PLAN RECORD REVISIONS ap- | CHECK- proven | ED SO wena soe naews [no DESCRIPTION (DATE) S Changed ship number from H.323 to H.105 a ~| AN (June. 29, 2004 K.M.) ee Be n=) S S S i S zs g 5 eo c[k 2 0 5 fob RPO Ez hae i TLE Ad x16 ABR x2 129 SHEET (S) WITH COVER cwowwnivenacan cesiover | TZAR PUERTOREAL H.105 /\ ‘APPROVED _F. Shimode MAIN BOILER (MB-4E) T.Yuki : ee ‘cHEcKeD LUchida BOILER INSTRUCTION AND praww —_K.Matsushita MAINTENAI JAL (I) CONFERRED/ SCALE ~ ‘ORDER Trew | DRAWING NO. RENN. FIS18 97000 97000-0006 (1) A ae MITSUBISHI HEAVY INDUSTRIES, LTD. NAGASAKI SHIPYARD & MACHINERY WORKS DRAWN Jun. 11,2002 ISSUEDMAIN BOILERS OPERATION AND MAINTENANCE INSTRUCTIONS FOR IZAR CONSTRCCIONES NAVALES, S.A. H.NO. 105 NAGASAKI SHIPYARD & MACHINERY WORKS MITSUBISHI HEAVY INDUSTRIES, LTD NAGASAKI JAPAN MI su BISHI HEAVY INDUSTRIES, LTD.A. INTRODUCTION 4 Principle Part 5 Outline of Main Boiler & Accessories 6 Boiler Accessories 10 Design Data W Performance Data 13 Performance Curve 1s Outline of Operation 2 Data for Operation 25 Outline of Maintenance 35 Check Point List 38 Condition of the Emergency Fuel Oil and Gas Cut 39 B, OPERATING PROCEDURE 40 Preparing for Service 41 Starting a Boiler from Dead Ship Conditions 44 Lighting up and Raising Pressure 47 Scouring a Boiler 56 Method for Cutting-In Another Boiler ST Operation of Stand-By Forced Draft Fan 60 I-Boiler Operation 61 Emergency Operation 62 Trouble Shooting 63 ©. GENERAL MAINTENANCE 65 Feed Water & Boiler Water Treatment 66 Low pH Treatment of Boiler & Feed Water 66 Limiting Values of Feed Water and Boiler Water 67 Explanation of Boiler Water Treatment and Its Limiting Values 68 Decision of Dosage B Measures to be taken when the Relation between pH Value of Boiler Water and Phosphate Ion Concentration becomes Deviating Off from the Theoretical Curve 75 Feed Water Treating B MI su BISHI HEAVY INDUSTRIES, LTD.Boiler Water Concentration and Blowing B Caution in Water Quality Measurement 81 Care of Boilers Out of Service 83 Hydrostatic Tes 86 Boiling Out 87 Water Washing Fireside 89 Acid Cleaning 90 Mechanical Waterside Cleaning 92 D. MAINTENANCE AND REPAIR OF BOILER PARTS 93 Maintenance of Refractory 94 Boiler and Water Wall Tube 7 Superheater lol Desuperheater 106 Steam Temperature Control System 106 Economizer 109 Use of Tube Expanders 10 Expander List ul Miscellaneous Boiler Parts 4 Attachment Arrangement of Boiler Mountings 116 Arrangement of Main Boiler 118 Arrangement of Superheater 19 Main Boiler General Piping 120 Diagram of Feed Water Piping 121 Diagram of Boiler Mountings 122 Diagram of Burner Piping 123 Diagram of Soot Blower Steam Piping 124 Diagram of Air and Gas Duct 125 Diagram of F.0. Pump and Heater 126 Diagram of Chemical and Sampling Pipe 127 Diagram of Dumping Desuperheater 128 Diagram of Seal Air 129 MI su BISHI HEAVY INDUSTRIES, LTD.A. INTRODUCTION MITSUBISHI HEAVY INDUSTRIES, LTD,PRINCIPLE PART Econmizer 4 Saturated __-Steam Air Heater Stean Pipe 7 I \ Steam Drum i Burner I / ™. i i 7 : see Hi\ MW \\\\\ Vimy TT 1 Voll fil eal [NO ZA "|. Superheater fear Bank Tube Long Retractable Soot Blower a Water Orun_- MITSUBISHI HEAVY INDUSTRIES, LTD.ae OUTLI OF MA BO R_& ACCESSORIES ts of two drum water tube “MITSUBISHI MB-4E” type marine boiler with oil and gas combination burners located in the furnace roof. The unit i composed of a steam drum and a water drum connected by a bank of inclined generating tubes. Other water side components include : front screen tubes shielding the superheater elements from direct radiant heat of the furnace, side and roof water wall, front and rear water wall tubes, down-commers, bottom headers, roof and bottom front wall headers, roof and bottom rear wall headers, and front ted ight envelop three side of the furnace. A supetheater, an internal desuperheater, a superheated steam and rear wall riser pipe. Each tube in the furnace floor, side & roof, front and rear wall are j to the adjacent tube by welding. In this welded wall construction, the tubes form a gas- control desuperheater, the economizer, steam air heater, and casing include the remaining principal components of construction. Since the combination burners are located in the furnace roof, the gas flow from the furnace is evenly distributed across the front bank, superheater, and generating banks, discharging through the economizer located at the uptake of boiler. DRUM INTERNALS Steam drum intemals consists of desuperheater, surface blow line, internal feed pipe, chemical feed line, baffles and dry box. Steam generated in the boiler tubes enters the steam drum, where it is forced to pass through a baffle located at the normal water level before entering the upper part of the steam drum, Before leaving the boiler through the outlet nozzle, the steam must pass through the dry box located at the top of the drum. A submerged type desuperheater located below the water level in the steam drum provides reduced temperature auxiliary steam. Since the desuperheater receives its steam supplied from the superheater outlet, a positive flow of steam is maintained through the supetheater at all times regardless of the demand for superheated steam. The superheater steam temperature control system incorporates a submerged type desuperheater located in the water drum to maintain normal steam temperature when the boiler is operated in excess of normal rating and, when necessary, to reduce the steam temperature at all ratings. Manholes fitted with hinged manhole covers are provided in the front head of the steam drum and water drum, The hinges allow the manhole covers to swing into the drum clear of the manhole. MITSUBISHI HEAVY INDUSTRIES, LTD,ae FURNACE Water cooled walls are provided by lining the furnace side, floor and roof with a single row of 63.5 mm tubes, and front and rear with a single row of 50.8 mm tubes. External down commers provide ample circulation to water drum, bottom header and front & rear water wall headers. The water cooled floor consists of 63.5 mm tubes traversing the furnace floor from the bottom header, then bending to form the furnace side and roof, which terminates in the steam drum, Furnace front and rear wall tubes arranged from the lower to the upper water wall headers cover front and rear furnace walls, Upper front and rear water wall headers are connected to the steam drum by 1 pipe, Because water wall tubes are jointed to their adjacent tubes in a welded wall construction, they form a gas tight envelops lining the furnace. Where openings are required for burners, access doors and soot blowers, they have been formed by bending tubes back and to the side to form the opening and then back to their original plane to continue the welded wall construction, The furnace water wall tubes are backed up by insulation buck-stays and a corrugated casing, SADDLES Saddles are provided under the water drum and the front & rear water wall headers to support the weight of the boiler. Rear saddle under the water drum is fixed and the front saddle has slotted bolt holes, grooves and grease fittings to allow easy movement and lubrication. Grease fittings are provided on both front and rear saddle of water wall header. The grooved saddles are free to slide to allow for expansion of the boiler as it is warmed up. The sliding feet should be inspected and cleaned as frequently as possible and should be greased at least each 600 boiler steaming hours. This procedure is extremely important and should be followed without failure, There are cases on record where pressure parts have failed because the sliding saddles and frozen in place, preventing movement required during normal expansion. SUPERHEATER ‘The superheater is of the vertical, interbank, convection type arranged for multipass steam flow Superheater elements are arranged in groups of six concentric hair pin loop elements, the ends of which are welded into the inlet-outlet headers and intermediate headers. The arrangement of elements is such that the superheater tubes are parallel to the boiler generating tubes, Guide castings welded to the superheater elements and two inch generating and screen tubes form a sliding joint which aids in tube alignment. The superheater inlet, outlet and intermediate header run parallel to the water drum through the depth of the boiler. Each header is sectioned internally by welded steel diaphragms to direct the steam through five consecutive passes between the headers. Complete drainage is provided by a small opening in the lower edge of plates allow access for inspecting and cleaning the superheater internally MITSUBISHI HEAVY INDUSTRIES, LTD,ECONOM! An extended surface type economizer is placed above the boiler tube bank. The economizer is made up of closely spaced continuous loop elements, which is welded to the terminal headers at both ends. Each element shall be of 50.8 mm tubes straight carbon steel tubes with spiral steel fin, connected by U-bends forming integral loop. All elements are supported at the front and rear side by tube plates. On the outside of the terminal headers, handholes with covers are provided. Insulated steel casings are provided around the economizer and large removable panels are fitted on the front and rear side for access and tube removal. Feedwater enters the inlet header at the top and flows through the elements counterflowing to the gas leaving the boiler, to the lower header, thence to the boiler steam drum BOIL ACCESSORIES Boiler accessories are listed on this section later with the manufacture’s name and identifying data, See instruction books of those accessories for detailed description. Following is the outlines: (1) Steam Air Heater The boiler has a steam air heater to heat combustion air by steam (2) Oil / Gas Combination Burner The boiler is equipped with three (3) sets of fuel oil and gas combination burners on the roof wall of the furnace, The fuel combination bumer is of steam assisted pressure jet type, consisting of atomizer gun, forced draft distributed to each burner from a burner manifold by branch connect register with fuel shut off valve, The fuel is n pipe. The oper: of increasing or decreasing the number of the burners is automatically operated by the automatic combustion control signal, and remotely operated by the push button when necessary. (3) Automatic Combustion Control “MADIC” electronic automatic combustion control equipment is installed for the boiler. The combustion control system regulates the fuel and air supply to the boiler so as to maintain steam pressure at the superheater outlet within predetermined limits. Combustion air supply is controlled automatically by actuating the inlet vane of forced draft fan. Fuel oil and gas fuel oil and supply is also controlled automatically by means of regulating valve locate ‘gas supply line, In case of control air supply failure, the regulating valves in the fuel oil supply is locked, while the air regulating vanes opened. 4 Superheated Steam Temperature Control The superheated steam temperature control system is provided to m the superheated steam temperature at less than 515°C. at the boiler load approaches normal steaming capacity and overload capacity. The steam is comprised of the superheater, a control desuperheater, at remote, pneumatically controlled valves, the control system for the valves, and the necessary connecting piping. A part of the steam leaving the four pass of the superheater is directed to MITSUBISHI HEAVY INDUSTRIES, LTD,ae the temperature control desuperheater, and lowered its temperature, mixed with the steam flowing the by-pass line, thence enters the five pass of the superheater. The steam flow to the control desuperheater is controlled with the air operated control valve. (5) Feed Water Regulator “MADIC” three-element type feed water regulator is equipped. The regulator is composed of differential pressure type water level sensing device, steam flow sensing device, auto-manual selector switch and feed water regulating valve. The feed water flow is controlled automatically by the regulating valve is accordance with the variation of water level in the boiler drum and steam flow at the superheater outlet to maintain the water level constant. The water flow can be also adjusted manually and independently. In case of control air supply failure, the regulating valve is locked (6) Soot Blower The boiler is equipped with soot blower system of steam nozzle tube type. The type and number of soot blowers are as follows: Position No. Type Superheater One (1) Long retractable Boiler bank tube Two (2) Stationary rotary Economizer Four (4) Stationary rotary Soot blower of long retractable and stationary rotary is driven by electric motor. Blowing medium of all these blowers is desuperheated steam. All soot blowers are automatically and sequentially operated from the soot blower operating panel at control room. MITSUBISHI HEAVY INDUSTRIES, LTD,BOILER ACCESSO) Equipment Manufacturer (1) [Steam Air Heater Dong Hwa Precision Ind. Co., Ltd. (2) |Oil / Gas Combination Burner Hamworthy Combustion Engineering Ltd. (3) |Safety & Relief Valve for BLR Fukui Seisakusho Co., Ltd (4) |Safety & Relief Valve for ECO Fukui Seisakusho Co., Ltd (5) |Soot Blower ‘Kikan Buhin MFG, Co., Ltd. (6) |Water Level Gauge Sawada Seisakusho Co., Ltd. (7) |Feed Water Motor Valve (Osaka Valve Co., Ltd. (8) |O2 Meter INGK Insulators, Ltd. (9) |Swing Check Valve Mitsumoto Valve Mfg Co., Ltd. (10) Piston Valve Konan Valve Co,, Ltd. INakakita Seisakusyo Co., Ltd (11) [Butterfly Valve NBS Co., Ltd, (12) |Forced Draft Fan ABB Solyvent-Ventec (13) |Fuel Oil Pump [Kosaka Laboratory Ltd. (14) [Fuel Oil Heater |Aalborg Industries KK (15) |Smoke Indicator ‘Shonan Kosakusho Co., Ltd. (16) |BLR Water Amine Injec. Equip Sakura Seisakusho, Ltd. (17) |Feed Water Hydrazine Injec. Equip. {Sakura Seisakusho, Ltd. (18) [Water Analysis Unit DKK.TOA Corporation (19) |Seal Air Fan |Azuma Sofuki Co., Ltd. (20) |Gas Content Sensor \Yamatake Co., Ltd (21) |Extemal Desupetheater Spray Nippon Keystone Corporation (22) |Air Duct Damper ‘Samwon Environment & Blower Co., Ltd. (23) | Viscosity. Meter Nakakita Seisakusyo Co., Ltd. (24) |F.O. Strainer INiikura Kogyo Co., Ltd. (25) |F.O. Flow Meter Nitto Seiko Co,, Ltd. (26) |F.O. Leak Flow Switch Sankyo Seisakusyo Co., Ltd. (27) Salinity Meter 3A Rika Co., Ltd MITSUBISHI HEAVY INDUSTRIES, LTD,PRESSURES (kg/cm?) Design’ Operating (Supetheater Outlet) « Hydrostatic Test (Maximum) « Safety Valve Settings: Steam Drum: ‘Superheater- Economizer TEMPERATURE (C. Steam at Normal rating Feed Water at Normal rating: Steam Air Heater Inlet Ai Steam Air heater Outlet Air at Normal rating ~ EVAPORATION (kg/h) ‘Normal rating ~ Maximum Capacity FURNACE VOLUME (m*, HEATING SURFACE (m’) 78.0 17.0 78 & 775 50,000 65,000 47.5 Total Cold Water to Fill Unit Completely Cold Water to Fill Boiler to Normal Level Cold Water Fill Superheater: Cold Water Fill Economizer Boiler, Dry, Complete with Burners and Soot Blower Economizer, Dry, Complete with fittings Boiler Water, Steaming Condition Economizer Water, Operating Condition-~ Total One Boiler, Steaming Conditios Total One Economizer, Operating Condition MITSUBISHI HEAVY INDUSTRIES, LTD, 30,110 120 970 40,900 37,900 14,404 2,767 55,304 40,667TUBE DATA (mm) ae Location Quantity | Diameter_| Thickness Rear Bank Tubes 1,610 38.1 32 Supetheater Support Tubes 40 50.8 45 Roof, Side & Floor Water Wall Tubes 57 63.5 55 Front Water Wall Tubes 2 50.8 45 Rear Water Wall Tubes 2 50.8 4s Front Bank Tubes 80 54.0 45 ‘Supetheater Element #1 35 38.1 45 Supetheater Element #2 35 38.1 45 Supetheater Element #3 SI 38.1 55 Supetheater Element #4 sl 38.1 55 Superheater Element #5 39 38.1 55 Superheater Element #6 39 38.1 55 Desuperheater Element 10 38.1 40 Control Desuperheater Element 12 38.1 40 MITSUBISHI HEAVY INDUSTRIES, LTD. 12PERFORMANCE DATA 2000-11 10 Main Boiler For BAZAN/AESA ENAGAS Boiler Type MB4E Oil. Firing Load Max | MCR | 100% ] 75% | 50% | 25% Nor, SH Steam kg/h] 63.000] 55.300] 49.000] 36.000] 24.000] 12.500) Evaporation DSH Steam kwh | 2.000| 1.000| 1.000 1.000] 1.000] 1.009] Total kwh __| 65.000] 56.300| 50.000] 37,000] 25.000|_13.s00] Steam Press. [Drum kwem'g] 69.7] 67.7] 66.5 64.4] 63] 62.1 ISH Outlet kyem’g] O18] 61.8) 618) os) 61s] 618 Eco Inlet A] 138] 138) 138] 138) 138] 138 Feed Water SH Inlet c 2ed] 282] ei] 279] 277] 277] Steam Temp. ISH Outlet c 515) S15 515] a5 Sul 471 DSH Outlet c 2oi| 287] 287] 287] 287] 287] Efficiency (HV Base) % 88.7] 88.7) 88.6) KI] 86.2 Caloritie HH keavke | 10.280] 10.280] 10,280| 10.280] 10.280| 10.280] Value LHV keavke | 9.713] 9.713] 9.713) 9.713] 9.713] 9.713 Fuel Consumption kg/h 4733| 4104] 3641] 2691] 1802] 9609] Excess Air Rate % 0) 10) lol 12s] 19.2 36] 02 Rate % [ee | |) Combution Air Flow keh | 71390] 61900] 54920) _41s10|_ 29450] _ 17900) Flue Gas Flow kesh | 76123] 66004] $8561) 44201 18860) Eco Outlet Gas Temp. c 176,171} _167|_ 60] 156] 8 Air Temp. FDF Outlet c 40) 40} 40 40} 40 40 SAH Outh c 120} 120) Tot mmAgPERFORMANCE DATA 20001110 Main Boiler For BAZAN/AESA Boiler Type MBE Gas Firing Nz: 0 Vol% CH: 100 Vol% Load Max | MCR | 100% | 75% | 50% | 25% Nor. SH Steam kesh] 63,000] 55.300] 49,000] 36,000] 24,000] 12,500] Evaporation keh] 2,000] 1,000 1.000] 1.000] 1,000] 1,000] kw/h__| 65,000] 36,300} 50,000] 37.000] 25,000] 13.500] Steam Press. [Drum 69.7| 67.7| 06.5] 644] 63] 62.1 SH Outlet 618] 618] G18] OLRL 618] 1} ECO Inlet °C iss] 138) 138] 138} 13s} 13s Feed Water SHI Inlet °C 284] 282] 21] 279277277] Steam ‘Temp. — [St Outlet °C. Sis| 515 515 508 DSH Outlet °C 291} 287] 287] 287] 287] 287] Efficiency (HHV Base) % 84.0) 84.2] 84.2] B41] 83.6) 81.7] Caloritie HV, kealiky | 13,270] 13.270| 13.270] 13.270] 13.270| 13.270} ‘alue LuV keal/ky | 11,950] 11,950] 11,950] 11,950] 11,980|_11.950] Fuel Consumption kg/h 3866] 3352| 2974/2198] 1489] 809] Excess Air Rate % | 10 Jo Jo ts} 19.2) 36 }O2 Rate % 19] 1.9 19 23 3.4] 5.0) |Combution Air Flow kg/h 73170] 63440] $6290} 42550] 30540} 18930] Flue Gas Flow kwh | 77036] 66792] S926 a4748| 32029] 19739) Eco Outlet Gas ‘Temp. °C 179| 173] 170} 163 159] 185] Air Temp. FDE Outlet c [ 40} 40 40 40 40] 40] SAH Outlet °c 120) 120] 120) 120) 120] 120] Votal Draft Loss mmag 497]__373] 294) 168} 87 33EXPECTED PERFORMANCE CURVE (OIL FIRING) 88.0 87.0 86.0 (og) Souaiouyya 29110 70.000 60,000 20,000 30,000 40,000 Evaporation (kg/h) 10,000 0 20,000 30,000 40.000 $0,000 60.000 70.000 10,000 0 Evaporation (kg/h)EXPECTED PERFORMANCE CURVE (OIL FIRING) ay) aunssoid WuedIS 70.000 60,000 50.000 (SUPERHEATER OUTLET: | 40,000 20,000 30,000 Evaporation (kg/h) 10,000 9 (9,) aumesaduia , wears 3 1300,4) 60,000 70,000 50,000 40.000, Evaporation (keh) 30,000 20,000 10,000 0EXPECTED PERFORMANCE CURVE (OIL FIRING) 50,000 60,000 70,000 40,000 (byway) sso] ye 20,000 30,000 40,000 30,000 60,000 70,000 Evaporation (kg/h) 10,000 0EXPECTED PERFORMANCE CURVE (GAS FIRING) 82.0 10,000 20,000 30,000 40,000 50,000 60.000 70.000 0 Evaporation (kg/h) (wy) uondwinsuo:9 HO [20d 30,000 40,000 50,000 60,000 70,000 Evaporation (kg/h) 20,000 10,000EXPECTED PERFORMANCE CURVE (GAS FIRING) (wo /ay) ainssorg tues 40,000 $0,000 60,000 70.000) 30,000 0.000 2 10,000 0 Evaporation (kg/h) TT : WATER INLET) || | FRED 20,000 30,000 40,000 50,000 40,000 70.000 Evaporation (kg/h) 10,000 070,000 gS Etrpre eg Seer creer eee een eee] z fens mai w 2 Pea aa PT EU CO | > s ae ere cere eee cee eee eect x eee liter tee Se . 2D eH EE

1. Ifitis necessary to start a boiler from dead ship conditions with neither shore power nor shore steam available, diesel oil may be used until steam has been raised enough to heat the bunker fuel. 2. Fill the boiler with deaerated water from a deaerator if at all possible. The feed tanks should be filled with condensate before securing the boilers to provide the water necessary for restarting, It is advisable to fill the boiler S0~80 mm above the normal water level to provide an additional storage until the feed pump can be started 3. Start the emergency diesel generator, and blow out the gas remaining in the furnace using the forced draft fan at low speed before lighting up the burner. 4. Prepare the boiler for service as outlined under the normal starting procedure Line up the emergency fuel oil pump to take suction from the diesel oil tank and to discharge to the burner manifold. 6. Start pumping diesel oil, bleed off enough through the recirculating line, or through the ‘bumer oil lead into a bucket to remove all heavy oil from the piping 7. The diesel fuel oil must to supplied to the bumers at designated oil pressure in order to obtain proper atomization 8. Open the following valves before lighting up. (1) Drum air vent valve (49B, SOB) (2) Superheater header drain valves (72B, 76B, 77B, 78B) (3) Starting valves (73B, 74B) (4) Control desuperheater drain valves (135B, 136B, 137B, 138B) 9. Light on a burner with air atomizing, Fuel oil pressure is 3.0 kg/cm? (Combustion rate is 250 kg/h), 10, When steam pressure is up to, 1.0 kg/cm? close drum air vent valve. In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line. 11, If completely drain, close the superheater header drain valves and control desuperheater drain valves. 12, After a drum pressure 2.0 kg/cm? has been reached, start warming up the auxiliary steam lines. Line up steam to the settling tank coils. Line up feed pump and have it ready for service when needed. The starting valve must be left open until the boiler has been cut in on the load 13. As soon as the fuel oil in the settling tank is warm enough to pump, prepare to change from diesel fuel to bunker fuel. Line up steam on the fuel oil heaters. 14, Secure the bumer, Circulate bunker fuel through the fuel oil heaters and piping until oil at the MIs BISHI HEAVY INDUSTRIES, LTD.15. 16 17. 18, 19, 20. 2 22, Note) ae proper temperature is available in the manifold, Relight the burner, normal conditions, and continue raising pressure as outlined under normal condition. When steam pressure is up to 10~15 kg/cm? start warming up the feed water pump, main ‘generator and other machineries After a drum pressure 15 kg/em? has been reached, change atomizing fluid from air to steam 1g pressure at 4.5 kg/cm? of fuel oil pressure as outlined under normal condition. Start the feed pump, as early as possible. After starting the feed pump, close starting valve. Start the main generator. When the generator is up to speed and capable of carrying a load, switch over to generator and secure the diesel generator Drain and warm up connecting piping to the main and auxiliary steam lines. It is essential that the connecting steam piping is clear of all water and warmed up to approximately operating temperature before cutting the boiler in on the load ‘When the steam pressure is about 3~4 kg/cm? below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply. Set up the burners with the proper sprayer plates for the service required, lighting up as necessary. 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to supetheater tubes, combustion rate should not be increased excessively. 2. When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve MIs BISHI HEAVY INDUSTRIES, LTD.| | 3| 3 Bi Z| gi a SI zy s a sI Cold Start (In case the other boiler is not used.) Note: 1. Combustion rate should be used as a guide for | yowwouoT we oMp LEIS, Sunseys ot Kp 950] puw ourqimy dund soe poay om) HEI Sp ‘ssid “Q'y aster pur 9/84, > Du OF JasaIp Woy Ho Jon} dsuyD) ‘ayvoy [0 fony 0} weais 1. Check the water level in the steam drum, When the water level gauge is lined up properly the water level will drop when the drain valve is opened, then retum to its original level when the drain valve is closed 2. Start the forced draft fan, open the damper and the bumer air slide door and ventilate the furnace thoroughly for at least five minutes before lighting up 3. Operate the steam air heater simultaneously with forced draft fan. Circulate fuel oil through the fuel oil heaters and the burner manifold, A re-circulating valve on the manifold and a re-circulating line to the service pump suction is provided for this purpose By-pass fuel oil meter until ready to light on When the fuel oil in the burner manifold is at the correct temperature, insert an atomizer assembled with a lighting-up sprayer plate in burner. Close the air registers of the other burners. 6. Reduce the forced draft pressure at the bumers to 10~20 mmAgq, Close the re-cireulating valve and see that the proper fuel oil pressure is available in the burner manifold 7. Light up the bumer following the instructions outlined in the bumer section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned. It is important that no unburned oil is sprayed into the furnace and that no heavy smoke is produced Frequently observe the smoke indicator and the burner flame, especially after making any change in firing rate or in forced draft pressure. 8. When steam pressure is up to 1.0 kg/m”, close drum air vent valve. In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line 9. Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork. Firing rate should be less than 250 kg/h by using the normal atomizer sprayer plate until the pressure of 5.0 kg/em? has been reached. Then fire the boiler at a rate which will raise the steam pressure in accordance with pressure raising curve, It takes at least 2~3 hours to raise steam pressure to about 5.0 kg/em?, Do not raise steam pressure too quickly. Tum the burner on/off if necessary 10, Close the valve on the steam pressure gauge and bleed the steam gauge line to be sure it is clear. Allow the line to cool for a few minutes before opening the pressure gauge valve. See that the gauge responds immediately as the valve is opened. 11. Check the water level again by opening the water gauge drain, nothing if the level drops immediately when the drain valve is opened ant returns to the original level as the valve is closed MIs BISHI HEAVY INDUSTRIES, LTD.ae 12, Drain and warm up connecting piping to the main and auxiliary steam lines. It is e: 1g temperature before cutting the boiler in on the load. ial that the connecting steam pi clear of all water and warmed up to approximately operating 13. When the steam pressure is about 3.0~4.0 kg/cm’ below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply. 14, Since the economizer is installed it may be found that steam will from in the tubes causing a water hammer. In this case run in enough feed water to lower the economizer temperature ight in the gauges. Never open Blow down the boiler if necessary to keep the water level in s water wall header drain valves unless the bumers are secured, 15, When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load, Close superheater outlet starting valve. Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation is to be used make sure regulators are working properly. 16, Set up the burners with the proper sprayer plates for the service required, lighting up as necessary. Operating procedure of each boiler condition shall be as follows, (1) Boiler Cold Start (In case the other boiler is normal used.) < Refer to “Boiler Start Up Procedure -2 > 1. _ Prepare the boiler for service as outlined under the normal starting procedure Start the forced draft fan, ventilate the fumace thoroughly before lighting up Circulate bunker fuel through the fuel oil heaters and piping until oil at the proper temperature is available in the manifold 4, Open the following valves before lighting up. (1) Drum air vent valve (2) Superheater header drain valves (3) Starting valves (4) Starting valve outlet drain valves (5) Control desuperheater drain valves (6) Steam temperature control valve Light up the burner at 3.0 kg/em? of fuel oil pressure (Combustion rate is 250 kg/h) When steam pressure is up to 1.0 kg/cm’, close drum air vent valve. In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line. 7. If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desuperheater drain valves. MIs BISHI HEAVY INDUSTRIES, LTD. 4810. u ae Then steam pressure shall be raise in accordance with pressure raising curve. Drain and warm up connecting piping to the main and auxiliary steam lines. It is essential that the connecting steam piping is clear of all water and warmed up to approximately operating temperature before cutting the boiler in on the load. When the steam pressure is about 3.0~4.0 kg/cm’ below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply. When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load. Close superheater outlet starting valve. Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation is to be used make sure regulators are working properly. Set up the burners with the proper sprayer plates for the service required, lighting up as necessary. Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively. 2. When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve At two-boiler operation, make sure to keep the starting valve open until the boiler under pressure raising takes on load (2) Boiler Hot Start (In case the other boiler is not used. < Refer to “Boiler Start Up Procedure -3 > 1 Check the water level in the steam drum, When the water level gauge is lined up properly the water level will drop when the drain valve is opened, then return to its original level when the drain valve is closed Start the forced draft fan, open the damper and the burner air slide door and ventilate the furnace thoroughly for at least one minutes before lighting up. Operate the steam air heater simultaneously with forced draft fan Circulate fuel oil through the fuel oil heaters and the burner manifold. A re-circulating valve on the manifold and a re-circulating line to the service pump suction is provided for this purpose, By-pass fuel oil meter until ready to light up When the fuel assembled in the burner manifold is at the correct temperature, insert an atomizer a lighting-up sprayer plate in burner. Close the air registers of the other burners Reduce the forced draft pressure at the burners to 10~20 mmg, Close the re-cireulating valve and sce that the proper fuel oil pressure is available in the burner manifold. Open the following valves before lighting up MIs BISHI HEAVY INDUSTRIES, LTD. 4915 16, 17. 18. ae (1) Air vent valve fitted on the steam drum : Full close (2) Drain valves of the superheater headers, drain valves on the starting valve outlet, drain valves of control desuperheater, steam temperature control valve : Full open (3) Starting valves on the superheater outlet : Half open Supply steam to fuel oil heater. Light up the burner following the instructions outlined in the burner section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned, It important that no unburned oil is sprayed into the furnace and that no heavy smoke is produced. Frequently observe the smoke indicator and the bumer flame, especially after making any change in firing rate or in forced draft pressure. Line up desuperheated steam to the each machinery. The starting valve must be left open until stable steam come into superheater Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork. Firing rate should be less than 250 kg/h by using the normal atomizer sprayer plate Then steam pressure shall be rise in accordance with pressure raising curve If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desuperheater drain valves. Close the valve on the steam pressure gauge and bleed the steam gauge line to be sure it is clear. Allow the line to cool for a few minutes before opening the pressure gauge valve. See that the gauge responds immediately as the valve is opened. Check the water level again by opening the water gauge drain, nothing if the level drops immediately when the drain valve is opened ant returns to the original level as the valve is closed After a drum pressure 15 kg/cm? has been reached, change atomizing fluid from air to steam. And continue raising pressure at 4.5 kg/cm? of fuel oil pressure as outlined under normal condition. Start the feed pump, as early as possible. After starting the feed pump, close starting valve After a steam pressure 20 kg/cm’ has been reached, start the main generator. Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to ively. superheater tubes, combustion rate should not be increased exces 2. When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve MIs BISHI HEAVY INDUSTRIES, LTD.GB) ae Boiler Hot Start (In case the other boiler is normal used. < Refer to “Boiler Start Up Procedure -4 > 1 6 10. u Start the forced draft fan, ventilate the furnace thoroughly before lighting up Circulate bunker fuel through the fuel oil heaters and piping until oil at the proper temperature is available in the manifold Open the following valves before lighting up, (1) Air vent valve fitted on the steam drum : Full close (2) Drain valves of the superheater headers, drain valves on the starting valve outlet, drain valves of control desuperheater, steam temperature control valve : Full open (3) Starting valves on the superheater outlet : Half open Light up the burner following the instructions outlined in the burner section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned It important that no unburned oil is sprayed into the furnace and that no heavy smoke is produced. Frequently observe the smoke indicator and the bumer flame, especially after making any change in firing rate or in forced draft pressure. Line up desuperheated steam to the each machinery. The starting valve must be left open until stable steam come into superheater Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork. Firing rate should be less than 250 kg/h by using the normal atomizer sprayer plate If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desupetheater drain valves. Then steam pressure shall be rise in accordance with pressure raising curve When the steam pressure is about 3.0~4.0 kg/cm’ below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply. When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load. Close superheater outlet starting valve. Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation properly. Set up the burners with the proper sprayer plates for the service required, lighting up as to be used make sure regulators are working necessary. Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively. MIs BISHI HEAVY INDUSTRIES, LTD.