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OPERATION MANUAL

BOILER FOR FUEL OIL

( NBO -TYPE )

BOOSTER Boiler Co., Ltd.

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Summary of Contents for NBO

Page 1: ...OPERATION MANUAL BOILER FOR FUEL OIL NBO TYPE BOOSTER Boiler Co Ltd ...

Page 2: ...General 1 1 Part Name and Function for the Boiler 4 1 Part Name and Function for the Boiler Main Body 4 2 Part Name and Function for the Control Panel 5 3 Part Name and Function for the Burner 6 4 Part Name and Function for the Concentration Blowing off Assembly and the Oil Pump 7 1 2 Steam Generation System 8 1 From Water feeding to Steam Generation 8 2 Flow sheet 9 Chapter 2 Boiler Operation 2 1...

Page 3: ...18 3 2 Brief Maintenance Check and Cleaning Method 19 1 Check for the Soft Water 19 2 Check for the Concentration Blowing off Device 20 3 Check and Cleaning for the Oil Strainer 20 4 Check and Cleaning for the Oil Heater Strainer 20 5 Check and Cleaning for the Feed Water Strainer and the Concentration Blowing off Strainer 21 6 Check and Cleaning for the Water Level Electrode Bar 21 7 Check and Cl...

Page 4: ...ction 27 5 2 Instruction for Blowing off of Water 27 Chapter 6 Maintenance for Boiler 6 1 Cause and Countermeasure for Trouble 29 6 2 Maintenance Checksheet 30 6 2 After Service 31 Chapter 7 Reference Document 7 1 Piping Instruction for the Feed Water Pump 32 7 2 Piping Diagram for the Feed Water Pump 33 7 3 Piping Drawing for Softener 34 ...

Page 5: ...ing the steam and the moisture 6 Pressure gauge A gauge which indicates the steam pressure in the boiler 7 Air Extraction Valve A valve extracting air and draining water when blowing off 8 Water level gauge A gauge which indicates water level in the boiler 9 Motor for oil gear pump A motor which supplies fuel to the burner by pressurizing fuel 10 Ladder A structure to climb up to the top of the bo...

Page 6: ...ch for burner motor Controls the burner motor operation 6 Terminal board for power Connects between wire on the control panel and the external power 7 Magnetic switch for feed water pump Controls operation of the feed water pump 8 Magnetic switch for oil pump Controls operation of the oil pump 9 Circuit breaker Shut off when over current and electrical leakage 10 Terminal board Connects wiring in ...

Page 7: ...lower motor Rotates the blower for supplying combustion air 5 Blower body Impeller is included in it 6 Damper motor A device which controls capacity automatically for complete combustion 7 Flame eye flame detector A device which detects ignition or flame failure and have stop operation 8 Wind box A box which supplies air for combustion in the furnace 9 Solenoid valve A device which controls fuel s...

Page 8: ...ater 4 Oil heater It is used for heating the fuel for heavy oil 5 Concentration blowing off solenoid valve A solenoid valve which drains and shut off the blowing off water automatically 6 Oil pump motor A motor which rotates the oil pump 7 Oil pump coupling It connects the oil pump to the oil pump motor 8 Oil pump A equipment which pressurizes and supplies fuel to the burner 9 Oil strainer It is u...

Page 9: ... is removed the foreign substance through the oil strainer 29 30 53 is pressurized up to the specified pressure 15 Kg cm2 for light oil 20 Kg cm2 by the oil pump 32 and is sprayed through nozzle When using the B heavy oil or C heavy oil the oil is sprayed after heating by the oil heater 31 due to its high viscosity at the ambient temperature 3 Ignition The lighting bar makes spark by the raised vo...

Page 10: ...pressure gauge 50 Blowing off valve 17 High pressure gauge 51 Pressure gauge 18 Steam pressure gauge 52 Air extraction valve 19 Safety valve 53 Oil strainer 20 Concentration blowing off valve 54 Oil nozzle 21 Concentration blowing off strainer 55 Steam control valve 22 Concentration blowing off valve 56 Steam strainer 23 Concentration blowing off solenoid valve 57 Steam solenoid valve 24 Blowing o...

Page 11: ...ntrol panel 5 Push the manipulation switch push button for boiler operation 6 Check ignition condition in the low and high fire through the reflection mirror after normal operation 7 Open the main steam valve slowly when the steam pressure is reached up to 3 Kg cm2 Control panel 2 3 Operation Stop 1 Operation switch OFF 2 Power switch OFF after post purge 3 In case of using bunker C oil it is to b...

Page 12: ...e three position control method The burning gas is also to be able to verified visually and checked as follows 1 When the flame color is red and black smoke in the stack 1 Lack of combustion air damper closed 2 Oil spray is not performed smoothly due to dust in the nozzle 3 Oil temperature is too low 4 Interval between flame panel and diffuser is in appropriate 5 Oil quality is no good 2 When the ...

Page 13: ...y overload protection device is working and then shut off the magnetic switch to stop the motor for protection of it When the thermal relay is working the lamp indicating overcurrent is lit up warning alarm is buzzing and reset lever of the thermal relay is raised up about 2mm Pushing the reset lever after checking and corrective action Thermal relay of the magnetic switch for motor it will be reo...

Page 14: ...exhausting the water in the pump in the no load condition for about 5 seconds to remove the residue attached on the impeller When operation the pump manually push the magnetic switch of P 5 7 using the screwdriver and then operate it for 5 to 10 seconds Feed water pump 4 Air Extraction Method for the Oil Heater For Heavy Oil Operate the oil pump and open the air cock valve for air extraction until...

Page 15: ... fire angle position adjusting BLACK L4 Position adjusting cam for 1st return Returning position adjusting from high fire to low fire YELLOW L5 Adjusting cam for 2nd solenoid open position Position adjusting for 2nd solenoid valve opening movement RED L6 Position adjusting cam for 2nd opening angle High fire opening angle position adjusting 2 The Wire Colors of the Damper Motor Blue S0 Green R0 Bl...

Page 16: ...ning angle Middle fire opening angle position adjusting GREEN L3 Adjusting cam for 2nd solenoid open position Position adjusting for 2nd solenoid valve opening movement BLACK L4 Position adjusting cam for 1st opening angle Low fire opening angle position adjusting YELLOW L5 Adjusting cam for 3rd solenoid open position Position adjusting for 3rd solenoid valve opening movement RED L6 Position adjus...

Page 17: ...n Time Check Conversion Mode When pushing the conversion switch on the left side of the water level unit the LED lamp of the high fire medium fire and low fire are changed in sequence and the accumulated combustion time is indicated on the monitor Ex In case that the following indication are shown on the monitor when pushing the conversion switch a When the high fire PH lamp is lit up and 1 3 indi...

Page 18: ... then solenoid valve will be closed automatically Note 1 The time indicated on the combustion time accumulation device is operated even in the power interruption by the battery 2 The battery is charged automatically when power on and can be used about 10 000 hours per one charge 3 For time initiation 0000 hours 00 minutes 00 seconds the reset switch inside is used 9 Concentration Blowing off Devic...

Page 19: ...pen Residual combustion gas exhaust Circuit check of the flame detector in the control Damper close Ignition transformer operation 1st combustion ignition Ignition transformer operation stop 2nd combustion ignition Normal operation Protect Relay Combustion Controller a b Ignition time b b Normal combustion b a Post purge Safe time in case of intermittent pilot Safe time in case of interrupted pilo...

Page 20: ...limit switch close shut off Check the polarity of the flame detector Ignition transformer failure Fuel valve failure Lack of flame stability 1 1st safety time Power failure Flame detector failure 2 2nd safety time Power failure Ignition failure of the burner 1st solenoid valve shut off or too much air volume Weak flame current Fuel supply suspension 2nd combustion Operation Power failure Abnormal ...

Page 21: ...he Oil Strainer For heavy oil 1 Close the main valve of the oil tank and unscrew the lower drain plug for draining the foreign substance deposited in the strainer 2 Unscrew the bolts 6 for taking off the cap 3 Take off the filter and clean it by using light oil etc Oil Strainer for Heavy Oil For light oil 1 Take off the cap by unscrewing the cap nut 2 Clean the filter Note Careful attention is req...

Page 22: ...and remove the scale and dirt on it using the soft cloth When reassembling the electrode bar careful attention is required not so as to be changed the wire connection In order for prevention of wire connection error sequential disassembling and cleaning is recommended once per 3 months After checking and cleaning the water level gauge must be checked whether it is being operated in the normal cond...

Page 23: ...the burner assembly When reassembling reverse sequence is applied Burner for Heavy oil fuel 2 Cleaning for the Lighting Bar and the Diffuser Clean the carbon attached to the lighting bar and the diffuser which is caused for ignition failure or back fire at least once a month Refer to the burner drawings When assembling it after cleaning careful cautions to keep the correct distance between the edg...

Page 24: ...itoring and normal operation If flame monitoring failure of the flame detector the flame is failed 4 5 seconds after ignition Flame Detector 5 Check and Cleaning for the Solenoid Valve Clean the solenoid valve by the light oil or others The foreign substance on the solenoid valve seat heavy oil light oil causes the gas explosion the smoke and the hydraulic oil pressure drop B C oil 1st solenoid va...

Page 25: ...ntrols the feed water pump and burner automatically for superheating prevention by the electrical signal from the computer by sensing the water level When the water level dropped down to the low water level limit the combustion circuit of burner is shut off automatically when the water level is not reached to the high water level limit in the initial operation stage the blower is not operated and ...

Page 26: ...0 C the power is cut off Superheating Prevention Switch 4 2 Freezing Prevention For the place where is possible to freeze in the winter time the blowing off after operation finished should be performed and preserve the boiler with the blow valve and main steam valve closed And also open the upper and lower cock of the feed water pump and drain the water in the water feeding pipe refer to figure of...

Page 27: ...hickness of tube is to be thinned by damaging of surface and come to rupture Conclusively the boiler harm by the water is the scale and corrosion 2 Scale Protection 1 Softener Use The boiler water is to be the soft water which is removed the hardening elements of Ca and Mg dissolved in the water which become to the scale by the softener 2 Chemical Use BOOSTER Cleaning Detergent Direct Heating 182 ...

Page 28: ... operation finished The amount of water sample is about 500cc 5 2 Instruction for Blowing off of Water The tap water or underground water used for boiler water is transparent and is seen as not included any foreign substance but it has a lot of organic and inorganic matter such as calcium magnesium silica etc The softener cannot remove the other foreign substance but calcium and magnesium which is...

Page 29: ...1 5 2 kg cm2 the operation switch OFF 4 After post purge the power switch OFF 5 Open the blowing off valve and perform blowing off 6 If steam pressure is 0 kg cm2 open the air extraction valve and perform blowing off continuously After finished the blowing off close the blowing off valve 7 Power switch ON Close the air extraction valve when the water is feeded by the feed water pump and the air ha...

Page 30: ...ut indicated normal water level on the water level gauge 1 Contamination or cut off of the low water level electrode bar 1 Check and clean the low water level electrode bar 2 Earthing conductor cut off or incomplete contact Feed water pump is not stopped keep operating 1 Contamination or cut off of the high water level electrode bar 1 Check and clean the high water level electrode bar 2 Earthing c...

Page 31: ...is performing normally Combus tion Smoke O Check if smoke out Abnormal Low water level O Check the low level status indication lamp and buzz operation status Automatic control device Pressure shut off O Check for automatic ON OFF at the setting pressure Oil strainer O Disassemble and clean the filter every month Strainer O Oil heater Blowing off O Blow off the sludge and foreign substance Tube wat...

Page 32: ...owing information 1 Boiler Type indicated on the Name Plate 2 Manufacturing Number and Date indicated on the Name Plate 3 Trouble situation as detail as possible 4 Fuel type Occasionally the BOOSTER engineer could request the recheck for the trouble item In this case your corporation would be highly appreciated ...

Page 33: ... front side of the feed water pump 2 The length of each pipe is to be as built 3 When the feed water pump is BFME the diameter of the pump outlet is 25A therefore 25 20 socket is to be used No Part Name Specification 1 Nipple 40A 2 Strainer 40A 3 Reducer 40A 25A 4 Tee 25A 15A 5 Bushing 15A 10A 6 Compound Pressure gauge φ 75 7 Nipple 25A 8 Nipple 20A 9 Flexible 20A ...

Page 34: ...he ground the feed water pump position is above the ground Note 1 The elevation of the feed water tank outlet is to be above the one of the feed water pump outlet 2 The pump may be positioned in the side of the boiler and the feed water tank side 3 Prior to start the operation fill the water fully in the pipe between the feed water tank and the water level gauge through the water filling hole 4 Fo...

Page 35: ...r Pump and Feed Water Tank Note 1 The length of each pipe is to be as built 2 Piping connection of softener is to be TK 12 20 30 40 3 If softener inlet pressure water head is 1 5 Kg cm2 and below the pressurizing pump is to be installed ...

Page 36: ...ANG DISTRICT BEIJING CHINA CHINA CHINA CHINA TEL 010 6663 4691 FAX 010 6463 4692 Booster Boiler Service Reservation Cheju 064 743 1290 Chonan 041 575 9769 Chongju 043 215 0273 Chonju 065 253 1286 Chunchon 033 243 0628 Euijongbu 031 846 7191 Inchon 032 874 8258 Kangbuk 02 359 1459 Kangdong 02 438 0385 Kangnam 02 579 8870 Kwagju 062 371 8112 Masan 055 296 3565 Pohang 054 275 2871 Puchon 032 675 2005...

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