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MLBORG
I N D U S T R I E S and reliability

1 1 59.600 DWT CRUDE OIL TANKF k I

AUXILIARY BOILER (112-212)

 Temperature sensor '-i. I,;,"
- -
.!

with welded connection :,~--.,I '

:1 22GE
-- ~ - -

Time P2202 D,I-~ October 1998

Temperature sensor, type P2202

ii 100 sensor or therniocouple (T'C)
:;fa,iclard sensors
C in accordance with D I N IEC 584 (DIN 113710)
Ft1L70 iii accordance with DIN IEC 751 (DIN J3;50)
.! ,r r o o s sensor tube diAmeters availa11ie
,,~j 17.7 06.08. 0 1 1 a n d 0 1 5 m n i
1 ?;igtJi from 50 fnm
5snsor tube with welded connection
.>7.G li2R nipple, 1 !5" I S 0 clamp
-
:!np,?ra!ure range
i t 1 0 0 -50- +800"C
% max. 850°C
; 'zrrn.?n?nl element or replaceable Miser1
. . ! % ~sensors
o , ? l available for specific applicat~or:~

TEPTPHESStemperature sensors can he supplletl

:is !';:00 ri?slstance thermomeler. type P22021 ...
.
hi ~ngleihermocouple, type P22022.. or the
, - I ' e tiii.rniocouple, lype P22023 ...
,... I 12 IS a serles of standard sensors wlth a
p:;,
vtol ? t i connection on the sensor tube. for example
2 r-' B npple or a 1"1" ISO clamp, and a prac!lcal
cr-8. iet:tl~?lihead. The series is employed in all
typi3i. a f inilustr~aland processing plants where
*Iit:'-ori~ctemperature measuring is required.
Ti-,. ;eii%clr is easily fitted wlth a DIN head whlch
i.ti:llrcs ilmple and easy connection to lhe clec-
i ~ i :i , s i l p r ~ l vThe cable seal is a PG rahle glancl.

T i l s.i~rli~!: I S ava13blew ~ t heither a permanent ele-

or replaceable measuring insert. The reacton
mi,,-!
1-
si:n:or
- .- -
tutl.: m o ~ c r : , l
Mnx .-lor,pri.>tt,ir., - -- I
s c,-~nsldsral~ly
11'-.?: shorter w t h a permanent elc-
n-I&- I ~!;tl~li,. with ttir; replaceable insert, the seninr
c;ir . .isl,f lie replaced
F'I; ) ceri;83rs are supplied with class B accuracy
311.I k i i i 2 tliermocoupI13s as stanclaril lealures.
I ,,r cl.;ises af accuracy can also be s u p p e r l .

,%;
.
. .. ..
.....
..... F 0 b r x 561, 2 4 C Gasvaerkivel
9100 Lalbnro, Denmark
TPI -.IS 051 304001J
tax. -45 ' 4 8 If5.$112,
AP$.'. ?G :' E-mati aalgeaalhnro~indurtriesdk
I N I F 5 http,'!.\;..'i". s ; i l l ~ ~ n r ~ i r ~ r i t ~ s t r i e s . c o n i
- ~
 Nipple

-.
,. ----.

Union I
see

I S 0 clamp

Temperature sensor, type P2202..., ordering key

 MIT GENMAR ORION

F;4LBORG BOILERS MISSION OL MODEL 35000

CAUSE FOR ALARM AND SHUT DOWN FOR LANCE REDRAWN

"LANCE REDRAWN" is a built in protection in case someone

should ret-Iove the lance while burning.

At the t o r of the boiler you'll find a proximity switch sensing

between t7e burner top and the lance. Try t o adjust it to a
smaller gao, or replace this proximity switch if i t continues to give
faulty alarms.

Lance proximity switch is connected to digital input 3 on your

local Unisab controller.
Instruction manual for boiler plant
volume 1

Boiler type: MISSIONTMOL model 35000

Burner type: KBSD 2650
Project No.: 734936137138139,735226127
Classification: ABS
Customer: Samsung Heavy Industries
Hull No.: H1353154,HI 389199,HI 400101
Date: 2001-08-07
 Table of contents

System concept (vol. 1)

Technical data .............................................................................................................. 1
Flow diagrams .................... . . . .............................................................................. 2

qrllSSIONTMOL boiler/accessories (vol. I )

Feed and boiler wate

Water level gauge .................................................................................................. 6

Feed water system

Chemical dosing pump

YBSD burnerlaccessories (vol. 1)

13
14
Oil flow regulation 1.5
i ci
Differential pressure transmitter 17
IX
Ignition burner pump 19

KBSD burnerlaccessories (vol. 2)

Cornbustion air fan ..................................................................................................... 1
Dra\vines........................................................................................................... 2
Data sheets ............................................................................................................... i
Performance curves ................................................................................................ -1

Lvlguage U K Pap? li?

Control system/electrical equipment (vol. 2)
MISSION control syste
Operating principles
Operating the panels ................................................................................................. 7
Commissioning and servic

Menu structure for the panels

PC monitoring and control system.
Electric drawings for local panel.
Electric drawings for power pane

Spare parts (vol. 2)

Spare parts for boiler ................................................................................................. 17
Spare parts for burner ............................................................................................... 18
Cvqr(~r<rreh f n , w g < v ! ~ md
nr d m i n ~ ~ l m l i o n : Adhorg lnduru~csNL B\'. IKTM-W!
.Aalhorg lnduclrics :i.'S IAAL-G) Ohmveg 8.3208 KE Spijkcnisse
P 0 Rox hbl, Gns\.x.,rksvej ?J P 0 Boa 145. 3300 AC Spiibcnis??
Q IlIO Aalhurg. D e n ~ ~ v k
The Netherlands
Tcl 4 5 9 9 .'ii@M Tcl.: +31 181 650 500
Fa: 4 5 9 8 163022 Fax: +31181650501
E-mxl: nalG1aalborg-industries.& E-mail: runw@anlhorg~industriesnl

.Soirr, Enginetrinp, /'*oducrion - Mnrinr & Inrlurmry: Aalborg Industries A/S (bmnc.hl 1lST)
Aalhorg lndusiries M S (AAL) Dilhayat Sok* no. 9
P 0 Box 844. Gasv>erksvcj?J TR-80600 Etiler. lsunhul
9100 Aalhorg. Denmvk Turkey
Tel : 4 5 99 30-1000 Tel.: +90 112 265 7671
4 5 40 1Llh686 (24 hrs marine service1 Fax: + 9 0 1 1 2 2 6 5 7411
Far. 4 5 98 lhS316 E l : ~_lurkey@ruperonIine.c~~ni
+45 98 191330 (Land-hascd boilers Sales) (Cr,mpany clonng 30 SEP 211011
4 5 99 301641 ( N e w Industry Sales)
4 5 98 103WI (Hezzlr exchangers Sales)
4 5 98 1 2 ~ 6 0 6(ProduciionAVorkshop) hUDDLE EAST
4 5 9 8 lil:Zi3 (Marme serv~ce/Sparesdept.)
4 5 99 201674 (Indusuid service dcpt.) Aalhorg Industries A/S (hronrli1 inSt31
F ~ m a i l . aal@ad!x~~:p-induslriesdk P O Box 51?10.Al JadaIShlpymd
Duba,
Srr-iicr o ( l n n d ~ t * n ir! burners: Ilnilei Arab Emirares
A2lhor.p Industries ,\IS (ODE) Tel.: +9:1 d 321 1061
+971 5 0 6538708 i?Jhrif
F : +971 4 324 1790
DK-5210 Odrnse \:V. Dcnmark E~mail: info(~~alborp-indusiri~.i~,Iib~
corn
I 4 5 66 11;176F
RLK: +A5 66 Ibi768
E-mail- hoG'.'3ol,l,?-g-indur1rlcs.ilii
ASIA r%CtF7(:

Aalhorg Induslries Pte. Lld rSl"11

14 Tuas Avcnue IRA. Sing:tporc 6XS62
Jurone Point P 0 Boa 2.54
Singapore 916409. Rcpuhlic of Sinppurc
Tel.: 4 5 261 0808
Fax: 4 5 266 1 I I I
Telex: rs 26720 alhorg
E-mxl: sin(onalhorg~indusrriei.c~~rnic

PT Aalborg lnduslrics iJtC1~1

JI. Rawa Sumur n. Blixk 111

+@?
FIN ?6101 R a u r n ~Finland Kav. CC. 6-7. K a w a a n Indusui Pulogxtli~ng
Tcl +358 :?'8 3100 JakmaTimur 13930. Republ~cof lodtnecm
Tel.: 21 461 0560
Fax: 6 2 21 361 0568
I;-mail: j k t @ ' a a I h o r ~ - i n ~ i u c ~ n c s ~ c c c ~ ~ ~

Tou cr Cowt Aalborg Industries L.~rnitcd ~I-lKi?l

0:ikilalp Kaad. Cililon M w r R w m 2304 N m Wn Hnng Rrl~!tl#ni.
148 Wins Lok SLrccr
Sheung Wan. Ilong Kong i S k K !
The People's Repuhlic oi C h ~ n n
Tcl: +852 2676 3826
FRX +852 18?4 SqO5
~ ~ sI:).~ r ~ c ~
E~m:ril n o l h o r ~ ( ~ n d h o r c - ~ n dcorn

1 I'li11005iAAL - 0 5 AUC 2001 hltp://wn~w.dborg-irrd!rstrics.com

 NORTI1 AMERICA

Aalba I! g Industries Lirnilcd (SII.4) Aalhorp Industries. Inc. I ERI)

Shan ' ' a j Representative Office 5300 Knowledge F'arku,.?y. Sulle 200
R m n I. 1I f f . New Shang!!~ In~ematlmalTower Fx~e.PA 16510-4660. US,\
No. ? , Pu Dong Nan Road Tel.: +I 814 R977030
Shan; l li ?(10120. The People's Repuh!ir of China Fax: +1814E97I(r?O
Tel.: +86 21 6886 3565 E-mail: infoeai-mcnm
Fzx: +66 2 1 6886 3440
E-m:l hk
sba@nslborg-in~lt~stries.c~~rn Aalhorg Industries. Inc.
6035 South Loop Eagt
Adh. r: lndusuies Ltd. (TAOI liouslon. TX 77033. USA
No. F : Guangrhou Road Nonh Tel: +I 713 643 3?S9
Jiaor $ 8 u City 266300. Sbnndong Provrnce Moblie: +I 281 ?50 5719
The i ? 9ple's Republic of China Fax: +1713M34100
1 . : +86 532 2?9 &(I? E-mail: l1ousIon~3alhi~rr1-1ndusViescam
+865322?9&14
Far. +66 532 229 5908
E-ma I aalborg@ns.c~naqingdao net
sdhorg@puhlic.qd.sd.cn I Sales dcpt.)
A d b x g loduswies S.A. trnnin nf/iceJ IRIO)
Adhq r :Industries Limited (DLC) Ru3 Divino Espirit~Santn, I . IM) - Bairro Cxangola
Dalia~i.lepreseotative Offiuc CEP 25715-410 PeuOpol!~- RJ. Bruil
Roon 501A, Dalian Gold Name Commercial Towrr Tel.: +55 24 2133 9Q63
68 Re iN n Road. Zhongshan District Fax: +55 24 2237 6603
D d i a 16001. Liaoning Prov.. The People's Rep. of China E-mail: rioeaalhorp-indusV~~s.com.hr
Tel.: 4 6 41 1 270 92'11 Web-site: www.aalborg-induc1rics.com.hr
Fw: +86411 27093'91
E-ma d l c @ a d b o r g - i n d u r u l e s . ~hk
~~:~~ Aalhorg lndusuies S.A. 1 inlr r "flier) 1S40)
Rua lrmael Ncri, 764 - b i r r < ,+\?ua Fria

.
Aalbn-, lndusuies Ltd.
5th Fl ,r. Saesam Bldg.
1485 Ja-Dong. Haeund7r-Ku
(PUS) CEPO23iS-001 S&>Pnulo - S?. B r a i l
Tcf.:
Fax:
+55 11 6262 ?(GO
+55 11 6262 2755 16262 2756
Pusan f I?-Sd2. Sou& Kore3 E-mail: san@anl\~nrg-indurviescomhr
TI: +82517036162/6163/i~I61
+6251626 l8Si
+6? 51 636 5800
Fax: +P? 51 624 687J
E-mai pusan@aalharg-induzlrics.:i..kr

a l b o i Industries K.K. (UKR)

Sanno I ya Intes, 6mFloor
1-8. 7 . iorne. Isoearni-dorl
Chuo ,. Kobe 6 ~ 1 . ~ 8Jxpan 6,
Tel.: +51 78 271 57?Ct
Far: +81 78271 5741
E-mail u h h ~ ~ & ~ l b o r g - i n ~ l u s I~C ~ c s . ~ ~ c

Aalho:? Industries K.K. (lironch) (TOY)

No. 9 ,. ,u,aBldg., Rekkan
6-7. 1- ame. Akarka
,Mlnali u. Tokyo 107-0052. Japan
?el 181 335836351
FLY: + % I 3 3584 8378
E-mail k;~h@~lhnrp~in~!~~sIries.c~~
 Table of contents

Technical data for boiler unit

Dimensions for boiler unit

Wateristeam process data
Combustion process dat

DaLa for electric system

Data for pressure part
Data for burner

Data for steam pressure operation

Technicall data for boiler unit

I General data

33oi6. 1 7 . -38. -39. 735226.27

H135'3. 51.89. 99, H14(u). 01
Classification societ,
* Pressure sauge calibratio
. .
Thermometer calrbrat~on:...................................................................... 'C
Language for sign ILK

2 Dimensions for boiler unit

~-

a Height to top of local control pane 1J.024rnni

Diameter incl. insulation: ........................................................... .3.570rnm
Total height incl. retraction of hurner 1:ini-e: .......................... 10.l150 mrn
Weight of boiler unit rxcl. water: ....................................... iS.l(!CI kc
Weight of boiler unit incl. wate -.?,iOiI kc

3 Wateristeam process data

Steam output: .............................................................................

> -
.>3.0i)O kg/!>
Working pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 16 I1
ii.(l kfdc111-
Max. allowable working prc.sstrre: . . . . . . . . . . . . . . . . . I S k:r!cnl-

. Working teniperatur ~ j ' ]2;1 1 1 ~ ( :

Feed water operation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ ~ ~ ~ L I ~ I I ~ I ~ ~

Fecd water temperature. operatic~n:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S j - ~ i i(:

Feed water tempcraturc. I~iyou~:

......................... c,ii (
.
'

4 Combustion process data

Min. calorific value of diescl oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.200 k J l k ~

MinJmax. viscosity of diesel uil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cSi :it -10' (-
Density of diesel oil ( IjcCi: . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 kz/ill'
 .-
Min. caloril~cvalue of fuel nil: ............................................... ..-lO.l_Oi)U/kp
Min./max. viscosity of fuel oil: .............................................. i>(iOcS1 at 503C
Density of fuel oil (15'C
Fuel oil temperature before pre-heate
Fuel oil viscosity at bumer inlet
Fuel oil temperature at burner inlet
Ambient air temperatur
Air excess No. at 100951103
Flue gas temperature (clean boiler): ................................................... .?S li'C'
Air consumption at 100% lorid: .................................................. 3R.687 ke/!i
Flue gas flow (appro 41.17.5 kclh
Pressure loss across pin elernen '17 rn[n\lJC

Data for atomising steam

Atomisins steam pressure at hunier. max.: .................................. (2.0 kdcni'

e Atomising steam consumption. mas.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4!l - 160 k ~ l l i

Atomisins air pressure at bumcr. mix.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0 keicm-

. .
Atorms~ngair consumption. ma:.:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 kc/h

6 Data for electric systems

Control volta_ge

Lnst~l;~tion
class: ...........
* Degree of protection
Colour of local control pane
Colour of power pi111el

7 Data for pressure part

- --

_;ir,zi. oil fired tmilcr

ssi(:)h'lb' 01.-
.?~o!I~I

Boiler No. starboard: .................. lO700. 107h3. 10704. 1070(,. 1 1090. I IO'9i:
Doiler No. pnn: ........................ 107.59, 10761. li1761. 10765. I 1095. I Ins7
Tect pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L:i.!cm'
 .Number of pin elements: ............................................................... lJ(l
l'rorection of boiler M y : ....................................................... IUC:II I-esistant
Colour of insulation plates: ................................................... Blu? KLU5002

8 Data for burner

-- --

earn aton~ising.modulating

..
KRSD 2650
Burner capacity on diesel oil. min./mnu.: ............................. 2 7 0 / 2.300 k"Jh
Burner capacity on fuel oil. min./mas.: ..... 3 0 1 2.491 k~/h
Colour of burner h!~lnsell 7.5 RG 712

9 Data for water level operation

- -

Too high water level alarm

High water level wamin.
Normal water leve
Start stand-by feed water pump:
Low water level ujarnin~:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -g5 mm
Too low water level alarni and burnei off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14.5 null
Tocl low water level alarm and burner off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -145 r11111

10 Data for steam pressure operati~n

Safety valv IR.0 kc1crn'

Safety valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I S . 0 k ~ l c m '
fish steam pressure alarrn and burner ofk ....................... 17sk~icm-
High steam pressure warnin?: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . ki./crn2

. Ste:lm dump opening prassurc: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner startlsto
Burner operatior
,.; 1 7 3 -

h
.. I7 1 kcicm.
lo..: 1 1' ?. k:~/c~i?-
0 i I O ( 1 i:dcnl-
Low steam pressure warnin- kdcm
11 Manuals

Language for manuals: ......................................................................... LiK

Set of instruction manuals: ...................................................................... 5
Document revision date: ........................................................... .200l-(!R-O(1
 Table of contents

Flow diagrams
Steamlwater system
List of parts for stearnlwater flow diagr:ln

List of parts for burner unit flow diagrain ........................................... QOSO2:OI1340

-
I;IIISII;ICC
I'K Pace I l l
1 Lict of P a r t s fo;Oil Fired Boiler T y..p e hlISSION'" O L I, Rev: r(*)
-,, 1 (-. k~-
c.: 11

I1
~

"SleamlWater Flow I)iagram", Dranming No.: S01:012331d / Date: 010223 AES

I t e m I Q t y Dint / :ipplications 1 Type / Ihta Shert
1 DN I o r Drawing
I Large nil lired hoiler i I 11

1
35000 kglh - I1
/ lhl18harg 11
('I 7 li5/lMI Safety valve S:~fttyv;llve 261 1174 7~
'i CZ I 1 ?O(I Main steam v;llve 1I Ston val\.r I 7iI 1122 / !

1 ~3 1 ' .;
-
I
I00
I
I Feed w:lter valve 1 Ston valv?
I
/ I.;.IOOh I
I/- 100 / Feed water valve
I
I Stop-check \:ilvc
I
/
I
764 109-1
1
I
C I / 10 Scum valve Stoa-check \.;~lve 2fv.l IO~IO

Ch 1 1 40 Scum valve Slop valve ' 5 I IOQO

('7 7 40 Blow down valve Ston-check valve /I 264 IOWJ i
1 Z j
I

-
JO
I
Blow down valve
I
I Sto!) vnlve 1 2iO l!!'li'~ IiI1
( '<I

I 1-10 1 1 1.1" :\ir escape valve 1 ~nstrurnenist:+ \.alvc / i22C1 t)nono: /

1 rll j I
I
M"
I
tiauye hoard valve
I
I Instrument strip \.al\c / 6170 000002 1
(.If/ / Mnin steam v;tlve / Check valve
I
2 i 1 111);
~ 1:I
I!

/ rij~ i B / - ~ ~ steam
ss v:iive
I
/ Stop \,nlvc
I
I 2 x 1 IIISS 'II:

1
i+17 25 1 \/\\tcr l e ~ e gauge
l left \Voter level $ail?:

I 1 I 11
I Heating coil
1 1 25 Villve for heating coil inlet Stor' \.aIvc 1 7511 IOSS
1
I1
15
1 Valve for he:~tinecoil outlet Stop vnlvc "C! IOSS

I A
12 Stop valve / LJP-unit 1 250 ti!:~,

Ci:li~;e hoard
Kcmore pull ftnr safety valvc
Smoke nptakc
\'nl\.e for soilt blniver
-
m,i. Z! 'f:>QG
1 11 i s

List of Parts for Oil Fired Roiler Type MISSION"' OL Rev: c ( * ) Class.:
"SteanllWater Flow Diagram". Drawing No.: X01:012334d Date: 010223 AllS
Item Qt? Din) '4pplications Type Data Sheet
No 1)N or Drawing
0 I Stc:!m trap
li'.
c'196 1 12 Drain valve for scx~thlower Instrumenl stop valrc 6220 000002
C199 2 50 H:!ll valve for soor blower Sior \,alvr B.3236
Boiler control panel
Low wmer level switch 8 101) OOOO(18

UP-unit Difi. prcssure tr:!n<. 7i17.:017131

R \r,rSli;l\RDiap:~- I ~ l h ~ , , r r l ~ ~ . h l l ~ ~ ~ 0 ~ ~ ~ ~ ~ \ 0 ( 1 drr
7 3 12.19May
3 6 \ 1x1
~~173~~1h
 m~ f~?+RG 8'.
::8

1 11 .L I

I.ict of Parts [or O i l Fired Boiler Tvpe M I S S I O N M OL Rev: c(*) Class. :

"Steam/31'ater I:lnw Diagram", D r a w i n g No.: X01:01233Jd Date: 010223
Type 1- Data Sheet
or Drawing
Large o i l fired hoiler 350(10 k@h -
I I6118 h a r g
(: 1 2 ' 5llOO Safety val\,e Safety v a l ~ e Z h l 117.1

('2 I j 200 M a i n steam valve Stnp valve

(? 3 2 10(1 Feed w:iter ~ a l v e Stop valve

(-J 2 IIK) Fecd w a e r valve

CF 1 40 Scum valve

(16 I 10 Scum valve Stop v n l w

'
C7 7 40 H l o w dou,n valve Stop-check \ a l \ e
-
CS 1 I 4n R l o w do\vn valve Stop halve

m1
/ qi.. Sample valve Instrument slop valve

Instrument stop valve

Gauge board valve Instrument stop ,AIYC

Stcop-check \.alvc

-
I-- 200 / M a i n steam valve Check \.alve

*I- 5 1 liy-pas, steam valve

Furnace drain valve
Stop val\.e

Slop valve

('17 \Vnter level ~ a u s eleft 1Vatv:r level :ILI:!~

25 Watcr level ~ a l l z erifht Watt:r level ::luge

Stop check v:~lvs

100 Circulatinn v:~lvc ~ n l e t Stop valve

CZ? 1 1 1 Heating coil

!I/] 215 / Valve icir heatinp coil inlet Stop valve

1- ' '
I, 2 / Valve Tklr heatins coil orttlet Stop valve

Safety valve for heat~nfcoil

25 Stnp \nl\,c

Rcmr>re pull for bafetv valve

Smoke uptahe

Stop valve
- ---- - ,- --
A&,- ?~?RG
1 1.1 i S

List of Parts for Oil Fired Boiler Type MISSIONm' 01, Rev: c ( * ) Class.:
"StrardW'ater i l n w Diagram", Drawing No.: XOI:fl12333d Date: 010223 ABS
Applications Type Ijnta Shcct
or Drawing
Steam trap
i

,
C14h
Clog
I
1-
''I"

50
Drain valve for smt hlower
Ball valve for soot hlowcr /
Instlument stop r3lvc-
Stop valve
6220 000002
P .?7ih
I!
/ WIJ / /1
I
II Lo\* water level sw~tch
I
1I
I
I 810110000nq !
I DP-unit D i f f pressure trans.
I
I 7OZ:OIdi01 ~
41
 List of Parts Boiler Type MISSION"' O L
"Steamnl'alrr Flow Diagram", Draninz No.: SUI:012331d
Item No Qty Dim Application
DN or Drawins
r. l~o.l . . I I Water \ ~ n s h i n rhose u,ith nozzle
li i ( nut shuwn o n the d ~ a c r a m)
1 t ~ i i1 I / Pressurr transm~tter 1
Fl l J I Pressurr tr:~nsmitter valvi: ' 1 5 4 1002

111211 :
Snot h h l u e r control valve
(IGS interl~>ck)
Temperature r ~ m s r i t t e r ?T 100 -41
11

I I / i I? / Feed \v;!ier ccmtrol \.alve

I

I with pneum3tic actu:ttor

I I
I Filter ri.:ul:~tor with automatic drain
! 291 5 1 0 1
/ Snot hlirirer control valve I
(IGS inrerlcickl
f ' 1 1 Temper:iture tr:~nsmittcr
I
I Chemical dosin: unit

2\V I 1 15 Fced w;itrr cnntrol valve KllSI

with pn.?umotic nctualnr

I -
:. \V 7

-
I\: >. '
I

1
50 Feed u::tcr contrul valve

F ~ l t e re:ul:ltor
r ivitli aulomatic drain
'
[;.I 177
291 ? I n 1

1 - 1' IL;
Cornrncn pna.cr panel

Rcni,,te cnntroi I T in E c R : 0320 oonnoi

 1
-+:-
I
Designation Pcs. Dimension Article No.
GI9 Strain?; 1
~~~ --
I
-~-i

_
G20 Steam regulating valve 1
. i-
I
G27 / s t o p v?!ve (for item G22) 2 1
I
G28 ( ~ e m p f r a l u r transmitter
G69
G70
e
stop valve
Strainrr
2
2.
t~1 ~
1

----
-~
~

--

~
- -

i
!
~

~ ~.
G72 Ignition oump vi~thmotor 2 I -- -. I
G73 /Stop va!ve -. 2 1- ~ II

r'
2 i--
G74 /Instrument stop valve .- -

G75 I ~ressu:egauge 2
- -- .-
G76 1 Non return valve / 1
-1
-~-

G77 S t o p v?ive
. 1 '1.
G78 1 Relief mlve I I 1
- .! I1

I
1
G97 Stop v-ive
- 1 1
G99 Pressif:? transmitter I I I
GI00 /oilpressure regulating valve 1 I I

G i o l ~ t o p v a- : v e ~ 1 1 i
--
i
-~
.- ~ ~

~
i
GI02 ; ~ ~ - ~ %
--
valve
i: 1-
1 - 1 ----- ~ - -- -

i_-- G105 'Instr~;-~-:ntstop MIae

1 1 1 .I
~.
I
/I
G I 11 1 Three v,ay valve 1 1 1
~
~
-- ~ -

G I 12 Pneupj- tic actuator (for item G1 11) ,1 ,

1 1
i
/ i
~

G113 Solenii.1 valve (for item G ? 1 1) j - 8

( ~ 1 1 4 e ~ d r : : i n setg with pressure Gauge ( G I 11) ! 1 I ~2

1 --
i
I G I 47 F u e l o 1 gurnp unit I ? ! - . -- 1
I G I 4 8 ! F O p;ijsure control unit 1 i 1 . !
!
1, G155
I,-
---
lgnitlo,: ail pump unit
L1
-
Boiier r ~ w e panel
r
I ?
?
I
~I
--.
~ ~-
--
. ..

!
-

-
I

--
!
,
- ~
- -1
lip- -R2
I R7
~ilencr
I Inlet vaiie damper
. - -. ~ .- UP
2 1
L -I i!
.- ~-PA.
1
3 -

I~
~

'F.0. !?-,, 2 1 1 -~- -

i R12 Servo P'ive unit

I - I > ; -

/ R14 Micro .rr.ritch 2~ -. - -

1 R15 Air rei~jj:ing set with pressure gauge l 2 :- - ~- - .- ~ -

I R16 1 lip co-i,erter (for item R71 -. . 1 2 ;

-
' !
-- ~ -

1, - ~ 1F , Burne- unit ~-
I A - -~

j 1 ~ 1 4 5ignitier
. --
oil pump unit - ! 1 --PA-
I -

i 1R F a-
n U!IV ~
1 !
- -- ~-

2F Burner t.lnit 1~ -
8 -

1 2 ~ 1 4 5lgnit~oroil pump unit 1

-.
Ttlle
...
. ...
....." .
....
.*...
.***.B.
Oil system
2 x KBSD Model 2650
OOO~~.!
Scale ..
... .
Burner operation modulating 1.1
. -.
8 .- . : xi
Flow diagram '- ' 1
. ~

90x02 : 012340 a ;
--
i n s dro*,ng i :.-o
4ei,4n $no-n wieln ,r ma propen" el ~ a b c r 2
pic? 1 21' 1 -2001 ,,c,,~8~o , : e . , p a e v ncr~rr./lucecfartnrdpam
 ~~

Item Designation Pcs. Dimension Article No.

2R 1 Fan
I

I
LJ:,~!

!
1

~ 1
I

!
-- -- .

1 :~
I I
I I
I

; I IiI
iI
i I
I
! 1
I

iI
' I
j
~ II
II
I1
I
I
I
I
I
i

...
I .....
.....
... 2 x KBSD Model 2650

1
,,,,:,
CF:,h.-L
1 31.8~.
_ .",,
Oil s y s t e m

I,.3oo Burner operation modulating

45 / Flow diagram
Scale I 5 :.
!
 Descriptior Ind~i Dote Drown Appr 1

NOTE.

F n? - C o r n p o n c n t s specified by ! e - r 70 o r e -r;ppIc,3 t , , :,!

-3:43h/37/55 '19 - t e r n s see s e p a r a l e hs! o f po Is
- Far elecirica c a n r ~ e c t ~ o n ssec
, actual e i e c t r ~ c n j -'J.'--,

- -~
- For connections - - e r turn.. c r r o n o - m ~ i " ~rchm.,,~

i.cr..

w>,c
T,'i.
- - ..-- , ,;
I - - - - k,,
... 1 x KBSL) Model 2 6 ~ 1 1 I
I L1..
- , ..,~,.,
Il:r,r
,<
I
 - -
(Item
I
1 Designation Pcs. Dimension I Article No.

-
3 ! !

1
--
- - - --
1
--- I
1
-

C48 ~ r e s s u r ?lransmitler
.-
1 I
1
~ -

F1 ~team-~:,rnisingburner 1
I Stop valb?
~

I , F17
1 .-
F18 Solenoii valve 1
- -. -- I
1 1 1 -

- -L~--
- ~
I
r -- -~

l 11 I
I . -,

-
F 4 3 l ~ a t e stparalor
r
urge s8-ut off valve
-. I i - I I
.-
F 4 5 l ~ h e c ki a ve
1 . 1 - ~ - ~ ~

/
F ~ o1nstrurnr:t stop valve 1 1 1 -- -

1 1 .- .- .. -..- --- -- ,

F56 Solenotd jalve (for atomising valve) I l l I

-- . - - !
F57 Pneurn:.: actuator (for atomising valve) 1 1 !
neumr'.: actuator (for
. ~. u "r a evalve) I : ! ! --I
F59 1~oleno;:l ialve (for purge valve) l l ! -~ i
- - - .-
i Pneun::; :
~ ~

F60 actuator (for fuel valve no.2) 1 I

- ,
I
F61 I Solenoirl valve (for fuel valve no.2) 1~ I I

F62 A i r redu::~,g set with pressure gauge , 1

7--
-
~
-
.--- ---

I
- i
F63 i ~ i reduc17g
r
--
set with pressure gauge i 1
~ -

~
- -- -~

..
F64 (Stop valve
~ - -- - 1 - ~ ~ ~
i
F65 Solenoll valve (for fuel valve n o l ) I
-- !- - --

I ~-I
~p ~

~6sTPneum:iIa;;ator . ( for fuel valve no.1) i i

I
~

' * I
F67 ~ u eshu:
l off valve n o 1
-- -- - - 1 ' ; -- - -..- - - -- - -

--
F68 b s i r ? ~ a u g e
...~ - -- ~ 1 1 ~ -
1 ~
I
F69 lnslrurnvt stop valve 1 : l I
.- - . ~

i
F73 ;Throtlls i i l v e j~gnitionburner purge) 1 1
-- ~~ --

F74 M i c r o s.?,Irh - p ~ s i l l o nsviitch 1 .- i

- .~ - - .

-
F75 ~ ~sh: e ?::valve
-- -- --
l i no2 1
-1 I - ~

- I -~
-~ -

F75 Dtfferen!t-I pressure transmitter - RDL 1 1

- -- .- -.- - - - . ~ -- ~p

F77 1 Check v r i e (~gnltionburner purge) 1~-~-- ~

I
- -- p
1 ~

-
F78
-,-
Solenci:
--
'?alve j ~ g n ~ t i oburner
.. --
n purge)
~ ~
1 '

- -
F80 C h e c k v y i ~ e - '
-- -- ' - . - --

...
.....
..

....*.;
~

. . . a .
1 x KBSD Model 2650
.a****
Burner unit

, , : . Burner operation modulating

I
1 ;. . , ,,,i$ 1
. .:,,,:.,, -.-: I Flow diagram A r z e ! C r a w n c ?1-
I
/ page : ?liC.:. 101 1 Tri,
2 - 2 mri,
."O Cei yn ,nmn herenis me prapeq a, *a7-,;
-: Ce r,el 3" or r ? P l m r c e l ' c r m,r, pan.
9.r.s.:
 -~
-

Designation / PCS. Dimension r A r t i c ~ NO.

e 1
F84
F85
lnstrunnnt stop valve
Micro svjitch - pos. switch (fuel valve no.1)
I
~I
I

I _~ .I
F86 Micro switch - pos. switch (fuel valve no.2)
-~ I

F87 Stop-c%ck valve for atomising air

-i ---
F91 Pressure regulating valve for atom. stearnlair 1 1
- . I - -
F92 Stop valve for atornising stearnlair
~--

1
3
F93

4
F95
1 Stop value for fuel oil return flow
oil flow regulating valve
lip converier
.~- - ~ ~
- - --

7- -

, . ~

1
.-
/
F108 ~ h e c vilve
k for atornising air 1
- 1
1 !
F135 Pressur;. gauge ) I 1
1.

1 F l 3 6 [Instrum-nt stop valve

I ?- 1 ,
I i
-~ .- ~ ~-

I- F137 Measuirig transducer

-- 1 1 I . -- I I

1
F-150 Solenc ' valve 1 1 - 2
I
-~ i
1 Solenc.6 valve
p~

F151 1 1 I
~.1
1 F152 l ~ h r o t i l cvalve ! 1 i
- .

._ ~ L I
'I
I-- F153 (Solenc~ri
valve
) - - i
1 1 I ~- I 1
F157 Temo+:alure indicator ! 1 1 !
I-I- L1 oiler pa7ier panel 1
I
1 ;
L2 Boiler cr,trol panel 1 I
1 1 I
I

. .. ..
.
......
..
........
...a.

Gurner unit
1 x KBSD Model 2650 1
I Li0052C

., . . , ,o Eurner operat~onmodulating
, I Flow d~agrarn .Ar:cle ! r1r;iu.n-j No
 Table of contents

Descriptions
MISSIOWMboiler
Boiler mountin
Water level co
Gauge boar
 OL boiler
MISS[aONTM

1 Description

The MISSION'M OL boiler is a venical two-drum boiler. insulated and pre-

assembled with hoiler mountings for easy installation and operation.
The boiler is top-fired and equipped witll a steam atolnising burner. As the burner.
the local control panel and all relevant boiler mountings :Ire mounted on top of the
boiler, this can easily be operated arid monitored fro111the bumcr platfom]. Most or
the cabling for instrumentation and drain are pre-wired heforc deliver)..
The control system supplied with the MISSIONT\' OL hoiler unit pro\,ides fully
automatic operation of the hoilcr and the stearn atomicing humcr.

1.IBoiler pressure part

The principal drawing of the MISSIONn' 91. boiler is slio\\,~ii n Fiprrr I . The steam
drum is cylindrical with two flat plates of equal thickness. Bec3ute of thc internal
pressure, the flat plates are niutually cr~nnectedby vcnic:11 snlitl <cays. The srcnrn
drum is furnished with the necessap internal fittings to ensure ari ?\'en distribution
of the feed water, of the circulation \vater fro111 111ci.rh;lurt hoilcr and t o erisurc 3
sufficient dryness of stesni.
The burner cone in the furnace opening arc an integrated p:m and ilccorilingly 1113
refractory are provided in the top of the furn;~ceroom.
Manholes are conveniently placed in both drums and inside the drr~nrsenough spncr
is available for inspection and maintenance.
The water drum is designed similar to tlie steam drum. The dnrm sirr rive< optirn??l
s p x e for the heating coil and elis). access for inspection.
For the foundation the hoiler is provided with four supports. one as fixed foot and
the others designed with possibility of thermal expansion5 ('nuliter plat?? :Ire
provided for welding to deck.
130th the furnace and the generating tube b;mk are locatcd :~symmctrically and are
separated by the screen wall. Besides tlie screen wall the furnac? iunsists of ?;IS
tight polygon shaped membrane ~valls.The ~sncraringtube hank cunsi5tc of vcriical
pin-tubes arranged in a staggered c o n l i g u ~ ~ ~ t i oTo
n . :1\oi11 :in! risk nf vibr;ltic,n
problems supports are arranged.
The flue ,oas passes through thc deflected tuhes at thc hott4oni t b f the Scrcsn \valI. u p
through the generating tube hank and out t l ~ r m ~ gtlie
h sniokc outlet \ > < I \ .
An effective circulation in the boiler is :rchieved hyc ~nc;iricof diiwii cnrncr:,.
The bottom rube plate is first co\,ered with coat o l insul;~ti~,ii reSr:lcton :tnd ;ibo\.i.
with castahle refractory.
Access to the furnace is possible ttuougli tlie access door ~t r11c b~>rroinof lli?
furnace. Further inspection to the yeneraring tuhes is possihle throurti the inspcctioli
door at the hottoniof the furnace as well as the access door providcd on the flue g 3 ~
outlet box. Inspection of the generating tulxs is also possiblc ;it the inspection door
provided in the middle of the pin element section.
Irispection of the burner flame is possihle through the tlro insptxtic~tllinlcs i ~ m ~ ~ n ~ e i i
in two heifihts on the furnace pancl wall.

Principal drawing of MISSIONTMOL boiler --

Inipeci,oo I i

h c i c c ? do?(
Boiler mountings

1 Mountings
T h e following is a brief description of thc most import:lnt items o f the hoiler
mountings. T h e components mentioned in t'iis secrion are referririr to the reneral
arrangement drawing of the boiler.
Safety valves
T w o safety valves are fitted to the pressure vessel o f the lwilcr. They arc inst;:lled
for security reasons, and designed 10 prevent the boilrr pressirre fr(im risinr obove
Ihe design value.
T h e safety valves must be supplied \vilh w s t ~stearil pipes and e1111eirxp:lnsion
devices, or k l l o w s .
Main steam valve
T h e main steam valve is a shut offlnon-return valve. \'vrhen clnwcl. 11 isc>lates tile
hoiler from the main steam lint.. \?'lien open. i t pri.\,enis t i n troni f l o \ i i n r
hackwards into the boiler.
l3y-pass valve
T h e by-pass val\,e is a shut off v;tlve. Thc puiposc of thc \,alve i \ t o sq:r:il~zc ltii.
pressure k t w e r n the boiler and the steam ;!stern \\.lien tile innin ctciim \.;iIvc 1 5
closed.
Fecd water valve 1 feed water val\~e(sdnr)
T w o groups of feed water valves are prwided in the hniler. Eacli ~ o u cori~priccs p ;I
shut-off valve and a non-return valve.
. .
T h e shut-off valve in the ordinary froup must bs opcn when thr hnilcr I S rri
operation. or if the boiler is used as a steam drum^
T h e shut-off valves should he closed w h c n thxt hoilcr i s not i r i u c r .
Water level gauges
T w o local water level gauge5 a r t connccled to thc. iron[ c ~ riir i hoilcs. r.;rs:li f~11r:c
h e i n provided with two shut-off \,alvts and ;!dr::in s;iIvr.
T h e shut+ff valves. lilted at the top and hcttoin o l !lie xieiit pl;tss. Ih:i\r .t quick-
closing mechanism to k used i l l case of b r o k n ?lass.
T h e pipes from the drain cocks on the \i;rtcr :csel g : ~ u vr i i t r i t l e d I < : n l i or',vn drain.
\,isible for inspection.
Blow-down valve
T u o b l o w d o w n valves of the shut-oifinon-rcturri t!.p? are mi\~ttiled; I ( ill:, i),ltrnr~ii l l '
the hoiler M y .
T h e shut-off function is for rccurily and tlic non-setitrti fltiictioii prr\,~.iit<
steamn/wa~erfrom flowing into 211 empty hoilcr !,I iiiii[aLtz
Air valve
Ths airlvcntilation valve located on top o i rlic boiler is 3 sli:~r-c~ffi n l \ c . It i h
normally closed except when the hoiler is k i n g filled or conipletely d m i n r d Tlic
cnd of the drain pipe from the air valve must hr \,icildr in c>rilerto tlct~rminc\!lic~i
water or steam is coming out.
Scum valve
The scum valve is a combined shut-offlnoll-return val\,e. I n the evcrit of scum in the
boiler, this scum can be blown off from (he water surfact hy i)penin$ this val\,c.
Valves for WHR inlet and outlet
The boiler is provided with two circulation valves for inlet and clutlct connections to
the exhaust jias boiler(s).
The valves should he shut-off valves. and depending on deviatic>iis i l l the sysum.
these valves can also have a non-return function.
Saniple valve
A sample valve is installed enabling connection to 3 sarnpl? conlcr tor tnkinr ccct
samples to perfomi boiler water analyses.
Insrpection hole
Two small inspection holes are provided in rhe furnace \\.;ill to en;~bl?inspection of
the burner flame. A proportion o i the air supply is bled off from the hurncr fan to
cool the window of the. inspection hole. and prevent soot tiepns~ts.
I n m t i o n door
The boiler is provided with two inspection doors t i ) cn;~hl? 111spectiori 01 [hi.
generating tube bank.
Manhole
Two manholes placed at the hoiler top and hoilcr hortorn : ~ l l i ) i iirisiJr inspcctioti 01'
the steadwater drum.
,Access door
Access to the furnace is possible througli tile access door plnczd a! tile hotton? or tile
furnace.
Drain for frunace
-
The furnace bottom is provided with a six kc^ for drain or tlie \vasliini '.\.I ircr.
Waiter level controll

1 Description
The water level control is a modulating systsm 3t this type nf boiler. The system is
illustrated in Figure I . The safety device system for too lotv water levrl alarm and
hurner cut-out consists of an external chamber with n lcvel float switch. For
measuring and control of the water lcvel, the boiler is equipped with a dp \rater level
transmitter unit. which includes external v2ference 2nd variable l e ~ s .and a dp-
transnlitter. The continuous 3-20 mA ou~put signal fro111 ttic dp-transnutter is
processed in the control system. which prolidrs le\.cl wamincsialarms :!nd control
of the replating feed water valves.

Water level contml system

-
Gauge board
1 Description
The function of the gauge board is to control the burner and tc rive 1;inrniny and
alarm for low and high steam pressure.
A pressure gauge is fitted for analogous reading of the actual steam pressure in
the boiler. The pressure gause is 1oc:lted on the local control pnncl
A pressure switch "high steam pressurs" gives :~larmand cut-on the humer
when the steam pressure rises abovs t!le pre-adjusted set point (one set point in
high pressure mode). Furthermore. the pressure s\vitch locks the humer in stop
mode. Operation of the burner is only possible when thc stcam pressure falls
below the differential set poinc of the preqsurs switch and thc alann is reset.
4 pressure transmitter connected direct]) on the boiler converts thc :ictunl steam
prcssure of the boiler into corresponding electric signols. The sirn;ils are used to
give warnings for lowniifh stsam pressure and ;~l;~rnfi/humcr cut-off for !iicli
steam pressure.
A pressure transmitter is located in tht: main stenni iinc The tr;~~~srnitter is
conunon for both hoilers and converts the ;~ctunlsteam pressure i n the common
steam line into corresponding electric sig~;ils.'The sigl~alsarc rlred to give
\r,ltmiogs for lowhigh slearn pressure :]nd : ~ l ; ~ r n ~ / h u rcnt-off
~ i r r for high steam
pressure. Furthermore. the signals are used to control st;rfi'stop and rncdulation
set point of the burners hoth in lo\<,and high pressur- mode. Thc signals from
the transmitter are also used tn contl-ol t11.z master/sl;~\~c operation.
 Table of contents

Operation and maintenance

Startlstop of the boiler ---

Boiler maintenance

Roiler maintenance ................................................................................................ 1

Inspection of the boiler ................................................................................ 2

Boiling out ~ .--.

~

Roiling out .............................................................................................. i

Water washing

Soot blowing
. .
Dzscnptlon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(:]caning procedure ....................................................................... ...... -
7

Preservation -

T'rcservation of boiler ......................................................... . I

Boiler repair - plugging of tubes

--

I'lli~yinzof tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

Boiler repair - refractory

Refractow repair ............. .. .................................................................................. i

1
hlaintenance of repair ....................................................................................
Lighting-up curve --

.~ L
curve ....................................................................
12iEhtinc-up . . . . . ............... I
Start/stop of the boiler

1 General
- --

The following chapten of the instruction manual d e s c r i k the operation and

maintenance of the presstire part. As this is only a pan of the conrpleie hoiler plant.
it is important to study the remaining chapters in this manual v e y thoroushly. It is
especially important that the opemtor of thr boiler plant becomes l.:~miliar \vith the
operation instructions of the burner and the control panc.1.

Important: T o ensure a safe and reliable operation of the hoiler plant, 311
operation and/or maintenance of the hoiler should he carried out
only hy skill personnel.

Start-up

When the boiler is started, the lighten-up raw of the hoiler must n u t ix ~icci.Ic.r~tcll
too much as this might cause an unncceisar! overstrain the hoiler m:lt?rinl by quick
and uneven temperature rises. 11 ~iliglit b~ necessary t r f 3 i r ~ l ~ i ~ h01'c r
stadstop sequences to reduce the lightrn-up rate.
Before start-up of the boiler plant. somc general work and clieck proiccl~in:(.1111rsthe
considered.
Step A: Check that the main steam \.aI\.s. by-pass valve and c i r c i ~ l ; ~ ~ iv:?lves
on I!
provided, scum valve. and hlo\r-down valves are cl(>red.

Step B: Open the iccd water valves and ills . ~ i valve.

r Fill hciilcr w i t h evaporalc-d
ill?
water to approximate.ly 50 mni belo~vnonnk~lwater lcvcl The w:itc.r lewl
rises due to expansion when the hniler is hea!c.il lr thr tempcr:lture
difference between the hoi1t.r and f?ed tvairr exceeds approxirn:~tc.l\5 i V ' ( -
the hoiler must he filled w r y slt~\\ly.

Note: When fillin:: a pressure lcss boiler. thc <hut-off \ a l \ e aftcr the feed r\:lter
pump must be throtlletl. O t h c n \ i s e the p u m p motor w i l l he o\erloatlcd.

Step C : Check the w;lier le\.el ill tlie \r.iter l r v ~ lg:rug?s. (~'liechtr~queiillydurini.
the complete start-up. The ivnter level gauges slioulcl hc lhlnivri d i l i ~ n
several times to ensure a correct i ~ i d l ~ a t i o ~ i .

Step D: Check that the water level contrnl system is cnnnrcird and opcrati~~nal
Stel) E: Check the oil system and start the fuel oil supply pump. Pri.-li?:!t thc illel oil
if the burner should operate on heavy fuel c)il

Step F: Check the burner and the safet) functions nccorditlq ril ti:? icpnrxtc
instruction.

2.2 Start and pressure rise

The following work procedures nlt~stiw follc,wed during str~n-upof t h boiler.

~
Step A: Chcck that the gauge hoard valve and pressure gauge ..:ilvzs arc ilpenrd.

Step B: Check that the air valve is open if the boiler pressure i i iwlo\v 1.0 hrir.

Step C: Start the burner on manual control and on la\v load. ('heck rliat the water
level does not rise too high during tlie pressure rising pcriorl.

Step D: Drain via the blow down valvcq if tlie water level is too Iii!:li

Step E: Close the air valve when only steatxi blous out. ,A presstire rending should
be indicated on the boiler pressure range hefort t l ~ ci~irv:rl\'e is closed.

Step F: Tighten all covers such as mi~nholes. hand holes. inspection iloors. etc.
during the pressure risins pcriod. If required. chcck :ill flange iciints on the
plant.

Step G: Change to automatic control of tlic humer \\.11cn the h81ili.r prcsure is 0.5
bar lower than the worliinf pressure of the boiler

Step H: Open the by-pass valve slowly to tier~t-upand pressurise rhc sti'Lirn sysrcri!.
If the boiler is not provided ivith a by-prlsi \':11vc. tll? mxin stearn vaI\.e
should be used to heat-up and pressarise tlie steam ryti.rii.

Step I: Open the main steam valve and close the by-pass \,:ilve.

Step J: Open the valves to the stca~iiconsumers c;uefiill\i ill iirilvr t i , :I\ oitl \vaier
chock?.

Step K: \Wien the boiler is i n normal i>per;~tion,

chcch th;ir rlic \ialcr l t \ e i c(mtrol
system and the gauze board functions ;Ire f11IIy oper;i~i(~n;il.

-- ~

Note: After 3-4 weeks in operation. mucl :an11 deposits in the piping system ma?.
have accumulated in the hoiler water. This may cause lcvcl variations
which disturb the steam generation, a n d it is therefore r e c o n ~ m e n d e dto
blow down the boiler. It should then he inspected. cle:inrcl. anrl relilled
with boiler water.
Boiler stop

3.1 Normal boiler shut down

If necessary, the boiler can be shut down at any load without rpeclnl prcparutions

Note: When the boiler is stopped, sudden temperature and pressure drops
should be avoided a s they might expose mount in^. pipe lines. a n d the
boiler plant to inadmissible temperature gradients.

S t e p A: When minimum load is obtained, stop the burner.

S t e p B: Keep the water level at normal level until the hoiler stc~psproduciny steam.

Step C : Stop the feed water pump dnd clote the feed water i ~ 1c,k
1

Step D: Close the main steam valve

3.2 Emergency shut down

The boiler must be taken out of service immcdintely ii:

pans of the heating surface have heen flowing or thr boiler >Roui rzcognisahlc.
deformations. The supervising authorities must he infor~ncd,and the hoilcr mu\t
not he used until approvnl from th?si. authorities is :~\,ail;ihl?
a substantial loss of water is noted
the feed water system is unable to provide the n e c e s s q amount of feed water.
e.:. due to failure of p a t s
the safety valve cannot function
sudden cracks or damage are notcd in the refr;ictory, and if sienin or ~noistureis
coming out of the refractory
oil in the feed water is detected
If an emergency shut dowl~must be carried out. the fuel supply sl~ouldhe stopp~'d.
The main steam val\,e should bc closrd yriidually. and the hoiler inust he cnnlcd.
Thc safety valves must not l x oper:ited. Parallel \sork~nr hoilcrs shoi~ld k
disconnected at once.

3.3 Stop for repair or inspection

The following describes the rneasures to be taken u'lien the boiler is shl~td o u ~for~
repair or inspection.
S t c p A: Clean the boiler from coot \I ith \r.;itr~

S t e p I%: Operate the burner for at least I5 nijnutes after the boo! removal ti: dr)' out
thc remaining water.
Step C: Stop the boiler as mentioned przviorlily

Step D: Check the fumace and the pin t ~ ~ b with

e s regard to cleanliness.

Step E: Empty the boiler from water and clean it. Check i f lime stone appears

Step F: Check and clean the outer littin~s.Change gaskets wl~srerequ~red

Step G : Clean the feed water tank 2nd feed water plper

Step H: Clean and grease the h e a r i n ~ sof motor. pump, and far!.

Step I: Check and align the burner, if necessay

Step .I: If the boiler is shut down for a lonz period of time. the pin t u k s mu71 k
thoroughly cleaned.

Step K: Check that the necessar). spare pans are available. Order c n r n p i e m e n t a ~
pans in time.

Warning: I t is of extreme importance that the boiler is & O T operated n i t h o o t

w a t e r when the oil hurner is in operation, e.g. due to tlisconnection
of the water level safety devices. Thi5 will immediately c a u w
complete break down of the hoiler.
Boiler maintenance

1 Boiler maintenance
The boiler maintenance should always be exrcuted with skill and in accordnnce with
valid rules and regulations from the aut!lorities, and helow ;Ire $ \ e n some
recommendations for periodical inspections and maintenance.

1.1 Daily operation

--

During normal operation of the boiler some work ~tndcheck proccdnrcs 113s to be
considered every day.
Step A: Check the boiler steam pressure and the water l e ~ e l

Step B: Check that the feed water control system is c>p?r:~tic~n:rl.

sec separate
instmctions.

Step C : Check the boiler water condition and ni:~henecessay count~~miensures with
regard to the feed and boilcr \vatcr treatment. If neci:isary hl~~\v-do\vn
the
boiler.

Step D: Check the function of thc oil hunier : ~ t different r:ip;iiit~i.i t h r i ~ u ~ the
ll
inspection holes on the boiler.

Step E: Check the flue gas 1emper:tture nndlnr draft 105s aCter [tic holler. lfcither the
temperature or the draft loss is too high, the pin-iul,c .;:ciinn must he
cleaned.

1.2 Weekly routine checks

Slep .4: Drain each water level glass for about lilbl5 scconcii
In case of contamin~redboiler water or insufficient \rarer tre:~rti~t:~it.
t/le dr:iilli~l~
of
the \\,ater level glasses must he done more nfrcn.
Step R: Check the safety water leiel de! IC?

Step C : Depending on the boiler water tzsts blo\\zn-down rlic Ih11t.1 Opcn the blow
down valves quickly for ;l few secend~.and thlrli ilost :~ndiopcii amin Cnr
about 5-10 seconds.
Repeat this operation when required ncccording to the holler ulit:r li'it\

Step D: Scum blow out by means o f the scum valve is m3de MIICII rilquir-etl. Thc
scum hlow out must he camicd out until the drained \<:itcr i' slc.:~n.
I.3 Monthly routine checks

Step A: Test all stand-hy pumps.

Step B: Check all boiler mountings l o r d a m a c e i>r leaks and repairireplace i S

necessary.

Step C: Check the function of the high steam pressure s\vitclr by lowering the set
point or by raising the steam pressure. e.g. hy closinr tlie main stcam valve
slowly.
T h e burner shall stop aittomatically.

lnspection of the boiler

2.1 lnspection of furnace

.. -- -

T h e furnace should be inspected at least twicl: a year. D u r i n this inspection thc

following issues should be taken into consideration:
Check for cracks at the refractory lining and that the furnace \~:1lIsarc free frnm
excessive soot deposits.
Examine carefully the area opposite the homer. Ton ~o
tii11~11 o deposits
t indic~~te
that the burner should k adjusted.
Check that the p i n - t u k elements are iiitact and that soor dcpoiits are ivitlrin
normal limits.

2.2 lnspection of boiler water side

T h e hoiler water side (interior) must be carefully inspected at lens! twice a year. This
inspection of great irnponance and no tlouht the most important of a11 the
maintenance measures, since it 113s a direct influence on tlie l~oilerlonccvity and on
the security.
At these inspections, hard deposits, corrosion :~ndc~rculatinn~listurhanccscan lx
found ar an early stage. and preventive measures must IF taketi to avoid i~tiexpectcd
material damage and boiler hre:tkdo\r,n
I'resence of hard deposits at the furnace w;lll and the pin-tuhes rcduccq [heir 1ie;rr
transfer properties and decrease the capacity of the h~lilcr.
Further, i t is possihle to rnakc out if the feed watcr twatmrtir h:~i l x c n \.itisf:~ctorily
and if the h l o w d o w n has hem carried out sufficiently
Incorrect feed water treatment is commonly causing li;~rddeposits or c o r n ~ i i o n .
Insufficient hlotv-down will cause sl11d~:e dcposits it1 ~ h rithr.:
? and nccrtrnulntion (lf
sludge in the hottom of b i l c r .
If hard deposits are not removed. it may lead to ovi.rIic.atinr i n thc hoiler plate
material which is exposed to tlic flarnc in the furn;rcu ir.;ill :ire:i Tliis may ci~usri
material damages.
Incorrect feed water treatment does not : ~ l w a ylead to hard dcpositc. For ex:~mplt..:I
too low o r too high 3 pH-value may pive an electrolytic reaction. c:lusinc corrosion
in tlie boiler.
When tlie boiler interior is inspecred. examine 311 p;lrts c;irefi~llyr ~ t ~lw
d :itrcntii.c ( ( 1
deposits, conosion and cracks. It is :~dvisablero pay spwi;11 ;~ttcnti~ln to tlii.
inspection. If any unusual signs are found. contact Aslhorg hidustrirs ar oncc for
advice.

2.3 Procedure and remarks for inspection

Step A: Shut off the boiler and allo\v 11 to c o d cbelou 100 ' C I

Note: T h e boiler should NOT be depressl~risedby lifting the safety val\es and
then filled with cold water since the stress irrtlrlcetl 11y too rapid cooling
may cause damage.

Step B: Empty the boiler and close all v;~lves

If the boiler is connected to a second boiler. check th:~rrhe vn1i.e~l ~ t i v c c t it h m i arc
closed.
Step C: Unscrew and remove the manhole h~tcli(s)011 the hoiler and cntcr the hoilcr
when it is sufficiently cold.
Check the welding in the boiler. .4 careful examination should hi, carried out u i t l i
respect to any possible corrosion or crack fom~ation.
Special care should be taken to the water line are;i in thc. preisure vt'cicl iiiierc
oxygen pitting rnay occur.
If deposia are found to be forming in the hoilrr tuhcs. the hc>ihrr ~ l ~ i i i ~ I,l< i l
che~nicallycleaned.
It is advisable to consult a company of c l e ~ n i n yspecinlists \iho will cx.:!:ii!nc tllc
hoiler deposits and treat the hoiler accordingly.

Note: After chemical treatment the boiler shoultl he hlown-down a t least t\\-ice
a day for approximately one w e e k This will ensure that excessive sludqe
deposits due to chemical treatment (lo not collect in the Iinttnm nf
pressure vessel.

2.4 Contamination

1 i the hoiler is contaminated with foreign substancr~like i~il.sheniicali. il!rrt,,i~lii

products etc., it is v s q imponant to act inlnl,:di;~tely t o avoid darnarcs to rt!z hoilcr.
Layers of thin oil films, mud, etc, cxpored to tlie heatinp surr;icc\ L.:I~ISC.; :I h:~dllcLlt
transfer in the boiler. leading to overheating follo\vcd h) hutni,d O I I I preksurc. j1;1:1\
In order to remove such contamination, ;I lboilinr 0111 or atid c l ~ , : i n i nII:IW
~ t i 1 I>:

performed immediately.

Note: Corrosion products from the pipe systeni o r insufficient hnilrr water
treatment rnay result in corrosion in the hoiler itself. It is thervfore
i m w r t a n t to ohsewe that such circumstances do not occur in t h c system.
Boiling out

1 Boiling out
Before putting the boiler into operation for the first time. it should he bniled out to
remove all protecting remedies and impurities on the boiler ivaterside.
The boiling out procedure is recommended til he cturied out ns described k l n \ s :

Caution: Extreme care sho~ildbe taken w l ~ i l ehandling the chemicals. T h e

person handling the cl~emicalslsolution choultl l ~ e properly
dressedlprotected.

Step A: Fill the boiler with a solution consistin: of 5-5 k~ trisodiurnphosphnte

Na3P03 per lfKKl kg water. The chcmic:ils can h- ~itldeci t h r o ~ i ~tlilt
h
manhole.

Step B: Add feed water until the solution is ~ i i i l l l ein tile uilitr y:iu:ei aho:,e
"lower water level".

Step C: Closc thc feed water \.;ilve (pump s ~ o p y e d )

Caution: Do never !ill feed water into the boiler if the temperatlire difference
behveen boiler and feed water exceeds 50°C.

Step D: Raise steam pressure slowly to working pressure. and keep thc pressure irlr
approx. 3-4 hours with closed main steam valve.

Step E: Scum until water level is hetujeen "Norm:ll ivii1t.r lc\.el" ;tntl "l~lirhh,titcr
levcl".
By this procedure gre.ase and o h e r impurities are rerlli~\cdf r r ~ tihc
i ~ internal \url:ic~.r
of the boiler.
Step F: Starts skimming by opening tile scum v a l ~ ? .and i n \ i i . ~llic \ i . ~ r ~ 1cvc.l
i iic
lowcr edge of "Normal water l e v ~ lmark
'

Step G: Close the scum valve

Step H: Refill the boiler with feed warer ;inj start shimmirlr nc:iln in inlcn;~l.;01' 30
minutes for a period 01two lic~trrs.

Step I: Stop the boiling out procedure hv switchin; off tlic humcr

Step J: Let the hoiler waler rest for ahout five rninult-
Step K: Cany out a final skimmin:

Stcp L: Blow off the boiler water hy opznlnt the hlo\v doicn v,iIbc\

Step M: Remember to open the air escape valve. to avoid a vacuum in the boiler
when the boiler pressure falls hack to approx. deprtss~~riscd/~~tmosphcric
pressure.

Step N: Open the manhole and lct the holler cool down to appro\ 1(tO2(

Step 0:The boiler is to be flushed with clean watcr on the boiler waterside, when
the temperature has decreased. The flushing removes remaining impurities.

Step P: Take the bottom blow down valves, to pieces for cleaning and inspection
because depositdforeign substances \\-ill i~suallyhe nccumulnted in these
valves and cause leaking if not cleaned.

S t e p Q : Inspect the boiler and remove any remainin deposits :ind forei~m
substances.

Stcp R: Finally, new gaskets to be fitted in all hand- clnd manholes before retillin:
the boiler with water to upper edge of "Lo~v\v:iter le\.el".

T h e boiler is now ready to he taken into s e n i c e .

Note: During the first two weeks in operalion we recommend lo c a r n out

frequently skimming ant1 bottom hlow down to rernovc impurities
entering the boiler from the pipe system.
Water washing

1 Description
In order to keep the heat transfer area sufficiently clean the hoiler is d e s i ~ n e dwith ;I
high flue gas velocity through the generating tuhe bank.
However, after long term operation, e.g. durins combustion of poor quality oil or
with reduced combustion quality. deposits can he fomied on tlie licoting surface. As
most deposits mainly consist of non-soluble particles, which are held togeth?r hy a
water soluble bonding material, it is possihle to clean the hwting surface with water
washing.

W a t e r washin:: of the generating tube hank

Smoke outlet

Drain

--
Figure 1 ol_wash.ctir
The MISSIONTh' OL boiler is easily cleanetl from the smoke nutlet b(,x will1 a water
hose. When water washing is carried out thr boiler niuct he nut o i operntion and the
boiler temperature below 1lO" C.
After the water washing is completed the refractory at the furnace bottom must he
cleaned with alkaline water due to the washing water is very corrosive. 11 must be
observed that all the washing water and loosened deposits :Ire removed from the
boiler.
When rhe water washing has besun it must k completed s o that all deposits :Ire
removed. This is because some types of coatings hardens and accordingly gets very
difficult to loosen when they first have been saturated and then d n nut.
The boiler must be boiled out inlmediately after the water washing lias k e n
completed in order to avoid damage on refractory and heatin? surfaces. The boiler
must be lighted-up and pressurised as described in the chapter "St:trtlscop of lhe
hoiler".
 Chief Engineer Survey Report

Subject: Auxiliary Boilers Soot blower Interlock

Reason: DNV Condition of Class
Date: 28. March, 2011.
This is to c o n f m that today 2gthof March 201 1 the Aux. Boiler #I and #2
soot blower interlock installation is completed and tested.
Test is carried out by me chief engineer Dusan Anic in presence of first
assistant engineer Sergey Kibirev and electrician Manuel Sao Marcos.
Test is carried out by starting IGS from Cargo Control Room and when the
1 8 s started the hydraulic actuators closed the soot blower stem valves.
All testing found in good order.

Chief engineer
b a n Mic
Soot blowing

1 Description

Generally, there will be a self cleaning effect of the generatins tuhc bank due to the
high flue gas velocity. However, deposits are formed on the heating surfaces. e.8.
due to combustion of poor quality oil or reduced combustion quality. These deposits
\\,ill accumulate on the heating surface of the generatin? tuh* h ~ n kir not removed by
cleaning.
The MISSIONm boiler is equipped with soot blowers for cleanill$ o f t h e feneratins
tube bank. The soot blowers are manually operated 2nd are nrr;lnged for direct
connection to the steam system of the ship. In order to obtain ;in efficient soor
cleaning. the steam pressure must be at nonnnl working pressure. 17urthemlore. the
boiler load should not Lw lower than 50%. This ensures a sufficielitly llifli velocity
of the flue gas. which is necessary to cany loosened soot deposits c~ulnf the hoiler.
Figure I shows a soot blowing arrangement.
Because of the varying combustion parameters. i t is impo.;sihlt to ipecify exact time
intervals hetween soot blowing. In general soot hlouinr is ri.coriimendcd every 24
hours.

Note: Excessi\e soot bloning by means of \team rninl~tcatlcc erosioo damage

on the generating tube bank.

During operation of the boiler plant. the operating persc>nnel shuuld determine the
necessity with regard to time intervals for soot blowing. This interval should then he
increased or decrease.d to fit the specified plant.

2 Cleaning procedure

Step A: Check that the steam pressure is at nonnal \vorking pri.iiir~

Step H: Check that the main valve flir <not lhlower ;ind ~ l i rI \ ~ . I > ni:~nil:lll! opcraied
hall valves are closed.

Step C: Opcn thz drain valve to drain ware- fro111 rhc rn;~iliI I I f~ ~ , r:I Seii; seconcls
arid close i t again.

Step D: Open the main valbe

StcpE:Open the lower manually nperated hall val\e .inti soot hlow I ~ ) I ~
approximately five seconds.

Step F: Cloze the lower manunlly operated ball valv~'.lcnln

 S t e p G : O p c n the upper manually t>prr:~ted h;~ll v:!lve :~ntl so01 hlnw tbr
approximately five secclnds.

Step H: Close the upper manually oper;~tedhall v;llvs acain.

Step I: Repeat step " D to "G"3 4 tim-s.

Step J: Close the main valve.

Step K: Check that both hall valves are closed.

Illustration o f a soot blowing arran,vcrnent

....-.-------

On sr-': 31 moues:

Figure 1 s o r ~ t h l u na.crlr
l

L l n c ~ ~ n cUK
c Pncc 3 2
Presewation

1 Preservation of boiler

If the boiler is to be shutdown for a period of 1-30 days. it sllould be top filled to
prevent corrosion. Before top filling, it should be cleaned from soot deposits.
If the boiler is to be shut down for Inore than one mnontli. different methods lo
prevent corrosion can be applied:
Dry preservation
Wet preservation.
Nitrogen preservation.
The work procedures related to each of- these preservation method\ are described in
the followin_g:

1.1 Dry preservation

When applying this method the boiler is totally emptied of water and dried out,
Step A: Emptying the boiler of water is done by bottom blo\vin$ Ihe boiler at 3-5
bar pressure. opening the boiler and drain in^ it of remaining water.

Step B: Manhole doors and hand hole covers to he opened 2s long as the boiler is
hot. and if there is water left in th? bottom it h a r,, hc. rtnlnved. e.g. hy
using a vacuum clcaner.

Step C: If the boiler is cold, drying of the boiler is done by fither circul:iting dried
air from a fan or by placing bags of silicayel in the boiler.

Step D: Before closing manhole doors. place a tray \vith burning ch:lrcnaI to remove
oxygen. As soon as you have placed the charcoal. close rnanliole doors with
new saskets.

Step E: Alternatively, n small steam phase inhibitor is to he added lo 111e hniler after
coolin? and careful draining. and [he hniler car1 :~fier\r,ardsIx closed
completely.

1.2 Wet preservation

--

While dry preservation is a question of draining off water t i ~:i\cld corrosion. tht
principle of wet preservation is to prevent oxygen from entering the h(7ili.r.
This method can bc: used for a short period of 'lay-up' I I-? monthsi
Step A: The boiler is filled with treated boiler water :rntl hvdr:rzine is added until an
excess of 100-200 PPM is obtained.

I-injiunee 1IK Page If2

 c: ""'$%G
I N ' E 8

S t r p R: The water should be sirculate~dcontinuo~lslyor at least once per \\ri.ck to

avoid corrosion from any penetration of oxygen, and it is necessiir!. to
check the hydrazine concentration and add the necessary amount to h:ivz an
excess of 100-200 PPM. Other oxygen binding agenls can he used. too.
The pH-\-alue should be 9.5-10.5.

Note: If there is any risk of temperature falling hack below P C , this method
should not be used to avoid frost damages.

As this preservation method involves applying hydrazine to the water inside the
boiler, the hoiler must be completely drained and refilled with ;I frcsh watcr before
taken into service again.

I.3 Nitroqen preservation

The hoiler has to be drained. dried and sealed in the same \<jay 3s mentinned n b ~ v i .
under D q Preservation above.
S t ~ A:
p Make a connection to the boltom of the boiler arid open air escape valve in
the top of the hoiler.

Step B: Connect cylinders with nitrogcn to the bottom via ;I reduction vnl\,e :~nd
purge the hoiler until you are sure that no oxyqen is I e f ~

Step C : Close air escape valve

Step D: L a v e a cylinder with nitrogen connected to the hoiler via reduction \.airs
and keep an overpressure of approx. 0.2 hw in the hnilzr.
 -
Boiler repair plugging of tubes

1 Plugging of tubes
In case of a leakage on a boiler tuhe. tlie burner must he stopped and tlrr pressure
lowered to atmospheric pressure.
If the leaking tube cannot k located immediately the boiler should lx set on
pressure by means of the feed water pi~rnpsso that tlie leakare will indicate whiclr
tube is damaged.
Step A: When the boiler is empt~edof water rernoLe the manhole covcrs in the
steam drum and the water drum

Step B: When the damaged tube is loc;~tedit must be pluggsd wit11 3 coriic3l tube
plug. Before the tube plug is mounted clean the inside of tlic tuhe ends with
a steel brush, so that nodeposits are present in the tulv.

Step C : When tubes have been plugred those should he renewed as soon ;IS
possible. Plugging of tubes results in reduced efficisrrt hrxting surface arid
accordingly the boiler erficiency will decrease.

Note: Temporary repairs require more attention than a normal working

boiler.

1.2 Plugging of furnace panel wall tubes

When rt furnace tube has been plugged the funlace side of thc. darn;iged tuhe should
he cut vertically along the connections with the fins k t w e e n the tnhcs in tht- ~ 3 1 1 ~ 1
w311. see Figure 1.
Inside the rest of the tube and on the llns ncxt to the darnilgcd 111hen iii~rnherof
anchors of heat resistant or stainless stccl must he \\,cldcd on^
After\vards erection of refractory asainst tl~rdamagcd tuhe ;~ndtlrc n c i ~ h h o u n n g
fins must be canied out in tlie ft~llheighr irrsids the fum:ice.
 Plueeine of furnace tubes

I t is possible to replace thc furn;~ccpancl w;~llrubes frcun the ouislde o l the hoilcr.
Alter location o f the d a m a y d tube or t ~ i k s tilose
. must hc r~:pl;~ccdaccording to the
follou.ing procedure:
Step 4: Adequate amount OF insul:rti~>n.lrou:id [lit d;~mnycilp;~nel\ \ ; ~ l l tuhts sllor~ld
he removed.

S t e p B: T h e damage tuhrs milst he cut rirht helow nntl ;alxi\c t!ic 1111*- plates

S t e p C : Afterwards the tubes arc rcnlo\i.d hy curtin? 011t In t l ~ viin.

S t e p D: Scraps of met31 nr \veldins in the lube h o l c ~2nd tilt: tuhc [11:1te< 11iust he
.qind off.

S t e p E: T h e new furnace p;lnel wall ~ u h nc u ~ s the uc-ldi.d or1 :ii illc'\r,11 ill Figure 2.

Lz!lpu.?ge UK Page 3 4
 Figure 2 plu:02.cclr

1.3 Plugging of generating tubes

P l u g z i n ~of the generating tubes are sho~vni n Figure .;.

IJp to 10% of all generation tubes can he plug_~ed\iith ;I c<>liic;tlplus hlir if inore
tuhes are damaged, an exchanyc of tubcs are necessary.
When the ~eneratingt u k s are replaced a n openins in thc s r ~ r r o ~ i n d ipanel
i r ~ u.;rli
rnusr he cut according to the s:ime proctdure ar descrihcd i n sc~.rion1.2.
New pin tubes are build-up one by one by \\eldin! i i r ~lo tli' tr~kpl:~rcs ;IS 5hown in
Figure 3.
The tubes are inserted 5-10 nlm in the l u k plates lwfori. \vcldine i n ~ i ~ the l e tuk
hole. During assembling the supports :Ire m a n z e d and :~djustttl.
Finally the opening in the panel wall must bc rebuild :IS dcscrihed in section 1.2.

Lingunpe VK Page 31J

Plugging and replacement of the generatin:: tuhes .-
 -
Boiler repair refractory

1 Refractory repair
-.

The furnace floor is lined with an insulating material (Vcril~lcRh). close to tile
casing covered with a layer of castablr refractory (Plicast i I I.
The refractory is made with expansion joints. which slior~ldilnd?r no circumstances
be blocked or filled on purpose.
Even though the refractory is made with expansion joint<. i t \ \ i l l tend to mlike
additional natural expansion joints, which \ r i l l lx seen 3s fissurc.i. tlowever. the
fissures will generally close when the boiler is put into servist. Please note the
following suidelines when examining the fissures:
whiteJlight fissures. which are gettin: darker over- the tirlic :~ndarc closine \vlit.n
the boiler is in service and opening in cold condition. nsrd no Tiifl11t.i 3rtsntion.
darMblack fissures suddenly occurred, seen in cold condition and :Ire not closing
when boiler is in service nced to hc repaired!fillcd up i r ~ t hrcir:iitory ~Plicast
31).
All refractory subjected to wear will. ~ventually.nerd to he rep:~ircrl Th15 can tr.
done as 3 temporary repair or on 3 pennnnent hasis.

1.1 Temporary repair

Smaller areas can be temporarily repaired makin: u>e o I the rrp;iir 1111~l'listix 1-1.
supplied separately with the boiler equipment
The durability of such a repair depends on the loc:~tion, hut tht: Inore exposed to
heat. the shorter lifetime. Generally. i t is recr,mmended to replncc n ternporav repalr
with a repair on a permanent hasis within one year.
Teniporary repairs in vertical places ought to he made 'sw;~llo\vtaiivd". see Figure
I . if possible. This secures a better atraciiment to tlic chistin: rci'raccor!.

Sketch indicating a "swallow tail" repair -.

., . . , ., , ... ,
' . . ,: , ,, , ..
,.. . ., .
The surfice to which the temporary repair is pefnrrnctl. mi~sla l \ ~ ; ~ Ibe
y s clean. d n
and rugged.
Mixing instructions for the castahle refractory appears froni the i~istructicnon the
plastic bucket.

Note: Plistix 14 must be applietl lo the site immetliately when mixed

The boiler can be lightened-up approx. I hour after the refractor). h n ~I)~:en applied.
The refractory needs no further time for hardening.
lf the boiler is pressurized, the lighting-up should be started with thc humer in "on"
position for one ( I ) minute and then in "off' for two ( 2 ) minutes, during the first
half ('h) hour. Then it can be started up according to the or din:^? lighting-up
procedure.

Note: Observe the safety rules regardin% the r e f r a c t o n lrhich can be reen on
the plastic bucket.

1.2 Permanent repair

Major repairs and renewal of temporary repairs sh;~llnl\v:iys hc carried out and
supervised by maker's specialists. among otilrr things seci~rin?tl1~11cerrecl drying-
nut time and lighting-up is ohscn~cd.

1.3 Boilers with membrane furnace wall

The refractory applied to a damaged mncmbr;lns furnacc \\,all nrust ht, carried out ns
shown in Figure 2.

Refractow aoolied to a membrane filmace wall

Furnace tube

,Pr Failed tube

Plicast 31 ," . .
B,i
p~ -.
Figure 2 pll~:refrac.cdr

Warning: Failed Y-anchors must only be replaced hy Y-anchor; made from

heat resistant steel. Y-ancl~orsmade from incorrect materials will
cause damage to the refractory.
Maintenance of refractory

Note: The refractory should he inspected once a year for 5hape and wear. I t is
reeommended to carry out an inspection in due tinie prior to long repair
periods such as dry docking, etc. Should a repair be required castable
refracton and bricklayers can then he ordered on short notice.

If the refractory has been exposed lo water. the refractop should hz dried out as
soon as possible. The dryins out can he (lone by hot air iapprox. 5O'C) or h y
operating the oil burner.

Warning: However, if the hurner is being used. the burner should he operated
with great care.

- -~ --

Warning: Generated steam evaporatetl from water absorbed into the

refractory might cause fissure$ and crackc when expanding. if tlie
heat input from the oil hurner i s too hcaty.

2.1 Typical refractory data

.- p~ -- -.

Below in Table 1 is a list of typical refractoy data shi>\vn.

Tahle 1
Lighti~g-upcurve

1 Lighting-up curve for MISSIONTMOL boiler

Figure 1 shows the lighting-up curve for the MISSlOWh' OL. When the burner is
started the firing capacity must he adjusted to match the liyhting-up curve. Funher
startlstop instructions is described in the chapter "Start/stop of the boiler".

Lighting-up curve for the MISSIOPh' OL boiler

-me i m n 1
- -. .-
Figure I rtartcur.ctlr
 Table of contents

Feed and boiler water

General .............................................. . . . . ......................... . . . . . ................ I
Layout of the treatment syste
Feed and boiler water characteristic
Feed and boiler water maintenance
Treatment systems I injection point
Feed and boiler water

1 General

Note: The recommended feed a n d boiler water characteristics a r e only valid

for boilen with a working pressure below 20 bar?.

There is a number of ways to produce got4 quality ferd \rater for hoiler plants.
Methods such as e.g. reverse osmosis plants or ion exchange plants p r d u c e good
quality distillate. Also evaporators generally produce good distill:lte. The important
thing is that the distillate used should k clean and \vithouc ioreirn salt
contamination.
In practice most distillates used contain t ~ n o pans
r of various s~rltwrnhin3tions
which can and must be cliemnically treated away. Furth~.rn~ore, thc Jis~illatemay
contain dissolved gases like for example oxygen (Oli and carbon dioxide tCO:)
which may lead to corrosion in tlie boiler, steam. and condensate system

Important: Boiler and feed n-ater must be c h e m i c ; ~ l ltreateil in o r d e r to avoid

corrosion and scaling in the boiler.

2 Layout of the treatment. system

The condition of the feed and hoiler water is an essential part of tlie lmilsr operation
and operation philosophy. The design and construction n i tlie treatment system
should therefore be considered carefully during lilyout of tlie pltlnt. Aalhorg
Industries gives some general requirements and recomrnrndatinns reyarding the
conditions of the feed and boiler water. Hou.cver. tlierc I S .;c\c.-nl \vays to ohlain this
results, or similx, by using different treatment systclns 'The fnllii\\,inr should
therefore be considered already at the layout ctafe:
- Choose the treatrncnt system that should he used
- Present the condensate and feed water s y t e m to thc supplier of rlic tr-caui~cni
system and inform about tlie operation pl~ilosoph!; of tile yliini.
- Let the supplier indicate where the injrction points itioi~iilhe Ioc;ltcJ 2nd also
inform if special equipment is required.
- Let the supplier infomi about which tcst fxilitics is nccd~,cl
- Purchase the recommended equipment and inxtall i t in the correct \vt~y

- LJse the treatment system as soon as thr boiler is takcn irlln iij??r;ltior~
3 Feed and boiler water characteristics

The following text regarding feed and boiler water treatment is tilt normal
recommendations given by Aalborg Industries. Tliess recommendations should he
followed strictly in order to have the best working conditions for the boiler plant and
to extend the working life of the plant. The requiremnentslrecomnieiidati(ins of the
various values for feed and boiler water ;ire listed in Table 1 th310~.~

Table 1
If hydrazine (N,Hd) is not used. scdi~inisulphate (Na,SO,') can ix- used inrtrr~d.:and
the excess should be 30 - 60 ppm.
In cases where other kinds of o x y p binding asents arc used, i t is rccolnmendcd
tli;~t an excess of oxygen bindins agents can bc measured ancl indicates that no
oxygen has been dissolved in tlie hoiler \vater.
If it is requested to measure the content or dissolved oxyct'n clirectiy. it is
recommended to keep the value < 0.02 ppmn.
In addition to the above values, the various water treatment companies u.ill add
further demands. depending on the mcthcd used for trcatnlent of feed and hoiler
water.
However, the most important point is that tlie ahove values or thcir cquiv3lents :lri.
ohserved and that a regular (daily) test of feed and boiler u'ater is cnrricd put.

3.1 Units of measurement

Concentrations are usually expressed in "ppm" i . ~ . pdns solute pzr million

Concentrations for p3rts solution hy weight ; r e the s:lme :IS "m~/lilre"

3.1.1 Specific gravity

,As guidance the following conversion [:an he used:
I Be" = 10.000 r n f l total dissol~.ec'solids (TDS)
1 mf/l total dissolved solids = 2 ~ S l c m
I pS/cm = 1 pmho
4 Feed and boiler water maintenance

The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together \\it11 the supplier of
chemicals for water treatment.

4.1.1 Daily

Step A: Analyses of feed and boiler \rater.

1.1.2 Weekly

Step A: Skimming (surface blow down) according to analyses. hut at least once per
week (2 minutes with fully open valve)

Step R: Blow down (bottom blow down) according to ;~nalyses.hut 31 le:ist once pzr
week (each blow down valve 1 minute in lo\\. load condition).

4.1.3 Monthly

Step A: Check the functions for salinity and oil detection systei?~r

4.1.4 Every six months

Step A: The boiler water side (interior) must he carefullv inspected ;It Ic-lct tivicc ;I
year.

4.1.5 Yearly

Step A: Check of the water side of the boiler and liot\\ell/de;~cratol--for corrocicin
and scaling.

Step R: Check the chemical pump unit,

5 Treatment systems I injection points

Ln the following tables and illustrations a number of different feed and hoiler water
treatment systems are shown together with the recommended location lor the
injection point of the individual chemicals as stated by the manufacturer. The
meneral information regarding the injection point principle can he used as zuidelines
C
lor the most common systems. But should there be any douht for a specific system
the manufacturerlsupplier should be consulted in order to ohtnin the corect result.
Notes for tabies/illustrations:
Note No. 1: the preferred injection point of c l i e n ~ ~ c ast.lted
l~ hy the
manufacturerlsupplier.
Note No. 2: the alternate injection point (of che~iiicals stated h!. the
manufacturerlsupplier.
Note No. 3. Valid for modulating feed w.lter system?
Note No. 4: valid for onloff operating feed water systems. Tile chemical pump
statts/stops together with the feed water [>u~iip.
Note No. 5: valid for two hoiler installation. Control of the chemicals in
question work properly at an equal load condition (feed \v:lter flow) oil the t\\,o
hoilers.
How to use the tables:
The tables can be used in different ways hut the main idea is to do followine:
Step A: Discover which manuPdcturer and type of clicniical~t h : ~ t sllnuld 1%: used for
the actual boiler plant.

Step B: Use the name of the manufacturer and type of cli~micnlsto select which
tables that can he used.

Step C: Check the flow diagrams (Figure I . F i ~ u r c2. or Firurs 3 ) to find a diamarn
that matches the actual boiler pl;tnt.

Step D: Find in the selected tables thC tahle which includes thc rnatcliing d i : ~ ~ r ; ~ r n

Step E: If more than one table is found to in:~tchthe actual hoiler plant in ql~estinni t
is recommended to use the methodltahle which includes note No. !

S t r p F: If no table is found to m:~tch the actual boiler plilnt in question i t is

recommended to seek assistance hy :he chemical m;inrrfnct~~rcrIsi~pplii.r.
 Chemical injection points
Ashland Chen~ical!D r e w Marinc Division
1 Table No. 1
1
I Pmtlac.1 name! method: II Standard with Drewplex OX
Chemical name I Injection point No. / Continuous 1 Batch I Note No. I\'alid flon diagram No.

P P

M a n u l c t u r c r i supplier: Ashland Chemical I Drew >larime Division

!

Prnducl usme i method: Standard with Amcrrinc

I
C h e m ~ c d namc
l I Injection polnt No. 1 Continuous 1 Batch I Note No I Valjd flow diagram No.
I

M a n u l ~ r t u r e ir supplier: Ashland Chemical i Drew Marine Division

1-
--

Produci name I method: Standard with Amrrrinc

Manufacturer / surrulier: Ashlaod Chemical I Drew Marine 1)ivision

. ~-
Ashland Chemical ! D r m hlarine Diviriim
1 Tuble N L ~
hlanukal-turer! supplier:

Producl name1 method: Drenplex T i OX

i!
C h c m i ~ namr
l Injection point No. Continnous natch Note Yo. \.;,lid flow diagram No.
Drca 1r.x AT 3 . 3 i~h I --!
2.2% ?h 1. ?. 4- i
-- i.2.;

h n ~ a r LIK
c Page / I ?
 Product oame / method:
ChenGc~dIname
D r e u y i e : n AT
-7cx OX
Injection point No.
2. 2a. 2h
3. ?a. 2b
Drewplex AT / OX
Continuous
S
S
Ralch N;l;,y

3.4
1 Valid flow dkazran~No,

I.?..:

~ -

hlanafacturer / supplier: Ashland Chemical / Drew hlarinc Division

--

Produr! name / method: rfwplcx AT nit11 Amelzine

-

Manu!?rturer 1 supplier: Ashland Chemical / Drew Marine Division

Prodlac: name / method: rcwplcx AT with Amrrrine

Product namr I method: I Drerplrx AT with Amerzine

I I , 1
--
-~
Amer. I e I I S 1
I
2. 3. -1, 5 -,
I 1
. ...
7 -
.
 Chemical injection points (continued)
hlanufar!:~rcrI supplier: Ashland Chemical 1 Drew hlarine Division
1 Table No. 1 1 1
raduct n;t!ne I method: GK-I00 with A m c n i n e

ManuT;lctnrer Isapplicr: Ashland Chemical I Drew Marinc Division

I TabIeN0.12 1
Product ".,meI metho~l: AGK-100 with Amrminc
Chcmicnl name Injection point No. Continuous Batch Note No. 1 \'slid flow diagram No.
AGK- [nil I s 2 , .?, 4. 5
Amcrriiit. 1 S 2 . ?. 4. i l;
I.?.? I,

-- - - - - -

Product n i m c 1 method: Standard

- ~-

M a n u f a c i ! : ! c r I supplier: Marichcm
r T n h l e ~ o IF,
.
~p - .-
Prrrdurt ~ i : . i n ie method: B \ W new lormulit
 -

Chemical injection points (continued)

Rlanufartarcr 1 supplier: Marichem
1-Table No. 16
-
I Product name / method: BWT new formula
Chemical "!me Injection point No. Continuous Ralch I Note No. >lid flow diagram No.
B.W.T. new o r m u l a I S I 1.3. 4. 5
Marichern {z:I 2. 2a. I h S I
I
3.4
I.?.?
t

Manufactlirer 1 supplier:
1 Table No. 17

. --

hlanufacturcr 1 supplier: Unitor Chemicals

1 -.
Tahle No. I9
- -- --

1
~

Table No. 20-

hlanuiact~trer1 supplier: Ilnitor Chenlirnls

Producf n:,we / nicthotl: I I

 Manulactorcr 1supplier: Unitor Chemicals

Product nsnle 1 method:

-
7Tsble NO. ~3.1
-

hlanuFactartr lsupplirr: Unitur Chemicals

.. - - --
1
- - - --

Product n:~rnelmethotl: Liquilrcat

Chemical nnme Injection point No. Continuous Batch Note No. ! \'slid flow diagram Yo. i
Liquiueal 3. 3a. 3h
Cnndcnsec mnuol
(Oxyeen r.n?croli
2. ?a. l b
2. 1a. 7h
N
X
1
'
I. 3 . 4 I I . 2. 3

Uoitor Chcn~icnls
--
Product name / method: Liquitrcat 1
Chemical name I lnjertion *p Continuous Ratrh Note N n l-\la~id_flnu*~ram No. 1
I
I

1 R1anuf;lcrmri.r i supplier: I Ilnitor Chcmieals

...rableN"_?b
H
1 . -
P m d u r t o:tnlei nrclhod: Combitrcat
i
Chcmical nzme lnjcction point Nn. Continuous Batch Notr S o . I Valid flow rIiagram>.- I
Combirrcal 7, ?a. ?h !
Conilmsalc ronirnl 2. 1a. ?h X 12.7
I
2. la. ?h X I. .I. 5 i!
I Chemical injection points (continued) 1
Manufa.lclt?rrrI supplier:
I
Llnitor Chemicals
/ Table No. 26
1
1
1
Product n a m c l method:
Chemical name
Comh~trezt
Condcnsati control
lnjcetion point No.
1
2
Combitreat
Continuous

X
Batch
S
Notc No.
-
3

i. l
Valid flow diagram No. 1
Oxygen tor:!:-ol 2 X
.
4
I I
-3. -- Y

Flow diagram No.: 1

Single boiler operalion with or without

forced circulation exhaust gas bojler

Figure 1 flowdiag_l.c~lr
Flow diagram No.: 2

Figure 2 flo~vcfiag_2.cdr
 Table of contents

'Water level gauge

-- ~

. .
Maintenance and servlce instructions ... .......... . ................ . . . .................... 1

UK
L~t~ellcil;ice Page 111
Water level gauge

Maintenance and service instructions

-.

This section describes the maintenance and sewice instnlctions for the water kvel
gauge.

Illustration of the water level gauge

-

, .,
, ,

I - llut
2 - Rnx hecrjs
3 - Jant nn@
4 - Rox hmdi
5 Tubs5
6 XIS%
7 - Xreus
8 - Cmk plug
D Drain c r r b
G CZU~W B
5 Cccb
W Cccb
~

Figure 1 I 0Ie.ctIr
-

1.1 Maintenance

The item nos. mentioned i n the followinf maintenance instn~ctionsrefer ti, Fic~lreI
When out of sewice with the gauge b l d y in cool and tleprt.ssurisrd condirion the
h e x a ~ o nscrews (6) can he re-tightened.
Step A: Start at the centre, working lo opposite sides alternawlv hlax torquc: 60
Nrn in cold and under working condition.

1.1.2 Maintenance during service check-up

Step A: Tighten the nuts (1).

Step B: Bolts on boiler flanges

Step C: Union nuts (4)

Step D: Bolt form screws (7) with cocks in open positions.

If a leak cannot be stopped by tightening the hottom screws ( 7 ) .[lie sealing surface
of the cock plug (8) may be damayed or- corroded. It can also he tiecessav to change
the packing (3).

1.2 Blowing down

The item nos. mentioned in this follouaing blo\viny d o ~ v nprcmdurcs rcfcr to Figure
1.
Step A: The gauge should he blown down hefore liehtinr up the hoilrr- ; ~ n djust
before closing down the hoiler.

1.2.2 clean in^ the water side:

Step A: Shut the cock S and open the cock W

Step B: Open the drain cock D for a short time. This sucks tllc a83teriiui of the glass
without, however, totally depressurisinz the gauge hom3y.

Step C: Shut the cock D and then water is forced up\r.;rrds imo the pl;r~s;ig;iin

Step D: Repeat tlus procedure several times. opening and shutting the coci: D. Thr
water level in glass rises and falls.

1.2.3 Cleaning the steam side:

Step A: Shut the cock W.

Step R: Open the cock S

Step C: Blow through the steam side id gauge body I,\ openiric 111ctlr;iii1 cock 1)
for 1-2 seconds.

Step D: A steam blowing of longer durc~tionis not advis:lble corisidcrin!: the servici-
life or glass.

Step E: Turn the cocks to operating position.

1.3 Dismantling

The following dismantling lnstructlons refer to F I ~ I II arid

~ ~ F' ~ r u r c1

Sectional view of the water level gauze ---

6 - Screws
9 -Wedge piece
10 - Centre piece
1 1 - Reflex
1 2 - Sealing gasket
13 - Cushion gasket
1 4 - Cover plate

-- - - --- -

Figure 2 kli-O5e.ctlr

Stcp A: Shut the cocks S and W

Stcp R: The d r ~ i ncock D to he opened until the glass is cornplctcly ernptieil.

Step C: Remove nuts (1) and lift off stuffin!; box heads ( 2 )togc.tlisr \villi ihc gaiige
bodv from the cocks S and W.

Step D: Slacken the union nuts (4) and pull ofrthe stuffing box lieatl (71

Step E: Place the gauge body iG) hori7ontally with the screuc ( h i il~r~iini.
upw~lrd
and loosen ihc screws.

Step F: Move the wedge piece ( 0 )lengh wiw dnd 11ft upwarclc

Stcp G : Lift off centre piece (10) refler. glass ( I I I arid @askersI 12 ant1 I i i

Step H: Clean sealing surface of cover plate (14) and c e ~ ~ t rpiece

i. I 101a n d ~,x;imine
for through going scars.

1.4 Assembling

The following assernblinfi instructions refer to Figure 2

Step A: Insert following items into the centre piece i 10'): si.:~linrgirskd i 12) reflex
glass ( 1 I) cushion gaskct (13).
 Step R: Place cover plate (14) on top

Step C: Insert wedge piece (9) and move lencth \rize for corrtct po\ltion

Step D: Tighten screws (6) evenly startine at the centre. \\*orking lo opposite
alternately. Max torque: 60 Nm in cold and under ivorking conditions.

1.5 Maintenance of the straight-through cock

1.5.1 Operation principle and maintenance

The following assembling instructions refer to Fieure

Detail drawing of the straight-through cock

\ I 5 !,
15 - Screw .-., jj

16 - Spl'rt ring
1 7 - Pocking sleeve - .
18 - Plug
r
-
- -

19 Bottom screw ,-
\ -
-
,.
1 1 h)., .~ ,

'.."--
~p

j, -.. .
-. --

, ,;'
/-- I

- -
': I- L : !
'
~. ;z,,,..--3C~.~.-.;
. ~. . ~
'-,' ,:

- .,
-. . : .,,7~
<-.
~~p

-=- L.- .-. - .

~ ~~

P
I, 13 )- -

,, :
-,
8
, .

.-
Figure 3 kli-0he.ctlr

The cylindrical plug (18) is sealed with ;I resilient packing slccvs (17).
Should leakage arise during service the packjng sleevs must be further compressed
hy tightening the bottom screw (19) un~ilthe lcakage i u stopped. Tliis must only lx
done with the cock in open position.

1.5.2 Dismantling

Step A: Remove bottom screw ( I t ? )

Step B: Remove screw (15). washer :~ndhandlc

Step C: Knock the plug (18) together u ith split rine ( Ibi :irid packiii? hleevi: 13) our
of the cock body by means of a soft iiiandrrl

Step D: Remove split ring and knock plug out of the packing sleeve.

Step E: Clean all sealing surfaces carefully and lubrica~etiireads wit11 a high
temperature pease before installation.

Langiayc liti Page 415

1.5.3 Assembly

Step A: Place the split ring (16) in the recess of the plug (18).

Step R: Push new packing sleeve onto plug.

Step C: Press the complete unit into cock body.

Note: Turn the packing sleeve until the ridge fits with the groove in the cock
hody. The eyelets of the packing sleeve rnilct neither protrude nor he
tilted.

Step D: Screw in bottom screw (19).

Step E: Place the handle and washer on the plue and lit scrriv ( 151

Step F: T ~ f h t e nthe bottom screw (10) .tnd check if the plug cdn IY turned
 Table of contents

Safety valves
General ......................................... . . .. .... ............. . . . .
... . ... . . . ............ . . . . . . . ..... I

Maintenance and start-up of boile

Adjustment and dismantling
Sadetv valves
d

1 General

In the following the measures required to achieve a safe and reliable maintenance or
the safety valves will be described, together with adjustment :ind disnn:~ntlin;
instructions.
.4n example of an installation of the safety valve is shown in Fi:ur-e I

Rfountioe of safe* valves. cxamnle

Waste steam plpe

-
I
Support r'

2 Maintenance and start-up of boiler

--.-

:1 regular inspection of the safety valve is rccommcnded 3~ Ir:~stonce 3 yc:tr. Sntiii.

media and appliances require n inore ':reqoCnt iilspection. this is ;~ccordinglo [he
experience of the supplier.

Warning: Before handling and dismantling of the ~ a f c hvalbr encure that the
system is NOT pressurised!

Before lighting-up the boiler the pipe connc.ctions must be thilrouchly clzaned for
dirt and foreixn bodies.
 If the valve is not completely tight. which often happens after startinz up the plant.
this is usually caused by imporitits helween the ce;ll and tile cone. In tlrllt'r- [in
remove these impurities the valve must he heavily hlo\\.n out by me:lns of tI11: IiCtin:
device. If the valve is not tight after several blows, it may he dus to thc f:lct that a
hard foreign body h3s got stuck hetween the cone and tile ce:lt. and it u.ill then he
necessary to dismount the valve for overhaul.

Warning: In case of a leaking safety valbe the v a h e must be inspectetl a n d

over-hauled a t earliest possible opportunity. I t must be ensured that
the boiler is totally depressurised before dismounting the valve.

Note: Before dismantling the safe@ halve in the workhop the position of the
adjusting screw must he measured a n d noted whicli will facilitate the
adiustment later when the valve is to be adjusted ~ v h e nin service.

If the facings k t w e e n the cone and t h e seat have heen damnsed. they must he
rinded.
Step A: The cone can be grinded against a C3st iron plate. ~isirli! ;I rille r a i n e d
carhorundom stirred in kerosene.

Stcp R: The seat in the valve body can he prindcd in the s:irnc \\.:I? by uiin: :I c:icl
iron punch of suitable size.

Note: Never use the cone itself when grinding the seat.

Warning: The spindle and the valve cone must al\va!s he secr~retl a ~ a i n s t
turning a s the seat and the cone may thus he darneqetl.

Step C : Refore assembly the vaI\,e m u s ~he thoroughly c1e:in-d. :i11iI :111 tr:lces <,I
grinding material and impurities 11lust he removed.
When the valve has been mounted the boiler is commissioned. and l11e val\i: is lli~:n
checked for leakage and adjusted to thc sft pressure.
S t r p D: The adjustment screw is secured by nicnns of its lock 11111.311dlllc v;il\.? is
sealed.

2.2 Routine check

.-

The following should be regarded as recommendations of roirtine ihecki on tlic

safety valves, in order to keep a proper functionins.

h n e u . i ~ eIJK ? w e 214
Yearly
Stcp A: The safety valve should he tested in operation hy r ~ i s i n gtlw hoiler pressure.

Step B: Expansion and exhaust pipe should k exanuned at tile same time

Monthly
Step A: Examine the safety valves for any leaking, such as:

Is water seeping from the drain plug at the \.alve hody?

Is the escape pipe hot due to seeping steam from the valve ie:it?

Step B: Examine the drain and expansion device at ihs escape pipe.

Step C: Examine the lifting gcar device. i.e. clean up and p ; i s s all sliding pans

Adjustment and dismantling

Safety valves are delivered with the rcqriired sprins setting n n t l 5enlcd :!gainst
t~nauthorisedadjustment.
Adjustments are only allowed in the ~ p r i n gmargins. Orlrsidc thc marsin a new
spring is required. The pressure in a system should not cxieed 00'5 ot tlie icl
pressure.
.\I1 item nos. mentioned in the following sections reffr 113 F i c ~ ~ ?r e

3.1 Dismantling of lifting device

--

Safety valve w ~ t hopen cap

Step A: Remove bolt(39) and remove IITI l e ~ ? (41)
r

3.2 Set Pressure change without spring change

Note: Pay attention to sprin:: ranzc

Step A: Spindle (14) must k. held fast hv all altcratinns

Step R: Loosen lock nut (21)

Step C : Turn the adjusting screw (171 clockwise for higlicr 2nd ; i ~ ~ r i c l ( w k ~for
~iss
low set pressures

Step D: Secure the new setting with the lock nut (21) and Ke~ssenihlrliftin!: devicc

3.3 Spring change

Step A: Spindle (14) murt he held fast hy all alteration\

s t e p R: Remove pin (16) from spindle cap (39)

Step C: Loosen lock nut (21) and turli adjusting screw (17) ;inticlock\viic. then ihc
spring (37) is not under tension

Step D: Loosen the nuts (8) and renio\c. the bonnet 112)

Step E: Remove the upper spring plate (26) .ind sprinc ( 3 7 )

Step F: Remove the spindle (14) with disc 112). guide plate (4') ;and lower spring
plate (26)

Step G : Clean the seat (2) and disc (12 I

Step H: Remount the spindle unit with rhe new spring and uppfr spnng pl;l[c

Step I: Assemble bonnet ( 3 2 )and adjust to the sprins r a n y

Step J: Secure the spring setting through the lock nut (21) ;111d ri'1110~i111liftill:
device

Assembling drawing of safety valve

-1 E d 1
42 -1
4 1 Lrmrg M
4 0 spn pn
39 Ban
l a screw
31 SF*^
?9 Cap
2 7 -&I
26 S p r w a e ?3
23 &L w ?b
22 muin sclw
21 L o c k n~
18 8711
17 MlrstinjSiRu
16 sand PM
I5-Wt
iil Srridn
13 U:i O d
12 m
10125wi mnur
9 L", Lnnumn nm
R Hlr nu'
I C d I
a sonjin rluoe
3 stirl v
2 Sroi
1 mli
 Table of contents

Ceed water system

.

Water level control

Feed water system
DP-transmitter, type 7MF443
DP water level control unit
 .... ..
.....
.....
AT,
It.
. - "?G ' I

Water Bevel control

1 Description
The water level control is a modulating system at this type of boiler. The system 1s
illustrated in Figure I. The safety device system for too low water le\.el alarm and
burner cut-out consists of an external chamber with a level float switch. For
measuring and control of the water level. the boiler is equipped Ivith a dp water l e ~ e l
transmitter unit, which includes external reference and variable legs, and a dp-
transmitter. The cootinuous 4-20 1x4 output signal from Lllc Jp-transmitter is
processed in the control system, which provides level \varningsl:~larnmsand control
of the regulating feed water valves.

Water level control system

Feed water system

1 General description
-

1.1 Water level control

The feed water supply to the boiler is handled by 3 one-elemcnt control system. i.c.
the addition of feed water is controlled accortling to the watcr level only.
The control system is designed to maintain the watcr level in the boiler 3s ~vell3s ro
provide the required alarm and safety shirtdown functions related 10 the water le\.el.
The water level transmitter is mounted on thc boiler as indicated nn thc arrangement
drawins in Figure 1.

: :; , ;
-
i-
-~ I I

1 - Filling valve
8 , '
2 / 3 - Stop valve
3 / 5- Drain valve , ,
1.
-~ -
6 - M anifa Id ;
,, ,
,, > > V:innhlc l n i p i i l v lec
7 - Diffefcrcntial plcssure transmitter . . '7' , \
-

All item numbers in brackets menticrned in this ch:tptcr r r k r 1,) I'ic.~ire I . I ! ~ ~ o t l i i n q

<Is< is stated.
The level control basically works as follows:
The differential pressure transmitter convsns tht c1etccti.d wltt:r lcvel impr~lsc
into a 4-20 mA DC si-g~aluscd as input for thc level contrdllcr.
 The level controller, located in the hoiler contrcll pancl. will in response also
give a 4-10 rnA DC output signal to the pneumatic contrtil v i l l i c
The level controller has a built-in level indicator device.
The valve is equipped with an electronic-pneumatic valve positioner for
conversion of the current input to a pneumatic sign31 and for control of the \,alve
stroke according to the input s i p a l .
The differential pressure transmitter s i ~ n n lcan ; ~ l s o11s used for remote level
indication in the engine control room.

1.2 Alarm system

The alami system consists of two independent autom3tic means of shutting off the
oil supply at too low water level (as required by thc classification society) and n
number of other d a m :
Separate low water level float swilch for shut-off of ths lu?l oil supply :at too
low \vater level (see arrangement of sockets1 list of hoiler mountinrsl.
Limit switches (located in hoiler control panel) conncctcd In the dii'rzrenti:il
pressure transmitter output s i p a l co:npricrd 01:
- shut-off of the oil supply ict too lo\? ivater level
- 1015 level alarm
- high level alarm
- slop of feed watfr pumps at too high water IcvcI
Extent of alam is shown in the i v i n n ~di3grall1s for the hoilcr co~ilrol!unzl (se?
separate instnlctionsi.

1.3 Feed water control valves

The pneumatic control valve is equipped i t 3 eleccrc>nic-pnei~malicval\,c

positioner for control of the valve stroke according to the input control sipnal from
the computer. The valve is "normal cl~sed".i.e. it will he c l o ~ din casc <>f power
andlor control air failure. By fault in the differential pressure transmitter sign;rl thc
control valve will be closed 3s well.
4 hand-wheel enahlcs rnanu;~loperation of the \,:il\'c.
The fi>llou.ing general installation reconimendatio~lsshnuld lw ohier-vrd.

2 Calibration and set point proposals

--
-.-

2.1 Differential pressure transmitter

-.

Notc: Refore .staling Ule boiler the reference irnpule leg musl hc tohllv filled with
water.
 Step A: The span and zero elevation should be checked and. if necess:lry. calibrated
to obtain a 20 m4 output signal when the water level is at the upper hoiler
connection and a 4 mA output when the level is at tht. lower conneitinn.

Step R: The damping adjustment slicxild lx sct at masimurn

1-
I
Calibration of differential pressure transmitter
Span hNuren I)ifTaent~alcalihnlion
\+'aim level T r n m ~ ~ nnutput.
tr m%
- conneciion, mm preccurc,mm\\C
I <-: I <, 9 I

Lou.er connection

Tnhle 1

2.2 Level indicator controller (PID-type)

The set point should correspond to the norrn;il \v:ttcr le\-el rnnrh on the hoilcr. i.e. the
controller is set on MV.
The control action should be reversed, i.2. increasing output itt decrc.~sinrtnpui.
Proportional bltnd, integral and derivative :ictinn tinle (PII)-v;tluer) slloitld be set
according to operation cxpencnces of the nctl~alhoilcr p l : ~ n ~ .

2.3 Electronic limit switches (in control panel)

-~

1.'. Calibration of limit switches

~

IIri&l ahore I o w a boiler connecUon.

n7."

/ \hut-ofiolo~lsupply at roo low I I

t o p o f leed i\,aler pump nl loo

ilieh u.atcr lc\,cl

Tahle 2
*) This is calculated as follows:

1+ ((height a h o l e lower connection 1 hrirt~thetween ronncctionrI \ 16)

2.4 Valve positioner

The positioner action should he direct. i e. incl-eaing output iait prc,<urel :I(
increasing input (current signal), correspondin_r to thc cnntrol riitii?n of t l ~ rlevel
conrroller.
The valve musl be smoked. so rhat it is completely closed :I( LII mi-\ Input and
complctcly open 31 4 d input.
3 Operation and maintenance
--

The operation and maintenance of the equipment is generally deccrikd in the

instructions from the various manufacturers.

3.1 Feed water control valves

The control valves are not completely tight especially after some time of operation.
If an oil-fued boiler is not operated for a longer period (and the exhaust gas boilers
are not connectedloperating), the hoiler runy he slo\\rly filled with f w d water due to
the valve leakage.
T o avoid this it is recommended to close a stop valve in the inlet feed water lint
manually until operation of the hoiler is resumed.

3.2 Water level transrnitte r

Before starting the boiler the reference impillse leg must he totally filled with watcr.
The impulse legs and must he drained regularly (oncz a \v?ekl to hlo\+,0111 sludfe
which might have accumulated in the pipes.
Step A: Isolate the differential pressure transmitter (71 by c l o s i n ~the line \'alves i l l
the manifold (6). This should preferably he done during slcady hoiler load
with a stable position of the feed water control v;ilve. In ail! case the water
level should he monitored closely and thc k e d control v:~lvc operated
manually if required.

S t e p R: Open the drain valve ( 5 ) and h l c 0111

~ the contents nithe rdercnce ley

Step C: Close the drain valve ( 5 ) and till the reference l e with
~ hoiler feed water hy
opening the filling vulvc (1) lor :i fell. minutes.

S t e p D: Open the drain valve (4) fora few seconds

S t e p E: Reconnect the transmitter (7)

Note: The blow down of the impulse legs can a l w be pcrfomed with benefit each
time the hoiler is taken out of s e n i r e

Thc trarlsmitter is calibrated to obtain 4 mA and 2 0 in.4 output signals at w:ltcr

levels corresponding to the positions nf thc stop \.:~lves(il and ( 2 ) rrspectively.
Taking the density difference between the iv3ter in thc reference le! 2nd i n the hoiler
water into account, the transmitter must he c;llihri~ted a: rlin\\n ,>n the curve
representing a water level of 525 mm to 1550 mm in 1-icurr 2~
To operate the l e ~ e transmitter
l pleas? see the special inctrustinils in [hi.; ii1:inunl.
 Calibration of level hurmitter - - - -- -

Water level above lower stop valve [mm]

1 w,?ter level = 525 rnrn

2 wrltsr level = 800 rnrn
3 wa!or level = 950 rnrn
4 wa!?r level = 11OO rnrn
5 wat?r level = 1240 rnm
6 water level = 1550 rnm

Fiyre 2

3.3 Feed water pumps

T h e feed water pumps must generally he operated and mainfainrd i~ci'c~rdii~: lo the
manufacturers instructions, and especially the follo\cing are import:~nt-
T h e pumps (and mechanic;~lseals) must k ploperly lillrd and vrlitetl ;lcri,rdii~r
t o the manufacturer's instn~ctionshefore stan is arrcmpted. Tlie pumps :ire ne\,cr
allowed to run dry.
Proper alignment between pumps :ind motors m l ~ s the \~,r~filrd :~l'ti.r inslallati~>n

.
and when the system is in operatins conditions ( p r c s s u r ~:lnd
, f?rnpcr:~lur~,).

T h e by-pass from thc pumps to tile condensarc r ~ ~ c e i \ ~ c r / d e a e [:ink

~ i ~ ~ must
c~r
always h e kept open t o secure minimum ;~llo\v:~hlc fl<:,\r ; ~ l s nu.heii tlic feed
water control valves are closed.
 Note: It should be checked daily lM the pumps are running smoothly without
vibration and noise and lhat the mechanical sc:tls are not leakins.

Proper functioning of the automatic start of the stand-by pump should he cllecked
once a week.

4 Calibration / set point record

-

The actual performed calibration and setting of the various compconcnts sllould
recorded in the tables below to provide valu;~hleinlonnatiim for operation and
maintenance.
Readjustments should always be written down also.

1 Level indicator controller (in boiler c o n t r o l panel) I

Tahle 4

Electronic limit s w i t c h e s (in c o n t r o l p a n e l )

Shut-,l!ToloiI supplv at l o o low water
icvc!. IIIA
--L*iw ih,icl darn m4 -.
-- - .-
A-
I ~~ -

i
- Hlei!
. l c v c i d x m . mA
Srnp ,,! reed water pump a1 Ion h i ~ w
h ter
( i levcl
.
--
i
Niltr
_-I - -
Table 5
.-

Table 6

Table 7
DD-transmitter, type 7MF4032

General
The following description is valid for a differential pressure transmitter SITRANS P.
tvpe 7MF4432

Warning: lhis equipment should o n l y k installed and opented after qualified

personnel have ensured that suitable pouer sl~ppllecarc availahlr. These
personoel must -c that the equipment is not w b j e c t ~ lto an!
hazardous voltage during n o m l operation or when a defer1 o r r u n in
the system.

\Varning: 7he equipment may he u s e d d e r hidl pressure .and with aegressire

media. lmpmper use of this equipment rimy tlicrefore result in sevcrr
personal injury or extensive clamnge to pmpcuty.

The silccessful and safe operation of [his cqoiprnt~ilis dependent upon I L S prc7pL.r
handlin:. installation. operation, and m.iintenanct..

2 Technical description

2.1 Application

The SITRANS P transmittzr can hz used to riieasui-e:

differential pressure
low pressures above or helow atmos?heric pressllri.
flow - pO' (in conjunction with :I primary dirrerc>ntialprcqsure dt.\ ice 1

r ~ FJXS,
f vapo~~rs,
atid liquids.

Measuring spans are possible kt\r.eer~I mhar :uid 30 lxir. Thc n~lrprlts i y n l is ;i
load-independent direct current c~f 4 to 20 m:\. .\ linear iproponi~lnnl to the
to r:lte ('I
diifcrential pressure) or square-ro8~itlpt~>ponional fl(l\vi cl1:11-i~ctcr~qric
can
he selected.
Transmitters conforming to protecticin type "lntriiisic safc" ;ind '.r'I:iliieprod
enclosure" may be installed within potentially explosive atmosphsrcs (zone l i.The
cc~nlbrniitycertificates corrcspond to thc European standard I CENEIZEC).
2.2 Mode of operation
.- -- -- - --

Figure I shows a function diagram of the SITRANS P difrerenti;~lpressure and no\\;

transmitter. The item numbers referred to in the rollowin: desct-iption :Ire tho.;e
rrientioned in the in the figure.
The differential pressure is applied via the diaphragms (1)ant1 the lillin: liquid ( 3 )
to the silicon pressure sensor (7). If the measuring limits are exceeded. the overload
diaphra-gn (6) is flexed until one of the diaphragm (4) rests on the meilsririn~csll
body ( 2 ) .thus protecting the silicon pressure sensor (7) from overloading.
The measuring diaphragm of the silicon pressure sensor is flexed by the applied
differential pressure. The resistance of four piezo-resistors firted in the diaphragm in
a bridge circuit thus changes. This chanfe in resistance results in ;i vnlta_ce output
from the bridge proportional to the differential pressure. This voll;igc is amplified
and converted into a frequency by means of a voltage-to-frcquenq convener (?).
This signal is evaluated by a micro controller (101, and its lincnrity and temperature
efCect corrected.
The processed signal is converted hy ;I digital-to-analogue converter I I I ) into ;in
output signal of 4 - 20 mA.
The data specific to the measuring cell as well as the pnramctcrs I I t ~l ~ r rtr;lnrmittcr
arc stored in 3 non-volatile mcmory (EEI'ROM).
The cahle termination point and the electronics are arranged oppositi. one ;inother.
Parameterisation of the transmitter is perforrnfd rising a i3plop. PC. 1-1.4~7'
Cornrnunicator, or the pushbuttons. Norrnallv thc pushhuttons :Ire u c d r i l sft-up the
transmitter.

Function diagram - --

D?lcren:~al pressure 3 OR!n?

I 1 as i n p ~variable
l 6 83.,?d, ,i,:f d,sDt,rd<?~,
r S ~ I I C Opioss,,rcscnio
1, Oulpul S ~ Q M ~ ~,
1 , POWWs"p@y 2 lnslrun~mt~rnplificr
' vollage~lo-tlcq~oncj :~mvn.-
1 P ~ x e t!awe
s~ 1C Uicruxn~rollr?

.:
2 Measuring cell b 3 ~
F i l l l Ihqud
4 U:?.n,lh:agm
~
i I Dy~la-to-an,lilg c?rl,,elor
I C LCD i;lptlon)
I ? a a 1 3 j n;~ca!oi ::;i>il,;nl

7nif3LOl.tif
 The following parameters can he set or their cunent in1crro::itzd
~neasuringranse
engineering unit
measured value in mA. ?. and ensinecnng l~nit

linear or square-root characteristic

cut-off point of square-root characteristic
damping
"loop check" function
output current when errors occur
* disabling of pushburtons

2.3 Dimensions

SITRANS P, differential pressure and flow hansnlitter, dimemion< - --.

: P r c r e ~1.mnection '!.-I8 NPT

2 Moun:l?i mead M10 h!12 oi7/,,-20 UNF
? Banlo^ : r,lu(l lwilh FC 13 5 :aemx ylann ir Han 7D dug an*)
2 E l r,nr;tinn
Pq 13.: =;mwirl glznd cx M2O x 1.5 female thread a
',-.-I.: P x ! 7 female Itliead n Ha? 7D Ovg
i., i e r r n ~ c ?;de analrm iridicalor as o~t,mn
6 Eleclrc:,~:, sllle. d,o~tallndicatw as oplnn
7 Pr3twl-': cover l w r he6
n Vrr,tklr ,'' vdvc
Installation

3.1 Place of installation

The transmitter can be installed above or k l o w the pressure tapping point. When
measuring gases, it is recommended to install the transmitter above the pressure
tapping point and the pressure pipe to be laid so it nins down to tlie prsssrlre tap.
This will permit any condensation in the pipe to drain off and not affect the
measurement. When measuring liquids, the transmitter should be installed k l o w the
pressure taping point and the pipe laid so it rises up to the pressure tap, thus cnahline
any gas in the pipe to dispersed.
The point of installation should he easilv accessihle. preferably close to the
measuring point and free from vibration. TI15 permitted ambient temperature limits
must not be violated. Protect the transmirter from direct heat sources. Before
installing the transmitter, compare the process data against the data <-.I> tlie r;lting
plate. Keep the transmitter closed during the installation process.
The transmitter can be fined direcily to the valve manifold r r ! with a
mounting bracket.

3.2 Fixing with a mounting bracket

- --

'The mounting bracket is fmed to either

a wall or mounting frame using 2 ?crew\
or to
a vefiical or horizontal mounting pipe (50 to 60 mrn in diamctcr) \!sin:: :! U-holt
(see Figure 3).
The transmitter is fastened to the mounting hriicket tising tlie fnur screws iupplieil

Fixing the hansmitter using a mou~ltinghwcket

3.3 Rotating the measuring unit in relation to the housing

If required, the measuring unit of the transmitter can he rotated i n relation ro the
electronics housing either:
lo reverse the process terminals

to rotate the electronics side (with digital indicator) to a \ ~cihleposition

Only limited rotation is permitted.
The range of rotation (7), see Figure 4, is marked at thc hottom of the electronics
housing. At the neck of the electronics housing there is ;I reverence mark (6) which
must always be within the marked range when rotated.
Step A: Undo the locking screw (8)

Step R: Rotate the housing within t l lurked

~ range (71

Step C: Tighten locking scre\r3(torqle 3 . ~ Nm)

~ '

Rotating the measuring unit in relation to the housing

-- - - -

Figure 4 7mt3Z-04.tif

3.4 Electrical connection

\Varning: Observe the relevant regulabns during the electrical in*llation. In

ha7ardous arras,pap partir~~l,uattention
to:

the regulations governing electrical systems i n Iiaz:~rJo~~i

.Iri':lx iEli,x I

the specifications regarding tlie installation or rlestric:~l yslt:rns i n 1ioz;lrdou.:

areas (VDE 0165), and
the conformance certificate
 Warning: Check that the auxiliary p o w s u p p l y nmtches that specified on the r ~ l i n ~
plate.

The transmitter should be powered from a SELV (safety extra-low voltage) source.
If other power sources are to be used, it is recommcndcd to cart11 the transmitter
housing. The earth terminal in the terminal housing is connected in the external eanh
terminal.
Please note that:
The sealing caps in the cable entries have to he replacrd hy relevant cable
glands or blanking plugs which must be terrified when using tmnsmitrers
conforming to protection type "Flame-proof enclosure".
The terminal strip (see Figure 5) can hr screwed on to four difkrent positions
(lf-90" or f180° rotation possible). Please notice that the rotation is limited to
f1x0' (proceeding from the fixed position as on delivery).
The following general guidelines apply when laying remiin31 ciiiaximum cross
section 1.5 mm')lsiFal cables:
- lay the s~gnalcable separately from cahlec carry in^ voltages > 00 \'
- use twisted-pair cables
- do not lay cables close to large electric;ll systsrns. or uce scrre11t:d iahlc.

3.1.1 Connecting to screw-type terminal

Electrical connection schematic

en sockets lor DC meter

$0ex.emal indicaloi p;rrihle i l l 5 r r r e r :
or c o n o m n ~

Terminals
Tem8mI 11'1:

StcpA:Remove housing cover of t 1 ~electronics ride cni:~rkcd 'FIELD

TERMINALS" on the housing).

Step R: Remove analogue indicator (if fitted'].

Iimgllage IIK Pare 6/22

Step C: Feed cable in through cablegland.

Step D: Connect to "+" and "-" terminals. observing polarity

Step E: Replace analogue indicator (if applicable).

Step F:Replace housing cover.

Note: With transmitters confcwming to protection type "Fbnie-pmol enclosure" the

housing cover has to be secured with the safety angle.

3.4.2 Connection using a plug connector

The contacts for the connector are suppl~edin d ha: \$it11 the ~n?tru~nent
Step A: Slide sleeve and gland on tothe cable

Step B: Remove about 8 lnm of insulatnon from the cnd of the cable

Step C: Crimp or solder the contactsto (he c:~bleends

Step D: Assemble connector.

Connection usine plue connector

,I output current
V, auxiliary power

-
Figure 6 7mf32-06.tir

3.5 Installing the analogue indicator

StepA:Remove the housing cover of the tenninal iidc 11n:lrked "IIELT)

TERMINALS" on the housins).

Step R: Plug analogue indicator intokhtt test iockets.

Depending on the transmitter position the analofue indicator can he plurgsd-in in
four different positions (?190° or +18O0 rotation possihlc).
Step C: Replace cover with viewingwindow
4 Commissioning
-- -

The process data must correspond to that on the r ~ t i n gplate. The transnxitter
r~lnctionsas soon as the power is turned on.

Warning: Seven. pemnal injury or d m q e to property mav result if:

the venting valve andlor the screw plug are missing or not fitted properly
andlor
the valves are improperly or incorrectly operated.

Warning: When working with a hot d u r n , the individual steps de~crihedhelou

must be performed in quick successionr, othenriw Uic ,alveq and
transmitter may overheat and be damaged.

4.1 Measuring gases

The lsolatlng valves should be operated in the f o l l o w u i ~ctquencr, r*:e F~grlrc7

Mea.suring gases
--

irmrm,ne. .bw. T r m m e r below

p r e s ~ u r erourm presylce source
(normal con6gurauul) I- standarm
--

1:ip-c 7 7mf.32-07.tiT

Step A: Initial setting: all valves c l o d

 Step B: Open both isolating valves (5)at the pressure tapping points.

Step C: Open the equalising valve (2).

Step D: Open the pressure inlet valve (:{A or 3B).

Step E: Check the zero point (4 n A ) a t start d s c a l e 0 and correct i F necessay.

Step F: Close equalising valve ( 2 ) .

Step G: Open the other pressure i n k v:llve (7A or 31%).

4.2 Measuring liquids

The isolating valves should be operate& in the followinf sequence. see Fieure S:

Measuring liquids
1 Tra~miUel
2 Eoualizing vake
3 Pressure !"let valves
4 l m p ~ l s liner
e
5 ISolating valves
7 OUflef uah*es
8 Vent~ngvalvez
10 Pressure source
12 Gastiao

TranYnlner below
pressure source
I n m a t configuranonl

Step A: Initial sening: all v3lves c1ou.d.

Step B: Open both isolating valves (5) ;it the pressure tappin? poin!:

Step C: Open the equalisinf valve ( 2 ) .

LAngr~:ipeUK Pare 9C1

Step D: If the transmitter is below tk pressure source: opcn hoth outlet valves ( 7 1
sli_ehtly.one after the other. until no more air escapc<~

Step E: If the transnlitter is above t1.e pressure source: open hot11 venting valves (8)
slightly, one after the other, until no more air escapes.

Step F: Close hoth outlet (7) or venting valves (8).

Step G: Open the pressure inlet v a l x (3Aj and venting on the positive lcg of the
transmitter ( I ) slightly until no more air escapri.

Step H: Close the venting valve.

Step 1: Open the venting valve on t k negative leg of the transmitter slichtly until nc,
more air escapes.

Step J: Close pressure inlet valve (3A).

Step K: Open the pressure inlet valle (3B) slightly until no in,,re air escapes. clow
after.

Step L: Close the venting valve on t

k negative leg of the trL1nsnutrcr( 1 1

Step M: Open the pressure ink[ valw (3.4) 5 2 a rot:~tio~i.

Step N: Check the zero point (3 rnAjagninst st;iri of scale 0 :ind c o r r ~ if~ tnccesscln.

Step 0: Close equalising valve ( 2 ) .

Step P: Open pressure inlet v:~lves(3:t znd 3B) fully

4.3 Measuring steam

The isolating valves should be operated in the following seqtlenc~?.

see Ficure 0:

Caution: The result will only be corrtd when Ule impulse lines (4) contain an
identical head of condensate at identical ten~pcraturrs. 7~1-0p i n t
calibration should lje repe;3tcd, if necesmq. ~rhen this condition is
satisfied.

Caution: The flow of steam may damp the lranm~itterif Ule eqtmlising ,,al,e (2)
is opened \+hen both the isolating valvrs (5) ant1 I I ~ ~ S Uinlet
~ T \alves ( 3 )
are open!
Step A: Initial setting: all valves c l o . d

Step B: Open both isolatinz valves ( 5 ) ;it the pressure upping poinrs

Step C: Open the equalising valve ( 2 )

Step D: Wait until the steam in the impulse line (4)and in the condcnsntc. resen'oirs
( 1 3) has condensed.

Step E: Open the pressure inlet valvz (.?A) and venting valve on thr. positive leg of
the transmitter slightly until ncl mop- air escapes.

Step F: Close the venting valve.

Step G: Open the venting valve on tk negr!tive le; of the tr;~nsmitterslightly until
no more air escapes.

Step H: Close pressure inlet valve (3.4)

Step I:Open the pressure inlet \,alvz(3R) slichtly until no nlrlrc air escape.;

Step J: Closc the venting valve on tlu nq:itive les of the tr;~nsrnitte~~

Step K: Open the pressure inlet ul\c (:<.A) I ? ;I rotation

Step L: Check the zero point ( 4 mA)apiinst start of scale 0 and corrccl if 1icccss;lry.

Step M: Close equalising valve ( 2 ) .

Step N: Open pressure inlet valves (3A and 3B 1 full).

5 Operation on the transmitter

5.1 General

The differential pressure and flow transmitter is adjusted in the iield by three
pushbuttons, located on the outside of the instrument. with which the start of scale
and full scale values are "set" or adjusted. By means of the digibl indicator
[optional, normally not fined) additional parameters can he adjusted. The
pushbuttons can be accessed by undoing the two screws holdine the protective cover
in place. which can then be moved out of the way.

T m i t t e r controls and displays

Engineering unit
I

Mode

Pushbuttons

Screws

Protective cover

Digital indicator

Figure 10

The functions listed in Table I can he selected using the "M" kt!.. When pressins
the " M key (Modus) 2 appears in %hebottom left corner on the LCD. Every
additional key press increases the mode by o n c The paramctsrs. tlie current value.
or ihr engineering unit can be modified using thc T' ' and .! keys. In case of error
situations "Ermi' is displayed on the LCD. (see section 5 . 3 7 1 . Tile transmitter
cIi;rnges to function "Measured value". if mode 14 is passed by pressilip "hl" key or
i f 2 minutes elapse without a key hcing pressed (except i n inode 8. "loop check'').
If the input pressure is displayed. selected in mode 13. (see section Y i 9 I. and
tlie square root characteristic in mode 1 I (see section 5.XI 1 ) the tliffcrentir~i
pressure correspond in^ to the flow and aJditionally thc ricn "." i s displayed i ~ n
the LCD.
If there is a LCD overflow then "9.93.9.9" appear? (with umi!ll engineel-i~ir
units like e.g. Pa).
 If a "L"" is displayed on the LCD. then the transmitter parameters are protected
against ovenvriting (write protecled by means of a HART" Communicator) and
the key are locked.
If a "C" is displayed on tlie LCD. the tr;~nsn~itter.
operating witli a PCilap~opor
HART'^ Communicator, works in the "lq~opcheck" function mode or multidrop
operation. The output current is independent of the applied differential pressure.
The keys are locked.
It applies to all modes (except 7 and 8). A set new value is only stored, when the
]node has been changed or when the transmitter reverts automatically to the
"Measured value" function approximately 2 minutes after last pressing the keys.

5.2 Operation without LCD

5.2.1 Setting start of scale and full scale witliout LCD

Please note that:
The start of scale and measuring span Jre non-interacti\,c.. (A~lcasurin~
span =
full scale minus start of scale).
Pushhuttons may be disahled (ivrite protected I,! nle:ini ~,1 s HART'
Communicator).

Step A: Undo the two screws holdin? the protective cover ill place, \vIiicl~can tli~:n
L.e moved out of the way.
Set start of scale (4 mA) and full scale (20 mA)
Assuming the pushbuttons are pressed as described helou. rlie transmitrsr scts the
start of scale to 4 mA and the full scale to 20 m.4. ,417amrnetcr i i 11ot required.
Start of scale

Step A: Apply a differential pressure corresponding to tlie start o i scale to the

transmitter. When the start of scale is O bar. cornpc.nsiits t11e pressure
between the positive and negative lsp of the trc~nslliittcr.

Step R: Press the T and -1 keys sirnultaneoosly for i~hilut2 <ecr~ncls.

Full scale
Step A: Apply a differential pressure corresponding to tI1f full c c ~ l c to tlir
transmilter.

Step 1%:Press all three keys, makin: s~lreyou press rli,? "31" kc! first. Iiold i t . and
press both the other keys.

Glihrate start of scale and full scale

l i t h e output current is not to he set but heel!, adjusted:
Step A: Connect a DC meter to tlie iw~rplltcircuit or the lest ri>ckrts Figure -5)
Warning: For intrinsic safe current cinrits only ccrtifid ctlmnt r n r t c ~.me
permitted.

\Yarning: It is forbidden to screw off tr b a m n ~ i t t c rcorer nhcn lrorljng in

hivardous locations and using lmmmitters conforming to protection type
" F l a m e - p f enclosure" (Explosion-poll.

For measuring at the test sockets:

Step R: Clean the transmitter to prewnt the ingresq of tl~rt

Step C: Open the housing cover of tle tsrminal side

Step D: Remove the analogue indicator (if fitted)

Step E: Connect the DC meter.

Start of scale

Stcp A: Apply a differential pressure correspondins to rlic stan o f scale to tlic

transmitter. When the start or scale is 0 har. cornpensate tile pressure
hetween the positive and n e p t i v c le: of the transmitter.

Step B: Set the output current for start of scale uslnr the arid 1LC),
Rill scale

StepA:Apply 3 differential pressurl: correspondir~g to tlic hill x ; l l c to tile

transmitter.

Step B: Set the output current for fun scale using the ..M" key and the ? key or tile
"M" key and thc -1 key. Alwayc prcss the '.hl" kc? firs,. hnld it. nnd press
either the T' ' or the key.
On completion of calibration:
Stcp C: Replace the analogue indicator ( i f ;~pplicrlhle'~.

Step D: Screw the housing cover back or1

Step E: Replace the protective co\,eran~:ltighten both SCI-rwi

 - P

Functions of the dp-transmitter, type SITRANS P 7MF4432

4
1
Function -1 hl& l1
i
Keg
L
"
Tand.12'
Display, decaiption Section i

Mcx5oicd vdue
1
Output current in IDAor '7 inr ifip~lipressure
et1rinee;ing units
in
1 5.39
~
Error disnlav 1 " I ! ! . when trmrrnitter iq dirrurhrd 1 5.3 7 :
S t m of scale

tan o ccalc in selected cnrinecrtnr utirtc

"hlind calihralion

Oulput current in

D i s ~ h l epuihbutlons
:nrUor fi~ncttons

toggles between the

(cut-ofiheluu hcli3u ir,u,si!~nn p>inti I ~i

,Adjusting rmoc inr linnril~r~n
p l n l i to 15"+, inie
quare-root o? flow

- -displav A
-
change in mA or % -
~ 3

-
Enginecnng unlts i input v m a l i l c ~ i,utpo! current
i
i

" I f ; ! "1." is displa?e.i on the LCD. then the transmitter parameter\ nre protected nnalnst ovemlltln. i \ \ i i t t ' prvrri-fed h\ mean.: <,I :I
H.\KT' Communic:r:i,r) and thc kcys arc locked.
I f a "C" 15 displayed -n rhc LCD. the Lransmitter. opfrating with 3 PC/laptop or HART" C~~lnn,i~nicaior. u<,ihii n !hi. -lilojl cllcii" illnclinn
rnoilr or rnultldmp i,!>sration. Tile output current is independent of the applied dliferrnt~nlprcisurc. lli~. kr!;c nrc loc!.eil
" Prrs; 7 and kcys ~.~rnultaneously for ahout 2 r . The display goes blank and rhc currcnt vniuc i r displ:iyr;i :,itrr nhout 2 ,.
'' It (lie cien "T1" is !)\played a1 thc Ich. the me:r~uringranee limirs have bccn vinlatcd
Table I
5.3 Operation with LCD - -~ ..

Please note that:

The start of scale and measuring span :Ire non-intzractive. ihleasurins span =
full scale minus start of scale).
Pushbuttons andlor functions may he disabled, see Tahle I. mode 10. section
5.3.8.
Depending on the transmitter po~ilion the LCD can he pluyrred Into four
different positions.
Step A: Undo the two screws holding the pmtecti\.e cover in place. ~ I i i c t can
i then
be moved out of the way.
On completion of calibration
S t e p B: Replace protective cover and tighten hoth \crc\vT

5.3.2 Setting stat of scale and Full scale

If no pressure source is available, the start of scale can he set i n mode i >[id thc hill
scale in mode 6. Both are specified in the selected eneineerin: unit. st-.? section
5.3.3.
Set start of scale

Step .4: Apply a differential pressure correspondirig to the st:in n i sc:ile to the
transmitter. When the stan of scals is 0 har. co~iipc~isate tfir prfssure
between the positive and negative lec of the ir:insniitter.

Step B: Select mode 7- using the "RI" hry

Step C: Set the output current correrpondin: to the staa of scale !isin: the I and .!
keys.
Or set the output current to 4 mA by:
Step D: Pressing the T and .1keys simultaneously for :~hnt~t
3 ~ecnnds
If [he sign "?.L3' is displayed at the lsft, lie me;~surin; rar~rclin~itsli:~ve I > ~ C I I
violatcd. The original value remains u n c h a n ~ c d .
Set full scale
S t e p A: Apply a differential prcssurecol~cspondingto full scale to [lie rrarismitlcl

Step R: Select mode 3 using the '%I"

k\

Step C: Set the output currcnt correqmndin~lo full sc;llc usin? 1111. 7 ;11ii1.I kcyo
Or set the output ccmmt to 20 niA hy:
Step D: Pressing the T and .1keys siniultaneously for ;~hc~ut
2 sccnritls.
If the sign ''?'L" is displayed at the left. [he measuring r3ri~cIiniit5 li;,ic hccn
violated. The original value remains unchanged.
 ...
...
.....
Jtiiit,
AT. "*QG
I. t 5

I f the sign "TL-.-.-.-.-"

is displayed the selected measuring span is more than twice
the maximum measuring span. When pressin; the ?' and keys simultnne~~usly for
about 2 seconds the full scale is set to 0.(!000.

5 3 3 Setting start of scale and Full scale without a pressure source

It is possible to set the start of scale and full scale of the uans~nittereven i C there is
no pressure line connected or pressure source available ("blind" calibration )~
T o set stut of scale

S t e p A: Select mode 14 using the " M k c y

S t e p B: Use the T or J- key to select engineer~ngunit

Step C: Select mode 5 using the "M"key.

Step D: Use the ? or key to set thestarc of scale in the selected en:incerinz unit.

Step E: When pressing both the ?' a r d L keys s~niultaneouslyf@rahout 1 i e ~ o n d the

r
start of scale 1s set to zero ( ~ the
n sel~ctcdenglneerlng 11n1tt

To set !he full scale

Stcp A: Select mode 6 using the 'Ifkey
"

Step R: Use the l'or key to set thefull scaltr in the sclected e~,_cinei.i-in:unit.

Step C: When pressing both the T a d keys simultaneously for about 3 seconds
the full scale is set to the upper measuring limit (in the selected enfineerinr
unit).

Esample 1
A transmitter with a maximum measuring span of 5 bar is 10 he cnlihrated to 3
measuring range of 0 to 3.52 bar to correspond to 4 ti3 30 n-LA:
Step A: Select engineering unit "bar" in mode 14,

S t r p B: For the start ofscale. sct the value '-O.(X)O(," i n mode 5

Stcp C: For the full scale, set the \ d u e ' 3 57iK)" In mode h

Example 2
A transmitter with a maximum measuriil; span of 1.6 bar is to hc. cnlihmtzd to :I
measuring rang? of 456.70 to -133.40 mm I-Ig to correspond to ito 7(1 m'i.
Stcp A: Select engineering unit "mm Hc" in mode I4

Stcp R: For the start of scale, set the \.slue "t45h.7" i n mode 5

S t r p C: For the full scale, set the value "-133.4" i n nlnrlc 6

A transmitter with a maximum measuring span of L5(J mhar IS clilihr:!ti~d ror :I

measuring rangc of 0 to 200 mbar to correspcmd to 3 to 20 nu\.
The measuring range is to be changed to a se~tingof 100 to 240 mh:lr:
Step A: For the start of scale, set thevaloe l('O.(U1" in mode 5

Step R: Select mode 6 using the '1M"key. The full scale "300.00 mhar" is displayed.

Step C: When trying to decrease thevalue using the "-1" key. the error note "1'L" is
displayed additionally to the (not changeable) value. This is hecause that if
the start of scale is changed the measuring span remains unchanged. The
full scale 300 mbar violates tlie nieasuring ranye linlits.

L
Step D: Press the ? and keys simultaneolisly for ahout 2 seconds. Then the full
scale is set to 250.00 mhar.

Step E: Use the key to set the full s a l e to 140.00 mhal-

5.3.4 CorrPetion of zero point

If the transmitter is installed and operational, external influer~ccssuch :ts a n ~ l eoS
installation, ambient temperature, or installation dependent pressure efSects ie.y.
head of Liquid in the impulse pipe line lo tlie transmitter) may cause an ofisct in tlie
transmitter's zero point. This offset (maximum 5 % of the maxi~nummeasuring
span) can be corrected in the transmitter without modifying ths st:m of scslc and full
scale settings in modes 5 and 6 (correction of zero point,.
Step A: Compensate the pressure between the positive and nseati\,e It.: of tlif
transmitter (see section 5 3 . 1 ) .

Step B: Select mode 7 using the " R l kc!.

Step C: Press the and -1 keys r~n~uluneously

for a h o ~ 7~ .;ccond\
t
The value 0 or 0.0 etc. to 0.0000 is displayed on the LCD. dcpcndinc on tlie
maximum measuring span of the transmitter ;ind the sclected engineering unit.
Esample
4 transmitter with a maximum measuring span of 1.6 hnr is c:~l~hr;~ted for :I
measuring range of 200 to 800 mhar (4 to 70 mA), i.e. start of scalc 100 (rnhar) in
mode 5 , full scale 800 (mbar) in mode 6 and engineering unit "mhar" in mode 14.
The transmitter is. however, being in hotter conditions. which is c;rusinc :in offset
1200.3 mbar) in the original zero point.
This offset is to be corrected:
Step A: Compensate the pressore

Step B: Press the ? and -1 keys simultaneou\ly for ;ttwut 7 sccontlr in rrrc>iJct 7 . Thc
value of "0.0 inbar" is displayed.

Step C: Apply the original diffcrentil Frcssur<. Thcn ' 7 0 0 mh:~r"is displa~cil.
The start of scale and full scale of 200 irnhar) and 300 imhnrl scr in n i o d c 5 :~nd0
respectively remain unchanged.
53.5 Setting elechieal damping
The time response of the transmitter is determined by the rlend time. the time
constant T6?.and the electrical damping value.
The transmitter is supplied with a damping value of 0.1 second. V;llues of 0.1 to
100.0 seconds in increments of 0.1 second are permitted. Th? \.slue can hi. changed
by:
Step A: Selecting mode 4 using the "R'f"kty.

Step B: Use the T and keys to change the darnping \,:llue.

5 3 . 6 "Loop check'' function

The following output current constants can he set to check the (iutput s i , ~ a loop.
l
e-g. during commissioning, irrespective of tb: pressure:

Step A: Select mode 8 using the "M" kev.

Step B: Press the ? and .1keys simultaneously for abix~t7 seconds. This ac1iv31es
the "loopcheck" function. An output current of 4.0 inA is tlicplayed.

Step C: Use the and .1keys to seltit t!ie required current

C h ~ n y l n gthe mode dlsables the "loop checA' functlo~i
5.3.7 Output current in e m situa lions
The pressure sensor and electronics are monitored continuously. I f a defcct i*rcurs
''Wis displayed. The output current is st?t to 3.6 or 22.8 m3.neither nf \vhich
are possible under normal conditions. Tlls value set is deternlincd using moile 9. Tlie
factory setting is 22.8 mA.
Step A: Select mode 9 using the "RI" he\

Step R: Use the ? or key to selcc13.6 1 1 ~o4r 22.8 m.4.

Changing the mode causes the selected value to k stored
5.3.8 Disable pushbuttons andlor fr~nctiom
The pushbuttons located under the pmtectiv,? co\,er can hi: protrctcd logrtl~erwith
their functions against accidental and un:~uthorisedus;.
Step A: Select mode 10 using the "M"kc\.

Step B: Use the T or key to select one nut c'f F D I I ~function5

"0" no pushbuttons or functions disabled (opsr:~ti(>nscc sr,t-tii~n 5 . 3 1.
"LA" all pushhuttons and functions disabled.
"1,W a11 functions disabled e\cept start i,C scale ( t i , set (31 ~llijilst st:~n of scale
see section 5.2).
"I>S" all h~nctionsdisahlcd except stan of sc:ile 2nd full si:ilc it,? <er <>rndju5r
stan of scalc or full scalc sce section 5.21.
Changing the mode causes the selected locking to he storcd. The disablins of
pushbuttons a n d o r functions is displayed. It is ca~icelled \\.hen the "31" kcv is
pressed more than 5 seconds.
Please note that:
When selecting lock "LO or "IS" the measured value display current in m4 or
% should be chosen beforehand in mode 11 (see section i ? 9 ) . Otherwise a
change of the output value is not noticeable when the I'or .1 keys are pressed.
If a " L IS displayed on the LCD, then the transrnltter parameters are protected
against overwriting (wnte protected hy means of a HART' Comn~un~cnror)

53.9 Select display ( c u n r o t 70,pressure)

It can be displayed either the input variable pressure in the selecrcd unit in niode 14
or the output variable current in m4 or 5;.
Step A: Select mode 13 using the "R.l"key.

Step B: Use the T or key to select the requ~red\.inal?lc

5-3.10 Select engineering unib

The following engineering units can he chosen froill:
. ft ~ ~ 0
Bar, mbar, in ~ ~ 0in. 'Hg, Inm" H.2 0 - ' .nun 1-13, psi. P:r. k P i ~Mp;i
.
" Reference temperature 20°C.

S t e p A: Select mode 14 usins the "M"1.q

S t e p R: Use the ? or .1key to select clie englr,eenn_run~ts

If there is a LCD overflow then "9.9.9.9.9" appears (with s~iialli:~iginci.riti~units
like e.g. Pa).
53.1 1 Select characteristic (lintar/squarr-mt)
The output characteristic is selected as f~?llou.s:
Linear (proportional to diffcrcntial pressure)
Square-root (proportional to rate of flow)
And below the transition point of the square root cliarnctenstic.
Linear
Cut-ff

Step 4: Select mode I I u5lng the " r \ " l " l a

Step R: Use the ? or key to sel-~ .c rirhcr:

t

"Lin" for linear characteristic

"SrLii" for square-root characteristic cline;!r up to the tr;ins~ti,>n
pi~irrtI
"SmFF' for square-root characteristic icut-off up to tiir transiti~onpt,inr)
Changing the mode causes the selectcd churazteristic to k stored
In the case of a square-root characteristic. the tr:insitiiln point can he spi.iifi?d (see
section 5.3.12). In all modes the sign "a" is displayed Ths rrnncrnittcr for flow
measurement will be delivered with the factory setting "SroFF'.
 Please note that if the input pressure is displayed. selected in mode: I3 (see section
5.3.9) and the square root cliaracteristic in mode 1 1 the difft.rential prrssure
corresponding to the flow and additionally the sign "."
is displn!.ed on the LCD.

5.3.12 Transition point of square-root characteristic

When measuring rate of flow with a pressure source, the transition point of the
square-root characteristic can be set between 5% and 15%)of the rate of flo\v. The
output characteristic is linear (see F i ~ u r eI l ( a ) ) k l o w this point or ci~t-off(cee
Figure 1 l(b)).
Step A: Select mode 12 using the " W k e y

Step B: Use the 1'or -1 key to selecttnntition point of the square-root charncterist~c
Changing the mode causes the selected transition point to hr storrd.
Please note that if the input pressure is displayed. selected in rnode 1 7 (see section
5.3.9) and the square root characteristic in rnode 1 1 (see section i.3.11) the
differential pressure corresponding to the flou' nnd ;~dditionally the sicn "a" 1 5
displayed on the LCD.

Transition mint of sauare-root characteristic

:00

Adl"i!i"g
iangn 13,
63 ,,zn2.'80n
polo,

,.
60 L-- -..

... . ,
,, ,
: 20 ,
,'
,
, ,
:I

: 0
0 : 20 "0 60 80 700
~ ...
pressure lo<!
Maintenance
The transmitter requires no maintenance. However. the start of sc;ile \~nlucshorlld he
checked occasionally.
If an error occurs:
the output current i s set to 22.8 mA or 3.6 n ~ 4 depending
, o n selrcrion (set
section 5.3.7)
using SIPROM P 3n appropriate mixsage is displayed in tlic "Mencured values"
field
"EmK" is displayed on the LCD
 Table of contents

Regulating feed water valve

Control valves, type 4701471

General .................................................................................................................. 1

Pneumatic actuator, type DP

Reversal of the actuator action

Manual operation device

Positioner, SIPART PS2 6DR4000

--

Electric connection of the positioner . . . . . . . . . . .

Pneumatic connection
. .
Coniniiss~on~ng ............................................................................................. 5

Language U K Pace 1 / 1
Contro! valves, type 470/471

1 General

This type of control valve is suited to regulate fluids. gases and steams. The valve
plug is normally a parabolic plus, hut can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always nzainct the closing direction.
However, with perforated plugs for steam and gases. it i s in rhc closing direction. If
;I valve with a perforated plug is operated by means of a pneumatic actuator with the

flow in the closing direction. the pneumatic actuator shol~ldhave :I stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can he fitted alternately with nianital-. pn5umatic-. cicctric- or
hydraulic operation devices.

Illustration of control valves tvpe 470 and

--
471

-- -
Figure 1 \ al.17x.tif
 .- -

Table 1

Operation

2.1 Fitting instructions

-

The valve should be inserted so that the spindle has LI venical position topcrlicr wilh
the actuator. The valve can also be tilted to 3 m:~xim~lrn hnrizont;ll position i f the
installation point does not allow any better condition.
To guarantee a disturbance free function or the control valve. tlic inlet and outlet
stretches of the piping should be of stmight pipin? Iengtl~iliiin. two times the pipe
diameter by inlet and six limes by outlet). The pipiny should Lw rinsed to clear out
any pollution, welding beads, rust, etc. hefore insenins tile control valves. !4 strainer
should be fitted in front of the control i'alve to catch illr rcn1;lininr particles. Bolt5
should be tightened after taking into operatic*.
The flow direction is signalled by an m o \ v on the v;~l\ehod?. The i . ; ~ l ~ 4lould
rs ht,
insulated against high temperatures to guard the actu:ltnr.

2.2 Actuator assembly

--

The control valves are normally delivered with :ictilators already fitted. For
alternations or maintenance of actuator. t h ~assrmhly .;hor~Idrrcur in accordance
with the operation instructions for the actu;ltm>r.

2.3 Setting into operation

Wliun the piping system is filled, the spindle sealing should he chtcked i;lr 1e:ih;lgc
and, i l necessary, tightened. A PTFE-\!-ring unit doe\ iiot rsquire any rightcning 11s
the spring tension maintains the necessary fcrcs.
The bolts must be tightened gradually in steps. diamc.lric:ill! in p;iirs. hut i i i ~ ttightcr
th;in it is necessary for the sealing. Flanfe connection holts should never he ioose~icd
or tightened when the valve is under te1nper:iture nr presrlrc e\.en i f a le3h:lge !nay
arise.
For actuators please see to the appropri:ite 3ctu:itor opcr3tioii instnrctioils
Maintenance

Before any maintenance of the control valve is carried out. the piping system must
be shut off and pressure free.

3.1 Exchange of the stufi ng-box packing

--

A leak stuffing-box packing should initially be carefully tightened to stop the

leakage. If this does not help, a new layer should he inserted. or the complete
packing should be replaced.

3.1.1 Additional packing layer

Step A: Open the valve fi~llyand unscrew the Iiexa~onnuts 1171

i gland flange (7) and thc sp~ndlegu~dlny(8) upw:1rd5

Step R: L ~ fthe

Step C: Insert adequate quantity of packing r i n g (split rins-displacement. splilting

at 180" to avoid overlapping).

Step D: Fix the hexagon nuts (17) properly

3.1.2 Exchange

Step A: Drive the actuator into middle position and dicrn:~ntlethe :~ctuator

Step R: Unscrem the hexagon nuts (17) [ram the ctudc (151

Step C: Remove the gland flange (7). the spindle guiding 181and the old stuffiny
box (10) and clean the packing comnartment.

Step D: Clean the valve spindle and check for damage and if nccesslny replace. I f
the damaged spindle is not replaced. the new pncking will leak after a shon
period.

Step E: Insert the new packing rings (split ring-displacement. splitling ai 1SO" to
avoid overlapping).

Step F: Fix rhc hexagon nuts (171 properly.

--

Note: Strenuous tightening will prevent leakage, but will also have a hrake
effect on the spindle which aggravates the movement of the spindle.

3.2 Exchange of a PTFE-V-ring sealing unit

,A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good
seal even by low operation pressures. It is replaced as mentioned nhovr.
The PTFE-V-ring sealing unit should hc lubricated &fore it is inserted. The sealin?
lips must face against the pressure direction.
 ...
.....
.....
~ ~

.liiiiit.
Ah. ' 'QG
I r [ '

Note: Special care should be given to the spindle surface. Rough surfaccs w e a r
the sealing lips enormously ant1 can be due to failure o f t h c packing unit.

3.3 Exchange of the bellow unit

Step A: Drive the actuator into middle position and dismantle the actuator.

Step R: Unscrew the screw joint (7.1 ).

Step C: Unscrew the hexagon nuts (17) and remove the l>elloi\' I~oc~siny(251.
Dismantle the plug as descrikd in the next section.

Step D: Unscrew the hexagon nuts (17.1) and dismantle the mountin? honnet (3.1 1.

Step E: The bellow unit (26) is removed from tile hellow housing I 75 1

Step F: Replace the two gaskets (15. l j and the gasket I I J i ~

Step G : When the bellow unit (26) is replaced. the proper position of the n n t i -
twisting device must be ohservt?d.

Stcp H: The set pins (21) have to drive within the s l o t of the nn!i-tivisting device.
Check for friction-free movement.

S t e p I : Replace mountlng honnet ( 3 1) and scren dn\rn the hs\arnn nut< (17 1)
crosswse.

3.4 Exchange of the plug-s pindle unit

-

Step A: Drive the actuator Into mtddle pocltlon and d~$rn,rntlethe .Ictuntnr

Step R: 'Clnscrcw the gland flangc ( 7 )

3.4.2 Control valve type 470

Stcp 4: llnscrew the hexason nuts ( 1 7 1and disrn:lntlc thc mnuntillq honnci (3').

Step R: Pull out the plug with the spintile and erchancc this u n i t .

Step C: Remove the spring-type straight pin I 19) :lnd rlnscrciv tlis spindlc ( 6 )

Step D: Replace the old parts and assernhle r t

Step E: Drill a hole through the plug shaft and inscti n neu pln

Step F: Replace the gasket (14) and assembl? the m o ~ ~ n l i nhnn~lct

p i?)

Step G : Tighten the nuts (17) evenly. crossu.ise.

3.4.3 Control valve type 471

Step A: Unscrew the hexagon nuts (17.1 and dismantle the hc.lln\v liousin~( 2 5 ) ivitti
plug (5).

Step B: Drive the spindle in the hotton1 position and remove the spriny-typc straight
pin (19).

Step C: Unscrew the plug

Step D: Screw a new plug at the spindle and drill t h r o u ~ hthi- shiifi. Drive the
spring-type straight pin (19) into the hole.

Step E: Replace the gasket (14)

Step F: Assemble the bellow housing (25) with plug (5) tosether u,ith thc hodv ( 1 )
and fix it by screwing the h e x a ~ o nnuts (17) crosswise.
The spindle can only be completely replaced together with the hclio\v.

3.5 Changing the seat ring

The seat ring is screwed into the valve body. The seat ring can hc o1~t;iined after
removing the honnet and can then be refinished or replaccd as reyaircd.
Step A: Clean and lubricate the thread and conical sealing siirkicc hcfore iiisertinn.
Pneumatic actuator, type dp

1 General

The pneumatic linear actuator is designed to be mounted directly on a control valve.

The pneumatic actuator converts positioning command signals into stern thrust
forces. The required back setting force is produced by the spring amngement inside
the actuator. The rol1ingdiaphra.m produces linear spindle movements over the
complete stroke.
The preferred mounting position is with the actuator and valve spindle in vertical
position.
The mode of operation for the actuator depends on how the sprinss are inserted
when the actuator is assembled. Even when ille actuator is fitted in :I piping system.
the mode of operation can be chaneed.
The pneumatic actuator can be operated as:
Spring opens valvdair closes \.alve operation mode
Air opens valvelspring closes valve operiltion mod,:

Illustration of a pneumatic actuator

Figure 1
Table 1 below shows a list of the pos~tionnumbers in Figure I .~ndFigure 1

Table 1

1.1 Pneumatic connection

The air supply should be dry and at a lour service tenlperature. ,4heat-guard should
he installed to prevent high service temperature.
The pneumatic supply tube must he connected to the diaphragm housing (2) by
operation mode "spring closzs" and to the diaphraem lid (3) h! oper~ltionmode
"spring opens".
By air failure the stem automatically returns into the orisin31 pocitinn caused by :lie
inserted springs.

Warning: The actuator diaphragm may onlv be prcssure loaded on the sidr
opposite of the springs. The v m t hole in the other connection must
remain open.

1.2 Assembly of the actuator on the valve

The assemblinfi of the actuator on the valve is shown in Figure 2. For both "spring
closes" and "spring opens" operation modes the follo\vinr ;issemhling prwedure
should he followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode "spri~ir.cli>ses" nr into the
open position for operation mode "spring opens"'

Warning: Make sure that the plug does not turu nhile pres\ing on the seat
during assembly.

Step B: Loosen the socket screws (13). remc~vetherotation guard ( 12) and the guidc
flange ( I I). The threaded hushing (14) is now free.
 Step C: Turn the locking hexagon nut ( 3 0 )onto the valve spindle, Pl;ice the rotation
guard (12) and the guide flange ( 1 1 ) ovcr the valve spindle and ihen turn
the threaded bushing (13) onto the wive spindle.

Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connectioli piece in the diaphrasm housing ( 2 ) for operation
mode "spring closes" or in the diaphr3gm lid (3) fnr operation mode "sprin:
opens".

Step E: Drive the actuator into approximately inid-stroke position over the air
supply and mount it onto the valve iread the value from the pressure gauge
- middle of the spring ranger.

Step F: Tighten the hexayon nut5 ( 3 1 )

,issernhly of the actuator on the valve

-
i1p.r ilirn rnodc Spnog closer valve Air OpenJ mlve O p e n i ~ o ii~iode
l Spnlic oi*.il%\ n l ~ -r :\ir closes r a l i e
 1.3 Adjustment of the starting pressure signal

Step A: Drive the actuator to the required spring-starting point over the air suppl!..

Step B: Turn the threaded bushing (14) up against the coupling flange 110) s o that
the collar enters into the flange and presses vainst it. Make surc that the
plug is lying on the valve seat.

Attention: Note that sufilcient thread of the valve spindle is inside t h e threaded
hushing (14). If not, t u r n the coupling flange (10) downwards from
the actuator spindle a n d pull the threaded bushin:! (14) a ~ a i n s it.
t

Step C : For operation mode: "spring c!oses"

- Attach the guide flange (11) and the rotation guard ( 1 1 1 xikh the c c x k e t screws
(13) to the coupling flange (10).
- Check that the plug lifts off the seat at the required sprinc rt:~rtincpoint.

S t e p D: For operation mode: "spring opens".

- Check that [lie plug leaves the end position at the requiretl s p r i n ~s!artine point.
and finishes the valve stroke at the spriny-ranfe end vnluz.
- The plug must then also press on the valve ceut

Step E: After the test operation set the stroke indicatc)rs (1.51i t i t ( > the cnd positions.

Step F: Lock the hexafon nuts (16 + 3il) at the valve mid-strmkc.

Step G : Do not turn the plug on the seat uhcn i t is under iorcc

2 Reversal of the actuator action

.- --

The actuator action can he reversed even when the v 3 l v t is installed in a pipins
system. The position numbers mentiont2d i n this section reltr 1.7 Ficurc. I arid Fijiure

Step A: Drive the actuator into appri>xirn.itely niid-strt:ke pc>cition with thc air
supply.

Step B: Loosen and remove the socket scre\\:s (131 from the couplin!: flange (111)
and drop the rotation p a r d ( l l i over the v:~lvecpindlc.

Step C: Remove the hexagon nuts ( 3 1) from the nctuittor ;?lid lift off thc. i.al\,r.

Step D: Reduce the air supply until the chamber i~ pressure frcc
Step E: Loosen and remove the diaphmgni lid screws

Step F: Remove the diaphragm lid (3).

Warning: T h e actuators DP 32 and DP 33 have two longer screws when fitted

with stronger spring ranges. T h e actuator DP 34 har four. These
screws should be the last screws lo I)e looqenetl, a n d must he
looseued evenly to reduce (he high sprinz tension.

Step G : For reversal from "spring close<" Into "spr~nyopen\'-

- Remove the springs (7) and the diaphragm plate ( 4 ) with the di:lphr:lgm ( I ) and
the spindle (5).
- Loosen and remove the seal lock nut (19) and remove thc spindle (5'1.Turn over
the diapluapm plate (4) with the diaphrayn ( I I and the di:~phra:nl clampin?
flange, and place it over tlie spindle ( 5 ) .
- Tighten with the seal lcrk nut (191. bl:~kesure th;i~thz spindle surl:tce is not
damaged.
Grease the spindle surface and the 0-rinr
- Place the d~aphragmplate (4) wlth the d~aphrayrnI I ) ~ n t othe t11.1phrazm11d ( 3 )
- Arrange the sprinzs (7) onto the rnol~ldspressed into the Ji:~plir;~i.m
pl;ltc (4).
- Place the diaphragm housing with [he spindle ssaling unit lover the spindle. and
screw it together. Make sure that the sprinys stay properly : t n a n ~ c d .
- Turn the hexagon nut (16) and the I ilupl~npf l ~ n r e(10) unto tlir \plndlC (5)
- Mount the actuator as described prc\,iously. and connect the ; ~ i supply
r tuhe to
the diaphragm lid (3).

Step H: For reversal from "spring opens" inro "spring close.;":

- Remove the diaphmgm ( I ) and the diap!lra:m plate ( ? \ \<it11 ihc spindle 1 5 ) :~nd
the springs (7).
- Loosen and remove the seal lock nut ( 1 9 ) from the spindle 1.51. Turn over tliie
diaphragm plate ( 3 ) with the diaphmgm ( I ) and the diaphr:~,zrnclnmping flnnee.
and place it on the spindle ( 5 ) ~
- Tighten with the seal lock nut t 19). M : ~ h csure 11131 flic ipindlc sur!ace is not
damaged.
- Grease the spindle surfacc and the O-ring
- Stick the diaphragm plate (4) with rlie diaphragm 1 l i and tlir spindle i i i inlo tlie
diaphragn~housing ( 2 ) .
- .-%mange the springs (7) onto the moulds pressed into the diapIir;r~inplate ( 4 ) .
 Place the diaphragm lid (3) on the top. and sore\\ ii iorether. 3I:ihr sui-e that the
springs (7) stay properly arranged.
- Turn the hexagon nut (16) and the coupling flange ( 10) onto i h u spindl6 ( 5 ) .
- Mount the actuator as described previously. and connect the ;ilr supply tube to
the diaphragm housing (2)

3 Manual operation device

Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new d i a p h r a ~ mlid, a spindlz extension with a USIT-rins
and a spindle sealing unit.
The manual operation device is equipped with stroke indic;ilors. Thc stroke
indicators of both the actuator and the manual operation de\ ice rnllst he in ihc sarne
cnd positions when the actuator is pressure free.
The manual operation device must be set into neutral pos~tionwlien the ;ictuator is
running automatically.
The locking device of the manual operation dcvice must hi. ~ t n l bcfc~re ~ ~ ~ d
operating.
The locking device prevents an unw:lnled disamangcment of tile sctliny during
operation. e.g. due to vibration. etc.

4 Maintenance

Thc pneumatic actuator is maintenance free. T o maintain n ~listurb:ince rree

operation. the air should he supplied by an air-supply static~n.
The diaphragm, spindle sealinf unit and r p r i n ~ s:ire wcnr p;in?- : ~ n dshould k
rzplaced when necessary.

4.1 Exchange of spindle sealing

.
. . -- -

When the spindle sealing is changed, the slotted PTFE-~uide1,e;~ringand the (1-rins
should he replaced. The spindle surfac' must he clean and i~ndamagcd.nerore the
actuator is assembled, the spindle unit 2nd the spindle milst he greaccd.
1 General

The electronic pneumatic positioner is used 3s the final control element of a

pneumatic linear actuator or a part-turn actwtor (rotary movements). The positioner
converts a current signal output (e.g. 4 to 20 mA) as a set point value by ;i process
controller or a control system into :I corresponding mo\'ement. The positiorler
changes the pressure in the actuator ch:~mber(s)until the pocition ccorresponds to the
set point value.
The positioner is available either as a single-action positiontr or a do~rble-action
positioner. The single-action positioner is mainly used together \vith a control valvc.
The opposite movement for the control vake is supplied b! means of springs. The
double-action positioner is mainly used to control an air dnrnptr via a pneumatic
cylinder (actuator). AIl movements of the pneumatic cylinder are supplied by the
positioner. An illustrations of tlie function diagram for tlie positioncr is shown in
Figure 1. The function diagram is shown with option n~odulcs.

1.I
Mode of operation

Cornparison of the set point and the actual value takes placc electronically iri :I micro
controller. If the micro controller detects 2 dc\,iatinn. i~ uses a five-poinl swilch
procedure to control the piezoelectric ~!:alveb. which in turn regulate the flow of air
into the actuating chambers. When connec~edin a t\r.r>-\virt system. tlic SWART
PS2 draws its power exclusively from tlie 4 to 20 mA set point sifnal.
If a large deviation arises hetwcen the sct point and the indicatetl operation position.
the actuator travels continuously d u . to 3 sustained current output from thi.
positioner (high-speed zone). Within the zone of rnocleiate system deviation (short-
step zone) travelling occurs in iinpulse sequences of minimum length. The pulses
a i f e c ~differences in the pressure of the actuator chamhcl-tsi : ~ n d consequently
initiate an adjustment. No positioning signal is O L I ~ ~ Li nI I the case or 3 sm:111 conlrr,l
deviation (adaptive or variable dead zone).
(:ommissioning (initialisation) is camed out aotomatically to 3 I:~rcce~tc'rid.Durillg
initialisation, the micro controller automatic311y deterriiines tlie zero. Cull-scale
value. direction of action and positioiiing speed 01' the acru:itor. It uses these lo
determine the n~inimumpulsetime and the dzad zone. tlius optirnisiilg lhi. control.
The positioner can also k operated manually hy {lie pushh~lt~orir : ~ n dthe 1-C'D oilhi.
SIPART PS2.
The installation of the positioner must t*.cmied out in tli? lollo\\ ing order.
Mechanic connection
Electric connection
Pneumatic connection
Commissioning
 Illustration of a function diagram
-- -- -- --

D
Micw
mnlroller -

-~ ~~
. .
LC? A, 112 9
, Travel

1 Molncrboara mi', -11croconrro1Ier and i n p d ciicull ;, ,\!arm module lor :i ..jI:krr oulp;lr Z
C
I 1 i r s r , a,,!:.~!
? Control panel w ' P LCD and pu;hbulIons 7 IiART TOCILIP
3 Plerwleclrlcvai:~ uhil always bulll-in 8 Sprincr-loaded prieurnallc a;!~i!l>r !s:nqlr~a~.':ii!
'. Vzlve unll, bultf-ln :s accessory in double-acllon posrroiler 7 snt~ncless pneumatic ac-ua1.r l n n t , ! ~ I i ~ i c : o - ~ ~
5 I, .indue far SIP:-T FS? roniinllei funcltandiagram

- -
Figure 1 sips2a.tif

2 Mechanic connection of the positioner

Nor~~iallythe positioner is pre-mounted on the actuator. I f not, follow the installation

guide lines below. Figure 2 shows the mechanic connrcrinn nf the pcisitioncr to an
actuator for a control valve.

2.1 Mechanic connection t o an actuator

.- -- -- -- - - --

Step A: Mount clamping assembly (311 with hexagon hz;id <crcu.s ( 1 7 ) :~ndspring
washers (16) on the actuator spindle.

Step R: Insert the pick-up bracket ( 2 ) into the recesses of the clampins assembly.
Set the required length and screw only so tight that thr pick-up bracket can
still he shifted.

the spring (13) and the guide wushcr ( 2 2 )onto the pin i?).
Step C : Place the roll (3,
Step D: Insert the pin into lever (6) and asscrnhle \vith not 1181. s p r i n washer (14)
and U-washer (12).

Step E: The value of the stroke mnge specified on the actuator is set or. i f this is not
present as a scale value, the next larger scale value. The centre of the pin
must be positioned to the scale value. The same. \'aluc must he set later for
"YWAY"during start-up.

Step F: Fit the hexagon head screw (17), spring \r.asher (16). I!-washer (12) and
square nut (19) on the lever.

Step G: Push the pre-mounted lever onto the positioner axis as far 3s possihle, and
secure the hexagon head screw (17).

StepH: Fit the mounting bracket ( I ) with two hexagon head screws (q). spring
washer (10) and U-washer (1 1) on the rear of the pocitioncr

Step I: Selection of the row of holes depends on the width of the actuator yoke. The
roll ( 5 ) should engage in the pick-up bracket (2) :IS close to the spindle as
possible, hut must not touch the clarnpine acs?mhly.

Step J: Hold the positioner with the mounting bracket on thc actuator sib [hilt the pin
(4) is guided within the pick-up bracket (71.

Step K: Tighten the pick-up bracket

Step L: Position the mountins parts according to the type of actu:liur~

- Actuator with ledge: hexagon head screw (S). U-wiisher i I I i and sprine wnshcr
(10).
- Actuator with plane surface: four hexagon head screws (8). L'-iv;~shcr1 I 1:) and
spring washer (10).
- Actuator with columns: two U-bolts (7). four hexagon nuts (21 I \vitli I.lL\vaslicr
( I I ) and spring washer (10).
Step M: Secure positioner onto the yoke using the previously po.;itioncd inouminc
parts.

Step N: Adjust the height of the positioner so that the horizontal lever p(~sitionis
reached as close as possible to the centre of the stroke. T l ~ ele\.er scale of
the actuator can be used for orientation. It must alivays hc. yuarn~ltredthat
the horizontal lever position is passed throuyli within t l x itrokc. range.
Mechanic connection of the positioner (linear actuator)

Figure 2 qips2b.lif
2.2 Mechanic connection to a pneumatic cylinder

The positioner is connected to the pneunwtic cylinder hy means of n fixing bracket.

a lever arm with an Allen screw. an extension a m and a roller.
The pneumatic piston is connected to a guide rail with an oblique angle via a
linkage. The guide rail moves together with the piston. and the rollerllever
connection senses the position of the piston. By operating both sides of the
pneumatic cylinder, the set point is reached. A spring inserted hstween the fixing
bracket and the lever arm secures that the roller is pressed down against the guide
rail.

2.3 Mechanic connection to a rotary actuator

Figure 3 shows the mechanic connection of the positioner to n rot;lu :Ictoator

Step A: Place mounting console ((9). actuator specitic) onto the rear of rhc
positioner and secure using hexagon head screws (13) nr~dlock washers
(15).

S t e p R: Adhere pointer (4.2) onto the mounting console in the centre of t l ~ ecentrinc
hole.

Step C : Push coupling wheel (2) onto the positioner axis as far :IS possible. pull
hack hy about 1 mm. and tighten hexagon socket scrcw i I X ) 11si11gthe .Allen
key.

Slep D: Place the driver (3) onto the end of the actuator sliafi and secure usin?
Fillister head screw ( 1 6) and washer ( I 7 ) .

Step E: Carefully place the positionsr with mounting console onto the ;ictuator cri
that the pin of the coupline wheel engases i n rlie dl-iwr

Step F: Align the positionerlmounting console assemhly in thc centrc of the

actuator and screw tight (screws are not included i n th? delivery. tl~evare
part of the actuator mountine console).

Step G : Follow the staa-up sequence 3s described later. L>rive the actuator lo the
end position and adhere the scale (3.1) onto tlic couplin: \\heel ( 2 )
according to the direction of rotation or the turning ranee. Th? scale is self-
adhesive.
Mechanic connection of the positioner (rotary actoator)
3 Electric connection of the positioner

When the positioner is connected in 3 two-wire system, the positioner draws its
power exclusively from the 4 to 20 nu%set point signal.
With ?-wire connection the compliance voltage must he 2 10 V ~vithontHART
module and 2 11 V with HART module.
With 3-wire or 4-wire connections the compliance voltage must 1x 0.8 V without
HART module and 1.8 V with HART module. The power supply Ill, must he
hetween +18 V to +35 V.
Figure 4 shows the input circuits for the positioner.

Illustration of input circuits

2-W(re system 314-wire system

Figure 3

4 Pneumatic connection

Warning: For safety reasons, pneumatic power may only he applied during
commissioning when an electric signal is prcsent. ant1 the positioner
i s in "P manual mocle".

1.1 . l Selection of P manual mode

Refore pneumatic power is connected. [he positionrr nilist hr in P moiiu:tl mode (set
Figure 6). The display must show "NOINlT" in the hortorn lint,.

1.1.2 Pneumatic connections

Figure 5 shows a view of the positioner controls and connectinns.
Step A: If required, connect a manometer to mcasure the supply air aridior the
positioning pressure(s'l (normally not connccredj.

Step R: The silencer in the exhaust output (E) can he rcrnovcd i f nccrss:lry.

Step C: Connect positioning pressure Y 1 and/or Y 2 accordiiig to the desired safety

setting. Y2 is only used in connection with douhle-actinn acruatnrs.
 Step D: Connect the supply air (PZ). Thc pressure should he k t w e c n 1 - 1to 7 ha1

4.1.3 Safety setting on failure of the electric suppl!

For a single-action actuator is Y 1 vented For a douhlc-action .Ictuator I< Y I cqual to
the inlet pressure and Y? is vented.

View of the controls and the connections

1
I
View of device (cover o ~ e n ) I

-- -
Figure 5 sipc2e.tif

Commissioning
-- -

Commissioning (initialisation) is carried out automatically to a large extend. Durins

initialisation, the micro controller automatically dctcrn~inesthc zero vitlue. rull-scale
value, direction of action and positioning speed of thc ;Ictustor. It uses ~ h c s elo
determine the minimum pulse time and tlic dcad zone, hereby oplirnising thc control.
The positioner can also be operated manually by the pl~shhuttnnsand tiit. !XI) of the
SIT.ART PS2.
The connmissioning of the positioner can he divided into the l l l o w i n p ctcpi:
Check the mechanic mounting
Start the automatic commisrioning prcxedurc
Set additional parameters if required
Select automatic mode
The table in Figure 6 shows the operating levels for the positioner. Thc lc.vrls are
automatic mode, manual mode, configuration mode and P-manual mode. From these
levels it is possible to select operation mode, set operation paramcrsrs. rectorc to
factory setting. run an automatic initialiyation. ctc.
Operation levels
Changing the input level
-- Display
-- .
Mode I
I

5.1 Check the mechanic mounting

5.1.1 Check the centre position

Without initialisation the positioner is in "P manual mode" and "NOINIT" tlashc.;.
This level can also he reached hy using "3h.PRSTW(see Tahle I I.
Step A: Check that the pneumatic supplv (inlet air) is switch?d on

Step B: Use the push buttons A V to carefully rnove the actuator nnd cl~cckthat tile
mechanics is functioning.

Step C: With linear actuators drive the actuator to Iiorirontal lever porition. The
display must indicate 48'7) to 5 2 ' i . If neccccary. correct the ;.slue h y
adjusting the sliding clutch.

Important: After the check is completed, the actuator must be approximatel!

halfway along its stroke. This is clue to estal)lishme~ltof the action
direction during automatic initialisation.

5.2 Automatic initialisatio n

-

Figure 7 shows the configuration level and the operation in this le\.el nr~dTahle I
shows the configuration list. Figure 8 shows the initialisation process of the
positioner. The initialisatinn process is stored in the microprcessnr. This m a n s that
an additional initialisation only is necessarl, if any parts ot the unit have been
changed.
 Note: The numerical values used in Figure 8 a r e examples.

Step A: Call configure mode by pressinq the hand symhol ke) (>5ccc t

Step B: Set the used actuator type rotary ( t n n ~ or

) l~near((WAY I in the rnenu item
"1.YFCT"

Step C: Set the rated angle of the feedback in menu item "?.YAGL" The value
must agree with the setting of the ratio selector on the powloner

Note: The angles 33" and 90" a r e possible when a lever with a stroke u p t o 35
m m is used. The long lever (stroke >35 mm) only operafes with an angle
of 90"

Step D: When a linear actuator is used the set levera~e(stroke r:lnrc) must be set in
menu item "3.YWAYU.

Step E: Start the automatic initialisation with the parameter rnlue "SLIT" in mcnu
item "4.INTT"

Step F: The positioner then runs throu;h thc initialisatiorl s t e p "RCrh' I " lo "RUN
5".

Step G: If problems occur, carr?; out the measures ;is descrilwd in the tnhle
"Possible messages" in Figure 2~

Overation in the confieuration level

Configuring
- - .-

L?npngr UK Psrc I O I l i
 lnitialisation process
. - - -
Possible messages
-- -
/ Oisptay I Meaning i Measures

A d v l o % q e message

C h e d restridor (6jand o w n
fnec~ssary

CDrrect height sentng

Continue using ,L.

Automatic initial startup

g a l 3 with factory sen!ng) continue using ''.,

L-.
0a"l"m
~e"Blo4

j n e a i anuatar ' Acknowledqe message

using

Addlionally posslhle wllh rotary

Checking of travel and adjustment

Dstermimtion of pxilbning time

Oisplay of posmning time

NUZZLE '0°

lnilial'lrationterminated successfully
Contlnuc using
[travel in mm fw linear aduators)
FINISH [angle of mtatlon for part-tum
actuators) -- .- - .-- - -
~~ --

Figure 8 \ipsth.tir
 5.3 Configuring

After the initialisation process, the positioner can he configt~red to mect the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed. Table 1 shows the configuration list for the positioner.
The parameter YCLS is normally enabled when the positioner is used tosether with
n control valve. It is not necessary to carry out n new initialisation process.

turn part-lurn 3ctu3torI

3 Y L V . ~ Y " Le:,:rare ratio (stroke rangel

rni!<t cnnespnnd to sct leucrz.gc ratio

-.,
Dryer pin must be set to ihc value of the
art'intor travel or, if this value is not scaled.
10 ill.: ncxt lager scale value
I:
30
.
lever "00
nxm
1
i
i
UFI

No" / # f . or OFF
I LNIT ln~l::?lisstton 11~1
So1 -.
SSCI IR Cri-inl r a n y of set p i n t
0 lo 20 mA
4to20m.A
0 rn.?
4 mi\
rn? 1 I,i
rising nSI:
6SDlR Sr: mint direcrion falling FALL
7SPRA S c i p i n t for s l m of split r q c 0.0 to 100.0
P SFRE t md of split range
S c i ~ p i n for 0.0 to I M . ~

10 S K T / Fqual-percentage I 25
Sc! n i n t functton
Equal percentage 1 50
Frcely adjustable
11.~1.0" /Fmlnl
!umlne mint at 0%
 . ....
..
. .. .
,liii.i.il.
. . .
API L.* 'QG
IE

Tii!i~iclosing wilh Top only

Bottom only I UP.
:dW I Ii
;lo

On!; message INC contact)

Onl! message (NO contact)
R!i>.:k confi-mring (NO contact)
Fi!iv:k configuring and manual (NO contact)

I
~~ ~ ~

A l = m x . A?=mau. MA:blA ! i
Lhreshold o f a l a m 1 1 0.0 to 100.0 1
threshold ofalaml 2 0.0 to 100.0
F!,-;<tion o f alarm output on f311lt I L 1 1 i
Fnt:lr + not zulomatic
i
,\i!tn i
0 LO Ioa I
1
Pr?,.:t (factory setting)
" n . 1 n o l h ~ activated
n no

EI I; Shn" s t m o l factory setting nfler pressing

? ~ . P R S T i... *or 5 sec.
" I ) ' XY" display following successful
1 5117 I j
i
I
iac;,~ryssttinp
C:,llTTON:
- preset results in "NO WIT" i
Table 1
"If turn is selected it is not possible to set 3 3 " ~
" Parameter only appears if I.YFCT=WAY has heen selected.
" Turning points only appear with selection IO.SFCT=FrEE.
' NC contact means: action with opened switch or low level.
NO contact means: action with closed switch or high level.
''Alternatively "no" if initialisation has not yet k e n carried o t i t .
 Table of contents

Chemical dosing pump

Instmction .......................................................................... . . . ......... . . . . .......... I
Operation and maintenance
 ...
...
.....
..... P 0 Box 661, 24 C Garvaerkrvej
9100 Aalborg, Denmark
Tel.: +45 99 304000
Fax: +45 98 163022
AACqi;(Cj?PG E-mail: aalg@aalborg-industriesdk
I h. http ~ / w w w ~ a a l b o r ~ - ~ n d ucorn
~tr~es

INSTRUCTION MANUAL
FOR INST4LLATION,
OPERATING,
AND MAINTENANCE.

r Dosing pump

This .:lanual shouid be made available to the person responsible for instsllaiion,
operating and maintenance.

.- ~~
-. ~
~.~
Date : 12/09 0 1 Ref : T.160.0401.001.Rev. E
 I GENERALITES
1.1 - INTRODiJCTION
The mRoy pump ti a dosing pump with incorporated hydraulic diaphragm, 01-lut.;ca!ea w ~ t hsealed ticuslng.
with a variable sivepl-volume adjustment which can be set when stopped or runnlni; It 1s des~gned:or
C O ~ ! I ~ L I O U service
S in industrial operation

1.2 - OPERATING PRINCIPLE

- Worm (052A) i l.ngent wheel (052) pair drives connecting rod (214) through n?eE,?r of tt-1~2
eccentric of whe;i (052)
- Connecting rod :214) gives piston (012) a reciprocating motion kith conslant stroke
- Tnrough meanc o f 011 contained in chamber (D), the piston drives diaphragm (2Pii.1, ihelr: fast
between 2 conto!!r plates (298).
- Relief valve (21::4) protects the pump.

Suction phase.
Piston (012) drav,- back and sucks in the oil (H) behind diapnragm (208A). The d!ferenial prsssure which is
created is transr.,'ted by flexible diaphragm (298A) enabling the pumped fluid tc be drawn in n'ith pedec!
n pump mechanical parts and the pumped fluid. When ad!ust!ng slee've (E) l i n k ~ d
SeparailGn b e t ~ i r : ~ ithe
nechanlcally lo +ton (012) opens orifice (B) of oil bypass (C), the additonal o!! is sucp!.--dby housing (081).

Discharge phase
Piston (012) rnov.:; forward and forces the oil back to housing ( E l ) throuah by-p?ss ( C j and orlilce (B) untl
thls orifice 1s bloc:?d by adjustment sleeve (E). The 011then pushes dizphragn i 2 E 5 h j u!hi:h moues forward
proporhonally to f r ? fraction of remaining swept-volume, after blocking orifice (B'.T i e di;s?zi liouid is pushed
back by the d ~ a p h r ~ i gthrough
m the discharge check-valves
Flo21rate ad~ustmi:lt.
-I he d~schargefc:.rate is adjustable when runnlng, from 0 to 1003;. by tur9ing adjus:nitnt knob (255) vihicn
displaces, i~ the -1 bath, and thus w~thoutany effort, adjustable liner (,?I;&) a n s i x i s it;e posiiion of ori.7ce
151
 1.3.3 Technicai characteristics for mRoy B with a 0 22.2 piston

I
( l i 121 Martmum 1 scharge pressure in bars relal8ve i Y 70 43 , il ..
i" hbnxlmcm so::lon pressure tn bars (Pa] :ii.
(3iPulaxlmumnci'?le in U H ( 0 1 at pressure or l o b

I
-
-
Speed in strokes ' min 3'1 55

htolor power in:'.I

M0:or $ w e d in rnni 900 11:O ::-

-
'
litO1or rnounl~ny Ibnge F155

Shah

;5) Maxrmum hzr;+.l of suction in mce (Ha) 1 C

I of puts-: #-,ndampener in ructlon
~cIume C13L

Volurre of p u ! r a : r l dampener m discharge C 13 1.

Pre-expanzmn o; i l ~ l s a l ~ odampener
n in d:scharge 60'; of sewice risism.:.?
lilD:52 level ACOL-:c piessuic c7Ode1,Li

S m l l e x pump w . ;hl EC
I I
i Duolex pump v;. ;-:
..
--
cz
--

1.3.4 Technical characteristics for rnRoy B with a 4

3 36.5 piston

i ill (21 Maximum .: szharye pressure in hars relo:ive 1: ZF I 14 I ?? I ..< 1 :I I :.< I 1s 1

: pressure in bars (pal
( 4 ) Maximum s ~ c -n E

.
..
.
I
~ ~

I I 1

I/ E : O ~ O ~power in i..2 1055/ 075 I G55 075 1 1 o:5 1 c,-c, 1 $ -

I
I rn>t-r speed in ri,

I/ ht>t>: mountno ~ 1 2 n a e I
P O ILI::

its.<

( 15) I.lar!mum he?>:afrvclion in mce (Ha) c .i

-- -., /I
1 V ? l ~ r r cof pulsa!:w-. dampener in sucllon 1 5 ~
p~ -

V l l u m ? a f p u l s a : ~dampener in discharge 05L

I,
1; re-expansion oi:,jsation dampener in discharge SO?; o i re-A:e p,e:,.v+
I-.
( h f x i e lcvcl Acou.: p:cssure :C d 5 (,A l1

z!
7 r

/ srn,"~ex pump w e 8 ;
. ~
is
--

@i-pler pump wnl:r! et

iti Contact us fo. i h i g h e r oressures

:.-I : O hars f o r t h ? P " v e r s l o n s
, ? I F/o.,v obtainec on standard c o n f i g u r a t ~ o n i, v ~ t h
water
,:. 6 Bars f o r " P " , ; ? r s i o n s
i n:co = Water :llurnn meter
 II. INSTALLATION
2.1 - UNPACK!NG AND STORAGE
The packing mu? be carefully examined at receplion in order to ensure that the contents have not suffered
zny obvious dar,age. Open the packing carefully: one should be careful not to darnaae certain accessories
vihich may be fl~stenedto the inside of the packing. Examine the contents and check them aga;nst the
dellvery slip.
The packing con!-ins
- One pump.
- Oil, depending r l verslons (see chapter 3.9)
- A list of wear-and-tear parts, accompanied by section drawings and space-requirement dra,r.,inas
- An instruction manual for pump installation, upkeep and maintenance

Storage precau",13115
For storage less tnan 6 months.
Storage 1s to b- carried out preferably in the original packing and protected from inclement weather
co!idtions.
For storage longer than 6 months
Preserue the ori-nal packing. Also provide packing under plastic heat-sealing wrapping 2nd dehydrating
b a g s Store the r : m p in protected, covered premises with full oil charge.

2.2 - RECOMF!ENDATION FOR INSTALLING THE P U M P

Put the sling under the motor terminal box and ~ ~ n d e r

the motor 9ance.
Cross the hvo ends of tile sling and close the loop
(see diagrams).
Before attempting to move it, check !nat the entire
unit is wel: balanced

Nota: As soon as the pump I . in pos;t!on, fasten it

down.

2.2.2 - Installing the pump

- Fssten the pumrJ :o a horizontal support using its fastening holes. Arrange enough free space around the
pump so as to be . ? ~ I to E have easy access, and to ensure the upkeep and adjustments (aczessibility to t i +
liouid end, filling, ;i.:d hous~ngoil draining).
- Connect the p r i r i q g drain of the liquid end to a drip-collecting tank
- If tne sewlce prr-sure is greater f!lan 3.5 bars. remove the spring i?caled in the discharge checi.-vslve box

CAUTION Pump! ! n s t I e ( i zutdoors must be protected from the e:.?rnents

2 2 3 Oil filling ( F - , 1;ii
-
- Unscrew the oil fil : plug located o n top of
tt,e pump
- Unscrew the level I-id!ca:sr localed on the
side 3f the pump
- Pou: tne o ~in i un:; ! reacics tt,e tireadlng
o i ti75 Ikiel indicat:,
- Scri-.h. tlie level ini.:ator back i~
- F11l(12w t h oil to th; m d d s c i tlie level
n31cator
-
- acr?,.A>It:= 011filler Yu? back g i
 2.5 - INSTALLATION SKETCHES
2.5.1 l n s t a l l a t i a l o n suction side

2.5.1 . I Recommended installations

FF. I+!. 1
~
.
.I
~

2
;
I

Flg 2
Fig.2- The pump n suctlon placed above the tank(Ha = maximu2 2 5 m water column) 1s equipped viith a
foot valve fitted a: the suction end (F). Vertical suction.

Fig 3: Long size: pipework (L) requires the installation o f a dzmper which is to be placed as closi as
possible to the r;.:mp. L1 = Maximum 10 metres water column

Fig. 4. The pum:, 'In suction"offset in relation to the tank (Height [Haj s:e chapter 1 S i IS e q 1 ~ 1 p vp~2i t ha
foot valve (F).

2.5.1.2 Installations to b e avoided

-

1 I

.. .

Inclined suctior, >ipe, risk of Suction piping long. Suction

height too great. kc~zumulationof gas ( o c i s ?
un-priming (See Fig. 4. Chap.
ne-4) and rlsk of unprimn?
2 5.1 ;)

2.5.1.3 Special installation

Degassing liquid-

i : Max le,veI
2:Min level
V: Valves
P :Vent
Edegasslng v e s ~ e l

Fig.8
Fig 9 Setting up a degassing vessel (Chap. 2 . 6 3 ) at the pump su~:tion (one thus avods freqasn: ur-
o r i n i n ) Connec! ::1 beween the pump and the inclined degassing vessr:l In order to iacllitate i!i2;iss"f
 2.6 - INSTALILATION OF ACCESSORIES
Proper functloni..) of the pump depends on whether certain acc?ssor es available from DOSAPRO MILTON
ROY are fitted c.: not. The salesman is at your disposal to determine t'ie access3ries which at? best adapted
to vour plant.

2.6.1 Non returi' valve (F)

Necessary whe:, .he pump is fitted above the suction point. Thus minmizing i h s risk of unpriming, it is iitted
with a filter.

2.6.2 Filter

It is very C A U 7 3 N when there is gravity feed: it a v o ~ d saccum~ilationof solid pa3icles ir, the valve
assemblies and ?'Jarantees precision and pump life.

2.6.3 Safety val~dr(C)

The safety valve ;to be vertically installed just above the liquid end, after the damper a r ~ dbefore any otner
accessory. The r+:urn line of the valve should be connected l o the drainage tank or to the sump .The safety
vahe protects tV- meteringpump, the piping and accessories in the event of accid~ntaloverpressure (e.g.
shutting ofi of v;i';/e). This accessory contributes to safety for users by eliminalinp risks of the burs:ing or
idpture of cornyovents under pressure. It is recommended that a safety valv? sihould b? fitted on all
!ns:allalions.

2.6.4 Damper ( C

Compressible gz:-resewe device; this dampens the flovd and pr%suie pulsat~onscaused naturally by the
dosing pump. It is absolutely essential that the pulsation dampener be installed ve'ilcally on tne discharge
andlor suction pi::,ilg of the dosing pump, as near as possible to the latter, beiore any atP,er accessor$ and
for it to be place6 -3 the flow. For the volume and the pre-expansion of the dampener, see chapter 1.5
CAUTION Dami:ner construction materials must be compatible with the Ihquid to be pun-:2td and v ~ i t hthe
pumping piessur?

2.6.5 Non return 'valve (A)

Tne non-return v-ive is to be installed in line on the delivery pioing 1:s operation n a y be improved by
installing a d a m p ~ e located
r upwards o n the line.

2.6.6 Injection nozzle (E)

F~!tedat the injei:on point, it acts as a non-return valve It isolates lhc p r o c i s s z d f i u ~ ij - r : the
~ mat? fluid
(aft?" ivater)

a
.
26.7 lns,~lationValve (F)
the pump 1s not running, it is essential to insulale it from the pressure circuit ivith a manual or automatic
i
va,u+, to prevent ? , ~ return
y pressure in the liquid end, whicil c o i ~ l ddamage thz pressurz p? l.:e c f the oil-
actuated dizphracr:
 I11 OPERATION AND MAINTENANCE

3 . 1 - C H E C K I N G BEFOR S W I T C H I N G ON
- Check t h a t tkw p u m p is properly mounted on its base
- Check the o i ievel.
- Check t h a t tk.3 p u m p is set a t 0%
- Check that a1 t h e isolating valves o n the suction and discharge circuits are 5pen
- Check t h a t t'-c p u m p is properly supplied with liquid.
- I f h o t cold machine parts lead t o a potential danger,
check t h a t tl~t,?these parts are protected against accidental constact at site.

3.2 - STARTUP
- T u n t h e p u m p ON
- Place the vernier o n t h e 50% position, for 10 minutes.
- Untighten b y ciround 1/4 turn, drain plug (8) located on the liquid end (Fig. 19) a n d (Fig.
20). Thus, t h e ~ itrapped
r i n the suction piping and t h e pump head can escape via the drain. Wait
u n t i l the liquid comes u p to the evacuation level of t h ~ sdrain.
Let i t flow for a few seconds i n order t o degas it completely, then retighten the d r a i n p l u s .

3.3 - R O U T I N E CHECKS
Periodically, i i i r necessary t o check:
- T h e ievel anc cleanliness o f the oil.
- Leaks o r u n u - i ~ a lnoises.

3.4 - PREVENTIVE MAINTENANCE

Before any ser-(icing operation o n the pump, it is necesszry to t v r n the motor powe:. supp!v OFF.

3.4.1 S e r v i c i n g - i n t e r v e n t i o n p r i n c i p l e s f o r p r e v e n t i v e m a i n t e n a n c e * :

Intervention F-'
I +OlJenCe I-

- Renewal o f ct,:ck-valve boxes (Chap. 3.7.1. to Chap. 3.7.:). SOOO i~

- R e n e w a l of dl-?hragrn(s) (Chap. 3 . 7 . 4 and Chap. 3 . 7 . 5 ) . 8008 n

- Eonewal o f s?(-?ty valve assembly (Chap. 3 . 8 . 1 and Chap. 3 . 8 . L j . ?,Ot3<3P,

- Renewal o f w-1-m bearings (Chap. 3.6.10j. :ClOOO i?

- P.enewal of w?,:m and wheel (Chap. 3.8.11).

--
.!ui?O!j il

- F ? n r w a l of S I C - v eliner O-rings (Chap. 3.8.3). 1 6 i ~ i 1l 0i

* S e e list nf weir parts for t h e ordering of the various parts.

* ' +.ppiovimate no o f hours when operating under may perfzrmaace and nsri;ii:l x n d ~ t ~ g n .of
;
US"
 3.7 - S E R V I C I N G A N D M A I N T E N A N C E OF L I Q U I D END
Before carrying out any servicing operation o n the met,zring u n i t o r pipes, t a k e t h e necessary

A Steps t c ~ensure that t h e h a r m f u l l i q u i d they contain cannot escape o r c c m e l n t c c o n t a c t w i t h

persortlei. Suitable protective e q u i p m e n t m u s t be provided. Check thz: :here
before :?roceed~ng w i t h dismantling.
IS no p r e s s u r e

3.7.1 R e n e w a l o f c h e c k - v a l v e b o x e s - G e n e r a l
Before any o t h i r servicing operation o n t h e check-valve boxes place the vernier on the O n h position, cli?ck
t h a t t h e isolatifi; valves are closed, t h e n disconnect t h e piping. When p u t t i n o the check-valve b o x e s hack
i n place, system,3tically replace a11 t h e seals.

3.7.2 R e n e w a l nf s e a l s / balls / valves - metallic version

Fig.14
3isrharge check valve assembly Fig.15
Suctio,? check valve zszemblv

Suction check valve assembly Discharge check v a l v e assembly

Disassembly Disassembly
- Unscreiv count?-nu: (209)by o n e - q u a r t e r - Unscrew cap ( 0 1 3 ) o f t h e check-:a!;?
o f a turn, box by one-quarter o f a t u r r
- Completely u n r , l r e w the cartridae o f - Completely unscrew t h e c a r t r d g e c f
check-valve bo:< ( O i l A ) , check-valve box ( 0 2 1 6 ) .
- Remove c i r c l i p ~ 030) and balls (437A) - Completely uns,:re5.A: c r ? (1313)f:cpn t h e
(437) check-valve box.
- Clean t h e box r - r p i e t e ! , f . - Remove saring (OSOA), ball p u i d ? (On_?),
halls (437), sezt ( 0 2 4 ) .
- Clean the check-valve brmx com;letrli..
Reassembly Reassembly
- Fit bali (437), !.:--a ball (437A) and - Fit O-ring ( 4 3 8 ) o n seat (0;G)
circlips (080) - Fit balls (437), seat ( 0 2 4 ) . ball pit;de
- Position spiral 5T.31 (406) in the sink of (003), spring (OSOA).
counternut (20-1 - Fit O-ring (4381) o n cap (013)
- Fit O - r i n g (438') against spiral seal (408). - Hand-tigkton cdp ( 0 1 3 ) on t h e check-
- Screw t h e box c l r t r i d g e in the liquid e n d valve box.
so as t o align i t v.ith the piping. - Fit O-ring (4388), screw :he check-valve
- Screw o n c o u n t i r n u t [209).' box on the liqui: end.
- Tighten t t ~ ecap o n the check-volve b o x '
- Connect ti-e pipinq r n a k n q i;~:i-e i peri,?r!
watertightcess.
N o t e : O-rings ( 4 3 3 6 ) and spiral seals ( 4 0 8 ) o f the check-valve b c r e s n u s r tse w:!lz:sd v i l ' i l rc::i, iez!s
each t i m e t h e y ?r,: removed.
For i n f o r m a t i o n .-mcernin? tightening t o r q u e as well as which s p l n n e . - ~t o use, it^ Ch;;?t:ii 3.77'
 3.7.4 D i a p h r a g m R e n e w a l

Before carrying :;:~tany operations, place t h e vernier on the 0 % position, check tt,at 611 ::he sola at inn viv.r-;
are closed, ther lisconnect the piping.

Disassembly Reassembly
- Grain the p u m i (Chapter 3.9.2). - Mount contour pl?te ( 2 9 6 8 ) . I t is Cn1JT1Ol'lfor
- Lay t h e Pump ' n the side opposite one o f holes in the contour plate to be clzced at
the liquid end the highest p?int (see detzil C).
- Remove suctica check valve
assembly (A) (Chapter 3.7.2 o r CAUTION: Fcr metallic versions, ccn:wr plate (2986) on
Chap. 3 . 7 . 3 ) the mechanic51 side is made o f steel z l d contour plate
- Remove screw; (405A) (Fig. 19) o r (296) on liquid end side is mzde of stzinless steel.
(405) (Fig. 2Oj :om the liquid end. - Fit diaphragm (29SA).
- Remove diaphrsgm (296A) and
- Fit contour plate (298). it is CAUTION for one
pressure plates (2q8), (2988) using a of t h e holes in the contour plate to b e placzd at
pointed object the highest point (see C detaii)
- Clean all the p 3 . t ~ . - Fit t h e liquid end and tighten scremvs( 4 0 5 A j or
(405) i n star-pattern (Fig. 22;.*
- Refit the silclion check valv? assembly
(Chap. 3.7.2 o r C h z p . 3.7.33.
- Fill u p with 0 1 (Chap. 3.9.2).
- Put into sewlce (Ck1ap. 3.1, Chzp 2 : :

F1g.19
1':tallic version

A I n order ':, prime t h e pump, i t is necessary to purae the I q u i d e n d ( t o reiras; ;:I

r u r g e no-:le ( 6 : . Filr toxic liquids, i t is recommended tr, -0Il2c: this il;~idtn i a i ? c:,:ir
? , 7 5 one::' on
5,. r.vr?nin?
point d~!rine

' For inf:rn:atian ,-' l c P i n f n ? tightening tc,-qur as well as which sp?nr.ri :, L,5e. 5;i ~ t ~ ; z;.,
- ~ :
3.7.6 Degassing of double-diaphragm
body, "C" t y p r

- Remove the de-ection (A)

- Remove the reriining ring (092)
- Remove the bzl: (437)
- Put a little oil i i the body o f nonreturn valve
(432).
- Set the adjustment knob o n lo%, then start
the pump up
- A l l o w to run for 1 0 minutes
- Fit the ball (43':
- Aliow to run for i O minutes
- Fit the retaininq ring (092)
- Fit the detectio? (A) on t h e nonreturn valve
(432)

Fig.2l.k
B detail o f Fig. 2 1

if the degassing r-tn not be done by the above procedure there some possibility to p r 6 r - r . this ooerstion
with a zvringe. TI :s syringe is available on request at the Spare P a r t D?pairemcnt

Degassing wit'. syringe

- Fit :he syringe ( 3 2 ) o r the nonreturn valve

(432)
- Inject and purnF 6 or 5 time slowly the
degassing liquid
- Remove the syri,?geand fit the ball (437) and
the retaining ring :092)
- Fit tne syringe (1, witout his olunqer
- Put :he pump in!c sewice a n d adjust the
capacity until 100'-
- Allolv to run for iil minutes
- Remove the syringe (1) with t h e degassing
liquid
- Fit :he detection ( A ) on the nonreturn valve
(432)
3.8 - SERVICING AND MAINTENANCE OF THE MECHANICAL ASSEMBLY

3.8.1 Relief valvr:

CAUTION: Set in the plant, it must in no case be put out of adjustment, since it protects your porn$
3.8.2 Renewal csf relief valve (Fig. 23)
Disassembly
- Place the verni??on the 0% position
- Clean the t h r e a i d hole of screw (023) to make it appear
- Note dimension H
- Completely uns:rew and remove screw (023) w~ththe hexagonal spanner
(Chap. 37.7:.
- Remove spring (080) and its valve (212A)

Reassembly
- Cause new val,;r- (212A) to adhere to spring (080) using a little grease
- Lower the assenihly into its housing.
- Screw in tighterilg screw (023) to the H measurement with the hexaoenal spanne!
(Chap. 3 7 . 7 )

Fia.23
Disassembly of the relief vali..?
GBI 3.8.4 Renewal c f eccentric shaft seals (Fig. 26).
For disassemb:? and reassembly of the eccentric shaft lhe pump adjustment knob must b.: opposite you
Disassembly
- Place the verfier on the 0% position
- Drain the pump (Chap. 3.9.2).
- Remove the 2 r.ircllps (434A) from eccentric shaft (068)
- Drive out eccentric shaft (068) to the right to release seal (438P.l
- Remove seal :.?38A)
- Drive out eccentric shaft (068) to the left to release seal (438A)
- Remove the c!'er seal (438A)
Reassembly
Before reassembly, degrease all parts
- Fit an O-ring (.:38A) on eccentric shaft (068)
- Put glue (ioctlt? 638) on the end of eccentric shaft (068) until it exceeds the other side of the housing by
one centlrnetre
- Flt the other C-.~ng(438A) on eccentric shaft (068); put glue (loc!ite 638) on the end of eccentric
shae (068)
- Posltlon eccen:,-tc shaft (068) in the centre of the housing (see F;g. 26)
- Fit circlips (4321;) on each end of eccentric shafi (068)
- Allow the glue 1.2 harden for 30 minutes
- Fill up with oil !??e chap. 3.9.2).

Fig 26
Simplex purno

Duplex pump
GB/
3.8.6 Renewal c f connecting r o d and shaft for mRoy 8,simplex (fig 26, Ftg 251

Disassembly Reassembly
- Drain the punip (Chap. 39.2). - Refit piston 6312) I connecting rod snail (011) i
- Sernove the lxntern (Chap. 3.8.8) connecting rod (214) assembly, being careful to
- Unscrew nut (.515F) and screws positton the lubric2ting groove (detzil A) o i
(435). (435E) Fbg. 26)'. connecting rod (214) oppostte th? thr~a:led holes o f
- Remove ecce-iric shaft (068) the piston. ( F i g 26)
(Chap. 3.8 4) - Screw in and glue (loctite S 6 5 j locking screw (435E)
- Remove drive I J I ~(214A) on the side where !he groove af conn.?c!tnq rod shaft
- Remove p l u n s - assembly (012) 1 (031) is located
connecting roe (214) 1 wheel (052) - Insert piston I connecting rod assembl;/ In housing
from the housi-2, by lift~ngwheel -Fit wheel (052) with connecting rod (2:4) (Fig.26)
(052) - F i t eccentric shaft (068) (Chap. 3 . 8 3 )
- Drive out conn?cting rod shaft (011) - Fit drive pin ('214A). then screw in and alee
(Fig 28) (loctite 221) screw (435) and nut ( 4 3 3 3
- Clean the houi ;a
and the parts - Refit lantern (chap. 3 8 . 8 )
removed -Allow glue to h a r d e ~3 0 minutes
- Fill up with oil (Chap. 3.9.2).
- Carry out stariup and operaling procedures
(Chap. 3.1, Chap. 1'2 )

3.6.7 Renewal connecting r o d a n d s h a f t for mRoy B, duplex

iF19 26. Fig 27 Fig 28).

Disassembly
- C8:atn the purnr {Chap. 3.9 2).
- Re-move the lai :ern (Chap 38.8)
- Unsc:ew 2 sc:~\-.s (402) (Fig. 27)
- Unscrcw nut (<25F] and screws
(.d3S), (43%) ( F . 3 26).
- Rernove drive F:-: (214A) (Fig. 26)
- o:,.
vie out the 2 s?afls of connecting
ri.d shaft (01 I ) b . the threaded holes
of screws ( 4 0 i !
- Csmove eccen:. ;Shaft (058)
(chap 3 8.4)
- Remove excent:: wheel (052) I
connecting rod C l 4 ) assembly in the
hcwslng
- Remove plunger assembly (012) 1
connecting rod (214) 1 wheel (052)
- Remove plunger 1012) off the housing
- Clean !he housir,: and the parts
i;.noved
Reassembly
-Place plunger (012) in the h o u s r , ~1 2 3 2 1 n?les up
ward
- Assemble connecticg rods ( i l d ) vi!h w;?eel (052)
being careful ta pos;!~onthe lubricating arm\,+
(detail: A) o f connecting rod (214) d~;:n.~v~r,'-
(Fig. 28)
- Place excentric wheel (052) i cinnec:n? rod (214j
assembly in the housing
- F i t eccentric shaft (058) (Chap. 3 8 . A )
-Fit the 2 s h a k of ccnnecting rsd s h a t ("1 1 ) !)y the
threaded holes of sc-ews (402) ~ F i g27''
- Screw in and glue (loctite 566) locl:inc scre~%.;s
(435E) of the s,de vihere the grncv? cf c o n ~ e z t l n g
rod shaft (01 I)is loczted
- Fit drive pin ( 2 1 4 ) then screi.1 In and gluc
(loctite 221) screw (435) and nut (435F) ( F ? 26)'
-Refit the lantern (Chap. 3 . 6 8 ) .
- Screw in and glue screws (4021 ,14ith loctlle aiue 22;
(Flg. 2 7 ) .
-Allow the glue t? hard33 30 n i n ~ t e s
- Fill up with oil (Chap. 3 9.2)
- Carry out startup and operatln? :-c:e,i~.::;-s
(Chap. 3 1 , Cilsu, 3 ;1

* F:- in:sr7lation r,:Icerning ivhich spanners are to be used, see C l l a p t e 3 7 . 7

I d

3.9 - LUBRICATION
The oil level must be checked every month. Fill the hous~ngup to the middle of the levei ind~cator.Use the oil
suppl~edwith th? pump or an equivalent oil (see table below). Tt,e oil must be changea every 2500 hours of
operation or e v q six months The pump must be placed in z0r.e where the arnbent temperature is
between -5°C anti 50°C.

3.9.1 Table o f oils

I S O V G 150 oil. Pure mineral oil

mROY A rnROY a
Simplex
Duplex 2L 4L

TABLE OF CHA'4CTERISTICS

Viscosity to 40'12 151 Cst

Viscosity to 100 " C :5 Cst
Viscosity Index 100
I S 0 VG 150
Density to 15 " C 0.897 ;(/I
Flash-point 244°C
Pour-point -12°C

EQUIVALENCY TABLE

3.9.2 Draining t h Dump

~
To drain the pumc ynscrew the filler plug and the drain plug cornpleiely (Fig. I k j .
TOfill up with oil. x:ew the drain plug back on with Teflon strip to ensure proper impern,~aSiiit;,~ and see
Chapter 2.2.2.
Note For inforrna::rrn concerning how much oil to use, see the table :a Chapter 3 9 1
 Micde Anlapenhau G m b H Heidlohstr. 3A 22.159 H a m b u q
I

TECHNICAL SPECIFICAT.ION

Chemical D o s i n q h i t
Type: P.E.l[.l:J/Si~~iplex ( a c c . t o drawing no. U41-5/73]

T h i s u n i t i s p r c v i d e d f o r m e t e r i n g of czter-treatment-chlmicals i n t o t h e
u a t e r s y s t e m up t o a b a c k p r e s s u r e o f rnzx. 123 bar.

The u n i t c o n s i s t s o f :

1. Dosing pump
I-lzke : Dosapro t.:ilton Roy
Type : mRoy A 112 F 1 H I 2 3 S X
6 z c k p r e ,rs u r e max. : 723 b a r
C a p a c i t ; ~a t 103% : 12.5 l t r . / h
Dgsing head : one,
Material: Stainless s t e e l
: s p e c i a l motor t o t a l l y e n c l o s e d (P 54), d i r e c t
c o u p l e d , 440 W/6Q c y c l e s
Cap3city adjustment : OYn t o 103% during pump o p e r a t i o n
Fccuracv : 5 1% w i t h i n 15%t c IOU% of c a p a c i t y r a n g e
Lubrication : a l l moving d r i v e p z r t s a r e s u h e r g e d i n l u b r i c a t i o n oi!
O i l quz;ity : T e r e s s o 10g and o t h e r
i l i l volwne : 1,O l t r . , f i r s t f i l l i n g c a p a c i t y i s p a r t of d e l i v e r )
2. safety L . ~ V P : s a f e t y vzlve is p z r t cf t h e h y d r a u l i c pimp c o n s t r u c : : ~
3. N3ne r e t u r n v a l v e : Within t h e l i q u i d end d o s i n g head, p r e s s u r e s i d e
4. Chemical Tank : Volume 100 l t r .
M a t e r i a l : Polyethylene
5. F u n d a t i ~ nf r m e : s t a i n l e s s steel
6. Suction f i t t i n g s : c o n s i s t i n g of tank l n s t a l l e t i o n t h r e a t u n i o n s ( b r a s s ?
gauge g l a s s with v a l v e ( b r a s s ) , h o s e a t e e l a n n o r e d ,
f i l t e r bronze, cornpressionring u n i o n s ( b r a s s )
The gaugeglass can be used e s an. c o n t r o l d e v i c e f o r t h e
pump o u t p u t r a t e - and f u n c t i o n . A f t e r c l o s i n g t h e g s g g r -
s h u t down valve t h e pump w i l l suck from t h e g a u g e - q l s s "
volume end showing c l e a r l y wether t h e pump o p e r a t e s
well o r n o t .
 TECHNICRL SPECIFICATION
I

1 Chemical Voslno U i i t
T y p e : P.E. l L U / S l ~ ~ l p l e x( a r c . t o d r a w i n g no. LL1-3/79)
I
T h i s u n i t 1s p r o v i d e d Tor m e t e r i n g O F u a t e r - t r e a t m e n t - c h n i c a l s i n t o tb,e
!
w a t e r s y s t e m u p t o a b a c k p r e s s u r e o f n t x . 123 b a r .

The u n i t c o r s i s t s o f :
I
1. D o s i n g Fi:,np
I
I.!.:. : D o s a p r o K i l t o n Eoy
-I y p e : mRoy A 112 F 1 H I 2 3 SX
e . z c k p r e s c u r e mtx. : 123 b a r
C z p z c i t v z t 103% : 12.5 1 t r . i n
Dosing l h ~ z d : one,
M a t ~ r l a l :S t a i n l e s s s t e e l
1.10 tor : s p e c i a l n o t o r '"tally e n c l o s e d ( P 3 ) ,d l r z c t
c o u p l e d , 3 x YYOL, - Hz
C a p ~ c i t va d j u s t n e n t : t o 1UOX d u r i n g p m p o p e r a t i 3 n
Cccurac,. : -+ 1% u i t h i n lGt o i@CX o f c z p a c i t y r a r ; g -
Lubrication : 211 n o v l n g d r l v e p a r t s a r ? z u h e r g o 3 i n l u b r i c a t i o n g;!~

O i l qua!i t y : T e r e s s o TOO aad o t h e r

! ! J i l volt:-e : l,U l t r . , f i r s t f i l l i r g c a p a c l t y i s p a r t oi del!..,~::.
Z. S a f e t y :.-lve : s a i e t y v a l v e is p 2 r t r: t h e h ~ j d r e ' ~ l ! cp.m? canstr~~r:l:-
3. ?!one r e i : ! r ~ i vzline : U i t h l n t h e l i q u i d =nd d o s i n g h z a d , c r e : : s u r c ~ i d e
4. Che-n!cz! Tznk : V o l c n e IOU l t r .
I-laterial: P o l y e t h ~ l e n e

E. Suction fittings : c o n s l s t l n g o r t z ~ ki n ~ t z l l a t l o nt h r ? z t un!cns ( b r z r r

gauge g l a s s u l t h 1,zlve ( b r a s s ) , hosz s t e D l a m o i e d ,
f l l t e r bronze, com?resslonring unicns ( b r e s s )
l l ~ eg t ? u g e g l a s s c e n b e u s e d c s en c o , t r n i
L'?v!ce f r : - : , - .
punp o u t p u t r a t e - and f u n c t ! m . R f t e r c l o s i n g tb.c : , ;c :: ~

s h u t d m n v a l v e t h e PUT,? u i l l . s u c k f r m t h e g a ~ g e - - ! ~ i - .
v o l c n e a n 3 shzrdlnc) c l ~ a r 1 . yw. e t t i e r t i c pen o p e r z t r ?
well or not.
 DOSIERPUMPEN mROY * POTilPE DOSATRICI
mROY DOSING PUMPS mROY '
SIMPLEX U N P DUPLEX SIMPLEX AND DUPLEX SIMPLEX E DUPLEX
BIS 1 2 3 BAR UP TO 1 2 3 BAR SltilO A 123 BAR

FUI!KTIC~IISPRIIIZIP OPERATING PRlllClPAL PRlllCli? [!I illli1101!Al.iEliTO

Funklion Operaling principal F~~nzionarnenlo

- D i e G c t r i e b e e i n h e i i . b e s l e h e n d aus
Schnecie ( I ) und Schnrckanrad (2). is1 ver-
bunden mil dem Exzentar (3).Oer Erzenler
(3) veiselzl dic Kolbens ?nge ( 4 ) in oszill>e.
rende Bc-ivegung von knislanler Hubling?
des Kolbens (51.
eeim Saughvbenlslahl i i r l r r mlt Olgclutllen
K a m n e r ( 6 ) ein Un1erdrr:ci Die Membrane
( i l folgl der Kolbenbec.=:~,na Z h s c h e n den
E a n t u r p l ~ l t c n(8).
P a s Sic?erheilsv?nlil(iG -chbt:l die P u m p
- T h e worm ( I ) and wlieel (2) enga;e lhe con
rod ( 4 ) by means 01 an eccenlric (3) Ih'8s triins-
mils a reciprocaling molion la pislon ( 5 ) .
-This pislon reciprocates ivilh cons!anl s l r ~ k c
lenghl and displaces oil into and oul 01 the
diaphragm (7) conlained belwsen Conlcur
plales (8).
-,Relie1 valve (16) prolecls the p u m l
L:! c033a a!:? ien;a line ( 1 ) ruolz el!coic!lli
(?) c c r i - - J ? :I LI ell2 ( d ) nedianle i'eccen:r~..~-,
(3).
La birllz ( 2 ) t ~ a ; m ~ I I ea l p i ~ l o n e(5) un r,.:.:.
menlo 8:1?:7~21i:a a C C ( S ~lissa
I l p i s l l n ? c l m ~ n d a~. t l i a v e r s o l ' o l i o c o r l e ~ . .Y i :
n3ll-i cansra (61,la m e n b r a n a (7) rarchiltr:!
1.a I?d?rizslre di appogaio (8).
Lai.%1~r';:ii~c::~.:::a(lE!pr0teg~~i~p~.-pi
 Regelung der Frirrlermenge Flow tale atljuslrlie~~l
AIISAUSPIIASE: SUCTION PHASE : F A S t O ! :SPIRi.:lQtlE :
DerKolben(5)t~~eichl:i::~1ckundsauoldas01 Tlie piston ( 5 ) draws back and sucks oii (1 5) 1
I pi;!;ne(5)arrelraeda;pir.; Iolio (15) r ' t . 2 : )
(1 5) hinlerderhlembrsnr (7)anDererzeugle bshind lliediaphragrn (7). Thnpressure l i l l e - la n;e?b:ana (7). L a pressione dil1ercr:i:I.~
Dlllerenlialdruck wird diirch die elaslische rential created is lransmilled bv !lie flexible cri2l;ri vieni I'a5rncisa d?lla mem!:.r2-;.
t.lenbrane (7) iibeilragril und bev~irktsomil diapllragm (7)allowing the pumped lluid lo be I l ? i s ~ t i l e(i)ccnsenlendo I'ascira:io>,c c!:!
ein AnzJ9g.n dec zu pcmpenden Flijssigkeil dra,:in in, viilh the mechanics01 the p u m p a n d 1l:liSa p ~ % p z ! 3 , c o nun3 s o p a r a i ~ n e p ~ r l ~ : ~ :
bei cine, vollkommenen Trennung zviischen lliepumpedllvidconiplelcly separaledivlien Ira nzccanica d ? l k ponipa e lluido pcrnpi!:,
der Purnpenmechanik u r d d e i Fdrderlliissig- llie pislon (9). mechanically lint.cd lo llle pislon C8.l21!2il pis!c,r.?19).leoalo n;ecc;ni:a;,cr,!..
i c i l v i c n n der Sleverkolhen (9). der meclla- (51, opens the orifice (10) lor llir bypass ail
nisch c:il dem Kolben (5) verbunden is!. den (111, llie make up oil is supplicd irom it>-.
C.:S;pz:s (1 I)ollnel.~;~:~idurclid~sGc1,5~,sel h o ~ s i n g ( l 2 ) .
( I 2 ) 01in dle Veidran~c'l.2rnmrrn a ~ l ~ g ~ l ~ l l l

ORilCt:?HISE: DISCtILRGE PiI:,SE:

C j ? i Kclbcn (5) driickl d ~ i 0 i 1 zuiuck in d75
G e l ~ a s i i .(12) uber der Sypar-5 (1 I)und d:e
6ct1ru-,3 IIO), bls dies: Eohrung d8~:ch den
t;olSen (9) geschloiser,i~.i,d.132s 01v~rlorr:;~
d i m ei? t.lernbiane (71. proporlional z u n
E f i l c h l i i l des verbleibcndin l i u b v c l n m ~ n s
n?cl>VF!s:l~lie~ender r , , h r u n.~.( l o .) Dasdo.
sierlc I.l?'i!,m ?;ird d l c h da; Druci.venlii
g.?1,2:<7 1
Tliepislsn(51~d.~anccsa:~dpush~r lhcoIinl.>
I h e l i o ~ s i n g ( l 2 ) b y v ~ a ; o l l l i e b y p a s s ( ll j a n d
lllecrilice (IO)cnlillIlisoril~ceis b!o~:iedt y !he
pislon (9). The cil then pushes l i ; ~ diaphragm
(71 vhich is displaced lori,iard prcporlior,naly
I s the fiaclisn 01 l ! 9;~cpl ~ volume remanin?
;lief (lie obslruclion 01 l l ~ e0:ilice (10). TI:?
dcsed liquid is discharged by lhe d i a p h r a g ~ i
ltzrcggh l i e discharce check v-i!.,e-.

FOE@EK:.IEI:GE~.IREGELU~UI;
Die idrdermenge is1 .#~,-l.l~irenri d m ieelriebs
vcnO 1,: 1Clg:b einslelltkirduicli Diehungdes ling from 0 lo 1 0 0 i l by lurning 117; adjurirncn:
E~nlcllLnoples{l.l),derii:himCilkreis~aulbe- conlrol (14) v;l.sich displaces in 1-11 oil. Ihc;
v ~ ~ ~ I , a l : o o l i n e B e l a s l u : :durchdenregelha-
i i:ilhaul ellorl. the s1eei.e (131 a9d llie pcrilisn
ren Scl~ieh?,(13)unddiizorilicnderBohrung 01 llle orillce (10)
(101

EElSPlEL ElllER AlJF 55% [':R IIEIIIIF~I!OER~

ILII5TUIIG CltlGESIELLTF:: FUlAPE
V i a l l r ~ n ' !35:bCes D r ! i : ~ I ~ ~ ~ h s ~ ~ i ~ d d a s 0 1 i n
c.;3r G ~ I ~ ~ ~ ~ ~ ~ ~ ( 1 2 ) g ? i ~ r . ! . r l pumped inlo llie 1;otus:ng ( I 2). . , . : k r l : , , : : : a r : < : ,( 1 2 )
E3i. F5;I des vcrh!c~!:.::-;den H t ~ h i c ' u n ~ c n r During Ihe rcrnnining 6596,1hnp::lon!r~n; . F..: 1 1 ,. :*~.r,1,:;5-,; ilpi:,~,:,r~c(5.1 I:;<<,~,.~#
irh?rlr3>1 c i r Ko1hi.n (51 ;'IJ~C!, @a,:,egcn der fills, by llic disp1air:i~enlol lhc ji;ipiir.::lm. !. c , , --,,.::~e:,~:rv,e;~{o (!el12z,emt:;r~ . ,I
l.\?r!,rrni. Ci96dl)s He! ,. ,Iu:na..ns P;e erlal. 65% ol llle sr:epl v:lluine Thnd:ll,.'?!y c:lai. 5 : LI,:..:.:;~;, ~ ~ ~ ~ , 1 ~ ~
1-n? irr.'crr;iengoislsr~;il65SLdcr r l a z ~ r r : ? . n'?dis lhus 654: 01 l l i inaririum
~ Ir-,v: ra:? ,I:;: .::q SU:',~: z : #:.5 :'" eclla p?r131?r 8 ~ , - ~
I?nFo:llcrici:lucg
 UOSIERPUMPEN rnnOY"-' POMPE DOSATRICI
I ~ I ~ O Y ~ DOSING PUMPS IIIROY~,
S I M P L E X UNLI DUPLEX SIMPLEX AND DUPLEX SlrvlPLEX E D U P L E X
B I S 123 BAR U P TO 123 BAR SII\JO A 123 BAR

t,\ERKP.4!,1€

trlenlbrane mil hydrau',:zherSleuerung . Hydraulicallyaclualeddiaptiragn,

.. !.le:br,?n3 2 co.7:3!>drci,3raulico.

.. Fdrderleislung : bis 3 11Vh.

1 . 4 ~Druck
~ : 123 bar
E~nlacl~oder@oppelnl.?mbrane .
Capacily : uplo 310 l!h.
Pfcssure : 123 bar max.
Sinaleordoublediaohraam .
Fcrt?lsrin;l 3 3 l 0 l h
P ! e h n c m a r : 1 2 3 bar.
l.lernbran? scinal~ceodoooia.

- 9 0 - C bei Melalldosinr'+opl
Rsgelungviahrendde:ielricbsundi~nSlill-
stand von 0 bis 1OO'b d - r Nennleislung.
Genauigkeil t l % b e i e )ern Bereicl~von10
. - 99.C lormelallic iiquid end
Flc~visadjuslable.whilesloppedorrunr.ing . - W C c r r i do;?lcre nelallico
Regolaziore dzIerr:losinmarcia Oa 10:1--
. I:om 0. I 0 0 9: ol nominal flow.
Accuracy? 1~:,~villiinIl1sranpe1010 1081":
de!laF.,rl2:?n2:cin?!e
F:ec;rioni. -i 1'6 'U un camp3 O 3 lor,-,

. bis 1OO"bder Elennleir11,ng

Olbadrchmic;ung .. 01 l!le nonlirlalllor:.
.. r;:::; pO'!;<:a nw:i.::le

.
0 1 bath lubricaled L~i;ilic?:i,:nr in h3i-,3C"ili?
'7
. G~11S:~seGraupO.
lrllegrierles Slcl~t.rl~.;i'~~.enlil, in der Slan-
Czsl iron housing
. C?rl?r in g!;ir;

.
lr.!?g:al relielvalve. normally sel al lhe Izc- '>'2'.3:id i:ccle::z i~leg;ala.laralain r ! '

.
!,(.
1,!..I da:d,crsion im l?'erke :?esleIll I"'>. c,na c a n e sI.n?;.e l i esecuzione.
E3i. C.:Gcken zr;icchen 10 bar und d e n For pressuresbclv,sen I0barandlhem;!ri- F?r . 1 ~ : , s r ' . ? n ic c r i a r e j e Ira 10 t - : z
I.larini>ldrurk des D,>rk.l~ubsder Pump? n:!ln oressuie 01 llle DumD . . inclvsiue. ihii -
. . m 2 ~i m~n.?;la dzlla pomp: !.?
gel11 d ' s F b i d s r m e r g ? ~ ~ ? ? 2Toie ca 10 bar llc,:ra:eis reducedby a~pr0x.2";~loieveiy . p:,:?Ie d;-:irdi:e~lrL'el Z;'ca.p.?rogn' 5.:

.
@ruckerl~ohungzurCci. :hne dleGlnauip- I 0 bar increase.viilhou1 elreclinq.l'ie p . rici~ : :ni i'i 1, k,?., zcn;a i;!lui:e sulla p:;:

. h ~ izu l be?inllujsea
Druckbedingung des ?zughubs : YO" 6 b15
sic?. c , -.
- - 8. . ~

.
Suclion pressure condilions :Iron, 6 lo T:?;5'3r!e c i ;:ri,r:,?ne : da 5 a 25 b;. :~

. 55 bar jc nach Fumy?. i l l e a n l r a g s n .

Lanae Lebensdaus: <-r i,lembrnne, die
Z0.003 Belrinbsslunliin je na:h Art des
. - ?

a 3 bar zccording lo llle pump, consull u;.

:'!arking kile ol (he diaphrzgm can erce3d
20 000 hours depending on lhe pumped
s ~ ~ d C e Ip:tr;;,;.
I a
L z d#j:?!ai i ~ l !m~?S::nzpub
:PC?? w e zec;;.;'
?
con~uiIarci.
supilrzri- ' c
il I:?o di prodollo pr 7
2epunip:cn l.lediun!s. der Bslriebs- und I!~~id.riorkinpcondilionsandinslallalioo r - l c F e :1nm!~::,.zi di f~nzinnamenl: 5 : ;
I r . i l ~ l l a l i ~ n s b e d i n g u n ; ~Gberscllreil~n
n C ~ m ~ ~ c I d ~ p ! e x i . e r swilh2
i o n s headsijyn- i?;!?l:z;i5.>e

. kann.
Ylrn;zLIs Duplervcrr2nen mil zwei iden.
lical or dillerenl in conskuclion cr per?:.
mane?.
\'.?f:i::,i d u p l ~ ? r c ~ m ~ : ,cl ol ?n z l e s ! ? iee-
I.:hrG ?:i,,c.-.r- -.---.
.
. ., . , . ..,Iu:ioneoprei',:

.
l i s c l ~ s n3d.r in K~nri:::~.Iionund Leislung
~:nli:r:l~iedl~cl~t.n Ccs i.l.6plen
Enlsc:i;l~l der APII!c,-7 6 ; s (0linj.,slrie
Ccnlo:mily >:il, API 675 slandard (011: i ! z ~
led indilslry slandazd) . .
-.
.-, ,
Cc,'s:mi2ng:r.. L'i 175 (nnrm21,va .XI
5c:l~,~p:.~!31,1:~?'
tlarnj

FIeI:lriccl~e Eleclrical cl~araclerislics C a r a l l e r i s l i c l ~~~l e l l r i c l r t :

T~lolor~i~erk~nalf: of IIIO~OIS [lei i ~ ~ o l u r i

, ,#.
5 i x n d a r d i r , o t o r d a : . . a : :.LI.>U 1 - j I ,
Performance curves Curve c a r a l l e r i s t i c h e
DUSIERPUPIPEN trlROY@ POMPE DOSATRICI
I~IROY DOSING PUMPS rnROY ?:
SIMPLEX UNU DUPLEX SIMPLEX AND DUPLEX SIMPLEX E DUPLEX
BIS 123 BAT: UP TO 123 BAR S I N 0 A 123 BAR

I,IERhI.I:%LE

Maleriale cii coslruzio~ir:

KOIdSiRUI(TIO1I 316 ( 1 ) PVC (2) CO~ISTRUCTIOCI 3 1 6 (IJ PTI (21

ELEf.lII!IE COlAPOIlENlS

Dasie:~nnlgehiuse 316 PVC Liquid end body 316 FVC Ccrpo dcwlor? 316 PVC
Vci~l~lgel~iusc 316L PVC Check n l v e cartridge 316 1 PVC Crrpo val,,cle 3 16 I. PC,:
Slze 316 L PVC Se~ls 316L PVC Sedi 216 L P\'i
Ku~cln 3161 GI23 B~fls 316 L Glass
Ko~llurjci?eibn 3161 PVC Conlour p l ~ l e 316 L PVC
hleo;blanr PTFE PTFE Diapllrag~~l PlfE FifE I.l?mhran? FTIE Pift
C!scllJige ball spring 31G L tl2sl T l oI I 315 L 1:z.I C
Szals I!ilon Vllon Gs?rni:ic.-,i I!I!~ \ri::r

O l l ~ e rliquid end nialerial :

' -
\ ' e r i i c n KPI!ZEI!TF f ? l E ii2SOI :
i,uslu!>r;~np31 6 nlil .'i-nl:lgeIi,?uie u n d S I -
. H2SO.I COIICEIITR4TED rc!si,n :
''

3 1 5 S.S. liguid e n d wilh cli?rl. v2!:.c c s r ~

. V c i i i o n c liZSTl4 C O l i i t I : T 2 4 1 @ ~.
'

cri'.:1~i3'l??:! c o n c a r p i \.?lv-;!~e c r : ~ ,.:

:e.i:n,ll!3~ ;0, K m : l un3 F e d z r i r H z s l e l ~ IriJeandseals ic?i.lloi 2 O : i j l l ~andrplir,?
i n H a s l e l l q C.
'ALLOY 20 version :
. i i i l c j 20, r ' ? : ~? rnoll? i n !i2;1?1l?u (;
vpr;ic,-e ' i L L l ? Y 20, .
;oslru:i-~n? ill;y20cn?sl:rr e mall- I'

.
Alloy 20 liquid e n d \iiIl> balls ;-~d ;"ling i n
tias!elloy C.
0lI:ei veision on r e q l l ? r l :
. 1c;:oy C
A I r c v?ii;c:i a ;;c,!;ieslr :
cin?~!I?:ci
..c~"c"II"s
..
Dte Pumpenober1l~cI~-2
sindgescliijlzl mil:
Einem Korrosionssrhulzvon 40 IAikron.
Dosing pumps receive :

.. An anli-corrosive lrealmenl 0140 misrons. .

Le psmpe sono p:oui*isle di :
Ura prolezione anliiuggineda 40 micr;:::.

.EinerPhosphalgru"'ierungsschichlvoni0
mikron
Einem s2~rebesl5-.~1:gen AnslrichPoiyure-
lhangiilbR4L i 0 i i ~~onmindeslens40l.li-
kron.
Oneprimercoalol 10microns(Phosphale)
0neacidresislanllopcaal.polyurelhanela-
quer, 01 40mic:ons yellow RPL 1024. .
Llra mano di primcr l o s l a t ~ n l eda 1 C r:ii
c!ms
L 1 2m2no di vernice anliacida poliu:r::::,~
c : ; ! ! 3 RAL lO>fi da 40 microns min

Scbrnierung Lubricalien
. T ~ m p ~ r a lzviisci
ui .?.I - 5'C und + E.OCC: . Temprralt>re lrom - 5 - C lo + 9;'C :
0 1n x h der I S 0 - i : q r n CC 150
Temperalur c 5:C. 6illr 2nliagen . Oil ISO. CCI 50 equivalenl
Temperalure < - Y C : conigl' us

. t.lengc :
- mROY A ' simpic:. 11
Ollanlily :
- n R O Y A ' simpler I L
- KROY A ' dupr: : 2 ? - mROY A ' duplex 2 L

- mROY 0 ' sirnpl?~: 3 L

- mROY 6 ' duplex : .! L

G e ~ ~ ~ i c h t e u n d V ~ ~ r p a c k ~ ~ n ~Packing
s m a f l eand d i m e n s i o n s Peso e d i m i ~ a l l o

IIETlOGEWICHT (mil 01) BRUTTOGE\\'ICrlT (mll \fe,paci.ui~g) ; ~ ~ ' . ' ~ S S L l l l G r (1-l l > 9 x IH)
I l l 1 VIEIGHT (?,ilh 0 1 ) GROSSVI'EIGHT (v:111 i.eckir?] ~ ! ~ ' , ~ l ; ~ (L l n l Il 5 1:)
FEZ0 l!FTTO [con c ' l t l l PESOLOfiDO (~mb?ll-ram?-rsnj l!!i::.!L'? (1 7 I r I ) !

(I! c d (i) - a p ~ o r
, ;! . :,,i;:
( C i - b'n:l,t?r,:rp3rli 1.7) - c,?il;.n (: 8 .: j;[;,';~ ,- < ~ 7 ~ ,:3
 Table of contents

Drawings
General arrangement ............................ ................. ......... .. ~~. ..,.. ., O.?>-:Ol ?J<)Eih
 --
ILL- - - '.- - i

\ , , .
~~

~-~
.,:===
,#-:
. ~ ~
.~

.
, .-Q
.:.

an'
.a'
.,..
~

, --.
 Table of contents

Data sheets for boiler and steamlwater system -

Safety valve, DN 651100, PN 4011

Stop valve. angle, DN 200. PN
Stop val\-e, angle, DN 100. PN
Stop valve straight, non ret
Stop valve straight, non return DN 40, PN
Stop val\,e, angle. DN 30. PN 2
Stop valve straight. DN 40
Stop valve straight, DN 8. PN 160
Stop valve straight. non return DN 20. PV
Check valve. DN 200. PN
Stop valve straight. DN 25
Stop valve straight. DN 50, PN
Water level Fause risht, 2 x 6 DN 25. P.Y 40
Watcr lcvel gauge left. 2 x 6 DN 25. PN 40
Stop val\.e straight. non return DN 65. PY
Stop val\.e angle, DN 100. PN 40
Safety valvr. DN 15. PN 40
Remote pull for safety valve
Stop valve straight. DN 65. PN 25 ....... ...... .......................... . . . . 250 10~2
Ball valve. regular bore, weld en
Level float switch RBA 24, DN 25. PN 40

Presc~rretransmitter. type MBS . .,

Needle valve. s t m i ~ h t %"xW.
. PN 4(
Flanfed-end Ball valve

Chemical d o i n s unit
Pneum:ltic control val\,e. type 23.470 DP with I.&' pinitinner K.11X1.1
Filter rerulator with automatic drain ........... . . . . . . . . . . . . . . ~ ~ . . K . 1 177.0
 -
.
Tjpe:
Safety v;ili,c. full lift
r,

Size:
. Nominal iliameter: DN 651100
Application:
To blo\i nff clenni.
Material:
.. Body: GGG 40.3

. Dm-Matrrial No.: 0.7043

Seat: X6 (:r Ni Mo Ti 17122

. DIN-Mnixial No.: 1.4571

Ilisc: 35 'r Mo I7
DIN-M;i!erinl No.: 1.1122.05
Technical data:
. Nominal !ressurc: PN 40116

. Weipht: 40 kg
Flanges ;,.ccordingto DIN

. Inlet: DV 65. PN40

Outlet: 11% 110. PNlb

Type NO.: 6040 Safety valve, DN 651100, PN 40116 I 2611174

Version: 4

\ I'XPP Ill
I;lnFIl"CL' UK
Type:
.. Stop glob- vnl\:e, angle
34.007
Hody: GS-C"5 N
Din-Malerial No. 1.(161!1.1
Seat: 570 Crl3
Size:
Din-Material Nu. 1.4021 .ni
Nomin;il diameter- DN 200 Disc: X20 C r l ?
Application: DIN-Material Nt!. 1 .A02 I Iti
For steain and/or water flow
Nominal pres.;ur?: I'N 25
Weight 138 kg
Flan$es accordin? to DIN

Type No.: FPlO

Version 0
Stop valve, angle, DN 200, PN 25
 Type: Angle form

Pressure class: PN 4 0

Dimenslans: Side lenghl DIN 3202, r o w F1

flanges DIN PN 4 0

Figur 35.007

Dats Sheet
..
....
...
Stop valve
AALBORG Angle form K.1006.2
S1.1NROD P a g e 1 of 1
I
 . Stop chc,:!; glohe valve, screw down non Rod?: GGG 40.3

. return, straisht
23.006 I:
DLY -Material No. 0.7013
Seat: XZOCrl3
DIN -Material No. I . 4 0 l l . i ~ 5

.
Size:
Nominal ~'iameler:DN IN1
Disc. X2O C r l ?
Dm -Material No. 1.11111.05
~ipplicatiox?: Technical data:
. For s t e w *andlor water flou Nominal pressure: PN 25
Weight: 39 Ly
Fl;~n;es according to DIN

Type NO.: 6010 Stop valve, straight, non return, 264 1094
Version: A DN 100, PN 25

L:u~&!u;t$rI!K ?:ice I i l
 .....
.....
...

iliiitt,
' '"G. .
> ,

Stop chczir globe valve, screw down non . Rod!: GGG 40.3

. return, straight
23.006 F
Dl& -Material No. O . S O l ?
Seat: X'_O C r l i
DIN -Material No 1.4021.05
Size:
. DN 40
Norn1n.11Ll~anieler.
Disc: XZO Crl3
DIK -hlnterial No. 1 4 O l l . 0 5
Application: Technical data:
For stenill andlor water flow Nominal pressure: PN 2.i
Weight: 10 kg
Flanres according to DIN

Type No.: eF30

Version: A
I Stop valve, straight, non return,
DN 40, PN 25
Type: hlaterial:
Stop lo'^ valve. angle * Bodv: GGG 40.3
23 007 Din-Material No. 0.7(11?
* Seat X20 C r l 3
Size:
. Nominal dia~ncter:DN 40
Din-Marerial No. I.lo2 1.05
Disc: X20 C r l 3
DIh-Material No. I ..lo2 l i l i
Application:
For stearxi and/or water flow Technical data:
. Nominal pressure: F'N 25
Weizht: 10 k;.
Flanges accordins to DIN

Type No.:6010
Version: P,
Stop valve, angle, DN 40, PN 25 251 1090
1
 Materill:
Stop gin',,: val\e. s t r i g h t D d y : GGG dO.3
73.000 Dm -Material No. 0.70-13
Seat X7O C r l ?
Size: D F J -Material No. 1.402 I 115
Nominai ~fiameter:DN 40 Disc: XZ0 Cr13
Application: DIN -Material KO. 1.4021 0 5
. For steniii aridlor water flow Technical data:
Nonunal pressure: PN 35

. Weight: 10 kg
Flanges according lo DIY

Type No.: 6010

Version. P
Stop valve, straight, DN 40. PN 25 250 1090

,' i
Type: Maleri:*I:
I n r ~ r u m ~ .qtop
l t cone valve. straight Body: C 22.S
DIN- Material No. IOJhO
Size: Seat: X?O Crl3
Dm- Material No. I .403 1
Neetlle tip: X35 CrMol7
,ipplication: Dm-'. Maten:iI No. 1 .-I1 11
For steal-I. water andlor air Technical data:
Nominal pressure: I'N 160
Inlet: G !./2" mnlc DIN
19205. fomi R
• 0utl~:t: For c r w l tube o 13
I\'ei:ht: O X kc

Type No.:E220
Version: P
Stop valve, straight, DN 8, PN 160 6220000002
Type: hlnteri:~l:
Stop c1ie:-;c globe valve. screw down nor1 Bodv: GGG 40.3
return. il~aight L3IN -Material No. 0.7043
73.006F Seat: X20 0 1 3
D m -Material No. l.41121.05
Size:
. Nominal iliameit'r: DN 20
* Disc: X20 Cr13
DIN -Material No. 1 ..ti.):1.05

. For steaiii and/or water flow

Technical datx

. Nominal presrurr: PN 2
Weight: 4.3 kr
Flanges nccordinr to DIN

Type No.: 6030 Stop valve, straight, non return,

Version: 0. DN 20, PN 25
 Technical d:~ta:
Type:
.. Water c h ~ valve
WCV 3-'7
k
Operating pressure mdx: 75 bar
Operating temperature mas: 3OVC
Weislit: 11 kg
Size:
Nominn! ~Iinmcter:DN 200
Application:
For stearr and liou~d<
media
The check valve can hc installed,
.-
sandwichetl between weld neck flanges.
wi~l~'
' I
Body: steel
DIN-M:.i:rial No. 1.0037
Waferdi..:: steel
DIN-h1;icrial No. 1.0037
Disc sr:i.;ilg: Metallic
 Type: hbterii~l:
. Stop gloi3~: valve. straight
23.006
Body: GGG 40.3
DIh -Material No. 0.7043
Seat: X20 C r l 3
Size: DTPi -Material No. 1.107 1.05
Nomin:li tliameler: DN 2.5 Disc: XZO C r l i
DIN -Material No. 1 .-lO?I .V
.
Application:
For steal11 andlor water flow Tcchnial d a k
Nominril pressure: PN 25
Weight: i . 4 kg
Flan?cs uccordi~igto L)IN

Type No.:€010
Version: 0
Stop valve, straight, DN 25, PN 25 250 1088

i i
I3ngu:tgc I'K I'agc Ill
 Type:
Stop valia:. gate straight
Size:
. Nominal tliamcter: DN 50
Application:
. Sea willcr. fresh \yarer, oil. steam etc

Body: GCi 25
Technical d:~ta:

..Nominal pressure:
Max. temperature:
Weight:
PN 10
150 "C
11.5 kg

Type No.: 60'0

Version: Stop valve, straight, DN 50, PN 10 253 1005

1 J
 Material:
. Reflecti\ :warcr level gauge, right, 2 x 6 Rody and cocks pizccs: Forred
carbon steel
Size: Trim of cocks sct: Stninles? stssl
Noniin:~l iiiameter: DN 25
Technical data:
!\pplication: Nominal prcssurc: PN JO
For boiler water level indicator
. Weight: 22 kg
Connection between body and cocks xi.
made by end tubes and stufin? hoxes

,
1-
,

L,'
,.
iL~Q
,'7
,'
-
1307-;

'
,.

., lL
!

I
I
,,
;
,

I
!
~

Type NO: 71310 Water level gauge, right, 2 x 6, 627 1012

Version: P- DN 25, PN 40
\ J
lA,:,~u:,gr 1.K P;,ec 1;1
 Ksflecti~c.water level gauze, left, 2 x 6 Body and cocks pieces: Forced
Size:
. Nominal iiiarneLer: DN 25
. carhnn steel
Trim of cocks set: Stainless steel
Technical data:
Application: Nominal pressure: PN 40
For boiler water level indicator Weixhr: 22 kc
connection hetween body and cocks arc
made by end tuhrs ;lnd sluffing bows

Type No: 7010

version: I Water level gauge, left, 2 x 6,
DN 25, PN 40
Type: h4aterial:
Stop chi.?; globe valve, screw down non Hod!: GGG 40.3
return. sir~ight DIN --hlaterinl No. 0.7043
23.006 F Seat: XZO C r l 3
DIh -Malerial No. 1.301 1.(11
Size:
. Nominal <dixnekr:DN 65
Disc XZO C r l 3
DIN -Material N o 1.4112I .Oi
Application
. For stc.~ii..~nd/orwater flow
Technical d a k
. Nominal pressure: PN 25
Weight: 18.4 kg
Manses according to DTh;

Type NO.: 6 ~ 3 0 Stop valve, straight, non return, 264 1092

Version: h DN 65, PN 25
Type:
Stop glolx: valve. angle Body: GS-C25N
35.007 DIN -Material No. I Oh 19.1
Sent: XZO Crl 3
Size : DIN -Material N o 1 .A02 1.05
Nornin:~l iiamnetcr: DN 100 Disc: X70 Cr I3
DLN Material NO. 1102 1.05
-
Application-
For srcnri: ;~nd/orwater flow Technical data:
Nonunrrl prrssurc: I'NJO
Weight: -34kg
Flanges according !ti DIN
 Type:
. Safety v;!!ve. f u l l lift
25.941
Size:
Nominal diamrtcr: DN 1.5
Application:
. To b l o ~ f steam
f andlor air
khterial:
Body: G I G 4O.i
DIN-Markrial No.: 0.7043
Technical data:
.. Nomin:ii pressure: PN 30
Weight: l . 5 ks

Type No.: 6040

Version. A
Safety valve, DN 15, Phi 40 1 261 1358

J
\
I .m.iiage ilK I'.,cc ill
m?-"4QRG
I N , t '

. Stop glob: valve. s t r a i ~ h t

23 000
Body: GCiG 50.3
DIN -Materi:~IN o 0 7013
Seat: X20 C r l 3
Size:
. Nornin~ildiameter: DN 65
Dm1 -Materi:ll No. 1.5071.05
Disc: X?O Crl.?
Dn\i -Materi:~lNo. 1.10310 5
Application:
For steam andlor water flow Technical data:
Nominal pressure: I'N 25
Weight: 18.4 kg
F l a n ~ e saccordine to DIN

!
Type No.: €010
Version: A
Stop valve, straight, DN 65, PN 25 250 1092

', i
 Regular bore
r INCil I D'X D Ell' KG Lh I
S9
S o l1
1
/
I52
151
193
1
I
/1
11.1
14.2
21
21.3
26.7
33.4
I .o
1 ,?
2.1 i
2.2
2.6
4,s -1
I
31 1 193 1 25.4 42.2 3,1 1 6.8
1 I12 4 '; -. I 225 I 31.7 3S,? ?,2 1 9.2
X " / 225 1 >S I GO,:] 5,5 1 !?,I

I n s l r u c l i o n for ;..cldin; lii.?\;Itc on !!.c I.;):

1 -Tack lycld i ! : foil! i:3i~:ls 011t > i ~ l C~II(I.:.:~!S
Ii
2 - I<i[1-out [llc ,::!~!c~ p;e,yt: a 1 \ ~CC~II~;~ICI:
1 IIIC~,.cI(lirl:
j .I i i s e r t [lie c : : ~ ~ l c1!1cic
r ::lid c o i ~ i o I;,!
l ;,i\ q ~ s r a l i o l l
 FIGURE A
.
Valve sir? Dimensions rnm (inti?) I
I Id 1
bore
11:
I -.ed
:,ore
ti

M 10x1 5
I
,E

1.15
lSC15211

M 10x1 5 3 ?3
(0.21)
112 2 I4 M 10x1

3 '4 1 M 7,5 14
12x1,25 (0.29)
FIGURE B --
M 7,5 20 10 12 2 .<,
,. . 1 FO4
12~1.25 (0.29) (0,78) (0.59)
-- (1.65) -1
112 f i l 15x1,5

M 15x1,5
8.9
(0,35)
6,9
27
(1.06)
28
13
(0.51)
1:
1 f.lS FQ5

,\ (0.35) (1 .I
0) (0.55) (1 .P6) -

.~~
,:;!
''3 s ; ~ ,i ~ . , :
Ball V a l v e - R e g u l a r Bcr:? i3: 3236.(?
Welci enci
L . . ~,.,
, , ,. : :. c.. i ':t
CONSTRUCTION STANDARD

D;.t2 Sh5-t
Ball Valve-Regular Bore 6 :3236.0
C. I I:
, 7 J c ,r, CJ I .:
-7

Weld end
PRESSURE LIMITATIONS FOR SEATS-SEALS
DRUCKGRENZEN FOR SITZRINGWERKSTOFFE

H. 3 MASTER STAR - S STARFILL

T VIRGIN PTFE
- - - E P T F E IS%G.F.
~
F.B.
R.E.
--- FULL BORE
REGULAR BORE
PSI BAR
2900 T 200
-
2755 - i - 190
i
2610 3-180
!.
2465 170
1~
I
2320 -- 160
1
2175 -1-
.,~
150

2030 '-
' 140

1685 -1-i 130

1760 TI 120
1
1595 7 110

D a t a Sheet
Ball Valve-Regular Bore 6: 3236.0
Weld end Fag? 6 of 5
' Suggesied r;;leriils zh$r 2 years service
Empfohlene r - s r ; l i l ? i l s fur 2 jahres belrieb

+.
. Suggested rr,s:erisls 2::er 5 years service
Empfohlen;- ?rs?;zlci!? fur 5 jahres belrieh

O l h e r rnaleriils are av;ll?.ble on request like

F:i-F51-MO:~'tL-F3?i-FS-F?-174PH
elc.

[I2: 1:, 5l, << <! t

Ball Valve-Regular Eore E: 37.26.0
V ~ I e l dend F r , c-: !-) if 5
Type:
. Level tl(>:ii s\vitcli
RR.4 24
Size:

. Low wa:z- level swirch

..
Material:
St. 3.i.Q
C 22.8
Technical tl:~ta:
Drain coznection: n 12 m m
Cable cc~iinection:PG 11
Nominal pressure: PN 40
Mrtx. \vciriinz pressure: 32 bar

.. Max. wrmrking temperature: 239°C

Flangrs cordin^ in^ lo DlN 3635-C

. Ma.v~netii s\vitcli: 3 x M l i O
Switchiii~:volra~e:6-250V

. Switch cl!rrcnt max: I A ac: 0.5.4 dc

Protcctis~i-of <\\itch hnusins: IP 5.1

Type No.: 8 i 00
Level float switch RBA 24, DN 25, PN 40 8100 000008
version: C
 ...
. . . . . .
.., , :.
:: , : :.. , .
... ....
.....
........ 7.

.,~..
---r-9-,;.,
.+ ;TI-pO68-17
.

...:
. . .. . -
. . - . . . . . . ,....-.
P 0 Box 661. 24 C Gasvaerks,cei
9100 Aalborg. Denmark
?.< T
.
:
..
. .'I L m~$s~,lgg&.2
cs ++, >;.
. . . Tel.: +45 99 304000 I:'> c..:(7is2.5~6 lm,
I .......
:
-
< - ..
......
,.-
- Fax: +45 98 163022 .'?>::~',!? r,;,:;,
. . .
MfP,f>RG -, E-mail: aalg@aalborg-industrierdk
L 2
.. -2

..3
:.:..A. 2.1 . . .:- ;...:
L_.

:..,
IN . . i i E 5 h t t p : l 1 w w aalborg-industr~escom . . c..,. ..
~... ,.;:, ,; i: j;?......
:I
. . -. .
-. -.
. . . .-
; .;
.-...-.,;,:,>:,~,>:;. . . . .
. .
. i ;: . . . . .. .. ... : .
I

.. 3
TD . ~ .,F
,, -.. .,.-. ..i. -
,
~. - .:
~.......~:. e,<; r ~ o ~ ySteam
. ..
<
. . . :
n a m iTrap
..
c -.:,
j
<.' ;:;. :.;
) :?
5.5: ? .: .,
..
: . ,: .

1 Description
The TO 3 ? F is o rnediur. Frezsure flanged ihermodyn2mic sleam
iI 1rapv:ilh integral slrainer zr,t.cn sulrabla lor mains drainage.

Sizes a n d pipe connections

DN 15LC. 15.20 and 25
Slan3a:d ll2nge:- BS < Z G !?N 4 2 , 9: 1553 Class 153 and 300

Limiting condition-
I..larimum body design csl,?i!ions Pr! 4 5
PI.M - hlzx. allov~ablep.i;surz 4 0 bar g
ThlA - I.!?r. a!lo:vrhIe :+-.?raia~lre '.31'13
Cold hy3:aalic Icsl €0 t.2. ;

Operating range

I C 10 3 z. LCI
I Resure t2: g

I 5 2 p,oducl c u r : 2 : : t , s c s z j :I !>is r e g i o
Phl3 - hlar. oper2lin~:.?ssu:e (:e:^m-;l2nrJed)
tiole: I.!-,:sm og?a:izg :;r;.Jrz t:: . : L : ' ~ c ~ ~ ~ ~c ~ + ~ C o n i s 0 2 5 b2rg
F1.13S - I . ! e x . o??r;:,rc k; :: c:~cs,.j:+ i; ~ 3 3 6a: u 2 s \ r E a n pizssu:e
 Dimensions ( a p p ~ a r i m a l e ) I nrniilirnetres .. WiIhd:aw-1 LYi~hdra,,~:
S~ze-DN A 0 C D E F G H Weigh1 Distance Dislanc? .1,
i5LC 150 55 $1 40 80 57 38 55 2.3kg lor Cap c9.,,:
lnsulaling
I5 150 55 4' 40 50 57 38 55 2.4 kg
20 150 60 4 ' 40 95 57 38 61 3.1kg
25 1EO 65 5 $0 iOO - - - 4.2 kg

/ Installation
Pre!erablr lilled in 2 hr,::onlal ~ i o ebul can be filled in other

Optional extras
lnsulaling covcr.. to prevznl Ihc'liep being unduly influenced by
excessive hea! loss such as when sublecled l o lovt oulside
1empera:u:es. viind, rain r ' c . (hi31 i.v8ilabl? lor D N 25)

1I The
S p a r e parts
spare pa.% available ;!is sho,.v;l in heavy oullln?. Pa?s drawn in
broken line are not s u p p l l 3 as spares.
AVAILASLE SPARE ITEt.1
nlcrI P Z ~"I 11 R

Wilhdra;.i,,
Dislance
131 SI:a;a..
How l o o i l e r

I Al.~a.jsordsr spares by u s n g the desciiplion given in the column

headzd Avail2512 Spare 2 1 0 staling the size and lype o l Irap.

Exampl?: 1 - S:;ain?r Sc,ee? lor DN 15 Spirax Sarco TD 32;

I How 13
Tr,e;nadyi-.n~cS:.?;m Tr29.

sewice

- , . , , .
sudace such 2 5 2 s u d z z ? 7i21e. A liguie O! eichl na:ion >nb a IiKIe
g r i l d i l g ccn?ound su2L :i: 132 Ca!to:undvn Co's Com:ound I F .
sives I'i? t e s : resu!!~.
I! 15%v.ea! i s loo area! l o br r e c l i l i 3 by simgls la?ping, the sealing
laces on I?? bo2v n c s l b i ::oun,5 f!2: e l 1 th?n 1200e3 end the disc

via:, si.o~.idfic: e x c e e d D.2; m n .

\'/hen re.iss?r;biing. I>? d.ic is r.or;??lly pl2:ed in posilion wilh the
gr3nve3 s:<? i;l conla;; v:i:? body s2a:ing Izzc-. Szrsvi on cap, nu
azs>.?:is c?sui:ed bu! a s,.:i:?ble h;n> 1zmoere:uis enli.seize areas:

I To c l e ~ ?

.! il t~-
or repiace Sli21?-ir
, Uascre;, s:r~ir,?rcap usi;,:: s?ann?:. i,,i:alr?,..i s t i z ? n 211 clean. or
-
i n z a 4 d , e~r~~
s l a e viilh n on2
l.;

/
~ ~

To ra.ajs?r,bl?. 17566 s;:i?n in ~ 2 2 then

. scrsv! ca? in:o place. No
gas'<?: i s re;iui:ed b2: z. tne s ~ z z r01 h l o l y b l e n ~ ~Dis~lphide
i
9;?21? 5to;ld b? a?pl#?: '.: Ih? Inreeds

i, 1:s- C'. ;-;r -

I
0' f ! 7

I
-
. -
1 >,
 Water \\,.~;liinfhose with nozzle Nozzle Couplings (2" Slorr) Hose

Size:
V-nozzlc. I ? mrn

. Length: I i metre (hose)

Inner diarwter 52 mm (hose)
Application:
For spraying of water
Material:
. Hose: fi~il-syntheticmaterial (polyester)
woven i n I l l binding, with inner rubber ,, ,
,
lining 2 connecllnn (male) Coupl~ngs( 2S o n )
Technical tlata:

.. Max allo\iable working pressure: 20 bar

Water ter~iperaturearea: -300C+60°C
Weight: 5.5 k~

llm~n
Water flow

1 2 3 4 5 5 ? 9 '06ar

Type No.: 8500

Version:
Water washing h o s e with nozzle
Data sheet

Pressure transmitter
type MSS 33M (Marine)
..
I?-ta sheet Pressure transmitter type MBS 33M (Marine)
The Danfoss MBS 33M is an electronic
pressure transmiller desiqned for direct
installation at the m e a s u r k j point. It has been
d e v e l o ~ e dlo monitor and reaulate oressure in
rnarilike and induslrial environrner;ts.
The MBS 33M pressure transmitter is
designed for operation in harsh industrial
environments.
The climafic envifonmenl
The pressure transmitter is reliable, even
when subjected to extreme humidity and
temperature. The enclosure is moulded in with
a silicone compound, vihich gives maximum
protection against dust and moisture.
The electricalenvironment
The pressure transmitter has a built-in H F filter
which gives high protection against electro-
magnetic noise. It offers increased protection
ageinst inlerference. This feature applies to
-
the ellecls of:
mobile telephones and walkie-talkies
(HF interference)
~tectricmotor start and stop
(!rznsient voltages)
The MBS 33M pressure transmitter has a
Description
stzinless steel enclosure end diaphragm.
b.ccuracy class i
The pressure range is from 1 to EOO bar.
The pressure connection is G ' 1 2 A, the supply
voltage 10 lo 30 V d.c. and the output signal 4
to 20 mA.
Elecirical wnneclion is by DIN plug (43650) or
with fixed a b l e (2 m cable fined to unit as
standard).
The transmitter is available in hvo versions.
e: relative (gauge) pressure transmitter
b: sealed gauge pressure transmitter
C:provals Lloyd's Regisler 0: Shipping
De! Norske Veritas
. Germanischer Lloyd
negistro llaliano Navale
American Bureau of Shipping
-- --
The output signal 18 an ampl~fled,linearized
and Iemperature-com~ensatedcurrent sianal
of 4 :o 20 rnA. The siinal can be lransmilkd
-
over a lona distance !.~i!t~ouldil:lcultv.
The mechanical env;ion,~en!
The construction make the pressure
Iransminer resistant lo pressure surge,
over~ressure,and vibratcn ug to 20 g
(g = 9.81 mls2) in It,e frzqucncy range
20 t i z to 2 kHz.
Examples of arzas \?hers M3S 3C.M is used:
Diesel engines, gears, compressors, pumps,
boilers, generator sets, hydraulic end pneu-
matiz control systens. liHs, pc./ferpacks.
-.lne relative pressure t:ansmiH2: uses
ebngspheric pressure as reference (e:fectiue
pressure, gauge ( P t j .
-to eliminzte the e F ~ c c!: a ' m o s ~ h e r i c
pressure on measu.,;~g eccurEcy, rela:ive
prsssure iransmittc,~u; :o an0 ir,i:uding 25
bar are vented 13 i : r 3 c ? h s i i - (bzhind t i e
me;.sunng di?.nhra?rrj)
Fressure tr2nsmi!lcrs far c,ver 25 b?r ere
supolied as sezted giuge pr9ssu:e
tiacsmit!ers ivhich mrzns they are calibrated
at atmospheric pre:.ss,ri ( ; i , l S n bar) as
reference.
On jezled gauge p:c;sL,:e trinsrri:lers belovi
25 bar, varialions in i..lnc,sphe:ic pressure
h,ai.s small effect a n nc2su:ing eccurecy.
-. ?.'.jreau Verilas
. @.:ulsche-SchiKs~fte:.,stjri
tl~?ponKaij~K y a b i ~
v d K1arsifika;ir:~.
. P~1sF.iRejestr.
IJ$,Sfi
S:ufkC,.,:
Regis!e: ci S:ipyln;
Data sheet Pressure transmitter tvpe MBS 33M (Marine)

Principle The MBS 33M pressure transmitter operates
on the piezoresistive principle, i.e, four
resislors (silicon strain gauges) of equal size
are diffused at particular points onto a silicon
chip that acts as a diaphragm in such a way
Lhat its geometric form changes when i l is
subjected to a pressure.
Since the resistors are connected in a
Wheatstone bridge, voltage proportional to :he
pressure is produced across Lhe bridge an5 is
led lo the signal converter. The converter is
based on thicklilrn and SMD (surface rncun:~.:
device) fechnolagy.

If the silicon chip is affected by pressure, the

chip and the four resistors become deformed
so that (due to the piezoresistive effect) they
are n o longer of equal size.
.-
D?ta s h e e t P r e s s u r e t r a n s m i n e r t y p e M B S 33M ( M a r i n e )
-

Trchnical data Output

Linearity (Besl fit straighl line)
Hysleresis and repeatability c r O . l % FS
Thermal zero point shin - $ 0 0 2 % FSPC
(compensated range from 0 lo +85 "C)
- tO C?YJ-C

Operaling temperature -10 :a 85 'C

Transpoll lernperalure

El~cfr;zalspecification
supply voltage (poladly proleded) 1 10 l o 3 0 V d.c.
Voltagedependency I <Ol%FS/lOV
Outpul signal I ito20mA
Currenl limitation

M a r . load
1 0.02 A
Rei?onseiime I r L rns I

E l e c l r i c a lc o n n e c l i o n
Pole plug (DIN 436503 Fa 1 3 , s
;: Supply +
2. Supply-
?: at in use
/

i
4 . Conneded to enclosure
Sc:?ened cable. Temperature ra:ing 4 5 "C l o + I 5 5 'C i Q l 5 : h 2 r,
(ETFE) Elhylene ietr~!iuo:oelhylene ~ 6 m m
Elue: Supolvr
.. . 2 ..-c . 7 5 m n '
812ck: Supply -
Screen insulated from enclosure

Hi.field
tii, conduc!ed
HF, conducled
LF, conducled
7 0 Vim
3 Vrms
1 VrmS
3 VrmS
26 MHz
150 kHz
10 kHz
50 Hz
- 1 Ghz
-1'0 MHz
- 150 kHz
- 10 kH:
1 !EC E C 1 - i
1 1
I
I
I.:C eoi-.:
, m m . mode / 1 kV diHmodeJ4 i.V clamp
T ~ ; ~ ~b u~: ~~t ~ 2I kV
E C en:-5
SEt.1351503 1
1rs;la:ion resislance 1 ..:15 l.li: C l o 0 V d c .
Data s h e e t Pressure transrnltier type MBS 33M (Marine)
- --

'7
Mechanical characleristics
Pans in conlacl wilh medium k l S l 3 1 6 1 W.No 1.4401
Alsl 3 1 6 L i w.bh. 1.4r::
Endosure malerial --
-
Vibration slability, Sinusoidal, 20 g 120 Hz 2 kHz IEC 68-2-6
-
Random, 7.5 RMS 120 Hz 1 kHz IEC 69-2-34! !
IEC 68-2-36
Shock resislance. Shock. 5W 9 1 rns IEC 68-2.27
Free {all lEC 68.2-32
I
Enclosure, plug version DIN 43650 IP 65
Enclosure, cable version I? 67
Cable, temperature raling I -65 l o +155'C -- I
Pressure conneclion (IS0 22811) (DIN 16.28e.Q) G 'bk
Width across llals 27 rnrn
Weight 0.5 kg

Max. load resistance as funclion of supply voltage

I 1
i

@ Function range
D?ta sheet Pressure transmitter type MBS 33M (Marine)

-~
I Supplied vii!h 2 rn cable anached plu; c-r,ni::lon
'L'J,!~

i
Elactrical connection
-
2-wire, 4 20 mA

Czble mnneclion:

: Black: s g ~ p ! Y-
A irruli!en ;:am
..?,.
.
. Z'.
CQC!~SU'E

: zu2[ly -
: su:l!;-
I no! i, u i e
=- eon:r,c,r' I? r'r8r,:82-.~
 Data s h e e t Pressure transrnltfer type MBS 33M (Marlne)

-- . -
Code numbers I
Operaling Max. lntn burs:ins
range
bar
0-1
lest pressure
tiar
2
prcssurc'
bar
50 1
Codc n o .

060G3121
ii
0 - 1.6 8 50 060G3122 1
0 - 2.5 B 50 / 060G3123 1
0-4 8 50 [ 060G312.: 1
0-6 20 50 060G3125 -i
0 - lo 20 0
i I 060G3126 - ~~--i
0-16 50 100 j 060~3127 -1
1 i
0-25
0
0-60
- 40
50
80
200
100
800
6W
1
I
060G3128
060G312i
060G3130
-__I -I
1
plug version
-
0.100 200 I E 00 i 060~3131 -7
Gauge pressure
0-160 320 1 SO0 i 060G3132 1
- - 0 250 600 / 06063133 -1
0 - 400 600 1600
0 - 600 900 2: 00 050G3135 1

Operaling
range
bar
0-4
1 hlax.
lest pressure
bar
e
Min bu:s:inr:
p:sssur~.'
Sa:
20Q
- I 060G31Sg
--
C o d e no.
1-
~1
0-6 20 I 200 / 050G313O 1
0-10 1 20 200 / 060G3141 --~,
I

0-16 1 50 I 200 / 060G3132 1

0-25 1 50 ?GO 1 060G3133 1
0-40 80 1 FOG 1 060G3141 1
200 1 SC0 1 060G31:j I
0-100 1 200 ;30 1 060G3165 .-
0-160 1 320 G33 1 060G3147 i
Cable version
Sealel: gauge"
0 - 250 1I 600 --
pressure 0-400 1 500 1 16GO 1 050G31;9 I
0 - 600 900 1 2,:OO 1 050G315t - --
I

.) ~h~ burning pressure is~t,epressure ,re I ~x i ; ~~ i ~ h i~l a - necla?icall;,

d. ~ xi:rr.:
~ IFakir~
~ ~ , ~
") See description on pase 2.
.- --

In p r e p a r a t i o n Applied for ship-approvzls on following versions:

Opersting range up lo 40 b ~ : ~ , ; .
.A ~ o l ~ ~ r n e a s trznsrniner.
ure
Mounted wilh plug connection (DIN 43650)
Mounled wilh damper-screw.
Pa.
 - -- -

r~ ' a sheet Pressure transminer type MBS 33M (Marine)

c r n v e r s l o n table

I I
Pascal NEKIG~PE~
(= Nowron sv;are
per square m#:!-?lie metre
metre1 I

9001 quality approval Danfoss AIS is cerlilicsled in accordance wi:h

international standard I S 0 0001. This means
that Danfoss lulfils the interna!ionel slandard
in respect of product developm~nt,design,
proc'uctinn 2nd sale

Danfoss I n d u s t r i a l Controls offers Data sheets containing technical speci!ica!ions available an request:
he f o l l o w i n g product rznqe:
!
; Conladors and thermal relays - Ine pnive:
i rInSe up l o 55 kW. - . .
Combined ci:cua breaker and manual motor rlzner. Iy:e CTI
, . Sainnaid valves and thernci!-'i; v?b,ar tsi
h t i ~ai n l a c l o r r ! p e r Cl 5 - 5 . Cl 4 - g and lheimal ,ehyr lvpe TI 5.TI 5 5
many Furposes. C a n l a d o i s t y ~ e sC i 60.CI 72, CI 85. Cl 105 a;.?
I thema1 relays ! p e s TI 80.TI 90.TI 310
lndurlriel vslvcs
Solenoid vaker tor building sewices ( l o c k i i ! i '
Solenoid valves lor 09.4s
H? ~ n e u - r a l i cvalves and 3-way solenoid vzlvei 0.2. EViP 2
AVTA. IVa. IVilhermastalic valves
and I V i s e n i n g section
Idadubling solenoid valve type N S l h t
with associated ESlC signal m n v e n e i
2-way solenoid vahe lor s e a m lyee N S l S 3 - L O
Solenoid valve mir wdh Er appioval

Therm05181S end pressure c o n l r o l l

FT lnormonalr and prerrure mnlrols
i:PS theimoifarr and prerrure a n t r o l i
CLS thennorlals and prerrure conlrol;
C 5 prerrure r u i c h e s
EtdP pressure irar.smhlerr
ELtT temperalure transrnnlers
Tnermoslalr and pressure canlrzlr lype K F 2 r d 59
P l e ~ s u r elranrminer lyee MBS 33
Pressure tialsminer lyoe LIES 33 a l e EM? 2 w l n sa-ilary prozr.ss ;cu?l.-,s
 INSTRUCTAONS
Pressure Transmitters type MBS 32, MBS 32R, MBS 33,
MBS 33M, MBS 2050, MBS 3000,MBS 3050, MBS 4010, MBS 4050,
MBS 4500, MBS 4510, MBS 5050, MBS 5100 and MBS 5150

-
_L
Forbvndel lli i ' 3 S kapsling
Connened la I.IBS enclosure
Mn t.!BS-Gei2,severbunb.n
Laisan ru bc : 6 . i l.lBS
Bmwn

Brun
Son
Black
sChrarz
Heir
ORod EO'ange

R a u ~ a Oran50
-F a h u o d e l l i h!BS b p r l i n g
_LCO~C~B C MSS
~ P ~enCloSurn
N'I ).43S-Gehau~(,vehundon
b i r s n a > 5 ~ 1 : e I.iPS
r

Sksrm: Iske !oibundet lil MBS iiapshg a F~nil;ons!~$:

Screen: Not mnnecled 11 endorurs Funi:cn lei1
' Schirm: Nichl mil hlBS.Gehaiie verbun6en Fun"ioni~i!un~
E i i a i 1" !cnCio-
Blinlage: Ira16 du boi:ier h435
I

Forbundel i !1-13skapclilg CRcd Cson OBrur Z'Or-=ge

Gannened I:- idES erclorure Red Black erowr Oiarq
MI: tAaS-Go':: :revahur.den iiot schwarz Eraun Orange
i iakona t , ~u MBS Rouge Hoir Biun O:a,~e

I =
Sksrm: like lorbundot li t.155 r a p a n g
Screen: Nol mnnecledlo N3.F ercbruis
Schi,m: Nichl mil hr3S-Gekd.~rc
Blindage: l i l l & du boiler hdSS
vert'unzen
-. I
i
I

i Forsyningsspmndlnq I Supply voltage IVersorgungsspannung I Tenslon d'allmentatlon [UP]

-
I

I /
'

i 4-20mA
0 ~V
5 1
:
,.!as
33
:O-30 V
MBS
33M
10-22V
. .
Mas
2050 1 t.tas
3000
125.28 V
..
1 hdas
3350
9-34 V
tsss
/31C
hrss
a350 1 1.m
L130
lC30 L
.. . . .
1 t.iss
'510

. .
/ t ~ s s
505C

. ... .
. . .
.. . ..
..
hras
51CQ

.
t.12~
515:
13-32 V

. . . .
1-5 V 030 V . . ..
. . 9-33V .. ' . . .: , . . .(
1-6V I . . . . I
0-l0V 15~30V I . I 1 1530V 1 I I -7
I
Iu$ L.75.7 J I 4 758 V I ---
Berniork 1 Note 1 A c I : u n g /Anention

~V

!
i!
I !i

.. ..
+

- ...
x,,
I
l,fES 2g5p .'.!3Z -010 !,<,555956 1
AWS 30.T-ri /.:<.5d51C ?.'_;S
5 iOf
lrlfiS 43517 n(.:s 5rsr
! ~
- - -~ --

11.27.G9.52
Justerlng I A d J u s t m e n ! !Justlerung IAJustage

MBS 4500/
M5S 4510

Montsge i Mountlng I I.'nntsge IInstallstion

 .l'!pe:
Pressure gauge vsli,e ncedle straight
Size:
. I/:'' I. I/-..
Application:
. For i n s t r ~ ~ ~ nconnections
ent
Material:

- Body: C13.8
DIN-m;~:i:ial No. I .(I460
Technical rf:~t?:
. Nomintrl pressure: PN do0
Test coni~cction: M20 x 1.5 mm threaded male
Wsisht: 0.3 kg

Type No.: 6210

Version: - Needle valve, straight, 112" x 1/2", PN 400 254 1002
1
L
L ~ n g ~ ! : %lgIF:
e P;$XL,I;\
 7
C"//
ior SUPER STAR N. 1 FLANGED-END BALL I.:~~~CS
;a DIMENSIONS DlM~NSlONS F~RFJEST APPROVED L-RNIB" Y~MOIM
PDB:*"*TWIWUnIPHEPIO,:I r.::
G O ACMESSUNGEN DlMENSlONES WITH ENCAPSULATED SEATS I A I ~ ~ A S O Crcr, COudaOr:
AALeiQ2G -- .- ~

1 ,1 I t 5
1 3202 F l I8nt:h DIE1 2526 form C
, . ; iirl>h01:; 2576 lorm C
PN16-PN25 - PN40

--

--
c . , >.>,I,, ..,.?<- :*e b,;? U>,STER sr>a
- ~ ~ - I

~~ -- - ~p

r;~~.";~ i : . ~ -:::,;.: '.:>.\<~;,;~Sl BlElC

.1. -Ir
G : :
1 ~. ::
. ,, , .. - : : .
'1:513165
.,.re z : r l r d a . I-r c r o o r
ANSI 150 RF or R'TJ
,\

,.
, 1
,/,'

i
/
~ ~ ~ ~ ~ ~ p -
~- .

-,:-, > ~ ,..

. ~ .; > - .,,::: , ~ ..- . . ~
~
,~ ..
. a : ?.
lcr ,-i c-:p.
ANSI 300 R F or RTJ

RTJ
-
i> 1
 ...
...
..... :,3P&,% c223
.dUn.
fi[qQRG AUTOMATION MOTORISAilOPl
MASTER STAR 11.3
I , 1 , ( 5 ilUiOMATiSlERUNG ACCiON~lh?iNTOi for SUPER STAR N.1
-- -. - - - -

HOW T O T R A N S F O R M A I I ~ l E I V A LO P E R A T E D V A L V E IN A U T O M A T E D VALVES
I - T a k e w ~ lISe
l handle nu1 2 Take "'A l i e I b e r 3- Fit again the h a n d l e nu1
. , . . -.~. .
- ~- --

~~~~~-
G'i.lE:15101lS At13 7 3 2 0 Q E T ' 3 SiiECT ACTUATOfi
51JITA3LE iCi ?TAfiL':!E E:LL V C L V i S
I
1 :
"A?,:!:
, 1 3::
1
1 a 1 i I c . c 2 i 1 0; 1 G
. ..>
,,,:,; :.?. - 8:S:c
X><<"
rs;c:i
1
I ,fi:\. I r , x I t-c: I nm. I m 7 I <,- I v- I - - . -- I C i I mm . I
d l . I . ! I : :i,:ilKi.i 5
3 ,1 1I 5 I U ' " : ! 5.- : ii I li 1 E d 9
! i : i ? l 1 : 1 : i 1 ? i l k d 12 1
. II I I I:
,, ,,,- ' I 2 I 1: 8 I I : 1 Id I
I I: I :: I :I 1 :i I U:XI l i i
1 li I il : I 11 1 I 33 -
I 31
1 2 1 3 I
i I l ? - l 65 1 2 I I :
5 5 : ; '3 I
1 1 3 : 1 i! 8 : I 0 0

.
. I ,I
: 3 i i I I 2 : I 51
: ii I il IUhlZ I 7s
G?n.'aifirlniii'

[ ? ~ d ~- ~ l : ! . :
$1 E Z - C ? i:r-p ib!c:r ,c:ul:,r: I-: 11 0,

3 . 19; < ?!,%?: >,rs,:;l, C,<?.? $?t

] ? I 1 ~ 8 3 c~ i 5VLL,J!: + I
[_PY! I1 1 A OPEU~~IOH TI
I
U T r ea
L ~I
tI
3 i ; uI
U n: +
~ S
hlrrrqti~
E A ~
+
~ ~SI>GC:~;:C
:
S:rm Fx;?;
.
T:ii:?i T) I ' L ~
- -

STARLINE" B R A C K E T S I S 0 5211 11.1 STAINLESS S T E E L

 '"1
single
solenoid spool valve

V
-
for piloting single a n d doubie acting actuators
i ; simply rotating the selector plake 1803, a 3/2 NC volvs ~ e c o r r e ;o 5/2 valve.

In I!,! i l L,n z octing v i r i i , ~ ~ ;

~:-ISolr
. . .
! n Ins actilctor
i n c \ , r j m t ~ r s is char:-
n-clel : the 3/% pilo:

,
\>1k,5i, d ? i n e r g i z e o , tr.3
,
. .
.. ret,.~rn c): ,:!er:n oir fr,am
t p i t ? th-7. spring
- chanb-r contributsi to the
,.,~.;s3:hi-,'z'
f~1ncii3n.
.
,

-\

A. mrosecced from *he environmem*

'-
I/
T h ~,31;,2's intsrr,ol components ore pro;.zl?d from I'P ei,.;ir-.:-~i.>?nto j thov are

. ~oi;.~:~I?tzl~ ~ i o l o t ~from
? the extsrior
TI.,,^ ,:!ronnri2d e x h ~ ~ parti
r ,
~ s t gvorontec be~isrpro!?:;;c:., c r 13- en,iirc:iirt.zr,f
f ..
o;j n!lov, 1h2ic 1?30l volves lo br- in;i?!l?ii in seri!:;? c-..--:s (.cl9on r,sim:,
~ ~ ~ : ~ ~f3ad
p ! ; ~ : ; - , ~ ~ , z ir,,<~;try, ~ a Iprocessing i n d u s t r y I
 p~- -.
I
Operating p r i s u r c P P O ~ U C F S iindusffrial
brlox. 10 bar 1
1 TP
; . 1 1/1 C :'.- 7
-
Ooeratina tei:~:,eroture

1
d

-25°C to +60::
~~c~!ll;:~:l:'
' !
!,!,t;,..? ?.,/I" . rI ,-. ,l ~.:. ;I Inisrnal
!Oplinnol : - 0, C
1
,
:,I:,,: 1 1 : 1nf1r1-I --:? poris iss~c,:-.~!
I I

Fio+i 700 I1n.l I c..'. : ,:\I,l.,.c 1: I

:;
I from ihs
! en'dironn;:;):
 ...
...
.....
..... p<:zl
& ~ - ~-
~ ~p
~~ ~ - -
'>$,.. ,.

EGO INDICATION BOX

TYPE M, I OG '-1
A~LRORG
I N ? t i
-- ~~
12.04
-

Description:
EGO indication t.:,i, with built in swilches or sensors.
Ths bow is to be 2sed for visuel- and remote indications,
for open!closed- 3. other positions of a valve or actuator.

. ~

Applicability:

EGO indication b:ox is used in installations in:

Chemical- and Petro Chemical industries.
Foo:! industries.
Farr-iceutical Industries.
P u p and Paper Industries.
Shlr: vards.
Pov:: stations and others. --

Approvals:
DE' ' <O
CE

E,GC) indindication box is supplyed with following types 01

si.;irhes and sen-rs
Mikroswit,:i:es.
Inductive.
IdAMUR crnsors.
Eex and E?xi.

S:.:zia! models. :-,~storn

made
;
,. . .
*.
~, ~ ~,- ~ , , I
Special connec!i:l acc. 13 custom standards.
~

.-., I
> ,. ,.,. I
I
Pct?n!iornetre 5i;ll00012000 ohm ,0-24 VDC. --

i ,. , ,, ..-, i
.,,. - .

, ..

,, .ir i
., -,,..,
I
-
,.,
~

-- -

RE. da:s 1.9.19'-,

Bradrene Dahl EC.: - ~ - ~ : ' : ~:
~
 ...
.....
..... EJ
VUAYUR

EGO INDICATlOFlSBOX M!.qWtG

TYPE M, I OG N 1 4, 11 r 5

~~ ~

[Tecnical data:
I I EGOBOXM I EGO BOX1 I EGO EOY I : I

I Type P! contacts I Mikroswi!ch I PNP inductive 1 N;imu: i

-
I YP' I VSCOlOTBIC I 992FS2-A9PV3-L I NJ2-V3-N-V5 I
I , ,,.
,.,llage I max.250VAC 1 9.6-50VDC I 6 VDC I

Ma,. irequency 2 KHz 1 KHz

+ 55% ti1 +85% - Zj0C tit -73°C 25.c ti1 +l
i 00"~ 1
Dlms--ion Lx3xH 82~80x67 82x60~57 F2x2grF7

.-

2 Brodrene Dahl - EGO-katalng n ~ ; dato

. 1.9.1990
Temperature sensor
with welded connection - -

Type P2202 D.s~- October 1998

Temperature sensor, type P2202

' t i ( i i J sensor or thermocouple (TIC)
-;I.?nonid sensors
- C m ,iccordance wrth DIN IEC 584 (DIN 437111)
"'100 if1 accordance with DIN IEC 751 (DIN 43-60)
!':~noi~s sensor tube diamefers available
,L;. 13:'. 06. 08. D l 1 a n d 0 1 5 m m
lrom 50 mm
P~I~~III

:;enst~r tube with welded connection

.p G 7QB nipple. I !i" I S 0 clamp
-ernperature range
'I i 0 P -50 - 1800°C
- L,- :nax R50'C
~ p i r i i ~ n eelement
nt or replaceable insert
Sl~rii:ia!sensors available :or specific appI~calicf?s
!!
.'
,. . .,

TLPIPRESS temperature Sensors can be suppl~ed

.'. -
t:00 resistance thermometer. type P22021 . . ..
!i. sngle thermocouple, type P22022. or the
: ,Ie iherrnocouple. type P22023. . .
7 : 202 IS 3 series of standard sensors with ri
v Iod connection on the sensor tube, for example
n I ?B n~ppleor a 1'4'' I S 0 clamp, and a practical
..,-n(;ct~onhead. The series is employed in all
I:.; :s al industrial and processing plants wliere
el-- :!rrJnlc temperature measuring is required.
T i . sensor IS easily f~tted with a DIN head wh~ch
,:I - ;res s~mpleand easy connection to the elec-
i s .L. SLIP;)~Y. The cable seal is a PG cable gland.

Tr si.ti.!s 1s available wlth eithera permanent ele-

:n.. t i l r iel>laceab!emeasuring insert. The reartion
! I I,: cconclderably shorter with a pernianent elr-
I-.~.., ! W I - I I ~ !ivth
, the replaceable insert. the sensi~r
r.. - r,asIv ile replaced.
I : (i ;t:n.iors are supplied with class B accuracv
I i:!asi 2 tiiermocouples as stantlartl features.
H I -.-! , 1.1 . al accuracy can also be rri~ppl~erl
..ssi?s

...
.....
~.

. ,, ..a*. P 0 E o x 661, 2 4 C Gaivaerks\;e!

9100 Aaliiora, D e n m a r k
Tel +J5?9204000
Fax -45 98 lh?DLL
E-mail a a l p ~ F a a I b o i ~ ~ ~ n d u 5 t r 1 e ~ 1 , ~
I N !S
Dimensions

sensor, type P2202..., ordering key

, , ., ,-i, ,.I

lp..-
1 -k
1
C i i,-, l
:%::..,- I , .
77 ".
1 I
i
lu,l- 03
I nr
I;! 1 0%
L-.,' 1 06
~- - -
1
i
-?-
~

I ::
8
I,.,

, , ,
~~ - ~
.-~
--
8 10 I
Type:
Dosing pilnp P.E. 100 with chemical Max pressure: 'I bar
tank Capacity: I 2 . ~i I/!?
Max pressure
Application: -
suction side: ~,> Ivir
For che~.'~ical
dosins Max operatine
Material: lempcrature: 0°C'
Enclosure ratiny: rP 11
Pump Insulation class: F
Liquid i ~ d : PVC Chenlic31 tank \olum~:: I 0 0 ltr
Check wive cartridge: PVC Colour: R!ll- 102s
Seats: PVC Weiyht: 7':
Balls: Glass
Contour plate: PVC
Seals: Vilon
Chernic.!l tank: Polyethylene
Dosin. :i.:ad: Stainless steel

=OFeed rater h n e lo baiar Chemical d o s i n g d l

F,ri?:.--~-
Ma, a 0 m 1- b,Si"Q @""ID
m t e a rater llir
r,n,fi 7 -
C i C h -7 rave -
F,,:,, .,
C.U343mr ~-
ti, :'I

E B ~ nee ~ S
ry S r c ' p i j r

Uor: :Durn#

Type No.: 9296

Version. I?
Chemical dosing unit
 Dosinq valve

-
.- -.
Type:
. Needle v.iive, straight
!
-
..
Li3

- .
I
Size: ',

. 318" BSI'
r I

Body: brass
Spindle: brass

. Packins:
Hand wIi,?,:I:
FTFE
steel
Technical tik~ta:
.- Working pressure:
1'4eigIit:
25 har
0.32 ks

Performance curves

Type No.: 9?% 884 01 05

Version r'
Chemical dosing unit
I
1
\ L
Conversioii factor for flow coefficient: cv = 1 . I 7 kv

I--- .....
....
..
..... Pneumatic Control Valve Dzra Shrst
&la Type 23.470 Df K.1182.1
M L R C :'G With VP - Positioner Page 1 0:'
I,,DLII, E 5
 Version: I Date: 27.09.96 I Group:

-
Designsfion
\Istcrial - Dl> KO. i
- -
PS 2 5 . 2 3 . 4 7 0 - -I
I / I1 circ,40.2 1 0 7013 1

~
BO~) 1
2 j Seawin: 1 X O i r 131 1 3 0 2 l . 0 ?
I 3 / Mounting bonnet 1 GGG 30.3 10.7013 I
I
I 4 bush (stuffin: box housinr) 1 X 2 0 C r l 3 I 1 4 0 2 1 0 5 - hardcncd
-.-
I
5 1 XOCr I31l40210i
i 6 !I X ? O C r 1 3 1 1 11021 0 5
Gland llanec
--- ;I C: 21 6 -I1
i x I ? c ~ P : , s I ~ ~ ' :i?ni
II
--

i
- -
Slurcng bar
--
:I i ' l ~ l T - V - r i n $ ufi,:,

-- -.
- - .-. - - -. I
I
i C S l i I I 1141 i
-- il C .?I :I 0501
19 --
1 I I L C r N i 177:l 4-j l C -
30
--
Actuator !~-I DP
~ ~ ~ --

Pneumatic Control Valve

Type 23.470 DP
With IN - Positioner
 Technical Data:
Medium: . . . . . . . . . . . . . . . . . . . . . . Comp.essrd air only
Maximum inlet pressure:. . . . . . . . . . 17 bar
Operating temperature: . . . . . . . . . . - 20 'C. to - 65 'C
Filter element: . . . . . . . . . . . . . . . . . . 5 Pm
Recommended regulating press: . . . 0.1 4 - i ' s i r
Gaugeports: . . . . . . . . . . . . . . . . . . . 118'' esp
Connections ports: . . . . . . . . . . . . . 114" ESP
Pressure gauge: . . . . . . . . . . . . . . . . O - lobar
Weight: . . . . . . . . . . . . . . . . . . . . . 0.4 k c

.".
...
..~.. Data Sheet
cdpjlfi,
Filter Regulator with Automatic Drain K.1177.0
M C 3RG
I . t i t 5 Page 7 of 1
 Table of contents

Descriptions
S k i m atomising burner. type ICBSD ........... ............................. ~~ . . . i
Steam atornising burner, type KBSD

1 General

Tlie burner is a steam atomisin: burner fur niodulatin: operation. Ttie hunicr is
capable of humins hoth diesel oil and heajy fucl oil. An illustr:i!i<,n 01' rlic KRSD
burner is shown in Figure 1
Thc burner system consists of the burner urtir. ci~mbustinn I I ; ~ n d iltppl!.
systems ror oil. steam. and cotnbusriort ail-. Tlic hurner utiit is nioi~rircdor1 top o ~ t l i c
hoiler and connected to the combustion air f.111x i;l ;In air duct.
The design of the KBSD burner ensures that !lie flalnr is kcpt liiplily stahlc :it all
loads. Due to the advanced wind-box and oil tlo\v control syirem. ~ I i cKBSD h i ~ m f r
c;tn provide inert :as at low loads and h:~sar: incre;lsed rilrn donjn intin

Illustration of the KBSD h u r n c r

1.1 Burner design

1.1.1 Wind-hox design

When the combustion process in all oil hurner is conu-ullcd. it is csieilrisl to liait. .I
stable and unifonn distribution of the c~?tiihustionair it1 ttir hurltrr r<r_isti.r and tile
air duct. A badly shaped air duct can cause instability of tlie flanie. ;iiiii tli?reforr tile
burner has been designed with a dynamicat w i n d - b o ~ .:is shown in F i r i ~ r e2. T l i ~ i
wind-hox, shaped as a spiral, in combination \vith the radially functinninc s\virlers
ensure a uniform air distribution in the hurnrr register ;is \\'?I1 ac in tht* furnace. Tliii
is an efficient way to achieve a stable combustion.
.Another advantage of the wind-box design is that i t minimices tile prt.i>ure loss.

Illustration of t h e dynamical wind-bos --

-Flame rtoti~l~sir

Figure 2

1.1.2 B u r n e r register
The humer register is the duct between the wind-hox and the furnnci.. Tile hurnci-
lance with atomiser, flame stabiliser. and isnition burner are placed ill rile burner
register.
For maintenance and inspection purposcs thc hurncr i;~iicc c:~ri Ix ~!i<ninunii.~l
separately from rhe top of the wind-box. This makes rclil.~cenii.ttt n l illi. atnniiscr
very easy.
The flanie stahiliser is desiprmed to create :In ititer~i~llre-circulatiixi ,,f l ~ c , i gases.
which provides the continuous ignition. and herch!. t i i stnhiliis the 1l;ini: rc-ultiii: in
less pulsation.

1 . I .3 Ignition b u r n e r
The ignition burner is aseparate diesel nil hunier with its uwn crll iuppl. \!<tern
\\'hen the burner is started. and tlie i ~ n i t i o tscqucncc.
~ stcp is i - c ; ~ ~ I i cth:
~ l . iyniti~m
hurner is moved into position hy means ~ I t l i air r servo c)liiid~er.
Tlic diesel oil flame is ignited by ;in electric spark hctiveeii t \ \ . , ~< l e ~ t i . ~ ~:Jihicli
< . .IT'
connected to :l high voltage ignition transformer.
Al'ter the ignition period has expired. the isnition hunlcr is pureed . < ~ i l iair , 1 1 i ~ i
clra\vn hack again
The bumer lance contains [lie Y-.jet art~niiser.in u.hicli sreiirii ;i~itli ' i ~ c ;\re
l 11i1si.J;rnd
eje~.red. This oil mist i s then mixed with combustion air. ;111d i l i e iornbus~iotii s
completed. The requested oil capacity o f the burner unit dc.rer~nitic\tlie t i l ~ t i i l ~ 311~1
cr
bore o f discharge ports in the atomiser.
The oil flow regulation i s based on flow measurement\. a i i i i rlicreiiirc the oil
pressure i s o f little importance to the atomisation quality. .As a c<~nstqu<riie o f this.
the atomis3tion quality does not vary over [he burner [urn down i-~ngi.even \\it11 tlic
o i l pressure operating between 2 and 25 bar. This i s why the cscesi :iir r::tio can he
kept as low as 1.1 at full load increasing to 1.77 at minimum Io;1t1.

1.1.5 Flame failure equipment

Flame failure during light up and nornial operation i s dettctsd hy pliot(>elt.elric cells
niounted on the burner unit :~ndcoupled to an amplifier rnilunted insiilc the lnc:~l
control panel. R y loss offl:~rne.this flame failure equipnie~it\\ill .ir~ti>ni:iiic:~ll!.\liin
down the burner.

1.2 Supply systems

1.2.1 Oil and atornising systcnis

The atomisins mediitni and oil are siipplietl from valves rlir-ouch llc\ild' lic-i\ei 11)
the bunier lance.
The automatic shut-off \'alves. re-circulation valve. hulenoid \alvzs. 2nd [lie rest o l
the necessary burner mountings 31-ea11 fixed nn the wii~d-hirr..All s l ~ t ~ t - o\;11vcs fl Jre
standard ball val\'es. and the automatic valves are witti cl~ctr~ciptieuniatic .~cti~;~loru.
The arrangement o f the components on the burner i s m:~de:I\ sitiiple :I< posrihlr ;~nd
i s therefore very user friendly regarding operation and maintensnie~
The oil flow control valve i s fitted tosether with a pneumatic con\'cner/pi>zi~i~~ner.
T o obtain a very accurate regulation o f the oil flo\v. which i s \.-r! inipon:irit to h;~ve
3 large t u n i i l o w n ratio. the valve i s also titled with an adiustahlc C'\:ttlju!.tcr. This
Cv-adjuster makes i t possible to adiust the pressure loss cwrficient c>f tlic valve
whereby the oil flow regulation can k optimiscd ro e;tch sinclt. ilirr:ill;~tio~l The oil
flow i s rneasurcd by a screw-type flow metei
The fuel oil pressure control loop includes d motorised control v:il\c. to cnsilrc the'
correct pressure at the fuel o i l inlet o f the bumcr. ;~ndtlicrehy ~itr,\,idiiic;I 1:iryr
turn-down ratio o f the control \,alve. A single loop PIT-conrrollcr rind :I ;t;iiiii::rd -1-
20 mA PI-cssure transmitter cnsurc. optimum and accuriite futictlcl~i:~lit\
The fuel oil temperature hefort thc burner inlet i s kept precisel! ;it ille i l c \ ~ t ~ i:llui. ~,d
by 1ne:tns o f a motorised flow control val\,e. ;l single loiip P l l ) ~ c o i ~ : t ~ ~;ind l l ~ .I~ r .
Pt 100 tcmper;iture transmitter.
The atomisins steam i s supplied t l u i v ~ g ha r n o t o r i ~ ~coi~trril
d I I rie:~~ii
pressure i s kept constant at high burner lolid. hut :II Io\v l h l ~ n i e lt,:~clq. ~ tlic W:IIII
pressure i s reduced. A sinrle loop PI])-cc~titrnller \vitli exrsrri;il \i,t pi31111: ~ ; i c l ;I
standard 4-70 mA prcssurrc tr~nsmittcrensure optiniuni and ;iccur.~~~, Iitiiiri~~~i:ili~\
Tlic external set point i\ relared lo the Suel t l i l l l o i r : ~ n di,h;itir~,c 1 o x 1 1 i ~'.+.itli
~ r rlii\.
making rerulation marc oplirnal.
Both steam and compressed air can bc used ior nroniication of 111~. luL,I i111.,Xnriii;iIl!
steam i s used for the atomisation. u h c h i s 51tpplit.d from tlic hr~ilerdrum 111 p I ~ ~ i i [ \
wirh t ~ v ohoilcrs. i t i s possihlr to supply stem1 f o ~thv ~ ~ t c ~ ~ i i i stlirou~l-t
i ~ t i o ~ i:I SOCI:~!
placed before the steam regulating \,;~IIc. t o m i s u t i ( ~ of
~ i tlie illL~l
i > i l ih! ciunpi-i.T\: :I
air should only i
x used during start-up c,r due: to failur~:i,l rile .rc;ini ,tlppl\
1.2.2 Combustion air system
The combustion air system supplies air to llie humsr ;lccordin~ro rlic demands nl
Ihe control system. The draft loss 01' the burner air resister 1 5 nieasurcd h! ;I
differential pressure transmitter, which c o n l e n s tllc sign;~lto ;I flow ci:n:~l used hy
the control system for automatic airloil r,~tiocontrol.
The combustion air is supplied hy :I directly driven centrifujiai la11 TI1e fan ic
mounted on a common bed frame with motvr. inlet v;incs. and si.r\o-dr~\eunit TIIC
fan impeller inside the spiral housing is mounted directly i r l i tlie inlotor sliali The :iir
flow to the burner is regulated by inlet vanes mounted on rl~efan suction side.
The inlet vanes are of a multi-blade design and reglllnted hi. ;I c~~-\.!~-d;iven unit
comprising an air cylinder and an IIP positioner. .A cile~lccrc.lri hi. 1 1 1 ( 1 ~ 1 1 1 t doil [lie
fan suction side.
Steam atomising burner

a General

The steam atomising burner is capable of burning both diesel oil and heavy fuel oil.
4 s the burner is a very vital component of the boiler plant, the operatins staff should
he thoroughly ilistmcted with regard to !he operation d t h e equipment nnd the safety
regulations. This is due to the fact that burner problems are olien caused hy inconect
hurner operation. With frequently occurring humer faults. the near?<[ srrvice centrr
should be consulted.
To ensure a safe and reliahle function of the burner i t mu?t he inrpcited ; ~ least
t once
a year, in addition to the normal maintenance intervals. The inspecrion sliould lr
c r i m z d out by a representative of the supplier or by ;~r~other
competent : ~ n dqualilied
person.
It should be clearly understood that for n plant oithis complcxit) i t i \ not practici~hle
to anticipate all the possible circumstancc.~which may arise duriny the i>peration lif?
of the plant. Therefore, should circumsta~iccs arise in plnrit nprr3tion irnd
maintenance which are not specifically covered by tli<se ilistrucrions. the matter
should be referred to Aalborg Industries for consideration and advice.
Repain, adjustments, alterations or changes to plant operntio~isnot covered by t l i e e
instructions should not k effected without reference i i i ivritin: r i r halhor;
Industries.
lnfonnation in this manual is subject to chanses without notice and does not
represent a commitment on the part of ..\albfirs Industries. It is nor nlloi\.cd to copy
this manual or part hereof for any purpose other than the purchi~ser'spersonal use.
Aalborg Industries shall not he held res~onsihlefor any damape or lossex c:~usedhy
the use of this manual.

1.I Safety regulations

Caution: T o ensure a safe h u r n e r opcr:ction, the b u r n e r has to he installed a n d

commissioned by qualilied personnel. and all guiclelines in these
instructions have to be follo~ved.

All safety equipment such as flame senror cquip~nentiin'd corl-xtiri: cIcil?crits m:l!
only be replaced by qualified personnel^

Warning: Repair of any of the safet?. components is NOT perrnittetl. Failnre to

comply may result in serious i n j u n o r death ;rnd may cause
considerable damages to the boiler plant.
If any unexpected plant khaviour. deterioration or similar evelit s11ot11d occur ~ i v i n g
rise to any reasonable doubt as to the continned safety of the plant. thc matter should
be reported at once to Aalborg Industries for their advice.

1.2 Qualified personnel -

Qualified personnel according to these operating insmctions are persons, who arc
confident in installing, regulating and conlmissiflnin~_the burner. and who have
qualifications to cany out this work, i.e.:
Persons who are trained to operate electric circuits and units ilccording to the
safety standards.
Persons who are qualified in [he ucs or daneerous file1 accord~ii: to tlic relevant
law5 and regulations
HandVng fuel oil

1 Precautions to be taken with fuel oil

Fuel oil is usually the residue of crude oil after the removal by distillation of the
most volatile oils and gasses. Fuel oil in its liquid state is very difficult to ignite iii
bulk and not capable of spontaneous combustion. However. the vapour is explosive
when mixed with air, and being heavier than air, it tends to accumulate in low levels
such as bilges and bottoms of tanks where it may remain undisco~crcduntil ignited
by a naked light or spark. It is always present in a partly filled oil tank or in a tank
which has contained fuel oil :~ndis given off through the i,mts fioin tanks in the
process of being filled.
If allowed to continue. a leak in :my part of tlie oil huniins s!.stem m:iy ri.rult iri :In
accumulation of this explosive vapour.
I~ynitionof the vapour can be caused hy an open light, electric spark. srnokinz, spark
caused by striking metal, heat from thc filament of a hroken clectric lamp. sparks
from funnel or can be communicated from _ealley or fires under hnilers.

Note: An oil fire cannot he extinguished by water, hot niay he extinguished h,

sand, steam o r chemical fire extinguishers.

An intelligent appreciation of the properties of fuel oil as desarikd ahnve. is a k , t e r

prevention of accident than adherence to an) set of rules that may be p r e d e s c r i k ( l .
However, the following detailed precautions should be rigidly eiifo~~~.etl:
When oil is being received, no naked light or electric apparatus liable to spark
should he permitted within 20 meters of the oil hose. t:ink or compartment.
containing the tank or the vent from the tank. esccpt when special arrangements
are carried out.
Wtlile receiving fuel oil. tlie storage rank must hc closcly watched for leaks. and

.
care must be taken thal all outlets from [lie tank. encspt tlie vent\. are closed^
No naked lights or electric apparatus liable to spark should he pcrriined at ;in!.
time in a compartment containing a fuel oil t:inI\. Electric I;~inp\used in sucli
compartments should have a wire protector around thc hulb or he of n trpe th:~t
will ensure the breaking of 3 circuit through the lamp i n rhi: cvcnt o l the lamp
k i n g broken.
No one should be allowed to enter ;I fuel oil tank until i t hns bccn 32s-freed. and
any person then entering the tank must have a prnperly rcndeil life line around
his body in order to he hauled out if ovcrconlc hy $:IS.
Electric fuses and switches, unless ihc enclosed type. should not 1~ pem1itti.d ill

compartments containing fuel oil pumps or piping.

Care must be taken that the wirc-gauze protectors in vent plpcs from fuel oil
tanks are intact at all tiincs,
 Dampers, where fitted in the uptakes of the boilers. must Lw kept fully ope11
while burning oil. Otherwise, this nuy result i n dangerous nccunlulntion of gas
in the furnace with a resultant blowin: out into the boiler or engine rooill.
The valves on glass gauges in fuel oil storage or settling lanks should hr kept
habitually shut. When a reading of the gauge is desireti. the vnlvcs may ht.
opened, but must be shut again at once.
In each boiler or engine room fitted for oil huming t1ie.r~ should he fire
extinguishing apparatus in accordance with the rcquirc~nentslrulesfrom rhe
authorities and classification societies in question such as. e.g.: Fire hose.
permanently coupled and of sufficient length to reach all parts of the boiler or
engine room and either:
- (a) a box containing at least 85 litres (2 cubic f t ) of drq. sand with 3 lnryc scoop
- (b) a chemical fire extinguisher of the tank type
When the fuel oil system has not been in use for a long period. or after joints in
the piping have been re-made. thc system should hc tcstrld ".iold" under n
pressure at least equal to the working pressure Izfore fires :lsc i ~ i t s d Durine
.
the test a careful inspection for leaks should be carriccl out.
Fuel oil should not be habitually heated above 65°C lor light oils and 130°C for
heavy oils and never above its flash point in any pan of tlis systsm cxc1:pt in thc
burners.
Care must be taken to prevent accumulation of oil or vnpour in any place o u l i d e
the system and in ships pmicularlv in hilses under rhc furnnci.. This can k
accomplished by rigid cleanliness.
llqnition burner
%

1 General description

The ignition burner is a separate diesel oil humer with its own oil supply system. It
operates on the principle of mechanical pressure jet atomisation. The ignition burner
is retractable and insertedldrawn back hy an air servo cylinder. Both in liutornatic
and emergency operation mode the ignition burner is fully ;~uttlmatic.An illustration
of the ignition burner is shown in Figure 1
The ignition system always operates on diesel oil whether the steam otomising
hurner operates on diesel oil or heavy flrel oil. This secures a relinhlt isnition. The
diesel oil is supplied by an ignition oil pump. wllich only npcrates iri i y i t i c : , l i mode.
Thc pump pressure should be set to 8-10 bar.
The combustion air to the ignition burner is supplied froin the compressed air
system and can be adjusted by means of the throttle v;ilve placed alter the solenoid.
At the end of the furnace purge period. the solenoid valves for dicsel nil and
cornbustion air open, and the diesel oil flame is ignited by an electric sp:irk hetween
two electrodes which are connected to it liigll v o l t a ~ signition tr:insformer. The
i-pition burner is simultaneously moved into ignition position. The ignition hurner
must ignite the main hurner within the present iynition psriod. At the cnd of the
ignition period. the solenoid valves are closed. and the ignition hurner is purged by
compressed air throuzh the solenoid valve in the purse air inlet. Af1c.r tlie purge
period the ignition bumer is drawn back.

1.ICommissioning

During commissioning the position of ths nozzle 2nd tlir elritrodcs should he
checked and adjusted if necessary (see Figure I ).

I .2 Maintenance

As the ignition burner is one of the most cnp~,cedculnponrnts. i t nerds Frcquent

inspection and maintenance.
The electrodes should bc cleaned. :ind the insul:~tioii rnatcrinl chccLcd for
damages.
The nozzle should be checked and cleained. If tlie spray pattern hits other pan\
of the ignition burner despi~eclcani~isit. thc norilc. ullntlld lx. chansi:d.

Note: Be careful not to change position of electrodes ac t h i ~nwy cxnre, c.g.

ignition prohlerns, instabilitj o r build-up of carbon tlepo~it.
Illustration of the ignition burner ~-
A N5erv0
~ ~ ~ ~ n ,
d - i 14
Photo cell

I Description
The RAR7 detector is used for supervision of yellow burning oil flames. If the photo
cell detects a missing flame, the burner stops instantaneously. It is not possible to
start the burner before the control system has been reset.
With this type of detector, the radiation of the oil flame in the visihlr hand of the
light spectrum is used to senerate a fl:mie signal. The. light-sensitive element is ;1
selenium photo cell. When illuminated. it genrrutes DC voltarc which causes a
current to flow to the input of the flame signal amplifier in tlie control unit. Hence.
the selenium photo cell is an active detector.
The cell is insensitive lo infrared radiation. If the burner is started with a11
illuminated combustion chamber. e.g. due to glowing firebrick, the s1:lrt sequence of
the burner commences, but an alann for flame failure will he indicated.
The number of photo cells for 3utornntic operation and emcrFenc!: operi~ti~w depend
on the classification society.

1.I
Commissioning

The intensity of the light radiation can be checked by measuring the detector current
hy means of a DC ammeter (internal resistance 5000 \\'). Firure I shows tlie
measuring circuit. The photo cell is adjusted by changing tlie position in proportion
to the oil flame in order to obtain the maximum detector currcnt.

Note: If the wiring of the photo cell is connected incnrrectly. it is not possihle to
start the oil hurner.

Measuring circuit -

Ammeter
connection

-- -

Figure 1 ~ihotcirc.cilr
Burner lance

1 General description
The burner lance contains the Y-jet atorniser in which steam and fuel are mixed and
ejected into the furnace. An illustration of the burner lance is shown in Figure 1
During nomlal start, the burner lance is purged with atomising steam through the
steam pipe line. This heats the burner lance and makes ignition nC the main flame
more reliable. During normal stop, the oil pipe is purged with ste;lni. By this. the
remaining fuel oil in the lance will be atomised into the furnace. Thc combustion air
fan, which also operates during this period. purees the furnacz lor the elected
oillsteam mist.
For maintenance and inspection purposes, the lance can be extracted iron1 the wind-
hox, and the atomiser can be dismounted rrom the lance. Thi.\ is done. hy
unscrewing two ,411en screws in tile flange connection and unccre\vi!ir the screw
cap.
Eventually. the atomiser will be covered with a layer of carhon depos~ts.To renlovc
these deposits, paraffin or carhon remover should be used. It is also possil?le to use :r
soft metal scraper. A hardened scraper should not he used as i t could damafe the
i~tomiser.The cleaned atomiser should ihen be examined for d ; ~ m ~and ~ ~ the
e , hole?
checked for wear. It should be replaced if necessary.
The O-rings must be replaced every time the atomizer has heen disrnoitnted. Refore
mounting the screw cap. the thread should be ccivcred with at1 unh~rdeninf h i ~ h
temperature compound.
When the burner is commissioned, the atomiser must be thorou:hl\i clz:tned before
any attempt is made to start the burner.

Illustration of the burner lance

- -m - i l , 8

m
- m
- .',
c .-z
~- - 1%
Protection tuba Screw (cap
km 6
\
Ranges
~ f ~ ~ , ~ , , ,

',
Gi
 -
Viscosity temperature chart

Description

The preheating temperature can be determined hy means of t l ~ e \.iscosity

temperature chart shown in Figure 1. In order to use the chart. tlic viscosity of the
fuel oil must be known at a reference temperature.
It should be noted that the preheating temperature should he ser someu.hat higher
than the temperature shown in the ch3lf due to the heat loss hztwesn pre-heater and
nozzlelcup.

1.1 Example

The example is based on a prcssure jet humcr

Known:
Oil viscosity: 380 cSt. at 50°C
Required:
Preheating temperature in "C
Procedure to he followed:
Step A: Follow the reference temper.1ture line at 50°C vcnically do\.in to ille
intersection with the 380 cSt. viscosity line.

Step R: From this point move parallel tlown with th? nearest fuel p d e iinc

Step C: When the line meets the recommended nozzle viscosity line. go \,enically
up to the temperature axis.

Step D: At this point read the desircd pieileatin? ~srnpernlure~ , fI 5 O C ~

 Viscosity - temperature chart

a ~oso-rrncndnln m l c uismrity far- U i n g hnaas

@ b r n m m d e d n o d e v k a r i r y for msm aiominmg b w

Fizure I

7
1.3nylage i j K I arc 2!7
Fuel ail supply system

1 General description

This section describes the oil system in general terms together with some of the
requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both diesel oil and heavy fuel oil
operation. A diagram of the oil system for steam atomising humcrs is sho\vn in
Figure I . The d i a g a m shown is for a plant with two steam atonusing hurncrs.
The oil system consists of oil tanks for diesel oil and heavy fuel nil. mixing tube. oil
pumps, heaters, ignition oil pumps, and e q u i p n ~ e nfor
~ oil pressure and tcmperclturc.
control.

Illustration of the oil system

Figure l
1.1 Oil tanks

The heavy fuel oil tank may be provided with a heating coil for heating up tlie fuel
oil in the tank to at least 50°C. at which temperature it will be possible to pump the
oil. The oil temperature in the tank should not exceed approximately 60"T in order
lo keep the oil temperature controlled by the heater units.
Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
fuel oil must be insulated and traced in order to keep a sufficiently low viscosity of
the oil. The tracing can be done either hy means of steam heatins or hy me:ins of
clectric heating cables.

1.2 Fuel selection

The fuel type is selected by manually operating the three-way val\,e i G l 151 in the
oil system
In an emergency case, heavy fuel oil can he taken from the heavy fuel oil settlin?
lank. In this case, the valve (G49) in tlie suction line from the mixin? tul?r to the
pump suction side must be closed so that any return flow is lzd hack to the hea\.y
fuel oil tank. In this mode. the tank temperature must he ohserved s n that the
temperature is kept helow ihe fuel oil flash point.

1.3 Return flow from the burner

-- -

When the burner is in stand-by mode. a minimum of fuel oil is returned via the oil
return line to the three-way valve ( G I I I ) . From here the fuel oil is either led to the
pump suction side via the mixing tube (G110) for degassing or to the heavy luel oil
settling tank. The three-way valve normally returns the fuel oil to the mixing tube.
If- the fuel is changed to diesel oil or heavy fuel oil hy means of the three-way valve.
iG1 15). the three-way valve (GI l I ) automaticnlly changes position and rcrums the
oil to the heavy fuel oil settling tank for a period of time.
The three-way valve is a pneumatically operated actuator controllcd by a solenoid
valve ((3113). The solenoid valve has a iilanual switch for emergency operation.
This arrangement is necessary to avoid a conlinuous heating of the rc-circulated
diesel oil when the fuel is changed from diesel oil to heav'y fuel oil. The viscosity of
the recirculated diesel oil decreases and with i t i~lsothe lubrication characteristic.
This will cause damage to the oil pumps~
The arrangemen1 is also necessary when the fuel is clial~gedfrum hci~vyFucl r>il t < i
diesel oil hecause the temperature of the reiirculated hcn\'y fuel r>il \\.ill dccrcirse
and might cause blockage of the piping system.
After the pre-set time period has expired, the thrcc-\vliy u l v e iC; l l l I retur-ns to
normal position. and the fuel flows to the mixing tube ( G I 101.
The time period must he set wit11 reyard to oil pressure and the q~i:tntilynT oil i n th?
system.

1.4 Fuel oil supply pump

The oil system is fitted with one set of supply oil punips cornn~undlr hotli di?sel oil
and heavy fuel oil (GO5 and Gl2).
The supply oil pump unit ((3147) is a twin type package unit in svllich two scrzn.
pumps with driving motors are connected by a switch across the vnlve housing. E ~ c h
pump is fitted with a pressure safety valve, :I filter (GO? and Ci09). a m:~ni-iivacuum
rnuge (CXM and GI I ) at the filter. and stop valves (GO7 and Gl-li.
The pumping capacities for the pumps are calculated in such a way that there will he
sufficient oil flow to the humer and the pressure reg11l:lting valve in full load
condition.
The control system receives a signal from the pressure transmitter (G99). If the
pressure drops below a pre-adjusted set point. the operating pump stops, and the
other pump starts. If the pressure continues :o drop, the control system gives alarm
for low oil pressure and stops the burneris).

1.5 Fuel oil pressure control

A part of the fuel oil returns to the pump suction side through the oil pressure
control valve (G100) which keeps a pre-set pressure in the fuel oil system.
The fuel oil pressure control loop includes a rnotorised control valve (G100) to
ensure the correct pressure at the fuel oil inlet of the hurncr. This provides l x g e r
turndown ratio of the oil flow regulation valve. A single loop PID-controller and a
standard 4-20 111.4 pressure transmitler ((399) ensure optimum :md accurate
functionality.

The oil system is provided with pre-heater(s1 ((322) heating the l~rnv! rue1 oil to the
correct temperature/viscosity hy means o f sLc:tm.
The fuel oil is changed by means of the manually operi~tcdthrcc-\vay valve ( G I 151.
When diesel oil is selected, the manually operated three-way valvt I C 3 1j must he in
a position which by-passes the pre-heater(s1, and thc stop valveisi iG2.5) must k
closed. When heavy fuel oil is selected, ihe stop valve(si lC;25i must opened. and
the manually operated three-way valve ((351) must he in a position i l l which the oil
flows through the pre-heater(s).

1.7 Fuel oil temperature control

The heavy fuel oil temperature after the pre-heater(s) is kept precisel) at the desired
value by means of a motorised flow control valve (G2ll1. a sinrle loop PID-
controller, and a Pt 100 temperature transmitt,?r (G28i.

1.8 Ignition oil system

-.

The ignition system always operates irn diesel oil \~'hcthi.r the slectm i~tornising
hurner operates on diesel oil or heavy fitel oil. This secures a rtlinhle ignition.
The diesel oil is supplied by an ignition oil pump (Ci72i \uith filter (G7UI. The pump
is only operated i n ignition mode. The ignition oil pump is a ys;ir pump fitted with n
pressure limiting valve and a filter inside ihe h o o s i n ~ Tile
. pmlp ~Iinuldhc. set to S-
10 bar.
.4 plant with two boilers is provided will1 two ignition oil purnpi. I S :r pump rails.
other can he selected to supply dicsel oil for ihe ignition to bi~thhr~rners.
Burner supply systems

1 General description
This section describes the bumer supply systems in general terms together with
some of the requirements needed to have a safe and reliable bunier operation.
The bumer and the oil system are desiged for both diesel oil and heavy fuel oil
operation. An illustration of the burnt-r supply systems for the steam ntomising
burner(s) is shown in Figure 1
The burner supply systems consist of a fuel oil system, a steam ritotnisin~system. 3
combustion air system, an ignition system. and a compressed air system.

Illustration of the KBSD burner -

+Diesel oil for ignition burner

,
., Atornising steam
' for burner

-
,Aux. atornising
steam supply

:-Atomising air

1 Condensate

2
Furnace pressure

Figure 1 hurnoilsy-a.cdr

l ~ n g u z g el l K Pnee li?
1.1 Fuel oil system
-

From the pre-heater(s) or the pre-heater by-pass line. fuel oil flows through the
three-way valve (F99). the flow meter (FlOO), and the oil flow regulation valve
(F94) to the pneumatic three-way shut-off valve (F75). From this point, the fuel oil
either returns to the fuel oil supply system (burner stopped) via stop valve (F93) or
to the burner lance (burner in operation) via the pneumatic shut-off valve (F67) and
the stop valve (F64).All pipes are traced to avoid blockage of HFO.
Both the fuel oil and the atomising medium are supplied from the stop valves (F41
and F64) through flexible hoses to the burner lance.
The burner lance contains the Y-jet atomiser where steam and fuel are mixed and
ejected. This oil mist is then mixed with combustion air. and the cornhustion is
completed.
The burner load is controlled by the control system. which receives a continuous
signal from a steam pressure transmitter. This signal is compared to different set
points, feed back signals, and parameters in the control system. The output from the
control system is used to control the oil regulation valve iFQ4). \vhich is
pneumatically operated by an ZIP positioner. T o ohtain a very accumte regulation of
the oil, which is very important to habe a l a r ~ erum-down ratio. the valxe is also
fitted with an adjustable Cv-adjuster.
The signal from the pressure transmitter together with feed hack signals from the oil
flow meter and the differential pressure uansmitter for co~nl?ustionair are handled i n
the control system to obtain a correct comhustion with reg;~rd to nirloil n t i o and
atomising steam pressure.
When the burner is in ignition position, minimum position. niaxlmum position. erc
the aidoil flow is fixed by settings in the control system.
Furthermore, the control system is designed to prevent poor co~~ihustiiin (black
smoke), which may arise during start-up, stop. and loud alter3tions.
The oil pressure is of little importance to the atomisation quality :is the oil f l o ~
regulation is based on flow measurements. As a consequence of tliis. the atomisation
quality does not vary over the bumer turn d w n range.

1.2 Steam atomising system

From the boiler drum the atornisinx steam llows through the steam regulating valve
(Fgl), the pneumatic shut-off valve (F32). and the stop valve (F4l) to tlie hurner
lance. The steam pressure is controlled by thc regulating valve iF91). The steam
pressure is kept at a constant level at hiyh humcr load. but at lolver hurner loads. the
steam pressure is reduced by the control system. A single loop PK-conrroller wit11
external set point and a standard 4-20 nv4 pressure transrnittcr ensure optimum and
accurate functionality. The external sel point is related lo tlie fuel nil flow and
changes together with this. making regulation rnorr opti~nol.
During n o m l stop of the hurner, the lance is purged with stcam. The pneunlatic
shut-off valve (F44) opens, and the reln3ining fuel oil i n tlie lance will he atonlissd
into the fumace. The conlbustion air kin, \vhich also operates during [his period.
purges the fumace for the unburned ejected oillstrani inist. Th: vi11ve F 3 1 i r closed
after the end of the purge period.
If atomising steam is not available from the hailer. it can h supplied from thc
auxiliary s t a m system via the stop valve (F92). Compressed air can also k used as
atomising medium (e.g. 3t s t m - u p ) 3nd I S supplied via the stop valve (F871.
Compressed air for atomising should only be used if stcam is not availshlc.
1.3 Combustion air svstem

The combustion air fan draws air from the engine room through the inlet vanes. The
inlet vanes regulate the necessary air flow for the combustion by means of an air
cylinder and an IIP positioner. The 1IP positioner receives a d-20 mA si-rmal from the
control system
From the fan discharge side, the combustion air flows through the air duct into the
burner wind box. From here the combustion air is distributed to the hurner register.
the flame stabiliser, and the furnace through the radially functioning swirl regulator
to ensure a uniform air flow. The swirler blades are factory set. It is possible,
however, to adjust the blades individually during commissioning in order lo ohtain a
more stable combustion.
The draft loss across the burner is measured by a differential pressure transmitter,
which converts the signal to a flow s i y a l used by tlie control system for nutomatic
airloil ratio control.

1.4 Ignition system

The ignition bumer is a separate diesei oil burner with its own oil supply system
which operates on the principle of meclianical pressure jet atomisation. The ignition
hurner is retractable and insertedldrawn back by an air servo cylinder. The diesel oil
flame is ignited by an electric spark hetween two electrodes xvhich arc connected t(1
a high voltage i-mition transformer. The conibusti~mair to ihr ignition hurner is
supplied from the compressed air system.
At the end of the furnace purge period. the solenoid val\.sc (FI 8. F i 9 . and F153i
open, and the ignition burner is ignited ;ind inserted.
The ignition burner must ignite [tie main burner within the present ignition period.
At the end of the ipition period, the solenoid val\,es (FIX and F19) to the ignition
burner are closed. and the ignition bumer is purged by compressed air throuyh the
stop valve (mi). the solenoid valve ( P R ) , and tli? nomi-return ~,aIve1F77). After the
purge period the ignition burner is draw11back.

1.5 Compressed air syste m

T h e compressed air syste~nconsists o l f o u r cysicnls wllich opcr;$tc w i t h different

pressures. The air system for atomising is a sep:lrate system. which includes the stop
valve (F87) and the non return valve (F!OR).
The air system for the ignition oil bumsr comprises the stop v;llvcs i F73 and F151).
the throttle valve (F152), the solenoid valves ( F 7 R and F157). and the ncnn rctum
valve (F77).
The air system for control of the pneumatic shut-oif valves consists of the air
filterlreduction unit (F63). the solenoid valves ( M I . FO5. F56. and F59). and the
pneumatic actuators (F60. F66, F57. and F i g 1 Tli?sr components are used for the
three-way shut-off valve (F75), the shtit-off valve (F67). the shut-off v:11\.e (F-12).
and the shutaff valve (F44) respectively.
e s air filtcrirrductio~iunits iF36 and
The air system for the oil flow control i ~ ~ c l u d the
F97). the W converter (F95). and connection to the oil flow reyulating v a l ~ e(F91).

Note: W converters andlor pnsitioners must be supplied n,ith instrument air.

Commissioning

1 General
-

The following commissioning instructions are valid for steam atomising burners
type KBSD with Y-atomisers and with a standard delivery of individual pans for the
burner unit and supply systems from AALBORG INDUSTRIES.
Prior to the commissioning, the instructions for the individual parts of the burner
unit and supply systems should he studied. The special instructions for the hoiler and
the conh.01 system should also be consulted. The instructions should only be
considered as a guideline. This is due to the fact tllat a c h plant Iiould he
commissioned individually to obtain the hest burner performance for tlic specific
plant.

Attention: If the burner unit and supply systems include part.;, which a r e not
standard delivery from rLA.41,BORG INDUSTRIES. the specific
instructions lor these parts should be ignored in the following
sections. The actual instructions for ibe specific parts should he
thoroughly studied and followed during commissioning.

During commissioning of the hurner unil and supply systems. it rnighi he necessary
to adjust some regulation parameters, timer settings. eic. in the control system to
optimise the function of the plant. These adjustments are not descrilxd in the
following sections, but should be carried out as the oprimis;~tion requiri.ments
emerge. Please see the instructions for t!le control systern.

1.I Pre-sewice checks

-

Before commissioning, the following work sreps must be caricd oul:

Step A: Check that the boiler is ready for c)peration accordin? la r11i- special
instructions for the boiler

Step B: Increase or decrease the water le\cl in the ho~lerio . ~ p p ~ n \ ~ ~ i i , i5t 0e lmrn
i
below normal Nater level

Step C: Check the electric wiring.

Step D: Switch on the power for the bniler plant and rcrer the system oil tllc loc;~l
panel or the computer.

Step E: Check that the control system is operdtion:~l accordinc t tile special
instructions for the control systcm.

Step F: Pre-adiust the pressure switch and pressure transmitter set points for boiler
operation.

Lmguage UK Pnre 1/70

The position nunlbers mentioned in the following sections refer to the illustrations i n
Figure 1 and Figure 2. The position numbers consist of an identific:~tion letter and a
position n u r n k r code. Position numbers with the identification letters "Ci and R"
refer to Figure 1, and position numbers with the identification letter "F" refer to
Figure 2. The oil system is shown as a plant with two boilers. hut is also valid for a
plant with only one boiler.

illustration of the oil system

Figure 1 F-oiIs~sIa.cdr
 Illustration o f t h e burner unit and supply systems

@Diesel oil for ignition burner

Fuel oil return

Instrument air

Atomising steam
' for burner

AUX. atomising
steam supply

: A t o m i s ~ n gair
I
(
I

1
Furnace pressure

2 Commissioning
-

2.1 Commissioning adjustments

-.
of the burner unit
--

On delivery from Aalborg Industries, the burner unit has k r t i pre-:~djustedto lit [hi,
task. Even though the burner unit has heen pre-adjusted. i t is :ldvisnhle tn c a p our
additional checks during commissioning. These checks should he carried out u-it11
regard to adjustment of the atomiser and flame stabiliser distance. swir1r.r blade
angle and ignition electrodes, etc. This means tllat it is nrces5ary to pr~llnut thc
burner lance, flame stabiliser, and ignition burner.
2.1.1 Dismantling

Step A: Remove the flame scanners.

Step B: Close the stop valves (F41 and F64)

Step C: Dismount the flexible hoses for fuel oil and atomising sieam to the burner
lance.

S t e p D: Dismount the flexible hose for combustion air to Lhe iLmitionhurner.

Step E: Dismount the flexible hoses for ignition 011 and purre atr to the i.mitlon
burncr.

Step F: Dismount the flexible hoses for the air srmo cylinder on the ignition humrr.

Step G : Dismount the cable for the magnetic switch on the ign~tinnhurner.

Step H: Remove the two spark plug caps from the ignition llurncr

Step I: Note the position of the front plate and unscrew lie nuts frum the fmnt plate

Step J: Lift up the front plate in the lifting eyes including tlic br~rner1;tnce. flame
stabiliser, and ignition bumer by means of a tackle. Be caref111 not to
damage the packing between thi: wind-box and front pl3tr.~

2.1.2 Adjustment of the atomiser a n d flamc stahiliser tYistance

Step A: Check the distance between the atonliser tip and the inner r i n ~o f the fl:lmt.
stabiliser. The factory setting is 25 rnm. A d j u ~ if
t necessary.

Note: An exact distance cannot be given. but has to he determined !\hen t h e

burner is in operation. If the flame has a t e n d e n o to pulsate a t lo\\
loads, it might be necessaq to readjust the distance.

Step B: Loosen the bolt, which fixes the flame stabiliszr to rlic b u n ~ c r lancr
protection tube. Adjust the fl:!me stahiliser to the dccirr:d pusitioii. aiid
tighten the bolt again.

Stcp C: Loosen the bolt, which fixes the hurner lrtnce protection lube to the front
plate. Adjust the protection tuhe into a position in \i.hicli the front of the
flame stabiliser and the beginning or the quarl (burncr cone) are a t the same
level. This corresponds to an opposite movement nf tlis protcctinn t u k to
the same numerical distance as the flame stahi1isi.r rno\.einent. Tirhtcn the
bolt again.

Step D: If an adjustment is carried out, loosen rhc fixing screbs that lhnld the air
servo cylinder of the ignition burner. M o v e it in t h c saliie direction and t o
the same numerical distance as the flame stabiliser nio\.ement. The f a c t o n
 setting between the. ignition hurner and tlic flnm? stnl~iliser is 5 t n m ~
Tighten the fixing screws again.

2.1.3 Adjustment of the ignition b u r n e r

Step A: Check the positiori of the oil nozzle for tlie ignition burner. The oil nozzle
tip should be at the same level a the end of the ignition burner mixing t u k .
Adjust if necessary.

Step B: Check the position of the ignition electrodes. The ignition electrodes should
be 10-12 mm in front of the atomiser tip and 8-12 mm above the atomiser
tip. The distance between the electrodes should be adjusted to 4 mm. Adjust
if necessary.

--

Note: An exact setting of the ignition electrodes cannot be civen, hut has to he
established when the ignition hurner is in operation.

Step C : Unscrew the two screws that f i n the mixing tuhe to the elcctrnde holder and
pull out the mixing tube.

Step D: Loosen the centre screw that fixes the oil supply pipe :~nd ndjrit to tlie
desired position. Tighten the centre screw again.

Step E: Dismount the oil nozzle from the oil supply pilw 311dcheck tllat tlie norzlr
is clean. Assemble after checkicleaning.

Step F: Loosen the two Allen screws that fix the ifnition ell-ctrotlcs and adjust rl~t

the desired position. Tighten the Allen scre\vs n f ; ~ i n ~

Step G: Assemble the electrode holder :md the mixing tub:. Screw in tlie t \ w
screws on the mixins tube.

2.1.1 Check the direction of the s w i r l c r blades

Step A: Check the direction of the swirlcr h l ~ d c z

Note: If the wind-box has a form, which provides the cornhostion a i r with a
clockwise rotation, the setting anzlc of the s n i r l e r l ~ l a d e s must 1)e
anticlockwise and vice versa.

2.1 .S Measurements

Step A: Before the bumer unit is assembled, check and notc the commissioning
measurements. The obtained measurements should i ~ rinscnetl in the
chapter "Measurement and settin~s"
2.1.6 Assembling

Step A: Check the condition of the packine hetwecn the wind-hox and the iron1
plate. Replace if necessary.

Step B: Mount the front plate including the burner lance. flarne stabiliser. and
ignition burner onto the wind-box. The front plate slic~uldhc mounted in the
same position as before.

Step C: Screw in the nuts on the front plate. The nuts must he tightened crirss\vlse

Stcp D: Mount the flexible hose for combustion air to the i~gnlt~on
hurner

Step E: Mount the flexible hoses for ignition oil and purre air to the ignition burner.

Step F: Mount the flexible hoses for the air s e n o cylinder on the ignition hurner

Step G: Mount the cable for the magnellc switch on [he irniuon burner

Step H: Mount the two spark plug caps on the ignition humer

Step I: Insert the flame scanners

2.1.7 Clean the burner lance and atomiser

Step A: Unscrew the two Allen screw? on the burner lancc fldnec ,~ndpull oilt ~ l i c
burner lance

Step R: Dismount the atomiscr and s c r w c ; ~ pfrom the humer lance and check that
the lance is clean.

Step C: Clean the atomiser and screw cap The f,rctory I1.1c greased the :itnrnlser to
protect it from corrosion.

Step D: Replace the two O-rings on the atomiser and ;~sternblethe atornisc.r. scrc\r
cap, and burner lance.

Step E: Insert the bumer lance into the prolcction tube and zcrcw i n llie t \ v o i\llcr!
screws into the flange connecti~:ln

Stcp F: Mount the flexible hoses for [lie1 oil and atomisin; steam to I I I C humcr
lance.

2.2 Adjustment of the swi rler blades

It is possible to adjust the shape of the flarne by means of the su.irlcr hl;~dcs.AII
increased swirl angle results i n a wide and shon flame. and the oppositc swirl angle
results in a slim and long flame.
The swirl angle for the burner can be determined hy means of Tahlc I . Tlie swirlcr
hlades for a burner must always he adjusted to the same anrle
 Note: T h e swirl angles shown in Table 1 should be considered as guideline
settings. T h e shape of the flame should be checked when the b u r n e r is in
full load operation, and the settings should be atljusted if necessary.

As shown in Table 1, the swirler blade angle increases with the burner size. This is
due to the fact that the outlet sectional area of the quarl (burner cone) decreases in
relation to its inlet sectional area when the burner size increases. The n ~ u l e blade
r
angle must then be increased to obtain the same combustion clu3lity.

2.2.1 Check the swirler blade a n g l e

Step A: Check the angle of the s\virler blades

Step R: Note the angle of the swirler blades. The s e t t i n ~ sshould he inseted in the
chapter "Measurement and settings".

S e t t i n g o f t h e swirler b l a d e a n g l e
Burner size Swirler blade angle
!
KBSD 950 17' j
/I KBSD 1200 17' 1
liBSD 1500 17' i
I
KRSD 1900 19' I

Table 1

2.3 C o m m i s s i o n i n g o f the o i l system

-

When the oil system is commissioned, it should initially he flushed by means of an

external pumping system. This must he done to cnsurc that the oil system is not
clogged-up and to prevent f o r e i y objects from entering the pump unit ivhich might
cause damage.
On delivery the oil system of the burner unit is hy-passed hy means of the threc-way
valve (F99). This prevents foreign objects from entcrinf the flow meter. oil flom
regulation valve, etc. The position of' the valve shoultl not he chanFd before
flushing of the oil system is completed. The \.;11\.c is lcxked in this position h!.
means of a screw.

Warning: When the oil system is commissioned on tliesel oil. the tracing of t h e
piping system must he off.

~.-
Language UK Page 7/70
2.3.1 Commissioning

Step A: Check that oil is present in the diesel oil tank. Open tlie quick closing valve
(G94), which connects the diesel oil tank to the oil syrtem.

Step B: Select diesel oil on the manually operated three-way valve ( G I 15). Check
that the local panel and computer indicate diesel oil operation. Open the
stop valve (G49) for the mixing t u k .

Step C: Open the inlet stop valves (GO1 and '308). and the outlet non-return \alve<
(GO7 and G14) for the oil pumps.

Step D: Open the stop valves for the pressure fauge? (CdM. (311. G16. and GJ7)

Note: T h e stop valves for the pressure gauges on thc pump unit s l i o ~ ~ only
l d be
opened for pressure control purposes. The stop valves should he clnwd
during normal operation.

Step E: Close the stop valves ((397 and G101). and open the by-pass valve 1G101).

Step F: By-pass the pre-heaters by means of thc manually operated tl~ree-\layv:llve

(1351). and close the stop valves (G15 and G2h) for hot11 prz-heaters.

Step G: Open the stop valves for the pressure gat~g"(GSS) and tlie pressunr
transmitter (G99).

Step H: Check that thc three-way v a l ~ e(F99) is locked in 3 poition which h y -

passes the oil system of the burner unit.

Step I: Apply air to the pneumatic three-way valve (GI l 1). :Idjut the :iir pressure
to 5-10 barg on the 3 u filterlreduction unit iG1 131.

Step .J: Check the position of the pneumatic three-way valve ( G I I I ) . In normal
position, the return oil is led to the mixing (tihe. The inicro switch hox
mounted on the valve and the control svstem should alco indicate this
position.

Note: When the fuel is changed by means of the three-way valve (GI 15). the
t h r e c w a y valve (GI 11) automatically changes position and returns the
fuel oil to the h c a ~ yfuel oil settling t a n k f o r a perintl of time. This time
period is set in the control system.

Step K: Rotate the or1 pumps by hand to ensure a free and an uri~iitcrn~pted
rvtJuon

Step L: Adjust the circuit breakers for both pumps tn suit full load current of rhc
motors. The current appears from the motor itlentific:itinn plate ;~nd/orthc
rlectric diagrams.
 Step M: The oil pumps must be filled with diesel oil prior ro operation. The vent
valve installed on the outlet side of the pump unit must he opened until the
air has escaped from the suction side of the pump. As soon as diesel oil
emerges, the vent valve may he closcd.

2.3.2 Flushing the oil system

S t e p A: Set the burner into manual operation mode on thc local panel or the
computer.

S t e p B: Start one of the oil pumps and check that it is running with the correct
direction of rotation. Open the vent valve again until only diesel nil
emerges.

Step C : Stop the pump and start the other oil pump Perfnrnl the same check and
venting procedures.

Note: T h e pressure relief valve installed in each p u m p is Pacton. set a n d

cheeked and should not be adjusted (loring commicsioning.

Step D: Flush the oil system for a few hours with one oil pump i n operation. The
total flushing time should be determined with regard to the size of the oil
system and the amount of impurities iparricles. greasc. i'tc.) C'heck 111s
complete oil system for leaks.

Step E: If the oil pressure is too low or too high. the pressure can he adjustcd on the
by-pass valve ((3102) to :I suitahle level.

Step F: Close the stop valves (G53, GSl, .lnd G109j Tliecz \al\ec muct bc. kept
closed during the complete fluch~rlgperiod

S t e p G : After 114 of the predetermined flushing period. open the stop valves ( G 7 i
and G26j for one of the pre-henters T I I ~ the
I I thrce-\\.a? v:llvc (GS1 ) f ~ l nil
r
flow through the pre-hcr~ters.

Note: T h e set points for the pre-heater s a f e h valres a r e facton. \et ; ~ n d

checked and should not be adjusted during commis-ioning.

Step H: After 112 of the predeterli~inedflushins period. open the stop valves ( G l i
and G26) for the other pre-healfr. Close the 5top \'alvcs 1G25 :lnd G7h) for
the first pre-heater.

Step I: After 314 of the pre-detcnn~nedfluth~ngper~nd.itnp the operat~on.~li ~ l

Pump

Step J: Ry-pass the pre-heaters hy means of the ~nanuallyoperated thrce-u:~yv:~l\r

(G51), and close the stop v:~I\.es(G2.i and GZhj for hoih pre-he~ifrrr.

L u ~ e u a IJK
~c P:L!C 0130
Step K: Commission the oil pressure regulating vcilve (GlOO). Set tlie \nl\,e into
manual mode on the local panel or computer.

Step L: Move the actuator mounted on the valve into mid-stroke position by means
of the hand wheel. By use of the local panel. apply shon irnpnlscs in each
direction of the movement and check that the directions of ~novemzntare
correct.

Step M: Set the oil pressure regulating valve iG100) into :~utomnticmode on the
local panel or computer again. Move the actuator to the end positions
(openlclosed) by means of the digital output test menu in the local panel.
Check that it is switched off automatically. Check that cstcrnal ~ n o \ , i n s
parts are able to move without obstruc~ion.

Note: I n a double boiler plant one of the local panels must he switched off
when the digital output test menu is used. O t h e m i s e tlie v a l t e m o w s
continuously u p and down because one panel sends u p signal<, and the
o t h e r sends down signals.

Step N: Open the stop valves (G97 and GlOl). and close lh? hy-p:is\ \.:~lvc((;102>.

Step 0: Adjust the set point to be 20-25 bar meacurlrd at the hr1r11c.rinlet flanre.

Note: A n exact value cannot he given. If the pressure loss in tlie actual oil
system is high, the oil pressure must he set a t a higher level to ensure
that the burner receives a sufficient amount of oil. If, on the other hand,
the pressure loss is low, the oil pressure must he set a t a lower level to
ensure that the oil flow regul:rtion valve is operating within a suitable
range.

S t e p P: Start one of the oil pumps for final flushing

Step Q: When flushing is completed. stop the oper;ition;ll oil pump and clean the oil
filters in the fuel oil supply pump unit Vent lhc oil pumps :iFter the filters
have k e n cleaned.

S t e p R: Commission the steam reful~~tinfI 2 ;IS descnhcd Ti~r thc nil

pressure replating valve (GI 001.

Step S: Open the stop valve7 (G51, (35-1 i

2.3.3 Check and adjust the pressure transmitter

Step A: Check that the oil pressure indicated on tlie l o s u l panel and cornputsr is
identical to the pressure indicated on the pressure gauze i(;.l-l).

Step B: Adjust the range of the pressure tr;lnsrnillcr ( G W ) in tile caliI~r;~t~i,~i

rncnu
of the local panel if necessary.
Note: If the pressure transmitter (G99) and pressure p u g e (G4-l) a r e mountctl
a t different height levels a n d f a r apart, the pressure loss resulting from
height difference a n d friction should be taken into consideration.

2.3.4 Check the lowwarning and start of stand-by oil p u m p function

Step A: Adjust the set point for low warnin? and start of the stand-b\ oil pump on
the local panel or the computer

Step B: Start one of the oil pumps and st-t the other pump into \tand-hv mode

Step C: Set the oil pressure regulating valve (GIOO) into manual mode on the imnl
panel or computer and decrease the pressure gradually until the set point is
reached. The operating oil pump should stop. and the pump in stand-h!
mode should stan. The local pzlnel 2nd the computer should indicate a low
warning. Readjust if necessary

Step D: Switch operation mode of the plirnpc and carry aul ttii. came procedure

2.3.5 Check the low oil pressure a l a r m and trip function

Step A: Adjust the set point for low alanu and trip on tile lix.,~l p:rncl or the
computer.

Step B: Decrease the pressure somc\bhnt until the set point is reached. T'hc
operating stand-by pump should stop, and an alarm slifluld lh. indicated on
the local panel and the computer. Readjust if neccssnn

Step C: Set the oil pressure regulating , ~ l \ (GlOO)

e Into dutcrnatlc mode . ~ n drecet
the alarms.

2.3.6 Check the trip function for overload

Stcp A: Check the trip function for overload by pressing l!ie test t?utton for the
pump in operation on thc circuit hrez~her.

Step B: The pump stops, and a warning for pump failure s l ~ o i ~ ir-
l d indicated on thr
local panel and the computer.

Step C: When the stand-by plirnp is starled. perlomi thc somi. test ~ v i t l ithis pump

Step D: Reset the circuit breakers and all alarmc after t e ~ t i n ~

2.3.7 Commissioning of thcoil system on the h n r n e r unit

Stcp A: Check that the oil pumps are stopped.

Step B: Open thc stop valves For the pressure court iF09) and thi: pres5ure
transmitter (FR3).
Step C: Unscrew the screw that locks the position of the three-way valve (F99).
Turn the three-way valve for oil flow through the h~lrnerunit. Lock the
valve in this position. Open the stop valve (F93).

Step D: Close the stop valve (F63) and check that the micro s\vitch on the valve 1s
activated. The position and an alarm will be indicated on the loc~11panel and
computer. Open the stop valve ( F 6 4 )again and reset the alarni.

Step E: Apply air to the pneumatic shut-off valves (F52. F45, and F67) and the
pneumatic three-way shut-off salve (F75). Adjust the air pressure lo 5-10
bar8 on the air filterlreduction unit (F63).

Step F: Check the position of the pneumatic three-way shut-off vaI\,e iF75) and the
pneumatic shut+ff valve ( F 6 7 ) . The valves must he in position closed
which means that the oil is led back to the oil system. \Vhen the micro
switches on the valves i F 6 7 and F75) :ire activated, the position is indicated
on the local panel and computer.

Step G : Commission the oil flow meter (F100). Check that rlre oil flu\+ iiieter. thc
pick-up sensor, and the measuring transducer are installed correctly. The
flow meter equipment sends a continuous pulse signal to the conrrol system.
This signal must he converted into an analosous I1mv h y s e t t i n s i n thc
control system.

Step H: Set the values for max. oil and he:~tsilitrei n the loc:ll panel or computer
The max. oil value is the maximum oil flow in llh :it lO(i":, b u n ~ r rload o n
heavy fuel oil. The value for heatsnitre can he taken from the identification
of the oil flow meter.

Step I: Dismount the cover of the m e a s u r i n ~transducer and unscrew the pick-i~p
sensor from the oil flow meter.

Step J: Tap the pick-up sensor quickly against a11 object and clieck tl~at the
measuring transducer records the s i p a l s . The red LED tlnslics.

Step K: Assemble the measuring transducer and mount the pick-t~prellsor ;leain

Step L: Check and adjust the oil flow settines for r n i n i ~ r ~load.
~ ~ m icnition 1o:ld. elc.
in the local panel or computer.

Step M: Co~nmissionthe oil flow recu1:lrion \ d v e (F91). Check that thc output
s i g a l range from the W convener (F95i correspontls to the instn~mcnr
input signal range on the oil tlow regul:~tion \,aI\.c 1 FO-1). The pressure<
appear from the identification p1:ltes.

Step N: Disassemble the cover of the oil flou. regulation i a l i e hy unscrcwin~r i i c

cover screws and lift up the coier. See also lli? specified instruction for t l ~ i .
oil flow regulation valve.

Step 0:Check and adjust Cv (valve cliaracteristic) to f i t the plug and scat ring hr
moving the adjustment knoh along tlic C\. scale. T:ihlc. 2 .;lio\v.; rhi. (',,
setting for each burner sire.
I Adjustment of Cv I

S t e p P : Apply air to the UP converter (F95). Adjust th? air pressure on the
filter/reduction unit 0 6 ) . The pressure settin? ;Ippenrs it-om the
identification plate on the convcrrer.

Step Q: Apply supply air to the oil flow regulation valvc 1F94). Adlust the air
pressure on thc filterireduction unit (F97). The pressure ccttinc appears
from the identification plate on the v:~l\'e.

Step R: Set the oil flow into manual mode on the loc,rl panel o r computer

Step S: Set the regulation output to 0':; (4 m4)hy mcrins or the soft krys nn thc
local panel or by settings on the computtr.

Step T: Adjust the pressure indicated the instrument p u g ' to tile low input
s i s a l range, by means of the zero adjustment scrctv on the I F converter.
The instrument gauge is the left pressure gauge on the oil flow regulation
valve. and the low input signal range appears from the idcnlification plate.

Step U: Set the regulation output to 10FlTo (20 mA) by means r ~ i t h esoft keys on th?
local panel or by settings on the computer.

Step V: Adjust the pressure indicated on the output gauge lo the hifh input sign:ii
range, hy means of the span adjustment screw on the I/P converter. Thc
output gauge is the right pressltre gauge on the oil flow regulation v:ilvca.
and the high input s i p a l ranpc :ippe:irs from the ideulification pl:lte.

mode I>n111rlocal parlzl or

Step W: Set the oil flow regulation valjr inlo a~~tom;ltic
compoter.

Step X: Start one of the oil pumps. Set the stand-by oil flo\u t i ) 0'7 it1 ihe li~:11 p:~nt.l
or compoter.

Step Y: Adjust the turn take-up screw o f the oil flow regl~latioi~ v:~lie until rh~.
piston rod just h e ~ i n sto move. The local p:lnel a i d cotnptltr.l- nuist indic;ttc=
0% oil flow. Tighten with the lock nut.

Step Z:Set the stand-by oil flow hack to the original set point
2.4 Commissioning of the ignition oil system

When the ignition oil pumps are comnlissioned. the burner should lx operated in
emergency mode. This is because the ignition oil pumps only operate in the ignition
sequence during burner start, and a number of stadstop operations are necessary to
check and adjust the system.

2.1.1 Commissioning

Step A: Turn the key placed inside the local control pmel into emergency
operation.

Step R: Check that the quick closing valve tG9J) is open and open the stop valves
((369 and G77).

Step C: Open the stop valve for the pressure S J L I ~ C((375)

Note: T h e stop valve for the pressure gauge shoulcl only he opened for pressure
control purposes. The stop valve should be clo5etl tlurinn normel
operation.

Step D: Close the stop valve (F17) on rhc humrr rtnil

Step E: Rotate the ignition oil pump by hand to ensure n Tree 2nd ;In uiiintemlpled
rotation.

Step F: Adjust the circuit breaker for the ignition oil pump to suit full luad currcnt
of the motor. The current appezirs from the motor ideiltific;~rionpli~tcandlor
the electric diagrams.

Step G : When the ignition oil pump is commissioned. the pomp and the pipe system
must be filled with diesel oil and ventilated. The vent valve iilstalled in the
pump must be opened until the air has escaped. 4 s rrmn 3 s diesel nil
emerges. the vent valve m3y hr closed.

Step FI: Press the ignition button on thr ernzrpncy p:lnel for llic pllrnp. and kcep it
pressed.

--

Caution: The ignition oil p u m p should only he operated for a limitetl period o f
time during the following comniissioning procctlure. I)uc to a
continuous re-circulation, the diesel oil is eventually Ilealed. This
could damage the p u m p due to the lo\v viscosity of the hcatetl diesel
oil.

Step I: Check that it is running \vith the correct direction of mtirtinn. Opcri the w n c
valve again until only diesel oil emerges.

Step .
I:Adjust the opening pressure on the pump lo S - 1 0 hdr
Note: T h e pressure a t the ignition oil b u r n e r should be approximately 4 bar.
This means that the pressure loss resulting from height difference a n d
friction should be taken into considcration.

Step K: Stop the pump and turn the key into automatic operation

Step L: Open the stop valve (F17).

Note: The pressure relief valve (G78) is factory set a n d checked a n d should not
be adjusted during commissioning.

Step M: In plants with two ignition oil pumps, the previously described prm-edures
should be perfomled.

2.1.2 Check the trip function for overload

Step A: Check the trip function for overload by pressinp the test lnitrc>n cin tlic
circuit breaker.

Note: An alarm for ignition oil pump failure will not be intlicatcd. I f this
failure arises during normal s t a r t - t ~ psequence, the burner will t r i p d u e
to flame failure.

Step B: Reset the circuit hreaker after testin?

2.5 Commissioning of the combustion air system

When the combustion air system is commissioned, it should he chccked that tlic
combustion air fan and the air duct system have heen installed and supponed
correctly. If possible, an inside inspection of the air duct system should also he
carried out to ensure that it is free of ohsmcles. e.c. loose parts. insulating nxiterial.
etc.

2.5.1 Commissioning of the IfP positioner

Step 4: Check that the IIP positioner i K 1 6 ) is connected ;is n 2-uirc iystern and
apply electric power to the I/P positioner.

Step B: Check that the VP positioner is in P manual mode. T l i ~display Inlist shoiv
"NOINIT". If this is not the case prcss the hand syriibol r'nce Tliis key
is located k h i n d the cover of the I F ' positiotier.

Step C: Apply air to the l/P positioner and adjust the 3ir preswrc to .I-6 hnr on tht,
filterlreduction unit (R15).
Step D: Unscrew the cover of the I/P positioner. Use the push buttons A V tu
carefully move the actuator and check that the mechanics is fi~nctioning.

Step E: Carry out an automatic initialisation of the 1P positionrr. Call configure

mode by pressing the hand symbol key (>Ssec.l. See the specified
instruction for the UP positioner.

Step F: Set the actuator type to linear (WAY) in the mer~uilem " I ITCT''

Step G : Set the rated angle of the feedback in menu item "2.YrZGL Tile \ d u e
should be set to 90".

Step H: Check that the ratio selector am1 is set to 90' on the JJT p o ~ i t ~ o n devise
er

Step I: Set the leverage (stroke range) in menu item "?.YW.AY". T11e stroke ranee i c
the height difference of the guide rail.

Step J: Start the automatic initialisation with the parameter \,due "Strc" in menu
item "4.1NITM. The JJT positioner then runs t h r o u ~ hthe initinlisation sreps
"RUN 1" to "RUN 5".

Step K: Set the UP positioner into manual mode. Open and close i11e inlet vane3
(R07) several times by manuzllv operating the IF' pc~sitioncrio demonstrate
an unintermpted operation

Step L: Set the UP positioncr Into automatic mode and mount the coiei .ir.iln

Step M: Check that the micro switch, which controls the closed position of the inlet
vanes, is activated. The inlet vanes must be in closed position when the
bumer is in normal stop mode. If the burner is siarted durir~f n o m l
operation condition, and the micro switch is dsactiv;ltr.d. ;I sequence failure
alarm will be indicated.

2.5.2 Commissioning o f t h e p r e s s u r e transmitter

It is possible to set the start of scale and full scale of the dp-transmitter even if there
is no pressure source available ("blind" calibration). Plcasc also see thr qpecificd
instruction for the dp-transmitter.
Step A: Set the alr flow Into manual mcqde on the l o c ~ panel
l or curnplltcr

Stcp R: Set the regulation output to 0Ci. ( 3 nlA) by meiins of tlic \oil kc!s on thc
local panel or by settings on the computer.

Stcp C : Unscrew the screws that hold the protective ewer of ilir dp-tr:lncinitter Tor
access 10 the push buttons.

Step D: Use the "Mu key to sclw-t modes on the dp-tr.insm~trcr \!'hen ,i rnode I\
selected, the keys 7 and are uqed tochdngs the mode \ , i l u ~ .

Step E: Set the values in mode 3 (electrical damp in.^). 9 (outpiit in error situation).
10 (pushbuttons functions). I I (characteristic). I I (tran~ilii>npoirit
 characteristic), 13 (value displr~yed).and 14 (engineering units~.mrn l.IIO
can e.g. be selected as engineering units in mode 14.

Step F: Select mode 5 using the " M key.

Step G : Use the or key to set the start of scale in the selected engineering unlt.
If mm HZOis selected as engineering units. then the sct stnn of scale ro 0
mm HzO.

Step H: Press both the 7 and keys simultaneously for about 2 seconds. and the
start of scale is set to zero (in the selzcted engineering unit I

Step I: Set the regulation output to 100Cf,(20 mA) bv means of the soft keys on the
local panel or by settings on the computer.

Step J: Select mode 6 using the " M key.

Step K: Use the ? or key to set the full sci~lein the selectd engineer in^ unit. Thc
full scale value should normally be set to 301) mrn M.C).

Step L: Set the regulation output to 0 % (4 mA) again by means nf the soft keys on
the local panel or by settings on the computer.

Step h1: Set the air flow into automatic mode on the local p'lnel or cr,riipur~.r

Step N: Mount the protective cover of the dp-trancmilttr :tg:lln

Important: T h e set range of the dp-transmitter should he checked when the

burner is in operation at 100% load on hea\y fuel oil. T h e actual
differential pressure must not exceed o r he too f a r helon the set
range of the dp-transmitter. Jf this i~ the cace, the full scale value
must be corrccted. This will affect all settings made of the airtoil
ratio and they must adjusted once more.

2.5.3 Commissioning checks and operation

Step A: Rotate the combustion air fan hv hand to ensure ;I free and a n uninternlptetl
rotation.

Step R: Check the electrical wiring at the terminals of 111e combustion :lir Can. Thc
wiring must he performed accordinc to the wirinr sho\vn in rlie clectric:ll
diapams.

Step C: Adjust the circuit breaker for the comhustion air i ~ to

n suit full load curreill
of the motor. The current appears from the motor identificarim pint? nndlor
the electric diagram.

Step D: Turn the keys placed inside the local control panrl :ind the pn\\.er p:~ncl into
emergency operation.
Step E: Close the inlet vanes by means of the potentiometer illside the local control
panel.

Step F: Start the combustion air fan (R09) on the operating switch ~nsidethe power
panel and check that it is running w ~ t hthe correct direction of rotation.

Step G : Check that the combustion air fan and the alr duct s??tcm d o not produce
any abnormal mechanical noiser

Step H: Check the combustion air fan and the air duct system for 3ny ;ihnomal
vibrations.

Step 1: Check the air duct system for l e ~ k s

Step J: Open the inlet vanes for the combustion air fan f~illyby mcans of the
potentiometer.

Step K: Check the current consumption of the co~iibustionair fan. The cunent must
not exceed the full load current stated on the mo!or identification plate
andlor the electric diagrams.

Step L: Set the comhurt~onair fan to rnrn~mumload hv mean? of tlir pntcntlorneter

Step M: Check the temperature of the ran bearings. The k a r i n g temperature must
be at a constant level after approxiniately 30 minutes of operation. If the
temperature continues to increase. stop the combt~srion31r fan and check
the hearings.

Step N: Close the inlet vanes for the cmnhustion air Sari by means of the
potentiometer inside the local control panel and stop the culnhustion air f i ~ n
on the operating switch inside the power panel

Step 0:Turn the keys placed inside the local col~trolpanel and the pourer panel into
automatic operation.

2.5.4 Check the trip function for overload

Step A: Start the combustion air Can by means of the digital outpr~rtest nicnu in ihc
local panel.

Note: I n a double boiler plant, one of the local panels nlust be switched off
when the digital output test menu is usetl. Othenvise the fan
continuously starts and stops b e c i ~ ~ sone
e panel sentls st:lrt sicnals, ant1
the other sends stop signals.

Step R: Press the test button on thc circuit hreaker for the ci~mhusti~~ri
air f i l l 1

Step C: The fan stops. and an alarm for colnbustion :rir (hn fnilurp ~ l i o l ~ lhc
d
indicated on thc local panel and computer.
Step D: Reset the circuit breaker.

2.6 Commissioning of the steam atomising system

In normal operation. ato~nisingsteam is supplied from tlie boiler d n ~ mor from an

auxiliary supply system. When the burner is commissioried. ;!tomising steam may
not be available. If this is the case, compressed air can he rlcrtl :IS the alomising
medium.
The function of the steam regulating valve can, however. he chcckcd at this point.

2.6.1 Commissioning of the steam regulating valve

Step A: Commission the steam regulating valve (F91). Set rhe \,;rive into manual
mode on the local panel or computer.

Step R: Move the actuator mounted on the valve into mid-stroke position by means
of the hand wheel. By use of the local panel. apply shon ilnpulscs in each
direction of the movement nrrd check that the dir<:ctions of movement are
COrTCLt.

Step C: Set the steam regulating valve iF91 j into acrtonwiic inode (In the l w a l panzl
or computer again. Move the actuator to the end positions (openlclosed) by
nleans of the dieital output lest menu in the lociil pi~nrl."lirck that i t is
switched off automatically. Check that external mo\'ine p:~rrs ;ire able to
move without obstruction.

Step D: Check and adjust the pressure seltings in the control system. :it low loads.
tlie steam atomisin8 presstlre should he set to appro\i~il,acely2-3 bar. The
pressure settings should he gradually increased to 6-7 h;rr :rt full load. The
final settings must be determined during burner opcl-atior~

Step E: Check and adjust the setting for low stearn atomisins pressure ;llnrm on rhe
local panel or computer. The al;rm should he chcckcd ivhzn thc burner is in
automatic operation.

2.6.2 Commissioning withuul alomising stearn

Slep A: Close the stop valvc (F92). and opcn the clop vnl\,cc I F S i .rnd F-11)

Step R: Open the stop valve for the prricure transmllter (Fc)ili

Step C: Check that the pneumatic slii~t-off valvc iF17) opcns :ind clnses \\he11
signals are applied to the valve by means of the diziral ncltplit rcst menu in
the local panel.

Step D: Open the non-return \.;live (F45). 2nd check 111;it 111,: ctop vi~lve(FOli I<
open.

Step E: Check that the pneumatic shut-off valvc tF1.C) . opens

.
and closes when
signals are applied to the valvc. by means of the d~citnlarltput test memi in
the local panel.
Start-up
--

T o continue the commissioning procedures, the oil system must be in nonn;~l

operation, and the atomising system must be set to compressed air operation if
atomising steam is not available. Funhermore. tlie ignition oil system and
combustion air system must be operational.
Prior to the actual star-up of the burner. some additional checks should he carried
out with regard to the ignition oil bumer and the burner start-up sequence. When
these checks are completed, the burner should be comnlissioned on diesel oil and
finally on heavy fuel oil.

Attention: Refore and during start-up, the furnace must he checked with
regular intervals for oil spillane. If an oil spillage ir present in the
iurnace, the cause must he rleterrnined and the failure rnuTt he
rectified. The furnace should be purzed until i t iu free of oil.

3.1 Additional commissioning checks

3.1.1 Check the ignition hurner

Step A: Turn the keys placed inside the local control panel and the po\\:cr p;~nelinto
emergency operation.

Step B: Close the inlet vanes of the cornhustion air Can 11100)hv mcans of the
potentiometer inside the local control panel. Start the cnmhustion air fan on
the operating switch inside the power pancl.

Step C: Open the inlet vanes for the cnmhustion air fan to npproximntel\ 15-20%.
by means of the potentiometer.

Step D: Open the throttle valve (F152) tor comhuctlon alr to the i y ~ t l o nhumer

Step E: Close the stop valve (F17) to tlie i-%ition 11ur11c.1

Step F: Press the ignition button on the cmersency p:~ncl:~ndkccp i t p r e s d

S t e p C: Check that the ignition bumer is inserted.

Step H: Check the ignition spark betwcen the electrodes. I~lscthc inspeclion holes
to visually check the ignition spark. The ignition clectrwiss should he
adjusted if necessary.

Step I: Release the ignition butron and check that the ignition htrrncr is dr.lwn h;~cl:
after the time period for purge has expired.

Step .I: Open the stop valvcs (F17. F7?, and F1511
Step K: Press the ignition button again and keep it pressed. Check that the solenoid
valves (F18, F19. and F153) are opened :riid !liar the i ~ n i t i o nhurncr is
inserted at the same time.

Step L: Check the ignition flame. Use the inspection holes to visu;rlly clieck the
ignition flame. Adjusi the ignition electrodes. tlie throttle valve for
combustion air, or the opening pressure on the i p i t i o n oil pump il
necessary.

Step M: Release the ignition button and check that the solenoid valves IFIF;.F19.
and F153) close.

Step N: Check that the solenoid valve (F78) opens dnd that the Ignition humer I<
purged with air.

Step 0:Check that the i~nitionhumer is drawn b:ick nfier [lie c.nd of thc purr?
period.

Step P: Adjust the time period for purge to :I suit:rble level on the timer placrd
inside the local control panel.

Step Q: Check the ignition burner several times to ensure ;I reliable ipiritin

Step R: Close the inlet vanes for the cc~mhustion air fan hv rncans of tile
potentiometer inside the local control panel and stop tlie combustion air kin
on the operating switch inside the power panel.

Step S: Turn the keys placed inside the local control p:inel ;rnd ihc p o w r pariel irilo
automatic operation.

3.1.2 Check the burner start-up sequence

In automatic mode, the slartlstop sequences of the hurner are carried out by the
control system. A condition for the initiation of the start-up sequence is that n o
safety interlock alarms are present. If a safety interlock alarm is present. the cause
must be corrected.
The following check of the start-up sequzncs sllould bc careiully monitored on sitc
to demonstrate the correct function or llit: stan-up sequent? I a l . The st:in
scquence is also indicated on the local panel :rnd computer.
Step A: Deactivate the micro switch on the stop valve (FO?) :ind c l ~ x etile valve.

Step B: Check that the air damper (R07i is in closed posirioii

Step C : Set the burner into manu:ll oper~rtionmode on tllr loc,~lp.ln?l or computer

Step D: Start one of the oil pumps.

Step E: Check that tlie oil flow regulation valve (F93i is in si;ind-hy pnsilii>ri r 5t:irid-
by oil flow).

Step F: Stan the burner on thc local panel or computcl-

S t e p G: Check that the combustion air fan (RO?) ct.irts

Note: T h e combustion a i r fan is set f o r a m i n i n ~ u m operation time of 20

minutes in automatic mode to avoid m o r e than three starts p e r hour.

S t e p 11: Check that the pneumatic shut-off valve iFJ?) opens and that the hurncr is
supplied with the atomising medium.

S t e p I: Check that the air damper is moved into purge posltlon

S t e p J: Check that the comhustion air fan damper is moved intrl ignition positinn
after the furnace purge period.

S t e p K: Check that the oil flow regulation valve is in ignition positioli (irnition r > i l
flow?.

S t e p L: Check that the ignition hurnsr is insencd and irni1c.d.

S t e p M: Check that the pneumatic three-way valve (175) arid tile pncuiil~ticSIILII-
off valve (F67) change position.

S t e p N: Check that diesel oil to the icnition burner is shut-off a ~ i th;it

~ i i t is purycci
with air.

S t e p 0: Because the stop valve (F611 is closed. tlle burner start-up Sails due to
flame failure. Check that thr pntumatic three-wa) valvc (177i) and 11it
pneumatic shut-off valve (F67)change position imnicdi:~tely:jfler the flsnir
failure alarm appears.

S t e p P: Open the stop valve (F63) and activate the rnicro c\\ircIl on tile v:ilve. Resct
a11 alarnu.

3.2 C o m m i s s i o n i n g o n diesel o i l

When the burner is commissioned. thc hoiler pressure and tempcr,tturr liiust not h :
intensified too rapidly as this might cause stresses in the hoilcr. The hurncr should
he kept in minimum firing position during the first conui~issioninpperiod. In n1:lnual
operation mode. the burner load can k col~trolledhy meniis of [hi. soft kc\s on thc
local panel andlor by settinjis on the computer.
When the burner is stopped d u r i n ~nonnal operation. the btlrn?r 1:rnce I S purgecf ivitil
atomising steam, and the remaining uil in the Inncc is i~tornisedinto frlrnace :!nil
hurned. T o ensure a complete comhustio!~of (lie oil d u r i n ~ste:lln p ~ ~ r ~ i inr ei.: .
imporiant to carny out this procedure tbith tllc cornct air1fut.l r;itin. If the cnlnhustion
air flow is too low. the combustion produces hlack smoke. :ind it ~ l i cair ili:iw is tni?
high, the flame blows out before the cc~mhustionis colnpleted.
The correct air flow for the combustion can k detelmilicd by ci>mp:iring tile oil
pressure 3t the atomiser and tlie steam atonusing pressurt. \!:lien these pressures arc
identical, the oil flour atornised into tlie furnace does not c h a n ~ c\rhen ste:l~iipurpi~lp
i~ initiated. This mcans that the present air flow suits tlic combu\tinn. This load is
the steam purge position load and must k hct in the control systeni~
When the burner is commissioned on diesel oil andlor when ihe ilto~nisingmedium
is compressed air, the steam purge position should he pre-adjustetl ro approximately
25%. The final setting should be determined when the burner is commissioned on
heavy fuel oil, and the atomising medium is steam.

3.2.1 Operation of the hurner

Due to the risk of stresses in the boiler. the burner should only he operated 31
relatively short intervals during the initial start-up. When the hurner is stopped
during this firing-up procedure. the remaining safety interlock alanns can he
checked and adjusted.
Step A: Check and adjust the steam purge poqrl~nnon the lm-,?I p.1nc.l or compute1

Step B: Strut the burner in manual operation mode on the 11x:llp:inel or computer

Step C: Check that the burner ignites when the oil v;llvc open and th:ri i t remains
ignited when the i ~ i t i o nburner is shut-off :inti retractrd

Note: A number of starts may be necessary before the h u r n c r ignites. If

ignition of the hurner fails despite of several attempts, adjust the iznition
oil flow, the correction factor for airlfuel ratio. o r the atomising preqcure
on the local panel o r computer.

Step D: Check that the humcr is in minimum firing position niter st:in-up

Step E: Check that the flame d w s not pulsate. !Idjust rlir cvrreciinn factor, airlfuel
ratio, andlor minimum load if necessary

Step F: Check the shape and colour of the flarnc. Me:isure rhc CO1 andlor the 0.
content and adjust the correction factor or airlil~elratio if 1ieci.ss3i-y.

Step G : Check the colour of the flue gas. Measur? tlie soot spot No. I t should not
exceed a soot spot No. of 1-3 (Bachracli). .4djust tile ctlrrection factor or
airlfuel ratio if necessary.

Note: T h e final adjustment of the combustion p:tmmeters, e.z. airlfuel ratio.

minimum load, steam atomising pressure, etc. shoeltl he carried o111
when the burner operates on heavy fuel oil and with stram as atomisinr
medium. It is therefore advisable to adjust the cnrrcctios factor instearl
of the airlfuel ratio when the hurner is conimiscione~lon cliesel oil.

3.2.2 Check the stop sequence

Step A: The stop sequence should also bc c:lrefully nlni~itore(lnri \ill, (1prr;tte 111,.
burner for a few minutes.

Step R: Set the burner load to steal11 puree positiorl .rnJ sicip illc Ii~ir~ii:r.
Step C: Check that the pneumatic three-wav valve ( F 7 i ) and the pneumatic shnt-off
valve (F67) change position.

Step D: Check that the pneumatic shut-off valve (F43) for steam purge opens at the
same time as the oil valves close. The tlanle failure equipment is inactive
when the burner is purged.

Step E: Check that the pneumatic shut-off valve (F42) Tor atornising steam closes
after the end of the steam purge 1 period.

Step F: Check that the pneumat~cshut-off v a l ~ e( F U ) for steam purye cloccs .ifter
the end of the steam purge 2 pf.nod

Step G: Check that the air damper nioves to post purFe (purrs, position if this
sequence step is active.

Step H: Check that the oil flow is in stand-by position arid rh31 (he air damper i s
closed after the end of the steam purge ?/post purge period

Step I: Check that the combustion air fan stops. The fan only slops if it has k e r i
operating more than 20 minu~cs.

Step .k Check that the furnace is free oioil spillage

3.2.3 Check the safety interlock a l a r m for flame failure equipment

Step A: When the burner is in operation. check the llarne failure cquiprncnt hy
removing one of the flame scanners from the holder :~ndcover the sensor.
The burner shuts down. and an al,arm for flame failure is indicated on the
local panel and computer. Reset all alnrrs.

Step B: Check and simulate a glowing furnace hy using ;I flash lirlit pointed
directly at the flame scanner.

Step C : Set the burner into start mode. The loc:ll panel 2nd 'ornp~lrcr clinl~ld
indicate an alarm for flame fa~lure.

Step D: Mount the flame scanner into [lie holder and reset all :ilnrnis

Step E: Perform the same checks with the other flame scanner.

3.2.4 Check the safety interlock a l a r m for oil valves

Step A: When the burner is in operation, check thr nlicro si\.itc!i o n (he t o p v;~lvc
(F64) by closing the valve. The hurner c l i ~ ~ tdcwn.
s rid :in alarm i q
indicated on the lwal panel and conipictcr.

Step B: Open the stop valve and reset the alarm. Start [lie 1111mcr:\:air1

Step C: Set the burner into stop mode, turn the pneumatic shut-oil valve (1;(17) ;!
few degrees from c l o e d position hy means of a toiil ,Ail nlnmi for nil v:rl\i.
 not in position should be indtcated on the local panel and computer Rctet
the alarm after testing and start the humer ruin

Step D: Set the burner into stop mode. turn the pncum:itic three-way valve (F75) a
few degrees from the present position by means of a tool. ,413alaml for oil
valve not in position should be indicated on the local panel and computer
Reset the alarm after testins.

3.2.5 Check the safety interlock a l a r m for low oil pressure

Step A: When the burner is in operation. check the low oil pressr~rea l n m and trip
function as described in the paragraph "Commissioning of the oil system".
The burner shuts down, and an alarm for low oil pressure is indicated on the
local panel and computer. Reset the alarnis after testin?.

3.2.6 Check the safety interlock a l a r m for too low water Icvcl

Step A: When the burner is i n operation. press the " ' f e ~ ts:~fctydcvicc" button on
the water level safety devise and keep i t pressed until the burner shuts
down. An alarm for too low Ivater level is intlicatcd on rlle l c c ; ~ lpanel and
computer.

Step B: When ihe burner is in operation, perfomi a live test nT the jvatzr lcvel safety
devise. The other too low water level allinn :ictuatcd by tlic \v:lter level
controller (level probe and level 1r:lnsmitter) must he dc:iclivated. This can
be done by temporarily lo\r~eringthe i~l:~rm set pcrint i n the lixal panel ur
computer. Decrease the water level until the hurner shuts dcl\vn. and an
alarm for too low water level is indicated on the loc;~lpttnel :~ndco~iiputcr.

Step C: Increase the water level in tht? hoiler and rescl the :il;irm. Adjust the set
point for too low water level actuated by the water le\el controller to a level
which is above the level for the alarm actu:iletl by ills natsr level cafety
devise.

Step D: When the burner is in operation. perform a live test oi ihc water levcl
controller. Decrease the water level until the hurner shuts d<,wn. and ;In
alartn for too low water level is indicated on the loc;ll pt~nel; ~ n dcornputcr~

Step E: Increase the water level in the boiler and reset thr :il;irnm. Adji~stthe set
point for too low water level nctu:ited by the water ltvel controlli:r to the
original level.

3.2.7 Change to atomising steam supply

When the boiler pressure is approxim:itelv 3 bar. the aloniicinf mv:dium sliciuld
changed to steam supply.
Step A: Stop the burner and close the ctop \.alvc iFXi1.

Step R: Check that the steam regul:~tin: v:ilve (F91) ic in :antomatic mode iin thr
local panel or computer.
Step C: Open the valve for atomising ste:rrn on the boiler.

Step D: Open the valves for the steam trap

Step E: Start the burner and carry out tlie rem:~iningcommissioning procctlures

Note: If the burner load is increasetl during start-up, the airifuel ratio should
be checked and adjusted a t the different loacls.

3.2.8 Check the safety interlock a l a r m for low steam a t n m i s i n ~pressure

S t e p A: Set the steam regulatinx valve iF91) Into manual mode ion ihe loc.11 panel or
computer

Step B: Lower the steam atomising pressure gradually until the set point for lo\\
warning is reached. The local panel and computer zliorrld indic:~te a low
uwning.

Step C: Lower the steam atomising pressure somewhat until tlie set poiiit for lo\\'
alarm is reached. The burner shuts down. and itn rrlnrm i q indicated on the
local control panel and computer.

Step D: Set the steam regulating valve iF9 l i into :~utomaticmode on the Icxal pancl
or computer 2nd reset the. a l m i .

3.2.9 Check the s a f e v interlock a l a r m for high steam pressure

Step A: When the burner is in operation, raise the boiler prmsurc until set point
for high warning is reached. The la-al panel and computer shotiid indicate :I
high warning.

Step B: With the burner in operation. check the alal-m and trip i ~ ~ n c t i ofor
n high
steam pressure. Deactivate one of the ulurnis. Raisc lllc sterrm prcrsure until
the burner shuts down, and a n a l : ~ r ~isn irldicnied on the 11x31 panel 2 n d
computer.

Step C: Perforn~the same check u,ith ilie oihcr hiyh steam pressurr ~1:irni

Step D: With both alarms activated, rekct all alanns

3.2.10 Check the active safety interlock alarms in emergency npcration

Step A: When the burner is stopped. turn the kcys placed insidc ills 1 ~ coritrol
~ 1
panel and power panel into cni8:rSency opcr~tion.

Step B: Operate the burner ;IS describc~iin the cl~:~pter

"hlanr~.!lnper,rt~i~n''

Step C: When the burner is in operation, check the s:~letyiriicrlock alarms for tlame
failure and too low water levcl as dtscrik-d previousi!..
Step D: When the safety interlock alarms have hcen tesred. rum thr. keys into
automatic operation and reset ;III alar~iis.

3.3 Commissioning on heavy fuel oil

When the burner has been commissioned on diesel oil and \vll?n steam is availahlc
for heating. the commissioning on Ilea\\ fuel oil can he carried out.

3.3.1 Change of fuel

The change of fuel from diesel oil to heavy fuel oil is achieved b y rnanually
operating the three-way valve (GI 15). When heavy fuel oil is selected. the threr-
way valve (G111) automatically changes position and rerums the oil to the heavy
fuel oil settling tank for a period of time. This arrangement is necessary to avoid ;I
continuous heating of the re-circulated diesel oil when the hurnrr is in stop rnode~
The viscosity of the re-circulated diesel oil decrases ;and with i t also the lul~rication
characteristic. This will cause damape to the. oil pumps.
After the pre-set time period has expired, the three-%;I! v a l ~ e(GI 1 l ' i returns to
normal position. The time period must be set with r e ~ a r dto minirnum oil flow :inti
the quantity of oil in the system.
Step A: Stop the burner

Step B: Check that oil is present in thr heavy file1 oil tank. Optti the quick closing
valve (G95) which connects the heavy fuel oil tank to the nil systeln T o
avoid cavitation of the oil pumps. the viscosity of the oil in the heavy fuel
oil tank should not exceed 780 cSt. If necessary. thc oil tank should hz
heated.

Step C : Check and adjust the switcho\er time for the tllr,:c-\v:~!; \.;live I(; I I I i on thz
local panel or computer.

Step D: Select heavy fuel oil on the manually operated tliree-\\say \ a l w ( G I 15 1

Check that the local panel and computer tnd~cateh r , ~ \ \Srtcl oper.itlon

S t e p E: Check that the three-way valve (G111) sh:ingcs position. 11 sl~vuldalso he

checked that the valve is chansed hack to norlnal position whcn thc timc
period has expired.

Step F: Select one of the pre-heaters lor opcrJtlon Tlle other pr~.-lle~tcl
?Ilould IY
In stand-by mode

S t e p G: Open the stop valves ( G I 5 :ind (326') for the i,peratinnnl prc-he;lter ilnd
check that the stop valves (G25 and G26) :\re cloki.rl fc>rthe <tatid-hy prc-
heater.

Step H: Turn the three-way valve ( G j l I for o ~ tlou

l ihrnityli the p r e - l i e ~ r c r ~

Step 1: Check that the steam regulating valve ( C i 2 O i fc>r tlic prc-I1c;iters iq it,
automatic mode on the local panel or computer.

Step J: Closc the stop valve (G73) for the stand-by p r e - l ~ e a t ~nntl
r o0r.n the ctop
valve ((373) slowly for the operatic~nalpre-hearer.
Step K: Adjust the temperature set point for the steam regulating valve (G20i on the
local panel or computer. The viscosity of the oil at tlie atomiser should be
between 15-20 cSt. The preheating tetnpsratore can tw determined by
means of tlie chart in the chapter "\'iscosity-teniperaturc chan".

Step L: Check that the tracing systems for the oil system and rlic hurner unit are
operational.

Step M: Check that the temperature is ra~sedto the desircd scr point. Adjust i f
necessar)..

Step N: Check the set points for low alarm, low warning. :inti high alarm oil thc
local panel or computer. Adjust if necess:~?.

3.3.2 Operation on heavy file1 oil

When the burner is cormnissioned on heavy Fuel oil. final adjustments of tlic
combustion process should he carried out to achieve high quality perconnance data.
The aim is to operate the bumer with lo\rrest possihle 0: content and highest
possible C 0 2 content without tlie risk of an ltncotnpleted comhuitinn r black smoke).
At the same time the reliability of the burner must be snsured.
A number of initiative actions can k pzrfonncd to iniprove ;~nd nptimisc tlic
combustion process such as adiusting the air/fitcI rcitio. the stcum iltoniisinc
pressure, and tlie angle of the swirler blades. Arljusttnents of tile airifnel ratio and
the steam atonusing pressure are trade by settings in tlie control system.
The airlfuel ratio should he checked :111dadiusted tliro~ighthe ciirnpletc burner rangc
to ensure a correct comhustion. The airifuel r:~tioc:~nbe cliecked by measurernenls
of the soot spot No. and the 0. content andior tlie CO? contcnt i n tlie tluc ?as. Thc
visual appearance of the flame should :\Is0 hc: checked. If the amount of combustion
air to the bumer for a given oil flow is tuo hiw. the combustion will he uncompletetl.
and it produces black smoke. Altliougli the O2 content is low. and the CO, content i b
high, the air flow should he increased. If, on the other hand. the 0, content is liigli
:ind the C 0 2 content is lo\c. it indicate. that the air flow for tile coriihustinn prl7cesr
must he decreased.
It is not only the airlfuel ratio whicil is 3n in1port:~nt (actnr i r , i the cnrnhu~rion
process, hut also the pressure of the ntnrnising steam.
The steam atoniising pressure slior~ld he adjusted ;incl nptimiszd to suit the
comhustion process through tlie complete hurner range. The pressure can lhe checked
hy measurements of the soot spot No. and \,isihlc control of the flame. If the ste;iril
r~tomisingpressure is too low at a gi\en hurner lo:rd. the fl:ime has ;I tendency to
sparkle, and the soot spot No. incrzasec. Funhemiore. tlie tlnme hitcomes unstable :I[
low loads due to poor atomisation of the oil. If the steam atomisin? pressure is too
high. the combustion zone is cooled. aiid the flanie hcconies unstahle a t Io~r.loads.
The shape of the flame can be adjusted by increasing or decreasing tlic angle of t h .
swirler blades. The flame should he adjusted lo a shape in \r.liicli ininirnum contacl
to the furnace walls and bottom is acliieved. The adiustment should he tamed oul
when the bumer is in full load condition. An increased swirl ;ir~plrresults in ii \<,itlc
and short flame, and the opposite swirl anrle results in a slim and long flame. ,An
adjustment of the swirler blc~desalso rcsulls in a C ~ ~ I I I Fof
C tli: ~listancehct\vecn thr
:)tomiser and the root of the flame

Note: T h e swirler blades must always be atljusted to t h e s n m e angle.

 "*'c!;QQ.G
I N . E ',

The following commissioning steps imply that thc. liglitinp-up pn>ceduri. of tlir
hoiler is completed and that a sufficient load dcrn~ind is present to c a r p out
adjustments at 100% load.
Step A: Set the correction factor of the airlfuel ratio in neutral position (corrcition
factor = 100) on the local panel or computer. T l ~ ecorrectiun f,lctor is used
to adjust the airlfuel ratio if the calorific v:~lucof the nil ii chimeed, e.p.
when the bunker type is changed.

Step R: Start the burner in manual operation mode and check that i t isnites \vhen
the oil valves open and remains ignited when tlie ignition burner i5 sllur<>fS
and retracted. Adjust the ignition oil flow. the airlfurl !ratio. or the ste:lm
atomising pressure i f necessar):.

Step C : Start the burner several times to ensure a rcliahllr ignitinri ofilir hurncr.

Step D: Adjust the oil flow to minimum load

Step E: Check that the flame is stable and carry out measurements 01. ths: soot spot
No. and 0: content andlor CO: content. Ac!just the minimum nil floiv. rhc
airlfuel ratio, or the steam atomising pressure if r i r c z s a p

Step F: Cany out the same measurements through the cotnplete hunlcr rangc in
steps of 10%. Adjust the airlfuel ratio andlor the stcam ;ltomising pressure i (
necessary. At full load the shape of the flame shc~ulclhc checked. and rhc
swirler blade angle should k adjusted if neces$;~l-!

Step G: The measurements obtained for the combustioi~ proci.zs tliriy$~ tlic
complete range together with ;1 numher of co~nparahlecornbustion data
should be noted and insened ill tlie chr1pti.r "Mr:isuren~cntsaiitl icttinps".

3.3.3 Adjust thesteam p u e e position

Step A: When the burner is in operation. increase or decrease the load until the oil
pressure at the atomiser and the steam alonusing prpssure are id~tllic;11.

Step R: Set this load as the steam p u r y position Io:id on I 11v;il pule1 ilr
computer.

Step C : Stop the burner and check i t during steam purging. TIlc ht~riiwrI I I L I S ~tic)f
produce black smoke or hlow out the flame bcfnre thc rcon~hustion I \
completed. Adjust the steam purge position ll):~dif iicces:~r!

3.3.4 Check the safety interlock a l a r n ~for high ant1 low oil tenlperatrlrr

Step A: When the burner is in operation, sct the steam rei.ul;~ting\ . ; ~ l \ ciG!Oi into
manual mode on the local pant1 or i.omprrtt.l-.

Step R: Increase the temperature gradually until the set poilit tc)r hiy!i ; ~ l ~ r 1sm
reached. The burner shuts down. and an ;~larnii \ indic;ited <,!I t11e Iw\c:~l
panel and computer.
Step C: Decrease the temperature and reset a11 al;!rnis Stan the burner spin

Step D: Decrease the temperature p d u a l l y until the set point for lo\v alarm I \
reached. The burner shuts dou~n,and an alarm is indicaled on the lnc;ll
panel and computer. The set point for low warnins should also hc checked
during this test.

Step E: Set the steam regulatins valve ((320) into automatic n3r)Jz on t!ic local panel
or computer and reset all slarnlc.

3.3.5 Additional function check

Step A: Checkdadjust additional safet? interlock alarms if provided. -4 numher t,f

alarms might be included in the safety interlock circuit depending on the
specified function andlor tliz c!:issification socictv.

Step R: If the boiler is intended to opcr;tte in a master-slave operating system. tlw

function of this system shoul~ibe checked with regard to opera~iorimod?
and burner load.

Step C: If the boiler is intended to operate in inert sas mode. the function of illis
operation mode should he cl~eckedwith r5pu-d to operation and humcr
load.
Opevting instructions

General

The following operation instructions are \,slid for steam atomising burners of type
KBSD with Y-atomisers and with a standard delivery of individual parts for the
burner unit and supply systems from AALRORG INDUSTRIES.

Attention: If the burner unit a n d supply systems include parts, which a r e not
standard delivery from AALRORG INDITSTRIES, the specific
instructions for these parts should be ignored in the followin::
sections. The actual instructions for the specific parts should h r
thoroughly studied and followed (luring operation of the burner.

The operation instructions in the following ssctions describe the normal burner
operations with regard to preparation for start-up on the selectcd fucl typtt. n o m a l
stadstop, change of fuel, etc. It is implied that the boiler. hurnsr. control system.
and additional equipment for the hoiler plant have, hzcn commissioned and are fully
operational.

1.1.1 Descriptions
In the following sections various opera tin^ procedures :ire dpscrihed such :IS:

Diesel oil mode

Heavy fuel oil mode
Nonnal start/stop
Change from diesel oil operation to heavy file1 oil operation
Change from heavy fuel oil operation to diesel oil opcr:rtii>n
Change of operational pre-heatel
Change of heavy fuel oil honker type
Prolonged stop

1.1.2 Position numbers

The position numbers mentioned in the following scctior~% r e k r lo tile illustrations i n
Figure 1 and Figure 2. The position numhers consist or an idcntific;~tionletter and ;I
position number code. Position numbers nit11 the idcntificarion lctters "(3 and I<"
refer lo Figure 1, and position numbers with the identilication letter '"7 refer to
F i ~ u r e2. The oil system is shown as a planr wit11 two hoilers. hit! is also lalid for II
plant with only one boiler.
Illustration of the oil systen~ -- -
 Illustration o f t b e burner unit and supply systems
F17

+Diesel oil for ignition burner

I &c/
F73

Fuel oil return

Atomising steam

"Atormising air

;,Condensate

Furnace pressure

Figure 2 I~urnoiisy2a.cdr

2 Operating Instructions
.--

2.1 Diesel oil mode

This section describes the actions that must be carricd ont hefor? lilt tmrnrr unit ant1
oil system are operational on diesel oil.
Step A: Check that oil is present in the diesel oil tank. Opcn the qoicl, closinc valw
(G94), which connects the diesel oil tank to the oil systrm.

Step B: Select diesel oil on the manually operated three-\\ny \ n l \ e I (; I 1 i1

Step C : Open the stop valve ((339) for the n~ixinr:t u k

S t e p D: Open the inlet stop valves (GO1 and G08) and the outlet non-return v n l v C \
(GO7 and G14) for the oil pumps (GO5 and G I ? ) .

Step E: Open the stop valves for the pressure gauges (GOI. GI 1. G 16. and ( 3 7 )

Note: T h e stop valves for the pressure gauges on the pump unit should only he
opened for pressure control purposes. During normal operation, the stop
valves should he closed.

S t e p F: Open the stop valves (G97 and GIOI). and close the by-pass val1.e (GI02 1.

S t e p G: By-pass the pre-heaters by means of the manually operated t h r e e - 1 ~ 3vul\e

~
(G5 I), and close the stop valves (G25 and G26) for both pre-heaters ((322).

Step H: Check that the stop valve ((3109) is closed

S t e p I: Close the stop valves (G73) for lhoth pre-heaters

S t e p J: Open the stop valves for the pressure g:lufes ((;A4 and F h S l .tnd the
pressure transmitters (G99 and F83).

S t e p K: Open the stop valves (Gh9 and G77) for the ignition oil pumps ( G 7 ? )

Step L: Open the stop valves (F93 ant1 F(A)

S t e p M: Check the posltlon of the three-way vdlve (F9Q) Thc po\ttllm mutt te \t.t
for oll flow through the burner unlt.

S t e p N: Open the stop valve (F17. F73. and F151)

S t e p 0: Check that the throttle valve (F1.121 IS not in closed pohtrion

Step P: Open the stop valve for the pre.sure transrnltter (FWi

S t e p Q: Open the stop valve (FJI) and rhe non-return \ . t l \ ~ . iF1.5)

Step R: Open the valve for atonlising sti.;lm on the boiler

Step S: Open the valves for the steam trnp

Step T: Set one of the oil pumps into operation mode and the otl~ernil pump into
stand-by mode. If the burner is in automatic operalion mode, the oil pumps
will not he operational hcfors start-up of the burner is initiated.

p~

Note: If atomising steam is not available from the boiler, open tlrc s t o p valve
(F92) for supply from the auxiliary steam systenl or open the s t o p valve
(F87) f o r supply from the compressed a i r system. C o ~ n p r e s s r da i r for
atomising should only he used if steam is not available.
 2.2 Heavy fuel oil mode - -

This section describes the actions, which must be carried out before the burner unit
and oil system are operational on heavy fuel oil. It is implied that steam is available
for heating and atomising.
Step A: Check that oil is present in the heavy fuel oil settling tank. Open the quick
closing valve (G95) that connects the heavy fuel oil settling tiink to the oil
system.

Step B: Select heavy fuel oil on the manually operated three-\v;iy valve ( G I 15)

Step C: Open the stop valve (G49) for the mixing tube.

Step D: Open the inlet stop valves (GO1 and GOX), and the outler non-retunl vcllves
(GO7 and G14) for the oil pumps (CdS and '312).

Step E: Open the stop valve5 for the prrswre gausec (G03. GI I . Ci 10. and G47)

Note: T h e stop valves for the pressure gauges on the pump unit s h o ~ l l donly be
opened for pressure control purposes. During normal operation. the stop
valves should be closed.

Step F: Open the stop valves (G97 2nd G101). and close ill? hy-pass v:~lie(GlO2j.

Step G : Open the stop valves for the pressure $:luges tG43 and F6S) and the
pressure transminers (GO9 and F831.

Step H: Open the stop valves (F93 and F641.

Step I: Check the position of the three-wav valve iF99). Tllr position inust he sct
for oil flow through the h u n ~ e runit.

Step d: Open the stop valves (G25 and G26) for 111~.pre-hcaier ( C i ? ? ) . \vhicli should
be in operation and check that the stop valve (G25 I is clns<:d for the stand-
by prc-heater.

Step K: Turn the manually operated three-way valve ( G S I ) h r coil flow through the
pre-heaters.

Step L: Check that the val\pes in the drain p i p e from the prr-hcatrrs art. c!osrd and
that the valves from tlie pre-healers to the steam txrp arc open.

Step M: Open the stop valves (G53 and G54) and close the 51op v:~IvciGl09)

Step N: Open the stop valve (G73) for the oper:ltionaI pre-liealer and close the stop
valve (G73) for the stand-by prs-hearer.

Step 0:Start one of the or1 pump? and ret the othcr into 5tmd h \ rnode

Lanetqee I I K Pare 518

Step P: Check that the tracing syste~nsfor the oil system ;ind tlle hurricr unit at-?
operational.

Step Q: Open the stop valves (G69 and G77) for the lmltlon o ~ pump?
l (Ci77,

Step R: Open the stop valve (F17, F77. and F154)

Step S: Check that the throttle valve (F152) 1s not in closed p o ~ t ~ o n

Step T: Open the stop valve for the pre5rure transmitter tFOO)

Step U: Open the stop valve (F41) and the non-return valve (F-45)

Step V: Open the valve for atomising steam on the holler or the slop \albc (F92) for
supply from the auxiliary steam system

Step W: Open the valves for the steam trap

2.3 Normal stadstop

The control system automatically s t a m , stops. and regulates the burner 111 normal
operation depending on the steam demand. Whcn the steam pressure is hi.lo\\r the sn
point for operation, the bumer commences the stan-up sequence. If the main steam
valve and by-pass valve are closed. the burner operates in minimum firing position
after stm-up until the differential pressure between the boiler and the main steam
line is within the set point for which tnodillation free mode is allnwcci. If. on the
other hand, the main steam valve and by-pass valve are open prior to hurncr stan-up.
the pressure in the hoiler and the pressure o f the main sre;lm line arc equalised. and
the burner operates in modulrltion free mods.
In modulation free mode. the control system attempts to maintain the stea111 pressure
at the desired set point by regulation of the burner loltd. The burner c:ln he regulated
tluough the complete load range from minimum firing load to full load.
However, should the steam demand decreace below the minimum firins load of the
burner, the steam pressure will increase to the set point for burner stop. The hurnsr
stops and remains stopped until the set point for burner operation is rc:iclicd : ~ ~ a i n .

2.4 Change from diesel oi I operation to heavy fuel oil operation

-

When the fuel supply is changed from dtescl o ~ loper,ilton to he.i\\ file1 crll
operation, the follow~ngwork steps should he carrrsd out

Step A: Check that oil is present in the heavy fils1 oil cettlitig tank Opcri ths quick
closing \,alve (G95) which cotlnects the heavy fuel oil s e t t l i n ~tank to thc
oil system. To avoid cavitation of 1he oil pumps. the \,iscnsity i ~ the f oil in
the heavy fuel oil tank should tint exceed 3x0 cSt. If iiccessnr\.. I l l ? oil tank
should he heated.

S t e p B : Select heavy fuel oil on the manually opsrated ihrce-\yay v;~l\,ci G l 1-51.
When heavy fuel oil is selecteti. the three-way \'al\,e ( G I I I ) a~itomaticallv
changes position and returns the oil to the heavy fuel oil settling tank for :I
period of time. This arrangement is necessary to avoid a continuous heating
of the re-circulated diesel oil when the hurner is in stop mode TI,? viscosit!.
 of the re~irculateddiesel oil decreases and with i t :112(1 the lubncntton
characteristic. This will cause damage to tlie oil pu~nps.After the prs-sei
time period has expired. the three-way vnlve ((i I I I ) r,-turns to nornial
position.

Note: When the fuel type i s changed from diesel oil to hea%yfuel oil, a n a l a r m
for low oil temperature may arise. If the b u r n e r is in operation, it will
s h u t down d u e to this alarm. T o prevent b u r n e r shut-down, the set point
for low oil temperature can be temporarily decreased in thc control
system.

Step C: Select one of the pre-heaters for operation. The other prc-licntcr should
in stand-by mode.

Step D: Open the stop valves (G25 and G26) for the operattonal prf-heater and
check that the stop valve (G25)IS c l o ~ e dfor the qtnnd-h\ pre-lie.~trr

Step E: Turn the mnually operated three-way valve IGS 1 ) for oil flo\\, tlirourh t l i t
pre-heaters.

Step F: Check that the valves in the drain pipes from the pre-heaters are closed and
that the valves from the pre-lleaters to the steam trap are open.

Step G : Check that the stop valves (G.'? and G51) are open and that the \top \kll\e
(G109)is closed.

Step H: Check that the steam regularinx valve (Ci?Ol for the pre-hcniers is in
automatic mode.

Step I: Open the stop valve (G73) for the operat~onalpre-heater .ind clo\: rlie stop
valve (G73) for the stand-by prc-hedter

Step J: Check that the tracing systems for the oil system :tnd th? humer unit :<re
operational.

Step K: Check the heavy fuel oil temperatul-e. Tlie visci>sity ill the nil at tllc
atomiser should k between 15-20 cSt. The pre-1ic;lting tcmptrature can bc
determined by means of the chart in t11c chaptzr "Viscosity-ternpcmturi.
chari".

2.5 Change from heavy fu el oil operation to diesel oil operation

When the fuel supply is changed from heavy fuel nil oprraiinn in diesel 011
operation, the following work steps shoilld hc caried oltt:
Step A: Check that oil is present in the diesel oil tank. Open the quick clnsinr vnlvr
((395). which connects the diesel oil tank to the oil system.

Step B: Select diesel oil on the manually operated three-\v;iy v:~lvc (G115). The
three-way valve (GI 11) automatically changes pocitinn :ind rccurns the oil
 to tlie heavy fuel oil settling tank for a period of time. After tlie pre-set time
period has expired, the three-way valve (GI l I ) returns to iiornial position.
If the burner is in stop mode. the oil pumps will not be oper;~ticinal.and tlie
pump will stop.

Step C: By-pass the pre-heaters by means of the manually operated tllree-u ay v a l w

(G51). and close the stop valve? ((325 and G26) for both pre-lieatsr? ( F 2 2 )

Step D: Close the stop valve (G73) for the operational ple-heater 'ind cliech that the
stop valve ((373) for the stand-hy pre-heater is c l o ~ e d

Step E: Check that the tracing of the piping system is off when thc hurrier i s i n
diesel oil operation.

Caution: Heating of diesel oil in the piping system must he avoirled.

2.6 Change of pre-heater

~-.~~p
~

When the pre-heater is changed, the following work steps zhi>uld tc c n m c d put:
Step A: Open the stop valves (G25 and W6) for the pre-l1c;ltt.r w l ~ i ~ .sliould
h he
operational.

Step B: Open the stop valve ((373) for lie pre-heater \rhlcli \Iiould lw i i p r r ~ t ~ o n a l

Step C: Close the stop valve (G7.1) for tlie pre-l~edte~

~vhlcli~ l l n ~ i lhc
d in qtnnd-hv
mode.

Step D: Close the stop valve (G25) for (lie pre-lleat~,r\\liich slioiiltl in. 111 <l,~nd-h\
mode

2.7 Change of heavy fuel oil bunker type

If the heavy fuel oil bunker type is changed and the calorific \.aluc of tlic oil
changes, the airlfuel ratio should be adiusted to obtain the correct combustion data.
This is done by changing the correction factor of thc air/fucl ratio 011 the local panel
or computer. If the correction factor is set t o a value above 100. tlir. iiir f l o ~ r 'for the
combustion process decreases. If the correction factor is set lo a v:ilui. h i o w 100.
the air flow for the corn bus ti or^ process increases. This means t h n l if tlie calorific
value of the oil increases, the value of the correction Pdctor 5llr)uld ht? clccre;ised to
ohtain the same combustion data and ~ '2i1 . versa.

2.8 Prolonged stop

When tlie boiler plant is stopped for a long period of time. tiif nil system including
the pre-heaters should be flushed u,itli diesel oil hcfnre tlie pl:int 1s \ l i l ~ t down.
Furthermore. the tracing must be switchsd off.
Emeraency operation

1 General

In the rare event of a total break down of the control system. the bunler unit with
helonging systems can be operated in emergency operation. L)us lo the klct that the
majority of the safety interlock trips and alarms are overruled in emerpency mode.
the safety precautions for the plant must he obscnsd \:en! carefull\.
Please note that in emergency operation mode the safety interlocks are reduced to:
Too low water level
Flame failure

Warning: When the burner operates in emergency rnotle, it ic \ e n inlportant

that the boiler plant is carefully and continooosl\ c u p e n i s e d by the
ship engineering personnel. Pa? qpecial attention lo the steam
pressure and water level.

In emergency mode, the burner unit and supply systems ;Ire operatcd from inside the
local control panel and the power panel. Various opcratin~ <\\.itches and
potentiometers are provided inside the panels for operiiting purposr.
Before emergency operation of the hurner is initir~teti.attempts to rest;lrt the control
system must be performed. If restart of the control system is iirlpc~ssihlc.thc work
steps of the following sections must he follou,ed.

1.2 Manual operation of the burner supply systems

Step A: Tun1 the key placed inside the powcr p;uicl into emcrTaicy opcr;lrion

Step l?: Start oneof the oil pumps on the optratin: snitch inside the pi>\\crpanel

Step C : Adjust the oil press~~re on the preshurc regulating v ; ~ l \ c11, a ls:el of 70-15
bar at the burner unit inlet flange. Tlie adjustment is carried out hy means of
the manually operated hand whc.el en the actuator

Step D: If the burner is operating on iieav? ftlel oil. [he oil tt.rnpt.r;lturr must he
adjusted on the steam regulatin~_valve for thc prc-hc:~lcrs.The viscosity of
the oil at the atomiser should k hctivccn 15-70 c S t Tlrc prc-healin:
temperature can he deternlincd by n1e:rns of thc chart in the chaptcr
"Viscosity-temperature charr". The adjustment is carried out hy means of
the manually operated hand whtzl on the actuator.
Note: T h e automatic water level regulation is not operational in emergency
mode. This means that the water level in the boiler must he adjusted in a
similar way as the regulation of the oil pressure and nil temperature. If
supplied by Aalborg Industries the feed water p u ~ n p scan be set into
operation by means of the operating switches inside the power panel.

1.3 Manual operation of the burner unit

Step A: Turn the key placed inside the local control panel into emergency
operation.

Step R: Close the inlet vanes for the combustion air itin hy rnc.:ins of the
potentiometer inside the local control panel. The inlst v:ines should k in
closed position before stan-up to reduce the ct~rrentcons~~mp~iori.

Step C: Stan the combustion air fan on the operating switch inside tile poi\?r panel.

S t c p n : Purge the furnace with combustion air by opening the inlct m n e s to

maximum position on the potentiometer for the comhustion air fan. Tlie
combustion air flow should k kept a t rn:tximur-n tlow for n! Isnst 60
seconds.

Warning: Insufticient purging may cause danger of furnace eaplosionq.

Step E: Close the steam regulating val\.e for atomising steam. The v;~l\.ec;ln
closed by means of the manually operated hand wheel on tiic actua!~>r.

Step F: Push the button for steam atonlising inride the local conlrol panel

Step G : Adjust the steam atomising pressure on t h e steam rqul:ltin$ v.il\r to ;I

level of 2-3 bar. The adjustment is carried out hy mr.:ins of thc rnnnu;illy
operated hand wheel on the actuator.

Step H: Set the air flow to ignition load position. approxinlatel? 15-20'; load. by
reducing the position of the inlet vanes on the po~entionieter for the
combustion air fan. When the percentage value of tlic :~irlloiv is ul~readahle
due to brenk down of the control system, the scale of thc pntc.niinmeter can
be used as a first-hand percentage indicator for the comhustion air flow.
The final setting of the potentiometsr for ignition Inad and all othcr l n ~ d s
must be determined hp visual cliccks of the flame and the flue Fa \vhen the
burner is in operation. The percentase values from th? control system and
the percentage values of the settings on the potentiomeler arc irrcon~parahle.
This is because the values from the control system arc ihe fecd h:ick s i & ~ a l s
from the combustion process (dp-tr:~nsmitlcr), and thc values from the
potentiometer are output signals to the positioner which (operates tiic inlet
vanes for the combustion air fan.
 .. .. ..
.....
.....
.1i'1 il.
I h
.*PC.
,
6 ?
: ? e
.- 1.. I

Step I: Set the oil flow to ignition load position, approximately 15.20% load. hy
means of the potentiometer for the oil flow regulation valve. When the oil
flow is unreadable due to break down of the control system, the pressure
indicated on the pressure gauge just hefore the hunier must be wed a s :in
indicator for the oil flow.

Step J: Press the button for ignition inside tlie local control panel and keep II
pressed.

Step K. When the ignition flame is established. push the button for oil valves inside
the Imal control panel.

Step L: Release the ignition button when the lamp that ind~cates flanlc on 17

illuminated.

Step M: The burner is now in operation, and ad.justnients of the burner load must :
b
carried out as descrihed in the follo\ving section.

1.4 Operating instructions in emergency mode

The request for regulations of the burner load should he deducible from the actu;il
dernand for process steam. The optimal operation for111for the hurner 1s to ininirnisi.
the number of load alterations as this will facilitate the bumcr operation in
emergency mode. Regulations of the bumer load must lx pcrfornied by nwnual
adjustments of the combustion parameters. s . g oil flow. ;iir flow. :~tornisingstcarn
pressure, etc.
When the bumer load is changed, it is important to differentiate between increases
or decreases of the load. This is due to the fact that an incorrect airlfuel ratio towards
a rich oil mixture causes an incomplete combustion that will produce black smoke.
If the hurner load is increased, the air flow should be replated k f o r e the oil f l o w
and opposite the oil flow should he re~ulatedbefore tlie air flow if the burner load is
decreased.
Step A: Adjust the air flow and oil flow to the desired load hy means of the
potentiometers inside the local control panel. The scale of tlie potentiometer
for the combustion air fan and the oil pressure indicated on the pressure
sauge just before the burner can be used for first-hand settings. Tlie final
settings must be determined by visual checks of the flame and tlie flue ~ 3 s .

Step R: Adjust the steam atomising pressure on the stcam regulating valve to suit
the combustion. The adjustment is camed out hy means o l the m~nua11y
operated hand wheel on tlie actuator. If tlie steam atomicing pressure is tvo
low at a given bumer load. the fliime 1131 a tendency lo sparkle
Furthermore. the flame beconies ur~stablc at low loads due to poor
atomisation of the oil. If the steam atornising pressure is too high. the
combustion zone is cooled, and the flarne hecomes onctahlc at low loads.

Step C: Readjust the oil pressure if necessary When the humcr opcratcs a t
increased loads. the oil pressure to the hurner will fall due to the increased
amount of oil for the combustion. To ensure that the humer receives a
sufftcient amount of oil. it might be necessary to adjust the oil pressure on
the pressure regulating valve. If tht load dccrcaseb. a reduction OF the oil
 pressure might also he necessary. The adlustments ,ire cnrr~ctlout h\ m c . ~ i i ~
of the manually operated hand utieel on thc actu,itor

Step D: If the burner is operating on heavy fuel oil. adjustments of the oil
temperature might he necessary at large humer load variations. The oil
temperature should he adjusted on the steam regulating valve for the prr-
heaters by means of the manually operated hand wheel on the actllator.

Step E: Adjust the water level in the boiler if necessay. The water Iei'tl must he
carefully and continuously supervised during operation of the boiler plant.
When one of the feed water pumps is in operation, tlie water level can
regulated on the feed water control valve by inzans of the manually
operated hand wheel on the actuator.

1.5 Stop the burner in emergency mode

Step A: Adjust the air flow and oil flow to steam pulpe position lnnd hv iiicans of
the potentiometers inside the l ~ acontrol
l panel.

Step R: Adjust the steam atomising pressure on the siealii regulating v:tlve to tlie
same level as the oil pressure just before the burner.

Step C : Press the button for steam purge inside the local control panel ilnd keep it
pressed. The oil valves close immediately, and the \;ll\.e for steam purge
opens.

Step D: When s t a m purging is conipleted. the release the button. The pl~rgingis
completed when the remaining oil in the hurner lance is atomisec! into the
furnace which is indicated by the extinction of the fla~nc.

Step E: Push the button for atomising steam inside the local control panel

StepF:Close the inlet vanes Tor tlie combustioil air f a n by Inenns of the
potentiometer.

Step G: Stop the combustion air fan. The fan should hc kept in opzrntion if i t is
contemplated to operate the burner with frzqurrit intervals. This is hecause
it should he avoided to start the fan more than ilirec rime5 per hour

Step H: Adjust the oil pressure and temperature if nececsar:

Step I: When the bumer is in stand-by mode. and oil is circulated in the oil sycte~n.
the oil flow must be adjuskd to nunimum oil flow position hy Incans of the
potentiometer for the oil flow regulation Y ~ V I ' .

Note: If the burner operates on diesel oil, the oil system should $topped if
h u r n e r operations a r e of infrequent occurrenccq. continuous re-
circulation of the diesel oil might damage the oil pump? d o e tn heating o r
the oil.
Step J: If the fuel supply is changed from diesel oil to heavy iuel oil, rhe position of
the pneumatic three-way valve. which leads the return oil to the nuxing tube
or the heavy fuel oil settling tank. should he changed for a period of time.
The position of the three-way valve can be clianped hy means o i a manual
switch on the solenoid valve. The time period must he determined with
regard to minimum oil flow and the quantity of oil in l l ~ esystem.
 .... ..
.....
.....
&
AACRQRG
Ih, . ' I '
'

Maintenance

I Recommended maintenance intervals

To ensure a safe and reliable function of the bunirr. inspection must take place with
frequent intervals as described helow. The inspection should he carried out hy
competent and properly trained personnel familiar \villi the operatins ;!nd
maintenance procedures relevant for this type of plant.

1.1 Safety regulations for maintenance work

Always ensure that the electrical power is off and thal n o h ~ d ycat1 stan the boilcr
unit before commencing maintenance work.
All pipes, drums, etc. must be depressurised hefore :in! mnintcnnncc work is carried
out on these.

1.2 Continuous maintenance

Control panels and other electrical equipment should he kept clcan and d n .
Check that no forei-rm matter accumulates in or around them.
Replace lamps. contactors, and other co~nponcntsu.heri thsy ccasc to function or
show signs of deterioration. A part. replaced before it ncti~nllyfails. could save 3
costly delay.

1.3 Periodical maintenance

The following check list should he followed every two ivccks. L3ependent on the
operation conditions, however, some items may nced more frequent attzntinn.
For maintenance work procedures. we refer to thc scp;lr:!ts instructions conccming
each item

1.3.1 Periodical rnaintcnance - h u r n e r ant1 fuel oil snpply s!.stcm

Check that ;ill connections are ti~htened and that tile wiring is it! a pilnd
condition.
Check that the fan inlet is kept clean of r~nintendcdohstrttciinns
Check pipe \vork for leaks, pzrticularly on f l a n ~ e \ .joi~it?.m d ci>nricctions.
Repair any leaks which may cause safct! risks
Check the general condition of pipe work. Ia_~gi~ig.
;itid i r i ~ ~ i n g
Check that the glands of m:inu:~l v:~lics arc tight rnil~yli t ~ , prcv~tnt racy
operation of the valve.
Oil filters should he inspected and clcaned
 Manually operated valves should he periodically o p e r ~ t f d if
. possible. lo ensure
free movement.
Check the pneumatic shut-off vahes, placed lost h e f o ~ sthe humcr lance, for
leaks
Check and clean the flame scanner.

1.3.2 B u r n e r a i r register and f l a m e stabiliser

If the burner plant is to perform according to the specilication. i[ is impcxlant that
the burner register and the flame stabiliser are kept cle:in and in ~ o o dcondition.
Inspection should be carried out at regular intervals.
Large quantities of dust-laden air will pass through the regisrcx. and inevitably this
tends to build up deposits. These deposits should be brushed off.
The flame stabiliser and all other surfaces exposed to r:~dlation he:lt should lhc
checked for being free of carbon or heat erosion.

1.3.3 Atomiser
Before any examination can he made, the atomiser must he cleaned. This i h
normally done by soaking in a parafin or carhon remover to n';lsii off any oil films.
This also has the purpose of loosening carbon deposits. It m a y also he necessary to
use a soft metal scraper to lift away any heavy carhon deposits. .A hnrdcned scraper
should not be used as it could possibly damage the atonliser.
The cleaned atomiser should then k examined for damare. and the holi-s cllcckcd
Tor wcar.
The O-ring must be replaced e v e q time the tonus user is disasscmhlcd.
Before fitting the cap n u t the thread should hr covered \+,ill1 311 untiardenine hirh
temperature compound.

1.3.4 Ignition burner

The ignition burner is one of the rnost exposed items and 11ccds I: frequent
maintenance.
The electrodes should be cleaned and the insulation n~aterialchecked for :in!
damage. Be careful not to damage the ceramic insulation pieccc.
The nozzle should be checked and cleaned.
If the spray pattern hits the other pans of the ignitcr dcspitc i t 1s clcancd. thc
nozzle should be changed.
- - --

Note: Be careful not to change position of nozzle ant1 clcctrodcs as this may
cause problems with, e.g. ipnition, instabilie. o r huild-up of carhon
deposit.
Faults and rectifying faults

1 Trouble shooting

T h e trouble shooting list is based on a proper set-up o f the burner plant during
commissioning andlor service and that n o funher ;tdjustn~entso f the air/fuel ratio.
etc. have taken place.
Please note that the trouhle shooting list is general for steam atomisins burners and
has not heen made for any panicular plant, but is hased on sr\,er:~l years of
experience. Therefore, the cause for your specific problem niay not he tncntioncd
and vice versa. You are always wi.lcome, lio\ve\ser. t i i contact our Scrvice
department for advice o r service assistance.
Check availability of power and fuel supplies k f o r e commencing detailed chccks.
Ensure that burner plant wiring diagrarns relevant to [lie p:irticl~lar installation :ire
available.
W h e n the cause of a lockout should be located. i t can be of assistance to know the
s t a d s t o p cycle or at which point of operation the lockout occurred. e.f. niodttl~in:.
T h e trouble shooting list can he seen in Table I

1 Fault finding chart

I No l,sn~t~un!~,!:;it~on
.
I.-:iult
.. .
1 Possible eausec
11 flnmi I l~nirionburner oil pump f i ~ u l t y
o i l pressure too low
Oil norzle hlockediwom out
1-mition elecuodes diqiout of adjucrmcnt
Ipitiotl transformer faulty
Solenoid valve faulty
I Burner control faulty
I:lme fxlurc I f mmn f l ~ m c/ Iplt~onflame not established
Oil valves not open
Atomising airisleam pressure too low
P u r ~ esteam valve open
Oil temperature too highilou.
I OII too low
Llnqrahle iii:!:n ll;~me 1 Oil amount too low
011temperature too lowihl~h
B l o c k ~ nof~ some orthc \Ie3mJotl holes In lht-
alomlcer
Water in the atornisinp steam
Too much fuel oil or loo liltlc air
Too much air or too ltttle oil
Poor alnmisation. low oil tcmpcraturc or aton~ihini:
1 ir/steam incorrect pressuri
Remcdv
Repair or rrplnrc ixl pump/ motor
Rcstorc 011prc:suir I
Clea11ircplat.c nhrtlc
Cledre~ii~iubl
Rcplacr i g n i l i ~ i nir.insfom,rr
Exchange socnoid valve un!t
Replacc/rcpa!r control unit
See ahove
Chcck :or prcsiur~lrsplocentl volvc
Chcck xiris1c:~rnprcssurc.
Check purre v n l i c
Adjust 1enIpcr:~lurc
-
Adjust nil lloaiclem i n i t i ~ ~ l ~ x r
Rice the :,#I nmount
Rendius: i,ll ic~?,pcr:itl~rc
Check the L I : L I C ~imp. I! provided
~ l or correction factor
Rcadco~ta i r l - ~ i.it~o
Readjost airI~>llrat? or corrcctinn Fdctor
Rcsct !11c1n ~ tlt m p lo ci~rrcctvnluc!cnsurc II

Table 1
 -
Measurements and settinqs

1 General description
Each plant has its individual service conditions depending on the actual desi-gn and
layout of the burner and the boiler pl:~nr. Exact values for the burner cannot he
given, but have to be determined at the commissioning or by later adjustments.
I'he following pages show the standard rneasurcments and settines for a plant which
includes two KBSD burners. This enahles the user to obtain soins of the most
important ~neasurementsand settings related to the hurner fol- later reference.
It is recommended that the user completes the schcme sliortly sfter the
commissioning when nomial service conditions have heen cstahlislicd.

Burner measurements and settings

Table I , Table 2. Table 3. and Table 4 s i l o \ ~llle standard nieasuriiig/settin: schemes
fur both burners. Figure I and Figure 7 show ;I d i a p a m in which it is possible to
mark the airlfuel ratio curve for humer No. I and burner N n 7 rcs1?w~i\.ely.Tli,:
values should he taken from No. I and Xo. 110 in the i:ibles.
Durins commissioning. an ndjustmcn~ of some rni.asuri.s rzlatcd to tile hurner
lancelsu~irlerdistance and the position o i the s\virli.r blades m:ly bc necess:lry. These
measures are shown in Figure 3 2nd Figure 1.
In Table 5. Table 6, Table 7. and Tahle 8.the ongin:ll nszisures for h o t humers are
given, and columns are reserved for writing rhc nicasilrcs cstahlishzd duririg
commissioning or by later adjustments.
 n,leasuringlsetting scheme for a steam atomising burner (KBSD) No. 1

l'lanf name: Oil Ij~viscmily/clensit~:

Il

Minimum Inad:

Roiler tjpefio.: Ignition load:

l l u m a t~p.Wes.: hhuinlum load:

Atornicer 11). No.: dplran~mitlasl'liinl: nncc firair no*:

LDadlnll flow

and ah;r prz-heater

.craturc nt
burner ,e
:lt

A1onil::iue s t c n m settinp

Table 1
 Oil t?pP/viscosity/den+y:

M i m u m load:

MaGrnurn load:

Atornicer 11). No.:

Talde 3

1.311;ilape LIK P a p 410

I Measuringlsetting scheme for a steam atomising burner (KBSD) No. 2 continued I
!
70 60% 70'% 80% 90% 100%

! I
In1 I

Oil prc<.:urc in oil system hay I

1
i
( I 011/
prv-we at hurner tnlet 1 barg I I I 1 1
Oil ten:perature in tank
Oil tcmreramre hefore and after

Oil te!i:perarure at hurner inlet

s t e m setting
Atnm~s~ns

S r a t ~ :,-~ssurc
i after cornhustion

p$;;;:::::"pt*e
Statlc ,;tssure in ujind hor; rnrn WC I I
1 17 1 Statlc: prlscure in furnace / mm WC I 1 1 1 1 1
rnrn WC

,-I
I I

"C
'j;
I 1
CO: 11, ilpt3l.c '7r I
Curve fnr ailfuel mfio (b~unerNo. 1)
-
m
,%I
-

Curve for ailfuel ratio (burner No. 2)

c4 k-
1.1

, ,
8 ,

8 '
..m--

.* ,, i ," rn U
i
dD " <., -r ", I, 8"
I ' i
:<.
a,,,m..-:,~,.>
8%)

F i w2 nir_furl.cdr
 Commissioningmeasures (IanceJswirler distances)

Figure 3 khulmeasl .cdr

Table 5

I Commissioning measures (lancelswirler distances) burner No. 2 I

Table 6
Commissioning measures (settings for swirler blades)
-- -- -
Commissioning measures (swirler blade settings) burner No. 2

Blade No 02 19" ACW I

Blade No 0' 19" 9CW I/ PI-

1-

Blade No.:Ol 19" ACW

-
Blade No.:O? 19" ACW 1 I
Blade No.:Oh 19' ACW
Blade No.07 19" ACW i
Blade No..O? 19' ACW
Blade No.:O" 19" ACW I !
Blade No.:lf! 19" ACW 1 I
Blade N o : l ! 19' ACIV
Blade No 1 2 19" ACW I I-
Blade N o 1 7 19" ACW
I
Blade No.:l.l 19' ACW
Rladc No.:li 19' ACW

Table 8

Attention: 7he direction should be notrd:rs either clockwise I O V ) or anliclockwice

(A03.
 Table of contents

Oil flow regulating valve

General . ............ . . .. . .. . . . . . . . ... . . . . . ... . . .. ... . ... . . . I

Commissionln
Oil flow regulating valve

General

The burner load is controlled by the control systcm, which receives a continuous
signal from a steam pressure transmitter. This signal is compared with diifrrent set
points, feed back signals, and parameters in the control system. The output from the
control system is used to control the oil tlo\v rejiulation a \<Iiich is
pneumatically operated by an IIP converter.
To obtain a very accurate replation of the oil flow. which is very imponant to have
a large turndown ratio, the valve is fitted with an adjustable Crndjustcr. This Cv-
adjuster makes it possible to adjust the pressure loss ~mefficient i,T ihe ~ : r l \ , i .
whereby the oil flow regulation can he optimised to each sinyle i~istnll;~tion.
The position numbers referred to iii thc fidlo\ving sections appear fro111 ille
illustrations shown in Figure I. Figure 2. Fi~clre3. Fi-uri. 1.Figur? 5 . :irid Firliri. 61.

2.1 Mid band setting

During calculation of the valve sizing. ;I trirn set hniild be chosen so that thc mean
estimated C, will he at the mid band setting. This is called the risA-free settiny since
it provides the means to either increase or deci-?:IS? thc aisnilni~lr:C.. i T thr ilctual
conditions change.
Figure 1 shows an example of the possihle settinys for a trinl set. : Imean (1, of 0.07
for a him No. 5 allows subsequent adjustment to C , nln. if tht flnu coefficient is
increased, or to C,. 0.04 in the opposite case.

2.2 Adjustment setting a t maximum C,

The adjustment knob should be set touiirds maximuni C, ni;tking i t po\s~hleto s i n k

downwards, if desired. This should h? don:? if valve sizin: c3Iculati1~~iis iind act~ial
service conditions indicate that the fiill rated (', of tli? v;llvc \ \ i l l i ~ ~ ~ t i alx
l l yrcclt~iri.d
but nay subsequently lessen

2.3 Adjustment setting at minimum C,

The adjustment knob should hc set to\v:lrds mininiuin C , 1n:iAinr i t pocsihle to sc;~le
upwards, if desired. This should he done if \:~lve sizing c;~lcul;~tinn~ and actu;il
service conditions indicate that initial conditions ieqt~irc.:I i-c?l:itivelyI:]\\ C', hrit will
then increase to a higher maximun~
Example of a valve adjusted at mid hand setting --

Cv plate Recommended Example Adjustment

adjustment of annlica!ion n~fion

M#dband s m n g
S e w w mndrlron'.
m y vary C'v :o tie
adjustilO upwarn?
07 I82wnw2rd9

Signal

Figure 1

Illustration of the name plate

,
' Y
i 'I
S I m I M N O ~ ~ ' V
AIR X) OPEN 1 S U P P L Y ~ S ~ 1
I riK?rMIN.CYIx:c<I
xu*x I
1I .r ~ q
BODY mxx
0 s PLUG p~

,
XXXXX I ,.

Z SEAT %<
~

-- - -
-- -i
SIGNAL 3 - 1 5 PSI I

TAG No I, x
X XK p~p

-- ~
- -'
~.
SERIAL N o l xw'-J ~~

I. . .- - - -_ ~. - --- -,'
p~
- ~ ~

Figure 2 n:imcvari.cdr
Illustration of the oil flow regulation valve (Tronl view) - -

U U -- ..
Figure 3 r i-04.cdr
Illustration of the oil flow regulation valve (side view)

\,, --
138a

Figure 1 I -07.cdr
 Tllustratiou o f the coupling details of levcr No. 1 and 2

Illustration of the air connections

Figure 6

L u l ~ u a g cLIK Page 7/17

 -
109
-
l lo
-
I I? ab.

Table I

Installation

T h e oil flow regulating valve must he installed as fl:lngc connected. T'lace the
y s k e t s according to the process between the val\.e hod? and tlis p ~ p eilan;es.
3.1.1 Alignment
Hold the \%I\.? body during installation o f tile stutls. Spcci:tl lx~sccs:uc pri.v ided t i )
centre the \.alve in the line and prevent rotation berore fin31 tiglltcning of lli? htudi.
T h e valve ~liusthe installed with the flow tending to open. Thc flo\v :irrn\v si~lniped
on the v a l x hody must he pointine in iIle d i r c t i o n o l llic flo,.~.In\tall l?~iltin?;111d
t i ~ h t e nevenlv in a cross fashion.

3.1.2 Air piping

Install pipe sopply and il~strurntntsignal l i n s to tile :1ppropn3tt. co~incctt~?riiin ilic
positioner Block (144). see Figure 6. Ilsc 11-1" 0.11.tubing or rqui\alent 1 ~ 1 1:iir litles

I m p o r t a n t : A i r s ~ ~ p ptloyt h e oil flow regulatinp valve must b c i n s t r u m e n t air-

4 Commissioning

In the following the work procedures ior commissiotiin; of ihe oil I l i scyulation
~

mlve are described:

Step A: Check that the output signal range from the M' con\.ertcr con-csponds to tlie
input signal range on the oil flow re~ulationvalve. Tlir pressures appe:tr
from the identification plates.

Step B: Loosen the cover screws ( 109). Back off the hand \vhecl lock: ( 12 1 ) and tur~i
the hand wheel anti-clockwise until the cover floats frw. Remove rile cover
( 1 10).

Step C: Check and adjust the valve characteristic (C,,). To adjust ille (?, . loosen :ind
move the adjustment knob (24) dong the scale ( 2 5 ) tixed in tlle top c f lever
No. 1 (21). The adjustment scalz (25) shows the :t\,ailahle C, \,alucs for the
specified valve, and Tahle 2 shows the Cv setting for i-:ich humer size
When the knob (24) is at the recluired position. tigilten the kn~>h.

Tahle 2

Step D: Apply air to thc I/? convener. Adjust [lie . ~ i rpressitrc ;h tlic t ~ e l ~ ~ t ~ y i t ~ :
filterireduction unit. The pres\are setting ;Ippcars irom tlic id,cntit?cntion
plate on the convener.

Step E: Apply supply air to the oil flotv regulation \:ilvc. :\dil~st the :?is pri.ssurc : ~ t
the belonging filterireduction unit. Tlic pre?<llre scttln: ;tppe;tr\ frorn thi,
identification plate on rlie vslve.
 Step F: Set the oil flow regulation valve into mnnu;ll mode on the cr>ritrol systrm.

Step G: Set the regulation output for the oil flow to OG 14 n ~ 4 <>n
1 tllc cont~ol
system

Step H: Adjust the pressure indicated on the instrument g ; ~ t ~ g1143)

e to the lou
input signal range by means of tlie zero adjustment screw cin the l!P
convener. The instrument gauze (113) is the left pres.;urc gauge on the oil
flow regulation valve. The input signal rnnqe appenrs from rlie
identification plate.

Step I: Set the regulation output for the oil flow to 1 0 0 " ~I20
~ m4) on the control
system.

Step J: Adjust the pressure indicated on the output p u r e 1'112) lo the high input
signal range by means of the span adjustment screw on the I!P converter.
The output gauge (142) is the right pressure gauge on the oil Oo\v
regulation valve. The input siqnal rnnye appears fro111 the identification
plate.

Step K: Set the oil flow regulation valve into automatic rnrlde on the control syytem.

Step L: Start one of the oil pumps. Set t h t stand-by oil flow in (1':; ,111 conunl
system.

Step M: Adjust the turn take-up screw 1116) of the oil flow regul;rtic~nvalve until
the piston (131) just begins to move. The control sysrcm 11it1stindicate 0";
oil flow. Tighten with the lock nu1 r 1171.

Step N: Set the stand-by oil flow back to the original set p ~ ~ i i i t

Note: I f the Cv setting is changed after the above-mentioned trork procedures

have been carried out, a nen zero atljuslment might he required lo
recalibrate the closing point.

5 Manual operation

5.1 Hand wheel

-

Tlie oil flow regulation valve can be m;~nuallyoperz~tedin c a s t 01 ;I hilur? on thr.

control system by means of the hand wheel. The Iixnd w l i ~ s li5 I(x-:]led on top or tlie
cover and fitted with a locking lever. Direct ~ c c e s sto i t doe? n i > t icqt~ireri.rnov:~l n T
parts.
It basically consists of a threaded rod fitred ~vitha hand wheel i1211) ;irid ;I lever ;Irlri
stop (122). The threaded rod freely rests on the 3ctu;ttor hr:icket ( IOS) and is ~ u i d c d
through the cover ( 1 10) by means of the hand wheel hushing I I I q l . The rtop I i 7.21
consists of a block screwed on the ttireaticd rod cuidcd in transl:rtion h y the ;rctunror
bracket ( 108).
Clockwise rotation of the hand wheel (120) moves tlie stop ( 1 2 1 ) up ,1lon9 tlic
threaded rod and drives up the le\'er No. 2 (22) compressing the spri~lg( 1341.
This action provides for the opening of the valve i f i t is :In open-on-air : ~ c t ~ i ~;in(!
tor
also the closing of the valve if it is a close-on-air actuator.
The return to automatic operation (neutral position) is :~ccomplislledby tl~rninythe
hand wheel anticlockwise until the stop (121) conracts the bracket I IOK!.

Note: During this operation the compression releases when the stop (122) no
longer contacts the lever (22). Then. continue this operation until a slizht
tension reappears and tighten the hand wheel lock (121).

Calibration

The oil flow control valve is factop c:rlibrared. If. for some reason. rhi. colibratior~
has k e n disturbrd (e.g. due to repair. change of pans. rtc. I. it is nrcessal? to carry
out some adjustments. In tlie followinc the work procedures for ad~ustrncnlsarc
described:
6.1.1 Adjustment of the piston r o d cle\is (IOlh)

Note: This adjustment should not be changed unless the piston (131) has been
disassembled. Then, it should he made during assenibl? I)efore couplinn
the levers to the clevises.

Step A: With the piston against the diaphragm cover ( 137 I. turn thc clevis i 10-lb) in
such a manner that tlie distance. between the actuator bracket top ( 108) and
the indicator bottom (126) is ktureen 0.5 mrn and I rnrn. Thc usc of :I shim
u.ill facilitate the operation.

Step B: Couple lever No. 2 to tlie clevic. Admit sufficient air prcssuri. to disengage
the nut (125) and tighten it ayainst tlie indic:~tor.'Take care that tli,, irrdic;!tcir
(126) is correctly positioned. Releast tlir ;lir pressurr

6.1.2 Plug stem adjustment

Witli levers No. 1 :ind 2 coupled. proceed :IS follo\v.;:
Step A: Admit sufficient air pressure t~ the actuaror to extend rh<r pirliv! rcxl ;,nil
place a shim under the indicator (176). llsc :I 1.5 rnm shin1 for ;~ir-to-opc~r
actuators or a 25 rnm shim i r i r t o c o c r Reir:cie itic :iir
pressure after placing the shim
Note: At this closing point without seating force, the slides of l e ~ e r sRo. 1 and 2
must be strictly parallel. This characteristic p e r n ~ i t s to change tlie
adjustment knob position to ohtain the truly requireti C \ .

Step B: Loosen the adjustment knob (24) and slide over the isvcr No. 1 to thc
position of maximum C, on (he Cv adjustment plate (2).
Tightcn thc knoh
(74).

Step C: Loosen the lock nut (103) by using a screwdriver :rpplied to the plug stem
end, and turn it until the plug slightly touclles the seat ring. If the valve was
removed from the pipe. a bubble leakage test performed on a calibration
bench will permit a very accurate adjustment. By using thr scrs\r,driver.
keep the plug stem in position and tighten the lock n u t (103) ni.ainst the
clevis ( l o l a ) .

Step D: Admit air pressure again to Jisen:ace the shim. 2nd rclsace the air pressurr
again.

--

Note: O n air-to-open actuators, the shim thickness can be changed plus o r

minus 0.1 - 0.2 mm so that the levers No. 1 and 2 a r e i n parallel position.
This is done to obtain the required tightness at closinz.

6.1.3 Positioner start-up pressure adjustmen1

Step A: Pipe air supply and instrument sisna1 li~lrsto the posilioncr-. Set tlie supply
pressure in relation to the ualvc Cv. Sec Tahlc 3.

Step B: Set the signal to minimum value if it is an air-to-open ;~ctuator.or ser tlie
maximum value if it is an :lir-co~lose;rctuator. Turn take-up screw ( I 161
until the piston rod just becins to m o w Tigli~cnthe lock nut I I I71

Spring r a n g e s a n d s u p p l y p r e s s u r e s I

Table 3
Maintenance

Warning: Maintenance andlor disassembly should bc performccl with the

valve, actuator, and positioner rrcc from all pressures.

7.1 Actuator diaphragm re placement

Step A: Unscrew the two pressure con~iectionnuts ( l i 8 a ) and pull the tubing (1 40)
out. Remove the four cap scrc.\i,c (179). the dinphrag~l!covcr i 137). and thc
diaphragm (136).

Step B: Form a new diaphra-gn and inseit i t over ihe piston i I I I. I'l:tce th~:
diaphragm roll into the bracket groove. Take tile Iicces?:q strps riot to t\vist
or bend the diaphragm during it,; replacement.

Step C : Replace the diaphra-gm c o u r ~ (1371 with the four scre\vs t l?O) arid
reconnect the pressure connzction nuts i118:1l. Check, the tirhtness of tlic
connections.

7.2 Adding packing

Step A: To add a ring of deprssurise the v:~lvc..and hack nff thr !>ackinr
flange nuts (8b) all the way.

Step B: Lift the packing flange and follower and insei-r one ring of packiiig. Tightcn
the nuts (8b) finger tight plus one full tun].

7.3 Disassembly

In some cases, it may he necessar). to djsassemhle the I(> rcpl:~ccthe pllri!

\ ; I ~ \ . L .C . C .
and seat ring assembly or to change paci:ing in u s e of 3 C', in:!\. < 0 . 1 3 .

Note: In the case of a C,. max. > 0.6 a quick way to replace the packin:
prevents full disassembly of the ya11.c (see t l ~ esection "Packing quick
change method").

Step A: Loosen the cover screw ( 10" j. [lack off ihc I1:rnd \vhrel Iwk i I2 1 ) and rum
the hand wheel anti-clockwisz until the c w s r fln:~tsSrer R t m n v c the cover
( I 10).

Step B: Adjust the signal for closiny o i the valve. Slighlly change the rignil1 so t11:11
the plug barely moves off (lie seat rinr. T u n ~ihr adjustmciit i.noh i Z 4 ) ti-.
minimum Cv position.
Step C: Loosen lock nut (103) and turn ;inti-clockwise tliroufli 1 314 turtir by itsin:
a screwdriver applied at the pluj: stern end. Shut off the signal aliil prcssilre
supplies. Slightly retighten the I I K ~ nut (103) against tlie clevis.

Step D: Loosen the lock nut (117) and fully unscrew tlic take-t~pscrew [ I I(I'I
Remove the spring clamp ( I 1') from lever No. ;lnd force IIIC? balance
spring ( I 14) from the positioner.

Step E: Remove the retainer clips ( 1 1 3 ) from tlie two pivcil pins t IS-11 and pull
them out from lever No. 1 and clevis (1013).

Note: This operation will he facilitated h? relieving the load on the pluq clevis
exerted by the conical compression spring (106). While drivinn, out the
nins. usins a screwdriver, push on the p l u ~
stem end.

Step F: Remove the two retainer c l i p 1 I l2c) from p i ~ o tpin N u -\ 124) :itld
disengage it to tlie uncouple pis~nncle\,is ( 104h) from levcr N o 2 122,.

Step G: Remove the two retainer clips ( I l2ai rrom pivot pin No. I I 105) ant1
disengage it to the uncouple lever No. I from lhi. :Ictu:ltor hr:~cl:e~(IOS).
Disengage the adjustment pin s~iioothelid ( 2 3 ) from t i i t l r w r l i t i i , No. 1 and
remove the adjustment knob (241 and :id,jilstrn~ntpi11 i 2 i i from lewr No. I

Step H: Drive out the pivot pin No. 5 ! I .i)and removc l t i r r KO.2 i 221

Step I: Hold the plug stem in place by using 3 sirewdn\,t.r put lo ils enti and unlixl,
the nut (101). Unscrew the clevis (103n) and I w k nut iI07). licrnoie the
spring button (102). sprinf (106). and _rrotiunel pl:~ti.I 1(11!.

Step J: Remove the two packing flange nuts (81)). packin: flange i 10). and packing
follower (9). Remove the two bracke~ecurin; nuts t S a i ;IS \icll as the
bracket (108).

Step K: By using a packing hook, remi)ve the largest numhrr o l pnckii:: rtngs ( 6 )
from the packing box. Remove (he snfetv pin ( 1 I ) and pull t l ~ epiug stem tc
remove the packing spacer (5). plur nnJ stern. ~o$elIierwill1 he ~rcstnf tlle
packing rings.

Step L: By using a 9/16" or 13 mm pi~,ce01 lic.; st<xk and :i wr,~tic.Ii. ~ i r i l i r k;ind

pull out the seat ring retainer (Il
.

Step M: pull out the seat ring (3) and then the ydrket 121 !,I 1tii11g :i hook inlade
from steel wire (diameter approxin-:atfly 3 mml. (';iref~~II!.feIIli, tile honk
end.
Note: The seat ring with a Cv mar. < 0.10 consists of hvo parts: The seat ring
proper (3e) and a spacer (30. The small size of the orifice or these p a r t s
does not allow for their removal by means of a hook. Tliercfore. it is
necessary for this operation to remove the body from the pipe and t u r n it
over and, if needed, to hit the bottom hy means of a wooden mallet.
Should the seat ring bc jammed in its housing, it is possible to move it
using a screwdriver inserted through the outlet orifice. Valves with C v
max. 3.8 d o not feature any seat ring gasket (2).

7.4 Assembly

Before assembly, clean thoroughly the inside of the valve ho2y :ind pafi?. Gasket
seating surfaces and surfaces in contact with otlirrs must be thnroudily cic:!ncd. On
assembly, a new seat ring gasket ( 2 ) and a new packins ( 0 ) must tv u s x .
Step A: Place a new seat ring gasket (21 in ihe valve body r 1 3 1 and install thc seat
ring (3) taking care to correctly centre the p s k e t <>ti1 1 1 ~se:it rill: ihoiilder.
Orient it in such a manner that rine nf irs ports lines up \vitli the Ihdy o ~ t l ~ t
orifice.

Note: In the event of a maximum C y smaller than 0.10. thc seat rinz (3e) must
first be positioned a n the new gasket (2) taking the same precaotions a s
shown above. Secondly, cngage the spacer (31) and orient one of its ports
towards the body outlet orilice. Valves with CI mxx. 3.8 d o lint feature
anv seat ring gasket (2).

Carefully apply grease (Never Serz or equivalent) on the ilucttls il:id hc)rtom r,i the
retainer (4). With a 9/16" or 14 mm piece of hex stock ;+nd :I \vreni.h. rnrqi~ethr
retainer to 8 Nm if equipped with a graphite gasket st. rc.inSnri.ed. >I! tn 5.5 N m i f
equipped with a glass filled P:T:F:E: casket.

Note: In case of a valve with maximum Cc 3.8, torque tlic rclailier t o 2 S n i .

Step B: Engage the plug and stcrii ~ s r c m b l yin the sear I I I ~ C . In rile c;tic 0 1 4
maximum Cv < 0.10, ensure that thcre is no hard point dr~sinrthe stncking
of the plug. In case of ;I hard point. loocai llir retxiier 141 rid replxi. rile
seat ring (3e) in the corrccr pocitioli until the steni .mootill! :.l~dcs..\lign
the hole in the spacer ( 5 ) ivith the t r ~ l t ypiti I, I I ) hrdc I I I ilic v;il\c boil!

Note: In the event of a maximum C y smaller than 0.10 ens~il-cthat the

retaining ring (182) is placed on the plug before cneaning i t in the spilcet-
(30. If the retainer ring is damaged. replace it.

Step C: Wrap the safety pin ( I I ) with rlro tiirns c ~ P:TF:E:

f idpi. IITi~lloiiI. Sirc\r. it
into the honner five :tntl a li;ilf lo cix runii I I tlic rhrr:id
 engagement starts. To find the stnn uf the 1iire:id cnc;igemcnt scri.\u on the
safety pin about one turn and p ~ ~tile
l l safety pin olitivards while unsx~.\vitig
it.

Step D: Install packing, positioning the skive cut of each packing i-inz 120" a\\>)
from the cut of an adjacent ring. Slightly push doivn the rings one i1ftt.r
another by using a tuhc 1/2" sch. Size 160. Install the packinc follower 1')') nn
the plug stem.

Step E: Install the actuator bracket (108) anti secure ir with the two nuts (S;]). Install
the packing flange nuts (10) on the plug stem. Hand tiyhtell rile t\so packin;
flange nuts (Rb) adding one full rum with a wrench.

Step F: In the following sequence. place the grommet plate ( I01 ). >prnng i l(161.; I I I ~
its spring button (102). Screw the nut (103) and clevis i I0l:ii on the plug
s t e m Adjust the nut and clev~swithout locking them cncerher until tlie
clevis holes are about 1.5 mrn above the nlipnmeiit r i f tlir pin linli. in tile
actuator bracket (10s).

Note: Measuring this distance can he made easirr I>y enearin: the pins (105.
184, and 18) in their respective hole.

Step G : Pin lever No. 2 (22) to the bracket i108) h i usins the pin ( I S ) . 13nsilre that
the hole of lever No. 2 destined for s p r i n ~clamp I 115) is 1ocati:d iin the top
and aligned with the force balance sr;lring i I l l l.

Step H: Place the adjustment pin (23) in the slide of lever iY 0 . 1 and screw rlic knob
(24) on its threaded end. Engare t11e pin smooth end 1 7 3 ) into the slide of
lever No. 2 and mount lever No. I on tlie hrackct ilO3i. Couplc Icvcr No. I
to the bracket (108) by using the pin (1051 and the twn retaiticr clips ( 11211.

Note: Ensure that the cleviy (104a) is corrcclly posilione(l 1)erore placinrr I"\ e r
No. 1 on the actuator bracket (108).

Step 1: Set the adjustment knoh ( 2 J ) on min:rnurn C,. p<~sifioti

Step .I: If the piston rod clevis 1 IOlb) has not heen disrui-twl i l l ~ ~ ~dis:~ricnihl!..
i~lg
couple it to the end of lever No. 2' hy u s ~ n fthC pi11 I 17-11 .iliil the rwi,
retainer clips ( 1 12c).

Note: This operation will he facilitated hy placing tlle [)iston rod in an

intermediate position hy admitting a i r to t h e d i a p h r a g m and hy sctting
the h o b in a position where the cnd of lever No. ? is left most accessihlc.
If the clevis (104b) has been distt~rhed. proceed with a d j ~ ~ s t r n c nanrlt
coupling a s described in tlie section "Calibration".
Step K: Couple the clevis (104a) to lever No. I. To perfom1 this nperation push I ( ,
align the holes in the clevis and lever No. I by mems of :I scre\vdriver o n
the plug stem end. Couple by means of the two pins (IS41 ;ind ret:~inerclip.
(1 1%).

Note: Insert the clips on the pins between the slides of the clevis a n d lever No.
1.

Step L: With the take-up screw (116) fully unscrewed from the spring clamp ( 1 15).
place the latter in position after hooking thc force halanccd spring ( 1 14)
first on the positioner spring bracket (151) and secondls on the spring
clamp ( 1 15).

Note: T h e spring clamp (115) has two holes. If it is a clo.;e-on-air failure

actuator the spring must be hooked in tlie upper 11ole. In case of r a l r c
open-on-air failure, the sprinz must be hooked in the l o n e r hole.

Step M: Admit supply and signal pressures and complete tlie cnlihmtioi~.Kcpl3ci.
the cover (110) and turn the hand uhec.1 c l c ~ k w i s cto c.iig:~gsit 111 tile Ievrri-
arm stop (122). T i ~ h t e nthc COYLY screws ( 109).

Step N: If the valve has heen removed from the line. rcinsrnll i~ :iicording tn rhc
section "Lnstallation" and then set tlie virlvc hack into ser\ic~-.

7.5 Packing quick change method

The fastest and simplest way to replace the packing is to remiovs tlie entirtt :icturlror
without disturbing the actuator parts or calibration. l+owe\,cr. 1111s is 1101
recommended for valves with a small C, (Cv < 0.6) due to thc vcr: finencs,, of thcir
plug. Vent the valve pressure and proceed as follo\\.s:
Step A: Be sure that the plug is off the seat ring. With :in air-lo-open v:~lve. admit
air pressure under the diaphragm or turn the hand wtisrl t i l niovc thr p l ~ i c
off its seat ring.

Step B: Remove the safety pin ( 1 1 ) from the hod!.. The s;ifcty pin uigngcs ill?
packing spacer ( 5 ) . The [unction of the safcr! pi11 and \p;iccr is lo prevent
the plug from being pushed out if the nctu:ltclr is removcci \ s l i t l i . tile v;~lve1 5
still pressurised. The val\'e internal pans c:innot *I. i-cilln\i.d r~iilrc%the
safety pin is removed first. Relnove the two packing l1;1ti;i. I I L I ~ \ 1 S h i .111d
back off the two mounting nuts I 8a) as fiir as posiihli.

Step C: With a block of wood and a mallet, tap the :lctlioto~p l u ~.issen~hlyoff rtw
valve. Clean the packing box and plug stem and carefully plat,: tllc new
rings of packing around thc stctn. Position thc ski\? crit (01'each pocking
ring 120" from that of the adjaccnt ring.
Step D: Assemble the actuator/plug assembly to the valv' t:tking care to align the
hole in the spacer ( 5 ) with the safety pin hole and to replilce the t\ro
mounting nuts (8a) during asseinhlq. Take extra care in pi din^ c:ich ring
into the packing box.

Step E: Wrap the safety pin (11) with two turns of I'.T.F.E. r:lpe ( T e t l o n ~Screw
. it
into the bonnet five and a half to six turns froni lvhere thz thread
engagement starts. To find the start of the. thread engqement screw the
safety pin about one tun1 and pull the s:if?ty pin out\vnrds \vhiIe unscrewinf
it.

Step F: Replace the packing follo\ver, packing flange. and flanec nuts 1Nb1Tighten
the nuts finger tight plus one full turn. With a n air-to-open actuator. vent the
air pressure or turn the hand wheel to move thr plug back in conriict with
the seat ring. Set the valve back into zervicz.

7.6 Positioner maintenance

Note: Shut off supply and signal pressures. By-pass srrd depressurise t h e valve
body.

Step A: Unscrew the two pressure connection nuis i 1 X a ) and pull 10111 ills tubin
( 140).

Step B: Unscrew the cap screws (141i1) and ~ i t i manillid

i hlwi. (144).
spring (158). gasket inclusive three O-rings I 13h1. pilot v:~lvc. :i'semhly
(155, 156. 157), shims (135). and O-ring i 15.1)

Caution: Handle the shims (145) carefully.

Step C: Loosen lock nut (117) and tak-ui) \crci+ I I l h ) and unli(>oh 1 1 1 ~rprln:
clamp ( 1 15) from the lever (211

Step D: Unscrew the cap screws (141b) from the positioner hluc'h ( 147, arid rcniovc
it from the actuator bracket. Remove tlir scrtivs (1581 ti3 sepnr.ite the
positioner diaphragm assembly ( 1 5:) and spring i1 5 1 from [lie positiontr
block. Examine all parts for \vex and rcpl:~cc.i f necei%arr,.

Step E: Assemble the positioner diaphrayn :issembly i 1521 witli the spriny I 154) ( ( v
the block and tighten the screws (147). Be sur? th:lt tllc ~ r n : ~ricnnl
ll pon 0-
ring is in its recess in the diaphragm a s s e ~ i ~ b l y ~

Step F: Assemble the block assembly to the 3ctuntor hr:lcket

Note: Orient the block(147) so that when the manifold hlork ( 1 1 4 ) 1% 111rltedon.
the gauges will face in the right direction.
Step G: Install O-ring (153), shins (1.15'). pilot valve assembly (155. 1.50. 1571.
gasket including three 0-ringc (1.16). sprinf i1551. and illanifold bl(x-k
(144). Tighten the cap screws I 1413). replace the tuhing ( 1.10). and tighten
the pressure connection nuts (1382).

Note: Gasket ports in (146) must align with the ports in the block (137).

Step H: Hook up the spring (1 15) on lever No. 2 (22). Admit supply 2nd signal
pressures. Adjust start-up presyure :IS descrikd in the section "C;tlihrdtion".
Set the valve back into service.
 Table of contents

9iI flow meter

General
Commissionin
Dismounting and mounting instructio
Trouhle shootin

Lsncuage LIK P z ~ eill

Oil flow meter

1 General

The oil flow meter unit is equipped with a set of spindles (M). polc wheel (P). pick-
11p sensor (0, and measuring transducer (T). see ;llso Figure I . The measuring
principle is positive displacement.
The oil flow causes the measuring spindles (M) to rotate, and in front of the pick-up
sensor (r) the pole wheel (P) is turning in an exactly defined distance (a). The pick-
up sensor (0 records an impulse for every pnle which lnovcs along. This electronic
impulse is then sent to the conlrol system via the measuring traiisduccr (T). With
each rotation an exact volume is given. ant1 hy settings in the control system the
impulses are converted into a 3-20 n+. flou, < i ~ ; l I .

Illustration of the oil flow meter unit

The oil flow meter can be instullcd in any position. Rul i t musi illiv;lys hc free from
tensions to prevent distortion of the oil flow metcr. Fuflhcrmore. i t sllol~ldhe Ir~caleil
in a position from where it is possible tn dismount the pick-up scnsor.
As shown on the nameplate indicated in Figure 1. both Ilo\v dirccric~nsare pvssiblc
But the preferable flow direction is indicated by the 311 white n r m u symbol.
The accuracy of the oil flow meter depends on the momerlt:~ry flnw. Figure 3 s h o \ v
the characteristic for the oil flow meter.
The oil flow meter is very sensitive towards larger nhiccts in the nil. arid these
objects can cause a total hlockage of the oil flon rncrer. To prevent I a r y objects
from enterins the oil flow metcr, the oil system must he provided wit11 a iilter (mas.
0.34.5mm mesh). The filters located in the oil pump i ~ n i t\ b i l l usually provide for
an adequate filtration.
The dry sleeve is mounted. adjusted. and tested with the pick-up sensor 3s a unit.
The pick-up sensor, including the milled nut and sprin!:. is scrcwed into the dr)/
sleeve. The spring must be ahle to press the pick-up insert srnoothl! to thr front side
of the dry sleeve. It is imponant for the ful~ctionof the senhilr tysccln that thc ilr\
sleeve is free of foreign substance. The sensor system is shown i n I-'ip~re1.
The sensor system (pick-up sensor. measuring transducer. and cnhle) must not he iri
an area of electromagnetic field pulses with high intensit!. This cauld causk.
measuring errors or even destruction of fhe smcor system

Illustration of the namenlate

XXX

Accuracy - diagram -

+0.3

-;+0.2
-0
+0.1
)I
0
0 1000 mrn'/s
F
2 150 rnm'ls
0 -0.1 40 mm'is
2 5 rnm'is
-0.2
-0.3
50 100 150
Flow rate ("0 Qrnax.)

Figure 3

Illustration of the sensor system

-
6
-- - ~ -~
.-

- - - --.
1. Dry sleeve
2. Pickup sensor
3. Spring Conncclion dligrarn
4. M ~ l l R nuf
l
5. Input
6. Measuring transdumr
7. output . .,
, -. ,
8. Plug a ~ i g n m e n l
--

F i ~ u r c4 I)eg34.etlr
Figure 6
 Commissioning

Step A: Ensure that the oil system has been thorou_rhly flushed for irnpuritie a n d
that it is free from air.

-- -

Note: Impurities cause the oil flow meter to be hlocketl, ant1 a i r affect? the
accuracy of the oil flow meter.

Step R: Check that the oil flow meter, the pick-up sensor. and the ~ncasurinr
transducer are installed correctly.

Step C: Set the values for rnax. oil and katsllitre in the control systern. The mas
oil value is the maximum oil flow in l/h at 100"o burner load on heavy fuel
oil. The value for katsllitre car] k taken from thc identilicotion of the oil
flow meter (see Figure 21.

Step D: Dismount the cover of the me;~suringtransducer and unccrew tile pick-up
sensor from the oil flow meter.

Step E: Tap the pick-up sensor quickly against an object and clii-ck that t!lc
measuring transducer records the signals. Thc red LED fl:lrile\.

Step F: Assemble the measuring trimsdricer and mount the pick-up sensor ;!rain

Stcp G : Check and adjust the oil flow si:ttin;;s for nli~lirnumhiad. irnirion load. ctc
in the control system.

3 Dismounting and mounting instructions

For dismounting and mounting the oil flow meter and sensor sysicm plc;lic a1.v scc
Figure 1 , Figure 3, Figure 5 , and Figure 6.

3.1 Oil flow meter

-

3.1.1 Dismounting

Step A: Remove the oil llow lnetrr from the p ~ p sl ~ n e

Step B: Remove the flange covers and end cJvers

Step C: Press out the spindle set with rollins he3rill:s ; ~ n dclist:inr? !.Iecve froni thc
measuring casing.

- -

Note: If the spindle set o r measuring casing mnct he replacetl, t l ~ eoil flow
meter must be re-calibrated.
3.1.2 Change of hearings

Step A: Remove the pressed-on pole wheel from the nieasurin: spindlt:

Step B: Remove the circlips, spacers. and rollins hearings.

Step C: Remove the 0-rincs.

-- -

Note: T h e O-rings a r e specially tiesigned for the oil flow meter. If a

replacement is necessary, only original O-rings must he used.

Step D: Clean all parts carefully. take c:lre not to scratch the sealing s~~rfiices

3.1.3 Mounting

Step A: Mount the 0-rinss

Step B: Press the rolling hearinss on tlic n~zasurincspindle and ~ i i o ~ l11e

~ n lcirclips
and spacers.

Step C: Press on the pole wheel

Step D: Insen the spindle set into the msasurin: case.

Step E: Press tlie distance sleeve into the ~neasurin: case

Step F: Mount the end covers and flange covsrs

Step G : Tighten the screws crosswise

Step H: Install the oil flow meter in the pipe line again.

3.2 Pick-up sensor

3.2.1 Cleaninnlreplacing the pic k-up sensor

Stcp A: Dismount the pick-up sensor by unscrtwiiig tlie niill?tl ntli

Step B: Clean or replace the pick-up sensor. The pick-i~prcnsor clrn he changed
without performing any rc_rulntion of tlle di<~;ini~c
hrtn.een [hi: pick-up
sensor and pole wheel.

Step C: Mount the pick-up sensor and qcrc\\ on the inillcd nut

Note: T h e d r y sleeve must not he turned.

3.2.2 Dismounting of the dry sleeve

Step A: Empty the oil flow meter

Step R: Dismount the pick-up sensor.

Step C: Open the counter nut by mean5 of a wrench clzs ZJ

Step D: Turn out the dry sleeve hy means of a wrench w e I5

3.2.3 Mounting of the dry sleeve

Step A: Turn in the dry sleeve until the O-ring is sealin;.

Step B: Fill the oil flow meter with oil and start one of tlie oil purnps.

Step C: Turn the dry sleevecarefully u n t i l il gazes softly on thc rotatinp pole wheel.
Then turn it 114 of n tum back :~ndtighten the counter riul

Step D: Mount the pick-t~psensor again.

Step E: Check that the signal from the pick-up sensor is fiinctionins. If not, adjust
the distance between the pole wheel and pick-up sensor a$:lin~
4 Trouble shooting

If :lfault occurs, the basic and necessary conditions Tor uperation mtlst he cIl~c!ied:
Is electric power supply available?
Is oil available in the tanks?
Are the oil pumps running correctly'.'
Are all the regulating controls correctly adjusted?
If the cause of the fault is not due to anv of these condition. t h ? fault tillding char?
in Table I can be consulted.

Fault a n d rectifying f a u l t s
A -. - - - -

Lcmpriature lihcch l!ie allirtvcrl tc~-;lpcrature

To<>li!,?h picssuic flow rate is ton hirlt range)
drop Rcduce flou, rxi.
-. sWfl!?\l 111- ~

Leah:!, e Seal is damaged Change seai

t
I Rlnr'.-d
-

flow meter
Foreign suhstancc

I Pick-up sensor mountcd too fx /

inside
CIS-ann ~ flna.
l
U h c Iiltratlon
~iiclrr

Adlust pick-up zcnwr i,

Not enouch inlet prccsurc

Alr lock Rrmovc :iir
Dcgasing Kale systcm presiiiic, rr~lllcctcnlp:r:!lilrc
Too hiph pulsalton 1 Ciian~e911pump. mudi!! s:>rrrn

.
Ovralion:
high flow fluctuarlon
Quantity too small
! Ch:~neenf nper;lull,:c c i , n ~ i , l t o n i

Differine.operating
. data
High wear 1
~--~
1 Ftlrration o f a h m x ~ ~matcn:ll
out
e
~ l c k ~ u p tiirih
~pp- ~

i i h i 1:tppinp the pick-up

1
/ Screw thc

,
Defective p ~ k - u pm e n >nil
\ensor ooicklv. nemn<l
. :>nohjcct Ciiccl It131 ihc mearurin~
Nn ?.:',a1 from pick- tr:insduicr rccorrls ihc \1?113ii T i c rctl LED I?.trllr, 1
up \,.v.;i,r Dcfcctive connectluri Lununoos d ~ o d c ;;
Cii~ckconncctlons
1 !\iron$ p w e r supply _+stclE-nlcb~p -- - -- - - -I

Defective pick-up inscn ~ c pick-up

w inl?n
Dcicctlve contacts C!,cck conrncls
Ertcrnal interfcrcncc Instdl c a h l (:in<!
~ ~ r n ~ e ~ b : ~ r t~ :n .? t ~ t ~ ~~ ~l !~r c~ i~! ~~ i~l y~~r
D~simceto the pol? uilrcl lint
concct Cr~rrccrdistnnre p~~- -. -

Table 1
 Table of contents

Differential transmitter - -- . - --

Technical description

Operation on the tralnsrnitte

 .....
...
.....
&du&
Aft ."'.'PG
IP I.

Dp-trmsmitter, type 7MF4432

1 General

The follow in^ description is valid for a differzntial pressurc transiiiitrer STTRANS 1'.
type 7MF4432

\I1arning: This equipment should only be installed and operated after qualified
personnel have ensured that suitable power supplies a r e available.
These personnel must ensure that the equipment is not suhjectetl to
any hazardous voltage durinp normal operation or- when ;I defect
occurs in the system.

lt'arning: The equipment may be used under high pressure and with
aggressive media. Improper use of this equipment may therefore
result in severe personal i n j u q o r extensive (lamape to p r o p e m .

The successful and safe operntlon of 1111sequlpnlcnt ir depe~ldentuptin ti\ pioper

hrlndllng, installatton, operation, and maintenance

Technical description
- -.

2.1 Application

The SITRANS P transmitter can he used lo llieasurc:

differential pressure
low pressures above or below atmospheric prcssurr
flow q - p"' (in conjunction with ;I prirn;~rydiffer?nt~:llpli13'-111.t,di.\ IL.~'I

of y s e s , vapours. and liquids.

Measuring spans are possihle hetween I nihar and 30 h ~ r Tlic . , I L I ~ ~ s

I Ii y
~ ~ ~ is
; ~ .Il
load-independent direct current of 4 I 2 0 n ~ \ ,1 !incar (pri>portinnal to t!ie
differential pressure) or square-root (pri~ponionallo r;~tc( 1 1 fln\i I il~:~racicriitic c.111
he selected.
Transmitters conforniing lo protection typc "lntrins~c I .~nd ,.Flanicproc:,f'
enclosure" may be installed within potentially esplosive a ~ n i o s p l ~ e ~17.imc
e s 1 1 . TI)?
conronnity cenificatcs correspond to lht: Europcan st;~ndardiCENEI,E('I
2.2 Mode of operation
-- - --

Figure I shows a function diagram of the SlTRAtYS P iiiffcrcntial pressure and t l w v

transmitter. The item numbcrs relsrrecl to in the fblln\~inydcscriptioii ;ire lhow
mentioned in the in the figure.
The differential pressure is applied v i 3 the diaphr;lgm (J) :itid the tilling liquid (31
to the silicon pressure sensor (7). If the incasuring limits art ~,rce,lrtlzd.the overlorrd
diaphragm (6) is flexed until one of the diaphragms (41 rest? oil the me;irrtriny cell
body (21, thus protecting the silicon pressure sensor ( 7 )from overloading.
The measuring diaphragm of the silicon pressure scnsor is flexed h y thc applied
dillerential pressure. The resistance of four piezo-resistors tittzd it1 the diaphragm i n
a bridge circuit thus changes. This change i n resist~riceresults in ;I voltare output
from the bridge propoilional to the differential pressure. This w~ltngeis amplified
and converted into a frequency by n1e;rns of a volti~ge-to-frecl~rency con\ertcr (91.
This s i ~ a isl evaluated by a micro controller (10). ailrl its liiienrity and tcmperaturz
effect conected.
The processed signal is converted by n dizital-to-nri3locui' convcncr i I 1 ) inrn :it1
output s i p a l of 4 - 20 mA.
The data s ~ c i f i cto the measuring cell :IS \\ell 3s t l p:irarni.t:rs
~ of the tr:!nsmittcr
are stored in a non-volatile memory (EEPROM).
The cable termination point and the electrcniis are arrangcd ioppositi. one another.
Paraiiieterisation of lie transmitter is performed using ;I 1;rptcip. PC'. HART'
Conimunicator, or the pushhuttons. Nor~uallytile pusltbuttons :Ire 115edin sct-up the
11-ansinitter.

Function diagram
 The following parameters can he set or [heir current inten-iie;~t'cl:
measuring range
engineering unit
measured value in mA. %. and engineering unit
linear or square-root characteristic
cut-off point of square-root characteristic
damping
"loop check" function
output current when errors occur
disabling of pushbuttons

2.3 Dimensions

SlTRANS P. differential nressure and flow transmitter. dimensions

i ' 3 , l B NPT
5 w e r : .~mnr^11,0n
2 Mninl8:l- Inrear1 M10. M I ? or 'l.,~?O UNT
3 alank~q rllug lwrth Pti 13.5 s c w ~ s dolana rx Han 10 pluq onvl
i E l e n r i -:.nneran
"9 13 C :i.:rilwm g1m M M2O x 1.5 female thread a
-
'1;~14 l i " T 1e111a113 illread m Hm 7D Mug
J i?rrnlnc i l d r anal- idlcalor as O D l a n
I, Eledm' i . i sldc, dq<!et n d s a t o r as amon
7 P r o t ~ i Mver
. ~ ~ Clver keys
...
8 "i.nl'-Jr , v:,,vc

Figure 2
3 Installation

3.1 Place of installation

---- -

The transmitter can be installed ahove or Felon, the pressure tappins poinl. When
measuring gases, it is recommended 1 4 ) install the rr;~nsmirtcrabove the pressure
tapping point and the pressure pipe to he hid so it runs down to [lie pressure tap.
This will permit any condensation it1 the pipe to drain off and not affect the
measurement. When measuring liquids. the rralismitter should he in~tnlledlxlow the
pressure taping point and the pipe laid so it rises lip ro the prcssurz tap. thus enahlitif
any gas in the pipe to dispersed.
Thc point of installation should k easily nccessiblz. preferably close to the
measuring point and free from vibration. T11e permitled ;~mhii.~it temperature limits
must not be violated. Protect the tr:~nstnitter from dir?ct heat cources. Before
installing the transmitter, compare thf process data ag:linsl the data on the rating
plate. Keep the tralisminer closed during the i~istallaticmprocess.
The transmitter can be fitted directb to the v;~lvcrn;ttiilold or secured u,itl~::
mounting bracket.

3.2 Fixing with a mounting bracket

.-- -. - -.
-.

The mounting bracket is fvted to either

a wall or mounting frame using 2 s~reivs.
or to
a vertical or horizontal mounting pipe 150 co 60 iilm in dinn~c.rc.11 uciil!! ;I TJ-boll
(see Figure 3).
The transmitter is fastened to the mount!n!: t,r;icket using tile four scre\vs 5iipplied.

Fixing the transmitter using a r n o u n t -

i n-~bracket

Figure 3
 .. .
...
.....
.....
AAI..RQRG
I N ' r '

3.3 Rotating the measuring unit in relation to the housing

--

I f required, the measuring unit of the trnnsmitter can he rotated in relation to thc
rlsctronics housing either:
to reverse the process terminals
andlor
to rotate the elecuonics side (with digital indicator) to :I visible poqiliclr~
Only limited rotation is permitted.
The range of rotation (7). see Figure 4. is marked ;I( the bottom or the electronic.;
housing. At the neck of the electronics housing [here is ;I reverence mark ( 6 ) \vhich
lnust always be within the marked range when rotated.
Stcp A: lJndo the locking screw (8).

Stcp B: Rotate the housing within the rnnrkcd range 1 7 )

Step C: T ~ g h t e nlocking screw (torque i34' Nm)

Rotating the measuring unit in relation to the housing - - - -- - - .

3.4 Electrical connection

.- -

Warning: Observe the rclcvant regulations d u r i n e the electr.ical inst:lll;~tion. I n

hazardous areas, pay particular attention to:

the replations go\,erning electrical :iystcm~in h;~r:rrdnus;Irc;ls i Elex \I.

the specifications regarding the in5tallation of electrical r\\terni i n Ihaz;rrtlc~~r\

areas (VDE 0165). and
the conformance certificate
Warning: Check that the anxiliary power s ~ ~ p p n~atclier
ly that specilied on tllr
rating plate.

The transmitter should he powered from a SELV (safety extrtl-low volt:~ge)source.

IT other power sources are to be used. it is recommended to eanh llle ir:~rismittcr
housing. Thceanh terminal in the terminal housing is connected lo the c.i.tcrnal e:lrrh
lerrninal
Please note that:
The sealing caps in the cable entries have to ht: replaced liy relevan1 c;lhli.
glands or blanking plugs which must be certified when usin? 11-ansmitter?
conforming to protection type "Flame-proof enclosurr"
The terminal strip (see Figure 5 ) can he screwed on 10 four dilfcrcnt posi[ions
(290" or i180° rotation possible). Please notice that the rotation is linlited ro
i180° (proceeding from the fixed position as on deliven'l.
The following general guidelines ;~pplywhen laying terminal r!nuritnum cmsk
section 1.5 mm')/signal cahles:
- lay the signal cable separately from cables carryin; vnltacss > (10 1'
- use twisted-pair cables
- d o not lay cables close to large elecrrical systems. or LISC scrcen~ilc :~hi~

3.4.1 Connecting to scrcw-typc terminal

Electrical connection schematic -

.
r
r2- NDPV

iert sockc!r lor DC meter

Step A: Remove housing cover o i the clectn>nics s ~ d e I masked "FIEI-IP

TERMINALS" on thc housinc).

Step B: Retnove a n a l o p e indicator (il lilted).

Step C: Feed cable i n through cable gland.

Step D: Connect to "+" and "-" termin:~ls,o l ~ s e r v i npnliiril!

~

Step E: Replace analogue indicator (if :ipplicable).

Step F: Replace housing cover.

Note: With transmitters conforming to pro~ection type " F l a m e p r o o f

enclosure" the housing cover has to be secured with the safety angle.

3.4.2 Connection using a plug connector

The contacts for the connector are suppl~edin a hag \\ it11 tlie inrrrumcnt
Step A: Slide sleeve and gland on to thc cable

Step B: Remove about 8 mm of insulatlnn from the end vf Ll~ecciL>lr

Step C : Crimp or solder the contacts ro the c;~hlrends

Step D: Assemble connector

Connection using plug connector

In output current
Vn auxiliary power

3.5 Installing the analogue indicator

StepA:Remove the housing cover of rlir lc.rnun;~l .id< t~ii;~ri;ed"FIEI-I)

TERMD'4ALSZ'on (he hollsin~).

Step B: Plug a n a l o p e indicator into the reqt s ~ k s r s

Depending on the transmitter position the analopue irltlic:~rorcan be plurced-in rn
four different positions (i90°or k180" rnt;lliiln pocsihlr I.
Step C: Replace cover w ~ t hvlewlng \rindo\\
4 Commissioning

The process data must correspond tc that on the r ~ ~ t i nIg . h tranrmirti.r

functions as soon as tlie power is turned on.

Warning: Severe personal injury or damage to prope* may- rcsult if:

tlie venting valve andlor the screw plug :ire missing or n o t fitted properly
andlor
the valves are improperly or incorrectly operated.

Warning: When working with a hot medium, the individual stcps described
below must be performed in quick successions, olhenvise the valves
and transmitter may overheat ant1 he tlaniaged.

4.1 Measuring gases

Tlie isolating valves should he opcrated in thc follow.inp sequence. see F i ~ l i r ?7

Measuring gases

Fixure 7

Step A: Initial setting: all valvcs closed

Step I%: Open both isolating valves ( 5 ) at the pressure tapping points

Stcp C: Open the equalising valve ( 2 )

Step D: Open the pressure inlet v;il\,e (3.4 or 3R).

Stcp E: Check the zero point (4 mA) at stan of scale 0 and c c r ~ z c if

t necrssary

Step F: Close equalising valve (2).

Step G: Open the other pressure inlet valve ( 1 4 or 3B)

4.2 Measuring liquids

--

The isolating valves should he operated in the following scqucncr.. see Fi,corc 8:

Measuring liquids
1 Trawmmer
2 Equalrung valve
3 Pressure tnlm rakes
4 Impulse 1,ner
5 lrolal~ngvalves
7 O~flet~bes
8 'Jentlng valvs
10 pressure source
12 Gas liaD

Tranvmner batow lranrm~nerabove

peasure source p r e s ~ u r cs o m e
l n m a l conAgunbOn1 ! n w - s!andsO;
--- --

Figure 8 'inn2-08.tii

Step A: Initial setting: all valve? closed

Step R: Open both isolating valves ( 5 ) the prc<cure i ~ p p l i i cpc'~~it\

Step C : Open the equalising valve (1-1

Step D: If the transmitter is k l o w tlic pressure sourcz: open hoth c?l~tlctv;~li.es1'71
slightly, one after the other, t~ntilno more air escapes.

Step E: I l the transmitter is above the pressure source: open both \cnting val\,es ( X I
slightly, one after the other. until no rnore air escapes.

Step F: Close hoth outlet (7) or ventlng valves (15)

Step G : Open the pressure inlet valve (3A) and \.enting on the positive It$ of the
transmitter ( I ) slightly until no rnors air escapes.

Step H: Close the ventlny valve

Step I: Open the venting valve on the negative ley of tlie trlinsrnittcr sli?htly uril~l
no more air escapes.

Step J: Close pressure irilet valve (3A).

Step K: Open the pressure inlet valve (78) sliylltly until no niorc :~irit:.caps. close
after.

Step L: Close the venting valve on the negative ley of tlie tr;~nsmitlcri I I

Step M: Open the pressure inlet valve (3.4)''2 a rorntion

Step N: Check the zero point ( 4 n ~ 4 iagainst ct;l~I of \c:~lt! (i :~nd cor-rfcl 11.
necessary

Step 0:Close equalisiny valve ( 2 )

Step P: Open pressure inlet valves t i 4 and ?R)fully.

4.3 Measuring steam

The isolating valves should he operared in the iollo~vings e q ~ ~ e n cscc

c . Fiyl~ri.0 :

Caution: T h e result will only hc correct when the impulse lines (4) contain an
identical head of condensate a t itlentical tcmperaturec. Zero point
calibration shollltl he repeated, if necessan. rrl~enthis condition is
satislied.

Caution: T h e flow of steam mav damage the transmitter if thc cqualising valve
(2) is opened when hotli the isolatinl: ~ a l v c s(5) anti ~ ~ r e s s ~inlet
lre
valves (3) a r e open!
Measuring steam

1 TranSmmN
2 Equalizing valve
3 Pressure lnlel v a m
4 Impulse $her
5 Isolating valves
7 OU!!~," a h *
10 Pressure source
13 Condr)r;sate rerewoir
I4 Jache'

Step 4: Lnitial setting: all valves closed.

Step R: Open both isolating valves ( 5 ) .IL the pressure tapping points

Step C: Open the equalising valve (21

Step D: Wait until the steam in the i m p ~ ~ l line

s e (4) and in tlie s o n d c n r : ~ tri.scrvoirs
~
( 13) has condensed.

Step E: Open the pressure inlet valve (:A) and venting valve on t h t positive leg of
the transmitter slightly until no more air escapes.

Step F: Close the venting valve.

Step G: Opcn tlie venting valve on the negative leg nf the tr;incmirtcr sliclill! until
no more air escapes.

Step H: Close pressure inlet valve (3.4)

Step I: Open the pressure inlet valve (3l3) sli~hrlyu ~ i ~no

il mar? air tscnpcc

Step J: Close the venting valve on the ncgntive leg of tlie t r ; ~ n s ~ n i l l ~ r

Step K: Open the pressure inlet valve (3.4) '81 ;j rotalion.

Step L: Check the zero point (4 m 4 ) against start of scale il 2nd cc?rrc.cI it

necessaF.

Step M: Close equalising valve (2)

Step N: Open pressure inlet valves (3A ; ~ n di R ) l~t~ll?.

5 Operation on the transmitter
~~p

5.1 General

The differential pressure and flon transmitter is adjusted in the lield hi. three
pushbuttons, located on the outside of the instrument. with which the slnn of scalc
and full scale values are "set" or adjusted. By means of the digital indicator
(optional. normally not fitted) additional parameters can he ;idjusted. The
pushhuttons can b? accessed by undoing the iwo screws holding the protective c o \ w
in place, which can then be moved out o r the way.

Transmitter controls and d i s n l a ~ s

Engineerrng unit
I
Current

Mode Li8
+- mbar m A

Pushbuttons
Dlgital ind~cator(optional)
Screws

Protective cover

Digital indicator

The functions listed in Tahlr I can k elected usins 1I1e "31" key. \Vllcn pressins
the "M" key (Modus) 2 appears in the bottom lelt conirr or1 the LCD. Every
additional key press increases the inode hy <me.The par;3mstsrs. rl~ccurrent value.
or the engineering unit can he modified using the T ;lnd -1 keys. 111 cacc of error
Fituations "Error" is displayed on the LCD. (see section i 3 7 i The ir;lnsnlittcr
changes to function "Measured v:llut.". if mode 13 is passed h!. pressin? .'>I" key or
i f 2 minutes elapse without a key being pressed (except i n 1111>dcX. ''loop cheek").
If the input pressure is displayed. selectecl in mode I i (see crction 5.3 q ) . dnd
the square root characteristic in rilcdc. I I (sce section 5.3. I I I the dii'f~rfntinl
pressure correspondins to the flow and additionally tile siyi "\:" is diip1:tyc.d 011
the LCD.
Ifthere is a LCD overflow then "9.9.9.9.9" ;\ppenr~i\vi~hvnall t.iicineerinr
units like e.8. Pa).
 If a " L is displayed on the LCD, then the transmitter pnr:inletcrs arc protected
"

gain st overwriting (write protected hy means of a HART' (~'ornmllnicator)and

the key are locked.
If a "C" is displayed on the LCD, the transnutter. operating wit11 a PC/laptop or
HART^ Communicator, works in the .'loop check" function mode or multidrop
operation. The output current is independent of the applied differential prcssurc.
The keys are locked.
It applies to all modes (except 7 and 8). .A set ne\v value is only stored. when the
mode has been changed or when the. transmitter reverts auto~naticallyto the
"Measured value" function approximatelv 7 minutes after l:~stpressing the keys.

5.2 Operation without LCD

5.2.1 Setting s t a r t of scale and full scale without LCD

Please note that:
The start of scale and measuring span :ire non-interactive. ihleasunnr span =
full scale minus start of scale).
Pushbuttons may be disabled (write protecrc~l hy means of :I HART''
Communicator).

Step A: Undo the two screws holding the protective cover in place. \filch can then
be moved out of the way.

Set start of scale (4 mA) and full scale (20 tnA)

.Assuming the pushbunons are pressed :IS d?scribed IxIo\v. tile Irans~llittcrsets the
slart of scale to 4 mA and the full scale 11) 20 m.4. An anunder is not required
S t a r t of scale

Step A: Apply a differential pressure corresponding to the start of sc;lle to the

transmitter. When the start of scale is 0 har. compensnlc thit pressure
between the positive and negative le? of the tmnsn~itter.

Step R: Press the and keys simultancoosly for aholtt 1 sccondk

Full scale
Step A: Apply a differential pressuw correspontlinr to ~llc r l ~ l l sc:~lr to th?
transmitter.

Step B: Press all t h r e keys, making sure y i u prcss ths "R1" kc). first. Ilold it. a n d
press both the other keys.

Calibrate start of scale and full scale

If the output current is not to he set but freely adjust?cl:
Step A: Connect a DC meter to the output circuit or the test icxketc (see Figure 51
Warning: F o r intrinsic safe current circuits only certified current n1eter.i a r c
permitted.

Warning: I t is forbidden to screw off the transmitter cover when working in

hazardous locations and using transmitters conformin:: to protection
type "Flame-proof enclosure" (E~plosion-proof).

For measuring at the test sockets:

Step B: Clean the transmitter to prevent the ingress of dirt

Step C : Open the housing cover of the terminal cide

Step D: Remove the analogue indicator (if fitted)

Step E: Connect the DC meter.

S t a r t of scale

Step A: Apply a differential pressure corrcspc>ndinf to thc t ; l n or sc:lle to tlle

transmitter. When the start of scale is O bar. compens:~lc the pressure
between the positive and negative leg ofthe tr:lncrnittcr.

Step B: Set the output current for start of scale using the 'r and keys

Full scale

Step A: .4pply a differential pressure corresponding to the f'(11I scale to thc

transmitter.

Step B: Set the output current for full scale using the "RI" key and ihi. ikey or the
" M key and the key. Always press tlic "M" h e y first. llold i t . a n d prrsc
either the T o r the -1 key.
On completion of calibration:
Step C : Replace the analogue indicator I if applicahlc)

Step D: Screw the housing cover back on

Step E: Replace the protective cover and tighten botli scrcivi

I Functions of the dp-transmitter, type SITRANS P 7MF4432 #,

Fui~rlien
t and " Itisplay. clesrripliun Section

5 3.9 '
encineerine units
--b

Error disnla\. : 'Error", when ~ransmittrrI.: d~srorhcd

set to
Slan o f scale i 2 increase dccrez~e
'' Oulput r-urreiil in 111.4 i 3.2 il
4 m.4
set to
I
Full scale ? increase dccrea?e
20 mA "
Ourput current i n m A 53.2
I1'
Electrical d m p j n g J inneae decrease
T!mc cons1:ml T,,;
Ranee: 0.1 to 10n
in lecondi
135 ~
1
Stan o f scale 1 setto s t m I
'blind" calibration I i incrczse decrease
of scale " Stan of icalc in selected cnpinxnoc ur~iis 5 3.3 ,,

Full scale set to upper

I

1 1
f, ~ncieae decrease FoII scale in sclrclcil enginccrlnr 11111ls 5 3.3
"hlind" calibration ! range limit "

, Compt-nsate pressure hctwcen posit~vc;md

~i
Set 7ero p i n 1 .. esecutc ncysuvc lcp 1Stm o f <cslc dries no1 i h n n ? ~ ; . i 3.3 !
..
' ' h l i n g cal8hration
I ~!
1
Measuring value in cnglncenne
--- !in115
-

Constar1 outpul cilrrerlt in n1.4

I c
536
I
inrrczw decrea$c initialc 3 (1 1 0 12 0 70 0 2 2 3
funclion
k e v _
Terminale ~ i i i n p"\I"
--
Clutpul current in ' toggles hctu.een the Sriecwd output ctlncnt. Lllllcr l 2 . S o r :. 6 nu i3.7
I CrrOr slt~3tioll i WO \,dues
"O" = n o n e
~~~ ~

I
Disahle poshhuttons toggles between the "1.4" =locked all
andlor funcuon?
I, In four VBIUCS "1.0.' =locked 311 scrrpl s I x l ,>I sc:lie
"LS" =locked all accepi sr.in of ic:ilr -. -and hili su;ile
"l.in" = iin~ar

I Chnr3ctcrisric
togles hetuzcen the
three values
I I "SrLin' = cqumr~rnul
111nc:ohclou, t r : , n \ i i i < ~p ~ l l r i l l
"SroFF" = square-ii,nl
~ ~ u ~ - o f f b c belou.
i o w i i ~ r i s i l l i l np ~ i n t i 1
. . II I

~ d j u s t m granie ior umsnion x ~ i n r5 1.3 l i '3 7 1 2 - !

increase decrease
of llow i
Il
hlcnsured \,slue

Engineerins urllts
i? change

change
Engineering units linpul v:in:ihle) or nulp~iirlinenl
in rnA or '7
Enginccnng unit<
-- -
5.1 9
1
~ - -

?
..L.. is rI!~pizy:tj un 111sLCD. then the t r ~ n \ m ~ t t epxarnel~is
r vc pro~ecti-il sga~nrtoi.ci\\iiline
i u ! ~ l pri!lm?rlrci
r h i nlc:ln, [ ~ i r ,
I-IART' Conlmun8c:?.or):uld the keys are locked.
IT a "C'ik d~splayedi a lllc LCD. the trmsmincr, operating with a POlaptop or HART? Comrnunic~or,unihr in tile "lilon clieck" iuncuon
mod? or rnult~dropn":iatiun. i h c output cunent 1s lndepcndenl of lhe applied differcnlld pressiirr. Thc kcys :iw li'rk?ri
' Prcss T :md .1k r y i !:irnullaneously for about 2 s. The display goes h l m k and :he cuiTenr \'aIuc i s cli?pl;\)zil ~ 1 l c . 1 3hnul ? -,
' l i l h r sign .TL" I> .l~spl:lvcd31 the left. the rncrnunng rmgc lirnils have heen viol3lcd
 5.3 Operation with LCD

Please note that:

The start of scale and measuring span :Ire non-intcracti\,c. tMc;~suring span =
full scale minus start of scale).
Pushbuttons andlor functions may lr disabled, see Tahle 1. mode 10. secticm
5.3.8.
Depending on the transmitter positior~ the LCD can he plugred inlo lour
different positions.

Step A: Undo the two screws holding the protective cover in place. which can then
be moved out of the way.
On completion of calibration
Step B: Replace protective cover and tirliten both screws

5.3.2 Setting start of scale and full scale

If no pressure source is available, the stxt of' scale can he set in mode 5 nnd the full
scale in mode 6. Both are specified in tile selected engineering unit. scc section
5.3.3.
Srt start of scale

Step A: Apply a differcntial pressure concsponding to thc start of sc:ilc lo the

transmitter. When the start of scale is O bar. compens3tc tlic pressure
between the positive and negative le! of the transmitter.

Step B: Select mode 2 usins tlie " M kc)

Stcp C : Set the output current correspondinp to the start c>f scale tising the T and J
keys.
O r set the output current to 4 mA by:
Step D: Pressing the T and J keys simultaneously for alm~rt2 secontis.
If the sign 'T.1" is displayed at the Icfi. ,he ~measul-ingrnnfe li~nitch:lve ksr
violated. The original value remains unclianrcd.
Set full scale
Step .\: Apply a differential pressure cor~espondingto frrll scale to the tr:~ilsmittcr.

Step B: Select mode 3 uslng thc "M" LC\

Stcp C: Set the output current correspondin? to fill1 scale osing the T m d -1 k e y
C)r set the output current tn 20 mA by:
Step D: Pressing the T and J hey5 ~rmultaneou~ly
for ,~hout2 \rconds
If the sign "T-1" is displayed at tlie left. the measurin~range limits li:~ve hecri
ii<~lared.
The original value remains unchanrcd.

1-anpage L'K Page l(i1?2

If the sign "T.1-.-.-.-.-" is displayed the ielectetl me;isurinp spati is tiiorc than twtce
the maximum measuring span. When pressing the T and kcys rirnu1t:lneously for
;ihout 2 seconds the full scalr is set to O.IW)(K).

5.3.3 Setting start of scale and full scale without a pressure source
It is possible to set the start of scale and full scale of the transmitter even if there is
no pressure line connected or pressure source available i"b1ilid" crliibrdtioll).
To set s t a r t of scale
Step A: Select mode 14 using the "M" hey

Step B: Use the T or .1key to select engineering unit

Step C: Select mode 5 using the " M hey

Step D: Use the T or .1key to set the stnn of sc:ile in the selected ensi~leeringunit

Step E: When pressing both the T and keys simultat~eouslylor ahout 2 seconds
the start of scale is set to zero (in the selected cnginecrinc unitl.

To set the full scale

Step A: Select mode 6 using the "M" LC!

Step B: Use the T o r .1key to set the full scale in the selectetl cnpineering unit.

Step C: When pressing both the T and .1 keys s i n i u l t a n e ~ ~ ~for

~ s labout
) 2 seconds
the full scale is set to the upper measuring limit ( i n the selccted enpincerin9
unit).

Example 1
A transmitter with a maximu~nmeasuring sp;m of 5 har is to he calibrated to a
measuring range of 0 to 3.52 bar to correspond to 4 to 20 mA:
Step A: Select engineering unit "bar" in mode 14

Step B: For the start of scale. set the value "0.000n" in mode i

Step C: For the full scale, set tlie value '1.5200" i n tnnds 0 .

Example 2
A transmitter with a maximum measuring span of I.(] bar 1 5 to lie calihrnted to ;I
measuring range of +456.70 to 1 2 3 . 4 0 iiun H? to con-espond to 1 i o 2 0 111.A:
Step A: Sclect engineering l t l i i t "mm H:" i n mrdz 14

Step B: For the start of scale. set the vali~e"t45h.7" in modc I

Step C: For the full scale. set the valtrc. '.-12.1.d" in mode h

Example 3
A transmitter with a tnaximum rneasurins span of 2 5 0 mhar I< c:~lihr~irt?dfor a
measuring range of 0 to Z(H)mbar to correspond to 4 to 2O m:\.
The measuring range 1s to be changed to a setting of 100 to 2111 mb.~r
Step A: For the start of scale. ~ e the
t \ ~ l u e100 00" in m ~ d c5

Step B: Select mode 6 using the "M" key. The f u l l 5c:ile "300.00 rnhar" i \
displayed.

Step C: When trying to decrease the value using the "J" key. the error note .'7'J"is
displayed additionally to the (nut changeable) value. This is Ixcause that if'
the start of scale is changed tlie measuring span rcniains unchanged. The
full scale 300 mbar violates thc measuring range limit5.

Step D: Press the 1' and keys simultaneously for about 2 szconds. Then the full
scale is set to 250.00 mbar.

Step E: Use the J key to szt the full cccile to 240.00 rnhar

5.3.4 Correction of zero point

If the transnlitter is installed and openitional, exlernal influences such as angle of
installation, ambient temperature. or installation dependent presqure effects (e.g.
head of liquid in the impulse pipe line to the transrnittzr'i may cause an offset in the
transmitter's zero point. This offset (maximurn 5% of the maximurn rrieasuring
span) can be corrected in the transmitter without modifying thc start nf scale and full
scale settings in modes 5 and 6 (correct~i~n of zero poilit).
Step A: Compensate the pressure het\keen the positi1.e and nee:iti\,e lsg of th?
transmitter (see section 5.3.2).

Step B: Select mode 7 uslng the "M" L?\

Step C: Press the 1'and keys sirnult:~nzc,uslyfor ahout 7 w o n d c

The value 0 or 0.0 etc. to 0.0000 is displayed on the LCD, depending on the
maximum measuring span of the transmitter 3nd the selected en~inceringunit.
Example
A transmitter with a maximum rn~asuring spun nf 1.6 h ~ is r c:ilibrated for a
measuring range of 200 to 800 mhar (4 to 10 mA). i e . start of scale 700 irnhar) in
mode 5, fill1 scale 800 (mbar) in mode h and enginecniig unit "mh:~r" i l l mode 1 4 ~
The transmitter is, however, [x-ing in hotter conditions. \\,Iiicli is causinp an offsct
(200.3 mbar) in the original zero point.
This offset is to he corrected:
Step A: Compensate the pressure

Stcp B: Press the 1' and keys s i m u l t a i ~ ~ o u for

s l ~ :~hout2 \cc,ond\ in inode 7. The
value of "0.0 mbar" is displayeil.

Step C: Apply the original differential pressure. Then "200 rnh;~r"is displayed.
The start of scale and full scale of 201) (mbar) ;and SO0 imhart \ct in modes 5 and 6
respectively remain unchangcd.
5.3.5 Setting electrical damping
The time response of the transmitter is determined hy t l ~ i . dead timc. the time
constant T6).and the electrical damping \value.
The transmitter is supplied with a damping \~alueof 0.1 second. \'slues of 0.1 lo
100.0 seconds in increments of 0.1 second are perniitted. The valuf can k c h a n ~ e d
by:
Step A: Selecting mode 4 using the "M" key

Step B: Use the T and .1keys to change the darnpins 1.3lue.

5.3.6 "Loop check" function

The following output current constants can be sel to cllecl; the output signal loop.
e.g. during commissioning. irrespective of the pressure:

Step A: Select mode 8 using the "M" lie\

Step B: Press the l' and .1 keys sim~~ltaneouslyfor about 2 seconds. This activates
the "loop check" function. An output current oC4.ll 11x4 is displayed.

Step C: Use the T and -1 keys to select thc rpqu~reilcurrent

Chancing the mode disables the "loop ci-ieck" li~nc.ti@n.

5.3.7 Output current in e r r o r situations

The pressure sensor and electronics are n1011iturc.dconti~~uously. I f a defect oi-curs
"Error" is displayed. The output current is set to 3.6 or 12.8 i d \ . neither of w.llich
are possible under normal conditions. The value set is deternmined using mode 9. The
factory setting is 22.8 d.
Step A: Select mode 9 using the "M" key.

Step B: Use the or .1key to select 3 6 mnA or 13 S 11~4

Chang~ngthe mode caures the <elected ialue to he \tr~rc(l

5.3.8 Disable pushbuttons andlo r functions

The pushhuttons locared under the protective cover CLII he prottctcd 10*nether with
their functions against accidental and un.~t~rhorised
u~c.
Step A: Select mode 10 using the "M" 1 . c ~ .

Step B: Use the T' ' or .1key to select onc out of four Cunct~un,
"0" no pushbuttons or fur~ctionsdisabled ioper:i[ion xt.ssction 5.3 I
"L.4" all pushbuttons and functions disabled.
"LO" all functions disahled except rt:in of scale (to set t ~ :idi~~st
r stnn of scale
see section 5.2).
"LS" all functions disabled except start of scale and full scale ( t o set or adjust
stan of scale or full scale cee section 5 . 3 ) .
Changing the mode causes the selected lockins to he stored. 'TIE dis:~hling 01'
pushbuttons andor functions is displayed. It is cancelled ivlicn the " R l " key is
pressed more than 5 seconds.
Please note that:
When selecting lock "LO" or "LS" the measured ~ a l u display
r current in nlA or
% should be chosen heforehand in mode 13 (see section 5.3.')) Otller!vise
A

change of the output value is not noticeable when the I or keys rue prtxsed.
If a "L" is displayed on the LCD, then the transmitter parameters are protected
against overwriting (write protected by means of a HART' Cominunicator).

5.3.9 Select display (current, %, pressure)

It can he displayed either the input variahle pressure in the sc.lectcd unit in rnode I4
or the output variahle current in m4 or C.
Step A: Select mode 13 using the "M" kcy.

Step 6: Use the i' or .1key to select the I-equired\,ari:~hle

5.3.10 Select engineering units

The following engineering units can he chosen froin:
Bar, mhar, in ~ ~ 0in "
Hg.. ft ~ ~ 0 "~
mrn . ~ 0 Inm" IHg.
. psi. Pa. kJ1:i. hlp:!
" Reference temperature 20°C.

Step A: Select inode 14 using the "M" key

Step B: Use the T or key 10 select the i.nginecring units.

If there is a LCD ovedlow then "9.9.9.9.9" appears lwilh s111:111cngincrrin: nits
like e.g. Pa).

5.3.11 Select characteristic (linearlsquare-root)

The output characteristic is selected as follou's:
Linear (proportional to differential pressu~eI
Square-root (proportional to rate of flow)
And below the transition point of the square root char;~cterislic-
Linear
Cut-off
Step A: Select mode I I usins the "M" key

Step R: Use the T or .1hey to select eitlitzr:

"Lin" for linear characteristic
"SrLin" for square-root ch;iracteristic (linear up to the transitioll point1
"SroFF' for square-root characteristic (cut-off up to thc transition point)
Changing the mode causes the selected characteristic to k. sti-)red.
In the case of a square-root characteristic. the transition poim can h2 specified (see
section 5.3.12). In all modcs the sign "\/" is displ;ryed. The transmitter for flow
measurement will be delivered with the factory settins "SroFF"~
 Please note that if the input pressure is displayed. selected in mode I 3 (see bection
5.3.9) and the square root characteristic in mode I I (he differtiitial pressuro
corresponding to the flow and additionally th~:sign "\h' is displayed o n the LCD.

5.3.12 Transition point of square-root cltaracteri<tic

When measuring rate of flow with a pressure source. the transition point of the
square-root characteristic can bz set between 5 % ~and 15% of the ratc crf flow The
output characteristic is linear (see Fipirre 1 l(a)) helow this point or cut-off (see
Figure 1l(b)).
Step A: Select mode 12 using the "M" key

StepR: Use the T or key to select transitlim pollit of the square-root

characteristic.
Changing the mode causes the selected transition point to he xiorzd.
Please note that if the input pressure is displayed, selected in mode 1.3 (see section
5.3.9) and the square root characteristic in rnode 11 (see sectin11 5 . 1 1 thc
differential pressure corresponding to the flow and ;~ddition;~lly thc s i ~ n"v'" I 5
displayed on the LCD.

Transition ~ o i nof
t sauare-root characteristic

IW

80

Aflurtlng
range :or
IraPS'!,O"
poio,
pressure

40

I I
,
',

. o
0 ' 20 40 GO RO 100
~ . ~ . . .
pressure /-A/
6 Maintenance

The transmitter requires no maintenance. However. the start of scale vnluc should he
checked occasionally.
If an error occurs:
the output current is set to 22.8 mA or 3.6 mA. depending nn selection (see
section 5.3.7)
using SIPROM P an appropriate message is displayed in [lie "Measured values"
field
"Error" is displayed on the LCD
 Table ~f contents

Regulating valves

Regulating valves for atornising steam, oil temperature and oil

pressure

Data for regulating valves ................................................................................... I

Electrical actuator, type Prernio

p~ - - -

. .
Putting Into operation .....................................................................

Care and servicing

I'ossible malfunctions
Information for repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ':

Control valves, type 4701471 -

 REGVAL

REGIJLATING VALVES ITEM F91. G20, GI 00.

ITEM I I F91
TYPE
SIZE
23.470
20 Q
PN
ACTUATOR TYPE
SIZE
[v1
25
PREMIO
2.2 KN I
i
PILOT VOLTAGE
FREOUEYCY [Hz]
1 X 220
60 1
i
PFTE-V-r~ngunit, spring loaded (I.) X j
I
Bellow seal with safety stuffing box (Ill.) :
I
Parabolic plug with plug shaft guidance X

ITEM I I GI00

TYPE 35.470 ~
1
SIZE DN32
PN
40
ACTUATOR TYPE PREMIO
SIZE 2.2 KN
PILOT \'OLTAGE [vl 1 X 220
FREQUENCY [ Hz 1 60
,I
PFTE-V-r,ng unit, spring loaded (I.) X
Bellow seal with safety stuffing box (Ill.)
Parabolic: plug with plug shaft guidance

Side 1
Electrical actuator, type ~ r e r n i o

General

1.IStorage I transport
- ~

Leave the actuator and complete setting device in tlie p:~cking until asscrnhly anti
store it in a dry room at a storage temperature of bcr\vecn - 20°C' and i- 70'C. The
actuator and setting device, must be protected from exfemal damage e.g.: In~pact.
vibration and k n x k s , clc. Used together wit11 heavy fittines \vith l a r ~ c rnominal
widths the setting device may only he transport and inst:illed with tllc aid of suitahlz
lifting equipment (e.g.: Forklift. crane. etc.). 'The actuator muTt he protected from
moisture and soiling (any installation position. hut the rnotor inliir no1 he 11anging
dotvnwards!).

1.2 Correct usage

Actuators of the PREMIO series are dccign to set the conical stroke of v;~l\.cs.'Tlic
actuators may only be used as set fourth in the data hlleet and the technical
infortnation on tlie specification plate. lise of the actuator outsid? tilcsi. technic:tl
specifications or for any purpose other thai~that ~ i v e 3hc)vr
~i is iiicorrcct. Correct
use also means observing the DIN \'L7E regulations and :rccidcilt prevention rules
and adopting a safe manner of operation when carrying our any activities deccrikd
in these instructions. Standard opcratinr practices arc to kc ohscn.i.[i.

Warning: This electrical appliance is designed for use in high voltage systems.
It may only be installed and used after qualified personnel h a r e
arcertained that appropriate power sopply units :Ire use. These
power sapply units must guarantee uncler normal operating
conditions and if the system o r its con~ponentsmalfunction that no
tlangerous voltage is ahle to reach the appliance. D ~ ~ r i noperation,
o
installation and adjustment, this appliance h:is d:inpcrous
electrically charged a n d nnt insulated parts and mo\.ing and rotating
components. Unaothorisetl ren~ovalo l t h c rcqoirecl covers, incorrect
use, incorrect operation o r adjustment and inadequate sen-icinc
may result in serious i n j u y o r considerable matel-ial dama:c.
1.3 Safety rules

~ ~-
-- ~ -

Warning: Mains separation, system-side: prior to removinn, the hood, e.g., for
mechanical servicing a n d adjustments, the rnains power must he
switched off with an appropriate cut-out device. This cut or11 device
must be designetl to prevent the power from unintentinnallv Iwinn,
switched on.

1.4 General information

--

These operating instructions are not a tzchnical manual and tlierc.lore only contain
the information n e c e s s q to install and operate the appliance in tlie prcscrihed
manner. Should any difficulties arise during installation or operation that cannot hi.
resolved with the aid of the operating instn~ctions.then funlier i~lforrnationshould
he obtained from the supplier. The operatin? instructions ;~lsodo not m:inifest ;I lecal
agreement.
Persons who do not fulfil these requirements niay not uce tlie I'UEMIO :ictuator I,)
perform any task, including those described in their nper:rtin: inslruction~

Description

2.1 Area of application

~-

PREMIO actuators are used to operate setting or check v:ili'es rcquu~ng'I straigllt
nominal setting path of up to 50 rnm and thrust force of 1.5 kK tcr 5.0 kN. Thc
actuators are set to the appropriate force When sr~ppliedtogether \\it11 :I v:~lvc. thc
stroke of the actuator is adjusted for thc setting path of the i,aI\,e.

2.2 Technical description

- --

The acruator, equipped with a yoke or columns. is mountr.d on tlic \'alve. The po\rer
transmission is accomplished via the cnupling which is secured tr~ninstt\vistine. T h i ~
anti-twist feature is at the same time the stroke display. TI1e stmkc positions can 1%:
read from a stroke scale mounted on 111,- yokc or hetween tile clamps mnl~niedon th;?
column.
The electrical parts are located separately from thc trnnsrnissi~~n i1ndc.r tile sealed
hood, protected from ambient and oper:~lin: conditinns.
The switching and indiclltine equipn?ent is c;~sily ;~cce<sihl<$mi.? rlic iiood I <
removed.
The rotary rnovcmcnt of thc motor is transmitted via a star wheel gc;lr to the spinillc
. .
nut. The actuator spindle. \~hicIiis secured against twlstlny. 5crcit.i itsclf into the
spindle nut and thus performs a thn~stc7r draw movement dcpcnding on rhi. direction
of rotation.
At the ends of the valve. the spindle nut is pressed agoinst ;I spring p:icket :in11
generates closing power. The motor is switched off via t\vo load-depende~ltand oric
pathdependent switch. The load-dcpcndcnt switches ;1ls<7s\vitch tlie iiietor o f f i t
 Foreign bodies penetrate k t w e e n the i a l v e s c : ~:md
~ the cotic. 711c lo:~d-drpendc-nr
switches protect the valve and the actu:ttor from d ; ~ r n a ~ .

Accessoric.
.Additional cut-not:
Polenl~omcrrr
Elcctronlc p~sitionindicator KILI 1
2 add. path bwilchcs. Tor
max. 2 unlts: Ohmc vniocs np..
.
r3tlni: l o \ . 350L'
00. 100n Ohm; 1.5 \4;:itr
p~

O ( 2 1 IOV O(J) .. 2Om.A. on1y I porcnuomctcr p s s i b l c

I- ,,
I
Electronic r o d i o n e r ESI I
Hcater
0 0 ) . IOV : 0iJ1... 20nbt only I potsn1iome:er pxsible
230\'-%Hz. I5 \ \ ' ~ t :
r
-

, Other volla?e!ireqorncy 2JV-SOHI; ZJV-CBHI I liY-iflll,. I I!\'-(fitlz. 230V-MHz

? a d d path sw~tchcs,for hcr uinng, r:illn; niax O I A . O-?O\~
2 torque and I pmh switch ior ircs uirine. rotirieIO,i.?50V -
.-

Table 1
Dimensions of premio actuator

r""""""
I Space requlred for R t m v a l

Premio 1.5 - 5 kN
Nnm. stroke max. 30 rnm
Diagram -

Cclurnnar c o n s t ~ c t l o n

Yoke construction * I

, ~
i '
6 I¶
--
Figure 2
3 Assembly
The following conditions are to he mct :ind oht;~irledprior to :~ssi'nihly.
valve operating instn~clions:~sail;lble:
complete valve with travcrse;
valve cone roughly in mid-stroke p<:~sitioii,
u11di.1-no circu~nstii~iccs
c(mt3ctin; :I
seat!
technical specifications of the actu;itor com~nensuratewit11 inn-site ratings and
conditions;
actuator complete with yokc cr colunin\ .inil cioiipling ci>mporiciits for
installation to the appropriate v;ilvc.
mains connection corresponding to the tl:it;r on the specification plats of :lie
actuators;
qualified personnel with kno\vledre of rlif nllcs for cc~tinrrly hirli-current
systems;
easily accessible installation point:
enough free space ahovc the actu3tnr to rernovc tlie hood. r , ? t Firurc !
actuator may installed in a n y position. csccpr wit11 the motor 1i;lrigin;
downwards.

Important: The safe operation of the actuator is only guaranteetl if i t is

correctly installed and put into operation I,? qualilied personnel
observing the warnings given in these operatin: instructions. T h e
ohservance of general installation and safer? rules f o r pipe and
plant construction and the correct use of tools and ;ill safeh.
equipment must be assured.

Important: The operating instructions for the \.alve must be o l ~ s e n r ( ldurino

all work on the valve ;~n(luse of il. Nnn-ohsc~-\ance m:r? rcsr~llin
death, serious i n j u w o r ronsideral~lematerial d:tn~:l('e.

3.1 Manual operation

With the motor stationary the actuator can he npericcl ; i n ~ ii . I n i ~ ~ l

wit11 illc h:inJ
wlieel firmly located in the transmission. sse Fi;irrc 3.
Proceed as follows:

Step A: open tlie pin ( 2 ) on tlie hand whcel ( I )

Step R: turn clockwise >valse c l n ? e ~ <

 Step C: turn anticlockwise >\.:tl\,e opens<

Caution: I n manual operation, the hand \vheel may only he turned a1 the end
positions until the torque switch actuates (audible click). o t h e m i s e
the actuator will be damagetl. Since the wheel always t u r n s in
automatic (motor) operation (running [lisplay) ?-ou should never
touch the wheel while the equipment is in this mode - d a n g e r o f
injury!!!

M a n u a l oneration of hand wheel

3.2 Installation with the valve

Proceed as follows to install the actuator on a valve with a nc'rninnl stroke or up Iu

30 mm, see also Figure 4.
Step A: unscrew the coupling (3) fmrn the anti-twist device i I l l o f thc i!ctu;ltor
(not shown in Fifure -1)

Step B: bring the valve cone roughly into mid-srrokc pniitii,ri

Slep C: if not available, turn flat hexag~lnnut ( Z i on valve hpiridle I I i I I'iorlre 1 :\ 1:

Step D: slide coupling (3) over the vnlbe spindle ( I ) i Fi~ul-e1.+I; i

Slcp E: screw the threaded hush fitting the valve ( 4 1iner tllc \ ' x i \ - spi~lillc1 I i ;itld
tishten with the liexngon scrsu

Step F: setting dimension (Y) for prc7.jection of firtinc 11)

60 nncl S7mm = IiP111ni

Step G: place the actuator on the valve [Figure 4 C)

Step H: fasten the actuator (5) to the fitting with t\io hammer ~scr?,ws I ( > ) . ti\'<>
washers (7), two spring washers ( K ) and two hes;~_conl~uts('1).

Lulguaee UK i7:icc i i l h
Step 1: fold out the hand wheel le\'er ( 10) and use it ro m o \ c [lie :~ctu;ltorout ulllil
the actuator spindle ( I I ) lics on tlic ~hrc:rdsdhush (1)(Fici~r?4 D I E ) :

Step J: screw the coupling ( 3 ) tightly into the anti-twist device I 1 2 ) ; ~ n d?,:cure \\'ilh
the threaded M6 drift (14) (Ficure 4 F)

Step K: bring the valve into the hottom-most pos~tion.

Step L: clip the stroke scale (13) on thc yoke so thnr thc top edge ~ l the f anti-t\vist
deviceis aligned with the tip of the arrow nxirkins on t l i t stroke scale;

Step M: move the valve to both end positions and check rli;\t tlicsc i . ; i ~ i hc properl\
reached.

Extension for valve stroke u p to 30 rnrn (yoke constroction)

Figure 4 prerniol.tif

3.3 Electrical connection

LVarning: Connection to the mains and commissioning of the ;ictu;rIor require

specialist knowledge in setting-up of high-voltazt systcms (L7)F:
0100), knowledge of the accident p r e ~ e n t i o nrules : I I I ~ the specific
commissioning c o ~ ~ d i t i o for
n s this actuator.

Warning: The tasks may only he per-forrnetl hv qualified personnel. Non-

obsen~ance may result in death, scrinos injur? o r cr)nsiderahle
material damage.
Circuit diagram

Figure I
3.4 Connection

The DLN VDE rules and those set forth by the local po\vcr utilrry ;ire to Lw O ~ S S ~ C L I
when laying electrical lines and connecting equipment.
The voltase of the mains must match the rating on the spccilic:~tion plate of the
actuator.
The cross-section of the line must be appropriate for the intahc ratir~gof thc :ictu31~11
and the length of the line.

JVarning: The power supply line connectino, to the actuator muqt be separated
from the mains (i.e., must not be under power) \r hile the $!stern k
being connected.

Proceetl as follows to electrically connect the actuator. usin: manual operation:

Stcp A: move the actuator a few nlm out of the hottom cnd position:

Step B: slacken the countersunk screw In the hood arid c:irefull\ lift olTthc hood:

Step C: unscrew one of the two cable inlets and rcplacc i t in tlir s:lmc w~i! withmrt
the blind washer supplied:

Step D: push the connectiori line into this cable inlet so that tlicri. is enourh lenrth
of wire to reach the tenninnls, and then tiyhtcn the cnhle inlcr until the
power line is fim~lyclarnped into it:

Step E: insulate the power line about I - 1.5 ctn ahovc the cahl? inlet:

Step F: insulate the individual wires about S n l n ~f r o ~ nt h ? elid :~ndco\,cr t h m \ v i t l ~

insulation sleeves:

Step G: connect the earth wire of the pouer line u.ith thc e:irIh 1cnnin;il of t h ?
actuator;

Step H: connect the impulse line for 111,: c n l e r ~ i ntIirtr<i

~ rod In I?-rnlinrll 1 1 on 111:.

connection panel of the actuator:

Stcp I: connect the fourth wire NIMP ti1 tet-mini I $117 i h ~ : connection p:inel of tlii!
actuator:

Step.1: connect the impulse line for tlic retractin? tliriist rid to tc~-t~lin:~l
I J o n tllc
connection panel of t h nctuatoi-:
~

Step I<: Refit the hood carcfillly rrom ahoi'e ~ r n dfils~cnit lightly tic tli? 3itl!a!cnr \ i r t h
the countersunk screw and rubher rr:ilinp rills:

Step L: connect the power supply line to the mains and mini. the L~ctuatorinto e:tcli
end position to make sure that the end pat11 s\vitcIie~; I C ~ L I ; I is\vitcIi
~~
and the direction of actuator ~novenientis correct.
Stcp M: if the direction of actuiltor movement is tile upp(,site of t11:lt ile~ired.t11r
impulse lines for emerging and retriictinr ihrust si~dnirls! be <witched
round;

Settings

Warning: The actuator may only be used without a hood for short periods for
unavoidable adjustments to the potentiometers, the path w i t c h a n d
the electrical options. While these tasks a r e heing carried out, the
actuator has dangerous, elcctrically charged and not insulated parts
and moving a n d rotating components. Incorrect o r incautious
performance of adjustment task may result in serious i n j u n o r
considerable material damage. These tasks may only he perrormed
by qualified personnel. It is forhidden to operatc thc :actuator
without a fitted hood for any purposes other than those tlcscrihetl
above.

4.1 Standard torque and p a t h switch

The actuators are series-fitted with the standard ho;~rd.This 1,orird inc(irporatcs :I
load-dependent cut-out switch ( S I ) for [he direction of closure. :I 1rl:lil-ditp?nde~it
cut-out switch (S2) for the direction of opening. ~ n ;Id pat!~-dt.p,-~~~lt.i~t
C I I ! - ~ switili
III~
( S i ) for the direction of opening.
Tile loaddependent cut-out switches (SI. S7) s\vitcI~nff th? !lioti)r oncc tile thrust
power set at the factory has heen reached

Important: Under no circumstances may the settino of the loatl-depentlent cut-

out switches be changed!

The pathdependent cut-out switch ( S 7 : switchcs off thc rnijtor oncc tlli. sct strohc
has been reached. If the actuator is supplied together \vith a t h n ~ u ~\,:live.
h the p:~tli-
dependent cut-out switch ( S i ) is set to switch off the motor ~ I I C I I tI1e nia?imum
valve stroke has been reached. If the actuator is silpp1ii.d t(!ytller \ ~ i t ! r .I ?-\V:I!
valve, the switch cam helonging to the cut-out si~'itcI1I S ? ) i \ set su f:lr d n u n in tilc,
direction of opening in the s\vitch carriages thr~ttllc iop end positin11 ul tilc \ : I I \ c I ,
reached k f o r e the cut-out switch S3 is reached. :lnd tlius tile nioiiir i i s \ i i ~ c l ~ill'!
~,J
by the S2 cut-out switch.
All three switches are force-wired on [hi. hoard for this lunctioi~.
If tlie standard cutdut switches are to hc directly integrated illto the s!\tern colltrid
the standard board can be replaced hy oiic of tlie optini1:il lboarrls .'I or N.1

4.2 PA and NA connection boards

On the PA and NA connection boards the standard cut-cut s\vitcllrs S l lIS21

S12/SZ? and S13123 are not force-wired iintl call he individually in~c.grnl~-cl
into tli',
system control.
The three contacts respectively of the swi~chesdesigned ns nltcmntors S l llS71.
S121S22 and S13123 on these v-hoards can be led out to coiin<ctinil tcrmin:~ls104s
and freely connected.
The switches of the optional board F.4 (standartl voltaye connectic>n ho:~rdi arc
designed for ratings of up to IOA. 250V AC.
The switches of the optional board NA (lo\+,voltage connectinn ho;~rd'I;Ire iicsirned
for ratings of up to 0.1A. 0-2OV (sold contacts).
The optional boards m y only be installed in the factory, since once tile ho:irils haye
heen installed the actuation points of !he load-depcndcnt twitches h:we to he re-
ad.justed.

Caution: When using optional boards P A and NA the owner must ensure by
individual connection that the motor of the actuator i s stopped
without a delay on actuation of the load-dependent cut-out s~r,itches
S I l I S 2 I and S121S22. This function is not facton-set Tor the optional
boards PA and NA!

1.2.1 .Adjusting the stantlard p a t h switch (S3):

If the actuator is supplied together with a valve, the standard p:11Ii su.itch I S ? ) is
already set to the valve stroke and the settin: spindle [or th? switch Si ( 1 1 ) is sealed
with screw sealing compound. This sctting docs not need tn he ch;~ngcilior nc)rnmal
operation.
When re-configuring the actuator for a t h r o ~ ~ evalve
h the pnth switch S3 must
be re-adjusted a s follows:

Step A: move the valve from thc hottom-most poition upwt1rd5 hy oili' YJIV?
stroke:

Step B: using a screwdriver, turn the r:etting spindle for \ \ i t c h S.7 ( I I ) until the
switch cam (6). coming from klo\v. actuates the switch (ati~lil~le click):

Step C: put the thrust briefly in the direction of closure and thcn I w l , into the
direction of opening and check that tlic actuator i \ c\sirch~~d n f i at the
desired point (nominal strokc):

Step D: adjust the setting 3 s dcscribcd. if neczssar!

When re-configuring the actuator for a 3-way vnlve the pat11 switch S3 lnr~sthe
re-adjusted a s follows:

Step A: put the valve in both end positions 2nd check at c:~chp(~si!irrn!11:1t illc v;llvi.
is switched off via the lo~d-tlepcndentx\r.itili:

Step B: check in the lop cnd position rh,it n1ii.r the actt~;~ti,rhas s\ritclied nlf 111s
switch cam (6) of the path switch 53 is k l o \ r the S.3 s\vitcli :inil h:15 i i o t
actuated it. If tile s ~ i t c l lcam ( 6 ) of tlic path switcll S is ~ l ~ o vthe
e $3
switch or has actuated it. the setting spindle for tlic pall1 b~litcliS 3 ( I 1 )
must be turned until the switch cam (6) of the path \ r i t c h SI i q h c l n ~rile
S3 switch and dcxs not actuate it;
Step C: put the actuator hack into both end positions and check at each position th:rt
the it is switched off via tile lo:~d-depentlc.iiti\vitcli:

Step D: adjust the setting as described. if nccess3y.

4.3 Potentiometer

The potentiometers a e used for electrical position reporting for the system control
unit or for the optional electronic positioner ESl l and the elsctrc~~iic positin11
indicator lUZ1.
.A maximum of 2 potentiometers can be installed (= I double potentiomcter).
The potentiometers can be supplied with various resistance values (se? technic;il
specifications). Special Ohm ratings can be supplied on requcit
Only 1000 Ohm potentiometers should be used for the electronic positioner ESI I
and the electronic position indicator RI21. The adjustment of lhe respective valve
stroke to the rotation angle of the potentiomcter is accomplishscl \,ia :I defined
translation for each valve stroke hetween the tootlied rack on the board c:tmer and
the pinion on the potentiometer shaft. Orily the pinion defined for the \,al\,e stroke is
to be used. If the actuator is supplied with a ijalvc and inst:illsd potentiometer, thi.
potentiometer is pre-set and ready for uq,:.

1.3.1 Installing the potentiometers

Proceed as follows for later installation of potention~eterr:

Step A: switch off the mains power and makc sure i t carinot ~~nintentiunally
switchcd hack on;

Stcp n: slacken the countersunk screw in the hood and carcfi~llylift offtlic hood:

Step C: put the flat plus of the green cahle of the potentiometer con~icctioncable on
the middle contact pin. the plug of the red cable on tile top contrtct pin and
the plug of the yellow cable on the hottom contact pin oftlie po!entiomcter
(Figure 6 ) ;

S t r p D: put the washer (3) on the potentiometsr (1)iFisure 71:

Step E: put the sliding block ( I ) (interior surfclcc of the lhoi: ill tlic dir~,crioriof th~.
circuit diagram) into the hoard c;trric,r:

Stcp F: insen the potentiometer (4) \\,it11 washcr ( 3 ) into thc slidi~ighlirh ( I ) from
hehind (surface of the potentiometer toward5 tlic circuil (li:igr:1111I.

Step G: tighten the potentiometer firinly (4) with a st;tr \vaslier I 0 ) ;iild Ii~,~:iron
nut
(7):

Step I*: put the pinion (8) (tooth nurnher accortlin; to tlic. v:ilve strokci wilh 111:.
toothed ring in front onto the potentiomcter shnft:

Step I: slide duo-clips (9) onto the potcntionletcr shaft. :ind (lying 3 rill!: spnn~irr
press firmly against the pinion 18)so that the pinion I S ) cnn o n l y h.2 turned
on the potentiometer shaft with i n c r ~ ~ s esffun
d (slip couplingl;
Step J: move the potentiometer unit in ihc sliding block entrance so that (I>? pinlor!
( 8 ) engages in the toothed rack of the switch c a r r i a ~ e :

Step K: ujith a valve Wokc up to 30 mm. hook the bar spring 121 into the I?h
window in the hoard carrier (I?) ahove the potentiometer guidc. po~ilionit
in the guide between the sliding block and the potentiometer guide an?
hook it into the notch below the potentiornetel-:

Step L: with a valve stroke 30-50 mm. the spiral sprinf ( 2 ) must k hoohcd in the
right window above the potentiometer guide:

Step M: check whether the pinion (8) is pressed hy the h3r spring ( 2 ) into the
toothed rack and lies against it withcut play;

Step N: if it does not, remove the sprinc, bend i t slightly and re-insen it ill tile sunlc
way;

Stcp 0:scrcw the socket panel of tlie c<:~nnection

cshle ( I 1 ) to the b u d c3rric.r i 171
using two self-tapping screws t i each:

Step P: fit the 3-pin additional plug (10) into the soc-kc.( p:lnel of the ci~nnrtcliorl
cable (11):

Step Q: adjust the potentiometer (sce next scctioni

Step R: refit the hood carelully on thc trrrnsmission and l';~s~en

it tiglitl\ to ihi:
actuator with tlie countersunk scrsw and rl~hbcrse:~lin: ~ i n c .

Potentiometer connection cable --

red 9reY

',\I
yellow
Figure 6
 Installation of potentiometer
~-

I- SIMhg blmk
2-!-rmng
--
3 Waaher DIN -10.5
4 Potemmeter
-
5 M-bpplng Daew
6-Sarwashnt
7 - k ~ n U l
8- P i n b
9 - Clrrdlps
-
10 3-pln p(ug
11 -Con- cable
12-Boadcsri!#
-
13 ciwn dieffam W e r

1.3.2 Adjusting the potentiometers

Proceed as follows to adjust thc potcntiomctcrs:

Stcp A: put the actuator into the closed position

Step H: switch off the mains power and makr sure it cannot r~nintcntii)~ialIy
he
switched back on:

Step C: using a screwdriver. turn the slotted porenriomrter shaft anticl~xkwiieuntil

i t reaches the stop. This puts the potcntiom2ter inlo [lie stan position 10
Ohm):

Step D: check the resistance value of tht potentiometer \vitll ;in ohrnnieler:

Step E: on potentiometer 1 the resis~anceniust he mcasurzcl hct\wen tennin;tls 25

and 26;

Step F: on potentiometer 2 t l ~ eresistance musi he rne3~trr~~ti

h c ~ \ \ ' e c nicrr?linals 7';
and 29:

Stcp G : the measured value in this actuntor position must 13-2 0 Olinl:

Stcp N:put the actuator into the top end position and rr:id 1 1 1 ~rzspccti\.e rcsistani~i.
value on the ohmmeter:
The resistance values mec~sured in this nay musl hi. taka1 into :iccoi~ril ~ ' 1 1 t : r l
:~d,justingthe system control unit.
Putting into operation

Warning: While in operation the actuator has moving and rotatin?

components and is connccted to an electrical circuit. Incorrect
operation and non-observance of the operating instructions a n d
s a f e 5 procedures may rcsult in serious i n j o n o r considerable
material damage!

Prior to commissioning a new system or re-using :In old (me :~fterrep;~irs:lnd

refitting work you must check:
that all installation and assembly work has heen propcrl! cornplcted.
that the system is electrically connccted as sct forth in tlic Dm VDE rules zan~l
those of the local power utility and that all safer! rep~lntionu;ire o!?scr\.?d.
that the h o d of the actuator is closc~l
that comniissioning work is only performed hy "C)ualified perionni.1
These procedures must be followed when cornn~issionin:: the system:

Step A: bring the actuacor roughly iriio ihe mid-stroke p i itsin!: 111- hnnd
\ctheel;

Step B: give short impulses lor each Jir~crionvf mov<mc.ilt or1 111s 8ciu:lrnr and
check that the directions of nlovcrncnt :ire correct. If 11rc.y :!re not. thc
impulse lines for openins and (:lasing in thrust c~pc~ariotl
rnmt I,? cli;tn&!?ti
round;

S t c p C : allow the actuator to m o \ r to [lie end position in cztclr Jircctiiln of

movement and check that it s\\,itches off :~ucomatic;!lly:~ndth:rt :III i.xtern:il
moving parts are able to move u:ithnr~t ohstn~ction:

S t e p D: if the system docs not opera[: correctly check all it~stall:~tionivork ;ind
adjustments. correcr i f ncccshilrq.. ;ttlcl yo t!~roi~rliI ! cotnmi?iiontrr?
procedure again.

Care and servicing

The actuator requires little servicing. ; t n i l no servicing is ncetlcd :)I rt1~~11:ir

tnllfr\,~I~
The actuator should be cleaned occ;iiionnlly tin rl~eoutside, depcricling iln lnc;~l
conditions. The actuator should not k cleaned \\.it11 high presstlrs squipn!cnr or with
dangerous. aggressive or easily inflammable s o l \ , e ~ ~ and t s cleansinr a:_.~:nts.Tlie
ser~ledpoints of the actuator should 1k cllrckcd during 2nd aftcr esch c l c ~ n ~ n c
session. The sealing elements require tiiaintenance il there is .in! iign ,>Icnicrgi~ir
lubricants or impuritirs entering the sycr8.m.
 Possible malfunctions

In t h e e v e n t of a malfunction. always c h c c k first that all installation a n d a d i u s t m e n t

w o r k h a s b e e n camed o u t i n a c c o r d a n c i ~w i t h t h e s e o p e r a t i n g instructions a n d that il
has been properly completed.
It s h o u l d a l s o he c h e c k e d w h e t h e r i h c p r e v a i l i n g c o n d i t i o n s ibr u s e c o r r e s p o n d w i t h
t h o s e g i v e n i n t h e technical specifications a n d tlie s p z c i f i c a t i o n plntr.
W h e n t r o u b l e s h o o t i n g , a l w a y s observe t h e safety r u l e s for the r e s p e c t i v e task
If a m a l f u n c t i o n c a n n o t he rectified u s i n g t h e i n f o r m a t i o n i v l o i v . 1!1e s y s t e m
s h o u l d he sent l o t h e m a n u f a c t u r e r or s u p p l i e r for r e p a i r s .

7 Trouble shootina- list I

Possible cause 1 Action i
Mans failure Find caosc nn,! rczrli? I
Fuse burned our
Actuator conneclcrl correctly
Replace iu\e
C'onnect acti~:itor:s\ \IIO.,VII in C I T C I I I Idingr:~m
I
S l ~ o ncircuit due to: Find C X ~ C ~I a ~ i \ e
- Moisture - 1w actuxtor ::nd I C Y I > ~ ~ ~ ~ l t ~ ~ l ! ~ : l c ~ ~
- \\'r~mg connccthon
Motor humed our
- Cr,nnucl acri8:ilor 33 ch<,\kn ariuit dlasmnl
Check thnt m a n < p n u ~ I,.r ~n Ilnc: iiilh that sivcn on
tl,c spec. plate
Rsnlace nioti,l
i
I
Plugs not properlv In sockct / ~ r i s ps ~ u g c ~ i r l nIn
l! xlc~ct\
I
:Actuator altema~-ihct~\ccii Motor condcnsator deicrtive Replace motor coni1en~:iIc~i

nntlclockwisc n,t:iiion
.\cru:~ior does nisi inow in
end p'sillonc :m! r.~ttle:
Actuator cuts 01;'
interrnjttently
Actuator su,itchc;l off in the
dlrecnon illopenlng hcforc
the lr,:~d-dspenclrn: c\vitch
17-wav valvei
-- 2
Load-depcndcnt cut~outru.itches 3rr Remove scru:::i>r :!rill \?nil ti? kl:lvr! !nr rcp:!tri.
oifsel/deicctive.
Pilwcr loss due to loo long pilwsr lines or lh!n Lay pnal-i lincs ivllh lhi, rrqll:rr-ii r:itlnpr
small line cross-section.
Power fluctilations outside thc coricrt thc 0hta111.'cIc;~n''p w r r )O\,LI: I I , ~ ?1h~Icr~nce
Ibnc
t o l e r m c ~line cro,s-section
/ Systempressure too hieh .- 8 Keducc svsleni presslire
1 Pou'cr line h s shxky contact Tlchlen ciinnccr:i7nxi s i ~ierrn~nzlpnncli
Path switch S3 is not properly adjortcd Ad~ustp:ith < i t itch S7 xs dcscnbr~li n ille r~pcral~ne
IO\LIIICII~II~
I

'Table 2
8 Information for repair work

If any tnalfunction on the actuator cannot be rectified as descrikd i n prc\-i[~uslytlle

:Ictuator should be dismantled and repaired.
Always specify the following information when making querics inr sending in ior
repairs:
Model number
Power voltage and frequency
Actuator features (options)
Serial number
Detailed description of ~iialfunction
Number of delivery note
Control valves, type 4701471

1 General

This type of control valve is suited to regulate fluids. gases and stcams. Tllc vnlvc
plug is normally a parabolic plug. hut can also be supplied in a prrforutcd design.
Both types of plugs can have either linear or equal percent;ige flow ch;tmcteristic.
The flow direction for parabolic plugs is always against the closing directio~l.
However, with perforated plugs for steam and gases. it is in the closing dirc?ction. If
a valve with a perforated plug is operated by means o f 3 pneumatic :Ictuator \vith the
flow in the closing direction. the pneumatic actuatc)r should liave a \trcon:cr thrust
force. This is necessary to prevent thumping near to the closins positicin.
,411 control valves can he fitted altern:hely with rnnnu;~l-.pnel~inntic-.clcct~~ic- or
hydraulic operation devices.

Illustration of control valves type 370 -

-
ant1
---
171

Figure 1
 Table 1

2 Operation

2.1 Fitting instructions

--.

The valve should he inserted so that the spindle has ;I vertical positiiorl tiyctlicr \vitli
the actuator. The valve can also be tiltid to a m:isiml~ni linri7.ont:~l posit1011if th,:
installation point does not allow any better conditic7n.
To guarantee 3 disturhance Cree function of the coritrrrl valic. 111~. inli'i .lnd outlet
stretches of the piping should be or str;ltght piping Icnyth 11nin. t\vo tir~v:~tlic pip:
diameter by inlet and six times by oiltlct). The pipins shnuld hc r i n s d to clear i i l t i
any pollution. welding beads, rust. etc. k f o r e inserting thc control v : ~ l \ c s .\ ,trainer
should be fitted in front of the control xalve to c:ttch rhe rc.-m:~iningpaniilcs. Bolts
should he tightened after taking into operation.
The flow direction is signalled by an arrow on the v;llve body Thc \;ri\*:i chould he
insulated against high temperature to p a r d the actuator.

2.2 Actuator assembly

--

The control valves are norni:illv delivered ivitli ;Icru:irilrs iilrc:~d\ lilted. For
al~crnationsor maintenance of actuator. the assembly should twcur in .riiordnnct
with the operation instructions lor the acTu:ltor.

2.3 Setting into operation

When the piping system is fillrd. tlre sp~ndlcseslii~fsl~ouldi l z i.lii.i.hi.ii i l ' r leahaye
and. if necessary, tightened. A H'FE-V-ring unit does not riyuir~,.III?tirliLrnini. .I.
the spnns tension maintains !lie necessary force
The bolts must he tightened yradually i r ~steps. din metric all^ i l l pair-. lhitt ri'd lielitcr
llinn it is necessary for t l ~ cscaling. F l a n ~ econnectio~lholts Ilould nevsr h.: loilscncd
or tiyhtened when the valve is under tenlperature irr pressure e \ c n ii :I ieLih;igem;iy
:rise.
For actuators please see to tlic appropri;rtc ;lctrlator ~ipcr:~tior~ in;tructii~rr\
Maintenance

Before any maintenance of the control valvr is camed out. the piping systcili musl
he shut off and pressure free.

3.1 Exchange of the stufi7 ng-box packing

4 leak stuffing-hox packing should initially he carefully tightened to stop the

leakage. If this does not help, a new layer should he inserted. or the complt~tc
packing should be replaced.

3.1.1 Additional packing layer

S t e p A: Open the valve fully and unscrcw the h e u s o n nut5 ( 1')

Step R: Lift the gland flange (7) and the spindle g,uiding ( 8 ) ~ipw'ards.

Step C : Insert adequate quantity of packins r i n ~ s(split rinr-displaceinerlt. ~ i i t t i i l r

at 180" to avoid overlappins).

Step D: Fix the hexagon nut? (17) properlv

3.1.2 Exchange

Step A: Drive the actuator into middle pocition and disrn3ntlr t h ~L.[~ % .,
i ~ 1 0 1

Step R: LJnscrcw the hexagon nut? (17) from the stud< (15)

Step C : Remove the gland f l a n ~ e(7). the cp~ndler u ~ d ~ t l g ' ~ n dthc old itltflinc
box (10) and clean the p3chtng iomoartmcnt

Step D: Clean the valve spindle and check for darnage and ii neccsslr) rcplace. I f
the damaged spindle is not replaced, the new packing will lcah '.I f 1 , ~- .I.1 si1olI
period.

Step E: Insert the new packing rings ~splicr i n ~ - d i s p l ; ~ c c . ms[?littii~'r

~ i ~ ~ . d r IS()' 1~2
avoid overlapping).

Step F: Fix the hexagon nuts (171propcrly

Note: Strenitous tightening will prevent leakage. hut \\ill also 11;1r-c a brake
effect on the spindle which aggravates tlle inor-ement o f the spindle.

3.2 Exchange of a PTFE-V-ring sealing unit

A PTFE-V-ring unit is spring loaded and ii:~s enough set pressure to zncurc :I gnoil
seal even by low operation pressures. It is replaced as riientioned aho\.r~
The PTFE-V-ring sealing unit should I x lubricated hcfore i t is insedcd. The sealin?
lips must face against the pressure direction.
Nnte: Special care should be given to the spindle sr~rface.Rouzh surface- \ r e a r
the sealing lips enormously ant1 can be due to failure of the p a r t i n g uuit.

3.3 Exchange of the bellow unit

--

Step A: Drive the actuator into middle position and dismantle tile actuator.

Step B: Unscrew the screw joint (7.1).

Step C: Unscrew the hexagon nuts (17) and remove the hc.llo\v tioucing 125).
Dismantle the plug as described in the next section.

Step D: Unscrew the hexagon nuts (17.1) 2nd dismantle thi. ~ i i a u n ~ i bnnnst
nr 13.1).

Stcp E: The hellow unit (26) is removed from the bello\v iiousinc I 2 5 ) .

Stcp F: Replace the twogasketr (14 I ) ,ind tlie casket (1 1)

Step G : When the bellow unit (26) is replaced. the proptr p~isitioncji tlie ailti-
twisting device must he observed.

Step H: The set pins (21) have to drive within the slots of the :inti-t\\istini: device.
Check for frictiori-free movemerit.

Step I: Replace mounting bonnet (3.1 I and scre\v di>wn rhc hex:icon nuls i I 7 11
crosswise.

3.4 Exchange of the plug-spindle unit

Stcp A: Drive the actuator into middle position and dismantle tile nctll:itor

Stcp R: Unscrew the gland flange (7)

3.1.2 Control valve type 470

Stcp :\: Unscrew the hexagon nuts (17) :lnd ~lisrnantlethe rnol~l~tin:hi>niieti ~?i.

Stcp B: Pull out the plug with the spindle :and escliange [his l i n t [

Step C: Remove the spring-type strairht pin ( l q ) and unscrctv !hi. hpindlc If11

Stcp D: Replace the old pans and assemhlc i~

Step E: Drill a hole through the plug rli:~ftand ln.;ert :I new pln

Step F: Replace the gasket (14) and asscnibli: the lnountinf ho111i~~t
( 3I

Step G : Tighten the nuts (17) evenly, crorswisc

3.4.3 Control valve type 471

Step A: Unscrew the hexagon nut5 ( 1 7 \ and d~qrnantlethe hello\\ hou<~ng( 7 5 ) ~ ~ t h

plus ( 5 ) .

Step B: Drive the spindle in the bottom position and remove the spriris-type straighl
pin i 19).

Step C: Unscrew the plug.

Step D: Screw a new plug at the spindle and drill through the shaft. Dnvc the
spring-type straight pin (19) into the hole.

Step E: Replace the gasket (14)

Step F: Assemble the bellow housin: 125)with plug (i) together ivitli the hod? I l i
and fix it by screwing the hexayon nuts (17) c r o s r \ ~ ~ i s ~ .
The spindle can only he completely replaced t o e t h e r i\,ith thi. helloiv.

3.5 Changing the seat ring

The seat ring is screwed into the valve body. The seat ring can he nl>t;~int.d;afisr
removinz the bonnet and can then he refinished or replaced as requirecl.
Step A: Clean and lubricate the tluead and conical sealing surF~cehefnrc inserlicln.
 Table of contents

iignition burner pump

- -

Ignition burner pump

Data sheet

Data sheets for pump .......................................................................................... 1

Ignition burner pump

1 Description

The ignition burner pump supplies the ignition burner upitlidiesel oil. The pump is
operated by the control system or the manual operating system. The ignition burner
pump is only in operation during the ignition sequence. An illustration of the
isnition burner pump is shown in Figurs 1.

Illustration of the ienition b u r n e r pump

6 Hall ualrs

I
I
p~

Figure 1 il:nibup.cclr

1.1 Function

When the pump is started, oil is drawn tllroueh the suction side porl "S" via the filtcr
"H" to the suction side of the gearwheel set "C" as shown ill Figurr 2. Thc
eeanvheel set pumps the oil to ihe pressure side.
L
The pressurised oil is led to the cut-off and regulatin~valve "\'". \'?hen the opening
set point is reached, the valve "C" opens. Hereby oil is distriliri~eclI I I r l ~ nozzle
t port
"P"and to the pump return side " R via the shaft seal " F .
The pressure is controlled and maintained at a constant level h! tile regulating valve
"V". The opening set point can be adjusted by means of an Allen key.
The quantity of oil supplied to the nozzle port " P is determined by the pressure set
on the regulating valve "V" and the resistance in the nozzle line and the oil nozzle.
When the pump is stopped. the pump output drops and produces a drop in the oil
pressure. The spring in the regulating valve presses the regulatinp piston forward
until it seats in port " P . This cuts the oil flow to the nozzle and ensures that the line
is effectively shut off.

Sketch of the oil pump system

Figure 2 icnil)upl.tif

If the pump is overloaded, i.e. more oil is demanded than ihc pcar~x'hcclis able to
pump under the given conditions, the oil pressure falls below [he sct value because
the regulating valve piston moves towards its closed positioi~; ~ n dp;lni;llly or \vholly
cuts off the return oil via port "O".
This condition can be renledied by:
Reducing the pump pressure
Reducing the capacity, i.e. sinaller oil nozzle or litrczr i-zsist;~il~i
Changing to a pump with higher capacity
1.2 Commissioning

When the pump is co~nmissioned,the pump and the pipe system must be filled with
oil and ventilated. The pump can be ventilated on the ventilating screw "M'. If thc
pump is running without oil for more than five minutes, it may catlse dani;~:e to the
Pump.
1.3 Pipe systems

One pipe system is used when the pump is placed lower chan tank level (positive
suction head).
Two pipe system is used when the pump is placed hisher than tank level (negative
suction head).
In two-pipe systems the oil is returned direct to the oil tank. In one-pipe systems thr
setting screw " A must be removed to give free flow to the suctio~iside via by-pass
" G with return port " R closed.
Normally the pump is delivered as a onc-pips system.
The pump is delivered with two suction ports and two return ports.