Ref No COC! 902/04 [RATINGS (F&A 100°C): Trova SOkg-v0 6800 ksh (10 bets Se ah, Bow oad Hi STANDARD WORKING PRESSURES: 4? 25% rid 10.4 QA {DESIG AViLMBIF LP “00 A) «Total package ircorsonites cerraustion: squapiment, eC wale Us lurkey 2oerhowse svapis gugseviemceaearnoteaen chet . * * etigendes Lares spon NG. of 39828 ler ie COCHRAN BOILERS LIMITED (Cedlnar Sales ea bans unto Ro ewe 0COCHRAN BORDERER PACKAGE STEAM BOILER (40.34.BAR G) ie Tr ian ime 2 tania FES bio ul Jor a os TH Ds To) DM a Met TIT SIF MS 8 Re mI Ie UP ei WE Ga 4G KO "SG san ae 1 7 Bo ee Tan on oe (iA wn 7H 8m Tes aw Ne GT WERE TREE ss an iE TE is Doan EE me Ae Tn ee Ie “Ta HO IeO ac ar far ns Tem TR Tio Ta Hen ad By 0 HN 3a Sw Bio a8 GE He) woe Pow TOR is Za Dap 190 DE Coe GRE TS an eT AA Ia ac 1 90 a0 Sareea oe ne SE Ea DO EE Se ise al ian Ban RAD 30 a 1a a ee eee hon Rn dae ie 1e oe ew dees a BD Mensptala iim oF oF Ce ue ) a 2H & % HM eS a nes Frat rp ei OS 3 bE ss 8 Bw BB OF zu nan & Riceopmay w 3e as Fe SS Ra tw oi me wo POTS TE Ie Ras aoa ata Se GeraniniGs) wh 19107 a BF tha Ae Hea ne iad a HE Dw mes ise Baeroagainay ew 08 Tu dS TSS Da Toke GGFeNOML Thee 15 TAS RE Sun 914 Sap ae ate 2H BAD 40D 4g BRE BM fe nm 1990 1899 sac ami ehver Wit WIS) 16 1 TW GS as a AS wos aes as a SUIS io 2 2 SS UGA SVE OO TF OOS Notes | Oi1Fus Consurion bysed un Chis 0-65 2968 NLCc35863 Ut ( 5422 ATL) 2 Gas Fiel Ceneurpton based or Gm HCVOARZE Wr (935 TUF) 3 Al Cimersers cn tight rx eaproote only tasta of aor erry pressure of 13 Bar 2 4 fue Corsurpns base ar ool working presse ot IC 34a COCHRAN BOILERS LIMITED Newale non, Anan, Bumifeire DGI2 SQU, Seatare ‘Wepre: O14Sl 20211 Bae +51 317219 @LREAL.G) fe O146! 70551! Aesaenrenacy nett clhesrerinatggen ‘tbicreraskpech gel ie rarer iro ie orem teenth Tein porary ec ereINTRODUCTION iv BOILER SPECIFICATION Your Boiler Serial Number is......25f%2 Maximum Continuous Rating.......4535 KGIHR........ Design Saturation Temperature:..18800. Working Pressure!...esene 2104 BAR ccssseunen Design Pressure: 11 BARA seen Hydraulic Test Pressure: 16.5 BAR... 10.9 BAR.. Safety Valve Setting: Electrical Supply:.. -.-380¥ 3PH 50HZ..... Controt Cirouit...... we R2OV. ceo Date of Manufacture:... 1996 vecessee Date of Hydraulic Test:. 1996... Design Codes: BS2799.... Drawings: GENERAL ARRANGEMENT AND NU-WAY ELECTRICALS Other Information: ..ssesseeeesseen BLA L4-0965' GENERAL DESCRIPTION OF BOILER DESCRIPTION FAX LID 3.0 AUG 2003 By. The COCHRAN BORDERER is a package unit covering a range of evaporaions. The boiler is a three pass reverse flame wet back design. The hot flue gases pass down the oylindrical intemal furnace (first pass), reflect off a wetor cooled rea’ end plate back along the furnace (second pass), then through 2 nest of straight small bore smoke tubes (third pass), before leaving the boiler via the flue gas outlet at the rear of the boiler. The required number of stay tubes and stay bars are fitted in all boilers. The smoke tubes are usually fitted with combustion gas furbutators. All stay tubes are welded into both tube plates. Plain tubes are welded into the front tube plate and are expanded into the rear tube plate. ” The boiler is of welded construction throughout and Is designed to British Stancard Specifications BS865 and/or BS2790 and AOTC Rutes. It is X-rayed as required for Class 1 Fusion Welded Pressure Vessels. The shell [s insulated with high quality insulation and in tum is completely encased with sheeting to provide a clean, easily maintained finish, Intemat access is through an ellipticat headhole or manhole with a removable door, which Is provided on top of the boller. ‘The hinge mounted front door gives clear access to the furnace ard tube nests. Rear mounted ifoff doors provide access to the rear of the tube nests. The combination of front and rear access doors. provide maximum tube exposure and optimum working: area, thus cutting inspection and leaning time to a minimum. A muddcor is positioned at the base of the rear tube plate. All pads and standpipes are welded to the shell for attachment of mountings and controls. An electrically driven, automatically-controlled:water feed pump with integral pipework is secured to a base plate on the. side of the. boiler sheeting, “The boler is suitable for either oll or gas-Tring and can be fitted with cil, gas or dual fuel bumers. GENERAL OPERATION OF BOILER NOTE Nurnbers in parentheses in the text refer to ilems shown on Figure At. The boiler is supplied with water by a feed pump (8). Water enters the boller through a feed check valve. When the water reaches normal water level, which is approximately the middle of the water gauge glasses (11), the feed pump is stopped by the dual controt (3), 264-1096a DESCRIPTION The burner (4) is bolted to the hinged front door. Air required for combustion is provided by a forced draught fan which is integral with the busner unit. PLEASE REFER TO DIAGRAM FIGURE A-l : TYPICAL BOILER ARRANGEMENT AS SHOWN ON PAGE NUMBER An12. The burner fires down the centre of the fumace. The hot combustion gases reverse back, travelling along the periphery of the furnace tube to the front chamber which is pull into the ‘ront door, The gases tur in the front chamber anc travel through a nest of smoke tubes, which are pitched circumferentially around the furnace, :0 the tear chamber. The smoke tubes are fitted with removable combustion gas turbulaters, which assist in the efficient transfer of heat. From the rear charbar the gacos pass out cf the boiler through the flue gas exit (6) to the chimney. As the steam pressure rises, the pressure in the boiler is shown. by the pressure gauge, When the pressure is auficlently high, the main stop valve (6) can be ‘pened to ellow stoam to pass to the process of heating system. When steam leaves the boiler, the wafer level will drop until it reaches 2 point approximately 12.5 mm (14) below the normal level. The dual control wili start the feed pump and more water will be fed into the boiler. Boilers with on/off burners are fitted with one pressure switch. This pressure switch acts ae a pressure limit control, which. controls the on/off operation of the bumer. Beiters with high/low bumers or with modulating burners are fitted with two prassure: switches, One acts as a pressure limit contral, the other is a pressure cortroller. The presauro controller will be a hichilow ofessurestat in the case of highfow burners and a modulating pressuretrol in the case of modulating bumers, which controls the firing rate of the bummer. PLEASE REFER TO DIAGRAM FIGURE A-2. SECTIONAL VIEW SHOWING GAS FLOW AS SHOWN ON PAGE NUMBER A-13. When the boiler pressure reaches the maximum required, the fimit preseurestat stilts down the burner. The burner wil restart aufomatically when the pressure falls toa preset point below the maximum. Should the limit prossurastat fail to stop the bumer, the safety valve (2) wil it and the excess pressure wil escape fo atmosphere, thus preventing any further rise In boiler pressure. CAUTION ‘The setting of the safety valve is checked by the valve supplier prior to despatch. If necassaty the valve stiould be adjusted during Pemimissioning. ‘The set prasslire should net be ‘altered except by © suitably qualified person, who is also able to fully assess the consequences of carrying out such an alteration Dah A1008io DESCRIPTION A4 i The safety valve is provided with easing gear for test purposes and supplied with a padiock to prevent unauthorised interference. The key should be retained in a secure place under the supervision of a responsible person. A steam accumulation test at the maximum evaporative capacity, with the stop valve closed, should be performed In the presenes of the inspecting authority before the boiler is put into operation. if for any reason water is not supplied to the boiler and the water level falls to a point approximately 50 mm (2") below the nonmal level, the dual control will sip the burner and activate the low water alarm. Provided the water feval is restored before reaching the extra low (lowest) water level, the alarm will stop and the burner will restart automatically. . iF, however, the water level continues to fell unit it reaches a point approximately 76 mm (3"} below the norma’ lavel, the over-riding control (4) will activate the extra low (lowest) water alarm, rendering the bummer in 2 ‘ock-out condition. ‘The bumer will not siart until the normal water level has been restored and the reset switch has been operated fo cancel the lock-out condition. If it is found necessary to let water out of the boiler, this can be done by opening the blowdown valve (7) at the rear of the boller. MOUNTINGS AND FITTINGS BURNER Your COCHRAN Borderer Steam Boller (s fitted with a specially designed fully matched burner (1), which has been selected to ensure maximum fuel utilisation with controf systems fo match your particular load:pattem-and.aperating conditions. A description of the Sumer fited to your COCHRAN boiler can be found in Section B of this manual. CONTROL PANEL ‘the standard Borderer:is: supplied with all external electrical components pre-wired to a centrol panel (S) which is normally mounted on the side of the boiler. Cocasionally all the electrical components associated with tho bumor may be mounted in 6 separalé bumer control panel, which may be mounted on the burner. Reference should also be made to Section B of this manual ‘Addlional feattztes may have been specified by the alient, e.g. modulating or sealing dampers and therefore the final electrical connections must be made at site: For delails of these, refer to the particular bolier wiring diagram. 2d 1206,a DESCRIPTION 5, The client is normally required to ‘supply and fit a 3 phace 4 wire supply to the isolator vathin the control panel, however the boiler may have heen supplied su table for other electrical configurations. ‘The panel also contains the following tems: Sequence Timer ‘ For regulation and flame supervision of the burner. Starters For forced draught fan/oil pump moter and feed pump metor. Fuses, Relays and Switches For contro! functions Indicator |_ights/Atarms For normal ang fault conditions CONTROL PANEL FASCIA A typical control panol fascia (10) on the COCHRAN Borderer Steam Eolfer wil contain the following lights'and switches, dependent on the rating of the boiler and type of bumer: Normal firing light This ig illuminated vetien normal firing conditions exist. Lock-out light This is illuminated when flame-tailure or second low water conditions heve ocoutred, On some boiler ratings the lockout light also o's as a RESET pushbutton. ‘The lamp when pressed will reset the control panel after lockout, Low water fight This is illuminated when the water level-drops:to‘the first ow water level, An alarm: will sound and the burner will shut-down::.The burnerswill restart:automnatically on restoration of the correct water level. Extra low water light This is illuminated if the water level falls to the second low water level, Bath low water lights would 6e illuminated, an alarm is sounded and the burner proceads fo lockout, The burner wil require to be manually reset after the water level is restored. . Mute alarm/run switch This is a two position switch, During riormial operation this ewitch would remain in the RUN position, only turning to MUTE ALARM to silence the alarm. 2oa1008DESCRIPTION AS Fault switch This is a spring loaded alarm switch which is fitted to some boilers as an alternative fo the Mute alarm/run switch and the press-to-eset lockoul light. This switch performs the same functions, i.e. stepping the alerm bell when rotated through 30° anti-clockwigo, or will reset the control panel after lockout when rotated through 30° clockwise. It wil always return to the vertical position immediately after rotation. Feed Pump Switch The weter feed pump switch has thrae positions, HAND/OFFIALTO. When placed in the HAND position, it will keep the pump running continuously, When placed in the OFF position, it will stop the pump running, When placed in the AUTO postion, it allows the pump te start and stop under the control of the dual control. Burner Switch (High'Low Burners only) This has three positions, OFF/LOW/AUTO. When placed in the OFF position the burner motor will not run. When placed in the LOW position, the burner wil only operate on low fire, When placed in the AUTO position, the firing rate of the burner wil bs controlled by the steam load demand. NOTE In elther the LOW er AUTO position, the bumer will start and stop under the ccntrot of the preseure limit stat. Burner On/Off Switch (On/Off and Modulating Burners) . When this switch'is placed in the OFF position, the bumer.will not fire. In the. ON position, the bummer firing sequence will be initiatad. Modulation Hand/Auto Switch (Modulating Burners only) When placed in the HAND position, any desired rate of firing can be obtained by manual operation cf the hand potentiometer. In the AUTO position, the burner will modulate automatically to meat load cemands Firing Rate Hand Potentiometer (Modulating Burners only) This item is only operational when the Hand/auto modulation switch is in the LAND position. Therdial is rotated to instease or decrease the firing rate as required BOILER STOP VALVE The boiler stop valve is fitted as an isolating valve between the boiler shell ard the pipework to the process or heating units. Screw fit stop valves should nevar be used to control or throttle the steam flow as erosion of the disc and seat will result. Valves are designed for specific duties and conditions of service. It is importart that a valve !s net subjected te conditions outwith the design epecification. 25A41985A DESCRIPTION AT NOTE Steam is compressible, A reduction of steam pressure results in an increase in steam volume, Therefore a valve designed fo pass a weight of steam at a pressure of say 17 bar (246 psi) can only pase a smell part of this weight at 5 ber (72 si), due to the inereased volume af steam. The valves ucod on steam boilers are designed for specific pressures and temperatures and to meet the requirements of the Factores Act and British Standards. When two o more bollers are connected.to a common steam.main, eech boiler rust be fitied with a screw lift stop valve ‘and @ screw lift stop and check valve, capable of being locked in the closed position. Alternatively, a. screw lift stop valve capable of being locked in the closed position end a separate check valve may be fitted. This arrangement of valves is necessary to comply with the Factories Ack, sahien requires all boiler valves, Including the stop valve, to bo checked periodically serefore It imust be possible to completely isolate the bolter and its stop valve from the rest of the plant. tts recommended that the boller stop valve be closed each time the boiler is shut ween at tha end of each working day of at weekends. “This will reduce the sting imposed by the variations of pressure and temperature and increase the overall aticiency. . BOILER SAFETY VALVE The boiler safety valve-ensures that the boiler cannet build up .excessive steam pressure, should the boiler limit control fail. The-type of safety valve fitted tc your COCHRAN Borderer Steam Boiler is defined:by tho British:Standards-as a high lift ‘type. ‘The-safety velve settings heve been’ adjusted prior tothe -boller leaving our feotory. A pisto on the safety valve specifies the operating conditions for which the valve ‘nas supplied: Once sel, the valve setting must rot be tampered with. 10 prevent, this, the padiock keys-should be kept In a gafe place under the supervision of a responsible person. COMBINED FEED CHECK AND SHUT-OFF VALVE - ‘The combined feed check and ghutoit valve assernbly Is filled betweon the water feed pump and the boiler shell, The assembly oomprises of a rightangle stp valve ped 4 spring-loaded nor-refum valve. When the feed pump is working, the non: aura selva is opened by the flow of feed water. When the water flow stops oF 8 Beak pressure Is produced, the spsing-loaded valve ‘automaticaly closes. This valve - Rall algo prevent flooding of the boiler, when the beiler fe ehuk-cown uncer pressure and allowed to cool. 241995DESCRIPTION MT NOTE Steam 's compressible. A reduction of steam pressure resuits in an increase In steam volume. Therefore a valve designed to pass a weight of steam at a pressure of say 17 bar (246 psi) can only pees 2 small part of this weight at 5 bar (72 psi), due to the Increased volume of steam. The valves used on steam boilers are designed for specific pressures and temperatures and to meet the requirements of the Factories Act and British Standards. When two or more boilers are connected to a common.sisam main, each pollet Must be fiied wth a sorew fit slop'valve and a sorew-lift stop and cheok velve, Capable of being locked in the closed position. Akernatively,-a screw tit stop valve Capable of being locked in the closed position and a separate check valve may 38 fited This errangement of valves is necessary to comply with the Factories Act, wefich requires all boiler valve, including the siop valve, te be checked perlodtcally. Rorofore it must be possible 1a completely isolale the boiler and its stop valve from the rest of the plant. Ii recommended that the boiler stop valve be closed each time the boiler is shut down at the end of each working day or at weekends. This will reduce the strains imposed by the vatlations of pressure and temperature and increase the overall efficiency. BOILER SAFETY VALVE The-boiler safety valve ensures that the boller cannot build up excessive stoam pressure, should the boller limit control fal. Tho type of safety valve fitted your COCHRAN Borderer Stoam Boiler is:defined:.by:the British Standards as a high lift ‘ype. Tho safety valve settings have been ‘adjusted prior to:the:boller leaving our factory A pate on the safety valve specifies the operating conditions for which the valve ‘wae supplied: Ones set, the valve setting must not be tampered with. “To prevent his, the padlock keye:should be kopt in a safe place under the supervisicn of a responsible person. COMBINED FEED CHECK AND SHUT-OFF VALVE ‘The combined feed check and shut-off valve assembly is fitted between the waler feed pump and the boiler shell, ‘The assembly comprises of a right-angle stop valve iad f spring-loaded non-return valve, When the feed pump is werking, the nor: rerum valve fs opened by the flow of feed water. When the water flow stoos or 8 buck pressure is produced, the springoaded valve automatically closes. hs valve Rill algo prevent flooding of the boiler, when the boiler is shut-down under pressure and allowed to cool. 2544-1096a DESCRIPTION BOILER BLOWDOWN VALVE The boiler blowdown valve ie fitted to the lowest pari of the boiler shell. The valve is used for blowing cown the boiler while it is under steam pressure to remove suspended solid matter from the boifer. Other uses are the draining of the coc! boiler and maintaining the correct water level when starting the boiler from cold, Blowdown valves are fitted with an operating key which can only be *emoved when the valve Is in the closed position, This device is a safety lock which must nat be interfered with PRESSURE CONTROLS PRESSURE LIMIT CONTROL Your COGHRAN Borderer Steam Soiler is fitted with a pressure limit control. This control breaks and makes automatically as the pressure rises and fails. When the: boiler pressure reaches the: maximum .pressure allowed ‘the limit pressurestat shuts dawn the burner. When the boiler pressure falls to a prese: point below the maximum pressure allowed, the limit pressurestat will cause the bumer to restart automatically. NOTE It is: recommended that where possible the differential pressure between cutin-and cut-out should be kept to less than 20% of the normal operating prassure. In the unlikely event of the. limit pressuréstatifailing-to:shut-dewn.the burner, the boiler safety valve will lit-and the excess:pressure.wil:escape-tovatmosphere, thus preventing any further rise in boiler pressure, PRESSURE CONTROLLER “The pressure Controlier is fitted to boilers requiring high/low or modulating operation. Boilers can-be “ited with elther-a controlling high/low. pressuréstal or. a.modulating pressuretrol, The controlling high/low pressurestat controls the firing rate of the burner from high fo low fire, The modulating pressuretrol measures variations in the boiler pressure, vihich proportionately changes the position. of the modulating motor controlling the burner, to increasé or cecrease the quantity of fuel and air to meet load-demands, 2604-1006a DESCRIPTION AS ) WATER LEVEL CONTROLS Your COCHRAN Eorderer Steam Boiler is fitted with boiler water level controls which are mounted directly onto the boller shell. Two controls are filled fo the bolier. One operates the water feed pump and shuts down the bumer at the firet low water level, The second control operates as an independent over-riding control, which activates the extra low (lowest) water alarm., rendering the burner in a locc-out. condition: FUNCTIONS OF OVER-RIDING CONTROL a) Activates the extra low (lowest) water level alarm. b) Renders the burner in a lock-out condition :¢) Optional plgh water alarm can be fitted. FUNCTIONS OF DUAL CONTROL 2) Operates feed pump on/aft. b) Activates the low water alarm. ©) Shuts humer down on first low water. WATER FEED PUMP The water feed pump supplies the boiler with water. When the feed pump is -operating normally under automatic control, it willbe switched ON or OFF according to the signal given by the dual control. WATER GAUGE ASSEMBLIES The water gauge assemblies provide a visual indication of the level of the water within the boiler. CAUTION At no fime.vhen the .bollet is ynder ‘pressure should the’ water gauge protection glasses'be removed. The wator gauge assemblies should be blown dawn daily or every shift. Regular shecks on the integrity of the assemblies Is recommended. 2eAS1E9SDESCRIPTION REFRACTORIES NOTE ‘The location of the refractories is shown on Figure A-3. The only refractory insulation used In the-boller Is the lining of the front door. The type of refractory insulation used is a ceramic fibre blanket, which provides vighly efficient insulation and protection to the boiler door and front chamber transfer area. The user however, should be aware that the surface of the blanket can be easily damaged by accidental contact by hand fools or any metal or soltd object when working within the area of the open boiler door, for example, during tube cleaning. in boilers burning fuels which coniain. high-evels of-sulphur or-vanadium (typically residual fuel oils} the ceramic fibve blanket is protected Boilerhouse personnel are advised to adopt reasonable care when work is required in the area of an open front door in order to avoid the posstbility of renewal due to accidental damage. During: the normal: inspection period careful attention should be given f the condition of the refractory and if any deterioration is apparent, repairs should be undertaken immediately. PLEASE REFER TO DIAGRAM FIGURE A3 : LAYOUT OF BOILER REFRACTORIES AS SHOWN ON PAGE NUMBER A-14, Should it eventually become necessaty te-renew the refractory. lining, a replacement can be supplied. We would recommend the user to contact COCHRAN BOILERS for advice and assistance, where arrangements can be made for any necessary Tepalrs or renewal work-{o be carried out by our own qualified tradesmen, We.have a duty under the Health and Safety at Work Act, to-warn the user of the following precautions fo be taken if-repairs:or-renewals-onsthisematerial are to be carried out by your own personnel. WARNING Whon ‘handling and-remaving used refractory blanket, take reasonable steps to minimise aitbome dust and wear an approved mask or respirator, Avoid contact with skin and eyes by wearing gloves and eye’protettion. After handling, tinse exposed skin areae with water. Work clothing should be washed separately. 25441908. : Bp DESCRIPTION ptt " ADDITIONAL FITTINGS The boiler is fitied with an observation port to facilitate the viewing of the flame. For boilers with eveporative outputs of 4500 kg F & A 100°C and below tho observation port is normally positioned in the front door of the boiler. Boilers wit) an avaporative output above 4500 kg/hi F & A 100°C, the observation port is located at the back of the boiler. A vant cock and point for the inapector’s test gauge is fitted in the copper piping to the pressure gauge. The cock is provided to vent the air from the boter when filing and fo relieve the’ vacuum: created by condensation following a prolonged shut down. Astandpipe for a salinometer cock is provided on the boiler. A low fire hold stat may be fitted for boilers operating on time clocks. The stat will prevent the burner going to high fire until the boiler has reached a preset pressure, normally approximately 2 bar (30 {b/in’). A teed water inlet strainer should be fitted on the suction fine to the water feed pump. ‘An antt-suction valve may be fitted to prevent over filling of the boller, by gravity from a high condensate tank or by suction following the creation of a vacuum in the boler. COCHRAN BOILERS should be consulted before this valve is fitted, because it will increase ‘the-pressure which-the feed-pump.must overcome. end it may affect the performance of the feed pump. 2541608a DESCRIPTION 4 4 a 3 2 ;o® 00 fa q| , 8 ’ 48 a 11 To ule al 25-4198 FIGURE A-1 = TYPICAL BOILER ARRANGEMENT& DESCRIPTION A13 FLUE SMOKE TUBES GAS A FRONT EXIT\ a & 2 Ae _ CHAMBER OL 7 /| Al tO REAR LL FURNACE CHAMBER FIGURE A-2 : SECTIONAL VIEW SHOWING GAS FLOW 254-1008OPERATION CONTENTS INTRODUCTION GENERAL NOTES ON VALVE OPERATION . Gracktng open a Valve Water Hammer .. Wire Drawing. PRELIMINARY PROCEDURE FILLING THE BOILER WITH WATER... PREPARING THE BURNER... GAS AND DUAL FUEL FIRED BOILERS .... STARTING-UP FROM COLD... RAISING STEAM FROM A WARM BOILER PUTTING THE BOILER ON FACTORY LOAD... SHUTTING DOWN THE BOILER Short Period Shut-Down Extended Period Shut-Down. EMERGENCY OPERATION Pressure Part... Fuel Systems... Fire, Electrical Power Supply 25-04-1086OPERATION C2 INTRODUCTION As far as is reasonably practicable, every care has been taken to ensure that the COCHRAN Borderer Steam Boller is safe and without risk to health when preperly used. [tis stressed that the boiler should only be operated by competent persornel GENERAL NOTES ON VALVE OPERATION Before operating a valve, check the valve position indicator and the direction of operation of the handwheel. Always ensure that the pipework system is operatanal If repairs are Deing carried out, focks, danger notices and warnings should be posted to prevent inadvertent operation of plant under repair. Valves should 5¢-operated slowly and should never be forced to the limit in either direction. Shutting a cold valve hard down may lead to its seizure when temperatures in the adjacent pipework are later increased. Never use excessive force to open or close a valve. The use of wheel spanners should be discouraged es valves are provided with hand wheels large encugh to give a turning force sufficient fo open or close the valve. If a valve is so tight that it ‘carnot be fully operated by the hand wheel alone, it is defective and the application of more force may make matters worse On steam lines always open the drains and crack open the valves to rid the sysiem ‘and valves of water prior to starting-up. On water lines, always vent any trapped air by opening the air cocks or by cracking open bypass valves or main valves. CRACKING OPEN A VALVE This means opening the valve slowly: out positively: Cracking open « valve zllows the pipework and valves to warm up ‘before’ the system is"subjected to full pressure and temperature, Failure to drain-and:warm through the-system in the correct mannet can produce.water hammer. WATER HAMMER This is an alarming and damaging condition which sounds similar to a series o” loud reports: ike -hamrner-blows within. the pipeline. These blows are caused by wave molion set up in the water lying in the line when'steam or hot watér is admitted too quickly. In some cases, the hammering of the water waves can cause damege to valves, fittings and pipework 2ECAAS9EOPERATION C3 WIRE DRAWING if a valve is not shut properly or is left cracked open for a long time, the valve seat may become scored which is described as wire drawing. We drawing takes place when steam, particularly wet steam, expands through a valve which ts partially open for prolonged periods. The scouring .action of the rapidly moving expanding steam erades the valve faces. The eroded grooves look asi they had been produced by drawing a wire through the valve and ovar the valve faces. PRELIMINARY PROCEDURE The initial commissioning of the boiler is generally carried -out-by COCHRAN Enginesrs. Commissioning must only be undertaken by competent personnel and the folowing procadure is recommended if commissioning.is carried out by. personnel other than our own qualified engineers. : WARNING Itis mandatory that gas and dual fuel boilers are only commissioned by C.O.R.G.1. registered personnel. Check that all mountings and front.and reer access. chambers are propetly-tigntened and have not worked loose in transit. Check all electrical connections are tight and have not worked loose fn transit. Remove plug from inspector's test point: which will-allow-alr to beexpelled. Open cock to pressure gauge and pressure switches. Close. main stop valve. Ensure-the steam and water cocks on gauge glasses are-open and the drain valves are closed Check biowdowrn yaive is ciosed. Crack open feed check vaive and open water supply from tank or softener but refer to procedure for "Filling the Boiler with Water’. (Page C-4) 26.04.1898a OPERATION C4 CAUTION No valve with a handwheel should be elther fully opened er fully closed, ie. the handwheel should be turned backwards or forwards nalfe turn as applicable fo orevent seizure, FILLING THE BOILER WITH WATER CAUTION The boiler feed pup must never be run against a clased valve. It is permissible, when using the boiler feed pump to fill the-boiler initially, te only cack open the boiler feed check valve-in order to create-a head resistance for the purnp fo operate against. When boiler is filled to the normal water level the Control Switch should be retumed to the -Oif or Auto position. The Feed Check Valve must be fully opened prior :o the boiler being pui to use. There are alternative methods of filing the boiler: Method A - Using the Feed Pump Method B - Using a Hose Ensure that the: system water.s treated in eccordance with your Water Treatment supplier's instructions. If Method A is preferred, the following .procedure should bo adopted: 1) Remove pre-heater fuses fronicontrokpane!: (Residuat-cils-only) 2) Set bumer switch Off. 3) Set pump switch Off. Ensure water supply is on. CAUTION {f the pump is operated without water for even a few seconds, it will be damaged. 4) _ ‘Prime water feed pump and check diréction of rotation of feed pump. &) When using the feed pump to fill the boiler, it is permissible initially t2 only crack open the bol'er feed check valve in order fo create a head rosistance for the pump to operate against. 15.0-4-4295i OPERATION C6 8) % 9) Set pump switch to Auto and pump will run. While the pump is running, the lookout lamp and the first and second tow water lamps will be illuminated and the alarm will ring. The alarm can be muted by operating tte spring loaded fault switch to the mute position er the Mute/Run switch to mute, dependent ‘on which switch is fitted to the panel. When the water ievel reaches a point above the second low water level, the alarm will ring again if previously muted. Itcan be muted again if desired. \When the water feed pump stops, the lockout light will remain illurrinated until lockout is cancelled by operation of the spring Iaaded fault switch to the reset position or by pressing the lockout lamp, which has a press-to-reset fagilily and is fitted on some boilers as.an alternative to the fault switch With boiler filed to the normal water level the feed check valve must he fully opened prior to the boiler being put to use, When the bolle and feed pump are operating all feed pump flow valves must be fully open. If however, Method B is preferred the following procedure should be adapted: Remove the manhole cover on top of the boiler. Fill the boiler up to normal water level with a hose pleced in the manhols. Make sure the joint faces are thoroughly clean and replace the manhole door. tig recommended that a new gasket is used oach time. Continue with steps 1) to 9) of Method A. PREPARING THE BURNER Reference should be made to theBurner:Manual located ‘in:Section B:of this manuel. GAS AND DUAL FUEL FIRED BOILERS. WARNING Itis mandatory that gas and dua! fuel boilers are.only commissioned by C.O.R.G.I. registered personnel. Its recommended that 6 dual fuel burner is cornmissioned first on the primary fuel and subsequently on the secondary tuel. 25.04.1996OPERATION C6 CAUTION tis important that prior to the commissioning or in the operating procadure, the fuel selector switch, mounted on the boiler control panel in dual fuel installatiors, is selected to the appropriate fuel to be used, i.¢, g2s or oil itis also eseentiel that the main gas manual isolating valve is in the closed position and that the micro-switch contacts are closed when commissioning or operatirg on oil. WARNING During oll commissioning, under no-circumstances open.the.main gas manual isolating valve. STARTING-UP FROM COLD Reference should also be made to the Burmer Manual located in Section B of this manual. Ensure that the burner has been prepared in accordance with the procedure specified in Section 8 of this manual. Check that the plug has been removed from the Inspector's test point and cock open to pressure gauge and pressure switches. Check the following valves: Steam stop valve shut Feed check valve open Boller blowdown valve shut Water gauge assemblies opon {all handles downwards) Sequencing blowdown valve (when fitted) In-the-nomal:position.;.. Fuel supply open Water supply open ‘Water feed pump-on automatic Ensure that the boller contains water up to the normal water level Ensure that the burner switch is in the OFF position and check that all fuses are in place. NOTE When fuel ois below 15.5 centistokes at 38°C (70 seconds Redwoed No. 1 @ 100°F) are usec, no oil heating is required. In this case, heater circuit fuses MUST be removed and the heater thormostat sheried out to simulate hot oil 260-4199ti OPERATION C7 Fer dual fuel burners, move the fuel selection switch to the appropriate fuel to be ead, If selected to GAS ensure that all oil fue! isolating valves are closed and all G2x isolating valves are open. Similarly, if selected to OIL, eneure that ths gas isclating valves are closed. NOTE H the bumer utilises 2 piot gas for ignition ensure that the gas isolating valvas on the pilot ignitian line to the burner are open. On dual fuel bumers, if the bumer is fitted with an automatic gas valve proving system, check that the proving pressure switch is set to approximately 50% of the nominal gas pressure. On dosing the main isolator an alarm will sound. Operats the reset switch, With the bumer at the lowost fiting rate switch the burner on. The flame can be viewed through the observation port assembly at the rear of the boiler, WARNING Observation of the flame should NEVER be undertaken by the naked eye, safety glasses preferably tinted should always be worn when viewing the flame. ‘As a precautionary measure, a careful observation should be made, fo ensure that the sight glass is not cracked and that there is no hot gas emission. It is important to remember that a cracked sight glass indicates-a-dangerous condition, it can. shatter. outwards from the boiler and should be renewed Immediately..THE BOILER OF ‘COURSE, MUST BE SHUT ‘DOWN BEFORE ANY REPLACEMENT IS MADE. IFfor any reason-the flame is not established, the burner will go fo lockout. WARNING If the burner fails to start after two or three attempts, there isa failure in the equipment that must be rectified before any further attempt Is made, A COCHRAN Service Engineer should be called in to Investigate the fault. It is most Important that no-more than three attempts are made to start the burner. Every tlme the burner fails to light a small quantity of fuel i injoctod into the furnace. This fuel will build up anda potentially explosive situation could arise.OPERATION cg The boiler should be warmed up slowly with the bumer on the lowest firing rate. Steam will blow through the open vent cock at the inspector's test point, Aliaw the steam to blow long enough to ensure that all gir has been expelled from the boiler. Glose the three-way cock off to atmosphere and replace the vent cock plug, cherking that the cock remains open to pressure gauge and pressure switches NOTE When the boiler pressure is being raised for the first time, the safety valve should be opened by means of the easing lever to plow out any foreign matter. As the boiler pressure increases, the water-level. will. rise due.to.expansion. The level should be restored to normat by-opening the biowdown'valve. ‘This wif also temove colder water from the betiony of the boiler and -help.to- maintain an even distibution of heat CAUTION. Care should be taken when opening the boiler blowdown valve. The valve should-be opened slowly fo avoid shock loading on the blowdown system, When the boiler pressure reaches 2.0 bar (20 Ib/in’). The firing rate of the burner can be inereased, The boller pressure will continue to rise and the burner wil stay on the highest firing rate until the pressure reaches the setting of the pressure controller. The burner will then go tothe lowest firing rate unti the pressure reaches the ceiling of the limit-pressure control-when the. flame-wil ease, the bumer will continue fo run on post-purge te clear gases frorn the boiler. Whon the:boiler has been'working for some hours:at full pressure, tighten. all doors and mountings egain. Inspect the.crains-atsthe:rear-of thesboiler, when water and steam atop issuing, replace the plugs. Should the bumer.go to lockouit,'the flame will be extinguished; the lockout light wil be-illuminated:and_an-alarm wili sound, When-the. fault Is rectified and-the. faull switch reset, the remainder of the cyole, Le. the pest-purge wil be completed. before the burner can start again RAISING STEAM FROM A WARM BOILER When raising steam form a warm boiler, i.e. a boiler which has less than 2 bar (30 ibfin’) pressure being recorded on the pressure gauge, proceed as in “Starting Up from Cold” (Page C-6) except of course steam can be raised much more rapidly and the ewitching ovar of the bumer tothe higher firing rate can fake place much sooner. Bec 386OPERATION C8 PUTTING THE BOILER ON FACTORY LOAD Ervure that the bumer and water feed pump ere operating automatically. Eee open the main steam stop valve. Wail for a few seconds, then cerry on opening the stop valve by quarter turns until fully open, then close ane quarter tum. NOTE No extra leverage should be applied to the stop valve handwheel as thia could result in the spindle becoming twisted. As the boiler preesure falis, the bumer -wil. respond: under the command of the preseure limit control (limit prassurestat) anc: the pressure:controller (usually cither a highfow pressurestat or a modulating pressuretto))... These-stats:are adjustable to sul: the load requirements of the factory. SHUTTING DOWN THE BOILER It is recommended that the main steam stop valve on the boiler be closad each time the boiler is shut down et the end of each working day or at weekends. Tais will Teduce the strains imposed by the variations of pressure and temperature and increase overall efficiency. SHORT PERIOD SHUT DOWN For a short-shut down such as ovemight, there are two alternative methods of shutting down the boiler. Method A Close the main steam siop valve. Set water feed pump to. HAND and raise the water level to 26 millimetres (1 inch) fromthe top-o7-the water gauge glasses. This allows for contraction as the boiler cools overnight Allow the 5urner ta cut-off on pressure. CAUTION If the boiler is to be shut down: overnight, leave the main isolator ON, burner OFF, water feed pump OFF and feed check valve SHUT.’ This wil prevent the boiler filing by gravity if the poller pressure falls ovemight. BE SURE TO OPEN FEED CHECK VALVE BEFORE SWITCHING PUMP ON at next start-up. 25.6-41908ae OPERATION S40 Ee Method B Cloze the main steam stop valve and leave the boiler with the burner switch and water feed pump on AUTO. This wil ansure that the boller is kept up to pressure all night and will help to reduce: any strains imposed by variations of pressure and temperature, NOTE The COCHRAN Borderer Steam Boiler is suitable for unattended operation. However, this course of action MUST be discussed with your Insurance Company to ensure that your policy covers this method of operation. Upon compietion of the shut-down ‘procedure (either method) the fellowing -asks should be performed:- Blowdown water gauge assemblies Clean photocell Inspect burner head and cleen if necessary Clean tear observetion port assembly EXTENDED PERIOD SHUT DOWN If the boiler is to be shut-down for a longer period, shut-down the boiler as per the instructions in “Short Period Shut Down" (Page C-9). Raise the water level and then shut-off all valves. Put all switches to OFF and open main isolator. Upen completion of the shut-down procedure the following tasks should be performed:- . Blowdown water gauge assemblies Clean photocell Inspect burner heed and clean if necessary Clean rear observation port assembly Any-boilar that is laid -off for.an extended period should be protected against corrosion. Details of recommended methods of laying .up boilers for extended periods can be found in:The Treatment of Water for Shell Boilers’. published by the Association of Shell Bollermakers. EMERGENCY OPERATION All members of staff shéuld be aware of the procedures; as defined by Company Policy Documents, to be adopted In the case of a major or minor accident or incident. Emergency ‘equipment must be readily available for use in emergency situations, 250-4409OPERATION crt WARNING Care should be taken when approaching the boiler during ail emergency conditions. PRESSURE PART Low water is potentially the most dangerous situation which can occur n the belernouse. ‘The energy content in.100 gallons of waler al 6.9 bar {100 Ib/ia*) would have sufficient explosive force to demolish a small factory. During a low water condition, the smoke fubes and furnace can become overheated and in the event of furnace collapse, a majot explosion may occur due to the sudden release of steam and water at the moment of failure, {fae water is visible in the gauge glasses the-following procedure will shut the boller down safely: WARNING Under no circumstances should.an attempt be made to fill the boiler with water until it has been allowed to cool. Switch off the bumer. Close fuel Isolating valves. Chse boller stop valves. Check that all boiler drains ars closed. Switch off water faed pump and close feed check valve isolate electrical supply at main isolator. Leave boiler plant to cool, NOTE Before attempting fo re-activate the plant, a thorough investigation must be carried cut by competent personnel FUEL SYSTEMS Any problems with the fuel systems should be attended fo immediately. 25-04-1996x OPERATION C-12 Oil System Switch off the burner Close boiler stop valves Check that all boiler drains are closed Switch off water feed pump and close teed check valve isolate electrical eupply at main isolator Close fus! supplies from fuel tanks. If a particular area is affected, also isolate the failed section of pioework. Contain spillage using oll absorbent materials, Protect adjacent equipment from spillage. Care should be taken to ensure that of does not enter the drainage system. Gas System WARNING Under no circumstances must naked flame be used for checking gas leaks. Any suspicion of a gas leak should be reported immediately to a responsible person and an ‘authorised’ inspection carried out. DO NOT DELAY Isolate -the main gas supply outside the affected area (if possible). Make no attempt to operate the plant whilst gae ‘s escaping. SAFETY NOTE ft is‘ Important to remember: that some gaseous fuels are heavier then air. These fuels tend to accumulate at ground level. FIRE Call the Fire Brigede Switch off the burner Close boiler stop valves. Check that all boi'er drains are closedea OPERATION O13 Switch off water feed pump and close fead check valve Disconnect all electric supplies Close al fuel supply lines Use firs appliances as applicaate to the type of fire. ELECTRICAL POWER SUPPLY The mein consideration in the formulation of actions required on the above occurrence Is to retain steam pressure in the boiler to onable a speedy recovery upon restoration. Switch eff the burner Close boiler stop valves Check thet ail boiler drains are closed. Switch off water feed pump and close feed check valve. Isolate electrical supply et main isolator. A thorough investigation into the cause of the power supply failure should be made belore reactivating the boiler. Upon resioration of the power supply the plant can be reactivated by following the pertinent procedures contained in Staring Up from Cold (Page C-6). Ensure that the burner cycle has completed the post purge before attempting to resart the burner. 29-0-44995OPERATION OF STEAM BOILER CHECK WATER LEVEL IN TANK CHECK LEVEL !N FUEL TANK CHECK INLET VALVE OPEN GHECK DISCHARGE VALVE CLOSED SWITCH WATER PUMP TO AUTO. WHEN. LEVEL REACHED MARK SWITCH PUMP.OFF SWITCH BURNER TO LOW FLAME AND SWITCH ON RUN BURNER 10 MIN SWITCH. BURNER OFF. ). WAIT 20 MIN SWITCH BURNER ON RUN.BURNER 15.MIN SWITCH BURNER OFF. WAIT-20 MIN SWITCH BURNER ON VENT.GAUGE GLASS UNTIL STEAM IS EXHAUSTING CLOSE GAUGE GLASS VENT . ALLOW PRESSURE TO RISE TO PRESET LIMIT SWITCH WATER PUMP TO AUTO. BOILER tS NOW READY TO GiVE STEAM CRACK DISCHARGE VALVE AND’ALLOW HOSE TO HEAT WHEN HOSE IS HOT OPEN DISCHARGE VALVE FULLY SLOWLY.