Auxiliary Boiler

PROJECT NAME: MISURATA COMBINED CYCLE PROJECT
PO DESCRIPTION: AUXILIARY BOILER
PO NO.: PU310-H1316
SUBJECT: Operation & maintenance manual
DOCUMENT NO.: MP-V-AB-92-001
For Information
CLIENT
PROJECT
CONSULTANT
CONTRACTOR
SUB. CONTRACTOR
H.Kang
F 31. JAN. 2014 FINAL S.W.BAEK H.Kang
Rev Prepared Checked Reviewed Approved

Date Description
No by by by by
It may NOT be used, disclosed or reproduced for other purpose pertaining to this document or its contents without specific, written prior
permission of Daewoo E&C Co., Ltd.
AP6-A-AA-NN-NNN Sheet 1 of 102

Doc. No. MP-V-AB-92-001
OPERATION & MAINTENANCE MANUAL
Project No. : PU310-H1316G
Project : Misurata Combined Cycle Projects
Client : GECOL / Lybia
Contractor : Daewoo E&C
Item No. : 90EKG51 AV001
Service : Auxiliary Boiler & Auxiliary Equipment
5
4
3
2
1 09. 11. 17. 2nd Issue. S. J. Lee BSW KH
0 09. 9. 29. 1st Issue. S. J. Lee BSW KH
Rev. Date Description Prepared Reviewed Approved
Hanil Heavy Industries Co., Ltd.
1500-11, Songjung-dong, Gangseo-gu, Busan, Korea, 618-270 Tel. 82 - 51 - 832 - 1715 ~ 1718
Homepage www.hanilhi.com Fax. 82 - 51 - 832 - 1719
E-mail lsj@hanilhi.com
HIHI Hanil Heavy Industries Co., Ltd.

Date 2009. 11. 17.
Rev. 1
Sheet No. 1 of 1
Table of Contents
Sheet No.
1. General
1.1 Introduction 1
1.2 References 1
1.3 General Cautions 1
2. Operation
2.1 Preparation for Start-up 2

2.2 Cold Start-up 3
2.3 Hot Start-up 3
2.4 Normal Operation 4
2.5 Shut-down
S 6
2.6 Abnormal Operation 6
2.7 Manual Operation 6
3. Recommended Maintenance
3.1 Routine Maintenance 7

3.2 Boiler Lay-up 9
33
3.3 Periodic
P i di Cleaning
Cl i 10
3.4 Repairs by Welding 11
3.5 Dry-out and Boil-out 12
4. Trouble Shooting
4.1 Water and Steam System 13

4.2 Fuel, Air and Flue Gas System 13
43
4.3 Trouble
T bl Shooting
Sh ti Guide
G id 14
5. Water Treatment
5.1 Boiler Water Problems 15

5.2 Water Quality Control 16
5.3 Water / Steam Analysis 16
5.4 Trouble Shooting Guide ( for Water Quality Control ) 17
6. Attachments
6.1 Precaution for Operation and Maintenance

6.2 Boiler Logging
6.3 Boiler Lay-up Procedure
6.4 Trouble Shooting Guide
6.5 Burner O&M Manual
66
6.6 F D Fan O&M Manual
F.D
6.7 Actuator O&M Manual
6.8 M.O.V Drawing

Date 2009. 11. 17.
Rev. 1
Sheet No. 1 of 17
1. General
1.1 Introduction
This manual is intended to provide informations for safe and proper operation and maintenance of
the following equipment(s).
- Packaged Boiler
For auxiliary equipments and components, their own manuals or instructions shall also be referred to.
For specific data or information, please refer to the relative data sheet, document or drawing.
1.2 References
The following documents shall be referred to as minimum.
- Final Vendor Print
- Inspection & Test Reports
1.3 General Cautions
Vendor's prints and the manuals for the auxiliary equipments and components shall also be read carefully
and understood together with this manual.
This manual shall be readily available in the boiler room/space and any operator shall be familiar
with this manual.
Prepare and follow a preventive maintenance schedule and a check list based on recommendations
in this manual. A log book shall be maintained to record inspection and maintenance.
The boiler room/space shall be always clean and clear of all unnecessary materials. Proper air
circualtion, naturally or forcedly, shall be ensured so that sufficient air is supplied to the burner
to prevent incomplete combustion.
Never operate the boiler under the following conditions, which can result in serious damage or
explosion.
- Dry Fire, i.e., the boiler not being filled with water
- A function, "Low Water Level Shut-down" being in disorder
- A function, "High Pressure Shut-down" being in disorder
For furthers, please refer to "Precaution for Operation and Maintenance", which is attached.

Date 2009. 11. 17.
Rev. 1
Sheet No. 2 of 17
2. Operation
2.1 Preparation for Start-up
The following steps shall be taken before firing.
1) Visual Inspection
Check that all foreign materials and tools have been removed.
Check that all doors and openings are closed.
Check that the flue gas damper, if installed, is open.
2) Valve postion
Close drain valves.
Close steam supply valves.
Open the boiler vent, manual vent valve or start-up vent valve if provided.
3) All Instruments shall be in good order.
4) All utilities such as electricity, instrument / service air and cooling water shall be available.
5) Fuel to be used shall be available.
6) Electrical systems shall be in service.
7) Auxiliary equipments shall be ready for operation.
8) Fill water into the boiler upto the normal water level.
CAUTION : High quality water shall be used to minimize water side corrosion.
Water temperature shall match the temperature of the boiler metal to prevent
thermal stresses. Excessive temperature difference shall be avoided.
Air shall be completely displaced with water using vents.

Date 2009. 11. 17.
Rev. 1
Sheet No. 3 of 17
2.2 Cold Start-up
The following procedure shall be reviewed and carefully followed for start-up after completing the
preparation steps for start-up.
1) Check that all indications on the boiler control panel are normal.
2) Set the selector switch for fuel to "Fuel GAS" or "FUEL OIL" position, if a dual fuel burner is equipped.
3) Set the selector switch for operation mode to "AUTO" position.
4) Push the push button, "BURNER START".
5) Hold on minimum fire until steam pressure reaches around 1~2 bar.g
C
CAUTION
O : Observe
O firing
f state and never go to high fire
f to avoid excessive thermal stresses.
6) Set the master controller to "AUTO" position when steam pressure reaches around the normal
operating pressure.
7) Watch the boiler water level.
8) Open the main steam valve.
CATION : Never open a valve under pressure quickly. The sudden change in pressure or
resulting water hammering may cause piping failure.
9) Check piping for leaks.
2 3 Hot
2.3 H t St
Start-up
t
The boiler pressure shall be above 2~3 bar.g
The procedure is as same as above 2.2 except that 5), 6) and 9) of 2.2 are not required.

Date 2009. 11. 17.
Rev. 1
Sheet No. 4 of 17
2.4 Normal Operation
Effective operation of a boiler is critical to maintaining system efficiency, reliability and availability.
General
Before firing, there must be no combustible material inside the furnace.

The furnace shall be purged to be ready for firing.
Once combustion is established, the correct air/fuel ratio shall be maintained.

Insufficient or too excessive air flow shall be avoided.
If the rate of steam flow from a boiler increases, the pressure drops because heat is carried
away faster than it is being supplied. If steam flow decreases, the pressure increases.
Visible water level is not always a true indication of the amount of water in a boiler because
steam bubbles, as well as water, are contained in the water space and cause the water to
swell.
If the steaming rate decreases, the amount of steam bubbles decreases, the water shrinks, and
the water level drops.
The tendency of water level to vary with steaming rate is known as "Swell" and "Shrink".
Swell and shrink shall be taken into consideration in controlling water flow so that the flow varies
properly with steam output.
Blowdown
The concentration of undesirable solids in boiler water can be reduced through blowdown, by which
a portion of boiler water is blown down and replaced by feedwater with a lower concentration.
The main purpose of blowdown is to maintain the solid concentration in boiler water within
acceptable limits.
Blowdown can be classified into two, continuous and intermittent.
Continuous Blowdown
Continuous blowdown rate is set to control boiler water within acceptable limits.
Intermittent Blowdown
Intermittent blowdown shall be performed at routine intervals to discharge sludge in the bottom.
Excessive blowdown results in energy loss and operating cost increase. Blowdown rate shall be
adjusted and minimized by sampling and testing boiler water routinely.

Date 2009. 11. 17.
Rev. 1
Sheet No. 5 of 17
Operating Guide for Maximum Efficiency
Fuel is a major cost in boiler operation.
It is therefore important to minimize fuel consumption and maximize steam production.
Although a boiler's efficiency is primarily a result of its design, the operator can maintain or
significantly improve efficiency.
Heat loss to flue gas
The total heat loss to flue gas is determined by quantity and temperature of the flue gas.
The quantity of the flue gas is dependent on the fuel being burnt, but is also influenced by
the amount of excess air supplied to the burner.
While sufficient air must be provided to complete the combustion process, excessive amount
of air simply carry extra heat to the flue gas.
The temperature of the flue gas is affected by the cleanliness of the boiler heat transfer
surfaces.
While high flue gas temperature waste energy, excessively low temperature may also be
unacceptable. Corrosion can occur at the water or acid dew point of the flue gas.
Burner Adjustment
Fuel and combustion air combine and release heat at the burner.
To maintain even heat distribution across the width of the furnace, air and fuel flows must
be evenly supplied.
Adjustment can typically vary the turbulence and flow rates in the burner.
Increased turbulence inceases the air - fuel mixing.
It also increases the combustion intensity, provides faster heat release, reduces unburnt
carbon, permits operation with less excess air and inceases boiler efficiency.
Water Treatment
The main function of a boiler is to transfer heat from combustion gas through tube walls
to heat water and produce steam.
Impurities in water can collect and deposit on the tube surfaces.
These deposits reduce heat transfer and thus boiler efficiency.
Water treatment is essential to minimize deposits.

Date 2009. 11. 17.
Rev. 1
Sheet No. 6 of 17
2.5 Shut-down
Two shut-down situations may occur, a controlled shut-down or one required in an emergency.
1) Controlled Shut-down
Push the push button, "BURNER STOP" after the firng rate has been gradually reduced to a minimum.
Then, the fuel is shut off and the furnace is post-purged.
The F. D. fan may be shut down or remain running for faster cool-down of the boiler.
The boiler pressure gradually lowers as heat is lost from the boiler surfaces.
2) Emergency Shut-down
Push the push button, "BURNER STOP" during normal operation.

Then, the fuel is shut off and the furnace is post-purged.
The boiler may be held at a reduced pressure or may be completely cooled down.
2.6 Abnormal Operation
1) Low Water Level
The boiler water level shall not be decreased to allow tubes to be exposed to steam.
If the level drops below the minimum required, shut down the boiler and feed water slowly
until normal level is restored.
If there is any possibility that tubes have been damaged, cool down and inspect the boiler.
2) Tube Failure
Operating a boiler with a known tube leak is not recommended.
By loss of water or steam, a tube failure can alter water circulation flow and result on other
tubes being overheated and failed.
2.7 Manual Operation
The selector swith for operation mode shall be set to "MANUAL" position.
The pilot burner, the main burner, etc. can be manually operated.
For further details, please refer to the instruction manual for burner.

Date 2009. 11. 17.
Rev. 1
Sheet No. 7 of 17
3. Recommended Maintenance
3.1 Routine Maintenance
Maintenance shall be scheduled and performed as follows as minimum.

However, the frequency and extent of maintenance will vary depending on the system and
service of a specific boiler.
1) Daily
Check the condition of the following.
- Water Level
- Steam Pressure
- Flue Gas Temperature
- Water or Steam Leakage
- Flue Gas or Combustion Air Leakage
- Fuel Level or Pressure
Carry out intermittent/bottom blowdowns.

`
Blow down water columns.
Make water analysis.
Check lubrication on auxiliary equipments, if provided.
2) Monthly
Test controls for start-up.
Check all strainers, and clean if required.
3) Quarterly
Examine the following for easy operation and leakage.
- Boiler Mountings
- Valve and fittings on pipe lines

Date 2009. 11. 17.
Rev. 1
Sheet No. 8 of 17
4) Semi-annually
Check the following.
- Safety Valves
- Pressure Instruments
- Level Instruments
- Controllers
5) Annually
Inspect the following.
- Internal Surfaces
- Fireside Surfaces
Prepare for the inspection by an authorized inspector, if required.

`
Replace and repair if required.
CAUTION : Consult an authorized inspector before proceeding to major repairs.
Review past records and logs.
For tabulation, please refer to "Boiler Logging", which is attached.

Date 2009. 11. 17.
Rev. 1
Sheet No. 9 of 17
3.2 Boiler Lay-up
When the boiler is removed from service, it shall be carefully prepared for the idle period.
During this period, excessive rusting and corrosion may occur on the water side and fire side surfaces.
Well planned procedures shall be followed for the boiler to be prepared for service.
There are two basic methods, " Wet Storage " and " Dry Storage " for the water side surfaces.
Wet storage is recommended for short term ( one month or shorter ) outage and has the advantage of allowing
the boiler to be returned to service on short notice.
Dry storage is recommended for long term ( one month or longer ) outage.
1) Wet Storage
The boiler shall be filled

f full
f with feedwater
f or condensate which is conditioned chemically.
For water conditioning, consult a boiler water treatment specialist.
Make periodic inspections to check water leakage. Replace all water loss from the boiler.
This method is not recommended where freezing may occur.

If this method is adopted with anti-freeze, consult an anti-freeze manufacturer and follow their
i t ti
instructions for
f the
th anti-freeze
ti f to
t be
b used.
d
2) Dry Storage
When the boiler is to be idle for a considerably long period, it shall be emptied, thoroughly
cleaned, dried and then closed to exclude both moisture and air.
D i
Desiccant
t Method
M th d
Silica gel or other moisture absorbent may be placed on trays inside the boiler.
Check periodically and replace it when necessary.
CAUTION : Moisture absorbent such as silica gel shall not contact metal surfaces of
the boiler. Absorbed moisture can cause corrosion.
Nitrogen Blanketing Method
The boiler shall be filled and pressurized with nitrogen to about 0.5 bar.g.
The pressure shall be maintained throughout the storage.
For further details, please refer to "Boiler Lay-up Procedure", which is attached.

Date 2009. 11. 17.
Rev. 1
Sheet No. 10 of 17
3.3 Periodic Cleaning
The boiler shall be cleaned at least once a year to maintain the high thermal efficiency and a long
life of the boiler.
If the boiler is to be shut down and taken out of service for a long period, the boiler shall be cleaned
immediately upon shut-down while flue gas passages are still warm. When the boiler gets cold,
deposits harden and make cleaning difficult. Further, hardened deposits would absorb moisture
and cause corrosion.
1) Internal Cleaning
The cleanliness of internal surfaces, water and steam side, is of prime importance because
internal deposits can lead to chemical attack, corrosion and overheating.
A manhole is provided for internal inspection.
Loose scales may be removed manually.
Light scales can be removed with water washing.
Hard scales shall be removed by performing "Boil-out Procedure", which is separately provided.
If corrosion is severe, acid cleaning shall be performed by a specialist.
2) Fireside Cleaning
The boiler shall be sufficiently cooled down after shut-down.
Flue gas shall be thoroughly removed and vented to the atmosphere.
Remove soots from flue gas passages including tube inside using tools such as brush.
Loose soot accumulations in windbox can be removed using a vacuum cleaner.
If soot deposits are difficult to remove manually, water cleaning shall be performed.
Drain water during water cleaning may be acidic. So, extreme care shall be taken to protect
personnel and to dispose of the effluent to avoid environmental pollution.
CAUTION : Wear protective means such as gloves, a mask, clothing, etc.

Date 2009. 11. 17.
Rev. 1
Sheet No. 11 of 17
3.4 Repairs by Welding
Performance monitoring and inspections establish the nature and extent of repair.
The equipment manufacturers can recommend, guide or carry our the work, but final decision
shall depend the operating company and inspectors.
Pressure part repairs must meet the requirements by the applicable code.
Repairs of pressure parts may be also made under the guidance of the local authority.
The welds in repair of a boiler can be divided into three(3) categories.
- Welds joining pressure parts
- Welds joining pressure parts to non-pressure parts
- Welds joining non-pressure parts
Welds joining pressure parts and Welds joining pressure parts to non-pressure parts
Welds joining pressure parts and welds joining pressure parts to non-pressure parts must
conform to the requirements of the applicable code.
The applicable code establishes the minimum requirements for base material selection,
qualification of welding procedures and welders, non-destructive examination, etc.
Welds joining non-pressure parts
Welds that are made between non-pressure parts such as flue gas ducts, casings, etc. shall
conform to the detailed engineering documents and drawings provided.

Date 2009. 11. 17.
Rev. 1
Sheet No. 12 of 17
3.5 Dry-out and Boil-out
A new boiler or boiler with major parts repaired shall be subject to pre-operational boil-out.
Boil-out shall be performed to remove debris, oil, grease and paint which may lower heat
transfer and lead to overheating.
Dry-out shall be performed to dry newly installed refractory inside the furnace.
Dry-out can be accomplished shortly during boil-out.
For details and procedure, please refer to "Boil-out Procedure", which is separately
provided.
Boil-out can be performed in accordance with a procedure by a water treatment company or a

recognized organization such as ABMA ( American Boiler Manufacturers Association ).

Date 2009. 11. 17.
Rev. 1
Sheet No. 13 of 17
4. Trouble Shooting
The following guidelines are for general trouble shooting.
For further details, if required, refer to operation & maintenance manuals or instructions for
auxiliary equipments and components.
4.1 Water and Steam System
Steam Pressure Too High
When the boiler has a severe over-pressure condition causing steam to blow out the safety,
assume that safety controls do not work.
The response to a severely over-pressurized condition shall be to shut down the boiler and
to allow the boiler to cool slowly. Never introduce cold water into the over-pressurized boiler.
The boiler shall be thoroughly inspected for damage. Before the boiler is returned to normal
service, the problems shall be fully corrected.
Water level too low
When boiler tubes are exposed to steam, the tubes become overheated and lead to tube
failure.
If a serious condition exists, take the boiler immediately out of service until the cause of the
problem is identified and corrected.
4.2 Fuel, Air and Flue Gas System
No Fire
Check power to the boiler control panel.
Check to see if the power switch is in "ON" position.
Check if fuel is available.
Check if shut-down conditions exist for the boiler.
- Water level too low
- Steam pressure too high, and etc
- Other Shut-downConditions
Consult the manual for the burner.

Date 2009. 11. 17.
Rev. 1
Sheet No. 14 of 17
Fuel Explosion
Check air flow and adjust to the correct air - fuel ratio.
Check and purge the furnace to remove combustible material inside.
No Fuel
Check if fuel is available.
- Supply Pressure of Fuel Gas
- Oil Level of Fuel Oil
4.3 Trouble Shooting Guide
Please refer to " Trouble Shooting Guide ", which is attached.

Date 2009. 11. 17.
Rev. 1
Sheet No. 15 of 17
5. Water Treatment
Water conditioning can increase the efficiency of the boiler as well as extend the boiler's life.
It also insures safe and reliable operation.
Without proper treatment, the boiler can suffer from serious damages, and thus can be destroyed.
5.1 Boiler Water Problems
Boiler water problems generally fall into two classes as follows.
Deposit Related Problems
One of the most common deposit problems is boiler scale.
This happens when calcium, magnesium and silica, common in most water, react with metal
in boilers to form a hard scale on the surfaces of the metal.
The hard scale formed reduces heat transfer and lower the boiler's efficiency.
If allowed to accumulate, boiler scale can eventually cause tubes to overheat and rupture.
Scaling is one of the leading causes of boiler tube failures.
Removing calcium and magnesium or other deposit-formimg materials from feedwater before
entering boilers is the best way to prevent scaling.
Corrosion Related Problems
Dissolved oxygen interacts with boiler surfaces, forming "pits" on the metal surface.
These pits may eventually grow large enough to penetrate the metal, forcing a boiler shut-down.
Controlling the oxygen content in feedwater can be done through deaeration and chemical
treatment.
Another of the most common causes of corrosion is the presence of carbon dioxide in the
condensate.
Carbon dioxide forms carbonic acid and reduces the pH of the condensate and causes acid
attack.
A third corrosion related problem is caused when boiler water pH drops below about 8.5.
Known as acid attack, the effect exhibits rough pitted surfaces.
Boiler water pH shall be periodically monitored and maintained within the recommended
limits.

Date 2009. 11. 17.
Rev. 1
Sheet No. 16 of 17
5.2 Water Quality Control
The boiler operators shall consult a water treatment specialist for actual operation conditions and
take proper steps for water quality control.
Water Quality Standard
The following is recommended.
Description Unit Feedwater Boiler Water
pH at 25 deg.C - 8.3 ~ 10 -
Dissolved Oxygen ppm max. 0.007 -
Total Iron ppm max. 0.1 -
Total Copper ppm max. 0.05 -
Total Hardness ppm max. 0.3 -
Nonvolatile TOC
OC ppm max. 1 -
Oily Matter ppm max. 1 -
TDS ppm max. - 3,500

Total Alkalinity, CaCO3 ppm max. - 700
Suspended Solids ppm max. - 15
Silica as SiO2 *1) ppm max. - 150
Phosphate PO43- *2) ppm - 20 ~ 40
Remarks
*1) from ASME.

*2) from JBMA.
*3) Total Dissoved Solid ( TDS ) in ppm = 0.7 x Conductivity in μS/cm
5.3 Water / Steam Analysis
Water analysis is essential in boiler operation.
Water analysis must be routinely carried out mainly for the following.
- to adjust blowdown rate.

- tto evaluate
l t performance
f off water
t treatment.
t t t
- to adjust chemical injection rate.
Steam analysis must also be routinely carried out together with water analysis.
Water / steam analysis records shall be kept available to maintain proper operation.

Date 2009. 11. 17.
Rev. 1
Sheet No. 17 of 17
5.4 Trouble Shooting Guide ( for Water Quality Control )
Symptom
Possible Scale Corrosion Weakening Carry Over Possible
Cause Feed Feed Condens Solution
Boiler Boiler Boiler Steam Line
System System System
Feedwater
pH △ △ to be adjusted.
Hardness ○ ● X to be reduced.
Dissolved ○ ● ○ deoxidization
Oxygen
Oil ○ ● filteration
Contamination blow-down
Boiler Water
pH, decreased ▲ chemical
pH, increased △ ○ distillation

chemical
Alkalinity X ○ chemical
Total Dissolved ○ X ● blow-down

Solids
Chlorine ○ distillation
chemical
Silica ○ ● distillation
to add chemical.
Condensed
Water
CO2 ○ anti-corrosive
Notes :
△ and ▲ indicate that the farther pH gets away from the suitable range, the severer corrosion
becomes.
Especially in case of ▲ mark, the degree is larger.
○ and ● indicate that the higher the concentration becomes, the severer the trouble becomes.
Especially in case of ● mark, the degree is larger.
X mark indicates the secondary trouble which is often caused by the primary trouble.

Doc. No. MP-V-AB-92-001-6.1
PRECAUTION for OPERATION & MAINTENANCE
Service Auxiliary Boiler & Auxiliary Equipment
5
4
3
2
1

PRECAUTION for OPERATION & MAINTENANCE
Doc. No. MP-V-AB-92-001-6.1

Date 2009. 10. 07.
Rev. 0
1. Introduction Sheet No. 1 of 1
The boiler shall be operated and maintained as designed for the specific service as possible.
Precautions for operation & maintenance are recommended to be followed.
2. Precautions
Safety Valves
The primary purpose of the safety valves is to prevent over-pressure in a pressure vessel such as the steam drum,
the superheater, the economizer and the deaerator.
The safety valves relieve over-pressure by discharigng steam or water in the vessel. Thus, there should be no obstructions
at the safety valves inlet and outlet.
Steam Quality and Purity
The moisture and solid contents in steam can cause troubles to equipments and piping downstream of the boiler.
The level shall be maintained within allowable limits with performing proper water treatment and control.
Carry-over
The moisture and solid contents in steam can be increased to a large extent due to priming.
A sudden load change and/or a high water level can cause priming, and thus shall be avoided.
Loss of Water
Water loss may be due to tube leakage, excessive blowdown or other causes.
The boiler shall be shut down, if the cause has not been remidied, to avoid a successive occurrence such as tube failure.
Furnace Explosion
In any case, the furnace shall be prevented from the explosion inside of the furnace.
Pre-purging shall be done before firing, and also post-purging shall be done after shut-down.

Doc. No. MP-V-AB-92-001-6.2
BOILER LOGGING
Project Nam : Misurata Combined Cycle Projects
Service : Auxiliary Boiler & Auxiliary Equipment
5
4
3
2
1

Doc. No. MP-V-AB-92-001-6.2
Date 2009. 10. 07.
BOILER LOGGING Rev. 0
Sheet No. 1 of 1
Table of Contents
1. Introduction
2. Scope
3. References
4. Attachment
- Operating Log
- Maintenance Log
- Daily
- Weekly
- Monthly
- Quarterly
- Semi-annual
- Annual

Doc. No. MP-V-AB-92-001-6.2
Date 2009. 10. 07.
BOILER LOGGING Rev. 0
Sheet No. 1 of 1
1. Introduction
Boiler logs are check lists for the boiler operators and provide a means of recording data for operation
and maintenance.
The logs can be used to evaluate the boiler conditions and correct troubles before they become accidents.
For safe operation and good maintenance, it is most important to keep the logs complete and accurate.
2. Scope
The log sheets are recommended ones.
Frequency and extent of recording will depend on operating and maintenance conditions and practices.
Items may be added to or deleted from the log sheets. Periods may also be adjusted.
It is not practical to cover all details which comes from the equipments' instructions
It is advisable for the operators to get familiar with the instructions ans add items to the log sheets.
There may be some requirements from the local Authority and the insurance company.
Those items shall be included in the log sheets.
3. References
Documents by Hartford Steam Boiler Inspection and Insurance Co. ( HSB )
Documents by National Board of Boiler and Pressure Vessel Inspectors Inc. ( NBBI )
ASME Sec. VI / VII
NFPA 70

LOG SHEET : Doc. No. LS - OL - 100
Date 2009. 10. 07.
OPERATING LOG Revision 0
Project : Misurata Combined Cycle Projects Item : Auxiliary Boiler & Auxiliary Equipment Sheet No. 1 of 1
Year :
Load Fuel Steam Flow Pressure, bar.g Temp., deg.C Flue Gas Water / Oil Level Water
Date Time Operator Remarks
%MCR Gas / Oil Flow,kg/h kg/h Boiler Deaerator Deaerator Flue Gas O2 Nox BoilerDeaerator Oil Tk Test
Notes : 1. Records shall be made once a day as minimum.

Reviewed by :
Date reviewed :

LOG SHEET : Doc. No. LS - DL - 100
Date 2009. 10. 07.
DAILY MAINTENANCE Rev. 0
Date :
Equipment / System Check / Action / Test Item Method Result Correction / Action if any Remarks
Blowdown Bottom Manual
Water Column Manual
Level Gauges Manual
Boiler Proper
Check steam / water leakage. Visual
Check flue gas leakage. Visual
Check noise and vibration. Auditory
Observe combustion state. Visual
Check fuel gas leakage. Visual
Burner Unit Check fuel oil leakage. Visual
Check combustion air leakage. Visual
Blowdown Storage Tank Manual
Water Column Manual
Deaerator Level Gauges Manual
Check steam / water leakage. Visual
Demi. Water System Inspect exterior. Visual
Feedwater System Check leakage. Visual
Steam System Check noise and vibration. Auditory
Blowdown System
Fuel Gas System
Fuel Oil System
Combustion Air System
Notes :
Reviewed by :
Date reviewed :

LOG SHEET : Doc. No. LS - WL - 100
Date 2009. 10. 07.
WEEKLY MAINTENANCE Rev. 0
Year -> 2009 2010 2011

Check / Action / Test Items Week Remarks
Month-> 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2
1
2
Test safety and interlock controls. 3
4
5
1
2
Check motor operating conditions. 3
4
5
1
2
Check lubrication and grease points. 3
4
5
1
2
3
4
5
1
2
3
4
5
Reviewed by :
Date reviewed :
Notes :

LOG SHEET : Doc. No. LS - ML - 100
Date 2009. 10. 07.
MONTHLY MAINTENANCE Rev. 0
Year -> 2009 2010 2011

Check / Action / Test Items Remarks
Month -> 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2
Safety Valves
Test by lifting and closing the lever.
Boiler Proper
Check hot spots on outsides of flue gas passes.
Reviewed by :
Date reviewed :
Notes :

LOG SHEET : Doc. No. LS - QL - 100
Date 2009. 10. 07.
QUARTERLY MAINTENANCE Rev. 0
Year -> 2010 2011

Quarter -> 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4
Burner Unit
Check and clean firters on fuel gas line.
Check and clean firters on fuel oil line.
Feedwater System
Check and clean strainers.
Valves
Examine for smooth operation and leakage.
Reviewed by :
Date reviewed :
Notes :

LOG SHEET : Doc. No. LS - SL - 100
Date 2009. 10. 07.
SEMI - ANNUAL MAINTENANCE Rev. 0
Year -> 2010 2011 2012

Half -> 1/2 2/2 1/2 2/2 1/2 2/2
Check and test.
Safety Valves
Pressure Instruments
Level Instruments
Temperature Instruments
Controllers
Burner Unit
Inspect components.
Adjust combustion.
Reviewed by :
Date reviewed :
Notes :

LOG SHEET : Doc. No. LS - AL - 100
Date 2009. 10. 07.
ANNUAL MAINTENANCE Rev. 0
Check / Action / Test Items Year -> 2010 2011 2012 2013 2014 2015 Remarks
Boiler Proper
Inspect and clean water / steam surfaces.
Inspect and clean fireside surfaces.
Oil Tank / Deaerator
Inspect internal sides.
Pumps
Inspect the conditions.
Electricals
Check and tighten electrical terminals.

Examine interior of panels and enclosures.
Review the past records and logs.
Prepare for and receive inspection by the authority.
Reviewed by :
Date reviewed :
Notes :

Doc. No. MP-V-AB-92-001-6.3
BOILER LAY-UP PROCEDURE
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Doc. No. MP-V-AB-92-001-6.3
Date 2009. 10. 07.
BOILER LAY-UP PROCEDURE Rev. 0
Sheet No. 1 of 1
Table of Contents
1. Introduction
2. References
3. Principle
4. Procedure
4.1 Wet Storage
4.2 Dry Storage
5. Fire Side Protection
6. Auxiliary Equipments

Doc. No. MP-V-AB-92-001-6.3
Date 2009. 10. 07.
BOILER LAY-UP PROCEDURE Rev. 0
Sheet No. 1 of 3
1. Introduction
This procedure covers requirements for Lay-up of the following equipment(s).
- Packaged Boiler
The purpose of Lay-up is to protect the boiler from corrosion and rusting during an idle period when the boiler
is taken out of service.
2. References
The following documents and drawings shall be referred to as minimum.
- Final Vendor Print
- Operation & Maintenance Manual
3. Principle
There are two basic methods, " Wet Storage " and " Dry Storage " for the water side surfaces.
Wet storage is recommended for short term ( one month or shorter ) outage and has the advantage of allowing
the boiler to be returned to service on short notice.
Dry storage is recommended for long term ( one month or longer ) outage.
1) Wet Storage
The boiler shall be filled full with feedwater or condensate which is conditioned chemically.
This method shall not be adopted where freezing may occur.
2) Dry Storage
Desiccant Method
Silica gel or other moisture absorbent may be placed on trays inside the boiler.
The boiler shall be filled and pressurized with nitrogen to about .

Doc. No. MP-V-AB-92-001-6.3
Date 2009. 10. 07.
Rev. 0
Sheet No. 2 of 3
4. Procedure
4.1 Wet Storage
The boiler shall be completely filled with chemically treated water and closed to prevent air from entering.
The following steps shall be taken for lay-up.
1) Add chemicals into the boiler just before the boiler has been shut down.
2) If the boiler is empty, fill the boiler with water and the chemical solution. And then, operate the boiler
on a low fire for a short time for water circulation and mixing of the chemicals.
3) Fill the boiler completely using air vents.
4) Close the boiler tightly.
5) Sample and test the water weekly to ensure that the chemical concentration is within the proper level.
If the concentration has been decreased below the level, add additional chemical into the boiler
by lowering the water level, and then take a step for circulation and mixing.
Concentraion : 100 ~ 200 ppm in case of Hydrazine

pH : about 10
* Superheater better be laid-up with dry storage.

* For water conditioning, consult a boiler water treatment specialist.
4.2 Dry Storage
The following steps shall be taken for lay-up.
1) Drain the boiler completely.

2) Inspect the boiler, and clean with clean water if required.
3) Dry the boiler with warm air.
Desiccant Method
4) Put moisture absorbent such as silica gel on trays, and place them inside the boiler.
5) Close
Cl the
th boiler
b il tightly.
ti htl
6) Check the moisture absorbent monthly, and replace if required.
CAUTION : Moisture absorbent such as silica gel shall not contact metal surfaces of
the boiler. Absorbed moisture can cause corrosion.
Warning signs shall be posted so that the boiler should not be operated
until the moisture absorbent inside have been removed.
4) Purge air from the boiler with nitrogen.

5) If the boiler does not have to be inspected and cleaned, drain the boiler with pressurizing the boiler
with nitrogen.
6) Maintain the pressure at about 0.5 bar.g.
7) Close the boiler tightly.
8) Check the pressure daily.
CAUTION : Warning signs shall be posted so that nitrogen only is, oxygen to breathe is not inside
the boiler, and thus anyone never enter inside the boiler.

Doc. No. MP-V-AB-92-001-6.3
Date 2009. 10. 07.
Rev. 0
Sheet No. 3 of 3
5. Fire Side Protection
Flue Gas and humid air can cause corrosion to steel surfaces during long term out-of-service.
The following steps are recommended for longer than three (3) month lay-up.
1) Inspect the fire side, and clean if necessary.
2) Put moisture absorbent such as silica gel on trays, and place them inside the furnace.
3) Close air duct inlet and gas duct outlet with installing plates to prevent air in-flow.
4) Clsoe any opening to prevent air and moisture in-leakage.
5) Check the moisture absorbent monthly, and replace if required.
6. Auxiliary Equipments
Equipments and/or their parts are subject to corrosion during long term lay-up.
Some parts need to be dis-assembled and stored indoor.
Shafts and bearings shall be routinely attended to check and keep them in good conditions.
For furthers and storage planning, please refer to their instructions.

Doc. No. MP-V-AB-92-001-6.4
TROUBLE SHOOTING GUIDE
5
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TROUBLE SHOOTING GUIDE
Doc. No. MP-V-AB-92-001-6.4

Date 2009. 10. 07.
Rev. 0
1. Introduction Sheet No. 1 of 1
This technical sheet provides information for trouble shooting in boiler operation.
2. Causes of Malfuctions and Solutions
Symptom Possible Causes Possible Solutions
Steam Pressure Too High
No Fire
Please refer to Operation & Maintenance Manual, Section 4. Trouble Shooting.
Fuel Explosion
No Fuel
Water Level Too High Larger Feedwater Flow Adjust the control valve.
Sudden Load Increase Reduce the load increase rate.
Water Level Too Low Less Feedwater Flow Adjust the control valve.
Sudden Load Decrease Reduce the load decrease rate.
Flue Gas Temp., Too High Severe Fouling of Heating Surface Clean the heating surface.
Tube Leakage Defective Material Plug or replace the tube.
Deposit on the Tube Surface Remove the deposit.
Blockage of Water Circulation Remove the blockage.
Flue Gas Fume or Odor Leakage in Flue Gas Ducting Locate and repair.

Doc. No. MP-V-AB-92-001-6.5
BU R N E R O & M M A N U A L
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Doc. No. MP-V-AB-92-001-6.6
F. D. F A N O & M M A N U A L
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Yujin Engineering Y J N
& Mfg. Co., Ltd. M-001E1
FAN INSTRUCTION MANUAL
DATE : 2005. 1. PAGE 1 OF 11
Industrial Air Is Our Business..
============================
============================
1. OPERATION MANUAL
2. MAINTENANCE MANUAL
Yujin Engineering & Mfg. Co., Ltd.

BUCHEON, KOREA
MANUAL\M001E1
& Mfg. Co., Ltd. M001E1
DATE : 2005. 1. PAGE 2 OF 11
1. OPERATION MANUAL
1-1 Cautions Prior to Operation
1) Make sure that every part is thoroughly equipped, clear around the machine, and make
sure that there is no foreign matter around the inlet opening or in the suction line piping.
2) Confirm that the power source is normal.
3) Lubricating Oil
Inspect the bearing grease. Excessive filling of grease will cause excessive heat in
bearings. The kinds of oil, generally speaking, for 150℃ or below, SHELL Alvania
grease No. 2, GULF Crown EP No. 2 or turbine oil GULF Harmony #32 is recom-
mended, and for temperature exceeding 150℃ , MOLUB alloy 850-2 or turbine oil GULF
harmony #64 is recommended.
(a) Lubricating by Grease
The amount of grease required for the lubrication of bearing is sufficient when filled
and approximately 1/3 for in the bearing case.
If the pillow type inlet is applied, with Alvania grease No. 2 is already filled,
there is no need for further feeding.
(b) Lubrication by Oil Bath & Oil Ring
Look at the oil level gauge and fill the oil up to the specified amount (approximately
to the middle of the gauge). In the case where a cooling water piping is provided,
pass approximately 1-2 kg/cm 2 of cooling water .
4) Turning by Hand
Make sure there is no unreasonable or forced arrangement in the suction and discharge
of ducts or air leakage. Also make sure there are no remainders of material used
during installation work. After confirming no irregularity, turn the blower by hand to
check abnormal contact in the interior.
MANUAL\M001E1
DATE : 2005. 1. PAGE 3 OF 11
5) In case of V-Belt transmission
Even though belt tension and alignment are set before shipping, the alignment and tension
can be checked at site before starting as follows :
* Alignment between both grooved pulleys for V-belts is to be checked either by applying
a stretch to the side of both pulleys or by stretching a thread. Adjustment is to be made
accordingly by moving the motor body on the slide base.
* Belt tension can also be adjusted by moving motor slide base back or forward. Care is
to be taken to ensure against whirling of overtightness of the belts. As a reference for
normal belt tension, 15mm per 1m of span length of deflection is appropriate when 1.5kg
for A type, 3kg for B type, 5kg for C type or 10kg for D type is applying on the middle
of belt span.
6) Starting
Start the blower with the air control damper closed. Sudden increase of speed should
be prohibited. Check the bearing, noise in the casing inside, vibration and temperature,
then increase the speed gradually to the speed.
1-2 Start-Up
During the start-up of the trial operation, the bearing temperature, vibration and contact
with the rotating member require special attention.
1) Check the direction of rotation of the fan.
2) Carefully observe the variation of the current during the start, and if any abnormality
is found, immediately stop the motor.
3) Pay attention the vibration and sound during the start. If any abnormality is noticed,
stop the fan to check for causes.
4) While carefully observing the variation of the current, gradually adjust the opening of
the suction and/or discharge valve to set the current predetermined value.
5) If the operation condition is smooth thus far, the bearing temperature becomes constant
after half an hour to an hour. Therefore, operate the fan at least for one hour to
check the operational condition such as the bearing temperature and vibration.
MANUAL\M001E1
DATE : 2005. 1. PAGE 4 OF 11
1-3 Operation
1) Damper Control
After the machine attains full speed, operating the air control damper closed for a long
time incurs danger, because the accumulation of compressed heat within the blower
casing may cause heat distortion. Therefore as soon as full speed is reached, when
using discharge damper, the air control damper needs to be opened with a minimum
amount of air quantity so that surging phenomenon may not occur. Then loading can
be successfully increased gradually.
When using the suction damper, there is no fear for surging. Control the damper by
watching the ammeter of the motor to make that the motor doesn't overload. Confirm
at this time that the motor ampere is below the rated value.
2) Temperature of the Bearing
Confirm the circulation of oil after full speed has been attained and measure the tem-
perature increase in bearing. This should be under 40℃ and the bearing temperature
should be kept under 70 ℃ under any condition. The temperature will become constant
after one hour from starting. It is considered safe if you can keep your palm on the
bearing for more than 10 seconds. For the blower which is provided with a gland, pay
attention so as not to tighten the gland unbalancedly. Then, operate the motor for a
moment to ascertain the revolving direction and inner contact.
If the bearing temperature is 70℃ or below, it is normal, however, should the tempera-
ture exceed that value, carry out an inspection of oil, bearings and the shaft alignment.
(Refer to the paragraph under Inspection and Maintenance.) Damage in the bearing or
oil shortage causes a small metallic noise.
3) Treatment of Gases of other Temperature than Normal
In the case where the gas has a smaller specific gravity than that of a normal tem-
perature air treated under normal temperature, it sometimes develops an overload.
Pay attention not to commit such an irregularity.
4) Surging
MANUAL\M001E1
DATE : 2005. 1. PAGE 5 OF 11
When the fan is operating in the ranges

between A and B in Fig. 1, a
backward flow is generated among the
vanes of the fan and this in turn gener-
ates periodic pulsation in the flow.
Metallic sound is due to this phenomenon.
Since the casing itself will vibrate
dangerously, avoid operation in the
ranges between A and B.
5) Measurement of the Bearing Vibration
Measure the bearing vibration and its amplitude of the fan at the centermost position of
each bearing horizontally, vertically and in an axial direction. Use 1/1000 mm as the
unit, and express the vibration in total amplitude. Check the reading of the instrument
whether it is in half amplitude or in total amplitude.
For everyday inspection, touching by hand may be applied. However, when the vibration
becomes big, measure it with a vibration gauge. If it exceeds the permissible value of
the bearing vibration, stop operation without delay to inspect and adjust.
When vibration starts and keeps of going, it becomes impossible to operate continuously.
Therefore the imbalance should be rectified immediately.
For a reference for permissible vibration, Fig 2 can be used as a guide.
e.g. the limit of permissible vibration is 165 ㎛ with 1750 rpm.
1-4 Stopping & Shut Down
After the complete closing of air control damper, stop the main electric motor. Make
sure that any abnormal sound is not heard, and that the drop of the number of revolution
is not abnormally fast until the rotor is completely stopped.
For a shut down of a long period, drain thoroughly the water such as the cooling water
in the bearing housing every part, and also the machine thoroughly. Coat the finished
faces of each section of the machine with appropriate corrosion inhibitor. Provide cover
over the necessary places to prevent dust, rain, etc., settling in the machine.
Pay special attention to the motor.
MANUAL\M001E1
M001E1
& Mfg. Co., Ltd. FAN INSTRUCTION MANUAL
DATE : 2005. 1. PAGE 6 OF 11
Fig. 2 Vibration Tolerance
MANUAL\M001E1
M001E1
DATE : 2005. 1. PAGE 7 OF 11
2. MAINTENANCE MANUAL
2-1 Daily Check Points
Pay attention to the following points everyday and carry out the inspection of the blower.
1) Is there any abnormal noise ?

2) Are the bearing temperature and vibration normal ?
3) Is the value shown by the ammeter normal ?
4) Is the V-belt correctly aligned and properly stretched ?
5) Is the oil quantity proper when using oil bath or oil ring lubrication ?
(Check by means of oil level gauge.)
2-2 Suspension of Operation
1) When the operation of the fan is to be suspended, pay much attention in cleaning,
rust prevention of the blower, and be cautious in preventing dust, dirt and water
getting into bearings.
2) Pay attention to prevent humidity against all electrical parts such as the motor and
other parts.
3) Remove water completely from the bearing cooling water piping and bearing cases.
2-3 Periodical Inspection
Carry out periodical inspection at least once a year, and inspect the following items:
1) Clean disassembled parts thoroughly.

2) Replace lubricating oil (or grease) with fresh ones\.
3) Examine the contacting surfaces of the rotating elements and the static sections.
4) Examine the condition of play at fitting sections.
5) Recheck the alignment.
2-4 Operation Diary
MANUAL\M001E1
M001E1
DATE : 2005. 1. PAGE 8 OF 11
Inasmuch as the operation diary is the data for making a diagnosis of the fan, keep a
meticulous entry for present and future reference. If the operating record is kept, it is
possible to find abnormality in the early stage, and even if trouble occurs, it is easy to
find the cause of trouble.
2-5 Causes of Troubles and Their Countermeasures
Even under the strictest observation, there may be a discrepancy the operator may have
never expected, which may lead to trouble. We will find out its causes and take proper
countermeasure for you provided that you supply us with history of operation since the
beginning and current situation of the problem. See Table 1 where causes of troubles
and their countermeasure are listed.
Table 1. Causes of Troubles & Their Countermeasures
Inspection
Troubles Causes Countermeasures
Point
High Bearing 1. Surplus or short Bearing Make the filling quantity

Temperature filling of grease proper
2. Defective fitting of Bearing & Adjust shaft
inner ring of roller Shaft
bearing and shaft
3. Defective fitting of Bearing & Replace bearing case
outer ring of roller Shaft
bearing and shaft
4. Damage of roller Bearing Replace bearing
bearing
5. Oil deterioration or Bearing Replacement or regeneration
water blend of oil
6. Excessively small Metal Machining for adjustment
clearance of metal
7. Cooling water for B'rg Housing Add cooling water
bearing is short & Piping
8. Defective turn of oil B'rg Housing Repair or replacement
ring
MANUAL\M001E1
M001E1
DATE : 2005. 1. PAGE 9 OF 11
Inspection
Point
High Bearing 9. Overheat of bearing Replacement of Metal

Temperature 10. Defective alignment Coupling Additional tightening of bolts
of coupling and nuts
11. Excessive tightening V-belt Correct the tension
of V-belt
12. Vibration Bearing Refer to "Vibration"
Excessive 1. Imbalance of impeller Rotor Correct balance & clean

Vibration adhered matters
2. Defective fitting of Rotor Replace boss or shaft
impeller boss and
shaft
3. Imbalance of shaft Coupling Replacement of coupling &
coupling check alignment
4. Bending of shaft Shaft Repair or replacement
5. Defective centering Coupling Repair
6. Excessively large B'rg Housing Repair or replacement
clearance in metal
7. Contact of rotor and Casing Re-installation of casing
Casing interior
8. Abnormal contact of Gland packing Repair
gland packing
9. Defective foundation Common bed Reinforcement of foundation
10. Defective tightening of V-belt Additional tightening of bolts
fitting belts and nuts
11. Surging
12. Concurrence with
critical speed
Abnormal 1. Contact with static Bearing Alter the position of oil

Noise section thrower collar, adjust the
contact of impeller & suction
cone.
2. Existence of foreign Remove foreign matter
matter
3. Damage of roller Overhaul inspection
bearing
MANUAL\M001E1
M001E1
DATE : 2005. 1. PAGE 10 OF 11
Inspection
Point
Abnormal 4. Defective gear Overhaul inspection

Noise coupling
5. Vane control device Inspection of lever and con-
necting rod, inspection of
wear of the pin of sliding ring
6. Damper Inspection of the play bet-
ween lever and connecting
rod.
Deterioration in 1. Drop in rpm, drop in Adjustment required

performance power cycle
2. Reverse revolution Change the motor wiring
3. Adherence of foreign Cleaning, repair or
matters to impeller, replacement
wear and corrosion
4. Clogging of suction Repair
filter
5. Defective opening / Repair
closing of suction &
discharge valves
6. Accumulation of dust Cleaning
in casing duct
7. Leakage through drain Repair
hole & other sections
8. Difference in the gas Measurement of the specific
specific gravity gravity of gas and analysis of
gas
9. Excessively large Planing of gas booster
actual resistance replacement of impeller
Vane control 1. Rusting of sliding ring Disassemble, feed grease and

device repair
2. Rusting of lever pin Disassemble, feed grease and
repair
MANUAL\M001E1
M001E1
DATE : 2005. 1. PAGE 11 OF 11
Inspection
Point
Suction damper 1. Rusting of lever Disassemble, feed grease and

repair
2. Rusting of bearing Disassemble, feed grease and
repair
3. Contacting of blades Repair the distortion of
blades, inspect its contact
duct
MANUAL\M001E1
Doc. No. MP-V-AB-92-001-6.7
A C T U A T O R O & M M A N U A L
5
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2005. 06.
PNEUMATIC ACTUATOR DRIVE

INSTRUCTION MANUAL
MODEL : SE-01H ∼ SE-18H
CONTENTS
1. GENERAL ··············································· 2
2. STANDARD SPECITICATION·························· 2
3. NOMENCLATURE········································· 3
4. STRUCTURES············································ 4
5. MOVEMENT & INSTALLATION ······················· 5
6. PIPING & WIRING ··································· 7
7. SWITCHING OF AUTO / MANUAL OPERATION ··· 8
8. ADJUSTMENT OF ACCESSORIES ··················· 10
9. CHANGING THE ACTING DIRECTION ············· 12

OF POWER SHAFT ROTATION
10. MAINTENANCE ········································ 12
1. GENERAL
Pneumatic Actuator is an equipment for remote position controlling of devices such as Dampers, Fan
inlet vanes, Butterfly valves, Lever operated valves and other final control elements.
The Actuator is totally enclosed structure consists of an air cylinder with well combined linkage, positioner,
air control sets and electrical position transmitter etc.
2. STANDRAD SPECIFICATIONS
* Construction : Totally Enclosed Outdoor Type
* Ambient Temperature : -10℃ ~ 50℃
* Relative Humidity : Below 85 %
* Rating : Continuous
* Input Signal : Current : DC 4 ~ 20mA
Air Pressure : 0.2 ~ 1.0 Kg/cm2G
* Supply Air Pressure : 1.4 ~ 7.0 Kg/cm2G
* Operating Angle : 90°
* Air Consumption : 25Nℓ/min. ( Balancing Position )
* Painted Color : Munsell 7.5 BG 6/1.5
※ Hysteresis : 2% ※ Linearity : ±3°
CYLINDER SIZE ( mm )
RATED TORQUE( Kgf-m ) APPROX. WEIGHT
MODEL
(S.A.P 5.5 Kg/cm2G) (Kg)
BORE STROKE ROD. DIA
SE-01H 17 Ø 100 100 Ø 30 70
SE-02H 26 Ø 125 100 Ø 36 80
SE-05H 45 Ø 160 100 Ø 40 160
SE-08H 85 Ø 180 150 Ø 45 190
SE-15H 140 Ø 200 200 Ø 50 280
SE-25H 210 Ø 200 300 Ø 50 380
SE-40H 330 Ø 250 300 Ø 60 440
SE-60H 560 Ø 300 350 Ø 70 620
SE-80H 720 Ø 300 450 Ø 70 670
SE-10H 920 Ø 300 550 Ø 70 820
SE-18H 1800 Ø 300(2ea) 500 Ø 70 1850
-2-
3. EXPLANATION OF NOMENCLATURE
SE-05H □□□□□□
Basic Model
SE-01H 80H (Rated Torque 17 ~ 720 kgf-m)
Manual Operator
H
Type
O Standard
N Explosionproof
Control Input Signal

Air Pressure ( 0.2 ~ 1.0 Kg/cm2G)
C Solenoid Valve
P
V
Position Transmitter
None
O Equipped (SRC-10)
F
Air Failure Lock-up Valve

None
O
Equipped (IL211-02)
U
Limit Switches
O None
L Equipped (2 SPDT Switches)
Space Heater
O None
cy
T Equipped (CYSH-O)
-3-
4. STRUCTURES
When the checking and maintenance of the Pneumatic Actuator, refer to following constructions.
4-1. Manual Lever Type
(SE-01H ~ 05H)
Power Arm
Positioner
Output Shaft Current

Transmitter
Lever Arm
Limit Switch
Pressure Gauge
Auto-Manual
Change Valve
Air Cylinder
Manual
Handle
Filter Regulator
Lock up Valve
Terminal Block
4-2. Manual Handle Type
(SE-08H ~ 18H)
Power Arm
Chain Sprocket
Current
Transmitter
Worm Wheel
Output
Shaft
Pressure Gauge
Clutch Lever
Lever Arm Auto-Manual

Change Valve
Manual Handle
Air
Cylinder
Positioner
Lock up Valve
Clutch Unit
Manual
Operator Unit
Filter Regulator Terminal Block
-4-
5. MOVEMENT AND INSTALLATION
5-1. MOVEMENT
In case of lifting up the Pneumatic Actuator,

attach the eye lug into the holes for lifting up
which is provided at upper of frame. ( Fig. 1 )
5-2. LOCATION OF INSTALLATION
The installation place of Pneumatic Actuator

should be selected a rigid and flat level
foundation in order to with-stand for the
pneumatic actuator output, and be determined
a location where will not inconvenient to the
setting of link mechanism between lever arm of
pneumatic actuator and opponent lever.
Fig. 1
Also the enough space for maintenance and inspection
services should be provided at the surrounding of pneumatic
actuator. The space will be at least 1 m.
5-3. INSTALLATION
1) Two anchor bolts should be get through at front side after removing of front cover, and the other two
anchor bolts should be get through installed at back side after removing of back cover.
The anchor bolts and nut should be tightened completely by use of offset wrench, etc. to avoid
shortage of tightening.
2) At the installation of connecting link, the following points should be observed carefully.
* In order to maintain the rated output of pneumatic actuator, adjust so that the angle create by
lever arm and connecting link ( turnbuckle ), should be 90°at 50% opening of pneumatic actuator.
( Fig. 2 )
Note : The installation angle of lever arm can be changed at any positions of 360°by 10 ~ 12°
pitch against torque shaft.
* The connecting link should be installed precisely so that the center line of connecting link is
matched with the center line of lever arm. ( Fig. 2 )
Note : As the lever arm is clutched to torque shaft by spline, it can be shifted to the axial
direction of torque shaft.
When the lever arm is shifted to shaft direction for the resetting between lever arm
and connecting link, the spline joint must be maintained with sufficient engaged
length.
-5-
Precisely measure
the center of connecting link
for installation.
90° at
the 50%
opening
Fig. 2
5-4. EXAMPLES OF INSTALLATION
Fig. 3
-6-
6. PIPING AND WIRING
6-1. PNEUMATIC PIPE CONNECTIONS
1) Supply air line shall be connected to the port as shown Fig. 1.
2) Both of the above ports are threaded KS PT 1/4" screw.
Conduit conn.
Terminal bolck
Supply air conn.
Fig. 1 Fig. 2
※ The case of explosion proof type connect the wire to positioner and limit switch
directly because terminal block is cannot used.
6-2. ELECTRIC WIRING (OPTION)

1) There are 3 ports for conduit connecting. Two PT 3/4" female
threaded ports are provided for conduit tube connection of electric wiring.(Fig. 1) And one is spare.
2) In case of the electric parts are not provided in the inside of Actuator, keep the cap as attached to
avoid penetration of rain water, etc.
3) in case of the non-explosion-proof type electric parts are installed in the inside of pneumatic actuator
a electric terminal block is provided in pneumatic actuator and the wiring between electric parts and
terminal block has been made at out factory.
4) When wiring to terminal from external are made, please connect the wire to specified terminal no.
Marked on block in accordance with wiring diagram. (Fig. 2)
-7-
6-3. BASIC PIPING DIAGRAM
AUTO POSITION MANUAL POSITION
7. CHANGING OF AUTO / MANUAL OPERATION
7-1. EXPLANATION OF PIPING
The switching from "AUTO" to "MANUAL" operation is made by operation of " AUTO / MANUAL "
changeover valve. When the changeover valve is switched to MANUAL position, the air pressure
supplied to positioner is cut, and simultaneously the air chambers of both upper and lower of power
cylinder are connected each other by by-passing, so that the manual operation can be admitted.
( Refer to 7-2 Auto/Manual Switching Procedure. )
CONTROL TYPE Air Accessories

3
1. Pressure Gauge 7. Solenoid Valve
2. Filter Regulator 8. Master Valve
1 3. Hand Valve 9. Check Valve
4. Lock up Valve 10. Air Reserve Tank
6
2 5. Air Cylinder 11. Speed Controller
6. Positioner
4 5
AIR SUPPLY INPUT SIGNAL
ON-OFF TYPE AUTO-SHUT(OPEN) TYPE when Air Failure.
3 3 10
8
9
1 1
5
11 6
2 2
4 4 5
7
7
AIR SUPPLY AIR SUPPLY INPUT SIGNAL
Fig. 3
-8-
7-2. AUTO / MANUAL SWITCHING PROCEDURE
1) LEVER TYPE MANUAL OPERATOR ( SE-01H ~ SE-05H )
As the manual operation lever is made solid with the output lever, manual operation can be
performed made simply. For switching over to a manual operation, turn the knob of transfer valve
mounted at front face of pneumatic actuator to " MANUAL " position. In this time, as the pneumatic
actuator will lose its output power, if unit is being loaded, tighten the lock lever located on the
manual operation lever by clockwise direction, then the lever can be locked. For the turning back to "
AUTO " operation, after matching the input signal to its opening of pneumatic actuator, the transfer
valve can be turned over to " AUTO " position.
AUTO → MANUAL MANUAL → AUTO
2) HANDLE TYPE MANUAL OPERATOR ( SE-08H ~ SE-80H )
For the Auto/Manual switching, the procedure should be conduced in accordance with the description
plate installed at front face to Pneumatic actuator.
A. FROM AUTO TO MANUAL CHANGEOVER
* Turn over the lever to manual position(manual clutch on position) in which is located on
left-upper side of hand wheel.
Note : This procedure is to be engaged the clutch unit in manual drive reduction mechanism.
However, as there is the case that the clutch engagement is not fitted with the relation
of clutch position, in that case, find the engaged point with rotating of hand wheel by
any directions, then turn over the lever.
* Next, turn over the changeover valve's knob located under the input signal pressure gauge
mounted on front face of Pneumatic actuator to manual position.
B. FROM MANUAL TO AUTO CHANGEOVER
* After the input signal corresponding to its opening of Pneumatic actuator has been, the knob of
changeover valve located at under side of pressure gauge mounted on front face of Pneumatic
actuator can be turned over to auto position.
* In order to make a complete matching the Pneumatic actuator opening and input signal, adjust to
-9-
the input signal corresponding to its opening until the manual handle can be operated lightly.
Then, the lever located on left-upper side of hand wheel can be turned over to auto
position( Manual clutch off position).
Note 1 : The switching operations for "Auto to Manual" and "Manual to Auto" should be
performed securely. If this operation is not perfect, the troubles such as spline teeth
damage of clutch unit may occur. So please operate this carefully.
Note 2 : In order to prevent the damage of clutch unit of manual mechanism, "Auto to Manual"
operation must be performed at the time when the drive unit is at standstill.
AUTO → MANUAL MANUAL → AUTO
8. ADJUSTMENT OF ACCESSORIES
8-1. POSITIONER
At 0% or 100% opening position of drive unit, the contact point of cam roller installed on the feedback
lever should be matched at start point of cam.
Provide the input signal of 0.2Kg/cm2G ( zero point ) to the positioner, and adjust the spring load by the
zero adjustment knob so that the opening of drive unit will be 0%( Full close or open ).
Next, for the input signal range from 0.2 to 1.0 Kg/cm2G, span adjuster so that the drive until will move its
full stroke.
Before the span adjustment, loosening the lock screw of span adjuster.
A repeat zero adjustment should be made because the zero point may be changed by touching of span
adjuster.
A repeat adjustment by the zero and span adjusting knobs should be continued until the 50%
opening( Linear Cam, when the using of Square Cam ; 22.4% ) at 0.6Kg/cm2G of input signal and full
stroke operation in input signal change from 0.2 to 1.0 Kg/cm2G can be obtained.
After the span adjustment, don't forget the locking of lock screw.
In the linearity has been deviated from specified value ( ±2°), it can be compensated by adjusting the
length of turnbuckle jointed with feedback lever of positioner and power arm installed on power shaft of
Pneumatic actuator.
- 10 -
Lock screw of Span adjustment Zero adjustment
Span adjuster Knob Knob
Feedback spring
Feedback Lever
Diaphragm
Cam
Torque motor unit
8-2. LIMIT SWITCHES
As the assembly position of limit switches has been adjusted at factory, so major adjustment may not be
necessary. If the adjustment of contact point is required, loosen the screw on cam attached to power
shaft, then change the cam position.
Set Screw
Limit Switch
Limit Cam Main Shaft
- 11 -
9.CHANGING THE ACTING DIRECTION OF POWER SHAFT ROTATION
9-1. DIRECT-ACTION
A Pneumatic actuator called direct-acting(DA) when an increase in the input signal causes the piston of
power cylinder moving upward. The power shaft moves counterclockwise in view from right side.
9-2. REVERSE-ACTION
The Pneumatic actuator is called reverse-acting(RA) when an increase in the input signal causes the
piston of power cylinder moving downward. The direction of shaft rotation for reverse-acting is reverse
motion of direct-acting.
For instance, in order to change made from direct-acting to reverse-acting, the pipe line from positioner
output-1 should be changed the connection to up from bottom of cylinder, and also output-2 should be
changed the connection to bottom from top of power cylinder.
Next, remove the positioner cover, then the characterized cam consisting in positioner mechanism
should be attached inside out. ( Confirm to the stamp on front face of cam. )
The changing method to direct-acting from reverse-acting should be made by reverse procedure to the
above.
10. MAINTENANCE
1) Check about every 3 months whether the pin and key part have no abnormality and also the manual
handle mechanism can be operated normally.
2) The packing of power cylinder should be inspected once a year and the packing replaced as required.
3) Lubrication Cycle
* We consist of a private type box

structure which pneumatic actuator
increases. The need the lubrication of
B Chain
the separate way does not exist in first
stage. They must do suitable lubrication
according to a driving environment.
Knuckle
Point A B C D Joint PIn A
Clutch Unit D
Capacity 5 cc 20 cc 100cc 5 cc
Cycle 1 Year Manual
C Operator Unit
Model EP 2
Manufac
turers Alvania No. 2
- 12 -
Doc. No. MP-V-AB-92-001-6.8
M. O. V. D R A W I N G
5
4
3
2
1

MOTOR OPERATED VALVE DATA SHEET.
DW CONTROLS CO., LTD. SHEET 1 OF 4
VALVE & ELECTRIC ACTUATOR DATA SHEET

JOB. NO.
CLIENT GENERAL ELECTRIC COMPANY OF LIBYA B 09.04.27 FOR APPROVAL L.Y.K L.Y.K I.Y.LEE
PROJECT MISURATA 20T/H AUX.BOILER A 09.03.11 FOR APPROVAL L.Y.K L.Y.K I.Y.LEE
LOCATION LIBYA REV NO. DATE DESCRIPTION PREP CHK APP'D
1 KKS NO 90QLB10AA001 ■ ON-OFF
GENERAL 2 SERVICE MAIN STEAM MOV SERVICE 39 CONDITION □ INCHING
3 QUANTITY 1 set(s) □ REGULATING
4 TYPE & SIZE GATE / 8" 40 SPACE HEATER ■ YES □ NO
5 RATING & ENDS 300# / BW POSITION □ YES
41
6 BODY MATERIAL A216-WCB ATTACH- TRANSMITTER ■ NO 4~20mA
7 TRIM MATERIAL 13Cr + STELLITE MENT □ YES
42 POTENTIOMETER
8 FLUID STEAM ■ NO
VALVE 9 TEMP.DESIGN 374 ℃ 43 POSITION INDICATOR ■ YES □ NO
10 PRESS.DESIGN 224.3 Kg/㎠g 44 STEM PROTECTION TUBE ■ YES □ NO
11 TURNS FOR O/C 34.2 REV 45 TYPE N/A
12 STEM ACTION RISING GEAR BOX 46 MODEL N/A
13 OPERATING TIME 33 SEC 47 FACTOR/RATIO N/A
14 REQUIRED TORQUE 105 Nm 48 OUTPUT TORQUE MAX -
15 TYPE 49 MATIC MODEL, MATIC AM01.1
16 MODEL 50 SA10.1 TYPE/MODE OF OPERATION INTEGRAL
17 ENCLOSURE IP67 51 REVERSING CONTACTOR ■ YES □ NO
CLOCKWISE ■ CLOSE OPEN-STOP-CLOSE ■ YES
18 ROTATION 52
□ OPEN PUSH BUTTONS □ NO
ACTUATOR 19 OUTPUT RPM 63 RPM REMOTE-OFF-LOCAL ■ YES
53
DECLUTCHABLE CLOCKWISE ■ CLOSE SELECTOR SWITCHES □ NO
20
SIDE HANDWHEEL □ OPEN CONTROLS 54 INDICATING LAMP OPEN.CLOSE.FAULT
SET TO 55 TRANSFORMER ■ YES □ NO
21 34.2 TURNS / STROKE
LIMIT SWITCHING 56 POSITIONER □ YES ■ NO
LIMIT SWITCH 2 NC 2 NO (OPEN,CLOSE) 57 PHASE DISCRIMINATOR ■ YES □ NO
22
INTERMEDIATE NC NO (OPEN,CLOSE) 58 M0NITOR RELAY ■ YES □ NO
23 TORQUE SWITCH 2 NC 2 NO (OPEN,CLOSE) 59 COLLECTIVE FAULT ■ YES □ NO
RATED TORQUE(Nm) OPEN 120 CLOSE 120
24 OPEN LIMIT
SETTING TORQUE(Nm) OPEN 120 CLOSE 120 60 SEATING METHOD
CLOSE LIMIT
25 AMB. TEMP. -25 ℃ ∼ + 70 ℃
26 MANUFACTURER AUMA 61 PAINTING PROTECTION KN / STANDARD
27 POWER SOURCE AC 400 V, 50 Hz, 3 Ph 62 LUBRICATION GREASE
28 CONTROL SOURCE DC 24V OTHERS 63 NAME PLATE ENGLISH / STAINLESS.S
29 MOTOR POWER 1.5 KW 64 WEIGHT ACTUATOR 33 Kg
30 RPM 2800 1/min 65 CABLE CONNECTION G1",G3/4",G1/2"
31 NOMINAL CURRENT 4 A 66 COLOR SILVERGREY(A0001)
MOTOR 32 MAX. CURRENT 5 A FINAL INSPECTION ■ YES
67
33 STARTING CURRENT 16 A RECORD □ NO
34 INSULATION F CLASS 68 QUALITY CERTIFICATE ■ YES □ NO
35 TEMP. RISE B CLASS DOCUMENT 69 OUT DIMENSION DWG. ■ YES □ NO
36 DUTY S2-15MIN MSP1810AC3--F18E1
70 WIRING DIAGRAM
37 MOTOR PROTECTION ■ YES 3 THERMO-S / W KMS TP110/301
38 TYPE TENV 71 OPERATING MANUAL ■ YES □ NO

NOTE.

JOB. NO.
CLIENT GENERAL ELECTRIC COMPANY OF LIBYA
1 KKS NO 90QLB20AA101 □ ON-OFF
GENERAL 2 SERVICE MAIN STEAM VENT MOV SERVICE 39 CONDITION ■ INCHING
4 TYPE & SIZE GLOBE / 4" 40 SPACE HEATER ■ YES □ NO
5 RATING & ENDS 300# / BW POSITION ■ YES
41
6 BODY MATERIAL A216-WCB ATTACH- TRANSMITTER □ NO 4~20mA
7 TRIM MATERIAL 13Cr + STELLITE MENT ■ YES
42 POTENTIOMETER
8 FLUID STEAM □ NO
10 PRESS.DESIGN 224.3 Kg/㎠g 44 STEM PROTECTION TUBE □ YES ■ NO
14 REQUIRED TORQUE 76 Nm 48 OUTPUT TORQUE MAX -
18 ROTATION 52
53
20
22
24 OPEN LIMIT
CLOSE LIMIT
25 AMB. TEMP. -25 ℃ ∼ + 70 ℃
31 NOMINAL CURRENT 1.4 A 66 COLOR SILVERGREY(A0001)
MOTOR 32 MAX. CURRENT 1.9 A FINAL INSPECTION ■ YES
67
33 STARTING CURRENT 4.5 A RECORD □ NO
70 WIRING DIAGRAM

NOTE.

JOB. NO.
1 KKS NO 90QHE12AA101 □ ON-OFF
GENERAL 2 SERVICE STEAM DRUM BLOW DOWN MOV SERVICE 39 CONDITION ■ INCHING
5 RATING & ENDS 600# / SW POSITION ■ YES
41
6 BODY MATERIAL A105 ATTACH- TRANSMITTER □ NO 4~20mA
42 POTENTIOMETER
8 FLUID STEAM □ NO
11 TURNS FOR O/C 8 REV 45 TYPE N/A
14 REQUIRED TORQUE 24.5 Nm 48 OUTPUT TORQUE MAX -
18 ROTATION 52
53
20
21 8 TURNS / STROKE
22
24 OPEN LIMIT
CLOSE TORQUE
25 AMB. TEMP. -25 ℃ ∼ + 70 ℃
67
70 WIRING DIAGRAM

NOTE.

JOB. NO.
1 KKS NO 90QHE11AA101 □ ON-OFF
GENERAL 2 SERVICE WATER DRUM BLOW DOWN MOV SERVICE 39 CONDITION ■ INCHING
5 RATING & ENDS 600# / SW POSITION ■ YES
41
6 BODY MATERIAL A105 ATTACH- TRANSMITTER □ NO 4~20mA
42 POTENTIOMETER
8 FLUID WATER □ NO
14 REQUIRED TORQUE 24.5 Nm 48 OUTPUT TORQUE MAX -
18 ROTATION 52
53
20
22
24 OPEN LIMIT
CLOSE TORQUE
25 AMB. TEMP. -25 ℃ ∼ + 70 ℃
67
70 WIRING DIAGRAM

NOTE.
VALVE (M.O.V) ASSEMBLY DRAWING.

Auxiliary Boiler

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Auxiliary Boiler

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PROJECT NAME: MISURATA COMBINED CYCLE PROJECT

PO DESCRIPTION: AUXILIARY BOILER

DOCUMENT NO.: MP-V-AB-92-001

F 31. JAN. 2014 FINAL S.W.BAEK H.Kang

Rev Prepared Checked Reviewed Approved

AP6-A-AA-NN-NNN Sheet 1 of 102

OPERATION & MAINTENANCE MANUAL

Project No. : PU310-H1316G

Project : Misurata Combined Cycle Projects

Client : GECOL / Lybia

Contractor : Daewoo E&C

Item No. : 90EKG51 AV001

Service : Auxiliary Boiler & Auxiliary Equipment

Hanil Heavy Industries Co., Ltd.

HIHI Hanil Heavy Industries Co., Ltd.

2.1 Preparation for Start-up 2

3.1 Routine Maintenance 7

4.1 Water and Steam System 13

5.1 Boiler Water Problems 15

6.1 Precaution for Operation and Maintenance

HIHI Hanil Heavy Industries Co., Ltd.

The following documents shall be referred to as minimum.

- Final Vendor Print

- Inspection & Test Reports

1.3 General Cautions

HIHI Hanil Heavy Industries Co., Ltd.

2.1 Preparation for Start-up

The following steps shall be taken before firing.

Check that all doors and openings are closed.

Check that the flue gas damper, if installed, is open.

Close drain valves.

Close steam supply valves.

3) All Instruments shall be in good order.

5) Fuel to be used shall be available.

6) Electrical systems shall be in service.

7) Auxiliary equipments shall be ready for operation.

Air shall be completely displaced with water using vents.

HIHI Hanil Heavy Industries Co., Ltd.

2.2 Cold Start-up

3) Set the selector switch for operation mode to "AUTO" position.

4) Push the push button, "BURNER START".

7) Watch the boiler water level.

8) Open the main steam valve.

9) Check piping for leaks.

The boiler pressure shall be above 2~3 bar.g

HIHI Hanil Heavy Industries Co., Ltd.

2.4 Normal Operation

Before firing, there must be no combustible material inside the furnace.

Once combustion is established, the correct air/fuel ratio shall be maintained.

Blowdown can be classified into two, continuous and intermittent.

HIHI Hanil Heavy Industries Co., Ltd.

Operating Guide for Maximum Efficiency

Fuel is a major cost in boiler operation.

It is therefore important to minimize fuel consumption and maximize steam production.

Heat loss to flue gas

Increased turbulence inceases the air - fuel mixing.

Impurities in water can collect and deposit on the tube surfaces.

These deposits reduce heat transfer and thus boiler efficiency.

Water treatment is essential to minimize deposits.

HIHI Hanil Heavy Industries Co., Ltd.

Push the push button, "BURNER STOP" during normal operation.

2.6 Abnormal Operation

1) Low Water Level

Operating a boiler with a known tube leak is not recommended.