PLAN HISTORY

DESIGN CHECKED REVIEWED APPROVED

NO. DATE DESCRIPTION
BY BY BY BY

1 11-12-13 FOR APPROVAL M.S.KIM - Y.C.KIM J.Y.JUNG

2 11-12-6 FOR REAPPROVAL M.S.KIM - Y.C.KIM J.Y.JUNG

3 11-12-17 FOR REAPPROVAL M.S.KIM - Y.C.KIM J.Y.JUNG

4 12-3-16 FOR WORKING J.E.KIM - Y.C.KIM J.Y.JUNG

4 14-12-11 FOR FINAL J.E.KIM - Y.C.KIM J.Y.JUNG

MACHINE TECH CO.,LTD.

INDEX

1. Specification of Exh. Gas Economizer

2. Drawings of Exh. Gas Economizer

3. Exh. Gas Economizer Accessories

4. Control Panel

5. Spare parts

6. Instruction maual

MACHINE TECH CO.,LTD.

 DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 1 of 14

CONTENTS

No. Title Page

1 Design/Construction 2
2 Operating Cycle 5
3 Installation 7
4 Caution on Hydraulic Test 9
5 Adjustment 10
6 Troubles and Shooting 12
7 Repair and Lapping 13
8 Reassembly 14
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1. DESIGN / CONSTRUCTION

Full Bore Type is provided that Seat Opening Diameter (SOD) is not less than 1.15 times the throat
Opening Diameter(TOD), and that the steam passage area of the seat when opened is not less than
1.05 times of the throat opening area, and that the area of the valve inlet and the connection nozzle
are not less than 1.7 times of the throat opening area.

Those valves have a unique Nozzle Seat which provides maximum capacity obtainable. The
discharge through this nozzle enters a body chamber which is carefully proportioned in the internal
contours and in the ratio of inlet to outlet area to minimize flow restriction and body pressure.

Especially for the positive proper adjustment of operating characteristic on fluid, One Ring is
adopted to obtain substantial adjustment to its pop action.

For easy access to resume normal seating face. if need due to failure of its trueness, the most
important characteristic of Flat Seat Nozzle Valve is the ease with which seating surface can be
reconditioned the slight deviation from the specific angles can lead leakage and faulty operation.

All important part are thermally balanced and precisely machined, thus assuring accurate alignment
regardless of temperature variation.

1.1 Valve trim

Trim parts in a safety relief valve include disc and nozzle seat only.
(1) Disc
A disc acts as the top guide and is guided by a cylindrical valve guide, standard
construction of safety relief valves includes metal-to-metal seats in a view of tightness
which provide commercial tightness acceptable for most applications or special bubble
tightness under certain conditions.

For reinforcement of seating faces both on disc and nozzle seat to insure their trueness from
violent and rapid shout down force during operating,
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Surfaces are carefully stilted and precisely lapped.

Maintaining the necessary operating clearance between disc and its guide assures free
movement under a certain temperature ranges given.
Please refer to limiting service conditions for keeping them from exposing thermal
expansion trouble as specified in catalog.

(2) Nozzle seat

As the nozzle seat is fully and tightly screwed up into the main body keeping seating face
same contour parallel, it will not come out of the position and any deviation from disc
contacting center.

Also, with a view to avoid any malfunction, leaks, or other problems which may be caused
by stress from the outlet piping or by thermal strains, the seat surface is designed to occupy
a position at the center of the body cylinder and separated as far as possible from the
contact position with body.

Since the fluid channel from the throat to the valve seat is the most important part
determining the performance of the valve, a logical Shape is provided so that there will be
no interruption in the fluid expansion.
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1.2 Adjust Ring

The ring screwed onto the circumference of nozzle seat,

The area expansion due to a small amount of fluid leakage just before the blow-off produces
pressure enough to lift the disc. this force causes a quick popping action of the valve. The
ring adjusts the simmer of the fluid.

The other name is (popping) Control Ring or Nozzle Ring.

1.3 Body

The body maintains tightness with its precise finishing and its stout construction ensures
safety against thermal stress due to the rapid variation in the temperature of the fluid to be
blown off as well as securing it against the reaction strength resulting from a large amount
of fluid blown off.

1.4 Bonnet

Standard construction of bonnet includes closed one to protect the internal spring and support
the adjusting screw.

On model SSRF open and yoke bonnet can be provided to ensure safety against thermal
stress due to rapid variation in the temperature of the discharging flow during blowing off

1.5 Cap construction and Lever

Standard caps for pressure relief valve are screwed or Bolted Top and Open Lever Top to
provide periodical test, for usage of which hermetic sealing is not required (with most uses
for steam and air) Adopted Test Gag on two kinds o top cap, when required, is handy for use
in hydraulic test.

On standard open lever, Fork lever are adopted to larger size valve.
 DOC. NO. JK-WIP-E-04
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SAFETY RELIEF VALVE
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1.6 Adjust cock (or needle)

When the safety valve is blowing off fluid, back pressure is applied to the back of disc and
the guide. The back pressure interferes with the valve when it is being lifted but assists it
when the valve is being closed.

To apply the back pressure most effectively, on additional cock which can be handled from
the outside, can be provided. Safety valve can be suitable provided with the adjust needle on
construction of open bonnet to prevent any trouble in the operation of it even if the throttle is
closed too much.

2. OPERATING CYCLE

All of safety-relief valves are of the direct spring loaded construction. The operating mechanism
of each type is as follows:

Should the pressure upstream of the valve rise abnormally and reach near to the set pressure, it
cause the balanced spring to push upward and the valve disc be slightly lifted up to make an
initial opening. Steam or gas gushing out of this initial opening will be guided by the properly
adjusted lower ring to exert dynamic pressures on the valve disc and the valve disc will be lifted
quickly, the valve will start to discharge.

In case of the Full Bore Type Valve. operating characteristic of which is controlled by the ring,
fluid discharged by the initial blowing-out will be deflected in a downward direction through
upper ring and this deflection as well as pressure generated between two ring are exerted on the
face of the valve disc to lift it to a higher position.

As the Low-Lift Type Valve is not provided with an upper ring, the fluid is deflected through a
chamber formed by the lower face of the valve disc and the lower ring. The valve disc is lifted by
static and dynamic pressure.

2.1 Close

when inner pressure is lower than set pressure, the valve disc keeps the condition of full close
due to differential power between the fluid pressure and the condition of full close due to
differential power between the fluid pressure and the counter-pressure by the adjusted spring
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SAFETY RELIEF VALVE
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2.2 Initial open

(Commence-to-blowout)
In case that the inner fluid pressure reaches near the set pressure, the power retaining valve
closed by the spring will be gradually overcome by the inner pressure allowing a little fluid
leakage into accumulating chamber which is formed between the lower and upper rings.

2.3 Full open

The pressure condensed in the accumulating chamber makers greater force to lift the disc
upward against spring force. This pressure leads popping action to lift up the disc quickly in
this case, the full open can be easily attained at the given overpressure above the set pressure.

2.4 Re-seating

Re-seating will be duly obtained at the adjusted ring mechanism after enhancement of
blow-off.
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4.2 Test gag

- Test gag should be used only when hydrostatic testing is performed at field
- Safety valve & safety relief valve are usually shipped with this gag
- The test gag should be furnished in accordance with following

5. ADJUSTMENT
consideration of service pressure characteristic
(differential between operating and set pressure)
In order to avoid unsatisfactory operation of safety relief valves in normal processing service. the
operating pressure of the system should not exceed 90% of the set pressure. in the pump and
compressor delivery line, however, the difference between the set pressure and the operating
pressure should be made large on account of the pulsation attributable to the pump delivery
pressure is a better method.
Before re-adjustment, remove a Pb seal to cap and set screws which is sealed to prevent arbitrary
adjustment by an incompetent and visual check of any external changes of set pressure or
blowdown pressure.

5.1 Adjustment of set pressure

The set pressure of each safety valve has precisely been adjusted and sealed
At our factory before the shipment, however in case that it is necessary to readjust at the
job-site to the state of the exhaust pipe, the amount of blowing capacity, and other factors,
readjustment can be done in the following procedure :
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Take off cap, loosen lock nut and turn down the adjusting screw to the right(clockwise
viewing from above) to raise set pressure and turn up the left (anti-clockwise viewing from
above) to lower the set pressure.

At the readjustment, be sure to lower the pressure of the system at below 90% of the set
pressure.
After completion of re-adjustment, screw up the adjusting screw with lock nut.

Tolerance of set pressure

unit : kg/cm2

SET PRESSURE TOLERANCE

5 excl. and under ± 0.14

over 5 and 23 excl. ± 3% (of set pressure)
 DOC. NO. JK-WIP-E-04
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DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 12 of 14

6. TROUBLES and SHOOTINGS

6.1 Leakage

The most frequent causes of leakage are from damages on the valve seat and adhering of
foreign materials on it. In these cases, pull the lever to blow off the dirt sticking from the
seat. If the leakage does not stop, the seat must have been damaged.
To avoid seating surfaces damaged by foreign materials. care should be taken thoroughly
from storage to installation which is the best practice after completely flushing out.
Refer to, when it is need, the repair and lapping procedures in para 7 for reconditioning

6.2 Incorrect popping pressure

If the safety valve does not operate at specified pressure, a major cause is accumulation of
dirt or scale between the disc and the guide or the change of the spring load due to bent of
stem. in the case, cleaning or
Dismounting for servicing is required.

6.3 Unstable operation

Unstable operation often results from wrong adjustment. the followings are the state of
unstable operation and its remedy.
(1) Simmer
When a simmer is present raise the lower ring(push the notches to the right while viewing
in front of notch) by one noter at a time. ( Never set the lower ring in contact with the
valve disc)
this is the case of the slightly weakening dynamic power to lower accumulation not
enough to lift up the disc.
(2) Chattering
This is a rapid reciprocating variations in valve lift during which the disc repeatedly
contacts the seat. It is because popping power is weak. In this case, bring up the lower ring
(closer to the bottom face of the disc but never contact each other)
(3) Hunting
This is the states where the disc repeats violent vertical motion during operation as if it
beat the seat violently. This is often caused when there is much flow restriction in the
piping connected with inlet and discharge side of the safety valve or when blowdown is
excessively too short, in this case, open the gland cock or needle valve or bring down the
upper ring to increase blowdown.

If hunting is not ceased despite the above adjustment, rechecking of the piping is
necessary.
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DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 13 of 14

7. REPAIR and LAPPING

In practice, the main necessary repair work will be lapping on the sealing surfaces of disc and
nozzle seat. Its procedure is as follows:

7.1 Kind of lapping compound

No. 1 Lapping compound:
Pasty mixture of compound No. 200 kneaded with rape oil into a cream form.
No. 2 Lapping compound:
Pasty mixture of compound No. 800 kneaded with rape oil into a form between cream and
liquid,
No. 3 Lapping compound:
Pasty mixture of compound No. 4000 kneaded with rape oil into a form between cream and
liquid.

7.2 Lapping procedure

(1) Coat a surface of lapping block thinly with No.1 lapping compound.
Elliptically move the lapping block to remove large scratches.
(2) Use No.2 lapping compound and make lapping in the same manner as procedure 1 to reduce
scratches in size.
(3) Finish with No.3 lapping compound. The lapping manner is the same as procedure 1.
(4) Finally, use No.3 lapping compounds and make mutual lapping of the valve disc and the
valve seat to finish them.
Mutual lapping is effected by lightly turning and reversing the valve disc on the valve seat.
The width of turning and reversing motion is 5 to 10mm, and mutual lapping should not be
continued too long. If it is continued too long, the outer side of the seating surface will
become dull. When the lapping is felt heavy by hand, stop doing it.

7.3 Washing
Carefully wash the valve seat and valve disc with cleaning oil or liquid after lapping to make
them completely free from lapping compound.

7.4 Inspection of lapped surfaces

Inspection of lapped surface is extremely difficult. Try the following method:
Lighten the lapped surface. If the brightness is even all over the surface, the lapping is
complete. If any shady portion is present, the lapping is incomplete.

Especially the following attention should be paid:

(1) Pay extra care not to damage or soil the lapped surfaces of valve disc and valve seat.
(2) Properly center the tip end of the valve spindle on the valve disc.
(3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
 DOC. NO. JK-WIP-E-04
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SAFETY RELIEF VALVE
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2.2 Initial open

(Commence-to-blowout)
In case that the inner fluid pressure reaches near the set pressure, the power retaining valve
closed by the spring will be gradually overcome by the inner pressure allowing a little fluid
leakage into accumulating chamber which is formed between the lower and upper rings.

2.3 Full open

The pressure condensed in the accumulating chamber makers greater force to lift the disc
upward against spring force. This pressure leads popping action to lift up the disc quickly in
this case, the full open can be easily attained at the given overpressure above the set pressure.

2.4 Re-seating

Re-seating will be duly obtained at the adjusted ring mechanism after enhancement of
blow-off.
 DOC. NO. JK-WIP-E-04
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SAFETY RELIEF VALVE
PAGE 7 of 14

3. INSTALLATION

3.1 Storage and Conveyance

Safety-relief valve are often off hand at the job site several months before they are actually
installed. Unless they are properly stored and protected their performance may be affected
deadly. Roughness in handling may damage valve appearance sharp, worst to crack, or cause
misalignment of the valve part. Furthermore carrying by pulling up the lever may cause
change of the spring set pressure and alignment of the stem.

3,2 Inlet side piping

It is the best practice to directly mount the safety and safety-relief valve in vertical position
on a nozzle of pressure vessel or a short connection which smooth flow of fluid.

Where rounded or beveled approaches can not be provided ahead of the safety-relief valve, it
is recommended that one size larger riser or fitting be used. The pressure drop in the valve
inlet piping should not exceed 3% of the set pressure.

Valves are sometimes badly damaged just as they go into service because of failure to clean
the connections.

It is essential that the boiler, pressure vessel, valve inlet, and all connections should be
cleaned thoroughly before the valve is mounted.

(1) Caution at inlet piping

Most of leak on valve performance are caused from failure to clean. Many valve are
damaged when first placed in service or even hydraulic pressure test under undue preparation
due to failure to properly clean the connections and piping when installed.

3.3 Outlet side piping

When arranging the discharge piping, pay due attention to the following points talking into
consideration that discharge piping should be simple and direct :

(1) Minimize the length and the number of bends of discharge piping so as to reduce the back
pressure of the valve to a minimum. Especially, when a silencer is used, note that the
discharge pipe tends to be long and
 DOC. NO. JK-WIP-E-04
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SAFETY RELIEF VALVE
PAGE 8 of 14

Gives a large pressure drop due to discharge exceed 10% of the set pressure.

(2) Discharge piping should be so designed that the weight of the piping will at no time be taken
up by the valve body.

A sufficient flexibility to the discharge piping is also essential to avoid strain on the valve
caused by thermal pipe expansion.

(3) Care on multi installation

When two more valves are installed to discharge into a common header the discharge
pressure due to the opening pressure of the remaining valves in the system.
(가) Valve with bonnet not vented
The discharge line pressure of these valves will increase the opening
pressure by the amount (kg/cm2) of the discharge pressure.
(나) Valve with bonnet vented
The set pressure of the remaining valves in the system will be reduced by the
amount (kg/cm2) of the discharge pressure.
 DOC. NO. JK-WIP-E-04
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SAFETY RELIEF VALVE
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※ Where either of the above conditions are unacceptable, the use of balanced bellows valves is
recommended.
Conventional valve with vented bonnet is not suitable for continuous back pressure.
Therefore never try to arrange discharge pipe from two or more valves into a common
header.

4. CAUTION on HYDRAULIC TEST

When hydraulic pressure test on the pressure vessel is conducted without removing the safety
valve installed on it. increase inner pressure of the vessel to 80 to 90% of the set pressure of the
valve, then mount the test gag to hold the end of the stem lightly in order to protect the valve
from damage caused by undue load.

Removal of the gag shall also be conducted at 80 to 90% of the set pressure.

When several valves are installed on a vessel or pipe line and one of the valves is being on
adjustment. The same caution should be taken at the mounting of the test gag or gags on the other
valve or valves to prevent it or them from blowing off.

4.1 Cautions
The test gag can not be mounted on the ordinary type caps. Therefore, the caps should be
replaced with those made for the purpose.

In case of pressure test for pressure vessels without using test gag, test them without the
safety valves for safety of it.

Removed valve should be covered at the flange parts against intrusion of dusts, etc.
Replace with a plug and gasket in case of closed top (or take off when open top) after the test,
otherwise the valve will not operate thereby creating a dangerous situation.
 DOC. NO. JK-WIP-E-04
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FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 10 of 14

4.2 Test gag

- Test gag should be used only when hydrostatic testing is performed at field
- Safety valve & safety relief valve are usually shipped with this gag
- The test gag should be furnished in accordance with following

5. ADJUSTMENT
consideration of service pressure characteristic
(differential between operating and set pressure)
In order to avoid unsatisfactory operation of safety relief valves in normal processing service. the
operating pressure of the system should not exceed 90% of the set pressure. in the pump and
compressor delivery line, however, the difference between the set pressure and the operating
pressure should be made large on account of the pulsation attributable to the pump delivery
pressure is a better method.
Before re-adjustment, remove a Pb seal to cap and set screws which is sealed to prevent arbitrary
adjustment by an incompetent and visual check of any external changes of set pressure or
blowdown pressure.

5.1 Adjustment of set pressure

The set pressure of each safety valve has precisely been adjusted and sealed
At our factory before the shipment, however in case that it is necessary to readjust at the
job-site to the state of the exhaust pipe, the amount of blowing capacity, and other factors,
readjustment can be done in the following procedure :
 DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 11 of 14

Take off cap, loosen lock nut and turn down the adjusting screw to the right(clockwise
viewing from above) to raise set pressure and turn up the left (anti-clockwise viewing from
above) to lower the set pressure.

At the readjustment, be sure to lower the pressure of the system at below 90% of the set
pressure.
After completion of re-adjustment, screw up the adjusting screw with lock nut.

Tolerance of set pressure

unit : kg/cm2

SET PRESSURE TOLERANCE

5 excl. and under ± 0.14

over 5 and 23 excl. ± 3% (of set pressure)
 DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 12 of 14

6. TROUBLES and SHOOTINGS

6.1 Leakage

The most frequent causes of leakage are from damages on the valve seat and adhering of
foreign materials on it. In these cases, pull the lever to blow off the dirt sticking from the
seat. If the leakage does not stop, the seat must have been damaged.
To avoid seating surfaces damaged by foreign materials. care should be taken thoroughly
from storage to installation which is the best practice after completely flushing out.
Refer to, when it is need, the repair and lapping procedures in para 7 for reconditioning

6.2 Incorrect popping pressure

If the safety valve does not operate at specified pressure, a major cause is accumulation of
dirt or scale between the disc and the guide or the change of the spring load due to bent of
stem. in the case, cleaning or
Dismounting for servicing is required.

6.3 Unstable operation

Unstable operation often results from wrong adjustment. the followings are the state of
unstable operation and its remedy.
(1) Simmer
When a simmer is present raise the lower ring(push the notches to the right while viewing
in front of notch) by one noter at a time. ( Never set the lower ring in contact with the
valve disc)
this is the case of the slightly weakening dynamic power to lower accumulation not
enough to lift up the disc.
(2) Chattering
This is a rapid reciprocating variations in valve lift during which the disc repeatedly
contacts the seat. It is because popping power is weak. In this case, bring up the lower ring
(closer to the bottom face of the disc but never contact each other)
(3) Hunting
This is the states where the disc repeats violent vertical motion during operation as if it
beat the seat violently. This is often caused when there is much flow restriction in the
piping connected with inlet and discharge side of the safety valve or when blowdown is
excessively too short, in this case, open the gland cock or needle valve or bring down the
upper ring to increase blowdown.

If hunting is not ceased despite the above adjustment, rechecking of the piping is
necessary.
 DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 13 of 14

7. REPAIR and LAPPING

In practice, the main necessary repair work will be lapping on the sealing surfaces of disc and
nozzle seat. Its procedure is as follows:

7.1 Kind of lapping compound

No. 1 Lapping compound:
Pasty mixture of compound No. 200 kneaded with rape oil into a cream form.
No. 2 Lapping compound:
Pasty mixture of compound No. 800 kneaded with rape oil into a form between cream and
liquid,
No. 3 Lapping compound:
Pasty mixture of compound No. 4000 kneaded with rape oil into a form between cream and
liquid.

7.2 Lapping procedure

(1) Coat a surface of lapping block thinly with No.1 lapping compound.
Elliptically move the lapping block to remove large scratches.
(2) Use No.2 lapping compound and make lapping in the same manner as procedure 1 to reduce
scratches in size.
(3) Finish with No.3 lapping compound. The lapping manner is the same as procedure 1.
(4) Finally, use No.3 lapping compounds and make mutual lapping of the valve disc and the
valve seat to finish them.
Mutual lapping is effected by lightly turning and reversing the valve disc on the valve seat.
The width of turning and reversing motion is 5 to 10mm, and mutual lapping should not be
continued too long. If it is continued too long, the outer side of the seating surface will
become dull. When the lapping is felt heavy by hand, stop doing it.

7.3 Washing
Carefully wash the valve seat and valve disc with cleaning oil or liquid after lapping to make
them completely free from lapping compound.

7.4 Inspection of lapped surfaces

Inspection of lapped surface is extremely difficult. Try the following method:
Lighten the lapped surface. If the brightness is even all over the surface, the lapping is
complete. If any shady portion is present, the lapping is incomplete.

Especially the following attention should be paid:

(1) Pay extra care not to damage or soil the lapped surfaces of valve disc and valve seat.
(2) Properly center the tip end of the valve spindle on the valve disc.
(3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
 DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2001. 10. 26
SAFETY RELIEF VALVE
PAGE 14 of 14

8. REASSEMBLY
Reassembly will be made following the reverse order of disassembly.

Especially the following attention should be paid:

(1) Care should be taken not to damage or soil the lapped surfaces of valve disc and valve seat.
(2) Properly center the tip end of the valve spindle on the valve disc.
(3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 1 OF 8

1. Description

A water tube exhaust gas boiler requires a continuous forced circulation of water through the boiler as dry running
would seriously increase the danger of a fatal soot fire. The forced circulation is provided by two circulating pumps.
One of the pumps must be kept in continuous operation ( also in port ) and the other pump in automatic standard -
by operation mode.
The circulation flow measurement control system will ensure a continuous water circulation.
The system consist in general or an orifice, differential pressure indicator switch, see Figure 1.

Illustration of the circulation flow measurement system

Figure 1

The office will protect the pump by reducing the discharge flow variations resulting from different working
conditions. The pressure drop in the boiler and circulation return pipe as well as the required static lift
(due to differences in specific volumes between water and steam / water mixture in the return pipe)
strongly depend on the boiler load and are smallest when no steam in generated.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 2 OF 8

This might give rise to large flow variations which would not be desirable for a reliable pump operation.
However, variations are reduced when the pressure drop across the orifice becomes considerable compared
to the total back pressure ( at design load ).
The differential pressure indicator switch has two switches which should be user for:
- Alarm in case of low circulating water flow.
- Start of the stand-by pump in case of too low circulating water flow.
In additional to this, the stand-by pump should also be started in case of overload on the motor of the operational
pump.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 3 OF 8

2. Recommendations

The typical system is shown in Figure 1. The actual system may be slightly different but the following descriptions
and recommendations would generally still be valid.
All the components of the circulating system have to be carefully designed and installed to ensure a reliable,
continuous circulation in the exhaust gas economizer under all working conditions.
The following working conditions must be taken into account when designing the circulating system:

2.1 Main engine not running

The boiler and pipes are all filled with water and pressure drops are relatively small. The total flow calculated
under these conditions is the maximum expected circulating pump discharge flow.

2.2 Start of the main engine

When the steam production starts, most of the water in the evaporator tubes and circulating return pipe will be
forced into the oil-fired boiler / steam drum causing a certain (considerable) water level increase (swell). The
feed water supply is temporarily closed until the water level has dropped again.
All the components of the circulating system have to be carefully designed and installed to ensure a reliable,
continuous circulation in the exhaust gas economizer under all working conditions.

2.3 Steady load on the main engine

The medium in the evaporator and return line is a mixture of steam and water, and the pressure drop will increase
considerably due to the high specific volume and velocity of the medium. The pressure drop depends on both main
engine load and circulating water flow. The height between the water levels of the oil-fired boiler / steam drum and
the exhaust gas economizer evaporator section should be taken into consideration when steam is generated due to
difference in the specific volumes of water to the evaporator and mixture of water and steam from the evaporator.

2.4 Changes in the steam demand

Sudden increases in the steam demand (e.g. due to tank cleaning, soot blowing, etc.) will inevitably cause the steam
pressure to drop creating instability in the system. Boiling will start (close) below the water level surface of the
oil-fired boiler / steam drum until the water temperature has stabilized again at the saturation point. The extent of
this phenomenon depends entirely on the pressure decrease rate and size. Very large and sudden drops could cause
boiling in the entire system. This again could cause cavitations in the circulating pumps eventually leading to
pump failure.
 DOC. NO. SPP-DM-001
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Circulation flow measurement DATE -
PAGE 4 OF 8
2.5 Shut-down of the main engine
The steam volume in the evaporator section and return pipe will be replaced gradually by water. As the feed pump
capacity is normally smaller then the circulating pump capacity, this will create a certain (considerable) water level
decrease (shrink).

2.6 Circulating pump calculations

Special attention must be paid to the circulating pump installation as it is vitally important that the pumps are
running without any problems at all.

2.7 Circulating pump capacity

The pump discharge flow must never be less than indicated and the discharge head must be sufficient to ensure this.
As a guideline for the circulation at design load the combined pressure drop across the orifice should not be less
than 1.0 bar.
The preliminary design derives from a calculation based on steady load on the main engine at design load
The system then has to be calculated at full boiler load to confirm that he total circulating water flow is not less
than the minimum specified. If the total flow turns out to be insufficient then the pump capacity must be increased
and the system recalculated at design load and full load.
The maximum flow determines the motor size required and the location of the pumps.

2.8 Circulating pump suction conditions

The overall aim is to ensure the best possible suction conditions so that cavitations in the circulating pumps will
not occur under any working conditions. Cavitation involves serious consequences such as:
- Increased risk of a fatal soot fire due to reduced or even stopped circulation of boiler water.
- Excessive wear on impellers, bearings, etc.
- Troubles with leaking or destroyed mechanical shaft seals.
Cavitation will not occur as long as the NPSH (net positive suction head) available at the pump suction inlet is
higher than the NPSH required by the pump. The following important points should be considered carefully:
- The NPSH required by the pump is entirely determined by the particular choice of circulating pump and depends
on the discharge flow as shown on the pump performance curves. The pump manufacturer has various means
for reducing the NPSH, if required (e.g. reduced speed, inducer, etc.).
- The suction pipe must be designed in accordance with the recommendations of the manufacturer. The water
velocity should not exceed 0.5 - 1.0 m/s and the pressure drop in general should be as small as possible.
- The suction pipe must have a continuous fall from the suction valve on the oil fired boiler / steam drum to
the pump.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 5 OF 8

3. Installation

The installation details are described in this section and in Figure 2. The important points mentioned below
should be observed.

Detail drawing of Installation

Figure 2

3.1 Orifice
The orifice must be installed in a straight pipe with a length of at least 25 and 10 times the nominal pipe size before
and after the orifice, respectively. The orifice must be properly centered by means of flange connection bolts.

3.2 Differential pressure indicator switch

The pipe connections for impulse legs should not be located closer to the orifice than 2 and 5 times the nominal
pipe size before and after the orifice, respectively. The connections should be located on the lower side of the pipe
for proper venting when installed in a horizontal pipe.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 6 OF 8

The impulse legs must be of sufficient length to avoid overheating of the pressure switch. The impulse legs must
be provided with isolating valves close to the circulating water pipe. Additional valves at the pressure switch as
well as drain cocks are recommended for easy blow-out of the impulse legs. The recommended minimum pipe
size is 8 mm (OD).
The pressure switch should always be located below the lower impulse leg connection. The high pressure impulse
leg (before the orifice) must be connected to “+” and the low pressure impulse leg connected to “-“.
The impulse legs must be designed in such a way that there is no strain on the pressure switch.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 7 OF 8

4. Operation

4.1 Operation
It is essential that the circulating water pumps are running continuously (also in port) without any problems.
The system behavior under all working conditions should be observed during the first period of operation,
especially at full load, no load (main engine stopped) and large load variations.
In case of low flow alarm at full load, the mixing valve should be re-adjusted (if required, to a higher total flow
rate) in accordance with the above instructions.
Check that the circulating water flow does not exceed the permissible range of the circulating pumps at any
load conditions. In case of automatic stand-by pump start, the cause should be investigated immediately so that
the necessary action can be taken to eliminate the operational problems.
The impulse legs for the differential pressure indicator switch should be regularly blown through to remove
deposits, if any. The switch should not be reconnected before the temperature is sufficiently low.

4.2 Set points

Set point record

Pressure drop across orfice
Object
[bar]
Design flow 0.5
Low folw alarm 0.33
Stand-by pump start 0.18

Enter corresponding water flow (㎥/h) at design flow, low flow alarm ( 80% of design flow ) and stand-by pump
start ( 60% of design flow ). Use throttle orifice performance curve ( provided in the documentation ) to find
pressure drop across orifice at the specified 3 conditions.
 DOC. NO. SPP-DM-001
REV.NO. -
Circulation flow measurement DATE -
PAGE 8 OF 8

4.3 Performance data of Orifice

6. Instruction Manual
 SECTION A. DESCRIPTION

1. INTRODUCTION

It is advisable that this instruction book should be read and understood throughout

prior to using or operating the “ EGE ” (Exhaust Gas Economizer) for Installation,

Operation, Handling, Maintenance and Precaution.

This instruction of EGE, somewhat differs from the others depending on the

arrangements of ships related to the each vessel, however, the general guidance

will be given to this instruction book for all SPP Machine Tech EGEs.

Page 1
2. EGE(ECONOMIZER)

SPP Machine Tech EGE, comprises sections of Heating Coils with their

characteristic function, a steam generator. The elements in each section are formed

from steel tubes with steel fins welded in position on each side.

The EGE is a waste heat recovery unit, generating steam from exhaust gas of

diesel engine or others. The EGE is always operated in conjunction with a steam

separator. (Aux. Boiler)

The construction is an assembly of horizontal elements which is comprised by coils

of tubes, the tubes being connected to each other by return-bends and to the

headers by stubs. Pressure part connections are separated from gas stream by

the tube and supports, access being provided by gas tight panels which are welded

on.

Access doors are provided in the end casing by bolting for inspection of return-

bends and headers or for removal of coils a substantial framework is incorporated

and casings are stiffened to withstand engine exhaust gas pulsation’s.

Page 2
3. WATER/STEAM FLOW

EGE is water tube, forced circulation type and works in combination with water tube

boiler at all times in order to separate the steam from the circulation water.

For EGE, the water saturated is drawn by a circulation pump from the generating

vessel, boiler and passing through the generator coils, is returned to the generating

vessel as water/steam flow is upwards through liberally proportioned paths with

single or double flow and the internal pressure losses are relatively low.

The feed water is direct into Aux. Boiler at a temperature as specified on the

drawing or the enclosed performance date sheet. To avoid low metal temperature of

heating tubes and possibility of corrosion, the Circ. water temperature should not be
below 115 degree C.

Page 3
 SECTION B. INSTALLATION

1. POSITIONING

1.1 The unit should be supported on a stable structure as pre-arranged, and

adequately stayed to a stiffened bulk head. Allowance for thermal expansion

must be made in the joints between the feet of the unit and the supporting

chocks and steel members.

For convenience of installation the base support plate of EGE is arranged by

slot-holes.

1.2 The units for very large one are built in two or more parts if necessary or

required. On installation, these parts must be carefully aligned.

Any distortions caused in transit or handling must be remedied before the

joints are bolted. After bolting, the joint must be seal welded on the outside,

also seal welded the heads of the bolts and the nuts.

1.3 On the gas side, the EGE is naturally arranged in the engine exhaust trunk

type, chamber type, with entry and exit connections to promote a good flow
distribution over all heating surface and to inspect the heating surface. The

inlet-outlet trunking connections, necessary fittings, accessories, inlet duck if

supplied and so on will have to be installed after installation of EGE body.

1.4 After perfect installation of EGE body, the bracing should be arranged in each

four direction of rectangle body in case the unit is over than 5 ton/hr – steam

evaporation capacity. The connections are to be made by slot holes and the

rolling and pitching movement of ship should be considered. But we not

recommend the installation of bracing of the height of EGE is less than

1500mm.

1.5 Facilities for water washing of heating surface and casings should be provided

Page 4
 above of the unit, and the collecting hopper, with large bore drain port, must

be positioned below of the unit to prevent any water entry into the main engine.

For routine on-load cleaning, conventional soot blowers are recommended and

for off-load cleaning, the water washing through the access door of outlet trunk

recommended.

Ample access above and below the unit should be arranged for inspection and

water washing.

1.6 The tube removal space to be arranged for inspection and maintenance.

External pipework should be clear and permit ready access to all inspection

doors, anchors to be of the main structure only.

1.7 The piping arrangement should incorporate stop valves and the necessary
complement of additional mountings and fittings as required by the overall

layout and the appropriate classification society.

Discharge pipework between the EGE and the boiler should be of ample size
and fitted with straight through valves for minimum pressure losses.

Provision for expansion is required to prevent undue stresses in the headers

and tubes of the unit.

1.8 All valves must be either fully open or closed and it is important to ensure that

any automatic valves in the circuit cannot be arrested in an intermediate

position.

Page 5
2. LIFTING AND HANDLING

2.1 Lifting Generally the lifting lug is fitted at the top of the unit according to the

quantity of column, I-BEAM. It is recommended that these lugs be only used

with wire rope and lifting beam when lifting the unit.

The wire rope to be decided and designed in accordance with the EGE weight.

When lifting, the total weight to be distributed to each rope uniformly and the

length to be equalized.

If the unit is less than 10 Tons, its advisable to use the bracing lug instead of

lifting lug. In this case the lifting method is identical with the above condition.

The wire rope should be arranged in parallel direction against the unit side

column, I-BEAM and should not become together at one point.

2.2 Handling

The EGE unit should always stand-up vertically because the heating coils are
supported by pipe sleeve of end supports for thermal expansion.

If the unit is less than 5 ton, it may be laid down on the ground with several

props.
When standing up on the ground, the proper prop also to be used and the

height should be a horizontal level at the each supporting point.

If wooden props are supplied, the additional supports will be not necessary.

Page 6
3. PREPARATION FOR CLEANING

Man-hole for inspection should be arranged at chamber (smoke box) of the above

and below of the unit, a large bore drain port also to be arranged at the bottom of

the unit to prevent water from going into Turbo-Generator.

The water washing for heating coils should be carried out through the man-hole of

outlet chamber side, therefore a suitable man-hole or access door required at the

gas outlet side of the unit.

Drainage for return-bends washing is provided by suitable drain holes at the bottom

side of EGE casing in order to inspect the cleaning situation when washing.

The mixed water with soot are dropped toward the inlet chamber and drained

through the drain nozzle of inlet chamber.

Page 7
4. SYSTEM PROVISION

If the damper system fitted to control the steam output, it is arranged over the unit.

The operation mechanism is linkage and may be hand operated or fitted with

automatic actuator by suitable control system.

Therefore lubrication provision to be provided at the linkage and bearing.

Where divided headers are arranged for steam output control, it must be served by

manifolds and it is necessary to eliminate pressure built-up in a closed pocket.

A further system for output control can, where convenient, be arranged by a direct

steam lead to the auxiliary condenser, dump system.

Page 8
 SECTION C. OPERATION

1. GENERAL

Operation of the EGE will be dependent upon the individual ship’s system but it is
possible to give some general guidance.

Under the operation, the circulation pump should always be kept running before

main engine started and after shut down of main engine the circulation pump to be
kept running for 12 hours or more. Valves except drain valve are to be opened.

2. START UP
2.1 Softened and deaerated feedwater is obviously preferable for reducing

interior fouling and corrosion.

2.2 Before start up, it is important to ensure that all valves, with the

exception of the circulation pump discharge valve, between the steam

generator section and the steam generating vessel are fully opened to permit

free flow conditions.

2.3 Open the air vent valves of each header and close the drain valves and open

the pressure gauge root valves.

2.4 It is also important to start the circulation pumps immediately prior to starting

the main engine. Pay attention to this point.

2.5 Open the circulation pump discharge valve gradually after confirm the above.

2.6 It is preferable for the circulation water to have a hot or pressurized steam
separating vessel(Aux. Boiler). In this way the tube warming must be kept and

effected before the engine commences to run, the corrosion is thereby

minimized, or alternatively, if the tubes are already hot, the element cooling

rate will be retarded when water is circulated through the tubes.

2.7 The circulation water flow should be gradually increased at the pump

discharge valve until the tube element temperatures are stabilized in

accordance with the gas and water temperatures, after that rapid circulation is

required for maximum steam output.

2.8 Close the air vent valves for generator section after ensuring thatwater or

Page 9
 steam is issuing from air vent valves.

2.9 Also check the steam evaporating at the air vent valve of steam generating

vessel and then close this valve when steam starts to evaporate.

2.10 When the pressure of Aux. Boiler reaches the specified value, operating

pressure, open the main steam outlet valve little by little.

Page 10
3. SHUT DOWN
3.1 The circulation pump should be continuously operated for twelve (12) hours

at least or more after main engine shut down. During this operation of pump

the followings should be checked and inspected.

- Check the inside, heating surface, through the manhole or inspection door

whether any sparks due to soot accumulations in the heating surface are

being generated or not. It must be eliminated.

- Inspect the situation of soot accumulation in heating coils. If it is

abnormality, water washing should be carried out.

- The EGE must be free from abnormality in appearance and also its surface

temperature should be normal.

3.2 Stop the circulation pump after inspection of above and then close the all

valves of circulation line and open the drain valves of each section.
3.3 Shut down would be in reverse procedure for start up, commencing with

isolating of the steam generator section.

3.4 If there is evidence of active corrosion under port conditions, it is advisable to

practice continuous water circulation from the auxiliary boiler in order to

maintain elevated metal temperature.

4. CONTROL
4.1 If divided headers are included, sections may be isolated so that amount of

heating surface actually in use is proportionate to steam requirements. Where

control conditions allow, the Economizer section should be carried out dry-

running before any steam generator paths are isolated. In these

circumstances the boiler should have direct feedwater. In this case, the

valves serving those sections not in use must be closd and water in those

sections should be fully drained after closure of the inlet/outlet valves.

“ SEE DRY-RUNNING ”

4.2 The steam output should not be controlled by curtailment of circulation water

flow at any case. This promotes deposition of water treatment additives and

solid matter within the tubes. These depositions decrease the heat transfer

Page 11
 efficiency consequently.

Furthermore, in the worst condition this deposition may clog the pipe inside

and sootfire may take place.

4.3 Under steaming condition, the unit should operate at all times with line valves

fully open to provide the maximum circulated water flow.

The circulation water should flow continuously at the maximum flow rate.

4.4 If the preheating section fitted, the inlet temperature at Economizer section
should be kept by specified value in this instruction or on specification sheet

and flow diagram in final drawing at any case during operation of main engine.

The exhaust gas contains the sulfur dioxide(SO2) forming from sulfur of fuel

oil.

If the water temperature in tube inside is decreased below the specified

temperature the condensation of sulfur dioxide will occur on the surface of the
heating tubes and then result in sulfur corrosion, called low temperature

corrosion of heating tubes in exhaust gas boiler system.

If low pressure evaporation section is provided(DUAL PRESSURE EGE), the

low pressure circulation water should be kept by specified temperature by

reason of the above.

4.5 No-water heating should not be performed generally except the emergency
condition or trouble of circulation pump. However, in case no-water

heating(dry-running) is unavoidable, followings are to be ensured as

emergency measures :

- The inside of header and heating tubes should be free from pressure and

water. The drain and air vent valves should be opened and also the

inlet/outlet of this section must be closed.

- The exhaust gas temperature at the inlet of EGE must be maintained below

the maximum allowable temperature for example, 400 Deg. C. for carbon

steel Boiler tube.

- When this condition is done, the inside temperature of the unit will be

increased and the soot fire may by occurred more easily. Therefore, the

heating surface must be kept clean throughout by soot-blowing or water-

Page 12
 washing before dry-running performed.

- See dry-running for the others.

4.6 If damper system is included, the flow of gas will be controlled by dampers.

These have a self lubricating bearing inside of the unit but the lubrication is

required for outside bearing and linkages of it. The damper system should be

operated throughout the full arc of travel at least once a day in order to

release the lubricant bearing and in order to ensure freedom of movement.

This system can be operated by automatic or manual remote or operating a

handle, where convenient.

Page 13
5. DRY-RUNNING

CATION: It is only allowable to perform dry running in case emergency measure, with
under paying attention to below points:

5.1 GENERAL GUIDANCE

① Prior to dry running, inspect and clean heating surface by water if any soot is

present, to prevent economizer from soot-fire.

② Close valve at inlet of EGE, leave outlet valve open.

③ Close all drain valves after draining.

④ The leaky tube-bundle must be drained and be kept dry.

⑤ Soot-blowing is increased frequently than usual to keep heating surface clean

during dry running.

CAUTION: If ignition (soot fire) has started, do not operate soot blowers not

to accelerate fire by air or steam.

⑥ Exh. Gas temperature of economizer inlet must be kept below 400℃.

⑦ Monitoring of the inlet and outlet gas temperatures in important to ensure that

no sudden rises occur. Temperature excursions may indicate the presence of

a soot-fire

⑧ Excessive thermal shock stress to tube-bundles by sudden change of

temperature must be avoided prior to dry running and before water circulation.

5.2 RE-OPERATION FROM DRY RUNNING

Open the air vent and drain valves and open outlet valve slowly. The inlet valve must

be opened little by little with checking the water or steam output from air vent and

drain valves. It is preferable to ensure that the heating coils are cooled and reach the

normal operating temperature before full open of the inlet valve. After that, close the

air vent and drain valve, open the inlet/outlet valves fully to permit normal operation.

Page 14
 SECTION D. MAINTENANCE

1. CLEANING “ IMPORTANCE ”

1.1 GENERAL

High velocity gas flow coupled with good combustion and maintained
operational temperatures ensure minimum deposit formation for heating

surface at exhaust gas side.

Conventional soot blowers should be used as required and water washing

should be carried out at times when the main engine is off.

The circulation water with good treatment of boiler water will reduce the scale

at tube inside and maintain the good efficiency of heat transfer.

Gas leakage check from the unit, manhole, inspection door and casings, and

circulation water treatment check are required as recommended. The draft

loss, differential pressure of gas, between the inlet and outlet of the EGE body
should be carefully inspected and recorded in order to judge the situation of

deposit formation in heating surface.

1.2 WATER WASHING

Under on-load of normal sea going, appropriate soot blowers are

recommended and under off-load water washing is recommended,

respectively. Before the water washing, ensure that the drain hole is clear and

the drain pipe line is free from clogging. A soaking spray with a 10 percent

soda ash solution is advisable before washing, particularly where deposits are

highly corrosive.

Water washing will be done by hand hose or convenient device if fitted. The

washing should be carried out through the manhole of outlet chamber of EGE

unit, smoke box. In this case the water must not enter into the Turbo-

Generator and the heating surface should be washed perfectly in the whole

surface, especially corners until the washed water is clear at the drain ports of

the bottom of hopper. The soot blowers can not be perfect to remove soot,

Page 15
 consequently water washing must be done with regular interval, once per two

months in case the heating surface has a normal condition. However, the

actual frequency of water washing should be determined by inspection of the

surface situation.

After water washing, open the inspection doors and access doors and then

inspect the inside of the unit throughout. It is advisable to perform the water

washing just after circulation pump shut down because the heating coils
remains hot and the corrosion will be thereby reduced. The exhaust gas

temperature, the casing surface temperature, the draft loss, gas color coming

from the funnel and the spark situation in exhaust gas etc. must be carefully

inspected to decide the frequency of water washing and soot blower operation

and also to prevent soot fire.

1.3 SOOTBLOWER OPERATION

The soot blowers will be always provided as required by steam type, air

blowing type and sometimes supersonic waves type.

The frequency of soot blower operation should be also dependent upon the
soot deposit conditions in the heating surface. Therefore regular inspection of

the heating surface through manholes and inspection doors is required. Soot

blowing is not the complete answer but will remove dry loose deposits until
washing can be carried out.

Under normal operation conditions, soot blowing should be carried out at

regular intervals determined by experience and inspection of the heating

surface.

If the unit is operated under adverse soot forming conditions and low speed

operation of main engine, the soot blowers should be operated more

frequently. Soot blowing should also be carried out immediately before

shutdown of the unit, before dry running, and after turbo blower washing.

The draft loss and gas temperature should be measured regularly and

recorded if necessary. If the draft loss is increased above 1.3 times as

Page 16
 compared with that of normal condition, it means that soot deposits were

accumulated on the heating surface.

In this case the soot blowers should be operated more frequently and water

washing should be done as soon as possible.

Furthermore, if the gas outlet temperature is increased abnormally, it means

that the heating surface was fouled and the heat transfer efficiency was
deteriorated. Also in this case the soot blowers have to be operated more

frequently and the sooner water washing performed, the better efficiency

promoted.

1.4 WATER SIDE CLEANING

The standard data of water quality should be in accordance with the below

table specified for the steam separating vessel.

The circulation water should be controlled as recommended in order to

prevent the tube inside from scale.

1.5 RECOMMENDED OPERATING METHOD OF SOOTBLOWER

1.5.1 Manual Operated Type

The recommended operating procedure is as follow. In case only 2 sets

are provided, it is general that the soot blowers will be installed at the
same height( same level). Firstly operate No.1(one set), and next

No.2(the other set), and then operate No.1 soot blower again. In case 4

sets or more are provided, the soot blowers will be installed at different

height(the upper 2 sets, the lower 2 sets).

1.5.2 Automatic-Manual Operated Type

Soot blower serves automatic mode and manual mode.

1.5.2.1 Automatic operation

① Turn the “AUTOMATIC-MANUAL” mode selector switch to

“AUTOMATIC” mode.

② Soot blowing is carried out every 8 hours.

- Soot Blowing Interval

Under automatic operation mode, soot blowing is carried out

Page 17
 every 8 hours. This time interval is recommended value, so it is

changeable for the condition of main engine, exhaust gas, etc.,

by changing of the digital timer setting.. This recommended

value is based on the conception of 3 times per day blowing to

remove the soot effectively. But the differential pressure is

higher than 120mmAq(your requirement value), the soot blowing

interval should be changed.

- Operator should observe the differential pressure of the U-Tube

manometer or differential pressure gauge and then manipulate

the soot blower suitably.

1.5.2.2. Manual operation

① Turn the “AUTOMATIC-MANUAL” mode selector switch to

“MANUAL” mode.
② Soot blowing is carried out by turning the “START-STOP” mode

selector switch to “START” position.

- Operator should observe the differential pressure of the U-Tube

manometer or differential pressure gauge and then manipulate the

soot blower suitably.

Page 18
 1.6 STANDARD DATA FOR WATER TREATMENT

Items Feed Water Boiler Water

PH at 25 Deg. C 7 or above 11.0 - 11.5

Hardness (CaCO3) ppm 2 or below -

Oily Content ppm Keep it close to zero -

Dissolved Oxygen (02) ppm Keep low -

P. Alkalinity (CaCO3) ppm - 350 or below

M. Alkalinity (CaCO3) ppm - 450 or below

Chlorine Ion (C1-) ppm - 100 or below

Phosphate (PO43-) ppm - 10 - 30

Silica (SiO2) ppm - 50 or below

Total Dissolved Solids ppm - 1500 or below

It is advisable to determine kind of compound, charging amount and method

of control for feedwater and boiler water in consultation with the compound

maker. It is also preferable to send some boiler water to the compound

maker and get the detailed analysis and recommendation in order to maintain

good quality of circulation water.

It is essential that the circulation water should be circulated sufficiently and

continuously and then the scale accumulation will be reduced accordingly.

If the scale has been accumulated on the inside of tube, it must be removed

by chemical cleaning.

Page 19
2. EMERGENCY REPAIR
In the unlikely event of a tube failure, a temporary repair may be done by cutting

free the terminal ends of the water(steam) path affected.

Insert the tube plug into the header stubs and weld to the headers stubs.

For a more permanent repair with minimum loss of heating surface, it is possible to

bypass the affected tube by welding straight piece across selected bends.

Where divided headers are fitted, that section containing the faulty tube may be

isolated by blanking plates between the joint flanges, or by other convenient means.

The effective heating surface is of course reduced considerably, and the output

may be severely restricted.

The procedures are as follows :

2.1 Find the position of failed tube through manholes and inspection doors by

operating the circulation pump.

It is advisable to inspect which point the water is leaked.

2.2 Open the and casing doors of header side.

Take care of them with no damage because they are used again.

2.3 Cut off the affected tube from the inlet and outlet headers with care of the

cutting position.

Refer to Figure 1 on page 26.

2.4 Provide the tube plug. The cross section is to be made by a right angle with

longitudinal axis of the tube and the stub should have a circle instead of oval

by using sand paper or another method to prevent leakage of water or steam.

2.5 Fix the body of plug at the tube stub tip.

2.6 After the plug is fixed in position, the hydrostatic test should be carried out to

ensure that no leakage occurs. The cutting points of coil side must be

plugged by means of convenient method and then close the doors finally.

3. PERMANENT REPAIR

It is dangerous to interfere with the pressure parts of the EGB while they are under

pressure. To carry out repairs, the EGB must be completely isolated on both the

flue gas side and the water side. Prior to draining the unit, it is necessary to

ascertain the correct position of the leak and mark the faulty element.

Page 20
 For a permanent repair it will be necessary to withdraw the affected coil from the

EGB unit. Remove the appropriate casing from each and of the unit and any end

casing supports which will interfere with the withdrawal of the coil.

3.1 Superheater Section

The superheater is sometimes split into sections with the supporting boxes

containing a multiple of elements.

In this case one complete section must be removed from the EGB.
Cut off the header bends, remove all the bolts from the end box at each end

of the unit, remove the sealing plate from over the element and boxes at each

end, and withdraw the section.

3.2 Steam Generator Section

The steam generator is arranged for either single or double flow on the water

side and the elements are built into coils, one element wide. See the removal
of coils.

3.3 Economizer Section

The Economizer section is usually arranged in flow paths which accompany

horizontal as well as vertical return-bends.

So all bends attaching the vertical column of tubes should be removed to the

column on each side, or to the headers before withdrawal of coil.

4. REMOVAL OF COILS (Refer to Figures 3,4 on page 27)

4.1 Remove the end casing doors of the both sides (1). These doors to be re-

used therefore, take care of them with no damage.

4.2 Cut off the connections (2), (3), (4) and (5).

The stubs of headers should not be shorter than that of original.

4.3 Remove the bolts (6), (7) and (9) for the both sides and then remove the flat

steel (8) except that of header side.

4.4 Remove the support (10).

4.5 Pull out the heating coil with failure by using a chain block. If the unit don’t

have intermediate supports it is possible to remove the tube one by one.

4.6 To assist in the withdrawal of a coil, it is advisable to insert a strip of steel

plate under the coil but over the support, on which the coil can slide.

Page 21
 The plate should be well greased and should have a lip fitted over the bottom

end support at the end opposite to the withdrawal end. Lift the coil a little to

give clearance for the plate to be inserted.

4.7 When the coils are withdrawn, use the shims where necessary to prevent the

fins interlocking with those on adjacent coils.

Page 22
5. RENEWAL OF COILS (Refer to Figure 2 on page 26)
5.1 Spares

The spares supplied with the unit include sufficient bend spares to enable

repairs to be carried out.

5.2 Renewal is the reverse procedure for removal of coils.

The end of all tubes and bends should be prepared in readiness for welding

by using a grinder.

The tube or bend ends should be cut back to the weld, or the equivalent

distance from the element end supports, before dressing the ends.

5.3 Insert the coil into the EGB and weld to the header stubs.

In the Economizer section, weld on the return bends in the same pattern as

they were prior to removal of the element column.

5.4 It is important to ensure correct fin alignment between the new element using
the welding clip provided in the tool box, tack weld the bends in position.

Remove the clips and finish welding the bends ensuring minimum internal

weld deposition.

Page 23
6. HYDROSTATIC TEST
Whenever repairs are made to any of the pressure parts of the EGB the unit must

be hydro statically tested to the satisfaction of the inspecting authority.

The original test pressure for the EGB will be shown on the pressure part drawing.

Under the emergency repair this test will be done less than the safety valve setting

pressure, normal working pressure recommended.

In case of a permanent repair, proceed as follows :

Fix the safety valve in position by using the pressure test tool.

The test pressure is 1.5 times of design pressure.

Use fresh water and close all valves except feed valve, air vent valve and pressure

gauge root valve.

Supply water slowly and check the water leakage at the air vent valve and then

close the air vent valve.

Increase the pressure gradually up to the test pressure and hold the test pressure

for a sufficient time order to inspect leakage at welding joints.

If the test is successful the water should be drained fully. After the test, remove

the pressure test tool of safety valve and put it back to the original position.

Page 24
7. FINAL PREPARATIONS
Clean out all debris from the flue gas side and ensure that there are no obstructions

to the flow of the flue gases over the heating surfaces.

Ensure that all water passages are clear.

Refit the end casing doors ensuring that a gas tight joint is made and also confirm

that all inspection doors and manholes are securely fitted into correct position.

8. DAMPER

Sometimes an integral bypass damper will be provided for steam output control if

required. These have self lubricating bearings but the outside ball bearings and

linkages should be lubricated by suitable grease for high temperature at least once

a month.
To ensure the freedom of movement, the damper must be operated throughout the

full arc of travel at least once a day to release the sliding bearing lubricant

accordingly.

Page 25
Page 26
Page 27
 SECTION E. SOOTFIRE “IMPORTANCE”

1. INTRODUCTION
Soot fires are a kind of second combustion in the heating surface of waste boilers

due to soot accumulation. On board fires, including fires in waste boilers of both

plain tube and extended surface design, receive considerable publicity.

The incidence of fires in EGE is fortunately very small. Nevertheless, because of

the seriousness of fires when they do occur and because they can occur and

because they can be avoided, these guidance is given in an attempt to prevent fire

hazards developing in the few EGE which may be at risk.

Fires are caused by mal-operation of the engine, or engine operation under adverse

conditions, with subsequent failure to clean the heating surfaces of the waste boiler
elements.

Carbon deposits coming from exhaust gas cannot always be prevented but, they do

occur, it is essential that they be removed from the boiler elements before a fire
hazard is created.

With adequate crew training, the conditions tending to create a fire hazard can be

prevented.
This instruction should be first understood in detail and the action should be taken if

a fire hazard has started.

Continue with causes, prevention, cleaning and detection.

A ship’s procedure for dealing with fires is strongly recommended but a routine for

prevention is considered to be more essential.

Page 28
2. AT EMERGENCY
If a fire has started :

 Stop the engine

 If fitted, close the outlet damper of tube side and open the bypass damper

 Seal turbo-charger air inlets.

 Keep boiler casing sealed

 If casing temperature rises noticeably, apply boundary cooling in the form of a

wide angle spray to slowly cool casings without producing thermal shock.

 Ascertain and inspect the severity of fire. In general, if minor fire occurs, keep

circulation pumps running, if major fire occurs, stop circulation pumps and drain

the boiler water completely

 Wait until temperatures drop before taking further action

 Do not use any soot blower or spray boiler internals with water.

In close navigational waters, the ship should be moved to a safe area before the

engine is stopped. The exhaust gases of engine contain at least 17 percent oxygen

which will naturally feed the fire. Therefore, it is essential to eliminate this source of

oxygen as soon as possible.

Page 29
3. CAUSE OF FIRES
Under normal conditions a fire is most unlikely.

If, however, carbon bearing deposits are allowed to accumulate on the

heating surfaces of the boiler, a potential fire hazard is created.

Incandescent particles carried over from the engine in the exhaust gases, made

oxygen rich by the scavenge air, will readily ignite the deposits particularly when

the boiler is not being circulated.

The incidence of fires is highest during maneuvering, leaving a port because the

exhaust gases are more generated.

The soot in exhaust gas will be increased when the ship is going to arrive at port, or

is sailing at a low speed, or is shifting to the wharf.

If dampers are fitted they should be set to allow the gases to pass through the
boiler bypass without passing over the heating surfaces on all occasions of above.

On engine shutdown, the circulation pump should be kept running, keeping the

elements cool, until most of the residual heat in the unit has been dissipated.

Mal-functioning of the engine will cause incomplete combustion of the fuel with

consequent dirty exhaust gases. This condition is affected by the fuel and its
treatment, the condition and setting of the engine, etc.

Slow running will cause engine inefficiency with increased carbon in the exhaust

gases and, with reduced gas velocity, the carbon is more readily deposited on the
element heating surfaces. The problem is aggravated if an incorrect type of fuel

valve nozzle for slow running is fitted.

When turbo blowers are washed in service there is a resultant increase in deposit in

the heating surfaces.

Page 30
4. PROGRESS OF FIRES
Soot fire usually progresses in three distinct phases as follows :

 Phase I is the early stage of the fire before overheating of the elements has

taken place. This can be accompanied by the emission of burning particles from

the funnel.

It is essential that the fire is dealt with quickly and efficiently at this stage before

it progresses to phase II.

If the engine is stopped and the air intake restricted, the fire will probably by

quickly extinguished.

 Phase II commences with localized overheating of the elements due to high

spot temperatures resulting in element rupture. If the fire progresses, the

steam may react with the tube material, steam dissociation causing rapid

oxidation.

At this stage, the boiler casing may start to glow, circulation pump be stopped

and the system fully drained.

 Phase III is the continuation of hydrogen fire causing increase of

temperatures in concentrated areas to 2500 Deg. C.

Disintegration of the unit is inevitable at this stage.

Page 31
5. PREVENTION OF FIRES
If carbon deposits are not present on the heating surface, the fires will not occur.

Engineers should be trained in observation of situations which may prove to be a

hazard. In the case of fires, however, the bridge crew may be the first to observe

unsatisfactory funnel emission.

The earliest indications in the engine room of the possible existence of a fire will be

an increase in the temperature of the exhaust gases and consideration should be

given to fitting flue gas temperature sensors in the boiler body with alarms in the

main control room.

A ship procedure should be established for dealing with soot fires and training

arranged to ensure that all aspects of the procedure can be carried out quickly and
effectively.

Consequently, early detection of a fire will reduce the damage of heating tubes from

soot fire. The best countermeasure to prevent soot fires is preventing the

accumulation of soot in heating surface and removing the carbon deposits on the

heating surface by soot blowers or water washing.

Page 32
6. CONCLUSION
Fires in waste heat boilers, EGE can occur if equipments are not maintained

correctly.

FIRES SHOULD BE AVOIDED BY :

 Preventing carbon deposits from accumulating in the heating surfaces of boilers.

 Cleaning off any deposits on the boiler heating surfaces.

 Never allowing deposits to build up to such an extent that they present a fire

hazard.

 Observing the exhaust gas differential pressures (draft loss) across the boiler

body. An increase may indicate build up of deposits.

 Cleaning the heating surfaces before and after maneuvering of engine.

 Bypassing gases during maneuvering if damper fitted.

 Cleaning more frequently during slow running periods.

 Cleaning after turbo blower in service.

 Running the circulation pump continuously when gases are passing through the

heating surfaces except under emergency conditions.

 Keeping the circulation pump running on shutdown until residual heat is lost from

the boilers.
 Washing when the need and the opportunity arises.

 Ensuring complete removal of deposits when washing.

 Ensuring that soot blowers, water washing equipment, and circulating pumps are
always in service condition and operating according to the design conditions.

 Ensuring that the main engine is operated under normal condition with good

function.

 Checking the exhaust gas temperature and the draft loss are abnormal.

Page 33
 SECTION F. INSPECTION

The inspection should be carried out regularly and whenever the opportunity arises,

especially the heating surface to be inspected whenever main engine is shut down.
When the main engine is shut down, the followings should be at least inspected.

- Circulation Pump
Boiler circulation pump to be run continuously for minimum 12 hours in order to

prevent soot fire hazard and cool the heating coils from the residual heat after

engine shut down.

- Heating Surface Condition

The heating surface to be inspected by using the hand lamp through the inspection
door or access holes.

In this case visual inspection is recommended.

All gas passage should be checked and confirmed thoroughly, whether any other
substance or carbon deposits is in the passage between the fins.

If the foreign substance or carbon deposits is in the passage, it should be removed

immediately.

If the surface condition is dusty and the deposits severely accumulated, the water

washing should be carried out.

- Boiler Inside Temperature (Unit Surface Temp.)

The unit inside temperature to be checked and compared with design value.
The abnormal high temperature may mean that the soot is burning.

In this case the inspection door or access hole should be kept closing until the

temperature is decreased, and any other air supply or soot blowing shall not be

permitted into the heating surface.

And also the circulation pump to be operated for long time more than 12 hours until

the unit cooled.

Page 34
Other inspection, gas differential pressure, spark situation at funnel outlet, main

engine function, gas inlet/outlet temperature, feed water temperature at pre-heating

section inlet if fitted, super heated steam temperature and so on should be checked

and recorded at all time during voyage.

This check point is different from ship’s system but the above item to be checked

and recorded regularly and always to be compared with each recording data,
respectively.

Page 35