PLAN RECORD REVISIONS [ap] cbc 180 were _scos noms | DESCRIPTION (DAB) eoven| ep 2-3 I: C N57-25M-M500 (1/2) cs -F MAC TYPE AUX. BOILER OPERATION AND MAINTENANCE INSTRUCTIONS (1/2) ee a es [a A ry ae | ae | | ls, fee)» 1 a RIN FINISHED PLAN hat [ee ER A4 x 440 gems) om ame exon] [| |ARINE BOILER DESINING SEC. TT MABARI S.NO.1384/144¢+ Tr TURBO & MARINE MACHIN, DESIN DEPT. ~ ee AUX. BOILER MAC-25B atts - —— OPERATION AND MAINTENANCE ears 5. Yamasaki eo aan INSTRUCTIONS a TaNIRe Wo ca 0 oan x1309/5/34%#H| 97000] | N57-25M-M500 (1/2) w& MITSUBISHI HEAVY INDUSTRIES, LTD. NAGASAKI SHIPYARD & MACHINERY WORKS DRAWN SEP. 24.2002 ISSUEDFOREWORD This instruction manual treats of affairs requiring attentions of workers in charge of this boiler with a view to giving them a guidance for proper operation to make the most of the boiler, to prevent injuries of damages that may be caused by improper hand] ing and to ensure high-efficiency service and perfect safety for a long time. However, this instruction manual refers to only fundamental rules necessary for operating handling the boiler. Consequently, those who are in charge of handling the boiler are expected to learn completely the subjects included in this manual and get well versed in all related appliances including pippins and fittings as well as the boiler itself so that they can handle the equipment perfectly. Warning Please strictly refrain from copying the contents of this manual or making an extract from them and revealing them to others.TABLE CONTENT SECTION A. INTRODUCTION . PRINCIPAL PART . DESIGN DATA . PERFORMANCE DATA . BOILER ACCESSORIES . CONSTRUCTION . OPERATING PROCEDURE . MAINTENANCE no |. OPERATING PROCEDURES. « INTRODUCTION . OPERATING OF AUXILIARY BOILER ALONE » FROM COMBINED OPERATING OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER TO OPERATING OF AUXILIARY BOILER ALONE 4, COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER. . FROM COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER TO OPERATING OF EXHAUST GAS ECONOMIZER 6. OPEATION OF EXHAUST GAS ECONOMIZER ALONE 7. BOILER HEATER OPEATION PROCEDURE . GENERAL MAINTENANCE . PEED WATER AND BOILER WATER TREATMENT . CARE OF BOILER OUT OF SERVICE . HYDROSTATIC TESTS . BOILING OUT - . WATER WASHING FIRESIDES ~ ACID CLEANING Sakene Ao 0) B-6 B-7 cl C-2 C-3D. MAINTENANCE AND REPAIR PrAerake we . MAINTENANCE OF REFRACTORY: . BOILER PRESSURE PART . HEADER END PLATE . FLANGED JOINT . SLIDING SADDLE . TUBE PLUGS ++ . REFERENCE DRAWINGS . STEAM CURVE . BOILER ACCESSORIES 1. AUTOMATIC BOILER CONTROL SYSTEM 2. OIL BURNER 3. SOOT BLOWER 4. 5. SAPETY VALVE 6. SMOKE INDICATOR 7. WATER TEST EQUIPMENT --+ WATER GAUGES 40 (2) D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 E-1 E-2 E-3 E-4 E-5 E-6 E-7AO (3) A. INTRODUCTION PRINCIPAL PART AL DESIGN DATA - A-2 PERFORMANCE CURVE A-3. BOILER ACCESSORIES A-4 CONSTRUCTION AS OPERATING PROCEDURE AG MAINTENANCE A-T CHECK LIST A-8AL 1. PRINCIPAL PART MITSUBISHI MAC-25B AUX. BOILER STEAM OUTLET A cas ouner sunyeg RAR CFHONT>ROOF_ HEADER Aik_IMEE eS { | SSDE_& FLOOR tuar GAS ouner SOE ALL TUBE ras crRoNTD Wait Use ACCESS DOOR. WATER wasting BLOW. PIPE WATER WASHING SLOW PPE REAR CFRONT? BOTTOM _ HEADER2. DESIGN DATA FOR 1 BOILER PRESSURE MPa(Ke/cm'g) Design Operation Hydrostatic test Safety valve setting TEMPERATURE °C Steam (at drum) Feed water Air to Burner EVAPORATION Kg/h Boiler Max 1.57MPa(16 k) MODE HEATING SURFACE nt FURNACE VOLUME _m? BOILER WATER WEIGHT kg Total cold water fill the unit completely Cold water to fill boiler to normal water level Water at operation BOILER WEIGHT kg Boiler dry (with burner & soot blower) Total operation Ae (i) 1.77 (18.0 1.57 (16.0) 2.65 (27.0 1.77 (18.0 203.4 (Saturates 60.0A? (2) THE DATE Location No. Tubes 0.D.(mm) Thickness(mm, Rear Bank Tubes 364 45.0 2.9 & 3.2 Front Water Wall Tubes ai 76.2 4.0 Rear Water Wall Tubes al 6.2 4.0 Front. Bank Tubes ra 76.2 4.5 Floor, Side, Roof, Wall Tubes at 76.2 4.5 Rear Bank Front Wall Tubes 14 76.2 4.0 Rear Bank Rear Wall Tubes 14 76.2 4.0 Gas Outlet Water Wall Tubes 14 76.2 45BOILER EXPECTED PEFORMANCE DATA ((1.57MPa(16K) x 25T/H)) LOAD 1/4 2/4 3/4 B.MAX EVAPORATION kg/h 6,250 12,500 18,750 25,000 MPa 1.57 1.57 1.57 1.57 a (ke/eme)| as) | (16) | cis) | (is) FEED WATER TEMP. c 60 60 60 60 SATURATED STEAM TEMP. Cc 203.4 203.4 203.4 203.4 BOILER EFFICIENCY (L.H.V. BASE) & 82.1 82.8 81.9 80.5 HIGH HEAT} = MJ/kg 43.0 43.0 43.0 43.0 UE 1, |, 280. Is 10, 0,28 CALORIFIC VALUE VALI (keal/kg) | (10,280) | (10,280) | (10,280) | (10,280) LOW HEAT MJ/kg 40.7 40.7 40.7 40.7 VALUE (keal/kg) | (9,713) (9,713) (9,713) (9,713) FUEL OIL CONSUMPTION ke/h 467 944 1,431 1,941 EXCESS AIR RATE % 31 16 15 15 0, RATE % 5.0 3.0 2.9 2.9 COMBUSTION AIR FLOW kg/h 8,730 15,340 23,040 31,260 FLUE GAS FLOW ke/h 9,210 16,280 24,480 33,200 AMBIENT AIR TEMP. °C 38 38 38. 38 OUTLET GAS TEMP. c 280 350 400 440F.0.C. MAC-25B BOILER EXPECTED PERFORMANCE CURVE a EFFICIENCY CURVE (L.H.V. BASE) EFFICIENCY (%) 0 1 2% 3% 4 50 60 7 8 9 100 ; F.0.C. CURVE ( * 1,000 kg/h) 16 - + + + 0.6 F-}—-}- 4 — 1} o o 22 3% 4 6 6 7 8 90 100 02 RATE CURVE (% BY VOLUME) o wo 2 3 4 50 6 7 8 9 100 BOILER LOAD % -3-A3 (3) AUX. BOILER MAC_TYPE. LEVEL - ALARM AND FUEL OIL CUT R.W.L, INDICATED RANGE REFLEX WATER BL REFLEX WATER a GAUGE VISIBLE RANGE Bea STACK TUBE, GAS OUTLET SIDE WALL _1U8 foAt 4. BOILER ACCESSORIES EQUIPMENT (1) COMBUSTION CONTROL, Electronic operated (2) FRED WATER REGULATOR Electronic/air operated (3) REMOTE WATER LEVEL INDICATOR Electronic operated (4) DRUM LEVEL SAFETY SYSTEM Electronic operated (5) OIL BURNER Steam atomizing venture type (6) SOOT BLOWER Rotary type (7) WATER LEVEL GAUGE (8) SAFETY VALVE (9) WATER TESTING EQUIPMENT (10) SMOKE INDICATOR MANUFACTURER NITSUBISHI HEAVY IND. MITSUBISHI HBAVY IND. ‘TURUGA ELECTRIC WORKS, LTD. YAMATAKE-HONEYWELL CO. LTD. VOLCANO CO., LTD. KIKAN BUHIN CO., LTD. SAWADA SEISAKUSHO CO., LTD. FUKUI SEISAKUSHO CO., LTD. DREW AMEROID SHONAN KOSAKUSHO CO., LTD. aa 5. CONSTRUCTION The boiler is named MITSUBISHI MARINE WATER TUBE BOILER. The description given below is an outline of its construction. For its further details, you are referred to the reference drawings for the ship equipment. 1. General construction The boiler is of two-drum construction with one steam drum and one water drum, and mainly consists of boiler proper, boiler casing, fuel firing equipment, mountings, fittings and other accessories. The boiler structure is supported with a water drum water wall lower headers as supporting bases. The whole boiler constructions is so designed as to be able to withstand the rolling, pitching and the shock of the ship. Careful consideration is also given to the movement by thermal expansion of the boiler. Combustion gas flows through the boiler in a return flow path where necessary, manholes, peep hole are provided for easy access and inspection. 2. Furnace closely spaced water wall tubes of 76.2 mm outside diameter are provided to the furnace side, rear, roof except burner opening and front wall in order to increase the heat absorption in the furnace and form it strong enough to withstand vibration, etc. (2AS (2) At the top and bottom of the front and rear walls are provided water wall headers respectively. The water that entered the bottom headers rises through the wall tubes to the top headers. As it rises, it is heated to saturation temperature and begins evaporating and from the top headers this water-steam mixture is led to the steam drum. One end of each top header is directly connected to the steam drum and one end of each bottom header is directly connected to the water drum. The roof, side and bottom water walls of the furnace are formed with welded water wall tubes connecting the water drum to the steam drum. No headers are provided for them. 3. Boiler casing The furnace of the boiler is made completely gas-tight by the adoption of welded water wall construction. The welded water wall construction is also adopted to the front and rear walls of the rear evaporating tube section where tubes are exposed to the combustion gas. On the outer surface of the furnace water walls, insulation are provided. Insulation’s are applied to the outer surface of the water walls and the outermost surface of the furnace is covered with galvanized steel casing except furnace roof and floor. 13AS 4, Steam Drum The steam drum and water drum are to be fabricated using boiler steel plate approved by applicable ship classification society. They are to be of all-welded construction, and welded joints are to be produced in accordance with the procedures approved by applicable ship classification society and then given the post-weld stress relieving. In the steam drum, a multi-perforated baffle plate covering the entire steam evaporation surface is provided to prevent the generation of water-saturated steam. Also, in the steam compartment the steam separator is provided to completely remove the moisture. The water compartment is provided with the feedwater internal pipe, surface blow-off internal pipe, chemical feed internal pipe, and sampling pipe. The baffle plate and steam separator in the steam compartment are of built-up type, permitting to be disassembled for bringing in and out of the drum by way of the manhole. Also, the steam drum, being used as a receiver for the exhaust-gas economizer while at sea, is equipped with the steam-water mixture inlet internal pipe. WY- a6 a 6. OPERATING PROCEDURE 1.Preparation Prior to beginning operation, check and prepare for the following. (1) Boiler proper Refractoriness, manhole covers, Header end plate covers and oi] residue in the burner wind box (2) Valve settings Water level gauge root valves, drum vent valves, safety valves, pressure gauge root valves, blow-off valves, and pressure detecting root valves for ACC. (3) Burners and accessories Heavy oil lines and atomizing steam lines and valves. Opening and closing of F.D. FAN inlet vane. Kind of fuel oil (Diesel oil or heavy oil C). (4) Ancillary equipment Proper functioning of automatic combustion control equipment, automatic feed water regulator, soot blowers and remote water level indicator. (5) Filling the boiler Fill the boiler up to the normal water level with distilled water or Demineralized water. Check feed water system. (6) Starting the forced draft fan Start the forced draft fan with inlet vane fully closed. st4-6 (2) (7) Starting the fuel oil burning pump Start the pump. In case of hot start, clean the oil line of cold heavy oil and warm-up the line with oil flow through the recirculation line. In case of cold start, discharge oil remaining in the line and fill it with diesel oil. 2. Lighting off and pressure raising Proceed in the following order. (1) Confirmation of response of water level gauges. (2) Purging the furnace Operate the fan with inlet vanes opened 100 % for more than 1.0 minute. (3) Lighting off the burner Use a nor tip for the burner, and light off it with a pilot burner. After lighting off, observe combustion condition. (4) Pressure raising Note drain discharge, air venting and water level fluctuation. (5) Inspection after completion of pressure rainsing Confirm response of water level gauges. Check indication of pressure gauges and functioning of safety valves. 3. Operation notes during normal service operation (1) Change load as slowly as possible when load is high. (2) Lower the steam pressure set point to prevent popping off of safety valves when the load fluctuation is severe Caution Operate the fan with inlet vanes opened 100 % for more than 1.0 minute. 46 (3) (3) Check various parts referring to the check list. (4) Check combustion condition and make a necessary adjustment to obtain good combustion. Reduce excess air as much as possible. (5) Analyze boiler water and feed water, and maintain proper condition of them. (6) Blow soot blowers to maintain heating surfaces clean. 4. Boiler shut-down Shut down the boiler in the following order. (1) Blow soot blowers. It should be made while the boiler is carrying not less than 50 % load. (2) Shut-down burner, one at a time. (3) Purge the furnace. (4) Stop the fan. (5) In case of boiler stand-by Burn a burner at times and maintain the boiler at about normal pressure vith boiler water at normal level. (6) In case of complete shut down; Close the feed water valve and the steam stop valve. Open the drum vent to release steam to lower the pressure. After that, laid-up the boiler dry or wet.(Refer to C-2.) 77(4) 5. Operation of ancillary equipment (1) Burner (3 4 Pay attention to excess air ratio, oil pressure and temperature atomizing steam pressure, and cleaness of burner tips to maintain good combustion. Never fail to purge the furnace before lighting off and after shutting down burner. Automatic combustion control equipment. Operators are requested to be well versed in change-over operation of the boiler control mode AUTO to and from MANUAL so as to be able to change control mode smoothly. Pay attention to indications of various controls and see whether they are all functioning properly or not. Blow off drain from supply air lines every 4 hours. Automatic feed water regulator Pay attention to water level fluctuation and see whether the feed water regulator is functioning properly or not. Soot blowers Soot blower shall be operated by the MANUALLY and must not be operated In IGS mode. 4BAT a) 7. MAINTENANCE 1. Feed water and boiler water treatment (refer to C-1) Feed water and boiler water shall be analyzed at least once a day. Amount of chemicals to be added and amount of boiler water to be blow down shall be controlled referring to the results of the analysis so as to maintain each chemical content of the water within the prescribed limit. Operators are requested to have correct understanding about the action and effect of each chemical and calculation method of required quantity of it. Recommended chemicals are as follows. For raising PH value AMEROID/GC For raising P0,* ADJUNCT ”B” 2. Maintenance during shutdown There are two ways of laying up the boiler, dry and wet. Either way may be adopted as the case may be. When the boiler is laid-up wet, care should be taken to the concentration of chemicals in the boiler water, and when the boiler is laid-up dry, care should be taken to the effectiveness of the drying agent. "7AT (2) 3. Hydrostatic test There are two kinds of hydrostatic test one for checking water tightness of pressure parts and the other for checking strength of the same. Test pressure should be determined to suit the case. 4. Boiling out Boiling out is intended to cleanse the boiler internal surface of oil and grease. The boiler is filled with high alkaline solution and is heated for a predetermined duration by means of steam or by burning oil whichever the occasion demands. Boiling out burning oil is often made to serve as burning and drying out refrectories used in the boiler setting, too. Recommended duration of boiling out for a new boiler is 2 to 3 days. 5. Hot water washing Hot water washing is intended to remove sludges sticking to the gas side of the boiler that can not be blown off by soot blowing. There are two ways for hot water washing, one by use of soot blowers and the other by use of a temporary hand nozzle, Both ways have their own merits, either way may be adopted as the case may be. Recommended hot water temperature is about 80 °C. zoAT 6. Acid cleaning Acid cleaning is intended to remove scales on the water side of the boiler. Inhibited hydrochloric acid solution is generally used for this purpose. But it is important to consult with the professional expert as to the details of cleaning job so as to take most suitable measures to the actual case and to prevent damage that may result otherwise. 7. Refractories Two kinds of refractories used are for this boiler, one is plastic refractory and the other is castable refractory. Both refractories are ‘ing work, too. As the plastic refractory needs to often used for repai be burned after placed, it is not used on the boiler pressure parts, where the castable refractory should be used instead. When the castable refractory is to be used on the pressure parts, it should be given necessary clearances for thermal expansion. After repairing refractory work. never fail to dry it out by firing. 8. Boiler proper and water walls Inspect both gas and water sides of the boiler whenever the opportunity is afforded and see whether it is necessary or not to clean the gas side, to acid-wash the water side or to replace tubes. Results of these inspections should be referred to in the subsequent burner operation, feed water control, etc. efAT (4) 9. Boiler drum support legs The water drum support legs on the boiler rear side are the only fixed legs, and all the other legs are of sliding type requiring the injection of grease once a year (Grease: SHELL ALVANIA EP NO.2, MOBIL PLEX 47 or equivalent). 10. Boiler repair The boiler repair work includes the tube plugging, header end plate enewal,, removal of manhole cover, tube renewal, expander renewal, packing renewal, etc. It is required that the boiler operator be familiar with the working procedures there in involved. 11, Maintenance of accessories (1) Burner The burner tip is to be cleaned periodical ly and examined for disorder. The swirler is to be maintained as clean as practicable, and also the burner throat area is to be always kept in good working order. (2) Soot blower ‘The soot blower steam line drain discharge, smoothness of rotary motion, and adequacy of lubrication are to be monitored. In the process of boiler open-up inspection, the element nozzle is to be examined for disorder and also the element for bend. 22AT (5) (3) Automatic Combustion Control System and Automatic Feedwater Regulator. By taking the control unit indicator reading, the control performance of each system is to be monitored. ‘The air supply line drain is to be blown out once every four hours. The moving parts of every equipment are to kept always clean. (4) Water level gauge The reflex gauge glass is to be blown clear at least once a day to ascertain its responsiveness. The remote-reading level gauge reading is to be compared with the reflex gauge glass geading (once a day) to ascertain its reliability. 238. CHECK LIST A-8 (a) For the safety of the boiler operation, at least the following items should be checked periodically. Item Reflex water level gauge Boiler water Remote water level indicator Burner flame-eye Water level alarm F.0. cut-off condition Steam leakage water leakage Checking method Open and close the drain valve and see the response of the water level in the gauge. Measure concentration of chemicals in boiler water and check water quality. Lower the drum water level down to -100 mm by operating the feed water regulator by hand and compare the indication of the remote water level indicator with that of the reflex water level gauge. When the burner only is in service, shut it down and see that the indicator lamp for loss of fire goes on. When the boiler is running under low load, change the drum water level. When the boiler is stopping, change the drum level (low-low), stop the F.D. FAN, and stop the F.0. PUMP. Check the boiler press, parts, flanges, and valves. Frequency Once a day Once a day Once per two weeks Once per six months Once per two weeks Once Per three months Once a dayB, OPERATING PROCEDURES INTRODUCTION OPERATION OF AUXILIARY BOILER ALONE. FROM COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST ~ GAS ECONOMIZER TO OPERATION OF AUXILIARY BOILER ALONE COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER FROM COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER TO OPERATION OF EXHAUST GAS ECONOMIZER ALONE OPERATION OF EXHAUST GAS ECONOMIZER ALONE BOILER HEATER OPERATION PROCEDURE B-1 B-2. B-4 zo"B+ qa) INTRODUCTION ‘The auxiliary boiler generates steam required for tanker service, and its steam drum can also be used as a steam receiver for the exhaust gas economizer. Therefore, the auxiliary boiler is, in some occasion, operated together with the exhaust gas economizer. When the main engine is out of service, the exhaust gas economizer can not naturally be used and the steam necessary for tanker service is supplied by the auxiliary boiler only. After starting the main engine, the exhaust gas economizer shal] be used. While the load of the main engine is low, the exhaust gas economizer and the auxiliary boiler shall be used together. As the engine load increases, the exhaust gas economizer evaporated more steam and the auxiliary boiler is placed out of service. The exhaust gas economizer thus remains in service alone. In this case, the steam drum of the auxiliary boiler is used as a steam receiver for the exhaust gas economizer. Such an independent operation of the exhaust gas economizer is generally the case while at sea. However, in case more steam than generated by the exhaust gas economizer is required, the auxiliary boiler must be placed in service to supplement the exhaust gas economizer. 26B (2) When in port, if the engine load is very low or the engine is at rest, the exhaust gas economizer is put out of service and the auxiliary boiler is used alone. ‘Therefore, there are three kinds of boiler operation modes as shown below. 1) Auxiliary boiler alone to be operated : TANKER SERVICE MODE 2) Auxiliary boiler and exhaust gas economizer : ECO. BACK-UP MODE to be operated together 3) Exhaust gas economizer alone to be operated : BEPOSE MODE 27B-2 (1) OPERATION OF AUXILIARY BOILER 1. General notes on boiler operation (1) Introduction The following notes on boiler operation are of general nature to be observed by the boiler operators. Although some basic rules must be strictly followed in operation and maintenance of the boiler and ancillary equipment, it is up to the operators familiarize themselves with characteristics of individual equipment. This can only be accomplished by diligently observing, recording, checking and comparing data and details. Such attentions and proper measures prompt ly taken by the operators often prevent boiler outages and repairs. (2) Performance a) The boiler is designed to deliver steam at required pressure and ‘temperature vhen supplied with feed water at the specified temperature. Operating conditions exceeding the design limitations will shorten the life of the boiler and component parts. b) The concentration of solids entrained in the steam leaving the steam drum depends to a great extend upon the quality of the feed water. Suitable feed water treatment and adequate blowdown should be used to maintain the boiler water alkalinity and concentration of total solids below a predetermined point. 4sBee (2) c) If each heating surface of the unit is kept clean, the temperature of the gas leaving the boiler and the draft loss through the boiler will normally be constant for a given load and excess air ratio. This illustrates the desirability of keeping records of boiler performance from the start of operation. If a standard is set up when the boiler is new, the deviation from it will serve as an indicator that shows the operating condition of the boiler as well as its own condition. Then, steps may be taken to determine and correct the cause for the discrepancy and often avoid the development of difficulties. It is desirable to keep records of operating data in a form that facilitates comparison of similar operating conditions. d) The amount of fuel oil consumed should be measured. Fuel oil should also be periodically sampled and analyzed to check calorific value, chemical composition, etc. d) The temperature and analysis of gases leaving the boiler are invaluable as an index of complete and economical combustion. The best percentage of excess air to use depends upon the nature of the fuel, the design of the fuel burning equipment and other factors. The most desirable conditions for different rates of evaporation should be established through the diligent study of the performance of the boiler. 2Be (3) (3) Operation a) When hot water is used to fill the boiler, care should be exercised to feed slowly to avoid severe temperature strains on drums, headers, ete. Always see that each part of the unit is properly vented, and fill it till water level appears in the level gauge. The vent valve of the steam drum should be kept open during the filling operation and should not be closed till all the air is ventted from the unit. The unit will have been completely vented by the time when the drum pressure reaches approximately 0.20 MPa(2 kg/cn’g). b) The time required to bring the boiler up to pressure and temperature depends upon the pressure and temperature at which it is to operate. During initial start-up of a new boiler, the longer time then the standard must be used for heating up and pressure raising so as to allow careful inspection of expansion movements and clearances of various parts. Increase of firing rate should not exceed a saturation temperature rise of 67°C (120°F) per hour for a natural circulation boiler. Ordinary start-up can be done at faster rate than the above. But, the operating procedure for starting up the boiler safety should be established through measurements of metal temperatures of important parts of the boiler, and the boiler should be started accordingly.Be (4) (4) Water level a) When the boiler is to be filled for operation, slowly feed water till the water appears 25 to 50 mm high in the level gauge. This is a precaution against. the swel] that occurs when the boiler water is heated and begins evaporating and also against the sudden fall of the boiler pressure when feeding comparatively cold water. b) Before lighting a fire, the operator should check the water level in the boiler by blowing down the water level gauge. Usually, slowly cracking the drain valve on the level gauge will suffice. A liberal plowdown will serve to clear the drain valve seat of any foreign matter that may be present. When the new boiler is in operation, routine check of the water level gauge should be made at least once a day. If the action of the water in the gauge is sluggish when the drain valve is opened or closed, investigation should be made of the cause and the condition should be corrected immediately. c) Even though the boiler is equipped with the reliable automatic feed water regulator and the remote water level indicator, the water level in the level gauge should be observed periodically during normal operation. Never shut off the feed water supply completely to the steaming boiler even for only a short period. 3fB2 (5) d) Unless otherwise instructed, the water level should be carried near the center of the gauge glass. Any adjustment of the water level should be gradual. If the water level is too high, priming may occur, especially when the steam demand is large or rapidly fluctuating. If priming occurs, blow down the boiler water and changing over the feed contro] to manual operation, reduce the water level. But, the water level should be maintained as such that is just sufficient to take care of a drop in level that may occur in the subsequent change in steam demand. Reduce the steaming rate if necessary. Investigate the condition of the boiler water with regard to concentration of alkalinity and total solids, and examine the condition of the drum internals when the opportunity is afforded. e) While the boiler is being brought up to pressure, gradually heat and properly drain all cold steam pipings. f) During the pressure raising operation, the drum water level often rises higher than the normal level due to the expansion of water. If it is desired to keep the water level visible in the level gauge at this time, boiler water should be blow down. g) Observe the drum water level at times to confirm the proper functioning of the automatic feed water regulator.B2 (6) (5) Others a) When re-igniting the burner to bring the boiler back into service from the standby state, the furnace still remains hot, filled with unburnt fuel particles and unburnt gas, and thus requires internal purging by means of forced draft fan (this is an exceptional instance in which the furnace, still hot, may be air-purged). b) Incase of relighting the burner, an igniter must be used. Never attempt to light the burner with hot refractories in the furnace. c) Check chemical contents of the boiler water at least once a day. Add chemicals or blow down the boiler water as required to maintain proper concentration of chemicals in the boiler water. c) Frequently check the smoke indicator to maintaining efficient combustion. e) Keep burner tips clean as they are adopt to be fouled with dirts and soots. Note : Be absolutely sure to use the steam drum surface blowoff valve when blowing boiler water during boiler operation and to blow boiler water using the water drum bottom blowoff valve only during boiler outage. 33B-2 mM 2. Preparations Prior to starting the boiler, attention should be paid to the following items and thorough checking should be made on them. Boiler (1) ALL foreign materials have been remove from pressure parts. (2) All gas side heating surface are clean and all refractories are in good condition. (3) The furnace bottom and the burner wind box have been cleaned of oil and others. (4) All personnel are clear. (5) All manhole covers are securely tightened. (6) Inspect safety valves and see that gags have been removed and easing levers are in good condition. (7) Open root valves for all instruments and controls connected to the boiler. (8) Open the vent valve of the steam drum. (9) Open all pressure gauge valves and check and see all valves on the pressure gauge pipings are open. (10) Check and close all blow-off valves and drain valves. (11) Fill the boiler till water level appears 25 to 50 mm high in the gauge glass. aeBee (8) ‘The boiler shall be filled in the following procedure and the feed water line shall be inspected simultaneously. (a) When the boiler was laid up wet (Refer to "Protection of the boiler during shutdown”.), drain the boiler till the water level falls down to the bottom of the gauge glass, and bring the water level up again to about 25 mm high in the gauge glass feeding through the auxiliary feed water line. ‘Then, bring the water level up further by about 25 mm feeding through the main feed water line. (b) When the boiler was laid up dry, first fill the boiler feeding through the auxiliary feed water line till the water level just appears at the bottom of the gauge glass. Then, raise the water level feeding through the main feed water line up to about 25 to 50 mm higher then the normal water level. This practice serves to check that both the auxiliary and the main feed water lines are ready for service. Use distilled water for feed water whenever possible. Boiler compound shall be added as instructed by the expert of boiler water treatment. Fuel burning equipment (1) Make sure that all fuel oil lines including oil filters, etc. are in good condition. (2) Make sure that no oil residue is in the burner wind box. (3) Make sure that F.D.FAN inlet vane is clean and moves smoothly.Be (9) 3. Lighting off and pressure _r: ig (1) Make sure of the drum water level by the water level gauge. That is, the water level should fall when the drain valve of the water level gauge is opened, and it should return to the previous level when the valve is closed. Attention must be paid not to take the empty level gauge for full of water or stains on the gauge glass for water level. (2 Start the forced draft fan Prior to lighting off, place the forced draft fan with inlet damper fully opened and purge the furnace for at least one minute. (3) Start the fuel oil burning-pump and begin the use of the fuel oil heater, using heavy fuel oil with normal tip which condition is operated by H.F.0. mode, MADIC auto mode. Start the fuel oil firing pump and open the oil recirculation valve to recirculate oil through the oil heater and burner manifold discharging cold heavy oil in the line. (4) Whenthe oil in the burner mainfold has reached a proper temperature, burner ignition sequence start. (5) Reduce air pressure at WIND BOX to 0.2(20) to 0.4 KPa(40 mmAq). And securely close the oil recirculation valve. Check the fuel oil control valve opening by the output signal of MADIC to ensure it is ready for service. 36B-2 (10) (6) Light off the burner and immediately make a necessary adjustment of oil (7. pressure and air pressure to ensure a stabilized combustion of the fuel. At this time, care should be taken to obtain such a burning condition that the fuel oil burns completely without scattering unburned practicles or producing heavy smoke. Frequently check the indication of the smoke indicator and the flame through the observation holes, especially after making any change in firing rate or burner inlet air pressure. when raising the pressure, keep the burner firing five minutes and out of service 15 minutes repeatedly at the lowest oil pressure 0.29 MPa (3.0 kg/cm’g)for one hour and then again repeatedly light off and shut down the burner to raise the steam pressure at the rate indicated in Fig. 2-1 or less. (8) When the drum pressure has risen to about 0.20 MPa(2 ke/cm’g), close the drum vent valve. (9) Close the valve of the pressure gauge and remove the gauge. Then, open the valve a crack and release steam to make sure the tubing for the gauge is clear. Reinstall the pressure gauge and see that it works as soon as the valve is opened. In this case, care should be taken to allow several minutes to cool the line before opening the valve. 37(ily (10) Check the water level gauge to see nothing is the matter with it by opening and closing its drain valve, and make sure of the drum water level again. (11) Drain and varm all stean supply lines to the ancillary equipment and devices. It is very important to discharge drain water from these lines and warm them up to near the operating temperature before loading the boiler. (12) When the drum pressure is raised to about0.30(3) to 0.39 MPa(4 kg/cn'g) below the normal operating pressure, check the safety valves with the easing gear. Care must be taken to open and close the valve quickly so as to prevent damaging the disc and the seat of the valve. Drun Press MPa(kg/cn’g) 1.77(18) 1.57(16) 1.37(14) 1.18(12) 0.98(10) 0.78(8) 0.59(6) 0.39(4) 0.20(2) 0.00(0) 0.5 1 1.5 2 2.5 Time (hr) FIG.2-1 RECOMMENDED PRESSURE RISE 35B-2 (12) 4, Cold Start-up (1) When the boiler is to be started from the cold state in which no steam is available from the land or the exhaust gas economizer, use the starting diesel oil for fuel till the steam necessary for the oil heater becomes available. (2) Fill the boiler with the best water available. For this,purpose, feed water tank as much as necessary to start the boiler before shutting down the boiler. It is advisable to fill the boiler up to 50 to 80 mm above the normal water level so that no additional feed water is required till the feed water pump is placed in service. (3) Start the diesel generator and light off the burner using diesel oil with the nor tip which condition is operated by AIR ATOMIZING F.0. TEMP. BY-PASS MODE AND burner manual mode. Before lighting off, never fail to purge the furnace adequately. (4) Take necessary measures as described in ”PREPARATION”. (5) Close valves of the heavy oil lines from the fuel oil tank to the burner manifold and open valves of the diesel oil line from the diesel oil tank. (6) Start the FUEL oil pump and open the oil recirculation valve to discharge heavy oil remaining in the line, burner manifold and oi! inlet pipes to burners thoroughly. evBz (13) (7) Set the atomizing air pressure at 0.49 MPa(5 K) and fuel oil pressure at. 0.29 MPa(3 K). (8) Run the forced draft fan at low revolutions and ignite the burner using the pilot burner. (9) When the steam pressure has risen to about 0.20 MPa(2 kg/cm’g), start warming the steam pipe lines and the feed water pump pipe lines, ant turn on steam to the settling tank. (10) When the heavy oil in the sett] ing tank has been heated enough to be pumped by the F.0. pump, turn on steam supply to the oil heater in preparation for changeover from diesel oil firing to heavy oil firing. (11) Circulate oi] through the oil heater and the oil recirculation line till the oil of the proper temperature is available in the burner manifold. Then, switch diesel oil firing to heavy oil C firing and continue pressure raising. (12) Start the feed water pump as early as possible so that it can feed water to the boiler immediately when the drum water level should fall.B-2 (14) 5. Shutting down (1) Blow all soot blovers before shutting down the boiler whenever possible. (2) Shut down one burner at a time. (2) Continue operation of the forced draft fan for a while after shutting down, keeping air pressure of about 1.47 KPa(150 mmAq) at burner inlet and then stop the forced draft fan and close the inlet damper (4) Maintain the drum water level visible about 50 mm in the gauge glass. (5) When it is necessary to stop the boiler temporarily and keep it in the standby state, ignite the burner from time to time for sporadic firing to maintain the steam pressure at 0.49(5)to 0.69 MPa(7 kg/cm’g) which is lower than the normal working pressure. (6) In order to maintain drum water level visible about 50 mm in the gauge glass even when the boiler in cold, raise the water level 70 to 120 mm above the normal water level before closing the feed water valve. (7) When the boiler is to be shut down completely, close the steam stop valve immediately after the boiler stops steaming. (8) when the boiler pressure has fallen to the atmospheric pressure, open the drum vent valve. ufB2 (15) (9) If it is 4 hours after shut down, the boiler may be cooled with the forced draft fan operation as the case may require. But, if possible, such a forced air cooling should be avoided not damage refractories in the furnace. Do not attempt to cool the boiler by blowing down the hot boiler water or by refilling the boiler with cold water after blowing down. sB2 (16) 6. Emergency operation Water level low Tf the water level falls down to 200 um or more below the normal water level due to failure of the feed water supply or neglect of the operator, the alarm lamp on the boiler control panel goes on and simultaneously the alarm buzzer sounds. If the level falls further down to 240 mm or more below the normal water level, the fuel oil emergency trip valve fully closes cutting of the fuel supply to the boiler automatically. Then, fully close the feed water valve and the steam stop valve and shut down a burner completely and stop the forced draft fan. In this case, never attempt to feed water to the boiler till the boiler has cooled sufficiently, since, otherwise, there may be a danger of quenching the hot pressure parts with comparatively cold feed water. Flame out. In the event of a flame out, immediately close the oil inlet valves and reduce air pressure at burner inlet so as to present overcooling the furnace. Prior to relighting burner, purge the furnace adequately following the procedure mentioned in "Lighting off and pressure raising”. A pilot burner must be used for relighting a burner. Never attempt to light a burner by the heat from the hot refractories in the furnace. 43B-2 a7) Failure of evaporating tube A. In case of a tube failure which results in a loss of water so great that the water level can not be maintained, use the method outlined below. (1) Shut off oil supply to burner to extinguish the fire. When the tube failure is resulted from low water, shut off feed water to the boiler closing the feed water valve and the steam stop valve. This is to avoid the damage that may be caused by quenching hot pressure parts other than the failed tube with comparatively cold feed water. Refer to Water level low”. (2) When the failur of the evaporating tube is resulted from the cause other than low water, maintain the water level, if possible, at the normal level till the boiler has cooled enough and then close the steam stop valve and open the drum vent valve. (3) In either case of the above, keep the forced draft fan in operation to maintain sufficient air flow to carry the escaping steam out through the stack, adjusting the F.D.FAN INLET VALVE to such an opening so as to avoid damaging refractories by quick cooling. (4) Do not blow down the boiler to lower the pressure rapidly unless the failure is so severe as to endanger the personnel near the boiler. (5) Dump the boiler water overboard through the bottom blow valve after cooled enough. qeBe2 (18) (6) When the furnace has cooled enough to permit a man to enter it, make a thorough inspection of all pressure parts for any indication of damage. After necessary repairs have made, apply a hydrostatic test to see whether the unit may be put back in service or not. B. In case of a leak which does not involve a serious difficulty, the water level should be maintained and the boiler taken out of service in the normal manner. (1) Blow soot bloers if circumstances permit. (2) Switch the combustion control equipment to manual control and reduce combustion rate following the normal procedure. (3) continue air flow throught the unit at reduced rate till all combustible gases, vapors, etc. have been removed. (4) Feed water to the boiler manual ly,maintaining a high level in the water gauge. When the boiler stops steaming, open the drum outlet drain valve to drain enough to reduce the saturation. Temperature by approximately 65°C per hour. When the drum pressure has fallen to 0.20 MPa(2 ke/cm’g), open the drum vent valve and when the boiler water has cooled to about 65,drain the boiler. aB2 (19) Fire inside the casing Shut off oil supply to the burners immediately and close the forced draft fan inlet vane. Failure of forced draft fan In case of a failure of the forced draft fan, oil supply to the burners is stopped automatically with the fuel oil emergency trip valve. Close oil inlet valves to the burner.7, Emergency case and measures to be taken Case Drum water level Flame out Tube failure Measures to be taken (1) Close F.0. emergency trip valve. Shut down burner. (2) Stop feeding water. (1) Close F.0. emergency trip valve. Shut down burner. (2) Purge furnace and relight off. (1) Close F. trip valve. Shut down burner. emergency (2) In case of low water. Stop feeding water. In case of not low water Maintain normal water level. B-2 (20) Causes = Too low feed water pressure + Inproper functioning of feed water control valve + Inproper functioning of feed water regulator + Faulty water level indication + Boiler tube failure + Too low oil pressure + Too high excess air + Faulty flame eye + Fouled burner tip + Improper atomizing steam pressure + Drain in atomizing steam + Too low water level + Tube corrosion (Improper water treatment) + Tube overheat (Scale deposit, poor boiler water circulation) + Too high combustion rateCase Fire inside the casing Failure of forced draft fan Sea water leakage into feed water line Measures to be taken (3) Keep forced draft fan in operation and reduce pressure gradually. Be (21) Causes (4) Start blowing down at 0.98 MPa (10 kg/cn’g) or less (5) Plug off or replace tube. (1) Close F.0. emergency trip vanes. Shut down burner. (2) Stop forced draft fan and fully close inlet banes. (3) Open somthering steam valve (1) Close F.0. emergency trip valve. Shut down burner. (2) Restart forced draft fan. (3) Purge furnace and relight off. (1) Reduce boiler load. (2) Raise PH value and 0,2 to upper limit of allovable range. (3) analyze feed water and boiler water every two hours. (4) Blown down boiler so as to maintain chlorine content within limitation. (5) Inspect inside of boiler, etc. at earliest opportunity. Apply acid cleaning if necessary. + Oil leak from burner + Unburned oil in furnace Incomplete combustion on burner + Failure in electric circuit + Failure of electric motor + Leakage in condenser + Faulty water-making equipment. 4Bs @ FROM COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER TO OPERATION OF AUXILIARY BOILER ALONE When entering port, the auxiliary boiler is in service together with the exhaust gas economizer. Changeover from such a state to the operation of auxiliary boiler alone can easily be done by stopping the operation of the exhaust gas economizer. For procedure and notes for taking the exhaust gas economizer out of service, the instruction book for the exhaust gas economizer should be referred to. “py1. Bo (a) COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER Introduction During the low load operation of the main engine, the steam from the exhaust gas economizer only is not enough to afford the steam requirement in the ship. Therefore, the auxiliary boiler must be operated together with the exhaust. gas economizer till the engine load goes up sufficiently high. After the main engine has reached the normal load operation, the exhaust gas economizer alone can generally afford steam sufficient to the ship service. It is, necessary, hovever, to place the auxiliary boiler in service when the steam consumption increases due to additional operation of machines. For example, when entering port, the auxiliary boiler is used to supplement the low evaporation in the exhaust gas economizer. ‘As stated above, the combined operation of the auxiliary boiler and the exhaust gas economizer can be entered from the independent operation of either the auxiliary boiler or the exhaust gas economizer. oDB-4 (2) 2. Fromoperation of auxiliary boiler alone to combined operation with exhaust gas economizer. When the exhaust gas economizer has to be placed in service with the auxiliary boiler in operation, it should be started according to the instructions given separately. This paragraph gives only an operation note particularly important at that time. When the empty exhaust gas economizer is connected to the auxiliary boiler, there occurs a flow of boiler water from the boiler to the exhaust gas economizer due to the pressure difference between them and results in the sudden fall of water level in the boiler. Therefore, the circulating pump discharge valve should be opened in the last stage of valve settings about the exhaust gas economizer to prevent the above. It should be opened gradually observing the drum water level. seBd (3) 3. From operation of exhaust gas economizer alone to combined operation with auxiliary boiler When the exhaust. gas economizer is in service, the steam drum of the auxiliary boiler is used as a steam receiver. So, the pressure in the auxiliary boiler is fairly low even when the boiler itself is at rest. ‘The auxiliary boiler in such a condition should also be started according to the instruction given in B-2 "Operation o auxiliary boiler alone” with care similar to that given in ”Cold start up”. In this case, there is no need to use diesel oil for starting the the boiler, as heavy oil can be heated by the steam from the exhaust gas economizer. When starting the auxiliary boiler, attention should be paid to the followings. (1) Drum water level rises due to swelling of boiler water during lighting off and pressure raising. (2) Refer to B-2 "General notes on boiler operation”.BS « FROM COMBINED OPERATION OF AUXILIARY BOILER AND EXHAUST GAS ECONOMIZER TO OPERATION OF EXHAUST GAS ECONOMIZER ALONE As previously mentioned the steam drum of the auxiliary boiler is used as a steam receiver for the exhaust gas economizer. When the load of the main engine has been raised to the normal load under such condition, the exhaust gas economizer can now afford steam sufficient to the ship service. Consequently, the auxiliary boiler that was in operation together with the exhaust gas economizer can be taken out of service. Thus, the combined operation of these two can easily be shifted to the operation of the exhaust gas economizer alone by taking the auxiliary boiler out of service. When shutting down the auxiliary boiler, proceed as follows; 1, Operate soot blowers, whenever possible, before shutting down the boiler. 2. Shut down burner at a time and immediately remove oil gun out of place. 3. Close the steam stop valve. 4, Keep the forced draft fan running for a while after shutting down burner and purge the furnace of combustible gases with burner inlet air pressure of about 0.25 KPa(25 mmAq). Then, stop the forced draft fan. For shutting down the auxiliary boiler, refer to B-2 "Shutting down”. $3B6 0) OPERATION OF EXHAUST GAS ECONOMIZER ALONE For start up, normal operation, and shutdown of the exhaust gas economizer, refer to the instructions given separately. syBT a) BOILER HEATER OPERATION PROCEDURE The heating coil is installed inside of water drum. When the boiler is not connected with economizer (not used as steam separator for economizer) during normal seagoing boiler to be heated up by heating coil. (Drum pressure to be kept over then 0.05 MPa(0.5 kg/cm’g) by handing valves 41B, 42B and 43B) . Valve name Boiler heater inlet valve ALB | Close Boiler heater outlet valve 428 Close Boiler heater leak test valve 438 OpenC, GENERAL MAINTENANCE FEED WATER AND BOILER WATER TREATMENT CARE OF BOILER OUT OF SERVICE HYDROSTATIC TESTS BOILING OUT WATER WASHING FIRESIDES ACID CLEANINGCt a) TREATMENT OF FEEDWATER AND BOILER WATER Mitsubishi Heavy Industries‘ Nagasaki Shipyard & Machinery Works has a wealth of experience and excel lent industrial research laboratory facilities to bank on as regards the treatment of feedwater and boiler water. It therefore is recommended that any questions or difficulties experienced as regards the treatment of feedwater and boiler water be referred to the Company for advice. Control of Feedwater and Boiler-vater_Impui Ss With boilers in service, it is recommended that at least once everyday feedwater and boiler water be sampled for analysis and appropriate measures taken for qualitative control. When sampling boiler water, care is to be exercised so as to take the sample that truly represents boiler water, by for example cleaning the sampling vessel twice to three times with boiler water beforehand. Feedwater and boiler water sampled are to be thoroughly and carefully analyzed using an appropriate analysis equipment, it accordance with instruction give on the use of the equipment. Every effort is to be made to control oxygen, pH, salt, dissolved solids phosphoric acid, etc. in feedwater and boiler water to with’ limits. Requirements specified for the ship’s boiler as regards the control of feedwater and boiler-water impurities follow. $9Feedwater (1) Oxygen (2) pH Boiler Water (1) pH (2) Salt CL (2) The oxygen content of feedwater is to be controlled to below 0.5 ppm. ‘The recommended pH value is 7.0 to 9.0. For the pi control purpose, however, it is recommended that the target be set at 8.5 to 9.0. : pH of boiler water requires to be controlled to 10.8 to 11.3. : The salt content of boiler water (as C1) requires to be controlled to 300 ppm as far below as possible, preferably below 150 ppm. (3) Dissolved solids : Dissolved solids in boiler water require to be controlled to 2000 ppm and as far below as possible. (4) Phosphoric acid : Phosphoric acid of boiler water (as P04”) requires to be controlled to 20 to 40 ppm. SFcH (3) FEED WATER AND BOILER WATER TREATMENT Limits of Chemical Concentration Item Water Boiler Water | Feed Water to Boiler pit (at 25°C) 10.8 - 11.3 7.0 - 9.0 Phenolphthalein _ Alkalinity (CaCO) ppm Lae Total Alkalinity (CaC0,) ppm Max.600 - Chloride (C1) ppm Max. 300 - Total Solid ‘Ppa Max. 2000 7 Excess - Phosphate (P0,") __ ppm ae Hardness (CaCO) ppm . Max.1.5 Oxygen mg/I - Max.0.5 Hydrazine ns/1 - Note : - (1) Feed water in this table means the mixture of condensate and distilled water to supply into the boiler. (2) When only the exhaust-gas economizer is in operation, perform the boiler-water treatment based on the results of circulating-water analysis. SfcL (4) (3) Estimate the pH value from alkalinity tends to give pH readings varying with silica, Ca, Mg, and other salt contents of boiler water and hence is not necessarily deeméd appropriate : resort to this method only as a means to obtain a rough guide (alkalinity serves merely as an auxiliary means in determining the pH level). Also, be sure to control pH to the target value while, on the other hand, keeping alkalinity at the minimum necessary level. Limiting the P alkalinity to within a certain range would make it possible to inhibit the alkali corrosion even if boiler water concentration should take place on the heating surface, etc. LocH (5) BOILER ANTISCALES AND THEIR INJECTION QUANTITIES (EX. ) 1. Boiler Antiscale The following chemicals of Ameroid Co. manufacture are to be used. pH enchanting agent (GC) or KALGEN 459 PO, enchanting agent (ADJUNCT B) or ALCON 401 (1) 6C Containing sodium hydroxide as its principal ingredient, this chemical is used for controlling pH of boiler water. (2) ADJUNCT B This chemical, the alkaline antiscale with tri-sodium phosphate as its principal ingredient, is used for controlling P04 content of boiler water. It serves to prevent the accumulation of scale deposits as well as to inhibit the boiler steel corrosion. 2. Injection Quantity (1) Initial injection Antiscale Initial injection qt’t (g/ton) pH & PO, values Resulting pH & ADJUNCT B Approx. 80 PO, values : = = — PO, : 20 ppm 6c Approx. 15 PH : 10.8 ppm Notes : 1) The injection quantities indicated are calculated with ° feedvater hardness at zero. 2) In the initial phase of operation, reaction with iron content of boiler steel produces iron phosphate film on the steel surfaces causing phosphoric acid to remain below the specified limit. In such an instance, inject additional doses of ADJUNCT B. of(2) Makeup injection According to the results of boiler-water analysis, makeup does of ct antiscales are to be injected with the values indicated in the following table as reference targets. Antiscale | Qt’y required to raise | Qty required to raise P alkalinity Phosphoric acid radical (as CaCO ppm) by (as PO,* ppm) by 10ppm, g/ton 10ppm,_g/ton ADJUNCT B - Approx. 40 ec Approx.8 - Notes : 1) The injection quantities indicated are calculated assuming distilled water to be used as boiler feedwater. 2) The values given are mere theoretical targets and hence require to be controlled as appropriate for actual boiler load and feedwater quality so that the desired boiler- water quality can be ensured in each particular application. 3. Deoxidizing Agent For removal and deactivation of residual oxygen in the feedwater system, hydrazine (N,H,) is to be injected into the cascade tank outlet (or feed pump suction inlet) by means of drip-injection device. Injection Quantity In case of 10% concentration of hydrazine solution. Initial injection : Approx. 70 g/ton (at 30deg.C and atm. press.) Makeup injection : MaApprox.50 g/ton (at 60deg.C and atm. press.) 62.ct () Boiler Blowdown Blowing down boiler water by operating the blowdown valve and replenishing the amount of water blown down with fresh water is of vital importance of reducing the concentration of boiler water to satisfactory level for operation. Also, the boiler blowdown is just as important to discharging sludge, oily substance, and other impurities accumulated in the boiler. The amount of boiler water to blowdown and how often to blowdown are to be decided based of factual data, such as the results of boiler-water analysis, turgidity of sampled boiler water, etc., so that the aforementioned requirements on boiler-water chemistry can be satisfied. Makeup-water_and Boiler-water Treatment The boiler disorders caused by inadequate control of boiler water and feedwater may be broadly defined as follows. (1) Overheating of heat-transfer surfaces due to accumulation of scale and oil/grease deposits (2) Corrosion (and caustic embattlement) (3) Turbine and other associated equipment disorders due to carryover. Some restrictions, therefore, require to be imposed as follows in order to prevent the above disorders. * To cope with (1) above, the hardness and oil/grease content of feedwater require to be controlled to within allowable limits, as does silicic acid contained in boiler water. b3Ct (8) * To deal with (2) above, feedwater pH and boiler-water pH require to be controlled to allowable levels. * Salts defy the generalization, some serving to inhibit the corrosion and some promoting the corrosion. Chlorine (chloride), however, generally promotes the corrosion when present ina large amount and hence requires to be controlled to as low a level as is practicable. * To prevent the problem (3), dissolved solids and oil/grease contained in boiler water require to be controlled to within allowable limits. (1) Hardness The formation of scale deposits on the boiler drum and evaporating tube internal surfaces and the accumulation of sludge within the boiler are attributable, principally, to hardness-constituting elements carried into the boiler by feedwater. Leaving the feedwater supply as it is while obviously high in hardness and treating it in the boiler has potential of having the impurities adhere to heat-absorbing surfaces and also can cause the rise in antiscale consumption and quantity of dissolved solids. The best practice dictates, therefore, that the hardness of feedwater be restricted to within an allowable limit and what is left of the hardness removed through boiler-water treatment in the boiler. bYct (9) Specifically, the hardness of feedwater for a 1.57 MPa(16 kg/cm’g) boiler is to becontrolled to 1 ppm. With makeup water produced by distilling seawater ina desalination plant, assuming impurities carried over through evaporation to be same as those in raw seawater (of total salts, (55%, Ca=1.2%, and Mg=3.7%), the hardness brought in per 1 ppm of chlorine (C) is 0.34 ppm. Then, even with the allowable limit of chlorine at 5 ppm, the hardness upon evaporation is 1.7 ppm, which suggests that judging from the rate of makeup feed, restricting the feedwater hardness to within the above mentioned limit is not difficult. In cases where the distilled-water tank is coated with water cement (definitely not encouraged) or where there is leakage in the condenser, however, large amounts of calcium and magnesium can eventually enter the boiler, warranting due precaution. In some instances the required hardness is specified for boiler water. The hardness values suggested for boiler water are prone to error and often turn out to be unrealistic. For this reason and also since the boiler-vater hardness should remain about 1 ppm as long as excess phosphoric acid and pH of boiler water are controlled to the values given in Table 1, MHI does not make it its practice to specify the hardness requirements. “co. (io) (2) pH Value (Alkalinity) The boilers are made almost entirely of steel, and iron, beside being susceptible to heavy corrosion in acidic environments, dissolves in neutral pure water to produce iron hydroxide as follows. Fe + 2H,0 = Fe(OH), + Hy Iron Mater Iron hydroxide Hydrogen When iron has dissolved in pure water, pH with Fe(OH), at. the saturation point is 0.9. The larger the pH value, I.e., the higher the alkalinity, the more sharply the amount of iron dissolution goes down. It therefore is necessary for the pH value to be maintained constantly at a high level in order for iron being prevented from becoming corroded. A word of caution is deened in order because pH at too high a level can backfire in the from of caustic corrosion or caustic eubattlement or carryover. Also, it is known that boiler water is not uniform in concentration throughout its body. So, everything considered, the reasonable proposition is that pH of boiler water should be maintained at 10.8 to 11.3. Alkalinity may be deviled into total alkalinity and active alkalinity. Included in the total alkalinity reading are caustic soda, potassium carbonate, and potassium bicarbonate, all these being put together. The active alkalinity, on the other hand, called phenolphthalein alkalinity (or P alkali, in short), represents the amount of alkali high enough in strength to turn phenolphthalein indicator in color. bct (i) It is the active alkalinity that serves as a rough guide to the pH level. With all the foregoing in consideration, therefore, the phenolphthalein alkalinity as CaCO, is to be controlled to about 50 to 300 ppm when boiler water is in excess of 1000 ppm in concentration and to about 30 to 100 ppm when boiler water concentration is below 1000 ppm. (3) Dissolved Oxygen The dissolved oxygen constitutes a single greatest factor in causing corrosion, being responsible for boiler steel corrosion in well more than 50% of the time. In reaction between water and iron, which is defined as Fe + 2H,0= Fe(OH) 2 +H,, hydrogen thereby produced is absorbed in metal surface to serve as anegative factor in the reaction. When oxygen is present, however, it causes hydrogen to disappear by oxidation, so the reaction progresses toward the right term of the formula with the dissolution of iron taking place continuously. In addition, iron hydroxide turns into ferric hydroxide by being oxidized by oxygen, ferric hydroxide settling down to produce rust, thereby causing the corrosion of iron to progress intermittently. ?cl (a2) 2Fe(OH), + 1/2 0, + H,0 = 2Fe(OH), Iron Ferric hydroxide hydroxide The pitting corrosion, found concentrated under the drum waterline, is attributable to the dissolved oxygen. Iron transported from the feedwater piping into the drum, plus iron oxide produced within the drum, accumulates as deposits or settles down to cause the pitting. The presence of carbon dioxide gas together with dissolved oxygen in saturated-steam piping or condensate piping can cause a total corrosion. Carbon dioxide gas is produced by dissolution of bicarbonate in makeup feed as well as by dissolution of sodium carbonate within the boiler. 2NaHlCO, > — Na,C0, + HO + CO, Sodium Sodium Carbon bicarbonate carbonate —_ dioxide gas Na,CO, + H,0 > 2Na0H + CO, Sodium Caustic Carbon carbonate soda dioxide gas The use of sodium carbonate as boiler antiscale, therefore, is not recommendable. Carbon dioxide gas dissolves in water and acts as carbonic acid but does not cause by itself so heavy corrosion. If there is oxygen together, however, the effect of the dissolved carbon dioxide gas becomes pronounced, as it to play a role of some oxidizing medium as indicated by the following reaction formulas.cH (13) Fe + 2H,C0, = Fe(HC0,) + H, Carbonic Ferrous acid bicarbonate 2Fe(HCO,), + 1/2 0, + 5H,0 = 2Fe(HCO,) + 4H,CO, - Ferric hydroxide The dissolved oxygen in feedvater, therefore, requires to be strictly controlled, preferably to below 0.05 ppm for 1.57 MPa(16 kg/cm’g) boiler even though it is specified to be 0.5 ppm. For renoval of dissolved oxygen, it is recommended that volatile hydrazine be continuously added to feedwater. Hydrazine reacts as follows Na, + 0, > Ny + 21,0 (4) Chlorine (Chloride) Salts, when present in large quantity, raise the electric conductivity of liquid to promote the corrosion and hence require to be controlled to as low a level in quantity as is practicable. Feedwater containing too large an amount of magnesium salt can produce the sediment of magnesium hydroxide upon entering the boiler, and this is said to raise the corrosiveness of boiler water by bringing down the boiler water pH value. All the same pH and oxygen remain the greatest factors in causing the corrosion. and the measurement of chloride is performed more or less to obtain a rough idea as to the amount of dissolved solids contained. aCt (14) ‘The relation between the dissolved solids and chlorine ion, though subject to some variations depending on the water quality or performance of the water-making device, can be established by measuring these elements in boiler water of each individual boiler beforehand. Then, it is possible, as well as does no harm for practical purposes, to estimate the amount of dissolved solids. It is assumed that the concentration of boiler water, as long as it is controlled using the amount of dissolved solids as a yardstick, can not rise to sucha level sas to greatly promote the corrosion except in special instances. The Feedwater Committee, therefore, sets forth no requirements in particular as to the allowable limit of chlorine. (5) Oil/Grease Oil/grease coming out of auxiliary machinery, especially those started in reciprocating motions, enters feedwater and then adheres to the boiler heat-absorbing surfaces to cause the overheating trouble there upon exidation. Also, since boiler water is alkaline, both animal and vegetable oils are liable to be emulsified in it. The results are foaming of boiler water and degradation in steam purity. Although the allowable limit is specified for the amount of oil/grease in boiler water in some instances, it seems highly likely that such an oil/grease will be several-hundreds fold greater in concentration at the boiler-water surface than the mean oil/grease content. As specifying such a limit is deemed to make not so much of sense, it is only requested that feedwater and boiler water should be controlled so that the amount of oil/grease can be kept to zero as far as is practicable. 2o(6) Silica (Silicic Acid) ‘The scale that contains silica is the poorest in heat transfer and thus the most harmful to boiler operation. Also, what is called the silica carryover takes place, in which silica carried in steam enters the turbine and deposits itself on the turbine blades as hard scale encrustation. This is the single most nettlesome phenomenon, which warrants a serious consideration in connection with the care of high-pressure boilers. For a 1.57 MPa( 16 kg/cn’g) boiler, it is reconmended that the silica content of boiler vater be controlled to below 50 ppm to cope with both the scale formation and silica carryover. Silica acid should be no cause of concern so long as distilled water produced from seavater is used as makeup feed in nearly all the instances. When vater is obtained from land, however, necessary precautions are to be taken in this respect. 77cl (18) (7) Dissolved solids ‘The larger the amount of dissolved solids in boiler water, the more dampened the steam becomes, to the point where a large amount of solids are carried in steam as carryover to the turbine. ‘The tendency of such a carryover varies with the steam evaporation rate, boiler type, and performance of the steam separator in the steam drum, as well as with constituents of solids even if the solids are same in quantity. . Although the relation between these factors still defies quantitative definition, at least a rough standard can be given for safe and practical operational purposes from the past experience. In normal operation, the amount of dissolved solids is to be kept to below 2000 ppm.ce w 2. CARE OF BOILER OUT OF SERVICE For the out-of-service boiler, exercise adequate care to minimize the corrosion of its pressure part and also inspect it closely. In cases vhere the boiler is put out of service for 24 hours or more, either fill the boiler completely with water (wet storage) or drain the boiler of water and thoroughly dry it (dry storage). Whether it is the wet storage or the dry storage, the purpose is to eliminate air and dissolved gas from within the boiler for prevention of boiler internal surface corrosion. Also, when placing the boiler in storage, be sure to keep the gas side completely clean. Any residual soot deposits on evaporating tube surfaces could absorb moisture from air and cause the surface corrosion. Wet _Lay-up Method The wet lay-up is preferable as it requires less preparation, the boiler can quickly be returned to service, and protection of the waterside is adequate. This method can be safely used for a lay-up of any length of time, if the fireroom temperature is not below freezing.ce (2) (1) When the boiler is being cooled down after shutting off firing ,boiler compound (Na/P0,=2.8 mole ration) of trisodium phosphate (Na,P0,) and dosodium phosphate (Na,HP0,) ,and hydrazine shall be added to the boiler water by the chemical injection system in such a manner as to make the boiler water of phosphoric acid (P0,*") of about 50 ppm and hydrazine (N,H,) of 100 200 ppm (pH is about 10.5~10.6). The boiler water should be kept in high alkalinity to protect the boiler from corrosion. Since the boiler water density during the wet laid-up period is very high compare with that of ordinary operating condition. The boiler should be carefully blown down when starting operating to bring the boiler water concentration down to the normal value (with the boiler water treating limits). For this ,some amount of make-up water is necessary and the distilled water should be prepared beforehand accodingly. (2) When the pressure has gone down to nearly zero, open the steam drum air-vent valve. (3) When the pressure is almost off the boiler, fill the boiler with distilled water until it issues from the air vent valves, then close the valve. (4) Put a hydrostatic pressure of 0.34(3.5) to 0.49 MPa(5 kg/cm’g) on the boiler. Hold this pressure until the boiler has cooled to fireroom temperature, then bleed the boiler, using the air vent valve, to be sure all air is out. Hold a hydrostatic pressure of about 0.20(2)to 0.34 MPa _ (3.5 kg/em’g) on the boiler. ”ce (3) (5) Maintaining the alkalinity at a uniform level throughout respective boiler parts is an important consideration, so periodically sample boiler water for analysis during the storage and replenish what have been spent of alkalinity and sodium sulfite. (6) Incase the atmospheric temperature threatens to fall below the freezing point, take care to maintain the boiler room temperature at higher than 5°C so as to prevent the boiler water from freezing. (7) When interrupting the wet storage to put the boiler back into service, bring down the steam drum water level. Dry Lay-up Method In case the wet lay-up method cannot be performed, resort to the dry lay-up method. (1) While the boiler still remains warm, drain out boiler water and open up the boiler for ventilation until completely dried internally. (2) Remove the end plate of the waterwall lover header, to check and make sure that no residual water remains collected inside the header. (3) If necessary, burn coke or charcoal in a container within the furnace to promote the internal surface drying. asce. (4) (4) When completely dried, put quick line or calcium chrolide in a shallow dish for placement in the drum and header and then close the end plate and manhole cover. Use 2 to 5 kg of moisture absorbent for 1000 kg of boiler water when quick line is employed and 1.8 kg of silica gel for 1000 kg of boiler water, as a matter of standard practice. (5) Be sure to close securely all the air-inlet openings into the furnace and provide the cover on the stack. (6) Check the moisture absorbent every one to two weeks at the beginning and every one to three months thereafter at the circumstances call for and renew deteriorated absorbent. Other Cares for Protection Do not forget the protection for the gas side, as well as for the boiler-water side. Have the gas side cleaned of soot or dust while in preparation for the storage. Soot or slug becoming moistened by moisture of air can cause the corrosion the gas side. Be absolutely sure to close the furnace and F.D.F. inlet vane and cover up the stack to prevent the ingress of air or moisture. Periodically open and close the F.D.F. inlet vane to make sure that it can operate successfully. Maintain the boiler gas side and casing in the dry state as far as is practicable. 2bC3 () 3. HYDROSTATIC TESTS Hydrostatic test pressure should not be higher than necessary to prove the intended test. The maximum allowable hydrostatic test pressure should be carried out only for design pressure. See the hydrostatic test planning particulars included in this Manual for the maximum test pressure to employ. The specified pressure is to be applied to ensure the boiler structural integrity, only for inspection by applicable ship classification society surveyor. (1) To check the boiler and fittings for leaks, a test pressure of about 85 percent of the safety valve popping pressure is sufficient. Caution should be used to avoid accidentally raising the pressure enough to open a safety valve. (2) Hydrostatic tests up to normal feed line pressure may be applied with the feed pump if handled carefully to avoid sudden changes in pressure, producing shock or impact stresses in the boiler. For maximum test pressure use the test pump. 27c-3 (2) (3) Before applying a hydrostatic pressure, it is advisable to cool the boiler to approximately fireroom temperature. The water used for filling should be warmer than the boiler metal, to avoid moisture condensation on the fireside. (4) Place test clamps (gags) on all safety valves, if the test pressure is to be higher than 85 percent of the safety valve popping pressure. Safety valves should never be opened by hydrostatic pressure. (5) The pressure gauge to be used should be checked, before applying the maximum test pressure. (6) When filling the boiler open the vent valves on the boiler drum, to bleed off all air, close the valves when water runs out. (7) Before lowering the pressure, take up the slack on the nuts of the inspection hole and manhole fittings, were new gaskets have been fitted. The nuts should be pulled just snug with the wrenches supplied for the purpose. Do not use a pipe or other extension on the wrench handle. (8) When inspection is completed, open the vent valves and lower the pressure slowly by cracking a drain valve. (9) Remove the safety valve gags, replace the lifting lever and easing gear. "FfC4 a) 4. BOILING OUT If the presence of oil is found on the waterside of the boiler, it must be removed by boiling out. This is necessary after assembly of a new boiler, after completion of repairs requiring extensive replacement of tubes, or if oil has entered the feed water from some other source. Boiling out is also a quick and efficient method of removing various types of scale. The chemicals to be used and the strength of solution required, depends on the character of the scale. Consult the boiler water chemist. Boiling out to remove oil requires the use of a fairly strong caustic solution. One such solution is 2 kg of caustic soda and 4 kg of tri-sodium phosphate, for each 1000 kg of cold water required to fill the boiler. This chemical solution is sufficient to remove ordinarily compounded lubricating oils or the usual protective oil coating applied to tubes before shipment. Straight mineral lubricating oils used for high temperature engines requires stronger solutions. If such oil is present in the boiler used 4 kg tri-sodium phosphate and 4 to 5 kg caustic soda per 1000 kg of water. In addition it is advisable to add detergent (wetting agent) amounting to about 0.5 percent of the boiler water. There are other chemical solutions which can be used. There are many satisfactory compounds for boiling out, they are sold under various trade names by reputable firms. When such compounds are used, follow the manufactures instructions. WFc-4 (2) Steaming Method This is a method in which steam is injected by way of a temporary piping externally connected to the air-vent valve, for soda boiling. Water is to be discharged by vay of the bottom blow-down valve and through a temporary discharge piping. The discharge piping is to be connected to the boiler water sampling tank, which is requires for inspection or analysis of boiler water. (1) Inject chemicals into the waterwall tubing as required, using the chemical injection device. Dissolve the chemicals in clean water, in proportion to the weight of water required to completely fill respective boiler parts, for injection. See ‘the “planning particulars” included in this Manual for the weight of water required to fill each of the boiler parts. (2) Upon finishing the injection of chemical solution, gradually blow in steam in such a manner as to permit condensed water to collect until the boiler is completely filled with water to the point where water begins to overflow by way of the air-vent valve. (3) Maintain the boiler pressure at about 0.34 MPa(3.5 ke/cm'g) and adjust each air-vent valve so that the quantity of overflowing water from each individual air-vent valve and bottom blow-down valve will be approximately in proportion to the quantity of water in each corresponding boiler part. poC4 (3) (4) Determine the progress in removal of oil through test of sample water taken from the discharge piping. Analyze the sample water for alkalinity and then add chemicals required to maintain the chemical concentration at the specified level : by so doing, continue the soda boiling until no trance of oil can be seen in the sampled water. The oil content can be detected by examining the surface of cooled sample water for sign of oil. If possible however, analysis by ether method, etc. should be in order. afC4 (4) Firing Method If steam and electric power are available and the auxiliaries are ready for service a boiler can be boiled out using a light fire. When the firing method can be used, it is much simpler and does not require temporary piping. The quantity of solution to use should be figures for the weight of cold water required to fill the boiler to normal steaming level. (See “Design Data”. ) (1) Dissolve the chemicals in water and inject into the boiler with the compound ejector. (2) Close the boiler and fill to the normal starting level. In cases where the boiler is of new construction with new refractories in it, avoid the sharp thermal expansion of the refractories by preheating (3. the furnace internals by burning firewood inside the furnace for 3 to 4 hours or by firing the burner intermittently. (4) Ignite and shut down burner using the burner tip, repeatedly until the pressure is gradually raised to the level corresponding to 85 to 88% of normal operating pressure. Maintain the pressure at that level, for soda boiling. If necessary to maintain the pressure, intermittently fire the burner. (5) If the refractory is new, alternate the burner at fifteen minute intervals. gzo-4 (5) (6) When the boiler is thoroughly heated, raise the water level slowly to about, 75 to 100 mm above normal operating level, then give a surface blow followed by several short bottom blows to bring the water level 30 to 50 mm below normal. (7) Refill the boiler slowly, until the water level is reached to about 75 to 100 mm above normal, and additional chemical based on the approximate amount of water blown down. (8) Perform the soda boiling continuously for 24 to 48 hours, blowing down boiler water every 6 to 8 hours through the blow-down valve by 100 to 150 mm on the level gauge each time. 3.2 Wash and Inspect (1) After boiling out is completed by the firing method, blow down the boiler through the water drum bottom blow off valve while the boiler is fairly warm. Discharge the water overboard, to avoid damaging paint in the bilges by the strong caustic solution. (2) Open up the boiler and wash it down with a high pressure water hose, playing the hose into all tubes. (3) Carefully inspect the boiler, and if any trace of oil remains, repeat the boiling out process. §35 a 5. WATER WASHING FIRESIDES Slag is a mixture composed of sodium sulphate or a mixture of sodium sulphate and van adium pentoxide, and lesser amounts of the oxides of other impurities. When burner is kept in proper adjustment, the burner tip kept clean and in good condition, and the soot blowers operated at correct intervals, slag formation nay be sloved down. However slag formation will eventually accumulate on the tubes and should be removed before it has bridged over between tubes. Awater washing schedule should be set to coincide with normal fireside cleaning. Operating practice will indicate at what intervals of fireside cleanings water washing is necessary. Since slag is soluble in hot fresh water, hot fresh water is sprayed on the slag encrusted tubes with a lace, using sufficient force to soften the slag and knock it off the tubes. There are two methods in water washing. One is to use a hand nozzle and the other is to utilize the soot blower in spraying hot water. ‘The former permits concentrated washing of important points so that effective washing can be done with relatively small quantity of water resulting in less noisture of the boiler ; but much time and labor is required. With the latter, washing can be done easily ina short space of time but it requires relatively much water resulting in larger moisture of the boiler. Water washing is usually carried out at a dock. A member of the crew can do it quite easily. evC5 (2) If preparation has been made in advance while the boiler is cooling, water washing will be done in 6 - 8 hours although it depends on the extent of dirtiness. The following is the order of process of water washing the fireside with a hand nozzle. (1) Prepare an apparatus to supply adequate quantity of hot water and a hose and nozzle for spouting hot water. (2) Remove casing access doors and dusting panels to facilitate the work. (3) Provide a means for immediate and constant draining of the waters and the removal of the sludge, resulting from washing down. (4) Water under 0.49MPa(5 ke/cm’g) and at a temperature of 80 deg. C should be sprayed on to the tubes, using an armored hose. Work from the top of the boiler down, in cases where slag removal is extremely difficult, secure from washing, and allow the water to soak into the slag for a period of 30 minutes to one hour. Then continue washing down the tubes. (5 ‘Attention should be paid not to let washing water penetrate behind the refractory. It will be effective to lay a sheet of canvas on the furnace floor. If small quantity of water is absorbed by refractory and heat- insulating materials, the bad effect will be removed by slowly drying soon after finish of washing. 8SC-5 (3) (6) Preferably complete the washing with warm water in short time : it is not desirable to continue the washing over 8 hours. (7) As soon as possible after washing is completed, light off the boiler at minum F.0. press. The drying out operation should be done very slowly and should be continued until the boiler is thoroughly dried out. When the boiler has entirely been washed, the drying should be made at least for 12 hours. 368 6. ACID CLEANING Thanks to development of good inhibitors, it has become possible to effectively remove scale on the waterside of the boiler by acid cleaning. However, acid cleaning requires a suitable treatment according to actual conditions of the boiler, otherwise it will not only damage the boiler but also be attended by dangers. So this work should be done by specialized constructors having experienced and competent personal with proper equipment. It is desirable for the work to be done under the leadership of Mitsubishi, Nagasaki Shipyard, if possible. Boiler operators should have a knowledge of the following general items. 6.1 Equipment The following devices should be prepared for the acid cleaning. (1) Anacid filling tank of sufficient capacity to hold the prescribed amount, of acid and inhibitor. (2) One centrifugal acid filling and circulating pump with bronze impeller designed to deliver a minimum of from 0.2 to 0.4 m/min at 35 m hd.or of such capacity as so fill the unit in not more than 2 hours. (3) Suitable temporary piping and fittings to connect both the pump and tank to the boiler. (4) A typical cleaning solution would contain 28 percent to 34 percent hydrochloric (muriatio) acid, an inhibitor and water. ‘The amount of acid used would be roughly 10 to 20 percent by volume of the volume of water necessary to fill the component to be cleaned. See “Design Data”. e?a (2 C-6 (2) Selection of the concentration of acid used (one to six percent by weight for any one unit) depends upon the type and amount of scale or rust and other impurities to be removed. Special attention must be given to ensure that the acid solution is not enriched by ferrio or cupric ion, which can be caused from the removed scale or deposits containing a large portion of ferrio or cupric oxide. ‘This will impair the effect of the inhibitor. In such a condition, keep the acid solution below the maximum allowable concentration of ferrio or cupric ion, by adding renewing the reducing agent. Procedure ) If a trace of oil is found in the boiler, it must first be boiled out with an alkaline solution. A boiling out period of from 6 to 10 hours is adequate when followed by acid cleaning. Remove all tools, rags and other foreign material from the waterside of the boiler. Secure all header end plates, the manhole plates and valves, that will make the boiler watertight and isolated from all boiler boiler accessories except the water gauges. (3) In order to ensure safe removal of hydrogen gas generated during the acid cleaning, connect a pipe line to the highest vent of the part to undergo acid cleaning. Never do welding while acid cleaning is being performed. 6co (3) (4) Temporary piping for pumping the acid liquid into the boiler should be connected from the tank to the pump suction, and from the pump discharge to the nozzle of the bottom blow pipe. Piping should also be connected. From the other steam pipe nozzle of the boiler steam drum to the tank. (5) Start filling the boiler with water 75 degree C to 90 degree C. While the feed water is being injected into boiler through the main or auxiliary feed system, start pumping the acid and inhibitor into the boiler through the chemical feed pipe. If all the acid has not been pumped into the boiler by the time the water shows in the gauge glass, secure feeding the boiler, until all the acid has been injected into the boiler. (6) When all of the acid liquid has been injected into the boiler, continue to fill the boiler with water until the level in the steam drum is high enough to cover all the tubes to undergo acid cleaning. This is necessary for the circulation of the cleaning solution and for cleaning all the tubes of the unit. (7) When acid-cleaning the entire steam drum, fill the boiler with water containing the same proportion of acid. (8) Run the circulating pumps 3 to 5 minutes each hour. If it is found that a wide temperature spread exists between various parts of the boiler or if the scale deposit is excessive, use a half hour cycle. oeC6 (4) (9) Check test samples of the cleaning solution with a standard sodium hydroxide solution and methyl orange indicator. The value of this depends upon being able to get a true representative sample. The acid concentration should be tested at the end of each circulation period. When the concentration has leveled off, and remains constant over two successive tests the dissolution can be considered complete. (10) Empty the boiler through the skin valve using compressed air. (11) Average acid contact time should be from 6 to 8 hours. If the scale has not been removed during this period, the probable cause is : (a) Weak solution ; repeat process. (b) Misidentified scale and wrong solution used, high in silicates, sulphates or oil. General Precaution (1) Before injecting the acid solution into the boiler it is good practice to check the effectiveness of the inhibitor. A weak inhibitor will permit excessive corrosion of the boiler metal. (2) A quick check of inhibition consists of diluting the concentrated acid to approximately 5 percent, then drop in a piece of coldrolled steel in the solution and heat to 65 degree C. Well mixed inhibited acid produces very few hydrogen bubbles which should be small and difficult to see. For comparison run a test with inhibited acid. GOc8 (5) (3) Check the metal temperatures particularly the steam drum before injecting acid, before and during each pumping operation. This can be down by using thermocouples located at critical points or by contact pyrometer. It should be noted that THE TEMPERATURE IS A MOST CRITICAL FACTOR in the procedure. Too low a temperature, under 50 degree C, will result in poor dissolution of most deposits. Too high a temperature, more than 80 degree C for most inhibitors, will increase the corrosion rate appreciably, if not to a damaging degree. Stay within the temperature limits prescribed by the manufacturer of the inhibitor. If there is any doubt, stay under a temperature of 65 degree C. (4) After draining out the acid, wash down the boiler with fresh water, using the same washing process as described after boiling out. (5) The boiler should be boiled out with an alkaline solution (see Boiling Out). This is to both clean the boiler of suspended particles and to return all surfaces to an alkaline base. (6) After boiling out, wash the boiler with a strong stream of hot fresh water with a hose. (7) After acid cleaning DO NOT ENTER OR WORK in the boiler until it has been filled at least once with water, and preferably after the boiling out process. aMAINTENANCE AND REPAIR MAINTENANCE OF REFRACTORY Dt BOILER PRESSURE PART D2 HEADER END PLATE D3 FLANGED JOINT D4 SLIDING SADDLE D5 TUBE PLUGS D-6 REFERENCE DRAWINGS D7DL wm 1, MAINTENANCE OF REFRACTORY ~ 1. Drying Out Anew refractory furance lining or one that has been extensively repaired should be carefully warmed up and dried out to avoid damage. 1.1 Drying out in Lighting up and Pressure Raising If the boiler is clean and ready for service, as after boiling out by the “Steaming Method”, prepare the boiler for service (1) Light off burner at min. firing rate. Secure the burner after five minutes and light off again after fifteen minutes. (2) Continue in this manner, for a period of six hours. (3) Allow an “off” period between securing burner and lighting off the next if necessary to prevent the steam pressure from going above 0.34(3.5) to 0.49(5.0kg/cm’g). (4) At the end of the first six hour period raise the steam pressure slowly during a second six hour period, cutting the boiler in on load at the end of the period. (5) During a third six hour period increase the firing rate slowly until at the end of the period the boiler is being fired at the maximum rate (up to normal power) under the load conditions existing at the time. Continue firing at the maximum rate (up to normal) possible for a fourth six hour period. 7Dt (2) 1.2 Drying out in aldali-boiling (1) If the boiler is to be boiled out by the “Piring Method” the burner in service for the first six hour period. Maintain the firing rate as required for the boiling out process. (2) After the boiling out is completed, and the boiler washed out, refilled and ready for service, light off and raise slowly to operating pressure in from four to six hours. (3) Cut the boiler in on the load and continue with the third and fourth periods as described above. 2. Burner Throat (1) Inspect the refractory burner throat. The surface of the flared opening should be smooth. Repair if roughened by spalling or burning. (2) The burner throat opening must be a true conical shape with the center exactly on a centerline through the center of the jacket tube. (3) The sweep used with plastic refractory throat molding tool can be used to check throats for accuracy. If these tools are not available use a lengh of spare pipe or tube in the jacket tube as a reference center. oeDA (3) 3. Plastic Refractory (1) Plastic refractory (or castable refractory) should not be in close contact with metal, either pressure parts or hanger bolts. Always coat metal with a heavy coat of bitumastic paint, wrap tubes with tar paper, which will burn out to allow some expansion clearance otherwise the refractory will crack and eventually fail. (2 Plastic refractory has a stiff clay consistency and should be used as it comes from the container with no additional water added. In the event it is necessary to use a plastic which has sliced in a broken container, spread wet burlap bags on a flat deck. Spread the plastic, broken into small chunks, over the bags and cover with wet bags. Sprinkle lightly to keep the covering bags wet. Allow to stand about twelve hours, then work the plastic with a mallet to uniform consistency. (3) If a large quantity of material in a container must be reconditioned, turn the container on end, punch several 25 mm¢ holes in the top and fill with water until the proper amount has been absorbed. If the surface of the plastic becomes wet as it is rammed, the material contains too much moisture. (4) When making repairs with plastic refractory remove enough old material to allow using a mass of new material which can be properly worked. Cut back to the insulation, making patches the full thickness of the wall. (5) Replace anchor bolts and ties to conform to the original design. Coat the anchors with two coats of “Bitumastic” paint before placing the refractory. (6) Wet the surfaces of oil refractory to which the new works is to be bonded. Be careful to leave expansion joints where indicated in the boiler bricking drawing. asDl (4) (7) Build up the patch from the bottom in horizontal layers, ramming the plastic thoroughly with wooden mallets or a pneumatic hammer to prevent voids. (8) When the ramming is completed, roughen the fireside surfaces except the burner throat opening with a wire brush or a hacksaw blade. Punch holes on approximately 40 mm centers in the face of the filled area, carrying the holes completely through the mass. Use for this purpose a 5 mm diameter rod tapering to a blunt point body of the plastic, avoiding possible rupture due to generation of steam. (9) Cut expansion joins 50 mm deep in the face of the refractory mass with a trowel so that the face of the refractory is cut into rectangles approximately 200 mm square. (10) The work should be planned so that a drying-out fire can be put in the furnace within 24 hours after completion. If it is not possible to fire the furnace within 24 hours, the work should be kept covered with damp cloths until a fire can be started.4. Castable Refractory (1) Castable refractory is used principally in locations requiring a refractory shield over pressure parts of the boiler or water wall headers to protect them from furnace heat. (2 The refractory should be one that will set and develop strength without. the application of heat. This characteristic is necessary because the close contact with the boiler or water wall surfaces prevents it from reaching the temperature required to vitrify. (3) This material is mixed with water and poured like concrete. The quantity of water used is important and should not vary from the amount recommended by the manufacturer. The usual time required for this material to set is from 6 to 8 hours, after which a fire can be started. 4 ‘To patch small portions of the header protection refractory, remove the old material to its full depth. (5) Replace the anchor bolts as necessary. Coat all anchor bolts or reinforcing with a heavy coat of “Bitumastic” paint. Forms can be made of wood or sheet metal, if needed. (6) Where the refractory is to placed around tubes, wrap the tube with tar paper or coat heavily with “Bitumastic” paint. This material burns out and will allow an expansion space and avoids cracking the refractory. Before it sets, slit the face of the refractory to a depth of 75 mm with a trowel to make expansion joints on approximately 350 mm centers. 39D2 a) 2. BOILER PRESSURE PARTS In repairing and checking the pressure parts of the boiler, confirm non- existence of pressure by the pressure gauge. If the boiler is under pressure, open the air vent valve to lower the pressure sufficiently. If the gauge shows no pressure, open the air vent valve to confirm non-existence of pressure. 1. Inspection of Fireside (1) Inspect the fireside at every shut-down. Be sure the tube bank is clean and free of any accumulation of soot or slag. Pay particular attention to the water drum and be sure there is no heavy accumulation of soot on it. Use a steam lance to clean the bank if necessary. (2) Accumulated soot is to be removed through the cleaning hole on the side of the water drum if necessary. (3) Ordinarily the boiler front bank tubes can be cleaned as much as is necessary by rattling or bumping the tubes with a fairly heavy hammer handle. Cleaning these tubes or the waterwall tubes with a scraper or wire brush is considered unnecessary except when making a careful surface inspection of the tubes. (4) Inspect the waterwall tubes and front bank tubes for any indication of cracking, blistering or over-heating. Replace any faulty tubes which may be found. oFDe (2) 2. Inspection of Waterside (1) Make an inspection of the waterside at least once every six months until certain that method of analysis and treatment of the feedwater and boiler are satisfactory and will permit longer steaming periods between inspections. (2) Open both drums and check the appearance of the drums and tubes carefully. Open end waterwall header end plate. See that the waterwall tubes and waterwall headers are free of sludge or other foreign material which may restrict the circulation. Boiler and waterwall tubes must. be kept free of scale deposits, oil and corrosion. (3) Scale deposits in the boiler and waterwall tubes can be prevented by maintaining the correct chemical conditions in the boiler water. This requires strict adherence to the boiler water chemist’s instructions. (4) Waterwall tubes and the front bank tubes which are exposed to the radiant heat of the furnace will overheat with a very thin layer of scale deposit. (5) Corrosion in the boiler is usually due to oxygen in the feed water, low alkalinity in the boiler water, failure to vent the boiler when starting to raise pressure or improper care of the boiler when not in service. (6) Oxygen pitting is the most common form of corrosion found in boilers. It usually occurs above the water level in the steam drum but it is often found also in tubes and water drums. The pits are usually covered with adull red, scabby oxide under which is a pit with a shiny black surface. ”D2 (3) (7) After completing inspections or any repair work in the boiler, be sure that all tools, bolts, etc., have been removed. Brush out all dirt, welding spatter and similar material. Wipe up any oil and wash the drums with a high pressure water hose. 3. Replacement of Boiler Tubes (1) Working in the inside of the drum, slot and crimp the faulty tube ends until the tube can be driven from the tube hole. Tubes which are easily accessible can be cut of the 30~50 mm from the drum. The remaining nipples can be removed, working either from the outside or the inside of the drum. (2 Clean the tube holes carefully, removing all scale and rust. Clean the replacement tube ends to bright metal with emery cloth. Clean the inside of the tube to remove the protective coating. This may be done by pulling a kerosene soaked swab through with a wire, then blowing out thoroughly with a steam hose. (3) Round the edges of the tube end before welding to avoid developing cracks. (4) Enter the tube in the tube holes and clamp in position. The tube ends must project into the drum to allow for belling.HEADER END PLATE (1) Use High Temperature Lubricant (Molykote, Elesco No. 100, etc.) on the header end plate volts and nuts. (2) To install fittings with Flexitallic gaskets, clean the gasket seats of the fitting and header end plate carefully. Do not use graphite or other compounds on the gaskets. (3 Center the fitting in the header end plate making sure the shoulder does not bind on the edges of the header end plate. Then slip on the bridge yoke and start the stud nuts. (4) Run the nuts on the stud hand tight plus a three-quarter turn with a wrench. It is important that the gasket is not mashed by excessive tightening of the stud nuts. (5) If anew gasket leaks while filling the boiler, slack off the stud nuts enough to loosen the bridge, then shake the header end plate to get it squarely on its seat and set up the stud nuts again. This will usually stop leakage through a new gasket. Sweat or slow drips ordinarily will take up under hydrostatic or steam pressure. (6) Before closing the cover panels put a hydrostatic pressure of about yorking pressure on the boiler and then go over the fittings and tighten the stud nuts hand tight plus one-quarter turn with a wrench. (7) Manhole gasket, are handled in the same manner. The nuts may be pulled ‘tight with the wrench furnished. Use no pipe or other handle extension. pot4, FLANGED JOINT All flanged connections to the boiler nozzles are made up with Flexitallic type, gaskets. (1) Clean the faces of the companion flanges perfectly. Apply gasket paste to the gasket or the gasket sheet thinly and evenly. Use no graphite or other compound on the gasket or the gasket seats. (2) See that the flanges match accurately with no strain. Pull up the flange bolt evenly. (3) When making up a flange joint pull up the nuts uniformly. Never pull the nuts more than one flat at a time. Never tighten the nuts in consecutive order around the flange, always cross over to a nut on the opposite side of the flange.D5 5. SLIDING SADDLE Check the sliding saddle provided to permit expansion of the boiler. Grease occasionally and see that the bearing surface and the slotted bolt holes are not fouled with dirt. The holding down bolts should be either shouldered or provided with sleeves to prevent pulling the bolts too tight and pinching the sliding saddle is the front saddle. 723D-6 TUBE PLUGS (1) Tube plugs are included with the shipboard tools to permit plugging a faulty tube until replacement can be made. A boiler can be safely operated with several tubes plugged. (2) Be sure the tube end and the plug are perfectly clean to assure a metal-to-metal contact when the plug is driven into the tube end. (3) Boiler tube that has been plugged should be replaced at the earliest opportunity.‘7. REFERENCE DRAWINGS D7 fos[PNS7—a25—asoi ff 3 wey ; a a | 8 v a Vivo soWRNOaS are SRT W @ a = a _ 9 ¢ ! ¥ ¢ ! ZzSESS [PR57—a25~a00 b@]N37A25~8501, ees) wR ond Saab SESSpt 123 Wvsovid ONidld YFN0E —19- v@y (ar Sar oRe ese ORDORET-LSH 11 /6/1/8/CORDHv » DIAGRAM °Q Zz es a ce i Zz ae 5 aE-1. A.B.C. SYSTEM LoOWNER mE SHIP YARI itt A BE | CO., LTD NAGASAKI SHIP YARD D | MITSUBISHI HEAVY. INDUSTRIES, su? 80. | TMABART | S.No. 1887/1/2/3/4 SHIP NAME i 4 AUX. BOILER (UAC~26B > 2) INSTRUCTION MANUAL OF BOILER CONTROL SYSTEM CLASS ABS a fe RE can |. ‘Asahi Mechatronic Corporation DATE ; 2 ate SEP. 23. 2002 PROD. NO. reeTABLE OF CONTENT A. — INSTRUCTION MANUAL OF BOILER CONTROL SYSTEM [1] CONFIGULATION OF CONTROL PANEL (I) CHECK @ OPERATIGN BEFORE RUNNING B, INSTRUCTION MANUAL OF BURNER CONTROL SYSTEM [1] SELECTION OF OPERATION MODES [11] OPERATION OF BURNER [I] AUTOMATIC RUNNING OF F.D.FAN, & P.O. PUMP LIV] SOOT BLOWER OPERATION CV] ALARMS C, INSTRUCTION MANUAL OF AUTOMATIC BOILER CONTROL SYSTEM C1] GENERAL DESCRIPTION CI] OPERATING INSTRUCTION CI] COMPONENTS CIV] ALARM DISPLAY | ___IMABARI) PAGE wz(1) CONFIGULATION OF CONTROL PANEL 1. BOILER CONTROL PANEL (BCP) LIL] CHECKS & OPERATION BEFORE RUNNING‘A, INSTRUCTION MANUAL OF BOILER CONTROL SYSTEM ‘The Boiler Control Panel is provided with built-in operation. control and interlock devices required for the running of the boiler. This control panel performs the automatic and manual runnings of the boiler,gives an alarm to varn the operator if an abnormality occurs during running. and stops the boiler in an emergency mode by immediately shutting dora the fuel oil supply to the boiler if such an abnormality should be too serious (o continue running any longer. CAUTION This manual has been prepared primarily for the instructions of remote~ control running of the boilers. In running. the boiler, boiler auxiliary machines, oil burners, boiler automalic control system, equipment attached to the boiler, and air flue, must have always been adjusted in good order CONFIGURATION OF CONTROL PANE] 1. BOILER CONTROL PANEL ‘This control panel is installed at the boiler side. | It contains the system pover supply unit, the sequencer for the burner control, the automatic boiler controller, and various necessary relay units. _TMABARI} ~ PAGE 3 wsIL)_CHECKS AND OPERATION BEFORE RUNNING. 1. Turn-on of Power Source The power switches of the boiler control panel are turned on, and the action of each pilot lamp and buzzer is checked by the "BZ. AND LAMP TEST" switch on the control panel 2. Actuation of Control Devices Bach control device is checked for having been supplied ith normal control air press. and also, for normal actuation when manually operated. 3. Reset of Boiler start Interlock Lamp The reset switches for the interlock alarm provided in the boiler control panel are turned on to check the interlock lamp for being turned off for normal operation. 1) AC SOURCE FAIL \ 2) SEQUENCER ABKOR 3) MANUAL TRIP 4) BLD.PAN TRIP 5) DRUM LEVEL LOW-LOF | 6) ATOMIZ PRESS LOW-LOF 1) IGNITION FALL > Alarm lamps shall be "OFF 8) FLAME FAIL 9) FLAME EYE ABNOR 10) IGNITION VALIDITY TERN OYER 11) BNR PISTOP ¥/¥ ABNOR 12) F.0.PRESS LO¥-LOW 13) CONTROL AIR PRESS LO¥-LOW (2) While in operation, the indication lamps on the contro! panel shall be observed and the boiler checked periodically. (2) By-pass operation must be carried out only by way of the "BY-PASS" switch. IVABARITBNvd TOMNOD BETIS Ws Ki ba BE ‘| 3 a a) |! a + & a i LL amine own OF URE SCY RAE Powe Toews BOPLOG4-OTL1F leoruen coves. anes. | 8H 82s = ydnaa we BOIS LON xo awn si awm[ | vase Tec ee eee oman] BCP 1064-0117 H} Bl Be, Wea G@BOILER SIDE)3, g i 23 pg 3 ape re j H@|d rr a 2 hag os q Bes — hae le | i 5 |G )ooo0000@) al J Ilo Hil @sooome Bil 7 ise may @ fEl@ 4 it Ee nil if I i 4 ‘| le) He if wf] i ii a © 34\© 0 <7 ql ¢ ¢ ¢ LE 2 o@ @ “wot sce [Rey PE me] mare | rages ors wy fe(140085 a) 1aNvd OEHAYTD (aioe 90 Hav 20 woTTISOHOD malts JFOOO EUS HMY ee ANQ TAT 1°0N [SE 0 | ing 4 anand Ina ]| _A“INOD dada} AND ATHYLY 1 UND YALSVH_ TON. noe A’ 1N00'0" 3) aNYK [ on EG oe oc te d O74 ALSH dSISK oo 0 oan tee AGMIY dSUIV OLLVE. oo eee ly Eee Mia's" Agi dSTAt oo 4 720 # BCP1064-099 eats 0 BERET rine s.imst| 10 a, = REFORMae iE marie | BCP1064—100 *. Foe 6.1m.)INSTRUCTION MANUAL OF BURNER CONTROL SYSTEM { 1] SELECTION OF OPERATION MODES ‘A. BOILER SIDE OPERATION B. SELECTION OF BOILER MODES C. MASTER/SLAVE BOILERS OPERATION LID] OPERATION OF BURNER A. MANUAL OPERATION OF BURNER START B. MANUAL OPERATION OF BURNER STOP C. AUTOMATIC RUNNING OF BOILER D. OPERATION PANEL GRAPHIC FLOW CHART EE. INTERLOCK BY-PASS OPERATION (L] AUTOMATIC RUNNING OF P.D.PAN, F.0. PUMP [IV] SOOT BLOWER OPERATION [V] ALARMS A. PATTERN OF ALARMS B. BOILER SET POINT LISTB,__INSTRUCTION NANUAL OF BURNER CONTROL SYSTEM In this control, the remote manual and automatic operations are available on one single-throat burner provided at the ceiling of the boiler Is control unit contains a programmable sequencer which can perform the sequential running of FURNACE PURGE and Pilot Burner and the automatic operation of the burner piston valve by linking with the boiler Protective System and the A.C.C. Also, it transmits the automatic adjustment commands of combustion air quantity and fuel oil quantity to the A.C.C.at the start/stop of the burner. In an emergency, this control system shuts off the fuel supply to the burner for the boiler protection. __IMABARI) PAGE 6 3(1) > SELECTION OF OPERATING MODES BOILER. § DE PION ‘ During the initial start-up and under "INTERLOCK BY-PASS" mode, the boiler is operated from (his BOILER CONTROL PANEL, from which you can select the following modes. 1. SELECTION OF AUTO/MAN. The operator can select his desired mode unless otherwise specified. (a) ALBLC.MAN, If controller is under ABNOR, this controller is forced to set A.B.C. to its manual mode. Also, the F.0.8 AIR controller is set to its manual mode in [IJ &-2 (@),@) (b) A.B.C.AUTO (Ce) BURNER MAN. INTERLOCK BY-PASS MODE, the Man Mode is forced to be selected. (4) BURNER AUTO While under this mode, the operation must be monitored at boiler side. (a) F.0, TEMP. BY-PASS MODE This mode must be selected when the F.0.heating steam is unavailable under the cold boiler start mode. In this by-pass mode. the starting interlock for F.0. temp low is by-passed. See [1] B-l,2 Cold Mode. See {I} E-1, F.0. TEMP. By-pass Mode. (tb) FLAME BYE BY-PASS MODE This mode must be selected only when there is no choice but to select the flame eye by-pass mode during operation of the burner, See [Il] E-2 FB. By-pass Mode. (Ce) BMERGENCY MODE This mode must be selected when the burner sequencer is unavailable. | See [Il] B-3 Emergency Operating Mode. PRG INABARI| peF BOILER MODE | (a) "168 TOP UP" MODE This mode must be selected for the IGS operation. When this mode be selected. burner operation become MAN mode | The A.C.C.is limited to its min load within the allowable limit of | the exh, gas oxygen content under this mode (tb) “TANKER SERVICE” MODE This mode must de selected for the tanker service operation. In the Burner AUTO Mode. the burner is automatically started at a 8.D.pressure of 1.18MPa(12K) and automatically stopped at a $.D.pressure of 1. 60MPa(16. 3K). (ce) "ECO BACK-UP" MODE | This mode aust be selected for the Exh.Gas Eco. back up operation during voyage. In the Burner AUTO Mode. the burner is automatically started at a S.D.pressure of 0. 54MPa(5S K)and automatically stopped at | a 8.D.pressure of 1. 0MPa(10. 0K). | (Cd) "REPOSE” MODE This mode must be selected to cancel alarms and lamp indications unnecessary during the boiler repose. IGS_OPERATION When in the IGS mode. the burner is normally kept in operation. ‘The IGS mode cannot be selected while sootblower is operated The sootblower cannot be operated while in the IGS mode. either. 1) IGS Mode Selection IGS mode can be selected with BOILER MODE SELECT. switch of boiler control | panel. 2) IGS Load Setting When in the IGS mode. ACC raises the minimum burner Joad over approx. 30% of boiler load. Mal PAGEJON OF BOILER START MODE One of the following start modes is selected. depending on the boiler condition. 1.._ BOILER COLD START This mode is selected to start from the cold boiler with the burner atomizing steam and the F.O.heating steam not provided. (1) Fuel oil used A HEAVY OL (2) Burner tip used LSIOV In use of compress air. (3) Mode switeh = "F.0. TENP. BY-PASS" -+++++++ F.0. temp. low sequence SWITCH ON interlock is by-passed. + BURNER OPERATION 1 Automatically set to "MAN" NODE "MAN" ss-When selected by + ALC.C, OPERATION F.0. temp. by-pass switches MODE "MAN" a CAUTION (1) In use of "A" heavy oil. atomizing air is to be used. This is because the use of steam causes the oil spray quantity to increase (approx. 20 percent). resulting in an unstable combustion. (2) For fuel oil used at normal temp.,fuel oil with viscosity exceeding 150 sec. RW No.1 at normal temp. aust not be used (3) Compressed air may be used instead of the burner atoniz. steam. In this case. compressed air exceeding 0.5MPa(5K) must be supplied upstream of the burner atoniz. control valve (4) In any case, "ATOMISING STEAM PRESS. LOW-LOW TRIP INTERLOCK” must not be by-passed. PAGE 9 i IWABARI P 6IM BOILER COLD MODE TO ITS NOT NODE This mode is selected to start from the hot boiler with the burner atomiz. steam provided and A-oil used. (1) Fuel oil used A HEAVY O1L | (2) Burner tip used: L $100 + Atomizer steam use: (2) altention (3) Mode switch + "RO. TEMP. BY-PASS” -0. Temp. low sequence SWITCH ON interlock is by-passed. + BURNER OPERATION NODE "MAN" |--- Automatically set to “MAN” + A.C.C, OPERATION when selected by F.0. temp. MODE "MAN" 7 by-pass switches. CAUTION. (1) This mode is to be used at the change-over of A-Oil to C-oil only. and watching at the boiler side must not be neglected at this change-over. After completion of this cohge-over, the Normal Mode or the Cold Mode ust be selected without delay. (2) To burn A-OiI by Steam Jet Atomizer. the air/fuel ration must be sufficiently adjusted. (3) Im any case, "ATOMIZING STEAM PRESS. LO¥-LOW TRIP INTERLOCK” must not be by-passed. _____INABARI PAGE 10 7This mode is selected to start from the hot boiler with the burner aloniz. steam provided and C-oil used. (1) Fuel oil used C-HEAVY O1L, (2) Burner tip used =: 2 S/O (3) Mode switeb + BURNER OPERATION ses The first start is set to "MAN" WODE “MAN” After the start. "AUTO" can be selected + ALC.C. OPERATION +++ When the drum press. has exceeded 0.5MPa(5K) "AUTO" can be selected However being less than 0. SMPa(5K) "AUTO" cannot be selected. cauTH N ! (1) When the boiler is operated with C-O1L and F.0.PUNP is put under { "AUTO" mode, F.0. temperature is set automatically and the following ' operations can be done. : (a) The P.0.pump automatically starts or stops according to : the (emp. of fuel oil before the burner. 4 F.0.temp. low (RW. NO.1 120SEC. or more)--++START : F.0.temp. high(RR. NO.1 80SEC. or less) --+-STOP (b) In the A.C.C.auto mode, the F.0. control valve slightly opens. And, in the MAN mode, the temperature rises tine can be controlled by adjusting the opening of the F.0. control valve. PAG IMABARI 1 P§(b) AVE BOILERS OPERATION WASTER/SLAVE BOILER OUTLINE OPERATING PRINCIPLE The master boiler operates singly or in combination with the Slave boiler, with the slave unit started and stopped automatically depending on the master boiler load: as the master boiler load exceeds 60% the slave boiler automatically starts operating for dual steam generation: as the master boiler load goes down to below 20% the slave unit automatically stops its operation leaving the master boiler alone in service. MASTER BOILER FUNCTIONS (1) Selection of master boiler Hither boiler may be selected as the master unil if its interlock system is in the normal setting (no trip), by depressing the designated "WASTER" push button. (2) Change to steam drum set pressure The master boiler drum pressure setting can be changed by the master boiler manual adjuster alone. And the slave boiler drum pressure setting will be kept to the same level as that of the master unit. (3) Master Boiler automatic start/stop with the master boiler burner in the “AUTO” mode, the master boiler A.C.C. signal (S.D.press.) cause the burner to automatically start and stop {iring (B ~ [I] — C to be referred to). Automatic start ‘The master boiler automatically starts up as the S.D. pressure reaches 1. 18NPa (12K). Automatic stop The master boiler autonatically stops operating as the S.D, _pressure reaches 1. 6ONPa(I6. 3K) 12 IMABARI Pp %(4) Slave boiler automatic start/stop NOTE Once the master/slave boilers operation is established, the slave unit is automatically started and stopped according’ to the change in master boiler load ( B- [1] ~C(e) to be referred to) . Automatic start ‘As the master boiler load increases and F.0. pressure reaches IMPa(1OK) (60% load), the slave boiler automatically start its operation Automatic stop “As the masier boiler load decreases and the F.0. pressure gose dovn to 0.4MPa(4k) (20% load), the slave boiler automatically stop its operation 2 Even vhen the slave-boiler burner was manually ignited and the steam pressure reached the set point thereafter thereby placing the slave boiler in the "AUTO RUN” wode and then only when the slave-boiler burner "AUTO" is selected, the slave boiler does not stop automatically unless the slave boiler steam pressure reaches 1. 6NPa(16.3K) even if the master boiler’s load goes down under 20%. usar B(ce) SLAVE BOILER FUNCTIONS The slave boiler fuctions may be classified as follows by the state of the "SLAVE" lamp. . (1) "SLAVE" Lamp off ‘The slave boiler is not in the “AUTO” mode (A.C.C. and burner AUTO") * The slave boiler is operated by its own A.C.C. signal (S.D. press.). With the "BURNER AUTO" mode, the burner automatically starts and stops firing controlled by the A.C.C. signal, as follows. Automatic start The burner automatically starts firing as the S.D. pressure reaches 1.18MPa(12K) Automatic st ‘he burner automatically stops firing as the S.D. pressure reaches 1. 60MPa(16. 3K). (2) "SLAVE" Lamp flickering The slave boiler is in the "AUTO" mode (A.C.C.and burner "AUTO"). Yhereas the master boiler is not in the “AUTO” mode (A.C. C.and burner “ AUTO"). ‘The slave boiler is operated by its own A.C.C. signal (S.D. PRESS.). With the "BURNER AUTO" mode. the burner automatically starls and stops firing as per ( £1] ~C()()) (3) "SLAVE" Jamp om ‘#The condition ( £1] —C(@)(1)) for master/slave boilers operation has been established. The slave boiler is automatically started and stopped (automatic steaming operation #1) by its own A.C.C. signal (S.D.press.) and also automatically started and stopped (loading operation #2) by the master boiler A.C.C. signal Automatic start When the slave boiler S.D,pressure has reached 1.3MPa(13K) or | when the master boiler F.0.pressure has reached 1. 0MPa (10K) Automatic stop When the slave boiler S.D.pressure has reached (o master set pressure or when the master boiler F.O.pressure has gone down to 0.4MPa (4K) and below _IMABART PAGE 14 2(Gd) MASTER/SLAVE BOILER OPERATION (1) Condition permitting master/stave boiler operation 1) When both the master and slave boilers have gone ino ‘the "AUTO" operation while in the A.C.C. (F.0.) and "BURNER AUTO" mode ( [1] —C(@) (2) to be referred to) The master/slave boilers operation is initiated when either 1) above is established. (2) Waster/slave boilers operation in TANKER SERVICE mode In the master/slave boilers operation. the two boilers are operated in parallel by the master boiler A.C.C. signal (3) Master/slave boilers operation in 1G8 mode. In the IGS mode. (he burner switches to the "MAN" mode and does not perform automatic start/stop operations With both the master and slave boilers in automatic running, they are controlled for parallel operation by the master boiler A.C.C. signal. Also, 30% load limit is applied to both boilers and the minimum combustion rate is limited to 30% of rated boiler load. Notes : #1) “automatic steaming operation” - operation to maintain the slave boiler to be stand-by condition by automatic start at 1.18MPa(12K) and stop at master set press. #2) “loading operation” ~ operation to supply steam to the plant, . a a —_IMABARI| ~ PAGE 15 p32Cn) OPERATION OF BURNER A. _ANUAL OPERATION OF BURNER START Burner Ignition. By turning on the "BNR ON" Button, the following burner ignition sequence starts to ignite the burner Also, the interlock conditions (mark ©) of the ignition sequence are established by automatic operation in A.C.C. Auto Mode. but in Man, node, the manual operation ([}) according to the sequence step is needed. Burner Ignition (1) Boiler start condition established © See (V] -B (2) Boiler run mode selected © See [1] (3) "BNR_ON" BUTTON © [ox [sumer IGNITION SEQUENCE STARTS FAN AUTO START | {F.0.puwp auto star] © FLD. PAN RUN (5) Furnace purge condition set F.D.fan vane opens FULLY ° «Burner atomiz. steam valve full opens “BOILER TRIP” LAMP OFF "BNR OFF" LAMP ON. ————~ WL. PILOT LAMP TO RUNNING MODE ON "BNR ON" LAMP FLICKER "R.D.EAN RUN" LAMP ON——— GL. 2 "F.0.PUMP RUN” LAMP ON——— GL : "FURNACE PURGE START” LAMP FLICKERS-~ Established at burner differential press above 1. 5kPa(150amAq) ATM, STM. V. OPEN" LAMP ON——> #L(6) Furnace purge condition + "FURNACE PURGE START” established LAMP oN. w. Maintained to furnace purge condition for ore than one minute. (7) Burner ign. condition — ; "FURNACE PURGE START” LAMP OFF established : "PURNACE PURGE FINISH" LAMP ON ——-¥L 2 TLGNITION F.0. RATE” LAMP FLICKER... WL" : THGNITION AIR RATE” LAMP FLICKER. - : “HGNITION READY LAMP FLICKER © Furnace purge completed © F.0. temp. is equal to or more than 150 sec.R.W.Nol in viscosity or A~Oil use node (P.0. temp. by-pass) © | F.0.recireula F.0. RECIRC. V. OPEN” LAMP OFF full close F.O.press. at burner header 2 1.0MPa(10 Kg/cm2) F.0. pump run © [Fo.control Y.to specified opening| 2° L, Established at F.0.header press.— above 1. 0MPa(10 Ke/em2) ———_ F fan inlet vane to specified opening | Hed differential air pressure LANP ON L. 0, 2~0. 4kPa(20~40mmAa) (8) Pilot ign. condition : IGNITION READY’————— established LANP ON <5 sec.> © Maintained to pilot ignition condition for 5 sec [+ Established at valve opening 2 “IGNITION F.0. RATE" — 20 ~ 40% LAMP ON * | OR — "FURNACE PURGE FINISH” Established al burner ——————> : "IGNITION AIR RATE” —> WL IMABARL, “PAGE 17 BY@ WAX < 85 a < 3s ) Pilot ignition PILOT BNR PUMP START PILOT BNR IGNITOR SPARK PILOT BNR FLAME EYE "ON" PILOT BNR SOL. VALVE OPEN © Flame eye malfunction — detected ec. > © IGNITION VALIDITY TERM OVER TRIP INTERLOCK CANCEL 0) Pilot ign. check (F.B.detects flame within & sec. ©} "ON" signal is output © “OFF” signal is output ec. > : "PILOT PUMP START” eins LANP. ON PILOT BNR ON WL LAMP ON Trip interlock for normal state al F.E.ORF is changed to interlock for normal state at FE. ON. Cancelled if ignition follows within § minutes after the burner start "IGNITION VALIDITY "RL" TERM OVER" LAMP FLICKER "ONITION PAIL” wee LAMP. FLICKER "BOILER TRIP" "RL" LAMP. FLICKER "BNR OFF” "WL" LAMP FLICKER after pilot ign. start) "PLANE ON" LAMP ON GL | : BOILER TRIP AT IGNITION FAIL *ONITION FAIL” "RL" LAMP. FLICKER "BOILER TRIP” "RLY LAMP FLICKER "BNR OFF" "WL" LAMP FLICKER - IARARI PAGE 18 135a F conruerion oF auver (1) Burner ignition (The following motion is made 3 sec. after check of the pilot burner ignition.) "B.0.Y.OPEN" LAMP ON WL "BNR. BURNING” LAMP. ON WL IGNITION B. 0. RATE" LANP OFF "IGNITION AIR RATE” LAMP OFF F.0. valve full open (12) PILOT BNR IGNITOR SPARK STOP | (F.0.valve opening must have been confirmed or 8 sec. must have passed after pilot BNR ign. start.) (13) Pilot stop (The following motion is made 15 sec. after pilot BNR ignition start) PILOT BNR PUMP STOP : "PILOT PUMP START" LAMP OFF PILOT BNR SOL. VALVE CLOSE "PILOT. BNR.ON” LAMP. OFF "IGNITION READY" LAMP OFF y, 14) Cancel of ignition mode and completion of burner ignition (ignition mode cancel and burner run signals are output to A.C.C.) © F.Bdetecters flame Boiler is made to trip at flame fail. fail and outputs OFF signal "FLAME FAIL” "RL" LAMP FLICKER "BOILER TRIP” LAMP FLICKER 2 "BNR OFF” "RL" LAMP FLICKER RL "| | IGNITION SEQUENCE ____ waar PAGE 19 136B. Mi (ANUAL OPERATI IRNER STOP By selecting the Burner Run Mode to “MAN” and turning on the “BNR ORF” Button. the burner shut-down sequence starts to stop the burner. ‘The interlock conditions (©) of the shut-down sequence are established by ATOMIZER automatic operation, under A.C.C.Auto Mode, but under A.C.C. Man.Mode, the manual operation ((—}) according to the sequence step is necessary. (1) Burner_run mode MANU. "BNR MANU.” LAMP ON WL @) Min. firing rate set. (The firing rate is set to burner ignition condition to pre-establish the burner purge condition.) F.0. CONTROL VALVE TO SPECIFIED OPENING B.D. PAN INLET VANE TO SPECIFIED OPENING (3) "BRR_OFF” BUTTON ON "BNR OFF" LAMP FLICKER =" WL” BURNER STOP SEQUENCE | v (4) Pilot ignition PILOT BNR. PUMP START ————-—>: "PILOT PUMP START” GL LAMP ON PILOT BNR IGNITOR SPARK " set 7 < dgee, > PILOT BNR FLAME EYE "ON" : "PILOT BNR ON" WL PILOT BRR SOL. VALVE OPEN LAMP ON (5) Burner extinguish Nol, 2, F.0.VALVE FULL CLOSE 2 7B.0.¥.OPEN” LAMP. OFF | 2 "BNR BURNING’ LAMP OFF (6) P.O. RECRC. node F.0. RECIRC. VALVE OPEN “P.O, RECIRC ¥. OPEN” wh LAMP ON F.0.PUNP AUTO ON-OFF i(1) Pilot burner check (R.B.detects flam within 6 sec. after the pilot ign. start.) | © ow signal is output {BLAME ON" LANP ON | : ] © “ORF? signal is output : (12) START AT IGNITION PAUL } : IGNITION FAIL" "RL" LAMP FLICKER BAR OFF" "RL" LAMP FLICKER (8) Burner purge start | (F.0.valve is closed and the residual oil within the burner sprayer body is incinerated.) BURNER PURGE VALVE FULL OPEN: "BNR. PURGE V." LAMP Ov (9) Pilot burner ignitor spark stop (6 or more sec. must have passed after pilot burner Ignition Start) iH Completion of burner purge © Burner purge to be held more than 30 sec. or flame is failed. BUR PURGE VALVE FULL CLOSE 1 "BNR. PURGE V." LAMP ORE | BUR ATOMIZ. STM. VALVE FULL CLOSE : "ATW. STM V OPEN’ LAMP OFF PILOT BNR. PUMP STOP PILOT PUMP START” LAMP OFF PILOT BNR. SOL. VALVE CLOSE | "PILOT BNR.ON" LAMP OFF | (ID Furnace after-purge start +: "BURNACE PURGE START" =--—*" WL” LAMP FLICKER Beast enero | = —— above 1. 5kPa(150xmq) | 1D Furnace after-purge condition: "FURNACE PURGE START" ---—> WL established LANP- OW © Maintained to furnace after purge conditions for 30 or more sec. IMABARI| “PAGE 21 135(13) Completion of furnace after-purge : "FURNACE PURGE START’ LANP OFF F.D.FAN AUTO STOP (14) Boiler stop "BNR OFF” LAMP ON-+>-+>+ WL ETION OF BURNER STOP SEQUENCINNING OF BOILER 1, BOILER INDEPENDENT AUTOMATIC OPERATION 4 By selecting the A.C.C.and the Burner Run Mode to “AUTO”. Boiler Automatic Running can be carried out The running conditions and operation are detailed below. () Boiler start condition established © See [V] —B (2) Boiler mode selected © see(I] -B @). A.C.C. rum mode Auto selected F.0.FLOW CONTROL ‘AUTO AIR FLOW CONTROL [AUTO | q selected (o[ MAN START BOILER AUTO OPERATION (4) Burner start ‘ (5) Burner auto mode (aura) jen Stm, Drum Press. is below : "BOILER TRIP” LAMP OFF "BNR OFF" LAMP ON--- - WL + PILOT LAMP TO RUNNING NODE ON © STEAM DRUM PRESS. 0. 5MPa(SK) AND UPPER 2 F.0. FLOW CONTROL "AUTO" INDICATE*<++++++++-> AUTO AIR FLOW CONTROL "AUTO" INDICATE: ++++++-+-—> AUTO 0. 5MPa(Sk) P.0.FLOW Control is and then (o [AUTO] after BNR Ignition start.) : See (I) A Completion of burner ignition : BNR "AUTO" LANP ON: ~BOILER AUTOMATIC OPERATION (6) Steaming up node "STEAMING UP" LAMP OW. WL} Pressure is raised automatically by limiting combusion load in proportion to steam drum pressure. : STEAM DRUM. PRESS LOAD LIMITER (MP a) 0.5 ~1. 0 60%LOAD 1. 0~ 100%LOAD (7) Auto run mode "AUTO RUN’ LAMP ON-+++-29—) WL © STW. Drum press. has reached Master Set Press. (8) Boiler auto stop See C(I} B © Under TANKER SERVICE MODE STM. Drum Press. has reached 1. 60MPa (16. 3K). (9) Boiler auto stand-by "STAND-BY" LAMP ON++=+s--—2 WL (Stand-by state until STM. Drum Press. reaches BOILER Re-Start Press.) (10) Boiler auto start tsee CI} A © Under TANKER SERVICE NODE. STM. Drum Press. has reached 1. 18MPa(I2K). (1D) BURNER ignition completed _1MABARI| PAGE ela @ v @) » AUTOMATIC RUNNING IN MASTER/SLAVE NODE By selecting master and slave boiler "AUTO RUNNIN naster/slave automatic running can be carried out The running condition and operation are detailed below WASTER/SLAVE CONDITION ESTABLISHED © AUTOMATIC RUNNING OF BOTH "SLAVE" LAMP ON-~ BOILER ONLY ESTABLISHED AUTOMATIC RUNNING OF "SLAVE" LANP OFF WASTER BOILER ONLY ESTABLISHED AUTOMATIC RUNNING OF "SLAVE" LAMP FLICKER:-++-—" WL" SLAVE BOILER ONLY ESTABLISHED © SELECT TANKER SERVICE MODE : “TANKER SERVICE" --~ > WL LAMP ON “WASTER/SLAVE™ MODE Automatic Operation Start | pseeeemeneenel| (a) Master boiler automatic operation The same automatic operation that is described in the preceding paragraph "1.Boiler Independent Automatic Operation" is performed. (b) Slave boiler automatic operation ‘The slave boiler automatic operation takes place as follows. STEAMING UP MODE "STEAMING UP" LAMP ON--*~ The steam pressure is raised automatically with the combustion rate controlled in response to the steam drum pressure. BOILER AUTO STOP se The master boiler load has reached 20% and slave steam pressure also has reached the level of master set pressure. or se The steam pressure has reached 1. 60MPa(16. 3K) The burner extinguishing completed. IMABARI E28 142(4) BOILER AUTO STAND-BY E "STAND-BY? LAMP ONe+222e-* WL “WASTER” FO. pressure to the restart level.) (5) BOILER AUTO START : See (1) — Ye The "MASTER" boiler load : The slave boiler load-sustaining has reached 60% operation or sk The “SLAVE” steam pressure : The slave boiler steaming-up has reached 1. 3MPa (13K) operation | (The stand-by state waiting for the “SLAVE” steam pressure or ¥ tion to continue CAUTION 1 SELECTION OF 1.6.8. MODE This selection is used to run the Inert Gas System. 1.6.$, MODE ON (1) Burner auto Stop is by-passed. : (2) The boiler minimum load is limited to the larger value of 30) (3) The soot blower steam valve is fully closed. 2 MASTER/SLAVE NODE SELECTION To be used when selecting either starboard boiler or port boiler as the master boiler. (1) The master/slave boiler automatic operation is performed only vfen the condition for the automatic operation has been established (2) In the master/slave boilers automatic operation. the A.C.C. targets the master boiler steam drum pressure in performing its control function. 3 LOADED OPERATION After the pressure rise is completed and steam drum pressure reaches the set pressure (AUTO RUN/LAMP ON). perform loaded operation of boiler. imap PAGE 26 1e3OPERATION PANEL GRAPHIC FLOW CHART No.1 BOILER Oo Oo oO echt] [gL O=O=O=O2 iin |©sx0s000@) $2 |O)# © oooscea Pe ee || ee) Ce O=0=O0=0=0= =O—=O=0= Osi ‘Toren O (oe ittin ae a aa ‘BURNER 08/0RF evecenct TP ere SELECT SH___MASTER BOWLER S@LECT st. PUSHBUTTON st Sgt un | ox ENERGENCY ore ee we TRIP eae: i, sano |]] aro sure 4,3. CONTROLLER i sito vo BURNER ALTO/NAN NODE SELECT Sf. SLAVE BOILER TRDLCATE. LAMP This is an operation panel fitted on “BOILER CONTROL PANEL”. The operations (A-l ~ B-6) described below show how to start and stop the boiler by way of "BNR ON" / "BNR OFF" switch, when the boiler is in the con! If the burner is in “AUTO mode, the boiler is started and stopped ditions 1 ~ 7 It is Master Boiler is in Burner is in Bach station F.D. fan is in F.0. pump is i automatically based on the boiler load. Thus, it is unnecessary to operate "BNR ON specified as follows. Boiler. "TANKER SERVICE” node. "WANT mode. of ACC is in “AUTO” mode. “AUTO mode. n “AUTO mode, "and “BNR OFF" switch. Boiler is in normal condition (not in alarm condition) TMABAR), PAGE 27 1841, LAMP [RDICATION FOR BURNER IGNITION (A=1) () Boiler stop condition ¥ ooo Fig. (A-1) is the operation panel ° for the boiler prior to operation ee If "BNR ON" is pressed here, the goo 0 ? operation panel will be changed i i é ae th as follows. ee JL [rave on si. ow (a=2) 7 anon st (2) F.D.FAN TRING CONDITION "BNR OFF” Lamp is off. ooo "BNR ON’ Lamp starts (o flicker ° (keeps flickering until F.0. valve popes: is open.) "F.O.P.RUNNING” lamp is on "P.D.FAN RUXNING” Lamp is on If B.D.fam and F.0.pump are in “AUTO” mode, automatically. they start running Atoniz piston valve open order. "ATM. STM. OPEN" lamp ison. See CF a) (A= 3) ooo [-O=8-@-@-<'. oe " =O=O-Cere's L$ @——«s) A AMP OW, LAMP FLICKER, a a [ (3) FURNACE PURGE ORDER START "FURNACE PURGE START" lamp flickers 20 seconds after F.D.fan starts, the mode is switched to “FURNACE PURGE” mode, and furnace purge order is sent from the burner sequencer to ACC. £ "AIR FLOW STATION’ is im “AUTO” node, P.D. fan vane will be opened to the specified degree, and furnace will be purged. Js + LAN OBE os - ___INABAR| PAGE 28 a es(PROW A 3) M7. (A-4) ooo tie ° i 6 6 Latter 45 sec. (a=5) oo°o ° L tronpatter 60506 (A v eit ih seat BE. -0e ox. Jat - + LAMP FLICKER, [ o @ 6) FURNACE PURGE CONDITION | "BURNACE PURGE START” lamp is on. When F.D.fan vane is opened to the specified degree and air draft rea-| ches at the purge rate, "FURNACE PURGE START" lamp is switched "ON" (and starts to count furnace purge time.) 60sec. purge will start If the purge rate is not establis~ hed, the operation will result in (* b) F.0, RECIRC. STOP CONDIDION *P.O.RECIRC. Y. OPEN" lamp is off F. 0, RECIRC. PISTON VALVE CLOSE order 1 "P.0.TBMP. INTERLOCK NORMAL” lamp is not on, F.0.RECIRC VALVE CLOSE order will be cancelled with | the operation resulting in (# b). Confira that the lamp is on before starting the boiler, (refer to * a) SWITCHING TO IGNITION MODE Ignition order is sent from the burner sequencer to ACC. "RURNACE PURGE START" lamp is off “PURNACE PURGE FINISH” Lamp is on “IGNITION F.0.RATE" Lamp is flicked| "IGNITION AIR RATE” Lamp is flicker] "IGNITION READY" lamp is flicker If the each rate (F.0. & AIR) is not established, the operation will) result in Cb). + LANP OFF,(7) ESTABLISED F. 0. RATE. CONDITION “FURNACE PURGE FINISH” lamp is off. “FINISH” lamp is switehed off when F.0. or AIR rate is reached. “IGNITION F.0.RATE" Lamp is on. when F.0.pressure and F.0.control | valve reach the specified rates: If not, the operation will result in (# bd) (A= 8) (8) IGNITION AIR RATE REACHED TOGETHER ooo WITH F.0.AND ATR RATES. cot | "IGNITION AIR RATE” Lamp is on when air draft reaches the speci- fied rate for ignition. If not, the operation will result in (#b). “IGNITION READY” lamp is on when F.O.and AIR rates are reached. If either F.0. or AIR rate is mot | reached, lamp starts to flicker and the operation will result in (*b) (9) PILOT PUNP START CONDITION "PILOT PUMP START amp is on vhen ignition rate is reached and the pilot pump is started. | ME | ove on. YEG «cane eusctsn, [+ - tau ove IMABARI| z 30 127(FROM_A~ 9) re | (A-10) (10) IGNITOR SPARK CONDITION. ooo “PILOT BNR.ON" lamp is on = tis PILOT SOL.V. OPEN order. | The lamp is switched on when } sett ignitor sparks and pilot flame a is given out. (11) F.0.PISTON VALVE OPEN IN IGNITION ooo MODE. “BNR.ON” Lamp is on. ° : 5 No.1 F.0.Y.OPEN” lamp is on. "No.2 F.0.¥. OPEN" Lamp is on. "BNR. BURNING’ lamp is on. 3° The F.0.V. open is made 3 sec. after check of the pilot burner ignition. "IGNITION P.O. RATE" lamp is off "IGNITION AIR RATE" lamp is off (A-12) (12) COMPLETION OF BNR. IGNITION ooo SEQUENCE ° [CeO erik “IGNITION READY” Lamp is off "PILOT PUMP START” Lamp is off. —O—0-0=@2< "i. a PILOT PUMP STOP order. j I “Pier m.OF 6 bo lamp is off. PILOT SOL.¥. CLOSE order. - | ‘ 1 WB. | - sane ow, c+ + LAMP PLICKER, [ [+ + + LAMP OFF. | JNABARI| - ~ ee PAGE 31 IS2, LANP INDICATE FOR BURNER EXTINGUISHMENT (B=) ooo eit ih set LI Le oF" 08] (B-2) ooo [=O=8=0-@2015, fe} rrr =O=O-O=O2015 a) L_—@—=' me Tt 4 After 2 sec. (B= 3) ooo [-O=@-6-—Or51Ki, @ Q=0=0=9=0=@= -0=0-0=@22ii: + + LAMP OW, + + LAMP OFF. ay @ @) BOILER FIRING CONDITION Fig(B-l) for the boiler firing condition. If "BNR OFF the operation panel will be changed as fol Lows. is the operation panel is pressed here, BURNER STOP PROCEDURES. "BNR OX" "BUR OFF” lamp starts to flicker (keeps flickering until the burner is extinguished.) “IGNITION READY” Lamp is on. Ignition order to A.C.C. "PILOT PUMP START” Lamp is on. PILOT PUMP START order. "PILOT BNR OX" lamp is on. PILOT SOL.V. OPEN order. Start of burner purge initial step. lamp is off. START OF BURNER GUN PURGE. "BNR. BURNING” Lamp is off "No.1 F.0.¥.OPEX” lamp is off. "No.2 F.0.V.OPEN” lamp is off. | P.O. PISTON VALVE CLOSE order. "P.O.P.RUNNING” lamp is off. F,0.PUNP STOP order. "P.0.RECIRC. V. OPEN" Lamp is on. F,0.RECIRC MODE order. "BNR. PURGE. V" Lamp is on. BNR. PURGE. VALVE OPEN order. If @ feedback signal contrary to the order is returned, the opera- tion will result in * a a ____IMABARI] PAGE 32 108(FROM B— 3) JL" FLAWE ov" continues (B-4) for max, 15 sec (A) START OF FURNACE PURGE. | ooo BNR. PURGE V." lamp is off ° ii BNR PURGE PISTON VALVE CLOSE order. IGNITION READY" lamp is of f The mode is changed to "FURNACE PURGE” from "IGNITION." "PILOT BNR.ON" lamp is off. PILOT SOL.Y. CLOSE order. "PILOT PUMP START” lamp is off. PILOT PUMP STOP order. "ATW. STH.Y.OPEN" Jaap is off ATOMIZ PISTON VALVE CLOSE order. | If @ feedback signal contrary to the order is returned, the operation vill result in * a. "PURNACE PURGE START" lamp is flicker. The lamp keeps flickering until F.D, fan vane is opened to the specified | degree and air draft reaches to the purge rate. (B~ 5) : (5) FURNACE PURGE CONDITION "PURNACE PURGE START” lamp is on. Air draft has reached at the purge rate (Purge time counting starts.) Purge for 30 seconds. - IMABARI ae Sneeaat PAGE 3: + LAMP FLICKER, [+ + + LAMP OFF, 190(ron B= 5) rh (B~ 6) (6) PURGE COMPLETED AND BOILER NOT IN OPERATION Ret “BNR OFF” Lamp is on. Burner is extinguished. "FURNACE PURGE START" Jamp is off Furnace purge node ended. "B.D.FAN RUNNING” Lamp is off F.D.FAN STOP order. * F.D.fan is automatically stopped if 15 minutes have passed since the start of boiler (A-1). Otherwise, it keeps operating until affer the 15 minutes: CAUTION a Ifa feed-back signal contrary to the burner sequence order signal is returned, the corresponding lamp flickers and an alarm is given. If something is wrong with "BOILER INTERLOCK”, the boiler is stopped immediately. *b If the specified rate is not reached and the lamp keeps flickering, the boiler is tripped by “IGNITION VALIDITY TERM OVER” after 5 minutes. Ws ave on, JEG town eurcxen, [+ = user or. AMABARI| PAGE 34 ‘sfE. _INTERLOCK BY-PASS OPERATION This mode is selected when the boiler run condition or the burner control system can not be used. The running mode is selected according to its purpose as follows. 1, F.0. TEMP. BY-PASS MODE Mode with Steam Jet Atomizer used an A-oil used. By-pass operation <0. T.BY-PASS" SW. | ON |———>: "F. 0.7. BY-PASS” +» ~~ LAMP FLICKER (see C1] — BD 2, F.E. BY-PASS MODE This mode is selected when the boiler can not be stopped though the cleaning and check of the flame eyes are headed during running of the boiler. or when it is desired to avoid the boiler trip due to the keen sensitivity of the flame eyes under sharp changes of the boiler load In this case. the flame must always be watched at the boiler side. B operation During normal running | () One of the flame eyes detects flame fail v "P.E.BY-PASS” SWITH = — PB. BY-PASS on LANP FLICKER > FLAME PAIL ALARM (BOILER NOT > BOILER TRIP (1) One of the flame eyes detectors flane fail (2) Both of F.E."s detect flame fail > FLANE FAIL BOILER TRIP CAUTION uring F.B. By-pass Run. walching must always take place at the boiler side, oP YL TRIP) IMABAR I PAGE 35, $eon EMERG. a @ @) a) 6) (6) EMERGENCY RUN MODE This mode is selected when the Burner Sequencer cannot be used. The burner start in this mode follows the operating procedure belby. IGNITE OPERATION START OPERATION MODE S¥ “EMERG.” —> : "EMERGENCY MODE” LAMP ON-—> RL Established of start condition © |The operator directly checks and confirms the conditions in (V] B Select of boiler run mode © | the operator directly checks and selects the running mode in (1] B Furnace purge © |The F.D.Pan is started. the F.D.Fan Inlet Vane is full opened. the furnace purge is maintained for 3 minutes. and Main burner ignition condition set F. 0, PUMP MANUAL. START © | FLO.CONTROL VALVE —> Opening 5 ~ 15% TO SPECIFIED OPENING © | F.D.PAN INLET VANE TO SPECIFIED OPENING Pilot burner ignition —> BNR. differential air press. 0.2 ~ 0. 4kPa (20~ 40mmAq) —>"PILOT BNR" LAN. OW “PILOT BNR" SWITCH © PILOT BURNER IGNITION» : "PLANE ON" ---- LAMP. ON se MABARI PAGE 36 153oO CAUTION 1, Time to (ry ignition of the pilot burner is to be 15 sec. at aaxiaun, i If the pilot burner fails 1o be ignited within 15 see, | the pilot BNR IGN. S¥ is to be turned OF Cheek of Ignition Fail. If the ignition fails. ignition is to be re-attempted from (4) Furnace Purge. Burner ignition (ignition of the pilot BNR is checked. F.0.Piston Valve is opened. and ignition is tried.) F.0, V/V SELECT S¥.——--——> No. 1 F.0.V. OPEN-+> WL No.2 F.0. V. OPEN: WL Ee eae nnn NRRRRROEEY| (U1 ENeOe CAUTION 1, Time to try ignition of the main burner is to be 10 sec. at maximus Pilot Burner Ign. Sw and F.0.Yalve Open SW are to be set to "Intermediate Position” (spring-return with hand off) within 10 sec. 2, If Ignition fails, ignition is to be re-attempted from (4) Furnace Purge. CAUTION 1, During the emergency running. the machine-side manual operation and watching at the machine side must always take place. The boiler trip interlock conditions are to be checked and confirmed by direct watching. _—_IMABARID PAGE 3 IS2, Interlock nor. condition of emergency run mode (1) FLD. FAN RUNNING (2) NOT DRUM WATER LEVEL LO¥-LOW (3) FLAME ON (F.0. VALVE OPEN CONDITION) (4) EMERG. STOP (MAN. TRIP) The boiler start conditions in [V] B, except the above. are to be checked and confirmed directly by the operator.1. Cm INNING OF F. FD. FAN (1) 2 F.D.fans in total (1 unit/I boiler) are provided Operate the F.D. fan for each boiler. (2) F.D.fam with its mode sviteh in "AUTO", automatically starts and stops running with burner start/stop conmands. Hovever. F.D.fan continues running for 15 minutes after starting to run automatically. In the case of boiler trip. F.D.fan continues its operation for 10 minute and stops running. F.0. PUNP (1) 2 F.0. pumps are provided per ship 1 F.0.pump is used normally as the working unit. (2) F.0.pump with ils mode switch in "AUTO", automatically starts and stops | running with burner start/stop commands. F.O.RECIC is carried out by automatically starting F.0.punp so that F.0. temperature of burner header does not fall too much while the burner is in operation. iMaBai| PAGE 39 Sb(Vv) SOOT BLOWER OPERATION | soor BLOWER OPERATION stant | ———— (1) | DRAIN VALY PULL OPEN (2)—"8.B.STM. INLET V/V" SELECT S¥, [om] © UP TAKE VALVE CLOSE 2 "UP TAKE VALVE OPEN" LAMP OFF © TANKER SERVICE MODE “TANKER SERVICE" LAMP ON-—* | WL (3) SOOT BLOWER STEAN VALVE OPEN < 3min > WARMING OF PIPING LINE | 4) | DRAIN VALVE FULL CLOSE (5) | No.1 SOOT BLOWER START/STOP No.1 SOOT BLOWER BLOWING (6) | No.2 SOOT BLOWER START/STOP No.2 SOOT BLOWER BLOWING (i) —"S.B.STHLINLET V/V" SELECT S¥. "SOOT BLOER PISTON V. | cuose OPEN" LAMP OFF (8) | DRAIN VALVE FULL OPEN | soor BLOWER OPERATION FINISH CAUTION 1, RELATION SOOT BLOBING AND BOILER LOAD The soot blower shall be operated. as a rule, during a boiler load exceeding 50% INTERLOCK BETWEEN SOOT BLOWER AND IGS The soot blower and the IGS are interlocked each other. During running of any soot blower, IGS can not be operated And during the IGS is operated, any soot blower can not be run.tv ALARMS A, — PATTERNS OF ALARM If an abnormality should occur during running of the boiler an alara is given to alert the operator. The pattern of alarms is deseribed below. The operation of these alarms must follow the sequential order. on ABNORMAL orr 1 J ! — \ on aie 1 ALARK. LAMP i Refer to botton of ovr this page \ ! i on al WITH "BZ. STOP" uzzeR { BUTTON ON. OFF t BUZZER STOPS. ieee a 4 "BL. STOP" on i BUTTON | $OFF \ | | “Lame reser? | BurToN #1: With “BZ. STOP” Buiton ON. {licker stops and continuous illumination follows. Lamp is disilluminated by turning on "LAMP RESET" Button after normal state is restored. NOTE The alarm lamp does not disilluminate, even after normal state has been restored, unless "LAMP RESET” Button is turned on after the turn-on of | "BZ STOP" Button. Also. the alarm lamp cau not be turned off before nomal state has been restored. | IMADART i SSBOILER SET POINT LIST /S9NBT-25¢-Y500 K1303/5/7/9/11 BOILER SET POINT LIST SMOKE CONTROL PANEL RCC ;ENGINE CONTROL CONSOLE TM ;TEMP. MONITOR FB. ;PLAME BYE TS, ;TEMP. SW. ‘SEQ. ;SEQUENCER FT ;BLOW TRANS PS. PRESS. SW. . MONITOR SF. }PRESS, TRANS. SET POINT TAG. No. DESCRIPTION aad TIMER alam | omaip) | Nog. 1578 | DRUM LEVEL HIGH us| 200m | - - | 10 sec. 1578 | DRUM LEVEL LOW us| -200un | - — | 10 sec. 1588 | DRUM LEVEL LOW-LoW 4s — | 240mm] - | 0600, 0.25 MPa 173B FUEL OIL PRESS. LOW PS (2.5 K) _ - 4 sec. 1743 | FUEL OIL PRESS.LOW-LOW | PS Soa 0 sec ~ ‘ATOMIZ. STEAM PRESS, 0.94 MPa _ 155B LOW PS (3.5K) a 4 sec. ‘ATOMIZ.. STEAM PRESS. — [ozwal _ ee PS an 0 see. 1.72 Ya - — | Sm, DRUM PRESS. HIGH Pee ate ae 4 sec. 0,49 MPa _ _ ‘STM. DRUM PRESS. LOW PT (5 K) ca 4 sec. 1198 | FEED WATER PRESS. LOW eo - 4 sec. a7X) 1708 | CONT. AIR PRESS. LOW ws [ee] fH - 4 sec. - CONT, AIR PRESS. y [osm] _ | eee PS a 0 sec. SMOKE | RENGELMAN | a 1648 | SHOKE HIGH Soria emer 5 sec. jeeK1303/5/7/9/11 N57-250-¥500 SET POINT TAG. No. DESCRIPTION ace ——J THER ALARM | TRIP Nor. 1475 | FUEL OIL TEMP. HIGH my | RA HOL) — | 10 sec. 50 sec. R.W.NO.1 1473 | FUEL OIL TEMP. LOW m | itt | oT — | 10 sec. y Z [RW NOT 147 | 7-0. PUMP AUTO START ™ - - 120 sec.| 10 sec. & STOP 7 ~ | > 60 sec. TGNITION VALIDITY = | 1408 | Tepe OVER | FB — | No FLang| = 5 ain, 14op | PILOT BURNER T6NITION ai ele Ae FAIL 14g | MAIN BURNER F6N7TION PE — | wo ruane} 7 see. 140B FLAME FAIL FAB. - NO FLAME oa 1 sec. _ FLAME ON | FLAME ON ~ 1408 | FLAME EYE ABNORMAL FB. at ar — | 10 see. - ___| bur.stor | Fur, PuRcE prt | BOILER AUTO stant a _ — [iiema] (AT TANKER SERVICE MODE) (12 ) py | BOUER AvTo STOP 8 _ _ 1.60 MPa _ (AT TANKER SERVICE MODE) (16.3 K) BOILER AUTO START q Z — [o.sdmPal PRL | (at eco Mone) ‘s (5.5 K) _, | BOULER AUTO STOP - — [o.gemraf _ PT | (at Boo 4o0e) s (10 X) prez | JONITION F.0. RATE ra - = [0.29 MPa} 19 coo, (3K) -9- EfK1303/5/7/9/11 N57-25C-¥500 =e eT POINT TAG. Yo. DBSCRIPTION aa TIMER auagd | TRIP | NOR. —_|— ——>- _ = 1.47 KPa . FX-1 | FURNACE PuRGE ATR RATE | Pr iso amp) 18 4 _ _ | LAT ka FX-1 AFTER PURGE AIR RATE PT (150 mmAq) 30 sec. 0.34 KPa PX-1 - a IGNITION ATR RARE Pr (os uaa) | 19 see. BoP-1 | FURNACE PURGE TIME TIMER - - - | tain, BCP-1 AFTER PURGE TIME TIMER > ol Oa BCP-1 BURNER POST PURGE TIME TIMER - > - 30 sec. Bop-1 | LGN. VALIDITY TERM TIMER s - - | Sain STOP AT BCP-1 F.D. FAN TRIP GSP oa BUR. RUN al 0 sec. — F.O.V. 1038, 1058, AMM. V. 698,638. | NOL us| purce.y | = — — | 10 sec. 658,538 RECIRC V. as a S.B. Ve F.0. VL 103B,105B | PISTION VALVE * Ls al ATM. V. > 5 sec. 698,658 | ABNORMAL PINE. - acp-1 | PILOT PUMP TRIP csp | TRIP - - | 0 sec. BCP-1 MAIN SOURCE FAILURE RELAY a JNO VOLTAGE} Ol 0 sec. | Bep-1 | ABC. ABNORMAL CONTROLLER} ABNORMAL | — ~ | 0 see. BoP-1 | BMS. ABNORMAL BCP-1 MANUAL TRIP. ‘SW. - ON - 0 sec. fbrC., INSTRUCTION MANUAL OF AUTONATIC BOILER CONTROL $ (11 (0 Ca) uv) GENERAL DESCRIPTION OF AUTOMATIC BOILER CONTROL SYSTEM 1. AUTOMATIC COMBUSTION CONTROL 2. AUTOMATIC FEED WATER CONTROL OPERATING INSTRUCTIONS OF AUTOMATIC BOILER CONTROL SYSTEN 1. MASTER STATION 2. AIR FLOW STATION 3. DRUN LEVEL STATION 4. STAND-BY MANUAL STATION CONFIGURATION OF AUTOMATIC BOILER CONTROL SYSTEM 1. NOMENCLATURE AND FUNCTION 2. FUNCTION OF KEYS 3. CHANGE METHOD OF DATA ALARM DISPLAY(1 }__ GENERAL DESCRIPTION OF AUTOMATIC BOILER CONTROL SYSTEM This system (A.B.C.) Is composed of the automatic combustion control system (A.C.C.) and the automatic feed water control system (P.¥.R.). Composition of Control System NASTER CONTROLLER r A.C. c [ AIR FLOW CONTROLLER A.B. c. W. C.— FLW, CONTROL 1, AUTOMATIC COMBUSTION CONTROL In this systew, the fuel oil injection, and the combustion air quantity for injection of fuel oil required for combustion are controlled at optimum in order to maintain steam pressure to a given point for the required steam (low rate. The control loops and functions of the A.C.C.are detailed belov. (1) MASTER CONTROL (a) MASTER CONTROL LOOP This loop detects the steam drum pressure (aaster press.) compares this pressure with a preset pressure (aster set press.). performs the "PH" operation. and outputs the F.0.flow control signal (naster signal) so as to set the deviation to "0" Also, the master control comprises the following sub-loops. (b) F.0.FLOW CASCADE CONTROL SUB-LOOP The fuel oil flow control signal (aster Signal) and the oil pressure before the burner are compared with the signal (feed back) converted to fuel oil flow rate. "PEI" operation is performed. and the operating signal to F.0.Cont.¥. is controlled so as to set the deviation to zero. (c) HOT START & STEAMING UP CONTROL SUB-LOOP The Master Set Press. is controlled so as to obtain press. rise rate. from steam drum press. of 0.5MPa(SK) to normal press. 1.5MPa(15K). (@) BURNER ON-OFF CONTROL SUB-LOOP Steam drum press. (Master Press.) is detected, and the burner is automatically ignited and shul-dovn, The set points for ignition and shout-down are automatically selected by Boiler Mode. __INABARI nec Ke(e) STEAM DUMP CONTROL SUB-LOOP The signal during activation of 1.6.5. adds a limiter to ihe fuel oil flow rate (Master Cont. Signal) (£) LOAD LIMITTER CIRCUIT This circuit Limits the increment of master signal. using the air flow signal (q) BURNER IGNITION SET CIRCUIT This circuit sets the F.0.control valve to an opening according to the burner ignition sequence. The "OPEN signal is detected to range withis the ignition rate, and output to the outside. (h) MASTER STATION The set point of the steam drum press. (master press.) is set and displayed, and the processed point is indicated. The F.0. Control Valve Open Order is changed over to Auto/Man. with | this change-over displayed. and the manual operation and output display and output display are perfomed. (2) AIR FLOW CONTROL (a) AIR FLOW CONTROL LooP This loop compares the demand windbox differential pressure as determined by the F.0.Flow control signal (master signal) with the windbox differential pressure as measured, performs the "P+I" operation, and controls the operating signal of the No.1 F.D.fan inlet vane control drive so as to set the deviation to "0". This is intended to maintain constantly the best combustion by controlling the air flow for an optimum ratio of air/fuel corresponding to a boiler load. Also, the air flow controls are composed of the following sub loops. (b) OPERATION CIRCUIT OF DEMANDED WINDBOX DIFFERENTIAL PRESSURE This circuit calculates the demanded windbox differential pressure by scompensating the windbox differential press. as deternind by the F.0 flow (F.0.Burning Press.) for the boiler characteristies and performing the variation addition (air, priority circuit) of the master signal # This compensation to be carried out at the combustion test of the boiler (c) SETTING OF F.0./AIR EXCESS AIR RATIO | The demanded windbox differential press. can be raised or reduced. using the fuel/air ratio adjuster. The excess air ratio is adjustable over a range of 0.5 to 1.8 and | IMABARI| acc 3 normally set to 1.0 MS2 «@) @ @) (b) BURNER IGNITION MODE The F.D.Fan Inlet Vane is set to opening according to the burner ignition sequence. ‘The air {low signal is detected to range within the Furnace Purge, and output to the outside. The air flow signal is detected to range within the Ign.Mode and output to the outside AIR FLOW STATION The ratio value of fuel oil/air flow is normally set and displayed, using this adjuster. The Air Flow Control Drive Open Order is changed over to Auto/Man, with this change-over displayed, and the manual operation and output display are performed AUTOMATIC FEED WATER CONTROL F.W. CONTROL LOOP The steam drum water level i water Level, and tvo-element the feed water quantity so a signal is supplied as feed-f The "PHI" operation is perfo water level set and the dete the operating signal of the as to zero the deviation Also, the F.W.C.comprises th DRUM LEVEL STATION The set point of the drum le point is indicated s detected and compared with the preset control is performed for the control of s to zero the deviation, and steam flow rd signal when load change. rned in comparison between the above cted water level of the steam drum, and feed water contro! valve is controlled so 1e functions below vel is set and displayed, and the process The F.¥.Control Valve Open Order is changed over to Auto/Man, with this change-over displayed, are perforned. and the manual operation and output display TMABARI| 166This section explains the instructions and indications on the | graphic panel (GP) of ABC system, The folloving screen is displayed once GP is started Please refer to the instruction manual of "Boiler Control Panel” for how to operate GP while the boiler is working. Fij(r2j(rs3j(r4|(rs5|(r6j(r7)[r 8] re] CF Le 2 [F.0. aoa CONT. z Run} our H lourrur Fo. dy} waa @ MSTSP. _NSTEV F. Ar aia we LVLSPLYLEV 8. FLW eqn Te No.1 LEVEL ONT : lel J(ent THE COMPOSITION OF A PICTURE (No.1 BOILER)1 ComasteR set POINT RAISE 2 LOVER S¥. (5-1)F.0. CONTROL, YALVE AUTO/ MAN. SELECTO s 0, CONTROL VALVE OPEN —Pamek_iwnicart! (6) F.0. CONTROL NSTPY Fo P. IF. 0. CONT. V lourpur fF 0. 0) VALVE RAISE # LOWER Sf. (5-2) F. 0. CONTROL VALVE avTO/ a @ @ @ The set and display of the set paint and process of the steam drum press: The change-over and display of Auto/Man of F.0.Comtrol Valve Order, as well as the manual operation and output diaplay, are performed. WASTER SET RAISE & LOWER SW. This is the switch for manual setting of the Master Set Point. The master set pressure can only be set on the master boiler alone. Also the initial set at power-on is made to 1. 6MPa (15k) BAR GRAPH OF MASTER SET POINT INDICATOR. The left-hand bar graph shows Waster pressure set point. BAR GRAPH OF MASTER PROCESS INDICATOR The senter bar graph shows Master Process point (Press) BAR GRAPH OF F.0.FLOW INDICATOR. The right-hand bar graph shows F. 0. burning pressure. (5) F.0. CONTROL MAN. /AUTO SELECTOR SW. Switches for selecting MAN or AUTO mode for the operation of F.0.control valve. (6) F.0.CONTROL VALVE RAISE & LOWER S¥. The F.0.Control Valve Open Order can be manually operated in the Man Mode. CAUTION In EMERGENCY MODE or F.0. TEMP. BY-PASS MODE, the Nan Mode is forced to be selected. “REC IMABARI 6 M68c | P i CD PUBL/ATR el tanto tise | Woes 1 | all || | s-p8.0.9H4 : Covrto. oni It AUTO/MAN, L The change-over and display of Auto/Man fal the F-O-FAN IMLET YAKE CONTROL DRIVE OPEN ORDER, as well as the manual operation and output display, are perfoned. | The manual set and indication of the Fuel/Air| OB) RATIO. AIRSP ALRPY Ratio (Excess Air Ratio) are perfoned. (1) FUBL/AIR RATIO RAISE & LOVER SW. This switeh is used for the manual set of the Puel/Air Ratio. The initial set at power-on is made to 0. CAUTION The fuel/air ratio is tested and adjusted } at the actual combustion adjustment test. } so that the optinum combustion air rate { canbe obtained at the set point of 0 unde normal running node Serene SELECTOR S¥. FAN CONT. DELVE OPEN -ORDERIADICATELIF DF VANE pow | oUTPUT (F_0-Gx|qanu CONTROL DEIVE| ») RAISE & LovER| : sh (2) BAR GRAPH OP FUBL/ATR RATIO. INDICATOR The left-hand bar graph indicates the scale factor (-50%~450%) to the combustion air quantity established at the combustion adjustment test. Also, the initial set at power-on is made too. (8-2) FD. FAN CONTROL DRIVE (3) BAR GRAPH OF AIR FLOW SET POINT The center bar graph shows Air Flow set point. (4) BAR GRAPH OF AIR FLOW(BURNER DRAFT LOSS) The right-hand bar graph shows AIR FLOW(O~ 100%) (5) F.D.FAN MAN. /AUTO SELECTOR SW. This switch is used to select the operation of the F.D.Fan Inlet Vane Control Drive to Man. or Auto. In EMERGENCY MODE or P.O. TEMP. BY-PASS MODE. the Man. Mode is forced to be selected. The F.D.Fan Inlet Vane Control Drive Open Order can be manually operated in the Man Mode. (6) F.D.PAN CONTROL DRIVE RAISE & LOWER SW a | _ltttan VOOf] LYLSP LVLPY The set and display of the steam drum water level, as well as the imdication of the process value, are performed. (opRUN LeveL set Port The change-over and display of Auto/Man of ee the F.¥.CONTROL VALVE OPEN ORDER. as well as the manual operation and output display, are performed (1) DRUM LEVEL SET POINT RAISE & LOWER S¥. This is the switch for the manual set of the drum level set point. At the time of power-on, the initial set | point is made to £0 (Wor). s-10F¥, CONTROL, VALVE AUTO/ MAN. SELECTOR (2) BAR GRAPH OF DRUM LEVEL SET POINT The left-hand bar graph shows Drum F.¥, CONTROL | vatve oven level set point FEED CONT (Lawn) oyr.r.covraot | [OUTPUT fF 0, ds)(MANU} (3) BAR GRAPH OF LEVEL PROCESS vavye >} ~~ The senter bar graph shows Drum POR level process point. ” No.1 LEVEL cnr (6-2). ¥, CONTROL, VALVE: (4) BAR GRAPH OF STEAM FLOW The right-hand bar graph shows Steam Flow. (5) F.W.CONTROL AUTO/MAN. SELECTOR S¥. This switch is for selecting the operation of F.¥.control valve to Man or Auto Mode. (6) F.W.CONTROL VALVE RAISE & LOWER S¥. The Feed Water Control Valve Open Order can be manually operated in the Man Node 172#3] 0CONT, JUNE DIGITAL & GRAPE ESPLAT F.D.R.CONTROL DRIVE DIGITAL & ‘BAR GRAPH DISPLAT. ERD HATER COT. VALVE DIGITAL & BAR GRAPH DISPLAY FLOCOMT.TALYE INC. HEY "STAND-BY MANUAL” STATION Vhen trouble happens at ABC controller [Ill] ~ a, and/or ABC operation panel (GP) CM] , concerned out-put become MANUAL mode automatically and make it possible to operate each control valve(F.0. FLOR, F.D.FAN DRIVE, FEED FATER)by manual Acst0 — ROC. STAMD-ST OBE DISPLAY 1 SIL MAE (0, CONT VALE) ALF.CONT. STANT ADD DISPLAY 31 SIOML MME. 0.. CON, DITE) FED FONT. STAND-OT HOE DISPLAY #1 SGML NME (PEED ATER CONT. YALE) .OLCONT. VALE ORC. EY FLO CONT. WUE HEY F.C RE I Bt a LECTIN EC, BT (<) (>) wm [vy fpscomame pr | 2 aE) ER CUT TE i. HE = ed WTR COM. HYE EC. EY (-<} (>) om [vm ED ATER CON. AUE EE MQe- Oo + MODE DISPLAY On normal condition, "AUTO" indication is always showed on said controller, and output signal from ABC controller pass through as out-put signal On abnormal condition, indication turn to "MANU" and out-put signal from ABC controller is cancelled. And valve increase/decrease operation should be done by %3 key. + NODE CHANGE KEY It is operative when %#1 mode indication shows “AUTO” On "WANU" indicated condition(abnormal condition), in order to out-put signal from ABC controller pass through to operation side, push 2 key for change over mode to "AUTO" after said controller recovered. (@rease refer following chapter [IV] indication of trouble regarding alarm indication.) + OUTPUT INCREASE & DECREASE KEY Operative only when %1 indication mode shows "MANU" (Weans controller is abnormal condition) 7 = CC IMABARI 9 1?10 GP COMMUNICATION TO ACS1O COMMUNICATION IGURATION OF AUTOMATIC TEM 1, NOMENCLATURE AND FUNCTION FUNCTION jG an eee o] & © ne 1 : ACSI OG 7 aR ROTATIONAL ec} (EE SWITCH a Bl) | pe to wae ‘| PAC ID | Rotational switch to set 1D numbers for communication between PAC and GP. * Setting Is unnecessary once oulfilted. 172FUNCTION LED indication of Self-Diagnosis (Please see (IV)Alarm display (2)-) Digital Input No.1 Input status is display LED lamp "ON" — DI Nol. ON LED lamp “OFF” — DI Nol. OFF Digital Input No.2 Input status is display LED lamp "ON" — DI No2. ON LED lamp “OFF” > D1 No2. OFF Digital Input No.3 Input status is display LED lamp "ON" — DI No3. ON LED Lamp "OFF" — DI No3. OFF Digital Input No.4 Input status is display LED lamp "ON" — DI Nod. ON LED lamp “OFF” — DI Nod. OFF Digital Input No.5 Input status is display LED lamp "ON" + DI NoS. OW LED lamp “OFF” > DI No5. OFF Digital Input No.6 Input status is display LED lamp "ON" > DI No6. ON LED lamp “OFF” — DI No6. OFF ital Input No.7 Inpul status is display LED lamp "ON" => DI Nov. OW LED lamp “ORF” > DI Nov. OFF CC IMABARI| in 123NAME LED LAMP FUNCTION Digital Output No.1 Output status is display LED lamp "ON" > DO Nol. ON | LED lamp "OFF" > DO Nol. OFF Digital Output No.2 Output status is display LED lamp "ON" —> DO No2. ON LED lamp "OFF" > DO No2. OFF Digital Output No.3 Output status is display LED Lamp "ON" DO No3. ON LED lamp “OFF” — DO No3. OFF Digital Output No.4 Output status is display LED Lamp "OX — DO Nod. ON LED Lamp "OFF" — DO Nod. OFF Digital Output No.5 Output status is display LED Lamp "ON" — DO Nos. ON LED lamp “OFF” —* DO No5. OFF Digital Output No.6 Output status is display LED lamp "ON" — DO Nob. ON LED lamp "OFF" —> DO No6. OFF Digital Output No.7 Output status is display LED lamp "ON" > DO NoT. ON LED lamp "OFF" — DO No7. OFF Digital Output No.8 output status is display LED lamp "ON" © DO No8. ON (CPU Run) LED lamp “ORR” > DO No8. OFF (CPU Stop) This lamp is "ON" while CPU is runningie As you press the [D |key, MENU is display. The menu switches function as follows, ([P 1D] : to display parameters and change set PID parameter screen [% P] : to display parameters and change set %-type parameter screen. (T P] : to display parameters and change set time parameter screen. [TBLJ : to display parameters and change set broken-line table screen. [A 10] : to display AI/AO data screen. [D100] : to display DI/D0 data screen [S W) : to display S¥ screen. : to display error screen. : to end menu sereen TEN KEY values values values values on on on on DATA ENTRY KEY IMABARI| 1B 178The switch sereen (Fig. 2) will be displayed for data setting on every screen called throught aenu (Fig. 1) The ten The ar and (Fig 2) END AM Lot 1 : Cursor Up [4 1 : Cursor Down [ = 1 : Cursor Left [= 1 : Cursor Right [ PJ :To next page [CLR] : Data Cancellation set data can be cheanged by using the above keys (fig 2)and keys (fig! —@) set data can only be changed for "PID", "XP", "TP", and "TBL", amanu is selected for those other that stated above, cursor key data cancellation key will not work.) ace IABARI 4 196When pressed. Hhen pressed (Fig 3-D, PID Paraneter Pip PCH) 999.9 Limin) 99. 99 Dimin) 99.99 EIE) Ly _ ie 8 Parameter (MIN) | No No 99 11 99.99 2-99.99 12 99.99 3 99.99 18 99.99 499.99 14 99.99 5 99.99 15 99.99 5 7 8 9 99.99 16 99.99 99.99 17 99.99 99.99 18 99.99 99.99 19 99.99 Lin s9.99 20 99.99 | (Fig 3-2) Percent Parameter(®) || No no 1 4999.9 U1 2 4999.9 12 3 4999.9 13, 4 4999.9 14 5 4999.9 15 5 4999.9 16 1 8 9 0 When pressed, 4999.9 ro0a.9 || 4999.9 4999.9 999.9 $999.9 ¥999.9 17 9 +9999 18 9 4999.9 19 9 4999. 9 +999. +999, +999. 1999) ae Table 1 @® When pressed.|| yoy) 'y, 999. 999. 999. 9 9 9 999.9 999.9 999.9 999.9 999.9 999.9 999.9 | eo | ae | el xD | 15 IABARII 177(Fig 3-5) ___ ig 3-6) PaceC) ripC} GRPC] 1. oC [po o Analog In/ourc | | | [ eretvai in/out on | When pressed, When pressed.! lies 4999.9 aol +999. 9) ea DIL oO DOL oO [aire +999.9 ao2 1999.9 biz 0 poz 0 |nira +9999 03 +999. 9 DIz.0 pos 0 1R4 1999.9 AOd 4999. 9| \|o1 0 p04 0 1R5 4999.9 A05 1999.9] D150 005 0 | | | (Fig 3-1) _ a po) & op Error tafonation | When pressed.) ||SW-AJ [SW-B When pressed.!| cy yyy ovmm 0 ovr 0 | | |[sw-c] fsw-p] | | AIERR 0 RST} | Rst | | CG) Eno IMABARI ‘AcePress Key +000 +4005 010 | 6 +010. 10_-080. Parameter 020. +000. +075. +100. + CHANGE METHOD OF DATA [Percent F This explains how to change % parameter No set point 1 4900.0 x (Example) (o change No.8 parameter fr 2 4005.0 E paid a avatate 10% to 25% 4 4003.0 (1) Press [D] key on the station screen 5 -020.0 of the controller you wish to change, § 4000.0 ae and the mem screen (2-(Fig-1)] 8 075.0 Will be display 9 4100.0 (2) Press the[ %P key, 10 -050.0 20 11 and (Fig 4) will be displayed. (8) Press the { 4] key of (Pig 4) twice to move the cursor to No.3, and (Pig §)will be displayed. @ Press [=] key of Fig.4 twice to move the cursor No Noi coco" to the second place of the 012 value. 0 {13 +030.0 Press| 2 |key and then[ 5 | re AR of the ten keys below GP. 0 15 +100.0 0 16 +500.0 (see 2-Fig 1-O) 0 17 500.0 = eet (6) Press[ENTR |key (2-Fig 1 -@) 0 19 4000.0 after confirming that the 0204 nunber has been changed * CAUTION : Please contact the boiler maker(Nitsubishi Heavy Ind.) before changing invariable numbers such as parameters. Invariable numbers other than ¥P can also be changed in the same way on the respective screen.CIV] ALARM DISPLAY GP displays reversible and communication errors. | The abnormality are displayed with GP.as follows. eI I. (ao Gl (2) @ (1) Reversible errors When the following errors occur in ACC CONTROLLER (ACS100), it will be indicated on GP as (1) Reversible errors item as follows. 1) Analog input range over 2) Arithmetic overflow | 3) Arithmetic overload | There are 8 LEDs after "Warm", and the location of lighted LEDs indicates the kind of error. % When a reversible error occurs under AUTO" mode, the mode is automatically switched to manual Only after the reversible error is corrected, the mode can be changed back to “AUTO” by pressing (A) (reset) key ___INABARI ACC 18. 1§0a Irreversible errors (Communication down) If GP detects 10 communication errors in a row from a controller, it displays an error indication such as Fig.6 (2) and stops communicating with the controller When an irreversible error occurs,” If an irreversible error is detected by self-diagnosis function, all the arithmetic functions will be ceased. ‘Thus, @ communication error is displayed on GP and an irreversible error can be confirmed. rrors"LED blinks. ( [I] @) The number of blinks, which repeats itself in every certain period of time, 1 2 3 4 5 6 1 8 9 10 ul 2 Blink Abnormal Blinks Abnormal Hl Abnormal Abnormal I Abnormal Abnormal Abnormal Wo Abnormal Ho Abnormal Wo Abnormal indicate the kind of the error. Program ROM Data ROW Data RAM Sampling Time Output Line Connection (Al) Analog output Communication (not transmissible) Analog input (hardware error) Program Parameter I PID arithmetic overflow Abnormal Output Line Connection (A02) * After the error is corrected, press [F 5] key (Fig 6 -(B)) and check connection, and GP can be resumed. IMABARI} ACC 19 LESQe Yd C200H Programmable Controllers Installation Guide (For CPU21-E/23-E/31-E) Revised May 1997 Rr ara a We28 "ssp019“tsnpoood ee yank aye 0 pos U0 oH SOREL “EEL co SPIY 1ensip ene Cuno 20) vopange ve peen rou pur Yopomsen oo eawunueitoid)OAUED PRUNE MOL, URNA UL, ‘ees gu ungenToop p44 eRNNEINE m pu DION, sveou uoyo ‘onpord NOUNO eues Le pe steep aus Uy sIEedde LOR UD. 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