Logic Heat Steam Boiler Operations and Training Manual - SAN PABLO OIL 150HP

Logic Heat Model LH100
OIL FIRED STEAM BOILER
Operations
2
is a registered trademark of Switchtek Construction Corporation as a brand of Thermal Fluid Heaters and
Steam Boilers. All Right reserved. Copyright 2001
Contacts: (632) 9282869, 426-4593, 9287769, Fax: (632) 4267593, Email: switchtekboilers@yahoo.com,
switchtek@pldtdsl.net
Logic heat
www.switchtek.com.ph
and Training Manual
Customer:
WHITE ROSE INDUSTRIES, INC.
Turbina, Laguna
3
Logic heat
This page is intentionally left blank
4
Logic heat
Table Of Contents
Table of Contents
Foreword
Steam Boiler Design and Specifications
Definition of Terms
Steam Boiler Parts Description

Steam Boiler
10
Accessories
11
Calorific Conversion
11
Burner Familiarization
12
Preliminary Inspection
12
Suggested Installation Checklist

Remarks
12
15
Additional Remarks
15
Operation Procedure & Guidelines
16
How to Operate the Boiler
16
Storing the Boiler at Long Periods
17
Maintenance and Inspection
17
Oil Burner Maintenance
18
Steam Boiler Maintenance Guideline
19
5
Logic heat
Maintenance Check Chart
20
Troubleshooting
21
Foreword
his operating manual presents information that will help properly operate and care
for the equipment. Study its contents carefully. The unit will provide good service
and continued operation, if maintenance instructions are followed. No attempt
should be made to operate the unit until all the principles of operation and all of the
components are thoroughly understood.
The Logic Heat Solid Fired Steam Boiler is designed and engineered to give
long life and excellent service on the job. The electrical and mechanical devices
supplied as part of the unit, were chosen because of their ability to perform. However,
proper operating techniques and maintenance procedures must be followed at all
times. Although these components afford high degree of protection and safety,
operation of equipment is not to be considered to free from all dangers and hazards
inherent in handling thermal fluid heating system.
Any automatic feature included in the design DO NOT RELIEVE the
attendant (boiler operator) of any responsibility. Such feature merely free him from
certain from certain repetitive chores and give him more time to devote to the proper
upkeep of the equipment. It is solely the operators responsibility to properly operate and
maintain the equipment. No amount of written instruction can replace intelligent thinking
and reasoning and this manual is not intended to relieve the attending personnel of the
responsibility for proper operation.
Because of state, local or other applicable codes, there are a variety of
electrical control and safety devices which vary considerably from one steam boiler to
another. This training manual contains information, designed to show how a Hybrid
Logic Heat Solid Fired Steam Boiler operates.
Operating controls will normally function for long periods of time and we
have found out that some operators become lax in their daily, weekly or monthly
testing activities assuming that normal operation will continue indefinitely. Malfunctions
of controls lead to uneconomical operations and damages and in most cases these
conditions can be traced directly to carelessness and deficiencies in testing and
maintenance. It is recommended that the steam boiler operations log or record be
maintained; recording of daily, monthly, yearly maintenance activities and recording of
any unusual operation will serve as a valuable guide to any troubleshooting.
It is customary to engage the services of the manufacturer and boiler
water treatment consultant to recommend proper boiler check-up and maintenance.
The operation of this equipment by the Owner and his operating personnel
must comply with all the requirements or regulations of his insurance company and/or
any other authority having jurisdiction.
Logic heat
6
Since product improvement

a continuing
thrust,
the information provided by
Steam Boilers. AllisRight
reserved. Copyright
2001
Switchtek
Construction
Corporation
in this
on specific
features is subject to
Contacts:
(632) 9282869, 426-4593,
9287769, Fax:
(632)manual
4267593, Email:
switchtekboilers@yahoo.com,
change without prior notice.
THE SWITCHTEK TEAM
This Page is intentionally left blank
7
Logic heat
LOGIC HEAT STEAM BOILER SPECIFICATIONS
BRAND:
LOGIC HEAT
MODEL:
LH100
SERIAL NUMBER:
LH100JO3073
YEAR BUILT:
EQUIPMENT:
Steam Boiler
DESIGNED USE:
Sterilization
DESIGNED PRESSURE:
150 psi
OPERATING PRESSURE:
THERMAL POWER:
980 Kilowatts
OPERATION:
Modulating in Operation
MOUNTING:
Horizontal in Orientation
STEAM CAPACITY:
POWER SUPPLY:
220/440V x 3
CONTROL VOLTAGE:
220v (+10%)
FREQUENCY:
60 Hz
FUEL:
BUNKER
2012
130 psi
3,450 lbs/hr.
8
Logic heat
TESTS:
DYE PENETRANT, HYDROSTATIC
INSPECTION:
ASME/ PSME B31.1
DEFINITION OF TERMS:
1. Steam Boiler: A pressure vessel fired by any fuel designed to contain water to
produce steam at desired pressure and temperature.
2. Reverse Flame Boiler -This is a variation on conventional boiler design. The
combustion chamber is in the form of a thimble, and the burner fires down the centre. The
flame doubles back on itself within the combustion chamber to come to the front of the
boiler. Smoke tubes surround the thimble and pass the flue gases to the rear of the boiler
and the chimney.
3. Water wall Section The watertube side section of the hybrid boiler.
4. Over Fire Combustion Air An extra supply of combustion air, mostly in
large boilers to compensate for the incomplete combustion.
5. Flue Chamber: The vessel holding the furnace heat.
6. Exhaust Temperature: The exit temperature of the flue gas.
7. Differential Pressure: The difference of the two pressures entering an orifice.
The system used in the Differential Pressure Switch.
8. Thermal Power (Kilowatts): The amount of thermal energy produced by the
burner per kilogram per hour of fuel burned.
9. Set Point Pressure: The set point in pressure where the burner starts to
modulate or cut-off.
10.Modulated Firing: The automatic reduction of thermal output based on load
demand.
11.Indicator Lights: provide visual information on operation of boiler as follows:
Power, Alarm and Burner On and others (may vary on other installations)
12.Forced Draft Fan and Motor: Furnishes all air, under pressure, for
combustion of pilot fuel and main fuel and provides purge air.
13.Stack Thermometer: Indicates temperature of ventilated flue gas.
9
Logic heat
STEAM BOILER PARTS DESCRIPTION:

1. Boiler Shell: Provides housing for the tubes and contain water to be fired
and converted as steam.
2. Fire tubes: Provides the holding tubes of the hot flue gases and aids in the
conduction of heat to produce steam.
3. Boiler Rear Door: The insulated door at the back of the steam boiler
where the flame sight port is located.
4. Boiler Front Door: The insulated door at the front area where the burner is
located. This also serves the access entry for shell desooting.
5. Flue Gas Outlet: The smoke stack where the products of combustion and
excess heat are released.
6. Boiler Skid: A sturdy metal foundation designed to hold the weight of
boiler shell and its contents.
7. External Cladding: Designed to hold the external insulation and produces
a firm body profile of the boiler. Since external shell is made up of
mirrorized stainless steel sheet, this produces aesthetic value.
8. External Insulation: Designed to conserve heat of the steam boiler.
Material used is made normally of fiberglass or Rockwood insulation.
9. Feedwater Inlet: The entry point for the raw water for the boiler.
10.Steam Outlet: The outlet port of the steam at required flowrates.
11.Flame Sight Port: A viewing port made up of temperature-resistant
glass like borosilicate installed at the rear section of the thermal heater
door to view flue chamber condition, flame color, size and shape. Also as
port when inspecting the overall internal conditions of the heater.
12.Gratings: A cast iron constructed metal bar to hold solid fuel while allowing
combustion air to pass through.
13.Furnace Wall: A barrier consisting of the water-walled section of the
furnace plus the external insulation of the solid fired furnace.
14.Connecting Pipe ( Watertube to Firetube): An insulated tube designed
to withhold high furnace temperature and connect the watertube to fire
tube section of the boiler.
15.Ash Pit: A port for removing ash as a result of complete combustion.
16.Air Ports: An additional port for the entry of fresh combustion air.
10
Logic heat
LOGIC HEAT STEAM BOILER ACCESSORIES:

1. Feedwater Tank: A tank designed to hold sufficient amount of raw treated
water for the make up of the boiler water which is converted to steam.
2. Water Softener: A vessel designed to remove unwanted minerals like
Magnesium, Calcium that causes the scaling formation in boilers. This
regularly requires the regeneration with the use of brine solution.
3. Steam Valves: Isolation valves designed to permit flow of steam.
4. Steam Check Valve: A valve with a swinging door designed to permit
unidirectional flow.
5. Steam Lines: Insulated and aluminum clad pipelines made up of steel
designed to hold steam and direct steam flow in the system.
6. Control Boards: The electrical section of the boiler designed to provide
controls on motor drives.
CALORIFIC CONVERSION:
The Calorific Power of Dry wood is:
4,565 Kcal/kg = 5.31 Kw/Kg = 7.09 Hp/Kg

The Calorific power of light oil is: DIESEL
10,200 Kcal/kg = 11.86 Kw/Kg = 15.89 Hp/kg
The calorific power of heavy oil is: BUNKER

9,600 Kcal/kg = 11.15 Kw/Kg = 14.96 Hp/ Kg
The conversion table from to are the following:
1 Kcal/h = 0.0012 Kw = 0.0016 Hp
1 Kw = 860 Kcal/h = 1.341 Hp
1 Hp = 641.2 Kcal/h = 0.745 Kw
1 Hp = 9.803 Kw
11
Logic heat
SOLID FIRED BOILER FAMILIARIZATION

Study the following illustrations taking special note of the PART NAMES as shown in
the callouts (nameplates).
Variations between systems are commonplace due to the many differences in job
conditions and agency requirements.
This manual contains information applicable to a solid fired system arrangement and
is not intended to be representative of any specific agency or code criteria.
PRELIMINARY INSPECTION
The boiler in general should be visually checked for damages and loose components
as these conditions can occur during shipment, through improper handling, by
tampering or through improper care and storage at the job site.
CHECK FOR:
Obvious damages on parts.

Tightness of electrical terminals and connections.
Accumulation of oil, dust, dirt, water or other foreign matter on, in, or near
other electrical / electronic components if fitted.
Fiber dust is an explosive material, when properly combined with air and heat it
can be explosive comparative with gaseous fuels. Keep working place near the
boiler tidy and clean.
SUGGESTED INSTALLATION INSPECTION CHECKLIST

Check when completed and provide notes:
If a refractory combustion chamber is part of the installation, is it

completely dry, cured and ready for firing at full boiler input?
Notes: ____________________________________________________
Has the proper electrical voltage been connected to the system as shown
on the electrical wiring diagram?
Notes: ____________________________________________________
12
Logic heat
Has the control components wiring been checked for completeness and
accuracy? Have 3-phase motors been properly wired and checked for
correct rotation?
Notes: ____________________________________________________
Are the boiler mounted limit controls such as the low water cutoffs, high
limit controls, operating controls, modulating controls, etc., properly
installed and wired?
Notes: ____________________________________________________
Are the boiler controls the right type and range for the installation?
Notes: ____________________________________________________
Is the boiler water supply, including feed pumps, properly connected and is
boiler filled with water?
Notes: ____________________________________________________
Is sufficient load connected to the boiler so that it can be fired continuously

at full rating?
Notes: ____________________________________________________
If boiler load is not connected, can steam be wasted so that the boiler can
be fired continuously at full rating without endangering personnel or
equipment?
Notes: ____________________________________________________
For new boiler installations, has the boiler been boiled out in accordance
with the manufacturers instructions?
Notes: ____________________________________________________
Have the boiler breeching connections to the stack been completed and are
they open and unobstructed?
Notes: ____________________________________________________
Is draft control equipment required and, if so, installed?

Notes: ____________________________________________________
Have adequate provisions for combustion air been installed?

Notes: ____________________________________________________
13
Logic heat
Have the persons listed below been notified of the solid fired boiler start-update?
Owners Representative
Mechanical Contractors Representative
Electrical Contractors Representative
Service Organizations Representative
Boiler Manufacturers Representative

Notes: ____________________________________________________
__________________________________________________________
Are all specified auxiliary equipment mounted and wired?

Notes: ____________________________________________________
Other Important Notes:
14
Logic heat
REMARKS:
Installation requirements and instructions should always be covered in appropriate
engineering drawings and specifications, which detail the applicable codes, etc.
Information contained herein is to be used as a guide ONLY and not as the final
authority.
For solid fired systems, the type of solid wastes fuel (biomass) must be within the
range as stated in the manual or the guarantee will be nullified.
Starting a boiler is an event, which normally culminates the efforts of several different
contractors, manufacturers, utility and engineering concerns, sales and factory
representatives, and others.
In order for the boiler to operate safely and meet its design capabilities, the
interfacing fuel, air, electrical, exhaust and plant heating control systems must be
properly sized, selected, installed and tested. Additionally, all conditions must be such
that the heat generated by the burner can be safely used or wasted without
endangering personnel or equipment.
It shall be the policy of SWITCHTEK CONSTRUCTION CORPORATION, that no
responsibility is assumed by the company nor any of its employees for any liability or
damages caused by inoperable, inadequate or unsafe boiler operation which is the
result, either directly or indirectly, of any of the improper or inadequate conditions
described above.
To ensure that a safe and satisfactory installation has been made, a pre-start
inspection is necessary. An individual who is thoroughly familiar with all aspects of
proper boiler/ burner installation must perform this inspection and how it interfaces
with overall plant operation.
15
Logic heat
ADDITIONAL REMARKS
This inspection should be performed before the boiler start-up specialist is called in. A
complete or inadequate installation may require additional time and effort by start-up
personnel and cause an untimely and costly delay.
The results of this inspection will often times identify corrections that must be made
prior to start-up as well as point out potential or long range problems in plant
operation if corrections are not made.
Boiler start-up is a serious matter and should not be viewed as a tine forcrowd
gathering by unconcerned, uninformed or unauthorized personnel. The number of
persons present should be held to an absolute minimum.
Instructions of operating and other concerned personnel should be done after the
burner has been successfully fired and adjusted by a qualified service agency or
factory start-up specialist.
OPERATION PROCEDURE AND GUIDELINES

1. Ensure that the person who will operate has thoroughly understood and read
the manual, and has familiarized himself with the piping and control system of
the LOGIC HEAT Steam Boiler. Especially this type - WOOD FIRED HYBRID
STEAM BOILER.
2. Verify that there is Fuel and that the air inlet and exhaust systems are free
from obstructions, meaning air/ exhaust events are opened.
3. Verify that the steam supply and condensate return system (if installed) is free
from obstructions, meaning supply and return valves are opened.
4. Verify that the control breakers, and drives are closed.
5. Supply appropriate system voltage to the main Control Console.
6. Ensure that the Feedwater pump is operational including its automatic controls.
7. Verify that there are no leaks in the steam, condensate and water lines.
8. Prior for turnover, settings have been preset, like for example the pressure
setting of the steam boiler.
9. Operate the boiler by means of the switch.
16
Logic heat
10.System is semi- automatic and will start, modulate and stop depending on the
program set by the Operator. Except the fuel feed which can be upgraded in
the future.
11.Log all data on a log sheet as soon as the operation stabilizes.
HOW TO OPERATE THE BOILER:
It is assumed that the boiler has been boiled out prior for initial firing at longer
periods and that a flue gas emission test has been performed on the unit.
1. Visually check the boiler unit, rear, front doors, door nuts and clips, burner,
gauges and its peripherals prior for operation. DO NOT OPERATE THE
BOILER WHEN UNSURE of the inspection conducted and call the
manufacturer immediately.
2. Check for the Boiler Water Level. The set water level can be verified at the
magnetic water level gauge/ or any similar device. Slowly drain some portion of
the roller display (If filled with water), to assure float movement.
3. Verify that the feedpump controls main circuit protection are closed.
4. Place the selector switch of the feedpump control in manual position. This
should operate the feedpump and increase water intake inside. Listen at the
pump and check motor rotation and report any unusual noise. The feedpump is
fitted with a gauge and registers the required pressure it delivers.
5. Place the feedpump control in off position (in the case of other designs, in
auto), the pump should stop.
6. Test the automatic filling of the Feedwater pump, by putting the feedpump
selector switch in automatic mode. Level set points can be tested by manually
draining the surface blow off valve or the bottom Blowdown valve. This should
start and stop the feedpump motor automatically.
7. Verify wood supply.
8. At pre-start conditions, vent the boiler to let fresh oxygen enter the furnace.
9. Manually ignite wood fuel to achieve an initial phase of combustion, increasing
the solid fuel. The combustion air blower will remove the smoke by making an
almost perfect combustion.
10.At firing conditions, visually inspect flame color.
11.At normal operations, the boiler should be maintained as prescribed here on
the manual.
12.The blowers will be turned off automatically as soon as the set pressure is
reached. The manual feed should be synchronized with the rise of pressure and
the load demand
13.It is recommended to log all the necessary data on a log book for verification of
its operating conditions. Examples are Steam Pressure, Operating Periods,
Exhaust Temperature, Wood per Kilogram (if applicable)
14.It must be noted however, warranty is voided when damages are caused by
the scale formation in the boiler watersides.
17
Logic heat
15.This system will continuously cycle in operations when the guidelines are
properly met.
16.Remove ash manually so as to provide adequate space on air and fuel.
17.Maintain wood stock dry and clean to prevent migration of undesirables pests
and rodents. If possible keep it dry at all times.
18.In the event of power failure and the boiler system is not linked on an
Emergency Power supply, try to extinguish the combustion in the furnace
slowly and monitor steam on the gauge. A provision should be put in the future
to supply emergency feedwater.
STORING THE BOILER AT LONG PERIODS:

1. When the boiler is to be stowed at longer periods, it is recommended that the
water is drained and boiler shell dried. Inside it is recommended to blanket
Nitrogen Gas to inhibit corrosion. Should blanketing gas is not available; a 1 kg.
of Silica Gel would serve the same effect.
MAINTENANCE AND INSPECTION

General
A well-planned maintenance program avoids unnecessary down time or costly
repairs, promotes safety and aids boiler code and local inspectors. An inspection
schedule listing the procedure should be established. It is recommended that a boiler
room log or record be maintained, recording the daily, weekly, monthly and yearly
maintenance activities. This provides valuable guide and aids in obtaining economies
and length of service from the boiler.
Periodic Inspection
There should be a schedule for inspection for annual, monthly or other periodic
maintenance program. This inspection pertains primarily to the water side and fire
side of the pressure vessel it provides the operator an excellent opportunity for
detailed inspection and check of all components of the boiler including piping, valves,
pumps, gaskets, refractory, etc.
Fire Side Cleaning
Soot and non-combustibles are effective insulators and if allowed to accumulate will
reduce heat transfer to the water and increase fuel consumption. Soot and other
deposits can be very moisture absorbent and may attract moisture to form corrosive
acids, which will deteriorate fireside metal.
Clean out should be performed at regular frequent intervals depending upon load,
type and quality of fuel, internal boiler temperature, and combustion efficiency. A
stack temperature thermometer, if used, can be a guide to clean-out intervals since
an accumulation of soot deposits will raise the flue gas temperature.
18
Logic heat
Opening front and rear doors accomplish tube cleaning. Tubes may be brushed from
either end. All loose soot and accumulations should be removed. Any soot or other
deposits should be removed from the furnace and tube sheets.
Electrical Controls
Most of the operating controls require very little maintenance beyond occasional
inspection. Examine tightness of electrical connections. Keep the controls clean.
Remove any dust that accumulates in the interior of the control using a low-pressure
air hose and taking care not to damage the mechanism.
Examine switches. Covers should be left on controls at all times.
Dust and dirt can cause excessive wear and overheating of motor starter and relay
contacts and maintenance of these is a requirement. Starter contacts plated with
silver and are not harmed by discoloration and slight pitting. Do not use files or
abrasive materials such as sandpaper on the contact points since it only wastes the
metallic silver with which the points are covered. Use a burnishing tool or a hard
surfaced paper to clean and polish contacts.
Thermal relay units (overloads) are of the melting-alloy type and when tripped, the
alloy must be given time to re-solidify before relay can be reset. If over-loads trip pout
repeatedly when motor current is normal replace them with new overloads. If this
condition continues after replacement it will be necessary to determine the cause of
excessive current draw.
Programming Controls (ON FITTED OIL BURNERS ONLY)
This control requires no adjustment, nor should any attempt to be made to alter
contact settings.
OIL BURNER MAINTENANCE (WHEN USING A BURNER)

The burner should be inspected for evidence of damage due to improperly adjusted
combustion. The seeing of the oil nozzle in relation to the diffuser and other
components is important for proper firing and should be checked.
The seal between oven liners is extremely important. Its conditions should be
checked periodically and repairs made as necessary.
Fuel Oil Strainer
The fuel oil strainer screen must be removed and cleaned at regular intervals. It is
advisable to remove this screen each month and clean thoroughly by immersing in
solvent and blowing dry with compressed air. To remove and loosen cover cap screw
being careful not to lose the copper gasket. Tap strainer cover gently to loosen. Check
cover gasket. Slip pliers on to the top of the strainer and twist counter clockwise to
remove the gasket. Re-assemble in reverse order.
Fuel Oil Treatment
19
Logic heat
Conditions and the quality of the fuel oil being supplied to the burner may vary to the
extent and degree that the use of the fuel oil additives may be advisable to obtain
proper combustion and to aid in pumping the oil. The fuel oil storage tank(s) should
be checked periodically and cleaned of any sludge deposits.
Cleaning the Oil Nozzle
The design of the burner, together with the oil purge system on a heavy oil burner,
makes it unnecessary to clean the oil nozzle during the periods of operation. A routine
check should be made during off periods or when the burner is firing on gas and any
necessary cleaning performed.
Perform any necessary cleaning with suitable solvent. Use brush or pointed piece of
soft wood for cleaning rather than wire or a sharp metallic object which is apt to
scratch or deform the orifices as well as the precision ground surfaces of the swirler
and tip. Inspect for scratches or signs of wear and erosion, which may make the
nozzle, unfit for further use. Take necessary precautions in working with the solvents.
Ignition System
Maintain the proper gap and dimensions of the ignition electrode for best ignition
result. Inspect electrode tip for signs of pitting or combustion deposits and dress as
required with a final file. Inspect the porcelain insulator for cracks that might be
present. If there are, replace electrode since they can cause grounding of the ignition
voltage. Carbon is an electrical conductor, so it is necessary to keep the insulating
portion of electrode wiped clean if any is present. Ammonia will aid in removing
carbon or soot.
Check ignition cables for cracks in the insulation. Also check that all connections
between transformer and electrode are tight.
Periodically remove the access plug from the gas pilot aspirator and clean out any
accumulated lint or other foreign material.
Forced Draft Fan
Check occasionally to see that fan is securely tightened to the motor shaft. If the
boiler is installed in a dusty location, check the vanes for deposits of dust or dirt since
air capacity or lead to an unbalanced condition.
STEAM BOILER MAINTENANCE GUIDELINE

Monitor Your System
Once every shift or at least daily, a log should be kept of the system operating
conditions. Record the readings from the pressure gauges, temperatures and
operating capacity. While these readings are being taken, visually and audibly check
the system for leaks, smoke or unusual noise. Any changes in condition should be
20
Logic heat
investigated and discussed with the system supplier if they are not understandable.
Contact us for typical log sheets.
Ensure Sufficient Venting in the Boiler Room
To dissipate heat lost through the boiler casing and to provide combustion air, the
boiler room should be adequately vented. Generally, the controls are in the boiler
room and they will have a longer lifer the lower the ambient temperature.
Maintain Pump(s)
The pumps and burners are the components of the system requiring the most
maintenance. Pump alignment is critical for maximum service life and should be
checked and adjusted when the system is cold, at operating temperatures and on a
regular schedule. Pumps should be inspected frequently for leaks, unusual noise and
overheating. Frequent seal failure (more than once a year) is often a sign of
particulate build up in the system and this should be checked. Pressure gauges at the
pump section and discharge are valuable for troubleshooting. A reduced inlet
pressure could indicate a strainer blockage, as usually the pump suction is connected
to the system expansion tank to provide the necessary suction head to avoid the
cavitations. Unsteady readings may indicate cavitations that can quite quickly cause
internal damage to a pump.
Conduct Emission Test(s)
The burner combustion efficiency should be checked regularly by measuring the
combustion products CO2 content. Too little combustion air (producing high CO) can
overheat the burner, produce soot and cause damage. Too much combustion air
reduces the system efficiency by increasing fuel consumption. Simply monitoring the
heater flue gas temperature can quickly indicate a problem. The lower the
temperature the higher the heater efficiency. Increased flue gas temperature could
indicate the burner is out of adjustment or soot build-up in the heater.
Inspect Boiler
A daily external inspection can catch boiler problems before they become serious.
Look for signs of overheating (discoloration, deformation) and schedule an internal
inspection if they appear. In many cases a minor refractory failure can be repaired
before it becomes a major problem. Keep an eye on the boiler exhaust as smoke may
indicate a poorly adjusted burner or a tube leak. Again a small tube leak caught early
will be easier to repair than a leak that has been allowed to develop over time. Like
most industrial systems, boilers increasingly use electronic controls. Like computers,
they require a reliable, stable power supply as surges or outages can cause them to
lose memory or may even cause damage.
MAINTENANCE CHECK CHART

CHECK
Daily
Weekl
y
Monthl
y
Annually
21
Logic heat
Check Boiler Water Level, Maintain

recommended level on magnetic roller
display
Check Feedwater Level on Level Gauge,
Ash Removal
Check Furnace and Flame
Check Motor Condition, overheating,

noise and vibration
Check Flame Condition, color, Shape and
Size
Insulation Test of Motors
X
X
X
Replacement of Motor Bearings
After 3 years
of continuous
running
X
X
Thermal Scanning of Motor Drives

Cleaning of fuel oil strainer
Regeneration of water softener
As
required
Replacement of Burner Nozzle Tip

Cleaning of Heater Tanks, burner
impellers and burner throat
Cleaning of Flue Chamber
Blowdown
Refractory Door Inspection

Insulation Inspection
Flue Gas Analysis
X
X
X
X
X
Four Times a
year to ensure
savings and
efficient
combustion
TROUBLE SHOOTING
BURNER DOES NOT START
1. Main disconnects switch open.
2.
Blown fuses overloads, and loose electrical connection.
3. Check burner programmer (when using an oil burner only).
4. No power to programmer terminal.
5. Limit circuit not completed.
Pressure or temperature is above setting of operating control.
Water below required level.
Fuel pressure must be within setting of low pressure and high-pressure

switches.
6.
Motor defective
NO IGNITION
1. Lack of spark
Electrode grounded or porcelain cracked

22
Logic heat

Improper electrode setting
Loose terminal on ignition cable; cable shorted
Inoperative transformer
Check appropriate program relay contacts.

2. Spark but no flame
Lack of fuel no pressure, closed valve, empty tank, broken line, etc.
Inoperative pilot solenoid
Insufficient or no voltage to gas pilot solenoid

3. Wood Fuel too high in moisture content.
PILOT FLAME, BUT NO MAIN FLAME
1. Insufficient pilot flame.
2. Oil fired unit
Oil supply cut off by obstruction, closed valve, or loss of suction
Supply pump in-operative
Fuel temp low
No fuel
In-operative solenoid valve
Check oil nozzle, gun and lines

3. In-Operative Programmer
Flame Detector
Relay is not energized

BURNER STAYS IN LOW FIRE
Check appropriate relay contacts
Check pressure transmitter.
Check set pressure range.

SHUT DOWN OCCURS DURING FIRING
1.
Loss or stoppage of fuel supply
2. If the programmer, lockout switch has not tripped, check the limit circuit controls,
interlock, or blower motor
The flame failure light is energized by ignition failure, main flame failure,
Inadequate flame signal or open control in the non-recycling interlock
Circuit.
The opening of any control in the limit circuit will not energize the light.
3. If the lockout switch has tripped.
Check fuel lines and valves
Visually check appropriate timer and relay contacts.
Check Blower motors and interlocks.
Lockout switch malfunctioning.
Stuck Contacts.
4. Interlock device inoperative or defective.
Should there be problems, please contact the manufacturer:
23
Logic heat
SWITCHTEK CONSTRUCTION CORPORATION

Controls, Automation, Instrumentation and Calibration Services
th
4 Floor Northridge Plaza, Congressional Ave, Quezon City, 1100, Philippines
Tel: 02+9287769, 9282869, 4537694, 4267593 Fax: 02+4267593
E-mail: switchtekboilers@yahoo.com, switchtek@pldtdsl.net
LOGIC HEAT STEAM BOILERS, THERMAL FLUID HEATERS, DESODORIZERS,
PROCESS VESSELS, WATER SOFTENERS, PROCESS PIPING
MARINE AUTOMATION AND CONTROLS, OILY WATER SEPARATORS
TANK GAUGING, PROCESS AUTOMATION AND CALIBRATION
24
Logic heat

Logic Heat Steam Boiler Operations and Training Manual - SAN PABLO OIL 150HP

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Logic Heat Steam Boiler Operations and Training Manual - SAN PABLO OIL 150HP

Transféré par

Droits d'auteur :

Formats disponibles

Logic Heat Model LH100

OIL FIRED STEAM BOILER

and Training Manual

This page is intentionally left blank

Steam Boiler Design and Specifications

Steam Boiler Parts Description

Suggested Installation Checklist

Operation Procedure & Guidelines

How to Operate the Boiler

Storing the Boiler at Long Periods

Maintenance and Inspection

Oil Burner Maintenance

Steam Boiler Maintenance Guideline

Maintenance Check Chart

Since product improvement

THE SWITCHTEK TEAM

This Page is intentionally left blank

LOGIC HEAT STEAM BOILER SPECIFICATIONS

DYE PENETRANT, HYDROSTATIC

ASME/ PSME B31.1

STEAM BOILER PARTS DESCRIPTION:

LOGIC HEAT STEAM BOILER ACCESSORIES:

4,565 Kcal/kg = 5.31 Kw/Kg = 7.09 Hp/Kg

The calorific power of heavy oil is: BUNKER

SOLID FIRED BOILER FAMILIARIZATION

Obvious damages on parts.

SUGGESTED INSTALLATION INSPECTION CHECKLIST

If a refractory combustion chamber is part of the installation, is it

Is sufficient load connected to the boiler so that it can be fired continuously

Is draft control equipment required and, if so, installed?

Have adequate provisions for combustion air been installed?

Mechanical Contractors Representative

Electrical Contractors Representative

Service Organizations Representative

Boiler Manufacturers Representative

Are all specified auxiliary equipment mounted and wired?

Other Important Notes:

OPERATION PROCEDURE AND GUIDELINES

STORING THE BOILER AT LONG PERIODS:

MAINTENANCE AND INSPECTION

OIL BURNER MAINTENANCE (WHEN USING A BURNER)

STEAM BOILER MAINTENANCE GUIDELINE

MAINTENANCE CHECK CHART

Check Boiler Water Level, Maintain

Check Furnace and Flame

Check Motor Condition, overheating,

Replacement of Motor Bearings

Thermal Scanning of Motor Drives

Replacement of Burner Nozzle Tip

Refractory Door Inspection

Pressure or temperature is above setting of operating control.

Water below required level.

Fuel pressure must be within setting of low pressure and high-pressure

Electrode grounded or porcelain cracked

Loose terminal on ignition cable; cable shorted

Check appropriate program relay contacts.

Inoperative pilot solenoid

Insufficient or no voltage to gas pilot solenoid

Oil supply cut off by obstruction, closed valve, or loss of suction

Supply pump in-operative

Fuel temp low

In-operative solenoid valve

Check oil nozzle, gun and lines