1/4” gauge glass 5/8” rubber gasket 5/8” brass gasket ½” water gauge valve w/ball checks ½” tri-cock Low water cut off probe – 17-1/8” cut to any length Low water probe High water probe ½” float valve ¾” float valve 4-1/2” float ball only ½” float valve disc 2.0 Obsolete Obsolete Obsolete .04 .2 .004 .002 1.5 .42 .5 .5 .5 .72 .76 .6 .01 .02 .09 0.0 0.0 .68 .19 .23 .23 .23 .33 .35 .27 0.0 .91 .5 .25 2.0 .52 .23 .11 .91 .24

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 55

2-12-000535 2-30-000332 Water Column 2-11-000106 5-20-000023 4-21-000010 2-21-000021 2-21-000013 2-45-000128 2-45-000128 2-45-000130 2-30-000149 4-75-000049 2-30-000019 2-35-000648 2-30-000398 2-30-000047 2-12-000065 2-12-000007 2-12-000017 2-12-000018 2-12-000071 2-12-000063 2-30-000255 2-12-000020 2-12-000019 2-12-000080 2-12-000024 2-35-000514 2-30-000330 2-12-000022 2-12-000023 2-12-000021 2-12-000024

¾” float valve disc 300# steam gauge

.01 .5

0.0 .23

Fulton water column bottle casting – 4-100hp Fulton water column bottle casting – w/tri-cock tappings Water column electrode basket & cover Water column probe cover – 4” Water column probe cover – 4” White wire for probe – per foot Black wire for probe – per foot Blk/wht striped wire for probe – per foot Water gauge glass valves w/ball checks Water gauge glass assy w/valves, rods, and glass ¼” ball valve ¼” x close brass nipple ¼” MxF ball valve – 200# Tri-cock 8-5/8” extra heavy gauge glass (9.5hp) 9-1/4” extra heavy gauge glass 9-1/4” water gauge glass – corning 10” water gauge glass 12” water gauge glass 14” water gauge glass Conbraco 250# GG valve w/ball check (9.5hp) Brass water gauge glass gasket Rubber water gauge glass gasket Teflon water gauge gaskets 8-5/8” gauge glass guard Brass packing nut for gauge glass valve Gauge glass protector rods Lucite gauge glass guard for 9-1/4” glass Lucite gauge glass guard for 10” glass Lucite gauge glass guard for 12” glass (53MM) Lucite gauge glass guard 9.5hp *NOTE: CUSTOM LENGTHS AVAILABLE

20.0 20.0 .5 .05 1.0

9.09 9.09 .23 .02 .45

1.5 2.5 .6

.68 1.14 .27

.6 .4 .05 .1 .05 .06 .07 .08 1.5 .0018 .004 .01 .18 .02 .05 .02 .03 .03 .04 .68 0.0 0.0 0.0

.1 .04 .4 .5 .06 .045

.05 .02 .18 .23 .03 .02

4-30-000052 4-30-000042 2-20-000010 2-20-000011 2-20-000012 2-20-000017 2-21-000012

Set of four (4) water level probes & plugs 6-100hp Set of 3 (3) water column probes Pump off probe – 7-1/4” Pump on probe – 9-1/4” Low water probe in water column – 11-1/4” Low water probe in boiler – 17-1/2” Probe cove PV – 2”

1.3 .8 .2 .2 .3 .5 1.0

.59 .36 .09 .09 .14 .23 .45

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 56

2-20-000057 2-20-000016 2-40-000227 2-40-000228 2-40-000229 2-30-000230 2-40-000231 2-40-000232 2-40-000233 2-40-000234 2-40-000101 2-40-000100 2-40-000102 2-40-000103 Miscpart 2-40-000322 2-40-000999 2-40-000994 2-40-000998 2-30-000225 2-30-000297 2-35-000395 2-30-000396 4-30-000030 2-30-000397 2-30-000449 2-30-000601 2-30-000602 2-30-000762 2-30-000603 2-30-000604 2-30-000398 2-30-000019 2-30-000008 2-30-000027 2-30-000026 2-30-000001 2-30-000017 2-30-000018 2-30-000025 2-30-000208 2-30-000787

Auburn plug – WCC-1112KH – 151 to 451 psi 16” brass rod – cut to length Pressuretrol L404A1354 – 2-15psi Pressuretrol L404A1370 5-50psi Pressuretrol L404A1396 10-150psi Pressuretrol L404A1404 20-300psi Pressuretrol L404C1147 2-15psi Pressuretrol L404C1154 5-50psi Pressuretrol L404C1162 10-150psi Pressuretrol L404C1139 20-300psi Pressuretrol L404F1078 5-50psi w/micro switch Pressuretrol L404F1060 2-15psi w/micro switch Pressuretrol L404F1102 10-150psi w/micro switch Pressuretrol L404F1094 20-300psi w/micro switch Pressuretrol L404FA1035 – M/R 2-15psi w/micro switch Pressuretrol L404FA1050 – M/R 10-150psi w/micro switch Pressure transducer 0-100psi Pressure transducer 0-200psi Pressure transducer 0-15psi ¼” spring loaded check valve ½” spring check valve ¾” spring loaded check valve – 200# 1” spring loaded check valve – 200# 1” stainless steel check valve – 200# 1-1/4” spring loaded check valve – 200# 1-1/2” spring loaded check valve – 200# ¾” swing check valve – 200psi 1” swing check valve – 200psi 1” swing check valve – 300psi 1-1/4” swing check valve – 200psi 1-1/2” swing check valve – 200psi ¼ ”MxF ball valve – 200# ¼” ball valve – 200# ½” ball valve – 200# ¾” ball valve – 200# 1” ball valve – 200# 1” MxF ball valve 1-1/4” ball valve – 200# 1-1/2” ball valve – 200# 2” ball valve – 200# 3” ball valve – 200# ¾” gate valve – 150#

.2 .1 1.7 2.0 2.0 2.7 2.0 2.0 2.0 2.7 2 2.0 2.0 2.0 2.0 2.0 .5 .5 .5 .5 .75 1.75 2.55 3.0 3.8 4.0 1.2 1.7 2.55 5.75 5.75 .6 .6 .7 1.4 1.75 2.0 3.1 4.7 6.35 18.0 1.2

.09 .04 .77 .91 .91 1.23 .91 .91 .91 1.23 .91 .91 .91 .91 .91 .91 .23 .23 .23 .22 .34 .8 1.16 1.36 1.73 1.81 .55 .77 1.16 2.61 2.61

.27 .32 .64 .8 .91 1.41 2.14 2.89 8.18 .55

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 57

2-30-000788 2-30-000789 2-30-000790 2-30-000791 2-30-000793 2-30-000391 2-30-000392 2-30-000393 2-30-000394 2-30-000007 2-30-000014 2-30-000023 2-30-000024 2-40-000311 2-40-000315 2-30-000130 2-30-000386 2-30-000387 2-30-000403 2-30-000389 2-30-000144 2-30-000090 2-30-001080 2-30-001066 2-30-000122 2-30-000146 2-30-000147 2-30-000149 2-30-000214 2-30-000215 2-30-000216 2-30-000016 2-30-000217 2-30-000062 2-30-000063 2-30-000143 2-30-000064 2-30-000065 2-30-000067 2-30-000068 2-30-000069 2-30-000070

1” gate valve – 150# 1-1/4” gate valve – 150# 1-1/2” gate valve – 150# 2” gate valve – 150# 3” gate valve – NPT, OS&Y 1” Y type blowdown valve – 225UT- 200# 1-1/4” Y type blowdown valve – 225UT – 200# 1-1/2” Y type blowdown valve – 225UT – 200# 2” Y type blowdown valve – 225UT – 200# 1” Everlasting blowdown valve – 4000A 1-1/4” Everlasting blowdown valve – 4000A 1-1/2” Everlasting blowdown valve – 4000A 2” Everlasting blowdown valve – 4000A Timer-Mueller/easy 412-AC-RC Timer-Mueller/easy 618-AC-RC Timer for automatic blowdown system-omron 1” Motorized valve for automatic blowoff 1-1/4” Motorized valve for automatic blowoff 1-1/2”motorized valve for automatic blowoff 2” hot water solenoid valve – 120v ½” hot water solenoid valve – 120v ¾” hot water solenoid valve – 120v 1” hot water solenoid valve – 120v ½” steam solenoid valve ¾” steam solenoid valve – 120v 1” steam solenoid valve – 120v 1-1/4” steam solenoid valve – 120v 1-1/2” steam solenoid valve – 120v ¾” 15# series 19 V-stamped safety valve 1” 15# series 19 V-stamped safety valve 1-1/4” 15# series 19 V-stamped safety valve 1-1/2” 15# series 19 V-stamped safety valve 2” 15# series 19 V-stamped safety valve ½” - 100# safety valve – 19KDCA100 ½” - 125# safety valve – 19KDCA125 ½” - 150# safety valve – 19KDCA150 ¾” - 15# safety valve - 13-202-08 ¾” - 30# safety valve - 19KEDA30 ¾” - 75# safety valve - 19KEDA 75

2.0 3.2 4.9 6.8 12.0 4.0 5.5 8.4 13.5 13.0 14.0 23.0 28.0 .5 .5 .8 9.8 10.7 12.6 13.7 1.8 1.9 4.0 2.3 2.5 4.5 4.9 6.3 2.0 4.3 6.75 12.4 14.85 1.2 1.3 1.3 1.0 1.8 3.2 2.0 2.0 1.4

.91 1.28 2.23 3.09 4.8 1.82 2.5 3.82 6.14 5.91 6.36 10.45 12.73

.23 .36 4.45 4.86 5.73 6.23 .82 .86 1.82 1.05 1.14 2.05 2.23 2.86 .9 1.95 3.1 5.63 6.75 .55 .59 1.0 .45 .82 1.45 .91 .91 .64

¾” - 100# safety valve - 19KEDA100 ¾” - 125# safety valve - 19KEDA125 ¾” - 150# safety valve - 19KEDA150

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 58

2-30-000071 2-30-000073 2-30-000074 2-30-000075 2-30-000076 2-30-000077 2-30-000078 2-30-000079 2-30-000081 2-30-000082 2-30-000083 2-30-000084 2-30-000085 2-30-000086 2-30-000087 2-30-000088 2-30-000089 2-30-000185 2-30-000980 2-30-000981 2-30-000985 2-30-000986 2-30-000987 2-30-001090 2-30-001091 2-30-000988 2-30-001079 2-30-001252 2-30-001251 Miscpart Miscpart Miscpart 2-35-000518 2-35-000519 2-30-000202 2-30-000174 2-30-000326 2-30-000334 2-30-000336 2-30-000333 2-30-000332 2-30-000327

¾” - 200# safety valve - 19KEDA200 ¾” - 300# safety valve - 19KEDA300 1” - 15# safety valve - 13-202-08 1” - 75# safety valve - 19FEA75 1” - 100# safety valve - 19FEA100 1” - 125# safety valve - 19FEA125 1” - 150# safety valve - 19FEA150 1” - 200# safety valve - 19FEA200 1” - 300# safety valve 1-1/4” - 15# safety valve - 13-213-08 1-1/4” - 100# safety valve - 19KGFA100 1-1/4” - 125# safety valve - 19KGFA125 1-1/4” - 150# safety valve - 19KGFA150 1-1/2” - 15# safety valve - 13-214-08 1-1/2” - 100# safety valve - 19KHGA100 1-1/2” - 125# safety valve - 19KHGA125 1-1/2” - 150# safety valve - 19KHGA150 1-1/2” - 200# safety valve - 19KHGA200 Steam trap UB850 ½” Steam trap UB850 ¾” Repair kit UB850 880 ½” 125# Armstrong trap 880 ¾” 125# Armstrong trap 890 ½” 125# Armstrong trap 890 ¾” 125# Armstrong trap Repair kit 7/16” Armstrong trap Trap gasket BIHS – 125 ½ 125 Spirex sarco BIH - 125 ½ 125 Spirex sarco 1031 - 125# Watson McDaniel trap 1041 - 125# Watson McDaniel trap PCA kit ¼” steel pigtail siphon for steam gauge assy-short ¼” steel pigtail siphon for steam gauge assy-long Pressure & Temp gauge (0-250 degrees F) 0-15psi W.C. gas pressure gauge 0-30psi Steam pressure gauge 0-60psi 0-100psi 0-200psi 0-300psi 0-600psi Steam pressure gauge Steam pressure gauge Steam pressure gauge Steam pressure gauge Steam pressure gauge

5.1 2.35 1.1 4.0 4.1 4.1 4.1 4.0 5.0 1.85 6.6 6.75 6.8 2.0 12.4 10.9 12.3 12.0 6.0 6.0 4.0 5.5 5.5 5.0 5.0 .1 .05 5.5 5.5 5.5 5.5 .01 .3 .6 1.0 1.0 .5 .5 .5 .5 .5 .5

2.23 1.07 .5 1.82 1.86 1.86 1.86 1.82 2.27 .84 3 2.07 3.09 .91 5.64 4.95 5.59 5.59 2.73 2.73 1.82 2.5 2.5 2.27 2.27 .05 .02 2.5 2.5 2.5 2.5 0.0 .14 .27 .45 .45 .23 .23

.23 .23 .23

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 59

2-12-000025 2-11-000015 2-12-000026 2-11-000016 2-12-000027 2-11-000017 2-11-000018 2-30-001062 2-30-001064 2-30-001061 2-30-001065 7-75-000000 7-75-000002 7-75-000004 7-75-000006 7-75-000008 7-75-000010 7-75-000012 7-75-000014 7-75-000016 7-75-000017 7-75-000018 7-75-000019 7-75-000040 7-75-000042 7-75-000044 7-75-000046 7-75-000048 7-75-000122 7-75-000124 7-75-000126 7-75-000128 7-75-000130 7-75-000132 7-75-000134 7-75-000136 7-75-000058 7-75-000100 7-75-000104 7-75-000106 7-75-000108 7-75-000110

Teflon disc for 1” Y valve Brass seat for 1” Y valve Teflon disc for 1-1/4” Y valve Brass seat for 1-1/4” Y valve Teflon disc for 1-1/2” Y valve Brass seat for 1-1/2” Y valve Brass seat for 2” Y valve PRV ½” 7-25# PRV ¾” 7-25# PRV 1” 50-140# PRV 1” 7-15# 14 x 24 Horiz. Tank only - HT8 old style 18 x 20 Horiz. Tank only - HT8 new style 18 x 30 Horiz. Tank only - HT10 18 x 36 Horiz. Tank only - HT20 18 x 42 Horiz. Tank only - HT300 24 x 36 Horiz. Tank only - HT50 24 x 48 Horiz. Tank only - HT60 28 x 48 Horiz. Tank only - HT80 30 x 48 Horiz. Tank only - HT100 30 x 72 Horiz. Tank only - HT150-200 36 x 72 Horiz. Tank only - HT250-300 42 x 72 Horiz. Tank only - HT350-400 16 x 20 Vertical Tank only - VT8 old style 18 x 20 Vertical Tank only - VT8 new style 18 x 30 Vertical Tank only - VT10 18 x 36 Vertical Tank only - VT20 18 x 42 Vertical Tank only - VT30 18 x 20 Vertical Tank & Stand - V8T 18 x 30 Vertical Tank & Stand - VT10 18 x 36 Vertical Tank & Stand - VT20 18 x 42 Vertical Tank & Stand - VT30 24 x 36 Vertical Return Tank & Stand 50- VT 24 x 48 Vertical Return Tank & Stand - 60VT 28 x 48 Vertical Return Tank & Stand - VT80 30 x 48 Vertical Return Tank & Stand - VT100 Stand for 18x20, 18x36, 18x42 Vertical tanks 18 x 20 Horiz. Tank & Stand - HT8 18 x 30 Horiz. Tank & Stand - HT10 18 x 36 Horiz. Tank & Stand - HT20 18 x 42 Horiz. Tank & Stand - HT30 24 x 36 Horiz. Tank & Stand - HT50

.2 .1 .5 .1 .2 .1 .1 7.0 7.0 7.0 7.0 70.0 80.0 95.0 105.0 115.0 180.0 175.0 215.0 265.0 300.0 325.0 350.0 65.0 80.0 95.0 105.0 115.0 85.0 120.0 125.0 140.0 225.0 255.0 275.0 305.0 25.0 125.0 130.0 135.0 140.0 225.0

.09 .05 .23 .05 .09 .05 .05 3.18 3.18 3.18 3.18 31.82 36.36 43.18 47.73 52.27 81.82 79.55 97.73 120.45 136.36 147.73 159.09 29.55 36.36 43.18 47.73 52.27 38.64 54.55 56.82 63.64 102.27 115.91 125.0 138.64 11.36 56.82 59.09 61.36 63.64 102.27

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 60

7-75-000112 7-75-000114 7-75-000116 7-75-000118 7-75-000119 7-75-000120 7-75-000035 7-75-000021 7-75-000022 7-75-000023 7-75-000024 7-75-000025 7-75-000026 7-75-000027 7-75-000028 4-75-000018 2-30-000384 2-35-000567 2-20-000079 4-75-000158

24 x 48 Horiz. Tank & Stand - HT60 28 x 48 Horiz. Tank & Stand - HT80 30 x 48 Horiz. Tank & Stand - HT100 30 x 72 Horiz. Tank & Stand - HT150-200 36 x 72 Horiz. Tank & Stand - HT250-300 42 x 72 Horiz. Tank & Stand - HT350-400 Horiz. Stand only for 18 x 20 Horiz. Stand only for 18 x 30 Horiz. Stand only for 18 x 36 Horiz. Stand only for 18 x 42 Horiz. Stand only for 24 x 36 Horiz. Stand only for 24 x 48 Horiz. Stand only for 28 x 48 Horiz. Stand only for 30 x 48 Horiz. Stand only for 30 x 72 8-1/2” end plate in herculite 8-1/2” end plate gasket for herculite Float valve bushing – herculite Magnetic anode Std. Preheat kit - 8-30HP- does not include sparge tube 150psi

255.0 275.0 305.0 380.0 405.0 440.0 25.0 25.0 27.0 30.0 35.0 40.0 45.0 55.0 70.0 2.0 .05 .04 2.0 16.0

115.91 125.0 138.64 172.73 184.09 200.0 11.36 11.36 12.27 13.64 15.91 18.18 20.46 25.0 31.82 .91 .02 .02 1.0 7.27

4-75-000159

Std. Preheat kit - 40-100HP- does not include sparge tube 150psi

16.0

7.27

4-75-000136

Std. Preheat kit - 8-30HP- does not include sparge tube 150psi

16.0

7.27

4-75-000137

Std. Preheat kit -40-100HP- does not include sparge tube 150psi

16.0

7.27

4-75-000188

Self-actuated preheat kit - 8-30 does not include sparge tube - 150psi

30.0

13.64

4-75-000189

Self-actuated preheat kit - 40-100 does not include sparge tube - 150psi

30.0

13.64

4-75-000196

Self-actuated preheat kit -150-200HP does not include sparge tube - 150psi

***

4-75-000198

Self-actuated preheat kit - 240-400HP -does not include sparge tube - 150psi

***

4-75-000194

Self-actuated preheat kit - 100-150HP - does not include sparge tube - 150psi

4-75-000138

Self-actuated preheat kit - 200-400HP include sparge tube - 150psi ***Special Sparge Tube Required

does not

Consult factory

4-50-000074

F-10 Cooling kit – 120v

12.0

5.45

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 61

4-50-000078 4-50-00075 4-50-000079 4-50-000076 4-50-000077 2-30-000551 7-21-000035 2-30-001410 2-30-001411 2-30-000362 2-40-000113 2-40-000112 2-40-000426 2-30-000205 2-30-000123 4-75-000010 4-75-000011 4-75-000013 4-75-000014 2-30-003000 4-75-000015 4-75-000017 2-30-000030 4-75-000019 4-75-000016 2-30-000031 5-10-000276 2-30-002999 5-10-000278 5-10-000278 2-30-002005

F-10 Cooling kit – 220v F20 – 150 Cooling kit – 120v F20 – 150 Cooling kit – 220v F10 Cooling kit – self actuated – 120v F20-150 Cooling kit – self actuated – 120v Liquid level HG-34 SqD Venturi steam injector (sparge tube) Self-actuated preheat valve w/sensor Self-actuated cooling valve w/sensor – 152F ½” strainer for preheat kit – Y type Aquastat L6006A1160 Aquastat L4006E1067 M/R 110-290 deg. Aquastat T991A1061 Well Hotwater thermometer 6-3/4” diameter – end plate with ½” coupling 6-3/4” diameter – end plate with ¾” coupling 6-3/4” diameter – end plate with 1” coupling 6-3/4” diameter – end plate for vertical tank 6-3/4” diameter – end plate gasket 7-14” diameter – end plate with ½” coupling 7-14” diameter – end plate with ¾” coupling 7-14” diameter – end plate gasket 7-14” diameter – end plate for vertical tank 8” diameter – end plate with ½” coupling 8” diameter – end plate gasket 9-12” diameter – end plate for vertical tank 9-1/2” end plate gasket 9-1/2” diameter – end plate – HT6-30 9-1/2” diameter – end plate – HT50-300 B&G #6 - ½” water PRV-use when incoming pressure exceeds 45#

12.0 12.0 12.0 20.0 20.0 4.3 7.0 6.5 6.5 1.0 1.0 1.0 1.0 .35 1.0 2.0 2.0 2.0 2.0 .05 2.0 2.0 .05 2.0 3.0 .05 3.0 .05 3.0 3.0 3.0

5.45 5.45 5.45 9.09 9.09 1.95 3.18 2.96 2.96 .45 .45 .45 .45 .16 .45 .9 .9 .9 .9 .02 .91 .91 .02 .91 1.36 .02 1.36 .02 1.36 1.36 1.36

2-30-002007

B&G #7 – ¾” water PRV-use when incoming pressure exceeds 45#

3.0

1.36

4-75-000048 4-75-000049 2-30-000405 2-12-000016 4-75-000050 4-75-000052 4-75-000051 4-75-000501

Set gauge glass valve complete with 7” glass & rods Set gauge glass valve complete with 9-1/4” glass & rods ¼” drain cock 7” water gauge glass ½” float valve assembly – short rod ¾” float valve assembly ½” float valve assembly - reg. ½” trim kit 10-30HP

2.0 2.5 .3 .05 2.0 2.0 1.8 4.0

.91 1.14 .13 .02 .91 .91 .82 1.82

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4-75-000502 4-75-000054 2-30-000029 2-30-000028 2-30-000142 2-12-000534 2-12-000535 2-12-000536 2-30-000124 2-11-000000 2-11-000001 2-30-000469 2-30-000466 2-30-000363 2-30-000364 2-30-000365 2-30-000366 2-30-000367 2-30-000368 2-30-000971 2-30-000970 2-30-000607 2-30-000608 Water Treatment 2-30-001508 2-30-001509 Miscpart 2-30-001502 2-30-001503 2-30-001505 2-30-001504 2-30-001507 2-30-001506

¾” trim kit 50-100HP 1” float valve assembly (HT-200) ½” float valve only ¾” float valve only 1” float valve only ½” float valve disc ¾” float valve disc 1” float valve disc Float ball only ¼” rod for float valve assembly – short ¼” rod for float valve assembly – long Strainer gasket – 1” Strainer gasket – 1-1/2” 1” strainer for return system 4-30HP – 1” inlet/1-1/4” out 1-1/2” strainer for return system 50HP-up-1-1/2” in/1-1/4” out 2-1/2” strainer for return system Screen for strainer 1” Screen for strainer 1-1/2” Screen for strainer 2-1/2” Strainer cap 1” Strainer cap 1-1/2” 1-1/4” suction hose – per foot 1-3/4” suction hose – per foot

4.0 2.1 .6 .8 1.2 .01 .01 .01 .6 .15 .2 .001 .001 3.7 6.2 8.0 .1 .1 .1 .5 .5 .5 .5

1.82 .95 .27 .36 .55 0.0 0.0 0.0 .27 .07 .09 0.0 0.0 1.68 2.82 3.64 .05 .05 .05 .23 .23 .23 .23

EHB10R1-PEH, chemical feeder, tank, agintator-120v EHB10R2-PEH, chemical feeder, tank, agitator – 120v Agitator for chemical feed tank FB-150-900 , 120V/60 water softener - 4-30 HP FB- 150-900, 220V/50 water softener - 4-30 HP FB-450-900 , 120V/60 water softener - 40-60 HP FB- 450-900, 220V/50 water softener – 40-60 HP FB- 600-900, 120V/60 water softener - 80-100 HP FB- 600-900, 220V/50 water softener – 80-100 HP Consult factory for larger sizes

30.0 30.0 8.0 120.0 120.0 250.0 250.0 310.0 310.0

13.64 13.64 3.64 54.55 54.55 114.0 114.0 141.0 141.0

Test Equipment & Tools 2-40-000090 2-40-000215 2-60-000102 2-60-000103 2-60-000104 2-60-000105 2-60-000106 Test leads Microampmeter – W136 Pocket draft meter All purpose draft meter CO tester – gas CO tubes Stack thermometer .6 2.0 1.0 3.0 15.0 .25 4.0 .27 .91 .45 1.36 6.82 .11 1.82

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2-60-000108 2-60-000110 2-30-000123 2-60-000112 2-60-000155 2-60-000247 2-60-000248 5-10-000397 8-00-000043 8-00-000042 2-30-001580 2-30-000382 5-10-000394 2-45-000109

Smoke tester – oil Fisher gauge – 50 PZ Hot water thermometer Flue cleanout brush – 1” Flue cleanout brush – 5/8” Edge Flue brush – pipetype – 2-1/2” – 80 & 100HP Flue brush – pipetype – 2” – 40/50/60HP VMP (80 oldstyle) Tee handle wrench – 1-1/4” Fan puller – 5/8” hub Fan puller – 1” hub Burks impeller puller Spanner wrench Oil pump alignment tool Terminal wire gun

2.0 1.0 1.0 .8 .8 1.0 1.0 2.7 2.0 2.0 2.0 1.0 2.0

.91 .45 .45 .36 .36 .45 .45 1.23 .91 .91 .91 .45 .9

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Standard Warranty for Fulton Thermal Fluid Heaters
Warranty Valid for Models FT-A, FT-C, FT-S, FT-N, FT-HC

One (1) Year (12 Month) Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of one (1) year from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused defective material or workmanship. Parts Warranty Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

9/10/09

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Section 6

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Section 6 –Product Specs & Data
Fulton SteamPac Packaged Heat Exchanger Systems

1. General Description
a) Contractor shall furnish and install a_____HP thermal fluid to steam heat exchanger package. The entire system shall be “Fulton” as manufactured by Fulton Thermal Corporation, Pulaski, New York. The system shall be a complete package including a thermal fluid to steam heat exchanger, condensate return tank with pump, blowdown tank, interconnecting piping with thermal fluid pneumatic control valve provided.

2. Heat Exchanger Size & Operating Temperature
a) The heat exchanger shall require thermal fluid at _____ degrees F at a minimum flow rate of ________GPM. It shall produce a minimum of ___________BHP (from and at 212 degrees F) (___________BTU/Hr.) output as measured at the steam outlet. The heat exchanger system shall be supplied complete with control panel, thermal fluid control valve and all required safety devices for a maximum operating steam pressure of 150 PSIG (consult factory for higher operation pressures). The heat exchanger shall incorporate a steam safety relief valve rated for use with a Section I vessel (“V” stamped) and the safety valve shall be located on the steam separator; set pressure 150 PSIG standard and sized according to exchanger maximum steaming capacity.

3. Heat Exchanger Design
a) Vertical or Horizontal b) Factory Piped, Wired and Tested c) Design Pressure - 150 PSIG d) Test Pressure: Per ASME Code, Section VlIl, Division I e) Construction Materials- Carbon Steel ASTM 53B and SA 285C Plate f) Stamped per ASME Code

4. Steam Separator Vertical Design Units
a) Vertical Centrifugal b) ASME Code Section l c) Design Pressure - 150 PSIG MAWP Standard d) Test Pressure -as per ASME Code Section I e) Construction Materials - SA-53B seamless pipe and SA 285C plate f) Stamped per ASME Code

5. Water Bottle Design
Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 69

a) Houses probes for electronic water level controller b) Sight glass incorporated into water bottle for visual inspection of water level c) Cast construction as per ASME Code Section I

6. Instrumentation & Controls
a) The following instrumentation/controls/safety devices shall be supplied as a minimum requirement: 1. Pressure Gauge – Fulton 2. Operating Pressure Control - Yokogawa UT-350 w/ pressure transducer 3. High Limit Pressure Control – Danfoss 4. Water Level Control - Fulton 5. Pump Motor Starter 6. Thermal Fluid 3-way Control Valve. Contractor to provide: 440/480/3/60 for pump operation and 120 volt/single phase for control circuit. Note: Smaller Steampacs will have 120 volt/single phase motor.

7. Tests
a) Shall include a hydrostatic test of the pressure vessels in the presence of an inspector having a National Board Commission. He shall certify a Data Report which shall be delivered with the heater as evidence of ASME Code compliance. b) Full electrical checks will be performed including testing of all controls and circuitry.

8. Operating Manual
a) Instructions for installation, operation, and maintenance of the heat transfer system shall be contained in a manual provided with each unit. b) A complete wiring diagram, corresponding to the equipment supplied, shall be part of the manual and one shall also be affixed to the inside of the heater’s panel box.

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Specifications and Dimensions
Horizontal SteamPacs
Specifications – Fulton Horizontal SteamPacs from 70 to 350 HP
Models Steam Output* LB/HR KG/HR Input BTU/HR (1000) KCAL/HR (1000) Flow Rate GPM M3/HR 160 37 228 52 342 78 411 94 456 104 570 130 684 156 798 182 2,343 590 3,347 843 5,021 1,265 6,025 1,518 6,694 1,687 8,368 2,108 10,041 2,530 11,715 2,952 2,415 1,096 3,450 1.565 5,175 2,347 6,210 2,817 6,900 3,130 8,625 3,912 10,350 4,695 12,075 5,477 FT 070XH 100XH 150XH 180XH 200XH 250XH 300XH 350XH

*From and at 212oF (100oC). Steam Output is based in a minimum thermal fluid temperature of 425oF (218oC)

Dimensions – Fulton Horizontal SteamPacs from 70 to 350 HP
Models A. Width IN MM B. Length IN MM C. Height IN MM 75 1,905 110 2,794 110 2,794 110 2,794 112 2,845 112 2,845 112 2,845 112 2,845 107 2,718 117 2,972 117 2,972 132 3,353 150 3,810 150 3,810 150 3,810 160 3,810 68 1,727 80 2,032 80 2,032 80 2,032 96 2,438 96 2,438 96 2,438 96 2,438 FT 070XH 100XH 150XH 180XH 200XH 250XH 300XH 350XH

All dimensions are based on 550oF thermal fluid temperature and are subject to change based on specific customer requirements.

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Specifications and Dimensions
Vertical SteamPacs
Specifications – Fulton Vertical SteamPacs from 10 to 100 HP
Models Steam Output* LB/HR KG/HR Input BTU/HR (1000) KCAL/HR (1000) Flow Rate GPM M3/HR 23 5.2 35 8 46 10.5 69 16 92 21 114 26 171 39 228 52 335 84 502 126 669 169 1,017 256 1,339 337 1,674 422 2,678 675 3,347 843 345 157 517 235 690 313 1,035 470 1,380 626 1,725 783 2,587 1,174 3,450 1,565 FT 010X 015X 020X 030X 040X 050X 075X 100X

*From and at 212oF (100oC). Steam Output is based in a minimum thermal fluid temperature of 425oF (218oC)

Dimensions – Fulton Horizontal SteamPacs from 10 to 100 HP
Models A. Width IN MM B. Length IN MM C. Height IN MM 125 3,3175 125 3,3175 125 3,3175 125 3,3175 143 3,632 143 3,632 169 4,93 169 4,293 72 1,829 84 2,134 72 1,829 72 1,829 72 1,829 72 1,829 92 2,337 92 2,337 84 2,134 72 1,829 92 2,337 92 2,337 92 2,337 92 2,337 92 2,337 92 2,337 FT 010X 015X 020X 030X 040X 050X 075X 100X

All dimensions are based on 550oF thermal fluid temperature and are subject to change based on specific customer requirements. Vertical SteamPac dimensions include feedwater tank and blowdown separator.

All SteamPac accessories including feedwater tanks, feedwater pumps, blowdown separators, chemical feed and water softeners are available from Fulton.

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No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies.

For more of the following patents apply to this unit: U.S. Patent Numbers 4856558, 4884963, 4926789, 4951706 and 5, 145, 345.
Swiss Registration Numbers 119122 and 119243. Swedish Registration Numbers 51873 and 51874. German Patent Number M9104923.7. Benelux Registration Numbers 21548-01/02, 03/04 and 21548-05/06. French Registration Numbers 0304011, 0304015, and 0304016. Other patents pending.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.

Fulton Thermal Corp.*SteamPac Unfired Steam Generators Manual* Version 2010-0201 Page 76

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