Shellmax SMDL Manual PDF

SHELLMAX – PACKAGED BOILERS
Capacities -1 TPH to 10TPH

Models – SM – 10DL, 15DL, 20DL, 30DL, 40DL, 50DL, 60DL, 80DL &
100DL
Fuel – LDO , HSD & Gas Fuels
Installation, Operation
And Maintenance Manual
Publication No: PSMDCM0003 Rev 0
Improving your
business is our
business
THERMAX LIMITED
Thermax Group
Thermax Ltd has a vision of becoming a globally respected high performance company offering
sustainable solutions in energy and environment.
The Thermax Group provides business to business solutions in the areas of heating, cooling,
captive power, water treatment, air pollution control, waste management & resource recovery
and chemicals to a wide range of industry in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power
and waste heat recovery. It also offers a range of heating equipment, energy efficient chillers
and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated
expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined
Heating Power and Cooling (CHPC) projects…
Thermax provides energy solutions to utilize waste heat to burn waste gases and biomass. These
include a variety of customized turnkey solutions to generate heat, steam and power. It
undertakes the entire range of activities from concept of commissioning.
Clientele includes Refineries, Petrochemicals, Fertilizers, Paper & Pulp, Distilleries, Independent
Power Plants, Chemicals and a wide range of other industries.
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of
solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has
emerged as a leading and reliable project management company with installations the world
over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries.
Leveraging its leadership position in electricity saving vapor absorption technology, it offers
process industries and commercial establishments like hotels, shopping malls and offices vapor
absorption chillers a boon in power-starved areas. These Eco-friendly, energy efficient
equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch,
Panasonic, Henry Ford Museum.
In the environment area Thermax offers waste management expertise for solid, liquid and air
pollution. Thermax provides solutions from pre-treatment to waste water treatment and
chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust
area for Thermax. Hi-grade resins from Thermax have found niche customers in US and Japanese
markets.
Thermax is a key player in the field of gaseous and particulate emission control, with special
focus on the emerging gaseous scrubbing business in India. Our state-of-the-art technology
enables us to offer turnkey projects well as air pollution control products.
And, the greatest utility of these solutions stems from the fact that they allow resource recovery
in process industries.
Thermax has an extensive international marketing network. Headquartered in Pune (Western

India), Thermax’s eleven international offices are located in South East Asia, Middle East, Africa,
Russia, UK and the US. Thermax’s 4 oversea subsidiaries play a significant role in generating
business in the International market. Thermax (Russia) Ltd., Thermax (Europe) Ltd., Thermax Inc.,
USA and ME Engineering, UK. Around 20 percent of the group’s turnover comes from exports to
the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS
countries.
The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area
of over 65,000Sq.Mts. are ISO-9000 and ISO-14001 accredited. Thermax manufactures to
international standards like ASME, BS, DIN and GOST. The facilities have been inspected by
Lloyds, Bureau Veritas, SGS and TUV.
Thermax’s business is inspired by the conviction that ‘Improving your business is our business’.
Division Profile
Cooling & Heating Division:

Heating Group
Cooling & Heating Division: Heating Group (C&H-Heating)

Heating group of C&H Division is the flagship Product Business Division of Thermax Ltd, which has
its core business in the area of providing cost effective process heating solutions for both energy
generation and energy conservation. Thermax has began its business way back in 1966 by
manufacturing baby boiler. C &H: Heating, is the seed for business growth for the company.
Today its high quality products are demand in India and in international markets. Its products
and expertise find applications in every conceivable heating application in the world.
History
C&H-Heating, earlier known as Process Heat Division, made a modest beginning to manufacture
by collaborating with Wanson of Belgium. The collaboration introduced baby boilers in India. The
baby boilers which we out side the purview of the Indian Boiler Regulation Act was the most
demanded product. The successful acceptance of the product lead to pioneering of Thermic
oil heating in India.
Thermal oil heating took the Indian industry by storm and today in India its brand Thermopac has
become to generic name. Thermal oil heating replaced several others heating methods such
Electrical, steam, steam-cum-electrical. The main reason is its highest energy saving capability
due to high system efficiency. To name a few industry which initially benefited the most are:
Textile, Footwear, Flatten Press, Rubber etc. Today every industry looks to thermal oil heating as a
most potential energy saving solution.
The division then made a modest beginning with a turnover of USD 0.05 million in 1968, and now
has grown to a USD 140 million group which offers a wide range of solutions to its customers in
the areas of energy generation & conservation and environment protection, all under one roof
with a singular mission.
To pursue this mission, C&H-Heating has been continuously designing and upgrading its products
and services that results in energy efficient heating solutions to the customer making optimum
use available energy resources - conventional, non conventional and the renewable energy
sources.
Over the last 30 years this Division has evolved into Engineering major well known for its core
competencies in the field of Process Heating and Energy conservation.
Division Profile
Products and Services
Our product portfolio encompasses providing process heating through different mediums such
as
Steam
Hot Oil
Hot Water
Hot Air
The product technology facilitates use of wide range of fuels viz.,
Light & Heavy Oil
Natural Gas
LPG
Bio-Gas
Cool Low and high Calorific values,
Lignite
Non conventional / agro based fuels
Rice Husk
Baggase
Groundnut Shell
Mustard stalk
De-oiled bran
De-oiled cake etc.

Division Profile
With the strengths C&H -Heating Division caters to the need of variety of application in
process industries like
Agro products Packaging
Bottling & beverages Drugs & pharmaceuticals
Breweries & distilleries Plywood
Chemical & petrochemicals Rubber
Engineering Edible oil / solvent extraction
Food & dairy Textile / Synthetic fibers
Hotels Hospitals
..And more
All these innovations of providing energy efficient solutions have been evolved through a close
interaction with the market to understand the changing needs of he customers across the world.
Thermax has an extensive national and international marketing network. Headquartered in Pune
(Western India), Thermax’s eleven international offices are located in South East Asia, Middle
East, Africa, Russia, UK and the US. ME Engineering (ME) a well-established UK boiler company is
a subsidiary of Thermax in UK offering quality solution to the energy markets in UK and Europe.
Thermax has also established a subsidiary in the United States that is catering to the markets in
North and South America. Around 20 percent of the group’s turnover comes from exports. We
have around 20,000 installations spanning 45 countries.
‘If you need the heat, we have the source’.

Contents
Sr. No. Chapter Page No.
Chapter 1: Introduction
1.1 Introduction : SHELLMAX BOILER – SM-DL Series
1.2 Product Features
1.3 Major components
Technical Specifications
Chapter 2: Installation
2.1 Transportation
2.2 Unloading Instructions
2.3 Unloading Guidelines
2.4 Storage
2.5 Drawings
2.6 Installation Guidelines
2.7 IBR Registration
2.8 Assembly Guidelines
Chapter 3: Instrumentation, controls & Safeties

3.1 Mobrey Water Level Controller
3.2 Fusible Plug
3.3 Boiler Safety Valve
3.4 Boiler Water Level Gauge
3.5 Digital Temperature Indicator
3.6 Pressure Controllers
3.7 Burner & Burner Management Systems
Chapter 4: Input Requirement

4.1 Fuel
4.2 Feed Water Quality
4.3 Boiler Water Quality
4.4 Electrical Input
Chapter 5: Commissioning Process

5.1 Pre-Commissioning
5.2 Commissioning
Chapter 6 : Operation
6.1 Boiler Startup Process
6.2 Boiler Stopping Procedure
6.3 Boiler Running Attention
6.4 Dos and Don’ts
Chapter 7: Maintenance
7.1 Maintenance Schedule
7.2 Log Book
7.3 SpareParts
Chapter 8: Troubleshooting
Chapter 9: Care of Idle Boilers

9.1 Wet Preservation
9.2 Dry Preservation
9.3 Chemical Boiling Out
Chapter 10: Annexure

IMPORTANT INSTRUCTIONS
Important Instructions
TO: Owners and persons responsible for installation, operation and maintenance.
This manual presents information that will help to install, operate and maintain the
equipment properly. It is expected that the contents be carefully read before handling
the unit.
A good installation is a permanent asset while a bad one can be a constant source of
trouble. It can cost much more to correct a bad installation than to put a new one.
Shellmax boilers are products of many years of design & engineering effort, to provide
long life & excellent service on the job. This unit will provide continued trouble free
service, if instructions on installation, operation and maintenance are properly followed.
It is expected that the personal involved in Installation, Operation & Maintenance

possess necessary qualification competence and license (if applicable). It is solely the
responsibility of the owner & user to ensure that all applicable statutory norms are
adhered to during Installation, Operation & Maintenance of the equipment.
The electrical and mechanical devices supplied as a part of the unit were chosen
because of their known ability to perform, with proper operating techniques and
maintenance procedures. Tempering with the safeties & controls or bypassing any of
these is not permissible at any time.
Any “Automatic” features included in the design do not relieve the attendant of any
responsibility. Such features may free him of certain repetitive chores and give him more
time to devote to the proper upkeep of equipment.
No amount of written communication can replace intelligent thinking & reasoning.
Since the product improvement is continuing process, the information given in this manual on
specific features is subject to change without notice.
Chapter 1
01 SMDL SERIES
SMDL SERIES :
Figure F-1. 1 : Shellmax Boiler
1
Chapter 1
1.0 SHELLMAX BOILER – SM-DL Series

1.1 INTRODUCTION
The SHELLMAX is a smoke tube, three flue pass, fully wet back, packaged boiler. Its unique
design makes it the most efficient & rugged smoke tube boiler in its class. The technical
expertise that goes in designing this excellent piece of equipment is backed by several years of
boiler manufacturing experience by THERMAX Ltd.
This high efficiency unit can be fired on liquid and or gaseous fuels. The configuration of this
boiler is such that it makes it suitable for burning liquid fuels & gases together, when fitted with a
special burner. However, the standard supply includes arrangement for firing one fuel at one
time. Shellmax Boilers consist of a combustion chamber where heat is generated by oxidising a
fuel and necessary heating surfaces to absorb this heat into water. The water so heated
converts into steam. The steam is separated out of the water by providing steam separation
area on the surface of the water. In order to ensure high efficiency of operation both the
combustion efficiency as well as heat absorption efficiency is to be maximised. Proper mixing of
fuel and air is engineered into a mutually supportive combination of burner and combustion
chamber to give the highest possible combustion efficiency. Sufficient heat transfer surface is
provided to obtain high absorption efficiency.
Combustion is the process of oxidation of fuel. Proper combustion of the fuel will be obtained if
all the components of the fuel get oxidised. Three basic conditions need to prevail in the
combustion chamber for proper oxidation i.e. TIME, TEMPERATURE AND TURBULENCE. In
SHELLMAX these three are achieved by a furnace of low volumetric heat release rate and highly
engineered burner design.
THREE FLUE PASS DESIGN:
The pressure part consists of a main shell. This has a combustion chamber fitted eccentrically on
the lower side of the shell. The rear end of the combustion chambers is connected to an internal
reversal chamber. The entire furnace assembly is held in position between the front and rear
tube plate. Stay bars are used to support rear end of internal reversal chamber.
The flue gases make three flue passes in the boiler for efficient transfer of heat to the water. 1st
pass is in the furnace itself where heat transfer is mainly by radiation.
INTERNAL REVERSAL CHAMBER
The last part of furnace is having larger diameter than the main furnace and forms the
beginning of the second pass. The flue gases reverse direction of travel to enter the tubes. The
chamber is surrounded by water to keep it cool.
The second flue pass is in the tubes between the reversal chamber and the front end plate. The
3rd flue pass is in the tubes between the front and the rear tube plate. In the second and third
pass the heat transfer is mainly by convective heat transfer
Water level is maintained sufficiently above the reversal chamber top and third pass tubes to
ensure safe operation. Adequate disengaging surface, free board height and a moisture
separator is provided to ensure very good quality of steam.
2
Chapter 1
WET BACK:
Cooling of rear side of the furnace (reversal chamber) takes place by the water itself. No
refractory is installed, hence maintenance and heat loss associated with the refractory are
eliminated.
SINGLE OR DOUBLE FLUE
Single or double flue means single or double furnace. Two furnaces are used for large boilers.
INDIAN BOILER ACT (IBR)
All boilers have to be designed, manufactured and inspected during manufacturing as well as
prior to installation. This is a government’s compulsory (mandatory) requirement. The steam
boilers have to be operated by qualified and certified boiler operators and offered for annual
inspection to the IBR authorities.
Figure F-1. 2 : Sectional View of Shellmax Boiler
3
Chapter 1
1.2 PRODUCT FEATURES

Some of the unique features of Shellmax boilers are:
• Higher water holding capacity leading • Large furnace leads to low volumetric
to high thermal energy hold up. This heat release rate which gives low
helps the boiler meet fluctuating steam thermal stress, complete combustion
demand and multi fuel ability, for oil and
gaseous fuel.
• Large disengaging surface area and
large free board reduces water • Optimum tube sizing maintains high
carryover. velocity of flue gases. This ensures
higher heat transfer coefficient and
• Direction changing steam separator higher efficiency.
ensures dry steam.
• Leak proof air damper gives higher
• Corrugated furnace (above 4TPH efficiency on part load.
Boilers)
• Hinged Oil /gas fired burner provides
easy and quick nozzle cleaning
Figure F-1. 3 : Corrugated Furnace
1.3 Major Components of the Boiler:
1.3.1 Feed Water Pump:
The feed pumps take the water from the feed water tank & supply the
water to the boiler. Two feed water pumps are provided, one working
and one standby. The pump is operated on off, by the water level
controller (Mobrey).
Each pump is of adequate capacity and head to meet the boiler

requirement. The feed pumps are selected considering reduction in pump
capacity and head due to normal wear & tear over a period of time.
The pumps are vertical, multistage, centrifugal types. Electric motor is

directly mounted on top of the pump. The pump is provided with single
mechanical seal.
Figure F-1. 4 : Boiler Feed Pump
4
Chapter 1
1.3.2 ELECTRICAL CONTROL PANEL:
The electrical control panel supplied along with

the boiler is designed to suit the boiler operating
logic and provides the electrical supply to the
boiler & its other electrical equipment like motors
of feed pumps, fans, controls etc. It also interlocks
fans, low water safety to ensure safe operation of
the boiler. The control panel consists of the main
on–off switch, switch gear for the operation of the
motors of feed pumps, Burner, and mounts
hooter, indicating lamps, power & control circuit
wiring.
The control panel is Mounted installed on Boiler.

The control panel is to be connected to the
various motors, safeties &controls of the boiler by
proper cables & wires.
Figure F-1. 5 : Electrical Control Panel SM
1.3.3 BURNER:
Burner is the heart of the boiler, which provides the fuel or heat input to the boiler. The high
thermal efficiency & the trouble free operation of the boiler will mainly depend on its design, its
compatibility with boiler, ability to burn the desired fuels with high efficiency & reliability of the
components.
All these desired features are incorporated in the design of the burners supplied by Thermax.
The burner which supplied with Shellmax boilers are:
Figure F-1. 6 : Monobloc Oilon Burner
5
Chapter 1
1.3.4 OPTIONAL ACCESSORIES
A. Economiser
In Shellmax boilers, Economizer (Optional), which is provided between boiler & chimney, to
recover heat taken away by flue gases.
This is a gas-to-liquid heat exchanger and uses heat from the outgoing flue gases to heat boiler
feed water. This heated water is fed into boiler. As hated water is given to boiler heat addition
required for converting water into steam reduces. Incorporation of Economiser increases the
boiler efficiency by @ 4-6 %. Feed water inlet temperature to economizer must be in the range of
80 -900 C.
Economiser is supplied for SM50DL onwards.
Figure F-1. 7 : General Arrangement for Economiser
6
Chapter 1
Economiser Construction
Economiser is a simple gas-to-liquid heat exchanger, where the flue gases heat the Feed water.
It contains horizontal rows of tubes connected to Inlet & Outlet header. Tubes are housed in a
Mild steel casing. Feed water from feed pump is passed through tubes. Hot flue gases coming
Figure F-1. 8 : Sectional View of Economiser
from boiler are made to flow over the tubes. Tubes are provided with MS fins. These fins increase
the heat transfer area, thus reducing size of economizer. Drain valves are provided on each Inlet
& Outlet header. Outlet header is provided with a vent valve & safety valve. A pressure gauge
with isolation valve is mounted on outlet header of economizer. Temperature gauges are
provided on inlet & outlet header to measure feed water temperature at both locations.
7
Chapter 1
B. SUPER HEATER:
1) INTERNAL SUPERHEATER
Figure F-1. 9 : Internal Super Heater Arrangement
Some of the chemical process equipments require dry steam at the inlet for efficient heating.
Normally, steam boiler is located away from the consuming point. Because of the heat loss from
the conveying pipeline the steam becomes wet by the time it reaches the utilities. In order to
overcome this problem, steam from the boiler is superheated to about 20 deg C maximum,
above its saturation point depending on the line length to take care of the radiation/convection
losses.
A convective bank in the form of a multi pass coil is incorporated between second and third
pass of the boiler. The coil assembly is housed in a casing and welded to the front plate of the
boiler. Super heater is constructed as per the Indian Boiler regulations (IBR) and has to be
installed as per the IBR regulations at the user’s end.
Super Heater Construction
In SHELLMAX the superheating is achieved by incorporating a convective bank between

second and third flue passes of the boiler. A multi-pass coil assembly is housed in a casing
welded to the boiler front end. The doors are fitted on the casing for maintenance. The steam
from the boiler drum is passed through this coil. Inlet and outlet headers are provided which are
outside the casing. Each header is provided with a drain and vent valve. A safety valve is
provided on the outlet header.
Since the construction of this super heater is such that it cannot be bypassed, adequate care to
be taken during starting. When the boiler is started from cold conditions there will not be any
steam passing through the super heater coils i.e. the super heater run dry. Because of this, boiler
should be operated in low flame (25% firing rate) conditions until adequate steam starts flowing
through the super heater coils.
8
Chapter 1
Error!
Figure F-1.10 : Internal Super Heater Construction
CAUTION
IN ORDER TO KEEP THE SUPERHEATER METAL TEMPERATURE WITHIN LIMITS BOILER SHOULD BE
OPERATED IN LOW FLAME TILL ADEQUATE PRESSURE (50% OF THE DESIGN PRESSURE) IS DEVELOPED
AND ADEQUATE QUANTITY OF STEAM FLOWING THROUGH THE SUPERHEATER.
External Super heater
It is provided to superheat steam up to 750C. This is an external heat exchanger and uses heat
from flue gases to super heat steam. This is an additional independent equipment with steam in
/ out and flue gas ducting in / out connections.
Figure F-1.11 : External Super Heater
9
Chapter 1
Table T-1.1 : Technical specifications: SHELLMAX Boilers SM series for Light Oil (with Oilon Burner)
TECH. SPECIFICATIONS SHELLMAX 10.54 kg/cm2(g)
DESCRIPTION UNITS SM-10DL SM-15DL SM-20DL SM-30DL SM-40DL SM-50DL SM-60DL SM-80DL SM-100DL
GENERAL
BoilerType Three pass wet back smoke tube boiler
Design Code IBR 1950 (With latest amendment)

0
Steam Output F & A 100 C kg / hr 1000 1500 2000 3000 4000 5000 6000 8000 10000
2
Design Pressure kg / cm (g) 10.54
2
Safety Valve Set Pressure * kg / cm (g) 10.54
Thermal Efficiency on NCV % 89 +/-2% (as per BS 845 Part -1 )
Dryness Fraction % 98
6
Heat Output 10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.39
6 3
Volumetric Heat Release Rate 10 kcal/hr.m 0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91
2
Heating Surface m 25 37 45 69 90 107 131 165 193
3
Water Holding Capacity Upto NWL m 3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type LDO / HSD
NCV of Light oil kcal/kg 10200(Min)
BURNER Oilon burner
Burner model KP-80 H KP - 90 H KP-140 H KP-150 M KP-280 M KP-300 MII KP-400 MI KP-500M KP-700 M
Type Mono - bloc
Light Up By High Voltage Spark

2
Fuel Supply Pressure( Oil ) kg/cm g 20-25
10
Chapter 1
TECH. SPECIFICATIONS
SHELLMAX 10.54 kg/cm2(g)
Turn Down ( Oil ) 1: 2 1:3 1 : 2.5 1 : 3.2 1 : 3.2 1:3.7 1:3.2 1:4 1:3.5
Modulation type Step(Two stage) Stepless

Cumbustion Blower motor KW 1.5 2.2 4.0 5.5 7.5 7.5 11 11 18.5
Fuel pump motor KW Coupled on blower shaft 1.5 1.5 2.2 4.0
Motor connection DOL

Fuel pump AJ 6 CC AJ 6 CC J 7 CC TA 2C TA 3 C TA 4 C TA 4 C TA 5C T3 C
ROTATING EQUIPMENTS
FEED WATER PUMP

Type Centrifugal Multistage - Vertical
3
Flow m /hr 2.7 5.2 6.75 11
Head MLC 120
NPSH Required MLC 3
Material Of Construction
Impellar Stainless Steel
Outer sleeve Stainless Steel
Shaft Stainless Steel
Type Of Seal Mechanical Seal
Speed RPM 2900

Motor KW KW 2.2 2.2 2.2 3.0 3.0 4.0 4.0 5.5 5.5
Motor connection starting DOL
11
Chapter 1
POWER SUPPLY
VOLTAGE/FREQUENCY
Power 415 Volts + 6% ; 50 Hz + 3% ; 3 Ph,3 / 4 Wire
Control 240 Volts AC, Single Phase
Control Panel Load KW 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Connected Load (excl stand-bys) KW 4.20 4.90 6.70 9.00 11.00 13.50 17.00 19.20 28.50
UTILITIES CONSUMPTION
Fuel oil consumption kg/hr 59 89 119 178 238 297 357 476 595
Note:-
1) The Mon bloc burner selection is for 500 meter altitude. For altitude more than 500 meter please revert back to HO for burner re -selection.
2) Refer P & I drawing for scope of supply and battery limits.

3) Refer GA TP drawing for overall dimensional
details.
4) Feed water pump is suitable for Minimum boiler operating pressure of 7 kg/cm2 , for boiler operating pressure lesser than 7 Kg/cm2
please revert back to HO for Feed pump re
selection
12
Chapter 1
Table T-1.2 : Technical specifications: SHELLMAX Boilers SM series for Light Oil (with Oilon Burner)
GENERAL

0
2
2
Thermal Efficiency on NCV % 88+/-2% (as per BS 845 Part -1 )
6
6 3
2
3
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type LDO / HSD
NCV of Light oil kcal/kg 10200 (Min)
BURNER Oilon burner
Burner model KP-80 H KP - 90 H KP-140 H KP-150 M KP-280 M KP-300 MII KP-400 MI KP-500M KP-700 M
Type Mono - bloc
Light Up By High Voltage Spark

2
113
Chapter 1
Turn Down ( Oil ) 1: 2 1:3 1 : 2.5 1 : 3.2 1 : 3.2 1:3.7 1:3.2 1:4 1:3.5
Fuel pump motor KW Coupled on blower shaft 1.5 1.5 2.2 4.0

ROTATING EQUIPMENTS
FEED WATER PUMP

3
Flow m /hr 2.51 5.47 8.93 16.6
Head MLC 120
NPSH Required MLC 3
Speed RPM 2900

Motor KW KW 3.0 3.0 3.0 5.5 5.5 7.5 7.5 15.0 15.0
14
Chapter 1
POWER SUPPLY
VOLTAGE/FREQUENCY
Note:-
2) Refer P & I drawing for scope of supply and battery limits.

3) Refer GA TP drawing for overall dimensional details.
please revert back to HO for Feed pump re selection
15
Chapter 1
Table T-1.3 : Technical specifications: SHELLMAX Boilers SM series for Light Oil / N.Gas (with Oilon Burner)
GENERAL

0
2
2
Thermal Efficiency on NCV (LO) % 89 +/-2% (as per BS 845 Part -1 )
Thermal Efficiency on NCV ( NG) % 88.5 +/-2% (as per BS 845 Part -1 )
6
6 3
2
3
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type LDO / HSD / Natural Gas
NCV of Natural Gas Kcal/Nm3 8500
BURNER Oilon burner
Burner model GKP-80 H GKP - 90 H GKP-140 H GKP-250 M GKP-280 M GKP-300 MII GKP-400 M I GKP-500M GKP-700 M
Type Mono - bloc
16
Chapter 1
Light Up By High Voltage Spark / Pilot flame

2
Fuel Supply Pressure( Gas ) 360 mbar / 1-2 bar 500 mbar / 1-2 bar
Turn Down ( Oil ) 1: 2 1:3 1 : 2.5 1 : 3.3 1 : 3.2 1:3.7 1:3.2 1:4 1:3.5
Turn Down ( Gas ) 1: 2 1:3 1 : 2.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5

Fuel pump motor KW - - 1.5 1.5 1.5 1.5 1.5 2.2 4.0

ROTATING EQUIPMENTS
FEED WATER PUMP

3
Flow m /hr 2.7 5.2 6.75 11
Head MLC 120
NPSH Required MLC 3
Speed RPM 2900

Motor KW KW 2.2 2.2 2.2 3.0 3.0 4.0 4.0 5.5 5.5
17
Chapter 1
POWER SUPPLY
VOLTAGE/FREQUENCY
Fuel Natural gas consumption Nm3/hr 71.8 107.7 143.6 215.4 287.1 358.9 430.7 574.3 717.8
Note:-
2 ) Refer P & I drawing for scope of supply and battery limits.

18
Chapter 1
Table T-1.4 : Technical specifications: SHELLMAX Boilers SM series for Light Oil / N.Gas (with Oilon Burner)
GENERAL

0
2
2
Thermal Efficiency on NCV (LO) % 88 +/-2% (as per BS 845 Part -1 )
Thermal Efficiency on NCV (NG) % 87.5 +/-2% (as per BS 845 Part -1 )
6
6 3
2
3
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type LDO / HSD / Natural Gas
NCV of Natural Gas (Min) Kcal/Nm3 8500
19
Chapter 1
BURNER Oilon burner
Burner model GKP-80 H GKP - 90 H GKP-140 H GKP-250 M GKP-280 M GKP-300 MII GKP-400 M I GKP-500M GKP-700 M
Type Mono - bloc

2
Fuel Supply Pressure( Gas ) mbar 360 mbar / 1-2 bar 500 mbar / 1-2 bar
Turn Down ( Oil ) 1: 2 1:3 1 : 2.5 1 : 3.3 1 : 3.2 1:3.7 1:3.2 1:4 1:3.5
Turn Down ( Gas ) 1: 2 1:3 1 : 2.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5

Fuel pump motor KW - - 1.5 1.5 1.5 1.5 1.5 2.2 4.0

ROTATING EQUIPMENTS
FEED WATER PUMP

3
Flow m /hr 2.51 5.47 8.93 16.6
Head MLC 195
NPSH Required MLC 3
20
Chapter 1
Speed RPM 2900

Motor KW KW 3.0 3.0 3.0 5.5 5.5 7.5 7.5 15.0 15.0
POWER SUPPLY
VOLTAGE/FREQUENCY
Note:-

21
Chapter 1
Table T-1.5 : Technical specifications: SHELLMAX Boilers SM series for N.Gas (with Oilon Burner)
GENERAL

0
2
2
Thermal Efficiency on NCV % 88.5 +/-2% (as per BS 845 Part -1 )
6
6 3
2
3
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type Natural Gas
BURNER Oilon burner
Burner model GP-80 H GP - 90 H GP-140 H GP-250 M GP-280 M GP-300 MII GP-400 M I GP-500M GP-700 M
Type Mono - bloc
22
Chapter 1
Turn Down ( Gas ) 1: 2 1:3 1 : 3.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5

Cumbustion Blower motor KW 1.5 2.2 4 5.5 7.5 7.5 11 11 18.5
ROTATING EQUIPMENTS
FEED WATER PUMP

3
Flow m /hr 2.7 5.2 6.75 11
Head MLC 120
NPSH Required MLC 3
Speed RPM 2900

Motor KW KW 2.2 2.2 2.2 3.0 3.0 4.0 4.0 5.5 5.5
POWER SUPPLY
VOLTAGE/FREQUENCY
223
Chapter 1
Note:-

24
Chapter 1
Table T-1.6 : Technical specifications: SHELLMAX Boilers SM series for N.Gas (with Oilon Burner)
GENERAL

0
2
2
Thermal Efficiency on NCV % 87.5 +/-2% (as per BS 845 Part -1 )
6
6 3
2
3
3
Steam Space m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
FUEL
Type Natural Gas
BURNER Oilon burner
Burner model GP-80 H GP - 90 H GP-140 H GP-250 M GP-280 M GP-300 MII GP-400 M I GP-500M GP-700 M
Type Mono - bloc
25
Chapter 1
Turn Down ( Gas ) 1: 2 1:3 1 : 3.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5

Cumbustion Blower motor KW 1.5 2.2 4 5.5 7.5 7.5 11 11 18.5
ROTATING EQUIPMENTS
FEED WATER PUMP

3
Flow m /hr 2.51 5.47 8.93 16.6
Head MLC 195
NPSH Required MLC 3
Speed RPM 2900

Motor KW KW 3.0 3.0 3.0 5.5 5.5 7.5 7.5 15.0 15.0
POWER SUPPLY
VOLTAGE/FREQUENCY
26
Chapter 1
Note:-

27
Chapter 1
28
Chapter 2
02 TRANSPORTATION & UNLOADING

INSTRUCTIONS
2.1 Transportation
SHELLMAX is dispatched from our factory in single package boiler and accessories. The IBR
valves and mountings, panel box, feed pump, FD fan etc. are packaged separately in wooden
cases and dispatched with the Boiler.
During transportation, extreme care is taken to ensure safe and intact delivery of the Boiler. The
Boiler and other wooden cases are loaded on the trucks as per upright markings.
Dispatch particulars are sent to the customer immediately after loading the trucks.
2.2 Unloading Instructions

• The boiler should be lifted for loading, unloading or shifting from one position to another, only
by means of lifting hooks provided on top of the boiler. Refer Table T-1.2.1 indicating the Dry
weight of pressure parts.
• The packing slip supplied with the material should be referred and the number of cases
supplied should be verified with the numbers received at site.
• The wooden / packed cases should be opened only in the presence of Thermax Engineer or
Thermax authorized person / dealer, for checking the inside materials as per the packing slip.
• If the cases are opened in the absence of Thermax Engineer / authorized person / dealer,
and if the material is found missing, the responsibility of Thermax shall cease.
• For any breakage / damages, insurance claim should be made.
• For any missing items, Thermax Engineer / authorized person / dealer shall report to Thermax
Limited for replenishment, provided the cases are opened in their presence.
• For any incorrect supply of material Thermax Engineer / authorized person / dealer shall
report to Thermax Limited for replacement.
29
Chapter 2
Table T-2.1: Shipping weight & dimensions of major parts: Standard Scope of Supply
Sr.No. Description of SM 10DL SM 15DL SM 20DL SM 30DL SM 40DL

parts Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM
(LXWXH) (LXWXH) (LXWXH) (LXWXH) (LXWXH)
10.54 17.5 10.54 17.5 10.54 17.5 10.54 17.5 FINISH 10.54 17.5
GATP 3.325 3.325 3.824 3.824 3.824 3.824 4.324 4.324 4.624 4.624
Door to S.C. x x x x x x x x x x
1 1.89 1.89 2.02 2.02 2.02 2.02 2.09 2.09 2.36 2.36
10.54kg/cm2 5.275 x x 6.076 x x 6.369 x x 7.698 x x 9.736 x x
17.5 kg/cm2 5.986 2.16 2.16 7.256 2.18 2.18 7.095 2.18 2.18 9.652 2.3 2.3 11.966 2.68 2.68
Main boiler 2.5 2.5 3 3 3 3 3.5 3.5 3.75 3.75

pressure part x x x x x x x x x x
2 1.89 1.89 2.02 2.02 2.02 2.02 2 2 2.27 2.27
10.54kg/cm2 3.034 x x 3.817 x x 4.015 x x 5.312 x x 7.244 x x
17.5 kg/cm2 3.722 2.16 2.16 4.957 2.18 2.18 5.18 2.18 2.18 7.234 2.3 2.3 9.456 2.66 2.66
Feed Water 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0.22
Pump x x x x x x x x x x
3 Assembly 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25
10.54kg/cm2 0.0834 x x 0.0834 x x 0.0834 x x 119.8 x x 119.8 x x
17.5kg/cm2 0.106 0.982 1.234 0.106 0.982 1.234 0.106 0.982 1.234 165.2 1.217 1.644 165.2 1.217 1.644
Mountings & 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62
Fittings x x x x x x x x x x
4 1.01 1.01 1.01 1.01 1.01 1.01 1.01 1.01 1.01 1.01
0.2 x x 0.2 x x 0.2 x x 0.2 x x 0.25 x x
0.81 0.81 0.81 0.81 0.81 0.81 0.81 0.81 0.81 0.81
Oil Oil & Gas Oil Oil & Gas Oil Oil & Gas Oil Oil & Gas Oil Oil & Gas
Burner Burner Burner Burner Burner Burner Burner Burner Burner Burner
Burner 1.314 1.672 1.314 1.672 1.314 1.672 1.314 1.672 1.412 1.682
Assembly x x x x x x x x x x
5 0.187 0.583 0.728 0.187 0.583 0.728 0.187 0.583 0.728 0.186 0.583 0.728 0.187 0.683 0.786
x x x x x x x x x x
0.479 0.702 0.479 0.702 0.479 0.702 0.479 0.702 0.534 0.635
30
Chapter 2
Sr.No. Description of SM 10DL SM 15DL SM 20DL SM 30DL SM 40DL

parts Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM
(LXWXH) (LXWXH) (LXWXH) (LXWXH) (LXWXH)
10.54 17.5 10.54 17.5 10.54 17.5 10.54 17.5 FINISH 10.54 17.5
Electrical 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Control x x x x x x x x x x
6 Panel 0.25 0.8 0.8 0.25 0.8 0.8 0.25 0.8 0.8 0.25 0.8 0.8 0.25 0.8 0.8
x x x x x x x x x x
2 2 2 2 2 2 2 2 2 2
7 Ladder 0.2 0.2 0.2 0.2 0.2
31
Chapter 2
Sr.No. Description of SM 50DL SM 60DL SM 80DL SM 100DL Remark

parts Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Packed/
(LXWXH) (LXWXH) (LXWXH) (LXWXH) Unpacked
FINISH 10.54 17.5 FINISH 10.54 17.5 FINISH 10.54 17.5 FINISH 10.54 17.5
GATP 4.874 4.874 5.425 5.425 5.975 5.975 6.475 6.475
Door to S.C. x x x x x x x x
1 2.36 2.36 2.51 2.51 2.61 2.61 2.81 2.81 unpacked
10.54kg/cm2 10.482 x x 12.192 x x 14.363 x x 17.189 x x
17.5 kg/cm2 12.632 2.68 2.68 14.409 2.83 2.83 17.256 2.95 2.95 21.566 3.152 3.152
Main boiler 4 4 4.5 4.5 5 5 6.25 6.25

pressure part x x x x x x x x
2 2.27 2.27 2.442 2.442 2.52 2.52 2.742 2.742 unpacked
10.54kg/cm2 7.882 x x 9.435 x x 11.469 x x 14.217 x x
17.5 kg/cm2 10.062 2.68 2.68 11.671 2.83 2.83 14.306 2.95 2.93 18.559 3.152 3.152
Feed Water 0.22 0.265 0.22 0.265 0.265 0.256 0.265 0.256
Pump x x x x x x x x packed
3 Assembly 0.25 0.28 0.25 0.28 0.2 0.3 0.2 0.3
10.54kg/cm2 126.6 x x 126.6 x x 184 x x 184 x x
17.5kg/cm2 210 1.325 1.391 210 1.325 1.391 314 1.211 1.682 314 1.211 1.682
Mountings & 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62
Fittings x x x x x x x x packed
4 1.01 1.01 1.01 1.01 1.01 1.01 1.01 1.01
0.3 x x 0.3 x x 0.45 x x 0.45 x x
0.96 0.96 0.96 0.96 0.96 0.96 0.96 0.96
Oil Oil & Gas Oil Oil & Gas Oil Oil & Gas Oil Oil & Gas
Burner Burner Burner Burner Burner Burner Burner Burner
Burner 1.412 1.682 1.412 1.692 1.412 1.692 1.492 1.697
Assembly x x x x x x x x Packed
5 0.191 0.683 0.786 0.237 0.735 0.836 0.207 0.735 0.836 0.25 0.751 0.902
x x x x x x x x
0.534 0.635 0.578 0.677 0.578 0.677 0.623 0.818
32
Chapter 2
Sr.No. Description of SM 50DL SM 60DL SM 80DL SM 100DL Remark

parts Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Wt (TON) DIM Packed/
(LXWXH) (LXWXH) (LXWXH) (LXWXH) Unpacked
FINISH 10.54 17.5 FINISH 10.54 17.5 FINISH 10.54 17.5 FINISH 10.54 17.5
Electrical 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4

Control x x x x x x x x Packed
6 Panel 0.25 0.8 0.8 0.25 0.8 0.8 0.25 0.8 0.8 0.25 0.8 0.8
x x x x x x x x
2 2 2 2 2 2 2 2
7 Ladder 0.2 0.2 0.2 0.2 Unpacked
Note:
• The main boiler pressure part dimensions do not change with change in Max working pressure of the boiler
(10.54 Or 17.5 kg/cm2).
• The above parts are the major parts of the boiler. There are some more smaller and light wooden cases / loose parts supplied
with the boiler, which are lesser in weight & dimensions, hence are not mentioned here.
• The dimensions given in above table are the outermost dimensions, to facilitate the unloading & shifting.
• Weight of wooden Packing is considered in the shipping weight, if the item is supplied in packed condition.
33
Chapter 2
2.3 Unloading Guidelines

A) All the parts should be unloaded with crane, tripod, suitable capacity as per the weight
& dimensions given in Table T-2.1.
Figure F-2.1 : Unloading Boiler with Crane
B) All parts should be unloaded in marked upright position only i.e. these should not be tilted
while unloading or shifting. If lifting tackles are not available, rollers, wooden slabs or
some skid should be placed beneath the frame of the boiler and wooden case and it
should be carefully guided for unload and shifting. Under no circumstances the boiler
and accessories should be dropped or turned to any other position other then marked
on the cases.
Figure F-2. 2 : Packing Cases should not be titled while unloading or shifting
34
Chapter 2
C) It is advisable to unload the boiler as closes as possible to the Boiler House; preferably just
outside the main door of the Boiler House, on some skids or pipes, so that pushing the
Boiler into the Boiler House for positioning it on the foundation is easier. The soil at the
place of unloading should be hard enough to bear the weight of the Boiler, to prevent it
from sinking. Likewise, when the Boiler is being shifted to the Boiler House, the approach
road to the Boiler House should also be made of hard ground.
Figure F-2. 3 : The soil at the place of unloading should be hard
2.4 Storage
A) All the material should be stored under roof and should be protected from rain, water or
direct sunlight.
Figure F-2. 4 : Boiler should be stored under roof
35
Chapter 2
B) Boiler & parts should not be stored under corrosive atmosphere.
Figure F-2. 5 : Boiler should not be stored under corrosive atmosphere
C) Do not pile up cases.
Figure F-2. 6 : Do not pile up cases
36
Chapter 2
D) Do not store heavy material on soft soil.
Figure F-2. 7 : Material should not be stored on soft soil
37
Chapter 2
2.5 Drawings
A set of the following drawings is given by Thermax Ltd to guide the site persons. These drawings
should be carefully preserved for the reference.
The drawing numbers with Alteration numbers to be recorded in the box below for future records
by the customer before installation:
• P& I Diagram Drawing No. ALT NO.
• GA TP & foundation details Drawing No. ALT NO.
• Electrical Diagram Drawing No. ALT NO.

(Supplied with Elect control Panel)
38
Chapter 2
2.6 Installation Guidelines

Thermax provides the post sales services to the customers through to guide from the services of
the qualified & trained Engineers Of Thermax or Authorized Representatives are made available
to the customers /users of the Boiler from the very next day of the receipt of the order.
Customer is provided with all the information & guidance on the complete Installation and
commissioning of the boiler through our qualified & trained Engineers /authorized dealers or
associates.
2.6.1 Boiler House Location:
The first step of the installation is the deciding the location & size of the boiler house.
Guidelines:
The following major factors decide the location of the boiler house is:
• Location of the steam utilities-the boiler house should be located nearest to the utilities to
reduce the losses in transportation i.e. steam pressure drop and condensation loses.
• Wind direction: To avoid smoke nuisance from the chimney.
• Safety of the plant & machinery.
• To avoid corrosive atmosphere or gases affecting boiler and to its accessories.
• Adequate area near boiler and other components for ease of operation & maintenance.
• Water softening & dosing plant and space required to house them near Boiler house.
• Coal storage and handling system should be planned closer to Boiler house for ease of
handling.
• Fuel storage should be enough to store min 15 days of the consumption.
WARNING: Consider the mandatory Rules and regulations for machinery i.e. Factory Act,
Fire Insurance Association, etc. for deciding the location of the boiler house.
39
Chapter 2
2.6.2 Boiler House layout:
A good Boiler house layout will provide adequate space for operation and maintenance. The
Boiler house layout should be finalized only in consultation with Thermax engineers or Thermax
authorized persons /dealers, well in advance before the delivery of the boiler.
Guidelines:
1. Typical “Boiler House Layout” is given in the layout drawing shall provide for the
reference in deciding the boiler house plan.
2. Refer to General Arrangement & Terminal Point) GATP and foundation drawings of boiler
and its accessories.
3. Locations of control panel, water treatment plant, Fuel pre heating station, Fuel day tank
(inside or outside of the boiler house), Chimney & other drain & exhaust pipe lines can be
decided referring the boiler house layout, GATP & P&I diagram.
4. Air Pre-heater (optional), soft water storage tank, chimney etc. is to be decided after
studying the system requirements, factory layout and space availability.
5. The boiler house floor loading for all models is approximately 25 MT/M². The floor in front
of the door of the boiler house is also to be prepared to withstand this load, since the
boiler would be unloaded on this floor and would, thereafter, be pushed inside the boiler
house.
6. Provide adequate ventilation and lighting.
CAUTION:
• Dimensions of openings of doors of your boiler house should be adequate enough to

push the boiler and accessories inside the boiler house.
• Provide free space equal to length of boiler in front, for opening of front doors,
cleaning of fire tubes and space for coal storage and for firing it.
• Do not provide Blow down Pit of Brickwork, but should be of M.S plates and Concrete
Slabs on Firm & hard Soil.
• Provide a blow down pit/tank with cover for safe discharge of blow down water near
boiler house.
• Locate the control panel at a location from where water level gauge glass, pressure
gauge, flame, and water level in water service tank are visible.
• Soft water Day tanks should be inside or very close to the boiler house.
WARNING:
• Do not finalize the boiler house layout without consulting the Thermax Engineers or
authorized dealers/representatives.
• Don't reduce the size of the boiler house unless confirmed by Thermax.
40
Chapter 2
2.6.3 Foundation Preparation and Details
2.6.3.1 General Arrangement & Terminal point (GATP) Drawing
A rigid, flat, leveled foundation is vitally essential for smooth, quiet operation, and lower
maintenance cost of the boiler and other equipment. An improperly constructed or inadequate
foundation may cause vibration and possible misalignment of the equipment, which may lead
to component & metal failure, breakage and Cracks.
Guidelines:
• All foundations must be flat, leveled and rigid.

• The floor loadings, for designing foundations of the boiler and accessories, are given in
‘General Arrangement and foundation detail’ drawing of the boiler and individual loads on
foundation is given below in Table no 2.2-.
• The height of any foundation should be minimum 100 mm above the finish floor level unless
otherwise specified. This is to prevent the structure of equipment from water etc. that may
corrode and reduce the life of equipment and foundation bolts.
• Cast the foundation as per the dimensions given in the drawing.
• Consider the soil conditions while designing the foundations.
• An allowance must be made for a minimum of 25 mm of shimming and grouting when
determining the top surface of the foundation.
Table T-2.2 : Weight (Tons) on Foundation: SM Boiler Components
Part Description Details SM10DL SM15DL SM20DL SM30DL SM40DL SM50DL SM60DL SM80DL SM100DL
Pressure
Pressure
Working
10.54kg/cm2 8670 10770 10865 13840 18400 19440 24415 28230 35625
Max.
Part -
Flooded
Weight 17.5kg/cm2 9080 11405 11560 15150 19980 21310 26340 30700 38860
Pressure
Working
10.54kg/cm2 130 130 130 180 180 190 190 290 290
Max.
Feed
Pump
17.5kg/cm2 160 160 160 250 250 310 310 475 475
41
Chapter 2
CAUTION:
• The rear end of boiler foundation block

should be provided with 10 mm thick M.S.
plate grouted in foundation as shown in
General Arrangement drawing. This is for
free thermal expansion movement of boiler
during operation.
• Proper and Sufficient Curing is to be done for

all civil foundations.
Figure F-2.8 : Foundation block.
WARNING:
Consult Civil engineering structural expert for designing the foundations based on soil
condition of your plant and live weight on the foundation.
The qualified & experienced civil engineer should supervise the foundations work.
42
Chapter 2
Figure F-2.9: GATP Drawing of Shellmax Boiler without Economiser.

43
Chapter 2
Figure F-2.10 : GATP Drawing of Shellmax Boiler with Economiser.

44
Chapter 2
2.6.4 Shifting On Foundation
In India Permission from the Indian Boiler Regulation (IBR) inspecting authority is to be taken
before erecting or placing the boiler on the foundation. Boiler erection on foundation is to be
done by the IBR authorized and licensed agency as per the IBR.
(REF the next chapter registration under Indian Boiler Regulations)
Note: Indian Boiler Regulation (IBR) is applicable for boilers installed in India. For boilers installed
in other countries, the local rules and regulations should be followed.
Guidelines
• It is advisable to use a spreader type sling when handling/shifting the boiler & other
equipment.
• Boiler should be moved to its foundation as a unit, with care being taken to prevent
distortion or damage.
• After the foundation holes in the unit are lined up with anchor bolts in the foundation, the
equipment should be lowered over the anchor bolts.
2.6.5 Grouting and Leveling
Guidelines
• All the accessories of the boiler i.e. F.D. Fan, Air Pre-heater (if applicable), Electrical
Control panel etc. can be placed on respective foundations and can be grouted &
leveled.
• Prior to placing the boiler and fan on the foundations, the location of anchor bolts should
be checked against the drawing to ensure that these bolts are placed correctly.
• Since the boiler and fan is mounted on separate foundations much care and attention to
alignment is required to match their inlets and outlets.
CAUTION:
• Anchor bolts in concrete should approximately 50

mm larger in diameter then the anchor
bolts to allow for be L or inverted T-
shaped, and should be placed in pipe or
sheet metal sleeves adjusting the bolts in
case they move slightly when concrete is
poured.
Figure F-2.11: Types of Anchor Bolts

45
Chapter 2
• Where some adjustment is required to

level the unit, leveling should be done
taking /smoke tube of the boiler shell as
reference. If the leveling is not done
correctly the water level gauges would
show different levels, also the minimum
water level above the top row of smoke
tubes would not be maintained properly,
which can be dangerous and fatal.
Figure F-2.12: Level Bottle
• Before final grouting of boiler, level the

boiler properly.
For leveling large area shims should be
placed under the pedestal before
tightening the anchor bolts. Distortion of
the equipment may occur when the bolts
are not tightened equally or if short thick
shims providing only limited surface
contact are used.
Figure F-2.13: Level Tubes
WARNING:
The boiler can be placed on foundation only when permitted by the Boiler Inspecting
Authority.
46
Chapter 2
2.7 Registration of Boiler under “Indian Boiler Regulations (IBR)”

(Applicable for boilers installed in India only)
2.7.1 Necessity of Registration
All steam boilers in India are required to be registered under section 7 of the Indian Boiler Act and
in accordance with Chapter 9 of the Indian Boiler Regulations. Section 6 of the Indian Boiler Act,
prohibits the use or permit to use any boiler which is unregistered or uncertified. This registration is
generally valid for 1 year from the date on which it is granted.
The installed boilers are also subjected to these tests to determine the fitness of boiler for the
purpose of renewal of Registration certificate.
In India, State of Jammu & Kashmir is exempted from this activity of IBR registration. Boilers installed
on Railway Engines are also exempted form this activity.
The following details and Instructions will guide the owners & users in getting their new boiler
registered as per the Indian Boiler Regulations.
2.7.2 Boiler IBR Certificates: IBR Folder
This folder is supplied to the user from our factory and contains all the original certificates of the
boiler manufacturing and the mountings /fittings. This needs to be submitted to Boiler
Inspectorate, while making the application for registration along with inspection fees.
This folder contains important and original documents like:
1. Manufacturing certificates in forms II, III and IV,

2. Approved boiler pressure part drawings,
3. Boiler mountings certificates in form III C.
Preserve the IBR folder and take one photocopy copy of the complete folder, for the records
& site reference. Ensure that all the certificates are intact & serially numbered in the folder.
47
Chapter 2
2.7.3 Application for Registration
The owner shall make application for the registration of a new boiler/renewal of Registration
certificate, to their Regional Boiler Inspectorate. Boiler Folder and receipt of Treasury Challan for
prescribed registration fees with the application be submitted to the Boiler Inspectorate. The Boiler
Registration Fees depends upon the heating surface area of the boiler, and details could be
obtained from the Boiler Inspectorate office. The Boiler Inspectorate office shall then
communicate the details of Inspector's visit for various Inspections.
2.7.4 IBR Boiler Inspection
The inspection as per IBR involves 3 Stages as under,
1. Open Inspection or ground Inspection

2. Hydraulic Test
3. Steam Test
2.7.4.1 Open Inspection
For new boilers, which are to be registered, this inspection is carried out with the purpose of
verifying the details recorded in the folder to the actual details of the boiler construction.
This inspection is carried out on the ground under the open condition and clean of the boiler and
the IBR mountings & fittings.
The boiler inspecting authority generally verifies/checks followings during this inspection:
1. Approval stamping made on the boiler as per the certificates.
2. For any damages or any alterations if made, other than details mentioned in
approved drawings.
3. Verification of Serial numbers and the inspecting authority's seal on various valves and
mountings with respect to their Certificates.
4. Measurements of the spring, body, valve and valve seats of the steam safety valves.
5. Verify the Certificate of the Boiler operator, if appointed by the Owner/user.
48
Chapter 2
Preparing the boiler for Open Inspection:
The following preparatory action is taken prior to the Inspector's visit.
a) All the water/smoke tubes and internal surfaces of boiler should be kept clean by using
suitable wire brush.
b) Any Insulation, Lagging, brick work, which is hiding the pressure part surface should be
removed for the inspection.
c) Safety valves should be opened out completely and cleaned so that the spring, body and
valve seats are available for inspection and measurements of various dimensions.
d) The side and manhole/hand holes covers are removed to facilitate the best possible view of
the tubes and internal surface for inspection.
e) All the IBR valves and mountings should be kept arranged for verification. It should be ensured
that the serial numbers/registration number and the inspecting authority's seal on the boiler
and on the IBR valves are clearly visible so that the Inspector can immediately relate them to
the corresponding certificate.
f) Necessary platforms are provided for ease of boiler inspection.
g) Measuring instruments like measuring tape, venire, measuring feet scale etc. should be kept
handy for checking the measurements.
h) Temporary provision of 24 volts Hand Lamp with lamp guard / powerful Torch must be made
for ease of inspection of each part.
NOTE: It is advisable to verify the Identification number and Inspecting authorities Seal on Boiler,
valves and mountings and fittings with relevant Certificates and Forms of boiler folder before the
visit of the inspecting authority (use the photocopy of the boiler folder).
Only after the inspecting authority clears the IBR inspection, the boiler can be prepared for next
IBR inspection i.e. Hydraulic Test… (Applicable for boilers installed in India. For boilers installed in
other countries, follow the local rules and regulations)
2.7.4.2 Hydraulic Test
Under regulation 377 of the IBR, important provisions of which, as applicable to the boilers are:
Every boiler shall be hydraulically tested in the presence of the IBR Inspecting authority, to not less
than one and half times the designed pressure, for registration/for renewal of registration
certificate.
49
Chapter 2
The boiler shall satisfactorily withstand such pressure without appreciable leakage or undue
deflection or distortion of its parts for at least ten consecutive minutes.
Preparing the boiler for Hydraulic test:
Note: Under above regulation, when a boiler is hydraulically tested for the first time, it should be
entirely cleared of lagging or brickwork; at subsequent tests the lagging or brickwork, or portion
thereof, should be removed if required by the Inspector.
a. Safety valves should be removed and the opening should be closed by blank flange.
Pressure switch connection should be removed and the opening plugged.
b. All side and manhole covers are placed properly with correct gaskets and checked for
tightness.
c. Following valves be kept closed in position during the test-
i. Main Steam Stop Valve
ii. Vent Valve
iii. Gauge Glass Cocks
1. Steam Cocks
2. Water Cocks
3. Drain Cocks
iv. Boiler blow down valve
d. Feed inlet, blow down lines are to be connected to the boiler. Feed pump can be
connected for filling water in the boiler.
e. A convenient inlet for the pressure test should be taken and suitable hydraulic test pump
connections be made.
f. The Boiler shall be completely filled with clean water and the pressure being applied
gradually, with a test hydraulic pump having a pumping capacity higher than that of
hydraulic pressure. Care is to be taken to avoid air pockets in the boiler pressure parts.
g. As a preliminary test, before Inspector's visit, raise the hydraulic pressure to working
pressure limit and ensure that no leakage is observed from the pressure part's joints and
then raise slowly to the required Hydraulic test pressure, to keep it for ten minutes. Check
for the leakages and sustenance of the pressure.
On satisfactory completion of Hydraulic Test in presence of boiler inspecting authority, the

Provisional Order for use of boiler is issued, valid for 6 months and the Registration Number for the
boiler is allotted.
IT IS NECESSARY TO COMPLETE THE IBR FORMALITIES OF IBR STEAM LINES & PIPES, SIMULTANEOUSLY
WITH THE HELP OF THE IBR APPROVED CONTRACTOR.
50
Chapter 2
Engraving Of Registration Number
The registration number allotted by Chief Inspector should be engraved in front plate in such
position as pointed out by the Inspector. This should be completed and reported to Chief
Inspector for verification within one month from the date of its receipt.
The Chief inspecting authority normally supplies the registration number engraving slip. This slip
should be pasted on the part of the boiler pointed out by the Inspector for engraving. The
engraving should not be less than 0.4 mm (1/64") in depth.
2.7.4.3 Steam Test
Every newly installed boiler, before the issue of a Registration Certificate, should be tested under
steam to the satisfaction of the Inspector. This should be done in accordance with the Provisional
Order issued by the Boiler Inspectorate after completion of hydraulic test and as per regulation
No. 380 of IBR.
A steam test is primarily intended for the purpose of ascertaining by actual test whether the safety
valves are sufficient to relieve boilers effectively of excess steam and whether they operate at the
time when the maximum working pressure is reached.
Preparing the boiler for Steam test:
a. Get the Boiler Registration number (allotted for the boiler after hydraulic test)
engraved on boiler pressure parts at any convenient location suggested by Boiler
Inspector.
b. Verify the safety valve settings done during commissioning of boiler.
c. Boiler attendant must be present during the test.
Steam Test in presence of Inspector:
At the time of test, the safety valve should be left free and capable of being adjusted to the
working pressure.
After adjustment of the safety valves to the correct blowing pressure, the boiler shall be tried
under full steam and firing with the stop valve closed. During this test the Boiler inspecting
authority shall note the accumulation of the pressure and other details of the test as well as verify
the performance of the safety valve.
On satisfactory completion of Steam Test, the Boiler Inspectorate issues Registration Certificate.
This needs to be protected and displayed in the boiler house as per the advice of Boiler
Inspecting authority.
51
Chapter 2
2.7.4.4 Safety Valve over Pressure
REGULATION NO. 294
The safety valve shall be so designed that they attain rated discharge capacity with the over
pressure not greater than that given in regulation 292; provided that the safety valve which have
a discharge area less than 80% of the flow area, the over pressure at which the design lift is
attained shall not exceed 10% of the set pressure. For safety valve having discharge area 80% or
more of the flow area, the over pressure at which the design lift is attained shall not exceed 5% of
the set pressure.
2.7.4.5 Safety Valve Pressure Drop
REGULATION NO. 295
The safety valve shall be reset at a pressure at least 2 % below, but not more then 5% below the
safety valve set pressure. The 5% limit is increased to 10% for valve having a body seat bore less
than 32 mm and/or having a set pressure of 2 bar gauge or less.
2.7.5 Prohibition of Use of Boiler
Prohibition of use of unregistered or uncertified boiler -

Important provision under Section: 6 of Indian Boiler Act.
Save as otherwise expressly provided in this Act, no owner of a boiler shall use the boiler or permit
it to be used -
(a) Unless it has been registered in accordance with the provisions of this Act.
(b) In the case of any boiler which has been transferred from one State to another, until the
transfer has been reported in the prescribed manner.
(c) Unless a certificate or provisional order authorizing the use of the boiler is for the time being
in force under this Act.
(d) At a pressure higher than the maximum pressure recorded in such certificate or provisional
order.
(e) Where the State Government has made rules requiring that boilers shall be in charge of
person holding [certificates of proficiency or competence], unless the boiler is in charge of
a person holding the certificate required by such rules:
Provided that any boiler registered, or any boiler certified or licensed, under any Act hereby
repealed shall be deemed to have been registered or certified, as the case may be, under this
Act.
52
Chapter 2
2.7.6 Renewal of Certificate
Important provision under Section: 8 of Indian Boiler Act.
(1) A certificate authorizing the use of a boiler shall cease to be in force -
(a) On the expiry of the period for which it was granted; or
(b) When any accident occurs to the boiler; or
(c) When the boiler is moved, the boiler not being a vertical boiler the heating surface
of which is less than [18.58 square meters], or a portable or vehicular boiler; or
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) If the Chief Inspector in any particular case so directs, when any structural
alteration, addition or renewal is made in or to any steam-pipe attached to the
boiler; or
(f) On the communication to the owner of the boiler or an order of the Chief
Inspector or Inspector prohibiting its use on the ground that it or any steam-pipe
attached thereto is in a dangerous condition.
(2) Where an order is made under clause (f) of sub section (1), the grounds on which the
order is made shall be communicated to the owner with the order.
(3) When a certificate ceases to be in force, the owner of the boiler may be apply to the
Inspector for a renewal thereof for such period not exceeding twelve months as he may
specify in the application:
(4) An application under sub-section (3) shall be accompanied by the prescribed fee and, or
receipt thereof, the Inspector shall fix a date, within thirty days or such shorter period as
may be prescribed from the date of the receipt, for the examination of the boiler and shall
give the owner thereof not less than ten day's notice of the date so fixed:
Provided that, where the certificate has ceased to be in force owing to the making of any
structural alteration, addition or renewal, the Chief Inspector may dispense with the
payment of any fee:
(5) On the said date, the Inspector shall examine the boiler in the prescribed manner, and if
he is satisfied that the boiler and the steam-pipe or steam-pipes attached thereto are in
good condition shall issue a renewed certificate authorizing the use of the boiler for such
period not exceeding twelve months and at a pressure not exceeding such maximum
pressure as he thinks fit and as is in accordance with the regulations made under this Act:
53
Chapter 2
The Inspector shall, within forty-eight hours of making the examination, inform the owner of
the boiler in writing of this opinion and the reasons therefore, and shall forthwith report the
case for orders to the Chief Inspector.
(6) The Chief Inspector, on receipt of the report under sub-section (5), may, subject to
provisions of this Act and of the regulations made hereunder, order the renewal of the
certificate in such terms and on such conditions, if any, as he thinks fit, or may refuse to
renew it:
Provided that where the Chief Inspector refuses to renew a certificate, he shall forthwith
communicate his refusal to the owner of the boiler, together with the reasons therefore.
(7) Nothing in this section shall be deemed to prevent an owner of a boiler from applying for
a renewed certificate therefore at any time during the currency of a certificate.
54
Chapter 2
2.8 Assembly Guidelines: Accessories And Other Assemblies

The Boiler installation consists of the following basic circuits:
• FEED WATER SYSTEM

• FLUE GAS DUCTING LAYOUT
• DRAIN, BLOW DOWN CIRCUIT AND STEAM PIPELINES
• ELECTRICAL SYSTEM
• FUEL SYSTEM
To complete the installation work of the boiler, these systems/circuits should be completed as per
the following guidelines & instructions:
GUIDELINES
General:
• Place other accessories i.e. F.D. fan, Air Pre-heater (if applicable), Feed water pump,
electrical control panel etc. on their respective foundations. These accessories should be
carefully leveled and physically aligned in their final position before grouting them.
• Complete the flue gas ducting work, connection of boiler to APH (if supplied) to Chimney.
Ensure that all the joints in flue gas path are airtight and the size of ducting and
connecting angle to chimney is correct.
2.8.1 Boiler Feed Water Circuit
• Ensure that water treatment plant should provide the water as per the specifications
mentioned in Chapter: Utility Requirement for feeding in the boiler.
• Refer the piping & instrumentation Diagram (P&I Diagram) for the boiler model for the layout
and sizing of the pipe lines, valves and other connection details.
A. Soft Water Tank Capacity
• Soft water storage tank of minimum 3 to 4 hrs. Capacity of boiler evaporation is

recommended for this purpose to have the time for the regeneration of the water treatment
plant.
• The minimum soft water tank capacities for various models of the boilers are as follows:
Table T-2.3: Soft Water Tank Capacities
MODEL SM 10DL 15DL 20DL 30DL 40DL 50DL 60DL 80DL 100DL
Minimum tank capacity 3000 4500 6000 9000 12000 15000 18000 24000 30000
55
Chapter 2
B. Feed Water Tank construction:
• The raw water storage and soft water tanks should have a hinged or bolted cover, an air
vent, a float valve, a water level gauge glass, preferably with calibration, a drain at the
bottom with a gate valve and an overflow connection.
• The outflow from the tank should be taken from a point of distance of minimum 100 mm
(4") from the bottom level of the tank, to avoid any sediments and foreign matter going
into the water pump and damaging it.
Feed Water Tank Elevation:
• Following table gives the elevation of water storage tank (NPSH) required for
corresponding feed water temperature for most of the pumps considering maximum
suction pipe length of 10 meters.
TEMP. OF WATER ( °C ) ELEVATION REQUIRED (M)
90 3
93 3.5
99 5
100 5.7
C. Feed Pump Suction Circuit:
The feed water pumps will perform better if NPSH available is very much higher than NPSH
required by the pump. In the NPSHav formula, only suction head (Tank Elevation) and
friction pressure drop in suction piping are in our hands. Suction piping pressure drop is
directly proportional to product of square of velocity and length. Hence, we want to
reduce velocity and reduce length to reduce friction pressure drop. Also sharp bands or
any fittings causing a sudden change in direction of flow will increase pressure drop in the
suction piping.
Therefore, in order to reduce suction piping pressure drop we should
- Use large suction piping size. At least one size higher than feed water pumps suction
size.
- Use only Gate / Ball valves. Avoid valves like Globe or needle.
- Use long radius bends.
- Use as short suction piping as possible.
56
Chapter 2
The logic of selecting suction piping size is explained above. The following may be ensured –
Suction piping is provided with a sample point for taking sample of water for analysis.
A Y type strainer is provided to prevent entry of any foreign particles in the pump.
Since suction piping recommended is one size larger than the pump suction size a pipe reducer is
required to connect suction piping to pump.
It is suggested to use GI pipes in the feed pump suction to avoid corrosion.
Boiler feed pipe-Feed Water Pump Discharge Piping
This conforms to ASTM A106 Gr. B and is an IBR approval piping. This pipe connects Feed Water
Pump to boiler. Non Return Valves and Globe Valves are provided on pump discharge for
isolation and throttling purpose.
NRV and a Globe Valve are provided at boiler inlet. All valves, flanges and fittings in the pipeline
are IBR approved.
CAUTION:
• Feed water service tank should never be constructed out of cement concrete, as soft water
will absorb Calcium and Magnesium salts from cement and the hardness will increase.
• The water level in the boiler feed water day tanks should be easily & clearly visible from the
ground level to the operators.
• Use G.I. Pipes and fewer fittings in the feed water pump suction lines.
• Use minimum bends & shortest possible route to connect the suction lines to the pumps
• Use only gate valves in the water pipe lines and avoid using globe valves.
• Provide proper support to the pipelines to avoid unwanted stress on valves and pumps.
• Pump suction pipe size should be one size higher then the pump suction size.
• Long radius bends may be used if necessary.
• The feed Pump suction pipe should be as short and direct as possible.
• The suction head pipelines should be laid with a downward slope towards the pump.
• The suction and delivery pipelines should be anchored in close proximity.
• All the pipe joints should be absolutely airtight.
• Don’t reduce the diameter of the pipes then what is given in P and I diagram of your boiler.
• Avoid use of Elbows and short bends.
• Never use the pump itself as an anchorage point for the piping.
• The gasket between pump and the pipe should not protrude inside the pipeline flange.
• The pipelines should be not transmitting any stress/ strain and pipeline weight, to the pump
body.
57
Chapter 2
2.8.2 Drain, Blow down And Steam Piping
Blow Down Pipe Line
• Blow down valve located at the bottom of the boiler shell should be connected to a pipe
of one size bigger and should be led to a blow down pit/tank located outside the boiler
house.
• The blow down pipe should be firmly clamped on the ground at every 3meters of running
length and at both sides of the bends.
• Use IBR pipes/seamless high pressure quality pipes for the blow down lines
• The lines should be properly insulated for safety purposes.
Blow down Pit
The blow down pit has to be constructed as per the sketch given. Brick wall structure should
not be used for building the blow down pit. Instead, use M S plates & concrete slab as
indicated to withstand excessive pressure & temperature to ensure safety.
The size of the pit should also to be maintained as per the sketch below
Figure F-2.14: Boiler Blow down Pit
58
Chapter 2
Safety Valve Exhaust Pipe
Safety Valve exhaust pipe connection is to be given as per the sketch given below:
Figure F-2.15: Safety Valve Exhaust Pipe Connection
• The discharge from the safety Valve/s should be piped as direct as possible to the
atmosphere with a pipe diameter of not less than the Safety Valve outlet.
• A drip pan elbow or a flexible connection between the valve and the escape pipe is
recommended to prevent build up of backpressure and accumulation of foreign
material around the valve seat.
• The discharge piping must be properly arranged, clamped and supported so that
their weight doses not bear upon the valve.
Drain Pipes
• Drainpipes from water level gauges, level controllers should be of the same size as
the outlet size of the valves to be to a common drain header.
59
Chapter 2
Steam Pipeline
The main steam line which carries the steam to the user equipment /to the plant has to be
of the same or higher size (if recommended) & never be of lower size than indicated in the
P& I diagram.
The boiler steam out let pipeline is to be designed, constructed, inspected and hydraulic
tested as per IBR (for the installations in India) as per the maximum working pressure of the
connected boiler.
The steam lines must have the drains with equal ‘T’ & the drain lines with adequate sizes of
steam traps assemblies.
The steam lines are to be insulated with the adequate thickness of the insulating material,
refer Table T-2.6 & T-2.7 for thickness & specifications of mineral & glass wool.
Expansion bends in steam pipeline within every 30 meters of straight run to be used to take
care of the line expansion.
Sliding / Roller support should be provided for all steam pipes, which will not restrict the
expansion.
Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
CAUTION:
• All drain; blow down & steam line must be properly insulated to avoid heat losses and
condensation.
• The steam piping from the main steam stop valve should be sized to match the steam valve
diameter. Never reduce the steam pipe diameter to lower size than recommended, as they
would restrict flow of steam & result in to high pressure drop in the pipe lines
• Sliding / Roller support should be provided for all steam pipes which will not restrict the
expansion.
• Expansion joint supports and roller type supports suitably anchored.
• Provide expansion bends in steam pipeline within every 30 meters of straight run.
• Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
• The steam piping should be sized to suit the evaporation capacity of the boiler to avoid
siphoning effects and steam/water hammering.
• Proper qualities of steam pipeline gaskets are to be used as per the pressure of the steam.
• The Steam jointing or the gaskets used should be checked for the proper placement during
construction of the lines. These should not be protruding inside the pipe line which will obstruct
the steam flow & also result in to high pressure drop.
60
Chapter 2
• The Steam jointing or the gaskets used should be checked for the proper placement during
construction of the lines. These should not be obstructing the steam flow.
• All steam line must be properly insulated to avoid heat losses and condensation.
• Provide thermodynamic steam trap before every expansion bend for condensate water
removal.
• Provide adequate steam traps in the steam pipeline.
• Never end the drain or blow down pipe in open, but provide pits.
• Brick wall structure should not be used for building the blow down pit. Instead use M S plates &
concrete slab as indicated to withstand excessive pressure & temperature
2.8.3 Flue Gas Ducting Layout:
The flue gas circuit means the path of the flue gases leaving the boiler, Heat recovery &
finally exit through chimney.
2.8.3.1 Chimney
Chimney can be either of the following designs:

a) Self supported
b) Guy rope Supported
c) Structural supported
d) Wall Mounted
However, Chimney for the boiler should be of the adequate top diameter as per the
recommendations given in the table T-2.4 below.
Guidelines:
• Chimney design Reference can be taken from the IS 6533 specifications and considering
the Local geological conditions
• Provide all the Accessories of the chimney i.e. Aviation Lamp, Lightening Arrestor etc as
per the recommendations of the local statutory norms.
61
Chapter 2
Figure F-2.16 : Chimney Structure
Table T-2.4 Chimney TOP Diameter
Chimney TOP Diameter( ID) : In millimeter

10DL 15DL 20DL 30DL 40DL 50DL 60DL 80DL 100DL
Boiler Model SM
350 400 400 450 550 600 650 750 800
With OR Without Economiser
WARNING:
• Follow rules and regulations of Smoke Nuisance Act and consult their local Pollution
Control Board’s office for further information & guidance on chimney design & height.
• Never reduce the Top Diameter of chimney than the recommended size.
• For boilers installed in countries other than India, follow the local regulations for stack
installation
62
Chapter 2
2.8.3.2 Flue Gas Ducts:
• The area or the size of the flue gas ducts needs to the same as recommended in the table
T-1.6.3 below to ensure that the flues gas leave the boiler & system easily without any
excessive pressure drop.
• The ducts can be of circular rectangular or square cross section.
• The pressure drop developed by the flues gas system should less than the suction capacity
of the Induced draught (ID) Fan.
Table T-2.5: FLUE GAS DUCT DIMENSIONS

Shellmax Models: SM
Flue Gas Duct Diameter(ID)
in MM : 10DL 15DL 20DL 30DL 40DL 50DL 60DL 80DL 100DL
Boiler to Chimney (with OR 300 350 350 400 450 500 550 650 700
Without Economiser )
CAUTION:
• Keep the cross sectional areas of the flue gas and same as recommended. Do not reduce
the cross sectional areas.
• All The Ducts should be of fully welded construction.
• Any leakage in duct means reduction in the capacity of the Fan and reduction in the
output of the boiler.
• Economiser duct connections should be fully welded to ensure leak proof.
• External columns, from ground, should support long ducts.
• Provide sockets with plugs at the inlet & outlet ducts of Air Pre-Heater, for checking the
pressure drops and temperature measurement, across these equipment.
• The dampers should be checked for correct opening & close indications and for the
smooth operation.
• Provide long radius bends & avoid sharp bends in the ducts.
• Insulation of the ducts should be done after through check for the leakages, after the
commissioning of the flue gas system.
• Provide Insulation of proper density & the thickness as indicated in the table T-1.6.4 below.
63
Chapter 2
2.8.3.3: Insulating material Pipe lines, Ducts & flue gas ducts
The table below gives recommended insulation thickness in mm required for different pipe sizes
and different operating / fluid temperatures.
a) Mineral Wool –
Table T-2.6:
Pipe Operating / fluid temperature oC
diameter
90 150 200 260 315 375
(NB) mm
25 25 40 65 65 75 90
40 25 40 65 65 75 90
50 25 40 65 65 75 90
80 25 40 65 65 75 90
100 25 50 75 75 100 100
150 40 50 75 75 100 115
200 40 50 75 75 100 115
250 40 65 90 90 100 125
300 40 65 90 90 100 125
Flat 40 65 90 90 100 125
Note: Insulation material assumed is Mineral wool having thermal conductivity 0.036 kcal/m hr o C,
average density about 100-200 kg/m3.
CAUTION:
1) The surface temperature after insulation is 55 – 60oC.

2) Insulation up to 65mm should be in single layer and above 65 mm, multiplayer, e.g.
80mm two layers of 40mm each for 90mm inner layer of 40 mm and outer of 50mm.
b) Glass Wool -
Table T-2.7:
Pipe Operating / Fluid temperature
diameter
90 150 200 260 315 3756
(NB) mm
25 25 25 25 25 40 40
40 25 25 25 25 50 50
50 25 25 25 25 50 50
80 25 25 40 40 50 65
100 25 25 40 40 50 65
150 25 25 40 40 65 75
200 25 40 40 40 65 75
250 40 40 40 40 65 75
300 40 40 40 40 65 75
Flat 40 40 50 50 65 75
Note: Insulation material assumed is Glass wool having thermal conductivity 0.045 kcal/m hr oC @
100oC and average density about 80 – 100 kg/m3.
64
Chapter 2
2.8.4: ELECTRICAL SYSTEM:
Figure F-2.17 : Internal View of Control Panel Figure F-2.18 : Control Panel
2.8.4.1: Guidelines:
Electrical Control Panel Box & External Electrical Switch
The Electrical Control Panel Box is supplied by Thermax, with the Boiler, separately packed and is
pre-wired with switches for all motors for boiler system.
• The control Panel to be erected as close to the boiler as possible. The foundation details of
the panel box are given in the "General Assembly" drawing.
• Three phases, 415 V, 50 cycles A.C. electric supply with neutral and earth is required for
operating the boiler.
• The supply to the boiler should be given through a main switch fuse having adequate
capacity as mentioned in the following table. The back-up fuse capacity to suit the total
electric loading should also be maintained.
• Switches for other pumps such as water pump for pumping water from raw water storage
tank to the water softener, etc. should be separately installed by the customer at points
convenient for operation.
65
Chapter 2
2.8.4.2: CABLE SCHEDULE: Following table should be referred for the details of the cable size, core, and type. These tables are segregated,
for the units with or without Economiseror oil fired and gas fired units.
Table T-2.8 :
CABLE SCHEDULE-SHELLMAX - LIGHT & HEAVY OIL FIRED
SM10DL SM15DL SM20DL SM30DL SM40DL

Equipment Cable Size in No. of Size in No. of Size in No. of Size in No. of Size in No. of
KW KW KW KW KW
mm2 core mm2 core mm2 core mm2 core mm2 core
POWER CABLES
FD Fan Motor Cu 1.5 2.5 4 2.2 2.5 4 4 2.5 4 5.5 2.5 4 7.5 4 4
FW Pump (Each
Motor) W Pr. Cu 2.2 2.5 4 2.2 2.5 4 2.2 2.5 4 3 2.5 4 3 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 3 2.5 4 3 2.5 4 3 2.5 4 5.5 2.5 4 5.5 2.5 4
17.5kg/cm2
Fuel Pump (Each

NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Motor)
CONTROL CABLES
Mobrey Cu NA 1.5 10 NA 1.5 10 NA 1.5 10 NA 1.5 10 NA 1.5 10

Burner Control Cu NA 1.5 10 NA 1.5 10 NA 1.5 10 NA 1.5 10 NA 1.5 10
Flame Sensor NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
RTD Cu NA 1 3# NA 1 3 # NA 1 3# NA 1 3# NA 1 3#
Gas Control NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Notes : a) Separate earthing to be given for all motors
b) Length of the cable to be decided as per the location.
c) Power supply 415V +/- 6%,50 Hz +/- 3%,3 Phase,4 Wire.
d) # Indicates shielded cable.
e) * indicates two runs of each core.
66
Chapter 2
Table T-2.9 :
CABLE SCHEDULE-SHELLMAX - LIGHT & HEAVY OIL FIRED
SM50DL SM60DL SM80DL SM100DL

Equipment Cable Size in No. of Size in No. of Size in No. of Size in No. of
KW mm2 core KW mm2 core KW mm2 core KW mm2 core
POWER CABLES
FD Fan Motor Cu 7.5 4 4 11.0 5 4 11.0 6 4 18.5 10 4

FW Pump (Each
Motor) W Pr. Cu 4.0 2.5 4 4 2.5 4 5.5 2.5 4 5.5 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 7.5 4 4 7.5 4 4 15.0 6 4 15.0 6 4
17.5kg/cm2
Fuel Pump (Each
Cu 1.5 2.5 4 1.5 2.5 4 2.2 2.5 4 4 2.5 4
Motor)
CONTROL CABLES
Mobrey Cu NA 1.5 10 NA 1.5 10 NA 1.5 10 NA 1.5 10

Burner Control Cu NA 1.5 16 * NA 1.5 16 * NA 1.5 16 * NA 1.5 16 *
Flame Sensor Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3#
RTD Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3#
Gas Control NA NA NA NA NA NA NA NA NA NA NA NA NA

e) * Indicates two runs of each core.
67
Chapter 2
Table T-2.10 :
CABLE SCHEDULE-SHELLMAX - LIGHT OIL CUM N.GAS FIRED

KW mm2 core KW mm2 core KW mm2 core KW mm2 core KW mm2 core
POWER CABLES
FD Fan Motor Cu 1.5 2.5 4 2.2 2.5 4 4 2.5 4 5.5 2.5 4 7.5 4 4
FW Pump (Each
Motor) W Pr. Cu 2.2 2.5 4 2.2 2.5 4 2.2 2.5 4 3.2 2.5 4 3 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 3 2.5 4 3 2.5 4 3 2.5 4 5.5 2.5 4 5.5 2.5 4
17.5kg/cm2
Fuel Pump (Each

Cu NA NA NA NA NA NA 1.5 2.5 4 1.5 2.5 4 1.5 2.5 4
Motor)
CONTROL CABLES
RTD Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3# NA 1 3#
68
Chapter 2
Table T-2.11 :
CABLE SCHEDULE-SHELLMAX - LIGHT OIL CUM N.GAS FIRED

POWER CABLES
FD Fan Motor Cu 7.5 4 4 11 6 4 11 6 4 18.5 10 4

FW Pump (Each
Motor) W Pr. Cu 4 2.5 4 4 2.5 4 5.5 2.5 4 5.5 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 7.5 4 4 7.5 4 4 15 6 4 15 6 4
17.5kg/cm2
Fuel Pump
Cu 1.5 2.5 4 1.5 2.5 4 2.2 2.5 4 4 2.5 4
(Each Motor)
CONTROL CABLES

RTD Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3#
Gas Control Cu NA 1.5 16 NA 1.5 16 NA 1.5 16 NA 1.5 16

69
Chapter 2
Table T-2.12 :
CABLE SCHEDULE-SHELLMAX - NATURAL GAS FIRED

KW mm2 core
POWER CABLES
FD Fan Motor Cu 1.5 2.5 4 2.2 2.5 4 4 2.5 4 5.5 2.5 4 7.5 4 4
FW Pump (Each
Motor) W Pr. Cu 2.2 2.5 4 2.2 2.5 4 2.2 2.5 4 3 2.5 4 3 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 3 2.5 4 3 2.5 4 3 2.5 4 5.5 2.5 4 5.5 2.5 4
17.5kg/cm2
Fuel Pump (Each
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Motor)
CONTROL CABLES

RTD Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3# NA 1 3#

70
Chapter 2
Table T-2.13 :
CABLE SCHEDULE-SHELLMAX - NATURAL GAS FIRED

POWER CABLES
FD Fan Motor Cu 7.5 4 4 11 6 4 11 6 4 18.5 10 4

FW Pump (Each
Motor) W Pr. Cu 4 2.5 4 4 2.5 4 5.5 2.5 4 5.5 2.5 4
10.54kg/cm2
FW Pump (Each
Motor) W Pr. Cu 7.5 4 4 7.5 4 4 15 6 4 15 6 4
17.5kg/cm2
Fuel Pump (Each
NA NA NA NA NA NA NA NA NA NA NA NA NA
Motor)
CONTROL CABLES

RTD Cu NA 1 3# NA 1 3# NA 1 3# NA 1 3#
Gas Control Cu NA 1.5 16 NA 1.5 16 NA 1.5 16 NA 1.5 16

71
Chapter 2
2.8.4.3: Earthing Of the Equipment
• Earthing wires of adequate cross-sections should be provided to link the boiler, the
electrical control panel box, various motors, etc. to a suitable earth plate, as per Indian
Electricity Act.
Following size of earth conductors can be used:
Up to 3.75 kW 8 SWG GI wire

5.5 kW to 30 kW 3/8" GI fine wire rope
37 kW to 55 kW 5/8" GI fine wire rope
CAUTION:
• Provide proper lugs to terminate the cables. Also provide ferrule numbers on cable for
identification.
• Provide adequate size switch fuse unit and cables.
• Provide cable glands at the panels
• If the voltage fluctuation is going to be more than ± 6% of the specified voltage, it is strongly
recommend installing a voltage stabilizer of 1 KVA for the control circuit.
• Provide proper sized glands for the cable at the entry to control panel and at motor terminal
box.
• Earthing pit should be as per the norms.
• Use cable trays or trenches for laying the cables.
• Never increase or decrease the back up fuse MCCB capacity.
• Never combine neutral & Earth connection.
• Laminate the electrical diagram, with plastic sheet and paste inside the control panel or near
to it.
• Take enough photocopies of the electrical diagram for records.
WARNING:
WHILE INSTALLING THE ELECTRICAL CABLES KEEP IN MIND THE RULES AND REGULATIONS
INVOLVED.
72
Chapter 2
2.8.5 Fuel Supply (Liquid Fuels)
A typical arrangement for fuel oil storage and flow to the unit is shown in P&I Drawing.
The fuel firing system is designed to operate on Light oil viz. LDO (Light Diesel Oil) / HSD (High
Speed Diesel).
In order to have flooded suction, these tanks are to be installed at a height not less then 3
meters from fuel pump. (For HSD tank, this height is not required). The P&I Diagram shows the
piping connections and their sizes, which needs to be followed strictly for trouble free, efficient
and comfortable operation.
2.8.5.1 STORAGE, HANDLING AND PREPARATION OF OIL
In many industries, little attention is often paid to oil storage, handling and preparation facilities.
The result ? Puddles of oil near the pump house and storage tanks - an indication of leaky joints,
flanges and pipelines. Clogged filters, which impose an additional duty on the pumps. And
poor combustion, manifested by smoky or spluttering flames leading to high fuel consumption.
Spilt oil is an easily avoidable waste, and renders the ground slippery and dangerous. For
efficient burning, foreign matter such as dust, water, coke and sludge particles in fuel oil should -
be removed by adequate filtration. It is also necessary to examine several aspects, such as
pumping ability of oil during winter months, type and capacity of the pump, the length of the -
pipelines, and the sizing of pipes. Correct pre-heating of fuel oil prior to combustion is very
important for fuel efficiency. We have covered some of these aspects, which have a significant -
effect on the fuel consumption in your boiler plant.
Spilt oil is irretrievable. A little care when oil is decanted from the tanker to the storage tanks
could lead to less spillage. All leaks from joints, flanges and pipelines must be attended to at the
earliest.
Loss of even one drop every second can cost you over 4,000 liters a year.
2.8.5.2 HOW TO STORE FUEL OIL
Large quantities of fuel oil are best stored in cylindrical tanks either above or below the ground.
Generally, the main storage tank is erected above ground when the capacity exceeds 70,000 -
liters. For lower capacities, underground storage may be more economical. When erecting a
storage tank above ground, remember to maintain safe distances from the surrounding
structures, as prescribed by the Explosive Department.
Storage tanks are generally made from welded mild steel plates. The overhead tank should be
mounted on concrete blocks, which provide a slight gradient of 1:50 towards the drain valve.
Each of the following fittings on storage tank has a definite role to play.
The outlet or draw-off pipe should be located at the raised tank end, no less than 15 Cms from
the bottom. It should be at least 15 Cms in diameter with outflow heater and provided with an -
outlet pipe line of 6 Cms with a strainer at the outlet.
The vent pipe, of goose-necked type, should be located at the highest point of the tank to
facilitate filling by venting air and oil vapor during the filling operation.
73
Chapter 2
The fill-pipe could be located either at the top or at the bottom of the tank. If located at the
top, it must be ensured that the pipe descends almost to the bottom of the tank. When located
near the bottom, it is important to position a non-return valve on the line to avoid fuel oil re-entry
into the oil tanker on account of back pressure. To avoid leakage of oil during decanting, it is
advisable to have a cam lock coupling at the filling end so that it fits easily on the delivery hose.
The drain pipe, which is fitted at the lower tank end bottom, is used to periodically remove the
accumulated water. It is a difficult task to drain the water and sludge from underground storage
tanks. The water and sludge which settle down at the bottom should, however, be removed by
a hand pump. It would be advantageous to have two suction pipes - one at a lower level and
the other at a higher level - so that in case the sludge accumulation is up to the lower point and
the suction line chokes up, the alternative line could be put into operation and adequate time
would be available to decide upon a time schedule for cleaning the tank.
Fuel oil as delivered may contain dust, dirt, gummy matter and water. During storage for
prolonged periods, these tend to form sludge, which accumulates in the various `dead spaces'
of the tank, where the oil is not agitated during normal operation of the tank. This results in
unsteady flames and clogging of filters. To avoid this, some means of agitation of oil in the tank
may be necessary.
Cleaning of storage tanks, about once a year, will remove the accumulated sludge. Besides
cleaning, periodic inspection and maintenance of the storage tank, out flow heater and
auxiliaries is important.
Capacity of storage tank depends on daily hours of operation & Frequency of Fuel oil tanker
receipt. Based on this storage tank capacity needs to be decided.
NOTE: PLEASE FOLLOW THE RULES AND REGULATIONS INVOLVED IN YOUR STATE FOR STORAGE OF
HEAVY OIL.
2.8.5.3 CHECKS BEFORE UNLOADING OF FUEL OIL
It would be worth while to check the quantity of oil into the storage tank. Road tankers are
provided with dip-sticks. Readings of oil level in the various compartments should be taken -
before decantation. The following procedure may be adopted before assessing the quantity of
oil in the road tankers:
a) Ensure that the tank lorry is parked on firm level ground.
b) The dip-stick should be checked to ensure that it is the one calibrated by the Weights and
Measures Department for the compartment concerned.
c) The dip readings of all the compartments should be checked, and shortfall, if any, can be
determined by topping up of the compartments with measured quantities of fuel oil from the
main storage tank.
d) Your storage tanks should also be calibrated. Though dip readings in storage tanks are more
or less reliable, a major deviation should be investigated. They may provide a clue to
malpractice.
74
Chapter 2
2.8.5.4 REMOVAL OF CONTAMINANTS
Fuel oil should be freed from possible contaminants such as dirt, sludge and water before it is
finally fed to the boiler.
Fuel oil arrives at the factory site either in tank Lorries by road or by rail. Oil is then decanted into
the main storage tank. To prevent the possibility of contaminants such as rags, cotton waste,
loose nuts or bolts or screws from entering the system and damaging the pump, position a
coarse strainer of 40 mesh size (not more than 6 holes per linear inch) on the entry pipe to the
storage tanks. Progressively finer strainers should be provided at various points in the oil supply
system to filter away finer contaminants such as external dust and dirt, sludge or free carbon.
It is advisable to provide these filters in duplicate to enable one filter to be cleaned while oil
supply is maintained through the other.
Table T-2.13: SIZING OF STRAINERS

________________________________________________________________________________________
Location Strainer sizes Mesh Holes/Linear inch
Between rail/tank lorry decanting

Point and main storage tank 40 6
Between storage tank and service tank 80 9
Between service tank and Burner 80 11
2.8.5.5: FUEL OIL SERVICE / DAY TANK
The service tank should be located in proximity to the boiler.
The service tank may be sized for a shift's consumption or daily consumption - the choice
depends on capacity required, ease of location of tank near the boiler house, pumping
capacity, horse power, etc. Certain additional precautions may, however, be taken with
respect to service tanks.
a) Service tanks should not be located above furnaces, hot air or flue gas ducts, etc.
b) They should be provided with overflow pipes which lead directly below to a sump. As a
further refinement, limit switches could be provided to avoid the possibility of oil overflow.
c) In gravity feed systems, the difference in height between the service tank and the fuel pump
should be at least 3 meters.
d) The tank should have hinged manhole, level indicator, drain, overflow, out flow heater, air
vent etc.
e) The level indicator should be positioned such that it can be seen from boiler control panel for
ease of operation.
f) In case of LDO as fuel & if ambient temperature falls below 150 C Out flow heater is required
on fuel oil service tank. This will maintain viscosity of LDO required for proper combustion.
75
Chapter 2
Figure F-2.19: Outflow heater arrangement & service tank
2.8.6: Fuel Supply (Gas Fuels)
The boiler user should ensure that the gas supply is pressure is in the range of 1-2 kg/cm2 at the
isolating valve of the boiler gas train. The boiler gas train components are selected & sized for
this pressure range only.
If the gas supply pressure is higher than above, the user should reduce it to 1-2 kg /cm2 before
connecting it to the boiler gas train.
Installation of the Gas Pipe line & burner Gas train
• Note that gas train components are designed for low pressure and hence testing with
compressed air/nitrogen can damage the gas train.
• The gas train should be installed at about 500 mm above the floor level to ensure easy
maintenance of its components, particularly the regulator, strainer and solenoid valves.
• The part of the Gas-train comprising main gas solenoid valves should be as near as
possible to the burner, so that gas flame is established quickly and residual gas burning is
lowest after burner shut down.
• The gas supply pressure at the inlet of the gas train should be checked to be in
conformity with specified pressure range. (Refer P&I Drg. for gas fired units )
• The manual quick shut-off valve should be opened very slowly so that the diaphragm of
the regulator is not subjected to sudden pressure surge.
• The pressure setting of the pilot and main gas regulator should be kept at near minimum
during initial start up of the burner, and the final setting should be done during burner
firing to achieve the required firing rate.
76
Chapter 2
• The supply gas pipe is to be connected to gas train inlet ball valve with the help of a
union or a flanged joint. The supply gas pipe should be thoroughly cleaned and flushed
out with air, to ensure that all dirt particles are removed before connection to gas train.
• Gas filter, pressure regulator and gas solenoid valves should be accessible for routine
maintenance and adjustments and suitable platform may be provided.
• Unauthorized tampering of gas pressure adjustment and other settings should be

prevented. Adjustments, if at all required, should be done by trained and authorized
personnel only.
• Brackets and supports for gas piping should not be welded to the gas pipe. Suitable
screwed clamps only should be used.
• After installing gas line with fittings, it is necessary to carry out leakage test using
compressed air/ nitrogen gas at a pressure of 7 kg/cm2 by isolating the gas train
components. All the lines with flanges should be tested for leakage with the help of soap
solution.
• Note that gas train components are designed for low pressure and hence testing with
compressed air/nitrogen can damage the gas train.
• Gas train and its components should be tested for leakage using air at pressure not more
than 2000 mm WC.
• If the gas is saturated with water vapor, drain point should be provided at lowest point in/
near the gas train for drawing the condensed water vapor.
• Vent Piping:
i. Vent shall terminate in a safe place, preferably in the open air above roof level.
ii. If it is not feasible or practical to terminate above roof level vent, line exit must be
at least 5 meters from potential ignition source.
iii. Vent line should not pass through electrical intake chambers, transformer rooms
and lift shafts.
iv. Care should be taken such that there will not be any ingress of foreign material
and water into vent line.
• It is advisable to install the gars train closer to the heater in heater house. Adequate
space shall be provided for gas train installation, maintenance and operation/access.
• The heater house should be properly ventilated, preferably by large windows on all sides.
• Please make sure that while installing the gas train, regulations of Fire Insurance
Association, Explosives Act, factory inspectorate etc. are strictly adhered to.
77
Chapter 2
78
Chapter 3
03 BOILER INSTRUMENTATION,
CONTROLS & SAFETIES
3.1 Mobrey water level controller:

One number top mounted mobrey level controller (KDG, U.K.) is supplied along with the boiler.
The magnetic level controller or

Mobrey keeps the water level under
control by running the feed water
pump in on off cycles. There are three
switches in the Mobrey. First top
switch is used to put off the feed
water pump. The second middle
switch is used to put on the feed
water pump. The third switch, at the
Figure F-3.1: Mobrey Level Controller
bottom, is used for providing extra
low-level alarm and burner trip. All the
switches are set at the time of Pre-
commissioning. Third Level switch is
adjusted so that it corresponds to water
level below the pump on switch. If the level
falls corresponding to the third switch, the
burner is tripped. This switch is water level
extra low. This third switch is connected in
the safety circuit of the burner
programmer. A photograph of the Mobrey
is enclosed in Figure F-3.1 and cross section
is enclosed in Figure F-3.2
Figure F-3.2: Cross Section of Mobrey
79
Chapter 3
3.2: Fusible Plug:
This has been provided as an ultimate safety, when all the water
level controls & safeties fail, this safety, finally protects the boiler
form major accident. As per Indian Boiler Regulations(IBR),
minimum two Fusible plugs are must for the web back boilers.
One fusible plug is fitted at the top most position of the internal
reversal chamber & the second one at the front tube plate, just
above the third pass flue tubes.
FIGURE F-3.3: Fusible Plug
When the water level falls below either of the plugs’ level the
plug being exposed to steam on one side & flue gas at the other side .The steam does not cool
the Fusible plug as much as the water. Hence, its temperature goes up. When the plug
temperature reaches about 400 – 420°C the lead alloy holding the plug in the housing fuses. As
soon as the alloy fuses the reversal, chamber plug is forced into the furnace. This creates a small
orifice on top of the reversal chamber from which steam rushes into the furnace quenching the
flame. Consequently, the boiler would be tripped by flame failure.
To replace and maintain the fusible plug of the reversal chamber, a hand hole is provided on
the bottom shell right above the plug location. When the Fusible plug of the front tube plate, is
fused due to low water conditions in the boiler, the steam, under pressure rushes out & enters the
smoke tubes and furnace, thus quenching the flame. The Fusible plug at the front tube plate
can be re-fixed, from the waterside by entering through the boiler manhole. The fusible plug is
manufactured as per IBR & hence, requires IBR certification.
Figure no. 3.4: Location of Fusible Plug
80
Chapter 3
3.3: Boiler Safety valve

Mechanical safety against steam pressure high is provided by two nos. Safety valves fitted on
the top of the boiler shell.
The Safety Valves of the boiler are the over pressure safety of the boiler. These are supplied in
two numbers as per the IBR. These safety valves are set at the maximum working pressure of the
boiler. One safety valve lift pressure is set little below the maximum working pressure (MWP) of
the boiler and the other one is set at the MWP.
When the pressure controller fails or the setting is more than the maximum working pressure of
the boiler then the safety valves lift & vent out steam thus reducing the excessive pressure of the
boiler.
The Lift & sit back operation of these valves should be exactly as per IBR, which is set at the time
of commissioning. After the IBR steam test (Ref Chapter 1.5 IBR Registration), the safety valves
setting nuts are locked by means of the spacer rings to ensure that the lift pressure is not
disturbed.
Photograph and cross section of a safety valve are enclosed below, in Figure F-3.5 and
F-3.6 respectively.
VALVE SETTING NUT

GUIDE ROD
SPRING
VALVE
SEAT
STEAM
OUTLET
Figure F-3.5: Safety Valve
BLOWDOWN RING
STEAM INLET
Figure F-3.6 – Cross Section of Safety Valve
81
Chapter 3
3.4: Boiler Water Level Gauges:

These are Reflex type toughened glass level
gauges and enclosed in the Metallic
enclosure to protect it from the breakage.
Two level gauges are provided in case of
shell boilers and on steam drums used in
water tube boilers. Each gauge glass
assembly comes with IBR approved isolation
and drain valves mode of Bronze / Gunmetal.
For high-pressure boilers above 17.5 kg/cm2
design pressure, cast steel material is used for
valves.
Figure F-3.7 : Reflex type Level gauge
3.5 Digital Temperature Indicator & controller

Two digital temperature indicator & controllers (TIC) are used in Shellmax; Fuel temperature TIC is
used for the control & indication of the fuel temperature which is heated by Oil pre heating station.
The fuel gas TIC is used for indication of flue gas temperature & as a safety, which cuts of the
burner incase of flue gas temperature rises above the set point. The TIC set point is +30 deg “C”
above the normal flue gas temperature, which will gain dependent upon the operating pressure of
the boiler. The safety temperature setting is done at the time of commissioning.
Resistance Temperature Detector (RTD) is used with each TIC to sense the temperature.
Figure F-3.8: Digital Temperature indicator Figure F-3.9: Temperature sensor (RTD)
3.6 Proportioning Pressure Controllers- Pressuretrol, Make- Honeywel

This is the boiler steam pressure controller, which regulates the steam pressure in the boiler by
modulating the fuel-firing rate & corresponding air of the burner. This is supplied with the boilers
This controller with other controls reduces the fuel & air, which is fed by the burner in the boiler
furnace, when the boiler steam pressure increases. In addition, it increases the firing rate & air
when the pressure in the boiler reduces .The increase or reduction in the firing rate is in proportion
to the increase or decrease of the steam pressure in the boiler.
82
Chapter 3
It is called as proportioning pressure controller because its action is in proportion to the increase or
decrease of steam pressure in the boiler. This control is also called step less modulation, as this
modulation is continuous.
This controller avoids the burner on-off operation of the boiler, which is undesirable to the boiler &
to the process. In short, it tries to maintain the steady steam pressure in the boiler, when the steam
load/pressure fluctuations are within the reasonable limits.
This pressure controller control the firing between lowest & highest firing range of the burner. The
ratio of the lowest firing rate to rated firing rate is called as burner /boiler turn down ratio, (33% for
SM 30C to 40 C & 25% for SM 50C to100C Models) of the rated fuel consumption in Shellmax boilers.
This pressuretrol is not used in lower capacity boilers SM 10c to 20 c, where, the Turn down is 50%.
If the steam demand reduces even with the lowest turn down (25% Or 50%,As the case may be),
the steam pressure rises further even at the lowest burner firing rate, then the steam pressure high
Pressure switch (On–Off) cuts off the burner.
This controller is provided with adjustable proportioning (throttling) range to allow selection of
desired pressure control range. A pressure scale in customary US units as well as metric units and
an indicator are provided. The adjustment is done with screws provided on the casing top. The
pressure controller can be mounted directly on process piping as well as on control panel.
Construction & Working
The pressure controller is provided with a pressure-sensing element in the form

of phosphor bronze bellows. The bellows are linked to a potentiometer wiper.
The potentiometer resistance is around 135 – 140 ohms. A terminal strip with
marking is provided for electrical connections. The construction is shown in
Figure F-3.11.
Figure F-3.10
Pressure variations cause the bellows

to expand or contract. Linkage
between the bellows and the
potentiometer wiper causes the wiper
to move across the potentiometer
windings. This varies the resistance
between R & B and R & W causing an
imbalance in the circuit connected to
the controller.
Figure F-3.11 : Proportional Pressure Controller
83
Chapter 3
The controller is used to regulate the firing rate of a burner by controlling a modulating motor /
modulating valve. The controller potentiometer, the feedback potentiometer in the modulating
motor and a balancing relay in the motor form an electric bridge circuit. As long as the pressure of
the controlled medium remains at the set point of the controller, the circuit is balanced; that is,
equal currents flow through both sides of the balancing relay and the relay contacts are open.
When the circuit is balanced, the motor does not run.
Figure F-3.12 : Pressure Variation
If the pressure of the steam rises, the wiper in the controller moves towards W. This unbalances the
circuit, so a larger current flows through one side of the balancing relay. The close contacts in the
relay make, causing the motor drive toward its closed position. As the motor runs, the wiper on the
feedback potentiometer moves in a direction to balance the circuit. When the circuit is again in
balance, the balancing relay contacts open and the motor stops. The valves and dampers
connected to the motor or actuator will be partially closed, decreasing the firing rate and
reducing the pressure.
Similarly, if the pressure of the steam falls, the wiper on the controller potentiometer moves toward
B, and the open contacts in the balancing relay close. The motor drive toward its open position
until circuit balance is achieved. The valves and dampers will be opened wider and the firing rate
will increase, thus increasing the steam pressure in the boiler.
A small change in the pressure of the steam will cause a change in the firing rate to compensate
for it, thus keeping the pressure constant. This process is called modulation.
84
Chapter 3
3.6.1 Steam pressure high controller: Pressure Switch
The control of steam pressure is provided by a pressure switch as mentioned above. If boiler
pressure increases above the set pressure of the pressure switch, the boiler is tripped by
automatically switching off the Burner. The Burner restarts automatically when steam pressure
reduces below the differential Pressure setting of the pressure switch. This automatic operation of
the boiler is known as on – Off control, and the boiler steam pressure is controlled by the pressure
switch.
All pressure switches use a sensing element, bellows being the most common. The bellows type
performs well in applications where even shock and vibrations are present. The sensing element
can be used for a variety of process fluids. The pressure switches can be made in weatherproof
housing (IP-66) or in explosion proof housings. The pressure switches used in boilers are of standard
design.
Figure F-3.13:
Pressure switch Figure F-3.14: Internal View of a Pressure Switch
Steam Pressure high
85
Chapter 3
3.6.2 Positioner Controller: Model: PEPC – 10
This is electronic equipment mounted in control panel. The Positioner controller is used with
transmitter potentiometer (GW) and a motor drive to get follow up controls or remote manual
settings. The transmitter potentiometer is connected with terminal 13, 11 (wiper) & 14. Feedback
potentiometer (mounted on modulating motor) is connected to terminals 8, 9 (variable) & 10 of
the Positioner controller.
The position of the transmitter is compared, with the position of the feedback potentiometer RW
built into the motor drive. When a deviation exists, the Positioner controller gives the corresponding
control signals to the motor drive until the position balance is established again. Transmitter
potentiometer and feedback potentiometers with a nominal value from 130 to 2000 ohms can be
used.
Figure F-3.15 : Positioner-PEPC
86
Chapter 3
3.7: BURNER & BURNER MANAGEMANT SYSTEMS:

Oilon burners are monobloc burners i.e. Combustion air fan, oil preheater, fuel pump are mounted
on a single unit. These burners are used to burn furnace oil & natural gas. (One fuel at a time)
Construction
Burner housing is made out of steel plates. It houses combustion air fan. Motor mounted on housing
runs the fan. Fuel pump is coupled with combustion air fan motor for burners used for boilers up to 4
tph, Separate motor is used for fuel pump in burners used for 5 to 10tph..Burner housing is equipped
with a hinged burner flange with safety interlock switch, enabling burner to be swung open to the
left or right. Due to burner flange it is possible to service the combustion head, nozzles, and ignition
electrodes. The combustion head is adjustable to optimize the mixing of fuel regardless of the firing
rate. The burner contains a sight glass for flame observation. On the suction side of the fan there is
an air damper that, together with the servomotor, automatically controls the amount of fuel and
air on the basis of the firing rate required. A removable upper cover makes electrical installations
and burner servicing easier.
Capacity regulation methods
Burners come in two types of capacity regulation

1) Two stage.
2) Modulating.
The two stage burners are equipped with an air damper servomotor, with a run time of 5 seconds
between capacity stages. The modulating burners are equipped with a servomotor with a run time
of 30 seconds/90o .The servomotor is connected to the oil regulator and compound regulator via
an axle.
Upto SM 40DL, Burner control panel is inside the burner. Burners for SM 10DL, SM15DL & SM20DL are
two stage burners. Two pressure switches are provided on boiler one for control shutdown &
another for two stage modulation. During startup Burner starts at 1st stage, if load is more then
boiler pressure drops which gives signal to burner panel to make 2nd stage on. Burners for SM 30DL
& SM 40DL are modulating burners. Pressure transmitter is provided to sense boiler pressure. This
signal is given to pressure controller in burner panel. Depending on load, firing rate is changed from
lower turndown to full firing.
From SM 50DL onwards burner control is built in thermax panel. Burner modulation system consists of
following.
87
Chapter 3
3.7.1 Burner Sequence Controller: ¾ Position the air dampers at open

Make siemens, Model -LAL 2.25 position, for “Pre-purging” of the
combustion space, to scavenge the
un-burnt gases/volatiles/ smoke from
the combustion chamber/burner
furnace.
¾ “Return” the air damper to” low
fire/Flame” position, to start the burner
Lockout indicator
in low fame position.
Circular scale
¾ Electrical Supply to “ignition
transformer” to turn on the “ignition
Spark”.
¾ Electrical Supply to “Burner solenoid
valve”, to spray the atomized fuel &
Figure F-3.16: Sequence controller establish the low flame.
¾ “Turn off the firing sequence”, in case
The sequence controller automatically of satisfactory flame establishment.
controls the firing sequence of the burner & ¾ “ Stop” the supply to the burner
ensures the safety of the operating personnel solenoid valve bring burner firing
/ equipment, in the event of improper or no sequence to” Lock out” position in
flame. case of no flame sensed in
It works in conjunction with the flame sensor predetermined time OR incase of
(Photo resister for oil fired units), which improper /flickering flame.
continuously monitors the flame & provides ¾ “Bring back” the air dampers to low
the feedback to the sequence controller. position.
The sequence controller provides the
following burner firing cycle or the firing Once the flame is established (in low flame),
sequence in the SM boilers: the sequence controller only monitors the
flame through the flame sensor and allows
¾ “Start the FD fan” motor .which the flame to continue in normal firing
supplies air to the burner conditions.
3.7.2 Photo Resister: Model: QRB 3 for Oil firing, Sequence controller Siemens- LAL 2.25.
This is called the eye of the burner .It senses the light from the flame &in case of steady flame
provides the supply to the sequence controller to stop the firing sequence. In case no- flame or
flickering flame, the feedback is given to the sequence controller & the electrical supply to the
burner is switched off, indicating “Lockout”.
This photo resister works on the principle of reduction in resistance by sensing light. It can sense
ordinary day light, artificial electrical illumination or light emitted by any source.
Figure F-3.17: Photo Resister
88
Chapter 3
3.7.3 Burner Sequence controller: Model Siemens. LFL 1.63…
The Gas burner requires pilot flame to ignite main gas flame, due to safety reasons; hence, the
timing of the firing sequence is different, in this model. More over, UV cell is used to sense the
flame, in place of Photo resister.
This sequence controller controls the operation of the pilot & main gas solenoid valves, in
conjunction with UV cell. The burner modulation logic is quite similar to that for the oil fired
burners, as explained above (Refer section 3.7.9) .The difference is in the Sequence controller
terminal numbers ,in the explanation above.
3.7.4 UV Cell: Model: QRA 2
As mentioned above, in gas-fired units UV cell is used to sense the flame, as these do not
respond to glowing of refractory in the combustion chamber, luminance of artificial light, day
light etc, ensuring complete safety to the operators & the equipment.
Figure F-3.18 : UV Cell
3.7.5 Burner modulation Logic

The following paragraphs will explain the burner modulation /firing control logic with the function
of each component involved with respect to the other.
Modulation
Once the unit fires, after preset time, power comes from the sequence controller terminal 20 and
if the modulation switch is ON, then the modulation contactor energizes. In that condition if
power comes to high terminal of servomotor , then burner goes to high flame till the maximum
position and if the power comes to low terminal of servomotor , burner goes to low flame till the
minimum position.
Modulation is of two types.

1. Step modulation (Applicable to Shellmax models SM-10,15 & 20)
In step modulation, unit works either in high flame or in low flame.
2. Step less modulation(Applicable to Shellmax models SM-30 onwards)

In step less modulation the firing can be anything between low flame and high flame.
For step modulation for boilers Pressure switch is used.
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Chapter 3
• Pressure switch for boilers
In this type of control the pressure switch senses pressure. When the process value or the steam
pressure is less than the pressure switch set valve, power comes to terminal high terminal of
servomotor & unit goes to high flame. Once the pressure becomes more than the set value, the
micro switch of pressure switch operates and gives power to low terminal of servomotor , and
burner comes to low flame.
For step less modulation the Combination of Proportioning Pressuretrol Controller and Positioner
Controller PEPC 10 is used.
• Combination of Proportioning (Pressuretrol)Controller and Positioner Controller PEPC 10.
In most of our boilers we use this kind of control system. We use Honeywell Pressuretrol.
In the Pressuretrol, pressure variation causes the

bellows inside to expand and contract. Linkage
between the bellows and the potentiometer
wiper causes the wiper to move across the
potentiometer windings. This varies the
resistance between Red & Blue and between
Red & White wires causing unbalance in the
circuit of Positioner controller PEPC 10. PEPC 10
is a P controller. The varied resistance or in other
words, position of the Pressuretrol is compared
with the position of the feedback
potentiometer of servomotor. When a deviation
exists, the Positioner controller gives the
corresponding control signals to the motor (High
or low terminal of motor), until the position
balance is established again.
Figure F-3.19
90
Chapter 3
Figure F-3.20: Burner Modulation Logic
91
Chapter 3
a) Boiler start up –No pressure in the boiler

Condition: Burner on, Modulation switch off
Pressure in the boiler is zero, all other controls / safeties in healthy condition and burner/ flame is
properly set:
Start
Pressuretrol –wiper in extreme low position of the range
Firing sequence of sequence controller is on (refer above 3.7.3-)
Positioner PEPC, in order to balance the resistance in the bridge, rotates the
potentiometer of AR 6 in the proper direction, with the help of Servomotor & clutch and
through the gear train.
The drum of AR 63 rotates and the lever of the air damper moves on the steel strip of the
drum.
Linkages of air damper move & close the air damper to its lowest opening position, up to
limit switch.
The AR 63 drum shaft rotation also moves the cam disc which is mounted on the drum
shaft it self. This rotation of the cam disc opens the by pass of the fuel regulating/metering
valve, to maximum.
Major quantity of Fuel is by passed after entering the burner Gun, through its bypass port.
Now combustion air is at minimum opening with fuel bypass at maximum i.e. burner at low
firing /flame position
Sequence controller sends the electrical input 220v AC to burner ignition transformer
(through External contactor), to provide 14.5 KV at burner ignition electrodes, to start
sparking.
Sequence controller gives the signal o burner solenoid valve (continuous current magnet),
through external circuit & rectifier, to provide 180V DC.
The continuous current magnet attracts the burner stem & opens the fuel inlet port to
nozzle, to come out in the form of fine spray
Spark ignites the fuel spray droplets & generates the flame, with lowest firing rate, called as
low flame
Stop
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Chapter 3
b. Boiler to Generate Steam at Maximum Rate: Burner to Fire at High Flame:
Condition: Burner On, Burner firming at low flame-boiler pressure lower than setting on the
pressuretrol & pressure high cut off Pressure switch:
Start
Modulation switch is switched ON
The wiper of the pressuretrol at an advance position due to steam pressure makes the
Positioner PEPC to balance resistance in the bridge & makes the potentiometer alter
resistance by rotation of Servomotor /Drum through gear train.
Drum of AR63 moves slowly towards its extreme (High) position, opens the air damper to its
maximum setting gradually, thus combustion air increases to maximum
At the same time, gradually closes the by pass of fuel regulating valve to maximum, thus
reducing the fuel bypass & increasing the fuel firing rate slowly
The flame gradually goes to highest firing rate .Thus increasing the steam generation.
The AR 63 Drum stops its rotation at high position by limit switch
Stop
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Chapter 3
c. Steam Demand Reduces and Steam Pressure Increases:
Condition: Burner firing at high flame, boiler pressure below the pressure setting of
pressuretrol and High Pressure Cut off (On-Off) Pressure switch:
Start
Pressure in the boiler rises towards the setting range of pressuetrol but below the setting of
on- off pressure switch
The wiper of pressuretrol moves towards the high setting, Positioner PEPC balances the
resistance in the bridge & by moving the Potentiometer (in the reverse direction) through
clutch & servomotor.
AR 63 gear train & the drum moves in the reverse direction slowly to match the rate of
increase of pressure sensed by the pressuretrol, so to close the air damper gradually,
reducing the combustion air
The AR 63 Drum & cam disc of the fuel regulating rotates in the reverse direction to increase
the fuel bypass to reduce the fuel-firing rate
This reduces the flame in proportion to the increase in the steam pressure, thus try to
maintain the constant pressure in the boiler.
The rotation of the Drum Stops at Low position by Limit Switch and Boiler burner fire reduces
to low flame.
Stop
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Chapter 3
d. Steam Demand Reduces Further & Boiler Pressure Increases:
Condition: Boiler pressure above the pressuretrol but below the on off Pressure switch setting
Start
With the pressuretrol wiper movement due to increase in the steam pressure and the
subsequent Potentiometer movement by Positioner PEPC (as per the condition no 3 above),
AR 63 gear train Moves in the reverse direction
The gradual movement of AR 63 in the reverse direction reduces the air damper to minimum
position (by limit switches) and increases the fuel bypass of fuel regulating valve through
cam disc movement. Thus, gradually reduces the fuel firing rate also
The burner goes in the low flame firing position.
The wiper of the pressuretrol reaches its extreme position and does not move further with the
increase in the steam pressure
With the further reduction in steam demand, the steam pressure still rises in low flame above
the setting of the steam pressure high cut off (On Off) pressure switch
The pressure switch cuts of the supply to the burner thus, cutting off the flame, without
stopping the blower
If the steam demand increases, the pressure reduces below the differential setting of the
pressure switch, the supply to burner is restored by pressure switch & sequence controller
starts burner-firing sequence again.
The flame is established in low firing rate/in-low flame
Stop
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Chapter 3
3.7.6 GAS TRAIN:

• The train is fitted close to the burner of the boiler in the boiler house. The function of the gas
train is to provide the clean ,regulated flow of gas at the desired pressure to the burner of
the boiler and to provide essential safety incase of abnormalities.
Gas Pressure gauge Gas Pressure gauge
Ball valve Gas filter Safety Shut Gas Pressure Gas pressure switch
off Valve Regulator
Figure F-3.21: Standard Gas Train
Figure F-3.22 : P&I Diagram: Gas Train Assembly
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Chapter 3
The gas train will also provide the following actions, with the help of the various components:
Table No 3.1
S no Component Description Function

a Manual Ball Valve/quick shut off Manual start/Isolation of gas supply
valve
b Gas filter Filtration of gas
c Safety Shut off valve: High pressure shut off of gas supply
d Gas Pressure regulator Regulation of the gas flow & pressure
e Gas Pressure gauges Indications of the gas pressures ,at inlet of the gas
train & at the inlet of the burner
f Safety relief valve Venting of the excessive gas pressure
The gas train shuts of the gas supply to the burner in case of abnormal conditions
The abnormal conditions will arise when,
• Gas pressure in the gas train, will rise above or fall below the set pressures in the gas
pressure switch. If the high gas pressure safeties fail to operate, the safety relief valve will
vent out the excess gas pressure.
• Burner Flame or ignition failure.
The pilot & main burner solenoid valves are connected to the sequence controller of the boiler.
The standard gas train supplied with Shellmax boiler consists of the following components.
GENERAL DESCRIPTION
a. Quick shut-off valve
This is manually operated quarter turn shut off valve to supply or cut off gas to the burner, and is
fitted at the start of the gas train.
Figure F-3.23 : Quick shut off valves
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Chapter 3
b. Filter
This is to prevent any dust/Rust particles or impurities from entering the pressure regulators and
solenoid valves, thereby avoiding leakages.
Figure F-3.24
c. Pressure Regulator (Gas governor)
i) Main Regulator
This is the most important part of gas train. It regulates the downstream pressure of the gas at
the set value required for correct firing rate of main burner. The set pressure of the regulator (#)
can be adjusted by changing the tension of spring located above the diaphragm.
(#) - For set pressure, (Refer chapter: 5.0 Commissioning-Section 5.2.1 G: Important Readings &
settings) This set pressure is for full load on unit and other parameters as per design conditions,
and hence may vary depending upon actual unit operating conditions.
ii) Pilot Regulator
The regulator is provided to supply gas at regulated pressure to the pilot burner for a steady pilot
flame, irrespective of the setting of the main gas pressure regulator.
Gas Regulator/Governor Main Burner Gas Regulator/Governor Pilot Burner
Figure F-3.25 Figure F-3.26
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Chapter 3
d. Safety Relief Valve
Safety relief valve is mainly required to relieve sudden pressure

surges in the line. A safety relief valve is positioned downstream
of the gas pressure regulator. The setting of relief valve is 20%
above regulator set pressure.
Figure F-3.27
e. Safety Shut off Valve (Slam Shut off Valve)
Safety shut off valve is used to protect the down stream

components in case supply pressure exceeds the withstanding
pressures of downstream components of pressure regulator.
The setting of the valve is 20% above safety relief valve pressure.
Main Gas safety shut off valve
Figure F-3.28
f. Pressure gauges
Pressure gauges are provided at different locations, one before the

regulator and the other after the regulator. The former indicates the gas
supply pressure, where as the latter indicates the pressure at which gas
enters main gas solenoid valves.
One pressure gauge is provided after the regulator (governor) in the gas
pilot line.
Figure F-3.29
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Chapter 3
100
Chapter 4
04 INPUT REQUIREMENTS
The following parameters are to be maintained, for the fuel, Feed water, boiler water, electrical
input for the boiler & its components to perform as desired.
4.1 Fuels:
4.1.1 Liquid fuels:
The standard specifications of the fuel oils to be used are;
Table T-4.1:
High Speed Diesel: Light diesel Oil:

Parameter
(HSD) (LDO)
Specific Gravity at 20 Deg ‘c’ 0.82-.83 0.85-0.87
Flash point Deg ‘C’ 32 66

Viscosity at 20
2- 4 15-17.5
Deg ‘c’
Sulphur % Up to 0.25 Up to1.8
Pour Point : Deg ‘c’ 4-5 18

Pre-heat temperature at
# **
out flow heater : Deg ‘c’
Pre-heat temperature at
NA NA
Oil Pre-heating tank Deg ‘c’
Required Fuel Viscosity in CST at Burner
NA NA
nozzle tip after preheating
Net calorific value
10200 10150
Kcal/kg
Note:
# Pre-heating of fuel oil is required at sites having ambient temperatures below 5oC
** Preheating may be required up to 60oC max for proper fuel atomization at burner
nozzle if fuel viscosity is high at ambient temperature.
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Chapter 4
4.1.2 Gas fuels:
The standard specifications of the following gas fuels used are;
Table T-4.2:
Natural Gas Liquefied Petroleum

Parameter
Gas (LPG)
Methane -76%,
Composition: Main Ethane-10% Propane: 10-40%
Constituents Propane- 2% Butane :60-70%
Density, Kg/M3 0.83 2.32
Net Calorific Value

8500 24950
Kcal/Nm3
4.2 Feed Water Quality

The water treatment plant should provide the boiler feed water of the following specifications for
the IFB boilers as per the requirements of the 20 Kg/cm2 max working pressure.
Table T-4.3:
Parameter 0-20 kg/cm2 Purpose-To control
pH Value 8.5 –9.5 Corrosion
Dissolved Oxygen, Mg/Lit

0.05 Oxygen Pitting
as O2 max.
Total Hardness, mg/Lit as

<5 PPM Scaling
Caco3 max.
Silica as SiO2,Mg/Lit Nil Scaling
Organic Matter Non Detectable Foam
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Chapter 4
4.3 Boiler Water quality:

Boiler water means the water, which is inside the boiler. The boiler water quality is maintained by
the blow down, as per the norms given in the following table.
Table T-4.4:
Parameter 0- 20 kg/cm2 Purpose: to Control
pH 11-12 Corrosion
Total Hardness Non detectable Scale
Total dissolved solids: TDS 3500 ppm Corrosion
Total Alkalinity (20% of TDS) 700 ppm Foam
Phenolphthalein Alkalinity (10% of TDS) 350 ppm Foam
Silica (40% of Caustic Alkalinity) 140 ppm Scale
Phosphates 20-40 ppm corrosion
Sulphite 30-50 ppm Oxygen
Hydrazine 0.1 ppm Oxygen
4.4 Electrical Input

The electrical input to the electrical control Panel of the boiler should be:
Three Phases, 415 +/- 6% Volts, 50+/- 3% Hz, A.C. Supply with Neutral & Earth connections.
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Chapter 4
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Chapter 5
05 COMMISSIONING PROCESS
The boiler user has to comply with all the IBR formalities and the provisional Order for the boiler
firing has to be obtained from the concerned Boiler Inspectorate, before Thermax
engineer/representative’s visit for commissioning.
The user has to send the written communication to Thermax on receipt of the provisional boiler
firing order from the Boiler Inspectorate. On the receipt of this written communication Thermax
engineers/representatives can start the commissioning activities.
5.1 Pre-Commissioning:
The pre-commissioning is the part of the commissioning activity of the boiler, only the firing of the
burner and steam generation is not done.
The firing of the boiler burner system is done only after the completion of the IBR formalities by
the user.
Pre Commissioning is commenced only on completion of all the assembly connections as per
the preceding chapters; P & I diagram, electrical diagram and the assembly work.
During Pre commissioning all the systems i.e. fuel, Feed Water, Drain, Steam Flue gas, electrical
etc are checked/rectified finally and all the possible instruments /parameter settings are done.
All the System are run in manual operation or independently, checked for their smooth and
satisfactory operation.
The persons entrusted with operation, servicing and observation (Boiler attendant for IBR boilers)
must be present during pre-commissioning. It would be better, during commissioning operation;
direct superiors of boiler man should be present.
Thermax representative shall provide the training, guidance & supervision of the critical activities
during Pre-commissioning & commissioning. Thermax representative shall ensure that all the
settings & actions are completed as per the detailed checklists. However, the users /customers
should ensure that the following and all other jobs, as suggested by Thermax representative are
completed before inviting them for commissioning.
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Chapter 5
CHECKS -
A. GENERAL:
) Ensure that the civil work of the boiler house is complete before taking the boiler for
commissioning
) Check and level all the equipment and tight their foundation bolts.
) Check all the motor windings for damage and moisture with meggar.
) Check and ensure that all the pipelines and ducting are supported properly.
) Check all the strainer and valves for its operation.
) Arrange the fuel as per the input quality requirements.
) Arrange boiler operators and other work force required to operate the boiler.
) Arrange boiling out and feed water treatment chemicals.
) Insulate all the lines and equipment after they have been tested completely.
B. FEED WATER SYSTEM:
) Get the water treatment plant commissioned and ensure the quality of Feed Water is
within the specified acceptable limits, and if needed Water treatment Chemicals are
also added to make it as per the Input requirements (Refer Chapter 4.0 - Input
Requirements)
) Clean & Flush the feed water storage tank and pipelines thoroughly by manual
scrubbing & draining the water.
) Flush the feed water pump completely before commissioning as this is filled with anti
corrosive compound before dispatch, to prevent rusting in storage. This compound
should be drained and the pump flushed completely.
) Check the operation of softener and dozer and make sure that the operators are well
trained on the softener.
) The water level extra low safety is provided in the tank & is in operation.
) Ensure that the Feed water pump foundation bolts are tightened.
) Ensure that the Feed water pumps rotations are correct.
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Chapter 5
) The float rod of the mobrey level controller is kept tightly secured at the top position by
rubber bands or during transportation .This should be removed & ensure that the float rod
is free to move up & down before filling water in the boiler.
) The mobery level controller is electrically connected to the control panel & air break
switches are secured at position.
) In Mobrey level controllers, set the pump “start” switch 35 % level , approximately, from
the bottom of the level gauge glass tube of the boiler
) In Mobrey level controllers ,set the pump “Stop” switch at 50% level, approximately from
the bottom of the level gauge glass tube of the boiler
) In mobery level controller, set the water level low Safety switch of boiler is to be set at the
level , higher than the top most third flue pass tube i.e. at 15% level, approximately from
the bottom of the level gauge glass tube of the boiler .
) Ensure that the feed pump on –off operation is satisfactory & consistently at the desired
levels.
) Check the Mobery; low level safety, for their satisfactory working, several times by boiler
water draining.
) The pressure gauge is fitted between the outlet valve & pump.
) The feed pumps operation should be smooth & without any undue noise & vibration.
) The feed pumps pressures should be steady ,if not steady clean the suction strainers
,remove air from pump, check pump coupling and input voltage
) The strainer at pump suction has the proper size of mesh (refer P & I diagram).
) The strainer at pump suction strainer is cleaned after flushing the lines.
) Ensure that the Valves are operating smoothly.
) Clean Water flow at the feed pump suction is available.
) Air is removed from the feed pump through the air vent plug & the pump is flooded with
water.
) Ensure that the valve at the pump outlet is throttled if there is no pressure in the boiler or
water is to be filled in the boiler in cold or low-pressure (less than 7kg/cm2) condition.
CAUTION
NEVER START THE WATER PUMP WITH DISCHARGE VALVE OPEN. INITIALLY THROTTLE THE
VALVE PARTIALLY.
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Chapter 5
C. FLUE GAS CIRCUIT :
) Check the chimney and duct connections and make sure that they are airtight.
) Check and provide supports to ducting.
) Check the functioning of various dampers provided in the ducting & mark Open -Close
positions with paint.
) Insulate the part of ducting inside the boiler house.
) Ensure that the flue gas sampling points are provided for the Smoke Index &Co2/O2
measurement
D. BURNER
) Check impeller locking screw and tighten it if found loose.
) Rotate impeller manually to see that it dose not rub and maintains proper cone/wheel
clearances and there is no undue noise form the fans.
) Check coupling for proper alignment.
) Check fan and duct for any loose material inside.
) Ensure that the suction air damper is free to rotate. Lubricate the damper bearing &
linkages.
) Check lubrication of motor bearings.
) Secure and check safety guards for its position.
) Check if nozzle is secured properly in nozzle holder.
) Check alignment of electrodes with respect to nozzles.
) Check burner settings as given in burner manual.
WARNING:
NEVER START ANY FAN WITH DISCHARGE FULL OPEN.
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Chapter 5
E. ELECTRICAL SYSTEM:
) Ensure that all external electrical cable connections to the control panel are as per
the electrical diagram of the boiler.
) Tighten all the terminals in control panel, as they might get loose during transportation.
) Check the functioning of main switch and provide correct fuse.
) Check whether proper earth wires have connected all the motors and panels.
) Check if all the settings of overload relays of motors, pressure switch (as), etc. are all
correct.
) Check for the earthing connection to elect panel, to all motors & instruments.
) Check for the correct electrical supply.
) Ensure that the Mobrey float cover is removed before filling water in the boiler.
) Check for the Trouble free operation of Mobrey level controllers.
) Mobrey water level controllers are set for feed pump on-off operation to maintain
proper water level.
) Ensure electrical interlocks of the FD fan motor & burner is operating.
) Check the functioning of all safeties & controls by manual simulation.
F. FUEL SYSTEMS:
i) Liquid fuels:
) Ensure that the Fuel system is complete in all respect as per the guidelines given in the
earlier chapter: 1.6 - Assembly Guide Lines & Accessories – Fuel System.
) Line sizes are correct & are supported & clamped properly.
) No Objection Certificate is obtained from the explosives dept. or the concerned

government agency for the storage of the fuel & that the fuel storage formalities are
completed before filling the fuel oil in the tanks
) Fuel storage tank & day tank are tested leakages & all leakages are rectified
) Manhole ,Vents, drains ,fuel level indicating arrangement, over flow ,out flow heater
arrangement, is properly made as per the instructions in the Assembly guidelines
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Chapter 5
) Ensure Use of oil quality gaskets in the fuel lines and at the tanks
) Fuel storage tank & day tank are cleaned dry & then flushed thoroughly before filling
the fuel oil.
) The pipelines are flushed thoroughly by air & fuel oil before connecting them to the
basket filter & Burner.
) For LDO the Out flow heater can be set at 50-55 deg ‘c’ if so needed.
) The air is removed from the basket filter, through air vent plug.
) Remove the air from the air plug of the fuel pump to ensure that the air is removed
completely. Ensure that the plug is re-fixed tightly.
) Set the fuel pump pressures.
) Clean the fuel strainers in line, as & when the fluctuations in the fuel pressures are
observed.
ii) Gas fuels:
) No Objection Certificate is obtained from the explosives dept. or the concerned

government agency for the storage of the fuel & that the fuel storage formalities are
completed before storing the fuel.
) Before supply is given to the burner, ensure that the user commissions the gas supply
system & the compliance to all the recommendations are made.
) The boiler user has to hand over a copy of the gas system commissioning & handing
over report to Thermax engineer/representative, before commencement for the
boiler /burner commissioning
) The user has to ensure the consistent supply of adequate quantity of the gas at desired
pressure is made available to the boiler burner.
) Check that the burner & components supplied along with the boiler are suitable for the
particular gas supply & its incoming pressure.
) Ensure that the gas supply pipeline sizes are correct, are supported & clamped
properly.
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Chapter 5
) When the gas is stored in the gas storage tanks ensure that the gas pressures is
reduced to the desired pressure with the help of proper gas trains & then supplied to
the boiler burner(Ref P & I diagram)
) Where ever the piped gas supply is given ensure that the gas pressure given to the
boiler burner is as desired (Ref P & I diagram)
) Ensure that the pipelines are tested to the desired pressure as recommended by the
gas supplier.
) Ensure that the safety & firefighting equipment are in place & are operative
) Dos & don’ts of the gas supply system are to be displayed in the boiler house near the
burner.
G. STEAM SYSTEMS:
) Check whether correct size of steam pipelines as recommended, are provided and IBR
hydraulic test certificate obtained.
) The steam traps are to be by-passed during the first steam flushing of the pipelines, to
avoid clogging of the steam traps due to dirt of the pipeline.
) Check for the steam traps & fittings, for proper clamping & free removal of condensate.
) Removal of air is very necessary from the pipeline & utilities when steam supply is opened
to the utilities.
) Insulation of the steam pipelines is done only after the successful hydraulic test in
presence of the IBR inspecting authority.
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Chapter 5
5.2 Commissioning:
The commissioning activity starts after all the pre commissioning activities are completed
satisfactorily and all the controls and safeties are working normally.
For commissioning and trial operation, steam or heat utility must be provided, for long duration
of steam generation or continuous boiler operation. This is required to set the firing system as well
as all controls and safety facilities can be adjusted.
The commissioning of the boiler consists of the following activities, which are carried out under
the guidance & supervision of Thermax engineer/representative .
5.2.1 Burner system commissioning & burner firing

5.2.2 Chemical boiling out
5.2.3 Steam generation & final settings
5.2.4 Safety valve setting
5.2.5 Efficiency /output trials & handing over
Warning:
• The commissioning of the boiler is to be done under the guidance & supervision of
Thermax Engineer / authorized representatives only to avail Thermax warrantee
benefits.
• If steam utilities are not ready, the steam will be vented out for the commissioning &
output efficiency trials.
• The Owner /User of the boiler must ensure that the Provisional order for firing the
boiler( In India) is obtained from the Inspectorate of boilers before informing
Thermax for commissioning
5.2.1 Burner System Commissioning & Burner firing:
The burner setting is required to be done, before attempting to the firing of the burner.
The burner setting for oil & gas burners is given in burner manual supplied along with burner
A. Burner Start Operation: Liquid fuels
The pre commissioning activities must ensure the satisfactory working of all the control & safeties
of the boiler, and then the burner can be started in the following sequence:
1. Fill up soft/DM water in the water service tank & open the valves in the water line.
2. Fill up fuel in the fuel service tank & open the valves in the fuel line. For gas fired units –
Open the valves in the gas lines
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Chapter 5
3. Put ON main switch & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
4. Keep the boiler vent valve open & main steam valve closed.
5. Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
6. Before starting the burner ensure that modulation switch is in OFF position.
7. After ensuring optimum water level in boiler & all safeties are fulfilled , the burner can be
started.
8. Put ON the burner selector switch.
9. The burner programmer cycle starts (with Siemens sequence controller model- LAL-2.25)
,Which consist of the following cycle of operation,
i) Pre-purging cycle: for 22.5 second’s time, then supply is fed to ignition transformer,
ii) Electrical sparking at ignition electrodes: for 6 Seconds
iii) Burner solenoid valve is energised, commencing fuel spray inside the combustion
Chamber & flame is established.
iv) Flame is detected by flame sensor. Thus, boiler starts in low flame. The low flame
Firing is to be continued so that heating is gradual.
10. If the firing is smooth then the flame & smoke colour are checked. The flame has to be set
bright for oil & Bluish for gas units & the smoke should not be visible, by setting the air
damper of the FD fan.
11. If the flame is smoky / flickering/does not get establish/creates vibrations/backfiring ,then
the air damper needs to be adjusted for getting smooth start of flame.
12. Even after setting the burner the flame start up is not smooth, then the burner diffuser
plate is to be adjusted along with air damper. Proper air fuel ratio is to be set at low flame
operation.
13. This procedure is repeated several times until a smooth flame start up is achieved with
colourless smoke.
14. The modulation switch is now put ON. The burner modulation would depend on steam
pressure, which is cold start will be zero.
15. The rotation of the servomotor moves the gear train, which is fitted at the FD fan suction &
increases the air supply .At the same time the fuel metering valve closes the fuel by pass
line of the burner gun, thus increases the fuel quantity also ( for Oil fired units ) .
16. for gas fired units The servomotor opens the air damper as well as gradually increases the
Gas supply
17. The burner thus moves to high flame fame & stops at the highest firing stage.
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Chapter 5
18. If the flame is improper as mentioned above the sequence of air fuel ratio setting is
repeated with resetting diffuser plate, air damper positions at various stages of transition
to high flame.
19. the transition from low to high flame has to be smooth ,with bright flame & almost invisible
smoke colour
20. To ensure complete combustion of fuel, checking of Smoke Index Number & Oxygen
percentage Or Co2 percentage is done with the combustion test kit.
21. For Oil fired units, the smoke index number should be set up to one for light fuels & up to
three for heavy fuels, with O2 percentage as 3-4 or CO2 percentage at 12-13, with low as
well as high flame conditions.
22. For Gas fired units the Ideal smoke Index should be zero & maximum Co2 % should be up
to 12 %.
23. Follow the chemical boiling out procedure as given below to clean the boiler surfaces
internally and raise the pressure for the boiling out.
5.2.2 Chemical Boil out Process:
Boiler chemical boiling out procedure can be done simultaneously with the burner system
commissioning
The primary objective of the boiling out procedure is to ensure removal of the more common
initial oil and grease and the other foreign matter.
The tube or plate manufacturers apply the coat of oil of readily soluble, non-hardening oil to
prevent from corrosion, which is to be removed by chemical boiling out.
Other than the metal failure, the oil also causes Priming & foaming inside the boiler, which is the
main reason of the Wet steam or water carryover. This may result into process problems.
Before chemical boil out, the following is required to be done.
a. Fill boiler up to 100 mm below normal water level.
b. Ensure all bottom header drains are fully closed.
c. Excepting direct level gauge, isolate all other instruments during boil out operation. This is
very important.
d. All drains & air vent are to be kept open initially.
e. Quantity of 100 KGs. Of Thermax MAXCLEAN - 07 chemical is required, for every 1000
KGs. of Water. Requirement will be proportional to the water holding capacity of the
boiler.
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Chapter 5
f. This Solutions (with water) should be poured through manhole of Boiler. Close the
manhole after charging chemicals.
g. Fire the boiler and keep it at low flame. This will help to raise the pressure slowly. Keep the
air vent valve of the boiler open.
h. When the drum pressure reaches about 2-kg/cm² close the drum vents. Continue to raise
the pressure at slow rate. This will avoid thermal stresses.
i. Fuel firing rate should be so regulated that approx. 50% of design pressure (max. working
pressure) is reached in about 4-6 hours. In no case should the pressure be increased
more than this for the boiling-out operation. Maintain this pressure for next 6-8 hours.
j. Now stop the fuel firing & boiler auxiliaries in proper sequence. Allow the steam pressure
to fall gradually. Maintain water level in the drum, such that it is visible in gauge glass.
k. When the steam pressure is approximately 5 kg/cm²g, give quick and short blow down.
This will greatly assist removal of sludge/sediment accumulated.
l. At hourly intervals, operate main blow down and drain valves on water level indicators
and water level controller in sequence. Make the first blow down of each series through
the surface blow down connection (if provided) in order to clear any scum or sludge on
the water surface.
m. Open the drum vents when steam pressure is approx 2 kg/cm². Take Soft/DM water in
boiler up to full gauge glass and drain it through different bottom header drains. This
procedure should be repeated 3-4 times for proper rinsing of internal surface of pressure
part.
n. The boiling out procedure will complete, when testing of boiler water, indicate same
amount of oil in consecutive samples tested.
p. Open the drum manhole, inspection ports (where available) of bottom headers for
inspection of the surfaces.
NOTE
It is important that all the precautions governing safe operation of boiler be duly observed
during the boiling-out period.
CAUTION
If considerable oil or oil sludge is found to be still adhering to the tubes, the entire process
should be repeated, until the pressure parts are free from all impurities.
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Chapter 5
5.2.3 Steam Generation:
After completion of chemical boiling out, and the complete flushing operation, the boiler is filled
in with the treat water and boiler.
The IBR licensed operator fires the boiler and steam pressure is raised up to the maximum
working pressure of the boiler.
This first operation of the boiler & steam generation is done in presence and under the guidance
of Thermax Engineer /authorized representative of the Thermax. The fine setting of FD fan
damper is to be set for the optimum combustion parameters of smoke Index & O2/Co2
percentage.
The Mobrey water level controller needs to be checked for its normal functioning and the
operation of the low level & extra low level safety.
5.2.4 Safety Valve setting:
The two safety valves are set at the maximum working pressure of the boiler, while the boiler is
generating steam to its full capacity. The exact lift pressures of the Safety valves, the pressure
build up in the boiler and the safety valve sit backpressure are observed and set. This is one of
the major and critical settings to be done on the boiler.
In India, the Indian Boiler regulations are followed for the over pressure & sit back pressure values
of the safety valves.
a. Pressure Switch Setting (High Pressure cut off):
After the settings of the safety valves, steam pressure high cut of pressure switch is set. This
pressure switch has to be set as per the maximum steam pressure requirement in the plant. The
setting has to be below the lift pressures of the safety valves, but in no case, it should not be lass
than 7kg/cm2.
The pressure switch controls the steam pressure of the boiler by cutting off or cutting in the
burner & FD fan. This stops the firing of the burner & reduces the steam generation. Hence this is
the device, which controls the steam pressure in the boiler.
During this commissioning process all the safeties & controls of the boilers are checked
thoroughly by operating the boiler at its full capacity and venting out the steam through Vent
valves or by passing the steam through the Steam lines for Flushing.
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Chapter 5
b. Flushing: Steam Lines
If the steam lines are newly fabricated these need flushing by passing the steam for min 4 hrs, to
ensure internally clean surfaces of the pipelines.
The steam Traps and strainers fitted should be removed from the lines during the flushing
operation. All air vents are opened and steam is flushed out for these valves. Only after the lines
are flushed the steam should be opened to the plant utilities.
c. Important Readings/Settings for Commissioning:
SR. ACTIVITY DESIGN DATA/ ACTUAL REMARK

NO. SET POINT DATA
a. FUEL CIRCUIT
1. Fuel consumption of - Refer technical specs

Boiler burner in
High flame
2. Fuel consumption of - Refer technical specs

Boiler burner
In low flame
(LIQUID FUELS)
3. Fuel pump pressure 20 kg/cm2 (g) (Approx.)
4. Burner fuel by pass 12-15 kg/cm2g (at 100%)

Pressure 4 - 7 kg/cm2g (at 25%) (Approximately)
(Gas Fuels)
5. Gas pressures -gas train inlet 500 mBar Or 1-2 Bar (as Applicable)
- Burner inlet 40-50 MBar
b. AIR / FLUE GAS CIRCUIT
1. Boiler outlet Flue gas 260ºC

Temperature high, (Approximately)
C. STEAM CIRCUIT
1. Steam pressure PCM for 10.54 kg/cm2g boiler set point should be
Switch (ON - OFF) 0.7 kg/cm2g more than low firing set point.
For 17.5 kg/cm2g boiler set point should be
1.3 kg/cm2g more than low firing set point
2. Steam safety SV SSV PR as per design

Valve setting
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Chapter 5
SR. ACTIVITY DESIGN DATA/ ACTUAL REMARK

NO. SET POINT DATA
3. Modulation: steam Pressure PCM Pressure band 1.5 kg/cm²}

Controller setting PT, PIC Pressure band 0.5 kg/cm²}
PIC Pressure band to start SSV pr
Minus 0.5 kg/cm² downwards
d. WATER CIRCUIT
1. High water level LSH 50% in

(Water Pump Off) gauge glass
2. Low water level LAL 35% in

(Water pump ON) Gauge Glass
3. Water level low alarm LAL 15% in

Gauge Glass
e. BURNER SETTINGS: Refer Burner manual for Burner settings.
NOTE:
All the above settings are only for reference; however, the actual settings may vary from site to
site and are to be recorded in the commissioning report
5.2.5 Efficiency & out Put Trials:
After the above procedures the boiler will be ready for the Output & efficiency trials.
It is mandatory for the customer to conduct the efficiency & out put trials, within a week’s time
of commissioning of the boiler, as per the guidance of Thermax Engineers/Authorized
representatives.
The efficiency trials are conducted as per BS 845 and in accordance of the Thermax standard
practices.
The observations of the trials are noted down and are signed by the Owner/user’s responsible
person and also by Thermax engineer/authorized representative.
Based on the Trial observations and the Out put & efficiency are calculated and informed to the
customer/user by Thermax.
These efficiency & output trials are conducted to ensure that the boiler is performing as per the
committed contractual norms of efficiency and steam output.
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Chapter 5
a. Training:
During the boiler Installation, pre-commissioning, commissioning and efficiency & output Trials,
Thermax engineers /authorized representatives ensure that the Boiler operators and other
technical personnel responsible for the operation and maintenance are trained to operate &
maintain the boiler as per the norms laid down by Thermax Ltd.
These norms and the good operation & maintenance practices of boiler are also explained in
the next Chapter of operation & maintenance. These should be read & practices for the trouble
free operation and long life of the boiler & its accessories.
b. Boiler handing over for commercial Use:
After the successful commissioning and efficiency /out put trials, the Boiler will be handed over
to the user/owner for the commercial use.
The boiler handing over procedure includes the signing and stamping of the Erection &
commissioning checklists and certificates of Thermax Ltd by the owner/user’s responsible person
and the commissioning engineer of Thermax / authorized Dealer.
These signed/stamped commissioning and handing over reports/certificates are forwarded to

the Customer Care /technical service department of Thermax ltd, for the scrutiny of the site
reports. If any discrepancies are observed in Installation, performance or settings, Thermax ltd
takes immediate corrective action by informing the concerned Thermax engineer/authorized
representative/dealer and also to the owner/user of the boiler.
Warning:
In no case, the owner /user should use the boiler for the commercial use /production,
without completing the Handing over formality from Thermax, to avail the committed
warrantees of the Boiler & its supplied parts/equipment.
In case of failure on the part of the owner/user to comply with the above handing over
procedure, all the warrantees of Thermax Ltd, as per the order terms, will cease to exist
and in such case Thermax shall not be responsible for any failure of the supplied
equipment or components.
119
Chapter 5
120
Chapter 6
06 OPERATING INSTRUCTIONS
Operation of the boiler needs to be properly under stood by the operational staff /operators.
The training has been imparted by Thermax /dealers during commissioning of the boiler.
Hence, the operation & maintenance of the boiler has to be as per the guidelines given in the
following chapters for the Starting, running & maintenance of the boiler.
6.1 Boiler Start up Process: Oil fired units
START
Fill up water in the water service tank & open the valves in the water line.
Fill up fuel in the fuel service tank & open the valves in the fuel line.
For gas fired units: Ensure that gas filters are clean.
For GAS fired Units; Check the main and pilot gas pressure and set it if required.
Put ON main switch & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
Keep the boiler vent valve open & main steam valve closed.
Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
. For gas fired units: Check the inlet gas pressure to gas train. If it is within acceptable
limit, open the inlet valve of gas train.
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Chapter 6
For Gas fired units: Check the main and pilot gas pressure and set it if required.
Before starting the burner ensure that modulation switch is in OFF position.
After ensuring optimum water level in boiler & all safeties are satisfied , the burner can be
started.
Put ON the burner selector switch in auto position.
The burner programmer cycle starts. After pre-purging time, supply is fed to ignition transformer,
commencing electrical sparking in the burner. At the same time burner/Gas solenoid
valve is energised, commencing fuel spray or gas supply inside the combustion chamber
& flame is established. Flame is detected by flame sensor. Thus boiler starts in low flame.
The low flame firing is to be continued so that heating is gradual.
When steam starts coming out through the air vent valve close the air vent.
When steam pressure builds up to the desire operating pressure, the main steam outlet can be
opened to the process.
Put ON the modulation switch, the burner would go in high flame position. The burner
modulation would depend on steam pressure, which in turn will vary depending on the
load.
End
122
Chapter 6
6.2 Boiler Stopping Procedure: For Oil & gas fired units
START
Put OFF the burner modulation switch.
Put OFF the burner switch.
Close the boiler steam stop valve. Keep the air vent valve slightly open.
Put OFF switches for all other equipments & close all relevant valves. .For gas fired unit ensure
that all gas isolating valves are closed.
Ensure that water & fuel service tank are full for subsequent operation. For gas fired units, check
gas availability for subsequent operation.
Isolate boiler control panel by putting OFF all electrical supply.
Clean the boiler & its surroundings off the dripped oil, water etc.
Blow down the boiler until water level drops by 1" (25 mm) or to the extent required depending
upon the quality of feed water. The boiler blow down should be such as to maintain a
TDS in the boiler to less than 3500 ppm. Close the blow down valve.
END
CAUTION
a) If the Boiler is being operated on LSHS. Make sure that at least one hour before stopping the
Boiler, the fuel firing is changed-over from LSHS to LDO/FO. This is for avoiding the choking of
Fuel oil pipe line due to LSHS solidification, at room temperature.
ii) When boiler is shut off for a short period, keep the vent valve slightly opened.
WARNING
• NEVER OPERATE THE BOILER WITH HARD WATER.
• NEVER PERMIT THE WATER TO DISAPPEAR FROM THE GAUGE GLASS WHEN ROUTINE BLOW
DOWN IS DONE.
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Chapter 6
6.3 Boiler Running Attention

It is advisable on part of the operator and the other operational staffs, to make it a practice
check the following points periodically during the running of the boiler.
Check that...
• The feed water softness is checked at the water treatment plant, after every one hour of
water treatment plant operation or more frequently. If feed water is found hard,
regenerate the water softener immediately.
• Maintain the desired boiler water quality, in the boiler. Add chemicals & give optimum
Blow down periodically. (Refer chapter Input requirement of feed water and boiler Water
• Maintain the soft/DM water level in the feed water tank up to its maximum capacity.
• If water treatment chemicals are being used ensure that the chemicals are added in
regular intervals, in the chemical tank.
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Chapter 6
• The flame is steady, bright & smoke is colorless.
• No backfiring or vibrations are observed from the burner.
• For oil fired units, the Fuel pre-heat temperatures & the fuel pressures are maintained as
per commissioning report.
• No excessive sound is heard from the motors pumps and Fans.
• All valves and joints are leak proof.
• Water pump is working ON OFF to ensure the functioning of Mobrey level control
switches.
• No sparking or loose contact is there in the electric circuit of the control panel of the
boiler.
• That a steady steam pressure is maintained.
• Always operate the boiler at or near to its working pressure. If steam pressure requirement
in the plant is low, then reduce the pressure to the desired in the plant By Pressure
reducing Station (PRS).
• No over firing of fuel is being done and correct fuel consumption is maintained.
• Combustion efficiency of the burner is to be regularly checked with the help of

combustion test kit and tune the burner to achieve optimum efficiency
• Blow down the Mobrey level controllers once in 8 hours.
• Blow down the gauge glasses once in 8 hours, and maintained the gauge glasses clean.
• The logbook is filled hourly and correctly for all the parameter of boiler. For Reference
format see below chapter “LOG BOOK”.
CAUTION:
1. Following procedure is to be adopted as guidance while blowing down the boiler, gauge
glass and Mobrey level switch. Blowing down, helps in removing sludge, loose scale and
other fine material that might accumulate in the boiler shell. Thus helps to maintain the water
quality.
• After the boiler is switched off. Blow down the boiler until water level drops by about 2"
(keep the air vent valve slightly open).
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Chapter 6
• To check the automatic operation of the feed pump, put on the selector switch and
blow down the boiler below normal water level, the pump motor should start and work till
the boiler is filled up to the top level.
2. If water quality is poor, Intermittent blow down water quantity / frequency of blow down
increases to keep the boiler water within specified limit. Prolonged Intermittent blow down
affects the water circulation in side the boiler, which is dangerous for boiler and tubes. Only
way to control the boiler water TDS is to feed specified soft/DM water or provide continuous
blow down. Intermittent blow down should be done only to remove sludge, loose scale and
other fine material that might have accumulated in the boiler shell.
3. During the Mobrey blow down, the operation of the water level extra low safety also can be
checked for its operation.
4. In the event of power failure or any failure of controls, safeties:
a) Close the steam stop valve and other valves.
b) Remove the un-burnt fuel from the grate. DO NOT SPRINKLE WATER TO EXTINGUISH THE
FIRE.
c) Ensure that water level is maintained in gauge glass, by emergency pump start switch.
d) Open the ash door for grate bar cooling.
5. Pre Heat the fuel up to the desired temperature only. Refer preheating charts, as per the,
Class and specific gravity of fuel oil. These charts can be given by the fuel supply companies
6. Avoid Over heating of fuel oil during Pre–heating of fuel oil .This will lead to Cracking,
Carbonizing of fuel oil & also to vapor generation. The vapors can damage the fuel pumps.
7. Maintain the ring main circuit pressures between 3 to 4 kg /Cm2, to increase the life of the
fuel pumps
8. In gas fired units, boiler gas supply pressures should be steady.
WARNING:
• During normal blow down never permit water to disappear from the gauge glass.
• Always operate the boiler at or near to its maximum working pressure.
126
Chapter 6
6.4 Do’s And Don’ts for Operation of Shellmax:
CAUTION:
Water System -
1. Do not use turbid water in the softener/DM/Water

treatment plant; it may choke the resins of this
equipment. Get the water (2 liters) and Resin (50 cc)
analyzed every year.
Operation -
2. Check the feed water quality every 4hrs of running &

ensure it is as per the requirement.
3. Feed only SOFT WATER into the boiler always. Never feed
hard water as this will result in scale formation. Scale
results in to low heat transfer to the water & over
heating of tubes.
4. Scaled tubes and metal parts like furnace don’t transfer

the heat to the water, hence overheating may take
place, resulting in to metal failure or bursting.
127
Chapter 6
5. Oxygen present in the water attacks the metal surface of

the boiler shell, which results into pitting.
The Low pH of water results into corrosion of the metal

surface.
Hence regular use of water treatment chemicals is

recommended.
Use water treatment chemicals for the treatment of

Oxygen Pitting, pH corrosion, residual hardness,
Alkalinity etc., and ensure that the dosing of these
chemicals is done regularly.
6. Ensure that proper quality and quantity of regenerates

are used in the water treatment plant and proper
procedure is adopted in running the plant with
specified
quality of regenerates.
7. Control Panel:
Check electrical input once in a day, to the control

panel.
Check all the controls and safeties regularly as
mentioned in the manual.
WARNING:
Never short circuit safeties and work the boiler. It may end up in costly damages.
128
Chapter 6
Boiler Unit:
8. Give blow down after regular intervals to maintain the

Boiler water quality: Chapter Refer Utility requirement.
9. Negligence in operation may cause severe damage to

the boiler. And automatic does not mean, no
attention required.
OK General:
Operation:
10. Maintain the Log book supplied with the boiler. It will
help in detecting faults, if any, at the early stages itself.
Refer Log Book section in next chapter.
11. Keep spares in stock to minimize down time due to

breakdowns, if any.
129
Chapter 6
130
Chapter 7
07 MAINTENANCE
7.0 Maintenance
The performance of a boiler depends greatly on the maintenance carried out. The boiler, its
surroundings, water pipelines, filters, strainers, etc. should be kept clean to maintain proper fluid
flow to the boiler so that it works efficiently.
For easy detection of faults and to know deviation from standard/normal setting/readings
obtained at the time of commissioning should be recorded and should be referred to after every
major servicing/repairs and replacement of parts, is carried out.
In the following paragraphs, the maintenance to be carried out is listed down as Daily, Weekly,
Monthly, etc. It is also necessary to check up whether all the parts of the boiler are working
properly.
The maintenance checks be carried out and preferably should be recorded on a logbook daily by
the boiler operator.
WARNING:
• DO NOT TAMPER WITH THE SETTINGS OF CONTROLS AND SAFETIES UNNECESSARILY.

IT IS TO BE NOTED THAT IT IS TOTALLY UNSAFE TO SHORT CIRCUIT SAFETIES AND
OPERATE THE BOILER.
• BURNER SETTINGS ARE VERY CRITICAL AND ANY TEMPERING WITHOUT KNLOLEDGE
MAY LEAD TO DISTURBED FIRING CONDITIONS & CAN LEAD TO SEVER BACK FIRE
/ACCIDENTS.
131
Chapter 7
7.1 Maintenance Schedule

Table T-7.1
Half
Maintenance Activity Daily Weekly Monthly Quarterly Yearly
yearly
Water treatment plant check &
*
regenerate if required
Check water treatment
*
chemical stock
Check feed water quality for
*
hardness, pH & Oxygen
Check feed water quality for TDS *
Check Steam pressure Switch
*
operation
Clean Fuel filters & basket filters *

Check Mobrey level controls’
*
For normal pump on –off
operation
Mobrey low safety check *

Boiler water quality check *
Clean front & rear viewing
*
glasses
Clean Burner Nozzle *

Calibrate all pressure gauges *
Calibrate fuel temperature
*
indicator & controllers.
Calibrate the flue gas
*
temperature indicator
Check Hooter operation *

Clean Strainers –feed pump
*
suction
Feed line NRVs check *

Check motor interlocks *
Check the stock of essential
*
spares
132
Chapter 7
Half
yearly
Safety Valves operation * *
Motor Current check
Burner , Feed pumps, Fuel *
Pumps & Ring-main pumps
Cleaning the smoke tubes &
*
smoke boxes
Cleaning of furnace *
Cleaning of boiler smoke tubes *
Dust removal from Elect control
panel *
Clean electrical contactor

contacts *
Check the connections of

Mobrey level controller *
Cleaning Gauge Glass protector

& glasses *
Check front reversal chamber
refractory and repair if required *
Grease all motors’ Bearings *

Clean the burner gas spuds.
For gas fired units *
Check resin quantities in the

water treatment plant *
De-scaling & internal cleaning

of boiler pressure part *
Dismantling, Cleaning & lapping

of all the Valves, NRVs, Safety *
valves, blow-down valve.
133
Chapter 7
Half
yearly
Smoke box Sealing rope
replacement *
Check resin quantities in the
water treatment plant *
De-scaling & internal cleaning
of boiler pressure part *
Removal & replacement of
Removal & replacement of all
Gaskets of valves, mountings & *
fittings, Manholes, hand-holes,
inspection doors.
Offer for the open inspection of

the boiler to the IBR authority *
Re-fixing of all Mountings &

fittings on the boiler *
Box up all the manholes /
hand-holes *
Hydraulic test, up to 1.5 times
the max. working pressure for *
15 minutes (max)
In case of leakages, Stop all

leakages & re- test *
Offer the boiler for the
hydraulic test to IBR authority *
Cleaning of feed water tank *
Ash removal from chimney
base ash opening *
All Insulation repairs of boiler,

steam line etc *
Tighten all foundation bolts *
134
Chapter 7
7.2 Log Book

Record of daily checks and servicing operation as well as other checks and servicing operation
must be kept in an operating log book and signed daily by the responsible operating personal.
It is suggested that these Logbooks are maintained by the users. An hourly record of the
observations of the operational parameters and maintenance instructions are filled in without fail
by the operating personnel of the boiler.
This is to ensure that the deviations, if any, from standard/normal readings, may be noted and
attended to immediately; this can avoid major breakdowns and unwanted stoppage of the plant.
135
Chapter 7
Table T-7.2 LOG BOOK - FOR OIL FIRED UNITS: (Shift Basis)
Fuel pressure
kg/cm2 Feed Water Pump
Boiler water Boiler Extra & Safeties & Consumption
Steam Stack HSD/LDO/FO/LSHS Softener / DM On-Off
Blow low level controls
Time Pressure temp. Regeneration (Mobrey)
Burner Burner down at safety Working
Kg/Cm2 Deg.C. Done At working Water Fuel
Inlet bypass Hardness time check Ok/not ok
pH TDS PH check
PPM
liters Kg.
Remark _________________________________________________________________________________________________
_________________________________________________________________________________________________
Signature of the Boiler operator Date Signature of the Engineer/Shift in charge
136
Chapter 7
Table T-7.3 LOG BOOK - FOR GAS FIRED UNITS: (Shift Basis)
GAS pressure Feed Water Pump Consumption

Boiler water Boiler Extra & Safeties &
Steam Stack Softener / DM On-Off Flow meter readings
Blow low level controls
Time Pressure temp. Regeneration (Mobrey)
Gas Train Burner down at safety Working Water Gas
Kg/Cm2 Deg.C. Done At Hardness working
Inlet Inlet pH TDS PH time check Ok/not ok
PPM check
BAR MBAR Liters Nm3
Remark _________________________________________________________________________________________________
_________________________________________________________________________________________________
Signature of the Boiler operator Date Signature of the Engineer/Shift in charge
137
Chapter 7
7.3 Spare Parts

It is suggested that certain essential spares may be kept in stock to avoid idle time due to
unpredictable breakdowns and non-availability of parts with you or with our dealer/office. It
may take some time for us to arrange for the part /component at site.
If there is any breakdown due to component failure, it is better to replace the defective
component and if possible repair the defective component if repairable, at leisure, as
replacement is faster and easier.
The list of essential parts for SHELLMAX Boilers is given below and can be used for guidance.
Part List, specific to the Model & serial no with part no of each component can be taken up
from nearest office. For the amount of the water conditioning and fuel additive chemicals to be
stored, approach our nearest Dealer /office.
Table T-7.4 SAPRES PART LIST: SHELLMAX BOILER WITHOUT BURNER PARTS
Sr. Component Description Quantity to be stocked
No at by user
a. Air break switches for Mobrey 2

b. Float rod assembly for Mobrey 1
Hooter –control panel 1
Indicating lamp holder 2
Indicating lamps 12
Feed water pump 1
IBR Pressure gauge 10” Dial –for boiler 1
Fusible plug 2
Blow Down valve-IBR 1
Non return valves-feed line-IBR 1
Gauge Glass assembly-IBR 1
Gauge Glass 2
Quick shut off valve size 1
138
Chapter 7
Table T-7.5 SAPRES PART LIST: SHELLMAX BOILER - OERTLI BURNER PARTS
Burner Spares : Oil Fired Burner

Fuel Pressure gauge 1
Burner nozzle -as per fuel consumption in Kg/hr 1
Sequence controller – Siemens 1
Photo resister 1
Sight glass- burner 2
View glass –rear 2
Ignition transformer 1
Burner gun 1
Pressure switch-High pressure cut off 1
Proportional Pressure controller 1
Rectifier 1
Burner diffuser plate 1
Burner solenoid valve 1
Fuel pump 1
Feedback potentiometer 1
Servomotor 1
Electrode assembly 2
Electrode Cap 2
Burner Spares : Gas Fired Burner
Gas pressure gauge: Range 0-10 Bar 1
Gas pressure gauge: range 0-100MBar 1
Main Gas pressure regulator range 1-4 bar 1
Main Gas Burner Solenoid valves 2
Gear Train assembly for GAS Regulation 1
Pilot burner solenoid Valve 1
Pressure switch -Gas pressure High 1
Pressure switch -Gas pressure Low 1
Diffuser Plate 1
Sequence controller 1
U V cell 1
139
Chapter 7
140
Chapter 8
08 TROUBLE SHOOTING
8.0 Trouble Shooting

Some of the common problems & remedial action is as given below :
1. The feed water pump motor does not start in Fill position of the Rotary switch.
In table below some of problems & their possible causes are given. This will be helpful in trouble
shooting, Shellmax boilers & its components.
Problem Possible cause

Temperature controller not working • Wrong connection
• Earthing Improper
• Ambient temperature more than specified
• Supply voltage fluctuation
• Wire cut in between
• Moisture ingress
Sequence controller Not working • No power supply to controller terminal
• Synchronous motor faulty
• Fuse blown
• Safety circuit open
• Not getting required feedbacks
• Ambient temperature more than specified
Blower motor failure • Motor overloaded
• Single phasing
• Starting method incorrect
• Overload relay bypassed
• Voltage & frequency variation more
• Fan impeller jammed / rubbing
RTD not working • Operating under high media temperature
• Soot deposition on sensor
• Continuos vibrations of sensor
• RTD sensor screw getting loose
• Shielded cable not used
• Sensor cable loose / open
141
Chapter 8

Flame sensor not working • Electrical connection mismatch
• Supply at sequence controller terminal not
available
• Sensor mounting not in visible range
• Flame intensity weak
• Shielded cable not used for sensor connection
• Noise pickup due to parallel laying of sensor
cable with power cable
Ignition spark not taking place • Transformer winding open / short
• Supply at sequence controller output terminal
not available
• Output connection loose in transformer
• Higher amount of primary air
• Electrode gap more than specified
• Accumulation of oil / carbon deposit on
electrode
Mobrey air switch not working • Electrical switch not as per connection
• Cable damaged
• Soldering damaged
• SS Float punctured / stuck due to bad water
quality
• Float wrapping paper not removed during
commissioning
• Magnet stuck
Steam pressure switch not working • Frequent pressure fluctuation
• Diaphragm damaged
• Dirt accumulation in pressure switch
• Switch stuck-up
Blowdown valve Stuck or Leaking • Welding bur or foreign material stuck-up
• Valve spindle not rotating
• Oversized gland packing used
• Very high scale in water
Steam safety valve leaking • Deposition on nozzle & disc due to bad water
quality
• Corrosion of nozzle & disc due to bad water
quality
• Foreign particles damaged valve seat
• Water getting accumulated in safety valve
bonnet & discharge
• Blowdown ring setting improper
• High water content in steam
142
Chapter 8

Water level fluctuation • Condensate contaminated
• Feed water pH high
• High total alkalinity / TDS
• Sudden fluctuation in load / Firing
Fuel oil pump pressure fluctuations • Cavitation of pump due to one of the following
reasons ( Filter chocking , water present in fuel
, Air lock in pump suction )
• Pump coupling loose / worn out
• Excessive sludge / impurity in fuel oil
• Viscosity range beyond specification
143
Chapter 8
144
Chapter 9
09 CARE OF IDLE BOILERS
9.0 Care Of Idle Boilers

Boilers used seasonally and idle for long period should be laid up "Dry" or "Wet" during the period
of idling.
9.1 Wet Preservation

If the boiler is to be kept idle for a short period, it should be laid up "Wet" as follows:
i. Fill the boiler completely with water, up to overflow level. By admixing an alkalizing
agent, (Use MAXTREAT 3100/3200) bring the pH value of the boiler water to 9.5 and add
a corresponding quantity of oxygen binding agent. Sodium hydroxide or a
corresponding phosphate, for instance, can be used as the alkalization agent.
Oxygen binding agents are, for instance: Hydrazine, Sodium Sulphite and sodium
bisulphate. Depending on the standstill period, the hydrazine content in the boiler water
should be for instance:
Standstill duration Hydrazine surplus g/m3 N2H4

Up to 1 week 20 to 30
Up to 1 month 50 to 100
Longer 100 to 300
For better mixing, the boiler should be heated briefly after admixing hydrazine, up to
about 85 °C, to drive out the oxygen in it. Take care that no pressure builds up in the
process.
Before renewed commissioning of boiler, the boiler water must be drained off until the
operational water level has been reached, provided the steam is allowed to contain
hydrazine (the steam must not contain hydrazine if it comes into contact, for instance,
with foodstuffs, clothing or dressings). Otherwise, the boiler must be drained and refilled.
Close all valves. In all cases the exhaust gas flaps or gate valves must be kept closed.
ii. Check for any leakage and take samples of water at regular intervals to ensure alkalinity
and Sulphite are maintained.
145
Chapter 9
9.2 Dry Preservation

If the boiler is to be kept idle for long period it should be laid up "Dry" as follows: -
i. Drain the boiler thoroughly, clean it internally and externally both fire and water side and
dry it out.
ii. Place trays of lime inside the boiler shell to absorb any moisture. Then close the door,
manholes, dampers, etc., properly so that no ingress of moisture or air can take place.
iii. Water service tank, pumps, and all piping should also be dried out.
It is essential that the boiler is thoroughly clean while using the wet or dry laying up method. To
prevent corrosion on the gas side of the heating surface, it is recommended that all heating
surfaces are dusted with hydrated magnesia to neutralize any acid remaining on the boiler
heating surfaces.
NOTE :
When working with caustic liquids or chemicals, it is imperative that the relevant accident
prevention regulations are observed and made accessible to the persons carrying out the work.
9.3 Chemical Boiling out

If any oil or grease gets into the boiler inadvertently, it will appear in the form of scum in the
gauge glass. This can be very harmful to the boiler and it should be cleaned as soon as it is
detected. Use of Thermax MAXCLEAN range of chemicals for boiling out should be done strictly
as per the instructions given in Boiling out procedure in this manual under Chapter 3.1
Commissioning.
Procedure for De-scaling
If the boiler water quality is not maintained as per the specifications the de-scaling of the boiler
may be required, to remove the water side deposits. The de-scaling is done by using chemicals.
Thermax chemicals are available to in the name of MAXTREAT CHEMICALS, which are
manufactured specially for the use in boilers without harming the metallic parts of the boiler. The
other commercial chemicals available in the market may cause harmful effect on the boiler
parts & may result into reduced life of the boiler components & pressure parts.
De-scaling is a very critical process & should be carried out by qualified personnel only and
following method to be adopted very carefully.
The procedure given below is for the MAX TREAT DESCALING CHEMICALS; the details of these
chemicals are given in the Section 3 of this manual.
146
Chapter 9
PROCEDURE: FOR CLEANING WATER SIDE DEPOSITS FROM BOILERS USING MAXCLEAN-04, 05 & 06.
The de-scaling method for any boiler depends much upon boiler design and nature of scales.
The general procedure to be followed while de-scaling with maxclean-05 and 06 is given below
for scales having following typical analysis
Silica - 42%
Calcium Oxide - 36%
Magnesium - 13%
Iron & Aluminium - 10%
STEP – 1 : FLUSHING
Allow boiler to cool. Open manholes and flush with plain water to remove loose
sludge/deposits. For complete removal of loose sludge use pressure jets or any similar
mechanical arrangement. At the end flushing loose scales, mud is removed facilitating easy de-
scaling with chemicals. Inspect tubes for complete blocking and try to clean them mechanically
to make passage for circulating de-scaling chemicals.
STEP – 2 : MAXCLEAN-06 TREATMENT
Fill boiler up to normal water level with 5% solution of Maxclean-06. Keep steam valve or safety
valve. Open and heat slowly till boiling. Boiling of water will ensure good circulation of
De-scaling solution, within the boiler. Continue slow boiling for 8 - 12 hours. Make-up with fresh
solution to maintain water loosened sludge accumulated in mud drum. Check concentration of
residual de-scaling using test kit.
Drain the Maxclean-06 solution in separate holding tank for reuse. Flush boiler with plain water
as given in Step-1. Cleaning with pressure jets with remove loosed scales.
STEP – 4 : MAXCLEAN-05 TREATMENT 1
Fill boiler with 5% solution of Maxclean-05. Keep steam valve/safety valve open to vent off
produced gases. Fire the boiler to raise temperature of solution to 60-80oC. Heating in boiler will
ensure circulation of Maxclean-05 solution within boiler. Continue slow heating for 8 hours. Give
blow-down periodically to remove accumulated mud. Make it up with fresh solution to maintain
level in boiler. Check concentration of residual Maxclean-05 every hour using test kit.
147
Chapter 9
Drain Maxclean-05 solution in separate tank for further use RINSE BOILER with fresh water till pH of
rinse water is above 5.0. Use pressure jets, if necessary to remove loose scales.
STEP – 6 : INSPECTION
After thorough flushing as in step-5, inspect boiler tubes and internals. If scales are still found,
repeat Step-2 to Step-6. If boiler is free of scales flush boiler with fresh make up water or
condensate.
STEP – 7 : PASSIVATION
After thorough flushing of boiler with condensate or fresh make-up, fill boiler with make up water.
While filling, add 100 ppm of MAXTREAT-3011 and 100 ppm of MAXTREAT-3100 and caustic to
boost pH of boiler water to 10.5 to 11.5. Boiler may be kept filled up with above solution till it is
commissioned.
STEP – 8 : COMMISSIONING
After passivation as given above for 8 hours, fire boiler slowly. Use normal make-up water and
internal treatment chemicals. Give heavy blow-down till normal conditions are obtained.
NOTE - 1
MAXCLEAN 05 or 06 SOLUTIONS should be circulated in boiler either by firing boiler or by using
external pump. When external pump is used; pass solution from the steam drum and take out
from mud drum.
NOTE - 2
Maxclean-05 and 06 solutions should never be mixed. They are not comparable. Therefore STEP
3 AND STEP 5 SHOULD BE FOLLOWED RELIGIOUSLY.
NOTE - 3
Time required for de-scaling depends much on nature of scales. Test kit will help to adjust time
of de-scaling.
NOTE - 4
Quantity of de-scalant consumed depends on quantity of scales and nature of scales in boiler.
For 1 KG of hardness scales, 1.5 KG of Maxclean-05 is required while 1 Kg of Maxclean-06 is
consumed for 1 Kg. of silica scales.
148
Chapter 9
Preparation Of Solutions:
MAXCLEAN-06
Use Carbon steel or HDPE tank equipped with stirrer or similar mixing arrangement. Take
sufficient quantity of make-up water in this tank to fill the boiler. (Generally 10% excess of hold up
volume of boiler). Add about 5 KGs of Maxclean-06 powder 95 litres of water taken in the tank.
Add power slowly while mixing. Maxclean-06 produce heat while dissolving and therefore,
powder should be added slowly (esp. when HDPE tank is used). Mix well to dissolve.
CAUTION:
Maxclean-06 is highly alkaline in nature. Use hand gloves and goggles while preparing
solution. Normal precaution of handling caustic solutions should be taken while making
Maxclean-06 solution. For further safety information, refer to materials Safety Data.
Maxclean-06 solution can be stored under normal conditions for 1 year and it can be
reused.
MAXCLEAN-05
Use HDPE tank equipped with stirrer or any similar mixing arrangement. Take sufficient quantity
of make up water in this tank to fill the boiler (Generally take 10% excess of hold up volume of
the boiler). Add about 5 KGs of Maxclean-05 per 95 litres of water in tank. Add power slowly
while mixing in the tank. Mix well to dissolve completely. Heat to 60oC for dissolving it quickly.
CAUTION:
Maxclean-05 is highly acidic in nature. Use hand gloves, goggles and masks while
preparing solution. Normal precautions of handling acid solution should be taken while
preparing Maxclean-05 solution, for further information, refer to material Safety Data.
Maxclean-05 solution can be stored in HDPE tank for 30 days under normal storage
conditions and it may be refused.
Please note that de-scaling procedure may be varied to suite boiler design and for ease
of handling. Kindly contact THERMAX for any further queries.
149
Chapter 9
150
Chapter 10
10 ANNEXURES
Contents
1. Basics Of Liquid Fuels & Combustion-
2. Grundfos Feed Water Pump-CR/ CRN
3. Burner Sequence Controller-Landis & Gyr
151
Chapter 10
10.1 Liquid Fuels And Combustion
10.1.1 FUEL FOR BOILER
Shellmax boiler is designed to operate on liquid as well as gaseous fuel. Fuels with a very wide
range of heating value can be used for heating in these boilers. Like water it is extremely
important that the quality of fuel going into the boiler is carefully controlled in order to obtain
good performance out of the boiler. While water quality affects the Boiler performance due to
its effects inside the heating surfaces the fuel quality affects the outside of the heating surfaces.
To ensure the optimum performance we need to know the properties of the fuel and make
necessary adjustments. We shall discuss below some of the important properties of fuels.
10.1.2 COMPOSITION OF FUELS
Most of the fuels comprise of compounds formed out of carbon and hydrogen and in some
cases other elements like sulphur etc. Very often fuels also contain oxygen in the molecules.
Most of the fuels used in Heaters are derived from petroleum. These fuels are very rich in carbon
and hydrogen. The liquid fuels generally have more carbon and less hydrogen when compare -
to gaseous fuels. The carbon content for petroleum based liquid fuels would be generally 82 -
88% and hydrogen content 10 to 14%. Petroleum based gaseous fuels generally have a carbon
content from 78 - 82% and hydrogen content from 13 - 18%. Natural gas has much higher
hydrogen content and much lower carbon content. Depending on the carbon hydrogen ratio
the burning characteristics change. Burners for burning these fuels need to be specially
designed for the purpose. It is also possible to design burners to burn a range of liquid fuels and
also liquid fuels as well as gaseous fuels usually one at a time, depending upon the specific fuel
composition in use it is necessary to adjust the burner. If fuel composition changes after initial -
adjustment it is necessary to readjust the burner to suit the new composition.
There are two popular ways of analyzing fuel composition. One method is to have a complete
chemical analysis of the quantities of various elements present called ultimate analysis. The
other method is to analyze quantities of behavioral groups of components present in the fuel,
called as proximate analysis of fuel.
As the ultimate analysis of the fuel gives the quantities of elements present this information can
be used for theoretical calculations of the air required to burn and the heat out put on burning.
It should be mentioned here that theoretical calculation of heating values may not be exact
due to the difficulties in judging exactly whether some of the combustible atoms are already
linked to oxygen or not.
The component wise analysis is used to judge how the fuel would behave during the burning
process. Typically, the quantity of wax content will indicate probable problems one may
encounter due to wax solidification. Generally, a higher viscosity of petroleum oils at room
temperature would indicate a higher carbon hydrogen ratio giving a higher flame luminosity
giving a higher radiant heat transfer in the flame, at the same time indicating a possibility of
sluggish combustion.
152
Chapter 10
There is a very important value to understand the burning behavior of the fuel called carbon
residue, also sometimes referred to as Conradson carbon. The carbon residue is not normally
reported either in the ultimate analysis or in the component wise analysis unless specifically
asked for. The carbon residue is very difficult to burn and a portion of this residue can be
expected to precipitate as soot unless very special care is taken in the geometry of the
combustion chamber, the temperature of the combustion chamber and the residence time of
burning and such other parameters.
101.3 CALORIFIC VALUE OF FUEL
The calorific value is the quantity of heat the fuel gives out due to combustion. Carbon burns
forming carbon dioxide. Hydrogen burns to form the oxide of hydrogen, which is water. Sulphur,
if present, forms sulphur dioxide and some sulphur trioxide
There are two different ways of evaluating the calorific value of fuel. One value is known as the
gross calorific value (GCV) The GCV is the heat given out due to the combustion of the fuel with
all the water which has been formed having already condensed. In other words, the GCV is the
heat which has been released by the combustion and includes the latent heat given off by the
steam which had formed during the combustion condensing to water later on. It can be clearly
seen that GCV is not available for use while using the fuel in actual practice because the steam
formed does not in practice condense but goes off to the atmosphere through the chimney.
Therefore, GCV is not a useful figure to evaluate the heat obtainable by using the fuel.
However, as GCV is the easier quantity to measure generally after the fuel is tested the calorific
value is reported in terms of GCV.
The useful heat available from the combustion of a fuel is known as the lower calorific value
(LCV). The LCV is the heat given out by the fuel during combustion in actual practice. The
value of LCV is arrived at during testing of the fuel by first obtaining the value of GCV using say a
bomb calorimeter and then deducting 539.6 kcal/kg of steam formed during combustion of a -
dry sample of fuel. Sometimes, calorific value is denoted by NCV (Nominal calorific value).
NCV is the same as LCV. Unit of calorific value is kcal/kg or kcal/Nm3.
10.1.4 PHYSICAL CONDITION OF FUEL
Combustion systems are designed taking into accounts not only the chemical composition or
calorific value but also physical parameters like viscosity, Lubricity etc. For proper atomisation in
a burner, it is necessary to maintain liquid fuels at a viscosity of 10 to 15 centistokes at the burner
tip.
153
Chapter 10
10.1.5 Cleanliness
The most important consideration in the physical condition of the fuel is the cleanliness of the
fuel. Unfortunately, this aspect is very often the most ignored resulting in a very sad state of
affairs with respect to the operational efficiency of the boiler, wear out of critical parts and
unreliable operation. In spite of actual experience of repeated tripping and unreliable
operation of Heaters resulting in production losses there have been many cases where instead
of ensuring cleanliness of fuel, energy has been wasted attempting retuning of burners changing
of electrical circuitry. The foremost priority in boiler operation after ensuring properly treated
feed water supply should be assuring a clean fuel. Cleanliness of the fuel can be assured only if
great care is taken right from the moment the fuel arrives in the plant by filtering at the time of -
taking the oil into the storage tank, further filtering between the storage tank and the day tank,
further filtering between the day tank and the fuel pump, and keeping these filters always clean.
Combustion is generally the oxidation of carbon, hydrogen and sulphur in the fuel. For all
practical purposes oxygen is supplied by providing sufficient atmospheric air. The air delivery is
so adjusted geometrically with respect to fuel delivery to ensure proper mixing. In spite of the
best possible mixing it is necessary to provide more than just sufficient air for the chemical
reaction to ensure complete combustion. This excess air necessarily needs to be kept a
minimum by as efficient a mixing as possible so that the flue gas quantities are kept a minimum
achieving minimum loss of heat through the chimney. The entire expertise of a burner design
revolves around this important concept.
10.1.6 Chemistry of combustion :-
Typical chemical reactions involved are-
C + O2 = CO2 (+ 8050 kcal/kg of carbon)
C + 0.5 O2 = CO (+ 2410 kcal/kg of carbon)
CO + 0.5 O2 = CO2 (+ 2410 kcal/kg of carbon)
H2 + 0.5 O2 = H2O (+ 33865 kcal/kg of H2)
S + O2 = SO2 (+ 2210 kcal/kg of S)
These calculation help estimating stoichiometric air required. Calorific values are estimated in
laboratory. (Some imperial formulae may be used for approximate estimates of cal-values for
different fuels).
Amount of stoichiometric air required is proportional to gross calorific value (GCV).

Approximately 1 kg air is required per 745 kcal of GCV.
In practice, certain amount of excess air has to be supplied in order to compensate for the lack
of contact between fuel and oxygen. This amount will vary from 30 to 80% depending upon fuel
and furnace design. In some cases (e.g. external refractory lined furnaces) further excess air
needs to be supplied to limit furnace temperature below caking/ash softening temperature.
154
Chapter 10
The total amount of air should be judiciously distributed as primary and secondary air. It shall be
noted that secondary air is very effective for combustion of gaseous products (including the CO
generated in the reducing zone of thick bed of low volatile matter fuels like coke). Pressure
required for primary air needs to be just sufficient to push it up to the top of fuel bed, without
pressurising the furnace. Secondary air should be supplied at high pressure through jets, which
will penetrate through the cross section of gas across it.
On complete combustion of solid fuels, amount of CO2 gas generated, on stoichiometric basis
by volume is between 18 to 20% for most of the fuels. However, with practical amount of excess
air, best CO2 could be between 13 to 14%. More than 14% CO2 may be associated with
incomplete combustion and presence of CO in flue gas. If furnaces need extra air for cooling,
the CO2 may reduce to 7 to 10%.
155
GRUNDFOS INSTRUCTIONS
CR, CRI, CRN

Installation and operating instructions
7
5
3
1
Start-up
TM01 1409 4497 TM01 1407 4497 TM01 1405 4497 TM01 1403 4497
8
6
4
2
?
TM01 9988 3600 TM01 1408 4497 TM01 1406 4497 TM01 1404 4497
4.9 Dimensions and weights 6. Electrical connection
Dimensions: See fig. C, page 69. The electrical connection should be carried out by an authorized
Weights: See label on the packing. electrician in accordance with local regulations.
Before removing the terminal box cover and before
4.10 Sound level any removal/dismantling of the pump, make sure that
See fig. D, page 70. the electricity supply has been switched off.
The pump must be connected to an external mains
5. Installation switch with a minimum contact gap of 3 mm in all
poles.
The pump must be secured to a solid foundation by bolts through
the holes in the flange or base plate. The operating voltage and frequency are marked on the motor
When installing the pump, follow the procedure below in order to nameplate. Make sure that the motor is suitable for the electricity
avoid damaging the pump. supply on which it will be used.
Single-phase Grundfos motors incorporate a thermal switch and
Step Action require no additional motor protection.
1 Three-phase motors must be connected to a motor starter.
The terminal box can be turned to four positions, in 90° steps:
Arrows on the pump base
TM02 0013 3800
1. If necessary, remove the coupling guards. Do not remove the

show the direction of flow of coupling.
liquid through the pump. 2. Remove the bolts securing the motor to the pump.
3. Turn the motor to the required position.
4. Replace and tighten the bolts.
2 Page 69 shows:
5. Replace the coupling guards.
• port-to-port lengths,
The electrical connection should be carried out as shown in the
TM00 2256 3393
4xø
• dimensions of the base, diagram inside the terminal box cover.
• pipework connections and
L1 B1
L2 B2 • diameter and position of 6.1 Frequency converter operation
foundation bolts. Motors supplied by Grundfos:
3 The pump can be installed All three-phase motors supplied by Grundfos can be connected to
vertically or horizontally. En- a frequency converter.
TM01 1241 4097
sure that an adequate supply Dependent on the frequency converter type, this may cause in-
of cool air reaches the motor creased acoustic noise from the motor. Furthermore, it may
cooling fan. However, the mo- cause the motor to be exposed to detrimental voltage peaks.
tor must never fall below the
Note: Grundfos motors types MG 71 and MG 80 as well as
horizontal plane.
MG 90 (1.5 kW, 2-pole), all for supply voltages up to and includ-
4 To minimize possible noise ing 440 V (see motor nameplate), must be protected against volt-
from the pump, it is advisable age peaks higher than 650 V (peak value) between the supply
to fit expansion joints either terminals.
side of the pump and anti-vi-
It is recommended to protect all other motors against voltage
bration mountings between
peaks higher than 850 V.
foundation and pump.
Isolating valves should be fit- The above disturbances, i.e. both increased acoustic noise and
ted either side of the pump to detrimental voltage peaks, can be eliminated by fitting an LC filter
avoid draining the system if between the frequency converter and the motor.
the pump needs to be For further information, please contact the frequency converter or
TM02 0116 3800
cleaned, repaired or replaced. motor supplier.

The pump must always be
Other motor makes than those supplied by Grundfos:
protected against backflow by
means of a non-return valve Please contact Grundfos or the motor manufacturer.
(foot valve).
5
Install the pipes so that air

TM02 0114 3800
locks are avoided, especially

on the suction side of the
pump.
6 In the case of installations in

which:
• the discharge pipe slopes
downwards away from the
pump,
• there is a risk of siphon
effect,
TM02 0115 3800
• protection against backflow

of unclean liquids is neces-
sary,
a vacuum valve must be fitted
close to the pump.
7. Start-up 9. Frost protection
Note: Do not start the pump until it has been filled with liquid and Pumps which are not being used during periods of frost should be
vented. If the pump runs dry, the pump bearings and the shaft drained to avoid damage.
seal may be damaged. Drain the pump by loosening the vent screw in the pump head
Pay attention to the direction of the vent hole and and by removing the drain plug from the base.
take care to ensure that the escaping water does not Care must be taken to ensure that the escaping water
cause injury to persons or damage to the motor or does not cause injury to persons or damage to the
other components. motor or other components.
In hot-water installations, special attention should be In hot-water installations, special attention should be
paid to the risk of injury caused by scalding hot water. paid to the risk of injury caused by scalding hot water.
Follow the instructions on page 4. Do not tighten the vent screw and replace the drain plug until the
CR, CRI, CRN 1s to 5: pump is to be used again.
For these pumps, it is advisable to open the bypass valve during CR, CRI, CRN 1s to 5:
start-up. The bypass valve connects the suction and discharge Before replacing the drain plug in the base, screw the bypass
sides of the pump, thus making the filling procedure easier. When valve out against the stop, see fig. 5.
the operation is stable, the bypass valve can be closed.
Fit the drain plug by tightening the large union nut followed by the
When pumping liquids containing air, it is advisable to leave the bypass valve.
bypass valve open if the operating pressure is lower than 6 bar.
If the operating pressure constantly exceeds 6 bar, the bypass 10. Service
valve must be closed. Otherwise the material at the opening will
Note: If a pump has been used for a liquid which is injurious to
be worn because of the high liquid velocity.
health or toxic, the pump will be classified as contaminated.
Fig. 5
If Grundfos is requested to service the pump, Grundfos must be
contacted with details about the pumped liquid, etc. before the
pump is returned for service. Otherwise Grundfos can refuse to
accept the pump for service.
Drain plug
Possible costs of returning the pump are paid by the customer.
Bypass valve
However, any application for service (no matter to whom it may
be made) must include details about the pumped liquid if the
pump has been used for liquids which are injurious to health or
toxic.
10.1 Service kits

Service kits for CR, CRI and CRN, see www.grundfos.com
(WebCAPS), WinCAPS or Service Kit Catalogue.
TM01 1243 4097
8. Maintenance
Before starting work on the pump, make sure that all
power supplies to the pump have been switched off
and that they cannot be accidentally switched on.
Pump bearings and shaft seal are maintenance-free.

If the pump is to be drained for a long period of inactivity, remove
one of the coupling guards to inject a few drops of silicone oil on
the shaft between the pump head and the coupling. This will pre-
vent the shaft seal faces from sticking.
Motor bearings:
Motors which are not fitted with grease nipples are maintenance-
free.
Motors fitted with grease nipples should be lubricated with a high-
temperature lithium-based grease, see the instructions on the fan
cover.
In the case of seasonal operation (motor is idle for more than
6 months of the year), it is recommended to grease the motor
when the pump is taken out of operation.
11. Fault finding chart
Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity sup-
ply has been switched off and that it cannot be accidentally switched on.
Fault Cause Remedy

1. Motor does not run a) Supply failure. Connect the electricity supply.
when started. b) Fuses are blown. Replace fuses.
c) Motor starter overload has tripped out. Reactivate the motor protection.
d) Thermal protection has tripped out. Reactivate the thermal protection.
e) Main contacts in motor starter are not making Replace contacts or magnetic coil.
contact or the coil is faulty.
f) Control circuit is defective. Repair the control circuit.
g) Motor is defective. Replace the motor.
2. Motor starter overload a) One fuse/automatic circuit breaker is blown. Cut in the fuse.
trips out immediately b) Contacts in motor starter overload are faulty. Replace motor starter contacts.
when supply is
c) Cable connection is loose or faulty. Fasten or replace the cable connection.
switched on.
d) Motor winding is defective. Replace the motor.
e) Pump mechanically blocked. Remove the mechanical blocking of the pump.
f) Overload setting is too low. Set the motor starter correctly.
3. Motor starter overload a) Overload setting is too low. Set the motor starter correctly.
trips out occasionally. b) Low voltage at peak times. Check the electricity supply.
4. Motor starter has not a) Check 1 a), b), d), e) and f).
tripped out but the
pump does not run.
5. Pump capacity not a) Pump inlet pressure is too low (cavitation). Check the suction conditions.
constant. b) Suction pipe/pump partly blocked by impurities. Clean the pump or suction pipe.
c) Pump draws in air. Check the suction conditions.
6. Pump runs but gives a) Suction pipe/pump blocked by impurities. Clean the pump or suction pipe.
no water. b) Foot or non-return valve blocked in closed po- Repair the foot or non-return valve.
sition.
c) Leakage in suction pipe. Repair the suction pipe.
d) Air in suction pipe or pump. Check the suction conditions.
e) Motor rotates in the wrong direction. Change the direction of rotation of the motor.
7. Pump runs back- a) Leakage in suction pipe. Repair the suction pipe.
wards when switched b) Foot or non-return valve is defective. Repair the foot or non-return valve.
off.
8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal.
9. Noise. a) Cavitation occurs in the pump. Check the suction conditions.
b) Pump does not rotate freely (frictional resist- Adjust the pump shaft.
ance) because of incorrect pump shaft position. Follow the procedure in fig. F, G or H at the end of
these instructions.
c) Frequency converter operation. See section 6.1 Frequency converter operation.
12. Disposal
Disposal of this product or parts of it must be carried out accord-
ing to the following guidelines:
1. Use the local public or private waste collection service.
2. In case such waste collection service does not exist or cannot
handle the materials used in the product, please deliver the
product or any hazardous materials from it to your nearest
Grundfos company or service workshop.
Subject to alterations.
CR, CRI, CRN 1s, 1, 3 and 5
Fig. F
A B
TM02 0459 4600
TM02 0460 4600

C D
M6 - 13 Nm
M8 - 31 Nm
M10 - 62 Nm
M5 - 2.5 Nm
x
TM02 1051 0501
TM02 1052 0501

0.5x
E
C
A
Fig. G
M8 - 31 Nm
M6 - 13 Nm
M10 - 62 Nm
CR, CRI, CRN 10, 15 and 20
TM02 8542 0404 TM02 7923 4403 TM02 1045 0501
F
D
B
M5 - 2.5 Nm
TM02 8515 0304 TM02 0459 4600 TM02 8500 0304

CR, CRN 32, 45, 64 and 90
Fig. H
1.7 mm
1 2
TM01 2144 3600

B
M10x25 62 Nm (6.2 kpm)
TM01 9878 3300
C
TM01 2146 3600
CR, CRI, CRN 1s, 1, 3 and 5
50a
51
36a
10a
8 9
10 49
64
105 65
4 45
7a
2 2 7 2
100 28 18
23 100 49
28 36
66a 64a
65
7
76a 4a 45
7a 76
60 26 47a
77 77
49
64c
37
66
67
65
5a 45
55
6 6
37
38
35 12 39 25
203
201
6 6 6
38 25
TM02 0455 3403
56 56 56
CR, CRI, CRN 10, 15 and 20
36a 51
62
61
69
10a
8 9 3
10
49
49c
10a
1 8 9 64
10
65
28a 45 4
105
18
2 2 2
100
28 36
23 66a
100 49
7 76a 49c
7 7a 76 64
65
26
45 4
77 77
60
37
80
49
49c
64a
65
45 4a
55
47a
37 64d
6 49
6 49c
38a
64b
25 64c
39 66
38 67
12
35 65
45 44a
203
201
6 6 6 26a
38a
44b
TM02 7383 3403
25
26c
38
26b
56 56 56
CR, CRN 32, 45, 64 and 90
48
49b
49
28a 49c
51
65
26b 45 45a
26c
9
7 8
4
3
47c
47d
7a 47c
1a 47d
26a
48
28
49b
36a 7a
48 49
7 49b 49c
65
7a 49a
58a 49c
105 45 45a
58
36 65 44
66a
76 45 45a
100 2
18 23
100 4a
37
60
47 47b 51
26 47e 66
66b
47a 67
37
55
31
32
6g
21
6
38a
31 38
32
6g
21
38a 6
21 38
38a 203 201 25
TM01 9996 3600
25
38
25
203 201 56
Pos. Description
no.
1 Adapter Zwischen- Bride Flangie Brida Flange do Φλάντζα Adapterflens Mellanfläns Välilaippa Mellemflange
flange flansch d’adaptation adattatrici acoplamiento adaptador προσαρ-
µογής
1a Motor stool Laterne Lanterne Lanterna del Acoplamiento Adaptador do Στήριγµα Lantaarnstuk Mellanstycke Moottorin ja- Mellemstykke
moteur motore motor κινητήρα lusta
2 Pump head Kopfstück Tête de Testa pompa Cabezal Cabeça da Κεφαλή Pompkop Toppstycke Pumppupää Topstykke
pompe bomba bomba αντλίας
3 Chamber, top Oberste Chambre Camera Cámara Câmara Θάλαµος, Bovenste Kammare, Pesä/ylin Kammer,
Kammer supérieure superiore superior superior άνω kamer övre øverste
3a Chamber Kammer ohne Chambre Camera Cámara sin Câmara sem Θάλαµος Kamer zonder Mallankam- Pesä, ilman Kammer uden
without neck Spaltring sans bague senza anillo de junta aro χωρίς spaltring mare utan kaularengasta tætningsring
ring d’étanchéité collarino δακτύλιο tätningsring
λαιµού
4 Chamber Kammer Chambre Camera Cámara Câmara Θάλαµος Kamer Kammare Täydellinen Kammer
complete komplett complète completa completa completa πλήρης compleet komplett pesä komplet
4a Chamber with Kammer mit Chambre Camera con Cámara con Câmara com Θάλαµος µε Kamer met Mellankam- Pesä laakeri- Kammer med
bearing ring Lagerring avec bague cuscinetto anillo cojinete casquilho δακτύλιο lager mare med renkailla lejering
de palier εδράνου lager
5a Chamber Kammer Chambre Camera Cámara Câmara Θάλαµος Kamer Kammare Täydellinen Kammer
complete komplett complète completa completa completa πλήρης compleet komplett pesä komplet
6 Base Fußstück Pied de Base Base Base Βάση Voetstuk Fotstycke Jalkakappale Fodstykke
pompe
6a Stop pin Sperrzapfen Goupille Molla di Pasador tope Pino Πείρος Anti rotatie Stoppsprint Pidätintappi, Rotationslås
d’arrêt arresto συγκράτησης stift lukitustappi
6d Guide plate Führungs- Plaque pour Guida per Placa guía Prato-guia da Πλάκα Geleideplaat Styrplatta till Ohjauslevy Styreplade til
for base platte für pied de basamento para base base οδηγός γιά τη voor voetstuk fotstycke jalustaan fodstykke
Fußstück pompe βάση
6g Bearing ring Lagerring Joint de palier Cuscinetto Anillo cojinete Casquilho ∆ακτύλιος Lager Bottenlager Laakeriren- Lejering
εδράνου gas
7 Coupling Schutzschirm Protège- Giunti di Protector Protecção do Προφυλα- Koppeling be- Kopplings- Kytkimen Skærm
guard accouplement protezione acoplamiento acoplamento κτήρας schermer skärm suoja
συνδέσµου
7a Screw Schraube Vis Vite Tornillo Parafuso Κοχλίας Schroef Skruv Ruuvi Skrue
8 Coupling Kupplung Accouple- Giunto Acoplamiento Acoplamento Σύνδεσµος Koppeling Koppling Täydellinen Kobling
complete komplett ment complet completo completo completo πλήρης compleet komplett kytkin komplet
9 Screw Schraube Vis Vite Tornillo Parafuso Κοχλίας Schroef Skruv Ruuvi Skrue
10 Shaft pin Zylinderstift Goupille Molla albero Pasador eje Pino do veio Πείρος άξονα Stift Cylinderstift Akselitappi Stift
cylindrique
18 Air vent screw Entlüftungs- Vis de purge Vite della Tornillo purga Parafuso de Τάπα Ontluchtings- Luftskruv Ilmausruuvi Luftskrue
schraube ventola aire purga εξαερισµού schroef
19 Pipe plug Stopfen Bouchon Tappo Tapón tubería Bujão da Τάπα σωλήνα Plug Rörpropp Putkitulppa Rørprop
tubagem
21 Plug Stopfen Bouchon Tappo Tapón Bujão da Τάπα Plug Propp Tulppa Prop
tubagem
23 Plug Stopfen Bouchon Tappo Tapón Bujão da Τάπα Plug Propp Tulppa Prop
tubagem
25 Drain plug Entleerungs- Bouchon de Tappo spurgo Tapón purga Bujão de Τάπα Aftapplug Tömnings- Tyhjennys- Tømmeprop
stopfen vidange drenagem αποστράγγι- propp tulppa
σης
26 Staybolt Stehbolzen Goujon Tiranti Espárrago Perno Κοχλίες Trekstag Stödbult Pinnapultti Støttebolt
sujeción συγκράτησης
26a Strap Spannband Tirant d’as- Tirante Tirante Tirante Τιράντα Spanband Spännband Haka (säppi) Spændebånd
semblage
26b Screw Schraube Vis Vite Tornillo Parafuso Κοχλίας Schroef Skruv Ruuvi Skrue
26c Washer Unterleg- Rondelle Rondella Arandela Anilha Ροδέλα Sluitring Bricka Aluslevy Spændeskive
scheibe
32a Washer Unterleg- Rondelle Rondella Arandela Anilha Ροδέλα Sluitring Bricka Aluslevy Spændeskive
scheibe
36 Nut Mutter Ecrou Dado Tuerca Fêmea Περικόχλιο Moer Mutter Mutteri Møtrik
36a Nut Mutter Ecrou Dado Tuerca Fêmea Περικόχλιο Moer Mutter Mutteri Møtrik
37 O-ring/gasket O-Ring/ Joint/bague O ring/ Junta tórica/ O-ring/junta ∆ακτύλιος-Ο/ O-ring O-ring/ O-rengas tii- O-ring/
Dichtung guranizione junta παρέµβυσµα pakking packning viste pakning
38 O-ring O-Ring Joint O ring Junta tórica O-ring ∆ακτύλιος-Ο O-ring O-ring O-rengas O-ring
38a O-ring O-Ring Joint O ring Junta tórica O-ring ∆ακτύλιος-Ο O-ring O-ring O-rengas O-ring
44 Inlet part Einlaufteil Partie Parte interna Parte aspira- Aspiração Πλήρες Inlaatdeel Inloppsdel Täydellinen Indløbsdel
complete komplett aspiration completa ción completa completa εσωτερικό compleet komplett sisäosa komplet
complète µέρος
45 Neck ring Spaltring Bague Collarino Anillo tope Aro ∆ακτύλιος Spaltring Tätningsring Kaularengas Tætningsring
d’étanchéité λαιµού
45a Neck ring Spaltring Bague Colalrino Anillo tope Aro completo ∆ακτύλιος Spaltring Tätningsring, Täydellinen Tætningsring
complete komplett d’étanchéité completo completo λαιµού compleet komplett kaularengas komplet
complète πλήρης
47 Bearing ring Lagerring Bague de Cuscinetto Anillo cojinete Casquilho ∆ακτύλιος Lager Lager Laakeriren- Lejering
palier εδράνου gas
47a Bearing ring, Lagerring, Bague de Cuscinetto Anillo Casquilho ∆ακτύλιος Lager Lagerring, Laakeriren- Lejering,
rotating rotierend palier tour- rotante cojinete rotativo εδράνου roterend roterande gas, pyörivä roterende
nante giratorio στρεφόµενος
47a Bearing with Lager mit Bague de Cuscinetto Cojinete con Casquilho Εδρανο µε Lager met Lager med Ohjainlaakeri Leje med
driver Mitnehmer palier avec con guida engranaje com guia οδηγό meenemer medbringare medbringer
driver
47b Bearing ring Lagerring Bague de Cuscinetto Anillo cojinete Casquilho ∆ακτύλιος Lager Axellager Laakeriren- Lejering
palier εδράνου gas
47c Bush Buchse Douille Boccola Manguito Manga Φωλιά Bus Bussning Holkki Bøsning
47d Retaining ring Haltering Bague de Anello di Anillo cierre Retentor ∆ακτύλιος Borgring Låsbricka Lukitusrengas Låsering
blocage arresto συγκράτησης
47e Retaining ring Haltering Bague de Anello di Anillo cierre Retentor ∆ακτύλιος Borgring Låsbricka Lukitusrengas Låsering
blocage arresto συγκράτησης
48 Split cone nut Mutter für Ecrou de Dado bus- Tuerca Fêmea cónica Περικόχλιο Klembusmoer Mutter för Kartioholkki Møtrik for
Klemm- cône de sola conica casquillo διαιρούµενου klämbussning mutteri klembøsning
buchse serrage cónico κώνου
49 Impeller Laufrad Roue Girante Impulsor Impulsor Πτερωτή Waaier Pumphjul Juoksupyörä Løber
49a Impeller Laufrad Roue Girante Impulsor Impulsor Πτερωτή Waaier Pumphjul Juoksupyörä Løber
Pos. Description
no.
49b Split cone Klemm- Cône de Bussola Casquillo Casquilho ∆ιαιρούµενος Klembus Klämbussning Kartioholkki Klembøsning
buchse serrage conica cónico cónico κώνος
49c Wear ring Verschleiß- Bague Anello di Anillo Aro de ∆ακτύλιος Slijtring Slitring Kulutusren- Slidring
ring d’usure usura desgaste desgaste φθοράς gas
51 Pump shaft Pumpenwelle Arbre de Albero pompa Eje bomba Veio Αξονας Pompas Pumpaxel Pumppuakseli Pumpeaksel
pompe αντλίας
55 Outer sleeve Mantel Chemise Camicia Camisa Camisa Εξωτερικό Mantel Mantel Ulompi Svøb
esterna exterior exterior χιτώνιο vaippa
56 Base plate Grundplatte Plaque de Basamento Placa base Base Πλάκα βάσης Voetplaat Fotstycke Jalustalevy Fodplade
base
57 O-ring O-Ring Joint O ring Junta tórica O-ring ∆ακτύλιος-Ο O-ring O-ring O-rengas O-ring
58 Seal carrier Halter für Toc d’entraî- Porta tenuta Soporte Suporte do Φορέας Houder voor Hållare för Tiivistekanna- Holder for
Wellen- nement cierre empanque στυπιοθλίπτη asafdichting axeltätning tin akseltætning
abdichtung
60 Spring Feder Ressort Molla Muelle Mola Ελατήριο Veer Fjäder Jousi Fjeder
61 Seal driver Mitnehmer Toc d’entrai- Guida guarni- Guía de Batente do Οδηγός Meenemer Medbringare Tiivisteen Medbringer
nement zione cierre espaçador στεγανο- vetotappi
ποιητικού
62 Stop ring Stopring Bague d’arrêt Anello di anillo de tope Mola de en- Τερµατικός Stopring Stoppring Pysäytinren- Stopring
arresto costo δακτύλιος gas
64 Spacing pipe Distanzhülse Douille Tubo Casquillo Espaçador Αποστάτης Afstandsbus Avstånds- Väliholkki Afstands-
d’entretoise distanziale espaciador bussning bøsning
64a Spacing pipe Distanzhülse Douille Tubo Casquillo Espaçador Αποστάτης Afstandsbus Avstånds- Väliholkki Afstands-
d’entretoise distanziale espaciador bussning bøsning
64c Clamp, Spannstück, Pièce de Giunto Casquillo Casquilho Στεφάνη µε Spanstuk, Avstånds- Kiristin, Spænde-
splined Vielnut serrage ranurado escatelado εγκοπές splined bussning rihlattu stykke, spline
(spline)
64d Spacing pipe Distanzhülse Douille Tubo Casquillo Espaçador Αποστάτης Afstandsbus Avstånds- Väliholkki Afstands-
entretoise distanziale espaciador bussning bøsning
65 Neck ring Halter für Support pour Fermo per Retιn anillo Retentor do Στήριγµα Houder voor Hållare för Kaulusren- Holder for
retainer Spaltring bague d’étan- collarino junta aro δακτυλίου spaltring tätningsring kaan pidin tætningsring
chéité λαιµού
66 Washer Unterleg- Rondelle Rondella Arandela Anilha Ροδέλα Sluitring Bricka Aluslevy Spændeskive
scheibe
66a Washer Unterleg- Rondelle Rondella Arandela Anilha Ροδέλα Sluitring Bricka Aluslevy Spændeskive
scheibe
66b Lock washer Sicherungs- Rondelle de Blocco per Arandela Anilha Συγκράτηση Borgring Låsbricka Lukitusalus- Låseskive
blech blocage rondella cierre retentora ροδέλας levy
67 Nut Mutter Ecrou Dado Tuerca Fêmea Περικόχλιο Moer Mutter Mutteri Møtrik
69 Spacing pipe Distanzhülse Douille Tubo Casquillo Espaçador Αποστάτης Afstandsbus Avstånds- Väliholkki Afstands-
entretoise distanziale espaciador bussning bøsning
76 Nameplate Schildersatz Plaque Targhetta Juego placa Chapa de Σετ πινακίδας Typeplaat set Typskylt Arvokilpisarja Skiltesæt
set d’identifica- identificaciσn identificação
tion
100 O-ring O-Ring Joint O ring Junta tσrica O-ring ∆ακτύλιος-Ο O-ring O-ring O-rengas O-ring
105 Shaft seal Wellen- Garniture Tenuta Cierre Empanque Στυπιοθλί- Asafdichting Axeltätning Akselitiiviste Akseltætning
abdichtung mécanique meccanica mecânico πτης
201 Flange Flansch Bride Flangia Brida Flange Φλάντζα Flens Fläns Laippa Flange
203 Retaining ring Haltering Bague de Blocca Anillo cierre Anel retentor ∆ακτύλιος Borgring Låsbricka Lukitusrengas Låsering
blocage flangia συγκράτησης
7 451
ISO 9001
Gas Burner Controls LFL1...
Supplementary data sheet 7712
Gas burner controls for gas, oil or dual-fuel forced draught burners of medium to
high capacity. Multistage or modulating burners in intermittent operation *) with air
pressure for checked supervised air damper control.
The gas burner controls are tested to EN 298 and CE-certified in compliance with
the directives for gas-fired appliances and electromagnetic compatibility.
The LFL1... and this data sheet are intended for use by OEMs that integrate the
burner controls in their products.
*) For safety reasons, at least one controlled shutdown must take place every
24 hours!
Use The burner controls of the LFL1... range are designed for the control and supervision of
forced draught gas burners of both expanding flame and interrupted pilot construction of
medium to high capacity. They are universally applicable and can be used for both
multistage and modulating burners as well as for dual-fuel burners and for burners of
stationary air heaters (WLE to DIN 4794).
The difference between series 01 and 02 lies in the duration of the safety time for the
pilot burner of burners using pilot gas valves.
For atmospheric burners of high capacity, type LFL1.638 is available.
For burner controls used with burners in continuous operation, refer to data sheet
7785, types LGK16... .
Mechanical design The burner controls are of plug-in design. Housing and plug-in baseplate consist of
shock- and heat-resistant black plastic.
The lockout indicator, the fault signal lamp and the reset button are located in the viewing
window of the unit. The burner control is supplied with an exchangeable unit fuse and a
spare fuse.
Landis & Staefa CC1N7451E October 06, 1997 1/13

Functions
With regard to The following LFL1.... features exceed the relevant standards, thus offering a high
standards level of additional safety:
– Detector and extraneous light tests are restarted immediately after the tolerated after-
burn time. This means that open or not fully closed fuel valves initiate a lockout
immediately after this time has elapsed. The tests end only on completion of the pre-
purge time of the next burner startup
– The correct functioning of the flame supervision circuit is automatically checked during
each burner startup sequence
– The control contacts for the fuel release are checked for welding during the post-purge
time
– A built-in unit fuse protects the control contacts against overloads
With regard to the – The units permit burner operation with or without post-purging
control of the burner – Fan motors with a current draw of up to 4 A (starting current 20 A max.) can be directly
connected
– Separate control outputs for OPEN, CLOSE and MIN of the air damper actuator
– Checked air damper control to ensure pre-purging with the nominal amount of air.
Checked positions: CLOSED or MIN (low-flame position) at the start, OPEN at the
beginning, and MIN on completion of the pre-purge time. In case the actuator does not
drive the air damper to the required position, the burner startup sequence will be
interrupted
– Functional test of the air pressure monitor before the startup and supervision of the air
pressure from the beginning of the required pre-purge time until controlled shutdown
occurs
– Separate control output for a pilot gas valve which is closed after the 2nd safety time
has elapsed
– Two control outputs for the release of the 2nd and, if necessary, 3rd output stage (or
load control)
– With burner controls of series 01 and expanding flame, it is possible to increase the
safety time from 2.5 to 5 s by a very simple measure (refer to "Engineering Notes"),
provided the longer safety time complies with the local safety regulations
– When load control is enabled, the control outputs for the air damper actuator are
galvanically separated from the control section of the unit
– Connection facilities for remote lockout warning device, remote reset and remote
emergency shutdown
With regard to flame Methods of flame supervision:

supervision
a) With an ionization current detector electrode, in networks with earthed or unearthed
neutral. For this supervision method, the flame supervision circuit is designed such
that possible disturbances of the ionization current due to the ignition spark normally
cannot have any influence on the establishment of the flame signal. A short-circuit
between detector electrode and burner ground cannot simulate a flame signal
b) With UV detectors of the QRA... range (gas and oil burners).
Refer to data sheet 7712
c) With simultaneous use of ionization current detector electrode and UV detector (e.g.
with interrupted pilot burners or gas-electrically ignited oil burners)
With regard to mounting – Mounting location and position optional (degree of protection IP40)
and electrical
installation
Baseplate – 24 connection terminals

– 2 auxiliary terminals, galvanically separated, with the markings «31» and «32»
– 3 earth terminals in the form of a latch for earthing the burner
– 3 neutral terminals, pre-wired to terminal 2, which is the neutral input
– 14 knockout entries for the cable entry by means of cable glands, 8 of which at the
side and 6 in the bottom of the baseplate
– 6 lateral threaded knockout entries for cable entry glands Pg11
2/13 CC1N7451E October 06, 1997 Landis & Staefa

Connection diagram
A z m a
t7 t16
t10
t11
P
t1
t3´
t12
t3
t2´ t2
t4 1
t4´
t9
t5 2
t5
B
AS C
D t6 t13
A
1 2 21 3 13 12 14 4 5 6 7 16 17 18 19 20 9 11 10 8 22 23 24
LR
+
d1 d2 QRA...
SB bv... W GP
1
SA v a z m
R N N
M
3)
EK2 22 23 24
H t2´, t3´, t4´, only with:
BV1 BV2 BV3 LFL1.335,
M1 M2 Z LFL1.635 and
S LK FE
AL LP LFL1.638
L ZBV BV1 BV2
N
2 3 4 5 7451a02e/0496 6
1 7
Control signals of burner control

Permissible input signals
Required input signals: if these signals are missing at the time marked by symbols or during the
shaded phases, the burner control interrupts the startup sequence or initiates lockout. Legend for the
symbols: see «Lockout indication»
Switches, fuses , earthing, etc., must be in compliance with the local regulations. For the connection of valves and
Engineering notes other components, refer to the diagram provided by the burner manufacturer.
① Phase and neutral may not be interchanged!

Safety limit thermostats (manual reset, e.g. STB) have to be connected in the line.
② Remote reset: when button «EK2» is connected to terminal 3, only remote reset is possible; when
connected to terminal 1, only emergency shutdown is possible.
③ Required switching capacity of the contacts between terminals 12 and 4 as well as between 4 and 14:
depending on the load on terminals 16 ... 19.
④ Air pressure supervision: if the air pressure is not monitored by means of an air pressure monitor «LP»,
terminal 4 must be connected to terminal 12 and terminal 6 to terminal 14. Terminal 13 remains unused!
Control contacts of other devices in the burner installation are to be connected in series as follows:
To terminal 12: contacts which must be closed only during startup (otherwise no start).
To terminal 4 or 5: contacts which must be closed from startup to the controlled shutdown (otherwise no
start or controlled shutdown).
To terminal 14: contacts which must be closed at the latest at the beginning of the pre-ignition time and
which must remain closed until controlled shutdown occurs (otherwise lockout). This is valid for both long
and short pre-ignition.
⑤ • Connection of fuel valves with expanding flame burners. With two-stage burners, BV2 is connected
instead of BV3.
•• Connection of fuel valves with interrupted pilot burners.
The direct connection of a fuel valve to terminal 20 is permitted only in
– installations with a main shutoff valve on the mains side (safety valve) which is controlled by
terminals 18 or 19, and
– if two-stages valves are used, provided they fully close when the 1st stage - which is controlled
by terminal 18 or 19 - is switched off.
⑥ For further examples of air damper control, refer to «Connection examples». In the case of air damper
actuators without limit switch «z» for the CLOSED position of the damper, terminal 11 must be connected
to terminal 10 (otherwise no burner start).
⑦ Simultaneous use of ionization and UV supervision is possible.

Connection diagram
L
LFL1... H
SB
1
AS FE
br1
a b 22 23 24
ar2
ar1 I a XV
a b b
4 12 6 7
QRA...
W +
LP d1 d2
GP
22 23 24
R M1 M2
N
5 13 14 V
FR
fr1 fr3 fr2
a b b a
XI (1) (2)
XIII
b a a b XII NTC
XIV a b
AR IV
a b
VII
3) br2 a b
EK1 VI V III ar3
L1 II X VIII
E M a b a b M
BR b a a b a b SM
A
3 21 2 15 16 17 18 19 20 9 11 10 8
LR
1 SA v a z m
AL Z M LK
3) BV2
EK2 ZBV BV1 BV1 7451a12/0496
H
N BV2
For the connection of the safety valve, refer to the diagram provided by the burner
manufacturer.
Legend a Changeover limit switch for OPEN position m Auxiliary switch for the MIN position of the
for the entire data sheet of air damper air damper
AL Remote lockout warning device (alarm) M... Fan or burner motor
AR Main relay (working relay) with contacts «ar...» NTC NTC resistor
AS Unit fuse QRA... UV detector
BR Lockout relay with contacts «br...» R Control thermostat or pressurestat
BV... Fuel valve RV Continuously adjustable fuel valve
bv... Control contact for the CLOSED position of S Fuse
gas valves SA Air damper actuator
d... Contactor or relay SB Safety limiter (temperature, pressure, etc.)
EK... Lockout reset button SM Synchronous motor of the sequence
FE Ionization current detector electrode mechanism
FR Flame relay with contacts «fr...» v In the actuator: auxiliary changeover
GP Gas pressure monitor switch for the release of fuel according to
H Mains isolator the air damper position
L1 Fault signal lamp V Flame signal amplifier
L3 Operational readiness indication W Limit thermostat or pressure monitor
LK Air damper z In the actuator: limit switch for the
LP Air pressure monitor CLOSED position of the air damper
LR Load controller Z Ignition transformer
ZBV Pilot gas valve
• Valid for expanding flame burners

•• Valid for interrupted pilot burners
(1) Input for the increase in operating voltage for the UV detector (detector test)
(2) Input for forced energizing of the flame relay during functional test of the flame supervision circuit
(contact XIV) and during safety time t2 (contact IV)
3) Do not press EK for more than 10 seconds!

Notes on the
program sequence
Sequence diagram
t2´, t3´, t4´:

These times are valid only for the burner controls of series 01, i.e. LFL1.335, LFL1.635
and LFL1.638.
They do not apply to the units of series 02, as cams X and VIII of these types switch
simultaneously.
Mode of operation The diagrams above show both the connection circuit and the control program of the
sequence mechanism.
A Start command (given by the control thermostat or pressurestat «R» of the installation)
A-B Startup sequence
B-C Burner operation (heat generation according to the control commands of load
controller «LR»)
C Controlled shutdown through «R»
C-D Sequence mechanism runs into start position «A», post-purging
During burner off periods, only control outputs 11 and 12 are under voltage and the air
damper is in its CLOSED position which is determined by limit switch «z» of the damper
actuator. In order to carry out the detector and extraneous light test, the flame supervision
circuit is under voltage, too (terminals 22/23 and 22/24).
Prerequisites for burner – Burner control not interlocked in lockout position

startup – Air damper closed, limit switch «z» for the CLOSED position must supply voltage from
terminal 11 to terminal 8
– The control contacts for the CLOSED position of fuel valves (BV...) or other contacts
between terminal 12 and «LP» with similar control functions must be closed
– The N.C. contact of the air pressure monitor «LP» must be closed (LP test), that is,
terminal 4 must be under voltage
– The contacts of the gas pressure monitor «GP» and of the limit thermostat or pressure
monitor «W» must also be closed

Startup sequence
A Start command by «R»
(«R» closes the control loop between terminals 4 and 5).
The sequence mechanism starts to run. At the same time, the fan motor receives voltage
via terminal 6 (only pre-purging). After t7 has elapsed, the fan motor or the flue gas fan
also receives voltage via terminal 7 (pre- and post-purging).
On completion of t16, the control command to open the air damper is given. During the
actuator's running time, the sequence mechanism stops, as terminal 8 - via which the
sequence mechanism is at first supplied with voltage - does not receive any voltage
during this time. The sequence mechanism continues to run only after the air damper has
fully opened.
t1 Pre-purge time with air damper fully open
During the pre-purge time, the correct functioning of the flame supervision circuit is tested
(de-energizing of flame relay). The burner control goes into lockout position, if the relay
does not function correctly.
Shortly after the beginning of the pre-purge time, the air pressure monitor must change
over from terminal 13 to terminal 14, otherwise the burner control initiates lockout (start of
air pressure check). At the same time, terminal 14 must be under voltage, as the ignition
transformer and the fuel valves are supplied with voltage via this current path of the
circuit.
After completion of the pre-purge time, the burner control drives the air damper via
terminal 10 into the low-flame position which is determined by the changeover point of
the auxiliary switch «m». During the running time, the sequence mechanism stops again.
Shortly after that, the motor of the sequence mechanism is switched onto the control
section of the burner control. That is why position signals to terminal 8 as of now do not
affect the further startup of the burner (and the subsequent burner operation):
t5 Interval. After t5 has elapsed, load controller «LR» is released via terminal 20.
With that, the startup sequence of the burner control ends. The sequence mechanism
switches itself off, either immediately or after some so-called «idle steps»; these are
steps without change of the contact positions, depending on the time variant.
Expanding flame
burners
t3 Pre-ignition time, then release of fuel on terminal 18
t2 Safety time (start load)
On completion of the safety time, a flame signal must be present at input 22 of the flame
signal amplifier. It must be continuously present until controlled shutdown takes place,
otherwise the burner control goes into lockout position and interlocks itself in this position.
t4 Interval. On completion of t4, terminal 19 is under voltage. Thus the fuel valve at auxiliary
switch «v» of the air damper actuator is supplied with voltage.
Interrupted pilot burners
t3 Pre-ignition time, then release of fuel for the pilot burner at terminal 17.
t3´
t2 1st safety time (pilot load)
t2´ On completion of the safety time, a flame signal must be present at input 22 of the flame
signal amplifier. It must be continuously present until controlled shutdown takes place,
otherwise the burner control goes into lockout position and interlocks itself in this position.
t4 Interval up to the release of the fuel valve at terminal 19 for the start load of the main
t4´ burner.
t9 2nd safety time. On completion of the 2nd safety time, the main burner must have been
ignited by the pilot burner, since terminal 17 becomes idle as soon as this time has
elapsed, causing the closure of the pilot gas valve.
B Operating position of burner
B-C Burner operation
During burner operation, the load controller drives the air damper to the nominal load or
low-flame position, depending on the demand for heat. The release of the nominal load is
carried out by auxiliary switch «v» in the air damper actuator.

C Controlled shutdown
During controlled shutdown, the fuel valves are immediately closed. At the same time,
the sequence mechanism starts and programs the
t6 Post-purge time (fan M2 at terminal 7).

Shortly after the start of the post-purge time, terminal 10 receives voltage, so that the air
damper is driven to the MIN position.
The complete closing of the damper starts only shortly before the post-purge time has
elapsed, initiated by the control signal on terminal 11, which also remains under voltage
during the following burner off period.
t13 Permissible after-burn time. During this time, the flame supervision circuit may still
receive a flame signal without initiating burner lockout.
D-A End of control program (start position)

As soon as the sequence mechanism has reset the control contacts into their start
position - on completion of t6 - the detector and extraneous light test starts again. During
the burner off period, a faulty flame signal of a few seconds only initiates lockout. Short
ignition pulses of the UV tube, e.g. caused by cosmic radiation, do not initiate burner
lockout.
Times t2´, t3´ and t4´ are only valid for burner controls of series 01.
Warning notes • In the geographical areas where DIN standards are in use, the installation must
be in compliance with VDE requirements, particularly with the standards DIN /
VDE 0100 and 0722!
• All regulations and standards applicable to the particular application must be
observed!
• Installation and commissioning work must always be carried out by qualified
personnel!
• Condensation and ingress of humidity must be avoided!
• To protect the flame signal amplifier from electric overloads, both ignition and
detector electrode must be located such that the ignition spark cannot arc over
to the detector electrode!
• Ignition cables must always be laid separately, maintaining the greatest
possible distance to the unit and other cables!
• Observe the notes on the laying of detector cables (refer to «Technical data»)!
• The electrical wiring must be made in compliance with national and local
standards and regulations!
• LFL1... are safety devices. It is therefore not permitted to open, interfere with or
modify the units!
• Check wiring carefully before putting the burner control into operation!
• The LFL1... must be completely isolated from the mains before performing any
work on it!
• Check all safety functions when putting the burner control into operation or after
performing service work!
• Ensure protection against electric shock on the unit and on all electrical
connections through appropriate mounting!
• Electromagnetic emissions must be checked from an application point of view!
• When used in connection with QRA..., terminal 22 must be earthed!
• Supervision with both detector electrode and UV detector QRA... is possible, but
for safety reasons, only one flame detector may be active at a time, with the
exception of safety time t9. At the end of the 2nd safety time, one of the
detectors must be inactive, that is, the detected flame must have extinguished,
e.g. by shutting down the pilot valve at terminal 17!
• UV detectors QRA... can be connected in parallel!

Control program In case of any disturbance, the sequence mechanism stops and with it the lockout
under fault indicator. The symbol above the reading mark of the indicator gives the type of
conditions and disturbance:
lock-out indication
No start, e.g. because one contact is not closed (also refer to «Prerequisites for
burner startup»). Lockout during or after control program sequence due to
extraneous light (e.g. non-extinguished flames, leaking fuel valves, defects in the
flame supervision circuit, etc.)
Interruption of startup sequence, because the OPEN signal has not been
delivered to terminal 8 by limit switch «a». Terminals 6, 7 and 14 remain under
voltage until the fault has been corrected!
Lockout, because there is no air pressure indication at the beginning of air

pressure control.
Every air pressure failure after this moment in time leads to lockout, too!
Lockout due to a fault in the flame supervision circuit.
Interruption of startup sequence, because the position signal for the low-flame
position has not been delivered to terminal 8 by auxiliary switch «m». Terminals 6,
7 and 14 remain under voltage until the fault has been corrected!
Lockout, because no flame signal is present after completion of the (1st) safety
time.
Lockout, because no flame signal has been received on completion of the 2nd
safety time (flame signal of the main flame with interrupted pilot burners).
Lockout, because the flame signal has been lost during burner operation.
If lockout occurs at any other moment in time between the start and the pre-ignition which
is not marked by a symbol, this is usually caused by a premature, i.e. faulty flame signal,
e.g. caused by a self-igniting UV tube.
Lockout indication a-b Startup sequence
b-b' «Idle steps»

(without contact confirmation)
b(b')-a Post-purge program
LFL1..., series 01 LFL1..., series 02
• Duration of safety time with expanding flame burners

•• Duration of safety time with interrupted pilot burners
When lockout occurs, the burner control can immediately be reset. After resetting (as
well as after correction of a fault which resulted in a controlled shutdown or after each
mains failure), the sequence mechanism always returns to its start position, whereby only
terminals 7, 9, 10 and 11 receive voltage in accordance with the control program. It is
only then that the burner control begins with a new burner startup.

Connection
examples
Doubling of safety time 16 17 18 19 Only when a burner control of series 01 is used.

with expanding flame Due to these circuit measures (connection of
BV2
burners terminals 17 and 18), the pre-ignition time is
Z BV1 reduced to 50 %.
N
7451a10/1295
Extension of the safety time is permitted only if this is in compliance with the standards of
the respective country.
Burner without air 6 11 10 8 In case of burners without air damper (or with an
damper air damper not controlled and supervised by the
burner control unit), terminal 8 must be connected
M to terminal 6, as otherwise the burner control
N 7451a11/0396 cannot carry out the burner startup.
Two-stage expanding Load control with an ON/OFF controller. The air damper is closed during burner off
flame burner periods.
16 17 18 19 9 20 11 10 8
LR L...
11 7 1 6 5 2 10 8 LR
SA
SA
IV I M II III
BV1/BV2
13 12 N 3 4 9
Z BV1 BV2 7451a03/0396 LK

N
A B C D
T P R
t7 t1 t6
M
M1
~ M2
t3
Z
t2
BV1
t4
R LR t5
100%
M
min.
LK 0...
BV2 t11 t12
t13
FS
7451a06/0396
Control of actuator «SA» according to the single-wire control principle (actuator «SA»:
e.g. type SQN3... according to data sheet 7808). For other connections, refer to
«Connection diagrams».

Modulating expanding Load control with a modulating controller with galvanically separated control contacts for
flame burner OPEN and CLOSED positions.
16 17 18 19 20 9 11 10 8
L...
LR LR
N SA SA RV
a z m BV1
M
Z BV1 RV LK
N
7451a04/1295
A B C D
T
P R
t7 t1 t6
M
~
M1
M2
t3
Z
t2
BV1
t4
R LR
t11 t12 t5
100%
M
min.
LK 0...
RV
t13
FS
7451a07/1295
The air damper is closed during burner off periods. For other connections, refer to
Two-stage interrupted Controlled and supervised by a burner control of series 01.

pilot burner
16 1 7 18 1 9 20 9 11 10 8
L...
LR
LR
ZBV SA v a z m SA
M
BV1/BV2
ZBV
Z BV1 BV2 LK
N 7451a05/0496
A B C D
T
P R
t7 t1 t6
M
M1
~
M2
t3´
Z
t2´
ZBV
t4´ t9
BV1
R LR
t5
M 100%
min.
LK 0...
BV2 t11 t12
t13
FS
7451a08/1295
The air damper is closed during burner off periods. For other connections, refer to

Mains voltage AC 220 V - 15 % ... 240 V + 10 % Required switching capacity of switching devices
Technical data AC 100 V - 15 % ... 110 V + 10% – Between terminals 4 and 5 1 A, AC 250 V
– Between terminals 4 and 12 1 A, AC 250 V
Mains frequency 50 Hz - 6 % ... 60 Hz + 6 % – Between terminals 4 and 14
Power consumption 3 VA depending on load on terminals 16 to 19,
1 A min., AC 250 V
Unit fuse,
built-in T6, 3H 250 V to IEC 127 Permissible mounting position optional
Degree of protection IP40
Unit fuse, external 16 A max., slow
Weight
Radio interference – Burner control approx. 1000 g
protection N to VDE 0875 – Baseplate approx. 165 g
Permissible input current

at terminal 1 5 A to VDE 0660 AC 3
Perm. loading of control

terminals 4 A to VDE 0660 AC 3
Environmental conditions CE conformity

- Transport IEC 721-3-2 According to the directives of the European
Community
Climatic conditions class 2K2 Electromagnetic compatibility EMC
Temperature -50...+70 °C 89/336 EEC incl. 92/31 EEC
Humidity < 95 % r.h. Gas appliance directive 90/396 EEC
Mechanical conditions class 2M2 Emissions EN 50081-1
- Operation IEC 721-3-3 Immunity EN 50082-2
Climatic conditions class 3K5
Temperature -20...+60 °C
Humidity < 95 % r.h.
Condensation, formation of ice and ingress of water are not permitted.
Ionization current supervision Voltage at detector electrode Maximum permissible length of detector cable
– Operation AC 330 V ± 10 % – Normal cable, laid separately ²) 80 m
– Test AC 380 V ± 10 % – Shielded cable, 140 m
e.g. high frequency cable; shielding connected to
Short-circuit current 0.5 mA max. terminal 22
Minimum ionization current required 6 µA
Recom. range of measuring instrument 0 ... 50 µA
UV supervision Supply voltage Weight

– Operation AC 330 V ± 10 % – QRA2 60 g
– Test AC 380 V ± 10 % – QRA10 450 g
Minimum detector current required ³) 70 µA Identification code to EN298:

all types (except LFL1.148) FBLLXN
Maximum detector current
– Operation 680 µA
– Test 1000 µA ¹)
Max. perm. length of detector cable

– Normal cable, laid separately ²) 100 m
– Shielded cable, 200 m
e.g. high frequency cable; shielding connected to
terminal 22
¹) During the pre-purge time with increased test voltage: self-ignition and extraneous light test
²) Laying in multi-core is not permitted
³) For better reading, connect an electrolytic capacitor of 100 µF, DC 10 V, parallel to the measuring
instrument, +pole of the instrument connected to terminal 23

Ordering
Available types Switching times are given in seconds, in the burner startup sequence, valid for a frequency of 50 Hz. In case of 60
Hz, the times are reduced by approx. 20 %.
LFL1.122 ¹) LFL1.133 ¹) LFL1.322 ¹) LFL1.333 ¹) LFL1.335 ¹)

Series 02 Series 02 Series 02 Series 02 Series 01
Preferred types for / in:

Flash Flash D (also A GB
steam steam for WLE) D
generator generator F
t1 10 9 36 31.5 37.5
t2 2 3 2 3 2.5
t2´ − 3 − − 5
t3 4 3 4 6 5
t3´ − − − − 2.5
t4 6 6 10 12 12.5
t4´ − − − − 15
t5 4 3 10 12 12.5
t6 10 14.5 12 18 15
t7 2 3 2 3 2.5
t8 30 29 60 72 78
t9 2 3 2 3 5
t10 6 6 8 12 10
t11 optional
t12 optional
t16 4 3 4 6 5
t13 10 14.5 12 18 15
t20 32 60 − 27 22.5
LFL1.622 ¹) LFL1.635 ¹) LFL1.638

Series 02 Series 01 Series 01
F B Large atmospheric
I NL ²) burner
t1 66 67.5 67.5
t2 2 2.5 2.5
t2´ − 5 5
t3 4 5 5
t3´ − 2.5 2.5
t4 10 12.5 12.5
t4´ − 15 15
t5 10 12.5 12.5
t6 12 15 15
t7 2 2.5 2.5
t8 96 105 105
t9 2 5 7.5
t10 8 10 10
t11 optional
t12 optional
t16 4 5 5
t13 12 15 15
t20 − − −
¹) Available in 100...110 V, please add AC 110 V to type reference when ordering

²) Reversed polarity protection according to Dutch installation standard: AGM30
Legend for the times t1 Pre-purge time with air damper open
t2 Safety time
t2' Safety time or 1st safety time with burners using pilot burners
t3 Pre-ignition time, short (ignition transformer on terminal 16)
t3' Pre-ignition time, long (ignition transformer on terminal 15)
t4 Interval between start of t2 and release of valve at terminal 19
t4' Interval between start of t2' and release of valve at terminal 19
t5 Interval between end of t4 and release of load controller or valve at terminal 20
t6 Post-purge time (with M2)
t7 Interval between start command and voltage on terminal 7 (start delay time for fan motor M2)
t8 Duration of startup (without t11 and t12)
t9 2nd safety time with burners using pilot burners
t10 Interval from startup to beginning of air pressure check without running time of air damper
t11 Running time of air damper into OPEN position
t12 Running time of air damper into low-flame position (MIN)
t13 Permissible after-burn time
t16 Interval until OPEN command for the air damper is given
t20 Interval until self-shutdown of the sequence mechanism after burner startup

7 153
ISO 9001
Oil Burner Controls LAL...
Oil burner controls

• With / without air pressure check for checked air damper control
• Flame supervision with
– photoresistive detectors QRB1...
– blue-flame detectors QRC1..., or
– selenium photocell detectors RAR...
The oil burner controls LAL... are tested and certified to EN 230. They carry the
CE mark in compliance with the directives for electromagnetic compatibility!
The LAL... and this data sheet are intended for use by OEMs which integrate the
burner controls in their products!
Use – Control and supervision of oil atomization burners

– For burners of medium to high capacity
– For intermittent operation (at least one controlled shutdown every 24 hours)
– Universally applicable for multistage or modulating burners
– For burners of stationary air heaters (WLE to DIN 4794)
LAL1... – Yellow- and blue-flame burners without air pressure

supervision
LAL2... – Yellow-flame burners with air pressure supervision
LAL3.25 – For special applications,
e.g. burners of incinerator plants
(refer to «Type summary» and «Notes»)
LAL4... – Yellow- and blue-flame burners with air pressure supervision
For burner controls used with burners in continuous operation, refer to data sheet 7785
(types LOK16...).
Landis & Staefa CC1N7153E June 26, 1998 1/17

Warning notes To avoid injury to persons, damage to property or the environment, the following
warning notes must be observed!
! • LAL... are safety devices. It is therefore not permitted to open, interfere with or
modify the units!
• The unit must be completely isolated from the mains supply before performing any
wiring changes in the connection area of the LAL...!
• Check all safety functions when putting the burner control into operation or after
performing service work!
• Ensure protection against electric shock on the unit itself and on all electrical
connections through appropriate mounting!
• Always press lockout reset button manually, without using any tools or pointed
objects!
Mounting notes • In the geographical areas where DIN standards are in use, the installation must be in
compliance with VDE requirements, particularly with the standards DIN / VDE 0100
and 0722! In all other areas in compliance with national and local standards and
regulations.
• All regulations and standards applicable to the particular application must be
observed!
Installation notes • Installation and commissioning work may only be carried out by qualified personnel!
• Observe the notes on the laying of detector cables (refer to «Technical data»)!
• Ignition cables must always be run separate from the unit and other cables while
observing the greatest possible distances!
• Check wiring carefully before putting the burner control into operation!
2/17 CC1N7153E June 26, 1998 Landis & Staefa

• Electromagnetic emissions must be checked from an application point of view!
Engineering notes
• Switches, fuses, earthing, etc., must be installed in compliance with local regulations!
• Valves and other components must be connected as specified in the documentation
provided by the burner manufacturer!
22 24
+
R A R ...
LAL2
1 2 21 3 13 12 14 4 5 6 7 15 16 17 18 19 20 9 11 10 8 22 23 24
1(3) LR B
Q R B 1 ...
SB AL W
EK2 z
LP R v a M m
SA
H
M1 M2 Z BV1 BV2
L
N LK
1 2 7 1 5 3 a 03 /049 8 3 4 5 6 7 8 9 10
① Live and neutral may not be Connect safety limit thermostat in the line
interchanged! – Manual reset (e.g. «SB»)
② Remote reset When connecting button «EK2» from terminal 21 to
– terminal 3, only remote reset
– terminal 1, remote reset and remote emergency shutdown
③ With LAL...:
Required switching capacity of switching devices connected between
terminals 4 and 5 max. AC 1 A
With LAL2... / LAL 3... / LAL 4...:
Required switching capacity – of switching devices connected between
terminal 12 and «LP» max. AC 1 A
– of «LP» max. AC 5 A
④ Control contacts of other devices in the burner plant must be connected as follows (when using series
connection):
To terminal 4 or 5 Contacts which must be closed from startup to controlled shutdown
⇒ Otherwise no start or shutdown
To terminal 12 Contacts which must only be closed on startup
(not with LAL1...) ⇒ Otherwise no startup
To terminal 14 Contacts which must be closed no later than at the beginning of «t3» or
(not with LAL1...) «t3´», and which must remain closed until controlled shutdown occurs
⇒ Otherwise lockout
⑤ Maximum amperage Refer to «Technical data»
⑥ «Z» connected to terminal 15 «t3´» and «t3n»
⑦ Connection of «BV...» to Refer to «Application examples»
terminal 20
⑧ When using a burner without air damper, or with an air damper not controlled and supervised by the LAL...,
terminal 8 must be connected to terminal 6!
⑨ Wire link «B» When wire link «B» is fitted, the LAL... initiates lockout if flame failure occurs
(clearly marked on the during operation.
underside of the LAL... ) For repetition of the startup sequence, wire link «B» on the plug-in section of
the LAL... must be cut away; just cutting is not permitted!
⑩ For permissible length and laying of detector lines, refer to «Flame supervision»

Mechanical design
LAL... – Plug-in design
– Exchangeable unit fuse (incl. spare fuse)
LAL3.25 Differences to LAL1... / LAL2... / LAL4...
– Extraneous light does not trigger lockout
- during burner off times
- during the pre-purge time
– Extraneous light prevents burner startup
Housing – Made of impact-proof and heat-resistant black plastic
– Lockout reset button with viewing window, located behind it are:
- The lockout warning lamp
- The lockout indicator
- coupled with the program spindle
- visible in the transparent lockout reset button
- uses easy-to-remember symbols to indicate the type of fault and the point in time
lockout occurred
Base – Base and plug-in section of the LAL... are designed such that only burner controls of
the LAL... type can be plugged in
– With 24 connection terminals
– With auxiliary terminals «31» and «32»
– With 3 earth terminals in the form of a lug for earthing the burner
– With 3 neutral terminals
- prewired to terminal 2
– With 14 knockout holes for the cable entry by means of cable glands
- 8 at the side
- 6 in the bottom of the base
– With 6 lateral knockout holes (threaded) for cable entry glands Pg11
Type summary Switching times are given in the burner startup sequence, valid for 50 Hz mains frequency. At 60 Hz, the
switching times are about 20 % shorter.
Flash steam generators Universal application Medium and heavy oil

burners
Flame supervision with QRB1... or QRC1... for blue- LAL1.25
flame burners LAL4.25A27
Flame supervision with QRB1... or RAR... LAL2.14 LAL2.25 LAL2.65
Possibility of air pressure supervision
Possibility of semi-automatic startup
Same as LAL2.25 with the following exception: Special application,
extraneous light does not cause burner lockout, but e.g. incinerator plants
prevents burner startup LAL3.25
t1 10 s 22.5 s 67.5 s
t2 4s 5s 5s
t3 2s 2.5 s 2.5 s
t3´ from start ¹) from start ¹) from start ¹)
t3n 10 s 15 s 15 s
t4 8s 7.5 s 7.5 s
t5 4s 7.5 s 7.5 s
t6 10 s 15 s 15 s
t7 2s 2.5 s 2.5 s
t8 30 s 47.5 s 92.5 s
t10 6s 10 s 10 s
t11 optional optional optional
t12 optional optional optional
t13 10 s 15 s 15 s
t16 4s 5s 5s
t20 32 s 35 s 12.5 s
¹) With air pressure supervision: from the time the air pressure signal is received

Technical data Operating voltage AC 230 V -15 / +10 % Power consumption AC 3.5 VA
With LAL2... also AC 100 V -15 %...AC 110 V +10 % Mounting position optional
Degree of protection IP 40
Mains frequency 50 Hz -6 %...60 Hz +6 %
Unit fuse (built-in) T6,3H250V to IEC 127 Permissible input current

at terminal 1 AC 5 A continuously
Prefuse (external) max. 10 A peaks of max. 20 A
Weight Permissible amperage

- Burner control approx. 1000 g at control terminals 3, 6, 7, 9...11, 15...20
- Base approx. 165 g 4 A continuously
peaks up to 20 A
QRB1... refer to data sheet 7714 total max. AC 5 A
QRC1... refer to data sheet 7716
RAR... refer to data sheet 7713 Required switching capacity of switching devices
- Connected between terminals 4 and 5 AC 1 A
peaks of 20 A
Environmental conditions CE conformity

Transport IEC 721-3-2 According to the directives of the European Union
Climatic conditions class 2K3 Electromagnetic compatibility EMC
Temperature range -50...+60 °C 89 / 336 EMC incl. 92 / 31 EEC
Humidity < 95 % r.h. Low voltage directive 73 / 23 EEC
Mechanical conditions class 2M2
Operation IEC 721-3-3
Climatic conditions class 3K5
Temperature range -20...+60 °C
Humidity < 95 % r.h.
Mechanical conditions class 3M2
Condensation, formation of ice and ingress of
!
water are not permitted!

Function
Two-stage expanding flame burner Modulating expanding flame burner
A B C D A B C D
TP R TP R
t7 t1 t6 t7 t1 t6
M1 M1
M M
~ M2 ~ M2
t3 t3n t3
Z Z
t3" TSA TSA
BV1 BV1
t4 t4
R LR R LR
t16 t5
t11 t12 t5
100%
M 100%
M
min.
LK min.
0... LK
0...
BV2
t11 t12
t13 RV
FS t13
7 15 3a09/0498
FS
7 153 a10/0498
Legend BV... Fuel valve M... Fan or burner motor

FS Flame signal amplifier R Control thermostat or pressurestat
LK Air damper RV Modulating fuel valve
LR Load controller Z Ignition transformer
General The following features of the LAL... exceed the standards, thus offering a high level of
additional safety:
– Detector and extraneous light test are restarted immediately on completion of the
after-burn time «t13».
This means that open or not fully closed valves immediately initiate lockout at the
end of «t13».
The test ends only on completion of «t1» of the next startup sequence
– The correct functioning of the flame supervision circuit is automatically checked
during each burner startup sequence
– The control contacts for the release of fuel are checked for welding during «t6»
– A built-in unit fuse protects the control contacts against overloading
Control of burner – Burner operation with or without post-purging

– Fan motors with an amperage up to 4 A can be connected directly
⇒Starting current max. 20 A
– Separate control outputs for
- pre-ignition from start command
- post-ignition until shortly before the burner startup sequence is completed
- short pre-ignition with post-ignition up to the end of «TSA»
– Separate control outputs for the positioning directions OPEN, CLOSE and MIN of the
actuator
– Checked air damper operation to ensure pre-purging with the nominal amount of air.
Checked positions:
- CLOSED or MIN on startup ⇒ Low flame position
- OPEN at the beginning, and
- MIN on completion of «t1»
If the actuator does not drive the air damper to the required position, the burner
startup sequence will be stopped
– Two control outputs for the release of the second and third output stage, or for load
control
– When load control is enabled, the control outputs for the actuator will be galvanically
separated from the unit's control section
– Connection facilities for:
- a remote lockout warning device
- remote reset
- remote emergency shutdown
– In addition, with LAL2... / LAL3... / LAL4...:
- possibility of air pressure supervision with functional test of the air pressure monitor on
startup
- possibility of semi-automatic burner startup

Flame supervision LAL...
With a photoresistive detector QRB1.... or, optionally,
LAL1... / LAL4...
With a blue-flame detector QRC1... for the supervision of blue-burning oil burners
LAL2... / LAL3...
With a selenium photocell detector RAR... ⇒ Active detector
– Detector and extraneous light test are carried out automatically during the burner off
times and the pre-purge time «t1»
– If loss of flame occurs during operation, the burner control initiates lockout
– If automatic repetition of the startup sequence is required, the clearly marked wire link
on the plug-in section of the LAL... must be cut away
⇒ Start repetition
LAL1... with LAL2... / LAL3... with LAL4... with
QRB1... QRC1... QRB1... RAR... QRB1... QRC1...
Min. detector current required at AC 230 V 95 µA 80 µA 8 µA 6.5 µA 95 µA 80 µA
Max. detector current required without flame 12 µA 12 µA 0.8 µA 0.7 µA 12 µA 12 µA
Max. detector current that can occur 160 µA 130 µA 35 µA 30 µA 160 µA 130 µA
Instrument's + pole to term. 23 to term. 23 to term. to term. to term. 23 to term. 23
22 22
Length of detector line
In the same cable as the control lines max. 30 m --- not perm. --- max. 30 m ---
Separate cable in the cable duct RAR7...: ---
max. 1000 m --- 20 m 30 m max. 1000 m
Three-wire cable --- max. 1 m --- --- --- max. 1 m
Two-wire cable for the detector line (bl, sw); separate --- max. 20 m --- --- --- max. 20 m
single-wire cable for the line (br)
Shielded cable (e.g. RG62, shielding insulated) --- --- 200 m RAR8...: --- ---
100 m
Shielding --- --- to term. --- --- ---
23
LA L 1... LA L1 ... LA L2 ... LA L 2...

22 23 LA L 4... 22 23 1 LA L4 ... 22 23 LA L3 ... 22 24 LA L 3...
7 1 5 3v0 1/0 4 .9 8 bl sw br 7 1 5 3 v0 5 /0 4 9 8 7 1 5 3 v0 2 /0 4 9 8 7 1 53 v03 /04 9 8
+ + + +
µA DC µA DC µA DC µA DC
Q R B 1... Q R B 1 ... R A R ... +
Q R C 1...
Prerequisites for – If the required input signals are not present,

operation - the burner control interrupts the startup sequence at the points marked by symbols
- the LAL...initiates lockout where this is required by safety regulations
⇒ Refer to diagram
– The symbols used are identical with those on the burner control's lockout indicator
Prerequisites for burner – Burner control not interlocked in lockout position
startup – Sequence switch in start position
⇒ With LAL1..., voltage present at terminals 4 and 11
⇒ With LAL2... / LAL3... / LAL4..., voltage present at terminals 11 and 12
– Air damper closed
– Limit switch «z» for the CLOSED position must feed voltage from terminal 11 to
terminal 8
– The contact of the limit thermostat or pressure monitor «W» as well as the contacts of
any other switching devices in the control loop between terminals 4 and 5 must be
closed
⇒ E.g. a control contact for the oil pre-heater temperature
Other prerequisites for With the exception of LAL1...
burner startup – Control contacts between terminal 12 and «LP» must be closed!
– Normally closed contact of the air pressure monitor must be closed ⇒ «LP» test

Startup sequence A Start command by «R»
⇒ «R» closes the start control loop between terminals 4 and 5
– The sequence switch starts to run
⇒ Only pre-purging:
Fan motor connected to terminal 6 immediately receives voltage
⇒ Pre- and post-purging:
Fan motor or flue gas fan connected to terminal 7 receives voltage on completion of «t7»
– On completion of «t16», the control command for opening the air damper is given via
terminal 9
– Terminal 8 receives no voltage during the positioning time
– The sequence switch continues to run only after the air damper has fully opened
t1 Pre-purge time with air damper fully open
– During «t1», the correct functioning of the flame supervision circuit is checked
– The burner control goes to lockout if correct functioning is not ensured
With LAL2... / LAL3... / LAL4...
Shortly after the beginning of «t1», the air pressure monitor must change over from
terminal 13 to terminal 14.
⇒ Otherwise, the burner control will initiate lockout
⇒ Start of air pressure check
TSA Ignition safety time
On completion of «TSA», a flame signal must be present at terminal 22. It must always
be available until controlled shutdown occurs.
⇒ Otherwise, the burner control will initiate lockout and lock itself in the lockout position
t3 Short pre-ignition time
«Z» must be connected to terminal 16, release of fuel via terminal 18.
t3´ Long pre-ignition time
«Z» connected to terminal 15.
With LAL1...
«Z» is switched on when the start command is given.
With LAL2... / LAL3... / LAL4...
«Z» is switched on only when «LP» changes over.
⇒ No later than at the end of «t10»
– On completion of «t1», the LAL... via terminal 10 drives the air damper to the low
flame position
⇒ The low flame position is determined by the changeover point of auxiliary switch
«m» in the actuator
– During the positioning time, the sequence switch does not move
⇒ Until terminal 8 receives voltage via «m»
– The sequence switch motor is connected to the control section of the LAL...
⇒ Positioning signals fed to terminal 8 have no influence now on the further startup
sequence and the subsequent burner operation
t3n Post-ignition time
– «Z» must be connected to terminal 15
– With short pre-ignition, «Z» remains switched on until «TSA» has elapsed
⇒ Connection to terminal 16
t4 Interval «BV1-BV2» or «BV1-LR»
– On completion of «t4», voltage is present at terminal 19
– The voltage is required to supply power to «BV2» connected to auxiliary switch «v» in
the actuator
t5 Interval
– On completion of «t5», terminal 20 receives voltage.
At the same time, control outputs 9 to 11 and input 8 are galvanically separated from
the LAL...'s control section
⇒ The LAL... is now protected against reverse voltages from the load control circuit
– With the release of «LR» at terminal 20, the start-up sequence of the burner control ends
– After a few idle steps (steps without contact position changes), the sequence switch
switches itself off

B Operating position of the burner
B-C Burner operation

– During burner operation, «LR» drives the air damper to the nominal load or low flame
position, depending on heat demand
– Release of the nominal load is given by auxiliary switch «v»in the actuator
– In the event of loss of flame during operation, the LAL... initiates lockout
– For automatic repetition of the startup sequence, the clearly marked wire link
«B» on the plug-in section of the LAL... must be cut away
C Controlled shutdown
In the case of a controlled shutdown, the «BV...» will immediately be closed. At the
same time, the sequence switch is started to program «t6».
C-D Sequence switch travels to the start position «A»
t6 Post-purge time
– Fan «M2» connected to terminal 7
– Shortly after the start of «t6», terminal 10 receives voltage
⇒ Air damper is driven to the MIN position
– Complete closing of the air damper starts only shortly before «t6» has elapsed
⇒ Initiated by the control signal at terminal 11
– During the following burner off time, terminal 11 remains under voltage
t13 Permissible after-burn time

During «t13», the flame signal input may still receive a flame signal
⇒ No lockout
D-A End of control program

⇒ Start position
As soon as the sequence switch has reached the start position, having thereby switched
itself off, the detector and extraneous light test will start again.
During burner off times, the flame supervision circuit is under voltage.
When the start position is reached:

With LAL1...: a voltage signal is fed to terminal 4
With LAL2... / LAL3... / LAL4...: a voltage signal is fed to terminal 12

Control program under
fault conditions and
lockout indication
Whenever a fault occurs, the sequence switch stops and with it the lockout indicator.
The symbol above the reading mark of the indicator gives the type of fault:
No start • One of the contacts has not Also refer to «Prerequisites for burner startup»
closed
• Extraneous light Lockout during or after completion of the control program
Examples:
– Flame not extinguished
– Leaking fuel valves
– Faulty flame supervision circuit
Interruption of startup sequence • OPEN signal of changeover limit switch «a» has not been delivered to terminal 8
• Terminals 6, 7 and 15 remain under voltage until fault has been corrected
• Does not apply to LAL1...
P Lockout No air pressure indication at the
beginning of the air pressure check
• Air pressure failure Does not apply to LAL1...
Lockout after air pressure check • Defect in the flame supervision circuit, faulty flame signal,
extraneous light
Interruption of startup sequence • Position signal of auxiliary switch «m» for the low flame
position has not been delivered to terminal 8
• Terminals 6, 7 and 15 remain under voltage until fault has
been corrected
•
1 Lockout No flame signal present on completion of the safety time
•
I Lockout Flame signal has been lost during operation
Lockout indicator
LAL1... LAL2... / LAL3... / LAL4...
a-b Startup sequence

b-b´ Idle steps (without contact confirmation)
b(b´)-a Post-purge program
• Burner control can be reset immediately after a lockout
! – Do not press the lockout reset button for more than 10 seconds!
• First, the sequence switch always travels to the start position

- after resetting
- after rectification of a fault which had led to a shutdown
- after each power failure
During this period of time, voltage is only fed to terminals 7, 9, 10 and 11
• Then, the LAL... programs a new burner startup

Connection
diagrams
LAL1...
A z ma
t16
t7
t11
t3 ´
t1
t12
T S A t3
t4
1
t3 n
AS
t5
B
C
t1 3
t6
D
1 A
2 21 3 4 5 6 7 15 16 17 18 19 20 9 11 10 8 22 23
1(3) LR B
Q R B 1 ...
SB AL W
EK2 a m
R SA v M z
H
M1 M2 Z BV1 BV2
S
LK
L
N 22 23 1
bl sw br
7 1 5 3 a 0 1 /0 3 9 8 Q R C 1 ...
For variants, refer to «Connection examples»
LAL2... / LAL3...
A z ma
t16
t1 0
t7
t11
P
t1
t12
t3 ´
T S A t3
t4
1
t3 n
t5
B
C
AS
t1 3
t6
D
1 2 21 3 A 13 12 14 4 5 6 7 15 16 17 18 19 20 9 11 10 8 22 23 24
1(3) LR B
Q R B 1 ...
SB AL W
EK2 R a z m
LP SA v M
H
M1 M2 Z BV1 BV2 22 24
S
+
L 7 1 5 3 a 0 2 /0 4 9 8 R A R ...
N LK
For variants, refer to « Connection examples »
LAL4...
A z ma
t16
t1 0
t7
t11
P
t1
t12
t3 ´
T S A t3
t4
1
t3 n
t5
B
C
AS
t1 3
t6
D
1 2 21 3 A 13 12 14 4 5 6 7 15 16 17 18 19 20 9 11 10 8 22 23 24
1(3) LR B
Q R B 1 ...
SB AL W
EK2 R a z m
LP SA v M
H
M1 M2 Z BV1 BV2
S
LK
L 7 1 5 3 a 0 4 /0 4 9 8
22 23 1
N
bl sw br
Q R C 1 ...
For variants, refer to « Connection examples »

C o ntrol o u tpu t
Sequence diagram A B C D a t term in al:
t6
t11 t1 t12
a 4 12 *
I b t7 7
t4
a 19
II b 16
a 10
III b 9
t3
IV 15
t3" t3 n
a 9
V b 11
t1 6 t5
VI 20
a
V II b 8
t20
a 17
V III b
IX t2
a 18
X b
a
XI b
a
X II b *
t10* t13
a
X III b
a
X IV b
t8
71 5 3d 01E /019 7
P o sitio ns of th e locko ut in dicator
P* 1
Legend a Changeover limit switch for air damper's QRC1... Blue-flame detector
OPEN position
AL Remote lockout indicator (alarm) QRB1... Photoresistive detector
AS Unit fuse RAR... Selenium photocell detector
B Wire link S Fuse
bl blue SA Air damper actuator
br brown sw black
EK... Lockout reset button v In the actuator: auxiliary changeover switch for
position-dependent release of fuel
H Mains isolator W Control thermostat or pressurestat
LP Air pressure monitor z In the actuator: limit switch for air damper's
CLOSED position
m Auxiliary changeover switch for air
damper's MIN position
Control signals delivered by LAL... Permitted input signals
Required input signals:
If these signals are not present during or

, the burner control will stop the
startup sequence and initiate lockout
TSA Ignition safety time t7 Interval between start command and

voltage at terminal 7 (start delay time for
«M2»)
t1 Pre-purge time with air damper open t8 Duration of startup sequence (excluding
«t11» and «t12»)
t3 Pre-ignition time, short («Z» connected to t10 Only with LAL2... / LAL3... / LAL4...: interval
terminal 16) from startup to beginning of air pressure check
t3´ Pre-ignition time, long («Z» connected to t11 Air damper running time to OPEN position
terminal 15)
t3n Post-ignition time («Z» connected to t12 Air damper running time to low flame
terminal 15) position (MIN)
t4 Interval between voltage at terminals 18 t13 Permissible after-burn time
and 19 («BV1-BV2»)
t5 Interval between voltage at terminals 19 t16 Interval to the OPEN command for the air
and 20 («BV2» load controller) damper
t6 Post-purge time (with «M2») t20 Not with all LAL...: for self-shutdown of
sequence switch
* These data do not apply to LAL1...

Connection
diagrams
LAL1...
L S Q R C 1 ...
H
bl sw br
SB
22 23 1
1
AS
b r1
a b
I
Q R B 1 ...
a b
ar1 a r2 22 23 24
4 6 7 V
W
FR
M1 M2
R a b
B N
X IV
5 a b
fr1 fr2
V II
a b a b
IX
a r3
XI X III X II IV II X V III V VI III

b a a b b aa b a b a b a b
EK1* AR
SM
b r2
L1 M M
E
BR
A
20
3 21 2 15 16 18 17 19 9 11 1 0 8
1 (3 ) LR
SA
H
AL v a
M
z m
LK
EK2*
Z BV1 BV2
N 7 1 5 3 a 0 7 /0 4 9 6
LAL2... / LAL3... L
H
SB
R A R ...
1 +
22 23 24
AS
br1
a b I Q R B 1 ...
a b
ar1 ar2 22 23 24
4 12 6 7 V
W
FR
M1 M2
B R LP a b
N
XIV
5 13 14 fr2 a b
fr1 VII
b a NTC a b
a b
IX XII
ar3
XI XIII IV II X VIII V VI III
AR
EK1*
SM
br2 M
L1
E M
BR A
20
3 21 2 15 16 1 8 17 19 9 LR
11 1 0 8
1 (3)
SA
H a z m
AL v M LK
EK2*
Z BV1 BV2
N 7153a08/0598

LAL4...
L
H
Q R C 1 ...
SB
1 bl sw br
AS
22 23 1
br1
a b I Q R B 1 ...
a b
ar1 ar2 22 23 24
4 12 6 7 V
W
FR
M1 M2
B R LP a b
N
XIV
5 13 14 fr2 a b
fr1 VII
a b b a a b
IX XII
ar3
XI XIII IV II X VIII V VI III
AR
EK1*
SM
br2 M
L1
E M
BR A
20
3 21 2 15 16 1 8 17 19 9 LR
11 1 0 8
1 (3 )
SA
H a z m
AL v
M LK
EK2*
Z BV1 B V2
N 7153a17/0498
! Do not press the lockout reset button for more than 10 seconds!
Legend AR Load relay with contacts «ar...» NTC Resistor (negative temperature coefficient)
BR Lockout relay with contacts «br...» SM Synchronous motor of sequence switch
FR Flame relay with contacts «fr...» V Flame signal amplifier
L... Lockout warning lamp Pre- and post-ignition when «Z» is

connected to terminal 15

Connection examples
Connection of actuators without 19 20 9 11 10 8 «z» adjusted to air volume for low

changeover limit switch for the LR flame operation
CLOSED position
SA v a z
M LK
BV2
N
7 1 53 a 1 1 /0 4 9 8
Control of actuator during operation 18 19 17 9 20 11 10 8 6 For signal path, refer to «Connection

by control signals fed to terminal 17 LR diagrams»
7 1 5 3 a1 2 /0 4 9 8
BV1 BV2 LK
N
Control of «BV...» via terminal 20 19 20 9 11 10 8 6 The relay is not required if «BV3»

connected to terminal 20 is
7 1 5 3 a 1 4 /0 4 9 8 hydraulically series-connected with
BV2 BV3
N «BV2».
«BV2» is controlled by terminal 18 or
terminal 19.
⇒ Burner without air damper or with
an air damper not controlled by
the LAL...
Wiring required with LAL2... for 7 If an auxiliary contact «d1 / d2» of

13 12 14 4 5 6
operation without air pressure the fan contactor is included in the
supervision R circuit as shown in the diagram,
ignition and release of fuel are
W
possible only when the contact is
d 1 /d 2 closed.
M
N 7 1 5 3 a 1 5 /0 4 9 8
Semi-automatic startup 3 12 13 14 4 5 The burner is switched on manually

AL I W 0 by pressing button «I».
Then, LAL... programs startup and
L3
LP flame supervision.
N Burner shutdown is also manual by
7 1 53 a 1 6 /0 4 9 8
pressing button «0», or automatically
when limit thermostat or pressure
monitor «W» responds.
«L3» indicates when the burner is
ready for startup. It extinguishes
shortly after the burner is started up.
For other connections, refer to
«Connection diagrams ».

Two-stage expanding flame burner
L... Load control with an on / off controller.

LR
During burner off times, the air damper is closed.
SA
BV1 BV2
1 5 (t3´/t3 n )
1 6 (t3) 17 18 19 9 20 11 10 8
LR
11 7 1 6 5 2 10 8
SA
IV I II III
M
13 12 N 3 4 9
Z BV1 BV2 7 1 53 a 0 5 /1 1 9 5 LK
N
A B C D
TP R Control of actuator based on single-wire control.
t7 t1 t6 ⇒ Actuator «SA» type SQN...,
M1
M
~ M2 refer to data sheet 7808.
t3 t3n
Z For other connections, refer to «Connection
BV1
t3 ´ TSA diagrams»
t4
R LR
t16 t5
100%
M Pre- and post-ignition when ignition
min.
LK
0... transformer is connected to terminal 15
BV2
t11 t12
t13
FS
7 1 5 3 a 0 9/0 4 9 8
Modulating expanding flame burner
L...
Load control with a modulating controller with
LR galvanically separated control contacts for OPEN and
SA RV CLOSED positions.
BV1
16 17 18 19 20 9 11 10 8
LR
N
SA
a z m
RV M
Z BV1 LK
N
7153a 06/119 5
A B C D
TP R
During burner off times, the air damper is closed.
t7 t1 t6 When using actuators without changeover limit switch
M1
M
~ M2 «z» for the CLOSED position, terminals 10 and 11 must
t3
Z
be interconnected.
TSA For other connections, refer to «Connection diagrams».
BV1
t4
R LR
t11 t12 t5
100%
M
LK min.
0...
RV
t13
FS
7 1 53 a 1 0/0 4 98

Dimensions Dimensions in mm
LAL... with base

AGM410490500
1,5
123
25 25
6
1 8,9
15,5
7,5 5
7
15 15 15
71 53m 02/039 6
2 7 ,5 2 7 ,5
37
103
7,5
10 3
40 1 8,5 13 ,5 5 ,7
Base AGM410490500 5 ,2 x6 ,7
13 14 15 16 17 18 19 20 21 22 23 24
12
51,5
7 ,5 18 ,9
5 ,7
11
40
10
9
1 2,8
1
8
31
7
15
4 ,4
6
26,8
5
51,5
4
25
N 1,5
3
32
2
1
7 1 5 3m 0 1 /0 3 96
5 ,2 5 ,2 x6 ,7
5 ,7 12,8 40
51,5 51,5
 1998 Landis & Staefa Produktion (Deutschland) GmbH

Dimensions LFL1... with baseplate AGM410490550
1,5
123
25 25
6
18,9
15,5
7,5 5 7
15 15 15
7451m02/0296
27,5 27,5
37
103
7,5
103
Baseplate AGM410490550
5,2x6,7 40 18,5 13,5 5,7
13 14 15 16 17 18 19 20 21 22 23 24
12
51,5 7,5 18,9 5,7
11
40
10
9
12,8
8 1
31
7
4,4 15
6
26,8
5
51,5 4
N 1,5 25
3
2
32
1
5,2 5,2x6,7
5,7 12,8 40
51,5 51,5 7454m01/0296
 1997 Landis & Staefa Produktion (Deutschland) GmbH

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SHELLMAX – PACKAGED BOILERS

Capacities -1 TPH to 10TPH

Thermax has an extensive international marketing network. Headquartered in Pune (Western

Cooling & Heating Division:

Cooling & Heating Division: Heating Group (C&H-Heating)

Products and Services

The product technology facilitates use of wide range of fuels viz.,

 Light & Heavy Oil

 Cool Low and high Calorific values,

Non conventional / agro based fuels

 De-oiled cake etc.

Agro products Packaging

Bottling & beverages Drugs & pharmaceuticals

Breweries & distilleries Plywood

Chemical & petrochemicals Rubber

Engineering Edible oil / solvent extraction

Food & dairy Textile / Synthetic fibers

‘If you need the heat, we have the source’.

Chapter 3: Instrumentation, controls & Safeties

Chapter 4: Input Requirement

Chapter 5: Commissioning Process

Chapter 9: Care of Idle Boilers

Chapter 10: Annexure

 It is expected that the personal involved in Installation, Operation & Maintenance

 No amount of written communication can replace intelligent thinking & reasoning.

Figure F-1. 1 : Shellmax Boiler

1.0 SHELLMAX BOILER – SM-DL Series

THREE FLUE PASS DESIGN:

INTERNAL REVERSAL CHAMBER

SINGLE OR DOUBLE FLUE

INDIAN BOILER ACT (IBR)

Figure F-1. 2 : Sectional View of Shellmax Boiler

1.2 PRODUCT FEATURES

Figure F-1. 3 : Corrugated Furnace

1.3 Major Components of the Boiler:

1.3.1 Feed Water Pump:

Each pump is of adequate capacity and head to meet the boiler

The pumps are vertical, multistage, centrifugal types. Electric motor is

1.3.2 ELECTRICAL CONTROL PANEL:

The electrical control panel supplied along with

The control panel is Mounted installed on Boiler.

Figure F-1. 6 : Monobloc Oilon Burner

1.3.4 OPTIONAL ACCESSORIES

Economiser is supplied for SM50DL onwards.

Figure F-1. 7 : General Arrangement for Economiser

Figure F-1. 8 : Sectional View of Economiser

Figure F-1. 9 : Internal Super Heater Arrangement

Super Heater Construction

In SHELLMAX the superheating is achieved by incorporating a convective bank between

External Super heater

Figure F-1.11 : External Super Heater

TECH. SPECIFICATIONS SHELLMAX 10.54 kg/cm2(g)

BoilerType Three pass wet back smoke tube boiler

Design Code IBR 1950 (With latest amendment)

Thermal Efficiency on NCV % 89 +/-2% (as per BS 845 Part -1 )

Type LDO / HSD

NCV of Light oil kcal/kg 10200(Min)

BURNER Oilon burner

Type Mono - bloc

Light Up By High Voltage Spark

Modulation type Step(Two stage) Stepless

Motor connection DOL

FEED WATER PUMP

Light & Heavy Oil

Cool Low and high Calorific values,

De-oiled cake etc.

It is expected that the personal involved in Installation, Operation & Maintenance

No amount of written communication can replace intelligent thinking & reasoning.