> Hada Boiler HANDLING MANUAL FOR MARINE BOILER TORTOISE EncIneERING CO., LTD. 700, KITAGAWARA, MASAKI-CHO, IYO-GUN, EHIME PREF, 791-8181 JAPAN ‘TRL +81-89-984-1851 FAX 481-89-984-8988 SRM 200751 AFOREWORD ‘Thank you very much for employing our beiler for your ship. Recently, the development of equipment for ship, boilers above all, has been repaid in its automation process. However, the basic ways of maintenance and control of the boiler itself has remained almost the same as before. ‘This Instruction Manual mainly deseribes how the beginner should operate the boiler, and how the user should carry out maintenance so that the boiler may be operated in its best conditions. Please read this Instruction Manual before use, so that. the boiler can be operated safely, and efficiently.CHAPTER 1 qa 12 138 14 15 CHAPTER 2 21 22 23 fo a Sea 3 Pewee CHAPTER 3 31 32 33 84 85 36 CONTENS HOW TO OPERATE Preparation for Operation ~~ Increasing Steam Pressure~ When Steam Pressure Increases When Steam Is First Supplied. When Steam Is Supplied~ FAILURES IN OPERAION, AND COUNTERMEASURE, Priming and Foaming: Rumbling Boiler ~ Damages to Boiler Proper Swelling and Collapse by Overheat, Short, Water ~ Accidental Increase of Boiler Water ~ Broken Smoke Tube Water Level Gauy Pressure Gauge Blow-off Valve Avoiding OverLoad Operation: FEED WATER AND BOILER WATER Why Water Treatment. Is Necessary Impurities Contained in Feed Water and Boiler Water ~ Boiler Proper Corroded by Boiler Water ~ Boiler Seale, Mud Drift, Condensed Boiler Water Limit. Values for Feed Water and Boiler Water Water Control and Water Treatment:CHAPTER 1 HOW TO OPERATE, 1.1 Preparation for Operation 118 lid LLB Make sure no fault is detected in the following units before ignition. Water level gauge After confirming that the drain cock is completely closed, and that the gauge cocks on the upside and downside of the water level gauge, and the stop valve of the water level gauge are all opened to the full to allow a completely free flow, make sure that, the correct, water level of the boiler drum is indieated by the water level gauge. This should be identified as the normal water level. However, it is essential that the water level never goes below the safety water level even when it fluctuates temporarily due to inerease of boiler water temperature, foaming by evaporation, or due to changes in water level as soen in starting to circulate boiler water, which may occur in case an exhaust gas economizer in installed. It is also important to supply water adequately, so that its level may stay within the water control range, not filling the scope of the water level gauge to the full. Pressure gauge Make sure that the rot cock is opened to the full, and that the pointer stands at level The pressure gauge, which is positioned in a low position ease to see, will indicate a water level a little higher than the true level due to the head pressure inside the steam pipe (0.0981MPa per head pressure 10m). Some type of pressure gauge has its head pressure regulated. If, however, the pointer drifts by 0.05-0.07 MPa when the pressure is zero, replace ar correct it, Blow-off valve Make sure that the valves in the sides of the boiler drum, middle valves and blow-off valve outside the ship are all completely closed. The leakage from the sides of the boiler drum should be checked by touching the conductor pipe. Water feed valve Keep the feed water stop valve always opened to start feeding water any time for adjusting the water level. Close the feed water check valve to a degree not affecting the capacity of feed water, so that the damage of the valve seat, or disc can be minimized when it is activated by feed water. Steam stop valve By opening closing the handlo, make sure that the valve is completely closed. If the dise diffors in material from the stem, unequal expansion could make it difficult to open or close the valve. Use an appropriate torque to close such valve,116 LLT Safety valve Make sure that no fault is detected in the manual valve opening devise, and that the drain pipe of the body is opened. Air vent valve Open the air vent valve to the full. When steam is first generated, close the air vent valve to the full after confirming that the air inside the boiler drum has been completely released. Other units To avoid failure during operation, cheek thoroughly each of the other units such as feed water, ventilation, combustion, ete, and automatic controls, air duet, the damper of uptake, ete. 1.2 Increasing Steam Pressure (Cold Start) 121 122 ‘To avoid excessive expansion caused by the difference in temperature of each section of the boiler drum, it is essential to increase the FO consumption slowly, taking enough time. (Carry out intermittence combustion with minimum flow rate of FO.) ‘The time needed to raise the steam pressure to the specified value varies according to each type and capacity of the boiler, or each temperature of the water supplied. It is necessary, above all, to raise the pressure slowly, taking enough time, when cold water is to be warmed, The small size oylindrical boiler (Type of MKSC or MVS) will need at least 4 hours, lange size cylindrical boiler (Type of MVW) will need 6 houre or more. When especially increasing the boiler pressure up to 0.1MPa don't fail to take 2 hours (Type of MKSC or MVS) or 3 hours (Type of MVW). Negligence in such care may lead to cracks in the boiler drum, and such cracks in the water tube, smoke tube or any joint may lead to a leakage, resulting in the rupture of the boiler in the most serious ease Other instructions to follow in increasing the pressure will be describes in the following paragraphs: Air vent, When the steam is first generated, and the air inside the boiler has been exhausted enough, the air vent valve shall be totally closed. Checking leakage When the steam is generated, and the pressure starts to rise, ensure the water level again Chock if any leakage occurs in water level gauge, blow-off valve, each cover and other. If any leakage is detected, take corrective actions ineluding re-tightening,12. Re+tightening Even if no leakage occurs in the manhole cover, each valve or cock, rettighten as required every part that is fastened with packing. * Carry out increase the boiler pressure by Cold Start procedure when having repaired with the fireproof material. 1.8 When Steam Pressure Inereases 13. 1 Adjustment of combustion When the steam pressure is applied, note how it rises, Adjust, combustion slowly, s0 that the steam pressure may not rise rapidly. Monitoring water level Check water level of water gauges several time when increasing of boiler pressure. Carry out performance test of glass water gauge several times so as to correctly read off water level Removing foreign matters Generally in initial stage of combustion, it is necessary to remove foreign matters form the boiler drum, When the pressure reaches about 1/4 of the normal working pressure, stop combustion temporarily, drain the boiler water from scum and bottom in order by opening/elosing the blow-off valve. ‘The boiler water shall be drained to a degree that it can be detected by water level gauge, and shall be re-filled up to the normal water level as a referenee. 1.4 When Steam Is First Supplied When the steam pressure reaches the specified value, and the steam is first used, pay enough attention to the following things If the main or auxiliary valve is opened, the steam that comes out will be eooled and become drain. This drain and the steam blows away the drain accumulated in the steam pipe, causing a water hammer which could destroy the steam pipe system and other units. ‘To prevent such accidents, open the steam valve a little first to warm up the inside of the pipe, and then exhaust the drain sufficiently by way of the drain valve of the pipe system. Open the steam valve as slowly and quietly as possible after the pipe system becomes hot, enough. 1.5 When Steam Is Supplied After completing the operations mentioned in the paragraphs do far, steam is supplied to each unit, and the boiler enters into a normal operation. To supply steam safely, and efficiently, necessary instruction will be given in the following paragraphs:1s. 16. 1 2 Adjustment of combustion The boiler must. be warmed, so that a uniform pressure is always kept, Violent changes in pressure may lead to a damaged boiler. The consumption of steam seldom stays equal throughout the day. If the consumption of steam load varies, combustion must also be changed, which will in turn change the volume of air to be sent. ‘The degree of openness of the damper must also be adjusted accordingly. Negligence in the adjustment may lead to an incomplete combustion and surplus of air, affecting the boiler efficiency adversely. Confirmation of water level The most important thing in operating a boiler is how to keep the boiler water stable, and prevent the water surface from falling below the safety low level. No matter how functional the automatic alarm system, automatic feed water system or remote indicator of water level, ete. may be, don't trust them 100percent. It could be dangerous. Be sure to confirm the water level regularly the water level gauge. Keep the water level gauge always clean, If it is fouled, replace or clean it, If any leakage oceurs in the water level gauge, cock(s) or connecting pipe, the correct water level may not be displayed. In such case, replace affected component immediately. (a) Testing water level gauge ‘The water level gauge in operation shalll be tested at lease deily. If any irregularity is detected in the water level, and if, for example, a low water level is suspected, tast it 8 required. () Blow -off test of water column If the water level gauge is installed on the water column, such water column shall be tested in a blown-off test, In this type of construction, a long connecting pipe and stop valve are used, and seale, mud and other foreign matters are likely to be accumulated. inside the connecting pipe, or a malfunction of a valve could lead to an error in the readings of the water level gauge, By carrying out a blow-off test before testing water level gauge, the dirt: from the water side passage and water column can be prevented from drifting into the water level gauge. Pressure gauge Pressure gauge shall be kept always clean, If any error occurs in its readings, such pressure gauge shall be replaced immediately. If priming or foaming occurs inside the boiler, it is suspected that the pressure gauge is clogged with scale, resulting in the difference between the reading of the pressure gauge and the pressure inside the boiler. Ploase note such an accident could happen in such a case.1.54 Safety valve 16. 5 {a) Confirmation of operations If the safety valve blows off, record the opening pressure and closing pressure by checking the pressure gauge, and then make sure that operation is normal. %) When valve is not activated If the valve does not blow off even when it reaches the opening pressure, blow off the valve temporarily by the manual lever, and then let the valve blow off automatically. If the valve does not blow off again, it shall be cleaned or repaired. (©) Dealing with leakage If the valve leaks below the closing pressure, change the contact of the blow-off valve slightly by the manual easing lever, If the leakage is not stopped, stop the operation of the boiler immediately, and repair the valve, Never tap or pry the safety valve in any case. (a) Blow-off test. and water level ‘The blow-off test of safety valve shall be carried out by an engineer accustomed to the structure of such safety valve, In this, don't raise the water level to the to 2/8 or more of the visible part of the water level gauge. Blow-off of boiler water Blow off the boiler water 30 minutes after stopping the combustion, or when the lease amount of steam is being used if the combustion can not be stopped. When the density of the boiler water gauge tends to increase, as in a case when low quality of water is supplied, or when more of precipitation is detected, blow off the boiler water more often. If, during the blow-off, the water level of the water level gauge con not be identified from the point of blow-off, keep communication with another worker who can see the water level, and perform such blo off, Never do any other thing until the blow-off is completed. 1.5.6 Soot blowing Carry out soot blowing as required according to the degree of adhered soot. (a) Oil fired side soot blower a. Carry out soot blowing after stopping the combustion. b. Handling(GH25 or SB25) + Exhaust drain properly. + After removing the advancing stopper, push the handle forward. + To prevent reaction by jet stream, set the stopper in the stud bolt, and then fix it with safety stopper. + Open the steam stop valve to the full slowly, and then turn the handle immediately. + After maintaining the jet stream for a fow minutes, close the steam valve, + Release the safety stopper, and then the stopper to let the handle come back. + Set the advancing stopper to prevent the nozzle from coming into the combustion chamber,{) Exhaust gas side soot blower a. Handling Exhaust drain properly. Open the steam stop valve to the full slowly, and then turn the handle immediately. While confirming the bolt indicating the nozzle direction, apply the jet stream mainly upon the smoke tube, ‘Turn the nozzle 360 degrees at a rate of 9:1, and apply the jet stream upon the internal walls of the smoke box. After maintaining the jet stream for a fow minutes, close the steam valve. (©) Instructions about jetting medium a. Steam Exhaust drain properly, and operate the soot blower after warming up the pipe. After blowing soot, turn the stop valve and steam stop valve both "Closed". “Open” the drain valve, so that any more of drain may not be accumulated, To carry out the soot blowing efficiently, keep the pressure as high as possible, b. Compressed air Be sure to change over the air reservoir valve. (1 unit of main air reservoir is used.) The air reservoir shalll be used at a pressure of more than 0.98MPa Be sure to close the stop valve and root valve.CHAPTER 2 FAILURES IN OPERATION, AND COUTERMEASURE 2.1 Priming and Foaming 218 Priming is a phenomenon in which some portion of the boiler water is carried away with the steam when boiled vehemently. Foaming is a phenomenon in which a mountain of bubbles is formed in the boiler when such bubbles are less likely to break up due to a stronger surface tension of the boiler water that becornes more condensed by and by. In some serious case of the above mentioned phenomenon, a portion of the boiler water is carried away with the steam. Hazards by priming and foaming (a) The level of the boiler water fluctuates violently, and it is difficult to identify the water level in the water level gauge. {b) Safety valve may be fouled, or the connecting hole of the pressure gauge may be clogged with seale or other foreign matters, or boiler water may come into the vent hole of the water level gauge, All these things could degrade the performance of each unit, (©) The portion of the boiler water carried away with the steam may be accumulated in the piping, and cause a water hammer, finally damaging the piping and each unit using such steam. (a) When priming or foaming occurs, the water level of the boiler drops suddenly, which could cause any accident due to low water levels. How priming and foaming occurs Too high water level, too rapid evaporation, too rapid inerease of steam volume used, and boiler water density excoeding a specified level may cause these phenomena, Also note that some drifting particles, organic matters, soap or oil that may be include in the boiler water could contribute to these phenomena, How to deal with problems If priming or foaming occurs, identify the true case for such problem first, and be sure to see what corrective action(s) ean be taken If'such problem occurs suddenly, restrict the combustion first, and allow the water level gauge to show the correct level. Take the following steps according for each cause of the problem: (a) When the water level is high, adjust it by blowing off the boiler water. (b) Open/close the steam valve slowly. If the problem is cased by a rapid increase of combustion load, restrict the combustion, and wait for the water level to stabilize, and then inerease the load slowly. (2) If the boiler water is of high density, repeat blow-off and feed water to decrease the density. -10-