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TABLE OF CONTENTS

Table of contents
General (Vol.1)
Preface / conditions for use of manual............................................................................1
General guarantee information.......................................................................................2
Safety precaution.........................................................................................................3

System Concept (Vol.1)


Technical data.............................................................................................................4
Steam Water System....................................................................................................5
Pressure atomizing burner.............................................................................................6
Fuel Oil Supply Pressure atomizing burner.....................................................................7
Control system Aalborg OC..........................................................................................8
Drawings....................................................................................................................9
Spare Parts................................................................................................................10

Aalborg OC boiler (Vol.1)


Descriptions..............................................................................................................11
Operation and maintenance.........................................................................................12
Feed and boiler water.................................................................................................13
Water level gauge......................................................................................................14
Safety valves.............................................................................................................15
Feed water system......................................................................................................16
Feed water pump unit.................................................................................................17
Salinity alarm equipment............................................................................................18
Oil detection equipment..............................................................................................19

Pressure atomizing burner (Vol.1)


Descriptions..............................................................................................................20
Operation and maintenance.........................................................................................21
Cooler unit................................................................................................................22
Fuel oil pump unit......................................................................................................23

Aalborg OC control system (Vol.1)


Aalborg control system...............................................................................................24
Operation of the panels...............................................................................................25
Language UK

TABLE OF CONTENTS

Commisioning and service..........................................................................................26


Burner sequence diagram............................................................................................27
Fuel flush sequence diagram........................................................................................28
Oil pump control........................................................................................................29
Flame safeguard.........................................................................................................30

Aalborg XS-2V boiler (Vol.2)


Descriptions..............................................................................................................1
Operation and maintenance.........................................................................................2
Feed and boiler water.................................................................................................3
Water level gauge......................................................................................................4
Safety valves.............................................................................................................5
Feed water system......................................................................................................6
Feed water pump unit.................................................................................................7
Steam dump equipment...............................................................................................8

Spare Parts Catalogue (Vol.2)


Spare parts for boiler..................................................................................................9
Spare parts for KBO-E 13-M.......................................................................................10

ii

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TABLE OF CONTENTS

Table of contents
Preface / conditions for use of manual
Description
Preface / conditions....................................................

Language UK

Document ID
Page
SD9010_40..................
1-2

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SD9010_40#B.1
PREFACE / CONDITIONS

Preface / conditions
1

Preface / conditions for use of manuals


1.1 Introduction
The present (set of) manual(s) have been produced with the intension of giving the
user the greatest benefit in relation to the scope of supply supplied by Alfa Laval.
However unless the user do read and understand the manual(s) in its full extend, this
may not be the result why it is important to emphasize that this takes place as intended.

1.2 Prequalification / required basic knowledge


The content of the manual(s) has been developed on the basis that the user has both
the necessary engineering qualification, as well as the understanding and knowledge
of the normal design and operations for the complete plant, within the maritime field.

1.3 Content of manual(s)


The content of the manual(s) have been composed by a number of standard documents
as well as scope of supply related documents. The intension is to cover the scope of
supply delivered by Alfa Laval, and as such there might be areas of the total plant
which is not covered by this manual(s). Drawings with dimension for installations,
maintenance space, data sheets, etc. have to be observed with care in order to obtain
the correct result. Many of the instructions contain pictures, sketches and drawings for
information and guide line purpose and should be used as intended only.

1.4 Responsibility
It is the users responsibility to use the manuals as intended, and where not found
sufficient to raise the relevant questions.

1.5 Subject to change


The manual has been compiled with great care. However, it may be necessary within
the scope of product care to make changes to the product and its operation without
prior notice which are not contained in this manual. Alfa Laval are not liable for any
costs ensuing for this reason.

1.6 Disclaimer of liability


We have checked the contents of this manual for agreement with the hardware and
software described. Since deviations cannot be precluded entirely, we cannot guarantee
full agreement. However, the documents and data in this manual are reviewed regularly
and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed.

1-2 / 2

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TABLE OF CONTENTS

Table of contents
General guarantee information
Description
General guarantee information....................................

Language UK

Document ID
Page
SD9010_39..................
2-2

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SD9010_39#E.1
GENERAL GUARANTEE INFORMATION

General guarantee information


1

Guarantee agreement and conditions


The guarantee agreement and conditions for the boiler plant are agreed on the contractual stage, and keep valid as long as the contract is in force. The guarantee agreement can not be transferred to another party without a written agreement with Alfa
Laval.

1.1 Conditions
The guarantee does not cover normal wear and tear on parts, unless this is stated in the
guarantee agreement, or if the plant/items are not operated or handled as intended per
the instruction manuals. Typical parts which are not covered by the guarantee due to
normal wear and tear is, but not limited to, Photo cells, Electrodes, Burner Nozzles,
Mechanical Seals, Bearings, Pump Impellers and Spindles, Gaskets, Water Level
Glasses, Refractory, Filter elements, Diaphragm of Membrane Pumps, and Valves
Stem seals. Typical items which are not covered due to wrong operation conditions
include, but not limited to, are: Valve damages, Pump Impellers and Spindles due to
foreign matters in the fluid.

1.2 Trouble shooting


Normal trouble shooting in order to identify failing items are not covered by the guarantee, however guidance by e-mail are available for such when needed.

1.3 Requirement for support


When needed support can be obtained, and if so following should be informed in order
to make the process smooth and fast.

Order number (is typically mentioned both on the outside of the instruction manual,
and on the first pages with the technical data of the plant
Short description of the observed trouble
Which alarms has been activated, and in which burner sequence step
If the failing item is known, the Tag number or Data Sheet number, and serial
number
Photos which can support the process
Use English language

1.4 Guarantee claim handling


Claim handling has to follow the contractual flow and condition. This means that a
claim has to be issued to the vendor, including the above mentioned information. This
causes that yard, or other dealers, in between the user and Alfa Laval has to be part of
a claim flow. This process might slow down the response time and therefore, in emer-

2-2 / 3

Language UK

SD9010_39#E.1
GENERAL GUARANTEE INFORMATION

gency matters where prompt action may be needed, Alfa Laval accept to be contacted
directly, provided this takes place as a parallel flow (cc in correspondence) not overruling the normal contractual flow and conditions.

Language UK

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TABLE OF CONTENTS

Table of contents
Safety precaution
Description
Safety precautions.....................................................

Language UK

Document ID
Page
SD9010_41..................
3-2

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SD9010_41#B.1
SAFETY PRECAUTIONS

Safety precautions
1

Purpose
The purpose of this document is to lay down general guidelines and precautions to the
user of the plant, and its components, in connection with operation and maintenance
of the plant, in order to ensure the safety of personnel as well as of the plant.
It is important to study the instruction manuals carefully and observe the warnings
before installation, operation, service and maintenance. Not following the instructions
can result in serious accidents.
In order to make the information clear and understandable, only foreseeable conditions
have been considered. No warnings are given for situations arising from the unintended
usage of the machine and its tools. The plant and its components shall be used as
intended only.

1.1 Exception
This document does not overrule other precautions given for specific equipment(s)
operations and maintenance instructions.

1.2 Education
The user of the equipment must be in possession of an education relevant for the operation and maintenance of the plant.
Operation and maintenance work must only be carried out by qualified and authorized
personnel.

1.3 Working clothes


Protective clothes must be of tight-fit.
If there is a possibility of your face coming in contact with metal splinters or dust, you
should wear a full face protection mask with protective goggles.
Always wear safety boots if there is a risk of heavy objects turning over, slipping off
or falling down and squashing your feet.
Use heat protective gloves to protect fingers and hands towards hot items.
Use ear protection in noisy environments.

1.4 Tools
As a measure to avoid injuries, only suitable/professional tools and working aids must
be used for maintenance, adjustment and repair work.

1.5 Lifting
Use correct lifting tools and follow lifting instructions.
Do not work under a hanging load.

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SD9010_41#B.1
SAFETY PRECAUTIONS

1.6 General maintenance and fault rectification practice


Allow the unit to cool prior to servicing and maintenance work to avoid injury through
high temperatures.
Necessary installation, service and inspection work should be carried out at the specified time.
Inform relevant staff before beginning any service work.
For all service, inspection and repair work, electrically isolate the equipment and ensure
the mains switch cannot be accidentally switched back on. Cut off the fuel supply.
If, during servicing or testing, seal/joints/packings have to be opened, these have to be
thoroughly cleaned to ensure tight sealing when re-assembling.
Damaged seals/joints/packings must be replaced. Carry out a pressure/leak test!
Flame monitoring devices, limit controls, correcting elements and all other safety devices must be commissioned by, and may only be replaced by, the manufacturer or
authorized personnel.
Screwed connections, which have been loosened, must be re-tightened without crossthreading.
Following service work, all related safety devices should be tested to ensure they are
functioning correctly.

1.7 Pressurized equipment and items


Always relieve the pressure before starting to work on pressure equipment and/or lines.
Close all shut-off valves. Vent all pressure lines.
Always be extremely careful when checking pressurized lines for leaks.
Pressure test with air/gas is dangerous, use hydraulic pressure test when possible.
Fluids or air escaping under pressure can penetrate clothes and skin.
Be careful when changing pressure hoses; mixing up pressure hoses by mistake may
reverse the function of the equipment.

1.8 Chemicals, cleaning agents, lubricants, etc.


When using/handling chemicals, cleaning agents, and similar articles make sure you
follow the general rules and regulations of protection as well as the suppliers recommendation regarding ventilation, personnel protection etc.

1.9 Electrical equipment


Make sure that the electric power supply is disconnected/switched off in relation to
maintenance. The touching of parts, which are connected to the electric power supply,
can cause immediate loss of life.
Always secure non-insulated and uncovered power lines and connectors against unintended touching.
Electric components stored and unused for longer periods of time should be carefully
inspected before use, to ensure that the integrity of any electrical insulation remains
intact.
Always check on wet electric components to determine whether parts that could be
touched are electrically live.

Language UK

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SD9010_41#B.1
SAFETY PRECAUTIONS

When working on high voltage equipment/groups, connect the mains supply cable to
earth after disconnecting/switching the power supply off in order to discharge components such as capacitors.

1.10 Hinged equipment


When opening doors or swinging out hinged equipments/parts, these must be fixed in
position during maintenance in order to prevent unintended movement of the item, for
instance due to ships rolling.

1.11 Valves
Shut-off valves may leak due to impurities or wear, whereas it must be ensured that
fluids, air or steam which might leak through, will not cause any dangerous situation
in connection with maintenance.
Do always disconnect actuators both electrically and pneumatically in case of maintenance and trouble shooting.
Do never use the fingers to check automatic valves as there might be springs which
may suddenly release their power always use tools for this purpose.

1.12 Rotating equipment


Rotating equipment must always be disconnected, electrically and/or hydraulically
and/or pneumatically, in connection with maintenance.
Do not touch rotating machines/parts when in operation.

1.13 Hot surfaces/equipment


Depending on the operating conditions many items may reach a temperature which
can harm the human body, for instance the boiler, all pipe lines, valve and actuator,
etc. Always let these items cool down before touching it or wear protective gloves.

1.14 Warning signs


Always follow the instructions given in relation to warning signs attached to parts and
machinery.

1.15 Alterations to the construction of the equipment


No alterations to the equipment are to be made without the approval of the manufacturer.
Any parts not in perfect working order should be replaced immediately.
No additional components may be fitted, which have not been tested for use with the
equipment.
Parts from other manufacturers are not guaranteed to be suitable to meet the necessary
operational and safety requirements.

1.16 Spare parts


Use only Alfa Laval genuine spare parts. Parts from other manufacturers are not guaranteed to be suitable to meet the necessary operational and safety requirements.

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SD9010_41#B.1
SAFETY PRECAUTIONS

1.17 Waste disposal


All materials used should be handled and disposed of correctly, with due regard to the
environment and valid rules/regulations/law.
Note: In case of any doubts please contact Alfa Laval.

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TABLE OF CONTENTS

Table of contents
Technical data
Description
Technical data for boiler plant.....................................
Technical data for Aalborg OC....................................
Technical data for Aalborg XS-2V...............................
Technical data for feed water pumps - OC....................
Technical data for feed water pumps XS-2V..............
Technical data for fuel oil pumps G147........................
Technical data for Cooler G429...................................

Language UK

Document ID
Page
106393........................
4-2
106393........................
4-3
106393........................
4-6
106393........................
4-8
106393........................
4-9
106393........................ 4-10
106393........................ 4-12

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TECHNICAL DATA FOR BOILER PLANT

Technical data for boiler plant


1

General data

General plant data

Classification society:......................................................................................BV
Sub-notification (Unattended operation):.............................................AUT-UMS
Service level:...........................................................................................Essential
Flange standard:...............................................................................................EN
Plant supply voltage:..............................................................................3 x 440 V
Plant control voltage:...................................................................................230 V
Pilot voltage:..................................................................................................24 V
Frequency:...................................................................................................60 Hz
Pressure gauge calibration:........................................................................MPa(g)
Thermometer calibration:...................................................................................C
Language on signs:....................................................................................English
Ambient air temperature:..............................................................................45 C

Documentation data

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Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443

Language for manuals:..............................................................................English


Set of approval manuals:.........................................................................8 + 1 CD
Set of working manuals:..........................................................................7 + 1 CD
Set of instruction manuals:..............................................................7 sets/per ship
Set of CD-rom instruction manuals:.................................................1 CD/per ship
Document revision date:...................................................................15 JAN 2013

Language UK

TECHNICAL DATA FOR AALBORG OC

Technical data for Aalborg OC


1

General data

Dimensions for boiler unit

Steam output, simultaneous operation:..................................................1,800 kg/h


Steam output, oil fired section:..............................................................1,400 kg/h
Steam output, exhaust section:.................................................................420 kg/h
Working pressure:..............................................................................0.70 MPa(g)
Working temperature:.................................................................................170 C
Max. allowable working pressure:.....................................................0.90 MPa(g)
Feed water operation:..................................................................................OnOff
Feed water temperature, layout:....................................................................85 C

Data for pressure part

Language UK

Height to top of smoke outlet box:.........................................................5,309 mm


Diameter incl. insulation:.......................................................................2,570 mm
Extension length of the water level device:............................See general arr. drw.
Weight of boiler unit excl. water:..............................................................15.3 ton
Weight of boiler unit incl. water:..............................................................23.9 ton

Water/steam process data

Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443

Boiler type:.......................................Vertical, composite smoke/water tube boiler


Boiler model:......................................................................................Aalborg OC
Test pressure:..........................................................1.5 x Design pressure MPa(g)
Protection of boiler body:.................................................................HeatResistant
Insulation thickness:...................................................................................75 mm
Cladding type:...............................................................................................Plain
Colour of insulation plates:..................................................................Galvanised

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TECHNICAL DATA FOR AALBORG OC

Combustion process data (oil-fired section)

Combustion process data (exhaust gas section)

Main engine:...........................................................................5S46ME-B8.2 - TII


Engine load, design:..............................................................................85 %MCR
Design condition:............................................................................................ISO
Exhaust gas flow:................................................................................37,700 kg/h
Inlet temperature of exhaust gas:.................................................................212 C
Outlet temperature of exhaust gas:..............................................................186 C

Data for pressure loss layout

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Min. calorific value of marine gas oil:...............................................42,200 kJ/kg


Min. viscosity of marine gas oil:......................................................2 cSt. at 40C
Max. viscosity ofmarine gas oil:.......................................................6 cSt. at 40C
Density of marine gas oil:.........................................................890 kg/m at 15C
Min. calorific value of diesel oil:.......................................................42,200 kJ/kg
Min. viscosity of diesel oil:..............................................................2 cSt. at 40C
Max. viscosity of diesel oil:............................................................11 cSt. at 40C
Density of diesel oil:.................................................................900 kg/m at 15C
Min. calorific value of fuel oil:..........................................................40,200 kJ/kg
Max. viscosity of fuel oil:.............................................................700 cSt. at 50C
Density of fuel oil:....................................................................991 kg/m at 15C
Turn down ratio on fuel oil:..............................................................................3:1
Fuel oil temperature before pre-heater:.........................................................60 C
Fuel oil viscosity at burner inlet:............................................................14-16 cSt.
Fuel oil temperature at burner inlet:............................................................145 C
Air excess No. at 100% load:............................................................................1.2
Flue gas temperature (clean boiler):............................................................322 C
Air consumption at 100% load:..............................................................1577 kg/h
Flue gas flow (approx.):.........................................................................1675 kg/h

Pressure loss across flue gas system, max.:...........................................10 mmWC


Pressure loss across boiler (oil-fired section):....................................56.0 mmWC
Pressure loss across boiler (exhaust gas section):................................110 mmWC

Language UK

TECHNICAL DATA FOR AALBORG OC

Data for burner

Data for control system

10

Power consumption for boiler plant, approx.:..............................................22 kW


Insulation class:...................................................................................................F
Degree of protection:......................................................................................IP54
Colour of boiler control panel:.....................................................Grey(RAL7035)
HMI unit:........................................................................................................Yes
Ethernet:...........................................................................................................No
MODBUS interface:.........................................................................................No

Operational data for boiler plant

Language UK

Burner type:.............................................................................Pressure atomizing


Burner regulation:...............................................................................Modulating
Model:.................................................................................Aalborg KBO-E-13M
Burner capacity on marine gas oil, min.:....................................................34 kg/h
Burner capacity on marine gas oil, max.:...................................................93 kg/h
Burner capacity on diesel oil, min.:............................................................34 kg/h
Burner capacity on diesel oil, max.:...........................................................93 kg/h
Burner capacity on fuel oil, min.:...............................................................34 kg/h
Burner capacity on fuel oil, max.:..............................................................98 kg/h
Nozzle:.............................................................................................12-W2-90-60
Flame tube:................................................................................................OD240
Diffuser disc:.............................................................................................165x60
Colour of burner unit:...........................................................................RAL 3002

Operation:......................................................................................24h unattended
Automatic mode:.............................................................................................Yes
Manual mode:..................................................................................................Yes
Emergency mode:............................................................................................Yes

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TECHNICAL DATA FOR AALBORG XS-2V

Technical data for Aalborg XS-2V


1

General data

Dimensions for boiler unit

Steam output per included boiler:.....................................390 kg/h (2 x 195 kg/h)


Working pressure:..............................................................................0.70 MPa(g)
Working temperature:.................................................................................170 C
Max. allowable working pressure:.....................................................0.90 MPa(g)
Feed water operation:..................................................................................OnOff
Feed water temperature, layout:....................................................................85 C

Data for pressure part

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Height excl. mountings and insulation:..................................................5,149 mm


Diameter incl. insulation:.......................................................................1,670 mm
Diameter excl. mountings and insulation:..............................................1,500 mm
Weight of boiler unit excl. water:................................................................7.1 ton
Weight of boiler unit incl. water:..............................................................13.5 ton

Water/steam process data

Request No.:...........................................................................................106393-3
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443

Boiler type:..............................Natural circulation exhaust gas boiler/ economiser


Boiler model:................................................................................Aalborg XS-2V
Test pressure:..........................................................1.5 x Design pressure MPa(g)
Protection of boiler body:.................................................................HeatResistant
Insulation thickness:...................................................................................75 mm
Cladding type:...............................................................................................Plain
Colour of insulation plates:..................................................................Galvanised

Language UK

TECHNICAL DATA FOR AALBORG XS-2V

Combustion process data

Data for pressure loss layout

Language UK

Main engine:.............................................................................MAN - 5L23/30H


Engine load, design:..............................................................................85 %MCR
Design condition:............................................................................................ISO
Exhaust gas flow:................................................................................10,180 kg/h
Inlet temperature of exhaust gas:.................................................................298 C
Outlet temperature of exhaust gas:..............................................................211 C

Pressure loss across boiler (excl. In/outlet boxes) at design load:......89.0 mmWC

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TECHNICAL DATA FOR FEED WATER PUMPS - OC

Technical data for feed water pumps - OC


1

General data

Data for pump

Pump operation type:...........................................................................Centrifugal


Pump type:...............................................................................................CR 3-17
Number of pumps:...............................................................................................2
F.W pump designed for simultaneous operation:.............................................Yes
Delivery head:.............................................................................................135 m
Pump capacity:.......................................................................................2.25 m/h
NPSH:..........................................................................................................1.7 m
Max. media temperature:............................................................................120 C
Weight of unit:...........................................................................................44.5 kg
Colour of unit:.............................................................................Makers standard

Data for pump motor

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Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443

Motor type:..................................................................................Makers standard


Power supply:........................................................................................3 x 440 A
Rated output for motor:..............................................................................2.2 kW
Rated current:..................................................................................................4 A
Starting method:..........................................................................................Direct
Starting current:.............................................................................................39 A
Revolutions:.......................................................................................3,500 r.p.m.
Ambient air temperature:..............................................................................45 C
Insulation class:...................................................................................................F
Degree of protection:......................................................................................IP55
Numbers of cable gland size:....................................................................2 x M20

Language UK

TECHNICAL DATA FOR FEED WATER PUMPS XS-2V

Technical data for feed water pumps


XS-2V
1

General data

Data for pump

Pump operation type:...........................................................................Centrifugal


Pump type:................................................................................................CR1-15
Number of pumps:...............................................................................................2
Delivery head:.............................................................................................130 m
Pump capacity:.......................................................................................0.65 m/h
NPSH:..........................................................................................................0.8 m
Max. media temperature:............................................................................120 C
Weight of unit:...........................................................................................39.3 kg
Colour of unit:.............................................................................Makers standard

Data for pump motor

Language UK

Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443

Motor type:..................................................................................Makers standard


Rated current:.............................................................................................2.86 A
Starting method:..............................................................................Direct on-line
Starting current:.............................................................................................27 A
Rated output for motor:..............................................................................1.5 kW
Revolutions:.......................................................................................3,500 r.p.m.
Heating element (standstill):.........................................................................50 W
Standby heating:...............................................................................................No
Insulation class:...................................................................................................F
Degree of protection:......................................................................................IP55
Numbers of cable gland size:...................................................................2 x M20

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TECHNICAL DATA FOR FUEL OIL PUMPS G147

Technical data for fuel oil pumps G147


1

General data

Data for pump

Pump type:...........................................................................DLC-600-L5-1,1 cSt.


Pump operation type:...........................................................................Screw type
Delivery head:..........................................................................................3.3 MPa
Relief valve set point (factory set):...........................................................3.6 MPa
Oil temperature, maximum: .......................................................................150 C
Pump capacity at 1,1 cSt.: ..........................................................................282 l/h
Pump capacity at 380 cSt.:..........................................................................702 l/h
NPSH at 1,1 cSt. (including filter):...............................................................5,0 m
NPSH at 380 cSt. (including filter):..............................................................2,4 m
Weight of fuel oil pump unit:......................................................................175 kg

Data for pump motor

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Project No.:.....................................................................106393-01, -02, -03, -04


Hull No.:................................................GWS440, GWS441, GWS442, GWS443
Classification society: .....................................................................................BV
Pressure gauge calibration: ............................................................................MPa
Thermometer calibration: ..................................................................................C
Language for signs: ..................................................................................English
Colour of fuel oil pump unit: ...................................................Munsell 7,5BG7/2

Motor make: ....................................................................................................AC


Motor type:........................................................................................FCA-80 B-2
Power supply: ............................................................................3 x 440 V, 60 Hz
Rated output for motor:............................................................................1,32 kW
Revolutions:........................................................................................3408 r.p.m.
Ambient air temperature: .............................................................................50 C
Starting method: .........................................................................................Direct
Starting current:........................................................................................17,15 A
Operating current (full load):......................................................................2,45 A
Power consumption at 1,1 cSt.:..................................................................0,8 kW
Language UK

TECHNICAL DATA FOR FUEL OIL PUMPS G147

Language UK

Power consumption at 380 cSt.:...............................................................0,95 kW


Numbers of cable gland size:........................................................2 pcs. M25X1,5
Thermostat protection: ...............................................................................NONE
Insulation class:...................................................................................................F
Degree of protection:......................................................................................IP55

4-11 / 12

TECHNICAL DATA FOR COOLER G429

Technical data for Cooler G429


1

General data

Data for Cooler

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Project No.:.....................................................................106393-01, -02, -03, -04


Hull No.:................................................GWS440, GWS441, GWS442, GWS443
Classification society:......................................................................................BV
Pressure gauge calibration:.............................................................................MPa
Thermometer calibration:..................................................................................C
Language for signs:...................................................................................English
Colour of cooler unit:...............................................................Munsell 7.5BG7/2

Cooler type:................................................................................MX10 T16 L600


Number of coolers:..............................................................................................1
Marine gas oil capacity:.........................................................................3000 kg/h
Design pressure (oil side):........................................................................1.6 MPa
Design pressure (water side):....................................................................1.6 MPa
Marine gas oil inlet temperature:...........................................................max 60 C
Marine gas oil outlet temperature:................................................................54 C
Cooling media:........................................................Technical treated fresh water.
Cooling water amount:.......................................................................... 3900 kg/h
Cooling water inlet temperature:...................................................................36 C
Cooling water outlet temperature:.................................................................38 C
Weight of heat-exchanger:............................................................................50 kg
Pressure drop (oil side).................................................................. 0.004476 MPa
Pressure drop (water side).............................................................. 0.013528 MPa

Language UK

TABLE OF CONTENTS

Table of contents
Steam Water System
Tag Number
...................................
...................................
1C1, 1C301..................
1C184, 1C484..............
1C186, 1C486..............
1C2.............................
1C3, 1C303, 1C6, 1C7,
1C307, 1C24, 1C25......
1C4, 1C304, 1C5..........
1C9, 1C10, 1C11..........
1C16...........................
1C17...........................
1C18...........................
1C187, 1C487..............
1C198.........................
1C26...........................
1M169, 1M170............
1M7............................
1M8............................
1M10..........................
1M130........................
1H2, 1W32..................
3C1, 3C301..................
3C184, 3C484..............
3C186, 3C486..............
3C2.............................
3C3, 3C303..................
3C4, 3C304,3C5...........
3C6, 3C7, 3C27, 3C327,
3C24, 3C25..................
3C9, 3C10, 3C11..........
3C17...........................
3C18...........................
3C187, 3C487..............
3W16..........................
3C26...........................
3M169, 3M170............
3M7............................
3M8............................
3M10, 3C31, H14.........
3M130.1, 3M130.2.......
3H2, 3W32..................
3C33...........................
3C35...........................
3C48...........................
.

Language UK

Description
Steam/water system...................................................
List of parts - steam/water...........................................
Safety valve, DN 32/50, PN 40/16...............................
Expansion joint, DN 50..............................................
Remote pull for safety valve.......................................
Stop valve, angle, DN 80, PN 25.................................

Document ID
Page
X01_068199................
5-3
X01_068199................
5-5
2611171...................... 5-11
85Y_013421................ 5-13
K03_032121................ 5-15
2511093...................... 5-17

Stop valve, straight, DN 25, PN 25..............................


Stop valve, straight, non return, DN 25, PN 25..............
Stop valve, straight, DN 8, PN 160..............................
Gate valve, straight, 1 1/2"..........................................
Water level gauge, left, 2 x 6, DN 25, PN 25.................
Water level gauge, right, 2 x 6, DN 25, PN 25...............
Remote pull for water level gauge................................
Stop valve, gate straight, DN 50, PN 10........................
Safety valve, DN 15, PN 100......................................
Feed water pump, type CR3-17...................................
Pressure gauge, 100.................................................
Pressure gauge, 100.................................................
Needle valve, straight, " x ", PN 400.......................
Remote start/stop box.................................................
LED indicator / limit switch........................................
Safety valve, DN 32/50, PN 40/16...............................
Expansion joint, DN 50..............................................
Remote pull for safety valve.......................................
Stop valve, straight, non return, DN 40, PN 25..............
Stop valve, angle, DN 25, PN 25.................................
Stop valve, straight, non return, DN 25, PN 25..............

2501088......................
2641088......................
6220000002.................
2931116......................
7010000431.................
7010000430.................
K03_032122................
2531005......................
6040000050.................
5540000049.................
8050000045.................
6666016......................
2541002......................
8001000003.................
8001000002.................
2611171......................
85Y_013421................
K03_032121................
2641090......................
2511088......................
2641088......................

5-18
5-19
5-20
5-21
5-22
5-24
5-27
5-29
5-30
5-31
5-34
5-35
5-36
5-37
5-38
5-40
5-41
5-43
5-45
5-46
5-47

Stop valve, straight, DN 25, PN 25..............................


Stop valve, straight, DN 8, PN 160..............................
Water level gauge, left, 2 x 6, DN 25, PN 25.................
Water level gauge, right, 2 x 6, DN 25, PN 25...............
Remote pull for water level gauge................................
Water level control unit (dp), DN 25............................
Safety valve, DN 15, PN 100......................................
Feed water pump, type CR 1-15..................................
Pressure gauge, 100.................................................
Pressure gauge, 100.................................................
Needle valve, straight, " x ", PN 400.......................
Remote emergency stop..............................................
LED indicator / limit switch........................................
Pressure gauge, 100.................................................
Pressure switch RT30AW 1-10 Bar.............................
Pressure transmitter 0 - 10 bar(g).................................

2501088......................
6220000002.................
7010000431.................
7010000430.................
K03_032122................
70Z_036686................
6040000050.................
5541002014.................
8050000045.................
6666016......................
2541002......................
8000000016.................
8001000002.................
6632973......................
6310310......................
8010000022.................

5-48
5-49
5-50
5-52
5-55
5-57
5-59
5-60
5-63
5-64
5-65
5-66
5-67
5-69
5-70
5-72

5-1 / 93

TABLE OF CONTENTS

3N5.............................
3N6.............................
M82............................
M83............................
M84............................
M85............................
M86............................
M87............................
M89............................
M145.1........................
M145.2........................
M146.1........................
M146.2........................
M146.3........................
M25............................
H3..............................
C191...........................
(c.fl.)...........................

5-2 / 93

Pneumatic control valve, DN 32, PN 25, with DP actuator


and I/P positioner.......................................................
Filter regulator with automatic drain............................
Stop valve, straight, DN 15, PN 25..............................
Filter, DN 15, PN 25..................................................
Control valve, DN 15, PN 25......................................
Temperature switch....................................................
Check valve, DN 15, PN 40........................................
Vacuum breaker, 1/2", PN 40......................................
Steam injector, 1/2", PN 25.........................................
Ultrasonic sensor for oil detection equipment................
Control unit for oil detection equipment.......................
Conductive electrode..................................................
Control device, salinometer.........................................
T-piece for salinity alarm equipment............................
Sample cooler...........................................................
Pressure transmitter 0 - 16 bar(g).................................
Water washing hose with nozzle..................................
Counter flange...........................................................

6050000240.................
2915101......................
2501086......................
7040000041.................
6050000458.................
8070000023.................
6020000101.................
6000000121.................
7000000085.................
8310000005.................
8210000025.................
8620000104.................
8210000032.................
8500000115.................
8750005......................
8010000023.................
2941001......................
K16_004096................

5-73
5-75
5-76
5-77
5-78
5-79
5-80
5-81
5-82
5-83
5-84
5-85
5-86
5-87
5-88
5-90
5-91
5-93

Language UK

X01_068199#A.2
STEAM/WATER SYSTEM

Steam/water system

Language UK

5-3 / 93

5-4 / 93

Language UK

LIST OF PARTS - STEAM/WATER

List of parts - steam/water


Boiler plant:.......................................................................................1 x Aalborg OC + 1 x Aalborg XS-2V
Request number:................................................................................................................................106393
Configuration number:............................................................................................................................1+ 3
Hull number(s):..............................................................................GWS440, GWS441, GWS442, GWS443
Project number(s):................................................................106393-01, 106393-02, 106393-03, 106393-04
P&I diagram drawing number:...................................................................................................X01_068199
P&I diagram revision:..................................................................................................................................e
Date:..........................................................................................................................................03 JUL 2013
Reading guide:
List of Parts reflects parts delivered by Alfa Laval.
Tag Numbers are given without the index used on the P&I diagram. E.g. C2" is found on the P&I Diagram
as "1C2" and "2C2" for boiler 1 and 2 respectively.

1
Tag no.

Aalborg OC boiler
Qty.

Dim (DN)

Application

Composite boiler (Qty. gives the number of parts per boiler)


C
1
N/A
Aalborg OC
C1
1
32/50
Safety valve
C301
1
32/50
Safety valve
C184
1
50
Expansion joint for safety valve
C484
1
50
Expansion joint for safety valve
C186
1
N/A
Remote pull for safety valve
C486
1
N/A
Remote pull for safety valve
C2
1
80
Main steam valve
C3
1
25
Feed water valve
C303
1
25
Feed water valve
C4
1
25
Feed water valve
C304
1
25
Feed water valve
C5
1
25
Scum valve
C6
1
25
Scum valve
C7
1
25
Blow down valve
C307
1
25
Blow down valve
C9
1
1/2"
Sample valve
C10
1
1/2"
Air escape valve
C11
1
1/2"
Gauge board valve
C16
1
1 1/2"
Furnace drain valve

Language UK

Type

Datasheet or drawing

Safety
Safety
Stop
Stop
Stop
Stop SDNR
Stop SDNR
Stop SDNR
Stop
Stop
Stop
Stop
Stop
Stop
Gate

04Y_068234
2611171
2611171
85Y_013421
85Y_013421
K03_032121
K03_032121
2511093
2501088
2501088
2641088
2641088
2641088
2501088
2501088
2501088
6220000002
6220000002
6220000002
2931116

5-5 / 93

LIST OF PARTS - STEAM/WATER

C17

25 / length
Water level gauge left
Reflective
7010000431
700
C18
1
25 / length
Water level gauge right
Reflective
7010000430
700
C187
1
N/A
Remote pull for water level gauge
K03_032122
C487
1
N/A
Remote pull for water level gauge
K03_032122
C198
1
50
Drain valve for exhaust gas part
Gate
2531005
W33
1
100
Water level meas. electrode
8125000010
Smoke outlet - Aalborg OC (Qty. gives the number of parts per boiler)
C179
1
Smoke outlet
Heating coil - Aalborg OC (Qty. gives the number of parts per boiler)
C24
1
25
Valve for heating coil inlet
Stop
2501088
C25
1
25
Valve for heating coil outlet
Stop
2501088
C26
1
1/2" / 3/4"
Safety valve for heating coil
Safety
6040000050
Feed water pump - Aalborg OC (Qty. gives the number of parts per boiler)
M169
1
32
Feed water pump
CR3-17
5540000049
M170
1
32
Feed water pump
CR3-17
5540000049
*M7
2
1/4"
Pressure gauge
-1 - +3 bar
8050000045
*M8
2
1/4"
Pressure gauge
0-25 bar
6666016
*M10
4
1/4"
Instrument valve
2541002
M130
1
Remote start/stop box
double
8001000003
Remote indication - Steam pressure and Water level - Aalborg OC (Qty. gives the number of parts per boiler)
H2
1
N/A
Remote indication ofSteam pressure
Digital
8001000002
W32
1
N/A
Remote indication ofWater level
Digital
8001000002
Gauge Board - Aalborg OC (Qty. gives the number of parts per boiler)
C30
1
Gauge board (Specified on the fuel oil diagram
61Z_050525
or connection"M"/"T" on the burner diagram therefore not shown on water/steam P&I-diagram).
Control system - Aalborg OC
L2
1
Local control panel
9306000025

5-6 / 93

Language UK

LIST OF PARTS - STEAM/WATER

2
Tag no.

Aalborg XS-2V boiler


Qty.

Dim (DN)

Application

Type

Datasheet or drawing

Exhaust gas fired boiler - Aalborg XS-2V (Qty. gives the number of parts per boiler)
C
1
N/A
Aalborg XS-2V
10Y_067260
C1
1
32/50
Safety valve
Safety
2611171
C301
1
32/50
Safety valve
Safety
2611171
C184
1
50
Expansion joint for safety valve
85Y_013421
C484
1
50
Expansion joint for safety valve
85Y_013421
C186
1
N/A
Remote pull for safety valve
K03_032121
C486
1
N/A
Remote pull for safety valve
K03_032121
C2
1
40
Main steam valve
Stop SDNR
2641090
C3
1
25
Feed water valve
Stop
2511088
C303
1
25
Feed water valve
Stop
2511088
C4
1
25
Feed water valve
Stop SDNR
2641088
C304
1
25
Feed water valve
Stop SDNR
2641088
C5
1
25
Scum valve
Stop SDNR
2641088
C6
1
25
Scum valve
Stop
2501088
C7
1
25
Blow down valve
Stop
2501088
C9
1
1/2"
Sample valve
Stop
6220000002
C10
1
1/2"
Air escape valve
Stop
6220000002
C11
1
1/2"
Gauge board valve
Stop
6220000002
C17
1
25 / length
Water level gauge left
Reflective
7010000431
700
C18
1
25 / length
Water level gauge right
Reflective
7010000430
700
C187
1
N/A
Remote pull for water level gauge
K03_032122
C487
1
N/A
Remote pull for water level gauge
K03_032122
C27
1
25
Stop valve, DP Unit
Stop
2501088
C327
1
25
Stop valve, DP Unit
Stop
2501088
W16
1
25
Water level control
DP control
70Z_036686
unit
Heating coil - Aalborg XS-2V (Qty. gives the number of parts per boiler)
C24
1
25
Valve for heating coil inlet
Stop
2501088
C25
1
25
Valve for heating coil outlet
Stop
2501088
C26
1
1/2" / 3/4"
Safety valve for heating coil
Safety
6040000050
Feed water pump - Aalborg XS-2V (Qty. gives the number of parts per boiler)
M169
1
32
Feed water pump
CR1-15
5541002014
M170
1
32
Feed water pump
CR1-15
5541002014
M7
2
1/4"
Pressure gauge
-1 - +3 bar
8050000045
M8
2
1/4"
Pressure gauge
0-25 bar
6666016
M10
4
1/4"
Instrument valve
2541002
M130.1
1
Remote stop box
8000000016
M130.2
1
Remote stop box
8000000016
Remote indication - Steam pressure and Water level - Aalborg XS-2V (Qty. gives the number of parts per boiler)
H2
1
N/A
Remote indication of Steam pressure
Digital
8001000002
W32
1
N/A
Remote indication of Water level
Digital
8001000002
Gauge Board - Aalborg XS-2V (Qty. gives the number of parts per boiler)

Language UK

5-7 / 93

LIST OF PARTS - STEAM/WATER

C30
C33

G "-m

Gauge board
Pressure gauge

C31
3
C35
1
C48
1
Steam dump valve
N5
1

1/2"
G 1/2"-m
G "-m

Instrument stop valve


Pressure switch, max. steam
Steam pressure transmitter

32

N6

1/4"

Steam dump control valve with pneumatic actuator


Filter regulator with auto. drain

5-8 / 93

1
1

0-16/1.6 bar/
kg/Mpa
Needle
0-10 bar
0-10 bar

61Z_050525
6632973

Control

6050000240

2915101

2541002
6310310
8010000022

Language UK

LIST OF PARTS - STEAM/WATER

3
Tag no.

Boiler Plant - Common


Qty.

Dim (DN)

Application

Hot well - steam injection


M82
1
15
Stop valve
M83
1
15
Strainer
M84
1
15
Control valve
M85
1
Temperature controller with probe
M86
1
15
Check valve
M87
1
1/2"
Vacuum breaker
M89
2
1/2"
Steam injector
Hot well - oil detection
M145
1
Oil detection equipment
M145.1
1
Sensor- 6 m cable
M145.2
1
Control unit
Salinity control
M146
1
Salinity control
M146.1
1
N/A
Salinity Electrode including wire
M146.2
1
N/A
Control device
M146.3
1
25
T-piece
Sample coolers
M25
1
N/A
Sample cooler
Common steam pressure measurement
H3
1
0-16 bar
Pressure transmitter
H14
1
1/2"
Pressure transmitter valve
Water hose and spray gun
C191
1
Water hose and spray gun
(not shown on the diagram)
Counter flanges
(c.fl.)
1
Set of counter flanges
(not shown on the P&I diagram)

Language UK

Type

Datasheet or drawing

Stop
Strainer
Control
Check
-

2501086
7040000041
6050000458
8070000023
6020000101
6000000121
7000000085

8310000005
8210000025

SL 78
SL 700
-

8620000104
8210000032
8500000115

SCS20

8750005

Stop

8010000023
2541002

2941001

K16:004096

5-9 / 93

DATA SHEET

50

125/ 4 x 18

Disc
29

115

165

330

Type:
Safety valve, full lift
25.912
Size:
Nominal diameter: DN 32/50
Application:
To blow off saturated steam, air or water
Material:
Body: GGG 40.3
DIN-Material No.: 0.7043
Seat: X6 Cr Ni Mo Ti 17122
DIN-Material No.: 1.4571
Disc: X35 Cr Mo 17
DIN-Material No.: 1.4122.05
Technical data:
Nominal pressure: PN 40/16
Weight: 14 kg
Flanges according to DIN
Inlet: DN 32, PN40
Outlet: DN 50, PN16

Min. 200

Tag No(s): 1C1, 1C301

Seat
Body

32
100 / 4 x 18
140
110

Type No.: 6040


Version: A.2

Language UK

Safety valve, DN 32/50, PN 40/16

2611171

5-11 / 93

5-12 / 93

Language UK

85Y_013421#B.1
EXPANSION JOINT, DN 50

Expansion joint, DN 50
1

Language UK

--- NO TITLE ---

5-13 / 93

85Y_013421#B.1
EXPANSION JOINT, DN 50

5-14 / 93

Language UK

K03_032121#C.1
REMOTE PULL FOR SAFETY VALVE

Remote pull for safety valve

Language UK

5-15 / 93

DATA SHEET

Tag No(s): 1C2


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN25
Weight: 22.6 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, angle
Size:
Nominal diameter: DN 80
Application:
For steam and/or water flow

265

32

200

Disc
Seat

155

Body

80
160 / 8 x 18
200
155

Type No.: 6010


Version: C.1

Language UK

Stop valve, angle, DN 80, PN 25

2511093

5-17 / 93

DATA SHEET

Tag No(s): 1C3, 1C303, 1C6, 1C7, 1C307, 1C24,


1C25
Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 5.4 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, straight
Size:
Nominal diameter: DN 25
Application:
For steam and/or water flow

Disc
Seat

25

85 / 4 x 14

115

190

13

140

Body

160

Type No.: 6010


Version: C.1

5-18 / 93

Stop valve, straight, DN 25, PN 25

2501088

Language UK

DATA SHEET

Tag No(s): 1C4, 1C304, 1C5


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 5.4 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop check globe valve, screw down non
return, straight
Size:
Nominal diameter: DN 25
Application:
For steam and/or water flow

Disc
Seat

25

85 / 4 x 14

115

190

13

140

Body

160

Type No.: 6030


Version: C.1

Language UK

Stop valve, straight, non return, DN 25, PN 25

2641088

5-19 / 93

DATA SHEET

Tag No(s): 1C9, 1C10, 1C11


Material:
Body: C 22.8
DIN- Material No. 1.0460

Type:
Instrument stop cone valve, straight, with
security plate
Size:
G " x 12
Nominal diameter: DN 8
Application:
For steam, water and/or air

Seat: X20 Cr13


DIN- Material No. 1.4021

Needle tip: X35 CrMo17


DIN- Material No. 1.4122
Technical data:
Nominal pressure: PN 160
Inlet: G " male DIN
19207, form R

Outlet: For steel tube 12


Weight: 0.8 kg

115

75

1/2 BSP

12

Security plate

22
90

Type No.: 6220


Version: A.2

5-20 / 93

Stop valve, straight, DN 8, PN 160

6220000002

Language UK

DATA SHEET

Tag No(s): 1C16


Type:
Gate valve, straight
Size:
Nominal diameter: 1 1/2"
Application:
Water, steam and diesel oil
Material:
Red brass
Technical data:
Max. working pressure: 16 bar
Max. temperature: 150C
Weight: 0.85 kg

53

Max. 126

70

1 "

23
57

Type No.: 6010


Version: A.2

Language UK

Gate valve, straight, 1 1/2"

2931116

5-21 / 93

DATA SHEET

Tag No(s): 1C17


Type:
Reflective water level gauge
Orientation: left
Model size: 26
9020
Size:
Connection, nominal: DN 25
Connection, drain: 10
Pressure rating:
Pressure of unit, nominal: PN 25
Pressure of connection valves, nominal:
PN 40
Pressure of drain valve, nominal:PN 40
Connection type:
Connection type: Flanges according to
DIN
Application:
For boiler water level indicator

Type No.: 7010


Version: B.1

5-22 / 93

Material:
Body: Carbon steel 45#
Connection valve body: WCB
Drain valve body: WCB
Technical data
Connection valves type: PX
Weight:16.3 kg
Dimension:
H: 700
H1: 530
H2:493
H3: 250
H4:160
H5:115
L: 84.5
W:125
W1:150
D: 10

Water level gauge, left, 2 x 6, DN 25, PN 25

7010000431

Language UK

DATA SHEET

Tag No(s): 1C17

W1
L

H1

H5

H4

H3

Visible length H2

Drain connection D

Type No.: 7010


Version: B.1

Language UK

Water level gauge, left, 2 x 6, DN 25, PN 25

7010000431

5-23 / 93

DATA SHEET

Tag No(s): 1C18


Type:
Reflective water level gauge
Orientation: right
Model size: 26
9020
Size:
Connection, nominal: DN 25
Connection, drain: 10
Pressure rating:
Pressure of unit, nominal: PN 25
Pressure of connection valves, nominal:
PN 40
Pressure of drain valve, nominal:PN 40
Connection type:
Connection type: Flanges according to
DIN
Application:
For boiler water level indicator

Type No.: 7010


Version: B.1

5-24 / 93

Material:
Body: Carbon steel 45#
Connection valve body: WCB
Drain valve body: WCB
Technical data
Connection valves type: PX
Weight:16.3 kg
Dimension:
H: 700
H1: 530
H2:493
H3: 250
H4:160
H5:115
L: 84.5
W:125
W1:150
D: 10

Water level gauge, right, 2 x 6, DN 25, PN 25

7010000430

Language UK

DATA SHEET

Tag No(s): 1C18

W1
L

H1

H5

H4

H3

Visible length H2

Drain connection D

Type No.: 7010


Version: B.1

Language UK

Water level gauge, right, 2 x 6, DN 25, PN 25

7010000430

5-25 / 93

5-26 / 93

Language UK

K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE

Remote pull for water level gauge


1

Language UK

5-27 / 93

DATA SHEET

Tag No(s): 1C198


Type:
Stop valve, gate straight
Size:
Nominal diameter: DN 50
Application:
Sea water, fresh water, oil, steam etc.
Material:
Body: GG 25
Technical data:
Nominal pressure: PN 10
Max. temperature: 150 C
Weight: 11.5 kg

Type No.: 6010


Version: A.2

Language UK

Stop valve, gate straight, DN 50, PN 10

2531005

5-29 / 93

DATA SHEET

3/4

189
34
15

Type:
Safety valve
Size:
Nominal diameter: DN 15
Inlet nominal: 1/2"
Outlet nominal: 3/4"
Pressure rating:
Nominal pressure: PN 100
Connection type:
Connection inlet: 1/2" Th-m-BSP
Connection outlet: 3/4 Th-f-BSP
Application:
To blow off steam, neutral gases, vapours and liquids
Material:
Body: GX5CrNiMoN19-11-2
DIN-material No.: 1.4581
Technical data:
Thread: DIN ISO 228 part 1
Set point: 22 bar
Weight: 1.2 kg

100

Tag No(s): 1C26

12
1/2
42

Type No.: 6040


Version: A.1

5-30 / 93

Safety valve, DN 15, PN 100

6040000050

Language UK

Technical
data
DATA SHEET

CR 3

Tag No(s): 1M169, 1M170


Net weight
[kg]

Pump
type

D1

G 1/2

B1

G 1/2

G 1/2

DIN

20

75

89
100
140

19 x 24.5

100
141
250

35

4 x 13.5

180
220

Oval

100
145
160

20

50

22

75
180
220

Electrical data

4 x 13.5

DIN flange

B2

D1

472

191

141 109

18.4

22.5

472

191

141 109

18.9

23.0

299

490

191

141 109

19.2

23.3

321

552

231

141 109

21.1

25.2

339

570

231

141 109

22.8

26.9

231

141 109

23.4

27.5

231

141 109

24.2

28.3
34.6

B1

B1 + B2

B1

B1 + B2

CR 3-2

256

447

281

CR 3-3

256

447

281

CR 3-4

274

465

CR 3-5

296

527

CR 3-6

314

545

CR 3-7

332

563

357

588

CR 3-8

350

581

375

606

D2

CR 3-9

384

665

409

690

281

178

110

30.5

CR 3-10

402

683

427

708

281

178

110

31.0

35.1

CR 3-11

420

701

445

726

281

178

110

31.5

35.6

CR 3-12

438

719

463

744

281

178

110

34.0

38.1

CR 3-13

456

737

481

762

281

178

110

34.2

38.3

CR 3-15

492

773

517

798

281

178

110

34.8

38.9

CR 3-17

528

809

553

834

281

178

110

35.3

39.4

CR 3-19

593

928

335

178

110

45.6

CR 3-21

629

964

335

178

110

46.4

CR 3-23

665

1000

335

178

110

47.2

CR 3-25

701

1073

372 220 134

57.1

TM02 0193 2501

Rp 1
M10 x 40

G 1/2

Oval flange

Oval

Dimensions [mm]

D2

B2

Dimensions and weights

3 x 220-255/380-440 V, 60 Hz
I
start
---------------I 1/1

Motor
P2 [kW]

Full load current


I1/1 [A]

Power factor
Cos 1/1

Motor efficiency
[%]

CR 3-2

0.37

1.58-1.46/0.91-0.84

0.88-0.82

78.0-79.0

4.80-6.00

CR 3-3

0.55

2.40-2.18/1.38-1.26

0.88-0.82

80.5-82.0

4.80-6.00

CR 3-4

0.55

2.40-2.18/1.38-1.26

0.88-0.82

80.5-82.0

4.80-6.00

CR 3-5

0.75

3.15-2.85/1.82-1.64

0.89-0.84

82.0-84.0

5.10-6.50

CR 3-6

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

CR 3-7

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

CR 3-8

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

Pump type

Electrical data
Pump type

3 x 220-277/380-480 V, 60 Hz
Motor
P2 [kW]

Full load current


I1/1 [A]

Power factor
Cos 1/1

Motor efficiency
[%]

I start
---------------I 1/1

CR 3-9

1.5

5.70-5.00/3.30-2.90

0.89-0.78

80.5-82.0

5.90-8.40

CR 3-10

1.5

5.70-5.00/3.30-2.90

0.89-0.78

80.5-82.0

5.90-8.40

CR 3-11

1.5

5.70-5.00/3.30-2.90

0.89-0.78

80.5-82.0

5.90-8.40

CR 3-12

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 3-13

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 3-15

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 3-17

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 3-19

3.0

10.6-9.00/6.10-5.20

0.90-0.83

85.0-86.0

7.40-11.0

CR 3-21

3.0

10.6-9.00/6.10-5.20

0.90-0.83

85.0-86.0

7.40-11.0

CR 3-23

3.0

10.6-9.00/6.10-5.20

0.90-0.83

85.0-86.0

7.40-11.0

CR 3-25

4.0

13.6-11.4/7.85-6.60

0.92-0.85

86.0-87.0

8.00-12.0

Version: E.1

Language
UK
Aalborg
Industries

DIN

Dimensional sketches

Feed water pump, type CR3-17

Data sheet No. 5540 000049

5540000049

5-31 / 93
1/3

General data

Vertical multistage centrifugal pumps

DATA SHEET

Tag No(s): 1M169, 1M170

CR 3

6
7

5
9
8

TM02 1194 0601Materials: CR, CRI, CRN 1, 3 and 5

10

Materials: CR
Pos.
1

Description
Pump head

Materials
Cast iron
EN-GJL-200

DIN W.-Nr.

AISI/ASTM

EN-JL1030

ASTM 25B

Shaft

Stainless steel

1.4401

AISI 316

Impeller

Stainless steel

1.4301

AISI 304

Chamber

Stainless steel

1.4301

AISI 304

Outer sleeve

Stainless steel

1.4301

AISI 304

O-ring for outer


sleeve

EPDM or FKM

Base

Cast iron
EN-GJL-200

EN-JL1030

ASTM 25B

Neck ring

PTFE

10

Shaft seal

Type cartridge

Rubber parts

EPDM or FKM

Version: E.1

5-32
/ 93 Industries
Aalborg

Feed water pump, type CR3-17

Data sheet No. 5540 000049

5540000049

Language UK

2/3

Performance
curves
DATA SHEET

CR 3

Tag No(s): 1M169, 1M170

p
[Mpa]

H
[m]
240

CR 3

-25

60 Hz
ISO 9906 Annex A

220
2.0

-23
-21

200
180

1.6

-19
-17

160

-15

140
1.2

-13

120

-12
-11

100
0.8

-10
-9

80

-8
-7

60

-6
-5

0.4

40

-4
-3

20
0.0

-2

0
0.0

0.4

0.0

0.8

1.2

0.2

1.6

0.4

2.0

2.4

0.6

2.8

3.2

0.8

3.6

4.0

1.0

4.4

4.8

1.2

5.2

1.4

Q [m/h]
Q [l/s]

P2
[hp]

P2
[kW]

0.16

0.12

P2

60

0.08

Eta

40

0.12

Eta
[%]

0.08

0.00

0.04

20

0.00

0
0.0

p
[kPa]
80
60

0.4

1.2

1.6

2.0

2.4

2.8

3.2

3.6

4.0

4.4

4.8

5.2

H
[m]

Q [m/h]

QH 3500 rpm

NPSH
[m]
6

40
20

0.8

NPSH

0
0.0

0.4

Version: E.1

Language
UK
Aalborg
Industries

0.8

1.2

1.6

2.0

2.4

2.8

3.2

3.6

4.0

4.4

Feed water pump, type CR3-17

Data sheet No. 5540 000049

4.8

5.2

Q [m/h]

TM02 1507 1301

0.04

5540000049

5-33 / 93
3/3

DATA SHEET

Tag No(s): 1M7


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Stainless steel
Liquid filling: Glycerine

Technical data:
Measuring unit: bar / Mpa / kg/cm
Measuring range: -1 to +3 / - 0.1 to +0.3 /
-1 to +3
Connection down: G -m BSP
Accuracy Class 1.0
Operating temperature, ambient : -20 to
+60C
Operating temperature, medium max:
+100C
Ingress protection: IP65 per EN 60 529 /
IEC 529
49.5

4.8

12
0

12

-1

bar
3
MPa=bar x 0.1
kg/cm

87

-1

117
BSP 1/2" -m

132

Type No.: 8050


Version: D.1

5-34 / 93

Pressure gauge, 100

8050000045

Language UK

DATA SHEET

Tag No(s): 1M8


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Cu-alloy
Liquid filling: Glycerine

Technical data:
Measuring unit: bar Mpa - kg/cm
Measuring range: 0 25 / 2.5/ 25 with
mechanical stop
Connection: BSP -m
Accuracy class: 1.0
Operating temperature:
Ambient: -20 to + 60C
Medium: + 60C maximum
Ingress protection: IP65 (EN 60 529 /
IEC 529)

48

4.8

12
0

12

bar
25
MPa=bar x 0.1
25
kg/cm

87

117
BSP 1/2" -m

132

Type No.: 8050


Version: B.1

Language UK

Pressure gauge, 100

6666016

5-35 / 93

DATA SHEET

Tag No(s): 1M10


Type:
Pressure gauge valve needle straight.
Size:
1/2 x 1/2
Application:
For instrument connections
Material:
Body: C22.8
DIN-material No. 1.0460
Technical data:
Nominal pressure: PN 400
Test connection: M20 x 1.5 mm threaded
male
Weight: 0.4 kg

Type No.: 6210


Version: C.1

5-36 / 93

Needle valve, straight, " x ", PN 400

2541002

Language UK

DATA SHEET

Tag No(s): 1M130


Technical data:
Nominal operating condition:
U = 600 V and I = 1.2 A or
U = 240 V and I = 3 A or
U = 120 V and I = 6 A
Protection: IP 65
Temperature: -25C to +70C

Type:
Remote start/stop box
Application:
For start/operation and stop of feed water
pumps
Material:
House: Polycarbonate
Colour: Grey

120
83

85

Feed water pumps


1
2

105

123

145

177

Start/operation
incl. lamp function

Stop

Cable glands M 32 (PG 29)


105

70

5.8

5.8

Type No.: 8001


Version: D.1

Language UK

Remote start/stop box

8001000003

5-37 / 93

DATA SHEET

Tag No(s): 1H2, 1W32

5714
1

OK

12
0

48

Type
LED indicator/limit switch
5714B
Application:

96

The 5714 with 2 relay outputs is designed


for digital readout of current / voltage or
temperature signals.
Relay outputs:
Are selected as either a make or a break
function. The relays can be used as a trip
amplifier.
Two yellow front LEDs indicate the relay status. The relays can be set up with
either delayed on or off. Active relay can
be selected for either an increasing or decreasing signal. The arrow keys can be
used for fast change of the set point.
Technical data:
Panel cut out: 44.5 x 91.5 mm
Weight: 230 g
Electrical specifications:
Common specifications:
Supply voltage:
Max. voltage: 24230 VA C, 10%50
60Hz
24250 VDC 20%
Internal consumption: 2.7W
Max. consumption: 3.0 W

Type No.: 8001


Version: E.1

5-38 / 93

Auxiliary voltages:
2-wire supply: 2516 VDC / 020 mA
EMC immunity influence: < 0.5% of
reading
Max. wire size: 1 x 2.5 mm
Relative air humidity:< 95% RH (non
condensing)
Tightness (mounted in a panel): IP65
Voltage input:
Measurement range: -20mV...12 VDC
Program measurement range :
01/0,21/010/210VDC
Input resistance: nominal 10 M
Current input:
Measurement range: -1...25 mA
Program, measurement range:
020 and 420mA
Input resistance:
Nominal20 + PTC 25
Sensor error detection: loop break
420mA..Yes
Display:
Display readout: -1999999 (4 digits)
Decimal point: programmable
Digit height: 13.8 mm
Display updating: 2.2 times/s
Input outside input range is indicated by:
Explanatory text
Relay outputs:
Relay function: setpoint
Hysteresis, in % display counts:
0.125%/12999
On and Off delay: 03600s
Max. voltage: 250 VRMS
Max. current: 2 A / AC
Max. AC power: 500 VA
Max. current at 24 VDC: 1A
Sensor error action: Make / break/hold

LED indicator / limit switch

8001000002

Language UK

DATA SHEET

Tag No(s): 1H2, 1W32

Connections

Supply

Input:
RTD, 2-wir e

Voltage

RTD, 3-wire

RTD, 4-wire

2-wire transmitter

Current

Potentiometer

Output:
Relays

R1

R2

Block Diagram

Type No.: 8001


Version: E.1

Language UK

LED indicator / limit switch

8001000002

5-39 / 93

DATA SHEET

50

125/ 4 x 18

Disc
29

115

165

330

Type:
Safety valve, full lift
25.912
Size:
Nominal diameter: DN 32/50
Application:
To blow off saturated steam, air or water
Material:
Body: GGG 40.3
DIN-Material No.: 0.7043
Seat: X6 Cr Ni Mo Ti 17122
DIN-Material No.: 1.4571
Disc: X35 Cr Mo 17
DIN-Material No.: 1.4122.05
Technical data:
Nominal pressure: PN 40/16
Weight: 14 kg
Flanges according to DIN
Inlet: DN 32, PN40
Outlet: DN 50, PN16

Min. 200

Tag No(s): 3C1, 3C301

Seat
Body

32
100 / 4 x 18
140
110

Type No.: 6040


Version: A.2

5-40 / 93

Safety valve, DN 32/50, PN 40/16

2611171

Language UK

85Y_013421#B.1
EXPANSION JOINT, DN 50

Expansion joint, DN 50
1

Language UK

--- NO TITLE ---

5-41 / 93

85Y_013421#B.1
EXPANSION JOINT, DN 50

5-42 / 93

Language UK

K03_032121#C.1
REMOTE PULL FOR SAFETY VALVE

Remote pull for safety valve

Language UK

5-43 / 93

DATA SHEET

Tag No(s): 3C2


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 10 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop check globe valve, screw down non
return, straight
Size:
Nominal diameter: DN 40
Application:
For steam and/or water flow

Disc
Seat

40

110 / 4 x 18

150

225

21

160

Body

200

Type No.: 6030


Version: B.1

Language UK

Stop valve, straight, non return, DN 40, PN 25

2641090

5-45 / 93

DATA SHEET

Tag No(s): 3C3, 3C303


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 5.6 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, angle
Size:
Nominal diameter: DN 25
Application:
For steam and/or water flow

165

13

140

Disc
Seat

100

Body

25
85 / 4 x 14
115
100

Type No.: 6010


Version: C.1

5-46 / 93

Stop valve, angle, DN 25, PN 25

2511088

Language UK

DATA SHEET

Tag No(s): 3C4, 3C304,3C5


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 5.4 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop check globe valve, screw down non
return, straight
Size:
Nominal diameter: DN 25
Application:
For steam and/or water flow

Disc
Seat

25

85 / 4 x 14

115

190

13

140

Body

160

Type No.: 6030


Version: C.1

Language UK

Stop valve, straight, non return, DN 25, PN 25

2641088

5-47 / 93

DATA SHEET

Tag No(s): 3C6, 3C7, 3C27, 3C327, 3C24, 3C25


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 5.4 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, straight
Size:
Nominal diameter: DN 25
Application:
For steam and/or water flow

Disc
Seat

25

85 / 4 x 14

115

190

13

140

Body

160

Type No.: 6010


Version: C.1

5-48 / 93

Stop valve, straight, DN 25, PN 25

2501088

Language UK

DATA SHEET

Tag No(s): 3C9, 3C10, 3C11


Material:
Body: C 22.8
DIN- Material No. 1.0460

Type:
Instrument stop cone valve, straight, with
security plate
Size:
G " x 12
Nominal diameter: DN 8
Application:
For steam, water and/or air

Seat: X20 Cr13


DIN- Material No. 1.4021

Needle tip: X35 CrMo17


DIN- Material No. 1.4122
Technical data:
Nominal pressure: PN 160
Inlet: G " male DIN
19207, form R

Outlet: For steel tube 12


Weight: 0.8 kg

115

75

1/2 BSP

12

Security plate

22
90

Type No.: 6220


Version: A.2

Language UK

Stop valve, straight, DN 8, PN 160

6220000002

5-49 / 93

DATA SHEET

Tag No(s): 3C17


Type:
Reflective water level gauge
Orientation: left
Model size: 26
9020
Size:
Connection, nominal: DN 25
Connection, drain: 10
Pressure rating:
Pressure of unit, nominal: PN 25
Pressure of connection valves, nominal:
PN 40
Pressure of drain valve, nominal:PN 40
Connection type:
Connection type: Flanges according to
DIN
Application:
For boiler water level indicator

Type No.: 7010


Version: B.1

5-50 / 93

Material:
Body: Carbon steel 45#
Connection valve body: WCB
Drain valve body: WCB
Technical data
Connection valves type: PX
Weight:16.3 kg
Dimension:
H: 700
H1: 530
H2:493
H3: 250
H4:160
H5:115
L: 84.5
W:125
W1:150
D: 10

Water level gauge, left, 2 x 6, DN 25, PN 25

7010000431

Language UK

DATA SHEET

Tag No(s): 3C17

W1
L

H1

H5

H4

H3

Visible length H2

Drain connection D

Type No.: 7010


Version: B.1

Language UK

Water level gauge, left, 2 x 6, DN 25, PN 25

7010000431

5-51 / 93

DATA SHEET

Tag No(s): 3C18


Type:
Reflective water level gauge
Orientation: right
Model size: 26
9020
Size:
Connection, nominal: DN 25
Connection, drain: 10
Pressure rating:
Pressure of unit, nominal: PN 25
Pressure of connection valves, nominal:
PN 40
Pressure of drain valve, nominal:PN 40
Connection type:
Connection type: Flanges according to
DIN
Application:
For boiler water level indicator

Type No.: 7010


Version: B.1

5-52 / 93

Material:
Body: Carbon steel 45#
Connection valve body: WCB
Drain valve body: WCB
Technical data
Connection valves type: PX
Weight:16.3 kg
Dimension:
H: 700
H1: 530
H2:493
H3: 250
H4:160
H5:115
L: 84.5
W:125
W1:150
D: 10

Water level gauge, right, 2 x 6, DN 25, PN 25

7010000430

Language UK

DATA SHEET

Tag No(s): 3C18

W1
L

H1

H5

H4

H3

Visible length H2

Drain connection D

Type No.: 7010


Version: B.1

Language UK

Water level gauge, right, 2 x 6, DN 25, PN 25

7010000430

5-53 / 93

5-54 / 93

Language UK

K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE

Remote pull for water level gauge


1

Language UK

5-55 / 93

K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE

5-56 / 93

Language UK

70Z_036686#D.1
WATER LEVEL CONTROL UNIT (DP), DN 25

Water level control unit (dp), DN 25


1

Language UK

--- NO TITLE ---

5-57 / 93

DATA SHEET

3/4

189
34
15

Type:
Safety valve
Size:
Nominal diameter: DN 15
Inlet nominal: 1/2"
Outlet nominal: 3/4"
Pressure rating:
Nominal pressure: PN 100
Connection type:
Connection inlet: 1/2" Th-m-BSP
Connection outlet: 3/4 Th-f-BSP
Application:
To blow off steam, neutral gases, vapours and liquids
Material:
Body: GX5CrNiMoN19-11-2
DIN-material No.: 1.4581
Technical data:
Thread: DIN ISO 228 part 1
Set point: 22 bar
Weight: 1.2 kg

100

Tag No(s): 3C26

12
1/2
42

Type No.: 6040


Version: A.1

Language UK

Safety valve, DN 15, PN 100

6040000050

5-59 / 93

Technical data

CR 1

DATA
SHEET
'$7$6+((7

Tag7DJ1R V 
No(s): 3M169, 3M170

D1

G 1/2

B1

G 1/2

G 1/2

DIN

20

75

89
100
140

19 x 24.5

100
141
250

35

4 x 13.5

180
220

Oval

75
180
220

Electrical data

4 x 13.5

TM02 0193 2501

100
145
160

20

50

22

Oval flange

DIN flange

B2

D1

472

191

141 109

18.4

22.5

472

191

141 109

18.4

22.5

299

490

191

141 109

18.7

22.8

483

317

508

191

141 109

19.5

23.6

501

335

526

191

141 109

19.7

23.8

332

563

357

588

231

141 109

22.0

26.1

CR 1-8

350

581

375

606

231

141 109

22.8

26.9

CR 1-9

368

599

393

624

231

141 109

23.2

27.3

CR 1-10

386

617

411

642

231

141 109

25.1

29.2

CR 1-11

404

635

429

660

231

141 109

25.6

29.7

CR 1-12

422

653

447

678

231

141 109

26.1

30.2

CR 1-13

440

671

465

696

231

141 109

26.3

30.4

CR 1-15

492

773

517

798

281 178

110

32.8

36.9

CR 1-17

528

809

553

834

281 178

110

33.3

589

870

281 178

110

40.1

CR 1-21

625

906

281 178

110

40.9

CR 1-23

661

942

281 178

110

41.7

CR 1-25

697

978

281 178

110

42.9

CR 1-27

737

1072

335

110

48.9

B1

B1 + B2

B1

B1 + B2

CR 1-2

256

447

281

CR 1-3

256

447

281

CR 1-4

274

465

CR 1-5

292

CR 1-6

310

CR 1-7

CR 1-19

Rp 1
M10 x 40

G 1/2

Net weight
[kg]

Dimensions [mm]

Pump
type

DIN

127,7/(

D2

B2



Dimensions and weights


Oval

Dimensional sketches

178

D2

3 x 220-255/380-440 V, 60 Hz
I
start
---------------I
1/1

Motor
P2 [kW]

Full load current


I1/1 [A]

Power factor
Cos 1/1

Motor efficiency
[%]

CR 1-2

0.37

1.58-1.46/0.91-0.84

0.88-0.82

78.0-79.0

4.80-6.00

CR 1-3

0.37

1.58-1.46/0.91-0.84

0.88-0.82

78.0-79.0

4.80-6.00

CR 1-4

0.37

1.58-1.46/0.91-0.84

0.88-0.82

78.0-79.0

4.80-6.00

CR 1-5

0.55

2.40-2.18/1.38-1.26

0.88-0.82

80.5-82.0

4.80-6.00

CR 1-6

0.55

2.40-2.18/1.38-1.26

0.88-0.82

80.5-82.0

4.80-6.00

CR 1-7

0.75

3.15-2.85/1.82-1.64

0.89-0.84

82.0-84.0

5.10-6.50

CR 1-8

0.75

3.15-2.85/1.82-1.64

0.89-0.84

82.0-84.0

5.10-6.50

CR 1-9

0.75

3.15-2.85/1.82-1.64

0.89-0.84

82.0-84.0

5.10-6.50

CR 1-10

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

Pump type

CR 1-11

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

CR 1-12

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

CR 1-13

1.1

4.50-4.00/2.60-2.32

0.89-0.84

82.0-85.0

5.10-6.50

Electrical data

3 x 220-277/380-480 V, 60 Hz
I start
---------------I 1/1

Motor
P2 [kW]

Full load current


I1/1 [A]

Power factor
Cos 1/1

Motor efficiency
[%]

CR 1-15

1.5

5.70-5.00/3.30-2.90

0.89-0.78

80.5-82.0

5.90-8.40

CR 1-17

1.5

5.70-5.00/3.30-2.90

0.89-0.78

80.5-82.0

5.90-8.40

CR 1-19

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 1-21

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 1-23

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 1-25

2.2

8.05-6.95/4.65-4.00

0.90-0.81

83.0-84.5

6.50-9.50

CR 1-27

3.0

10.6-9.00/6.10-5.20

0.90-0.83

85.0-86.0

7.40-11.0

Pump type

Version:
A.2
9HUVLRQ%

5-60   /Alfa
/DQJXDJH8.
  93
    Laval


37.4

Feed water)HHGZDWHUSXPS
pump, type CR 1-15

Data sheet 5541002014

5541002014

Language1 UK
of 3 

General
data
DATA SHEET
'$7$6+((7

Vertical multistage centrifugal pumps

Tag No(s): 3M169, 3M170


7DJ1R V 

CR 1

3
10

TM02 1194 0601Materials: CR, CRI, CRN 1, 3 and 5

4
5
9

Materials: CR
Pos.
1

Description
Pump head

Materials
Cast iron
EN-GJL-200

DIN W.-Nr.

AISI/ASTM

EN-JL1030

ASTM 25B

Shaft

Stainless steel

1.4401

AISI 316

Impeller

Stainless steel

1.4301

AISI 304

Chamber

Stainless steel

1.4301

AISI 304

Outer sleeve

Stainless steel

1.4301

AISI 304

O-ring for outer


sleeve

EPDM or FKM

Base

Cast iron
EN-GJL-200

EN-JL1030

ASTM 25B

Neck ring

PTFE

10

Shaft seal

Type cartridge

Rubber parts

EPDM or FKM

Version: A.2
9HUVLRQ%

Language
 Alfa
Laval UK

Feed
water pump, type CR 1-15
)HHGZDWHUSXPS

Data sheet 5541002014

5541002014

/DQJXDJH8.
2 5-61
of 3 / 93

Performance curves

CR 1

DATA
SHEET
'$7$6+((7

Tag7DJ1R V 
No(s): 3M169, 3M170

p
[kPa]

H
[m]

CR 1

-27

240

60 Hz

220
2000

ISO 9906 Annex A

-25
-23

200

-21
180
-19
1600

160
-17
140
-15

1200

120
-13
-12
100

-11
-10

800

80

-9
-8
-7

60
-6
400

-5

40

-4
-3

20
0
0.0

0.2

0.0

0.4

0.6

0.1

P2
[kW]

0.8

0.2

1.0

1.2

0.3

1.4

1.6

0.4

1.8

2.0

0.5

2.2

2.4

0.6

2.6

0.7

2.8

Q [m/h]

0.8

Q [l/s]

40

P2
Eta

0.06

30

0.04

20

0.02

10

0.00

0
0.0

H
[m]
10

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

2.8

Q [m/h]

NPSH
[m]
5

QH 3500 rpm

2
NPSH

0
0.0

0.2

Version:
A.2
9HUVLRQ%

5-62 /Alfa
93 Laval
/DQJXDJH8.

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

Feed water)HHGZDWHUSXPS
pump, type CR 1-15

Data sheet 5541002014

2.4

2.6

2.8

Q [m/h]

Technical dataCR 1

50

0.08

curves/

0.10

Eta
[%]

TM02 1504 1902Performance

-2

5541002014


Language3 UK
of 3 

DATA SHEET

Tag No(s): 3M7


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Stainless steel
Liquid filling: Glycerine

Technical data:
Measuring unit: bar / Mpa / kg/cm
Measuring range: -1 to +3 / - 0.1 to +0.3 /
-1 to +3
Connection down: G -m BSP
Accuracy Class 1.0
Operating temperature, ambient : -20 to
+60C
Operating temperature, medium max:
+100C
Ingress protection: IP65 per EN 60 529 /
IEC 529
49.5

4.8

12
0

12

-1

bar
3
MPa=bar x 0.1
kg/cm

87

-1

117
BSP 1/2" -m

132

Type No.: 8050


Version: D.1

Language UK

Pressure gauge, 100

8050000045

5-63 / 93

DATA SHEET

Tag No(s): 3M8


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Cu-alloy
Liquid filling: Glycerine

Technical data:
Measuring unit: bar Mpa - kg/cm
Measuring range: 0 25 / 2.5/ 25 with
mechanical stop
Connection: BSP -m
Accuracy class: 1.0
Operating temperature:
Ambient: -20 to + 60C
Medium: + 60C maximum
Ingress protection: IP65 (EN 60 529 /
IEC 529)

48

4.8

12
0

12

bar
25
MPa=bar x 0.1
25
kg/cm

87

117
BSP 1/2" -m

132

Type No.: 8050


Version: B.1

5-64 / 93

Pressure gauge, 100

6666016

Language UK

DATA SHEET

Tag No(s): 3M10, 3C31, H14


Type:
Pressure gauge valve needle straight.
Size:
1/2 x 1/2
Application:
For instrument connections
Material:
Body: C22.8
DIN-material No. 1.0460
Technical data:
Nominal pressure: PN 400
Test connection: M20 x 1.5 mm threaded
male
Weight: 0.4 kg

Type No.: 6210


Version: C.1

Language UK

Needle valve, straight, " x ", PN 400

2541002

5-65 / 93

DATA SHEET

Tag No(s): 3M130.1, 3M130.2


Material:
Polycarbonate
Colour: Front RAL 7035
PG-gland: Brass
Technical data:
Cable glands: M 20
Ambient temperature: - 25C to + 70C
Protection: IP 65

Type:
Remote emergency stop system box, included PG-gland cable connection
Application:
For emergency stop

68

Cable gland connection

53

Cable gland connection

68

34

34

91

Type No.: 8000


Version: A.2

5-66 / 93

54

Remote emergency stop

8000000016

Language UK

DATA SHEET

Tag No(s): 3H2, 3W32

5714
1

OK

12
0

48

Type
LED indicator/limit switch
5714B
Application:

96

The 5714 with 2 relay outputs is designed


for digital readout of current / voltage or
temperature signals.
Relay outputs:
Are selected as either a make or a break
function. The relays can be used as a trip
amplifier.
Two yellow front LEDs indicate the relay status. The relays can be set up with
either delayed on or off. Active relay can
be selected for either an increasing or decreasing signal. The arrow keys can be
used for fast change of the set point.
Technical data:
Panel cut out: 44.5 x 91.5 mm
Weight: 230 g
Electrical specifications:
Common specifications:
Supply voltage:
Max. voltage: 24230 VA C, 10%50
60Hz
24250 VDC 20%
Internal consumption: 2.7W
Max. consumption: 3.0 W

Type No.: 8001


Version: E.1

Language UK

Auxiliary voltages:
2-wire supply: 2516 VDC / 020 mA
EMC immunity influence: < 0.5% of
reading
Max. wire size: 1 x 2.5 mm
Relative air humidity:< 95% RH (non
condensing)
Tightness (mounted in a panel): IP65
Voltage input:
Measurement range: -20mV...12 VDC
Program measurement range :
01/0,21/010/210VDC
Input resistance: nominal 10 M
Current input:
Measurement range: -1...25 mA
Program, measurement range:
020 and 420mA
Input resistance:
Nominal20 + PTC 25
Sensor error detection: loop break
420mA..Yes
Display:
Display readout: -1999999 (4 digits)
Decimal point: programmable
Digit height: 13.8 mm
Display updating: 2.2 times/s
Input outside input range is indicated by:
Explanatory text
Relay outputs:
Relay function: setpoint
Hysteresis, in % display counts:
0.125%/12999
On and Off delay: 03600s
Max. voltage: 250 VRMS
Max. current: 2 A / AC
Max. AC power: 500 VA
Max. current at 24 VDC: 1A
Sensor error action: Make / break/hold

LED indicator / limit switch

8001000002

5-67 / 93

DATA SHEET

Tag No(s): 3H2, 3W32

Connections

Supply

Input:
RTD, 2-wir e

Voltage

RTD, 3-wire

RTD, 4-wire

2-wire transmitter

Current

Potentiometer

Output:
Relays

R1

R2

Block Diagram

Type No.: 8001


Version: E.1

5-68 / 93

LED indicator / limit switch

8001000002

Language UK

DATA SHEET

Tag No(s): 3C33


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Cu-alloy
Liquid filling: Glycerine

Technical data:
Measuring unit: bar Mpa - kg/cm
Measuring range: 0 16 / 1.6 /16 with
mechanical stop
Connection: BSP 1/2-m
Operating temperature:
Ambient: -20to + 60C
Medium, max.: + 60C
Protection: IP 65

30
0
0

bar
16
MPa=bar x 0.1
16
kg/cm

Type No.: 8050


Version: C.1

Language UK

100

81.5

107

Pressure gauge, 100

BSP 1/2-m

6632973

5-69 / 93

DATA SHEET

Tag No(s): 3C35

Version: B.2

5-70 / 93

Pressure switch RT30AW 1-10 Bar

6310310

Language UK

DATA SHEET

Tag No(s): 3C35

Version: B.2

Language UK

Pressure switch RT30AW 1-10 Bar

6310310

5-71 / 93

DATA SHEET

Tag No(s): 3C48

Type No.: 8010


Version: B.2

5-72 / 93

52
36

PG 11

106

24
SW 24

25

55

Type:
Pressure transmitter
Range:
0 - 10 bar(g)
Application:
The pressure transmitter converts pressure to an electric signal. The units are
supplied as passive two wire transmitters. The output current is linearly proportional to the input pressure.
Material:
Housing: Stainless steel with piezoresistive measuring cell and electronics module.
Process connection: Stainless steel
Technical data:
Electrical specification:
Current output signal: 4 to 20 mA
Power supply terminal voltage for current output: 7 to 33VDC
Accuracy:
Response time T99: < 5 ms
Influence of ambient temperature at start
of scale: 0.25%/10K of full scale value
Influence of ambient temperature at full
scale value: 0.25%/10K of full scale value
Mechanical:
Process temperature: -30C to +120C
Ambient temperature: -25C to +85C
Max pressure: 25 bar(g)
Min pressure: -1 bar(g)
Degree of protection to EN 60529: IP65
Cable gland: PG11
(cable size 5 to 10 mm)
Weight: 0.09 kg

G 1/2 -m

Connection diagram:

Pressure transmitter 0 - 10 bar(g)

8010000022

Language UK

DATA SHEET

Tag No(s): 3N5


Type:
Control globe valve, straight with pneumatic actuator and I/P positioner
23.470, DP 32
Size:
Nominal diameter: DN 32
Application:
For cooling, water, steam, brine and/or
gas flow
Material valve:
Body: EN-GSJ-400-18U-LT
Material No.: EN-JS1049
Seat: X20 Cr13 + QT
Material No.: 1.4021 + QT
Plug: X20 Cr13 + QT
Material No.: 1.4021 + QT
Stuffing box: PTFE V-ring unit(-10C to
+ 220C)
Technical data, valve:
Nominal pressure: PN 25
Positioning ratio: 50:1
Flow characteristic: Equal percentage
Kvs value: 6.3 m/h
Travel: 20 mm
Plug type: Parabolic shaft guided
Flanges according to DIN
Technical data, actuator:
Spring range: 0.4 1.2 bar
Closing pressure: 16.8 bar
Diaphragm area: 250 cm
Filling volume:1.1 l
Max air supply pressure: 6 bar
Action: Spring closes valve on air failure
Technical data, I/P positioner:
Air connection: G
Inlet air supply: 1.4 to 6 bar, instrument
air
Air inlet consumption in stable state:
0.036 Nm/h
Cable inlet: M20 x 1.5
Input signal: 4-20 mA
Ambient temperature: -30C to +80C
Protection: IP65

Type No.: 6050


Version: B.3

Language UK

Technical data unit:


Weight: 35 kg

Pneumatic control valve, DN 32, PN 25, with DP


actuator and I/P positioner

6050000240

5-73 / 93

DATA SHEET

Tag No(s): 3N5


Installation:
Only as shown in the picture
O.D.2

O.D.1

Hand wheel

H1

Stroke indicator

Dimension:
L = 180
H = 473
H1 = 270
I.D. = 32
n x I.D.1 = 4 x 18
P.D.C. = 100
O.D. = 140
O.D.1 = 225
O.D.2 = 250

Actuator

I/P Positioner

Stuffing box

Plug
I.D.

P.D.C. n x I.D.1

O.D.

Body

Seat

Type No.: 6050


Version: B.3

5-74 / 93

Pneumatic control valve, DN 32, PN 25, with DP


actuator and I/P positioner

6050000240

Language UK

DATA SHEET

Tag No(s): 3N6


Type:
Filter regulator with automatic drain
Size:
Connections ports 1/4 BSP
Gauge ports 1/8 BSP
Application:
Instrument air for regulating pressure
Technical data:
Medium: instrument air only
Max. inlet pressure: 17 bar
Operating temp.: 20 C to + 65 C
Filter element: 5 m
Recommend pressure regulating range:
0.14-7.0 bar
Pressure gauge: 0 10 bar
Weight: 0.4 kg
Material:
Body: Steel
Bin: Steel
Handle: Acetal

30

66

Max. 6

23
2.5

44

7.5

Di smantel length 138

14

Gauge por ts

28
99

18

38

Connections ports

41

R1
9

SW19

31

Inlet pressure 7 bar

7
Outlet pressure [bar]

Fitting

Bin

Flow characteristics

H andle

Body

6
5
4
3
2
1
1

10

Air flow [dm /s]

Type No.: 8000


Version: B.1

Language UK

Filter regulator with automatic drain

2915101

5-75 / 93

DATA SHEET

Tag No(s): M82


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 3.9 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, straight
Size:
Nominal diameter: DN 15
Application:
For steam and/or water flow

Disc
Seat

15

65 / 4 x 14

95

180

120

Body

130

Type No.: 6010


Version: C.1

5-76 / 93

Stop valve, straight, DN 15, PN 25

2501086

Language UK

DATA SHEET

Tag No(s): M83


Type
Filter
Size:
Nominal diameter: DN 15
Application
For mechanical cleaning of different medias in tube systems before control
valves, reduction valves, pumps, steam
traps and flow meters
Material:
Body: EN-GJS-400-18U-LT
Din-Material No. EN-JS1049
Cover: EN-GJS-400-18U-LT
Din-Material No. EN-JS1049
Screen: X 5 CrNi 18-10
Din-Material No. 1.4301

Technical data:
Nominal pressure: PN 25
Filtration: 1.0
Flange according to DIN
Weight: 3.5 kg
Installation:
The filter can be mounted in optional positions with the flow following the direction of the arrow.
For steam installations the filter basket
should be installed horizontally with the
flow following the direction of the arrow.
Dimension:
H: 90
H1: 135
L: 130
L1: 10
O.D: 95
P.D.C: 65
I.D: 15
I.D.1: 14
n: 4
L

L1

Body

H1

I.D

P.D.C / n x I.D.1

O.D

Screen

Cover

Type No.: 7040


Version: B.1

Language UK

Filter, DN 15, PN 25

7040000041

5-77 / 93

DATA SHEET

Tag No(s): M84

Type No.: 6050


Version: B.1

5-78 / 93

Seat
I.D.

O.D.

L
P.D.C. / n x I.D.1

Type
Thermal-closing valve, straight through
with flanges and cooling spacer
Size:
Connection nominal: DN 15
Pressure rating:
Pressure nominal: PN 25
Connection type:
Connection type: flanges according to
DIN en 1092-2
Application:
For regulating temperature of fluids, air
and steam
Material:
Body: EN-GJS-400-18U-LT
DIN material No. EN-JS1049
Seat:X6CrNIiTi8-10
DIN material No: 1.7218
Spindle unit: X6CrNiTi18-10
DIN material No: 1.4541
Technical data:
Kvs-value: 4.0 m3/h
Closing pressure: 16 bar
Weight: 4.3 kg
Dimension:
L = 130
H = 305
I.D. = 15
O.D = 95
P.D.C. = 65
I.D.1: = 14
n=4
Installation:
Spindle and cooling spacer vertical
downwards

Control valve, DN 15, PN 25

Body
Spindel unit

Cooling spacer

M 38 x 1.5

6050000458

Language UK

DATA SHEET

Tag No(s): M85


Type:
Temperature switch with 8 m capillary
tube
Temperature range:
Temperature range: 60C to 130C
Material:
Actuator: CuZn37, CW614N
(nickel plated)
Technical data:
Weight 1.8 kg

Dimension:
H = 339
H1 = 269
H2 = 275
L1 = 8000
O.D. = 23
R min. = 50

Pipe

H1

Indicator unit

L1
M38 x 1.5

Thermal sensor

H2

Actuator

m
in
.

O.D.

Type No.: 8070


Version: F.1

Language UK

Temperature switch

8070000023

5-79 / 93

DATA SHEET

Tag No(s): M86


Type:
Check valve
Disc-spring
Size:
Connection nominal: DN 15
Pressure rating:
Pressure nominal: PN 40
Application:
The check valves are designed to be
sandwiched between flanges. They are
suitable for use on a wide range of fluids
for applications in process lines, hot water systems, steam and condensate systems etc.
Material:
Body: GX5CrNiMo19-11-2
DIN material No. 1.4408
Spring: X10CrNi18-8
DIN material No. 1.4310
Valve plate: X6CrNiMoTi17-12-2
DIN material No. 1.4571
Spring plate: X6CrNiMoTi17-12-2
DIN material No. 1.4571
Retaining ring: X39CrMo17-1+QT
DIN material No. 1.4122+QT
Retaining ring
Spring plate

I.D.

O.D.

Valve plate

Technical data:
Weight: 0.14 kg
Kvs-value: 4.4 m/h
Set pressure: 0.02 bar(g)
Installation:
The Check valves must be fitted in accordance with the direction of flow arrow
indicating correct fluid flow direction.
The Check valves can be installed in any
position, except upside down.
The cam design of the body allows the
various flange types to be accommodated. The body is rotated to touch the
flange joint bolts ensuring that the valve
is centred in the pipeline.
Disc check valves are not suitable for use
where heavily pulsating flow exists, such
as close to a compressor.
Dimension:
I.D. = 13
O.D. = 45
O.D.1 = 95
W = 16

Spring
Preparation for
eart connection

Type No.: 6020


Version: A.3

5-80 / 93

Check valve, DN 15, PN 40

6020000101

Language UK

DATA SHEET

Tag No(s): M87


Type:
Vacuum breaker
Size:
Connection: G 1/2" BSPP
Pressure rating:
Pressure, nominal: PN 40
Application:
Ventilation valve for pipelines, condensing vapour (steam) or liquid systems,
where the system pressure should not fall
below the atmospheric pressure.
Material:
Body: X5CrNi18-10
DIN material No. 1.4301
Ball: X20Cr13+QT
DIN material No. 1.4021+QT
Cap: X17CrNi16-2
DIN material No. 1.4057
Technical data:
Operating temperature: 220C
Operating pressure: 21 bar(g)
Set pressure: 7 mbar
Kvs-value: 0.55 m/h
Weight: 0.38 kg
Installation:
The Vacuum Breaker must be installed
in a vertical position, cap on top. System
connection downwards.
Dimension:
H = 57
H1 = 10
W = 42
HEX = 36
HEX1 = 32

Type No.: 6000


Version: A.5

Language UK

Cap

Vacuum breaker, 1/2", PN 40

6000000121

5-81 / 93

DATA SHEET

Tag No(s): M89


Type:
Steam injector
Size:
Connection, internal: G 1/2" BSPP
Connection, external: G 1" BSPT
Pressure rating:
Pressure, nominal: PN 25
Application:
Steam injectors are designed to inject
steam into water or process liquor to ensure quiet and efficient heating of the liquid. The injector draws in cold liquid,
mixes it with steam within the injector
nozzle and distributes the hot liquid. In
many applications the circulation induced by the injector is an advantage ensuring thorough mixing and avoiding
temperature stratification.
Material:
Head: X5CrNi18-10
DIN material No. 1.4301
Pipe: X5CrNi18-10
DIN material No. 1.4301

Technical data:
Operating pressure: 17 bar(g)
Operating temperature: 207 C
Weight: 0.4 kg
Installation:
The steam injectors must be installed
horizontally.
The steam injectors are designed to operate with the minimum noise provided
the installation is correct.
Dimension:
HEX = 36 mm
O.D. = 29 mm
L =200 mm

G 1" BSPT

O.D.

G 1/2" BSPP

Type No.: 7000


Version: A.4

5-82 / 93

Head

Pipe

Steam injector, 1/2", PN 25

7000000085

Language UK

DATA SHEET

Tag No(s): M145.1


Material:
Sensor: Stainless steel
Technical data:
Temperature: -70C to 150C
Design of duty: Chemical interface
Liquid type: Clean, viscous with solids
Cable: 6 metre

Type:
Ultrasonic sensor for oil detection equipment
Application:
The ultrasonic sensor is operated together with a control unit.
The equipment provides for oil detection
in feed/make-up water.
258
20

25

152

26

22

11

10

"

Type No.: 8310


Version: B.4

Language UK

Ultrasonic sensor for oil detection equipment

8310000005

5-83 / 93

DATA SHEET

Tag No(s): M145.2


Technical data:
Power supply (selector switch):
110/120V or 220/240V AC
Relay output: DPCO
Enclosure: IP 65
Holes for glands 3 of 16

Type:
Control unit for oil detection equipment
Application:
The control unit is operated together with
an ultrasonic sensor.
The equipment provides for oil detection
in feed/make-up water.
Material:
Control device cabinet: Polycarbonate

Normal
Fault

Holes for mounting

40

60

188

75

88

120

Alarm

Holes for glands


40
130
160
200

Type No.: 8210


Version: B.1

5-84 / 93

Control unit for oil detection equipment

8210000025

Language UK

DATA SHEET

Tag No(s): M146.1


Type:
Conductive electrode
Application:
The conductive electrode is used in combination with a control device to measure
and supervise the salinity of feed water.
Technical data:
Instrument:
Salinity range: 0 to 100 ppm (sea salt)
Pressure range: 0 to 1 bar(g)
Temperature range: 0 to 100C
Accuracy: +/- 10%
Weight: 0.3 kg

Electrical:
Connection to control device via junction
box:
Sensor pin 1 to pin 11 (brown)
Sensor pin 2 to pin 12 (blue)
Sensor pin 3 to pin 13 (grey)
Sensor pin 4 to pin 14 (shield)
Sensor pin 5 to pin 15 (black)
Installation:
The conductive electrode must be installed in the supplied T-piece (item 8500
000115). The cable must be connected to
the control device via a junction box (not
Alfa Laval supply).
Maximum pressure in line: 1 bar(g)
Note:
The electrode is totally sealed and must
not be opened. The guarantee is void if
opening of the electrode is attempted.

Cable lenght: 2.5 metre

Blue top cap

Gasket

Gold-plated
electrodes

Type No.: 8620


Version: A.1

Language UK

Conductive electrode

8620000104

5-85 / 93

DATA SHEET

Tag No(s): M146.2


Electrical:
Mains supply: 98 122 VAC or
196 244 VAC, 50 60 Hz
Mains current: mains supply must be secured against over current externally by
using a fuse (max. 100 mA)
Power: max. 3.5 W
Cable connections:
Terminal 1-4: mains supply
Terminal 5-10: relay contacts for alarm
and solenoid
Terminal 11-16: electrode unit
Terminal 17-18: 4-20 mA current loop
mA =(0.16 x ppm) + 4 mA)
Relay contacts: 8 A / 24 VDC

86

Type:
Control device for salinometer
Application:
The control device is used in combination with a conductive electrode to measure and supervise the salinity of feed water.
Technical data:
Instrument:
Salinity range: 0 100 ppm (sea salt)
Accuracy: +/- 10% of displayed value
Adjustable alarm range:1 100 ppm
Display: LED indication bar

105

Type No.: 8210


Version: D.1

5-86 / 93

Control device, salinometer

8210000032

Language UK

DATA SHEET

Tag No(s): M146.3


Type:
T-piece for salinity alarm equipment
Size:
DN 25
Application:
Housing for salinity electrode
Material:
Housing: RG 5
Nut for electrode: RG5
110
10

Technical data:
Pressure range: 0 to 1 bar(g)
Flanges according to DIN 2501
Weight: 2.65 kg

115

PCD 85
4 x 12

Type No.: 8500


Version: C.1

Language UK

T-piece for salinity alarm equipment

8500000115

5-87 / 93

DATA SHEET

Tag No(s): M25


Type:
Sample cooler
Size:
SCS 20
Application:
The sample cooler is designed for taking
manual samples of boiler water for analysis. The cooling water is turned on and
the sample inlet valve is adjusted until a
sample of boiler water is obtained at a
suitable temperature. For manual sampling it is not normally necessary to
measure sample or cooling water flow
rates.

Material:
Sample cooler: austenitic stainless steel
grade 316L
Cooling water inlet valve: stainless steel
Sample inlet valve: stainless steel.
Compression fitting: carbon steel
Technical data:
Coil design pressure: 32 bar g
Coil design temperature: 300C
Body design pressure: 10 bar g
Body design temperature: 100C
Weight: 4 kg
90

2. Sample inlet valve


1/4 BSP (each ends)
3. Compression fittings
for sample in 1/4 BSP

13

Sample in 6 mm O/D
Customer supply

Cooling water out 1/2 BSP


Customer supply

1. Sample cooler

4. Cooling water
inlet valve 1/2 BSP

Sample out

Cooling water in1/2 BSP


Customer supply

Type No.: 7050


Version: D.1

5-88 / 93

Sample cooler

8750005

Language UK

DATA SHEET

Tag No(s): M25


Installation:
Fit the SCS 20 so that the bottom of the
unit is accessible for the collection of the
cooled sample.
Connect the cooling water inlet in
nominal bore pipe via an inlet valve.
The cooling water outlet should be piped
to an open drain or tundish.
The sample inlet pipe should be in 6 mm
O/D tubes.
The sample inlet to the cooler can be taken direct from a boiler or steam line isolating valve.
Operation:
Sample pipe work will become very hot
under normal working conditions, and
will cause burns if touched.
Open the cooling water inlet valve first
and ensure that a flow can be seen at the
cooling water outlet.
It is essential that cooling water is flowing before opening the sample inlet
valve.
Gradually open the samples inlet valve
and regulate the flow to achieve a cooled
sample at about 25C.
Sample flow rate

l/h
10
20
30
40
50
60
80
100
120

l/min
0.17
0.33
0.50
0.67
0.83
1.00
1.33
1.67
2.00

Allow the sample to run for a while before collection. This will ensure that a
true sample is collected for analysis.
When enough liquid has been collected
close the sample inlet valve first and then
the cooling water inlet valve.
After closing the sample inlet valve the
sample out connection may drip for a few
minutes while the coil drains.
Performance:
When it is required to predict the performance of the sample cooler system,
the table below gives the sample outlet
temperature to be expected for two boiler
pressures an for two cooling water flow
rates.
Example
A sample flow rate of 30 l/h is required
from a boiler operating at 10 barg. For a
cooling water flow rate of 0.4 l/s, from
the table the sample outlet temperature
would be 4K (4C) above the cooling
water inlet temperature. If the cooling
water is 15C, the sample temperatures
would be 19C.

Cooling water flow rate


Cooling water flow rate
0.25 l/s (900 l/h)
0.4 l/s (1440 l/h)
Boiler pressure
10 barg
20 barg
10 barg
20 barg
Sample outlet temperature above cooling water inlet temperature K (C)
3
3
1
1
5
5
2
3
7
9
4
5
8
10
5
7
10
12
6
8
11
13
7
10
12
16
8
12
15
19
9
14
17
22
10
16

Table 1

Type No.: 7050


Version: D.1

Language UK

Sample cooler

8750005

5-89 / 93

DATA SHEET

Tag No(s): H3

Type No.: 8010


Version: B.2

5-90 / 93

52
36

PG 11

106

24
SW 24

25

55

Type:
Pressure transmitter
Range:
0 16 bar(g)
Application:
The pressure transmitter converts pressure to an electric signal. The units are
supplied as passive two wire transmitters. The output current is linearly proportional to the input pressure.
Material:
Housing: Stainless steel with piezoresistive measuring cell and electronics module.
Process connection: Stainless steel
Technical data:
Electrical specification:
Current output signal: 4 to 20 mA
Power supply terminal voltage for current output: 7 to 33VDC
Accuracy:
Response time T99: < 5 ms
Influence of ambient temperature at start
of scale: 0.25%/10K of full scale value
Influence of ambient temperature at full
scale value: 0.25%/10K of full scale value
Mechanical:
Process temperature: -30C to +120C
Ambient temperature: -25C to +85C
Max pressure: 40 bar(g)
Min pressure: -1 bar(g)
Degree of protection to EN 60529: IP65
Cable gland: PG11
(cable size 5 to 10 mm)
Weight: 0.09 kg

G 1/2 -m

Connection diagram:

Pressure transmitter 0 - 16 bar(g)

8010000023

Language UK

DATA SHEET

Tag No(s): C191


Type:
Water washing hose with nozzle
Size:
V-nozzle: 12 mm
Length: 15 metre (hose)
Inner diameter: 52 mm (hose)
Application:
For spraying of water
Material:
Hose: full-synthetic material (polyester)
woven in 1/1 binding, with inner rubber
lining
Technical data:
Max allowable working pressure: 20 bar
Water temperature area: -30C-+60C
Weight: 5.5 kg

Nozzle,
item No. 294 1101

Couplings (2 Storz)

2 BSP connection
(male)

Hose,
item No. 294 1001

Couplings (2 Storz),
item No. 294 1201

Water flow

I/min
210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
1

Type No.: 8615


Version: A.2

Language UK

10 Bar

Water washing hose with nozzle

2941001

5-91 / 93

5-92 / 93

Language UK

K16_004096#D.1
COUNTER FLANGE

Counter flange
1

Language UK

--- NO TITLE ---

5-93 / 93

TABLE OF CONTENTS

Table of contents
Pressure atomizing burner
Description
Aalborg KBO-E burner flow diagram...........................
List of parts - KBO-E burner.......................................

Language UK

Document ID
Page
94X02_066454.............
6-3
94X02_066454.............
6-4

6-1 / 5

TABLE OF CONTENTS

6-2 / 5

Language UK

AALBORG KBO-E BURNER FLOW DIAGRAM

Aalborg KBO-E burner flow diagram

Language UK

6-3 / 5

LIST OF PARTS - KBO-E BURNER

List of parts - KBO-E burner


Boiler plant:........................................................................................1 x Aalborg OC+ 1 x Aalborg XS-2V
Request No.:.......................................................................................................................................106393
Configuration No.:.......................................................................................................................................1
Hull No./Nos.:................................................................................GWS440, GWS441, GWS442, GWS443
Project No./Nos.:..................................................................106393-01, 106393-02, 106393-03, 106393-04
P&I Diagram drawing No.:....................................................................................................94X02_066454
P&I Diagram revision:.................................................................................................................................a
Date:.........................................................................................................................................17 JAN 2013
Reading guide:
List of Parts reflects parts included in the burner unit. The parts are related to the P&I diagram for functionality
and no separate data sheet for each part is prepared.
Tag No.
Qty.
Dim.
Application
Pressure atomizing burner (Qty. gives the number of parts per burner)
F32
1
N/A
Flame scanner
F33
1
N/A
Flame scanner
F120
1
L=500
Hose for sealing air
F166
1
N/A
Ignition transformer, 1 x 230V
F182
1
N/A
Orifice
F183
1
N/A
Junction box
F201
1
N/A
Solenoid valve, N.O., 1 x 230V
F202
1
N/A
Solenoid valve, N.C., 1 x 230V
F203
1
N/A
Solenoid valve, N.O., 1 x 230V
F204
1
N/A
Solenoid valve, N.C., 1 x 230V
F205
1
N/A
Solenoid valve, N.C., 1 x 230V
F206
1
N/A
Burner nozzle valve
F207
1
N/A
Electrical heater
F208
1
N/A
Servo motor for oil regulating, 1 x230V
F212
1
3/2
Temp. transmitter, 4-20 mA, 0 200 C
F212.1
1
1/2
Pocket for temperature transmitter
F214
1
NA
High oil pressure switch, 0 - 10 bar (g)
F217
1
N/A
Oil regulating valve
F218
1
N/A
Pressure gauge, 0 - 60 bar (g)
F219
1
N/A
Pressure gauge, 0 - 60 bar (g)
F222
1
N/A
Temperature sensor fuel oil heater
F223
1
N/A
Temperature switch fuel oil heater with safety
device
F224
1
N/A
Limit Switch burner in position
F225
1
N/A
Pressure transmitter, 4-20 m, 0 40 bar (g)
F235
1
N/A
Non return valve
F240
1
N/A
Electrical tracing, 1 x 230V
R1
1
N/A
Fan

6-4 / 5

Type

Part no.

6310720
6310720
8500000002
9692801684
Part of F1
9692801695
9692801696
9692801695
9692801694
9692801696
9692801481
9692801662
8030000013
8050000054
8050000054
9692801715
9692801208

9692801701
8010000017
80000000067
-

Language UK

LIST OF PARTS - KBO-E BURNER

R3
R7
R15
R16

Language UK

1
1
1
1

N/A
N/A
N/A
N/A

Low combustion air pressure, 2.5 50 m bar (g)


Air damper
Fan motor, 3 x 440V, 60Hz
Servo motor for air damper, 1 x230V

9692801216
-

6-5 / 5

TABLE OF CONTENTS

Table of contents
Fuel Oil Supply Pressure atomizing burner
Tag Number
...................................
...................................
...................................
...................................
F1...............................
C331, C431..................
C33.............................
C35.............................
C225...........................
G115, G441.................
G340...........................
G147...........................
G224...........................
G432...........................
G433, G470.................
G434...........................
G435...........................
G468, G469.................
.

G436...........................
G448...........................
G437, G439.................
G441...........................
G472...........................
G482...........................
G114...........................
G471, G481.................
G477...........................
G466...........................
G274...........................
(c.fl.)...........................

Language UK

Description
Fuel oil system..........................................................
List of parts - fuel oil supply for Aalborg KBO-E..........
Performance Calculation - heavy fuel oil......................
Performance culculation - diesel oil.............................
Pressure atomizing burner, modulating.........................
Needle valve, straight, " x ", PN 400.......................
Pressure gauge, 100.................................................
Pressure switch RT30AW 1-10 Bar.............................
Pressure transmitter 0 - 10 bar(g).................................
Three-way valve Ball DN32 BW.................................
Flow meter unit DN20, ring line..................................
Fuel oil supply unit, with filter, size 600, 33 bar............
Remote start/stop box.................................................
Heat Exchanger MX10 T16 L=600..............................
Safety valve, DN 15, PN 100......................................
Stop valve, ball straight, DN 15, PN 40........................
Needle valve 1/2" x 1/2".............................................
Stop valve, straight, DN 20, PN 25..............................
Three-way valve, ball DN 32 build together with actuator,
solenoid valve and switch box.....................................
Stop valve, ball, straight, DN 32..................................
Three-way valve, ball DN 25 build together with actuator,
solenoid valve and switch box.....................................
Three-way valve Ball DN32 BW.................................
Twin quick closing valve unit, DN25, PN40.................
Three-way valve, ball DN 25 build together with actuator
and solenoid valve.....................................................
Filter regulator with automatic drain............................
Pressure control valve, 1/2".........................................
Check valve, DN 32, PN 40........................................
Sample Unit..............................................................
Temperature transmitter in ring line.............................
Counter flange...........................................................

Document ID
Page
94X02_065598.............
7-3
94X02_065598.............
7-5
106393........................
7-7
106393........................ 7-11
5561000011................. 7-15
2541002...................... 7-16
6632973...................... 7-17
6310310...................... 7-18
8010000022................. 7-20
6070000013................. 7-21
71Z20_065692............. 7-25
9294002601................. 7-27
8001000005................. 7-30
15K7603..................... 7-31
87S0032...................... 7-33
6666106...................... 7-34
87N6004..................... 7-35
2501087...................... 7-36
6070000029.................
87D3066.....................

7-37
7-39

6070000017.................
6070000013.................
6000000111.................

7-40
7-42
7-45

6070000047.................
2915101......................
6050000542.................
6020000088.................
6000000119.................
71Z20_056461.............
K16_004096................

7-46
7-48
7-49
7-50
7-51
7-53
7-55

7-1 / 55

7-2 / 55

Language UK

94X02_065598#A.2
FUEL OIL SYSTEM

Fuel oil system

Language UK

7-3 / 55

7-4 / 55

Language UK

LIST OF PARTS - FUEL OIL SUPPLY FOR AALBORG KBOE

List of parts - fuel oil supply for Aalborg


KBO-E
Boiler plant:..........................................................................................1 x Aalborg OC + 1 Aalborg XS-2V
Request number:................................................................................................................................106393
Configuration number:.................................................................................................................................1
Hull number(s):..............................................................................GWS440, GWS441, GWS442, GWS443
Project number(s):................................................................106393-01, 106393-02, 106393-03, 106393-04
P&I diagram drawing number:...............................................................................................94X02_065598
P&I diagram revision:..................................................................................................................................c
Date:.........................................................................................................................................23 JAN 2013
Reading guide:
List of Parts reflects parts delivered by Alfa Laval.
Tag Numbers are given without the index used on the P&I diagram. E.g. C2" is found on the P&I Diagram
as "1C2" and "2C2" for boiler 1 and 2 respectively.

1
Tag no.

Pressure atomizing burner


Qty.

Dim (DN)

Pressure atomizing burner


F1
1
R13M
F113
1
R 1/2"
F115
1
R 1/2"
Gauge Board
C30
1
C331
1
1/2"
C431
2
1/2"
C33
1
100, BSP
1/2"-m
C35
1
G 1/2"-m
C225
1
G 1/2"-m
Change over valve(s)
G115
1
32
Oil flowmeter
G340
1
20
Fuel oil supply pump
G147
1
N/A
G224
1
N/A

Language UK

Application

Type

Datasheet or drawing

Burner unit
Flexible hose, approved by BV
Flexible hose, approved by BV

KBO-E
Inlet
Outlet

5561000011
8615000111
8615000111

Gauge board
Instrument stop valve for C35
Instrument stop valve for C33 and C225
Pressure gauge

Needle
Needle
0-16 bar

2541002
2541002
6632973

Pressure switch, max. steam


Pressure transmitter

0-10 bar
0-10 bar

6310310
8010000022

Three-way valve (incl. micro switches)

6070000013

Oil flow meter incl. filter & bypass with remote


pulser

71Z20_065692

Fuel oil supply pump unit


Remote start/stop box

DLC-600
-

9294002601
8001000005

7-5 / 55

LIST OF PARTS - FUEL OIL SUPPLY FOR AALBORG KBOE

Cooling unit
G429
1
N/A
G432
1
N/A
G433
1
15
G434
1
15
G435
1
1/2"
Cooling unit line
G468
1
20
G469
1
20
G470
1
1/2"
MGO/HFO select at cooler
G436
1
32
Stop valve at cooling unit
G448
1
32
At mixing tube
G437
1
25

Cooler unit
Heat exchanger (incl. in G429)
Safety valve (incl. in G429)
Drain valve (incl. in G429)
Air escape valve (incl. in G429)

8670004070
15K7603
87S0032
6666106
87N6004

Stop valve cooling water inlet


Stop valve cooling water outlet
Safety valve cooling water

2501087
2501087
87S0032

Three-way valve incl. actuator, solenoid and


switch box

6070000029

Stop valve

87D3066

6070000017

6070000017

6070000013

6000000111

6070000047

2915101

SPV M10

6050000542

SPV M10

6050000542

6020000088

6000000119

71Z20_056461

9306000025

K16_004096

Three-way valve incl. actuator, solenoid and


switch box
Return to MGO HFO tank (return from G437)
G439
1
25
Three-way valve incl. actuator, solenoid and
switch box
MGO/MDO select suction side
G441
1
32
Three-way valve incl. switch - manual
Quick closing valve unit
G472
1
25
Quick closing valve unit
Three-way valve select at pressure control valves (G471 and G481)
G482
1
25
Three-way valve incl. actuator and solenoid
Air filter regulator
G114
4
Air filter/reduction
Pressure control valve
G471
1
1/2"
Pressure control valve
Pressure control valve
G481
1
1/2"
Pressure control valve
Non return valve between HFO tank MGO tank
G477
1
32
Non return valve
Sample stop valve unit
G466
1
1/4"
Sample stop valve unit
Temperature transmitter
G274
1
Temperature transmitter
Control system
L2
1
Local control panel
Counter flanges
(c.fl.)
1
Set of counter flanges
(not shown on the P&I diagram)

7-6 / 55

Language UK

Performance Calculation

106393#A.2

PERFORMANCE CALCULATION - HEAVY FUEL OIL

MISSION OC

Standard Size: 1600 kg/h


Customer:

Request no.:
106393

Config. no.:

Performance Calculation - heavy fuel oil


Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2


Language UK

User: lkh

Heavy Fuel Oil


40200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:02:41

Page 3 of 6
7-7 / 55

Performance Calculation

PERFORMANCE CALCULATION - HEAVY FUEL OIL

MISSION OC
Standard Size: 1600 kg/h
Customer:

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2


7-8 / 55

User: lkh

Config. no.:

Heavy Fuel Oil


40200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:02:41

Page 4 of 6
Language UK

Performance Calculation

106393#A.2

PERFORMANCE CALCULATION - HEAVY FUEL OIL

MISSION OC

Standard Size: 1600 kg/h


Customer:

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2


Language UK

User: lkh

Config. no.:

Heavy Fuel Oil


40200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:02:41

Page 5 of 6
7-9 / 55

Performance Calculation

PERFORMANCE CALCULATION - HEAVY FUEL OIL

MISSION OC
Standard Size: 1600 kg/h
Customer:

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2


7-10 / 55

User: lkh

Config. no.:

Heavy Fuel Oil


40200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:02:41

Page 6 of 6
Language UK

Performance Calculation

106393#A.2

PERFORMANCE CULCULATION - DIESEL OIL

MISSION OC

Standard Size: 1600 kg/h


Customer:

Request no.:
106393

Config. no.:

Performance culculation - diesel oil

Language UK

Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2

User: lkh

Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:03:31

7-11 / 55

Page 3 of 6

Performance Calculation

PERFORMANCE CULCULATION - DIESEL OIL

MISSION OC
Standard Size: 1600 kg/h
Customer:

7-12 / 55

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2

User: lkh

Config. no.:

Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C

Language UK

Date/Time: 15/Jan/2013 - 16:03:31

Page 4 of 6

Performance Calculation

106393#A.2

PERFORMANCE CULCULATION - DIESEL OIL

MISSION OC

Standard Size: 1600 kg/h


Customer:

Language UK

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2

User: lkh

Config. no.:

Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C

Date/Time: 15/Jan/2013 - 16:03:31

7-13 / 55

Page 5 of 6

Performance Calculation

PERFORMANCE CULCULATION - DIESEL OIL

MISSION OC
Standard Size: 1600 kg/h
Customer:

7-14 / 55

Request no.:
106393
Fuel type
Calorific value

:
:

Working pressure
Feed water temperature

:
:

Version no.: 6.11.2

User: lkh

Config. no.:

Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C

Language UK

Date/Time: 15/Jan/2013 - 16:03:31

Page 6 of 6

DATA SHEET

Tag No(s): F1
Type:
Pressure atomizing
Operation: Modulating
Aalborg KBO-E-13M
Application:
Burning of marine diesel oil, marine gas
oil and heavy fuel oil according to ISO
8217/2010.
Distilate fuels type DMA, DMB.
Residual fuels type RMA, RMB, RMD,
RME, RMG 180 , RMG/K 380, RMG/K
500 and RMG/K 700.
Technical data:
Viscosity of oil at burner inlet, min. 1,1
cSt
Viscosity of oil at burner inlet, max. 380
cSt
El-preheater: 7.2 kW
Insulation class: F
Weight:110 kg

Installation:
The burner is left hinged. It can be right
hinged on request.
Dimension:
L: 1000
L1: 200
H: 620
H1: 420
W: 920
W1: 490
W2: 430
O.D.: 200
r: 1150

The items are not included


in burner item No.

H1

In- and outlet oil hoses


1 BSP x L = 2000 mm
item No. 8615 000050
Class BV: 8615000111

L1

W1

O.D.

W2

Type No.: 5561


Version: C.1

Language UK

Pressure atomizing burner, modulating

5561000011

7-15 / 55

DATA SHEET

Tag No(s): C331, C431


Type:
Pressure gauge valve needle straight.
Size:
1/2 x 1/2
Application:
For instrument connections
Material:
Body: C22.8
DIN-material No. 1.0460
Technical data:
Nominal pressure: PN 400
Test connection: M20 x 1.5 mm threaded
male
Weight: 0.4 kg

Type No.: 6210


Version: C.1

7-16 / 55

Needle valve, straight, " x ", PN 400

2541002

Language UK

DATA SHEET

Tag No(s): C33


Type:
Pressure gauge
Size:
100
Application:
For all gaseous and liquid media
Material:
Case: Stainless steel
Socket: Cu-alloy
Liquid filling: Glycerine

Technical data:
Measuring unit: bar Mpa - kg/cm
Measuring range: 0 16 / 1.6 /16 with
mechanical stop
Connection: BSP 1/2-m
Operating temperature:
Ambient: -20to + 60C
Medium, max.: + 60C
Protection: IP 65

30
0
0

bar
16
MPa=bar x 0.1
16
kg/cm

Type No.: 8050


Version: C.1

Language UK

100

81.5

107

Pressure gauge, 100

BSP 1/2-m

6632973

7-17 / 55

DATA SHEET

Tag No(s): C35

Version: B.2

7-18 / 55

Pressure switch RT30AW 1-10 Bar

6310310

Language UK

DATA SHEET

Tag No(s): C35

Version: B.2

Language UK

Pressure switch RT30AW 1-10 Bar

6310310

7-19 / 55

DATA SHEET

Tag No(s): C225

Type No.: 8010


Version: B.2

7-20 / 55

52
36

PG 11

106

24
SW 24

25

55

Type:
Pressure transmitter
Range:
0 - 10 bar(g)
Application:
The pressure transmitter converts pressure to an electric signal. The units are
supplied as passive two wire transmitters. The output current is linearly proportional to the input pressure.
Material:
Housing: Stainless steel with piezoresistive measuring cell and electronics module.
Process connection: Stainless steel
Technical data:
Electrical specification:
Current output signal: 4 to 20 mA
Power supply terminal voltage for current output: 7 to 33VDC
Accuracy:
Response time T99: < 5 ms
Influence of ambient temperature at start
of scale: 0.25%/10K of full scale value
Influence of ambient temperature at full
scale value: 0.25%/10K of full scale value
Mechanical:
Process temperature: -30C to +120C
Ambient temperature: -25C to +85C
Max pressure: 25 bar(g)
Min pressure: -1 bar(g)
Degree of protection to EN 60529: IP65
Cable gland: PG11
(cable size 5 to 10 mm)
Weight: 0.09 kg

G 1/2 -m

Connection diagram:

Pressure transmitter 0 - 10 bar(g)

8010000022

Language UK

DATA SHEET

DATA SHEET

Tag No(s): G115, G441

--- NO TITLE ---

Type:

Installation:

Three-way valve, ball


LB 283 BW, reduced bore

Information and caution before installation


of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball is
lubricated with a pure vaseline oil,
which can be easily removed with a
solvent, if required.
Ball valves normally have a space
between ball and inside cavity of the
body, which could trap the product, care
should be taken to drain the cavity.

Size:

DN 32

Application:

For air, steam, or oil flow

Material

Body: ASTM A105


End connections: ASTM A105

Technical data:

Min./max. temperature at 30 bar:


- 29C to + 230C
End connections: Butt weld according to
ASME/ANSI B16.25 - XS-80
Pipe size: DN 32
Weight: 7 kg

Instruction for welding the valve on the pipe


line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the
gaskets against damage and complete
the welding.
Insert the centre part and ensure easy
operation.

4.9
1.6

42.2
32.7

Detail A

37.5

225
Centre part

L-Bore

Bolt

98

Detail A

Port 1

Port 2
Port 3

End connections

Port 1

121.5

158

60

Type No.: 6070


Version: B.1
Version: A
B

Language UK
UK
Language

Port 2

Three-way
valve
Ball
DN32
BW
Three-way
valve,
ball
DN 32

Port 3

6070
000013
6070000013
87D3073

7-21
55
Page/ 1/1
1/3

DATA SHEET

EGO SWITCHBOX
TYPE M
Tag No(s): G115, G441
Description:
EGO switchbox with integrated mikroswitches to be used
for remote as well as visual indication of valve position
The switchbox include bracket for mounting on a
pneumatic actuator. With use of a special bracket the box
can be mounted on a gearbox or directly on a valve.

SSpecifications
pecifikations

Version: B.1

7-22 / 55

Aalborg Industries

Box B us

Polycarbonat

ShaftAksel

POM

Kaplate
mskive
Cam

Nylon

Bundpplate
lade
Ground

Pertimax

Kamhoved
Cam

M
essing
Brass

Ttningsgrad
Protection

IP 65

Indikaindicator
tor
Position

POM

Three-way valve Ball DN32 O


BW
-rings ttning
O-ring

Data sheet No. 6070 000013

6070000013
Viton

Language UK

2/3

DATA SHEET

EGO SWITCHBOX
TYPE M
Tag No(s): G115, G441
Teknisk ddata
ata:
Technical
EGO BOX M

EGO BOX I

EGO BOX N

Kontakt antal
No. of switches

1+1

1+1

1+1

ontakttype
Type of K
switch

Mikroswitch

PNP induktiv

Namur

Fabrikat
Manufacture

Honeywell

Honeywell

Pepperl + Fuchs

pe No.
ManufactureTy
item

V5C010TB1C

992FS2-A9PV3-L

NJ2-V3-N-V5

Voltage Spnding

max. 250 VAC

9,6 - 50 VDC

8 VDC

Forbrug
Consumption

10 mA

Max. belastning
Max. load

10 (3) A

200 mA

Max. frekvens
Max. frequency

2 KHz

1 KHz

Ambitemperature
ent temperatur
Ambient

55oC til +85oC

25oC til +75oC

25oC til +100oC

Dimensioner LxBxH
Dimensions

82x80x67

82x80x67

82x80x67

Cable size:

Version: B.1

Language UK

Aalborg Industries

PG 11 (o.d. 5mm to 10 mm)

Three-way valve Ball DN32 BW

Data sheet No. 6070 000013

6070000013

7-23 / 55

2/3

7-24 / 55

Language UK

71Z20_065692#B.1
FLOW METER UNIT DN20, RING LINE

Flow meter unit DN20, ring line

Language UK

7-25 / 55

DATA SHEET

Tag No(s): G147


Type:
Fuel oil supply pump unit, with filter
Size:
Pump: L5
Connection type:
Connection inlet and outlet, pipe size inside / outside diameter: 38 / 48.6
Connection type: Flange according to
SAE, hole pattern 3.000PSI
Cable connection: 2 x M 25 x 1.5
Application:
For handling fuel oils - DMA, DMB,
DMZ and RMx according to ISO 8217
Material:
Station block, casing: EN-GJS-400-15
Station block, filter cover: S235JR
Pump, casing: EN-GJS-400-15
Pump, screw set: 16MnCrS5
Pump, flange cover: EN-GJS-400-15
Pump, end cover: EN-GJS-400-15
Technical data:
Ambient air temperature: 50C
Pressure, max. supply: 5.0 bar(g)
Pressure, relief design: 36 bar(g)
Pressure, discharge outlet: 33 bar(g)
Temperature max. fuel oil: 150C
Foundation bolts: M16
Oil viscosity min.: 1.1 cSt
Oil viscosity max.: 380 cSt
Oil viscosity: 1.1 cSt
Oil capacity: 282 l/h
NPSH: 5.0 mWC
Oil viscosity: 3 cSt
Oil capacity: 426 l/h
NPSH: 2.0 mWC
Viscosity: 380 cSt
Oil capacity: 702 l/h
NPSH: 2.4 mWC
Filtration: 250
Weight, motor: 9.5 kg
Weight, unit: 175 kg

Type No.: 9294


Version: B.1

Language UK

Electrical specification:
Rated output for motor: 1.32 kW
Starting method: Direct
Starting current: 17.15 A
Operating current (full load): 2.45 A
Revolutions: 3408 r.p.m.
Heating element motor: Not fitted
Power supply: 3 x 440V
Frequency: 60 Hz
Insulation class: F
Degree of protection: IP55

Fuel oil supply unit, with filter, size 600, 33 bar

9294002601

7-27 / 55

DATA SHEET

Tag No(s): G147

L8
L11

H6

H7

L12

H5

Lifting eye

H1

L4
SAE 1 "
3000PSI

G 1/2"

L5

H3

L4
L6

L7

L9

4
W

5
W

H2

H4

H8

Lifting eye

H9

L10

L3

36

W2

W3

W1

I.D.

L2
L1
L

Type No.: 9294


Version: B.1

7-28 / 55

Fuel oil supply unit, with filter, size 600, 33 bar

9294002601

Language UK

DATA SHEET

Tag No(s): G147


Dimension:
L: 700
L1: 650
L2: 580
L3: 374
L4: 110
L5: 90
L6: 270
L7:190
L8: 636
L9: 23
L10: 53
L11: 155
L12: 219
W: 573
W1: 550
W2: 68
W3: 418
W4: 101
W5: 130
H: 740
H1: 80
H2: 217
H3: 297
H4: 20
H5: 247
H6: min. 16
H7: 35
H8: 61
H9: 200 height for strainer removal
I.D.: 19

Type No.: 9294


Version: B.1

Language UK

Installation:
The pump/motor assemblies are of a vertical design and are delivered with
mounting feet and oil sump. For safety
purposes, the arrangement with motor
downwards is not admissible
Connections / flanges:
Counter flanges according to SAE. Bolts
and gaskets will be included in the supply.
Connection diagram:

1 Pump
2 Pressure-side pressure gauge
3 Reversing valve
4 Filter
5 Suction-side pressure gauge
6 Pressure relief valve
7 Non return valve

Fuel oil supply unit, with filter, size 600, 33 bar

9294002601

7-29 / 55

DATA SHEET

Tag No(s): G224


Technical data:
Nominal operating condition:
U = 600 V and I = 1.2 A or
U = 240 V and I = 3 A or
U = 120 V and I = 6 A
Protection: IP 65
Temperature: -25C to +70C

Type:
Remote start/stop box
Application:
For start/operation and stop of fuel oil
pumps
Material:
House: Polycarbonate
Colour: Grey

120
83

85

Fuel oil pumps


1
2

105

123

145

177

Start/operation
incl. lamp function

Stop

Cable glands M 32 (PG 29)


105

70

5.8

5.8

Type No.: 8001


Version: B.1

7-30 / 55

Remote start/stop box

8001000005

Language UK

15K7603#D.1
HEAT EXCHANGER MX10 T16 L=600

Heat Exchanger MX10 T16 L=600

Language UK

7-31 / 55

DATA SHEET

15

34

1/2

187

Type:
Safety valve
Size:
Nominal diameter: DN 15
Application:
To blow off steam, neutral gases, vapours and liquids
Material:
Body: GGG 40.3
DIN-material No.: 1.4581
Technical data:
Nominal pressure: PN 100
Thread: DIN ISO 228 part 1
Set point:10 bar
Weight: 1.2 kg

100

Tag No(s): G433, G470

12
1/2
42

Type No.: 6040


Version: C.1

Language UK

Safety valve, DN 15, PN 100

87S0032

7-33 / 55

DATA SHEET

Tag No(s): G434


Type:
Stop valve, ball straight
Size:
DN 15
Application:
For water, compressed air and oil
Material:
Body: Nickel-plated brass (MS 58)
Ball: Hard chromium plating brass
(MS 58)
Stem: Brass (MS 58)
Stem nut: Galvanized steel
Seat rings: Teflon (PTFE)
Stem gasket: Teflon (PTFE)

Technical data:
Max. workingpressure at 80C: 32 bar
Max. working pressure at 150C: 10 bar
Weight: 0.18 kg

44

85

BSP

60

Type No.: 6010


Version: A.2

7-34 / 55

31

Stop valve, ball straight, DN 15, PN 40

6666106

Language UK

DATA SHEET

Tag No(s): G435


Type:
Needle valve
Size:
1/2" x 1/2"
Application:
For air and oil flow
Material:
Body: Brass CuZn39Pb3
Gasket: Teflon
Handle: Nylon 6.6
Technical data:
Working pressure: 250 bar(g)
Working temperature max.: 200C
Dimension:
A: 1/2" BSPP
B: 1/2" BSPP
H max.: 53
L: 46

Type No.: 6000


Version: A.2

Language UK

Needle valve 1/2" x 1/2"

87N6004

7-35 / 55

DATA SHEET

Tag No(s): G468, G469


Material:
Body: EN-GJS-400-18U-LT
DIN-materiale No: EN-JS1049
Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Disc: X20Cr13+QT
DIN-materiale No: 1.4021+QT
Technical data:
Nominal pressure: PN 25
Weight: 4.3 kg
Flanges according to DIN
Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard

Type:
Stop globe valve, straight
Size:
Nominal diameter: DN 20
Application:
For steam and/or water flow

Disc
Seat

20

75 / 4 x 14

105

180

120

Body

150

Type No.: 6010


Version: D.1

7-36 / 55

Stop valve, straight, DN 20, PN 25

2501087

Language UK

DATA SHEET

Tag No(s): G436

Type No.: 6070


Version: H.1

Language UK

W
Switchbox

Actuator

Solenoid valve

Three-way valve

Detail A

W2

L1

W1

T1
T

I.D.

Detail A

O.D.

H1

Type:
Three-way ball valve (reduced L-bore)
with actuator and solenoid valve
Size:
Connection nominal: DN 32
Cable connection, switch box: PG 11
Cable connection, solenoid valve: PG 9
Pipe connection: 1/4"
Connection type:
Connection type: Butt welded ends according to ASME/ANSI B16.25 - XS-80
Application:
For air, steam, or oil flow
Material, three-way valve:
Body: ASTM LF2 ( A105)
End connections: ASTM LF2 ( A105)
Material, actuator:
Body: Alodur (special hard anodized)
Material, solenoid valve:
Body: Aluminium, black anodized
Technical data, valve:
Temperature at 30 bar min.: - 29C
Temperature at 30 bar max.: + 230C
Technical data, actuator:
Actuator: Spring return (SR)
Air supply pressure min.: 5 bar
Air supply pressure max.: 8 bar
Temperature, min. operating: -20C
Temperature, max. operating: +80C
Technical data, solenoid valve:
Orifice size: 6 mm
Flow coefficient: 0.6 m/h
Technical data switch box:
Temperature min., ambient: - 55C
Temperature max., ambient: + 80C
Technical data, unit:
Weight: 14 kg

Dimension:
L: 268.5
L1: 158
H: 228
H1: 303
W: 163
W1: 121.5
W2: 79
T: 1.6
T1: 4.9
r: 37.5
I.D.: 32.7
O.D.: 42.2

Three-way valve, ball DN 32 build together with


actuator, solenoid valve and switch box

6070000029

7-37 / 55

DATA SHEET

Tag No(s): G436


Electrical data:
Power supply: 230 V
Frequency: 50 / 60Hz
Installation:
Information and caution before installation
of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball
is lubricated with a pure vaseline oil,
which can be easily removed with a solvent, if required.
Ball valves normally have a space between ball and inside cavity of the body,
which could trap the product, care should
be taken to drain the cavity.
Instruction for welding the valve on the pipe
line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the gaskets against damage and complete the
welding.
Insert the centre part and ensure easy operation.

Micro switch connection:

L-Bore
Port 1

Port 2
Port 3

Port 2

Port 1
Port 3

Type No.: 6070


Version: H.1

7-38 / 55

Three-way valve, ball DN 32 build together with


actuator, solenoid valve and switch box

6070000029

Language UK

DATA SHEET

Tag No(s): G448


Type:
Stop ball valve, straight
133 BW, full bore
Size:
DN 32
Application:
For air, steam, or oil flow
Material
Body: ASTM A105
End connections: ASTM A105
Technical data:
Min./max. temperature at 30 bar:
- 29C to + 230C
End connections: Butt weld according to
ASME/ANSI B16.25 - XS-80
Pipe size: DN 32
Weight: 4.3 kg

4.9
1.6

42.2
32.7

Detail A

37.5

Installation:
Information and caution before installation
of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball
is lubricated with a pure vaseline oil,
which can be easily removed with a solvent, if required.
Ball valves normally have a space between ball and inside cavity of the body,
which could trap the product, care should
be taken to drain the cavity.
Instruction for welding the valve on the pipe
line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the gaskets against damage and complete the
welding.
Insert the centre part and ensure easy operation.

225

Bolt

108

Detail A

End connection
Center part
120

Type No.: 6010


Version: B.1

Language UK

Stop valve, ball, straight, DN 32

85

87D3066

7-39 / 55

DATA SHEET

Tag No(s): G437, G439

Version: D.1

7-40 / 55

W
Switchbox

Actuator

Solenoid valve

Three-way valve

Detail A

W2

L1

W1

T1
T

I.D.

Detail A

O.D.

H1

Type:
Three-way ball valve (reduced L-bore)
with actuator and solenoid valve
Size:
Connection nominal: DN 25
Cable connection, switch box: PG 11
Cable connection, solenoid valve: PG 9
Pipe connection, solenoid valve: 1/4"
Connection type:
Connection type: Butt welded ends according to ASME/ANSI B16.25 - XS-80
Application:
For air, steam, or oil flow
Material, three-way valve:
Body: ASTM LF2 (A105)
End connections: ASTM LF2 (A105)
Material, actuator:
Body: Alodur (special hard anodized)
Material, solenoid valve:
Body: Aluminium, black anodized
Technical data, valve:
Temperature at 30 bar min.: - 29C
Temperature at 30 bar max.: + 230C
Technical data, actuator:
Actuator: Spring return (SR)
Air supply pressure min.: 5 bar
Air supply pressure max.: 8 bar
Temperature, min. operating: -20C
Temperature, max. operating: +80C
Technical data, solenoid valve:
Orifice size: 6 mm
Flow coefficient: 0.6 m/h
Technical data switch box:
Temperature min., ambient: - 55C
Temperature max., ambient: + 80C
Technical data, unit:
Weight: 15 kg

Dimension:
L: 268.5
L1: 150
H: 221
H1: 393
W: 163
W1: 114
W2: 75
T: 1.6
T1: 4.6
r: 37.5
I.D.: 24.3
O.D.: 33.4

Three-way valve, ball DN 25 build together with


actuator, solenoid valve and switch box

6070000017

Language UK

DATA SHEET

Tag No(s): G437, G439


Electrical data:
Power supply: 230 V
Frequency: 50 / 60Hz
Installation:
Information and caution before installation
of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball
is lubricated with a pure vaseline oil,
which can be easily removed with a solvent, if required.
Ball valves normally have a space between ball and inside cavity of the body,
which could trap the product, care should
be taken to drain the cavity.
Instruction for welding the valve on the pipe
line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the gaskets against damage and complete the
welding.
Insert the centre part and ensure easy operation.

Micro switch connection:

L-Bore
Port 1

Port 2
Port 3

Port 2

Port 1
Port 3

Version: D.1

Language UK

Three-way valve, ball DN 25 build together with


actuator, solenoid valve and switch box

6070000017

7-41 / 55

DATA SHEET

DATA SHEET

Tag No(s): G441

--- NO TITLE --Type:

Installation:

Three-way valve, ball


LB 283 BW, reduced bore

Information and caution before installation


of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball is
lubricated with a pure vaseline oil,
which can be easily removed with a
solvent, if required.
Ball valves normally have a space
between ball and inside cavity of the
body, which could trap the product, care
should be taken to drain the cavity.

Size:

DN 32

Application:

For air, steam, or oil flow

Material

Body: ASTM A105


End connections: ASTM A105

Technical data:

Min./max. temperature at 30 bar:


- 29C to + 230C
End connections: Butt weld according to
ASME/ANSI B16.25 - XS-80
Pipe size: DN 32
Weight: 7 kg

Instruction for welding the valve on the pipe


line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the
gaskets against damage and complete
the welding.
Insert the centre part and ensure easy
operation.

4.9
1.6

42.2
32.7

Detail A

37.5

225
Centre part

L-Bore

Bolt

98

Detail A

Port 1

Port 2
Port 3

End connections

Port 1

121.5

158

60

Type No.: 6070


Version: B.1
Version: A
B

7-42 /Language
55
UK

Port 2

Three-way
valvevalve,
Ball DN32
BW32
Three-way
ball DN

Port 3

6070
000013
6070000013
87D3073

Language UK
Page 1/1
1/3

DATA SHEET

EGO SWITCHBOX
TYPE M
Tag No(s): G441
Description:
EGO switchbox with integrated mikroswitches to be used
for remote as well as visual indication of valve position
The switchbox include bracket for mounting on a
pneumatic actuator. With use of a special bracket the box
can be mounted on a gearbox or directly on a valve.

SSpecifications
pecifikations

Version: B.1

Language UK

Aalborg Industries

Box B us

Polycarbonat

ShaftAksel

POM

Kaplate
mskive
Cam

Nylon

Bundpplate
lade
Ground

Pertimax

Kamhoved
Cam

M
essing
Brass

Ttningsgrad
Protection

IP 65

Indikaindicator
tor
Position

POM

Three-way valve Ball DN32


O
-ringBW
s ttning
O-ring

Data sheet No. 6070 000013

6070000013
Viton

7-43 / 55

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DATA SHEET

EGO SWITCHBOX
TYPE M
Tag No(s): G441
Teknisk ddata
ata:
Technical
EGO BOX M

EGO BOX I

EGO BOX N

Kontakt antal
No. of switches

1+1

1+1

1+1

ontakttype
Type of K
switch

Mikroswitch

PNP induktiv

Namur

Fabrikat
Manufacture

Honeywell

Honeywell

Pepperl + Fuchs

pe No.
ManufactureTy
item

V5C010TB1C

992FS2-A9PV3-L

NJ2-V3-N-V5

Voltage Spnding

max. 250 VAC

9,6 - 50 VDC

8 VDC

Forbrug
Consumption

10 mA

Max. belastning
Max. load

10 (3) A

200 mA

Max. frekvens
Max. frequency

2 KHz

1 KHz

Ambitemperature
ent temperatur
Ambient

55oC til +85oC

25oC til +75oC

25oC til +100oC

Dimensioner LxBxH
Dimensions

82x80x67

82x80x67

82x80x67

Cable size:

Version: B.1

7-44 / 55

Aalborg Industries

PG 11 (o.d. 5mm to 10 mm)

Three-way valve Ball DN32 BW

Data sheet No. 6070 000013

6070000013

Language UK

2/3

DATA SHEET

Tag No(s): G472


Pressure rating:
Pressure nominal: PN 40
Application:
For safety shut down

Type:
Twin quick closing valve unit
Size:
Connection nominal: DN25
Connection, hose: 18
Cable gland: M16 x1.5

344.5

Limit switch
Cable gland M16x1.5

Oil to burner 18

185

Dn25 PN 40
Oil to tank

Type No.: 6000


Version: B.1

Language UK

Twin quick closing valve unit, DN25, PN40

120

61.5

313.5

255

DN25 PN 40
Oil from tank

252

Non return
valve

31.5

353

Oil from burner 18

6000000111

7-45 / 55

DATA SHEET

Tag No(s): G482

Type No.: 6070


Version: F.1

7-46 / 55

W
Actuator

Solenoid valve

Three-way valve

Detail A

W2

L1

W1

T1
T

I.D.

Detail A

O.D.

H1

Type:
Three-way ball valve (reduced L-bore)
with actuator and solenoid valve
Size:
Connection nominal: DN 25
Cable connection, solenoid valve: PG9
Connection type:
Connection type: Butt welded ends according to ASME/ANSI B16.25 - XS-80
Application:
For air, steam, or oil flow
Material, three-way valve:
Body: ASTM A105
End connections: ASTM A105
Material, actuator:
Body: Alodur (special hard anodized)
Material, solenoid valve:
Body: Aluminium, black anodized
Technical data, valve:
Temperature at 30 bar min.: - 29C
Temperature at 30 bar max.: + 230C
Technical data, actuator:
Actuator: Spring return (SR)
Air supply pressure min.: 5 bar
Air supply pressure max.: 8 bar
Temperature, min. operating: -20C
Temperature, max. operating: +80C
Technical data, solenoid valve:
Pipe connection: 1/4"
Orifice size: 6 mm
Flow coefficient: 0.6 m/h
Technical data, unit:
Weight: 13 kg
Electrical data:
Power supply: 230 V
Frequency: 50 / 60Hz

Dimension:
L: 268.5
L1: 150
H: 221
H1: 263
W: 163
W1: 114
W2: 75
T: 1.6
T1: 4.6
r: 37.5
I.D.: 24.3
O.D.: 33.4

Three-way valve, ball DN 25 build together with


actuator and solenoid valve

6070000047

Language UK

DATA SHEET

Tag No(s): G482


Installation:
Information and caution before installation
of the valve:
Pipe must be free of tension.
Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
which would damage the ball and seat.
The valve must be kept in open position
during installation. Protective plastic
covers must not be removed before the
installation work commences.
At the moment of the shipment the ball
is lubricated with a pure vaseline oil,
which can be easily removed with a solvent, if required.
Ball valves normally have a space between ball and inside cavity of the body,
which could trap the product, care should
be taken to drain the cavity.
Instruction for welding the valve on the pipe
line:
Tack weld in four points on both endconnections.
Lift out the centre part to protect the gaskets against damage and complete the
welding.
Insert the centre part and ensure easy operation.

L-Bore
Port 1

Port 2
Port 3

Port 2

Port 1
Port 3

Type No.: 6070


Version: F.1

Language UK

Three-way valve, ball DN 25 build together with


actuator and solenoid valve

6070000047

7-47 / 55

DATA SHEET

Tag No(s): G114


Type:
Filter regulator with automatic drain
Size:
Connections ports 1/4 BSP
Gauge ports 1/8 BSP
Application:
Instrument air for regulating pressure
Technical data:
Medium: instrument air only
Max. inlet pressure: 17 bar
Operating temp.: 20 C to + 65 C
Filter element: 5 m
Recommend pressure regulating range:
0.14-7.0 bar
Pressure gauge: 0 10 bar
Weight: 0.4 kg
Material:
Body: Steel
Bin: Steel
Handle: Acetal

30

66

Max. 6

23
2.5

44

7.5

Di smantel length 138

14

Gauge por ts

28
99

18

38

Connections ports

41

R1
9

SW19

31

Inlet pressure 7 bar

7
Outlet pressure [bar]

Fitting

Bin

Flow characteristics

H andle

Body

6
5
4
3
2
1
1

10

Air flow [dm /s]

Type No.: 8000


Version: B.1

7-48 / 55

Filter regulator with automatic drain

2915101

Language UK

DATA SHEET

Tag No(s): G471, G481


Type:
Pressure control valve
Connection type:
Connection type: 1/2" BSP
Pressure rating:
Pressure design: 30 bar
Applilction:
For handling fuel oils - DMA, DMB,
DMZ and RMx according to ISO 8217
Material:
Housing: GJS-400
Technical data:
Flow range: 2400 l/h
Setting range: 10 to 30 bar
Fluid temperature min.: -20C
Fluid temperature max.: 220C
Temperature min., ambient: - 20C
Temperature max., ambient: 60C
Weight: 1.3 kg
Installation:
In pipe line
Recomended pipe size up stream and
down stream of pressure control valve DN25
Pipe line pressure loss is to be kept at
minimum
Set screw down (preferred)

To burner

Diagram:
From pump

To burner

Return line

40

142

182

35

G 1/2

40

35

From pump

Return to
Mixing tube/tank

Type No.: 6050


Version: O.1

Language UK

Pressure control valve, 1/2"

6050000542

7-49 / 55

DATA SHEET

Tag No(s): G477


Type
Check valve
Disc-spring
Connection type:
DN 32
Pressure rating:
Pressure nominal: PN 40
Application:
For steam and oil flow
Material:
House: Stainless steel 1.4408
Disc: Stainless steel 1.4436
Spring: Stainless steel

Type No.: 6020


Version: B.1

7-50 / 55

Technical data
Temperature max: 200C
Weight: 0.6 kg
Dimension:
d = 30
D = 75
L = 28
F = 84
W = 78

Check valve, DN 32, PN 40

6020000088

Language UK

DATA SHEET

Tag No(s): G466


Type:
Sample Unit
Size:
DN 8
Connection type:
Connection type: Butt welded end
Application:
For oil flow
Material:
1. Body: ASTM A216-WCB
2. Body: Carbon Steel

Technical data:
Weight: 1.5 kg Approx.
Dimension:
L: 100 Approx.
L1: 113.5
H: 57
O.D.: 13.5
I.D.: 8

Item. 6010000372

L1

O.D.

Item. 6000000109

I.D.

1
L

1. Stop valve - ball type.


2. Spring loaded stop valve (normally closed)
push to open.

Type No.: 6000


Version: C.1

Language UK

Sample Unit

6000000119

7-51 / 55

DATA SHEET

Tag No(s): G466


Installation, welded end :
With the valve in the open position, remove body connector bolts (or screws).
Separate pipe ends from body and remove seat rings, and body seals, taking
care not to damage plastic parts. Place
ball in part-open position to assist removal of seat.
Support ball to prevent it from falling out
of body and turn valve to closed position
for removal.
Place all components removed in clean
secure position, clear of welding splatter.
Replacing two bolts reassemble body
connectors with body.
Align valve to pipe line, ensuring proper
fit to minimize pipe load. Tack weld only.
Undo body bolts and remove body to
clean secure area.
Protect body connector faces from welding splatter and complete welding. Allow
enough time for cooling.
Replace the ball carefully in the body and
turn to fully open position. Replace body
seals (from attached package).
Assemble seats in the body.
Ease body assembly between body connectors, taking care not to score faces or
damage seals.
Replace body bolts and nuts (or screws)
and tighten firmly.

Type No.: 6000


Version: C.1

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Sample Unit

6000000119

Language UK

71Z20_056461#E.1
TEMPERATURE TRANSMITTER IN RING LINE

Temperature transmitter in ring line

Language UK

7-53 / 55

71Z20_056461#E.1
TEMPERATURE TRANSMITTER IN RING LINE

7-54 / 55

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K16_004096#D.1
COUNTER FLANGE

Counter flange
1

Language UK

--- NO TITLE ---

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TABLE OF CONTENTS

Table of contents
Control system Aalborg OC
Description
Electrical drawings for boiler control panel - 3L2..........
Set point list..............................................................
Alarm & shutdowns list..............................................
Menu tree.................................................................

Language UK

Document ID
Page
101X03_617934...........
8-2
106393........................ 8-73
106393........................ 8-74
106393........................ 8-76

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0-16

Range

Set point

9.0

(proposal)

7MF 4433

Type

Indication

Remote water level Indication

bar(g)
deg. C

-100

Page 1

Potential free signal

Feed water reg. On/off

39X2(298-299)

39X2(298-299)

Potential free signal

Alarm Low water level

51X2(110-111)

44X2(52-53)

44X2(54-55)

80X1(202-203)

80X1(200-201)

40X1(122-123)

50X1(116-117)

39X2(298-299)

44B13F

44B14F

82P5D

82P1D

40A2F

50A9F

Potential free signal

3W32

3H2

3C48

50X1(118-119)

Alarm High water level

HIGH TEMPERATURE UPTAKE

HIGH STEAM PRESSURE SWITCH

BOILER PRESSURE LOW

BOILER PRESSURE HIGH

BOILER PRESSURE HIGH

50A10F

51X2(112-113)

JUMO

KPS 37

PR5714

PR5714

PS-4000-1

MBS 5100

WATER LEVEL LOW


WATER LEVEL LOW

3W16

Potential free signal

400

8.5

n/a

4.0

7.0

7.5

-150

WATER LEVEL HIGH

Alarm common

20-500

6-18

4-20

4-20

4-20

250
150

diagram

in wiring

Digital output

Shut down

Pressure switch high steam pressure (9 bar(g)) Shut down

mA

mA

mA

Temp. switch high temp. in uptake

Digital input

Operation

Indication

bar(g)

Low Alarm

I/P positioner water level valve 1

bar(g)

Remote steam pressure Indication

Analog output

bar(g)

Low Shutdown

High Alarm

mm
mm

Low Alarm

High Shutdown

mm
mm

High Shutdown

High Alarm

100X03: 617934

Element
terminal No.
diagram

wiring

Physical Remarks
location

Alarm output
terminal in

Set point list

Boiler steam pressure transmitter

Water level transmitter

Analog input
WATER LEVEL HIGH

3) Wiring diagram:

display

2) Flow diagram:

in controller

ITEM NO IN DRAWING
1) General arrangement:

Indicator
Shutdown/Alarm text

C1

bar(g)

Units

Safety valve

Steam blow off

Function

L2

Language UK

BOILER CONTROL PANEL

Item

Project Number:106393

106393#A.2

SET POINT LIST

8-73 / 78

Shutdowns And Alarms

x
x
x

x
x
x

x
x
x

x
x
x
x

x
x
x
x

13, Post purge

x
x
x

9, Mod. Free

x
x
x

8, Rising

x
x
x

7, Low fire

6, Flame stable

4, Ignition

5, Safty time

3, Ingition pos.

2, Pre-Purge

1, Starting

0, Ready

x
x
x
x

Stopped

x
x
x
x

x
x
x

Number

ALARM & SHUTDOWNS LIST

Step

Shutdown

106393#A.2

Burner Type: KBO-E

7.12 Rev 4200 (Released 2012-12-14)


Burner Type: KBO-E
Boiler Type: Aalborg OC + XS2V
Oil System: 6

Text

1
2
3
5
6
7
11
14
15
16
21
24
26
27
28
29
30
34
35
37
40
58
61
62
63
64
66
67
68
69
71
72
73
74

HIGH STEAM PRESSURE SWITCH


TOO LOW WATER LEVEL SWITCH
BURNER NOT READY
FLAME OUT
AIR SERVO ERROR
NO FUEL PUMPS AVAILABLE
OIL SERVO ERROR
START SEQUENCE MAX TIME EXPIRED
PHOTO CELL FAILURE
QUICK CLOSING VALVE NOT OPEN
BURNER SWING OUT
HIGH OIL PRESSURE RETURN LINE
HEAVY FUEL OIL TEMPERATURE LOW
HEAVY FUEL OIL PRESSURE LOW
WATER LEVEL HIGH
WATER LEVEL LOW
BOILER PRESSURE HIGH
LOW COMB AIR PRESS SWITCH
BURNER MOTOR OVERLOAD
SALINITY HIGH
EXTERNAL SHUTDOWN 1
OIL CONTENT HIGH
HIGH OIL TEMP SW IN PREHEATER
HEAVY FUEL OIL PRESSURE HIGH
FUEL OIL TEMPERATURE HIGH IN BURNER
FUEL OIL TEMPERATURE LOW IN BURNER
FLAME OUT SCANNER 2
OIL TYPE CHANGED WHILE FLUSHING
EXTENDED IO COMMUNICATION ERROR
FLUSH STARTED WHILE RUNNING
FEEDBACK ERROR ON VALVE
GAS OIL TEMPERATURE HIGH
GAS OIL PRESSURE HIGH
GAS OIL PRESSURE LOW

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

76

DIESEL OIL PRESSURE LOW

77

DIESEL OIL PRESSURE HIGH

78

HIGH DP MGO SUCTION FILTER

79

HIGH DP HFO SUCTION FILTER

80

DIESEL OIL TEMPERATURE HIGH

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

Shutdowns

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

x
x
x
x
x
x

Alarm & shutdowns list


x
x
x
x

x
x
x
x

x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x

x
x

x
x

x
x
x
x

x
x
x
x

x
x
x
x

8-74 / 78

x
x

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x

Language UK

Page 1 of 2

Shutdowns And Alarms


7.12 Rev 4200 (Released 2012-12-14)
Burner Type: KBO-E
Boiler Type: Aalborg OC + XS2V
Oil System: 6

Shutdown

Stopped

0, Ready

1, Starting

2, Pre-Purge

3, Ingition pos.

4, Ignition

5, Safty time

6, Flame stable

7, Low fire

8, Rising

9, Mod. Free

13, Post purge

Step
Burner Type: KBO-E

106393#A.2

FUEL PUMP 1 NO FEEDBACK

FUEL PUMP 2 NO FEEDBACK

WATER PUMP 1 NO FEEDBACK

WATER PUMP 2 NO FEEDBACK

OIL CONTENT HIGH

SALINITY HIGH

15

BOILER PRESSURE LOW

17

WATER LEVEL HIGH

18

WATER LEVEL LOW

19

HEAVY FUEL OIL PRESSURE LOW

20

HEAVY FUEL OIL TEMPERATURE LOW

24

FUEL PUMP 1 OVERLOAD

25

FUEL PUMP 2 OVERLOAD

26

WATER PUMP 1 OVERLOAD

27

WATER PUMP 2 OVERLOAD

32

ST. BY FUEL PUMP STARTED

33

ST. BY WATER PUMP STARTED

35

SALINITY HIGH ANALOG

37

EXTERNAL STOP 1

38

BOILER PRESS. HIGH

40

HEAVY FUEL OIL TEMPERATURE HIGH

64

HIGH DP HFO SUCTION FILTER

68

DIESEL OIL TEMPERATURE LOW

73

GAS OIL TEMPERATURE HIGH

74

GAS OIL TEMPERATURE LOW

75

GAS OIL PRESSURE LOW

76

DIESEL OIL PRESSURE LOW

77

DIESEL OIL PRESSURE HIGH

78

HEAVY FUEL OIL PRESSURE HIGH

79

GAS OIL PRESSURE HIGH

80

DIESEL OIL TEMPERATURE HIGH

83

FUEL OIL PUMP NOT RUNNING

89

FEEDBACK ERROR ON VALVE G439

94

FEEDBACK ERROR ON VALVE G115

98

OIL TEMPERATURE NOT REACHED

100 FEEDBACK ERROR ON VALVE G436

103 FEEDBACK ERROR ON VALVE G441

109 FW PUMPS STOPPED OIL DETECTED

110 FW PUMPS STOPPED SALINITY DETECTED

Number

ALARM & SHUTDOWNS LIST

Text

Alarms

111 EGB FW PUMPS STOPPED OIL DETECTED

112 EGB FW PUMPS STOPPED SALINITY DETECTED

115 POWER SUPPLY 1 NO FEEDBACK

116 POWER SUPPLY 2 NO FEEDBACK

118 FEED WATER PUMP AUTO STARTED

119 ST. BY WATER PUMP B1 STARTED

120 ST. BY WATER PUMP B2 STARTED

121 BOILER TEMPERATURE HIGH

122 BOILER TEMPERATURE LOW

124 BOILER PRESSURE MANUAL

127 WATER LEVEL MANUAL

134 STEAM DUMP MANUAL

135 KEY SYSTEM DISABLED

137 BURNER MOTOR NEED SERVICE

139 FUEL PUMP 1 NEED SERVICE

140 FUEL PUMP 2 NEED SERVICE

143 CHEMICAL PUMP 1 NEED SERVICE

144 CHEMICAL PUMP 2 NEED SERVICE

145 FEED WATER PUMP 1 NEED SERVICE

146 FEED WATER PUMP 2 NEED SERVICE

149 OIL SUMMARIZER CAUSED SERVICE

152 BURNER LOAD >25% CAUSED SERVICE

153 BURNER LOAD >50% CAUSED SERVICE

154 BURNER LOAD >75% CAUSED SERVICE

155 BURNER LOAD CAUSED SERVICE

158 OIL SERVO MANUAL

159 AIR SERVO MANUAL

163 BOILER TEMP MANUAL


164 COMMON OIL SUM. CAUSED SERVICE

2
2

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

x
x

Language UK

8-75 / 78

Page 2 of 2

YORK Refrigeration, Marine & Controls

106393#A.2
0

MENU TREE FOR BOILER PLANT (POWER PANEL 1)


FRONT MENU
MAIN MENU
MENU
TREE
[INFO 1]

LINE
1
2
3
4
5
Burner
Boiler
Oil
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129

SUB MENU LEVEL 1

Printed: 15/01/2013 14:53

Pow1
SUB MENU LEVEL 2

SUB MENU LEVEL 3

SUB MENU LEVEL 4

[INFO 2]
[STATE 1]
[STATE 2]

Burner type:

1xKBSD, 2xKBSD, MS, RMS

PASSW.

HIGHEST

LOWEST

DEFAULT

Burner Type: All

N
N
PUMP CTRL
OIL PUMP

Menu tree

8-76 / 78

[VAL]

PUMP 1-1 MODE


STATE
PUMP 1-2 MODE
STATE
PUMP 2-1 MODE
STATE
PUMP 2-2 MODE
STATE
F.PMP1 REM START
F.PMP1 REM STOP
F.PMP2 REM START
F.PMP2 REM STOP
G.PMP1 REM START
G.PMP1 REM STOP
G.PMP2 REM START
G.PMP2 REM STOP

N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

CHEM PMP1
STATE
CHEM PMP2
STATE

N
N
N
N

F.W.PMP1 SEL.
MODE
STATE
F.W.PMP2 SEL.
MODE
STATE
F.W.PMP3 SEL.
MODE
STATE
F.W.PMP4 SEL.
MODE
STATE
F.PMP1 REM START
F.PMP1 REM STOP
F.PMP2 REM START
F.PMP2 REM STOP
F.PMP3 REM START
F.PMP3 REM STOP
F.PMP4 REM START
F.PMP4 REM STOP

N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

EGB FWP1 SEL.


MODE
STATE
EGB FWP2 SEL.
MODE
STATE

N
N
N
N
N
N

F.O.PMP 1
F.O.PMP 2
FUEL PRESS
F.O.PMP DEL
FLUSH TIMER 1
FLUSH TIMER 2
FLUSH TIMER 3
FLUSH TIMER 4
FLUSH TIMER 5
FLUSH TIMER 6
FLUSH TIMER 7
FLUSH TIMER 8
FLUSH TIMER 9
KEY TIMEOUT
G.OIL. PMP 1
G.OIL. PMP 2
GAS PRESS
G.O. PMP DEL
HFO P.LO.SD
HFO P.HI.SD
RL P.LO.SD
RL P.HI.SD
DO P.LO.SD
DO P.HI.SD
MGO P.LO.SD
MGO P.HI.SD
CHM.PMP1 DL
CHM.PMP2 DL

N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC
N SEC

[PANEL TYPE]
[VERSION]
[INFO 1]
[INFO 2]

N
N
N
N

DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
DI 9
DI 10
DI 11
DI 12
DI 13
DI 14
DI 15
DI 16
DI 17
DI 18
DI 19
DI 20
DI 21
DI 22
DI 23
DI 24
DI 25
EXT DI 1
EXT DI 2
EXT DI 3
EXT DI 4
EXT DI 5
EXT DI 6
EXT DI 7
EXT DI 8
EXT DI 9
EXT DI 10
EXT DI 11

N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

CHEM PMP

FEED PMP
FEED PMP

FEED PMP EGB

SETUP
DIAGNOSES
TIMERS INSPECT

SOFTWARE VERSION

DIGITAL INPUT

Language UK

YORK Refrigeration, Marine & Controls

106393#A.2
0

MENU TREE FOR BOILER PLANT (POWER PANEL 1)


LINE
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258

MENU SUB MENU LEVEL 1


MENUMAINTREE

FRONT MENU

Printed: 15/01/2013 14:53

Pow1
SUB MENU LEVEL 2

SUB MENU LEVEL 3

SUB MENU LEVEL 4

[VAL]

EXT DI 12
EXT DI 13
EXT DI 14
EXT DI 15
EXT DI 16

N
N
N
N
N

DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
DO 9
DO 10
DO 11
DO 12
DO 13
DO 14
DO 15
DO 16
DO 17
DO 18
EXT DO 1
EXT DO 2
EXT DO 3
EXT DO 4
EXT DO 5
EXT DO 6
EXT DO 7
EXT DO 8

N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
DO 9
DO 10
DO 11
DO 12
DO 13
DO 14
DO 15
DO 16
DO 17
DO 18
EXT DO 1
EXT DO 2
EXT DO 3
EXT DO 4
EXT DO 5
EXT DO 6
EXT DO 7
EXT DO 8

N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

Burner type:

1xKBSD, 2xKBSD, MS, RMS

PASSW.

HIGHEST

LOWEST

DEFAULT

Burner Type: All

DIGITAL OUTPUT

DIGITAL OUTPUT TEST

pw:su

ANALOG INPUT

pw:su
AI 1
AI 2
AI 3
AI 4
AI 5
AI 6
AI 7
AI 8
AI 9
AI 10
AI 11
AI 12
TACHO
EXT AI 1
EXT AI 2
EXT AI 3
EXT AI 4

ANALOG OUTPUT

pw:su
AO 1
AO 2
AO 3
AO 4

ANALOG OUTPUT TEST

pw:su
AO 1
AO 2
AO 3
AO 4

EXAMINE MEMORY
[ARD][CONTENT]

ACTUAL SP.
NEUTRALZONE
I-LOW LIMIT
I-HIGH LIMIT
P
T.SAMPLE
T.INT.
T.DIFF.
P.PART
I.PART
D.PART
MIN PULSE
RUN TIME
MV SAVE
REG OUTPUT
NON INVERTE
SYMMETRICAL
REMOTE CTRL

N C
N C
N
N
N
N SEC
N SEC
N SEC
N%
N%
N%
N SEC
N SEC
N C
N%
N
N
N
N BAR
N BAR
N BAR
N
N
N
N SEC
N SEC
N SEC
N%
N%
N%
N SEC
N SEC
N BAR
N%
N
N
N
N BAR

REGULATOR INSPECT
F.OIL TEMP

F.OIL PRES
ACTUAL SP.
NEUTRALZONE
I-LOW LIMIT
I-HIGH LIMIT
P
T.SAMPLE
T.INT.
T.DIFF.
P.PART
I.PART
D.PART
MIN PULSE
RUN TIME
MV SAVE
REG OUTPUT
NON INVERTE
SYMMETRICAL
REMOTE CTRL
STEAM DUMP

Language UK

8-77 / 78

YORK Refrigeration, Marine & Controls

106393#A.2
0

MENU TREE FOR BOILER PLANT (POWER PANEL 1)


FRONT MENU
MAIN MENU
MENU
TREE

LINE
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293

SUB MENU LEVEL 1

Printed: 15/01/2013 14:53

Pow1
SUB MENU LEVEL 2

SUB MENU LEVEL 3

SUB MENU LEVEL 4

[VAL]

ACTUAL SP.
NEUTRALZONE
I-LOW LIMIT
I-HIGH LIMIT
P
T.SAMPLE
T.INT.
T.DIFF.
P.PART
I.PART
D.PART
MIN PULSE
RUN TIME
MV SAVE
REG OUTPUT
NON INVERTE
SYMMETRICAL
REMOTE CTRL

N BAR
N BAR
N
N
N
N SEC
N SEC
N SEC
N%
N%
N%
N SEC
N SEC
N BAR
N%
N
N
N

COMMON PRES
F.OIL PRES
F.OIL TEMP
SMK. DEN. 1
SMK. DEN. 2
SALINITY

N BAR
N
N
N
N
N

PANEL TYPE
BURNER FAMILY
NODE NO.OFFSET
PART NO. OFFSET
BAUD RATE
MODBUS IO

N
N
N
N
N
N

CONTRAST
LANGUAGE

N
N

Burner type:

1xKBSD, 2xKBSD, MS, RMS

PASSW.

LOWEST

HIGHEST

DEFAULT

Burner Type: All

lo: 0

hi: 125

def: not def


def: multi
def: 1

com set:
com set:
com set:

lo: 600

hi: 38400

def: 19200
def: cre

com set:

lo: 20

hi: 80

def: 25
def: GB

com set:

DATA INSPECT

CONFIG
pw:su
pw:su
pw:su
pw:su
pw:su
pw:su

LANGUAGE

8-78 / 78

Language UK

TABLE OF CONTENTS

Table of contents
Drawings
Description
General arrangement drawing - Aalborg OC.................
General arrangement drawing - Aalborg XS-2V............
Spray shields for fuel oil system..................................
Flow meter unit DN20, ring line..................................

Language UK

Document ID
Page
04Y_068234................
9-3
10Y_067260................
9-5
94K_033645................
9-7
71Z20_065692.............
9-9

9-1 / 9

9-2 / 9

Language UK

04Y_068234#A.2
GENERAL ARRANGEMENT DRAWING - AALBORG OC

General arrangement drawing - Aalborg OC

Language UK

9-3 / 9

9-4 / 9

Language UK

Alteration

Affix

Date

Drawn

Appr.

Internal revision
Inlet and outlet dividing flanges added.
General boiler size changed

10Y_067260#A.3

Text on the leader for inlet and outlet flanges has been corrected.
GB has been relocated. Two 2-eyed lifting lugs is added

GENERAL ARRANGEMENT DRAWING - AALBORG XS-2V


C484
C301

A
C17

C18

C2

C10

C184
C1
C11

Specification of in- & outlet flanges has been updated

View B-B

Lifting eye(1-eye)

145(LW)

260

C27
C327

5149

5594(C1/C301)

5179(C1/C301)

4052(C327)

4052(C17)

C9

3394

4689

4384(NW)

5264(C2)
4990

C303
C304

5164(C10/C11)

C30

C3
C4

3639

C6
C5

5644(C184/C484)

200(HW)

18(C184/C484)

General arrangement drawing - Aalborg XS-2V

Manhole

C26

Manhole
2100

C24

Design data

225
85

275

225

1135

1050

C7
C

600

1000

650

C25

Handhole
Foundation console

Main engine load


Steam output

%
kg/h)

Working pressure
Design pressure
Approx. weight (excl. Water)
Approx. weight (incl. Water)

MPa
MPa
ton
ton

Lifting eye(1-eye)

X (C184, C484)
X (C1/C301)

C-C

X (C2)

(Shown with hidden lines)

X (C2)

View A-A

View A-A
Fix foot

CL Boiler

Sliding foot
X-axis

Manhole

C30

C11

R7

60

Guided foot

C24
5
22

26

17
6

C7
C25
C26

ain
Dr

C17

Size of lifting eye =

ton

17

C2

17

ain

20

10

Sliding foot
Y-axis

Dr

C9
C10

C18
C301
C484
Manhole

C1
C184

All drain lines indicated with symbols should be led


to hopper with a minimum inclination of 15 degrees

C4
C3

Approx. weight (excl water)


Approx. weight (incl water)

W16
C304
C303

C5
C6

Yes
Transport Mountings supply
Attach the Lifting Sketch to the boiler body.

TAG No., see List of Parts.


Dimensions shown without tolerances shall be according to:
Machine: DS/EN 22768-1. Table 1-m, Table 3-c
Welding: DS/EN ISO 13920. Table 1-B, Table 2-B
Title:

Language UK

Customer
Society
Newb. No.
Project No.
Boiler No.

Guangzhou Wenchong Shipyard Co Ltd -Guangzhou GD

RQ No.
Config No.
Boiler

RQ106397
CF2

7.1 ton
13.5 ton

Drawn

Date

Appr.

Date

Type of drawing:

Scale:

9-5 / 9

Article/Drawing No:

: 067260

Size

9-6 / 9

Language UK

94K_033645#D.1
SPRAY SHIELDS FOR FUEL OIL SYSTEM

Spray shields for fuel oil system

Language UK

9-7 / 9

SPRAY SHIELDS FOR FUEL OIL SYSTEM

9-8 / 9

Language UK

71Z20_065692#B.1
FLOW METER UNIT DN20, RING LINE

Flow meter unit DN20, ring line

Language UK

9-9 / 9

TABLE OF CONTENTS

Table of contents
Spare Parts
Description
Spare parts for Aalborg OC.........................................
Spare parts for Aalborg XS-2V....................................
Spare parts for Aalborg KBO-E...................................

Language UK

Document ID
106393......................
106393......................
106393......................

Page
10-2
10-3
10-4

10-1 / 4

SPARE PARTS FOR AALBORG OC

Spare parts for Aalborg OC


Boiler plant:.......................................................................................1 x Aalborg OC + 1 x Aalborg XS-2V
Request No.:...................................................................................................................................... 106393
Configuration No.:.......................................................................................................................................1
Hull No./Nos.:................................................................................GWS440, GWS441, GWS442, GWS443
Project No./Nos:...................................................................106393-01, 106393-02, 106393-03, 106393-04
Date:.........................................................................................................................................15 JAN 2013
The spare parts supplied in the scope of delivery for included Aalborg OC boilers are listed in the table below.

Spare parts

Tag No.
Qty.
Spare parts for the boiler
S-C1-3
1
S-C17-1/S-C18-1
2
S-C17-2/S-C18-2
6
S-C17-6/S-C18-6
1
S-C-1
4
S-C-2
16
S-C-3
4
S-C-7
12
S-C-8
1
S-C1-13
1
S-C33-1
1
S-C-17
1
Spare parts for commissioning
S-C-5
2
S-C-6
8

10-2 / 4

Application

Spare part No.

Spring for safety valve, OD32


Water level glass, Size 16, Dim. 250x30x17 mm
Gasket for water gauge stud
Inst., maintenance and operation manual
Gasket for manhole
Gasket for hand hole
Plug for pin element
Plug for smoke tube, OD35/OD41
Moulding Powder
Test gag for safety valve OD 32
Pressure gauge 100
Inspection mirror

8580000001
8590000019
2163719
8500001056
2158320
2158609
6494971
6494106
2118236
7000000053
6632973
8500000362

Gasket for manhole


Gasket for hand hole

2158320
2158609

Language UK

SPARE PARTS FOR AALBORG XS-2V

Spare parts for Aalborg XS-2V


Boiler plant:.......................................................................................1 x Aalborg OC + 1 x Aalborg XS-2V
Request No.:...................................................................................................................................... 106393
Configuration No.:.......................................................................................................................................3
Hull No./Nos.:................................................................................GWS440, GWS441, GWS442, GWS443
Project No./Nos:...................................................................106393-01, 106393-02, 106393-03, 106393-04
Date:.........................................................................................................................................18 JAN 2013
The spare parts supplied in the scope of delivery for includedx Aalborgx XS-2V boilers are listed in the table
below.

Spare parts

Tag No.
Qty.
Spare parts for the boiler
S-C1-3
1
S-C17-1/S-C18-1
2
S-C17-2/S-C18-2
6
S-C17-6/S-C18-6
1
S-C-1
2
S-C-2
10
S-C-7
12
S-C33-1
1
S-C1-13
1
Spare parts for commissioning
S-C-5
2
S-C-6
6

Language UK

Application

Spare part No.

Spring for safety valve, OD32


Water level glass, Size 16, Dim. 250x30x17 mm
Gasket for water gauge stud
Inst., maintenance and operation manual
Gasket for manhole
Gasket for hand hole
Tubeplug for boiler tube 51x3.6
Pressure gauge, OD100
Test gag for safety valve OD 32

8580000001
8590000019
2163719
8500001056
2158320
2158609
6494104
6632973
7000000053

Gasket for man hole


Gasket for hand hole

2158320
2158609

10-3 / 4

SPARE PARTS FOR AALBORG KBO-E

Spare parts for Aalborg KBO-E


Boiler plant:.......................................................................................1 x Aalborg OC + 1 x Aalborg XS-2V
Request No.:...................................................................................................................................... 106393
Configuration No.:.......................................................................................................................................1
Hull No./Nos.:................................................................................GWS440, GWS441, GWS442, GWS443
Project No./Nos.:..................................................................106393-01, 106393-02, 106393-03, 106393-04
Date:.........................................................................................................................................17 JAN 2013
The spare parts included in the scope of delivery of a standard modulating pressure atomizing burner are listed
in the table below.

Spare parts

Tag No.
Spare parts for the burner
S-F1-1
S-F1-3
S-F1-8
S-F1-8.1
S-F1-62
S-F1-112
Spare parts for the oil pumps
S-G147-1
CS-G147-9
CS-G147-10
Tools
F121

10-4 / 4

Qty.

Application

Spare part No.

1
1
1
1
1
1

Pressure gauge
Nozzle for burner
Photo cell
Rubber cover for photo cell
Set of ignition electrodes (left and right)
Nozzle Head repair set

8050000054
8610000107
6310720
8500001086
8620000084
8500000775

2
2
2

O-ring for Filter cover


O-ring for mechanical seal inner
O-ring for mechanical seal outer

3520000089
3520000195
3520000198

Hooking device for oil burner

8500000780

Language UK

TABLE OF CONTENTS

Table of contents
Descriptions
Description
Aalborg OC boiler.....................................................
Boiler mountings.......................................................
Water level control....................................................
Gauge board.............................................................

Language UK

Document ID
SD9210_02................
SD9220_17................
SD9230_10................
SD9240_14................

Page
11-2
11-6
11-8
11-9

11-1 / 9

SD9210_02#B.1
AALBORG OC BOILER

Aalborg OC boiler
1

Description
The Aalborg OC boiler is a combined oil and exhaust gas fired vertical marine boiler,
insulated and assembled as a unit with the boiler mountings mounted on the boiler
body.
The boiler mountings are mainly mounted on top of the boiler body in order to allow
a simple connection to the piping systems on board the ship.
The burner is ready for mounting in the furnace and connection of pre-marked electric
wiring.
The control system supplied with the Aalborg OC boiler unit provides fully automatic
operation of the boiler and burner.

1.1 Boiler pressure part


The pressure part of the Aalborg OC boiler is shown in Figure 1. The combined oil
fired and exhaust gas fired boiler is designed as a vertical boiler with a cylindrical shell
surrounding the oil fired and the exhaust gas fired sections. The oil fired section comprises the cylindrical furnace, the steam space, and the convection section consisting
of pin tube elements. The exhaust gas fired section comprises the stay tubes and smoke
tubes.
The pressure part is made of mild carbon steel with elevated temperature properties.
This means that stress concentrations in corner welding are minimised by the design
of the cylindrical shell with the flat endplates of equal thickness.
The cylindrical shell with the two flat endplates welded on is supported by the stay
tubes, the pin-tube elements, and the furnace. Also the steam drum is a cylindrical
vessel welded on the top plate and upper tube plate. The drum acts as a dividing plate
to the exhaust gas fired section. This unique design ensures that no supports are required.
The pin tube elements consist of an outer tube enclosing the pin tube. The pin tube is
a plain seamless steel tube provided with an inlet pipe at the bottom and an outlet pipe
at the top. A large number of pins are welded around the outside of the tube creating
an extended heating surface. This extended heating surface transfers heat from the flue
gas to the steam/water mixture in the pin tube.

11-2 / 9

Language UK

SD9210_02#B.1
AALBORG OC BOILER

The tubes in the exhaust gas fired section consist of a small number of stay tubes and
a large number of smoke tubes. The stay tubes with an increased diameter act as support
for the boiler. Both types are welded onto the endplates.
The furnace is cylindrical with two flat plates. The bottom steel plate is protected from
radiation of heat by refractory. Furthermore, the furnace bottom is provided with a
socket for drain of washing water.
For inside inspection, the Aalborg OC boiler is arranged with both hand holes and
manholes. Two manholes are arranged on the boiler shell for convenient access both
into the oil fired section and into the exhaust gas fired section. For visual check of the
smoke tubes, a number of hand holes are arranged in a suitable distance at the bottom
of the boiler drum. For inspection of the flue gas side, inspection doors are arranged
on the flue gas inlet and outlet chamber.
The boiler mountings such as safety valves, steam outlet valve, water level electrodes,
etc. are mainly mounted on top of the boiler body in order to allow simple connection
to the piping system on board the ship. Furthermore, inlet and outlet boxes are included
in the delivery.
Boilers with a diameter up to 3,000 mm are prepared for tack welding along the boiler
shell. For boilers with a diameter above 3,000 mm, the boiler foundation is arranged
as a flanged type which reduces the thermal mechanical stresses to a minimum during
operation. The counter flange is included and ready for welding to the deck. In both
cases, vent holes in suitable numbers are arranged to ensure the circulation of air below
the boiler.
The boiler is prepared for mounting of a compact silencer to suit any type of engine.
The optimal silencer dimensions suitable for each installation should be calculated on
basis of the data for the engine, exhaust gas system, and level of sound absorption.

Language UK

11-3 / 9

SD9210_02#B.1
AALBORG OC BOILER

Principle drawing of the Aalborg OC boiler


Stay tubes

Smoke tubes

Inspection door

Upper tube plate

Pin-tube

Steam drum

End plate
(top plate)

Smoke/stay tubes
Pin-tube
Boiler drum
Outer tube

Manhole
Furnace
Fire hole
Hand hole
Refractory

End plate
Inspection door
Foundation

Figure 1

sd9210_02_oc1x0063660en.wmf

1.2 Heat transfer and water circulation


Oil ignition and combustion take place in the furnace. The produced heat is transferred
mainly by radiation from the flame to the furnace shell. Leaving the furnace, the flue
gases enter the vertical uptakes where heat is transferred to the pin-tube elements
mainly by convection.
In the exhaust gas fired section, heat from the engine exhaust gas is transferred to the
water side by convection.
On the water side, the heat is transferred by evaporation of the saturated water adjacent
to the furnace shell or tube wall (smoke- and pin tubes) where steam bubbles are
formed. As the steam bubbles have a much lower specific density than the water, they
will rise rapidly to the steam space where water and steam are separated.
The natural circulation in the pin-tube element occurs because the density of water is
higher than the density of steam. The density of the water outside the pin-tube element
is higher than the steam/water mixture inside the pin tube element. The difference in
the static pressure at the bottom connection to the pin tube creates the driving force for
the circulation. The steam/water mixture is discharged into the steam space where the
heavier water particles separate from the steam and flow back into the water.
The oil fired section of the boiler is designed so that approximately half of the steam
is generated in the pin-tube elements and the rest by radiation in the furnace.

11-4 / 9

Language UK

SD9210_02#B.1
AALBORG OC BOILER

1.3 Steam space


The steam space in the oil fired boiler is designed to absorb the shrink and swell volumes. It is advisable, however, to avoid sudden and large load variations as this might
create instability in the steam system, and cause level alarms.

Language UK

11-5 / 9

SD9220_17#D.1
BOILER MOUNTINGS

Boiler mountings
1

Mountings
The following is a brief description of the most important items of the boiler mountings.
The components mentioned in this section are referring to the general arrangement
drawing of the boiler.
Safety valves
Two safety valves are fitted to the pressure vessel of the boiler. They are installed for
security reasons, and designed to prevent the boiler pressure from rising above the
design value.
The safety valves must be supplied with waste steam pipes and either expansion devices, or bellows.
Main steam valve
The main steam valve is a shut off/non-return valve. When closed, it isolates the boiler
from the main steam line. When open, it prevents steam from flowing backwards into
the boiler.
Feed water valve / feed water valve (sdnr)
Two feed water lines are provided in the boiler. Each line is fitted with a shut-off valve
and a non-return valve.
The shut-off valve in the primary line must be open when the boiler is in operation.
This also applies if only the exhaust gas fired section is in operation.
The shut-off valves should be closed when the boiler is not in use.
Water level gauges
Two local water level gauges are connected to the front of the boiler, each gauge being
provided with two shut-off valves and a drain valve.
The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-self
closing mechanism to be used in case of broken glass.
The pipes from the drain cocks on the water level gauge must lead to an open drain,
visible for inspection.

11-6 / 9

Language UK

SD9220_17#D.1
BOILER MOUNTINGS

Blow-down valve / blow-down valve (sdnr)


Two blow-down valves are mounted at the bottom of the boiler body. If connected to
a separate drainage system the valves are of the ball type. When connected to a common
drainage system two valves are provided in each group, one shut-off valve and one
shut-off/non-return valve. The shut-off function is for security and the non-return
function prevents steam/water from flowing into an empty boiler by mistake.
Air valve
The air/ventilation valve located on top of the boiler is a shut-off valve. It is normally
closed except when the boiler is being filled or completely drained. The end of the
drain pipe from the air valve must be visible in order to determine when air or steam
is coming out.
Scum valve
The scum valve is mounted at the top of the boiler body. In the event of scum in the
boiler, this scum can be blown off from the water surface by opening this valve. If
connected to a separate drainage system the valve is of the ball type. When connected
to a common drainage system two valves are provided, one shut-off valve and one
shut-off/non-return valve.
Sample valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Manhole
Two manholes are arranged on the boiler shell which allow inside inspection of the oil
fired section and the exhaust gas fired section.
Hand hole
A number of hand holes are distributed regularly around the circumference of the boiler
and at the bottom of the boiler drum for visual check and cleaning of the smoke tubes.
Inspection hole
A small inspection hole is provided in the furnace wall to enable inspection of the
burner flame. A proportion of the air supply is bled off from the burner fan to cool the
window of the inspection hole, and prevent soot deposits.
Inspection door
The boiler is provided with two inspection doors to enable inspection of the flue gas
inlet and outlet chambers.
Access to the furnace is gained by swinging out the burner unit or dismount the burner
in case of KBP type.
Drain for furnace
The furnace bottom is provided with a socket for drain of the washing water.

Language UK

11-7 / 9

SD9230_10#A.2
WATER LEVEL CONTROL

Water level control


1

Description
The water level control is an on/off regulating system at this type of boiler. The system
is illustrated in Figure 1. The system consists of one independent safety device electrode for too low water level shut down and burner stop. For measuring and control of
the water level, one capacitance level electrode is provided, and it is used to give water
level alarms/shut downs and start/stop of the feed water pumps.
Water level control system
Compact system
(level transmitter
and level electrode)
Water level control system
Feed water
valves

Flange

Safety device

HW

Boiler

NW
Control
system
(panel)

LW
Protection tube
Electrode stand
Vent hole

Feed water pumps

Figure 1

11-8 / 9

sd9230_10_ges_1_x0063930en.wmf

Language UK

SD9240_14#B.1
GAUGE BOARD

Gauge board
1

Description
The function of the gauge board is to control the burner and to give alarm and shut
down for low and high steam pressure.

Language UK

A pressure gauge is fitted for analogous reading of the actual steam pressure in the
boiler.
A pressure switch "high steam pressure" gives shut down and burner cut-off when
the steam pressure rises above the pre-adjusted set point. The pressure switch locks
the burner in stop mode. Operation of the burner is only possible when the steam
pressure falls below the differential set point of the pressure switch and the shut
down function is reset.
A pressure transmitter connected directly on the boiler converts the actual steam
pressure of the boiler into corresponding electric signals. The signals are used to
give alarms for low/high steam pressure and shut down/burner cut-off for high
steam pressure. The signals also control start/stop and modulation set point of the
burner. Furthermore, the pressure transmitter can be used for remote steam pressure indication.

11-9 / 9

TABLE OF CONTENTS

Table of contents
Operation and maintenance
Description
Start/stop of the boiler................................................
Boiler maintenance....................................................
Boiling out................................................................
Gaskets for boiler body..............................................
Cleaning pin-tube elements.........................................
Cleaning smoke tubes................................................
Preservation..............................................................
Boiler repair - pin-tube element...................................
Plugging of smoke tubes.............................................
Boiler repair - refractory.............................................
Lighting-up curve......................................................

Language UK

Document ID
OM9210_02...............
OM9210_09...............
OM9210_11...............
OM9010_39...............
OM9210_12...............
OM9210_14...............
OM9210_13...............
OM9210_20...............
OM9210_22...............
OM9210_25...............
OM9210_31...............

Page
12-2
12-8
12-12
12-14
12-16
12-19
12-22
12-24
12-26
12-29
12-32

12-1 / 32

OM9210_02#D.1
START/STOP OF THE BOILER

Start/stop of the boiler


1

General
The following chapters of the instruction manual describe the operation and maintenance of the pressure part. As this is only a part of the complete boiler plant, it is
important to study the remaining chapters in this manual very thoroughly. It is especially important that the operator of the boiler plant becomes familiar with the operation
instructions of the burner and the control panel.
Important: To ensure a safe and reliable operation of the boiler plant, all operation and/or maintenance of the boiler should be carried out only by
skilled personnel.

Boiler operation modes


The Aalborg OC (-TCi) boiler is a combined oil fired and exhaust gas fired boiler. The
combination between an oil fired section and an exhaust gas fired section makes it
possible to operate the boiler in different modes. The different modes are:
-

Operation only on the oil fired section


Operation only on the exhaust gas fired section
Operation on both the oil fired and exhaust gas fired section

2.1 Boiler operation modes


2.1.1 Combined operation mode
In normal operation, the boiler operates as a combined oil fired and exhaust gas fired
boiler. The steam production is controlled by the amount of exhaust gas from the engine
and the gauge board which controls the oil burner. If the engine produces an insufficient
amount of exhaust gas to maintain the steam pressure, the gauge board gives a signal
to initiate start of the oil burner. The oil burner operates as long as the steam pressure
does not exceed the set point for burner stop. If the steam pressure increases above this
set point, the gauge board gives a signal to initiate stop of the oil burner.
The combined operation mode always requires that the water level is within the normal
limits of the boiler.

12-2 / 32

Language UK

OM9210_02#D.1
START/STOP OF THE BOILER

2.1.2 Oil fired operation mode


If the engine is stopped, the only heat source is the oil burner. When the steam pressure
is below the set point for start of the burner, it will be in operation. By means of signals
from the gauge board, the control system aims to maintain the desired steam pressure
regardless of the steam output. The oil burner operates as long as the steam pressure
does not exceed the set point for burner stop.
The oil fired operation mode always requires that the water level is within the normal
limits of the boiler.
2.1.3 Exhaust gas fired operation mode
When the exhaust gas flow through the boiler, produced by the main engine, is sufficient to maintain the steam pressure, the burner will not be in operation. If the exhaust
gas flow is above the required flow to maintain the steam pressure at a given steam
output, the pressure increases. At a pre-selected set point the steam dump equipment,
located elsewhere in the steam system, opens the dump valve and regulates the steam
line pressure. If, however, the steam dump equipment is not operational the boiler
pressure may rise above the set point for high steam pressure shut down and even up
to the maximum allowable working pressure. At this point, the safety valves open and
ensure any further increase of the steam pressure. Please note that some classification
societies require a separate switch which reduces the engine load before the maximum
allowable working pressure is reached.
Note: If the high steam pressure shut down has been activated, the oil burner will
not be operational until the shut down function can be and is reset in the
control system.
The construction of the Aalborg OC (-TCi) boiler permits operation with low water
level and even without water in exhaust gas mode with the full exhaust gas flow through
the smoke tubes. In the latter case the boiler must be operated depressurised.
Please note that operation without water should be considered as an emergency operation mode and should only be used if no other operation alternatives are present. The
most effectual operation of the boiler is with the water level within the normal limits
as this creates the most stable operating conditions
Warning: Before start of the boiler it must be drained and the manhole cover
should be dismounted to ensure that it is operated completely depressurised. Please note that the temperature inside the boiler must not
exceed 400C.
If the boiler operates without water, it will gradually be heated to the same temperature
as the exhaust gas. It is therefore important to allow the boiler to cool before refilling
it with feed water. If this is not possible, the feed water should be pre-heated, and the
refilling should be carried out very carefully.

Language UK

12-3 / 32

OM9210_02#D.1
START/STOP OF THE BOILER

Note: If the too low water level shut down has been activated, the oil burner will
not be operational until the shut down function can be and is reset in the
control system.
Furthermore, operation of the boiler without water eventually dries out the gaskets,
and a replacement of the gaskets is necessary.

Start-up
When the boiler is commissioned or started during normal operation, it is preferable
to lighten-up the boiler with the oil burner as the heat source. This is because the oil
burner load is much easier to control than the exhaust gas amount from the engine.
It is possible, however, to start the boiler when exhaust gas is used as heat source. This
requires more attention with regard to water level control, pressurising pipes, etc.
When the boiler is started and lightened-up by means of the exhaust gas flow, it is
important to reduce the heating-up rate in order not to cause stresses in the boiler.
This can be done by reducing the engine load to fit the appropriate heating-up rate or
by by-passing some of the exhaust gas flow if a by-pass system is provided.

3.1 Before start-up


When the boiler is started, the lighten-up rate of the boiler must not be accelerated too
much as this might cause an unnecessary overstrain of the boiler material by quick and
uneven temperature rises. It might be necessary to perform a number of start/stop
sequences to reduce the lighten-up rate.
Attention: At the commissioning start-up of the boiler and after any repair work
of the refractory, it is very important to further reduce the lightingup rate. This is because the new refractory still contains a small
amount of water. When heated the water vaporises and expands
which might cause fissures and cracks in the refractory. The burner
must therefore only be operated at minimum load and in intervals of
1-2 minutes for the first hours. Between each operation interval the
burner should remain stopped for approximately 8-10 minutes.
Before start-up of the boiler plant, some general work and check procedures must be
considered.
Step A: Check that all pipelines are ready for operation and that possible blind
flanges used during pressure tests have been removed.
Step B: Check that the main steam valve, scum valve, and blow-down valves are
closed.

12-4 / 32

Language UK

OM9210_02#D.1
START/STOP OF THE BOILER

Step C: Open the feed water valves and the air valve. Fill the boiler with feed water
to approximately 50 mm below normal water level. The water level rises
due to expansion when the boiler is heated. If the temperature difference
between the boiler and feed water exceeds approximately 50C, the boiler
must be filled very slowly.
Note: When filling a pressure less boiler, the shut-off valve after the feed water
pump must be throttled. Otherwise the pump motor will be overloaded.
Step D: Check the water level in the water level gauges. Check frequently during the
complete start-up. The water level gauges should be blown down several
times to ensure a correct indication.
Step E: Check that the water level control system is connected and operational.
Step F: Check the oil system and start the fuel oil supply pump. Pre-heat the fuel oil
if the burner should operate on heavy fuel oil.
Step G: Check the burner and the safety functions according to the separate instruction.

3.2 Start and pressure rise


The following work procedures must be followed during start-up of the boiler.
3.2.1 Start and pressure rise by means of the oil burner:
Step A: Check that the gauge board valve and pressure gauge valves are opened.
Step B: Check that the air valve is open if the boiler pressure is below 1.0 barg.
Step C: Start the burner on manual control and on low load. Check that the water
level does not rise too high during the pressure rising period.
Step D: Drain via the blow down valves if the water level is too high.
Step E: If the air valve was opened close it when only steam blows out. A pressure
reading should be indicated on the boiler pressure gauge before the air valve
is closed.
Step F: Check that any connected remote indicators are working correctly.
Step G: Re-tighten all covers such as manholes, hand holes, inspection doors, flanges, etc. during the pressure rising period. If required, check all flange joints
on the plant.
Step H: Change to automatic control of the burner when the boiler pressure is 0.5
barg lower than the working pressure of the boiler.
Step I: Open the main steam valve slowly to heat-up and pressurise the steam system.
Step J: Open the valves to the steam consumers carefully in order to avoid water
chocks.
Step K: When the boiler is in normal operation, check that the water level control
system and the gauge board functions are fully operational.
3.2.2 Start and pressure rise by means of the exhaust gas section:
The following start-up procedure is described on the assumption that the engine is in
operation and the exhaust gas flow is sufficiently high to lighten-up the boiler.
Step A: Check that the gauge board valve and pressure gauge valves are opened.
Step B: Check that the air valve is open if the boiler pressure is below 1.0 barg.

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OM9210_02#D.1
START/STOP OF THE BOILER

Step C: Check the water level and fill the boiler with evaporated water as described
previously, if necessary.
Step D: Drain via the blow-down valve if the water level is too high.
Step E: If the air valve was opened close it when only steam blows out. A pressure
reading should be indicated on the boiler pressure gauge before the air valve
is closed.
Step F: Check that any connected remote indicators are working correctly.
Step G: Re-tighten all covers such as manholes, hand holes, inspection doors, flanges, etc. during the pressure rising period. If required, check all flange joints
on the plant.
Step H: When the boiler pressure is approximately 1.5-2.0 barg and if the steam
system is not pressurised, open the main steam valve slowly to heat-up and
pressurise the steam system.
Step I: Open manually the steam dump valve somewhat to create an increased water
replacement in the boiler.
Step J: When the normal working pressure is reached, set the steam dump valve to
automatic mode and open the valves to the steam consumers carefully in
order to avoid water chocks.
Step K: When the boiler is in normal operation, check that the water level control
system and the gauge board functions are fully operational.
3.2.3 Commissioning notes
When an accumulation test of the safety valves is performed the water level inside the
boiler might increase and cause high level alarm. This is due to an increased water
temperature and acorresponding larger water volume. The water surface also becomes
more unstable during the accumulation test.
After 3-4 weeks in operation, mud and deposits in the piping system may have accumulated in the boiler water. This may cause level variations which disturb the steam
generation, and it is therefore recommended to blow down the boiler. It should then
be inspected, cleaned, and refilled with boiler water.

Boiler stop
4.1 Normal boiler shut down
If necessary, the boiler can be shut down at any load without special preparations.
Note: When the boiler is stopped, sudden temperature and pressure drops should
be avoided as they might expose mountings, pipe lines, and the boiler plant
to inadmissible temperature gradients.
If the engine is in operation and must remain in operation, it is not possible to stop the
boiler unless the exhaust gas system is provided with a by-pass system. When the
engine is stopped and the boiler should be stopped, the following work procedures
should be carried out:
Step A: When minimum load is obtained, stop the burner.

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START/STOP OF THE BOILER

Step B: Keep the water level at normal level until the boiler stops producing steam.
Stop the feed water pump and close the feed water valves.
Step C: Close the main steam valve.

4.2 Emergency shut down


The boiler must be taken out of service immediately if:

parts of the heating surface have been glowing or the boiler shows recognisable
deformations. The supervising authorities must be informed, and the boiler must
not be used until approval from these authorities is available
a substantial loss of water is noted
the feed water system is unable to provide the necessary amount of feed water, e.g.
due to failure of parts
the safety valve cannot function
sudden cracks or damage are noted in the refractory, and if steam or moisture is
coming out of the refractory
oil in the feed water is detected
too high salinity level is detected
If an emergency shut down must be carried out, the fuel supply should be stopped. The
main steam valve should be closed gradually, and the boiler must be cooled. The safety
valves must not be operated. Parallel working boilers should be disconnected at once.

4.3 Stop for repair or inspection


The following describes the measures to be taken when the boiler is shut down for
repair or inspection.
Step A: Clean the boiler from soot with water.
Step B: Operate the burner for at least 15 minutes after the soot removal to dry out
the remaining water.
Step C: Stop the boiler as mentioned previously.
Step D: Check the furnaceand smoke tubes, for the oil fired as well as exhaust gas
part, with regard to cleanliness.
Step E: Empty the boiler from water and clean it. Check if lime stone appears.
Step F: Check and clean the outer fittings. Change gaskets where required.
Step G: Clean the feed water tank and feed water pipes.
Step H: Clean and grease the bearings of motor, pump, and fan.
Step I: Check and align the burner, if necessary.
Step J: If the boiler is shut down for a long period of time, the smoke tubes, for the
oil fired as well as the exhaust gas part, must be thoroughly cleaned.
Step K: Check that the necessary spare parts are available. Order complementary
parts in time.
Warning: It is of extreme importance that the boiler is NOT operated without
water when the oil burner is in operation, e.g. due to disconnection of
the water level safety devices. This will immediately cause complete
break down of the boiler.

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OM9210_09#B.1
BOILER MAINTENANCE

Boiler maintenance
1

Boiler maintenance
The boiler maintenance should always be executed with skill and in accordance with
valid rules and regulations from the authorities. Below some recommendations are
given for periodical inspections and maintenance.

1.1 Daily operation


During normal operation of the boiler, some work and check procedures have to be
considered every day.
Step A: Check the boiler steam pressure and the water level.
Step B: Check that the feed water control system is operational, see separate instructions.
Step C: Check the boiler water condition and make necessary counter measures with
regard to the feed and boiler water treatment. If necessary, blow-down the
boiler.
Step D: Check the function of the oil burner at different capacities through the inspection holes on the boiler.
Step E: Check the flue gas temperature after and/or the draft loss across the boiler.
If either the temperature or the draft loss is too high, the smoke tube section,
for the oil fired as well as the exhaust gas part, must be cleaned.

1.2 Weekly routine checks


Step A: Drain each water level glass for about 10-15 seconds.
In case of contaminated boiler water or insufficient water treatment, the draining of
the water level glasses must be done more often.
Step B: Check the safety water level device.
Step C: Depending on the boiler water tests, blow-down the boiler. Open the blowdown valves quickly for a few seconds, and then close and open again for
about 5-10 seconds.
Repeat this operation when required according to the boiler water tests.
Step D: Perform scum blow out by means of the scum valve when required. The
scum blow out must be carried out until the drained water is clean.

1.3 Monthly routine checks


Step A: Test all stand-by pumps.
Step B: Check all boiler mountings for damage or leaks and repair/replace if necessary.

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BOILER MAINTENANCE

Step C: Check the function of the high steam pressure switch by lowering the set
point or by raising the steam pressure, e.g. by closing the main steam valve
slowly.
The burner must stop automatically.

Inspection of the boiler


2.1 Inspection of furnace
The furnace should be inspected at least twice a year. During this inspection, the following issues should be taken into consideration:

Check for cracks at the refractory lining and that the furnace walls are free from
excessive soot deposits.
Examine carefully the area opposite the burner. Too much soot deposits indicate
that the burner should be adjusted.
Check that the smoke and stay tubes, are intact and that soot deposits are within
normal limits.

2.2 Inspection of exhaust gas section


The exhaust gas section should be inspected at least twice a year. During this inspection, the following issues should be taken into consideration:

Check the welding in the exhaust gas section. A careful examination should be
carried out with respect to any possible corrosion or crack formation.
Check that the inlet box and outlet box are intact and that soot deposits are within
normal limits.
Check that the smoke tubes and stay tubes are intact and that soot deposits are
within normal limits.

2.3 Inspection of boiler water side


The boiler water side (interior) must be carefully inspected at least twice a year. This
inspection is of great importance and no doubt the most important of all the maintenance measures, since it has a direct influence on the boiler longevity and on the security.
At these inspections, hard deposits, corrosion, and circulation disturbances can be
found at an early stage, and preventive measures must be taken to avoid unexpected
material damage and boiler breakdown.
The presence of hard deposits at the furnace wall and the smoke tubes reduces their
heat transfer properties and decreases the capacity of the boiler.
Further, it can be established whether the feed water treatment is satisfactory, and
whether the blow-down is carried out sufficiently.
Incorrect feed water treatment is commonly causing hard deposits or corrosion.

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BOILER MAINTENANCE

Insufficient blow-down will cause sludge deposits in the tubes and accumulation of
sludge in the bottom of the boiler.
If hard deposits are not removed, it may lead to overheating in the boiler plate material,
which is exposed to the flame in the furnace wall area. This may cause material damages.
Incorrect feed water treatment does not always lead to hard deposits. For example, a
too low or too high pH-value may give an electrolytic reaction, causing corrosion in
the boiler.
When the boiler interior is inspected, examine all parts carefully and be attentive to
deposits, corrosion, and cracks. It is advisable to pay special attention to this inspection.
If any unusual signs are found, contact Alfa Laval at once for advice.

2.4 Procedure and remarks for inspection


Step A: Shut off the boiler and allow it to cool (below 100C).
Note: The boiler should NOT be depressurised by lifting the safety valves and
then filled with cold feed water as the stress induced by too rapid cooling
may cause damage.
Step B: Empty the boiler and close all valves.
If the boiler is connected to a second boiler, check that the valves between them are
closed.
Step C: Unscrew and remove the manhole hatch(es) on the boiler and enter the boiler
when it is sufficiently cold.
Check the welding in the boiler. A careful examination should be carried out with
respect to any possible corrosion or crack formation.Special care should be taken to
the water line area in the pressure vessel where oxygen pitting may occur.If deposits
are forming in the boiler tubes, the boiler should be chemically cleaned.It is advisable
to consult a company of cleaning specialists who will examine the boiler deposits and
treat the boiler accordingly.
Note: After chemical treatment the boiler should be blown-down at least twice a
day for approximately one week. This will ensure that excessive sludge
deposits due to chemical treatment do not collect in the bottom of the pressure vessel.

2.5 Contamination
If the boiler is contaminated with foreign substances like oil, chemicals, corrosion
products etc., it is very important to act immediately to avoid damage to the boiler.
Layers of thin oil films, mud, etc. exposed to the heating surfaces cause a bad heat
transfer in the boiler, leading to overheating followed by burned out pressure parts. In

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OM9210_09#B.1
BOILER MAINTENANCE

order to remove such contamination, a boiling out or acid cleaning should be performed
immediately.
Note: Corrosion products from the pipe system or insufficient boiler water treatment may result in corrosion in the boiler itself. It is therefore important
to observe that such circumstances do not occur in the system.

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OM9210_11#B.1
BOILING OUT

Boiling out
1

Boiling out
Before putting the boiler into operation for the first time, it should be boiled out to
remove all protecting remedies and impurities on the boiler waterside.
The boiling out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling the chemicals. The person
handling the chemicals/solution should be properly dressed/protected.
Step A: Fill the boiler with a solution consisting of 4-5 kg trisodiumphosphate
Na3PO4 per 1000 kg water. The chemicals can be added through the manhole.
Step B: Add feed water until the solution is visible in the water gauges above lower
water level.
Step C: Close the feed water valve (pump stopped).
Caution: Do never fill feed water into the boiler if the temperature difference
between boiler and feed water exceeds 50C.
Step D: Raise steam pressure slowly to working pressure, and keep the pressure for
approx. 3-4 hours with closed main steam valve.
Step E: Scum until water level is between Normal water level and High water
level.
By this procedure grease and other impurities are removed from the internal surfaces
of the boiler.
Step F: Start skimming by opening the scum valve, and lower the water level to
lower edge of Normal water level mark.
Step G: Close the scum valve.
Step H: Refill the boiler with feed water and start skimming again in intervals of 30
minutes for a period of two hours.
Step I: Stop the boiling out procedure by switching off the burner.
Step J: Let the boiler water rest for about five minutes.
Step K: Carry out a final skimming.
Step L: Blow off the boiler water by opening the blow down valves.
Step M: Remember to open the air escape valve, to avoid a vacuum in the boiler when
the boiler pressure decreases to approx. depressurised/atmospheric pressure.
Step N: Open the manhole and let the boiler cool down to approx. 100C.
Step O: The boiler is to be flushed with clean water on the boiler waterside, when
the temperature has decreased. The flushing removes remaining impurities.

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BOILING OUT

Step P: Dismantle the bottom blow down valves, for cleaning and inspection because deposits/foreign substances will usually be accumulated in these
valves and cause leaking if not cleaned.
Step Q: Inspect the boiler and remove any remaining deposits and foreign substances.
Step R: Finally, new gaskets to be fitted in all hand- and manholes before refilling
the boiler with water to upper edge of Low water level.
The boiler is now ready to be taken into service.
Note: During the first two weeks in operation we recommend to carry out frequently skimming and bottom blow down to remove impurities entering
the boiler from the pipe system.

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OM9010_39#D.1
GASKETS FOR BOILER BODY

Gaskets for boiler body


1

Gaskets
The gaskets for boiler body can be seperated into three types. which is manhole, head
hole and hand hole gaskets depending of the boiler types. The chosen types is shown
on the general arrangement drawing of boiler
The gaskets are of a high-tech, compressed fibre material which makes them ideal for
steam.

1.1 Storage and handling


The gaskets should always be stored horizontally to avoid tensions. Also, they should
be stored in clean condition and in a dark storage room.
Ideal temperature: < 25C.
Ideal air humidity: 50-60%.
Never bend the gaskets or damage their surfaces.

1.2 Installation
Note: For safety reasons, never re-use a gasket.
Make sure that all sealing surfaces are clean and dry. Be sure not to damage/scratch
sealing surfaces while cleaning. Also check that sealing surfaces are parallel and free
of damages and cracks.
All gaskets should be installed clean and dry. No form of gasket compounds can be
used for installation. These might damage the gaskets and result in possible blowouts
of the gaskets. The gaskets are coated with a non-sticking film.
Ensure that bolts and nuts are clean and free of corrosion and apply lubricant on the
threads.The lubricant must not contaminate gaskets or sealing surfaces. Insert the gaskets carefully in the covers and place the covers with the new gaskets in the manholes/
hand holes. Ensure that the coversare centralized in the manholes/hand holes.
Make at least 4 stages to the required torque.
Finger-tighten the bolts.
Use 30% of the required torque.
Use 60% of the required torque.
Use the required torque.

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GASKETS FOR BOILER BODY

1.3 Recommended torque

Manhole : 250 Nm.


Head hole : 160 Nm
Hand hole: 500 Nm.

1.4 Re-tightening
Re-tightening must be done in hot condition during the first 24 hours of the startingup of the plant. Re-tightening of high-tech, compressed fibre gaskets under pressure
and after a long period of operation might lead to leaking gaskets and possible blowouts.

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OM9210_12#B.1
CLEANING PIN-TUBE ELEMENTS

Cleaning pin-tube elements


1

General
In order to keep the heat transfer area sufficiently clean, the boiler has been designed
with a high flue-gas velocity through the pin-tube elements. Therefore fouling will be
minimised, under normal circumstances, with a correct combustion.
After a certain time in operation, soot deposits are however accumulated inside the
boiler. The quantity of soot and the time of forming it, depends on factors such as oil
quality, boiler load, and burner adjustment. It is impossible to specify exact time intervals in which the boiler should be soot cleaned. However, some general guidelines
are given below.
There are three methods to check if soot cleaning is necessary:

Inside inspection.
Check of the flue gas temperature. The boiler should be cleaned if the flue gas
temperature is approximately 20C above the temperature for a clean boiler.
Check of the pressure loss. The boiler should be cleaned if the pressure loss is
approximately 20 mm WC above the pressure loss for a clean boiler.
It is recommended to keep a consecutive record of the flue gas temperature and the
pressure loss related to different boiler loads for a clean boiler. These original data
should be used for comparison, and it is recommended to plot the measurements in a
chart like the one shown in Figure 1. In this way it is possible to monitor the fouling
condition of the pin-tubes and determine when they need to be cleaned.
Checkscheme for flue gas measurement

Figure 1

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om9210_12_dp_tubx0059610en.wmf

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OM9210_12#B.1
CLEANING PIN-TUBE ELEMENTS

Water washing procedure


The most effective way of soot cleaning is water washing, as most of the deposits
consist mainly of non-soluble particles held together by a water soluble bonding material. Water washing will have the following benefits:

Dissolves the bonding material.


Washes the loosened insoluble deposits away.
Water washing must be carried out when the oil burner is stopped and the boiler has
been cooled down. However, the boiler should be warm enough for the water to evaporate so that the pin-tube elements and furnace will not remain moist after washing.
Both fresh and sea water can be used. However, if sea water is used, the boiler must
be thoroughly washed afterwards with fresh water in order to remove all salt deposits.
Where deposits are highly corrosive or bonded, a soaking spray with a 10% soda ash
solution is advisable before washing.
Step
Step
Step
Step
Step

A:
B:
C:
D:
E:

Ensure that the oil burner is stopped and remains stopped.


Wait a minimum of time allowing the boiler to cool (below 100C).
Unlock the burner unit and swing it out of the furnace.
If loose particles or soot are found on the furnace floor remove these.
Open furnace drain valve and check that the pipe is not blocked. If the drain
pipe at the furnace bottom is provided with a plug this must also be removed.
Step F: Unlock and remove the inspection hatches of the smoke outlet box located
on top of the boiler.
Step G: Start water washing using a hand water lance or fire hose inserted through
the inspection hatch of the smoke outlet box and direct the jet of water directly at each of the vertical uptakes. In the beginning the water supply
should only be slightly opened, just enough to have a small amount of water
to ensure that the drain is working properly.
Warning: When the pin-tube elements are water washed, there is a risk of generating steam. It is therefore very important that all of your body is
outside the smoke outlet box in order not to get your skin burned by
the steam.
Step H: When it has been ensured that the washing water is running freely down
through the drain system, increase the water flow and flush carefully over
each tube for 20-30 seconds. The water flow should be approximately 50 l/
min at a water pressure between 4-6 bar.
Note: Care should be taken not to let water get in contact with the burner throat
refractory.
Step I:

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It is important to check that the drain and soot collecting system are working
properly during the whole water washing procedure.

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CLEANING PIN-TUBE ELEMENTS

Step J: When the water washing has begun, it must be completed until the pin-tube
elements are thoroughly washed and all deposits are removed. This is due
to the fact that some types of coatings harden and accordingly get very difficult to loosen when they have been saturated and then dry out.
Step K: When the water washing has been completed, the pin-tube elements and
furnace floor must be cleaned with alkaline water because the washing water
is very corrosive.
Step L: It must be ensure that all the washing water is drained away and loosened
deposits are removed from the furnace floor by looking into the furnace.
Step M: Mount the inspection hatches on the smoke outlet box and secure them.
Step N: Swing the burner back into position and dry out the boiler by starting the
burner fan in manual operation for approximately 15 minutes. It is essential
that the boiler is dried out immediately after water washing. This is because
soot formations produced by an oil burner, contains sulphur compounds.
Any residual soot and water will therefore react chemically to form a highly
corrosive sulphuric acid.
Step O: Check that the furnace drain pipe has not become blocked and close the drain
valve. If the drain pipe at the furnace bottom is provided with a plug it will
be necessary to swing out the burner again to insert the plug.
Important: The refractory in the furnace must be heated slowly up in order to
let the water absorbed by the refractory evaporate slowly.
Step P: Within the first hour; start the burner at minimum load for one (1) minute.
Then stop it and wait for three (3) minutes before restarting it again.
Step Q: Within the second hour; start the burner at minimum load for two (2) minutes. Then stop it and wait for two (2) minutes before restarting it again.
Step R: Within the third hour; start the burner at minimum load for two (2) minutes.
Then stop it and wait one (1) minute before restarting it again.
Step S: Finally start the burner at minimum load and let it operate at that load for
the next two hours.
Step T: The boiler can now be brought back into normal service. During normal
operation check that the flue gas temperature is now within the correct limits.

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OM9210_14#B.1
CLEANING SMOKE TUBES

Cleaning smoke tubes


1

General
The heating surface dimensions of the smoke tubes are designed to maintain a sufficient
exhaust gas velocity giving the best self-cleaning effect within the design limits. However, after long term operation soot deposits can be accumulated inside the smoke
tubes. The main engine exhaust gas contains carbon particles and un-burnt residues
(soot, etc.) and the amount is strongly dependent on the state of the engine and the
supply of scavenging air. These soot/un-burnt residues will accumulate in the smoke
tubes if not removed by cleaning. Furthermore, the combustion quality of the engine
is changing together with the load, where the best combustion is in the high load range
and the lower range is giving a more contaminated (black/coloured) exhaust gas.
And the more contaminated the exhaust gas is, the more fouling will appear in the
smoke tubes.Therefore, it is impossible to specify exact time intervals in which the
smoke tubes should be soot cleaned. However, some general guidelines are given below:

Inside inspection.
Check of the exhaust gas temperature on the outlet side of the boiler. The boiler
should be cleaned if the outlet exhaust gas temperature lies approx. 20C above
the temperature in a clean boiler at a specified engine load.
Check of the pressure loss. The boiler should be cleaned if the pressure loss lies
approx. 20 mm WC above the pressure loss in a clean boiler.
It is recommended to keep a consecutive record of the exhaust gas temperature and
pressure loss related to different engine loads in a clean boiler. These original data
should be used for comparison, and plotted into a measurement chart like the one shown
in Figure 1. In this way it is possible to monitor the fouling condition of the smoke
tubes and determine when they need to be cleaned.

Diff. Pre ssure [m m WC]

Outle t Ga s Te m p. [C]

Check scheme for exhaust gas measurements

Outle t te mp.

Diff. pre ssure

10

20

30

40

50

60

70

80

90

100

Loa d %

Figure 1

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OM9210_14#B.1
CLEANING SMOKE TUBES

Water washing procedure


The most effective way of soot cleaning is water washing, as most of the deposits
consist mainly of non-soluble particles held together by a water soluble bonding material. Water washing will have the following benefits:

Dissolves the bonding material.


Washes the loosened insoluble deposits away.
Water washing must be carried out when the main engine is stopped and the boiler has
been cooled down. However, the boiler should be warm enough for the water to evaporate so that the tubes will not remain moist after washing.
Both fresh and sea water can be used. However if sea water is used, the boiler must be
thoroughly washed afterwards with fresh water in order to remove all salt deposits.
Where deposits are highly corrosive or bonded, a soaking spray with a 10% soda ash
solution is advisable before washing.
Step A: Ensure that the main engine is stopped or by-pass the exhaust gas flow, if
possible. Also secure that the oil burner is stopped and remains stopped.
Step B: Wait a minimum of time allowing the boiler to cool.
Step C: Unlock and remove the inspection doors at the exhaust gas inlet box and
outlet box.
Step D: Open the drain at the bottom of the inlet box to the soot collecting system,
and make sure that there is free passage.
Step E: Open drains at the turbo chargers and make sure that there is free passage.
Step F: If there is a risk that the washing water will run into the exhaust gas pipe
and down to the turbo chargers, the exhaust gas pipe must be covered. This
can be done by e.g. covering the exhaust gas inlet pipe with a waterproof
tarpaulin as indicated inFigure 2.
Step G: Start water washing using a hand water lance or fire hose inserted through
the inspection door of the outlet box and direct the jet of water directly at
the smoke tubes. In the beginning the water supply should only be slightly
opened, just enough to have a small amount of water to ensure that the
drainsare working properly.
Step H: When it has been ensured that the washing water is running freely down
through the drain system into the soot collecting system, the water amount
can slowly be increased, until a flow of approximately 50 l/minat a water
pressure between 4 to 6 bar is obtained.
Warning: When the smoke tubes are water washed, there is a risk of generating
steam. It is therefore very important that all of your body is outside
the outlet box in order not to get your skin burned by the steam.
Step I:

It is important to check that the drain and soot collecting system are working
properly during the whole water washing procedure.
Step J: When the water washing has begun, it must be completed until the smoke
tubes are thoroughly washed and all deposits are removed. This is due to the
fact that some types of coatings harden and accordingly get very difficult to
loosen when they have been saturated and then dry out.
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OM9210_14#B.1
CLEANING SMOKE TUBES

Water washing of the exhaust gas side


Exhaust gas outlet
Inspection door
Water washing hose

Inspection door
Waterproof tarpaulin
Inlet box drain
Exhaust gas inlet

Figure 2

om9210_14_oc2x0059630en.wmf

Step K: When the water washing has been completed, it must be ensure that all the
washing water is drained awayby looking into the inlet box from the inspection door. The bottom of the inlet box must be cleaned with alkaline
water because the washing water is very corrosive.It must be observed that
all the washing water and loosened deposits are removed from the boiler.
Step L: The boiler must be dried out immediately after water washingby having a
natural air circulation through the boiler or by heating it up with feed water.
This is because soot formations produced by the combustion process in the
engine contain sulphur compounds. Any residual soot and water will therefore react chemically to form a highly corrosive sulphuric acid.
Step M: Remove the waterproof tarpaulin from the exhaust gas inlet pipe, if inserted,
and close drains as well as inspection doors.
Step N: The boiler can now be brought back into normal service.

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OM9210_13#C.1
PRESERVATION

Preservation
1

Preservation of the boiler


If the boiler is to be shutdown for a period of 1-30 days, it should be top filled to prevent
corrosion. Before top filling, it should be cleaned from soot deposits.
If the boiler is to be shut down for more than one month, different methods to prevent
corrosion can be applied:

Dry preservation.
Wet preservation.
Nitrogen preservation.
VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:

1.1 Dry preservation


When this method is applied the boiler should be totally emptied off water and dried
out.
Step A: Empty the water/steam contents inside the boiler by means of the bottom
blow down at a boiler pressure of 3-5 barg. Open the boiler when it is depressurised and drain offany remaining water.
Step B: Manhole doors and hand hole covers should be opened when the boiler is
still hot. If there is water left in the bottom of the boiler it must be removed,
e.g., by using a vacuum cleaner.
Step C: If the boiler is cold, drying of the boiler can be done by either circulating
dried air from a fan or by placing bags of silicagel inside the boiler.
Step D: Before the manhole doorsand hand hole covers are closed, place a tray with
burning charcoal to remove oxygen. As soon as the tray with charcoal is in
position, close the manhole doors and hand hole covers using new gaskets.
Step E: Alternatively, a small steam phase inhibitor can be added to the boiler after
cooling and careful draining. Afterwards the boiler should be closed completely.

1.2 Wet preservation


While dry preservation is a question of draining off water to avoid corrosion, the principle of wet preservation is to prevent oxygen from entering the boiler.
This method can be used for a short period of lay-up (1-3 months).
Step A: The boiler is filled with treated boiler water and oxygen binding agents according to suppliers specification.

12-22 / 32

Language UK

OM9210_13#C.1
PRESERVATION

Step B: The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen, and it is necessary to check
the concentration of oxygen binding agents and add the necessary amount
to maintain supplier specifications.
The pH-value should be 9.5-10.5.
Note: If there is any risk of the temperature falling back below 0C, this method
should not be used to avoid frost damages.
If this preservation method involves applying hydrazine to the water inside the boiler,
the boiler must be completely drained and refilled with fresh water before taken into
service again.

1.3 Nitrogen preservation


The boiler should be drained, dried and sealed in the same way as mentioned in section
1.1,Dry preservation.
Step A: Make a connection point to the bottom of the boiler and open the air escape
valve on top of the boiler.
Step B: Connect cylinders with nitrogen to the bottom connection point via a reduction valve and purge the boiler until there is no oxygen left.
Step C: Close the air escape valve.
Step D: Leave a cylinder with nitrogen connected to the boiler via a reduction valve
and keep an overpressure of approximately 0.2 bar inside the boiler.

1.4 VCI preservation


An alternative to the above mentioned preservation methods may be the use of a socalled volatile corrosion inhibitor (VCI).
The VCI is a water soluble chemical which partly evaporates and protects both the
water and steam spaces of the boiler. It should be able to eliminate the need for complete
drainage and/or application of nitrogen, and may in particular be interesting when a
forced circulation type exhaust gas boiler is installed in the steam system. The boiler
must be effectively sealed from the atmosphere to maintain the corrosion protection.
The VCI is offered by various chemical companies and must be used in accordance
with their recommendations.

Language UK

12-23 / 32

OM9210_20#B.1
BOILER REPAIR - PIN-TUBE ELEMENT

Boiler repair - pin-tube element


1

Repair of a pin-tube element


In the unlikely event of a leaking pin-tube element, the burner and feed water pump
must be stopped and the boiler depressurised.
Step A: Open the blow-down valves and drain the boiler for water.
Step B: Removed the manhole cover.
Step C: The boiler should now be inspected in order to locate the damaged pin-tube
element.

1.1 In case of a damaged pin-tube element


The pin-tube element must be blocked by welding circular plates, with the same diameter as the outer tube, at the inlet and outlet of the outer tube (see Figure 1).
The circular plates must be made of boiler plate and should be approx. 15 mm thick.
The welding must be performed by skilled personnel with knowledge and qualifications to perform certified welding.
Step A: Gain access to the damaged tube through the smoke outlet box, furnace, and/
or manhole.
Step B: Before repairing a damaged pin-tube element the inner and outer tube should
be cleaned.
Step C: Cut two holes in the outer tube prior to mounting the circular plates, as shown
in Figure 1.
Step D: Fit and weld the circular plates at the inlet and outlet of the outer tube. After
completion of the repair work clean the working area.
Step E: Close all access doors and mount the manhole cover. Replace the gasket if
necessary.
Step F: Refill the boiler with feed water and check for leaks before starting up.
Step G: Start the boiler and check for leaks when the boiler is pressurised.
Note: When a pin-tube element has been plugged as described above, a new pintube element should be mounted as soon as possible. The boiler should NOT
be operated with more than one blocked pin-tube element, without approval from the supplier.
Attention: The classification society should be notified about the repair work and
a schedule must be made for exchange of the damaged tubes.

12-24 / 32

Language UK

OM9210_20#B.1
BOILER REPAIR - PIN-TUBE ELEMENT

Temporary repair of pin-tube elements has naturally an influence on the efficiency


since the heating surface is reduced. It can therefore be expected that the flue gas
temperature will rise. It should be noted that the flue gas temperature never must exceed
400C. If the temperature exceeds 400C the burner must be stopped or fired at a low
firing rate.
Note: Temporary repairs require more attention than a normal working boiler.
Illustration of how to block a pin-tube element
min. 100 mm

Repair plate

Repair plates:
MISSION OS, OC boilers: 256
MISSION OM boilers: 252

Holes to be cut before welding


of the repair plates (35)

Repair plate
min. 100 mm

Figure 1

Language UK

om9210_20_pin_rex0059690en.wmf

12-25 / 32

OM9210_22#C.2
PLUGGING OF SMOKE TUBES

Plugging of smoke tubes


1

General
In case of a leakage tube, the boiler must be stopped and the pressure lowered to
atmospheric pressure. If the leaking tube cannot be located immediately via the inspection doors at the exhaust gas inlet and outlet boxes, the boiler should be set on
pressure by means of the feed water pumps so that the leakage indicates the damaged
tube.

1.1 Plugging of smoke tubes


Step A: The oil burner and main engine must be stopped during the repair work.
Step B: Open and, if necessary, remove the inspection doors in the exhaust gas inlet
box and outlet box.
Step C: Exhaust gas tubes: When the damaged tube has been located, clean the
inside of the tube ends with a steel brush so that no deposits are present in
the tube.
or
Oil fired helix tubes: When the damaged tube has been located then a small
hole shall be made in each end of the tube approx.10-20 mm from the tube
plate, and then clean the inside of the tube ends with a steel brush so that no
deposits are present in the tube.
Step D: Exhaust gas tubes: Plug and seal weld both tube ends with a conical plug,
see Figure 1.
or
Oil fired helix tubes: Plug and seal weld both tube ends with a conical plug,
see Figure 1. The plug and seal weld should be grinded down so the protrusion into the furnace are as small as possible.
Attention: All welding should be performed with great care and unless necessary
only on the tube, not on the tube plate.
Note: Temporary repairs require more attention than a normal working boiler.
Tube plugging results in reduced efficient heating surface, and accordingly
the boiler efficiency will decrease.
Attention: The classification society should be notified about the repair work and
a schedule must be made for exchange of the damaged tubes.

12-26 / 32

Language UK

OM9210_22#C.2
PLUGGING OF SMOKE TUBES

1.2 Exchange of smoke tubes


From an operational point of view up to 10% to 15% of all smoke tubes can be plugged
with a conical plug, but if more tubes are damaged, an exchange of tubes is necessary.It
is possible to replace the smoke tubes from the outside of the boiler. After location of
the damaged tube or tubes, they must be replaced according to the following procedure:
Step A: The oil burner and main engine must be stopped during the repair work.
Step B: Ensure that the boiler pressure is lowered to atmospheric pressure and that
it is completely drained of water.
Step C: Open inspection doors, manhole cover, and hand hole covers.
Step D: Adequate amounts of insulation material as well as shell plate should be
removed for the repair work.
Step E: The damaged tubes must be cut right below and above the tube plates.
Step F: Remove the damaged tubes.
Step G: Scraps of metal and welding material in the tube holes as well as the end
plates must be grinded off.
Step H: Depending on the present conditions the new smoke tubes should be inserted
from either the top or bottom. This means that either parts of the smoke outlet
or the boiler bottom must be removed.
Step I: The new tubes should be placed in the tube holes one by one and seal welded
onto the tube plates as shown in Figure 1. During the assembling the supports
are arranged and adjusted.
Note: Only skilled personnel with knowledge and qualifications to perform certified welding should perform repair work.
Illustration of how to exchange and block a smoke tube
Top end plate

Plugging of tube

Exchange of tube

2.5
3.5

Bottom end plate

Figure 1

Conical tube plug

om9210_22_oc03x0059720en.wmf

Step J: The tubes should be rolled after the welding work has been completed.

Language UK

12-27 / 32

OM9210_22#C.2
PLUGGING OF SMOKE TUBES

Step K: After completion of the repair work, clean the working area.
Step L: Previously removed boiler shell plate as well as smoke outlet or boiler bottom must be rebuilt and insulated.
Step M: Mount manhole cover and hand hole covers. Renew gaskets if necessary.
Step N: Refill the boiler with water and check for leaks through the inspection doors
before starting up.
Step O: Mount and close the inspection doors again.

12-28 / 32

Language UK

OM9210_25#F.1
BOILER REPAIR - REFRACTORY

Boiler repair - refractory


1

Refractory repair
The furnace floor is lined with an insulating material (Verilite R6), close to the casing
covered with a layer of castable refractory (Plicast 31).
The refractory is made with expansion joints, which should under no circumstances
be blocked or filled on purpose.
Even though the refractory is made with expansion joints, it will tend to make additional
natural expansion joints, which will be seen as fissures. However, the fissures will
generally close when the boiler is put into service. Please note the following guidelines
when examining the fissures:

white/light fissures, which are getting darker over the time and are closing when
the boiler is in service and opening in cold condition, need no further attention.
dark/black fissures suddenly occurred, seen in cold condition and are not closing
when boiler is in service need to be repaired/filled up with refractory (Plicast 31).
All refractory subjected to wear will, eventually, need to be repaired. This can be done
as a temporary repair or on a permanent basis.

1.1 Temporary repair


Smaller areas can be temporarily repaired making use of the moulding powder
(Caldetm stix 14), supplied separately with the boiler equipment.
The durability of such a repair depends on the location, but the more exposed to heat,
the shorter lifetime. Generally, it is recommended to replace a temporary repair with
a repair on a permanent basis within one year.
Temporary repairs in vertical places ought to be made swallow tailed, see Figure 1,
if possible. This secures a better attachment to the existing refractory.
Sketch indicating a swallow tail repair

Refractory

Figure 1

Language UK

Swallowtail
(filled in with moulding powder)

swaltail_1x1986360en.wmf

12-29 / 32

OM9210_25#F.1
BOILER REPAIR - REFRACTORY

The surface to which the temporary repair is performed, must always be clean, dry and
rugged.
Mixing instructions for the castable refractory appears from the instruction on the
plastic bucket.
Note: Caldetm stix 14 must be applied to the site immediately when mixed.
The boiler can be lightened-up approx. 1 hour after the refractory has been applied.
The refractory needs no further time for hardening.
If the boiler is pressurized, the lighting-up should be started with the burner in on
position for one (1) minute and then in off for two (2) minutes, during the first half
() hour. Then it can be started up according to the ordinary lighting-up procedure.
Note: Observe the safety rules regarding the refractory which can be seen on the
plastic bucket.

1.2 Permanent repair


Major repairs and renewal of temporary repairs shall always be carried out and supervised by makers specialists, among other things securing that correct drying-out time
and lighting-up is observed.

1.3 Boilers with membrane furnace wall


The refractory applied to a damaged membrane furnace wall must be carried out as
shown in Figure 2.
Refractory applied to a membrane furnace wall

Furnace tube
Failed tube

Plicast 31
Figure 2

om9210_25_plugrex0059770en.wmf

Warning: Failed Y-anchors must only be replaced by Y-anchors made from heat
resistant steel. Y-anchors made from incorrect materials will cause
damage to the refractory.

12-30 / 32

Language UK

OM9210_25#F.1
BOILER REPAIR - REFRACTORY

Maintenance of refractory
Note: The refractory should be inspected once a year for shape and wear. It is
recommended to carry out an inspection in due time prior to long repair
periods such as dry docking, etc. Should a repair be required castable refractors and bricklayers can then be ordered on short notice.
If the refractory has been exposed to water, the refractory should be dried out as soon
as possible. The drying out can be done by hot air (approx. 50C) or by operating the
oil burner.
Warning: However, if the burner is being used, the burner should be operated
with great care.
Warning: Generated steam evaporated from water absorbed into the refractory
might cause fissures and cracks when expanding, if the heat input from
the oil burner is too heavy.

2.1 Typical refractory data


Below in Table 1 is a list of typical refractory data shown.

Refractory data
Al2O3
SiO2
Fe2O2
TiO2
CaO
MgO
Alkanes
Na2O
K2O
Operating range

Verilite R6
32%
24%
12%
1.6%
23.3%
6.1%
1%
100-1000C

Plicast 31
44%
46%
1%
1%
6.5%
0.5%
1%
20-1450C

Caldetm stix 14
48%
43%
1%
1.9%
4.8%
0.2%
0.1%
0.2%
100-1420C

Table 1

Language UK

12-31 / 32

OM9210_31#C.1
LIGHTING-UP CURVE

Lighting-up curve
1

Lighting-up curve for Aalborg boilers


Figure 1 shows the lighting-up curve for Aalborg boilers. When the burner is started
the firing capacity must be adjusted to match the lighting-up curve. Further start/stop
instructions are described in the chapter Start/stop of the boiler.
Lighting-up curve for Aalborg boilers
Boiler pressure (barg)

t: Boiler temperature at start

Temperature ( C)

25

225
150

20
18
16

100

50

30

15

200

14
12
10

175

8
7
6
5
4

150

3
2
125
1

100

75

50

25

0
0

Figure 1

12-32 / 32

15

30

45

60

75
Time (min.)

90

105

120

135

150

om9210_31_startcx0059840en.wmf

Language UK

TABLE OF CONTENTS

Table of contents
Feed and boiler water
Description
Feed and boiler water.................................................

Language UK

Document ID
OM9210_99...............

Page
13-2

13-1 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Feed and boiler water


1

General
Note: The recommended feed and boiler water characteristics are only valid for
boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants. Methods
such as e.g. reverse osmosis plants or ion exchange plants produce good quality distillate. Also evaporators generally produce good distillate. The important thing is that
the distillate used should be clean and without foreign salt contamination.
In practice most distillates used contain minor parts of various salt combinations which
can and must be chemically treated away. Furthermore, the distillate may contain dissolved gases like for example oxygen (O2) and carbon dioxide (CO2) which may lead
to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically treated in order to avoid
corrosion and scaling in the boiler.

Layout of the treatment system


The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system should
therefore be considered carefully during layout of the plant. Alfa Laval gives some
general requirements and recommendations regarding the conditions of the feed and
boiler water. However, there is several ways to obtain this results, or similar, by using
different treatment systems. The following should therefore be considered already at
the layout stage:
-

13-2 / 15

Choose the treatment system that should be used.


Present the condensate and feed water system to the supplier of the treatment system and inform about the operation philosophy of the plant.
Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
Let the supplier inform about which test facilities is needed.
Purchase the recommended equipment and install it in the correct way.
Use the treatment system as soon as the boiler is taken into operation.

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Feed and boiler water characteristics


The following text regarding feed and boiler water treatment is the normal recommendations given by Alfa Laval. These recommendations should be followed strictly
in order to have the best working conditions for the boiler plant and to extend the
working life of the plant. The requirements/recommendations of the various values for
feed and boiler water are listed in Table 1 below.

Requirements for feed and boiler water


Appearance
Hardness
Chloride content
"P" alkalinity
Total (T) alkalinity
PH-value at 25C
Hydrazine excess
Phosphate excess
Specific density at 20C
Conductivity at 25C
Oil content
Copper content

Unit
ppm CaCO3
ppm Clppm CaCO3
ppm CaCO3
ppm N2H4
ppm PO4
Kg/m3
S/cm
ppm

Feed water
Clear and free of mud
0-5
15
8.5 - 9.5
NIL
<0.02

Boiler water
Clear and free of mud
100
100 - 150
2 x "P" - Alkalinity
10.5 - 11.5
0.1 - 0.2
20 - 50
1.003
2000
NIL
<0.3

Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2SO3) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended that
an excess of oxygen binding agents can be measured and indicates that no oxygen has
been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is recommended
to keep the value 0.02 ppm.
In addition to the above values, the various water treatment companies will add further
demands, depending on the method used for treatment of feed and boiler water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.

3.1 Units of measurement


Concentrations are usually expressed in "ppm" i.e. parts solute per million. Concentrations for parts solution by weight are the same as "mg/litre".

Language UK

13-3 / 15

OM9210_99#D.1
FEED AND BOILER WATER

3.1.1 Specific gravity


As guidance the following conversion can be used:

1 Be = 10.000 mg/l total dissolved solids (TDS)


1 mg/l total dissolved solids = 2 S/cm
1 S/cm = 1 mho

Feed and boiler water maintenance


The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together with the supplier of
chemicals for water treatment.

4.1 Recommended water maintenance


4.1.1 Daily
Step A: Analyses of feed and boiler water.
4.1.2 Weekly
Step A: Skimming (surface blow down) according to analyses, but at least once per
week (2 minutes with fully open valve).
Step B: Blow down (bottom blow down) according to analyses, but at least once per
week (each blow down valve 1 minute in low load condition).
If the copper content is on a stable level below the value in table 1, the analyse frequence
can be reduced to once per week.
4.1.3 Monthly
Step A: Check the functions for salinity and oil detection systems.
4.1.4 Every six months
Step A: The boiler water side (interior) must be carefully inspected at least twice a
year.
4.1.5 Yearly
Step A: Check of the water side of the boiler and hotwell/deaerator for corrosion and
scaling.
Step B: Check the chemical pump unit.

Treatment systems / injection points


In the following tables and illustrations a number of different feed and boiler water
treatment systems are shown together with the recommended location for the injection
point of the individual chemicals as stated by the manufacturer. The general information regarding the injection point principle can be used as guidelines for the most
common systems. But should there be any doubt for a specific system the manufacturer/
supplier should be consulted in order to obtain the correct result.

13-4 / 15

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Notes for tables/illustrations:


Note No. 1: the preferred injection point of chemicals stated by the manufacturer/
supplier.
Note No. 2: the alternate injection point of chemicals stated by the manufacturer/
supplier.
Note No. 3: Valid for modulating feed water systems.
Note No. 4: valid for on/off operating feed water systems. The chemical pump
starts/stops together with the feed water pump.
Note No. 5: valid for two boiler installation. Control of the chemicals in question
work properly at an equal load condition (feed water flow) on the two boilers.
How to use the tables:
The tables can be used in different ways but the main idea is to do following:
Step A: Discover which manufacturer and type of chemicals that should be used for
the actual boiler plant.
Step B: Use the name of the manufacturer and type of chemicals to select which
tables that can be used.
Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram
that matches the actual boiler plant.
Step D: Find in the selected tables the table which includes the matching diagram.
Step E: If more than one table is found to match the actual boiler plant in question
it is recommended to use the method/table which includes note No. 1.
Step F: If no table is found to match the actual boiler plant in question it is recommended to seek assistance by the chemical manufacturer/supplier.

Language UK

13-5 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3, 3a, 3b
GC
3, 3a, 3b
SLCC-A
3, 3a, 3b
Drewplex OX
2, 2a, 2b

Standard with Drewplex OX


Continuous
Batch
X
X
X
X

Note No.
1
1
1
1, 3, 4

Table No. 1

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3, 3a, 3b
GC
3, 3a, 3b
SLCC-A
3, 3a, 3b
Amerzine
2, 2a, 2b

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.
1
1
1
1, 3, 4

Table No. 2

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3
GC
3
SLCC-A
3
Amerzine
1

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.

Table No. 3

Valid flow diagram No.


1

2, 3, 4

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3a, 3b
GC
3a, 3b
SLCC-A
3a, 3b
Amerzine
1

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.

Table No. 4

Valid flow diagram No.


2, 3

2, 3, 4, 5

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
3, 3a, 3b
Drewplex OX
2, 2a, 2b

Drewplex AT / OX
Continuous
X
X

13-6 / 15

Batch

Note No.
1
1, 3, 4

Table No. 5

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Drewplex OX
2, 2a, 2b

Drewplex AT / OX
Continuous
X
X

Batch

Note No.
2, 3, 4
3, 4

Table No. 6

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
3, 3a, 3b
Amerzine
2, 2a, 2b

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
1, 3, 4
1, 3, 4

Table No. 7

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Amerzine
2, 2a, 2b

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4
3, 4

Table No. 8

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Amerzine
1

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4
2, 3, 4, 5

Table No. 9

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
2, 2a, 2b
Amerzine
2, 2a, 2b

AGK-100 with Amerzine


Continuous
Batch
X
X

Language UK

Note No.
1, 3, 4
1, 3, 4

Table No. 10

Valid flow diagram No.


1, 2, 3

13-7 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
2, 2a, 2b
Amerzine
1

AGK-100 with Amerzine


Continuous
Batch
X
X

Note No.
3, 4
2, 3, 4, 5

Table No. 11

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
1
Amerzine
1

AGK-100 with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4, 5
2, 3, 4, 5

Table No. 12

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
Alkalinity control
3, 3a, 3b
Phosphate
3, 3a, 3b
Oxycontrol
2, 2a, 2b
Marichem CCI
2, 2a, 2b

Standard
Continuous

Table No. 13

Batch
X
X

X
X

Note No.
1, 3, 4
1, 3, 4
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
Alkalinity control
1
Phosphate
1
Oxycontrol
2
Marichem CCI
2

Standard
Continuous

Table No. 14

Batch
X
X

X
X

Note No.
2, 3, 4
2, 3, 4
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT new formula
2, 2a, 2b
Marichem CCI
2, 2a, 2b

BWT new formula


Continuous
X
X

13-8 / 15

Table No. 15

Batch

Note No.
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT new formula
1
Marichem CCI
2, 2a, 2b

BWT new formula


Continuous

Table No. 16

Batch
X

Note No.
2, 3, 4, 5
3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT powder
2, 2a, 2b
Marichem CCI
2, 2a, 2b

BWT
Continuous
X
X

Table No. 17

Batch

Note No.
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT powder
1
Marichem CCI
2, 2a, 2b

BWT
Continuous

Table No. 18

Batch
X

Note No.
2, 3, 4, 5
3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Oxygen control
2, 2a, 2b
Condensate control
2, 2a, 2b

I
Continuous

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Table No. 19

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Oxygen control
2
Condensate control
2

Language UK

Continuous

X
X

Table No. 20

Batch
X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

13-9 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Cat sulphite L (CSL)
2, 2a, 2b
Condensate control
2, 2a, 2b

II
Continuous

Table No. 21

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Cat sulphite L (CSL)
2
Condensate control
2

II
Continuous

Table No. 22

Batch
X
X

X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Liquitreat
3, 3a, 3b
Condensate control
2, 2a, 2b
(Oxygen control)
2, 2a, 2b

Liquitreat
Continuous

Table No. 23

Batch
X

X
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Liquitreat
1
Condensate control
2, 2a, 2b
(Oxygen control)
2, 2a, 2b

Liquitreat
Continuous

Table No. 24

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Combitreat
3, 3a, 3b
Condensate control
2, 2a, 2b
Oxygen control
2, 2a, 2b

Combitreat
Continuous

13-10 / 15

X
X

Table No. 25

Batch
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Combitreat
1
Condensate control
2
Oxygen control
2

Combitreat
Continuous

Table No. 26

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Hydrazine
2, 2a, 2b
Condensate control
2, 2a, 2b

I
Continuous

Table No. 27

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Hydrazine
2
Condensate control
2

I
Continuous

Table No. 28

Batch
X
X

X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Oxygen control
2, 2a, 2b
Condensate control
2, 2a, 2b

II
Continuous

Table No. 29

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Oxygen control
2
Condensate control
2

II
Continuous

Language UK

X
X

Table No. 30

Batch
X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

13-11 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
BWT One Shot
3, 3a, 3b
Alkalinity control
3, 3a, 3b
(Hydrazine)
2, 2a, 2b

One Shot
Continuous

Table No. 31

Batch
X

X
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
BWT One Shot
1
Alkalinity control
2, 2a, 2b
(Hydrazine)
2, 2a, 2b

One Shot
Continuous

Table No. 32

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
OBWT 3
3, 3a, 3b
OBWT 4
2, 2a, 2b

Organic Treatment
Continuous
Batch
X
X

Table No. 33

Note No.
1
1, 3, 4

Valid flow diagram No.


1, 2, 3

Table 2

13-12 / 15

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 1


Service
steam

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate
Make-up

Boiler

Overflow
Hot well
Drain

1
2
PI

PI

PI

PI

PS

Single boiler operation with or without


forced circulation exhaust gas boiler

Figure 1

Language UK

Feed water
pumps

om9210_99_flowdix0060010en.wmf

13-13 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 2


3b

Service
steam

3a

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate

Boiler

Make-up

Boiler

Overflow
Hot well
Drain

1
2a
PI

PI

PI

PI

PS

2b

PI

PI

PI

PI

Feed water
pumps

PS

Double boiler operation with separate feed water pumps


with or without forced circulation exhaust gas boiler

Figure 2

13-14 / 15

Feed water
pumps

om9210_99_flowdix0060020en.wmf

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 3


3b

Service
steam

3a

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate

Boiler

Make-up

Boiler

Overflow
Hot well
Drain

1
2a

2b

PS PI

PI

PS PI

PI

PS PI

PI

Feed water
pumps

Double boiler operation with common feed water pumps


with or without forced circulation exhaust gas boiler

Figure 3

Language UK

om9210_99_flowdix0060030en.wmf

13-15 / 15

TABLE OF CONTENTS

Table of contents
Water level gauge
Description
Water level gauge......................................................

Language UK

Document ID
OM7010_03...............

Page
14-2

14-1 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Water level gauge


1

Maintenance and service instructions


This section describes the maintenance and service instructions for the water level
gauge.
Illustration of the water level gauge

1 - Nut
2 - Box heads
3 - Joint rings
4 - Box heads
5 - Tubes
6 - Screws
7 - Screws
8 - Cock plug
D - Drain cocks
G - Gauge body
S - Cocks
W - Cocks

W
5
4
1

Figure 1

om7010_03_kli_01x0057060en.wmf

1.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure 1.

14-2 / 6

Language UK

OM7010_03#A.2
WATER LEVEL GAUGE

When out of service with the gauge body in cool and depressurised condition the hexagon screws (6) can be re-tightened.
Illustration of tightening sequence

1
3
5
4
2

Figure 2

om7010_03_level1x0057090en.wmf

Step A: Start at the top, working to opposite sides alternately. Max torque: 35 Nm.
1.1.1 Maintenance during service check-up
Step
Step
Step
Step

A:
B:
C:
D:

Tighten the nuts (1).


Bolts on boiler flanges.
Union nuts (4).
Bolt form screws (7) with cocks in open positions.If a leak cannot be stopped
by tightening the bottom screws (7), the sealing surface of the cock plug (8)
may be damaged or corroded. It can also be necessary to change the packing
(3).

1.2 Blowing down


The item nos. mentioned in this following blowing down procedures refers to Figure 1.
Step A: The gauge should be blown down before lighting up the boiler and just before
closing down the boiler.
1.2.1 Cleaning the water side:
Step A: Shut the cock S and open the cock W.
Step B: Open the drain cock D for a short time. This sucks the water out of the glass
without, however, totally depressurising the gauge body.
Step C: Shut the cock D and then water is forced upwards into the glass again.
Step D: Repeat this procedure several times, opening and shutting the cock D. The
water level in glass rises and falls.
1.2.2 Cleaning the steam side:
Step A: Shut the cock W.
Step B: Open the cock S.
Step C: Blow through the steam side and gauge body by opening the drain cock D
for 1-2 seconds.

Language UK

14-3 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Step D: A steam blowing of longer duration is not advisable considering the service
life of glass.
Step E: Turn the cocks to operating position.

1.3 Dismantling
The following dismantling instructions refer to Figure 1 and Figure 3.
Sectional view of the water level gauge
6

6 - Screws
9 - Wedge piece
10 - Centre piece
11 - Reflex
12 - Sealing gasket
13 - Cushion gasket
14 - Cover plate

9
14
10

12
11
13

Figure 3

om7010_03_kli_05x0057070en.wmf

Step A: Shut the cocks S and W.


Step B: The drain cock D to be opened until the glass is completely emptied.
Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge
body from the cocks S and W.
Step D: Slacken the union nuts (4) and pull off the stuffing box head (2).
Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards
and loosen the screws.
Step F: Move the wedge piece (9) length wise and lift upwards.
Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine
for through going scars.

1.4 Assembling
The following assembling instructions refer to Figure 2 and Figure 3.
Step A: Insert following items into the centre piece (10): sealing gasket (12) reflex
glass (11) cushion gasket (13).
Step B: Place cover plate (14) on top.
Step C: Insert wedge piece (9) and move length wise for correct position.
Step D: Tighten screws (6) evenly starting at top, working to opposite sides alternately. Max torque: 35 Nm
14-4 / 6

Language UK

OM7010_03#A.2
WATER LEVEL GAUGE

Step E: When the boiler is started again and normal working pressure has been
reached re-tighten the screws (6) once again.

1.5 Maintenance of the straight-through cock


1.5.1 Operation principle and maintenance
The following assembling instructions refer to Figure 4.
Detail drawing of the straight-through cock
15

15 - Screw
16 - Split ring
17 - Packing sleeve
18 - Plug
19 - Bottom screw
16
17
18

19

Figure 4

om7010_03_kli_06x0057080en.wmf

The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be further compressed by
tightening the bottom screw (19) until the leakage is stopped. This must only be done
with the cock in open position.
1.5.2 Dismantling
Step A: Remove bottom screw (19).
Step B: Remove screw (15), washer and handle.
Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out
of the cock body by means of a soft mandrel.
Step D: Remove split ring and knock plug out of the packing sleeve.
Step E: Clean all sealing surfaces carefully and lubricate threads with a high temperature grease before installation.
1.5.3 Assembly
Step A: Place the split ring (16) in the recess of the plug (18).
Step B: Push new packing sleeve onto plug.
Step C: Press the complete unit into cock body.
Note: Turn the packing sleeve until the ridge fits with the groove in the cock body.
The eyelets of the packing sleeve must neither protrude nor be tilted.

Language UK

14-5 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Step D: Screw in bottom screw (19).


Step E: Place the handle and washer on the plug and fit screw (15).
Step F: Tighten the bottom screw (19) and check if the plug can be turned.

14-6 / 6

Language UK

TABLE OF CONTENTS

Table of contents
Safety valves
Description
Safety valves.............................................................
Temporary locking of a safety valve............................

Language UK

Document ID
OM6040_01...............
OM6040_02...............

Page
15-2
15-6

15-1 / 7

OM6040_01#A.2
SAFETY VALVES

Safety valves
1

General
In the following the measures required to achieve a safe and reliable operation as well
asmaintenance of the safety valves will be described, together with adjustment and
dismantling instructions.An installation example of the safety valve is shown in Figure 1.
Mounting of safety valves, example
Waste steam pipe

Support

Drain

Expansion joint
with sealing ring

Drain
Drain

If safety valve = DN50/80


drain connection is G1/4" BSP
If safety valve = DN65/100
drain connection is G3/8" BSP

Figure 1

om6040_01_safe_0x0056591en.wmf

Maintenance and start-up of boiler


A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspections, this is according to the
experience of the supplier.

15-2 / 7

Language UK

OM6040_01#A.2
SAFETY VALVES

Warning: Prior to any handling and dismantling of the safety valve ensure that
the system is depressurised.
Before lighting-up the boiler, pipe connections must be thoroughly cleaned for dirt and
foreign bodies.If the valve is not completely tight, which often is the case after start
up of the plant, this is usually caused by impurities between the seat and the cone. In
order to remove these impurities the valve must be heavily blown out by means of the
lifting device. If the valve is not tight after several blows, it may be due to the fact that
a hard foreign body has got stuck between the cone and the seat, and it will then be
necessary to dismount the valve for overhaul.
Warning: In case of a leaking safety valve the valve must be inspected and overhauled as soon as possible. It must be ensured that the boiler is totally
depressurised before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the adjustment later when the valve is to be adjusted when in service.
In case the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained carborundom stirred in kerosene.
Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against turning
as the seat and the cone may thus be damaged.
Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
Step D: When the valve has been mounted and the boiler is commissioned, the valve
must be checked for leakage and adjusted to the set pressure.
Step E: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.

2.1 Routine check


The following should be regarded as recommendations of routine checks on the safety
valves, in order to secure a correct function:

Language UK

15-3 / 7

OM6040_01#A.2
SAFETY VALVES

Monthly
Step A: Examine the safety valves for any leaking, such as:
- Is water seeping from the drain plug at the valve body?
- Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.
Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.
Step B: Expansion and exhaust pipe should be examined at the same time.

Adjustment and dismantling


Safety valves are delivered with the required spring setting and sealed against unauthorised adjustment.Adjustments are only allowed in the spring margins. Outside the
margin a new spring is required. The pressure in a system should not exceed 90% of
the set pressure.
All item numbers mentioned in the following sections refer to Figure 2.

3.1 Dismantling of lifting device


Safety valve with open cap:
Step A: Remove bolt(39) and remove lift lever (41)

3.2 Set pressure change without spring change


Note: Pay attention to spring range.
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21).
Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for
low set pressures.
Step D: Secure the new setting with the lock nut (21) and reassemble lifting device.

3.3 Spring change


Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the
spring (37) is not under tension.
Step C: Loosen the nuts (8) and remove the bonnet (42).
Step D: Remove the upper spring plate (26), spring (37), spindle (14) with disc (12),
guide plate (4), and lower spring plate (26).
Step E: Clean the seat (2) and disc (12).
Step F: Remount the spindle unit with the new spring and upper spring plate.Assemble bonnet (42) and adjust to the spring range.
Step G: Secure the spring setting through the lock nut (21) and remount lifting device.
15-4 / 7

Language UK

OM6040_01#A.2
SAFETY VALVES

Assembling drawing of safety valve


47 Ball
42 Bonnet
41 Lifting lever
40 Split pin
39 Bolt
38 Screw
37 Spring
29 Cap
27 Gasket
26 Springplate
23 Lead seal
22 Drain screw
21 Lock nut
18 Ball
17 Adjusting screw
16 Slotted pin
15 Gasket
14 Spindle
13 Lift aid
12 Disc
10/25 Split cotters
9 Lift limitation ring
8 Hex. nut
7 Gasket
4 Spindle guide
3 Stud
2 Seat
1 Body

39, 40
41
17

21

29
23

38, 47

26
27

37
42
14
10, 25
8

16
18
12
13
15, 22
2
1

Figure 2

Language UK

om6040_01_safe_0x0056600en.wmf

15-5 / 7

OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE

Temporary locking of a safety valve


1

General
During commissioning work or later tests of the opening pressure for the safety valves,
only one safety valve should be checked at a time. This means that the other safety
valve must be locked. The following instruction describes the temporary locking of a
safety valve.

1.1 Procedure for locking of a safety valve


Step
Step
Step
Step
Step

A:
B:
C:
D:
E:

Remove the bolt (39) and split pin (40), see Figure 1.
Remove the lifting lever (41).
Unscrew the screw (38) and break the lead seal (23), if provided.
Unscrew the cap (29).
Place one or two bolts (48) on top of the spindle. The height of the bolts
should be approximately 1-2 mm higher than the normal distance between
the top of the spindle and the inside top of the cap (29).
Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety
valve will be completely locked when the bolts cannot be moved anymore.
Step G: The other safety valve can now be tested without any interference from the
locked safety valve.

1.2 Procedure for unlocking of a safety valve


Warning: As soon as the test procedure for the safety valve has been carried out
the locked safety valve must be unlocked.
Step
Step
Step
Step

15-6 / 7

A:
B:
C:
D:

Unscrew the cap (29) and remove the bolts (48).


Mount the cap (29) again and screw in the screw (38).
Mount the lifting lever (41), bolt (39), and split pin (40).
Provide the safety valve with a lead seal (23), if necessary. This depends on
the local rules of the classification society.

Language UK

OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE

Temporary locking of a safety valve


48
39, 40
41

29
23

Figure 1

Language UK

38

om6040_02_safe_0x0056610en.wmf

15-7 / 7

TABLE OF CONTENTS

Table of contents
Feed water system
Description
Water level control....................................................
Safety device.............................................................
Water level control system..........................................

Language UK

Document ID
SD9230_10................
OM8210_42...............
OM8210_13...............

Page
16-2
16-3
16-17

16-1 / 22

SD9230_10#A.2
WATER LEVEL CONTROL

Water level control


1

Description
The water level control is an on/off regulating system at this type of boiler. The system
is illustrated in Figure 1. The system consists of one independent safety device electrode for too low water level shut down and burner stop. For measuring and control of
the water level, one capacitance level electrode is provided, and it is used to give water
level alarms/shut downs and start/stop of the feed water pumps.
Water level control system
Compact system
(level transmitter
and level electrode)
Water level control system
Feed water
valves

Flange

Safety device

HW

Boiler

NW
Control
system
(panel)

LW
Protection tube
Electrode stand
Vent hole

Feed water pumps

Figure 1

16-2 / 22

sd9230_10_ges_1_x0063930en.wmf

Language UK

OM8210_42#B.3
SAFETY DEVICE

Safety device
1

General
The safety device consists of a level electrode and a level switch. The level electrode
is mounted in an electrode stand on top of the boiler, and the level switch is placed
inside the control system. Depending on the rules of the classification society, the boiler
can be provided with a safety device together with one or two sets of electrodes. The
function of the safety device is to continuously supervise the water level in the boiler
and subsequently give a shut down and cut out of the burner if the water level is too
low.
The combination of one or two level electrodes NRG 16-11 and a level switch NRS
1-50 provides a fail-safe protection against a first fault, i.e. the system will still continue
to provide the safety function even after a first fault.
The self-monitoring design ensures an interruption of the burner circuit in case of a
failure of the electrode, supply cables, level switch, or in the power supply.
The safety device has a built-in response delay, which is indicated on the name plate.
This eliminates unintentional cut-out of the burner circuit caused by interference from
splash, level fluctuations, etc.

Level electrode
2.1 Operation
The too low level electrode operates on the conductive measuring principle using the
electrical conductivity of the boiler water for level signalling. An illustration of the
level electrode type NRG 16-11 is shown in Figure 1. The length of the electrode is
adjusted to the correct length before mounting in the electrode stand.
In normal operation the electrode tip is submerged in the water, and the imbalance of
the bridge circuit is positive. If the water level is below the electrode tip or in case of
a fault, the electrode produces a negative imbalance of the bridge circuit provided in
the level switch (NRS 1-50). This produces the too low level shut down signal and
consequent cut-out of the burner circuit.
The level electrode consists of two single electrodes (measuring electrode and compensating electrode), which are concentrically arranged and insulated from each other
by special insulating seals. The electric connection of the two electrodes is effected
coaxially with a tube, contact ring, and stud. A system of compression springs in the

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OM8210_42#B.3
SAFETY DEVICE

electrode body ensures sufficient sealing forces at the insulating seals, even if the
temperatures vary. The stud is insulated by a Teflon foil. PTFE insulated wires connect
the contact ring and body to the terminal block.
If the insulating seals placed between the electrodes and body are no longer tight due
to deterioration caused by mechanical or chemical breakdown, liquid will penetrate
into the cavities between the body, tube, and stud. This produces a strong negative
imbalance of the bridge circuit, which causes a too low level shut down signal. But in
this case the signal is due to a malfunction. This means that the water level in the boiler
must be checked in the water level gauges if the level switch signals an shut down.
Level electrode type NRG 16-11

Figure 1

om8210_04_nrg16-x0058280en.wmf

2.2 Cleaning/exchanging the electrode


The following work procedures must be carried out if the level electrode is cleaned or
replaced:
Dismantling:
Step A: Stop the boiler plant according to the separate instructions for start/stop of
the boiler.
Warning: When the level electrode is loosen, steam or hot water might escape.
This presents the danger of severe injury. It is therefore essential not
to dismantle the level electrode unless the boiler pressure is zero.
Step B: Disconnect the wires for the compact system and safety device.
Step C: Unscrew the bolts on the flange for the compact system and safety device.
Step D: Pull out the flange including the compact system and safety device from the
electrode stand.
16-4 / 22

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OM8210_42#B.3
SAFETY DEVICE

Step E: Unscrew the locking screw, which locks the level electrode to the flange.
Step F: Unscrew the level electrode from the flange by means of a 36 mm ring
spanner.
Step G: Pull out the level electrode from the flange and electrode holders.
Cleaning:
Note: The interval for cleaning of the electrode rod depends on the present boiler
water conditions. Therefore an exact time interval cannot be given.
Step A: Clean the rod of the level electrode with a wet cloth.
Replacing the level electrode:
Step A: Exchange the defect level electrode.
Replacing the electrode tip:
Step A: Screw the electrode tip "D" into the measuring electrode "A", see Figure 2.
Step B: Carefully determine the required measuring length and mark the length of
the electrode tip "D".
Step C: Unscrew the electrode tip "D" from the measuring electrode "A" and cut the
tip. If provided with a PTFE insulation this must be cut min. 150 mm above
the electrode tip and fixed with a starlock washer.
Step D: Screw the electrode tip "D" into the measuring electrode "A" and tighten.
Slide the spring "C" along the electrode tip "D" so that its bend end completely enters into the small bore "B".
Assembling:
Step A: Check the seating surfaces of the level electrode thread and flange, see
Figure 1.
Step B: Place the joint ring "K" onto the seating surface "J" of the level electrode.
Use only a joint ring (stainless steel) D 27 x 32.
Step C: Apply a light smear of silicone grease (e.g., DOW Corning 111 compound)
to the level electrode thread "I".
Attention: Do not insulate the electrode thread with hemp or PTFE tape.
Step D: Screw the level electrode into the flange and electrode holders. The torque
required is 160 Nm (when cold).
Step E: Screw the locking screw into the level electrode.
Step F: Check the seating surfaces of the electrode stand flange and level electrode
flange. Place a flat gasket on the electrode stand flange.
Step G: Place the flange including the compact system and safety device onto the
electrode stand flange. Fix the flanges with bolts and tighten the bolts in
diagonally opposite pairs.
Step H: Connect the wires for the compact system and safety device.

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OM8210_42#B.3
SAFETY DEVICE

Assembling of the NRG 16-11 level electrode

Figure 2

om8210_04_nrg16-x0058290en.wmf

Level switch
3.1 Operation
The level switch NRS 1-50 is designed for different electrical conductivities of the
boiler water and for connecting one or two level electrodes.
When the water level falls below the low level, the level electrodes are exposed and a
low level alarm is triggered in the level switch. This switchpoint is determined by the
length of the electrode rod (level electrode NRG 1...-50, NRG 1...-11, NRG 16-36).
After the de-energizing delay has elapsed, the two output contacts of the level switch
will open the safety circuit. The switching-off is interlocked in the external safety
circuit and can only be deactivated when the level electrode enters the water again.
In addition, two signal outputs for external signalling devices close instantaneously.
An alarm will also be raised if a malfunction occurs in the level electrode and/or the
electrical connection.
An automatic self-testing routine monitors the safety functions in the level switch and
the level electrodes. In the event of a malfunction the safety circuit opens instantaneously.
Alarm and error messages are indicated by LEDs and a signal output for each level
electrode is energized without delay.
An alarm can be simulated by pressing the test button.

16-6 / 22

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OM8210_42#B.3
SAFETY DEVICE

Level switch type NRS 1-50

Figure 3

om8210_13_2x2689210en.wmf

Dimensions and functional elements

Figure 4

om8210_13_1ax2692030en.wmf

The code switches are accessible after removing the lower terminal strip. The terminal
strips can be unplugged after undoing the right and the left fixing screws.
1: Upper terminal strip
2: Lower terminal strip
3: Fixing screws (cross recess head screws M3)
4: Code switch for switching on/off level electrode 1 / 2
5: Code switch for switching on/off level electrode 1 / 2
6: Enclosure
7: Supporting rail type TH 35, EN 60715
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OM8210_42#B.3
SAFETY DEVICE

Electrical connection
4.1 Wiring diagram for level switch NRS 1-50
Wiring diagram for level switch NRS 1-50

Figure 5

om8210_13_3ax2692080en.wmf

8:Mains supply
9:Signal output 1 / 2 for external alarm 24-230 V AC/DC 100 mA
10:Safety circuit, input and output
11:Wire link, on site, when used as water level limiter acc. to TRD, EN 12952 / EN
12953
12:Stand-by input 1 / 2, 24 V DC
13:Level electrode NRG 1...-50, NRG 1...-11 or NRG 16-36

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OM8210_42#B.3
SAFETY DEVICE

4.2 Schematic representations of arrangements


Schematic representations of arrangements

Fig. 6a

Fig. 6b

Fig. 6c

Fig. 6d

Fig. 6e

Fig. 6f

Figure 6

om8210_13_4ax2691960en.wmf

14: Level electrode(s) NRG 1...-50


15: Level switch NRS 1-50
16: Safety circuit
17: Level switch NRS 1-50 for low-level pre-alarm

Basic Settings
5.1 Factory setting
Level Switch NRS 1-50
The level switch features the following factory set default values:

Language UK

De-energizing delay: 3 sec., 15 sec. for marine applications.


Configuration: Operation with one or two level electrodes NRG 1 ...-50. S1/S2 of
code switches 4 and 5 set to OFF.

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OM8210_42#B.3
SAFETY DEVICE

Commissioning
Warning: The terminal strips of the NRS 1-50 are live during operation. This
presents the danger of electric shock! Always cut off power supply to
the equipment before mounting, removing or connecting the terminal
strips!

6.1 Changing configuration


If only one electrode is used for operation (e. g. in case of emergency operation) change
the settings as follows:
Step A: Switch off mains voltage.
Step B: Unscrew the right and left fixing screws 3 and remove the lower terminal
strip 2, please see Fig. 4
Step C: Depending on which electrode shall be deactivated, set S1/S2 of code
switches 4 and 5 to ON.
Step D: Attach lower terminal strip and fasten fixing screws.
Step E: Apply mains voltage, equipment is re-started.

Code switch 4
Level electrode 1 activated
Level electrode 1 deactivated
Level electrode 2 activated
Level electrode 2 deactivated

S1
OFF
ON

S2

OFF
ON

Code switch 5
S1
OFF
ON

S2

OFF
ON

Table 1
Note: If only one level electrode is switched on, only the LEDs for power and
alarm of the corresponding channels will be illuminated.

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OM8210_42#B.3
SAFETY DEVICE

6.2 Checking switchpoint and function

Figure 7

om8210_13_5ax2691680en.wmf
Start

Activity
Apply mains voltage.

Indication
All LEDs are illuminated.

All LEDs are illuminated for


more than 10 sec.
Raise water in boiler until the
switchpoint low water level
(LW) is exceeded. Level electrode(s) make(s) contact with the
water.

Green LEDs for level electrode 1 / 2 illuminated.

Function
System is being started and tested, this takes approx. 10 sec.
Output contacts are open. Signal outputs 1 and 2 are closed.
System malfunction. Possible
causes: Faulty power supply,
level switch defective.
Output contacts are closed. Signal outputs 1 and 2 open.

Table 2
Checking switchpoint and function
Lower water level until it is below
the switchpoint low water level
(LW). Level electrode(s) is/are exposed.

Red LEDs for level electrode


1 / 2 are flashing.
Red LEDs for level electrode
1 / 2 illuminated.

De-energizing delay is running.


Signal outputs 1 and 2 are
closed instantaneously.
Delay time has elapsed, output
contacts open. Signal outputs 1
and 2 are closed.

Table 3

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OM8210_42#B.3
SAFETY DEVICE

Possible installation faults


Status and indication
Sightglass indicates level below
switchpoint low water (LW), red
LEDs for level electrodes not illuminated. Safety circuit closed.

Water level sufficient. Red LEDs


for level electrodes 1 / 2 illuminated! Safety circuit open.

Fault
Electrode rod(s) is/are too
long.
If installed inside the boiler:
Upper vent hole in protection
tube does not exist or is obstructed.
Electrode rod(s) is/are too
short.
The earth connection to the
vessel is interrupted.

Electrical conductivity of the


boiler water too low.
Upper vent hole flooded.

Remedy
Cut electrode rod(s) to the
length dictated by the switchpoint LW.
Check installation of level electrode. Make sure that the level
in the protection tube corresponds to the actual water level.
Replace electrode rod(s) and cut
new rods to the length dictated
by the switchpoint LW.
Clean seating surfaces and
screw in level electrode with
metallic joint ring. Do not insulate the electrode with hemp or
PTFE tape!
Set response sensitivity of the
level switch to 0.5 S/cm.
Check installation of level electrode. Make sure that the level
in the protection tube corresponds to the actual water level.

Table 4

Operation, alarm and test


7.1 Indicators and adjustors

Figure 8

om8210_13_5ax2691680en.wmf
Operation

Activity
Level electrode(s) submerged

Indication
Green LEDs for level electrode 1 / 2 illuminated.

Function
Output contacts are closed. Signal outputs 1 / 2 open.

Table 5

16-12 / 22

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OM8210_42#B.3
SAFETY DEVICE

Alarm
Level electrode(s) exposed, level below low water level (LW).

Red LEDs for level electrode 1 / 2 are flashing.


Red LEDs for level electrode 1 / 2 illuminated.

De-energizing delay is running.


Signal outputs 1 / 2 are closed
instantaneously.
Delay time has elapsed, output
contacts open. Signal outputs 1 /
2 are closed.

Table 6
Test channel 1 and 2
During operation: Press key 1 or 2
and hold it down until the end of the
test, level switch must react as if there
was an alarm.

Red LEDs for level electrode 1 / 2 are flashing.

Red LEDs for level electrode 1 / 2 illuminated.

Alarm simulated in channel 1 or


2. De-energizing delay is running. Signal outputs 1 / 2 are
closed instantaneously.
Delay time has elapsed, output
contacts open. Signal outputs 1 /
2 are closed. Test finished.

Table 7

Fault indication and troubleshooting


8.1 Indication, diagnosis and remedy
Fault indication
Status
Faulty evaluation of level
electrode 1, channel 1
Faulty evaluation of level
electrode 2, channel 2

Malfunction in level
switch detected.

Diagnosis
Diagnosis LED 1
and LED alarm 1 illuminated.
Diagnosis LED 2
and LED alarm 2 illuminated.
Diagnosis LED 3
and LED alarm 1
and 2 illuminated.

Function
Output contacts are opened
instantaneously. Signal output 1 closes instantaneously.
Output contacts are opened
instantaneously. Signal outputs 1 and 2 are closed instantaneously.
Output contacts are opened
instantaneously. Signal outputs 1 and 2 are closed instantaneously.

Function
next:
Press key 1.
next:
Press key 2.

next:
Press key 1 or key
2.

Table 8

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OM8210_42#B.3
SAFETY DEVICE

Diagnosis
Display 1 and activity
LED alarm 1 and diagnosis
LED 1 illuminated. Press
and hold down key 1.

Display 2
Diagnosis
LED 1
flashing.

LED alarm 2 and Diagnosis


LED 2 illuminated. Press
and hold down key 2.

Diagnosis
LED 2
flashing.
Diagnosis
LED 3
flashing.
Diagnosis
LED 1
flashing.

LED alarm 1 and 2 and Diagnosis LED 3 illuminated.


Press and hold down key 1
or 2.

Diagnosis
LED 2
flashing.
Diagnosis
LED 3
flashing.
Diagnosis
LED 1
flashing.

Fault
Malfunction in level electrode 1, malfunction in level
switch, faulty wiring, faulty
measuring voltage.
Malfunction in level electrode 1, malfunction in level
switch, faulty wiring.
Interference voltage causing
malfunction, boiler earth
without PE
Malfunction in level electrode 2, malfunction in level
switch, faulty wiring, faulty
measuring voltage.
Malfunction in level electrode 2, malfunction in level
switch, faulty wiring.
Interference voltage causing
malfunction, boiler earth
without PE.
Malfunction in processor,
standby fault.

Remedy
check wiring,
measure electrode voltages,
clean and, if necessary,
exchange
level electrode,
exchange level switch.
Provide screen and earthing, connect boiler with
PE.
check wiring,
measure electrode voltages,
clean and, if necessary,
exchange
level electrode,
exchange level switch.
Provide screen and earthing, connect boiler with
PE.
Observe operating instructions for the logic
unit SRL. Replace level
switch.
Replace level switch.

Diagnosis
Internal voltage fault.
LED 2
flashing.
Diagnosis
Malfunction in relay.
LED 3
flashing.
Once the fault is eliminated, the level switch returns to normal operation.
After elimination of the fault switch off the mains voltage and switch it on again after approx. 5 sec.

Table 9

16-14 / 22

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OM8210_42#B.3
SAFETY DEVICE

Checking Level Electrodes


9.1 Measuring voltage across level electrode
Measure the electrode voltage in order to check whether the level electrode is immersed
or if there is a malfunction. Please see Fig. 9.

Figure 9

om8210_13_6bx2692860en.wmf

12: Stand-by input 1 / 2, 24 V DC, for connecting the logic unit SRL
13: Level electrode NRG 1...-50, NRG 1...-11 or NRG 16-36
Note: The self-checking routine of the level switch NRS 1-50 reduces U1-2 to 0
Volt, if executed cyclically.

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OM8210_42#B.3
SAFETY DEVICE

10

Emergency operation
10.1 Emergency operation for water level limiter
If the level switch NRS 1-50 works with two level electrodes NRG 1...-50 (water level
limiter to TRD 604, EN 12952-07, EN 12953-06), the installation can continue operating in emergency operation mode according to TRD 401 and EN 12952 and EN
12953 under constant supervision with only 1 level electrode, in case that one of the
two installed level electrodes fails.
If only one electrode is used for operation change the settings as follows:
Step A: Switch off mains voltage.
Step B: Unscrew the right and left fixing screws 3 and remove the lower terminal
strip 2, please see Fig. 4
Step C: Depending on which electrode shall be deactivated, set S1 or S2 of code
switches 4 and 5 to ON.
Step D: Attach lower terminal strip and fasten fixing screws.
Step E: Apply mains voltage, equipment is re-started.

Code switch 4
Level electrode 1 activated
Level electrode 1 deactivated
Level electrode 2 activated
Level electrode 2 deactivated

S1
OFF
ON

S2

OFF
ON

Code switch 5
S1
OFF
ON

S2

OFF
ON

Table 10
Attention: -Record the beginning of emergency operation in the boiler log.
-An installation operating in emergency mode has to be constantly
supervised.
-Immediately replace faulty level electrode.
-Record the end of emergency operation in the boiler log.
-When the emergency operation is over, restore original settings.

16-16 / 22

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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Water level control system


1

General
The compact system of type NRGT 26-1 consists of a level electrode, protection tube,
and level transmitter. Via a flange the level electrode is inserted in an electrode stand
mounted on top of the boiler. Inside the electrode stand the protection tube is connected
to the flange and surrounds the level electrode. The integrated level transmitter is
placed on top of the level electrode. Figure 1 illustrates the compact system of type
NRGT 26-1. In the first illustration the compact system is shown without the protection
tube and flange. The flange shown in the second illustration can be of a different type.
The compact system works according to the capacitance measurement principle and
is used for signalling different water levels in the boiler. The electrode rod and protection tube form a capacitor. If the level of the dielectric (boiler water) located between
the two capacitor plates changes, the current which flows through the plates changes
proportionally to the level. The level transmitter produces a standard analogue output
of 4-20 mA, which is sent to the control system. Figure 2 illustrates the level transmitter.
Compact system type NRGT 26-1

Figure 1

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om8210_13_nrgt26x0058440en.wmf

16-17 / 22

OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Compact system type NRGT 26-1 (level transmitter)

Figure 2

om8210_13_nrgt26x0058430en.wmf

Table for position numbers illustrated in Figure 1 and Figure 2


A
B
C
D
E
F
G
H
I

Electrode thread 3/4" BSP, DIN 228


Sealing surface
Joint ring (of stainless steel) D 27 x 32 to
DIN 7603
Flange (different ones are used)
Protection tube
Spacer disc
Housing screw M 4
Cable entry PG 9 / PG 16
Housing cover

J
K
L
M
N
O
P
Q
R
S

Measuring range switch


Potentiometer for lower measuring point
Red LED "level 0%"
Green LED "level > 0%, < 100%"
Red LED "level 100%"
Potentiometer for upper measuring point
Thermal fuse Tmax 102C
Terminal strip
PE connection
Screw

Table 1

16-18 / 22

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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Cleaning/exchanging the electrode


The following work procedures must be carried out if the level electrode is cleaned or
replaced:
Dismantling:
Step A: Stop the boiler plant according to the separate instructions for start/stop of
the boiler.
Warning: When the level electrode is loosen, steam or hot water might escape.
This presents the danger of severe injury. It is therefore essential not
to dismantle the level electrode unless the boiler pressure is zero.
Step B: Disconnect the wires for the compact system and safety device.
Warning: The terminal strip and the electronic components of the NRGT 26-1
are live during operation. This presents the danger of electric shock.
Cut off the power supply before fixing or removing the housing cover.
During commissioning use only completely insulated spanner for adjusting the measuring points.
Step C: Unscrew the bolts on the flange for the compact system and safety device.
Step D: Pull out the flange including the compact system and safety device from the
electrode stand.
Step E: Unscrew the locking screw, which locks the level electrode to the flange.
Step F: Unscrew the level electrode from the flange by means of a 41 mm open-end
spanner.
Step G: Pull out the level electrode from the flange and protection tube.
Cleaning:
Note: The interval for cleaning of the electrode rod depends on the present boiler
water conditions. Therefore an exact time interval cannot be given.
Step A: Clean the rod of the level electrode with a wet cloth.
Replacing:
Step A: Exchange the defect level electrode including the level transmitter.
Assembling:
Step A: Check the seating surfaces of the level electrode thread and flange.
Step B: Place the joint ring "C" onto the seating surface "B" of the level electrode
(see Figure 1). Use only a joint ring (stainless steel) D 27 x 32.
Step C: Apply a light smear of silicone grease (e.g., DOW Corning 111 compound)
to the level electrode thread "A".
Attention: Do not insulate the electrode thread with hemp or PTFE tape.

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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Step D: Screw the level electrode into the flange and protection tube. The torque
required is 160 Nm (when cold).
Step E: Screw the locking screw into the level electrode.
Step F: Check the seating surfaces of the electrode stand flange and level electrode
flange. Place a flat gasket on the electrode stand flange.
Step G: Place the flange including the compact system and safety device onto the
electrode stand flange.
Step H: Fix the flanges with bolts and tighten the bolts in diagonally opposite pairs.
Step I: Connect the wires for the compact system and safety device. A wiring diagram for the compact system can be seen in Figure 3.

230 V
or
115 V

24 V

Wiring diagram

4-20 mA

Figure 3

PE

N
Mains

om8210_13_nrgt26x0058420en.wmf

Standard setting
The purpose of the switch "J" is to set the optimal frequency band for the internal
measurement inside the compact system. To obtain the best measuring conditions, the
switch "J" is set to a position determined by the active measuring length of the level
electrode. The compact system is delivered with the following factory settings:
-

Measuring range 275 mm: switch "J" position 3, water 20 S/cm


Measuring range 375 mm to 675 mm: switch "J" position 4, water 20 S/cm
Measuring range 775 mm to 1375 mm: switch "J" position 5, water 20 S/cm
Measuring range 1475 mm to 1975 mm: switch "J" position 6, water 20 S/cm

Commissioning
Wiring check:
Step A: Check that the system has been wired according to the wiring diagram (see
Figure 3 and the electrical drawings).
Step B: Check that the mains supply corresponds to the value shown on the label of
the equipment.

16-20 / 22

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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Application of mains voltage:


Step A: Unscrew the screws "G" and remove the housing cover "I".
Step B: Apply mains voltage. The LED "L" will light up (see the position in Figure 2).
Adjustment of the lower measuring point:
Step A: Fill the boiler with water until the lower measuring point is reached.
Step B: Start the boiler according to the separate instructions for start/stop of the
boiler.
Step C: Raise the boiler pressure till normal working pressure.
Step D: Turn the potentiometer "K" to the left. The red LED "L" lights up.
Step E: Turn the potentiometer "K" to the right until only the green LED "M" lights
up.The lower measuring point is now adjusted.
Adjustment of the upper measuring point:
Step A: Fill the boiler with water until the upper measuring point is reached.
Step B: Operate the burner until the boiler pressure has reached normal working
pressure.
Step C: Turn the potentiometer "O" to the right until only the red LED "N" lights
up.
Step D: Turn the potentiometer "O" to the left until the green LED "M" lights up.
Step E: Turn the potentiometer "O" to the right until the green LED "M" extinguishes.
Step F: Mount the housing cover "I" and screw in the screws "G".The upper measuring point is now adjusted.
Note: When adjusting the measuring points of the electrode in a cold boiler, the
measuring points will shift with rising temperature as a result of the longitudinal expansion of the electrode rod. The adjustment must be corrected
proportionally.

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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM

Fault finding
Fault finding chart

Fault
The equipment does not work
Mains voltage has not been applied.
The thermal fuse has failed.

The electrode housing does not have earth connection to the


boiler.
The electronic board is defective.
The equipment does not work accurately
The electrode has been installed without the protection tube. The
protection tube serves as reference electrode.
The vent hole in the protection tube does not exist, is obstructed,
or flooded.
The desired zero point does not lie within the measuring range
of the electrode. The electrode is too short.
The adjustment of the measuring range is wrong.
Dirt deposits have been accumulated on the electrode rod.
The gasket of the electrode rod is damaged. Measure the current
at terminal 1 and 2 (20 mA).

Remedy
Apply mains voltage. Wire the equipment according to the wiring diagram.
In the case of a defective thermal fuse, the mains voltage has not
been connected to terminal "Q". Replace the defective thermal
fuse.
The ambient temperature must not exceed 70C.
Clean the seating surfaces and insert the metal joint ring (of
stainless steel) 27 x 32 to DIN 7605.
Do not insulate the compact system with hemp or PTFE tape.
Replace the board.
Install the protection tube.
Check the protection tube and, if necessary, provide a vent hole.
Replace the compact system. Choose an adequate electrode
length.
Adjust switch "J" correctly (see the instructions).
Remove the compact system and clean the electrode rod with a
wet cloth.
Replace the compact system.

Table 2

16-22 / 22

Language UK

TABLE OF CONTENTS

Table of contents
Feed water pump unit
Description
Pumps, type CR, CRN................................................

Language UK

Document ID
OM5540_20...............

Page
17-2

17-1 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Pumps, type CR, CRN


1

General
The multistage in-line centrifugal pumps are used as condensate, make-up, and feed
water pumps in boiler plants. To have a proper functioning of the centrifugal pumps it
is essential that the pumped liquid does not contain any steam, air, solid particles or
fibres. Furthermore the liquid must not attack the pump material chemically.

1.1 Technical data

17-2 / 12

Electrical data: see motor nameplate.


Ambient temperature: Max. 45C.
Minimum inlet pressure: see section 2.
Maximum inlet pressure: see Table 1. However, the actual inlet pressure + pressure
when the pump is running against a closed valve must always be lower than the
maximum permissible operating pressure".

Language UK

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Maximum inlet pressure


50 Hz
CR, CRN 1
CR, CRN 1s-2 CR, CRN 1s-36
CR, CRN 1-2 CR, CRN 1-36
CR, CRN 3
CR, CRN 3-2 CR, CRN 3-29
CR, CRN 3-31 CR, CRN 3-36
CR, CRN 5
CR, CRN 5-2 CR, CRN 5-16
CR, CRN 5-18 CR, CRN 5-36
CR, CRN 10
CR, CRN 10-1 CR, CRN 10-6
CR, CRN 10-7 CR, CRN 10-22
CR, CRN 15
CR, CRN 15-1 CR, CRN 15-3
CR, CRN 15-4 CR, CRN 15-17
CR, CRN 20
CR, CRN 20-1 CR, CRN 20-3
CR, CRN 20-4 CR, CRN 20-17
CR, CRN 32
CR, CRN 32-1-1 CR, CRN 32-4
CR, CRN 32-5-2 CR, CRN 32-10
CR, CRN 32-11-2 CR, CRN 32-14
CR, CRN 45
CR, CRN 45-1-1 CR, CRN 45-2
CR, CRN 45-3-2 CR, CRN 45-5
CR,CRN 45-6-2 CR,CRN 45-13-2
CR, CRN 64
CR, CRN 64-1-1 CR, CRN 64-2-2
CR, CRN 64-2-1 CR, CRN 64-4-2
CR, CRN 64-4-1 CR, CRN 64-8-1
CR, CRN 90
CR, CRN 90-1-1 CR, CRN 90-1
CR, CRN 90-2-2 CR, CRN 90-3-2
CR, CRN 90-3 CR, CRN 90-6

60 Hz
10 bar
10 bar

CR, CRN 1s-2 CR, CRN 1s-27


CR, CRN 1-2 CR, CRN 1-25
CR, CRN 1-27

10 bar
10 bar
15 bar

10 bar
15 bar

CR, CRN 3-2 CR, CRN 3-15


CR, CRN 3-17 CR, CRN 3-25

10 bar
15 bar

10 bar
15 bar

CR, CRN 5-2 CR, CRN 5-9


CR, CRN 5-10 CR, CRN 5-24

10 bar
15 bar

8 bar
10 bar

CR, CRN 10-1 CR, CRN 10-5


CR, CRN 10-6 CR, CRN 10-17

8 bar
10 bar

8 bar
10 bar

CR, CRN 15-1 CR, CRN 15-2


CR, CRN 15-3 CR, CRN 15-12

8 bar
10 bar

8 bar
10 bar

CR, CRN 20-1


CR, CRN 20-2 CR, CRN 20-10

8 bar
10 bar

4 bar
10 bar
15 bar

CR, CRN 32-1-1 CR, CRN 32-2


CR, CRN 32-3-2 CR, CRN 32-6
CR,CRN 32-7-2 CR,CRN
32-10-2

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 45-1-1 CR, CRN 45-1


CR, CRN 45-2-2 CR, CRN 45-3
CR, CRN 45-4-2 CR, CRN 45-7

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 64-1-1


CR, CRN 64-1 CR, CRN 64-2-1
CR, CRN 64-2 CR, CRN 64-5-2

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 90-1-1 CR, CRN 90-2-1


CR, CRN 90-2-2 CR, CRN 90-4-2

10 bar
15 bar

Table 1

Language UK

17-3 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Maximum permissible operating pressure: see Table 2.


Maximum permissible operating pressure

Frequency

50 Hz

60 Hz

Pump type
CR, CRN 1s, 1
CR, CRN 3
CR, CRN 5
CR, CRN 10-1 CR, CRN 10-22
CR, CRN 15-1 CR, CRN 15-17
CR, CRN 20-1 CR, CRN 20-17
CR, CRN 32-1-1 CR, CRN 32-7
CR, CRN 32-8-2 CR, CRN 32-12
CR, CRN 32-13-2 CR, CRN 32-14
CR, CRN 45-1-1 CR, CRN 45-5
CR, CRN 45-6-2 CR, CRN 45-9
CR, CRN 45-10-2 CR, CRN 45-10
CR, CRN 64-1-1 CR, CRN 64-5
CR, CRN 64-6-2 CR, CRN 64-7-1
CR, CRN 90-1-1 CR, CRN 90-4
CR, CRN 90-5-2 CR, CRN 90-6
CR, CRN 1s, 1
CR, CRN 3
CR, CRN 5
CR, CRN 10-1 CR, CRN 10-17
CR, CRN 15-1 CR, CRN 15-12
CR, CRN 20-8 CR, CRN 20-10
CR, CRN 32-1-1 CR, CRN 32-5
CR, CRN 32-6-2 CR, CRN 32-8
CR, CRN 32-9-2 CR, CRN 32-10-2
CR, CRN 45-1-1 CR, CRN 45-4
CR, CRN 45-5-2 CR, CRN 45-6
CR, CRN 64-1-1 CR, CRN 64-3
CR, CRN 64-4-2 CR, CRN 64-4-1
CR, CRN 90-1-1 CR, CRN 90-3
CR, CRN 90-4-2

Temperature range

-20C to +120C

-20C to +120C

Operating pressure
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
16 bar
25 bar
30 bar
16 bar
25 bar
33 bar
16 bar
25 bar
16 bar
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
16 bar
25 bar
40 bar
16 bar
25 bar
16 bar
25 bar
16 bar
25 bar

Table 2

17-4 / 12

Language UK

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Minimum flow rates: See Table 3.


Minimum flow rates
Liquid temperature
Up to + 80C
0.1 m3/h
0.1 m3/h
0.4 m3/h
0.6 m3/h
1.2 m3/h
1.8 m3/h
2.4 m3/h
3.8 m3/h
5.4 m3/h
7.7 m3/h
11.0 m3/h

Pump type
CR, CRN 1s
CR, CRN 1
CR, CRN 3
CR, CRN 5
CR, CRN 10
CR, CRN 15
CR, CRN 20
CR, CRN 32
CR, CRN 45
CR, CRN 64
CR, CRN 90

+ 80C to + 120C
0.2 m3/h
0.3 m3/h
0.8 m3/h
1.3 m3/h
2.6 m3/h
3.8 m3/h
5.0 m3/h
7.6 m3/h
11.0 m3/h
16.0 m3/h
24.0 m3/h

Table 3

Liquid temperature: -20C to 120C. See also Table 2 which indicates the relationship between liquid temperature and maximum permissible operating pressure.

Note: In condensate and feed water systems where an open hot-well is used it is
recommended to keep a temperature in the hot-well of 85-95C.

Further technical data can be found on the data sheet related to the pumps.

Calculation of minimum inlet pressure


The minimum inlet pressure "H" in metres head required to avoid cavitation in the
pump is calculated as follows:
H = pb x 10.2 - NPSH - Hf - Hv - Hs

pb = barometric pressure in bar (barometric pressure can be set to 1.0 bar). In closed
systems pb indicates the system pressure in bar.
NPSH = net positive suction head in metres head (to be read from the NPSH curves
in Figure 2and Figure 3at the highest flow the pump will be delivering).
Hf = friction loss in suction pipe in metres head at the highest flow.
Hv = vapour pressure in metres head, see Figure 1. Tm = liquid temperature
Hs = safety margin = 0.5 metres head.
If the calculated H is positive, the pump can operate at a suction lift of maximum
H metres head. If the calculated H is negative, an inlet pressure of minimum H
metres head is required. There must be a pressure equal to the calculated H during
operation.
Example:
Pump type = CR 20 - 60 Hz, flow rate = 24 m3/h, pb = 1.0 bar.

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17-5 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Hf = 3.0 metres head, liquid temperature = + 90C.


Hv (from Figure 1) = 7.5 metres head.
NPSH (from Figure 2) = 2.5 metres head.
H = pb x 10.2 - NPSH - Hf - Hv - Hs
H = 1 x 10.2 - 2.5 - 3.0 - 7.5 - 0.5 = -3.3 metres head.
This means that an inlet pressure of minimum 3.3 metres head is required.
Relationship between Hv and Tm

Figure 1

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om5540_20_cr02ax0054100en.wmf

Language UK

OM5540_20#C.1
PUMPS, TYPE CR, CRN

NPSH curves

Figure 2

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om5540_20_cr03bx0054110en.wmf

17-7 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

NPSH curves, continued

Figure 3

om5540_20_cr07ax0054130en.wmf

Start-up
Note: The pump is not allowed to run against a closed discharge valve as this will
cause an increase in temperature/formation of steam in the pump which
may cause damage to the pump.
If there is any danger of the pump running against a closed discharge valve, a minimum
liquid flow through the pump should be ensured by connecting a by-pass / drain to the
discharge pipe. The drain can for instance be connected to a hot-well / tank.
Warning: Do not start the pump until it is filled with liquid and has been primed
and vented.

3.1 Priming
Note: The following does only apply to systems where the liquid level is above
the pump inlet
Step A: Close the discharge isolating valve and loosen the vent screw in the pump
head, see Figure 4.
Note: Pay attention to the direction of the vent hole and take care to ensure that
the escaping water does not cause injury to persons or damage to the motor
or other components. In hot water installations, special attention should
be paid to the risk of injury caused by scalding hot water.
Step B: Slowly open the isolating valve in the suction pipe until a steady stream of
liquid runs out the vent hole.
Step C: Tighten the vent screw and completely open the isolating valve(s).

17-8 / 12

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Illustration of the centrifugal pumps

Figure 4

om5540_20_cr06x0054120en.wmf

3.2 Checking direction of rotation


Do not start the pump to check direction of rotation until it has been filled with liquid.
Note: The direction of rotation should not be checked with the motor alone, as
an adjustment of the shaft position is required when the coupling has been
removed.
The correct direction of rotation is shown by arrows on the pump head and/or on the
motor fan cover. When seen from the fan, the pump should rotate counter-clockwise.

3.3 Starting
Before starting the pump:
Step A: Open the isolating valve completely on the suction side of the pump and
leave the discharge isolating valve almost closed.
Step B: Start the pump.
Step C: Vent the pump during starting by loosening the vent screw in the pump head
until a steady stream of liquid runs out the vent hole, see Figure 4.
Warning: Pay attention to the direction of the vent hole and take care to ensure
that the escaping water does not cause injury to persons or damage to
the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot
water.
When the piping system has been filled with liquid:
Step D: Slowly open the discharge isolating valve until it is completely open.When
pumping liquids containing air, it is advisable to vent the pump regularly.
To vent the pump:
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17-9 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Step E: Loosen the vent screw in the pump head during operation.

3.4 Frequency of starts and stops


Motors smaller than 4 kW should not start more than 100 times per hour.
Other motors should not start more than 20 times per hour.

Maintenance
Caution: Before starting work on the pump, make sure that no power is supplied
to the pump and that it cannot be accidentally switched on. Before removing the cover of the electrical terminal box and before any removal/
dismantling of the pump, make sure that the electricity supply has been
switched off.
Pump bearings and shaft seal are maintenance-free.
If the pump is to be drained for a long period of inactivity then:
Step A: Remove one of the coupling guards to inject a few drops of silicone oil on
the shaft between the pump head and the coupling.
This will prevent the shaft seal faces from sticking. When fitting the coupling guards,
make sure that they are centred vertically in the recesses in the pump head.

4.1 Motor bearings


Motors which are not fitted with grease nipples are maintenance-free.
Motors fitted with grease nipples should be lubricated with a high-temperature lithiumbased grease.
In the case of seasonal operation (motor is idle for more than 6 months of the year), it
is recommended to grease the motor when the pump is taken out of operation.

Frost protection
Pumps which are not used during periods of frost should be drained to avoid damage.
Step A: Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base.
Warning: Care must be taken to ensure that the escaping water does not cause
injury to persons or damage to the motor or other components. In hot
water installations, special attention should be paid to the risk of injury
caused by scalding hot water.

17-10 / 12

Language UK

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Do not tighten the vent screw and replace the drain plug until the pump is to be used
again.
Step B: Before replacing the drain plug in the base, screw the by-pass valve out
against the stop, see Figure 4.
Step C: Fit the drain plug by tightening the large union nut followed by the bypass
valve.

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17-11 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Fault finding chart


Before removing the terminal box cover and before any removal/dismantling of the
pump, make sure that the electricity supply has been switched off.

Fault finding chart


Fault
1. Motor does not run when
started.

2. Motor starter overload trips


out immediately when supply is
switched on.

3. Motor starter overload trips


out occasionally.
4. Motor starter has not tripped
out but the pump does not run.
5. Pump capacity not constant.

6. Pump runs but gives no water.

7. Pump runs backwards when


switched off.
8. Leakage in shaft seal.
9. Noise.

Cause
a) Supply failure.
b) Fuses blown.
c) Motor starter overload has tripped out.
d) Main contacts in motor starter are not making contact
or the coil is faulty.
e) Control circuit fuses are defective.
f) Motor is defective.
a) One fuse is blown/automatic circuit breaker is blown.
b) Contacts in motor starter overload are faulty.
c) Cable connection is loose or faulty.
d) Motor winding is defective.
e) Pump mechanically blocked.
f) Overload setting too low.
a) Overload setting too low.
b) Low voltage at peak times.

Remedy
Connect the electrical supply.
Replace fuse.
Reactivate the motor protection.

a) Check 1 a), b), d) and e).

a) Pump inlet pressure is too low (cavitation).


b) Suction pipe/pump partly blocked by impurities.
c) Pump draws in air.
a) Suction pipe/pump blocked by impurities.
b) Foot or non-return valve blocked in closed position.
c) Leakage in suction pipe.
d) Air in suction pipe or pump.
e) Motor rotates in the wrong direction.

Check the suction conditions.


Clean the pump or suction side.
Check the suction conditions.
Clean the pump or suction side.
Repair the foot or non-return valve.
Repair the suction pipe.
Check the suction conditions.
Change the direction of rotation of
the motor.
Repair the suction pipe.
Repair the foot or non-return valve.
Replace the shaft seal.
Check the suction conditions.

a) Leakage in suction pipe.


b) Foot or non-return valve defective.
a) Shaft seal is defective.
a) Cavitation occurs in the pump.
b) Pump does not rotate freely (frictional resistance) because of incorrect pump shaft position.

Replace contacts or magnetic coil.


Repair the control circuit.
Replace the motor.
Cut the fuse.
Replace motor starter contacts.
Fasten/replace the cable connection.
Replace the motor.
Remove blocking of the pump.
Set the motor starter correctly.
Set the motor starter correctly.
Check the electrical supply.

Adjust the pump shaft.

Table 4

17-12 / 12

Language UK

TABLE OF CONTENTS

Table of contents
Salinity alarm equipment
Description
Salinometer...............................................................

Language UK

Document ID
OM8210_41...............

Page
18-2

18-1 / 6

OM8210_41#G.1
SALINOMETER

Salinometer
1

Description
The salinometer is used in combination with a conductive electrode to measure and
supervise the salinity of feed water. Figure 1 illustrates the control device and electrode.
The control device is provided with indication LEDs for monitoring the salinity level
and two LEDs for alarm purpose. The measuring range as well as the adjustable alarm
range is 0 100 ppm (sea salt). The alarm limit can be adjusted by means of the set
screw located on the front panel. The alarm limit is indicated by a flashing LED in the
indication LED row. If the salinity level exceeds the alarm limit the alarm LEDs start
flashing.
During commissioning it is not necessary to carry out any adjustments of the equipment
except setting the alarm limit. When the power is turned on, the salinometer will perform a self test. This calibration will take approximately 5 sec.
Illustration of the control device
Control
device

Indication
LEDs

PG 13.5

Gasket

Terminals

Figure 1

Gold-plated
electrodes

sl700g_bx3194020en.wmf

Note: The electrode is totally sealed and must not be opened. The guarantee is
void if opening of the electrode is attempted.

18-2 / 6

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OM8210_41#G.1
SALINOMETER

Installation
The conductive electrode may be installed vertically, horizontally, or radial inclined.
However, the electrodes must be constantly submerged in feed water. Figure 2 illustrates the salinity system.
Illustration of the salinity system
Make-up
Condensate

Hot well

T-piece
Electrode
Cable lenght 2.5 m
Junction box
(not Alfa Laval supply)
Cable lenght max. 200 m
(not Alfa Laval supply)
PI

PI

Salinometer
(mounted in
power panel)

PS

To boiler

PI

Figure 2

Language UK

PI

Feed water
pumps

sl700d_bx3198720en.wmf

18-3 / 6

OM8210_41#G.1
SALINOMETER

2.1 Wiring
The wiring should be carried out in accordance with the diagram shown in Figure 3.

Black

Shield

Grey

Blue

Brown

Wiring diagram

Figure 3

Black

Shield

Grey

Blue

Brown

Junction box
(not Alfa Laval supply)

sl700i_ax3115920en.wmf

The mains supply of the control device is 98-122 VAC or 196-244 VAC, 50-60 Hz.Ensure that the mains supply is secured against over current by a fuse (max.100mA).
The recommended cable for the conductive electrode is a multi-screened twin twisted,
where the screen is connected to connector 14, one pair is used for connector 11+12,
and the other pair is used for connector 13+15. The length of the cable must not exceed
200 m.
Important: The cable may not be placed together with power cables, as this will
cause damage to the gold plating on the electrodes.

Maintenance
The accuracy of the salinometer equipment is very dependent on the electrodes are
kept clean. The electrodes should be taken out and cleaned at least once a week. Use
only a clean and soft cloth. When cleaning the electrodes it is important that oil or other
chemicals do not pollute the electrodes. Any pollution will immediately result in an
inaccurate measurement of the salinometer.
Note: Avoid damaging the gold plating.If the gold plating is damaged, the conductive electrode must be replaced.
The expected longevity of the conductive electrode is approximately 1.2 2.2 years.

18-4 / 6

Language UK

OM8210_41#G.1
SALINOMETER

Troubleshooting

Step

Problem

Description

No lights in
Salinometer
(1)
No lights in
Salinometer
(2)

Check external fuse.


Check AC power on Salinometer terminals .Check the cable
connections to the Salinometer.
Check voltage between pin 12 and 14.
Voltage from electrode shall be approx. 2 VDC.
If the voltage is low (near 0 Vdc), disconnect the electrode unit
and check that the light in the salinometer is on again.
Disconnect the connector to the electrode unit. Salinity level
shall increase to approx. 100 PPM and the alarm will be flashing.
Remove Electrode unit and inspect/clean the electrodes. Use a
clean and dry rag. Avoid touching the electrodes with the fingers. Check that the gold plating not is damaged. This should
be done at least once a week.

Wrong reading
of salinity.

Wrong reading
of salinity.

Wrong reading
of salinity.

Corrosion
electrodes.

of

This test has to be done with electrode in open air (not in water).
a) Check voltage between pin 11 and 14
(Voltage from electrode: 0 VDC).
b) Check voltage between pin 12 and 14
(Voltage from electrode: 2 VDC).
c) Check voltage between pin 13 and 14
(Voltage from salinometer: +12 to 15 VDC).
d) Check voltage between pin 15 and 14
(Voltage from salinometer: -12 to 15 VDC).
e) Disconnect electrode unit and check voltage between pin 11
and 14
(Voltage from electrode more than: 2 VDC).
Check that the sensor cable is mounted at far as possible from
high power cables.

Posible causes
Salinometer has no power.

Electrode unit is defective or cable


failure (reference voltage from
electrode unit is missing).
If no reaction: The salinometer is
defective.
Electrodes dirty or damaged.
We recommend replacement of the
electrode unit every 18 months depending on the condition of the
gold plating.
Cable failure: Check connections.

The cable to the Salinometer sensor is mounted near some high


power cables. The induction from
the high power cables gives a high
voltage on the sensor cable and the
sensor. A high voltage on the sensor will cause corrosion faster than
normal.

Table 1

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18-5 / 6

OM8210_41#G.1
SALINOMETER

No.

Picture

Description

What to do

Electrode unit in good condition. No visible damages.

The unit is ready for installation.

Electrode unit with damaged


gold platin

The unit is ready for exchange. We recommend replacement of


the electrode unit every 18 months depending on the condition of
the gold plating.
Send a request for a new sparepart.

Electrode unit with serious


corrosion/erosion.
One of the sensors has almost
disappeared.

The cable to the Salinometer sensor is mounted near some high


power cables. The induction from the high power cables gives a
high voltage on the sensor cable and the sensor. A high voltage
on the sensor will cause corrosion faster than normal.
Relocate the cables and send a request for a new sparepart.

Electrode unit with crack in


the white moulding.
The gold platin is in good
condition.

Under normal circumstances the electrode unit is covered by warranty (as long as the electrode unit is not tampered with). When
discovering an electrode units with this fault please send following
information to your supplier:
1. Serial number of the salinometer
2. Photos of the electrode unit, showing the crack and the golden
plated electrodes
3. Name of the vessel
4. Your reference no.

Warning:
Do not try to open the electrode unit. Warranty will be
void if the electrode unit is
open or damaged.

Send a request for a new sparepart.

Table 2

18-6 / 6

Language UK

TABLE OF CONTENTS

Table of contents
Oil detection equipment
Description
Oil detection equipment..............................................

Language UK

Document ID
OM9410_01...............

Page
19-2

19-1 / 11

OM9410_01#C.1
OIL DETECTION EQUIPMENT

Oil detection equipment


1

General
This chapter contains installation, operation, and maintenance instructions for the ultrasonic interface detection system, Mobrey type 402 SD, using control unit type
MCU200.
Each Mobrey ultrasonic control system requires a sensor to suit the specific application,
plus a control unit. These instructions cover the control units in the MCU200 series.

Sensor installation
2.1 General description
The ultrasonic sensor contains two piezoelectric crystals. A high frequency signal (3.7
MHz) generated by the control unit is transmitted to one piezoelectric crystal by coaxial
cable. This crystal converts the electrical signal into an ultrasonic oscillation.The sensor design allows the ultrasonic oscillation to pass from the transmitter crystal to the
receiver piezoelectric crystal. The sensors of type 402 are gap type sensors, where
the two piezoelectric crystals are separated by a gap. When the gap is in liquid the
signal reaches the receiver, because of the low ultrasonic attenuation of the liquid.
When the gap is filled with air, no ultrasonic signal can pass from transmitter to receiver. See Figure 1.
Working principle of the oil detection equipment

Figure 1

19-2 / 11

om9410_01_mobreyx0063070en.wmf

Language UK

OM9410_01#C.1
OIL DETECTION EQUIPMENT

When the gap is filled with liquid, the piezoelectric receiver crystal converts the ultrasonic wave into an electrical signal, which is transmitted back to the control unit
using a second coaxial cable. Usually the two coaxial cables to the sensor are in one
overall sheath. The control unit circuitry is a feedback amplifier, which oscillates when
the sensor is wet, and is quiescent for the sensor dry. The oscillating or non-oscillating sensor states dictate the output relay states of the MCU200.
For interface detection the sensor oscillates in a clear liquid, and is non-oscillating
at the interface.

2.2 Switching levels and orientation


The gap sensors should normally be mounted with the gap vertical, to avoid build up
of solids on the sensor faces on either side of the gap. In this condition the switching
level will be half way up the face: if the sensor is mounted from the side of the tank
this is normally on the centreline of the cylindrical body.
Occasionally such sensors are mounted with the sensor faces horizontal, either to avoid
air bubbles passing through the gap or for convenience of installation. In this case the
switching level will be at the sensor face at the top of the gap.

2.3 Installation of sensor


The sensor must be handled with care - it is a measuring instrument. Before installation,
check that sensor, cable and control unit have not been damaged in transit. Drill and
tap a hole with a suitable thread. It is advisable to use a boss or similar on thin walls.
The sensor has a tapered thread. Use Ptfe tape or similar to seal the thread. Mark the
sensor hexagon to identify the gap orientation of the sensor, if appropriate. Take care
not to damage the sensor cable during tightening.
The cable should be laid on cable trays and separated from any high voltage or mains
cables. The normal cable termination is a plastic gland (to fit the MCU200 control box
drilled hole) and crimped terminal pins to suit the MCU200 terminals.

2.4 Extensions cables


Extension cables up to 50 metres long can be fitted to most Mobrey ultrasonic sensors
in the factory to special order but a better site arrangement is to have a separate extension cable. Table 1 shows a list of suitable extension cables.

Suitable extension cables


50 m
RG174
RG178

50 - 100 m
URM76
RG58

Above 100 m
Consult Alfa Laval

Table 1

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19-3 / 11

OM9410_01#C.1
OIL DETECTION EQUIPMENT

When double coaxial cable needs to be extended, two sets of coaxial plugs and sockets
will be needed, one set for transmit and one receive. Care must be taken that the connectors are not connected to earth or shorted together in any way, to prevent cross-talk
or pick-up. The coaxial connections must be made in a waterproof junction box. Terminal blocks should not be used.
The extension cable needs to be of 50 Ohm characteristic impedance. Suitable dual
coaxial extension cables can be purchased from Alfa Laval. For extensions over 50
metres it is recommended two runs of single coaxial low loss cable is used, with the
transmit and return cable runs separated by 0.15 metres to minimise cross-talk.
If several sensor cables are being run together then all the transmit cables (those connected to E2) should be grouped together and all receive cables (those connected to
1E) grouped together maintaining the separation specified above.
Two cables are required per sensor. The RG178 should be used where the cable itself
is subject to temperatures exceeding 74C.

Control unit installation


3.1 Mechanical
The control unit is supplied with three holes drilled in the bottom (longer) side of the
box. Two glands are supplied for the power input cable and relay output cable. The
sensor is normally supplied fitted with a suitable gland on the cable. Two further holes
can be drilled in the bottom side of the box should these be needed: it is recommended
that the circuit board is removed whilst drilling extra gland holes.
Figure 2 shows the dimensions of the MCU200 housing box.

19-4 / 11

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OM9410_01#C.1
OIL DETECTION EQUIPMENT

MCU200 Housing dimensions

Figure 2

om9410_01_mobreyx0063080en.wmf

All cable connections are made to the terminal blocks along the bottom edge of the
pcb, see Figure 3. Release the terminal screw before inserting the wire.
MCU201 PC board

Figure 3

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om9410_01_mobreyx0063090en.wmf

19-5 / 11

OM9410_01#C.1
OIL DETECTION EQUIPMENT

3.2 External connections


3.2.1 AC mains
AC mains is connected between the N terminal for neutral and one of the 115V
or 230V terminals depending on the voltage supply available - BEWARE - the terminal not connected externally will be live once the transformer is powered via the
other terminals.
3.2.2 Mains earth
Mains earth should be connected to the terminal marked E. This provides an earth
contact for the pcb mounting pints.
3.2.3 The relay
The relay output connections are labelled:

NC - Normally closed (relay de-energised)


C - Common
NO - Normally open (relay de-energised)
There are also two sets of contacts for DPCO relay, labelled 1 & 2.
3.2.4 The sensor
The sensor connections are labelled "1", "E" for the receiver crystal and "2", "E" for
the coax cable to the transmitter crystal. The screens of these coax cables are connected
to the terminals marked "E".
3.2.5 The auxiliary input
The auxiliary input is a terminal which can be connected to a "push to reset" button to
achieve a latching alarm, or to another Mobrey Control unit, to give a pump control
from the MCU200 unit relay output. If a short circuit is connected between terminals
3 & 4, the MCU200 relay, once de-energised, is held de-energised. Even if the sensor
attached to the MCU200 changes state, to that which should energise the output relay,
this relay will not energise until the link between terminals 3 & 4 is broken in the circuit
external to the MCU200.

3.3 Switch settings in MCU200 series


3.3.1 Gain switch and potentiometer
See section 4.
3.3.2 Frequency selection
This slide switch is labelled "FREQ" and is located between the sensor terminal block
E2, and the Aux. input terminals. This selects the operating frequency of the MCU200
oscillator, which for the present installation must be set to 3.7 MHz (switch in the up
position). The setting required is dictated by the sensor type connected to the control
unit.

19-6 / 11

Language UK

OM9410_01#C.1
OIL DETECTION EQUIPMENT

3.3.3 Cable check option selection


This slide switch is located directly above the sensor terminal block E2. It is labelled
"Cable Check" and the ex factory setting is "OUT" with the slide switch to the right.
By sliding this switch to the left, the cable check circuitry is brought into action. This
circuitry monitors the continuity of the screens of the two coaxial cables attached to
the sensors: normally these are linked at the sensor to the metal body of the fitting (or
to each other in the case of non metallic sensors). If this continuity is broken, the
"FAULT LED" will illuminate giving an indication that the sensor cable is damaged,
and the MCU200 will give the "ALARM" output relay state (see Figure 4).
3.3.4 Relay output and LED logic selection
The bank of six slide switches towards the top of the pcb sets the relay output state
logic relative to the sensor state, associated time delays and the LEDs. These are slide
switches, best adjusted with a pencil, and the ex factory wetting is with all switches to
the right.
Each switch is colour coded as shown in Figure 4, and the PC board labels give brief
function information.
Relay output and LED logic switch

Figure 4

om9410_01_mobreyx0063130en.wmf

Note: At Figure 4 OSC means sensor oscillating. E means relay energised, NE


means de-energised.
Set the switches in the following order, starting at the bottom and working upwards:
BLUE:
If the MCU200 relay is to be energised (E) when the sensor is oscillating (OSC) then
set the No 6 blue switch to the right (OSC=E). This is the preferred setting, to give a
de-energised relay in the ALARM state for a gap sensor as a low level alarm.

Language UK

19-7 / 11

OM9410_01#C.1
OIL DETECTION EQUIPMENT

GREEN:
This selects the relay change which is subject to the time delay selected on the top
switches. When the No.5 green switch is set to the right, the delay occurs between the
sensor changing state and the relay de-energising or becoming not energised (NE).
This time delay is a minimum of 0.l5 seconds, (achieved by switching the top BROWN
switch to the right) and is used to prevent relay chatter at the changeover point. Longer
time delays are selected on the top three slide switches as shown in Figure 5.
The relay change in the opposite direction is immediate (within 50 milliseconds).
The top three slide switches

Figure 5

om9410_01_mobreyx0063100en.wmf

YELLOW:
Only one of the GREEN or RED LEDs will be illuminated at any one time. These
LEDs show the state of the MCU200 output relay. The RED LED is labelled "ALARM"
and the GREEN LED is labelled "NORMAL". The yellow slide switch (Number 4)
determines which LED will be illuminated when the relay is energised (E). It is usual
to have the GREEN/NORMAL condition occur with the relay energised, i.e. with
switch Number 4 to the right (E=GREEN).

Applications
4.1 Gain adjustment
Correct adjustment of the gain (HI/LO switch and potentiometer) is essential for proper
operation of any ultrasonic sensor system. This adjusts the gain of the feedback amplifier in the control unit, which produces oscillation of the sensor when the coupling
between the ultrasonic crystals is sufficient. Therefore the higher the gain setting, the
lower the coupling needed to produce an oscillating sensor.
The universal control unit of the MCU200 operates with many sensors, so the correct
setting for the particular sensor and application should be found on site by experiment,
if possible. This will take account of particular site conditions like RF coupling between
extension cables, which can affect the maximum allowed gain. Other liquid characteristics, such as presence of suspended solids, or air bubbles, can mean that for reliable
operation the MCU200 gain must be set as high as possible, to overcome future solids

19-8 / 11

Language UK

OM9410_01#C.1
OIL DETECTION EQUIPMENT

build up, but at least one potentiometer division below the maximum allowed level, to
ensure temperature and component ageing stability.
The particular procedures outlined below for gain adjustments give the mid point gain
settings, which may need to be adjusted to meet specific site/sensor future requirements
as indicated above.

4.2 Interface detection


4.2.1 Interface detection between two dissimilar liquids
Viscous liquids, emulsions and liquids containing solid particles have a greater ultrasonic attenuation than clear liquids. This technique is used to detect which liquid is
present at the sensor, for example for the separation of oil and water. For this duty
Mobrey 402 sensors are used, operating at 3.7 MHz to produce the maximum ultrasonic
difference between two liquids monitored.
The gain is adjusted so that the sensor oscillates only in the liquid with the lower
ultrasonic attenuation: this is usually the clearer liquid (water in the example of Figure 6). Note that the signal when oil is present in the sensor gap will be the same as
that for air in the gasp, and that emulsion layers give a very high attenuation.
Mobrey 402 Sensor as oil/water interface

Figure 6

om9410_01_mobreyx0063110en.wmf

Step A: Reduce the gain potentiometer with the sensor immersed in one of the liquids
until a "false dry" indication is obtained. Note the position of the pot.
Step B: Repeat for the sensor immersed in the other liquid.

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19-9 / 11

OM9410_01#C.1
OIL DETECTION EQUIPMENT

Step C: Set the potentiometer half way between these two values. Correct performance requires a total difference between the two set points of at least 3 divisions.
Interface detection between two immiscible similar liquidsWhen liquids are
ultrasonically very similar - as happens for example with paraffin or oil and
water - the procedure in section 4.2.1. produces very little difference between
the two "false dry" points. In this case the "reflection" method of interface
detection is used. An illustration of this method is shown in Figure 7.
Note: The Mobrey 402 sensor in the hot well tank is installed as shown in Figure 7.
If an ultrasonic beam is transmitted from one liquid to another at a suitable angle (10%)
it is split at the interface into a reflected and a refracted beam, so that it does not reach
the receiver crystal. If there is no interference in the gap, but only one liquid, the beam
is received and the sensor oscillates.
Interface detector by reflection method

Figure 7

om9410_01_mobreyx0063120en.wmf

The gain adjustment is made so that the gain is 3 divisions higher than the highest false
dry position obtained, as in section 4.2.1. Performance at the interface should then be
checked.
Note: That the non oscillating state of the sensor, at the interface, also occurs
throughout any emulsion layer at the interface, and also when the sensor
is in air.

19-10 / 11

Language UK

OM9410_01#C.1
OIL DETECTION EQUIPMENT

Spares and fault finding


5.1 Spares
The following parts are suitable for replacements on the MCU201:

Main pcb complete: K2641


LED indicator pcb: K2643
LED pcb spacers: K2623
LED pcb connector: K2624/50
Box assembly: K2662
Gland Assembly: K746/K747/K748
There are no consumable items such as fuses.

5.2 Fault finding


Step A: At least one LED should be illuminated. If not check the power supply to
the unit.
Step B: If the "Fault" LED is on, check the coax cable to the sensor for incorrect
wiring or damage. Particularly check continuity of extension cables, connection of crimped connectors on cable ends. The pcb board can be checked
by linking the two terminals labelled E on the sensor terminals - this should
cancel the fault indication LED.
Step C: If the sensor is giving incorrect indications check the gain adjustment (see
section 4.0).
Check for correct sensor operation whenever the gain is adjusted away from the normal
set point. Assume an overlap of 2 divisions between the "LO" and "HI" gain ranges.
Step D: Check that the incorrect operation has not been produced by incorrect setting
of the frequency selection switch, or an external short circuit on the Auxiliary
input terminals.
Step E: The circuit board can be checked by linking the sensor terminals 1 and 2
with a wire, to simulate an oscillating sensor.

Language UK

19-11 / 11

TABLE OF CONTENTS

Table of contents
Descriptions
Description
Pressure atomizing burner, type Aalborg KBO-E...........

Language UK

Document ID
SD5560_12................

Page
20-2

20-1 / 3

SD5560_12#G.1
PRESSURE ATOMIZING BURNER, TYPE AALBORG KBOE

Pressure atomizing burner, type Aalborg


KBO-E
1

Burner description
The Aalborg KBO-E burner is a pressure atomizing burner of the monoblock type
designed for modulating operation. It is capable of burning marine diesel oil, MDO
with a viscosity of min. 4 cSt. at 20C. Marine gas oil with a viscosity of min. 1.5 cSt.
at 40C. And heavy fuel oil HFO, with a viscosity of max. 700 cSt. at 50C. All internal
pipes are traced. The design of the burner makes installation, adjustment and servicing
easy. Furthermore, it ensures that the flame is kept highly stable at all loads. An illustration of the Aalborg KBO-E burner is shown in Figure 1.
Illustration of the pressure atomizing burner, type Aalborg KBO-E

Figure 1

kbo-ex1301530en.jpg

The burner housing is mounted on the boiler front with a hinged flange that can be
turned either to left or right. In case of burner swing out during operation a micro switch
stops the burner.
The electrical fan motor is fitted on the side of the housing and is directly connected
to the fan wheel. A pressure switch monitors and secures against too low combustion
air pressure. In case of too high oil pressure after the oil regulator a pressure switch
shuts down the burner.
A combustion head and diffuser disc are placed in front of the nozzle with the purpose
of mixing air and oil mist into a suitable mixture.

20-2 / 3

Language UK

SD5560_12#G.1
PRESSURE ATOMIZING BURNER, TYPE AALBORG KBOE

The oil is supplied through a ring line system and connections to the burner unit are
made of flexible hoses.
Heavy fuel oil is heated in the pre-heater. The oil atomizing temperature is controlled
by an electronic regulator which has to be set so that the viscosity of the heavy fuel oil
at the nozzle is between 14 16 cSt.
Heating cartridges are placed in the solenoid valves and nozzle head in order to keep
a sufficiently high temperature close to the nozzle.
The burner operation is handled by the control system. Electric signals corresponding
to the pressure gauge board signals are processed in the control system. Start/stop
signals as well as load regulation impulses are then send to the two servo motors, which
drive the oil regulator and air dampers respectively.In the event of fault conditions the
oil supply is always interrupted immediately.
The oil regulator regulates the oil flow through the nozzle by increasing or decreasing
the flow resistance. This causes that more or less oil is pressed through the nozzle as
the supply pressure from the oil pump is constant. The air dampers are connected
directly to the second servo motor. The control system provides the regulation of the
air quantity in proportion to the oil quantity fired.
When the burner starts, and the ignition sequence step is reached, the oil flame is ignited
by means of the two ignition electrodes which are connected to a high voltage ignition
transformer. The electrodes are mounted just above the oil nozzle.
Flame failure during start-up and normal operation is detected by photo cells mounted
on the burner unit and coupled to the control system. By loss of flame, the flame failure
equipment will automatically shut down the burner.

Language UK

20-3 / 3

TABLE OF CONTENTS

Table of contents
Operation and maintenance
Description
Modulating oil burner................................................
Handling fuel oil........................................................
Electric oil-heater......................................................
Oil/air regulation.......................................................
Ignition electrodes.....................................................
Combustion head.......................................................
Photo cell.................................................................
Nozzle selection........................................................
Nozzles....................................................................
Viscosity - temperature chart.......................................
Fuel oil supply system................................................
Burner supply systems...............................................
Operating instructions................................................
Burner operation........................................................
Emergency operation.................................................
Commissioning.........................................................
Maintenance.............................................................
Faults and rectifying faults..........................................

Language UK

Document ID
OM5560_03...............
OM9280_02...............
OM5560_88...............
OM5560_95...............
OM5560_84...............
OM5560_87...............
OM8630_01...............
OM5560_38...............
OM5560_37...............
OM9280_01...............
OM5560_116.............
OM5560_117.............
OM5560_110.............
OM5560_98...............
OM5560_234.............
OM5560_118.............
OM5560_85...............
OM5560_92...............

Page
21-2
21-4
21-6
21-8
21-12
21-13
21-16
21-17
21-22
21-23
21-25
21-31
21-34
21-38
21-42
21-46
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21-1 / 60

OM5560_03#E.1
MODULATING OIL BURNER

Modulating oil burner


1

General
The modulating oil burner is a pressure atomizing burner capable of burning marine
gas oil MGO, marine diesel oil MDO and heavy fuel oil HFO.
MGO and MDO with properties according to ISO 8217:2010 type DMA, DMZ and
DMB. HFO with properties according to ISO 8217:2010 type RMA 10, RMB 30, RMD
80, RME/RMG 180, RMG/RMK 380, 500, 700.
For burners only operating with MGO no fuel oil heaters are fitted and limited fuel oil
viscosity range to burner is to be observed.
As the burner is a very vital component of the boiler plant, the operating staff should
be thoroughly instructed with regard to the operation of the equipment and the safety
regulations. This is due to the fact that burner problems are often caused by incorrect
burner operation. With frequently occurring burner faults, the nearest service centre
should be consulted.
To ensure a safe and reliable function of the burner it must be inspected at least once
a year by a representative of the supplier or by another competent and qualified person.

1.1 Safety regulations


Caution: To ensure safe burner operation, the burner has to be installed and
commissioned by qualified personnel, and all guidelines in these instructions have to be followed.
All safety equipment such as flame sensor equipment and correcting elements may
only be replaced by qualified personnel, which can be ordered by contacting Alfa
Laval.
Warning: Repair of any of the safety components is NOT permitted. Failure to
comply may result in serious injury or death and may cause considerable damages to the boiler plant.

1.2 Qualified personnel


Qualified personnel according to these operating instructions are persons, who are
confident in installing, regulating and commissioning the burner, and who have qualifications to carry out this work i.e.:

21-2 / 60

Language UK

OM5560_03#E.1
MODULATING OIL BURNER

Language UK

Persons who are trained to operate electric circuits and units according to the safety
standards.
Persons who are qualified in the use of dangerous fuel according to the relevant
laws and regulations.

21-3 / 60

OM9280_02#F.1
HANDLING FUEL OIL

Handling fuel oil


1

Precautions to be taken with fuel oil


Marine gas oil MGO and marine diesel oil MDO are distillates of crude oil. Heavy fuel
HFO is the residual of the crude oil after the removal of distillates.
Liquid oil is very difficult to ignite in bulk and not capable of spontaneous combustion.
However both the distillates and the residuals are capable of forming vapours which
are explosive when mixed with air. As the vapours can be heavier that air, it tends to
accumulate in low levels such as bilges and bottoms of tanks where it may remain
undiscovered until ignited by a naked light or spark. It is always present in a partly
filled oil tank or in a tank which has contained fuel oil and is given off through the
vents from tanks in the process of being filled.
If allowed to continue, a leak in any part of the oil burning system may result in an
accumulation of this explosive vapour.
Ignition of the vapour can be caused by an open light, electric spark, smoking, spark
caused by striking metal, heat from the filament of a broken electric lamp, sparks from
funnel or can be communicated from galley or fires under boilers.
Note: An oil fire cannot be extinguished by water, but may be extinguished by
sand, steam or chemical fire extinguishers.
An intelligent appreciation of the properties of fuel oil as described above is a better
prevention of accident than adherence to any set of rules that may be pre-described.

21-4 / 60

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OM9280_02#F.1
HANDLING FUEL OIL

However, the following detailed precautions should be rigidly enforced:

Language UK

When oil is being received, no naked light or electric apparatus liable to spark
should be permitted within 20 meters of the oil hose, tank or compartment, containing the tank or the vent from the tank, except when special arrangements are
carried out.
While receiving fuel oil, the storage tank must be closely watched for leaks, and
care must be taken that all outlets from the tank, except the vents, are closed.
No naked lights or electric apparatus liable to spark should be permitted at any
time in a compartment containing a fuel oil tank. Electric lamps used in such compartments should have a wire protector around the bulb or be of a type that will
ensure the breaking of a circuit through the lamp in the event of the lamp being
broken.
No one should be allowed to enter a fuel oil tank until it has been gas-freed, and
any person then entering the tank must have a properly tended life-line around his
body in order to be hauled out if overcome by gas.
Electric fuses and switches, unless the enclosed type, should not be permitted in
compartments containing fuel oil pumps or piping.
Care must be taken that the wire-gauze protectors in vent pipes from fuel oil tanks
are intact at all times.
Dampers, where fitted in the uptakes of the boilers, must be kept fully open while
burning oil. Otherwise, this may result in dangerous accumulation of gas in the
furnace with a resultant blowing out into the boiler or engine room.
The valves on glass gauges in fuel oil storage or service tanks should be kept
habitually shut. When a reading of the gauge is desired, the valves may be opened,
but must be shut again at once.
In each boiler or engine room fitted for oil burning there should be fire extinguishing apparatus in accordance with the requirements/rules from the authorities
and classification societies in question such as, e.g.: Fire hose, permanently coupled and of sufficient length to reach all parts of the boiler or engine room, and
either:
(a) a box containing at least 85 litres (2 cubic ft) of dry sand with a large scoop
(b) a chemical fire extinguisher of the tank type
When the fuel oil system has not been in use for a long period, or after joints in
the piping have been re-made, the system should be tested cold under a pressure
at least equal to the working pressure before fires are ignited. During the test a
careful inspection for leaks should be carried out.
Fuel oil should not be habitually heated above 60C for marine gas oil / diesel oil
and 120C for heavy oils and never above its flash point in any part of the system
except in the burners.
Care must be taken to prevent accumulation of oil or vapour in any place outside
the system and in ships particularly in bilges under the furnace. This can be accomplished by rigid cleanliness.

21-5 / 60

OM5560_88#C.1
ELECTRIC OIL-HEATER

Electric oil-heater
1

Oil-heater
The electric oil heater, illustrated in Figure 1, is used for heating of fuel oil. The heater
is provided with electric heating elements, which conduct the produced heat to the fuel
oil. The heater is rated to 7.2 kW at 440 V. Depending on the fuel oil flow rate and
viscosity, a burner can be equipped with one or more pre-heaters. Irrespective of the
number of oil heaters there is only one common temperature controller. However, each
heater is provided with its own safety temperature limit thermostat, STL. Inlet and
outlet is a 10 mm bite type connection.
Attention: Attention: The inlet must be mounted correct. If the oil flows backwards through the heater, the PT 100 sensor, measures the temperature of the cold oil, consequently the temperature control can not
work.
Illustration of the electric oil-heater
Thermo pocket STL
Inlet

Bracket

Outlet

Inlet

STL

L2
L3
L1

STL

STL

Outlet

Inlet

L1

PT100

Thermo pocket PT100


Thermo pocket PT100

Outlet

PT100
STL

L2

L1
L2

L3

STL

Thermo pocket STL

Figure 1

STL

STL = Safety temperatore limiter

oil_heaterel_ax2442550en.wmf

Note: Referring to figure 1, please note that the inlet always is in the same side
as the bracket.

21-6 / 60

Language UK

L3

OM5560_88#C.1
ELECTRIC OIL-HEATER

1.1 STL
The STL has an adjustable temperature range between 50 and 300C.It is fitted with a
reset button. If the oil temperature becomes too high, the STL stops the burner. The
shut down is indicated in the control system. In case of failure, the fault has to be
repaired. Before the heater can be taken into service again, the reset button on the
temperature limit thermostat must be activated and the shut down in the control system
must be reset. There are 3 pockets for the STL temperature sensor. All indicated on
figure 1.
Warning: Surface temperatures above 200, may cause cracking of the oil. Note:
Reset must be carried out when the STL is not under voltage.

1.2 Temperature controller for heater


The desired fuel oil temperature can be set in the control system together with alarm
set points and shut down set points. The fuel oil temperature in the heater is registered
by a Pt 100 resistance temperature sensor and supplied to the control system. Fluctuations in oil temperature are minimized by the Pt 100 sensor which is placed directly
in the heating plate. If the oil temperature becomes too low or too high during operation,
e.g. if the heater elements are faulty, the control system stops the burner and actuates
a shut down indication.

1.3 Test of the functions


The function of the STL can be tested by dismantling one of the wires at the terminals
to the temperature limit thermostat. The burner stops immediately. The low oil temperature shut down can be tested by disconnecting the electric power to the pre-heater.
When the oil temperature drops below the shut down limit the burner stops. .

Language UK

21-7 / 60

OM5560_95#A.2
OIL/AIR REGULATION

Oil/air regulation
1

Oil/air regulator
The oil and air regulation for the burner are handled by two servomotors. The oil flow
is regulated bya valve, which is regulated by a servomotor. The air damper is regulated
by a second servomotor.Figure 1 illustrates the regulator system.
The servomotorsare controlled by the control system during start-up/stop and operation
of the burner.
Illustration of the regulator system

1
2
3
4
5
6

Air damper
Servomotor
Oil regulator
Dosing nozzle
Dosing shaft
Servomotor

A Oil inlet
B Oil return
C Air

Figure 1

om5560_95_oilburx0055900en.wmf

The oil quantity burned is determined by nozzle size and oil pump pressure. The oil
regulator regulates the return oil flow according to the capacity demand. At partial load
the oil regulator is open so that the oil throughput in the valve is at maximum and the
return oil flow pressure at minimum. At full load the oil regulator is closed whereupon
the oil throughput is at minimum and the pressure at maximum.

21-8 / 60

Language UK

OM5560_95#A.2
OIL/AIR REGULATION

The air quantity is matched to the fired oil quantity by means of the control system,
which controls the servomotor for the air dampers.

Servomotor
The servomotorswhich operate the oil regulator and air dampers are equipped with a
number of cam switches and a potentiometer. The outer scale on the camshaft serves
as a position indicator. Figure 2 shows an illustration of the servomotor.
Illustration of the servomotor
R1
fail-safe

S2

S1
1

3
II

N
Figure 2

I Right-handed operation
II Left-handed operation

D1
om5560_95_oilburx0055890en.wmf

In automatic operation of the burner, signals are sent from the control system to the
servomotor for positioning the air dampers dependent on the sequence step for the
burner. The potentiometer provides feedback signals to the control system when the
burner operates in this mode.
In emergency operation of the burner, the servomotor is operated by pressing the increase and decrease buttons located inside the boiler control panel.
Cam switches No. 1 and No. 2, which are the switches for purge/full load position and
closed position respectively, are active in automatic operation mode. Therefore, the
servomotor cannot open or close the air dampers beyond the setting of the switches
regardless of the signals sent from the control system. By this, an extra control of the
combustion process is added to the burner operation. Please note that cam switch No.
1 is also active in emergency operation mode.

2.1 Calibration of the servomotor range


During commissioning, the servomotor range must be calibrated. The low and high
range should be set to 0 and 90 opening of the air dampers respectively.
The output signal from the potentiometer is a voltage signal, which is converted into
a resistance signal in the control system. On the local panel the resistance signal is

Language UK

21-9 / 60

OM5560_95#A.2
OIL/AIR REGULATION

displayed in the menu setup/calibrate/servo motor/raw data. When the position of the
servomotor is set to 0, which can be seen on the outer scale, the raw data line displays
a numerical value. This value must be entered in low range menu line.
After calibration of the low range position, the servomotor should be set to 90. The
new numerical value, which is displayed in the raw data line, should be entered as the
high range. In this way the operation range of the servomotor is calibrated for an operating range between 0 and 90 corresponding to 0-100%.
The position of the servomotor will be handled and displayed as a percentage value in
all other menus.
Furthermore, the time to operate the servomotor from 0 to 90 and the accepted response threshold can be set on the local control panel.

2.2 Pre-adjustment of the servomotor settings


The following servomotor positions for operation should be set as preliminary settings
on the local control panel in the menu setup/settings:

Stand-by position (burner stopped) 0% (0)


Ignition position 22% (20)
Minimum firing position 33% (30)
Purge and full load position 67% (60)
Please consider the proposed settings as guidelines only as the final settings should be
performed after measuring the flue gas (CO2/O2 content).

Oil regulator
The oil regulator is driven by the servomotor in a continuous movement from partial
load to full load, thus regulating the return oil flow from the nozzle head. Figure 3
illustrates the oil regulator. It is provided with indicator and scale.

Indicator in position 1: dosing shaft open. The return flow is at maximum and the
return pressure at minimum.
Indicator in position 13: dosing shaft closed. The return flow is at minimum and
the return pressure at maximum.
There is a number on the dosing shaft and on the indicator which shows the size of the
groove on the shaft.

21-10 / 60

Language UK

OM5560_95#A.2
OIL/AIR REGULATION

Illustration of the oil regulator

1 Body
2 Dosing shaft
3 Dosing nozzle
4 Nipple
5 Compression spring
6 Thrust washer
7 Roller bearing
8 Spring cotter
9 End flange
10 Hexagonal socket screw
11 Coupling
12 O-ring
13 X-ring

Figure 3

Language UK

14 O-ring
15 Needle valve
16 Needle valve
17 Retaining ring
18 Retaining ring
19 Non-return valve
20 Coupling
21 Washer
22 Indicator
23 Scale
B Oil to valve
C Oil from valve

om5560_95_oilburx0055910en.wmf

21-11 / 60

OM5560_84#B.1
IGNITION ELECTRODES

Ignition electrodes
1

Setting of the ignition electrodes


The ignition electrodes for the burner are shown in Figure 1 together with the adjustment dimensions. As the conditions may vary from boiler to boiler, the indicated dimensions should only be considered as guidelines. If ignition problems emerge, a more
favourable adjustment of the electrodes, suitable for the present conditions, must be
found by experiments.
Illustration of the ignition electrode settings

Burner type
KBO-R13M
KBO-R14M
KBO-R15M
KBO-R25M
KBO-R30M
KBO-R40M
KBO-R50M

Figure 1

H
17
17
17
17
9
9
9

K
3.5
3.5
3.5
3.5
3
3
3

L
6
6
6
6
10
10
10

om5560_84_oilburx0055750en.wmf

When the ignition electrodes are adjusted, the following must be observed:

21-12 / 60

The distance of the ignition electrodes to the nozzle and diffuser should be checked.
The atomizing oil spray must never touch the ignition electrodes.
The distance of the ignition electrodes to the diffuser and the nozzle must always
be lager than the distance of the spark gap.
If a nozzle with a larger spray angle is fitted, the electrodes must be adjusted backwards, or perhaps be adjusted slightly upwards.

Language UK

OM5560_87#A.2
COMBUSTION HEAD

Combustion head
1

Adjustment ofthe combustion head


The oil burner is delivered with a combustion head and an air diffuser disc that suit the
specified boiler type and oil quantity in the best way.Figure 1 illustrates the combustion
head for KBO-R13/14M burners,Figure 2 for a KBO-R15M burner, and finally Figure 3 for KBO-R20/60M burners.
To obtain the best possible combustion performance the combustion head should be
adjusted to fit the actual boiler furnace. The combustion quality can be checked by
means of flue gas analysis.The air velocity in the combustion head can be adjusted by
loosening the fixing screwin the adjustment ring and moving the ring (4) in the direction
of the flame tube (6) to change the distance between the adjustment ring and the edge
of the diffuser disc (5). On low capacity the adjustment ring is advanced and on high
capacity retracted. If the adjustment ring is set too far forward, the combustion air
velocity in the combustion head is too high, the ignition is more difficult or there is
not enough air to support the combustion (high CO content). If the adjustment ring is
too far back, the combustion air velocity is too low and the combustion characteristics
become worse (O2 content is too high).
Combustion head for KBO-R13/14M burners

1 Burner housing
2 Fixing screw for combustion head
3 Combustion head guide
4 Adjustment ring
5 Diffuser disc
6 Flame tube
7 Oil nozzle
9 Fixing nut for diffuser disc
10 Fixing screw for combustion head guide
8 mm

Figure 1

Language UK

om5560_87_oilburx0055780en.wmf

21-13 / 60

OM5560_87#A.2
COMBUSTION HEAD

Combustion head for a KBO-R15M burner

1 Burner housing
2 Fixing screw for combustion head
3 Combustion head guide
4 Adjustment ring
5 Diffuser disc
6 Flame tube
7 Oil nozzle
9 Fixing nut for diffuser disc
10 Fixing screw for combustion head guide
8 mm

Figure 2

om5560_87_oilburx0055780en.wmf

Combustion head for a KBO-R20/60M burners

8 mm

3
4
5
7

Figure 3

21-14 / 60

Combustion head
Adjustment ring
Diffuser disc
Oil nozzle

om5560_87_oilburx0055790en.wmf

Language UK

OM5560_87#A.2
COMBUSTION HEAD

Note: If the position of the adjustment ring has to be altered in relation to the
diffuser disc, the air velocity and quantity in the combustion head will
change. Check the combustion values by means of flue gas analysis and, if
necessary, adjust the combustion air quantity to be adequate.

1.1 Dismounting the combustion head


If the combustion head has to be dismounted, e.g. due to cleaning, the following work
steps must be carried out:
Dismounting the combustion head for KBO-R13/14M burners
Step A: Ensure that the burner is stopped.
Step B: Close the quick-closing valves and swing out the burner.
Step C: Unscrew the fixing screws for the combustion head, see Figure 1.
Step D: Withdraw the combustion head. The flame tube is fixed with cotters to the
combustion head guide.
Step E: Reassemble in reverse order.
Dismounting the combustion head for a KBO-R15M burner
Step A: Ensure that the burner is stopped.
Step B: Close the quick-closing valves and swing out the burner.
Step C: Unscrew the fixing screws for the combustion head guide and adjustment
ring, see Figure 2.
Step D: Withdraw the adjustment ring from the combustion head.
Step E: Unscrew the fixing nuts for the diffuser disc.
Step F: Withdraw the diffuser disc from the combustion head.
Step G: Withdraw the combustion head guide with flame tube out of its place from
the combustion chamber side. The flame tube is fixed with cotters to the
combustion head guide.
Step H: Reassemble in reverse order.

Language UK

21-15 / 60

OM8630_01#C.1
PHOTO CELL

Photo cell
1

Description
The RAR detector is used for supervision of yellow burning oil flames. If the photo
cell detects a missing flame, the burner stops instantaneously. It is not possible to start
the burner before the control system has been reset.
With this type of detector, the radiation of the oil flame in the visible band of the light
spectrum is used to generate a flame signal. The light-sensitive element is a photo cell.
When illuminated, it generates DC voltage which causes a current to flow to the input
of the flame signal amplifier in the control unit. Hence, the photo cell is an active
detector.
The cell is insensitive to infrared radiation. If the burner is started with an illuminated
combustion chamber, the start sequence of the burner breaks, and an alarm for flame
failure will be indicated.
The number of photo cells for automatic operation and emergency operation depend
on the classification society.

1.1 Commissioning
The intensity of the light radiation can be checked by measuring the detector current
by means of a DC ampere meter (internal resistance 5000 ohm). Figure 1 shows the
measuring circuit.
Note: If the wiring of the photo cell is connected incorrectly, it is not possible to
start the oil burner.
Measuring circuit

M
A

RAR

Figure 1

21-16 / 60

-22 24 LAL2.../LAL3...
LOK16...
22 24
LAE10...
9 10
14 13
LAE1...

+
photcircax0460930en.wmf

Language UK

OM5560_38#J.1
NOZZLE SELECTION

Nozzle selection
1

Description
The selection of a nozzle to a modulating oil burner can be done on basis of Table 1
and two calculations. The table shows the nozzle number and oil throughput for max.
and min. load at a specified reference pressure. The supply pressure should be between
25 - 30 bar when running on both MDO and HFO. If the burner only operates on MDO/
MGO, the supply pressure can be between 20 - 30 bar.
The nozzle is a spill return type nozzle 12-W2 with a spray angle of 60. The regulating
range for this type of nozzle is between 25 - 100% of the total oil throughput.
Note: Ensure that the supply pressure does not fall below the above mentioned
settings. The burner can only operate if the pressure is sufficiently high in
order to withdraw the spring inside the nozzle head.

1.1 Selecting a nozzle size


When a nozzle is selected the required oil throughput must be known. The selection
should be made with regard to the above mentioned supply pressure settings.
If the gap between two nozzles sizes results in a lower supply pressure than required,
the pressure must be increased to minimum 25 bar for HFO and 20 bar for MDO/MGO.
The higher oil throughput caused by an increase of the supply pressure can be reduced
by limiting the oil regulator movement. This is done by adjusting the full load limit
switch in the servomotor to an appropriate lower position. The range of regulation is
reduced by this action.

1.2 Nozzle size selection


Determining the nozzle size and supply pressure can be done either by using the charts
in Figure 1 or by using Table 1 and the following formulas.

Language UK

21-17 / 60

OM5560_38#J.1
NOZZLE SELECTION

Nozzle size
W2 Nozzle capacity

W2 Nozzle capacity

340

W2-275

320
W2-250

300
280

W2-225

240

W2-200

220

W2-180

200

W2-160

180

W2-145

160

W2-130

140

W2-115

120

W2-100
W2-90

100

W2-80

80
25

26

27

28

29

Atomizing pressure bar

Figure 1

30

Output HFO kg/h

Output HFO kg/h

260

880
860
840
820
800
780
760
740
720
700
680
660
640
620
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
25

W2-700

W2-650

W2-600

W2-550

W2-500

W2-450

W2-400
W2-360
W2-330
W2-300

26

27

28

29

30

Atomizing pressure bar

om5560_38_noz_cax0055520en..wmf

Figure 1 is only applicable, when the viscosity is 15 cSt.


The nozzle size and supply pressure can be determined by means of the following
equations provided the required oil throughput and the medium viscosity are known:

- mref: reference mass flow (nozzle number) [kg/h]


- m: required oil mass flow [kg/h]
- : kinematic viscosity [cSt]
- ref: kinematic viscosity, reference (5) [cSt]
- P: Supply pressure [bar]
- Pref: Reference pressure (25)[bar]
Calculation of nozzle size and supply pressure is carried out by the following steps:
Determine the nozzle size by assuming a supply pressure at 27 bar.

21-18 / 60

Language UK

OM5560_38#J.1
NOZZLE SELECTION

Select from the left column in Table 1 the nozzle number, which is closest to the
calculated nozzle size.
Determine the actual supply pressure.
Note: If the calculated supply pressure is not within the required limits select
another nozzle size and re-calculated. If the result is still not acceptable,
consider the actions described in section 1.1.

1.3 Example
Known:
Required oil throughput: 260 kg/h HFO, viscosity 14 cSt.
Required:
The nozzle size and actual supply pressure
1.3.1 Using the chart
When looking at the left part of Figure 2, finding 260 kg/h HFO on the vertical axis,
gives nozzle number: W2-225 and a supply pressure at app. 28 bar.

Language UK

21-19 / 60

OM5560_38#J.1
NOZZLE SELECTION

Nozzle size example


W2 Nozzle capacity

W2 Nozzle capacity

340

W2-275

320
W2-250

300
280

W2-225

240

W2-200

220

W2-180

200

W2-160

180

W2-145

160

W2-130

140

W2-115

120

W2-100
W2-90

100

W2-80

80
25

26

27

28

29

Atomizing pressure bar

Figure 2

30

Output HFO kg/h

Output HFO kg/h

260

880
860
840
820
800
780
760
740
720
700
680
660
640
620
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
25

W2-700

W2-650

W2-600

W2-550

W2-500

W2-450

W2-400
W2-360
W2-330
W2-300

26

27

28

29

30

Atomizing pressure bar

om5560_38_moz_cax0055510en..wmf

1.3.2 Using the formulas


Calculations:
Determine nozzle size:

Select nozzle size:


Nozzle No selected: 225

21-20 / 60

Language UK

OM5560_38#J.1
NOZZLE SELECTION

Determine actual supply pressure:

1.4 Nozzle selection chart


Nozzle selection table
Nozzle No.

12-W2-40-60
12-W2-50-60
12-W2-60-60
12-W2-70-60
12-W2-80-60
12-W2-90-60
12-W2-100-60
12-W2-112-60
12-W2-125-60
12-W2-140-60
12-W2-160-60
12-W2-180-60
12-W2-200-60
12-W2-225-60
12-W2-250-60
12-W2-275-60
12-W2-300-60
12-W2-330-60
12-W2-360-60
12-W2-400-60
12-W2-450-60
12-W2-500-60
12-W2-550-60
12-W2-600-60
12-W2-650-60
12-W2-700-60

Max. oil throughput [kg/h] at an oil


pump pressure of 25 bar and a viscosity at 5 cSt, when the return line is
closed.
40
50
60
70
80
90
100
112
125
140
160
180
200
225
250
275
300
330
360
400
450
500
550
600
650
700

Min. oil throughput [kg/h] at an oil pump


pressure of 25 bar and a viscosity at 5 cSt,
when the return line pressure is 7 10 bar.
10
12
15
18
20
22
25
28
31
35
40
45
50
56
62
68
75
82
90
100
112
125
138
150
162
175

Table 1

Language UK

21-21 / 60

OM5560_37#B.1
NOZZLES

Nozzles
1

Fitting and removal of nozzles


A nozzle can be replaced without affecting the function of the hydraulic nozzle shutoff valves.
Inspection and change of the nozzles are easily done as the burner is constructed with
a swing flange.
Exchanging of an oil nozzle:
Unscrew the lock-nut, and the casing can be swung out
For mounting/dismounting use a spanner and keep the nozzle head fixed by means
of another spanner
After replacing the nozzle ensure that it is tight
To prevent entry of air into the oil system it is advisable to close the stop valves in the
suction intake and return line during exchange of the nozzle.
As a general rule a nozzle should always be exchanged if it is dirty or worn out. A good
burner performance can only be guaranteed with a new and/or a clean nozzle.
The nozzles should only be cleaned due to a shortage of nozzles.
The nozzles should be dismantled into individual parts and washed in a suitable fluid
such as benzine or petrol. If available, compressed air is the most suitable cleaning
medium.
Note: Solid objects such as steel needles are completely unusable, and they are
under NO circumstances to be used as cleaning tools.
Note: Nozzles cannot be returned for credit or exchange.
When extra oil nozzles are ordered please state the through-put in US Gal/h and the
spray angle.

21-22 / 60

Language UK

OM9280_01#E.1
VISCOSITY - TEMPERATURE CHART

Viscosity - temperature chart


1

Description
The preheating temperature can be determined by means of the viscosity - temperature
chart shown in Figure 1. In order to use the chart, the viscosity of the fuel oil must be
known at a reference temperature.
It should be noted that the preheating temperature should be set somewhat higher than
the temperature shown in the chart due to the heat loss between pre-heater and nozzle/
cup.

1.1 Example
The example is based on a pressure atomizing burner type MS or RMS.
Known:
Oil viscosity: 380 cSt. at 50C
Required:
Preheating temperature in C
Procedure to be followed:
Step A: Follow the reference temperature line at 50C vertically down to the intersection with the 380 cSt. viscosity line.
Step B: From this point move parallel down with the nearest fuel grade line.
Step C: When the line meets the recommended nozzle viscosity line, go vertically
up to the temperature axis.
Step D: At this point read the desired preheating temperature of 150C.

Language UK

21-23 / 60

OM9280_01#E.1
VISCOSITY - TEMPERATURE CHART

40,000
30,000
20,000
15,000
10,000
8,000

-15
10,000
9,000
8,000
7,000
6,000
5,000
4,500
4,000
3,500
3,000
2,500

Centigrade

-10

TEMPERATURE

20

10

30

40

60

50

70

80

90

100

120

110

130

140

150

160

170

cSt.

cSt.

Redwood
1 sec.

Viscosity - temperature chart


180
10,000
9,000
8,000
7,000
6,000
5,000
4,500
4,000
3,500
3,000
2,500

Viscosity - temperature chart

2,000

2,000

1,500

1,500

1,000
900
800
700
600

1,000
900
800
700
600

500
450
400
350
300
250

500
450
400
350
300
250

200

200

150

150

100
90
80
70
60

100
90
80
70
60

3,000
2,000

REDWOOD, 1 SECOND

1,000
800
600
500
400
300
200

KINEMATIC, CENTISTOKES

1,500

150
100
90
80
70

50
45
40
35
30
25
20

40

28.5

20

15

15

60
50

50
45
40
35
30
25

10
9
8
7
6

10
9
8
7
6

1
5 10

1
30

20
o

40

50

60

70

80

90

Fahrenheit

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

TEMPERATURE

280

290

300

310

320

330

340

350
o

Recommended cup viscosity for rotary cup burners 45-60 cSt.

Recommended nozzle viscosity for steam atomizing burners 15-20 cSt.

Recommended nozzle viscosity for pressure atomizing burners type MS, RMS and Aalborg KBP 8-10 cSt.

Recommended nozzle viscosity for pressure atomizing burners type KBM and KBO 14-16 cSt.

Figure 1

21-24 / 60

KINEMATIC, CENTISTOKES

5,000
4,000

visc1ex3264790en.wmf

Language UK

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

Fuel oil supply system


1

General description
This section describes the oil system in general terms together with some of the requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both marine diesel oil MDO, marine
gas oil MGO and heavy fuel oil HFO, operation.
The diagram of the oil system is shown in Figure 1.
The system is a single line oil supply system.
The diagram is for plants with only one burner.
The oil system consists of oil tanks for; marine diesel oil MDO, marine gas oil MGO
and heavy fuel oil HFO, mixing tube, cooler unit, thermometer/temperature transmitter, oil pumps and valves for the selection of fuels.

Language UK

21-25 / 60

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

Pressure
atomizing
burner F1

Single line system

Figure 1

21-26 / 60

f_oilsyskboe1ax3102800en.wmf

Language UK

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

1.1 Oil tanks


The oil in the tanks shall be kept within the viscosity limits mentioned on the drawings
and in the specifications. Concerning fuels that requires heating for the combustion:
The viscosity shall not be reduced below the limit, were it no longer is the burner heater
unit, that determines the condition of the oil, at the burner. For viscosity vs. temperature
relations please see instruction OM9280#01.
Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
heavy fuel oil must be insulated and traced in order to keep a sufficiently low viscosity
of the oil. The tracing can be done either by means of steam heating or by means of
electric heating cables. Tracing heat input must be controlled.

1.2 Mixing tube


During operation on any oil, all oil returned from the burner is returned to the mixing
tube.

1.3 Cooler unit


The cooler G432 is supplied complete with isolating valves and safety valve for the
water system, G46, G469 and G470 as well as safety, drain, and relief valves for the
oil side G433, G434 and G435.
By cooling the oil the viscosity can be raised to a level above the limit for the pumps.
The source for the cooler is LT water. The temperature of the water should be kept
below 36C.

1.4 Oil flow meter


The oil flow meter is only used to show accumulated flow. Since it is mounted on the
outlet of the tanks, it only measures the oil consumed in the burner plus the amount of
oil used for flushing.

1.5 Fuel oil temperature control


The fuel oil system is equipped with a thermometer and a temperature transmitter
mounted at the inlet to the pump unit. The output from the temperature transmitter is
used in the control system to check if the temperature is within the limits applicable
for the actual operation.

1.6 Fuel oil supply pumps


The oil system is fitted with one set of supply oil pumps.
The pumps G147 for MDO, MGO and HFO, viscosity of minimum 1.1 cSt.
The supply oil pump unit G147, is a twin type package unit, with two screw pumps
connected to separate driving motors.

Language UK

21-27 / 60

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

The pumps are fitted with a common pressure safety valve, a filter, a manometer gauge
between the pump and the filter, and non return valves.
The pumping capacities for the pumps are calculated in such a way that there will be
sufficient oil flow to the burner and the pressure regulating valve in full load condition.

1.7 Heat tracing


All piping carrying HFO must be heat traced. Heat tracing can be either electric or
stream tracing. Heat tracing must be controllable. From the control panel we offer a
potential free switch to turn it on and off. Heat tracing is not part of the supply from
Alfa Laval.

1.8 Piping
The piping is sized to a maximum flow velocity of 0,5 m/s in the suction pipes and 1.0
m/s in the pressure pipes.

1.9 Fuel selection


Note: Before any fuel selection is changed, the burner must be stopped. After the
selection is done, an oil flushing will be performed.
MGO is selected by setting valve G441 in MGO position and G115 in MGO/MDO
position.
MDO is selected by setting valve G441 in MDO position and G115 in MGO/MDO
position.
HFO is selected by setting G115 in HFO position.

1.10 Return flow from the burner.


HFO operation.
When the burner is in stand-by mode, a minimum of fuel oil is returned from burners
via the oil return line to the three-way valve G437. From here the fuel oil is led to the
pump suction side via the mixing tube for degassing. The three-way valve normally
returns the fuel oil to the mixing tube.
MDO operation.
When the burner is in stand-by mode, the fuel oil pump G147 is stopped. When the
burner is in operation mode, a minimum of MDO is returned via the oil return line to
the three-way valve G437. From here the MDO is led to the mixing tube.
MGO operation.
When the burner is in stand-by mode, the fuel oil pump G147 is stopped. When the
burner is in operation mode, a minimum of MGO is returned via the oil return line to
the three-way valve G437. From here the MGO is led to the mixing tube. The threeway valve is pneumatically operated, controlled by a solenoid valve. The solenoid
valve has a manual switch for emergency operation.
21-28 / 60

Language UK

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

1.11 Return flow from the burner. Fuel change sequence.


MGO/MDO to HFO.
The only difference in changing from MGO, respectively MDO, to HFO is the position
of the valve G441.
Changing is then a matter of shifting position of valve G115 from MGO/MDO position
to HFO position. Doing so the pump G147 is activated, the valve G436 is set in position
by-pass, the valves G437/G439 and valves on the burner are opened and closed in a
sequence that ensures, with the exception of the cooler, a complete system flushing
with HFO.
Flushing with HFO when changing from MDO/MGO, is done to avoid heating of the
MDO/MGO which would decrease the viscosity and consequently reduce the lubrication capability of the MDO/MGO trapped in the system. The reduced lubrication
capability could cause damage to the pumps.
HFO to MGO/MDO.
The only difference in changing from HFO, to MGO, respectively MDO is the position
of the valve G441.
Changing is then a matter of shifting position of valve G115 from HFO position to
MGO/MDO position. Doing so the pump G147 is activated, the valves G437/G439
and valves on the burner are opened and closed in a sequence that ensures a complete
system flushing with MGO/MDO. When this is completed the valve G436 is set in
position cooler.
Flushing with MDO/MGO when changing from HFO, is done mainly to avoid contamination of the cooler and the MDO tank, but also in order to avoid firing with HFO
in places were this is not allowed.
Heat tracing must be deactivated for MDO/MGO operation, and reactivated for HFO
operation.
MGO to MDO.
This is only a matter of changing position of G441. No flushing is done.
MDO to MGO. This is done by changing of position of G441. Doing so the pump G147
is activated, the valves G437/G439 and valves on the burner are opened and closed in
a sequence that ensures a complete system flushing with MGO. This is required in
order to avoid firing with MDO in places were this is not allowed.

1.12 Fuel oil pressure control


To ensure an easy and safe change from light to heavy fuel oil, the fuel oil pressure is
controlled with two separate pressure regulators, G471 and G481. As default G471
controls the light fuel oil pressure and G481 controls the heavy fuel oil pressure. The
3-way valve G482 is used by the BMS to change from one oil pressure to another.

Language UK

21-29 / 60

OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM

Normally the setting of the light oil fuel is higher than the setting of the heavy oil fuel.
Note: The calorific value of fuels can change, so after each bunker please check
the combustion quality. If nessecary re-adjust the relevant regulator.

21-30 / 60

Language UK

OM5560_117#B.1
BURNER SUPPLY SYSTEMS

Burner supply systems


1

General description
This section describes the burner supply systems in general terms together with some
of the requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both marine diesel oil MDO, marine
gas oil MGO and heavy fuel oil HFO operation.
An illustration of the burner supply systems for the Aalborg KBO-E pressure atomizing
burner, is shown in Figure 1.
The burner supply systems consist of a fuel oil system, a combustion air system, and
an electric control system.
Illustration of the Aalborg KBO-E burner

Figure 1

Language UK

kboe_oilsys1x1357420en.wmf

21-31 / 60

OM5560_117#B.1
BURNER SUPPLY SYSTEMS

1.1 Fuel oil system


The pressure control and quick closing arrangement of the oil supply is shown on the
Fuel Oil Supply P & ID drawing. And it is descreibed in the Fuel Oil Supply System
chapter.
HFO is heated by the electric heater F207. The heater is equipped with a temperature
sensor and a thermo switch, F222 respectively F223. Oil pressure and temperature is
measured by pressure transmitter F225 and temperature sensor F212.
There is a by-pass to the outlet controlled by solenoid valve F201 and the orifice F182
The inlet pressure can be read at the manometer F218.
Automatic on/off oil control are done with the two main stop solenoid valves F202 and
F205. The burner nozzle is opened and closed with the solenoid valves F204 and F203.
F206 is the burner nozzle.
The outlet pressure is read on manometer F219, and the oil flow rate is controlled by
valve F217 and servomotor F208. High return pressure is indicated by pressure switch
F214. Back flow is prevented by check valve F235. Heat tracing F240 temperature is
not controlled by the burner management system. It only ofers a switch to turn the heat
tracing on and off. All pipes are traced to avoid blockage of HFO.

1.2 Combustion air system


The combustion air fan draws air from the engine room through the inlet vanes. The
inlet vanes regulate the necessary air flow for the combustion by means of an air cylinder and an I/P positioner. The I/P positioner receives a 4-20 mA signal from the
control system.
From the fan discharge side, the combustion air flows through the air duct into the
burner wind box. From here the combustion air is distributed to the burner register, the
swirlers/flame stabiliser, and the furnace through the radially fixed guide vanes to
ensure a uniform air flow.
The draft loss across the burner is measured by a differential pressure transmitter,
which converts the signal to a flow signal used by the control system for automatic air/
oil ratio control.

1.3 Control system


Generally the control system ensures the correct sequenced measure and activation of
the components in the oil and air system. Further the system controls the three following
components:
A precondition for the operation of the burner is that the switch for closed burner F224
is active.

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OM5560_117#B.1
BURNER SUPPLY SYSTEMS

The Aalborg KBO-E burner is ignited by applying high voltage to the ignition electrodes F166. The supervision of the flame is done via the photo cells F32 and F33.

Language UK

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OM5560_110#G.2
OPERATING INSTRUCTIONS

Operating instructions
1

General
The following operating instructions are valid for pressure atomizing burner type Aalborg KBP, KBM and Aalborg KBO-E with a standard delivery of individual parts for
the burner unit and supply systems from Alfa Laval.
Attention: If the burner unit and supply systems include parts, which are not
standard delivery from Alfa Laval, the specific instructions for these
parts should be ignored in the following sections. The actual instructions for the specific parts should be thoroughly studied and followed
during operation of the burner.
The operation instructions in the following sections describe the normal burner operations with regard to preparation for start-up on the selected fuel type, normal start/
stop, change of fuel, etc. It is implied that the boiler, burner, control system, and additional equipment for the boiler plant have been commissioned and are fully operational.

1.1 Descriptions
1.1.1 Descriptions
In the following sections various operating procedures are described such as:

Marine gas oil, MGO, mode.


Marine diesel oil, MDO, mode.
Heavy fuel oil, HFO, mode.
Normal start/stop.
Change from heavy fuel oil bunker type.
Prolonged stop

Operating Instructions
2.1 MGO mode
This section describes the activities needed for the change to or start on MGO.
Step A: Check that oil is present in the MGO tank. Open the stop valves, which
connect the MGO tank to the oil system.

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OM5560_110#G.2
OPERATING INSTRUCTIONS

Step B: Select MGO on the manually operated three-way valve G 441. Select MGO/
MDO on the manually operated three-way valve G115.
The control system will indicate MGO operation.
Step C: Open the stop valve at the inlet and the outlet from the oil meter G340. Check
that the by-pass valve is closed.
Step D: Select the pump to run, by positioning the 3-way valve at the pump unit inlet
G147.
Step E: Open the stop valves for the pressure gauges on the oil pumps.
Note: The stop valves for the pressure gauges on the pump unit should only be
opened for pressure control purposes. The stop valves should be closed
during normal operation.
Step F: Open the quick closing valves for the burner unit. For Aalborg KBO-E it is
TAG no. G472, for Aalborg KBP and KBM it is TAG F220.
Step G: Check that the outlet valve from the mixing tube G49 is open.
Step H: Check that the outlet valve from the oil cooler G448 is open. And check that
the cooling water valves G468 and G469 are open.
Note: After the pump is started the control system initiates a flushing procedure.
The flushing procedure flushes the oil in the system either to the MDO or
the HFO tank, depending on which fuel was used before the change to
MGO.
Step I: Check that there is free volume for the flushing in either MDO or HFO tank.
Step J: Start the fuel oil pump chosen by the 3-way valve, and set the other into
stand-by mode (if two are delivered).
Step K: After the flushing; check that the oil pressure in the ring line is at the correct
level.
Step L: The burner is now ready for operation.

2.2 MDO mode


This section describes the activities needed for the change to or start on MDO.
Step A: Check that oil is present in the MDO tank. Open the stop valves, which
connect the MDO tank to the oil system.
Step B: Select MDO on the manually operated three-way valve G 441. Select MGO/
MDO on the manually operated three-way valve G115.
The control system will indicate MDO operation.
Step C: Open the stop valve at the inlet and the outlet from the oil meter G340. Check
that the by-pass valve is closed .
Step D: Select the pump to run, by positioning the 3-way valve at the pump unit inlet
G147.
Step E: Open the stop valves for the pressure gauges on the oil pumps.
Note: The stop valves for the pressure gauges on the pump unit should only be
opened for pressure control purposes. The stop valves should be closed
during normal operation.

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OM5560_110#G.2
OPERATING INSTRUCTIONS

Step F: Open the quick closing valves for the burner unit. For Aalborg KBO-E it is
TAG no. G472, for Aalborg KBP it is TAG F220.
Step G: Check that the outlet valve from the mixing tube G49 is open.
Step H: Check that the outlet valve from the oil cooler G448 is closed.
Note: After the pump is started the control system initiates a flushing procedure.
The flushing procedure flushes the oil in the system either to the MDO or
the HFO tank, depending on which fuel was used before the change to
MDO.
Step I: Check that there is free volume for the flushing in either MDO or HFO tank.
Step J: Start the fuel oil pump chosen by the 3-way valve, and set the other into
stand-by mode (if two are delivered).
Step K: After the flushing; check that the oil pressure in the ring line is at the correct
level.
Step L: The burner is now ready for operation.

2.3 HFO mode


This section describes the activities needed for the change to or start on HFO.
Step A: Check that oil is present in the HFO tank. Open the stop valves, which connect the HFO tank to the oil system.
Step B: Select HFO on the manually operated three-way valve G115.
The control system will indicate HFO operation.
Step C: Open the stop valve at the inlet and the outlet from the oil meter G340. Check
that the by-pass valve is closed.
Step D: Select the pump to run, by positioning the 3-way valve at the pump unit inlet
G147.
Step E: Open the stop valves for the pressure gauges on the oil pumps.
Note: The stop valves for the pressure gauges on the pump unit should only be
opened for pressure control purposes. The stop valves should be closed
during normal operation.
Step F: Open the quick closing valves for the burner unit. For Aalborg KBO-E it is
TAG no. G472, for Aalborg KBP and KBM it is TAG F220.
Step G: Check that the outlet valve from the mixing tube G49 is open.
Step H: Check that the outlet valve from the oil cooler G448 is closed.
Note: After the pump is started the control system initiates a flushing procedure.
The flushing procedure flushes the oil in the system to the HFO tank, depending on which fuel was used before the change to HFO.
Step I: Check that there is free volume for the flushing in either MDO or HFO tank.
Step J: Start the fuel oil pump chosen by the 3-way valve, and set the other into
stand-by mode (if two are delivered).
Step K: After the flushing; check that the oil pressure in the ring line is at the correct
level.
Step L: The burner is now ready for operation.

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OM5560_110#G.2
OPERATING INSTRUCTIONS

Note: When the fuel type is changed from MDO/MGO to heavy fuel oil, the
burner might wait for a increase in the oil temperature. Until the operational temperature for HFO is reached, the burner will not initiate the start
sequence.

2.4 Normal start/stop


The control system automatically starts, stops, and regulates the burner in normal operation depending on the steam demand. When the steam pressure is below the set
point for operation, the burner commences the start-up sequence.
In operation mode, the control system attempts to maintain the steam pressure at the
desired set point by regulation of the burner load. The burner can be regulated through
the complete load range from minimum load to full load.
However, should the steam demand decrease below the minimum firing load of the
burner, the steam pressure will increase to the set point for burner stop. The burner
stops and remains stopped until the set point for burner operation is reached again.

2.5 Change of heavy fuel oil bunker type


If the heavy fuel oil bunker type is changed and the calorific value of the oil changes,
the oil/air ratio should be checked and adjusted to obtain the correct combustion data.
For further information about adjustment of the oil/air ratio please see the chapter
Commissioning.

2.6 Prolonged stop


When the boiler plant is stopped for a long period of time, the burner should be shortly
operated on diesel oil before the plant is shut down in order to flush the complete oil
system. Furthermore, tracing must be switched off.

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OM5560_98#F.2
BURNER OPERATION

Burner operation
1

General
This section describes the burner operation for burner type KBO-E. Figure 1 illustrates
the internal oil piping at the burner for KBO-E 13 to 28M. Figure 2 shows the oil flow
in different burner modes for KBO-E 13 to 28M. Figure 3 illustrates the internal oil
piping at the burner for KBO-E 30 to 60M. Figure 4 shows the oil flow in different
burner modes for KBO-E 30 to 60M. Figure 5 illustrates the nozzle valve.

1.1 Start sequence for burners with microprocessor control systems


Pre-purge takes place with the air quantity of full load. During pre-purge period solenoid valves (4), (5), and (8) are closed and solenoid valves (3) and (15) is open, see
Figure 1 and Figure 2 for burner size KBO-E 13 to 28M and Figure 3 and Figure 4 for
burner size KBO-E 30 to 60M. At the end of the purging period the servomotors turn
to the position of ignition load, solenoid valve (5) and (8) opens, solenoid valve (15)
closes and a flushing sequence will take place, the nozzle valve is purged (pre-heated)
during this period. The oil temperature regulation controls that the oil temperature is
adequate during purging and atomizing periods.
After the flushing period is completed the solenoid valves (5) and (8) will close, solenoid valve (15) will open and the oil in the pre-heater will be heated. The burner will
then go into the ignition step; solenoid valves (4), (5) and (8) are opened and solenoid
valves (3) and (15) are closed. The electric arc between the ignition electrodes ignites
the oil spraying from the nozzle.

1.2 Burner operation


The oil quantity to be fired is regulated by means of the oil regulator (12) by throttling
the return flow. At partial load the oil regulator is open and at full load closed. During
burner operation the control system drives the servomotors, which again drives the oil
regulator and the air dampers between partial load and full load according to the steam
demand. If the burner shuts down, solenoid valves (4), (5), and (8) close, and solenoid
valves (3) and (15) opens. The oil pressure is released from the nozzle valve.
The nozzle valve spring-back closes the needle valve in the nozzle and closes the oil
flow in the nozzle. At full load the atomising pressure is approx. 20-25 bar when
operating on MDO or MGO and approx. 25-30 bar on heavy fuel oil. The return pressure of the oil measured at manometer position 2 can vary from the lowest possible for
the nozzle at low load and up to max 30 bar(g) at full load. The return flow pressure
is determined according to the position of the oil regulator.

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OM5560_98#F.2
BURNER OPERATION

Illustration of the oil piping at the burner - KBO-E 13 to 28M

1 Nozzle valve
2 Pressure gauge
3 Solenoid valve
4 Solenoid valve and throttle plug
5 Solenoid valve
6 Pressure gauge
7 Pressure transmitter
8 Solenoid valve
9 Thermometer
10 Non-return valve
11 Pre-heater
12 Oil regulator/servomotor
13 Orifice
14 Pressure switch
15 Solenoid valve
16 Temperature transmitter
A Oil to burner
B Oil from burner

Figure 1

oilburn-kbo_e1ax3684550en.wmf

Illustration of the oil flow for burners with microprocessor control systems KBO-E 13 to 28M

Purging and flush end periods

Figure 2

Language UK

Flushing period

Atomizing period

Stop period

oilburn_m100x3684080en.wmf

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OM5560_98#F.2
BURNER OPERATION

Illustration of the oil piping at the burner - KBO-E 30 to 60M

1 Nozzle valve
2 Pressure gauge
3 Solenoid valve
4 Solenoid valve and throttle plug
5 Solenoid valve
6 Pressure gauge
7 Pressure transmitter
8 Solenoid valve
9 Thermometer
10 Non-return valve
11 Pre-heater
12 Oil regulator/servomotor
13 Orifice
14 Pressure switch
15 Solenoid valve
16 Temperature transmitter
A Oil to burner
B Oil from burner

Figure 3

oilburn-kbo_e2x3684070en.wmf

Illustration of the oil flow for burners with microprocessor control systems KBO-E 30 to 60M
Purging and flush end periods

12

Flushing period

Atomising period

Stop period

8
15

Figure 4

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oilburn-m113x3697480en.wmf

Language UK

OM5560_98#F.2
BURNER OPERATION

Illustration of the nozzle valve

1 Body
2 Break spring
3 End cover
4 Hexagonal socket screw
5 O-ring for cover 18.72 x 2.62 V
6 O-ring for piston 12 x 2 V
7 O-ring for bottom plate 18.72 x 2.62 V
8 O-ring for spindle 6 x 2 V
9 Oil nozzle
10 O-ring for oil nozzle 7 x 1.5 V
(for large burners)

Figure 5

Language UK

11 Cylinder
12 Piston
13 Spindle
C
R
S
L

Control circuit
Return from nozzle
Outlet to nozzle
Nominal size of nozzle valve

om5560_98_oilburx0055930en.wmf

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OM5560_234#B.1
EMERGENCY OPERATION

Emergency operation
1

General
In the rare event of a total break down of the control system, the burner unit with
belonging systems can be operated in manual operation (also called emergency operation). Due to the fact that the majority of the safety interlocks trips and alarms are
overruled in emergency mode, the safety precautions for the plant must be observed
very carefully.
Please note that in emergency operation mode the safety interlocks are reduced
to:
Too low water level
Flame failure
Low combustion air pressure
Warning: Warning: When the burner operates in emergency mode, it is very
important that the boiler plant is carefully and continuously supervised by the ship engineering personnel. Pay special attention to the
steam pressure and water level.
In emergency mode, the burner unit and supply systems are operated from inside the
(local) control panel and the power panel. Various operating switches are provided
inside the panels for operating purposes.
Before emergency operation of the burner is initiated, attempts to restart the control
system must be performed. If restart of the control system is impossible, the work steps
of the following sections must be followed.
Since the control of the power released in the electric heaters in the burner oil system
is done by the control system, we can not run on HFO in emergency mode. This applies
to all our pressure atomizing burners were the fuel oil system is with high pressure
pumps only.

Preparing the fuel oil system for emergency


operation of the burner
Warning: Make sure to stop the oil supply pump when ever the burner is stopped.
Note: Default position of the valves is HFO operation.

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OM5560_234#B.1
EMERGENCY OPERATION

2.1 Single string, MGO and HFO tanks


Set valve G115 in MGO position.
Use the manual override function on solenoid valve G482 to ensure oil pressure control
is done by valve G471.
Check that valve G437 directs oil to the mixing tube
During operation check the temperature of the oil on the thermometer just before the
pumps, if the temperature reaches 58C, open valve G448 and set valve G438 in position oil to cooler. If this does not lower the oil temperature, the burner must be stopped.

2.2 Single string, MGO, MDO and HFO tanks


Here we can run the burner on either MGO or MDO.
To run with MGO:
Put valve G441 in MGO position. Else proceed as in section 2.1 above.
To run with MDO:
Put valve G441 in MDO position.
Check that the oil pressure control is done by valve G471.
If not: Use the manual override function on solenoid valve G482.
Check that valve G437 directs oil to the mixing tube.

2.3 Double string, MGO and HFO tanks.


Use the manual override function on the inlet/outlet solenoid control valves G460/
G461 as applicable, to change their position from HFO operation to MGO operation.
During operation check the temperature of the oil on the thermometer just before the
pumps, if the temperature reaches 61C, the burner must be stopped.

2.4 Double string, MGO, MDO and HFO tanks


To run with MGO:
Proceed as in section 2.3 above.
To run with MDO:
Put valve G115 in MDO position.
Check that the inlet / outlet valves G460/G461 to the burner is in position HFO.
If not: Use the manual override function on the inlet solenoid control valves to change
their position from MGO operation to HFO operation.

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OM5560_234#B.1
EMERGENCY OPERATION

Manual operation of the burner


3.1 Start and stop of the burner
3.1.1 Start of the burner
Step A: Turn the "/MANUAL" key-operated switch inside (or mounted on the front
of ) the control panel into position manual.
Step B: Start one of the fuel oil pumps on the operating switch inside (or mounted
on the front of) the power panel.
For single string systems it is either:
"FUEL OIL PUMP 1 START/STOP" or "FUEL OIL PUMP 2 START/STOP".
For double string systems running MGO it is either:
MGO pump 1 Start/Stop or MGO pump 2 Start/ Stop.
For double string systems running MDO it is either:
"FUEL OIL PUMP 1 START/STOP" or "FUEL OIL PUMP 2 START/STOP".
Step C: Switch the selector "BURNER MOTOR" to position ON, and the burner
motor starts.
Step D: Press the "AIR SERVO LOAD UP" push button until the burner reaches its
maximum firing position to purge the furnace. The pre-purge time should
be minimum 60 seconds.
Warning: Insufficient purging may cause danger of furnace explosions. If the
operator suspects that there is a risk of an oil spillage in the furnace,
it must be completely dried out before start of the burner is attempted.
Step E: When the furnace has been sufficiently purged press the "LOAD DOWN"
push button until the burner reaches its minimum firing position.
Step F: Press the "IGNITION" push button and keep it pressed. The ignition transformer is energised.
Step G: Press the "OIL VALVES" push button and keep it pressed. At the same time
the safety valves open.
Step H: Release the "IGNITION" and "OIL VALVES" push buttons when the lamp
"FLAME"is illuminated. If the flame is not established within maximum 5
seconds, immediately return to step D.
Step I: When the flame is established the burner remains firing at minimum load.
The burner load can be changed by pressing the push buttons "LOAD
DOWN" and "LOAD UP" for both air servomotor and oil servomotor.
Note: If the flame is distinguished during operation, immediately return to step
D. If the flame cannot be established in the following attempt, please see
the section for faults and rectifying faults.

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OM5560_234#B.1
EMERGENCY OPERATION

Note: The automatic water level regulation is not operational in emergency


mode. This means that the water level in the boiler must be adjusted manually.
Step J: In boiler plants with on/off regulation of the water level, one of the feed
water pumps should be started and stopped according to the water level in
the boiler.
Step K: In boiler plants with modulating control of the water level, one of the feed
water pumps should be started. The water level can then be regulated on the
feed water control valve by means of the manually operated hand wheel on
the actuator.
3.1.2 Stop of the burner
Step A: Press the "STOP" push button inside (or mounted on the front of ) the local
control panel to stop the burner. The safety valves immediately close.
Step B: In boiler plants with modulating control of the water level, one of the feed
water pumps should be started. The water level can then be regulated on the
feed water control valve by means of the manually operated hand wheel on
the actuator.
Step C: Switch the selector "BURNER MOTOR" to position OFF inside (or
mounted on the front of ) the control panel to stop the burner motor.

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OM5560_118#D.2
COMMISSIONING

Commissioning
1

General
The following commissioning instructions are valid for pressure atomizing burners
type Aalborg KBO-E with a standard delivery of individual parts for the burner unit
and supply systems from Alfa Laval.
Prior to commissioning, the instructions for the individual parts of the burner unit and
supply systems should be studied. The special instructions for the boiler and control
system should also be consulted. The instructions should only be considered as a
guideline. This is due to the fact that each plant should be commissioned individually
to obtain the best burner performance for the specific plant.
Attention: If the burner unit and supply systems include parts, which are not
standard delivery from Alfa Laval, the specific instructions for these
parts should be ignored in the following sections. The actual instructions for the specific parts should be thoroughly studied and followed
during commissioning.
During commissioning of the burner unit and supply systems, it might be necessary to
adjust some regulation parameters, timer settings, etc. in the control system to optimise
the function of the plant. These adjustments are not described in the following sections,
but should be carried out as the optimisation requirements emerge. Please see the instructions for the control system.

1.1 Pre-service checks


Before commissioning of the burner, the following work steps must be carried out:
Step A: Check that the boiler is ready for operation according to the special instructions for the boiler.
Step B: Increase or decrease the water level in the boiler to approximately 50 mm
below normal water level.
Step C: Check the electric wiring.
Step D: Switch on the power for the boiler plant and reset the system on the local
panel. Ensure that the burner is in stopped mode.
Step E: Check that the control system is operational according to the special instructions for the control system.
Step F: Pre-adjust the set points for boiler operation on the pressure switches and/
or pressure transmitter.

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OM5560_118#D.2
COMMISSIONING

1.2 Commissioning adjustments of the burner unit


On delivery from Alfa Laval, the burner unit has been pre-adjusted to fit the task. Even
though the burner unit has been pre-adjusted, it is advisable to carry out additional
checks during commissioning. These checks are described in the following.
1.2.1 Dismantling
Step A: Ensure that the power is switched off before any work is carried out on the
burner unit.
Step B: Close the quick closing valves for the burner unit.
Step C: Unscrew the screw that holds the burner flange and swing out the burner.
Step D: Dismount the cover for the servo motors.
1.2.2 Adjustment of the combustion head
Step A: Check that the distance between the oil nozzle and diffuser disc is approximately 8 mm.
Step B: Adjust the position of the adjustment ring in relation to the edge of the diffuser disc according to the special instruction for this; see the chapter Combustion head.
Note: Exact distances cannot be given, but has to be determined when the burner
is in operation. It is possible to affect the air velocity and thereby the shape
and quality of the flame by optimising the positions of the adjustment ring
and diffuser disc.
1.2.3 Adjustment of the ignition electrodes
Step A: Check the position of the ignition electrodes and adjust if necessary. Please
see the special instruction Ignition electrodes.
Note: An exact setting of the ignition electrodes cannot be given, but has to be
established when the burner is ignited during operation.
1.2.4 Adjustment of the servomotor
Step A: Disengage the servomotor camshaft from the drive by means of the lever
fitted to the gear box.
Step B: Calibrate the servomotor range in the control system. The low and high range
should be set to 0 and 120 opening of the air dampers respectively. Set the
position of the servomotor to 0, which can be seen on the outer scale. The
raw data line on the control panel displays a numerical value. This value
must be entered in low range menu line.
Step C: Set the position of the servomotor to 120. The new numerical value, which
is displayed in the raw data line, must be entered as the high range.
Step D: Set the time to operate the servomotor from 0 to 120 on the control panel
(normally 15 seconds).

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OM5560_118#D.2
COMMISSIONING

Note: Please consider the following proposed settings as guidelines only as the
final settings should be performed after measuring the flue gas (CO2/O2
content). The local control panel settings and cam switch settings depend
on burner size, nozzle size, furnace pressure, etc.
Step E: Pre-adjust the stand-by position (burner stopped) to 0% (0) on the control
panel.
Step F: Pre-adjust the ignition position to 22% (20) on the control panel.
Step G: Pre-adjust the minimum firing position (partial load) to 33% (30) on the
control panel.
Step H: Pre-adjust the purge and full load position to 67% (60) on the control panel.
1.2.5 Assembling
Step A: Mount the cover for the servo motors.
Step B: Close the burner and secure with the screw.
Step C: Switch on power and reset the control system.

1.3 Commissioning of the oil system


When the oil system is commissioned, it should initially be flushed by means of an
external pumping system. This must be done to ensure that the oil system is not clogged-up and to prevent foreign objects from entering the pump unit which might cause
damage.
Warning: When the oil system is commissioned on marine diesel oil/marine gas
oil MDO/MGO, the tracing of the piping system must be off.
Step A: Check that oil is present in the marine diesel oil/marine gas oil MDO/MGO
tank. Open the stop valves, which connect the marine diesel oil/marine gas
oil MDO/MGO tank to the oil system.
Step B: Select marine diesel oil/marine gas oil MDO/MGO on the manually operated
three-way valves. Check that the control system indicates marine diesel oil/
marine gas oil MDO/MGO operation.
Step C: Open the inlet stop valves, and the outlet non-return valves for the oil pumps.
Step D: Open the stop valves for the pressure gauges on the oil pumps.
Note: The stop valves for the pressure gauges on the pump unit should only be
opened for pressure control purposes. The stop valves should be closed
during normal operation.
Step E: Open the stop valve for the pressure transmitter and/or switches.
Step F: Close the quick closing valves for the burner unit. Check that the micro
switch is activated and that a shut down appears in the control system.
Step G: Rotate the oil pump by hand to ensure a free and an uninterrupted rotation.
Step H: Adjust the circuit break for the pump to suit full load current of the motor.
The current appears from the motor identification plate and/or the electric
diagrams.

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OM5560_118#D.2
COMMISSIONING

Step I:

The oil pump must be filled with marine diesel oil / marine gas oil MDO/
MGO prior to operation. The vent valve installed on the outlet side of the
pump unit must be opened until the air has escaped from the suction side of
the pump. As soon as marine diesel oil/marine gas oil MDO/MGO emerges,
the vent valve may be closed.
Step J: Start the oil pump and check that it is running with the correct direction of
rotation. Open the vent valve again until only marine diesel oil/marine gas
oil MDO/MGO emerges.
Step K: Adjust the oil pressure in the ring line on the pressure regulating valve to
minimum 20.0 barg and maximum 25.0 barg at the burner for marine diesel
oil/marine gas oil MDO/MGO.
Note: The pressure relief valve installed in each pump is factory set and checked
and should not be adjusted during commissioning.
Step L: Flush the oil system for some time with the oil pump in operation. The total
flushing time should be determined with regard to the size of the oil system
and the amount of impurities (particles, grease, etc.). Check the complete
oil system for leaks.
Step M: When flushing is completed, stop the operational oil pump and clean the oil
filters in the fuel oil supply pump unit. Vent the oil pumps after the filters
have been cleaned.
1.3.1 Check and adjust the pressure transmitter
Step A: Open the quick closing valves for the burner unit.
Step B: Check that the oil pressure indicated on the control panel is identical to the
pressure indicated on the pressure gauge in the oil line.
Step C: Adjust the zero point and/or the span on the oil pressure transmitter if necessary.
1.3.2 Check the low and high alarm for oil pressure and start of stand-by oil pump
Step A: Check and adjust the set point for low and high alarm in the control system.
Step B: Start the oil pump and set the other pump into stand-by mode.
Step C: Decrease the oil pressure on the pressure regulating valve gradually until the
set point is reached. The operating oil pump should stop, and the pump in
stand-by mode should start. The control system should indicate an alarm.
Readjust if necessary.
Step D: Switch operation mode of the pumps and carry out the same procedure.
1.3.3 Check the low oil pressure shut down and trip function
Step A: Check and adjust the set point for low shut down and trip in the control
system.
Step B: Decrease the pressure somewhat more until the set point is reached. The
operating stand-by pump should stop, and a shut down should be indicated
on the control system. Readjust if necessary.
Step C: Readjust the oil pressure to approximately 25.0 barg on the pressure regulating valve and reset the alarms and shut downs.
1.3.4 Check the trip function for overload
Step A: Check the trip function for overload by pressing the test button for the pump
in operation on the circuit breaker.

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OM5560_118#D.2
COMMISSIONING

Step B: The pump stops, and a shut down for pump failure should be indicated in
the control system.
Step C: Reset the circuit breakers and all shut downs after testing.

Start-up
To continue the commissioning procedures, the oil system must be in normal operation.
Prior to the actual start-up of the burner, some additional checks should be carried out
with regard to ignition and start-up of the burner. When these checks are completed,
the burner should be commissioned on marine diesel oil/marine gas oil MDO/MGO
oil and finally on heavy fuel oil.
Attention: Before and during start-up, the furnace must be checked with regular
intervals for oil spillage. If an oil spillage is present in the furnace, the
cause must be determined and the failure must be rectified. The furnace should be purged until it is free of oil.

2.1 Additional commissioning checks


2.1.1 Check the burner motor
Step A: Rotate the burner motor by hand to ensure a free and an uninterrupted rotation.
Step B: Adjust the circuit breaker for the burner motor to suit full load current of the
motor. The current appears from the motor identification plate and/or the
electric diagrams.
Step C: Open the quick closing valves for the burner unit.
Step D: Start the ring line fuel oil pump.
Step E: Operate the burner as described in the chapter Manual operation Press the
BURNER MOTOR push button.
Step F: Check that the burner motor is running with the correct direction of rotation.
Step G: Check that the burner motor does not produce any abnormal mechanical
noises or vibrations.
2.1.2 Check the ignition electrodes
Step A: With the burner motor running press the IGNITION push button and keep
it pressed. The ignition transformer will be energised and the electrodes
ignite.
Step B: Check that the ignition spark appears, re-adjust the electrodes, if necessary,
as described the section Commissioning adjustments of the burner unit.
Step C: Stop the burner motor after the check procedure has been carried out.

2.2 Commissioning on marine diesel oil/marine gas oil


When the burner is commissioned, the boiler pressure and temperature must not be
intensified too rapidly as this might cause stresses in the boiler. The burner should be
kept in minimum firing position during the first commissioning period. The burner
should also only be operated at relatively short intervals during the initial start-up.

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OM5560_118#D.2
COMMISSIONING

When the burner is stopped during this firing-up procedure, the safety interlock shut
downs can be checked and adjusted.
2.2.1 Operation of the burner
Step A: ed at a pressure of 20 - 25 bar g. This pressure is adjusted on oil pressure
regulator G471. When firering heavy fuel oil HFO the atomizing pressure
must be between 25 and 30 bar g. This pressure is adjusted on oil pressure
regulator G481.
Step B: The final pressure setting can be seen in the Technical data section.
Step C: Check that the burner is in ignition position after start-up.
Step D: Check that the flame does not pulsate. Adjust the oil/air ratio, and/or air
velocity if necessary.
Step E: Check the shape and colour of the flame. Measure the CO2 and/or O2 content
and adjust the oil/air ratio if necessary.
Step F: Check the colour of the flue gas. Measure the soot spot No. it should not
exceed a soot spot No. of 1-3 (Bacharach). Adjust the oil/air ratio if necessary.
Note: The final adjustment of the combustion parameters should be carried out
when the burner operates on heavy fuel oil if this is the main fuel.
Step A: ed at a pressure of 20 - 25 bar g. This pressure is adjusted on oil pressure
regulator G471. When firering heavy fuel oil HFO the atomizing pressure
must be between 25 and 30 bar g. This pressure is adjusted on oil pressure
regulator G481.
Step B: The final pressure setting can be seen in the Technical data section.
Step C: Check that the burner is in ignition position after start-up.
Step D: Check that the flame does not pulsate. Adjust the oil/air ratio, and/or air
velocity if necessary.
Step E: Check the shape and colour of the flame. Measure the CO2 and/or O2 content
and adjust the oil/air ratio if necessary.
Step F: Check the colour of the flue gas. Measure the soot spot No. it should not
exceed a soot spot No. of 1-3 (Bacharach). Adjust the oil/air ratio if necessary.
Note: The final adjustment of the combustion parameters should be carried out
when the burner operates on heavy fuel oil if this is the main fuel.
2.2.2 Check the stop sequence
Step A: The stop sequence should also be carefully monitored on site. Operate the
burner for a few minutes and stop it from the control system.
Step B: Check that the solenoid valves are activated and that the air dampers are
moved into closed position.
Step C: Check that the burner motor stops.
Step D: Check that the furnace is free of oil spillage.

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2.2.3 Setting and testing of the minimum air pressure switch


Step A: When the burner is in operation, check the minimum air pressure switch by
increasing the switch point for the switch. Unscrew the protective cover of
the switch and increase the switch point at the setting wheel. The burner
stops, and a shut down is indicated in the control system.
Step B: Decrease the switch point again. Reset the shut down after testing and start
the burner again.
Step C: Measure the pressure difference between the suction and pressure side of
the fan at minimum burner load. Use this value for determination of the
switch point. It should be approximately 80% of this value.
Step D: Adjust the setting wheel of the minimum pressure switch to the calculated
value and mount the protective cover.
2.2.4 Setting and testing of the high oil pressure switch
Step A: When the burner is in operation, check the high oil pressure switch by decreasing the switch point for the switch. The burner stops, and a shut down
is indicated in the control system.
Step B: Decrease the switch point again. It should be adjusted to 6 bar. Reset the
shut down after testing.
2.2.5 Check the safety interlock shut down for flame failure equipment
Step A: When the burner is in operation, check the flame failure equipment by removing one of the flame scanners from the holder and cover the sensor. The
burner stops, and a shut down for flame failure is indicated in the control
system. Reset all shut downs.
Step B: Check and simulate a glowing furnace by using a flash light pointed directly
at the flame scanner.
Step C: Set the burner into start mode. The control system should indicate a shut
down for flame failure.
Step D: Mount the flame scanner into the holder and reset all shut downs.
Step E: Perform the same checks with the other flame scanner.
2.2.6 Check the safety interlock shut down for burner swing out
Step A: When the burner is in operation, unscrew the screw that holds the burner
flange and carefully swing out the burner a few mm. The burner stops, and
a shut down for burner swing out is indicated in the control system.
Step B: Close the burner and secure with the screw. Reset all shut downs.
2.2.7 Check the safety interlock shut down for high oil pressure
Step A: When the burner is in operation, check the high oil pressure shut down and
trip function as described in the paragraph Commissioning of the oil system. The burner stops, and a shut down for high oil pressure is indicated in
the control system. Reset the shut downs after testing.
2.2.8 Check the trip function for burner motor overload
Step A: When the burner is in operation, check the trip function for burner motor
overload by pressing the test button for the burner motor on the circuit
breaker.
Step B: The burner motor stops and a shut down for burner motor failure is indicated
in the control system.
Step C: Reset the circuit breakers and all shut downs after testing.

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COMMISSIONING

2.2.9 Check the safety interlock shut down for too low water level
Step A: When the burner is in operation, perform a live test of both of the water level
safety devises. One of the alarms must be deactivated while testing the other
and opposite.
Step B: Decrease the water level in the boiler by means of the blow-down valves
until the water level has fallen below the too low level mark. After the response delay has expired the burner stops and a shut down is indicated in
the control system.
Step C: Increase the water level in the boiler and reset the shut down. Perform the
same test for the other safety device.
Step D: Increase the water level in the boiler and reset all alarms and shut downs.
Activate all safety devices again.
2.2.10 Check the safety interlock shut down for high steam pressure
Step A: When the burner is in operation, raise the boiler pressure until the set point
for high alarm is reached. The control system must indicate a high alarm.
Step B: With the burner in operation, check the shut down and trip function for high
steam pressure. Raise the steam pressure until the burner stops. A shut down
is indicated in the control system.
Step C: If the boiler safety system is equipped with more than one high steam pressure shut down it is necessary to perform the same check with both high
steam pressure shut downs. One of the shut downs must be deactivated while
testing the other and opposite.
Step D: With all steam pressure safety interlocks activated, reset all alarms and shut
downs.
2.2.11 Check the active safety interlock shut downs in emergency operation
Step A: Operate the burner as described in the chapter Manual operation.
Step B: When the burner is in operation, check the active safety interlock shut downs
such as e.g. flame failure, too low water level, etc. as described previously.

2.3 Commissioning on heavy fuel oil


When the burner has been commissioned on MDO/ MGO marine diesel oil / marine
gas oil the final commissioning on heavy fuel oil can be carried out.
2.3.1 Change of fuel
Step A: Stop the burner.
Step B: Check that oil is present in the heavy fuel oil tank. Open the stop valves,
which connect the heavy fuel oil tank to the oil system. To avoid cavitation
of the ring line oil pumps, the viscosity of the oil in the heavy fuel oil tank
should not exceed 380 cSt. If necessary, the oil tank should be heated.
Step C: Check the tracing systems for the oil system and the burner unit is operational.
Step D: Select heavy fuel oil on the manually operated three-way valve. Check that
the control system indicates heavy fuel oil operation.
Step E: Adjust the oil temperature set point as well as the low and high limit set
points on the temperature controller in the control system; see also the chapter Electric pre-heater. The viscosity of the oil at the nozzle head should
be between 14 - 16 cSt. The pre-heating temperature can be determined by
means of the chart in the chapter "Viscosity-temperature chart".

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COMMISSIONING

Step F: Adjust the set points for low shut down, low alarm, and high alarm on the
control panel. Adjust if necessary.
Step G: Start the burner from the control system. It might be necessary to start the
burner several times before the pre-heating temperature is sufficiently high.
Step H: Check that the temperature is raised to the desired set point. Adjust if necessary.
2.3.2 Operation on heavy fuel oil
When the burner is commissioned on heavy fuel oil, final adjustments of the combustion process should be carried out to achieve high quality performance data. The aim
is to operate the burner with lowest possible O2 content and highest possible CO2
content without the risk of an uncompleted combustion (black smoke). At the same
time the reliability of the burner must be ensured.
The oil/air ratio should be checked and adjusted through the complete burner range to
ensure a correct combustion. The oil/air ratio can be checked by measurements of the
soot spot No. and the O2 content and/or the CO2 content in the flue gas. The visual
appearance of the flame should also be checked. If the amount of fuel oil to the burner
for a given combustion air flow is too high, the combustion will be uncomplete and it
will produce black smoke. Althoug the O2 content is low and the CO2 content is high,
the oil flow should be decreased. If on the other hand the O2 content is high and the
CO2 content is low , it indicates that the oil flow must be increased.
It is not only the oil/air ratio which is an important factor for the combustion process,
but also the air velocity for the combustion.
The air velocity in the combustion head can be adjusted by moving the adjustment ring
in relation to the flame tube to change the distance between the adjustment ring and
the edge of the diffuser disc. On low capacity the adjustment ring is advanced and on
high capacity retracted. If the adjustment ring is set too far forward, the combustion
air velocity in the combustion head is too high, the ignition is more difficult or there
is not enough air to support the combustion (high CO content). If the adjustment ring
is too far back, the combustion air velocity is too low and the combustion characteristics
become worse (O2 content is too high).
The following commissioning steps imply that the lighting-up procedure of the boiler
is completed and that a sufficient load demand is present to carry out adjustments at
100% load.
Step A: Start the burner and check that it ignites when the ignition is on and the oil
valves are activated. It must also be checked that the burner remains ignited
when the ignition sequence step is completed. Adjust the oil/air ratio setting
in the control system, and/or the air velocity if necessary.
Step B: Start the burner several times to ensure a reliable ignition of the burner.
Step C: Check that the flame is stable and does not pulsate when the burner operates
at ignition load. Carry out measurements of the soot spot No. and O2 content
and/or CO2 content. Adjust the oil/air ratio setting in the control system, and/
or the air velocity if necessary.
Step D: The shape and colour of the flame must also be checked, adjust if necessary.

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COMMISSIONING

Note: If the position of the adjustment ring has to be altered in relation to the
diffuser disc, the air velocity and quantity in the combustion head will
change. Check the combustion values by means of flue gas analysis and, if
necessary, adjust the combustion air quantity to be adequate.
Step E: Carry out the same measurements through the complete burner range in steps
of 10% (from minimum load to full load). Adjust the oil/air ratio setting in
the control system if necessary.
Step F: Operate the burner as described in the chapter Manual operation.Carry out
measurements when the burner operates in ignition position. Adjust the oil/
air ratio setting in the control system if necessary.
2.3.3 Check the safety interlock shut down for low and high oil temperature
Step A: Decrease the temperature gradually on the temperature controller located in
the control system until the set point for low shut down is reached. The
burner stops, and a shut down is indicated in the control system.
2.3.4 Check the safety interlock shut down for the pre-heater limit thermostat
Step A: When the burner is in operation, check the high temperature limit thermostat
by dismantling one of the wires at the terminals. The burner stops, and a shut
down is indicated in the control system.
Step B: Connect the wire again and reset the shut down
2.3.5 Additional function checks
Step A: Check/adjust additional safety interlock shut downs if provided. A number
of shut downs might be included in the safety interlock circuit depending on
the specified function and/or the classification society.

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OM5560_85#A.2
MAINTENANCE

Maintenance
1

Recommended maintenance intervals


To ensure a safe and reliable function of the burner, inspection must take place with
frequent intervals as described below. The inspection should be carried out by competent and properly trained personnel familiar with the operating and maintenance
procedures relevant for this type of plant.

1.1 Safety regulations for maintenance work


Always ensure that the electrical power is off and that nobody can start the boiler unit
before commencing maintenance work.
All pipes, drums, etc. must be depressurised before any maintenance work is carried
out on these.

1.2 Continuous maintenance


The burner, control panels and other equipment should be kept clean and dry. Check
that no foreign matter accumulates in or around them.
Replace lamps, contactors, and other components when they cease to function or show
signs of deterioration. A part, replaced before it actually fails, could save a costly delay.

1.3 Periodical maintenance


The following check list should be followed frequently. Dependent on the operation
conditions, however, some items may need more attention.
1.3.1 Burner and fuel oil supply system

Check that all connections are tightened and that the wiring is in a good condition.
Check pipe work for leaks, particularly on flanges, joints, and connections. Repair
any leaks which may cause safety risks.
Check that the glands of manual valves are tight enough to prevent easy operation
of the valve. Operate the valves periodically, if possible, to ensure free movement.
Oil filters should be inspected and cleaned if necessary.
Check and clean the flame scanner.
Clean the ignition electrodes and check their setting.
Change the oil nozzle if it is worn or damaged.
Check the combustion values by flue gas analysis.

1.3.2 Electrical system


The electrical and mechanical connections of the local panels and power panels must
be checked and tightened at least once a year.

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MAINTENANCE

1.3.3 Oil tanks


The oil tanks must be inspected and cleaned at least every four to five years.

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OM5560_92#C.1
FAULTS AND RECTIFYING FAULTS

Faults and rectifying faults


1

Trouble shooting
In the event of fault conditions the basic requirements for correct operation must be
examined first:

Check the electric supply (control and supply voltages).


Check that all regulating and control devices are correctly set.
Are the safety devices in normal operating condition?
Is the burner getting fuel, are valves in the fuel line open, is there oil in the tank?
When it is established, that the fault is not due to the above mentioned, the individual
burner functions and parts must be checked according to the fault finding chart in
Table 1.

Fault finding chart


Caution
Motor
Burner motor does not start. Lockout occurs .

Burner motor does not start.


Start failure
Control loop closed (signal lamp of control
loop is lit), but the program of the control
unit does not start.

Burner motor starts, program remains at prepurge period.

Possible cause

Remedy

Break in main circuit.


Motor overload relay released.
Faulty motor contactor.
Faulty motor.
Break in motor control circuit:
faulty control unit.
incorrect setting on cam disk in servo motor.
faulty servo motor.

Find cause and remedy.


Check setting, reset.
Replace.
Replace.
Find cause and remedy.
Replace control unit.
Adjust.
Replace servo motor.

Incorrect setting on cam disk in servo motor.


Faulty servo motor.
Faulty control unit.
Servo motor does not reach the position of
full load of air dampers:
faulty servo motor.
faulty limit switch in servo motor.
incorrect setting on cam switch.
jammed air dampers.

Adjust.
Replace.
Replace.

Replace.
Replace.
Check and adjust.
Check and adjust.

Ignition failure
Clean or replace.
Burner motor starts, control voltage from
control unit to ignition transformer is
switched on, no ignition and after a short
time lockout occurs.

Dirty or worn ignition electrodes, insulator


cracked.
Ignition electrodes too far apart.
Cable damaged.
Faulty ignition transformer.

Adjust according to instructions.


Replace.
Replace.

Caution

Possible cause

Remedy

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FAULTS AND RECTIFYING FAULTS

Fault finding chart


No flame formation

Burner motor starts, ignition is in order, nozzle supplies no oil or nozzle valve does not
function. After a short time lockout occurs.

Oil pressure too low.


Main oil valve does not open.

Solenoid valve does not function:


faulty solenoid valve or coil.
cable damaged.
faulty control unit.
nozzle needle does not open.
faulty O-ring in nozzle.
Possible couse oil to hot and evaporates instead of forming a flame.
Direction of rotation in burner motor wrong.
Pressure of return oil is too high.
Faulty pressure switch (max.).

Replace.
Replace.
Replace.
Replace.
Replace.
Remedy ensure heater and tracing is
off.
Reconnect motor.
Find cause and remedy.
Replace.

Oil pump
Supplies no oil or atomizing pressure is too
low.

Dirty filter.
Leaking suction line of transfer pump.
Pump capacity decreases due to faulty or
worn pump.

Clean.
Seal.
Replace.

Pump sucks air.


Too low inlet pressure to pump.

Tighten joints.
Clean filter, check and adjust pressure.

Flame forms. When burner runs to full load,


flame extinguishes and lockout occurs.

Incorrect burner adjustment.


Dirty filters.
Blocked nozzle.

Adjust.
Clean.
Replace.

Flame forms. Shut down occurs and then restart.

Oil temperature is too low:


pre-heater faulty or its capacity inadequate.
incorrect setting on lower limit thermostat.

Severe mechanical noise.


After flame establishment lockout occurs

Repair or replace.
Check and adjust temperature of incoming oil.

Oil flows into the furnace


Oil flows into the furnace during shut down.
Oil flows into the furnace during pre-purge
period.
Flame monitoring fault
Burner motor starts, flame forms and then
lockout occur.

Lockout during pre-purge period.

Lockout during shut down.

Language UK

Nozzle valve and main oil valve or nozzle


valve and non-return valve do not close.
Leaking nozzle valve.

Clean, repair or replace.


Clean, repair or replace.

Incorrect position of flame detector.


Dirty flame detector.
Illumination (flame) too weak.
Faulty flame detector.
Faulty control unit.

Adjust.
Clean.
Check burner adjustment.
Replace.
Replace.

Faulty flame detector.


Faulty control unit.
Incorrect flame signal due to extraneous
light.

Replace.
Replace.
Find cause and remedy.

Faulty or aged flame detector.

Replace.
Replace.

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FAULTS AND RECTIFYING FAULTS

Fault finding chart

Combustion head
Diffuser disc burned out.

Inside oily or has heavy carbon deposits.

Faulty control unit.


Nozzle valve and main oil valve or nozzle
valve and non-return valve do not close.

Clean, repair or replace.

Worn out.

Replace diffuser disc, if necessary.

Distance between diffuser disc and nozzle


incorrect.
Incorrect combustion air adjustment.
Furnace not adequately ventilated.
Nozzle incorrect sized or of wrong type.
Nozzle worn.
Too small partial load.

Adjust.
Adjust.
Increase air supply.
Change nozzle as appropriate.
Replace.
Increase.

Table 1

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TABLE OF CONTENTS

Table of contents
Cooler unit
Description
Cooler for marine gas oil............................................

Language UK

Document ID
OM8640_06...............

Page
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OM8640_06#C.1
COOLER FOR MARINE GAS OIL

Cooler for marine gas oil


1

General description
This chapter describes the operation and the maintenance of the cooler. An illustration
of the cooler is shown in Figure 1.
The cooler is of the shell and tube type with u-bent tubes.
The cooler has been hydrostatically tested before delivery. The cooler is type approved
by all major classification societies.
Illustration of the cooler
Oil inlet

Air vent valve

Oil outlet

Water inlet
Safety valve

Drain valve
Water outlet

Figure 1

cooler2x1462770en.wmf

Operation
Before proceeding with start-up of the cooler make sure that all connections to the
cooler are securely tightened.
Start-up of the cooler:
Step A: Adjust the safety valve to the maximum design pressure. The safety valve
can be set to a lower set point.
Step B: Fill the cooler with oil.
Step C: Ventilate the cooler. Make sure that the cooler and all connecting pipes are
completely free of air.
Step D: Remember to tighten the air ventilation plug after ventilation.
Step E: Establish oil flow through the cooler.
Step F: Establish LT fresh water flow through the cooler.
Step G: Operate the cooler for approximately one hour.

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COOLER FOR MARINE GAS OIL

Step H: Stop the cooler by closing the water inlet valve.


Step I: Stop the oil flow after ten minutes and tighten all screws again.
To obtain the full output of the cooler, it must be supplied with water at the correct
temperature. The maximum cooling water temperature and required flow appears from
the section Technical data.

Maintenance and cleaning


The cooler should be cleaned every six month and in the event of a drop in the output
which is not related to other causes.
Step
Step
Step
Step
Step

A:
B:
C:
D:
E:

Step F:
Step G:
Step H:
Step I:
Step J:

Stop the cooler as mentioned above.


Empty the cooler.
Remove the tube insert.
Check for deposits inside and outside the tube insert.
The outside tube system should be cleaned by using a sharp liquid jet (use
e.g. citric acid or water).
The inside tube system should be cleaned by flushing the tubes with e.g.
citric acid.
If the cooler is heavily contaminated with carbon deposits, it is recommended to chemically clean the cooler with a carbon remover.
The cooler must be flushed carefully with clean water and dried after the
tubes have been cleaned.
After the tube insert has been replaced, the bolts must be securely fastened
and the cooler checked for leaks.
Once every year the set point of the safety valve must be checked.

3.1 Dismantling and installation of the tube section


The tube section is inserted into the cooler and fastened tightly between the shell flange
and the end flange. The back end of the tube section is free to move.
The water connections must be dismantled before dismantling the tube section for
inspection, cleaning, etc. The tube flange has threaded holes for dismantling screws
and for mounting eye bolts for lifting device.
Packing surfaces should be cleaned and protected against damages. A new packing
must be mounted every time the flange connection has been dismantled.
When the flange connection is mounted again, all bolts should be tightened evenly and
crosswise. A pressure test will show if the joint leaks.
Operate the cooler for one hour, stop and tighten all screws.

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COOLER FOR MARINE GAS OIL

3.2 Conservation during shut-down periods


Corrosion which occurs in shut-down periods is mainly caused by oxygen. The corrosion appears where non-distilled or even slightly alkaline water has remained in the
cooler. However, even when empty, the cooler is exposed to corrosion caused by water
residues or condensation. For this reason an unused cooler should be given an anticorrosion treatment.
In the event of prolonged off-cycle periods - in particular during winter time with frost
- the cooler must be carefully emptied. Open the air valve and check for clogging.

3.3 Spare parts


When spare parts are ordered, please state the serial No. (See the name plate of the
cooler).
For spare parts and further information please contact Alfa Laval.

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TABLE OF CONTENTS

Table of contents
Fuel oil pump unit
Description
Fuel oil pumps series DKC, DLC and DMC.................
Fuel oil pump serie L.................................................

Language UK

Document ID
OM9294_10...............
OM9294_11...............

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OM9294_10.0

FUEL OIL PUMPS SERIES DKC, DLC AND DMC

Fuel oil pumps series DKC, DLC and DMC

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FUEL OIL PUMPS SERIES DKC, DLC AND DMC

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FUEL OIL PUMPS SERIES DKC, DLC AND DMC

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Fuel oil pump serie L

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TABLE OF CONTENTS

Table of contents
Aalborg control system
Description
Touch control system.................................................

Language UK

Document ID
SD9306_14................

Page
24-2

24-1 / 5

SD9306_14#F.1
TOUCH CONTROL SYSTEM

Touch control system


1

General
The Aalborg Control Touch control system is designed to provide safe and functional
operation of the boiler plant both at the boiler and from a remote location such as the
engine control room. The general design is a common panel solution. Each panel is
capable of controlling one oilfired boiler and one exhaust gas boiler and consist of a
local control part and a power part integrated into one panel. The panel is locally
controlled by means of a touch screen in the front of the panel.
Figure 1 illustrates a typical configuration for a boiler system. The example shown is
for a Aalborg OS boiler plant with a Aalborg XS exhaust gas boiler. The control system
is constructed in a similar way for other boiler installations.
The communication between the common panel and touch screen is achieved through
a 2-wire RS485 network. The cable type is a twisted pair with shield. The 2 x 0.5-1.5
mm2 cable should not exceed 1000 metres in total length.
Illustration of the control system

RS485

Ethernet

Figure 1

contouch_01x0195512en.wmf

Common panel
The common panel holds two Aalborg controllers, communication interface, relays,
flame monitoring equipment, water level control equipment, switches for emergency
operation but also power supply systems, motor starters, input/output modules and

24-2 / 5

Language UK

SD9306_14#F.1
TOUCH CONTROL SYSTEM

optional components like smoke density monitoring system, salinity alarm equipment,
oil detection equipment, etc.
The cabinet gives an IP 55 insulation class and can be located in ambient temperatures
between 0-45C with a relative humidity up to 90%. The maximum vibration level is
100 Gal at 10-30 Hz. And the power supply is 115 or 230 V AC, 45-65 Hz. The
maximum power consumption of the local panel is approximately 50 VA.
The two Aalborg controllers constitute a computerised control and monitoring system.
The panels are equipped with a number of digital and analogue input/output connections. These input and output connections are handled by the CPU, which operates the
panels. Two EPROMs contain the programme, and an E2PROM stores specified plant
data.
One of the two Aalborg controllers is the local controller (LP1) which handles operation of the boilers such as e.g. control and monitoring of flow, temperature, pressure
and, dependent of boiler system, change of oil type. The second Aalborg controller is
the common controller (PP1) which handles common tasks such as e.g. control of oil
pumps and, if provided, feed water pumps.
The complete boiler system can be operated from the controllers inside the local panel
with or without the touch screen in service. By use of the soft keys placed to the left
of the display, the burner can be operated in manual mode, and shut downs/alarms can
be acknowledged. The soft keys placed to the right of the display give access to the
menu structure. The actual menu levels or menu item lines are displayed on the four
line Liquid Crystal Display (LCD). Figure 2 illustrates the interface of the controllers.
It is also through these controllers that the basic configuration of the system is done
during commissioning. Access to a number of different parameters, settings, etc. is
limited by password entering. This secures the operation from unintentional entering
and modification, which might cause damage to the boiler plant. The password routine
is divided into two steps. The entering of the common user password provides access
to the most common menu items. The super user password, which is only known by
Alfa Laval, provides unlimited access.
Illustration of the controller interface

Figure 2

contouch_02x0197680en.wmf

Monitoring and control from the touch screen


The control system is provided with a touch screen which contains a graphic user
interface for a quick user-friendly overview of the boiler operation. This touch screen
can be installed anywhere, as long as the length of the cables does not exceed 1000

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24-3 / 5

SD9306_14#F.1
TOUCH CONTROL SYSTEM

metres. The boiler plant can be monitored and operated from the touch screen as well
as from the local controller(s). Furthermore, trend curves for the plant can be viewed
and alarms can be acknowledged.
In Figure 3 the main screen of the touch screen is shown. By use of the touch screen,
shutdowns/alarms can be acknowledged from the [ALARM] button in the upper right
corner. The buttons on the right side of the display give access to detailed information
on the steam system, feed water system, fuel system, and burner operation. From the
buttons on the left side of the touch screen, key lock, trend curves and the set-up menu
can be accessed. The button [BOILER] gives access to an overview of the operation
of the boiler system.
Illustration of the main page of the touch screen

Figure 3

contouch_03x0197690en.wmf

A password system provides the logged-on user with permissions/restrictions and ensures that no parameters can be changed by unauthorised personnel.
Modbus interface
An optional communication interface via Modbus protocol (RS485) to other systems
on board the ship can be provided.
The Modbus interface feature offers external control and monitoring of a limited number of parameters in the boiler control system from an external operating place such
as e.g. the cargo control room. It is possible to control and/or monitor parameters such
as boiler operation mode, state (stopped, starting, purge, etc.), manual start/stop and
load, selection of master/slave boiler, inert gas mode (if provided), boiler/system pressure, and water level.
If Modbus is selected, Alfa Laval supplies a complete address list and a separate communication port on the touch screen including a 9-pin DB9 plug.

24-4 / 5

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SD9306_14#F.1
TOUCH CONTROL SYSTEM

Remote desktop
The system supports remote desktop using a web browser. Communication is carried
out over an ordinary Ethernet network (see Figure 1) using an Ethernet cable with RJ45
connectors (not supplied by Alfa Laval).
With the remote desktop feature it is possible to remote control the touch display seeing
the same picture as on the actual touch screen and using the computer mouse as input
device instead of the touch functionality.
For details please refer to the document Touch Remote Desktop.
Common LSFO power section
The common LSFO power section contains various equipment, e.g. power supply
equipment including an uninterruptible power supply (UPS), motor starters and motor
protecting switches for the separate LSFO pumps (if available), and various relays and
input/output modules. It can be located almost anywhere in the engine room, but it
should be easy accessible because it must be in operation during emergency operation.
The panel (measures 600x600mm) is needed to control extra pumps and to handle
additional in and outputs required for LSFO (if the system is configured with this
service). The panel does not have a LCD display, so to control any additional equipment
which is added in the existing plant, parameters, settings, etc. must be entered from
local control panel section, and/or power panel section.
Illustration of LSFO power section

Figure 4

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24-5 / 5

TABLE OF CONTENTS

Table of contents
Operation of the panels
Description
Operation of the panels (ACT)....................................
Operation of the touch screen......................................
Key operation lock.....................................................

Language UK

Document ID
OM9306_63...............
OM9306_70...............
OM9306_67...............

Page
25-2
25-21
25-34

25-1 / 37

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Operation of the panels (ACT)


1

General
The Aalborg Control Touch (ACT) is, besides the touch screen, equipped with both
local panels and common panels. The number of panels for each boiler plant depends
on the number of boilers included and the accessories provided in the plant.
The local panels are configured to control the boiler and burner operation, and operation of the boiler plant can be performed from here.
The common panels are configured to control accessories such as fuel oil pumps, feed
water pumps, exhaust gas boilers, salinity, etc. Figure 1 illustrates the local panel and
the operation of the soft keys.
On ACT systems normal operation will be carried out from the touch screen but for
system configuration or in case the touch screen breaks down operation is carried out
from the controllers.

25-2 / 37

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Illustration of a panel

USER DEFINED VALUE 1


USER DEFINED VALUE 2
USER DEFINED VALUE 3
[STATE]
[MODE]

[VALUE 1]
[VALUE 2]
[VALUE 3]
[LOAD%]

Manual increase of the burner load. This


facility is only available in manual operation
mode. Or manual increase of other remote
control settings = 1.

Entering of different menu items for


modification of settings, parameters,
etc. Password entering is required
when this soft key is used.

Manual decrease of the burner load. This


facility is only available in manual operation
mode. Or manual decrease of other remote
control settings = 1.

Moves further out of a branch in the


menu structure and changes digit
position towards left.

Selection between automatic and manual


operation mode. The yellow LED above
the soft key shines in manual operation
mode.

Move further into a branch in the


menu structure and changes digit
position towards right.

Acknowledgment of alarms and shut downs.


Low frequent flashes on the red LED
above the soft key indicate alarms, and
high frequent flashes indicate shut downs/
burner cut-off.

Moves upwards in the menu structure


and increases to a higher value.

Starts the burner in manual operation mode.


The green LED above the soft key flashes.
When a feedback signal for combustion air
fan running is received, the LED shines.

Moves downwards in the menu structure


and decreases to a lower value.

Stops the burner in manual operation mode.


The green LED above the ON soft key is
switched off simultaneously.

BOILER PRES
WATER LEVEL
HFO PRES
[
STOPPED

Figure 1

0.0 BAR
0 mm
0.0 BAR
0%

Display for surveillance of operation, servicing, and modification.


The display is a 4-line display with maximum 20 characters in each line.
If the sign
is indicated the boiler plant is operating in inert gas mode.
If the sign
is indicated the boiler plant is stopped by an external stop.
If the sign
is indicated the key operation lock is opened.

unisab2dx2411290en.wmf

By use of the soft keys placed to the left of the display, the burner can be operated in
manual mode, and shut downs/alarms can be acknowledged. Furthermore, a number
of remote controls (e.g. oil pressure, water level, etc.) can be operated/controlled from
here provided the actual remote control setting is selected to "1" in the menu structure.
The soft keys placed to the right of the display give access to the menu structure. The
actual menu levels or menu item lines are displayed on the four line crystal display
(LCD).
The menu structure for the local and common panels can be found elsewhere in this
manual.
The communication between the panels included in a boiler plant is achieved through
wire connections.

Language UK

25-3 / 37

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Operating examples
In this section a number of operating examples are illustrated. The examples shown
are valid for a boiler plant which contains two Aalborg boilers with steam atomizing
burners. However, the operating principles are identical for all other boiler and burner
types. This means that regardless of the parameter, setting, etc., which should be entered or modified, the procedure for operating the panels is the same.
Examples No. 2 to No. 5 imply that the key operation lock is unlocked. If this is not
the case then please refer to example No. 1 or the specific instruction for unlocking
the key operation lock.
The following operating examples are shown:

25-4 / 37

Operating example No. 1:


Unlock of the key operation lock for local panel 1. See Figure 2 and Figure 3.
Operating example No. 2:
Change of burner operation mode from stopped mode to automatic mode. See
Figure 4, Figure 5, and Figure 6.
Operating example No. 3:
Change of set point for low steam pressure alarm. See Figure 7, Figure 8, and
Figure 9.
Operating example No. 4:
Inspection of the shut down list. See Figure 10, Figure 11, and Figure 12.
Operating example No. 5:
Manual start and stop of the burner. See Figure 13 and Figure 14.
Operating example No. 6:
Status of the flushing sequence. See Figure 15, Figure 16 Figure 17 and Figure 18.

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 1: unlock the key operation lock

BOILER PRES
WATER LEVEL
HFO PRES
STOPPED

0.0 BAR
0 mm
0.0 BAR
0%

Press once

KEY POSITION
REQUEST KEY

PP1
NO

STOPPED

0%

Press once

Continued in next picture

Figure 2

Language UK

KEY POSITION
REQUEST KEY

PP1
NO

STOPPED

0%

Press once

unisab701ax2411370en.wmf

25-5 / 37

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 1: unlock the key operation lock (continued)


Continued from previous picture

KEY POSITION
REQUEST KEY

PP1
YES

STOPPED

0%

Press once

KEY POSITION
RELEASE KEY

LP1
NO

STOPPED

0%

Press once

BOILER PRES
WATER LEVEL
HFO PRES
STOPPED

Figure 3

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0.0 BAR
0 mm
0.0 BAR
0%

unisab702ax2411380en.wmf

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 2: Change of operation mode

BOILER PRES
WATER LEVEL
HFO PRES
STOPPED

0.0 BAR
0 mm
0.0 BAR
0%

Press twice

BOILER
FUEL OIL
AIR
COMBUST

PARTNER
CMN CTRL
SURVEIL
SETUP

Press 7 times

BOILER
FUEL OIL
AIR
COMBUST

PARTNER
CMN CTRL
SURVEIL
SETUP

Continued in next picture


Press once

Figure 4

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unisab301cx2411300en.wmf

25-7 / 37

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 2: Change of operation mode (continued)


Continued from previous picture

CTRL MODE
TIMERS
SETTINGS
DIAGNOSES

LOGGINGS
CALIBRATE
CONFIG
LANGUAGE

Press once

BURNER CTRL MODE


STOPPED
SETPOINT SELECT
LOW

Press once

BURNER CTRL MODE


STOPPED
SETPOINT SELECT
LOW

Continued in next picture


Press once

Figure 5

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om9306_58_unisabx0062920en.wmf

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 2: Change of operation mode (continued)


Continued from previous picture

BURNER CTRL MODE


AUTO
SETPOINT SELECT
LOW

Press once

BURNER CTRL MODE


AUTO
SETPOINT SELECT
LOW

Press 4 times

BOILER PRES
WATER LEVEL
HFO PRES
STARTING

Figure 6

Language UK

0.0 BAR
0 mm
0.0 BAR
0%

unisab303cx2411310en.wmf

25-9 / 37

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 3: Change of set point

BOILER PRES
WATER LEVEL
HFO PRES
READY

16.5 BAR
12 mm
22.0 BAR
0%

Press twice

BOILER
FUEL OIL
AIR
COMBUST

PARTNER
CMN CTRL
SURVEIL
SETUP

Press once

BOILER PRES
WATER LEVEL
COMMON PRES
READY

16.5 BAR
20 mm
16.5 BAR
0%

Press once

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

18.0 BAR
17.5 BAR
4.0 BAR
0.0 %

Continued in next picture


Press twice

Figure 7

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unisab401dx2412000en.wmf

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 3: Change of set point (continued)


Continued from previous picture

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

18.0 BAR
17.5 BAR
4.0 BAR
0.0 %

Press once for


a few sec.

PASSWORD
1234
SET TO ACCEPT / QUIT

Press once

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

18.0 BAR
17.5 BAR
+004.0 BAR
0.0 %

Press twice

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

Continued in next picture

Figure 8

Language UK

18.0 BAR
17.5 BAR
+004.0 BAR
0.0 %

Press once

om9306_58_unisabx0062950en.wmf

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 3: Change of set point (continued)


Continued from previous picture

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

18.0 BAR
17.5 BAR
+005.0 BAR
0.0 %

Press once

HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT

18.0 BAR
17.5 BAR
5.0 BAR
0.0 %

Press 4 times

BOILER PRES
WATER LEVEL
HFO PRES
READY

Figure 9

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16.5 BAR
12 mm
22.0 BAR
0%

unisab403dx2411330en.wmf

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 4: Inspection of the shut down list

BOILER PRES
WATER LEVEL
HFO PRES
READY

7.5 BAR
12 mm
22.0 BAR
0%

Press twice

BOILER
FUEL OIL
AIR
COMBUST

PARTNER
CMN CTRL
SURVEIL
SETUP

Press 7 times

BOILER
FUEL OIL
AIR
COMBUST

PARTNER
CMN CTRL
SURVEIL
SETUP

Continued in next picture


Press once

Figure 10

Language UK

unisab501cx2411340en.wmf

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 4: Inspection of the shut down list (continued)


Continued from previous picture

CTRL MODE
TIMERS
SETTINGS
DIAGNOSES

LOGGINGS
CALIBRATE
CONFIG
LANGUAGE

Press 4 times

CTRL MODE
TIMERS
SETTINGS
DIAGNOSES

LOGGINGS
CALIBRATE
CONFIG
LANGUAGE

Press once

DATA LOG
INSPECT SHT.DWN. LOG
OIL SUMMARIZER

Continued in next picture


Press once

Figure 11

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om9306_58_unisabx0062980en.wmf

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 4: Inspection of the shut down list (continued)


Continued from previous picture

SHT.DWN.

990530-1230

HFO PRESSURE LOW

Press soft key to


inspect shut down list
(maximum 20 shut downs)

SHT.DWN.

990530-1230

HFO PRESSURE LOW

Press 5 times

BOILER PRES
WATER LEVEL
HFO PRES
READY

Figure 12

Language UK

7.5 BAR
12 mm
22.0 BAR
0%

unisab503fx2428980en.wmf

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 5: Manual start/stop

BOILER PRES
WATER LEVEL
HFO PRES
READY

7.5 BAR
12 mm
22.0 BAR
0%

Press once for manual


operation mode if auto
is selected in the
SETUP/CONTROL MODE

BOILER PRES
WATER LEVEL
HFO PRES
READY

7.5 BAR
12 mm
22.0 BAR
0%

Press once, and the


burner initiates a
start up sequence

BOILER PRES
WATER LEVEL
HFO PRES
MAN LOAD

Press to increase
the burner load

Figure 13

25-16 / 37

7.5 BAR
12 mm
22.0 BAR
10%

Continued in next picture

unisab601cx2411360en.wmf

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 5: Manual start/stop (continued)


Continued from previous picture

BOILER PRES
WATER LEVEL
HFO PRES
MAN LOAD

7.5 BAR
12 mm
22.0 BAR
50%

BOILER PRES
WATER LEVEL
HFO PRES
MAN LOAD

8.2 BAR
12 mm
22.0 BAR
10%

Press to decrease
the burner load

Press once to
stop the burner

BOILER PRES
WATER LEVEL
HFO PRES
READY

Figure 14

8.0 BAR
12 mm
22.0 BAR
0%

unisab602cx2411430en.wmf

Status of the flushing sequence


When the oil supply is changed, a flushing sequence is initiated. In the Local Control
Panel the actual status of the flushing sequence is displayed in the bottom line of the
display. Four status texts are displayed, shown in following example:

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Example No. 6: Ready

BOILER PRES
WATER LEVEL
HFO PRES
READY

7.0 Bar
12 mm
22.0 Bar
0%

Figure 15

unisab901ax2411390en.wmf

Figure 15 shows burner status.


Example No. 6: Flushing

BOILER PRES
WATER LEVEL
HFO PRES
FLUSHING

7.0 Bar
12 mm
22.0 Bar
0%

Figure 16

unisab902ax2411400en.wmf

Figure 16 shows the system is flushing. The burner can not be started until the flushing
sequence is completed.
Example No. 6: DO->MGO

BOILER PRES
WATER LEVEL
HFO PRES
D0->MGO

7.0 Bar
12 mm
22 Bar
0%

Figure 17

unisab903ax2411410en.wmf

Figure 17 shows which flushing sequence is being performed.


Example No. 7: Wait timer

BOILER PRES
WATER LEVEL
HFO PRES
WAIT TIMER

Figure 18

7.0 Bar
12 mm
22 Bar
0%

unisab904ax2411420en.wmf

Figure 18 shows current status of the flushing sequence.

25-18 / 37

Language UK

OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

3.1 Current status of the flushing sequence


The current status of the flushing sequence is divided into the following categories:
Wait timer
A flushing timer is counting down from a preset period of time set to secure a proper
flushing. The next event in the sequence will occur when the timer has expired.
Flow rising
The set point for the oil flow is increased to ensure a sufficient flushing. The next event
in the sequence will occur when the oil flow has reached the set point.
Temp falling
The oil system and the burner are cooled before allowing MGO or DO to enter the
system. The next event in the sequence will occur when the temperature has decreased
to a value below a preset limit.
Temp rising
The temperature of the HFO is increasing. The next event in the sequence will occur
when the temperature is above the limit of the low temperature alarm for HFO operation.
Wait valves
Outputs to the automatically operated valves are activated or deactivated. The next
event in the sequence will occur when the valve feedback to the control system indicates that the valves are in the correct position.
Wait pump
Outputs to the fuel- or, if supplied, gas oil pumps are activated. The next event in the
sequence will occur when the pump feedback to the control system indicates that the
requested pump is running.
Wait booster
To ensure sufficient fuel- or, if supplied, gas oil pressure at the booster pump suction
side at booster pump start-up, a preset timer will delay the booster pump start-up output
from the controller. The next event in the sequence will occur when the booster pump
feedback to the control system indicates that the booster pump is running.
Note: Applies for systems configured with low and high pressure fuel circuits
only.
Flushing
A flushing sequence is in progress. The burner will be ready for operation when the
flushing sequence has been successfully completed.

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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)

Flush stop
The flushing sequence is stopped if a shutdown related to the oil system is activated
or if an oil pump is stopped manually. The surveil menu reveals what have caused the
flushing sequence to stop. The flushing sequence will automatically continue, when
the event that caused the shutdown is rectified, the shutdown acknowledged in the
control system, the oil pump set back in AUTO mode and subsequently the last shutdown(s) acknowledged in the control system.
Ready
The fuel flush sequence is completed and the burner is ready for operation provided
that the burner state in the control system is either AUTO or MANUAL.

25-20 / 37

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Operation of the touch screen


1

General
The control system is equipped with a touch screen, where the system can be controlled
and monitored from. The boiler operation, which can be performed from the local
panel(s) can also be performed from the touch screen. Operation by use of the local
panels can be found elsewhere in the manual. Figure 1 illustrates the main picture of
the touch screen.
Main picture of touch screen

Figure 1

om9306_57_pic_0x0062860en.wmf

[ALARM]: The alarm button in the upper right corner is accessible from any screen
view. This button gives access to the alarm and shutdown list. Alarms and shutdowns
can be reset by pressing the Check Mark button in the list provided that the reason(s)
that caused the active alarm/shutdown has been rectified.
[STEAM] The steam button gives access to an overview of the steam system, to set
the alarm and shutdown limits, to control the feed water pumps and to access an overview of the exhaust gas boiler, if present.
[WATER] The water button gives access to an overview of the feed water system, to
set the alarm and shutdown limits, and to control the feed water pumps.
[FUEL] The fuel button gives access to an overview of the fuel system, to set the alarm
and shutdown limits, and to control the fuel pumps.
[BURNER] The burner button gives access to an overview of the burner system, including fans, and to set the alarm and shutdown limits.

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

[BOILER] The boiler button gives access to an overview of the performance of the
boiler system. Alarm and shutdown limits for the system can be set.
[KEY] The key button gives access to get and release the key for operation.
[TREND] The trend button gives access to trend curves of the performance of the boiler
system.
[SET-UP] The set-up button gives access to the set-up menu, e.g. timers, plant limits,
and diagnostic information. This menu is described elsewhere in the manual.
The key in the top left corner indicates if present that the user has unlocked the system
and therefore can modify different parameters.

Operating examples
In this section a number of operating examples are illustrated. The examples show a
generic boiler with a Aalborg KBP burner attached but the operating principles are
identical for all other boiler and burner types. This means that regardless of the parameter, setting, etc., which should be entered or modified, the procedure for operating
the touch screen is the same.
Examples No. 2 to No. 5 imply that the key operation lock is unlocked. If this is not
the case then please refer to example No. 1 or the specific instruction for unlocking
the key operation lock.
The following operating examples are shown:

25-22 / 37

Operating example No. 1:


Unlock of the key operation lock for touch screen. See Figure 2 for a general
method and Figure 3 for a shortcut in parameter menus.
Operating example No. 2:
Change of burner operation mode from stopped mode to automatic mode. See
Figure 4 and Figure 5.
Operating example No. 3:
Change of set point for low steam pressure alarm. See Figure 6 and Figure 7.
Operating example No. 4:
Inspection of the alarm and shutdown list. See Figure 8.
Operating example No. 5:
Manual start and stop of the burner. See Figure 9 and Figure 10.

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 1: unlock the operation lock

PP1
Request key:

Figure 2

Language UK

contouch_108x0200400en.wmf

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 1: unlock the operation lock in a parameter menu

Figure 3

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contouch_116x0200480en.wmf

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 2: change of operation mode

Figure 4

Language UK

contouch_121ax1762780en.wmf

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 2: change op operation mode (continued)

Figure 5

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contouch_117bx1610420en.wmf

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 3: change of set point

Figure 6

Language UK

contouch_122ax1762790en.wmf

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 3: Change of set point (continued)

Figure 7

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contouch_112x0200440en.wmf

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 4: Inspection of the alarm and shutdown list

Figure 8

Language UK

contouch_113x0200450en.wmf

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 5: Manual start/stop

Figure 9

25-30 / 37

contouch_123ax1762800en.wmf

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Example No. 5: Manual start/stop (continued)

Figure 10

Language UK

contouch_120bx1610430en.wmf

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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

2.1 Status of the flushing sequence


When the oil supply type is changed, a flushing sequence is initiated. At the Local
Control Panel the actual status of the flushing sequence is displayed in the upper half
of the touch screen display.
Wait timer

Figure 11

contouch_126x1761570en.wmf

Following status texts can displayed during a fuel flush sequence:


Wait timer
A flushing timer is counting down from a preset period of time set to ensure a proper
flushing. The next event in the sequence will occur when the timer has expired.
Flow rising
The set point for the oil flow is increased to ensure a sufficient flushing. The next event
in the sequence will occur when the oil flow has reached the set point.
Temp falling
The oil system and the burner are cooled before allowing MGO to enter the system.
The next event in the sequence will occur when the temperature has decreased to a
value below a preset limit.
Temp rising
The temperature of the HFO is increasing. The next event in the sequence will occur
when the temperature is above the limit of the low temperature alarm for HFO operation.
Wait valves
Outputs to the automatically operated valves are activated or deactivated. The next
event in the sequence will occur when the valve feedback to the control system indicates that the valves are in the correct position.
Wait pump
Outputs to the oil pumps are activated. The next event in the sequence will occur when
the pump feedback to the control system indicates that the requested pump is running.

25-32 / 37

Language UK

OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN

Wait booster
To ensure sufficient oil pressure at the booster pump suction side at booster pump startup, a preset timer will delay the booster pump start-up output from the controller. The
next event in the sequence will occur when the booster pump feedback to the control
system indicates that the booster pump is running.
Note: Applies for systems configured with low and high pressure fuel circuits
only.
Flushing
A flushing sequence is in progress. The burner will be ready for operation when the
flushing sequence has been successfully completed.
Flush stop
The flushing sequence is stopped if a shutdown related to the oil system is activated
or if an oil pump is stopped manually. The surveil menus reveals what have caused the
flushing sequence to stop. The flushing sequence will automatically continue, when
the event that caused the shutdown is rectified, the shutdown acknowledged in the
control system, the oil pump set back in AUTO mode and subsequently the last shutdown(s) acknowledged in the control system.
Ready
The fuel flush sequence is completed and the burner is ready for operation provided
that the burner state in the control system is either AUTO or MANUAL.

Language UK

25-33 / 37

OM9306_67#D.2
KEY OPERATION LOCK

Key operation lock


1

General
In the following the key operation lock system for the control system is described with
regard to function and operation.

1.1 Function
Operation of the boiler plant must be performed from the local panel(s) or the touch
remote desktop, if provided. To ensure that operation of the boiler plant can only take
place from one place at the time, the control system is provided with a key operation
lock system. This prohibits unintentional alterations of settings, parameters, etc., which
might cause damage to the complete boiler plant. Even though the control system is
locked, it still controls the boiler plant automatically, and complete monitoring is also
possible. Only the operation of the boiler plant is limited.
However, it is possible to change between manual and automatic operation modes on
the local panel provided that the burner has been set to "AUTO" operation.

1.2 Operation
When the control system is powered up, the operation of the boiler plant is as default
set for key operation lock position to power panel 1. But as all operation of the boiler
plant must be performed from a local panel or any external connected equipment, the
system is locked. To unlock the operation of the control system, the position of the key
operation lock must be changed. The key operation lock can be in one of the following
positions:
- PP1 (power panel 1)
- LP1 (local panel 1 this is also the position when using the touch creen)
- LP2 (local panel 2, in twin boiler plants)
- MB1 or MB2 (Any Modbus connected equipment, e.g. a HMI touch panel)
- PC (If the control system additionally is configured with remote operation by PC)
In order to operate the boiler plant, the key operation lock must be obtained on either
one of the local panels, on the touch screen, or at any external connected equipment.
Then operation can take place from the chosen location (local panel 1, local panel 2,
touch screen, PC or other external connected equipment).
Note: Operation location can only be selected if the key operation lock is unlocked
and thereby positioned at PP1 (power panel 1).

25-34 / 37

Language UK

OM9306_67#D.2
KEY OPERATION LOCK

1.2.1 Operation from a local panel


Step A: When the front menu is displayed on the local panel press the soft key
once, and the menu for the key operation lock appears in the local panel
display. The top menu line shows the actual position of the key, and in the
next line an opening of the key can be requested on the actual panel.
Step B: Press the SET soft key, and the black bar will be placed in the [NO] position.
Step C: Press the soft key, and [YES] appears in the position of the black bar.
Step D: Press the SET soft key again, and the actual local panel will be active for
operation. The display of the actual key position in the top menu line changes
to the actual local panel (LP1 or LP2).
An unlocked local panel is also indicated by a key symbol in the bottom menu line.
Note: Key operation lock has to be done by same procedure as request of key
operation unlock.
1.2.2 Operation from the touch screen
The key status is always indicated in the top left part of the picture. When a key is
shown, the system is unlocked. If the key is blinking (warning the user when in a
parameter menu), the system is locked. There are two ways of unlocking the system
when using the touch panel.
Method 1 - Advanced:
Step A: This method can e.g. be used for checking who currently holds the key. In
the main picture of the touch panel press the [KEY] button in the left side
of the touch screen, and the menu for the key operation lock appears in the
display. Illustrated in Figure 1
Step B: The top field indicates current key position. By means of the bottom key
(dark grey) it is possible to toggle between releasing or requesting key operation lock on the chosen local panel. In Figure 1 the local panel is unlocked
and the choice displayed is between returning key operation lock to power
panel 1 (YES) or cancel (NO).
Method 2 Quick access:
Step A: This method is useful when altering parameters (requiring the key). To avoid
having to leave the current parameter picture to unlock the system one can
instead just press the key to toggle the status. Illustrated in Figure 2.
The number of key operation locks depends on the number of configured boiler systems
for the actual plant, e.g. one Aalborg OL boiler and one Aalborg OC boiler will include
two key operation locks.

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OM9306_67#D.2
KEY OPERATION LOCK

Illustration of key operation - method 1

Figure 1

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contouch_106x0197660en.wmf

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OM9306_67#D.2
KEY OPERATION LOCK

Illustration of key operation - method 2

Figure 2

contouch_107x0197670en.wmf

Note: If any operation has not taken place within one minute, the key operation
lock automatically changes back to PP1 (power panel 1). A new unlocking
procedure must be performed before any operation can take place. Please
note that the time period for automatic change back to PP1 can be set to a
different value in the timer set-up menu. The name of the timer is "KEY
HOLD".

1.3 Commissioning
In order to ease the commissioning work the key operation lock system is provided
with a feature which makes it possible to operate the control system from all operation
places. In the menu SETUP/CONFIG/BURNER OPTION on the local panel the key
operation lock can be disabled by KEY DISABLE. Thus with the key operation lock
disabled on the local panel(s), operation can be carried out from all operation places.
E.g. in a twin boiler plant with pressure atomizing burners and no touch screen, operation can take place from LP1 (local panel 1) and LP2 (local panel 2). However, the
time period for non-operation of the local panel is still active. So it might be advisable
to set this time hold period to a higher value during commissioning. The time period
value can be changed in the SETUP/TIMERS/TIMER SETUP/SURVEILLANCE
menu and the name of the timer is "KEY HOLD". After commissioning the timer must
be set back to its original value.

Language UK

25-37 / 37

TABLE OF CONTENTS

Table of contents
Commisioning and service
Description
Commissioning and service........................................
Monitoring and control via touch screen.......................

Language UK

Document ID
OM9306_62...............
OM9306_68...............

Page
26-2
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OM9306_62#F.1
COMMISSIONING AND SERVICE

Commissioning and service


1

General
The following sections describe some of the parts provided in the controller and the
actions which must be performed when the controller is commissioned or serviced.
The controller is designed as a computerised control and monitoring unit which provides the boiler plant with the necessary functions to have a safe and reliable operation.
The main parts of the controller consist of:

The cabinet.
The keyboard with soft keys for operation and entering the menu structure.
The four line crystal display (LCD).
The relay print, which includes the battery, relays, fuse, and connections for wiring,
power supply, and communication.
The DI relay print for additional digital input connections.
The CPU print, which includes the CPU, 2 x EPROM, and EEPROM. The CPU
print is fitted onto the relay print.
Figure 1 shows the keyboard and display, and Figure 2 shows the inside of the controller.
Please note that the operation of the soft keys and the structure of the menus are not
described in this chapter, but can be found elsewhere in the instruction manual.
Illustration of the keyboard and display

USER DEFINED VALUE 1


USER DEFINED VALUE 2
USER DEFINED VALUE 3
[STATE]
[MODE]

Figure 1

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[VALUE 1]
[VALUE 2]
[VALUE 3]
[LOAD%]

om9306_59_unisabx0063040en.wmf

Language UK

OM9306_62#F.1
COMMISSIONING AND SERVICE

Illustration of the inside of the controller

Figure 2

unisab19x1478340en.bmp

Technical data for the controller:

Power supply: 115/230 VAC, 45-65 HZ


Voltage tolerance: +10 to -15%
Consumption: 50 VA
Ambient temperature: 0-55C (operation)
Humidity: 20-90% relative humidity (not condensing)
Density: IP 54
Vibration: maximum 100 Gal at 10-30 Hz

1.1 Light diodes


Both the relay print and CPU print are equipped with a number of light diodes (LEDs).
The LEDs can be used during commissioning or servicing to determine the state of the
input/output signals, communication signals, etc. When the hinged door is open, the
LEDs can be inspected. The printed circuit boards are equipped with the following
LEDs:

Digital input (12 LEDs, green).


Digital output (18 LEDs, red).
Communication (3 LEDs, red, yellow, and green).
Supply (1 LED, red).
CPU (2 LEDs, red and green).
The position and identification of the LEDs are shown in Figure 2.

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26-3 / 99

OM9306_62#F.1
COMMISSIONING AND SERVICE

Digital input
The green LEDs are marked from DI1 to DI12. The attached functions appear from
the electrical diagrams. When a specific LED is illuminated, the input is active.
Digital output
The red LEDs are marked from DRL1 to DRL18. The attached functions appear from
the electrical diagrams. When a specific LED is illuminated, the output is active.
Communication
When the panel communicates with other panels, the LEDs flash irregularly. The red
LED indicates that the panel is transmitting information, and the green LED indicates
that information is received.
Supply
This LED flashes briefly when the power supply to the panel is switched on. During
normal operation the light is off. If the LED makes repeated flashes, it may be an
indication of a power supply error.
CPU print
The green idle LED (ACT1) flashes irregularly when the power supply to the panel is
on. A constant light or no light indicate malfunction.
The red reset LED (RST1) is normally not illuminated. The LED is only illuminated
for a brief moment when the CPU restarts the programme. This only occurs when the
power supply to the panel is switched on.

Commissioning of the panels


This instruction deals primarily with the initial work procedures which must be performed to obtain a functional control system.
Note: Only qualified and skilled personnel are permitted to commission the panels.
Prior to the initial commissioning precaution must be taken to avoid an unintentional
start of the boiler plant when the power supply to the control system is switched on.
This means that the power supply to motors, fans, pumps, etc. must be switched off.
Manually operated oil valves, which connect the oil system to the burner, should also
be closed.
Warning: The panels contain live parts making it absolutely necessary that the
service engineer complies with the safety regulations prescribed on
site. Failure to do so may cause damage to equipment and affect personal safety. Even though the power supply to the panels is switched
off, some of the terminals may still be live.

26-4 / 99

Language UK

OM9306_62#F.1
COMMISSIONING AND SERVICE

In the following sections it is assumed that the key operation lock has been unlocked
before any operation, alterations, etc. of the menu structure settings are performed.

2.1 Initial start-up


On delivery from Alfa Laval the electrical wiring inside the control panel is completed.
This also means that the electrical wiring, power supply, and data communication cable
between the terminal rows of the control panels and the controllers are connected. Even
though the internal wiring has been completed, some additional checks regarding the
controllers must be carried out. These procedures, among others, are described in the
following sections.
Some of the work procedures require visual checks inside the controllers. Therefore
access to the controllers should be provided by opening the hinged door.

2.2 Connection of the external wires


Prior to commissioning the connection of the external wires must be completed on site
in accordance with the electrical diagrams. This means that wires from pump motors,
transmitters, switches, regulating valves, etc. should be connected to the terminal rows
of the control panel.
During this work the power supply for the complete boiler plant must be switched off.
Furthermore, it must be ensured that no outside voltage is applied to the digital input
connections of the control panel.
If and when functional errors of connected electrical equipment are established prior
to or during the actual commissioning of the boiler plant, the fault must be corrected.
Functional errors might be present as a result of incorrect electrical wire connections.
If this is the case, the wires should be rearranged either at the terminal rows of control
panel or at the specified electrical equipment.

2.3 Check the setting of the jumpers


2.3.1 Check the bridge connection of the terminal row
Check that the controllers are provided with a bridge connection between terminal 137
and 139.
2.3.2 Check the setting of the RC jumper
The controllers are capable of operation in different modes (RC mode or non-RC
mode). This is achieved by means of the RC jumper. The jumper position that must be
applied for boiler plants can be seen in Figure 2.
2.3.3 Check the setting of the PNP/NPN jumper
When the control system should handle signals from a pick-up sensor/measuring
transducer (e.g. oil flow signals) the PNP/NPN signal jumper must be set in the correct
position. The jumper position that normally must be applied for boiler plants can be
seen in Figure 2.

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OM9306_62#F.1
COMMISSIONING AND SERVICE

2.3.4 Check the external communication plug


The external communication plug is not used for boiler plants and should therefore not
be connected.

2.4 Installation of the data communication cable


The communication between controllers is achieved through a 2-wire RS485 network.
To obtain a correct function of the data communication between the controllers, the
communication cable must be connected according to the electrical wiring diagrams.
Please see the electrical drawings for details.
As indicated in the electrical wiring diagrams, the communication cable must be connected in a string line from controller to controller. This applies both for the two conductors and the screening. The total length of the cable must not exceed 1,000 m.
When the data communication cable is installed, and the power supply to the controller
is switched on, the function can be checked. The communication LEDs placed inside
the controller must flash irregularly. If this is not the case, the data communication
string should be carefully examined, and the error corrected. The position of the LEDs
can be seen in Figure 2.

2.5 Connection of the power supply to the controllers


Before the power supply to the controllers is switched on, it must once again be ensured
that the boiler plant is not unintentionally started.
Step A: Check that the EPROMs, EEPROM, and CPU are inserted in the CPU-print
for all included controllers.
Step B: Switch on the power supply to one of the controllers.
Step C: Check that the power LED and reset LED flash briefly when the power
supply is switched on.
Step D: Check that the idle LED and communication LEDs flash irregularly after
the power has been switched on.
Step E: Carry out the same procedures for all other included controllers.

2.6 Commissioning of the EPROM


When the control system is commissioned or the software is upgraded to a different
version number, the control system must be configured to fit the task. The items, which
must be configured to obtain an operational system, are, e.g. panel type, burner type,
number of burners, etc. Please note that the version number of the EPROMs in all
included controllers must be identical. Also note that each set of EPROMs should
match the panel in which the EPROMs are installed. The EPROMs are divided into
three different sets (Local, Power and EGB/EGE). In the following sections the startup procedure is described in work steps.

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2.6.1 Start-up procedure


Step A: When the electrical power to a controller is switched on, a message will be
displayed for 2-3 seconds, which indicates version number, time, and company names.
After this message the controller displays the menu item line "COPY EEPROM
[YES]". Please note that this menu only appears initially at start up if the EPROMs
have been changed or new software has been programmed onto the EPROMs.
The controller is among other things equipped with an EEPROM, which is used to
store settings that deviate from the default settings provided in the EPROMs (e.g.
settings for shut downs, alarms, start/stop set points, etc.). It is therefore important to
distinguish between commissioning of the plant and upgrade of the software.When the
control system is commissioned for the first time, "NO" should be selected because
the EEPROM does not contain any settings which deviate from the default settings. If,
on the other hand, the software is upgraded, it might be advisable to select "YES". In
this way all settings, which were set at the initial commissioning or at a later point,
will be maintained.
Step B: Press the SET soft key for a few seconds. Select "YES" or "NO" on the soft
keys / and press the set key.
Step C: If it is intended to select "YES", menu item B can be skipped by pressing
the soft key . This is because the default setting is already "YES". In this
way the controller goes directly to the next menu.
Step D: When a selection has been made in the "COPY EEPROM" menu, press the
soft key once, and the controller displays screen menu for setup of control
panel.
The displayed menu is the configuration menu where panel type, burner type, burner
family, baud rate, and communication are set. The default settings must be changed to
fit task.
Step E: With the black bar placed on "PANEL TYPE", press the SET soft key for a
few seconds. Enter the super user password and press the SET key once
more.
Step F: Select the panel type (LOCAL 1, LOCAL 2, POWER 1, POWER 2, EGE
or EGB) by means of the soft keys / and press the SET key again.
Step G: Move the black bar to the menu item line "BURNER TYPE" and press the
SET soft key for a few seconds.
Step H: Select the burner type (Aalborg KBSD, KBO-E, KBO-M, WH-RMS,
WHMSZ, Aalborg KBP, Aalborg KBE, KBO-H, Aalborg KBM, WH-LZ,
WH-RL or NOT DEF) by means of the soft keys / and press the SET
key again.
Step I: Move the black bar to the menu item line "F. O. SYSTEM" and press the
SET soft key for a few seconds.
Step J: Select the fuel oil system type (S, 0 17) by means of the soft keys /
and press the SET key again.

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Note: The menu item line SOFTWARE ID is a non-edit line configured to


display the corresponding software ID from the configuration input from
BURNER TYPE and F. O. SYSTEM. This unique software ID must
be identical to the software ID stated at the oil system PI diagram for the
actual oil system. The software ID must be stated in enquiries concerning
the software. The software ID is not to be mistaken for software version as
these are two different parameters.
Step K: Move the black bar to the menu item line "IO CFG" and press the SET soft
key for a few seconds.
Step L: Select the input/output configuration of the system (AC or ACT) by means
of the soft keys / and press the SET key again.
Step M: Move the black bar to the menu item line "BURNER FAMILY" and press
the SET soft key for a few seconds.
Step N: Select burner family "MULTI" or "ALONE" by means of the soft keys /
and press the SET key again. If the plant includes two boilers, and master/
slave operation is intended, "MULTI" must be selected.
Step O: Move the black bar to the menu item line "NODE NO.OFFSET" and press
the SET soft key for a few seconds.
Step P: Select the communication channel (1-125) by means of the soft keys //
/ and press the SET key again. The node No. offset should be selected
to the same value for all included controllers in case of a single boiler plant
or a multi boiler plant with common supply systems. For a multi boiler plant
with separate supply systems the node No. offset must be divided into
groups. This means that all included controllers for the first boiler should
have the same identical number and all included controllers for the second
boiler should have another identical number.The difference in the number
value must always be minimum 12. E.g. if the node number for the first
group of controllers is 1, then the second group of controllers must be set to
1 + 12 = 13.
Step Q: Move the black bar to the menu item line "PART NO.OFFSET" and press
the SET soft key for a few seconds.
Step R: Select the partner communication channel (1-125) by means of the soft keys
/// and press the SET key again.The "node No.offset" of the partner
boiler panels in a multi boiler plant must be entered in the menu item line.
In case of a single boiler plant it is advisable also to enter the node No. offset
in this menu item line.
Step S: Move the black bar to the menu item line "BAUD RATE" and press the SET
soft key for a few seconds.
Step T: Select the baud rate (300, 600, 1200, 2400, 4800, 9600, 19200, or 38400)
by means of the soft keys / and press the SET key again. The baud rate
should be selected to the same value for all included controllers in the plant
and as high as possible to obtain a high transmission speed.
Step U: Press the soft key once. After a few seconds the control system performs
an automatic reboot of the system. In this way the changed configuration
will be active.
2.6.2 Additional configuration
When the controller is restarted, the front menu is displayed, or if one or more shut
downs are present, the shut down list is displayed.

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By means of the arrow and SET soft keys the menu items listed in the following work
steps should be checked and/or configured. The menu tree and the explanation list
found in this manual can be used to guide the operator through the system.
When the additional checks and set-up procedures are performed the LOCAL 1 controller (LP1), and if provided, LOCAL 2 controller (LP2), must be used.
Step A: Enter the menu item line "SETUP/CTRL MODE/BURNER CTRL MODE"
by means of the soft keys and check/set that the burner is in "STOPPED"
mode.
Step B: If "MULTI" was selected in the menu item line "SETUP/CONFIG/PANEL
SYSTEM/BURNER FAMILY", enter the menu item line "SETUP/CONFIG/ BURNER SYSTEM/MASTER-SLAVE". By means of the soft keys
set the burner operation to "MASTER or SLAVE".
Step C: Enter the menu item line "SETUP/CONFIG/BURNER OPTIONS" by
means of the soft keys and choose the relevant options for the boiler plant.
The actual options included in the boiler plant appear from the flow diagrams
and technical data found in the manual.
Step D: Enter the menu item line "SETUP/TIMERS/DATE/TIME" by means of the
soft keys and set the date and time.
Step E: Enter all menu items for "REMOTE CTRL" (sub menu level 4 or 5) by
means of the soft keys and check/set that the remote control output is "0".
This concludes the initial start-up procedure when the EPROMs are commissioned or
changed.

2.7 Additional start-up procedures


In the following section the actions which must be carried out before the boiler plant
is fully operational are briefly described.
2.7.1 Continue with the commissioning process
Before proceeding with the actual commissioning, the instructions for the boiler, burner, and control system should be studied. The instructions must only be considered as
guidelines. This is due to the fact that each plant should be commissioned individually
to obtain the best burner performance for the specific plant. It is therefore difficult to
give an exact commissioning procedure to follow.
Prior to and during the commissioning of the boiler plant a number of settings, timers,
parameters, etc. should be checked and adjusted to optimise the function of the plant.
Adjustments should be carried out as the optimisation requirements emerge.
By means of the menu tree, the explanation list, sequence diagram, instructions, etc.
the commissioning engineer can be guided through the system.
2.7.2 Continue after exchange of EPROMs
All vital parameters and settings should be checked prior to start-up of the boiler plant.
A new version of the software might contain new or moved menu items, which should
be checked and/or set before start-up.

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2.8 Commissioning of the EEPROM


The EEPROM does not require any commissioning work because all settings, configurations, etc. are automatically stored in the EEPROM. But in plants which include
two identical boilers the commissioning work can be facilitated by copying the contents
of an EEPROM to another. The plants in question are, e.g. two Aalborg OS boilers
with two stage pressure atomizing burners.
Before the copy procedure is possible, a number of conditions must be fulfilled:

The boilers, burners, water level control equipment, etc. must be completely identical.
One of the boilers should be fully commissioned with regard to parameters, settings, values, etc.
The serial numbers must be different.
If these requirements are fulfilled, the contents of an EEPROM can be copied as described in the following work procedures:
Step A: Switch off the power supply to the controller on the commissioned boiler.
Step B: Remove the EEPROM. See section 3.2 for instruction regarding insertion
and removal of an EPROM.
Step C: Switch off the power supply to the controller on the boiler, which should be
commissioned, and remove the EEPROM.
Step D: Insert the EEPROM from the non-commissioned boiler into the controller
of the commissioned boiler and switch on the power supply.
Step E: If the menu item line "COPY EEPROM [YES]" appears in the display, press
the SET soft key for a few seconds. Select "NO" on the soft keys /, press
the SET key and the soft key. In this way the commissioning data, which
are saved in the RAM store circuit of the controller, will automatically be
copied into the EEPROM.
Step F: Switch off the power supply again and remove the EEPROM from the commissioned boiler.
Step G: Insert the original EEPROM into the controller, which was commissioned
first, and switch on the power supply.
Step H: Insert the "copied" EEPROM into the controller of the non-commissioned
boiler and switch on the power supply.
Step I: When the menu item line "COPY EEPROM [YES]" appears in the display,
press the soft key. The controller will then automatically reboot and the
data of the EEPROM will be copied into the RAM store circuit of the controller.
Step J: If the boilers are operating as master/slave boilers, the local panels must be
set as "LOCAL 1" and "LOCAL 2" respectively. Select ""SETUP/CONFIG/
PANEL SYSTEM/PANEL TYPE", press SET for a few seconds, choose
panel type by the soft keys /, then press the soft key. The control
system automatically performs a restart of the system.
In this way the EEPROM of the non-commissioned boiler will now contain the same
data as the EEPROM of the commissioned boiler. Please note that during the actual
commissioning of this boiler it might be necessary to readjust a number of settings,
timers, parameters, etc. to optimise the function of the boiler.

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Note: The copying process should not be performed between a local controller
and a common controller. If this is done, e.g. copying the contents of an
EEPROM from a local controller to the EEPROM from a common controller, the common controller will be configured as a local controller.

Servicing of the panels


The following instruction describes the work procedures which should be carried out
in case some of the main parts of the controller are defective and must be replaced. It
is recommended that Alfa Laval is contacted before changing any of these parts.
Replacement of parts must be performed with the power supply to the controller
switched off. Please remember that outside control voltage may be connected. Furthermore, precaution must be taken to avoid an unintentional start of the boiler plant
during servicing of the controllers.

3.1 General service notes


The general service notes describe the general initiatives which must be performed
whenever parts of the controller are serviced or replaced.
In the following sections references to section 3.1 are made. Each time such a reference
appears, the service engineer should consult the section for further information.
Step A: Switch off the power supply to the controller.
Note: When replacing the battery the power supply to the controller should remain switched on, if possible.
Step B: Open the door and remove the transparent plate, which covers the printed
boards.
Step C: Carry out the necessary work procedures as described in the following sections.
Step D: Mount the transparent plate and door again.
Step E: Switch on the power supply to the controller.
Caution: Electronic parts can be damaged by static electricity. To avoid this,
damage precautions must be taken to discharge the static electricity
without the current passing through the electronic parts. E.g. touch
physically the part, upon which the electronic part is placed, both before
and while removing it. And touch physically the metal of the controller
cabinet, in which the electronic part should be positioned both before
and while fitting it. Naturally, the same hand must be used that holds
(or is going to hold) the electronic part.

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3.2 Replacing an EPROM


The EPROM is a programmable module, placed in a socket on the CPU print, which
contains software for the control system. When the software is upgraded (or commissioned) to a different version number, the control system must be configured to fit the
task. The configuration process includes setting of panel type, burner type, etc. If, on
the other hand, the EPROMs are exchanged to EPROMs with the same version number,
the reconfiguration procedure should not be performed. This also applies if one or both
EPROMs for some reason have been removed from the socket holder for a period of
time.
When the EPROM is replaced, the following work procedures must be carried out:
Step A: Before the power supply is switched off, note all settings. Even though the
EEPROM store all settings that deviate from the default settings provided
in the EPROMs, it is advisable to carry out this initiative. This is due to the
fact that if an irreversible error occurs during the replacement, the data will
still be available.
Step B: See section 3.1 for disassembling instructions.
Step C: Remove the EPROM from the socket on the CPU print. The position can be
seen in Figure 2.
Note: It is of great importance that the EPROM is handled with extreme care
because it is a sophisticated electronic device. An EPROM must always be
carefully manoeuvred in and out of the socket holder due to the risk of
bending the pins on the EPROM.
Step D: Check the version number on the new EPROM. The version number appears
from the white label on the surface of the EPROM. Please note that the
version number of the EPROM must be identical in all included controllers.
Step E: Insert the new EPROM in the appertaining socket (socket U17 or U18 dependent of software package programmed onto EPROM) by using the fingers. Take care that all pins on the EPROM are fitted into the socket. One
of the EPROM ends is provided with a notch. When the EPROM is inserted
in the socket holder, this notch must be in the same direction as the notch
indicated on the protection plate. Please see Figure 2. If the EPROM is inserted in the reversed direction, the display flashes when the power supply
is switched on again.
Step F: See section 3.1 for assembling instructions.
Step G: Carry out the work procedures described in section 2.6 if a re-configuration
of the control system is necessary (if the software is upgraded to a different
version number).

3.3 Replacing the EEPROM


The EEPROM is a programmable module, placed in a socket on the CPU print, in
which the settings are stored that deviate from the default settings provided in the
EPROM (e.g. settings for shut downs, alarms, start/stop set points, etc.).

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The panels should always be operated with the EEPROM inserted. But operation is
possible without the EEPROM inserted, and settings, configuration, etc. can be
changed and remembered even if the power supply is switched off. The data are also
stored in the RAM store circuit, which is supplied with power from the battery. When
the EEPROM is inserted in the CPU print again, these changes will automatically be
stored in the EEPROM.
If the EPROMs are replaced, e.g. due to upgrading of the software, and the EEPROM
is removed, all settings set during commissioning or at a later point will be lost.
When the EEPROM is replaced, the following work procedures must be followed:
Step A: Before the power supply is switched off, note all settings. If an irreversible
error occurs during the replacement, the data will still be available.
Step B: See section 3.1 for disassembling instructions.
Step C: Remove the EEPROM from the socket on the CPU print. The position can
be seen in Figure 2. When the EEPROM is replaced, the same precautions
must be taken with regard to removal and insertion as during the replacement
of an EPROM, see section 3.2.
Step D: Insert the new EEPROM in the socket by using the fingers. Take care that
all pins on the EEPROM are fitted into the socket and that the direction is
correct.
Step E: See section 3.1 for assembling instructions.
The control system is now in normal operation, and no further initiatives are necessary.
The current settings, configuration, etc. are automatically transferred and stored into
the new empty EEPROM. This also applies when changes have been made after the
old EEPROM became defective or was removed.

3.4 Replacing the CPU


If the CPU is defect or removed, the display will be out, and several of the relays switch
continuously. The following work procedures should be performed when the CPU is
replaced:
Step A: See section 3.1 for disassembling instructions.
Step B: Remove the CPU from the socket on the CPU print. The position can be
seen in Figure 2. When the CPU is replaced, the same precautions must be
taken with regard to removal and insertion as during the replacement of an
EPROM, see section 3.2.
Step C: Insert the new CPU in the socket by using the fingers. Take care that all pins
on the CPU are fitted into the socket and that the direction is correct.
Step D: See section 3.1 for assembling instructions.

3.5 Replacing the CPU print


If the CPU print, which holds the EPROMs, EEPROM, and CPU (see Figure 2), must
be replaced, the following work procedures should be carried out:
Step A: Before the power supply is switched off, note all settings. If an irreversible
error occurs during the replacement, the data will still be available.
Step B: See section 3.1 for disassembling instructions.

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Step C: Remove the screws by which the CPU print is fixed.


Step D: Carefully pull out the CPU print. It should be pulled out at the side in which
the connecting plugs are positioned. This is the side opposite the position of
the EPROMs.
Step E: Remove the EPROMs and EEPROM from the CPU print. Please see sections
3.2 and 3.3 for instructions regarding removal and insertion of respectively,
EPROMs and EEPROM.
Step F: Insert the EPROMs and EEPROM in the new CPU print by using the fingers.
Take care that all pins on the EPROMs and EEPROM are fitted into the
sockets and that the directions are correct.
Step G: Insert the new CPU print into the socket connections on the DI relay print
and fix it with the screws.
Step H: See section 3.1 for assembling instructions.
Step I: When the menu item line "COPY EEPROM [YES]" appears in the display,
press the soft key a few times. The controller automatically reboots and
the data of the EEPROM will be copied into the RAM store circuit of the
local panel.
If "NO" is selected in the menu item "COPY EEPROM", the system must be re-configured once again. This is also the case if a new EEPROM is inserted in connection
with the replacement of a CPU print.

3.6 Replacing the DI relay print


If the DI relay print must be replaced, the following work procedures should be carried
out:
Step A: Before the power supply is switched off, note all settings. If an irreversible
error occurs during the replacement, the data will still be available.
Step B: See section 3.1 for disassembling instructions.
Step C: Remove the CPU print, see section 3.5 for disassembling instructions.
Step D: Remove the screws by which the DI relay print is fixed.
Step E: Carefully pull out the DI relay print. It should be pulled out at the side in
which the connecting plugs are positioned.
Step F: Insert the new DI relay print into the socket connections on the relay print
and fix it with the screws.
Step G: Insert the CPU print into the socket connections on the DI relay print and
fix it with the screws.
Step H: See section 3.1 for assembling instructions.
Step I: When the menu item line "COPY EEPROM [YES]" appears in the display,
press the soft key a few times and the data of the EEPROM will be copied
into the RAM store circuit of the local panel.
If "NO" is selected in the menu item "COPY EEPROM", the system must be re-configured once again. This is also the case if a new EEPROM is inserted in connection
with the replacement of a CPU print.

3.7 Replacing the relay print


When the relay print must be replaced, the following work procedures should be followed:

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Step A: Before the power supply is switched off, note all settings. If an irreversible
error occurs during the replacement, the data will still be available.
Step B: See section 3.1 for disassembling instructions.
Step C: Mark all connected wires and disconnect these from the terminal rows of
the relay print. The position of the terminal rows, relay print, etc. can be seen
in Figure 2.
Warning: Some of the wires may still be live, and precautions must be taken to
secure personal safety.
Step D: Remove the screws that fix the print and tilt the print out of the plastic holders
positioned below the terminal row.
Step E: Pull the print off the guide opposite the terminal row and out of the cabinet.
Step F: Move the CPU print with the EPROMs and EEPROM onto the new relay
print, see section 3.5.
Step G: Insert the new relay print into the guide and click it into position at the plastic
holders. Fix the relay print by means of the screws.
Step H: Connect all the marked wires to the terminal rows in the correct order.
Step I: See section 3.1 for assembling instructions.
If the menu item line "COPY EEPROM [YES]" appears in the display when the control
system is restarted, perform the same work procedures as described in section 3.5.

3.8 Replacing an exchangeable relay


The digital output DRL1 to DRL4 are equipped with exchangeable relays. This is
because the actions that are controlled by these output signals cause an increased number of relay changes which increases the risk of wearing down these relays.
The following work procedures should be performed when an exchangeable relay is
replaced:
Step A: See section 3.1 for disassembling instructions.
Step B: Push the black plastic clamp, which holds the relay to the side.
Step C: Pull up the relay and replace it. The relay must be inserted correctly, see the
connections on the relay bottom plate and the legs on the relay. Be careful
not to bend the legs on the relay.
Step D: Push back the clamp over the relay.
Step E: See section 3.1 for assembling instructions.

3.9 Replacing the display


If the display must be replaced, the following work procedures should be carried out:
Step A: See section 3.1 for disassembling instructions.
Step B: Disconnect the connection plug for the display on the connection socket of
the relay print. The position can be seen in Figure 2.
Step C: Unscrew the two nuts that fix the top display print and carefully pull it out.
The two power supply wires to the bottom display print should also be disconnected.

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Step D: Unscrew the four nuts that fix the display protection plate and bottom display
print, which includes the display.
Step E: Replace the defective part (top display print, bottom display print, or both).
Step F: Assemble the bottom display print, display protection plate, and top display
print by means of the nuts and distance pieces. When assembled, the nuts
must not be fastened too mush or else several horizontal lines may appear
in the display.
Step G: Connect the two power supply wires between the prints and the connection
plug for the display into the connection socket of the relay print.
Step H: See section 3.1 for assembling instructions.

3.10 Replacing the soft keys


If the soft keys must be replaced, the following work procedures should be followed:
Step A: See section 3.1 for disassembling instructions.
Step B: Disconnect the connection plug for the soft keys on the connection socket
of the relay print. The position can be seen in Figure 2.
Step C: Carefully remove the plastic cover that covers the soft key section.
Step D: Replace the soft key section.
Step E: Carefully mount the plastic cover again using silicone for sealing.
Step F: See section 3.1 for assembling instructions.

3.11 Replacing the door on power panels


If the door of a power panel must be replaced, the following work procedures should
be performed:
Step A: See section 3.1 for disassembling instructions.
Step B: Disconnect the two connection plugs for the display and soft keys on the
connection sockets of the relay print. The positions can be seen in Figure 2.
Step C: Remove the two fuse straps as well as the earth connections and remove the
defective door.
Step D: Mount the two fuse straps and connect the earth connections between the
door and the panel cabinet.
Step E: Connect the connection plugs for the display and soft keys on the new door
to the connection sockets on the relay print.
Step F: See section 3.1 for assembling instructions.

3.12 Replacing the circuit fuse


If the circuit fuse needs to be replaced, the four line crystal display will be off. A new
circuit fuse with the specifications 3.15T/250 V, 5 x 20 glass should be inserted.
The following work procedures should be carried out when the circuit fuse is replaced:
Step A: See section 3.1 for disassembling instructions.
Step B: Screw out the top of the fuse holder and replace the circuit fuse. The location
of the circuit fuse can be seen in Figure 2.
Step C: Screw in the top of the fuse holder with the circuit fuse.

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Step D: See section 3.1 for assembling instructions.

3.13 Replacing the battery


The battery is primarily used to ensure that the internal watch runs accurately after
power cut. This is done by supplying the RAM-stores during power cuts.
The battery is of the Lithium type (size AA) and has an expected life up to five years,
depending on the actual conditions such as humidity, ambient temperature, etc. Please
note that it is not recharged by the electronic circuit in the controller.
If the menu item line "COPY EEPROM [YES]" appears in the display after power cut,
the battery should most likely be replaced.
The following work procedures should be followed when the battery is replaced:
Step A: See section 3.1 for disassembling instructions.
Step B: Cut off the cable binders, which hold the battery. The location of the battery
can be seen in Figure 2.
Step C: Disconnect the battery wires and replace the battery.
Note: Disposal of the old battery should be in accordance with the environmental
rules in force.
Step D: Use two new cable binders to fix the new battery in its correct place.
Step E: See section 3.1 for assembling instructions.
Step F: If the menu item line "COPY EEPROM [YES]" appears in the display, press
the soft key a few times and the data of the EEPROM will be copied into
the RAM store circuit of the controller.
The controller is now ready for normal operation. If a new battery is not available,
"YES" must be selected in the menu item line "COPY EEPROM" every time the panel
is started.

3.14 Replacing the data communication cable


If the communication cable is damaged, it must be replaced. The installation and commissioning work should be performed as described in section 2.4. When the cable is
replaced at one of the controllers, the screen must be connected correctly in the screwed
joint as shown in Figure 3.
The new cable must be of the same type as the original cable delivered by Alfa Laval
and as a minimum have the following data:

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Cable type: 2-conductor data cable with screening


Loop resistance: 74 /min.
Insulation resistance, minimum: 100 M-km
Pair capacity: 85 pF/m

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Finishing of the cable screening in a screwed joint


1.

2.

3.

4.

Panel cabinet

5.

Figure 3

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MONITORING AND CONTROL VIA TOUCH SCREEN

Monitoring and control via touch screen


1

General
This section describes the mimic pictures, dialog boxes, lists, etc. for a standard monitoring and control system. In the example pictures is shown a generic boiler with a
Aalborg KBP, Aalborg KBO-E, Aalborg KBM burner and an Aalborg exhaust gas
boiler (EGB). The illustrations and descriptions do not show the complete touch screen
system, but gives an insight into the system concept. Notice also that the pictures show
a maximum configuration, meaning that e.g. inert gas is shown. On the real system
this will not be present if the system is not configured for inert gas.
The touch screen is connected to the boiler control panels via a RS485 communication
network. By means of this connection the touch screen monitoring and control system
can receive, handle, and transmit data to and from the control panels. This enables
control of the boiler plant from the touch screen. The mimic pictures and lists are used
to monitor the boiler plant and the dialog windows are used to control and operate the
boiler plant.
Notice that it is still necessary to configure the basic settings such as burner type on
the local controller.

Operation of the touch screen system


When the touch screen is switched on, it will automatically start the monitoring and
control program after a short initialisation period. Figure 1 illustrates the start-up mimic
picture.
From the main picture, it is possible to acknowledge alarms and to access the different
subsystems of the plant such as: steam- (and exhaust gas boiler), water-, fuel-, boiler-,
and burner system. From the main window trend curves for the performance of the
plant can be viewed and the set-up menu can be accessed. Key access can be retrieved
from both the key access menu in the main picture and from relevant subsystem pictures. A detailed description of the different menus is given in the following. The
subsystem pictures steam, water, fuel, burner and boiler as well as the main- and alarm
pictures are all accessible from each subsystem picture.

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Start-up picture on the touch screen

Figure 1

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The key in the upper left corner shows that the system is unlocked allowing parameter
changes from the touch screen.How to retrieve and release the key lock can be seen in
the document Key Operation Lock.

2.1 Contact information


From the main picture access is given to contact information on Aalborg Industries
A/S by clicking the logo as illustrated in Figure 2.
Access to contact information

Figure 2

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Contact information picture

Figure 3

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From the picture containing contact information access is given to the main menu by
clicking the arrow in the lower left corner (Figure 3).

2.2 Alarm / Shutdown menu


The [ALARM] button, illustrated in Figure 4, is placed in the upper right corner of the
screen. The button is displayed in all menus and submenus to ensure full access to
acknowledge and reset of alarms and shutdowns independent of which picture is
present on the screen. Return to the previous picture can be done by pressing the
[BACK] button in the lower left corner.

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Alarm button

Figure 4

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The [ALARM] button gives access to the alarm / shutdown list as illustrated Figure 5.
Alarm / Shutdown list

Figure 5

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The alarm / shutdown list functions are operated by use of six operation buttons as
illustrated in Figure 6.
Operation buttons

Figure 6

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Division between display of alarms, shutdowns, or both can be made at the selection
buttons located in the bottom of the alarm / shutdown list as illustrated in Figure 7.
Selection buttons

Figure 7

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The display of alarms and shutdowns is divided in four categories as illustrated Figure 8 and Figure 9.

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Active Unacknowledged
State
An alarm / shutdown have become active and the cause of the alarm / shutdown is still
present.
The alarm / shutdown have not been acknowledged by the [RESET] button illustrated
in Figure 6.
Display
A shutdown will appear on the display as black text on red background.
An alarm will appear on the display as black text on yellow background.
Both shutdowns and alarms will be marked with an asterisk in the upper left corner.
Note: Acknowledge of an alarm or a shutdown from the local Aalborg Control
panel will not change the appearance of alarms and shutdowns in this category.
Active Acknowledged
State
An alarm / shutdown have become active and the cause of the alarm / shutdown is still
present.
The alarm / shutdown have been acknowledged by the [RESET] button illustrated in
Figure 6.
Display
A shutdown will appear on the display as white text on red background.
An alarm will appear on the display as red text on yellow background.
Both shutdowns and alarms will be marked with a hyphen in the left corner.
Note: Acknowledge of an alarm or a shutdown from the local Aalborg Control
panel will not change the appearance of alarms and shutdowns in this category.
Inactive Unacknowledged
State
An alarm / shutdown have become inactive and the cause of the alarm / shutdown is
no longer present.
The alarm / shutdown have not been acknowledged by the [RESET] button illustrated
in Figure 6.
Display
A shutdown will appear on the display as black text on red background.
An alarm will appear on the display as black text on yellow background.

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Both shutdowns and alarms will be marked with an asterisk in the upper left corner.
Note: Acknowledge of an alarm or a shutdown from the local Aalborg Control
panel will change the appearance of alarms and shutdowns in this category
to black text on white background. Both shutdowns and alarms will be
marked with a dollar sign in the left corner.
Inactive - Acknowledged
State
An alarm / shutdown have become inactive and the cause of the alarm / shutdown is
no longer present.
The alarm / shutdown have been acknowledged by the [RESET] button illustrated in
Figure 6.
Display
A shutdown will appear on the display as light-grey text on white background.
An alarm will appear on the display as light-grey text on white background.
Neither shutdowns nor alarms will be marked with a symbol in the left corner.
Note: Note: Acknowledge of an alarm or a shutdown from the local Aalborg
Control panel will not change the appearance of alarms and shutdowns in
this category.
Colour graduation

Figure 8

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Symbol graduation

Figure 9

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Selection on the [TIMESTAMP] button illustrated in Figure 6 will divide display of


the alarms / shutdowns in three categories besides the default display in Figure 8:
S
Displays date and time for when the alarm / shutdown was activated as illustrated in
Figure 10.
The time the alarm / shutdown was first activated is shown for repeated alarms / shutdowns.
Activated alarms / shutdowns

Figure 10

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A
Displays date and time for when the alarm / shutdown was acknowledged as illustrated
in Figure 11. No date and time stamp will be shown if the alarm / shutdown have not
been acknowledged by the [RESET] button illustrated in Figure 6.

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Note: Acknowledge of an alarm or a shutdown from the local Aalborg Control


panel will not supply the alarm / shutdown with a date and time stamp in
the alarm / shutdown list.
Acknowledged alarms / shutdowns

Figure 11

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E
Displays date and time for when the alarm / shutdown was inactivated as illustrated in
Figure 12. The time the alarm / shutdown was last inactive is shown for repeated
alarms / shutdowns. No date and time stamp will be shown if the alarm / shutdown is
still active and the cause of the alarm / shutdown is still present.
Inactivated alarms / shutdowns

Figure 12

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2.3 Steam system menu


The steam system menu gives access to an overview of the steam system including
steam dump and inert gas status, parameters and exhaust gas boiler menu if such is
part of the system. The structure of the steam menu is illustrated in Figure 13.
Menu structure for the steam menu

Figure 13

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The steam system menu is entered from the main menu by clicking the [STEAM]
button (Figure 14).
Steam system menu

Figure 14

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The steam menu overview picture supplies an overview of the steam circuit as illustrated in (Figure 15).

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Steam system overview

Figure 15

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In the steam overview picture, the actual values for boiler pressure, water level, and
burner load can be seen as well as the state of the steam dump valve and inert gas.
Parameters for the steam system are set under the [PARAM] button in the lower right
corner. In the middle left of the dialog picture access to the exhaust gas boiler picture
through the [EGB] button can be done provided that the system is configured with an
EGB.
2.3.1 Parameters for the steam menu
From the steam menu there is access to the parameters submenu by clicking the [PARAM] button in the lower right corner of the steam menu (see Figure 16).

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Entering parameter sub menu for the steam menu

Figure 16

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In the parameter sub menu illustrated in Figure 17, an overview of the steam dump
parameters is displayed.
Set point
The set point for which boiler steam pressure the steam dump valve regulates to achieve. E.g. if the boiler steam pressure exceeds the stated set point, the steam dump
valve will open according to the regulator parameters stated in Figure 18 in order to
maintain the boiler steam pressure set point.
The boiler steam pressure set point can be adjusted by pressing the dark-grey display
field. Password may be prompted.
Process value
The current boiler steam pressure.
Valve control mode
The steam dump valve is intended to operate automatically according to the set point
and the current boiler steam pressure. However, the steam dump valve can also be
operated manually if necessary. By pressing the dark-grey display field, the steam
dump valve control mode can be changed between Auto and Manual. Password may
be prompted.
Caution: Maintaining the steam dump valve in Manual mode will inhibit the
control system to automatically control the boiler steam pressure when
e.g. supplying inert gas, if the plant is configured with this feature. This
may result in a burner shutdown due to high steam pressure. Operating
the steam dump valve in Manual mode must always be attended to with
utmost attention.

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Regulator output
The regulator output displays the steam dump valve regulator output supplied by the
control system. The regulator output will increase/decrease in order to maintain the set
point stated above. If the steam dump valve is operated in Manual mode, regulation
+/- can be done by pressing the up/down arrows located directly below the regulator
output menu line.
Parameter sub menu under the steam menu

Figure 17

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Regulator parameters
The regulator sub menu illustrated in Figure 18 provides access to monitoring and
changing of the regulation parameters: sampling time, proportional gain, integral time,
and the derivative time. From this sub menu it is possible to return to the parameter
submenu (Arrow) or the main menu.

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Regulator parameteres under the steam dump sub menu

Figure 18

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Inert gas sub menu


From the parameters sub menu there is access to the inert gas menu by pressing the
button [Inert gas] (Figure 19).
Parameters submenu under the steam menu

Figure 19

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In the inert gas menu illustrated in Figure 20, an overview of the inert gas parameters
is displayed. Please note that this menu will only appear if the plant is configured with
this feature.

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Load
Displays the minimum burner load for operation in inert gas mode. If changed to a
different value during operation the burner load will be adjusted to the new set point.
When the boiler operates as master/slave/alone and inert gas mode is selected (internal
or external) the burner will be forced to start, if not already started. The burner load
will ramp up to minimum inert gas load. If the steam pressure in the common line drops
below the set point the burner load follows the common steam pressure regulator.
However, if the common steam pressure regulator sets the load below the minimum
inert gas load, the burner load is kept on minimum inert gas load. Note that if the master
boiler starts the slave boiler and inert gas mode is not selected for the slave boiler, the
minimum load for this boiler will be minimum inert gas load provided this set point is
higher than the normal set point for stop. In inert gas mode the normal set point for
stop is inactive and the burner is only stopped by an off signal for inert gas mode or a
high steam pressure shutdown. The minimum burner load can be changed by pressing
the dark-grey display field.
Password may be prompted.
Forced load
Forces the boiler "ON" or "OFF" in inert gas mode from the local control panel. Note
that the external inert gas on/off function (switch) overrides the forced function. The
forced load can be changed ON/OFF by pressing the dark-grey display field. Password
may be prompted.
Inert gas menu

Figure 20

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From the Inert gas menu there is access to the main menu, the steam dump parameters
using the [steam dump] button, and the steam menu, when pressing the arrow in the
lower left corner.

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2.3.2 Exhaust gas boiler picture


If the boiler system is configured with both an oil fired boiler and an exhaust gas boiler,
the steam overview picture will also show an EGE or EGB button depending on which
type of exhaust gas boiler is configured.
Exhaust gas boiler

Figure 21

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Pressing the button brings the user to the exhaust gas menu (see Figure 22).
Exhaust gas boiler menu

Figure 22

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In Figure 22 one feed water pump is stopped and one is running. Manual control of the
pumps can be done by pressing the pump icon. Notice the * besides the pump.* marks
that the icon (pump) is a button. The different icons for feed water pumps and circulation pumps, respectively, mark the state and mode of the pump. Water supply pumps
for an oil fired boiler and an EGB, respectively, are referred to as Feed Water Pumps.
Water supply pumps for an EGE are referred to as Circulation Pumps.
For feed water pumps supplying either an oil fired boiler or an EGB, following feed
water pump icons illustrated in Figure 23 can be displayed. The pumps are described
according to their number on the illustration.
Pump #1: The pump is in AUTO mode and the pump state is AUTO-RUNNING.
Pump #2: The pump is in AUTO mode and the pump state is AUTO-STOPPED.
Pump #3: The pump is in STANDBY mode and the pump state is STOPPED.
Pump #4: The pump is in START mode and the pump state is RUNNING.
Pump #5: The pump is in STOP mode and the pump state is STOPPED.
Feed water pump mode/state

Figure 23

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For circulation pumps supplying an EGE, following circulation pump icons illustrated
in Figure 24 can be displayed. The pumps are described according to their number on
the illustration.
Pump #1: The pump is in START mode and the pump state is RUNNING.
Pump #2: The pump is in STOP mode and the pump state is STOPPED.
Pump #3: The pump is in STANDBY mode and the pump state is STOPPED.

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Circulation pump mode/state

Figure 24

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2.3.3 Circulation/EGB feed water pumps


In the following, water pumps will just be referred to as EGB feed water pumps.
Changing the state of these pumps is done by pressing the pump icon button (Figure 25).
Accessing EGB feed water pumps sub menu

Figure 25

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The dialog window for the feed water pump is illustrated in Figure 26. In this dialog
box, the mode of the pump (stop, start, standby and auto) can be set by pressing the
buttons. The status of the pump is also displayed in the dialog window. If any alarms
concerning the feed water pump were present, they would be marked in the Alarms
section of the window. It will be marked if the alarm is due to no feedback or overload
(Circulation pumps also have a low flow alarm).
Please note that the auto mode is only shown if the feed water pumps are configured
with on/off control. The feed water regulating valve will only be shown if the feed
water pumps are configured with modulating control.

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EGB Feed Water pump

Figure 26

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From the pump dialog picture, it is possible to navigate back to the exhaust gas boiler
picture by pressing the arrow icon in the lower left corner, to the main menu by pressing
the [MAIN] button in the upper left corner or to go to the next pump on the exhaust
gas boiler (if available) by pressing the arrow icon in the lower right corner of the
picture.
The EGB feed water pump(s) will stop if high salinity and/or high oil content is detected
in the feed water. The pumps cannot be started remote, but it is possible to start from
HMI.
Note: Alarm(s) will appear if pumps are stopped due to salinity and/or oil. Pumps
must be manual started again when salinity and/or oil is no longer detected
in the feed water.
2.3.4 Chemical dosing pump(s)
Depending on the boiler configuration, chemical dosing pumps will be available from
the EGB overview and the Steam and Water overview, respectively. If the boiler is
configured with an EGE a chemical dosing pump will not be displayed at the EGE
overview. Changing the state of the pump(s) is done by pressing the pump icon as
illustrated in Figure 27.
The dialog window for the chemical dosing pumps is illustrated in Figure 28. In this
dialog box, the mode of the pump AUTO/OFF can be set by pressing the buttons. The
status of the pump is also displayed in the dialog window.

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AUTO mode
The chemical dosing pump is automatically activated or deactivated by the control
system. The pump will be deactivated if no feed water pumps are running or if the feed
water valve is closed. The chemical dosing pump will automatically activate again
when one of above stated conditions are present.
OFF mode
The chemical dosing pump is deactivated.
State
Displays if the chemical dosing pump is Running or Stopped. Most chemical dosing
pumps are piston pumps which are configured to operate only in intervals. As a consequence by this the pump state will display Running when the pump is in Auto mode
regardless of whether the pump is actually operating.
The chemical dosing pump start/stop cycle in correlation with feed water pumps or a
feed water valve is furthermore regulated by a timer and assigned set points which are
set during commissioning of the boiler plant.
Accessing chemical dosing pump(s) sub menu

Figure 27

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Dialog window for Chemical dosing pump(s)

Figure 28

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2.4 Water Menu


The water menu gives access to an overview of the feed water system and to change
the parameters of the system. The structure of the feed water menu is illustrated in
Figure 29.
Menu structure for the water menu

Figure 29

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The water menu is entered from the main menu (Figure 30) or from any of the other
overview pictures.

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Water menu access

Figure 30

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The mimic picture of the water menu gives an overview of the feed water system
(Figure 31).
Please note that the feed water regulating valve will only be shown if the feed water
pumps are configured with modulating control.
Feed water system overview

Figure 31

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At the feed water overview, the steam pressure, water level and the burner load of the
system can be monitored. Furthermore, the status of the feed water valve is seen as a
percentage of open, in this example (Figure 31) the valve is closed. Please note that
some menu buttons may vary dependent on the boiler system configuration.
A measurement of the salinity is also visible (if the boiler system is configured with
this service) as well as it is possible to see if the feed water pumps are running or
stopped. In Figure 31 the two feed water pumps from the hotwell are Running and
Stopped, respectively. The chemical dosing pump is stopped.
From the feed water menu the different pumps can be monitored and controlled by
pressing the pump icons. Parameters for the feed water system can be set under the
[PARAM] button in the lower right corner.
2.4.1 Feed water pump
Control and monitoring of the feed water pumps can be done by pressing the pump
icon as illustrated in Figure 32.
Accessing feed water pump(s) sub menu

Figure 32

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The dialog window for the feed water pump is illustrated in Figure 33. Please note that
the auto mode is only shown if the feed water pumps are configured with on/off control.

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Dialog window for feed water pump(s)

Figure 33

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Accessing chemical dosing pump(s), as illustrated in Figure 32, is done with same
procedure as described in Section 2.3.4.
As seen in the figure the pump control resembles the control described in Section 2.3.3.
From the dialog window of a water pump there is access to the overview of the feed
water system by pressing the button in the lower left corner.
The feed water pump(s) will stop if high salinity and/or high oil content is detected in
the feed water. The pumps cannot be started remote, but it is possible to start from
HMI.
Note: Alarm(s) will appear if pumps are stopped due to salinity and/or oil. Pumps
must be manual started again when salinity and/or oil is no longer detected
in the feed water.
2.4.2 Parameters
The feed water parameter submenu supplies an overview over all parameters and alarm/
shutdown limits concerning the feed water system. The submenu is entered as illustrated in Figure 34.

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Access to the parameter submenu

Figure 34

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Salinity limits
The shutdown limits and the alarm limits for salinity, (if the boiler system is configured
with salinity surveillance), can be monitored and changed from the Salinity limits
button on the left side of the picture as illustrated in Figure 35. The grey shade of the
parameter boxes indicates that the values can be changed by pressing the icons.
The salinity alarm and shutdown limits shown in figure 35 are for the analogue measuring from salinity equipment. The salinity equipment also has digital input on the
Aalborg controller, and this is used to activate the stop function of feedwater pumps
if the boiler system are configured with feed water pump(s) stop, due to salinity (and/
or oil content)

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Salinity limits

Figure 35

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Water level regulation


Access to the regulation and monitoring of the water level is done by pressing the
button on the left side of the picture (Figure 36).
Please note that this submenu will appear with different screen interface dependent on
feed water pump configuration.
Access to water level regulation

Figure 36

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The water level regulation and monitoring is handled in the mimic picture illustrated
in Figure 37. In the upper part of the level regulation dialog window the actual values
are monitored, i.e. the actual set point, the actual value, and the regulator output. The
set point and the process value are measured in mm from normal water level, where a
minus indicates that the water level is below normal water level, and no sign in front
of the figure means above normal water level. The lower part of the dialog window is
for changing the values of the set points and the normal/standby limits.
Water level regulation dialog window

Figure 37

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From the water level regulation dialog window, there is access to the salinity limits,
(if the boiler system is configured with this service), the ON/OFF regulation menu as
well as return to the overview of the feed water system (the button in the lower left of
Figure 37).
Feed water ON/OFF regulation
The last menu point in the feed water menu is the feed water ON/OFF regulation menu.
Please note that this submenu will only appear if the feed water pumps are configured
with the ON/OFF feature.
The menu can be accessed by the FW reg. ON/OFF button illustrated in Figure 38.

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Access to feed water ON/OFF regulation

Figure 38

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The menu shows the status of the pumps when running an ON/OFF feed water regulation as illustrated in Figure 39.
Feed water ON/OFF regulation dialog window

Figure 39

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From the feed water ON/OFF regulation dialog window there is access to the Salinity
limits, (if the boiler system is configured with this service), and the Level regulation
menu as well as return to the overview of the feed water system (the button in the lower
left of Figure 39).

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2.5 Fuel menu


From the fuel menu an overview of the oil system and control of the oil pumps in the
system is provided. The structure of the fuel menu is illustrated in Figure 40. Please
note that the menu structure will vary dependent on the oil system configuration.
Menu structure for the fuel menu

Figure 40

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The fuel menu is entered from the main menu as illustrated in Figure 41 or any of the
other system menus.
Access to the fuel menu

Figure 41

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The oil system dialog picture, illustrated in Figure 42, represents an overview of the
oil system. Please note that the oil system illustration will vary dependent on the oil
system configuration.

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Fuel overview

Figure 42

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From the fuel overview monitoring and administration of oil pumps, oil ring line and
parameters can be performed. Furthermore, oil temperature and oil pressure can be
monitored, dependent of oil system configuration.
For some oil systems configured with fuel oil steam preheater, the icon for the preheater
will be placed at the fuel overview dialog picture for correspondence with the actual
burner design. A three-way valve will indicate whether or not the steam preheater is
active.
2.5.1 Fuel oil pumps / Gas oil pumps
The following instructions are based upon the fuel oil pumps but apply to the gas oil
pumps as well as the dialog pictures and menus are identical.
From the Fuel overview, access is given to the fuel oil pumps by pressing the pump
icon as illustrated in Figure 43.

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Access to fuel oil pump

Figure 43

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As seen in Figure 44 the pump control resembles the control described in Section 2.3.3.
Fuel oil pump dialog window

Figure 44

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From the fuel oil pump dialog picture return to the overview of the fuel oil system can
be made by pressing the button in the lower left corner. By pressing the arrow in the

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lower right corner the picture switches to the next fuel oil pump as illustrated in Figure 45.
Fuel oil pump dialog window

Figure 45

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In the fuel oil pump dialog window information about the Mode and State for the
chosen oil pump can be monitored and administrated. The system may require Key
Operation Lock to administrate the oil pumps which can be achieved directly from the
dialog window by pressing the Key button in the top left corner. When the key icon
stops flashing, Key Operation Lock is achieved. The user may be prompted for password in the process.
In Figure 45 the Standby button is active where as in Figure 44 the Standby button is
deactivated which is illustrated with faded grey colour. This is due to the fact that an
oil pump can only be set in Standby mode if an oil pump is in AUTO mode. In Figure 44 the fuel oil pump is in AUTO mode which restricts the same fuel oil pump from
being set in Standby mode. Same restriction would apply if the fuel oil pump was set
in STOP mode. In Figure 45 it is possible to select Standby mode for the fuel oil pump
since the other fuel oil pump in Figure 44 is in AUTO mode.
Indicator fields supplies information of oil pump feedback and overload.
Note: For further information on administration and functionality of oil pumps
please refer to the chapter Oil Pump Control. Please note that the oil
pump Standby functionality only applies if the control system is configured
with this feature at commisioning and the oil pumps are intended for operation with this feature.

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2.5.2 Ring line selection


The status bar in the upper half of the Fuel overview dialog window, Figure 46, provides information about current oil type operation and sequence steps. Change between
MGO ring line and DO/HFO ring line can be performed by pressing the ring line button
next to the status bar. To execute this action key operation lock must first be obtained
and the burner stopped. Selection of ring line will activate the appertaining fuel flush
sequence.
Fuel overview

Figure 46

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Note: For further information about the status bar and ring line selection, please
refer to the chapter Operation of the touch screen.

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2.5.3 Cooler bypass


This menu only appears for systems configured with one oil ring line as illustrated in
Figure 47.
Fuel overview Single ring line

Figure 47

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When the system is configured with a MGO or DO cooler, and the cooler oil inlet valve
is automatically operated by the control system, a feature is installed to render bypass
of the cooler possible. During normal conditions the control system will initiate a
burner and oil pump shutdown should the cooler oil inlet valve not be in the requested
position. Additionally an alarm is generated if the oil cooler inlet valve is not in position
subsequent to an automatic controlled command. This alarm is a general valve position
alarm.
Please note that some systems are configured without automatic control of the cooler
oil inlet valve. During e.g. a fuel oil flush sequence in these systems, any operation of
the cooler oil inlet valve must be performed manually upon request from the control
system. The control system will display a user command on the display and remain in
idle position until the cooler oil inlet valve supplies an in position feedback signal.
Simultaneously with the valve command, a timer initiates. Is the cooler oil inlet valve
not in the requested position within expiration of the timer, an alarm is generated but
the system will still remain in idle an automatically re-commence the fuel oil flush
sequence when the cooler oil inlet valve supplies an in position feedback signal. The
alarm can subsequent be reset.
Should the need to bypass the cooler occur during operation with the cooler enabled,
e.g. if the cooler is leaking, the cooler oil inlet valve can be forced to bypass position.
This feature will simultaneously direct the oil return flow to tank and thus use the tank
oil temperature as cooling.

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Caution: Not all system are configured with the possibility to return MGO to the
MGO tank for which reason the MGO will keep circulating in the oil
ring line without cooling during operation. The oil temperature must
be surveilled closely and attended to with utmost importance to avoid
damage of equipment.
To enter the oil cooler dialog picture, press the cooler icon and Figure 48 will appear.
Cooler bypass dialog picture

Figure 48

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In the cooler bypass dialog picture the current status of the cooler can be seen as well
as the position of the cooler oil inlet valve.
To bypass the cooler during operation with the cooler enabled, press the dark-grey icon
next to the text Cooler Bypass, and Figure 49 will appear.

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Activation of cooler bypass

Figure 49

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Press the icon button [YES] and the cooler state will change to bypassed as illustrated
in Figure 50. To enable the cooler again, simply repeat the process just described and
press the [NO] icon button.
Cooler bypassed

Figure 50

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2.5.4 Parameters for the oil system


Access to the parameter settings of the oil system can be achieved by pressing the
Parameter button in the lower left corner as illustrated in Figure 51.

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Access to oil system parameter settings

Figure 51

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The dialog window for the parameter settings for the oil system is illustrated in Figure 52. The available oil system parameters are sorted by categories and accessible
through the buttons in the left side of the dialog window. The available categories will
be described further in the following.
Oil system parameter settings

Figure 52

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Oil limits choice


This menu holds all alarm and shutdown limits concerning the oil pressure and oil
temperature. Return to the oil system dialog picture can be done by pressing the button
in the lower left corner.
Each oil type is assigned an individual set of alarm and shutdown limit values. The
control system will only display parameters applying for the oil types, which are available at the individual boiler plant. In Figure 52 a maximum configuration is illustrated.
HFO/DO/MGO pressure limits
Limit values for surveillance of the individual oil pressure.
HFO/DO/MGO temperature limits
Limit values for surveillance of the individual oil temperature.
Reduced oil pressure limits
This surveillance feature applies for two-stage pressure atomizing burners only. The
feature initiates a separate set of oil pressure limits, which applies when the burner oil
nozzles are not opened. An oil shunt valve is reducing the oil pressure by partly bypassing the oil flow to the burner when the burner oil valve is closed. This is to avoid
unintended opening of any of the oil nozzles in the burner due to high oil pressure,
when no main flame is present.
HFO burner temperature limits
This surveillance feature applies for boiler plants configured with common fuel oil
heating and/or two boilers (Master/Slave). By common fuel oil heating means preheating of HFO by a steam preheater in the common fuel oil supply circuit.
When the HFO is heated in the common oil circuit, the analogue input to the normal
HFO temperature limits is received from a temperature transmitter mounted at the
steam preheater in the common oil circuit. As a consequence of this it is not possible
to surveil the oil temperature at each individual oil burner. To resolve this problem an
oil temperature transmitter has been mounted at each burner and will, simultaneously
with the oil temperature at the common steam preheater, surveil the oil temperature.
This surveillance menu is for additional safety measures constant active when operating on DO or HFO, irrespective of whether the boiler system is configured with
common preheater and one or two boilers.
Oil ring line pressure limits
This surveillance feature applies for oil systems configured with a low and high oil
pressure circuit. When the burner is operating on e.g. HFO, the oil ring line pressure
limits apply for the oil pressure in the low pressure circuit at the oil supply pumps,
while the HFO oil pressure limits apply for the oil pressure in the high pressure circuit
at the oil booster pump.
The oil ring line pressure limits also apply when the burner is operating on oil from
one ring line, and HFO is circulating in the other ring line. Then oil pressure surveillance of the HFO circulation must also be present. However, since the burner is operating on an other oil type and thus not dependent of the HFO oil pump operation, any

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oil pressure shutdown of the HFO circulating oil pumps will not affect the burner
operation.
Change of any limits can be done by pressing the limit value in the dark-grey display
field. Password may be prompted and key operation lock must be obtained.
For further information concerning the oil pressure and oil temperature surveillance,
please refer to the chapter Oil pump control.
Display of all alarm and shutdown limits concerning oil temperature and oil pressure
is extensive for which reason an additional feature is supplied. In Figure 53 it is illustrated how selection between display of all existing limits or only the current limits
can be done. By pressing the dark-grey field, a pop-up box appears and selection can
be made.
Oil limits display

Figure 53

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All
By selecting the ALL function, all alarm and shutdown limits concerning oil temperature and oil pressure are shown regardless of whether they are active.
Current
By selecting the CURRENT function, only the active alarm and shutdown limits concerning oil temperature and oil pressure are shown. By active means current limits in
use. Limits that are not currently in use are hidden. However, hidden limits can always
be displayed by selecting ALL as illustrated in Figure 53.
The display default setting is ALL.

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In Figure 54 the HFO pressure limits are illustrated. These limits can be displayed by
pressing the HFO pressure button illustrated in Figure 52 provided that the limits are
in use if CURRENT display is selected as illustrated in Figure 53.
The limits can be altered by pressing the dark grey display field. The user may be
prompted for password in the process. Please note that key operation lock must be
obtained before any alteration can take place.
Caution: Oil pressure and oil temperature limits are set by Alfa Laval in order
to correspond with the oil system configuration. Any change from these
limits can cause damage to oil pumps and equipment.
HFO pressure limits

Figure 54

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Fuel oil temperature regulation by preheater


This menu holds all set points and regulation options concerning the fuel oil preheater.
The set points can be altered by pressing the dark grey display field. The user may be
prompted for password in the process. Return to the previous dialog picture can be
done by pressing the button in the lower left corner.
In Figure 55 the fuel oil preheater regulation parameters applying for burner operation
on HFO are displayed. The dialog window can be accessed by pressing the Oil temperature regulation button when already navigating in the oil system parameter menu.

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Fuel oil temperature regulation

Figure 55

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Notice that some burners have two set points for the fuel oil temperature; one for
standby and one for operation. This refers to the main part of fuel oil systems configured
without high & low fuel oil pressure circuits. In these fuel oil systems circulation of
HFO will have to be done over the entire pipe system which will increase the heat loss
from the HFO despite heat tracing of the piping. To reduce the heat loss, a lower set
point for the preheater during burner standby mode has been added.
If the fuel system is configured with a steam preheater, as it is the case in Figure 55,
the menu also displays control buttons used for controlling the steam valve in the
preheater. The actuator can be set in manual mode allowing manual control of its
position by pressing the up arrow for increasing the opening degree of the valve or
down arrow for decreasing the opening degree. By pressing the Regulator Parameter
button in the bottom of Figure 55 it is possible to configure the regulator parameters.
These parameters are illustrated in Figure 56 and described in the list below.

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Fuel oil temperature regulation parameters

Figure 56

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Fuel oil temperature regulator parameters, which can be set:


[Neutral zone] A band around the set point where regulation is not carried out (the
process value error is ignored).
[Proportional Gain] Regulator parameter Proportional gain.
[Sampling time] The time between two samples.
[Integral time] Regulator parameter.
Differencel time] Regulator parameter.
[Minimum pulse] The minimum time the preheater can be on in each PWM period.
[Run time] Time for one PWM period.
Flush timers menu
This menu holds all timers concerning fuel flush sequences of the oil system. The
timers can be altered by pressing the dark grey display field. Return to the previous
dialog picture can be done by pressing the button in the lower left corner.
Caution: Fuel flush timers are specific for each individual fuel system and are
set by Alfa Laval during commissioning of the plant. The timers are not
intended for subsequent alteration and are thus protected by password.
In Figure 57 a maximum configuration of the fuel flush timers are displayed. Please
note that the timer display may vary dependent of the system configuration. Each
individual fuel flush sequence is allocated specific flush timers dependent of flush
sequence. The flush timer dialog window can be accessed by pressing the Flush Timers
button when already navigating in the oil system parameter menu.

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Flush Timers

Figure 57

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Note: For further information on administration and functionality of flush


timers please refer to the chapter Fuel flush sequence diagram.
Flush settings menu
This menu holds all fuel flush specific parameters concerning the oil system. The
parameters can be altered by pressing the dark grey display field. The user may be
prompted for password in the process. Return to the previous dialog picture can be
done by pressing the button in the lower left corner.
Caution: Fuel flush settings are specific for each individual fuel system and are
set by Alfa Laval during commissioning of the plant. Subsequent alteration may result in insufficient flush of the fuel system, unstable
burner operation and malfunctioning equipment.
In Figure 58 a maximum configuration of the fuel flush specific parameters is displayed. Please note that the parameter display may vary dependent of the system configuration. The parameters apply for the individual fuel flush sequences and will be
active dependent of flush sequence step. The parameter functionality will be elaborated
in the following:
HFO MGO Temperature
This parameter establishes the temperature limit in degrees Celsius from which the
heavy fuel oil temperature must be below before a flush against marine gas oil can be
commenced. When activating the flush sequence the control system will automatically
position the flush sequence in idle until the measured temperature is below the stated
parameter. The status line in the fuel system overview illustrated in Figure 46 will

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alternately display the texts Flushing and Temperature Falling while the heavy fuel oil
temperature is decreasing.
HFO DO Temperature
This parameter establishes the temperature limit in degrees Celsius from which the
heavy fuel oil temperature must be below before a flush against diesel oil can be commenced. When activating the flush sequence the control system will automatically
position the flush sequence in idle until the measured temperature is below the stated
parameter. The status line in the fuel system overview illustrated in Figure 46 will
alternately display the texts Flushing and Temperature Falling while the heavy fuel oil
temperature is decreasing.
Alarm Fuel Oil Pressure
This parameter establishes the fuel oil pressure limit in bar from which the heavy fuel
oil pressure must be above when the burner is operating on marine gas oil in one ring
line and heavy fuel oil is circulating in idle mode in the other ring line. If the measured
heavy fuel oil pressure drops below the parameter stated an alarm will become active
but the burner operation on marine gas oil will not be influenced.
If the HFO circulation pumps are configured with standby function and an oil pump
is set in standby mode, this oil pump will start, the other oil pump will stop and an
alarm will be displayed. For further information please refer to the chapter Oil pump
control.
Temperature Increase Time
This parameter establishes the maximum time in seconds that is allowed to elapse
before the required heavy fuel oil temperature during a fuel flush is reached. Please
notice that this maximum time limit applies for both Temperature Increasing as well
as Temperature Decreasing. The status line in the fuel system overview illustrated in
Figure 46 will alternately display the texts Flushing and Temperature Falling while the
heavy fuel oil temperature is decreasing. If the fuel flush sequence request the heavy
fuel oil temperature to increase the status line will alternately display the texts Flushing
and Temperature Rising. When flushing against HFO, the HFO temperature must be
above the HFO low temperature alarm limit before a fuel flush against heavy fuel oil
can be completed. Until the HFO low temperature alarm limit has been reached, the
status line in the fuel system overview illustrated in Figure 46 will alternately display
the texts Flushing and Temperature Increasing while the heavy fuel oil temperature is
increasing. This parameter is stated as a sequence condition and appears from the respective fuel flush sequence diagram.
Note: For further information on fuel flush sequences please refer to the chapter
Fuel flush sequence diagram.
Set Point Flush
This parameter establishes the opening degree in percent of the burner fuel inlet regulating valve during a fuel flush. Please notice that this parameter applies for oil systems with a burner fuel regulating valve mounted on the inlet side of the burner only,
e.g. rotary cup burners as illustrated in Figure 59. Remaining systems, constructed with
a burner fuel regulating valve, have the valve mounted on the outlet side of the burner,

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e.g. pressure atomizing burners as illustrated in Figure 62. The parameter that establishes the opening degree of the valve is, for the latter mentioned oil systems, the Oil
Standby Position value stated in the menu Plant Settings described in chapter 2.9.5.
The purpose with the burner fuel regulating valve parameter in both described oil
system types is to achieve an equal flow to determine the fuel flush timer length thus
ensuring a thorough fuel flush of the oil system.
Note: This parameter applies for oil systems with a burner fuel regulating valve
mounted on the inlet side of the burner only.
Flush Settings

Figure 58

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Burner fuel inlet regulating valve

Figure 59

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The flush settings dialog window can be accessed by pressing the Flush Settings button
when already navigating in the oil system parameter menu.

2.6 Burner menu


The burner menu gives access to an overview of the burner system and to alarm settings
of the system. The structure of the burner menu is illustrated in Figure 60.
Menu structure for the burner menu

Figure 60

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Access to the burner menu is given from the main picture (Figure 61) or from any of
the other system menus.

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Access to the burner menu

Figure 61

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The overview of the burner system is illustrated in Figure 62.


Burner overview Pressure atomizing burner

Figure 62

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In the overview picture illustrated in Figure 62 a diagram of a burner system with max
configuration is shown. As a result of this some menus, components or parameters may

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vary from the actual burner configuration. On the left side are the boiler pressure, water
level and burner load as well as a status bar that display the current boiler status. On
the right side are shown the main burner components that are important for illustration
of the system state:
Burner fuel regulating valve
This valve regulates the oil flow to the burner according to the set points specified for
respectively burner operation and fuel flush, illustrated in Figure 58. Information on
set point for oil flow concerning fuel flush can also be found in the appertaining fuel
flush sequence diagram. Please note that set points for the burner fuel regulating valve
vary dependent on burner type as described in chapter 2.5.3, Flush settings menu.
Note: For further information on fuel flush sequences please refer to the chapter
Fuel flush sequence diagram.
Oil valves
The oil safety valves and the oil bypass valve mounted at the burner are activated or
deactivated, respectively, dependent on whether oil flow through the burner or bypass
of the burner is requested by the control system. The valve state is displayed by two
colours: Green, meaning activated (open), and grey, meaning deactivated (closed).
Air damper
The air damper regulates the air flow to the burner supplied by the combustion air fan.
Please note that the air damper is placed differently dependent on burner type.
For pressure atomizing burners the air damper is placed before the combustion air fan,
thus regulating the air supply to the fan. From the combustion air fan the air is guided
through a swirler and mixed with the oil mist after the oil nozzle.
For rotary cup burners the air damper is placed between the combustion air fan and the
forced draft fan, thus regulating the air supply to the forced draft fan. Latter mentioned
is due to the fact that the air supply to the combustion is divided into two steps for
rotary cup burners. First step is the combustion air fan which supplies air to the forced
draft fan as well as the combustion chamber. Step two is the forced draft fan which
supplies atomizing air to the rotary cup. The forced draft fan is fixed to the burner
motor shaft which also drives the rotary cup.
Preheater
For oil systems configured with electric oil preheater the icon for the preheater will be
placed at the burner overview dialog picture for correspondence with the actual burner
design. This also applies for some oil systems with steam preheater. For the electric
oil preheater a green bar at the preheater icon will indicate whether or not the preheater
is active. Green, meaning activated (ON), and grey, meaning deactivated (OFF). For
the steam preheater a three-way valve will indicate whether the preheater is bypassed
or not. The steam preheater is active when the three-way valve is positioned for the
steam preheater as illustrated in Figure 63.

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Burner motor
The state of the burner motor is illustrated with an icon. For pressure atomizing burners
the burner motor is mounted inside the burner and drives an air fan that supplies the
combustion process with air. For rotary cup burners the burner motor is mounted outside the burner and drives both a forced draft fan and the rotary cup. The green rotation
icon indicates that the burner motor is running as illustrated in Figure 62. A green cross
icon indicates that the burner motor is AUTO stopped.
Combustion air pressure switch
The combustion air pressure switch indicates whether the air pressure is high enough.
If the air pressure switch detects too low air pressure the switch symbol changes to red
as illustrated in Figure 64 and a burner shutdown is commenced.
Oil flow
The fuel flow is indicated as percentage of the maximum flow. The measurement is
based upon the feedback from a potentiometer mounted on the burner fuel regulating
valve. For rotary cup burners the measurement is based upon feedback from a flow
meter. This flow meter feedback is for monitoring only. Regulation by the control
system is based upon burner fuel regulating valve feedback as for pressure atomizing
burners.
Uptake temperature
The uptake temperature supplies a temperature measurement of the exhaust gas in the
exhaust gas vent. This indicates, among other things, whether the boiler is increasingly
soothed in which case the exhaust gas temperature after the boiler will be significantly
higher. The parameter is assigned two temperature limits for high alarm and high
shutdown, respectively, as illustrated in Figure 65. This feature applies for oil fired
boilers only. If the boiler plant is configured with an exhaust gas boiler, indication on
whether the exhaust gas boiler is soothed will be indicated by a difference measurement
in exhaust gas temperature and/or exhaust gas pressure as illustrated in Figure 22.
Note: The uptake limits feature is optional and will not appear unless the boiler
plant is configured with this feature by Alfa Laval.
Oil pressure
A pressure transmitter mounted at the burner displays the oil pressure at the burner
inlet.
Oil temperature
Two temperature transmitters are available for burners configured with electric oil
preheater. One transmitter is build into the electric oil preheater and used by the control
system to regulate the heavy fuel oil temperature. At normal stop by burner operation
on heavy fuel oil, oil flow through the burner is stopped and the electric oil preheater
is deactivated. However, residual heat in the electric oil preheater will continue to warm
up the now stagnant heavy fuel oil in the oil preheater and as a result of this an incorrect
oil temperature measurement will be displayed. To compensate for this transient deviation an additionally temperature transmitter has been mounted after the electric oil
preheater which will supply the accurate oil temperature outside the oil preheater to

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the control system. The oil temperature measurement from this temperature transmitter
also indicates whether the oil temperature is optimal for the oil nozzle or rotary cup,
dependent of burner type.
For burners configured with steam preheater the two transmitters are both mounted
after the steam preheater as illustrated in Figure 63.
Note: If a pressure or temperature measurement is not available on the Burner
overview, the common oil pressure or temperature is used. The measurement can therefore be found at the Fuel overview which represents the
common circuit.
Burner overview steam preheater

Figure 63

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Burner parameters can be modified from inside the parameter menu.


2.6.1 Parameter settings
The parameter settings or alarm limit settings related to the burner system is accessed
from the burner overview picture by clicking the [PARAM] button (Figure 64).

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Access to the parameter settings in the burner system

Figure 64

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Uptake limits
The uptake limits menu is available on burners that is configured with this feature and
can be accessed by pressing the uptake limits button on the left side of the screen. Here
limits can be set for the high alarm and the high shutdown uptake temperature (see
Figure 65). For some burners (e.g. RMS) the preheater is placed on the burner picture
for better correspondence with the actual burner design. Placement for menus relevant
for the preheater will therefore move as well.

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Uptake limits list for burner system

Figure 65

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From the uptake limits menu, access is given to the main menu and back to the burner
overview (lower left arrow).
Windbox limits
The windbox limits menu illustrated in Figure 66 is available on burners that are configured with such and can be accessed by pressing the windbox limits button on the
left side of the screen.
The windbox limits consist of a high temperature alarm limit and a high temperature
shutdown limit. The high temperature shutdown limit is used to determine a threshold
for the fire in windbox shutdown.

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Windbox limits list for the burner system

Figure 66

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The last menu available is the servo valves menu.


Servo valves
The servo valves menu allows for manual or automatic control of the oil (valve) servo
and air (damper) servo as well as setting different parameters relevant to this. The menu
is illustrated in Figure 67.
Please note that the display will vary dependent on system configuration, e.g. some
systems may be configured with only one servo motor.
The servo valve control menu

Figure 67
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In the menu the air damper and oil valve position can be monitored. The actuators can
be set in manual mode allowing manual control of their position by either entering the
position (as a percentage of full open) in the setpoint (dark grey) box or by pressing
the arrows. For each servo it is possible to set the regulator parameters used by the
control system during automatic regulation. This is done by pressing the servo reg.
param. button below the servo that is to be changed (See Figure 68).
Access to the servo valve settings

Figure 68

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The servo regulator parameters menu allows the user to change the regulator parameters. The menu for the air servo is displayed in Figure 69.

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Air damper servo control

Figure 69

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Parameters which can be set are:


Position neutral zone
The accepted distance from the actual position to the set point position.
Sampling time
The time between two samples
Proportional Gain
Regulator parameter
Integral time
Regulator parameter
Derivative time
Regulator parameter
Minimum pulse
The minimum on time that the servo relay can be activated.
Run time
A parameter indicating the time period in which the regulator operates. This is not the
same as the period the actuator is active but it affects this.
From the servo control menu access is given to the main menu, alarm limit list and
back to the parameter menu (arrow in lower left corner).

2.7 Boiler Menu


The boiler menu gives access to an overview of the entire boiler system. Relevant alarm
and shutdown limits can be set and the burner can be manually controlled. The menu
structure of the boiler menu is illustrated in Figure 70.
Menu structure of the boiler menu

Main
Figure 70

Boiler

Parameters
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Access to the boiler menu is given from the main picture as illustrated in Figure 71.

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Access to the boiler menu

Figure 71

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In the boiler overview picture illustrated in Figure 72, the boiler pressure, water level,
and the load of the burner can be monitored as well as oxygen level and the smoke
density.
Boiler menu overview

Figure 72

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2.7.1 Parameter settings for the boiler system


From the boiler overview picture access is given to parameter settings of the boiler as
illustrated in Figure 73. Any alteration of parameters values or limit values in the
[Parameter] menu can be done by pressing the relevant parameter box provided that it
is displayed with dark-grey colour.
Password may be prompted in the process.
Access to the parameter settings for the boiler menu

Figure 73

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Pressure regulation
If the button [Pressure regulation] in the left side bar is pressed, the boiler steam pressure regulation parameters, illustrated in Figure 74, will appear. Return to the previous
picture can be done by pressing the return button in the lower left corner.
The boiler steam pressure regulation parameters cover following:
Status values
Actual set point
The current set point for the boiler steam pressure which the control system will regulate according to.
Process value
The current boiler steam pressure.

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Regulator output
The burner load. The control system will attempt to achieve the boiler steam pressure
set point. To achieve this, the control system will set a regulator output (burner load
in percent of max load) which will set the air/oil ratio accordingly.
Settings
Set point
The boiler steam pressure set point if the LOW set point mode is selected in the control
system.
Set point high
The boiler steam pressure set point if the HIGH set point mode is selected in the control
system.
Pressure regulation parameters default values

Figure 74

contouch_211x2328850en.bmp

Regulator parameter
If the button [Regulator parameter] in the bottom of Figure 74 is pressed, Figure 75
will appear. Return to the previous picture can be done by pressing the return button
in the lower left corner.
The boiler steam pressure regulator parameters cover following:
PID regulator parameter
Sampling time
The control system PID calculations proceed at the rate that data samples are placed
into the PID input. The sampling rate should allow sufficient time for the system to

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respond between samples, but should be sufficiently fast for observing system changes
as they are happening.
Proportional gain
The proportional term makes a change to the output that is proportional to the current
error value. The proportional response can be adjusted by multiplying the error by the
proportional gain. A high proportional gain results in a large change in the output for
a given change in the error. If the proportional gain is too high, the system can become
unstable. In contrast, a small gain results in a small output response to a large input
error, and a less responsive (or sensitive) controller. If the proportional gain is too low,
the control action may be too small when responding to system disturbances.
Integral time
The contribution from the integral term is proportional to both the magnitude of the
error and the duration of the error. Summing the instantaneous error over time (integrating the error) gives the accumulated offset that should have been corrected previously. The accumulated error is then multiplied by the integral gain and added to the
controller output. The magnitude of the contribution of the integral term to the overall
control action is determined by the integral gain. The integral term (when added to the
proportional term) accelerates the movement of the process towards the set point and
eliminates the residual steady-state error that occurs with a proportional only controller.
However, since the integral term is responding to accumulated errors from the past, it
can cause the present value to overshoot the set point value (cross over the set point
and then create a deviation in the other direction).
Derivative time
The rate of change of the process error is calculated by determining the slope of the
error over time (i.e., its first derivative with respect to time) and multiplying this rate
of change by the derivative gain. The magnitude of the contribution of the derivative
term to the overall control action is termed the derivative gain. The derivative term
slows the rate of change of the controller output and this effect is most noticeable close
to the controller set point. Hence, derivative control is used to reduce the magnitude
of the overshoot produced by the integral component and improve the combined controller-process stability.

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Regulator parameters default values

Figure 75

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If the system is configured with a two-stage pressure atomizing burner, Figure 76 will
appear by pressing the [Regulator button] in the bottom of Figure 74.
A two-stage pressure atomizing burner does not have the option of load modulation
but is instead, as the name indicates, limited to two load positions (nozzle 1 or nozzle
1+2). As a consequence of this, no PID parameters apply for the load control, but
instead a hysteresis around the set point applies.
The neutral zone defines that hysteresis around the set point, e.g. if the set point is 7
[bar] steam pressure and the neutral zone is 2 [bar], the burner will apply nozzle 1+2
until the steam pressure is 8 [bar]. Subsequently the burner will close nozzle 2 and not
open it again until the steam pressure has dropped to 6 [bar].
As a two-stage pressure atomizing burner does not have the option of load modulation,
the parameter Regulator output in Figure 74 will not appear.

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Regulator parameters, two-stage default values

Figure 76

contouch_213x2328870en.bmp

Level limits
If the button [Level limits] in the left side bar is pressed, the boiler water level and the
boiler steam pressure surveillance limits, illustrated in Figure 77, will appear. Return
to the previous picture can be done by pressing the return button in the lower left corner.
Level limits default values

Figure 77

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Smoke density
If the button [Smoke density] in the left side bar is pressed, the smoke density surveillance limits, illustrated in Figure 78, will appear. Return to the previous picture can be
done by pressing the return button in the lower left corner.
The smoke density surveillance feature will only be active and illustrated in the screen
interface if the option Smoke Monitor is selected in the control system. The option
is protected by password and can only be selected and configured by Alfa Laval authorized personnel.
High alarm limit
If the smoke density current measurement exceeds the limit stated in Figure 78, an
alarm will be generated and displayed in the alarm list.
Smoke blower
If the system is configured with smoke density measurement equipment, a fan will
mounted in such way that it will keep the surface of the light sensitive surfaces free of
smoke and thereby reducing the risk of malfunctioning caused by soot deposits. This
fan will not start/stop automatically but is instead switched ON/OFF manually by selecting the smoke blower option to YES/NO, respectively.
Smoke density default values

Figure 78

contouch_215x2328890en.bmp

Oxygen limits
If the button [Oxygen limits] in the left side bar is pressed, the burner exhaust gas
oxygen surveillance limit, illustrated in Figure 79, will appear. Return to the previous
picture can be done by pressing the return button in the lower left corner.

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The oxygen surveillance feature will only be active and illustrated in the screen interface if the option Oxygen is selected in the control system. The option is protected
by password and can only be selected and configured by Alfa Laval authorized personnel.
High alarm limit
If the current burner exhaust gas oxygen content measurement exceeds the limit stated
in Figure 79, an alarm will be generated and displayed in the alarm list. This surveillance will be utilized during, e.g. inert gas operation of the burner.
Oxygen limits default values

Figure 79

contouch_216x2328900en.bmp

Load control
The manual load control illustrated in Figure 80 is not only for monitoring and controlling the burner load. It is also to be used as a general inspection screen.
The actual load of the burner can be monitored at the bar in the left part of the window.
The burner load is displayed using a bar graph showing the burner load as a percentage
of the full burner load. For a precise readout the burner load value is also displayed
numerically in the middle of the bar. The mode of the burner is seen in the middle of
the screen. The burner mode can be set to either Stopped, Automatic or Manual. If the
burner is in Manual mode, the burner can be started/stopped and the load increased/
decreased pressing the respective touch buttons. In the top of the picture is the current
boiler steam pressure displayed for additional overview when controlling the burner
load manually. In the lower right part of the picture is the set point choice for easy
changing of set points, especially when the burner is operating in automatic mode. To
the left is the total oil consumption value for easy readout of this common task.

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Manual load control dialog window

Figure 80

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2.8 Trend
From the main menu access is given to trend curves for selected parameters of the
plant. Access to the trend information is illustrated in Figure 81.
Access to the trend menu

Figure 81

contouch_231ax2336240en.wmf

The trend menu is illustrated in Figure 82. From this dialog window access is given to
trends of different plant variables, e.g. boiler pressure, load, oil pressure, etc. A trend

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curve for each of these variables is accessible by clicking the variable button on the
dialog window. A trend example is shown in Figure 83.
Plant view for trend curves

Figure 82

om9306_56_pic_50x0062660en.wmf

Example of trend curve

Figure 83

om9306_56_trendx0062780en.wmf

There are several ways of controlling how the trend curve is displayed.
The vertical scaling (value) can be adjusted by setting the max and min value in the
lower right corner.
To adjust the horizontal axis (time / history) simply press anywhere on the graph to
bring up the history control buttons (see Figure 84).

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Activating history control

Figure 84

contouch_82x0198540en.wmf

The buttons function as follows:


[<<] Large jump back in measurement history
[<] Jump back in measurement history
[-] Zoom in / decrease shown time span.
[^] Reset view
[+] Zoom out / increase shown time span.
[>] Jump forward in measurement history
[>>] Large jump forward in measurement history

2.9 Set-up
The set-up menu provides access to a number of sub menus containing timers, alarm
limits, diagnostics, configuration of the displayed system, etc. The structure of the setup menu is illustrated in Figure 85.

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Menu structure of the set up menu

Figure 85

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Access to the set-up menu is given from the main picture as illustrated in Figure 86.
Access to set-up menu

Figure 86

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2.9.1 System
Under system setup, illustrated in Figure 87, information is given on the type of the
panel and the burner. The system clock and date can be monitored and set.
System dialog picture

Figure 87

contouch_234x2333120en.bmp

Diagnostic
From the system dialog window access is given to a number of sub menus containing
the diagnostic information on the digital/analogue inputs/outputs in the lower right
corner as illustrated in Figure 88.
In Figure 88 the digital inputs are illustrated. The status (Activated/Deactivated) of
each input is illustrated with colour. Green colour indicates an activated input. By
pressing the arrow on the lower right corner of the picture the next window with digital
inputs are presented.
In the left column change between digital/analogue inputs/outputs can be done. Return
to the System menu can be done by pressing the return arrow in the lower left corner.

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Digital inputs dialog picture

Figure 88

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2.9.2 Program versions


From the set-up menu access is given to monitor information on the software installed
as illustrated on Figure 89.
Information on the version number of the HMI software and the version number and
version date of the Aalborg Control software version are displayed.
Furthermore by pressing the [Visible] button, picture numbers will be illustrated on all
dialog pictures. Each picture is assigned a unique picture number. This feature can be
selected when experiencing unstable or malfunctioning behaviour of the HMI in which
case the picture number must be stated when contacting Alfa Laval for support.

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Program versions dialog picture

Figure 89

contouch_236x2333140en.bmp

2.9.3 Plant layout


Information on communication addresses, communication speed and set-up of the units
used for pressure measurements are accessed from the system dialog window as illustrated in Figure 90.
Plant layout dialog picture

Figure 90

contouch_237x2333150en.bmp

2.9.4 Display layout


The parameters displayed on the touch screen depend on which options the Aalborg
control system is configured to support. The display layout menu, illustrated in Figure 91, displays the current status of the individual parameters configured in the control

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system. By pressing the arrow on the lower right corner of the picture the next window
with parameters are presented.
Display layout dialog picture

Figure 91

contouch_238x2333160en.bmp

2.9.5 Plant settings


Selection between dialog pictures concerning timer settings, hour counters, plant settings and the oil summarizer data log can be made from the system dialog window as
illustrated in Figure 92. The parameters displayed on the touch screen depend on which
options the Aalborg control system is configured to support.
Plant settings dialog picture

Figure 92

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Timer settings
Several timers are used in the system. These timers are accessible in the timer settings
dialog picture, accessed from the plant settings dialog picture illustrated in Figure 92.
The parameters displayed on the touch screen depend on which options the Aalborg
control system is configured to support.
The timers menu is divided into five sub menus: Sequence, Surveil, Power 1-2, Shared
and Communication. Notice that each menu may contain several pictures. If available
the next pictures are accessed by pressing the arrow located in the lower right corner.
The value for a timer can be modified by pressing the dark grey button next to the timer
name. As example see Figure 93.
Return to the Plant settings menu can be done by pressing the return arrow in the lower
left corner.
Sequence
Timers concerning sequence operation of the burner and appertaining equipment are
displayed in this menu.
Surveil
Timers concerning surveillance features are displayed in this menu.
Power 1-2
Timers concerning pump operation and any oil flush operation are displayed in this
menu.

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Shared
Shared timers between the local panel and the common panel (power panel) are displayed in this menu.
Communication
Surveillance timers concerning communication between the different panels are displayed here.
Sequence timers dialog picture

Figure 93

contouch_240x2333180en.bmp

Hour counters
The hour counters concerning materiel configured for this feature are all displayed in
a general overview from where selection can be made. The hour counter overview will
only be displayed if the Aalborg Control is configured to support this feature.
The hour counter overview, illustrated in Figure 94, is accessible from the plant settings
dialog picture illustrated in Figure 92.
Return to the Plant settings menu can be done by pressing the return arrow in the lower
left corner.

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Hour counters dialog picture

Figure 94

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When selecting an hour counter in Figure 94, the specific hour counter concerning the
chosen component will be illustrated. In Figure 95 the hour counter for the burner
motor is illustrated.
Total hour
This counter displays the total amount of working hours concerning the chosen component. This counter can not be reset unless the control system is re-configured.
Total service hour
This counter displays the amount of service working hours, concerning the chosen
component, since the last service hour reset. The service hour feature is to be considered
as a user defined hour counter which can always be reset by pressing the [Reset] button
placed left of the service hour counter field. Password may be prompted.
Service limit
The hour counter service limit displays the amount of working hours the chosen component is allowed to operate. If the hour counter service limit is exceeded, an alarm
will be generated and displayed in the control system alarm menu. The hour counter
service limit is to be considered as a user defined hour counter service limit which can
always be altered by pressing the dark grey field. Password may be prompted.
Total starts
This counter displays the total amount of starts of the chosen component. This counter
can not be reset unless the control system is re-configured.
Total service starts

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This counter displays the amount of starts of the chosen component since the last
service hour reset. By resetting the service hour counter as described, the component
service start counter will also be reset.
Burner hour/start counter dialog picture

Figure 95

contouch_242x2333200en.bmp

Plant settings
The plant settings menu displays a number of sub menus containing system parameters
which defines the behaviour of the system. Please note that some sub menus may not
be displayed dependent of the individual system configuration.
Caution: Plant settings are configured by Alfa Laval during commissioning of
the boiler plant. Subsequent alteration may result in insufficient operation efficiency or malfunctioning of the burner.
Plant limits
This menu, illustrated in Figure 96, contains parameters concerning servo positions of
the oil servo and the air servo. The servo positions are set by the control system according to either the burner operation sequence or a fuel flush sequence, if the plant is
configured with this feature.
Furthermore the menu also contains pressure limits applying for the boiler steam pressure.
Notice that several pictures are available by pressing the arrow in the lower right corner.
Ratio
This menu, illustrated in Figure 97, contains parameters concerning the interaction
between the oil and the air servo.
Air/Oil flow ratio defines the set point of the air servo (which defines the air flow)
according to the oil servo set point (which defines the burner load). E.g. by 30% burner

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load (30% oil flow) the air flow can be either decreased or increased dependent of need.
As default the air flow is set to equal the oil flow. Air In correction defines the input
signal to the air servo motor from the control system. E.g. by 30% oil flow the air servo
motor can be adjusted to deviate from the control system command of 30% air flow.
Oil In correction is adjusted as for the Air In correction.
Notice the correction value in the lower right corner. This correction factor is multiplied
on all flows allowing for an overall displacement of the air/oil ratio curve. The factor
is especially used for inert gas systems.
Notice that several pictures are available by pressing the arrow in the lower right corner.
WHR settings
This menu, illustrated in Figure 98, contains parameters concerning the co-operation
between the control system and any waste heat recovery unit, if the plant is configured
with this feature. Furthermore, the menu contains parameters concerning the x-track
functionality in continuation of the WHR feature.
Alteration of any of the values in the sub menus can be done by pressing the dark-grey
display field. Password may be prompted in the process. Please note that some parameters are not intended for user defined alteration for which reason the user password
will not be valid.
Plant limits dialog picture

Figure 96

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Ratio parameter dialog picture

Figure 97

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WHR settings dialog picture

Figure 98

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Oil summarizer
This menu supplies an overview of the oil consumption. The value is an integration of
the oil flow meter measurement, if available.
Total litre
This summarizer displays the total litres of consumed oil by the burner(s). The summarizer can not be reset unless the control system is re-configured.

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Total service litre


This counter displays the amount of service litres of consumed oil by the burner(s)
since the last service litre reset. The service litre feature is to be considered as a user
defined oil summarizer which can always be reset by pressing the [Reset] button placed
left of the service litre summarizer field. Password may be prompted. Notice that the
value will loop when the maximum number is reached much like a normal mechanical
counter.
Service limit
The oil summarizer service limit displays the amount of service litres of consumed oil
the burner(s) is allowed to consume. If the oil summarizer service limit is exceeded,
an alarm will be generated and displayed in the control system alarm menu. The oil
summarizer service limit is to be considered as a user defined oil summarizer service
limit which can always be altered by pressing the dark grey field. Password may be
prompted.
Copy trend to USB
This feature, illustrated in Figure 92, can be used when experiencing unstable or malfunctioning behaviour of the boiler plant or the burner in which case the trend log with
great advantage can be enclosed when contacting Alfa Laval for support.
Simply connect a USB storage device to the USB port located at the backside of the
HMI and push the [Copy trend to USB] button. When the HMI is uploading, the [Copy
trend to USB] button becomes bold and returns to normal appearance when uploading
is completed. It may be necessary to open the cabinet to access the backside of the
HMI.
Copy Alarms to USB
This feature, illustrated in Figure 92, can be used when experiencing unstable or malfunctioning behaviour of the boiler plant or the burner in which case the alarm and
shutdown log with great advantage can be enclosed when contacting Alfa Laval for
support.
Simply connect a USB storage device to the USB port located at the backside of the
HMI and push the [Copy Alarms to USB] button. When the HMI is uploading, the
[Copy Alarms to USB] button becomes bold and returns to normal appearance when
uploading is completed.
It may be necessary to open the cabinet to access the backside of the HMI.
Note: Up to 60 seconds idle time may be expected in order for the HMI to detect
a USB storage device in the USB port.
Erase alarm list
This feature, illustrated in Figure 92, can be utilized when e.g. a new component has
been installed and a clear overview of subsequent alarms or shutdowns is requested.
Simply press the [Erase alarm list] button and the memory will be cleared. When the
HMI is erasing the memory, the [Erase alarm list] button becomes bold and returns to
normal appearance when erasing memory is completed.

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Password may be prompted.


Oil summarizer dialog picture

Figure 99

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2.9.6 Log-out
Trying to change a parameter often requires a password as illustrated in Figure 100.
Password prompt dialog picture

Figure 100

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After the correct password has been entered access is granted for 45 minutes. After an
expiration of the 45 minutes, the control system again requires the password to be

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entered. It is possible to remove the grant before the 45 minutes by pressing the [Logout] button illustrated in Figure 101.
Log-out dialog picture

Figure 101

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TABLE OF CONTENTS

Table of contents
Burner sequence diagram
Description
Burner sequence diagram - oil fuel...............................

Language UK

Document ID
OM5560_131.............

Page
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BURNER SEQUENCE DIAGRAM - OIL FUEL

Burner sequence diagram - oil fuel


1

General
The following section describes the burner firing sequence for dual fuel and single fuel
modulating pressure atomizing burners. Figure 2 shows a guide to the diagrams, and
Figure 3 to Figure 6 show the burner firing sequence. Figure 1 gives fuel selection
facility in case of dual fuel burner.
The burner firing sequence, e.g. start, purge, ignition, etc., is handled by the control
system. The sequence is divided into a number of steps, which are executed one by
one. When a specified step is active, the control system activates a number of output
signals and timers. In this way the necessary execution and surveillance of these actions
can be performed. On the control panel the actual sequence step will be indicated.
The burner firing sequence consists of 13 steps. The steps 0-8 handle the burner start
sequence, and the steps 10-13 concern the burner stop sequence. In the normal operation of the burner, step 8 (mod free) will be active. In this step the burner operates in
modulation free mode, and the load is controlled by the steam pressure regulation
output. If the steam pressure rises above the set point for stop of the burner, the control
system initiates the burner stop sequence. When the stop sequence is completed, the
burner will be in step 0 (ready). If the steam pressure falls below the set point for start
of the burner, a new start-up sequence will be initiated.
In addition to these steps, the sequence is provided with a stop step and a shutdown
step. The stop step must be selected on the control panel. In this step the burner remains
stopped regardless of the steam pressure. The shutdown step is active if one or more
safety interlock shut downs are present. If a safety interlock shut down arises in any
one of the sequence steps, the burner firing sequence is immediately interrupted. When
the safety interlock circuit is restored, and the shut down is reset, the sequence returns
to step 0 (ready).
In Figure 7 a selection of burner sequence related parameters is shown.

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BURNER SEQUENCE DIAGRAM - OIL FUEL

Fuel selection facility in case of dual fuel burner


Burner Firing Sequence dual fuel

Power ON

Initial

Power ON?

Not initial
Valid for oil fuel and gas
fuel firing modes in case
of dual fuel burner

Default fuel select


= oil

Oil

Last selected
fuel?
Gas

Continue in
"Burner sequence
diagram oil fuel" in
case of dual fuel or oil
burner only

Continue in
"Burner sequence
diagram gas fuel" in
case of dual fuel burner

Figure 1

om5560151_01cx3929780en.wmf

Refer to "Burner sequence diagram gas fuel" for gas fuel burner sequence details in
case of dual fuel burner.
Guide to diagram
Guide to diagram

When entering a sequence step, the associated outputs


will be active, and the described actions will be executed

STEP No.
Sequence

Conditions which must be fulfilled before leaving the above


step and entering the next step

Continuance of sequence step

Figure 2

Language UK

STEP No.
Sequence
(continued)

Shut-down of the burner


due to one or more active
safety interlocks. The
sequence will return to
step shut-down

Normal stop
of the burner

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BURNER SEQUENCE DIAGRAM - OIL FUEL

Sequence diagram
Burner firing sequence
Power on

One or more safety interlocks active


Deactivate start request to PMS
Stop ignition (switch off power to ignition transformer)
Deactivate oil valves
Close oil safety valves 1 + 2
Deactivate start signal to burner motor
Set servo motors to closed position
Set all timers to zero, except timers for water level alarms/
shut downs
If MGO Purge selection is MGO or ON and
operating on MGO:
- Set air flow to maximum position
- Start timer for MGO Purge
- When timer for MGO Purge and start start of combustion
air fan have expired, stop combustion air fan
and set air flow to stand-by position

STEP
Shut-down

Safety interlocks OK. When all shut downs can be and are
reset change to step 0 (ready)

To enter this step it must be chosen on the control panel


Set all timers to zero
Set burner to stop mode
When the step is changed to step 0 (ready) on the control
panel, the burner stop mode is canceled

Set servo motors to closed position


Stop burner motor

Shut-down
Stay in shut-down step if
safety interlocks are not OK
STEP
Stopped

Stop
Stay in step stopped

Shut-down

Stop
Stay in step 0 (ready)

Shut-down

Stop
Change to step 0 (ready)

Shut-down

Stop
Change to step 0 (ready)
Reset timer for maximum
start sequence time

STEP 0
Ready

In automatic mode change step if boiler pressure is


lower than set point chosen + master start difference
and if no flushing sequence is initiated
In manual mode change step if soft key for start is
activated and if no flushing sequence is initiated
Send start request to PMS system, if this possibility is
provided in the control system
Start timer for PMS feedback signal

Shut-down

STEP 1
Starting

Start permission from PMS system given

Start burner motor


Reset timer for PMS feedback
Start timer for maximum start sequence time
Start timer for burner motor start

STEP 1
Starting
(continued)

Feedback signal for burner motor running

Continued in next figure

Figure 3

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BURNER SEQUENCE DIAGRAM - OIL FUEL

Sequence diagram, continued


Burner firing sequence continued from previous figure

STEP 2
Purge

Set servo motors to purge position


Start timer for servo motors in position

Feedback signal for servo motors in position


Shut-down

Stop
Change to step 0 (ready)
Reset timer for maximum
start sequence time

Shut-down

Stop
Change to step 0 (ready)
Reset timers for maximum
start sequence time and
purge time

Shut-down

Stop
Stop burner motor
Change to step 0 (ready)
Reset timers for maximum
start sequence time and
ignition position and
oil heating

Shut-down

Stop
Stop ignition, close oil
safety valves 1 + 2
Reset timer for maximum
start sequence time
Change to step 0 (ready)

Shut-down

Stop
Stop ignition
Reset timer for maximum
start sequence time
Change to step 10
(steam purge position)

STEP 2
Purge
(continued)

Start timer for purge

If servo motors position are OK during purge period, change


step
If servo motors position are not OK, return to step 2 again
Set servo motors to ignition position
Start timer for servo motor in position
Start timer for oil heating

STEP 3
Ignition
position

Feedback signal for servo motors in position


Continue when timer periods for oil heating have expired

Start ignition (energize ignition transformer)


Open oil safety valves 1 + 2
Start timer for ignition

STEP 4
Ignition

Change step when timer period for ignition has expired

Activate oil valves


Start timer for safety time

STEP 5
Safety time

Continue when timer period for safety time has expired

Continued in next figure

Figure 4

Language UK

om5560_94_seqrmsx0055860en.wmf

27-5 / 7

OM5560_131#H.2
BURNER SEQUENCE DIAGRAM - OIL FUEL

Sequence diagram, continued


Burner firing sequence continued from previous figure

STEP 5
Safety time
(continued)

Activate flame surveillance


Reset timer for maximum start sequence time

Shut-down

Stop
Stop ignition
stop sequence initiates
Change to step 10
(steam purge position)

Shut-down

Stop
Change to step 10
(steam purge position)

Shut-down

Stop
Change to step 10
(Steam purge position)

STEP 6
Flame
stable

Start timer for flame stable


Stop ignition (switch off ignition transformer)

Change step when timer period for flame stable has expired

Modulating operation of the burner according to the signals


from the steam pressure transmitter

STEP 8
Rising/
mod. free
(continued)

In automatic mode change step if boiler pressure is


higher than set point chosen + stop differential set point
In manual mode change step if soft key for stop is activated

Deactivate oil valves


Close oil safety valves 1 + 2
Deactivate flame surveillance

STEP 11
Steam
purge 1

Shut-down

Set servo motors to purge position


Start timer for servo motors in position

STEP 13
Postpurge

Feedback signal for servo motors in position


Shut-down

Continued in next figure

Figure 5

27-6 / 7

om5560_94_seqrmsx0055870en.wmf

Language UK

OM5560_131#H.2
BURNER SEQUENCE DIAGRAM - OIL FUEL

Sequence diagram, continued


Burner firing sequence continued from previous figure

Start timer for postpurge. If timer is set to 0 sec. the


furnace will not be purged.

STEP 13
Postpurge
(continued)

Change to step 0 (ready) when timer period for postpurge


has expired
Shut-down

STEP 0
Ready

Figure 6

om5560_94_seqrmsx0055880en.wmf

Burner sequence related parameters

Figure 7

Language UK

seq100x2316330en.png

27-7 / 7

TABLE OF CONTENTS

Table of contents
Fuel flush sequence diagram
Description
Fuel flush sequence diagram.......................................

Language UK

Document ID
OM5560_162.............

Page
28-2

28-1 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Fuel flush sequence diagram


1

General
The following section describes the burner and fuel ring line flush sequences for pressure atomizing burners. Figure 1 shows a guide to the diagrams. Figure 2 shows a
general fuel flush overview. Figure 3 to Figure 5 show burner sequence additions.
Figure 6 to Figure 10 show the burner and fuel ring line flush sequences. Figure 11
shows the flush stop shutdown sequence.
The fuel flush sequences, e.g. start of fuel pumps, change of some valves, fuel temperature heating/cooling, etc., are handled by the control system. The sequences are
divided into a number of steps which are executed one by one. When a specific step is
active the control system activates a number of output signals and timers. In this way
the necessary execution and surveillance of these actions can be performed. On the
local panel(s) the actual sequence step will be indicated at the control system HMI and
the controller four line crystal display (LCD).
The fuel flush can be performed in five different sequences dependent on operator fuel
request:

HFO MGO
DO MGO
X HFO
HFO DO
MGO DO
In addition to this a general fuel flush sequence overview, Change Logic, sums up the
interaction between the fuel oil flush sequences and burner fuel oil operation.
These individual interactions from Change Logic is also defined separately as burner
sequence additions where the different stages and options between fuel flush and burner
operation are available in a more comprehensive overview.
Incorporated in the fuel oil flush sequences are some general errors which, if provoked,
will cause a flush stop. The flush stop shutdown will be displayed at the control system
HMI and the controller four line crystal display (LCD) together with information in
the alarm and shutdown menus on, which error caused the flush stop. To reactivate the
flushing sequence the error(s) must first be rectified which will allow the specific
shutdown(s) to be reset at the local control panel. Subsequently a fuel oil pump must
be set in AUTO mode which will allow the fuel oil pump availability shutdown to be
reset. The last mentioned shutdown reset will reactivate the fuel oil flushing sequence
which will reload the step prior to the flush stop and continue the fuel oil flush.
Also incorporated in the fuel oil flush sequences are some inhibits. These represent
actions which are not allowed as long as a fuel oil system flush is active.

28-2 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

The operator fuel oil request is performed from three way valves G115 and G441 where
selection between HFO, DO and MGO can be made.
By manually operating three-way valve G115, fuel oil selection between DO/MGO
and HFO can be made manually. Further selection between DO and MGO can be made
manually at three way valve G441.
Selection at either three-way valve G115 or G441 will automatically activate the appertaining fuel oil flush sequence.
For the fuel oil ring line system applies that the fuel oil pump will be stopped after
completed flush sequence. Subsequently burner operation request from either operator
or boiler system will automatically start and stop the active fuel oil pump.
This does not apply, however, if HFO is present in the ring line in which case the active
fuel oil pump will be running continuously to keep the HFO circulating.
When fuel oil flush sequence is completed the burner is ready for operation provided
that the burner operation mode STOPPED is changed to AUTO or MANUEL in the
control system menu.
Note: The burner must be stopped before any fuel oil flush/change is requested.
Diagram Guide

Figure 1

Language UK

seq111x1754650en.bmp

28-3 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Change Logic
The Change Logic diagram in Figure 2 is a general fuel oil flush sequence overview
that sums up the interaction between the fuel oil flush sequences and burner fuel oil
operation. The diagram defines all the possible choices for fuel oil flushing and fuel
oil operation.
When making a fuel oil selection, the relevant fuel oil flush diagram initiates from
Change Logic and returns to Change Logic after completed fuel oil flush.
It is in some cases possible to change fuel oil selection while already flushing where
the new fuel oil selection will just initiate the appertaining flush sequence according
to Change Logic. Other flush sequences will initiate a flush stop together with information in the alarm and shutdown menus if fuel oil selection is changed while flushing.
In this case the flush sequence will not recommence until the fuel oil selection has been
set back to the original choice, the flush stop shutdown been reset, the pump set back
in AUTO mode and the remaining shutdowns reset.
Change Logic
Events
evG115_MGO_DO: G115 switched to MGO/DO position.
evG115_HFO:
G115 switched to HFO position.
evG441_MGO:
G441 switched to MGO position.
evG441_DO:
G441 switched to DO position.

evG115_HFO

MGO operation

evG441_DO
evG441_MGO

evG441_MGO
(123)
Flushing
X -> HFO

(101)
Flushing
HFO -> MGO

(131)
Flushing
HFO -> DO

(141)
Flushing
MGO -> DO

(112)
Flushing
DO -> MGO

evG441_DO
evG441_DO
[G441==MGO]

[G441==DO]

evG115_MGO_DO

HFO operation

DO operation

evG441_MGO

evG115_HFO

Figure 2

28-4 / 17

seq112x1754660en.wmf

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Burner sequence additions


The burner sequence additions display in full the different interactions between fuel
oil flush sequences and burner operation sequence. This includes the individual steps
separating or connecting flushing sequences and burner availability in the different
burner modes. The burner sequence additions are to be considered fuel oil flush related
extensions to the original burner operation sequence.
As it appears from the burner sequence additions it is not possible to start the burner
while flushing. However, it is possible to initiate a fuel oil flush when the burner status
is either Shutdown", Stopped" or Ready". If fuel oil selection is changed during
burner operation a boiler shutdown will commence.

3.1 MGO operation


Burner sequence additions concerning MGO burner operation.
MGO burner sequence addition

Change logic
If return from Burner sequence step 5-13
and MGO purge = MGO or ON,
then set air servo in full open pos.
Start MGO purge timer.
When the timer expires, set air servo in standby pos.

Step
Shutdown

Flushing sequence
initiated

Change logic

Change logic
Step
Stopped

Flushing sequence
initiated

Change logic

Change logic
Step 0
Ready

Flushing sequence inactive


G147 in AUTO mode

Flushing sequence
initiated
Change logic
Step 1
Starting

Flushing sequence
initiated
Burner sequence

Figure 3

Language UK

seq113x1754670en.wmf

28-5 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

3.2 HFO operation


Burner sequence additions concerning HFO burner operation.
HFO burner sequence addition

Change logic
If return from Burner sequence step 5-13
and MGO purge = ON,
then set air servo in full open pos.
Start MGO purge timer.
When the timer expires, set air servo in standby pos.

Step
Shutdown

Flushing sequence
initiated

Change logic

Change logic
Step
Stopped

Flushing sequence
initiated

Change logic

Change logic
Step 0
Ready

Flushing sequence inactive


G147 in AUTO mode

Flushing sequence
initiated
Change logic
Step 1
Starting

Flushing sequence
initiated
Burner sequence

Figure 4

28-6 / 17

seq114x1754680en.wmf

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

3.3 DO operation
Burner sequence additions concerning DO burner operation.
DO burner sequence addition

Change logic
If return from Burner sequence step 5-13
and MGO purge = ON,
then set air servo in full open pos.
Start MGO purge timer.
When the timer expires, set air servo in standby pos.

Step
Shutdown

Flushing sequence
initiated

Change logic

Change logic
Step
Stopped

Flushing sequence
initiated

Change logic

Change logic
Step 0
Ready

Flushing sequence inactive


G147 in AUTO mode

Flushing sequence
initiated
Change logic
Step 1
Starting

Flushing sequence
initiated
Burner sequence

Figure 5

seq115x1754690en.wmf

Fuel oil flush sequences


Dependent on which position three-way valves G115 and G441 are manually moved
to, a fuel oil flush sequence will commence.
In the following chapters all fuel oil flush sequences will be described.

Language UK

28-7 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

4.1 HFO MGO


Change from heavy fuel oil to marine gas oil
HFO to MGO
Inhibit:
G147 Manual start

Change logic

If Burner Family = MULTI


Then also:
Flush stop

2F207
2F217
2F202
2F205
2F201

2F217
2F222

Component
G437
G439
G436
G482
F207
F217
G147
F202
F205
F201

Action
TANK
HFO
Bypass
G481
OFF
SP = Standby
Stop
Open
Open
Close

Step 101
MGO
Temp
Falling

G437 Feedback in position


G439 Feedback in position
G436 Feedback in position
F217 Feedback in position
F222
t < X degrees celsius
G147

Run

Feedback from valves is a condition for


proceeding. Fuel oil temperature in the
entire oil system must be reduced to or
below setpoint before proceeding.
Step 102
MGO
Wait
Valves

2F202
2F205
2F201

Start

F Timer 2

Time expired

F Timer 2
G437
F202
F205
F201
G482

Reset
Mix tube
Close
Close
Open
G471

Step 103
MGO
Wait Timer

Start

Flushing from tank selection valve to


tank return valve is commenced.
Flush timer 2 expired is a condition for
proceeding.

Step 104
MGO
Wait
Valves

The fuel oil return valve is set to mixing


tube and the fuel pressure control valve
is set for DO/MGO. The oil safety valves
are closed and the oil bypass valve at
the burner is opened.
Feedback from fuel oil return valve is a
condition for proceeding.

G437 Feedback in position

F Timer 3

The fuel oil pump is started.

Feedback from the fuel oil pump is a


condition for proceeding.

G147 Feedback - running

F Timer 2

The fuel oil pump is stopped and the


preheater deactivated. The fuel oil return
valve is set to tank and the tank return
valve is set to HFO. The oil safety valves
are opened and the oil bypass valve at
the burner is closed. Fuel pressure
control selection valve is set for HFO
and the DO/MGO cooler is bypassed.
The fuel flow regulating valve is set to
standby position in order to keep a
sufficient flow through the burner.

Step 105
MGO
Wait Timer

Flushing from fuel oil return valve to


burner return line is commenced.
Flush timer 3 expired a condition for proceeding.

Cooler Bypass = NO
F Timer 3
Time expired
F Timer 3
G437
G436

Reset
Tank
Cooler

G437 Feedback in position


G436 Feedback in position

Cooler bypass = YES


F Timer 3
Time expired
Step 109
MGO
Wait
Valves

F Timer 3
G437
G436

Reset
Tank
Bypass

Step 106
MGO
Wait
Valves

G437 Feedback in position


G436 Feedback in position

F Timer 6

Start

F Timer 6

Time expired

F Timer 6
G147

Reset
Stop

- If the DO/MGO cooler is selected to forced


bypass in the control system the cooler will
remain bypassed and the fuel oil return valve set
for tank.
- If the DO/MGO cooler is not selected to forced
bypass in the control system the oil flow will be
directed through the cooler and the fuel oil return
valve set for tank.
Feedback from fuel oil return valve and cooler
bypass valve is a condition for proceeding.

Step 107
MGO
Wait Timer

Flushing from burner return line to tank


return valve.
Flush timer 6 expired is a condition for
proceeding.

Step 108
MGO
Wait
Pump

The fuel oil pump is stopped.

Change logic

Figure 6

seq116ax1754780en.wmf

Note: The burner must be stopped before any fuel oil flush/change is requested.
Caution: Any heat tracing must be deactivated when flushing to MGO.

28-8 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

4.2 DO MGO
Change from diesel oil to marine gas oil
DO to MGO
Inhibit:
G147 Manual start
Change logic

If Burner Family = MULTI


Then also:

Flush stop

2F207
2F217
2F202
2F205
2F201

2F217

2F202
2F205
2F201

Component
G437
G439
G436
G482
F207
F217
G147
F202
F205
F201

Action
TANK
DO
Bypass
G471
OFF
SP = Standby
Run
Open
Open
Close

Step 109
MGO
Wait
Valves

G437 Feedback in position


G439 Feedback in position
G436 Feedback in position
F217 Feedback in position
G147 Feedback running
F Timer 2

Start

F Timer 2

Time expired

F Timer 2
G437
F202
F205
F201

Reset
Mix tube
Close
Close
Open

Feedback from valves and the fuel oil


pump are a condition for proceeding.

Step 110
MGO
Wait Timer

Start

Flushing from tank selection valve to


tank return valve is commenced.
Flush timer 2 expired is a condition for
proceeding.

Step 111
MGO
Wait
Valves

The fuel oil return valve is set to mixing


tube. The oil safety valves are closed
and the oil bypass valve at the burner is
opened.

Feedback from fuel oil return valve is a


condition for proceeding.

G437 Feedback in position

F Timer 3

The fuel oil pump is started and the


preheater deactivated. The fuel oil return
valve is set to tank and the tank return
valve is set to DO. The oil safety valves
are opened and the oil bypass valve at
the burner is closed. Fuel pressure
control selection valve is set for DO/
MGO and the DO/MGO cooler is
bypassed. The fuel flow regulating valve
is set to standby position in order to keep
a sufficient flow through the burner.

Step 112
MGO
Wait Timer

Flushing from fuel oil return valve to


burner return line is commenced.
Flush timer 3 expired a condition for proceeding.

Cooler bypass = YES


F Timer 3
Time expired

Cooler bypass = NO
F Timer 3
Time expired
F Timer 3
G437
G436

Reset
Tank
Cooler

G437 Feedback in position


G436 Feedback in position

Step 113
MGO
Wait
Valves

F Timer 3
G437
G436

Reset
Tank
Bypass

Step 114
MGO
Wait
Valves

G437 Feedback in position


G436 Feedback in position

F Timer 6

Start

F Timer 6

Time expired

F Timer 6
G147

Reset
Stop

- If the DO/MGO cooler is selected to forced


bypass in the control system the cooler will
remain bypassed and the fuel oil return valve set
for tank.
- If the DO/MGO cooler is not selected to forced
bypass in the control system the oil flow will be
directed through the cooler and the fuel oil return
valve set for tank.
Feedback from fuel oil return valve and cooler
bypass valve is a condition for proceeding.

Step 115
MGO
Wait Timer

Flushing from burner return line to tank


return valve.
Flush timer 6 expired is a condition for
proceeding.

Step 116
MGO
Wait
Pump

The fuel oil pump is stopped.

Change logic

Figure 7

seq117x1754710en.wmf

Note: The burner must be stopped before any fuel oil flush/change is requested.
Caution: Any heat tracing must be deactivated when flushing to MGO.

Language UK

28-9 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

4.3 X HFO
Change from either diesel oil or marine gas oil to heavy fuel oil
X to HFO
Inhibit:
G147 Manual start
Change logic

Flush stop

If Burner Family = MULTI


Then also:

2F207
2F217
2F202
2F205
2F201

2F217

2F202
2F205
2F201

Component
G437
G439
G436
G482
F207
F217
G147
F202
F205
F201

Action
TANK
HFO
Bypass
G481
OFF
SP = Standby
RUN
Open
Open
Close

Step 117
HFO
Wait
Valves

G437 Feedback in position


G439 Feedback in position
G436 Feedback in position
F217 Feedback in position
G147 Feedback running

F Timer 2

Start

F Timer 2

Time expired

F Timer 2
G437
F202
F205
F201

Reset
Mix tube
Close
Close
Open

Feedback from valves and the fuel oil


pump is a condition for proceeding.

Step 118
HFO
Wait Timer

Start

F Timer 3

Time expired

F Timer 3
G437
F207

Reset
Tank
ON

Flushing from tank selection valve to


tank return valve is commenced.
Flush timer 2 expired is a condition for
proceeding.

Step 119
HFO
Wait
Valves

The fuel oil return valve is set to mixing


tube. The oil safety valves are closed
and the oil bypass valve at the burner is
opened.
Feedback from fuel oil return valve is a
condition for proceeding.

G437 Feedback in position

F Timer 3

The fuel oil pump is started and the


preheater deactivated. The fuel oil return
valve is set to tank and the tank return
valve is set to HFO. The oil safety valves
are opened and the oil bypass valve at
the burner is closed. Fuel pressure
control selection valve is set for HFO
and the DO/MGO cooler is bypassed.
The fuel flow regulating valve is set to
standby position in order to keep a
sufficient flow through the burner.

Step 120
HFO
Wait Timer

Flushing from fuel oil return valve to


burner return line is commenced.
Flush timer 3 expired a condition for
proceeding.

Step 121
HFO
Wait Valve

The fuel oil return valve is set for tank


and the preheater activated.

2F207
Feedback from fuel oil return valve is a
condition for proceeding.

G437 Feedback in position

2F222

F Timer 6

Start

F Timer 6

Time expired

F Timer 6
G437

Reset
Mix Tube

Step 122
HFO
Wait Timer

Flush timer 6 expired is a condition for


proceeding.
Step 123
HFO
Temp
Rising

G437 Feedback in position


F222 t > Low temp. alarm
Change logic

Figure 8

Flushing from burner return line to tank


return valve.

The fuel oil return valve is set for mixing


tube.
Fuel oil system temperature increased to
above the value of the Low F.O.
temperature alarm and feedback from
fuel oil return valve are a condition for
proceeding.

seq118x1754720en.wmf

Note: The burner must be stopped before any fuel oil flush/change is requested.
Note: Any heat tracing should be activated when flushing to HFO.

28-10 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

4.4 HFO DO
Change from heavy fuel oil to diesel oil
HFO to DO
Inhibit:
G147 Manual start
Change logic

Flush stop

Component

If Burner Family = MULTI


Then also:

G437
G439
G436
G482
F207
F217
G147
F202
F205
F201

2F207
2F217
2F202
2F205
2F201

Action
TANK
HFO
Bypass
G481
OFF
SP = Standby
RUN
Open
Open
Close

The fuel oil pump is started and the


preheater deactivated. The fuel oil return
valve is set to tank and the tank return
valve is set to HFO. The oil safety valves
are opened and the oil bypass valve at
the burner is closed. Fuel pressure
control selection valve is set for HFO
and the DO/MGO cooler is bypassed.
The fuel flow regulating valve is set to
standby position in order to keep a
sufficient flow through the burner.

Step 124
DO
Wait
Valves

G437 Feedback in position


G439 Feedback in position
G436 Feedback in position
F217 Feedback in position
G147 Feedback running

2F217

2F202
2F205
2F201

F Timer 2

Start

F Timer 2

Time expired

F Timer 2
G437
F202
F205
F201
G482

Reset
Mix tube
Close
Close
Open
G471

Feedback from valves and the fuel oil


pump is a condition for proceeding.

Step 125
DO
Wait Timer

Flushing from tank selection valve to


tank return valve is commenced.
Flush timer 2 expired is a condition for
proceeding.
The fuel oil return valve is set to mixing
tube. The oil safety valves are closed
and the oil bypass valve at the burner is
opened. The fuel pressure control valve
is set for DO/MGO.

Step 126
DO
Wait
Valves

Feedback from fuel oil return valve is a


condition for proceeding.

G437 Feedback in position

F Timer 3

Cooler bypass = NO
F Timer 3
Time expired

F Timer 3
G436

Reset
Cooler

Step 127
DO
Wait Timer

Start

Flushing from fuel oil return valve to


burner return line is commenced.
Flush timer 3 expired a condition for
proceeding.

Cooler bypass = YES


F Timer 3
Time expired

Step 128
DO
Wait Valve

G436 Feedback in position

F Timer 3
G436

Reset
Bypass

- If the DO/MGO cooler is selected to


forced bypass in the control system the
cooler will remain bypassed.

Step 129
DO
Wait Valve

- If the DO/MGO cooler is not selected to


forced bypass in the control system the
oil flow will be directed through the
cooler.

G436 Feedback in position


Feedback from cooler bypass valve is a
condition for proceeding.

G437

Tank

Step 130
DO
Wait Valve

The fuel oil return valve is set for tank.

Feedback from fuel oil return valve is a


condition for proceeding.

G437 Feedback in position

F Timer 6

Start

F Timer 6

Time expired

F Timer 6
G437

Reset
Mix tube

Step 131
DO
Wait Timer

Flushing from burner return line to tank


return valve.
Flush timer 6 expired is a condition for
proceeding.

Step 132
DO
Wait Valve

The fuel oil return valve is set for mixing


tube.
Feedback from fuel oil return valve is a
condition for proceeding.

G437 Feedback in position

G147

Stop

Step 133
DO
Wait
Pump

The fuel oil pump is stopped.

Change logic

Figure 9

Language UK

seq120x1754740en.wmf

28-11 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Note: The burner must be stopped before any fuel oil flush/change is requested.
Note: Any heat tracing should be deactivated when flushing to DO.

28-12 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

4.5 MGO DO
Change from marine gas oil to diesel oil
MGO to DO
Inhibit:
G147 Manual start
Change logic

Flush stop

If Burner Family = MULTI


Then also:

2F207
2F217
2F202
2F205
2F201

2F217

2F202
2F205
2F201

Component
G437
G439
G436
G482
F207
F217
G147
F202
F205
F201

Action
TANK
DO
Bypass
G471
OFF
SP = Standby
RUN
Open
Open
Close

The fuel oil pump is started and the


preheater deactivated. The fuel oil return
valve is set to tank and the tank return
valve is set to DO. The oil safety valves
are opened and the oil bypass valve at
the burner is closed. Fuel pressure
control selection valve is set for DO/
MGO and the DO/MGO cooler is
bypassed. The fuel flow regulating valve
is set to standby position in order to keep
a sufficient flow through the burner.

Step 134
DO
Wait
Valves

G437 Feedback in position


G439 Feedback in position
G436 Feedback in position
F217 Feedback in position
G147 Feedback running

F Timer 2

Start

F Timer 2

Time expired

F Timer 2
G437
F202
F205
F201

Reset
Mix tube
Close
Close
Open

Feedback from valves and the fuel oil


pump is a condition for proceeding.

Step 135
DO
Wait Timer

Flushing from tank selection valve to


tank return valve is commenced.
Flush timer 2 expired is a condition for
proceeding.
The fuel oil return valve is set to mixing
tube. The oil safety valves are closed
and the oil bypass valve at the burner is
opened.

Step 136
DO
Wait
Valves

Feedback from fuel oil return valve is a


condition for proceeding.

G437 Feedback in position

F Timer 3

Cooler bypass = NO
F Timer 3
Time expired

F Timer 3
G436

Reset
Cooler

Step 137
DO
Wait Timer

Start

Flushing from fuel oil return valve to


burner return line is commenced.
Flush timer 3 expired a condition for
proceeding.

Cooler bypass = YES


F Timer 3
Time expired

Step 138
DO
Wait Valve

G436 Feedback in position

F Timer 3
G436

- If the DO/MGO cooler is selected to


forced bypass in the control system the
cooler will remain bypassed.
Step 139
DO
Wait Valve

Reset
Bypass

- If the DO/MGO cooler is not selected to


forced bypass in the control system the
oil flow will be directed through the
cooler.

G436 Feedback in position


Feedback from cooler bypass valve is a
condition for proceeding.

G437

Tank

Step 140
DO
Wait Valve

The fuel oil return valve is set for tank.

Feedback from fuel oil return valve is a


condition for proceeding.

G437 Feedback in position

F Timer 6

Start

F Timer 6

Time expired

F Timer 6
G437

Reset
Mix tube

Step 141
DO
Wait Timer

Flushing from burner return line to tank


return valve.
Flush timer 6 expired is a condition for
proceeding.

Step 142
DO
Wait Valve

The fuel oil return valve is set for mixing


tube.
Feedback from fuel oil return valve is a
condition for proceeding.

G437 Feedback in position

G147

Stop

Step 143
DO
Wait
Pump

The fuel oil pump is stopped.

Change logic

Figure 10

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seq119x1754730en.wmf

28-13 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Note: The burner must be stopped before any fuel oil flush/change is requested.
Note: Any heat tracing should be deactivated when flushing to DO.

28-14 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

Flush stop
During fuel oil flush sequence a number of general errors, oil safety interlocks, will
provoke a flush sequence stop. Only errors in relation to the fuel oil system will influence the flush sequence. When the error has been rectified the flush stop shutdown
can be reset in the control system at the local control panel(s). Subsequently the active
fuel oil pump must be set in AUTO mode and the remaining shutdown(s) reset. This
will reactivate the fuel oil flush and the flush sequence will automatically recommence
from the beginning of the step active when the flush stop arose.
Setting a fuel oil pump in AUTO mode can be made either in the control system at the
local panel(s) or by activating manual start of the fuel oil pump locally. For further
information of fuel supply pumps please refer to the chapter Pump Control".
The flush stop sequence is illustrated in Figure 11, where the different steps of the
sequence are described. The general errors, oil safety interlocks, which will cause a
flush stop, are described in the following paragraphs.
Flush Stop Shutdown Sequence
Oil safety interlock error
Stop G147 (STOP-stopped)
Stop flush sequence
Inhibit G147 = AUTO
Inhibit AL/SD Reset for:
No fuel oil pumps available

Flush stop
1

Oil safety interlock OK


AL/SD Reset

Undo inhibit G147 = AUTO

Flush stop
2

Required oil pump in AUTO


(AUTO-Stopped)
Undo inhibit AL/SD Reset for:
No fuel oil pumps available

AL/SD Reset

Oil safety interlock


error
Change to step
Flush stop 1

Flush stop
3

Oil safety interlock


error
Change to step
Flush stop 1

Figure 11

seq121x1754750en.wmf

5.1 G147 in STOP-STOPPED, when required


The fuel oil supply pump unit G147 do not have a pump in AUTO mode. This can be
caused by e.g. a fuel oil system related shutdown or a manual stop of the fuel pump.

Language UK

28-15 / 17

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

5.2 Fuel-/Gas oil pressure shutdown


The fuel-/gas oil pressure is detected to exceed the low/high shutdown limits which
will cause the control system to activate a fuel system shutdown and thereby deactivating all oil pumps in the oil pump unit covered by the shutdown. If the burner is in
operation a burner shutdown will also initiate.

5.3 Gas oil temperature high shutdown


The gas oil temperature is detected to exceed the high shutdown limit which will cause
the control system to activate a fuel system shutdown and thereby deactivating all oil
pumps in the oil pump unit covered by the shutdown. If the burner is in operation a
burner shutdown will also initiate.

5.4 Feedback error on valve


All automatic controlled valves are assigned a feedback timer of 5 seconds. If the timer
expires following a control system position command, e.g. if the valve is blocked from
shifting to the requested position or slowly moving, a flush stop will be executed. This
also applies if the control system detects an incorrect feedback, e.g. if a valve is positioned in a different position than requested.

5.5 Oil type changed while flushing


One or both fuel selection valves G115 and G441 have been repositioned manually
after a fuel oil flush has commenced.
Note: It is in some systems allowed to change oil type on fuel selection valves while
flushing. In this case the control system will automatically initiate the fuel
oil flush sequence corresponding to the position of the fuel selection valves.
For further information please refer to the section Change Logic".

5.6 Quick closing valve(s) not open


The quick closing arrangement G472 mounted on the inlet and outlet of the burner fuel
supply is activated. This will cause the control system to activate a burner shutdown
which will also deactivate any fuel oil pumps in operation.

5.7 High pressure burner return line


If the fuel-/gas oil pressure in the burner return line is detected at pressure switch F214
to exceed the maximum limit the control system will activate a burner shutdown which
also will deactivate any fuel oil pumps in operation.

5.8 Extended I/O communication error


Any disturbance or loss of communication between the control system and the connected relays and external modules will activate a burner shutdown which also will
deactivate any fuel oil pumps in operation.

28-16 / 17

Language UK

OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM

5.9 High fuel-/gas oil differential pressure


The differential pressure between fuel tank inlet and the oil system is measured to
excess the preset limit. This may indicate a clogged fuel strainer or a malfunctioning
oil flow meter.
Note: This shutdown feature is optional and will not influence the fuel flushing
sequence or burner operation if the current fuel system is not configured
with this service.

Language UK

28-17 / 17

TABLE OF CONTENTS

Table of contents
Oil pump control
Description
Oil pump control.......................................................

Language UK

Document ID
OM9294_07...............

Page
29-2

29-1 / 11

OM9294_07#C.2
OIL PUMP CONTROL

Oil pump control


1

General
The following section describes the fuel oil pump operation sequences. For fuel oil
systems with fuel oil pumps and additionally gas oil pumps these descriptions also
apply.
Figure 1 shows a guide to the structure of the Logic diagrams in the following sections.
Figure 2 shows the monitor display of the different states available for the fuel oil
pump.
Figure 3 shows the monitor display of the different modes available for the fuel oil
pump.
Figure 4 shows the interaction between the different operation modes of the individual
fuel oil pump (Pump Control Logic).
Figure 5 shows the event list that is corresponding with the Pump Control Logic.
Figure 6 shows how the flush and burner operation sequences are influenced by the
fuel pump operation mode settings (Pump Operation Logic).
The pump operation is handled by the control system. To ensure an optimal and safe
fuel oil pump operation the control system handles the local fuel pump START/STOP
signals as well as feedback from burner and fuel oil flush related operations.
The Pump Control Logic is divided into possible states and operation modes for each
individual fuel oil pump in a fuel oil pump unit. These boxes are connected by events
which, if appears, will change state/operation mode for the pumps if specified conditions are fulfilled. If the event is allowed to be executed, another event concerning the
opposite pump can be generated at the same time if specified. By means of the Pump
Control Logic a comprehensive overview of the fuel oil pump state and operation mode
can be achieved.
The Pump Operation Logic sums up in an overview how the fuel oil pump operation
mode affects the interaction between burner operation and fuel oil flush sequences.
This diagram is to be seen as a guiding overview and sequence details are for that
reason not included.

29-2 / 11

Language UK

OM9294_07#C.2
OIL PUMP CONTROL

Sequence Guide
Entering point
State selection for the pump in CMN CTRL
If FO. P STBY START = YES -> (AUTO, STOP or STANDBY)
If FO. P STBY START = NO -> (AUTO or STOP)
Pump X Selection
State

Actual state of the pump


(Running or stopped)
An event can trigger a state change
if belonging conditions are fulfilled.

evAn_event
[Conditions]/
GEN(evAn_event)

Conditions which must be fulfilled


before changing state
Another event for the opposite
pump is generated at the same
time.

Figure 1

pumpc16x2036240en.wmf

Pump Control Logic


The Pump Control Logic, Figure 4, illustrates the possible states and operation modes
for every fuel oil pump unit regardless of type. The diagram displays how the fuel oil
pump state and operation mode interacts as a function of occurred events and conditions. Furthermore it is defined which actions will be generated when the fuel oil pumps
shift between the different stages. How the fuel oil pump state and mode are displayed
at the different panels and screens, respectively, are illustrated in Figure 2 and Figure 3.
Oil pump state

Figure 2

pumpc8x2031850en.png

Oil pump mode

Figure 3

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pumpc15x2036480en.png

29-3 / 11

OM9294_07#C.2
OIL PUMP CONTROL

Warning: One of the pumps has to be set in AUTO mode in the control system
before any pump operation can take place. This can be done either by
pressing the local oil pump START button or by changing pump operation mode in the control system.

29-4 / 11

Language UK

Language UK

Figure 4

P1 Auto

Stopped

P1 AUTO

evBurner_Stop_MGO/DO operation
or evFlush_stop_command

Running

P1 AUTO

[Else]

Stopped

P1 STANDBY

evP1_Standby_start/
GEN(evP2_Forced_Stop)

evP1_AUTO/
GEN(evP2_Forced_STOP)

evP1_Forced_STOP

evP1_Forced_STOP

evBurner_Start
or evFlush_start_command
or evP1_AUTO

[Flushing active]

evP1_STOP

evP2_AUTO
[P2 remote stop not activated]/
GEN(evP1_Forced_Stop)

Stopped

P2 AUTO

Running

P2 AUTO

[Else]

evBurner_Stop_MGO/DO operation
or evFlush_stop_command

evBurner_Start
or evFlush_start_command
or evP2_AUTO

[Flushing active]

P2 Auto

Stopped

P2 STANDBY

evP2_STANDBY
[FO. P STBY START = YES
and P1_AUTO
and P2 remote stop not activated]

evP2_Standby_start/
GEN(evP1_Forced_Stop)

evP2_AUTO/
GEN(evP1_Forced_STOP)

evP2_Forced_STOP

evP2_STOP

evP2_Forced_STOP

evP2_STOP/
GEN(evP1_Forced_STOP)

Stopped

Stopped

evP1_STOP/
GEN(evP2_Forced_STOP)

evP1_AUTO
[P1 remote stop not activated]/
GEN(evP2_Forced_Stop)

P2 STOP

P1 STOP
evP1_STANDBY
[FO. P STBY START = YES
and P2_AUTO
and P1 remote stop not activated]

Power on

Power on

OM9294_07#C.2

OIL PUMP CONTROL

Pump Control Logic

pumpc17x2036250en.wmf

29-5 / 11

OM9294_07#C.2
OIL PUMP CONTROL

To reactivate an oil pump after a shutdown the cause of the shutdown(s) has to be
rectified first. Then the oil pump can be set in AUTO mode, and any remaining alarms
can be reset. Please note that an oil pump not necessarily will start when set in AUTO
mode, e.g. in specific steps during a fuel oil flushing sequence, oil pumps are not
required and the oil pump(s) reactivation will initiate as [AUTO_OFF]. The oil
pump(s) is, however, in AUTO mode and the control system will automatically start
the oil pump when required. When no specific oil pump start inhibits are present, an
oil pump will always start up when set in AUTO mode.
If the oil pump set in AUTO mode, is set in STOP mode either in the control system
or by activating the local stop button at the oil pump, all oil pumps in the respective
oil pump unit will for security reasons change to STOP (forced stop). It is not possible
to set an oil pump in standby mode if no oil pump initially is set to AUTO mode.
If an oil pump set in STANDBY mode is set in STOP mode either in the control system
or by activating the local stop button at the oil pump, only the oil pump in STANDBY
mode will change to STOP. An oil pump can only be set in STANDBY mode in the
control system menu.
Activation of the general emergency stop at the local panel(s) will immediately set all
oil pumps in STOP mode when power is recovered.
During burner operation on heavy fuel oil, the active oil pump will not stop when the
burner stops or is set in STOPPED mode. This is to keep the heavy fuel oil circulating
in the oil ring line. However, please notice that setting the burner in STOPPED mode
will deactivate the burner heat tracing plus the oil preheater for which reason close
surveillance of the active oil pump operating on heavy fuel oil must be attended by the
operator to avoid any overload of the oil pump. It is not possible to set an oil pump
operating on heavy fuel oil in STOP mode without generating a burner and oil pump
shutdown.
If an oil pump is operating on other fuel types than heavy fuel oil, the oil pump will
start and stop automatically in step with burner operation.
In Figure 5 an event list is displayed. These events correspond to the events indicated
on the Pump Control Logic and elaborate which actions the different event categories
cover.

29-6 / 11

Language UK

OM9294_07#C.2
OIL PUMP CONTROL

Event List
Events
evP1_AUTO:
- P1 Remote start
- P1 AUTO selection in controller
evP1_STOP:
- P1 Remote stop
- P1 STOP selection in controller
- P1 Safety interlock stop (Oil system) safety interlocks that will cause the oil
pump to stop.
evP1_Forced_Stop:
- Stop of P1 generated by P2 state change.
evP1_STANDBY:
- P1 STANDBY selection in controller
evP1_Standby_start
- Low oil pressure registered at the surveilling PT.
- Overload on P2
- No feedback from P2
evP2_AUTO:
- P2 Remote start
- P2 AUTO selection in controller
evP2_STOP:
- P2 Remote stop
- P2 STOP selection in controller
- P2 Safety interlock stop (Oil system) safety interlocks that will cause the oil
pump to stop.
evP2_Forced_Stop:
- Stop of P2 generated by P1 state change.
evP2_STANDBY:
- P2 STANDBY selection in controller
evP2_Standby_start
- Low oil pressure registered at the surveilling PT.
- Overload on P1
- No feedback from P1
evBurner_Start
- Burner startet manual or auto
evBurner_Stop_MGO/DO operation
- Burner stopped manual or auto after burner operation on MGO or DO.
evFlush_stop_command
- Pump stop request generated by flushing sequence.
evFlush_start_command
- Pump start request generated by flushing sequence.

Figure 5

pumpc18x2036260en.wmf

2.1 Oil pressure


High/low fuel oil pressure will activate either an alarm or a shutdown dependent of the
active oil pressure limits in the control system.
A high/low oil pressure shutdown will occur if following conditions are met:

The active oil pump is ON/RUNNING.


The oil pressure is detected to exceed the high/low oil pressure shutdown limit.
The expiry of a timer intended for allowing oil pumps to build up oil pressure at
start-up.
A high/low oil pressure shutdown will deactivate all oil pumps in the active oil pump
unit immediately including any oil pump set in STANDBY mode.

Language UK

29-7 / 11

OM9294_07#C.2
OIL PUMP CONTROL

A high oil pressure alarm will occur if following conditions are met:

The active oil pump is ON/RUNNING.


The oil pressure is detected to exceed the high oil pressure alarm limit.
The expiry of a timer intended for allowing oil pumps to build up oil pressure at
start-up.
A high oil pressure alarm will be displayed at the control system display but have no
effect on the oil pump operation.
A low oil pressure alarm will occur if following conditions are met:

The active oil pump is ON/RUNNING.


The oil pressure is detected to exceed the low oil pressure alarm limit.
The expiry of a timer intended for allowing oil pumps to build up oil pressure at
start-up.
The expiry of a timer intended for allowing any standby oil pumps to build up the
oil pressure.
A low oil pressure alarm will be displayed at the control system display. If no oil pump
is set in standby mode and the oil pressure does not drop below the low oil pressure
shutdown limit, the low oil pressure alarm will have no effect on the oil pump operation.
If an oil pump is set in standby mode, the standby oil pump will activate if one of the
three following conditions occur:

An active oil pump is ON/RUNNING, the oil pressure is detected to exceed the
low oil pressure alarm limit, the expiry of a timer intended for allowing oil pumps
to build up oil pressure at start-up and the expiry of a short timer intended for
elimination of oil pump standby start caused by sporadic fluctuations in the oil
pressure.
Feedback from the oil pump in AUTO mode is not detected within a specified
timer period.
Overload of the oil pump in AUTO mode is detected.
If an oil pump in standby mode activates, the oil pump in AUTO mode will for operational safety reasons be set in STOP mode. An alarm message indicating the standby
oil pump start will be displayed in the control system. Subsequent has the activated
standby oil pump, which is now changed to AUTO mode, not build up the oil pressure
to a level within the specified oil pressure limits, a low oil pressure alarm will occur
provided that the conditions stated in the low oil pressure alarm description are met.
After rectifying the cause of the low oil pressure, reactivation of the initial oil pump
can be done by changing pump mode in the control system and the remaining alarm(s)
can be reset.
Note: A shutdown of the oil pumps will immediately cause a shutdown of the
burner.

29-8 / 11

Language UK

OM9294_07#C.2
OIL PUMP CONTROL

2.2 Oil temperature


High/low fuel oil temperature will activate either an alarm or a shutdown dependent
of the active oil temperature limits in the control system. A high/low oil temperature
shutdown will occur if following conditions are met:

The oil temperature is detected to exceed the high/low oil temperature shutdown
limit.
A high/low oil temperature shutdown will be displayed at the control system display
and cause a shutdown of the burner. Oil pump modes will not be set to STOP by the
burner shutdown or be affected in any way. However, this does not apply for oil pumps
operating with marine gas oil since a high temperature shutdown will immediately set
the active pump, and any oil pump in the oil pump unit in STANDBY mode, to STOP
mode. This do not apply for a low temperature shutdown since only high marine gas
oil temperature directly affects the oil pumps through too low oil viscosity.
The oil temperature highly affects the oil viscosity for which reason a burner shutdown
caused by a high/low oil temperature shutdown always must be attended to with upmost
importance.
If the burner is operating on heavy fuel oil, the oil pumps will continue to circulate the
heavy fuel oil unaffected by the burner shutdown.
If the burner is operating on other fuels than heavy fuel oil, the oil pumps will stop in
step with the burner for which reason a burner shutdown will stop the oil pumps. The
oil pumps will, however, in the latter mentioned case remain in AUTO mode and thus
re-start when the burner is re-activated. This does not apply in case of a high temperature shutdown on marine gas oil, where the oil pumps will stop as mentioned above.
Note: For oil systems with two oil ring lines, and thereby two oil pump units, one
oil pump unit is not related to another for which reason e.g. one oil pump
unit circulating heavy fuel oil will not start/stop in step with the burner if
the burner is operating on oil supplied from the other oil ring line.
A high/low oil temperature shutdown will not affect any oil pumps in standby mode.
This does not apply, however, in case of a high temperature shutdown on marine gas
oil, where the oil pumps will stop as mentioned above.
A high/low oil temperature alarm will occur if following conditions are met:

The oil temperature is detected to exceed the high/low oil temperature alarm limit.
A high/low oil temperature alarm will be displayed at the control system display but
have no effect on the oil pump operation.
The oil temperature will, however, affect the oil viscosity for which reason a high/low
oil temperature alarm always must be attended to with upmost importance.
A high/low oil temperature alarm will not affect any oil pumps in standby mode.

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29-9 / 11

OM9294_07#C.2
OIL PUMP CONTROL

Note: The oil temperature limits are intended for surveillance of the burner operation. To attain optimum oil combustion, the combustion process requires a specific oil temperature dependent of burner type and oil type.

Pump Operation Logic


The Pump Operation Logic illustrates how the flush and burner operation sequences
are influenced by the fuel/gas oil pump operation mode settings. To initiate a burner
sequence a fuel oil pump always has to be available in AUTO mode. A fuel flush
sequence, however, is possible to initiate without a fuel pump in AUTO mode but the
flush sequence will generate a FLUSH STOP when the sequence requires fuel pump
availability.
The diagram is to be seen as a guiding overview and sequence details are for that reason
not included.

29-10 / 11

Language UK

OM9294_07#C.2
OIL PUMP CONTROL

Pump Operation Logic


Power on

All oil pumps in state


STOP.

Operation

Burner stopped
(STEP SHUTDOWN,
STOPPED, READY)

evBurner_Stop

evShutdown_acknowledgded

evBurner_Start

[One pump from required


pump station in AUTO]

[No pump from required


pump station in AUTO]

Burner shutdown
NO FUEL/GAS OIL
PUMPS AVAILABLE

Burner running
(STEP 1-13)

evFlushing sequence initiated


[No pump in one of the pump stations
that will be activated by the flushing
sequence is in AUTO state]

evFlushing sequence completed

[One pump in each pump station


that will be activated by the flushing
sequence is in AUTO state]

Flushing
Required pump
in AUTO state

Flushing
Required pump
not in AUTO state

evRequired_pump_in_AUTO
[Flushing sequence step in which
one of the pump stations
will be activated]
Shutdown
NO FUEL/GAS OIL
PUMPS AVAILABLE

evRequired_pump_not_in_AUTO

Figure 6

Language UK

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29-11 / 11

TABLE OF CONTENTS

Table of contents
Flame safeguard
Description
Flame safeguard........................................................

Language UK

Document ID
OM8200_07...............

Page
30-2

30-1 / 2

OM8200_07#C.1
FLAME SAFEGUARD

Flame safeguard
1

Description
The flame safeguard LAE10 is designed for the supervision of the oil flame in connection with a photo cell when the burner is in operation (Auto/Manual/Emergency).
It comprises a power section, a flame signal amplifier, a flame relay, and a flame
indication lamp located in the unit cover behind a viewing window.
All Alfa Laval burners are mounted with two flame safeguard units operating simultaneously in manual and automatic mode. This enables the control system to detect if
one flame safeguard unit malfunctions, thus increasing the burner operating safety.
In emergency mode only one flame safeguard unit is active and is connected directly
to a relay in the local panel.
In the event of non-ignition of the flame or loss of flame during burner operation, the
supply of fuel is always interrupted instantaneously. The flame safeguard unit detect
by means of the photocells whether or not a flame is present. This information is converted into a digital signal that is continuously transmitted to the control system. The
control system will activate an immediate burner shutdown if a flame is not detected
when required. Any flame signal - in normal operation or a faulty flame signal - is also
signalled by the indicator lamp.
The switching function needed to enter the flame signal to the control circuit of the
burner system is provided by the flame relay FR of the flame safeguard. Figure 1
shows an illustration of the connection diagram for the flame safeguard. The connection of the terminals can be found in the chapter containing the electric diagrams.
Connection diagram

Figure 1

30-2 / 2

om8200_04_lae10x0058160en.wmf

Language UK

TABLE OF CONTENTS

Table of contents
Descriptions
Description
Aalborg XS-2V boiler................................................
Boiler mountings.......................................................
Gauge board.............................................................

Language UK

Document ID
SD9210_13................
SD9220_22................
SD9240_20................

Page
31-2
31-4
31-6

31-1 / 6

SD9210_13#B.1
AALBORG XS-2V BOILER

Aalborg XS-2V boiler


1

Description
The Aalborg XS-2V boiler is a smoke tube exhaust gas boiler with steam space used
for heat recovery from engine exhaust gas. An illustration of the boiler is shown in
Figure 1. The boiler is designed as a vertical boiler with a cylindrical shell surrounding
the boiler tubes and water drum as well as the steam space. The tubes consist of a large
number of smoke tubes and a small number of stay tubes. The stay tubes with an
increased diameter act as support for the boiler. Both types are welded onto the lower
and upper tube plates. The steam space is formed by the shell plate and internal cone.
At the top it is closed by means of the end plate.
In the boiler tubes, heat from the engine exhaust gas is transferred to the water side by
convection. On the water side, the heat is transferred by evaporation of the saturated
water adjacent to the tubes where steam bubbles are formed. As the steam bubbles have
a much lower specific density than the water, they will rise rapidly to the steam space
where water and steam are separated. The steam space of the Aalborg XS-2V boiler is
designed to absorb the shrink and swell volumes. It is advisable, however, to avoid
sudden and large load variations as this might create instability in the steam system,
and cause level alarms.
Illustration of the Aalborg XS-2V boiler
End plate

Outlet flange

Upper tube plate

Steam space

Internal cone

NW
Scum tube

Feed tube
Smoke tubes
Shell plate
Water drum
Manhole

Stay
tubes

Blow down
tube

Smoke
tubes

Lower tube plate


Inlet flange

Exhaust gas flow

Figure 1

31-2 / 6

Foundation console

sd9210_13_aq2_drx0063790en.wmf

Language UK

SD9210_13#B.1
AALBORG XS-2V BOILER

As the pressure part is made of mild carbon steel with elevated temperature properties
stress concentrations in corner welding are minimised. In emergency mode the boiler
can therefore be operated with low water level and even without water with the full
exhaust gas flow through the boiler tubes, provided the boiler is operated depressurised
and the inside temperature does not exceed 400C.
For inside inspection, the Aalborg XS-2V boiler is arranged with both hand holes and
manholes. Two manholes are arranged at the bottom end of the boiler shell for convenient access into the water drum. For visual check of the smoke tubes and steam
space, a number of hand holes are arranged in a suitable distance at the bottom and top
of the boiler shell.
The boiler foundation consists of four foundation consoles giving the necessary support
and absorption of the thermal expansion.
Finally, the heating surface dimensions of the boiler are designed to maintain a sufficient exhaust gas velocity giving the best self-cleaning effect within the design limits.However, after long term operation soot deposits can be accumulated inside the
boiler tubes. The heating surface of the Aalborg XS-2V boiler can be cleaned easily
by means of water washing or by adding soot remover into the exhaust gas flow using
compressed air.

Language UK

31-3 / 6

SD9220_22#B.1
BOILER MOUNTINGS

Boiler mountings
1

Mountings
The following is a brief description of the most important items of the boiler mountings.
The components mentioned in this section are referring to the general arrangement
drawing of the boiler.
Safety valves
Two safety valves are fitted to the pressure vessel of the boiler. They are installed for
security reasons, and designed to prevent the boiler pressure from rising above the
design value.
The safety valves must be supplied with waste steam pipes and either expansion devices, or bellows.
Main steam valve
The main steam valve is a shut off/non-return valve. When closed, it isolates the boiler
from the main steam line. When open, it prevents steam from flowing backwards into
the boiler.
Feed water valves / feed water valves (sdnr)
Two feed water lines are provided in the boiler. Each line is fitted with a shut-off valve
and a non-return valve.
The shut-off valve in the ordinary group must be open when the boiler is in operation
and closed when the boiler is not in use.
Water level gauges
Two local water level gauges are connected to the front of the boiler, each gauge being
provided with two shut-off valves and a drain valve.
The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-closing
mechanism to be used in case of broken glass.
The pipes from the drain cocks on the water level gauge must lead to an open drain,
visible for inspection.
Blow-down valves
Two blow-down valves are mounted at the bottom of the boiler body. If connected to
a separate drainage system the valves are of the ball type. When connected to a common
drainage system two valves are provided in each group, one shut-off valve and one

31-4 / 6

Language UK

SD9220_22#B.1
BOILER MOUNTINGS

shut-off/non-return valve. The shut-off function is for security and the non-return
function prevents steam/water from flowing into an empty boiler by mistake.
Air valve
The air/ventilation valve located on top of the boiler is a shut-off valve. It is normally
closed except when the boiler is being filled or completely drained. The end of the
drain pipe from the air valve must be visible in order to determine when air or steam
is coming out.
Gauge board valve(s)
One or two gauge board valves are located on the top of the boiler and are of the shutoff type. The valves must always be opened during boiler operation.
Scum valve
The scum valve is mounted at the top of the boiler body. In the event of scum in the
boiler, this scum can be blown off from the water surface by opening this valve. If
connected to a separate drainage system the valve is of the ball type. When connected
to a common drainage system two valves are provided, one shut-off valve and one
shut-off/non-return valve.
Valves for heating coil
If provided with heating coil, the boiler is equipped with two shut-off valves for inlet
and outlet connection of the heating coil as well as a safety valve. The valves should
only be opened when the boiler is filled with water.
Sample valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Manholes
Two manholes are arranged on the boiler shell which allow inside inspection of the
pressure vessel.
Hand holes
A number of hand holes are distributed regularly around the circumference of the boiler
at the top and bottom for visual check of the smoke tubes.
Inspection doors
The boiler is or must be provided with an inspection door in both the exhaust gas inlet
and outlet boxes to enable inspection and cleaning of the heating surface.

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SD9240_20#B.1
GAUGE BOARD

Gauge board
1

Description
The function of the gauge board is for monitoring of the boiler parameters.

31-6 / 6

The pressure gauge is fitted for analogous reading of the actual steam pressure in
the boiler.
The pressure transmitter converts the actual steam pressure into corresponding
electric signals which are used for remote steam pressure indication. Furthermore,
the pressure transmitter can be used to give alarm for min. steam pressure.
The pressure switch high steam pressure gives alarm when the steam pressure
rises above the pre-adjusted set point. Reset of the alarm is only possible when the
steam pressure falls below the differential set point of the pressure switch.
Two temperature gauges can be fitted for analogous reading of the inlet and outlet
exhaust gas temperatures respectively.
A U-tube differential pressure indicator can be fitted. It indicates the differential
pressure between the inlet and outlet exhaust gas boxes.
A differential pressure transmitter can be fitted. It converts the actual differential
pressure between the inlet and outlet exhaust gas boxes into corresponding electric
signals which are used for remote indication.

Language UK

TABLE OF CONTENTS

Table of contents
Operation and maintenance
Description
Start/stop of the boiler................................................
Boiling out................................................................
Gaskets for boiler body..............................................
Boiler maintenance....................................................
Cleaning smoke tubes................................................
Preservation..............................................................
Boiler repair..............................................................

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Document ID
OM9210_05...............
OM9210_11...............
OM9010_39...............
OM9210_16...............
OM9210_38...............
OM9210_13...............
OM9210_17...............

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OM9210_05#B.1
START/STOP OF THE BOILER

Start/stop of the boiler


1

General
The following chapters of the instruction manual describe the commissioning, operation, and maintenance of the exhaust gas boiler. As this is only a part of the complete
boiler plant, it is important to study the remaining chapters in this manual very thoroughly. It is especially important that the operator of the boiler plant becomes familiar
with the operation instructions of the feed water system, steam dump equipment, and
control system.
Note: To ensure a safe and reliable operation of the boiler plant, all operation
and/or maintenance of the boiler should be carried out only by skilled personnel.

Commissioning
In connection with the boiler plant installation the entire system must be thoroughly
cleaned in order to remove all welding beads, grease, dirt, etc. It must be ensured that
all pipelines are ready for operation and that possible blind flanges used during pressure
tests have been removed.
Before putting the boiler into operation for the first time or after repair works, it should
be boiled out to remove all protecting remedies and impurities on the boiler waterside.
When the exhaust gas boiler is commissioned the following work procedures should
be carried out:

2.1 Initial commissioning


Step A: Check that the main steam valve, scum valve, blow-down valves, and sample
valve are closed.
Step B: Open the feed water valves, water level gauge valves, air escape valve, and
gauge board valve.
Step C: Fill the boiler with feed water to approximately 50 mm below normal water
level. The water level rises due to expansion when the boiler is heated. If
the temperature difference between the boiler and feed water exceeds approximately 50C, the boiler must be filled very slowly.
Note: When filling a depressurised boiler, the shut-off valve after the feed water
pump must be throttled. Otherwise the pump motor will be overloaded.If
filling takes place after the boiler has been heated by exhaust gas the feed
water should be pre-heated as much as possible.

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OM9210_05#B.1
START/STOP OF THE BOILER

Step D: Check the water level in the water level gauges. Check frequently during the
complete start-up. The water level gauges should be blown through several
times to ensure a correct indication.
Step E: Check that the water level control system is connected and operational.

2.2 Final commissioning


When the boiler is started and lightened-up, it is important to reduce the heating-up
rate in order not to cause stresses in the boiler.This can be done by reducing the engine
load to fit the appropriate heating-up rate or by by-passing some of the exhaust gas
flow if a by-pass system is provided.
The following start-up procedure assumes that the engine is in operation and the exhaust gas flow is sufficiently high to lighten-up the boiler.
Step A: Check again that the gauge board valve is open.
Step B: Check that the air escape valve is open if the boiler pressure is below 1.0
barg.
Step C: Check the water level frequently and fill the boiler with evaporated water as
described previously, if necessary.
Step D: Drain via the blow-down valves if the water level is too high.
Step E: If the air escape valve was opened, close it when only steam blows out. A
pressure reading should be indicated on the boiler pressure gauge before the
air escape valve is closed.
Step F: Re-tighten all covers such as manholes, hand holes, inspection doors, flanges, etc. during the pressure rising period. If required, check all flange joints
on the plant.
Step G: When the boiler pressure is approximately 1.5-2.0 barg and if the steam
system is not pressurised, open the main steam valve slowly to heat-up and
pressurise the steam system.
Step H: Check that any connected remote indicators are working correctly.
Step I: Open manually the steam dump valve somewhat to create an increased water
replacement in the boiler.
Step J: When the normal working pressure is reached, set the steam dump valve to
automatic mode and open the valves to the steam consumers carefully in
order to avoid water chocks.
Step K: When the boiler is in normal operation, check that the water level control
system and the gauge board functions are fully operational.
Step L: Check the opening pressure of the safety valves for the exhaust gas boiler
by closing the main steam valve and gauge board valve until the pressure
increases to the set point, adjust if necessary.

2.3 Commissioning notes


When an accumulation test of the safety valves is performed the water level inside the
boiler might increase and cause high level alarm. This is due to an increased water
temperature and a corresponding larger water volume. The water surface also becomes
more unstable during the accumulation test.
After 3-4 weeks in operation, mud and deposits in the piping system may have accumulated in the boiler water. This may cause level variations which disturb the steam

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32-3 / 21

OM9210_05#B.1
START/STOP OF THE BOILER

generation, and it is therefore recommended to blow-down the boiler. It should then


be inspected, cleaned, and refilled with boiler water.

32-4 / 21

Language UK

OM9210_05#B.1
START/STOP OF THE BOILER

Boiler operation
3.1 Boiler operation mode
The exhaust gas boiler is normally operated in connection with one or more oil fired
boilers. The combination between an exhaust gas boiler and oil fired boilers makes it
possible to operate the exhaust boiler plant in different modes. The different modes
are:
- Operation on both the oil fired boilers and exhaust gas boiler.
- Operation only on the exhaust gas boiler
Combined operation mode
The steam production is controlled by the amount of exhaust gas from the main engine
and the gauge boards of the oil fired boilers which control the burners. If the main
engine produces an insufficient amount of exhaust gas to maintain the steam pressure,
the boiler gauge boards initiate start of the burners. The burners operate as long as the
steam pressure does not exceed the set point for stop. If the steam pressure increases
above this set point, the boiler gauge boards initiate stop of the burners.
Exhaust gas boiler operation mode
When the exhaust gas flow through the boiler, produced by the main engine, is sufficient to maintain the steam pressure, the burners of the oil fired boilers will not be in
operation. If the exhaust gas flow is above the required flow to maintain the steam
pressure at a given steam output, the pressure increases. At a pre-selected set point the
steam dump equipment, located elsewhere in the steam system, opens the dump valve
and regulates the steam line pressure. If, however, the steam dump equipment is not
operational the boiler pressure may rise above the set point for high steam pressure
shut down and even up to the maximum allowable working pressure. At this point, the
safety valves open and ensure any further increase of the steam pressure. Please note
that some classification societies require a separate switch which reduces the engine
load before the maximum allowable working pressure is reached.

3.2 Normal operation


When an exhaust gas boiler has been put into service it requires only little attendance.
However, the following items must be ensured:
-

All alarms, especially feed water failure/start of stand-by pump, must be attended
to immediately and the cause must be established and rectified as soon as possible.
- The routine maintenance including cleaning of heating surface must be followed
according to the recommendations. Please see the sections for Boiler maintenance and Cleaning smoke tubes.
When the above mentioned items are followed the exhaust gas boiler operation (generating steam or stand-by) automatically follows the operation pattern of the main
engine.

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OM9210_05#B.1
START/STOP OF THE BOILER

It is strongly recommended to continuously keep the boiler operational in order to have


the system heated and pressurised. This reduces thermal stresses during the heat-up
period, and the system will be protected from ingress of oxygen which would cause
undesirable corrosion in the system.

3.3 Dry running


The design of the boiler allows operation with low water level and even without water
with the full exhaust gas flow through the smoke tubes, provided the boiler is operated
depressurised.Although the boiler materials are selected to accept unlimited dry running, there is always the risk of a soot fire and every effort tore-establish the feed water
circulation should be made in order to reduce the dry running period to a minimum.
Furthermore, operation of the boiler without water eventually dries out the gaskets,
and a replacement of the gaskets is necessary.
Attention: Dry running must be limited as far as possible and only allowed in
case of emergencyif no other operation alternatives are present. Before start of the boiler it must be drained and the manhole cover
should be dismounted to ensure that it is operated completely depressurised. Please note that the temperature inside the boiler must not
exceed 400C.
When the boiler operates without water, it will gradually be heated to the same temperature as the exhaust gas. It is therefore important to allow the boiler to cool before
refilling it with feed water. If this is not possible, the feed water should be pre-heated,
and the refilling should be carried out very carefully.

Boiler stop
4.1 Stop to normal stand-by condition
The main engine can be stopped at any time without special preparations regarding the
boiler plant. A slow engine turn-down/stop sequence is obviously preferable, as this
will reduce the thermal stresses to the equipment.
-

The circulation of water through the exhaust gas boiler must be maintained at
normal level until the boiler stops producing steam.
Stop the feed water pump and close the feed water valves, if desired.
Close the main steam valve, if desired.

4.2 Emergency stop


The boiler must be taken out of service immediately if:

32-6 / 21

A substantial loss of water is noted.


The safety valve cannot function.
Oil in the boiler water is detected.
Too high salinity level is detected.

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OM9210_05#B.1
START/STOP OF THE BOILER

If an emergency shut down must be carried out the main steam valve should be closed
gradually and the boiler must be cooled. The safety valves must not be operated. Parallel working boilers should be disconnected at once.

4.3 Stop for repair or inspection


When the boiler is stopped for repair and inspection the following measures should be
taken:

Language UK

Stop the boiler as described in section 4.1.


Check the fouling factor of the smoke tubes and water wash if necessary.
Inspect the exhaust gas side as well as the steam/water side.
Check and clean the outer fittings. Change gaskets where required.
Clean the feed water tank and feed water pipes.
Check that the necessary spare parts are available. Order complementary parts in
time.

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OM9210_11#B.1
BOILING OUT

Boiling out
1

Boiling out
Before putting the boiler into operation for the first time, it should be boiled out to
remove all protecting remedies and impurities on the boiler waterside.
The boiling out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling the chemicals. The person
handling the chemicals/solution should be properly dressed/protected.
Step A: Fill the boiler with a solution consisting of 4-5 kg trisodiumphosphate
Na3PO4 per 1000 kg water. The chemicals can be added through the manhole.
Step B: Add feed water until the solution is visible in the water gauges above lower
water level.
Step C: Close the feed water valve (pump stopped).
Caution: Do never fill feed water into the boiler if the temperature difference
between boiler and feed water exceeds 50C.
Step D: Raise steam pressure slowly to working pressure, and keep the pressure for
approx. 3-4 hours with closed main steam valve.
Step E: Scum until water level is between Normal water level and High water
level.
By this procedure grease and other impurities are removed from the internal surfaces
of the boiler.
Step F: Start skimming by opening the scum valve, and lower the water level to
lower edge of Normal water level mark.
Step G: Close the scum valve.
Step H: Refill the boiler with feed water and start skimming again in intervals of 30
minutes for a period of two hours.
Step I: Stop the boiling out procedure by switching off the burner.
Step J: Let the boiler water rest for about five minutes.
Step K: Carry out a final skimming.
Step L: Blow off the boiler water by opening the blow down valves.
Step M: Remember to open the air escape valve, to avoid a vacuum in the boiler when
the boiler pressure decreases to approx. depressurised/atmospheric pressure.
Step N: Open the manhole and let the boiler cool down to approx. 100C.
Step O: The boiler is to be flushed with clean water on the boiler waterside, when
the temperature has decreased. The flushing removes remaining impurities.

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OM9210_11#B.1
BOILING OUT

Step P: Dismantle the bottom blow down valves, for cleaning and inspection because deposits/foreign substances will usually be accumulated in these
valves and cause leaking if not cleaned.
Step Q: Inspect the boiler and remove any remaining deposits and foreign substances.
Step R: Finally, new gaskets to be fitted in all hand- and manholes before refilling
the boiler with water to upper edge of Low water level.
The boiler is now ready to be taken into service.
Note: During the first two weeks in operation we recommend to carry out frequently skimming and bottom blow down to remove impurities entering
the boiler from the pipe system.

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32-9 / 21

OM9010_39#D.1
GASKETS FOR BOILER BODY

Gaskets for boiler body


1

Gaskets
The gaskets for boiler body can be seperated into three types. which is manhole, head
hole and hand hole gaskets depending of the boiler types. The chosen types is shown
on the general arrangement drawing of boiler
The gaskets are of a high-tech, compressed fibre material which makes them ideal for
steam.

1.1 Storage and handling


The gaskets should always be stored horizontally to avoid tensions. Also, they should
be stored in clean condition and in a dark storage room.
Ideal temperature: < 25C.
Ideal air humidity: 50-60%.
Never bend the gaskets or damage their surfaces.

1.2 Installation
Note: For safety reasons, never re-use a gasket.
Make sure that all sealing surfaces are clean and dry. Be sure not to damage/scratch
sealing surfaces while cleaning. Also check that sealing surfaces are parallel and free
of damages and cracks.
All gaskets should be installed clean and dry. No form of gasket compounds can be
used for installation. These might damage the gaskets and result in possible blowouts
of the gaskets. The gaskets are coated with a non-sticking film.
Ensure that bolts and nuts are clean and free of corrosion and apply lubricant on the
threads.The lubricant must not contaminate gaskets or sealing surfaces. Insert the gaskets carefully in the covers and place the covers with the new gaskets in the manholes/
hand holes. Ensure that the coversare centralized in the manholes/hand holes.
Make at least 4 stages to the required torque.
Finger-tighten the bolts.
Use 30% of the required torque.
Use 60% of the required torque.
Use the required torque.

32-10 / 21

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OM9010_39#D.1
GASKETS FOR BOILER BODY

1.3 Recommended torque

Manhole : 250 Nm.


Head hole : 160 Nm
Hand hole: 500 Nm.

1.4 Re-tightening
Re-tightening must be done in hot condition during the first 24 hours of the startingup of the plant. Re-tightening of high-tech, compressed fibre gaskets under pressure
and after a long period of operation might lead to leaking gaskets and possible blowouts.

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32-11 / 21

OM9210_16#B.1
BOILER MAINTENANCE

Boiler maintenance
1

Boiler maintenance
The boiler maintenance should always be executed with skill and in accordance with
valid rules and regulations from the authorities. Below some recommendations are
given for periodical inspections and maintenance.

1.1 Daily operation


During normal operation of the boiler, some work and check procedures have to be
considered every day.
Step A: Check the boiler steam pressure and the water level.
Step B: Check that the feed water control system is operational, see separate instructions.
Step C: Check that the feed water pumps are running smoothly without vibration or
noise.
Step D: Check the boiler water condition and make necessary counter measures with
regard to the feed and boiler water treatment. If necessary, blow down the
boiler.
Step E: Check and record the exhaust gas inlet and outlet temperatures as well as
the exhaust gas pressure loss across the boiler at the actual main engine loads.
An outlet temperature or a pressure loss higher than expected indicate that
the heating surface may be fouled and need to be cleaned.

1.2 Weekly routine checks


Step A: Drain each water level glass for about 10-15 seconds. In case of contaminated boiler water or insufficient water treatment draining of the water level
glasses must be done more often.
Step B: Depending on the boiler water tests blow down the boiler. Open the blow
down valves quickly for a few seconds and then close and open again for
about 5-10 seconds. Repeat this operation when required according to the
boiler water tests.
Step C: Perform scum blow out by means of the scum valve when required. The
scum blow out must be carried out until the drained water is clean.

1.3 Monthly routine checks


Step A: Test the function for automatic stand-by start of the non operational feed
water pump by stopping the operational pump.
Step B: Check all boiler mountings for damage or leaks and repair/replace if necessary.
Step C: Check the function of the high steam pressure switch and, if provided, the
main engine slow down switch. This can be done by lowering the set point
or by raising the steam pressure, e.g. by closing the main steam valve slowly.

32-12 / 21

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OM9210_16#B.1
BOILER MAINTENANCE

Inspection of the boiler


2.1 Inspection of boiler exhaust gas side
The exhaust gas section should be inspected at least once a year. During this inspection,
the following issues should be taken into consideration:

Check the welding in the exhaust gas section. A careful examination should be
carried out with respect to any possible corrosion or crack formation.
Check that the smoke tubes and stay tubes are intact and that soot deposits are
within normal limits.
Check that the inlet box and outlet box are intact and that soot deposits are within
normal limits.

2.2 Inspection of boiler steam/water side


The boiler steam/water side (interior) must be carefully inspected at least once a year.
This inspection is of great importance since it has a direct influence on the boiler
longevity and on the security.
At these inspections, hard deposits, corrosion, and circulation disturbances can be
found at an early stage and preventive measures must be taken to avoid unexpected
material damage and boiler breakdown. The presence of hard deposits at the boiler
tubes reduce their heat transfer properties and decrease the capacity of the boiler. Further, it can be established whether the feed water treatment is satisfactory, and whether
the blow-down is carried out sufficiently. Insufficient blow-down will cause accumulation of sludge in the bottom of the boiler. Incorrect feed water treatment is commonly
causing hard deposits or corrosion. If hard deposits are not removed, it may lead to
overheating. Incorrect feed water treatment does, however, not always lead to hard
deposits. For example, a too low or too high pH-value may give an electrolytic reaction,
causing corrosion in the boiler.
When the boiler interior is inspected, examine all parts carefully and be attentive to
deposits, corrosion, and cracks. It is advisable to pay special attention to this inspection.
If any unusual signs are found, contact Alfa Laval at once for advice.

2.3 Procedure and remarks for inspection


Step A: Stop the boiler and allow it to cool.The boiler should not be depressurised
by lifting the safety valves and then filling it with cold feed water as the
stress induced by too rapid cooling may cause damage.
Step B: Ensure that the boiler is depressurised and that all valves are closed.
Step C: Access for inspection is achieved through the manholes, hand holes and
inspection doors. The boiler can be entered when it is sufficiently cold.
Step D: Check the welding in the boiler. A careful examination should be carried
out with respect to any possible corrosion or crack formation.
Step E: Special care should be taken with regard to inspection of the water line area
in the pressure vessel where oxygen pitting may occur.

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OM9210_16#B.1
BOILER MAINTENANCE

Step F: If deposits are forming at the boiler tubes, the boiler should be chemically
cleaned. It is advisable to consult a company of cleaning specialists who will
examine the boiler deposits and treat the boiler accordingly.
Step G: After chemical treatment the boiler should be blown down at least twice a
day for approximately one week. This will ensure that excessive sludge deposits due to chemical treatment do not collect in the bottom of the pressure
vessel.

2.4 Contamination
If the steam/water side of the boiler is contaminated with foreign substances like oil,
chemicals, corrosion products etc., it is very important to act immediately to avoid
damage of the boiler. Layers of thin oil films, mud, etc. exposed to the heating surfaces
cause poor heat transfer in the boiler, leading to overheating followed by burned out
pressure parts. In order to remove such contamination, a boiling out or acid cleaning
should be performed immediately.
Note: Corrosion products from the pipe system or insufficient boiler water treatment may result in corrosion in the boiler itself. It is therefore important
to observe that such circumstances do not occur in the system.

32-14 / 21

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OM9210_38#B.1
CLEANING SMOKE TUBES

Cleaning smoke tubes


1

General
The heating surface dimensions of the boiler are designed to maintain a sufficient
exhaust gas velocity giving the best self-cleaning effect within the design limits. However, after long term operation soot deposits can be accumulated inside the smoke
tubes. The main engine exhaust gas contains carbon particles and un-burnt residues
(soot, etc.) and the amount is strongly dependent on the state of the engine and the
supply of scavenging air. These soot/un-burnt residues will accumulate on the boiler
heating surface if not removed by cleaning.Furthermore, the combustion quality of the
engine is changing together with the load, where the best combustion is in the high
load range and the lower range is giving a more contaminated (black/coloured) exhaust gas. And the more contaminated the exhaust gas is, the more fouling will appear
in the exhaust gas boiler.Therefore, it is impossible to specify exact time intervals in
which the smoke tubes should be soot cleaned. However, some general guidelines are
given below:

Inside inspection.
Check of the exhaust gas temperature on the outlet side of the boiler. The boiler
should be cleaned if the outlet exhaust gas temperature lies approx. 20C above
the temperature in a clean boiler at a specified engine load.
Check of the pressure loss. The boiler should be cleaned if the pressure loss lies
approx. 20 mm WC above the pressure loss in a clean boiler.
It is recommended to keep a consecutive record of the exhaust gas temperature and
pressure loss related to different engine loads in a clean boiler. These original data
should be used for comparison, and plotted into a measurement chart like the one shown
in Figure 1. In this way it is possible to monitor the fouling condition of the smoke
tubes and determine when they need to be cleaned.

Outlet temp.

Diff. pressure

10

20

30

40

50

60

70

80

Diff. Pressure [mmWC]

Outlet Gas Temp. [C]

Check scheme for exhaust gas measurements

90 100

Load %

Figure 1

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om9210_38_dp_tubx0059900en.wmf

32-15 / 21

OM9210_38#B.1
CLEANING SMOKE TUBES

Water washing procedure


The most effective way of soot cleaning is water washing, as most of the deposits
consist mainly of non-soluble particles held together by a water soluble bonding material. Water washing will have the following benefits:

Dissolves the bonding material.


Washes the loosened insoluble deposits away.
Water washing must be carried out when the main engine is stopped and the boiler has
been cooled down. However, the boiler should be warm enough for the water to evaporate so that the tubes will not remain moist after washing.
Both fresh and sea water can be used. However if sea water is used, the boiler must be
thoroughly washed afterwards with fresh water in order to remove all salt deposits.
Where deposits are highly corrosive or bonded, a soaking spray with a 10% soda ash
solution is advisable before washing.
Step A: Ensure that the main engine is stopped or by-pass the exhaust gas flow, if
possible.
Step B: Wait a minimum of time allowing the boiler to cool.
Step C: Open the inspection doors above and below the boiler.
Step D: Open the drain at the bottom of the inlet box to the soot collecting system,
and make sure that there is free passage.
Step E: Open drains at the turbo chargers and make sure that there is free passage.
Step F: If there is a risk that the washing water will run into the exhaust gas pipe
and down to the turbo chargers, the exhaust gas pipe must be covered. This
can be done by e.g. covering the exhaust gas inlet pipe with a waterproof
tarpaulin as indicated inFigure 2.
Step G: Start water washing using a hand water lance or fire hose inserted through
the inspection door of the outlet box and direct the jet of water directly at
the smoke tubes. In the beginning the water supply should only be slightly
opened, just enough to have a small amount of water to ensure that the
drainsare working properly.
Step H: When it has been ensured that the washing water is running freely down
through the drain system into the soot collecting system, the water amount
can slowly be increased, until a flow of approximately 50 l/minat a water
pressure between 4 to 6 bar is obtained.
Warning: When the smoke tubes are water washed, there is a risk of generating
steam. It is therefore very important that all of your body is outside
the outlet box in order not to get your skin burned by the steam.
Step I:

It is important to check that the drain and soot collecting system are working
properly during the whole water washing procedure.
Step J: When the water washing has begun, it must be completed until the heating
surface is thoroughly washed and all deposits are removed. This is due to
the fact that some types of coatings harden and accordingly get very difficult
to loosen when they have been saturated and then dry out.

32-16 / 21

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OM9210_38#B.1
CLEANING SMOKE TUBES

Water washing of the smoke tubes


Exhaust gas outlet

Inspection door
Water washing hose

Exhaust gas inlet

Inspection door

Insert a waterproof
tarpaulin into the
exhaust gas pipe
Inlet box drain

Figure 2

om9210_38_aq2_wax0059890en.wmf

Step K: When the water washing has been completed, it must be ensure that all the
washing water is drained awayby looking into the inlet box from the inspection door. The bottom of the inlet box must be cleaned with alkaline
water because the washing water is very corrosive.
Step L: The boiler must be dried out immediately after water washingby having a
natural air circulation through the boiler or by heating it up with feed water.
This is because soot formations produced by the combustion process in the
engine contain sulphur compounds. Any residual soot and water will therefore react chemically to form a highly corrosive sulphuric acid.
Step M: Remove the waterproof tarpaulin from the exhaust gas inlet pipe, if inserted,
and close drains as well as inspection doors.
Step N: The boiler can now be brought back into normal service.

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32-17 / 21

OM9210_13#C.1
PRESERVATION

Preservation
1

Preservation of the boiler


If the boiler is to be shutdown for a period of 1-30 days, it should be top filled to prevent
corrosion. Before top filling, it should be cleaned from soot deposits.
If the boiler is to be shut down for more than one month, different methods to prevent
corrosion can be applied:

Dry preservation.
Wet preservation.
Nitrogen preservation.
VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:

1.1 Dry preservation


When this method is applied the boiler should be totally emptied off water and dried
out.
Step A: Empty the water/steam contents inside the boiler by means of the bottom
blow down at a boiler pressure of 3-5 barg. Open the boiler when it is depressurised and drain offany remaining water.
Step B: Manhole doors and hand hole covers should be opened when the boiler is
still hot. If there is water left in the bottom of the boiler it must be removed,
e.g., by using a vacuum cleaner.
Step C: If the boiler is cold, drying of the boiler can be done by either circulating
dried air from a fan or by placing bags of silicagel inside the boiler.
Step D: Before the manhole doorsand hand hole covers are closed, place a tray with
burning charcoal to remove oxygen. As soon as the tray with charcoal is in
position, close the manhole doors and hand hole covers using new gaskets.
Step E: Alternatively, a small steam phase inhibitor can be added to the boiler after
cooling and careful draining. Afterwards the boiler should be closed completely.

1.2 Wet preservation


While dry preservation is a question of draining off water to avoid corrosion, the principle of wet preservation is to prevent oxygen from entering the boiler.
This method can be used for a short period of lay-up (1-3 months).
Step A: The boiler is filled with treated boiler water and oxygen binding agents according to suppliers specification.

32-18 / 21

Language UK

OM9210_13#C.1
PRESERVATION

Step B: The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen, and it is necessary to check
the concentration of oxygen binding agents and add the necessary amount
to maintain supplier specifications.
The pH-value should be 9.5-10.5.
Note: If there is any risk of the temperature falling back below 0C, this method
should not be used to avoid frost damages.
If this preservation method involves applying hydrazine to the water inside the boiler,
the boiler must be completely drained and refilled with fresh water before taken into
service again.

1.3 Nitrogen preservation


The boiler should be drained, dried and sealed in the same way as mentioned in section
1.1,Dry preservation.
Step A: Make a connection point to the bottom of the boiler and open the air escape
valve on top of the boiler.
Step B: Connect cylinders with nitrogen to the bottom connection point via a reduction valve and purge the boiler until there is no oxygen left.
Step C: Close the air escape valve.
Step D: Leave a cylinder with nitrogen connected to the boiler via a reduction valve
and keep an overpressure of approximately 0.2 bar inside the boiler.

1.4 VCI preservation


An alternative to the above mentioned preservation methods may be the use of a socalled volatile corrosion inhibitor (VCI).
The VCI is a water soluble chemical which partly evaporates and protects both the
water and steam spaces of the boiler. It should be able to eliminate the need for complete
drainage and/or application of nitrogen, and may in particular be interesting when a
forced circulation type exhaust gas boiler is installed in the steam system. The boiler
must be effectively sealed from the atmosphere to maintain the corrosion protection.
The VCI is offered by various chemical companies and must be used in accordance
with their recommendations.

Language UK

32-19 / 21

OM9210_17#C.1
BOILER REPAIR

Boiler repair
1

Plugging of tubes
In case of a leakage tube, the boiler must be stopped and the pressure lowered to
atmospheric pressure. If the leaking tube cannot be located immediately via the inspection doors, the boiler should be set on pressure by means of the feed water pumps
so that the leakage indicates the damaged tube.
Step A: The main engine must be stopped during the repair work.
Step B: Open and, if necessary, remove the inspection doors in the exhaust gas inlet
box and outlet box.
Step C: When the damaged tube has been located, clean the inside of the tube ends
with a steel brush so that no deposits are present in the tube.
Step D: Plug and seal weld both tube ends with a conical plug, see Figure 1.
Note: Tube plugging results in reduced efficient heating surface, and accordingly
the boiler efficiency will decrease.
Attention: The classification society should be notified about the repair work and
a schedule must be made for exchange of the damaged tubes.

Exchange of tubes
From an operational point of view up to 10% to 15% of all tubes can be plugged with
a conical plug, but if more tubes are damaged, an exchange of tubes is necessary.It is
possible to replace the tubes from the outside of the boiler. After location of the damaged tubes, they must be replaced according to the following procedure:
Step A: The main engine must be stopped during the repair work.
Step B: Ensure that the boiler pressure is lowered to atmospheric pressure and that
it is completely drained of water.
Step C: Open and remove the inspection doors in the exhaust gas inlet box and outlet
box. If necessary remove the inlet box and/or outlet box.
Step D: The damaged tubes must be cut right below and above the tube plates.
Step E: Remove the damaged tubes.
Step F: Scraps of metal and welding material in the tube holes as well as the tube
plates must be grinded off.
Step G: The new tubes should be placed in the tube holes one by one and seal welded
onto the tube plates as shown in Figure 1.

32-20 / 21

Language UK

OM9210_17#C.1
BOILER REPAIR

Note: Only skilled personnel with knowledge and qualifications to perform certified welding should perform repair work.
Step H: The tubes should be rolled after the welding work has been completed.
Step I: After completion of the repair work, clean the working area.
Step J: Refill the boiler with feed water and check for leaks through the inspection
doors before starting up.
Step K: Mount and close the inspection doors again.
Illustration of how to plug and exchange tubes
Upper tube plate

Plugging of tube

Exchange of tube

2.5
3.5

Lower tube plate

Figure 1

Language UK

Conical tube plug

om9210_17_aq2_rex0059660en.wmf

32-21 / 21

TABLE OF CONTENTS

Table of contents
Feed and boiler water
Description
Feed and boiler water.................................................

Language UK

Document ID
OM9210_99...............

Page
33-2

33-1 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Feed and boiler water


1

General
Note: The recommended feed and boiler water characteristics are only valid for
boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants. Methods
such as e.g. reverse osmosis plants or ion exchange plants produce good quality distillate. Also evaporators generally produce good distillate. The important thing is that
the distillate used should be clean and without foreign salt contamination.
In practice most distillates used contain minor parts of various salt combinations which
can and must be chemically treated away. Furthermore, the distillate may contain dissolved gases like for example oxygen (O2) and carbon dioxide (CO2) which may lead
to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically treated in order to avoid
corrosion and scaling in the boiler.

Layout of the treatment system


The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system should
therefore be considered carefully during layout of the plant. Alfa Laval gives some
general requirements and recommendations regarding the conditions of the feed and
boiler water. However, there is several ways to obtain this results, or similar, by using
different treatment systems. The following should therefore be considered already at
the layout stage:
-

33-2 / 15

Choose the treatment system that should be used.


Present the condensate and feed water system to the supplier of the treatment system and inform about the operation philosophy of the plant.
Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
Let the supplier inform about which test facilities is needed.
Purchase the recommended equipment and install it in the correct way.
Use the treatment system as soon as the boiler is taken into operation.

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Feed and boiler water characteristics


The following text regarding feed and boiler water treatment is the normal recommendations given by Alfa Laval. These recommendations should be followed strictly
in order to have the best working conditions for the boiler plant and to extend the
working life of the plant. The requirements/recommendations of the various values for
feed and boiler water are listed in Table 1 below.

Requirements for feed and boiler water


Appearance
Hardness
Chloride content
"P" alkalinity
Total (T) alkalinity
PH-value at 25C
Hydrazine excess
Phosphate excess
Specific density at 20C
Conductivity at 25C
Oil content
Copper content

Unit
ppm CaCO3
ppm Clppm CaCO3
ppm CaCO3
ppm N2H4
ppm PO4
Kg/m3
S/cm
ppm

Feed water
Clear and free of mud
0-5
15
8.5 - 9.5
NIL
<0.02

Boiler water
Clear and free of mud
100
100 - 150
2 x "P" - Alkalinity
10.5 - 11.5
0.1 - 0.2
20 - 50
1.003
2000
NIL
<0.3

Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2SO3) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended that
an excess of oxygen binding agents can be measured and indicates that no oxygen has
been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is recommended
to keep the value 0.02 ppm.
In addition to the above values, the various water treatment companies will add further
demands, depending on the method used for treatment of feed and boiler water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.

3.1 Units of measurement


Concentrations are usually expressed in "ppm" i.e. parts solute per million. Concentrations for parts solution by weight are the same as "mg/litre".

Language UK

33-3 / 15

OM9210_99#D.1
FEED AND BOILER WATER

3.1.1 Specific gravity


As guidance the following conversion can be used:

1 Be = 10.000 mg/l total dissolved solids (TDS)


1 mg/l total dissolved solids = 2 S/cm
1 S/cm = 1 mho

Feed and boiler water maintenance


The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together with the supplier of
chemicals for water treatment.

4.1 Recommended water maintenance


4.1.1 Daily
Step A: Analyses of feed and boiler water.
4.1.2 Weekly
Step A: Skimming (surface blow down) according to analyses, but at least once per
week (2 minutes with fully open valve).
Step B: Blow down (bottom blow down) according to analyses, but at least once per
week (each blow down valve 1 minute in low load condition).
If the copper content is on a stable level below the value in table 1, the analyse frequence
can be reduced to once per week.
4.1.3 Monthly
Step A: Check the functions for salinity and oil detection systems.
4.1.4 Every six months
Step A: The boiler water side (interior) must be carefully inspected at least twice a
year.
4.1.5 Yearly
Step A: Check of the water side of the boiler and hotwell/deaerator for corrosion and
scaling.
Step B: Check the chemical pump unit.

Treatment systems / injection points


In the following tables and illustrations a number of different feed and boiler water
treatment systems are shown together with the recommended location for the injection
point of the individual chemicals as stated by the manufacturer. The general information regarding the injection point principle can be used as guidelines for the most
common systems. But should there be any doubt for a specific system the manufacturer/
supplier should be consulted in order to obtain the correct result.

33-4 / 15

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Notes for tables/illustrations:


Note No. 1: the preferred injection point of chemicals stated by the manufacturer/
supplier.
Note No. 2: the alternate injection point of chemicals stated by the manufacturer/
supplier.
Note No. 3: Valid for modulating feed water systems.
Note No. 4: valid for on/off operating feed water systems. The chemical pump
starts/stops together with the feed water pump.
Note No. 5: valid for two boiler installation. Control of the chemicals in question
work properly at an equal load condition (feed water flow) on the two boilers.
How to use the tables:
The tables can be used in different ways but the main idea is to do following:
Step A: Discover which manufacturer and type of chemicals that should be used for
the actual boiler plant.
Step B: Use the name of the manufacturer and type of chemicals to select which
tables that can be used.
Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram
that matches the actual boiler plant.
Step D: Find in the selected tables the table which includes the matching diagram.
Step E: If more than one table is found to match the actual boiler plant in question
it is recommended to use the method/table which includes note No. 1.
Step F: If no table is found to match the actual boiler plant in question it is recommended to seek assistance by the chemical manufacturer/supplier.

Language UK

33-5 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3, 3a, 3b
GC
3, 3a, 3b
SLCC-A
3, 3a, 3b
Drewplex OX
2, 2a, 2b

Standard with Drewplex OX


Continuous
Batch
X
X
X
X

Note No.
1
1
1
1, 3, 4

Table No. 1

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3, 3a, 3b
GC
3, 3a, 3b
SLCC-A
3, 3a, 3b
Amerzine
2, 2a, 2b

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.
1
1
1
1, 3, 4

Table No. 2

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3
GC
3
SLCC-A
3
Amerzine
1

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.

Table No. 3

Valid flow diagram No.


1

2, 3, 4

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Adjunct B
3a, 3b
GC
3a, 3b
SLCC-A
3a, 3b
Amerzine
1

Standard with Amerzine


Continuous
Batch
X
X
X
X

Note No.

Table No. 4

Valid flow diagram No.


2, 3

2, 3, 4, 5

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
3, 3a, 3b
Drewplex OX
2, 2a, 2b

Drewplex AT / OX
Continuous
X
X

33-6 / 15

Batch

Note No.
1
1, 3, 4

Table No. 5

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Drewplex OX
2, 2a, 2b

Drewplex AT / OX
Continuous
X
X

Batch

Note No.
2, 3, 4
3, 4

Table No. 6

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
3, 3a, 3b
Amerzine
2, 2a, 2b

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
1, 3, 4
1, 3, 4

Table No. 7

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Amerzine
2, 2a, 2b

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4
3, 4

Table No. 8

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Drewplex AT
2, 2a, 2b
Amerzine
1

Drewplex AT with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4
2, 3, 4, 5

Table No. 9

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
2, 2a, 2b
Amerzine
2, 2a, 2b

AGK-100 with Amerzine


Continuous
Batch
X
X

Language UK

Note No.
1, 3, 4
1, 3, 4

Table No. 10

Valid flow diagram No.


1, 2, 3

33-7 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
2, 2a, 2b
Amerzine
1

AGK-100 with Amerzine


Continuous
Batch
X
X

Note No.
3, 4
2, 3, 4, 5

Table No. 11

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
AGK-100
1
Amerzine
1

AGK-100 with Amerzine


Continuous
Batch
X
X

Note No.
2, 3, 4, 5
2, 3, 4, 5

Table No. 12

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
Alkalinity control
3, 3a, 3b
Phosphate
3, 3a, 3b
Oxycontrol
2, 2a, 2b
Marichem CCI
2, 2a, 2b

Standard
Continuous

Table No. 13

Batch
X
X

X
X

Note No.
1, 3, 4
1, 3, 4
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
Alkalinity control
1
Phosphate
1
Oxycontrol
2
Marichem CCI
2

Standard
Continuous

Table No. 14

Batch
X
X

X
X

Note No.
2, 3, 4
2, 3, 4
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT new formula
2, 2a, 2b
Marichem CCI
2, 2a, 2b

BWT new formula


Continuous
X
X

33-8 / 15

Table No. 15

Batch

Note No.
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT new formula
1
Marichem CCI
2, 2a, 2b

BWT new formula


Continuous

Table No. 16

Batch
X

Note No.
2, 3, 4, 5
3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT powder
2, 2a, 2b
Marichem CCI
2, 2a, 2b

BWT
Continuous
X
X

Table No. 17

Batch

Note No.
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Marichem

Product name / method:


Chemical name
Injection point No.
BWT powder
1
Marichem CCI
2, 2a, 2b

BWT
Continuous

Table No. 18

Batch
X

Note No.
2, 3, 4, 5
3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Ashland Chemical / Drew Marine Division

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Oxygen control
2, 2a, 2b
Condensate control
2, 2a, 2b

I
Continuous

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Table No. 19

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Oxygen control
2
Condensate control
2

Language UK

Continuous

X
X

Table No. 20

Batch
X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

33-9 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Cat sulphite L (CSL)
2, 2a, 2b
Condensate control
2, 2a, 2b

II
Continuous

Table No. 21

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Cat sulphite L (CSL)
2
Condensate control
2

II
Continuous

Table No. 22

Batch
X
X

X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Liquitreat
3, 3a, 3b
Condensate control
2, 2a, 2b
(Oxygen control)
2, 2a, 2b

Liquitreat
Continuous

Table No. 23

Batch
X

X
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Liquitreat
1
Condensate control
2, 2a, 2b
(Oxygen control)
2, 2a, 2b

Liquitreat
Continuous

Table No. 24

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Combitreat
3, 3a, 3b
Condensate control
2, 2a, 2b
Oxygen control
2, 2a, 2b

Combitreat
Continuous

33-10 / 15

X
X

Table No. 25

Batch
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Combitreat
1
Condensate control
2
Oxygen control
2

Combitreat
Continuous

Table No. 26

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Unitor Chemicals

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Hydrazine
2, 2a, 2b
Condensate control
2, 2a, 2b

I
Continuous

Table No. 27

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Hydrazine
2
Condensate control
2

I
Continuous

Table No. 28

Batch
X
X

X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
3, 3a, 3b
Alkalinity control
3, 3a, 3b
Oxygen control
2, 2a, 2b
Condensate control
2, 2a, 2b

II
Continuous

Table No. 29

Batch
X
X

X
X

Note No.
1
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
Hardness control
1
Alkalinity control
1
Oxygen control
2
Condensate control
2

II
Continuous

Language UK

X
X

Table No. 30

Batch
X
X

Note No.
2
2
3, 4
3, 4

Valid flow diagram No.


1

33-11 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
BWT One Shot
3, 3a, 3b
Alkalinity control
3, 3a, 3b
(Hydrazine)
2, 2a, 2b

One Shot
Continuous

Table No. 31

Batch
X

X
X

Note No.
1
1, 3, 4
1, 3, 4

Valid flow diagram No.


1, 2, 3

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
BWT One Shot
1
Alkalinity control
2, 2a, 2b
(Hydrazine)
2, 2a, 2b

One Shot
Continuous

Table No. 32

Batch
X

X
X

Note No.
2
3, 4
3, 4

Valid flow diagram No.


1

Chemical injection points (continued)


Manufacturer / supplier:

Uniservice Group

Product name / method:


Chemical name
Injection point No.
OBWT 3
3, 3a, 3b
OBWT 4
2, 2a, 2b

Organic Treatment
Continuous
Batch
X
X

Table No. 33

Note No.
1
1, 3, 4

Valid flow diagram No.


1, 2, 3

Table 2

33-12 / 15

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 1


Service
steam

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate
Make-up

Boiler

Overflow
Hot well
Drain

1
2
PI

PI

PI

PI

PS

Single boiler operation with or without


forced circulation exhaust gas boiler

Figure 1

Language UK

Feed water
pumps

om9210_99_flowdix0060010en.wmf

33-13 / 15

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 2


3b

Service
steam

3a

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate

Boiler

Make-up

Boiler

Overflow
Hot well
Drain

1
2a
PI

PI

PI

PI

PS

2b

PI

PI

PI

PI

Feed water
pumps

PS

Double boiler operation with separate feed water pumps


with or without forced circulation exhaust gas boiler

Figure 2

33-14 / 15

Feed water
pumps

om9210_99_flowdix0060020en.wmf

Language UK

OM9210_99#D.1
FEED AND BOILER WATER

Flow diagram No.: 3


3b

Service
steam

3a

PT

Steam
dump
valve

Condenser

Cooling
water

Condensate

Boiler

Make-up

Boiler

Overflow
Hot well
Drain

1
2a

2b

PS PI

PI

PS PI

PI

PS PI

PI

Feed water
pumps

Double boiler operation with common feed water pumps


with or without forced circulation exhaust gas boiler

Figure 3

Language UK

om9210_99_flowdix0060030en.wmf

33-15 / 15

TABLE OF CONTENTS

Table of contents
Water level gauge
Description
Water level gauge......................................................

Language UK

Document ID
OM7010_03...............

Page
34-2

34-1 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Water level gauge


1

Maintenance and service instructions


This section describes the maintenance and service instructions for the water level
gauge.
Illustration of the water level gauge

1 - Nut
2 - Box heads
3 - Joint rings
4 - Box heads
5 - Tubes
6 - Screws
7 - Screws
8 - Cock plug
D - Drain cocks
G - Gauge body
S - Cocks
W - Cocks

W
5
4
1

Figure 1

om7010_03_kli_01x0057060en.wmf

1.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure 1.

34-2 / 6

Language UK

OM7010_03#A.2
WATER LEVEL GAUGE

When out of service with the gauge body in cool and depressurised condition the hexagon screws (6) can be re-tightened.
Illustration of tightening sequence

1
3
5
4
2

Figure 2

om7010_03_level1x0057090en.wmf

Step A: Start at the top, working to opposite sides alternately. Max torque: 35 Nm.
1.1.1 Maintenance during service check-up
Step
Step
Step
Step

A:
B:
C:
D:

Tighten the nuts (1).


Bolts on boiler flanges.
Union nuts (4).
Bolt form screws (7) with cocks in open positions.If a leak cannot be stopped
by tightening the bottom screws (7), the sealing surface of the cock plug (8)
may be damaged or corroded. It can also be necessary to change the packing
(3).

1.2 Blowing down


The item nos. mentioned in this following blowing down procedures refers to Figure 1.
Step A: The gauge should be blown down before lighting up the boiler and just before
closing down the boiler.
1.2.1 Cleaning the water side:
Step A: Shut the cock S and open the cock W.
Step B: Open the drain cock D for a short time. This sucks the water out of the glass
without, however, totally depressurising the gauge body.
Step C: Shut the cock D and then water is forced upwards into the glass again.
Step D: Repeat this procedure several times, opening and shutting the cock D. The
water level in glass rises and falls.
1.2.2 Cleaning the steam side:
Step A: Shut the cock W.
Step B: Open the cock S.
Step C: Blow through the steam side and gauge body by opening the drain cock D
for 1-2 seconds.

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34-3 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Step D: A steam blowing of longer duration is not advisable considering the service
life of glass.
Step E: Turn the cocks to operating position.

1.3 Dismantling
The following dismantling instructions refer to Figure 1 and Figure 3.
Sectional view of the water level gauge
6

6 - Screws
9 - Wedge piece
10 - Centre piece
11 - Reflex
12 - Sealing gasket
13 - Cushion gasket
14 - Cover plate

9
14
10

12
11
13

Figure 3

om7010_03_kli_05x0057070en.wmf

Step A: Shut the cocks S and W.


Step B: The drain cock D to be opened until the glass is completely emptied.
Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge
body from the cocks S and W.
Step D: Slacken the union nuts (4) and pull off the stuffing box head (2).
Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards
and loosen the screws.
Step F: Move the wedge piece (9) length wise and lift upwards.
Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine
for through going scars.

1.4 Assembling
The following assembling instructions refer to Figure 2 and Figure 3.
Step A: Insert following items into the centre piece (10): sealing gasket (12) reflex
glass (11) cushion gasket (13).
Step B: Place cover plate (14) on top.
Step C: Insert wedge piece (9) and move length wise for correct position.
Step D: Tighten screws (6) evenly starting at top, working to opposite sides alternately. Max torque: 35 Nm
34-4 / 6

Language UK

OM7010_03#A.2
WATER LEVEL GAUGE

Step E: When the boiler is started again and normal working pressure has been
reached re-tighten the screws (6) once again.

1.5 Maintenance of the straight-through cock


1.5.1 Operation principle and maintenance
The following assembling instructions refer to Figure 4.
Detail drawing of the straight-through cock
15

15 - Screw
16 - Split ring
17 - Packing sleeve
18 - Plug
19 - Bottom screw
16
17
18

19

Figure 4

om7010_03_kli_06x0057080en.wmf

The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be further compressed by
tightening the bottom screw (19) until the leakage is stopped. This must only be done
with the cock in open position.
1.5.2 Dismantling
Step A: Remove bottom screw (19).
Step B: Remove screw (15), washer and handle.
Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out
of the cock body by means of a soft mandrel.
Step D: Remove split ring and knock plug out of the packing sleeve.
Step E: Clean all sealing surfaces carefully and lubricate threads with a high temperature grease before installation.
1.5.3 Assembly
Step A: Place the split ring (16) in the recess of the plug (18).
Step B: Push new packing sleeve onto plug.
Step C: Press the complete unit into cock body.
Note: Turn the packing sleeve until the ridge fits with the groove in the cock body.
The eyelets of the packing sleeve must neither protrude nor be tilted.

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34-5 / 6

OM7010_03#A.2
WATER LEVEL GAUGE

Step D: Screw in bottom screw (19).


Step E: Place the handle and washer on the plug and fit screw (15).
Step F: Tighten the bottom screw (19) and check if the plug can be turned.

34-6 / 6

Language UK

TABLE OF CONTENTS

Table of contents
Safety valves
Description
Safety valves.............................................................
Temporary locking of a safety valve............................

Language UK

Document ID
OM6040_01...............
OM6040_02...............

Page
35-2
35-6

35-1 / 7

OM6040_01#A.2
SAFETY VALVES

Safety valves
1

General
In the following the measures required to achieve a safe and reliable operation as well
asmaintenance of the safety valves will be described, together with adjustment and
dismantling instructions.An installation example of the safety valve is shown in Figure 1.
Mounting of safety valves, example
Waste steam pipe

Support

Drain

Expansion joint
with sealing ring

Drain
Drain

If safety valve = DN50/80


drain connection is G1/4" BSP
If safety valve = DN65/100
drain connection is G3/8" BSP

Figure 1

om6040_01_safe_0x0056591en.wmf

Maintenance and start-up of boiler


A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspections, this is according to the
experience of the supplier.

35-2 / 7

Language UK

OM6040_01#A.2
SAFETY VALVES

Warning: Prior to any handling and dismantling of the safety valve ensure that
the system is depressurised.
Before lighting-up the boiler, pipe connections must be thoroughly cleaned for dirt and
foreign bodies.If the valve is not completely tight, which often is the case after start
up of the plant, this is usually caused by impurities between the seat and the cone. In
order to remove these impurities the valve must be heavily blown out by means of the
lifting device. If the valve is not tight after several blows, it may be due to the fact that
a hard foreign body has got stuck between the cone and the seat, and it will then be
necessary to dismount the valve for overhaul.
Warning: In case of a leaking safety valve the valve must be inspected and overhauled as soon as possible. It must be ensured that the boiler is totally
depressurised before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the adjustment later when the valve is to be adjusted when in service.
In case the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained carborundom stirred in kerosene.
Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against turning
as the seat and the cone may thus be damaged.
Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
Step D: When the valve has been mounted and the boiler is commissioned, the valve
must be checked for leakage and adjusted to the set pressure.
Step E: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.

2.1 Routine check


The following should be regarded as recommendations of routine checks on the safety
valves, in order to secure a correct function:

Language UK

35-3 / 7

OM6040_01#A.2
SAFETY VALVES

Monthly
Step A: Examine the safety valves for any leaking, such as:
- Is water seeping from the drain plug at the valve body?
- Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.
Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.
Step B: Expansion and exhaust pipe should be examined at the same time.

Adjustment and dismantling


Safety valves are delivered with the required spring setting and sealed against unauthorised adjustment.Adjustments are only allowed in the spring margins. Outside the
margin a new spring is required. The pressure in a system should not exceed 90% of
the set pressure.
All item numbers mentioned in the following sections refer to Figure 2.

3.1 Dismantling of lifting device


Safety valve with open cap:
Step A: Remove bolt(39) and remove lift lever (41)

3.2 Set pressure change without spring change


Note: Pay attention to spring range.
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21).
Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for
low set pressures.
Step D: Secure the new setting with the lock nut (21) and reassemble lifting device.

3.3 Spring change


Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the
spring (37) is not under tension.
Step C: Loosen the nuts (8) and remove the bonnet (42).
Step D: Remove the upper spring plate (26), spring (37), spindle (14) with disc (12),
guide plate (4), and lower spring plate (26).
Step E: Clean the seat (2) and disc (12).
Step F: Remount the spindle unit with the new spring and upper spring plate.Assemble bonnet (42) and adjust to the spring range.
Step G: Secure the spring setting through the lock nut (21) and remount lifting device.
35-4 / 7

Language UK

OM6040_01#A.2
SAFETY VALVES

Assembling drawing of safety valve


47 Ball
42 Bonnet
41 Lifting lever
40 Split pin
39 Bolt
38 Screw
37 Spring
29 Cap
27 Gasket
26 Springplate
23 Lead seal
22 Drain screw
21 Lock nut
18 Ball
17 Adjusting screw
16 Slotted pin
15 Gasket
14 Spindle
13 Lift aid
12 Disc
10/25 Split cotters
9 Lift limitation ring
8 Hex. nut
7 Gasket
4 Spindle guide
3 Stud
2 Seat
1 Body

39, 40
41
17

21

29
23

38, 47

26
27

37
42
14
10, 25
8

16
18
12
13
15, 22
2
1

Figure 2

Language UK

om6040_01_safe_0x0056600en.wmf

35-5 / 7

OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE

Temporary locking of a safety valve


1

General
During commissioning work or later tests of the opening pressure for the safety valves,
only one safety valve should be checked at a time. This means that the other safety
valve must be locked. The following instruction describes the temporary locking of a
safety valve.

1.1 Procedure for locking of a safety valve


Step
Step
Step
Step
Step

A:
B:
C:
D:
E:

Remove the bolt (39) and split pin (40), see Figure 1.
Remove the lifting lever (41).
Unscrew the screw (38) and break the lead seal (23), if provided.
Unscrew the cap (29).
Place one or two bolts (48) on top of the spindle. The height of the bolts
should be approximately 1-2 mm higher than the normal distance between
the top of the spindle and the inside top of the cap (29).
Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety
valve will be completely locked when the bolts cannot be moved anymore.
Step G: The other safety valve can now be tested without any interference from the
locked safety valve.

1.2 Procedure for unlocking of a safety valve


Warning: As soon as the test procedure for the safety valve has been carried out
the locked safety valve must be unlocked.
Step
Step
Step
Step

35-6 / 7

A:
B:
C:
D:

Unscrew the cap (29) and remove the bolts (48).


Mount the cap (29) again and screw in the screw (38).
Mount the lifting lever (41), bolt (39), and split pin (40).
Provide the safety valve with a lead seal (23), if necessary. This depends on
the local rules of the classification society.

Language UK

OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE

Temporary locking of a safety valve


48
39, 40
41

29
23

Figure 1

Language UK

38

om6040_02_safe_0x0056610en.wmf

35-7 / 7

TABLE OF CONTENTS

Table of contents
Feed water system
Description
dp water level transmitter unit.....................................

Language UK

Document ID
OM8210_35...............

Page
36-2

36-1 / 10

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

dp water level transmitter unit


1

General
The dp water level transmitter unit controls and supervises the water level in the boiler.
The complete unit is installed in a vertical position and connected to the boiler sockets,
provided for this purpose, by means of shut-off valves (see Figure 1).
The dp water level transmitter unit includes reference leg, variable leg, transmitter
connection valves mounted on a manifold, and a differential pressure transmitter. The
differential pressure transmitter converts the detected water level into an analogue
signal (4-20 mA) which is transmitted to the control system. The signal can also be
used for remote level indication in the engine control room.
Illustration of the dp water level transmitter unit
Shut-off valves
Filling plug
Reference leg

Drain valve

Boiler
Filling plug
Variable leg

Drain valve
Valve manifold
Connection
valves
Equalising valve
dp-transmitter

Figure 1

om8210_35_dpunitx0058930en.wmf

The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5) from
the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low pressure connection (-).

36-2 / 10

Language UK

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

Note: The dp water level transmitter unit or any part of it must not be insulated
to ensure the correct function.

Commissioning
2.1 Initial commissioning
Before the boiler is pressurised and started for the first time some initial commissioning
procedures can be performed with regard to the valves of the dp water level transmitter
unit. The shut-off valves, transmitter connection valves, and equalising valve should
be operated in the following sequence during the initial commissioning:
Step A: Initial setting; all valves of the dp water level transmitter unit closed (see
Figure 1).
Step B: Open the equalising valve located on the valve manifold.
Step C: Unscrew the filling plugs for the reference leg and variable leg. Fill the legs
with feed water.
Step D: Open the transmitter connection valve and venting facility on the reference
leg side of the transmitter.
Step E: Close the venting facility on the reference leg side of the transmitter when
no more air escapes.
Step F: Open the venting facility on the variable leg side of the transmitter.
Step G: Close the transmitter connection valve on the reference leg side of the transmitter when no more air escapes.
Step H: Open the transmitter connection valve on the variable leg side of the transmitter.
Step I: Close the venting facility on the variable leg side of the transmitter when no
more air escapes.
Step J: Close the transmitter connection valve on the variable leg side of the transmitter.
Step K: Close the equalising valve.
Step L: Refill the legs with feed water and screw on the filling plugs for the reference
leg and variable leg.
Step M: Open both transmitter connection valves fully.

2.2 Commissioning of the differential pressure transmitter


The differential pressure transmitter can be commissioned either through "blind calibration" or "live calibration". In the following sections both methods are described.
2.2.1 Blind calibration
Blind calibration of the differential pressure transmitter can be performed if no pressure
source is available. This means when the boiler cannot be operated at normal working
pressure and the water level cannot be increased/decreased. The "start of scale" and
"full scale" differential pressures are calibrated on the basis of calculated values. The
start of scale value should be calibrated to obtain a 4 mA output signal from the transmitter when the water level is at the lower connection point and the full scale value to

Language UK

36-3 / 10

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

obtain a 20 mA output signal when the water level is at the upper connection point. To
ensure an accurate calibration it is necessary to take the density difference between the
water in the reference leg and in the boiler into consideration when calculating the
differential pressure values.
4 mA output signal from the differential pressure transmitter:
- When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection points
(column of water) corrected with the density of the water in the reference leg. The
value must be specified and entered in engineering unit, e.g. in mm H2O.
20 mA output signal from the differential pressure transmitter:
- When the water level in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection points
corrected with the density difference between the water in the reference leg and in
the boiler. The value must be specified and entered in engineering unit, e.g. in mm
H2O.
Figure 2 indicates the calculation procedures of the differential pressures. As standard
it is assumed that the temperature in the reference leg (condensate receiver) is 40C.
Table 1 shows the calculated values for some standard heights between the connection
points. If the actual boiler plant does not fit any of the standard calculations the specified calculated values can be entered in the table for calibration record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure mode)
the differential pressure transmitter must be calibrated so that the minimum indicated
"Too low water level" on the control system not is lower than the actual "Too low water
level" mark. Because of the density difference in the boiler water at different working
pressures/temperatures the indicated water levels will not be identical. This means that
the differential pressures for start of scale and full scale should be calculated using the
parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of scale" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential pressure
transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys and are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H2O" as engineering units.
Step D: Select mode 5 using the "M" key.
Step E: Use the or key to set the start of scale in the selected engineering unit.
If mm H2O is selected as engineering units, then set the start of scale to the
calculated value in mm H2O (differential pressure at 4 mA).
Step F: Press both the and keys simultaneously for about 2 seconds, and the start
of scale is set to zero (in the selected engineering unit).
Step G: Select mode 6 using the "M" key.

36-4 / 10

Language UK

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

Step H: Use the or key to set the full scale in the selected engineering unit. If
mm H2O is selected as engineering units, then set the full scale to the calculated value in mm H2O (differential pressure at 20 mA).
Step I: Press both the and keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).
Step J: Mount the protective cover of the differential pressure transmitter again.
Calibration of differential pressure transmitter
Height between connection [mm]

Working pressure
[barg - kg/cm 2 ]

Connection point

Transmitter output,
[mA]

Calculations for standard heights, working pressures, and ambient temperature (40C)
Lower connection
7.0
Upper connection
525
Lower connection
16.0
Upper connection
Lower connection
7.0
Upper connection
700
Lower connection
16.0
Upper connection
Lower connection
7.0
Upper connection
800
Lower connection
16.0
Upper connection
Calculation records for other heights, working pressures, and/or ambient temperatures
Lower connection
Upper connection
Lower connection
Upper connection
Lower connection
Upper connection
Lower connection
Upper connection
Lower connection
Upper connection
Lower connection
Upper connection

4
20
4
20
4
20
4
20
4
20
4
20

Differential pressure
calibration [mm H 2
O]
521
50
521
70
695
67
695
93
794
76
794
106

4
20
4
20
4
20
4
20
4
20
4
20

Table 1

Language UK

36-5 / 10

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

Calculation of the differential pressures


o

t2 = 40 C, density: 992.2 kg/m

t1 = not existing

Differential pressure
between connections:
525 x 0.9922 =

Height between
connections, e.g.:
525 mm

521 mm H2O (at 4 mA)

Water level

t3 = 170 C at 7 barg,
204oC at 16 barg

t2 = 40 C, density: 992.2 kg/m

Differential pressure
between connections
(at 7 barg):
525 x (0.9922 - 0.8970) =
50.0 mm H2O (at 20 mA)

t1 = not existing
Water level

Height between
connections, e.g.:
525 mm

Differential pressure
between connections
(at 16 barg):
525 x (0.9922 - 0.8596) =
69.6 mm H2O (at 20 mA)
o

t3 = 170 C at 7 barg,
3
density 897.0 kg/m
o

204 C at 16 barg,
3
density 859.6 kg/m

Figure 2

om8210_35_dpunitx0058940en.wmf

2.2.2 Live calibration


Live calibration of the differential pressure transmitter can be performed when a pressure source is available. This means when the boiler can be operated at normal working
pressure and the water level can be increased/decreased. The "start of scale" and "full
scale" output signals of the differential pressure transmitter are set during actual operating conditions. It is therefore not necessary to take the density difference between
the water in the reference leg and in the boiler into consideration.

36-6 / 10

Language UK

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

However, if the boiler plant is intended to operate at different set points (high/low
pressure mode) the differential pressure transmitter must be calibrated so that the minimum indicated "Too low water level" on the control system not is lower than the actual
"Too low water level" mark. Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels will not be identical. This means that the differential pressure transmitter should be calibrated when
the boiler plant operates in high pressure mode.
When the boiler operates at normal working pressure carry out the following work
steps (please also see the specific instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential pressure
transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys and are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select "mA" as engineering units.
Step D: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step E: Slowly decrease the water level in the boiler until the lower connection point
is reached (socket centre line of the variable leg). The water level can be
decreased by means of the blow down valves.
Step F: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step G: Select mode 2 using the "M" key.
Step H: Set the output current corresponding to the start of scale using the and
keys. Or set the output current to 4 mA by pressing the and keys simultaneously for about 2 seconds.
Step I: Slowly increase the water level in the boiler until the upper connection point
is reached (socket centre line of the reference leg). The water level can be
increased by means of the feed water pumps.
Step J: When the water level is increased it must ensured that the boiler pressure is
kept at normal working pressure.
Step K: Select mode 3 using the "M" key.
Step L: Set the output current corresponding to the full scale using the and keys.
Or set the output current to 20 mA by pressing the and keys simultaneously for about 2 seconds.
Step M: Mount the protective cover of the differential pressure transmitter again.

2.3 Final commissioning


During final commissioning a function test of the dp water level transmitter unit must
be performed before the boiler plant is put into normal operation. The purpose of the
function test is to check that the output signals from the differential pressure transmitter
are correct. Furthermore, it should be checked that the connected alarms/shut downs
and control functions are operational. The boiler should be operated at normal working

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36-7 / 10

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

pressure during the test to provide for correct indications. When the boiler is at normal
water level carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. A shut down should be indicated on the control system, (if provided).
Step C: Increase the water level somewhat until the upper connection point is
reached (socket centre line of the reference leg). Check that the output signal
from the differential pressure transmitter is at 20 mA or the full scale value
in the selected engineering units.
Step D: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step E: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step F: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.
Step G: Decrease the water level somewhat until the "Too low water level" mark is
reached. A shut down should be indicated on the control system.
Step H: Decrease the water level somewhat until the lower connection point is
reached (socket centre line of the variable leg). Check that the output signal
from the differential pressure transmitter is at 4 mA or the start of scale value
in the selected engineering units.
Step I: After completion of the function test open the feed water valves or start the
feed water pumps.

Operation and maintenance


Attention: Both shut-off valves between the boiler and impulse legs must always
be fully open and the reference leg must be totally filled with water
during normal operation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the dp water level
transmitter unit whenever an opportunity occurs by comparing the water level indicated
by the control system with the level indicated in the water level gauges.
A great difference in the water levels may indicate blocked connections to the differential pressure transmitter. Therefore it is recommended to blow-through the impulse
legs and connection pipes frequently. The blow-through procedures can be performed,
e.g. in connection with stopping the boiler plant, in order to get rid of dissolved particles

36-8 / 10

Language UK

OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

that could settle during the stop periods. In case of prolonged standstill the dp water
level transmitter unit should be checked for the correct function before the boiler plant
is restarted.

3.1 Blow-through procedure of the impulse legs


3.1.1 Blow-through procedure of the impulse legs
The blow-through procedure should be performed as describe below when the boiler
plant is in operation and in steady load condition. The procedure should be carried out
at least once each month. When the blow-through procedure is carried out, it is very
important that the water level in the boiler is carefully and continuously supervised by
the ship engineering personnel. The feed water control valve must be operated manually, if necessary.
Step A: Isolate the differential pressure transmitter by closing the two transmitter
connection valves in the manifold. The equalising valve must remain closed
during the blow-through procedure and normal operation.
Step B: Slowly open the drain valves of the impulse legs, and allow the legs to blowthrough for a few seconds.
Step C: Close the shut-off valve for the reference leg.
Step D: Close the drain valves again when the reference leg is completely depressurised.
Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step F: Screw on the filling plug and slowly open the shut-off valve for the reference
leg.
Step G: Open the two transmitter connection valves in the manifold.
Step H: After performing the blow-through check that the dp water level transmitter
unit and feed water control valve are fully operational.
In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the impulse legs must be done more often.
3.1.2 Blow-through procedure of the connection pipes
The blow-through procedure should be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least once
each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transmitter connection valves must remain open and the equalising
valve closed during the blow-through procedure.
Step B: Close the venting facilities on the valve manifold when only clean water
escapes.
Step C: Close the shut-off valve for the reference leg.
Step D: Slowly open the drain valve of the reference leg.
Step E: Close the drain valve again when the reference leg is completely depressurised.
Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step G: Screw on the filling plug and slowly open the shut-off valve for the reference
leg.
In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the connection pipes must be done more often.

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OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT

3.1.3 Function test of the dp water level transmitter unit


During normal operation of the boiler plant a function test of dp water level transmitter
unit should be carried out at least once each month. The purpose of the function test is
to check that the connected alarms/shut downs and control functions are operational.
The boiler should be operated at normal working pressure during the test to provide
for correct indications. When the boiler is at normal water level carry out the following
work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. A shut down should be indicated on the control system, (if provided).
Step C: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step D: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the "Low water level" level. The control
system should indicate an alarm.
Step E: Decrease the water level somewhat until the "Too low water level" mark is
reached. A shut down should be indicated on the control system.
Step F: After completion of the function test open the feed water valves or start the
feed water pumps.

36-10 / 10

Language UK

TABLE OF CONTENTS

Table of contents
Feed water pump unit
Description
Pumps, type CR, CRN................................................

Language UK

Document ID
OM5540_20...............

Page
37-2

37-1 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Pumps, type CR, CRN


1

General
The multistage in-line centrifugal pumps are used as condensate, make-up, and feed
water pumps in boiler plants. To have a proper functioning of the centrifugal pumps it
is essential that the pumped liquid does not contain any steam, air, solid particles or
fibres. Furthermore the liquid must not attack the pump material chemically.

1.1 Technical data

37-2 / 12

Electrical data: see motor nameplate.


Ambient temperature: Max. 45C.
Minimum inlet pressure: see section 2.
Maximum inlet pressure: see Table 1. However, the actual inlet pressure + pressure
when the pump is running against a closed valve must always be lower than the
maximum permissible operating pressure".

Language UK

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Maximum inlet pressure


50 Hz
CR, CRN 1
CR, CRN 1s-2 CR, CRN 1s-36
CR, CRN 1-2 CR, CRN 1-36
CR, CRN 3
CR, CRN 3-2 CR, CRN 3-29
CR, CRN 3-31 CR, CRN 3-36
CR, CRN 5
CR, CRN 5-2 CR, CRN 5-16
CR, CRN 5-18 CR, CRN 5-36
CR, CRN 10
CR, CRN 10-1 CR, CRN 10-6
CR, CRN 10-7 CR, CRN 10-22
CR, CRN 15
CR, CRN 15-1 CR, CRN 15-3
CR, CRN 15-4 CR, CRN 15-17
CR, CRN 20
CR, CRN 20-1 CR, CRN 20-3
CR, CRN 20-4 CR, CRN 20-17
CR, CRN 32
CR, CRN 32-1-1 CR, CRN 32-4
CR, CRN 32-5-2 CR, CRN 32-10
CR, CRN 32-11-2 CR, CRN 32-14
CR, CRN 45
CR, CRN 45-1-1 CR, CRN 45-2
CR, CRN 45-3-2 CR, CRN 45-5
CR,CRN 45-6-2 CR,CRN 45-13-2
CR, CRN 64
CR, CRN 64-1-1 CR, CRN 64-2-2
CR, CRN 64-2-1 CR, CRN 64-4-2
CR, CRN 64-4-1 CR, CRN 64-8-1
CR, CRN 90
CR, CRN 90-1-1 CR, CRN 90-1
CR, CRN 90-2-2 CR, CRN 90-3-2
CR, CRN 90-3 CR, CRN 90-6

60 Hz
10 bar
10 bar

CR, CRN 1s-2 CR, CRN 1s-27


CR, CRN 1-2 CR, CRN 1-25
CR, CRN 1-27

10 bar
10 bar
15 bar

10 bar
15 bar

CR, CRN 3-2 CR, CRN 3-15


CR, CRN 3-17 CR, CRN 3-25

10 bar
15 bar

10 bar
15 bar

CR, CRN 5-2 CR, CRN 5-9


CR, CRN 5-10 CR, CRN 5-24

10 bar
15 bar

8 bar
10 bar

CR, CRN 10-1 CR, CRN 10-5


CR, CRN 10-6 CR, CRN 10-17

8 bar
10 bar

8 bar
10 bar

CR, CRN 15-1 CR, CRN 15-2


CR, CRN 15-3 CR, CRN 15-12

8 bar
10 bar

8 bar
10 bar

CR, CRN 20-1


CR, CRN 20-2 CR, CRN 20-10

8 bar
10 bar

4 bar
10 bar
15 bar

CR, CRN 32-1-1 CR, CRN 32-2


CR, CRN 32-3-2 CR, CRN 32-6
CR,CRN 32-7-2 CR,CRN
32-10-2

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 45-1-1 CR, CRN 45-1


CR, CRN 45-2-2 CR, CRN 45-3
CR, CRN 45-4-2 CR, CRN 45-7

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 64-1-1


CR, CRN 64-1 CR, CRN 64-2-1
CR, CRN 64-2 CR, CRN 64-5-2

4 bar
10 bar
15 bar

4 bar
10 bar
15 bar

CR, CRN 90-1-1 CR, CRN 90-2-1


CR, CRN 90-2-2 CR, CRN 90-4-2

10 bar
15 bar

Table 1

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Maximum permissible operating pressure: see Table 2.


Maximum permissible operating pressure

Frequency

50 Hz

60 Hz

Pump type
CR, CRN 1s, 1
CR, CRN 3
CR, CRN 5
CR, CRN 10-1 CR, CRN 10-22
CR, CRN 15-1 CR, CRN 15-17
CR, CRN 20-1 CR, CRN 20-17
CR, CRN 32-1-1 CR, CRN 32-7
CR, CRN 32-8-2 CR, CRN 32-12
CR, CRN 32-13-2 CR, CRN 32-14
CR, CRN 45-1-1 CR, CRN 45-5
CR, CRN 45-6-2 CR, CRN 45-9
CR, CRN 45-10-2 CR, CRN 45-10
CR, CRN 64-1-1 CR, CRN 64-5
CR, CRN 64-6-2 CR, CRN 64-7-1
CR, CRN 90-1-1 CR, CRN 90-4
CR, CRN 90-5-2 CR, CRN 90-6
CR, CRN 1s, 1
CR, CRN 3
CR, CRN 5
CR, CRN 10-1 CR, CRN 10-17
CR, CRN 15-1 CR, CRN 15-12
CR, CRN 20-8 CR, CRN 20-10
CR, CRN 32-1-1 CR, CRN 32-5
CR, CRN 32-6-2 CR, CRN 32-8
CR, CRN 32-9-2 CR, CRN 32-10-2
CR, CRN 45-1-1 CR, CRN 45-4
CR, CRN 45-5-2 CR, CRN 45-6
CR, CRN 64-1-1 CR, CRN 64-3
CR, CRN 64-4-2 CR, CRN 64-4-1
CR, CRN 90-1-1 CR, CRN 90-3
CR, CRN 90-4-2

Temperature range

-20C to +120C

-20C to +120C

Operating pressure
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
16 bar
25 bar
30 bar
16 bar
25 bar
33 bar
16 bar
25 bar
16 bar
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
25 bar
16 bar
25 bar
40 bar
16 bar
25 bar
16 bar
25 bar
16 bar
25 bar

Table 2

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Minimum flow rates: See Table 3.


Minimum flow rates
Liquid temperature
Up to + 80C
0.1 m3/h
0.1 m3/h
0.4 m3/h
0.6 m3/h
1.2 m3/h
1.8 m3/h
2.4 m3/h
3.8 m3/h
5.4 m3/h
7.7 m3/h
11.0 m3/h

Pump type
CR, CRN 1s
CR, CRN 1
CR, CRN 3
CR, CRN 5
CR, CRN 10
CR, CRN 15
CR, CRN 20
CR, CRN 32
CR, CRN 45
CR, CRN 64
CR, CRN 90

+ 80C to + 120C
0.2 m3/h
0.3 m3/h
0.8 m3/h
1.3 m3/h
2.6 m3/h
3.8 m3/h
5.0 m3/h
7.6 m3/h
11.0 m3/h
16.0 m3/h
24.0 m3/h

Table 3

Liquid temperature: -20C to 120C. See also Table 2 which indicates the relationship between liquid temperature and maximum permissible operating pressure.

Note: In condensate and feed water systems where an open hot-well is used it is
recommended to keep a temperature in the hot-well of 85-95C.

Further technical data can be found on the data sheet related to the pumps.

Calculation of minimum inlet pressure


The minimum inlet pressure "H" in metres head required to avoid cavitation in the
pump is calculated as follows:
H = pb x 10.2 - NPSH - Hf - Hv - Hs

pb = barometric pressure in bar (barometric pressure can be set to 1.0 bar). In closed
systems pb indicates the system pressure in bar.
NPSH = net positive suction head in metres head (to be read from the NPSH curves
in Figure 2and Figure 3at the highest flow the pump will be delivering).
Hf = friction loss in suction pipe in metres head at the highest flow.
Hv = vapour pressure in metres head, see Figure 1. Tm = liquid temperature
Hs = safety margin = 0.5 metres head.
If the calculated H is positive, the pump can operate at a suction lift of maximum
H metres head. If the calculated H is negative, an inlet pressure of minimum H
metres head is required. There must be a pressure equal to the calculated H during
operation.
Example:
Pump type = CR 20 - 60 Hz, flow rate = 24 m3/h, pb = 1.0 bar.

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Hf = 3.0 metres head, liquid temperature = + 90C.


Hv (from Figure 1) = 7.5 metres head.
NPSH (from Figure 2) = 2.5 metres head.
H = pb x 10.2 - NPSH - Hf - Hv - Hs
H = 1 x 10.2 - 2.5 - 3.0 - 7.5 - 0.5 = -3.3 metres head.
This means that an inlet pressure of minimum 3.3 metres head is required.
Relationship between Hv and Tm

Figure 1

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om5540_20_cr02ax0054100en.wmf

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

NPSH curves

Figure 2

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om5540_20_cr03bx0054110en.wmf

37-7 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

NPSH curves, continued

Figure 3

om5540_20_cr07ax0054130en.wmf

Start-up
Note: The pump is not allowed to run against a closed discharge valve as this will
cause an increase in temperature/formation of steam in the pump which
may cause damage to the pump.
If there is any danger of the pump running against a closed discharge valve, a minimum
liquid flow through the pump should be ensured by connecting a by-pass / drain to the
discharge pipe. The drain can for instance be connected to a hot-well / tank.
Warning: Do not start the pump until it is filled with liquid and has been primed
and vented.

3.1 Priming
Note: The following does only apply to systems where the liquid level is above
the pump inlet
Step A: Close the discharge isolating valve and loosen the vent screw in the pump
head, see Figure 4.
Note: Pay attention to the direction of the vent hole and take care to ensure that
the escaping water does not cause injury to persons or damage to the motor
or other components. In hot water installations, special attention should
be paid to the risk of injury caused by scalding hot water.
Step B: Slowly open the isolating valve in the suction pipe until a steady stream of
liquid runs out the vent hole.
Step C: Tighten the vent screw and completely open the isolating valve(s).

37-8 / 12

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Illustration of the centrifugal pumps

Figure 4

om5540_20_cr06x0054120en.wmf

3.2 Checking direction of rotation


Do not start the pump to check direction of rotation until it has been filled with liquid.
Note: The direction of rotation should not be checked with the motor alone, as
an adjustment of the shaft position is required when the coupling has been
removed.
The correct direction of rotation is shown by arrows on the pump head and/or on the
motor fan cover. When seen from the fan, the pump should rotate counter-clockwise.

3.3 Starting
Before starting the pump:
Step A: Open the isolating valve completely on the suction side of the pump and
leave the discharge isolating valve almost closed.
Step B: Start the pump.
Step C: Vent the pump during starting by loosening the vent screw in the pump head
until a steady stream of liquid runs out the vent hole, see Figure 4.
Warning: Pay attention to the direction of the vent hole and take care to ensure
that the escaping water does not cause injury to persons or damage to
the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot
water.
When the piping system has been filled with liquid:
Step D: Slowly open the discharge isolating valve until it is completely open.When
pumping liquids containing air, it is advisable to vent the pump regularly.
To vent the pump:
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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Step E: Loosen the vent screw in the pump head during operation.

3.4 Frequency of starts and stops


Motors smaller than 4 kW should not start more than 100 times per hour.
Other motors should not start more than 20 times per hour.

Maintenance
Caution: Before starting work on the pump, make sure that no power is supplied
to the pump and that it cannot be accidentally switched on. Before removing the cover of the electrical terminal box and before any removal/
dismantling of the pump, make sure that the electricity supply has been
switched off.
Pump bearings and shaft seal are maintenance-free.
If the pump is to be drained for a long period of inactivity then:
Step A: Remove one of the coupling guards to inject a few drops of silicone oil on
the shaft between the pump head and the coupling.
This will prevent the shaft seal faces from sticking. When fitting the coupling guards,
make sure that they are centred vertically in the recesses in the pump head.

4.1 Motor bearings


Motors which are not fitted with grease nipples are maintenance-free.
Motors fitted with grease nipples should be lubricated with a high-temperature lithiumbased grease.
In the case of seasonal operation (motor is idle for more than 6 months of the year), it
is recommended to grease the motor when the pump is taken out of operation.

Frost protection
Pumps which are not used during periods of frost should be drained to avoid damage.
Step A: Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base.
Warning: Care must be taken to ensure that the escaping water does not cause
injury to persons or damage to the motor or other components. In hot
water installations, special attention should be paid to the risk of injury
caused by scalding hot water.

37-10 / 12

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OM5540_20#C.1
PUMPS, TYPE CR, CRN

Do not tighten the vent screw and replace the drain plug until the pump is to be used
again.
Step B: Before replacing the drain plug in the base, screw the by-pass valve out
against the stop, see Figure 4.
Step C: Fit the drain plug by tightening the large union nut followed by the bypass
valve.

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37-11 / 12

OM5540_20#C.1
PUMPS, TYPE CR, CRN

Fault finding chart


Before removing the terminal box cover and before any removal/dismantling of the
pump, make sure that the electricity supply has been switched off.

Fault finding chart


Fault
1. Motor does not run when
started.

2. Motor starter overload trips


out immediately when supply is
switched on.

3. Motor starter overload trips


out occasionally.
4. Motor starter has not tripped
out but the pump does not run.
5. Pump capacity not constant.

6. Pump runs but gives no water.

7. Pump runs backwards when


switched off.
8. Leakage in shaft seal.
9. Noise.

Cause
a) Supply failure.
b) Fuses blown.
c) Motor starter overload has tripped out.
d) Main contacts in motor starter are not making contact
or the coil is faulty.
e) Control circuit fuses are defective.
f) Motor is defective.
a) One fuse is blown/automatic circuit breaker is blown.
b) Contacts in motor starter overload are faulty.
c) Cable connection is loose or faulty.
d) Motor winding is defective.
e) Pump mechanically blocked.
f) Overload setting too low.
a) Overload setting too low.
b) Low voltage at peak times.

Remedy
Connect the electrical supply.
Replace fuse.
Reactivate the motor protection.

a) Check 1 a), b), d) and e).

a) Pump inlet pressure is too low (cavitation).


b) Suction pipe/pump partly blocked by impurities.
c) Pump draws in air.
a) Suction pipe/pump blocked by impurities.
b) Foot or non-return valve blocked in closed position.
c) Leakage in suction pipe.
d) Air in suction pipe or pump.
e) Motor rotates in the wrong direction.

Check the suction conditions.


Clean the pump or suction side.
Check the suction conditions.
Clean the pump or suction side.
Repair the foot or non-return valve.
Repair the suction pipe.
Check the suction conditions.
Change the direction of rotation of
the motor.
Repair the suction pipe.
Repair the foot or non-return valve.
Replace the shaft seal.
Check the suction conditions.

a) Leakage in suction pipe.


b) Foot or non-return valve defective.
a) Shaft seal is defective.
a) Cavitation occurs in the pump.
b) Pump does not rotate freely (frictional resistance) because of incorrect pump shaft position.

Replace contacts or magnetic coil.


Repair the control circuit.
Replace the motor.
Cut the fuse.
Replace motor starter contacts.
Fasten/replace the cable connection.
Replace the motor.
Remove blocking of the pump.
Set the motor starter correctly.
Set the motor starter correctly.
Check the electrical supply.

Adjust the pump shaft.

Table 4

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TABLE OF CONTENTS

Table of contents
Steam dump equipment
Description
Steam dump equipment..............................................
Control valves, type 470/471.......................................
Pneumatic actuator, type dp........................................
Positioner, SIPART PS2 6DR5000..............................

Language UK

Document ID
OM6050_03...............
OM6010_02...............
OM5520_01...............
OM5510_05...............

Page
38-2
38-11
38-15
38-22

38-1 / 38

OM6050_03#C.1
STEAM DUMP EQUIPMENT

Steam dump equipment


1

General description
The steam dump equipment is designed for dumping excess steam generated by the
exhaust gas boiler from the steam system to an atmospheric dump condenser.
This chapter contains some general instructions, which should be taken into consideration before installing and during operation of the steam dump equipment. More
detailed instructions related to the components of the equipment can be found in other
sections.
Note: It is essential that the condenser is dimensioned to be able to absorb the
amount of steam generated in the exhaust gas boiler(s). Or if a composite
boiler is installed the amount of steam generated by the exhaust gas part
of the composite boiler(s).
Schematic illustration of the steam dump system for exhaust gas operation
Service steam line

1 - Steam dump valve


2 - I/P positioner
3 - Pneumatic actuator
4 - Air reducing set
5 - Process controller/local panel
6 - Pressure transmitter
7 - Steam trap

4 - 20 mA

Boiler/
steam drum

Control panel
1

2
3

P
4

AIR inlet
(max. 17 bar)

Steam/condensate line
Control air (instrument air)
To atmospheric dump condenser

Figure 1

Electrical signal

om6050_03_1ax0756600en.wmf

Figure 1 shows a schematically illustration of the system, which consists of the following components:

38-2 / 38

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OM6050_03#C.1
STEAM DUMP EQUIPMENT

Control valve with pneumatic actuator.


I/P positioner.
Air reduction set.
Process controller or local panel.
Pressure transmitter.
Steam trap.
The equipment is working by measuring the steam pressure (e.g. in the boiler, the steam
drum or the main steam pipe) with a pressure transmitter (6). The transmitter sends an
electrical signal (4-20 mA DC) to the process controller/local panel (5). In the control
system the signal is compared with a pre-set adjustable value.
The steam pressure is then regulated when the control system sends an electrical signal
to the I/P positioner (2). It converts the signal and via the pneumatic actuator (3) controls the position of the steam dump valve (1), through which the excess steam is lead
to the atmospheric dump condenser.
The control valve will automatically close in case of air or power failure. A hand wheel
enables manual operation of the valve. Figure 2 shows a complete control valve arrangement consisting of valve, I/P positioner and actuator.
Arrangement of control valve, positioner and actuator

Figure 2

om6050_03_k7462_x0056760en.wmf

Under normal circumstances the control valve, actuator and I/P positioner is delivered
as a complete unit already assembled.

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38-3 / 38

OM6050_03#C.1
STEAM DUMP EQUIPMENT

The air supply to the actuator is controlled by the air reduction set (4). The compressed
air at the inlet of the air filter must have a max. pressure of 17 bar and a temperature
laying in the interval from -20 to +65C. Furthermore, the supplied air must be instrument air.
Any adjustment of the system must be carried out on the process controller/local panel
(5).
Note: All pipes must be thoroughly cleaned before commissioning

Steam dump valve


The system is designed to be able to dump the amount for the control valve type 23.470
DP.
The construction of the valve can be seen on Figure 3.
The steam dump valve together with actuator and positioner are suitable for installation
in dry or damp locations, and in order to avoid damage to the drives it is recommended
to install the components in an right position.
Ambient temperatures on the valve drive should not fall below -15C or rise above
50C. Precautions should however be taken when using the equipment where the ambient temperature are likely to drop below 0C to prevent condensation of water in the
instrument air.
Drawing of of control valves
23.470 DP
1 - Body
2 - Seatring
3 - Mounting bonnet
4 - Guiding bush
5 - Plug
6 - Spindle
7 - Gland flange
8 - Spindle guiding
10 - Stuffing box
14 - Gasket
15 - Studs
17 - Hexagon nut
19 - Spring-type straight pin

Figure 3

38-4 / 38

om6050_03_3ax0756610en.wmf

Language UK

OM6050_03#C.1
STEAM DUMP EQUIPMENT

2.1 Fitting instructions


The installation point should allow sufficient space to ensure correct maintenance of
the valve and actuator. The valve should be inserted so that the spindle has a vertical
position and the actuator being up above. The valve can also be tilted to a maximum
horizontal position if the installation point does not allow any better condition. If
painting is necessary, ensure that valve and actuator spindle as well as mechanical links
are free from paint. The flow direction is signalled through an arrow on the valve body.
The valves should be insulated against high temperatures to guard the actuator. Sufficient space must be left to undertake maintenance on the spindle-sealing.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length min. 2 times pipe diameter
by inlet and 6 times by outlet. The piping must be aligned to prevent any strain on the
valve. Precautions to restrict strain on the piping should be regarded. In no case supporting must be fitted to the valve to hold the piping system.
The piping should be rinsed to clear out any pollution, welding beads, rust etc. before
inserting the control valves. A strainer should be fitted in front of the control valve to
catch remaining particles. Bolts should be re-tightened after taking into operation.
When the piping system is filled and set under pressure, the spindle sealing should be
checked for leakage, and if necessary be carefully tightened until the leakage is stopped.
The PTFE-V-ring unit does not require any re-tightening, the spring tension maintains
the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs but not tighter
than it is necessary for sealing.
Flange connections bolts should never be loosened or tightened when the valve is under
temperature or pressure, even if a leakage may arise.

Actuator
Select the site of installation so that the actuator is readily accessible and that there is
adequate room for later maintenance work.
The mounting position is preferably with the actuator and valve spindle in the vertical
position. For assembly onto the valve please see the separate instructions described in
the sections for valve and actuator (see also Figure 4).
The instrument air supply should be dry for low temperature service. A heat-guard
should be installed for high temperature service.
Note: Please observe the maintenance instructions for valves.

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38-5 / 38

OM6050_03#C.1
STEAM DUMP EQUIPMENT

3.1 Pneumatic connection


The pneumatic supply tube must be connected to the diaphragm housing.
The thread connection for the actuators DP 32 and DP 33 is R 1/4" and for the actuator
DP 34 is R 3/8".
Warning: The actuator diaphragm may only be pressure loaded on the side opposite of the springs. The vent hole in the other connection must stay
free.
Assembling of the actuator on valve

Figure 4

om6050_03_acu_06x0056730en.wmf

I/P positioner
The positioner must be installed and commissioned in exactly the same sequence as
described in the section for the positioner. It is essential that the warnings in the relevant
sections are heeded during this process.
Warning: This instrument must only be installed and commissioned by qualified
personnel. The degree of electrical safety is determined solely by the
devices supplying the power.

38-6 / 38

Language UK

OM6050_03#C.1
STEAM DUMP EQUIPMENT

Warning: Pneumatic drives generate considerable positioning forces. Safety precautions must therefore be scrupulously observed during installation
and commissioning in order to prevent injuries. Your attention is
drawn, if applicable, to the relevant regulations regarding operation
in hazardous areas.

Steam pipe connections to dump valve


Referring to the diagram in Figure 1, some remarks have to be made on the piping
system before and after the dump valve. This is due to the fact that a proper functioning
of the steam dump equipment (i.e. the equipment is able to blow off the required amount
of steam) requires as low a resistance in the piping system as possible.
In order to obtain this low resistance the following topics should be considered:

The dump valve should be placed as near the dump condenser as possible.
According to the amount of steam that the system is dimensioned to dump the
diameter of the pipe before and after the dump valve must be of a certain size,
which can be deduced from Table 1.
It is essential the transitions from pipes to the dump valve both before and after
the valve are smooth and without any sudden contractions or expansions.
Furthermore should the pipe section be as short as possible and preferably without
bends.
If there are valves placed in the system before and/or after the dump valve these
should be of the straightway type and of the same size as the pipes.

Amount of dumped steam related to min. pipe diameter


Operating pressure 6 bar(g) / Dump pressure: 7.3bar(g)
Size of dump valve, DN
25
32
40
Max. steam amount, kg/h
380
598
949
Pipe size before valve, DN
40
50
65
Pipe size after valve, DN
50
65
80
Operating pressure 7 bar(g) / Dump pressure: 8.3 bar(g)
Size of dump valve, DN
25
32
40
Max. steam amount, kg/h
414
652
1033
Pipe size before valve, DN
40
50
65
Pipe size after valve, DN
50
65
80
Operating pressure 8 bar(g) / Dump pressure: 9.3 bar(g)
Size of dump valve, DN
25
32
40
Max. steam amount, kg/h
448
707
1121
Pipe size before valve, DN
40
50
65
Pipe size after valve, DN
50
65
80

50
1519
80
100

65
2373
100
125

80
3797
125
200

100
5980
150
200

125
9492
200
250

50
1654
80
100

65
2589
100
125

80
4142
125
150

100
6520
150
200

125
10342
200
250

50
1793
80
100

65
2800
100
125

80
4487
125
150

100
7068
150
200

125
11205
200
250

Table 1

Language UK

38-7 / 38

OM6050_03#C.1
STEAM DUMP EQUIPMENT

Process controller/local panel


The process controller or local panel are installed in the boiler control panel. For instructions regarding one or the other please see the specified instructions in the control
system sections.
Warning: This is an electrically-operated device. Certain parts in electrical devices carry dangerous voltages during operation. Severe injury or
damage to property could therefore occur if the warnings are not observed. Staff working with this device should be suitably qualified.
Reliable and safe operation of these devices depend on correct transport, storage, assembly and operation.

Pressure transmitter
The pressure transmitter converts the steam pressure to an electrical signal proportional
with the pressure. The unit is supplied as two-wire transmitters with an output signal
of 4-20 mA.

7.1 Installation conditions


The zero point is factory-set with the pressure connector pointing downwards. If the
unit is installed in another position the zero point will be displaced approx. 1% as far
as the lowest pressure range is concerned, decreasing in the higher pressure ranges.
The displacement can be eliminated by using a zero-point potentiometer.
To protect the pressure element against temperatures higher than the maximum permissible temperature of the element (100C), it is recommended to insert a water-filled
loop. An example of such an installation is shown on Figure 5, which also shows an
example of insulation against radiant heat.

38-8 / 38

Language UK

OM6050_03#C.1
STEAM DUMP EQUIPMENT

Example of installation/connection of transmitter


Max. 70 C

Thin (= Low heat co nductivity) uninsulated tube

Steam
e.g. 170 C

Insulation
against radiant heat

reliable, good convection

Figure 5

Condensed liquid

om6050_03_emp2_2x0056750en.wmf

There are facilities for adjusting zero point and span. Zero point adjustment is necessary
to equalise pressure arising from any differences in level between the pressure transmitter and the medium being measured. Zero point adjustment results in a parallel
adjustment of span.

Air reducing set


8.1 Installation
Before installation the operating conditions of temperature and pressure must be
checked.The unit should be mounted securely in an accessible and visible location
upstream from lubricators and near components being served. Strain on pipe work and
fittings should be avoided and directional flow arrows observed.
With cyclic demand systems the filter-regulator should be installed upstream of directional control valves. Airline piping should be the same size as unit ports with airflow in the direction of the arrow.A pressure gauge may be connected to the appropriate
1/8 port after removing the plug and should have a range exceeding the maximum
proposed outlet setting.Figure 6 shows an illustration of the filter-regulator.

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38-9 / 38

OM6050_03#C.1
STEAM DUMP EQUIPMENT

Filter-regulator

Figure 6

om6050_03_b07_fx0056740en.wmf

8.2 Adjustment
With the regulator adjustment completely backed-off the air supply can be turned on.
The adjusting knob can be rotated clockwise to increase the spring load and the pressure
increase observed on the gauge.
Minor adjustment after setting changes can be avoided by always approaching the
desired setting from the lower level. When a lower setting is required, firstly reduce
to a lower level and then increase to the desired setting.
Decreasing the pressure setting on a relieving type regulator will cause air to exhaust
through the bonnet vent hole.
The non rising adjusting knob includes a locking feature;

Push knob in after setting to lock and prevent adjustment.


To release pull knob out.
If the adjustment knob is fitted with the tamper resistant screw option, the screw must
be removed to enable the knob to be unlocked.
Auto drain units should have a 1/4" (6 mm) bore flexible tube pushed over the bottom
protrusion to pipe away expelled liquid. Avoid restricting the drain pipe.
Manual drain units must be drained before the contaminant level reaches the element.
Should this occur then liquid contaminant will be carried downstream.

38-10 / 38

Language UK

OM6010_02#B.1
CONTROL VALVES, TYPE 470/471

Control valves, type 470/471


1

General
This type of control valve is suited to regulate fluids, gases and steams. The valve plug
is normally a parabolic plug, but can also be supplied in a perforated design. Both types
of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction. However,
with perforated plugs for feed water, it is in the closing direction. If a valve with a
perforated plug is operated by means of a pneumatic actuator with the flow in the
closing direction, the pneumatic actuator should have a stronger thrust force. This is
necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or hydraulic operation devices.
Illustration of control valves type 470 and 471

Figure 1

Language UK

om6010_02_val47xx0056570en..wmf

38-11 / 38

OM6010_02#B.1
CONTROL VALVES, TYPE 470/471

Table of position numbers in Figure 1


Part
1
2
3
3.1
4
5
6
6.1

Designation
Body
Seat ring
Mounting bonnet
Mounting bonnet
Guiding bush
Plug
Spindle
Spindle

Part
7
7.1
8
10
10.1
14
14.1
15

Designation
Gland flange
Screw joint
Spindle guiding
Stuffing box
Stuffing-box packing
Gasket
Gasket
Studs

Part
15.1
17
17.1
19
21
25
26

Designation
Studs
Hexagon nuts
Hexagon nuts
Spring-type straight pin
Set-pin
Bellow housing
Bellow unit

Table 1

Operation
2.1 Fitting instructions
The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out any
pollution, welding beads, rust, etc. before inserting the control valves. A strainer should
be fitted in front of the control valve to catch the remaining particles. Bolts should be
tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.

2.2 Actuator assembly


The control valves are normally delivered with actuators already fitted. For alternations
or maintenance of actuator, the assembly should occur in accordance with the operation
instructions for the actuator.

2.3 Setting into operation


When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.

38-12 / 38

Language UK

OM6010_02#B.1
CONTROL VALVES, TYPE 470/471

For actuators please see to the appropriate actuator operation instructions.

Maintenance
Before any maintenance of the control valve is carried out, the piping system must be
shut off and pressure free.

3.1 Exchange of the stuffing-box packing


A leak stuffing-box packing should initially be carefully tightened to stop the leakage.
If this does not help, a new layer should be inserted, or the complete packing should
be replaced.
3.1.1 Additional packing layer
Step A: Open the valve fully and unscrew the hexagon nuts (17).
Step B: Lift the gland flange (7) and the spindle guiding (8) upwards.
Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting
at 180 to avoid overlapping).
Step D: Fix the hexagon nuts (17) properly.
3.1.2 Exchange
Step A: Drive the actuator into middle position and dismantle the actuator.
Step B: Unscrew the hexagon nuts (17) from the studs (15).
Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing
box (10) and clean the packing compartment.
Step D: Clean the valve spindle and check for damage and if necessary replace. If
the damaged spindle is not replaced, the new packing will leak after a short
period.
Step E: Insert the new packing rings (split ring-displacement, splitting at 180 to
avoid overlapping).
Step F: Fix the hexagon nuts (17) properly.
Note: Strenuous tightening will prevent leakage, but will also have a brake effect
on the spindle which aggravates the movement of the spindle.

3.2 Exchange of a PTFE-V-ring sealing unit


A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good seal
even by low operation pressures. It is replaced as mentioned above.
The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing
lips must face against the pressure direction.
Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.

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38-13 / 38

OM6010_02#B.1
CONTROL VALVES, TYPE 470/471

3.3 Exchange of the bellow unit


Step A: Drive the actuator into middle position and dismantle the actuator.
Step B: Unscrew the screw joint (7.1).
Step C: Unscrew the hexagon nuts (17) and remove the bellow housing (25). Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-twisting
device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1)
crosswise.

3.4 Exchange of the plug-spindle unit


Step A: Drive the actuator into middle position and dismantle the actuator.
Step B: Unscrew the gland flange (7).
3.4.1 Control valve type 470
Step
Step
Step
Step
Step
Step
Step

A:
B:
C:
D:
E:
F:
G:

Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Pull out the plug with the spindle and exchange this unit.
Remove the spring-type straight pin (19) and unscrew the spindle (6).
Replace the old parts and assemble it.
Drill a hole through the plug shaft and insert a new pin.
Replace the gasket (14) and assemble the mounting bonnet (3).
Tighten the nuts (17) evenly, crosswise.

3.4.2 Control valve type 471


Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the springtype straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.The spindle can only
be completely replaced together with the bellow.

3.5 Changing the seat ring


The seat ring is screwed into the valve body. The seat ring can be obtained after removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

38-14 / 38

Language UK

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

Pneumatic actuator, type dp


1

General
The pneumatic linear actuator is designed to be mounted directly on a control valve.
The pneumatic actuator converts positioning command signals into stem thrust forces.
The required back setting force is produced by the spring arrangement inside the actuator. The rolling-diaphragm produces linear spindle movements over the complete
stroke.
The preferred mounting position is with the actuator and valve spindle in vertical position.
The mode of operation for the actuator depends on how the springs are inserted when
the actuator is assembled. Even when the actuator is fitted in a piping system, the mode
of operation can be changed.
The pneumatic actuator can be operated as:

Language UK

Spring opens valve/air closes valve operation mode


Air opens valve/spring closes valve operation mode

38-15 / 38

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

Illustration of a pneumatic actuator

Figure 1

om5520_01_dpactux0053610en.wmf

Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.

Table of position numbers in Figure 1


Part
1
2
3
4
5
7
10
11
12
13
14

Denomination
Rolling diaphragm
Diaphragm housing
Diaphragm lid
Diaphragm plate
Spindle
Spring
Coupling flange
Guide flange
Rotation guard
Socket screw
Threaded bushing

Part
15
16
17
18
19
21
22
26
27
30
31

Denomination
Stroke indicator
Hexagon nut
Mounting rod
Bellow
Collar nut
O-ring (spindle)
O-ring (bushing)
Slotted guide bearing
Spindle guide
Hexagon nut
Hexagon nut

Table 1

1.1 Pneumatic connection


The air supply should be dry and at a low service temperature. A heat-guard should be
installed to prevent high service temperature.

38-16 / 38

Language UK

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

The pneumatic supply tube must be connected to the diaphragm housing (2) by operation mode spring closes" and to the diaphragm lid (3) by operation mode spring
opens.
By air failure the stem automatically returns into the original position caused by the
inserted springs.
Warning: The actuator diaphragm may only be pressure loaded on the side opposite of the springs. The vent hole in the other connection must remain
open.

1.2 Assembly of the actuator on the valve


The assembling of the actuator on the valve is shown in Figure 2. For both spring
closes and spring opens operation modes the following assembling procedure
should be followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode spring closes or into the
open position for operation mode spring opens.
Warning: Make sure that the plug does not turn while pressing on the seat during
assembly.
Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide
flange (11). The threaded bushing (14) is now free.
Step C: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotation
guard (12) and the guide flange (11) over the valve spindle and then turn the
threaded bushing (14) onto the valve spindle.
Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connection piece in the diaphragm housing (2) for operation
mode spring closes or in the diaphragm lid (3) for operation mode spring
opens.
Step E: Drive the actuator into approximately mid-stroke position over the air supply
and mount it onto the valve (read the value from the pressure gauge - middle
of the spring range).
Step F: Tighten the hexagon nuts (31).

Language UK

38-17 / 38

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

Assembly of the actuator on the valve

Figure 2

om5520_01_dpactsx0053600en.wmf

1.3 Adjustment of the starting pressure signal


Step A: Drive the actuator to the required spring-starting point over the air supply.
Step B: Turn the threaded bushing (14) up against the coupling flange (l0) so that
the collar enters into the flange and presses against it. Make sure that the
plug is lying on the valve seat.
Attention: Note that sufficient thread of the valve spindle is inside the threaded
bushing (14). If not, turn the coupling flange (10) downwards from
the actuator spindle and pull the threaded bushing (14) against it.
Step C: For operation mode: spring closes:
- Attach the guide flange (11) and the rotation guard (12) with the socket
screws (13) to the coupling flange (10).
- Check that the plug lifts off the seat at the required spring starting point.
Step D: For operation mode: spring opens:
- Check that the plug leaves the end position at the required spring starting
point, and finishes the valve stroke at the spring-range end value.
- The plug must then also press on the valve seat.
Step E: After the test operation set the stroke indicators (15) into the end positions.
Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.
Step G: Do not turn the plug on the seat when it is under force.

38-18 / 38

Language UK

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

Reversal of the actuator action


The actuator action can be reversed even when the valve is installed in a piping system.
The position numbers mentioned in this section refer to Figure 1 and Figure 2.
Step A: Drive the actuator into approximately mid-stroke position with the air supply.
Step B: Loosen and remove the socket screws (13) from the coupling flange (10)
and drop the rotation guard (12) over the valve spindle.
Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve.
Step D: Reduce the air supply until the chamber is pressure free.
Step E: Loosen and remove the diaphragm lid screws.
Step F: Remove the diaphragm lid (3).
Warning: The actuators DP 32 and DP 33 have two longer screws when fitted
with stronger spring ranges. The actuator DP 34 has four. These
screws should be the last screws to be loosened, and must be loosened
evenly to reduce the high spring tension.
Step G: For reversal from spring closes into spring opens:
- Remove the springs (7) and the diaphragm plate (4) with the diaphragm
(1) and the spindle (5).
- Loosen and remove the seal lock nut (19) and remove the spindle (5).
Turn over the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange, and place it over the spindle (5).
- Tighten with the seal lock nut (19). Make sure that the spindle surface
is not damaged.
- Grease the spindle surface and the 0-ring.
- Place the diaphragm plate (4) with the diaphragm (1) into the diaphragm
lid (3).
- Arrange the springs (7) onto the moulds pressed into the diaphragm plate
(4).
- Place the diaphragm housing with the spindle sealing unit over the spindle, and screw it together. Make sure that the springs stay properly arranged.
- Turn the hexagon nut (16) and the coupling flange (10) onto the spindle
(5).
- Mount the actuator as described previously, and connect the air supply
tube to the diaphragm lid (3).

Language UK

38-19 / 38

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

Step H: For reversal from spring opens into spring closes:


- Remove the diaphragm (1) and the diaphragm plate (4) with the spindle
(5) and the springs (7).
- Loosen and remove the seal lock nut (19) from the spindle (5). Turn over
the diaphragm plate (4) with the diaphragm (1) and the diaphragm
clamping flange, and place it on the spindle (5).
- Tighten with the seal lock nut (19). Make sure that the spindle surface
is not damaged.
- Grease the spindle surface and the 0-ring.
- Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5)
into the diaphragm housing (2).
- Arrange the springs (7) onto the moulds pressed into the diaphragm plate
(4).Place the diaphragm lid (3) on the top, and screw it together. Make
sure that the springs (7) stay properly arranged.
- Turn the hexagon nut (16) and the coupling flange (10) onto the spindle
(5).
- Mount the actuator as described previously, and connect the air supply
tube to the diaphragm housing (2).

Manual operation device


Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring
and a spindle sealing unit.
The manual operation device is equipped with stroke indicators. The stroke indicators
of both the actuator and the manual operation device must be in the same end positions
when the actuator is pressure free.
The manual operation device must be set into neutral position when the actuator is
running automatically.
The locking device of the manual operation device must be unlocked before operating.
The locking device prevents an unwanted disarrangement of the setting during operation, e.g. due to vibration, etc.

Maintenance
The pneumatic actuator is maintenance free. To maintain a disturbance free operation,
the air should be supplied by an air-supply station.
The diaphragm, spindle sealing unit and springs are wear parts and should be replaced
when necessary.

38-20 / 38

Language UK

OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP

4.1 Exchange of spindle sealing


When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring
should be replaced. The spindle surface must be clean and undamaged. Before the
actuator is assembled, the spindle unit and the spindle must be greased.

Language UK

38-21 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Positioner, SIPART PS2 6DR5000


1

General
The following instruction is a general description of SIPART positioners and covers
the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a pneumatic
linear actuator or a part-turn actuator (rotary movements). The positioner converts a
current output signal (4 to 20 mA) from a process controller or control system to a set
point value and into a corresponding movement. The positioner changes the pressure
in a pneumatic actuator chamber or cylinder until the position corresponds to the set
point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic cylinder (actuator). All movements of the pneumatic cylinder are supplied by the positioner. An illustration of the function diagram for the positioner is shown in Figure 1.
The function diagram is shown with option modules.

1.1 Mode of operation


Comparison of the set point and the actual value takes place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch procedure
to control the piezoelectric valves, which in turn regulate the flow of air into the actuating chambers. When connected in a two-wire system, the SIPART PS2 draws its
power exclusively from the 4 to 20 mA set point signal.
The piezoelectric valve converts the command into a pneumatic positional increment.
The positioner outputs a continuous signal in the area where there is a large control
deviation (high-speed zone). In areas of moderate control deviation (slow-speed zone)
it outputs a sequence of pulses. No positioning signals are output in the case of a small
control deviation (adaptive or variable dead zone).
Commissioning (initialisation) is carried out automatically to a large extend. During
initialisation, the micro controller automatically determines the zero, full-scale value,
direction of action, and positioning speed of the actuator. It uses these to determine the
minimum pulse time and dead zone, thus optimising the control.
The positioner can also be operated manually by the pushbuttons and the LCD of the
SIPART PS2.

38-22 / 38

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

The installation of the positioner must be carried out in the following order:

Mechanic connection
Electric connection
Pneumatic connection
Commissioning

Illustration of a function diagram

Figure 1

om5510_05_sips2_x0053470en.wmf

Mechanic connection of the positioner


Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.

2.1 Mechanic connection to an actuator


Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.

Language UK

38-23 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and lock
washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.
Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).
Step D: Insert the pin in the lever (6) and assemble with nut (18), spring washer (14),
and U-washer (12).
Step E: The value of the stroke range specified on the actuator should be set or if
this does not exist as a scaling value, the next greatest scaling value should
be set. The centre of the pin must be in line with the scaling value. The same
value can be set later under parameter 3.YWAY in commissioning to display the way in [mm] after initialisation.
Step F: Assemble the hexagon socket cap screw (17), spring washer (16), washer
(12), and square nut (19) on the lever.
Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix
with the hexagon socket cap screw (17).
Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock washer
(10), and flat washer (11) on the rear of the positioner.
Step I: Selection of the row of holes depends on the width of the actuator yoke. The
roll (5) should engage in the pick-up bracket (2) as close as possible to the
spindle but may not touch the clamping assembly.
Step J: Hold the positioner with the mounting bracket on the actuator so that the pin
(4) is guided within the pick-up bracket (2).
Step K: Tighten the pick-up bracket.
Step L: Position the mounting parts according to the type of actuator.
- Actuator with ledge: hexagon head screw (8), flat washer (11), and lock
washer (10).
- Actuator with plane surface: four hexagon head screws (8), flat washer
(11), and lock washer (10).
- Actuator with columns: two U-bolts (7), four hexagon nuts (21) with
flat washer (11), and lock washer (10).
Step M: Secure the positioner onto the yoke using the previously positioned mounting parts.
Note: Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke centre as possible. The lever scale can be used
as orientation. It must be guaranteed that the horizontal lever position is
passed through within the stroke range.

38-24 / 38

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Mechanic connection of the positioner (linear actuator)

Figure 2

om5510_05_sips2_x0053480en.wmf

2.2 Mechanic connection to a pneumatic cylinder


The positioner is connected to a pneumatic cylinder by means of fixing bracket, lever
arm with Allen screw, extension arm, and roller.

Language UK

38-25 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

The pneumatic piston is connected to a guide rail with an oblique angle via a linkage.
The guide rail moves together with the piston, and the roller/lever connection senses
the position of the piston. By operating both sides of the pneumatic cylinder, the set
point is reached. A spring inserted between the fixing bracket and the lever arm secures
that the roller is pressed down against the guide rail.

2.3 Mechanic connection to a rotary actuator


Figure 3 shows the mechanic connection of the positioner to a rotary actuator.
Step A: Attach the mounting console (9, actuator specific) onto the rear of the positioner and secure using the hexagon head screws (14) and lock washers
(15).
Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring
hole.
Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm
and tighten the hexagon socket head screw (18) with the Allen key provided.
Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister
head screw (16) and washer (17).
Step E: Carefully place the positioner with mounting console onto the actuator such
that the pin of the coupling wheel engages in the driver.
Step F: Align the positioner/mounting console assembly in the centre of the actuator
and screw tight (screws are not included in the delivery, they are part of the
actuator mounting console).
Step G: Follow the start-up sequence as described later. Drive the actuator to the end
position and adhere the scale (4.1) onto the coupling wheel (2) according to
the direction of rotation and rotaryactuator. The scale is self-adhesive.

38-26 / 38

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Mechanic connection of the positioner (rotary actuator)

Figure 3

Language UK

om5510_05_sips2_x0053490en.wmf

38-27 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Electric connection of the positioner


When the positioner is connected in a two-wire system, the positioner draws its power
exclusively from the 4 to 20 mA set point signal. Figure 4 indicates the input circuits
for the positioner.
View of the controls and connections

Figure 4

om5510_05_sips2_x0053500en.wmf

Pneumatic connection
Ensure that the air quality is suitable. Grease-free instrumental air with a solid content
<30 m and a pressure dew point 20 K below the lowest ambient temperature must be
supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level P manual operation with electrical signal applied.

4.1 Selection of P manual mode

38-28 / 38

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

4.1.1 Selection of P manual mode


Before pneumatic power is connected, the positioner must be in P manual mode. The
display must show NOINIT in the bottom line.
4.1.2 Pneumatic connections
Figure 4 shows a view of the positioner controls and connections.
Step A: If required, connect a manometer block for supply air and actuating pressure.
Step B: The silencer in the exhaust output can be removed if necessary.
Step C: Connect actuating pressure Y1 and/or Y2 (Y2*) is only used with doubleacting actuators) according to the desired safety position.
Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar.
Note: In order for spring-loaded pneumatic actuators to be able to reliably exploit the maximum possible actuating path, the supply pressure must be
sufficiently greater than the maximum required final pressure of the actuator.
4.1.3 Safety positionwhen the electric power supply fails
For a single-action actuator is Y1 deaerated. For a double-action actuator is Y1 equal
to the supply air pressure and Y2 is deaerated.
4.1.4 Restrictors
To increase the positioning times for fast actuators when necessary, the air flow can
be reduced with the restrictors Y1 and Y2 (only for double-action valves). Turning the
restrictors in the clockwise direction reduces the air flow until it is shut off. To set the
restrictors it is recommended to first close them and then open them again slowly (see
initialisation process RUN 3).
4.1.5 Purging air switchover
The purging air changeover switch located above the pneumatic terminal block on the
valve manifold can be accessed when the housing is open. When the switch is in position IN the interior of the housing is purged with very small quantities of clean and
dry instrument air. In position OUT the purging air is led directly out of the instrument.

Commissioning
Commissioning (initialisation) is carried out automatically to a large extend. During
initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to determine the minimum pulse time and dead zone, hereby optimising the control.
The positioner can also be operated manually by the pushbuttons and the LCD of the
SIPART PS2.

Language UK

38-29 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

The commissioning of the positioner can be divided into the following steps:

Preparation for initialisation


Start the automatic initialisation procedure
Set additional parameters if required
Select automatic mode
Figure 5 shows the possible operation modes for the positioner and gives an overview
of how to change between them. The levels are P-manual mode, configuration and
initialisation, manual mode, automatic mode, and diagnostic display. From these
modes it is possible to select operation mode, set operation parameters, restore to factory setting, run an automatic initialisation, etc.
Operation levels

Figure 5

om5510_05_sips2_x0053510en.wmf

5.1 Preparation for initialisation


Step A: Check and set the gear transmission switch to the correct position. Figure 4(position 8) indicates the location of the switch. For linear actuators the
gear transmission switch is set according to the stroke range as described in
Table 2 for the parameter 3.YWAY. For part-turn actuators 90 must be
selected.

38-30 / 38

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Step B: Check that the pneumatic supply power (inlet air) is present. The operating
pressure should be at least one bar greater than is necessary for closing/
opening the valve during initialisation.
Step C: Without initialisation the positioner is in P manual mode and NOINIT
flashes in the display. This level can also be reached by using
55.PRSTfunction (see Table 2).
Step D: Check the free running of the mechanics in the whole actuating range by
moving the actuator with the keys and and driving to the respective
end position.
Step E: With linear actuators drive the actuator to horizontal lever position. The
display must indicate 48% to 52%. If necessary, correct the value by adjusting the sliding clutch. After the check is completed, the actuator must be
approximately half way along its stroke. This is due to establishment of the
action direction during automatic initialisation.

5.2 Automatic initialisation


Figure 6 shows the configuration modeincluding the operation in this mode and Table 2 shows the parameter/configuration list. Figure 7 shows the initialisation process
of the positioner. The initialisation process is stored in the microprocessor. This means
that an additional initialisation only is necessary if any parts of the unit have been
changed.
Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are examples.
Step A: Call the configuration mode by pressing the hand symbol key for longer than
5 seconds.
Step B: Set the actuator type, linear or part-turn, in the menuitem line 1.YFCT.
Step C: Switch to the second parameter by pressing the hand symbol key briefly.
Step D: Set the rated angle of rotation for feedback in the menu item line 2.YAGL.
It is vital that this value corresponds to the setting of the gear transmission
ratio selector (Figure 4, position 8), 33 or 90.
Step E: Switch to the next parameter by pressing the hand symbol key briefly.
Step F: This parameter (3.YWAY) is only set for linear actuators and if the total
stroke in mm should be displayed at the end of the initialisation phase. To
do this, select the same value in the display to which the carrier pin to the
scale on the lever is set to.
Step G: Switch to the following parameter by pressing the hand symbol key briefly.
Step H: Start the initialisation (4.INITA) by pressing the key for longer than
5 seconds.
Step I: During the initialisation phase RUN1 to RUN5 appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the hand
symbol key. The previous settings are retained. All the parameters are reset
to the factory setting only after performing a preset 55.PRST.
Step J: If problems occur, carry out the measures as described in the table Possible
messages shown in Figure 7.

Language UK

38-31 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Step K: The initialisation is completed when FINSH appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line 4.INITA
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5 seconds. The instrument is in manual operationafter releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the key
once as indicated in Figure 5.
Step O: The automatic mode is the normal mode. In this mode the positioner compares the set point current with the current position and moves the actuator
until the control deviation reaches the dead zone.
Operation in the configuration mode

Figure 6

38-32 / 38

om5510_05_sips2_x0053520en.wmf

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Initialisation process
Automatic initi al start-up (starting with factory setting)
Step
1.)

Me aning

Part-t urn
actuator
Linear
actuator

Possible messages
Display

Me aning

turn

90

1 YF CT

2 YAGL

WAY

33

Strt

1 YF CT

2 YAGL

3 YWAY

32.4
RU N 1

Actuator does
not move

32.4

2.)

INITA

Check restr ictor (6) and open


if necessar y
Drive actuator to working range
using the up and down keys

ERR OR

Strt

Me asures
Acknowled ge message
using the hand symbol key

Press the up key for > 5 sec.

Restart initi alisation

Remaining steps are carried out automatically


Change gea ring (7)

3.)

R UN 1

4.)

5.)

92.4
R UN 2

82.4
R UN 3

6.)

7.)

8.)

32.4

32.4
R UN 4

52.4
R UN 5

32.4
F INSH

Continue us ing up key

Direction of action is determined

88.4
d u IU

Checking of travel and adjustment of


zero and s troke (from stop to stop)

Down tolerance
band violated

Or adjust sliding clutch up


to display

6.4

d 0 IU

Then only
Continue us ing the down key

Determina tion and display of positioning time


down (dxx .x), up (uxx.x). Stop with the down key
Pressing t he up key initiates leakage measurement

S Et
Determina tion of minimum incre ment length

MID DL

Once the slipp ing


clutch has bee n
adjusted

Optimisati on of transient respon se

98.3
UP

Initialisation terminated success fully


(travel in m m for linear actuators )
(angle of r otation for part-turn ac tuators)
Continue u sing hand symbol ke y

>

Up tolerance b and
violated

Linear actuator: set pick-up


lever into ho rizontal position
using the up and down keys
Continue us ing hand symbol key
Acknowled ge message
using the hand symbol key
Set the nex t highest travel
value on the lever
Restart initi alisation
Additionally possible with rotary
actuators:
Adjust using up and down keys
up to displa y:

92.8

90_9 5

Continue u sing hand symbol key

19.8
U-d <

Up/down span
violated

Acknowledge message
using the ha nd symbol key
Set the nex t lowest travel
value on the lever
Restart initi alisation

1.3
NO ZZL

1.8
NO ZZL

Figure 7

Actuator does
not move.
Positioning
time is possibl e
to adjust

Adjust positioning time using


restrictor(s)
Continue us ing the
up or down key

om5510_05_sips2_x0053530en.wmf

5.3 Parameters
Table 2 shows the parameter list for the positioner. The parameter name is written in
plain text in the menu line column. The function of the parameter is described briefly
in the Function column. In addition, the possible parameter values, the physical unit
and the factory setting of the parameters are shown.
After the initialisation process, the positioner can be configured to meet the requirements of a specified task. The factory settings correspond to the requirements for a
typical application. This means that normally only a few parameters will need to be
changed.
The positioner can be installed and configured to fit linear and part-turn actuators with
reverse action. E.g. linear actuators with the set point in the falling direction or partturn actuators for counter clockwise operation direction. In this case the parameters
7.SDIR and 38.YDIR should be set to FALL.

Language UK

38-33 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Parameter list
Menu line

1.YFCT

Function

Type of actuator

2.YAGL1)

Rated angle of rotation for feedback


(must correspond to gear ratio)

3.YWAY2)

Stroke range (optional setting)


When used, the value must correspond
with the set of the leverage ratio on the actuator
Driver pin must be set to the value of the
actuator travel or, if this value is not
scaled, to the next lager scale value

4.INITA
5.INITM

Initialisation (automatically)
Initialisation (manually)

6.SCUR

Current range of set point

8.SPRA
9.SPRE

0 to 20 mA
4 to 20 mA
rising
Set point direction
falling
Set point for start of split range
Set point for end of split range

10.TSUP

Set point ramp up

11.TSDO

Set point ramp down

7.SDIR

13.SL03)
14.SL1
to
32.SL19
33.SL20

Set point function


Linear
Equal-percentage 1:25, 1:33, 1:50
Inverse equal-percentage 1:25, 1:33, 1:50
Freely adjustable
Set point turning point at 0%
5%
to
95%
100%

34.DEBA

Dead zone of controller

12.SFCT

35.YA
36.YE
37.YNRM
38.YDIR

38-34 / 38

Start of manipulated variable limiting


End of manipulated variable limiting
Standardisation of
To mech. travel
manipulated variable
To flow
Direction of manipulated
Rising

Parameter values
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
ncSt (part-turn actuator
with NCS)
-ncSt (part-turn actuator with NCS, inverted)
90
33
OFF
5 , 10 , 15 , 20
(short lever 33)
25 , 30 , 35
(short lever 90)
40 , 50 , 60 , 70 ,
90 , 110 , 130
(long lever 90)
noini / no / ###.# / Strt
noini / ###.# / Strt
0 MA
4 MA
riSE
FALL
0.0 to 100.0
0.0 to 100.0
Auto
0 to 400
0 to 400
Lin
125 , 133 , 150
n125 , n133 , n150
FrEE

0.0 to 100.0

Auto
0.1 to 10.0
0.0 to 100.0
0.0 to 100.0
MPOS
FLOW
riSE

Unit

Factory setting

Customer
setting

WAY

Degrees

33

mm

OFF

no
no
4 MA
riSE
%
%

0.0
0.0

Lin

0.0
5.0
to
95.0
100.0

Auto

%
%

0.0
100.0
MPOS
riSE

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Parameter list
variable for display
39.YCLS

Tight closing with


manipulated variable

Falling
Without
Top only
Bottom only
Top and bottom

FALL
no
uP
do
uPdo

no

Table 1

Language UK

38-35 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Parameter list continued


Menu line

Function

Parameter values

Unit

40.YCDO
41.YCUP

Value for tight closing, bottom


Value for tight closing, top
Function of BI 1:
None
Only message (NO/NC contact)
Block configuring (NO contact)
Block configuring and manual (NO contact)
Drive valve to pos. up (NO/NC contact)
Drive valve to pos. down (NO/NC contact)
Block movement (NO/NC contact)
Function of BI 2:
None
Only message (NO/NC contact)
Drive valve to pos. up (NO/NC contact)
Drive valve to pos. down (NO/NC contact)
Block movement (NO/NC contact)
Without
A1=min. A2=max.
Alarm function
A1=min. A2=min.
A1=max. A2=max.
Response threshold of alarm 1
Response threshold of alarm 2
Function of alarm output
On fault
Fault + not automatic
Fault + not automatic + BI
(+ means logical OR operation)
Monitoring time for fault message
control deviation
Response threshold for fault message
control deviation

0.0 to 100.0
0.0 to 100.0

%
%

42.BIN14)

43.BIN24)

44.AFCT5)
45.A1
46.A2
47.FCT
6)

48.TIM
49.LIM
50.STR
K
51.DCH
G
52.ZER
O
53.OPE
N
54.DEBA

55.PRST

38-36 / 38

Limit for stroke integral


Limit for direction change
Limit for end stop monitoring, bottom
Limit for end stop monitoring, top
Limit for dead zone monitoring
Preset (factory setting)
no nothing activated
Strt start of factory setting after pressing
key for 5 sec.
oCAY display following successful factory setting
CAUTION: preset results in NO INIT

Factory setting
0.5
99.5

OFF
on / -on
bLoc1
bLoc2
uP / -uP
doWn / -doWn
StoP / - StoP

OFF

OFF
on / -on
uP / -uP
doWn / -doWn
StoP / -StoP

OFF

oFF
N , NA
N,N
NA , NA
0.0 to 100.0
0.0 to 100.0

OFF
%
%

nA
nAb
Auto
0 to 100
Auto
0.0 to 100.0
OFF
1 to 1.00E9
OFF
1 to 1.00E9
OFF
0.0 to 100.0
OFF
0.0 to 100.0
OFF
0.0 to 100.0

Customer
setting

10.0
90.0

Auto

Auto
OFF
OFF

OFF

OFF

OFF

no
Strt
oCAY

Language UK

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Parameter list continued


1)

If turn is selected it is not possible to set 33.


Parameter does not appear if 1.YFCT = turn has been selected.
3) Turning points only appear with selection 12.SFCT = FrEE.
4) Alternatively no if initialisation has not yet been carried out.
5) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.
6)Normal means: high level without fault. Inverted means: low level without fault.
2)

Table 2

Diagnosis
In the diagnostic mode the current operating data (such as number of strokes, number
of changes in direction, number of fault messages, etc.) can be displayed.From the
automatic or manual modes the diagnostic mode can be reached by simultaneously
pressing all three keys for at least 2 seconds.
Table 3 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic value
can be selected with the hand symbol key. Certain values can be set to zero by pressing
the key for at least 5 seconds. These are menu item line 1, 2, 3, and 4. Some
diagnostic values may be greater than 99999. In this case the display switches to exponential display.

Diagnostic list
No.:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Abbreviation
STRKS
CHDIR
CNT
A1CNT
A2CNT
HOURS
WAY
TUP
TDOWN
LEAK
P0
P100
IMPUP
IMPDN
DBOP
DBDN
SSUP
SSDN
TEMP
TMIN

Language UK

Meaning
Number of strokes
Changes of direction
Fault counter
Alarm counter 1
Alarm counter 2
Operating hours
Determined actuating path
Travel time up
Travel time down
Leakage
Potentiometer value below stop (0%)
Potentiometer value bottom stop (100%)
Impulse length up
Impulse length down
Dead zone up
Dead zone down
Short step zone up
Short step zone down
Current temperature
Minimum temperature

Displayable
value
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 130
0 to 1000
0 to 1000
0.0 to 100.0
0.0 to 100.0
0.0 to 100.0
2 to 100
2 to 100
0.1 to 100.0
0.1 to 100.0
0.1 to 100.0
0.1 to 100.0
-45 to 85
-45 to 85

Unit
Hours
mm or
s
s
%
%
%
ms
ms
%
%
%
%
C
C

38-37 / 38

OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000

Diagnostic list
21
22
23
24
25
26
27
28
29
30
31
32

TMAX
T1
T2
T3
T4
T5
T6
T7
T8
T9
VENT1
VENT2

33

STORE

Maximum temperature
Number of operating hours in Temperature range 1
Number of operating hours in Temperature range 2
Number of operating hours in Temperature range 3
Number of operating hours in Temperature range 4
Number of operating hours in Temperature range 5
Number of operating hours in Temperature range 6
Number of operating hours in Temperature range 7
Number of operating hours in Temperature range 8
Number of operating hours in Temperature range 9
Number of cycles pre-control valve 1
Number of cycles pre-control valve 2
Store current values as last maintenance
Press the up key for at least 5 seconds (store)

-45 to 85
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9
0 to 4.29E9

C
Hours
Hours
Hours
Hours
Hours
Hours
Hours
Hours
Hours
-

Table 3

Service and maintenance


The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the function
of the positioner. In this case the filters can be cleaned as follows:
Step
Step
Step
Step
Step
Step

A:
B:
C:
D:
E:
F:

Switch off the pneumatic power supply and remove the pipes.
Unscrew the cover.
Remove the three screws from the pneumatic connector strip.
Remove the filters and O-rings behind the connector strip.
Clean the filters (e.g. with compressed air).
After cleaning first insert the filters in the recesses in the housing and then
place the O-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anticlockwise until they snap into the thread audibly. Only then should the
screws be tightened.

38-38 / 38

Language UK

TABLE OF CONTENTS

Table of contents
Spare parts for boiler
Description
Boiler unit Aalborg OC..............................................
Boiler unit Aalborg XS-2V.........................................
Stop valve.................................................................
Stop valve.................................................................
Stop valve.................................................................
Stop valve.................................................................
Safety valve..............................................................
Stop valve.................................................................
Stop valve.................................................................
Feed water pump.......................................................
Gauge board.............................................................
Check valve..............................................................
Control valve............................................................
Control valve............................................................
Water level control unit..............................................
Water level gauge......................................................
Water level gauge......................................................
Filter........................................................................

Language UK

Document ID
SP 9011000002..........
SP 9011000006..........
SP 2501086................
SP 2501088................
SP 2511088................
SP 2511093................
SP 2611171................
SP 2641088................
SP 2641090................
SP 5541002014..........
SP 61Z_050525..........
SP 6020000101..........
SP 6050000240..........
SP 6050000458..........
SP 70Z_036686..........
SP 7010000430..........
SP 7010000431..........
SP 7040000041..........

Page
39-2
39-3
39-4
39-5
39-6
39-7
39-8
39-9
39-10
39-11
39-13
39-15
39-16
39-18
39-19
39-20
39-23
39-26

39-1 / 26

SP 9011000002#C.1
BOILER
UNIT AALBORG
SP 9011000002
B OC

SPARE PARTS FOR BOILER UNIT

Spare parts for Boiler unit Aalborg OC


For further information,
please see operation and
maintenance instructions
Boiler
unit Aalborg
OC

1
2
3

Position
1.1
1.2
2.1
2.2
2.3
3.1
3.2

Item number
9011000002-1.1
2158320
6492914
2147542
3000000042
9011000002-3.1
2158609

4.1

2118224

4.2

2118232

4.3
5

2118236
6494971

Item name
Manhole cover
Gaskets for manholes
Glass for inspectionholes
Gaskets for inspectionholes, L=245
Circlip ring for inspectionholes
Handhole cover
Gaskets for handholes
Moulding powder for refractory
(25kg/sack)
Moulding powder for refractory
(20kg/sack)
Moulding powder for refractory
(25kg/box)
Plug for pinelement 246 t=16

Application Qty
1
4
2
2
2
2
8
Permanent
repair
4
Insulating
material
5
Temporary
repair
4
4

Notes/Recommended

No item on drawing
No item on drawing
No item on drawing
No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com
39-2 Language
/ 26
UK

Language UK
Page 1/1

SP 9011000006#C.2
BOILER
UNIT AALBORG
XS-2V
SP 9011000006
B

SPARE PARTS FOR BOILER UNIT

Spare parts for Boiler unit Aalborg XS-2V


For further information,
see operation and maintenance
instructions
Boiler
unitpleaseAalborg
XS-2V

1
2

Position
1.1
1.2
2.1
2.2
3

Item number
9011000006-1.1
2158320
9011000006-2.1
2158609
9011000006-3

Item name
Manhole cover
Gaskets for manholes
Handhole cover
Gaskets for handholes
Tubeplug

Application Qty Notes/Recommended


1
4
2
8
4

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

Language UK
UK
Language

39-3
26
Page/ 1/1

SP 2501086#C.1
STOP
SPVALVE
2501086 A
SPARE PARTS FOR VALVE

Spare parts for stop valve


Size: DN15
PN25
Stop
valve
In/out orientation: Straight
For further technical information, please see data sheet for stop valve

2
4

7
8

Position

Item number

Item name

Application

Qty

9660100049

Handwheel

2
3
4
5

9660100037
9660100013
9660100061
9660100085

Stem
Bonnet
Packing
Gasket

1
1
1
1

6
7
8
9
10

9660100073
9660100025
2501086-8
9660100001
3510000006

Studs and hexagon nuts


Plug
Seat ring
Body
Gasket for flange DN15

1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-4 Language
/ 26
UK

Language UK
Page 1/1

SP 2501088#C.1
STOP VALVE
SP 2501088 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Size: DN25 PN25


Stop
valve

In/out orientation: Straight


For further technical information, please see data sheet for stop valve

2
4

7
8

Position

Item number

Item name

Application

Qty

9660100051

Handwheel

2
3
4
5

9660100039
9660100015
9660100063
9660100087

Stem
Bonnet
Packing
Gasket

1
1
1
1

6
7
8
9
10

9660100075
9660100027
2501088-8
9660100003
3510000008

Studs and hexagon nuts


Plug
Seat ring
Body
Gasket for flange DN25

1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

LanguageUK
UK
Language

39-5
26
Page/ 1/1

SP 2511088#C.1
STOP VALVE
SP 2511088 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Stop
valve
Size: DN25
PN25

In/out orientation: Angle


For further technical information, please see data sheet for stop valve

1
2
3
4
5
6
7
8
9

Position
1
2
3
4
5
6
7
8
9
10

Item number
9660100051
9660100039
9660100123
9660100063
9660100183
9660100087
9660100027
2511088-8
9660100111
3510000008

Item name
Handwheel
Stem
Bonnet
Packing
Studs and hexagon nuts
Gasket
Plug
Seat ring
Body
Gasket for flange DN25

Application

Qty
1
1
1
1
1
1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-6 Language
/ 26
UK

Language UK
Page 1/1

SP 2511093#C.1
STOP VALVE
SP 2511093 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Size: DN80 PN25


Stop
valve

In/out orientation: Angle


For further technical information, please see data sheet for stop valve

1
2
3
4
5
6
7
8
9

Position
1
2
3
4
5
6
7
8
9
10

Item number
9660100164
9660100044
9660100128
9660100176
9660100188
9660100200
9660100032
2511093-8
9660100116
3510000013

Item name
Handwheel
Stem
Bonnet
Packing
Studs and hexagon nuts
Gasket
Plug
Seat ring
Body
Gasket for flange DN80

Application

Qty
1
1
1
1
1
1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

LanguageUK
UK
Language

39-7
26
Page/ 1/1

SP 2611171#C.1
SAFETY VALVE
SP 2611171 A
SPARE PARTS FOR VALVE

Spare parts for safety valve

Size: DN32 PN40/16


Safety
valve

In/out orientation: Full lift


For further technical information,
please see data sheet for safety valve
TAG no.: C1/C301

1
2
3
4
5
6
7

Position
1
2
3
4
5
6
7
8
9
10
11
12
13

Item number
9660400144
9660400205
9660400180
8580000001
9660400073
9660400135
9660400198
9660400162
9660400153
9660400127
9660400118
9660400109
9660400100

14

3510000009

Item name
Cap
Lifting device
Adjusting screw
Spring
Spindle
Bonnet
Stud and Hexagon nut
Guide/spring plate
Disc, hardened
Body
Snap ring
Spindelring
Gasket
Gasket for flange
DN32 PN40

11

12

10

13
Application

TAG no.
C1.1/C301.1

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-8 Language
/ 26
UK

Language UK
Page 1/1

SP 2641088#C.1
STOP VALVE
SP 2641088 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Size: DN25 PN25


Stop
valve

In/out orientation: Straight, non return


For further technical information, please see data sheet for stop valve

1
2
4

6
7
8
9
10

Position
1
2
3
4
5
6
7
8
9
10
11

Item number
9660100051
9660100040
9660100015
9660100063
9660100087
9660100075
9660100099
9660100028
2641088-9
9660100003
3510000008

Item name
Handwheel
Stem
Bonnet
Packing
Gasket
Studs and hexagon nuts
Spring
Plug
Seat ring
Body
Gasket for flange DN25

Application

Qty
1
1
1
1
1
1
1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

LanguageUK
UK
Language

39-9
26
Page/ 1/1

SP 2641090#C.1
STOP VALVE
SP 2641090 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Size: DN40
PN25
Stop
valve

In/out orientation: Straight, non return


For further technical information, please see data sheet for stop valve

1
2
4

6
7
8
9
10

Position
1
2
3
4
5
6
7
8
9
10
11

Item number
9660100053
9660100042
9660100017
9660100065
9660100089
9660100077
9660100101
9660100137
2641090-9
9660100005
3510000010

Item name
Handwheel
Stem
Bonnet
Packing
Gasket
Studs and hexagon nuts
Spring
Plug
Seat ring
Body
Gasket for flange DN40

Application

Qty
1
1
1
1
1
1
1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-10Language
/ 26
UK

Language UK
Page 1/1

SP 5541002014#C.1
FEED
WATER PUMP
SP 5541002014
A

SPARE PARTS FOR PUMP

Spare parts for feed water pump


Head pressure: 120 mWC
Feed
water pump
Capacity: 0.65 m3/h
For further technical information, please see data sheet for feed water pump

Language UK
UK
Language

39-11
26
Page/ 1/2

SP 5541002014#C.1
FEED
PUMPA
SPWATER
5541002014

SPARE PARTS FOR PUMP


Pos.
Item number
1 5541002014-1
2 5541002014-2
3 5541002014-3
4

5541002014-4

5
6
7
8
9
10
11
12
13
14
15
16
17
18

5541002014-5
5541002014-6
5541002014-7
5541002014-8
5541002014-9
5541002014-10
5541002014-11
5541002014-12
5541002014-13
5541002014-14
5541002014-15
5541002014-16
5541002014-17
5541002014-18

Item name
Kit, Gaskets, Rubber type: FKM
Kit, Gaskets, Rubber type: EPDM
Kit, shaft seal HQQE
Kit, wear parts, Material type: BRONZE
Kit, wear parts, Material type: SILICON
CARBIDE
Motor
Kit, coupling
Pump head
Bulk, Chamber complete (10 PC)
Chamber, bottom
Base
Bulk, Coupling guard (10 PC)
Drain plug with bypass valve
Staybolt
Bulk, Impeller complete (24 PC)
Pump shaft
Sleeve
Chamber stack

Application

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1

Notes/Recommended
Pos. No. 100,37,38
Pos. No. 100,37,38
Pos. No. 105
Pos. No.
65,45,64a,4a,47a,64c,66,67,39
Pos. No.
65,45,64a,4a,47a,64c,66,67,39
Pos. No. 8,10a,9,10
Pos. No. 2
Pos. No. 4
Pos. No. 5a
Pos. No. 6
Pos. No. 7
Pos. No. 25
Pos. No. 26
Pos. No. 49
Pos. No. 51
Pos. No. 55
Pos. No. 80

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com

39-12Language
/ 26
UK

Language UK
Page 2/2

SP 61Z_050525#F.2
GAUGE
BOARDC
SP 61Z:050525

SPARE PARTS FOR GAUGE BOARD

Spare parts for Gauge board


For boiler type Aalborg
OC
Gauge
board
Class: ABS, BV, CCS, DNV, LRS, NK, RINA.
For boiler type Aalborg OS (Aalborg XS-2V)
Class: ABS, BV, CCS, DNV, LRS, NK, RINA, GL, GL + SeeBG.
Tag No. C30

Position
1
2
3
4
5
6
7
8
11
12
13
14
15
16
17
Language UK
UK
Language

Item number
K33:023589
6632973
8010000022
6310310
2541002
K33:004887
61Z:050525-7
61Z:050525-8
2911602
61K39:050515
3255010
3215162
2462207
2000000062
8560000026

Item name
Application
Support for gauge board valve
Pressure gauge 100
Pressure transmitter
Pressure switch RT 30 AW
Pressure gauge valve
Support for gauge board valves
Sign
Sign
Gasket
Manifold
Allen screw
Machine screw with pozidriv
Coupling
Pipe plug
Stabilizing pl. for accessories

Pcs.
1
1
1
1
3
6
1
1
6
1
12
4
1
1
1

Notes/Recommended

39-13
26
Page/ 1/2

SP 61Z_050525#F.2
GAUGE
BOARD
SP 61Z:050525
C

SPARE PARTS FOR GAUGE BOARD

Position
18
19

Item number
K33:023566
2911605

20
21
22
23
24

K23:015930
2453430
3254717
61Z:050525-23
K33:026089

Item name
Mounting shape
Compress. gasket
Streamer STEAM
PRESSURE
Coupling
Hexagon set screw
Gauge board cabinet complete
Mounting shape

Application

Pcs.
1
1

Notes/Recommended

1
1
4
1
1

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com

39-14Language
/ 26
UK

Language UK
Page 2/2

SP 6020000101#A.1
CHECK
VALVE A
SP 6020000101

SPARE PARTS FOR CHECK VALVE

Spare parts for check valve

Check
valve
Size: DN15 PN40

Kvs value: 4,4 m/h


For further technical information, please see data sheet for control valve

1
2
4
3

Position
1
2
3
4
5

Item number
6020000101-1
6020000101-2
6020000101-3
6020000101-4
6020000101-5

Item name
Body
Retaining ring
Spring plate
Valve plate
Spring

Application

Qty
1
1
1
1
1

Notes/Recommended

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com

Language UK
UK
Language

39-15
26
Page/ 1/1

SP 6050000240#B.1
SP 6050000240 B
CONTROL VALVE
SPARE PARTS FOR CONTROL VALVE

Spare parts for control valve

Control valve

Size: DN32 PN25


Kvs value: 6.3 m3/h
Actuator: Pneumatic
Closing pressure: 16.8
For further technical information, please see data sheet for control valve

2
3
4
5
6
7
8

39-16Language
/ 26
UK

Language Page
UK 1/2

SP 6050000240#B.1
SP 6050000240 B
CONTROL VALVE
SPARE PARTS FOR CONTROL VALVE

Position
1
2
3

Item number
6050000240-1
9685000003
9660500111

4
5
6
7
8
9

9660500144
9660100089
9660500133
9660500103
6050000240-8
2159108

Item name
Hand wheel
I/P Positioner
Spindle
PTFE-V unit: PTFE ring, Washer,
Spring, Guide band, Scraper and
Spindle guide.

Application

Qty
1
1
1

1
1
1
1
1
2

Gasket
Guiding bush
Seatring
Parabolic plug
Gasket DN 32 PN 25 for flange

Notes/Recommended

No item on drawing

10
11
12
13
14

Position
10
11
12

Item number
9660500164
9660500170
9660500173

13
14

9660500176
9660500167

Item name
Diaphragm
Diaphragm plate
Spring
Stem Sealing: Spindle guide,
Guiding band, O-ring (spindle),
O-ring (guiding) and Scraper
Bellow

Application

Qty
1
1
1

Notes/Recommended

1
1

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com
Language UK
Language
UK

39-17
26
Page/ 2/2

SP 6050000458#A.1
CONTROL
VALVE A
SP 6050000458

SPARE PARTS FOR CONTROL VALVE

Spare parts for control valve

Control
valve
Size: DN15 PN25

Kvs value: 4.0 m/h


Cooling spacer
For further technical information, please see data sheet for control valve

Position
1
2
3
4
5
6
7
8
9
10
11
12

Item number
6050000458-1
6050000458-2
6050000458-3
6050000458-4
6050000458-5
6050000458-6
6050000458-7
6050000458-8
6050000458-9
6050000458-10
6050000458-11
6050000458-12

Item name
Body
Seat ring
Cylinder screw
Guide bushing
Gasket
Hood
Spindle unit
Pressure piece
Hexagon nut
Cooling spacer
Spring
Balanced bellow

Application

Qty
1
1
1
1
1
1
3
1
2
1
1
1

Notes/Recommended

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com
39-18Language
/ 26
UK

Language UK
Page 1/1

SP 70Z_036686#B.1
WATER
LEVEL CONTROL
UNIT
SP 70Z:036686
B

SPARE PARTS FOR WATER LEVEL CONTROL UNIT

Spare parts for water level control unit


Size: DN25
Water
level control unit
Tag no.: W16

Position
1
2

Item number
70Z:036686
70Z:034478

400000390

4
5
6
7
8
9
10

400000395
351000008
3271382
3292124
3090000004
3000000033
6220000001

11
12
13

8020000001
3520000013
6230000002

Item name
Application
Upper level tube complete
DP water level control unit complete
Level tube L=1446 mm, to be
shortened in actual size
Level tube L=146 mm, to be
shortened in actual size
Gasket
Stud
Nut
Washer
Allen screw
Indtrument stop valve
Difference pressure transmitter 2.5250 mBar
Gasket
Valve manifold

Qty
1
1

Notes/Recommended
TAG W16.1
TAG W16.2

1
1
2
8
16
4
4
1
1
2
1

For ordering spare parts and further information: E-mail:


aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com
Language UK
UK
Language

39-19
26
Page/ 1/1

SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A

SPARE PARTS FOR WATER LEVEL GAUGE

Spare parts for Water level gauge


Type: Reflective,
size 26 (shown
model is size 16)
Water
level
gauge
Valve operation: Right
Dimension: DN25 PN40, centre distance: 700 mm
For further technical information, please see data sheet for water level gauge
Tag no. C18

39-20Language
/ 26
UK

Language UK
Page 1/3

SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A

SPARE PARTS FOR WATER LEVEL GAUGE

Language UK
UK
Language

39-21
26
Page/ 2/3

SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A

SPARE PARTS FOR WATER LEVEL GAUGE

Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Item number
9670100202
7010000430-2
2163720
2163719
7010000430-5
7010000430-6
7010000430-7
7010000432
8590000019
3520000042
6000000103
9670100171
8500000455
9670100198
7010000430-15
7010000430-16
7010000430-17
7010000430-18
7010000430-19

Item name
Complete set of cocks DN25 PN40 right
Stuffing box head
Packing sleeve for cocks
Gland ring
Union nut
Connection tube
Bolts and nuts
Body gauge size 26, c to c 700mm
Reflex glass incl. 2 packing
Complete packing set for glass
Drain cock
Packing sleeve for drain valve
Repair kit for cocks
Joint ring
Washer
Screw
Split ring
Cock plug
Tightening nut

Application Qty Notes/Recommended


1
2
2
2
2
2
1
1
2
2
1
1
1 Pos. no. 3, 4, 12 + 14
2
2
2
2
2
2

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-22Language
/ 26
UK

Language UK
Page 3/3

SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A

SPARE PARTS FOR WATER LEVEL GAUGE

Spare parts for Water level gauge


Type: Reflective,level
size 26 (shown
model is size 16)
Water
gauge
Valve operation: Left
Dimension: DN25 PN40, centre distance: 700 mm
For further technical information, please see data sheet for water level gauge
Tag no. C17

Language UK
UK
Language

39-23
26
Page/ 1/3

SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A

SPARE PARTS FOR WATER LEVEL GAUGE

39-24Language
/ 26
UK

Language UK
Page 2/3

SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A

SPARE PARTS FOR WATER LEVEL GAUGE

Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Item number
9670100203
7010000431-2
2163720
2163719
7010000431-5
7010000431-6
7010000431-7
7010000432
8590000019
3520000042
6000000103
9670100171
8500000455
9670100198
7010000431-15
7010000431-16
7010000431-17
7010000431-18
7010000431-19

Item name
Complete set of cocks DN25 PN40 left
Stuffing box head
Packing sleeve for cocks
Gland ring
Union nut
Connection tube
Bolts and nuts
Body gauge size 26, c to c 700mm
Reflex glass incl. 2 packing
Complete packing set for glass
Drain cock
Packing sleeve for drain valve
Repair kit for cocks
Joint ring
Washer
Screw
Split ring
Cock plug
Tightening nut

Application Qty Notes/Recommended


1
2
2
2
2
2
1
1
2
2
1
1
1 Pos. no. 3, 4, 12 + 14
2
2
2
2
2
2

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

Language UK
UK
Language

39-25
26
Page/ 3/3

SP 7040000041#B.1
SP 7040000041 A
FILTER
SPARE PARTS FOR FILTER

Spare parts for filter

Size: DN15 PN25


Filter

For further technical information, please see data sheet for filter

1
2
3
4
5

Position
1
2
3
4
5

Item number
9670400020
9670400008
9670400026
7040000041-4
9670400014

Item name
Screen
Body
Gasket
Studs and hexagon nuts
Cover

Application

Qty
1
1
1
1
1

Notes/Recommended

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

39-26Language
/ 26
UK

Language UK
Page 1/1

TABLE OF CONTENTS

Table of contents
Spare parts for KBO-E 13-M
Description
KBO-E-13M.............................................................
Spare parts for heat exchanger type MX.......................
Stop valve.................................................................
Three way ball valve..................................................
Three way ball valve..................................................

Language UK

Document ID
SP 5561000011..........
15I4003.....................
SP 2501087................
SP 6070000013..........
SP 6070000047..........

Page
40-2
40-7
40-8
40-9
40-10

40-1 / 10

SP 5561000011#F.1
KBO-E-13M

SP 5561000011 C
SPARE PARTS FOR BURNER

Spare parts for Aalborg KBO-E-13M

KBO-E-13M
Type: Pressure atomizing burner

Operation: Modulating
Control system: Aalborg control touch
For further technical information, please see data sheet for burner
Tag No.: F1

Position

Item number

5561000011-1

Burner Housing

5561000011-2

Protective cover

5561000011-3

8060000014

5
6
7
8

8050000054
6210000007
9692801209
6310720

8500001086

10
11
12

8050000054
6210000007
9692801482

Side cover
Temperature transmitter
0-200 C
Pressure gauge
0-60 Bar/kg/cm2
Gauge valve G1/4"
Limit thermostat
Photo cell
Rubber cover
for photo cell
Pressure gauge
0-60 Bar/kg/cm2
Gauge valve G1/4"
Nozzle valve

13
14

5561000011-13
9692801195

40-2 Language
/ 10
UK

Item name

Nozzle valve guide


Heating cartridge

Application

Qty

Notes/Recommended
Not normally available as
spare
Not normally available as
spare
Not normally available as
spare

1
1
1
1
2
2
1
1
1
1
1

Not normally available as


spare

Language UK
Page 1/4

SP 5561000011#F.1
KBO-E-13M

SP 5561000011 C
SPARE PARTS FOR BURNER
Position
15
16
17

Item number
8620000084
9692801703
5561000011-17

17.1
18
19
20
21
22
23

8500000775
9692801696
8645000022
9692801715
5561000011-21
9692801195
9692801695

Item name
Ignition electrode
Ignition cable
Nozzle
Repair kit for nozzle
head
Solenoid valve 1/2"
Preheater
Temperature sensor
Pocket
Heating cartridge
Solenoid valve 1/4"

24

5561000011-24

Pipe 12 x 3.0

25
26

5561000011-25
5561000011-26

1
1

27
28

9692801558
9692801694

Pipe 15 x 3.0
Temperature sensor
Thermometer
0-160 C D12
Solenoid valve 1/4"

Position
32

Item number
5561000011-32

32.1
33
34
35
36
37
38
39
40

5561000011-32.1
5561000011-33
5561000011-34
5561000011-35
5561000011-36
5561000011-37
5561000011-38
5561000011-39
5561000011-40

Language UK
UK
Language

Item name
Electric motor
Bearing set for electric
motor
Motor flange
Bushing
Key
Bushing
Coupling
Fan wheel
Air cone
Air dampers

Apllication

Qty
1
1
1

Notes/Recommended

Please check capacity

1
1
1
1
1
1
1

1
1

Application

Qty
1

Not normally available as


spare
Not normally available as
spare

Check if D10/D12

Notes/Recommended

1
1
1
1
1
1
1
1
1
40-3
10
Page/ 2/4

SP 5561000011#F.1
KBO-E-13M

SP 5561000011 C
SPARE PARTS FOR BURNER

Position
29
30
31
41
42
43
44
45
46
47
48
49
50
50.1

Item number
5561000011-29
5561000011-30
5561000011-31
8030000013
9692801695
5561000011-43
9692801720
8030000012
9692801684
9692801701
5561000011-48
5561000011-49
5561000011-50
9692801704

51
52
52.1
52.2
53
53.1
54
55
56
57

5561000011-51
5561000011-52
5561000011-52.1
5561000011-52.2
5561000011-53
5561000011-53.1
9692801720
8010000017
5561000011-56
5561000011-57

40-4 Language
/ 10
UK

Item name
Application
Hinge pin
Distance plate
Retaining ring
Pressure switch 1-10 bar
Solenoid valve 1/4"
Throttle coupling
Servo motor
Diff. Pressure switch
Ignition transformer
Limit switch
Cotter bolt
Mounting bracket for limit switch
Mounting flange
Flange gasket
Gasket tape
Combustion head
Head extension
Diffuser disc
Compound regulator
Gasket set for oil regulator
Servo motor
Pressure transmitter 0-40 bar
Cable seal
Back nut

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3

Notes/Recommended

Not normally available


as spare

Language UK
Page 3/4

SP 5561000011#F.1
KBO-E-13M

SP 5561000011 C
SPARE PARTS FOR BURNER
Position
58
59
60
61
62
63

Item number
5561000011-58
5561000011-59
5561000011-60
5561000011-61
5561000011-62
5561000011-63

Item name
Cable seal
Back nut
Cable seal
Back nut
Cable seal
Back nut

64

8615000050

Flexible hose x 2000 mm

64
-

8615000111
8500000780

Flexible hose x 2000 mm


Hooking device

Application

Oil, inlet
and outlet
Oil, inlet
and outlet

Qty
2
2
1
1
1
1

Notes/Recommended

Type approved by DNV,


GL, LR, ABS, RINA

2
1

Approved by BV
No item on drawing

For ordering spare parts and further information:


E-mail: aalborgparts.aalborg@alfalaval.com
www.alfalaval.com - www.aalborg-industries.com

Language UK
UK
Language

40-5
10
Page/ 4/4

SP 5561000011#F.1
KBO-E-13M

40-6 / 10

Language UK

15I4003#C.1
SPARE PARTS FOR HEAT EXCHANGER TYPE MX

Spare parts for heat exchanger type MX

Language UK

40-7 / 10

SP 2501087#C.1
STOP VALVE
SP 2501087 A
SPARE PARTS FOR VALVE

Spare parts for stop valve

Size: DN20
PN25
Stop
valve

In/out orientation: Straight


For further technical information, please see data sheet for stop valve

2
4

7
8

Position

Item number

Item name

Application

Qty

9660100049

Handwheel

2
3
4
5

9660100037
9660100014
9660100061
9660100085

Stem
Bonnet
Packing
Gasket

1
1
1
1

6
7
8
9
10

9660100074
9660100025
2501087-8
9660100002
3510000007

Studs and hexagon nuts


Plug
Seat ring
Body
Gasket for flange DN20

1
1
1
1
2

Notes/Recommended

No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

40-8 Language
/ 10
UK

Language UK
Page 1/1

SP 6070000013#B.1
THREE WAY BALL VALVE
SP 6070000013 A
SPARE PARTS FOR VALVE

Spare parts for three way ball valve

Size: DN32
Three
way ball valve

Max. fuel oil flow: 1111.6 kg/h


For further technical information, please see data sheet for three way ball valve

Position
1
2

Item number
9660000013
9660000017

Item name
Repair kit for valve
Box type M

Application

Qty
1
1

Notes/Recommended
No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

LanguageUK
UK
Language

40-9
10
Page/ 1/1

SP 6070000047#B.1
THREE WAY BALL VALVE
SP 6070000047 A
SPARE PARTS FOR VALVE

Spare parts for three way ball valve

Size: DN25 way ball valve


Three

Max. fuel oil flow: 8940.4 kg/h


Control voltage: 230V
For further technical information, please see data sheet for three way ball valve

2
3

Position
1
2
3

Item number
9660000012
9660000025
9660000018

Item name
Repair kit for valve
Packing set for actuator
Solenoid valve

Application

Qty
1
1
1

Notes/Recommended
No item on drawing

For ordering spare parts and further information: E-mail: aalborgparts.aalborg@alfalaval.com


www.alfalaval.com - www.aalborg-industries.com

40-10Language
/ 10
UK

Language UK
Page 1/1

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