hb-t e990-1112-03

OPERATION MANUAL

MARINE AUXILIARY BOILER

HB-T

Operation Manual No. E990-1112-03

i

Important Safety Information

In handling marine auxiliary boiler HB-T type (hereinafter called this boiler), read and fully understand

this manual and follow instruction that is contained in this manual.

This boiler contains hot parts that may cause burn, high-pressure parts that may cause injury due to

pressure break, moving parts in which a part of body may get caught, and high-voltage parts that may

cause electrical shock. Improper handling of these parts may cause accident involving death, fire, or

other disasters.

This boiler can be operated in automatic operation mode (normal mode) and manual operation

mode for emergency. In manual operation mode, fire or burn due to backfire (*) may be caused

unless boiler is handled properly. Use manual operation mode only in emergency.

To ensure safety of operation and maintenance of this boiler, it is essential to know possible causes of

disasters in advance. We cannot predict all potential dangers, but present dangers involved in

handling of boiler in this manual to the best of our knowledge. Following warnings or instructions that

are contained in this manual better ensures safety of work.

In this manual, harm and damage are categorized into following three levels. These are attached on

this boiler as warning labels (*) and also described in this manual.

DANGERIndicates any condition or practice that, if not observed,

causes imminent danger of death or serious injury to user.

WARNINGIndicates any condition or practice that, if not observed, may

cause death or serious injury to user.

CAUTIONIndicates any condition or practice that, if not observed, may

cause minor injury to user or property damage.

If failed components are found, contact MIURA offices and replace them with genuine parts. Using

different model part may reduce safety of boiler.

Remodeling this boiler without consultation with MIURA or repairing it in way that is not specified in this

manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.

ii

IntroductionThis manual describes procedures for handling this boiler for proper operation. Precautions relating to

operating method and safety indicated in this manual from damages to measures only relate to usage

for specified purposes. Do not use boiler by methods that are not mentioned in this manual. Be aware

that MIURA cannot be held responsible if boiler is used by methods that are not mentioned in this

manual.

Before using this boiler, those who use it for the first time as well as those familiar with handling of it

must read this manual thoroughly and understand proper method of handling it.

Keep this manual in place so that it can be consulted whenever there is any uncertainty about this

boiler.

In addition to this manual, following booklets are provided as information that is needed to use this

boiler. Before using boiler, thoroughly read these booklets in addition to this manual.

[1] Final Drawing:······ Final drawing is documents containing all specifications for customer. Look

over and understand final drawing before use. Refer to this document for

information that depends on capacity or options.

[2] Procedure: ·········· Manual for Installation: Procedure manual for installation contains information

on installation of this boiler and incidental parts. Install this boiler according to

this procedure manual (This procedure manual is contained in final drawings).

[3] Instruction manuals for incidental equipment:

Handle incidental equipment according to respective instruction manuals.

[4] Manual for Water ·· Treatment: Manual for water treatment describes procedure of water treatment

that is needed to use this boiler. Understand content of manual, and handle

chemicals and carry out water treatment work according to instructions that

are contained in this manual.

iii

[Graphical symbols]

Graphical symbols used in this manual have following meanings:

Prohibition

Indicates certain behavior is prohibited.

Do Not Touch

Indicates touching certain area may cause personal injury.

Do Not Touchwith Wet Hands

Indicates handling with wet hands may cause electrical shock.

Instruction

Provides instruction to be followed (action to be taken).

ConnectGround Wire

Indicates ground wires must be connected.

Caution

Indicates a precaution to be remembered.

Caution: Hot

Indicates potential danger of injury from heat under certain

conditions.

Provides precaution to prevent boiler failure, point to be

remembered for effective operation, or other useful information.

Indicates related page(s).

Note

iv

Term DefinitionsTerms that are used in this manual are defined as follows.

These terms are marked with asterisk (*) in manual.

Term Description

H.F.O. Abbreviation of fuel oil. Fuel used with main burner. When this boiler is used

in Japan, term refers to heavy oil C.

M.D.O. Abbreviation of marine diesel oil. When this boiler is used in Japan, term

refers to heavy oil A. Fuel used with pilot burner.

Flammable

Dangerous

Substance

Substance with low ignition temperature that is fire hazard (A handling place

for flammable dangerous substance refers to place where such a substance

is stored).

Wind Box Wind box in which burner is installed. It controls air flow from fan.

Oil Air Separator Container that is designed to separate components evaporated from fuel oil

or air retaining in fuel oil circulation line or other gas phases from liquid

phases. Oil air separator is installed on inlet side of fuel oil pump.

Air Supply Fan Air supply system designed to bring air into furnace.

Warning Label Label to call attention to operating precaution.

Ventilation (draft) Phenomenon that exhaust gas with higher temperature and smaller specific

gravity than surrounding air rises toward outlet of funnel.

Differential Differential means control width that is set with controller. It is control width

between when contact of controller is turned off (on) and when it is turned on

(off) again.

Ignition Transformer High voltage supply system designed to generate sparks for igniting pilot

burner or main burner.

F.O. Heater Heater that is designed to heat fuel to suitable temperature to be atomized by

burner. This heater is included as standard when H.F.O. is used as main fuel.

Pilot Flame Fire source for igniting main burner when H.F.O. is used as main fuel. Pilot

flame is formed by igniting pilot burner.

Backfire Phenomenon that fire source is generated in furnace under poorly ventilated

conditions before combustion is started or when combustion is stopped, and

combustible gas mixture in furnace is ignited to cause explosion.

Flame eye Sensor that is designed to detect flame in furnace.

v

Term Description

Pre purge Pre-purge is ventilating combustion chamber of boiler before combustion.

Post purgePost-purge is ventilating combustion chamber of boiler when combustion is

stopped.

Main fuel Fuel used with main burner.

vi

CONTENTS

Important Safety Information.............................................................. i

Introduction........................................................................................ ii

Term Definitions................................................................................ iv

CHAPTER 1: SAFETY.........................................................................1

1. Safety Regulations ........................................................................1

2. Knowledge and Skill Required for Safe Handling .........................1

3. Protective Equipment ....................................................................1

4. Prohibition of Remodeling without Permission..............................1

5. Use of Specified Fuels ..................................................................2

6. Warning Labels (*) on Products......................................................2

7. Precautions for Safe Handling ......................................................3

7.1 Safety Precautions in Installation ................................................................................3

7.2 Safety Precautions in Pre-operation Inspection and Preparation ................................4

7.3 Safety Precautions in Operating Boiler........................................................................5

7.4 Safety Precautions in Bringing Boiler to Emergency Stop...........................................7

7.5 Safety Precautions in Inspections and Maintenance...................................................7

7.6 Safety Precautions in Replacing Parts ........................................................................9

7.7 Safety Precautions in Working on Failures..................................................................9

7.8 Safety Precautions in Storage Work..........................................................................10

vii

CHAPTER 2: OVERVIEW ................................................................. 11

1. Features of Product..................................................................... 11

1.1 Functions and Operating Principle ............................................................................ 11

1.1.1 Functions .................................................................................................. 11

1.1.2 Operating Principle ................................................................................... 11

1.2 Product Components ................................................................................................ 11

2. Water and Steam Supply Flow....................................................12

2.1 Water and Steam Pipe System .................................................................................12

3. Fuel Supply Flow.........................................................................13

3.1 Fuel Pipe System......................................................................................................13

4. Basic Specifications ....................................................................14

5. Part Names and Functions..........................................................15

5.1 Boiler Body................................................................................................................15

5.2 Burner and Burner Piping Structure ..........................................................................16

5.3 Internal Structure of Boiler Body ...............................................................................17

6. Boiler Automatic Operation by Sequencer ..................................19

6.1 Overview ...................................................................................................................19

6.2 Flowchart ..................................................................................................................19

6.3 Operation Explanation of Steam Pressure Control....................................................21

6.3.1 Proportional Control..................................................................................21

CHAPTER 3: BASIC OPERATION....................................................22

1. Details of Control Panel and Display ..........................................22

1.1 Details of Control Panel and Display.........................................................................22

1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch) .................23

1.3 Details of Alarm Display ............................................................................................23

viii

CHAPTER 4: OPERATION................................................................24

1. Inspection and Preparation before Operation .............................24

1.1 Inspection and Preparation of Boiler and Peripheral Equipment ...............................24

1.2 Inspection of Boiler Body and Accessories................................................................25

1.3 Inspection and Preparation of Feed Water System ...................................................26

1.3.1 Inspection Items........................................................................................26

1.3.2 Flushing of Pipes ......................................................................................27

1.3.3 Air Vent .....................................................................................................27

1.4 Inspection and Preparation of Fuel System...............................................................28

1.4.1 Preliminary Inspection...............................................................................28

1.4.2 Air Vent .....................................................................................................29

1.5 Inspection and Preparation of Burner........................................................................29

1.6 Inspection and Preparation of Electrical System .......................................................30

1.7 Inspection and Preparation of Steam System ...........................................................30

2. Automatic Operation (Normal Operation) ....................................31

2.1 Checking of Control Panel Switches .........................................................................31

2.2 Feeding Water to Boiler.............................................................................................31

2.3 Feeding Water to Boiler by Differential Transmitter ...................................................32

2.3.1 Feeding Water to Differential Transmitter..................................................32

2.4 Starting Combustion with M.D.O.(*)............................................................................34

2.4.1 Combustion with Air Atomization...............................................................34

2.4.2 Control and Checking during Operation (Combustion with Air

Atomization)..............................................................................................35

2.4.3 Combustion with Steam Atomization ........................................................35

2.4.4 Control and Checking during Operation (Combustion with Steam

Atomization) .............................................................................................35

2.5 Combustion Stop.......................................................................................................36

2.6 Shift from M.D.O. to H.F.O. .......................................................................................36

2.7 Shift from H.F.O. to M.D.O. .......................................................................................37

3. Emergency Operation .................................................................38

3.1 Emergency Combustion Operation ...........................................................................38

3.2 Control and Checking during Operation ....................................................................38

3.3 Restoration to Normal Combustion and Checking of Combustion ...........................38

ix

4. Manual Operation (Use Only in Emergency) ..............................40

4.1 Starting/Stopping Manual Feed Water Pump Operation ...........................................41

4.1.1 Starting Manual Operation........................................................................41

4.1.2 Stopping Manual Operation ......................................................................41

4.2 Manual Combustion ..................................................................................................42

4.3 Manual Combustion Stop..........................................................................................43

5. Emergency Stop..........................................................................44

5.1 Emergency Stop of Combustion System...................................................................44

5.1.1Cases in which Emegency Stop is Required ...........................................44

5.1.2 Stop Procedure.........................................................................................44

5.2 Emergency Stop of Entire Boiler ...............................................................................44

5.2.1 Cases in which Emegency Stop of Entire Boiler is Required....................44

5.2.2 Stop Procedure.........................................................................................44

6. Cold Start ....................................................................................45

CHAPTER 5: INSPECTION AND MAINTENANCE...........................46

1. List of Inspection Items and Inspection Frequencies ..................46

1.1 Regular Inspection and Maintenance........................................................................47

1.2 Safety Valve ..............................................................................................................49

1.2.1Internal Structure of Safety Valve ..............................................................49

1.2.2 Adjustment of Safety Valve.......................................................................50

1.3 Other Important Inspection Items..............................................................................50

2. Daily Inspection and Maintenance ..............................................51

3. Weekly Inspection and Maintenance ..........................................52

3.1 Main Burner ..............................................................................................................52

3.1.1 Overview...................................................................................................52

3.1.2 Disassembly and Adjustment....................................................................52

3.2 Nozzle Tip .................................................................................................................53

3.3 Pilot Burner ...............................................................................................................54

3.3.1 Overview...................................................................................................54

3.3.2 Disassembly and Adjustment....................................................................55

x

4. Monthly Inspection and Maintenance..........................................55

4.1 Fan............................................................................................................................55

4.1.1 Overview...................................................................................................55

4.1.2 Regular Maintenance................................................................................56

4.2 Suction Damper (Attachment of Blower) ...................................................................57

4.2.1 Overview...................................................................................................57

4.2.2 Inspection .................................................................................................57

4.2.3 Measures on Failures (Fixing Fully Open State).......................................58

4.3 Fuel Flexible Tube.....................................................................................................59

4.4 Oil Flow Control Valve, Air Flow Controller, and Damper ..........................................59

4.4.1 Overview...................................................................................................59

4.4.2 Inspection..................................................................................................60

4.5 Control Motor ............................................................................................................61

4.5.1 Overview...................................................................................................61

4.5.2 Inspection .................................................................................................61

4.6 Flame Eye (*)..............................................................................................................62

4.6.1 Overview...................................................................................................62

4.6.2 Inspection and Cleaning ...........................................................................62

4.7 Strainer for Fuel.........................................................................................................63

4.7.1 T-type Auto-cleaner...................................................................................63

4.7.2 Y-type Strainer ..........................................................................................64

4.7.3 Double Strainer.........................................................................................64

4.8 Fuel Oil Pump............................................................................................................66

4.8.1 GFS Type (for Pilot Burner) ......................................................................66

4.8.2 Main Fuel Oil Pump ..................................................................................67

4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting .........................67

4.8.4 Circulation Relief Valve .............................................................................69

5. Quarterly Inspection and Maintenance .......................................70

5.1 Inspection and Blow of Boiler Water..........................................................................70

5.2 Equipment around Burner .........................................................................................70

5.2.1 Solenoid Valve ..........................................................................................70

5.2.1-1 Solenoid Valve for Pilot Burner...........................................................71

5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve ..............................71

5.2.1-3 Solenoid Valve for Atomized Air .........................................................72

5.2.1-4 Solenoid Valve for Atomized Steam ...................................................73

xi

5.2.2 Other Equipment ......................................................................................74

5.2.2-1 Pneumatic Fuel Shutoff Valve ............................................................74

5.2.2-2 Filter Regulator ..................................................................................75

5.2.2-3 Pressure Reducing Valve...................................................................76

5.2.2-4 Seal Pot .............................................................................................77

5.2.2-5 Equalizing Valve.................................................................................78

5.3 Fuel Oil Thermostat (for Fuel Oil Heater) ..................................................................79

5.3.1 Dial Type...................................................................................................79

5.3.2 RT Type ....................................................................................................80

5.3.3 Heavy Oil Heating Temperature................................................................81

5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil).......................................82

5.4.1 Steam Pressure Switch ............................................................................82

5.4.2 Atomized Fluid Pressure Switch ...............................................................83

5.4.3 Fuel Oil Pressure Switch ..........................................................................83

5.4.4 Pressure Switch Adjustment Procedure....................................................84

5.5 Differential Transmitter ..............................................................................................85

5.6 Flow Control Valve ....................................................................................................86

5.7 Operation Check of Each Safety System..................................................................87

5.7.1 Ignition Failure Alarm................................................................................87

5.7.2 Fan Abnormal Stop Alarm.........................................................................87

5.7.3 Flame-out Alarm .......................................................................................88

5.7.4 Abnormal Fire Alarm .................................................................................88

5.7.5 Low Oil Pressure Alarm ............................................................................88

5.7.6 Low Oil Temperature Alarm ......................................................................89

5.7.7 High Oil Temperature Alarm......................................................................89

5.7.8 Exhaust Gas High Temperature Alarm......................................................90

5.7.9 High Steam Pressure Alarm .....................................................................90

5.7.10 Low Steam Pressure Alarm ....................................................................91

5.7.11 Low Water Level Alarm ...........................................................................91

5.7.12 Low Low Water Level Alarm ...................................................................91

5.7.13 Power-off Alarm ......................................................................................91

5.7.14 Sequencer Error Alarm ...........................................................................91

5.7.15 Low Atomized Steam Pressure Alarm.....................................................92

5.7.16 Low Atomized Air Pressure Alarm...........................................................92

5.7.17 Damper Control Alarm ............................................................................92

5.7.18 Operation Check by differential transmitter（Low Water Level, Low Low

Water Level, High Water Level） ..........................................................92

5.7.19 Suction Damper Error Alarm...................................................................94

xii

6. Yearly Inspection and Maintenance ............................................95

6.1 Fuel Oil Heater ..........................................................................................................95

6.1.1 Combined Use of Electricity and Steam....................................................95

6.1.2 Solenoid Valve for Steam Heater..............................................................96

6.2 Water Level Gauge and Water Level Detecting Rod .................................................97

6.3 Flame Detector (FS-901)...........................................................................................98

7. Inspection and Maintenance on Vessel Docking.......................100

7.1 Soot Cleaning of Furnace........................................................................................100

8. Parts Information about Replacement.......................................101

8.1 Ignition Transformer (*) .............................................................................................101

8.2 Sequencer (Programmable Controller)....................................................................102

8.2.1 Description of Component Unit of CJ2M.................................................102

8.2.2 Function of Display .................................................................................105

8.2.3 Errors and Countermeasures..................................................................106

8.3 Steam Pressure Regulator ......................................................................................107

8.4 Fuel Oil Temperature Controller ..............................................................................108

8.4.1 Name and Function ................................................................................108

8.4.2 Setting Procedure ...................................................................................108

8.5 Water Level Detector (LM1-200) .............................................................................109

8.6 Water Level Indicator...............................................................................................110

CHAPTER 6: TROUBLE SHOOTING.............................................. 111

1. Feed Water System................................................................................................... 111

2. Fuel System .............................................................................................................. 114

3. Combustion System .................................................................................................. 116

4. Control System..........................................................................................................122

5. Trouble Shooting for Boiler Body...............................................................................123

6. Repairing Damaged Water Tubes .............................................................................124

6.1 Insertion of Stoppers from Inside of Water Drum.................................................124

6.2 Stopper Welding from Combustion Chamber ......................................................125

xiii

CHAPTER 7: STORAGE.................................................................126

1. Maintenance When Boiler is Shut Down for a Long Time.........126

2. Movement or Resale .................................................................126

3. Export........................................................................................126

CHAPTER 8: DISPOSAL ................................................................127

1. Disposal Procedure...................................................................127

CHAPTER 9: GUARANTEE ............................................................128

1. Description of Guarantee ..........................................................128

2. Contact Information for Inquiries about Products and Instruction

Manual.......................................................................................128

3. Sale of Instruction Manual.........................................................128

4. Sale of Parts..............................................................................128

1

CHAPTER 1: SAFETY

1. Safety RegulationsIn sailing in the high seas, observe the Rules and Regulations for the Classification of Ships, the

SOLAS Convention, the MARPOL Convention, and other international conventions. Also observe

regulations in way ports or the country in which vessel is registered and other applicable regulations.

2. Knowledge and Skill Required for Safe HandlingHandling of this boiler includes operating boiler, operating controller for controlling operation of boiler,

and maintaining them. Before carrying out work, fully understand this manual.

People who satisfy all of following requirements are qualified to handle this boiler. They are called

operators.

[Requirements to be satisfied by operators]

Those who have received explanation of handling from our service staff during trial operation or

those who have received explanation of handling directly from them

Those who have thoroughly read instruction manual for this boiler and have full understanding of

content

Those who have been permitted to handle this boiler by chief engineer

Appoint chief operator from among operators.

3. Protective EquipmentDo not forget to wear helmet, protection eyewear, safety shoes, safety belts, leather gloves, protective

masks, or other appropriate protective equipment when working on device.

4. Prohibition of Remodeling without PermissionRemodeling this boiler without consultation with MIURA or repairing it in a way not specified in this

manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.

2

5. Use of Specified FuelsDo not use fuel that is not specified with this boiler. Failure to observe this instruction may seriously

affect safety of boiler.

6. Warning Labels (*) on ProductsFor safe use of boiler, warning labels are attached on locations where attention to operating precaution

is called for.

If warning label comes off or tears, replace it with new warning label.

For more details about warning labels, contact MIURA offices.

Attached near parts with hazard of scalding or hot parts

(Parts with surface temperature of over 60°C).

Do not touch surface around this warning label.

Attached on rotating parts with gaps in structure that

could catch fingers (Fingers might get trapped).

Do not get close to area near warning label before parts

are operated or when they are in operation.

Attached on or around electric equipment that cannot be

insulated (or covered) completely.

To prevent electrical shock or electric leakage, prevent

objects or body from coming in contact with such

Scald Warning Label:······················

Electric Shock Warning Label:··········

Catch Warning Label: ·····················

Damage Warning Label: ················· Attached on water gauge glass as there is possibility of

damage by aged deterioration when it is used for long

periods. When deterioration, cracks, or other problems are

found, promptly replace part.

3

7. Precautions for Safe Handling7.1 Safety Precautions in Installation

In carrying out installation work, observe following safety precautions:

WARNING

Instruction

Secure ventilation (draft) (*) in funnel (exhaust stack) and ensure that exhaust from outlet

does not have harmful influence on surrounding environment.

(Refer to “1. Safety Regulations.”)

In engine room, secure adequate area for air inlet, exhaust outlet, and air supply fan (*). If

these are not installed and managed properly, carbon monoxide poisoning due to exhaust

gas may be caused.

Ensure that ventilation fan, air inlet, and exhaust outlet are installed in engine room.

Insufficient air supply or exhaust ventilation may cause carbon monoxide poisoning due to

exhaust gas or explosion.

Ensure that boiler is not installed in handling place for flammable dangerous substance(*).Install it on floor made of noncombustible material. Ensure that boiler is more than 45 cm

away from flammable materials. They may ignite due to hot part of boiler to cause fire,

resulting in accident involving death.

Ignition due to hot part may cause fire.

If exhaust stack or steam piping is passed through wall that is made of flammable material,

use noncombustible material for fire protection.

Water discharged from boiler is extremely hot and may cause burn.

Ensure that drainage piping is fixed to prevent it from being forced to move by discharged

water and that the end of piping is released into safe place.

ConnectGround Wire

Connect power supply using cables with specified diameters.

Use special wiring breaker.

Failure to observe this instruction may cause electrical shock, burn, or other serious

accidents.

Wiring breaker

Breakercapacity

Wiring

Wiring breaker

4

7.2 Safety Precautions in Pre-operation Inspection and Preparation (Excerpt from

page 24-)

In pre-operation inspection and preparation, observe following safety precautions:

WARNING

Prohibition

Keep flammable materials away from boiler.

They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.

Do not put flammable materials in control box.

They may ignite to cause fire, resulting in accident involving death.

Do Not Touch

If you touch coupling of pump that is spinning rapidly, you may get caught in it. Do not touch

coupling of pump during pump operation.


Do not operate breaker of main power supply and equipment in control panel with wet

hands.

Failure to observe this instruction may cause electrical shock due to high voltage, resulting

in injury or death.

Instruction

Check that funnel (exhaust stack) is properly constructed.

Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may

cause carbon monoxide poisoning due to exhaust gas or fire.

Check for water or oil leaks around boiler related equipment.

Switching on or off wet equipment may cause electrical shock or fire from short circuit.

Run ventilation (air supply and exhaust equipment) in engine room and check that air vent

is not blocked off.

If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may

be caused.

If you touch hot piping of feed water system, you may suffer burn. Wear protective

equipment while working with it. If insulation of piping deteriorates or falls off, repair it.

If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving

death. Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage

and waste cloth used to wipe off oil immediately in an appropriate manner.

Caution: Hot

If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear

protective equipment while working around tank.

If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.

CAUTION

Instruction

If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures

to prevent fuel oil spill and establish method for coping with spillage in advance.

5

7.3 Safety Precautions in Operating Boiler (Excerpt from page 31-)

In operating boiler, observe following safety precautions:

WARNING

Prohibition

If automatic operation is hindered by parts damage or another reason, remove cause of

problem and start automatic operation again.

This boiler has manual operation circuit for emergency operation when automatic operation

is hindered. Operating error in manual operation mode, in which some safety systems are

disabled, may cause accident involving death. Do not use manual operation mode except in

emergency. If manual operation circuit must be used for unavoidable reason, follow

instructions in this manual.

Cases in which automatic operation cannot be continued are as follow:

<Feed water pump circuit>

Failure of instrumentation

<Combustion circuit>

Sequencer trouble

Sensor trouble, interlock by abnormality detection

In manual operation mode, backfire (*) or other accidents involving death by ignition error or

fire by empty heating may be caused. Do not use manual operation mode except in



During manual combustion operation, do not shift fuel (M.D.O. (*) ↔ H.F.O. (*)).Failure to

observe this instruction may cause backfire or other accidents involving death.



hands.


in injury or death.

Instruction

If water or steam leaks out of system, burn, blindness, or accidents involving death may be

caused. During operation and after operation stop, check connections of piping and air vent

valve for leaks.

If you touch hot piping of water and steam systems, you may suffer burn. Wear protective


If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving death.

Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage and

waste cloth used to wipe off oil immediately in an appropriate manner.

Surface temperature of upper part of boiler exceeds 60°C and may cause burn if surface is

touched. When working with upper part of boiler, wear gloves and other protective

equipment to prevent direct contact.

6

WARNING

Instruction

Perform purge operation sufficiently before ignition and when combustion is stopped.

Insufficient purge operation may cause backfire(*) or other accidents involving death.

Pre-purge (*) (before ignition): 20 seconds or longer *

Post-purge (*) (when combustion is stopped): 60 seconds or longer *

*In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit

after 20-second or longer pre-purge.

Switch fuel when boiler is in automatic operation mode. Operating error in manual operation

mode may cause backfire or other accidents involving death.

Caution

In manual operation mode, following interlock functions of safety system are disabled.

Improper operation may cause accidents involving death. Be careful with operating boiler in

manual operation mode.

Interlock functions disabled when manual combustion circuit is used:

Fuel oil pressure low (fuel)

Fuel oil temperature high (fuel)

Fuel oil temperature low (fuel)

Steam pressure high

Steam pressure low

Abnormal fire

These interlock functions work only when all functions are working properly. When there are

problems with sensors or other parts, interlock functions may not work properly.

In feed water control by differential transmitter, feed water pump control does not operate

properly when feeding water and adjustment of differential transmitter is not completed.

Boiler becomes fill with water and high water level, it may cause hot water blow out from

safety valve during boiler combustion.

Caution: Hot




7

7.4 Safety Precautions in Bringing Boiler to Emergency Stop (Excerpt from page 44-)

In bringing boiler to emergency stop, observe following safety precautions:

DANGER

Caution

Emergency stop is operation that gives top priority to stopping boiler immediately in

emergency. If breakers are turned off inadvertently, feed water and circulation pumps may

be stopped to cause soot fire, explosions in furnace, or other accidents. Do not use this

function except in emergency.


emergency. Emergency stop skips safety checks for ongoing operation and may cause

unexpected accident or failure. Use this function only when there is unavoidable reason for

bringing boiler to emergency stop. Users must judge when and how boiler should be

brought to emergency stop because it depends on situation.

When resuming operation after emergency stop, ensure that switches are turned on or off to

stop all ancillary equipment before turning power on. Otherwise, equipment may start to

work unexpectedly to cause accidents.

7.5 Safety Precautions in Inspections and Maintenance (Excerpt from page 46-)

In inspections and maintenance, observe following safety precautions:

DANGER

Instruction

Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to

deterioration of impeller or external force, resulting in injury or death.

WARNING

Prohibition

Improper adjustment of blow off pressure of safety valve may damage boiler body.

As a rule, do not adjust blow off pressure of safety valve.

Remodeling of safety valve may damage boiler body.

As a rule, do not remodel safety valve.

Instruction

If steam leak from safety valve is found, replace part and repair it immediately.

When steam leak is left, function of safety valve is decreased and there is possibility of

leading to serious accident

Complete purge by fan before burner opening and inspection to make combustion chamber

cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.

Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it

properly.

8

WARNING

Instruction

Before moving impeller by hand, turn off main power supply. If impeller is rotated

accidentally during maintenance, physical injury may be caused.

Inspect suction damper once a month. Failure to inspect suction damper may cause

damage of part and malfunction due to looseness of part, resulting in injury or death.

Do not give impact to boiler fuel pipe or bend any part of it.

Failure to observe this instruction may cause fuel oil leak, resulting in fire.

Equipment has been brought into optimum state in trial operation. Do not make changes to

state after trial operation. Failure to observe this instruction may cause poor combustion,

backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA

offices and ask for instructions.

In order to prevent serious accident, check solenoid valves and valve seats for oil leaks after

cleaning, inspecting, or replacing.

Before inspection or adjustment, check that there is no internal pressure present.

Compressed air or steam may blow out, causing burn or laceration.

Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to

change setting as a rule. Failure to observe this instruction may cause poor combustion,

backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for

instructions.

Caution

Surface temperature of the top of boiler exceeds 60°C and may cause burn if surface is

touched. Take extra care in daily inspection work.

Blow valve and sample water (blow water) are hot. When carrying out inspection and

maintenance work, wear protective equipment to prevent burn.

During inspection work, hot steam may blow out to cause burn. Be careful when operating

valves.

Before wiring work, be sure to turn control panel power off. Failure to observe this instruction

may cause electrical shock due to high voltage, resulting in injury or death.

Do not pull out lead wire with wet hands. Failure to observe this instruction may cause

electrical shock due to high voltage, resulting in injury or death.

CAUTION

Instruction

When cleaning strainer or performing other work using oil, wear protective equipment to

protect eyes and body from splashes of oil.

This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating

valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil

pump is deteriorated over time and its performance is gradually declined.

9

CAUTION

Caution

Improper spray volume, spray angle, and spray form cause poor combustion and sometimes

cause backfire. Use only genuine parts.

7.6 Safety Precautions in Replacing Parts (Excerpt from page 101-)

In replacing parts, observe following safety precautions:

WARNING

Instruction

Ignition transformer (*) conducts high voltage. Touching live wiring may cause electrical

shock. Turn power off before working with ignition transformer.

Do not make changes to state after trial operation. Failure to observe this instruction may

cause poor combustion, backfire (*), or other accidents.

CAUTION

Instruction

Improper setting of water level may damage boiler body.

Do not change setting from trial operation.

Do not change internal parameters.


7.7 Safety Precautions in Working on Failures (Excerpt from page 111-)

In working on failures, observe following safety precautions:

WARNING

Instruction

Stopper treatment and furnace building with refractory is temporary treatment. Do not

operate for a long time; otherwise, there is possibility of serious accident. Contact each

classification in advance and replace water tubes (or body) immediately at periodical

inspection. Contact with MIURA offices about replacement of water tubes (or body).

Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool

both the inside of drum and combustion chamber. Then make sure that pressure inside the

drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan

during inspection.

10

CAUTION

Caution: Hot

Before working on water tube leaks, check water tubes and burner funnel that may be

touched are fully cooled. Otherwise, you may suffer from burn. For more information,

contact with MIURA offices.

7.8 Safety Precautions in Storage Work (Excerpt from page 126-)

In storage work, observe following safety precautions:

WARNING

Prohibition

Do not perform installation work and connection of incidental equipment unless it is

specified.

Failure to observe this instruction may cause physical injury.

11

CHAPTER 2: OVERVIEW

1. Features of Product

1.1 Functions and Operating Principle

1.1.1 Functions

This boiler burns fuel oil and collects resultant heat to provide high-temperature, high-pressure

steam.

1.1.2 Operating Principle

<Feed water>

Feed water is pressurized by feed water pump and supplied to upper drum.

Water that is fed to upper drum is loaded into boiler body (upper drum, water tubes, and lower

drum).

<Combustion>

Heat to generate steam comes from combustion heat by burner. Fuel oil heated and pressurized

by fuel oil pump unit to right temperature and pressure, respectively, is supplied to burner. Boiler

employs two-fluid burner that uses atomized fluid (steam or compressed air) to atomize fuel oil

and combines atomized particles with air supplied by fan to cause combustion.

<Generation of steam>

Water in water tubes is heated by combustion heat from burner into gas-liquid phase, which rises

to upper drum. Liquid phase in water tubes without thermal load drops down to lower drum. This

series of actions causes natural circulation inside boiler body and allows heat recovery. Steam

generated in drum is subjected to steam separation to obtain saturated steam, which is supplied

to load side through main steam valve.

1.2 Product Components

This boiler consists of boiler body and following units:

Boiler body

Feed water pump (including feed water strainer and valves)

Fuel oil pump unit

Control panel

Fan

*This is standard configuration. For details about configuration of product that is delivered, refer to

final drawing.

12

2. Water and Steam Supply FlowTypical flow for this boiler is described here. Actual flow may be different from flow described here,

depending on specifications. Check pipe system diagram in final drawing before use.

2.1 Water and Steam Pipe System

Water in system is supplied to boiler body by feed water pump. Water sent to boiler is heated by

combustion heat into high-temperature, high-pressure steam. Generated steam is supplied to load

side and used as a heat source.

Figure 2-1 Water and Steam Pipe System Diagram (Example)

13

3. Fuel Supply FlowTypical flow for fuel pipe system of this boiler is described here. Actual flow may be different from flow

described here, depending on specification. For details about flow for product that is delivered, refer to

pipe system diagram in final drawing.

3.1 Fuel Pipe System

Figure 2-2 Fuel Pipe System Diagram

<Description of operation> (H.F.O.(*))a) All solenoid valves (SV-1 to SV-4) are closed when operation is stopped. When operation is started

and main fuel (*) oil pump (M-2) is brought into operation, fuel oil is circulated throughout fuel pipesystem leading back to oil air separator (*) via circulation relief valve (RV) and is heated by heater.

b) When H.F.O. is heated and pre-purge (*) is performed, solenoid valve for atomized fluid (SV-2) isopened. When pre-purge is completed, pilot fuel oil pump (M-4), ignition transformer(*), and solenoidvalve for pilot burner (SV-1) are started to form pilot flame(*).

c) When flame eye (*) detects pilot flame, solenoid valve for air-driven valve (SV-3) is started to openair-driven valve (AC-1), allowing main burner and pilot burner to form mixed flame. After mixedflame is formed, solenoid valve for pilot burner (SV-1) is shut off to put out pilot flame, and flamefrom main burner is formed.

d) While combustion is continued, pressurized fuel oil is still circulated throughout fuel pipe system viacirculation relief valve (RV) to keep fuel oil temperature and oil pressure stable.

F.O. TANKF.O. TANK

D.O. TANKD.O. TANK

14

4. Basic SpecificationsTable 2-1 lists specifications of different types of boilers and different capacities. Specifications may be

different from those listed here, depending on special order requirements. For detailed specifications of

product that is delivered, refer to list of principle items on final drawing.

Table 2-1 Basic Specifications of HB-T Type Boiler

Model HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T

Max. Design Press. MPa 1.0

Heating Surface Area m2 104 115.5 131.6 184.2 224.6

Actual Evaporation

Water 60°C

Steam 0.69 MPa

kg/h 8,000 10,000 12,000 15,000 18,000 20,000

Net Heat Output

kW 5,580 6,980 8,380 10,470 12,570 13,970

kcal/

h4,806,800 6,008,500 7,210,200 9,012,750 10,815,300 12,017,000

Fuel Oil - Heavy Fuel Oil: Up To 380 cSt (at 50 °C)

Fuel Consumption kg/h 578 722 866 1,082 1,299 1,444

Installed Electric Capacity kW 62.5 65.5 77.5 96 121 124.5

Bu

rne

r

Type - Steam Atomizing Type

IgnitionSystem

- High Voltage Spark System

FlameDetector

- Flame Eye Type

F.O

.P

um

p Capacity m3/h 1.41 2.4

Pressure MPa 1.5

Motor kW 2.2 3.7

Fa

n

Capacity m3/min 160 200 240 300 360 395

Motor kW 30 37 45 55 75

F.O

.

Heate

r Type - Electric Heater With Steam

Electric Power kW 17 13 17 20 25

Fe

ed

Wate

r

Pu

mp

Capacity m3/h 12 14 18 22 23

Pressure MPa 0.98 1.08

Motor kW 11 15 18.5

Control System - Proportional Control

Boiler Weight(Dry) kg 14,200 17,300 18,000 21,600 23,500

Normal Weight of BoilerWater

kg 5,020 6,650 6,890 8,200 9,170

Note 1: Power supply is 60Hz, 3 AC 220V or 440V.

Note 2: H.F.O.(*) with low calorific value of 41,000 kJ/kg (9,800 kcal/kg) is used.

15

5. Part Names and FunctionsPart names and functions are described here. Appearance and layout depend on type and capacity.

For details of product that is delivered, refer to final drawing.

5.1 Boiler Body

Figure 2-3 External View of Boiler

No Part name No Part name

1 Main steam valve 8 Fan

2 Burner 9 Control panel

3 Water level gauge 10 Fuel oil pump unit

4Boiler water

sampling valve11 Manhole (lower)

5 Manhole (upper) 12 Bottom blow valve

6Surface blow

valve13

Steam pressure gauge

unit

7 Funnel flange

(1) Main steam valve

Valve to supply steam to load side

(2) Burner

Equipment to burn fuel and to generate heatsource

(3) Water level gauge

Equipment that indicates water level of boiler

(4) Boiler water sampling valve

Valve to sample boiler water

(5) Manhole (upper)

This manhole is used to inspect and cleanboiler and water tubes.

(6) Surface blow valve

Valve to discharge concentrated boiler wateraround evaporation surface

(7) Funnel flange

Outlet of exhaust gas generated bycombustion of heavy oil (leading to funnel)

(8) Fan * 1

Equipment to send burner air for combustion

(9) Control panel * 1

Equipment to operate boiler

(10) Fuel oil pump unit * 1

Equipment to pressurize and heat fuel andsend it to burner

(11) Manhole (lower)

Same as (5)

(12) Bottom blow valve

Valve to discharge concentrated boiler water(including sludge)

(13) Steam pressure gauge unit *2

Unit of boiler pressure gauge and pressureswitches for combustion control

*1: Equipment installed separately from boiler.Installed into a unit here just for simplicity ofillustration.

*2: Equipment installed separately from boiler forstandard specifications. Depending onspecifications, it can be provided as part ofboiler.

16

5.2 Burner and Burner Piping Structure

1 Oil flow control valve 11 Atomized steam valve

2 Pneumatic fuel shutoff valve 12 Pressure reducing valve

3 Circulation relief valve 13 Solenoid valve for atomized steam

4 Emergency fuel switch valve (main) 14 Seal pot

5 Emergency fuel switch valve (pilot) 15 Equalizing valve

6 Solenoid valve for pilot burner 16 Cock for equalizing valve oil detection

7 Filter regulator 17 Main burner ASSY

8 Solenoid valve for fuel shutoff valve 18 Main baffle plate

9 Atomized air valve 19 Pilot burner ASSY

10 Solenoid valve for atomized air 20 Inner cylinder

Figure 2-4 Structural Diagram of Burner Figure 2-5 Structural Diagram of Burner Piping

17

5.3 Internal Structure of Boiler Body

Figure 2-6 Internal Structure of Boiler Body

Figure 2-7 Water Tube Arrangement

BurnerWind box

Upper drum

Water tube

Expansion ring

Heat insulator

Castable

Funnel flange

Lower drum

FunnelCombustion chamber

Inner casing

Stay

Outer casing

18

Boiler consists of doughnut shaped upper drum and lower drum that are connected through water

tubes. Water tubes with narrow ends are arranged as shown Figure 2-7. Combustion gas flows in

two directions as shown by arrows and meets again at exit to be discharged from funnel. While water

in innermost water tubes is subjected to flame, other water tubes are subjected to combustion gas

that passes through them. This allows efficient transfer of heat to water.

Casing consists of welded inner casing and outer casing. Heat insulating material is placed between

water tubes and inner and outer casing to restrict radiation of heat.

Inner lower part of furnace and narrow end part of water tubes are insulated with castable to prevent

short path of combustion gas.

Upper and lower drums have manhole to check inside. Check condition of scaling, corrosion,

pitching on tubes, and reflect results in boiler water treatment (For more details, refer to Manual for

Water Treatment). At furnace inspection, check for soot adherence, peeling of castable, fuel leakage

on furnace bottom, traces of water leakage and accumulations of unburnable materials.

19

6. Boiler Automatic Operation by Sequencer

6.1 Overview

Sequence control is automatic control that completes each control step following procedure that is

provided in advance.

This boiler starts fuel oil pump and fan operation, and after pre purge is completed sufficiently, ignition

device is started; after fuel valve is opened to ignite burner, start-stop of burner is controlled by steam

pressure switch. These steps are carried out automatically.

6.2 Flowchart

Figure 2-8 shows flowchart of basic operation of boiler; actual flow may be different depending on

specifications.

燃焼SW ON

ボイラ運転（燃焼モード）表示灯点灯

燃焼要求あり

送風機運転

点火トランス作動

パイロット電磁弁開

炎センサ炎検出

燃焼表示灯点灯

YES

YES

NO

プレパージ20秒

不着火警報報知点火トランス停止パイロット電磁弁閉

ボイラ運転表示灯消灯

NO

リセット操作

警報発生時燃焼遮断後リセット操作へ

イロ

｜

Fuel oil SW ON

Flame censorFlame Detector

Reset

Pilot solenoid valveopen

Fan operation

Ignitiontransformer on

Boiler operation(Combustion mode)Indicator lump on

Misfire alarmIgnition transformer off

Pilot solenoid valve closeBoiler operation lamp off

Combustion lampon

Combustionis requested.

Pre

-pu

rge

(20

sec.)

Wh

en

ala

rmis

sta

rted

,re

se

ta

fte

rcom

bu

stio

nin

terc

epte

d.

(A) (B)

Figure 2-8 Flowchart of Basic Operation

20

Note

When alarm lamp related to burner interlock lights up, automatic recovery does not take place. Be

sure to perform reset operation.

燃焼電磁弁開

点火トランス停止パイロット電磁弁閉

電磁弁閉燃焼表示灯消灯

送風機停止

ポストパージ35秒

比例燃焼（状態移行初期30秒間は低負荷燃焼を継続）

燃焼要求あり

NO

YES

イロ

警報発生時燃焼遮断後リセット操作へ

(A)

Wh

en

ala

rmis

sta

rted

,re

se

ta

fte

rcom

bu

stio

nin

terc

epte

d.

Combustion solenoidvalve open

Ignition transformerstopped.

Pilot solenoid valve close.

Solenoid valve close.Combustion lamp off

Post-purge 35S

Fan stopped

Figure 2-8 Flowchart of Basic Operation (Continued)

(A) (B)

Combustion isrequested.

Proportional control combustion(Low combustion is continued for 30

seconds after combustion isentered.)

21

6.3 Operation Explanation of Steam Pressure Control

6.3.1 Proportional Control

Steam pressure regulator installed on control panel controls boiler burner and adjusts steam

pressure.

a) For 30 seconds after ignition, low combustion (20% load) is kept not to put boiler under heavy load.

30 seconds later, boiler is held under proportional control so that normal working pressure can be

kept in response to changes in steam pressure.

b) When steam consumption is lowered and boiler steam pressure is increased to reach higher

pressure limit, burner is stopped and post-purge(*) is performed.

c) When boiler steam pressure is decreased to lower pressure limit, combustion is started again

under proportional control so that normal working pressure is kept.

*1: At start of operation, atomized air is used (with M.D.O.(*)) to increase boiler steam pressure to 0.7

MPa.

Refer to page 34 “2.4 Starting Combustion with M.D.O” in Chapter 4.

Note

When air is used as atomized fluid, only M.D.O. can be used as fuel, and proportional control

cannot be used. (Forced low fire)

Sample settings of steam pressure regulator

Boiler steam pressure

Higher pressure limit

Normal working pressure

Lower pressure limit

Time

22

CHAPTER 3: BASIC OPERATION

1.Details of Control Panel and DisplayLayout and functions of control panel and display are described here. Actual layout and functions may

be different from those described here, depending on specifications. For details about layout of control

panel and display, refer to external view of control panel in final drawings.

1.1 Details of Control Panel and Display

Figure 3-1 Layout and Functions of Control Panel and Display

Turning this switch on starts boosterpump.

This switch can be used to check lamps on display.When switch is pressed, all the indicator lamps are lit.

Alarm display

Alarm lamps blink orlight up to warn of failures.

Lamp is on when combustionswitch is on.

Combustion lamp

Lamp is on whencombustion is continued.

Combustion switch

Pressing this switchallows boiler to start combustion.

Combustion stop switch

Pressing this switch allowsboiler to stop combustion.

Manual combustioncontrol part

Manual combustion switch

Auxiliary equipment is startedoperation by cam switch turning.Theignition transformer is not started untilpre-purge time elapses.For automatic combustion, set cam atAUTO.

Ammeter (fan)

It indicates current value of fan.

Buzzer stop switch

When alarm is started, this switch can be pressedto stop buzzer.

Alarm reset switch

This switch can be pressed to reset alarm.

Lamp test switch

Pre-purge completion lamp

This lamp lights up when operation time of fanexceeds set time in manual operation.When sufficient pre-purge lamp lights up, ignitiontransformer for manual operation is started.

Steam pressure regulator

Control equipment for proportional combustioncontrol based on boiler steam pressure.

Booster pump operation lamp

This lamp lights up when boosterpump is in operation.Booster pump operation switch

Atomized fluid selection switch

This switch can be used to switch atomized fluidbetween air and steam.

This switch can be used to switch main fuel oilpump between No. 1 and No. 2.

Fuel oil pump selection switch

This switch can be used during manual combustion toswitch between low combustion and proportionalcombustion control.

Indicator lamp (G: green, O: orange, W: white)

Selection switch

Push-button switch

It indicates current value of fan.

Boiler operation (COM MODE) lamp

Ammeter (fan)

Fuel heater switch

This switch can be used to switch by fuel oil type.When it isswitched to A, fuel heater is stopped.When it is switched to C,low oil temperature alarm function is enabled.When it isswitched to A, fuel heater is stopped.

Combustion changeover switch

Water level indicator Control equipment for opens and closes flow controlvalve depending on signal from differential transmitter.

23

1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch)

Figure 3-2 Manual Combustion Switch

Note

Do not use manual combustion switch except emergency.

1.3 Details of Alarm Display

Figure 3-3 Details of Alarm Display

Ignition transformer (pilot burner) is started.

It is not started until operation time of fan exceeds pre-purge time.If switch is shifted to IGNITION position before pre-purge time elapses,ignition transformer (pilot burner) remains stopped.

Fan is started.

Fuel oil pump and fuel oil heater are started.

All equipment is stopped.

Some self-diagnosisfunctions are also stopped.

Shifting switch to this position enables with ON.

Fuel oil pump and fuel oil heater are started.(When selecting C. A/C)Some self-diagnosis functions are enabled.

Fuel solenoid valve is opened.

Ignition transformer (pilot burner) remains running.

Ignition transformer (pilot burner) is stopped.

Combustion with main burner alone is continued.When combustion lamp is off, close combustion solenoidvalve.When combustion lamp is turned off, immediately shiftswitch back to FAN RUNNING position and perform purgefor 60 seconds or longer.Starting combustion without sufficient purge may cause fireor an explosion.

Circles (O) in the figure represent (red) indicator lamps.

24

CHAPTER 4: OPERATION

1. Inspection and Preparation before Operation1.1 Inspection and Preparation of Boiler and Peripheral Equipment

Before starting operation, check followings:

WARNING

Prohibition

Keep flammable materials away from boiler.

They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.

Do not put flammable materials in control box.

They may ignite to cause fire, resulting in accident involving death.

Instruction

Check that funnel (exhaust stack) is properly constructed.

Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may

cause carbon monoxide poisoning due to exhaust gas or fire.

Check for water or oil leaks around boiler related equipment.

Switching on or off wet equipment may cause electrical shock or fire from a short circuit.

Run ventilation (air supply and exhaust equipment) in engine room and check that air vent is

not blocked off.

If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may be

caused.

a) Check that funnel (exhaust stack) has been properly constructed.

If problem is found with funnel, do not operate boiler.

Restore funnel (exhaust stack) to normal state.

b) Check for water or oil leaks around boiler.

If leak is found, do not operate boiler. Turn off breaker of main power supply.

Remove cause of leak and dry the area completely.

c) Check where air inlet of engine room is and check that ventilation (air supply and exhaust

equipment) is working.

If engine room does not have air inlet, provide air inlet.

If air supply and exhaust equipment is stopped, bring it into operation.

25

d) Check that there are no flammable materials around boiler.

If flammable materials are found, remove them to safe place where flame is not used.

Improper storage of cloth stained with fuel or oil may cause it to ignite spontaneously. Handle

such materials carefully and dispose of them properly.

Wipe up spilt oil immediately.

e) Check where fire extinguishing system and first-aid kit are placed.

If these are not available, put them in place.

f) Check that contact numbers in case of fire or accident and how to handle such emergencies have

been established.

g) Check that there are no obstacles around boiler and in walkways.

If obstacles are found, put them back in place.

h) Check that air pressure in engine room is positive.

If air pressure in engine room is negative, install additional ventilator.

1.2 Inspection of Boiler Body and Accessories

a) Check equipment, inspection holes, covers, valves, and connections for water leaks.

If leak is found, fasten part or install it again to make it watertight.

b) Check that valves are opened and closed properly.

Check that outlet and inlet valves are opened.

Check that air vent valve is closed.

c) Check that drain pipe of safety valve is installed in safe place.

Check that wiring for operation of safety valves’ lever is operated normally.

d) Check that water level gauge glass is not stained and not damaged.

e) Check that needles of pressure gauges work properly.

When pumps are stopped, they are under head pressure only.

For details about inspection items, refer to page 47 “1.1 Regular Inspection and

Maintenance” in Chapter 5.

26

1.3 Inspection and Preparation of Feed Water System

WARNING

Do Not Touch

If you touch coupling of pump, which is spinning rapidly, you may get caught in it. Do not

touch coupling of pump during pump operation.

Instruction

If you touch hot piping of feed water system, you may suffer burn. Wear protective


Caution: Hot



1.3.1 Inspection Items

a) Check that cascade tank contains sufficient amount of water.

b) Check that feed water is clean.

c) Check that oil has not gotten into feed water (Use observation measure to check that oil has not

gotten into feed water).

d) Check that automatic feed water valve (ball tap) works properly.

e) Check that valves on feed water line are opened and closed properly.

Check that all valves on feed water line of feed water pump in use are opened.

(Check that opening instruction of flow control valve is proper.)

Check that feed water pump in use matches switch number in control panel.

f) Check pipes for clogging, air inclusion, leaks, or loose connections.

g) Check that strainer on suction side is not clogged.

h) Check that seal of feed water pump has no leaks.

i) Check that needles of pressure gauge and compound gauge work properly.

j) Check chloride ion concentration of water in cascade tank (once a week).

For more details, refer to Manual for Water Treatment.

27

1.3.2 Flushing of Pipes

Note Following preparation procedure is needed when boiler is used for the first time or when pipe

system is repaired.

There may remain in pipes welding chips, rust or other foreign matters that may have bad

influence on feed water. Before feeding water, flush pipes with treated water or pressurized gas as

needed.

Whether flushing is needed or not depends on how pipes have been constructed. Before flushing

pipes, consult with constructor about procedure and safety precautions.

1.3.3 Air Vent

Note Following preparation procedure is needed when boiler is used for the first time or when pipe

system is repaired.

Let out air of pipes on suction side. Air remaining in pipes may cause cavitation, resulting in

damage of pump.

Prepare for operation of feed water pump according to instruction manual for feed water

pump.

28

1.4 Inspection and Preparation of Fuel System

WARNING

Instruction




Caution: Hot


CAUTION

Instruction

If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures

to prevent fuel oil spill and establish method for coping with spillage in advance.

1.4.1 Preliminary Inspection

a) Check that F.O. service tank contains specified fuel.

b) Check that F.O. service tank is heated moderately.

When H.F.O. (*) is used, heat it so that temperature reaches over 65°C at main fuel pump inlet.

c) Discharge drainage from F.O. service tank.

d) Check valves open-close condition on fuel piping between F.O. service tank and boiler.

Open all valves on supply line.

Close all air vent valves.

e) Check that there are no pipes clogging, loose connections, or fuel leaks.

Especially, check the top of boiler carefully because burner is often removed for inspections.

f) Check that pipe system has no place where air tends to build up.

g) Check fuel strainer has no clogging.

h) Check that fuel is supplied properly from service tanks to fuel oil pump.

If problems are found or fuel is not supplied properly, check whether or not booster pump is

working properly.

i) Check that needles of pressure gauges and thermometers are working properly.

29

1.4.2 Air Vent

a) Open valves of fuel system.

b) Open strainer air vent valve to remove air.

c) Close air vent valve after removing air.

Remove air for both main and pilot.

d) Close valve V-1 in Figure 4-1.Check that drain valve V-2

is closed.

e) Shift manual combustion switch to AUTO COMB.

position.

Main fuel oil pump starts running.

Check that main fuel oil pump motor is running in

right direction with no abnormal noise.

f) Open drain valve V-2 and remove air sufficiently.

g) Check fuel system for leaks.

If leak is found, immediately stop fuel oil pump to stop

leak.

h) Check in fuel oil temperature controller that fuel is heated to right temperature.

Refer to page 108 “8.4 Fuel Oil Temperature Controller” in Chapter 5.

1.5 Inspection and Preparation of Burner

a) Check that ignition rod is clean and parts size is normal.

b) Check that pilot nozzle tip and main burner nozzle are not clogged.

c) Check that flame eye (*) and glass are clean.

d) Check that lead wire is installed properly between ignition transformer (*) and ignition rod.

e) Check that screws, levers, lock nuts, and other parts of damper are not loosened.

f) Check that equipment around burner is installed properly.

g) Check that there is no fallen object (insulation materials, castable, etc.) in furnace.

h) Check furnace for boiler water or traces of fuel oil leaks.

i) Check that inner cylinder is not damaged.

j)) Check generating tubes for heavy soil, wastage, or pinholes.

k) Check that atomized air pressure is between 0.6 MPa and 0.9 MPa.

Figure 4-1 Valves around Oil Air

Separator (*)

To F.O. Tank or D.O.Tank

Oil air separatorFrom burner

30

1.6 Inspection and Preparation of Electrical System

WARNING



hands.

Failure to observe this instruction may cause electrical shock due to high voltage, resulting in

injury or death.

a) Check that motors of fun, feed water pump, fuel oil pump, and other equipment run properly in

right direction.

b) Check that thermostats (exhaust gas, fuel oil heater (*), etc.), fuel oil temperature controller, and

pressure switch are set properly (Check setting values in list of principle items in final drawings).

c) Check that control panel is not damaged and that each equipment is installed properly.

d) Check for broken wires, loose screws, or damaged lamps or switches.

e) Check that power supply is as specified in list of principle items in final drawings.

f) Check external wiring of each equipment for broken wires or other problems.

1.7 Inspection and Preparation of Steam System

a) Check that valves on boiler and on steam piping are opened and closed properly.

b) Check that valves on boiler and on piping are installed properly.

If loose connections or other problems are found, retighten that part or install it again to bring

it back to normal condition.

c) Check that outboard valve for boiler water blow is closed.

d) Check that cooling water is circulating throughout drain cooler.

e) Check that excess steam dump valve is installed and set to specified pressure.

31

2. Automatic Operation (Normal Operation)

WARNING



hands.


in injury or death.

Instruction

If water or steam leaks out of system, burn, blindness, or accidents involving death may be

caused. During operation and after stop, check connections of piping and air vent valve for

leaks.

If you touch hot piping of water and steam system, you may suffer burn. Wear protective





Surface temperature of upper part of boiler exceeds 60°C and may cause burn if surface is

touched. When working with upper part of boiler, wear gloves and other protective

equipment to prevent direct contact.

Switch fuel when boiler is in automatic operation mode. Operating error in manual

operation mode may cause backfire(*) or other accidents involving death.

Caution: Hot




2.1 Checking of Control Panel Switches

Check that all switches on control panel are set at OFF position.

If switch is not set at OFF, shift it to OFF position.

2.2 Feeding Water to Boiler

Before starting burner, feed water to boiler according to following procedure:

a) Open all valves from cascade tank to boiler.

b) Turn on boiler power supply.

c) Set feed water shift switch to AUTO and select pump to operate by feed water pump shift switch.

d) Turn on feed water pump start switch.

Operation indicator lamp of feed water pump lights up.

Buzzer of low low water level sounds. Press buzzer stop switch.

Check feed water pump and motor for abnormal noise or abnormal heating.

32

e) Check compound and pressure gauges on inlet and outlet of feed water pump.

f) Check in water level gauge that water supply is stopped at right level.

Check that water level gauge is cleaned and easy to read.

If it is dirty and difficult to read, clean it.

g) Check pipe system for water leaks.

h) Press alarm reset switch and check that low low water level lamp is turned off.

2.3 Feeding Water to Boiler by Differential Transmitter

CAUTION

Caution

In feed water control by differential transmitter, feed water pump control does not operate

properly when feeding water and adjustment of differential transmitter is not completed.

Boiler becomes fill with water and high water level, it may cause hot water blow out from

safety valve during boiler combustion.

Note

Supply water to differential transmitter when pressure of boiler body is atmospheric pressure

and temperature of water is normal. Feeding water to differential transmitter under high

temperature and high pressure may cause damage of differential transmitter.

Set feed water shift switch to AUTO after feeding water to piping of differential transmitter and

close bypass valve of manifold valve.

In case that feed water pump is operated before adjustment, feed water pump is not stopped

until high water level. Stop feed water pump manually.

2.3.1 Feeding Water to Differential Transmitter

Before feeding water to differential transmitter, flush pipes. Recommend procedure is described

below. Start operation when close all valve and plug.

a）Check that all manifold valve of differential transmitter is closed.

Feed water to boiler manually to upper level of root valve for low pressure side (position

above middle of water level gauge)

Open root valve for low pressure and drain valve of low pressure side piping when water is

accumulated.

Blow low pressure side piping until drain water is not dirty.

b）When drain water is not dirty, open all manifold valves, and close drain valve of low pressure side.

Open drain valve of high pressure side piping.

Take off plug of air vent valve of seal pot, and open air vent valve. Blow high pressure side

piping.

33

c）When drain water is not dirty, close manifold valve (bypass valve).

Supply water from air vent valve of seal pot. Or feed water to seal pot after raising water level

of boiler and opening root valve for high pressure side.

Continue to blow high pressure side piping.

Note

Select feed water from air vent valve of seal pot in case it can’t blow from high water level to return

to normal water level.

d）When drain water is not dirty, close drain valve of high pressure side pipng.

e）Accumulate water to air vent valve of seal pot.

Open root valve for high pressure side in case of feed water to boiler from air vent valve. Stop

supplying water and close air vent valve and install plug.

Close air vent valve and install plug in case that feed water from boiler. And blow to boiler

normal water level.

f）Feeding water of differential transmitter is completed in above procedure.

Figure 4-2 Reference piping layout of differential transmitter(Remote level gauge）

34

2.4 Starting Combustion with M.D.O. (*)

Note

When H.F.O (*) is used as main fuel (*), switch main fuel to M.D.O. in advance for cold start. If H.F.O

is used in cold start, poor combustion or failure of fuel oil pump may be caused. Similarly, before

stop operation, switch to M.D.O. in advance if it is expected that fuel oil pump will not be used for a

long period of time.

2.4.1 Combustion with Air Atomization

a) Close air vent valve of oil air separator (*).

b) Open and close return lines of booster pump leading to D.O. tank and to F.O. tank, respectively.

c) Open D.O. tank valve and close F.O. tank valve.

d) Open outlet and inlet valves of booster pump and start booster pump.

As for use of booster pump with M.D.O. combustion, follow rules of vessel.

e) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.

f) Shift fuel oil heater (*) switch to A position.

g) Shift atomized fluid selection switch to AIR position.

h) Close main steam valve and atomized steam valve and open atomized air valve.

i) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot

side.

j) Check that filter regulator pressure is set at 0.4 MPa.

k) Select pump to be used by fuel oil pump selection switch.

Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.

l) Shift manual combustion switch on AUTO COMB. position.

m) Press combustion switch.

After fan starts running and pre-purge (*) is completed, combustion operation is started.

Several seconds later, combustion is started and combustion lamp lights up.

Check fuel oil pump and fan for abnormal noise.

35

2.4.2 Control and Checking during Operation (Combustion with Air Atomization)

After combustion is started, check that boiler is in normal operation.

Check that fuel flow amount, fuel oil pump discharge pressure, damper opening, and current

are not different substantially from those recorded on trial operation report.

Check that color, expansion, and stability of flame are the same as usual.

Check color of smoke (black) and check for any gas leakage from its path.

Check for vibration or abnormal noise.

If any problem is found, stop combustion and remove cause of problem.

Check fuel pipe system for fuel leaks.

Check that needles of pressure gauges do not jump.

2.4.3 Combustion with Steam Atomization

a) Check that boiler steam pressure is 0.7 MPa or above.If it is below 0.7 MPa, increase steam

pressure by combustion with air atomization.

b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized

steam.

c) Shift atomized fluid selection switch to STEAM position.

d) Check that main steam valve is closed.

e) Check that emergency fuel switch valve on main side is opened and emergency fuel switch valve

on pilot side is closed.

f) Check that filter regulator pressure is set at 0.4 MPa.

g) Select pump to be used by fuel oil pump selection switch.

Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.

h) Check that manual combustion switch is set at AUTO.COMB.

i) Press combustion switch.




Check that after about 30-second low combustion, proportional control combustion based on

steam pressure is started.

2.4.4 Control and Checking during Operation (Combustion with Steam Atomization)

a) Check that boiler is in normal operation.

Refer to “2.4.2 Control and Checking during Operation (Combustion with Air Atomization)”

in Chapter 4.

b) Check that when steam pressure increases and reaches max. design pressure, combustion is

automatically stopped.

Main fuel oil pump is stopped.

After about 35-second post-purge (*), fun stops running.

36

c) Open main steam valve gradually to send air to steam system.

Check steam system for leaks.

2.5 Combustion Stop

Press combustion stop switch.

Main fuel oil pump is stopped.

(When H.F.O.(*) is used, it continues to operate.)


<Perform following operations as needed :>

○ Blow of boiler through surface, bottom and of water level gauge

○ Closing valves of feed water system and fuel system

Note

When switching fuel from M.D.O.(*) to H.F.O., check that boiler steam pressure is 0.7 MPa or

above, and then close mail steam valve and stop combustion.

2.6 Shift from M.D.O. to H.F.O.

a) Operate boiler with M.D.O. properly.

b) Heat F.O. service tank to proper temperature (between 80°C and 90°C).

Heat tank so that temperature reaches over 65°C at main fuel oil pump inlet.

c) According to procedure in 2.4, stop boiler and F.O. booster pump.

d) Open and close return lines of booster pump leading to F.O. tank and to D.O. tank, respectively.

e) Open F.O. tank valve and close D.O. tank valve.

f) Run booster pump.

Check that heated H.F.O. is flowing through return lines of booster pump.

g) Shift manual combustion switch to AUTO.COMB position.

h) Press combustion switch.

Main fuel oil pump is started.






i) Shift fuel oil heater (*) switch to A/C position.

Note

When fuel oil heater switch is shifted to A/C position, fuel oil heater is turned on with low oil

temperature alarm function disabled.

37

j) Adjust opening of air vent valve of oil air separator (*).

Adjust opening according to combustion state.

k) Open steam trace valve of boiler fuel oil pipe.

l) When indication of fuel oil heater (*) temperature controller reaches setting value (refer to page 78

“5.3.3 Heavy Oil Heating Temperature” in Chapter 5.), and pressure is settled, slightly open drain

valve on fuel return line of oil air separator and visually check that oil has been fully replaced.

m) Shift fuel oil heater switch from A/C position to C position.

Low oil temperature alarm function is enabled.

n) Check that boiler is in normal operation.

Refer to page 35 “2.4.2 Control and Checking during Operation (Combustion with Air

Atomization)” in Chapter 4.

Note

If fuel is heated before M.D.O.(*) is fully replaced with H.F.O.(*), fuel is vaporized to cause cavitation

in fuel oil pump. If abnormal noise or rapid change of pressure gauge value is observed,

immediately shift fuel oil heater switch to A position (turn off fuel oil heater) and check again that

M.D.O. has been fully replaced with H.F.O.

2.7 Shift from H.F.O. to M.D.O.

a) Operate boiler with H.F.O. properly.

b) Open M.D.O supply valve, and close H.F.O. supply valve quickly.

c) Close steam trace valve on boiler fuel oil pipe.

d) Shift fuel oil heater switch to A position.

e) Check that fuel oil heater outlet temperature is decreased and pressure is stable.

f) Fully close air vent valve of oil air separator.

g) Slightly open drain valve on fuel return line of oil air separator and visually check that oil has been

fully replaced.

h) Open and close return lines of relief valve of F.O. booster pump leading to D.O. tank and to F.O.

tank, respectively.

i) Check that boiler is in normal operation.



Note

Switch fuel to M.D.O. when boiler is shut down for a long period. Low temperature F.O. may

damage fuel oil pump, mechanical seal, solenoid valves and fuel oil heater.

38

3. Emergency OperationEmergency operation is function that restarts boiler quickly when low atomized steam pressure alarm is

issued or when boiler steam pressure is temporarily decreased during combustion with H.F.O.(*).

This function switches atomized fluid to air, circulates H.F.O. in fuel piping, and temporarily causes main

burner to burn M.D.O.(*) in pilot burner line.

This is emergency operation, and cannot be used in other situations.

3.1 Emergency Combustion Operation

a) Press combustion stop button and check that combustion is stopped.

Main fuel oil pump continues to operate.


b) Close main steam valve, atomized steam valve, and valve on boiler body for atomized steam and

open atomized air valve.

c) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.

d) Check that filter regulator pressure is set at 0.4 MPa.

e) Shift atomized fluid selection switch to AIR position.

f) Close emergency fuel switch valve on main side and open emergency fuel switch valve on pilot

side.

g) Check that manual combustion switch is set at AUTO.COMB.

h) Press combustion switch.




3.2 Control and Checking during Operation

Check that boiler is in normal operation.



3.3 Restoration to Normal Combustion and Checking of Combustion

a) Check that boiler steam pressure is 0.7 MPa or above.

If it is below 0.7 MPa, increase steam pressure by emergency combustion.

b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized

steam

c) Shift atomized fluid selection switch to STEAM position.

39

d) Check that main steam valve is closed.

e) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot

side.

f) Press combustion switch.

After fan starts running and pre-purge is completed, combustion operation is started.





g) Check that boiler is in normal operation.



40

4. Manual Operation (Use Only in Emergency)

WARNING

Prohibition

If automatic operation is hindered by parts damage or another reason, remove cause of

problem and start automatic operation again.

This boiler has manual operation circuit for emergency operation when automatic operation

is hindered. Operating error in manual operation mode, in which some safety systems are

disabled, may cause accident involving death. Do not use manual operation mode except in



Cases in which automatic operation cannot be continued are as follow:

<Feed water pump circuit>

Failure of instrumentation

<Combustion circuit>

Sequencer trouble

Sensor trouble, interlock by abnormality detection

In manual operation mode, backfire (*) or other accidents involving death by ignition error or

fire by empty heating may be caused. Do not use manual operation mode except in



During manual combustion operation, do not shift fuel (M.D.O.(*) ↔ H.F.O.(*)).Failure to

observe this instruction may cause backfire or other accidents involving death.

Instruction

Perform purge operation sufficiently before ignition and when combustion is stopped.

Insufficient purge operation may cause backfire or other accidents involving death.

Pre-purge (*) (before ignition): 20 seconds or longer *

Post-purge (*) (when combustion is stopped): 60 seconds or longer.

* In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit after

20-second or longer pre-purge.

41

WARNING

Caution

In manual operation mode, following interlock functions of safety system are disabled.

Improper operation may cause accidents involving death. Be careful with operating boiler in

manual operation mode.

Interlock functions disabled when manual combustion circuit is used:

Fuel oil pressure low (fuel)

Fuel oil temperature high (fuel)

Fuel oil temperature low (fuel)

Steam pressure high

Steam pressure low

Abnormal fire

These interlock functions work only when all functions are working properly. When there are

problems with sensors or other parts, interlock functions may not work properly.

There are two circuits for manual operation: one for manual feed water pump operation and another for

manual combustion operation.

4.1 Starting/Stopping Manual Feed Water Pump Operation

Note

When feeding water manually, do not leave boiler.

Proportional control from differential pressure is operated, but high level alarm is disabled.

4.1.1 Starting Manual Operation

a) Turn on breaker of main power supply.

Power lamp lights up.

b) Select pump to be operated by feed water pump shift switch.

Check that outlet and inlet valves of feed water pump to be used are opened and closed

properly.

c) Set feed water shift switch to MANU.

Feed water pump is started.

4.1.2 Stopping Manual Operation

Set feed water shift switch to OFF.

Feed water pump is stopped.

42

4.2 Manual Combustion

Note

When manual combustion is performed, do not leave boiler. If there is any problem, it is not

controlled automatically.

Enter manual operation by shifting manual combustion switch in order. Manual combustion switch

can be set to the following positions: [OFF], [F.O. PUMP/HEATER], [FAN RUNNING], [IGNITION]

(ignition (pilot burner)),[ PRI.COMB.] (preliminary combustion (double combustion with pilot burner

and main burner), [COMB.] (combustion (single combustion with main burner). These positions are

arranged in this order. Boiler also has combustion changeover switch that can be used to switch

between low combustion and proportional control combustion. Because individual operation of each

equipment is not allowed for safety reasons, turn cam switch in order to check operation.

Procedure for starting combustion with air atomization using M.D.O. (*) as main fuel (*) is described

below:

a) Check that manual combustion switch is set at [OFF].

b) Check that combustion changeover switch is set at [LOW] (low

combustion).

c) Follow steps a) to k) in 2.4.1.

Refer to page 34 “2.4.1 Combustion with Air

Atomization” in Chapter 4.

d) Shift manual combustion switch to [F.O. PUMP/HEATER].

Main fuel oil pump is started.

Check that fuel is circulating properly (Check oil pressure gauge).

e) Shift manual combustion switch to [FAN RUNNING].

Fan is started.

Check for abnormal noise.

f) Check that pre-purge (*) completion lamp lights up.

Combustion can be started when pre-purge completion lamp

lights up.

g) Shift manual combustion switch to [IGNITION].

Ignition rod sparks and pilot burner ignites.

Check through sight glass that pilot burner is burning.

Note

If pilot burner is not burning, immediately shift manual combustion switch back to [FAN RUNNING]

and repeat f) and subsequent steps in 4.2.

43

h) Shift manual combustion switch to [PRI.COMB.].

Double combustion with pilot burner and main burner is started.

Check through sight glass that it is burning.

Note

If main burner is not burning, immediately shift manual combustion switch back to [FAN

RUNNING] and repeat f) and subsequent steps in 4.2.

i) Shift manual combustion switch to [COMB.] position.

Pilot burner is put out, and combustion is continued with main burner alone.

Check through sight glass that it is burning.

Note

If main burner is not burning, immediately shift manual combustion switch back to [FAN

RUNNING] and repeat f) and subsequent steps in 4.2.

j) When combustion changeover switch is shifted to [AUTO.] (proportional control combustion)

during combustion with steam atomization, proportional control combustion is started.

4.3 Manual Combustion Stop

a) Shift manual combustion switch from [COMB.] to [FAN RUNNING].

Combustion is stopped. Only fan continues to operate.

Keep switch at [FAN RUNNING] for 60 seconds or longer for post-purge (*).

b) Shift manual combustion switch to [OFF].

Fan and main fuel oil pump are stopped.

44

5. Emergency Stop

DANGER

Caution


emergency. If breakers are turned off inadvertently, feed water and circulating water pumps

may be stopped to cause soot fire or furnace explosion. Do not use this function except in

emergency.


emergency. Emergency stop skips safety checks for ongoing operation and may cause

unexpected accident or failure. Use this function only when there is unavoidable reason for

bringing boiler to emergency stop. Users must judge when and how boiler should be

brought to emergency stop because it depends on situation.

When resuming operation after emergency stop, ensure that switches are turned on or off to

stop all ancillary equipment before turning power on. Otherwise, equipment may start to

work unexpectedly to cause accidents.

Procedure of boiler emergency stop because of accident or other necessity to stop boiler urgently is

described here.

5.1 Emergency Stop of Combustion System

5.1.1 Cases in which Emergency Stop is Required

Fuel oil leaks

Considerably poor combustion

Abnormal noise from fan or fuel oil pump

Exhaust gas leaks

When part of body or object gets caught in rotating parts of fan or fuel oil pump, etc.

5.1.2 Stop Procedure

a) Shift manual combustion switch to OFF position.

Fuel oil pump and fan are stopped, and combustion is stopped.

b) Close main fuel valve.

5.2 Emergency Stop of Entire Boiler

5.2.1 Cases in which Emergency Stop of Entire Boiler is Required

Fire

When all running equipment should be stopped immediately, etc.

5.2.2 Stop Procedure

Stop power supply to boiler or turn off power supply breaker in control panel.

All equipment is stopped.

45

6. Cold StartWhen boiler water becomes completely cold and especially when trial operation is started or new boiler

is brought into operation, start boiler with followings in mind:

For cold start, it needs to take enough time until steam pressure is raised to 0.1 MPa because each

part of boiler is completely cold.

Note

Do not raise steam pressure rapidly.

a) Raise steam pressure gradually to 0.1 MPa by repeating 1 minute combustion and 4 minute

purge.

Keep steam pressure at 0.1 MPa for 10 minutes.

While steam pressure is between 0.1 MPa and 0.2 MPa, repeat 2 minute combustion and

3 minute purge to raise pressure.

b) When steam pressure reaches around 0.2 MPa, stop boiler.

Retighten bolts and nuts around fastening parts and connections of valves on body, manhole

packing and water level gauge.

c) Blow water level gauge to make it easy to check.

d) Blow boiler water and purify water.

Make boiler water purify.

e) After steps a) to d) are finished, turn on combustion switch to start combustion again.

f) When steam pressure is increased to maximum pressure for general use, check for steam

leaks.

g) Open main steam valve and start automatic operation.

46

CHAPTER 5: INSPECTION AND MAINTENANCE

1. List of Inspection Items and Inspection Frequencies

WARNING

Caution

Surface temperature of the top of boiler exceeds 60°C and may cause burn if surface is

touched. Take extra care in daily inspection work.

CAUTION

Instruction

When cleaning strainer or performing other work using oil, wear protective equipment to

protect eyes and body from splashes of oil.

In order to prevent accidents, carry out inspection and cleaning listed below regularly.

(Some items should be inspected depends on system.)

List shows standard inspection frequencies. More frequent inspections may be required, depending on

use conditions or environments.

Carry out inspections with appropriate frequency on your own responsibility.

Note

When carrying out inspections, put sign on boiler stating that it is under inspection.

47

1.1 Regular Inspection and Maintenance

Inspection/maintenance itemEveryday

Everyweek

Everymonth

Every 3months

Everyyear

Whendocked

Check of ventilation ●

Check of surroundings for flammable materials ●

Check of funnel (exhaust pipe) ●

Check of feed water pump for leaks or abnormal noiseand check of pressure gauge

●

Retightening of valves, gland, and flanges (only whensigns of leaks are found)

●

Drainage of fuel service tank ●

Blow of water level gauge P 97 ●

Inspection and adjustment of drive part of dampers P 59 ●

Sampling of boiler waterManual for

WaterTreatment (●)

Blow of boiler through surface and bottomManual for


Hardness check of water softenerManual for


Cleaning of fuel strainer P 63 - 65 (●) ●

Maintenance of burner body (Baffle plate, rectifier grid, etc.) P 52 - 55 ●

Inspection of burner nozzle P 52 - 55 ●

Inspection of ignition rod for cracks and adjustment ●

Inspection of wind box(*)

●

Inspection of fan P 55 ●

Inspection of link of blower suction damper P 57 ●

Measurement of insulation resistance of each motor P 56 ●

Inspection of flexible tube P 59 ●

Inspection of oil flow control valve, air flow controllerand damper

P59,60 ●

Inspection of control motor P 61 ●

Inspection of dirt on flame eye(*)

/glass. P 62 ●

Inspection and adjustment of discharge pressure offuel oil pump

P 66-68 ●

Inspection and adjustment of circulation relief valve P 69 ●

Visual inspection of wiring ●

Inspection of motor ball bearings P 56 ●

Inspection and cleaning of dirt on feed water strainer ●

Drainage of cascade tank ●

Inspection of drive valve for burner control P 70~ ●

Inspection and adjustment of fuel oil thermostat P79,80 ●

Inspection and adjustment of pressure switch P 82 - 84 ●

Operation check of each safety system P 87~ ●

Operation test of exhaust gas thermostat P 90 ●

Check of main burner assembly for fuel oil leaks ●

Inspection and adjustment of coupling for fuel oil pump ●

Inspection of inner cylinder of burner ●

Greasing of bearing of blower suction damper P 57 ●

Cleaning of water level detecting rods and holder andcheck of continuity and insulation

P 97 - 98 ●

Inspection of differential transmitter P 85 ●

Inspection of flow control valve P 86 ●

Cleaning and inspection of fuel oil heater P 95 ●

Inspection of feed water check valve ●

Voltage check of flame detector P 99 ●

48

Inspection/maintenance itemEveryday

Everyweek

Everymonth

Every 3months

Everyyear

Whendocked

Inspection of inside of boiler ●

Inspection of combustion chamber and cleaning of

furnace with water to remove sootP 100 ●

Inspection and cleaning of inside of fuel service tank ●

Inspection of inside of chimney ●

Inspection of valve on boiler ●

Cleaning of inside of cascade tank ●

Inner inspection and maintenance of differential transmitter ●

49

1.2 Safety Valve

WARNING

Prohibition

Improper adjustment of blow off pressure of safety valve may damage boiler body.

As a rule, do not adjust blow off pressure of safety valve.

Remodeling of safety valve may damage boiler body.

As a rule, do not remodel safety valve.

Instruction

If steam leak from safety valve is found, replace part and repair it immediately.

When steam leak is left, function of safety valve is decreased and there is possibility of

leading to serious accident

Safety valve is safety device that is installed to prevent boiler steam pressure from exceeding

maximum allowable working pressure; full-bore safety valve is used for this boiler. Normally, safety

valve does not operate because steam pressure switch works. When pressure switch does not work

for some reason and combustion is continued to cause abnormal steam pressure increase or rapid

pressure increase is caused by rapid load change, safety valve protects boiler by blowing steam off

and lowering steam pressure. As a rule, two or more safety valves are installed and they are

selected so that total blow off level exceeds the maximum evaporation level of boiler for safety.

Boiler safety valve is set at presence of inspector, so as to blow off at strictly limited pressure;

nobody is allowed to make attempt of further adjustment on board. However, only in case of

emergency, such as when safety valve leaks, some countermeasures, such as opening or adjusting

valve, can be taken at discretion of chief engineer. In that case, adjust blow off pressure of safety

valve according to procedure that is described in next page.

1.2.1 Internal Structure of Safety Valve

<50A or less>

No. Part name

1 Valve casing

2 Valve seat

3 Valve body

4 Adjustment ring

5 Valve cylinder

6 Lift control bush

7 Spring

8 Valve stem

9 Adjusting bolt and nut

10 Cap

11 Valve lift lever

Figure 5-1 Internal Structure of Safety Valve : 50A or less

50

＜65A or more＞

1.2.2 Adjustment Procedure of Safety Valve

a) Unlock key on shaft of valve lift lever (11), pull out shaft, and remove lift lever.

b) Remove cap (10) by loosening setting bolt.

c) Loosen nut (9) of adjusting bolt and activate safety valve.

● Switch to manual operation of boiler and check that steam goes up and blow off pressure of

safety valve.

d) Turn adjusting bolt (9) to left if blow off pressure is higher than pressure limit and to right if it is

lower than that, so that it blows off at limited pressure.

e) After adjustment, fasten adjusting nut (9) tightly to fix it securely.

f) Put cap back in place, set valve lift lever, and lock and fix key.

1.3 Other Important Inspection Items

<Boiler Water Treatment>

The procedure for water treatment is described in Manual for Water Treatment. Most of boiler

accidents come from faulty water treatment; read and understand instruction manual thoroughly for

water treatment.

Manual also describes procedure of long-term boiler shutdown. Refer to "Manual for Water

Treatment".

Note

If boiler that is designed 60 Hz power supply inside of vessel is docked and operated in 50 Hz land

power supply, each motor capacity for 60 Hz is decreased and cases lack of combustible air,

insufficient fuel flow rate. Be sure to use power supply on vessel. If boiler that is designed 50 Hz

power supply is operated in 60 Hz land power supply, motor is burned and magnetic contactor is

tripped.

No. Part name

1 Valve casing

2 Valve seat

3 Lower ring

4 Set bolt

5 Valve body

6 Upper ring

7 Guide

8 Valve stem

9 Adjusting bolt and nut

10 Cap

11 Valve lift lever

12 Spring

Figure 5-1 Internal Structure of Safety Valve : 65A or more

Stud bolt

Nut

51

2. Daily Inspection and Maintenance

Peripheral equipment depends on system. Use equipment properly according to instruction manual.

Put instruction manuals together with this manual in place so that they can be read whenever they are

needed.

For details about inspections of equipment around boiler before operation and monitoring for problems

during operation, refer to “1. Inspections and Preparation Before Operation,” "2.4.2 Control and

Checking during Operation (Combustion with Air Atomization),” and "2.4.4 Control and Checking during

Operation (Combustion with Steam Atomization" in Chapter 4.

Refer to page 24 “1. Inspections and Preparation Before Operation” in Chapter 4.



Refer to page 35 “2.4.4 Control and Checking during Operation (Combustion with Steam


52

3. Weekly Inspection and Maintenance

3.1 Main Burner

WARNING

Instruction

Complete purge by fan before burner opening and inspection to make combustion chamber

cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.

Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it

properly.

3.1.1 Overview

Main burner consists of main burner body with burner nozzle and guide pipe with baffle plate. In

burner nozzle, fuel oil sent by fuel oil pump is mixed with fluid for atomization (air or steam). The

mixture is squirted out of cap end and atomized.

Burner nozzle consists of cap, mixer, nozzle, check valve, and ferrule. Fuel oil sent from center of

burner nozzle and fluid for atomization supplied from circumference are squirted out of nozzle, mixed

in mixer, and then atomized through opening in cap. Check valve is installed before nozzle to prevent

oil dripping when combustion is stopped.

Clean main burner on a weekly basis.

3.1.2 Disassembly and Adjustment

< Main burner>

a) Loosen 2 hexagon socket set bolts on top of guide pipe and pull out burner gun.

b) Remove burner nozzle from main burner in ferrule position.

c) Disassemble burner nozzle into cap, mixer, nozzle, check valve, and ferrule.

● When disassembling it, pull out lock screws completely. Failure to pull out lock screws may

damage burner nozzle.

d) Wash these components with light oil, clean them with air, and assemble them by following

disassembly steps in reverse.

53

<Guide pipe>

a) Remove nut on upper plate and pull out guide pipe.

b) Remove baffle plate, wash these components with light oil, clean them with air, and assemble

them by following disassembly steps in reverse.

Figure 5-3 Structure of Burner

3.2 Nozzle Tip

CAUTION

Caution

Improper spray volume, spray angle, and spray form cause poor combustion and sometimes

cause backfire (*). Use only genuine parts.

No. Part name

1 Guide pipe

2 Main burner

3 Pilot burner

4 Cap

5 Mixer

6 Nozzle

7 Check valve

8 Ferrule

9 Lock screw

10 Upper plate

Enlarged View of Section A

Fuel oil inlet

Atomized fluid inletD.O. inlet

x 3 x 3 x 3

Atomized fluid

Fluid oil

54

3.3 Pilot Burner

3.3.1 Overview

This burner comes with pilot burner designed for use with M.D.O.(*). Pilot burner consists of baffle

plate, nozzle tip, nozzle holder, check valve, ignition rod, and nozzle pipe.

Oil entering nozzle tip of pilot burner goes through strainer and trench of distributor and enters

evolution room. Conical evolution room has orifice in its end. Oil increases its speed while swirling in

evolution room, passes through orifice, and then is sprayed to combustion chamber.

Nozzle tip is made of hard material as high-pressure, high-speed oil wears away orifice and other

parts. Replace it on a yearly basis.

No. Part name

1 Baffle plate

2 Nozzle tip

3 Nozzle holder

4 Check valve

5 Ignition rod

6 Nozzle pipe

Body Distributor Strainer

Figure 5-4 Structure of Pilot Burner

Figure 5-5 Nozzle Tip of Pilot Burner

55

3.3.2 Disassembly and Adjustment

a) Remove bolt on pilot burner and pull out pilot burner.

b) Remove nozzle tip, baffle plate, and ignition rod from pilot burner.

c) Disassemble nozzle tip into strainer, distributor, and strainer, wash these parts and baffle plate

with light oil, and clean them with air.

d) Remove soot out of ignition rod with brush.

e) After cleaning these parts, adjust their dimensions with reference to pilot burner dimensions

shown in Figure 5-3 and burner dimensions measured in trial operation, and assemble them.

4. Monthly Inspection and Maintenance

4.1 Fan

DANGER

Instruction

Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to

deterioration of impeller or external force, resulting in injury or death.

WARNING

Instruction

Before moving impeller by hand, turn off main power supply. If impeller is rotated accidentally

during maintenance, physical injury may be caused.

4.1.1 Overview

Fan, which forces air into boiler, secures wind pressure and wind flow by rotating impeller by motor.

This boiler has fan with high wind pressure and high revolution speed because combustion gas

speed is high for efficient heat exchange with combustion gas.

Attention and care are required to prevent foreign particles from clogging wire mesh of suction.

When there is significant vibration even after impeller is cleaned, bearing replacement or impeller

adjustment is required.

56

4.1.2 Regular Maintenance

a) Inspect fan once a month.

b) Check for vibration, strange noises, and abnormal bearing temperature increase during

operation. When fan is not in operation, turn off power supply, and move impeller by hand to

check for problems.

● Conduct insulation test once a month, after long-term shutdown, and when it is necessary. If

insulation resistance is below 1 MΩ, replace motor or unship and repair it.

● Motor bearing requires grease injection.

Grease motor bearing regularly according to notes on greasing on motor. Greasing is not

needed for HB-08T type because grease is sealed in bearing.

① HB-10T, 12T ② HB-15T, 18T, 20T

Figure 5-6 Bearing Grease Inlet

Table 5-1 List of Bearing Greases

Model

GreasingAmountto inject

(g)

Interval(hrs)

Recommended grease

①12T10T

20 1200

Exxon Mobil :Beacon 325

Nippon Oil Corporation :multinoc SDX

JOMO :LT Grease

Shell :Albania Grease HVQ

②20T18T15T

35 800

Esso :UnirexN2,N3 or S2(lithium complex base)

Mobil :Mobilith SHC 100(lithium complex base)

Shell :Albida EMS2(lithium complex base)

SKF :LGHQ3(lithium complex base)

Klumber :Kluberplex BEM 41-132(spectial lithium base)

FAG :Arcanol TEMP110(lithium complex base)

※ 08T Greasing is not needed because grease is sealed in bearing.

57

4.2 Suction Damper (Attachment of Blower)

WARNING

Instruction

Inspect suction damper once a month. Failure to inspect suction damper may cause damage

of part and malfunction due to looseness of part, resulting in injury or death.

4.2.1 Overview

Suction damper opens fully when combustion is started and it closes fully after post purge(*) of

combustion stop for restraining heat loss due to blowing of continuous-running fan motor.

3 damper plates are connected to motor with damper arm. They open and close in interlock with

rotation of motor. Limit switch is installed on damper arm part to check that damper opens fully during

combustion.

Oscillation and external force apply to damper continually, so pay attention to looseness of part etc.

Figure 5-7 Suction Damper

4.2.2 Inspection

a) Confirm that there is no looseness of fastening part once a month.

(Link block, damper arm and damper plate)

b) Grease bearing of damper shaft once every three months.

・Required grease is alvania grease S3 (SHOWA SHELL SEKIYU K. K.). Greasing amount is 1.4g.

c) Confirm that there is no looseness of fixed screw and wiring once a month.

・This boiler doesn’t shift to automatic combustion if motor is damaged.

Motor

Damper body

Limit Switch

Damper arm

Motor arm

Motor wiring hole

Wiring fixing base×3

Wiring holeLink block

58

4.2.3 Measures on Failures (Fixing Fully Open State)

In case that damper doesn’t fully open automatically due to malfunction of motor, this boiler doesn’t

shift to automatic combustion, so damper needs to be fixed in open state forcibly.

Follow the following instructions for fixing damper.

a) Remove link block of tip part of motor arm A.

b) Pull up connecting rod until damper opens fully.

Confirm that damper arm touches limit switch in that position.

c) Let removed link block through connecting rod and fix motor arm B and connecting rod firmly.

d) Confirm that damper is fixed in open state.

Figure 5-8 Diagram of fixed position of open state (Left: Fully closed, Right: Fully open)

Connecting rod

ucture of Safety

Link block

Motor arm B

Motor arm A

59

4.3 Fuel Flexible Tube

WARNING

Instruction

Do not give impact to boiler fuel pipe or bend any part of it.

Failure to observe this instruction may cause fuel oil leak, resulting in fire.

Flexible tube on burner is used at high temperature and high pressure.

Generally, it needs to be replaced once every 1 or 2 years.

4.4 Oil Flow Control Valve, Air Flow Controller, and Damper

WARNING

Instruction

Equipment has been brought into optimum state in trial operation. Do not make changes to

state after trial operation. Failure to observe this instruction may cause poor combustion,

backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA

offices and ask for instructions.

4.4.1 Overview

Fuel oil flow rate and air flow rate are adjusted by oil flow control valve, air flow controller, and

damper.

Oil flow control valve changes its opening to adjust fuel oil flow rate. By rotating control motor on oil

flow control valve shaft, slot in shaft is rotated to change inner opening.

Air flow controller attunes throttling characteristics of oil flow control valve to air flow throttling

characteristics of damper. It has leaf spring bent into a fan-like shape, along which damper drive arm

moves. This leaf spring has 8 adjustment bolts, with which spring's shape can be changed to adjust

air flow throttling characteristics of damper. This mechanism adjusts air flow to optimum rate for

combustion levels at different combustion loads.

Damper is subject to continuous vibration and external force and must be checked for loose parts.

60

4.4.2 Inspection

Loose parts of damper cause changes in damper opening. Check damper drive arm and leaf spring

for loose lock screws on a monthly basis. If loose parts are found, retighten them or apply grease.

Coupling is connects motor and air flow controller shaft by tightening lock screw. Inspect looseness

of lock screw once a month because it can not control combustion normally when lock screw is

loosened. If loose parts are found, retighten them additionally and check that control motor opening

and air flow control valve opening have not deviated from position in trial operation.

図 5-6 燃焼調整ダンパ

Figure 5-9 Oil Flow Control Valve and Air Flow Controller

Damper

Damper drive arm

Lock nut

Damper drive arm

Damper drive arm

Lock nut

Control motor

Leaf springAir flow controller

Air flow controller

Leaf spring

adjusting bolt

Oil flow control

valve

Coupling

Control valve

opening instruction

plate

Coupling

Lock screwControl motor opening

Coupling

Air flow controller

Leaf spring

adjusting bolt

Lock screw

61

4.5 Control Motor

4.5.1 Overview

Control motor controls oil flow control valve and damper to realize proper combustion conditions for

different pressure conditions according to signals from steam pressure regulator. It also has cam

switches in it, which notify control panel of damper position.

Because it repeats opening and closing constantly during combustion control, parts of control motor

inside are consumed gradually. Generally, it needs to be replaced at every docking.

Figure 5-10 Control Motor

4.5.2 Inspection

If control motor is failed, it cannot be burned normally.

Inspect fixed screw and wiring for looseness every month.

62

4.6 Flame Eye (*)

Figure 5-11 Flame Eye

4.6.1 Overview

Flame eye is a device that detects flame during combustion and gives instruction to combustion

circuit. It monitors flame by using photosensitive characteristic of CdS (cadmium sulfide cell)

(Normally, when resistance of 100 kΩ catches flame, it drops under 500 Ω).

If flame eye is damaged or protection glass is blackened with soot, it cannot detect flame and

stops burner and brings it to the same state as when ignition failure or flame-out occurs.

4.6.2 Inspection and Cleaning

Ignite burner with burner switch and look in furnace through sight window. If flame dies out about 3

or 4 seconds after burner is ignited, flame eye or flame detector may be out of order or protection

glass soiled. Inspect and clean protection glass on a monthly basis.

Refer to page 99 “6.3 Flame Detector (FS-901) ” in Chapter 5.

1 Flame eye

2 Flame eye fitting box

3 Flame eye fitting stand

4 Protection glass

5 Packing (2 pcs.)

63

4.7 Strainer for Fuel

4.7.1 T-type Auto-cleaner

T-type auto cleaner removes dust and other impurities from fuel to prevent them from entering and

damaging fuel oil pump, solenoid valves, or burner nozzle. It is installed on suction side of fuel oil

pump.

<Cleaning>

Element of auto cleaner can be cleaned during operation. To prevent it from being clogged, turn

handle and clean it at least once a day.

Drain all water and sludge from strainer once a month.

Figure 5-12 Oil Strainer

1 Cleaner cover 9 Air vent plug 17 Square rod

2 Oil tank 10 Packing 18 Round rod

3 Handle 11 Upper end 19 Drain plug

4 Main shaft 12 Lower end 20 Packing

5 Gland 13 Fixing plate 21 Washer

6 O ring 14 Packing 22 Nut

7 Ring 15 Filter plate 23 Cap nut

8 Packing 16 Scrapper plate

64

a) Draining strainer

Close main valve of fuel service tank, loosen drain plug (19) in lower part of strainer, and drain

water and impurities from strainer.

b) Disassembling and cleaning

● Check main valve of oil tank is closed.

● After draining of strainer, remove bolt on the upper part of oil strainer to remove cup.

● Clean dust off plate filter with oil.

● Assemble strainer in reverse order.

c) Air vent

● Open main valve of oil tank and slightly loosen air vent plug (9) on the upper part of auto cleaner.

● When air is removed and oil starts to come out of loosened screw, fasten screw.

4.7.2 Y-type Strainer

Y-type strainers are installed on outlet of fuel oil heater (*) and inlet of burner. Remove foreign

materials that are contained in fuel oil to prevent solenoid valves and other parts from being

damaged.

● Cleaning

Open and clean Y-type strainer and inspect element for deformation or damage about once

every 3 months; frequency depends on property of fuel oil.

Replace a deformed element with new one.

4.7.3 Double Strainer

Double strainer removes dust, sand, and other impurities from fuel that is used with boiler to prevent

them from entering and damaging fuel oil pump, solenoid valves, or burner nozzle. Double strainer is

installed on suction side of fuel oil pump.

1 Body

2 Cover

3 Upper cock cover

4 Lower cock cover

5 Cock plug

6 Cock switch handle

7 Cock lift handle

8 Spindle

9 Cover retainer

10 Fastening bolt

11 Ring

12 Packing retainer

13 Filter tube handle

14 Filter tube

15 Filter rope

16 Drain plug

17 Air vent plug

18 O ring

19 O ring

20 O ring

21 O ring

22 Gasket

23 GasketFigure 5-13 Double Strainer

65

<Procedure of screen switching>

a) Close line valve first.

b) Pull up cock lift handle (7), give it two turns

counterclockwise when viewed in Figure 5-13, and pull

up cock plug (5).

c) Turn cock plug (5) in desired direction by using cock

switch handle (6).

● If cock switch handle (6) is turned rightward (refer to

Figure (a)), strainer B is used.

● If cock switch handle (6) is turned leftward (refer to

Figure (b)), strainer A is used.

d) Pull up cock lever (7) and turn it clockwise to allow cock

plug (5) to adhere closely to body (1).

e) Fully open line valve gradually.

f) When oil passes through strainer A or B, air is

accumulated in upper part of body (1). Loosen air vent

plug (17), and close it after checking that oil comes out

slightly.

<Procedure of disassembling and cleaning of strainer>

Disassemble and clean strainer that is not used according to following procedure:

a) Check that screen that is disassembled is not used.

b) Loosen drain plug (16) and air vent plug (17) to drain oil.

c) Loosen fastening bolt (10) and remove cover retainer (9) and cover (2) after oil is completely

discharged.

d) Take out screen (14) by using screen handle (13).

e) Clean screen filter (15).

f) Assemble strainer in reverse order. Set screen (14) in strainer body.

g) Close drain plug (16) and air vent plug (17).

h) Fully open line valve gradually, and close air vent plug when oil comes out from air vent plug (17)

that fills stop side with oil.

Figure

Figur

Figure 5-14 Double Strainer

Screen Switching

Figure (a)

Figure (b)

66

4.8 Fuel Oil Pump

4.8.1 GD Type (for Pilot Burner)

This boiler uses GD type pilot pump. This pump is connected to motor through a coupling and runs

at a speed of about 3500 rpm to send fuel to pilot burner nozzle though solenoid valve.

Figure 5-15 Rotors of Fuel Oil Pump (Trochoid System)

Fuel oil pump employs trochoid system as shown above and it generates high pressure by rotation of

inner and outer rotors. Rotor has profile as shown above and inner and outer rotors rotate in light

contact with each other and tooth surface slippage is quite limited. Almost no noise is generated

because oil is not contained.

However, inspect fuel oil pumps and adjust discharge pressure once a month.

Refer to page 67 “4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting” in Chapter 5.

Figure 5-16 GD Type

< Adjustment>

● Adjust pressure by using pressure regulating valve.

● Turning it to right increases pressure, and turning it to left decreases pressure.

Note Pump rotates clockwise when viewed from the end of pump shaft.

< Inspection and maintenance>

Check cover and oil seals for leaks on a daily basis.

● It does not contain strainer. In case of trouble, do not disassemble unit, and unship and have it

repaired.

Return opening

Suctionopening

Discharge opening

Note: Do not disassemble rotors and other major partsfor repair. It cannot be repaired disassembledpump that is not covered by guarantee.

Pressure regulating valve

67

4.8.2 Main Fuel Oil Pump

This pump is connected to motor through a coupling and sends fuel to burner nozzle though fuel oil

heater (*), oil flow control valve, and fuel shutoff valve.

Prepare for operation of main fuel oil pump according to instruction manual for screw pump.

4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting

CAUTION

Instruction

This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating

valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil

pump is deteriorated over time and its performance is gradually declined.

If fuel oil pump is used for many years without adjustment, it deteriorates and becomes worn and

causes decreases in oil pressure.

In order to maintain proper oil temperature and circulation level, check and adjust discharge

pressure of fuel oil pump once a month according to following procedure. If oil pressure is adjusted

with M.D.O. (*), adjust it again when fuel oil is switched to H.F.O. (*).

Note Ensure that safety valve pressure setting of fuel oil heater is not exceeded.

a) Stop combustion and run fuel oil pump.

b) Slowly close fuel return pipe valve (1) shown in Figure 5-17.

● Pressure indicated in fuel oil pump discharge pressure gauge (2) is increased slowly.

c) Adjust pressure indicated in fuel oil pump discharge pressure gauge (2) to value set in trial

operation by using pressure regulating valve (3) of fuel oil pump unit.

d) Slowly open fuel return pipe valve (1). Pressure indicated in fuel oil pump discharge pressure

gauge (2) is decreased slowly.

e) Open discharge valve (4), check that fuel oil is circulating, and close it.

Figure 5-17 Fuel Oil Pump Discharge Pressure Setting

F.O. return

F.O. inlet

68

<Adjustment of Pressure Regulating Valve>

(1) Remove adjustment screw cover of fuel pressure regulating valve and loosen lock nut.

(2) Turn adjustment screw of fuel pressure regulating valve to adjust pressure.

● Turn screw clockwise to increase pressure.

● Turn screw counterclockwise to decrease pressure.

(3) Check indicated pressure and tighten lock nut.

(4) Install adjustment screw cover.

69

4.8.4 Circulation Relief Valve

Fuel oil is pressurized by fuel oil pump and heated by fuel oil heater, and its pressure is adjusted

properly by circulation relief valve on top of boiler. Part of fuel oil circulates throughout system and

heats fuel return pipes during combustion, keeping fuel at constant temperature. Circulation relief

valve is important part that controls combustion level and temperature of combustion system. Inspect

this valve and adjust pressure once a month.

<Inspection>

Circulation relief valve is adjusted to optimum pressure in trial operation.

a) Check that inlet pressure of adjusting flow valve when H.F.O. (*) is circulating is pressure set in

trial operation.

b) Check that lock nut is not loosened.

● If lock nut is loosened, retighten it.

<Adjustment>

If pressure gauge indicates pressure set in trial operation, combustion level does not need to be

adjusted. If pressure gauge does not indicate pressure set in trial operation, adjust combustion level.

a) Adjust fuel oil pump discharge pressure according to procedure in 4.8.3.

b) Adjust circulation relief valve according to 3) <Adjustment of pressure regulating valve> in

4.8.3.

Refer to page 67 “4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting” in

Chapter 5.

List of standard pressure settings (reference)

HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T

M.D.O.（＊）［MPa］ 0.8 0.8 0.9 1.1 1.2 1.2

H.F.O. ［MPa］ 1.0 1.0 1.1 1.3 1.4 1.4

Figure 5-18 Circulation Relief Valve

No. Part name

1 Relief valve body

2 Relief valve plunger

3 Spring retaining nut

4 Spring strike plate

5 Relief spring

6 Relief valve cap

7 Pressure adjusting bolt

8 Hexagon nut

9 O ring

10 O ring

13 Relief valve packing

14 Relief valve stand

15 Packing

16 Hexagon bolt

17 Spring washer

70

5. Quarterly Inspection and Maintenance

5.1 Inspection and Blow of Boiler Water

WARNING

Caution

Blow valve and sample water (blow water) are hot. Wear protective equipment while working

with them to prevent burn.

Treat and blow boiler water regularly according to Manual for Water Treatment.

5.2 Equipment around Burner

5.2.1 Solenoid Valve

WARNING

Instruction



Solenoid valve opens and closes by electric activation and non-activation to control supply of fuel

oil to burner nozzle and other control equipment.

If seat of any of solenoid valves is clogged due to foreign particles on seat, oil leak into combustion

chamber, ignition failure, or other combustion related problems may be caused. Visually check

flow meter when combustion is stopped or check for oil leaks in bottom of furnace on quarterly

basis. In disassembling device, be careful not to lose internal parts. When replacing valve, check

flow direction.

71

5.2.1-1 Solenoid Valve for Pilot Burner

This solenoid valve is used to control fuel used with pilot burner.

It is opened when activated and two valves are used for combustion.

When pre-purge (*) is completed, this solenoid valve is activated and opened.

5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve

This solenoid valve controls air that drives pneumatic fuel shutoff valve. It uses compressed air in

line for atomized air to drive main fuel shutoff valve. When it detects flame of pilot burner, it is

opened to start air supply to pneumatic fuel shutoff valve. This solenoid valve is installed in each of

air supply lines leading to 2 main fuel shutoff valves.

Figure 5-19 YS301 Type

No. Part name

A1 Tube & base ASSY

A2 O ring

A3 Top plate

A4 Spring washer

A5 Coil

A6 O ring

A7 Base nut

A8 O ring

A13 Terminal box

N Neon lamp

1 Plunger ASSY

2 O ring

3 Spring

Figure 5-20 062E1 Type

Lead wire

Movable element

Solenoid

Spring

Poppet set screw

V seal

Poppet shaft

Body

72

O-ring

Bracket(Option)

Bolt

Bonnet

Diaphragm ASSY

Body

Coil

Washer A

Washer B

Base nut

Tube ASSY

Spring

Plunger ASSY

Springwasher

Name plate

Lock washer

Nut

O-ring

O-ring

Housing

5.2.1-3 Solenoid Valve for Atomized Air

This solenoid valve is used to control atomized air. A single solenoid valve for atomized air is

installed in atomized air line and is opened when activated. When "AIR" is selected as atomized

fluid, it is opened following detection of flame of pilot burner to supply atomized air to main burner

and atomize fuel.

Figure 5-21 YS211 Type

73

5.2.1-4 Solenoid Valve for Atomized Steam

This solenoid valve is used to control atomized steam. A single solenoid valve for atomized steam

is installed in atomized steam line and is opened when activated. When "STEAM" is selected as

atomized fluid, it is opened following detection of flame of pilot burner to supply atomized steam to

main burner and atomize fuel.

Figure 5-22 DP Type

No. Part name

1 Valve casing

2 Cover

3 Spring pin

4 Pipe

5 Valve body

6 Valve disk

7 Valve body washer

8 Connecting spring

9 Piston ring

10 Pilot ring

11 Pilot disk

12 Spring retainer

13 Plunger

14 Pin

15 Valve body spring

16 Gasket

19 O ring

20 Coil

21 O ring

29 Pilot spring

74

5.2.2 Other Equipment

WARNING

Instruction



Before inspection or adjustment, check that there is no internal pressure present.

Compressed air or steam may blow out, causing burn or laceration.

If seat of any equipment is clogged due to foreign particles on seat, oil leak into combustion

chamber, ignition failure, or other combustion related problems may be caused. Visually check

flow meter when combustion is stopped or check for oil leaks in bottom of furnace on a quarterly

basis, along with carrying out inspection specified in each section.

5.2.2-1 Pneumatic Fuel Shutoff Valve

This is pneumatic actuator used to control fuel oil supplied to main burner. Two pneumatic fuel

shutoff valves are installed in main fuel oil (*) line and actuated by compressed air. This valve is

closed under no pressure and opened to start fuel oil supply to main burner when it detects

compressed air from filter regulator or solenoid valve for fuel shutoff valve.

<Inspection>

Carry out following inspections while boiler is in operation:

Check positions of valve when it is fully opened and fully

closed.

Check valve and pneumatic pipe connections for leaks.

Check valve and pneumatic pipe for abnormal noise.

Check for vibration when it is actuated.

Check for loose bolts or nuts.

No. Part name

1 Valve casing

2 Cover

3 Valve stem

4 Ball

7A Packing retainer

7B Packing retainer ring

8 Packing

19 Gasket

20 Packing washer

30 Ball seat

33 Nut for cover bolt

34A Nut for packing retainer

34B Nut

35 Cover bolt

36 Packing retainer bolt

47 Thrust washer

67 Stem bearing

92 Connector

93 Bracket

94 Bolt

96 Pneumatic actuator

99 Set bolt

124A Spring & pin

124B Spring

145 Spring washer

155 Spacer

Figure 5-23 FAS-2 Type

Nominal diameter:50 or below

Nominal diameter:25 or below

75

5.2.2-2 Filter Regulator

Filter regulator is used to reduce pressure of compressed air supplied to solenoid valve for fuel

shutoff valve and to remove sludge. Installed in inlet of atomized air line, filter regulator reduces

pressure of air supplied to fuel shutoff valve to 0.4 MPa as well as removes dust in air with inner

filter to prevent solenoid valve for fuel shutoff valve from including dust.

<Inspection>

a) Check that pressure is set at 0.4 MPa.

b) Drain filter regulator.

If drain level exceeds upper limit, drain filter regulator in shorter intervals than inspection.

c) Check plastic bowl in filter regulator for cracks, scratches,

or deterioration.

<Adjustment>

Pull pressure adjusting knob a notch to unlock it.

Turning pressure adjusting knob in "H" direction shown in upper

surface increases secondary pressure, and turning it in "L"

direction decreases secondary pressure.

After adjusting secondary pressure, push pressure adjusting

knob a notch to lock it.

<Draining Procedure>

Turn cock in "O" direction to drain filter regulator and in "S"

direction to stop draining it

<Inspection of Plastic Bowl>

Stop compressed air flow, check that there is no pressure present in product, and then remove bowl.

a) Turn bowl and bowl guard by about 45° until they are stopped while pushing them up (Figures

[1] and [2]).

By pulling bowl and bowl guard out downward, they can be removed (Figures [2] and [3]).

b) Assemble them in reverse order (Turn them until they are stopped).

c) Before letting compressed air in, check that marks of bowl guard and body meet each other in

point A (Figure [1]).

Figure 5-25 Detailed View ofDrain Outlet

Figure 5-26

Procedure forRemoving Bowl Guard

Figure 5-24 Detailed Viewof Pressure Adjusting Knob

Pressureadjusting knob

[2][1] [3]

Body

Bowl guard

76

5.2.2-3 Pressure Reducing Valve

This valve reduces pressure of steam for atomization supplied by boiler. It adjusts secondary

steam pressure to 0.5 MPa.

<Inspection>

a) Check that lock nut of adjusting screw (9) is not loosened.

b) Check secondary pressure.

Check secondary pressure when primary pressure is 0.6 MPa or above.

c) Check for abnormal noise.

d) Check for steam leaks.

<Adjustment>

If secondary pressure cannot be adjusted to 0.5 MPa, adjust it by steps below:

a) Check that atomized steam can be supplied and run fan in manual operation mode. After a while,

solenoid valve for atomized steam is opened.

Refer to page 40 “4. Manual Operation” in Chapter 4.

b) Loosen lock nut of adjusting screw (9).

Turn adjusting screw to adjust pressure to 0.5 MPa while checking atomized steam pressure

gauge.

Turn screw clockwise to increase pressure.

Turn screw counterclockwise to decrease pressure.

c) After adjusting pressure, tighten lock nut.

Figure 5-27 GP Type

No. Part name

1 Body

5 Diaphragm

8 Adjusting spring

9 Adjusting screw

11 Main valve

12 Valve seat

13 Main valve spring

14 Piston

15 Cylinder

19 Pilot valve body

20 Pilot valve seat

28 Strainer

42Primary

communicating port

43Secondary pressure

detection port

44 Diaphragm chamber

77

5.2.2-4 Seal Pot

This is a pot filled with ethylene glycol. Ethylene glycol is a liquid used to transmit fuel atomizing

pressure to equalizing valve. If seal pot does not contain a sufficient amount of ethylene glycol,

atomized steam pressure is not set properly to cause poor combustion.

<Inspection>

Follow steps below to check ethylene glycol level and fill seal pot with this liquid.

Use ethylene glycol that meets following specifications:

Purity: 99.5% or above

Density (20°C): 1.12 to 1.15 g/ml

Water content: 0.2% or above

<Procedure>

a) Close cock for equalizing valve oil detection connected to fuel piping.

b) Remove air vent plug on top of seal pot and open cock.

c) Loosen air vent plug of equalizing valve body, check that ethylene glycol comes out, and then

tighten it.

d) Pour ethylene glycol until it comes out of air vent cock on top of seal pot.

Ethylene glycol comes out soon if there is no vent.

e) Close air vent cock.

f) Open cock for equalizing valve oil detection connected to fuel piping.

g) Put air vent plug back in place.

Air vent plug onequalizing valve body

Seal pot

Cock for equalizingvalve oil detection

Air vent cock and plug

78

5.2.2-5 Equalizing Valve

WARNING

Instruction

Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to

change setting as a rule. Failure to observe this instruction may cause poor combustion,

backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for

instructions.

Equalizing valve adjusts atomized steam flow rate appropriately for different combustion levels. It

also detects fuel oil pressure and keeps difference from steam pressure constant. Reference

differential pressure settings for different models at combustion load of 20% (low combustion) are

shown below:

Model HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T

Differential pressuresetting of atomizedsteam equalizing valve

MPa 0.05 0.08

Differential pressure setting of atomized steam equalizing valve = (steam) pressure at exit of

equalizing valve - (fuel) pressure at exit of shutoff valve (MPa)

<Inspection>

a) Check secondary pressure of equalizing valve at

combustion load of 20%.

Confirm that primary steam pressure of equalizing valve

is around 0.5 MPa.

b) Check for abnormal noise.

c) Check for steam leaks.

<Adjustment>

If difference between secondary pressure and fuel

pressure at combustion load of 20% has deviated from

value set in trial operation, adjust it by following steps

below:

a) Ensure that combustion is taking place at load of 20%.

b) Remove cap (13) .

c) Turn adjusting screw (11) to adjust secondary pressure.

Turn screw clockwise to increase pressure.

Turn screw counterclockwise to decrease pressure.

d) After adjusting pressure, put cap (13) back in place.

(Reference value)

1 Body 16 Spring

2 Lower cover 17 Gasket

3 Valve Sheet (upper) 18 Bellows unit

4 Valve Sheet(lower) 19 Packing

5 Spring Sheet(upper) 20 Plug

6 Stud bolt 21 Air vent plug

7 Lower cover gasket 22 Hexagon bolt

8 Adjusting screw guide 23 Spring washer

9 Valve Stem 24 Hexagon nut

10 Lower cover 25 Hard lock

11 Adjusting screw 26 Plate spring washer

12 Packing retainer 27 Gland packing

13 Cap 28 Spring Sheet（lower）

14 Upper cover gasket

15 Setting spring

Figure 5-28 Inter structure ofequalizing valve RCV Type

79

5.3 Fuel Oil Thermostat (for Fuel Oil Heater)

Carry out operation test of each alarm once every three months. Check that temperature at which

alarm is activated is almost the same as dial setting.

Temperature setting of thermostat for low and high temperature alarm depends on viscosity of fuel.

Refer to temperature chart.

Refer to page 81 “5.3.3 Heavy Oil Heating Temperature” in Chapter 5.

5.3.1 Dial Type

Thermostat for fuel oil senses temperature and turns electrical switch on or off. It uses fluid with

high expansion coefficient in thermo sensor. When it senses temperature, fluid is expanded and

pressure inflates diaphragm of body inside to activate lever for opening electrical contact. When

diaphragm is deflated, electrical contact is closed.

< Adjustment>

As shown in below figure, thermostat is dial type. After loosening dial set fittings, set dial to given

temperature and fasten it with set fittings.

Set thermostat for heater protection at 180°C (Unchangeable).

Figure 5-29 Fuel Oil Thermostat (Dial Type)

EGO thermostat specification Thermostat for heater protection

Thermostat for hightemperature alarm

Thermostat for lowtemperature alarm

80

5.3.2 RT Type

Note

Some boiler use thermostat of RT type depending on specification.

< Adjusting operation temperature>

Adjust temperature by setting knob with reference to value on setting scale plate.

Set differential (*) to the minimum.

Figure 5-30 Fuel Oil Thermostat (RT Type)

1. Setting knob

2. Setting scale plate

3. Differential setting disk

81

5.3.3 Heavy Oil Heating Temperature

For effective combustion ability, keep viscosity of fuel oil in nozzle section at 12 cSt or less.

For proper fuel oil heating temperature for different viscosity standards of fuel oil, refer to following

chart.

Table 5-2 Temperature Setting for Viscosity (Example)

Redwood No.1Sec./100゜F 1500sec. 2500sec. 3500sec.

Kinematic Viscosity（cSt）at 50℃

（IF）Residual Fuels, cSt/50℃

IF-180

180cSt（280cSt）

IF-380

380cSt

Kinematic Viscosity（cSt）at 100℃

CIMAC and ISO Fuels, cSt/100℃

25cSt

CIMAC/RM-25

－ 35cSt

CIMAC/RM-35

Fuel oil heating temperature

(Setting temperature of temperature

controller)

～125°C 130°C 135～140°C

Table 5-3 Heavy Oil Heating Temperature Chart

When 300cSt (at 50°C)

82

5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil)

WARNING

Caution

During inspection work, hot steam may blow out to cause burn. Be careful with operating

valves.

Before wiring work, be sure to turn control panel power off. Failure to observe this instruction

may cause electrical shock due to high voltage, resulting in injury or death.

Note

Inspect pressure switches and check their operation once every 3 months according to steps

below:

5.4.1 Steam Pressure Switch

Steam pressure switch is used to issue alarms. Contact of pressure switch for low pressure alarm

is opened to issue alarm when steam pressure falls below set pressure. Contact of pressure

switch for high pressure alarm is opened to issue alarm and stop combustion when steam

pressure exceeds set pressure.

<Inspection>

Check connections for steam leaks.

Carry out inspections with reference to Sections 5.7.9 and 5.7.10 in "5.7 Operation Check of

Each Safety System" in Chapter 5.

Refer to page 90 “5.7.9 High Steam Pressure Alarm” and page 91 "5.7.10 Low Steam

Pressure Alarm" in Chapter 5.

Figure 5-31 Steam Pressure Switch and Pressure Gauge

83

5.4.2 Atomized Fluid Pressure Switch

Atomized fluid pressure switch is used to issue low atomized fluid pressure alarm. When atomized

fluid pressure falls below set pressure, contact is opened to issue alarm and stop combustion.

<Inspection>


Carry out inspections with reference to Sections 5.7.15 and 5.7.16 in "5.7 Operation Check of

Each Safety System" in Chapter 5.

Refer to page 92 “5.7.15 Low Atomized Steam Pressure Alarm” and "5.7.16 Low

Atomized Air Pressure Alarm" in Chapter 5.

5.4.3 Fuel Oil Pressure Switch

This pressure switch is used to issue alarm when fuel oil pressure drops for some reason during

combustion.

Note Some boilers use fuel oil pressure switch of RT type, depending on specifications (Standard

boilers use SNS-P type).

<Inspection>


Carry out inspections with reference to Sections 5.7.5 in "5.7 Operation Check of Each Safety

System" in Chapter 5.

Refer to page 88 “5.7.5 Low Oil Pressure Alarm” in Chapter 5.

Figure 5-33 Fuel Oil Pressure Switch

Figure 5-32 Atomized Fluid (Air / Steam)

Pressure Switch and Pressure Gauge

84

5.4.4 Pressure Switch Adjustment Procedure

Note

Do not adjust working position adjustment screw. Adjusting screw may cause trouble.

<Adjusting working pressure>

a) Turn pressure regulating screw counterclockwise. (pressure regulating spring is compressed)

Contact pressure goes up as shown on gauge.

b) When contact pressure goes up, disconnection pressure goes up, logically.

< Adjusting differential (*)>

Set differential for pressure switch that is used for alarm to the minimum by turning differential

pressure regulating screw counterclockwise.

a) SNS Typeb) RT type

1. Setting knob2. Setting scale plate3. Differential setting disk

Pressure differentialregulating screw

Pressureregulating screw

Pressure pointerDifferential pressure pointer

Scale plate

Working positionadjustment screw

Figure 5-34 Pressure Switch

85

5.5 Differential Transmitter

Differential transmitter detects differential pressure occurred by boiler water level and sends

electric signal accordingly differential pressure to water level indicator inside of boiler control

panel .

<Inspection>

a）Confirm that there is no difference between water level indicator display and water level gauge

display.

・In case difference is big, perform zero adjustment by normal water level at zero adjustment

trimmer of side of differential transmitter.

b）Check for water leakage.

<Zero adjustment>

a）Adjust water level to normal water level while checking water level of water level gauge.

b）Adjust zero while pushing adjustment trimmer and turn trimmer.

c）Confirm water level indicator displays 0mm, for normal water level of water level gauge.

Note

Adjust normal water level during combustion at pressure for general use. Display of water level

gauge and water level indicator occur error due to steam pressure and operation condition. And,

display of water level gauge and water level meter occur error during combustion stop, because

water level ware adjusted to normal level during combustion at pressure for general use at the

time boiler is delivered.

Figure 5-35 Differential transmitter

Zero adjustment trimmerManifold valve

86

5.6 Flow Control Valve

Flow control valve opens and closes by electric signal from water level indicator, and controls

amount of feed water with target of normal water level.（Feed water pump is always in operation.）

<Inspection>

a）Check for water leaks.

b）Confirm opening indication and operation time is in normal range.

c）Check for abnormal noise.

d）Check there is no water or dew condensation inside of controller.

Figure 5-36 Flow control valve

No Part name Material Quantity

Body

Cap

Ball

Sheet

StemPacking

Bracket

Connector

Direction of flow

Stellite

Temper

Temper

Temper

Electric operate machine

87

5.7 Operation Check of Each Safety System

WARNING

Caution

Do not pull out lead wire with wet hands. Failure to observe this instruction may cause

electrical shock due to high voltage, resulting in injury or death.

5.7.1 Ignition Failure Alarm

a) Before igniting burner, remove flame eye (*) on the top surface of wind box (*) and put your hand

over tip.

b) Press combustion switch.

Ignition is attempted after pre-purge (*); however, flame eye does not detect flame and

determines that there is something wrong.

c) Check that audio and visual alarms are issued.

Check that combustion is stopped.

d) Press buzzer stop switch.

Audio alarm is stopped.

Alarm lamp does not turn off and comes to remain on.

e) Put flame eye back in place.

Alarm lamp does not turn off but remains on.

f) Press alarm reset switch.

Alarm lamp turns off and alarm is reset.

5.7.2 Fan Abnormal Stop Alarm

a) Trip fan thermal relay during combustion.

b) Check that audio and visual alarms are issued.

Check that combustion is stopped.

c) Press buzzer stop switch.


Alarm lamp does not turn off and comes to remain on.

d) Reset fan thermal relay.

Alarm lamp does not turn off but remains on.

e) Press alarm reset switch.


88

5.7.3 Flame-out Alarm

a) Remove flame eye (*) during combustion, and put your hand over tip.


• Check that combustion is stopped.


• Audio alarm is stopped.

• Alarm lamp does not turn off and comes to remain on.

d) Put flame eye back in place.

• Alarm lamp does not turn off but remains on.


• Alarm lamp turns off and alarm is reset.

5.7.4 Abnormal Flame Alarm

a) Remove flame eye during post-purge (*), and illuminate flame eye.


• Check that post-purge is continued.




d) Put flame eye back in place.

• Check that post-purge is stopped 35 seconds after flame eye is put back in place.




5.7.5 Low Oil Pressure Alarm

a) Press combustion switch.

b) Lower flow rate of fuel oil by adjusting fuel oil pump outlet valve or pump oil pressure.

c) Check that audio and visual alarms are issued. There should be 2-second delay before they are

issued.


d) Press buzzer stop switch.





f) Adjust flow rate of fuel oil.

89

5.7.6 Low Oil Temperature Alarm

a) Switch fuel to M.D.O. (*).Shift fuel oil heater (*) switch to A.

• Check that fuel oil heater is stopped, and fuel oil is no longer heated.

b) Shift manual combustion switch to AUTO position, and press combustion switch.

c) Shift fuel oil heater switch to C position.

d) Check that audio and visual alarms are issued.


e) Press buzzer stop switch.



f) Shift fuel oil heater switch to A position.

• Check that fuel oil pump is stopped.


g) Press alarm reset switch.


h) Switch fuel to H.F.O. (*). Shift fuel oil heater switch to C position.

5.7.7 High Oil Temperature Alarm

a) Lower setting of thermostat for high oil temperature during combustion.

b) Check that audio and visual alarms are issued. When fuel oil heater is not working, there should

be 10-second delay before they are issued. There is no such delay if fuel oil heater is in

operation.

• Check that combustion is continued.




d) Reset thermostat for high oil temperature to value in list of principle items.

• Alarm lamp turns off.

90

5.7.8 Exhaust Gas High Temperature Alarm

Figure 5-37 Exhaust Gas Thermostat

<Operation check>

a) Lower setting of thermostat by turning dial during combustion.


5.7.9 High Steam Pressure Alarm

a) Turn off main power supply of control panel.

b) Disconnect wiring from back surface of pressure regulator (see right figure).

c) Turn on main power supply of control panel and start combustion.

• Boiler continues combustion at pressure above set pressure.

• Check that pressure switch (for high steam pressure) is activated

when set pressure is reached and combustion is stopped following

issuance of alarm.

d) Turn off main power supply of control panel and connect wiring

disconnected above.

e) Open main steam valve to make boiler pressure fall within normal

working pressure range.

Boiler flue has thermostat to measure temperature of

exhaust gas. If there is abnormal temperature, alarm is

started and operation is stopped electrically.

At the time thermostat is delivered from factory, it is set at

450°C (Unchangeable).

If thermostat is activated to stop boiler during operation,

measure gas temperature with thermometer, and

determine whether problem is due to failure of thermostat

or temperature is actually increasing.

If temperature of exhaust gas exceeds 450°C, there is high

possibility that there is some sort of malfunction in

combustion chamber. Open furnace, and check for fallen

refractory materials, or other causes. If there is

malfunction, immediately take corrective action.

If incomplete combustion continues for a long time, soot

may be accumulated on heating pipes to increase

temperature of exhaust gas.

Pay constant attention to furnace to keep complete

combustion.

Figure 5-38 Back Surface

of Pressure Regulator

Disconnect wiring of

Y434 or Y515.

91

5.7.10 Low Steam Pressure Alarm

a) Increase boiler pressure to normal working pressure.

b) Close steam pressure gauge valve.

c) Check that test cock is closed and remove plug.

d) Open test cock gradually.

Note

Hot, high-temperature steam blows out. Be careful not to get burned.

• Check that pressure gauge reading decreases and that pressure switch is activated when set

value of pressure switch is reached. Combustion is not stopped.

e) Close test cock, put plug back in place, and open steam pressure gauge valve.

5.7.11 Low Water Level Alarm

a) Close upper and lower water level gauge valves.

b) Open water level gauge drain valve slightly.

• Check that boiler water is discharged from inside water level gauge and that low water level

alarm is issued.

• Combustion is not stopped.

c) Close water level gauge drain valve and open upper and lower water level gauge valves.

5.7.12 Low Low Water Level Alarm

a) Perform steps a) and b) in 5.7.11.

• Check that boiler water is discharged from inside water level gauge and that combustion is

stopped following issuance of low low water level alarm.

b) Close water level gauge drain valve and open upper and lower water level gauge valves.

5.7.13 Power-off Alarm

a) Turn power off during combustion.

• Check that burner is stopped.

b) Turn power on.

5.7.14 Sequencer Error Alarm

• When malfunction of sequencer is detected, lamp lights up as visual alarm.

Note

To allow sequencer operating normally to malfunction intentionally, special equipment must be

used.

For more details, contact MIURA offices.

92

5.7.15 Low Atomized Steam Pressure Alarm

a) Switch atomized fuel to "STEAM" and bring boiler into automatic combustion.

b) Close atomized steam valve.

• Check that pressure gauge reading decreases and that pressure switch is activated to stop

combustion when set value of pressure switch is reached.

c) Open atomized steam valve.

5.7.16 Low Atomized Air Pressure Alarm

a) Switch atomized fuel to "AIR" and bring boiler into automatic combustion.

b) Close atomized air valve.

• Check that pressure gauge reading decreases and that pressure switch is activated to stop

combustion when set value of pressure switch is reached.

c) Open atomized air valve.

5.7.17 Damper Control Alarm

a）Turn off main power supply of control panel.

b）Disconnect wiring of external wiring terminal ”23” on control panel.

c）Turn on main power supply of control panel and start combustion.

d）Check that audio and visual alarm are issued within 90 seconds after combustion is started.

e）Press stop buzzer switch.


• Blinking alarm lamp does not turn off and comes to remain on.

f）Press combustion stop switch.

• Alarm is reset.

g）Turn off main power supply of control panel and connect wiring disconnected above.

5.7.18 Operation Check by differential transmitter（Low Water Level, Low Low Water Level,

High Water Level）

Adjust water level of water level gauge to proper level and close upper and lower water level

gauge valves on water level gauges of water level electrode to check differential transmitter.

Check water level by water level indicator. Check water level control and adjust water level to

proper, before check open upper and lower water level gauge valves on water level gauges.

Note

• Perform operations after ensure that boiler combustion is stopped.

• Water level alarm detects at each water level electrode and differential transmitter. Checking

water level control by differential transmitter is described here. For details about checking

water level control by water level electrode, refer to “5.7.11 Low Water Level Alarm” and

“5.7.12 Low Low Water Level Alarm” in Chapter 5.

Refer to page 91 “5.7.11 Low Water Level Alarm” in Chapter 5.

Refer to page 91 “5.7.12 Low Low Water Level Alarm” in Chapter 5.

93

＜Low Water Level Alarm＞

a）Set feed water pump shift switch to OFF, open bottom blow valve slowly.

Check that water level is lowered to low water level.

When water level is lowered to low water level, close bottom blow valve.

b）Check that audio and visual alarms are issued. There should be 10-second delay before they are

issued.

c）Press stop buzzer switch.


Blinking alarm lamp does not turn off and comes to remain on.

d）Select pump for operation by feed water pump shift switch.

Operation indicator lamp of feed water pump is lightened. Feed water to boiler uppered to low

water level, set feed water pump shift switch to OFF. Alarm lamp turns off.

＜Low Low Water Level Alarm＞

a）Set feed water pump shift switch to OFF, open bottom blow valve slowly.

Check that water level is lowered to low low water level limit.

When water level is lowered to low low water level limit, close bottom blow valve.

b）Check that audio and visual alarms are issued.

c）Press stop buzzer switch



d）Select pump for operation by feed water pump shift switch.

Operation indicator lamp of feed water pump is lightened. Alarm lamp does not turn off but

remains on when water level rises over low low water level.

e）Press alarm reset switch.


＜High Water Level Alarm＞

a）Set feed water shift pump to MANU and select pump for operation by feed water pump shift

switch.

Operation indicator lamp of feed water pump is lightened.

Ensure that water level does not reach upper limit.

b）When water level is uppered to high water level, set feed water pump shift switch to OFF.

c）Check that audio and visual alarms are issued. There should be 30-second delay before they are

issued.

d）Press stop buzzer switch



e）Open bottom blow valve slowly.

When water level is lowered to high water level, alarm lamp turns off.

94

5.7.19 Suction Damper Error Alarma）Turn off main power supply of control panel.

b）Disconnect wiring of external wiring terminal ”49” on control panel.

c）Turn on main power supply of control panel and start combustion.

d）Check that audio and visual alarm are issued in 50 seconds after combustion is started.

e）Press stop buzzer switch. Audio alarm is stopped.


f）Press alarm reset switch.


g）Turn off main power supply of control panel and connect wiring disconnected above.

95

6. Yearly Inspection and Maintenance

6.1 Fuel Oil Heater (*)

6.1.1 Combined Use of Electricity and Steam

Heater that uses both electricity and steam as shown in figure below is used to heat heavy oil to

proper temperature.

Figure 5-39 Fuel Oil Heater (Electricity/Steam)

Electric heater contains nichrome wire coil with high thermal conductivity as heating element in the

center of pipe, and is filled with special fused powder with excellent electric insulation at high

temperature.

To save electric capacity, heater body is heated by steam from outside. Thus, electric heater is

combined with steam.

Both steam and electric heater are controlled by opening or closing steam solenoid valve with fuel

oil temperature controller.

If sludge adheres to heater, poor combustion or abnormal heating may be caused due to unstable

control. Clean inside of heater on a yearly basis.

<Overview>

Electric heater as shown in figure is used as standard to heat heavy oil used as fuel to proper

temperature. Heater is installed on outlet side of oil pump and oil temperature is regulated by

temperature controller.

Fuel oil heater contains nichrome wire coil as heating element in the center of pipe for high

conductivity, and is filled with special powder that has excellent electric insulation at high

temperature; these materials are solidified under high pressure.

<Inspection and maintenance>

Long-term use of fuel oil heater causes accumulation of oily sludge in heater, which may lower

heating temperature or damage element due to insulation failure.

Open and clean fuel oil heater on a yearly basis.

In addition, raise discharge pressure of fuel oil pump and check operation of safety valve.

Note Sludge remaining after cleaning may cause leaks from solenoid valves.

Remove it completely by flushing or by another method.

Safety valve

F.O. outlet

F.O. inlet

Drain

Drain

Steam outlet

Steam inlet

96

6.1.2 Solenoid Valve for Steam Heater

Figure 5-40 Solenoid Valve for Steam Heater

< Inspection and maintenance>

Check valve and seat for scratches, check for coil burnout, and clean them regularly.

In disassembling device, be careful not to lose internal parts. When replacing valve, check flow

direction.

1 Core assembly (fixed iron core)

2 Coil

3 Plunger spring

4 Plunger

5 Tension spring

6 Stuffing

7 Main valve assembly

8 Body

97

6.2 Water Level Gauge and Water Level Detecting Rod

Note

Replace water level gauge glass once a year. If it is not replaced, it may be deteriorated with time

and damaged to cause hot water or steam to blow out from damaged part and cause a burn.

Water level gauge is integrated with water level detecting rod as shown below:

1 Water level gauge column 7 Hexagon nut

2 Water level gauge glass seat 8 Spring washer

3 Water level gauge glass holder 9 Plain washer

4 Water level gauge glass 10 Connecting pipe

5 Water level gauge glass packing 11 Water level gauge cover

6 Hexagon bolt 12 Water level gauge drain valve

Figure 5-41 Water Level Gauge and Water Level Detecting Rod

Water level detecting rod is installed on the top and bottom of steam drum (on steam side and water

side) with valves. Rod contains water level gauge glass to serve as both water level gauge and water

level detecting rod.

Water level gauge is important device for safety to check if prescribed water level is kept in boiler. As

glass of water level gauge must be kept clean, clean it by blowing water level gauge at least once a

day.

Reflective gauge glass is used for water level gauge, and size depends on rules of vessel

classification.

Boiler body Upper water levelgauge valve

Upper water leveldetecting rod

connecting pipe

Lower water leveldetecting rod

connecting pipe

Lower water levelgauge valve

Section viewalong line A-A

98

Aside from water level gauge, which is designed to visually check water level, water gauge column

has four (or five) water level detecting rods (3) with different lengths, which electrically detect water

level and put out signal to automatically start/stop feed water pump or to automatically stop burner

when low low level is detected. Stainless detecting rod is screwed in electrode holder and further

tightened with set screws. As water level detecting rod may get dirty with concentrated boiler water

and cause malfunction, pull water level detecting rods out and clean them at least once every three

months.

1 Electrode holder

2 Water gauge column

3 Water level detecting rod

4 Drain valve flange

Figure 5-42 Water Level Detecting Rods

<Inspection and Maintenance>

a) Continuity and insulation check of electrode holder.

• Check continuity and insulation of electrode holder every three months.

• Replace electrode holder periodically (once every 2 years) as aged deterioration causes

insulation and continuity failure.

Continuity check ○a to ○c : 0Ω

Insulation check ○a to ○b : 0.1 MΩ or above

b) If continuity or insulation failure is found, replace electrode holder.

<How to blow water level gauge>

Blow water level gauge once a day.

a) Close upper water level gauge valve and open water level gauge drain valve.

• Boiler water is discharged from inside water level gauge, and lower water gauge column

connecting pipe is cleaned.

b) Close water level gauge drain valve and lower water level gauge valve, and open upper water

level gauge valve.

c) Open water level gauge drain valve.

• Steam is discharged, and upper water gauge column connecting pipe and inside of water

gauge column are cleaned.

d) Close water level gauge drain valve and open lower water level gauge valve.

99

6.3 Flame Detector (FS-901)

Flame detector is auxiliary relay that is installed to detect burner flame and output electric signal.

Figure 5-43 Flame Detector

<Inspection>

Check on a yearly basis that voltage between terminals [3] and [4] of flame detector during

combustion does not exceed 2.5 V. If voltage exceeds 2.5 V, check whether or not flame eye (*)

glass and light sensitive surface of flame eye are dirty. If they are dirty, clean them.

Refer to page 62 “4.5 Flame Eye” in Chapter 5.

If voltage exceeds 2.5 V even after cleaning, there is possibility of failure of flame eye or flame

detector. In that case, replace flame eye with a spare one. If voltage exceeds 2.5 V again, there is

high possibility of failure of flame detector. In that case, replace flame detector.

100

7. Inspection and Maintenance on Vessel Docking

7.1 Soot Cleaning of Furnace

a) Remove burner from boiler.

b) Open inspection opening of funnel.

c) Visually inspect inside of combustion chamber and check conditions of castable and whether or

not inside is blackened by soot.

d) Clean combustion chamber with high-pressure water cleaner. Also clean boiler body from

inspection opening of funnel.

Refer to page 15 “5.1 Boiler Body” in Chapter 2.

e) Suck out cleaning solution in bottom of furnace with pump.

Note

Dispose of wastewater after cleaning, which has a low pH of around 1, properly.

MIURA cleans furnace to remove soot. For more details, contact MIURA offices.

101

8. Parts Information about Replacement

8.1 Ignition Transformer (*)

WARNING

Instruction

Ignition transformer conducts high voltage. Touching live wiring may cause electrical shock.

Turn power off before working with ignition transformer.

Figure 5-44 Ignition Transformer

Ignition transformer is important device for creating sparks from ignition rod by converting voltage of

100 V on primary side to a high voltage of 10 KV. Primary voltage of transformer can be 100 V or 200

Wiring is different depending on primary voltage.

Figure 5-45 Ignition Transformer Wiring Diagram

Note

Avoid insulating ignition transformer from boiler by rubber or other materials. Otherwise, it cannot

be earthed and may be burned.

Control voltage 100V Control voltage 200V

102

8.2 Sequencer (Programmable Controller)

8.2.1 Description of Component Unit of CJ2M

<Name and explanation of each part of CPU unit>

Figure 5-46 External View of the Sequencer Unit

Figure 5-47 Name of Part of CPU Unit

CPUOutput unitInput unit

LED display

SliderFix adjacent units

ConnectorConnect between adjacent units.Memory card cover

There is memory card in cover.

Battery storage coverWhen cover is opened, there are battery andfront dip switch.Memory cassette is also installed inside ofcover.

103

＜Dip Switch＞

Shows standard condition of dip switch

Figure 5-48 Dip switch

＜How to install memory card＞

・Pull the top of memory card to remove.

・Insert memory card back with label is on left side.

Figure 5-49 Installing/Removing of Memory Card

1 OFF

2 ON

3 OFF

4 OFF

5 OFF

6 OFF

7 OFF

8 OFF

Condition of dip switch

Label

104

<Battery>

Battery is built in CPU unit.

Following data is backed up by battery.

I/O memory (including PC system configuration)

Clock data (when memory cassette with clock function is installed)

Battery lasts for 5 years in 25°C ambient temperature. When battery runs out, front ERR/ALM

LED flashes.

It must be replaced with new battery. Contact with MIURA offices.

<Procedure of battery replacement>

Replace battery according to following steps.

a) Turn off boiler power.

If power is off, turn on power once and leave it at least for 5 minutes.

b) Pull out connector of battery in battery storage cover and replace battery with new one.

Once old battery is removed, install new battery within

5 minutes. If power is not supplied to CPU for 5

minutes or more, stored data may be lost.

Figure 5-50 Replacement of Battery

<Input unit>

Operation switch, pressure switch on detector and thermostat are connected to work as joint.

<Output unit>

Electromagnetic relay, solenoid valve and indication lights are connected. Relay contact output

is adopted.

It can be checked operation status of output points with LED on unit surface.

(Light is on when output relay is ON)

105

8.2.2 Function of Display

Figure 5-51 Description of Sequencer Display

CPU unit front

LED display

FlashLight up Turn off

Green

Red

Yellow

Yellow

Yellow

Yellow

CJ2 CPU unit is running normally with「Operation」or「Monitor」mode.

Dip switch setting abnormal.

Operation is stopped with「Program」mode or operation is stopped because of operation stop abnormal

Operation stop abnormal (including FALSE command action) or hardware abnormal (WDTabnormal) are occurred based on self diagnosis.

CJ2 CPU unit operation is stopped and all outputs are intercepted (OFF)

Operation stop abnormal (including FALSE command action) is occurred base on self diagnosis

CJ2 CPU unit operation is continued

CJ2 CPU unit is running normally.

Specific auxiliary relay for load interception (A50015) is ON

All outputs of output unit are intercepted (OFF)

CJ2 CPU unit peripheral (USB) port is communicating (either send or receive)

CJ2 CPU unit serial port (RS-232C) is communicating (either send or receive)

It is lightened during insert into built in flash memory (back up memory)It is also lightened during restoration of user program when PLC power supply is set fromOFF to ON (*).

CJ2 CPU unit peripheral (USB) port is not communicating

CJ2 CPU unit serial port (RS-232C) is not communicating

It is not lightened during un insert into built in flash memory (back up memory)

Specific auxiliary relay for load interception (A50015) is OFF

LED NAME ConditionStatusColor

106

8.2.3 Errors and Countermeasures

Table 5-4 Sequencer Trouble Shooting

Abnormal phenomenon Probable cause Countermeasure

1POWER LED does not light

up.

Loose connection of power

terminal block connector

Terminal block: Correctly insert

connector.

2 RUN LED does not light up.Power line failure

Program mistake

Replace CPU unit.

Correct programs.

3All of output (input) units are

not turned on.

Loose connection of unit

Loose connection of terminal

block connector

Correctly insert unit.

Correctly insert terminal block

connector.

4All of output (input) units are

not turned off.Input circuit failure Replace output (input) unit.

5Outputs (inputs) irregularly

turn on and off.

Low external voltage

Loose terminal screw

Loose connection of terminal

block connector

Use rated external voltage.

Correctly insert and lock

terminal block.

6

Output (input) operation

indicator LED does not light

up (although operation is

normal).

LED failure Replace output (input) unit.

107

8.3 Steam Pressure Regulator

WARNING

Instruction

Do not make changes to state after trial operation. Failure to observe this instruction may

cause poor combustion, backfire (*), or other accidents.

Steam pressure regulator controls steam pressure by sending signals from pressure transmitter to

control motor under proportional control.

This steam pressure regulator controls combustion level under proportional control as well as sends

combustion stop and start signals. It can also be used to change combustion level setting.

Figure 5-54 Display of Steam Pressure Regulator

Figure 5-52 Pressure Transmitter

Figure 5-53 Steam Pressure Regulator

Manual (MAN) mode lamp (green)

Present value (PV) indicator

Shows boiler steam pressure in MPa.

Memory area indicator

Bar graph

Direct key

Set key

Down key

Up key

Output (OUT1 and OUT2) lamps (green)Digital output (D01 to D04) lamps (green)

Alarm (ALM) lamp (red)

Remote (REM) mode lamp (green)

Auto tuning (AT) lamp (green)

Manipulated value (MV) lamp (green)

Set value (SV) indicator

Shift key

108

8.4 Fuel Oil Temperature Controller

8.4.1 Name and Function

No. Name Function

1 Measurement indicator

(PV)

Measurement is indicated.

2 Set value indicator(SV) Set value is indicated.

3 Up Key Value is increased by 1 whenpressed once. Value isincreased by keeping on press.

4 Down Key Value is decreased by 1 whenpressed once. Value isdecreased by keeping on press.

Note

Appropriate heating temperature of fuel oil depends on viscosity of oil. Determine temperature

following Heavy Oil Heating Temperature Chart.

Refer to page 81 “5.3.3 Heavy Oil Heating Temperature” in Chapter 5.

Set data by pressing key firmly with fingertip.

Data is automatically registered 3 seconds after it is set.

Do not press SEL key.


8.4.2 Setting Procedure

Example: Changing set value (SV) from 120°C to 130°C

Press Up key until changed value reaches 130. Value is automatically registered 3 seconds

after set up.

1

2

3 4

Figure 5-55 Temperature controller (For temperature of fuel oil control)

109

8.5 Water Level Detector (LM1-200)

Water level detector (LM1-200) has following features:

• It can be used at voltage of 100 V or 200 V.

• No relay is used and open collector is used for output.

Figure 5-56 Sequence Diagram (Water Level Detector (LM1-200))

Water level detectorLM1-200

Logic circuitLevel detecting

circuit Pow

er

circuit

110

8.6 Water Level Indicator

CAUTION

Instruction


Do not change setting from trial operation.



Water level indicator opens and closes flow control valve depending on signal from differential

transmitter.

Figure 5-57 Water level indicator

Note

In case of trouble or wiring disconnection of differential transmitter, water level indicator

displays B.OUT that means out range of display.

Adjust normal water level (0mm) during combustion at pressure for general use. Display of

water level gauge and water level meter of control panel occur error due to steam pressure

and operation condition. Display of water level gauge and water level meter occur error during

combustion stop, because water level ware adjusted to normal level during combustion at

pressure for general use at the time boiler is delivered. Refer to manual for External zero

adjustment of differential transmitter when adjust normal water level.

Water level display（unit：mm）

Normal water level display

(unit：mm）

※Normal water level was set to 0mm.

Alarm lamp

1：Low Low water level

2：Low water level

3：High water level

111

CHAPTER 6: TROUBLE SHOOTING

Trouble shooting for each system is described in this chapter. If problem is not resolved by taking

measures in this chapter, there may be another cause. In that case, stop operation, and contact MIURA

offices.

1. Feed Water System

Table 6-1 Trouble Shooting (Feed Water System)

Phenomenon Item to be checked Cause Countermeasure

Feed water pump

does not run.

Confirm that power is

turned on.

Power is not turned on. Turn power on.

Confirm that terminal is

inserted properly.

Wiring disconnection or

contact failure.

Check wire connection.

Confirm that thermal relay

is not run.

(1) Thermal relay failure

(2) Overload of motor

(1) Manually restore

thermal relay and

check set value.

(2) Check whether motor is

overloaded or not.

Confirm that water level

detecting rod is not dirty.

Water level not detected. Clean water level

detecting rods.

Confirm that motor is not

burned or coil is not

broken.

Motor failure and other. Contact MIURA offices.

Confirm that bearing,

mechanical seal, and

impeller are not burned.


Confirm that breaker for

feed water pump is not

tripped.

Insulation failure. Contact MIURA offices.

Feed water pump

is running, but

indicator lamp

does not light up.

Confirm that there is no

disconnection of wiring on

control panel.

Disconnection. Replace wiring.


contact failure of wiring on

control panel.

Contact failure. Fasten connection screws

tightly.

Abnormal noise or

heat is generated.

Confirm that bearing and

gland packing are not

burned.


112


Abnormal noise or

heat is generated.

Confirm that foreign

materials have not gotten

into pump.

Inclusion of foreign

materials in pump.

Remove cause of inclusion

of foreign materials.

Confirm that impeller is not

in contact with guide plate.

Partial contact between

impeller and guide plate

Contact MIURA offices.

Feed water pump

is running, but it

does not feed

water.

Confirm that air does not

come into pump from

suction side.

Defective piping. Install feed water pipes

properly.

Confirm that air is not built

up.

Insufficient air vent. Vent air sufficiently.

Confirm that there is water

in cascade tank.

No water in cascade tank Feed water into cascade

tank.

Confirm that feed water

pipes and valves are not

clogged.

Clogging of feed water

pipes.

Clean inside of pipes.

Confirm that strainer is not

clogged.

Clogging of strainer. Clean strainer.


leakage from feed water

check valve.

Cavitation. Clean, adjust, or replace

check valve.

Confirm that temperature

of feed water is kept within

specifications of pump.

Cavitation. Lower temperature of feed

water.

Confirm that shaft center

of feed water pump is

aligned with motor.

Misalignment of shaft. Align shaft center of feed

water pump with motor.

Confirm that impeller and

guide plate are not worn

abnormally.

Decline of performance of

feed water pump.


Confirm that remote level

gauge valves are opened.

Differential pressure

detection failure.

Open remote level gauge

valves.

Confirm that flow control

valve is working properly.

(1) It is controlled to be

closed.（Normal）

(2) Wiring disconnection or

Contact failure

(3) Failure

(1) Valve is closed when

feed water is not required

(water level is over normal

water level) because of

proportional control.

(2) Check wire connection.

(3) Contact MIURA offices.


indicator is displayed

B.OUT.

(1) Wiring disconnection or

Contact failure

(2) Failure of indicator.

(1) Check wire connection.

(2) Contact MIURA offices.

113


Pump is feeding

water, but water

level is lowered to

low water level

easily.

Confirm that performance

of feed water pump is not

declined.

Decline of performance of

feed water pump.

Switch to another pump

and inspect pump.

Confirm that zero

adjustment position of

differential transmitter is

proper.

Zero adjustment position is

low.

Readjust position during

combustion at pressure for

general use.

Confirm that pressure

gauge is working properly.

Failure of pressure gauge. Replace pressure gauge.

Discharge

pressure of feed

water pump is

increased too

much.

Confirm that pipes and

valves on discharge side

are not clogged.

Clogging of discharge line. Remove clogging of

discharge line.

Confirm that pressure

gauge is working properly.


Confirm that orifice of feed

water pump outlet is not

clogged.

Clogging of orifice. Clean orifice.

Water leakage

from feed water

pump.

Confirm that seal parts,

such as gland packing and

O rings, are not

deteriorated.

Deterioration of seal parts. Replace seal parts.


leakage from cocks and

instrumentation parts.

Failure of cocks or

instrumentation pipes and

defective installation.

Install problematic parts

correctly.

Water level that is

indicated by water

level gauge cannot

be read.


gauge glass is not dirty.

Dirt on water level gauge

glass.

Clean water level gauge

glass.


gauge is not filled with

boiler water.

Failure of water level

control system.



gauge valves are opened.

Water level remains

unchanged.

Open water level gauge

valves.


control cylinder connecting

pipe is not clogged.

Water level remains

unchanged.

Clean water level control

cylinder connecting pipes.

Water leakage

from water level

gauge.


gauge glass packing is not

deteriorated.

Deterioration of seal parts. Replace water level gauge

glass.


gauge glass is fastened on

the both sides.

Defective installation of

water level gauge glass.

Install water level gauge

glass properly.

Note For details about problems of feed water pumps, refer to instruction manual for feed water pump.

114

2. Fuel System

Table 6-2 Trouble Shooting (Fuel System)


Fuel oil pump does

not run.

Confirm that power is

turned on.


Confirm that rotor is not

burned.

Rotor burning. Contact MIURA offices.


materials are not

entangled in rotor.


materials in pump.


of foreign materials and

replace pump.

Confirm that bearing or

mechanical seal is not

burned.

Bearing burning. Contact MIURA offices.

Confirm that shock

absorbing rubber of

coupling is not damaged.

Defective coupling. Replace coupling.


burned or coil is not

broken.

Burnout of motor. Contact MIURA offices.


inserted properly.


contact failure.


Confirm that thermal relay

is not run.




thermal relay and check

set value.


overloaded or not.

Confirm that breaker for

auxiliary equipment is not

tripped.


Running fuel oil

pump sounds loud.

Fuel oil pump is

heated.

Confirm that fuel oil pump

is filled with fuel.

Idling of pump. Feed pump with fuel.

Confirm that discharge

pressure of fuel oil pump is

normal.

Pressure is too high. Adjust pressure to

specified pressure.


pipes and valves are not

clogged.

Clogging of flow path. Clean pipes and open and

close valves properly.

Confirm that air does not

come into pump from

suction side.

Inclusion of air. Remove cause of inclusion

of air, and let out air.

Confirm that bearing or

mechanical seal is not

burned.


115


Running fuel oil

pump sounds loud.

Fuel oil pump is

heated.

Confirm that rotor is not

burned.

Rotor burning. Contact MIURA offices.


materials are not

entangled in rotor.


materials in pump.


of foreign materials and

replace pump.

Confirm that fuel

temperature is not too

high.

Inclusion of air due to

evaporation of volatile

components in fuel.

Lower fuel temperature.

Confirm that sludge is not

contained in fuel oil.

Inclusion of dust, air, or

other foreign materials.

Drain fuel service tank.

Confirm that shaft center

of feed water pump is

aligned with motor.

Misalignment of shaft. Align shaft center of fuel oil

pump with motor.

Confirm that shock

absorbing rubber of

coupling is not damaged.

Defective coupling. Replace coupling.

Discharge

pressure of fuel oil

pump is too high.

Confirm that there is not

anything wrong with

pressure gauge.


Confirm that pressure is

adjusted.

Maladjustment of pressure

gauge.

Adjust pressure.

Confirm that pipes and

valves on outlet side of

pump are not clogged.

Clogging of pipes and

valves.

Clean pipes and open and

close valves properly.

Confirm that solenoid


Failure of solenoid valves. Replace solenoid valves.


clogging in burner ASSY.

Clogging of flow path. Clean burner ASSY.

Confirm that viscosity of

fuel is appropriate.

Viscosity of fuel is high. Replace fuel.

Confirm that heating

temperature of heater is

normal.

Failure of fuel oil heater(*)

(wrong setting).

Check heating

temperature.

Fuel oil

temperature does

not rise.


inclusion of air.

Heating failure due to

inclusion of air.

Vent air sufficiently.

Confirm that temperature

controller is set properly.

Set value is low. Change set value.


broken wire in fuel oil

heater coil.

Failure of fuel oil heater

coil.

Replace coil for heating

heater.

Confirm that wiring of fuel

oil heater is connected.


tightly.

116


Fuel oil

temperature does

not rise.

Confirm that solenoid

valve for steam and steam

trap are working properly.

Failure of solenoid valve

and steam trap.

Disassemble and clean

solenoid valve and steam

trap.

Confirm that inside of

heater is not dirty.

Performance decline due

to dirt.

Clean inside of heater.


error indication in fuel oil


Failure of thermocouple. Failure of thermocouple.

3. Combustion System

Table 6-3 Trouble Shooting (Combustion System)


Fan does not run. Confirm that power is turned

on.


Confirm that steam pressure

is not higher than setting of

steam pressure switch.

Steam pressure is high. Open main steam valve to

lower steam pressure.


burned or coil is not broken.



inserted properly.


contact failure.


Confirm that thermal relay is

not run.




thermal relay and check

set value.


overloaded or not.

Confirm that motor is

insulated.


Confirm that bearing is not

burned.


Fan is running, but

ignition is not

started.


inserted properly.


contact failure.


Misfire / ignition

failure


anything wrong with flame

eye(*)

.

Failure of flame eye(*)

or

dirt on glass.

Replace flame eye or

clean glass.

Confirm that damper is

opened properly.

Improper adjustment of

damper.


117


Misfire / ignition

failure


pressure of fuel oil pump is

high enough.

(including pilot pump)

(1) Clogging of pipes

(2) Pump failure

(3) Decline of

performance of pump

(1) Remove cause of

clogging.

(2) Replace fuel oil pump.

(3) Readjust pressure. If

this does not work,

replace parts.

Confirm that burner nozzle

and baffle plate are correctly

positioned relative to each

other.

Flame blowout. Adjust their positions with

reference to burner

dimensions in final

drawing.

Confirm that pilot nozzle tip

and baffle plate are correctly


other.

Flame blowout. Adjust their positions with

reference to Figure 5-3 in

Chapter 5.

Confirm that flame eye is

installed and fixed correctly.

Flame eye does not

catch flame.

Install and fix flame eye

correctly.

Confirm that moisture is not

included in fuel.

Pressure drop due to

evaporation of moisture

in fuel (cavitation).

Drain fuel service tank to

remove moisture.

Confirm that air flow

controller is working with

running of control motor.

Looseness of coupling. Contact MIURA offices.

Confirm that fuel remains in

fuel service tank.

Tank is out of fuel. Supply fuel to fuel service

tank.

Confirm that burner nozzle is

not dirty or is not clogged.

Burner nozzle is clogged

with dust.

Clean burner nozzle.

Confirm that pilot nozzle tip is

not dirty or is not clogged.

Pilot nozzle tip is

clogged with dust.

Clean pilot nozzle tip.


leakage from burner nozzle.

Leakage from joint of

burner nozzle.

Fasten joint of burner

nozzle tightly.


leakage from pilot nozzle tip.

Leakage from joint of

pilot nozzle tip.

Fasten joint of pilot nozzle

tip tightly.

Confirm that fuel system is

not clogged.

Clogging of fuel system. Remove cause of

clogging.

Confirm that oil pressure

switch is working properly.

Failure of oil pressure

switch.

Check and adjust setting

of pressure switch. If this

does not work, replace it.

Confirm that ignition spark

flies.

(1) Failure of ignition

transformer(*)

.

(2) Defective wiring.

(1) Replace parts.

(2) Connect wire properly.

Confirm that opening in the

tip of ignition rod is the same

as specified in final drawing.

Dimension failure of

ignition rod.

Check final drawing and

adjust dimensions.

Confirm that the tip of ignition

rod is not dirty.

Miss spark. Clean ignition rod.

118


Misfire / ignition

failure


anything wrong with fuel

temperature.

Fuel temperature is low. Adjust fuel temperature

properly by fuel oil


Confirm that equalizing valve

seal pot is filled with ethylene

glycol.

(1) Excessive amount of

atomized steam.

(2) Insufficient amount

of atomized steam.

(1) Fill seal pot with

ethylene glycol.

(2) Fill seal pot with

ethylene glycol and

clean strainer.

Confirm that pressure setting

of pressure reducing valve is

proper.

(1) Excessive amount of

atomized steam.

(2) Insufficient amount

of atomized steam.

(1) Adjust pressure setting

of pressure reducing

valve.

(2) Adjust pressure setting

of pressure reducing

valve and clean strainer.

Confirm that air-driven valve

is working properly.

(1) Insufficient operating

air.

(2) Clogging of

operating air system.

(1) Adjust pressure of

compressed air and

pressure setting of filter

regulator.

(2) Clean operating air

system.

Confirm that solenoid valve

for air-driven valve is working

properly.

(1) Inclusion of dust in

solenoid valve for

air-driven valve.

(2) Failure

(3) Compressed air

valve is closed.

(4) Clogging or setting

error of filter regulator.

(1) Disassemble and clean

solenoid valve for

air-driven valve.

(2) Replace parts.

(3) Open compressed air

valve.

(4) Clean filter regulator

and adjust pressure

setting.

Confirm that atomized air

pressure is 0.4 MPa or

above.

(1) Atomized air

pressure drop

(2) Clogging of atomized

air line.

(3) Atomized air valve is

closed.

(1) Adjust atomized air

supply pressure

between 0.6 MPa and

0.9 MPa.

(2) Remove cause of

clogging.

(3) Open atomized air

valve.



below.

Atomized air pressure

increase.

Adjust atomized air supply

pressure between 0.6 MPa

and 0.9 MPa.

Confirm that fuel oil is

circulating at proper

pressure.

Flame blowout due to

fuel shortage.

Clean fuel strainer and

adjust pressure of relief

valve.

Confirm that hydraulic line

valve of seal pot is opened.

Lack of atomized steam. Open valve.

119


Misfire / ignition

failure


and steam valves are

opened and closed properly.

Lack of atomized fluid. Open valve.

Confirm that solenoid valves

for atomized air and steam

are working properly.


solenoid valves for

atomized air and

steam

(2) Failure


solenoid valves for

atomized air and steam.

(2) Replace parts.

Combustion can

be observed, but

combustion lamp

does not light up.


disconnection of wiring on

control panel.

Disconnection. Replace wiring.


contact failure of wiring on

control panel.


tightly.

Combustion is not

stopped even after

steam pressure

rises up to

specified pressure.

Or, combustion is

stopped

independently of

specified pressure.

Confirm that steam pressure

regulator and pressure

transmitter are working

properly.

Failure of steam

pressure regulator or

pressure transmitter.



anything wrong with pressure

gauge.

Failure of pressure

gauge.

Replace pressure gauge.

Confirm that pressure shown

in steam pressure gauge is

not decreasing.

(1) Clogging of steam

pressure gauge line.

(2) Steam pressure

gauge valve is closed.

(1) Clean steam pressure

gauge line.

(2) Open steam pressure

gauge valve.

Confirm that drive valve is

working properly.


drive valve

(2) Failure


drive valve.

(2) Replace parts.

Flame is not

stabilized

(Unbalanced

flame).



temperature.





opened properly.

Excessive air flow.

(Improper adjustment of

damper opening)

Adjust position of damper

based on results of trial

operation.


not clogged with dust.


with dust.


Confirm that pilot burner,

burner nozzle, baffle plate,

and other parts are correctly


other.

Eccentric installation of

burner.

Adjust their positions


operation.

Confirm that fuel oil pressure

is proper.

Fuel oil pressure is low

or oscillating.

Readjust pressure. If this

does not work, replace

parts.

120


Exhaust gas is

black.


opened properly.

Insufficient air flow.


damper opening)



operation.

Confirm that lock nut on link

arm is not loosened.

Insufficient air flow.


damper opening)



is proper.

Fuel oil pressure is high. Readjust pressure. If this


parts.



temperature.




Confirm that inner cylinder

and baffle plate are not

burned.

Burnout of parts. Replace parts.

Confirm that burner nozzle,

baffle plate, and other parts

are correctly positioned

relative to each other.


burner.



operation.

Confirm that fan is running in

right direction.

Defective wiring. Check wire connection.

Exhaust gas is

white.


opened properly.

Excessive air flow.


damper opening)



operation.

Confirm that lock nut on link

arm is not loosened.

Excessive air flow.


damper opening)



is proper.

Fuel oil pressure is low. Readjust pressure. If this


parts.

Confirm that fuel pipes are

not clogged.

Clogging of fuel pipes Clean fuel pipes.


not clogged with dust.


with dust.


Confirm that burner nozzle,

baffle plate, and other parts

are correctly positioned

relative to each other.


burner.



operation.


is not too high.

Failure of drive valve.

Decline of performance

of pump

Readjust pressure. If this


parts.

Vibration

combustion

occurs.

Confirm that air is not

included.

Inclusion of air. Remove air from fuel line

sufficiently.

Confirm that atomized steam

pressure is not too high.

Excessive amount of

atomized steam.

Adjust pressure setting of

pressure reducing valve.

121


Vibration

combustion

occurs.



temperature.

Fuel oil temperature is

too high or too low.

Adjust fuel temperature




opened properly.

Excessive or insufficient

air flow.


damper opening)



operation.

Confirm that oil accumulated

in the bottom of furnace is

not burning.

Failure of burner nozzle.

Failure of drive valve.

Stop operation and contact

MIURA offices.

Confirm that inner cylinder

and baffle plate are not

burned.

Burnout of parts. Replace parts.

Confirm that main air-driven


(1) Insufficient operating

air.

(2) Clogging of

operating air system.

(1) Adjust pressure of

compressed air and

pressure setting of filter

regulator.

(2) Clean operating air

system.

Confirm that solenoid valve

for air-driven valve is working

properly.


solenoid valve for

air-driven valve

(2) Failure

(3) Compressed air

valve is closed.

(4) Clogging or setting

error of filter

regulator.

(1) Disassemble and

clean solenoid valve for

air-driven valve.

(2) Replace parts.

(3) Open compressed air

valve.

(4) Clean filter regulator

and adjust pressure

setting.

Low atomized

steam/air pressure

alarm is issued.

Confirm that atomized fluid

selection switch on control

panel is set properly.

Operation error of

atomized fluid selection

switch.

Check atomized fluid

selection switch.


and steam valves are

opened and closed properly.

Lack of atomized fluid. Open valve.


strainer is not clogged.

Lack of atomized fluid. Clean strainer.

Confirm that atomized fluid

pressure switch is working

properly.

Failure of pressure

switch.

Check and adjust setting

of pressure switch. If this

does not work, replace it.



above.

(1) Atomized air

pressure drop


air line.

(1) Adjust atomized air

supply pressure

between 0.6 MPa and

0.9 MPa.

(2) Remove cause of

clogging.

122


Low atomized

steam/air pressure

alarm is issued



above.

(1) Atomized steam

pressure drop


steam line.

(1) Close main steam

valve, etc.

(2) Remove cause of

clogging.

4. Control System

Table 6-4 Trouble Shooting (Control System)


Pressing

combustion switch

does not start

combustion.

Confirm that manual

combustion switch is not

set at OFF position.

Manual combustion switch

is set at OFF position.

Shift burner selection

switch to automatic

position.

Confirm that safety

systems are not activated.

Safety system activated. Remove cause of alarm

issuance and press reset

button.

Ignition failure

lamp does not light

up and alarm does

not sound following

ignition failure.


anything wrong with flame

detector.

Refer to P99

"6.3 Flame Detector

(FS-901)" in Chapter5

Failure of flame detector. Replace parts.


anything wrong with lamp,

socket, or buzzer.

Failure of lamp, socket, or

buzzer.

Replace parts.


anything wrong with

buzzer stop switch.

Failure of buzzer stop

switch.

Replace parts.

Damper control

error alarm is

issued.

Confirm that control motor

is working properly.

Failure of control motor. Contact MIURA offices.

Confirm that steam

pressure controller, parts

in control panel is proper.

Failure of steam pressure

controller parts in control

panel



disconnection or contact

failure of wiring.


contact failure.

Check wiring.

123

5. Trouble Shooting for Boiler Body

CAUTION

Caution: Hot

Before working on water tube leaks, check water tubes and burner funnel that may be

touched are fully cooled. Otherwise, you may suffer from burn. For more information,

contact MIURA offices.

Checking Leaked Water Tubes

No leakage from water tube of GK type boiler occurs if water quality control is carried out properly.

Boiler external treatment and boiler internal treatment with boiler compound are absolutely essential.

If leakage is found from boiler water tube due to improper boiler water treatment, check it as follows:

a) Remove burner and wind box (*) from the upper part of boiler. Open manhole of funnel on

exhaust gas side.

b) Enter boiler combustion chamber and funnel inside on exhaust gas side to check water tube wall

(Obvious leakage may be detected at glance in this stage).

c) Switch feed water pump to manual operation and perform a hydraulic test.

d) If water is leaking from joint of water tube and tube plate, remove refractory castable around

water tube swaged area and inspect whole area.

When water is leaking from back side of the first row of tubes toward the second row of tubes, it is

easily considered that water is leaking from the second row of tubes. Therefore, check it carefully

in full consideration of above.

e) When leaking water tubes are found, insert stoppers or replace tubes with new ones.

Refer to page 124 “6. Repairing Damaged Water Tubes” in Chapter 6.

f) Investigate cause of water tube leakage for future reference. If leakage came from improper

water treatment, take secure measures to prevent recurrence.

If leakage is found on exhaust gas economizer side, open manhole on exhaust gas

inlet and outlet and hand holes in the middle part and find where leakage is occurring.

124

6. Repairing Damaged Water Tubes

WARNING

Instruction

Stopper treatment and furnace building with refractory is temporary treatment. Do not

operate for a long time; otherwise, there is possibility of serious accident. Contact each

classification in advance and replace water tubes (or body) immediately at periodical

inspection. Contact MIURA offices about replacement of water tubes (or body).

Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool

both the inside of drum and combustion chamber. Then make sure that pressure inside the

drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan

during inspection.

This boiler is vertical natural-circulation boiler.

If boiler water is not controlled according to "Manual for Water Treatment,” that is provided separately,

impurities in feed water (calcium, magnesium, and silica) may be accumulated and turned into scale

on heating surface, that could hinder heat exchange process, damage water tubes, or cause

leakage.

To operate this boiler most economically and efficiently, it is essential to control boiler water by

blowing down boiler and using proper boiler compounds and water softener. This chapter describes

ways to fix damaged water tubes and leakage that are caused by unsatisfactory boiler water

treatment.

6.1 Insertion of Stoppers from Inside of Water Drum

This method uses iron stoppers that are included as spare

parts to plug tubes from inside the upper and lower steam

drums and water drum. Before inserting the stoppers,

determine which water tube(s) is/are leaking.

Refer to page 123. “5. Trouble Shooting for Boiler

Body” in Chapter 6

Once it is identified leaking water tube(s), enter drum

through manhole and insert stoppers from inside as it is

shown in the figure.

In this case, clean thoroughly contact surface between

stopper and water tube so that dust or other foreign materials

do not get caught in surface; this is especially important if

there is some sort of damage. It is also effective to polish

parts with carborundum or a similar material.

Figure 6-1 Insertion of Stoppers from Inside of Water Tube

Stopper

Stopper

CombustionChamber

125

6.2 Stopper Welding from Combustion Chamber

Figure 6-2 Stopper Welding from Combustion Chamber

This method is the same as the previous method up to the point that water pressure test is conducted inside

combustion chamber to determine which pipe(s) is/are leaking. However, stoppers are used in completely

different way. In this method, stoppers are welded from inside of combustion chamber as it is shown in

figure. Therefore, the first prerequisite for using this method is to have certified welder on board.

Figure 6-3 Stopper Welding from Inside of Combustion Chamber

If it is undertaken stopper treatment from just the top and bottom without welding stoppers, there is

possibility that water tube (that does not contain water) is damaged and water is leaked to exhaust gas side.

Therefore, the previous type of work should be completed only in case of emergency; it is strongly

recommended that stoppers are welded once ship reaches port. However, if there is some technical issue,

such as with welders, or application of refractory castable is omitted (refer to above figure), other problems

may be caused. Therefore, it is necessary to follow instructions of MIURA offices.

CombustionChamber

Cuto

ffth

isp

ort

ion

with

gas

(Cuto

ffth

esecon

dand

su

bsequ

entw

ate

rtu

bes).

1 Steam drum

2 Water drum

3 Water tube

4 Castable

CombustionChamber

Sea

lth

eo

pen

ing

by

we

ldin

g.

CombustionChamber

App

lycasta

ble

(only

toth

ein

nerm

ostro

w).

Anchor

126

CHAPTER 7: STORAGE

1. Maintenance When Boiler is Shut Down for a Long TimeWhen boiler is shut down for a long time, it is important to store it properly. Before boiler is shut down,

wash soot off boiler and clean and fully dry inside of furnace. In addition, pour silica gel to protect

against rust.

Conduct procedure for shutdown according to Manual for Water Treatment.

2. Movement or Resale

WARNING

Prohibition

Do not perform installation work and connection of incidental equipment unless it is

specified.

Failure to observe this instruction may cause physical injury.

In reselling or reusing boiler, procedure that is based on rules of vessel classification must be taken.

Contact MIURA offices since it must be checked that vessel equipment does not affect normal

operation of boiler. Installation work or connection of incidental equipment that is not specified may

cause physical injury. If our products are resold, deliver instruction manuals and related materials along

with product to new owner, and inform us of resale (We need to transfer maintenance records that kept

since it was placed in service).

3．Export

When exporting products whose export is regulated under the Foreign Exchange and Foreign Trade

Act, approval of the Japanese government for export must be obtained. When MIURA products are

exported, products and their use are subjected to many laws and regulations in the destination country.

If there is plan to export MIURA products, contact MIURA offices.

127

CHAPTER 8: DISPOSAL

1. Disposal ProcedureThis boiler must be disposed of as industrial waste.

Dispose of boiler properly according to the laws in the country where it is to be disposed of. For details

about recycling of materials that are used in this boiler, contact MIURA offices.

128

CHAPTER 9: GUARANTEE

1. Description of GuaranteeGuarantee period is either of following, whichever comes first:

12 months after vessel is delivered.

18 months after equipment is shipped

If boiler has trouble within this guarantee period, trouble is repaired or parts are replaced for free so

that boiler functions as required in agreement as long as it has been installed and used properly

according to instruction manual, warning labels, and other instructions.

Trouble with equipment other than MIURA products that is installed on vessel is not covered by this

guarantee. Deterioration of consumable parts is not covered by this guarantee unless it is abnormal

deterioration.

In any of following cases, repair work is charged even within guarantee period:

[1] Failure or damage that is caused by wrong use, poor maintenance, or improper repair or

remodeling

[2] Failure or burnout due to natural disasters such as fires, typhoons, or tsunamis, or other external

factors

[3] Replacement of consumable parts

[4] Other matters that are specified in the agreement

If repair work is required outside Japan, travel expenses including accommodation and transportation

fees are charged. Repair service outside Japan cannot be provided if travel to that country is banned.

If there is any question about repair service within or after guarantee period, contact MIURA offices.

2. Contact Information for Inquiries about Products and Instruction

ManualIf you have any question about products that you purchased or about this instruction manual, contact

MIURA offices.

(Contact information can be found on back cover.)

3. Sale of Instruction ManualIf you need instruction manual for this boiler, contact MIURA offices.

In that case, let us know vessel name, nationality of vessel, vessel number, boiler number, and manual

number on cover of instruction manual.

4. Sale of PartsIf you need parts that are used with this boiler, contact MIURA offices.

In that case, let us know vessel name, nationality of vessel, vessel number, and boiler number.

DOMESTIC SERVICE STATION*HEAD OFFICE:MIURA Co.,Ltd.

SHIP MACHINERY DEPT.

*BRANCH:TOKYO MAINTENANCE DIV.

SHIMANAMI MAINTENANCE DIV.

KYUSHU MAINTENANCE DIV.

*AUTHORIZED DISTRIBUTORS:N.Y.CO.,LTD.

CHUOKIKI CO.,LTD.

OVERSEAS SERVICE STATIONMIURA SOUTH EAST ASIA PTE. LTD.

MIURA Co., Ltd ROTTERDAM OFFICE

7, Horie, Matsuyama, Ehime, Japan,

799-2696

2-15-35 Takanawa, Minato-Ku, Tokyo,

Japan, 108-0074

3-20-9 Matsunaga-Cho, Fukuyama,

Hiroshima, Japan, 729-0104

3-19-20, Hakataekiminami Hakata-ku

Fukuoka,Japan, 812-0016

1-3-10, Shibaura, Minato-Ku, Tokyo,

Japan, 105-0023

4-28-2, Abraya-Cho, Minato-Ku,

Nagoya, Aichi, Japan, 455-0824

No.3 Soon Lee Street #03-36-37-38,

Pioneer Junction Singapore 627606

Rotterdam Business Centre. Westblaak 140,

3012KM Rotterdam The Netherlands

TEL: (+81)89 979 7066

FAX: (+81)89 979 7067

TEL: (+81)3 5793 1047

FAX: (+81)3 5793 1045

TEL: (+81)84 930 0740

FAX: (+81)84 930 0741

TEL: (+81)92 432 3277

FAX: (+81)92 432 3278

TEL: (+81)3 6809 4540

FAX: (+81)3 6809 4541

TEL: (+81)52 383 3166

FAX: (+81)52 383 3607

TEL: (+65)6465 1147

FAX: (+65)6465 1148

TEL: (+31)10 412 2015

FAX: (+31)10 412 4109

OVERSEAS NETWORK1.CHINAIHI MARINE (SHANGHAI) CO., LTD.Room No.706-707, Information Tower No.1403Minsheng Rd, Pudong New Area, Shanghai, 200135,P.R.ChinaTel : (+86)21 6351 8029Fax: (+86)21 6351 8028SHANGHAI WEN CHIUAN MARINESERVICE&ENGINEERING CO., LTD.No.951 Kesheng Rd. Beiguan, Malutown, Jiading districtShanghai, 201801, P.R.ChinaTel : (+86)21 6915 2475Fax: (+86)21 6915 2476

2.GERMANYTAKNAS MARINE ENGINEERING GMBH"Fruchthof" Oberhafenstr.1 20097 Hamburg, GermanyTel : (+49)40 32 1305Fax: (+49)40 33 0608

3.KOREADONG YANG ENGINEERING#10-11,2Ka Myeong-Ryun-Dong Dongrae-Ku Busan,607-802, KoreaTel : (+82)51 552 6503Fax: (+82)51 557 4830SEIN BESTECH302, 64 Keumo-5Gil, Dong-Myeon, Yangsan,626-821, KoreaTel : (+82)51 961 7771Fax: (+82)51 961 7772

4.PHILIPPINESPHIL-NIPPON KYOEI CORP.S-705 Royal Plaza Twin Towers 684 Romedios St.,Malate Manila, PhilippinesTel : (+63)2 400 5778Fax: (+63)2 400 9130

5.SINGAPORETAKNAS ENGINEERING PTE.LTD.102, Pandan Loop, Singapore 128310Tel : (+65)6777 5856Fax: (+65)6779 6711

6.TAIWANAL SEA-LAND ENGINEERING CO.,LTD.1F,No.51, Lane 164, Chung He Rd, Chung Shan Dist.,,Keelung, TaiwanTel : (+886) 2 24367812Fax: (+886) 2 24373219MING YUNG MACHINERY.,LTD.27.Shin Shing St., Yan Cherng District Kaohsiung,TaiwanTel : (+886)7 521 6266Fax: (+886)7 521 9368

7.THE NETHERLANDSNICOVERKEN HOLLAND B.V.Algerastraat 20 3125 BS Schiedam, The NetherlandsTel : (+31)10 2380999Fax: (+31)10 2380990FUJI TRADING (MARINE) B.V.Kortenoord 2-8 3087 AR Rotterdam, The NetherlandsTel : (+31)10 429 8833Fax: (+31)10 429 5227

8.USACISCO BOILER SERVICE CO., INC.5935 Griggs Road, Houston, TX 77023, U.S.A.Tel : (+1)713 928 5700Fax: (+1)713 928 5795INDUSTRIAL BOILER SERVICE, INC.23132 East Echo Lake Rd., Snohomish, WA 98296,U.S.A.Tel : (+1)206 624 1171Fax: (+1)206 483 9112

9.VIETNAMSHM-VLK CO.,LTD64 D2 Street, Van Thanh Bac Precinct, Ward 25,Binh Thanh District, Ho Chi Minh, S.R. VietnamTel : (+84)8 3512 8379

OPERATION MANUAL

MARINE AUXILIARY BOILER HB-TPublished by MIURA Co.,Ltd. Ship machinery Dept. Dec. 2011.

3rd edition Aug. 2014 No. E990-1112-03

Visit us at www.miuraz.co.jp and get the latest information and Service News!

Printed in Japan

All rights reserved, Copyright © 2014 MIURA Co.,Ltd.

No part of this publication may not be reproduced, transmitted, distributed or

modified, in any form or by any means, without the written permission of the

publisher MIURA Co.,Ltd.

hb-t e990-1112-03

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