Steam Generator NGC

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Fire Tube Steam Boilers

GPT, GPT/R, NG/C, NG/V, NG3/R3 Introduction
FIRE TUBE STEAM BOILERS

GPT, GPT/R, NG/C, NG/V, NG3/R3
USE INSTRUCTIONS
WARNING
THE USE OF THE BOILER IS ALLOWED ONLY TO SKILLED

PERSONNEL
CAREFULLY READ THIS MANUAL BEFORE MACHINE
START-UP
GARIONI NAVAL
Viale dei Caduti, 3 – 25030 Castelmella (Bs) – Italy
Ph. +39/030/2681541 – Fax +39/030/2680910
www.garioninaval.com.
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GPT, NG INGLESE Rev. 2.3
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This manual must be regarded as an integral part of the Boiler, therefore it must be always kept together with
this latter and within reach of the Skilled Installer, of the Trained User and of the Skilled Maintenance
Operator.
We remind you to read and understand its content before starting up the Boiler.
We remind you to scrupulously keep to all the notices given in this manual since they describe the modalities
of execution of particular operation or maintenance activities which may cause damages to the persons or to
the Boiler if they are carried out in a wrong way.
By scrupulously keeping to the instructions given, you’ll be able to make a rational use of the installation and
assure cost-saving.
In case of failure or any other problem concerning your Boiler, immediately consult the Garioni Naval’s
service centre.
We remind you that, in case of need, the use of original SPARE-PARTS assures the efficiency and long
working life of your boiler.
This manual is general, please take into account only parts referring to the assembly specified in the first
page of this manual.
This boiler shall be operated and maintained according to present instructions; relevant non observance will
immediately delete our guarantee.
GUARANTEE
Each product is supplied after regular test and inspection and guaranteed in accordance with the contractual
provisions.
The guarantee applies only to the Purchaser in agreement with
!
the contractual and administrative Provisions and, should the
fitting and the following use be carried out by the User, in
compliance with the instructions contained in this manual,
which must have been read and understood in all its details.
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INDEX GPT, GPT/R, NG/C, NG/V, NG3/R3
1. SAFETY PRESCRIPTIONS 7
1.1 GENERAL PURPOSE AND RANGE OF APPLICATION 7
1.2 HEATING PLANT 7
1.2.1 PRELIMINARY SAFETY CHECKS 8
1.3 SAFETY PRESCRIPTIONS DURING INSTALLATION AND FIRST
COMMISSIONING 9
1.4 SAFETY PRESCRIPTIONS DURING MAINTENANCE 10
1.4.1 GENERAL PRESCRIPTIONS, BEFORE ANY INTERVENTION 10
1.4.2 FUEL CIRCUIT 10
1.4.3 ELECTRICAL CABINET 11
1.4.4 STEAM CIRCUIT 11
1.5 SAFETY PRESCRIPTIONS DURING MACHINE WORKING 12
2. GENERAL DESCRIPTION 13
2.1 BOILER SECTION 13
2.1.1 BOILERS SERIES GPT 13
2.1.2 BOILERS SERIES GPT/R 14
2.1.3 BOILERS SERIES NG/C 15
2.1.4 BOILERS SERIES NG/V 16
2.1.5 BOILERS SERIES NG3/R3 17
2.2 BOILER LAY-OUT 18
2.2.1 BOILERS SERIES GPT 18
2.2.2 BOILERS SERIES GPT/R 19
2.2.3 BOILERS SERIES GPT/R WITH ECONOMIZER AND MODULATING FEED
WATER 20
2.2.4 BOILERS SERIES GPT, GPT/R WITH AIR PREHEATER 21
2.2.5 BOILERS SERIES NG/C 22
2.2.6 BOILERS SERIES NG/V 23
2.2.7 BOILERS SERIES NG3/R3 24
2.3 P&I BOILER 25
2.3.1 BOILERS SERIES GPT, GPT/R 25
2.3.2 BOILERS SERIES GPT, GPT/R WITH ECONOMIZER AND MODULATING FEED
WATER 26
2.3.3 BOILERS SERIES NG/C, NG/V AND NG3/R3 27
2.4 GENERAL 28
2.4.1 BURNER 28
2.4.2 AUTOMATISMS AND ELECTRICAL SYSTEM 29
3. INSTALLATION 30
3.1 GENERAL 30
3.1.1 TRANSPORT 30
3.1.2 INSTALLATION 30
3.1.3 VIBRATIONS 31
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3.2 PLANT 32
3.2.1 CONNECTIONS TO BE CARRIED OUT 32
3.3 THERMAL POWER PLANT 33
3.4 STACK 34
3.4.1 FLANGED SMOKES CONNECTIONS 35
3.5 FEED WATER 35
3.5.1 FEED WATER AND CONDENSATE TANK 36
3.5.2 CONDENSATE RETURN SYSTEM 36
3.6 CHARACTERISTICS OF WATER 36
3.6.1 BRIEF NOTES ON PARAMETERS AND CONVERSION BETWEEN THE
MEASURING UNITS 38
3.7 WATER TREATMENT 40
3.7.1 WATER FILTRATION 40
3.7.2 WATER SOFTENING 40
3.7.3 REVERSE OSMOSIS 41
3.8 BLEEDING 42
3.9 PIPING 43
3.9.1 EXPANSION JOINTS 46
3.10 SAFETY VALVES DISCHARGE 46
3.11 BLOW DOWN 47
3.12 FUEL FEEDING LINE 47
3.13 ELECTRICAL CONNECTIONS 47
4. ACCESSORIES 48
4.1 GENERAL 48
4.2 PRESSURE MEASUREMENT DEVICES 49
4.2.1 PRESSURE GAUGE 49
4.2.2 PRESSURE TRANSMITTER 49
4.2.3 SAFETY PRESSURE SWITCH 49
4.2.4 SAFETY VALVES 50
4.3 LEVEL MEASUREMENT DEVICES 51
4.3.1 LEVEL INDICATORS 51
4.3.2 PROBES AND AUTOMATIC LEVEL REGULATOR 51
4.3.3 TESTING OF CAPACITIVE LEVEL PROBES 53
4.4 WATER SUPPLY 54
4.4.1 MOTOR-DRIVEN PUMP 54
4.5 FUEL FEEDING LINE 55
4.5.1 NATURAL GAS SYSTEM 55
4.5.2 DIESEL OIL FUEL SYSTEM WITHOUT TRANSFER PUMP 56
4.5.3 HEAVY OIL FUEL SYSTEM WITH FEEDING TANK 56
4.5.4 HEAVY OIL FUEL SYSTEM WITH LOW PRESSURE FUEL CIRCULATION
SYSTEM 57
4.5.5 FUEL CHANGE OVER FROM DIESEL OIL (MDO) TO HEAVY FUEL OIL (HFO)
AND VICEVERSA 58
5. OPERATION 60
5.1 CONSIDERATIONS ABOUT SMOKE TUBE BOILERS 60
5.2 OPERATION WITHOUT PERMANENT SUPERVISION 61
5.2.1 INLAND APPLICATIONS 61
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5.2.2 MARINE APPLICATIONS 61

5.2.3 OPERATION 62
5.2.4 TRAINING OF PERSONNEL 62
5.2.5 OPERATING INSTRUCTIONS 62
5.2.6 RECORDS 62
5.3 PRELIMINARY OPERATIONS 63
5.3.1 PRESSURE PARTS 63
5.3.2 SAFETY VALVES 63
5.3.3 VALVES 63
5.3.4 REGULATION AND CONTROL EQUIPMENT 64
5.3.5 BURNER EQUIPMENT 64
5.3.6 FIRE PROTECTIONS 64
5.3.7 CHIMNEYS AND CLOSURES 64
5.3.8 MOTORS 64
5.4 START-UP 65
5.4.1 BOILERS WITH ON/OFF WATER CONTROL 65
5.4.2 BOILERS WITH MODULATING WATER CONTROL 66
5.5 NORMAL OPERATION 66
5.6 PERIODICAL INSPECTIONS 67
6. TROUBLESHOOTING 68
6.1 GENERAL 68
6.2 THE BURNER DOES NOT START 68
6.3 THE BURNER STARTS AND STOPS AFTER A FEW SECONDS 68
6.4 SMOKY FLAME 68
6.5 PULSATING FLAME 69
6.6 ELECTRICAL CABINET DOES NOT START 69
6.7 PUMP DOES NOT STOP (AT MAXIMUM LEVEL) 69
6.8 PUMP DOES NOT START (AT MINIMUM LEVEL) 69
6.9 PUMP DOES NOT TURN AND/OR ALARM LIGHT IS ON 69
6.10 BURNER STOPS FOR WATER AND/OR PRESSURE ALARM 70
6.11 BURNER DOES NOT STOP FOR WATER AND/OR PRESSURE ALARM 70
6.12 LOW LEVEL ALARM 70
6.13 HIGH LEVEL ALARM 71
6.14 WATER FAILURE ALARM 71
6.15 PRESSURE ALARM 71
6.16 BURNER ALARM 72
7. MAINTENANCE 73
7.1 GENERAL 73
7.2 MAINTENANCE OPERATIONS (IN ADDITION TO PERIODICAL INSPECTIONS)73
7.2.1 MONTHLY MAINTENANCE 73
7.2.2 SEMI-ANNUALLY MAINTENANCE 74
7.2.3 EXTRAORDINARY BOILER MAINTENANCE 74
7.3 INSTRUCTIONS FOR CLEANING OF AIR PREHEATER (/AR ONLY) 75
7.4 STANDSTILL 75
7.4.1 DRY CONSERVATION 75
7.4.2 WET CONSERVATION 76
7.5 OPENING OF REAR SMOKE CHAMBER 77
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7.6 SPARE PARTS 78
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Fire Tube Steam Boilers Safety
GPT, GPT/R, NG/C, NG/V, NG3/R3 prescriptions
1. SAFETY PRESCRIPTIONS
1.1 GENERAL PURPOSE AND RANGE OF APPLICATION

Before setting the boiler in operation and before starting any maintenance intervention, it is absolutely
necessary that the operators responsible have read and understood all the NOTICES AND WARNINGS
given in this section and in all the documents relevant to the Instructions of Use which are provided together
with the GARIONI NAVAL boilers.
GARIONI NAVAL cannot anyway foresee all the circumstances which might cause potential risks when the
boiler is in operation.
The various maintenance operations and/or procedures which have not been explicitly recommended and/or
stated in the Use Instructions, shall always be reported to GARIONI NAVAL for approval.
If a special, not specifically suggested procedure must be carried out, the user has a duty to ascertain
whether it is safe and make sure that it causes no damages to persons or things.
Purpose of this section is to provide all necessary instructions concerning the precautions to be absolutely
taken in order to assure protection and safety to persons and things.
1.2 HEATING PLANT

The room or the area where the boiler has been installed shall be considered a heating plant. As such, it
must be installed and operated only by skilled and suitably trained personnel.
The following prohibition boards must be therefore affixed:
- Only authorized personnel admitted
- Wear the personal protection devices
- All maintenance operations must be carried out with the electrical shutdown switch in the open
position (0 – off).
For the automatic-ignition boilers an additional warning-board must be affixed noticing the possibility of
automatic start-up of the boiler.
National regulations shall be taken into account.
If necessary, the purchaser shall integrate the equipment supplied by GARIONI NAVAL with other equipment
in order to comply with requirements specified in this manual.
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1.2.1 Preliminary Safety Checks

Before carrying out any start-up procedure, it is extremely important that you make yourself “familiar” with the
boiler and the installation. Besides, a visual safety inspection of the working area of the boiler and of the
installation must be carried out. Said inspection shall include all the positions listed hereunder besides any
other which may be of utmost importance for the installation. Any source of actual or potential hazard must
be removed before getting on.
- Locate the position of the emergency stop push-buttons, of the fuel quick on-off valves, of the
switches and any other emergency device.
- Have good knowledge of the particular emergency procedures relevant to the installation concerned.
- Be acquainted with the procedures and the First Aid means which must be stated on suitable notice-
boards affixed in a clearly visible position close to the installation and/or to the boiler.
- Locate the position of the Fire-Fighting Protection systems (fire-extinguishers, fire hydrants, etc.) and
have good knowledge of their working.
- Find out danger sources, for example leaks of fuel, oil, acid solutions, condensate in the drippers,
high voltages, high pressures, high temperatures and other dangers.
- Make sure that the boiler and the adjacent area are clean and free of foreign matters. Check that
there are no obstructions and/or foreign matters in the air intake ducts and of the engine cooling.
- Make sure that the workers operating on other units in the close proximity do not carry out
dangerous activities which might somehow prevent the correct working of the boiler and/or – should
the operation of the boiler be dangerous for the working staff.
! Start-up the boiler only when the highest safety conditions can
be assured.
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1.3 SAFETY PRESCRIPTIONS DURING INSTALLATION AND FIRST

COMMISSIONING
- Do not remove the original protections from all the exposed rotating parts, from the hot surfaces,
from the air intakes or parts under tension.
- Install all the necessary protections to assure the safety of the installation. Connect the remote alarm
signals, if any, to the electrical check panel.
- Never leave loose parts, equipment or anything else not belonging to the installation, in the boiler
room or in the next proximity of the boiler.
- Take all the precautionary measures in order to avoid any risk of fulmination; check that the
grounding system has been duly realised in accordance with the Regulations.
- Verify and check that the power electrical connections and those of the ancillary services have been
duly carried out.
- Make sure that the direction of rotation of the electrical motors corresponds to their original
movement.
- Verify that the alarm and stop devices of the boiler perfectly work. In detail:
• Due to high pressure
• Due to high smokes temperature (if installed)
• Due to burner stopping
• Due to fuel leakage (only for the boilers with gaseous fuel)
• Due to power supply failure
• Due to possible repetitions of remote alarms

- Verify the function of safety valves
- Check that the room is well-ventilated. Check that the chimney is free and that the exhaust gases
can be discharged without problems. Besides, make sure that the piping and the electrical ducts are
properly supported, provided with expansion joints and protected against accidental contacts.
- Check the steam, water and fuel (liquid and/or gaseous) piping and make sure that there are no
leakages.
- As far as combustible is concerned check:
• Maximum/minimum gas pressure and seal (natural gas)
• Flame failure (diesel oil)
• Heavy oil maximum minimum temperature (if applicable).
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1.4 SAFETY PRESCRIPTIONS DURING MAINTENANCE
1.4.1 General Prescriptions, before any Intervention

All maintenance operations must be carried out when the boiler is at a standstill.
Before starting the maintenance operations, affix the boards noticing Danger: works in progress.
Stop and advise, by making use of special boards, that any kind of operation is prohibited due to works in
progress on all the devices which insulate the boiler.
Wear the personal protection means required:
- Gloves and protective goggles
- Noise dampening shrouds
- Accident prevention shoes and overalls
- If works are to be carried out a height above 2 metres, make use of fall prevention means.
Never try to carry out operations you are not familiar with;
! always FOLLOW the instructions and, if no instructions are

present, contact the GARIONI NAVAL service centre (phone
++39 030 2681541) gnservice@garioninaval.com .
1.4.2 Fuel Circuit

The fuel circuit, both liquid and gaseous, must be realized according to applicable regulations and laws by
skilled personnel.
- It is advisable that you check, at regular intervals, the presence of fuel leakages.
- Always wear personal protection means (gloves, goggles, overalls and accident-prevention shoes)
before carrying out any maintenance operation.
- Absolutely avoid any use of free flames and/or the presence of heat sources in the next proximity of the
fuel circuit: Fire risk.
- Never start the boiler if the fuel filters have not been correctly installed.
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1.4.3 Electrical cabinet

All the maintenance operations to be realized on the electrical system must be carried out by skilled
personnel.
- Do not remove and/or execute electric jumper-connections of the emergency or alarm signals.
- Replace the safety devices (fuses, thermal switches) only with spare parts having the same protection
and intervention characteristics.
- Before modifying the working of the control electrical panel always contact the GARIONI NAVAL service
centre.
- Do not carry out any operation when the equipment is under tension. Before carrying out any
maintenance intervention inside the electrical panel, open the main switch and affix the boards noticing:
Danger works in progress.
- The electrical panel, as well as all the electrical equipment, is particularly moisture-sensitive. Therefore,
provide for an accurate cleaning of the air intakes (if present) and the proper closing of all the fittings.
- At regular intervals, check that the bolts and the fastening screws of the components and of the electrical
connections are tight.
! Always perform boiler connection to ground.
1.4.4 Steam Circuit

- The steam circuit must be realized according to applicable regulations and laws by skilled personnel
- It is advisable to check - at regular intervals - the presence of any possible leakage or dripping.
Necessary repairs to avoid any risk of damage shall be immediately provided.
- On account of the high operating temperature of the installation, you’d better insulate the hot surfaces
with suitable insulating materials and, should this not be possible, paint the above mentioned parts with
special varnish (silver colour).
- Before starting the boiler, make sure that the on-off valves are open, that the safety valves are free and
the drains are tightly closed.
- At regular intervals, verify the tightness of the bolts and of the valves
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1.5 SAFETY PRESCRIPTIONS DURING MACHINE WORKING

- The access to the boiler room should be allowed only to authorized personnel in charge of its operation
by affixing the relevant notice-board.
- Never carry out alone maintenance works requiring more than one person, especially if interventions on
operating organs such as switches, disconnecting switches and/or other electrical appliances are to be
carried out.
- Always wear the noise-dampening shrouds in order to avoid damages to the operator’s auditory canals if
the operator’s presence in the room where the boiler is working is required.
- When the height of the working area is above 2 metres, it is compulsory to make use of the fall-
prevention means and helmet.
!
Do not touch the boiler when it is working. Burns hazard.
Alarm bell must be installed in a frequently occupied room by
boiler operator.
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Fire Tube Steam Boilers General
GPT, GPT/R, NG/C, NG/V, NG3/R3 description
2. GENERAL DESCRIPTION
2.1 BOILER SECTION
2.1.1 Boilers series GPT
Position Description Position Description

1 Burner 6 Smoke tubes
2 Steam outlet 7 Inversion chamber
8 Insulation
4 Shell 9 Chimney
5 Combustion chamber
NOTE: drawings are purely indicative and cannot be considered as restrictive of fabrication. GARIONI
NAVAL reserves its rights of modification at any moment, depending on any reason and on continuous
evolution of technology and production.
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2.1.2 Boilers series GPT/R

8 Insulation
4 Shell 9 Chimney
14
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2.1.3 Boilers series NG/C

8 Insulation
4 Shell 9 Chimney
15
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2.1.4 Boilers series NG/V

8 Insulation
4 Shell 9 Chimney
16
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2.1.5 Boilers series NG3/R3
Disegno NG 1041 Rev.0

1 Insulation 6
2 Combustion chamber 7 Smoke tubes
3 Shell
4 Sightglass
5 Insulation
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2.2 BOILER LAY-OUT
2.2.1 Boilers series GPT
KSB
BSK
KS B

1 Safety valve 11 Pressure transmitter
2 Steam outlet valve 12 Auxiliary connection
3 Discharge valve 13 Salinometer connection (optional)
4 Water inlet connection 14 Auxiliary connection
5A Feed pump 15 Electrical panel
5B Feed pump (optional) 16 Burner
6 Safety probe connection 17 Manifold connection
7 Level indicator 18 Feed water valve
8 Chimney 19 Check valve
9 Pressure gauge 20 Probe manifold
10 Safety pressure switch
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2.2.2 Boilers series GPT/R
KSB
KSB
KSB

1 Steam outlet valve 8 Pressure transmitter
2 Safety valve 9 Pressure gauge
3 Discharge valve 10 Level indicator
4 Feed pump 11 Feed water valve
4a Feed water valve 12 Check valve
4b Check valve 13 Lifting lugs
5 Auxiliary connection 14 Electrical panel
6 Safety probe connection 15 Chimney
7 Safety pressure switch 16 Burner
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2.2.3 Boilers series GPT/R with economizer and modulating feed water
KSB
BSK
BS K
BS K
2 Safety valve 11-12 Pressure gauge
3 Discharge valve 13 Thermometer
4 Feed pump 14 Level indicator
4a Feed water valve 15 Economizer
4b Check valve 16 By-pass valve
5 Feed water valve 17 Safety valve
5a By-pass valve 18 Thermometer
6 Continuous blowdown 19 Feed water valve
6a Sample cooler 19a Check valve
6b Level blowdown valve 20 Lifting lugs
7 Feed water control connection 21 Electrical panel
8 Safety probe connection 22-22a Regulation probes connection
9 Safety pressure switch 23 Condensate discharge
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2.2.4 Boilers series GPT, GPT/R with air preheater
KSB
M1 6
M
1
6

1 Water inlet connection 4 Chimney
2 Steam outlet valve 5 Burner
3 Fan
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2.2.5 Boilers series NG/C
KSB
KSB
KS
B

1 Safety valve 9 Pressure gauge
2 Steam outlet valve 10 Safety pressure switch
3 Discharge valve 11 Pressure transmitter
5A Feed pump 13 Salinometer connection (optional)
5B Feed pump (optional) 14 Auxiliary connection
6 Safety probe connection 15 Electrical panel
7 Level indicator 16 Burner
8 Chimney 17
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2.2.6 Boilers series NG/V

1 Shell 11 Chimney
2 Blow down valve 12 Salinometer connection
4 Water inlet valve 14 Water control connection
5 Handhole 15 Safety pressure switch
6 Manhole 16 Pressure transmitter
7 Level indicator 17 Manifold blow down
8 Manifold with safety probes 18 Burner
9 Safety valve 21 Smoke chamber inspection
10 Steam outlet valve
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2.2.7 Boilers series NG3/R3
KSB
KSB

1 Safety valve 10 Safety pressure switch
3 Discharge valve 12 Pressure gauge valve
5A Feed pump 14 Electrical panel
5B Feed water valve 15 Safety valve connection
6 Safety probe connection 16 Feed water valve
7 Level indicator 17 Check valve
8 Chimney 18 Probe manifold
9 Pressure gauge
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2.3 P&I BOILER
2.3.1 Boilers series GPT, GPT/R

LSLL Safety probe low-low level PSHH Safety pressure switch
LSL Safety probe low level PIC Regulation pressure switch
LSH Safety probe high level PI Pressure indicator
LC Level control PT Pressure transmitter
LI Level indicator PSV Steam safety valve
M Motor TI Temperature indicator
I Interlock TE Temperature element
R Manual start
L Logic
A Alarm
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2.3.2 Boilers series GPT, GPT/R with economizer and modulating feed water

LSLL Safety probe low-low level PSHH Safety pressure switch
LSL Safety probe low level PIC Regulation pressure switch
LSH Safety probe high level PI Pressure indicator
LC Level control PT Pressure transmitter
LI Level indicator PSV Steam safety valve
M Motor TI Temperature indicator
I Interlock TE Temperature element
R Manual start
L Logic
A Alarm
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2.3.3 Boilers series NG/C, NG/V and NG3/R3

LSLL Safety probe low-low level R Manual start
LSL Safety probe low level L Logic
LSHL Level regulation probe PSHH Safety pressure switch
LC Level control PSH Limit pressure switch
LI Level indicator PSHL Regulation pressure switch
M Motor PI Pressure indicator
I Interlock PSV Steam safety valve
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2.4 GENERAL
Boilers GPT, GPT/R are horizontal semifixed boilers, with passing flame burner and three smoke pipes,
suitable for steam generation with capacity from 2.000 to 20.000 kg/h up to 18 bar pressure. Extremely
compact units, in the standard design they are provided of all safety protections for overpressure, overload of
electric motors, flame failure.
Boilers NG/C and NG/V are horizontal or vertical semifixed boilers, with passing flame burner and two smoke
pipes, suitable for steam generation with capacity from 300 to 6.000 kg/h up to 15 bar pressure. Extremely
compact units, in the standard design they are provided of all safety protections for overpressure, overload of
electric motors, flame failure.
Boilers NG3/R3 are horizontal semifixed boilers, with passing flame burner, flame inversion and three smoke
pipes, suitable for steam generation with capacity up to 3.000 kg/h up to 15 bar pressure. Extremely compact
units, in the standard design they are provided of all safety protections for overpressure, overload of electric
motors, flame failure.
2.4.1 Burner
The burner is foreseen both for liquid and gaseous liquids.
Incorporated in the structure, it is supplied with command and control equipment:
• Solenoid valves for fuel control and fuel stop
• Sleeve with spray nozzles or gas outflow ring
• Ignition electrodes
• Heater complete with resistance (for heavy oil)
• Fuel filter (for heavy oil / diesel oil)
• Air electric fan
• Heavy oil / diesel oil pump
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2.4.2 Automatisms and electrical system

• Safety devices (safety valves, safety level switch or safety pressure switch for burner cut-out, safety
pressure switch)
• Observation devices (level indicators, pressure gauge, pilot flame)
• Regulation devices (level switches, pressure switches, pressure regulator)
• Alimentation devices (centrifugal pump)
• Operating devices (cut-off valves, discharge valve)
• Burner management system
• Electrical cabinet including protection and control device for the electric motors, ancillary relays,
timers, pilot lamps, …
• Electric connections from cabinet to the equipment
Any damages suffered by the boiler during transportation and

unloading must be immediately informed to the forwarding
! agent.
If installation of the boiler occurs later, it must be kept in a
protected and dry place in order to preserve it from any
damage.
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GPT, GPT/R, NG/C, NG/V, NG3/R3 Installation
3. INSTALLATION
3.1 GENERAL
The boiler must be suitably installed, operated and inspected according to the instructions given in the
handbook, this in order to guarantee the best working conditions. The boiler is supplied as a perfectly
operating mono-bloc unit.
3.1.1 Transport
Transport is performed with boiler in horizontal position. For lifting and tilting, if any, dedicated lugs are
foreseen.
Storage shall be performed at temperature between 5 and 50 °C.
3.1.2 Installation
The boiler must be installed on a stiff, levelled base, preferably on a concrete slab or steel frame, in a room
enabling an easy access to the equipment and to the personnel. For horizontal boilers, front plate (close to
the burner) shall be fixed to the floor, while rear plate shall be left free to move in order to compensate
thermal expansion.
For vertical boilers, base plate is designed to be fixed to floor.

For marine applications of vertical boilers, when height is greater than 3 meters or it is larger than diameter, it
is recommended to support the boiler in the upper position due to the relatively high location of centre of
gravity. The top part of the boiler is provided with fixing eyes that shall be connected to fixing beams. At least
one beam shall be arranged in the vessel longitudinal direction, and at least one beam in the vessel
transverse direction. In order to minimise the influence of thermal expansion, the optimal installation angle of
beams is +/- 15˚ from the horizontal. Furthermore, it must be ensured that the thermal expansion does not
create any tension on the beam arrangement by enough clearance between link holes and fixing bolts.
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The room must be well-ventilated in order to supply sufficient air for the combustion and the temperature
must be suitable for the correct working of the electrical equipment, anyway not above 35-40°C.
!
The installation in the open air – even under a roofing – is
absolutely forbidden, unless the boiler has been built
expressly to that purpose.
3.1.3 Vibrations
In case of marine applications, particular attention shall be paid to vibrations, that:
- can subject structural elements and welds to dangerous fatigue stresses;
- can impair correct operation of essential equipments;
- can damage the burner;
- can damage the refractory.
In consideration of the above, installation with excessive vibrations is not allowed. As a reference, vibrations
can be considered excessive in case of frequencies higher than 200Hz and/or velocity higher than 25mm/s.
In case of excessive vibrations, special antivibration joints shall be adopted, designed in such a way to avoid
vibrations to equipment supplied by GARIONI NAVAL.
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3.2 PLANT
B01 Steam generator V01A/B Water softener

BR01 Burner V02 Salt storage tank
P01A/B Feed water pump(s) V03 Condensate return tank
P02 Metering pump V04 Metering tank
3.2.1 Connections to be carried out

- Water inlet
- Steam piping to the installation
- Safety valves discharge
- Water blow down
- Chimney pipe for smoke exhaust
- Fuel feeding line
- Power supply to the panel
Upon installation, first carry out the hydraulic and then the
! electrical connections.
Threaded connections shall be performed carefully in order to
avoid any damage to threads and component.
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3.3 THERMAL POWER PLANT

National rules and any other rule of installation place shall be taken into account as far as fire prevention and
safety precautions are concerned.
The rooms destined to hold steam boilers should have access doors opening from the inside to the outside.
Moreover, such rooms shall be designed exclusively for operation of the boilers; unauthorised access for
tasks other than those directly related to the operation of the generations must be forbidden and a clearly
visible sign must be placed at the entrances to the rooms indicating this condition.
Pipes and connection system existing at a level above the boilers must be installed in a manner which does
not obstruct the work or the movement of the operator when accessing the upper part of the boiler itself in
order to inspect or repair accessory fittings.
The boiler discharge sewers must always be easily accessible and free for inspections.
Position Description
1 Steam Boiler
2 Burner
3 Electrical Cabinet
4 Feed Pump
5 Steam Outlet Valve
It is good practice to observe the following general
rules:
- Between the maximum side and rear bulk of the
boiler and the walls of the installation site, there
should be a space of at least 0,60 meters; this
ensures easy movement of boiler operating
staff.
- Between the highest walkway for operation and
surveillance of valves and lowest obstacle on
the roof of the boiler room, there should be a
minimum headroom of a 1,80 meters.
- It is also advisable to leave a space behind the
boiler sufficient to allow the opening of any
hinged doors.
- Between the front hatch of the boiler and the
facing wall of the installation room, there should
be a space at least equal to the length of the
free pipe bundle; this facilitates pipe cleaning
and replacement, if necessary.
Ventilation openings of boiler room shall have total minimum opening area equal to:
Capacity [kcal/h]
Cross section [cm²] >=
80
In case thermal power plant is located in places with outside temperature above 25°C, installation of fans for
hot air circulation is recommended. Materials with 120 minutes resistance to fire are recommended.
In case aeration channel is foreseen, in particular for marine applications, air entrance shall not be located
close to burner air aspiration.
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3.4 STACK
Steam boilers operate under pressure, which means that exhaust gases are released under pressure from
the flue duct, but this does not allow a bad installation of the chimney. Remember to avoid in all cases elbow
bends and, whenever possible, long horizontal runs. To discharge into an existing chimney, create a suitable
lead section so as to avoid interfering with other boilers.
The cross section of the stack pipe shall not be smaller than that of the boiler outlet connection and its height
must be in compliance with the normative provisions in force.
The stack shall follow the shortest route, avoiding straight-angle bends and elbow bends. Throttling or
localized pressure drop must be anyway avoided since they might impair the regular working of the boiler.
Height has no influence over performance. It is however advisable that chimney be higher than the buildings
in its vicinities.
If the stack is higher than 6 meters, avoid discharging its weight completely on the connecting flange to the
boiler.
An inspection opening shall be foreseen at base of chimney or in its lower part, at least in the case of non
gaseous fuels.
HOW TO INSTALL CHIMNEYS
NO YES
Boiler Boiler
Horizontal runs are to be avoided Sloping is recommended
Existing chimney Lead Existing chimney
Smokes from generator Smokes from generator
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3.4.1 Flanged smokes connections

All flanged smokes connections (stack, economizers and ducts) shall be made in such a way to guarantee
perfect sealing. Employed gaskets must have proper dimensions compared to the joint, shall not be
excessively compressed and must be correctly positioned. Bolts shall not be excessively tightened, to avoid
deformation of connecting flanges and impair smokes sealing.
YES NO NO
3.5 FEED WATER

Feed water is usually supplied from a tank that is also used to collect return condensate.
Always provide a filter and a check valve before the water pump.
In order to avoid corrosion, water temperature shall never be lower than 50÷60 °C. In case condensate water
is not available, or it is not enough to maintain required temperature, feed water shall be heated with steam
or other ways.
The diameter of the pipes shall not be smaller than that of the connections to the boiler, no throttling and no
internal edges are admitted in order to limit the pressure drop.
The pipe connection is supplied flanged. The designer did not

foresee any kind of load on the a.m. connections.
! It is therefore compulsory to avoid any kind of mechanical

stress due to the weight of the pipes or to the expansion
stresses. Otherwise, you’d better provide for an expansion
joint and/or supports of suitable dimensions.
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3.5.1 Feed Water and Condensate Tank

The condensate tank is mandatory both to receive return condensate from plant, both to collect depurated
reintegration water from softener. It must have a capacity at least twice the steam produced by the boiler and
must be closed, not only to avoid steam loss, but also because condensate is oxygen-hungry and would take
up too much oxygen if the drum is open. An air vent shall be installed.
Considering that condensate is at high temperature (70/80°C), water surface inside the tank shall be at least
2 meters higher than pump. Otherwise, a circulator shall be installed between tank and pump. For more
information please refer to paragraph dedicated to feed water pump.
3.5.2 Condensate return system

Condensate is discharged by the steam trap at a pressure which is equivalent to the intake pressure of
steam, less pressure drops.
This means that if the intake pressure of steam into a machine is 3 bar, the condensate will be discharged at
approximately the same pressure and, consequently, it can go up vertically and also it can go through
reasonably long runs of pipe, even on counterslop.
If there are several machines installed in parallel, it is advisable to connect to the system only those
machines that discharge condensate at the same pressure. In case of different pressure, it will be necessary
to install separate pipes.
If the condensate is to be raised, a siphon must be provided after the steam trap.
3.6 CHARACTERISTICS OF WATER

The opinion of steam generator users is often that water treatment is an optional, something extra, a request
on the part of boiler manufacturers, and accepted, as it were, out of courtesy.
This opinion is completely wrong, and often causes an enormous number of problems right from the start of
operation of the boiler and whole system.
If a hole forms in the boiler, it gets encrusted or cracks, unfailingly the unfortunate customer will telephone
the boiler manufacturer requiring intervention after intervention covered by the guarantee, and never or
almost never accepting the idea that the cause of his problems stem from bad feed water treatment.
But the pipes and sheet metal do not get encrusted on their own, nor do holes or cracks form without the
intervention of external agents.
In these cases the external agent is the water that contains dissolved salts such as calcium and magnesium
or silica which on precipitating with the temperature, deposits on the iron surfaces, causing incrustations
leading to complete blocking where pipes are concerned or a gradual decrease in heat exchange if sheet
metal is involved (with consequent failure to cool and successive cracking).
Then, when the feed water, due to the temperature and contact with the condensate becomes rich in
oxygen, it is certain that the iron in contact with this water will cause holes to form (corrosion from oxygen).
Pages could be filled on this subject.
This is why not only is correct feed water treatment encouraged but has become obligatory through the
regulations in force and above all it is CONDICIO SINE QUA NON for the issuing and validity of the
guarantee on the part of the manufacturer.
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Therefore, to carry out an analysis of the feed water of the steam generators is necessary for correct choice
and size of the water conditioning system. Equally important and necessary for the guarantee is the
periodical analysis both of the feed water and the boiler water.
Compliance with these simple rules will guarantee:
• maximum management savings;
• maximum safety;
• maximum duration of the system over the years.

These objectives can be reached simultaneously in that the safety management also means saving on
running costs and protection of the system from corrosion. Economy achieved by saving on the choice of
type of treatment system and/or type of softener is only wishful thinking. Already on a short or medium term
the first problems and stops have to be faced. Subsequently, if provisions are not adopted, perforating
corrosion forms which means parts or all the generator have to be replaced. At the same time often
incrustations or deposits reduce the heat exchange and cause conspicuous waste of energy.
To avoid all these possible drawbacks rules have existed for some time now that establish the optimal
conditions aimed at managing the feed water of boilers and steam generators in the most correct way.
In the following pages are reported the limit values for the parameters that characterize the water.
Remember that the following considerations must be taken into account:
• The limits are valid for normal management but may also be exceeded for reasonably brief lengths
of time and in particular during the lighting up phase up to the operating condition and during
switching off.
• For correct management of the system, not all the parameters have the same importance. This fact
can be discovered immediately by observing the frequency envisaged for the analyses: the most
important parameters for ordinary management are those which require more frequent controls.
• All the rules foresee the control of the normal parameters for all power plants. Particular situations
such as for example extracting solvents using steam, sugarhouses, oil mills, etc which have to cope
with almost continual pollution of the condensate and/or even accidental pollution caused by
substances not provided for in the regulations, require specific analytic controls with a frequency and
precision depending on the possibility of pollution and danger, for the generator of the pollutant.
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3.6.1 Brief notes on parameters and conversion between the measuring units
The pH is defined as the inverse of the logarithm (co logarithm) of the concentration of the hydrogen ions
(H+) in an aqueous solution. This parameter indicates the degree of acidity or alkalinity of the water at 20°C.
The pH scale goes from 0 to 14. The 0 value means maximum acidity; value 7 means neutral; value 14
means maximum basicity.
Hardness is given by the presence if calcium and magnesium salts. It is expressed in mg/liter CaCO3, ppm
CaCO3, in French degrees (grams of CaCO3 contained in 100 liters of water), in German degrees (grams of
CaCO3 contained in 100 liters of water), in English degrees (grams of CaCO3 = 0,0648g per imperial gallon =
4.54 liters), in American degrees (grams of CaCO3 = 0,0648g per American gallon = 3,785 liters), with the
following equivalents:
English
mg/liter ppm French German American
Degrees
CaCO3 CaCO3 Degrees Degrees Degrees
1 mg/liter
1,000 1,000 0,100 0,056 0,070 0,058
CaCO3 =
1 ppm
1,000 1,000 0,100 0,056 0,070 0,058
CaCO3 =
1 French
10,000 10,000 1,000 0,560 0,700 0,580
Degree =
1 German
17,900 17,900 1,790 1,000 1,250 1,054
Degree =
1 English
14,300 14,300 1,430 0,800 1,000 0,830
Degree =
1 American
17,100 17,100 1,710 0,950 1,200 1,000
Degree =
38
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Limit Values of the Parameters (EN 12952-12; EN 12953-10)

Super Fire tubes Water pipes
Water pipes natural circulation GEV/HP, GMT/HP,
Type of generator heated GBP GEV GPT NG forced
GWT, KEELER, REVOLUTION
water NPR VPR circulation GMT
Operating pressure (bar) <= 40 <= 20 > 20 <= 20 <= 40 <= 60 <= 80 <= 130 Below critic
Feed Water
pH (25°C) 8,5 - 9,5 8,5 - 9,5 8,5 - 9,5 8,5 - 9,3 8,5 - 9,3 9 - 9,3 9 - 9,3 9 - 9,3 9 - 9,3
Total hardness mg/kg CaCO3 5 5 5 5 2 - - - 0,5
Oxygen µg/kg O2 50 20 20 20 10 7 7 5
Carbon dioxide µg/kg CO2 200 200
Iron µg/kg Fe 100 100 50 30 20 20 20 10
Copper µg/kg Cu 50 30 20 10 3 3 3 2
Oily substances mg/kg 3 1 1 1 0,5 0,5 0,5 0,5 0,5
Organic substances mg/kg 5 3 3 3 3
Total Diluted Solids µg/kg 50
Total Conductivity µS/cm 10 10 10 6
Acid Conductivity µS/cm 1 1
Silicon dioxide µg/kg SiO2 10
Aspect Clear, limpid, without persistent foam
Generator Water
pH (25°C) 9 – 10 9 - 12 9 - 11,5 9 - 11,7 9 - 11 9 - 10,6 9 - 10,4 9 – 10
Total Alkalinity mg/kg CaCO3 1000 750 750 300 200 100 20
See feed water

Total hardness mg/kg CaCO3 5 5 5
Total Conductivity µS/cm 2000 7000 5000 7000 6000 3500 2500 400
Total Diluted Solids mg/kg 1000 3500 2500 3500 2500 1500 1000 100
Silicon dioxide µg/kg SiO2 150 150 50 100 35 8 5 1
Phosphates mg/kg PO4 30 30 30 30 10 5 5 5
Acid Conductivity µS/cm
Control frequency
Super Fire tubes Water pipes
Water pipes natural circulation GEV/HP, GMT/HP,
Type of generator heated GBP GEV GPT NG forced
GWT, KEELER, REVOLUTION
water NPR VPR circulation GMT
Operating pressure (bar) <= 40 <= 20 >20 <= 20 <= 40 <= 60 <= 80 <= 130 Below critic
Feed Water
pH T/S T/S T/S T A/T A/T A/T A/T
Total hardness mg/kg CaCO3 T T T T T T T T A/T
Oxygen µg/kg O2 S S S S G G G A/T
Carbon dioxide µg/kg CO2 S S
Iron µg/kg Fe S S S S2 S2 S2 S2 S2
Copper µg/kg Cu S S S S2 S2 S2 S2 S2
Oily substances mg/kg T T T
Organic substances mg/kg S S S S S
Total Diluted Solids µg/kg G
Total Conductivity µS/cm A/T A/T A/T
Silicon dioxide µg/kg SiO2 G
Generator Water
pH T/S T/S T/S T T A/T A/T A/T
Total Alkalinity mg/kg CaCO3 T T T T T T T
See feed water
Total hardness mg/kg CaCO3 T T T

Total Conductivity µS/cm G G G G T T A/T A/T
Total Diluted Solids mg/kg S S S S S S S S
Silicon dioxide µg/kg SiO2 S S S S G G G G
Phosphates mg/kg PO4 S S S S G G G G
S: weekly T: each shift A: continual analyzer
S2: fortnightly G: daily
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In order to maintain the values shown, besides the use of correct water treatment and bleeding systems, the
use of conditioners is envisaged. The doses of these reagents and limits depend on the nature of the same.
The frequency of relative analyses also depends on their function; in some cases determination of the
parameters on which to act (e.g. pH,O2, …) can be carried out.
! In order to allow proper operation of level probes total

conductivity shall not be less than 100 µS/cm.
3.7 WATER TREATMENT

Many breakdowns and sometimes serious accidents are caused by the use of water with inappropriate
characteristics. The choice of the appropriate water treatment and/or conditioning system for a steam
generator must take into consideration a series of parameters:
• construction and operating characteristics of the generator;
• characteristics of the water available for filling and topping up;
• amount of condensate collected compared with the total feed of the generator.
Here following is a summary of the different water treatment processes. To be sure the correct process has
been chosen we recommend consulting specialized companies who will make the choice based on and
following accurate analysis of the water available.
3.7.1 Water filtration

Filtration means removal of torpidity from the water, from the most coarse to the colloidal, absorption of
odors, unpleasant smells and colors, removal of Iron and Manganese, other heavy metals such as arsenic,
Chromium, ... or to neutralize acidity.
All these results can be achieved by appropriate filtering treatment, in some cases in cooperation with an
oxidation and/or coagulation process. Filtration is the most important but also the most difficult water
treatment. The main applications are:
• treatment of water for industrial use
• pre-treatment for reverse osmosis or ionic exchange systems.

The main filter technologies are cartridge filter and multi-layer filtration
3.7.2 Water softening

In civil and industrial use, the excessive quantity of limestone in the water causes unpleasant and costly
complications.
The softening process takes place thanks to an exchange between sodium ions, fixed on particular resins,
and calcium and magnesium ions present in the water. This continual exchange transforms normal water
into softened water. When all the sodium ions have been exchanged, the cycle ends. To restore efficiency to
the resin it has to be regenerated using Sodium Chloride (coarse salt).
40
3
The main applications for water softeners are:
• production of steam generator feed water and cooling towers.
• production of water for laundries and dyeing plants
• production of water for industrial processes
• production of drinking water for the food industry

Conductivity at input and output of a water softener is roughly the same, because the difference in
conductivity between the calcium and magnesium salts in water and relative sodium salts is negligible.
Therefore conductivity of raw water is hardly modified by softening. The conductivity can be used to establish
the concentration of sodium downstream if the softener. As is known, conductivity is a perfunctory measure
of the total salinity of the water.
3.7.3 Reverse osmosis

Natural osmosis is the transport through a semipermeable membrane separating two solutions of different
solute concentration, from the solution that is dilute in solute to the solution that is concentrated. By applying
a higher pressure than the osmotic pressure a reverse flow is created with transport of the pure water of the
concentrated solution. The water obtained in this way will be without dissolved mineral salts, bacteria, micro
organisms and all solid suspended substances.
The reverse osmosis process is, as of today, the safest water desalination and ecologically compatible
technique available.
The main technological applications of membranes are:
• production of feed water for steam generators;
• water production for the pharmaceutical, electronic and food industries;
• water production in food processes;
• production of drinking water;
• conditioning, re-use of discharged and technological water.

The main advantages of a reverse osmosis plant are primarily:
• simple and safe construction and management;
• low running costs;
• no interruption for regeneration;
• no use of caustic soda (NaOH) and hydrochloric acid (HCI) to regenerate resins;
• no need for conditioning of discharged water, therefore total absence of post-treatment plants,
necessary in the case of traditional systems.
The reverse osmosis systems are the result of an accurate selection of the components and functional and
reliable technical solutions.
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3.8 BLEEDING
When the boiler is operating provisions must be made to carry out regular bleeding operations using the
manual valve provided.
To establish the frequency and duration of these bleeding operations here following are some suggestions.
The salinity of the water contained inside the boiler naturally tends to increase due to the steam evacuating
without the salts getting eliminated.
The bleeding operation is needed to maintain the salinity characteristics inside the body of the boiler under
pressure within the maximum limits given in the table.
The concentration of a critical parameter of the feed water and the one for the same parameter in the water
inside the boiler are connected to the bleeding by the following formula:
Ca
S% = 100 x
Cc
Where:
S% = Entity of the bleeding as a percentage compared with the water that is reintegrated
during the boiler operation.
Ca = Concentration of a critical element in the feed water in mg/kg
Cc = Maximum concentration of that parameter in the boiler water in mg/kg
The ratio shows the number of concentrations possible of salt or the critical parameter contained in the feed
water.
The formula will always contain the most critical parameter, the one that reaches the maximum permissible
value first.
For the calculation the ratio between a critical parameter and one which is easier to analyse can be
calculated, as for example the chlorides and establish the number of bleedings depending on the
concentration of the chlorides.
Here following is an example:
Let’s suppose that we have a P alkalinity (ppmCaCO3) in the feed water equal to 100. Whereas the
maximum permissible value operating at 15 bar is 750 ppm as shown in the table. The calculation of the
number of bleedings is as follows:
100
S% = 100 x
750
The bleeding is equal to 13.3% compared with the top up water delivery.
!
During the bleeding operation it is important for the water level
never to drop below the alarm level therefore frequency must
be timed correctly based on the quantity of water removed at
each bleeding operation.
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3.9 PIPING
Connections must be carried out between the steam outlet valve and piping. Seamless pipes shall be used
for steam piping.
internal edges are admitted in order to limit the pressure drop.
Steam piping shall be installed as illustrated on Figures 1A and 1B.
If horizontal runs longer than 10 meters are to be laid, it will be necessary to install expansion joints (see
Figure 2).
Steam piping must not be restrained and must be free to expand, since the metal extends as temperature
rises.
It is advisable, in order to reduce the loss of heat along the piping, to line the pipes with thermo-insulating
materials.
A well designed steam distribution system from the boiler to the user equipment is an essential prerequisite
for a satisfactory operation of a plant.
It is essential to correctly size steam distribution piping according to the flow of steam: if undersized, there
will be insufficient flow to the farthest users, if oversized, there would be a pointless dispersion and a higher
cost.
Table 1 assists in calculating the required diameters on the basis of flow expressed in Kilo/hour of steam and
according to the delivery pressure. The recommended velocity is 25 mt/second.
Pressure Velocity Nominal diameter (mm)

bar m/s 15 20 25 32 40 50 65 80 100 125 150 200 250 300
15 7 14 24 37 52 99 145 213 394 648 917 1606 2590 3678
0,4 25 10 25 60 42 92 162 265 384 675 972 1457 2806 4101 5936
40 17 35 64 102 142 265 403 576 1037 1670 2303 4318 6909 9500
15 8 17 29 43 65 112 182 260 470 694 1020 1864 2814 4045
1,0 25 12 26 48 15 100 193 300 445 730 1160 1660 3099 4869 6751
40 19 39 71 112 172 311 465 640 1150 1800 2500 4815 73333 10370
15 12 25 45 70 100 182 280 410 715 1125 1580 2814 4545 6277
2,0 25 19 43 70 112 162 295 428 656 1215 1755 2520 4815 7425 10575
40 30 64 115 178 275 475 745 1010 1895 2925 4175 7678 11997 16796
15 16 37 60 93 127 245 385 535 925 1505 2040 3983 6217 8743
3,0 25 26 56 100 152 225 425 632 910 1580 2480 3440 6779 10269 14316
40 41 87 157 250 357 595 1025 1460 2540 4050 5940 10476 16470 22950
15 19 42 70 108 156 281 432 635 1166 1685 2460 4618 7121 10358
4,0 25 30 63 115 180 270 450 742 1080 1980 2925 4225 7866 12225 17304
40 49 116 197 295 456 796 1247 1825 3120 4940 7050 12661 19668 27816
15 22 49 87 128 187 352 526 770 1295 21058 2835 5548 8586 11947
5,0 25 36 81 135 211 308 548 885 1265 2110 3540 5150 8865 14268 20051
40 59 131 225 338 495 855 1350 1890 3510 5400 7870 13761 23205 32244
15 26 59 105 153 225 425 632 925 1555 2525 3400 6654 10297 14328
6,0 25 43 97 162 253 370 658 1065 1520 2530 4250 6175 10629 17108 24042
40 71 157 270 405 595 1025 1620 2270 2410 6475 9445 16515 27849 38697
15 32 70 126 190 285 475 800 1125 1990 3025 4540 8042 12625 17728
8,0 25 54 122 205 320 465 810 1260 1870 3240 5220 7120 13140 21600 33210
40 84 192 327 510 730 1370 2065 3120 5135 8395 12470 21247 33669 46858
15 41 95 155 250 372 626 1012 1465 2495 3995 5860 9994 16172 22713
10,0 25 66 145 257 405 562 990 1530 2205 3825 6295 8995 15966 25860 35890
40 104 216 408 615 910 1635 2545 3600 6230 9880 14930 26621 41011 57560
15 50 121 205 310 465 810 1270 1870 3220 5215 7390 12921 20538 29016
14,0 25 85 195 331 520 740 1375 2080 3120 5200 8500 12560 21720 34193 47218
40 126 305 555 825 1210 2195 3425 4735 8510 13050 18630 35548 54883 76534
Table 1
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YES
Steam intake
Main steam pipe
Steam
Steam
YES
Steam intake Steam
Main steam pipe
Steam
NO
Main steam pipe
Steam
Steam intake
Steam
Figure 1A
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STEAM PIPES LAY-OUT
Figure 1B
The pipe connection is supplied flanged. The designer did not

foresee any kind of load on the a.m. connections.
! It is therefore compulsory to avoid any kind of mechanical

stress due to the weight of the pipes or to the expansion
stresses. Otherwise, you’d better provide for an expansion
joint and/or supports of suitable dimensions.
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3.9.1 Expansion joints

Expansion joints, under the effect of heat, undergo
a dilation. Wherever installations are designed with
small diameter piping, short runs and numerous
bends, there is a sufficient capability for a self-
compensation of dilatation movements. As pipe
diameter increases (above 2”), in particular in case
of long horizontal runs, it will be necessary to install
expansion joints or bends, whenever possible.
Figure 2
Attention: at every change of direction, pressure exerts a thrust on the pipe wall, which tends to elongate the
pipe. If in the length subject to dilation an unanchored joint is inserted, the pipe will tend to elongate due to
the pressure and would damage the joint. Therefore it will be necessary to apply, at each end of a straight
length of piping, special anchors called main resistance points, which will suffice to compensate for any
displacement.
3.10 SAFETY VALVES DISCHARGE

The safety valves installed on steam boilers must have the discharge conveyed outside the boiler room.
Special care must be given to the installation of the discharge pipes; here after some examples:
- It is advisable to install discharge pipes using a pipe diameter at least equal to the diameter of the
output flange of the safety valve.
- Any curves/bends in the discharge pipe must have a large radius.
- All discharge pipes must be installed in such a manner to avoid the formation of condensate. Pipes
should therefore be installed at a sufficient angle to ensure complete drainage.
- Water condensate shall not remain on safety valves seat, complete and continuous drainage shall be
allowed.
- Solid fixing points of discharge pipes shall be installed in such a way to compensate the very high
reaction forces due to safety valve outlet.
- When several valves are linked on a single discharge line, the line must have a throughout area at
least equal to the sum of all sections linked together.
- The discharge must be conveyed in a place where no damage can occur to people or equipment
located nearby.
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3.11 BLOW DOWN

Manifold blow down and boiler blow down shall be connected to water discharge.
internal edges are admitted.
Hot water or steam will be discharged through this pipe, therefore all safety precautions shall be applied in
order to avoid any damage to people, equipment or wastewater network.
3.12 FUEL FEEDING LINE

Always make reference to burner manual attached.
Fuel oil tank shall be connected to burner flexible pipes, or methane decompression cabinet shall be
connected to burner gas ramp.
Throttling of pipes shall be avoided.
3.13 ELECTRICAL CONNECTIONS

Always refer to the enclosed wiring diagram.
Check that the voltage and the electrical supply frequency correspond to the values stated on the enclosed
wiring diagram. Make sure that actual voltage does not differ +/- 10% from nominal voltage.
The connection and the laying of the electrical supply cable are at the customer’s charge. The electrical
installation must be realized workmanlike and according to the EN 60204 regulation in force.
Always fit a differential magnetothermic switch with suitable amperage upstream the power-supply line.
Cables for electrical connection of burner shall be long enough to allow burner pull out for required periodical
maintenance operations.
! Always perform boiler connection to ground.
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GPT, GPT/R, NG/C, NG/V, NG3/R3 Accessories
4. ACCESSORIES
4.1 GENERAL
Before setting the boiler in operation and before starting any maintenance intervention, it is absolutely
necessary that the operators responsible have read and understood all the NOTICES AND WARNINGS
given in this section and in all the documents relevant to the Instructions of Use which are provided together
with the GARIONI NAVAL boilers.
KSB
KSB
KS
B

1 Safety probe low-low level 9 Pressure gauge
2 Safety probe low level 10 Safety pressure switch
3 Level regulation probe 11 Pressure transmitter
4 Level control 12 Auxiliary connection
5A Level indicator 13 Salinometer connection (optional)
5B Motor 14 Auxiliary connection
6 Interlock 15 Electrical panel
7 Manual start 16 Burner
8 Logic 17
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4.2 PRESSURE MEASUREMENT DEVICES
4.2.1 Pressure gauge

It is Bourdon type, with a metal pipe having a tight, elliptical cross-section bent into an arc. One end is open
and it is connected to the inside of the boiler or the device of which the pressure has to be measured; the
other end is free to move and it is connected by means of a system of levers and a toothed sector.
The red dot on the pressure gauge indicates the rated pressure.
Between pressure gauge and boiler a siphon pipe is fitted, where the steam can be condensed. Thus, only
cold water come into with the sensitive elements of the pressure gauge.
The pressure gauge is fitted on a three-way cock which allows the following operations:
- communication between boiler and pressure gauge (normal operating position);
- communication between pressure gauge and the outside (position for bleeding the siphon);
- communication between boiler, pressure gauge and test pressure gauge (position for checking pressure
gauge operation).
4.2.2 Pressure transmitter

It is specifically designed for use in specific industrial applications, with temperature compensation and laser
calibration. It produces a signal depending on boiler pressure. This signal is used to control boiler pressure
and maintain it within minimum and maximum defined levels.
Between pressure transmitter and boiler a siphon pipe is fitted, where the steam can be condensed. Thus,
only cold water come into with the sensitive elements of the pressure transmitter.
4.2.3 Safety pressure switch

It is a pressure gauge normally used for check of liquid, vapors and gases pressure. It is calibrated at higher
pressure than the maximum one of limit pressure switch, but always lower or equal to the one of safety
valves. Safety pressure switch intervenes in case of limit pressure switch damage; the burner starts only
after removal of the stop with manual operation on electrical panel.
Between safety pressure switch and boiler a siphon pipe is fitted, where the steam can be condensed. Thus,
only cold water come into with the sensitive elements of the safety pressure switch.
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4.2.4 Safety valves

They are installed in order to discharge the steam when the maximum set pressure is reached. They can be
one or two, depending on the boiler type and are either weight and lever or direct spring type.
The operator must take particular care and specific maintenance to the safety valves. They are the most
important and delicate devices of the boiler and they also represent the most valid warranty of the fact that
the internal pressure is limited below the maximum design pressure.
Considering that usually during normal operation the safety valves never intervene, it is good practice that,
with periodical frequency, the same are checked to be free, that is the shutter is not stuck to the seat,
acting as follows:
- for weight and lever valves, lift the lever until steam is discharged;
- for direct spring valves, operate the lifting lever until steam is discharged.
Special care must also be given to the sanding of the seat shutter, should this operation be necessary to
correct leaks or blow-bys, use silicon carbide-based abrasives of carborundum and oil. It is recommended to
perform a first sanding operation with a fine-grain abrasive and a second pass with a very fine-grain
abrasive.
Position Description
1 Valve body
2 Lever
3 Spring
4 Plate
5 Spring pusher pin
6 Pin locknut
7 Lever support nut
8 Safety nut
9 Cap
10 Nut
11 Lever pin
12 Cap screw
13 Rod
14 Casing
15 Frame screw
16 Guide plate
17 Shutter
18 Slit washers
19 Seat
Figure 1
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4
4.3 LEVEL MEASUREMENT DEVICES
4.3.1 Level indicators

Steel reflex gauges are supplied.
Each indicator communicates with the boiler through two cut-off cocks; a third bleed valve is mounted at the
lower end off the indicator itself.
These cocks are required in order to be able to check the efficiency of the level indicators at intervals, as
follows:
- Open the bleed cock for a few seconds and then close it again.
- If the water disappears and then returns quickly to the previous level with large oscillations, the gauge
can be considered to be in good working order.
- If, on the other hand, the water returns slowly to the previous level or halts at a different level, this
means that communication with the boiler is obstructed.
- In order to detect which of the two routes is obstructed and in order to try to bleed it, close the steam
cock, leaving the water cock open, and then open the bleed cock: water should emerge.
- The water escaping from the bleed cock, given its flow rate, will carry with it any sludge deposits formed
in the ducts.
- Close the water cock and open the steam cock: steam should emerge from the bleed cock.
- Closing the bleed cock the leaving the water and steam cock open, the water should return to its
previous level.
- If this does not take place the connecting ducts linking the level indicator to the boiler need cleaning.
4.3.2 Probes and automatic level regulator

Level probes are conduction type, level regulation is made by means of electronic relays located in the
control panel. Operation is based on water pump start and stop and low level safety protection. Probes may
be installed as per Figures 2, 3, 4.
- A: pump stop probe
- B: pump start probe
- C: minimum level safety probe (burner and water
stop with manual reset, alarm)
- D: minimum level safety probe (burner and water
stop with manual reset, alarm)
- E: mass probe
- F: mass probe
- I: pressure gauge
- L: safety pressure switch
- M: pressure transducer
Figure 2 – horizontal boilers with one external manifold (refer to actual boiler)
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4
KSB
KSB
- C: minimum level safety probe (burner and water stop
with manual reset, alarm)
- D: minimum level safety probe (burner and water stop
with manual reset, alarm)
- E: mass probe
- F: mass probe
- G: mass probe
- H: maximum level probe
- I: pressure gauge
Figure 3 – horizontal boilers with three external manifolds (refer to actual boiler)

- C: minimum level safety probe
(burner and water stop with
manual reset, alarm)
- D: minimum level safety probe
(burner and water stop with
manual reset, alarm)
- E: mass probe
- F: mass probe
- H: maximum level probe
- I: pressure gauge
Figure 4 – vertical boilers with two external manifolds (refer to actual boiler)
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!
It is recommended to install not only alarm bell in the boiler
room but also a sound or visual alarm in a frequently occupied
room.
4.3.3 Testing of capacitive level probes

Proper operation of normal level probes used for minimum and maximum
safety levels must be periodically checked.
On the other hand, self-controlled level probes may be installed, with self-
checking operation carried out by the probe and its associated controller.
The self-monitoring equipment continuously and electronically checks for
faults such as: build-up of scale or dirt on the probe and moisture leakage
in the probe. If any fault is detected, the control system initiates an alarm
and stops the boiler.
The advantage of self-controlled water level probes is not only increased
safety conditions, but also that periodical testing is not necessary.
Self-controlled level probes are optional supply, based specific
requirements from Customer and/or local authorities (i.e. for operation
without permanent supervision).
Self-controlled level probe
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4.4 WATER SUPPLY

Water supplies for steam boilers shall be covered by:
- centrifugal motor-driven pump for delivery and head to the boiler
- emergency inlet line.
4.4.1 Motor-driven pump

Feed water temperature shall be higher than 60°C and lower than 85°C.
On the other hand, high pressure boilers are equipped with multistage pumps. These pumps consist of a set
of impellers which the water progressively passes through, thus increasing pressure.
The pump must not exert any intake action on the intake opening, but should rather be “under head”, that
means under the pressure of a column of water resulting from the difference in height between the water in
the collection tank and pump itself. Whereas a pump may intake cold water from a tank (5-6 meters), when
the water is heated, the pump is not only unable to intake the water but it has to flow to the pump under a
certain pressure. The height of the tank varies with temperature variations, as show in the table:
Feed water temperature [ °C ] Head on intake [ m ]

60 0,5
70 1,5
80 2,5
90 4,0
100 5,0
!
Use of inlet water at temperature lower than 60°C shall be
avoided, because condensate may be generated and therefore
corrosion may occur.
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4.5 FUEL FEEDING LINE

Here after you can find the most common schemes used to realize burner feeding line. Other solutions are
possible, but before check with specialized installer.
4.5.1 Natural gas system

The plant is based on gas train for gaseous fuel. In the following the simples configuration is shown.
1 Interception cock 8 Safety electrovalve

2 Antivibration joint 9 Flow regulator
3 Gas pressure sample connection 11 Protection grid
4 Filter 12 Combustion air regulator
5 Pressure regulator 13 Fan
7 Minimum pressure switch 15 Air pressure sample connection
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4.5.2 Diesel oil fuel system without transfer pump

This is the simplest plant for liquid fuel feeding; it is based on a tank from which the fuel is aspirated by
means of burner pump; therefore the tank must be located close to the burner.
Load
Vent pipe
Tank Bottom valve
4.5.3 Heavy oil fuel system with feeding tank

In this case a pump takes the liquid fuel from the tank and loads the tank feeding the burner. This type of
plant is good for fuels that need preheating before burning.
Vent pipe
Starter of electrical
floating pump
Overload pipe
Thermostat
resistance for
heavy oil
Load
>5°E Blow down
Vent pipe
Bottom valve
Tank
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4
4.5.4 Heavy oil fuel system with low pressure fuel circulation system
A dedicated circulation pump (with capacity 2 – 3 times the maximum burners consumption) takes the liquid
fuel from the tank and circulates it inside a pressure ring; from this ring the fuel feeding the burners is taken
through dedicated deaerators. Ring circulation pump is over designed in order to guarantee stable fuel
pressure not depending by burners operation.
Load
Deaerator Deaerator
Vent pipe
Circulation pump
Tank Bottom valve
In case heavy oil circulation ring is foreseen, the burner shall

be started only when at least one ring circulation pump is in
!
operation. In all cases, manual operation of burner pump shall
not exceed 20 seconds; alternatively, burner pump may be
subjected to anticipated end of life and rupture.
Maximum distance between deaerator and burner shall be
lower than two meters.
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4
4.5.5 Fuel change over from diesel oil (MDO) to heavy fuel oil (HFO) and viceversa
Design of electrical cabinets is foreseen to avoid wrong operations, that may lead for example to long time
and unnecessary heating of diesel oil. Nevertheless, fuel change over procedure shall occur with burner
off, in the shortest possible time. The time depends upon distance of circulation fuel ring, viscosity of
employed fuel, relevant temperature and installed heating elements.
F3301V
F3302V
System is designed for MDO and HFO with maximum viscosity 380Cst at 50°C.
Change over from heavy fuel oil (HFO) to diesel oil (MDO)
At beginning, in this phase the fuel ring is heated by means of steam or electrical resistances.
Switch off the burner using dedicated selector located on electrical cabinet; fuel ring pump remains working.
Locate fuel selection switch to MDO; heating elements of deaerator, filters and on board of burner are
switched off.
Rotate three way valves of fuel ring to MDO. HFO shall be avoided into the MDO tank, therefore first of all
valve F3302V shall be positioned to MDO, then after 1 minute valve F3301V shall be positioned to MDO too.
Switch off heating elements of fuel ring.
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4
Use drain valve located at lower part of deaerator to check that fuel ring is free from HFO and that MDO is
really circulating.
Start burner with MDO at maximum load for time enough to guarantee evacuation of any HFO remained
inside piping.
The light of electrical cabined indicating type of fuel depends by position of microswitch at three way valve of
fuel ring. Both position of fuel selector, and microswitch of three way valve, are consents to burner operation,
therefore them both must be correctly positioned.
Burner preheating group is operated through 0/1 burner selector, fuel selector and three way valve
positioning.
Change over from diesel oil (MDO) to heavy fuel oil (HFO)
Switch off the burner using dedicated selector located on electrical cabinet; fuel ring pump remains working.
Start heating elements of fuel ring, when piping is warm enough change position of three way valves to HFO.
HFO shall be avoided into the MDO tank, therefore first of all valve F3301V shall be positioned to HFO, then
after 1 minute valve F3302V shall be positioned to HFO too.
Use drain valve located at lower part of deaerator to check that fuel ring is free from MDO and that HFO is
really circulating.
Start burner with HFO.
The light of electrical cabined indicating type of fuel depends by position of microswitch at three way valve of
fuel ring. Both position of fuel selector, and microswitch of three way valve, are consents to burner operation,
therefore them both must be correctly positioned.
Burner preheating group is operated through 0/1 burner selector, fuel selector and three way valve
positioning.
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GPT, GPT/R, NG/C, NG/V, NG3/R3 Operation
5. OPERATION
5.1 CONSIDERATIONS ABOUT SMOKE TUBE BOILERS

The cold start-up of smoke tube boilers involves for the boilers a very high mechanical stress in comparison
to what they are subjected during the normal working situation in temperature.
The cold start-up is inevitable both during the first start-up, and during the normal operation when the boiler
is lighted in the morning or after a weekend, if it does not work 24 hours on 24.
Cold start-ups are characterized by the fact that the water inside the boiler does not boil. During that phase,
water temperature is normally around 20°C, that is to say approx 80°C colder than the temperature of the
same when it starts to boil at an absolute pressure of 1 bar.
The reason for higher mechanical stress during cold start-up phase is mainly due to the fact that temperature
differences among furnace and shell is much higher than during normal operation. For this reason the
furnace expands much more than shell than what it usually done during operation. This creates a
considerable increase of the mechanical stress between furnace and shell, also between smoke pipes and
tubesheets, between plating and inversion chambers, and so on.
In detail, heating process starts with the steam outlet valve open and at 1 bar absolute pressure. The feed
water temperature is of 20°C and then grows in time till the boiling point. After, the pressure increases
usually of 1 bar per minute (with burner at maximum load.
The shell of a fire tube boiler has more or less the same temperature of contained water and therefore it is
subjected to length expansions due to temperatures, much lower to those subjected by the furnace, normally
licked by the flame.
The temperature difference between furnace and shell causes the expansion difference among both items,
and reaches in this phase also 90°C (1,96 times more than the normal temperature difference). This
expansion difference must therefore be absorbed by the elements joining the two pieces. Detail analysis
underline that in this phase, the furnace expansions are 2,5 times higher in comparison to those of the shell,
causing a strong stress that can shorten the life of the boiler.
At project stage, such problem can be minimized by using good quality materials, optimized welding
processes and good quality with the aim to maximize symmetric disposal of furnace, smoke tubes and shell.
At operation stage, it is important to heat up the water with minimum temperature increases in time in order
to minimize the temperature differences mentioned above.
! Dry operation is forbidden.
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5.2 OPERATION WITHOUT PERMANENT SUPERVISION
5.2.1 Inland applications

Boilers for inland applications may be equipped with regulation, control and safety accessories designed in
order to allow self-controlled operation without permanent supervision. Mode of operation is described at first
page of this manual and applicable drawings. National rules and any other rule of installation place shall be
taken into account as far as fire prevention and safety precautions are concerned. Operation without
permanent supervision is only possible where local applicable regulations allow it.
5.2.2 Marine applications

As far as marine applications are concerned, boilers are designed and manufactured as per applicable rules,
also regarding safety accessories. Usually, required safety accessories are enough in order to allow
operation without permanent supervision. Nevertheless, in order to take final decision also other
considerations shall be taken into account such as type of ship where boiler is installed, service of the boiler,
and so on. Finally, boiler operation is subject to applicable rules, therefore what follows only refer to boilers
for inland applications.
Example of boiler designed for self-controlled operation. Refer to actual boiler.
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5.2.3 Operation
Operation of boilers without permanent supervision is based on essential safety requirements that must be
granted by stoker and plant owner:
- In case of alarm, personnel designed for plant operation must be automatically warned in order to
allow for prompt intervention.
- Personnel designed to plant operation must be capable, physically fit and not younger than 18 years.
- Stoker and/or owner must establish operating instructions.
- Updated booklet indicating all performed activities must be kept in the boiler room.
- Personnel designed for plant operation must perform checks in order to be ensured about proper
plant conditions at each visit, as per following instructions.
- Preventive maintenance must be performed as per specific section of this manual. Maintenance to
safety equipments must be performed every not more than 6 months.
- Periodical plant inspection and preventive maintenance do not substitute prescribed inspections as
per applicable local regulations.
5.2.4 Training of personnel

Personnel designed to plant operation must be capable to take all required countermeasures in any possible
situation that may occur, always in safe conditions.
Such personnel must be periodically reconfirmed in charge, also taking part to updating courses if needed.
Training and updating courses must be recorder in a personnel registration booklet.
5.2.5 Operating instructions

All boilers and accessories must be object of a specific regulation.
Operating instructions must be established by stoker and/or owner on the basis of boiler manual provided by
manufacturer.
Operating instructions must be kept available close to boiler and control panel. As a minimum, they shall
include operating instructions, list of qualified personnel designed to plant operation, all requirements in for
safety condition of devices and fluid circuits, list of periodical inspection and monitoring activities of safety
equipments.
5.2.6 Records
Following documents must be regularly updated and properly stored by personnel designed to plant
operation after every intervention:
- Register of intervention, for every boiler.
- Boiler booklet, including:
• identification of personnel that carried out the intervention and reason of it;
• detail list of performed checks at each periodical visit;
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• list of incidents, repairs and performed activities.

If automatic recording is used, above elements must be reported in the boiler booklet. Boiler booklet must be
available at every inspection.
5.3 PRELIMINARY OPERATIONS

The boiler works completely automatic.
Before setting the boiler in operation, carry out the following checks:
- Check that all fittings are well tightened and that any blank disks used for the hydraulic tests are
removed.
- Check that manhole covers are well closed.
- Check the opening and closing of all the valves fitted to the installation.
- Check that the burner control selectors, if any, are in position “0”.
- Check that all the burner devices are positioned according to the manufacturer’s instructions.
5.3.1 Pressure parts

Before closure of manholes, make sure that no extraneous items remained in the water and steam circuit.
Carefully check blow down and surface blow down valves, dismount and operate them, reassembly before
filling.
Connecting pipes to the boiler must be restrained in such a way to allow free elongation.
5.3.2 Safety valves

Check that discharge of safety valves is conveyed and fixed in order to avoid vibrations on the valves.
Check that safety valves can be easily operated.
5.3.3 Valves
Check that all the discharge valves are closed.
Check the water level in the boiler.
Check the closing system of the main steam valve.
Open the pressure gauge tap.
Check the placing of the three-way taps of the fuel ring and select the fuel to be used (when operating is
envisaged with different types of fuel).
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5.3.4 Regulation and control equipment

It is mandatory that before start-up regulation equipments are checked and verified and they result in good
operating order and connected to all their components.
5.3.5 Burner equipment

Check that all the terminals are connected and correctly fed, that the control instruments are not intercepted,
they are in a good state and lubricated, by means of the indicators check position of fuel valves.
Check that all the burner devices are positioned according to the manufacturer’s instructions.
5.3.6 Fire protections

Check that fire protections are in order, during transport and erection they might have been damaged.
Check that fixing to the structures have been correctly performed and that boiler dilations are not impaired.
Check that all junctions are in optimal conditions.
5.3.7 Chimneys and closures

Check that no debris or extraneous item remained inside air and smokes ducts. Check compensation joints.
Operate closures and verify correct function.
Check that indicators coincide with open and close position.
Check that bolts of the inspection doors are well tightened.
5.3.8 Motors
Check that motors are not restrained.
Check motors electrical connection.
Make sure that rotating direction is correct. To lubricate use recommended lubricants.
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5.4 START-UP
Close the discharge, steam connection, auxiliary connection, level discharge and tank valves.
Check closure of front and rear hatches, manholes, handholes, ...
Open the breathing, level cut-out, feed (up-line and down-line of water pump), pressure gauge connection
valves.
5.4.1 Boilers with ON/OFF water control

Start the boiler, as follows:
1. Any emergency or reset push-button must be pressed before operating the main switch;
2. Check main burner switch opening and power up the boiler control panel;
3. Place the pump selector switch to MAN;
4. Start-up the pump;
5. When water reaches minimum level, place the pump selector switch to AUT;
6. Make sure that the pumps stops when the maximum level is reached, observing level indicators and
checking the position of their cocks;
7. Open the steam outlet valve and check on the level indicator the intervention point of minimum level
probe (pump start);
8. Place the pump selector switch to 0, leaving the steam outlet valve open, and check the intervention
level of safety probes;
9. Close the discharge, place pump selector switch to MAN;
12. Start the burner;
13. Bring boiler pressure up making safety pressure switch intervene (for boilers with steam production
higher than 3000 kg/h, increase the pressure with burner at minimum up to 7 bar, stop the burner for one
hour and then re-start the burner increasing the fuel feeding);
14. With the burner at a standstill because of safety pressure switch intervention, lower the boiler pressure
(by carefully opening the steam outlet valve), calibrate the work pressure-switch, setting its intervention
point and the differential for stop and re-start;
15. Gradually open the steam outlet valve in order to heat the piping and eliminate any condensation in the
lines.
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5.4.2 Boilers with modulating water control

Start the boiler, as follows:
1. Any emergency or reset push-button must be pressed before operating the main switch;
2. Check main burner switch opening and power up the boiler control panel
3. Place the pump selector switch to MAN;
6. Make sure that the pumps stops when the maximum level is reached, observing level indicators and
checking the position of their cocks;
7. Open the steam outlet valve and check on the level indicator the intervention point of minimum level
probe (pump start);
8. Place the pump selector switch to 0, leaving the steam outlet valve open, and check the intervention
level of safety probes;
9. Close the discharge, place pump selector switch to MAN;
10. Regulate water level one centimeter above safety probes;
11. Start the burner at minimum load and wait steam operating pressure;
12. Gradually open the steam outlet valve in order to heat the piping and eliminate any condensation in the
lines;
13. Place the pump selector switch to AUT.
For boilers fitted with a manhole, it is very important during

first start-up to progressively tighten the two nuts on the
! manhole cover as pressure gradually increases. A dangerous

situation may otherwise arise, caused by steam flows which,
once they have occurred, damage the gasket and cause risks
to plant operating personnel
5.5 NORMAL OPERATION

Check hatch seal and adjust tie-rods if necessary.
In case of intervention of one of the safety devices while the installation is working, the burner immediately
stops and an acoustic and luminous alarm signals one of the following causes of trouble:
After having perceived the alarm and once the cause has been removed, press the “RESET” push-button in
order to put the burner in motion.
Some special models require a post-wash period of the combustion chamber and of the exhaust gas circuit
anytime the burner stops; during this period, the programmer returns to the initial starting position. In this
case you must confirm the ignition by pressing the relevant push-button.
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5.6 PERIODICAL INSPECTIONS

At each periodical visit the personnel designed to plant operation must first of all check general plant
conditions and coherence between measured parameters and indications.
Moreover, as a minimum, following controls of good operation condition must be performed and recorded in
the boiler booklet:
24 hours
72 hours Weekly
(1)
Check of water level (2) X
Check of safety protection against low water level (normal level
X
probes)
Check of safety protection against low water level (self-controlled
X
level probes)
Check of safety protection against high water level X
Check of safety protection against high pressure, with manual
X
change of set-up value
Check proper operation of any automatic discharge, with manual
X
operation
Water quality measurement, particularly of conductivity X
Ensure that feed water pump is operating properly X
Control the flame through the inspection holes X
Check of safety protection against burner flame failure X
Check of safety protection against low gas pressure (for gaseous
X
fuel)
Check of safety protection against absence of combustion air with
X
manual disconnection of safety pressure switch
Check of any fuel leakage with visual inspection and research of
X
smell in the boiler room
Bottom bleed with burner off using a sequence of 3 to 4 openings,
X
each for 10” at intervals of 2-3 minutes
Bleed the probe-holder tank, the level indicators X
Control the cleanliness of the generator by means of fumes
temperature. Should it be found to be too high, schedule a cleaning X
operation
(1) Frequency required for periodical visits can be reduced if optional equipment for regulation, safety
and control is installed; make reference to what indicated at CE assembly certificate. In case of
certification for 72 hours without supervision, inspections requested every 24 hours shall be
performed every 72 hours.
(2) Check the proper water level. Because during heating this level tends to rise, with boiler at standstill
water level shall show the minimum. If the water level should rise excessively because of the
increase in volume caused by heating, open the boiler discharge at regular intervals in order to
return the level to about halfway up the indicator.
At each stocking of new fuel, check the calibration of the burner and the adjustment of the preheating
temperature.
In case occurs any situation causing boiler stop and block, intervention of personnel qualified for analysis
and plant restart shall be required. After start-up, check proper working conditions of boiler main safety
protections.
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GPT, GPT/R, NG/C, NG/V, NG3/R3 Troubleshooting
6. TROUBLESHOOTING
6.1 GENERAL
Keep to the enclosed instructions for the boiler start-up.
Should the following troubles occur during the boiler start-up or in the normal working conditions, follow the
suggestions given in this section.
If – despite the suggestions given in this section – the trouble cannot be solved, contact the GARIONI
NAVAL’s service centre (phone ++39 030-2681541) – gnservice@garioninaval.com .
No modification and/or tampering of the boiler equipment is allowed.
6.2 THE BURNER DOES NOT START

Look at attached use and maintenance manual.
6.3 THE BURNER STARTS AND STOPS AFTER A FEW SECONDS

• Photoelectric cell dirty and/or wrongly positioned - remove and clean the photoelectric cell
- check the direction of orientation
• Insufficient fuel - check the correct opening of the solenoid valve

- check the fuel delivery pressure
- clean the fuel filter, if necessary
6.4 SMOKY FLAME

• Air - fuel setting unit out of calibration - check the calibration
• Fan impeller dirty - clean the impeller
• Nozzle dirty - clean the nozzle
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6.5 PULSATING FLAME

• Air in excess - adjust the position of air lock
• Dirty nozzle - clean the nozzle
• Unsteady fuel pressure - adjust fuel pressure
6.6 ELECTRICAL CABINET DOES NOT START

Check line fuses and substitute with others having same characteristics.
6.7 PUMP DOES NOT STOP (AT MAXIMUM LEVEL)

Check connections between probes and electrical cabinet, verify that probes are not connected to ground
through the manifold, that ceramic is not broken, that level regulator installed in the cabinet properly works.
6.8 PUMP DOES NOT START (AT MINIMUM LEVEL)

Check probes and pump protection fuses.
6.9 PUMP DOES NOT TURN AND/OR ALARM LIGHT IS ON

Check relay, verify that impeller is not blocked, that filter is not stopped. Press unblock button when motor is
cool.
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6.10 BURNER STOPS FOR WATER AND/OR PRESSURE ALARM

Check safety and minimum level probe.
Check electrical connections.
Check water temperature.
Check seat of check valve and clean if necessary.
Check pressure switch and water failure alarm reset.
Check that combustible arrives.
Check rotation sense of burner fan.
6.11 BURNER DOES NOT STOP FOR WATER AND/OR PRESSURE ALARM
Check electrical connections between cabinet and burner.
Check equipment and call burner operator.
6.12 LOW LEVEL ALARM

This alarm appears when the water level is lower than the normal working level.
Should it appear, the operator must:
- check the feed water delivery and the steam delivery
- make sure the calibration device is functioning correctly
- change calibration device to manual and reduce the burner load
- check water quality
- check level probe
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6.13 HIGH LEVEL ALARM

This alarm appears when the water level exceeds the normal working level.
The operator must:
- check the level indicators
- change calibration to manual and switch off the pump of the water supply unit
- check intervention adjustment
- check water quality
- check level probe
6.14 WATER FAILURE ALARM

The light “water failure alarm” is ON, water pump stops and burner stops.
It may be due by lack of feeding water, feed water too high temperature, or by leakage defect of check valve.
Check if water reaches the boiler.
Empty and clean seat of check valve, increase static height or insert a circulation pump between tank and
pump.
Check gaskets of water pump piston and replace if necessary.
In case the malfunction persists, try changing feed pump(s).
When cooled down, perform careful examination of the generator before filling again.
Clean water filter.
6.15 PRESSURE ALARM

Safety pressure switch intervenes and boiler is in stop with manual reset indicated by “pressure alarm” light.
Check the reason and restore operation conditions pressing “reset” button.
Check operation of safety pressure switch and regulation pressure switch.
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6.16 BURNER ALARM

It is due to lack of combustion, combustible impurities, flame strap, … , light “burner alarm” is ON.
After removal of defect (eventually with assistance of burner operator), press “reset” button on boiler cabinet
and burner cabinet.
!
To restart the boiler after a shutdown caused by a safety
protection, first manually remove the block by pressing the
pushbutton on the electric panel.
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GPT, GPT/R, NG/C, NG/V, NG3/R3 Maintenance
7. MAINTENANCE
7.1 GENERAL
The boiler works completely automatic and requires no particular measures for its operation.
The operations to be carried out at regular intervals have been stated in the paragraph below.
The fulfillment of the control and inspection operations stated in this manual assures a longer working-life to
the installation and the prevention of possible failures and malfunctions.
7.2 MAINTENANCE OPERATIONS (IN ADDITION TO PERIODICAL INSPECTIONS)
WARNING : before any maintenance operation, cut off tension

to the installation by turning the switch positioned upstream
! the line and the main switch positioned on the control board.
Affix the notice board:
“MAINTENANCE OPERATIONS IN PROGRESS or STANDSTILL
FOR MAINTENANCE”
7.2.1 Monthly maintenance

Check that the regulation and control instruments are in good working order, carefully examining electrical
parts (including connections) and mechanical parts (pressure-switches and, when fitted, the containers of
ballcock-type level-switches).
Perform burner maintenance (as per instructions provided).
Check the condition of the coating inside the hatches.
Check that the boiler tube bundle and the turbolators are clean.
Check that the bearings and the stuffing box of the motor-driven pump are in good working order (lubricate
greasers); check the state of wear of the discharge and bleed valves, which tend to suffer wear before other
valves because of the abrasive effects of the sludge.
Clean the level indicators.
Check motor starter contacts for burns.
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7.2.2 Semi-annually maintenance

Check the tightening of bolts on the flanges and the condition of the gaskets.
7.2.3 Extraordinary boiler maintenance

Every boiler must be stopped at intervals for inspection and maintenance; the time between such operations
is a question of experience, operating conditions, quality and features of the water and the type of fuel
employed.
Before entering the boiler for inspection or cleaning, carefully check that neither steam nor water can enter
the boiler through the various connections: every valve should be closed and, if necessary, totally isolated by
detaching a section of pipe down-line or inserting a blank disk between the flanges.
Check the general conditions of the boiler and – especially for the heavy oil / diesel oil boilers – detect and
possible fuel leakage.
The interior of parts under pressure must be carefully examined to detect any presence of scale, corrosion of
other potential sources of danger attributable to the feed water: remove deposits by chipping them away or
by using chemical cleaning agents. Every mark or other type of corrosion should be scraped and cleaned
with a metal brush until bare metal appears; every fume stack which shows signs of leaks from the pipe plate
fitting must be reworked or replaced.
Internal inspection must also include the condition of fittings, making sure that everything is in good working
order: particular attention should be given to all feed pipes, steam separators, safety valves, discharges,
levels, pressure measurement devices and all other accessories included in the water or steam circuits.
Inspect the combustion chamber in order to check the conditions of the refractory materials. If they are
damaged, they must be repaired by making use of specific refractory cement.
Check that the electric terminals are tight, in particular the supply terminals of the electric motors.
Remove any possible dust deposit or oily sludge from the surface of the fan.
In any case, you’d better contact the GARIONI NAVAL’s service centre (phone ++39 030/2681541) –
gnservice@garioninaval.com .
74
7
7.3 INSTRUCTIONS FOR CLEANING OF AIR PREHEATER (/AR ONLY)

For a trouble-free and economical operation of steam boiler with comburent air preheater, regular
maintenance and periodical cleaning is mandatory. Such operations can only be done when the boiler is
cooled down. Then the cleaning and inspection hatch can be opened easily and without any danger.
In case of burners with gas fuel the cleaning shall be performed at least twice a year, while in case of
burners with liquid fuels the cleaning shall be made every three months, with monthly check of cleaning
conditions.
First of all switch off the boiler, check burner off and close fuel valves.
Unscrew hatch fixing bolts and open it.
Pulverized fuel deposits as well as dirt particles can be blown off by means of a cleaning lance and
compressed air (at 6 to 8 bar pressure).
Close the hatch screwing fixing bolts.
Open fuel valves, start the boiler and check combustion parameters.
7.4 STANDSTILL
The most serious problems of corrosion often arise when the boiler is not being used. The operations
thereby required to ensure good boiler conservation essentially depend on the expected duration of the
period of inactivity.
Dry conservation may be used when the boiler is to remain inactive for long periods, or wet conservation for
shorter periods or when the boiler is a back-up system which must be capable of coming quickly into
operation. In both cases, the operations to be performed aim at eliminating the potential causes of
corrosions.
7.4.1 Dry conservation

Carry out a careful cleaning of the exhaust gas side of the boiler by making use of compressed air.
Detach the connection to the chimney pipe and hermetically seal the boiler connection with blind flange and
gasket.
Carefully empty and dry the boiler.
Disassemble the burner and introduce a vessel containing quicklime to absorb moisture. Then re-assemble
the burner and tighten the screws.
Lubricate the tightening screws of the valves and all the bolts and screw studs of the boiler.
Protect the electrical panel and all the electrical appliances from the dust and external moisture.
Disconnect the power supply switch.
Close the fuel cut-off valves.
75
7
7.4.2 Wet conservation

This is performed by eliminating every trace of oxygen from the water and then attempting to prevent its
subsequent access to the system.
An oxygen-absorbing substance should then be added ( such as hydrazine, sodium sulphate, etc.) and
checking the basicity of the water at the same time. Then fill the boiler completely with depurated water.
Disconnect the power supply switch.
Close the fuel cut-off valves.
76
7
7.5 OPENING OF REAR SMOKE CHAMBER

Following operation may be performed
in order to allow easy cleaning of
horizontal boilers tubes.
• Connect lug of smoke chamber to

proper lifting equipment (i.e. crane,
overhead crane, forklift, …).
• Unscrew fixing nuts of smoke

chamber. Usually, depending on
boiler model, you will find 12 to 20
nuts M18 or M20.
• Remove smoke chamber.

As far as vertical boilers are concerned,
in the some chambers are foreseen
specific doors to be opened for cleaning
of tubes.
77
7
7.6 SPARE PARTS

- Burner liquid fuel: Electrodes
Start-up transformer
Nozzle diesel oil
Nozzle heavy fuel oil
Return nozzle
High temperature cables
Gasket
Photocell
- Burner gas fuel: Electrodes
Start-up transformer
Ionization probe
High temperature cables
Gasket
Air pressure switch
- Electrical cabinet: Relays 4 contacts 24V 6562100
Relays 4 contacts 220V 6562100
NEW GARIOMATIC controller (if installed)
- control panel with LCD display
- electric card “base”
- electric card “confort”
GEFRAN regulator 24V 1600V (if installed) 6991358
GEFRAN regulator 24V 800-RRRR-03 (if installed) RCA009
GEFRAN regulator 24V 800V-RRRR-03 (if installed) 6991363
GEFRAN regulator 24V 800V-RRRR-07 mA (if installed) 6991372
GEFRAN regulator 24V 400 (if installed) 6991356
GEFRAN regulator 24V 40 (if installed) 6991357
- Valves: Check valve
- Accessories: Level gauge 240mm RCA0026
Level gauge 340mm RCA0027
Crystal glass for level gauge RCA0049
Level probe RCA0078
Level controller MMT 201 RCA0074
Level controller MMT 202 RCA0284
Modulating level controller MMT 442 L=500 6560609
Modulating level controller MMT 442 L=1000 6560608
MBS pressure transmitter (if installed) RCA0060
SENSORTECH pressure transmitter (if installed) RCA0255
MBS 0-25bar pressure transmitter (if installed) 6505030
0-100bar pressure transmitter (if installed) RCA0079
Pressure switch RCA0003
Pressure gauge 6520500
- Boiler body: Asbestos free gaskets for main doors
Manhole gasket RCA0076
When ordering spare parts, always inform serial number of boiler and voltage of instruments.
In any case, you’d better contact the GARIONI NAVAL’s service centre (phone ++39 030/2681541) –
gnservice@garioninaval.com .
78

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Fire Tube Steam Boilers

FIRE TUBE STEAM BOILERS

THE USE OF THE BOILER IS ALLOWED ONLY TO SKILLED

The guarantee applies only to the Purchaser in agreement with

INDEX GPT, GPT/R, NG/C, NG/V, NG3/R3

5.2.2 MARINE APPLICATIONS 61

7.6 SPARE PARTS 78

1.1 GENERAL PURPOSE AND RANGE OF APPLICATION

1.2 HEATING PLANT

1.2.1 Preliminary Safety Checks

1.3 SAFETY PRESCRIPTIONS DURING INSTALLATION AND FIRST

• Due to high pressure

• Due to high smokes temperature (if installed)

• Due to burner stopping

• Due to power supply failure

• Due to possible repetitions of remote alarms

• Maximum/minimum gas pressure and seal (natural gas)

• Flame failure (diesel oil)

• Heavy oil maximum minimum temperature (if applicable).

1.4 SAFETY PRESCRIPTIONS DURING MAINTENANCE

1.4.1 General Prescriptions, before any Intervention

! always FOLLOW the instructions and, if no instructions are

1.4.2 Fuel Circuit

1.4.3 Electrical cabinet

! Always perform boiler connection to ground.

1.4.4 Steam Circuit

1.5 SAFETY PRESCRIPTIONS DURING MACHINE WORKING

2.1 BOILER SECTION

2.1.1 Boilers series GPT

Position Description Position Description

2.1.2 Boilers series GPT/R

Position Description Position Description

2.1.3 Boilers series NG/C

Position Description Position Description

2.1.4 Boilers series NG/V

Position Description Position Description

2.1.5 Boilers series NG3/R3

Disegno NG 1041 Rev.0

Position Description Position Description

2.2 BOILER LAY-OUT

2.2.1 Boilers series GPT

Position Description Position Description

2.2.2 Boilers series GPT/R

Position Description Position Description

2.2.4 Boilers series GPT, GPT/R with air preheater

Position Description Position Description

2.2.5 Boilers series NG/C

Position Description Position Description

2.2.6 Boilers series NG/V

Position Description Position Description

2.2.7 Boilers series NG3/R3

Position Description Position Description

2.3 P&I BOILER

2.3.1 Boilers series GPT, GPT/R

Position Description Position Description

Position Description Position Description