Boiler in parallel operation

For your proper operation of the boilers, we write down the start-up sequences as
follows:
< Boiler Start-up >
1) Select master boiler/PIC C/O SW to “No.1 ”-Stbd boiler
2) Select “PARA” mode
3) Select “16K mode”
4) Set the air controller (port and Stbd boiler) to “cascade mode”
5) Confirm the burners of both boilers are under the firing of B-C oil.
6) Operator increases oil flow of the Stbd boiler manually until the master
pressure rises to 13K around. And then take note the value of oil flow for Stbd
boiler in order to decide the output value of master controller. For example, if
the value of oil flow is 2.5K, master controller output shall be set to 10% ( 4
times is the conversion factor to match range scaling between oil and master
controller, oil : 0 ~ 25K, master: 0 ~ 100%)
7) Steam drum pressure controller(PICP) for Stbd boiler(NO.1) shall be selected
to manual mode and its output shall be set to “4 x oil flow value” for bump-
less transfer at the time of changing the oil controller to Auto mode.
8) Change the oil controller of Stbd boiler to “Auto.”
9) When the above steps are completed, the value of oil flow for port boiler
(No.2) shall be adjusted to match the output value of No.1 master controller.
For example, if the master output value of Stbd boiler (No.1) is 10%, oil flow
value of port boiler (No.2) shall be 2.5K–dividing 10 by 4.
10) Change the oil controller of port boiler (No.2) to “Auto” mode.
11) When the oil flow of both boiler are equal, operator may increase or
decrease the output value of master controller until drum pressure reaches to
the 16K set point.
12) When the drum pressure approaches to +/- 1K of the 16K set value, then
operator is allowed to change the master controller from “manual” to “Auto”
mode.
13) If all the steps are taken successfully, then both boilers will cover the steam
load simultaneously.

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 Note: please keep in mind that boiler should be run slowly for stability at any
time of load increase or decrease. So the governor control of COPT and output
value of the controllers related to boiler ACC including master controller should
be changed slowly during the manual operation. And also note that the number of
boilers to be in service should be selected depending on the steam consumption
of the COPTs in running.

< Further tips for boiler controls>

Please read out following additional tips to run aux. boilers more properly.

** Drum level control

1. Drum level is controlled by two elements: measured value from drum level
transmitter is fed to the controller as Process Value (PV) and percentage value
of steam flow is added to the controller output as feed-forward signal.
2. As drum level variation depends on the load change, increasing or decreasing
boiler load abruptly/quickly should be avoided especially at low load
operation.
3. In certain cases, if drum level fluctuates too much, load change should be
stopped and operator shall switch the controller to manual mode and
manipulate both the drum levels to be kept at nearly same position. Once the
unbalance of both levels is cleared, operator may change the control mode of
controller to “AUTO”

** Operation procedure of marine auxiliary boiler.

1. Master boiler/PIC C/O SW (No.1 or No.2)

- The master controller output signal of selected boiler (C/O SW: No.1 or
No.2) is fed to both the FO controllers as PV regardless of either in
parallel or Master/Slave mode.
- Not in parallel but in Master/Slave mode, the selected boiler (C/O SW:
No.1 or No.2) is in “Master” operation and remaining the other boiler is in
“Slave” operation.
- If Both the No.1 and No.2 boiler are under service of B-C firing, operator
can select any one of the No.1 or No.2 C/O SW. however, in case that
No.1 boiler is in service and No.2 boiler is not in service or vice versa,

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 operator should be careful that Master boiler/PIC C/O SW must be set to
the boiler in service prior to changing each dedicated FO controller to
Auto mode.

2. Master/Slave and PARA mode

1) PARA mode
-During the COPT in running, this mode of operation is recommended so
that both the boilers can share equal load of steam consumption.
-In this mode both the burners are to be fired at the drum pressure of
13.5K and stopped at 17K. To prevent frequent burner start and/or stop at
low load of steam consumption during the COPT initial rolling and/or
stop, Master controller shall be in Manual mode with its output around
10%. If Master controller is in Auto mode at the time of COPT start
and/or stop, there will be a lot of fluctuation on the flow of FO and
COMB AIR due to great difference between 16K SP and burner auto
firing pressure(13.5K steam pressure) , which cause unstable combustion
and sometimes result in boiler trip.

2) Master/Slave mode
-In this mode of operation the boiler selected as Master which fires at
13.5K and stop at 17K will follow the steam load. If FO pressure reaches
12K while drum pressure keeps above 11K, remaining the other boiler
called “Slave” in this case of operation will be started and its FO pressure
will be increased slowly for 15 minutes to cover up the steam
consumption. Then, if FO pressure decreases to reach 4.5K, Slave boiler
will be stopped regardless of steam pressure.
-Meanwhile, Slave boiler will also start and stop when the drum pressure
reaches 13K and 16.5K respectively.

3. 6K, 16K, or IGS mode

1) 6K mode
-This mode of operation should be set during either the sea travel or M/E
warming-up.
-In this mode, burner starts 6K and stops 10K of steam pressure.

2) 16K mode

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 -In general this mode shall be used at the time of COPT operation..
-At low load of boiler operation when COPT starts and stops, the burner
are to be fired at the drum pressure of 13.5K and stopped at 17K, Master
controller should be set Manual with its output about 10% due to the
reasons as described under 2. 1) above.

3) IGS mode
-This mode of operation can be selected in case that cargo tanks are to be
filled with inert gas (less than 5% O2 content). However, this IGS mode
is not recommended, instead during the filling of inert gas to tanks it is
recommended for operator to observe and make sure that O2 content
should not increase to more than 5% under the 16K mode of one boiler
operation with above 25% MCR load.
-Before change to IGS mode, boiler load must be above 25% MCR under
the 16K mode to avoid any nuisance boiler trip which might be caused by
sharp increase of FO pressure to 6K if select IGS mode at less than 25%
MCR load.
-In this mode boiler will be tripped at 17.5K instead of 17 K of steam
pressure.
-Make sure that boiler load shall be more than 40% MCR in case of IGS
mode of boiler operation and most of steam produced by boiler will flow
through the dump system. (recommend to operate dump valve manually

4. Stop/Auto/Manual and Hard manual switch

1) Stop
- If select to “stop” mode, burner will stop immediately and never start
again.

2) Auto mode
- In this mode, burner will start and stop automatically depending on the
drum pressure variation as stated above.
- All interlock signals will be activated.
- This is the normal mode of boiler operation.

3) Manual mode
- In this mode, burner will start automatically and keep on operation until

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 trip when steam pressure reaches 17.5K. Meanwhile, there will be no
automatic stop of burners depending on the set pressure as described
above.
- This mode can be used in a special case like at the time of safety valve test.

4) Hard manual mode

- This mode can be applicable in emergency case only when controllers and
PLC programs are out of work
- For safety reason, this mode shall be avoided in any case. If required to
start boiler by all means, operator should read carefully both the procedure
described on the front of control panel and instruction manual enclosed in
the operation book.

5. FO temp by-pass S/W

- the purpose of this switch is to by-pass the temperature interlock when
lower temperature of DO is in service instead of FO which requires
temperature interlock for burner firing.
- When FO temperature rises to more than 100℃, this switch shall be
selected to Normal.

6. F.D Fan Avail By-pass S/W

- One of the interlocks for F.D Fan starting is the confirmed signal from the
generator control panel that at least two generators as minimum should be
run to avoid black-out which may be caused by the required high initial
current at the time of fan starting.
- In case that F.D.Fan is in need of starting under the condition of only one
generator in running, this by-pass switch can be available: that is, if this
switch is selected to “by-pass” position, PLC logic will be in the sequence
of activating Fan to start. Once the electric power from generation is
enough to cover the whole load including initial current of F.D.Fan, there
will be no “black-out.”
- If this switch is positioned to “normal” under one generator in operation,
prior to starting Fan PLC logic will send a signal to the generator control
panel to start up one of the stand-by generators and when received
confirmed feed back signal from generator control panel that at least two
generators are in operation to cover up the whole electric power

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 consumption, F.D.Fan starting logic will be activated.

7. How to operate controllers

- In order to operate boilers, just following keys are enough:
A/M, DISP, four arrow keys, R/L or CAS
- Every time pushing the A/M key, controller mode will be changed in turn
to “manual” from “auto” and to “auto” from “manual.”
- Once push DISP key, controller will return to normal display mode from
any data setting mode. After returned to normal display mode, whenever
push this button, controller will display predetermined data such as PV,
SV, etc in turn.
- If controllers are set to manual mode, arrow keys can be used to increase
or decrease the controller output.
- R/L or CAS key shall be used to set the controller in normal mode.
Normal modes are as follows:
Combustion air controller: CAS mode
FO controller: REMOTE mode
Drum level controller: AUTO mode
Master controller: AUTO mode
- when the others keys on the controller are to be used, operator should be
careful and make sure that he is fully in acquaintance with instructions
described in the section of operation manual, volume 3.