HB-T E990-1112-03
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Transcript of HB-T E990-1112-03
OPERATION MANUAL
MARINE AUXILIARY BOILER
HB-T
Operation Manual No. E990-1112-03
i
Important Safety Information
In handling marine auxiliary boiler HB-T type (hereinafter called this boiler), read and fully understand
this manual and follow instruction that is contained in this manual.
This boiler contains hot parts that may cause burn, high-pressure parts that may cause injury due to
pressure break, moving parts in which a part of body may get caught, and high-voltage parts that may
cause electrical shock. Improper handling of these parts may cause accident involving death, fire, or
other disasters.
This boiler can be operated in automatic operation mode (normal mode) and manual operation
mode for emergency. In manual operation mode, fire or burn due to backfire (*) may be caused
unless boiler is handled properly. Use manual operation mode only in emergency.
To ensure safety of operation and maintenance of this boiler, it is essential to know possible causes of
disasters in advance. We cannot predict all potential dangers, but present dangers involved in
handling of boiler in this manual to the best of our knowledge. Following warnings or instructions that
are contained in this manual better ensures safety of work.
In this manual, harm and damage are categorized into following three levels. These are attached on
this boiler as warning labels (*) and also described in this manual.
DANGERIndicates any condition or practice that, if not observed,
causes imminent danger of death or serious injury to user.
WARNINGIndicates any condition or practice that, if not observed, may
cause death or serious injury to user.
CAUTIONIndicates any condition or practice that, if not observed, may
cause minor injury to user or property damage.
If failed components are found, contact MIURA offices and replace them with genuine parts. Using
different model part may reduce safety of boiler.
Remodeling this boiler without consultation with MIURA or repairing it in way that is not specified in this
manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.
ii
IntroductionThis manual describes procedures for handling this boiler for proper operation. Precautions relating to
operating method and safety indicated in this manual from damages to measures only relate to usage
for specified purposes. Do not use boiler by methods that are not mentioned in this manual. Be aware
that MIURA cannot be held responsible if boiler is used by methods that are not mentioned in this
manual.
Before using this boiler, those who use it for the first time as well as those familiar with handling of it
must read this manual thoroughly and understand proper method of handling it.
Keep this manual in place so that it can be consulted whenever there is any uncertainty about this
boiler.
In addition to this manual, following booklets are provided as information that is needed to use this
boiler. Before using boiler, thoroughly read these booklets in addition to this manual.
[1] Final Drawing:······ Final drawing is documents containing all specifications for customer. Look
over and understand final drawing before use. Refer to this document for
information that depends on capacity or options.
[2] Procedure: ·········· Manual for Installation: Procedure manual for installation contains information
on installation of this boiler and incidental parts. Install this boiler according to
this procedure manual (This procedure manual is contained in final drawings).
[3] Instruction manuals for incidental equipment:
Handle incidental equipment according to respective instruction manuals.
[4] Manual for Water ·· Treatment: Manual for water treatment describes procedure of water treatment
that is needed to use this boiler. Understand content of manual, and handle
chemicals and carry out water treatment work according to instructions that
are contained in this manual.
iii
[Graphical symbols]
Graphical symbols used in this manual have following meanings:
Prohibition
Indicates certain behavior is prohibited.
Do Not Touch
Indicates touching certain area may cause personal injury.
Do Not Touchwith Wet Hands
Indicates handling with wet hands may cause electrical shock.
Instruction
Provides instruction to be followed (action to be taken).
ConnectGround Wire
Indicates ground wires must be connected.
Caution
Indicates a precaution to be remembered.
Caution: Hot
Indicates potential danger of injury from heat under certain
conditions.
Provides precaution to prevent boiler failure, point to be
remembered for effective operation, or other useful information.
Indicates related page(s).
Note
iv
Term DefinitionsTerms that are used in this manual are defined as follows.
These terms are marked with asterisk (*) in manual.
Term Description
H.F.O. Abbreviation of fuel oil. Fuel used with main burner. When this boiler is used
in Japan, term refers to heavy oil C.
M.D.O. Abbreviation of marine diesel oil. When this boiler is used in Japan, term
refers to heavy oil A. Fuel used with pilot burner.
Flammable
Dangerous
Substance
Substance with low ignition temperature that is fire hazard (A handling place
for flammable dangerous substance refers to place where such a substance
is stored).
Wind Box Wind box in which burner is installed. It controls air flow from fan.
Oil Air Separator Container that is designed to separate components evaporated from fuel oil
or air retaining in fuel oil circulation line or other gas phases from liquid
phases. Oil air separator is installed on inlet side of fuel oil pump.
Air Supply Fan Air supply system designed to bring air into furnace.
Warning Label Label to call attention to operating precaution.
Ventilation (draft) Phenomenon that exhaust gas with higher temperature and smaller specific
gravity than surrounding air rises toward outlet of funnel.
Differential Differential means control width that is set with controller. It is control width
between when contact of controller is turned off (on) and when it is turned on
(off) again.
Ignition Transformer High voltage supply system designed to generate sparks for igniting pilot
burner or main burner.
F.O. Heater Heater that is designed to heat fuel to suitable temperature to be atomized by
burner. This heater is included as standard when H.F.O. is used as main fuel.
Pilot Flame Fire source for igniting main burner when H.F.O. is used as main fuel. Pilot
flame is formed by igniting pilot burner.
Backfire Phenomenon that fire source is generated in furnace under poorly ventilated
conditions before combustion is started or when combustion is stopped, and
combustible gas mixture in furnace is ignited to cause explosion.
Flame eye Sensor that is designed to detect flame in furnace.
v
Term Description
Pre purge Pre-purge is ventilating combustion chamber of boiler before combustion.
Post purgePost-purge is ventilating combustion chamber of boiler when combustion is
stopped.
Main fuel Fuel used with main burner.
vi
CONTENTS
Important Safety Information.............................................................. i
Introduction........................................................................................ ii
Term Definitions................................................................................ iv
CHAPTER 1: SAFETY.........................................................................1
1. Safety Regulations ........................................................................1
2. Knowledge and Skill Required for Safe Handling .........................1
3. Protective Equipment ....................................................................1
4. Prohibition of Remodeling without Permission..............................1
5. Use of Specified Fuels ..................................................................2
6. Warning Labels (*) on Products......................................................2
7. Precautions for Safe Handling ......................................................3
7.1 Safety Precautions in Installation ................................................................................3
7.2 Safety Precautions in Pre-operation Inspection and Preparation ................................4
7.3 Safety Precautions in Operating Boiler........................................................................5
7.4 Safety Precautions in Bringing Boiler to Emergency Stop...........................................7
7.5 Safety Precautions in Inspections and Maintenance...................................................7
7.6 Safety Precautions in Replacing Parts ........................................................................9
7.7 Safety Precautions in Working on Failures..................................................................9
7.8 Safety Precautions in Storage Work..........................................................................10
vii
CHAPTER 2: OVERVIEW ................................................................. 11
1. Features of Product..................................................................... 11
1.1 Functions and Operating Principle ............................................................................ 11
1.1.1 Functions .................................................................................................. 11
1.1.2 Operating Principle ................................................................................... 11
1.2 Product Components ................................................................................................ 11
2. Water and Steam Supply Flow....................................................12
2.1 Water and Steam Pipe System .................................................................................12
3. Fuel Supply Flow.........................................................................13
3.1 Fuel Pipe System......................................................................................................13
4. Basic Specifications ....................................................................14
5. Part Names and Functions..........................................................15
5.1 Boiler Body................................................................................................................15
5.2 Burner and Burner Piping Structure ..........................................................................16
5.3 Internal Structure of Boiler Body ...............................................................................17
6. Boiler Automatic Operation by Sequencer ..................................19
6.1 Overview ...................................................................................................................19
6.2 Flowchart ..................................................................................................................19
6.3 Operation Explanation of Steam Pressure Control....................................................21
6.3.1 Proportional Control..................................................................................21
CHAPTER 3: BASIC OPERATION....................................................22
1. Details of Control Panel and Display ..........................................22
1.1 Details of Control Panel and Display.........................................................................22
1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch) .................23
1.3 Details of Alarm Display ............................................................................................23
viii
CHAPTER 4: OPERATION................................................................24
1. Inspection and Preparation before Operation .............................24
1.1 Inspection and Preparation of Boiler and Peripheral Equipment ...............................24
1.2 Inspection of Boiler Body and Accessories................................................................25
1.3 Inspection and Preparation of Feed Water System ...................................................26
1.3.1 Inspection Items........................................................................................26
1.3.2 Flushing of Pipes ......................................................................................27
1.3.3 Air Vent .....................................................................................................27
1.4 Inspection and Preparation of Fuel System...............................................................28
1.4.1 Preliminary Inspection...............................................................................28
1.4.2 Air Vent .....................................................................................................29
1.5 Inspection and Preparation of Burner........................................................................29
1.6 Inspection and Preparation of Electrical System .......................................................30
1.7 Inspection and Preparation of Steam System ...........................................................30
2. Automatic Operation (Normal Operation) ....................................31
2.1 Checking of Control Panel Switches .........................................................................31
2.2 Feeding Water to Boiler.............................................................................................31
2.3 Feeding Water to Boiler by Differential Transmitter ...................................................32
2.3.1 Feeding Water to Differential Transmitter..................................................32
2.4 Starting Combustion with M.D.O.(*)............................................................................34
2.4.1 Combustion with Air Atomization...............................................................34
2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)..............................................................................................35
2.4.3 Combustion with Steam Atomization ........................................................35
2.4.4 Control and Checking during Operation (Combustion with Steam
Atomization) .............................................................................................35
2.5 Combustion Stop.......................................................................................................36
2.6 Shift from M.D.O. to H.F.O. .......................................................................................36
2.7 Shift from H.F.O. to M.D.O. .......................................................................................37
3. Emergency Operation .................................................................38
3.1 Emergency Combustion Operation ...........................................................................38
3.2 Control and Checking during Operation ....................................................................38
3.3 Restoration to Normal Combustion and Checking of Combustion ...........................38
ix
4. Manual Operation (Use Only in Emergency) ..............................40
4.1 Starting/Stopping Manual Feed Water Pump Operation ...........................................41
4.1.1 Starting Manual Operation........................................................................41
4.1.2 Stopping Manual Operation ......................................................................41
4.2 Manual Combustion ..................................................................................................42
4.3 Manual Combustion Stop..........................................................................................43
5. Emergency Stop..........................................................................44
5.1 Emergency Stop of Combustion System...................................................................44
5.1.1Cases in which Emegency Stop is Required ...........................................44
5.1.2 Stop Procedure.........................................................................................44
5.2 Emergency Stop of Entire Boiler ...............................................................................44
5.2.1 Cases in which Emegency Stop of Entire Boiler is Required....................44
5.2.2 Stop Procedure.........................................................................................44
6. Cold Start ....................................................................................45
CHAPTER 5: INSPECTION AND MAINTENANCE...........................46
1. List of Inspection Items and Inspection Frequencies ..................46
1.1 Regular Inspection and Maintenance........................................................................47
1.2 Safety Valve ..............................................................................................................49
1.2.1Internal Structure of Safety Valve ..............................................................49
1.2.2 Adjustment of Safety Valve.......................................................................50
1.3 Other Important Inspection Items..............................................................................50
2. Daily Inspection and Maintenance ..............................................51
3. Weekly Inspection and Maintenance ..........................................52
3.1 Main Burner ..............................................................................................................52
3.1.1 Overview...................................................................................................52
3.1.2 Disassembly and Adjustment....................................................................52
3.2 Nozzle Tip .................................................................................................................53
3.3 Pilot Burner ...............................................................................................................54
3.3.1 Overview...................................................................................................54
3.3.2 Disassembly and Adjustment....................................................................55
x
4. Monthly Inspection and Maintenance..........................................55
4.1 Fan............................................................................................................................55
4.1.1 Overview...................................................................................................55
4.1.2 Regular Maintenance................................................................................56
4.2 Suction Damper (Attachment of Blower) ...................................................................57
4.2.1 Overview...................................................................................................57
4.2.2 Inspection .................................................................................................57
4.2.3 Measures on Failures (Fixing Fully Open State).......................................58
4.3 Fuel Flexible Tube.....................................................................................................59
4.4 Oil Flow Control Valve, Air Flow Controller, and Damper ..........................................59
4.4.1 Overview...................................................................................................59
4.4.2 Inspection..................................................................................................60
4.5 Control Motor ............................................................................................................61
4.5.1 Overview...................................................................................................61
4.5.2 Inspection .................................................................................................61
4.6 Flame Eye (*)..............................................................................................................62
4.6.1 Overview...................................................................................................62
4.6.2 Inspection and Cleaning ...........................................................................62
4.7 Strainer for Fuel.........................................................................................................63
4.7.1 T-type Auto-cleaner...................................................................................63
4.7.2 Y-type Strainer ..........................................................................................64
4.7.3 Double Strainer.........................................................................................64
4.8 Fuel Oil Pump............................................................................................................66
4.8.1 GFS Type (for Pilot Burner) ......................................................................66
4.8.2 Main Fuel Oil Pump ..................................................................................67
4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting .........................67
4.8.4 Circulation Relief Valve .............................................................................69
5. Quarterly Inspection and Maintenance .......................................70
5.1 Inspection and Blow of Boiler Water..........................................................................70
5.2 Equipment around Burner .........................................................................................70
5.2.1 Solenoid Valve ..........................................................................................70
5.2.1-1 Solenoid Valve for Pilot Burner...........................................................71
5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve ..............................71
5.2.1-3 Solenoid Valve for Atomized Air .........................................................72
5.2.1-4 Solenoid Valve for Atomized Steam ...................................................73
xi
5.2.2 Other Equipment ......................................................................................74
5.2.2-1 Pneumatic Fuel Shutoff Valve ............................................................74
5.2.2-2 Filter Regulator ..................................................................................75
5.2.2-3 Pressure Reducing Valve...................................................................76
5.2.2-4 Seal Pot .............................................................................................77
5.2.2-5 Equalizing Valve.................................................................................78
5.3 Fuel Oil Thermostat (for Fuel Oil Heater) ..................................................................79
5.3.1 Dial Type...................................................................................................79
5.3.2 RT Type ....................................................................................................80
5.3.3 Heavy Oil Heating Temperature................................................................81
5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil).......................................82
5.4.1 Steam Pressure Switch ............................................................................82
5.4.2 Atomized Fluid Pressure Switch ...............................................................83
5.4.3 Fuel Oil Pressure Switch ..........................................................................83
5.4.4 Pressure Switch Adjustment Procedure....................................................84
5.5 Differential Transmitter ..............................................................................................85
5.6 Flow Control Valve ....................................................................................................86
5.7 Operation Check of Each Safety System..................................................................87
5.7.1 Ignition Failure Alarm................................................................................87
5.7.2 Fan Abnormal Stop Alarm.........................................................................87
5.7.3 Flame-out Alarm .......................................................................................88
5.7.4 Abnormal Fire Alarm .................................................................................88
5.7.5 Low Oil Pressure Alarm ............................................................................88
5.7.6 Low Oil Temperature Alarm ......................................................................89
5.7.7 High Oil Temperature Alarm......................................................................89
5.7.8 Exhaust Gas High Temperature Alarm......................................................90
5.7.9 High Steam Pressure Alarm .....................................................................90
5.7.10 Low Steam Pressure Alarm ....................................................................91
5.7.11 Low Water Level Alarm ...........................................................................91
5.7.12 Low Low Water Level Alarm ...................................................................91
5.7.13 Power-off Alarm ......................................................................................91
5.7.14 Sequencer Error Alarm ...........................................................................91
5.7.15 Low Atomized Steam Pressure Alarm.....................................................92
5.7.16 Low Atomized Air Pressure Alarm...........................................................92
5.7.17 Damper Control Alarm ............................................................................92
5.7.18 Operation Check by differential transmitter(Low Water Level, Low Low
Water Level, High Water Level) ..........................................................92
5.7.19 Suction Damper Error Alarm...................................................................94
xii
6. Yearly Inspection and Maintenance ............................................95
6.1 Fuel Oil Heater ..........................................................................................................95
6.1.1 Combined Use of Electricity and Steam....................................................95
6.1.2 Solenoid Valve for Steam Heater..............................................................96
6.2 Water Level Gauge and Water Level Detecting Rod .................................................97
6.3 Flame Detector (FS-901)...........................................................................................98
7. Inspection and Maintenance on Vessel Docking.......................100
7.1 Soot Cleaning of Furnace........................................................................................100
8. Parts Information about Replacement.......................................101
8.1 Ignition Transformer (*) .............................................................................................101
8.2 Sequencer (Programmable Controller)....................................................................102
8.2.1 Description of Component Unit of CJ2M.................................................102
8.2.2 Function of Display .................................................................................105
8.2.3 Errors and Countermeasures..................................................................106
8.3 Steam Pressure Regulator ......................................................................................107
8.4 Fuel Oil Temperature Controller ..............................................................................108
8.4.1 Name and Function ................................................................................108
8.4.2 Setting Procedure ...................................................................................108
8.5 Water Level Detector (LM1-200) .............................................................................109
8.6 Water Level Indicator...............................................................................................110
CHAPTER 6: TROUBLE SHOOTING.............................................. 111
1. Feed Water System................................................................................................... 111
2. Fuel System .............................................................................................................. 114
3. Combustion System .................................................................................................. 116
4. Control System..........................................................................................................122
5. Trouble Shooting for Boiler Body...............................................................................123
6. Repairing Damaged Water Tubes .............................................................................124
6.1 Insertion of Stoppers from Inside of Water Drum.................................................124
6.2 Stopper Welding from Combustion Chamber ......................................................125
xiii
CHAPTER 7: STORAGE.................................................................126
1. Maintenance When Boiler is Shut Down for a Long Time.........126
2. Movement or Resale .................................................................126
3. Export........................................................................................126
CHAPTER 8: DISPOSAL ................................................................127
1. Disposal Procedure...................................................................127
CHAPTER 9: GUARANTEE ............................................................128
1. Description of Guarantee ..........................................................128
2. Contact Information for Inquiries about Products and Instruction
Manual.......................................................................................128
3. Sale of Instruction Manual.........................................................128
4. Sale of Parts..............................................................................128
1
CHAPTER 1: SAFETY
1. Safety RegulationsIn sailing in the high seas, observe the Rules and Regulations for the Classification of Ships, the
SOLAS Convention, the MARPOL Convention, and other international conventions. Also observe
regulations in way ports or the country in which vessel is registered and other applicable regulations.
2. Knowledge and Skill Required for Safe HandlingHandling of this boiler includes operating boiler, operating controller for controlling operation of boiler,
and maintaining them. Before carrying out work, fully understand this manual.
People who satisfy all of following requirements are qualified to handle this boiler. They are called
operators.
[Requirements to be satisfied by operators]
Those who have received explanation of handling from our service staff during trial operation or
those who have received explanation of handling directly from them
Those who have thoroughly read instruction manual for this boiler and have full understanding of
content
Those who have been permitted to handle this boiler by chief engineer
Appoint chief operator from among operators.
3. Protective EquipmentDo not forget to wear helmet, protection eyewear, safety shoes, safety belts, leather gloves, protective
masks, or other appropriate protective equipment when working on device.
4. Prohibition of Remodeling without PermissionRemodeling this boiler without consultation with MIURA or repairing it in a way not specified in this
manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.
2
5. Use of Specified FuelsDo not use fuel that is not specified with this boiler. Failure to observe this instruction may seriously
affect safety of boiler.
6. Warning Labels (*) on ProductsFor safe use of boiler, warning labels are attached on locations where attention to operating precaution
is called for.
If warning label comes off or tears, replace it with new warning label.
For more details about warning labels, contact MIURA offices.
Attached near parts with hazard of scalding or hot parts
(Parts with surface temperature of over 60°C).
Do not touch surface around this warning label.
Attached on rotating parts with gaps in structure that
could catch fingers (Fingers might get trapped).
Do not get close to area near warning label before parts
are operated or when they are in operation.
Attached on or around electric equipment that cannot be
insulated (or covered) completely.
To prevent electrical shock or electric leakage, prevent
objects or body from coming in contact with such
Scald Warning Label:······················
Electric Shock Warning Label:··········
Catch Warning Label: ·····················
Damage Warning Label: ················· Attached on water gauge glass as there is possibility of
damage by aged deterioration when it is used for long
periods. When deterioration, cracks, or other problems are
found, promptly replace part.
3
7. Precautions for Safe Handling7.1 Safety Precautions in Installation
In carrying out installation work, observe following safety precautions:
WARNING
Instruction
Secure ventilation (draft) (*) in funnel (exhaust stack) and ensure that exhaust from outlet
does not have harmful influence on surrounding environment.
(Refer to “1. Safety Regulations.”)
In engine room, secure adequate area for air inlet, exhaust outlet, and air supply fan (*). If
these are not installed and managed properly, carbon monoxide poisoning due to exhaust
gas may be caused.
Ensure that ventilation fan, air inlet, and exhaust outlet are installed in engine room.
Insufficient air supply or exhaust ventilation may cause carbon monoxide poisoning due to
exhaust gas or explosion.
Ensure that boiler is not installed in handling place for flammable dangerous substance(*).Install it on floor made of noncombustible material. Ensure that boiler is more than 45 cm
away from flammable materials. They may ignite due to hot part of boiler to cause fire,
resulting in accident involving death.
Ignition due to hot part may cause fire.
If exhaust stack or steam piping is passed through wall that is made of flammable material,
use noncombustible material for fire protection.
Water discharged from boiler is extremely hot and may cause burn.
Ensure that drainage piping is fixed to prevent it from being forced to move by discharged
water and that the end of piping is released into safe place.
ConnectGround Wire
Connect power supply using cables with specified diameters.
Use special wiring breaker.
Failure to observe this instruction may cause electrical shock, burn, or other serious
accidents.
Wiring breaker
Breakercapacity
Wiring
Wiring breaker
4
7.2 Safety Precautions in Pre-operation Inspection and Preparation (Excerpt from
page 24-)
In pre-operation inspection and preparation, observe following safety precautions:
WARNING
Prohibition
Keep flammable materials away from boiler.
They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.
Do not put flammable materials in control box.
They may ignite to cause fire, resulting in accident involving death.
Do Not Touch
If you touch coupling of pump that is spinning rapidly, you may get caught in it. Do not touch
coupling of pump during pump operation.
Do Not Touchwith Wet Hands
Do not operate breaker of main power supply and equipment in control panel with wet
hands.
Failure to observe this instruction may cause electrical shock due to high voltage, resulting
in injury or death.
Instruction
Check that funnel (exhaust stack) is properly constructed.
Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around boiler related equipment.
Switching on or off wet equipment may cause electrical shock or fire from short circuit.
Run ventilation (air supply and exhaust equipment) in engine room and check that air vent
is not blocked off.
If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may
be caused.
If you touch hot piping of feed water system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving
death. Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage
and waste cloth used to wipe off oil immediately in an appropriate manner.
Caution: Hot
If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear
protective equipment while working around tank.
If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.
CAUTION
Instruction
If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures
to prevent fuel oil spill and establish method for coping with spillage in advance.
5
7.3 Safety Precautions in Operating Boiler (Excerpt from page 31-)
In operating boiler, observe following safety precautions:
WARNING
Prohibition
If automatic operation is hindered by parts damage or another reason, remove cause of
problem and start automatic operation again.
This boiler has manual operation circuit for emergency operation when automatic operation
is hindered. Operating error in manual operation mode, in which some safety systems are
disabled, may cause accident involving death. Do not use manual operation mode except in
emergency. If manual operation circuit must be used for unavoidable reason, follow
instructions in this manual.
Cases in which automatic operation cannot be continued are as follow:
<Feed water pump circuit>
Failure of instrumentation
<Combustion circuit>
Sequencer trouble
Sensor trouble, interlock by abnormality detection
In manual operation mode, backfire (*) or other accidents involving death by ignition error or
fire by empty heating may be caused. Do not use manual operation mode except in
emergency. If manual operation circuit must be used for unavoidable reason, follow
instructions in this manual.
During manual combustion operation, do not shift fuel (M.D.O. (*) ↔ H.F.O. (*)).Failure to
observe this instruction may cause backfire or other accidents involving death.
Do Not Touchwith Wet Hands
Do not operate breaker of main power supply and equipment in control panel with wet
hands.
Failure to observe this instruction may cause electrical shock due to high voltage, resulting
in injury or death.
Instruction
If water or steam leaks out of system, burn, blindness, or accidents involving death may be
caused. During operation and after operation stop, check connections of piping and air vent
valve for leaks.
If you touch hot piping of water and steam systems, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving death.
Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage and
waste cloth used to wipe off oil immediately in an appropriate manner.
Surface temperature of upper part of boiler exceeds 60°C and may cause burn if surface is
touched. When working with upper part of boiler, wear gloves and other protective
equipment to prevent direct contact.
6
WARNING
Instruction
Perform purge operation sufficiently before ignition and when combustion is stopped.
Insufficient purge operation may cause backfire(*) or other accidents involving death.
Pre-purge (*) (before ignition): 20 seconds or longer *
Post-purge (*) (when combustion is stopped): 60 seconds or longer *
*In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit
after 20-second or longer pre-purge.
Switch fuel when boiler is in automatic operation mode. Operating error in manual operation
mode may cause backfire or other accidents involving death.
Caution
In manual operation mode, following interlock functions of safety system are disabled.
Improper operation may cause accidents involving death. Be careful with operating boiler in
manual operation mode.
Interlock functions disabled when manual combustion circuit is used:
Fuel oil pressure low (fuel)
Fuel oil temperature high (fuel)
Fuel oil temperature low (fuel)
Steam pressure high
Steam pressure low
Abnormal fire
These interlock functions work only when all functions are working properly. When there are
problems with sensors or other parts, interlock functions may not work properly.
In feed water control by differential transmitter, feed water pump control does not operate
properly when feeding water and adjustment of differential transmitter is not completed.
Boiler becomes fill with water and high water level, it may cause hot water blow out from
safety valve during boiler combustion.
Caution: Hot
If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear
protective equipment while working around tank.
If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.
7
7.4 Safety Precautions in Bringing Boiler to Emergency Stop (Excerpt from page 44-)
In bringing boiler to emergency stop, observe following safety precautions:
DANGER
Caution
Emergency stop is operation that gives top priority to stopping boiler immediately in
emergency. If breakers are turned off inadvertently, feed water and circulation pumps may
be stopped to cause soot fire, explosions in furnace, or other accidents. Do not use this
function except in emergency.
Emergency stop is operation that gives top priority to stopping boiler immediately in
emergency. Emergency stop skips safety checks for ongoing operation and may cause
unexpected accident or failure. Use this function only when there is unavoidable reason for
bringing boiler to emergency stop. Users must judge when and how boiler should be
brought to emergency stop because it depends on situation.
When resuming operation after emergency stop, ensure that switches are turned on or off to
stop all ancillary equipment before turning power on. Otherwise, equipment may start to
work unexpectedly to cause accidents.
7.5 Safety Precautions in Inspections and Maintenance (Excerpt from page 46-)
In inspections and maintenance, observe following safety precautions:
DANGER
Instruction
Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to
deterioration of impeller or external force, resulting in injury or death.
WARNING
Prohibition
Improper adjustment of blow off pressure of safety valve may damage boiler body.
As a rule, do not adjust blow off pressure of safety valve.
Remodeling of safety valve may damage boiler body.
As a rule, do not remodel safety valve.
Instruction
If steam leak from safety valve is found, replace part and repair it immediately.
When steam leak is left, function of safety valve is decreased and there is possibility of
leading to serious accident
Complete purge by fan before burner opening and inspection to make combustion chamber
cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.
Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it
properly.
8
WARNING
Instruction
Before moving impeller by hand, turn off main power supply. If impeller is rotated
accidentally during maintenance, physical injury may be caused.
Inspect suction damper once a month. Failure to inspect suction damper may cause
damage of part and malfunction due to looseness of part, resulting in injury or death.
Do not give impact to boiler fuel pipe or bend any part of it.
Failure to observe this instruction may cause fuel oil leak, resulting in fire.
Equipment has been brought into optimum state in trial operation. Do not make changes to
state after trial operation. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA
offices and ask for instructions.
In order to prevent serious accident, check solenoid valves and valve seats for oil leaks after
cleaning, inspecting, or replacing.
Before inspection or adjustment, check that there is no internal pressure present.
Compressed air or steam may blow out, causing burn or laceration.
Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to
change setting as a rule. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for
instructions.
Caution
Surface temperature of the top of boiler exceeds 60°C and may cause burn if surface is
touched. Take extra care in daily inspection work.
Blow valve and sample water (blow water) are hot. When carrying out inspection and
maintenance work, wear protective equipment to prevent burn.
During inspection work, hot steam may blow out to cause burn. Be careful when operating
valves.
Before wiring work, be sure to turn control panel power off. Failure to observe this instruction
may cause electrical shock due to high voltage, resulting in injury or death.
Do not pull out lead wire with wet hands. Failure to observe this instruction may cause
electrical shock due to high voltage, resulting in injury or death.
CAUTION
Instruction
When cleaning strainer or performing other work using oil, wear protective equipment to
protect eyes and body from splashes of oil.
This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating
valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil
pump is deteriorated over time and its performance is gradually declined.
9
CAUTION
Caution
Improper spray volume, spray angle, and spray form cause poor combustion and sometimes
cause backfire. Use only genuine parts.
7.6 Safety Precautions in Replacing Parts (Excerpt from page 101-)
In replacing parts, observe following safety precautions:
WARNING
Instruction
Ignition transformer (*) conducts high voltage. Touching live wiring may cause electrical
shock. Turn power off before working with ignition transformer.
Do not make changes to state after trial operation. Failure to observe this instruction may
cause poor combustion, backfire (*), or other accidents.
CAUTION
Instruction
Improper setting of water level may damage boiler body.
Do not change setting from trial operation.
Do not change internal parameters.
Improper setting of water level may damage boiler body.
7.7 Safety Precautions in Working on Failures (Excerpt from page 111-)
In working on failures, observe following safety precautions:
WARNING
Instruction
Stopper treatment and furnace building with refractory is temporary treatment. Do not
operate for a long time; otherwise, there is possibility of serious accident. Contact each
classification in advance and replace water tubes (or body) immediately at periodical
inspection. Contact with MIURA offices about replacement of water tubes (or body).
Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool
both the inside of drum and combustion chamber. Then make sure that pressure inside the
drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan
during inspection.
10
CAUTION
Caution: Hot
Before working on water tube leaks, check water tubes and burner funnel that may be
touched are fully cooled. Otherwise, you may suffer from burn. For more information,
contact with MIURA offices.
7.8 Safety Precautions in Storage Work (Excerpt from page 126-)
In storage work, observe following safety precautions:
WARNING
Prohibition
Do not perform installation work and connection of incidental equipment unless it is
specified.
Failure to observe this instruction may cause physical injury.
11
CHAPTER 2: OVERVIEW
1. Features of Product
1.1 Functions and Operating Principle
1.1.1 Functions
This boiler burns fuel oil and collects resultant heat to provide high-temperature, high-pressure
steam.
1.1.2 Operating Principle
<Feed water>
Feed water is pressurized by feed water pump and supplied to upper drum.
Water that is fed to upper drum is loaded into boiler body (upper drum, water tubes, and lower
drum).
<Combustion>
Heat to generate steam comes from combustion heat by burner. Fuel oil heated and pressurized
by fuel oil pump unit to right temperature and pressure, respectively, is supplied to burner. Boiler
employs two-fluid burner that uses atomized fluid (steam or compressed air) to atomize fuel oil
and combines atomized particles with air supplied by fan to cause combustion.
<Generation of steam>
Water in water tubes is heated by combustion heat from burner into gas-liquid phase, which rises
to upper drum. Liquid phase in water tubes without thermal load drops down to lower drum. This
series of actions causes natural circulation inside boiler body and allows heat recovery. Steam
generated in drum is subjected to steam separation to obtain saturated steam, which is supplied
to load side through main steam valve.
1.2 Product Components
This boiler consists of boiler body and following units:
Boiler body
Feed water pump (including feed water strainer and valves)
Fuel oil pump unit
Control panel
Fan
*This is standard configuration. For details about configuration of product that is delivered, refer to
final drawing.
12
2. Water and Steam Supply FlowTypical flow for this boiler is described here. Actual flow may be different from flow described here,
depending on specifications. Check pipe system diagram in final drawing before use.
2.1 Water and Steam Pipe System
Water in system is supplied to boiler body by feed water pump. Water sent to boiler is heated by
combustion heat into high-temperature, high-pressure steam. Generated steam is supplied to load
side and used as a heat source.
Figure 2-1 Water and Steam Pipe System Diagram (Example)
13
3. Fuel Supply FlowTypical flow for fuel pipe system of this boiler is described here. Actual flow may be different from flow
described here, depending on specification. For details about flow for product that is delivered, refer to
pipe system diagram in final drawing.
3.1 Fuel Pipe System
Figure 2-2 Fuel Pipe System Diagram
<Description of operation> (H.F.O.(*))a) All solenoid valves (SV-1 to SV-4) are closed when operation is stopped. When operation is started
and main fuel (*) oil pump (M-2) is brought into operation, fuel oil is circulated throughout fuel pipesystem leading back to oil air separator (*) via circulation relief valve (RV) and is heated by heater.
b) When H.F.O. is heated and pre-purge (*) is performed, solenoid valve for atomized fluid (SV-2) isopened. When pre-purge is completed, pilot fuel oil pump (M-4), ignition transformer(*), and solenoidvalve for pilot burner (SV-1) are started to form pilot flame(*).
c) When flame eye (*) detects pilot flame, solenoid valve for air-driven valve (SV-3) is started to openair-driven valve (AC-1), allowing main burner and pilot burner to form mixed flame. After mixedflame is formed, solenoid valve for pilot burner (SV-1) is shut off to put out pilot flame, and flamefrom main burner is formed.
d) While combustion is continued, pressurized fuel oil is still circulated throughout fuel pipe system viacirculation relief valve (RV) to keep fuel oil temperature and oil pressure stable.
F.O. TANKF.O. TANK
D.O. TANKD.O. TANK
14
4. Basic SpecificationsTable 2-1 lists specifications of different types of boilers and different capacities. Specifications may be
different from those listed here, depending on special order requirements. For detailed specifications of
product that is delivered, refer to list of principle items on final drawing.
Table 2-1 Basic Specifications of HB-T Type Boiler
Model HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T
Max. Design Press. MPa 1.0
Heating Surface Area m2 104 115.5 131.6 184.2 224.6
Actual Evaporation
Water 60°C
Steam 0.69 MPa
kg/h 8,000 10,000 12,000 15,000 18,000 20,000
Net Heat Output
kW 5,580 6,980 8,380 10,470 12,570 13,970
kcal/
h4,806,800 6,008,500 7,210,200 9,012,750 10,815,300 12,017,000
Fuel Oil - Heavy Fuel Oil: Up To 380 cSt (at 50 °C)
Fuel Consumption kg/h 578 722 866 1,082 1,299 1,444
Installed Electric Capacity kW 62.5 65.5 77.5 96 121 124.5
Bu
rne
r
Type - Steam Atomizing Type
IgnitionSystem
- High Voltage Spark System
FlameDetector
- Flame Eye Type
F.O
.P
um
p Capacity m3/h 1.41 2.4
Pressure MPa 1.5
Motor kW 2.2 3.7
Fa
n
Capacity m3/min 160 200 240 300 360 395
Motor kW 30 37 45 55 75
F.O
.
Heate
r Type - Electric Heater With Steam
Electric Power kW 17 13 17 20 25
Fe
ed
Wate
r
Pu
mp
Capacity m3/h 12 14 18 22 23
Pressure MPa 0.98 1.08
Motor kW 11 15 18.5
Control System - Proportional Control
Boiler Weight(Dry) kg 14,200 17,300 18,000 21,600 23,500
Normal Weight of BoilerWater
kg 5,020 6,650 6,890 8,200 9,170
Note 1: Power supply is 60Hz, 3 AC 220V or 440V.
Note 2: H.F.O.(*) with low calorific value of 41,000 kJ/kg (9,800 kcal/kg) is used.
15
5. Part Names and FunctionsPart names and functions are described here. Appearance and layout depend on type and capacity.
For details of product that is delivered, refer to final drawing.
5.1 Boiler Body
Figure 2-3 External View of Boiler
No Part name No Part name
1 Main steam valve 8 Fan
2 Burner 9 Control panel
3 Water level gauge 10 Fuel oil pump unit
4Boiler water
sampling valve11 Manhole (lower)
5 Manhole (upper) 12 Bottom blow valve
6Surface blow
valve13
Steam pressure gauge
unit
7 Funnel flange
(1) Main steam valve
Valve to supply steam to load side
(2) Burner
Equipment to burn fuel and to generate heatsource
(3) Water level gauge
Equipment that indicates water level of boiler
(4) Boiler water sampling valve
Valve to sample boiler water
(5) Manhole (upper)
This manhole is used to inspect and cleanboiler and water tubes.
(6) Surface blow valve
Valve to discharge concentrated boiler wateraround evaporation surface
(7) Funnel flange
Outlet of exhaust gas generated bycombustion of heavy oil (leading to funnel)
(8) Fan * 1
Equipment to send burner air for combustion
(9) Control panel * 1
Equipment to operate boiler
(10) Fuel oil pump unit * 1
Equipment to pressurize and heat fuel andsend it to burner
(11) Manhole (lower)
Same as (5)
(12) Bottom blow valve
Valve to discharge concentrated boiler water(including sludge)
(13) Steam pressure gauge unit *2
Unit of boiler pressure gauge and pressureswitches for combustion control
*1: Equipment installed separately from boiler.Installed into a unit here just for simplicity ofillustration.
*2: Equipment installed separately from boiler forstandard specifications. Depending onspecifications, it can be provided as part ofboiler.
16
5.2 Burner and Burner Piping Structure
1 Oil flow control valve 11 Atomized steam valve
2 Pneumatic fuel shutoff valve 12 Pressure reducing valve
3 Circulation relief valve 13 Solenoid valve for atomized steam
4 Emergency fuel switch valve (main) 14 Seal pot
5 Emergency fuel switch valve (pilot) 15 Equalizing valve
6 Solenoid valve for pilot burner 16 Cock for equalizing valve oil detection
7 Filter regulator 17 Main burner ASSY
8 Solenoid valve for fuel shutoff valve 18 Main baffle plate
9 Atomized air valve 19 Pilot burner ASSY
10 Solenoid valve for atomized air 20 Inner cylinder
Figure 2-4 Structural Diagram of Burner Figure 2-5 Structural Diagram of Burner Piping
17
5.3 Internal Structure of Boiler Body
Figure 2-6 Internal Structure of Boiler Body
Figure 2-7 Water Tube Arrangement
BurnerWind box
Upper drum
Water tube
Expansion ring
Heat insulator
Castable
Funnel flange
Lower drum
FunnelCombustion chamber
Inner casing
Stay
Outer casing
18
Boiler consists of doughnut shaped upper drum and lower drum that are connected through water
tubes. Water tubes with narrow ends are arranged as shown Figure 2-7. Combustion gas flows in
two directions as shown by arrows and meets again at exit to be discharged from funnel. While water
in innermost water tubes is subjected to flame, other water tubes are subjected to combustion gas
that passes through them. This allows efficient transfer of heat to water.
Casing consists of welded inner casing and outer casing. Heat insulating material is placed between
water tubes and inner and outer casing to restrict radiation of heat.
Inner lower part of furnace and narrow end part of water tubes are insulated with castable to prevent
short path of combustion gas.
Upper and lower drums have manhole to check inside. Check condition of scaling, corrosion,
pitching on tubes, and reflect results in boiler water treatment (For more details, refer to Manual for
Water Treatment). At furnace inspection, check for soot adherence, peeling of castable, fuel leakage
on furnace bottom, traces of water leakage and accumulations of unburnable materials.
19
6. Boiler Automatic Operation by Sequencer
6.1 Overview
Sequence control is automatic control that completes each control step following procedure that is
provided in advance.
This boiler starts fuel oil pump and fan operation, and after pre purge is completed sufficiently, ignition
device is started; after fuel valve is opened to ignite burner, start-stop of burner is controlled by steam
pressure switch. These steps are carried out automatically.
6.2 Flowchart
Figure 2-8 shows flowchart of basic operation of boiler; actual flow may be different depending on
specifications.
燃焼SW ON
ボイラ運転(燃焼モード)表示灯点灯
燃焼要求あり
送風機運転
点火トランス作動
パイロット電磁弁開
炎センサ炎検出
燃焼表示灯点灯
YES
YES
NO
プレパージ20秒
不着火警報報知点火トランス停止パイロット電磁弁閉
ボイラ運転表示灯消灯
NO
リセット操作
警報発生時燃焼遮断後リセット操作へ
イ ロ
|
Fuel oil SW ON
Flame censorFlame Detector
Reset
Pilot solenoid valveopen
Fan operation
Ignitiontransformer on
Boiler operation(Combustion mode)Indicator lump on
Misfire alarmIgnition transformer off
Pilot solenoid valve closeBoiler operation lamp off
Combustion lampon
Combustionis requested.
Pre
-pu
rge
(20
sec.)
Wh
en
ala
rmis
sta
rted
,re
se
ta
fte
rcom
bu
stio
nin
terc
epte
d.
(A) (B)
Figure 2-8 Flowchart of Basic Operation
20
Note
When alarm lamp related to burner interlock lights up, automatic recovery does not take place. Be
sure to perform reset operation.
燃焼電磁弁開
点火トランス停止パイロット電磁弁閉
電磁弁閉燃焼表示灯消灯
送風機停止
ポストパージ35秒
比例燃焼(状態移行初期30秒間は低負荷燃焼を継続)
燃焼要求あり
NO
YES
イ ロ
警報発生時燃焼遮断後リセット操作へ
(A)
Wh
en
ala
rmis
sta
rted
,re
se
ta
fte
rcom
bu
stio
nin
terc
epte
d.
Combustion solenoidvalve open
Ignition transformerstopped.
Pilot solenoid valve close.
Solenoid valve close.Combustion lamp off
Post-purge 35S
Fan stopped
Figure 2-8 Flowchart of Basic Operation (Continued)
(A) (B)
Combustion isrequested.
Proportional control combustion(Low combustion is continued for 30
seconds after combustion isentered.)
21
6.3 Operation Explanation of Steam Pressure Control
6.3.1 Proportional Control
Steam pressure regulator installed on control panel controls boiler burner and adjusts steam
pressure.
a) For 30 seconds after ignition, low combustion (20% load) is kept not to put boiler under heavy load.
30 seconds later, boiler is held under proportional control so that normal working pressure can be
kept in response to changes in steam pressure.
b) When steam consumption is lowered and boiler steam pressure is increased to reach higher
pressure limit, burner is stopped and post-purge(*) is performed.
c) When boiler steam pressure is decreased to lower pressure limit, combustion is started again
under proportional control so that normal working pressure is kept.
*1: At start of operation, atomized air is used (with M.D.O.(*)) to increase boiler steam pressure to 0.7
MPa.
Refer to page 34 “2.4 Starting Combustion with M.D.O” in Chapter 4.
Note
When air is used as atomized fluid, only M.D.O. can be used as fuel, and proportional control
cannot be used. (Forced low fire)
Sample settings of steam pressure regulator
Boiler steam pressure
Higher pressure limit
Normal working pressure
Lower pressure limit
Time
22
CHAPTER 3: BASIC OPERATION
1.Details of Control Panel and DisplayLayout and functions of control panel and display are described here. Actual layout and functions may
be different from those described here, depending on specifications. For details about layout of control
panel and display, refer to external view of control panel in final drawings.
1.1 Details of Control Panel and Display
Figure 3-1 Layout and Functions of Control Panel and Display
Turning this switch on starts boosterpump.
This switch can be used to check lamps on display.When switch is pressed, all the indicator lamps are lit.
Alarm display
Alarm lamps blink orlight up to warn of failures.
Lamp is on when combustionswitch is on.
Combustion lamp
Lamp is on whencombustion is continued.
Combustion switch
Pressing this switchallows boiler to start combustion.
Combustion stop switch
Pressing this switch allowsboiler to stop combustion.
Manual combustioncontrol part
Manual combustion switch
Auxiliary equipment is startedoperation by cam switch turning.Theignition transformer is not started untilpre-purge time elapses.For automatic combustion, set cam atAUTO.
Ammeter (fan)
It indicates current value of fan.
Buzzer stop switch
When alarm is started, this switch can be pressedto stop buzzer.
Alarm reset switch
This switch can be pressed to reset alarm.
Lamp test switch
Pre-purge completion lamp
This lamp lights up when operation time of fanexceeds set time in manual operation.When sufficient pre-purge lamp lights up, ignitiontransformer for manual operation is started.
Steam pressure regulator
Control equipment for proportional combustioncontrol based on boiler steam pressure.
Booster pump operation lamp
This lamp lights up when boosterpump is in operation.Booster pump operation switch
Atomized fluid selection switch
This switch can be used to switch atomized fluidbetween air and steam.
This switch can be used to switch main fuel oilpump between No. 1 and No. 2.
Fuel oil pump selection switch
This switch can be used during manual combustion toswitch between low combustion and proportionalcombustion control.
Indicator lamp (G: green, O: orange, W: white)
Selection switch
Push-button switch
It indicates current value of fan.
Boiler operation (COM MODE) lamp
Ammeter (fan)
Fuel heater switch
This switch can be used to switch by fuel oil type.When it isswitched to A, fuel heater is stopped.When it is switched to C,low oil temperature alarm function is enabled.When it isswitched to A, fuel heater is stopped.
Combustion changeover switch
Water level indicator Control equipment for opens and closes flow controlvalve depending on signal from differential transmitter.
23
1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch)
Figure 3-2 Manual Combustion Switch
Note
Do not use manual combustion switch except emergency.
1.3 Details of Alarm Display
Figure 3-3 Details of Alarm Display
Ignition transformer (pilot burner) is started.
It is not started until operation time of fan exceeds pre-purge time.If switch is shifted to IGNITION position before pre-purge time elapses,ignition transformer (pilot burner) remains stopped.
Fan is started.
Fuel oil pump and fuel oil heater are started.
All equipment is stopped.
Some self-diagnosisfunctions are also stopped.
Shifting switch to this position enables with ON.
Fuel oil pump and fuel oil heater are started.(When selecting C. A/C)Some self-diagnosis functions are enabled.
Fuel solenoid valve is opened.
Ignition transformer (pilot burner) remains running.
Ignition transformer (pilot burner) is stopped.
Combustion with main burner alone is continued.When combustion lamp is off, close combustion solenoidvalve.When combustion lamp is turned off, immediately shiftswitch back to FAN RUNNING position and perform purgefor 60 seconds or longer.Starting combustion without sufficient purge may cause fireor an explosion.
Circles (O) in the figure represent (red) indicator lamps.
24
CHAPTER 4: OPERATION
1. Inspection and Preparation before Operation1.1 Inspection and Preparation of Boiler and Peripheral Equipment
Before starting operation, check followings:
WARNING
Prohibition
Keep flammable materials away from boiler.
They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.
Do not put flammable materials in control box.
They may ignite to cause fire, resulting in accident involving death.
Instruction
Check that funnel (exhaust stack) is properly constructed.
Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around boiler related equipment.
Switching on or off wet equipment may cause electrical shock or fire from a short circuit.
Run ventilation (air supply and exhaust equipment) in engine room and check that air vent is
not blocked off.
If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may be
caused.
a) Check that funnel (exhaust stack) has been properly constructed.
If problem is found with funnel, do not operate boiler.
Restore funnel (exhaust stack) to normal state.
b) Check for water or oil leaks around boiler.
If leak is found, do not operate boiler. Turn off breaker of main power supply.
Remove cause of leak and dry the area completely.
c) Check where air inlet of engine room is and check that ventilation (air supply and exhaust
equipment) is working.
If engine room does not have air inlet, provide air inlet.
If air supply and exhaust equipment is stopped, bring it into operation.
25
d) Check that there are no flammable materials around boiler.
If flammable materials are found, remove them to safe place where flame is not used.
Improper storage of cloth stained with fuel or oil may cause it to ignite spontaneously. Handle
such materials carefully and dispose of them properly.
Wipe up spilt oil immediately.
e) Check where fire extinguishing system and first-aid kit are placed.
If these are not available, put them in place.
f) Check that contact numbers in case of fire or accident and how to handle such emergencies have
been established.
g) Check that there are no obstacles around boiler and in walkways.
If obstacles are found, put them back in place.
h) Check that air pressure in engine room is positive.
If air pressure in engine room is negative, install additional ventilator.
1.2 Inspection of Boiler Body and Accessories
a) Check equipment, inspection holes, covers, valves, and connections for water leaks.
If leak is found, fasten part or install it again to make it watertight.
b) Check that valves are opened and closed properly.
Check that outlet and inlet valves are opened.
Check that air vent valve is closed.
c) Check that drain pipe of safety valve is installed in safe place.
Check that wiring for operation of safety valves’ lever is operated normally.
d) Check that water level gauge glass is not stained and not damaged.
e) Check that needles of pressure gauges work properly.
When pumps are stopped, they are under head pressure only.
For details about inspection items, refer to page 47 “1.1 Regular Inspection and
Maintenance” in Chapter 5.
26
1.3 Inspection and Preparation of Feed Water System
WARNING
Do Not Touch
If you touch coupling of pump, which is spinning rapidly, you may get caught in it. Do not
touch coupling of pump during pump operation.
Instruction
If you touch hot piping of feed water system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
Caution: Hot
If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear
protective equipment while working around tank.
1.3.1 Inspection Items
a) Check that cascade tank contains sufficient amount of water.
b) Check that feed water is clean.
c) Check that oil has not gotten into feed water (Use observation measure to check that oil has not
gotten into feed water).
d) Check that automatic feed water valve (ball tap) works properly.
e) Check that valves on feed water line are opened and closed properly.
Check that all valves on feed water line of feed water pump in use are opened.
(Check that opening instruction of flow control valve is proper.)
Check that feed water pump in use matches switch number in control panel.
f) Check pipes for clogging, air inclusion, leaks, or loose connections.
g) Check that strainer on suction side is not clogged.
h) Check that seal of feed water pump has no leaks.
i) Check that needles of pressure gauge and compound gauge work properly.
j) Check chloride ion concentration of water in cascade tank (once a week).
For more details, refer to Manual for Water Treatment.
27
1.3.2 Flushing of Pipes
Note Following preparation procedure is needed when boiler is used for the first time or when pipe
system is repaired.
There may remain in pipes welding chips, rust or other foreign matters that may have bad
influence on feed water. Before feeding water, flush pipes with treated water or pressurized gas as
needed.
Whether flushing is needed or not depends on how pipes have been constructed. Before flushing
pipes, consult with constructor about procedure and safety precautions.
1.3.3 Air Vent
Note Following preparation procedure is needed when boiler is used for the first time or when pipe
system is repaired.
Let out air of pipes on suction side. Air remaining in pipes may cause cavitation, resulting in
damage of pump.
Prepare for operation of feed water pump according to instruction manual for feed water
pump.
28
1.4 Inspection and Preparation of Fuel System
WARNING
Instruction
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving
death. Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage
and waste cloth used to wipe off oil immediately in an appropriate manner.
Caution: Hot
If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.
CAUTION
Instruction
If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures
to prevent fuel oil spill and establish method for coping with spillage in advance.
1.4.1 Preliminary Inspection
a) Check that F.O. service tank contains specified fuel.
b) Check that F.O. service tank is heated moderately.
When H.F.O. (*) is used, heat it so that temperature reaches over 65°C at main fuel pump inlet.
c) Discharge drainage from F.O. service tank.
d) Check valves open-close condition on fuel piping between F.O. service tank and boiler.
Open all valves on supply line.
Close all air vent valves.
e) Check that there are no pipes clogging, loose connections, or fuel leaks.
Especially, check the top of boiler carefully because burner is often removed for inspections.
f) Check that pipe system has no place where air tends to build up.
g) Check fuel strainer has no clogging.
h) Check that fuel is supplied properly from service tanks to fuel oil pump.
If problems are found or fuel is not supplied properly, check whether or not booster pump is
working properly.
i) Check that needles of pressure gauges and thermometers are working properly.
29
1.4.2 Air Vent
a) Open valves of fuel system.
b) Open strainer air vent valve to remove air.
c) Close air vent valve after removing air.
Remove air for both main and pilot.
d) Close valve V-1 in Figure 4-1.Check that drain valve V-2
is closed.
e) Shift manual combustion switch to AUTO COMB.
position.
Main fuel oil pump starts running.
Check that main fuel oil pump motor is running in
right direction with no abnormal noise.
f) Open drain valve V-2 and remove air sufficiently.
g) Check fuel system for leaks.
If leak is found, immediately stop fuel oil pump to stop
leak.
h) Check in fuel oil temperature controller that fuel is heated to right temperature.
Refer to page 108 “8.4 Fuel Oil Temperature Controller” in Chapter 5.
1.5 Inspection and Preparation of Burner
a) Check that ignition rod is clean and parts size is normal.
b) Check that pilot nozzle tip and main burner nozzle are not clogged.
c) Check that flame eye (*) and glass are clean.
d) Check that lead wire is installed properly between ignition transformer (*) and ignition rod.
e) Check that screws, levers, lock nuts, and other parts of damper are not loosened.
f) Check that equipment around burner is installed properly.
g) Check that there is no fallen object (insulation materials, castable, etc.) in furnace.
h) Check furnace for boiler water or traces of fuel oil leaks.
i) Check that inner cylinder is not damaged.
j)) Check generating tubes for heavy soil, wastage, or pinholes.
k) Check that atomized air pressure is between 0.6 MPa and 0.9 MPa.
Figure 4-1 Valves around Oil Air
Separator (*)
To F.O. Tank or D.O.Tank
Oil air separatorFrom burner
30
1.6 Inspection and Preparation of Electrical System
WARNING
Do Not Touchwith Wet Hands
Do not operate breaker of main power supply and equipment in control panel with wet
hands.
Failure to observe this instruction may cause electrical shock due to high voltage, resulting in
injury or death.
a) Check that motors of fun, feed water pump, fuel oil pump, and other equipment run properly in
right direction.
b) Check that thermostats (exhaust gas, fuel oil heater (*), etc.), fuel oil temperature controller, and
pressure switch are set properly (Check setting values in list of principle items in final drawings).
c) Check that control panel is not damaged and that each equipment is installed properly.
d) Check for broken wires, loose screws, or damaged lamps or switches.
e) Check that power supply is as specified in list of principle items in final drawings.
f) Check external wiring of each equipment for broken wires or other problems.
1.7 Inspection and Preparation of Steam System
a) Check that valves on boiler and on steam piping are opened and closed properly.
b) Check that valves on boiler and on piping are installed properly.
If loose connections or other problems are found, retighten that part or install it again to bring
it back to normal condition.
c) Check that outboard valve for boiler water blow is closed.
d) Check that cooling water is circulating throughout drain cooler.
e) Check that excess steam dump valve is installed and set to specified pressure.
31
2. Automatic Operation (Normal Operation)
WARNING
Do Not Touchwith Wet Hands
Do not operate breaker of main power supply and equipment in control panel with wet
hands.
Failure to observe this instruction may cause electrical shock due to high voltage, resulting
in injury or death.
Instruction
If water or steam leaks out of system, burn, blindness, or accidents involving death may be
caused. During operation and after stop, check connections of piping and air vent valve for
leaks.
If you touch hot piping of water and steam system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving
death. Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage
and waste cloth used to wipe off oil immediately in an appropriate manner.
Surface temperature of upper part of boiler exceeds 60°C and may cause burn if surface is
touched. When working with upper part of boiler, wear gloves and other protective
equipment to prevent direct contact.
Switch fuel when boiler is in automatic operation mode. Operating error in manual
operation mode may cause backfire(*) or other accidents involving death.
Caution: Hot
If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear
protective equipment while working around tank.
If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.
2.1 Checking of Control Panel Switches
Check that all switches on control panel are set at OFF position.
If switch is not set at OFF, shift it to OFF position.
2.2 Feeding Water to Boiler
Before starting burner, feed water to boiler according to following procedure:
a) Open all valves from cascade tank to boiler.
b) Turn on boiler power supply.
c) Set feed water shift switch to AUTO and select pump to operate by feed water pump shift switch.
d) Turn on feed water pump start switch.
Operation indicator lamp of feed water pump lights up.
Buzzer of low low water level sounds. Press buzzer stop switch.
Check feed water pump and motor for abnormal noise or abnormal heating.
32
e) Check compound and pressure gauges on inlet and outlet of feed water pump.
f) Check in water level gauge that water supply is stopped at right level.
Check that water level gauge is cleaned and easy to read.
If it is dirty and difficult to read, clean it.
g) Check pipe system for water leaks.
h) Press alarm reset switch and check that low low water level lamp is turned off.
2.3 Feeding Water to Boiler by Differential Transmitter
CAUTION
Caution
In feed water control by differential transmitter, feed water pump control does not operate
properly when feeding water and adjustment of differential transmitter is not completed.
Boiler becomes fill with water and high water level, it may cause hot water blow out from
safety valve during boiler combustion.
Note
Supply water to differential transmitter when pressure of boiler body is atmospheric pressure
and temperature of water is normal. Feeding water to differential transmitter under high
temperature and high pressure may cause damage of differential transmitter.
Set feed water shift switch to AUTO after feeding water to piping of differential transmitter and
close bypass valve of manifold valve.
In case that feed water pump is operated before adjustment, feed water pump is not stopped
until high water level. Stop feed water pump manually.
2.3.1 Feeding Water to Differential Transmitter
Before feeding water to differential transmitter, flush pipes. Recommend procedure is described
below. Start operation when close all valve and plug.
a)Check that all manifold valve of differential transmitter is closed.
Feed water to boiler manually to upper level of root valve for low pressure side (position
above middle of water level gauge)
Open root valve for low pressure and drain valve of low pressure side piping when water is
accumulated.
Blow low pressure side piping until drain water is not dirty.
b)When drain water is not dirty, open all manifold valves, and close drain valve of low pressure side.
Open drain valve of high pressure side piping.
Take off plug of air vent valve of seal pot, and open air vent valve. Blow high pressure side
piping.
33
c)When drain water is not dirty, close manifold valve (bypass valve).
Supply water from air vent valve of seal pot. Or feed water to seal pot after raising water level
of boiler and opening root valve for high pressure side.
Continue to blow high pressure side piping.
Note
Select feed water from air vent valve of seal pot in case it can’t blow from high water level to return
to normal water level.
d)When drain water is not dirty, close drain valve of high pressure side pipng.
e)Accumulate water to air vent valve of seal pot.
Open root valve for high pressure side in case of feed water to boiler from air vent valve. Stop
supplying water and close air vent valve and install plug.
Close air vent valve and install plug in case that feed water from boiler. And blow to boiler
normal water level.
f)Feeding water of differential transmitter is completed in above procedure.
Figure 4-2 Reference piping layout of differential transmitter(Remote level gauge)
34
2.4 Starting Combustion with M.D.O. (*)
Note
When H.F.O (*) is used as main fuel (*), switch main fuel to M.D.O. in advance for cold start. If H.F.O
is used in cold start, poor combustion or failure of fuel oil pump may be caused. Similarly, before
stop operation, switch to M.D.O. in advance if it is expected that fuel oil pump will not be used for a
long period of time.
2.4.1 Combustion with Air Atomization
a) Close air vent valve of oil air separator (*).
b) Open and close return lines of booster pump leading to D.O. tank and to F.O. tank, respectively.
c) Open D.O. tank valve and close F.O. tank valve.
d) Open outlet and inlet valves of booster pump and start booster pump.
As for use of booster pump with M.D.O. combustion, follow rules of vessel.
e) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.
f) Shift fuel oil heater (*) switch to A position.
g) Shift atomized fluid selection switch to AIR position.
h) Close main steam valve and atomized steam valve and open atomized air valve.
i) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot
side.
j) Check that filter regulator pressure is set at 0.4 MPa.
k) Select pump to be used by fuel oil pump selection switch.
Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.
l) Shift manual combustion switch on AUTO COMB. position.
m) Press combustion switch.
After fan starts running and pre-purge (*) is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
35
2.4.2 Control and Checking during Operation (Combustion with Air Atomization)
After combustion is started, check that boiler is in normal operation.
Check that fuel flow amount, fuel oil pump discharge pressure, damper opening, and current
are not different substantially from those recorded on trial operation report.
Check that color, expansion, and stability of flame are the same as usual.
Check color of smoke (black) and check for any gas leakage from its path.
Check for vibration or abnormal noise.
If any problem is found, stop combustion and remove cause of problem.
Check fuel pipe system for fuel leaks.
Check that needles of pressure gauges do not jump.
2.4.3 Combustion with Steam Atomization
a) Check that boiler steam pressure is 0.7 MPa or above.If it is below 0.7 MPa, increase steam
pressure by combustion with air atomization.
b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized
steam.
c) Shift atomized fluid selection switch to STEAM position.
d) Check that main steam valve is closed.
e) Check that emergency fuel switch valve on main side is opened and emergency fuel switch valve
on pilot side is closed.
f) Check that filter regulator pressure is set at 0.4 MPa.
g) Select pump to be used by fuel oil pump selection switch.
Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.
h) Check that manual combustion switch is set at AUTO.COMB.
i) Press combustion switch.
After fan starts running and pre-purge (*) is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
Check that after about 30-second low combustion, proportional control combustion based on
steam pressure is started.
2.4.4 Control and Checking during Operation (Combustion with Steam Atomization)
a) Check that boiler is in normal operation.
Refer to “2.4.2 Control and Checking during Operation (Combustion with Air Atomization)”
in Chapter 4.
b) Check that when steam pressure increases and reaches max. design pressure, combustion is
automatically stopped.
Main fuel oil pump is stopped.
After about 35-second post-purge (*), fun stops running.
36
c) Open main steam valve gradually to send air to steam system.
Check steam system for leaks.
2.5 Combustion Stop
Press combustion stop switch.
Main fuel oil pump is stopped.
(When H.F.O.(*) is used, it continues to operate.)
After about 35-second post-purge (*), fun stops running.
<Perform following operations as needed :>
○ Blow of boiler through surface, bottom and of water level gauge
○ Closing valves of feed water system and fuel system
Note
When switching fuel from M.D.O.(*) to H.F.O., check that boiler steam pressure is 0.7 MPa or
above, and then close mail steam valve and stop combustion.
2.6 Shift from M.D.O. to H.F.O.
a) Operate boiler with M.D.O. properly.
b) Heat F.O. service tank to proper temperature (between 80°C and 90°C).
Heat tank so that temperature reaches over 65°C at main fuel oil pump inlet.
c) According to procedure in 2.4, stop boiler and F.O. booster pump.
d) Open and close return lines of booster pump leading to F.O. tank and to D.O. tank, respectively.
e) Open F.O. tank valve and close D.O. tank valve.
f) Run booster pump.
Check that heated H.F.O. is flowing through return lines of booster pump.
g) Shift manual combustion switch to AUTO.COMB position.
h) Press combustion switch.
Main fuel oil pump is started.
After fan starts running and pre-purge (*) is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
Check that after about 30-second low combustion, proportional control combustion based on
steam pressure is started.
i) Shift fuel oil heater (*) switch to A/C position.
Note
When fuel oil heater switch is shifted to A/C position, fuel oil heater is turned on with low oil
temperature alarm function disabled.
37
j) Adjust opening of air vent valve of oil air separator (*).
Adjust opening according to combustion state.
k) Open steam trace valve of boiler fuel oil pipe.
l) When indication of fuel oil heater (*) temperature controller reaches setting value (refer to page 78
“5.3.3 Heavy Oil Heating Temperature” in Chapter 5.), and pressure is settled, slightly open drain
valve on fuel return line of oil air separator and visually check that oil has been fully replaced.
m) Shift fuel oil heater switch from A/C position to C position.
Low oil temperature alarm function is enabled.
n) Check that boiler is in normal operation.
Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)” in Chapter 4.
Note
If fuel is heated before M.D.O.(*) is fully replaced with H.F.O.(*), fuel is vaporized to cause cavitation
in fuel oil pump. If abnormal noise or rapid change of pressure gauge value is observed,
immediately shift fuel oil heater switch to A position (turn off fuel oil heater) and check again that
M.D.O. has been fully replaced with H.F.O.
2.7 Shift from H.F.O. to M.D.O.
a) Operate boiler with H.F.O. properly.
b) Open M.D.O supply valve, and close H.F.O. supply valve quickly.
c) Close steam trace valve on boiler fuel oil pipe.
d) Shift fuel oil heater switch to A position.
e) Check that fuel oil heater outlet temperature is decreased and pressure is stable.
f) Fully close air vent valve of oil air separator.
g) Slightly open drain valve on fuel return line of oil air separator and visually check that oil has been
fully replaced.
h) Open and close return lines of relief valve of F.O. booster pump leading to D.O. tank and to F.O.
tank, respectively.
i) Check that boiler is in normal operation.
Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)” in Chapter 5.
Note
Switch fuel to M.D.O. when boiler is shut down for a long period. Low temperature F.O. may
damage fuel oil pump, mechanical seal, solenoid valves and fuel oil heater.
38
3. Emergency OperationEmergency operation is function that restarts boiler quickly when low atomized steam pressure alarm is
issued or when boiler steam pressure is temporarily decreased during combustion with H.F.O.(*).
This function switches atomized fluid to air, circulates H.F.O. in fuel piping, and temporarily causes main
burner to burn M.D.O.(*) in pilot burner line.
This is emergency operation, and cannot be used in other situations.
3.1 Emergency Combustion Operation
a) Press combustion stop button and check that combustion is stopped.
Main fuel oil pump continues to operate.
After about 35-second post-purge (*), fun stops running.
b) Close main steam valve, atomized steam valve, and valve on boiler body for atomized steam and
open atomized air valve.
c) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.
d) Check that filter regulator pressure is set at 0.4 MPa.
e) Shift atomized fluid selection switch to AIR position.
f) Close emergency fuel switch valve on main side and open emergency fuel switch valve on pilot
side.
g) Check that manual combustion switch is set at AUTO.COMB.
h) Press combustion switch.
After fan starts running and pre-purge (*) is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
3.2 Control and Checking during Operation
Check that boiler is in normal operation.
Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)” in Chapter 4.
3.3 Restoration to Normal Combustion and Checking of Combustion
a) Check that boiler steam pressure is 0.7 MPa or above.
If it is below 0.7 MPa, increase steam pressure by emergency combustion.
b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized
steam
c) Shift atomized fluid selection switch to STEAM position.
39
d) Check that main steam valve is closed.
e) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot
side.
f) Press combustion switch.
After fan starts running and pre-purge is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
Check that after about 30-second low combustion, proportional control combustion based on
steam pressure is started.
g) Check that boiler is in normal operation.
Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)” in Chapter 4.
40
4. Manual Operation (Use Only in Emergency)
WARNING
Prohibition
If automatic operation is hindered by parts damage or another reason, remove cause of
problem and start automatic operation again.
This boiler has manual operation circuit for emergency operation when automatic operation
is hindered. Operating error in manual operation mode, in which some safety systems are
disabled, may cause accident involving death. Do not use manual operation mode except in
emergency. If manual operation circuit must be used for unavoidable reason, follow
instructions in this manual.
Cases in which automatic operation cannot be continued are as follow:
<Feed water pump circuit>
Failure of instrumentation
<Combustion circuit>
Sequencer trouble
Sensor trouble, interlock by abnormality detection
In manual operation mode, backfire (*) or other accidents involving death by ignition error or
fire by empty heating may be caused. Do not use manual operation mode except in
emergency. If manual operation circuit must be used for unavoidable reason, follow
instructions in this manual.
During manual combustion operation, do not shift fuel (M.D.O.(*) ↔ H.F.O.(*)).Failure to
observe this instruction may cause backfire or other accidents involving death.
Instruction
Perform purge operation sufficiently before ignition and when combustion is stopped.
Insufficient purge operation may cause backfire or other accidents involving death.
Pre-purge (*) (before ignition): 20 seconds or longer *
Post-purge (*) (when combustion is stopped): 60 seconds or longer.
* In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit after
20-second or longer pre-purge.
41
WARNING
Caution
In manual operation mode, following interlock functions of safety system are disabled.
Improper operation may cause accidents involving death. Be careful with operating boiler in
manual operation mode.
Interlock functions disabled when manual combustion circuit is used:
Fuel oil pressure low (fuel)
Fuel oil temperature high (fuel)
Fuel oil temperature low (fuel)
Steam pressure high
Steam pressure low
Abnormal fire
These interlock functions work only when all functions are working properly. When there are
problems with sensors or other parts, interlock functions may not work properly.
There are two circuits for manual operation: one for manual feed water pump operation and another for
manual combustion operation.
4.1 Starting/Stopping Manual Feed Water Pump Operation
Note
When feeding water manually, do not leave boiler.
Proportional control from differential pressure is operated, but high level alarm is disabled.
4.1.1 Starting Manual Operation
a) Turn on breaker of main power supply.
Power lamp lights up.
b) Select pump to be operated by feed water pump shift switch.
Check that outlet and inlet valves of feed water pump to be used are opened and closed
properly.
c) Set feed water shift switch to MANU.
Feed water pump is started.
4.1.2 Stopping Manual Operation
Set feed water shift switch to OFF.
Feed water pump is stopped.
42
4.2 Manual Combustion
Note
When manual combustion is performed, do not leave boiler. If there is any problem, it is not
controlled automatically.
Enter manual operation by shifting manual combustion switch in order. Manual combustion switch
can be set to the following positions: [OFF], [F.O. PUMP/HEATER], [FAN RUNNING], [IGNITION]
(ignition (pilot burner)),[ PRI.COMB.] (preliminary combustion (double combustion with pilot burner
and main burner), [COMB.] (combustion (single combustion with main burner). These positions are
arranged in this order. Boiler also has combustion changeover switch that can be used to switch
between low combustion and proportional control combustion. Because individual operation of each
equipment is not allowed for safety reasons, turn cam switch in order to check operation.
Procedure for starting combustion with air atomization using M.D.O. (*) as main fuel (*) is described
below:
a) Check that manual combustion switch is set at [OFF].
b) Check that combustion changeover switch is set at [LOW] (low
combustion).
c) Follow steps a) to k) in 2.4.1.
Refer to page 34 “2.4.1 Combustion with Air
Atomization” in Chapter 4.
d) Shift manual combustion switch to [F.O. PUMP/HEATER].
Main fuel oil pump is started.
Check that fuel is circulating properly (Check oil pressure gauge).
e) Shift manual combustion switch to [FAN RUNNING].
Fan is started.
Check for abnormal noise.
f) Check that pre-purge (*) completion lamp lights up.
Combustion can be started when pre-purge completion lamp
lights up.
g) Shift manual combustion switch to [IGNITION].
Ignition rod sparks and pilot burner ignites.
Check through sight glass that pilot burner is burning.
Note
If pilot burner is not burning, immediately shift manual combustion switch back to [FAN RUNNING]
and repeat f) and subsequent steps in 4.2.
43
h) Shift manual combustion switch to [PRI.COMB.].
Double combustion with pilot burner and main burner is started.
Check through sight glass that it is burning.
Note
If main burner is not burning, immediately shift manual combustion switch back to [FAN
RUNNING] and repeat f) and subsequent steps in 4.2.
i) Shift manual combustion switch to [COMB.] position.
Pilot burner is put out, and combustion is continued with main burner alone.
Check through sight glass that it is burning.
Note
If main burner is not burning, immediately shift manual combustion switch back to [FAN
RUNNING] and repeat f) and subsequent steps in 4.2.
j) When combustion changeover switch is shifted to [AUTO.] (proportional control combustion)
during combustion with steam atomization, proportional control combustion is started.
4.3 Manual Combustion Stop
a) Shift manual combustion switch from [COMB.] to [FAN RUNNING].
Combustion is stopped. Only fan continues to operate.
Keep switch at [FAN RUNNING] for 60 seconds or longer for post-purge (*).
b) Shift manual combustion switch to [OFF].
Fan and main fuel oil pump are stopped.
44
5. Emergency Stop
DANGER
Caution
Emergency stop is operation that gives top priority to stopping boiler immediately in
emergency. If breakers are turned off inadvertently, feed water and circulating water pumps
may be stopped to cause soot fire or furnace explosion. Do not use this function except in
emergency.
Emergency stop is operation that gives top priority to stopping boiler immediately in
emergency. Emergency stop skips safety checks for ongoing operation and may cause
unexpected accident or failure. Use this function only when there is unavoidable reason for
bringing boiler to emergency stop. Users must judge when and how boiler should be
brought to emergency stop because it depends on situation.
When resuming operation after emergency stop, ensure that switches are turned on or off to
stop all ancillary equipment before turning power on. Otherwise, equipment may start to
work unexpectedly to cause accidents.
Procedure of boiler emergency stop because of accident or other necessity to stop boiler urgently is
described here.
5.1 Emergency Stop of Combustion System
5.1.1 Cases in which Emergency Stop is Required
Fuel oil leaks
Considerably poor combustion
Abnormal noise from fan or fuel oil pump
Exhaust gas leaks
When part of body or object gets caught in rotating parts of fan or fuel oil pump, etc.
5.1.2 Stop Procedure
a) Shift manual combustion switch to OFF position.
Fuel oil pump and fan are stopped, and combustion is stopped.
b) Close main fuel valve.
5.2 Emergency Stop of Entire Boiler
5.2.1 Cases in which Emergency Stop of Entire Boiler is Required
Fire
When all running equipment should be stopped immediately, etc.
5.2.2 Stop Procedure
Stop power supply to boiler or turn off power supply breaker in control panel.
All equipment is stopped.
45
6. Cold StartWhen boiler water becomes completely cold and especially when trial operation is started or new boiler
is brought into operation, start boiler with followings in mind:
For cold start, it needs to take enough time until steam pressure is raised to 0.1 MPa because each
part of boiler is completely cold.
Note
Do not raise steam pressure rapidly.
a) Raise steam pressure gradually to 0.1 MPa by repeating 1 minute combustion and 4 minute
purge.
Keep steam pressure at 0.1 MPa for 10 minutes.
While steam pressure is between 0.1 MPa and 0.2 MPa, repeat 2 minute combustion and
3 minute purge to raise pressure.
b) When steam pressure reaches around 0.2 MPa, stop boiler.
Retighten bolts and nuts around fastening parts and connections of valves on body, manhole
packing and water level gauge.
c) Blow water level gauge to make it easy to check.
d) Blow boiler water and purify water.
Make boiler water purify.
e) After steps a) to d) are finished, turn on combustion switch to start combustion again.
f) When steam pressure is increased to maximum pressure for general use, check for steam
leaks.
g) Open main steam valve and start automatic operation.
46
CHAPTER 5: INSPECTION AND MAINTENANCE
1. List of Inspection Items and Inspection Frequencies
WARNING
Caution
Surface temperature of the top of boiler exceeds 60°C and may cause burn if surface is
touched. Take extra care in daily inspection work.
CAUTION
Instruction
When cleaning strainer or performing other work using oil, wear protective equipment to
protect eyes and body from splashes of oil.
In order to prevent accidents, carry out inspection and cleaning listed below regularly.
(Some items should be inspected depends on system.)
List shows standard inspection frequencies. More frequent inspections may be required, depending on
use conditions or environments.
Carry out inspections with appropriate frequency on your own responsibility.
Note
When carrying out inspections, put sign on boiler stating that it is under inspection.
47
1.1 Regular Inspection and Maintenance
Inspection/maintenance itemEveryday
Everyweek
Everymonth
Every 3months
Everyyear
Whendocked
Check of ventilation ●
Check of surroundings for flammable materials ●
Check of funnel (exhaust pipe) ●
Check of feed water pump for leaks or abnormal noiseand check of pressure gauge
●
Retightening of valves, gland, and flanges (only whensigns of leaks are found)
●
Drainage of fuel service tank ●
Blow of water level gauge P 97 ●
Inspection and adjustment of drive part of dampers P 59 ●
Sampling of boiler waterManual for
WaterTreatment (●)
Blow of boiler through surface and bottomManual for
WaterTreatment (●)
Hardness check of water softenerManual for
WaterTreatment (●)
Cleaning of fuel strainer P 63 - 65 (●) ●
Maintenance of burner body (Baffle plate, rectifier grid, etc.) P 52 - 55 ●
Inspection of burner nozzle P 52 - 55 ●
Inspection of ignition rod for cracks and adjustment ●
Inspection of wind box(*)
●
Inspection of fan P 55 ●
Inspection of link of blower suction damper P 57 ●
Measurement of insulation resistance of each motor P 56 ●
Inspection of flexible tube P 59 ●
Inspection of oil flow control valve, air flow controllerand damper
P59,60 ●
Inspection of control motor P 61 ●
Inspection of dirt on flame eye(*)
/glass. P 62 ●
Inspection and adjustment of discharge pressure offuel oil pump
P 66-68 ●
Inspection and adjustment of circulation relief valve P 69 ●
Visual inspection of wiring ●
Inspection of motor ball bearings P 56 ●
Inspection and cleaning of dirt on feed water strainer ●
Drainage of cascade tank ●
Inspection of drive valve for burner control P 70~ ●
Inspection and adjustment of fuel oil thermostat P79,80 ●
Inspection and adjustment of pressure switch P 82 - 84 ●
Operation check of each safety system P 87~ ●
Operation test of exhaust gas thermostat P 90 ●
Check of main burner assembly for fuel oil leaks ●
Inspection and adjustment of coupling for fuel oil pump ●
Inspection of inner cylinder of burner ●
Greasing of bearing of blower suction damper P 57 ●
Cleaning of water level detecting rods and holder andcheck of continuity and insulation
P 97 - 98 ●
Inspection of differential transmitter P 85 ●
Inspection of flow control valve P 86 ●
Cleaning and inspection of fuel oil heater P 95 ●
Inspection of feed water check valve ●
Voltage check of flame detector P 99 ●
48
Inspection/maintenance itemEveryday
Everyweek
Everymonth
Every 3months
Everyyear
Whendocked
Inspection of inside of boiler ●
Inspection of combustion chamber and cleaning of
furnace with water to remove sootP 100 ●
Inspection and cleaning of inside of fuel service tank ●
Inspection of inside of chimney ●
Inspection of valve on boiler ●
Cleaning of inside of cascade tank ●
Inner inspection and maintenance of differential transmitter ●
49
1.2 Safety Valve
WARNING
Prohibition
Improper adjustment of blow off pressure of safety valve may damage boiler body.
As a rule, do not adjust blow off pressure of safety valve.
Remodeling of safety valve may damage boiler body.
As a rule, do not remodel safety valve.
Instruction
If steam leak from safety valve is found, replace part and repair it immediately.
When steam leak is left, function of safety valve is decreased and there is possibility of
leading to serious accident
Safety valve is safety device that is installed to prevent boiler steam pressure from exceeding
maximum allowable working pressure; full-bore safety valve is used for this boiler. Normally, safety
valve does not operate because steam pressure switch works. When pressure switch does not work
for some reason and combustion is continued to cause abnormal steam pressure increase or rapid
pressure increase is caused by rapid load change, safety valve protects boiler by blowing steam off
and lowering steam pressure. As a rule, two or more safety valves are installed and they are
selected so that total blow off level exceeds the maximum evaporation level of boiler for safety.
Boiler safety valve is set at presence of inspector, so as to blow off at strictly limited pressure;
nobody is allowed to make attempt of further adjustment on board. However, only in case of
emergency, such as when safety valve leaks, some countermeasures, such as opening or adjusting
valve, can be taken at discretion of chief engineer. In that case, adjust blow off pressure of safety
valve according to procedure that is described in next page.
1.2.1 Internal Structure of Safety Valve
<50A or less>
No. Part name
1 Valve casing
2 Valve seat
3 Valve body
4 Adjustment ring
5 Valve cylinder
6 Lift control bush
7 Spring
8 Valve stem
9 Adjusting bolt and nut
10 Cap
11 Valve lift lever
Figure 5-1 Internal Structure of Safety Valve : 50A or less
50
<65A or more>
1.2.2 Adjustment Procedure of Safety Valve
a) Unlock key on shaft of valve lift lever (11), pull out shaft, and remove lift lever.
b) Remove cap (10) by loosening setting bolt.
c) Loosen nut (9) of adjusting bolt and activate safety valve.
● Switch to manual operation of boiler and check that steam goes up and blow off pressure of
safety valve.
d) Turn adjusting bolt (9) to left if blow off pressure is higher than pressure limit and to right if it is
lower than that, so that it blows off at limited pressure.
e) After adjustment, fasten adjusting nut (9) tightly to fix it securely.
f) Put cap back in place, set valve lift lever, and lock and fix key.
1.3 Other Important Inspection Items
<Boiler Water Treatment>
The procedure for water treatment is described in Manual for Water Treatment. Most of boiler
accidents come from faulty water treatment; read and understand instruction manual thoroughly for
water treatment.
Manual also describes procedure of long-term boiler shutdown. Refer to "Manual for Water
Treatment".
Note
If boiler that is designed 60 Hz power supply inside of vessel is docked and operated in 50 Hz land
power supply, each motor capacity for 60 Hz is decreased and cases lack of combustible air,
insufficient fuel flow rate. Be sure to use power supply on vessel. If boiler that is designed 50 Hz
power supply is operated in 60 Hz land power supply, motor is burned and magnetic contactor is
tripped.
No. Part name
1 Valve casing
2 Valve seat
3 Lower ring
4 Set bolt
5 Valve body
6 Upper ring
7 Guide
8 Valve stem
9 Adjusting bolt and nut
10 Cap
11 Valve lift lever
12 Spring
Figure 5-1 Internal Structure of Safety Valve : 65A or more
Stud bolt
Nut
51
2. Daily Inspection and Maintenance
Peripheral equipment depends on system. Use equipment properly according to instruction manual.
Put instruction manuals together with this manual in place so that they can be read whenever they are
needed.
For details about inspections of equipment around boiler before operation and monitoring for problems
during operation, refer to “1. Inspections and Preparation Before Operation,” "2.4.2 Control and
Checking during Operation (Combustion with Air Atomization),” and "2.4.4 Control and Checking during
Operation (Combustion with Steam Atomization" in Chapter 4.
Refer to page 24 “1. Inspections and Preparation Before Operation” in Chapter 4.
Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)” in Chapter 4.
Refer to page 35 “2.4.4 Control and Checking during Operation (Combustion with Steam
Atomization)” in Chapter 4.
52
3. Weekly Inspection and Maintenance
3.1 Main Burner
WARNING
Instruction
Complete purge by fan before burner opening and inspection to make combustion chamber
cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.
Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it
properly.
3.1.1 Overview
Main burner consists of main burner body with burner nozzle and guide pipe with baffle plate. In
burner nozzle, fuel oil sent by fuel oil pump is mixed with fluid for atomization (air or steam). The
mixture is squirted out of cap end and atomized.
Burner nozzle consists of cap, mixer, nozzle, check valve, and ferrule. Fuel oil sent from center of
burner nozzle and fluid for atomization supplied from circumference are squirted out of nozzle, mixed
in mixer, and then atomized through opening in cap. Check valve is installed before nozzle to prevent
oil dripping when combustion is stopped.
Clean main burner on a weekly basis.
3.1.2 Disassembly and Adjustment
< Main burner>
a) Loosen 2 hexagon socket set bolts on top of guide pipe and pull out burner gun.
b) Remove burner nozzle from main burner in ferrule position.
c) Disassemble burner nozzle into cap, mixer, nozzle, check valve, and ferrule.
● When disassembling it, pull out lock screws completely. Failure to pull out lock screws may
damage burner nozzle.
d) Wash these components with light oil, clean them with air, and assemble them by following
disassembly steps in reverse.
53
<Guide pipe>
a) Remove nut on upper plate and pull out guide pipe.
b) Remove baffle plate, wash these components with light oil, clean them with air, and assemble
them by following disassembly steps in reverse.
Figure 5-3 Structure of Burner
3.2 Nozzle Tip
CAUTION
Caution
Improper spray volume, spray angle, and spray form cause poor combustion and sometimes
cause backfire (*). Use only genuine parts.
No. Part name
1 Guide pipe
2 Main burner
3 Pilot burner
4 Cap
5 Mixer
6 Nozzle
7 Check valve
8 Ferrule
9 Lock screw
10 Upper plate
Enlarged View of Section A
Fuel oil inlet
Atomized fluid inletD.O. inlet
x 3 x 3 x 3
Atomized fluid
Fluid oil
54
3.3 Pilot Burner
3.3.1 Overview
This burner comes with pilot burner designed for use with M.D.O.(*). Pilot burner consists of baffle
plate, nozzle tip, nozzle holder, check valve, ignition rod, and nozzle pipe.
Oil entering nozzle tip of pilot burner goes through strainer and trench of distributor and enters
evolution room. Conical evolution room has orifice in its end. Oil increases its speed while swirling in
evolution room, passes through orifice, and then is sprayed to combustion chamber.
Nozzle tip is made of hard material as high-pressure, high-speed oil wears away orifice and other
parts. Replace it on a yearly basis.
No. Part name
1 Baffle plate
2 Nozzle tip
3 Nozzle holder
4 Check valve
5 Ignition rod
6 Nozzle pipe
Body Distributor Strainer
Figure 5-4 Structure of Pilot Burner
Figure 5-5 Nozzle Tip of Pilot Burner
55
3.3.2 Disassembly and Adjustment
a) Remove bolt on pilot burner and pull out pilot burner.
b) Remove nozzle tip, baffle plate, and ignition rod from pilot burner.
c) Disassemble nozzle tip into strainer, distributor, and strainer, wash these parts and baffle plate
with light oil, and clean them with air.
d) Remove soot out of ignition rod with brush.
e) After cleaning these parts, adjust their dimensions with reference to pilot burner dimensions
shown in Figure 5-3 and burner dimensions measured in trial operation, and assemble them.
4. Monthly Inspection and Maintenance
4.1 Fan
DANGER
Instruction
Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to
deterioration of impeller or external force, resulting in injury or death.
WARNING
Instruction
Before moving impeller by hand, turn off main power supply. If impeller is rotated accidentally
during maintenance, physical injury may be caused.
4.1.1 Overview
Fan, which forces air into boiler, secures wind pressure and wind flow by rotating impeller by motor.
This boiler has fan with high wind pressure and high revolution speed because combustion gas
speed is high for efficient heat exchange with combustion gas.
Attention and care are required to prevent foreign particles from clogging wire mesh of suction.
When there is significant vibration even after impeller is cleaned, bearing replacement or impeller
adjustment is required.
56
4.1.2 Regular Maintenance
a) Inspect fan once a month.
b) Check for vibration, strange noises, and abnormal bearing temperature increase during
operation. When fan is not in operation, turn off power supply, and move impeller by hand to
check for problems.
● Conduct insulation test once a month, after long-term shutdown, and when it is necessary. If
insulation resistance is below 1 MΩ, replace motor or unship and repair it.
● Motor bearing requires grease injection.
Grease motor bearing regularly according to notes on greasing on motor. Greasing is not
needed for HB-08T type because grease is sealed in bearing.
① HB-10T, 12T ② HB-15T, 18T, 20T
Figure 5-6 Bearing Grease Inlet
Table 5-1 List of Bearing Greases
Model
GreasingAmountto inject
(g)
Interval(hrs)
Recommended grease
①12T10T
20 1200
Exxon Mobil :Beacon 325
Nippon Oil Corporation :multinoc SDX
JOMO :LT Grease
Shell :Albania Grease HVQ
②20T18T15T
35 800
Esso :UnirexN2,N3 or S2(lithium complex base)
Mobil :Mobilith SHC 100(lithium complex base)
Shell :Albida EMS2(lithium complex base)
SKF :LGHQ3(lithium complex base)
Klumber :Kluberplex BEM 41-132(spectial lithium base)
FAG :Arcanol TEMP110(lithium complex base)
※ 08T Greasing is not needed because grease is sealed in bearing.
57
4.2 Suction Damper (Attachment of Blower)
WARNING
Instruction
Inspect suction damper once a month. Failure to inspect suction damper may cause damage
of part and malfunction due to looseness of part, resulting in injury or death.
4.2.1 Overview
Suction damper opens fully when combustion is started and it closes fully after post purge(*) of
combustion stop for restraining heat loss due to blowing of continuous-running fan motor.
3 damper plates are connected to motor with damper arm. They open and close in interlock with
rotation of motor. Limit switch is installed on damper arm part to check that damper opens fully during
combustion.
Oscillation and external force apply to damper continually, so pay attention to looseness of part etc.
Figure 5-7 Suction Damper
4.2.2 Inspection
a) Confirm that there is no looseness of fastening part once a month.
(Link block, damper arm and damper plate)
b) Grease bearing of damper shaft once every three months.
・Required grease is alvania grease S3 (SHOWA SHELL SEKIYU K. K.). Greasing amount is 1.4g.
c) Confirm that there is no looseness of fixed screw and wiring once a month.
・This boiler doesn’t shift to automatic combustion if motor is damaged.
Motor
Damper body
Limit Switch
Damper arm
Motor arm
Motor wiring hole
Wiring fixing base×3
Wiring holeLink block
58
4.2.3 Measures on Failures (Fixing Fully Open State)
In case that damper doesn’t fully open automatically due to malfunction of motor, this boiler doesn’t
shift to automatic combustion, so damper needs to be fixed in open state forcibly.
Follow the following instructions for fixing damper.
a) Remove link block of tip part of motor arm A.
b) Pull up connecting rod until damper opens fully.
Confirm that damper arm touches limit switch in that position.
c) Let removed link block through connecting rod and fix motor arm B and connecting rod firmly.
d) Confirm that damper is fixed in open state.
Figure 5-8 Diagram of fixed position of open state (Left: Fully closed, Right: Fully open)
Connecting rod
ucture of Safety
Link block
Motor arm B
Motor arm A
59
4.3 Fuel Flexible Tube
WARNING
Instruction
Do not give impact to boiler fuel pipe or bend any part of it.
Failure to observe this instruction may cause fuel oil leak, resulting in fire.
Flexible tube on burner is used at high temperature and high pressure.
Generally, it needs to be replaced once every 1 or 2 years.
4.4 Oil Flow Control Valve, Air Flow Controller, and Damper
WARNING
Instruction
Equipment has been brought into optimum state in trial operation. Do not make changes to
state after trial operation. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA
offices and ask for instructions.
4.4.1 Overview
Fuel oil flow rate and air flow rate are adjusted by oil flow control valve, air flow controller, and
damper.
Oil flow control valve changes its opening to adjust fuel oil flow rate. By rotating control motor on oil
flow control valve shaft, slot in shaft is rotated to change inner opening.
Air flow controller attunes throttling characteristics of oil flow control valve to air flow throttling
characteristics of damper. It has leaf spring bent into a fan-like shape, along which damper drive arm
moves. This leaf spring has 8 adjustment bolts, with which spring's shape can be changed to adjust
air flow throttling characteristics of damper. This mechanism adjusts air flow to optimum rate for
combustion levels at different combustion loads.
Damper is subject to continuous vibration and external force and must be checked for loose parts.
60
4.4.2 Inspection
Loose parts of damper cause changes in damper opening. Check damper drive arm and leaf spring
for loose lock screws on a monthly basis. If loose parts are found, retighten them or apply grease.
Coupling is connects motor and air flow controller shaft by tightening lock screw. Inspect looseness
of lock screw once a month because it can not control combustion normally when lock screw is
loosened. If loose parts are found, retighten them additionally and check that control motor opening
and air flow control valve opening have not deviated from position in trial operation.
図 5-6 燃焼調整ダンパ
Figure 5-9 Oil Flow Control Valve and Air Flow Controller
Damper
Damper drive arm
Lock nut
Damper drive arm
Damper drive arm
Lock nut
Control motor
Leaf springAir flow controller
Air flow controller
Leaf spring
adjusting bolt
Oil flow control
valve
Coupling
Control valve
opening instruction
plate
Coupling
Lock screwControl motor opening
Coupling
Air flow controller
Leaf spring
adjusting bolt
Lock screw
61
4.5 Control Motor
4.5.1 Overview
Control motor controls oil flow control valve and damper to realize proper combustion conditions for
different pressure conditions according to signals from steam pressure regulator. It also has cam
switches in it, which notify control panel of damper position.
Because it repeats opening and closing constantly during combustion control, parts of control motor
inside are consumed gradually. Generally, it needs to be replaced at every docking.
Figure 5-10 Control Motor
4.5.2 Inspection
If control motor is failed, it cannot be burned normally.
Inspect fixed screw and wiring for looseness every month.
62
4.6 Flame Eye (*)
Figure 5-11 Flame Eye
4.6.1 Overview
Flame eye is a device that detects flame during combustion and gives instruction to combustion
circuit. It monitors flame by using photosensitive characteristic of CdS (cadmium sulfide cell)
(Normally, when resistance of 100 kΩ catches flame, it drops under 500 Ω).
If flame eye is damaged or protection glass is blackened with soot, it cannot detect flame and
stops burner and brings it to the same state as when ignition failure or flame-out occurs.
4.6.2 Inspection and Cleaning
Ignite burner with burner switch and look in furnace through sight window. If flame dies out about 3
or 4 seconds after burner is ignited, flame eye or flame detector may be out of order or protection
glass soiled. Inspect and clean protection glass on a monthly basis.
Refer to page 99 “6.3 Flame Detector (FS-901) ” in Chapter 5.
1 Flame eye
2 Flame eye fitting box
3 Flame eye fitting stand
4 Protection glass
5 Packing (2 pcs.)
63
4.7 Strainer for Fuel
4.7.1 T-type Auto-cleaner
T-type auto cleaner removes dust and other impurities from fuel to prevent them from entering and
damaging fuel oil pump, solenoid valves, or burner nozzle. It is installed on suction side of fuel oil
pump.
<Cleaning>
Element of auto cleaner can be cleaned during operation. To prevent it from being clogged, turn
handle and clean it at least once a day.
Drain all water and sludge from strainer once a month.
Figure 5-12 Oil Strainer
1 Cleaner cover 9 Air vent plug 17 Square rod
2 Oil tank 10 Packing 18 Round rod
3 Handle 11 Upper end 19 Drain plug
4 Main shaft 12 Lower end 20 Packing
5 Gland 13 Fixing plate 21 Washer
6 O ring 14 Packing 22 Nut
7 Ring 15 Filter plate 23 Cap nut
8 Packing 16 Scrapper plate
64
a) Draining strainer
Close main valve of fuel service tank, loosen drain plug (19) in lower part of strainer, and drain
water and impurities from strainer.
b) Disassembling and cleaning
● Check main valve of oil tank is closed.
● After draining of strainer, remove bolt on the upper part of oil strainer to remove cup.
● Clean dust off plate filter with oil.
● Assemble strainer in reverse order.
c) Air vent
● Open main valve of oil tank and slightly loosen air vent plug (9) on the upper part of auto cleaner.
● When air is removed and oil starts to come out of loosened screw, fasten screw.
4.7.2 Y-type Strainer
Y-type strainers are installed on outlet of fuel oil heater (*) and inlet of burner. Remove foreign
materials that are contained in fuel oil to prevent solenoid valves and other parts from being
damaged.
● Cleaning
Open and clean Y-type strainer and inspect element for deformation or damage about once
every 3 months; frequency depends on property of fuel oil.
Replace a deformed element with new one.
4.7.3 Double Strainer
Double strainer removes dust, sand, and other impurities from fuel that is used with boiler to prevent
them from entering and damaging fuel oil pump, solenoid valves, or burner nozzle. Double strainer is
installed on suction side of fuel oil pump.
1 Body
2 Cover
3 Upper cock cover
4 Lower cock cover
5 Cock plug
6 Cock switch handle
7 Cock lift handle
8 Spindle
9 Cover retainer
10 Fastening bolt
11 Ring
12 Packing retainer
13 Filter tube handle
14 Filter tube
15 Filter rope
16 Drain plug
17 Air vent plug
18 O ring
19 O ring
20 O ring
21 O ring
22 Gasket
23 GasketFigure 5-13 Double Strainer
65
<Procedure of screen switching>
a) Close line valve first.
b) Pull up cock lift handle (7), give it two turns
counterclockwise when viewed in Figure 5-13, and pull
up cock plug (5).
c) Turn cock plug (5) in desired direction by using cock
switch handle (6).
● If cock switch handle (6) is turned rightward (refer to
Figure (a)), strainer B is used.
● If cock switch handle (6) is turned leftward (refer to
Figure (b)), strainer A is used.
d) Pull up cock lever (7) and turn it clockwise to allow cock
plug (5) to adhere closely to body (1).
e) Fully open line valve gradually.
f) When oil passes through strainer A or B, air is
accumulated in upper part of body (1). Loosen air vent
plug (17), and close it after checking that oil comes out
slightly.
<Procedure of disassembling and cleaning of strainer>
Disassemble and clean strainer that is not used according to following procedure:
a) Check that screen that is disassembled is not used.
b) Loosen drain plug (16) and air vent plug (17) to drain oil.
c) Loosen fastening bolt (10) and remove cover retainer (9) and cover (2) after oil is completely
discharged.
d) Take out screen (14) by using screen handle (13).
e) Clean screen filter (15).
f) Assemble strainer in reverse order. Set screen (14) in strainer body.
g) Close drain plug (16) and air vent plug (17).
h) Fully open line valve gradually, and close air vent plug when oil comes out from air vent plug (17)
that fills stop side with oil.
Figure
Figur
Figure 5-14 Double Strainer
Screen Switching
Figure (a)
Figure (b)
66
4.8 Fuel Oil Pump
4.8.1 GD Type (for Pilot Burner)
This boiler uses GD type pilot pump. This pump is connected to motor through a coupling and runs
at a speed of about 3500 rpm to send fuel to pilot burner nozzle though solenoid valve.
Figure 5-15 Rotors of Fuel Oil Pump (Trochoid System)
Fuel oil pump employs trochoid system as shown above and it generates high pressure by rotation of
inner and outer rotors. Rotor has profile as shown above and inner and outer rotors rotate in light
contact with each other and tooth surface slippage is quite limited. Almost no noise is generated
because oil is not contained.
However, inspect fuel oil pumps and adjust discharge pressure once a month.
Refer to page 67 “4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting” in Chapter 5.
Figure 5-16 GD Type
< Adjustment>
● Adjust pressure by using pressure regulating valve.
● Turning it to right increases pressure, and turning it to left decreases pressure.
Note Pump rotates clockwise when viewed from the end of pump shaft.
< Inspection and maintenance>
Check cover and oil seals for leaks on a daily basis.
● It does not contain strainer. In case of trouble, do not disassemble unit, and unship and have it
repaired.
Return opening
Suctionopening
Discharge opening
Note: Do not disassemble rotors and other major partsfor repair. It cannot be repaired disassembledpump that is not covered by guarantee.
Pressure regulating valve
67
4.8.2 Main Fuel Oil Pump
This pump is connected to motor through a coupling and sends fuel to burner nozzle though fuel oil
heater (*), oil flow control valve, and fuel shutoff valve.
Prepare for operation of main fuel oil pump according to instruction manual for screw pump.
4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting
CAUTION
Instruction
This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating
valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil
pump is deteriorated over time and its performance is gradually declined.
If fuel oil pump is used for many years without adjustment, it deteriorates and becomes worn and
causes decreases in oil pressure.
In order to maintain proper oil temperature and circulation level, check and adjust discharge
pressure of fuel oil pump once a month according to following procedure. If oil pressure is adjusted
with M.D.O. (*), adjust it again when fuel oil is switched to H.F.O. (*).
Note Ensure that safety valve pressure setting of fuel oil heater is not exceeded.
a) Stop combustion and run fuel oil pump.
b) Slowly close fuel return pipe valve (1) shown in Figure 5-17.
● Pressure indicated in fuel oil pump discharge pressure gauge (2) is increased slowly.
c) Adjust pressure indicated in fuel oil pump discharge pressure gauge (2) to value set in trial
operation by using pressure regulating valve (3) of fuel oil pump unit.
d) Slowly open fuel return pipe valve (1). Pressure indicated in fuel oil pump discharge pressure
gauge (2) is decreased slowly.
e) Open discharge valve (4), check that fuel oil is circulating, and close it.
Figure 5-17 Fuel Oil Pump Discharge Pressure Setting
F.O. return
F.O. inlet
68
<Adjustment of Pressure Regulating Valve>
(1) Remove adjustment screw cover of fuel pressure regulating valve and loosen lock nut.
(2) Turn adjustment screw of fuel pressure regulating valve to adjust pressure.
● Turn screw clockwise to increase pressure.
● Turn screw counterclockwise to decrease pressure.
(3) Check indicated pressure and tighten lock nut.
(4) Install adjustment screw cover.
69
4.8.4 Circulation Relief Valve
Fuel oil is pressurized by fuel oil pump and heated by fuel oil heater, and its pressure is adjusted
properly by circulation relief valve on top of boiler. Part of fuel oil circulates throughout system and
heats fuel return pipes during combustion, keeping fuel at constant temperature. Circulation relief
valve is important part that controls combustion level and temperature of combustion system. Inspect
this valve and adjust pressure once a month.
<Inspection>
Circulation relief valve is adjusted to optimum pressure in trial operation.
a) Check that inlet pressure of adjusting flow valve when H.F.O. (*) is circulating is pressure set in
trial operation.
b) Check that lock nut is not loosened.
● If lock nut is loosened, retighten it.
<Adjustment>
If pressure gauge indicates pressure set in trial operation, combustion level does not need to be
adjusted. If pressure gauge does not indicate pressure set in trial operation, adjust combustion level.
a) Adjust fuel oil pump discharge pressure according to procedure in 4.8.3.
b) Adjust circulation relief valve according to 3) <Adjustment of pressure regulating valve> in
4.8.3.
Refer to page 67 “4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting” in
Chapter 5.
List of standard pressure settings (reference)
HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T
M.D.O.(*)[MPa] 0.8 0.8 0.9 1.1 1.2 1.2
H.F.O. [MPa] 1.0 1.0 1.1 1.3 1.4 1.4
Figure 5-18 Circulation Relief Valve
No. Part name
1 Relief valve body
2 Relief valve plunger
3 Spring retaining nut
4 Spring strike plate
5 Relief spring
6 Relief valve cap
7 Pressure adjusting bolt
8 Hexagon nut
9 O ring
10 O ring
13 Relief valve packing
14 Relief valve stand
15 Packing
16 Hexagon bolt
17 Spring washer
70
5. Quarterly Inspection and Maintenance
5.1 Inspection and Blow of Boiler Water
WARNING
Caution
Blow valve and sample water (blow water) are hot. Wear protective equipment while working
with them to prevent burn.
Treat and blow boiler water regularly according to Manual for Water Treatment.
5.2 Equipment around Burner
5.2.1 Solenoid Valve
WARNING
Instruction
In order to prevent serious accident, check solenoid valves and valve seats for oil leaks after
cleaning, inspecting, or replacing.
Solenoid valve opens and closes by electric activation and non-activation to control supply of fuel
oil to burner nozzle and other control equipment.
If seat of any of solenoid valves is clogged due to foreign particles on seat, oil leak into combustion
chamber, ignition failure, or other combustion related problems may be caused. Visually check
flow meter when combustion is stopped or check for oil leaks in bottom of furnace on quarterly
basis. In disassembling device, be careful not to lose internal parts. When replacing valve, check
flow direction.
71
5.2.1-1 Solenoid Valve for Pilot Burner
This solenoid valve is used to control fuel used with pilot burner.
It is opened when activated and two valves are used for combustion.
When pre-purge (*) is completed, this solenoid valve is activated and opened.
5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve
This solenoid valve controls air that drives pneumatic fuel shutoff valve. It uses compressed air in
line for atomized air to drive main fuel shutoff valve. When it detects flame of pilot burner, it is
opened to start air supply to pneumatic fuel shutoff valve. This solenoid valve is installed in each of
air supply lines leading to 2 main fuel shutoff valves.
Figure 5-19 YS301 Type
No. Part name
A1 Tube & base ASSY
A2 O ring
A3 Top plate
A4 Spring washer
A5 Coil
A6 O ring
A7 Base nut
A8 O ring
A13 Terminal box
N Neon lamp
1 Plunger ASSY
2 O ring
3 Spring
Figure 5-20 062E1 Type
Lead wire
Movable element
Solenoid
Spring
Poppet set screw
V seal
Poppet shaft
Body
72
O-ring
Bracket(Option)
Bolt
Bonnet
Diaphragm ASSY
Body
Coil
Washer A
Washer B
Base nut
Tube ASSY
Spring
Plunger ASSY
Springwasher
Name plate
Lock washer
Nut
O-ring
O-ring
Housing
5.2.1-3 Solenoid Valve for Atomized Air
This solenoid valve is used to control atomized air. A single solenoid valve for atomized air is
installed in atomized air line and is opened when activated. When "AIR" is selected as atomized
fluid, it is opened following detection of flame of pilot burner to supply atomized air to main burner
and atomize fuel.
Figure 5-21 YS211 Type
73
5.2.1-4 Solenoid Valve for Atomized Steam
This solenoid valve is used to control atomized steam. A single solenoid valve for atomized steam
is installed in atomized steam line and is opened when activated. When "STEAM" is selected as
atomized fluid, it is opened following detection of flame of pilot burner to supply atomized steam to
main burner and atomize fuel.
Figure 5-22 DP Type
No. Part name
1 Valve casing
2 Cover
3 Spring pin
4 Pipe
5 Valve body
6 Valve disk
7 Valve body washer
8 Connecting spring
9 Piston ring
10 Pilot ring
11 Pilot disk
12 Spring retainer
13 Plunger
14 Pin
15 Valve body spring
16 Gasket
19 O ring
20 Coil
21 O ring
29 Pilot spring
74
5.2.2 Other Equipment
WARNING
Instruction
In order to prevent serious accident, check solenoid valves and valve seats for oil leaks after
cleaning, inspecting, or replacing.
Before inspection or adjustment, check that there is no internal pressure present.
Compressed air or steam may blow out, causing burn or laceration.
If seat of any equipment is clogged due to foreign particles on seat, oil leak into combustion
chamber, ignition failure, or other combustion related problems may be caused. Visually check
flow meter when combustion is stopped or check for oil leaks in bottom of furnace on a quarterly
basis, along with carrying out inspection specified in each section.
5.2.2-1 Pneumatic Fuel Shutoff Valve
This is pneumatic actuator used to control fuel oil supplied to main burner. Two pneumatic fuel
shutoff valves are installed in main fuel oil (*) line and actuated by compressed air. This valve is
closed under no pressure and opened to start fuel oil supply to main burner when it detects
compressed air from filter regulator or solenoid valve for fuel shutoff valve.
<Inspection>
Carry out following inspections while boiler is in operation:
Check positions of valve when it is fully opened and fully
closed.
Check valve and pneumatic pipe connections for leaks.
Check valve and pneumatic pipe for abnormal noise.
Check for vibration when it is actuated.
Check for loose bolts or nuts.
No. Part name
1 Valve casing
2 Cover
3 Valve stem
4 Ball
7A Packing retainer
7B Packing retainer ring
8 Packing
19 Gasket
20 Packing washer
30 Ball seat
33 Nut for cover bolt
34A Nut for packing retainer
34B Nut
35 Cover bolt
36 Packing retainer bolt
47 Thrust washer
67 Stem bearing
92 Connector
93 Bracket
94 Bolt
96 Pneumatic actuator
99 Set bolt
124A Spring & pin
124B Spring
145 Spring washer
155 Spacer
Figure 5-23 FAS-2 Type
Nominal diameter:50 or below
Nominal diameter:25 or below
75
5.2.2-2 Filter Regulator
Filter regulator is used to reduce pressure of compressed air supplied to solenoid valve for fuel
shutoff valve and to remove sludge. Installed in inlet of atomized air line, filter regulator reduces
pressure of air supplied to fuel shutoff valve to 0.4 MPa as well as removes dust in air with inner
filter to prevent solenoid valve for fuel shutoff valve from including dust.
<Inspection>
a) Check that pressure is set at 0.4 MPa.
b) Drain filter regulator.
If drain level exceeds upper limit, drain filter regulator in shorter intervals than inspection.
c) Check plastic bowl in filter regulator for cracks, scratches,
or deterioration.
<Adjustment>
Pull pressure adjusting knob a notch to unlock it.
Turning pressure adjusting knob in "H" direction shown in upper
surface increases secondary pressure, and turning it in "L"
direction decreases secondary pressure.
After adjusting secondary pressure, push pressure adjusting
knob a notch to lock it.
<Draining Procedure>
Turn cock in "O" direction to drain filter regulator and in "S"
direction to stop draining it
<Inspection of Plastic Bowl>
Stop compressed air flow, check that there is no pressure present in product, and then remove bowl.
a) Turn bowl and bowl guard by about 45° until they are stopped while pushing them up (Figures
[1] and [2]).
By pulling bowl and bowl guard out downward, they can be removed (Figures [2] and [3]).
b) Assemble them in reverse order (Turn them until they are stopped).
c) Before letting compressed air in, check that marks of bowl guard and body meet each other in
point A (Figure [1]).
Figure 5-25 Detailed View ofDrain Outlet
Figure 5-26
Procedure forRemoving Bowl Guard
Figure 5-24 Detailed Viewof Pressure Adjusting Knob
Pressureadjusting knob
[2][1] [3]
Body
Bowl guard
76
5.2.2-3 Pressure Reducing Valve
This valve reduces pressure of steam for atomization supplied by boiler. It adjusts secondary
steam pressure to 0.5 MPa.
<Inspection>
a) Check that lock nut of adjusting screw (9) is not loosened.
b) Check secondary pressure.
Check secondary pressure when primary pressure is 0.6 MPa or above.
c) Check for abnormal noise.
d) Check for steam leaks.
<Adjustment>
If secondary pressure cannot be adjusted to 0.5 MPa, adjust it by steps below:
a) Check that atomized steam can be supplied and run fan in manual operation mode. After a while,
solenoid valve for atomized steam is opened.
Refer to page 40 “4. Manual Operation” in Chapter 4.
b) Loosen lock nut of adjusting screw (9).
Turn adjusting screw to adjust pressure to 0.5 MPa while checking atomized steam pressure
gauge.
Turn screw clockwise to increase pressure.
Turn screw counterclockwise to decrease pressure.
c) After adjusting pressure, tighten lock nut.
Figure 5-27 GP Type
No. Part name
1 Body
5 Diaphragm
8 Adjusting spring
9 Adjusting screw
11 Main valve
12 Valve seat
13 Main valve spring
14 Piston
15 Cylinder
19 Pilot valve body
20 Pilot valve seat
28 Strainer
42Primary
communicating port
43Secondary pressure
detection port
44 Diaphragm chamber
77
5.2.2-4 Seal Pot
This is a pot filled with ethylene glycol. Ethylene glycol is a liquid used to transmit fuel atomizing
pressure to equalizing valve. If seal pot does not contain a sufficient amount of ethylene glycol,
atomized steam pressure is not set properly to cause poor combustion.
<Inspection>
Follow steps below to check ethylene glycol level and fill seal pot with this liquid.
Use ethylene glycol that meets following specifications:
Purity: 99.5% or above
Density (20°C): 1.12 to 1.15 g/ml
Water content: 0.2% or above
<Procedure>
a) Close cock for equalizing valve oil detection connected to fuel piping.
b) Remove air vent plug on top of seal pot and open cock.
c) Loosen air vent plug of equalizing valve body, check that ethylene glycol comes out, and then
tighten it.
d) Pour ethylene glycol until it comes out of air vent cock on top of seal pot.
Ethylene glycol comes out soon if there is no vent.
e) Close air vent cock.
f) Open cock for equalizing valve oil detection connected to fuel piping.
g) Put air vent plug back in place.
Air vent plug onequalizing valve body
Seal pot
Cock for equalizingvalve oil detection
Air vent cock and plug
78
5.2.2-5 Equalizing Valve
WARNING
Instruction
Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to
change setting as a rule. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for
instructions.
Equalizing valve adjusts atomized steam flow rate appropriately for different combustion levels. It
also detects fuel oil pressure and keeps difference from steam pressure constant. Reference
differential pressure settings for different models at combustion load of 20% (low combustion) are
shown below:
Model HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T
Differential pressuresetting of atomizedsteam equalizing valve
MPa 0.05 0.08
Differential pressure setting of atomized steam equalizing valve = (steam) pressure at exit of
equalizing valve - (fuel) pressure at exit of shutoff valve (MPa)
<Inspection>
a) Check secondary pressure of equalizing valve at
combustion load of 20%.
Confirm that primary steam pressure of equalizing valve
is around 0.5 MPa.
b) Check for abnormal noise.
c) Check for steam leaks.
<Adjustment>
If difference between secondary pressure and fuel
pressure at combustion load of 20% has deviated from
value set in trial operation, adjust it by following steps
below:
a) Ensure that combustion is taking place at load of 20%.
b) Remove cap (13) .
c) Turn adjusting screw (11) to adjust secondary pressure.
Turn screw clockwise to increase pressure.
Turn screw counterclockwise to decrease pressure.
d) After adjusting pressure, put cap (13) back in place.
(Reference value)
1 Body 16 Spring
2 Lower cover 17 Gasket
3 Valve Sheet (upper) 18 Bellows unit
4 Valve Sheet(lower) 19 Packing
5 Spring Sheet(upper) 20 Plug
6 Stud bolt 21 Air vent plug
7 Lower cover gasket 22 Hexagon bolt
8 Adjusting screw guide 23 Spring washer
9 Valve Stem 24 Hexagon nut
10 Lower cover 25 Hard lock
11 Adjusting screw 26 Plate spring washer
12 Packing retainer 27 Gland packing
13 Cap 28 Spring Sheet(lower)
14 Upper cover gasket
15 Setting spring
Figure 5-28 Inter structure ofequalizing valve RCV Type
79
5.3 Fuel Oil Thermostat (for Fuel Oil Heater)
Carry out operation test of each alarm once every three months. Check that temperature at which
alarm is activated is almost the same as dial setting.
Temperature setting of thermostat for low and high temperature alarm depends on viscosity of fuel.
Refer to temperature chart.
Refer to page 81 “5.3.3 Heavy Oil Heating Temperature” in Chapter 5.
5.3.1 Dial Type
Thermostat for fuel oil senses temperature and turns electrical switch on or off. It uses fluid with
high expansion coefficient in thermo sensor. When it senses temperature, fluid is expanded and
pressure inflates diaphragm of body inside to activate lever for opening electrical contact. When
diaphragm is deflated, electrical contact is closed.
< Adjustment>
As shown in below figure, thermostat is dial type. After loosening dial set fittings, set dial to given
temperature and fasten it with set fittings.
Set thermostat for heater protection at 180°C (Unchangeable).
Figure 5-29 Fuel Oil Thermostat (Dial Type)
EGO thermostat specification Thermostat for heater protection
Thermostat for hightemperature alarm
Thermostat for lowtemperature alarm
80
5.3.2 RT Type
Note
Some boiler use thermostat of RT type depending on specification.
< Adjusting operation temperature>
Adjust temperature by setting knob with reference to value on setting scale plate.
Set differential (*) to the minimum.
Figure 5-30 Fuel Oil Thermostat (RT Type)
1. Setting knob
2. Setting scale plate
3. Differential setting disk
81
5.3.3 Heavy Oil Heating Temperature
For effective combustion ability, keep viscosity of fuel oil in nozzle section at 12 cSt or less.
For proper fuel oil heating temperature for different viscosity standards of fuel oil, refer to following
chart.
Table 5-2 Temperature Setting for Viscosity (Example)
Redwood No.1Sec./100゜F 1500sec. 2500sec. 3500sec.
Kinematic Viscosity(cSt)at 50℃
(IF)Residual Fuels, cSt/50℃
IF-180
180cSt(280cSt)
IF-380
380cSt
Kinematic Viscosity(cSt)at 100℃
CIMAC and ISO Fuels, cSt/100℃
25cSt
CIMAC/RM-25
- 35cSt
CIMAC/RM-35
Fuel oil heating temperature
(Setting temperature of temperature
controller)
~125°C 130°C 135~140°C
Table 5-3 Heavy Oil Heating Temperature Chart
When 300cSt (at 50°C)
82
5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil)
WARNING
Caution
During inspection work, hot steam may blow out to cause burn. Be careful with operating
valves.
Before wiring work, be sure to turn control panel power off. Failure to observe this instruction
may cause electrical shock due to high voltage, resulting in injury or death.
Note
Inspect pressure switches and check their operation once every 3 months according to steps
below:
5.4.1 Steam Pressure Switch
Steam pressure switch is used to issue alarms. Contact of pressure switch for low pressure alarm
is opened to issue alarm when steam pressure falls below set pressure. Contact of pressure
switch for high pressure alarm is opened to issue alarm and stop combustion when steam
pressure exceeds set pressure.
<Inspection>
Check connections for steam leaks.
Carry out inspections with reference to Sections 5.7.9 and 5.7.10 in "5.7 Operation Check of
Each Safety System" in Chapter 5.
Refer to page 90 “5.7.9 High Steam Pressure Alarm” and page 91 "5.7.10 Low Steam
Pressure Alarm" in Chapter 5.
Figure 5-31 Steam Pressure Switch and Pressure Gauge
83
5.4.2 Atomized Fluid Pressure Switch
Atomized fluid pressure switch is used to issue low atomized fluid pressure alarm. When atomized
fluid pressure falls below set pressure, contact is opened to issue alarm and stop combustion.
<Inspection>
Check connections for steam leaks.
Carry out inspections with reference to Sections 5.7.15 and 5.7.16 in "5.7 Operation Check of
Each Safety System" in Chapter 5.
Refer to page 92 “5.7.15 Low Atomized Steam Pressure Alarm” and "5.7.16 Low
Atomized Air Pressure Alarm" in Chapter 5.
5.4.3 Fuel Oil Pressure Switch
This pressure switch is used to issue alarm when fuel oil pressure drops for some reason during
combustion.
Note Some boilers use fuel oil pressure switch of RT type, depending on specifications (Standard
boilers use SNS-P type).
<Inspection>
Check connections for steam leaks.
Carry out inspections with reference to Sections 5.7.5 in "5.7 Operation Check of Each Safety
System" in Chapter 5.
Refer to page 88 “5.7.5 Low Oil Pressure Alarm” in Chapter 5.
Figure 5-33 Fuel Oil Pressure Switch
Figure 5-32 Atomized Fluid (Air / Steam)
Pressure Switch and Pressure Gauge
84
5.4.4 Pressure Switch Adjustment Procedure
Note
Do not adjust working position adjustment screw. Adjusting screw may cause trouble.
<Adjusting working pressure>
a) Turn pressure regulating screw counterclockwise. (pressure regulating spring is compressed)
Contact pressure goes up as shown on gauge.
b) When contact pressure goes up, disconnection pressure goes up, logically.
< Adjusting differential (*)>
Set differential for pressure switch that is used for alarm to the minimum by turning differential
pressure regulating screw counterclockwise.
a) SNS Typeb) RT type
1. Setting knob2. Setting scale plate3. Differential setting disk
Pressure differentialregulating screw
Pressureregulating screw
Pressure pointerDifferential pressure pointer
Scale plate
Working positionadjustment screw
Figure 5-34 Pressure Switch
85
5.5 Differential Transmitter
Differential transmitter detects differential pressure occurred by boiler water level and sends
electric signal accordingly differential pressure to water level indicator inside of boiler control
panel .
<Inspection>
a)Confirm that there is no difference between water level indicator display and water level gauge
display.
・In case difference is big, perform zero adjustment by normal water level at zero adjustment
trimmer of side of differential transmitter.
b)Check for water leakage.
<Zero adjustment>
a)Adjust water level to normal water level while checking water level of water level gauge.
b)Adjust zero while pushing adjustment trimmer and turn trimmer.
c)Confirm water level indicator displays 0mm, for normal water level of water level gauge.
Note
Adjust normal water level during combustion at pressure for general use. Display of water level
gauge and water level indicator occur error due to steam pressure and operation condition. And,
display of water level gauge and water level meter occur error during combustion stop, because
water level ware adjusted to normal level during combustion at pressure for general use at the
time boiler is delivered.
Figure 5-35 Differential transmitter
Zero adjustment trimmerManifold valve
86
5.6 Flow Control Valve
Flow control valve opens and closes by electric signal from water level indicator, and controls
amount of feed water with target of normal water level.(Feed water pump is always in operation.)
<Inspection>
a)Check for water leaks.
b)Confirm opening indication and operation time is in normal range.
c)Check for abnormal noise.
d)Check there is no water or dew condensation inside of controller.
Figure 5-36 Flow control valve
No Part name Material Quantity
Body
Cap
Ball
Sheet
StemPacking
Bracket
Connector
Direction of flow
Stellite
Temper
Temper
Temper
Electric operate machine
87
5.7 Operation Check of Each Safety System
WARNING
Caution
Do not pull out lead wire with wet hands. Failure to observe this instruction may cause
electrical shock due to high voltage, resulting in injury or death.
5.7.1 Ignition Failure Alarm
a) Before igniting burner, remove flame eye (*) on the top surface of wind box (*) and put your hand
over tip.
b) Press combustion switch.
Ignition is attempted after pre-purge (*); however, flame eye does not detect flame and
determines that there is something wrong.
c) Check that audio and visual alarms are issued.
Check that combustion is stopped.
d) Press buzzer stop switch.
Audio alarm is stopped.
Alarm lamp does not turn off and comes to remain on.
e) Put flame eye back in place.
Alarm lamp does not turn off but remains on.
f) Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
5.7.2 Fan Abnormal Stop Alarm
a) Trip fan thermal relay during combustion.
b) Check that audio and visual alarms are issued.
Check that combustion is stopped.
c) Press buzzer stop switch.
Audio alarm is stopped.
Alarm lamp does not turn off and comes to remain on.
d) Reset fan thermal relay.
Alarm lamp does not turn off but remains on.
e) Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
88
5.7.3 Flame-out Alarm
a) Remove flame eye (*) during combustion, and put your hand over tip.
b) Check that audio and visual alarms are issued.
• Check that combustion is stopped.
c) Press buzzer stop switch.
• Audio alarm is stopped.
• Alarm lamp does not turn off and comes to remain on.
d) Put flame eye back in place.
• Alarm lamp does not turn off but remains on.
e) Press alarm reset switch.
• Alarm lamp turns off and alarm is reset.
5.7.4 Abnormal Flame Alarm
a) Remove flame eye during post-purge (*), and illuminate flame eye.
b) Check that audio and visual alarms are issued.
• Check that post-purge is continued.
c) Press buzzer stop switch.
• Audio alarm is stopped.
• Alarm lamp does not turn off and comes to remain on.
d) Put flame eye back in place.
• Check that post-purge is stopped 35 seconds after flame eye is put back in place.
• Alarm lamp does not turn off but remains on.
e) Press alarm reset switch.
• Alarm lamp turns off and alarm is reset.
5.7.5 Low Oil Pressure Alarm
a) Press combustion switch.
b) Lower flow rate of fuel oil by adjusting fuel oil pump outlet valve or pump oil pressure.
c) Check that audio and visual alarms are issued. There should be 2-second delay before they are
issued.
• Check that combustion is stopped.
d) Press buzzer stop switch.
• Audio alarm is stopped.
• Alarm lamp does not turn off and comes to remain on.
e) Press alarm reset switch.
• Alarm lamp turns off and alarm is reset.
f) Adjust flow rate of fuel oil.
89
5.7.6 Low Oil Temperature Alarm
a) Switch fuel to M.D.O. (*).Shift fuel oil heater (*) switch to A.
• Check that fuel oil heater is stopped, and fuel oil is no longer heated.
b) Shift manual combustion switch to AUTO position, and press combustion switch.
c) Shift fuel oil heater switch to C position.
d) Check that audio and visual alarms are issued.
• Check that combustion is stopped.
e) Press buzzer stop switch.
• Audio alarm is stopped.
• Alarm lamp does not turn off and comes to remain on.
f) Shift fuel oil heater switch to A position.
• Check that fuel oil pump is stopped.
• Alarm lamp does not turn off but remains on.
g) Press alarm reset switch.
• Alarm lamp turns off and alarm is reset.
h) Switch fuel to H.F.O. (*). Shift fuel oil heater switch to C position.
5.7.7 High Oil Temperature Alarm
a) Lower setting of thermostat for high oil temperature during combustion.
b) Check that audio and visual alarms are issued. When fuel oil heater is not working, there should
be 10-second delay before they are issued. There is no such delay if fuel oil heater is in
operation.
• Check that combustion is continued.
c) Press buzzer stop switch.
• Audio alarm is stopped.
• Alarm lamp does not turn off and comes to remain on.
d) Reset thermostat for high oil temperature to value in list of principle items.
• Alarm lamp turns off.
90
5.7.8 Exhaust Gas High Temperature Alarm
Figure 5-37 Exhaust Gas Thermostat
<Operation check>
a) Lower setting of thermostat by turning dial during combustion.
b) Check that audio and visual alarms are issued.
5.7.9 High Steam Pressure Alarm
a) Turn off main power supply of control panel.
b) Disconnect wiring from back surface of pressure regulator (see right figure).
c) Turn on main power supply of control panel and start combustion.
• Boiler continues combustion at pressure above set pressure.
• Check that pressure switch (for high steam pressure) is activated
when set pressure is reached and combustion is stopped following
issuance of alarm.
d) Turn off main power supply of control panel and connect wiring
disconnected above.
e) Open main steam valve to make boiler pressure fall within normal
working pressure range.
Boiler flue has thermostat to measure temperature of
exhaust gas. If there is abnormal temperature, alarm is
started and operation is stopped electrically.
At the time thermostat is delivered from factory, it is set at
450°C (Unchangeable).
If thermostat is activated to stop boiler during operation,
measure gas temperature with thermometer, and
determine whether problem is due to failure of thermostat
or temperature is actually increasing.
If temperature of exhaust gas exceeds 450°C, there is high
possibility that there is some sort of malfunction in
combustion chamber. Open furnace, and check for fallen
refractory materials, or other causes. If there is
malfunction, immediately take corrective action.
If incomplete combustion continues for a long time, soot
may be accumulated on heating pipes to increase
temperature of exhaust gas.
Pay constant attention to furnace to keep complete
combustion.
Figure 5-38 Back Surface
of Pressure Regulator
Disconnect wiring of
Y434 or Y515.
91
5.7.10 Low Steam Pressure Alarm
a) Increase boiler pressure to normal working pressure.
b) Close steam pressure gauge valve.
c) Check that test cock is closed and remove plug.
d) Open test cock gradually.
Note
Hot, high-temperature steam blows out. Be careful not to get burned.
• Check that pressure gauge reading decreases and that pressure switch is activated when set
value of pressure switch is reached. Combustion is not stopped.
e) Close test cock, put plug back in place, and open steam pressure gauge valve.
5.7.11 Low Water Level Alarm
a) Close upper and lower water level gauge valves.
b) Open water level gauge drain valve slightly.
• Check that boiler water is discharged from inside water level gauge and that low water level
alarm is issued.
• Combustion is not stopped.
c) Close water level gauge drain valve and open upper and lower water level gauge valves.
5.7.12 Low Low Water Level Alarm
a) Perform steps a) and b) in 5.7.11.
• Check that boiler water is discharged from inside water level gauge and that combustion is
stopped following issuance of low low water level alarm.
b) Close water level gauge drain valve and open upper and lower water level gauge valves.
5.7.13 Power-off Alarm
a) Turn power off during combustion.
• Check that burner is stopped.
b) Turn power on.
5.7.14 Sequencer Error Alarm
• When malfunction of sequencer is detected, lamp lights up as visual alarm.
Note
To allow sequencer operating normally to malfunction intentionally, special equipment must be
used.
For more details, contact MIURA offices.
92
5.7.15 Low Atomized Steam Pressure Alarm
a) Switch atomized fuel to "STEAM" and bring boiler into automatic combustion.
b) Close atomized steam valve.
• Check that pressure gauge reading decreases and that pressure switch is activated to stop
combustion when set value of pressure switch is reached.
c) Open atomized steam valve.
5.7.16 Low Atomized Air Pressure Alarm
a) Switch atomized fuel to "AIR" and bring boiler into automatic combustion.
b) Close atomized air valve.
• Check that pressure gauge reading decreases and that pressure switch is activated to stop
combustion when set value of pressure switch is reached.
c) Open atomized air valve.
5.7.17 Damper Control Alarm
a)Turn off main power supply of control panel.
b)Disconnect wiring of external wiring terminal ”23” on control panel.
c)Turn on main power supply of control panel and start combustion.
d)Check that audio and visual alarm are issued within 90 seconds after combustion is started.
e)Press stop buzzer switch.
• Audio alarm is stopped.
• Blinking alarm lamp does not turn off and comes to remain on.
f)Press combustion stop switch.
• Alarm is reset.
g)Turn off main power supply of control panel and connect wiring disconnected above.
5.7.18 Operation Check by differential transmitter(Low Water Level, Low Low Water Level,
High Water Level)
Adjust water level of water level gauge to proper level and close upper and lower water level
gauge valves on water level gauges of water level electrode to check differential transmitter.
Check water level by water level indicator. Check water level control and adjust water level to
proper, before check open upper and lower water level gauge valves on water level gauges.
Note
• Perform operations after ensure that boiler combustion is stopped.
• Water level alarm detects at each water level electrode and differential transmitter. Checking
water level control by differential transmitter is described here. For details about checking
water level control by water level electrode, refer to “5.7.11 Low Water Level Alarm” and
“5.7.12 Low Low Water Level Alarm” in Chapter 5.
Refer to page 91 “5.7.11 Low Water Level Alarm” in Chapter 5.
Refer to page 91 “5.7.12 Low Low Water Level Alarm” in Chapter 5.
93
<Low Water Level Alarm>
a)Set feed water pump shift switch to OFF, open bottom blow valve slowly.
Check that water level is lowered to low water level.
When water level is lowered to low water level, close bottom blow valve.
b)Check that audio and visual alarms are issued. There should be 10-second delay before they are
issued.
c)Press stop buzzer switch.
Audio alarm is stopped.
Blinking alarm lamp does not turn off and comes to remain on.
d)Select pump for operation by feed water pump shift switch.
Operation indicator lamp of feed water pump is lightened. Feed water to boiler uppered to low
water level, set feed water pump shift switch to OFF. Alarm lamp turns off.
<Low Low Water Level Alarm>
a)Set feed water pump shift switch to OFF, open bottom blow valve slowly.
Check that water level is lowered to low low water level limit.
When water level is lowered to low low water level limit, close bottom blow valve.
b)Check that audio and visual alarms are issued.
c)Press stop buzzer switch
Audio alarm is stopped.
Blinking alarm lamp does not turn off and comes to remain on.
d)Select pump for operation by feed water pump shift switch.
Operation indicator lamp of feed water pump is lightened. Alarm lamp does not turn off but
remains on when water level rises over low low water level.
e)Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
<High Water Level Alarm>
a)Set feed water shift pump to MANU and select pump for operation by feed water pump shift
switch.
Operation indicator lamp of feed water pump is lightened.
Ensure that water level does not reach upper limit.
b)When water level is uppered to high water level, set feed water pump shift switch to OFF.
c)Check that audio and visual alarms are issued. There should be 30-second delay before they are
issued.
d)Press stop buzzer switch
Audio alarm is stopped.
Blinking alarm lamp does not turn off and comes to remain on.
e)Open bottom blow valve slowly.
When water level is lowered to high water level, alarm lamp turns off.
94
5.7.19 Suction Damper Error Alarma)Turn off main power supply of control panel.
b)Disconnect wiring of external wiring terminal ”49” on control panel.
c)Turn on main power supply of control panel and start combustion.
d)Check that audio and visual alarm are issued in 50 seconds after combustion is started.
e)Press stop buzzer switch. Audio alarm is stopped.
Blinking alarm lamp does not turn off and comes to remain on.
f)Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
g)Turn off main power supply of control panel and connect wiring disconnected above.
95
6. Yearly Inspection and Maintenance
6.1 Fuel Oil Heater (*)
6.1.1 Combined Use of Electricity and Steam
Heater that uses both electricity and steam as shown in figure below is used to heat heavy oil to
proper temperature.
Figure 5-39 Fuel Oil Heater (Electricity/Steam)
Electric heater contains nichrome wire coil with high thermal conductivity as heating element in the
center of pipe, and is filled with special fused powder with excellent electric insulation at high
temperature.
To save electric capacity, heater body is heated by steam from outside. Thus, electric heater is
combined with steam.
Both steam and electric heater are controlled by opening or closing steam solenoid valve with fuel
oil temperature controller.
If sludge adheres to heater, poor combustion or abnormal heating may be caused due to unstable
control. Clean inside of heater on a yearly basis.
<Overview>
Electric heater as shown in figure is used as standard to heat heavy oil used as fuel to proper
temperature. Heater is installed on outlet side of oil pump and oil temperature is regulated by
temperature controller.
Fuel oil heater contains nichrome wire coil as heating element in the center of pipe for high
conductivity, and is filled with special powder that has excellent electric insulation at high
temperature; these materials are solidified under high pressure.
<Inspection and maintenance>
Long-term use of fuel oil heater causes accumulation of oily sludge in heater, which may lower
heating temperature or damage element due to insulation failure.
Open and clean fuel oil heater on a yearly basis.
In addition, raise discharge pressure of fuel oil pump and check operation of safety valve.
Note Sludge remaining after cleaning may cause leaks from solenoid valves.
Remove it completely by flushing or by another method.
Safety valve
F.O. outlet
F.O. inlet
Drain
Drain
Steam outlet
Steam inlet
96
6.1.2 Solenoid Valve for Steam Heater
Figure 5-40 Solenoid Valve for Steam Heater
< Inspection and maintenance>
Check valve and seat for scratches, check for coil burnout, and clean them regularly.
In disassembling device, be careful not to lose internal parts. When replacing valve, check flow
direction.
1 Core assembly (fixed iron core)
2 Coil
3 Plunger spring
4 Plunger
5 Tension spring
6 Stuffing
7 Main valve assembly
8 Body
97
6.2 Water Level Gauge and Water Level Detecting Rod
Note
Replace water level gauge glass once a year. If it is not replaced, it may be deteriorated with time
and damaged to cause hot water or steam to blow out from damaged part and cause a burn.
Water level gauge is integrated with water level detecting rod as shown below:
1 Water level gauge column 7 Hexagon nut
2 Water level gauge glass seat 8 Spring washer
3 Water level gauge glass holder 9 Plain washer
4 Water level gauge glass 10 Connecting pipe
5 Water level gauge glass packing 11 Water level gauge cover
6 Hexagon bolt 12 Water level gauge drain valve
Figure 5-41 Water Level Gauge and Water Level Detecting Rod
Water level detecting rod is installed on the top and bottom of steam drum (on steam side and water
side) with valves. Rod contains water level gauge glass to serve as both water level gauge and water
level detecting rod.
Water level gauge is important device for safety to check if prescribed water level is kept in boiler. As
glass of water level gauge must be kept clean, clean it by blowing water level gauge at least once a
day.
Reflective gauge glass is used for water level gauge, and size depends on rules of vessel
classification.
Boiler body Upper water levelgauge valve
Upper water leveldetecting rod
connecting pipe
Lower water leveldetecting rod
connecting pipe
Lower water levelgauge valve
Section viewalong line A-A
98
Aside from water level gauge, which is designed to visually check water level, water gauge column
has four (or five) water level detecting rods (3) with different lengths, which electrically detect water
level and put out signal to automatically start/stop feed water pump or to automatically stop burner
when low low level is detected. Stainless detecting rod is screwed in electrode holder and further
tightened with set screws. As water level detecting rod may get dirty with concentrated boiler water
and cause malfunction, pull water level detecting rods out and clean them at least once every three
months.
1 Electrode holder
2 Water gauge column
3 Water level detecting rod
4 Drain valve flange
Figure 5-42 Water Level Detecting Rods
<Inspection and Maintenance>
a) Continuity and insulation check of electrode holder.
• Check continuity and insulation of electrode holder every three months.
• Replace electrode holder periodically (once every 2 years) as aged deterioration causes
insulation and continuity failure.
Continuity check ○a to ○c : 0Ω
Insulation check ○a to ○b : 0.1 MΩ or above
b) If continuity or insulation failure is found, replace electrode holder.
<How to blow water level gauge>
Blow water level gauge once a day.
a) Close upper water level gauge valve and open water level gauge drain valve.
• Boiler water is discharged from inside water level gauge, and lower water gauge column
connecting pipe is cleaned.
b) Close water level gauge drain valve and lower water level gauge valve, and open upper water
level gauge valve.
c) Open water level gauge drain valve.
• Steam is discharged, and upper water gauge column connecting pipe and inside of water
gauge column are cleaned.
d) Close water level gauge drain valve and open lower water level gauge valve.
99
6.3 Flame Detector (FS-901)
Flame detector is auxiliary relay that is installed to detect burner flame and output electric signal.
Figure 5-43 Flame Detector
<Inspection>
Check on a yearly basis that voltage between terminals [3] and [4] of flame detector during
combustion does not exceed 2.5 V. If voltage exceeds 2.5 V, check whether or not flame eye (*)
glass and light sensitive surface of flame eye are dirty. If they are dirty, clean them.
Refer to page 62 “4.5 Flame Eye” in Chapter 5.
If voltage exceeds 2.5 V even after cleaning, there is possibility of failure of flame eye or flame
detector. In that case, replace flame eye with a spare one. If voltage exceeds 2.5 V again, there is
high possibility of failure of flame detector. In that case, replace flame detector.
100
7. Inspection and Maintenance on Vessel Docking
7.1 Soot Cleaning of Furnace
a) Remove burner from boiler.
b) Open inspection opening of funnel.
c) Visually inspect inside of combustion chamber and check conditions of castable and whether or
not inside is blackened by soot.
d) Clean combustion chamber with high-pressure water cleaner. Also clean boiler body from
inspection opening of funnel.
Refer to page 15 “5.1 Boiler Body” in Chapter 2.
e) Suck out cleaning solution in bottom of furnace with pump.
Note
Dispose of wastewater after cleaning, which has a low pH of around 1, properly.
MIURA cleans furnace to remove soot. For more details, contact MIURA offices.
101
8. Parts Information about Replacement
8.1 Ignition Transformer (*)
WARNING
Instruction
Ignition transformer conducts high voltage. Touching live wiring may cause electrical shock.
Turn power off before working with ignition transformer.
Figure 5-44 Ignition Transformer
Ignition transformer is important device for creating sparks from ignition rod by converting voltage of
100 V on primary side to a high voltage of 10 KV. Primary voltage of transformer can be 100 V or 200
Wiring is different depending on primary voltage.
Figure 5-45 Ignition Transformer Wiring Diagram
Note
Avoid insulating ignition transformer from boiler by rubber or other materials. Otherwise, it cannot
be earthed and may be burned.
Control voltage 100V Control voltage 200V
102
8.2 Sequencer (Programmable Controller)
8.2.1 Description of Component Unit of CJ2M
<Name and explanation of each part of CPU unit>
Figure 5-46 External View of the Sequencer Unit
Figure 5-47 Name of Part of CPU Unit
CPUOutput unitInput unit
LED display
SliderFix adjacent units
ConnectorConnect between adjacent units.Memory card cover
There is memory card in cover.
Battery storage coverWhen cover is opened, there are battery andfront dip switch.Memory cassette is also installed inside ofcover.
103
<Dip Switch>
Shows standard condition of dip switch
Figure 5-48 Dip switch
<How to install memory card>
・Pull the top of memory card to remove.
・Insert memory card back with label is on left side.
Figure 5-49 Installing/Removing of Memory Card
1 OFF
2 ON
3 OFF
4 OFF
5 OFF
6 OFF
7 OFF
8 OFF
Condition of dip switch
Label
104
<Battery>
Battery is built in CPU unit.
Following data is backed up by battery.
I/O memory (including PC system configuration)
Clock data (when memory cassette with clock function is installed)
Battery lasts for 5 years in 25°C ambient temperature. When battery runs out, front ERR/ALM
LED flashes.
It must be replaced with new battery. Contact with MIURA offices.
<Procedure of battery replacement>
Replace battery according to following steps.
a) Turn off boiler power.
If power is off, turn on power once and leave it at least for 5 minutes.
b) Pull out connector of battery in battery storage cover and replace battery with new one.
Once old battery is removed, install new battery within
5 minutes. If power is not supplied to CPU for 5
minutes or more, stored data may be lost.
Figure 5-50 Replacement of Battery
<Input unit>
Operation switch, pressure switch on detector and thermostat are connected to work as joint.
<Output unit>
Electromagnetic relay, solenoid valve and indication lights are connected. Relay contact output
is adopted.
It can be checked operation status of output points with LED on unit surface.
(Light is on when output relay is ON)
105
8.2.2 Function of Display
Figure 5-51 Description of Sequencer Display
CPU unit front
LED display
FlashLight up Turn off
Green
Red
Yellow
Yellow
Yellow
Yellow
CJ2 CPU unit is running normally with「Operation」or「Monitor」mode.
Dip switch setting abnormal.
Operation is stopped with「Program」mode or operation is stopped because of operation stop abnormal
Operation stop abnormal (including FALSE command action) or hardware abnormal (WDTabnormal) are occurred based on self diagnosis.
CJ2 CPU unit operation is stopped and all outputs are intercepted (OFF)
Operation stop abnormal (including FALSE command action) is occurred base on self diagnosis
CJ2 CPU unit operation is continued
CJ2 CPU unit is running normally.
Specific auxiliary relay for load interception (A50015) is ON
All outputs of output unit are intercepted (OFF)
CJ2 CPU unit peripheral (USB) port is communicating (either send or receive)
CJ2 CPU unit serial port (RS-232C) is communicating (either send or receive)
It is lightened during insert into built in flash memory (back up memory)It is also lightened during restoration of user program when PLC power supply is set fromOFF to ON (*).
CJ2 CPU unit peripheral (USB) port is not communicating
CJ2 CPU unit serial port (RS-232C) is not communicating
It is not lightened during un insert into built in flash memory (back up memory)
Specific auxiliary relay for load interception (A50015) is OFF
LED NAME ConditionStatusColor
106
8.2.3 Errors and Countermeasures
Table 5-4 Sequencer Trouble Shooting
Abnormal phenomenon Probable cause Countermeasure
1POWER LED does not light
up.
Loose connection of power
terminal block connector
Terminal block: Correctly insert
connector.
2 RUN LED does not light up.Power line failure
Program mistake
Replace CPU unit.
Correct programs.
3All of output (input) units are
not turned on.
Loose connection of unit
Loose connection of terminal
block connector
Correctly insert unit.
Correctly insert terminal block
connector.
4All of output (input) units are
not turned off.Input circuit failure Replace output (input) unit.
5Outputs (inputs) irregularly
turn on and off.
Low external voltage
Loose terminal screw
Loose connection of terminal
block connector
Use rated external voltage.
Correctly insert and lock
terminal block.
6
Output (input) operation
indicator LED does not light
up (although operation is
normal).
LED failure Replace output (input) unit.
107
8.3 Steam Pressure Regulator
WARNING
Instruction
Do not make changes to state after trial operation. Failure to observe this instruction may
cause poor combustion, backfire (*), or other accidents.
Steam pressure regulator controls steam pressure by sending signals from pressure transmitter to
control motor under proportional control.
This steam pressure regulator controls combustion level under proportional control as well as sends
combustion stop and start signals. It can also be used to change combustion level setting.
Figure 5-54 Display of Steam Pressure Regulator
Figure 5-52 Pressure Transmitter
Figure 5-53 Steam Pressure Regulator
Manual (MAN) mode lamp (green)
Present value (PV) indicator
Shows boiler steam pressure in MPa.
Memory area indicator
Bar graph
Direct key
Set key
Down key
Up key
Output (OUT1 and OUT2) lamps (green)Digital output (D01 to D04) lamps (green)
Alarm (ALM) lamp (red)
Remote (REM) mode lamp (green)
Auto tuning (AT) lamp (green)
Manipulated value (MV) lamp (green)
Set value (SV) indicator
Shift key
108
8.4 Fuel Oil Temperature Controller
8.4.1 Name and Function
No. Name Function
1 Measurement indicator
(PV)
Measurement is indicated.
2 Set value indicator(SV) Set value is indicated.
3 Up Key Value is increased by 1 whenpressed once. Value isincreased by keeping on press.
4 Down Key Value is decreased by 1 whenpressed once. Value isdecreased by keeping on press.
Note
Appropriate heating temperature of fuel oil depends on viscosity of oil. Determine temperature
following Heavy Oil Heating Temperature Chart.
Refer to page 81 “5.3.3 Heavy Oil Heating Temperature” in Chapter 5.
Set data by pressing key firmly with fingertip.
Data is automatically registered 3 seconds after it is set.
Do not press SEL key.
Do not change internal parameters.
8.4.2 Setting Procedure
Example: Changing set value (SV) from 120°C to 130°C
Press Up key until changed value reaches 130. Value is automatically registered 3 seconds
after set up.
1
2
3 4
Figure 5-55 Temperature controller (For temperature of fuel oil control)
109
8.5 Water Level Detector (LM1-200)
Water level detector (LM1-200) has following features:
• It can be used at voltage of 100 V or 200 V.
• No relay is used and open collector is used for output.
Figure 5-56 Sequence Diagram (Water Level Detector (LM1-200))
Water level detectorLM1-200
Logic circuitLevel detecting
circuit Pow
er
circuit
110
8.6 Water Level Indicator
CAUTION
Instruction
Improper setting of water level may damage boiler body.
Do not change setting from trial operation.
Do not change internal parameters.
Improper setting of water level may damage boiler body.
Water level indicator opens and closes flow control valve depending on signal from differential
transmitter.
Figure 5-57 Water level indicator
Note
In case of trouble or wiring disconnection of differential transmitter, water level indicator
displays B.OUT that means out range of display.
Adjust normal water level (0mm) during combustion at pressure for general use. Display of
water level gauge and water level meter of control panel occur error due to steam pressure
and operation condition. Display of water level gauge and water level meter occur error during
combustion stop, because water level ware adjusted to normal level during combustion at
pressure for general use at the time boiler is delivered. Refer to manual for External zero
adjustment of differential transmitter when adjust normal water level.
Water level display(unit:mm)
Normal water level display
(unit:mm)
※Normal water level was set to 0mm.
Alarm lamp
1:Low Low water level
2:Low water level
3:High water level
111
CHAPTER 6: TROUBLE SHOOTING
Trouble shooting for each system is described in this chapter. If problem is not resolved by taking
measures in this chapter, there may be another cause. In that case, stop operation, and contact MIURA
offices.
1. Feed Water System
Table 6-1 Trouble Shooting (Feed Water System)
Phenomenon Item to be checked Cause Countermeasure
Feed water pump
does not run.
Confirm that power is
turned on.
Power is not turned on. Turn power on.
Confirm that terminal is
inserted properly.
Wiring disconnection or
contact failure.
Check wire connection.
Confirm that thermal relay
is not run.
(1) Thermal relay failure
(2) Overload of motor
(1) Manually restore
thermal relay and
check set value.
(2) Check whether motor is
overloaded or not.
Confirm that water level
detecting rod is not dirty.
Water level not detected. Clean water level
detecting rods.
Confirm that motor is not
burned or coil is not
broken.
Motor failure and other. Contact MIURA offices.
Confirm that bearing,
mechanical seal, and
impeller are not burned.
Motor failure and other. Contact MIURA offices.
Confirm that breaker for
feed water pump is not
tripped.
Insulation failure. Contact MIURA offices.
Feed water pump
is running, but
indicator lamp
does not light up.
Confirm that there is no
disconnection of wiring on
control panel.
Disconnection. Replace wiring.
Confirm that there is no
contact failure of wiring on
control panel.
Contact failure. Fasten connection screws
tightly.
Abnormal noise or
heat is generated.
Confirm that bearing and
gland packing are not
burned.
Motor failure and other. Contact MIURA offices.
112
Phenomenon Item to be checked Cause Countermeasure
Abnormal noise or
heat is generated.
Confirm that foreign
materials have not gotten
into pump.
Inclusion of foreign
materials in pump.
Remove cause of inclusion
of foreign materials.
Confirm that impeller is not
in contact with guide plate.
Partial contact between
impeller and guide plate
Contact MIURA offices.
Feed water pump
is running, but it
does not feed
water.
Confirm that air does not
come into pump from
suction side.
Defective piping. Install feed water pipes
properly.
Confirm that air is not built
up.
Insufficient air vent. Vent air sufficiently.
Confirm that there is water
in cascade tank.
No water in cascade tank Feed water into cascade
tank.
Confirm that feed water
pipes and valves are not
clogged.
Clogging of feed water
pipes.
Clean inside of pipes.
Confirm that strainer is not
clogged.
Clogging of strainer. Clean strainer.
Confirm that there is no
leakage from feed water
check valve.
Cavitation. Clean, adjust, or replace
check valve.
Confirm that temperature
of feed water is kept within
specifications of pump.
Cavitation. Lower temperature of feed
water.
Confirm that shaft center
of feed water pump is
aligned with motor.
Misalignment of shaft. Align shaft center of feed
water pump with motor.
Confirm that impeller and
guide plate are not worn
abnormally.
Decline of performance of
feed water pump.
Contact MIURA offices.
Confirm that remote level
gauge valves are opened.
Differential pressure
detection failure.
Open remote level gauge
valves.
Confirm that flow control
valve is working properly.
(1) It is controlled to be
closed.(Normal)
(2) Wiring disconnection or
Contact failure
(3) Failure
(1) Valve is closed when
feed water is not required
(water level is over normal
water level) because of
proportional control.
(2) Check wire connection.
(3) Contact MIURA offices.
Confirm that water level
indicator is displayed
B.OUT.
(1) Wiring disconnection or
Contact failure
(2) Failure of indicator.
(1) Check wire connection.
(2) Contact MIURA offices.
113
Phenomenon Item to be checked Cause Countermeasure
Pump is feeding
water, but water
level is lowered to
low water level
easily.
Confirm that performance
of feed water pump is not
declined.
Decline of performance of
feed water pump.
Switch to another pump
and inspect pump.
Confirm that zero
adjustment position of
differential transmitter is
proper.
Zero adjustment position is
low.
Readjust position during
combustion at pressure for
general use.
Confirm that pressure
gauge is working properly.
Failure of pressure gauge. Replace pressure gauge.
Discharge
pressure of feed
water pump is
increased too
much.
Confirm that pipes and
valves on discharge side
are not clogged.
Clogging of discharge line. Remove clogging of
discharge line.
Confirm that pressure
gauge is working properly.
Failure of pressure gauge. Replace pressure gauge.
Confirm that orifice of feed
water pump outlet is not
clogged.
Clogging of orifice. Clean orifice.
Water leakage
from feed water
pump.
Confirm that seal parts,
such as gland packing and
O rings, are not
deteriorated.
Deterioration of seal parts. Replace seal parts.
Confirm that there is no
leakage from cocks and
instrumentation parts.
Failure of cocks or
instrumentation pipes and
defective installation.
Install problematic parts
correctly.
Water level that is
indicated by water
level gauge cannot
be read.
Confirm that water level
gauge glass is not dirty.
Dirt on water level gauge
glass.
Clean water level gauge
glass.
Confirm that water level
gauge is not filled with
boiler water.
Failure of water level
control system.
Contact MIURA offices.
Confirm that water level
gauge valves are opened.
Water level remains
unchanged.
Open water level gauge
valves.
Confirm that water level
control cylinder connecting
pipe is not clogged.
Water level remains
unchanged.
Clean water level control
cylinder connecting pipes.
Water leakage
from water level
gauge.
Confirm that water level
gauge glass packing is not
deteriorated.
Deterioration of seal parts. Replace water level gauge
glass.
Confirm that water level
gauge glass is fastened on
the both sides.
Defective installation of
water level gauge glass.
Install water level gauge
glass properly.
Note For details about problems of feed water pumps, refer to instruction manual for feed water pump.
114
2. Fuel System
Table 6-2 Trouble Shooting (Fuel System)
Phenomenon Item to be checked Cause Countermeasure
Fuel oil pump does
not run.
Confirm that power is
turned on.
Power is not turned on. Turn power on.
Confirm that rotor is not
burned.
Rotor burning. Contact MIURA offices.
Confirm that foreign
materials are not
entangled in rotor.
Inclusion of foreign
materials in pump.
Remove cause of inclusion
of foreign materials and
replace pump.
Confirm that bearing or
mechanical seal is not
burned.
Bearing burning. Contact MIURA offices.
Confirm that shock
absorbing rubber of
coupling is not damaged.
Defective coupling. Replace coupling.
Confirm that motor is not
burned or coil is not
broken.
Burnout of motor. Contact MIURA offices.
Confirm that terminal is
inserted properly.
Wiring disconnection or
contact failure.
Check wire connection.
Confirm that thermal relay
is not run.
(1) Thermal relay failure
(2) Overload of motor
(1) Manually restore
thermal relay and check
set value.
(2) Check whether motor is
overloaded or not.
Confirm that breaker for
auxiliary equipment is not
tripped.
Insulation failure. Contact MIURA offices.
Running fuel oil
pump sounds loud.
Fuel oil pump is
heated.
Confirm that fuel oil pump
is filled with fuel.
Idling of pump. Feed pump with fuel.
Confirm that discharge
pressure of fuel oil pump is
normal.
Pressure is too high. Adjust pressure to
specified pressure.
Confirm that discharge
pipes and valves are not
clogged.
Clogging of flow path. Clean pipes and open and
close valves properly.
Confirm that air does not
come into pump from
suction side.
Inclusion of air. Remove cause of inclusion
of air, and let out air.
Confirm that bearing or
mechanical seal is not
burned.
Bearing burning. Contact MIURA offices.
115
Phenomenon Item to be checked Cause Countermeasure
Running fuel oil
pump sounds loud.
Fuel oil pump is
heated.
Confirm that rotor is not
burned.
Rotor burning. Contact MIURA offices.
Confirm that foreign
materials are not
entangled in rotor.
Inclusion of foreign
materials in pump.
Remove cause of inclusion
of foreign materials and
replace pump.
Confirm that fuel
temperature is not too
high.
Inclusion of air due to
evaporation of volatile
components in fuel.
Lower fuel temperature.
Confirm that sludge is not
contained in fuel oil.
Inclusion of dust, air, or
other foreign materials.
Drain fuel service tank.
Confirm that shaft center
of feed water pump is
aligned with motor.
Misalignment of shaft. Align shaft center of fuel oil
pump with motor.
Confirm that shock
absorbing rubber of
coupling is not damaged.
Defective coupling. Replace coupling.
Discharge
pressure of fuel oil
pump is too high.
Confirm that there is not
anything wrong with
pressure gauge.
Failure of pressure gauge. Replace pressure gauge.
Confirm that pressure is
adjusted.
Maladjustment of pressure
gauge.
Adjust pressure.
Confirm that pipes and
valves on outlet side of
pump are not clogged.
Clogging of pipes and
valves.
Clean pipes and open and
close valves properly.
Confirm that solenoid
valve is working properly.
Failure of solenoid valves. Replace solenoid valves.
Confirm that there is no
clogging in burner ASSY.
Clogging of flow path. Clean burner ASSY.
Confirm that viscosity of
fuel is appropriate.
Viscosity of fuel is high. Replace fuel.
Confirm that heating
temperature of heater is
normal.
Failure of fuel oil heater(*)
(wrong setting).
Check heating
temperature.
Fuel oil
temperature does
not rise.
Confirm that there is no
inclusion of air.
Heating failure due to
inclusion of air.
Vent air sufficiently.
Confirm that temperature
controller is set properly.
Set value is low. Change set value.
Confirm that there is no
broken wire in fuel oil
heater coil.
Failure of fuel oil heater
coil.
Replace coil for heating
heater.
Confirm that wiring of fuel
oil heater is connected.
Contact failure. Fasten connection screws
tightly.
116
Phenomenon Item to be checked Cause Countermeasure
Fuel oil
temperature does
not rise.
Confirm that solenoid
valve for steam and steam
trap are working properly.
Failure of solenoid valve
and steam trap.
Disassemble and clean
solenoid valve and steam
trap.
Confirm that inside of
heater is not dirty.
Performance decline due
to dirt.
Clean inside of heater.
Confirm that there is no
error indication in fuel oil
temperature controller.
Failure of thermocouple. Failure of thermocouple.
3. Combustion System
Table 6-3 Trouble Shooting (Combustion System)
Phenomenon Item to be checked Cause Countermeasure
Fan does not run. Confirm that power is turned
on.
Power is not turned on. Turn power on.
Confirm that steam pressure
is not higher than setting of
steam pressure switch.
Steam pressure is high. Open main steam valve to
lower steam pressure.
Confirm that motor is not
burned or coil is not broken.
Motor failure and other. Contact MIURA offices.
Confirm that terminal is
inserted properly.
Wiring disconnection or
contact failure.
Check wire connection.
Confirm that thermal relay is
not run.
(1) Thermal relay failure
(2) Overload of motor
(1) Manually restore
thermal relay and check
set value.
(2) Check whether motor is
overloaded or not.
Confirm that motor is
insulated.
Insulation failure. Contact MIURA offices.
Confirm that bearing is not
burned.
Bearing burning. Contact MIURA offices.
Fan is running, but
ignition is not
started.
Confirm that terminal is
inserted properly.
Wiring disconnection or
contact failure.
Check wire connection.
Misfire / ignition
failure
Confirm that there is not
anything wrong with flame
eye(*)
.
Failure of flame eye(*)
or
dirt on glass.
Replace flame eye or
clean glass.
Confirm that damper is
opened properly.
Improper adjustment of
damper.
Contact MIURA offices.
117
Phenomenon Item to be checked Cause Countermeasure
Misfire / ignition
failure
Confirm that discharge
pressure of fuel oil pump is
high enough.
(including pilot pump)
(1) Clogging of pipes
(2) Pump failure
(3) Decline of
performance of pump
(1) Remove cause of
clogging.
(2) Replace fuel oil pump.
(3) Readjust pressure. If
this does not work,
replace parts.
Confirm that burner nozzle
and baffle plate are correctly
positioned relative to each
other.
Flame blowout. Adjust their positions with
reference to burner
dimensions in final
drawing.
Confirm that pilot nozzle tip
and baffle plate are correctly
positioned relative to each
other.
Flame blowout. Adjust their positions with
reference to Figure 5-3 in
Chapter 5.
Confirm that flame eye is
installed and fixed correctly.
Flame eye does not
catch flame.
Install and fix flame eye
correctly.
Confirm that moisture is not
included in fuel.
Pressure drop due to
evaporation of moisture
in fuel (cavitation).
Drain fuel service tank to
remove moisture.
Confirm that air flow
controller is working with
running of control motor.
Looseness of coupling. Contact MIURA offices.
Confirm that fuel remains in
fuel service tank.
Tank is out of fuel. Supply fuel to fuel service
tank.
Confirm that burner nozzle is
not dirty or is not clogged.
Burner nozzle is clogged
with dust.
Clean burner nozzle.
Confirm that pilot nozzle tip is
not dirty or is not clogged.
Pilot nozzle tip is
clogged with dust.
Clean pilot nozzle tip.
Confirm that there is no
leakage from burner nozzle.
Leakage from joint of
burner nozzle.
Fasten joint of burner
nozzle tightly.
Confirm that there is no
leakage from pilot nozzle tip.
Leakage from joint of
pilot nozzle tip.
Fasten joint of pilot nozzle
tip tightly.
Confirm that fuel system is
not clogged.
Clogging of fuel system. Remove cause of
clogging.
Confirm that oil pressure
switch is working properly.
Failure of oil pressure
switch.
Check and adjust setting
of pressure switch. If this
does not work, replace it.
Confirm that ignition spark
flies.
(1) Failure of ignition
transformer(*)
.
(2) Defective wiring.
(1) Replace parts.
(2) Connect wire properly.
Confirm that opening in the
tip of ignition rod is the same
as specified in final drawing.
Dimension failure of
ignition rod.
Check final drawing and
adjust dimensions.
Confirm that the tip of ignition
rod is not dirty.
Miss spark. Clean ignition rod.
118
Phenomenon Item to be checked Cause Countermeasure
Misfire / ignition
failure
Confirm that there is not
anything wrong with fuel
temperature.
Fuel temperature is low. Adjust fuel temperature
properly by fuel oil
temperature controller.
Confirm that equalizing valve
seal pot is filled with ethylene
glycol.
(1) Excessive amount of
atomized steam.
(2) Insufficient amount
of atomized steam.
(1) Fill seal pot with
ethylene glycol.
(2) Fill seal pot with
ethylene glycol and
clean strainer.
Confirm that pressure setting
of pressure reducing valve is
proper.
(1) Excessive amount of
atomized steam.
(2) Insufficient amount
of atomized steam.
(1) Adjust pressure setting
of pressure reducing
valve.
(2) Adjust pressure setting
of pressure reducing
valve and clean strainer.
Confirm that air-driven valve
is working properly.
(1) Insufficient operating
air.
(2) Clogging of
operating air system.
(1) Adjust pressure of
compressed air and
pressure setting of filter
regulator.
(2) Clean operating air
system.
Confirm that solenoid valve
for air-driven valve is working
properly.
(1) Inclusion of dust in
solenoid valve for
air-driven valve.
(2) Failure
(3) Compressed air
valve is closed.
(4) Clogging or setting
error of filter regulator.
(1) Disassemble and clean
solenoid valve for
air-driven valve.
(2) Replace parts.
(3) Open compressed air
valve.
(4) Clean filter regulator
and adjust pressure
setting.
Confirm that atomized air
pressure is 0.4 MPa or
above.
(1) Atomized air
pressure drop
(2) Clogging of atomized
air line.
(3) Atomized air valve is
closed.
(1) Adjust atomized air
supply pressure
between 0.6 MPa and
0.9 MPa.
(2) Remove cause of
clogging.
(3) Open atomized air
valve.
Confirm that atomized air
pressure is 0.9 MPa or
below.
Atomized air pressure
increase.
Adjust atomized air supply
pressure between 0.6 MPa
and 0.9 MPa.
Confirm that fuel oil is
circulating at proper
pressure.
Flame blowout due to
fuel shortage.
Clean fuel strainer and
adjust pressure of relief
valve.
Confirm that hydraulic line
valve of seal pot is opened.
Lack of atomized steam. Open valve.
119
Phenomenon Item to be checked Cause Countermeasure
Misfire / ignition
failure
Confirm that atomized air
and steam valves are
opened and closed properly.
Lack of atomized fluid. Open valve.
Confirm that solenoid valves
for atomized air and steam
are working properly.
(1) Inclusion of dust in
solenoid valves for
atomized air and
steam
(2) Failure
(1) Disassemble and clean
solenoid valves for
atomized air and steam.
(2) Replace parts.
Combustion can
be observed, but
combustion lamp
does not light up.
Confirm that there is no
disconnection of wiring on
control panel.
Disconnection. Replace wiring.
Confirm that there is no
contact failure of wiring on
control panel.
Contact failure. Fasten connection screws
tightly.
Combustion is not
stopped even after
steam pressure
rises up to
specified pressure.
Or, combustion is
stopped
independently of
specified pressure.
Confirm that steam pressure
regulator and pressure
transmitter are working
properly.
Failure of steam
pressure regulator or
pressure transmitter.
Contact MIURA offices.
Confirm that there is not
anything wrong with pressure
gauge.
Failure of pressure
gauge.
Replace pressure gauge.
Confirm that pressure shown
in steam pressure gauge is
not decreasing.
(1) Clogging of steam
pressure gauge line.
(2) Steam pressure
gauge valve is closed.
(1) Clean steam pressure
gauge line.
(2) Open steam pressure
gauge valve.
Confirm that drive valve is
working properly.
(1) Inclusion of dust in
drive valve
(2) Failure
(1) Disassemble and clean
drive valve.
(2) Replace parts.
Flame is not
stabilized
(Unbalanced
flame).
Confirm that there is not
anything wrong with fuel
temperature.
Fuel temperature is low. Adjust fuel temperature
properly by fuel oil
temperature controller.
Confirm that damper is
opened properly.
Excessive air flow.
(Improper adjustment of
damper opening)
Adjust position of damper
based on results of trial
operation.
Confirm that burner nozzle is
not clogged with dust.
Burner nozzle is clogged
with dust.
Clean burner nozzle.
Confirm that pilot burner,
burner nozzle, baffle plate,
and other parts are correctly
positioned relative to each
other.
Eccentric installation of
burner.
Adjust their positions
based on results of trial
operation.
Confirm that fuel oil pressure
is proper.
Fuel oil pressure is low
or oscillating.
Readjust pressure. If this
does not work, replace
parts.
120
Phenomenon Item to be checked Cause Countermeasure
Exhaust gas is
black.
Confirm that damper is
opened properly.
Insufficient air flow.
(Improper adjustment of
damper opening)
Adjust position of damper
based on results of trial
operation.
Confirm that lock nut on link
arm is not loosened.
Insufficient air flow.
(Improper adjustment of
damper opening)
Contact MIURA offices.
Confirm that fuel oil pressure
is proper.
Fuel oil pressure is high. Readjust pressure. If this
does not work, replace
parts.
Confirm that there is not
anything wrong with fuel
temperature.
Fuel temperature is low. Adjust fuel temperature
properly by fuel oil
temperature controller.
Confirm that inner cylinder
and baffle plate are not
burned.
Burnout of parts. Replace parts.
Confirm that burner nozzle,
baffle plate, and other parts
are correctly positioned
relative to each other.
Dimension failure of
burner.
Adjust their positions
based on results of trial
operation.
Confirm that fan is running in
right direction.
Defective wiring. Check wire connection.
Exhaust gas is
white.
Confirm that damper is
opened properly.
Excessive air flow.
(Improper adjustment of
damper opening)
Adjust position of damper
based on results of trial
operation.
Confirm that lock nut on link
arm is not loosened.
Excessive air flow.
(Improper adjustment of
damper opening)
Contact MIURA offices.
Confirm that fuel oil pressure
is proper.
Fuel oil pressure is low. Readjust pressure. If this
does not work, replace
parts.
Confirm that fuel pipes are
not clogged.
Clogging of fuel pipes Clean fuel pipes.
Confirm that burner nozzle is
not clogged with dust.
Burner nozzle is clogged
with dust.
Clean burner nozzle.
Confirm that burner nozzle,
baffle plate, and other parts
are correctly positioned
relative to each other.
Dimension failure of
burner.
Adjust their positions
based on results of trial
operation.
Confirm that fuel oil pressure
is not too high.
Failure of drive valve.
Decline of performance
of pump
Readjust pressure. If this
does not work, replace
parts.
Vibration
combustion
occurs.
Confirm that air is not
included.
Inclusion of air. Remove air from fuel line
sufficiently.
Confirm that atomized steam
pressure is not too high.
Excessive amount of
atomized steam.
Adjust pressure setting of
pressure reducing valve.
121
Phenomenon Item to be checked Cause Countermeasure
Vibration
combustion
occurs.
Confirm that there is not
anything wrong with fuel
temperature.
Fuel oil temperature is
too high or too low.
Adjust fuel temperature
properly by fuel oil
temperature controller.
Confirm that damper is
opened properly.
Excessive or insufficient
air flow.
(Improper adjustment of
damper opening)
Adjust position of damper
based on results of trial
operation.
Confirm that oil accumulated
in the bottom of furnace is
not burning.
Failure of burner nozzle.
Failure of drive valve.
Stop operation and contact
MIURA offices.
Confirm that inner cylinder
and baffle plate are not
burned.
Burnout of parts. Replace parts.
Confirm that main air-driven
valve is working properly.
(1) Insufficient operating
air.
(2) Clogging of
operating air system.
(1) Adjust pressure of
compressed air and
pressure setting of filter
regulator.
(2) Clean operating air
system.
Confirm that solenoid valve
for air-driven valve is working
properly.
(1) Inclusion of dust in
solenoid valve for
air-driven valve
(2) Failure
(3) Compressed air
valve is closed.
(4) Clogging or setting
error of filter
regulator.
(1) Disassemble and
clean solenoid valve for
air-driven valve.
(2) Replace parts.
(3) Open compressed air
valve.
(4) Clean filter regulator
and adjust pressure
setting.
Low atomized
steam/air pressure
alarm is issued.
Confirm that atomized fluid
selection switch on control
panel is set properly.
Operation error of
atomized fluid selection
switch.
Check atomized fluid
selection switch.
Confirm that atomized air
and steam valves are
opened and closed properly.
Lack of atomized fluid. Open valve.
Confirm that atomized steam
strainer is not clogged.
Lack of atomized fluid. Clean strainer.
Confirm that atomized fluid
pressure switch is working
properly.
Failure of pressure
switch.
Check and adjust setting
of pressure switch. If this
does not work, replace it.
Confirm that atomized air
pressure is 0.4 MPa or
above.
(1) Atomized air
pressure drop
(2) Clogging of atomized
air line.
(1) Adjust atomized air
supply pressure
between 0.6 MPa and
0.9 MPa.
(2) Remove cause of
clogging.
122
Phenomenon Item to be checked Cause Countermeasure
Low atomized
steam/air pressure
alarm is issued
Confirm that atomized steam
pressure is 0.25 MPa or
above.
(1) Atomized steam
pressure drop
(2) Clogging of atomized
steam line.
(1) Close main steam
valve, etc.
(2) Remove cause of
clogging.
4. Control System
Table 6-4 Trouble Shooting (Control System)
Phenomenon Item to be checked Cause Countermeasure
Pressing
combustion switch
does not start
combustion.
Confirm that manual
combustion switch is not
set at OFF position.
Manual combustion switch
is set at OFF position.
Shift burner selection
switch to automatic
position.
Confirm that safety
systems are not activated.
Safety system activated. Remove cause of alarm
issuance and press reset
button.
Ignition failure
lamp does not light
up and alarm does
not sound following
ignition failure.
Confirm that there is not
anything wrong with flame
detector.
Refer to P99
"6.3 Flame Detector
(FS-901)" in Chapter5
Failure of flame detector. Replace parts.
Confirm that there is not
anything wrong with lamp,
socket, or buzzer.
Failure of lamp, socket, or
buzzer.
Replace parts.
Confirm that there is not
anything wrong with
buzzer stop switch.
Failure of buzzer stop
switch.
Replace parts.
Damper control
error alarm is
issued.
Confirm that control motor
is working properly.
Failure of control motor. Contact MIURA offices.
Confirm that steam
pressure controller, parts
in control panel is proper.
Failure of steam pressure
controller parts in control
panel
Contact MIURA offices.
Confirm that there is no
disconnection or contact
failure of wiring.
Wiring disconnection or
contact failure.
Check wiring.
123
5. Trouble Shooting for Boiler Body
CAUTION
Caution: Hot
Before working on water tube leaks, check water tubes and burner funnel that may be
touched are fully cooled. Otherwise, you may suffer from burn. For more information,
contact MIURA offices.
Checking Leaked Water Tubes
No leakage from water tube of GK type boiler occurs if water quality control is carried out properly.
Boiler external treatment and boiler internal treatment with boiler compound are absolutely essential.
If leakage is found from boiler water tube due to improper boiler water treatment, check it as follows:
a) Remove burner and wind box (*) from the upper part of boiler. Open manhole of funnel on
exhaust gas side.
b) Enter boiler combustion chamber and funnel inside on exhaust gas side to check water tube wall
(Obvious leakage may be detected at glance in this stage).
c) Switch feed water pump to manual operation and perform a hydraulic test.
d) If water is leaking from joint of water tube and tube plate, remove refractory castable around
water tube swaged area and inspect whole area.
When water is leaking from back side of the first row of tubes toward the second row of tubes, it is
easily considered that water is leaking from the second row of tubes. Therefore, check it carefully
in full consideration of above.
e) When leaking water tubes are found, insert stoppers or replace tubes with new ones.
Refer to page 124 “6. Repairing Damaged Water Tubes” in Chapter 6.
f) Investigate cause of water tube leakage for future reference. If leakage came from improper
water treatment, take secure measures to prevent recurrence.
If leakage is found on exhaust gas economizer side, open manhole on exhaust gas
inlet and outlet and hand holes in the middle part and find where leakage is occurring.
124
6. Repairing Damaged Water Tubes
WARNING
Instruction
Stopper treatment and furnace building with refractory is temporary treatment. Do not
operate for a long time; otherwise, there is possibility of serious accident. Contact each
classification in advance and replace water tubes (or body) immediately at periodical
inspection. Contact MIURA offices about replacement of water tubes (or body).
Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool
both the inside of drum and combustion chamber. Then make sure that pressure inside the
drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan
during inspection.
This boiler is vertical natural-circulation boiler.
If boiler water is not controlled according to "Manual for Water Treatment,” that is provided separately,
impurities in feed water (calcium, magnesium, and silica) may be accumulated and turned into scale
on heating surface, that could hinder heat exchange process, damage water tubes, or cause
leakage.
To operate this boiler most economically and efficiently, it is essential to control boiler water by
blowing down boiler and using proper boiler compounds and water softener. This chapter describes
ways to fix damaged water tubes and leakage that are caused by unsatisfactory boiler water
treatment.
6.1 Insertion of Stoppers from Inside of Water Drum
This method uses iron stoppers that are included as spare
parts to plug tubes from inside the upper and lower steam
drums and water drum. Before inserting the stoppers,
determine which water tube(s) is/are leaking.
Refer to page 123. “5. Trouble Shooting for Boiler
Body” in Chapter 6
Once it is identified leaking water tube(s), enter drum
through manhole and insert stoppers from inside as it is
shown in the figure.
In this case, clean thoroughly contact surface between
stopper and water tube so that dust or other foreign materials
do not get caught in surface; this is especially important if
there is some sort of damage. It is also effective to polish
parts with carborundum or a similar material.
Figure 6-1 Insertion of Stoppers from Inside of Water Tube
Stopper
Stopper
CombustionChamber
125
6.2 Stopper Welding from Combustion Chamber
Figure 6-2 Stopper Welding from Combustion Chamber
This method is the same as the previous method up to the point that water pressure test is conducted inside
combustion chamber to determine which pipe(s) is/are leaking. However, stoppers are used in completely
different way. In this method, stoppers are welded from inside of combustion chamber as it is shown in
figure. Therefore, the first prerequisite for using this method is to have certified welder on board.
Figure 6-3 Stopper Welding from Inside of Combustion Chamber
If it is undertaken stopper treatment from just the top and bottom without welding stoppers, there is
possibility that water tube (that does not contain water) is damaged and water is leaked to exhaust gas side.
Therefore, the previous type of work should be completed only in case of emergency; it is strongly
recommended that stoppers are welded once ship reaches port. However, if there is some technical issue,
such as with welders, or application of refractory castable is omitted (refer to above figure), other problems
may be caused. Therefore, it is necessary to follow instructions of MIURA offices.
CombustionChamber
Cuto
ffth
isp
ort
ion
with
gas
(Cuto
ffth
esecon
dand
su
bsequ
entw
ate
rtu
bes).
1 Steam drum
2 Water drum
3 Water tube
4 Castable
CombustionChamber
Sea
lth
eo
pen
ing
by
we
ldin
g.
CombustionChamber
App
lycasta
ble
(only
toth
ein
nerm
ostro
w).
Anchor
126
CHAPTER 7: STORAGE
1. Maintenance When Boiler is Shut Down for a Long TimeWhen boiler is shut down for a long time, it is important to store it properly. Before boiler is shut down,
wash soot off boiler and clean and fully dry inside of furnace. In addition, pour silica gel to protect
against rust.
Conduct procedure for shutdown according to Manual for Water Treatment.
2. Movement or Resale
WARNING
Prohibition
Do not perform installation work and connection of incidental equipment unless it is
specified.
Failure to observe this instruction may cause physical injury.
In reselling or reusing boiler, procedure that is based on rules of vessel classification must be taken.
Contact MIURA offices since it must be checked that vessel equipment does not affect normal
operation of boiler. Installation work or connection of incidental equipment that is not specified may
cause physical injury. If our products are resold, deliver instruction manuals and related materials along
with product to new owner, and inform us of resale (We need to transfer maintenance records that kept
since it was placed in service).
3.Export
When exporting products whose export is regulated under the Foreign Exchange and Foreign Trade
Act, approval of the Japanese government for export must be obtained. When MIURA products are
exported, products and their use are subjected to many laws and regulations in the destination country.
If there is plan to export MIURA products, contact MIURA offices.
127
CHAPTER 8: DISPOSAL
1. Disposal ProcedureThis boiler must be disposed of as industrial waste.
Dispose of boiler properly according to the laws in the country where it is to be disposed of. For details
about recycling of materials that are used in this boiler, contact MIURA offices.
128
CHAPTER 9: GUARANTEE
1. Description of GuaranteeGuarantee period is either of following, whichever comes first:
12 months after vessel is delivered.
18 months after equipment is shipped
If boiler has trouble within this guarantee period, trouble is repaired or parts are replaced for free so
that boiler functions as required in agreement as long as it has been installed and used properly
according to instruction manual, warning labels, and other instructions.
Trouble with equipment other than MIURA products that is installed on vessel is not covered by this
guarantee. Deterioration of consumable parts is not covered by this guarantee unless it is abnormal
deterioration.
In any of following cases, repair work is charged even within guarantee period:
[1] Failure or damage that is caused by wrong use, poor maintenance, or improper repair or
remodeling
[2] Failure or burnout due to natural disasters such as fires, typhoons, or tsunamis, or other external
factors
[3] Replacement of consumable parts
[4] Other matters that are specified in the agreement
If repair work is required outside Japan, travel expenses including accommodation and transportation
fees are charged. Repair service outside Japan cannot be provided if travel to that country is banned.
If there is any question about repair service within or after guarantee period, contact MIURA offices.
2. Contact Information for Inquiries about Products and Instruction
ManualIf you have any question about products that you purchased or about this instruction manual, contact
MIURA offices.
(Contact information can be found on back cover.)
3. Sale of Instruction ManualIf you need instruction manual for this boiler, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, boiler number, and manual
number on cover of instruction manual.
4. Sale of PartsIf you need parts that are used with this boiler, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, and boiler number.
DOMESTIC SERVICE STATION*HEAD OFFICE:MIURA Co.,Ltd.
SHIP MACHINERY DEPT.
*BRANCH:TOKYO MAINTENANCE DIV.
SHIMANAMI MAINTENANCE DIV.
KYUSHU MAINTENANCE DIV.
*AUTHORIZED DISTRIBUTORS:N.Y.CO.,LTD.
CHUOKIKI CO.,LTD.
OVERSEAS SERVICE STATIONMIURA SOUTH EAST ASIA PTE. LTD.
MIURA Co., Ltd ROTTERDAM OFFICE
7, Horie, Matsuyama, Ehime, Japan,
799-2696
2-15-35 Takanawa, Minato-Ku, Tokyo,
Japan, 108-0074
3-20-9 Matsunaga-Cho, Fukuyama,
Hiroshima, Japan, 729-0104
3-19-20, Hakataekiminami Hakata-ku
Fukuoka,Japan, 812-0016
1-3-10, Shibaura, Minato-Ku, Tokyo,
Japan, 105-0023
4-28-2, Abraya-Cho, Minato-Ku,
Nagoya, Aichi, Japan, 455-0824
No.3 Soon Lee Street #03-36-37-38,
Pioneer Junction Singapore 627606
Rotterdam Business Centre. Westblaak 140,
3012KM Rotterdam The Netherlands
TEL: (+81)89 979 7066
FAX: (+81)89 979 7067
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TEL: (+65)6465 1147
FAX: (+65)6465 1148
TEL: (+31)10 412 2015
FAX: (+31)10 412 4109
OVERSEAS NETWORK1.CHINAIHI MARINE (SHANGHAI) CO., LTD.Room No.706-707, Information Tower No.1403Minsheng Rd, Pudong New Area, Shanghai, 200135,P.R.ChinaTel : (+86)21 6351 8029Fax: (+86)21 6351 8028SHANGHAI WEN CHIUAN MARINESERVICE&ENGINEERING CO., LTD.No.951 Kesheng Rd. Beiguan, Malutown, Jiading districtShanghai, 201801, P.R.ChinaTel : (+86)21 6915 2475Fax: (+86)21 6915 2476
2.GERMANYTAKNAS MARINE ENGINEERING GMBH"Fruchthof" Oberhafenstr.1 20097 Hamburg, GermanyTel : (+49)40 32 1305Fax: (+49)40 33 0608
3.KOREADONG YANG ENGINEERING#10-11,2Ka Myeong-Ryun-Dong Dongrae-Ku Busan,607-802, KoreaTel : (+82)51 552 6503Fax: (+82)51 557 4830SEIN BESTECH302, 64 Keumo-5Gil, Dong-Myeon, Yangsan,626-821, KoreaTel : (+82)51 961 7771Fax: (+82)51 961 7772
4.PHILIPPINESPHIL-NIPPON KYOEI CORP.S-705 Royal Plaza Twin Towers 684 Romedios St.,Malate Manila, PhilippinesTel : (+63)2 400 5778Fax: (+63)2 400 9130
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6.TAIWANAL SEA-LAND ENGINEERING CO.,LTD.1F,No.51, Lane 164, Chung He Rd, Chung Shan Dist.,,Keelung, TaiwanTel : (+886) 2 24367812Fax: (+886) 2 24373219MING YUNG MACHINERY.,LTD.27.Shin Shing St., Yan Cherng District Kaohsiung,TaiwanTel : (+886)7 521 6266Fax: (+886)7 521 9368
7.THE NETHERLANDSNICOVERKEN HOLLAND B.V.Algerastraat 20 3125 BS Schiedam, The NetherlandsTel : (+31)10 2380999Fax: (+31)10 2380990FUJI TRADING (MARINE) B.V.Kortenoord 2-8 3087 AR Rotterdam, The NetherlandsTel : (+31)10 429 8833Fax: (+31)10 429 5227
8.USACISCO BOILER SERVICE CO., INC.5935 Griggs Road, Houston, TX 77023, U.S.A.Tel : (+1)713 928 5700Fax: (+1)713 928 5795INDUSTRIAL BOILER SERVICE, INC.23132 East Echo Lake Rd., Snohomish, WA 98296,U.S.A.Tel : (+1)206 624 1171Fax: (+1)206 483 9112
9.VIETNAMSHM-VLK CO.,LTD64 D2 Street, Van Thanh Bac Precinct, Ward 25,Binh Thanh District, Ho Chi Minh, S.R. VietnamTel : (+84)8 3512 8379
OPERATION MANUAL
MARINE AUXILIARY BOILER HB-TPublished by MIURA Co.,Ltd. Ship machinery Dept. Dec. 2011.
3rd edition Aug. 2014 No. E990-1112-03
Visit us at www.miuraz.co.jp and get the latest information and Service News!
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No part of this publication may not be reproduced, transmitted, distributed or
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