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2. Instruction Manual

2. Instruction Manual
2. Instruction Manual
2. Instruction Manual
   

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OPERATION AND MAINTENANCE

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OPERATION AND MAINTENANCE

  • 1. General

  • 2. Preparation for service

  • 3. Lighting-up and service

  • 4. Taking out of service

  • 5. Cleaning

  • 6. Boiling out

  • 7. Plugging of tubes and Replacing with new tube

 
  • 8. Feed and boiler water

KANGRIM INDUSTRIES CO., LTD.

DATA SHEET INSTRUCTION OPERATION AND MAINTENANCE NO. : FOR PAGE : 2 OF 10 VERTICAL WATER
DATA
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INSTRUCTION
OPERATION AND MAINTENANCE
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VERTICAL WATER TUBE BOILER
TYPE
MC

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OPERATION AND MAINTENANCE

 

PAGE :

3

OF

10

 

1.

General

 
  • 1.1 rests with the boiler attendant

It

to

see

to service

and supervision of the

boiler plant.

He

is

to

see

to

it

that all

parts

of

the plant

are properly

 

maintained, if the

task has

not been assigned to other persons.

 

On sea - going vessels the tasks and responsibility of the boiler attendant

rest

with the ship's

officer from the

machine section on duty.

 
  • 1.2 The boiler attendant is to follow the below working and operation

instructions.

If there are interruptions of service and damages and other

irregularities this must be reported to the nearest superior after, of course,

the operational measures, which are necessary in order situation of danger, have been carried out.

to obviate

a

2.

Preparation for service

 
 
 
  • 2.1 of

Before filling

water

it

must be checked that all strange objects have

 

been removed from

the

interior of the

boilers, that all drain mountings are

closed,

that

all loose

parts

have

been

fastened, and

that

built - in

blind

flanges, if any, have been removed.

 

If

the boiler

has been

 

out of service

fore

quite

a

long time

the

walls are

to be examined for possible damages arisen during the standstill period.

The temperature of the water

which

is

to

be

led into

the boiler

is

to

be

fairly corresponding to the temperature of the walls.

 

If

there

is

a bigger

difference than abt.

50the

boiler

is

to

be filled

 

quite slowly.

 

Before heating

  • 2.2 is

begun it

must

be checked

if

the gas

openings are open

( danger of explosion ), that all safety devices are OK, accurately adjusted

and

ready

for service,

 

and

that the

water

in

the boiler

is between the

 

lowest and normal water level.

 
  • 2.3 Valves and shut - off

devices ought to

be served slowly, connection pipes

must, if necessary,

be emptied of water and ventilated ( water chock,

 

cooling, at sudden differences in temperature ).

 
  • 2.4 Before

the

boiler is

used

for the

first time

it

must be

boiled

out

in order

to remove all protecting

materials

and

dirt

in

pipes and drums.

See paragraph about boiling out.

 
  • 2.5 During the first filling with

boiler

water

the water

level indicators to be

 

controlled by opening the blow - off valve

and upper and lower

water level

valve

to

open by

turns.

A weak

air flow should then

be heard.

 

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10

 

3.

Lighting - up and service

 
 
 
  • 3.1 This boiler is provided to work :

 
 
  • A) a separate

As

oil fired boiler.

 
  • B) a combined oil fired / exhaust

As

fired boiler.

 
  • C) As a separate exhaust fired boiler

 

The mode of operation

of

A)

and

B)

will required constant water level

 

of

the boiler because of danger of burning down in operation.

 

Constant water level is not required

at

C).

However, this is recommended, as the most favorable water circulation and most be stable operating conditions will be obtained.

 

As

to

the construction

and the

strength

it

is fully

proper

at

C)

to lover

the

water

level of

the

exhaust tube section and even empty the boiler

from

water, while the whole gas volume flows through the tube section.

The

boiler will

in

such case,

gradually, get the

same temperature as that

of the exhaust gas.

The boiler

should

be

cooled before refilling it with

 

feed water.

Where this could not

be

done

the

feed

water

is

to be

preheated, and the feeding should commence very

carefully ( slowly ).

 
  • 3.2 When the boiler has

been ignited the

lighting - up

rate must

not

be

 

speeded up too much

in

order

not unnecessarily to overstrain the boiler

material by quick, uneven temperature rises.

 

The

lighting - up time

ought

to

be

abt.

1 1/2 hours.

 
  • 3.3 The air escape

valve

at

the boiler

is

to

be

kept open

until

a

heavy

 
 

steam jet

is flowing

out, this

occurs

at

a

steam pressure of abt.1, 5 bar.

 
  • 3.4 The pressure gauge and its connecting pipe

line are

regularly to be tested

 

carefully as regards free passage.

By this

must be stated

if

the

indicator

can

reach

the

O - point

without obstructions at slow relief of the pressure

gauge,

and

if

it

can reach

its

former position at slow load.

 

Further,

it

must be

stated if the pressure gauge shows the indicated

 

allowable working pressure.

 

At and

after

every blow - through of the connecting pipe line the pressure

gauge

may

not

be

connected until sufficient steam is condensed in the

pipe loop.

 

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10

  • 3.5 service the water

During

level

may

not fall below

the mark

for lowest

 

water level.

If

the

water level cannot with certainty

be said

 

to

be

sufficient

the firing

must

be

stopped

at

once ( see

also paragraph 4.1 )

 

and the nearest superior informed immediately.

 

If

the water level

goes

beyond the top visible water

level without

 

Perceptible reason the

firing

must be

stopped

at

once

if

you

cannot with

 

Other measures again reduce the water level.

 
  • 3.6 All the water level indication instruments are currently used and have,

 

therefore, to be kept clean.

The same thing applies for water level

 

regulator and limiter.

Cocks

and valves

are

to

be opened slowly

and

to

be

closed

in

the

same way.

Lacks, especially obstructions, are to be

 

removed at once.

 

Before the

  • 3.7 connected it is

boiler is

necessary that the

safety

valves are

 

adjusted so that they can

begin to function at the prescribed pressure.

Alteration of the

adjustment is

to

be

carried out

only

by

an

expert

 

from the local classification society.

 

If the steam pressure rises above

 

the allowable working pressure, which is marked

by

a

red

line, the

firing

I reduced and the feeding intensified.

 

If

the

safety

valves

do

not

blow

they are

to be checked

at once.

 

If

the

cause is

not

stated the

firing

must be

stopped and the superior

 

informed.

Once

  • 3.8 blown from the boiler through the

a

day

mud is

bottom blow - off

 

valve

until clear water is coming.

 

If

  • 3.9 priming takes place as

a

consequence

of pollution

of

oil

or

the like

 

in

the boiler

water

( is

normally

seen

as

a

brown

layer in

the water

gauge glasses ), the impurities

are

blown out through the scum valve

( see paragraph about boiling out ).

 

3.10

Should

the firing

fail,

for

some reason, during a heavy steam

demand

 

period,

then

the

steam outlet valve is

to

be closed immediately, and

the

feed

pump is

to

kept in service

until

a

normal

water level is reached.

3.11

If priming takes place because

of

a

sudden pressure drop in the pipe,

the

firing to

be reduced, the feeding increased and if necessary the steam

outlet to

be reduce, too.

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4.

Taking out of service

 
 
 

4.1

The boiler

must be taken

out of service immediately and the superior

 
 

informed

as soon

as

possible

if

 

you

have a

suspicion that something

dangerous is arising.

 

The applies especially when :

 

1) Heating or deformation of the boiler walls are found somewhere

 

2)

A

big

loss

of

water is noted.

 

3)

The feed

water system is unable to provide the necessary feed

 
 

water

amount

due

to

failure of parts.

 
 

4) The safety valve cannot function

 

5) Sudden cracks

or

big

damages

are

noted

in

the

refractory on the

 
 

furnace side,

or

steam

or moisture is coming

out

of

the refractory.

 
 

This can also

be

the case when pipe damages, plate crack

or the

like

( I. e.

 

at

steam

outlet )

are

stated.

 
 
  • 4.2 If

the

boiler is

to

be

taken out

of

service

in

a

emergency the fuel supply

 
 

is stopped.

The

steam valve

is

to

be closed gradually and the boiler

 

must stand

until

it

is cooled.

The

safety valves may not be touched.

Parallel working boilers are to be disconnected at once.

 
 
  • 4.3 If

part

of the heating

surface

has

been glowing or the boiler shows

 
 

recognizable deformations the supervising authorities must be informed,

 

and

the

boiler

is

not

to

be

used until approval from these authorities is

available.

 
 
  • 4.4 When stopping

the

service,

so much

feed water

to

be

filled on

that

a

 

suitable water level is

present

at next

firing ( between lower and normal

 

water level ).

 
 

5.

Cleaning of fired section

 
 
 

5.1

If

the

feed

water is properly

treated the possibility of impurities at the

 
 

water

and steam side

of

the boiler

should be minimal.

 

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10

5.2

Deposits in the tubes are notoriously extremely small owing to the heavy

water circulation.

If

impurities which cannot be boiled out should come

 

inside

the tubes,

the tubes

can

be

cleaned by scraper and

brush.

 

5.3

Once

a

day

mud

is

blown

from

the boiler

through the bottom blow - off

 

valve until clear water is coming.

 

5.4

If

the

oil burner is functioning correctly and the combustion is complete

 

the

soot

hardly

be

deposit on the avoided that

tubes

will

soot

will

deposit

be minimal,

it

can

 

in

the

but in practice course of time,

I. e.

due

to

 

the

starting

periods of

the

oil burner.

Attached soot

deposits can

be

removed

by

water

washing

with

a

10 per

 

cent soda solution through

the

inlet

door in

the

uptake,

drain

pipe at

the

bottom of

the fire

box is available.

 

5.5

Cleaning of exhaust gas fired section.

 

Outside the

tubes

are

to

be

cleaned by boiling out,

possible by using

 

scraper and brush.

 

5.6

Inside the

tubes can

be cleaned for attached soot deposits by

washing

 

with water

with

a

10

per

cent soda solution through the inlet door

of

the uptake, drain

pipe

at the

bottom

of

the boiler is available.

 

The cleaning can possibly

be

mode by

brushes mounted in

chains.

 
 

6.

Boiling out

 
 
 

The boiling out is made in the following way :

 
 

6.1

In

the boiler

is

to

be

filled a solution consisting of

4 - 5 kg.

 

tri - sodiumphosphate ( Na3

Po4 )

per 1000 kg water.

It

is preferable to

add the

chemicals through the manhole.

 

Then

water is filled

in,

until the solution

is

just

visible

in

the

water gauge.

Untreated water can be use.

 

6.2

The

boiler is slowly brought on working

pressure and kept on this pressure

in

abt.

6 - 8

hours with closed main

stop

valve,

after which

fat and

 

other

impurities

should

be

boiled

out

of

the

interior

surfaces of the boiler.

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  • 6.3 Then to be skimmed

of

( through

the

scum valve ),

 

however, it must

be

 

seen that

before

the water

level

is

20 - 30 mm

above the scum funnel.

If

the boiler

is equipped with automatic water level control

it

may

be

necessary to close for this unit during the skimming.

 

After

  • 6.4 boiling out the burner

the

is

switched off, and after abt.1

quarter

 

the

bottom blow - off valve

and

the

air valve

at

the

boiler top

is

to

be

opened,

and

all

the water

is

to

be blown

out

of

the boiler.

 

Then

the

boiler is

washed and brushed

inside, and the bottom

blow - off

 

valve

is examined in such a way that possible oxide scales and welding

pearls, which have been collected there, can be removed

( if necessary

the

bottom

valve

is

to be dismounted ).

The handholes in the

bottom of

blow - off the boiler

is

to

be opened and the boiler carefully cleaned.

  • 6.5 Treated, softened

water

to

be

added to

a

little

below normal water level

when the bottom valve and handholes have been closed.

 
  • 6.6 If

the boiler

shows

a

tendency to priming it is recommended to

carry

 

out

an extra

boiling out.

 

Besides, it is recommended to carry out another

boiling

out

after a

time

of

operation

of

2

to

3

months with a subsequent

inside cleaning and inspection.

 

7.

Plugging of tubes and replacing with new tubes

 
 
 
  • 7.1 Plugging of tubes

 

(1)

In case

of

leakage

on

a water tube

the

pressure is to

be removed from

the

boiler, and the

oil

burner is to be dismantled.

 

(2)

If

the

tube

in

question cannot be pointed out immediately from

the

 

furnace, the

boiler

is

to

be

put

on

pressure

by

means

of

 

the feed

pump

so

that the leakage will indicate which

 

tube has been damaged.

 

(3)

The

boiler is

emptied of water, and

the

manhole cover in the bottom

 

receiver is dismantled.

 

(4)

When a

furnace

tube has

been plugged, the damaged tube is

to

be

removed.

 

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(5)

When the damaged tube has

been

removed,

you

can

by

means

of

a

torch see from the bottom receiver

through the remaining piece of tube

which

tube

is

to be plugged.

 

(6)

Plugging

of

a

furnace

tube

can

be

carried

out

from the

furnace and the

bottom receiver.

It

is

not necessary to remove insulation and casing on

the outside of the furnace.

 

(7)

When a

furnace

tube

has

been

plugged,

a

new

tube should be

mounted

as

soon

as possible.

As

operation

for

a longer period

involves the risk

 

that

the

casing plate is

damaged by

the increased

heat affection.

 

7.2

Replacing with new tube

 

(1)

The boiler is emptied receiver is dismantled.

of water,

and

the

manhole cover in the bottom

 

(2)

After taken off, the damaged

tube

is

replaced with new tube.

 

KANGRIM INDUSTRIES CO., LTD.

8.
8.
8.
8.

INSTRUCTION

OPERATION AND MAINTENANCE

FOR

unless special conditions are to

boiler type MA

for KANGRIM

kept

are,

be

SHEET DATA NO. :
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For feed and boiler water

The below values Consideration, to

Hardness It
Hardness
Hardness
Hardness It
Hardness It
Hardness It
Hardness It
Hardness It
Hardness It
Hardness It
It
It
   

Feed water

 

Boiler water

 

Appearance

 

Clear and free of mud

 

-

 
   

< 0, 2 ° dH

 

-

 
 

Chloride content C1 ÷

Max. 100 PPM

 

Max. 300 PPM

 

Alkalinity P

 

-

 

100 – 150

 

pH-valve at 25

 

7 - 9

 

10.5 - 11.0

 

Hydrazine excess

 

-

 

0.2 - 0.5 PPM

 
 

Phosphate excess (P 2 O 5 )

-

 

20 - 40 PPM

 
 

Specific gravity at 20

-

 

Max. 0.5 °

 

Oil content

 

0

 

0

 
Feed water Boiler water Appearance Clear and free of mud - < 0, 2 ° dH

The tabulation indicates in general terms the desired water conditions. is suggested that in any particular case the recommendations of a

Recognized boiler water chemist should be sought, and there are a number of reputable firms offering this service. Some of these will offer refinements additional to the requirements of the Above table, and may recommend slightly different methods of achieving the desired water conditions. The important point is that these conditions should be obtained and Maintained by regular testing applying corrective measures where Indicated.

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SOOT CLEANING PROCEDURE

PAGE :

1

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4

 

SOOT CLEANING PROCEDURE

  • 1. Cleaning of Oil firing setion

  • 2. Cleaning of Exh. Gas section

  • 3. Procedure for Soot cleaning

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SOOT CLEANING PROCEDURE

PAGE :

 

2

OF

4

1. Cleaning of Oil firing section

 

If the feed water is properly treated, the possibility of impurities

 

at

the water

and

steam side of the boiler should be minimal.

Deposits in the tubes are notoriously extremely small owing to the heavy water circulation. If impurities which can’t be boiled out should come inside the tubes,

 

the tubes

can be cleaned by scraper and brush.

 

Once a

day

mud

is

blown from the

boiler through the bottom blow–off valve

 

until clear water is coming.

 

If the oil burner is functioning correctly and the combustion is complete

 

the

soot

deposit

on

be minimal, but in

practice it can hardly

be

avoided that soot

the tubes will will deposit

in

the course of time,

 

i. e.

due

to the starting periods

of

the

oil

burner.

Attached soot deposits can be removed by water washing

with

a

10

percent soda solution through the inlet door in

the uptake,

 

drain

pipe

at

the bottom of

the

fire

box

is

available.

2. Cleaning of Exh. gas section

 

The main engine exhaust gas contains a certain amount of carbon particles and unburnt residues (soot etc.). The amount is strongly dependent on the condition of the engine. These soot/unburnt residues will accumulate on the boiler heating surface if not removed by cleaning.

 

It is important that the general maintenance standard of the combustion equipment, i.e. fuel injectors, injection pumps, turbo charges, air coolers, cleanliness of scavenge parts, etc., is satisfactory so that the soot/residue production is reduced to a minimum.

A regular exhaust gas testing procedure should be applied in order to reveal an abnormal increase of the soot content.

 

Every endeavor must be made to eliminate accumulation of soot deposits

 

in

so efficiency is achieved.

the boiler

that the

risk

of

soot

fire is diminished, and a high thermal

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SOOT CLEANING PROCEDURE

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4

2-1. Soot blowing

 

The boiler is equipped with inspection doors in both ends. This enables access to clean the boiler manually by means of a suitable hand-carried cleaning tool.

 

The cleaning medium might be fresh water or alternatively compressed air.

If the

boiler is

water washed,

the

drain

on the

exhaust gas inlet side

 

should be closely monitored to avoid overflow conditions in case the drain

 

should block, and it is important that

the washing is continued, until the

boiler is completely clean. Large soot accumulations which might be present after unfinished cleaning will not only result in reduced boiler efficiency, but

 

also

increase the risk of

a

soot fire.

 

KANGRIM INDUSTRIES CO., LTD.

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3. Procedure for Soot cleaning
Removal of
Soot
by
Use of Hand Lance
Water
is
used
for
soot removal with a hand lance. This soot removing method is
very simple and quite effective. When the
main engine is stopped, check the soot
accumulation condition and remove soot in accordance with the below instructions :
(1) Make sure that the main engine has been completely stopped.
(2) Open the inspection doors of the exhaust gas boiler body and the inlet/outlet
ducts and check the condition of soot accumulation.
(3)
Take care never to make cleaning water flow
into the main engine
through the gas inlet duct.
(4) Open the change-over flange or valve at the cleaning water outlet.
(5) Adjust washing water pressure to 4 – 7 ㎏/㎠G
(6)
Note that 5 – 10liter
water will be needed for cleaning
per 1㎡
heating surface.
(7) Direct washing nozzle as perpendicularly with the element surface as
possible so that cleaning will be most effective.
(8)
When soot is clogged
between studs, prick
soot
with
a
flat
bar
or
the
like.
(9) Check the
drain
tube
to
see
whether exhaust water is being discharged .
(10)
When one cycle of cleaning has been done, check
each
part for
any
soot and,
if necessary, repeat cleaning.
(11) Close tightly the inspection doors.
(12) Close the change-over flange or valve at the cleaning water outlet.

KANGRIM INDUSTRIES CO., LTD.

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