SM DH Series Manual

SHELLMAX – PACKAGED BOILERS
Capacities -1 TPH to 16TPH

Models – SM 10DH -160DH
Fuel – Liquid & Gas Fuels
Installation, Operation
And Maintenance Manual
Improving your
business is our
business
THERMAX LIMITED
Thermax Group
Thermax Ltd has a vision of becoming a globally respected high performance company offering
sustainable solutions in energy and environment.
The Thermax Group provides business to business solutions in the areas of heating, cooling,
captive power, water treatment, air pollution control, waste management & resource recovery
and chemicals to a wide range of industry in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power
and waste heat recovery. It also offers a range of heating equipment, energy efficient chillers
and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated
expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined
Heating Power and Cooling (CHPC) projects…
Thermax provides energy solutions to utilize waste heat to burn waste gases and biomass. These
include a variety of customized turnkey solutions to generate heat, steam and power. It
undertakes the entire range of activities from concept of commissioning.
Clientele includes Refineries, Petrochemicals, Fertilizers, Paper & Pulp, Distilleries, Independent
Power Plants, Chemicals and a wide range of other industries.
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of
solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has
emerged as a leading and reliable project management company with installations the world
over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries.
Leveraging its leadership position in electricity saving vapor absorption technology, it offers
process industries and commercial establishments like hotels, shopping malls and offices vapor
absorption chillers a boon in power-starved areas. These Eco-friendly, energy efficient
equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch,
Panasonic, Henry Ford Museum.
In the environment area Thermax offers waste management expertise for solid, liquid and air
pollution. Thermax provides solutions from pre-treatment to waste water treatment and
chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust
area for Thermax. Hi-grade resins from Thermax have found niche customers in US and Japanese
markets.
Thermax is a key player in the field of gaseous and particulate emission control, with special
focus on the emerging gaseous scrubbing business in India. Our state-of-the-art technology
enables us to offer turnkey projects well as air pollution control products.
And, the greatest utility of these solutions stems from the fact that they allow resource recovery
in process industries.
Thermax has an extensive international marketing network. Headquartered in Pune (Western

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

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

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

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

3.1 Mobrey Water Level Controller
3.2 Fusible Plug
3.3 Boiler Safety Valve
3.4 Boiler Water Level Gauges
3.5 Digital Temperature Indicator & Controller
3.2 Burner & Burner management System
Chapter 4: Input Requirement

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

5.1 Pre-Commissioning
5.2 Commissioning
Chapter 6 : Operating Instructions

6.1 Boiler Startup Process
6.2 Boiler Stopping Procedure
6.3 Boiler Running Attention
6.4 Do’s & Don’ts for Operation
Chapter 7: Maintenance
7.1 Maintenance Schedule
7.2 Log Book
7.3 Spare Parts List
Chapter 8: Troubleshooting
Chapter 9: Care of Idle Boilers

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

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

possess necessary qualification competence and license (if applicable). It is solely the
responsibility of the owner & user to ensure that all applicable statutory norms are
adhered to during Installation, Operation & Maintenance of the equipment.
The electrical and mechanical devices supplied as a part of the unit were chosen
because of their known ability to perform, with proper operating techniques and
maintenance procedures. Tempering with the safeties & controls or bypassing any of
these is not permissible at any time.
Any “Automatic” features included in the design do not relieve the attendant of any
responsibility. Such features may free him of certain repetitive chores and give him more
time to devote to the proper upkeep of equipment.
No amount of written communication can replace intelligent thinking & reasoning.
Since the product improvement is continuing process, the information given in this manual on
specific features is subject to change without notice.
01 SMDH SERIES
SMDH SERIES :
Figure F-1.1: Shellmax Boiler

1.0 SHELLMAX BOILER – SMDH Series
1.1 INTRODUCTION
The SHELLMAX is a smoke tube, three flue pass, fully wet back, packaged boiler. It's unique
design makes it the most efficient & rugged smoke tube boiler in its class. The technical
expertise that goes in designing this excellent piece of equipment is backed by several years of
boiler manufacturing experience by THERMAX Ltd.
This high efficiency unit can be fired on liquid and or gaseous fuels. The configuration of this
boiler is such that it makes it suitable for burning liquid fuels & gases together, when fitted with a
special burner. However, the standard supply includes arrangement for firing one fuel at one
time.
Shellmax Boilers consist of a combustion chamber where heat is generated by oxidising a fuel
and necessary heating surfaces to absorb this heat into water. The water so heated converts
into steam. The steam is separated out of the water by providing steam separation area on the
surface of the water. In order to ensure high efficiency of operation both the combustion
efficiency as well as heat absorption efficiency is to be maximised. Proper mixing of fuel and air
is engineered into a mutually supportive combination of burner and combustion chamber to
give the highest possible combustion efficiency. Sufficient heat transfer surface is provided to
obtain high absorption efficiency.
Combustion is the process of oxidation of fuel. Proper combustion of the fuel will be obtained if
all the components of the fuel get oxidised. Three basic conditions need to prevail in the
combustion chamber for proper oxidation i.e. TIME, TEMPERATURE AND TURBULENCE. In
SHELLMAX these three are achieved by a furnace of low volumetric heat release rate and highly
engineered burner design.
THREE FLUE PASS DESIGN:

The pressure part consists of a main shell. This has a combustion chamber fitted eccentrically on
the lower side of the shell. The rear end of the combustion chambers is connected to an internal
reversal chamber. The entire furnace assembly is held in position between the front and rear
tube plate. Stay bars are used to support rear end of internal reversal chamber.
The flue gases make three flue passes in the boiler for efficient transfer of heat to the water. 1st
pass is in the furnace itself where heat transfer is mainly by radiation.
INTERNAL REVERSAL CHAMBER

The last part of furnace is having larger diameter than the main furnace and forms the
beginning of the second pass. The flue gases reverse direction of travel to enter the tubes. The
chamber is surrounded by water to keep it cool.
The second flue pass is in the tubes between the reversal chamber and the front end plate. The
3rd flue pass is in the tubes between the front and the rear tube plate. In the second and third
pass the heat transfer is mainly by convective heat transfer
Water level is maintained sufficiently above the reversal chamber top and third pass tubes to
ensure safe operation. Adequate disengaging surface, free board height and a moisture
separator is provided to ensure very good quality of steam.
WET BACK:
Cooling of rear side of the furnace (reversal chamber) takes place by the water itself. No
refractory is installed, hence maintenance and heat loss associated with the refractory are
eliminated.
SINGLE OR DOUBLE FLUE

Single or double flue means single or double furnace. Two furnaces are used for large boilers.
INDIAN BOILER ACT (IBR)

All boilers have to be designed, manufactured and inspected during manufacturing as well as
prior to installation. This is a government’s compulsory (mandatory) requirement. The steam
boilers have to be operated by qualified and certified boiler operators and offered for annual
inspection to the IBR authorities.
Figure F-1.2 : Sectional view of Shellmax Boiler

1.2 PRODUCT FEATURES
Some of the unique features of Shellmax boilers are:
x Higher water holding capacity x Large furnace leads to low

leading to high thermal energy hold volumetric heat release rate which
up. This helps the boiler meet gives low thermal stress, complete
fluctuating steam demand combustion and multi fuel ability, for
oil and gaseous fuel.
x Large disengaging surface area and
large free board reduces water x Optimum tube sizing maintains high
carryover. velocity of flue gases. This ensures
higher heat transfer coefficient and
x Direction changing steam separator higher efficiency.
ensures dry steam.
x Leak proof air damper gives higher
x Corrugated furnace (above 4TPH efficiency on part load.
Boilers)
x Hinged Oil /gas fired burner provides
easy and quick nozzle cleaning.
Figure F-1.3 : Corrugated Furnace of

Shellmax Boiler
1.3 Major Components of the Boiler:
1.3.1) Feed Water Pump
The feed pumps take the water from the feed water tank & supply the water to
the boiler. Two feed water pumps are provided, one working and one standby.
The pump is operated on off, by the water level controller (Mobrey).
Each pump is of adequate capacity and head to meet the boiler requirement.
The feed pumps are selected considering reduction in pump capacity and
head due to normal wear & tear over a period of time.
The pumps are vertical, multistage, centrifugal types. Electric motor is directly
mounted on top of the pump. The pump is provided with single mechanical
seal.
Figure F-1.4 : Feed Water Pump

1.3.2) FORCED DRAUGHT (FD) FAN
The forced draught fans are centrifugal fans, used to supply combustion air to the boiler.
The combustion air is supplied from below the grate of the boiler furnace. Since this fan supplies
the air with some force to penetrate the burning fuel bed, it is called as Forced Draught fan or
primary Air fan.
FD fan is designed and selected to supply the desired air quantity with the desired pressure to
overcome the pressure drops across the boiler unit and the optional Heat recovery units.
Figure F-1.5 : Forced Draught (FD) Fan
This FD fan is directly coupled to the electrical motor. The boiler furnace is connected to the FD
fan through the canvas and M.S. Duct, with air damper at the suction of the fan.
The FD fan is installed close to the boiler on separate foundation.
1.3.3) ELECTRICAL CONTROL PANEL
The electrical control panel supplied along with the boiler is designed to suit the boiler operating
logic and provides the electrical supply to the boiler & its other electrical equipment like motors
of feed pumps, fans, controls etc. It also interlocks fans, low water safety to ensure safe
operation of the boiler. The control panel consists of the main on–off switch, switch gear for the
operation of the motors of feed pumps, Fans, and mounts hooter, indicating lamps, power &
control circuit wiring.
Figure F-1.6 : Electrical Control Panel SM
The control panel is installed on a separate foundation, at a convenient location in the boiler
house. The control panel is to be connected to the various motors, safeties &controls of the
boiler by proper cables & wires.
1.3.4) BURNER
Burner is the heart of the boiler, which provides the fuel or heat input to the boiler. The high
thermal efficiency & the trouble free operation of the boiler will mainly depend on its design, its
compatibility with boiler, ability to burn the desired fuels with high efficiency & reliability of the
components.
All these desired features are incorporated in the design of the burners supplied by Thermax.
The burner which supplied with Shellmax boilers are:
Figure F-1.7 : Dual Block – Oertli Burner Figure F-1.8 : Mono Block – Oilon Burner
1.3.5) OIL PRE-HEATING & PUMPING STATION- (OPH)
Heavy Oil fired Burner operation can be efficient & trouble free only when it is fed with the right
pressure & precise pre heated temperature. Oil pre heating station supplied by Thermax along
with the boiler ensures right fuel Pressure & temperature with Rugged components. The
components which are supplied from Thermax factory are pre assembled on the skid, which is to
be installed on the concrete foundations.
The components which are included in OPH station supplied are:
x Fuel Filters-2nos ( be fitted separately )

x Fuel Pumps-2nos
x Oil Pre heating Tank assembly with
electric heater & steam heating
arrangement.
x Pressure switch ,pressure gauge
x Interconnecting pipelines
x Isolating Valves, NRVs
x Interconnecting Electrical cables for
pumps ,heater, Pressure switch etc with
junction box ( for connection to the boiler
control panel)
The fuel supply to the OPH station is given

through Ring main fuel System which is to be
made at the installation site by the
customer/User, as per the details/drawing
supplied by Thermax Figure No: F 1.9 : OPH Station
1.3.6) FUEL PUMP
The fuel pump is the most sensitive component of the boiler, which has
to develop the consistent fuel pressure during the burner operation. The
fuel pump of liquid fuel fired Shellmax boiler is internal gear type positive
displacement pump directly coupled to the motor. It is a part of the Oil
Pre-heating & pumping station.
The burners of Shellmax boilers are pressure jet type, which require high
pressures to atomize the fuels. The fuel pump develops the required fuel
Figure No: F-1.10: pressure for the proper atomization of the fuel at the burner spray nozzle.
Fuel Pump
The required fuel pressure will depend upon the fuel used. The fuel
pressures will be lower for light fuels as compared to the heavy fuels. The model of the fuel
pumps will be different for Light Oil &heavy oils. Also there is a limitation on the interchangeability
of the fuel pumps, with the change of fuel oils.
1.3.7) OPTIONAL ACCESSORIES
A. Heat Recovery Equipment-Air Pre Heater, Economiser,
B. Internal Super Heater/External Super Heater
A. AIR PRE-HEATER
Figure No: F-1.11: Air Pre Heater of Shellmax Boiler
In Shellmax boilers, Air Pre-heater (Optional), which is provided between boiler & chimney, can
utilize the heat of the flue gases in preheating of combustion air.
It is provided to extract heat from outgoing flue gases. This is a gas-to-gas heat exchanger and
uses heat from the outgoing flue gases to heat air for combustion. Air can be heated up to
1100C. Incorporation of air pre heater increases the boiler efficiency by 4%.
Air pre heater is supplied for SM30 onwards and is a non-IBR component.
Corrosion Management System can be provided with Air pre heater. With this system stack,
temperature is always maintained above sulfuric acid dew point temperature even when boiler
works on low load. The higher temperature is achieved by passing air through the air pre heater
by a temperature controller on Air pre heater flue gas outlet, which in turn controls a damper in
air by pass line.
Corrosion Management System can be used only with Air pre heater and is suggested for boilers
using fuels containing high sulfur.
Air Pre-heater Construction
Air pre-heater is a simple gas-to-gas heat exchanger, where the flue gases heat the air without
mixing with each other. The forced draught fan or burner blower installed near the Air Pre-heater
provides the air.
Figure No: F-1.12: Air Pre Heater Construction
The optimum design of the Air Pre-heater ensures the maximum extraction of heat to reduce the
flue gas temperature up to the dew point temperature of the sulphur present in the flue gas.
This has parallel cross configuration to maximize heat transfer with optimal metal temperature
profile. Due to cross configuration, it has high heat transfer efficiency.
This consists two air & two flue gas passes with parallel arrangement, which assures good metal
temperature profile in all zones. This gives provision for auto cleaning using soot blower.
The Pre-heated air given to the burner helps in burning the fuel completely in the boiler furnace,
thus enhancing the combustion efficiency.
B. SUPER HEATER:
1) INTERNAL SUPERHEATER
Figure No: F-1.13: Internal Superheater Arrangement

Some of the chemical process equipments require dry steam at the inlet for efficient heating.
Normally, steam boiler is located away from the consuming point. Because of the heat loss from
the conveying pipeline the steam becomes wet by the time it reaches the utilities. In order to
overcome this problem, steam from the boiler is superheated to about 20 deg C maximum,
above its saturation point depending on the line length to take care of the radiation/convection
losses.
A convective bank in the form of a multi pass coil is incorporated between second and third
pass of the boiler. The coil assembly is housed in a casing and welded to the front plate of the
boiler. Super heater is constructed as per the Indian Boiler regulations (IBR) and has to be
installed as per the IBR regulations at the user’s end.
Super Heater Construction
In SHELLMAX the superheating is achieved by incorporating a convective bank between

second and third flue passes of the boiler. A multi-pass coil assembly is housed in a casing
welded to the boiler front end. The doors are fitted on the casing for maintenance. The steam
from the boiler drum is passed through this coil. Inlet and outlet headers are provided which are
outside the casing. Each header is provided with a drain and vent valve. A safety valve is
provided on the outlet header.
Since the construction of this super heater is such that it cannot be bypassed, adequate care to
be taken during starting. When the boiler is started from cold conditions there will not be any
steam passing through the super heater coils i.e. the super heater run dry. Because of this, boiler
should be operated in low flame (25% firing rate) conditions until adequate steam starts flowing
through the super heater coils.
Figure No: F-1.14: Internal Superheater Construction
CAUTION
IN ORDER TO KEEP THE SUPERHEATER METAL TEMPERATURE WITHIN LIMITS BOILER SHOULD BE
OPERATED IN LOW FLAME TILL ADEQUATE PRESSURE (50% OF THE DESIGN PRESSURE) IS DEVELOPED
AND ADEQUATE QUANTITY OF STEAM FLOWING THROUGH THE SUPERHEATER.
2) External Super heater
It is provided to superheat steam up to 750C. This is an external heat exchanger and uses heat
from flue gases to super heat steam. This is an additional independent equipment with steam in
/ out and flue gas ducting in / out connections.
Figure No: F-1.15: External Super Heater

Table 1.1 Technical specifications:
02 TRANSPORTATION & UNLOADING
INSTRUCTIONS
2.1 Transportation
SHELLMAX is dispatched from our factory in single package boiler and accessories. The IBR
valves and mountings, panel box, feed pump, FD fan etc. are packaged separately in wooden
cases and dispatched with the Boiler.
During transportation, extreme care is taken to ensure safe and intact delivery of the Boiler. The
Boiler and other wooden cases are loaded on the trucks as per upright markings.
Dispatch particulars are sent to the customer immediately after loading the trucks.
2.2 Unloading Instructions

x The boiler should be lifted for loading, unloading or shifting from one position to another,
only by means of lifting hooks provided on top of the boiler. Refer Table T-1.2.1 indicating
the Dry weight of pressure parts.
x The packing slip supplied with the material should be referred and the number of cases
supplied should be verified with the numbers received at site.
x The wooden / packed cases should be opened only in the presence of Thermax
Engineer or Thermax authorized person / dealer, for checking the inside materials as per
the packing slip.
x If the cases are opened in the absence of Thermax Engineer / authorized person /
dealer, and if the material is found missing, the responsibility of Thermax shall cease.
x For any breakage / damages, insurance claim should be made.
x For any missing items, Thermax Engineer / authorized person / dealer shall report to
Thermax Limited for replenishment, provided the cases are opened in their presence.
x For any incorrect supply of material Thermax Engineer / authorized person / dealer shall
report to Thermax Limited for replacement.
Table T-2.1: Shipping weight & dimensions of major parts: Standard Scope of Supply
2.3 Unloading Guidelines
A) All the parts should be unloaded with crane, tripod, suitable capacity as per the weight
& dimensions given in Table T-2.2
Figure F-2.1: Unloading Boiler with crane.
B) All parts should be unloaded in marked upright position only i.e. these should not be tilted
while unloading or shifting. If lifting tackles are not available, rollers, wooden slabs or
some skid should be placed beneath the frame of the boiler and wooden case and it
should be carefully guided for unload and shifting. Under no circumstances the boiler
and accessories should be dropped or turned to any other position other then marked
on the cases.
Figure F-2.2: Packing Cases should not be tilted while unloading or shifting.
C) It is advisable to unload the boiler as closes as possible to the Boiler House; preferably just
outside the main door of the Boiler House, on some skids or pipes, so that pushing the
Boiler into the Boiler House for positioning it on the foundation is easier. The soil at the
place of unloading should be hard enough to bear the weight of the Boiler, to prevent it
from sinking. Likewise, when the Boiler is being shifted to the Boiler House, the approach
road to the Boiler House should also be made of hard ground.
Figure F-2.3: The soil at the place of unloading should be hard.
2.4 Storage
A) All the material should be stored under roof and should be protected from rain, water or
direct sunlight.
Figure F-2.4: Boiler should be stored under roof.

B) Boiler & parts should not be stored under corrosive atmosphere.
Figure F-2.5: Boiler should not be stored under corrosive atmosphere.
C) Do not pile up cases.
Figure F-2.6: Do not pile up cases.

D) Do not store heavy material on soft soil.
Figure F-2.7: Material should not be stored on soft soil.

2.5 Drawings
A set of the following drawings is given by Thermax Ltd to guide the site persons. These drawings
should be carefully preserved for the reference.
The drawing numbers with Alteration numbers to be recorded in the box below for future records
by the customer before installation:
x P& I Diagram Drawing No. ALT NO.
x GATP Drawing No. ALT NO.
x Foundation plan Drawing No. ALT NO.
x Air Pre-heater general arrangement Drawing No.

(Optional) ALT NO.
x Electrical Diagram Drawing No.

ALT NO.
(Supplied with Elect control Panel)
2.6 Installation Guidelines
Thermax provides the post sales services to the customers through to guide from the services of
the qualified & trained Engineers Of Thermax or Authorized Representatives are made available
to the customers /users of the Boiler from the very next day of the receipt of the order.
Customer is provided with all the information & guidance on the complete Installation and
commissioning of the boiler through our qualified & trained Engineers /authorized dealers or
associates.
2.6.1 Boiler House Location:

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

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

x The floor loadings, for designing foundations of the boiler and accessories, are given in
‘ Foundation plan’ drawing.
x The height of any foundation should be minimum 100 mm above the finish floor level unless
otherwise specified. This is to prevent the structure of equipment from water etc. that may
corrode and reduce the life of equipment and foundation bolts.
x Cast the foundation as per the dimensions given in the drawing.
x Consider the soil conditions while designing the foundations.
x An allowance must be made for a minimum of 25 mm of shimming and grouting when
determining the top surface of the foundation.
CAUTION:
x The rear end of boiler foundation block

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

all civil foundations.
Figure F-2.8: Foundation block.
WARNING:
Consult Civil engineering structural expert for designing the foundations based on soil
condition of your plant and live weight on the foundation.
The qualified & experienced civil engineer should supervise the foundations work.
Table no: 2.2 Weight (Tons) on Foundation: SM Boiler Components
Figure F-2.9: GATP Drawing of Shellmax Boiler without APH.
Figure F-2.10: GATP Drawing of Shellmax Boiler with APH.
2.6.4 Shifting On Foundation
In India Permission from the Indian Boiler Regulation (IBR) inspecting authority is to be taken before
erecting or placing the boiler on the foundation. Boiler erection on foundation is to be done by
the IBR authorized and licensed agency as per the IBR.
(REF the next chapter registration under Indian Boiler Regulations)
Note: Indian Boiler Regulation (IBR) is applicable for boilers installed in India. For boilers installed
in other countries, the local rules and regulations should be followed.
Guidelines
x It is advisable to use a spreader type sling when handling/shifting the boiler & other
equipment.
x Boiler should be moved to its foundation as a unit, with care being taken to prevent
distortion or damage.
x After the foundation holes in the unit are lined up with anchor bolts in the foundation, the
equipment should be lowered over the anchor bolts.
2.6.5 Grouting and Leveling

Guidelines
x All the accessories of the boiler i.e. F.D. Fan, Air Pre-heater (if applicable), Electrical
Control panel etc. can be placed on respective foundations and can be grouted &
leveled.
x Prior to placing the boiler and fan on the foundations, the location of anchor bolts should
be checked against the drawing to ensure that these bolts are placed correctly.
x Since the boiler and fan is mounted on separate foundations much care and attention to
alignment is required to match their inlets and outlets.
CAUTION:
x Anchor bolts in concrete should approximately 50

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

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

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

All steam boilers in India are required to be registered under section 7 of the Indian Boiler Act and
in accordance with Chapter 9 of the Indian Boiler Regulations. Section 6 of the Indian Boiler Act,
prohibits the use or permit to use any boiler which is unregistered or uncertified. This registration is
generally valid for 1 year from the date on which it is granted.
The installed boilers are also subjected to these tests to determine the fitness of boiler for the
purpose of renewal of Registration certificate.
In India, State of Jammu & Kashmir is exempted from this activity of IBR registration. Boilers installed
on Railway Engines are also exempted form this activity.
The following details and Instructions will guide the owners & users in getting their new boiler
registered as per the Indian Boiler Regulations.
2.7.2 Boiler IBR Certificates: IBR Folder

This folder is supplied to the user from our factory and contains all the original certificates of the
boiler manufacturing and the mountings /fittings. This needs to be submitted to Boiler
Inspectorate, while making the application for registration along with inspection fees.
This folder contains important and original documents like:

1. Manufacturing certificates in forms II, III and IV,
2. Approved boiler pressure part drawings,
3. Boiler mountings certificates in form III C.
Preserve the IBR folder and take one photocopy copy of the complete folder, for the records
& site reference. Ensure that all the certificates are intact & serially numbered in the folder.
2.7.3 Application for Registration

The owner shall make application for the registration of a new boiler/renewal of Registration
certificate, to their Regional Boiler Inspectorate. Boiler Folder and receipt of Treasury Challan for
prescribed registration fees with the application be submitted to the Boiler Inspectorate. The Boiler
Registration Fees depends upon the heating surface area of the boiler, and details could be
obtained from the Boiler Inspectorate office. The Boiler Inspectorate office shall then
communicate the details of Inspector's visit for various Inspections.
2.7.4 IBR Boiler Inspection
The inspection as per IBR involves 3 Stages as under,
1. Open Inspection or ground Inspection

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

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

Prohibition of use of unregistered or uncertified boiler -
Important provision under Section: 6 of Indian Boiler Act.
Save as otherwise expressly provided in this Act, no owner of a boiler shall use the boiler or permit
it to be used -
(a) Unless it has been registered in accordance with the provisions of this Act.
(b) In the case of any boiler which has been transferred from one State to another, until the
transfer has been reported in the prescribed manner.
(c) Unless a certificate or provisional order authorizing the use of the boiler is for the time being
in force under this Act.
(d) At a pressure higher than the maximum pressure recorded in such certificate or provisional
order.
(e) Where the State Government has made rules requiring that boilers shall be in charge of
person holding [certificates of proficiency or competence], unless the boiler is in charge of
a person holding the certificate required by such rules:
Provided that any boiler registered, or any boiler certified or licensed, under any Act hereby
repealed shall be deemed to have been registered or certified, as the case may be, under this
Act.
2.7.6 Renewal of Certificate

Important provision under Section: 8 of Indian Boiler Act.
(1) A certificate authorizing the use of a boiler shall cease to be in force -
(a) On the expiry of the period for which it was granted; or
(b) When any accident occurs to the boiler; or
(c) When the boiler is moved, the boiler not being a vertical boiler the heating surface
of which is less than [18.58 square meters], or a portable or vehicular boiler; or
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) If the Chief Inspector in any particular case so directs, when any structural
alteration, addition or renewal is made in or to any steam-pipe attached to the
boiler; or
(f) On the communication to the owner of the boiler or an order of the Chief
Inspector or Inspector prohibiting its use on the ground that it or any steam-pipe
attached thereto is in a dangerous condition.
(2) Where an order is made under clause (f) of sub section (1), the grounds on which the
order is made shall be communicated to the owner with the order.
(3) When a certificate ceases to be in force, the owner of the boiler may be apply to the
Inspector for a renewal thereof for such period not exceeding twelve months as he may
specify in the application:
(4) An application under sub-section (3) shall be accompanied by the prescribed fee and, or
receipt thereof, the Inspector shall fix a date, within thirty days or such shorter period as
may be prescribed from the date of the receipt, for the examination of the boiler and shall
give the owner thereof not less than ten day's notice of the date so fixed:
Provided that, where the certificate has ceased to be in force owing to the making of any
structural alteration, addition or renewal, the Chief Inspector may dispense with the
payment of any fee:
(5) On the said date, the Inspector shall examine the boiler in the prescribed manner, and if
he is satisfied that the boiler and the steam-pipe or steam-pipes attached thereto are in
good condition shall issue a renewed certificate authorizing the use of the boiler for such
period not exceeding twelve months and at a pressure not exceeding such maximum
pressure as he thinks fit and as is in accordance with the regulations made under this Act:
The Inspector shall, within forty-eight hours of making the examination, inform the owner of
the boiler in writing of this opinion and the reasons therefore, and shall forthwith report the
case for orders to the Chief Inspector.
(6) The Chief Inspector, on receipt of the report under sub-section (5), may, subject to
provisions of this Act and of the regulations made hereunder, order the renewal of the
certificate in such terms and on such conditions, if any, as he thinks fit, or may refuse to
renew it:
Provided that where the Chief Inspector refuses to renew a certificate, he shall forthwith
communicate his refusal to the owner of the boiler, together with the reasons therefore.
(7) Nothing in this section shall be deemed to prevent an owner of a boiler from applying for
a renewed certificate therefore at any time during the currency of a certificate.
2.8 Assembly Guidelines: Accessories And Other Assemblies
The Boiler installation consists of the following basic circuits:
x FEED WATER SYSTEM

x FLUE GAS DUCTING LAYOUT
x DRAIN, BLOW DOWN CIRCUIT AND STEAM PIPELINES
x ELECTRICAL SYSTEM
x FUEL SYSTEM
To complete the installation work of the boiler, these systems/circuits should be completed as per
the following guidelines & instructions:
GUIDELINES
x Place other accessories i.e. F.D. fan, Air Pre-heater (if applicable), Feed water pump,
electrical control panel etc. on their respective foundations. These accessories should be
carefully leveled and physically aligned in their final position before grouting them.
x Complete the flue gas ducting work, connection of boiler to APH (if supplied) to Chimney.
Ensure that all the joints in flue gas path are airtight and the size of ducting and
connecting angle to chimney is correct.
2.8.1 Boiler Feed Water Circuit

x Ensure that water treatment plant should provide the water as per the specifications
mentioned in Chapter: Utility Requirement for feeding in the boiler.
x Refer the piping & instrumentation Diagram (P&I Diagram) for the boiler model for the layout
and sizing of the pipe lines, valves and other connection details.
A. Soft Water Tank Capacity
x Soft water storage tank of minimum 1.5 to 2 hrs. Capacity of boiler evaporation is
recommended for this purpose to have the time for the regeneration of the water treatment
plant.
x The minimum soft water tank capacities for various models of the boilers are as follows:
Table T-2.4: Soft Water Tank Capacities
MODEL SM 10DH 15DH 20DH 30DH 40DH 50DH

Minimum tank
capacity in KL 2 3 4 6 8 10
MODEL SM 60DH 80DH 100DH 120DH 140DH 160DH

Minimum tank
capacity in KL 12 16 20 24 28 30
B. Feed Water Tank construction:
x The raw water storage and soft water tanks should have a hinged or bolted cover, an air
vent, a float valve, a water level gauge glass, preferably with calibration, a drain at the
bottom with a gate valve and an overflow connection.
x The outflow from the tank should be taken from a point of distance of minimum 100 mm (4")
from the bottom level of the tank, to avoid any sediments and foreign matter going into the
water pump and damaging it.
Feed Water Tank Elevation:
x Following table gives the elevation of water storage tank (NPSH) required for corresponding
feed water temperature for most of the pumps considering maximum suction pipe length of
10 meters.
TEMP. OF WATER ( qC ) ELEVATION REQUIRED (M)
90 3
93 3.5
99 5
100 5.7
C. Feed Pump Suction Circuit:
The feed water pumps will perform better if NPSH available is very much higher than NPSH
required by the pump. In the NPSHav formula, only suction head (Tank Elevation) and friction
pressure drop in suction piping are in our hands. Suction piping pressure drop is directly
proportional to product of square of velocity and length. Hence, we want to reduce velocity and
reduce length to reduce friction pressure drop. Also sharp bands or any fittings causing a sudden
change in direction of flow will increase pressure drop in the suction piping.
Therefore, in order to reduce suction piping pressure drop we should
- Use large suction piping size. At least one size higher than feed water pumps suction size.
- Use only Gate / Ball valves. Avoid valves like Globe or needle.
- Use long radius bends.
- Use as short suction piping as possible.
The logic of selecting suction piping size is explained above. The following may be ensured –
x Suction piping is provided with a sample point for taking sample of water for analysis.
x A Y type strainer is provided to prevent entry of any foreign particles in the pump.
x Since suction piping recommended is one size larger than the pump suction size a pipe
reducer is required to connect suction piping to pump.
x It is suggested to use GI pipes in the feed pump suction to avoid corrosion.
Boiler feed pipe-Feed Water Pump Discharge Piping
This conforms to ASTM A106 Gr. B and is an IBR approval piping. This pipe connects Feed Water
Pump to boiler. Non Return Valves and Globe Valves are provided on pump discharge for
isolation and throttling purpose.
NRV and a Globe Valve are provided at boiler inlet. All valves, flanges and fittings in the pipeline
are IBR approved.
CAUTION:
x Feed water service tank should never be constructed out of cement concrete, as soft water
will absorb Calcium and Magnesium salts from cement and the hardness will increase.
x The water level in the boiler feed water day tanks should be easily & clearly visible from the
ground level to the operators.
x Use G.I. Pipes and fewer fittings in the feed water pump suction lines.
x Use minimum bends & shortest possible route to connect the suction lines to the pumps
x Use only gate valves in the water pipe lines and avoid using globe valves.
x Provide proper support to the pipelines to avoid unwanted stress on valves and pumps.
x Pump suction pipe size should be one size higher then the pump suction size.
x Long radius bends may be used if necessary.
x The feed Pump suction pipe should be as short and direct as possible.
x The suction head pipelines should be laid with a downward slope towards the pump.
x The suction and delivery pipelines should be anchored in close proximity.
x All the pipe joints should be absolutely airtight.
x Don’t reduce the diameter of the pipes then what is given in P and I diagram of your boiler.
x Avoid use of Elbows and short bends.
x Never use the pump itself as an anchorage point for the piping.
x The gasket between pump and the pipe should not protrude inside the pipeline flange.
x The pipelines should be not transmitting any stress/ strain and pipeline weight, to the pump
body.
2.8.2 Drain, Blow down And Steam Piping
Blow Down Pipe Line
x Blow down valve located at the bottom of the boiler shell should be connected to a pipe
of one size bigger and should be led to a blow down pit/tank located outside the boiler
house.
x The blow down pipe should be firmly clamped on the ground at every 3meters of running
length and at both sides of the bends.
x Use IBR pipes/seamless high pressure quality pipes for the blow down lines
x The lines should be properly insulated for safety purposes.
Blow Down Pit
The blow down pit has to be constructed as per the sketch given. Brick wall structure should
not be used for building the blow down pit. Instead, use M S plates & concrete slab as
indicated to withstand excessive pressure & temperature to ensure safety.
The size of the pit should also to be maintained as per the sketch below
Figure F-2.14: Boiler Blow down Pit

Safety Valve Exhaust Pipe
Safety Valve exhaust pipe connection is to be given as per the sketch given below:
Figure F-2.15: Safety Valve Exhaust Pipe Connection
x The discharge from the safety Valve/s should be piped as direct as possible to the
atmosphere with a pipe diameter of not less than the Safety Valve outlet.
x A drip pan elbow or a flexible connection between the valve and the escape pipe is
recommended to prevent build up of backpressure and accumulation of foreign
material around the valve seat.
x The discharge piping must be properly arranged, clamped and supported so that
their weight doses not bear upon the valve.
Drain Pipes
x Drainpipes from water level gauges, level controllers should be of the same size as
the outlet size of the valves to be to a common drain header.
Steam Pipeline
The main steam line which carries the steam to the user equipment /to the plant has to be
of the same or higher size (if recommended) & never be of lower size than indicated in
the P& I diagram.
The boiler steam out let pipeline is to be designed, constructed, inspected and hydraulic
tested as per IBR (for the installations in India) as per the maximum working pressure of the
connected boiler.
The steam lines must have the drains with equal ‘T’ & the drain lines with adequate sizes of
steam traps assemblies.
The steam lines are to be insulated with the adequate thickness of the insulating material,
refer Table T-2.8 & T-2.9 for thickness & specifications of mineral & glass wool.
Expansion bends in steam pipeline within every 30 meters of straight run to be used to take
care of the line expansion. Sliding / Roller support should be provided for all steam pipes,
which will not restrict the expansion.
Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
CAUTION:
x All drain; blow down & steam line must be properly insulated to avoid heat losses and
condensation.
x The steam piping from the main steam stop valve should be sized to match the steam valve
diameter. Never reduce the steam pipe diameter to lower size than recommended, as they
would restrict flow of steam & result in to high pressure drop in the pipe lines
x Sliding / Roller support should be provided for all steam pipes which will not restrict the
expansion.
x Expansion joint supports and roller type supports suitably anchored.
x Provide expansion bends in steam pipeline within every 30 meters of straight run.
x Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
x The steam piping should be sized to suit the evaporation capacity of the boiler to avoid
siphoning effects and steam/water hammering.
x Proper qualities of steam pipeline gaskets are to be used as per the pressure of the steam.
x The Steam jointing or the gaskets used should be checked for the proper placement during
construction of the lines. These should not be protruding inside the pipe line which will obstruct
the steam flow & also result in to high pressure drop.
x The Steam jointing or the gaskets used should be checked for the proper placement during
construction of the lines. These should not be obstructing the steam flow.
x All steam line must be properly insulated to avoid heat losses and condensation.
x Provide thermodynamic steam trap before every expansion bend for condensate water
removal.
x Provide adequate steam traps in the steam pipeline.
x Never end the drain or blow down pipe in open, but provide pits.
x Brick wall structure should not be used for building the blow down pit. Instead use M S plates &
concrete slab as indicated to withstand excessive pressure & temperature
2.8.3 Flue Gas Ducting Layout:

The flue gas circuit means the path of the flue gases leaving the boiler, Heat recovery &
finally exit through chimney.
2.8.3.1 Chimney
Chimney can be either of the following designs:
a) Self supported
b) Guy rope Supported
c) Structural supported
d) Wall Mounted
However, Chimney for the boiler should be of the adequate top diameter as per the
recommendations given in the table T-2.5 below.
Guidelines:
x Chimney design Reference can be taken from the IS 6533 specifications and considering
the Local geological conditions
x Provide all the Accessories of the chimney i.e. Aviation Lamp, Lightening Arrestor etc as
per the recommendations of the local statutory norms.
Figure F-2.15 : Self Supported Chimney
Table T-2.5 Chimney TOP Diameter
Chimney Top
10DH 15DH 20DH 30DH 40DH 50DH
Diameter (ID) mm
Boiler to chimney 350 400 400 450 500 600
Chimney Top
60DH 80DH 100DH 120DH 140DH 160DH
Diameter (ID) mm
WARNING:
x Follow rules and regulations of Smoke Nuisance Act and consult their local Pollution
Control Board’s office for further information & guidance on chimney design & height.
x Never reduce the Top Diameter of chimney than the recommended size.
x For boilers installed in countries other than India, follow the local regulations for stack
installation
2.8.3.2 Flue Gas Ducts:
x The area or the size of the flue gas ducts needs to the same as recommended in the table
T-2.6 below to ensure that the flues gas leave the boiler & system easily without any
excessive pressure drop.
x The ducts can be of circular rectangular or square cross section.
x The pressure drop developed by the flues gas system should less than the suction capacity
of the Induced draught (ID) Fan.
x For Shellmax boilers without Air Pre-heater, the air Duct from FD fan To Burner is supplied by
Thermax,
Table T-2.6: FLUE GAS DUCT DIMENSIONS
Flue gas duct

diameter (ID) in mm
Flue gas duct

60DH 80DH 100DH 120DH 140DH 160DH
diameter (ID) in mm
Table T-2.7: AIR DUCT DIMENSIONS
Air duct: SQ Cross

section in mm
Air preheater to
250 x 250 350 350 400 450 500
boiler
Air duct: SQ Cross

60DH 80DH 100DH 120DH 140DH 160DH
section in mm
Air preheater to
550 650 700 750
boiler
CAUTION:
x Keep the cross sectional areas of the flue gas and air duct same as recommended. Do not
reduce the cross sectional areas.
x All The Ducts should be of fully welded construction.

x Any leakage in air duct means reduction in the capacity of the Fan and reduction in the
output of the boiler.
x Air pre heater duct connections should be fully welded to ensure leak proof.
x External columns, from ground, should support long ducts.
x Provide sockets with plugs at the inlet & outlet ducts of Air Pre-Heater, for checking the
pressure drops and temperature measurement, across these equipment.
x The dampers should be checked for correct opening & close indications and for the
smooth operation.
x Provide long radius bends & avoid sharp bends in the ducts.
x Insulation of the ducts should be done after through check for the leakages, after the
commissioning of the flue gas system.
x Provide Insulation of proper density & the thickness as indicated in the table T-2.8 below.
2.8.3.3: Insulating material Pipe lines, Ducts & flue gas ducts
The table below gives recommended insulation thickness in mm required for different pipe sizes
and different operating / fluid temperatures.
a) Mineral Wool – Table T-2.8:

Pipe Operating / fluid temperature oC
diameter
90 150 200 260 315 375
(NB) mm
25 25 40 65 65 75 90
40 25 40 65 65 75 90
50 25 40 65 65 75 90
80 25 40 65 65 75 90
100 25 50 75 75 100 100
150 40 50 75 75 100 115
200 40 50 75 75 100 115
250 40 65 90 90 100 125
300 40 65 90 90 100 125
Flat 40 65 90 90 100 125
Note: Insulation material assumed is Mineral wool having thermal conductivity 0.036 kcal/m hr o C,
average density about 100-200 kg/m3.
CAUTION:
1) The surface temperature after insulation is 55 – 60oC.
2) Insulation up to 65mm should be in single layer and above 65 mm, multiplayer, e.g.
80mm two layers of 40mm each for 90mm inner layer of 40 mm and outer of 50mm.
b) Glass Wool - Table T-2.9:
Pipe Operating / Fluid temperature
diameter
90 150 200 260 315 3756
(NB) mm
25 25 25 25 25 40 40
40 25 25 25 25 50 50
50 25 25 25 25 50 50
80 25 25 40 40 50 65
100 25 25 40 40 50 65
150 25 25 40 40 65 75
200 25 40 40 40 65 75
250 40 40 40 40 65 75
300 40 40 40 40 65 75
Flat 40 40 50 50 65 75
Note: Insulation material assumed is Glass wool having thermal conductivity 0.045 kcal/m hr oC @
100oC and average density about 80 – 100 kg/m3.
2.8.4: ELECTRICAL SYSTEM:
Control Circuit
Power Circuit
Figure F-2.17: Inside of Electrical

Figure F-2.16: Electrical Control
Control Panel
Panel -Front View
2.8.4.1: Guidelines:
Electrical Control Panel Box & External Electrical Switch
The Electrical Control Panel Box is supplied by Thermax, with the Boiler, separately packed and is
pre-wired with switches for all motors for boiler system.
x The control Panel to be erected as close to the boiler as possible. The foundation details of
the panel box are given in the "General Assembly" drawing.
x Three phases, 415 V, 50 cycles A.C. electric supply with neutral and earth is required for
operating the boiler.
x The supply to the boiler should be given through a main switch fuse having adequate
capacity as mentioned in the following table. The back-up fuse capacity to suit the total
electric loading should also be maintained.
x Switches for other pumps such as water pump for pumping water from raw water storage
tank to the water softener, etc. should be separately installed by the customer at points
convenient for operation.
2.8.4.2: CABLE SCHEDULE: Following table should be referred for the details of the cable size, core, and type. These tables are
segregated, for the units with or without Air Pre Heater or oil fired and gas fired units.
Table no T 2.10: CABLE SCHEDULE

2.8.4.3: Earthing Of the Equipment
x Earthing wires of adequate cross-sections should be provided to link the boiler,

the electrical control panel box, various motors, etc. to a suitable earth plate, as
per Indian Electricity Act.
Following size of earth conductors can be used:
Up to 3.75 kW 8 SWG GI wire

5.5 kW to 30 kW 3/8" GI fine wire rope
37 kW to 55 kW 5/8" GI fine wire rope
CAUTION:
x Provide proper lugs to terminate the cables. Also provide ferrule numbers on cable
for identification.
x Provide adequate size switch fuse unit and cables.
x Provide cable glands at the panels
x If the voltage fluctuation is going to be more than ± 6% of the specified voltage, it is

strongly recommend installing a voltage stabilizer of 1 KVA for the control circuit.
x Provide proper sized glands for the cable at the entry to control panel and at motor
terminal box.
x Earthing pit should be as per the norms.
x Use cable trays or trenches for laying the cables.
x Never increase or decrease the back up fuse MCCB capacity.
x Never combine neutral & Earth connection.
x Laminate the electrical diagram, with plastic sheet and paste inside the control panel
or near to it.
x Take enough photocopies of the electrical diagram for records.
WARNING:
WHILE INSTALLING THE ELECTRICAL CABLES KEEP IN MIND THE RULES AND
REGULATIONS INVOLVED.
2.8.5 Fuel Supply (Liquid Fuels)
A typical arrangement for fuel oil storage and flow to the unit is shown in P&I Drawing.
The fuel firing system is designed to operate on FO (Furnace Oil) / LDO (Light Diesel Oil) /
HSD (High Speed Diesel) / LSHS (Low Sulphur Heavy Stock). Since FO and LSHS is viscous
and requires pre-heating to make it flow, the fuel system is provided accordingly.
In order to have flooded suction, these tanks are to be installed at a height not less then
3 meters from fuel pump. (For HSD tank, this height is not required). The P&I Diagram
shows the piping connections and their sizes, which needs to be followed strictly for
trouble free, efficient and comfortable operation.
2.8.5.1 Storage, Handling And Preparation of Oil
In many industries, little attention is often paid to oil storage, handling and preparation
facilities. The result? Puddles of oil near the pump house and storage tanks - an -
indication of leaky joints, flanges and pipelines. Clogged filters, which impose an
additional duty on the pumps. And poor combustion, manifested by smoky or spluttering
flames leading to high fuel consumption.
Spilt oil is an easily avoidable waste, and renders the ground slippery and dangerous. For
efficient burning, foreign matter such as dust, water, coke and sludge particles in fuel oil
should be removed by adequate filtration. It is also necessary to examine several
aspects, such as pumping ability of oil during winter months, type and capacity of the
pump, the length of the pipelines, and the sizing of pipes. Correct pre-heating of fuel oil
prior to combustion is very important for fuel efficiency. We have covered some of these
aspects, which have a significant effect on the fuel consumption in your boiler plant.
Spilt oil is irretrievable. A little care when oil is decanted from the tanker to the storage
tanks could lead to less spillage. All leaks from joints, flanges and pipelines must be
attended to at the earliest.
Loss of even one drop every second can cost you over 4,000 liters a year.
2.8.5.2 How to store Fuel Oil
Large quantities of fuel oil are best stored in cylindrical tanks either above or below the
ground. Generally, the main storage tank is erected above ground when the capacity
exceeds 70,000 liters. For lower capacities, underground storage may be more
economical. When erecting a storage tank above ground, remember to maintain safe
distances from the surrounding structures, as prescribed by the Explosive Department.
Storage tanks are generally made from welded mild steel plates. The overhead tank
should be mounted on concrete blocks, which provide a slight gradient of 1:50 towards
the drain valve. Each of the following fittings on storage tank has a definite role to play.
The outlet or draw-off pipe should be located at the raised tank end, no less than 15 Cms
from the bottom. It should be at least 15 Cms in diameter with outflow heater and
provided with an outlet pipe line of 6 Cms with a strainer at the outlet.
The vent pipe, of goose-necked type, should be located at the highest point of the tank
to facilitate filling by venting air and oil vapor during the filling operation.
The fill-pipe could be located either at the top or at the bottom of the tank. If located at
the top, it must be ensured that the pipe descends almost to the bottom of the tank.
When located near the bottom, it is important to position a non-return valve on the line
to avoid fuel oil re-entry into the oil tanker on account of back pressure. To avoid
leakage of oil during decanting, it is advisable to have a cam lock coupling at the filling
end so that it fits easily on the delivery hose.
The drain pipe, which is fitted at the lower tank end bottom, is used to periodically
remove the accumulated water. It is a difficult task to drain the water and sludge from
underground storage tanks. The water and sludge which settle down at the bottom
should, however, be removed by a hand pump. It would be advantageous to have two
suction pipes - one at a lower level and the other at a higher level - so that in case the
sludge accumulation is up to the lower point and the suction line chokes up, the
alternative line could be put into operation and adequate time would be available to
decide upon a time schedule for cleaning the tank.
Fuel oil as delivered may contain dust, dirt, gummy matter and water. During storage for
prolonged periods, these tend to form sludge, which accumulates in the various `dead
spaces' of the tank, where the oil is not agitated during normal operation of the tank.
This results in unsteady flames and clogging of filters. To avoid this, some means of
agitation of oil in the tank may be necessary.
Cleaning of storage tanks, about once a year, will remove the accumulated sludge.
Besides cleaning, periodic inspection and maintenance of the storage tank, out flow
heater and auxiliaries is important.
Capacity of storage tank depends on daily hours of operation & Frequency of Fuel oil
tanker receipt. Based on this storage tank capacity needs to be decided.
NOTE: PLEASE FOLLOW THE RULES AND REGULATIONS INVOLVED IN YOUR STATE FOR
STORAGE OF HEAVY OIL.
2.8.5.3 Checks Before Unloading of Fuel Oil
It would be worth while to check the quantity of oil into the storage tank. Road tankers
are provided with dip-sticks. Readings of oil level in the various compartments should be
taken before decantation. The following procedure may be adopted before assessing
the quantity of oil in the road tankers:
a) Ensure that the tank lorry is parked on firm level ground.
b) The dip-stick should be checked to ensure that it is the one calibrated by the Weights
and Measures Department for the compartment concerned.
c) The dip readings of all the compartments should be checked, and shortfall, if any,
can be determined by topping up of the compartments with measured quantities of
fuel oil from the main storage tank.
d) If the tank truck has been filled hot, the product in the compartment is likely to shrink
to the extent of 0.7 liters/KL per degree centigrade fall in temperature. If the shortfall
is higher, it may be due to pilferage.
e) Your storage tanks should also be calibrated. Though dip readings in storage tanks
are more or less reliable, a major deviation should be investigated. They may provide
a clue to malpractice.
2.8.5.4 Removal of Contaminants
Fuel oil should be freed from possible contaminants such as dirt, sludge and water before
it is finally fed to the boiler.
Fuel oil arrives at the factory site either in tank Lorries by road or by rail. Oil is then
decanted into the main storage tank. To prevent the possibility of contaminants such as
rags, cotton waste, loose nuts or bolts or screws from entering the system and damaging
the pump, position a coarse strainer of 40 mesh size (not more than 6 holes per linear
inch) on the entry pipe to the storage tanks. Progressively finer strainers should be
provided at various points in the oil supply system to filter away finer contaminants such
as external dust and dirt, sludge or free carbon.
It is advisable to provide these filters in duplicate to enable one filter to be cleaned while
oil supply is maintained through the other.
Table T-2.16: SIZING OF STRAINERS

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

Point and main storage tank 40 6
Between storage tank and service tank 80 9
Between service tank and Oil pre-heating

& pumping station of boiler 80 11
2.8.5.5: PUMP CAPACITY-from Storage tank to Day or Service tank
It is advisable to use a positive displacement pump such as a screw/internal gear pump,

for pumping heavy/LSHS oil. Sometimes no oil gets transferred through the pipes
because of excessive pressure drop and cavitations at the pump. A centrifugal pump is
therefore, not recommended, as the oil viscosity increases, the efficiency of the pump
drops sharply and the horse power required increases.
It is also necessary to size the pipelines properly so that there is no excessive pressure
drop and the required oil flow rates are obtained. On expansion of facilities, the
adequacy of pipe sizes for transporting larger quantities of oil should be reviewed. It is
preferable to lay the oil pipelines over ground as any oil leaks would then be visible and
could be quickly attended to.
Fuel oil has to be pumped from the main storage tank to the day service tank.
Depending upon the desired quantity of oil to be pumped, and the distance between
the storage tank and the service tanks, adequate pumping capacity will have to be
provided. A gear pump of 2000 Liters/hr. at a pressure of 3 to 4 bar (50 PSI) is sufficient for
these boilers.
2.8.5.6: FUEL OIL PRE-HEATING- from Storage tanks to Day or Service tank
Fuel oil increases in viscosity as temperature drops, which makes handling a little difficult,
particularly in winter. At low ambient temperatures, heavy oil is not easily pumping
ability.
Recommended pre-heat temperature for pumping is 40øC for heavy oil and 70øC for
LSHS. The pre-heating of oil in the storage tank to render it pumping ability can be
accomplished in two ways. Either the entire tank can be maintained at the pumping
temperature (bulk heating) or an outflow heater may be fitted to heat the oil as it flows
out. Bulk heating, which uses steam coils positioned at the floor of the tank, requires
additional heat to compensate for the heat losses from the tank surface. To reduce
steam requirements, it is advisable to insulate tanks where bulk heating is used.
In the case of outflow heating, only the oil, which leaves the tank, is heated to the
pumping temperature.
While the outflow heater is the preferred choice, bulk heating may be necessary where
flow rates are so high that outflow heaters of adequate capacity cannot be easily
installed, or when using special fuels such as low sulphur heavy stock (LSHS).
The outflow heater is essentially a heat exchanger, with steam or electricity as the
heating medium. The heater protrudes from the suction connection into the oil space.
The arrangements of outflow heaters are as under.
2.8.5.7 ELECTRICAL OUTFLOW HEATER- At Storage tank
A pipe of about 150 mm NB is welded to the tank and the oil supply pipe is taken at the
bottom of this pipe. An electric immersion type single phase or three-phase heater with
a temperature sensor is inserted in the pipe. Capacity of this heater is 3 kW. An electric
heating tape or steam tracing should be used to heat the oil in the pipe line from the
tank to the boiler. For pipe lengths less than 20 feet, heating tape of 220 V AC, 2 KW
capacity should be wound. For longer pipes the heating tapes should be of 3 KW
capacity.
Whenever electrical heater is used for outflow heating, it is essential that a minimum oil
level switch and a Digital temperature indicator cum controller, is installed and
preferably with additional dial type indicator installed very close to it.
The TIC should be set at 45øC.This TIC is to be interconnected with heater contactor to
switch off the heater in case of the pre heat temperature is increased above the set
point.
Also if level of oil in service tank drops to about 150 mm above the heater level then also
the heater should be switched off this will prevent the heater element getting
overheated/burst.
IMPORTANT
Digital TIC for fuel temperature control is necessary for the following reasons:
To prevent overheating of fuel oil.

x This may result in to fire, if heating is uncontrolled & goes above the flash point of
the fuel oil.
x heater damage ,incase of low or no fuel level
x To avoid damage of fuel pump mechanical seal as it gets damaged if the fuel oil
temperature goes beyond 100øC.
A Dial type temperature indicator is also very essential for the following reason:
If the TIC fails to cut off the heater or the set point of the heater cut off is above the flash
point of the fuel oil, then the fuel oil can start evaporating due to excess heating and the
fuel rich gases can catch fire and can even blow up the tank. Hence, a dial type
temperature indicator is also very essential which will indicate the temperature & this is to
be installed very close to the TIC sensor.
All the switch gear, TIC etc used for the out flow heater should be in Flame proof
enclosure ( if these are installed very close to the fuel day/service tank. From the service
tank the oil enters the circulation header, which would be erected at a height not less
than 1 m from the boiler floor level. Recommended capacity of circulation header is 70
liter. Suction of fuel pump is connected to the circulation header. Two pipe lines each
of 20 mm, one from the fuel pump bypass and one from burner circulation is connected
back to the circulation header. A non-return valve is to be provided in each line. The
pipe line size from service tank to fuel oil pre-heating unit is given in following Table III.
It is recommended to install a bucket type filter of about 30 liters capacity with large filter
area before oil service tank. This shall reduce the maintenance time and frequency of
cleaning the filter due to its large capacity.
All the pipe lines and circulation header are to be insulated if fuel is heavy/LSHS oil to
minimize the heat loss.
If the ambient temperature, during any part of the year, is going to fall below the pour
point of the oil used, then all the pipe lines, fuel oil circulation header and pump should
be provided with suitable steam/electrical heat tracing arrangement.
2.8.5.8: FUEL OIL SERVICE/DAY TANK
The service tank should be located in proximity to the boiler.
The principles enumerated earlier for the maintenance of main storage tanks apply here
too. The service tank may be sized for a shift's consumption or daily consumption - the
choice depends on capacity required, ease of location of tank near the boiler house,
pumping capacity, horse power, etc. Certain additional precautions may, however, be
taken with respect to service tanks. Capacity of service tank should be 4.5 KL maximum
when placed outside the boiler house or less than 1KL if placed inside the boiler house
(as per the recommendations of explosives dept. in India). In case LSHS is being used a
small (>1 KL) tank should be provided for start-up and flushing fuel (LDO or FO). If ring
main system is provided, in this case the service tank is not called for.
a) Service tanks should not be located above furnaces, hot air or flue gas ducts, etc.
b) They should be provided with overflow pipes which lead directly below to a sump. As
a further refinement, limit switches could be provided to avoid the possibility of oil -
overflow.
c) In gravity feed systems, the difference in height between the service tank and the
fuel pump should be at least 3 meters.
d) The tank should have hinged manhole, level indicator, drain, overflow, out flow
heater, air vent etc.
e) The level indicator should be positioned such that it can be seen from boiler control
panel for ease of operation.
Figure no 2.18: Outflow heater arrangement & service tank
2.8.5.9: Preparation of Fuel Oil For Combustion
The pre-heating of heavy/LSHS oil in the storage tanks renders it pump-able. However,
heavy/LSHS oil generally has to be heated further so that its viscosity is appreciably
lowered to about 10-12 CST to suit the burner. This operation is extremely vital if we are to
ensure that fuel oil is properly atomized by the burner - an essential condition for efficient
combustion.
The oil can be pre-heated by either electricity or steam or combination of both. The
capacity of the pre-heater depends on the oil flow rate and the required rise in
temperature. A suitable capacity oil pre-heating and pumping station is provided with
the Boiler for this purpose.
Figure No F 2.19
2.8.5.10: RING MAIN SYSTEM (APPLICABLE FOR HEAVY LIQUID FUELS)
Medium & heavy fuel oils require pre-heating in the Oil Pre heating Stations, to lower their
viscosity up to 10 -12 CST so that satisfactory atomization & combustion takes place. In
most of the fuel oil systems, to save heat, a part of the heated oil is returned to the fuel oil
header, at the fuel pump suction. This therefore raises the fuel oil temperature in the
pump suction header beyond 100 degrees “C”, especially when the burner operates
continuously in low load.
Since the fuel oil has some amount of water & low boiling oil fractions, present, this could
evaporate at temperatures beyond 100°C causing cavitations problems in the main
pressurizing pump. The rise of temperature up to 120 degrees ”C” & variation in fuel oil
temperature tends to cause cavitations & variation in burner fuel pump pressure. Many
times this causes premature failure of fuel pumps.
In addition, the key parameter to be maintained in the pressure jet burner system is the
oil pressure at the burner inlet. Any variation in this could adversely affect the
combustion parameters.
An effective method of avoiding such failures & performance problems is to adopt fuel
oil ring main systems, particularly for multiple burner installations, as well as for
modulating burners of firing capacities above 100 kg/hr.
Operating principle of a ring main is that the fuel pressure in burner pump suction line
should be maintained higher than the vapor pressures corresponding to oil preheat
temperature.
Table No T-2.17 Ring Main Circuit Pressures
Fuel pre-heat
Temperature in 100 105 110 115 120 125 130 135 140 145
deg C
Ring main
pressure 1.5 1.7 1.9 2.1 2.3 2.5 2.9 3.3 3.9 4.5
kg/cm2
Figure No F-2.20: Ring Main system

Figure No F-2.21: Fuel Pumps circuit
Figure No F-2.22: Fuel pipeline-from OPH to Burner & return to Ring Main Header
CAUTION:
x Use only M.S. pipes with welded or flanged joints.

x Avoid using elbows and short bends as far as possible.
x Fuel piping should be thoroughly flushed before being connected to the heater.
x Never reduce the diameter of the pipelines than mentioned in the drawing.
x Use only gate valves. Globe valves offer more resistance and hence pressure drop is
more than gate valves,
x Select fuel storage tank of adequate capacity. Keep in mind the rules and
regulations involved in your state.
x Use outflow Heater For heavy oil and insulate the pipelines to reduce heat loss.
x Provide the digital temperature indicator cum controller with the out flow heater to
cut off the heating at preset temperature. Also, provide dial type fuel temperature
indicator near to the digital TIC.
x Avoid over heating of the fuel oil at the out flow heater.
x Use flame proof enclosure for the out flow heater switch gear ,if installed near the fuel
tank
x Air vent of the fuel day/service tanks should be taken out side of the boiler house to
prevent vapors of the low boiling fractions of the fuel oil to get accumulated in side
the boiler house.
x Use recommended (size and mesh) strainers to clean the fuel at every stage.
2.8.6: Fuel Supply (Gas Fuels)

The boiler user should ensure that the gas supply is pressure is in the range of 1-2 kg/cm2
at the isolating valve of the boiler gas train. The boiler gas train components are selected
& sized for this pressure range only.
If the gas supply pressure is higher than above, the user should reduce it to 1-2 kg /cm2
before connecting it to the boiler gas train.
Installation of the Gas Pipe line & burner Gas train
x Note that gas train components are designed for low pressure and hence testing
with compressed air/nitrogen can damage the gas train.
x The gas train should be installed at about 500 mm above the floor level to ensure
easy maintenance of its components, particularly the regulator, strainer and
solenoid valves.
x The part of the Gas-train comprising main gas solenoid valves should be as near
as possible to the burner, so that gas flame is established quickly and residual gas
burning is lowest after burner shut down.
x The gas supply pressure at the inlet of the gas train should be checked to be in
conformity with specified pressure range. (Refer P&I Drg. for gas fired units )
x The manual quick shut-off valve should be opened very slowly so that the
diaphragm of the regulator is not subjected to sudden pressure surge.
x The pressure setting of the pilot and main gas regulator should be kept at near
minimum during initial start up of the burner, and the final setting should be done
during burner firing to achieve the required firing rate.
x The supply gas pipe is to be connected to gas train inlet ball valve with the help
of a union or a flanged joint. The supply gas pipe should be thoroughly cleaned
and flushed out with air, to ensure that all dirt particles are removed before
connection to gas train.
x Gas filter, pressure regulator and gas solenoid valves should be accessible for
routine maintenance and adjustments and suitable platform may be provided.
x Unauthorized tampering of gas pressure adjustment and other settings should be

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

all sides.
x Please make sure that while installing the gas train, regulations of Fire Insurance
Association, Explosives Act, factory inspectorate etc. are strictly adhered to.
03 BOILER INSTRUMENTATION,
CONTROLS & SAFETIES
3.1 Mobrey water level controller:

Two mobery level controllers are supplied, in place of one, as a standard scope for the supplies
in India. This is to provide additional safety to take care of available water quality; however, for
other countries one-mobrey level controller (KDG, U.K.) is supplied.
The magnetic level controller or Mobrey keeps the water level

under control by running the feed water pump in on off cycles.
There are three switches in the Mobrey. First top switch is used to
put off the feed water pump. The second middle switch is used
to put on the feed water pump. The third switch, at the bottom,
is used for providing extra low-level alarm and burner trip. All the
switches are set at the time of Pre-commissioning. Third Level
switch is adjusted so that it corresponds to water level below the
pump on switch. If the level falls corresponding to the third
switch, the burner is tripped. This switch is water level extra low.
This third switch is connected in the safety circuit of the burner
Figure F-3.1.1: programmer. A photograph of the Mobrey is enclosed in Figure
Mobrey Level Controller F-3.2.1 and cross section is enclosed in Figure F-3.2.2
When two level controllers are supplied, the water pump start when any one pump ON switch
(middle) of any one mobery operates .however the pump stops when both the two switches
(Top) for pump OFF operate. The Boiler goes in to safety lock out when any one switch (at
bottom) operate at low level or extra low level of water in the boiler.
Figure F-3.1.2: Cross Section of Mobrey

3.2: Fusible Plug:
This has been provided as an ultimate safety, when all the water
level controls & safeties fail, this safety, finally protects the boiler
form major accident. As per Indian Boiler Regulations(IBR),
minimum two Fusible plugs are must for the web back boilers.
One fusible plug is fitted at the top most position of the internal
reversal chamber & the second one at the front tube plate, just
above the third pass flue tubes.
FIGURE No 3.2.1: Fusible Plug
When the water level falls below either of the plugs’ level the
plug being exposed to steam on one side & flue gas at the other side .The steam does not cool
the Fusible plug as much as the water. Hence, its temperature goes up. When the plug
temperature reaches about 400 – 420°C the lead alloy holding the plug in the housing fuses. As
soon as the alloy fuses the reversal, chamber plug is forced into the furnace. This creates a small
orifice on top of the reversal chamber from which steam rushes into the furnace quenching the
flame. Consequently, the boiler would be tripped by flame failure.
To replace and maintain the fusible plug of the reversal chamber, a hand hole is provided on
the bottom shell right above the plug location. When the Fusible plug of the front tube plate, is
fused due to low water conditions in the boiler, the steam, under pressure rushes out & enters the
smoke tubes and furnace, thus quenching the flame. The Fusible plug at the front tube plate
can be re-fixed, from the waterside by entering through the boiler manhole.
The fusible plug is manufactured as per IBR & hence, requires IBR certification.
Figure no. 3.2.2: Location of Fusible Plug

3.3: Boiler Safety valve
Mechanical safety against steam pressure high is provided by two nos. Safety valves fitted
on the top of the boiler shell.
The Safety Valves of the boiler are the over pressure safety of the boiler. These are supplied in
two numbers as per the IBR. These safety valves are set at the maximum working pressure of
the boiler. One safety valve lift pressure is set little below the maximum working pressure
(MWP) of the boiler and the other one is set at the MWP.
When the pressure controller fails or the setting is more than the maximum working pressure
of the boiler then the safety valves lift & vent out steam thus reducing the excessive pressure
of the boiler.
The Lift & sit back operation of these valves should be exactly as per IBR, which is set at the
time of commissioning. After the IBR steam test (Ref Chapter 1.5 IBR Registration), the safety
valves setting nuts are locked by means of the spacer rings to ensure that the lift pressure is
not disturbed.
Photograph and cross section of a safety valve are enclosed below, in Figure F-3.3.1 and
F-3.3.2,respectively.
VALVE SETTING NUT

GUIDE ROD
SPRING
VALVE
SEAT
STEAM
OUTLET
Figure F-3.3.1: Safety Valve
BLOWDOWN RING
STEAM INLET
Figure F-3.3.2 – Cross Section of Safety Valve

3.4: Boiler Water Level Gauges:
These are Reflex type toughened glass
level gauges and enclosed in the
Metallic enclosure to protect it from the
breakage. Two level gauges are
provided in case of shell boilers and on
steam drums used in water tube boilers.
Each gauge glass assembly comes with
IBR approved isolation and drain valves
mode of Bronze / Gunmetal. For high-
pressure boilers above 17.5 kg/cm2
design pressure, cast steel material is
used for valves.
Figure No F 3.4.1: Reflex type Level gauge
3.5 Digital Temperature Indicator & controller;
Two digital temperature indicator & Resistance Temperature Detector (RTD) is

controllers (TIC) are used in Shellmax; Fuel used with each TIC to sense the temperature.
temperature TIC is used for the control &
indication of the fuel temperature which is
heated by Oil pre heating station.
The fuel gas TIC is used for indication of flue
gas temperature & as a safety, which cuts of
the burner incase of flue gas temperature
rises above the set point .The TIC set point is
+30 deg “C” above the normal flue gas
temperature, which will gain dependent
upon the operating pressure of the boiler. The
safety temperature setting is done at the time Figure F 3.6.1: Digital Temperature
of commissioning. indicator Figure F 3.6.2: Temperature
sensor (RTD)
3.6: BURNER & BURNER MANAGEMANT SYSTEMS:

The principle of burner management system remains the same for all burners,
however, the components change with the make & model of the burner. The
component change results in to minor changes in the functioning of the burner
system.
Thermax supplies two types of the burners systems, as the standard scope:
A) OERTLI BURNER: The components, their Operation have been discussed in details in the
following paragraphs.
Apart from the burner models, the FD fan models also change, with Shellmax boiler model.
B) Oilon Buners: The Oilon burners are imported burners and these are explained in details
in the burner operation & maintenance manuals, separately attached in the Section:
Annexure of this Manual.
The following Paragraphs shall describe in detail about the

“OERTLI BURNER MANAGEMANT SYSTEM”
A) OERTLI BURNERB & ITS MANAGEMANT SYSTEM: FOR LIQUID FUEL FIRED UNITS
The Oertli Burners are indigenous and there are four burner models, used in nine Shellmax
boiler models: Table no T 3.6.1: Shellmax –Oertli Burner Models
S no SHELLMAX MODEL OERTLI OIL BURNER MODEL
1 SMDH 10 to 30 IB- 3
2 SMDH 40 to 50 IB- 5
3 SMDH 60to 80 IB- 7
4 SMDH 100 to 120 IB- 9
5 SMDH 140 to 160 IB- 13
The Oertli burner management system consists of the various components &
instruments, which are fitted at different locations on the boiler.
The components /instruments, which control the burner modulation & fuel firing
rate, of the burner with respect to the steam pressure in the boiler are:
Table no T 3.6.2: Oertli Burner Components

S no Component Change with Shellmax model
1 Burner Gun & Spray Nozzle Burner Gun – length Changes with SM models
Spray nozzle capacity - Changes with SM
models & Fuels used
2 Burner Sequence controller Model different for oil & Gas firing
3 Photo resister Common for all models
4 Ignition Transformer Common for all models
5 Proportioning Pressure Controller- Changes only with Boiler working pressure &
Pressurtrol not with SM models
6 Air & Oil regulator assembly – AR Common for all models
63
7 Fuel regulating/metering valve Common for all Shellmax models but
Changes with light or heavy fuels
8 Positioner control- PEPC-10 Common for all models
9 Rectifier Common for all models
10 Pressure switch- Pressure high Changes only with Boiler working pressure&
not with SM models
The paragraphs below explain the functioning of each of these components

3.6.1 Burner Gun:
x When the burner solenoid valve get the electrical supply through the sequence controller,
the stem of the burner gun opens the inlet port at the nozzle holder & sprays it through the
burner nozzle.
x The excess fuel oil is by passed by the bypass port of the burner gun & back to the fuel
supply header.
x The by pass quantity is controlled by the fuel metering valve ,which is linked to AR 63 Gear
Train
Stem Fuel inlet connection Fuel inlet port
Spray Nozzle
Connection
Fuel by –pass connection Fuel by –pass port
Figure No F 3.6.1: Burner Gun
3.6.2 Burner Spray nozzle:
b. Spray angle: In degrees

c. Capacity: kg/hr, as per the capacity of
the boiler
The details of the capacities & type of nozzles

used are given in table no T 3.7.11
When the fuel under pressure enters

the burner nozzle, the nozzle swirler,
converges the fuel towards the center
hole of the nozzle and the fuel, which
is under pressure, comes out of the
nozzle in the form of very fine spray.
This spray consists of very small
droplets of the fuel.
During the burner start up, these
droplets, get vaporize & ignite under
the high temperature of the electrical
spark at the ignition electrodes. When
the flame is established, these
Figure No F 3.6.2.A &B: Burner Nozzle droplets vaporize & ignite with the
heat of the existing flame.
The sizes of the nozzle are denoted, by:

a. Type: for heavy fuels & for light fuels
The diffuser plate distributes the
combustion air inside the air cone, for
the proper combustion of fuel. The
combustion air is supplied by the FD
fan.
Burner Gun
Electrode Assembly
Burner Nozzle
Diffuser Plate
Air Cone
Figure no F 3.6.2.C Burner Assembly
3.6.3 Burner Sequence Controller: un-burnt gases/volatiles/ smoke from

Make siemens, Model -LAL 2.25 the combustion chamber/burner
furnace.
¾ “Return” the air damper to” low
fire/Flame” position, to start the burner
in low fame position.
¾ Electrical Supply to “ignition
transformer” to turn on the “ignition
Lockout indicator
Spark”.
Circular scale ¾ Electrical Supply to “Burner solenoid
valve”, to spray the atomized fuel &
establish the low flame.
¾ “Turn off the firing sequence”, in case
of satisfactory flame establishment.
Figure no F 3.6.3: Sequence controller ¾ “ Stop” the supply to the burner
The sequence controller automatically solenoid valve bring burner firing
controls the firing sequence of the burner & sequence to” Lock out” position in
ensures the safety of the operating personnel case of no flame sensed in
/ equipment, in the event of improper or no predetermined time OR incase of
flame. improper /flickering flame.
It works in conjunction with the flame sensor ¾ “Bring back” the air dampers to low
(Photo resister for oil fired units), which position.
continuously monitors the flame & provides
the feedback to the sequence controller. Once the flame is established (in low flame),
The sequence controller provides the the sequence controller only monitors the
following burner firing cycle or the firing flame through the flame sensor and allows
sequence in the SM boilers: the flame to continue in normal firing
conditions.
¾ “Start the FD fan” motor .which
supplies air to the burner
¾ Position the air dampers at open
position, for “Pre-purging” of the
combustion space, to scavenge the
3.6.4. Photo Resister:
(Model: QRB 3 for Oil firing, Sequence controller Siemens- LAL 2.25.)
This is called the eye of the burner .It senses the light from the flame &in case of
steady flame provides the supply to the sequence controller to stop the firing
sequence.
In case no- flame or flickering flame, the feedback is given to the sequence
controller & the electrical supply to the burner is switched off, indicating “Lockout”.
This photo resister works on the principle of reduction in resistance by sensing light. It
can sense ordinary day light, artificial electrical illumination or light emitted by any
source.
Figure No: 3.6.4: Photo Resister
3.6.5. Ignition Transformer
This transformer provides high out put voltage of 14.5 KV for the oil fired units .This
is connected with the high-tension cable to the burner ignition electrodes.
The electrical supply is given to the ignition transformer, by the sequence
controller, as per the firing sequence.
These electrodes are adjusted with the air gap of 5-6 mm & are positioned close
to the burner nozzle tip. The high Voltage generates the spark at the electrodes
tip & ignites the fuel spray to establish the flame. This transformer is meant for
ignition of the burner flame only and is switch off as soon as the flame is
established or at the predetermined time set in the sequence controller.
Figure No 3.6.5.1: Ignition Transformer
3.6.6. Proportioning Pressure Controllers- Pressuretrol, Make- Honeywel
This is the boiler steam pressure controller, which regulates the steam pressure in the
boiler by modulating the fuel-firing rate & corresponding air of the burner. This is
supplied with the boilers.
This controller with other controls reduces the fuel & air, which is fed by the burner in
the boiler furnace, when the boiler steam pressure increases. In addition, it increases
the firing rate & air when the pressure in the boiler reduces .The increase or reduction
in the firing rate is in proportion to the increase or decrease of the steam pressure in
the boiler.
It is called as proportioning pressure controller because its action is in proportion to
the increase or decrease of steam pressure in the boiler. This control is also called
step less modulation, as this modulation is continuous.
This controller avoids the burner on-off operation of the boiler, which is undesirable to
the boiler & to the process. In short, it tries to maintain the steady steam pressure in
the boiler, when the steam load/pressure fluctuations are within the reasonable limits.
This pressure controller control the firing between lowest & highest firing range of the
burner. The ratio of the lowest firing rate to rated firing rate is called as burner /boiler
turn down ratio, (33% for SM 30C to 40 C & 25% for SM 50C to100C Models) of the
rated fuel consumption in Shellmax boilers.
This pressuretrol is not used in lower capacity boilers SM 10c to 20 c, where, the Turn
down is 50%.
If the steam demand reduces even with the lowest turn down ( 25% Or 50%,As the
case may be),the steam pressure rises further even at the lowest burner firing rate,
then the steam pressure high Pressure switch (On –Off) cuts off the burner .
This controller is provided with adjustable proportioning (throttling) range to allow

selection of desired pressure control range. A pressure scale in customary US units as
well as metric units and an indicator are provided. The adjustment is done with
screws provided on the casing top. The pressure controller can be mounted directly
on process piping as well as on control panel.
Construction & Working
The pressure controller is provided with a pressure-sensing element in the form of

phosphor bronze bellows. The bellows are linked to a potentiometer wiper. The
potentiometer resistance is around 135 – 140 ohms. A terminal strip with marking is
provided for electrical connections. The construction is shown in Figure no 3.6.6.1.
Pressure variations cause the bellows to expand or contract. Linkage between the
bellows and the potentiometer wiper causes the wiper to move across the
potentiometer windings. This varies the resistance between R & B and R & W causing
an imbalance in the circuit connected to the controller.
Figure No F 3.6.6.1
Figure No F 3 6 6 2 - Proportional Pressure Controller

The controller is used to regulate the firing rate of a burner by controlling a
modulating motor / modulating valve. The controller potentiometer, the feedback
potentiometer in the modulating motor and a balancing relay in the motor form an
electric bridge circuit. As long as the pressure of the controlled medium remains at
the set point of the controller, the circuit is balanced; that is, equal currents flow
through both sides of the balancing relay and the relay contacts are open. When
the circuit is balanced, the motor does not run.
Figure No F 3.6.6.2 - Pressure Variation
If the pressure of the steam rises, the wiper in the controller moves towards W. This
unbalances the circuit, so a larger current flows through one side of the balancing
relay. The close contacts in the relay make, causing the motor drive toward its
closed position. As the motor runs, the wiper on the feedback potentiometer moves
in a direction to balance the circuit. When the circuit is again in balance, the
balancing relay contacts open and the motor stops. The valves and dampers
connected to the motor or actuator will be partially closed, decreasing the firing rate
and reducing the pressure.
Similarly, if the pressure of the steam falls, the wiper on the controller potentiometer
moves toward B, and the open contacts in the balancing relay close. The motor
drive toward its open position until circuit balance is achieved. The valves and
dampers will be opened wider and the firing rate will increase, thus increasing the
steam pressure in the boiler.
A small change in the pressure of the steam will cause a change in the firing rate to
compensate for it, thus keeping the pressure constant. This process is called
modulation.
3.6.7 Steam pressure high controller: Pressure Switch
The control of steam pressure is provided by a pressure switch as mentioned above. If

boiler pressure increases above the set pressure of the pressure switch, the boiler is
tripped by automatically switching off the Burner. The Burner restarts automatically when
steam pressure reduces below the differential Pressure setting of the pressure switch. This
automatic operation of the boiler is known as on – Off control, and the boiler steam
pressure is controlled by the pressure switch.
All pressure switches use a sensing element, bellows being the most common. The
bellows type performs well in applications where even shock and vibrations are present.
The sensing element can be used for a variety of process fluids. The pressure switches
can be made in weatherproof housing (IP-66) or in explosion proof housings. The pressure
switches used in boilers are of standard design.
Figure No 3.6.7.A:
Pressure switch Figure F-3.6.7.B: Internal View of a Pressure
Steam Pressure high
3.6.8. Air & Oil Regulator Assembly – (Burner modulation control):
Model - AR 63 -For - Liquid Fuels
FIGURE NO F 3.6.7.1: AIR OIL REGULATOR ASSEMBLY: Type: AR 63
THE MAIN COMPONENTS:
The main function of this assembly is to provide a mechanism for modulation of fuel firing
rate & corresponding air supply rate.
Based on the feedback from the boiler proportional pressure switch-pressurtrol, the
feedback Potentiometer makes the servomotor to rotate in either direction. When the
servomotor receives the input signal from the pressure troll through Positioner PEPC-10,
the clutch assembly energizes, and the motor starts rotating in the desired direction. The
speed of the motor is reduced by means of a gear train and is transmitted to the
regulating drum.
a. Servomotor: d. Linkage –To inlet air damper & to

b. Gear train fuel metering Valve
c. Drum & adjusting cam assembly e. Feed back Potentiometer
with spiral strip f. Clutch assembly
g. Limit switches
FIGURE NO F 3.6.7.A FIGURE NO F 3.6.7.B

FIGURE NO F 3.6.7.C FIGURE NO F 3.6.7.D
A. SERVOMOTOR: Input: 220V, 50 Hz, Output 90 Watt
It is a single phase, double pole split motor. The main function of this servomotor is to
provide a drive for the gear train to rotate in clockwise as well as anticlockwise. The high
rpm of the motor is reduced with the help of the gear train, which finally transmits about
30 rpm to the regulating drum. The running time of the AR63 assembly, from low position
to high position is 27 seconds. In order to close the air damper flaps completely another
14 seconds are required
B. Regulating Drum:
The drum of the AR 63 assembly is rotated by the servomotor through the gear train to
reduce the speed of rotation. A steel spring band is mounted circumferentially on the
drum. This band is secured by 16 adjusting bolts /cams.
A lever connecting the damper runs along the length of the spring band
circumferentially, which in turn operates the damper to open or close. An eccentric disc
is mounted at the end of the drum shaft, which rotates with the drum.
The eccentric disc moves the plunger of the fuel-regulating valve or fuel-metering valve,
which, in turn varies the fuel input to the burner nozzle. (Refer fuel metering valve 3.6.7G)
Thus, with the rotation of the drum, the fuel & air supply increase or decrease together,
without changing set the air fuel ratio. This is called the burner modulation.
Bolts for
Adjustment
Adjusting cams Steel spring band Lever
FIGURE NO F 3.6.7.B1 FIGURE NO F 3.6.7.B2

There are 16 adjusting cams for the spring band on the regulating drum. The first 5 cam
are for the air lock & the remaining 11 are for the regulation of the damper as required.
C. Feedback potentiometer: Capacity: 100 Ohm, Range: 180 Degrees (rotation)
This is a 100-ohm potentiometer used in the AR- 63 assembly to provide varying resistance
signal to the Positioner, which in turn gives the signal to the motor to rotate in the either
direction.
FIGURE NO F 3.6.7.C1 FIGURE NO F 3.6.7.C21
The feedback potentiometer is mounted on the Burner modulating Gear Train assembly
as shown. The movement of this feedback potentiometer is with respect to the
proportional pressure controller (Ref above 3.6.7.C, C1, C2), which senses the pressure in
the boiler moving its bellows & the pointer on the potentiometer.
It provides the positional feedback of the gear train to the Positioner controller by
applying its resistance in the Circuit.
Hence, by positioning the gear train the air damper & the fuel metering valves get the
movement according to the pressure in the boiler. This action changes the fuel-firing rate
& the corresponding air quantity of the burner & is called the burner modulation.
The burner can position it self at any position as per the feed back received from the
Proportional pressure controller & with the help of the feedback Potentiometer.
D. Clutch Assembly:
The clutch assembly transmits the torque of the

motor to the gear train of the air–oil regulator
assembly.
This is a magnetic type of clutch & engages the
motor with the gears only when the electrical
supply is given to its terminals along with the
servomotor.
Figure No F 3.6.7.D
E. Limit Switches:
The limit switches, limit the movement of

the servomotor, to highest or lowest
position. These are operated by the
cams, which move with the servomotor,
through the gear train.
There are five limit switches fitted in the
AR 63 assembly, out of which four are
used.
Limit switches 3 & 1 are used for stopping
the drum movement at lowest position
on the steel spring band; however, 4 & 2
are used for stopping the drum
Cam assembly
movement at the highest position on the
Figure No F 3.6.7.E steel spring band.
F. Positioner Controller: Model: PEPC – 10
This is electronic equipment mounted in control panel.
The Positioner controller is used with

transmitter potentiometer (GW) and a
motor drive to get follow up controls or
remote manual settings. The transmitter
potentiometer is connected with
terminal 13, 11 (wiper) & 14. Feedback
Figure No 3.6.7.F-Positioner-PEPC potentiometer (mounted on modulating
motor) is connected to terminals 8, 9
(variable) & 10 of the Positioner
controller.
The position of the transmitter is compared, with the position of the feedback
potentiometer RW built into the motor drive. When a deviation exists, the Positioner
controller gives the corresponding control signals to the motor drive until the position
balance is established again. Transmitter potentiometer and feedback potentiometers
with a nominal value from 130 to 2000 ohms can be used.
G. Rectifier:
This is placed inside the electrical control panel.

The electrical signal to the burner gun-solenoid
valve or the continuous current magnet, it is
routed through the “rectifier” to provide 180
volts DC supply to it. The solenoid valve
energizes & opens the port to allow the
Figure No 3.6.7.G: Rectifier pressurized fuel to spray in the furnace.
H. Fuel Regulating Valve:
Its function is to regulate the fuel by pass quantity from the burner gun, thus to increase
or decrease the fuel spray quantity in the boiler furnace.
When the fuel bypass quantity is high, the burner fires in low flame or vice versa when the
bypass quantity is low.
The fuel regulating or metering valve does this function by the movement of its plunger,
which is moved by the eccentric disc.
The drum shaft of the AR 63 modulation assembly operates this eccentric disc.
The cylinder of the regulating valve, for Furnace oil has longitudinal slots, where as for
light oil (LDO/HSD), it has radial grooves .The-regulating valve has to be checked for its
suitability for the fuel oil used i.e. light oil /heavy oil. It will be required change the cylinder
to suit the oil as the cylinder for light oil will not be suitable for heavy oil & vice versa.
Figure No F 3.6.7.H1: Fuel regulating /metering Valve
Valve
body
Pressure Adjusting Screw

Spring Spindle
support
End Cap
Roller
Valve Cylinder for

Cone
Heavy fuel Oils
Valve Cylinder
For Light fuel oils
Figure No: F 3.6.7.H2: Exploded view of fuel Regulating/metering valve

3.6.8 Burner modulation Logic
The following paragraphs will explain the burner modulation /firing control logic with
the function of each component involved with respect to the other.
Modulation Logic Diagram
SEQUENCE
CONTROLLER
PRESSURETROL
On-Off PRESSURE
SWITCH
PEPC
BOILER
BURNER
POTENTIOMETER • Resistance output-

• Electrical output
ELECTRICAL CONTROL • Mechanical Output::

PANEL • Pressure Input:
FEEDBACK AR 63
Figure No: 3.6.8: Burner Modulation Logic

a) Boiler start up –No pressure in the boiler
Condition: Burner on, Modulation switch off. Pressure in the boiler is zero, all other
controls / safeties in healthy condition and burner/ flame is properly set:
Start
Pressuretrol –wiper in extreme low position of the range
Firing sequence of sequence controller is on (refer above 3.7.3-)
Positioner PEPC, in order to balance the resistance in the bridge, rotates the
potentiometer of AR 6 in the proper direction, with the help of Servomotor &
clutch and through the gear train.
The drum of AR 63 rotates and the lever of the air damper moves on the steel strip
of the drum.
Linkages of air damper move & close the air damper to its lowest opening
position, up to limit switch.
The AR 63 drum shaft rotation also moves the cam disc which is mounted on the
drum shaft it self. This rotation of the cam disc opens the by pass of the fuel
regulating/metering valve, to maximum.
Major quantity of Fuel is by passed after entering the burner Gun, through its
bypass port.
Now combustion air is at minimum opening with fuel bypass at maximum i.e. burner
at low firing /flame position
Sequence controller sends the electrical input 220v AC to burner ignition

transformer (through External contactor), to provide 14.5 KV at burner ignition
electrodes, to start sparking.
Sequence controller gives the signal o burner solenoid valve (continuous current
magnet), through external circuit & rectifier, to provide 180V DC.
The continuous current magnet attracts the burner stem & opens the fuel inlet port
to nozzle, to come out in the form of fine spray
Spark ignites the fuel spray droplets & generates the flame, with lowest firing rate,
called as low flame
Stop
b. Boiler to Generate Steam at Maximum Rate: burner to fire at high flame:
Condition: Burner On, Burner firming at low flame-boiler pressure lower than
setting on the pressuretrol & pressure high cut off Pressure switch:
Start
Modulation switch is switched ON
The wiper of the pressuretrol at an advance position due to steam pressure makes
the Positioner PEPC to balance resistance in the bridge & makes the potentiometer
alter resistance by rotation of Servomotor /Drum through gear train.
Drum of AR63 moves slowly towards its extreme (High) position, opens the air
damper to its maximum setting gradually, thus combustion air increases to
maximum
At the same time, gradually closes the by pass of fuel regulating valve to
maximum, thus reducing the fuel bypass & increasing the fuel firing rate slowly
The flame gradually goes to highest firing rate .Thus increasing the steam
generation.
The AR 63 Drum stops its rotation at high position by limit switch
Stop
c. Steam Demand Reduces and Steam Pressure Increases:
Condition: Burner firing at high flame, boiler pressure below the pressure
setting of pressuretrol and High Pressure Cut off (On-Off) Pressure switch:
Start
Pressure in the boiler rises towards the setting range of pressuetrol but below the
setting of on- off pressure switch
The wiper of pressuretrol moves towards the high setting, Positioner PEPC balances
the resistance in the bridge & by moving the Potentiometer (in the reverse direction)
through clutch & servomotor.
AR 63 gear train & the drum moves in the reverse direction slowly to match the rate
of increase of pressure sensed by the pressuretrol, so to close the air damper
gradually, reducing the combustion air
The AR 63 Drum & cam disc of the fuel regulating rotates in the reverse direction to
increase the fuel bypass to reduce the fuel-firing rate
This reduces the flame in proportion to the increase in the steam pressure, thus try to
maintain the constant pressure in the boiler.
The rotation of the Drum Stops at Low position by Limit Switch and Boiler burner fire
reduces to low flame.
Stop
d. Steam Demand Reduces Further & Boiler Pressure Increases:
Condition: Boiler pressure above the pressuretrol but below the on off Pressure switch
setting
Start
With the pressuretrol wiper movement due to increase in the steam pressure and the
subsequent Potentiometer movement by Positioner PEPC (as per the condition no 3
above), AR 63 gear train Moves in the reverse direction
The gradual movement of AR 63 in the reverse direction reduces the air damper to
minimum position (by limit switches) and increases the fuel bypass of fuel regulating
valve through cam disc movement. Thus, gradually reduces the fuel firing rate also
The burner goes in the low flame firing position.
The wiper of the pressuretrol reaches its extreme position and does not move further
with the increase in the steam pressure
With the further reduction in steam demand, the steam pressure still rises in low flame
above the setting of the steam pressure high cut off (On Off) pressure switch
The pressure switch cuts of the supply to the burner thus, cutting off the flame,
without stopping the blower
If the steam demand increases, the pressure reduces below the differential setting of
the pressure switch, the supply to burner is restored by pressure switch & sequence
controller starts burner-firing sequence again.
The flame is established in low firing rate/in-low flame
Stop
For Gas fired units the burner modulation logic is the same, except for the change in
some of the components of the burner, as explained below.
x In place of continuous current magnet, gas train solenoid valves get the supply of
220V AC-rectifier not used in gas fired units
x In place of fuel regulating valve & cam disc, one more regulating drum is used for
gas consumption regulation.
3.6.9 Burner modulation –Instrumentation:
After understanding the burner function of each of the burner components and
modulation logic, it will be easier to understand the interlinking & wiring connection of
the instruments in detail, as given below.
The Instruments involved in modulation of the oil burner are:

Burner Sequence controller, Proportioning Pressure Controller (Pressuretrol)”, “Air & fuel
Regulating Assembly-AR 63” and “Positioner (PEPC)”.
Sequence Positioner
Rectifier
controller PEPC
Figure no F 3.6.9 a
Air oil regulator, AR63 comes into the operation for.

1. Pre purge sequence, and
2. For modulation.
It is required to know sequence controller operation along with AR63 to understanding

the entire operation of Pre-purge and modulation. For oil firing Siemens LAL 2.25
sequence controllers is used
Refer to the wiring diagram (figure no 3.6.9 b) of AR63 on the next page. In this wiring
diagram, terminal number, ferrule no of wires and the connection of the limit switches is
shown. To understand the logic of pre-purge & modulation it is required to study that
diagram.
The following components are shown directly connected to the AR 63 for simplicity,
however, in actual practice, the wiring diagram of the boiler will indicate, more contacts
& detailed wiring details
1. Ignition transformer.
2. Continuous current magnet or the solenoid valve.
3. Photo sensor.
The limit switch number 5 of AR 63 has been removed as the same is not used.
Figure no F 3.6.9 b
In the following paragraphs below the actions related to AR63 –burner modulation bare
explained.
Pre-purge
The lockout indicator of sequence controller LAL 2.25 is like this.

a–b Start up sequence
b – b’ Idle steps up to the self shut down of the

sequence switch
b (b’) – a Post purge sequence
The sequence of firing starts with this symbol on the lock out indicator. Here the blower
Stops, fuel pump starts and after that the blower restarts, provided the
blower and fuel pump contactor connections are taken from the sequence
controller. Otherwise blower and fuel pump is started from their respective
switches and runs continuously.
But there will be no start if 8 and 11 terminal of sequence controller is not shorted and can
also happen if contact has not been closed between terminals 12 & 4 and 4 & 5.
Then the lock out indicator rotates further and stops at this symbol and power comes at
Terminal number 9 of the sequence controller. Terminal 9 is connected to
terminal 163 of AR63. Through limit switch no.2, power goes to motor.
Capacitor is connected, as it is a single phase motor. The clutch is
connected
in series with the motor. When power comes, clutch energizes and the motor starts
rotating towards high. When the motor reaches high position, limit switch no.2 operates. It
stops the power supply to motor and clutch. So the motor stops and as the clutch de-
energizes, motor does not rotate further. Through the limit switch power comes to 164 of
AR63 terminal and reaches to terminal 8 of the sequence controller and the sequence
goes ahead and lockout indicator rotates further.
When the lockout indicator reaches this symbol, the sequence stops and the power
comes
to terminal 10 of sequence controller, which is connected to terminal 160 of
AR63. Through limit switch no 3 and 1 power comes to the modulation
motor and clutch. The clutch energizes and the motor reaches the low
position. When it reaches, limit switch 3 operates first, stops the power to
the motor and clutch. As clutch de energizes, motor stops there itself. Due to operation
of limit switch 3, power comes to terminal 161 through limit switch no 4, which is in turn
connected to terminal 8 of sequence controller. After power comes to 8, the sequence
goes ahead and firing starts. For details of remaining part of firing sequence please refer
sequence controller manual.
If there is any problem with the limit switches, the unit can be fired by shorting the 8, 9, 10,
and 11 terminal of sequence controller. In that case, the air damper will not go to the
high position during pre-purge.
Modulation
Once the unit fires, after preset time, power comes from the sequence controller terminal
20 and if the modulation switch is ON, then the modulation contactor energizes. In that
condition if power comes to terminal 163 of AR63, then burner goes to high flame till the
maximum position and if the power comes to terminal 160 of AR63, burner goes to low
flame till the minimum position. Motor power supply automatically cuts off by limit switch
no 2 and 3 in low flame and high flame respectively.
Modulation is of two types.

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

In step less modulation the firing can be anything between low flame and high
flame.
For step modulation for boilers Pressure switch is used
x Pressure switch for boilers
In this type of control the pressure switch senses pressure. When the process value or the
steam pressure is less than the pressure switch set valve, power comes to terminal 163 of
AR63 and unit goes to high flame. Once the pressure becomes more than the set value,
the micro switch of pressure switch operates and gives power to terminal 160 of AR63,
and burner comes to low flame.
For step less modulation the Combination of Proportioning Pressuretrol Controller and
Positioner Controller PEPC 10 is used.
x Combination of Proportioning (Pressuretrol)Controller and Positioner Controller

PEPC 10.
In most of our boilers we use this kind of control system. We use Honeywell Pressuretrol.
In the Pressuretrol, pressure variation causes the
bellows inside to expand and contract. Linkage
between the bellows and the potentiometer
wiper causes the wiper to move across the
potentiometer windings. This varies the
resistance between Red & Blue and between
Red & White wires causing unbalance in the
circuit of Positioner controller PEPC 10. PEPC 10
is a P controller. The varied resistance or in other
words, position of the Pressuretrol is compared
with the position of the feedback
potentiometer of AR63. When a deviation exists,
the Positioner controller gives the corresponding
control signals to the motor ( to
Terminal 160 or 163 of AR 63), until the position balance is established again.
Figure no F 3.6.9 c
3.6.10 Burner setting: Liquid fuels (HSD/LDO/FO/LSHS):
When the burner supplied with the boiler is of OERLTLI pressure jet design, refer
the following paragraphs, to understand the settings.
OERTLI BURNER:
Figure No 3.6.10.1: OERTLI OIL CUM GAS BURNER
Air In Burner Gun Air cone Diffuser plate
Figure No 3.6.10.2: OERTLI PRESSURE JET BURNAR -SECTIONAL VIEW: For Liquid fuels
3.6.10.1 Setting Rated Fuel Consumption:
Ensure that the burner spray nozzle is of right “Type” for the fuel to be used, right
discharge Capacity (Kg/hr or GPH) and correct Spray angle (In Degrees).
This is done by setting the fuel pressures at the burner inlet & at the burner by pass
(indicated by Burner inlet & by pass pressure gauges) at the desired pre-heat
temperature of the fuel oil. Ensure that the viscosity of fuel oil is between 10-12 CST for
heavy fuels (Ref chapter 4: Input requirements)
The settings given in the table below are the reference settings:
3.6.10.2. BURNER SETTING:
A) Oertli OIL Fired Burner Settings:
Different models of the Oertli burners which are used and the settings are given in the
table below-
The Oertli Burner consists of the following main components, which are to be set for their
respective gaps.
1) AIR CONE: This is a straight cylinder. Air from the FD fan is forced through this
cylinder to the boiler
2) DIFFUSER PLATE: this is a circular plate of having swirls or slots through which the air
passes & get distributed in side the air cone
3) BURNER GUN & BURNER NOZZLE: the pressurized fuel is sent through the burner gun,
when allowed by the fuel solenoid valve .This gun has Burner nozzle at the end,
through which the fuel is atomized & sprayed inside the furnace. Some of the fuel
is by passed through this gun, which is controlled by the Fuel metering valve.
4) IGNITION ELECTRODES: These two electrodes ignite the atomized fuel passing
through the burner nozzle & produce the flame inside the furnace.
The burner setting or the gaps to be maintained between these are indicated in the
Below:
B A
Cone
edge
C
Figure No F 3.6.10.2 a
Table no T 3.6.10.2: OERTLI BURNER SETTING-0IL FIRED BURNER
SHELLMAX OERTLI Settings /Gaps In MM

MODEL OIL Air Cone Burner Nozzle Nozzle to Between
BURNER Edge to tip TO Diffuser Electrodes Electrodes
MODEL Diffuser Plate Plate (B) (C)
(A)
SMDH 10 to 30 IB- 3 90-95 15 7 6
SMDH 40 & 50 IB- 5 105-115 15 7 6
SMDH 60 & 80 IB- 7 105-115 15 7 6
SMDH 100 & IB- 9 105-115 15 7 6
120
SMDH 140 & IB-13 105-115 15 7 6
160
3.6.11: GAS FIRED ORTLI BURNERS:

3.6.11.1GAS TRAIN:
x The train is fitted close to the burner of the boiler in the boiler house .The function of
the gas train is to provide the clean ,regulated flow of gas at the desired pressure
to the burner of the boiler and to provide essential safety incase of abnormalities .
Gas Pressure gauge Gas Pressure gauge
Ball valve Gas filter Safety Shut Gas Pressure Gas pressure switch Main Gas Solenoid Valves
off Valve Regulator
Figure No 3.6.11.1: Standard Gas Train

Figure No 3.6.11.2: P&I Diagram: Gas Train Assembly
The gas train will also provide the following actions, with the help of the various
components:
Table No 3.6.11.1
S no Component Description Function
a Manual Ball Valve/quick shut off Manual start/Isolation of gas supply
valve
b Gas filter Filtration of gas
c Safety Shut off valve: High pressure shut off of gas supply
d Gas Pressure regulator Regulation of the gas flow & pressure
e Gas Pressure gauges Indications of the gas pressures ,at inlet of the gas
train & at the inlet of the burner
f Safety relief valve Venting of the excessive gas pressure
g Solenoid valve–pilot burner Supply gas to pilot burner
h Main Gas Solenoid valves ( 2nos) Supply gas to main gas burner ,
after establishing normal pilot flame -
i High & Low Gas pressure switches. Gas pressure high & low-pressure
Shut off gas supply
Where gas inlet pressure to gas train is below 500 mbar safety shut off valve & safety relief
valve is not required.
The gas train shuts of the gas supply to the burner in case of abnormal conditions
The abnormal conditions will arise when,
x Gas pressure in the gas train, will rise above or fall below the set pressures in the gas
pressure switch. If the high gas pressure safeties fail to operate, the safety relief
valve will vent out the excess gas pressure.
x Burner Flame or ignition failure.
The pilot & main burner solenoid valves are connected to the sequence controller of the
boiler.
The standard gas train supplied with Shellmax boiler consists of the following
components.
GENERAL DESCRIPTION
a. Quick shut-off valve
This is manually operated quarter turn shut off valve to supply or cut off gas to the burner,
and is fitted at the start of the gas train.
Figure No: 3.6.10. a: Quick shut off valves
b. Filter
This is to prevent any dust/Rust particles or impurities from entering the pressure regulators
and solenoid valves, thereby avoiding leakages.
Figure No .F 3.6.10.b
c. Pressure Regulator (Gas governor)
i) Main Regulator
This is the most important part of gas train. It regulates the downstream pressure of the
gas at the set value required for correct firing rate of main burner. The set pressure of the
regulator (#) can be adjusted by changing the tension of spring located above the
diaphragm.
(#) - For set pressure, (Refer chapter: 5.0 Commissioning-Section 5.2.1 G: Important
Readings & settings) This set pressure is for full load on unit and other parameters as per
design conditions, and hence may vary depending upon actual unit operating
conditions.
ii) Pilot Regulator
The regulator is provided to supply gas at regulated pressure to the pilot burner for a
steady pilot flame, irrespective of the setting of the main gas pressure regulator.
Gas Regulator/Governor Main Burner Gas Regulator/Governor Pilot Burner
Figure No.: F 3.6.10.c1 Figure No: F 3.6.10.c2
d. Safety Relief Valve
Safety relief valve is mainly required to relieve sudden pressure

surges in the line. A safety relief valve is positioned
downstream of the gas pressure regulator. The setting of relief
valve is 20% above regulator set pressure.
Figure No 3.6.10.d
e. Safety Shut off Valve (Slam Shut off Valve)
Safety shut off valve is used to protect the down stream

components in case supply pressure exceeds the
withstanding pressures of downstream components of
pressure regulator.
The setting of the valve is 20% above safety relief valve
pressure.
Figure no: F3.6.10.e
f. Pressure switch (Gas pressure high) - optional
This is a protection of safe guard the burner from over firing in

the event of high gas pressure occurring downstream of the
regulators. If the pressure of gas increases above the set limit
the gas pressure switch de-energizes safety circuit and cuts
off the burners, giving audio-visual alarm.
Figure No 3.6.10.f
g. Pressure switch (Air pressure low) - With Air Pre Heater
It is fitted at the pre-heated air after APH & before the Burner inlet. This Air duct is in the
scope of work of the user.
During operation, due to any reason if the Air pressure falls below required level, it will
result into heavy backfiring. This can be dangerous for the boiler operating staff. Under
such conditions, the Low air pressure switch will shut of the firing, by closing the burner
Gas solenoid valves. It operates in the reverse way to the gas pressure high Pressure
switch, and has higher operating pressure range.
h. Burner Solenoid valves
Every time the burner trips(safety interlock) or is put off

(controlled shutdown in ON-OFF operations), two solenoid
valves on the main gas line shut tightly isolating the burner from
the gas flow.
In addition, the solenoid valves should close when there is
power failure, without extra energy. These are NC type solenoid
valves. When the power fails, the burner blower switches off. If
solenoid valves are not closed, then gas will continuously flow
and accumulate into furnace without any firing, which may
result in fire hazard, while restarting the burner.
Figure No. F 3.6.10.h

i) Quick opening solenoid valve: - It is installed first out of two solenoid valve. The
valve is closed when not connected to power supply. After voltage is supplied to drive
unit the valve opens and gas flows.
ii) Slow opening solenoid valve: - It is installed after quick opening valve, when
voltage is applied the disk is pulled upwards by the drive unit. The damping prevents the
movement being too fast. The valve opens slowly.
I. Pressure gauges
Pressure gauges are provided at different locations, one before

the regulator and the other after the regulator. The former
indicates the gas supply pressure, where as the latter indicates
the pressure at which gas enters main gas solenoid valves.
One pressure gauge is provided after the regulator (governor)
in the gas pilot line.
Figure No. F 3.6.10.i
3.6.11.2 AIR & FUEL REGULATOR: GAS FUELS: Model: ARG63
The air supply to the burner is regulated by AR 63 Regulator assembly, as in case of oil
firing. However, in gas fired units, on more AR 63 regulator assembly is used to regulate
the main gas supply to burner (In oil fired units, fuel regulating/metering valve is used).
One regulating drum is used for air regulation and the second drum is used in
regulation of gas. Both the drums are mounted one above the other, on the same
shaft run by the gear train assembly.
Gas Flow Regulator

- Drum
Air Flow regulator -Drum
Figure No.: F 3.6.11

3.6.11.3 Burner Sequence controller: Model Siemens. LFL 1.63…
The Gas burner requires pilot flame to ignite main gas flame, due to safety reasons;
hence, the timing of the firing sequence is different, in this model. More over, UV cell is
used to sense the flame, in place of Photo resister.
This sequence controller controls the operation of the pilot & main gas solenoid valves, in
conjunction with UV cell.
The burner modulation logic is quite similar to that for the oil fired burners, as explained
above (Refer section 3.7.9) .The difference is in the Sequence controller terminal numbers
,in the explanation above.
3.6.11.4 UV cell: Model: QRA 2
As mentioned above, in gas-fired units UV cell is used to sense the flame, as these do not
respond to glowing of refractory in the combustion chamber ,luminance of artificial light,
day light etc, ensuring complete safety to the operators & the equipment.
Figure No F 3.6.13:
3.6.11.5: Oertli Gas Burner Settings:
After setting the gas pressures of the gas train, the burner needs to be set, as per the
following reference setting:
Cone edge
Diffuser plate
Pilot Burner
Main Gas supply

B A
Figure No F 3.6.11.5
Table No T 3.6.11.5: GAS BURNER SETTINGS
SHELLMAX OERTLI Settings /Gaps In MM

MODEL GAS Air Cone Edge to Pilot gas spuds to pilot Electrodes
BURNER Diffuser Plate (A) main gas spuds
MODEL (B)
SMDH 10 to 30 IB- 3 90-95 100-120 6
SMDH 40 & 50 IB- 5 105-115 100-120 6
SMDH 60 & 80 IB- 7 105-115 100-120 6
SMDH 100 & IB- 9 105-115 100-120 6
120
SMDH 140 & IB-13 105-115 100-120 6
160
04 INPUT REQUIREMENTS
The following parameters are to be maintained, for the fuel, Feed water, boiler water, electrical
input for the boiler & its components to perform as desired.
4.1 Fuels:
4.1.1 Liquid fuels:
The standard specifications of the fuel oils to be used are;

Table T-4.1:
Superior High Speed Light diesel Furnace Low Sulphur
Parameter kerosene Oil Diesel: Oil: oil: Heavy Stock:
( SKO) (HSD) (LDO) (FO) (LSHS)
Specific Gravity at
0.82-.83 0.85-0.87 0.89-0.95 0.88-0.98
20 Deg ‘c’ 0.79-0.81
Flash point Deg ‘C’ 32 32 66 66 93
Viscosity at 20 1.4-1.8
2- 4 15-17.5 >200 >550
Deg ‘c’
Sulphur % Up to 0.2 Up to 0.25 Up to1.8 Up to4 0.5
Pour Point : Deg ‘c’ <4 4-5 18 20 72

Pre-heat
temperature at #
# ** 40-45 80
out flow heater :
Deg ‘c’
Pre-heat NA
temperature at
NA NA 115-125 95-100
Oil Pre-heating tank
Deg ‘c’
Required Fuel NA
Viscosity in CST at
NA NA 10-12 10-12
Burner nozzle tip
after preheating
Net calorific value 10500
10200 10150 9650 9750
Kcal/kg
Note:
# Pre-heating of fuel oil is required at sites having ambient temperatures below 5 deg
‘c’
** preheating may be required up to 60 deg ‘c’ max for proper fuel atomization at
burner nozzle if fuel viscosity is high at ambient temperature.
4.1.2 Gas fuels:
The standard specifications of the following gas fuels used are;
Table T-2.1:
Natural Gas Liquefied Petroleum
Parameter
Gas (LPG)
Methane -76%,
Composition: Main Ethane-10% Propane: 10-40%
Constituents Propane- 2% Butane :60-70%
Density,Kg/M3 2.32
0.83
Net Calorific Value 8500
24950
Kcal/Nm3
4.2 Feed Water Quality

The water treatment plant should provide the boiler feed water of the following specifications for
the Fire tube shell type boilers as per the requirements of the 20 Kg/cm2 max working pressure.
Table T-4.2:
Parameter 0-20 kg/cm2 Purpose-To control
pH Value 8.5 –9.5 Corrosion
Dissolved Oxygen, Mg/Lit

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

<5 PPM Scaling
Caco3 max.
Silica as SiO2,Mg/Lit Nil Scaling
Organic Matter Non Detectable Foam

4.3 Boiler Water quality:
Boiler water means the water, which is inside the boiler. The boiler water quality is maintained by
the blow down, as per the norms given in the following table.
Table T-4.3:
Parameter 0- 20 kg/cm2 Purpose: to Control
pH 11-12 Corrosion
Total Hardness Non detectable Scale
Total dissolved solids: TDS 3500 ppm Corrosion
Total Alkalinity (20% of TDS) 700 ppm Foam
Phenolphthalein Alkalinity (10% of TDS) 350 ppm Foam
Silica (40% of Caustic Alkalinity) 140 ppm Scale
Phosphates 20-40 ppm corrosion
Sulphite 30-50 ppm Oxygen
Hydrazine 0.1 ppm Oxygen
4.4 Electrical Input

The electrical input to the electrical control Panel of the boiler should be:
Three Phases, 415 +/- 6% Volts, 50+/- 3% Hz, A.C. Supply with Neutral & Earth connections.
05 COMMISSIONING PROCESS
The boiler user has to comply with all the IBR formalities and the provisional Order for the boiler
firing has to be obtained from the concerned Boiler Inspectorate, before Thermax
engineer/representative’s visit for commissioning.
The user has to send the written communication to Thermax on receipt of the provisional boiler
firing order from the Boiler Inspectorate. On the receipt of this written communication Thermax
engineers/representatives can start the commissioning activities.
5.1 Pre-Commissioning:
The pre-commissioning is the part of the commissioning activity of the boiler, only the firing of the
burner and steam generation is not done.
The firing of the boiler burner system is done only after the completion of the IBR formalities by
the user.
Pre Commissioning is commenced only on completion of all the assembly connections as per
the preceding chapters; P & I diagram, electrical diagram and the assembly work.
During Pre commissioning all the systems i.e. fuel, Feed Water, Drain, Steam Flue gas, electrical
etc are checked/rectified finally and all the possible instruments /parameter settings are done.
All the System are run in manual operation or independently, checked for their smooth and
satisfactory operation.
The persons entrusted with operation, servicing and observation (Boiler attendant for IBR boilers)
must be present during pre-commissioning. It would be better, during commissioning operation;
direct superiors of boiler man should be present.
Thermax representative shall provide the training, guidance & supervision of the critical activities
during Pre-commissioning & commissioning. Thermax representative shall ensure that all the
settings & actions are completed as per the detailed checklists. However, the users /customers
should ensure that the following and all other jobs, as suggested by Thermax representative are
completed before inviting them for commissioning.
CHECKS -
A. GENERAL:
) Ensure that the civil work of the boiler house is complete before taking the boiler for
commissioning
) Check and level all the equipment and tight their foundation bolts.
) Check all the motor windings for damage and moisture with meggar.
) Check and ensure that all the pipelines and ducting are supported properly.
) Check all the strainer and valves for its operation.
) Arrange the fuel as per the input quality requirements.
) Arrange boiler operators and other work force required to operate the boiler.
) Arrange boiling out and feed water treatment chemicals.
) Insulate all the lines and equipment after they have been tested completely.
B. FEED WATER SYSTEM:
) Get the water treatment plant commissioned and ensure the quality of Feed Water is
within the specified acceptable limits, and if needed Water treatment Chemicals are
also added to make it as per the Input requirements (Refer Chapter 2.0 -Input
Requirements)..
) Clean & Flush the feed water storage tank and pipelines thoroughly by manual
scrubbing & draining the water.
) Flush the feed water pump completely before commissioning as this is filled with anti
corrosive compound before dispatch, to prevent rusting in storage. This compound
should be drained and the pump flushed completely.
) Check the operation of softener and dozer and make sure that the operators are well
trained on the softener.
) The water level extra low safety is provided in the tank & is in operation.
) Ensure that the Feed water pump foundation bolts are tightened.
) Ensure that the Feed water pumps rotations are correct.
) The float rod of each of the mobrey level controller is kept tightly secured at the top
position by rubber bands or during transportation .This should be removed & ensure that
the float rod is free to move up & down before filling water in the boiler.
) The two-mobery level controllers are electrically connected to the control panel & air
break switches are secured at position.
) In Mobrey level controllers, set the pump “start” switches at 40% level , approximately,
from the bottom of the level gauge glass tube of the boiler
) In Mobrey level controllers ,set the pump “Stop” switches at 60% level, approximately
from the bottom of the level gauge glass tube of the boiler
) In one of the mobery level controller, set the water level low Safety switch of boiler is to
be set at the level , higher than the top most third flue pass tube i.e. at 20 % level,
approximately from the bottom of the level gauge glass tube of the boiler .
) In the second mobery level controller (Optional), set the water level ‘extra’ low Safety
switch of boiler is to be set at the level, higher than the first mobrey’s extra low level
switch i.e. at 15 % level, approximately from the bottom of the level gauge glass tube of
the boiler.
) Ensure that the feed pump on –off operation is satisfactory & consistently at the desired
levels.
) Check the Mobery; low & extra level safeties, for their satisfactory working, several times
by boiler water draining & also by mobrey controller draining.
) The pressure gauge is fitted between the outlet valve & pump.
) The feed pumps operation should be smooth & without any undue noise & vibration.
) The feed pumps pressures should be steady ,if not steady clean the suction strainers
,remove air from pump, check pump coupling and input voltage
) The strainer at pump suction has the proper size of mesh (refer P & I diagram).
) The strainer at pump suction strainer is cleaned after flushing the lines.
) Ensure that the Valves are operating smoothly.
) Clean Water flow at the feed pump suction is available.
) Air is removed from the feed pump through the air vent plug & the pump is flooded with
water.
) Ensure that the valve at the pump outlet is throttled if there is no pressure in the boiler or
water is to be filled in the boiler in cold or low-pressure (less than 7kg/cm2) condition.
CAUTION
NEVER START THE WATER PUMP WITH DISCHARGE VALVE OPEN. INITIALLY THROTTLE THE
VALVE PARTIALLY.
C. FLUE GAS CIRCUIT :
) Check the chimney and duct connections and make sure that they are airtight.
) Check and provide supports to ducting.
) Check the functioning of various dampers provided in the ducting & mark Open -Close
positions with paint.
) Insulate the part of ducting inside the boiler house.
) Ensure that the flue gas sampling points are provided for the Smoke Index &Co2/O2
measurement
D. F.D. FAN
) Check impeller locking screw and tighten it if found loose.
) Rotate impeller manually to see that it dose not rub and maintains proper cone/wheel
clearances and there is no undue noise form the fans.
) Check coupling for proper alignment.
) Check fan and duct for any loose material inside.
) Ensure that the suction air damper is free to rotate. Lubricate the damper bearing &
linkages.
) The flexible or Canvas duct should be secured with 4 inches gap between the duct & the
burner inlet.
) The flexible 0r canvas duct should be tightened equally from all sides to ensure no air
leakage
) Check lubrication of motor bearings.
) Secure and check safety guards for its position.
WARNING:
NEVER START ANY FAN WITH DISCHARGE FULL OPEN.
E. ELECTRICAL SYSTEM:
) Ensure that all external electrical cable connections to the control panel are as per
the electrical diagram of the boiler.
) Tighten all the terminals in control panel, as they might get loose during transportation.
) Check the functioning of main switch and provide correct fuse.
) Check whether proper earth wires have connected all the motors and panels.
) Check if all the settings of overload relays of motors, pressure switch (as), etc. are all
correct.
) Check for the earthing connection to elect panel, to all motors & instruments.
) Check for the correct electrical supply.
) Ensure that the Mobrey float cover is removed before filling water in the boiler.
) Check for the Trouble free operation of Mobrey level controllers.
) Mobrey water level controllers are set for feed pump on-off operation to maintain
proper water level.
) Ensure electrical interlocks of the FD fan motor & burner is operating.
) Check the functioning of all safeties & controls by manual simulation.
F. FUEL SYSTEMS:
i) Liquid fuels:
) Ensure that the Fuel system is complete in all respect as per the guidelines given in the
earlier chapter: 1.6 - Assembly Guide Lines & Accessories – Fuel System.
) Line sizes are correct & are supported & clamped properly.
) No Objection Certificate is obtained from the explosives dept. or the concerned
government agency for the storage of the fuel & that the fuel storage formalities are
completed before filling the fuel oil in the tanks
) Fuel storage tank & day tank are tested leakages & all leakages are rectified
) Manhole ,Vents, drains ,fuel level indicating arrangement, over flow ,out flow heater
arrangement, is properly made as per the instructions in the Assembly guidelines
) Ensure Use of oil quality gaskets in the fuel lines and at the tanks
) Fuel storage tank & day tank are cleaned dry & then flushed thoroughly before filling
the fuel oil.
) Ensure that Ring main system is constructed as per the P & I diagram.
) The pipelines are flushed thoroughly by air & fuel oil before connecting them to the
basket filter of Ring main system & of OPH station.
) Start the outflow heater, after ensuring the proper electrical connections to the TIC &
to the heater.
) Check that the Outflow heater is cutting off the electrical supply at the temperature
set point of the TIC.
) If TIC is having two set points set both at 5deg ‘c’ differential to ensure hat if one fails
other set cuts off the heater.
) Ensure that dial type temperature indicator is also fitted very close to the out flow
heater.
) Set the outflow heater at 40 deg ‘c’ maximum for FO & 70 deg ‘c’ for LSHS.
) For LDO the Out flow heater can be set at 50-55 deg ‘c’ if so needed.
) Electrical tracing is a must for the FO & LSHS pipelines from Main Storage tank to day
tank & from day tank (after outflow heater) and if the ambient temperatures are
below the pour points of the fuels (Refer Chapter 2.0 -Input Requirements).
) The air is removed from the basket filter, through air vent plug.
) Check the direction of rotation of fuel pumps by Kick Start only. Do not run the fuel
pumps for more than 3-4 seconds to check the direction of rotation.
) Correct the direction of rotation if found incorrect by changing the phase.
) Remove the air from the air plug of the fuel pump to ensure that the air is removed
completely. Ensure that the plug is re-fixed tightly.
) Ensure that only soft water/DM is filled in the OPH tank.
) TIC of OPH tanks is set at the required proper preheat temperature, as per fuel oil the
suppliers specifications.
) Ensure that the pressure gauges are fitted at the ring main system ,Burner fuel
pump(OPH) out let ,burner inlet & By pass lines (Ref. Fuel pipe line Diagrams-Figure No
2.9.5.1,2 & 3)
) Circulate the Fuel oil in the system by staring the Ring main & Main Fuel pumps, after
starting the heaters (Service /day tank out flow heater, heat tracing & OPH tank).
) Set the fuel pump pressures ( Ring main & main Fuel Pump)
) Clean the fuel strainers in line, as & when the fluctuations in the fuel pressures are
observed.
) The circulation should continue until the fuel pre-heat temperature is achieved & the
fuel system is clean from dirt or burrs.
) Maintain the ring main pressure up to 3-4 kg/cm2 & the main fuel pump pressures near
to 25 kg/cm2 (or as per the requirement to achieve the rated fuel consumption).
ii) Gas fuels:
) No Objection Certificate is obtained from the explosives dept. or the concerned

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

5.3.2 Chemical boiling out
5.4.3 Steam generation & final settings
5.5.4 Safety valve setting
5.6.5 Efficiency /output trials & handing over
Warning:
x The commissioning of the boiler is to be done under the guidance & supervision of
Thermax Engineer / authorized representatives only to avail Thermax warrantee
benefits.
x If steam utilities are not ready, the steam will be vented out for the commissioning &
output efficiency trials.
x The Owner /User of the boiler must ensure that the Provisional order for firing the
boiler( In India) is obtained from the Inspectorate of boilers before informing
Thermax for commissioning
5.2.1 Burner System Commissioning & Burner firing:
The burner setting is required to be done, before attempting to the firing of the burner.
The burner setting for oil & gas burners is given in the chapter 3.0 section 3.7.11 & 3.7.12
A. Burner Start Operation: Liquid fuels
The pre commissioning activities must ensure the satisfactory working of all the control & safeties
of the boiler, and then the burner can be started in the following sequence:
1. Fill up soft/DM water in the water service tank & open the valves in the water line.
2. Fill up fuel in the fuel service tank & open the valves in the fuel line. The boiler starting
can be done only on LDO/FO (For Oil fired Units).
For gas fired units –Open the valves in the gas lines
3. Put ON main switch & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
4. Select & put ON one of the fuel pump & fill up fuel lines by circulating fuel (For Oil Fired
Units)
5. Keep the boiler vent valve open & main steam valve closed.
6. Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
7. Put ON the Oil pre-heating tank electrical heater (for Oil Fired Units).
8. Put ON the blower motor, with air suction damper slightly open.
9. Before starting the burner ensure that modulation switch is in OFF position.
10. After ensuring optimum water level in boiler & optimum fuel temperature, the burner can
be started.
11. Put ON the burner selector switch.
12. The burner programmer cycle starts (with Siemens sequence controller model- LAL-2.25)
,Which consist of the following cycle of operation,
i) Pre-purging cycle: for 22.5 second’s time, then supply is fed to ignition transformer,
ii) Electrical sparking at ignition electrodes: for 6 Seconds
iii) Burner solenoid valve is energised, commencing fuel spray inside the combustion
Chamber & flame is established.
iv) Flame is detected by flame sensor. Thus, boiler starts in low flame. The low flame
Firing is to be continued so that heating is gradual.
13. If the firing is smooth then the flame & smoke colour are checked. The flame has to be
set bright for oil & Bluish for gas units & the smoke should not be visible, by setting the air
damper of the FD fan.
14. If the flame is smoky / flickering/does not get establish/creates vibrations/backfiring ,then
the air damper needs to be adjusted for getting smooth start of flame.
15. Even after setting the burner the flame start up is not smooth, then the burner diffuser
plate is to be adjusted along with air damper. Proper air fuel ratio is to be set at low
flame operation.
16. This procedure is repeated several times until a smooth flame start up is achieved with
colourless smoke.
17. The modulation switch is now put ON. The burner modulation would depend on steam
pressure, which is cold start will be zero.
18. The rotation of the servomotor moves the gear train, which is fitted at the FD fan suction
& increases the air supply .At the same time the fuel metering valve closes the fuel by
pass line of the burner gun, thus increases the fuel quantity also ( for Oil fired units ) .
19. for gas fired units The servomotor opens the air damper as well as gradually increases the
Gas supply
20. The burner thus moves to high flame fame & stops at the highest firing stage.
21. If the flame is improper as mentioned above the sequence of air fuel ratio setting is
repeated with resetting diffuser plate, air damper positions at various stages of transition
to high flame.
22. the transition from low to high flame has to be smooth ,with bright flame & almost
invisible smoke colour
23. To ensure complete combustion of fuel, checking of Smoke Index Number & Oxygen
percentage Or Co2 percentage is done with the combustion test kit.
24. For Oil fired units, the smoke index number should be set up to one for light fuels & up to
three for heavy fuels, with O2 percentage as 3-4 or CO2 percentage at 12-13, with low as
well as high flame conditions.
25. For Gas fired units the Ideal smoke Index should be zero & maximum Co2 % should be up
to 12 %.
26. Follow the chemical boiling out procedure as given below to clean the boiler surfaces
internally and raise the pressure for the boiling out.
B. Chemical Boil out Process:

Boiler chemical boiling out procedure can be done simultaneously with the burner system
commissioning
The primary objective of the boiling out procedure is to ensure removal of the more common
initial oil and grease and the other foreign matter.
The tube or plate manufacturers apply the coat of oil of readily soluble, non-hardening oil to
prevent from corrosion, which is to be removed by chemical boiling out.
Other than the metal failure, the oil also causes Priming & foaming inside the boiler, which is the
main reason of the Wet steam or water carryover. This may result into process problems.
Before chemical boil out, the following is required to be done.
a. Fill boiler up to 100 mm below normal water level.
b. Ensure all bottom header drains are fully closed.
c. Excepting direct level gauge, isolate all other instruments during boil out operation. This is
very important.
d. All drains & air vent are to be kept open initially.
e. Quantity of 100 KGs. Of Thermax MAXCLEAN - 07 chemical is required, for every 1000
KGs. of Water. Requirement will be proportional to the water holding capacity of the
boiler.
f. This Solutions (with water) should be poured through manhole of Boiler. Close the
manhole after charging chemicals.
g. Fire the boiler and keep it at low flame. This will help to raise the pressure slowly. Keep the
air vent valve of the boiler open.
h. When the drum pressure reaches about 2-kg/cm² close the drum vents. Continue to raise
the pressure at slow rate. This will avoid thermal stresses.
i. Fuel firing rate should be so regulated that approx. 50% of design pressure (max. working
pressure) is reached in about 4-6 hours. In no case should the pressure be increased
more than this for the boiling-out operation. Maintain this pressure for next 6-8 hours.
j. Now stop the fuel firing & boiler auxiliaries in proper sequence. Allow the steam pressure
to fall gradually. Maintain water level in the drum, such that it is visible in gauge glass.
k. When the steam pressure is approximately 5 kg/cm²g, give quick and short blow down.
This will greatly assist removal of sludge/sediment accumulated.
l. At hourly intervals, operate main blow down and drain valves on water level indicators
and water level controller in sequence. Make the first blow down of each series through
the surface blow down connection (if provided) in order to clear any scum or sludge on
the water surface.
m. Open the drum vents when steam pressure is approx 2 kg/cm². Take Soft/DM water in
boiler up to full gauge glass and drain it through different bottom header drains. This
procedure should be repeated 3-4 times for proper rinsing of internal surface of pressure
part.
n. The boiling out procedure will complete, when testing of boiler water, indicate same
amount of oil in consecutive samples tested.
p. Open the drum manhole, inspection ports (where available) of bottom headers for
inspection of the surfaces.
NOTE
It is important that all the precautions governing safe operation of boiler be duly observed
during the boiling-out period.
CAUTION
If considerable oil or oil sludge is found to be still adhering to the tubes, the entire process
should be repeated, until the pressure parts are free from all impurities.
C. Steam Generation:
After completion of chemical boiling out, and the complete flushing operation, the boiler is filled
in with the treat water and boiler.
The IBR licensed operator fires the boiler and steam pressure is raised up to the maximum
working pressure of the boiler.
This first operation of the boiler & steam generation is done in presence and under the guidance
of Thermax Engineer /authorized representative of the Thermax. The fine setting of FD fan
damper is to be set for the optimum combustion parameters of smoke Index & O2/Co2
percentage.
The Mobrey water level controller needs to be checked for its normal functioning and the
operation of the low level & extra low level safety.
D. Safety Valve setting:

The two safety valves are set at the maximum working pressure of the boiler, while the boiler is
generating steam to its full capacity. The exact lift pressures of the Safety valves, the pressure
build up in the boiler and the safety valve sit backpressure are observed and set. This is one of
the major and critical settings to be done on the boiler.
In India, the Indian Boiler regulations are followed for the over pressure & sit back pressure values
of the safety valves.
E. Pressure Switch Setting (High Pressure cut off):

After the settings of the safety valves, steam pressure high cut of pressure switch is set. This
pressure switch has to be set as per the maximum steam pressure requirement in the plant.
The setting has to be below the lift pressures of the safety valves, but in no case, it should not be
lass than 7kg/cm2.
The pressure switch controls the steam pressure of the boiler by cutting off or cutting in the
burner & FD fan. This stops the firing of the burner & reduces the steam generation. Hence this is
the device, which controls the steam pressure in the boiler.
During this commissioning process all the safeties & controls of the boilers are checked
thoroughly by operating the boiler at its full capacity and venting out the steam through Vent
valves or by passing the steam through the Steam lines for Flushing.
F. Flushing: Steam Lines

If the steam lines are newly fabricated these need flushing by passing the steam for min 4 hrs, to
ensure internally clean surfaces of the pipelines.
The steam Traps and strainers fitted should be removed from the lines during the flushing
operation. All air vents are opened and steam is flushed out for these valves. Only after the lines
are flushed the steam should be opened to the plant utilities.
G. Important Readings/Settings for Commissioning:
SR. ACTIVITY DESIGN DATA/ ACTUAL

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

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

Boiler burner (High flame consumption /
In low flame turndown)
(LIQUID FUELS)
3. Fuel pump pressure 25 kg/cm2 (g) (Approx.)
4. Burner fuel by pass 12-15 kg/cm2g (at 100%)

Pressure 4 - 7 kg/cm2g (at 25%) (Approximately)
5. Fuel oil Pre-heat (heavy Fuels) 120°C
Temperature high control OPH
6. Fuel oil Pre-heat (heavy Fuels) 110°C

Temperature low Alarm OPH
7. Fuel oil service tank 45°C

Temperature (Client scope)
(Gas Fuels)
8. Gas pressures -gas train inlet 1-2 Bar Or 500 mbar (as Applicable)
b. AIR / FLUE GAS CIRCUIT
1. Boiler outlet Flue gas 260ºC

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

Valve setting
3. Modulation: steam Pressure PCM Pressure band 1.5 kg/cm²}
Controller setting PT, PIC Pressure band 0.5 kg/cm²}
PIC Pressure band to start SSV pr
Minus 0.5 kg/cm² downwards
d. WATER CIRCUIT
1. High water level LSH 60% in

(Water Pump Off) gauge glass
2. Low water level LAL 40% in

(Water pump ON) Gauge Glass
3. Water level low alarm LAL 20% in

Gauge Glass
4. Water Level Extra LALL 15% in

Low Alarm (Optional) Gauge Glass
e. BURNER SETTINGS: (This will depend on Burner system used-Oertli /Oilon and the fuel used
Oil/gas)
1. Distance between diffuser A

Plate to cone edge
2. Distance between Nozzle B

To diffuser plate
3. Gap between Nozzle to C

Electrodes
4. Gap between electrodes D
NOTE: All the above settings are only for reference; however, the actual settings may vary from
site to site and are to be recorded in the commissioning report.
H. Efficiency & out Put Trials:

After the above procedures the boiler will be ready for the Output & efficiency trials.
It is mandatory for the customer to conduct the efficiency & out put trials, within a week’s time
of commissioning of the boiler, as per the guidance of Thermax Engineers/Authorized
representatives.
The efficiency trials are conducted as per BS 845 and in accordance of the Thermax standard
practices.
The observations of the trials are noted down and are signed by the Owner/user’s responsible
person and also by Thermax engineer/authorized representative.
Based on the Trial observations and the Out put & efficiency are calculated and informed to the
customer/user by Thermax.
These efficiency & output trials are conducted to ensure that the boiler is performing as per the
committed contractual norms of efficiency and steam output.
I. Training:
During the boiler Installation, pre-commissioning, commissioning and efficiency & output Trials,
Thermax engineers /authorized representatives ensure that the Boiler operators and other
technical personnel responsible for the operation and maintenance are trained to operate &
maintain the boiler as per the norms laid down by Thermax Ltd.
These norms and the good operation & maintenance practices of boiler are also explained in
the next Chapter of operation & maintenance. These should be read & practices for the trouble
free operation and long life of the boiler & its accessories.
J. Boiler handing over for commercial Use:

After the successful commissioning and efficiency /out put trials, the Boiler will be handed over
to the user/owner for the commercial use.
The boiler handing over procedure includes the signing and stamping of the Erection &
commissioning checklists and certificates of Thermax Ltd by the owner/user’s responsible person
and the commissioning engineer of Thermax / authorized Dealer.
These signed/stamped commissioning and handing over reports/certificates are forwarded to

the Customer Care /technical service department of Thermax ltd, for the scrutiny of the site
reports. If any discrepancies are observed in Installation, performance or settings, Thermax ltd
takes immediate corrective action by informing the concerned Thermax engineer/authorized
representative/dealer and also to the owner/user of the boiler.
Warning:
In no case, the owner /user should use the boiler for the commercial use /production,
without completing the Handing over formality from Thermax, to avail the committed
warrantees of the Boiler & its supplied parts/equipment.
In case of failure on the part of the owner/user to comply with the above handing over
procedure, all the warrantees of Thermax Ltd, as per the order terms, will cease to exist
and in such case Thermax shall not be responsible for any failure of the supplied
equipment or components.
06 OPERATING INSTRUCTIONS
Operation of the boiler needs to be properly under stood by the operational staff /operators.
The training has been imparted by Thermax /dealers during commissioning of the boiler.
Hence, the operation & maintenance of the boiler has to be as per the guidelines given in the
following chapters for the Starting, running & maintenance of the boiler.
6.1 Boiler Start up Process: Oil fired units

START
Fill up water in the water service tank & open the valves in the water line.
Fill up fuel in the fuel service tank & open the valves in the fuel line. The boiler starting
can be done only on LDO/FO.
For gas fired units: Ensure that gas filters are clean.
For GAS fired Units; Check the main and pilot gas pressure and set it if required.
Put ON main switch & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
Select & put ON one of the fuel pump & fill up fuel lines by circulating fuel.
Not applicable -For GAS fired Units
Keep the boiler vent valve open & main steam valve closed.
Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
A
A
For Oil fired Units: Put ON the Oil pre-heating tank electrical heater. For gas fired units: Check the
inlet gas pressure to gas train. If it is within acceptable limit, open the inlet valve of gas train.
For Gas fired units: Check the main and pilot gas pressure and set it if required.
Put ON the FD Fan
Before starting the burner ensure that modulation switch is in OFF position.
After ensuring optimum water level in boiler & optimum fuel temperature, the burner can be
started.
Put ON the burner selector switch in auto position.
The burner programmer cycle starts. After pre-purging time, supply is fed to ignition transformer,
commencing electrical sparking in the burner. At the same time burner/Gas solenoid
valve is energised, commencing fuel spray or gas supply inside the combustion chamber
& flame is established. Flame is detected by flame sensor. Thus boiler starts in low flame.
The low flame firing is to be continued so that heating is gradual.
When steam starts coming out through the air vent valve close the air vent.
When the steam pressure is about 4 kg/cm2g the fuel-heating mode can be changed over to
steam heating.
When steam pressure builds up to the desire operating pressure, the main steam outlet can be
opened to the process.
Put ON the modulation switch, the burner would go in high flame position. The burner
modulation would depend on steam pressure, which in turn will vary depending on the load.
End
6.2 Boiler Stopping Procedure: For Oil & gas fired units
START
Change the fuel from LSHS/FO to LDO and run the boiler for some time.
Put OFF the burner modulation switch.
Put OFF the burner switch.
Close the boiler steam stop valve. Keep the air vent valve slightly open.
Put OFF the FD Fan switch.
Put OFF switches for all other equipments & close all relevant valves. .For gas fired unit ensure
that all gas isolating valves are closed.
Ensure that water & fuel service tank are full for subsequent operation. For gas fired units, check
gas availability for subsequent operation.
Isolate boiler control panel by putting OFF all electrical supply.
Clean the boiler & its surroundings off the dripped oil, water etc.
Blow down the boiler until water level drops by 1" (25 mm) or to the extent required depending
upon the quality of feed water. The boiler blow down should be such as to maintain a
TDS in the boiler to less than 3500 ppm. Close the blow down valve.
END
CAUTION
a) If the Boiler is being operated on LSHS. Make sure that at least one hour before
Stopping the Boiler, the fuel firing is changed-over from LSHS to LDO/FO. This is for avoiding
the choking of Fuel oil pipe line due to LSHS solidification, at room temperature.
ii) When boiler is shut off for a short period, keep the vent valve slightly opened.
WARNING
x NEVER OPERATE THE BOILER WITH HARD WATER.
x NEVER PERMIT THE WATER TO DISAPPEAR FROM THE GAUGE GLASS WHEN ROUTINE BLOW
DOWN IS DONE.
6.3 Boiler Running Attention
It is advisable on part of the operator and the other operational staffs, to make it a practice
check the following points periodically during the running of the boiler.
Check that...
x The feed water softness is checked at the water treatment plant, after every one hour of
water treatment plant operation or more frequently. If feed water is found hard,
regenerate the water softener immediately.
x Maintain the desired boiler water quality, in the boiler. Add chemicals & give optimum
Blow down periodically. (Refer chapter Input requirement of feed water and boiler Water
x Maintain the soft/DM water level in the feed water tank up to its maximum capacity.
x If water treatment chemicals are being used ensure that the chemicals are added in
regular intervals, in the chemical tank.
x The flame is steady, bright & smoke is colorless.
x No backfiring or vibrations are observed from the burner.
x For oil fired units, the Fuel pre-heat temperatures & the fuel pressures are maintained as
per commissioning report.
x No excessive sound is heard from the motors pumps and Fans.
x All valves and joints are leak proof.
x Water pump is working ON OFF to ensure the functioning of Mobrey level control
switches.
x No sparking or loose contact is there in the electric circuit of the control panel of the
boiler.
x That a steady steam pressure is maintained.
x Always operate the boiler at or near to its working pressure. If steam pressure requirement
in the plant is low, then reduce the pressure to the desired in the plant By Pressure
reducing Station (PRS).
x No over firing of fuel is being done and correct fuel consumption is maintained.
x Combustion efficiency of the burner is to be regularly checked with the help of

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

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

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

the heat to the water, hence overheating may take
place, resulting in to metal failure or bursting.
5. Oxygen present in the water attacks the metal surface of
the boiler shell, which results into pitting.
The Low pH of water results into corrosion of the metal

surface.
Hence regular use of water treatment chemicals is

recommended.
Use water treatment chemicals for the treatment of

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

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

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

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

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

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

IT IS TO BE NOTED THAT IT IS TOTALLY UNSAFE TO SHORT CIRCUIT SAFETIES AND
OPERATE THE BOILER.
x BURNER SETTINGS ARE VERY CRITICAL AND ANY TEMPERING WITHOUT KNLOLEDGE
MAY LEAD TO DISTURBED FIRING CONDITIONS & CAN LEAD TO SEVER BACK FIRE
/ACCIDENTS.
7.1 Maintenance Schedule
Table T 7.1
Half
Maintenance Activity Daily Weekly Monthly Quarterly Yearly
yearly
Water treatment plant check &
*
regenerate if required
Check water treatment
*
chemical stock
Check feed water quality for
*
hardness, pH & Oxygen
Check feed water quality for TDS *
Check Steam pressure Switch
*
operation
Clean Fuel filters & basket filters *

Check Mobrey level controls’
*
For normal pump on –off
operation
Mobrey low & extra level low
*
safety check
Boiler water quality check *

Clean front & rear viewing
*
glasses
Clean Burner Nozzle *

Calibrate all pressure gauges *
Calibrate fuel temperature
*
indicator & controllers.
Calibrate the flue gas
*
temperature indicator
Check the out flow heater
*
operation & its Temperature
indicator cum controller-cut –off
Check the working of heat
*
tracing lines
Check the Explosion door for its
*
working
Check Hooter operation *

Clean Strainers –feed pump
*
suction
Half
yearly
Feed line NRVs check *
Check motor interlocks *
Check the stock of essential
*
spares
Safety Valves operation * *
Motor Current check
F.D. fan , Feed pumps, Fuel *
Pumps & Ring-main pumps
Cleaning the smoke tubes &
*
smoke boxes
Cleaning of furnace *
Cleaning of boiler smoke tubes *
Dust removal from Elect control
panel *
Clean electrical contactor

contacts *
Check the connections of
Mobrey level controller *
Cleaning Gauge Glass protector
& glasses *
Replacement of gauge glass
rubber cones & sleeves *
Check front reversal chamber
refractory and repair if required *
Grease all motors’ Bearings *

Clean the burner gas spuds.
For gas fired units *
Check resin quantities in the
water treatment plant *
De-scaling & internal cleaning

of boiler pressure part *
Half
yearly
Dismantling, Cleaning & lapping
of all the Valves, NRVs, Safety *
valves, blow-down valve.
Smoke box Sealing rope

replacement *
Check resin quantities in the
water treatment plant *
De-scaling & internal cleaning
of boiler pressure part *
Removal & replacement of
Removal & replacement of all
Gaskets of valves, mountings & *
fittings, Manholes, hand-holes,
inspection doors.
Offer for the open inspection of
the boiler to the IBR authority *
Re-fixing of all Mountings &
fittings on the boiler *
Box up all the manholes / hand-
holes *
Hydraulic test, up to 1.5 times
the max. working pressure for 15 *
minutes (max)
In case of leakages, Stop all

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

7.2 Log Book
Record of daily checks and servicing operation as well as other checks and servicing operation
must be kept in an operating log book and signed daily by the responsible operating personal.
It is suggested that these Logbooks are maintained by the users. An hourly record of the
observations of the operational parameters and maintenance instructions are filled in without
fail by the operating personnel of the boiler.
This is to ensure that the deviations, if any, from standard/normal readings, may be noted and
attended to immediately; this can avoid major breakdowns and unwanted stoppage of the
plant.
Table no T 7.2.1 LOG BOOK - FOR OIL FIRED UNITS: (Shift Basis)
Fuel pressure
kg/cm2 Feed Water Pump
Boiler water Boiler Extra & Safeties & Consumption
Steam Stack HSD/LDO/FO/LSHS Softener / DM On-Off
Blow low level controls
Time Pressure temp. Regeneration (Mobrey)
Burner Burner down at safety Working
Kg/Cm2 Deg.C. Done At working Water Fuel
Inlet bypass Hardness time check Ok/not ok
pH TDS PH check
PPM
liters Kg.
Remark _________________________________________________________________________________________________
_________________________________________________________________________________________________
Signature of the Boiler operator Date Signature of the Engineer/Shift in charge

Table no T 7.2.2 LOG BOOK - FOR GAS FIRED UNITS: (Shift Basis)
GAS pressure Feed Water Pump Consumption

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

7.3 Spare Parts
It is suggested that certain essential spares may be kept in stock to avoid idle time due to
unpredictable breakdowns and non-availability of parts with you or with our
dealer/office. It may take some time for us to arrange for the part /component at site.
If there is any breakdown due to component failure, it is better to replace the defective
component and if possible repair the defective component if repairable, at leisure, as
replacement is faster and easier.
The list of essential parts for SHELLMAX Boilers is given below and can be used for
guidance.
Part List, specific to the Model & serial no with part no of each component can be taken
up from nearest office. For the amount of the water conditioning and fuel additive
chemicals to be stored, approach our nearest Dealer /office.
Table no T 7.3.1 SAPRES PART LIST: SHELLMAX BOILER WITHOUT BURNER PARTS
Sr. Component Description Quantity to be stocked
No at by user
a. Air break switches for Mobrey 2

b. Float rod assembly for Mobrey 1
Hooter –control panel 1
Indicating lamp holder 2
Indicating lamps 12
Feed water pump 1
IBR Pressure gauge 10” Dial –for boiler 1
Fusible plug 2
Blow Down valve-IBR 1
Non return valves-feed line-IBR 1
Gauge Glass assembly-IBR 1
Gauge Glass 2
Quick shut off valve size 1
Table no T 7.3.2 SAPRES PART LIST: SHELLMAX BOILER - OERTLI BURNER PARTS
Burner Spares : OERTLI BURNER:OIL FIRED Qty
Fuel Pressure gauge- 65mm Dial 2
Burner nozzle -as per fuel consumption in Kg/hr 1
Sequence controller – Siemens 1
Photo resister 1
Sight glass- burner 2
View glass –rear 2
Ignition transformer 1
Burner gun 1
Pressure switch-High pressure cut off 1
Proportional Pressure controller 1
Rectifier 1
Burner diffuser plate 1
Burner solenoid valve 1
Fuel pump 1
Fuel metering /regulating valve –heavy oil 1
Fuel metering /regulating valve -Light fuel 1
Gear Train Assembly –AR 63 1
Feedback potentiometer 1
Servomotor 1
Electrode assembly 2
Burner Spares : OERTLI BURNER: GAS FIRED
Gas pressure gauge: Range 0-10 Bar 1
Gas pressure gauge: range 0-100MBar 1
Main Gas pressure regulator range 1-4 bar 1
Main Gas Burner Solenoid valves 2
Gear Train assembly for GAS Regulation 1
Pilot burner solenoid Valve 1
Pressure switch 1
Diffuser Plate 1
Sequence controller 1
U V cell 1
Note: FOR OILON BURNERS, REFER SPARE PART LIST GIVEN IN THE OIL ON BURNER
MANAGEMENTSYSTEM CHAPTER 3.7.11 & 3.7.12
08
8.0 Trouble Shooting
TROUBLESHOOTING
Some of the common problems & remedial action is as given below :
1. The feed water pump motor does not start in Fill position of the Rotary switch.
In table below some of problems & their possible causes are given. This will be helpful in
troubleshooting, Shellmax boilers & its components.
Problem Possible cause

Temperature controller not working x Wrong connection
x Earthing Improper
x Ambient temperature more than specified
x Supply voltage fluctuation
x Wire cut in between
x Moisture ingress
Sequence controller Not working x No power supply to controller terminal

x Synchronous motor faulty
x Fuse blown
x Safety circuit open
x Not getting required feedbacks
x Ambient temperature more than specified
Centrifugal fan motor failure x Motor overloaded
x Single phasing
x Starting method incorrect
x Overload relay bypassed
x Voltage & frequency variation more
x Fan impeller jammed / rubbing
RTD not working x Operating under high media temperature

x Soot deposition on sensor
x Continuos vibrations of sensor
x RTD sensor screw getting loose
x Shielded cable not used
x Sensor cable loose / open
Modulation (AR-63) not working x Positioner relay not working
x Servomotor shaft jammed
x Motor clutch assembly problem
x Supply not available at motor terminal
x Wires broken / open
x Loose connection
x Modulation motor coil burnt
Problem Possible cause
Solenoid coil of burner not getting x Low voltage available at rectifier output
energized x Loose / open terminal at burner
x Electrical cable open
x Rectifier open / Defective
Flame sensor not working x Electrical connection mismatch

x Supply at sequence controller terminal not
available
x Sensor mounting not in visible range
x Flame intensity weak
x Shielded cable not used for sensor connection
x Noise pickup due to parallel laying of sensor cable
with power cable
Ignition spark not taking place x Transformer winding open / short

x Supply at sequence controller output terminal not
available
x Output connection loose in transformer
x Higher amount of primary air
x Electrode gap more than specified
x Accumulation of oil / carbon deposit on electrode
Mobrey air switch not working x Electrical switch not as per connection
x Cable damaged
x Soldering damaged
x SS Float punctured / stuck due to bad water quality
x Float wrapping paper not removed during
commissioning
x Magnet stuck
OPH electrical heater not working x Electrical supply not available

x Heater element burnt due to low water level
x Cable damaged or touching to body
x Wrong wiring
Steam pressure switch not working x Frequent pressure fluctuation

x Diaphragm damaged
x Dirt accumulation in pressure switch
x Switch stuck-up
Problem Possible causes
Blowdown valve Stuck or Leaking x Welding bur or foreign material stuck-up
x Valve spindle not rotating
x Oversized gland packing used
x Very high scale in water
Steam safety valve leaking x Deposition on nozzle & disc due to bad water
quality
x Corrosion of nozzle & disc due to bad water quality
x Foreign particles damaged valve seat
x Water getting accumulated in safety valve bonnet
& discharge
x Blowdown ring setting improper
x High water content in steam
Water level fluctuation x Condensate contaminated

x Feed water pH high
x High total alkalinity / TDS
x Sudden fluctuation in load / Firing
Fuel oil pump pressure fluctuations x Cavitation of pump due to one of the following
reasons ( Filter chocking , water present in fuel ,
Ring main pressure less , Air lock in pump suction )
x Pump coupling loose / worn out
x Excessive sludge / impurity in fuel oil
x Viscosity range beyond specification
09 CARE OF IDLE BOILERS
Boilers used seasonally and idle for long period should be laid up "Dry" or "Wet" during the period
of idling.
9.1 Wet Preservation

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

Up to 1 week 20 to 30
Up to 1 month 50 to 100
Longer 100 to 300
For better mixing, the boiler should be heated briefly after admixing hydrazine, up to
about 85 °C, to drive out the oxygen in it. Take care that no pressure builds up in the
process.
Before renewed commissioning of boiler, the boiler water must be drained off until the
operational water level has been reached, provided the steam is allowed to contain
hydrazine (the steam must not contain hydrazine if it comes into contact, for instance,
with foodstuffs, clothing or dressings). Otherwise, the boiler must be drained and refilled.
Close all valves. In all cases the exhaust gas flaps or gate valves must be kept closed.
ii. Check for any leakage and take samples of water at regular intervals to ensure alkalinity
and Sulphite are maintained.
9.2 Dry Preservation
If the boiler is to be kept idle for long period it should be laid up "Dry" as follows: -
i. Drain the boiler thoroughly, clean it internally and externally both fire and water side and
dry it out.
ii. Place trays of lime inside the boiler shell to absorb any moisture. Then close the door,
manholes, dampers, etc., properly so that no ingress of moisture or air can take place.
iii. Water service tank, pumps, and all piping should also be dried out.
It is essential that the boiler is thoroughly clean while using the wet or dry laying up method. To
prevent corrosion on the gas side of the heating surface, it is recommended that all heating
surfaces are dusted with hydrated magnesia to neutralize any acid remaining on the boiler
heating surfaces.
NOTE :
When working with caustic liquids or chemicals, it is imperative that the relevant accident
prevention regulations are observed and made accessible to the persons carrying out the work.
9.3 Chemical Boiling out

If any oil or grease gets into the boiler inadvertently, it will appear in the form of scum in the
gauge glass. This can be very harmful to the boiler and it should be cleaned as soon as it is
detected. Use of Thermax MAXCLEAN range of chemicals for boiling out should be done strictly
as per the instructions given in Boiling out procedure in this manual under Chapter 3.1
Commissioning.
Procedure for De-scaling

If the boiler water quality is not maintained as per the specifications the de-scaling of the boiler
may be required, to remove the water side deposits. The de-scaling is done by using chemicals.
Thermax chemicals are available to in the name of MAXTREAT CHEMICALS, which are
manufactured specially for the use in boilers without harming the metallic parts of the boiler. The
other commercial chemicals available in the market may cause harmful effect on the boiler
parts & may result into reduced life of the boiler components & pressure parts.
De-scaling is a very critical process & should be carried out by qualified personnel only and
following method to be adopted very carefully.
The procedure given below is for the MAX TREAT DESCALING CHEMICALS; the details of these
chemicals are given in the Section 3 of this manual.
PROCEDURE: FOR CLEANING WATER SIDE DEPOSITS FROM BOILERS USING MAXCLEAN-04, 05 & 06.
The de-scaling method for any boiler depends much upon boiler design and nature of scales.
The general procedure to be followed while de-scaling with maxclean-05 and 06 is given below
for scales having following typical analysis
Silica - 42%
Calcium Oxide - 36%
Magnesium - 13%
Iron & Aluminium - 10%
STEP – 1 : FLUSHING
Allow boiler to cool. Open manholes and flush with plain water to remove loose
sludge/deposits. For complete removal of loose sludge use pressure jets or any similar
mechanical arrangement. At the end flushing loose scales, mud is removed facilitating easy de-
scaling with chemicals. Inspect tubes for complete blocking and try to clean them mechanically
to make passage for circulating de-scaling chemicals.
STEP – 2 : MAXCLEAN-06 TREATMENT
Fill boiler up to normal water level with 5% solution of Maxclean-06. Keep steam valve or safety
valve. Open and heat slowly till boiling. Boiling of water will ensure good circulation of
De-scaling solution, within the boiler. Continue slow boiling for 8 - 12 hours. Make-up with fresh
solution to maintain water loosened sludge accumulated in mud drum. Check concentration of
residual de-scaling using test kit.
Drain the Maxclean-06 solution in separate holding tank for reuse. Flush boiler with plain water
as given in Step-1. Cleaning with pressure jets with remove loosed scales.
STEP – 4 : MAXCLEAN-05 TREATMENT 1
Fill boiler with 5% solution of Maxclean-05. Keep steam valve/safety valve open to vent off
produced gases. Fire the boiler to raise temperature of solution to 60-80oC. Heating in boiler will
ensure circulation of Maxclean-05 solution within boiler. Continue slow heating for 8 hours. Give
blow-down periodically to remove accumulated mud. Make it up with fresh solution to maintain
level in boiler. Check concentration of residual Maxclean-05 every hour using test kit.
Drain Maxclean-05 solution in separate tank for further use RINSE BOILER with fresh water till pH of
rinse water is above 5.0. Use pressure jets, if necessary to remove loose scales.
STEP – 6 : INSPECTION
After thorough flushing as in step-5, inspect boiler tubes and internals. If scales are still found,
repeat Step-2 to Step-6. If boiler is free of scales flush boiler with fresh make up water or
condensate.
STEP – 7 : PASSIVATION
After thorough flushing of boiler with condensate or fresh make-up, fill boiler with make up water.
While filling, add 100 ppm of MAXTREAT-3011 and 100 ppm of MAXTREAT-3100 and caustic to
boost pH of boiler water to 10.5 to 11.5. Boiler may be kept filled up with above solution till it is
commissioned.
STEP-8 : COMMISSIONING
After passivation as given above for 8 hours, fire boiler slowly. Use normal make-up water and
internal treatment chemicals. Give heavy blow-down till normal conditions are obtained.
NOTE - 1
MAXCLEAN 05 or 06 SOLUTIONS should be circulated in boiler either by firing boiler or by using
external pump. When external pump is used; pass solution from the steam drum and take out
from mud drum.
NOTE - 2
Maxclean-05 and 06 solutions should never be mixed. They are not comparable. Therefore STEP
3 AND STEP 5 SHOULD BE FOLLOWED RELIGIOUSLY.
NOTE - 3
Time required for de-scaling depends much on nature of scales. Test kit will help to adjust time
of de-scaling.
NOTE - 4
Quantity of de-scalant consumed depends on quantity of scales and nature of scales in boiler.
For 1 KG of hardness scales, 1.5 KG of Maxclean-05 is required while 1 Kg of Maxclean-06 is
consumed for 1 Kg. of silica scales.
Preparation of Solutions:
MAXCLEAN-06
Use Carbon steel or HDPE tank equipped with stirrer or similar mixing arrangement. Take
sufficient quantity of make-up water in this tank to fill the boiler. (Generally 10% excess of hold up
volume of boiler). Add about 5 KGs of Maxclean-06 powder 95 litres of water taken in the tank.
Add power slowly while mixing. Maxclean-06 produce heat while dissolving and therefore,
powder should be added slowly (esp. when HDPE tank is used). Mix well to dissolve.
CAUTION:
Maxclean-06 is highly alkaline in nature. Use hand gloves and goggles while preparing
solution. Normal precaution of handling caustic solutions should be taken while making
Maxclean-06 solution. For further safety information, refer to materials Safety Data.
Maxclean-06 solution can be stored under normal conditions for 1 year and it can be
reused.
MAXCLEAN-05
Use HDPE tank equipped with stirrer or any similar mixing arrangement. Take sufficient quantity
of make up water in this tank to fill the boiler (Generally take 10% excess of hold up volume of
the boiler). Add about 5 KGs of Maxclean-05 per 95 litres of water in tank. Add power slowly
while mixing in the tank. Mix well to dissolve completely. Heat to 60 oC for dissolving it quickly.
CAUTION:
Maxclean-05 is highly acidic in nature. Use hand gloves, goggles and masks while
preparing solution. Normal precautions of handling acid solution should be taken while
preparing Maxclean-05 solution, for further information, refer to material Safety Data.
Maxclean-05 solution can be stored in HDPE tank for 30 days under normal storage
conditions and it may be refused.
Please note that de-scaling procedure may be varied to suite boiler design and for ease
of handling. Kindly contact THERMAX for any further queries.
10 ANNEXURES
Contents
1. Basics Of Liquid Fuels & Combustion-
2. Burner - OILON
3. Grundfos Feed Water Pump-CR/ CRN
4. Burner Sequence Controller-Landis & Gyr

10.1 Liquid Fuels And Combustion
10.1.1 FUEL FOR BOILER
Shellmax boiler is designed to operate on liquid as well as gaseous fuel. Fuels with a very wide
range of heating value can be used for heating in these boilers. Like water it is extremely
important that the quality of fuel going into the boiler is carefully controlled in order to obtain
good performance out of the boiler. While water quality affects the Boiler performance due to
its effects inside the heating surfaces the fuel quality affects the outside of the heating surfaces.
To ensure the optimum performance we need to know the properties of the fuel and make
necessary adjustments. We shall discuss below some of the important properties of fuels.
10.1.2 COMPOSITION OF FUELS
Most of the fuels comprise of compounds formed out of carbon and hydrogen and in some
cases other elements like sulphur etc. Very often fuels also contain oxygen in the molecules.
Most of the fuels used in Heaters are derived from petroleum. These fuels are very rich in carbon
and hydrogen. The liquid fuels generally have more carbon and less hydrogen when compare -
to gaseous fuels. The carbon content for petroleum based liquid fuels would be generally 82 -
88% and hydrogen content 10 to 14%. Petroleum based gaseous fuels generally have a carbon
content from 78 - 82% and hydrogen content from 13 - 18%. Natural gas has much higher
hydrogen content and much lower carbon content. Depending on the carbon hydrogen ratio
the burning characteristics change. Burners for burning these fuels need to be specially
designed for the purpose. It is also possible to design burners to burn a range of liquid fuels and
also liquid fuels as well as gaseous fuels usually one at a time, depending upon the specific fuel
composition in use it is necessary to adjust the burner. If fuel composition changes after initial -
adjustment it is necessary to readjust the burner to suit the new composition.
There are two popular ways of analyzing fuel composition. One method is to have a complete
chemical analysis of the quantities of various elements present called ultimate analysis. The
other method is to analyze quantities of behavioral groups of components present in the fuel,
called as proximate analysis of fuel.
As the ultimate analysis of the fuel gives the quantities of elements present this information can
be used for theoretical calculations of the air required to burn and the heat out put on burning.
It should be mentioned here that theoretical calculation of heating values may not be exact
due to the difficulties in judging exactly whether some of the combustible atoms are already
linked to oxygen or not.
The component wise analysis is used to judge how the fuel would behave during the burning
process. Typically, the quantity of wax content will indicate probable problems one may
encounter due to wax solidification. Generally, a higher viscosity of petroleum oils at room
temperature would indicate a higher carbon hydrogen ratio giving a higher flame luminosity
giving a higher radiant heat transfer in the flame, at the same time indicating a possibility of
sluggish combustion.
There is a very important value to understand the burning behavior of the fuel called carbon
residue, also sometimes referred to as Conradson carbon. The carbon residue is not normally
reported either in the ultimate analysis or in the component wise analysis unless specifically
asked for. The carbon residue is very difficult to burn and a portion of this residue can be
expected to precipitate as soot unless very special care is taken in the geometry of the
combustion chamber, the temperature of the combustion chamber and the residence time of
burning and such other parameters.
10.1.3 CALORIFIC VALUE OF FUEL
The calorific value is the quantity of heat the fuel gives out due to combustion. Carbon burns
forming carbon dioxide. Hydrogen burns to form the oxide of hydrogen, which is water. Sulphur,
if present, forms sulphur dioxide and some sulphur trioxide
There are two different ways of evaluating the calorific value of fuel. One value is known as the
gross calorific value (GCV) The GCV is the heat given out due to the combustion of the fuel with
all the water which has been formed having already condensed. In other words, the GCV is the
heat which has been released by the combustion and includes the latent heat given off by the
steam which had formed during the combustion condensing to water later on. It can be clearly
seen that GCV is not available for use while using the fuel in actual practice because the steam
formed does not in practice condense but goes off to the atmosphere through the chimney.
Therefore, GCV is not a useful figure to evaluate the heat obtainable by using the fuel.
However, as GCV is the easier quantity to measure generally after the fuel is tested the calorific
value is reported in terms of GCV.
The useful heat available from the combustion of a fuel is known as the lower calorific value
(LCV). The LCV is the heat given out by the fuel during combustion in actual practice. The
value of LCV is arrived at during testing of the fuel by first obtaining the value of GCV using say a
bomb calorimeter and then deducting 539.6 kcal/kg of steam formed during combustion of a -
dry sample of fuel. Sometimes, calorific value is denoted by NCV (Nominal calorific value).
NCV is the same as LCV. Unit of calorific value is kcal/kg or kcal/Nm.
10.1.4 PHYSICAL CONDITION OF FUEL
Combustion systems are designed taking into accounts not only the chemical composition or
calorific value but also physical parameters like viscosity, Lubricity etc. For proper atomization in
a burner, it is necessary to maintain liquid fuels at a viscosity of 10 to 15 centistokes at the burner
tip.
10.1.5 CLEANLINESS
The most important consideration in the physical condition of the fuel is the cleanliness of the
fuel. Unfortunately, this aspect is very often the most ignored resulting in a very sad state of
affairs with respect to the operational efficiency of the boiler, wear out of critical parts and
unreliable operation. In spite of actual experience of repeated tripping and unreliable
operation of Heaters resulting in production losses there have been many cases where instead
of ensuring cleanliness of fuel, energy has been wasted attempting retuning of burners changing
of electrical circuitry. The foremost priority in boiler operation after ensuring properly treated
feed water supply should be assuring a clean fuel. Cleanliness of the fuel can be assured only if
great care is taken right from the moment the fuel arrives in the plant by filtering at the time of -
taking the oil into the storage tank, further filtering between the storage tank and the day tank,
further filtering between the day tank and the fuel pump, and keeping these filters always clean.
Combustion is generally the oxidation of carbon, hydrogen and sulphur in the fuel. For all
practical purposes oxygen is supplied by providing sufficient atmospheric air. The air delivery is
so adjusted geometrically with respect to fuel delivery to ensure proper mixing. In spite of the
best possible mixing it is necessary to provide more than just sufficient air for the chemical
reaction to ensure complete combustion. This excess air necessarily needs to be kept a
minimum by as efficient a mixing as possible so that the flue gas quantities are kept a minimum
achieving minimum loss of heat through the chimney. The entire expertise of a burner design
revolves around this important concept.
10.1.6 Chemistry of combustion :-
Typical chemical reactions involved are-
C + O2 = CO2 (+ 8050 kcal/kg of carbon)
C + 0.5 O2 = CO (+ 2410 kcal/kg of carbon)
CO + 0.5 O2 = CO2 (+ 2410 kcal/kg of carbon)
H2 + 0.5 O2 = H2O (+ 33865 kcal/kg of H2)
S + O2 = SO2 (+ 2210 kcal/kg of S)
These calculation help estimating stoichiometric air required. Calorific values are estimated in
laboratory. (Some imperial formulae may be used for approximate estimates of cal-values for
different fuels).
Amount of stoichiometric air required is proportional to gross calorific value (GCV).

Approximately 1 kg air is required per 745 kcal of GCV.
In practice, certain amount of excess air has to be supplied in order to compensate for the lack
of contact between fuel and oxygen. This amount will vary from 30 to 80% depending upon fuel
and furnace design. In some cases (e.g. external refractory lined furnaces) further excess air
needs to be supplied to limit furnace temperature below caking/ash softening temperature.
The total amount of air should be judiciously distributed as primary and secondary air. It shall be
noted that secondary air is very effective for combustion of gaseous products (including the CO
generated in the reducing zone of thick bed of low volatile matter fuels like coke). Pressure
required for primary air needs to be just sufficient to push it up to the top of fuel bed, without
pressurising the furnace. Secondary air should be supplied at high pressure through jets, which
will penetrate through the cross section of gas across it.
On complete combustion of solid fuels, amount of CO2 gas generated, on stoichiometric basis
by volume is between 18 to 20% for most of the fuels. However, with practical amount of excess
air, best CO2 could be between 13 to 14%. More than 14% CO2 may be associated with
incomplete combustion and presence of CO in flue gas. If furnaces need extra air for cooling,
the CO2 may reduce to 7 to 10%.
10.2 BURNER - OILON
Oilon burners are monobloc burners i.e. Combustion air fan, oil preheater, fuel pump are
mounted on a single unit. These burners are used to burn furnace oil & natural gas. (One fuel at
a time)
Construction
Burner housing is made out of steel plates. It houses combustion air fan. Motor mounted on
housing runs the fan. Fuel pump is coupled with combustion air fan motor for burners used for
boilers up to 4 tph, Separate motor is used for fuel pump in burners used for 5 to 10tph. Burner
housing is equipped with a hinged burner flange with safety interlock switch, enabling burner to
be swung open to the left or right. Due to burner flange it is possible to service the combustion
head, nozzles, and ignition electrodes. The combustion head is adjustable to optimize the mixing
of fuel regardless of the firing rate. The burner contains a sight glass for flame observation. On
the suction side of the fan there is an air damper that, together with the servomotor, automatically
controls the amount of fuel and air on the basis of the firing rate required. A removable upper
cover makes electrical installations and burner servicing easier.
Capacity regulation methods
Burners come in two types of capacity regulation

1) Two stage.
2) Modulating.
The two stage burners are equipped with an air damper servomotor, with a run time of 5 seconds
between capacity stages. The modulating burners are equipped with a servomotor with a run time
of 30 seconds/90o .The servomotor is connected to the oil regulator and compound regulator via
an axle.
Oil preheater and oil lines.
Burners are equipped with oil shut-off valves and a filter, and with an electric mass preheater.
The oil temperature at outlet of preheater is controlled via an electronic regulator that keeps the
oil temperature stable. Stable oil temperature makes it easier to obtain optimal combustion
conditions. In heavy oil burners, oil heated during the prepurge phase flows to the nozzle through
the preheater to ensure that the oil temperature is high enough during the ignition phase. Two-
stage burner is equipped with two once through nozzles along with three solenoid valves (One
main valve and one valve for each nozzle). Modulating burner is equipped with one modulating
nozzle wit three solenoid valves. The oil regulator for the modulating burner is located on the oil
line returning from the nozzle .The oil filter is located on the suction side of the pump. The two
oil hoses enable the burner to be hinged. All burners are equipped with automatic flame
monitoring via photocell or UV cell depending on the fuel fired.

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SHELLMAX – PACKAGED BOILERS

Capacities -1 TPH to 16TPH

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

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

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

 Light & Heavy Oil

 Cool Low and high Calorific values,

Non conventional / agro based fuels

 De-oiled cake etc.

Agro products Packaging

Bottling & beverages Drugs & pharmaceuticals

Breweries & distilleries Plywood

Chemical & petrochemicals Rubber

Engineering Edible oil / solvent extraction

Food & dairy Textile / Synthetic fibers

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

Chapter 3: Instrumentation, controls & Safeties

Chapter 4: Input Requirement

Chapter 5: Commissioning Process

Chapter 6 : Operating Instructions

Chapter 9: Care of Idle Boilers

Chapter 10: Annexure

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

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

Figure F-1.1: Shellmax Boiler

THREE FLUE PASS DESIGN:

INTERNAL REVERSAL CHAMBER

SINGLE OR DOUBLE FLUE

INDIAN BOILER ACT (IBR)

Figure F-1.2 : Sectional view of Shellmax Boiler

Some of the unique features of Shellmax boilers are:

x Higher water holding capacity x Large furnace leads to low

Figure F-1.3 : Corrugated Furnace of

1.3 Major Components of the Boiler:

1.3.1) Feed Water Pump

Figure F-1.4 : Feed Water Pump

Figure F-1.5 : Forced Draught (FD) Fan

1.3.3) ELECTRICAL CONTROL PANEL

The components which are included in OPH station supplied are:

x Fuel Filters-2nos ( be fitted separately )

The fuel supply to the OPH station is given

1.3.6) FUEL PUMP

A. Heat Recovery Equipment-Air Pre Heater, Economiser,

B. Internal Super Heater/External Super Heater

Figure No: F-1.11: Air Pre Heater of Shellmax Boiler

Figure No: F-1.12: Air Pre Heater Construction

Figure No: F-1.13: Internal Superheater Arrangement

Super Heater Construction

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

Figure No: F-1.14: Internal Superheater Construction

Figure No: F-1.15: External Super Heater

2.2 Unloading Instructions

x For any breakage / damages, insurance claim should be made.

Figure F-2.1: Unloading Boiler with crane.

Figure F-2.3: The soil at the place of unloading should be hard.

Figure F-2.4: Boiler should be stored under roof.

Figure F-2.5: Boiler should not be stored under corrosive atmosphere.

C) Do not pile up cases.

Figure F-2.6: Do not pile up cases.

Figure F-2.7: Material should not be stored on soft soil.

x P& I Diagram Drawing No. ALT NO.

x GATP Drawing No. ALT NO.

x Foundation plan Drawing No. ALT NO.

Light & Heavy Oil

Cool Low and high Calorific values,

De-oiled cake etc.

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

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