Fulton Companies Gas Fired Steam Boiler VMP-80

Remove the burner plate and top plate assembly up and out of the air to air heat exchanger

Remove the stainless steel combustion ring from the furnace

Remove the clean-out plugs from the bottom sides of the boiler

Break off the top holding clips that were used to keep the refractory in position during shipping

Break up the top and/or bottom refractories and remove the pieces from the boiler through the clean-out plugs

Round and bevel the outer edges of the new refractories

Lower the bottom refractory down the furnace with wire fastened around the refractory in three positions

Install the top refractory in the same manner as the bottom refractory

Seal the outer edges of the top refractory with insulcrete

WARNING! Make sure main power switch is off before starting work

1. Cleaning the water gauge glass

CAUTION! Do not clean the gauge or gauge glass while pressurized or in operation

a. Clean the water gauge glass using a commercial non-abrasive glass cleaner. Use diluted acids such as hydrochloric (muriatic) acid when regular cleaners do not seem to work. Do not use wire brushes or any other abrasive materials which could scratch the glass. If any leakage is evident, replace the gaskets

b. Always replace the high impact plastic gauge glass protector which is standard on all Fulton Boilers

3. Check scanner or flame rod and ignition electrodes

4. Check starter contacts. Burned or pitted contacts should be replaced. Do not use sand paper or file to clean

5. Clean water traps and strainers in fuel lines

1. Have combustion (CO2, O2, CO) and input checked by responsible personnel

2. Dirty flues can cause air flow restrictions resulting in poor combustion and loss of efficiency. Clean flues as follows

a. Remove the outer flue cover plate

b. Remove inner plate and turbultors

c. Remove clean out plugs at lowest part of unit and clean the bottom of combustion chamber

d. Remove all soot from the top, and from the clean out plugs at the bottom with a vacuum cleaner

e. Replace clean out plugs carefully so as not to damage insulation and replace burner and flue cover plates

3. Flush boiler out if necessary. See Section 2 for proper procedure for "Cleaning the Pressure Vessel."

4. Provide annual inspection by a qualified ASME Boiler inspector;

Boiler started and generating not more than 10 PSI (.703 kg/cm2) of steam?

Tap water turned on to blow-down separator?

Boiler blow-down valves opened for approximately 10 seconds?

Tap water to blow-down separator shut off?

Water column and the water gauge blow-down valves opened for approximately 5 seconds?

Ceramic fiber burner tile removed

Burner tile bottom holding clips need replacement?

Scroll assembly replaced without damaging the ceramic fiber burner tile

Sign off on the burner tile replacement