Dear User

Thank you for purchasing Forbes Marshall Packaged Boiler. If you experience difficulty during the
installation or operation of this equipment; please contact our Customer Service representative. To
maximize your benefits from this product, we request that you read this manual thoroughly before
installing the system. A record of the product’s maintenance history should be kept in this manual’s
Service Record.

An IBR certified boiler operator is required to run the IBR boiler. It is assumed that the operators
are trained in operation of IBR boilers & are certified to operate IBR boilers by the State Boiler
Inspectorate.
Forbes Marshall conducts a workshop at Steam Engineering Training Center, Pune specially
designed for Maintenance/Utility/Design/Plant Managers & Engineers. This is a 5 day paid program
designed using relevant case studies along with hands-on time on our unique simulation rigs. It
covers all aspects of steam circuit and the participants are made to draw up an energy conservation
plan with the knowledge acquired in the course and to enable them to take forward meaningful
Energy Conservation measures for their respective industries.

Apart from above Forbes Marshall conducts a three day free (non-residential) program for the
operators, technicians and maintenance personnel strictly for those who are operating and
maintaining our boilers. The contents are

1. Basic Concepts & Operation of packaged boilers

2. Burners & Associated Controls
3. Boiler Accessories, Mounting & Controls
4. Automatic Blowdown of Boiler & Associated Equipment
5. Flue Gas Monitoring
6. Energy Efficient Operation of Boilers

For more information about Training Program please send mail to sec@forbesmarshall.com

Boiler Manual -1-

What’s inside?
1. About us

2. About The Product

3. Transportation, Unloading and Storage

4. Getting Started

5. Startup & Standard Operating Procedures

6. IBR Formalities

7. Commissioning of Boiler

8. Boiler Operations

9. Mountings, Control & Safety Systems

10. Operation and Maintenance

11. Safety

12. Fixing Problems

13. Log Book Details

14. Do’s and Don’ts for Operations

15. Service & Spare Parts List

16. Fuels & Combustion

17. Accessories Manual

18. Contact Us

Boiler Manual -2-

ABOUT US

For over half a century, Forbes Marshall has been building steam engineering and control
instrumentation solutions that work for process industry. Forbes Marshall's goal is to provide
solutions in Energy, Efficiency and Process Automation, using the best technology the world has to
offer. 50 years ago we started out with steam generation solutions. Today we are comprised of
twelve business divisions; most of them partnering with the world technology leaders in respective
fields, manufacturing products that cover the entire spectrum of energy generation, energy
efficiency, control and instrumentation for the process and power industry.

But we are proud of much more than just the products we make. We are committed to creating a
progressive work culture that uniquely puts people first. We are concerned with the community
beyond our factory's gate. Putting people first is the way we have become industry's first choice in
their efforts to better harness steam, air and water. We do much more than sell products. We build
steam engineering and control instrumentation solutions that work for you.

From our unique corporate structure and commitment to quality, to our extensive community and
social service programs, there's a lot that makes us stand out from the rest.

In the last six decades Forbes Marshall has grown from a modest, Mumbai based trading company to
a multi-divisional, ISO 9001 certified global company manufacturing advanced engineering products
for process and power industries across the World. Forbes Marshall is probably the only company in
the world to have extensive expertise in both steam and control instrumentation. The dual expertise
has allowed us to engineer industry specific systems that focus on energy efficiency and utilities
management for sectors as diverse as textiles, food processing, paper, power and chemicals etc.

Trusted Partners
Innovative Solutions

Boiler Manual -3-

CORPORATE PROFILE

Forbes Marshall- The name synonymous with “Steam Engineering & Control Instrumentation”
for over five decades, is a group of seven ISO–9001 companies with joint venture partners in
Germany, France, U.K. and the U.S.A.

Our Group Activities -

Forbes Marshall – We make steam

We manufacture high efficiency three-pass wet-back packaged Boilers and Burners. We also offer a
total Boiler Efficiency Monitoring System to incorporate every important parameter into one
package. We design & supply complete steam distribution & condensate return systems that result in
increased efficiency and major energy savings.

Spirax Marshall – Get the Most from the Steam

This is our oldest and largest divisional company providing Knowledge, Service and Products for the
efficient use of steam, in joint venture with Spirax Sarco, U.K. Our agreement with our Principals
allows us to market these products in India and neighbouring countries viz, Sri Lanka, Bangladesh &
Nepal only.

Krohne Marshall – Every Kind of Flow meter for Every Kind of Flow
We manufacture an extensive range of flow meters & level instruments in joint venture with Krohne
Messtechnik of Germany. These include Magnetic flowmeters, Rotameters, Vortex Flowmeters, flow
switches etc. We also have in-house state-of-the-art hydraulic & pneumatic calibration rigs. It is a
matter of pride that both Krohne, Germany & Spirax Sarco,UK source our indigenously designed
and manufactured Vortex flow meters for their world-wide market requirements. Our agreement with
our Principals allows us to market these products in India and neighbouring countries viz, Sri Lanka,
Bangladesh & Nepal and through Krohne Messtechnik offices worldwide.

Forbes Polymetron – How good is the Water you use?

Whether it is water or any other process media, you need accurate monitoring, analysis & control of
pH & conductivity in your process. Errors can lead to costly equipment damage or wasted time &
materials. We manufacture the Polymetron range of on-line pH & Conductivity analysers and also
offer a wide range of other Water Quality Analysers such as Silica, DO2, Sodium, Chlorine,
Ammonia etc. We also design, manufacture & supply customized Steam & Water Analysis System
packages (SWAS). Analyser systems for fermentor, foam and concentration are also available
besides those for Water & Effluent Treatment Plants.

Forbes Marshall Arca – Control Valves for Every Process

We manufacture a wide range of Control Valves as well as Steam Conditioning Valves & Stations in
joint venture with Arca Regler, Germany. These include revolutionary one-piece Pressure Reducing
and Desuperheating (PRDS) Valves. We also offer variable nozzle desuperheaters called
Attemperators to match any process needs. Our new generation microprocessor-based pneumatic
positioner makes your control valve intelligent.

Gauge Division – Gauging for higher technology

At our Hyderabad manufacturing unit, we manufacture Pressure & Temperature Gauges and Circular
Chart Recorders. Our Bimetallic thermometers from USA offer a unique 5-year warranty.

Forbes Marshall – When it’s Time to Take Control, High Performance Valves for the Toughest
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 Jobs & Turnkey Solutions

Whether you are a huge plant or a small batch producer, any loss of control can mean ruined batches,
poor product quality, or equipment damage. That means massive losses. Our Control Systems &
Products are designed to keep your process, and your expenses, in check - Plant wide.

We offer I/P Converters, Multi-loop digital Controllers, Smart Transmitters, besides Distributed
Control Systems for special safety requirements.

A valve that fails is not just a nuisance. If it leads to shut-downs, it becomes an expensive liability.
From extreme pressures & temperatures to precision control applications, our high pressure Stop &
Check Valves as well as Safety Relief Valves are the most dependable assets on your process line.
They combine unflagging resistance to extreme operating conditions with utmost ease of
maintenance.

Besides, because of our wide & complementary product mix, un-matched expertise in both steam &
instrumentation, and half a century process experience, no company is better suited to engineer
complete turnkey solutions for process industry in the country. Our process specialists are experts in
chemical, pharmaceutical, steel plants, thermal & nuclear power sector, sugar, distillery, paper and
for that matter any process. We also undertake site erection & commissioning jobs through our
country-wide network of sales and customer support engineers located at more than 20 places in
India. We also cater to customers in neighboring countries through our International Operations. We
have recently established Forbes Marshall Inc. in USA to promote some of our products like Control
Valves & Vortex Flowmeters, in the American market.

We also offer some of the imported, Agency products from our Principals such as Shinkawa
Vibration Monitoring Equipment, Watson Marlow Peristatic Pumps and Codel Pollution Monitoring
Analyzers etc.

Utilities Management – Save Energy, Save Money

For Utilities Management, we now offer three services: Steam Engineering Centre, Energy Audits
and Consultancy.

EDUCATION: In our Steam Engineering Center, we conduct focused & structured programs for
Industry Professionals / Practicing Engineers and also provide maintenance oriented hands-on
training courses we hold every month in steam system design.

ENERGY AUDITS: We undertake detailed surveys of process plants to identify energy saving
potential. Detailed reports include a heat-balance for the plant, detailed payback calculations for each
suggestion, and prioritization of all energy saving proposals.

PROJECT CONSULTANCY: We undertake detailed engineering of all plant utilities, for new
projects and revamps. Scope includes detailed P & I diagrams, piping layouts and isometrics, and a
detailed BOM for all utilities. Our designs are fully consistent with the latest Good Engineering
Practices world-wide.

Community Service & Medicare –

Besides serving customers and making pioneering contributions to Indian Industry, we have always
been concerned about meeting obligations to society. Our community service programs are guided
by our desire to be an economic, intellectual and social asset to the nation and the community in

Boiler Manual -5-

which we operate. These aim at improving the quality of life of people living in our neighboring
areas and include adult literacy classes, job training and establishing income generation programs for
women.

Our Shehernaz Medicare Centre is a 35-bed hospital that provides free medical treatment to our
members & their families and also to all residents of the neighboring towns of Kasarwadi &
Bopkhel.

Knowledge is Power
Ultimately any organization is only as good as its people. Our members are the source of our success
today and our only chance of success tomorrow. We believe that a member must have every
opportunity to realize his or her fullest potential and that it is our duty to provide those opportunities
to grow.

All of this adds up to our corporate mission : being a developed company in developing country.

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 SECTION-1

About The Product

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1 About the Product
1.1 General Description
Modern packaged boilers are designed to produce steam, efficiently and reliably, twenty-four hours a
day and seven days week without interruption. To achieve the best performance of boiler operation,
it is essential that the boiler is operated correctly and maintained regularly. It is equally important
that the boiler operators and maintenance personnel are well trained to carry out regular checks and
make adjustments and repairs.

Marshall Range of package modular boiler is of three-pass design. The first pass is the furnace and
the second and third passes are two nests of smoke tubes.The flue gas outlet is positioned at the rear
side of the boiler, just after the third pass.

All working parts of the boiler are accessible for ease of inspection &maintenance. The design and
construction confirms to IBR 1950 with latest amendments. All mountings, fittings, & accessories
used conform to above standards and codes.

1000 of our three-pass wetback boilers are generating steam in plant all over India, the Gulf, Africa
and South East Asia. These boilers provide the driest steam possible from the least amount of fuel &
floor space. The true three pass fully wetback design ensures low flue exit temperatures resulting in
high thermal efficiency.

Boiler Manual -8-

ADVANTAGES

Truly Packaged

• Pre-Wired
• Skid Mounted
• Pre-insulated

Compact Design

• Less Floor Space required

• Helps keep radiation losses lower
• No requirement of heavy civil foundation

Specially developed pressure jet monobloc burner

• Takes care of practical aspects of maintenance

• The only company in India offering monobloc design, a preferred burner worldwide

Boiler & Burner – Same design source

• Design source for boiler and burner are same

• Optimum flame configuration hence enhanced furnace life

Easy access to working parts

• Ease of inspection & Maintenance

1.2 MOUNTINGS AND ACCESSORIES

All mounting & accessories comply to highest quality standards

1.2.1 Feed Water Pump

Boiler Manual -9-

Feedwater pumps from WILO, Germany. The Feed pumps take the water from the feed water tank &
supply the water to the boiler. Two feed water pumps are provided, one working and one standby.
The pump is operated on off, by the water level controller.

Each pump is of adequate capacity and head to meet the boiler requirement. The feed pumps are
selected considering reduction in pump capacity and head due to normal wear & tear over a period of
time.
The pumps are vertical, multistage, centrifugal types. Electric motor is the directly mounted on top of
the pump. The pump is provided with single mechanical seal.

1.2.2 Disk Check Valves from Spirax Marshall

1.2.3 Piston Valves

All steam line and water line valves are Piston Valves

1.2.4 Efficiency Monitoring System

Boilers are equipped with online boiler efficiency monitoring system for continuous monitoring of
Boiler efficiency.

Boiler Manual -10-

1.2.5 Electrical Control Panel

The electrical control panel supplied along with the boiler is designed to suit the boiler operating
logic and provides the electrical supply to the boiler & its other electrical equipments like motors of
feed pumps, fans, controls etc. It also interlocks fans, low water safety to ensure safe operation of the
boiler. The control panel consists of the main on-off switch, switch gear for the operation of the
motors of feed pumps, burner, and mounts hooter, indicating lamps, power and control circuit
wiring.
The control panel is mounted installed on boiler. The control panel is to be connected to the various
motors, safeties and controls of the boiler by proper cables and wires

1.2.6 Burner

Burner is the heart of the boiler, which provides the fuel or heat input to the boiler. The high thermal
efficiency & the trouble free operation of the boiler will mainly depend on its design, its
compatibility with boiler, ability to burn the desired fuels with high efficiency & reliability of the
components.

Boiler Manual -11-

1.3 SPECIFICATIONS

• Insulation : Rock Wool mattress 75 mm thick,

Density 100 kg/m3
• Cladding : Steel Sheet, duly painted

Electrical
• Power supply voltage : 440 V 3 Phase
• Frequency : 50Hz
• Control voltage : 230 V Single Phases

Boiler Manual -12-

 SECTION-2

Transportation,
Unloading and Storage

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2.1 Transportation
Marshall B boiler is dispatched from our factory in single package boiler & accessories. The IBR
valves & mountings, panel box, feed pump, FD fan etc. are packed separately in wooden cases &
dispatched with the boiler.

During transportation, extreme care is taken to ensure safe & intact delivery of the boiler. The boiler
& other wooden cases are loaded on the truck as per uprights markings.

Dispatch particulars are sent to the customer immediately after loading the trucks.

2.2 Unloading Instructions

• The boiler should be lifted for loading, unloading or shifting from one position to another,
only by means of lifting hooks provided on top of the boiler.

• The packing slip supplied with the material should be referred & the no. of cases supplied
should be verified with the no’s received at site.

• The wooden/packaged cases should be opened only in the presence of Forbes Marshall
Engineer or Forbes authorized person, for checking the inside materials as per the packing
slip.

• If the cases are opened in the absence of Forbes Marshall Engineer./authorized person, & if
the material is found missing, the responsibility of Forbes Marshall shall cease.

• For any damages, insurance claim should be made.

• For any missing items, Forbes Marshall Engineer./authorized person shall report to Forbes
Marshall ltd for replenishment, provided the cases are opened in the presence.

• For any incorrect supply of material Forbes Marshall Engineer /authorized person shall report
to Forbes Marshall ltd. for replacement.

Boiler Manual -14-

2.3 Unloading Guidelines
A) All the parts should be unloaded with crane, tripod, suitable capacity as per the weight &
dimensions (Figure 1)

Figure 1: Unloading Boiler with crane.

Boiler Manual -15-

 B) All parts should be unloaded in marked upright position only i.e. these should not be tilted
while unloading or shifting. (Refer Figure 2). If lifting tackles are not available, rollers,
wooden slabs or some skid should be placed beneath the frame of the boiler and wooden case
and it should be carefully guided for unload and shifting. Under no circumstances the boiler
and accessories should be dropped or turned to any other position other then marked on the
cases.

Figure 2: Packing Cases should not be tilted while unloading or shifting.

C) It is advisable to unload the boiler as closes as possible to the Boiler House; preferably just
outside the main door of the Boiler House, on some skids or pipes, so that pushing the Boiler
into the Boiler House for positioning it on the foundation is easier. The soil at the place of
unloading should be hard enough to bear the weight of the Boiler, to prevent it from sinking.
(Refer Figure 3). Likewise, when the Boiler is being shifted to the Boiler House, the approach
road to the Boiler House should also be made of hard ground.

Figure 3: The soil at the place of unloading should be hard.

Boiler Manual -16-

2.4 Storage

A) All the material should be stored under roof and should be protected from rain, water or direct
sunlight. (Refer Figure 4).

Figure 4 : Boiler should be stored under roof.

B) Boiler & parts should not be stored under corrosive atmosphere. (Refer Figure 5).

Figure 5: Boiler should not be stored under corrosive atmosphere.

Boiler Manual -17-

C) Do not pile up cases. (Refer Figure 6)

Figure 6: Do not pile up cases.

D) Do not store heavy material on soft soil. (Refer Figure 7).

Figure 7 : Material should not be stored on soft soil.

Boiler Manual -18-

2.5 Drawings
A set of the following drawings is given by Forbes Marshall to guide the site persons. These
drawings are sent from Forbes Marshall, Kasarwadi factory as a part of Start Up Folder.These
drawings should be carefully preserved for the refrence.

The Drawing numbers with Alteration numbers to be recorded for future records by the customer
before installation:

• P & I Diagram
• Boiler House Layout
• General Arrangement
• Electrical Diagram
(Supplied with Elec. Control panel)

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 SECTION-3

Getting Started

Boiler Manual -20-

 GETTING STARTED

3.1 INCLUDED ITEMS

A. Pressure parts
Tube Plates
Boiler Tubes
Stays (tubes, Bars, Gussets)
Mud hole on tube plate
Manhole
Stand pipes for stop, feed check and safety and blow down valves
Stand pipes for gauge glass and level controller

B. General Construction Parts

Front casing with hinged door
Rear smoke chamber with removable doors
Flue outlet Box
75 mm thick Insulation and Steel Sheet Cover for boiler shell
Platform & ladder assembly
Rear Access Door

C. Mountings
Safety valve (2Nos.)
Main Steam Stop Valve (1No.)
Feed Check Valve (2Nos.)
Blow down Valve (1No.)
Water level gauge glass (2 sets)
Water level controls (2 sets)
Pressure gauge (1No.)
Inspector’s test connection (1No.)

D. Feed Pumps
2 Nos. electrically driven centrifugal multistage pump with motor, interconnected
pipe work between pumps, Strainers, isolation valves and feed check valves.

E. Combustion Equipment
The Burner is supplied by Forbes Marshall, Pune along with Boiler

F. Instruments and control

Main steam pressure gauge with cock,
Level controller for feed pump operation and low & extra low water level alarm
Pressure switch for boiler pressure
Audio / visual alarm in case of unsafe operation.
Pressure gauge
Control panel housing with switchgears, relays & connectors

G. GENERAL ITEMS
Painting
Feed water piping from FW pumps & between feed check valves to Boiler.
Drain piping from level controller, water level gauge & header assembly
Boiler Manual -21-
3.2 WHAT YOU NEED?
A. Chimney and ducting with insulation between the chimney and boiler
B. Expansion bellows between boiler flue gas outlet ducting & Chimney
C. All civil structural work for boiler installation
D. Water treatment plant with chemical dozer to maintain required water quality
E. IBR inspection, registration and approval.
F. Structural approach ladders, platforms in the boiler house
G. Electrical work in the boiler house up to our terminal point.
H. Water & oil storage tank of adequate capacity located at suitable height as advised by JNM.
I. Steam, water, oil piping beyond terminal points.
J. Water & fuel handling system.
K. Tools, tackles, utilities & consumables required for assembling, erecting & commissioning of
the boiler.

L. Spares for installation, operation maintenance of boiler.

M. Approved boiler operator.
3.3 BOILER FEED WATER CIRCUIT
• Ensure that water treatment plant should provide the water as per the specifications for feeding in
the boiler.

3.3.1 Recommended Water Characteristics for shell boilers as per IS: 10392 & BS-2486-1978
a) Feed Water
Sr.No. Characteristics Value
1.0 Total hardness max. ppm (asCaCo3) 5
2.0 PH value 8.5-9.5
3.0 Dissolved Oxygen max. mg/lit Nil
4.0 Total dissolved solids ppm (Minimum to reduce blow
down quantity)

b) Boiler Water
Sr.No. Characteristics Value
1.0 Total hardness max. ppm (as CaCo3) Not detectable
2.0 Total Alkalinity max. ppm (as CaCo3) 700
3.0 Total dissolved solids max. ppm 3000
4.0 Sodium Phosphate max. ppm(Na3 50-70
5.0 Po4) Caustic Alkalinity min. ppm (as CaCo3) 350
6.0 Silica as SiO2 0.4 of Caustic Alkalinity
7.0 Sodium Sulphite ppm (as Na2So3) 30-70
8.0 pH Value 11-12
9.0 Hydrazine-ppm as (N2H4) (If added) 0.1-1
10.0 Suspended Solids max. ppm 50
Boiler Manual -22-
• Refer the piping & instrumentation Diagram (P&I Diagram) for the boiler model for the layout
and sizing of the pipe lines, valves and other connection details.

3.3.1.1 Feed Water Tank Capacity

• Feed water storage tank of minimum 3 to 4 hours capacity of boiler evaporation is recommended
for this purpose to have the time for the regeneration of the water treatment plant.

3.3.1.2 Feed Water Tank construction

• The raw water storage and soft water tanks should have a hinged or bolted cover, an air vent, a
float valve, a water level gauge glass, preferably with calibration, a drain at the bottom with a
gate valve and an overflow connection.

• The outflow from the tank should be taken from a point of distance of minimum 100 mm (4")
from the bottom level of the tank, to avoid any sediments and foreign matter going into the water
pump and damaging it.

3.3.1.3 Feed Water Tank Elevation

• Following table gives the elevation of water storage tank (NPSH) required for corresponding
feed water temperature for most of the pumps considering maximum suction pipe length of
10 meters

TEMP. OF WATER ( °C ) ELEVATION REQUIRED (M)

90 3
93 3.5
99 5
100 5.7

3.3.2 Feed Pump Suction Circuit

The feed water pumps will perform better if NPSH available is very much higher than NPSH
required by the pump. In the NPSH formula only suction head (Tank Elevation) and friction
pressure drop in suction piping are in our hands. Suction piping pressure drop is directly proportional
to product of square of velocity and length. Hence we want to reduce velocity and reduce length to
reduce friction pressure drop. Also sharp bends or any fittings causing a sudden change in direction
of flow will increase pressure drop in the suction piping.

Therefore in order to reduce suction piping pressure drop we should:

- Use large suction piping size. At least one size higher than feed water pump suction
size.
- Use only Piston/Gate / Ball valves. Avoid valves like Globe or Needle.
- Use long radius bends.
Boiler Manual -23-
 - Use as short suction piping as possible.

The logic of selecting suction piping size is explained above. The following may be ensured –

1. Suction piping is provided with a sample point for taking sample of water for analysis.

2. A Y type strainer is provided to prevent entry of any foreign particles in the pump.

3. Since suction piping recommended is one size larger than the pump suction size a pipe
reducer is required to connect suction piping to pump.

4. It is suggested to use GI pipes to avoid corrosion.

3.3.3 Boiler feed pipe-Feed Water Pump Discharge Piping

This conforms to ASTM A106 Gr. B and is an IBR approval piping. This pipe connects Feed
Water Pump to boiler. Disc Check Valves and Piston Valves are provided on pump discharge for
isolation and throttling purpose.

All valves, flanges and fittings in the pipeline are IBR approved.

Oil Line Size

Oil Line Size from DOT Water line size FWT to
Total Boiler from Oil Header to
to Oil Header Pump pump
Capacity (TPH)
Selected m/s Selected m/s Selected
0.5 50 50 40
0.75 50 50 40
1 50 50 50
1.5 50 50 65
2 50 50 65
2.5 50 50 80
3 50 50 80
3.5 50 50 80
4 50 50 100
4.5 50 50 100
5 50 50 100
6.3 50 50 100
7 50 50 100
8 50 50 125
10 50 65 125
12 65 65 125
15 65 65 150
16 65 65 150
18 80 65 150
20 80 80 200
22 80 80 200
24 80 80 200
26 100 80 200
28 100 80 200
30 100 80 200
Boiler Manual -24-
 CAUTION:
• Feed water service tank should never be constructed out of cement concrete, as soft water
will absorb Calcium and Magnesium salts from cement and the hardness will increase.
• The water level in the boiler feed water day tanks should be easily & clearly visible from
the ground level to the operators.
• Use G.I. Pipes and fewer fittings.
• Avoid using globe valves.
• Provide proper support to the pipelines to avoid unwanted stress on valves and pumps.
• Pump suction pipe size should be one size higher than the pump suction size.
• Long radius bends may be used, if necessary.
• The feed Pump suction pipe should be as short and direct as possible.
• The suction head pipelines should be laid with a downward slope towards the pump.
• The suction pipeline must be anchored in close proximity.
• All the pipe joints should be absolutely airtight.
• Don’t reduce the diameter of the pipes than what is mentioned in P and I diagram.
• Avoid use of Elbows and short bends.
• Never use the pump itself as an anchorage point for the piping.
• The gasket between pump and the pipe should not protrude inside the pipeline flange.
• The pipelines should be not transmitting any stress/ strain and pipeline weight, to the pump
body.

3.4 DRAIN, BLOW DOWN AND STEAM PIPING

3.4.1 Blow down Pipe Line

• Blow down valve located at the bottom of the boiler shell should be connected to a pipe of
one size bigger and should be led to a blow down pit/tank located outside the boiler house.
• The blow down pipe should be properly clamped and insulated for safety purposes.
• Use IBR pipes for the blow down lines.
• The lines should be properly clamped at every 3 meters and at all the two sides of the bends.

3.4.2 Blow down Pit

• Blow down pit should be made of concrete or mild steel plates of proper size as indicated
below.

Boiler Manual -25-

 Figure: Blow down Pit.

3.4.3 Safety Valve Exhaust Pipe

Safety Valve exhaust pipe connection is to be given as per the sketch given below:

Figure: Safety Valve Exhaust Pipe Connection

Boiler Manual -26-

 • The discharge from the safety Valve/s should be piped as direct as possible to the atmosphere
with a pipe diameter of not less than the Safety Valve outlet.
• A drip pan elbow or a flexible connection between the valve and the escape pipe is
recommended to prevent build up of backpressure and accumulation of foreign material
around the valve seat.
• The discharge piping must be properly arranged, clamped and supported so that its weight
dose not bare upon the valve.

3.4.4 Drain Pipes

• Drain pipes from water level gauges, level controllers should preferably be led with the same
size of piping as fitted on the valves to a common header.

CAUTION:

• All drain, blowdown & steam line must be properly insulated to avoid heat losses and
condensation.
• The steam piping from the main steam stop valve should be sized to match the steam valve
diameter.
• Provide expansion bends in steam pipeline within every 30 meters of straight run.
• Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
• The steam piping should be so sized to suit the evaporation capacity of the boiler to avoid
siphoning effects and steam/water hammering.
• Provide thermodynamic steam trap before every expansion bend for condensate water
removal.
• Provide adequate steam traps in the steam pipeline.
• Never reduce the steam pipe diameter, as they would restrict flow of steam.
• Never leave the drain or blow down pipe in open.

3.5 RECOMMENDED FUEL OIL/GAS CHARACTERISTICS

1) Furnace Oil
Composition (% v/v)
C H2 S N O2 H2O Ash
84.00 11.00 3.50 Nil Nil 1 0.5
NCV of the fuel 9650 Kcal/kg
Ash % Wt Max 0.1
Flash Point 0C 66
Kinematic Viscosity 125-180 Cst at 500C
Pour Point 0C 27 Max
Sediment % Wt 0.25 max
CCR (Conradson Carbon Residue) Less than 8%

Boiler Manual -27-

2) Light Diesel Oil
Composition (% v/v)
C H2 S N O2 H2O Ash
85.50 11.50 3.00 Nil Nil Nil Nil
NCV of the fuel 10100 Kcal/kg
Ash % Wt Max 0.02
Flash Point 0C 66
Kinematic viscosity, cSt, at 40o C 2.5 to 15.7
Pour Point 0C 12(winter)
18(summer)
Sediment % Wt 0.1 max

3) High Speed Diesel

Composition (% v/v)
C H2 S N O2 H2O Ash
85.70 14.00 0.5 0 0 0 0
NCV of the fuel 10500 Kcal/kg
Ash % Wt Max 0.01
Flash Point 0C 32
Kinematic viscosity, cSt, at 40o C 1.8 to 5.0
Pour Point 0C 5 Max
Sediment % Wt 1 max

4) Natural Gas
Composition (% v/v)
Methane C1 96.434
Ethane C2 1.102
Propane C3 0.543
I- Butane IC4 0.147
N-Butane NC4 0.127
Neo-Pentane 0.002
I- Pentane IC5 0.042
N-Pentane NC5 0.04
Hexane C6 0.005
Carbone Dioxide 0.188
Nitrogen N2 1.371
GCV 12750 kcal/kg
NCV 11250 kcal/kg

Boiler Manual -28-

3.6 FLUE GAS DUCTING LAYOUT
The flue gas circuit means the path of the flue gases leaving the boiler, Heat recovery (if applicable)
& finally exit through chimney.

3.6.1 Chimney

Chimney can be either of the following designs:

a) Self supported
b) Guy rope Supported
c) Structural supported
d) Wall Mounted

However, Chimney for the boiler should be of the adequate top diameter as per the recommendations
given by Forbes Marshall Engineers.

Guidelines:
• Chimney design Reference can be taken from the IS : 6533 specifications and considering the
Local geological conditions
• Provide all the Accessories of the chimney i.e. Aviation Lamp, Lightening Arrestor etc as per
the recommendations of the local statutory norms.

Figure: Self Supported Chimney.

WARNING:
• Follow rules and regulations of Smoke Nuisance Act and consult their local Pollution
Control Board’s office for further information & guidance on chimney design & height.
• Never reduce the Top Diameter of chimney than the recommended size.

Boiler Manual -29-

3.6.2 Flue Gas Ducts:

• The area or the size of the flue gas ducts needs to the same as recommended in the GA
drawing to ensure that the flues gas leave the boiler & system easily without any excessive
pressure drop.
• The recommended duct is of circular cross section.

CAUTION:

• Keep the cross sectional areas of the flue gas same as recommended. Do not reduce the
cross sectional areas.
• All the ducts should preferably be of fully welded construction.
• Any leakage means reduction in the capacity of the fans and reduction in the output of
the boiler.
• External columns, from ground, should support long ducts.
• Provide sockets with plugs at the inlet & outlet ducts for checking the pressure drops
and temperature measurement, across these equipment.
• The dampers should be checked for correct opening & close indications and for the
smooth operation.
• Provide long radius bends & avoid sharp bends in the ducts.
• Insulation of the ducts should be done after through check for the leakages, after the
commissioning of the flue gas system.
• Provide Insulation of proper density & the thickness as indicated in the table below.

3.7 INSULATION GUIDELINES

The table below gives recommended insulation thickness in mm required for different pipe sizes and
different operating / fluid temperatures.

3.7.1 Mineral Wool –

Pipe dia Operating / Fluid temperature oC

(NB) mm 90 150 200 260 315 375
25 25 40 65 65 75 90
40 25 40 65 65 75 90
50 25 40 65 65 75 90
80 25 40 65 65 75 90
100 25 50 75 75 100 100
150 40 50 75 75 100 115
200 40 50 75 75 100 115
250 40 65 90 90 100 125
300 40 65 90 90 100 125
Flat 40 65 90 90 100 125

Note: Mineral wool is assumed to have a thermal conductivity 0.036 kcal/m hr oC and average
density about 100-200 kg/m3.

Boiler Manual -30-

 CAUTION:

1) The surface temperature after insulation is 55 – 60oC.

2) Insulation up to 65mm should be in single layer and above 65 mm, multiplayer, e.g.
80mm two layers of 40mm each, for 90mm inner layer of 40 mm and outer of 50mm.

3.7.2 Glass Wool

Pipe dia Operating / Fluid temperature oC

(NB) mm 90 150 200 260 315 3756
25 25 25 25 25 40 40
40 25 25 25 25 50 50
50 25 25 25 25 50 50
80 25 25 40 40 50 65
100 25 25 40 40 50 65
150 25 25 40 40 65 75
200 25 40 40 40 65 75
250 40 40 40 40 65 75
300 40 40 40 40 65 75
Flat 40 40 50 50 65 75

Note: Glass wool is assumed to have a thermal conductivity 0.045 kcal/hr oC @ 100oC and average
density about 80 – 100 kg/m3.

Boiler Manual -31-

 SECTION-4

IBR Formalities

Boiler Manual -32-

4.1 Registration of Boiler under “Indian Boiler Regulations (IBR)”
4.1.1 Necessity of Registration

All steam boilers in India are required to be registered under section 7 of the Indian Boiler Act and in
accordance with Chapter 9 of the Indian Boiler Regulations. Section 6 of the Indian Boiler Act,
prohibits the use or permit to use any boiler which is unregistered or uncertified. This registration is
generally valid for 1 year from the date on which it is granted.

The installed boilers are also subjected to these tests to determine the fitness of boiler for the purpose
of renewal of Registration certificate.

In India, State of Jammu & Kashmir is exempted from this activity of IBR registration. Boilers
installed on Railway Engines are also exempted from this activity.

The following details and Instructions will guide the owners & users in getting their new boiler
registered as per the Indian Boiler Regulations

4.1.2 Boiler IBR Certificates: IBR Folder

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

This folder contains important and original documents like:

1. Manufacturing certificates in forms II, III and IV,
2. Approved boiler pressure part drawings,
3. Boiler mountings certificates in form III C.

Preserve the IBR folder and take one photocopy copy of the complete folder, for the records & site
reference. Ensure that all the certificates are intact & serially numbered in the folder

4.1.3 Application for Registration

The owner shall make application for the registration of a new boiler/renewal of Registration
certificate, to their Regional Boiler Inspectorate. Boiler Folder and receipt of Treasury Challan for
prescribed registration fees with the application be submitted to the Boiler Inspectorate. The Boiler
Registration Fees depends upon the heating surface area of the boiler, and details could be obtained
from the Boiler Inspectorate office. The Boiler Inspectorate office shall then communicate the details
of Inspector's visit for various Inspections.

4.1.4 IBR Boiler Inspection

The inspection as per IBR involves 3 Stages as under,

1. Open Inspection or ground Inspection
2. Hydraulic Test
3. Steam Test

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4.1.4.1 Open Inspection

For new boilers, which are to be registered, this inspection is carried out with the purpose of
verifying the details recorded in the folder to the actual details of the boiler construction.

This inspection is carried out on the ground under the open condition and clean of the boiler and the
IBR mountings & fittings.

The boiler inspecting authority generally verifies/checks followings during this inspection:

1. Approval stamping made on the boiler as per the certificates.

2. For any damages or any alterations if made, other than details mentioned in
approved drawings.
3. Verification of Serial numbers and the inspecting authority's seal on various valves and
mountings with respect to their Certificates.
4. Measurements of the spring, body, valve and valve seats of the steam safety valves.
5. Verify the Certificate of the Boiler operator, if appointed by the Owner/user.

Preparing the boiler for Open Inspection:

The following preparatory action is taken prior to the Inspector's visit.

a) All the smoke tubes and internal surfaces of boiler should be kept clean by using suitable
wire brush.
b) Any Insulation & Cladding which is hiding the pressure part surface should be removed for
the inspection.
c) Safety valves should be opened out completely and cleaned so that the spring, body and valve
seats are available for inspection and measurements of various dimensions.
d) The side and manhole/mudholes covers are removed to facilitate the best possible view of the
tubes and internal surface for inspection.
e) All the IBR valves and mountings should be kept arranged for verification. It should be
ensured that the serial numbers/registration number and the inspecting authority's seal on the
boiler and on the IBR valves are clearly visible so that the Inspector can immediately relate
them to the corresponding certificate.
f) Necessary platforms are provided for ease of boiler inspection.
g) Measuring instruments like measuring tape, venier, measuring feet scale etc. should be kept
handy for checking the measurements.
h) Temporary provision of 24 volts Hand Lamp with lamp guard / powerful Torch must be
made for ease of inspection of each part.

NOTE: It is advisable to verify the Identification number and Inspecting authorities Seal on Boiler,
valves and mountings and fittings with relevant Certificates and Forms of boiler folder before the
visit of the IBR inspecting authority (use the photocopy of the IBR folder).

Only after the inspecting authority clears the IBR inspection, the boiler can be prepared for next IBR
inspection i.e. Hydraulic Test.

Boiler Manual -34-

4.1.4.2 Hydraulic Test

Under regulation 377 of the IBR, important provisions of which, as applicable to the boilers are:

Every boiler shall be hydraulically tested in the presence of the IBR Inspecting authority, to not less
than one and half times the designed pressure, for registration/for renewal of registration certificate.

The boiler shall satisfactorily withstand such pressure without appreciable leakage or undue
deflection or distortion of its parts for at least ten consecutive minutes.

Preparing the boiler for Hydraulic test:

Note: Under above regulation, when a boiler is hydraulically tested for the first time, it should be
entirely cleared of insulation & cladding; at subsequent tests the insulation & cladding, or portion
thereof, should be removed if required by the Inspector.

a. Safety valves should be removed and the opening should be closed by blank flange. Pressure
switch connection should be removed and the opening plugged.
b. All side and manhole covers are placed properly with correct gaskets and checked for
tightness.
c. Following valves be kept closed in position during the test-
ii. Main Steam Stop Valve
iii. Vent Valve
iv. Gauge Glass Valves
1. Steam Valves
2. Water Valves
3. Drain Valves
v. Mobray blow down valve
vi. Boiler blow down valve

d. Feed inlet, blow down lines are to be connected to the boiler. Feed pump can be connected
for filling water in the boiler.
e. A convenient inlet for the pressure test should be taken and suitable hydraulic test pump
connections be made.
f. The Boiler shall be completely filled with clean water and the pressure being applied
gradually, with a test hydraulic pump having a pumping capacity higher than that of
hydraulic pressure. Care is to be taken to avoid air pockets in the boiler pressure parts.
g. As a preliminary test, before Inspector's visit, raise the hydraulic pressure to working pressure
limit and ensure that no leakage is observed from the pressure part's joints and then raise
slowly to the required Hydraulic test pressure, to keep it for ten minutes. Check for the
leakages and sustenance of the pressure.

On satisfactory completion of Hydraulic Test in presence of boiler inspecting authority, the

Provisional Order for use of boiler is issued, valid for 6 months and the Registration Number for the
boiler is allotted.

IT IS NECESSARY TO COMPLETE THE IBR FORMALITIES OF IBR STEAM LINES & PIPES,
SIMULTANEOUSLY WITH THE HELP OF THE IBR APPROVED CONTRACTOR. BOILER CAN
BE FIRED ONLY AFTER RECEIPT OF PROVISIONAL FIRING ORDER (FORM V)

Boiler Manual -35-

Engraving of Registration Number

The registration number allotted by Chief Inspector should be engraved in front plate in such
position as pointed out by the Inspector. This should be completed and reported to Chief Inspector
for verification within one month from the date of its receipt.

The Chief inspecting authority normally supplies the registration number engraving slip. This slip
should be pasted on the part of the boiler pointed out by the Inspector for engraving. The engraving
should not be less than 0.4 mm (1/64") in depth.

4.1.4.3 Steam Test

Every newly installed boiler, before the issue of a Registration Certificate, should be tested under
steam to the satisfaction of the Inspector. This should be done in accordance with the Provisional
Order issued by the Boiler Inspectorate after completion of hydraulic test and as per regulation No.
380 of IBR within Six Months from the date of registration of Hydro test.

A steam test is primarily intended for the purpose of ascertaining by actual test whether the safety
valves are sufficient to relieve boilers effectively of excess steam and whether they operate at the
time when the maximum working pressure is reached.

Preparing the boiler for Steam test:

a. Get the Boiler Registration number (allotted for the boiler after hydraulic test) engraved
on boiler pressure parts at any convenient location suggested by Boiler Inspector.
b. Verify the safety valve settings done during commissioning of boiler.
c. Boiler attendant must be present during the test.

Steam Test in presence of Inspector:

At the time of test, the safety valve should be left free and capable of being adjusted to the working
pressure.

After adjustment of the safety valves to the correct blowing pressure, the boiler shall be tried under
full steam and firing with the stop valve closed. During this test the Boiler inspecting authority shall
note the accumulation of the pressure and other details of the test as well as verify the performance
of the safety valve.

On satisfactory completion of Steam Test, the Boiler Inspectorate issues Registration Certificate in
Form VI. This needs to be protected and displayed in the boiler house as per the advice of Boiler
Inspecting authority.

4.1.5 Safety Valve over Pressure

REGULATION NO. 294

The safety valve shall be so designed that they attain rated discharge capacity with the over pressure
not greater than that given in regulation 292; provided that the safety valve which have a discharge
area less than 80% of the flow area, the over pressure at which the design lift is attained shall not

Boiler Manual -36-

exceed 10% of the set pressure. For safety valve having discharge area 80% or more of the flow area,
the over pressure at which the design lift is attained shall not exceed 5% of the set pressure.

4.1.6 Safety Valve Pressure Drop

REGULATION NO. 295

The safety valve shall be reset at a pressure at least 2 % below, but not more then 5% below the
safety valve set pressure. The 5% limit is increased to 10% for valve having a body seat bore less
than 32 mm and/or having a set pressure of 2 bar gauge or less.

4.1.7 Prohibition of Use of Boiler

Prohibition of use of unregistered or uncertified boiler -

Important provision under Section 6 of Indian Boiler Act.

Save as otherwise expressly provided in this Act, no owner of a boiler shall use the boiler or permit it
to be used -

(a) Unless it has been registered in accordance with the provisions of this Act.
(b) In the case of any boiler which has been transferred from one State to another, until the
transfer has been reported in the prescribed manner.
(c) Unless a certificate or provisional order authorizing the use of the boiler is for the time being
in force under this Act.
(d) At a pressure higher than the maximum pressure recorded in such certificate or provisional
order.
(e) Where the State Government has made rules requiring that boilers shall be in charge of
person holding [certificates of proficiency or competence], unless the boiler is in charge of a
person holding the certificate required by such rules:

Provided that any boiler registered, or any boiler certified or licensed, under any Act hereby repealed
shall be deemed to have been registered or certified, as the case may be, under this Act.

4.1.8 Renewal of Certificate

Important provision under Section 8 of Indian Boiler Act.

(1) A certificate authorizing the use of a boiler shall cease to be in force -

(a) On the expiry of the period for which it was granted; or

(b) When any accident occurs to the boiler; or
(c) When the boiler is moved, the boiler not being a vertical boiler the heating surface of
which is less than [18.58 square meters], or a portable or vehicular boiler; or
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) If the Chief Inspector in any particular case so directs, when any structural alteration,
addition or renewal is made in or to any steam-pipe attached to the boiler; or
(f) On the communication to the owner of the boiler or an order of the Chief Inspector or
Inspector prohibiting its use on the ground that it or any steam-pipe attached thereto is
in a dangerous condition.

Boiler Manual -37-

(2) Where an order is made under clause (f) of sub section (1), the grounds on which the order is
made shall be communicated to the owner with the order.
(3) When a certificate ceases to be in force, the owner of the boiler may be apply to the Inspector
for a renewal thereof for such period not exceeding twelve months as he may specify in the
application:

(4) An application under sub-section (3) shall be accompanied by the prescribed fee and, or
receipt thereof, the Inspector shall fix a date, within thirty days or such shorter period as may
be prescribed from the date of the receipt, for the examination of the boiler and shall give the
owner thereof not less than ten day's notice of the date so fixed:
Provided that, where the certificate has ceased to be in force owing to the making of any
structural alteration, addition or renewal, the Chief Inspector may dispense with the payment
of any fee:

(5) On the said date, the Inspector shall examine the boiler in the prescribed manner, and if he is
satisfied that the boiler and the steam-pipe or steam-pipes attached thereto are in good
condition shall issue a renewed certificate authorizing the use of the boiler for such period not
exceeding twelve months and at a pressure not exceeding such maximum pressure as he
thinks fit and as is in accordance with the regulations made under this Act:

The Inspector shall, within forty-eight hours of making the examination, inform the owner of
the boiler in writing of this opinion and the reasons therefore, and shall forthwith report the
case for orders to the Chief Inspector.

(6) The Chief Inspector, on receipt of the report under sub-section (5), may, subject to provisions
of this Act and of the regulations made hereunder, order the renewal of the certificate in such
terms and on such conditions, if any, as he thinks fit, or may refuse to renew it:

Provided that where the Chief Inspector refuses to renew a certificate, he shall forthwith
communicate his refusal to the owner of the boiler, together with the reasons therefore.

(7) Nothing in this section shall be deemed to prevent an owner of a boiler from applying for a
renewed certificate therefore at any time during the currency of a certificate.

Boiler Manual -38-

 SECTION-5

Commissioning of the
Boiler

Boiler Manual -39-

5.1 PRE-COMMISSIONING
The pre-commissioning is the part of the commissioning activity of the boiler.

Pre Commissioning is commenced on completion of all the connections as per the preceding
chapters; P & I diagram electrical diagram and the assembly work.

The persons entrusted with operation, servicing and observation (Boiler attendant for IBR boilers)
must be present during pre-commissioning. It would be better, during commissioning operation;
direct superiors of boiler man should be present.

Forbes Marshall representative shall provide the guidance & supervision of the critical activities
during Pre-commissioning & Commissioning. Forbes Marshall representative shall ensure that all the
settings & actions are completed as per the detailed checklists. However the users /customers should
ensure that the following and all other jobs, as suggested by our representative are completed before
inviting them for commissioning.

Following points may be taken as guidance while blowing down the boiler, gauge glass and Mobray
level switch. Blowing down helps in removing sludge, loose scale and other fine material that might
accumulate in the boiler shell.

The blow down water quality -

1. After the boiler is switched off. Blow down the boiler until water level drops by about 2"
(keep the air vent valve slightly open).

2. To check the automatic operation of the feed pump, put on the selector switch and blow down
the boiler below normal water level, the pump motor should start and work till the boiler is
filled up to the top level.

NOTE:
DURING NORMAL BLOWDOWN NEVER PERMIT WATER TO DISAPPEAR FROM THE
GAUGE GLASS.

CAUTION:
If water quality is poor, intermittent blow down water quantity / frequency of blow
down increases to keep the allowable boiler water TDS within specified limit of 3000
ppm. Prolonged Intermittent blow down affects the water circulation in side the boiler,
which is dangerous for boiler and tubes. Only way to control the boiler water TDS is to
feed specified soft/DM water or provide continuous blow down. Intermittent blow down
should be done only to remove sludge, loose scale and other fine material that might
have accumulated in the boiler shell.

Boiler Manual -40-

5.1.1 CHECK LIST

5.1.1.1 GENERAL:

Check and level all the equipment and tighten their foundation bolts.

Check all the motor windings for damage and moisture with megger.

Check and ensure that all the pipe lines and ducting are supported properly.

Remove manhole cover

Check inside of Boiler for scale, foreign objects etc.

Refit manhole cover with new gasket and ensure manhole is tightly secured

Check all the mountings, front and rear smoke chambers are properly tightened and have not
become loose during transit.

Arrange boiler operators and other manpower required to operate the boiler.

Open Air Vent Valve

Check and ensure that Blow Down Valve is closed.

Open valves to pressure gauge and pressure switches

Close Main Steam Stop Valve. Ensure steam and water valves on gauges are open and the
drain valves are closed.

Arrange feed water treatment chemicals, as recommended.

Insulate all the lines and equipment after they have been tested completely.

5.1.1.2 FEED WATER SYSTEM:

Get the water treatment plant commissioned and ensure the quality of Feed Water is within
the specified acceptable limits.

Flush the feed water storage tank and pipelines.

Flush the feed water pump completely before commissioning.

Check the operation of softener and doser and make sure that the operators are well trained
on the softener, if applicable

Mobray water level controller is set for feed pump on-off operation to at maintain proper
water level.

The water level extra low safety is working.

Boiler Manual -41-

The pressure gauge is fitted at pump outlet.

The strainer at pump suction strainer is cleaned.

CAUTION
1. NEVER START THE WATER PUMP WITH DISCHARGE VALVE OPEN.
INITIALLY THROTTLE THE VALVE PARTIALLY.
2. NO VALVE WITH THE HANDWHEEL SHOULD BE TURNED FULLY OPENED
OR FULLY TIGHTENED, I.E THE HAND WHEEL SHOULD BE TURNED
BACKWARD AND FORWARD HALF A TURN AS TO PREVENT SIEZURE OR
LOCKING

5.1.1.3 FLUE GAS CIRCUIT

Check the chimney and duct connections and make sure that they are airtight.

Check and provide supports to ducting.

Check the functioning of various dampers provided in the ducting.

Insulate the part of ducting inside the boiler house.

5.1.1.4 ELECTRICAL SYSTEM:

Tighten all the terminals in control panel, as they might get loose during transportation.

Check the functioning of main switch and provide correct fuse.

Check whether proper earth wires have connected on all the motors and panels.

Check if all the settings of overload relays of motors, pressure switch(es) etc. are all right.

Check for the correct electrical supply.

Check for the Trouble free operation of Mobra level controller.

5.1.1.5 STEAM SYSTEMS:

Check whether correct size of steam pipe lines as recommended, are provided and IBR
hydraulic test certificate obtained.

Check for the steam traps & fittings, for proper clamping & free removal of condensate.

Boiler Manual -42-

5.1.2 FILLING THE BOILER WITH WATER

Open auxiliary/ air vent valve of boiler.

Check strainers on FW line for any foreign material; open both isolation valves on feed water
line.

Ensure water supply is on. Let the boiler be filled partially by gravity. Remove vent plug on
delivery head and ensure trapped air is removed.

Set feed pump switch on.

Replace plug.

Check direction of rotation of feed pump motor, which should be counter – clockwise
looking from the motor end. This can be done by having a person observing the motor
rotation, while other switches on the pump for a second. If rotation is not correct, supply
phase to motor should be interchanged.

If rotation is correct set feed pump switch to auto and pump will run. While the pump is
running the lock out lamp will be illuminated and the alarm will ring. The alarm can be
muted by operating the mute/run switch.

When feed pump stops the lockout light will remain illuminated until the lockout is canceled
by pressing reset switch on panel.

CAUTION:
If, the pump is operated without water even for a few seconds it will be
damaged.

5.2 COMMISSIONING
The commissioning activity starts after all the pre commissioning activities are completed
satisfactorily and all the controls and safeties are working normally.

For commissioning and trial operation, steam or heat utility must be provided, for long duration of
steam generation or continuous boiler operation. This is required to set the firing system as well as
all controls and safety facilities can be adjusted.

Warning:
• The commissioning of the boiler is to be done in the presence of FORBES
Marshall Engineer only, to avail our warrantee benefits.
• If steam utilities are not ready the steam will be vented out for the
Commissioning & output efficiency trials.

Boiler Manual -43-

5.2.1 STEAM GENERATION

After completion of chemical boiling out, and the complete flushing operation, the boiler is filled in
with the treat water and boiler.

The IBR licensed operator fires the boiler and steam pressure is raised up to the maximum working
pressure of the boiler.

This first operation of the boiler & steam generation is done in presence and under the guidance of
Forbes Marshall Engineer /authorized representative.

The Mobray water level controller needs to be checked for its normal functioning and the operation
of the extra low level safety.

5.2.2 SAFETY VALVE SETTING

The two safety valves are set by Forbes Marshall Engineers /representatives as per the IBR, while
boiler is generating steam with its full capacity. The exact lift pressures of the Safety valves, the
pressure build up in the boiler and the safety valve sit back pressure is observed. Till the satisfactory
operation of the safety valves the steam is vented out through these. This is one of the major and
critical settings to be done on the boiler.

5.2.3 PRESSURE SWITCH SETTING

Pressure switch controls the steam pressure of the boiler by switching the Burner in different modes
of firing, depending on load.

After the settings of the safety valves, steam pressure high cut of pressure switch is set. This pressure
switch has to be set below the lift pressure of the minimum lift pressure of either of the safety valves.
The pressure switch controls the steam pressure of the boiler by operating the solenoid valves on the
Burner. This stops the burning of the fuel & reduces the steam generation. Hence this is the device,
which controls the steam pressure in the boiler.

During this commissioning process all the safeties & controls of the boilers are checked thoroughly
by operating the boiler at its full capacity and venting out the steam through Vent valves or by
passing the steam through the Steam lines for Flushing.

5.2.4 FLUSHING THE STEAM LINES

All newly fabricated steam lines need flushing by passing the steam for minimum 4 hours, to ensure
clean internal surface of the pipelines.

The steam traps and strainers fitted should be removed from the lines during the flushing operation.
All air vents are opened and steam is flushed out for these valves. Only after the lines are flushed the
steam should be opened to the plant utilities.

Boiler Manual -44-

5.2.5 EFFICIENCY & OUTPUT TRIALS

After the above procedures the boiler will be ready for the Output & efficiency trials.

It is mandatory for the customer to conduct the efficiency & out put trials, within a week’s time of
commissioning of the boiler, as per the guidance of our engineers/authorized representatives.

The efficiency trials are conducted as per BS 845 and in accordance of the performance standard practices.

The observations of the trials are noted down and are signed by the Owner/user’s responsible person and also
by Forbes Marshall engineer.

These efficiency & output trials are conducted to ensure that the boiler is performing as per the committed
contractual norms of efficiency and steam output.

5.2.6 TRAINING

During the boiler Installation, pre-commissioning, commissioning and efficiency & output Trials, our
engineers /authorized representatives ensure that the Boiler operators and other technical personnel
responsible for the operation and maintenance are geared up & trained to operate & maintain the boiler as per
the norms laid down by Forbes Marshall.

These norms and the good operation & maintenance practices of boiler are also explained in the section of
operation & maintenance. These should be read & practices for the trouble free operation and long life of the
boiler & its accessories.

5.3 BOILER HANDING OVER FOR COMMERCIAL USE

After the successful commissioning and efficiency /output trials, the Boiler will be handed over to the
user/owner for the commercial use.

The boiler handing over procedure includes the signing and stamping of the Erection & commissioning
checklists and certificates of Forbes Marshall by the owner/user’s responsible person and our commissioning
engineer.

The signed/stamped commissioning and handing over reports/certificates are forwarded to Head office of
Forbes Marshall for the scrutiny of the site reports. If any discrepancies are observed in Installation,
performance or settings, we take immediate corrective action by informing the concerned engineer/authorized
representative and also to the owner/user of the boiler.

Warning:
In no case the owner /user should use the boiler for the commercial use /production,
without completing the Handing over formality from Forbes Marshall, to avail the
committed warrantees of the Boiler & its supplied parts/equipment.

In case of failure on the part of the owner/user to comply with the above handing over
procedure, all the warrantees provided by Forbes Marshall Pvt Ltd, as per the order
terms, will cease to exist and in such case and we shall not be responsible for any failure
of the supplied equipment or components.

Boiler Manual -45-

 SECTION-6

Start Up & Standard

Operating Procedure

Boiler Manual -46-

6.0 Startup & Standard Operating Procedure for FM Boilers

• Purpose: BOILER-BURENR START UP FOR SMOOTH OPERATION &

LOGEVITY OF OUR FM BOILER.
• Scope: 1 / 2 / 3 / 4 / 5 TPH fuel oil fired Boiler with 3 stage burner.
• Procedure to commission steam boiler.

 Ensure all IBR formalities have been completed before the boiler is to be commissioned.

6.1 The IBR formalities consists of

6.1.1 Submission of IBR folder to LOCAL IBR office.
6.1.2 Open inspection of the NEW boiler.
6.1.3 Hydraulic test of the boiler and connected steam line if newly laid
6.1.4 Engraving Registration number on the boiler.
6.1.5 Getting Provisional firing order certificate FORM V from IBR office.

 Ensure boiler operators holding Competency certificate are available at site.

 Ensure treated soft feed water is available & filled in FWDT.
6.2 The treated water parameter requirements are,
6.2.1 Soft water with hardness less than 5ppm.
6.2.2 Ph of water between 8.5 to 9.5.

 Ensure FO / LDO / HSD / LSHS fuel is made available & same has been filled in DOT.
The DOT should have the following minimum arrangement made
6.3.1 out flow heater with Temperature controller in case of F O/LSHS fuel oil .
6.3.2 Drain line at the bottom with isolation valve.
6.3.3 Vent line arrangement.

 Ensure the cabling is done and wiring completed and checked as per the control panel wiring
drawing.
 Ensure the blow down valve is in closed position & the vent valve (1inch air vent ) located on
the boiler top is in open position for boiler cold start .
 Ensure the isolation valves of the main boiler pressure gauge & pressure switches .are open.
 Ensure the boiler water level controller steam & water side isolation valves are opened and the
drain valves closed.
 Ensure the boiler water level indicator steam side and water side valves are open and the drain
valve closed.
 Check the Boiler exhaust flue gas damper (if fitted) is in open position before switching on the
panel.
 Ensure feed water pumps are vertically installed and the feed water inlet line is connected with
80 size mesh strainers.
 Ensure the feed water line strainer is cleaned and the feed water line is flushed before switching
on the pumps
 Check Feed water Pump connection,

Boiler Manual -47-

 Feed water pump motor with less than 4 kW - 3 phase star connection.
 feed water pump motor with more than 4 kw and upto 7.5 kw , 3 phase delta connection
Rotational Direction for vertically installed motor.
Rotational direction of the feed water pump motor when viewed from the motor
End should be clockwise direction.
 Ensure 3 ph + neutral supply connection to the panel incomer.
 Ensure electrical trml connection of the water level controller for, feed pump, low water & extra
low water magnetic switch are as per the panel wiring drawing & mobrey switches are set right.
Each boiler has 2 water level controllers with control box having 2 magnetic Switches.
One level controller will have the boiler feed pump operation and 1st low level alarm.
The top magnetic switch in this controller is for Boiler feed water pump on/off operation. And
the bottom one is for 1st low water alarm.
In the 2nd level Controller the top magnetic switch is for boiler high water level (optional) and
2nd switch for Extra low water level alarm. (Extra low water alarm)
For connection detail refer control panel wiring
Before switching on the panel ensures the following,
 The heater selector switch is in off position .( for FO fuel )
 The pump auto/manual selector is in off position.
 The burner on/off switch is in off position
 The EMS switch is in EM mode.
 Switch on panel , The panel will buzz with indication for low water , extra low water & lockout
indication (if the wiring is proper) since there is no water in the boiler
 Move the run/mute switch to mute position and mute the buzzer ,
 Select the Auto/Manual pump selector switch to manually mode , select any one feed pump
operate the pump and maintain 50 to 55 % water level in the boiler .Cross check the boiler level
by operating the drain valve of the boiler level gauge also..
 At this level both the alarm for low water and extra low water condition should get cancelled
and panel is reset and lockout indication is also cancelled
 If the alarm continuous to buzz check the respective wiring and setting.
 Switch off the feed pump and the panel and close the Feed water pump inlet valve to prevent
filling of water in the boiler by gravity flow since boiler is not pressurized.
 Earthing needs to be checked & should be connected to our Electrical boiler / utility panel.
 Ensure wire connections of Pressure switch / pressure transmitters are checked.
The pressure switch has 3 trmls the connection is to be done between comm. and NC trml contact
for burner start operation and the NO contact for the high Pr /cutoff indication.
The pressure transmitter is 2 wire /3 wire system connected to PID trml.
 Check the control wiring connection.
 Check & set operation of the feed water pump, mobrey switches of LWA & ELWA are working.
 Through EMS switch Check the operation and direction of the fuel oil pump & blower motor and
ignition.
 For oil pump direction refer arrow mark punched on the pump port it is clockwise direction
when viewed from the motor end
To check the blower motor directions remove the blower motor silencer and check the direction.
The motor direction should be in anticlockwise when viewed from the motor fan end.
To check the Ignition move the EMS switch to Ignition position and check the electrode sparking
through the access door flame window.

Boiler Manual -48-

 Next Ensure FO / LDO / HSD / LSHS fuel line is flushed & air removed from one inch flexible
hose connected to the fuel oil pump.
 After flushing the oil supply line refit the 1” supply hose to the oil pump inlet, next remove the
3/8” flx hose connected to the 1” return line from the IPRV relief port.
 Run the fuel oil pump in manual mode till the fuel oil flows out smoothly and the air is removed
from the system .This also ensure the heater body is filled with oil.
 Reconnect the 3/8” inch hose to the return line. Loosen the IPRV and run the oil pump in manual
mode open the pump regulator plug and slowly tighten the pump regulator grub screw using
suitable L& Key to maximum .This ensure the pump is set for maximum discharge.
 Once the Pump discharge capacity is set slowly tighten the IPRV regulator and set the oil
circulating pressure between 20 to 22 kg/cm2.
 Open the junction box and Set the check start thermostat between 100 to 105 Deg C in case of
FO / LSHS fuel oil or to minimum setting in case of HSD/LDO.
 Set the set point of burner heater Temperature controller to 110 Deg C
 Switch on the heater , run the oil pump and check the Temperature controller operation
 Ensure oil circulating pressure of 20-22 kg/cm2 at oil temperature of 110 Deg C .
 Check whether temperature on dial thermometer has reached above 105 deg.
 Boiler- burner is now ready to be operated on Auto & on low fire mode.
 Ensure EMS switch in AUTO position
 Move the burner switch to low position. The command for the burner run will start as soon as
the safety loop of the controller is made
 The burner auto operation sequencing will start with pre purging cycle, ignition, low and
actuation of low fire solenoid valve operation,.
 The burner will operate on low flame, allow it to run & let gradual heating take place.
 Check the firing from the rear side, flame should be bright golden in color. If it is not bright set
the low fire air damper by operating the damper motor.
 Ensure 50-55 % water level is maintained. During warming up/cold start of the boiler.
 It may take approx. 45 – 60 minutes for water to heat.
 Check and record the current drawn by the Feed water pumps motor, FD fan motor, electric
heaters & fuel oil pump motor current drawn along with flue gas temperature.
 Open the feed water inlet valve when the boiler pressure reaches above 1.5 kg/cm2 pressure
.Steam will start coming out from air vent valve, allow it to come out upto 3.5 kg/cm2& stop the
boiler operation.
 Operate the water level indicator drain valve and flush the level indicator from steam and water
side.
 Flush the Water level header by operating the drain valve.
 Operate the blow down valve and check auto operation of the Feed water pump ,
 Open the drain valve of the level controller and flush the level controller.
Above activities can be completed within a day.

Boiler operators need to be informed to release the steam gradually & drain the water next day
morning & fill fresh soft water inside the boiler upto 50% level.

 Hot bolting of the complete boiler to be done.

 The front door furnace sealing ropes bolts to be tightened.
Boiler Manual -49-
 Ensure normal water level is maintained and fuel oil pump etc to be checked & heater to be
started.
 started the boiler on low fire only & gradually raise the steam pressure to 3.5kg/cm2
 Check the pressure switch function. Throttle the air vent valve slightly.
 Check feed water pumps auto & manual mode operation and position the switch in Auto mode
operation.
 Move the Burner MODULATION switch to mid fire and check & set air to fuel ratio up to 5 bar
boiler pressure, check mid fire pressure switch operation. Also
 Move the burner modulation switch to high fire position and check & set air to fuel ratio & cut
off the steam boiler at 7 kg/cm2 by operating pressure switch. Ensure water level in the boilers is
continuously checked.
 Operate the drain valve of water level controller & check FW pump starts operation in Auto
mode& boiler low water level alarm, burner trip condition with audible alarm & lock out signal.
 Operate the drain valve of the extra low water level controller & check audible alarm & lockout
signal.
 Check photo cell operation during burner operation the burner should trip when the flame sensor
is removed from the burner.
 Check the Check stat operation by increasing the setting above the actual valve, the burner firing
should trip immediately. Reset to the earlier setting after the testing.
 Boiler can now be re started & gradually steam pressure can be increased to 10 kg/cm2&
 Set the high pressure switch for boiler cuts off at 10 kg/cm2 . Set the pressure switch setting
looking at the pressure gauge.
 Safety valves top cap need to be opened & ensure to loosen the check nut.
 Ensure the air vent valve is closed completely.
 Slowly increase the pressure of steam above 10 kg/cm2 on manual fire & ensure first safety valve
is lifted at 10.3 kg/cm2& the second safety valve is lifted at 10.5 kg/cm2, accordingly one needs
to set the safety valves at site by locking & unlocking check nut first & then operating middle
tightening nut.
 Ensure that the boiler is running on high fire& both the safety valves have fully lifted & have
started discharging to their full capacity at 10.5 kg/cm2.boiler pressure
 Steam pressure should not increase in the boiler main pressure gauge. Same needs to be tested
twice. Stop the firing allow the safety valves to reset & note the lift / set readings.
 Tighten the lock nuts of both safety valves & close the top dome of same accordingly.
 Boiler Steam valve can now be opened very slowly & steam header can be charged accordingly
for further usage of steam in the plant through our PRS etc.
 Train the boiler operators / engineers at site, create a confidence in them dismantle burner, clean
nozzles, diffuser plate etc & ask them to operate our FM boiler in our presence.
 Explain electrical circuit diagram to their operator / electrical / Boiler engineer on site.

DO’S
 Operate FM boiler in presence of boiler operator only or qualified BOE.
 Always use treated water during boiler operation. .
 Maintain water level at safe operating level of 50 – 55% of gauge glass level.
 Check all safety locks in presence of client.
Boiler Manual -50-
 Lubricate all piston valves once & ask operators to ensure to lubricate once a month.
 Ask them to maintain a logbook & log all boiler parameters which should be recorded once every
hour.
 Maintain feed water & boiler water parameters & same to be logged in log book once a shift like
TDS, PH, hardness, etc.
 Mobreys to be drained & checked when boiler operator takes charge in his shift daily.
 Gauge glasses need to be drained every 2 – 3 hours in each shift & same to be recorded in log
book.
 Burner needs to be overhauled once a week & records to be maintained.
 Tube cleaning to be done at least once a month if FO is used.

Don’ts
 Do not operate boiler without valid Provisional Order from IBR office.
 Do not operate steam boiler without a qualified Boiler Operator.
 Do not bypass any safeties at any given time.
 Ensure both feed water pumps are working always.
 Do not tighten the safety valves beyond its set pressure.
 Do not increase pressure switch settings beyond the design working pressure of the boiler

If any water leakage found report the same ASAP to FM.

Boiler Manual -51-

 SECTION-7

Boiler Operation

Boiler Manual -52-

7 BOILER OPERATION
Water is supplied to the boiler through a feed pump and enters the boiler through the feed check
valve. When the water reaches 12.5 mm above the normal level, (which is about the middle of the
gauge glass) refer Fig 2, the feed pump is stopped by level controller refer fig. 3. The burner is bolted
to the front door. The combustion air is provided by a forced draught fan, which is integral to the
burner unit. The furnace receives radiant heat from the flame and the gases after combustion give up
heat to the tubes in the second pass as they travel to the front chamber. Gases turn in the front
chamber and give up more heat to the tubes in the third pass as they travel to the rear chamber. Gases
leave the boiler through the gas outlet connection at the top of the rear chamber. Pressure in the
boiler is indicated by a pressure gauge.

When the pressure is sufficiently high more than 7 Kg/cm2, the main stop valve can be opened to
allow steam to pass to the process or heating system. When steam leaves the boiler the water level
will drop until it reaches a point 12.5 mm below normal level. The level controller will start the feed
pump and more water will be fed into the boiler.

As the steam pressure falls, the controlling pressure stat will cause the burner to operate on the high
fire mode. If the pressure rises, the controlling pressure stat will initiate the burner to operate on the
low fire mode. When the boiler pressure reaches the maximum allowable pressure limit, the limit
pressure switch shuts down the burner. When the boiler pressure falls to a preset point the pressure
limit switch will cause the burner to restart. If the limit pressure switch fails stop the burner, the
safety valve will lift and excess steam will escape, thus preventing any further rise in boiler pressure.
If for any reason the water level falls to a point about 50mm below normal level the level controller
will stop the burner & send an alarm signal so that problem can be attended immediately. The burner
will start automatically once the water level is restored. If however the water level continues to fall
until it reaches a point about 75mm below normal level, the overriding control will ring the alarm
and cause the burner to trip and a lockout condition occurs. The burner will not start until the water
level is restored and the reset switch has been operated. If it is found necessary to let water out of the
boiler, open the blow down valve. An isolation valve & connection for the inspector’s Test gauge is
on top of water level gauge header.

Caution: The set pressure for safety valve should not be altered except by a suitably qualified
person, who is able to fully assess the consequence of carrying out such an alteration.

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FIG. 2 Water Control Levels with reference to Water Level Gauge Glass Assembly

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FIG. 3 Water Level Controller with Multi Switch box & Float Rod Assembly

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 SECTION-8

Mountings, Control &

Safety System

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8 MOUNTINGS, CONTROL & SAFETY SYSTEM

8.1 PRESSURE LIMIT CONTROL

The pressure control has a snap acting micro-switch which automatically switches off or on with
increase or decrease in boiler pressure respectively at pre-determined pressure settings. The lower
and higher limit of pressure is adjustable.

Setting and adjustments:

For proper setting:

1) Set the main scale for cut-out pressure; and

2) Adjust the differential for desired set in pressure. To set pressure control main indicator turn
the pressure adjusting screw until pressure setting indicator on the front of the case is in line
with required set point at which the pressure control. The indicator setting is the point at
which pressure control breaks contact. There is a separate adjusting screw to set the
differential scale.

3) For boiler with ON/OFF control the pressure controller is of this type.

8.2 WATER LEVEL CONTROLLER

Boiler is equipped with single water level controller having three limit switches. First operates the
feed pump, second operates as over-riding control at the first low water level. Third operates extra
low water alarm & burner goes into lock out mode and switches off the FD fan.

Boiler Manual -57-

8.3 LEVEL GAUGES

Refer fig. below two nos. of gauges are provided for each boiler as per IBR requirements. Packed
cocks are fitted on level gauges to allow the glasses to be blown down or isolated. The water gauge
cocks are fitted with Automatic Shut off system. A ball check valve is fitted with the help of circlip in
water as well as steam incomers. In the event of gauge glass failure these balls prevents water and
steam flow from gauge glass, which may lead to accidents due to imbalance of steam & water in
gauge glass assembly.

Operation
The cocks are rotated through 900 to operate. The handle indicates the position of port. Gauge glasses
should be blown periodically to ensure removal of mud and scale deposits collected in the
connecting pipes.

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8.4 BOILER SAFETY VALVE
The safety valve ensures that excessive steam pressure does not built up in boiler. Failure to test
these valves at regular intervals can result in over-pressure leading to serious consequences. A
common cause of safety valve failure is accumulation of foreign particles, which cause the valve to
stick. This often results from slight leakage through valve over a period of time. To prevent such
failures a regular testing and maintenance program should be set up.

Operation of safety valve

The safety valve operation is automatic. As steam pressure rises above the pre-set level, safety valve
will pop open. When sufficient quantity of steam is vented through safety valve, causing boiler
pressure to fall to preset level, safety valve will close. Under pressurized condition safety valve can
be eased or lifted by applying hand pressure to the easing gear lever. Any steam leakage between the
valve faces should be attended to at the first convenient opportunity. Safety valves are not usually
fitted with glands around the valve seat or spindles, so during discharge of steam, some leakage will
take place and get vented into the boiler house. Condensate is drained from the bottom of the valve
through the drain line.

Safety valve is commissioned; in the presence of IBR inspector, during steam test. The boiler
inspectorate defines the spacer to be provided for permanent adjustment of valve. He also makes a
note of the height. If in future safety valve is changed or opened for maintenance; with concurrence
of boiler inspectorate, again the safety valve can be set with this spacer.

Note: The valve loading or setting must not be tampered with any adjustment. Any alteration should
first be approved by the boiler inspector.

Boiler Manual -59-

8.5 MAIN STEAM STOP VALVE

This is valve is an isolating valve between boiler shell and pipe work to process or heating units.
When two or more boilers are connected to a common steam main each boiler must be fitted with a
check valve and stop valve capable of being locked in closed position. This arrangement of valves is
necessary to comply with IBR act, which requires all boiler valves including the stop valve to be
checked periodically. Therefore it must be possible to completely isolate & its stop valve from the
rest of the plant.

The stop valve is usually manually operated using a hand wheel. A ‘wheel spanner’ must never be
used as excessive closing torque may warp the disc and seat or twist the stem. The valve should be
operated slowly and never forced to the limit of its travel in either direction. A cold valve in
particular should never be tightly shut as a later increase in temperature may promote valve seizure.
On steam lines always open drains to rid the pipe work of condensate and allow pipe work to heat
through slowly by ‘cracking open’ the stop valve very slowly. Failure to drain and warm the system
before fully opening the valve will result in ‘water hammer’, which could damage the installation.

8.6 ISOLATION VALVE IN FEED LINE

Feed lines are equipped with piston valves between feed pump and boiler shell
and are mounted on boiler shell. These feed lines are provided with DCV
(disk check valve) for assuring unidirectional flow in boiler. During feed
pump is operating DCV opens. When pressure on outlet side exceeds that of
inlet side, DCV automatically shuts and prevents a reversal of flow. The
piston valve should be operated slowly and should never be forced to the limit
of its travel in either direction. A cold valve should never be tightly shut.

8.7 BOILER BLOW DOWN VALVE

This valve is fitted to the lowest part of the boiler shell. This valve
is used for blowing down the boiler while it is under steam pressure to
maintain TDS of boiler water within the limits and to remove suspended
of the boiler under cold conditions and maintaining the correct water
level when starting the boiler from cold condition.

Boiler Manual -60-

The blow down valve is equipped with gland packing. Care should be taken for leakages through
these glands, as they can be replaced only after totally draining all water from boiler.

Note: Blow down valves is fitted with an operating key, which can only be removed when the valve
is closed position. This device is a safety lock, which must not be interfered with.

8.8 Fusible Plug

By definition fusible plug is a “non resetting safety device, which relieves pressure through melting
of a fusible alloy.” The body is typically made of bronze and the fusible alloy is generally composed
of lead and tin with certain additive elements. The composition is designed such that the alloy will
melt once the temperature exceeds a certain limit. As such the fusible plug is a mechanical safety
device and is typically the last line of safety.

IBR requires the alloy to be designed in such a way that the alloy melts at least 83oC (150F) above
the operating temperature of the boiler. (IBR does not specify the higher limit for melting
temperature). In boilers with the wetback design two fusible plugs are required – one on either the
FTP or BTP and one on the top of the combustion chamber.

The fusible plug is typically screwed to the boiler plate,such that it is exposed to smoke on one side
and water on the other. It is submerged under water which keeps the temperature of the plug at close
to the boiler water temperature. In the event that the water level drops below the fusible plug, (this is
possible only after all the earlier safety locks have failed to operate), the plug is no longer cooled by
the surrounding water. Since it is exposed to direct hot flue on the other side, the temperature rises
and once it crosses the melting temperature of the alloy, it fuses and the water/steam pressure pushes
the pellet out. Steam/water from the shell rushes in the flue space and drops the temperature of the
furnace, thereby protecting the boiler from thermal damage.

The fusible plug on the FTP is located at least 100 mm below the Extra Low Water Level. If the
water level drops to this level the plug will melt per its design. The fusible plug on the crown of the
combustion chamber is situated at a slightly lower level than the level for the first plug. In the
eventuality that the water level drops further and reaches below the second fusible plug, then the
second plug will melt too. Thus both the plugs act as a last resort for boiler safety.

Boiler Manual -61-

 SECTION-9

Operation &
Maintenance

Boiler Manual -62-

9.0 OPERATION & MAINTENANCE
Procedure explained in this section is applicable for start up of Packaged Boilers already
commissioned with an assumption, that the operators are fully familiar with the design &
construction features described in earlier sections.

Procedure to put the boiler on factory load

To put the boiler on factory load process as follows:
1. Ensure that the Burner Switch and the Feed Pump Switch Are in Auto position.
2. Crack open the main steam stop value. Wait for few seconds, and then start opening the stop
valve slowly until it gets fully open, then close it by a quarter turn only. As the pressure rises or
falls the burner will respond under the command of the controlling pressure switches.

Note: No extra leverage should be applied to stop valve hand wheel as this could result in twisting of
spindle.

9.1Boiler shut-down procedure

9.1.1 Short Period Shut Down

There are two alternative procedures of shutting down the boiler.

Procedure I:

1) Close main stop valve.

2) Set feed pump switch to ‘Manual’ position and raise water level to 25 mm from top of gauge
glass to allow the contraction as the boiler cools overnight.
3) Open auxiliary / air vent valve to ensure no vacuum is generated inside boiler.

Caution: If the boiler is to be shut down over night leave main isolator on, feed pump off and feed
check valve shut. This will prevent boiler filling by gravity if pressure falls overnight. Be sure to
open feed valve before switching pump ‘on’ at next start up.

Procedure II:
Close stop valve and leave burner with switch and feed pump on ‘Auto’.
1) This will ensure that the boiler is kept unto pressure all night and will help to reduce any
strain imposed by variations of pressure and temperature.
Note: The boiler is suitable for unattended operation but this method of operation is not permitted by
‘IBR’ and therefore it should be adopted for a short shutdown only and under presence of boiler
attendant.

9.1.2 Extended Period Shut Down

If the boiler is to be shut down for a long period raises the water level and then shut off all valves.
Put all switches to “OFF” and open the main isolator. When the shut down procedure by either
procedure I or II is completed proceed as follows:
Boiler Manual -63-
 1) Shut down gauge glasses.
2) Clean sight whole glass at rear end of boiler.
3) Refer table 1 for details of storage methods

Note: Boiler, after shutdown has to be cooled carefully. Permissible cooling rate of the boiler is half
the permissible rate of heating. If the boiler cooling is accelerated, thermal stresses develop in the
shell, headers etc.

Boilers used seasonally and idle for long period should be laid up "Dry" or "Wet" during the period
of idling.

9.1.2.1 Wet Preservation

If the boiler is to be kept idle for a short period, it should be laid up "Wet" as follows:

i. Fill the boiler completely with water, up to overflow level. By admixing an alkalizing agent,
bring the pH value of the boiler water to 9.5 and add a corresponding quantity of oxygen
binding agent. Sodium hydroxide or a corresponding phosphate, for instance, can be used as
the alkalization agent.

Oxygen binding agents are, for instance: Hydrazine, Sodium Sulphite and sodium bisulphate.
Depending on the standstill period, the hydrazine content in the boiler water should be for
instance :

Standstill duration Hydrazine surplus g/m3 N2H4

Up to 1 week 20 to 30
Up to 1 month 50 to 100
Longer 100 to 300

For better mixing, the boiler should be heated briefly after admixing hydrazine, up to about
85 °C, to drive out the oxygen in it. Take care that no pressure builds up in the process.

Before renewed commissioning of boiler, the boiler water must be drained off until the
operational water level has been reached, provided the steam is allowed to contain hydrazine
(the steam must not contain hydrazine if it comes into contact, for instance, with foodstuffs,
Boiler Manual -64-
 clothing or dressings). Otherwise, the boiler must be drained and refilled. Close all valves. In
all cases the exhaust gas flaps or gate valves must be kept closed.

ii. Check for any leakage and take samples of water at regular intervals to ensure alkalinity and
Sulphite are maintained.

9.1.2.2 Dry Preservation

If the boiler is to be kept idle for long period it should be laid up "Dry" as follows: -

i. Drain the boiler thoroughly, clean it internally and externally both fire and water side and dry
it out.

ii. Place trays of lime inside the boiler shell to absorb any moisture. Then close the door,
manholes, dampers, etc., properly so that no ingress of moisture or air can take place.

iii. Water service tank, pumps, and all piping should also be dried out.

It is essential that the boiler is thoroughly clean while using the wet or dry laying up method. To
prevent corrosion on the gas side of the heating surface, it is recommended that all heating surfaces
are dusted with hydrated magnesia to neutralize any acid remaining on the boiler heating surfaces.

NOTE :
When working with caustic liquids or chemicals, it is imperative that the relevant accident
prevention regulations are observed and made accessible to the persons carrying out the work.

9.2 Refractory Spot Repairs

Areas of refractory lining, where distress in the form of spalling or erosion of material or cracking is
noticed, can be properly repaired with the use of an appropriate grade of above castable. Before such
repairs are made, it is necessary to clean and dress the surface to proper size and depth for adherence
of the castable. Pre-shrunk castable should be rammed hard on to the surface and cured for at least 10

Boiler Manual -65-

– 12 hours. Above castables can be relied upon to render satisfactory service provided the correct
grade of castable is selected, placed well, batching of minimum water and thorough mixing is
ensured, it is properly vibrated and cured, and initial heat-up schedule is meticulously adhered to.

9.3 Procedure for Descaling

If the boiler water quality is not maintained as per the specifications the descaling of the boiler may
be required, to remove the water side deposits. The descaling is done by using chemicals.

Chemicals are available which are manufactured specially for the use in boilers without harming the
metallic parts of the boiler. Care to be taken to avoid commercial chemicals available in the market
which may cause harmful effect on the boiler parts & may result into reduced life of the boiler
components & pressure parts.

Descaling is a very critical process & should be carried out by qualified personnel only.

Boiler Manual -66-

9.4 MAINTENANCE
9.4.1 Daily maintenance

Carry out preventive maintenance on modular boilers as follows:

1. Blow- down water gauge glass as follows:

Close water cock. Open drain cock and allow blowing for a few seconds. Close drain cock. Open water
cock. The water should return rapidly to its correct level. If returns slowly, clean orifice. Close the
steam cock. Open drain cock and allow blowing for 4-5 seconds. Close the drain cock open the stream
cock. The water should return rapidly to its correct level. If returns slowly, clean the water cock
orifice.

2. Blow down boiler as required by water treatment suppliers.

Note: Water treatment procedure and chemical dosage must be discussed with your water treatment
suppliers bearing in mind the minimum quantity of water blow out during the testing of direct mounted
water level controls.

3. Clean rear sight glass if found directly.

9.4.2 Weekly maintenance

With boiler firing test water level control as follows:

1. With boiler attendant standing by feed pump switch off and allow water level to fall by evaporation.
2. At the level approximately 50 mm bellow normal the burner should stop and the bell should ring.
3. When the water drops a further 25mm the lock out light will become illuminated and the bell will ring
again if previously muted.
4. Check the alarm signals operate and that boiler stops.
5. Put pump switch to ‘auto’ and when pump stops operate spring loaded ‘reset’ switch position when the
burner will restart.
6. Feed pump- check feed pump filter when installed.

Boiler Manual -67-

Periodic Maintenance and Checking of Various Parameters for Forbes Marshall
Boiler
A. Fuel /Fire Side Maintenance

Parameters to be Half
Daily Weekly Monthly Quarterly Yearly
Checked yearly
Duplex 1 Bucket filters Y
to check & clean
Drain water from all oil Y
tank
Tube brushing & Y
cleaning to be done
Chimneys & ductings to Y
be cleaned
Fuel oil transfer pumps Y
to check
Furnace & fireside Y
cleaning to be done
Check furnace & rear Y
refractory
Fuel oil analysis to be Y
done
To replace both door Y
sealing ropes
Clean Outflow heater Y
coils
Cleaning of main oil Y
storage tank
Cleaning of day oil tank Y

Boiler Manual -68-

B. Burner Maintenance

Parameters to be Half
Daily Weekly Monthly Quarterly Yearly
Checked yearly
All nozzles to clean Y

Diffuser plate to be Y
cleaned
Electrodes to be cleaned Y
& set
Lance assembly to be Y
cleaned
Photo cell to be cleaned Y
& checked
Air damper to clean Y

Fuel oil leakages from Y

burner to check
Burner strainers 1 Y
filters to be cleaned
Rear view glass to check Y
& clean
IPRV 1 BPRV to check Y
& clean
Solenoid valve to be Y
cleaned & check
Air intake silencer to Y
clean
Oil heater elements to Y
check & clean
FD fan impeller to Y
check & clean
Volute casing 1 wind Y
box to clean
Fuel oil pump to be Y
overhauled

Boiler Manual -69-

C. Water/Steam Side Maintenance

Parameters to be Half
Weekly Monthly Quarterly Yearly
Checked yearly
All mobreys to be Y
drained
Water gauge cocks to be Y
drained
Chemical dosing pump Y
to be checked
Extra low water mobrey Y
to check
Boiler feed water Y
analysis to be done
Strainers & filters in Y
FW line to be cleaned
Leakages to be checked Y
from FW pumps
Reflex gauge glass to Y
remove & clean
Water side internal Y
cleaning to be done
Safety valves to be Y
checked
Feed water check valves
to be cleaned
Feed water pump to be Y
overhauled
Feed water tank to be Y
cleaned
Boiler mountings to be Y
overhauled
Fusible plug to be Y
checked

Boiler Manual -70-

D. Electrical Side Maintenance

Parameters to be Half
Daily Weekly Monthly Quarterly Yearly
Checked yearly
All indicating lamps to Y
check
Check ignition Y
transformer
Check HT cable of Y
ignition transformer
Check sequence Y
controller
Modulation motor to be Y
checked
Pressure switches to Y
check & clean
Amperes to be checked Y
& recorded
All contractors relays to Y
check & clean
Mobreys switches to Y
check
Thermostats to check Y

Electrical panel to Y
check & clean
Motors to be greased & Y
overhauled

Boiler Manual -71-

 Maintenance Schedule
8
Half
Maintenance Activity hourly / Daily Weekly Monthly Quarterly Yearly
yearly
Shift
Water treatment plant
check & regenerate, if *
required
Steam Pressure Switch
*
check
Mobray level control
check
*
For normal pump on –
off operation
Mobray extra level low
*
safety check
Boiler water quality
*
check
Check Hooter operation *
Electrical Supply check
*
& correct, if required
Clean Strainers –feed
*
pump suction
Feed line NRVs check *

Check motor interlocks *

Safety Valves operation *

Motor Current check
F.D. fan *
Feed pumps
Cleaning of Burner
*
Nozzles
Cleaning of furnace *
Cleaning of boiler *
smoke tubes

Boiler Manual -72-

 Maintenance 8hourly Half
Daily Weekly Monthly Quarterly Yearly
Activity / Shift yearly
Dust removal from
Electrical control *
panel

Clean electrical
*
contactor contacts

Check the
connections of
*
Mobray level
controller
Cleaning Gauge
Glass protector & *
glasses

Replacement of
gauge glass rubber *
cones & sleeves

Check Furnace and

*
Door Ropes

Burner refractory
*
wall check

Furnace refractory
*
wall check

Grease F.D fan

*
Bearings

Grease Feed pumps

*
Bearings

Boiler Manual -73-

 Maintenance 8hourly Half
Daily Weekly Monthly Quarterly Yearly
Activity / Shift yearly

Smoke box Sealing

*
tape replacement

Smoke box patch up

*
/ maintenance

Check resin
quantities in the
*
water treatment
plant, as applicable

Grease bearings of
*
electrical motors

De-scaling &
internal cleaning of *
boiler pressure part

Cleaning the smoke

tubes & smoke *
boxes

Dismantling,
Cleaning & lapping
of all the Valves, *
NRVs, Safety valves,
blowdown valve.

Removal &
replacement of
Removal &
replacement of all
Gaskets of valves, *
mountings &
fittings, Manholes,
mudholes, inspection
doors.

Boiler Manual -74-

 8 hourly Half
Maintenance Activity Daily Weekly Monthly Quarterly Yearly
/ Shift yearly
Offer for Open
inspection of the
*
boiler to the IBR
authority

Refixing of all
Mountings & fittings *
on the boiler

Box up all the

*
manholes / mudholes

Hydraulic test, up to
1.5 times the max.
*
working pressure for
15 minutes (max)

In case of leakages,
Stop all leakages & *
re- test

Offer the boiler for

the hydraulic test to *
IBR authority
Cleaning of feed
water tank, as *
applicable
All Insulation repairs
of boiler, steam line *
etc
Tighten all
*
foundation bolts

Boiler Manual -75-

9.4.3 Burner

A burner which is working under good combustion condition should require little service but the following
points should be checked weekly:
1. With burner running remove photocell and check flame failure circuit clean and replace.
2. The ignition electrodes and air diffuser plate should be checked and any deposits removed.
3. For further details on maintenance of burner refer Burner Manual.

9.4.4 Boiler cleaning

9.4.4.1 Tubes

A definite ruling cannot be given on the frequency of cleaning as this depends on the loading and the
quality of oil. We suggest that the boiler be opened up after first four weeks or alternatively if the fuel gas
temperature rises by 100C more than usual temperature when the boiler is in clean condition whichever is
the earliest. All soot deposit should be removed and the tubes cleaned. On the basis of findings after the
first four week a definite program of cleaning should be formulated.
Considering normal factory requirement for steam it is recommended that in any case periods between
cleaning of the boiler should not extend beyond 2 months. It is important to arrange the cleaning while the
boiler is warm. Cleaning should never be undertaken on a cold boiler.
Always bear in mind that the boiler will operate at high efficiency if the heating surface is cleaned
regularly. If they are not cleaned for a long periods the efficiency will fall and extra fuel must be burned to
meet steam requirements. It is much cheaper to clean at regular intervals than to burn fuel at low
efficiency.

9.4.4.2 Methods of cleaning

Clean the tubes as follows:

1. All tubes are accessible from the front of the boiler access to the tubes is achieved by opening the
hinged door on front & removing doors from rear smoke chambers.
2. As the tubes are cleaned all the soot will be deposited at the back of boiler. This soot can be easily
removed.
3. On replacing the doors particular attention should be paid to the sealing both of the door & smoke
chamber frame.
4. The asbestos tape should be renewed each time the door is opened if there is any sign of deterioration.
Bad seals will cause low efficiency and high maintenance cost.
5. The smoke boxes need to be cleaned in addition to the cleaning so as to ensure free path of flue gas
and low-pressure drop on gas side.

Boiler Manual -76-

9.4.5 Valves maintenance

General
To ensure easy and efficiency operation valve steams should be cleaned and lightly lubricated as required
at periodic intervals.

It leakage through a valve occur the worn or damage disks and seats should be re-faced and ground or
replaced at first opportunity as a leaking valve will quickly deteriorate if neglected.

All valves should be operated from time to time and a regular schedule of inspection of emergency valves
should take place to ensure that isolating and emergency valves will operate when required.

9.4.5.1 Repairing a leaking valve

1) Gland packing and cover gasket joints should always be of the correct material and size. During the re
assembly of the valve it is important that the faces and mechanism are kept clean and that all traces go
grinding or lapping components are removed.
2) Never use excess force to open or close a valve. The use of wheel spanners should be discouraged as
valve are provided with hand wheel large enough to give a turning force sufficient to open or close the
valve. If the valve is so tight that it cannot be fully operates by the hand wheel alone it is defective and
application of more force may make matters worse.
Valves should be operated slowly and should never be forced to its limit in either direction. Shutting a clod
valve hard down may lead to its seizure when temperature in the adjacent pipe work are later increased.

Safety Note:
Ensure that valve to be repaired is isolated. Release any pressure in the line and drain carefully.
Attach WARNING NOTICES on the isolating valves or blanking flanges.

3) Before applying force to operate a valve check the valve position indicator and the direction of
operation of the hand wheel. Always ensure that the pipe work system is operational. If repairs are
being carried out locks danger notices and warning should be posted to prevent inadvertent operation
of plant under repair.
4) It is important to ensure that the valve to be repaired can be isolated with due regard to safety, e.g. the
valve may control the water supply to the boiler which have to be shut down.

Boiler Manual -77-

9.4.5.2 Safety valve- maintenance

Keep the safety valve and easing gear clean and free from obstruction. Lubricate the easier gear. Check the
valve operation periodically.

9.4.5.2.1 Valve and Seats

The work entailed in the operation of valve and seat faces should be under control of a skilled engineer
preferably one specializing in this type of work.
1) Remove the column and spring.
2) Before grinding the faces of the valve and seat an abrasive is very sparingly smeared on the faces.
Appropriately observes such as rich or fine carborundum and oil are used.
3) Ensure that the piston chamber is correctly positioned in the body recess and seat faces by firmly
rotating the spindle clockwise and anti-clockwise between the palms of the hands.
4) Should the valve or seat face have indentations or score marks it is essential that the faces be skimmed
up until all the marks have disappeared taking off as little material as possible and maintaining the
same seat angle and width as originally supplied.
5) The valve and seat may then be ground to a polished finish as described in b and c.
6) If valve leaks or keep passing the steam it is necessary to adjust the blow down ring. Contact our
service engineer.

Warning:
The set pressure should be altered expect by a suitable qualified person authorized by your local IBR
Inspector.

If and when the settings require to be altered the following is a guide to the method that can adopt:

1) Close the main stop valve.

2) Start burner and bring pressure up to 0.7 bars below working cut out pressure.
3) Isolated pressure switch.
4) The boiler pressure will rise above normal working pressure and safety to feather (i.e. pass a small
quantity of steam). Upon a further slight rise in pressure the safety valve will blow off.
5) Should the valve lift before the required blow off pressure remove valve cap. The adjusting screw
should be then screwed down until the valve does not lift and the required pressure is reached. During
this operation care should be taken not to rotate the valve spindle which should be held stationary by
means of a rod or screwdriver inserted through the cotter hole.
6) If the valve does not fit until after the required pressure the adjusting screw should be screwed up to
obtain the necessary setting taking care to hold the spindle stationary.
7) After the valve has been set replace valve cap and cotter and padlock valve.
8) Put the pressure switches back on line.
9) NOTE: On no account must the valve be set to lift at a pressure in excess of the boiler design pressure
or in excess of any lower pressure specified by IBR / Customer.

Boiler Manual -78-

9.4.6 Water Level Controls- Maintenance

To replace complete unit proceed as follows:

Check, the Boiler is at Atmospheric Pressure
1. Shut off stop valves.
2. Switch off the electric supply at the control panel isolator switch.

9.4.6.1 Periodic Check

A thorough inspection of the controls should be made at least once per annum in the following manner:
Check, the boiler is at atmospheric pressure

1. Switch off the electric supply at the control panel isolator switch.

2. After ensuring that the unit is isolated electrically withdraw screw on switch box and remove cover.

3. Warning: Dismantling the switch units is not recommended and replacement of complete switch is
advised:

Where emergency action is unavoidable however it is important to note that:

1. The secondary magnet pivot pin is a lose assembly.

2. If the secondary magnet is inadvertently removed it must be re assembled in repulsion to the tertiary
magnet.

4. Disconnect the electric wiring ensuring that leads are marked to facilitate re-connection.

5. Remove nuts holding switch head flange to boiler flange and withdraw complete unit.

6. Remove clip securing stop cap and withdraw float assembly.

Caution:
The magnet not touch any magnetic material such as the boiler tools steel bench tops etc. and the assembly
must ably be put down in a clean place where there is not danger of the magnet collecting magnetic
particles.

7. Examine the guide tube to ensure that it is clean.

8. Check that the inside of the center tube is clean and that no scarf is attached to the magnet.

9. Check that the float is not waterlogged. Examine float rod not for alignment and wear. Check that the
float-locking nuts are tight and ensure that the whole assembly is clean and free deposits.
Caution: Before refitting the control to the boiler, it is essential that the switch head is checked for correct
operation

10. Fit the float rod assembly with its magnet into the center tube check that it moves freely up and down
before securing the stop cap with clip provided. Slowly move the float assembly to the top of its travel
and slowly lower thaw float assembly. Check visually that the float rod magnet operates the switch

Boiler Manual -79-

 units as it passes them. Fit the control back into boiler using a new joint ring(s) and tighten all holding
nuts.

11. Re-connect all electric connections. Replace switch head cover and tighten securing screw.

9.4.7 Feed pump – Maintenance

The feed pump is designed to operate for long period with only the following maintenance:

9.4.7.1 Quarterly:

Check the following:

1. The pump is developing the correct pressure and flow and is not noisy or vibrating.
2. The gland is not leaking.
3. The motor is not overheating.
4. Clean the strainer if provided.

9.4.7.2 Half Yearly:

In addition to quarterly checks:

1. Check electric installation thoroughly.
2. Check that the feed water tank is open interconnecting piping between tank and pump is clean and
water supply is satisfactory.

9.4.8 Day Oil and Feed Water Tank (In client’s scope)

Day Oil tank to be maintained to achieve better hassle free operating of boiler &burner.

9.4.8.1 Daily

1. Drain oil tank, till water settled in tank is removed.

2. Drain both level controllers so to remove any SPM in gauge glass.

9.4.8.2 Monthly

1. Drain oil & water tanks fully so to remove all sludge (in case of oil) & sediments, SPM etc from tanks.
2. Check thermostat working & adjustment.

9.4.8.3 Yearly

1. Both tank should be fully cleaned from inside.

2. Clean outflow heater & element coils so to get better heating.

All strainers & filters should be cleaned for any foreign material in bucket mesh.
Note: If it is found that oil is of better quality, then the cleaning cycle time can be increased as alternate or
bi weekly etc required as per case to case basis.

Boiler Manual -80-

 SECTION-10

Safety

Boiler Manual -81-

10 SAFETY
We have incorporated all the possible safeties in the Boiler; however, the user is advised to follow the
safety precautions during installation, operation and maintenance.

WARNING

The equipment must be operated and maintained by authorized and trained operators only. It is
mandatory to strictly follow all the instructions given for safe installation, operation and maintenance
of the equipment. The user will not hold us responsible for the mishaps or the accident occurring due
to negligence or by not following the instructions.

Few suggestions are summarized below, which may help to work with modular boiler, assuming that, the
final user will evolve a comprehensive safety code for all operations in the plant.

 The installation and commissioning of the equipments must be performed by trained / licensed
operators under supervision of Authorized staff.

 The boiler operation & maintenance staff should be well known with hazards of high pressure,
high temperature steam, water, gases etc.

 Before starting the boiler after shutdown, it should be checked for all maintenance personnel, tools,
scaffolding etc have been withdrawn from boiler.

 Boiler house should have proper ventilation and lighting arrangement.

 The installation of units should be done as per the instruction manual and drawings supplied along
with the unit

 None of the safeties and controls should be bypassed during the operation of the unit.

 It is mandatory to check the tightness of manhole, mud hole, smoke chamber doors, explosion door
for leak free operating before boiler startup. Do not attempt to open these doors while boiler is in
operating condition.

 Before entering into the furnace for maintenance, care should be taken to vent out all the flue gases
by running the blowers. Before entering the furnace ensure that the oil and electrical supply to the
FD fans is disconnected and the furnace is cooled to ambient temperature

 All electricity supply should be switched off and maintenance staff should ensure that no electric
supply is available at the equipment by:
 Switching of mains supply
 Removing the fuses / Switching off the MCBS
 Removing the cables from terminal strips
 Put “shutdown” board on equipment control
 Introduce work permit system and record on logbook.

Boiler Manual -82-

  If there is requirement of illumination for working in boiler, it should be ensured that, it is with
using low voltage bulbs, extension cords properly earthed & through an Earth Leak Circuit Breaker
(ELCB).

 Maintenance staff should use proper tools and tackles, Safety Shoes, Helmets, Safety Belts, etc.
wherever applicable

 Do not use nylon / polyester clothing, during the operation and maintenance of the boilers/ heaters.

 If more than one unit is connected to one common duct / chimney, ensure that the flue gas duct of
the unit under maintenance is removed / disconnected from the main flue gas duct or chimney.

 If more than one unit is connected to common steam header, disconnect the steam line from the
common header to take care of any reverse flow of steam.

 Before opening the pressure part of the boiler ensure that the pressure is released completely and
the air vent valve is full open and ensure that there is no discharge of vapor from the air vent line.
Also ensure that the water has cooled down to ambient temperature.

 Boiler pressure part or the furnace should not be taken for maintenance before 24 hours (minimum)
from the time of shut down. The faster cooling is harmful to the pressure part and furnace

 Use only genuine spare parts for the safety of units.

 All the users, operational and maintenance personnel should make sure that during installation,
operation and maintenance of the boiler and heater, regulations under Boiler Act, Factories Act,
Fire Insurance and Explosives Act, Pollution Control Act are strictly adhered to.

 All the safety precaution mentioned above and also in the product instruction manuals are to be
strictly followed by the user

 Always follow & maintain a system for maintenance or troubleshooting of any part by tagging or
noting respective records.

 Always remember, fire fighting, first aid, handling electric shocks etc trained personnel may save
lives & property in an emergency.

Boiler Manual -83-

 SECTION-11

Fixing Problems

Boiler Manual -84-

11.0 FIXING PROBLEMS
Some of the common problems & remedial action is as given below:

11.1 The feed water pump motor does not start

OBSERVATION CAUSE REMEDY

Overload tripped/ defective Reset/change
Contactor defective Change

Switch defective Change

Phase supply is not available at
water pump motor contactor Control fuse blown Change

Auxiliary contact defective Change

Mobray switches
Contactor is energized
Control phase not available in
mains
Mobray air break switch NC
contacts not getting activated
Supply not available from the
switches
Motor winding defective
Connections on motor loose
Check & correct mains and fuses
Check the switch contacts
Rectify/replace
Check & correct the connections
Rewind/Replace motor
Check/tighten

11.2 In BURNER ON position of Switch, FD Motors do not start and there is an alarm (while starting), water
level low safety lamp glows.
OBSERVATION
Auxiliary contactor for the
Extra low level Switch is
not energized
Auxiliary contactor for the
Float switch is Not energized
Feed water Pump does not start.
CAUSE
Low level switch/Relay
Defective
Contactor coil defective/Loose
Actual Water in the Boiler ‘Low
or ‘Extra Low”
Float stuck
Float defective/puncture
Contactor coil defective
Overload protection
Motor Contactor
Mobray Level Control –Air break
Switches
Water pump motor
REMEDY
Change
Change
Fill Water
Open/Clean
Change
Change
Check the overload relay of the
motor.
Check the contactor coil and
proper neutral connection. Check
the contacts of the contactor.
If timer is not energizing, check
the Mobray contacts. Rectify or
replace air break switch.
Check the motor windings.
Rewind/Replace as required.

Boiler Manual -85-

11.3 Insufficient or no water supply to the boiler. Pump is ON but there is insufficient or
no supply of water to the boiler.

OBSERVATION CAUSE REMEDY

Check whether the stop valve is open.
Check whether there is sufficient water
Disc Check Valve and stop in the tank.
valve Check whether there is any air lock at
the water pump suction
Check the mounting direction of disc
Insufficient or no water supply to check valve
the boiler. Pump is ON but there
CHECK:
is insufficient or no supply of
-Direction of rotation,
water to the boiler. -Feed water Suction Strainer,
clean if found chocked.
Water Pump -Feed Water temperature more
NPSH required is more- ref
Pump Manual
-Remove the air from vent plug
of Feed Water pump

11.4 Boiler does not maintain the desired steam pressure/ lower than rated Steam out put

OBSERVATION CAUSE REMEDY

Steam load on boiler, if more than
Process steam load
actual capacity, Reduce the load
Low calorific value of fuel: Use
Fuel quality correct calorific value fuel
Check Moisture in the fuel
Boiler does not maintain the Firing method not correct:
desired steam pressure/ Lower Frequent opening of front doors
than rated Steam out put. Low fuel firing rate
Atomizing Nozzle chocked
Operational problems
Lower feed water temp.
High blow down rates
Excessive scale formation inside the
boiler: low heat transfer to water.
-Check the Rotation & Speed
of FD fan & correct if required.
-Check the F.D fan damper & open
F.D fan
more
- Check the air duct from FD fan for
the blockage/damper getting stuck
Check that there is no gap between
the furnace and the rope on the main
Furnace door. Tighten the furnace sealing
bolts provided on the front door
uniformly

Boiler Manual -86-

11.5 High Stack temperature.
OBSERVATION
High Stack temperature
11.6 Low thermal efficiency /higher fuel consumption.
OBSERVATION
Low thermal efficiency
/higher fuel consumption
11.7 Erratic operation of Mobray–pump On–Off level gets disturbed.
OBSERVATION
Erratic operation of Mobray –
pump on –off level gets
disturbed
Boiler Manual
CAUSE REMEDY
Fuel firing rate high Reduce fuel firing rate
Over loading of boiler /Higher
rate of steam generation than
Process Steam load the boiler capacity
High calorific value of fuel &
high firing rate
Excessive scale formation
Operational problems inside the boiler: low heat
transfer to water.
Tune the Burner/Set the
Excess Air Level
Damper
CAUSE REMEDY
Over firing of fuel
Wrong firing method
Low calorific value of fuel,
fuel with high sludge,
Frequent opening of fire door
Over loading of boiler /Higher
rate of steam generation than the
Fuel firing rate
boiler capacity
Excessive scale formation inside
the boiler: low heat transfer to
water
Higher blow down rates: bad
feed water quality –high
TDS/Alkalinity in boiler water
CAUSE REMEDY
Mobray float getting stuck up
inside and not moving
Mobray rod bent
Scale inside the Mobray float
chamber
Mobray float /rod Float punctured –
-Maintain boiler water quality
by blow down or proper water
treatment
- Check chlorides level in the
boiler water
-87-

Air break switches
11.8 Water carries over or wet steam from boiler.
OBSERVATION CAUSE
Fluctuating Steam load
Boiler Water quality
Water carry over or Wet steam
from boiler
Boiler Over loading
Wrong operation
11.9. Frequent blowing of Fusible plug.
OBSERVATION CAUSE
Mobray level controller
faulty
Frequent blowing of Fusible
plug. Low water conditions in
boiler
Low discharge from the feed
pump
Fusible plug
Boiler Manual
Heavier float
– Check with FORBESMarshall
Air break switches –
-Wrong /disturbed position
of Air break switches,
tighten at proper position
-Check Electrical
connections
REMEDY
Process should be controlled so as
to avoid steam jerks or sudden
surges of steam.
- High TDS or alkalinity in boiler
water, resulting in to high water
level fluctuations. -Increase the
blow down rate.
- Add chemical for reducing the
alkalinity
- Oil/Organic matter in the boiler
water – Boil out the boiler.
- Higher than rated steam, load
on the boiler- check the steam
output from the boiler & restrict
to the rated load.
- Steam Valves should be
opened & closed very slowly
in the process.
- Operate the boiler at the
maximum working pressure
& avoid low pressure boiler
operation.
REMEDY
- Improper water level setting
in the boiler
- And Water level extra low
safety not working.
- Also Ref above Mobray
level controller problems/
Ref above the feed pump
problems
Ref above the feed pump
problems
Poor quality of fusible
plug/wrong fitting of plug.
-88-
 Higher discharge of boiler
water, leaving the boiler water
Blow down
at very low level exposing the
fusible plug to steam.
- High water level
fluctuations – excessive
high level or extra low level,
Boiler water quality
due boiler water quality
problems -Ref. Water carry
Over.
Change Sealing Rope
Short Circuit of Flue Gases
Tighten the main door sealing
from Furnace Sealing Rope
bolts

11.10 Bulging of doors (front & rear), over heating of smoke boxes

OBSERVATION CAUSE REMEDY

Bulging of doors front and
rear, over heating of smoke
boxes
Due to physical damages
during opening or closing the
Refractory to be
doors or excessive fuel firing
repaired/replaced -Ref below
/back firing.
the chapter Spot Repairs of
Insulation.
Access Door Refractory
cracked or fallen
Replace the Furnace Rope and
Damage to Furnace Sealing
tighten the sealing bolts
Rope
provided on the door.

11.11 Front Door overheating

The front door of the furnace design has male-female parts which should properly fit into each other.
These two mating parts have to be packed by using furnace sealing ropes, refractory and door has to be
tightened to avoid leakages.

How to Avoid Overheating of the Front Door

1. The front door should be properly tightened. The loose bolts on the door should be checked first
and tightened.

2. Proper Matching of refractory: The refractory of both the male and female part should be exactly
matching without leaving any gap for the leakage.

3. Furnace Sealing Rope: The standard 32X32 size furnace sealing rope should be used to pack the
mating parts to avoid leakage.

Boiler Manual -89-

Symptoms of front door overheating

1. White ring:
If the front door overheats during the operation of the boiler, the periphery of the door develops a
white ring which is visible when the door is open.

2. Bulging:
Due to excessive heating of the front door for a long time can result in development of bulge of the
front door.

3. High heat radiation:

As the hot flue gases of the combustion due to leakage for various reasons causes heating of the
door and heat is radiated from the door. Thus is one of the symptoms of front door heating.

S. No Probable Causes Remedies

1 Front door sealing rope not Supply sealing rope/tighten the rope
provided or tightened. without any clearance.

2 Large gap between burner and The refractory should be aligned

refractory. with the burner so that there is no
clearance between the two.

3 Furnace refractory damaged. Refractory material to be replaced.

4 Furnace extension ring burnt out Furnace extension ring to be

replaced.

Boiler Manual -90-

 SECTION-12

Log Book Detail

Boiler Manual -91-

12.0 LOG BOOK DETAILS
Every boiler should be maintained with its own log book. The contents of log book can be identified with
the help of following table.

Boiler log book

Shift Operator Name Sign Date:

I
II
III

Time Oil Steam Oil Water Blow TDS Remarks

Level in Level in Down Time
Press Temp Pressure Flow meter Tank Tank
H:M Kg/Cm2 O
C Kg/Cm2 Kg Mtr Mtr Hr : Min

The remark column facilitates operator, during shift changeover. The happenings during one shift should
be conveyed to next shift and has to be documented.

Following are benefits of maintaining Log Book:

1. The log book helps to monitor the performance of boiler
2. Planning maintenance shut down etc.
3. Monitor water quality fed in the boiler.

Log Book may incorporate details like chemical dosing, stack temperature details, time of water pumped
in boiler etc.

Boiler Manual -92-

 SECTION-13

Do’s and Don’ts for

Operations

Boiler Manual -93-

 CAUTION:

13.1 Water System -

1. Do not use turbid water in the softener/DM/Water treatment plant,

this may choke the resins of these equipment. Get the water (2
liters) and Resin (50 cc) analyzed every year.

13.2 Operation -

2. Check the feed water quality every 4hrs of running & ensure it is
as per the requirement.

3. Feed only SOFT WATER into the boiler always. Never feed hard
water as this will result in scale formation. Scale results in to low
heat transfer to the water & over heating of tubes.

4. Scaled tubes and metal parts like furnace don’t transfer the heat to
the water, hence overheating may take place, resulting in to metal
failure or bursting.

Boiler Manual -94-

 5. Oxygen present in the water attacks the metal surface of the boiler
shell, which results into pitting.

The Low pH of water results into corrosion of the metal surface.

Hence regular use of water treatment chemicals is recommended.

Use water treatment chemicals for the treatment of Oxygen

Pitting, pH corrosion, residual hardness, Alkalinity etc., and
ensure that the dosing of these chemicals is done regularly.

6. Ensure that proper quality and quantity of regenerates are used in

the water treatment plant and proper procedure is adopted in
running the plant with specified quality of regenerates.

13.3 Electricals:

7. Control Panel:

 Check electrical input once in a day, to the control panel.

 Check all the controls and safeties regularly as mentioned in

the manual.

WARNING:
Never short circuit safeties and work the boiler. It may end up in costly damages.

Boiler Manual -95-

 13.4 Boiler Unit:

8. Give blow down after regular intervals to maintain the Boiler

water quality.

9. Negligence in operation may cause severe damage to the boiler.

And automatic does not mean, no attention required.

13.5 General:

Operation:

10. Maintain the Log book supplied with the boiler. It will help in
detecting faults, if any, at the early stages itself.

Refer Log Book section.

11. Keep spares in stock to minimize down time due to breakdowns,

if any.

Boiler Manual -96-

 SECTION-14

Service & Spare Parts List

Boiler Manual -97-

14.0 Service
If you still need help please contact your nearest FORBES Marshall representative. The address and
contact number of our major branches are listed on the back of this manual. They’ll be happy to direct you
to any representative in your area or provide service themselves.

Product Serial Number:

Please record all instance of field problems and actions taken in the space below.

Date Problem Action Taken Serviced By

Boiler Manual -98-

14.1 Field Service Report
This form should be used to report filled problems. A copy should be filled out by your Forbes Marshall
customer service engineer. Any product which requires servicing to be sent back to Works cannot be
completed without this report. If the product is returned to our Works you should include either the
original excise gate pass or our invoice number and date.
If you’d prefer an estimate before proceeding with repair:
You should clarify on the form weather you weather you would like to see a cost estimate before we make
any necessary repairs. If you indicate that an estimate is required our works engineer will complete part 6
of the form and return it you. If this estimate is satisfactory you should approve the estimate and return the
approved form to your Forbes Marshall representative. Only then will servicing proceed.

14.2 SPARES

It is suggested that certain essential spares may be kept in stock to avoid idle time due to unpredictable
breakdowns and non-availability of parts with you. It may take some time for us to arrange for the part
/component at site.

If there is any breakdown due to component failure, it is better to replace the defective component and if
possible repair the defective component if repairable, at leisure, as replacement is faster and easier.

The list of essential parts for the Boiler is given below and can be used for guidance.
List with ordering No. of each component can be taken up from nearest office. For the amount of the water
conditioning and fuel additive chemicals to be stored, approach our nearest office.

Boiler Manual -99-

We recommend the following spares for better performance:

0.75 TPH BOILER SPARES LIST

Boiler Manual -100-

 Field Service Report:

Report: Date:

Division:

1) Customer Information:

Customer name:

Address :

Site:

Contact person: Phone:

Reference:

2) Product Information

Product description :

Serial number: Original Invoice # Date:

Input/Inlet Details:

Output/Outlet Details:

The product is online offline

Connections flanged screwed welded

Mounting Details:

3) Application Information

Process media:

Pressure: temperature:

Sensor Details (if any)

Mounting Details:

Boiler Manual -101-

 4) Observed Problems or symptoms

5) Proposed Action:

Repair at site return to estimate first

Works under warranty
Field Engineer’s sign customer sign

6) To Be filled in for Estimate Purposes

Estimated cost:

List any important spares which must be provided by customer:

Signature of MFG/CSD Engineer:

7) Customer’s Endorsement

We accept the above repair estimate.

Signature and stamp:

Boiler Manual -102-

 SECTION-15

FUELS &
COMBUSTION

Boiler Manual -103-

FUELS AND COMBUSTION

• FUEL FOR BOILER

Forbes Marshall boiler in general is designed to operate on liquid as well as gaseous fuel. Fuels
with a very wide range of heating value can be used for heating in these boilers. Like water it is
extremely important that the quality of the fuel going into the boiler is carefully controlled in
order to obtain good performance out of the boiler. While water quality affects the Boiler
performance due to its effects inside the heating surfaces, the fuel quality affects the outside of
the heating surfaces.To insure the optimum performance we need to know the properties of the
fuel and make necessary adjustments. We shall discuss below some of the important properties
of fuels.

• COMPOSITION OF FUELS

Most of the fuels comprise of compounds formed out of carbon and hydrogen and in some cases
other elements like sulphur etc. Very often fuels also contain oxygen in the molecules.

Most of the fuels used in the boilers are derived from petroleum. These fuels are very rich in
carbon and hydrogen. The liquid fuels generally have more carbon and less hydrogen when
compare to gaseous fuels. The carbon content for petroleum based liquid fuels would be
generally 82-88% and hydrogen content 10-14%. Petroleum based gaseous fuel generally have a
carbon content from 78-82% and hydrogen content from 13-18%. Natural gas has much higher
hydrogen content and much lower carbon content. Depending on the carbon hydrogen ratio, the
burning characteristics change. Burners for burning these fuels need to be specially designed for
purpose. It is also possible to design burners to burn a range of liquid fuels as well as gaseous
fuels usually one at a time. Depending upon the specific fuel composition in use it is necessary to
adjust the burner. If fuel composition changes after initial-adjustment, it is necessary to re-adjust
the burner to suit the new composition.

There are two popular ways of analyzing fuel composition. One method is to have a complete
chemical analysis of the quantities of various elements present called ultimate analysis. The
other method is to analyze quantities of behavioral groups of components present in the fuel,
called as proximate analysis of fuel.

As the ultimate analysis of the fuel gives the quantities of elements present, this information can
be used for theoretical calculations of the air required to burn and the heat output on burning. It
should be mentioned here that, theoretical calculation of heating values may not be exact due to
the difficulties in judging exactly whether some of the combustible atoms are already linked to
oxygen or not.

The component wise analysis is used to judge how the fuel would behave during the burning
process. Typically, the quantity of wax content will indicate probable problems one may
encounter due to wax solidification. Generally, a higher viscosity of petroleum oils at room
temperature would indicate a higher carbon hydrogen ratio giving a higher flame luminosity
giving a higher radiant heat transfer in the flame, at the same time indicating a possibility of
sluggish combustion.

There is a very important value to understand the burning behavior of the fuel called carbon
residue, also sometimes referred to as Conradson carbon. The carbon residue is not normally
reported either in the ultimate analysis or in the component wise analysis unless specifically
asked for. The carbon residue is very difficult to burn and a portion of this residue can be
expected to precipitate as soot unless very special care is taken in the geometry of the
combustion chamber, the temperature of the combustion chamber and the residence time of
burning and such other parameters.

• CALORIFIC VALUE OF FUEL

The calorific value is the quantity of heat the fuel gives out due to combustion. Carbon burns
forming carbon dioxide. Hydrogen burns to form the oxide of hydrogen, which is water. Sulphur,
if present, forms sulphur dioxide and some sulphur trioxide.

There are two different ways of evaluating the calorific value of fuel. One value is known as the
gross calorific value (GCV). The GCV is the heat given out due to the combustion of the fuel
with all the water which has been formed having already condensed. In other words, the GCV is
the heat which has been released by the combustion and includes the latent heat given off by the
steam which had formed during the combustion condensing to water later on. It can be clearly
seen that GCV is not available for use while using the fuel in actual practice, because the steam
formed does not in practice condense, but goes off to the atmosphere through the chimney.
Therefore, GCV is not a useful figure to evaluate the heat obtainable by using the fuel. However,
as GCV is the easier quantity to measure, generally after the fuel is tested the calorific value is
reported in terms of GCV.

The useful heat available from the combustion of a fuel is known as the lower calorific
value(LCV). The LCV is the heat given out by the fuel during combustion in actual practice. The
value of LCV is arrived at during testing of the fuel by first obtaining the value of GCV using
say a bomb calorimeter then deducting 539.6 kcal/kg of steam formed during combustion of a
dry sample of fuel. Sometimes, calorific value is denoted by NCV (Nominal calorific value).
NCV is the same as LCV. Unit of calorific value is kcal/kg or kcal/Nm3
• PHYSICAL CONDITION OF FUEL

Combustion system are designed taking into accounts not only the chemical composition or
calorific value but also physical parameters like viscosity, lubricity etc. For proper atomization in
a burner, it is necessary to maintain liquid fuel at a viscosity of 10-15 centistokes at the burner
tip.

• CLEANLINESS
The most important considerations in the physical condition of the fuel, is the cleanliness of the
fuel. Unfortunately, this aspect is very often the most ignored resulting in a very sad state of
affairs with respect to the operational efficiency of the boiler, wear out of critical parts and
unreliable operation. In spite of actual experience of repeated tripping and unreliable operation of
boilers resulting in production losses, there have been many cases where instead of ensuring
cleanliness of fuel, energy has been wasted attempting retuning of burners, changing of electrical
circuitry etc. The foremost priority in boiler operation after ensuring properly treated feed water
supply, should be assuring a clean fuel. Cleanliness of the fuel can be assured only if great care is
taken right from the moment the fuel arrives in the plant, by filtering at the time of taking the oil
in to the storage tank, further filtering between the storage tank and day tank, further filtering
between the day tank and the fuel pump, and keeping these filers always clean.

Combustion is generally the oxidation of carbon, hydrogen and sulphur in the fuel. For all
practical purposes oxygen is supplied by providing sufficient atmospheric air. The air delivery is
so adjusted geometrically with respect to fuel delivery to ensure proper mixing. In spite of the
best possible mixing, it is necessary to provide more than just sufficient air for the chemical
reaction to ensure complete combustion. This excess air necessarily needs to be kept a minimum
by as efficient a mixing as possible so that the flue gas quantities are kept a minimum, achieving
minimum loss of heat through the chimney. The entire expertise of a burner design revolves
around this important concept.

• CHEMISTRY OF COMBUSTION:

Typical chemical reactions involved are:

C+O2 = CO2 (+8050 kcal/kg of carbon)

C+0.5O2 = CO (+2410 kcal/kg of carbon)

CO+0.5O2 = CO2 (+2410 kcal/kg of carbon)

H2+0.5O2 = H2O (+33865 kcal/kg of H2)

S+O2 = SO2 (+2210 kcal/kg of S)

These calculation help estimating stoichiometric air required. Calorific values are estimated in
laboratory. (Some imperial formulae may be used for approximate estimate of cal-values for
different fuels).

In practice, certain amount of excess air has to be supplied in order to compensate for the lack of
contact between fuel and oxygen. This amount will vary from 30 to 80% depending upon fuel
and furnace design. In some cases (e.g. external refractory lined furnaces) further excess air
needs to be supplied to limit furnace temperature below caking/ash softening temperature.

The total amount of air should be judiciously distributed as primary and secondary air. It shall be
noted that, secondary air is very effective for combustion of gaseous products (including CO
generated in the reducing zone of thick bed of low volatile matter fuels like coke). Pressure
required for primary air needs to be just sufficient to push up to the top of fuel bed, without
pressuring the furnace. Secondary air should be supplied at high pressure through jets, which will
penetrate through the cross section of gases across it.
 SECTION-16

ACCESSORIES
MANUAL
SAFETY VALVE
 BOILER SAFETY VALVE

A boiler safety valve is a mechanically operated spring load Safety valve mounted on the top section in
horizontal smoke tube boilers. The function of this valve is to discharge the excessive steam pressure built
up above its set pressure in the boiler.

OPERATION OF THE SAFETY VALVE

The safety valve operates and lifts with the rise in steam pressure above the set pressure of the safety valve
which is also the maximum working pressure of the boiler.

The operation is automatic and the lift is against the compression of the spring which is set to the
maximum working pressure of the boiler by the adjustable nut .The discharge will ceases when the boiler
pressure drops down below the set pressure.

All FML boiler mounted safety valves are full lift, angle pattern spring load safety valve as per API 526
and meets the requirement of ASME SEC VIII DIV 1 and are offered with IBR certificate form.

TERMINOLOGY OF THE SAFETY VALVE SETTING

• Set Pressure: - This is the rated pressure of the safety valve.

• Blow off Pressure: - This is the pressure at which the safety valve opens to its full lift .The blow off
pressure is limited to 5% of the set pressure.

• Re set Pressure: - This is the pressure at which the safety valve shuts off after the blow off pressure
.The reset pressure is 2.5% to 5% of the set pressure for safety valve having body seat bore of more
than 32 mm. The 5% reset limit is extended to 10% for safety valve having body bore less than 32 mm.

• Typical safety valve setting for a F M L smoke tube boiler with working pressure 10.55 kg/cm2 (
Gauge pressure ) is as follows.

o Safety valve Set pressure: - 10.55 Kg/cm2 (Gauge Pressure).

o Blow off pressure: - 11.08 Kg/cm2 (Gauge Pressure) which is 5% of the set
pressure.
o Reset Pressure: - 9.5kg/cm2 (Gauge Pressure) which is 10% of the set Pressure since the body
bore is less than 32 mm.
Boiler safety valve
When the boiler is under steam pressure the safety valve can be eased or lifted by applying hand pressure
to the easing gear lever. Any steam leakage between the valve faces should be attended to at the first
convenient opportunity. Safety valves are not usually fitted with glands around the valve steam or spindles
so during the discharge of steam some leakage will take place and vent into the boiler house. Condensate
is drained from the bottom of the valve through the drain line. The valve loading or setting must not be
tampered with any adjustment or change of setting should be authorized by the boiler inspectorate.

Maintenance
Keep the safety valve and easing gear clean and free from obstruction. Lubricate the easier gear. Check the
valve operation periodically.

Valve and Seats

The work entailed in the operation of valve and seat faces should be under control of a skilled engineer
preferably one specializing in this type of work.

Remove the column and spring

Before grinding the faces of the valve and seat an abrasive is very sparingly smeared on the faces.
Appropriately observes such as rich or fine carborundum and oil are used.

Ensure that the piston chamber is correctly positioned in the body recess and seat faces by firmly
rotating the spindle clockwise and anti-clockwise between the palms of the hands.

Should the valve or seat face have indentations or score marks it is essential that the faces be
skimmed up until all the marks have disappeared taking off as little material as possible and
maintaining the same seat angle and width as originally supplied.

The valve and seat may then be ground to a polished finish as described in b and c.

If valve leaks or keep passing the steam it is necessary to adjust the blow down ring. Contact our
service engineer.

Warning

The set pressure should be altered except by a suitable qualified person authorized by your local IBR
Inspector.

If and when the settings requires to be altered the following is a guide to the method that can adopt:

 Close the main stop valve.

 Start burner and bring pressure up to 0.7 bars below working cut out pressure.
 Isolated pressure switch.
The boiler pressure will rise above normal working pressure and safety to feather (i.e. pass a small
quantity of steam). Upon a further slight rise in pressure the safety valve will blow off. Should the
valve lift before the required blow off pressure remove valve cap. The adjusting screw should be
then screwed down until the valve does not lift and the required pressure is reached. During this
operation care should be taken not to rotate the valve spindle which should be held stationary by
means of a rod or screwdriver inserted through the cotter hole.
 If the valve does not fit until after the required pressure the adjusting screw should be screwed up
to obtain the necessary setting taking care to hold the spindle stationary.
  After the valve has been set replace valve cap and cotter and padlock valve.
 Put the pressure switches back on line.

NOTE:
On no account must the valve be set to lift at a pressure in excess of the boiler design pressure or in excess
of any lower pressure specified by IBR / Customer.
FEED WATER PUMP
(WILO MAKE )
 STARTING AND
MAINTENANCE INSTRUCTION
FOR
MULTI-V/MVI-6”
 N° 4 007 765
Ed. 14 - Page 1/12

MULTI – V / MVI – 6"

SERIE/SERIAL 1/2/4/8/16

TECHNICAL INFORMATIONS

STARTING AND MAINTENANCE INSTRUCTIONS

L.Aillerie
C.Bricier
L Costaouec
L Costaouec
P. Cordellier

P. Cordellier
P. Cordellier
P. Cordellier
P. Cordellier
P. Cordellier
JC. Peu
J.C. Peu

VISA VERIFIE PAR VISA

Signature Checked by Signature
 N° 4 007 765
Ed. 14 - Page 2/12

1 - GENERAL

Equipement described in this manual complies with provisions of "MACHINES" directive 98/37/EC
and ELECTROMAGNETIC COMPATIBILITY" 89/336/EEC and also with European standards EN 809
& EN 60034-1
1.1. Applications
Pumps aimed at clear liquids in building, agriculture and industry areas :
water supply – water tower - sprinkling, irrigation, high pressure washing , fire protection, boiler
supply (with mandatory by-pass kit) – lifting of condensates – air conditioning – industrial circuits and
integration in all modular systems.

1.2. Technical characteristics

Maximum operating pressure

- Pump casing PN 25: 16 bar (50&60Hz- 4poles)
25 bar (50&60Hz - 2 poles)
- Pump casing PN 16: 16 bar (50 et 60 Hz - 2 poles)
- Pump casing PN 25, rapid coupling for Victaulic bracket 16 bar (50Hz - 4 poles)
25 bar (50Hz - 2 poles)
- Maximum suction pressure :10 bar

Temperature range
Standard versions EPDM O’rings and mechanical seal (potable water KTW/WRAS* approved
versions) :
- 15°C to + 120°C
Versions for aggressive water (Viton O'rings and mechanical seal ) :
- 15°C to + 90°C
Maximum suction head : according to NPSH of the pump
Ambient temperature (standard product) :
+ 40° C maxi : + 40°C maxi
* (WRAS : according to British standard – KTW : according to German standard).

Sound level
Depends on pump size, rotation speed, working point, motor type : it can reach 73 dB(A) in 50 Hz
and 77 dB(A) in 60 Hz.

2 - SAFETY

Read this instruction carefully before installing and starting up. Pay special attention to the points
concerning the safety of the equipment as regards the intermediate or final user.

2.1 Symbols used in the instruction

Security instruction : non respect can induce injury.

Electrical security : non respect can induce injury.

CAUTION !
Security instruction : non respect can be induce material damages.

3 - TRANSPORT, HANDLING AND STORAGE

When receiving the material, check that there has been no damage during the transport. If any
defect has been stated, take the required steps with the carrier within the allowed time.

CAUTION !
 N° 4 007 765
Ed. 14 - Page 3/12

If the delivered material is to be installed later on, store it in a dry place and protect it
from impacts and any outside influences (humidity, frost etc...).

Due to high position of centre of gravity and small ground surface of this type of
pumps, beware of unstability during handling to avoid any falling down and take
necessary means to avoid injuries or damaging.

Handle the pump carefully so as not to alter the geometry and the alignment of the hydraulic unit.

4 - PRODUCTS AND ACCESSORIES

4.1. Description (see figures 1 and 2)

1 - Strainer-foot valve
2 - Pump suction valve
3 - Pump discharge valve
4 - Non-return valve
5 - Venting and filling plug
6 - Drain-priming plug
7 - Pipe supports
8 - Strainer
9 - Storage tank
10 - Town water supply
11 - Motor overload release
12 - Lifting hook
13 - Foundation block
HA : Maximum suction head
HC : Minimum inlet pressure

4.2. The pump

• Vertical multistage pump (2 to 24 stages) not self-priming, with ports in line on the same
axis at the bottom part.
• Shaft tightness with standard mechanical seal.
• Flanges :
- oval for pump casing PN 16 : pump delivered with oval counter-flanges in cast iron for
screw-on tube, gaskets and bolts,
- round for pump casing PN 25 : pump delivered with gaskets and bolts without counter-
flanges (accessories as option),
- with rapid hose coupling for Victaulic bracket : pump delivered without brackets
(accessories as option).

4.3. The motor

Cage induction motor with standardized flange and shaft end for vertical operation.
Motor-pump linked by a coupling with safety guards.

Protection index : IP 55
Insulation class : F

For motor variator fitted on MULTI-VE or MVIE pumps, see specific electronic
leaflet.
60 Hz
4 pôles / 2 pôles
2900 1750 3500
220/380 V à/to 254/440 V
380 V ∆ à/to 440 V ∆
*Moteur avec tension standard : tolérance sur tension réseau ± 10 % en 50 Hz & ± 6 % en 60 Hz
*Standard voltage motors : tolerance on network ± 10 % in 50 Hz & ± 6 % in 60 Hz
 N° 4 007 765
Ed. 14 - Page 4/12

ATTENTION ! Nombres de démarrages maxi par heure / Maximun number of starts per hour

0,37 0,55 0,75 1,1 1,5 1,85 2,2 3 4 5,5 7,5

Direct/direct 100 75 60 50 40 30 30 25 20 20 15
Etoile/triangle Υ/∆ / / / / / / / / 30 30 25
Star/delta Υ/∆

4.4. Accessories as option

By-pass kit – isolating valves – bladder or galvanised tank – tank for antihammer blow effect –
control box – PN 25 weld-on counter-flange (steel) or tapped (stainless steel) – tapped oval
counter-flange PN 16 in stainless steel - motor overload release – non-return valves – strainer-
foot valve – vibrationless sleeves – dry-running protection kit – flexible collar type Victaulic style
77 – threaded muff joint (stainless steel) Q

5 - INSTALLATION
Two standard cases :
Fig. 1 : pump in suction
Fig. 2 : pump under pressure on storage tank (9) or town water supply (10) with dry-running
protection system.

5.1. Installation

Install the pump in a place easy to reach, protected against frost and as close as possible from
the drawing point.
For heavy pumps provide a point of attachment (lifting hook) in the pump axis (12) to facilitate
removal.
Install the pump on a concrete block (at least 10 cm high) (13) and fix with anchor bolts
(installation plan figure 3).
Foresee an isolating material under the concrete block (cork or reinforced rubber) to avoid any
noise and vibration transmission into the installation.
Before final tightening of anchor bolts, ensure that the pump axis is vertical : use shims if
necessary.

Bear in mind that the altitude of the installation place and water temperature may reduce
the suction head of the pump.

Altitude Perte de hauteur Température Perte de hauteur

Altitude Loss of head Temperature Loss of head
0 m 0 mCL 20°C 0,20 mCL
500 m 0,60 mCL 30°C 0,40 mCL
1000 m 1,15 mCL 40°C 0,70 mCL
1500 m 1,70 mCL 50°C 1,20 mCL
2000 m 2,20 mCL 60°C 1,90 mCL
2500 m 2,65 mCL 70°C 3,10 mCL
3000 m 3,20 mCL 80°C 4,70 mCL
90°C 7,10 mCL
100°C 10,30 mCL

CAUTION ! Above 80°C, plan to install the pump under pressure.

5.2. Hydraulic connections

- Pump with oval flange pump casing : with threaded tubes to screw directly on the oval
tapped counter-flanges delivered with the pump.
- Pump with round flange pump casing: with tube to weld or to screw in the counter-flanges
(counter-flanges, avai-lable as option). If counter flange in steel, by counter flange in
 N° 4 007 765
Ed. 14 - Page 5/12

stainless steel to screw (as option)

- Pump with rapid hose coupling : with bracket, to be installed with an end to fix on the hose
(bracket and threaded end available as accessories).
- The diameter of the pipe must never be smaller than the one of the counterflange.
- The circulation sense of the fluid is indicated on the identification label of the pump.
- Limit the length of the suction pipe and avoid all features that cause losses of head
(bends, valves, tapers). Connections has to correctly sealed:No air entrance is
allowed on the suction pipe which is showing a mounting declivity (2 %). See
figure 1
- Use supports or collars so that the pump does not bear the weight of the pipes.

- Pump under pressure : connect the non-return valve to the pump discharge to protect it
from hammer blow effects.
Note : To pump water with a large content of air or hot water, we recommend installing the by-
pass kit.

5.3. Electrical connections

The electrical connections and the inspections have to be done by a
qualified electrician and comply with the applicable local standards.

For the electrical connections and starting of the motor variator fitted on
Multi-VE or MVIE pumps, see specific electronic leaflet.
The electrical characteristics (frequency, voltage, nominal current) of the motor are
mentionned on the name plate : check if it complies with the mains supply used.
Motors must be protected by a circuit-breaker set to the current mentionned on the name
plate of the motor.
Provide a fuse disconnecting switch (type aM) to protect the mains supply.
Supply network :
- Use an electrical cable conforming with the National Electric Supply Company
- Three-phase : 4 conductors (3 phases + earth)
The position of the terminal box can be changed a quarter turn by removing the motor
attachment screws (if necessary, remove the coupling guards) and turning the motor to the
desired position.
Refit the attachment screws of the motor and the coupling guards.

If necessary, cut an opening in the terminal box, fit the cable gland stuffing box and connect
the motor as shown by the diagram inside the cover of the terminal box (or see figure 4).
Do not forget the connection to earth.
A connection error would damage the motor. The power cable must never
touch the pipe or the pump; make sure that it is sheltered from any
humidity.
The electric motors used on the pumps can be connected to a frequency converter. Strictly
follow the instructions given by the data sheet of the converter's manufacturer.
The converter must not generate voltage peaks at the motor terminals higher than 1000V
(14) and dU/dt (Voltage/Time variation) higher than 2500 V/µs. If the value of the voltage signal
are higher than those, risk of damage the motor are to forecast.

In the contrary provide a LC filter (inductance – capacitor) between the converter and the
motor.
It must be connected to the motor with a minimum length cable, armoured if necessary.

DO NOT FORGET TO CONNECT TO EARTH.

6 - STARTING UP
 N° 4 007 765
Ed. 14 - Page 6/12

6.1. Prior cleaning

An hydraulic test is carried out for each pump in our factory. If some water stays
inside them. It is recommended for hygien reasons to clean the pump before using
it with potable water supply.

6.2. Filling – degassing

CAUTION
Never operate the pump dry, even briefly.
Pump under pressure (see fig. 2)
- Close the discharge valve (3)
- Open the venting plug (5), and the suction valve (2) and completely fill the pump.

Close the venting plug only after water flows out and complete air exit.

In hot water, a stream of water may escape from the venting port.Take all
required precautions as regards persons and motor.

Pump in suction : Two possible cases :

st
1 case (see fig. 5.1)
- Close the discharge valve (3), open the suction valve (2)
- Remove the venting plug (5)
- Unscrew the bottom drain-priming plug (6) located on the pump casing 4 to 5 turns.
- Put a funnel into the venting plug port and completely fill the pump and the suction pipe.
- After water flows out and total air exit, filling is complete.
- Screw the venting plug and the bottom drain-priming plug back in.
nd
2 case (see fig. 5.2)
Filling can be made easier by fitting on the suction pipe of the pump, a vertical pipe fitted with
a Ø ½" stopcock and a funnel.
CAUTION ! The length of the pipe must be
at least 50 mm taller than the
venting level.
- Close the discharge valve (3), open the suction valve (2).
- Open the stopcock and the venting plug.
- Unscrew 4 to 5 turns the drain-priming plug (6).
- Fill the pump and the suction pipe completely until water flows out of the venting plug (5).
- Close the stopcock (which can be left in place), remove the pipe and close the bleed device
(5) and screw again the drain-priming plug (6).

Dry-running protection
To ensure that the pump is always primed, we recommend to protect it with a pressure
switch or a float switch.

6.3. Check the motor sense of rotation

Remove the coupling guards.

Turn the coupling by hand to make sure that the pump turns freely without sticking.
Then set again the coupling guards.

THREE-PHASE MOTOR
Switch on the motor by briefly pressing the circuit-breaker and check that it turns in the
direction indicated by the arrow located on the lantern or on the identification label of the
pump.
In the contrary case cross the two phase wires on the motor terminal block or on the motor
overload release.
SINGLE PHASE MOTOR
The sense of rotation is adjusted when assembling the product and is independent from the
network connection.
 N° 4 007 765
Ed. 14 - Page 7/12

6.4. Starting up
Depending on conveyed fluid and running of pump, surface temperature can
exceed 68°C. Take necessary means to avoid injuries.

CAUTION The pump must not operate at zero flow (closed discharge valve) for more
than 10 minutes with cold water (T < 40° C) and more than 5 minutes above
60° C.
We recommend to ensure a minimum flow of about 10 % of the nominal flow of the pump to
avoid the formation of a vapour lock at the top of the pump.
Keep the discharge valve closed.
Start the pump
Open venting plug to drain air. If no water leaks within 20', close the plug and stop the
pump, then wait 20' to allow air to settle.
Start again the pump.
If necessary (particularly if the suction height exceeds 5 m) repeat these operations.
If water leaks at draining plug (it means the pump delivers its pressure), slowly open the
discharge valve.
The pump has to be primed.
Check pressure stability at discharge with a manometer, if instability, perfect air draining.
In case of failure, do the filling in again and start the operation again.
To perfect air draining, close the discharge valve and the draining plug, then stop the pump
20', start the pump again and open the draining plug. Do it as long as air comes out
Open the discharge valve in order to have the wished working point.
Check that the current input does not exceed the value indicated on the motor data plate.

7- MAINTENANCE
Before any operation, switch off the pump(s).

For MULTI-VE or MVIE pumps fitted with motor variator, see the specific
leaflet.

No special maintenance in operation.

Keep the pump and the motor perfectly clean.
In case of prolonged stopping, if there is no risk of frost, it is best not to drain the pump.
The bearing holding the coupling is lubricated for its total lifetime and does not require any
lubrication.

It is recommended to grease the motor shaft end as well as the coupling boring with a high
adhering grease (type type D321R Molikote or 8191 Loctite for example) to facilitate any further
diassembling.

Motors without lubricating devices

Bearings are lubricated for their lifetime and do not require any lubrication.

Motors with lubricating devices

See instructions put on motor. If missing, lubricate every 5 000 hours with a grease resistant to
high temperature.
Mechanical seals
The mechanical seal does not require any maintenance in operation. It must never operate dry.

8 - OPERATING DEFAULTS

Before any operation SWITCH OFF the pump.

For MULTI-VE or MVIE pumps fitted with motor variator, see the specific leaflet.
 N° 4 007 765
Ed. 14 - Page 8/12

DEFAULTS/CAUSES REMEDIES
1) Pump turns but no delivery
a) The internal parts are a) Dismantle the pump and clean it
obstructed by
particles.
b) Suction pipe b) Clean all the pipes
obstructed
c) Air in suction pipes c) Check tightness of the whole pipe up to the pump and make it tight.
d) Fill the pump to prime again. Check foot valve is tight.

d) Pump is no more
primed.
e) Suction pressure is e) Too high loss of head on suction or suction head (check the NPSH of the
too low, it causes pump installed and of the installation).
cavitation noise.
f) Check the voltage on the terminals of the motor and the cross-section of
the conductors.

f) The supply voltage of

the motor is too low
 N° 4 007 765
Ed. 14 - Page 9/12

2) The pump vibrates

a) Loose on its a) Check and tighten completely the nuts of the stud bolts.
foundation
b) Dismantle the pump and clean it.
c) Check the pump turns freely without abnormal sticking.
b) Particles obstructing
the pump d) Check the connections to the pump motor.
c) Difficult rotation of
the pump

d) Bad electrical
connection
3) The motor overheats
a) Voltage too low a) Check voltage on terminals of the motor, it should be within ± 10 % in 50 Hz or
± 6 % in 60 Hz of the rated voltage
b) Dismantle the pump and clean it

b) Pump obstructed by
particles
c) Ambient c) The motor is aimed at operating at a maximum ambient temperature of + 40°C.
temperature above d) Be in conformity with the motor plate and see figure 4.
+40°C

d) Coupling failure in
the terminal box
 N° 4 007 765
Ed. 14 - Page 10/12

4) The pump delivers insufficient pressure

a) The motor fails to run a) Dismantle the pump and solve the defect
at its normal speed
(particles...)
b) Replace the motor
b) The motor is
defective c) Open the bleeding device and drain until there are no more air bubbles

c) Bad filling of the d) Reverse the sense of rotation by interchanging the two phase wires on
pump the motor terminal box
e) Check it and screw it again

d) The motor turns in

the wrong way (three- f) Check the voltage on the terminals of the motor and the cross-section of
phase motor) the conductors.

e) The drain-priming
plug is not correctly
tightened

f) The supply voltage of

the motor is too low.

5) The circuit-breaker device is on.

a) The setting of the a) Check the current with an ammeter or set the value of the current rating
thermal relay is not on the motor data plate.
adequate (too low)
b) Check the adequate cross-section of the conductors of the electrical
cable.
c) Check it and change the electrical cable if necessary
b) The voltage is too
low

c) A phase is cut
d) The thermal relay of d) Replace it
the circuit-breaker is
defective
e) A fuse is off. e) Replace it
 N° 4 007 765
Ed. 14 - Page 11/12

6) The flow is irregular

a) The suction head a) Study again the installation conditions and the recommendations
(Ha) is not adequate described in this instruction.
b) The suction pipe must have the same diameter as the suction pump port

b) The suction pipe has

a lower diameter than
the one of the pump

c) The strainer and the c) Remove and clean.

suction pipe are
partially obstructed.

If the liquid is toxic, corrosive or dangerous for human being, SALMSON

must be informed or the qualified person in charge of the repairing. In this
case, clean the pump to ensure a complete safety to the repairing man.

9 - MAINTENANCE – SERVICING
Attention do not mix many parts.
SWITCH OFF the pump.

9.1 - Disassembly
See the technical information concerning disassembly – reassembling n° 4051292.

9.2 - Reassembly

See the technical information concerning disassembly – reassembling n° 4051292.

Information to add in Salmson leaflet :
To get our instruction leaflet for assembly and dismantling, contact our after sales service.
See the technical information concerning disassembly – reassembling n° 4051292.
 N° 4 007 765
Ed. 14 - Page 12/12
 STARTING AND
MAINTENANCE INSTRUCTION
FOR
MULTI-V/MVI-8” & 10”
 N° 4 033 725
Ed. 07 - Page 1/19

MULTI–V / MVI
8" & 10"

SERIE 18/36/60/80/100
SERIAL 16/32/52/70/95

CONTENU DE BASE TECHNICAL INFORMATION

NOTICE DE MISE EN STARTING AND MAINTENANCE

SERVICE ET DE INSTRUCTIONS
MAINTENANCE

07 29.08.05 076003 COSTAOUEC AILLERIE

06 24.02.05 075804 COSTAOUEC PEU
05 16.04.03 075277 BERTHELOT PEU
04 26.07.02 075014 PEU DE LA GASTINE
075667
03 25.01.01 074511 MARGUERITE PEU
02 03.03.98 073668 MARGUERITE CORDELLIER
01 05.01.98 MARGUERITE PEU
EDT DATE N°AC ETABLI PAR VERIFIE PAR
AC N° ESTABLISHED BY CHECKED BY

1 - GENERALITES
Les matériels désignés dans la présente
notice sont conformes aux dispositions des
directives "MACHINES" 98/37/CE et
"COMPATIBILITE
ELECTROMAGNETIQUES" 89/336/CEE
ainsi qu'aux dispositions des normes
européennes harmonisées EN 809 & EN
60034-1
1.1. Applications
Pompes destinées au pompage de liquides
clairs dans les secteurs de l'habitat, de
l'agriculture de l'industrie...
(adduction d'eau, distribution d'eau -
Alimentation de château d'eau - Arrosage,
irrigation - Lavage haute pression - Protection
incendie - Alimentation de chaudières (avec
kit by-pass obligatoire) - Relevage de
condensats - Climatisation - Circuits
industriels) et en incorporation dans tous les
systèmes modulaires.
1.2. Caractéristiques techniques
Pression maxi de service
- Corps PN 25: 25 bar (50 et 60 Hz - 2
pôles)
- Corps PN 16: 16 bar (50 et 60 Hz - 2 et 4
pôles)
- Pression maxi à l'aspiration :10 bar
Plage de température
• -15°C à +120°C pour versions joints et
garnitures mécaniques EPDM
(homologuées KTW/WRAS*)
• -15°C à +90°C pour versions joints et
garnitures mécaniques Viton
Hauteur d'aspiration maxi : suivant NPSH de
la pompe.
Température ambiante (produit standard) :
+40 °C maxi
* : WRAS : selon réglementation anglaise
KTW : selon réglementation allemande
Niveau sonore
Il dépend de la taille de la pompe , de la
vitesse de rotation, du point de
fonctionnement et du type de moteur : dans
certains cas, il peut atteindre 81 dB(A) en 50
Hz et 86 dB(A) en 60 Hz.
2 - SECURITE
N° 4 033 725
Ed. 07 - Page 2/19
1 - GENERAL
Equipement described in this manual
complies with provisions of "MACHINES"
directive 98/37/EC and
“ELECTROMAGNETIC COMPATIBILITY"
89/336/EEC and also with European
standards EN 809 & EN 60034-1
1.1. Applications
Pumps aimed at clear liquids in building,
agriculture and industry areas F
(water supply – water tower - sprinkling,
irrigation, high pressure washing , fire
protection, boiler supply (with mandatory by-
pass kit) – lifting of condensates – air
conditioning – industrial circuits) and
integration in all modular systems.
1.2. Technical characteristics
Maximum operating pressure
- Pump casing PN 25: 25 bar (50 and 60
Hz – 2 poles)
- Pump casing PN 16: 16 bar (50 and 60
Hz - 2 and 4 poles)
- Maximum suction pressure :10 bar
Temperature range
• -15°C to +120°C for standard versions
EPDM O’rings and mechanical seal
(KTW/WRAS* approved versions)
• -15°C to +90°C for aggressive water
versions (Viton O'rings and mechanical
seal)
Maximum suction head : according to NPSH
of the pump.
Ambient temperature (standard product) :
+40 °C maxi
* : WRAS : according to British standard
KTW : according to German standard.
Sound level
It depends on pump size, rotation speed,
running point and motor type : it can reach 81
dB(A) at 50 Hz and 86 dB(A) at 60 Hz.
2 - SAFETY

La présente notice devra être lue avec
attention avant installation et mise en service.
On veillera en particulier, au respect des
points concernant la sécurité du matériel vis à
vis de l'utilisateur intermédiaire ou final.
2.1 Symboles des consignes du manuel
Consigne de sécurité dont le
non respect présente un
danger pour la sécurité des
personnes
Consignes de sécurité
électrique dont le non
respect présente un danger
pour la sécurité des
personnes.
Consignes de sécurité dont
la non-observation peut
ATTENTION ! engendrer un dommage
pour le matériel et son
fonctionnement
3 - TRANSPORT, MANUTENTION ET
STOCKAGE
Dès réception du matériel, vérifier s'il n'a pas
subi de dommages durant son transport. En
cas de défaut constaté, prendre dans les
délais prévus toutes dispositions nécessaires
auprès du transporteur.
Si le matériel livré devait être
installé ultérieurement,
stockez-le dans un endroit
ATTENTION ! sec et protégez-le contre les
chocs et toutes influences
extérieures (humidité, gel,
G).
En raison de la position
haute du centre de gravité et
de la faible surface au sol de
ces pompes, prendre les
précautions nécessaires lors
de la manutention pour
éviter tout basculement
pouvant présenter un risque
pour la sécurité des
personnes.
Manipuler la pompe avec précautions pour
respecter la géométrie et l'alignement de
l'ensemble hydraulique.
Pour une installation plus sûre et plus facile,
un outil de levage (référence 4091365) est
disponible pour les modèles Multi-V36C,
N° 4 033 725
Ed. 07 - Page 3/19
Read first this instruction carefully before
installing and starting up. Take care to points
related to safety of the equipment regarding
intermediate or final users.
2.1 Symbols used in the manuals
Security instruction : non
respect can induce injury.
Electrical security : non
respect can induce injury .
Security instruction : non
CAUTION ! respect can induce material
damages.
3 - TRANSPORT, HANDLING AND STORAGE
When receiving the material, check that there
has been no damage during the transport. If
some defect has been stated, take the
required steps with the carrier within the
allowed time.
If the delivered material is to
be installed later on, store it
in a dry place and protect it
CAUTION !
from impacts and any
outside influences (humidity,
frost, G).
Due to high position of
centre of gravity and small
ground surface of this type
of pumps, beware of
unstability during handling
to avoid any falling down
and take necessary means to
avoid injuries or damaging.
Handle the pump carefully so as not to alter
the geometry and the alignment of the
hydraulic unit.
For an easier and safer installation, a
dedicated handling tool is available (article
number 4091365) for biggest pumps

Multi-V60C, Multi-V80 et Multi-V100.
Contacter votre revendeur pour plus de
renseignements.
4 - PRODUITS ET ACCESSOIRES
4.1. Descriptif (voir fig. 1 et 2)
1 - Clapet de pied de crépine
2 - Vanne à l'aspiration pompe
3 - Vanne au refoulement
pompe
4 - Clapet anti-retour
5 - Bouchon remplissage et
purge d'air
6 - Bouchon vidange - amorçage
7 - Supports de tuyauterie ou
colliers
8 - Crépine
9 - Bâche de stockage
10 - Réseau d'eau de ville
11 - Discontacteur de protection
moteur
12 - Crochet de levage
13 - Massif
14 - Robinet
HA : Hauteur d'aspiration maxi
HC : Hauteur de charge mini
4.2. La pompe
• Pompe verticale multicellulaire
(1 à 16 étages) non auto-
amorçante, avec orifices en
ligne sur le même axe en partie
basse.
• Etanchéité au passage de
l'arbre par garniture mécanique
normalisée. Système à
cartouche facilitant la
maintenance sur Multi-V36C,
(7) Multi-V60C, Multi-V80 et Multi-
V100.
N° 4 033 725
Ed. 07 - Page 4/19
(MVI32C, MVI52C, MVI70 and MVI95).
Please contact your reseller for more
information.
Fichier
handling_tool.jpg
4 - PRODUCTS AND ACCESSORIES
4.1. Description (see figures 1 and 2)
1 - Strainer-foot valve
2 - Pump suction valve
3 - Pump discharge valve
4 - Non-return valve
5 - Air-bleed and filling plug
6 - Drain-priming plug
7 - Pipe supports
8 - Strainer
9 - Storage tank
10 - Town water supply
11 - Motor protection relay
12 - Lifting hook
13 - Foundation block
14 - Cock
HA : Maximum suction head
HC : Minimum discharge head
4.2. The pump
• Multistage vertical pump (1 to 16
stages) not self-priming, ports in
line on the same axis in bottom
part.
• Shaft sealing by standardized
mechanical seal. Cartridge system
for an easier maintenance on
MVI32C, MVI52C, MVI70 and
MVI95.
• “Spacer” feature to avoid big size
motor disassembling (greater than
11kW) on MVI32C, MVI52C,
 N° 4 033 725
Ed. 07 - Page 5/19

• Fonction « spacer » pour éviter MVI70 and MVI95.

la dépose des moteurs de plus • Round flanges : pump supplied
de 11kW sur Multi-V36C, Multi- with gaskets and bolts without
V60C, Multi-V80 et Multi-V100. counterflanges (accessories in
• Brides rondes : pompe fournie option).
avec joints et boulons sans
contre-brides (accessoires en
option).
4.3. Le moteur 4.3. The motor
Moteur fermé à bride et bout d'arbre Sealed motor with standardized flange
normalisés pour fonctionnement and shaft end for vertical operation.
vertical.

Liaison moteur-pompe assurée par Motor-pump linked by a coupling with

un accouplement avec protecteurs safety guards.
de sécurité. Protection index : IP 55
Indice de protection : IP 55 Insulation class : F
Classe d'isolation : F

Pour les caractéristiques For frequency converter fitted

du moto-variateur on MVIE pumps, see specific
équipant nos pompes electronic leaflet.
Multi-VE, voir la notice
spécifique.

Fréquence/Frequency 50 Hz 60 Hz
4 pôles / 2 pôles 4 pôles / 2 pôles
Vitesse/ tr/mn
~1450 ~2900 ~1750 ~3500
Speed : Rpm
Tri ≤ 4 kW
230/400 V 220/380 V à/to 254/440 V
Bobinage/ 3 phases
Winding* Tri > 4 kW
400 V ∆ 380 V ∆ à/to 440 V ∆
3 phases
* Tension standard : tolérance ± 10 % en 50 Hz et ± 6 % en 60 Hz
* Standard voltage : tolerance ± 10 % in 50 Hz and ± 6 % in 60 Hz

Nombres de démarrages Maximun number of starts

ATTENTION ! CAUTION !
maxi par heure : per hour :

P2 (kW) 1,1 1,5 2,2 3 4 5,5 7,5 9 11 15 18,5 22 30 37 45

Direct/direct 50 40 30 25 20 20 15 15 15 12 10 10 6 6 4
Etoile/triangle Υ/∆
∆
/ / / / 30 30 25 25 25 25 20 20 12 12 8
Star/delta Υ/∆

4.4. Accessoires optionnels 4.4. Accessories as option

Kit by-pass - vannes d'isolement - By-pass kit – isolating valves –

réservoir à vessie ou galvanisé -
réservoir anti bélier - coffre de
commande - discontacteur de
protection moteur - contre bride à
souder ou à visser (Acier ou Inox) -
clapets anti-retour - clapet de pied de
crépine - manchons anti-vibratoires -
kit protection manque d'eau.
bladder or galvanised tank – tank for
antihammer blow effect – control box
– motor protection relay – weld-on or
screw-on counterflange (steel or
stainless steel) – non-return valves –
strainer-foot valve – vibrationless
sleeves – dry-running protection kit
 N° 4 033 725
Ed. 07 - Page 6/19

5 - INSTALLATION 5 - INSTALLATION

Deux cas type : Two standard cases :

Fig. 1 : pompe en aspiration
Fig. 2 : pompe en charge sur bâche de
stockage (rep.9) ou sur réseau
d'eau de ville (rep.10) avec système
de protection manque d'eau.
Fig. 1 : pump in suction
Fig. 2 : pump under pressure on storage
tank (see 9) or town water supply
(see 10) with dry-running protection
system.

5.1. Montage 5.1. Installation

Installer la pompe dans un endroit Install the pump in a place easy to

facilement accessible, protégé du gel
et aussi près que possible du lieu de
puisage.
Pour les pompes dont la masse est
importante, prévoir un point d'attache
(crochet de levage) dans l'axe de la
pompe (rep 12) pour permettre un
démontage aisé.
Montage sur massif en béton (10 cm
de hauteur mini) (rep. 13) avec fixation
par boulons de scellement (plan de
pose voir fig. 3).
Prévoir sous le massif de béton un
matériau isolant (liège ou caoutchouc
armé) pour éviter la transmission des
bruits et des vibrations dans
l'installation.
Avant le serrage définitif des boulons
de scellement, s'assurer que l'axe de
la pompe est bien vertical : utiliser des
cales si nécessaires.
Tenir compte que l'altitude du
lieu d'installation et la
température de l'eau pompée
réduisent les possibilités
d'aspiration de la pompe
reach, protected against frost and as
close as possible from the drawing
point.
For heavy pumps provide a point of
attachment (lifting hook) in the pump
axis (see 12) to facilitate removal.
Install the pump on a concrete block
(at least 10 cm high) (see 13) and fix
with anchor bolts (installation plan
figure 3).
Foresee an isolating material under
the concrete block (cork or reinforced
rubber) to avoid any noise and
vibration transmission into the
installation.
Before final tightening of anchor bolts,
ensure that the pump axis is vertical :
use shims if necessary.
Keep in mind that the altitude
of the installation place and
water temperature may
reduce the suction head of
the pump.

Altitude Perte de hauteur Température Perte de hauteur

Altitude Loss of head Temperature Loss of head
0 m 0 mCL 20°C 0,20 mCL
500 m 0,60 mCL 30°C 0,40 mCL
1000 m 1,15 mCL 40°C 0,70 mCL
1500 m 1,70 mCL 50°C 1,20 mCL
2000 m 2,20 mCL 60°C 1,90 mCL
2500 m 2,65 mCL 70°C 3,10 mCL
3000 m 3,20 mCL 80°C 4,70 mCL
90°C 7,10 mCL
100°C 10,30 mCL

Au-delà de 80°C, prévoir

Above 80°C, plan to install
une installation pompe en
the pump under pressure.
charge.

5.2. Raccordements hydrauliques 5.2. Hydraulic connections

- Par tube à souder ou à visser dans - By weld-on or screw-on pipe in the

les contrebrides (contre brides, counterflanges (counterflanges

disponibles en accessoires).
- Le diamètre de la tuyauterie ne doit
jamais être inférieur à celui de la
contre-bride.
- Une flèche sur le corps de pompe
indique le sens de circulation du
fluide.
- Limiter la longueur de la tuyauterie
d'aspiration et éviter au maximum les
causes de pertes de charge (coudes,
vannes, rétrécissements). Bien
étancher les raccordements avec
des produits adaptés : aucune
prise d'air ne doit être tolérée sur
cette tuyauterie qui sera en pente
montante d'au moins 2%. Voir
figure 1.
- Utiliser des supports ou colliers pour
éviter que le poids des tuyauteries ne
soit supporté par la pompe.
- Pompe en charge : raccorder un
clapet anti-retour au refoulement de
la pompe pour la protéger contre les
risques de coup de bélier
Nota : Pour le pompage d'eau fortement
aérée ou d'eau chaude, nous
recommandons la mise en place d'un
kit by-pass (voir figure 1).
5.3. Raccordements électriques
Les raccordements
électriques et les contrôles
doivent être effectués par
un électricien agréé et
conformément aux normes
locales en vigueur.
Pour les raccordements et
la mise en route du moto-
variateur équipant nos
pompes Multi-VE, voir la
notice spécifique.
Les caractéristiques électriques
(fréquence, tension, intensité
nominale) du moteur sont indiquées
sur sa plaque signalétique : vérifier qu'il
est adapté au réseau sur lequel il va
être utilisé.
La protection électrique des moteurs
est obligatoire et doit être assurée par
un disjoncteur réglé à l'intensité
figurant sur la plaque du moteur.
Prévoir un sectionneur à fusibles (type
aM) pour protéger le réseau.
Réseau d'alimentation :
- Utiliser un câble électrique
conforme aux normes EDF
- Triphasé : 4 conducteurs (3
phases + terre)
N° 4 033 725
Ed. 07 - Page 7/19
available as accessories).
- The diameter of the pipe must never
be smaller than the one of the
counterflange.
- An arrow on the pump casing shows
the direction of the fluid flow.
- Limit the length of the suction pipe
and avoid all features that cause
losses of head (bends, valves,
tapers). Connections has to
correctly sealed : No air entrance
is allowed on the suction pipe
which is showing a mounting
declivity (2%). See figure 1.
- Use supports or collars so that the
pump does not bear the weight of the
pipes.
- Pump under pressure : connect the
non-return valve to the pump
discharge to protect it from hammer
blow effects.
Note : To pump water with a large content of
air or hot water, we recommend
installing the by-pass kit (see figure
1).
5.3. Electrical connections
The electrical connections
and the inspections have
to be done by a qualified
electrician and comply with
the applicable local
standards.
For the electrical
connections and starting of
the frequency converter
fitted on MVIE pumps, see
specific leaflet.
The electrical characteristics
(frequency, voltage, nominal current) of
the motor are mentionned on the name
plate : check if it complies with the
mains supply used.
The motors must be protected by a
circuit-breaker set to the current
mentionned on the name plate of the
motor.
Provide a fuse disconnecting switch
(type aM) to protect the main supply.
Supply network :
- Use an electrical cable
conforming with the National
Electric Supply Company
- Three-phase : 4 conductors (3
phases + earth)

Il est possible de modifier par
l'orientation du moteur la position de la
boîte à bornes par quart de tour :
retirer les vis de fixation moteur (si
besoin retirer les protecteurs
d'accouplements) et réorienter le
moteur à la position souhaitée.
Remettre les vis de fixation
moteur et les protecteurs
d'accouplement.
Si nécessaire, découper l'opercule sur
la boîte à bornes, monter le presse-
étoupe et raccorder le moteur
conformément au schéma figurant
dans le couvercle de la boîte à bornes
(ou voir fig. 4).
Une erreur de branchement
électrique endommagerait
le moteur. Le câble
électrique ne devra jamais
être en contact ni avec la
tuyauterie, ni avec la
pompe et être à l'abri de
toute humidité.
Les moteurs électriques équipant les
pompes peuvent être raccordés à un
convertisseur de fréquence. Se
conformer scrupuleusement à la
notice du fabricant du
convertisseur.
Celui-ci ne devra pas générer aux
bornes du moteur des pics de tension
(7) supérieur à 1000V et des dU/dt
(variation Tension/Temps) supérieure
à 2500 V/µs.
Si le signal de tension présente des
valeurs supérieures à celles précitées,
des risques de dégradation du
bobinage moteur sont à craindre.
Dans le cas contraire, prévoir un filtre
LC (inductance - condensateur) entre
le convertisseur et le moteur.
Il devra être connecté au moteur avec
un cable de longueur minimale, blindé
si nécessaire.
NE PAS OUBLIER DE
RACCORDER LA MISE A
LA TERRE.
6 - MISE EN ROUTE
6.1. Rinçage préliminaire
N° 4 033 725
Ed. 07 - Page 8/19
The position of the terminal box can be
changed a quarter turn by removing
the motor attachment screws (if
necessary, remove the coupling
guards) and turning the motor to the
desired position.
Refit the attachment
screws of the motor and
the coupling guards.
If necessary, cut an opening in the
terminal box, fit the cable gland stuffing
box and connect the motor as shown
by the diagram inside the cover of the
terminal box (or see figure 4).
A connection error would
damage the motor. The
power cable must never
touch the pipe or the
pump; make sure that it is
sheltered from any
humidity.
The electric motors used on the pumps
can be connected to a frequency
converter. Strictly follow the
instructions given by the data sheet
of the converter's manufacturer.
The converter must not generate
voltage peaks at the motor terminals
higher than 1000V and dU/dt
(Voltage/Time variation) higher than
2500 V/µs. If the value of the voltage
signal are higher than those, risk of
damage the motor are to forecast.
In the contrary provide a LC filter
(inductance – capacitor) between the
converter and the motor.
It must be connected to the motor with
a minimum length cable, armoured if
necessary.
DO NOT FORGET TO
CONNECT TO EARTH.
6 - STARTING UP
6.1. Prior cleaning

Nos pompes peuvent être
testées hydrauliquement en
usine. S'il subsiste de l'eau
dans celles-ci, il est
recommandé pour des raisons
d'hygiène d'effectuer un
rinçage de la pompe avant
toute utilisation sur réseau
d'eau potable.
6.2. Remplissage – dégazage
NE JAMAIS FAIRE TOURNER
ATTENTION ! LA POMPE A SEC MEME UN
COURT INSTANT.
Pompe en charge (voir fig. 2) :
- Fermer la vanne au refoulement (rep.
3)
- Ouvrir le purgeur (rep. 5), ouvrir la
vanne à l'aspiration (rep. 2) et procéder
au remplissage complet de la pompe.
Ne refermer le purgeur qu'après sortie
d'eau et totale évacuation de l'air.
En eau chaude, un jet d'eau
peut s'échapper de l'orifice
de purge. Prendre toutes les
ATTENTION !
précautions nécessaires vis
à vis des personnes et du
moteur.
Pompe en aspiration : deux possibiltés
pour le remplissage de la pompe :
er
1 cas (voir fig. 5.1)
- Fermer la vanne au refoulement (rep.
3), ouvrir la vanne à l'aspiration (rep. 2)
- Retirer le bouchon-purgeur (rep. 5)
- Dévisser de 3 tours le bouchon
inférieur de vidange-amorçage (rep. 6)
situé sur le corps de pompe.
- A l'aide d'un entonnoir, engagé dans
l'orifice du purgeur, remplir
complètement la pompe et la
tuyauterie d'aspiration.
- Après sortie d'eau et évacuation totale
de l'air, le remplissage est terminé.
- Revisser le bouchon-purgeur et le
bouchon inférieur de vidange
amorçage.
ème
2 cas (voir fig. 5.2)
Le remplissage peut être facilité en
installant sur la conduite d'aspiration de
la pompe un tuyau vertical muni d'un
robinet de fermeture (rep. 14) Ø ½" et
d'un entonnoir.
N° 4 033 725
Ed. 07 - Page 9/19
An hydraulic test is carried out
for each pump in our factory. If
some water stays inside them.
It is recommended for hygien
reasons to clean the pump
before using it with potable
water supply.
6.2. Filling - degassing
NEVER OPERATE THE
CAUTION !
PUMP DRY, EVEN BRIEFLY.
Pump under pressure (see fig. 2) :
- Close the discharge valve (see 3)
- Open the bleed device (see 5), and the
suction valve (see 2) and completely fill
the pump.
Close the bleed device only after water
flows out and complete aeration.
In hot water, a stream of
water may escape from the
venting port. Take all
CAUTION !
required precautions
regarding persons and
motor.
Pump in suction : Two possible cases
for filling of the pump.
st
1 case (see fig. 5.1)
- Close the discharge valve (see 3),
open the suction valve (see 2)
- Remove the bleed plug (see 5)
- Unscrew the bottom drain-priming plug
(see 6) located on the pump casing
three turns.
- Put a funnel into the bleed port and
completely fill the pump and the
suction pipe.
- After water flows out and total air
evacuation, filling is complete.
- Screw the bleed-plug and the bottom
drain-priming plug back in.
nd
2 case (see fig. 5.2)
Filling can be made easier by fitting on
the suction pipe of the pump, a vertical
pipe (see 14) fitted with a Ø ½" stopcock
and a funnel.

La longueur du tuyau doit
ATTENTION ! dépasser le niveau du
purgeur d'au moins 50 mm
- Fermer la vanne au refoulement (rep.
3), ouvrir la vanne à l'aspiration (rep.
2).
- Ouvrir le robinet (rep. 14) et le purgeur
(rep. 15).
- Dévisser de 3 tours le bouchon
d'amorçage-vidange (rep. 6).
- Procéder au remplissage complet de la
pompe et de la conduite d'aspiration,
jusqu'à écoulement d'eau par le
purgeur (rep. 5).
- Fermer le robinet (rep. 14), retirer le
tuyau et fermer le purgeur (rep. 5) et
revisser le bouchon
d'amorçage/vidange (rep. 6).
Protection manque d'eau
Pour éviter les désamorçages
accidentels de la pompe, nous
recommandons sa protection par un
pressostat ou un interrupteur à flotteur.
6.3 Contrôle du sens de rotation du
moteur
Retirer les protecteurs d'accouplement.
Faire tourner l'accouplement à la main,
pour s'assurer que la pompe tourne
librement sans point dur.
Replacer ensuite les protecteurs
d'accouplement.
Mettre le moteur sous tension, par une
brève impulsion sur le discontacteur et
vérifier que celui-ci tourne bien dans le
sens indiqué par la flèche située sur la
lanterne pompe (tête de pompe).
Dans le cas contraire croiser deux fils de
phase au bornier moteur, ou sur le
discontacteur.
6.4. Démarrage
Suivant la température du
fluide véhiculé et les cycles
de fonctionnement de la
pompe, la température des
surfaces (pompe, moteur)
peut dépasser 68 °C : mettre
en place des protections vis
à vis des personnes si
nécessaire.
N° 4 033 725
Ed. 07 - Page 10/19
The length of the pipe must
CAUTION ! be at least 50 mm taller than
the venting level.
- Close the discharge valve (see 3),
open the suction valve (see 2).
- Open the stopcock (see 14) and the
bleed device (see 15).
- Unscrew 3 turns the drain-priming plug
(see 6).
- Fill the pump and the suction pipe
completely until water flows out of the
bleed device (see 5).
- Close the stopcock, remove the pipe
and close the bleed device (see 5) and
screw again the drain-priming plug
(see 6).
Dry-running protection
To avoid any accidental loss of priming
of the pump, we recommend to protect it
with a pressure switch or a float switch.
6.3 Check the motor sense of rotation
Remove the coupling guards.
Turn the coupling by hand to make sure
that the pump turns freely without
sticking.
Then set again the coupling guards.
Switch on the motor by briefly pressing
the circuit-breaker and check that it turns
in the direction indicated by the arrow
located on the pump lantern (head of the
pump).
In the contrary case cross the two phase
wires on the motor terminal block or on
the motor protection relay.
6.4. Starting up
Depending on conveyed
fluid and running of pump,
surface temperature can
exceed 68 °C. Take
necessary means to avoid
injuries.

La pompe ne doit pas
fonctionner à débit nul
(vanne au refoulement
fermée) plus de 10 minutes
ATTENTION ! en eau froide (T°C < 40 °C) et
plus de 5 mn au-delà de 60
°C (respectivement 5 et 2
minutes si la puissance
moteur dépasse 22 kW).
Nous recommandons d'assurer un débit
minimum égal à 10 % environ du débit
nominal de la pompe afin d'éviter la
formation d'une poche gazeuse en partie
haute de la pompe.
Maintenir fermée la vanne au
refoulement.
Démarrer la pompe.
Ouvrir le purgeur pour évacuer l'air. En
l'absence d'un jet d'eau franc dans les
20s, refermer le purgeur et arréter la
pompe puis attendre 20s environ pour
laisser l'air décanter.
Redémarrer la pompe.
Si nécessaire (surtout si la hauteur
d'aspiration dépasse 5m), renouveler
ces opérations.
Si un jet d'eau franc apparait au purgeur
(signe que la pompe délivre sa
pression), ouvrir lentement la vanne au
refoulement. La pompe doit être
amorcée.
Contrôler la stabilité de la pression au
refoulement à l'aide d'un manomètre ;
en cas d'instabilité parfaire la purge d'air.
En cas d'échec, refaire le remplissage et
recommencer l'opération
Pour parfaire la purge d'air, fermer la
vanne au refoulement et le purgeur, puis
arréter la pompe 20s, remettre en route
la pompe et ouvrir le purgeur. A
renouveler tant qu'il sort de l'air.
Ouvrir la vanne au refoulement pour
avoir le point de fonctionnement
souhaité.
Vérifier que l'intensité absorbée est
inférieure ou égale à celle indiquée sur
la plaque moteur.
7 - ENTRETIEN
Avant toute intervention,
mettre hors tension la (ou
les) pompe(s).
Pour nos pompes Multi-VE
équipées de moto-variateur,
voir la notice spécifique
Aucun entretien particulier en cours de
fonctionnement.
Maintenir la pompe et le moteur en parfait
état de propreté.
N° 4 033 725
Ed. 07 - Page 11/19
The pump must not operate
at zero flow (closed
discharge valve) for more
than 10 minutes with cold
CAUTION ! water (T°C < 40 °C) and more
than 5 minutes above 60 °C
(respectively 5 and 2
minutes for motor power
greater than 22 kW).
We recommend to ensure a minimum
flow of about 10 % of the nominal flow of
the pump to avoid the formation of a
vapour lock at the top of the pump.
Keep the discharge valve closed.
Start the pump
Open venting plug to vent air. If no water
leaks within 20s, close the plug and
stop the pump, then wait 20s to allow air
to settle.
Start again the pump.
If necessary (particularly if the suction
height exceeds 5 m) repeat these
operations.
If water leaks at draining plug (it means
the pump delivers its pressure), slowly
open the discharge valve.
The pump has to be primed.
Check pressure stability at discharge
with a manometer, if instability, perfect
air draining.
In case of failure, do the filling in again
and start the operation again.
To perfect air draining, close the
discharge valve and the draining plug,
then stop the pump 20s, start the pump
again and open the draining plug. Do it
as long as air comes out
Open the discharge valve in order to
have the wished working point.
Check that the current input does not
exceed the value indicated on the motor
data plate.
7 - MAINTENANCE
Before any operation, switch
off the pump(s).
For MVIE pumps equipped
with frequency converter, see
the specific leaflet.
No special maintenance in operation.
Keep the pump and the motor perfectly clean.

En cas d'arrêt prolongé, s'il n'y a pas risque
de gel, il est déconseillé de vidanger la
pompe.
Pour les pompes équipées d'un graisseur
sous le boitier de roulement (tableau ci-
dessous), voir les instructions de regraissage
figurant sur l'étiquette collée sur celui-ci :
Sur les autres types, le roulement supportant
l'accouplement est graissé pour sa durée de
vie.
Si le moteur se monte par simple
emboitement dans l’accouplement (pas de
vis de serrage), il est fortement recommandé
de graisser son bout d'arbre ainsi que
l'alésage de l'accouplement avec une graisse
à forte adhérence (type D321R Molikote ou
8191 Loctite par exemple) à chaque montage
ou remontage du moteur afin de faciliter des
démontages ultérieurs.
Pour les pompes équipées d’un tampon
d’accouplement, s’assurer du bon état avant
tout remontage.
N° 4 033 725
Ed. 07 - Page 12/19
In case of prolonged stopping, if there is no
risk of frost, it is best not to drain the pump.
On pumps equipped with greaser under
bearing box (table below), see regreasing
instructions written on sticker put on it:
Fichier greasing_X.jpg
On other models, the bearing holding the
coupling is lubricated for its total lifetime.
If the motor assembling is done only by fitting
into the bearing (no screw for tightening of
the coupling on the motor shaft), it is
recommended to grease the shaft end as well
as the coupling boring with a high adhering
grease (type type D321R Molikote or 8191
Loctite for example) to facilitate any further
diassembling.
For pumps equipped with coupling bush,
check it before reassembling.
 N° 4 033 725
Ed. 07 - Page 13/19

Fichier coupling.jpg

(7) Moteurs sans graisseurs Motors without lubricating devices

(7) Les roulements des moteurs standards sont Motor bearings are lubricated for their lifetime
graissés pour leur durée de vie et ne and do not require any lubrication.
nécessitent donc pas de graissage.

Garnitures mécaniques Mechanical seals

La garniture mécanique ne nécessite aucun
entretien en cours de fonctionnement.
Elle ne doit jamais
ATTENTION !
fonctionner à sec.
Les Multi-V36C, Multi-V60C, Multi-V80 et
Multi-V100 sont équipées d’un système
cartouche permettant le remplacement de la
garniture sans démontage de la partie
hydraulique
The mechanical seal does not require any
maintenance in operation.
CAUTION ! It must never operate dry.
MVI32C, MVI52C, MVI70 and MVI95 are
equipped with a cartridge system in order to
ease standard mechanical seal replacement
without disassembling the hydraulic parts.

Fichier cartouche.jpg

La fonction “spacer” permet son “Spacer” feature allows not to disassemble

remplacement sans depose du moteur pour
(7)
les puissances supérieures à 11kW sur les
Multi-V36C, Multi-V60C, Multi-V80 et Multi-
V100
motor on MVI32C, MVI52C, MVI70 and
MVI95 (for power greater than 11kW) when
removing mechanical seal cartridge.

8 - INCIDENTS DE FONCTIONNEMENT 8 - OPERATING DEFAULTS

Avant toute intervention, Before any operation

mettre HORS TENSION SWITCH OFF the
la pompe. pump.
Pour nos pompes For or MVIE pumps
Multi-VE équipées de equipped with
moto-variateur, voir la frequency
notice spécifique converter, see the
specific leaflet.
 N° 4 033 725
Ed. 07 - Page 14/19

INCIDENTS/CAUSES REPARATION DEFAULTS/CAUSES REMEDIES

1) La pompe tourne mais ne débite pas 1) Pump turns but no delivery

a) Les organes internes a) Faire démonter la a) The internal parts are a) Dismantle the pump
sont obstrués par pompe et la nettoyer. obstructed by foreign and clean it.
des corps étrangers. matters.

b) Tuyauterie b) Nettoyer toute la b) Suction pipe b) Clean all the pipes.

d'aspiration obstruée. tuyauterie. obstructed.

c) Entrées d'air par la c) Contrôler l'étanchéité c) Air in suction pipes. c) Check tightness of
tuyauterie de toute la conduite the whole pipe up to
d'aspiration. jusqu'à la pompe et the pump and make
étancher. it tight.

d) La pompe est d) Réamorcer par d) Pump is no more d) Fill the pump to

désamorcée ou non remplissage pompe. primed. prime again. Check
amorcée. Vérifier l'étanchéité foot valve is tight.
du clapet de pied.

e) La pression à e) Trop de pertes de e) Suction pressure is e) Too high loss of head

l'aspiration est trop charge à l'aspiration too low, it causes on suction or suction
faible, elle est ou la hauteur cavitation noise. head (check the
généralement d'aspiration est trop NPSH of the pump
accompagnée de élevée (contrôler le installed and of the
bruit de cavitation. NPSH de la pompe installation).
installée et de
l'installation).

f) Le moteur est f) Contrôler la tension f) The supply voltage of f) Check the voltage on
alimenté à une aux bornes du the motor is too low the terminals of the
tension insuffisante moteur et la bonne motor and the cross-
section des section of the
conducteurs conductors.

2) La pompe vibre 2) The pump vibrates

a) Mal serrée sur son a) Vérifier et visser a) Loose on its a) Check and tighten
socle. complètement les foundation. completely the nuts
écrous des boulons of the stud bolts.
de scellement.

b) Corps étrangers b) Faire démonter la b) Foreign matters b) Dismantle the pump

obstruant la pompe. pompe et la nettoyer. obstructing the and clean it.
pump.
c) Rotation dure de la c) Vérifier que la pompe c) Check the pump
pompe. tourne librement c) Difficult rotation of turns freely without
sans opposer de the pump. abnormal sticking.
résistance anormale.

d) Mauvais d) Vérifier les d) Check the

branchement connexions au d) Bad electrical connections to the
électrique moteur de la pompe. connection. pump motor.
 N° 4 033 725
Ed. 07 - Page 15/19

3) Le moteur chauffe anormalement 3) The motor overheats

a) Tension insuffisante. a) Vérifier la tension aux a) Voltage too low a) Check voltage on
bornes du moteur, terminals of the
cette tension doit se motor, it should be
situer à ± 10 % en within ± 10 % in
50 Hz ou ± 6 % en 50 Hz or ± 6 % in
60 Hz de la tension 60 Hz of the rated
nominale. voltage.

b) Pompe obstruée par b) Faire démonter la b) Pump obstructed by b) Dismantle the pump
des corps étrangers. pompe et nettoyer. foreign matters and clean it.

c) Température c) Le moteur est prévu c) Ambient temperature c) The motor is aimed

ambiante supérieure pour fonctionner à above + 40°C at operating at a
à + 40°C. une température maximum ambient
ambiante maxi de + temperature of
40°C. + 40°C.

d) Erreur de couplage d) Se conformer à la d) Coupling failure in d) Be in conformity with

dans la boîte à plaque moteur et à la the terminal box the motor plate and
bornes. figure 4. see figure 4.

4) La pompe ne donne pas une pression 4) The pump delivers insufficient pressure
suffisante
a) Le moteur ne tourne a) Faire démonter la a) The motor fails to run a) Dismantle the pump
pas à sa vitesse pompe et remédier à at its normal speed and solve the defect.
normale (corps l'anomalie. (foreign matters...).
étrangers...).

b) Le moteur est b) Le remplacer. b) The motor is b) Replace the motor.

défectueux. defective.

c) Mauvais remplissage c) Ouvrir le purgeur de c) Bad filling of the c) Open the bleeding
de la pompe. la pompe et purger pump. device and drain until
jusqu'à complète there are no more air
disparition des bulles bubbles.
d'air.

d) Le moteur tourne à d) Inverser le sens de d) The motor turns in d) Reverse the sense of
l'envers. rotation en croisant the wrong way. rotation by
deux fils de phase au interchanging the two
bornier du moteur. phase wires on the
motor terminal box.

e) Le bouchon de e) Le contrôler et le e) The drain-priming e) Check it and screw it

vidange-amorçage revisser. plug is not correctly again.
n'est pas vissé à tightened.
fond.

f) Le moteur est f) Contrôler la tension f) The supply voltage of f) Check the voltage on
alimenté à une aux bornes du the motor is too low. the terminals of the
tension insuffisante. moteur et la bonne motor and the cross-
section des section of the
conducteurs ainsi conductors.
que le couplage.
 N° 4 033 725
Ed. 07 - Page 16/19

5) Le disjoncteur se déclenche 5) The circuit-breaker device is on.

a) Le réglage du relais a) Contrôler l'intensité à
thermique est l'aide d'un
incorrect (valeur trop ampèremètre ou
faible). afficher la valeur de
l'intensité inscrite sur
la plaque moteur.
a) The setting of the a) Check the current
thermal relay is not with an ammeter or
adequate (too low). set the value of the
current rating on the
motor data plate.

b) La tension est trop b) Vérifier la bonne b) The voltage is too b) Check the adequate
faible. section des low. cross-section of the
conducteurs du câble conductors of the
électrique. electrical cable.

c) Une phase est c) Le vérifier et changer c) A phase is cut. c) Check it and change
coupée. le câble électrique si the electrical cable if
nécessaire. necessary.

d) Le relais thermique d) Le remplacer. d) The thermal relay of d) Replace it.

du disjoncteur est the circuit-breaker is
défectueux. defective.

f) Un fusible a sauté. e) Le remplacer. e) A fuse is off. e) Replace it.

6) Le débit n'est pas régulier 6) The flow is irregular

a) La hauteur a) Revoir les conditions
d'aspiration (HA) d'installation et les
n'est pas respectée. recommandations
décrites dans ce
manuel.
a) The suction head a) Study again the
(HA) is not adequate. installation conditions
and the
recommendations
described in this
instruction.

b) La tuyauterie b) La tuyauterie b) The suction pipe has b) The suction pipe

d'aspiration est d'un d'aspiration doit être a lower diameter than must have the same
diamètre inférieur à de même diamètre the one of the pump diameter as the
celui de la pompe. que l'orifice suction pump port.
d'aspiration pompe.

c) La crépine et la c) Démonter et c) The strainer and the c) Remove and clean.

tuyauterie nettoyer. suction pipe are
d'aspiration sont partially obstructed.
partiellement
obstruées.

Si le liquide est toxique, corrosif If the liquid is toxic, corrosive or

ou dangereux pour l'homme en
informer impérativement
SALMSON ou le réparateur
agréé. Dans ce cas, nettoyer la
pompe de manière à assurer une
totale sécurité au réparateur.
dangerous for human being,
WILO must be informed or the
qualified person in charge of the
repairing. In this case, clean the
pump to ensure a complete
safety for the repairing man.

9 - MAINTENANCE - ENTRETIEN 9 - MAINTENANCE - SERVICING

Attention à ne pas mélanger plusieurs pièces. Pay attention not to mix parts.
Mettre HORS TENSION la pompe. SWITCH OFF the pump.
 N° 4 033 725
Ed. 07 - Page 17/19

Pour toute intervention sur la pompe, se Before any operation on the pump, please
reporter aux notices de montage / démontage refer to technical leaflets:
: - n° 4051293 for MVI 16/32/52
- n° 4047569 pour les Multi-V 18/36/60 - n° 4084155 for MVI 70/95.
- n° 4084157 pour Multi-V 80/100.

Fichier Fichier
NDR_salmson.jpg NDR_vierge.jpg

Fig 1

Fichier Fig_1.jpg
 N° 4 033 725
Ed. 07 - Page 18/19

Fig 2

Fichier Fig_2.jpg

Fig 3

Fichier Fig_3.jpg

Type 50Hz 60Hz N PN L P X Y E

poles mm mm mm mm mm
Multi-V 18 02
08 02
06 2 16 252 194 215 130 20
MVI 16 02
14 02
10 2 25 252 194 215 130 20
09
16 07
14 4 16 252 194 215 130 20
Multi-V 36 02
07 02
05 2 16 235 235 195 195 35
MVI 32 02
13 02
09 2 25 260 260 220 220 35
07
16 06
16 4 16 235 235 195 195 35
Multi-V 60 02
07 02
05 2 16 260 260 220 220 30
MVI 52 02
12 02
08 2 25 260 260 220 220 30
05
12 04
12 4 16 260 260 220 220 30
Multi-V 80 01
05 01
04 2 16 350 261 280 199 45
MVI 70 01
07 01
05 2 25 350 261 280 199 45
Multi-V 100 01
04 01
03 2 16 350 261 280 199 45
MVI 95 01
05 01
03 2 25 350 261 280 199 45
 N° 4 033 725
Ed. 07 - Page 19/19

Fig 4

Fichier Fig_4.jpg

Fig 5

Fichier Fig_5.jpg
 WILO PUMP MOTOR
ELECTRICAL CONNECTIONS
 WILO PUMP MOTOR ELECTRICAL CONNECTIONS
(BELOW 4 KW)
• Always use D.O.L. Starter of same power rating as
of motor.
• Before connecting the supply cable to motor check
insulation resistance with 500 Volts megger.
(Between Phase & Body of the motor).
• For 3 phase 415V, 50 Hz. Supply, motor terminal
connections shall be always star connected.(Link
shall be connected between U2,V2 & W2. Supply
wires shall be connected to U1, V1 & W1).
• Set overload relay in DOL starter at full load current
of motor (given on name plate of motor).
• Decouple the pump & take no load trial of motor to
check direction of rotation. If the direction of
rotation is not as marked on Pump, change the
direction by interchanging the two phase wires of
cable at motor end.
√ X
• If the direction of rotation is correct stop the motor,
couple the pump & take load trial of pump.
• Always use independent starters & ammeters for
each pump.

(ABOVE 4 KW MOTOR)

• Select the starter (DOL or Star Delta) as per

operation requirement.
• In case the starter is DOL .For Three phase
415V,50 Hz. Supply always connect motor
terminal connections in delta.(Link shall be
connected as per drawing no1).
• If the starter is of Star delta type remove all the
three links in motor terminal box & connect all the
six wires in star delta starter.
• Before connecting the supply cable to motor check
insulation resistance with 500 Volts
megger.(Between Phase & Body of the motor).
DOL STAR-DELTA
• Set overload relay in starter at full load current of
motor (given on name plate of motor).
• Decouple the pump & take no load trial of motor to
check direction of rotation. If the direction of
rotation is not as marked on Pump.
• In case of DOL starter Change the direction by
interchanging the two phase wires of cable at motor
end. And in case of star delta starter change the
direction of motor by interchanging two phase wires
at incoming cable of star delta starter.
• If the direction of rotation is correct stop the motor
,couple the pump & take load trial of pump.
Always use independent starters & ammeters for each
pump.
OPERATION GUIDELINES FOR
THE MAIN PUMPS
 MATHER & PLATT PUMPS LTD
Operation Guidelines for The Main Pumps

• Make sure that the suction valve is fully open.

• Prime the suction lines & Pumps through the Air Vent Plug. Ensure all the
air is removed from the Pump.
• Check the Wet Well Level & ensure that sufficient Water Level is available
for the operation of the Pumps.
• Check that all the Air Release Valves are open at the Delivery side.
• Ensure that Bearings are greased properly as per standards.
• Check the Free rotation of all the Pumps before operating.
• Do not run the Pumps Dry.
• Ensure that all the Control Systems, Signal Systems, Alarm Systems, Relay
Settings & Interlock Systems are functioning properly.
• Ensure Stuffing Box Sealing Water Connections are proper & open.
• Ensure that the Delivery side Valve is open.
• Ensure the Direction of rotation is proper & motor acquires the rated rpm.
• Ensure that the Non Return Valve is opened after achieving the proper
delivery pressure.
• Ensure the NRV is fully opened to open the delivery valves 100%.
• Ensure the Temperatures of the Bearings of Pump & Motor units are within
limit.
• Ensure the Stuffing Boxes are not overheating.
• Ensure that the Vibration & Noise levels are within specified limits.
• Press the “Stop” button for stopping the Pump.
• Ensure the NRV is closing properly when the pump is stopping.
• In event of any Malfunction press the “Emergency Stop” button to isolate
the unit.
PRECOMMISSIONING CHECKS
FOR PUMP SETS
 PRECOMMISSIONING CHECKS FOR PUMP SETS

Pump Sr. No: Pump Type:

SR INSTRUMENT ACCEPTABLE
ACTIVITIES REMARKS
NO USED LIMIT
1 Check any pipe stress on pump
Flushing of pipe lines and ensure no
2
leakages
Availability of sufficient liquid in sump /
3 suction as per specifications.

Installation of all instruments

A) suction and delivery pressure gauges

4 B) pressure switches
C) temperature gauges
D) any other as supplied / specified

Operation of suction, delivery and inline

5
valves
Proper supports for piping and other
6
allied equipments.
Free rotation of pump and drive shafts
7

Checking of insulation resistance

8

Proper cable termination (client’s scope)

9

Motor protection relay settings (check

10
with client)
Check all interlocks as specified /
11
provided
Coupling of pump and drive and free
12
rotation of shafts in coupled condition
Suction valve is fully opened
13

Pump is fully primed and all air is vented

14 delivery valve is closed (if required)

Emergency shut down is possible.

15
FAULT FINDING CHART
 FAULT FINDING CHART
Symptom
Pump does not deliver water.
Insufficient capacity delivered.
Insufficient pressure developed.
Pump loses prime after starting.
Pump requires excessive power.
Pump vibrates or it is noisy.
Bearings have short life.
Pump overheats and seizes.
Suction troubles
1. Pump not primed.
2. Pump or suction pipe not completely
filled with liquid.
3. Suction lift too high.
4. Insufficient margin between pressure
and vapour pressure.
5. Excessive amount of air or in liquid.
6. Air pocket in suction line.
7. Air leaks into suction line.
8.
9. Foot valve too small or leaking.
10. Foot valve partially clogged.
11. Inlet of suction pipe not sufficiently
submerged.
12. Water seal pipe clogged.
13.
14. Speed too low.
15. Speed too high.
16. Direction of rotating wrong.
17.Total head of system higher
than design head of pump.
18.Total head of system lower
than pump design head.
19.Specific gravity of liquid
different from design.
20. Viscosity of liquid different from
design.
21. Operation at very low capacity.
22. Parallel operation of pumps unsuitable for
such operation.
Possible cause of trouble and remedies
(each number is defined in the list below)
1,2,3,4,6,11,14,16,17,22,23
2,3,4,5,6,7,9,10,11,14,17,20,22,23,30,31
5,14,16,17,20,22,30,31
2,3,5,6,7,11,12
15,16,17,18,19,20,23,26,27
2,3,4,9,10,11,21, 23,25,26,27,28,30,41,45,46,47
26,27,28,41,46,47
1,4,21,22,,27,28,41
Remedies
Ensure that casing fully filled and water comes
out from air cock.
Check leaking foot valve in case of negative suction.
Reduce by lowering pump elevation or increase water level.
Check that NPSH available is at least 1 meter suction more
than NPSH required.
Check the reasons and eliminate. Gas entrapped gas in liquid.
Air may be passing through suction joints.
Ensure pipe fully filled, no concentric bend for
Negative suction.
Tighten pipe joints with solution.
Replace / Attend.
Clean.
Ensure adequate submergence that foot valve is. not
exposed.
Clean or change.
Check motor RPM, supply frequency Motor nameplate, speed
should be as specified on pump nameplate.
Check motor RPM, supply frequency.
Check correct direction of rotation for motor before coupling to
motor.
Check the causes and refer to M&P. Measure with pressure
gauge.
Check the causes and refer to M&P. Measure with pressure
gauge.
Refer to M&P.
Refer to M&P.
Check the causes and refer to M&P, Operate
pump at rated duty.
Refer to M&P with characteristics curves of pump.
 Mechanical troubles Remedies

23. Foreign matter in impeller. Open and clean.

25.Foundations not rigid Check vibration on Baseframe, check hollowness
26.Shaft bent Dismantle and check, Replace shaft
27.Rotating part rubbing on Incorrect assembly, correct assembly
stationary part
28.Bearing worn Shaft run out, replace if required

30.Impeller damaged Replace

31.Casing gasket defective, Replace
permitting internal leakage
32.Shaft or shaft bushes worn Replace
or scored at packing
41. Excessive thrust caused by mechanical Check pump operation and assembly
failure inside pump or by failure of
hydraulic balancing device.
45.Dirt in bearings Investigate the cause and clean bearing
46.Rusting of bearings from water in housing Arrest water ingress
47.Excessive cooling of water- cooled Reduce cooling water flow
bearing, resulting in condensation of
atmospheric moisture in bearing housing
MVI COMPONENT PHOTOS
 MVI COMPONENTS PHOTO
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

1 MACHINING BASE

2
PUMP CASING

3
PUMP SHAFT

4
LINER TUBE

PAGE 1 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

5
O RING FOR LINER TUBE

6
FILLING PLUG

7
O RING FOR FILLING PLUG

8
O RING DRAIN & PRIMING PLUG

PAGE 2 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

9
O RING DRAIN & PRIMING PLUG

10
DRAIN & PRIMING PLUG

11
STATIONARY RING HOLDER

12
STAGE CASING W/O R.G.V

PAGE 3 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

13
TIE BOLT

14
NUT BOLT

14
1/2 STOP RUSH

15
THRUST RING IMPELLER

PAGE 4 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

16
CENTERING END STAGE WITH R.G.V

17
IMPELLER SPACER

18
IMPELLER

19
STAGE CASING WITH R.G.V

PAGE 5 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

20
SHAFT SLEEVE SPACER

21
SHAFT SLEEVE

22 STAGE CASING WITH R.G.V &

INTERMEDIAT BEARING

23
SHAFT END WASHER

PAGE 6 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

24
LOCK WASHER M8

25

INFERIOR SCREW

Please tight with L-Key 5mm

4220 4240

26 MECHANICAL SEAL

27
MACHINING LANTERN

PAGE 7 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

28
LOCK WASHER

30
O RING FOR BALL BEARING

31
MACHINING COUPLING

32
CIRCLIP FOR BALL BEARING

PAGE 8 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

33 FLAT WASHER

34

SUPERIOR SCREW

35

LOCK WASHER

COUPLING SCREW
36

PAGE 9 OF 10
SR.NO PHOTO COMPONENTS DESCRIPTION / REF. NO.

37
MOTOR FIXING SCREW

38 THREE PHASE MOTOR

39 COUPLING GUARD

40 CLIP FOR COUPLING GUARD

PAGE 10 OF 10
WATER LEVEL
CONTROLLER
(MALHOTRA MAKE)
 Installation, Operating and Maintenance of Air Break
Vertical Controls for Industrial Steam Boilers
1 9
1. Top Cover
10
2 11
2. Switch Box
3. Lower Cover
3
12 4. Top Flange
4 5. Float Chamber
13
6. Steam Side Flange
14 7. Water Side Flange
6
8. Reducer
5 9. S. S. Pipe
10. Magnet Of Float Rod
15 11. Air Break Switch
7 12. Spacer Pipe
13. Stopper Nut
14. Float Rod
8 15. S. S. Float

Introduction
Magnetically - operated controls of the vertical type in float chambers for external mounting on steam boilers and
pressure vessels, are designed to meet all requirements for automatic on/off control of boiler feed pump, burner cut-out
or lock-out high and / or low level alarm or a combination of these.
Operation
A primary permanent magnet attached to the float rod slides vertically inside a non-magnetic stainless steel centre tube
and transmits the movement of the float to a secondary magnet in each switch unit, which are operated with a snap
action.
Switch Units
Electrical Characteristics
Single-pole double-throw operation capable of carrying the following currents :
AC (25 to 60 c.p.s.) Power Factor 1 to 0.4
4 A at 110 V 2 A at 250 V 1 A at 440 V
DC Inductive Loads —Time Constant L/R = 40 milisec. max.
0.25 A at 250 V 0.17 A at 110 V 0.17 A at 250 V

A four-way terminal block labelled A-A and B-B is provided for each switch unit. The A-A circuit makes on a rise of
water level and the B-B circuit makes on a fall of water level.
Switch mechanisms are interchangeable and may be fitted with any float chamber provided the control range does
not exceed the maximum for which the float chamber is designed.
Each switch unit has a nominal differential of 25 mm (1") If a differential greater than 25 mm is required for pump
control, two switch units must be used and a holding circuit arranged for the starter control circuit. Wider differential
may obtained by increasing the separation between the switches.
Adjustments
Any required adjustment to the operating level(s) of controls is made entirely within the switch head.
The switch units allow variable adjustment between the circlip stops on the support rods and are secured in position
by clamp screws.
To avoid two switches operating together, their centres must be at least 8 mm (5/16") apart.

Control Range
Switch should always remain between circlips. Control range is 6" (150 mm).
Important : Blow- Down the Air Break Vertical Control Twice daily.
Switches can be moved up & down and water level controlled in the boiler as desired.Adjustments

Any required adjustment to the operating level(s) of controls is made entirely within the switch head.

INSTALLATION
1. A horizontal raised band is provided externally on the float chambers
of all Air Break Vertical Controls. This raised band indicates the lowest
level at which the control can operate and the range of the control is
measured upwards from this band.

A A
IT IS IMPORTANT THAT AIR BREAK VERTICAL CONTROLS
OPERATE WITHIN THE VISUAL LIMITS OF THE GAUGE GLASS AT
ALL TIMES. B B

Control
2. The steam and water connections between the boiler and the float Range
chamber of the control must be independent of any other boiler mounting,
relatively short and free from sharp bends or packets. A A

If Boiler connecting Pads and valves have any obstruction , then the
B B
differential pressure is created which can effect the up and down
movements of float assembly, hence the working of Mobray.

It is Important that the controls should be mounted vertically, close to the

Boiler guage glasses and with the water leg as short as possible.

This will minimise any differences in water level between the guage glass and the control float chamber.

3. Steam and water stop valves must be provided so that the chamber can be isolated from the boiler for inspection
purposes. All mounting arrangements should include a blow-down valve provided at the lowest point in the water
connection.
Float and Float Rod Assembly
S
N 11 11. Magnet of Float Rod 13. Stopper Nut 15. S. S. Float

12. Spacer Pipe 14. Float Rod

14
L (See the table 1)
4 MM
12 Type Of Mobray Standard Length of Float
rod (L)
1. CC 216 mm side & side 310 mm
13 2. CC 295 mm side & side 395 mm
63mm 2. CC 300 mm side & side 400 mm
152mm

70.5mm 3. CC 370 mm side & bottom 365 mm

15 3. CC 400 mm side & side 500 mm
4. CC 450 mm side & side 550 mm

Note : Length of the Float Rod as well as weight of the Float and Rod assembly is set as such , when the pump
on/off Switch is fixed in the centre of the Control Box then Pump should starts from 1/2” ( 12.5 mm ) below the
centre of guage glass and stops 1/2” above the centre of guage glass.

If in case, the Pump On is desired from 60-65 % of Guage Glass , then the length of the Float Rod should be
shortened, accordingly.

Float Dimension :- (I) Outer Dia - 63 mm, (ii) Outer Dia of Welding Part - 70.5 mm
(iii) Length - 152 mm, (iv) Cap Internal Threading - 6 mm

Important : Blow- Down the Air Break Vertical Control Twice daily.
 SIDE AND SIDE ENTRY CHAMBER ON STEAM DRUM

1. Pump should start from 1/2” ( 12.5 mm ) below the centre of

guage glass and stops 1/2” above the centre of guage glass
Each switch unit has a nominal differential of 25 mm (1") If a
differential greater than 25 mm is required for pump control,
High Level Alarm

two switch units must be used and a holding circuit arranged Pump Off N W L
Pump On

for the starter control circuit. Wider differential may obtained Low Level Alarm

by increasing the separation between the switches.

To avoid two switches operating together , their centres must be
at least 8 mm (5/16”) apart.

2 Low Level Alarm switch should be set 1.1/2” ( 28 mm ) below the Pump on/off switch.

3. High Level Alarm switch ( If provided ) should be set 1.1/2” ( 28 mm ) above the Pump on/off switch.

Electrical Wiring diagram

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
A A
Starter OFF ON
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch
A

Pump Motor A Relay

B
R1
B
Pump
Diagram Shows Starter Fitted With 250 V Coil Stop A A

Switch B B

B
Pump
N R B Y Start A A Live Supply From
N/V Coil Auxiliary B B 2 A Fuse
Contacts
Switch Pump Starter
To Pump
On Starter Motor Starter
2 A Fuse

A
Two Switch Pump Control Circuit Using
A
Holding Relay For Starters Without Auxiliary Contacts
B
Pump
B
Motor
A A
Starter OFF ON
B B
Auto Pump On/Off
( 1” Differential )
A

B
Pump Motor
B

A A
B B

Two Switch Pump Control Circuit Using

Auxiliary Contacts On Starter

Important : Blow- Down the Air Break Vertical Control Twice daily.
 Applications
One Switch Operation
N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Pump
B
Motor
A A
Starter OFF ON
B B
Auto Pump On/Off
( 1” Differential )
Pump
Start/Stop
Switch

Pump Motor

Two Switch Operation

N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

Upper Switch
A

A
Solenoid
B
Pump 2A Fuse Valve
A

{
B
Motor X P Low In Oil
A A
Starter OFF ON A Level Fired
B B N Trip Boilers
B
Auto Pump On/Off P
( 1” Differential ) B 2A Fuse
Pump Low Level
Start/Stop Alarm
Switch A A N
B B Hooter
Pump Motor
Lower Switch

Three Switch Operation- I

A
P High
A Hooter
Level
B 2A Fuse Alarm N R B Y
N N/V Coil Auxiliary
Contacts
B On Starter
2 A Fuse

A A A
B B A

B
Pump
B
Motor
A A
Starter OFF ON
Upper Switch B B

Auto Pump On/Off

Solenoid Pump ( 1” Differential )
2A Fuse Valve Start/Stop
A

{
X P Low In Oil Switch
A Level Fired
N Trip Boilers Pump Motor
B
2A Fuse
P
B
Low Level Middle Switch
Alarm
A A N
B B Hooter

Lower Switch

Please note, in certain wiring portion it is mentioned P ( Phase ) and N ( Neutral ) for the circuit
operating at 220 V ac , incase it is working on 440 Vac P and N can be replaced by R B , R Y. , B Y .

Important : Blow- Down the Air Break Vertical Control Twice daily.
 Applications
Three Switch Operation - II
N/V Coil N R B Y
Auxiliary
Contacts
On Starter
2 A Fuse

B
Upper Switch

Pump
B
Motor
Starter
A A OFF ON Auto Pump On / Off
B B
(1"-4" Differential)
Solenoid
2A Fuse Valve
A A
A

B
Pump Motor A

B
X P
N
Low
Level
Trip
{ In Oil
Fired
Boilers

A A
2A Fuse
P
B B
B
Low Level
Alarm
A A N
B B Hooter
Middle Switch

Lower Switch

Four Switch Operation

A
P High N/V Coil N R B Y
A Hooter Auxiliary
Contacts
Level On Starter
2 A Fuse
B 2A Fuse Alarm
N A

B A

B
Pump
B
A A Motor
Starter
B B
A A OFF ON Auto Pump On / Off
B B
(1"-4" Differential)

Upper Switch A

B
Pump Motor
B

A A
B B

Middle Switch

Solenoid
2A Fuse Valve
A

B
X P
N
Low
Level
Trip
{ In Oil
Fired
Boilers

2A Fuse
P
B
Low Level
Alarm
A A N
B B Hooter

Lower Switch

Please note, in certain wiring portion it is mentioned P ( Phase ) and N ( Neutral ) for the circuit
operating at 220 V ac , incase it is working on 440 Vac P and N can be replaced by R B , R Y. , B Y .

Important : Blow- Down the Air Break Vertical Control Twice daily.
 SAFETY AND PRECAUTIONS
It is Important that the controls should be mounted vertically, close to the Boiler gauge glasses and with the water
leg as short as possible.

Switches must not be used for the direct starting of motors. Contacts should be wired in series with the operating
coils of relays, contactor starters or solenoid valves, and fused separately.

The temperature of the switch head may at times approach the temperature of the boiler and suitable heat resisting
cables should therefore be used.

Switches must be positioned with centres not less than 8 mm (5/16") apart to avoid simultaneous operation.
Switches should always remains between circlips.

The A-A circuit makes on a rise of water level and the B-B circuit makes on a fall of water level.

A horizontal raised band indicates the lowest level at which the control can operate and the range
of the control is measured upward from the band.

IT IS IMPORTANT THAT AIR BREAK VERTICAL CONTROLS OPERATE WITHIN THE VISUAL
LIMITS OF THE GAUGE GLASS AT ALL TIMES.

Steam and water stop valves must be provided so that the chamber can be isolated from the boiler for
inspection purposes. All mounting arrangements should include a blow-down valve provided at the
lowest point in the water connection.

Important: Blow- Down the Air Break Vertical Control Twice in 8 hour shift.

Advantage of Blow Down

By blow-downing first, comes the hot water followed by steam, this way float and rod assembly would come down, thereby
tripping the lower switch stopping the firing and sounding the alarm. And as the blow-down valve is closed the lower part of
float chamber got waterlogged and there by pushing the float and rod assembly upward by buoyancy force which results in
toggle of lower switch, stopping the low level alarm and commencing the firing.

By blow-downing the mobray firstly all the switches got tested automatically and secondly it cleans the float chamber from
sediments in the boiler water, thereby ensuring the smooth movement of float and rod assembly.

Boiler must be operated by Competent Certified Boiler Attendant at all times.

Any change in operating level from the set position may be indicative either of blocked connections
to the float chamber, a waterlogged float or a loose switch unit and should be investigated immediately.

It is advisable to periodically check the electrical wiring, positions of switches and external valves of air break vertical control,
condition and any deposits on float and float rod with magnet.

Warning:- Any unauthorised interference or modification to the mechanisms of these machines can be detrimental to their
correct operation.
Trouble Shooting
1. Mobray not maintaining level.
Move the pump control switch up and down to achieve the required level.
2. Pump is running and filling water in the boiler , but not stopping.
A. Check the SS Float
i If puncture, replace the same with a new one.
ii Strucking in the float chamber
Isolate the Mobray open the top flange, clean the chamber and fit it again.
B. Check the Float Rod
If bend either make it straight or replace the same
C. Check the Top flange SS Pipe , it should be perpendicular with the flange.
If tilting on one side, either get it set on lathe machine or send it to our works.
D. Check the Spacer Pipe.
If missing
Put it in the float rod above the brass Stopper Nut.
E. Check the water side valve , If closed , open it.
Important : Blow- Down the Air Break Vertical Control Twice daily.
3. Pump is not filling water in the boiler.
A. Check electrical connections of mobray and pump motor
B. Check the pump control Air Break Switch.
If faulty replace the same with a new one.
C. Check the pump Motor.
D. Check the water and steam connecting valves.
If closed , open it.
E. Check the water in the feeding Tank.
4. Mobray maintaining level out side the visible range of gauge glass
A. Check the Padding of Mobray , it should coincide with the Padding of gauge Glass.
i. If maintaining level outside the upper limit of Gauge Glass
Shorten the length of float rod, accordingly.
ii. If maintaining level outside the lower limit of Gauge Glass
Increase the length of float rod, accordingly.
B. Check the obstruction in the water and steam side mounting of the boiler connecting mobray.
5. Float rod is climbing upward , but not coming down.
A. Check the Steam connecting valve
If closed, open it.
6. Low Level Alarm not working.
A. Check the alarm unit ( Hooter ) and its electrical wiring.
B. Check the Lower Air Break Switch BB point and its continuity by Multimeter.
If the continuity shows its open , replace the same with a new switch.
If
SS Float Puncture -i Pump is running & filling water in the boiler, but not stopping.
ii Low Level Alarm would sound.
Float Rod having Bend - Float with Rod assembly cannot move up and down.
Mobray is not fitted Vertical - Float with Rod assembly cannot move up and down.
Top SS Tube has a Bend - Float with Rod assembly cannot move up and down.
Steam side connecting Padding/Valve has an obstruction - Pump will not start even after water level in the
Guage glass goes down because of partial vaccum in the float chamber.
Water side connecting Padding/Valve has an obstruction - Pump is running but not stopping even after water
level in the Guage glass goes up because float chamber does not have sufficient water.
Float Rod Magnet Polarity is Reverse - all operation related to switches get reversed.
Float Rod Magnet Strength goes down - Air Break Switch will not actuate on passing of primary Magnet of Float Rod.
Mobray fitted with shorter length of Float rod than standard length-
Mobray will maintain the water level and low level alarm out side the upper range of guage glass.
Mobray fitted with larger length of Float rod than standard length-
Mobray will maintain the water level and low level alarm out side the lower range of guage glass.
To test pump control switch
Under normal operating conditions:
(A) Allow the water level to rise until the ‘Pump Cut-out’ level is reached.
At this point the pump should stop.
(B) Allow the water level to fall until the ‘Pump Cut-in’ level is reached.
At this point the pump should start.

To test low water alarm and cut-out switch.

Shut off the feed water to the boiler, either by closing down the feed pump or in certain cases closing the feed valve.

WITH A COMPETENT ATTENDANTS STANDING BY, allow the water level to fall by evaporation until the low alarm
level is reached. At this point the machine should operate the low alarm and the firing apparatus should cease to
operate. With the feed pump under hand control, restore the feed water to the boiler. Upon a short rise in water level
the low alarm should re-set and the firing apparatus should commence to operate. Restore normal feed water control
to the boiler. Any change in operating level from these set position may be indicative either of blocked connections to
the float chamber, a waterlogged float or a loose switch until and should be investigated immediately.
Important : Blow- Down the Air Break Vertical Control Twice daily.
 S

SPARES N

Top Control Box Air Break Switch Float Rod Assembly

TYPICAL MOUNTING ARRANGEMENTS OF

AIR BREAK VERTICAL CONTROLS ON VARIOUS TYPES OF BOILER

N W L N W L

SIDE AND BOTTOM ENTRY

SIDE AND SIDE ENTRY
CHAMBER WITH SEQUENCING
BLOW - DOWN VALVE CONTINENTAL CHAMBER

N W L

SIDE AND BOTTOM ENTRY

CHAMBER WITH SEQUENCING SIDE AND SIDE ENTRY
BLOW - DOWN VALVE ON
CHAMBER ON STEAM DRUM
VERTICAL BOILER
OF WATER TUBE BOILER

Malhotra Bros & Co.

Works : B-21, DSIDC Engg. Complex
Mangolpuri Indl. Area, Phase-I
New Delhi - 110083
Ph. : Office : 42133632, 25461405 Works : 27914009
Tel. / Fax : 42133632 Mobile : 098100 52558
E-mail : mobray@vsnl.com, mobrays@gmail.com
Important : Blow- Down the Air Break Vertical Control Twice daily.
BLOWDOWN VALVE
(LEVCON MAKE)
 MANUAL
FOR

INSTALLATION, OPERATION & MAINTENANCE

OF
PARALLEL SLIDE BLOW DOWN VALVE

GENERAL

All Industries use different types of valves for controlling flow of fluids through the pipeline.
Different types of valves are available for different applications and end-use. Selection of valves
should be done depending on the actual service condition, i.e., type of medium, operating
pressure and temperature, etc. Valves, although considered hardware items, are extremely
important because mal-functioning of valves may cause serious disruption of production and even
result in costly shutdown. Hence it is very important to properly install, operate and maintain
valves to ensure long trouble –free service.

CARE BEFORE INSTALLATION

Valves are generally protected from damage during dispatch from Factory. This protection should
be left in place until the valve is to be installed. If the valves are left exposed, sand and other
gravity materials may get into the working parts. Unless all such foreign material is thoroughly
cleaned out, it may cause trouble when the valve has been places in service.

Valves should be stored where they are protected from corrosive fumes, and in such a manner
that they will not fall or where other heavy material will not fall on to the valves.

Prior to installation it is advisable to have all valves either blown out with cleaned compressed air
or flushed out with water to remove all dirt and grit. Piping should be cleaned out in the same
manner, or swabbed out to remove dirt or metal chips left from threading operations or welding on
the pipe. All joint bolts are to be tightened before installation.

INSTALLATION

When installing valves, make sure that all pipe stains are kept off the valves. The valves should
not carry the weight of the line. Distortion from this cause results inefficient operation, jamming,
and necessity of early maintenance. It will be difficult to tighten the end flanges of the valves.
Piping should be supported by hangers placed on either side of the valves to take up the weight.
Large heavy valves should be supported independently of the piping system so as not to induce
stress into the piping system. Flange bolts of the end flanges are to be tightened by pulling down
the nuts diametrically opposite to each other. All bolts should be pulled down gradually to uniform
tightness. Make all bolts finger tight first, and then take 3 or 4 turns with a wrench.

Apply the same number of turns, on each bolt, following the order. Repeat the procedure as many
times as required until the joint is tight. Uniform stress across the entire cross section of the
flange eliminates a leaky gasket.

OPERATION

Valves should only be used in services where they can always be either fully opened or fully
closed. The bottom of the Parallel Discs and Seat will erode very rapidly if Discs are left in
intermediate position. In addition, the Discs will tend to chatter and cause noise in the line.
 (2)

Valves should be opened slowly to prevent shock in the line. Closing the valve slowly will help to
flush trapped sediment and dirt, if any. When the valve has been fully opened, rotate the spindle
by operating wrench (or Key) one turn towards the closed position so as not to leave the spindle
jammed in the open position.

MAINTENANCE

Periodical examination should be made for possible leakage from the cover Joint and Gland; after
the valve has been in service for a short time follow up gland nuts if necessary. DO NOT ALLOW
GALANDS TO LEAK. Packing leaks should be corrected immediately by tightening the gland,
which compress the packing. If left unattended long enough, corrosive fluids will ruin the stem. In
addition, a leaking spindle can lead the valve to chatter in which the vibration will damage the
working parts of the valve. If it is apparent that Gland has been compressed the packing to its
limit, replacement with new packing is necessary.

Before replacing gland, make sure that there is no steam pressure in the system. The repacking
is done as follows:
a) Release gland nuts and lift gland clear of stuffing box. Remove old packing, especially
from the sides of the stuffing box and spindle.
b) Repack with fresh gland packing. See that each coil of packing is packed down before
inserting the next coil.
c) Replace gland and gland nuts make certain that the gland is correctly positioned with
lettering on the lock guard.
d) Tighten the gland nut alternatively and evenly and follow up periodically as occasion
demands.

Lubrication of the valves is especially important and should be done on an established schedule.
Valves, which are opened and closed frequently, should be lubricated at least once in a month.
Threads of spindle rack and pinion are lubricated by opening the cover. The threads left dry and
unprotected will become worn by grit and other abrasives, threatening stem failure.

For inspection and repair for maintenance, dismantling of valve is done as follows: -

a) Release cover bolts and left off cover complete with top gear. Clean Disc and Seat faces
by rubbing the surfaces with fine carborandum paper (grade 400C). Slightly pitted or
scored surfaces may be reconditioned by lapping, badly damaged surfaces should be
replaced by grinding or very fine machining followed by lapping or by replacing the parts.

b) When it is required to remove the spindle rack pinion, release the gland and back cover
nuts and remove the gland and back cover. The Pinion Spindle can now be withdrawn
through the back cover port and pinion rack through the bass of the cover.

c) When reseating the valve, be sure to mark the discs so that the disc is inserted in the
valve body the same way it was removed. Otherwise light closure may not be obtained.

The refacing of seats can be done by lapping the seats in the body with the help of Lapping Tool.
Thoroughly clean the seats and lap faces with coarse compound, e.g., Powder Alokite (grit 60) by
applying a thin layer of the same and rubbing the seat faces gently with the Lapping Tool. The
Tool is to be operated slowly with reciprocating motion through a small angle exerting only light
pressure on the handle, occasionally changing the position of the Tool. Continue lapping until a
good joint face is obtained. If the faces cannot be restored by lapping, mount complete body in a
lathe and check with a dial indicator to see that the seat is running perfectly true, Grind off just
sufficient metal to obtain smooth clean face. Finally lap as stated above.
 (3)

If Disc faces are slightly pitted or scored, take out the discs and renew by lapping on a flat lapping
block in the following manner, after making sure that the joint face and surface of the lapping
block are perfectly clean: -
a) Firstly, lap with coarse compound, e.g., Powder Alokite (grit 60) by applying a thin layer
of the same to the joint face and rubbing the Disc gently over the lapping block.
b) Finish lapping with a fine compound having a grain of about 280 e.g. Powder
Carborundum (grit F) or Paste Carborundum (Fine).
c) Finally, polish with a mixture of paraffin and oil to remove surplus compound.

If joint face of Disc is badly cut or scored, mount the Disc in a lathe using copper or any other
shaft material between chuck jaws and Disc. Check with a Dial indicator to see the face is running
true and grit off or fine machine just sufficient metal to obtain smooth clean face. Finally lap as
described above.

Re-assembly of the valve component parts is to be done as follows:-

a) Clean all parts thoroughly before replacing in the Body, especially joint faces, screw
threads and working surfaces.

b) The Discs should be moved freely together and small porthole in each Disc
Should be clear of obstruction.
c) Now cover joint gaskets should be fitted of a similar material and quality of the
old one unless alternative material is given.
d) Make certain that pinion and rack spindles engage correctly, pinion should be
replaced so that stop position is reached when rack is in the fully closed condition.
e) Tighten cover bolts evenly, i.e. after lightening first bolts follow up with bolt
diametrically opposite. Repeat with pair of bolt.

Before replacing the valve in line, it is advisable to test disc and seat faces for tightness by
hydraulic testing by gravity method or with the help of test pump. When testing by gravity press
the Top Disc downwards to allow water to pass in the remainder of the body. By hydraulic testing,
leakage through Disc and Seat faces is checked.
Levcon Valves Private
Limited
"RAJKAMAL", 6th Floor,13, Camac Street, Kolkata 700
017.
Phones : 033 2283 2766
Fax : 033 2283 2719; 2280 9645;
e-mail: levconh@vsnl.net
REFLEX LEVEL
GAUGE
(CHEMTROL MAKE)
 REFLEX LEVEL GAUGE

IIN
NSST
TRRU
UCCT
TIIO
ONNSS &
&MMA
AIIN
NTTA
AIIN
NAAN
NCCE
EMMA
ANNU
UAAL
L

IM/RLG-1/2003 – REV. 00

CHEMTROLS SAMIL (INDIA) PVT. LTD.

Amar Hill, Saki – Vihar Road,
Powai, Mumbai – 400 072
Tel : 91 – 22 – 2857 9993, 2857 9994
Fax : 91 – 22 – 2857 9995
E-mail : chesam@vol.net.in
Website : www.chemtrolssamil.com

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

INTRODUCTION: Chemtrols Samil reflex level gauges are widely used in

chemical, hydrocarbon and power generating plant, i.e. wherever visual inspection of
fluid is necessary. These gauges are simple, constructed to give you direct, clear
indication of liquid level. These gauges gives reliable and inexpensive indication of fluid
in tank or vessel. Auto shut off valves provided at the process connections added safety in
service. Fig.1 shows the typical assembly of reflex level gauge.
Reflex level gauge is designed to produce dark area for liquid and light area for
vapour space. The reflex type design is chosen for liquid, which is colourless, clean and
non-viscous.

FIG. 1 TYPICAL ASSEMBLY OF REFLEX LEVEL GAUGE

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

OPERATION

OPERATING PRINCIPLE: Reflex level gauge employ the principle of refractive

indices of the liquid and vapour. The glass which is clamped in level gauge have
prisamatic right angle grooves on the side facing of liquid or vapour as shown in fig. 2.
Light rays entering from outside the gauge are either absorbed or reflected depending
upon whether they enter the liquid or vapour space. If rays of light enters through the
grooves and then the liquid space, the rays get absorbed into the water as shown in
fig.2(a), therefore liquid space appears as dark space and when it enters the vapour space,
the rays get deflected as shown in fig. 2(b), and thus vapour space appears as silvery
white.

FIG. 2 OPERATING PRINCIPLE

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

CONSTRUCTION

CONSTRUCTION: Chemtrols reflex level gauges are made in four different

connections. Normally side/side, side/bottom, top/bottom and top/side to fit on the vessel
or tank for variety of applications and installation needs. The connection between gauge
and the vessel shall be threaded, socket welded or flanged. The major parts of the gauge
are as follows - Figure No.3

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

Ø Chamber

Ø Cover plates

Ø Toughened borosilicate reflex glass

Ø Precisely cut gasket and cushion

Ø Two auto-shut off ball check valve of straight or offset pattern, with corrosion
resistant ball checks, for automatic closure in the event of glass breakage.

Ø Union or nipple connection between gauges to valve

Ø Studs or “U” bolts, nuts and washers.

OPTIONS AND ACCESSORIES:

Ø Drain or vent valve, nipple or flange

Ø Anti frost extension for low temperature application.

Ø Internal heating arrangement

Ø External Heating arrangement

APPLICATION:

Ø For colorless, clean and non-viscous liquids.

Ø Pressure up to 220 Kg/cm2 and temperature up to 400 °C

Ø For saturated steam application up to a pressure of 35 Kg/cm2

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

STORAGE & HANDLING

After inspection and despatch, storage and handling plays vital role in the
operation of the level gauge.
While unpacking, check the units for any damage during shipment. Re port any
concealed damage to carrier within 24 hrs. Check the contents of packing list and
purchase order, note the serial number for future reference when ordering spare parts.

For proper functioning and long life of level gauges, the following guidelines
for storing level gauges should be adopted.

Ø Units must be handled with utmost care, so that no damage is caused to the fragile
glass, chamber and process connections.

Ø Units should be stored where they will be protected from the elements and
corrosive fumes and should be in a secure manner where they can neither fall nor
be struck by any other objects.

Ø The packing cases of level gauge must not be kept or stored in upright position to
avoid damage of glasses that can happen due to the accidental falling of the
packing cases.

Ø The packing cases must be protected from direct sunlight and water.

Ø While storing the packing cases, ensure that no heavy items are placed over it,
which may bend the chamber and damage the glass.

Ø Individual pieces should be kept properly or stored in a manner to avoid damage

while awaiting for installation.

Ø Never lift the gauges holding at valve or valve joints. This may lead to bending of
the valve stem or may damage the internal parts, which further may cause
malfunctioning of the gauge.

Ø Keep spare glasses in their boxes until needed for use and should be stored in a
secure manner to avoid bumping or sliding of polished surfaces across any other
object.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

INSTALLATION
GENERAL INSTRUCTIONS: After unpacking, the units shall be checked to ensure
that they contain no foreign matter and that the end connections, i.e. flanged, screwed or
plain end nipples are clean, undamaged and in line with the requirement.

The following instructions should be carefully studied before attempting to

install or operate the unit. This will also help in the event of servicing becomes
necessary.

Ø Avoid imposing piping strain on the gauge chamber, connect and mount the
gauge so that it does not support the piping.

Ø Examine the glass carefully for any indication of scratches or cloudiness. If any
type of surface flaw is apparent, the unit should not be installed until the glass has
been replaced.

Ø For heavy units prepare proper supports to ensure that pipeline stresses will not be
transmitted to the level gauges. Misalignment between adjacent connection should
be corrected rather than forcing a fit-up. Large, heavy units should be
independently supported to avoid stressing the piping. Keep suitable safe distance
for viewing and maintenance as well as keeping the unit so that damage cannot be
inflicted by traffic.

Ø Consideration should be given to location where the glass will not be subjected to
large temperature variation.

Ø Auto shut off valves are recommended between gauge and vessel, which allow
maintenance of the gauge without dismantling the gauge from the vessel.

Ø Be sure that shut off valves are mounted in exact alignment, a slight “off center”
position will strain glass and glass may get damaged.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

START UP

CAUTION : Reflex level gauge carry nameplate indicating process parameters. This
information is reviewed prior to installation and again prior to start up to ensure
proper operation of the unit.

CAUTION: Rapid opening of shut off valves can cause glass breakage, loss of
process.

Follow the guidelines prior to start-up,

Ø Keep the auto shut off valves and drain plug closed.

Ø Open the top auto shut off valve slowly to bring the vessel process parameter in
the gauge

Ø Then open the bottom shut off valve slowly, to prevent the back seating of the ball
checks and wait till unit get fully warmed up and pressure is equalised before
opening valves fully.

CAUTION: While the valves are in operation, they must be in the fully open
position. A partially closed valve will prevent automatic ball checks from seating,
which could result physical injury and loss of process.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

MAINTENANCE

ROUTINE MAINTENANCE : Periodic inspection and routine maintenance are

necessary means to keep product in good working condition and increasing the service
life of the product. Therefore, a systematic programmed should be implemented when
unit is placed into service.

When decided to carry out servicing of the gauge, ensure availability of the glasses,
gaskets, “U” bolts, nuts or unions for replacement.

Ø Periodic inspection of level gauges should be made to ensure that no leaks

through glass, gasket, no scratching and clouding of the glass.

Ø Keep glasses clean using commercial glass cleaners. Cleaning should bedone
without removing glass. Never use abrasives, wire brush or metal scrappers etc.
that could scratch the glass.

Ø To examine for scratches, shine a very bright concentrated light about 45°.

Ø If inner surface appears cloudy or roughened and will not respond to cleaning
procedure, this is evidence of chemical attack and glass needs replacement.

Ø Vibration sometimes may cause studs, nuts of level gauge get loosen, check the
cover plate studs and nuts for tightness.

Ø Once glass or gasket has been removed from it’s seating, regardless of the reason
for removal, discard it and substitute with new one. (Be sure that the replaced
glass is proper for service.)

Ø Should leakage around the glass occur, check the window, if it is not broken drop
the system pressure to zero and torque the glass cover plate to the proper value. If
the leakage persists after the repressurising, dismantle the unit according to the
section (disassembly), and replace the gasket.

NOTE: As a matter of good practice, spare glasses, gaskets a nd studs should be

kept, at all times.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

SERVICE INSTRUCTIONS
Ø When it has been determined that service is required on the level gauges,
nameplate information should compared with actual service condition.

Ø Confirm with the maintenance supervisor or engineer for availability of glass,

gasket, studs, nuts and washer for replacement.

Ø A clean area should be available for placing the unit and its parts, if it is removed
from the tank or vessel

DISASSEMBLY: The gauge would start leaking after prolonged usage. This is
because the gasket, cushion get hardened due to long contact with high temperature fluid
and loose its compressibility or worn out and cause leakage through glass seating surface.

CAUTION: Drop the system pressure to zero, before attempting to any service on
the level gauge and the fluid has been drained. Be certain that pressure cannot put
back into the line, while service is in progress. Failure to do this may result in a
sudden release of pressure or glass breakage and loss of process.

If leakage through glass seating surface occurs, the following steps should be taken-

Ø Unscrew the cover plate fasteners in a regular pattern to avoid uneven load or
stresses on the glass, which may cause cracking of the glass. Typical tightening
sequences are shown in fig.3 for proper torquing.

Ø Level gauge glasses, gaskets and cushions can be disassembled or reassembled in

their installed position

Ø Carefully remove the glass, gasket, cushion from their seating surface and keep
them on a clean surface.

Ø Blow off the unit with air after assembly for dirt, residue and foreign particles.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

SERVICE INSTRUCTION FOR AUTO SHUT OFF VALVE

(UNION BONNET)

NOTE : When valves are first placed in service. Slight leakage through stem
packing gland may occur. This is the result of small additional set taken by the stem
packing, when valves reach system temperature. If such leakage does develop it can
be easily stopped by tightening the packing nut as required. If leak persists after
tightening, dismantle the valve and replace the packing as instructed below -

TO REPLACE STEM PACKING -

CAUTION : The valves should not be dismantled, while the unit is in operation.

Ø Close the both top as well as bottom isolation valves and drain the fluid.

Ø Unscrew the gland nut from sleeve.

Ø Pull out the gland from the sleeve.

Ø Remove the old stem packing from its seating.

Ø Clean the packing seating surface for old fragments.

Ø Insert the new packing and put the gland and engage the gland nut with the sleeve
and tighten enough to stop the leakage.

TO REPLACE SEAT, UNION GASKET AND BODY GASKET.

CAUTION : Prior to disassembly of the gauge, ensure that the gauge is relieved
from all internal pressure, temperature is ambient and the fluid has been drained.

Ø Remove the gauge from the vessel and place on the clean surface.

Ø Remove the valve from the gauge, if it is provided with threaded nipple.

Ø Unscrew the handle nut and remove the handle.

Ø Remove the gland nut, gland and gland packing from sleeve.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

Ø Pull out the sleeve from the valve body.

Ø Disengage the stem from the sleeve.

Ø Remove the body gasket.

Ø Unscrew and remove the union nut, union, gasket and ball.

Ø Use angular punch and hammer the punch on the seat from bottom of the valve
body for removal of seat.

Ø Clean the seat, packing and gasket-seating surface thoroughly.

Ø Install new seat and ensure that the seat is properly seated.

Ø Engage the stem threads with the sleeve threads properly and Slide the body
gasket on the sleeve.

Ø Insert the sleeve into the valve body, taking care stem needle should not get
damaged.

Ø Engage the body nut and tighten enough to prevent leakage.

Ø Insert the new packing into the sleeve, install the gland and engage the gland nut.

Ø Place the handle on the stem and tighten the nut.

Ø Reinstall the ball, union and union nut with new union gasket.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

FIG. 4 TYPICAL ASSEMBLY OF UNION BONNET AUTO SHUT OFF BALL CHECK
VALVE

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

SERVICE INSTRUCTION FOR AUTO SHUT OFF VALVE

(BOLTED BONNET)

TO REPLACE STEM PACKING -

CAUTION: The valves should not be dismantled, while the unit is in operation.

Ø Close the both top as well as bottom isolation valves and drain the fluid.

Ø Remove the gland flange and gland from the bonnet.

Ø Remove the old stem packing from its seating.

Ø Clean the packing seating surface for old fragments.

Ø Insert the new packing and reinstall the gland and gland flange by tightening the
eyebolt nut enough to stop the leakage.

TO REPLACE SEAT, UNION GASKET AND BODY GASKET.

CAUTION: Prior to disassembly of the gauge, ensure that the gauge is relieved from
all internal pressure, temperature is ambient and the fluid has been drained.

Ø Remove the gauge from the vessel and place on the clean surface.

Ø Remove the valve from the gauge, if it is provided with threaded nipple.

Ø Unscrew the handle nut and remove thehandle.

Ø Unscrew the gland flange nut, take out the gland flange, gland and packing from
its seating.

Ø Remove the stem from the bonnet.

Ø Remove the body gasket.

Ø Unscrew and remove the union nut, union, gasket and ball.

Ø Use angular punch to remove the seat.

Ø Clean the seat, packing and gasket-seating surface thoroughly.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

Ø Apply light coat of lubricant on the valve body threading.

Ø Install new seat and ensure that the seat is properly seated.

Ø Engage the stem thread with the bonnet yoke thread properly.

Ø Place the bonnet on the valve body gasket, taking care stem needle should not
damage.

Ø Tighten the valve bonnet studs and nut.

Ø Place the handle on the stem and tighten the nut.

Ø Reinstall ball, union and union nut with new gasket.

FIG.5 TYPICAL ASSEMBLY OF BOLTED BONNET AUTO SHUT OFF BALL

CHECK VALVE

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

INSPECTION:
After disassembly inspect the unit for any damage.The glass seating surface in the body
or in the covers should be carefully cleaned or checked to insure that there are no pieces
of old gasket material, chips, residue, dirt or other foreign material on the surface. Other
foreign particles left on the surface could cause high local stresses in the glass and might
cause failure.

Due to uneven bolt or stud torquing, excess pressure or foreign particles on the glass-
seating surface, glass may get crack. So it is important to determine the cause for the need
for replacement. Simply putting new glass will not alleviate the cause for replacement.
Check your operating condition against the parameters on the nameplate. If there be any
dought about applicability of the unit for the service intended, do not proceed without
verifying the unit with maintenance engineer.

REASSEMBLY:

Ø Clean the glass-seating surface for any foreign particles or old gasket material
before reassembling the unit. The surfaces must be flat, smooth and completely
free of all fragments.

Ø Always assemble level gauges using new glass and gasket.

Ø Verify the glass and gaskets that were in the unit before reassembly.

Ø Check the new glass to insure that there are no bumps, chips, scratches or other
imperfections, and to be certain that the gaskets are clean.

Ø Use only gaskets, which are specified by the manufacturer or the supervising
engineer.

Ø After insuring that all glass and gasket-seating surface in the body and covers are
clean, assemble the glass and gasket into their seats. Be certain that the gaskets
are centered and are completely within the recessed surface.

Ø Care should be taken while placing the glass in he

t seat, so that the edge cannot be
chipped.

Ø Place the cushion gasket and covers on flat glass, again be sure that the glass and
gasket are completely seated in the recess.

Ø Bring the fasteners and cover plate to the fingure snug, and rotate in its seat,to be
certain that everything is seated properly. Ensure that glass should not come in

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

contact with any metal surface while in operation, temperature difference at points
of contacts will set up high stresses on the glass and may break the glass.

Ø Then insert the fasteners through the holes and tighten in the regular pattern to
avoid uneven load on the glass. Typical tightening sequence shown in fig no. 5
Torque individual fasteners in small amounts, moving to the next fastener after
each increment of torque.

NOTE: After reassembly please carry out the hydrostatic testing.

REMEMBER: Place the glass in such a way that grooves should come in contact
with the fluid.

REMEMBER: Proper torque as shown in fig. 6 in the sequence is important.

Improper torque may result the glass breakage, gasket rupture and leakage through
the gauge.

FIG. 6 TYPICAL TIGHTENING SEQUENCE

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 REFLEX LEVEL GAUGE

Do’s and Don’ts

Do’s

Ø If the system subjected to heat during operation, the system should be taken to
ambient temperature and pressure after few hours of operation and fasteners
should be re-torque to the proper value.

Ø Be sure that retainer is always on the unit, keeps the unit leak-proof. Should the
glass holder damage or misplaced order a replacement.

Ø Whenever required to be cleaned, the unit may be dismantled from the vessel.

Ø Keep glass clean using commercial glass cleaners such as soap or with soft cloths.

Ø Always use the new gaskets.

Ø Torque the gauge valve and cover plate fasteners after every few hours of
operation.

Don’ts
Ø Do not operate the level gauges under defective or misaligned condition.

Ø Do not attempt to tight any fasteners, while unit is in operation.

Ø Do not open cover plate, unless you’re sure that the process flow has been turned
off.

Ø Do not attempt to clean glass, while unit is in operation.

Ø Do not attempt to clean gasket seating surface using wire brush and metal
scrapper, which may cause failure of gasket and which may further cause leak
through gasket seating surface.

Ø Do not use chipped or scratched glasses.

Ø Do not make adjustments or replacements without reading instructions carefully.

IN THE SERVICE OF CHEMCIAL PROCESS INDUSTRIES

 SECTION-16

Contact Us
17.1 OFFICES
During any problem condition in case of boiler, please feel free to contact following:

Head Office (Kasarwadi)

P B # 29, Mumbai-Pune Rd.,
Kasarwadi, Pune 411 034
Tel: 91 (0) 20-27145595 / 39858555
Fax: 91 (0) 20-27147413
Website: www.forbesmarshall.com
E-mail:ccmidc@forbesmarshall.com

Manufacturing (Chakan)
B-85, Phase-II, Chakan Industrial Area,
Sawardari, Chakan
Tal: Khed, Dist :Pune
CHAKAN-410501
Tel: 91 (0) 21-35393400
Tel: 91 (0) 21-35393554
Website: www.forbesmarshall.com

Control Instrumentation Group

A -34 / 35 MIDC, 'H' Block, Pimpri,
Pune 411 018
Tel: 91 (0) 20-27442020
Fax: 91 (0) 20-27442040
After Office Hrs: 020-27477762
Website: www.forbesmarshall.com
E-mail: ccmidc@forbesmarshall.com

Gauges Manufacturing Unit

Plot No. A-19/2 and T-4/2
I.D.A Nacharam,
Hyderabad - 500 076
Tel: 040-27153918 / 27152276
27171909 /27170732
Fax: 91-040-27173235 /27179223
Website: www.forbesmarshall.com
17.2 BRANCHES
Ahmedabad Alibag
Forbes Marshall Forbes Marshall
4, Shetoor Bunglows, Row house No.14, ‘B’ wing,
Opp. Drive in Petrol Pump, Bafna Baug Complx-B,
Ahmedabad - 380 054 Behind Big Splash Hotel Chendhare,
Tel : 079-26851738 / 26856374 Alibag - 404201
Direct : 079-26859395 Tel : 02141-223795(O)
Fax : 079-26854014 Fax : 02141-223796(O)
ahmedabad@forbesmarshall.com Tel : 02141-224699(R)
alibag@forbesmarshall.com

Bangalore Chandigarh
Forbes Marshall Forbes Marshall
No.373, HBR Layout SCO # 107,
Stage-1, Block II Top Floor,
A Main, Kalyangar Post Sector 47-C,
Bangalore - 560 043 Chandigarh
(Land Mark: Near Hennur Depot / Petrol Bunk) Tel : 0172-5080285
Tel : 080-25435965 / 25436400 Fax : 0172-695098
Fax : 080-25499971 chandigarh@forbesmarshall.com
bangalore@forbesmarshall.com

Chennai Coimbatore
Forbes Marshall Forbes Marshall
Flat No. III-B, 10/21, V.R. Gardens,
Calve Chateau Complex Thottipalayam Pirivu
808 P.H. Road, Kilpauk Kalapatti, Coimbatore - 641 014.
Chennai - 600010 Phone: 0422-3054990 / 991
Tel.:044-26611238/26611228 Fax No.:0422-3054999
Fax:044-26611236 coimbatore@forbesmarshall.com
chennai@forbesmarshall.com

Delhi (Control Instrumentation) Delhi (Steam Engineering)

Forbes Marshall Forbes Marshall
Anupama Arcade,2nd Floor, D-109 & 110, 1st Floor
Opp.Samachar Apts., Okhla Indl. Area Phase - 1
Mayur Vihar Extn., New Delhi – 110 020.
Phase I Mobile: 09910481600
New Delhi - 110 091 TEL: 91 (0) 11 26814540, 41, 42 Ext. 204
Tel : 011-22713485/22712902/3 FAX : 91 (0) 11 42831522
Fax : 011-22710484 delhiseg@forbesmarshall.com
delhicig@forbesmarshall.com
Hyderabad Indore
Forbes Marshall Forbes Marshall
Plot No. A-19/2 and T-4/2 , E 21, Ground Floor,
I.D.A. Nacharam Ravi Shankar Shukla Nagar,
Hyderabad - 500 076 HIG Colony, Indore - 452 003
Tel: 040-27152276/27150691 Tel : 0731 – 2552561
Fax : 040-27152193
hydcig@forbesmarshall.com

Jamshedpur Kochi (Steam Eng.)

Forbes Marshall Forbes Marshall
59,Rajendra Nagar, Mr. J. J. Thomas
Jamshedpur - 831 001, II/147 A, Nereveettil Bldg.
Jharkhand Vazhakkala, Thrikkakkara PO
Tel : 0657-2437721 Kochi - 682 021
Telefax : 0657-2427983 Tel.: 0484-2425444
jamshedpur@forbesmarshall.com Cellular - 098950-41210
cochin@forbesmarshall.com
jthomas@forbesmarshall.com

Kolkata Mumbai
Forbes Marshall Forbes Marshall
Rishi Tower, Premises No. 02/315, 107 MG Road,Fort,
New Town, Kolkata, Mumbai - 400 023
West Bengal - 700 156. Tel : 022-22673821, 22673822
Behind Tata Medical Centre and opposite Fax : 022-22672970
Unitech Building Gate No.2. mumbaicig@forbesmarshall.com,
Tel : 033- 3026 1254 mumbaiseg@forbesmarshall.com
Fax : 033- 3026 1260
kolkata@forbesmarshall.com

Nagpur Navi Mumbai

Forbes Marshall Forbes Marshall
50, ASHA 2nd Floor, 101/102, Building No: 4,
Lendra Park, Sector: 3,
New Ramdaspeth, Millenium Business Park,
Nagpur - 440 010 Mahape,
Tel : 0712-2539386 Navi Mumbai – 400 710
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Pune Surat
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PB 29 Mumbai Pune Rd., 7B Ground Floor,
Kasarwadi, Pune - 411 034 Navchetan Society,
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10, Shreeji Krupa Society,
Gotri Rd.,
B/H Kalpavruksha Complex
Vadodara - 390 023
Tel : 0265-2343733
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Visakhapatnam
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