PLAN RECORD REVISIONS AP CHECK 5 PROVED | ED SO werere scxew ruReans| yo, DESCRIPTION (DATE) = S = = a an = sw Se z 2 5 = RPO FINISHED PLAN Mx And ABR x2 129 SHEET(S) WITH COVER Noannoonosenes | DAEWOO H.No.2229/30/31/32 appRoveD___ for Y.Ono MAIN BOILER (MB-4-KS) ¥.Ono! K.Matsushita 3 ~ oicortd rena BOILER INSTRUCTION AND DRAWN K.Kasagi MAINTENANCE MANUAL (1) CONF ERRED/| SCALE ~ ORDER iTew | DRAWING NO REN. NO K1A48/49/65/66 | 97000 N51-99M-MO001 0 ane MITSUBISHI HEAVY INDUSTRIES, LTD. NAGASAKI SHIPYARD & MACHINERY WORKS DRAWN 2006/11/08MAIN BOILERS OPERATION AND MAINTENANCE INSTRUCTIONS FOR DAEWOO SHIPBUILDING & MARINE ENGINEERING CO., LTD. H.NO.2229/2230/223 1/2232 H2229: NOVEMBER 2005 H2230: © DECEMBER 2005 H2231: SEPTEMBER 2006 H2232: APRIL 2007 NAGASAKI SHIPYARD & MACHINERY WORKS MITSUBISHI HEAVY INDUSTRIES, LTD ——— MITSUBISHI HEAVY INDUSTRIES, LTD,_§ ————————————NAGASAKI JAPAN FOREWORD This instruction manual treats of affairs requiring attentions of workers in charge of this boiler with a view to giving them a guidance for proper operation to make the most of the boiler, to prevent injuries of damages that may be caused by improper handling and to ensure high-efficiency service and perfect safety for a long time However, this instruction manual refers to only fundamental rules necessary for operating handling the boiler. Consequently, those who are in charge of handling the boiler are expected to learn completely the subjects included in this manual and get well versed in all related appliances including pippins and fittings as well as the boiler itself so that they can handle the equipment perfectly Warning Please strictly refrain from copying the contents of this manual or making an extract from them and revealing them to others. CAUTION MARK QQ: CAUTION IN ORDER TO AVOID THE TROUBLE cy DO NOT TOUCH BECAUSR OF HIGH TEMPERATURE. ——— MITSUBISHI HEAVY INDUSTRIES, LTD.a CAUTION For operation, to be understood this instruction manual in advance. Fuel (Oil, Gas) is very dangerous if ignited. Therefore, full attention to be paid so as not to | leak the fuel, and to be handled carefully. To be kept the good combustion condition at any time. If abnormality appears, shut down the fuel, or suitable measures to be taken to recover to good condition. To be checked that boiler drum is filled | with water. Do not touch the high temperature part (Burner, Piping, Valve, Detecting equipment, etc.)TAB A INTRODUCTION 6 ‘inciple Part 7 Outline of Main Boiler & Accessories 8 Boiler Accessories 12 Design Data 13 Performance Data 15 Performance Curve 16 Outline of Operation 21 Data for Operation 24 Outline of Maintenance 34 Check Point List 37 Condition of the Emergency Fuel Oil and Gas Cut 38 B. OPERATING PROCEDURE 39 Preparing for Service 40 Starting a Boiler from Dead Ship Conditions 43 Lighting up and Raising Pressure 46 Securing a Boiler 35 Method for Cutting-In Another Boiler 56 Operation of Stand-By Forced Draft Fan 59 1-Boiler Operation 60 Emergency Operation 61 Trouble Shooting 62 c. GENERAL MAINTENANCE 64 Feed Water & Boiler Water Treatment 65 Low pH Treatment of Boiler & Feed Water 65 Limiting Values of Feed Water and Boiler Water 66 Explanation of Boiler Water Treatment and Its Limiting Values 67 Decision of Dosage 2 Measures to be taken when the Relation between pH Value of Boiler Water and Phosphate Ion Concentration becomes Deviating Off from the Theoretical Curve 74 Feed Water Treating 1 ——— MITSUBISHI HEAVY INDUSTRIES, LTD.Boiler Water Concentration and Blowing 7 Caution in Water Quality Measurement 80 Care of Boilers Out of Service 82 Hydrostatic Tests 85 Boiling Out 86 Water Washing Fireside 88 Acid Cleaning 89 Mechanical Waterside Cleaning 91 D. MAINTENANCE AND REPAIR OF BOILER PARTS 92 Maintenance of Refractory 93 Boiler and Water Wall Tube 96 Supetheater 100 Desuperheater 108 Steam Temperature Control System 105 Economizer 108 Use of Tube Expanders 109 Expander List 110 Miscellaneous Boiler Parts 113 Attachment Arrangement of Boiler Mountings 11s Arrangement of Main Boiler M7 Arrangement of Superheater 118 Main Boiler General Piping 119 Diagram of Feed Water Piping 120 Diagram of Boiler Mountings 121 Diagram of Bumer Piping 122 Diagram of Soot Blower Steam Piping 123 Diagram of Air and Gas Duct 124 Diagram of F.0, Pump and Heater 125 Diagram of Chemical and Sampling Pipe 126 Diagram of Dumping Desuperheater 127 Diagram of Seal Air 128 ——— MITSUBISHI HEAVY INDUSTRIES, LTD.A. INTRODUCTION MITSUBISHI HEAVY INDUSTRIES, LTD,PRINCIPLE PART GAS AIR HEATER savuRaTeD z ecouowzeR Steau Pe 5 sumnen Mm fT DOWNCENER novany | | A Sof Bowen SEAR Bank TUBE i : | cove rerencrance Bec MY 3 soor power WATER DRUM [ | 4 MITSUBISHI HEAVY INDUSTRIES, LTD,os OUTLINE OF MAIN BOILER & ACCESSORIES BOILERS This installation consists of two drum water tube “MITSUBISHI MB-4-KS” type marine boiler with oil and gas combination bumers located in the furnace roof. The unit is composed of a steam drum and a water drum connected by a bank of inclined generating tubes, Other water side components include : front screen tubes shielding the superheater elements from direct radiant heat of the furnace, side and roof water wall, front and rear water wall tubes, down-commers, bottom headers, roof and bottom front wall headers, roof and bottom rear wall headers, and front and rear wall riser pipe. Each tube in the furnace floor, side & roof, front and rear wall are jointed to the adjacent tube by welding, In this welded wall construction, the tubes form a gas-tight envelop three side of the furnace. A supetheater, an internal desuperheater, a superheated steam control desuperheater, the economizer, gas air heater, and casing include the remaining principal components of construction. Since the combination burners are located in the furnace roof, the gas flow from the furnace is evenly distributed across the front bank, superheater, and generating banks, discharging through the economizer and gas air heater located at the uptake of boiler DRUM INTERNAL! Steam drum internals consists of desuperheater, surface blow line, intemal feed pipe, chemical feed line, baffles and dry box. Steam generated in the boiler tubes enters the steam drum, where it is forced to pass through a bafile located at the normal water level before entering the upper part of the steam drum, Before leaving the boiler through the outlet nozzle, the steam must pass through the dry box located at the top of the drum, A submerged type desuperheater located below the water level in the steam drum provides reduced temperature auxiliary steam, Since the desuperheater receives its steam supplied from the superheater outlet, a positive flow of steam is maintained through the superheater at all times regardless of the demand for superheated steam The superheater steam temperature control system incorporates a submerged type desuperheater located in the water drum to maintain normal steam temperature when the boiler is operated in excess of normal rating and, when necessary, to reduce the steam temperature at all ratings Manholes fitted and water drum. The hinges allow the manhole covers to swing into the drum clear of the hinged manhole covers are provided in the front head of the steam drum manhole. JBISHI HEAVY INDUSTRIES, LTD.os FURNACE Water cooled walls are provided by lining the furnace side, floor and roof with a single row of 63.5 mm tubes, and front and rear with a single row of 50.8 mm tubes. External down commers provide ample circulation to water drum, bottom header and front & rear water wall headers, The water cooled floor consists of 63.5 mm tubes traversing the furnace floor from the bottom header, then bending to form the furnace side and roof, which terminates in the steam drum, Fumace front and rear wall tubes arranged from the lower to the upper water wall headers cover front and rear furnace walls. Upper front and rear water wall headers are connected to the steam drum by riser pipe, Because water wall tubes are jointed to their adjacent tubes in a welded wall construction, they form a gas tight envelops lining the furnace. Where openings are required for bumers, access doors and soot blowers, they have been formed by bending tubes back and to the side to form the opening and then back to their original plane to continue the welded wall construction, The furnace water wall tubes are backed up by insulation buck-stays and a corrugated casing SADDLE! Saddles are provided under the water drum and the front & rear water wall headers to support the weight of the boiler. Rear saddle under the water drum is fixed and the front saddle has slotted bolt holes, grooves and grease fittings to allow easy movement and lubrication. Grease fittings are provided on both front and rear saddle of water wall header. The grooved saddles are free to slide to allow for expansion of the boiler as it is warmed up. The sliding feet should be inspected and cleaned as frequently as possible and should be greased at least each 600 boiler steaming hours. Th jis procedure is extremely important and should be followed without failure. There are cases on record where pressure parts have failed because the sliding saddles and frozen in place, preventing movement required during normal expansion. SUPERHEATER ‘The superheater is of the vertical, interbank, convection type arranged for multipass steam flow Superheater elements are arranged in groups of six concentric hair pin loop elements, the ends of which are welded into the inlet-outlet headers and intermediate headers. The arrangement of ide castings welded to the superheater elements and two inch generating and screen tubes form a elements is such that the superheater tubes are parallel to the boiler generating tubes sliding joint which aids in tube alignment. The superheater inlet, outlet and intermediate header run parallel to the water drum through the depth of the boiler. Each header is sectioned internally by welded steel diaphragms to direct the steam through five consecutive passes between the headers. Complete drainage is provided by a small opening in the lower edge of plates allow access for inspecting and cleaning the superheater internally. JBISHI HEAVY INDUSTRIES, LTD.os ECONOMIZER An extended surface type economizer is placed above the boiler tube bank. The economizer is made up of closely spaced continuous loop elements, which is welded to the terminal headers at both ends. Each element shall be of 50.8 mm tubes straight carbon steel tubes with spiral steel fin, connected by U-bends forming integral loop. All elements are supported at the front and rear le by tube plates. On the out Insulated steel casings are provided around the economizer and large removable panels are fitted le of the terminal headers, handholes with covers are provided. on the front and rear side for access and tube removal. Feedwater enters the inlet header at the top and flows through the elements counterflowing to the gas leaving the boiler, to the lower header, thence to the boiler steam drum BOILER ACCESSORIES Boiler accessories are listed on this section later with the manufacture’s name and identifying data, See instruction books of those accessories for detailed description. Following is the outlines: (1) Gas Air Heater Each boiler shall be equipped with a vertical, continuous conter flow regenerative type gas heater to raise a temperature of combustion air before entering the boiler wind box above 200°C at NCR condition. The gas air heater shall consists of hot and cold heating elements Cold heating elements shall be consist of enamel coating steel to prevent its corrosion, and hot heating elements shall be of corrosion resistant alloy stee! (2) Oil / Gas Combination Burner The boiler is equipped with three (3) sets of fuel oil and gas combination bumers on the roof, wall of the fumace. The fuel combination burner is of steam assisted pressure jet type, consisting of atomizer gun, forced draft air register with fuel shut off valve. The fuel is distributed to each burner from a bumer manifold by branch connection pipe. The operation of increasing or decreasing the number of the bumers is automatically operated by the automatic combustion control signal, and remotely operated by the push button when necessary. (3) Automatic Combustion Control ACC (Automatic Combustion Control) is incorporated with sh 's IAS (Integrated Automatic System). The combustion control system regulates the fuel and air supply to the boiler so as to maintain steam pressure at the superheater outlet within predetermined limits. Combustion air supply is controlled automatically by actuating the inlet vane of forced draft fan, Fuel oi and gas supply is also controlled automatically by means of regulating valve located in fuel oil and gas supply line. In case of control air supply failure, the regulating valves in the fuel oil supply is locked, while the air regulating vanes opened. JBISHI HEAVY INDUSTRIES, LTD. 10os (4) Superheated Steam Temperature Control The superheated steam temperature control system is provided to maintain the superheated steam temperature at less than 515°C. at the boiler load approaches normal steaming capacity and overload capacity. The steam comprised of the superheater, a control desuperheater, at remote, pneumatically controlled valves, the control system for the valves, and the necessary connecting piping, A part of the steam leaving the four pass of the supetheater is directed to the temperature control desuperheater, and lowered its temperature, mixed with the steam flowing the by-pass line, thence enters the five pass of the superheater. The steam flow to the control desuperheater is controlled with the air operated control valve (5) Feed Water Regulator Feed Water Control is included in ship’s IAS (Integrated Automatic System), The regulator is composed of differential pressure type water level sensing device, steam flow sensing device, auto-manual selector switch and feed water regulating valve. The feed water flow is controlled automatically by the regulating valve is accordance with the variation of water level in the boiler drum and steam flow at the superheater outlet to maintain the water level constant, The water flow can be also adjusted manually and independently. In case of control supply failure, the regulating valve is locked. (6) Soot Blower The boiler is equipped with soot blower system of steam nozzle tube type. The type and number of soot blowers are as follows: Position No. ‘Type Superheater Two (2) Long retractable Boiler bank tube Two (2) Stationary rotary Economizer Two (2) Stationary rotary Gas air heater One (1) Swing type Soot blower of long retractable and stationary rotary is driven by electric motor. Blowing medium of all these blowers is desuperheated steam. All soot blowers are automatically and sequentially operated from the soot blower operating panel at control room, JBISHI HEAVY INDUSTRIES, LTD, ——————BOL ER ACCESSORL Equipment Manufacturer (1) [Gas Air Heater Alstom Co., Lid (2) |Oil / Gas Combination Bummer Hamworthy Combustion Engineering Ltd. (3) |Safety & Relief Valve for BLR [Fukui Seisakusho Co,, Ltd. (4) |Safety & Relief Valve for ECO Fukui Seisakusho Co., Ltd. (5) |Soot Blower IKikan Buhin MFG, Co., Ltd. (6) |Water Level Gauge |Sawada Seisakusho Co., Ltd. (7) |Feed Water Motor Valve IMitsumoto Valve Mf, Co,, Ltd (8) |O2 Meter lEnergy Support Corp. (9) [Swing Check Valve IMitsumoto Valve Mfz Co., Ltd. (10) [Boiler Piston Valve INakakita Seisakusyo Co., Ltd (11) [Burner Piston Valve |Nakakita Seisakusyo Co., Ltd. (12) [Butterfly Valve Tomoe Valve Co., I (13) |Forced Draft Fan \Samwon E & B Co., Ltd, (14) [Fuel Oil Pump Kosaka Laboratory Ltd. (15) |Smoke Indicator |Shonan Kosakusho Co., Ltd. (16) |Seal Air Fan JAzuma Sofuki Co., Ltd (17) |Strainer: JMisuzu Seiko Co., Ltd. (18) [External Desupetheater Spray [Tyco Flow Control K.K. (19) |Colioris F. O. Flow Meter |Endress Hauser Japan Co., Ltd. (20) |Vortex Gas Flow Meter [Endress Hauser Japan Co., Ltd MITSUBISHI HEAVY INDUSTRIES, LTD, 12PRESSURES (bar} Design, + 765 Operating (Superheater Outlet) - + 603 Hydrostatic Test (Maximum)- 1148 Safety Valve Settings: Steam Drum Superheater 63.5 Economizer 95.6 TEMPERATURE (C) Steam at Normal rating sis Feed Water at Normal rating 202 Gas Air Heater Inlet Air 38 Gas Air heater Outlet Air at Normal rating 190 EVAPORATION (kg/h) Normal rating: 52,700 Maximum Capacity 60,700 FURNACE VOLUME (m’) . 80.2 HEATING SURFACE (mn? Boiler 952 Superheater 318 Economizer 597 Gas Air Heater (Gas Side Only), 878 Aux. Desupetheater 10 Control Desuperheater ~ 7 WEIGHT (kg) Total Cold Water to Fill Unit Completely ~ 29,640 Cold Water to Fill Boiler to Normal Level « 21,630 Cold Water Fill Supetheater 180 Cold Water Fill Economizer ~ 1,240 Boiler, Dry, Complete with Burners and Soot Blower 148,000 Economizer, Dry, Complete with fittings: 13,000 Boiler Water, Steaming Condition 15,191 Economizer Water, Operating Condition “1,153 Total One Boiler, Steaming Condition: - 163,191 Total One Economizer, Operating Condition 14,153 MITSUBISHI HEAVY INDUSTRIES, LTD, "76,5 & 76.0 2BTUBE DATA (mm) os Location Quantit Diameter_| Thickness Rear Bank Tubes 1,610 38.1 32 Superheater Support Tubes 40 50.8 45 Roof, Side & Floor Water Wall Tubes 57. 63.5 55 Front Water Wall Tubes 2 50.8 45 Rear Water Wall Tubes 2 508 45 Screen Tubes 80. 54.0 45 Superheater Element #1 60 38.1 4s Supetheater Element #2 60 38.1 45 Supetheater Element #3 56 38.1 6.0 Supetheater Element #4 56 38.1 6.0 Supetheater Element #5 44 38.1 6.0 Supetheater Element #6 44 38.1 6.0 Desuperheater Element 10 38.1 40 Control Desuperheater Element 12 38.1 40 MITSUBISHI HEAVY INDUSTRIES, LTD, ———————_ 14Performance Data Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS Oil firing at [otal 1 60,700] 52,700] 30,775] 26,850] 13,925] Evaporation [SHSteam |_kgh_| 58.700] 51.700] 38.775] 25,850] 12,925] DSH Stean{ kg _| 2.000] 1.000] 1,000| 1.000] 1.000] pressure Dum bar e6.4[— e4.9[ 62.9 67.5| 60.6} ISH Outlet_|— bar 603, 60.3, 60.3| 60.3] 60.3] Water & Eco. Infet_| 202.0] 202.0| 193.0| 193.0 193.0] Stes [SH Inlet c 2e3.3[ 2817] 279.7| 278.2 277.3) 5H Outlet_[ Cc 515.0] _515.0| _513.9| 490.8| 449.1 Temperature [BSH Outlet] Cc 257.4] 286.3} 286.3] 286.3] 286.3] Ar FOF Outiet| 38 38 38 38 33 [Temperature _|GAH Oullel_“C 733 730] 736| 773] Ti fEfiiciency (HV Base] —% 30.0[ 80.0] 88.8] 88.3 87-7] Calorie Value [HEV Keallkg| 10280 10280 10280| 10280| 10280] HV. Keallkg| —9713| 9713] 9713] 9713| 9713] Fuel O1 consumption Kofh 4o14|__ 3495] 2675] ___1777|___ 886] xcess Air Rate % 70.0] 10.0] 125] 25.0] 36.0} [O2 Rate % 13 73 2.3] 42] 5.5] [Combustion Air Flow Kgh_| 61.476] _53.527| 47,908] 30.929] 16.975] Flue Gas Flow kgih_| 65.490] 87.022] 44,580] 32,706] 17.872] GAH Outlet Gas Temp. c 728 125] 120] T16| 11 [Total Draft Loss, Tibar B57] 422] 258] 13.9] 4 Load TAX] _NOR [75% NOR50% NOR|25% Ni Total Fgh [60.700] 52,700] 30,775] 26,850] 15,925] Evaporation [SHSteam [_kg/h_| 58,700 51,700] 38.775] 25.850 12.925] DSH Stean{_kgin | 2.000] 1,000] 1,000 1,000] 1.000] Drum bar e6.4[—64.9[ 62.9[ _67.5| 60.6] Pressure [SH Ouet_|_bar 60.3, 60.3] 60.3| 60.3] 60.3] Water Eco. Infet_[_C 202.0| _202.0| 193.0| 193.0] 193.9] Steam [SH Inlet c 283.3[ 281 7|_279.7| 278.2 277.3] ¥ H Outlet_|C 515.0] 515.0] 515.0| 515.0 485.5] ‘emperature [DSH Outlet —C 201.4| 286.9 286.9] 286.9] 286.9] Ar FOF Outiet| Cc 38 38 38 38 33 Temperature [GAH Out Dis Trap 190s] 16.5) 737] Efiiency _|(HHV Base] —% 5.2) 85.3] 85.3| 84.7! 83.3] Caloric Value HH Keallkg| 13270] 13270] 3270 13270| 13270] LAV. Keallkg | 11964] 11964] 11964] 11964] 11964] Fuel Gas Consumption —[_ kg/h 3297] 2870| 2198] 1489] 759] Excess Air Rate % 70.0] 10.0] 12.5| 25.0 36.0 [02 Rate % 7.3] 7.3] Px 42] 5.6] combustion Air Flow Kgh_| 63,226] 55,023] 43,098] 32.439] 16,002] Flue Gas Flow kgih_| 66.523] _57.898| _45.295| _33.928| 18.761 GAH Outlet Gas Temp. c 34] 130] 24] 713] Tia] [Total Draft Loss. Tibar Bral_43.5| 266] 14.9) 45 Note; 1, GAH outlet gas temp. is not considered air Leakage of GAH. 2. Boiler efficiency is not considered GAH air by pass damper opened condition.Expected Performance Curve (Oil Firing) Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS 910 8 Boller Etclency (%) 2 3 30,000 40,000 «$0,000» 60,000 70,000 5,000 kam) 3 8 Fuel Consumption ( 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 Evaporation (kg/h)Expected Performance Curve (Oil Firing) Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS- 67.0 66.0 65.0 640 63.0 620 2610 60.0 58.0 rum Pressure (bar) ° 10.000 20.000 30,000 40,000 Evaporation (ka/h) 8 g 8 g Excess Air Ratio (96) 19.000 20,000 30,000 40,000 $0,000 60,000 70,000 Evaporation (kg/h) Total Draft Loss (mbar) ° 10,000 20000 30,000 40,000 50,000 60,000 70,000 Evaporation (kg/h)Expected Performance Curve (Gas Firing) Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS 86.0 850 240 Boiler Efficiency (%) B10 ° 19000 20,000 «30,000 40,000 60,000 80.000 70, Evaporation (kgin) 000 4,000 3,000 2,000 1,000 Fuel Consumption (ka/h) 0 10,000 20,000 30,000 40,000 Evaporation (kam) Steam Temperature (°C) 0 10,000 20,000 30,000 40,000 0,000 60,000 70,000 Evaporation (ka/h)Expected Performance Curve (Gas Firing) Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS- 67.0 66.0 g Excess Air Ratio (26) S Total Draft Loss (mbar) o 10,000 20,000 30,000 40,000 «$0,000 69,000 70,000 Evaporation (ka/h)Performance Curve for Desuperheater Main Boiler For DAEWOO H2229/30/31/32 Boiler Type MB-4-KS Drum Pressure 66.4 bar 61 0 5009 10000 15000 20000 25000 30000 35000 40000 45000 Temperature ('c) 8 8 8 0 $000 + 10000 16000 20000 © 25000 30000 36000 40000 45000 Desuperheated Steam Flow (kg/h)1 OUTLINE OF OPERATIO! Preparations for Operation Before starting operation, inspect the following places and make the following preparations. (1) Boiler Refractory material, manhole cover, residual oil in double casing, handhole cover (2) Opening and Closing Position of Valves Water level gauge root valve, drain air vent valve, starting valve, safety valve, pressure gauge root valve, blow down valve, water wall header drain valve, ACC pressure detecting valve root valve, superheater header drain valve, economizer air vent valve (3) Gas Air Heater Check the lubricating oil level in the gauge glass for support bearing and guide bearing Open fully the air by-pass dampers, Start the gas air heater prior to starting of FD Fan. In detail, refer to N51-99M-M002( II) E-1 GAS AIR HEATER. (4) Around Bumer Oil and gas piping and valves (emergency shut-off valve, distribution valve, automatic operation valve, etc.) function of air register, tip size, kind of fuel (diesel oil or “C” heavy oil) (5) Other Accessories Automatic combustion control equipment, automatic feed water regulator, operating condition of soot blower and remote water level gauge (6) Boiler Water Fill the boiler with distilled water or demineralized water up to the specified level. At the same time, inspect feed water system (7). Start-up of Fan Start up the fan with suction vane fully closed. (8) Start-up of Fuel Oil Injection Pump Using recirculation line after start-up, remove cold oil and heat fuel oil in case of hot start In case of cold start, remove residual oil from pipe and lead in diesel oil Light up and Pressure Raising Perform in the following order (1) Response of water level gauge (2) Purge of furnace Open for 1 minute with the fan at low speed and suction vane at about 80% open position. (Open all burners.) Furnace purge should be carry out before lighting off the burner. (3) Light-up of Base Burner Light up the base burner using the normal tip and observe the condition of combustion afier lighting up. For burner operating procedure at light-up, refer to the section "Bumer." Do not forget to open the starting steam valve before lighting off the burner. MITSUBISHI HEAVY INDUSTRIES, LTD.(4) Pressure Raising Pay attention to prevention of burning of heater tubes, removal of drain, air venting and water level fluctuation, For procedure, refer to “Operating Data” (5) Inspection after Pressure Raising Check response of water level gauge and indication of pressure gauge and inspect operation of safety valve Instructions for Normal Operation | (1) Athigh load operation, make load change as slowly as possible. | @) When load change is large, lower the set point of steam pressure to prevent the safety | valve from blowing | A (3) Make inspections in accordance with the inspection list. | | (4) Observe combustion and maintain a good combustion condition. Throttle combustion air as much as possible. (5) Make water analysis and keep feed water and boiler water in good condition (6) Perform soot blowing and keep the heating surface clean. 3. Shut-down of Boiler Shut down the boiler in accordance with the following order. (1) Soot blowing Soot blowing should be made at 50% or higher boiler load (2) Burner shut-down Bumer shut-down should be made one burner at a time. (3) Firing box purge (4) Fan stop (5) Temporary Boiler Shut-down Light up burners occasionally and keep pressure near the normal pressure and water level at the specified level (6) Complete Boiler Shut-down Close feed water valve, main steam stop valve and desuperheater outlet valve and reduce pressure by releasing steam from the starting valve 4, Two-boiler Operating Procedure When two boilers are in operation, drain may be produced and pressure and water level may fluctuate, so valve operation should be made properly with due attention paid to these phenomena, For this purpose, it is necessary to decide the operating procedure beforehand. An example is given in "Two-boiler Operating Procedure." 5. Special Operation of Boiler (1) Economizer Bypass Operation When the economizer cannot be used, economizer bypass operation can be made by switching over feed water pipe. (2) Stand-By fan Operation At failure of each forced draft fan, failed boiler can be operated with stand-by forced draft fan, Attention should be paid to air distribution to both boilers by controlling air flow manually. MITSUBISHI HEAVY INDUSTRIES, LTD.6 ae (3) One-boiler Operation Completely isolate from the other boiler. When boiler load is hig! combustion condition, load change and steam temperature. pay attention to Operation of Boiler Accessories (1) Burmer Make efforts to maintain a good combustion condition, paying attention to air excess ratio, oil pressure, fuel oil temperature, use of steam atomizing, cleaning of bumer tip, gas pressure, gas temperature, efc. At light-up and shut-down of bumers, make sure to perform furnace purge. To carry out maintenance of F.O, burner during operation, switch over to a gas bummer (2) Automatic Combustion Control Equipment Familiarize yourself with auto/manual switch-over operations and perform switch-over operations smoothly. Check that there is no abnormality in control function, paying attention to indication of each instrument. Blow out drain from supply air line once a day. 3) Automatic Feed Water Regulator Check that there is no abnormality in control function, paying attention to fluctuation of water level. (4) Soot Blower Soot blowers can be operated remotely from the control panel. Time required for soot blowing is about 30 minutes per cycle —————— MITSUBISHI HEAVY INDUSTRIES, LTD,DATA FOR OPERATIO! Characteristic Curves of Burner (Oil & Gas) Relation between Fuel Oil and Temperature Limits of Chemical Concentration Chemicals and Quantity for Boiler Water & Feed Water Fuel Trip and Alarm Point of Water Level Relation between Drum Water Level and Water Content Boiler Pressure Raising Curve Estimated Excess Air Ratio Curve ———_——— MITSUBISHI HEAVY INDUSTRIES, LTD. —————————ae HFO PRESSURE (ber.g) EERING CS 30104 STEAM ATOMISED HFO CALIBRATION CURVE CLIENT REF: Daewoo H.2229 | H.2230 / H.2231 | H.2232 ATOMISING STEAM PRESSURE CONSTANT @ 8 bar.g ATOMISING VISCOSITY 17 cSt 2 roy 420 20 100 18 16 80 “ 12 60 40 8 0 6 4 20 2 o ° 0 200-400» 600 80010001200 1400 ©1600 18002000, HFO FLOW (kg/hr) MITSUBISHI HEAVY INDUSTRIES, LTD. STEAM FLOW (kg/hr)sooz/romsiea ed9 “20L0deINd oN Weuneg Pu ANBOH ISIINSHA IUCN 26 4u/6y- 01a SO Jon ooct cz 001-000-008 OLSSON: ECCS — ++ ——_—_- ° | ~ T 00} | ' t 4 i Tq jt }— of —} psp ewe | | 008 equ | | sunsro.g —+— + { + seg jong - : 4 f oor 1 | —- ~ + 0s - | t | jp 00 OLY XON mo7] aseydiiL TOXH ‘aunssaid Se Jang SNSIOA O}eY SED [ONS MITSUBISHI HEAVY INDUSTRIES, LTD. GALINIT ONINSSNIDNA NOILSNEWOD AHLYOMNVH2. Relation between Fuel Oil and Temperature MITSUBISHI HEAVY INDUSTRIES, LTD.os 3. Limits of Chemical Concentration Boiler Water Feed Water pHat 25°C 9.6~103 8.0~9.0 Chloride fon (CP) ppm 20 or less - NaPO, mol ratio 26~3.0 - Dissolved Solid ppm 200 or less - (Conductivity) (u@yem) (400 or less) Phosphate lon (PO,*) ppm 10~20 - Silica (Si0.) ppm 3 orless - Hardness (as CaCOs) ppm - 0 Dissolved Oxygen coll - 0.05 or less (ppm) (0.028 or less) Residual Hydrazine (NH) ppm - 0.01 or above oil ppm Close to 0 Close to 0 Note: (1) Feed water in this table means the mixture of condensate and distilled water to supply into the boiler. (2) Maximum hydrazine density of feed water is in the region that the feed water pH is not over the upper limit. (3) Low pH coordinated phosphate treatment was developed as one of the method that can perfectly prevent the alkaline corrosion. We recommended this treatment method for 60 bar marine boiler. During the Hydrostatic Test, Chloride Ion shall be kept less than 0.1 ppm when stainless tubes | as superheater tube are applied. | MITSUBISHI HEAVY INDUSTRIES, LTD. 28os 4, Chemicals and Quantity for Boiler Water & Feed Water Treatment (1) Chemicals to be used For adjusting pH value and PO,” Na3HPO, and Na;PO, For deoxidization and rising pH value Hydrazine hydrate (2) Dosage A. Initial dosage When the water content at steaming condition is 22 ton and Na?O, mol ratio is 2.8, chemical dosage required to keep ?O,* concentration at 15 ppm will be NasPO,+12H;0 768 g/boiler Na;HPO,*12H.0 180 g/boiler The weight of initial dosage varies due to the water quality of the initial filling water, so, after the boiler warming-up, water quality shall be checked again by analysis, and shall be adjusted with additional dosing when necessary. B. Supplementary dosage (per one boiler) The increase of | NasPO,+12H,O |NasHPO,+12H30 phosphate ion S ppm 256 g 60g 10 ppm 512g 120g 15 ppm 168 180g 20 ppm 1,024 g 240 ¢ Note: 1, Na PO2.8 (mol ratio) 2, Water content during operation is 16.4 ton MITSUBISHI HEAVY INDUSTRIES, LTD. 295, Fuel Trip and Alarm Point of Water Level Visible Range of Remote Water Level Gauge Steam Drum Water Level Gauge Drum level Ex-High Trip Feed Water Valye Shut Drum level V-High Turbine Trip Turbine Auto Slow Down ‘Turbine Program Interlock (180mm) Drum Level High Alarm - Normal Water Level Drum Level Low Alarm Turbine Auto Slow Down {. Drum Level Ex-Low Trip Down Commeros 6. Relation between Drum Water Level and Water Content DRUM WATER LEVEL & WATER CONTENT Drum Water Level (m) MITSUBISHI HEAVY INDUSTRIES, LTD. 317. Boiler Pressure Raising Curve 70 . | : | Se 2 s Drum Pressure (barg) 20 10 0 60, 120 180 240 Operating Time After Light on (minute) MITSUBISHI HEAVY INDUSTRIES, LTD. 328. Estimated Excess Air Ratio Curve pa0-90L0aaWa ¥eu oN, sayj8npU] haboH TSASHMY 20019 ou 04 06 Bows MI Swann ©. Sous Ni Swann Ta peo seH0— 09 os 7 svo and NI‘ 84 avo7 uz IOS oz o ° G7 ONIIZANIONS NOILSNGWOO AHLYOMAWH MITSUBISHI HEAVY INDUSTRIES, LTD.OUTLINE OF MAIN -ENANCE Feed Water & Boiler Water Treatment Feed water and boiler water shall be analyzed at least twice a day. Amount of chemicals to be added and amount of boiler water to be blow down shall be controlled referring to the results of the analysis so as to maintain each chemical content of the water within the prescribed limit. Operators are required to have correct understanding about the action and effect of each chemical and calculation method of required quantity of Recommended chemicals are as follows For adjusting pH value and PO,” NasHPO, and NasPO, For deoxidization and ising pH value Hydrazine hydrate Maintenance during Shutdown There are two ways of laying up the boiler, dry and wet. Either way may be adopted as the case may be, When the boiler is laid-up wet, care should be taken to the concentration of chemicals in the boiler water, and when the boiler is laid-up dry, care should be taken to the effectiveness of the drying agent Hydrostatic Test There are two kind of hydrostatic test, one for checking water-tightness of pressure parts and the other for checking strength of the same. Test pressure should be determined to suit the case Boiling Out Boiling out is intended to cleanse the boiler internal surface of oil and grease. The boiler is filled with high alka or by burning oil whichever the occasion demands. Boiling out by burning oil is often made to ine solution and is heated for a predetermined duration by means of steam serve as buming and drying out refractory used in the boiler setting, too, Recommended duration of boiling out for a new boiler is 2~3 days, Water Washing Hot water washing is intended to remove sludge sticking to the gas side of the boiler that cannot be blown off by soot blowing. There are two ways for hot water washing, one by use of soot blowers and the other by use of a temporary hand nozzle, Both ways have their own m either way may be adopted as the case may be. Hot water washing is generally required 6~8 hours. Gas air heater shall be washed by use of water hose, Recommended hot water temperature is about 80°C and pure water of 50 ton, sea water of 100 ton shall be required MITSUBISHI HEAVY INDUSTRIES, LTD.os 6. Acid cleaning Acid cleaning is intended to remove scales on the water side of the boiler. Inhibited hydrochloric acid solution is generally used for this purpose. But it is important to consult with the professional expert as to the details of cleaning job so as to take most suitable measures to the actual case and to prevent damage that may result otherwise. 7. Refractory Two kinds of refractory are used for this boiler, one is plastic refractory and the other is castable refractory. Both refractory are often used for repairing work, too. As the plastic refractory needs to be burned after placed, it is not used on the boiler pressure parts, where the castable refractory should be used instead, When the castable refractory is to be used on the pressure parts, it should be given necessary clearances for thermal expansion, After repairing reftactory work, never fail to dry it out by firing, 8. Boiler Proper and Water Walls Inspect both gas and water sides of the boiler whenever the opportunity is afforded and see whether it is necessary or not to clean the gas side, to acid cleaning the water side or to replace tubes. Results of these inspections should be referred to in the subsequent burner operation, feed water control, etc. 9. Superheater Operators shall always consider to avoid tube burning. It is essential that a flow of steam be maintained through the superheater at all times while the boiler is being fired. Especially, when the boiler is being fired to raise pressure, attention should be paid starting valve condition and firing rate, Scale shall be accumulated on supetheater tube intemal due to carry-over of boiler water, Therefore, attention should be paid drum level at boiler high load. 10. Desuperheater If any leaks occur, the boiler water will leak into the steam line. It is advisable to put a hydrostatic test on the desuperheater at regular intervals. By-pass valve of steam temperature control valve shall be open at all time to avoid drain accumulation in control desuperheater. 11. Economizer By-pass operation can be applied when economizer tubes are damaged, Faulty tubes shall be repair as earlier as possible. Do not worry about low temperature corrosion because of operating temperature is high MITSUBISHI HEAVY INDUSTRIES, LTD.os 12, 13 Boiler Drum Support Legs The water drum support legs on the boiler rear side are the only fixed legs, and all the other legs are of sliding type requiring the injection of grease once a year (Grease : SHELL ALVANIA EP NO.2, MOBIL PL 47 or equivalent), Boiler Repair The boiler repair work includes the tube plugging, header end plate renewal, removal of manhole cover, tube renewal, expander renewal, packing renewal, etc, It is required that the boiler operator be familiar with the working procedures therein involved Maintenance of Accessories (1) Gas Air Heater The boiler has a vertical rotary gas air heater of the continuous counter flow regenerative type. The heater contains heat transfer elements in two layers The cold end element is called “DNF”. The surface of this element is provided with a corrosion-resisting enamel-coating (Enameling) The hot end element is called “DUN”. The hot end element is made of corrosion-resistant low alloy steel without enamel-coating, The element is to be cleaned by soot blowing or water washing periodically Large components such as heating element, rotor seal, bearing and rotor are to be inspected and replaced properly. (2) Burner The bumer tip is to be cleaned periodically and examined for disorder. The swirler is to be maintained as clean as possible, and also the burner throat area is to be always kept in good working order (3) Soot blower The soot blower steam line drain discharge, smoothness of rotary motion, and adequacy of lubrication are to be monitored. In the process of boiler open-up inspection, the element nozzle is to be examined for disorder and also the element for bend (4) Automatic Combustion Control System and Automatic Feed Water Regulator By taking the control unit indicator reading, the control performance of each system is to be monitored. The air supply line drain is to be blown out once every four hours, The moving parts of every equipment are to be kept always clean. (5) Water Level Gauge The transparent gauge glass is to be blown clear at least once a day to ascertain its responsiveness. The remote-reading level gauge reading is to be compared with the transparent gauge glass reading (once a day) to ascertain its reliability MITSUBISHI HEAVY INDUSTRIES, LTD.CHECK POINT LIS The followings are to be checked periodically to operate boiler safely. (Confirm no sulfur in BOG piping caused by combus gas back flow.) Item Check Method Check Interval Water Gauge Check Water level response at opening or shutting} 1/Day blow valve Remote Water Compare the remote water level indicator with| 1/2 Weeks Level Indicator transparent level indicator at 100 mm decreased water level below normal. Manually operate FWR. Flame Detector I's normal condition to indicate bumer flame failure | 1 / Day to each burner at only each burner firin; Air Slide Operation | Close or open the air slide manually at boiler side. 1/2 Week of Burner Water Level Alarm | Check the water level alarm point, manually to| 1/3 Month Point operate FWR at boiler lower load Supetheated Steam | Check the thermometer by official approved gage. 1/6 Month Thermometer Leakage of Steam | Inspect boiler pressure parts, flanges and valves. or Water BOGExpansion | Inspection leakage and Inside condition. 1/2 Year MITSUBISHI HEAVY INDUSTRIES, LTD.os CONDITION OF THE EMERGENCY FUEL OIL AND GAS CUT Boiler is shut down by the condition as follows. Particular Set Point Location Remarks Drum Level Ex-Low -240 mm Local After 5 sec., off signal Drum Level Ex-High +240 mm. Local__| After 5 sec., off signal Control Power Failure - Local Emergency Manual Trip = ECR&Local Forced Draft Fan Trip Over current | _ Starter All Burner Flame Failure Flame Out _| Local _| After 2 sec, off signal Superheater Steam Temp. High | _545°C Local Emergency fuel oil cut valve is shut down by the condition as follows. Particular Set Point Location Remarks Fuel Oil Pressure Low-Low 1.0 bar Local Fuel Oil Temp. Low-Low 80°C Local Atom. Steam Press, Low-Low | _ 3.0 bar Local Fuel Oil Pump Stop No voltage | _ Starter Emergency fuel gas cut valve is shut down by the condition as follows, Particular Set Point_| Location Remarks BOG Pressure High- High 736 mbar Local BOG Pressure Low-Low 7 mbar Local Emergency master fuel gas cut valve is shut down by the condition as follows Particular Set Point_| Location Remarks Gas Leak Detection : Local BOG Temp. Low-Low sc Local Gas Duct Fan Stop - Local ESDS Activated - Local MITSUBISHI HEAVY INDUSTRIES, LTD.B._ OPERATING PROCEDURE —_———MITSUBISHI HEAVY INDUSTRIES, LTD.PREPARING FOR SERVICE Prior to the start of the boiler, attention should be paid to the following items and thorough checking should be carried out on them. BOILER 1 2. 10. ul Be sure the fire sides are clean and the furnace refractory is in good condition Be certain that no oil nor gas has accumulated in the furnace bottom or in the burner wind box. Wipe up all oil spills and remove any combustible material from burner area. Check the boiler to be sure all repair work has been completed, all tools, ete, have been removed, the handhole fittings and manhole covers properly installed and that all access doors and casing panels have been replaced and properly secured Check the safety valves to see that the gag have been removed, the lifting levers replaced and that the easing gear is not fouled. Insure that the hand easing gear and safety valves are free and clear. The hand gear for lifting safety valves should be thoroughly examined and operated so far as this can be done without lifting the safety valves. Check the water level gauge root valves to be sure they are open. Open the air vent valve fitted on the steam drum. Open the starting valve on the superheater outlet line. Open the drain valves of the superheater headers. Open the shu gauges and made sure that all the valves for the gauges are open. off valves for the pressure gauges of the boiler, check the pipe lines up to the Check and make sure blow-off valves and water wall header drain valves are closed. Bring the water level to about normal water level in the steam drum as instructed below and at the same time check the feed water line. (a) If the boiler is full of water (See instructions on "Care of Boilers Out of Service"), drain the boiler water until the water level is at the bottom of the water gauge. Bring the level up about 100 mm, feeding through the auxiliary feed line, Then bring up the Normal Water Level, feeding through the main feed line (b) If the boiler is empty, fill until the level is just in sight in the water gauge, feeding through the auxiliary feed line, Then raise to Normal Water Level, feeding through the main feed line. This practice serves to check that both the auxiliary and the main feed lines are ready for service, Use condensate for filling a boiler, preferably from a deaerator in service if possible, Compound boiler as per instructions of a boiler water consultant, —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 40os SUPERHEATER 1 Drain both superheater headers before lighting a fire. Scale in superheater tubes is usually soluble in water. By draining the superheater such soluble matter which has gone into solution is removed from the tubes, but if the water is allowed to remain it will be quickly evaporated and the soluble material re-deposited in the tubes, A Open the starting valve on the superheater outlet line. The superheater is protected by the starting valve to permit maintaining a flow of cooling, steam to pass through the tubes during lighting up, securing and stand by periods, The vent must be open while the boiler is being fired and no normal steam flow exists. The vent valve must be open any time there is danger of overheating the superheater from the radiant heat of a hot furnace. The valves in the superheater vent line should be wide open until a pressure of at least 6.86 barhas been reached. If a thermometer is fitted in the steam line between the superheater outlet flange and the superheater protection line a valve in the protection line can be throttled after a pressure of 6,86 bar is reached, providing close watch is maintained on the steam temperature to prevent it going above the design temperature The header drain headers. Close the drain valves as soon as the superheater tubes and headers are thoroughly alves can be lefi cracked open to be sure no condensate collects in the warmed up. At no time should a large volume of steam be permitted to blow from the drains while the boiler is being fired ECONOMIZER Be sure the economizer is full of water. While filling the boiler open the vent and bleed off all air, closing the valve when water appears. UPTAKES Close all access doors that have been removed for repairs or cleaning. Be sure that uptakes are clear for firing and that no one is working in the stack area JRNERS Check fuel oil strainers and entire fuel system to be sure everything is in good condition, Inspect the burner air casing to be certain no oil had dripped to the space around the bumers creating a fire hazard. If drip pans are fitted see that the connecting pipe of drip pans is clear. See that the air slide work freely, that the air slide doors are clean and close properly. If the burners are new or if atomizer or housing tube parts have been replaced check the —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 41os positions of the sprayer plate, this setting is very important, (Refer to Section “Oil Burners”) 5. Fuel gas is not used for lighting up. After lighting up, change the gas firing, According to schedule, check entire fuel gas system to be sure everything is in good condition 6. Check that purge steam pressure is abt. 1.96 bar GAS AIR HEATER 1. Check the lubricating oil level in the gauge glass for support bearing and guide bearing. Open fully the air by-pass dampers. 3. Start the gas air heater prior to starting of FD Fan. —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 42os STARTING A BOILER FROM DEAD SHIP CONDITIONS (Boiler cold start, in case the other boiler is not used.) < Refer to “Boiler Start Up Procedure -1 > 1 10, i If it is necessary to start a boiler from dead ship conditions with neither shore power nor shore steam available, diesel oil may be used until steam has been raised enough to heat the bunker fuel Fill the boiler with deaerated water from a deaerator if at all possible, The feed tanks should be filled with condensate before securing the boilers to provide the water necessary for restarting. It is advisable to fill the boiler S0~80 mm above the normal water level to provide an additional storage until the feed pump can be started Start the emergeney diesel generator A Blow out the gas remaining in the furnace using the forced draft fan before lighting off the burner. Prepare the boiler for service as outlined under the normal starting procedure. Line up the emergency fuel oil pump to take suction from the diesel oil tank and to discharge to the burner manifold Start pumping diesel oil, bleed off enough through the recirculating line, or through the burner oil lead into a bucket to remove all heavy oil from the piping. The diesel fuel oil must to supplied to the burners at designated oil pressure in order to obtain proper atomization Open the following valves before lighting up (1) Drum air vent valve (2) Superheater header drain valves (3) Starting valves (4) Starting valve outlet drain valves (5) Control desuperheater drain valves (6) Steam temperature control valve Light on a bumer with air atomizing, Fuel oil pressure is 2.94 bar (Combustion rate is 400 kg/h), When steam pressure is up to, 0.98 bar el ¢ drum air vent valve. In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line If completely drain, close the superheater header drain valves, starting valve outlet drain valves \d control desuperheater drain valves —_———MITSUBISHI HEAVY INDUSTRIES, LTD.os 12, After a drum pressure 1.96 barhas been reached, start warming up the auxiliary steam lines Line up steam to the settling tank coils, Line up feed pump and have it ready for service when needed. The start load. 13, As soon as the fuel oil in the sett 2 valve must be left open until the boiler has been cut in on the ig tank is warm enough to pump, prepare to change from diesel fuel to bunker fuel. Line up steam on the fuel oil heaters 14, Secure the burner. Circulate bunker fuel through the fuel oil heaters and piping until oil at the proper temperature is available in the manifold, Relight the burner, normal conditions, and continue raising pressure as outlined under normal condition 15, When steam pressure is up to 10~15 bar start warming up the feed water pump, main ‘generator and other machineries 16, After a drum pressure 14.7 barhas been reached, change atomizing fluid from air to steam. And continue raising pressure at 4.41 bar of fuel oil pressure as outlined under normal condition 17. Start the feed pump, as early as possible. After starting the feed pump, close starting valve. 18, Start the main generator 19, When the generator is up to speed and capable of carrying a load, switch over to generator and secure the diesel generator. 20. Drain and warm up connecting piping to the main and auxiliary steam lines. It is essential that the connecting steam piping is clear of all water and warmed up to approximately operating temperature before cutting the boiler in on the load 21. When the steam pressure is about 3~4 bar below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply 22. Set up the bumers with the proper sprayer plates for the service required, lighting up as necessary Note) 1, Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively. 2, When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 44Pp soyesoued wrew ayn weg, ——L axyes Sues og os0j9 pur oungamy dun soya pooy o4p HIS 7 oq gp ssaud Qiy A814 pue Ho ,.), 01 [9SOIP woy [oO Jang aBuey.) 1274 0 [ay 01 wes Sydng ~*~ | 4p 1oyBayLadnsap Jones AeA uNeIp BUNIEIS op asoK Cold Start (In case the other boiler is not used.) Note: 1. Combustion rate should be used as a guide for Ay sayeoyiodns r Start Up Procedure start-up and should be controlled appropriately so as to follow the pressureraising curve. ‘uresp so}woyrodnsop joss puv sopeoy x yyorso “und XjouoA9s weo}s 24) ose U] “DAyEA JOA ATE LUMP 250].) aires 0p 9010 mssud po 9 967 ose fon amend spp ses ss wp pay AE Pop g 8 7 2 ° (aq) aanssoxg nag 50 45 120 180 240 60 Operating Time After Light Up (minute) MITSUBISHI HEAVY INDUSTRIES, LTD,os LIGHTING UP ) RAISING PRESSURE < Refer to “Boiler Start Up Procedure -1 > 1, Check the water level in the steam drum. When the water level gauge is lined up properly the water level will drop when the drain valve is opened, then return to its original level when the drain valve is closed. 2, Start the forced draft fan, open the damper and the bumer air slide door and ventilate the furnace thoroughly for at least five minutes before lighting up. 3. Operate the gas air heater simultaneously with forced draft fan 4, Circulate fuel oil through the fuel oil heaters and the bumer manifold, A re-circulating valve on the manifold and a re-circulating line to the service pump suction is provided for this purpose. By-pass fuel oil meter until ready to light on. 5. When the fuel oil in the burner manifold is at the correct temperature, insert an atomizer assembled with a lighting-up sprayer plate in burner, Close the air registers of the other bumers 6, Reduce the forced draft pressure at the bumers to 1~2 mbar. Close the re-circulating valve and see that the proper fuel oil pressure is available in the bumner manifold. 7. Light up the bumer following the instructions outlined in the bumer section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned. It is important that no unbumed oil is sprayed into the fumace and that no heavy smoke is produced. Frequently observe the smoke indicator and the bumer flame, especially after making any change in firing rate or in forced draft pressure. 8. When steam pressure is up to 0.98 bar, close drum air vent valve, In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line 9. Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork, Firing rate should be less than 380 kg/h by using the normal atomizer sprayer plate until the pressure of 4.90 bar has been reached, Then fire the boiler at a rate which will raise the steam pressure in accordance with pressure raising curve. It takes at least 2~3 hours to raise steam pressure to about 4.90 bar. Do not raise steam pressure too quickly. Turn the burner on/off if necessary. 10, Close the valve on the steam pressure gauge and bleed the steam gauge line to be sure it is clear. Allow the line to cool for a few minutes before opening the pressure gauge valve. See that the gauge responds immediately as the valve is opened 11, Check the water level again by opening the water gauge drain, nothing if the level drops immediately when the drain valve is opened ant returns to the original level as the valve is closed —_———MITSUBISHI HEAVY INDUSTRIES, LTD.os 12, Drain and warm up connecting piping to the main and auxiliary steam lines, It is essential that the connecting steam piping is clear of all water and warmed up to approximately operating temperature before cutting the boiler in on the load 13. When the steam pressure is about 3.0~4.0 bar below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply 14, Since the economizer is installed it may be found that steam will from in the tubes causing a water hammer. In this case run in enough feed water to lower the economizer temperature. Blow down the boiler if necessary to keep the water level in sight in the gauges. Never open water wall header drain valves unless the bumers are secured. 15, When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load, Close superheater outlet starting valve, Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation is to be used make sure regulators are working properly 16, Set up the bumers with the proper sprayer plates for the service required, lighting up as necessary. Operating procedure of each boiler condition shall be as follows. (1) Boiler Cold Start (In case the other boiler is normal used. 1. Prepare the boiler for service as outlined under the normal starting procedure. 2. Start the forced draft fan, ventilate the furnace thoroughly before lighting up 3. Circulate bunker fuel through the fuel oil heaters and piping until oil at the proper temperature is available in the manifold 4. Open the following valves before lighting up (1) Drum air vent valve (2) Superheater header drain valves (3) Starting valves (4) Starting valve outlet drain valves (5) Control desuperheater drain valves (6) Steam temperature control valve 5. Light up the bumer at 2.94 bar of fuel oil pressure (Combustion rate is 210 kg/h) 6. When steam pressure is up to 0.98 bar, close drum air vent valve. In case the steam severely spurt, crack open the superheater header and control desuperheater drain valve The superheater outlet header vent valve must be left open until the boiler is put on the line 7. If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desuperheater drain valves. —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 47os 12 Then steam pressure shall be raise in accordance with pressure raising curve Drain and warm up connecting piping to the main and auxiliary steam lines. It is essential that the connecting steam piping is clear of all water and warmed up to approximately operating temperature before cutting the boiler in on the load ‘When the steam pressure is about 3.0~4.0 bar below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply. When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load. Close superheater outlet starting valve, Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation is to be used make sure regulators are working properly, Set up the burners with the proper sprayer plates for the service required, lighting up as necessary. Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively 2. When it takes time to (throttled) so that the combu: 3. At two-boiler operation, make sure to keep the starting valve open until the boiler e pressure, the starting valve should be operated n rate will follow the pressure raising curve under pressure raising takes on load (2) Boiler Hot Start (In case the other boiler is not used. < Refer to “Boiler Start Up Procedure ~ 1 Check the water level in the steam drum, When the water level gauge is lined up properly the water level will drop when the drain valve is opened, then return to its original level when the drain valve is closed Start the forced draft fan, open the damper and the burner air slide door and ventilate the furnace thoroughly for at least one minutes before lighting up. Operate the gas air heater simultaneously with forced draft fan Circulate fuel oil through the fuel oil heaters and the burner manifold. A re-circulating valve on the manifold and a re- lating line to the service pump suction is provided for this purpose, By-pass fuel oil meter until ready to light up. When the fuel oil in the burner manifold is at the correct temperature, insert an atomizer assembled with a lighting-up sprayer plate in burner. Close the air registers of the other burners Reduce the forced draft pressure at the bumers to 1~2 mbar, Close the re-circulating valve and see that the proper fuel oil pressure is available in the burner manifold Open the following valves before lighting up. —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 48os (1) Air vent valve fitted on the steam drum : Full close (2) Drain valves of the superheater headers, drain valves on the starting valve outlet, drain valves of control desuperheater, steam temperature control valve : Full open (3) Starting valves on the superheater outlet - Half open Supply steam to fuel oil heater Light up the burner following the instructions outlined in the burner section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned. It is important that no unburned oil is sprayed into the furnace and that no heavy smoke is produced, Frequently observe the smoke indicator and the burner flame, especially after making any change in firing rate or in forced draft pressure. 10. Line up desuperheated steam to the each machinery. The starting valve must be left open until stable steam come into superheater 11. Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork. Firing rate should be less than 380 kg/h by using the normal atomizer sprayer plate 12. Then steam pressure shall be rise in accordance with pressure raising curve 13. If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desuperheater drain valves. 14. Close the valve on the steam pressure gauge and bleed the steam gauge line to be sure it is clear. Allow the line to cool for a few minutes before opening the pressure gauge valve. See that the gauge responds immediately as the valve is opened 15. Check the water level again by opening the water gauge drain, nothing if the level drops immediately when the drain valve is opened ant returns to the original level as the valve closed 16, After a drum pressure 14.7 bar has been reached, change atomizing fluid from air to steam. And continue raising pressure at 4.41 bar of fuel oil pressure as outlined under normal condition 17. Start the feed pump, as early as possible, After starting the feed pump, close starting valve 18. After a steam pressure 19.6 bar has been reached, start the main generator. Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively. 2. When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 49GB) Boiler Hot Start (In case the other boiler is normal used.) < Refer to “Boiler Start Up Procedure -4 > 1 2 10. ul Start the forced draft fan, ventilate the furnace thoroughly before lighting up Circulate bunker fuel through the fuel oil heaters and piping until oil at the proper ‘temperature is available in the manifold. Open the following valves before lighting up. (1) Air vent valve fitted on the steam drum : Full close (2) Drain valves of the superheater headers, drain valves on the starting valve outlet, drain valves of control desuperheater, steam temperature control valve : Full open (3) Starting valves on the superheater outlet : Half open Light up the burner following the instructions outlined in the burner section and burner instruction book. Adjust the fuel oil pressure and forced draft pressure to establish a full steady flame with ignition close to the atomizer. The fuel oil must be completely burned. It is important that no unburned oil is sprayed into the furnace and that no heavy smoke is produced, Frequently observe the smoke indicator and the burner flame, especially afier making any change in firing rate or in forced draft pressure. Line up desuperheated steam to the each machinery. The starting valve must be left open until stable steam come into superheater. Take plenty of time bringing the boiler to working pressure to avoid overheating the superheater elements or damaging the brickwork. Firing rate should be less than 280 kg/h by using the normal atomizer sprayer plate If completely drain, close the superheater header drain valves, starting valve outlet drain valves and control desuperheater drain valves Then steam pressure shall be rise in accordance with pressure raising curve When the steam pressure is about 3.0~4.0 bar below normal operating pressure, check the safety valves with the easing gear. Lift the disc well off the seat to give a strong blow and release the lifting lever quickly to reseat the valves sharply When the boiler pressure reaches operating pressure, open the valves cutting the boiler in on load. Close superheater outlet starting valve. Make sure all other drain valves, vent valves and by-pass valves are closed. At this point carefully observe the water level in the boiler. If automatic water regulation is to be used make sure regulators are working properly Set up the burners with the proper sprayer plates for the service required, lighting up as necessary Note) 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately so as to follow the pressure raising curve. To prevent damage to superheater tubes, combustion rate should not be increased excessively. —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 50os When it takes time to raise pressure, the starting valve should be operated (throttled) so that the combustion rate will follow the pressure raising curve. At two-boiler operation, make sure to keep the starting valve open until the boiler under pressure raising takes on load —_———MITSUBISHI HEAVY INDUSTRIES, LTD. 51Boiler Start Up Procedure Cold Start (In case the other boiler is normal used.) Note: 1, Combustion rate should be used as a guide for start-up and should be controlled appropriately 70 so as to follow the pressureraising curve. 2. At two boiler operation, make sure to keep the starting valve open until the boiler under —— 60 s 50 2 3 ge “4 3 3e 3 : Bay} Be e = ST 38 g 2 / Be & 3 2 BE Bs s 2 | EBs $8 3 2 | gfe 82 g a. | 88 gs 3 g 30 gus 35 2 5 ass Be 2 z gee 2 2 4 Seg a 3 |-325 25 2 B28 83 a gee Gt 2 2) 255 2s 23 5 : g8k 23 gas 53 a8 toy 533 ae 533 éf T 1. 0 0 60 120 180 Operating Time After Light Up (minute) MITSUBISHI HEAVY INDUSTRIES, LTD, 240 52£| 5| S| g| £| a | yy 5| a | Hot Start (In case the other boiler is not used.) Note: 1. Combustion rate should be used as a guide for start-up and should be controlled appropriately s0 as to follow the pressure raising curve. soywIoUs UreU ay) Les Suns oy) 25019 pur ugar meq [pp ounssoud dumd sores poay om unig pay 4 4784 utesp s9pooy savwoMLodns “ospeA utesp SunsEs ax aso|o “BururEAp Na,FeO, + 2H 3Na,FeO, +4H,0 > — ONaOH + Fe,0, +2H If oxygen exists anasho, 3.0440, emaOH 10. This is alkaline corrosion. Low pH coordinated phosphate treatment was developed as one of the methods that can perfectly prevent this alkaline corrosion, and has been widely used for land power plants, We recommend this treating method also for 60 bar marine boiler. Principle of low coordinated phosphate treatment This is a method that controls pH value of boiler water by sodium phosphate and maintains the mole ratio of Na’PO, in a determined value. Though the appropriate value of this mole ratio varies due to the boiler water temperature, it is 2.8-2.9 for the 60 bar class boilers. Even when the boiler water is highly concentrated in a boundary film, sodium phosphate is educed in this mole ratio, So, caustic soda does not isolate, concentrated alkaline film is not formed, thus, alkaline corrosion does not proceed. If sodium phosphate is used, in one hand, alone to maintain pH value of boiler water as high as it used to be, solids in boiler water increases, The pH value in the boiler, on the other hand, of which oxygen content is small, needs not to be increased as before. Therefore, in high pressure boiler, pH value of water is kept lower than hitherto maintained by the caustic alkaline treatment, This practice is designated "Low pH coordinated phosphate treatment" or simply "Low pH treatment" as commonly called. For 60 bar class marine boilers, we recommend the treatment that keeps mole ratio of Na/PO, at 2.8 by using tertiary sodium phosphate (NasPO,+/2H,0) and secondary sodium phosphate (NasHPO, + 12H;0), Let the mole of NasHPO,+12H,O (Molecular weight ~ 358) be "X" against one mole of Na;PO,+12H.O (Molecular weight ~ 380) which is req id to keep the mole ratio of Na’ PO, at MITSUBISHI HEAVY INDUSTRIES, LTD.os 2.8, Then, Na _3x142%¥_ PO,” Tx1+1xX Therefore, X= 0.25, that is, the mixing ratio by weight of Na;PO,+12H.O to NasHPO,*12H.0 is 4:1 28 Chemicals to be used Forboiler water; Tertiary sodium phosphate (Na,PO, + 12H,0) and secondary sodium phosphate (Na,HPO,+12H.0) shall be used in mole ratio Na’PO, = 2.8. For feed water Hydrazine hydrate (N-H,“H-O) Compounding procedure of tertiary and secondary sodium phosphates In order to keep mole ratio Na’PO, in 2.8, required mole of NasHPO,+12H,0 is 0.25 to | mole of NajPO,+12H,0. Therefore, their weight ratio becomes 4.25:1 Na,PO,-12H,O _ 3804 ee =425 Na,HPO,-12H,O 3581 LIMI iG VALUES OF FEED WATER AND BOILER WATER For the boiler in operation, boiler water shall be sampled and analyzed at least twice a day, and necessary measures shall be taken for the boiler water accordingly, When you got familiar with boiler water treatment, you can do it once a day. In sampling boiler water, care should be taken to sample the boiler water that represents the real condition of boiler water. Feed water and boiler water analysis shall be carefully done according to the instructions of analyzing instruments and gauges to be used utilizing chemicals specified. Efforts should be exercised to maintain pH value, phosphate ion, chloride ion and dissolved solid of feed water and boiler water within the specified limit. Limiting values for feed water and boiler water in low pH coordinated phosphate treatment for 60 bar marine boilers are as follows: Feed water (1)_ Dissolved oxygen: Oxygen content of ed water must be kept not more than 0.02 cciliter. Q) pH pH value of feed water shall be kept at 8.0 ~ 9.0, (target value 8.7) (3) Hardness Hardness (CaCO;) of feed water at economizer inlet shall be 0.0 ppm. (4) Oil Oil in feed water at economizer inlet shall be 0.0 ppm when ever possible. (8) Hydrazine Hydrazine (W2H,) in feed water at economizer inlet shall be more than 0.01 ppm. (It shall not exceed the upper limit for pH value of feed water.) MITSUBISHI HEAVY INDUSTRIES, LTD. 66Boiler water (1) pH pH value shall be kept at 9.6 ~ 10.3. (2) Chloride ion Chloride ion shall be not more than 20 ppm and be kept as low as possible. (3) Dissolved solid: Dissolved solid shall be not more than 200 ppm. Presumption of the amount of dissolved solid by means of electric conductivity is not always correct as the relation between them varies due to the water quality. But, for the boilers in this ship, the amount of dissolved solid can be maintained below the limiting value 200 ppm by making electric conductivity of boiler water not more than 400 ,:@5/mm of which alkalinity is neutralized with boric acid-glycerin or other acid solution using phenolphthalein as indicator. (4) Phosphate ion Phosphate ion (?O,*) shall be 10 ~ 20 ppm. (8) Silica Silica (SiO.) shall be not more than 3 ppm. EXPLANATION OF BOILER WATER TREATMENT AND ITS LIMITING VALUES Treating method of feed water and boiler water that is necessary for boiler maintenance shall be outlined below. Troubles caused by feed water and boiler water can be roughly divided as follows. (1) Overheating of the heating surface due to scale and oil sticking (2) Corrosion (alkaline embrittlement) (3) Troubles in the superheater or the turbine due to carry-over To prevent the above, some li for feed water and boiler water are necessary. For (1), hardness and oil in feed water and silica in boiler water shall he limited. For (2), pH values of feed water and boiler water shall be limited. Some salts prevent corrosion and other salts promote it. So it is not practical to set limit equally upon them, But generally, when contained excessively, salt (chloride) promotes corrosion, so they shall be kept as little as practicable, For (3), dissolved solids and oil in feed water shall be limited, For silica carry-over, silica in boiler water shall be limited. Feed water pH Purpose of adjusting the feed water pH is to prevent corrosion in the feed water system. If the feed water pH is not correct, the feed water system will be corroded and their corrosion products will be brought into the boiler and they will form scale and sludge in the boiler, Therefore, the feed water pH control is one of the important items of boiler maintenance. As pH value of water rises high, corrosiveness of water becomes less. But, copper alloy is corroded by high pH water. MITSUBISHI HEAVY INDUSTRIES, LTD. —————————— o7