FULTON FT-C Series User manual
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
must be observed to prevent serious
injury or death to personnel.
must be observed to prevent damage
or destruction of equipment or loss of operating
effectiveness.
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 operation and maintenance of this
equipment to fully understand the
and 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.
!
!
!
!
Do not try to do repairs or any other maintenance work you
do not understand. Obtain a Service Manual from
Fulton Ltd or call a Fulton Service Engineer.
It is the responsibility of the installer to ensure all parts
supplied with the boiler are tted in a correct and safe manner.
The instructions provided for the operation and maintenance of the system MUST be observed.
Failure to do so could result in damage to the boiler and serious personal injury.
!
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
Rigging your heater into position should be handled by a competent rigger experienced in handling heavy
equipment.
The customer should examine the heater for any damage, especially the refractories.
!
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and or damage.
A defective heater can injure you or others. Do not operate
a which is defective or has missing parts. Make sure
that all maintenance procedures are completed before using
the system. Do not attempt repairs or any other maintenance
work you do not understand. Obtain a Service Manual from
Fulton or call a Fulton Service Engineer.
!
!
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the re de-
partment.
!
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
During operation, any leaks are usually detected by a small
amount of vapour. Leaks should be attended to as soon
as possible because under certain circumstances, such as
saturated insulation, thermal uid can ignite when exposed
to air and heat.
Fulton Ltd cannot be held responsible in the case of
accident or damage resulting from the use of
inadequate uid.
Unless specially ltered, compressed air will introduce
moisture into the system. Dry air or Nitrogen is
recommended.
Some plastics can be dissolved by thermal uid.
Do not use system circulating pump for system lling.
A pump that has been used for water or for a
different thermal uid should not be used prior to
extensive cleaning. Thermal uid can be damaged by
contact with moisture or other uids.
Pressurising a drum to force uid into the system is not
recommended. The drum can easily explode, creating a
hazard to personnel and equipment.
Tanks are non-code as a standard. Non-code tanks
cannot be pressurised over 0.5 barg. Tanks built to
BS EN13445:2009 are available upon request.
Do not run the pump before lling it with uid.
1. Use extreme caution opening plug when system
temperature is elevated.
2. Wear eye and hand protection.
3. Back the plug out slowly to the last two or three threads.
Allow any pressure under the plug to bleed slowly to
prevent a spray of hot oil.
NoFlash steam may be generated at any point up to the
operating temperature. Watch for gauge uctuations.
All of the above maintenance procedures should be
completed by trained personnel. Appropriate training
and instructions are available from the Fulton Service
Department.
Obey all laws and local regulations which affect you and
your boiler.
Make sure that lifting equipment complies with all local
regulations and is suitable for the job. You can be injured
if you use faulty lifting equipment. Make sure the lifting
equipment is in good condition.
Operating the heater beyond its design limits can damage the
heater, it can also be dangerous. Do not operate the heater
outside its limits. Do not try to upgrade the heater performance
by unapproved modications. Unapproved modications can
cause injury and damage. Contact your Fulton dealer before
modifying the heater.
Only qualied persons should be allowed to operate and
maintain the boiler and its equipment.
Do not store or use gasoline or other ammable vapours
and liquids in the vicinity of this or any other appliances.
Thermal Fluid Heaters have high temperature surfaces, that
if touched may cause serious burns. Only competent and
qualied personnel should work on or in the locality of a
thermal uid heater and ancillary equipment. Always ensure
the working area and oor are clear of potential hazards,
work slowly and methodically.
Max. room temperature not to exceed 38 °C.
In no case should any part of the drive side of the
pump be insulated.
Max. operating temperature for air cooled pumps
varies by manufacturer. Consult instruction manual to
verify.
If the tank is located outdoors nitrogen is required.
High temperature thermal uid, steam and combustible
vapours may be vented through the DA vent connection.
Once the system has been lled, any modication to the
tank or connected piping requires purging of the work area
to prevent ignition of potentially ammable vapours. Consult
factory prior to beginning work. Consult the MSDS (mate-
rial data safety sheet) for your thermal uid for ammability
limits.
Unless the system is pressurised, the inlet to the
deaerator section of the combonation tank must be
higher than or equal to the highest point in the system
to prevent pockets of air from collecting in the system
piping.
!
!
!
!
!
!
!
!
!
!
!
Note: If the burner loses ame while driving to a point then:
• Turn the main ON/OFF switch to OFF. Reset the loss of
ame fault. Press Escape on the AZL once. Press Enter on
the AZL to reset the control. The red light on the panel box
door should go out.
• Adjust the air and gas servos for that point while the burner
is off. Follow steps 28-29.
• Turn the main ON/OFF switch to ON.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
General 1.1
Technical Data (Heat Output) 1.2
General 2.1
Transport 2.2
Siting 2.3
Gas & Oil Supply 2.4
Oil Supply 2.5
Access 2.6
Minimum Clearance for Coil Removal 2.6.1
System Connections 2.7
Drain/Fill Connection 2.7.1
Heater Connections 2.7.2
Electrical Connections 2.7.3
Voltage and Frequency 2.7.3.1
Pipework Systems 2.8
Combination Expansion/Deaerator/Thermal Buffer Tank 2.9
Expansion Section 2.9.1
Deaerator Section 2.9.2
Thermal Buffer Section 2.9.3
Sizing the Tank for the System 2.9.4
Location 2.9.5
Pressurised Systems 2.9.6
Connections 2.9.7
Oil and Gas Circulating Pump 2.10
Location 2.10.1
Connections and Piping 2.10.2
Alignment 2.10.3
Lubrication 2.10.4
Seals 2.10.5
Air Cooling 2.10.6
Water Cooling 2.10.7
Catch Tank 2.11
Gauges 2.12
Valves 2.13
Piping 2.14
Gasket Installation Instructions 2.15
Testing 2.16
Insulation 2.17
Thermal Fluids 2.18
Thermal Fluids at Elevated Temperatures 2.18.1
Selecting a Thermal Fluid 2.18.2
Routine Analysis of Heat Transfer Liquid 2.18.3
Thermal Fluid Breakdown 2.18.4
Multi-Skid Systems 2.19
General 3.1
Start-Up Preparation and Installation Review 3.2
Filling the System 3.3
Filling Procedure 3.3.1
For Systems Equipped with Inert Blankets 3.4
Circulating Pump 3.5
Mechanical/Air Cooled Seal 3.5.1
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Initial Start-Up 3.6
Start-Up Service 3.6.1
Cold Circulation 3.6.2
Filtering the System 3.6.3
Sytem Boilout 3.6.4
Procedure For First Shutdown 3.6.5
Sequence of Operation 3.6.6
Duel Fuel Burner-Changing Fuel 3.6.7
Gas Fired Modulating Burner 3.6.8
Setting Main Burner Ignition 3.6.9
Setting Main Run Modulation 3.6.10
Setting Low Fire 3.6.11
Setting the Complete Range 3.6.12
Changing Set Point on the AZL 3.6.13
For Manual Operation 3.6.14
Required Pressure Drop Across the Heater 3.7
Required Flow Through the Heater 3.8
Operating Controls 3.9
Liquid Level Switch - When Combination Tank is Supplied 3.9.1
Required Maintenance at First Shutdown 4.1
Maintenance Procedures 4.2
Lubrication 4.2.1
Soot Cleaning 4.2.2
Schedule of Operator Tests and Checks 4.3
Daily 4.3.1
Weekly 4.3.2
Monthly 4.3.3
Six Monthly 4.3.4
Annually 4.3.5
Safety Check Procedures 4.4
Temperature Limits 4.4.1
Air Switch 4.4.2
Air Filter Box Switch 4.4.2.1
Liquid Level Switch 4.4.3
Differential Pressure Switch 4.4.4
Low Inlet Pressure Switch 4.4.5
High Outlet Pressure Switch 4.4.6
High/Low Gas Pressure Switch 4.4.7
Troubleshooting 4.5
Troubleshooting: Flow Circuit/Circulating Pump(s) 4.5.1
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Troubleshooting: Tripped High Outlet Pressure Switch 4.5.2
Troubleshooting: Differential Pressure Switch Break 4.5.3
Troubleshooting: Call for Heat 4.5.4
Troubleshooting: Safety Interlock 4.5.5
Maintenance Log 4.6
General Dimensions 5.1
FT-C Specication 5.2
Electrical Diagrams 5.3
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
General Arrangement 1
FT-C Component View 2
CSD-I Fuel Train 3
NFPA Fuel Train 4
Oil Fired Fuel Train 5
Drain and Fill Connection 6
Thermal Fluid Heater Nameplate 7
FT-L Expansion/Deaeration/Thermal Buffer Sections 8
FT-L Combination Expansion/Deaerator/Thermal Buffer Tank 9
Liquid Level Switch 10
Oil and Gas Circulating Pump 11
Typical Water Cooled Pump 12
Pressure Gauges 13
Typical Thermal Piping Shematic 14
Bolting Seqeunce 4 and 8 Bolt Flanges 15
Drain and Fill Connections 16
Proper Fluid Level in Dearator Tank Expansion Section 17
Oil Nozzle Dual Fuel Burner (FT-0400-C - FT-1400-C) 18
Gas Nozzle with Orice Dual Fuel Burner (FT-0400-C - FT-1400-C) 19
Complete Dual Fuel Assembly 20
Control Panel Fascia 21
Electrical Panel 22
Thermal Fluid Circulating Pump 23
Pump Coupling 24
Strainer 25
Operating Temperature Control 26
Differential Pressure Switch 28
Inlet and Outlet Pressure Gauges 29
High Outlet Pressure Switch 30
Electrical Diagram: FT-C 0430 Electrical Thermal Fluid Heater On/Off 31
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
FT-C vertical
thermal uid
heater
Electrical panel
box contains
all operating
safety controls
FT-L combination
expansion/dearaetor/
thermal buffer tank
Thermal uid
circulating
pump
Skid-mounted
FT-C thermal uid
system
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
The Fulton FT-C is a vertical thermal uid heater with a range of 11 models. The Fulton FT-C Thermal
Fluid Heater offers a compact fuel red 4-pass heater design capable of operating temperatures up
to 345°C
The heater is of a vertical, helical coil self venting design, and the pressure vessel coil construction
shall be carbon steel ASME SA106B, Schedule 40 or equal. The design pressure is 13.8 barg
standard at 370°C. The heater will be per ASME Code Section I stamped at 10.34 barg maximum
working pressure, trimmed at 6.9 barg unless otherwise specied. Test pressure will be per ASME
Code Section I. Minimal refractory lining shall be supplied in heater combustion chamber to avoid
thermal inertia and overheating of the thermal uid should a pump or power failure occur.
The shell, coil and burner are surrounded by the pre-heater jacket. This jacket is a welded steel
construction with an integral oor plate and bolted top cover to facilitate coil removal, access panels
for air chamber inspection and has an aluminium inner air bafe. This pre-heater obviates the
requirement for insulation of the heater and simultaneously boosts thermal efciency by preheating
incoming combustion air.
for a full specication please refer to .
234
351
468
703
937
1171
1757
2342
2928
3514
4100
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
A - Fluid Outlet
B - Top Mounted Burner
C - Fluid Inlet
D - Control Panel
E - Fan Inlet
Notes
1. Thermal uid heater is of four-pass combustion design.
2. First pass (radiant): combustion air enters burner fan and travels upward between inner and
outer jacket before it enters top-mounted burner.
3. Second pass (convection): Gases travel back across the inner row of coils.
4. Third pass (convection): Gases continue back down between inner and outer coil.
5. Fourth pass: Upward between the outer coil and inner jacket to the ue outlet.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
The installation of a FT-C thermal uid heater should be carried out by competent personnel in
accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that
these regulations are complied with.
a) All components exposed to thermal uid ow, including pipe, valves, and screens, must not be
made out of copper, copper alloys, aluminium, or cast iron. Cast iron is porous to thermal uids,
and copper and aluminium act as catalysts in the degradation of some thermal uids. Carbon or
stainless steel, or ductile iron, are recommended.
b) For standard applications, all components must be rated to 350°C unless otherwise stipulated.
c) All pipework, valves, and user equipment must be suited to the maximum operating pressure
of the heater. The maximum pressure stamped on the heater nameplate is typically 10.34 barg
(150 psig).
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 6.9 barg (100 psig), an alternative safeguard is to install
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.
f) During construction of the installation, ensure that no dirt, water, or residue from welding is left
in the system.
All Fulton Coil Design Heaters are shipped vertically and all units are crated for forklift transport. Once
uncrated, all units with the exception of freestanding Models FT-0080-C, FT-0120-C, FT-0160-C, and
FT-0240-C can be transported with a forklift.
These four models can only be lifted for unloading and moving by means of lifting lugs at the top of
the heaters. If means of lifting are not available, rollers should be placed beneath the frame of the
heater, and it should be guided to the position of where it is to be installed. Under no circumstances
should weight be allowed to bear on the jacket, control panel, or fan housing of any Fulton Thermal
Fluid Heater.
All stand alone heaters can be moved via a crane utilizing lifting lugs on top of the heater. The
FT-0320-C and larger stand alone heaters can also be moved using a fork lift. All skidded units can
be moved with forklifts.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Reference should be made to to ascertain the relevant dimensions and weights.
a) Authorities with jurisdiction over any national or local codes which might be applicable to
thermal uid applications should be consulted before installations are made.
b) The heater should be located as close as possible to the place where the heat will be used in
order to keep pipe work costs to a minimum.
c) A level, hard, non-combustible surface is required for a suitable base for mounting the unit. It is
suggested that a 100 mm curb be installed completely around the unit. In the event of a large
spill, this will help contain the uid.
d) Approximations for the oor loading of each heater can be calculated using the weights given in
section 5.1. Check building specications for permissible oor loading.
e) The heater should be placed in a suitable heater house or well ventilated separate room through
which personnel do not normally pass. This is not essential, but the layout should eliminate
trafc in potentially hazardous areas. For instance, the service engineer or the operator should
not have to pass exposed, hot pipe work to make adjustments to the heater controls.
f) Ventilation must be sufcient to maintain a building temperature of 38°C or less and the panel
box temperature must not exceed 52°C. Natural ventilation should be provided by means of
grilles at oor and ceiling level.
g) To burn fuel properly, the burner must have an adequate supply of air.
See Technical Information sheet for the heater for minimum make up air required and the
recommended area of opening for each heater.
If positive forced ventilation is adopted, you must ensure that there will be no appreciable
pressure variation in the heater room.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Adhere to the following for gas supply installation:
1) Install gas piping in accordance with all applicable codes.
2) Ensure pipe and ttings used are new and free of dirt or other deposits.
3) Ensure piping is of the proper size for adequate gas supply to the gas head assembly. Consult
your gas company for specic recommendations.
4) When making gas piping joints, use a sealing compound resistant to the action of liqueed
petroleum gases. Do not use Teon tape on gas line heads.
5) Ensure no piping stresses are transmitted to the equipment. The equipment shall not be used
as a pipe anchor.
6) Ensure all vent connections on diaphragms, gas valves, pressure regulators, and pressure
switches (gas-red units) are vented per local code.
7) On gas-red units with NFPA valve trains, ensure the vent valve is piped to atmosphere per
local code. See Figure 4.
8) During any pressure testing of the system at pressures in excess of 34 mbar (0.5psi),
disconnect the heater at the heater manual shutoff valve (located at the end of the supplied gas
train) from the gas supply piping system.
9) Ensure the supply pressure is regulated by a non-stacking, tight, shutoff regulator.
10) Arrange gas piping so that it does not interfere with any cover or burner, inhibit service or
maintenance, or prevent access between unit and walls or another unit.The burner assembly
and gas controls terminate at a manual stop valve to which the gas supply should be
connected. Piping must be sized for a gas ow consistent with the required kW input. Large
pressure drops must be avoided. Fulton recommends that the supply piping between the
pressure regulator and the inlet to the heater be kept to a minimum. The minimum required gas
pressure at the stop valve varies with the model of heater. The requirements for natural
gas-red coil design models are as follows:
• Models FT-0080-C to FT-0400-C 34 mbar (0.5 psi)
• Models FT-0600-C to FT-0800-C 149 mbar (2.2psi)
• Models FT-1000-C to FT-1400-C 299 mbar (4.3psi)
Low emissions burners for all models require 345 mbar (5psi).
Even when the unit is shut down, the gas supply pressure must never exceed these values.
When operating, the supply pressure must not drop below these limits: Not less than 27 mbar where 34
mbar is required. Not less than 125 mbar where 149 mbar is required. Not less than 249 mbar where 299 mbar
is required.
11) After gas piping is completed and before wiring installation is started, carefully check
all piping connections, (factory and eld), for gas leaks. Use a soap and water solution.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Gas Safety
Shutoff Valve
Main Gas
Regulator
Manual Gas
Valve
Pilot Gas
Regulator
Pilot Gas
Valve Manual Gas
Valve
Butterfly
Valve
HI / LOW
Gas Pressure Switch
2” N.P.T. Gas
Connection
2” N.P.T. Gas
Connection
Manual Gas
Regulator
Manual Gas
Valve
Vent Valve
Gas Safety
Shutoff Valve
Manual Gas
Valve
HI/LOW
Gas Pressure Switch
Butterfly
Valve
Pilot Gas
Regulator
Pilot Gas
Valves
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Adhere to the following for installation:
1) Fuel pipes must be of approved materials and of a diameter suitable for the quantity of oil being
delivered to the burner and the static head available.
Make fuel connection in accordance with the details on the enclosed fuel pump cut sheet.
2) Ensure fuel oil piping is in accordance with local/national requirements.
In addition, if a two pipe system is employed, a check valve must be tted into the return pipe.
Fuel Oil Viscosity Specic Gravity Sulfur Content
#2 Less than 31.9 Seconds Redwood
#1 at 38°C (100°F)
0.824 to 0.852 at 15°C (59°F) Less than 0.40% by
weight.
#4 Less than 81 Seconds Redwood
#1 at 38°C (100°F)
0.90 to 0.93 at 15°C (59°F) Less than 1.6% by
weight.
#6* Less than 3000 Seconds Red-
wood #1 at 38°C (100°F)
0.95 to 0.98 at 15°C (59°F) Less than 2.12% by
weight
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
a) All heaters will also require a minimum clearance overhead for coil removal. In cases where
the available height is insufcient, a roof or ceiling trap might be considered.
b) Pipes should not be run within 250 mm of any control cabinets or combustible material.
c) Failure to provide suitable and safe access at the time of commissioning may cause delays, as
our Service Engineers are instructed not to commence commissioning if hazardous conditions
exist.
a) Access around the heater should be provided to facilitate maintenance. Appropriate clearances
for all sides follow.
b) Place heater with clearances to unprotected combustible materials, including plaster or
combustible supports, not less than the following:
1
0.5
0.5
0.5
2835
3097
3180
3554
4153
4655
6005
6038
6062
6031
6851
For minimum clearances for personnel access and burner removal, refer to Technical Information
sheet for the heater.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
If screwed connections have to be made, e.g. to items of control equipment, then a thread sealant
suitable for use with uids at elevated temperature must be used. Teon tape, standard pipe dope, or
hemp and paste are not acceptable. Screw threads must be carefully and accurately cut. If possible,
new tools should be used. Threaded connections larger than DN25 are not to be used. It is
recommended that class 8.8 or better tensile steel bolts be used for all anged joints.
a) The outlet of the pump should connect directly to the inlet of the heater via an isolating valve
and pump exible connector.
b) The heater outlet should be piped directly to the system, via an isolating valve.
c) A safety relief valve may be shipped in the parts box accompanying the electric heater, and
must be installed in the outlet manifold. On all units, the outlet of the safety relief valve must
be piped to a catch tank. The discharge ow must not be restricted, i.e. no valve should be
installed, there should be no reduction in pipe size, and the minimum number of bends possible.
The weight of the piping must be properly supported in order to prevent damage to the safety
valve. If the valve body becomes warped, leakage may result.
The system is usually lled from the lowest point, with the aid of a pump. On skid-mounted units, a
drain and ll connection is provided in the inlet piping to the pump.
The system pump is not to be used to ll the system.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Normal supply will be 400 volts, 3 phase, 50 Hz, AC unless otherwise specied.
Make sure the information on the electrical drawing 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.
a) A wall-mounted, fused disconnect sized for the unit must be provided and tted by the
client/contractor, if a disconnect is not supplied on the panel.
b) Fuses must be sized according to motor name plates and local electrical codes.
c) Heaters and single skid systems are generally shipped completely prewired. The liquid level
switch on the expansion tank, when supplied, will be shipped in the parts box and must be
installed in the eld. Multiple skid systems may require wiring between the skids.
d) If the unit is not skid-mounted at the factory, the client/contractor is required to wire the
circulating pump starter.
e) When using a SCR, a Shunt Trip Breaker is required to be installed by the customer. It will
be used to remove power to the panel in the event of an over temperature/pressure
condition. The Shunt Trip Coil needs to be wired to the boiler electrical panel as indicated on
the electrical drawing.
If the circulating pump motor is not supplied by Fulton Ltd, the motor starter will not be supplied.
Certain properties of thermal uid, including low surface tension, make it necessary to pay
particular attention to containing the uid. Good pipework system design, welded construction,
proper anging, gaskets, and other appropriate means of eliminating potential leakage must be
employed.
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Fulton Ltd's efcient design combines the operation of the expansion, deaerator, and thermal buffer
tanks. Installation is considerably simplied by virtue of this arrangement.
The tank will be constructed of carbon steel. It shall be supplied with expansion section liquid level
switch and PN16 anged connections.
The tank may be built to BS EN 13445: 2009 upon request. Non-coded tanks should not be
pressurised above 0.5 barg.
The expansion section is vital to the thermal uid system. From ambient to operating temperature,
the thermal uid in the system will typically expand in the range of 25%-50%, and a vessel capable
of handling this expansion is mandatory. The customer should conrm the expansion rate of the
chosen uid and system volume.
At start up the primary purpose of the deaerator section is to remove all volatiles from the system to
avoid pump cavitation. The deaerator section also allows oxygen to be vented from the system on a
continuous basis during operation to avoid oxidation of the thermal uid, and removes other volatile
particles generated by the uid itself during system operation. This section of the tank should be
insulated.
A system of interconnecting pipe work in the thermal buffer tank section prevents the movement of
any oil that has not cooled sufciently into the expansion section. This avoids contact of very high
thermal uid temperature with oxygen contained in the atmosphere, which causes uid breakdown.
DO NOT insulate this section.
Please see
FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1
Combination tank capacity is the total volume of the tank. It is necessary to have some air space
available at the top of the tank to avoid spillage or overow. At initial ll (for system volume
calculations) the deaerator and thermal buffer sections must be lled completely and the
expansion section must be lled to a level of 100 mm to "make" the liquid level switch.
The volume between the initial ll level and the safe "full" level is the amount available for
expansion. That volume is used to decide which tank is suitable for the system expansion.
A system contains 660 litres, including the heater, but not the tank. You select the FT-200-L, so you
add 95 litres to 660. You must look up the expansion rate for the thermal uid. (Assume it is 25%).
755 litres x 1.25 = 945 litres. 945-755 = 190 litres expansion. The FT-200-L has only 75 litres
available for expansion, so the correct selection is the FT-500-L.
a) The combination tank must be installed in accordance with Fulton Ltd's specications.
b) Unless the system is pressurised, the inlet to the deaerator section must be higher than or equal
to the highest point in the system to prevent pockets of air from collecting in system piping.
c) The head required at the circulation pump suction inlet must also be taken into account to avoid
the possibility of pump cavitation. In systems operating close to maximum uid temperature, the
tank must be elevated enough, possibly well above the highest point in the system to prevent
pump cavitation by increasing the static head. An inert pressurising blanket may be considered
as an alternative. See
d) Supports for tank mounting should be provided by the client/contractor. These should be suited
for supporting the tank by the side rails. The eyelets tted to the tank are for lifting only.
This manual suits for next models
11
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