SM Global Manual 10-160

SHELLMAX GLOBAL – PACKAGED
BOILERS
Capacities -1 TPH to 10TPH
Models – SM Global – 10, 15, 20, 30, 40, 50, 60, 80,100,120,140,160
Fuel – LDO, HSD, FO & Gas Fuels
OC Number –
Client –
Publication Number –
Installation, Operation
And Maintenance Manual
Improving your
business is our
business
THERMAX LIMITED
Thermax Group
Thermax Ltd has a vision is to be a globally respected high performance company offering
sustainable solutions in energy and environment.
Thermax Group provides business to business solutions in the areas of heating, cooling, captive
power, water treatment, air pollution control, waste management & resource recovery and
chemicals to a wide range of industry in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power
and waste heat recovery. It also offers a range of heating equipment, energy efficient chillers
and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated
expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined
Heating Power and Cooling (CHPC) projects…
Thermax provides energy solutions to utilize waste heat to burn waste gases and biomass. These
include a variety of customized turnkey solutions to generate heat, steam and power. It
undertakes the entire range of activities from concept to commissioning.
Clientele includes Refineries, Petrochemicals, Fertilizers, Paper & Pulp, Distilleries, Independent
Power Plants, Chemicals and food processing, pharmaceuticals a wide range of other industries.
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of
solid fuels including biomass. Thermax emerged as a leading and reliable project management
company with installations the world over; in the US, Saudi Arabia, Thailand, Egypt, Philippines
and several other countries.
Leveraging its leadership position in electricity saving vapor absorption technology, it offers
process industries and commercial establishments like hotels, shopping malls and offices vapor
absorption chillers a boon in power-starved areas. These Eco-friendly, energy efficient
equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch,
Panasonic, Henry Ford Museum,BMW
In the environment area Thermax offers waste management expertise for solid, liquid and air
pollution. Thermax provides solutions from pre-treatment to waste water treatment and
chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust
area for Thermax. Hi-grade resins from Thermax have found niche customers in US and Japanese
markets.
Thermax is a key player in the field of gaseous and particulate emission control, with special
focus on the emerging gaseous scrubbing business in India. Our state-of-the-art technology
enables us to offer turnkey projects well as air pollution control products.
And, the greatest utility of these solutions stems from the fact that they allow resource recovery
in process industries.
Thermax has an extensive international marketing network. Headquartered in Pune (Western

India), Thermax’s eleven international offices are located in South East Asia, Middle East, Africa,
Russia, UK and the US. Thermax’s 4 oversea subsidiaries play a significant role in generating
business in the International market. Thermax (Russia) Ltd., Thermax (Europe) Ltd., Thermax Inc.,
USA. Around 20 percent of the group’s turnover comes from exports to the US and European
markets, Japan, East Africa, the Middle East, South East Asian and CIS countries.
The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area
of over 65,000Sq.Mts. are ISO-9000 and ISO-14001 and ISO 18000 accredited. Thermax
manufactures to international standards like ASME, BS, DIN and GOST. The facilities have been
inspected by Lloyds, Bureau Veritas, SGS and TUV.
Thermax’s business is inspired by the conviction that ‘Improving your business is our business’.
Division Profile
Cooling & Heating Division:

Heating Group
Cooling & Heating Division: Heating Group (C&H-Heating)

Heating group of C&H Division is the flagship Product Business Division of Thermax Ltd, which has
its core business in the area of providing cost effective process heating solutions for both energy
generation and energy conservation. Thermax has begun its business way back in 1966 by
manufacturing baby boiler. C &H: Heating, is the seed for business growth for the company.
Today its high quality products are demand in India and in international markets. Its products
and expertise find applications in every conceivable heating application in the world.
History
C&H-Heating, earlier known as Process Heat Division, made a modest beginning to manufacture
by collaborating with Wanson of Belgium. The collaboration introduced baby boilers in India. The
baby boilers which we were outside the purview of the Indian Boiler Regulation Act was the most
demanded product. The successful acceptance of the product led to pioneering of Thermic oil
heating in India.
Thermal oil heating took the Indian industry by storm and today in India its brand Thermopac has
become to generic name. Thermal oil heating replaced several others heating methods such
Electrical, steam, steam-cum-electrical. The main reason is its highest energy saving capability
due to high system efficiency. To name a few industry which initially benefited the most are:
Textile, Footwear, Flatten Press, Rubber etc. Today every industry looks to thermal oil heating as a
most potential energy saving solution.
The division then made a modest beginning with a turnover of USD 0.05 million in 1968, and now
has grown to a USD 85 million group which offers a wide range of solutions to its customers in the
areas of energy generation & conservation and environment protection, all under one roof with
a singular mission.
To pursue this mission, C&H-Heating has been continuously designing and upgrading its products
and services that results in energy efficient heating solutions to the customer making optimum
use available energy resources - conventional, non conventional and the renewable energy
sources.
Over the last 30 years this Division has evolved into Engineering major well known for its core
competencies in the field of Process Heating and Energy conservation.
Division Profile
Products and Services
Our product portfolio encompasses providing process heating through different mediums such
as
 Steam
 Hot Oil
 Hot Water
 Hot Air
The product technology facilitates use of wide range of fuels viz.,
 Light & Heavy Oil
 Natural Gas
 LPG
 Bio-Gas
 Cool Low and high Calorific values,
 Lignite
Non conventional / agro based fuels
 Rice Husk
 Bagasse
 Groundnut Shell
 Mustard stalk
 De-oiled bran
 De-oiled cake etc.

Division Profile
With the strengths C&H -Heating Division caters to the need of variety of application in
process industries like
Agro products Packaging
Bottling & beverages Drugs & pharmaceuticals
Breweries & distilleries Plywood
Chemical & petrochemicals Rubber
Engineering Edible oil / solvent extraction
Food & dairy Textile / Synthetic fibers
Hotels Hospitals
..And more
All these innovations of providing energy efficient solutions have been evolved through a close
interaction with the market to understand the changing needs of he customers across the world.
Thermax has an extensive national and international marketing network. Headquartered in Pune
(Western India), Thermax’s eleven international offices are located in South East Asia, Middle
East, Africa, Russia and the US. Thermax has also established a subsidiary in the United States that
is catering to the markets in North and South America. Around 20 percent of the group’s
turnover comes from exports. We have around 20,000 installations spanning 45 countries.
‘If you need the heat, we have the source’.

Contents
Sr. No. Chapter Page No.
Chapter 1: Introduction
1.1 Introduction : SHELLMAX BOILER – SM-Global Series 2
1.2 Product Features 4
1.3 Major components 5
Technical Specifications
Chapter 2: Installation
2.1 Transportation 31
2.2 Unloading Instructions 31
2.3 Unloading Guidelines 35
2.4 Storage 36
2.5 Drawings 38
2.6 Installation Guidelines 39
2.7 IBR Registration 47
2.8 Assembly Guidelines 55
Chapter 3: Instrumentation, controls & Safeties

3.1 Igema Level Probe 78
3.2 Fusible Plug 80
3.3 Boiler Safety Valve 81
3.4 Boiler Water Level Gauge 82
3.5 Digital Temperature Indicator 82
3.6 Pressure Controllers 83
3.7 Burner & Burner Management Systems 85
Chapter 4: Input Requirement

4.1 Fuel 92
4.2 Feed Water Quality 93
4.3 Boiler Water Quality 94
4.4 Electrical Input 94
Chapter 5: Commissioning Process

5.1 Pre-Commissioning 95
5.2 Commissioning 102
Chapter 6 : Operation
6.1 Boiler Startup Process 111
6.2 Boiler Stopping Procedure 113
6.3 Boiler Running Attention 114
6.4 Dos and Don’ts 117
Chapter 7: Maintenance
7.1 Maintenance Schedule 120
7.2 Log Book 124
7.3 Spare Parts 128
Chapter 8: Troubleshooting 129
Chapter 9: Care of Idle Boilers

9.1 Wet Preservation 132
9.2 Dry Preservation 133
9.3 Chemical Boiling Out 133
Chapter 10: Annexure 138

IMPORTANT INSTRUCTIONS
Important Instructions
TO: Owners and persons responsible for installation, operation and maintenance.
 This manual presents information that will help to install, operate and maintain the
equipment properly. It is expected that the contents be carefully read before handling
the unit.
 A good installation is a permanent asset while a bad one can be a constant source of
trouble. It can cost much more to correct a bad installation than to put a new one.
 Shellmax boilers are products of many years of design & engineering effort, to provide
long life & excellent service on the field. This unit will provide continued trouble free
service, if instructions on installation, operation and maintenance are properly followed.
 It is expected that the personnel involved in Installation, Operation & Maintenance

possess necessary qualification competence and license (if applicable). It is solely the
responsibility of the owner & user to ensure that all applicable statutory norms are
adhered to during Installation, Operation & Maintenance of the equipment.
 The electrical and mechanical devices supplied as a part of the unit were chosen
because of their known ability to perform, with proper operating techniques and
maintenance procedures. Tempering with the safeties & controls or bypassing any of
these is not permissible at any time.
 Any “Automatic” features included in the design do not relieve the attendant of any
responsibility. Such features may free him of certain repetitive chores and give him more
time to devote to the proper upkeep of equipment.
 No amount of written communication can replace intelligent thinking & reasoning.
Since the product improvement is continuing process, the information given in this manual on
specific features is subject to change without notice.
Chapter 1
01 SM Global
Fig:1.1 Shellmax Global
1
Chapter 1
1.0 SHELLMAX GLOBAL BOILER

1.1 INTRODUCTION
The SHELLMAX is a smoke tube, three flue pass, fully wet back, packaged boiler. Its unique
design makes it the most efficient & rugged smoke tube boiler in its class. The technical
expertise that goes in designing this excellent piece of equipment is backed by several
years of boiler manufacturing experience by THERMAX Ltd.
This high efficiency unit can be fired on liquid and or gaseous fuels. The configuration of
this boiler is such that it makes it suitable for burning liquid fuels & gases together, when
fitted with a special burner. However, the standard supply includes arrangement for firing
one fuel at one time. Shellmax Boilers consist of a combustion chamber where heat is
generated by oxidising a fuel and necessary heating surfaces to absorb this heat into
water. The water so heated converts into steam. The steam is separated out of the water
by providing steam separation area on the surface of the water. In order to ensure high
efficiency of operation both the combustion efficiency as well as heat absorption
efficiency is to be maximised. Proper mixing of fuel and air is engineered into a mutually
supportive combination of burner and combustion chamber to give the highest possible
combustion efficiency. Sufficient heat transfer surface is provided to obtain high
absorption efficiency.
Combustion is the process of oxidation of fuel. Proper combustion of the fuel will be
obtained if all the components of the fuel get oxidised. Three basic conditions need to
prevail in the combustion chamber for proper oxidation i.e. TIME, TEMPERATURE AND
TURBULENCE. In SHELLMAX these three are achieved by a furnace of low volumetric heat
release rate and highly engineered burner design.
SHELLMAX Global utilizes patented heat recovery technology (Effimizer) to improve fuel
flexibility, reduce low end corrosion & improves efficiency at different operating loads .
THREE FLUE PASS DESIGN:
The pressure part consists of a main shell. This has a combustion chamber fitted
eccentrically on the lower side of the shell. The rear end of the combustion chambers is
connected to an internal reversal chamber. The entire furnace assembly is held in position
between the front and rear tube plate. Stay bars are used to support rear end of internal
reversal chamber.
The flue gases make three flue passes in the boiler for efficient transfer of heat to the
water. 1st pass is in the furnace itself where heat transfer is mainly by radiation.
INTERNAL REVERSAL CHAMBER
At rear side of furnace larger diameter reversible chamber than the main furnace is
welded and it forms the beginning of the second pass. The flue gases reverse direction of
travel to enter the tubes. The chamber is surrounded by water to keep it cool.
2
Chapter 1
The second flue pass is in the tubes between the reversal chamber and the front end
plate. The 3rd flue pass is in the tubes between the front and the rear tube plate. In the
second and third pass the heat transfer is mainly by convective heat transfer
Water level is maintained sufficiently above the reversal chamber top and third passes
tubes to ensure safe operation. Adequate disengaging surface, free board height and a
moisture separator is provided to ensure very good quality (98% dry steam) of steam.
WET BACK:
Cooling of rear side of the furnace (reversal chamber) takes place by the water itself. No
refractory is installed, hence maintenance and heat loss associated with the refractory are
eliminated.
SINGLE OR DOUBLE FLUE
Single or double flue means single or double furnace. Two furnaces are used for large
boilers.
INDIAN BOILER ACT (IBR)
All boilers have to be designed, manufactured and inspected during manufacturing as

well as prior to installation. This is a government’s compulsory (mandatory) requirement.
The steam boilers have to be operated by qualified and certified boiler operators and
offered for annual inspection to the IBR authorities.
Fig: 1.2 Sectional View of Shellmax Global Boiler
3
Chapter 1
1.2 PRODUCT FEATURES

Some of the unique features of Shellmax boilers are:
 Higher water holding capacity  Optimum tube sizing maintains high

leading to high thermal energy hold velocity of flue gases. This ensures
up. This helps the boiler meet higher heat transfer coefficient and
fluctuating steam demand higher efficiency.
 Large disengaging surface area  Leak proof air damper gives higher
and large free board reduces water efficiency on part load.
carryover.
 Hinged Oil /gas fired burner
 Direction changing steam separator provides easy and quick nozzle
ensures dry steam. cleaning
 Corrugated furnace (6 TPH & above  EFFIMIZER is Integrated Economizer

Boilers) with extra efficiency at all load
conditions and Recover heat with
variety of fuels. It also save space,
avoid complicate ducting & piping
and without need of bypass at low
loads.
 Skid boiler assembly - Separate

Fig: 1.3 Corrugated Furnace
foundation for boiler accessories not
required.
 Large furnace leads to low
volumetric heat release rate which  Prewired and Pre insulated boiler
gives low thermal stress, complete which avoids complicated cabling
combustion and multi fuel ability, for and insulation, cladding work at
oil and gaseous fuel. site.
4
Chapter 1
1.3 Major Components of the Boiler:
1.3.1 Feed Water Pump:
The feed pumps take the water from the feed water
tank & supply the water to the boiler. Two feed water
pumps are provided, one working and one standby. The
pump is operated on off, by the water level controller.
Each pump is of adequate capacity and head to meet

the boiler requirement. The feed pumps are selected
considering reduction in pump capacity and head due
to normal wear & tear over a period of time.
Fig: 1.2 Boiler Feed Pump
The pumps are vertical, multistage, centrifugal types. Electric motor is directly mounted on
top of the pump. The pump is provided with single mechanical seal.
1.3.2 THERMOWIZ:
Shellmax Global series boilers are equipped with SMART controller based power cum
control panel. It controls entire operation of burner as well as boiler. In comparison with
conventional relay based panel, SMART controller panel is compact and less complicated
to operate. It has following key features,
 Touch Screen graphical operator interface and Monitoring
 All boiler operations from 5.7” crystal clear TFT-65K
 On screen real-time display of all connected process Parameters.
 System alarms & faults indication.
 On screen settings of boiler performance parameters
 On screen Run/Trip indication of all electrical drives/motors
 Selection between Auto and Manual mode of operation.
 Availability of separate commissioning mode.
 It has facility to integrate with third party device or controller.
 Smart controller has in built embedded communication ports. USB, Serial & CAN
open (driving distributed devices), Ethernet port (Networking locally & remotely)
 Data protection with password.
 Smart controller can connect remotely for free via Web Gate, using a PC browser
to visualize and control the boiler.
5
Chapter 1
 Smart controller gives remote access with a fully operable mirror view of the boiler
for Android based devices like smart phones, Tablets etc.
 Smart controller can connect remotely for debugging & troubleshooting or for
online modification of the logic/program
 Controller can support external USB drive up to 8 GB for data storage.
Fig: 1.3 Electrical Control Panel
6
Chapter 1
1.3.3 BURNER:
Burner is the heart of the boiler, which provides the fuel or heat input to the boiler. The high
thermal efficiency & the trouble free operation of the boiler will mainly depend on its
design, its compatibility with boiler, ability to burn the desired fuels with high efficiency &
reliability of the components.
All these desired features are incorporated in the design of the burners supplied by
Thermax.
The burner which supplied with Shellmax boilers are: For LO-NG/NG/LO it will be monobloc
burner and for FO and FO-NG it will be dual bloc burner.
Fig: 1. 4 Oilon Burner
1.3.4 OIL PRE-HEATING & PUMPING STATION- (OPH)- 12 TPH and onwards for
FO
Heavy Oil fired Burner operation can be efficient & trouble free only when it is fed with the
right pressure & precise pre heated temperature. Oil pre heating station supplied by
Thermax along with the boiler ensures right fuel Pressure & temperature with Rugged
components. The components which are supplied from Thermax factory are pre-
assembled on the skid, which is to be installed on the concrete foundations.
The components which are included in OPH station supplied are:
7
Chapter 1
 Fuel Filter - duplex type -1 no

 Fuel Pumps-2nos
 Oil Pre heating Tank assembly with
electric heater & steam heating
arrangement.
 Pressure switch ,pressure gauge
 Interconnecting pipelines
 Isolating Valves, NRVs
 Interconnecting Electrical cables for
pumps ,heater, Pressure switch etc with
junction box ( for connection to the boiler
control panel)
The fuel supply to the OPH station is given

through Ring main fuel System which is to be
made at the installation site by the customer/User, Fig: 1.7 OPH Station
as per the details/drawing supplied by Thermax
1.3.5 FUEL PUMP- 12TPH and Onwards
The fuel pump is the most sensitive component of the boiler, which
has to develop the consistent fuel pressure during the burner
operation. The fuel pump of liquid fuel fired Shellmax boiler is
internal gear type/screw type pump directly coupled to the
motor. It is a part of the Oil Pre-heating & pumping station. The
burners of Shellmax boilers are pressure jet type, which require
high pressures to atomize the fuels. The fuel pump develops the
required fuel pressure for the proper atomization of the fuel at the
burner spray nozzle.
Fig: 1.10 Fuel Pump
The required fuel pressure will depend upon the fuel used. The
fuel pressures will be lower for light fuels as compared to the heavy fuels. The model of the
fuel pumps will be different for Light Oil &heavy oils. Also there is a limitation on the
interchangeability of the fuel pumps, with the change of fuel oils.
8
Chapter 1
1.3.6 FORCED DRAUGHT (FD) FAN-12TPH and onward for FO
The forced draught fans are centrifugal fans, used to supply combustion air to the boiler.
The combustion air is supplied to furnace since this fan supplies

The air with some force to handle the pressure drop till the end of the boiler, it is called as
Forced Draught fan or primary Air fan.
FD fan is designed and selected to supply the desired air quantity with the desired pressure
to overcome the pressure drops across the boiler unit and the optional Heat recovery units
Fig: 1.11 Forced Draft Fan
This FD fan is directly coupled to the electrical motor. The boiler furnace is connected to
the FD fan through the canvas and M.S. Duct, with air damper at the suction of the fan.
And it is installed close to the boiler on separate foundation.
9
Chapter 1
1.3.7 OPTIONAL ACCESSORIES
A. Effimiser
Fig: 1.12 : Integral Economizer Arrangement
Heat recovery from the flue gas of a boiler is normally limited due to presence of sulphur,
which gets converted to oxides of sulphur, causing condensation of sulphuric & sulphurous
acid at low temperature heat transfer surface. It occurs primarily in heat recovery units
having metal temperature less than the dew point temperature of these acids is referred
to as dew point corrosion or low temperature corrosion. Percentage of sulphur varies from
fuel to fuel. This necessitates different metal temperature to eliminate the corrosion
problem. As a result, same heat recovery unit cannot be used for multiple fuels.
THERMAX has come out with the solution to this problem – EFFIMIZER. It is an integral
economizer that can recover heat from flue gas containing different levels of sulphur and
can still resist corrosion. This makes it suitable for variety of fuels. Sitting on top of smoke
chamber it operates in lower space. That results in lower foot print, eliminates completes
ducting and piping and reduces the installation cost and time. This design helps to
achieve the higher efficiency (1% higher than conventional HRU) on fuel oil fired boiler.
EFFIMIZER is available for all capacities.
Boiler Efficiencies (IN %)
Fuel LO FO NG
With Effimizer 93 92.5 95
Without Effimizer 89 89 88.5
10
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO / ECO
DESCRIPTION UNITS SM-10 SM-15 SM-20 SM-30 SM-40 SM-50 SM-60 SM-80 SM-100 SM 120 SM 140 SM 160
GENERAL
0
Steam Output F & A 100 C kg / hr 1000 1500 2000 3000 4000 5000 6000 8000 10000 12000 14000 16000
Heat Output 6 6.48 7.56 8.64
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40
Volumetric Heat Release Rate 6 3 0.77 0.70 0.63
10 kcal/hr.m 0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91
Heating Surface 2 236 290 365
m 25 37 45 69 90 107 131 165 193
Water Holding Capacity Up to 3 18.49 22.98 28.35
m 3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28
NWL
Steam Space 3 3.08 4.26 6.05
m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
BURNER
Burner model KP KP KP KP KP KP KP KP KP KP KP KP
80H 90H 6140H 150M 280M 300 MII 400 MI 500 M 700M 1000 M 1000 M 1200 M
Fuel Supply Pressure( Oil ) kg/cm2(g) 20-25
Burner Turn Down (Oil) 1:2.8 1:4.3 1:4.2 1:4.3 1:3.9 1:4.7 1:3.8 1:4.3 1:4.2 1:3 1:3 1:3
Modulation type Step(Two Stage) Stepless
Combustion Blower motor KW 1.5 2.2 4 5.5 7.5 7.5 11 11 18.5 37 37 45
Fuel Pump Motor KW Coupled on blower shaft 1.5 1.5 2.2 4.0 5.5 5.5 5.5
Motor connection DOL
Fuel Pump AJ6CC AJ6CC J7CC TA2C TA3C TA 4 C TA 4 C TA 5C T3C ALLWEILER
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
Head for 10.54 kg/cm2 135
MLC
NPSH Required MLC 3
Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
11
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO / ECO
Motor connection starting DOL
ECO CIRCUIT WATER PUMP
Flow 3
m /hr 10 15 20
Head MLC 9 15.5 12
NPSH Required MLC 0.84 0.55 0.8
Material Of Construction
Speed RPM 1426 1456 1460
Motor KW KW 0.55 1.5 1.5
Control Panel Load KW 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Connected Load (except stand-
bys) 4.75 5.45 7 9.55 12.5 15 18.5 20.7 30
KW 55.5 55.5 63.5
5.5 6.25 8 12.05 15 18.5 22 30.2 39.5
UTILITIES CONSUMPTION
Fuel Light Diesel Oil
kg/hr 57 85 114 171 228 285 342 455 569 683 797 911
Consumption
Fuel High Speed Diesel
kg/hr 55 83 111 166 221 276 332 442 553 664 774 885
Consumption
12
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG/ECO

0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
Volumetric Heat Release Rate 6
10 kcal/hr.m
3
0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91 0.77 0.70 0.63
Heating Surface m
2
25 37 45 69 90 107 131 165 193 236 290 365
Water Holding Capacity Up to NWL m
3
3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28 18.49 22.98 28.35
Steam Space m
3
0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55 3.08 4.26 6.05
BURNER
Burner model GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP
80H 90H 140H 250M 280M 300 MII 400 M I 500 M 700M 1000 M 1200 M 1200 M
Fuel Supply Pressure( Gas ) mbar 360 mbar / 1- 4 bar 500 mbar / 1- 4 bar
Burner Turn Down (Gas) 1:2.9 1:4.3 1:4.3 1:7.0 1:7.0 1:4.7 1:4.3 1:4.8 1:4.2 1:5 1:5 1:5
Fuel Pump Motor KW NA NA 1.5 1.5 1.5 1.5 1.5 2.2 4.0 5.5 5.5 5.5
Motor connection DOL/STAR DELTA
Fuel Pump AJ6CC AJ6CC J7CC TA3C TA3C TA4C TA5C TA5C T3C ALLWEILER
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
MLC
NPSH Required MLC 3
13
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG/ECO

Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
Type Close Coupled - Vertical
Flow 3
m /hr 10 15 20
Head MLC 9 15.5 12
Speed RPM 1426 1456 1460
Motor KW KW 0.55 1.5 1.5
POWER SUPPLY
Connected Load (except stand-bys) 4.75 5.45 8.75 11.05 14 15 18.5 20.7 30 55.5 63.5 63.5
KW
5.5 6.25 9.55 13.55 16.50 18.50 22 30.20 39.5 59.5 71 71
Fuel Light Diesel Oil Consumption kg/hr 57 85 114 171 228 285 342 455 569 683 797 911
Fuel High Speed Diesel Consumption kg/hr 55 83 111 166 221 276 332 442 553 664 774 885
Fuel Natural gas consumption Nm3/hr 68 101 135 203 270 338 406 541 676 811 946 1081
14
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 10 TPH - 10.54/17.5 kg/cm2(g) / NG / ECO

GENERAL
0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
10 kcal/hr.m
3
0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91 0.77 0.70 0.63
Heating Surface m
2
25 37 45 69 90 107 131 165 193 236 290 365
3
3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28 18.49 22.98 28.35
Steam Space m
3
0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55 3.08 4.26 6.05
Boiler Turn Down ( Gas ) 1: 2 1:3 1 : 3.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5 1:4.5 1:5 1:5
BURNER
Burner model GP GP GP GP GP GP GP GP GP GP GP GP
80H 90H 140H 250M 280M 300 MII 400 MI 500M 700M 1000M 1000M 1200M
Type Mono - bloc
ROTATING EQUIPMENTS
FEED WATER PUMP
Type Centrifugal Multistage - Vertical
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
MLC
NPSH Required MLC 3
Type Of Seal Mechanical Seal
15
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 10 TPH - 10.54/17.5 kg/cm2(g) / NG / ECO

Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
Flow 3
m /hr 10 15 20
Head MLC 9 15.5 12
Impeller Grey Cast Iron
Outer sleeve Steel
Shaft Steel
Type Of Seal Mechanical
Speed RPM 1426 1456 1460
Motor KW KW 0.55 1.5 1.5
POWER SUPPLY
Control Panel Load KW 0.5
Connected Load (excl stand-bys) 4.75 5.45 7 9.55 12.5 13.5 17 18.5 26 50 50 58
KW
5.5 6.25 8 12.05 15 17 20.5 28 35.5 54 57.5 65.5
16
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16TPH - 10.54/17.5 kg/cm2(g) / FO/ECO
0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
Boiler Turn Down ( Oil ) 1: 2 1:2.1 1:2.1 00:01 1:3.2 01:04 1;2.7 1;4.1 1:3.5 1:3.7 1:3.5 1:3.3
FUEL
Type
Furnace Oil
NCV of Furnace oil Kcal/kg 9650
BURNER
Burner model RP RP RP RP RP RP RP RP RP RP RP
RP 600M
130H 130H 140 H 250M 280 M 300MII 500M 700 M 800ME 1000ME 1200ME
Type Mono - bloc
Light Up By High Voltage Spark
Burner Turn Down (Oil) 1:2.8 1:2.8 1:3 1:4.9 1:3.9 1:4.78 1:3.8 1:4.8 1:4.17 1:3.7 1:3.5 1:3.3
Combustion Blower motor KW 3 3 4 7.5 7.5 7.5 11 15 18.5 30 37 45
Fuel Pump Motor KW NA NA NA NA NA 1.5 2.2 2.2 4.0 3.7 5.5 5.5
Electric Heater KW 6 6 6 12 12 12 18 18 24.0 18 24 24
Fuel Pump SPF10R SPF10R SPF20R HP
E7 E7 E7 TA3 TA3 SPF20R38 ALLWEILER
46 56 56 TECH
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
MLC
17
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16TPH - 10.54/17.5 kg/cm2(g) / FO/ECO
NPSH Required MLC 3
Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
Flow 3
m /hr 10 15 20
Head MLC 9 15.5 12
Speed RPM 1426 1456 1460
Motor KW KW 0.55 1.5 1.5
Motor connection starting DOL DOL DOL
POWER SUPPLY
Connected Load (excl stand- 12.62 12.62 13.62 23.92 24.87 25.87 35.37 40.87 50.37 65.07 79.8 87.87
bys) KW
13.4 13.4 14.4 26.4 27.4 30.9 41.1 52.6 63.9 65.4 81.9 89.9
Consumption
kg/hr 60 91 121 181 242 302 363 484 605 726 847 968
18
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / FO-NG/ECO

SM SM 140 SM 160
DESCRIPTION UNITS SM-10 SM-15 SM-20 SM-30 SM-40 SM-50 SM-60 SM-80 SM-100 120
Boiler Type Three pass wet back smoke tube boiler
Design Code IBR 1950 (With latest amendment) / EN12953
0
Steam Output F & A 100 12000 14000 16000
kg / hr 1000 1500 2000 3000 4000 5000 6000 8000 10000
C
Boiler Turn Down (gas ) 1:2 1:2.8 1:3.5 1:5.8 1:5.7 1:4.0 1:2.7 1:4.1 1:3.7 1:4.5 1:5 1:5
FUEL
Type Furnace Oil-Natural Gas
NCV of NG Kcal/Nm3 8500
BURNER
GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP
Burner Model (Oil )
130M 130M 140M 250M 280M 300M II 500M 600M 700M 800ME 1000ME 1200ME
Fuel Supply Pressure(Gas) 360 mbar / 1-2 bar 500 mbar / 1-2 bar
Burner Turn Down (Gas) 1:4.5 1:5 1:5 1:7.0 1:7 1:4.7 1:3.8 1:4.8 1:4.18 1:5 1:5 1:5
Fuel Pump Motor KW 1.5 1.5 1.5 1.5 1.5 1.5 2.2 2.2 4 3.7 5.5 5.5
Electric Heater KW 6 6 6 12 12 12 18 18 24 18 24 24
Fuel Pump SPF20R SPF20R5 HP ALLWEILER
TA2 TA2 TA2 TA3 TA3 SPF10R46 SPF10R56
38 6 TECH
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
MLC
NPSH Required MLC 3
Speed RPM 2900
19
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / FO-NG/ECO

SM SM 140 SM 160
DESCRIPTION UNITS SM-10 SM-15 SM-20 SM-30 SM-40 SM-50 SM-60 SM-80 SM-100 120
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
ECO CIRCUIT WATER
PUMP
3
Flow m /hr 10 15 20
Head MLC 9 15.5 12
Impeller Grey Cast Iron
Outer sleeve Steel
Shaft Steel
Type Of Seal Mechanical
Speed RPM 1426 1456 1460
Motor KW KW 0.55 1.5 1.5
POWER SUPPLY
Connected Load 14.12 14.12 15.12 23.42 26.37 27.37 37.57 43.07 54.37 65.07 79.87 87.87
KW
14.92 14.92 15.92 25.92 28.87 30.87 41.07 52.57 63.87 69.37 87.37 95.37
Fuel Heavy Oil kg/hr 60 91 121 181 242 302 363 484 605 726 847 968
Fuel Natural Gas Nm3/hr 68 101 135 203 270 338 406 541 676 811 946 1081
20
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO
GENERAL
0
Heat Output 6 6.48 7.56 8.64
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40
Volumetric Heat Release Rate 6 3 0.77 0.70 0.63
10 kcal/hr.m 0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91
Heating Surface 2 236 290 365
m 25 37 45 69 90 107 131 165 193
Water Holding Capacity Up to 3 18.49 22.98 28.35
m 3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28
NWL
Steam Space 3 3.08 4.26 6.05
m 0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55
BURNER
Burner model KP KP KP KP KP KP KP KP 1000 KP 1200
KP 80H KP 90H KP 140H 150M 280M 300 MII 400 MI 500 M 700M 1000 M M M
Type Mono - bloc
Light Up By High Voltage Spark
Fuel Pump Motor KW Coupled on blower shaft 1.5 1.5 2.2 4.0 5.5 5.5 5.5
Fuel Pump AJ6CC AJ6CC J7CC TA2C TA3C TA 4 C TA 4 C TA 5C T3C ALLWEILER
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
MLC
21
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO
NPSH Required MLC 3
Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
POWER SUPPLY
Connected Load (except stand- 4.2 4.9 6.7 9 11 13.5 17 19.2 28.5 54 54 62
bys) KW
5 5.7 7.5 11.5 13.5 17 20.5 28.7 39 58 61.5 69.5
Consumption
kg/hr 59 89 119 178 238 297 357 476 569 714 833 952
Fuel High Speed Diesel
Consumption
kg/hr 58 87 116 173 231 289 347 462 553 693 809 925
22
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG

0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
10 kcal/hr.m
3
0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91 0.77 0.70 0.63
Heating Surface m
2
25 37 45 69 90 107 131 165 193 236 290 365
3
3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28 18.49 22.98 28.35
Steam Space m
3
0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55 3.08 4.26 6.05
BURNER
Burner model GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP GKP
80H 90H 140H 250M 280M 300 MII 400 M I 500 M 700M 1000 M 1200 M 1200 M
Fuel Pump Motor KW NA NA 1.5 1.5 1.5 1.5 1.5 2.2 4.0 5.5 5.5 5.5
Fuel Pump AJ6CC AJ6CC J7CC TA3C TA3C TA4C TA5C TA5C T3C ALLWEILER
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
23
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG

Head 135
MLC
210
NPSH Required MLC 3
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
POWER SUPPLY
Connected Load (except stand-bys) 4.2 4.9 8.2 10.5 12.5 13.5 17 19.2 28.5 54 62 62
KW
5 5.7 9 12 15 17 20.5 28.7 38 58 69.5 69.5
Fuel Light Diesel Oil Consumption kg/hr 59 89 119 178 238 297 357 476 569 714 833 911
Fuel High Speed Diesel Consumption kg/hr 58 87 116 173 231 289 347 462 553 693 809 885
24
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / NG

SM- SM SM
DESCRIPTION UNITS SM-10 SM-15 SM-20 SM-30 SM-40 SM-50 SM-60 SM-80 SM 140
100 120 160
GENERAL
0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
6
Volumetric Heat Release Rate 10 kcal/hr.m
3 0.68 0.67 0.85 0.90 0.86 0.96 0.93 0.91 0.91 0.77 0.70 0.63
Heating Surface m
2
25 37 45 69 90 107 131 165 193 236 290 365
3
3.22 4.41 4.33 5.76 7.52 7.88 10.23 11.84 15.28 18.49 22.98 28.35
Steam Space m
3
0.8 1.07 0.99 1.08 1.8 1.7 2.35 2.41 3.55 3.08 4.26 6.05
Boiler Turn Down ( Gas ) 1: 2 1:3 1 : 3.5 1:5 1:5 1:3.7 1:3.3 1:4 1:3.5 1:4.5 1:5 1:5
BURNER
Burner model GP GP GP GP GP GP GP GP GP GP GP GP
80H 90H 140H 250M 280M 300 MII 400 MI 500M 700M 1000M 1000M 1200M
Type Mono - bloc
Light Up By High Voltage Spark / Pilot flame
ROTATING EQUIPMENTS
FEED WATER PUMP
25
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / NG

SM- SM SM
DESCRIPTION UNITS SM-10 SM-15 SM-20 SM-30 SM-40 SM-50 SM-60 SM-80 SM 140
100 120 160
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
Head 135
MLC
210
NPSH Required MLC 3
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
POWER SUPPLY
Connected Load (excl stand-bys) 4.2 4.9 6.7 9 11 12 15.5 17 24.5 48.5 48.5 56.5
KW
5 5.7 7.5 11.5 13.5 15.5 19 26.5 34 52.5 56 64
26
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16TPH - 10.54/17.5 kg/cm2(g) / FO
Boiler Type
Three pass wet back smoke tube boiler
Design Code
IBR 1950 (With latest amendment) / EN12953
0
Heat Output 6
10 kcal/hr 0.54 0.81 1.08 1.62 2.16 2.70 3.24 4.32 5.40 6.48 7.56 8.64
BURNER
Burner model RP RP RP 140 RP RP 280 RP RP RP 700 RP RP RP
RP 600M
130H 130H H 250M M 300MII 500M M 800ME 1000ME 1200ME
Burner Turn Down (Oil) 1:2.8 1:2.8 1:3 1:4.9 1:3.9 1:4.78 1:3.8 1:4.8 1:4.17 1:3.7 1:3.5 1:3.3
Fuel Pump Motor KW NA NA NA NA NA 1.5 2.2 2.2 4.0 3.7 5.5 5.5
Electric Heater KW 6 6 6 12 12 12 18 18 24.0 18 24 24
Fuel Pump SPF10R4 SPF10R5 SPF20R5 HP TECH
E7 E7 E7 TA3 TA3 SPF20R38 ALLWEILER
6 6 6
ROTATING EQUIPMENTS
FEED WATER PUMP
Flow for 10.54 kg/cm2 3 2.5 2.5 2.5 4.5 4.5 6.5 6.5 10.8 10.8 18 18 10
m /hr
Flow for 17.5 kg/cm2 2.5 2.5 2.5 5 5 8.5 8.5 15.7 15.7 15.2 19 19
Head 135
MLC
210
NPSH Required MLC 3
Motor 10.54 kg/cm2 KW 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
27
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16TPH - 10.54/17.5 kg/cm2(g) / FO
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
POWER SUPPLY
Connected Load (excl stand- 11.7 11.7 12.7 23 23 25.5 35.7 41.2 52.5 63.2 78 86
bys) KW
12.5 12.5 13.5 25.5 25.5 29 39.20 50.70 62.0 67.20 85.5 93.5
Consumption
kg/hr 63 94 126 189 251 314 377 503 629 754 880 1006
28
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / FO-NG

0
Steam Output F & A 100
kg / hr 1000 1500 2000 3000 4000 5000 6000 8000 10000 12000 14000 16000
C
Boiler Turn Down (gas ) 1:2 1:2.8 1:3.5 1:5.8 1:5.7 1:4.0 1:2.7 1:4.1 1:3.7 1:4.5 1:5 1:5
FUEL
Type Furnace Oil-Natural Gas
NCV of NG Kcal/Nm3 8500
BURNER
GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP GRP
Burner Model (Oil )
130M 130M 140M 250M 280M 300M II 500M 600M 700M 800ME 1000ME 1200ME
Fuel Supply Pressure(Gas) 360 mbar / 1-2 bar 500 mbar / 1-2 bar
Burner Turn Down (Gas) 1:4.5 1:5 1:5 1:7.0 1:7 1:4.7 1:3.8 1:4.8 1:4.18 1:5 1:5 1:5
Fuel Pump Motor KW 1.5 1.5 1.5 1.5 1.5 1.5 2.2 2.2 4 3.7 5.5 5.5
Electric Heater KW 6 6 6 12 12 12 18 18 24 18 24 24
Fuel Pump SPF20R SPF20R5 HP TECH ALLWEILER
TA2 TA2 TA2 TA3 TA3 SPF10R46 SPF10R56
38 6
ROTATING EQUIPMENTS
FEED WATER PUMP
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
Head MLC 135
NPSH Required MLC 3
Speed RPM 2900
Motor 10.54 kg/cm2 2.2 2.2 2.2 3 3 4 4 5.5 5.5 11 11 11
KW
Motor 17.5 kg/cm2 3 3 3 5.5 5.5 7.5 7.5 15 15 15 18.5 18.5
29
Chapter 1
SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / FO-NG

POWER SUPPLY
Connected Load 13.2 13.2 14.2 22.5 24.5 25.5 35.7 41.2 52.5 63.2 78 86
KW
14 14 15 25 27 29 39.20 50.70 62 67.57 85.87 93.87
Fuel Heavy Oil kg/hr 63 94 126 189 251 314 377 503 629 754 880 1006
Fuel Natural Gas Nm3/hr 72 108 144 215 287 359 431 574 718 861 1005 1149
30
Chapter 2
02 TRANSPORTATION & UNLOADING

INSTRUCTIONS
2.1 Transportation
SHELLMAX GLOBAL is dispatched from our factory as a modular boiler.
During transportation, extreme care is taken to ensure safe and intact delivery of the Boiler.
The Boiler and other wooden cases are loaded on the trucks as per upright markings.
Dispatch particulars are sent to the customer immediately after loading the trucks.
2.2 Unloading Instructions

 The boiler should be lifted for loading, unloading or shifting from one position to another,
only by means of lifting hooks provided on top of the boiler. Refer Table T-1.2.1 indicating
the Dry weight of pressure parts.
 The packing slip supplied with the material should be referred and the number of cases
supplied should be verified with the numbers received at site.
 The wooden / packed cases should be opened only in the presence of Thermax
Engineer or Thermax authorized person / dealer, for checking the inside materials as per
the packing slip.
 If the cases are opened in the absence of Thermax Engineer / authorized person /
dealer, and if the material is found missing, the responsibility of Thermax shall cease.
 For any breakage / damages, insurance claim should be made.
 For any missing items, Thermax Engineer / authorized person / dealer shall report to
Thermax Limited for replenishment, provided the cases are opened in their presence.
 For any incorrect supply of material Thermax Engineer / authorized person / dealer shall
report to Thermax Limited for replacement.
31
Chapter 2
2.3 Shipping weight & dimensions of major parts
Fig 2.1: Shipping weight & dimensions of major parts: Standard Scope of Supply with Effimiser
32
Chapter 2
Table 2.1: Shipping Weight and Dimensions of Unit Assembly with Effimizer
Capacity SM
10 15 20 30 40 50 60 80 100
Global
Pressure
10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54
(kg/cm2)
Length (m) 3.34 3.34 3.84 3.84 3.86 3.86 4.37 4.37 4.67 4.67 5.28 5.28 5.83 5.83 6.75 6.75 7.06 7.06
Height (m) 2.82 2.82 2.95 2.95 3.04 3.04 3.21 3.21 3.46 3.46 3.66 3.66 3.69 3.69 4.05 4.05 4.22 4.22
Width (m) 3.2 3.2 3.29 3.29 3.29 3.29 3.4 3.4 3.6 3.6 3.46 3.46 3.61 3.61 3.75 3.75 3.94 3.94
Dry weight
5409 5824 6581 7221 6918 7608 8859 10170 11290 12876 12493 14358 14555 16475 17767 20232 21455 24292
(kg)
Table 2.2: Shipping Weight and Dimensions of Unit Assembly without Effimizer
Capacity SM
10 15 20 30 40 50 60 80 100
Global
Pressure
10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54 10.54 17.54
(kg/cm2)
Length (m) 3.34 3.34 3.84 3.84 3.86 3.86 4.37 4.37 4.67 4.67 5.28 5.28 5.83 5.83 6.75 6.75 7.06 7.06
Height (m) 2.5 2.5 2.6 2.6 2.6 2.6 2.07 2.07 3.02 3.02 3.02 3.02 3.2 3.2 3.4 3.4 3.6 3.6
Width (m) 3.2 3.2 3.29 3.29 3.29 3.29 3.4 3.4 3.6 3.6 3.46 3.46 3.61 3.61 3.75 3.75 3.94 3.94
Dry weight
4688 5103 5689 6329 5970 6660 7536 8846 9713 11298 10673 12538 12711 14631 15023 17488 17845 21282
(kg)
33
Chapter 2
Table 2.3: Shipping Weight and Dimensions of Unit Assembly without Effimizer
Shipping dimension and weight of Burner Assembly

Capacity SM Global 10 15 20 30 40 50 60 80 100
Length (m) 1.5 1.7 1.8 1.8 1.8 2 2.2 2.5 2.5
Width (m) 1.3 1.4 1.4 1.34 1.4 1.4 1.5 1.7 1.7
Height (m) 0.8 0.8 0.82 0.9 0.9 1.1 1.3 1.3 1.3
Weight (m) 200 200 210 300 370 470 610 620 690
Note:
 The main boiler pressure part dimensions and burner weights/dimension do not change with change in Max working
pressure of the boiler
(10.54 Or 17.5 kg/cm2).
 The above parts are the major parts of the boiler. There are some more smaller and light wooden cases / loose parts
supplied with the boiler, which are lesser in weight & dimensions, hence are not mentioned here.
 The dimensions given in above table are the outermost dimensions, to facilitate the unloading & shifting.
 Weight of wooden Packing is considered in the shipping weight, if the item is supplied in packed condition.
34
Chapter 2
2.3 Unloading Guidelines

A) All the parts should be unloaded with crane, tripod, suitable capacity as per the weight
& dimensions given in Table T-2.1.
Fig.2.2 : Unloading Boiler with Crane
B) All parts should be unloaded in marked upright position only i.e. these should not be tilted
while unloading or shifting. If lifting tackles are not available, rollers, wooden slabs or
some skid should be placed beneath the frame of the boiler and wooden case and it
should be carefully guided for unloading and shifting. Under no circumstances the boiler
and accessories should be dropped or turned to any other position other then marked
on the cases.
Fig.2. 3 : Packing Cases should not be titled while unloading or shifting
35
Chapter 2
C) It is advisable to unload the boiler as closes as possible to the Boiler House; preferably just
outside the main door of the Boiler House, on some skids or pipes, so that pushing the
Boiler into the Boiler House for positioning it on the foundation is easier. The soil at the
place of unloading should be hard enough to bear the weight of the Boiler, to prevent it
from sinking. Likewise, when the Boiler is being shifted to the Boiler House, the approach
road to the Boiler House should also be made of hard ground.
Fig.2. 4 : The soil at the place of unloading should be hard
2.4 Storage
A) All the material should be stored under roof and should be protected from rain, water or
direct sunlight.
Fig.2. 1 : Boiler should be stored under roof
36
Chapter 2
B) Boiler & parts should not be stored under corrosive atmosphere.
Fig.2. 2 : Boiler should not be stored under corrosive atmosphere
C) Do not pile up cases.
Fig.2. 3 : Do not pile up cases
37
Chapter 2
D) Do not store heavy material on soft soil.
Fig.2. 6 : Material should not be stored on soft soil
2.5 Drawings
A set of the following drawings is given by Thermax Ltd to guide the site persons. These drawings
should be carefully preserved for the reference.
The drawing numbers with Alteration numbers to be recorded in the box below for future records
by the customer before installation:
 P& I Diagram Drawing No. ALT NO.
 GA TP & foundation details Drawing No. ALT NO.
 Electrical Diagram Drawing No. ALT NO.

(Supplied with Elect control Panel)
38
Chapter 2
2.6 Installation Guidelines

Thermax provides the post sales services to the customers from trained Engineers of Thermax or
Authorized Representatives to the customers /users of the Boiler from the very next day of the
receipt of the order.
Customer is provided with all the information & guidance on the complete Installation and
commissioning of the boiler through our qualified & trained Engineers /authorized dealers or
associates.
2.6.1 Boiler House Location:
The first step of the installation is the deciding the location & size of the boiler house.
Guidelines:
The following major factors decide the location of the boiler house is:
 Location of the steam utilities-the boiler house should be located nearest to the utilities to
reduce the losses in transportation i.e. steam pressure drop and condensation loses.
 Wind direction: To avoid smoke nuisance from the chimney.
 Safety of the plant & machinery.
 To avoid corrosive atmosphere or gases affecting boiler and to its accessories.

 Adequate area near boiler and other components for ease of operation & maintenance.
 Water softening & dosing plant and space required to house them near Boiler house.
 Fuel storage and handling system should be planned closer to Boiler house for ease of
handling.
 Fuel storage should be enough to store min 15 days of the consumption.
WARNING: Consider the mandatory Rules and regulations for machinery i.e. Factory Act,
Fire Insurance Association, etc. for deciding the location of the boiler house.
39
Chapter 2
2.6.2 Boiler House layout:
A good Boiler house layout will provide adequate space for operation and maintenance. The
Boiler house layout should be finalized only in consultation with Thermax engineers or Thermax
authorized persons /dealers, well in advance before the delivery of the boiler.
Guidelines:
1. Typical “Boiler House Layout” is given in the layout drawing shall provide for the
reference in deciding the boiler house plan.
2. Refer to General Arrangement & Terminal Point) GATP and foundation drawings of boiler
and its accessories.
3. Locations of control panel, water treatment plant, Fuel pre heating station, Fuel day tank
(inside or outside of the boiler house), Chimney & other drain & exhaust pipe lines can be
decided referring the boiler house layout, GATP & P&I diagram.
4. Air Pre-heater (optional), soft water storage tank, chimney etc. is to be decided after
studying the system requirements, factory layout and space availability.
5. The boiler house floor loading for all models is approximately 25 MT/M². The floor in front
of the door of the boiler house is also to be prepared to withstand this load, since the
boiler would be unloaded on this floor and would, thereafter, be pushed inside the boiler
house.
6. Provide adequate ventilation and lighting.
CAUTION:
 Dimensions of openings of doors of your boiler house should be adequate enough to

push the boiler and accessories inside the boiler house.
 Provide free space equal to length of boiler in front, for opening of front doors,
cleaning of fire tubes and space for coal storage and for firing it.
 Do not provide Blow down Pit of Brickwork, but should be of M.S plates and Concrete
Slabs on Firm & hard Soil.
 Provide a blow down pit/tank with cover for safe discharge of blow down water near
boiler house.
 Locate the control panel at a location from where water level gauge glass, pressure
gauge, flame, and water level in water service tank are visible.
 Soft water Day tanks should be inside or very close to the boiler house.
WARNING:
 Do not finalize the boiler house layout without consulting the Thermax Engineers or
authorized dealers/representatives.
40
Chapter 2
 Don't reduce the size of the boiler house unless confirmed by Thermax.
2.6.3 Foundation Preparation and Details
2.6.3.1 General Arrangement & Terminal point (GATP) Drawing
A rigid, flat, leveled foundation is vitally essential for smooth, quiet operation, and lower
maintenance cost of the boiler and other equipment. An improperly constructed or inadequate
foundation may cause vibration and possible misalignment of the equipment, which may lead
to component & metal failure, breakage and Cracks.
Guidelines:
 All foundations must be flat, leveled and rigid.

 The floor loadings, for designing foundations of the boiler and accessories, are given in
‘General Arrangement and foundation detail’ drawing of the boiler and individual loads on
foundation is given below in Table no 2.2-.
 The height of any foundation should be minimum 100 mm above the finish floor level unless
otherwise specified. This is to prevent the structure of equipment from water etc. that may
corrode and reduce the life of equipment and foundation bolts.
 Cast the foundation as per the dimensions given in the drawing.
 Consider the soil conditions while designing the foundations.
 An allowance must be made for a minimum of 25 mm of shimming and grouting when
determining the top surface of the foundation.
Table-2.4: Weight (kg) on Foundation: SM Global Components (Without Effimiser)
SM SM SM SM SM SM SM SM SM
Part Description Details Global Global Global Global Global Global Global Global Global
10 15 20 30 40 50 60 80 100
10.54kg
Pressure
Pressure 8706 11172 11289 14379 19029 20251 25289 29274 36751
Working
/cm2
Max.
Part -
Flooded 17.5kg/
Weight cm2
9121 11812 11979 15690 20615 22116 27209 31739 40112
10.54kg
Pressure
90 90 90 140 140 140 140 250 250

Working
/cm2
Max.
Feed
Pump 17.5kg/
cm2
90 90 90 140 140 140 140 250 250
41
Chapter 2
Table-2.5: Weight (kg) on Foundation: SM Global Components (With Effimiser)
SM SM SM SM SM SM SM SM SM
Part Description Details Global Global Global Global Global Global Global Global Global
10 15 20 30 40 50 60 80 100
Pressur 10.54kg
Pressure
9427.2 12064 12237 15703.9 20607.9 22071.3 27133.3 32018 40361
Working
e Part - /cm2
Max.
Floode
d 17.5kg/
cm2
9842 12704 12927 17014 22193 23936 29053 34483 43722
Weight
10.54kg
Pressure
90 90 90 140 140 140 140 250 250

Working
/cm2
Max.
Feed
Pump 17.5kg/
cm2
90 90 90 140 140 140 140 250 250
CAUTION:
 The rear end of boiler foundation block

should be provided with 10 mm thick M.S.
plate grouted in foundation as shown in
General Arrangement drawing. This is for
free thermal expansion movement of boiler
during operation.
 Proper and Sufficient Curing is to be done for

all civil foundations.
Fig.2.7: Foundation block.
WARNING:
Consult Civil engineering structural expert for designing the foundations based on soil
condition of your plant and live weight on the foundation.
The qualified & experienced civil engineer should supervise the foundations work.
42
Chapter 2
Fig.2.8: GATP Drawing of Shellmax Global Boiler without Economizer.

43
Chapter 2
Fig.2.9: GATP Drawing of Shellmax Global Boiler without Economizer.

44
Chapter 2
2.6.4 Shifting On Foundation
In India Permission from the Indian Boiler Regulation (IBR) inspecting authority is to be taken
before erecting or placing the boiler on the foundation.
(REF the next chapter registration under Indian Boiler Regulations)
Note: Indian Boiler Regulation (IBR) is applicable for boilers installed in India. For boilers installed
in other countries, the local rules and regulations should be followed.
Guidelines
 It is advisable to use a spreader type sling when handling/shifting the boiler & other
equipment.
 Boiler should be moved to its foundation as a unit, with care being taken to prevent
distortion or damage.
 After the foundation holes in the unit are lined up with anchor bolts in the foundation, the
equipment should be lowered over the anchor bolts.
2.6.5 Grouting and Leveling
Guidelines
 All the accessories of the boiler i.e. F.D. Fan, Air Pre-heater (if applicable), Electrical
Control panel etc. can be placed on respective foundations and can be grouted &
leveled.
 Prior to placing the boiler and fan on the foundations, the location of anchor bolts should
be checked against the drawing to ensure that these bolts are placed correctly.
 Since the boiler and fan is mounted on separate foundations much care and attention
to alignment is required to match their inlets and outlets.
CAUTION:
 Anchor bolts in concrete should approximately

50 mm larger in diameter it should be placed
in pipe or sheet metal sleeves adjusting the
bolts in case they move slightly when concrete
is poured.


Fig.2.10: Types of Anchor Bolts
45
Chapter 2
 Where some adjustment is required to

level the unit, leveling should be done
taking /smoke tube of the boiler shell as
reference. If the leveling is not done
correctly the water level gauges would
show different levels, also the minimum
water level above the top row of smoke
tubes would not be maintained
properly, which can be dangerous and
fatal.
Fig.2.11: Level Bottle
 Before final grouting of boiler, level the

boiler properly.
For leveling large area shims should be
placed under the pedestal before
tightening the anchor bolts. Distortion of
the equipment may occur when the
bolts are not tightened equally or if short
thick shims providing only limited surface
contact are used.
Fig.2.12: Level Tubes
WARNING:
The boiler can be placed on foundation only when permitted by the Boiler Inspecting
Authority.
46
Chapter 2
2.7 Registration of Boiler under “Indian Boiler Regulations (IBR)”

(Applicable for boilers installed in India only)
2.7.1 Necessity of Registration
All steam boilers in India are required to be registered under section 7 of the Indian Boiler Act
and in accordance with Chapter 9 of the Indian Boiler Regulations. Section 6 of the Indian Boiler
Act, prohibits the use or permit to use any boiler which is unregistered or uncertified. This
registration is generally valid for 1 year from the date on which it is granted.
The installed boilers are also subjected to these tests to determine the fitness of boiler for the
purpose of renewal of Registration certificate.
In India, State of Jammu & Kashmir is exempted from this activity of IBR registration. Boilers
installed on Railway Engines are also exempted from this activity.
The following details and Instructions will guide the owners & users in getting their new boiler
registered as per the Indian Boiler Regulations.
2.7.2 Boiler IBR Certificates: IBR Folder
This folder is supplied to the user from our factory and contains all the original certificates of the
boiler manufacturing and the mountings /fittings. This needs to be submitted to Boiler
Inspectorate, while making the application for registration along with inspection fees.
This folder contains important and original documents like:
1. Manufacturing certificates in forms II, III and IV,

2. Approved boiler pressure part drawings,
3. Boiler mountings certificates in form III C.
Preserve the IBR folder and take one photocopy copy of the complete folder, for the records
& site reference. Ensure that all the certificates are intact & serially numbered in the folder.
47
Chapter 2
2.7.3 Application for Registration
The owner shall make application for the registration of a new boiler/renewal of Registration
certificate, to their Regional Boiler Inspectorate. Boiler Folder and receipt of Treasury Challan for
prescribed registration fees with the application be submitted to the Boiler Inspectorate. The
Boiler Registration Fees depends upon the heating surface area of the boiler. The Boiler
Inspectorate office shall then communicate the details of Inspector's visit for various Inspections.
2.7.4 IBR Boiler Inspection
The inspection as per IBR involves 3 Stages as under,
1. Open Inspection or ground Inspection

2. Hydraulic Test
3. Steam Test
2.7.4.1 Open Inspection
For new boilers, which are to be registered, this inspection is carried out with the purpose of
verifying the details recorded in the folder to the actual details of the boiler construction.
This inspection is carried out on the ground under the open condition and clean of the boiler
and the IBR mountings & fittings.
The boiler inspecting authority generally verifies/checks followings during this inspection:
1. Approval stamping made on the boiler as per the certificates.
2. For any damages or any alterations if made, other than details mentioned in
Approved drawings.
3. Verification of Serial numbers and the inspecting authority's seal on various valves
and mountings with respect to their Certificates.
4. Measurements of the spring, body, valve and valve seats of the steam safety valves.
5. Verify the Certificate of the Boiler operator, if appointed by the Owner/user.
Preparing the boiler for Open Inspection:
48
Chapter 2
The following preparatory action is taken prior to the Inspector's visit.
a) All the water/smoke tubes and internal surfaces of boiler should be kept clean by using
suitable wire brush.
b) Any Insulation, Lagging, brick work, which is hiding the pressure part surface should be
removed for the inspection.
c) Safety valves should be opened out completely and cleaned so that the spring, body and
valve seats are available for inspection and measurements of various dimensions.
d) The side and manhole/hand holes covers are removed to facilitate the best possible view of
the tubes and internal surface for inspection.
e) All the IBR valves and mountings should be kept arranged for verification. It should be
ensured that the serial numbers/registration number and the inspecting authority's seal on
the boiler and on the IBR valves are clearly visible so that the Inspector can immediately
relate them to the corresponding certificate.
f) Necessary platforms are provided for ease of boiler inspection.
g) Measuring instruments like measuring tape, venire, measuring feet scale etc. should be kept
handy for checking the measurements.
h) Temporary provision of 24 volts Hand Lamp with lamp guard / powerful Torch must be made
for ease of inspection of each part.
NOTE: It is advisable to verify the Identification number and Inspecting authorities Seal on Boiler,
valves and mountings and fittings with relevant Certificates and Forms of boiler folder before the
visit of the inspecting authority (use the photocopy of the boiler folder).
Only after the inspecting authority clears the IBR inspection, the boiler can be prepared for next
IBR inspection i.e. Hydraulic Test… (Applicable for boilers installed in India. For boilers installed in
other countries, follow the local rules and regulations)
2.7.4.2 Hydraulic Test
Under regulation 377 of the IBR, important provisions of which, as applicable to the boilers are:
Every boiler shall be hydraulically tested in the presence of the IBR Inspecting authority, to not
less than one and half times the designed pressure, for registration/for renewal of registration
certificate.
49
Chapter 2
The boiler shall satisfactorily withstand such pressure without appreciable leakage or undue
deflection or distortion of its parts for at least ten consecutive minutes.
Preparing the boiler for Hydraulic test:
Note: Under above regulation, when a boiler is hydraulically tested for the first time, it should be
entirely cleared of lagging or brickwork; at subsequent tests the lagging or brickwork, or portion
thereof, should be removed if required by the Inspector.
a. Safety valves should be removed and the opening should be closed by blank flange.
Pressure switch connection should be removed and the opening plugged.
b. All side and manhole covers are placed properly with correct gaskets and checked for
tightness.
c. Following valves be kept closed in position during the test-
i. Main Steam Stop Valve
ii. Vent Valve
iii. Gauge Glass Cocks
1. Steam Cocks
2. Water Cocks
3. Drain Cocks
iv. Boiler blow down valve
d. Feed inlet, blow down lines are to be connected to the boiler. Feed pump can be
connected for filling water in the boiler.
e. A convenient inlet for the pressure test should be taken and suitable hydraulic test pump
connections be made.
f. The Boiler shall be completely filled with clean water and the pressure being applied
gradually, with a test hydraulic pump having a pumping capacity higher than that of
hydraulic pressure. Care is to be taken to avoid air pockets in the boiler pressure parts.
g. As a preliminary test, before Inspector's visit, raise the hydraulic pressure to working
pressure limit and ensure that no leakage is observed from the pressure part's joints and
then raise slowly to the required Hydraulic test pressure, to keep it for ten minutes. Check
for the leakages and sustenance of the pressure.
On satisfactory completion of Hydraulic Test in presence of boiler inspecting authority, the

Provisional Order for use of boiler is issued, valid for 6 months and the Registration Number for the
boiler is allotted.
IT IS NECESSARY TO COMPLETE THE IBR FORMALITIES OF IBR STEAM LINES & PIPES, SIMULTANEOUSLY
WITH THE HELP OF THE IBR APPROVED CONTRACTOR.
50
Chapter 2
Engraving Of Registration Number
The registration number allotted by Chief Inspector should be engraved in front plate in such
position as pointed out by the Inspector. This should be completed and reported to Chief
Inspector for verification within one month from the date of its receipt.
The Chief inspecting authority normally supplies the registration number engraving slip. This slip
should be pasted on the part of the boiler pointed out by the Inspector for engraving. The
engraving should not be less than 0.4 mm (1/64") in depth.
2.7.4.3 Steam Test
Every newly installed boiler, before the issue of a Registration Certificate, should be tested under
steam to the satisfaction of the Inspector. This should be done in accordance with the
Provisional Order issued by the Boiler Inspectorate after completion of hydraulic test and as per
regulation No. 380 of IBR.
A steam test is primarily intended for the purpose of ascertaining by actual test whether the
safety valves are sufficient to relieve boilers effectively of excess steam and whether they
operate at the time when the maximum working pressure is reached.
Preparing the boiler for Steam test:
a. Get the Boiler Registration number (allotted for the boiler after hydraulic test)
engraved on boiler pressure parts at any convenient location suggested by Boiler
Inspector.
b. Verify the safety valve settings done during commissioning of boiler.
c. Boiler attendant must be present during the test.
Steam Test in presence of Inspector:
At the time of test, the safety valve should be left free and capable of being adjusted to the
working pressure.
After adjustment of the safety valves to the correct blowing pressure, the boiler shall be tried
under full steam and firing with the stop valve closed. During this test the Boiler inspecting
authority shall note the accumulation of the pressure and other details of the test as well as verify
the performance of the safety valve.
On satisfactory completion of Steam Test, the Boiler Inspectorate issues Registration Certificate.
This needs to be protected and displayed in the boiler house as per the advice of Boiler
Inspecting authority.
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Chapter 2
2.7.4.4 Safety Valve over Pressure
REGULATION NO. 294
The safety valve shall be so designed that they attain rated discharge capacity with the over
pressure not greater than that given in regulation 292; provided that the safety valve which
have a discharge area less than 80% of the flow area, the over pressure at which the design lift is
attained shall not exceed 10% of the set pressure. For safety valve having discharge area 80% or
more of the flow area, the over pressure at which the design lift is attained shall not exceed 5%
of the set pressure.
2.7.4.5 Safety Valve Pressure Drop
REGULATION NO. 295
The safety valve shall be reset at a pressure at least 2 % below, but not more then 5% below the
safety valve set pressure. The 5% limit is increased to 10% for valve having a body seat bore less
than 32 mm and/or having a set pressure of 2 bar gauge or less.
2.7.5 Prohibition of Use of Boiler
Prohibition of use of unregistered or uncertified boiler -

Important provision under Section: 6 of Indian Boiler Act.
AS expressly provided in this Act, no owner of a boiler shall use the boiler or permit it to be used -
(a) Unless it has been registered in accordance with the provisions of this Act.
(b) In the case of any boiler which has been transferred from one State to another, until the
transfer has been reported in the prescribed manner.
(c) Unless a certificate or provisional order authorizing the use of the boiler is for the time
being in force under this Act.
(d) At a pressure higher than the maximum pressure recorded in such certificate or
provisional order.
(e) Where the State Government has made rules requiring that boilers shall be in charge of
person holding [certificates of proficiency or competence], unless the boiler is in charge
of a person holding the certificate required by such rules:
Provided that any boiler registered, or any boiler certified or licensed, under any Act hereby shall
be deemed to have been repealed registered or certified, as the case may be, under this Act.
52
Chapter 2
2.7.6 Renewal of Certificate
Important provision under Section: 8 of Indian Boiler Act.
(1) A certificate authorizing the use of a boiler shall cease to be in force -
(a) On the expiry of the period for which it was granted; or
(b) When any accident occurs to the boiler; or
(c) When the boiler is moved, the boiler not being a vertical boiler the heating
surface of which is less than [18.58 square meters], or a portable or vehicular
boiler; or
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) If the Chief Inspector in any particular case so directs, when any structural
alteration, addition or renewal is made in or to any steam-pipe attached to the
boiler; or
(f) On the communication to the owner of the boiler or an order of the Chief
Inspector or Inspector prohibiting its use on the ground that it or any steam-pipe
attached thereto is in a dangerous condition.
(2) Where an order is made under clause (f) of sub section (1), the grounds on which the
order is made shall be communicated to the owner with the order.
(3) When a certificate ceases to be in force, the owner of the boiler may be apply to the
Inspector for a renewal thereof for such period not exceeding twelve months as he may
specify in the application:
(4) An application under sub-section (3) shall be accompanied by the prescribed fee and,
or receipt thereof, the Inspector shall fix a date, within thirty days or such shorter period
as may be prescribed from the date of the receipt, for the examination of the boiler and
shall give the owner thereof not less than ten day's notice of the date so fixed:
Provided that, where the certificate has ceased to be in force owing to the making of
any structural alteration, addition or renewal, the Chief Inspector may dispense with the
payment of any fee:
(5) On the said date, the Inspector shall examine the boiler in the prescribed manner, and if
he is satisfied that the boiler and the steam-pipe or steam-pipes attached thereto are in
good condition shall issue a renewed certificate authorizing the use of the boiler for such
period not exceeding twelve months and at a pressure not exceeding such maximum
pressure as he thinks fit and as is in accordance with the regulations made under this Act:
53
Chapter 2
The Inspector shall, within forty-eight hours of making the examination, inform the owner
of the boiler in writing of this opinion and the reasons therefore, and shall forthwith report
the case for orders to the Chief Inspector.
(6) The Chief Inspector, on receipt of the report under sub-section (5), may, subject to
provisions of this Act and of the regulations made hereunder, order the renewal of the
certificate in such terms and on such conditions, if any, as he thinks fit, or may refuse to
renew it:
Provided that where the Chief Inspector refuses to renew a certificate, he shall forthwith
communicate his refusal to the owner of the boiler, together with the reasons therefore.
(7) Nothing in this section shall be deemed to prevent an owner of a boiler from applying for
a renewed certificate therefore at any time during the validity of a certificate.
2.8 Assembly Guidelines: Accessories and Other Assemblies
54
Chapter 2
The Boiler installation consists of the following basic circuits:
 FEED WATER SYSTEM

 FLUE GAS DUCTING LAYOUT
 DRAIN, BLOW DOWN CIRCUIT AND STEAM PIPELINES
 ELECTRICAL SYSTEM
 FUEL SYSTEM
To complete the installation work of the boiler, these systems/circuits should be completed as
per the following guidelines & instructions:
GUIDELINES
General:
 Place other accessories i.e. F.D. fan, Air Pre-heater (if applicable), Feed water pump,
electrical control panel etc. on their respective foundations. These accessories should be
carefully leveled and physically aligned in their final position before grouting them.
 Complete the flue gas ducting work, connection of boiler to APH (if supplied) to
Chimney. Ensure that all the joints in flue gas path are airtight and the size of ducting and
connecting angle to chimney is correct.
2.8.1 Boiler Feed Water Circuit
 Ensure that water treatment plant should provide the water as per the specifications
mentioned in Chapter: Utility Requirement for feeding in the boiler.
 Refer the piping & instrumentation Diagram (P&I Diagram) for the boiler model for the layout
and sizing of the pipe lines, valves and other connection details.
A. Soft Water Tank Capacity
 Soft water storage tank of minimum 3 to 4 hrs. Capacity of boiler evaporation is

recommended for this purpose to have the time for the regeneration in the water treatment
plant.
 The minimum soft water tank capacities for various models of the boilers are as follows:
55
Chapter 2
Table -2.3: Soft Water Tank Capacities
MODEL SM Global 10 15 20 30 40 50 60 80 100 120 140 160

Minimum tank capacity (ltrs.)
3000 4500 6000 9000 12000 15000 18000 24000 30000 36000 42000 48000
B. Feed Water Tank construction:
 The raw water storage and soft water tanks should have a hinged or bolted cover, an air
vent, a float valve, a water level gauge glass, preferably with calibration, a drain at the
bottom with a gate valve and an overflow connection.
 The outflow from the tank should be taken from a point minimum 100 mm (4") the
bottom level of the tank, to avoid any sediments and foreign matter going into the
water pump and damaging it.
Feed Water Tank Elevation:
 Following table gives the elevation of water storage tank (NPSH) required for
corresponding feed water temperature for most of the pumps considering maximum
suction pipe length of 10 meters.
TEMP. OF WATER ( C ) ELEVATION REQUIRED (M)
90 3
93 3.5
C. Feed Pump Suction Circuit:
The feed water pumps will perform better if NPSH available is very much higher than
NPSH required by the pump. In the NPSHav formula, only suction head (Tank Elevation)
and friction pressure drop in suction piping are in our hands. Suction piping pressure drop
is directly proportional to product of square of velocity and length. Hence, we want to
reduce velocity and reduce length to reduce friction pressure drop. Also sharp bands or
any fittings causing a sudden change in direction of flow will increase pressure drop in
the suction piping.
Therefore, in order to reduce suction piping pressure drop we should
- Use large suction piping size. At least one size higher than feed water pumps suction
size.
- Use only Gate / Ball valves. Avoid valves like Globe or needle.
- Use long radius bends.
56
Chapter 2
- Use as short suction piping as possible.

The logic of selecting suction piping size is explained above. The following may be ensured –
Suction piping is provided with a sample point for taking sample of water for analysis.
A Y type strainer is provided to prevent entry of any foreign particles in the pump.
Since suction piping recommended is one size larger than the pump suction size a pipe reducer
is required to connect suction piping to pump.
It is suggested to use GI pipes in the feed pump suction to avoid corrosion.
Boiler feed pipe-Feed Water Pump Discharge Piping
This conforms to ASTM A106 Gr. B and is an IBR approval piping. This pipe connects Feed Water
Pump to boiler. Non Return Valves and Globe Valves are provided on pump discharge for
isolation and throttling purpose.
NRV and a Globe Valve are provided at boiler inlet. All valves, flanges and fittings in the pipeline
are IBR approved.
CAUTION:
 Feed water service tank should never be constructed out of cement concrete, as soft water
will absorb Calcium and Magnesium salts from cement and the hardness will increase.
 The water level in the boiler feed water day tanks should be easily & clearly visible from the
ground level to the operators.
 Use G.I. Pipes and fewer fittings in the feed water pump suction lines.
 Use minimum bends & shortest possible route to connect the suction lines to the pumps
 Use only gate valves in the water pipe lines and avoid using globe valves.
 Provide proper support to the pipelines to avoid unwanted stress on valves and pumps.
 Pump suction pipe size should be one size higher then the pump suction size.
 Long radius bends may be used if necessary.
 The feed Pump suction pipe should be as short and direct as possible.
 The suction head pipelines should be laid with a downward slope towards the pump.
 The suction and delivery pipelines should be anchored in close proximity.
 All the pipe joints should be absolutely airtight.
 Don’t reduce the diameter of the pipes then what is given in P and I diagram of your boiler.
 Avoid use of Elbows and short bends.
 Never use the pump itself as an anchorage point for the piping.
 The gasket between pump and the pipe should not protrude inside the pipeline flange.
 The pipelines should be not transmitting any stress/ strain and pipeline weight, to the pump
body.
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Chapter 2
2.8.2 Drain, Blow down And Steam Piping
Blow Down Pipe Line
 Blow down valve located at the bottom of the boiler shell should be connected to a
pipe of one size bigger and should be led to a blow down pit/tank located outside the
boiler house.
 The blow down pipe should be firmly clamped on the ground at every 3meters of running
length and at both sides of the bends.
 Use IBR pipes/seamless high pressure quality pipes for the blow down lines
 The lines should be properly insulated for safety purposes.
Blow down Pit
The blow down pit has to be constructed as per the sketch given. Brick wall structure
should not be used for building the blow down pit. Instead, use M S plates & concrete slab
as indicated to withstand excessive pressure & temperature to ensure safety.
The size of the pit should also to be maintained as per the sketch below
Fig.-2.14: Boiler Blow down Pit
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Chapter 2
Safety Valve Exhaust Pipe
Safety Valve exhaust pipe connection is to be given as per the sketch given below:
Fig.-2.15: Safety Valve Exhaust Pipe Connection
 The discharge from the safety Valve/s should be piped as direct as possible to the
atmosphere with a pipe diameter of not less than the Safety Valve outlet.
 A drip pan elbow or a flexible connection between the valve and the escape pipe
is recommended to prevent build up of backpressure and accumulation of foreign
material around the valve seat.
 The discharge piping must be properly arranged, clamped and supported so that
their weight doses not bear upon the valve.
Drain Pipes
 Drainpipes from water level gauges, level controllers should be of the same size as
the outlet size of the valves and to a common drain header.
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Chapter 2
Steam Pipeline
 The main steam line which carries the steam to the user equipment /to the plant has to
be of the same or higher size (if recommended) & never be of lower size than indicated
in the P& I diagram.
 The boiler steam out let pipeline is to be designed, constructed, inspected and hydraulic
tested as per IBR (for the installations in India) as per the maximum working pressure of
the connected boiler.
 The steam lines must have the drains with equal ‘T’ & the drain lines with adequate sizes
of steam traps assemblies.
 The steam lines are to be insulated with the adequate thickness of the insulating material,
refer Table 2.6 & 2.7 for thickness & specifications of mineral & glass wool.
 Expansion bends in steam pipeline within every 30 meters of straight run to be used to
take care of the line expansion.
 Sliding / Roller support should be provided for all steam pipes, which will not restrict the
expansion.
 Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
CAUTION:
 All drain; blow down & steam line must be properly insulated to avoid heat losses and
condensation and safety.
 The steam piping from the main steam stop valve should be sized to match the steam valve
diameter. Never reduce the steam pipe diameter to lower size than recommended, as they
would restrict flow of steam & result in to high pressure drop in the pipe lines
 Sliding / Roller support should be provided for all steam pipes which will not restrict the
expansion.
 Expansion joint supports and roller type supports suitably anchored.
 Provide expansion bends in steam pipeline within every 30 meters of straight run.
 Always provide a non-return valve at Boiler steam outlet, in case of two or more boilers
connected to the common header.
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Chapter 2
 The steam piping should be sized to suit the evaporation capacity of the boiler to avoid
siphoning effects and steam/water hammering.
 Proper qualities of steam pipeline gaskets are to be used as per the pressure of the steam.
 The gaskets used should be checked for the proper placement during construction of the
lines. These should not be protruding inside the pipe line which will obstruct the steam flow &
also result in to high pressure drop.
 All steam line must be properly insulated to avoid heat losses and condensation.
 Provide thermodynamic steam trap before every expansion bend for condensate water
removal.
 Provide adequate steam traps in the steam pipeline.
 Never end the drain or blow down pipe in open, but provide pits.
 Brick wall structure should not be used for building the blow down pit. Instead use M S plates
& concrete slab as indicated to withstand excessive pressure & temperature
2.8.3 Flue Gas Ducting Layout:
The flue gas circuit means the path of the flue gases leaving the boiler, Heat recovery &
finally exits through chimney.
2.8.3.1 Chimney
Chimney can be either of the following designs:

a) Self supported
b) Guy rope Supported
c) Structural supported
d) Wall Mounted
However, Chimney for the boiler should be of the adequate top diameter as per the
recommendations given in the table 2.4 below.
Guidelines:
 Chimney design Reference can be taken from the IS 6533 specifications and considering
the Local geological conditions
 Provide all the Accessories of the chimney i.e. Aviation Lamp, Lightening Arrestor etc as
per the recommendations of the local statutory norms.
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Chapter 2
Fig.-2.16: Chimney Structure
Table T-2.4 Chimney TOP Diameter
Chimney TOP Diameter( ID) : In millimeter

10 15 20 30 40 50 60 80 100 120 140 160
Boiler Model SM Global
Without 350 400 400 450 550 600 650 700 800 800 900 950
Economizer
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Chapter 2
WARNING:
 Follow rules and regulations of Smoke Nuisance Act and consult their local Pollution
Control Board’s office for further information & guidance on chimney design & height.
 Never reduce the Top Diameter of chimney than the recommended size.
 For boilers installed in countries other than India, follow the local regulations for stack
installation
2.8.3.2 Flue Gas Ducts:
 The area or the size of the flue gas ducts needs to the same as recommended in the
table T-1.6.3 below to ensure that the flues gas leave the boiler & system easily without
any excessive pressure drop.
 The ducts can be of circular rectangular or square cross section.
 The pressure drop developed by the flues gas system should less than the suction
capacity of the chimney.
Table -2.5: FLUE GAS DUCT DIMENSIONS
Shellmax Models: SM Global

Flue Gas Duct
Diameter(ID) in MM : 10 15 20 30 40 50 60 80 100 120 140 160
Boiler to Chimney 300 350 350 400 450 500 550 650 700 750 850 900
Without Economizer
CAUTION:
 Keep the cross sectional areas of the flue gas and same as recommended. Do not
reduce the cross sectional areas.
 All the Ducts should be of fully welded construction.
 Any leakage in duct means reduction in the capacity of the Fan and reduction in the
output of the boiler.
 Economizer duct connections should be fully welded to ensure leak proof.
 External columns, from ground, should support long ducts.
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Chapter 2
 Provide sockets with plugs at the inlet & outlet ducts of Air Pre-Heater, for checking the
pressure drops and temperature measurement, across these equipment.
 The dampers should be checked for correct opening & close indications and for the
smooth operation.
 Provide long radius bends & avoid sharp bends in the ducts.
 Insulation of the ducts should be done after through check for the leakages, after the
commissioning of the flue gas system.
 Provide Insulation of proper density & the thickness as indicated in the table T-1.6.4
below.
2.8.3.3: Insulating material Pipe lines, Ducts & flue gas ducts
The table below gives recommended insulation thickness in mm required for different pipe sizes
and different operating / fluid temperatures.
a) Mineral Wool –Table -2.6:

Pipe Operating / fluid temperature oC
diameter
90 150 200 260 315 375
(NB) mm
25 25 40 65 65 75 90
40 25 40 65 65 75 90
50 25 40 65 65 75 90
80 25 40 65 65 75 90
100 25 50 75 75 100 100
150 40 50 75 75 100 115
200 40 50 75 75 100 115
250 40 65 90 90 100 125
300 40 65 90 90 100 125
Flat 40 65 90 90 100 125
Note: Insulation material assumed is Mineral wool having thermal conductivity 0.036 kcal/m hr o C,
average density about 100-200 kg/m3.
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Chapter 2
CAUTION:
1) The surface temperature after insulation is 55 – 60oC.

2) Insulation up to 65mm should be in single layer and above 65 mm, multiplayer, e.g.
80mm two layers of 40mm each for 90mm inner layer of 40 mm and outer of 50mm.
b) Glass Wool - Table -2.7:
Pipe Operating / Fluid temperature

diameter
90 150 200 260 315 3756
(NB) mm
25 25 25 25 25 40 40
40 25 25 25 25 50 50
50 25 25 25 25 50 50
80 25 25 40 40 50 65
100 25 25 40 40 50 65
150 25 25 40 40 65 75
200 25 40 40 40 65 75
250 40 40 40 40 65 75
300 40 40 40 40 65 75
Flat 40 40 50 50 65 75
Note: Insulation material assumed is Glass wool having thermal conductivity 0.045 kcal/m hr oC @
100oC and average density about 80 – 100 kg/m3.
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Chapter 2
2.8.4: ELECTRICAL SYSTEM:
Fig.-2.17: Control Panel
2.8.4.1: Guidelines:
Electrical Control Panel Box & External Electrical Switch
The Electrical Control Panel Box is supplied by Thermax, with the Boiler, separately packed and is
pre-wired with switches for all motors for boiler system.
 Three phases, 415 V, 50 cycles A.C. electric supply with neutral and earth is required for
operating the boiler.
 The supply to the boiler should be given through a main switch fuse having adequate
capacity as mentioned in the following table. The back-up fuse capacity to suit the total
electric loading should also be maintained.
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Chapter 2
 Switches for other pumps such as water pump for pumping water from raw water storage
tank to the water softener, etc. should be separately installed by the customer at points
convenient for operation.
2.8.4.3: Earthing Of the Equipment
 Earthing wires of adequate cross-sections should be provided to link the boiler, the
electrical control panel box, various motors, etc. to a suitable earth pit, as per Indian
Electricity Act.
Following size of earth conductors can be used:
Up to 3.75 kW 8 SWG GI wire

5.5 kW to 30 kW 3/8" GI fine wire rope
37 kW to 55 kW 5/8" GI fine wire rope
CAUTION:
 Provide proper lugs to terminate the cables. Also provide ferrule numbers on cable for
identification.
 Provide adequate size switch fuse unit and cables.
 Provide cable glands at the panels
 If the voltage fluctuation is going to be more than ± 6% of the specified voltage, it is strongly
recommend installing a voltage stabilizer of 1 KVA for the control circuit.
 Provide proper sized glands for the cable at the entry to control panel and at motor terminal
box.
 Earthing pit should be as per the norms.
 Use cable trays or trenches for laying the cables.
 Never increase or decrease the back up fuse MCCB capacity.
 Never combine neutral & Earth connection.
 Laminate the electrical diagram, with plastic sheet and paste inside the control panel or near
to it.
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Chapter 2
 Take enough photocopies of the electrical diagram for records.
WARNING:
WHILE INSTALLING THE ELECTRICAL CABLES KEEP IN MIND THE RULES AND REGULATIONS INVOLVED.
2.8.5 Fuel Supply (Liquid Fuels)
A typical arrangement for fuel oil storage and flow to the unit is shown in P&I Drawing. The fuel
firing system is designed to operate on Light oil viz. LDO (Light Diesel Oil) / HSD (High Speed
Diesel).
In order to have flooded suction, these tanks are to be installed at a height not less then 3
meters from fuel pump. (For HSD tank, this height is not required). The P&I Diagram shows the
piping connections and their sizes, which needs to be followed strictly for trouble free, efficient
and comfortable operation.
2.8.5.1 STORAGE, HANDLING AND PREPARATION OF OIL
In many industries, little attention is often paid to oil storage, handling and preparation facilities.
The result Puddles of oil near the pump house and storage tanks - an indication of leaky joints,
flanges and pipelines. Clogged filters, which impose an additional duty on the pumps. And poor
combustion, manifested by smoky or spluttering flames leading to high fuel consumption.
Spilt oil is an easily avoidable waste, and renders the ground slippery and dangerous. For
efficient burning, foreign matter such as dust, water, coke and sludge particles in fuel oil should -
be removed by adequate filtration. It is also necessary to examine several aspects, such as
pumping ability of oil during winter months, type and capacity of the pump, the length of the -
pipelines, and the sizing of pipes. Correct pre-heating of fuel oil prior to combustion is very
important for fuel efficiency. We have covered some of these aspects, which have a significant -
effect on the fuel consumption in your boiler plant.
Spilt oil is irretrievable. A little care when oil is decanted from the tanker to the storage tanks
could lead to less spillage. All leaks from joints, flanges and pipelines must be attended to at the
earliest.
Loss of even one drop every second can cost you over 4,000 liters a year.
2.8.5.2 HOW TO STORE FUEL OIL
Large quantities of fuel oil are best stored in cylindrical tanks either above or below the ground.
Generally, the main storage tank is erected above ground when the capacity exceeds 70,000 -
liters. For lower capacities, underground storage may be more economical. When erecting a
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Chapter 2
storage tank above ground, remember to maintain safe distances from the surrounding
structures, as prescribed by the Explosive Department.
Storage tanks are generally made from welded mild steel plates. The overhead tank should be
mounted on concrete blocks, which provide a slight gradient of 1:50 towards the drain valve.
Each of the following fittings on storage tank has a definite role to play.
The outlet or draw-off pipe should be located at the raised tank end, no less than 15 cms from
the bottom. It should be at least 15 cms in diameter with outflow heater and provided with an -
outlet pipe line of 6 cms with a strainer at the outlet.
The vent pipe, of goose-necked type, should be located at the highest point of the tank to
facilitate filling by venting air and oil vapor during the filling operation.
The fill-pipe could be located either at the top or at the bottom of the tank. If located at the
top, it must be ensured that the pipe descends almost to the bottom of the tank. When located
near the bottom, it is important to position a non-return valve on the line to avoid fuel oil re-entry
into the oil tanker on account of back pressure. To avoid leakage of oil during decanting, it is
advisable to have a cam lock coupling at the filling end so that it fits easily on the delivery hose.
The drain pipe, which is fitted at the bottom of the tank, is used to periodically remove the
accumulated water. It is a difficult task to drain the water and sludge from underground storage
tanks. The water and sludge which settle down at the bottom should, however, be removed by
a hand pump. It would be advantageous to have two suction pipes - one at a lower level and
the other at a higher level - so that in case the sludge accumulation is up to the lower point and
the suction line chokes up, the alternative line could be put into operation and adequate time
would be available to decide upon a time schedule for cleaning the tank.
Fuel oil as delivered may contain dust, dirt, gummy matter and water. During storage for
prolonged periods, these tend to form sludge, which accumulates in the various `dead spaces'
of the tank, where the oil is not agitated during normal operation of the tank. This results in
unsteady flames and clogging of filters. To avoid this, some means of agitation of oil in the tank
may be necessary.
Cleaning of storage tanks, about once a year, will remove the accumulated sludge. Besides
cleaning, periodic inspection and maintenance of the storage tank, out flow heater and
auxiliaries is important.
Capacity of storage tank depends on daily hours of operation & Frequency of Fuel oil tanker
receipt. Based on this storage tank capacity needs to be decided.
NOTE: PLEASE FOLLOW THE RULES AND REGULATIONS INVOLVED IN YOUR STATE FOR STORAGE OF
HEAVY OIL.
2.8.5.3 CHECKS BEFORE UNLOADING OF FUEL OIL
It would be worthwhile to check the quantity of oil into the storage tank. Road tankers are
provided with dip-sticks. Readings of oil level in the various compartments should be taken -
before decantation. The following procedure may be adopted before assessing the quantity of
oil in the road tankers:
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Chapter 2
a) Ensure that the tank lorry is parked on firm level ground.
b) The dip-stick should be checked to ensure that it is the one calibrated by the Weights and
Measures Department for the compartment concerned.
c) The dip readings of all the compartments should be checked, and shortfall, if any, can be
determined by topping up of the compartments with measured quantities of fuel oil from the
main storage tank.
d) Your storage tanks should also be calibrated. Though dip readings in storage tanks are more
or less reliable, a major deviation should be investigated. They may provide a clue to
malpractice.
2.8.5.4 REMOVAL OF CONTAMINANTS
Fuel oil should be freed from possible contaminants such as dirt, sludge and water before it is
finally fed to the boiler.
Fuel oil arrives at the factory site either in tank Lorries by road or by rail. Oil is then decanted into
the main storage tank. To prevent the possibility of contaminants such as rags, cotton waste,
loose nuts or bolts or screws from entering the system and damaging the pump, position a
coarse strainer of 40 mesh size (not more than 6 holes per linear inch) on the entry pipe to the
storage tanks. Progressively finer strainers should be provided at various points in the oil supply
system to filter away finer contaminants such as external dust and dirt, sludge or free carbon.
It is advisable to provide these filters in duplicate to enable one filter to be cleaned while oil
supply is maintained through the other.
Table T-2.13: SIZING OF STRAINERS

________________________________________________________________________________________
Location Strainer sizes Mesh Holes/Linear inch
Between rail/tank lorry decanting

Point and main storage tank 40 6
Between storage tank and service tank 80 9
Between service tank and Burner 80 11
2.8.5.5: FUEL OIL SERVICE / DAY TANK
The service tank should be located in proximity to the boiler.
The service tank may be sized for a shift's consumption or daily consumption - the choice
depends on capacity required, ease of location of tank near the boiler house, pumping
capacity, horse power, etc. Certain additional precautions may, however, be taken with
respect to service tanks.
a) Service tanks should not be located above furnaces, hot air or flue gas ducts, etc.
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Chapter 2
b) They should be provided with overflow pipes which lead directly below to a sump. As a
further refinement, limit switches could be provided to avoid the possibility of oil overflow.
c) In gravity feed systems, the difference in height between the service tank and the fuel pump
should be at least 3 meters.
d) The tank should have hinged manhole, level indicator, drain, overflow, out flow heater, air
vent etc.
e) The level indicator should be positioned such that it can be seen from boiler control panel for
ease of operation.
f) In case of LDO as fuel & if ambient temperature falls below 150 C Out flow heater is required
on fuel oil service tank. This will maintain viscosity of LDO required for proper combustion.
Figure F-2.18: Outflow heater arrangement & service tank
2.8.5.6: RING MAIN SYSTEM (APPLICABLE FOR HEAVY LIQUID FUELS)
Medium & heavy fuel oils require pre-heating in the Oil Pre heating Stations, to lower their
viscosity up to 10 -12 CST so that satisfactory atomization & combustion takes place. In most of
the fuel oil systems, to save heat, a part of the heated oil is returned to the fuel oil header, at the
fuel pump suction. This therefore raises the fuel oil temperature in the pump suction header
beyond 100 degrees “C”, especially when the burner operates continuously in low load.
Since the fuel oil has some amount of water & low boiling oil fractions, present, this could
evaporate at temperatures beyond 100°C causing cavitations problems in the main pressurizing
pump. The rise of temperature up to 120 degrees ”C” & variation in fuel oil temperature tends to
cause cavitations & variation in burner fuel pump pressure. Many times this causes premature
failure of fuel pumps.
71
Chapter 2
In addition, the key parameter to be maintained in the pressure jet burner system is the oil
pressure at the burner inlet. Any variation in this could adversely affect the combustion
parameters.
An effective method of avoiding such failures & performance problems is to adopt fuel oil ring
main systems, particularly for multiple burner installations, as well as for modulating burners of
firing capacities above 100 kg/hr.
Operating principle of a ring main is that the fuel pressure in burner pump suction line should be
maintained higher than the vapor pressures corresponding to oil preheat temperature.
Table No T-2.29 Ring Main Circuit Pressures
Fuel pre-heat
Temperature in 100 105 110 115 120 125 130 135 140 145
deg C
Ring main
pressure 1.5 1.7 1.9 2.1 2.3 2.5 2.9 3.3 3.9 4.5
kg/cm2
Fig.-2.19: Ring Main system
72
Chapter 2
Fig.2.20: Fuel Pumps circuit
73
Chapter 2
Figure No F-2.22: Fuel pipeline-from OPH to Burner & return to Ring Main Header
CAUTION:
 Use only M.S. pipes with welded or flanged joints.

 Avoid using elbows and short bends as far as possible.
 Fuel piping should be thoroughly flushed before being connected to the heater.
 Never reduce the diameter of the pipelines than mentioned in the drawing.
 Use only gate valves. Globe valves offer more resistance and hence pressure drop is more
than gate valves,
 Select fuel storage tank of adequate capacity. Keep in mind the rules and regulations
involved in your state.
 Use outflow Heater For heavy oil and insulate the pipelines to reduce heat loss.
 Provide the digital temperature indicator cum controller with the out flow heater to cut off the
heating at preset temperature. Also, provide dial type fuel temperature indicator near to the
digital TIC.
 Avoid over heating of the fuel oil at the out flow heater.
 Use flame proof enclosure for the out flow heater switch gear ,if installed near the fuel tank
 Air vent of the fuel day/service tanks should be taken out side of the boiler house to prevent
vapors of the low boiling fractions of the fuel oil to get accumulated inside the boiler house.
 Use recommended (size and mesh) strainers to clean the fuel at every stage.
2.8.6: Fuel Supply (Gas Fuels)
The boiler user should ensure that the gas supply is pressure is in the range of 1-2 kg/cm2 at the
isolating valve of the boiler gas train. The boiler gas train components are selected & sized for
this pressure range only.
If the gas supply pressure is higher than above, the user should reduce it to 1-2 kg /cm2 before
connecting it to the boiler gas train.
Installation of the Gas Pipe line & burner Gas train
 Note that gas train components are designed for low pressure and hence testing with
compressed air/nitrogen can damage the gas train.
 The gas train should be installed at about 500 mm above the floor level to ensure easy
maintenance of its components, particularly the regulator, strainer and solenoid valves.
 The part of the Gas-train comprising main gas solenoid valves should be as near as
possible to the burner, so that gas flame is established quickly and residual gas burning is
lowest after burner shut down.
 The gas supply pressure at the inlet of the gas train should be checked to be in
conformity with specified pressure range. (Refer P&I Drg. for gas fired units )
 The manual quick shut-off valve should be opened very slowly so that the diaphragm of
the regulator is not subjected to sudden pressure surge.
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Chapter 2
 The pressure setting of the pilot and main gas regulator should be kept at near minimum
during initial start up of the burner, and the final setting should be done during burner
firing to achieve the required firing rate.
 The supply gas pipe is to be connected to gas train inlet ball valve with the help of a
union or a flanged joint. The supply gas pipe should be thoroughly cleaned and flushed
out with air, to ensure that all dirt particles are removed before connection to gas train.
 Gas filter, pressure regulator and gas solenoid valves should be accessible for routine
maintenance and adjustments and suitable platform may be provided.
 Unauthorized tampering of gas pressure adjustment and other settings should be

prevented. Adjustments, if at all required, should be done by trained and authorized
personnel only.
 Brackets and supports for gas piping should not be welded to the gas pipe. Suitable
screwed clamps only should be used.
 After installing gas line with fittings, it is necessary to carry out leakage test using
compressed air/ nitrogen gas at a pressure of 7 kg/cm2 by isolating the gas train
components. All the lines with flanges should be tested for leakage with the help of soap
solution.
 Note that gas train components are designed for low pressure and hence testing with
compressed air/nitrogen can damage the gas train.
 Gas train and its components should be tested for leakage using air at pressure not more
than 2000 mm WC.
 If the gas is saturated with water vapor, drain point should be provided at lowest point in/
near the gas train for drawing the condensed water vapor.
 Vent Piping:
i. Vent shall terminate in a safe place, preferably in the open air above roof level.
ii. If it is not feasible or practical to terminate above roof level vent, line exit must be
at least 5 meters from potential ignition source.
iii. Vent line should not pass through electrical intake chambers, transformer rooms
and lift shafts.
iv. Care should be taken such that there will not be any ingress of foreign material
and water into vent line.
 The heater house should be properly ventilated, preferably by large windows on all sides.
 Please make sure that while installing the gas train, regulations of Fire Insurance
Association, Explosives Act, factory inspectorate etc. are strictly adhered to.
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Chapter 3
03 BOILER INSTRUMENTATION,
CONTROLS & SAFETIES
3.1 IGEMA LEVEL PROBE
Shellmax Global series boilers are provided with

probe type level controllers for monitoring boiler water level.
Water level control is one of the most important safety functions
in boiler system. Probe type level monitoring technology works
on basis of conductive fill level method of measurement,
whereby the electric conductivity of water medium is used. It
has Zero moving part. It is easy to install and energy efficient
product.
Fig: 3.1 Igema Level Probe
It has 3 probes as shown in fig: 3.2. Each probe is of different length. Length of probe will help to
control water level in boiler.
Probe Type Purpose Action

Longest Extra Low water level Burner Trip
Middle low water level Pump ON
Shortest High water level Pump OFF
78
Chapter 3
Fig.3.2: Electrode for Igema Level Probe
79
Chapter 3
3.2: Fusible Plug:

This has been provided as an ultimate safety, when all the water
level controls & safeties fail, this safety, finally protects the boiler
form major accident. As per Indian Boiler Regulations(IBR),
minimum two Fusible plugs are must for the web back boilers.
One fusible plug is fitted at the top most position of the internal
reversal chamber & the second one at the front tube plate, just
above the third pass flue tubes.
FIGURE F-3.3: Fusible Plug
When the water level falls below either of the plugs’ level the
plug being exposed to steam on one side & flue gas at the other side .The steam does not cool
the Fusible plug as much as the water. Hence, its temperature goes up. When the plug
temperature reaches about 400 – 420°C the lead alloy holding the plug in the housing fuses. As
soon as the alloy fuses the reversal, chamber plug is forced into the furnace. This creates a small
orifice on top of the reversal chamber from which steam rushes into the furnace quenching the
flame. Consequently, the boiler would be tripped by flame failure.
To replace and maintain the fusible plug of the reversal chamber. When the Fusible plug of the
front tube plate, is fused due to low water conditions in the boiler, the steam, under pressure
rushes out & enters the smoke tubes and furnace, thus quenching the flame. The Fusible plug at
the front tube plate can be re-fixed, from the waterside by entering through the boiler manhole.
The fusible plug is manufactured as per IBR & hence, requires IBR certification.
Fig.3.4: Location of Fusible Plug
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Chapter 3
3.3: Boiler Safety valve

Mechanical safety against steam pressure high is provided by two
nos. Safety valves fitted on the top of the boiler shell.
The Safety Valves of the boiler are the over pressure safety of the
boiler. These are supplied in two numbers as per the IBR. These
safety valves are set at the maximum working pressure of the
boiler. One safety valve lift pressure is set little below the maximum
working pressure (MWP) of the boiler and the other one is set at the
MWP.
When the pressure controller fails or the setting is more than the
maximum working pressure of the boiler then the safety valves lift &
Fig.3.5: Safety Valve vent out steam thus reducing the excessive pressure of the boiler.
The Lift & sit back operation of these valves should be exactly as per IBR, which is set at the time
of commissioning. After the IBR steam test (Ref Chapter 1.5 IBR Registration), the safety valves
setting nuts are locked by means of the spacer rings to ensure that the lift pressure is not
disturbed.
VALVE SETTING NUT

GUIDE ROD
SPRING
VALVE SEAT
STEAM OUTLET
BLOWDOWN RING
STEAM
INLET
Fig.3.6: Cross Section of Safety Valve
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Chapter 3
3.4: Boiler Water Level Gauges:

These are Reflex type toughened glass level
gauges and enclosed in the Metallic
enclosure to protect it from the breakage.
Two level gauges are provided in case of
shell boilers and on steam drums used in
water tube boilers. Each gauge glass
assembly comes with IBR approved isolation
and drain valves mode of Bronze / Gunmetal.
For high-pressure boilers above 17.5 kg/cm2
design pressure, cast steel material is used for
valves.
Fig.3.7: Reflex type Level gauge
3.5 Temperature Sensor:

RTD is a temperature sensor used in Shellmax;
1) The flue gas RTD is used for indication of flue gas temperature & as a safety, which cuts of
the burner incase of flue gas temperature rises above the set point. The RTD set point is +20
deg “C”
2) Oil temperature (For FO fired Unit). If oil temperature is high, burner will get trip.
3) Circulation water temperature (For unit with effimizer). Opening and closing of control
valve (in circulation water line) will be decided on the input given by RTD
The safety temperature setting is done at the time of commissioning.
Fig.3.8: Temperature sensor (RTD)
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Chapter 3
3.6 Pressure transmitter: Make- Danfoss

Pressure transmitter is used for boiler pressure sensing and controlling fuel firing of burner. It is
mounted on boiler.
This transmitter with other controls reduces the fuel & air, which is fed by
the burner in the boiler furnace, when the boiler steam pressure increases.
In addition, it increases the firing rate & air when the pressure in the boiler
reduces. The increase or reduction in the firing rate is in proportion to the
increase or decrease of the steam pressure in the boiler.
This control is also called step less modulation, as this modulation is

continuous. This transmitter avoids the burner on-off operation of the
boiler, which is undesirable to the boiler & to the process. In short, it tries to
maintain the steady steam pressure in the boiler, when the steam
load/pressure fluctuations are within reasonable limits.
This pressure controller control the firing between lowest & highest firing
range of the burner.
Fig: 3.9 Pressure Transmitters
The ratio of the lowest firing rate to rated firing rate is called as boiler turn down ratio, of the rated
fuel consumption in Shellmax boilers. This pressure transmitter is not used in SM GLOBAL 10, 15 and
20. AS these are step burners, so pressure switch is used for step modulation.
Danfoss MBS 3250 with integrated pulse-snubber is designed for use in heavy industrial applications
with severe medium influences like cavitations; liquid hammer or pressure peaks and offers a
reliable pressure measurement, even under harsh environmental conditions.
The flexible pressure transmitter programme covers different output signals, absolute or gauge
(relative) versions, a wide range of pressure and electrical connections.
A robust design, excellent vibration stability and a high degree of EMC / EMI protection equip the
pressure transmitter to meet the most stringent industrial requirements.
Features:
Designed for use in harsh industrial environments

• For medium and ambient temperatures up to 125 °C
• With integrated pulse-snubber. Protected against cavitations, liquid hammering and pressure
peaks (MBS 3250)
• All standard output signals: 4 – 20 mA
• Enclosure and wetted parts of AISI 316L
• A wide range of pressure and electrical connections
• Temperature compensated, linearised and laser adjusted
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Chapter 3
Pressure transmitter senses the pressure and gives signal to PLC. The difference between set value
and present value is manipulated in CPU. This will generate a MV (manipulated value) which is
given to burner for modulation.
Pressure Rise MV reduces Burner firing rate reduces
Pressure Reduces MV increases Burner firing rate increase
3.6.1 Pressure Switch for controlling steam pressure:
The control of steam pressure is provided by a pressure switch as mentioned above. If boiler
pressure increases above the set pressure of the pressure switch, the boiler is tripped by
automatically switching off the Burner. The Burner restarts automatically when steam pressure
reduces below the differential Pressure setting of the pressure switch. This automatic operation of
the boiler is known as on – Off control, and the boiler steam pressure is controlled by the pressure
switch.
Fig.3.10: Pressure Switch

All pressure switches use a sensing element, bellows being the most common. The bellows type
performs well in applications where even shock and vibrations are present. The sensing element
can be used for a variety of process fluids. The pressure switches can be made in weatherproof
housing (IP-66) or in explosion proof housings. The pressure switches used in boilers are of standard
design.
3.6.2 Pressure Switch for step modulation:
Pressure switch is used for step modulation in SM Global 10, 15 & 20. If the steam demand reduces
even with the lowest turn down , the steam pressure rises further even at the lowest burner firing
rate, then the steam pressure high Pressure switch (On–Off) cuts off the burner.
Pressure above set point Stage 1 (low Firing)
Pressure below set point Stage 2 (high Firing)
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Chapter 3
3.6.3: Furnace Pressure Switch:
This is safety provided for furnace pressure. This will cut off the burner, if burner pressure exceeds the
set pressure. Range of this pressure switch is 0-25mbar. This reduces chances of back firing of
burner.
3.8: BURNER & BURNER MANAGEMANT SYSTEMS:

Oilon burners are monobloc burners i.e. Combustion air fan, oil preheater, fuel pump are mounted
on a single unit. These burners are used to burn Light Oil/HSD/FO/NG (One fuel at a time) (For FO
from 12TPH onwards, OPU, OPH are inclusive of burner – Dual Bloc
Construction
Burner housing is made out of steel plates. It houses combustion air fan. Motor mounted on housing
runs the fan. Fuel pump is coupled with combustion air fan motor for burners used for boilers up to 4
tph, Separate motor is used for fuel pump in burners used for 5 to 10tph.Burner housing is equipped
with a hinged burner flange with safety interlock switch, enabling burner to be swung open to the
left or right. Due to burner flange it is possible to service the combustion head, nozzles, and ignition
electrodes. The combustion head is adjustable to optimize the mixing of fuel regardless of the firing
rate. The burner contains a sight glass for flame observation. On the suction side of the fan there is
an air damper that, together with the servomotor, automatically controls the amount of fuel and
air on the basis of the firing rate required. A removable upper cover makes electrical installations
and burner servicing easier.
Capacity regulation methods
Burners come in two types of capacity regulation

1) Two stage.
2) Modulating.
The two stage burners are equipped with an air damper servomotor, with a run time of 5 seconds
between capacity stages. The modulating burners are equipped with a servomotor with a run time
of 30 seconds/90o .The servomotor is connected to the oil regulator and compound regulator via
an axle.
Burners for SM GLOBAL 10, 15 and 20 are two stage burners. Two pressure switches are provided on
boiler one for control shutdown & another for two stage modulation. During startup Burner starts at
1st stage, if load is more then boiler pressure drops which gives signal to burner panel to make 2 nd
stage on.
3.8.1 UV Cell: Model: QRA 2
This is called the eye of the burner. It senses the light from the flame and in case of steady flame
provides the supply to the sequence. In case no flame or flickering flame, the feedback is given
to stop the firing sequence. In case no-flame or flickering flame, the feedback is given to the
PLC to switch off the burner.
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Chapter 3
The photo resister works on the principle of reduction in resistance by sensing light. As mentioned
above, in gas-fired units UV cell is used to sense the flame, as these do not respond to glowing of
refractory in the combustion chamber, luminance of artificial light, day light etc, ensuring
complete safety to the operators & the equipment.
Fig.3.11: UV Cell
3.8.5 Burner modulation Logic
The following paragraphs will explain the burner modulation /firing control logic with the function
of each component involved with respect to the other.
Modulation
Once the unit fires, after preset time, power comes from the control panel and if the modulation
switch is ON, then the modulation contactor energizes. In that condition if power comes to high
terminal of servomotor, then burner goes to high flame till the maximum position and if the
power comes to low terminal of servomotor, burner goes to low flame till the minimum position.
Modulation is of two types.

1. Step modulation (Applicable to Shellmax models SM-10,15 & 20)
In step modulation, unit works either in high flame or in low flame.
2. Step less modulation(Applicable to Shellmax models SM-30 onwards)

In step less modulation the firing can be anything between low flame and high flame.
In Step type of control the pressure switch senses pressure. When the process value or the steam
pressure is less than the pressure switch set valve, power comes to high terminal of servomotor &
unit goes to high flame. Once the pressure becomes more than the set value, the micro switch
of pressure switch operates and gives power to low terminal of servomotor , and burner comes
to low flame. And For step less modulation Pressure transmitter is used.
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Chapter 3
Fig.3.12: Burner Modulation Logic
87
Chapter 3
3.9 GAS TRAIN:
 The train is fitted close to the burner of the boiler in the boiler house. The function of the gas
train is to provide the clean, regulated flow of gas at the desired pressure to the burner of
the boiler and to provide essential safety incase of abnormalities.
Gas Pressure gauge Gas Pressure gauge
Ball valve Gas filter Safety Shut Gas Pressure Gas pressure switch
off Valve Regulator
Fig. 3.13: Standard Gas Train
Fig.3.14: P&I Diagram: Gas Train Assembly

The gas train will also provide the following actions, with the help of the various components:
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Chapter 3
Table No 3.1
S no Component Description Function

a Manual Ball Valve/quick shut off Manual start/Isolation of gas supply
valve
b Gas filter Filtration of gas
c Safety Shut off valve: High pressure shut off of gas supply
d Gas Pressure regulator Regulation of the gas flow & pressure
e Gas Pressure gauges Indications of the gas pressures ,at inlet of the gas
train & at the inlet of the burner
f Safety relief valve Venting of the excessive gas pressure
The gas train shuts of the gas supply to the burner in case of abnormal conditions
The abnormal conditions will arise when,
 Gas pressure in the gas train, will rise above or fall below the set pressures in the gas
pressure switch. If the high gas pressure safeties fail to operate, the safety relief valve will
vent out the excess gas pressure.
 Burner Flame or ignition failure.
The pilot & main burner solenoid valves are connected to the sequence controller of the boiler.
The standard gas train supplied with Shellmax boiler consists of the following components.
GENERAL DESCRIPTION
a. Quick shut-off valve
This is manually operated quarter turn shut off valve to supply or cut off gas to the burner, and is
fitted at the start of the gas train.
Fig.3.15: Quick shut off valves
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Chapter 3
b. Filter
This is to prevent any dust/Rust particles or impurities from entering the pressure regulators and
solenoid valves, thereby avoiding leakages.
Fig.3.16: Filter
c. Pressure Regulator (Gas governor)
i) Main Regulator
This is the most important part of gas train. It regulates the downstream pressure of the gas at
the set value required for correct firing rate of main burner. The set pressure of the regulator (#)
can be adjusted by changing the tension of spring located above the diaphragm.
(#) - For set pressure, (Refer chapter: 5.0 Commissioning-Section 5.2.1 G: Important Readings &
settings) this set pressure is for full load on unit and other parameters as per design conditions,
and hence may vary depending upon actual unit operating conditions.
ii) Pilot Regulator
The regulator is provided to supply gas at regulated pressure to the pilot burner for a steady pilot
flame, irrespective of the setting of the main gas pressure regulator.
Fig.3.17 Fig.3.18
Gas Regulator/Governor Main Burner Gas Regulator/Governor Pilot Burner
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Chapter 3
d. Safety Relief Valve
Safety relief valve is mainly required to relieve sudden pressure surges

in the line. A safety relief valve is positioned downstream of the gas
pressure regulator. The setting of relief valve is 20% above regulator
set pressure.
Fig.3.19
e. Safety Shut off Valve (Slam Shut off Valve)
Safety shut off valve is used to protect the down stream

components in case supply pressure exceeds the withstanding
pressures of downstream components of pressure regulator.
The setting of the valve is 20% above safety relief valve pressure.
Main Gas safety shut off valve
Fig.3.20
f. Pressure gauges
Pressure gauges are provided at different locations, one before the

regulator and the other after the regulator. The former indicates the gas
supply pressure, where as the latter indicates the pressure at which gas
enters main gas solenoid valves.
One pressure gauge is provided after the regulator (governor) in the gas
pilot line.
Fig.3.21
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Chapter 4
04 INPUT REQUIREMENTS
The following parameters are to be maintained, for the fuel, Feed water, boiler water, electrical
input for the boiler & its components to perform as desired.
4.1 Fuels:
4.1.1 Liquid fuels:
The standard specifications of the fuel oils to be used are;
Table -4.1:
Superior High Speed Light diesel Furnace Low Sulphur

Parameter kerosene Oil Diesel: Oil: oil: Heavy Stock:
( SKO) (HSD) (LDO) (FO) (LSHS)
Specific Gravity at
0.82-.83 0.85-0.87 0.89-0.95 0.88-0.98
20 Deg ‘c’ 0.79-0.81
Flash point Deg ‘C’ 32 32 66 66 93
Viscosity at 20 1.4-1.8
2- 4 15-17.5 >200 >550
Deg ‘c’
Sulphur % Up to 0.2 Up to 0.25 Up to1.8 Up to4 0.5
Pour Point : Deg ‘c’ <4 4-5 18 20 72

Pre-heat
temperature at #
# ** 40-45 80
out flow heater :
Deg ‘c’
Pre-heat
temperature at
NA NA NA 115-125 95-100
Oil Pre-heating tank
Deg ‘c’
Required Fuel
Viscosity in CST at
NA NA NA 10-12 10-12
Burner nozzle tip
after preheating
Net calorific value
10500 10200 10150 9650 9750
Kcal/kg
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Chapter 4
Note:
# Pre-heating of light oil is required at sites having ambient temperatures below 5oC
** Preheating may be required up to 60oC max for proper fuel atomization at burner
nozzle if fuel viscosity is high at ambient temperature.
4.1.2 Gas fuels:
The standard specifications of the following gas fuels used are;
Table -4.2:
Natural Gas Liquefied Petroleum

Parameter
Gas (LPG)
Methane -76%,
Composition: Main Ethane-10% Propane: 10-40%
Constituents Propane- 2% Butane :60-70%
Density, Kg/M3 0.83 2.32
Net Calorific Value

8500 24950
Kcal/Nm3
4.2 Feed Water Quality

The water treatment plant should provide the boiler feed water of the following specifications for
boiler as per the requirements of the 20 Kg/cm 2 max working pressure.
Table -4.3:
Parameter 0-20 kg/cm2 Purpose-To control
pH Value 8.5 –9.5 Corrosion
Dissolved Oxygen, Mg/Lit

0.05 Oxygen Pitting
as O2 max.
Total Hardness, mg/Lit as

<5 PPM Scaling
Caco3 max.
Silica as SiO2,Mg/Lit Nil Scaling
Organic Matter Non Detectable Foam
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Chapter 4
4.3 Boiler Water quality:

Boiler water means the water, which is inside the boiler. The boiler water quality is maintained by
the blow down, as per the norms given in the following table.
Table-4.4:
Parameter 0- 20 kg/cm2 Purpose: to Control
pH 11-12 Corrosion
Total Hardness Non detectable Scale
Total dissolved solids: TDS 3500 ppm Corrosion
Total Alkalinity (20% of TDS) 700 ppm Foam
Phenolphthalein Alkalinity (10% of TDS) 350 ppm Foam
Silica (40% of Caustic Alkalinity) 140 ppm Scale
Phosphates 20-40 ppm corrosion
Sulphite 30-50 ppm Oxygen pitting
Hydrazine 0.1 ppm Oxygen pitting
4.4 Electrical Input

The electrical input to the electrical control Panel of the boiler should be:
Three Phases, 415 +/- 6% Volts, 50+/- 3% Hz, A.C. Supply with Neutral & Earth connections.
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Chapter 5
05 COMMISSIONING PROCESS
The boiler user has to comply with all the IBR formalities and the provisional Order for the boiler
firing has to be obtained from the concerned Boiler Inspectorate, before Thermax
engineer/representative’s visit for commissioning.
The user has to send the written communication to Thermax on receipt of the provisional boiler
firing order from the Boiler Inspectorate. On the receipt of this written communication Thermax
engineers/representatives can start the commissioning activities.
5.1 Pre-Commissioning:
The pre-commissioning is the part of the commissioning activity of the boiler, only the firing of the
burner and steam generation is not done.
The firing of the boiler burner system is done only after the completion of the IBR formalities by
the user.
Pre Commissioning is commenced only on completion of all the assembly connections as per
the preceding chapters; P & I diagram, electrical diagram and the assembly work.
During Pre commissioning all the systems i.e. fuel, Feed Water, Drain, Steam Flue gas, electrical
etc are checked/rectified finally and all the possible instruments /parameter settings are done.
All the System are run in manual operation or independently, checked for their smooth and
satisfactory operation.
The persons entrusted with operation, servicing and observation (Boiler attendant for IBR boilers)
must be present during pre-commissioning. It would be better, during commissioning operation;
direct superiors of boiler attendant should be present.
Thermax representative shall provide the training, guidance & supervision of the critical activities
during Pre-commissioning & commissioning. Thermax representative shall ensure that all the
settings & actions are completed as per the detailed checklists. However, the users /customers
should ensure that the following and all other jobs, as suggested by Thermax representative are
completed before inviting them for commissioning.
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Chapter 5
CHECKS -
A. GENERAL:
 Ensure that the civil work of the boiler house is complete before taking the boiler for
commissioning
 Check and level all the equipment and tight their foundation bolts.
 Check all the motor windings for damage and moisture with meggar test.
 Check and ensure that all the pipelines and ducting are supported properly.
 Check all the strainer and valves for its operation.
 Arrange the fuel as per the input quality requirements.
 Arrange boiler operators and other work force required to operate the boiler.
 Arrange boiling out and feed water treatment chemicals.
 Insulate all the lines and equipment after they have been tested completely.
B. FEED WATER SYSTEM:
 Get the water treatment plant commissioned and ensure the quality of Feed Water is
within the specified acceptable limits, and if needed Water treatment Chemicals are
also added to make it as per the Input requirements (Refer Chapter 4.0 - Input
Requirements)
 Clean & Flush the feed water storage tank and pipelines thoroughly by manual
scrubbing & draining the water.
 Flush the feed water pump completely before commissioning as this is filled with anti
corrosive compound before dispatch, to prevent rusting in storage. This compound
should be drained and the pump should be flushed completely.
 Check the operation of softener and dozer and make sure that the operators are well
trained on the softener equipment and operation.
 Confirm that the water level extra low safety is provided in the tank & is in operation.
 Ensure that the Feed water pump foundation bolts are tightened.
 Ensure that the Feed water pumps rotations are correct.
 Ensure that the feed pump on –off operation is satisfactory & consistently at the desired
levels.
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Chapter 5
 The level probe lengths are preset from factory and will operate the feed water pump at
required water level.
 The pressure gauge is fitted between the outlet valve & pump.
 The feed pumps operation should be smooth & without any undue noise & vibration.
 The feed pumps pressures should be steady ,if not steady clean the suction strainers,
remove air from pump, check pump coupling and input voltage
 The strainer at pump suction has the proper size of mesh (refer P & I diagram).
 The strainer at pump suction strainer is cleaned after flushing the lines.
 Ensure that the Valves are operating smoothly.
 Clean Water flow at the feed pump suction is available.
 Air is removed from the feed pump through the air vent plug & the pump is flooded with
water.
 Ensure that the valve at the pump outlet is throttled if there is no pressure in the boiler or
water is to be filled in the boiler in cold or low-pressure (less than 7kg/cm2) condition.
CAUTION
NEVER START THE WATER PUMP WITH DISCHARGE VALVE OPEN. INITIALLY THROTTLE THE
VALVE PARTIALLY.
C. FLUE GAS CIRCUIT :
 Check the chimney and duct connections and make sure that they are airtight.
 Check and provide supports to ducting.
 Check the functioning of various dampers provided in the ducting & mark Open -Close
positions with paint.
 Insulate the part of ducting inside the boiler house.
 Ensure that the flue gas sampling points are provided for the Smoke Index &Co2/O2
measurement
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Chapter 5
D. BURNER
 Rotate impeller manually to see that it dose not rub and maintains proper cone/wheel
clearances and there is no undue noise form the fans.
 Check coupling for proper alignment.
 Check fan and duct for any loose material inside.
 Ensure that the suction air damper is free to rotate. Lubricate the damper bearing &
linkages.
 Check lubrication of motor bearings.
 Secure and check safety guards for its position.
 Check if nozzle is secured properly in nozzle holder.
 Check alignment of electrodes with respect to nozzles.
 Check burner settings as given in burner manual.
WARNING:
NEVER START ANY FAN WITH DISCHARGE FULL OPEN.
E. ELECTRICAL SYSTEM:
 Ensure that all external electrical cable connections to the control panel are as per the
electrical diagram of the boiler.
 Tighten all the terminals in control panel, as they might get loose during transportation.
 Check the functioning of main switch and provide correct fuse.
 Check whether proper earth wires have connected all the motors and panels.
 Check if all the settings of overload relays of motors, pressure switch (as), etc. are all
correct.
 Check for the earthing connection to elect panel, to all motors & instruments.
 Check for the correct electrical supply.
 Check and ensure that IGEMA probe connection is proper.
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Chapter 5
 Ensure electrical interlocks of the FD fan motor & burner is operating.
 Check the functioning of all safeties & controls by manual simulation.
F. FUEL SYSTEMS:
i) Liquid fuels:
 Ensure that the Fuel system is complete in all respect as per the guidelines given in the
earlier chapter: 1.6 - Assembly Guide Lines & Accessories – Fuel System.
 Line sizes are correct & are supported & clamped properly.
 No Objection Certificate is obtained from the explosives dept. or the concerned

government agency for the storage of the fuel & that the fuel storage formalities are
completed before filling the fuel oil in the tanks
 Fuel storage tank & day tank are tested leakages & all leakages are rectified
 Manhole ,Vents, drains ,fuel level indicating arrangement, over flow ,out flow heater
arrangement, is properly made as per the instructions in the Assembly guidelines
 Ensure Use of quality oil gaskets in the fuel lines and at the tanks
 Fuel storage tank & day tank are cleaned dry & then flushed thoroughly before filling
the fuel oil.
 The pipelines are flushed thoroughly by air & fuel oil before connecting them to the
basket filter & Burner.
 For LDO the Out flow heater can be set at 50-55 deg ‘c’ if so needed.
 The air is removed from the basket filter, through air vent plug.
 Remove the air from the air plug of the fuel pump to ensure that the air is removed
completely. Ensure that the plug is re-fixed tightly.
 Set the fuel pump pressures.
 Clean the fuel strainers in line, as & when the fluctuations in the fuel pressures are
observed.
ii) Gas fuels:
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Chapter 5
 No Objection Certificate is obtained from the explosives dept. or the concerned

government agency for the storage of the fuel & that the fuel storage formalities are
completed before storing the fuel.
 Before supply is given to the burner, ensure that the user commissions the gas supply
system & the compliance to all the recommendations are made.
 The boiler user has to hand over a copy of the gas system commissioning & handing
over report to Thermax engineer/representative, before commencement for the
boiler /burner commissioning
 The user has to ensure the consistent supply of adequate quantity of the gas at desired
pressure is made available to the boiler burner.
 Check that the burner & components supplied along with the boiler are suitable for the
particular gas supply & its incoming pressure.
 Ensure that the gas supply pipeline sizes are correct, are supported & clamped
properly.
 When the gas is stored in the gas storage tanks ensure that the gas pressures is
reduced to the desired pressure with the help of proper gas trains & then supplied to
the boiler burner(Ref P & I diagram)
 Where ever the piped gas supply is given ensure that the gas pressure given to the
boiler burner is as desired (Ref P & I diagram)
 Ensure that the pipelines are tested to the desired pressure as recommended by the
gas supplier.
 Ensure that the safety & firefighting equipment are in place & are operative
 Dos & don’ts of the gas supply system are to be displayed in the boiler house near the
burner.
G. STEAM SYSTEMS:
 Check whether correct size of steam pipelines as recommended, are provided and IBR
hydraulic test certificate obtained.
 The steam traps are to be by-passed during the first steam flushing of the pipelines, to
avoid clogging of the steam traps due to dirt of the pipeline.
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Chapter 5
 Check for the steam traps & fittings, for proper clamping & free removal of condensate.
 Removal of air is very necessary from the pipeline & utilities when steam supply is opened
to the utilities.
 Insulation of the steam pipelines is done only after the successful hydraulic test in
presence of the IBR inspecting authority.
H. CIRCULATION WATER SYSTEM :
 Get the water treatment plant commissioned and ensure the quality of Circulation
Water is within the specified acceptable limits, and if needed Water treatment
Chemicals are also added to make it as per the Input requirements (Refer Chapter 4.0 -
Input Requirements)
 Flush the Circulation water pump completely before commissioning as this is filled with
anti corrosive compound before dispatch, to prevent rusting in storage. This compound
should be drained and the pump flushed completely.
 Check the operation of softener and dozer and make sure that the operators are well
trained on the softener.
 Guide lines to fill water in circulation circuit:

 Ensure the air vent plug on primary hex inlet header, is loosened and the outlet
valve on expansion valve is open
 Open the inlet valve to the circulation circuit to start water filling with gravity.
(water level in feed water tank should always remain above the level of
expansion vessel outlet valve)
 When water overflowing from the air vent close the plug tightly.
 Once the entire circuit is filled with water and water starts over flowing from
expansion vessel outlet, close the valve.
 After ensuring entire water circuit is filled close the inlet valve to the circulation
circuit.
 Ensure that the Circulation water pumps rotations are correct.
 The pressure gauge is fitted between the outlet valve & pump.
 The circulation pumps operation should be smooth & without any undue noise &
vibration.
 The circulation pumps pressures should be steady ,if not steady clean the suction
strainers, remove air from pump, check pump coupling and input voltage
 The strainer at pump suction has the proper size of mesh (refer P & I diagram).
 The strainer at pump suction strainer is cleaned after flushing the lines.
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Chapter 5
 Ensure that the Valves are operating smoothly.
 Clean Water flow at the circulation pump suction is available.
 Air is removed from the feed pump through the air vent plug & the pump is flooded with
water.
5.2 Commissioning:
The commissioning activity starts after all the pre commissioning activities are completed
satisfactorily and all the controls and safeties are working normally.
For commissioning and trial operation, steam or heat utility must be provided, for long duration
of steam generation or continuous boiler operation. This is required to set the firing system as well
as all controls and safety facilities can be adjusted.
The commissioning of the boiler consists of the following activities, which are carried out under
the guidance & supervision of Thermax engineer/representative .
5.2.1 Burner system commissioning & burner firing

5.2.2 Chemical boiling out
5.2.3 Steam generation & final settings
5.2.4 Safety valve setting
5.2.5 Efficiency /output trials & handing over
Warning:
 The commissioning of the boiler is to be done under the guidance & supervision of
Thermax Engineer / authorized representatives only to avail Thermax warrantee
benefits.
 If steam utilities are not ready, the steam will be vented out for the commissioning &
output efficiency trials.
 The Owner /User of the boiler must ensure that the Provisional order for firing the
boiler( In India) is obtained from the Inspectorate of boilers before informing
Thermax for commissioning
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Chapter 5
5.2.1 Burner System Commissioning & Burner firing:
The burner setting is required to be done, before attempting to the firing of the burner.
The burner setting for oil & gas burners is given in burner manual supplied along with burner
A. Burner Start Operation: Liquid fuels
The pre commissioning activities must ensure the satisfactory working of all the control & safeties
of the boiler, and then the burner can be started in the following sequence:
1. Fill up soft/DM water in the water service tank & open the valves in the water line.
2. Fill up fuel in the fuel service tank & open the valves in the fuel line. For gas fired units –
Open the valves in the gas lines
3. Put ON main switch & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
4. Keep the boiler vent valve open & main steam valve closed.
5. Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
6. Before starting the burner ensure that modulation switch is in OFF position.
7. After ensuring optimum water level in boiler & all safeties are fulfilled, the burner can be
started.
8. Put ON the burner selector switch.
9. The burner programmer cycle starts (with Siemens sequence controller model- LAL-2.25),
which consist of the following cycle of operation,
i) Pre-purging cycle: for 22.5 second’s time, then supply is fed to ignition transformer,
ii) Electrical sparking at ignition electrodes: for 6 Seconds
iii) Burner solenoid valve is energised, commencing fuel spray inside the combustion
Chamber & flame is established.
iv) Flame is detected by flame sensor. Thus, boiler starts in low flame. The low flame
Firing is to be continued so that heating is gradual.
10. If the firing is smooth then the flame & smoke colour are checked. The flame has to be set
bright for oil & Bluish for gas units & the smoke should not be visible, by setting the air
damper of the FD fan.
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Chapter 5
11. If the flame is smoky / flickering/does not get establish/creates vibrations/backfiring ,then
the air damper needs to be adjusted for getting smooth start of flame.
12. Even after setting the burner the flame start up is not smooth, then the burner diffuser
plate is to be adjusted along with air damper. Proper air fuel ratio is to be set at low flame
operation.
13. This procedure is repeated several times until a smooth flame start up is achieved with
colourless smoke.
14. The modulation switch is now put ON. The burner modulation would depend on steam
pressure, which is cold start will be zero.
15. The rotation of the servomotor moves the gear train, which is fitted at the FD fan suction &
increases the air supply .At the same time the fuel metering valve closes the fuel by pass
line of the burner gun, thus increases the fuel quantity also ( for Oil fired units ) .
16. for gas fired units The servomotor opens the air damper as well as gradually increases the
Gas supply
17. The burner thus moves to high flame fame & stops at the highest firing stage.
18. If the flame is improper as mentioned above the sequence of air fuel ratio setting is
repeated with resetting diffuser plate, air damper positions at various stages of transition
to high flame.
19. the transition from low to high flame has to be smooth ,with bright flame & almost invisible
smoke colour
20. To ensure complete combustion of fuel, checking of Smoke Index Number & Oxygen
percentage Or Co2 percentage is done with the combustion test kit.
21. For Oil fired units, the smoke index number should be set up to one for light fuels & up to
three for heavy fuels, with O2 percentage as 3-4 or CO2 percentage at 12-13, with low as
well as high flame conditions.
22. For Gas fired units the Ideal smoke Index should be zero & maximum Co2 % should be up
to 12 %.
23. Follow the chemical boiling out procedure as given below to clean the boiler surfaces
internally and raise the pressure for the boiling out.
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Chapter 5
5.2.2 Chemical Boil out Process:
Boiler chemical boiling out procedure can be done simultaneously with the burner system
commissioning
The primary objective of the boiling out procedure is to ensure removal of the more common
initial oil and grease and the other foreign matter.
The tube or plate manufacturers apply the coat of oil of readily soluble, non-hardening oil to
prevent from corrosion, which is to be removed by chemical boiling out.
Other than the metal failure, the oil also causes Priming & foaming inside the boiler, which is the
main reason of the Wet steam or water carryover. This may result into process problems.
Before chemical boil out, the following is required to be done.
a. Fill boiler up to 100 mm below normal water level.
b. Ensure all bottom header drains are fully closed.
c. Excepting direct level gauge, isolate all other instruments during boil out operation. This is
very important.
d. All drains & air vent are to be kept open initially.
e. Quantity of 100 KGs. Of Thermax MAXCLEAN - 07 chemical is required, for every 1000
KGs. of Water. Requirement will be proportional to the water holding capacity of the
boiler.
f. This Solutions (with water) should be poured through manhole of Boiler. Close the
manhole after charging chemicals.
g. Fire the boiler and keep it at low flame. This will help to raise the pressure slowly. Keep the
air vent valve of the boiler open.
h. When the drum pressure reaches about 2-kg/cm² close the drum vents. Continue to raise
the pressure at slow rate. This will avoid thermal stresses.
i. Fuel firing rate should be so regulated that approx. 50% of design pressure (max. working
pressure) is reached in about 4-6 hours. In no case should the pressure be increased
more than this for the boiling-out operation. Maintain this pressure for next 6-8 hours.
j. Now stop the fuel firing & boiler auxiliaries in proper sequence. Allow the steam pressure
to fall gradually. Maintain water level in the drum, such that it is visible in gauge glass.
105
Chapter 5
k. When the steam pressure is approximately 5 kg/cm²g, give quick and short blow down.
This will greatly assist removal of sludge/sediment accumulated.
l. At hourly intervals, operate main blow down and drain valves on water level indicators
and water level controller in sequence. Make the first blow down of each series through
the surface blow down connection (if provided) in order to clear any scum or sludge on
the water surface.
m. Open the drum vents when steam pressure is approx 2 kg/cm². Take Soft/DM water in
boiler up to full gauge glass and drain it through different bottom header drains. This
procedure should be repeated 3-4 times for proper rinsing of internal surface of pressure
part.
n. The boiling out procedure will complete, when testing of boiler water, indicate same
amount of oil in consecutive samples tested.
p. Open the drum manhole, inspection ports (where available) of bottom headers for
inspection of the surfaces.
NOTE
It is important that all the precautions governing safe operation of boiler be duly observed
during the boiling-out period.
CAUTION
If considerable oil or oil sludge is found to be still adhering to the tubes, the entire process
should be repeated, until the pressure parts are free from all impurities.
5.2.3 Steam Generation:
After completion of chemical boiling out, and the complete flushing operation, the boiler is filled
in with the treat water and boiler.
The IBR licensed operator fires the boiler and steam pressure is raised up to the maximum
working pressure of the boiler.
This first operation of the boiler & steam generation is done in presence and under the guidance
of Thermax Engineer /authorized representative of the Thermax. The fine setting of FD fan
damper is to be set for the optimum combustion parameters of smoke Index & O 2/Co2
percentage.
IGEMA water controller needs to be checked for its normal functioning
106
Chapter 5
5.2.4 Safety Valve setting:
The two safety valves are set at the maximum working pressure of the boiler, while the boiler is
generating steam to its full capacity. The exact lift pressures of the Safety valves, the pressure
build up in the boiler and the safety valve sit backpressure are observed and set. This is one of
the major and critical settings to be done on the boiler.
In India, the Indian Boiler regulations are followed for the over pressure & sit back pressure values
of the safety valves.
a. Pressure Switch Setting (High Pressure cut off):
After the settings of the safety valves, steam pressure high cut of pressure switch is set. This
pressure switch has to be set as per the maximum steam pressure requirement in the plant. The
setting has to be below the lift pressures of the safety valves, but in no case, it should not be lass
than 7kg/cm2.
The pressure switch controls the steam pressure of the boiler by cutting off or cutting in the
burner & FD fan. This stops the firing of the burner & reduces the steam generation. Hence this is
the device, which controls the steam pressure in the boiler.
During this commissioning process all the safeties & controls of the boilers are checked
thoroughly by operating the boiler at its full capacity and venting out the steam through Vent
valves or by passing the steam through the Steam lines for Flushing.
b. Flushing: Steam Lines
If the steam lines are newly fabricated these need flushing by passing the steam for min 4 hrs, to
ensure internally clean surfaces of the pipelines.
The steam Traps and strainers fitted should be removed from the lines during the flushing
operation. All air vents are opened and steam is flushed out for these valves. Only after the lines
are flushed the steam should be opened to the plant utilities.
c. Important Readings/Settings for Commissioning:
SR. ACTIVITY DESIGN DATA/ ACTUAL REMARK

NO. SET POINT DATA
107
Chapter 5
a. FUEL CIRCUIT
1. Fuel consumption of - Refer technical specs

Boiler burner in
High flame
2. Fuel consumption of - Refer technical specs

Boiler burner
In low flame
(LIQUID FUELS)
3. Fuel pump pressure 20 kg/cm2 (g) (Approx.)
4. Burner fuel by pass 12-15 kg/cm2g (at 100%)

Pressure 4 - 7 kg/cm2g (at 25%) (Approximately)
(Gas Fuels)
5. Gas pressures -gas train inlet 500 mBar Or 1-2 Bar (as Applicable)
- Burner inlet 40-50 mBar
b. AIR / FLUE GAS CIRCUIT
1. Boiler outlet Flue gas 260ºC

Temperature high, (Approximately)
C. STEAM CIRCUIT
1. Steam pressure PCM for 10.54 kg/cm2g boiler set point should be
Switch (ON - OFF) 0.7 kg/cm2g more than low firing set point.
For 17.5 kg/cm2g boiler set point should be
1.3 kg/cm2g more than low firing set point
2. Steam safety SV SSV PR as per design

Valve setting
SR. ACTIVITY DESIGN DATA/ ACTUAL REMARK

NO. SET POINT DATA
3. Modulation: steam Pressure PCM Pressure band 1.5 kg/cm²}

Controller setting PT, PIC Pressure band 0.5 kg/cm²}
PIC Pressure band to start SSV pr
Minus 0.5 kg/cm² downwards
d. WATER CIRCUIT
108
Chapter 5
1. High water level LSH 50% in

(Water Pump Off) gauge glass
2. Low water level LAL 35% in

(Water pump ON) Gauge Glass
3. Water level low alarm LAL 15% in

Gauge Glass
e. BURNER SETTINGS: Refer Burner manual for Burner settings.
NOTE:
All the above settings are only for reference; however, the actual settings may vary from site to
site and are to be recorded in the commissioning report
5.2.5 Efficiency & out Put Trials:
After the above procedures the boiler will be ready for the Output & efficiency trials.
It is mandatory for the customer to conduct the efficiency & out put trials, within a week’s time
of commissioning of the boiler, as per the guidance of Thermax Engineers/Authorized
representatives.
The efficiency trials are conducted as per BS 845 and in accordance of the Thermax standard
practices.
The observations of the trials are noted down and are signed by the Owner/user’s responsible
person and also by Thermax engineer/authorized representative.
Based on the Trial observations and the Out put & efficiency are calculated and informed to the
customer/user by Thermax.
These efficiency & output trials are conducted to ensure that the boiler is performing as per the
committed contractual norms of efficiency and steam output.
a. Training:
During the boiler Installation, pre-commissioning, commissioning and efficiency & output Trials,
Thermax engineers /authorized representatives ensure that the Boiler operators and other
technical personnel responsible for the operation and maintenance are trained to operate &
maintain the boiler as per the norms laid down by Thermax Ltd.
109
Chapter 5
These norms and the good operation & maintenance practices of boiler are also explained in
the next Chapter of operation & maintenance. These should be read & practices for the trouble
free operation and long life of the boiler & its accessories.
b. Boiler handing over for commercial Use:
After the successful commissioning and efficiency /out put trials, the Boiler will be handed over
to the user/owner for the commercial use.
The boiler handing over procedure includes the signing and stamping of the Erection &
commissioning checklists and certificates of Thermax Ltd by the owner/user’s responsible person
and the commissioning engineer of Thermax / authorized Dealer.
These signed/stamped commissioning and handing over reports/certificates are forwarded to

the Customer Care /technical service department of Thermax ltd, for the scrutiny of the site
reports. If any discrepancies are observed in Installation, performance or settings, Thermax ltd
takes immediate corrective action by informing the concerned Thermax engineer/authorized
representative/dealer and also to the owner/user of the boiler.
Warning:
In no case, the owner /user should use the boiler for the commercial use /production,
without completing the Handing over formality from Thermax, to avail the committed
warrantees of the Boiler & its supplied parts/equipment.
In case of failure on the part of the owner/user to comply with the above handing over
procedure, all the warrantees of Thermax Ltd, as per the order terms, will cease to exist
and in such case Thermax shall not be responsible for any failure of the supplied
equipment or components.
110
Chapter 6
06 OPERATING INSTRUCTIONS
4
Operation of the boiler needs to be properly under stood by the operational staff /operators.
The training is imparted by Thermax /dealers during commissioning of the boiler.
6.1 Boiler Start up Process:
START
Fill up water in the water service tank & open the valves in the water line.
Fill up fuel in the fuel service tank & open the valves in the fuel line.
For gas fired units: Ensure that gas filters are clean.
For GAS fired Units; Check the main and pilot gas pressure and set it if required.
Put main switch ON & individual isolator switches for all equipments & control supplies to
Boiler Control Panel.
Keep the boiler vent valve open & main steam valve closed.
Put ON the circulation water pump. (Refer guidelines chapter 5 for filling circulation line)
Select & put ON one of the water pump. The water level is controlled by level controller
depending upon the water level.
. For gas fired units: Check the inlet gas pressure to gas train. If it is within acceptable
limit, open the inlet valve of gas trail
111
Chapter 6
For Gas fired units: Check the main and pilot gas pressure and set it if required.
Before starting the burner ensure that modulation switch is in OFF position.
After ensuring optimum water level in boiler & all safeties are satisfied, the burner can be started.
Put ON the burner selector switch in auto position.
The burner programmer cycle starts. After pre-purging time, supply is fed to ignition transformer,
commencing electrical sparking in the burner. At the same time burner/Gas solenoid
valve is energised, commencing fuel spray or gas supply inside the combustion chamber
& flame is established. Flame is detected by flame sensor. Thus boiler starts in low flame.
The low flame firing is to be continued so that heating is gradual.
When steam starts coming out through the air vent valve close the air vent.
When steam pressure builds up to the desire operating pressure, the main steam outlet can be
opened to the process.
Put ON the modulation switch, the burner would go in high flame position. The burner
modulation would depend on steam pressure, which in turn will vary depending on the
load.
End
112
Chapter 6
6.2 Boiler Stopping Procedure: For Oil & gas fired units
START
Put OFF the burner modulation switch.
Put OFF the burner switch.
Close the boiler steam stop valve. Keep the air vent valve slightly open.
Put OFF switches for all other equipments & close all relevant valves. .For gas fired unit ensure
that all gas isolating valves are closed.
Ensure that water & fuel service tank are full for subsequent operation. For gas fired units, check
gas availability for subsequent operation.
Isolate boiler control panel by putting OFF all electrical supply.
Clean the boiler & its surroundings off the dripped oil, water etc.
Blow down the boiler until water level drops by 1" (25 mm) or to the extent required depending
upon the quality of feed water. The boiler blow down should be such as to maintain a
TDS in the boiler to less than 3500 ppm. Close the blow down valve.
END
CAUTION
a) If the Boiler is being operated on LSHS. Make sure that at least one hour before stopping the
Boiler, the fuel firing is changed-over from LSHS to LDO/FO. This is for avoiding the choking of
Fuel oil pipe line due to LSHS solidification, at room temperature.
ii) When boiler is shut off for a short period, keep the vent valve slightly opened.
WARNING
 NEVER OPERATE THE BOILER WITH HARD WATER.
 NEVER PERMIT THE WATER TO DISAPPEAR FROM THE GAUGE GLASS WHEN ROUTINE BLOW
DOWN IS DONE.
113
Chapter 6
6.3 Boiler Running Attention

It is advisable on part of the operator and the other operational staffs, to make it a practice
check the following points periodically during the running of the boiler.
Check that...
 The feed water softness is checked at the water treatment plant, after every one hour of
water treatment plant operation or more frequently. If feed water is found hard,
regenerate the water softener immediately.
 Maintain the desired boiler water quality, in the boiler. Add chemicals & give optimum
Blow down periodically. (Refer chapter Input requirement of feed water and boiler Water
 Maintain the soft/DM water level in the feed water tank up to its maximum capacity.
 If water treatment chemicals are being used ensure that the chemicals are added in
regular intervals, in the chemical tank.
114
Chapter 6
 The flame is steady, bright & smoke is colorless.
 No backfiring or vibrations are observed from the burner.
 For oil fired units, the Fuel pre-heat temperatures & the fuel pressures are maintained as
per commissioning report.
 No excessive sound is heard from the motors pumps and Fans.
 All valves and joints are leak proof.
 Water pump is working ON OFF to ensure the functioning of Igema level control switches.
 No sparking or loose contact is there in the electric circuit of the control panel of the
boiler.
 That a steady steam pressure is maintained.
 Always operate the boiler at or near to its working pressure. If steam pressure requirement
in the plant is low, then reduce the pressure to the desired in the plant By Pressure
reducing Station (PRS).
 No over firing of fuel is being done and correct fuel consumption is maintained.
 Combustion efficiency of the burner is to be regularly checked with the help of

combustion test kit and tune the burner to achieve optimum efficiency
 Blow down the gauge glasses once in 8 hours, and maintained the gauge glasses clean.
 The logbook is filled hourly and correctly for all the parameter of boiler. For Reference
format see below chapter “LOG BOOK”.
CAUTION:
1. Following procedure is to be adopted as guidance while blowing down the boiler, gauge
glass. Blowing down, helps in removing sludge, loose scale and other fine material that might
accumulate in the boiler shell. Thus helps to maintain the water quality.
 After the boiler is switched off. Blow down the boiler until water level drops by about 2"
(keep the air vent valve slightly open).
 To check the automatic operation of the feed pump, put on the selector switch and
blow down the boiler below normal water level, the pump motor should start and work till
the boiler is filled up to the top level.
115
Chapter 6
2. If water quality is poor, Intermittent blow down water quantity / frequency of blow down
increases to keep the boiler water within specified limit. Prolonged Intermittent blow down
affects the water circulation in side the boiler, which is dangerous for boiler and tubes. Only
way to control the boiler water TDS is to feed specified soft/DM water or provide continuous
blow down. Intermittent blow down should be done only to remove sludge, loose scale and
other fine material that might have accumulated in the boiler shell.
3. In the event of power failure or any failure of controls, safeties:
a) Close the steam stop valve and other valves.
b) Remove the un-burnt fuel from the grate. DO NOT SPRINKLE WATER TO EXTINGUISH THE
FIRE.
c) Ensure that water level is maintained in gauge glass, by emergency pump start switch.
d) Open the ash door for grate bar cooling.
4. Pre Heat the fuel up to the desired temperature only. Refer preheating charts, as per the,
Class and specific gravity of fuel oil. These charts can be given by the fuel supply companies
5. Avoid Over heating of fuel oil during Pre–heating of fuel oil .This will lead to Cracking,
Carbonizing of fuel oil & also to vapor generation. The vapors can damage the fuel pumps.
6. Maintain the ring main circuit pressures between 3 to 4 kg /cm2, to increase the life of the fuel
pumps
7. In gas fired units, boiler gas supply pressures should be steady.
WARNING:
 During normal blow down never permit water to disappear from the gauge glass.
 Always operate the boiler at or near to its maximum working pressure.
116
Chapter 6
6.4 Do’s And Don’ts for Operation of Shellmax:
CAUTION:
Water System -
1. Do not use turbid water in the softener/DM/Water

treatment plant; it may choke the resins of this
equipment. Get the water (2 liters) and Resin (50 cc)
analyzed every year.
Operation -
2. Check the feed water quality every 4hrs of running &

ensure it is as per the requirement.
3. Feed only SOFT WATER into the boiler always. Never feed
hard water as this will result in scale formation. Scale
results in to low heat transfer to the water & over
heating of tubes.
4. Scaled tubes and metal parts like furnace don’t transfer

the heat to the water, hence overheating may take
place, resulting in to metal failure or bursting.
117
Chapter 6
5. Oxygen present in the water attacks the metal surface of

the boiler shell, which results into pitting.
The Low pH of water results into corrosion of the metal

surface.
Hence regular use of water treatment chemicals is

recommended.
Use water treatment chemicals for the treatment of

Oxygen Pitting, pH corrosion, residual hardness,
Alkalinity etc., and ensure that the dosing of these
chemicals is done regularly.
6. Ensure that proper quality and quantity of regenerates

are used in the water treatment plant and proper
procedure is adopted in running the plant with
specified
quality of regenerates.
7.Control Panel: Check electrical input once in a day, to

Check all the controls and safeties regularly as
mentioned in the manual.
118
Chapter 6
WARNING:
Never short circuit safeties and work the boiler. It may end up in costly damages.
Boiler Unit:
8. Give blow down after regular intervals to maintain the

Boiler water quality: Chapter Refer Utility requirement.
9. Negligence in operation may cause severe damage to

the boiler. And automatic does not mean, no
attention required.
OK General:
Operation:
10. Maintain the Log book supplied with the boiler. It will
help in detecting faults, if any, at the early stages itself.
Refer Log Book section in next chapter.
11. Keep spares in stock to minimize down time due to

breakdowns, if any.
119
Chapter 6
120
Chapter 7
07 MAINTENANCE
7.0 Maintenance
The performance of a boiler depends greatly on the maintenance carried out. The boiler, its
surroundings, water pipelines, filters, strainers, etc. should be kept clean to maintain proper fluid
flow to the boiler so that it works efficiently.
For easy detection of faults and to know deviation from standard/normal setting/readings
obtained at the time of commissioning should be recorded and should be referred to after every
major servicing/repairs and replacement of parts, is carried out.
In the following paragraphs, the maintenance to be carried out is listed down as Daily, Weekly,
Monthly, etc. It is also necessary to check up whether all the parts of the boiler are working
properly.
The maintenance checks be carried out and preferably should be recorded on a logbook daily by
the boiler operator.
WARNING:
 DO NOT TAMPER WITH THE SETTINGS OF CONTROLS AND SAFETIES UNNECESSARILY.

IT IS TO BE NOTED THAT IT IS TOTALLY UNSAFE TO SHORT CIRCUIT SAFETIES AND
OPERATE THE BOILER.
 BURNER SETTINGS ARE VERY CRITICAL AND ANY TEMPERING WITHOUT KNLOLEDGE
MAY LEAD TO DISTURBED FIRING CONDITIONS & CAN LEAD TO SEVER BACK FIRE
/ACCIDENTS.
120
Chapter 7
7.1 Maintenance Schedule

Table T-7.1
Half
Maintenance Activity Daily Weekly Monthly Quarterly Yearly
yearly
Water treatment plant check &
*
regenerate if required
Check water treatment
*
chemical stock
Check feed water quality for
*
hardness, pH & Oxygen
Check feed water quality for TDS *
Check Steam pressure Switch
*
operation
Clean Fuel filters & basket filters *

Check Mobrey level controls’
*
For normal pump on –off
operation
Mobrey low safety check *

Boiler water quality check *
Clean front & rear viewing
*
glasses
Clean Burner Nozzle *

Calibrate all pressure gauges *
Calibrate fuel temperature
*
indicator & controllers.
Calibrate the flue gas
*
temperature indicator
Check Hooter operation *

Clean Strainers –feed pump
*
suction
Feed line NRVs check *

Check motor interlocks *
Check the stock of essential
*
spares
121
Chapter 7
Half
yearly
Safety Valves operation * *
Motor Current check
Burner , Feed pumps, Fuel *
Pumps & Ring-main pumps
Cleaning the smoke tubes &
*
smoke boxes
Cleaning of furnace *
Cleaning of boiler smoke tubes *
Dust removal from Elect control
panel *
Clean electrical contactor

contacts *
Check the connections of

Mobrey level controller *
Cleaning Gauge Glass protector

& glasses *
Check front reversal chamber
refractory and repair if required *
Grease all motors’ Bearings *

Clean the burner gas spuds.
For gas fired units *
Check resin quantities in the

water treatment plant *
De-scaling & internal cleaning

of boiler pressure part *
Dismantling, Cleaning & lapping

of all the Valves, NRVs, Safety *
valves, blow-down valve.
122
Chapter 7
Half
yearly
Smoke box Sealing rope
replacement *
Check resin quantities in the
water treatment plant *
De-scaling & internal cleaning
of boiler pressure part *
Removal & replacement of
Removal & replacement of all
Gaskets of valves, mountings & *
fittings, Manholes, hand-holes,
inspection doors.
Offer for the open inspection of

the boiler to the IBR authority *
Re-fixing of all Mountings &

fittings on the boiler *
Box up all the manholes /
hand-holes *
Hydraulic test, up to 1.5 times
the max. working pressure for *
15 minutes (max)
In case of leakages, Stop all

leakages & re- test *
Offer the boiler for the
hydraulic test to IBR authority *
Cleaning of feed water tank *
Ash removal from chimney
base ash opening *
All Insulation repairs of boiler,

steam line etc *
Tighten all foundation bolts *
123
Chapter 7
7.2 Log Book

Record of daily checks and servicing operation as well as other checks and servicing operation
must be kept in an operating log book and signed daily by the responsible operating personal.
It is suggested that these Logbooks are maintained by the users. An hourly record of the
observations of the operational parameters and maintenance instructions are filled in without fail
by the operating personnel of the boiler.
This is to ensure that the deviations, if any, from standard/normal readings, may be noted and
attended to immediately; this can avoid major breakdowns and unwanted stoppage of the plant.
124
Table T-7.2 LOG BOOK - FOR OIL FIRED UNITS: (Shift Basis)
Fuel pressure
kg/cm2 Feed Water
Boiler water Pump Consumption
HSD/LDO/FO/LSHS Softener / DM Boiler Extra & Safeties &
Steam Stack On-Off
Blow low level controls
Time Pressure temp. Regeneration (Mobrey)
Burner Burner down at safety Working
Kg/Cm2 Deg. C. Done At working Water Fuel
Inlet bypass Hardness time check Ok/not ok
pH TDS PH check
PPM
liters Kg.
Remark _________________________________________________________________________________________________
_________________________________________________________________________________________________
Signature of the Boiler operator Date Signature of the Engineer/Shift in charge

Chapter 7
Table T-7.3 LOG BOOK - FOR GAS FIRED UNITS: (Shift Basis)
GAS pressure Feed Water Pump Consumption

Boiler water Boiler Extra & Safeties &
Steam Stack Softener / DM On-Off Flow meter readings
Blow low level controls
Time Pressure temp. Regeneration (Mobrey)
Gas Train Burner down at safety Working Water Gas
Kg/Cm2 Deg. C. Done At Hardness working
Inlet Inlet pH TDS PH time check Ok/not ok
PPM check
BAR MBAR Liters Nm3
Remark _________________________________________________________________________________________________
_________________________________________________________________________________________________
Signature of the Boiler operator Date Signature of the Engineer/Shift in charge
126
Chapter 7
7.3 Spare Parts

It is suggested that certain essential spares may be kept in stock to avoid idle time due to
unpredictable breakdowns and non-availability of parts with you or with our dealer/office. It
may take some time for us to arrange for the part /component at site.
If there is any breakdown due to component failure, it is better to replace the defective
component and if possible repair the defective component if repairable, at leisure, as
replacement is faster and easier.
The list of essential parts for SHELLMAX Boilers is given below and can be used for guidance.
Part List, specific to the Model & serial no with part no of each component can be taken up
from nearest office. For the amount of the water conditioning and fuel additive chemicals to be
stored, approach our nearest Dealer /office.
Table T-7.4 SARES PART LIST: SHELLMAX BOILER WITHOUT BURNER PARTS
Component Description Quantity to be stocked

at by user
Level Probe 1
Hooter –control panel 1
Indicating lamp holder 2
Indicating lamps 12
Feed water pump 1
Circulation Water Pump ( With Effimiser) 1
IBR Pressure gauge 10” Dial –for boiler 1
Fusible plug 2
Blow Down valve-IBR 1
Non return valves-feed line-IBR 1
Reflex Water Level Glass 1
Quick shut off valve size 1
127
Chapter 7
Table T-7.5 SPARES PART LIST: SHELLMAX BOILER - OILON BURNER PARTS
Burner Spares : Oil Fired Burner

Fuel Pressure gauge 1
Burner nozzle -as per fuel consumption in Kg/hr 1
Flame sensor 1
View glass –rear 2
Ignition transformer 1
Burner gun 1
Pressure switch-High pressure cut off 1
Pressure switch – SM Global 10 -SM Global 20
1
Pressure transmitter – SM Global 30 –SM Global 100
Burner diffuser plate 1
Burner solenoid valve 1
Fuel pump 1
Feedback potentiometer 1
Servomotor 1
Electrode assembly 2
Electrode Cap 2
Burner Spares : Gas Fired Burner
Gas pressure gauge: Range 0-10 Bar 1
Gas pressure gauge: range 0-100MBar 1
Main Gas pressure regulator range 1-4 bar 1
Main Gas Burner Solenoid valves 2
Pilot burner solenoid Valve 1
Pressure switch -Gas pressure High 1
Pressure switch -Gas pressure Low 1
Diffuser Plate 1
Flame sensor 1
128
Chapter 8
08 TROUBLE SHOOTING
8.0 Trouble Shooting

Some of the common problems & remedial action is as given below:
1. The feed water pump motor does not start in Fill position of the Rotary switch.
In table below some of problems & their possible causes are given. This will be helpful in trouble
shooting, Shellmax boilers & its components.
Problem Possible cause

Temperature controller not working  Wrong connection
 Earthing Improper
 Ambient temperature more than specified
 Supply voltage fluctuation
 Wire cut in between
 Moisture ingress
Blower motor failure  Motor overloaded
 Single phasing
 Starting method incorrect
 Overload relay bypassed
 Voltage & frequency variation more
 Fan impeller jammed / rubbing
RTD not working  Operating under high media temperature
 Soot deposition on sensor
 Continues vibrations of sensor
 RTD sensor screw getting loose
 Shielded cable not used
 Sensor cable loose / open
129
Chapter 8

Flame sensor not working  Electrical connection mismatch
 Supply at sequence controller terminal not
available
 Sensor mounting not in visible range
 Flame intensity weak
 Shielded cable not used for sensor connection
 Noise pickup due to parallel laying of sensor
cable with power cable
Ignition spark not taking place  Transformer winding open / short
 Supply at sequence controller output terminal
not available
 Output connection loose in transformer
 Higher amount of primary air
 Electrode gap more than specified
 Accumulation of oil / carbon deposit on
electrode
Igema Water Controller  Electrical switch not as per connection
 Cable damaged
 Soldering damaged
 SS probe damaged
Steam pressure switch not working  Frequent pressure fluctuation

 Diaphragm damaged
 Dirt accumulation in pressure switch
 Switch stuck-up
Blowdown valve Stuck or Leaking  Welding bur or foreign material stuck-up
 Valve spindle not rotating
 Oversized gland packing used
 Very high scale in water
Steam safety valve leaking  Deposition on nozzle & disc due to bad water
quality
 Corrosion of nozzle & disc due to bad water
quality
 Foreign particles damaged valve seat
 Water getting accumulated in safety valve
bonnet & discharge
 Blowdown ring setting improper
 High water content in steam
130
Chapter 8

Water level fluctuation  Condensate contaminated
 Feed water pH high
 High total alkalinity / TDS
 Sudden fluctuation in load / Firing
Fuel oil pump pressure fluctuations  Cavitations of pump due to one of the
following reasons ( Filter chocking , water
present in fuel , Air lock in pump suction )
 Pump coupling loose / worn out
 Excessive sludge / impurity in fuel oil
 Viscosity range beyond specification
131
Chapter 9
09 CARE OF IDLE BOILERS
9.0 Care Of Idle Boilers

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

If the boiler is to be kept idle for a short period, it should be laid up "Wet" as follows:
i. Fill the boiler completely with water, up to overflow level. By admixing an alkalizing
agent, (Use MAXTREAT 3100/3200) bring the pH value of the boiler water to 9.5 and add
a corresponding quantity of oxygen binding agent. Sodium hydroxide or a
corresponding phosphate, for instance, can be used as the alkalization agent.
Oxygen binding agents are, for instance: Hydrazine, Sodium Sulphite and sodium
bisulphate. Depending on the standstill period, the hydrazine content in the boiler water
should be for instance:
Standstill duration Hydrazine surplus g/m3 N2H4

Up to 1 week 20 to 30
Up to 1 month 50 to 100
Longer 100 to 300
For better mixing, the boiler should be heated briefly after admixing hydrazine, up to
about 85 °C, to drive out the oxygen in it. Take care that no pressure builds up in the
process.
Before renewed commissioning of boiler, the boiler water must be drained off until the
operational water level has been reached, provided the steam is allowed to contain
hydrazine (the steam must not contain hydrazine if it comes into contact, for instance,
with foodstuffs, clothing or dressings). Otherwise, the boiler must be drained and refilled.
Close all valves. In all cases the exhaust gas flaps or gate valves must be kept closed.
ii. Check for any leakage and take samples of water at regular intervals to ensure alkalinity
and Sulphite are maintained.
132
Chapter 9
9.2 Dry Preservation

If the boiler is to be kept idle for long period it should be laid up "Dry" as follows: -
i. Drain the boiler thoroughly, clean it internally and externally both fire and water side and
dry it out.
ii. Place trays of lime inside the boiler shell to absorb any moisture. Then close the door,
manholes, dampers, etc., properly so that no ingress of moisture or air can take place.
iii. Water service tank, pumps, and all piping should also be dried out.
It is essential that the boiler is thoroughly clean while using the wet or dry laying up method. To
prevent corrosion on the gas side of the heating surface, it is recommended that all heating
surfaces are dusted with hydrated magnesia to neutralize any acid remaining on the boiler
heating surfaces.
NOTE :
When working with caustic liquids or chemicals, it is imperative that the relevant accident
prevention regulations are observed and made accessible to the persons carrying out the work.
9.3 Chemical Boiling out

If any oil or grease gets into the boiler inadvertently, it will appear in the form of scum in the
gauge glass. This can be very harmful to the boiler and it should be cleaned as soon as it is
detected. Use of Thermax MAXCLEAN range of chemicals for boiling out should be done strictly
as per the instructions given in Boiling out procedure in this manual under Chapter 3.1
Commissioning.
Procedure for De-scaling
If the boiler water quality is not maintained as per the specifications the de-scaling of the boiler
may be required, to remove the water side deposits. The de-scaling is done by using chemicals.
Thermax chemicals are available to in the name of MAXTREAT CHEMICALS, which are
manufactured specially for the use in boilers without harming the metallic parts of the boiler. The
other commercial chemicals available in the market may cause harmful effect on the boiler
parts & may result into reduced life of the boiler components & pressure parts.
De-scaling is a very critical process & should be carried out by qualified personnel only and
following method to be adopted very carefully.
The procedure given below is for the MAX TREAT DESCALING CHEMICALS; the details of these
chemicals are given in the Section 3 of this manual.
133
Chapter 9
PROCEDURE: FOR CLEANING WATER SIDE DEPOSITS FROM BOILERS USING MAXCLEAN-04, 05 & 06.
The de-scaling method for any boiler depends much upon boiler design and nature of scales.
The general procedure to be followed while de-scaling with maxclean-05 and 06 is given below
for scales having following typical analysis
Silica - 42%
Calcium Oxide - 36%
Magnesium - 13%
Iron & Aluminium - 10%
STEP – 1 : FLUSHING
Allow boiler to cool. Open manholes and flush with plain water to remove loose
sludge/deposits. For complete removal of loose sludge use pressure jets or any similar
mechanical arrangement. At the end flushing loose scales, mud is removed facilitating easy de-
scaling with chemicals. Inspect tubes for complete blocking and try to clean them mechanically
to make passage for circulating de-scaling chemicals.
STEP – 2 : MAXCLEAN-06 TREATMENT
Fill boiler up to normal water level with 5% solution of Maxclean-06. Keep steam valve or safety
valve. Open and heat slowly till boiling. Boiling of water will ensure good circulation of
De-scaling solution, within the boiler. Continue slow boiling for 8 - 12 hours. Make-up with fresh
solution to maintain water loosened sludge accumulated in mud drum. Check concentration of
residual de-scaling using test kit.
Drain the Maxclean-06 solution in separate holding tank for reuse. Flush boiler with plain water
as given in Step-1. Cleaning with pressure jets with remove loosed scales.
STEP – 4 : MAXCLEAN-05 TREATMENT 1
Fill boiler with 5% solution of Maxclean-05. Keep steam valve/safety valve open to vent off
produced gases. Fire the boiler to raise temperature of solution to 60-80oC. Heating in boiler will
ensure circulation of Maxclean-05 solution within boiler. Continue slow heating for 8 hours. Give
blow-down periodically to remove accumulated mud. Make it up with fresh solution to maintain
level in boiler. Check concentration of residual Maxclean-05 every hour using test kit.
134
Chapter 9
Drain Maxclean-05 solution in separate tank for further use RINSE BOILER with fresh water till pH of
rinse water is above 5.0. Use pressure jets, if necessary to remove loose scales.
STEP – 6 : INSPECTION
After thorough flushing as in step-5, inspect boiler tubes and internals. If scales are still found,
repeat Step-2 to Step-6. If boiler is free of scales flush boiler with fresh make up water or
condensate.
STEP – 7 : PASSIVATION
After thorough flushing of boiler with condensate or fresh make-up, fill boiler with make up water.
While filling, add 100 ppm of MAXTREAT-3011 and 100 ppm of MAXTREAT-3100 and caustic to
boost pH of boiler water to 10.5 to 11.5. Boiler may be kept filled up with above solution till it is
commissioned.
STEP – 8 : COMMISSIONING
After passivation as given above for 8 hours, fire boiler slowly. Use normal make-up water and
internal treatment chemicals. Give heavy blow-down till normal conditions are obtained.
NOTE - 1
MAXCLEAN 05 or 06 SOLUTIONS should be circulated in boiler either by firing boiler or by using
external pump. When external pump is used; pass solution from the steam drum and take out
from mud drum.
NOTE - 2
Maxclean-05 and 06 solutions should never be mixed. They are not comparable. Therefore STEP
3 AND STEP 5 SHOULD BE FOLLOWED RELIGIOUSLY.
NOTE - 3
Time required for de-scaling depends much on nature of scales. Test kit will help to adjust time
of de-scaling.
NOTE - 4
Quantity of de-scalant consumed depends on quantity of scales and nature of scales in boiler.
For 1 KG of hardness scales, 1.5 KG of Maxclean-05 is required while 1 Kg of Maxclean-06 is
consumed for 1 Kg. of silica scales.
135
Chapter 9
Preparation Of Solutions:
MAXCLEAN-06
Use Carbon steel or HDPE tank equipped with stirrer or similar mixing arrangement. Take
sufficient quantity of make-up water in this tank to fill the boiler. (Generally 10% excess of hold up
volume of boiler). Add about 5 KGs of Maxclean-06 powder 95 litres of water taken in the tank.
Add power slowly while mixing. Maxclean-06 produce heat while dissolving and therefore,
powder should be added slowly (esp. when HDPE tank is used). Mix well to dissolve.
CAUTION:
Maxclean-06 is highly alkaline in nature. Use hand gloves and goggles while preparing
solution. Normal precaution of handling caustic solutions should be taken while making
Maxclean-06 solution. For further safety information, refer to materials Safety Data.
Maxclean-06 solution can be stored under normal conditions for 1 year and it can be
reused.
MAXCLEAN-05
Use HDPE tank equipped with stirrer or any similar mixing arrangement. Take sufficient quantity
of make up water in this tank to fill the boiler (Generally take 10% excess of hold up volume of
the boiler). Add about 5 KGs of Maxclean-05 per 95 litres of water in tank. Add power slowly
while mixing in the tank. Mix well to dissolve completely. Heat to 60 oC for dissolving it quickly.
CAUTION:
Maxclean-05 is highly acidic in nature. Use hand gloves, goggles and masks while
preparing solution. Normal precautions of handling acid solution should be taken while
preparing Maxclean-05 solution, for further information, refer to material Safety Data.
Maxclean-05 solution can be stored in HDPE tank for 30 days under normal storage
conditions and it may be refused.
Please note that de-scaling procedure may be varied to suite boiler design and for ease
of handling. Kindly contact THERMAX for any further queries.
136
Chapter 10
10 ANNEXURES
Contents

1. Basics Of Liquid Fuels & Combustion 139
2. Soot Blower (For FO) 143
138
Chapter 10
10.1 Liquid Fuels and Combustion
10.1.1 FUEL FOR BOILER
Shellmax Global boiler is designed to operate on liquid as well as gaseous fuel. Fuels with a very
wide range of heating value can be used for heating in these boilers. Like water it is extremely
important that the quality of fuel going into the boiler is carefully controlled in order to obtain
good performance out of the boiler. While water quality affects the Boiler performance due to
its effects inside the heating surfaces the fuel quality affects the outside of the heating surfaces.
To ensure the optimum performance we need to know the properties of the fuel and make
necessary adjustments. We shall discuss below some of the important properties of fuels.
10.1.2 COMPOSITION OF FUELS
Most of the fuels comprise of compounds formed out of carbon and hydrogen and in some
cases other elements like sulphur etc. Very often fuels also contain oxygen in the molecules.
Most of the fuels used in Heaters are derived from petroleum. These fuels are very rich in carbon
and hydrogen. The liquid fuels generally have more carbon and less hydrogen when compare -
to gaseous fuels. The carbon content for petroleum based liquid fuels would be generally 82 -
88% and hydrogen content 10 to 14%. Petroleum based gaseous fuels generally have a carbon
content from 78 - 82% and hydrogen content from 13 - 18%. Natural gas has much higher
hydrogen content and much lower carbon content. Depending on the carbon hydrogen ratio
the burning characteristics change. Burners for burning these fuels need to be specially
designed for the purpose. It is also possible to design burners to burn a range of liquid fuels and
also liquid fuels as well as gaseous fuels usually one at a time, depending upon the specific fuel
composition in use it is necessary to adjust the burner. If fuel composition changes after initial -
adjustment it is necessary to readjust the burner to suit the new composition.
There are two popular ways of analyzing fuel composition. One method is to have a complete
chemical analysis of the quantities of various elements present called ultimate analysis. The
other method is to analyze quantities of behavioral groups of components present in the fuel,
called as proximate analysis of fuel.
As the ultimate analysis of the fuel gives the quantities of elements present this information can
be used for theoretical calculations of the air required to burn and the heat out put on burning.
It should be mentioned here that theoretical calculation of heating values may not be exact
due to the difficulties in judging exactly whether some of the combustible atoms are already
linked to oxygen or not.
The component wise analysis is used to judge how the fuel would behave during the burning
process. Typically, the quantity of wax content will indicate probable problems one may
encounter due to wax solidification. Generally, a higher viscosity of petroleum oils at room
temperature would indicate a higher carbon hydrogen ratio giving a higher flame luminosity
giving a higher radiant heat transfer in the flame, at the same time indicating a possibility of
sluggish combustion.
139
Chapter 10
There is a very important value to understand the burning behavior of the fuel called carbon
residue, also sometimes referred to as Conradson carbon. The carbon residue is not normally
reported either in the ultimate analysis or in the component wise analysis unless specifically
asked for. The carbon residue is very difficult to burn and a portion of this residue can be
expected to precipitate as soot unless very special care is taken in the geometry of the
combustion chamber, the temperature of the combustion chamber and the residence time of
burning and such other parameters.
101.3 CALORIFIC VALUE OF FUEL
The calorific value is the quantity of heat the fuel gives out due to combustion. Carbon burns
forming carbon dioxide. Hydrogen burns to form the oxide of hydrogen, which is water. Sulphur,
if present, forms sulphur dioxide and some sulphur trioxide
There are two different ways of evaluating the calorific value of fuel. One value is known as the
gross calorific value (GCV) The GCV is the heat given out due to the combustion of the fuel with
all the water which has been formed having already condensed. In other words, the GCV is the
heat which has been released by the combustion and includes the latent heat given off by the
steam which had formed during the combustion condensing to water later on. It can be clearly
seen that GCV is not available for use while using the fuel in actual practice because the steam
formed does not in practice condense but goes off to the atmosphere through the chimney.
Therefore, GCV is not a useful figure to evaluate the heat obtainable by using the fuel.
However, as GCV is the easier quantity to measure generally after the fuel is tested the calorific
value is reported in terms of GCV.
The useful heat available from the combustion of a fuel is known as the lower calorific value
(LCV). The LCV is the heat given out by the fuel during combustion in actual practice. The
value of LCV is arrived at during testing of the fuel by first obtaining the value of GCV using say a
bomb calorimeter and then deducting 539.6 kcal/kg of steam formed during combustion of a -
dry sample of fuel. Sometimes, calorific value is denoted by NCV (Nominal calorific value).
NCV is the same as LCV. Unit of calorific value is kcal/kg or kcal/Nm .
10.1.4 PHYSICAL CONDITION OF FUEL
Combustion systems are designed taking into accounts not only the chemical composition or
calorific value but also physical parameters like viscosity, Lubricity etc. For proper atomization in
a burner, it is necessary to maintain liquid fuels at a viscosity of 10 to 15 centistokes at the burner
tip.
10.1.5 Cleanliness
The most important consideration in the physical condition of the fuel is the cleanliness of the
fuel. Unfortunately, this aspect is very often the most ignored resulting in a very sad state of
affairs with respect to the operational efficiency of the boiler, wear out of critical parts and
unreliable operation. In spite of actual experience of repeated tripping and unreliable
operation of Heaters resulting in production losses there have been many cases where instead
of ensuring cleanliness of fuel, energy has been wasted attempting retuning of burners changing
of electrical circuitry. The foremost priority in boiler operation after ensuring properly treated
feed water supply should be assuring a clean fuel. Cleanliness of the fuel can be assured only if
140
Chapter 10
great care is taken right from the moment the fuel arrives in the plant by filtering at the time of -
taking the oil into the storage tank, further filtering between the storage tank and the day tank,
further filtering between the day tank and the fuel pump, and keeping these filters always clean.
Combustion is generally the oxidation of carbon, hydrogen and sulphur in the fuel. For all
practical purposes oxygen is supplied by providing sufficient atmospheric air. The air delivery is
so adjusted geometrically with respect to fuel delivery to ensure proper mixing. In spite of the
best possible mixing it is necessary to provide more than just sufficient air for the chemical
reaction to ensure complete combustion. This excess air necessarily needs to be kept a
minimum by as efficient a mixing as possible so that the flue gas quantities are kept a minimum
achieving minimum loss of heat through the chimney. The entire expertise of a burner design
revolves around this important concept.
10.1.6 Chemistry of combustion:-
Typical chemical reactions involved are-
C + O2 = CO2 (+ 8050 kcal/kg of carbon)
C + 0.5 O2 = CO (+ 2410 kcal/kg of carbon)
CO + 0.5 O2 = CO2 (+ 2410 kcal/kg of carbon)
H2 + 0.5 O2 = H 2O (+ 33865 kcal/kg of H2)
S + O2 = SO2 (+ 2210 kcal/kg of S)
These calculation help estimating stoichiometric air required. Calorific values are estimated in
laboratory. (Some imperial formulae may be used for approximate estimates of cal-values for
different fuels).
Amount of stoichiometric air required is proportional to gross calorific value (GCV).

Approximately 1 kg air is required per 745 kcal of GCV.
In practice, certain amount of excess air has to be supplied in order to compensate for the lack
of contact between fuel and oxygen. This amount will vary from 30 to 80% depending upon fuel
and furnace design. In some cases (e.g. external refractory lined furnaces) further excess air
needs to be supplied to limit furnace temperature below caking/ash softening temperature.
The total amount of air should be judiciously distributed as primary and secondary air. It shall be
noted that secondary air is very effective for combustion of gaseous products (including the CO
generated in the reducing zone of thick bed of low volatile matter fuels like coke). Pressure
required for primary air needs to be just sufficient to push it up to the top of fuel bed, without
pressurising the furnace. Secondary air should be supplied at high pressure through jets, which
will penetrate through the cross section of gas across it.
141
Chapter 10
On complete combustion of solid fuels, amount of CO2 gas generated, on stoichiometric basis
by volume is between 18 to 20% for most of the fuels. However, with practical amount of excess
air, best CO2 could be between 13 to 14%. More than 14% CO2 may be associated with
incomplete combustion and presence of CO in flue gas. If furnaces need extra air for cooling,
the CO2 may reduce to 7 to 10%.
142
Chapter 10
10.2 SOOT BLOWER (SITSON manual)
WHAT IS SOOT BLOWER?
Soot Blower is a mechanism consisting of Soot Blower head mounting box, branch element.
The function of Soot Blowers is to keep the Boiler clean & are not expected to remove slag
and old deposits which are the result of previous neglect. Steam passes through the head
and element throughout nozzles, cleaning the loose soot deposited on Boiler Tubes and
Super Heater coils and Economizer.
PROCEDURE TO ASSEMBLE THE RAKE TYPE SOOT BLOWER UNITS AT SITE
1) After opening of soot blower box, confirm physically that soot blower rotation is free.
2) Mark the position of soot blower mounting box on casing.
3) Drive end resting supporting bracket to be provide before full welding of mounting box.
4) Take care that soot blower is horizontal (i.e. perpendicular to casing)
5) Do not turn upside down the soot blower. See that bolted cover remains at the top
only.
6) Once soot blower box is tack welded & soot blower drive end is supported on bracket;
fixing of element & trolley has to be carried out from inside of casing.
7) Tack weld the rails (pipes) as per drawing at a distance shown from the center line of
element pipe
X 63.5 OD tubes
S.B. flange centre line.
Support these pipe in the end support at other end. Check that there is 10mm gap (min) end
cover plate and pipe (rail) end.
8) Mount element over rails.
9) Check free movement of trolley.
143
Chapter 10
10) Confirm that at least 3 rollers are touching at a time.
11) Full weld pipe ends.
12) Confirm gasket is put at flanged joint.
13) After full welding of mounting box check soot blower rotation is free.
14) Check whether movement of element is obstructed by casing or any other part.
15) Connect pipe line without putting any strain of soot blower. Do not use excessive force,
to match steam inlet flange with pipe line flange.
16) If furnace is pressured furnace then provide scavenging air connection after valve on
pipe line. This will not allow flue gases to enter inside element nozzles. Otherwise nozzles
will get chocked.
17) Provide sealing air connection, so that flue gases o not enter inside soot blower.
18) If soot blowers are laying for more than six months in open atmosphere then they
should be re-assembled, properly greased before erection is started.
19) Client should be informed about regular operation once in a shift oiling, greasing
points.
20) Gland packing should be tightened if steam leakage is observed. Gland packing to be
replaced if leakage is not stopping even after tightens.
21) Open soot blower covers clean from inside if dust is accumulated in the box. The
frequency will depend on the amount of dust accumulation in box.
22) Keep some spares in stock.
144
Chapter 10
HOW SOOT BLOWER OPERATES
Rake type soot blower has a head for moving the branch element to & fro. Element does not
rotate 3600 as other soot blowers.
The head consist of geared motor, valves, valve operating mechanism, S.S. Screw & moving
block; which is connected to branch element through additional pipe.
When soot blower starts, valve mechanism opens the valve and steam is blown through
specially designed nozzles. Nozzles are placed at pitch of coils. Heating surface is cleaned while
branch element moves to & fro.
Limit switch is provided at rear end which gives signal to reverse the geared motor direction.
After branch element traverses back, forward limit switch is operated and motor stops.
I. GENERAL INSTRUCTIONS:
1. Before putting Soot Blowers in operation, be sure that the Boiler is clean of all old deposits and
slag. The function of the Blower is to keep the Boiler clean, and they should to be expected to
remove slag and old deposits, which are the results of previous neglect
2. Soot Blowers should never be permitted to lie idle for several days at a time. As soon as the
fire is lighted in the Boiler, operation of the Blowers at regular intervals should begin, and should
continue until the Boilers are shut down if this is not done, soot may collect on the Boiler Tubes
and burn to slag. Slag may often form around the blower itself so that it is hard to turn; or
unequal heating, due to the blower remaining in one position for a very long time, may cause
deterioration as long as the boiler is in operation.
3. The highest efficiency is obtained by using the Soot Blower at regular intervals, these
intervals are to be determined by as careful a consideration of conditions as possible at that
time the blower are first put in operation in the absence of any better information the blowers
should be operated once every eight hours, or three times per day, in a twenty-four hours run.
4. The matter of proper drainage is one of vital importance if the blowers are to give good
cleaning services and satisfactory life. Moisture must not allow entering the elements. It not only
causes sticky soot (which may result in deterioration), corrosion in the outside piping (if there is
sulphar in the coal, or mineral in the steam) and a number of other unsatisfactory conditions. To
prevent this, the main valve should be kept closed, and the drain valve of the blower header
open, open valve when the blower are being used. When the blowers are to be used the
drain valve should be open after steam has been admitted into the header, until dry steam
appears at the end of the drain line, and should be left slightly open even when using the
blowers. The drain lines from the blower header should never be run to trap or automatic valve
and of possible should end at some point where the boiler room staff can see whether the
water or steam is coming out of it. The main valve should be tested from time to time to see
that it is tight, as a leaky valve will result in moisture in the header, even when the drainage is
145
Chapter 10
fairly good. No other apparatus should be connected to the steam header supplying the
blower. Main valve should be closed after soot blower cycle is completed.
II. FREQUENCY OF OPERATION:
Experience has shown that under normal conditions each soot blower unit should be
operated every eight hours to ensure best results, but this is not an arbitrary rule and the
frequency of blowing should be determined by the condition of the tube surfaces.
III STEAM CONNECTING PIPING:
It is essential that the pipe work should be made so that the drainage of the
condensation is properly carried out. Superheated steam should be used where possible.
Particular attention must be paid to the fact that there must be a continuous fall throughout the
system to allow for the drainage of condensate. Vertical branch pipes from the main supply
pipe to be as short as practically possible. All pipe line must be lagged. The drain valve should
always be slightly open, so that there is always a leakage in the closed position. This is done so
that any accumulation of moisture in the pipe, in the case of the main control valve leaking, is
eliminated.
ERECTION;
1. Before commencing to erect the soot blower drawings submitted by SITSON should be
carefully examined. Each blower has to be fixed for a particular position and soot blowers are
given numbers like SB1, SB2, as per G. A. Drawing of Soot Blower. The number is punched on
outlet flange of Soot Blower and inlet flange of element. While connecting both flanges the
match mark should match. Element are designed for a particular position on boiler and hence
care should be taken while connecting the element with Soot Blower. Wrong assembly causes
damages to Boiler Tubes and Soot Blower will not be useful.
2. While mounting the Soot Blower; care should be taken so that while steaming head should
be horizontal.
3. All Steam Lines, Drain Lines should be cared before connecting to soot blower of all grit and
cutting by blowing steam or air until they are clean.
4. While connecting Steam line no force should be exerted on Soot Blower flange to watch
the holes. In case of Boilers having Steel casing, care should be taken so that if location of
Soot Blower head changes piping also should be free to move with head, otherwise head
will not be horizontal while operating.
5. Erection of Soot Blower is very important point but it is being neglected by most of the
erectors assuming small auxiliary plant compared to boiler. Wrong erection of Soot Blower
results in damages of element and Soot Blower parts.
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Chapter 10
FREQUENCY OF OPERATION :
The interval between soot blowing periods should be determined by observation under
service condition.
As a guide line the boiler should be cleaned.
a) Shortly after start up when full W.P. obtained.
b) Approximately every eight-hour service.
The boiler should be on @ 75% load when soot blowing to ensure that increased gas velocity
through the boiler helps to carry away the loosened deposits originating from the soot blowing.
* Do not start two soot blowers at a time.
* Never run a soot blower without steam when boiler is running.
* Normal sequence of soot blowing is to follow the gas flow through the boiler. The first soot
blower to be Operated should be nearest the burner.
WARMING UP:
To avoid damage to the boiler and to the blowers necessitates the use of dry steam. Hence
it is important to use a
Certain procedure for warming up.
1) ‘Crack’ the steam supply valve to warm up the steam pipes to allow drainage of
condensate through the drain valves.
2) After approximately 5 minutes the drain valve has to be closed allowing the steam valve
to be opened fully.
SCAVENGE AIR / SCALING AIR:
Each blower is provided with air scaled mounting box with air inlet of 1" BSP. The inlet pressure
required should be 50 to 76mm of water gauge more than boiler furnace pressure. In
positive pressure installations it is necessary to fit separate scaling and scavenging air-piping
systems from the F.D. fan ducting.
147
Chapter 10
LIST FOR MOTORISED RAKE TYPE SOOT BLOWERS SPARES
Sr. No. Items
1. Screw SS304
2. G M nut
3. Thurst bearing
4. C I block
5. Feed pipe (ss)
6. Element pipe
7. Trigger arrangement
8. Geared motor
9. Gear
10. Pinion
11. Limit Switch
12. Gland Packing Set
13 Branch Element (Inside the boiler)
14 Railing Pipe (SS304)
15 Technician charges
148
Chapter 10
Motorised Rake Type Soot blowers
Recommended Lubrication Chart.
Lubrication Filling Obervation Method of QM per

Part Lubrication
Point Frequency Frequency Application Filling.
Fill from top

Geared HP 90 of geared
1. Six month 3 months 0.5 lit.
motor or equi. motor
Gears C.I. & One

2. Grease 15 days Apply manually 0.20 kgs
M.S. all month
Through hole
Oil
provided
3. Bracket bush Machine 15 days. Weekly 0.01 lit
Oil 45 On the bracket
Through nipple
Intermediate
4. Grease 15 days. Weekly provided on 0.01 kg.
Gears
double gear.
149

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Thermax has an extensive international marketing network. Headquartered in Pune (Western

Cooling & Heating Division:

Cooling & Heating Division: Heating Group (C&H-Heating)

Products and Services

The product technology facilitates use of wide range of fuels viz.,

 Light & Heavy Oil

 Cool Low and high Calorific values,

Non conventional / agro based fuels

 De-oiled cake etc.

Agro products Packaging

Bottling & beverages Drugs & pharmaceuticals

Breweries & distilleries Plywood

Chemical & petrochemicals Rubber

Engineering Edible oil / solvent extraction

Food & dairy Textile / Synthetic fibers

‘If you need the heat, we have the source’.

Chapter 3: Instrumentation, controls & Safeties

Chapter 4: Input Requirement

Chapter 5: Commissioning Process

Chapter 8: Troubleshooting 129

Chapter 9: Care of Idle Boilers

Chapter 10: Annexure 138

 It is expected that the personnel involved in Installation, Operation & Maintenance

 No amount of written communication can replace intelligent thinking & reasoning.

Fig:1.1 Shellmax Global

1.0 SHELLMAX GLOBAL BOILER

THREE FLUE PASS DESIGN:

INTERNAL REVERSAL CHAMBER

SINGLE OR DOUBLE FLUE

INDIAN BOILER ACT (IBR)

All boilers have to be designed, manufactured and inspected during manufacturing as

Fig: 1.2 Sectional View of Shellmax Global Boiler

1.2 PRODUCT FEATURES

 Higher water holding capacity  Optimum tube sizing maintains high

 Corrugated furnace (6 TPH & above  EFFIMIZER is Integrated Economizer

 Skid boiler assembly - Separate

1.3 Major Components of the Boiler:

1.3.1 Feed Water Pump:

Each pump is of adequate capacity and head to meet

Fig: 1.2 Boiler Feed Pump

Fig: 1.3 Electrical Control Panel

Fig: 1. 4 Oilon Burner

The components which are included in OPH station supplied are:

 Fuel Filter - duplex type -1 no

The fuel supply to the OPH station is given

1.3.5 FUEL PUMP- 12TPH and Onwards

1.3.6 FORCED DRAUGHT (FD) FAN-12TPH and onward for FO

The combustion air is supplied to furnace since this fan supplies

Fig: 1.11 Forced Draft Fan

1.3.7 OPTIONAL ACCESSORIES

Fig: 1.12 : Integral Economizer Arrangement

Boiler Efficiencies (IN %)

SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO / ECO

SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO / ECO

SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG/ECO

SM GLOBAL - TECHNICAL SPECIFICATIONS - 1 TO 16 TPH - 10.54/17.5 kg/cm2(g) / LO-NG/ECO