Professional Documents
Culture Documents
Table of contents
General (Vol.1)
Preface / conditions for use of manual............................................................................1
General guarantee information.......................................................................................2
Safety precaution.........................................................................................................3
TABLE OF CONTENTS
ii
Language UK
TABLE OF CONTENTS
Table of contents
Preface / conditions for use of manual
Description
Preface / conditions....................................................
Language UK
Document ID
Page
SD9010_40..................
1-2
1-1 / 2
SD9010_40#B.1
PREFACE / CONDITIONS
Preface / conditions
1
1.4 Responsibility
It is the users responsibility to use the manuals as intended, and where not found
sufficient to raise the relevant questions.
1-2 / 2
Language UK
TABLE OF CONTENTS
Table of contents
General guarantee information
Description
General guarantee information....................................
Language UK
Document ID
Page
SD9010_39..................
2-2
2-1 / 3
SD9010_39#E.1
GENERAL GUARANTEE INFORMATION
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.
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
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
2-3 / 3
TABLE OF CONTENTS
Table of contents
Safety precaution
Description
Safety precautions.....................................................
Language UK
Document ID
Page
SD9010_41..................
3-2
3-1 / 5
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.
1.4 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.
3-2 / 5
Language UK
SD9010_41#B.1
SAFETY PRECAUTIONS
Language UK
3-3 / 5
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.
1.11 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.
3-4 / 5
Language UK
SD9010_41#B.1
SAFETY PRECAUTIONS
Language UK
3-5 / 5
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
4-1 / 12
General 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
4-2 / 12
Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443
Language UK
General data
Language UK
Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443
4-3 / 12
4-4 / 12
Language UK
10
Language UK
Operation:......................................................................................24h unattended
Automatic mode:.............................................................................................Yes
Manual mode:..................................................................................................Yes
Emergency mode:............................................................................................Yes
4-5 / 12
General data
4-6 / 12
Request No.:...........................................................................................106393-3
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443
Language UK
Language UK
Pressure loss across boiler (excl. In/outlet boxes) at design load:......89.0 mmWC
4-7 / 12
General data
4-8 / 12
Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443
Language UK
General data
Language UK
Request No.:...........................................................................................106393-1
Order No.:....................................106393-01, 106393-02, 106393-03, 106393-04
Hull Nos.:..............................................GWS440, GWS441, GWS442, GWS443
4-9 / 12
General data
4-10 / 12
Language UK
4-11 / 12
General data
4-12 / 12
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
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
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
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
1
Tag no.
Aalborg OC boiler
Qty.
Dim (DN)
Application
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
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
2
Tag no.
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
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
32
N6
1/4"
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
3
Tag no.
Dim (DN)
Application
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
Seat
Body
32
100 / 4 x 18
140
110
Language UK
2611171
5-11 / 93
5-12 / 93
Language UK
85Y_013421#B.1
EXPANSION JOINT, DN 50
Expansion joint, DN 50
1
Language UK
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
Language UK
5-15 / 93
DATA SHEET
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
Language UK
2511093
5-17 / 93
DATA SHEET
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
5-18 / 93
2501088
Language UK
DATA SHEET
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
Language UK
2641088
5-19 / 93
DATA SHEET
Type:
Instrument stop cone valve, straight, with
security plate
Size:
G " x 12
Nominal diameter: DN 8
Application:
For steam, water and/or air
115
75
1/2 BSP
12
Security plate
22
90
5-20 / 93
6220000002
Language UK
DATA SHEET
53
Max. 126
70
1 "
23
57
Language UK
2931116
5-21 / 93
DATA SHEET
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
7010000431
Language UK
DATA SHEET
W1
L
H1
H5
H4
H3
Visible length H2
Drain connection D
Language UK
7010000431
5-23 / 93
DATA SHEET
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
7010000430
Language UK
DATA SHEET
W1
L
H1
H5
H4
H3
Visible length H2
Drain connection D
Language UK
7010000430
5-25 / 93
5-26 / 93
Language UK
K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE
Language UK
5-27 / 93
DATA SHEET
Language UK
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
12
1/2
42
5-30 / 93
6040000050
Language UK
Technical
data
DATA SHEET
CR 3
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
57.1
Rp 1
M10 x 40
G 1/2
Oval flange
Oval
Dimensions [mm]
D2
B2
3 x 220-255/380-440 V, 60 Hz
I
start
---------------I 1/1
Motor
P2 [kW]
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]
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
5540000049
5-31 / 93
1/3
General data
DATA SHEET
CR 3
6
7
5
9
8
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
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
5540000049
Language UK
2/3
Performance
curves
DATA SHEET
CR 3
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
4.8
5.2
Q [m/h]
0.04
5540000049
5-33 / 93
3/3
DATA SHEET
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
5-34 / 93
8050000045
Language UK
DATA SHEET
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
Language UK
6666016
5-35 / 93
DATA SHEET
5-36 / 93
2541002
Language UK
DATA SHEET
Type:
Remote start/stop box
Application:
For start/operation and stop of feed water
pumps
Material:
House: Polycarbonate
Colour: Grey
120
83
85
105
123
145
177
Start/operation
incl. lamp function
Stop
70
5.8
5.8
Language UK
8001000003
5-37 / 93
DATA SHEET
5714
1
OK
12
0
48
Type
LED indicator/limit switch
5714B
Application:
96
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
8001000002
Language UK
DATA SHEET
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
Language UK
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
Seat
Body
32
100 / 4 x 18
140
110
5-40 / 93
2611171
Language UK
85Y_013421#B.1
EXPANSION JOINT, DN 50
Expansion joint, DN 50
1
Language UK
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
Language UK
5-43 / 93
DATA SHEET
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
Language UK
2641090
5-45 / 93
DATA SHEET
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
5-46 / 93
2511088
Language UK
DATA SHEET
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
Language UK
2641088
5-47 / 93
DATA SHEET
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
5-48 / 93
2501088
Language UK
DATA SHEET
Type:
Instrument stop cone valve, straight, with
security plate
Size:
G " x 12
Nominal diameter: DN 8
Application:
For steam, water and/or air
115
75
1/2 BSP
12
Security plate
22
90
Language UK
6220000002
5-49 / 93
DATA SHEET
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
7010000431
Language UK
DATA SHEET
W1
L
H1
H5
H4
H3
Visible length H2
Drain connection D
Language UK
7010000431
5-51 / 93
DATA SHEET
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
7010000430
Language UK
DATA SHEET
W1
L
H1
H5
H4
H3
Visible length H2
Drain connection D
Language UK
7010000430
5-53 / 93
5-54 / 93
Language UK
K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE
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
Language UK
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
12
1/2
42
Language UK
6040000050
5-59 / 93
Technical data
CR 1
DATA
SHEET
'$7$6+((7
Tag7DJ1RV
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
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
Dimensional sketches
178
D2
3 x 220-255/380-440 V, 60 Hz
I
start
---------------I
1/1
Motor
P2 [kW]
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]
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
5541002014
Language1 UK
of 3
General
data
DATA SHEET
'$7$6+((7
CR 1
3
10
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
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
5541002014
/DQJXDJH8.
2 5-61
of 3 / 93
Performance curves
CR 1
DATA
SHEET
'$7$6+((7
Tag7DJ1RV
No(s): 3M169, 3M170
p
[kPa]
H
[m]
CR 1
-27
240
60 Hz
220
2000
-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
2.4
2.6
2.8
Q [m/h]
Technical dataCR 1
50
0.08
curves/
0.10
Eta
[%]
-2
5541002014
Language3 UK
of 3
DATA SHEET
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
Language UK
8050000045
5-63 / 93
DATA SHEET
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
5-64 / 93
6666016
Language UK
DATA SHEET
Language UK
2541002
5-65 / 93
DATA SHEET
Type:
Remote emergency stop system box, included PG-gland cable connection
Application:
For emergency stop
68
53
68
34
34
91
5-66 / 93
54
8000000016
Language UK
DATA SHEET
5714
1
OK
12
0
48
Type
LED indicator/limit switch
5714B
Application:
96
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
8001000002
5-67 / 93
DATA SHEET
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
5-68 / 93
8001000002
Language UK
DATA SHEET
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
Language UK
100
81.5
107
BSP 1/2-m
6632973
5-69 / 93
DATA SHEET
Version: B.2
5-70 / 93
6310310
Language UK
DATA SHEET
Version: B.2
Language UK
6310310
5-71 / 93
DATA SHEET
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:
8010000022
Language UK
DATA SHEET
Language UK
6050000240
5-73 / 93
DATA SHEET
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
5-74 / 93
6050000240
Language UK
DATA SHEET
30
66
Max. 6
23
2.5
44
7.5
14
Gauge por ts
28
99
18
38
Connections ports
41
R1
9
SW19
31
7
Outlet pressure [bar]
Fitting
Bin
Flow characteristics
H andle
Body
6
5
4
3
2
1
1
10
Language UK
2915101
5-75 / 93
DATA SHEET
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
5-76 / 93
2501086
Language UK
DATA SHEET
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
Language UK
Filter, DN 15, PN 25
7040000041
5-77 / 93
DATA SHEET
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
Body
Spindel unit
Cooling spacer
M 38 x 1.5
6050000458
Language UK
DATA SHEET
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.
Language UK
Temperature switch
8070000023
5-79 / 93
DATA SHEET
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
5-80 / 93
6020000101
Language UK
DATA SHEET
Language UK
Cap
6000000121
5-81 / 93
DATA SHEET
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
5-82 / 93
Head
Pipe
7000000085
Language UK
DATA SHEET
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
"
Language UK
8310000005
5-83 / 93
DATA SHEET
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
40
60
188
75
88
120
Alarm
5-84 / 93
8210000025
Language UK
DATA SHEET
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.
Gasket
Gold-plated
electrodes
Language UK
Conductive electrode
8620000104
5-85 / 93
DATA SHEET
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
5-86 / 93
8210000032
Language UK
DATA SHEET
Technical data:
Pressure range: 0 to 1 bar(g)
Flanges according to DIN 2501
Weight: 2.65 kg
115
PCD 85
4 x 12
Language UK
8500000115
5-87 / 93
DATA SHEET
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
13
Sample in 6 mm O/D
Customer supply
1. Sample cooler
4. Cooling water
inlet valve 1/2 BSP
Sample out
5-88 / 93
Sample cooler
8750005
Language UK
DATA SHEET
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.
Table 1
Language UK
Sample cooler
8750005
5-89 / 93
DATA SHEET
Tag No(s): H3
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:
8010000023
Language UK
DATA SHEET
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
Language UK
10 Bar
2941001
5-91 / 93
5-92 / 93
Language UK
K16_004096#D.1
COUNTER FLANGE
Counter flange
1
Language UK
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
Language UK
6-3 / 5
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
R3
R7
R15
R16
Language UK
1
1
1
1
N/A
N/A
N/A
N/A
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
Language UK
7-3 / 55
7-4 / 55
Language UK
1
Tag no.
Dim (DN)
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
0-10 bar
0-10 bar
6310310
8010000022
6070000013
71Z20_065692
DLC-600
-
9294002601
8001000005
7-5 / 55
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
2501087
2501087
87S0032
6070000029
Stop valve
87D3066
6070000017
6070000017
6070000013
6000000111
6070000047
2915101
SPV M10
6050000542
SPV M10
6050000542
6020000088
6000000119
71Z20_056461
9306000025
K16_004096
7-6 / 55
Language UK
Performance Calculation
106393#A.2
MISSION OC
Request no.:
106393
Config. no.:
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Page 3 of 6
7-7 / 55
Performance Calculation
MISSION OC
Standard Size: 1600 kg/h
Customer:
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Page 4 of 6
Language UK
Performance Calculation
106393#A.2
MISSION OC
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Page 5 of 6
7-9 / 55
Performance Calculation
MISSION OC
Standard Size: 1600 kg/h
Customer:
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Page 6 of 6
Language UK
Performance Calculation
106393#A.2
MISSION OC
Request no.:
106393
Config. no.:
Language UK
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C
7-11 / 55
Page 3 of 6
Performance Calculation
MISSION OC
Standard Size: 1600 kg/h
Customer:
7-12 / 55
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C
Language UK
Page 4 of 6
Performance Calculation
106393#A.2
MISSION OC
Language UK
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C
7-13 / 55
Page 5 of 6
Performance Calculation
MISSION OC
Standard Size: 1600 kg/h
Customer:
7-14 / 55
Request no.:
106393
Fuel type
Calorific value
:
:
Working pressure
Feed water temperature
:
:
User: lkh
Config. no.:
Diesel Oil
42200 kJ/kg
7.0 bar g
85 deg. C
Language UK
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
H1
L1
W1
O.D.
W2
Language UK
5561000011
7-15 / 55
DATA SHEET
7-16 / 55
2541002
Language UK
DATA SHEET
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
Language UK
100
81.5
107
BSP 1/2-m
6632973
7-17 / 55
DATA SHEET
Version: B.2
7-18 / 55
6310310
Language UK
DATA SHEET
Version: B.2
Language UK
6310310
7-19 / 55
DATA SHEET
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:
8010000022
Language UK
DATA SHEET
DATA SHEET
Type:
Installation:
Size:
DN 32
Application:
Material
Technical data:
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
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
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
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
Dimensioner LxBxH
Dimensions
82x80x67
82x80x67
82x80x67
Cable size:
Version: B.1
Language UK
Aalborg Industries
6070000013
7-23 / 55
2/3
7-24 / 55
Language UK
71Z20_065692#B.1
FLOW METER UNIT DN20, RING LINE
Language UK
7-25 / 55
DATA SHEET
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
9294002601
7-27 / 55
DATA SHEET
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
7-28 / 55
9294002601
Language UK
DATA SHEET
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
9294002601
7-29 / 55
DATA SHEET
Type:
Remote start/stop box
Application:
For start/operation and stop of fuel oil
pumps
Material:
House: Polycarbonate
Colour: Grey
120
83
85
105
123
145
177
Start/operation
incl. lamp function
Stop
70
5.8
5.8
7-30 / 55
8001000005
Language UK
15K7603#D.1
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
12
1/2
42
Language UK
87S0032
7-33 / 55
DATA SHEET
Technical data:
Max. workingpressure at 80C: 32 bar
Max. working pressure at 150C: 10 bar
Weight: 0.18 kg
44
85
BSP
60
7-34 / 55
31
6666106
Language UK
DATA SHEET
Language UK
87N6004
7-35 / 55
DATA SHEET
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
7-36 / 55
2501087
Language UK
DATA SHEET
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
6070000029
7-37 / 55
DATA SHEET
L-Bore
Port 1
Port 2
Port 3
Port 2
Port 1
Port 3
7-38 / 55
6070000029
Language UK
DATA SHEET
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
Language UK
85
87D3066
7-39 / 55
DATA SHEET
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
6070000017
Language UK
DATA SHEET
L-Bore
Port 1
Port 2
Port 3
Port 2
Port 1
Port 3
Version: D.1
Language UK
6070000017
7-41 / 55
DATA SHEET
DATA SHEET
Installation:
Size:
DN 32
Application:
Material
Technical data:
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
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
6070000013
Viton
7-43 / 55
2/3
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
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
Dimensioner LxBxH
Dimensions
82x80x67
82x80x67
82x80x67
Cable size:
Version: B.1
7-44 / 55
Aalborg Industries
6070000013
Language UK
2/3
DATA SHEET
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
Language UK
120
61.5
313.5
255
DN25 PN 40
Oil from tank
252
Non return
valve
31.5
353
6000000111
7-45 / 55
DATA SHEET
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
6070000047
Language UK
DATA SHEET
L-Bore
Port 1
Port 2
Port 3
Port 2
Port 1
Port 3
Language UK
6070000047
7-47 / 55
DATA SHEET
30
66
Max. 6
23
2.5
44
7.5
14
Gauge por ts
28
99
18
38
Connections ports
41
R1
9
SW19
31
7
Outlet pressure [bar]
Fitting
Bin
Flow characteristics
H andle
Body
6
5
4
3
2
1
1
10
7-48 / 55
2915101
Language UK
DATA SHEET
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
Language UK
6050000542
7-49 / 55
DATA SHEET
7-50 / 55
Technical data
Temperature max: 200C
Weight: 0.6 kg
Dimension:
d = 30
D = 75
L = 28
F = 84
W = 78
6020000088
Language UK
DATA SHEET
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
Language UK
Sample Unit
6000000119
7-51 / 55
DATA SHEET
7-52 / 55
Sample Unit
6000000119
Language UK
71Z20_056461#E.1
TEMPERATURE TRANSMITTER IN RING LINE
Language UK
7-53 / 55
71Z20_056461#E.1
TEMPERATURE TRANSMITTER IN RING LINE
7-54 / 55
Language UK
K16_004096#D.1
COUNTER FLANGE
Counter flange
1
Language UK
7-55 / 55
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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ELECTRICAL DRAWINGS FOR BOILER CONTROL PANEL
- 3L2
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- 3L2
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ELECTRICAL DRAWINGS FOR BOILER CONTROL PANEL
- 3L2
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0-16
Range
Set point
9.0
(proposal)
7MF 4433
Type
Indication
bar(g)
deg. C
-100
Page 1
39X2(298-299)
39X2(298-299)
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
3W32
3H2
3C48
50X1(118-119)
50A10F
51X2(112-113)
JUMO
KPS 37
PR5714
PR5714
PS-4000-1
MBS 5100
3W16
400
8.5
n/a
4.0
7.0
7.5
-150
Alarm common
20-500
6-18
4-20
4-20
4-20
250
150
diagram
in wiring
Digital output
Shut down
mA
mA
mA
Digital input
Operation
Indication
bar(g)
Low Alarm
bar(g)
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
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
Function
L2
Language UK
Item
Project Number:106393
106393#A.2
8-73 / 78
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9, Mod. Free
x
x
x
8, Rising
x
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x
7, Low fire
6, Flame stable
4, Ignition
5, Safty time
3, Ingition pos.
2, Pre-Purge
1, Starting
0, Ready
x
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Stopped
x
x
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Number
Step
Shutdown
106393#A.2
Text
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Language UK
Page 1 of 2
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
Step
Burner Type: KBO-E
106393#A.2
SALINITY HIGH
15
17
18
19
20
24
25
26
27
32
33
35
37
EXTERNAL STOP 1
38
40
64
68
73
74
75
76
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79
80
83
89
94
98
Number
Text
Alarms
2
2
x
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x
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8-75 / 78
Page 2 of 2
106393#A.2
0
LINE
1
2
3
4
5
Burner
Boiler
Oil
9
10
11
12
13
14
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16
17
18
19
20
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126
127
128
129
Pow1
SUB MENU LEVEL 2
[INFO 2]
[STATE 1]
[STATE 2]
Burner type:
PASSW.
HIGHEST
LOWEST
DEFAULT
N
N
PUMP CTRL
OIL PUMP
Menu tree
8-76 / 78
[VAL]
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
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
SETUP
DIAGNOSES
TIMERS INSPECT
SOFTWARE VERSION
DIGITAL INPUT
Language UK
106393#A.2
0
FRONT MENU
Pow1
SUB MENU LEVEL 2
[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:
PASSW.
HIGHEST
LOWEST
DEFAULT
DIGITAL OUTPUT
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
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
106393#A.2
0
LINE
259
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Pow1
SUB MENU LEVEL 2
[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:
PASSW.
LOWEST
HIGHEST
DEFAULT
lo: 0
hi: 125
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
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
A
C17
C18
C2
C10
C184
C1
C11
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)
Manhole
C26
Manhole
2100
C24
Design data
225
85
275
225
1135
1050
C7
C
600
1000
650
C25
Handhole
Foundation console
%
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)
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
ton
17
C2
17
ain
20
10
Sliding foot
Y-axis
Dr
C9
C10
C18
C301
C484
Manhole
C1
C184
C4
C3
W16
C304
C303
C5
C6
Yes
Transport Mountings supply
Attach the Lifting Sketch to the boiler body.
Language UK
Customer
Society
Newb. No.
Project No.
Boiler No.
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
Language UK
9-7 / 9
9-8 / 9
Language UK
71Z20_065692#B.1
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
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
8580000001
8590000019
2163719
8500001056
2158320
2158609
6494971
6494106
2118236
7000000053
6632973
8500000362
2158320
2158609
Language UK
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
8580000001
8590000019
2163719
8500001056
2158320
2158609
6494104
6632973
7000000053
2158320
2158609
10-3 / 4
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
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
3520000089
3520000195
3520000198
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
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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.
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
Smoke tubes
Inspection door
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
11-4 / 9
Language UK
SD9210_02#B.1
AALBORG OC BOILER
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
Language UK
11-7 / 9
SD9230_10#A.2
WATER LEVEL CONTROL
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
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
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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
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.
12-2 / 32
Language UK
OM9210_02#D.1
START/STOP OF THE BOILER
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.
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.
Language UK
12-5 / 32
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.
12-6 / 32
Language UK
OM9210_02#D.1
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.
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.
Language UK
12-7 / 32
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.
12-8 / 32
Language UK
OM9210_09#B.1
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.
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.
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.
Language UK
12-9 / 32
OM9210_09#B.1
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.
2.5 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
12-10 / 32
Language UK
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.
Language UK
12-11 / 32
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.
12-12 / 32
Language UK
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.
Language UK
12-13 / 32
OM9010_39#D.1
GASKETS FOR BOILER BODY
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.
1.2 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.
12-14 / 32
Language UK
OM9010_39#D.1
GASKETS FOR BOILER BODY
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.
Language UK
12-15 / 32
OM9210_12#B.1
CLEANING PIN-TUBE ELEMENTS
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
12-16 / 32
om9210_12_dp_tubx0059610en.wmf
Language UK
OM9210_12#B.1
CLEANING PIN-TUBE ELEMENTS
A:
B:
C:
D:
E:
Language UK
It is important to check that the drain and soot collecting system are working
properly during the whole water washing procedure.
12-17 / 32
OM9210_12#B.1
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.
12-18 / 32
Language UK
OM9210_14#B.1
CLEANING SMOKE TUBES
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.
Outle t Ga s Te m p. [C]
Outle t te mp.
10
20
30
40
50
60
70
80
90
100
Loa d %
Figure 1
Language UK
om9210_14_dp_tobx0059620en.wmf
12-19 / 32
OM9210_14#B.1
CLEANING SMOKE TUBES
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.
12-20 / 32
Language UK
OM9210_14#B.1
CLEANING SMOKE TUBES
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.
Language UK
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OM9210_13#C.1
PRESERVATION
Preservation
1
Dry preservation.
Wet preservation.
Nitrogen preservation.
VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:
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.
Language UK
12-23 / 32
OM9210_20#B.1
BOILER REPAIR - PIN-TUBE ELEMENT
12-24 / 32
Language UK
OM9210_20#B.1
BOILER REPAIR - PIN-TUBE ELEMENT
Repair plate
Repair plates:
MISSION OS, OC boilers: 256
MISSION OM boilers: 252
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
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.
12-26 / 32
Language UK
OM9210_22#C.2
PLUGGING OF SMOKE TUBES
Plugging of tube
Exchange of tube
2.5
3.5
Figure 1
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
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.
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.
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.
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
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
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.
13-2 / 15
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
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.
Language UK
13-3 / 15
OM9210_99#D.1
FEED AND BOILER WATER
13-4 / 15
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Language UK
13-5 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Note No.
1
1
1
1, 3, 4
Table No. 1
Note No.
1
1
1
1, 3, 4
Table No. 2
Note No.
Table No. 3
2, 3, 4
Note No.
Table No. 4
2, 3, 4, 5
Drewplex AT / OX
Continuous
X
X
13-6 / 15
Batch
Note No.
1
1, 3, 4
Table No. 5
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Drewplex AT / OX
Continuous
X
X
Batch
Note No.
2, 3, 4
3, 4
Table No. 6
Note No.
1, 3, 4
1, 3, 4
Table No. 7
Note No.
2, 3, 4
3, 4
Table No. 8
Note No.
2, 3, 4
2, 3, 4, 5
Table No. 9
Language UK
Note No.
1, 3, 4
1, 3, 4
Table No. 10
13-7 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Note No.
3, 4
2, 3, 4, 5
Table No. 11
Note No.
2, 3, 4, 5
2, 3, 4, 5
Table No. 12
Marichem
Standard
Continuous
Table No. 13
Batch
X
X
X
X
Note No.
1, 3, 4
1, 3, 4
1, 3, 4
1, 3, 4
Marichem
Standard
Continuous
Table No. 14
Batch
X
X
X
X
Note No.
2, 3, 4
2, 3, 4
3, 4
3, 4
Marichem
13-8 / 15
Table No. 15
Batch
Note No.
1, 3, 4
1, 3, 4
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Marichem
Table No. 16
Batch
X
Note No.
2, 3, 4, 5
3, 4
Marichem
BWT
Continuous
X
X
Table No. 17
Batch
Note No.
1, 3, 4
1, 3, 4
Marichem
BWT
Continuous
Table No. 18
Batch
X
Note No.
2, 3, 4, 5
3, 4
I
Continuous
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Table No. 19
Unitor Chemicals
Language UK
Continuous
X
X
Table No. 20
Batch
X
X
Note No.
2
2
3, 4
3, 4
13-9 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Unitor Chemicals
II
Continuous
Table No. 21
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Unitor Chemicals
II
Continuous
Table No. 22
Batch
X
X
X
X
Note No.
2
2
3, 4
3, 4
Unitor Chemicals
Liquitreat
Continuous
Table No. 23
Batch
X
X
X
Note No.
1
1, 3, 4
1, 3, 4
Unitor Chemicals
Liquitreat
Continuous
Table No. 24
Batch
X
X
X
Note No.
2
3, 4
3, 4
Unitor Chemicals
Combitreat
Continuous
13-10 / 15
X
X
Table No. 25
Batch
X
Note No.
1
1, 3, 4
1, 3, 4
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Unitor Chemicals
Combitreat
Continuous
Table No. 26
Batch
X
X
X
Note No.
2
3, 4
3, 4
Unitor Chemicals
I
Continuous
Table No. 27
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Uniservice Group
I
Continuous
Table No. 28
Batch
X
X
X
X
Note No.
2
2
3, 4
3, 4
Uniservice Group
II
Continuous
Table No. 29
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Uniservice Group
II
Continuous
Language UK
X
X
Table No. 30
Batch
X
X
Note No.
2
2
3, 4
3, 4
13-11 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Uniservice Group
One Shot
Continuous
Table No. 31
Batch
X
X
X
Note No.
1
1, 3, 4
1, 3, 4
Uniservice Group
One Shot
Continuous
Table No. 32
Batch
X
X
X
Note No.
2
3, 4
3, 4
Uniservice Group
Organic Treatment
Continuous
Batch
X
X
Table No. 33
Note No.
1
1, 3, 4
Table 2
13-12 / 15
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
PT
Steam
dump
valve
Condenser
Cooling
water
Condensate
Make-up
Boiler
Overflow
Hot well
Drain
1
2
PI
PI
PI
PI
PS
Figure 1
Language UK
Feed water
pumps
om9210_99_flowdix0060010en.wmf
13-13 / 15
OM9210_99#D.1
FEED AND BOILER WATER
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
Figure 2
13-14 / 15
Feed water
pumps
om9210_99_flowdix0060020en.wmf
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
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
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
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:
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
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.
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
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
Figure 1
om6040_01_safe_0x0056591en.wmf
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.
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.
Language UK
OM6040_01#A.2
SAFETY VALVES
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
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.
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.
15-6 / 7
A:
B:
C:
D:
Language UK
OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE
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
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
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
Language UK
16-3 / 22
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
Language UK
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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16-5 / 22
OM8210_42#B.3
SAFETY DEVICE
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
Figure 3
om8210_13_2x2689210en.wmf
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
16-8 / 22
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OM8210_42#B.3
SAFETY DEVICE
Fig. 6a
Fig. 6b
Fig. 6c
Fig. 6d
Fig. 6e
Fig. 6f
Figure 6
om8210_13_4ax2691960en.wmf
Basic Settings
5.1 Factory setting
Level Switch NRS 1-50
The level switch features the following factory set default values:
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16-9 / 22
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!
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.
16-10 / 22
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OM8210_42#B.3
SAFETY DEVICE
Figure 7
om8210_13_5ax2691680en.wmf
Start
Activity
Apply mains voltage.
Indication
All LEDs are 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.
Table 3
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OM8210_42#B.3
SAFETY DEVICE
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.
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
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).
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.
Table 7
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.
Diagnosis
LED 2
flashing.
Diagnosis
LED 3
flashing.
Diagnosis
LED 1
flashing.
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
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
Language UK
OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM
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
Figure 2
om8210_13_nrgt26x0058430en.wmf
J
K
L
M
N
O
P
Q
R
S
Table 1
16-18 / 22
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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM
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16-19 / 22
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:
-
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.
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OM8210_13#A.2
WATER LEVEL CONTROL SYSTEM
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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.
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
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.
17-2 / 12
Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
60 Hz
10 bar
10 bar
10 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
10 bar
15 bar
Table 1
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17-3 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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
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.
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
Figure 1
17-6 / 12
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
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).
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Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Figure 4
om5540_20_cr06x0054120en.wmf
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.
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.
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.
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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.
Language UK
17-11 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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.
Table 4
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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
Language UK
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)
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.
Table 1
Language UK
18-5 / 6
OM8210_41#G.1
SALINOMETER
No.
Picture
Description
What to do
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.
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
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.
50 - 100 m
URM76
RG58
Above 100 m
Consult Alfa Laval
Table 1
Language UK
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.
19-4 / 11
Language UK
OM9410_01#C.1
OIL DETECTION EQUIPMENT
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
Language UK
om9410_01_mobreyx0063090en.wmf
19-5 / 11
OM9410_01#C.1
OIL DETECTION EQUIPMENT
19-6 / 11
Language UK
OM9410_01#C.1
OIL DETECTION EQUIPMENT
Figure 4
om9410_01_mobreyx0063130en.wmf
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.
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.
Language UK
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
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
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
21-56
21-58
21-1 / 60
OM5560_03#E.1
MODULATING OIL BURNER
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.
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
21-4 / 60
Language UK
OM9280_02#F.1
HANDLING FUEL OIL
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
Outlet
PT100
STL
L2
L1
L2
L3
STL
Figure 1
STL
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.
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.
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.
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
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
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
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
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
8 mm
3
4
5
7
Figure 3
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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.
Language UK
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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
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-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.
Language UK
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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
Figure 1
30
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
om5560_38_noz_cax0055520en..wmf
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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
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
Figure 2
30
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
om5560_38_moz_cax0055510en..wmf
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Language UK
OM5560_38#J.1
NOZZLE SELECTION
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
Table 1
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OM5560_37#B.1
NOZZLES
Nozzles
1
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Language UK
OM9280_01#E.1
VISCOSITY - TEMPERATURE CHART
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
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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.
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 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
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KINEMATIC, CENTISTOKES
5,000
4,000
visc1ex3264790en.wmf
Language UK
OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM
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
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OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM
Pressure
atomizing
burner F1
Figure 1
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f_oilsyskboe1ax3102800en.wmf
Language UK
OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM
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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.
1.8 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.
Language UK
OM5560_116#B.1
FUEL OIL SUPPLY SYSTEM
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.
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Language UK
OM5560_117#B.1
BURNER SUPPLY SYSTEMS
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
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kboe_oilsys1x1357420en.wmf
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OM5560_117#B.1
BURNER SUPPLY SYSTEMS
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Language UK
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:
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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Language UK
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.
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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.
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Language UK
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.
Language UK
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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.
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Language UK
OM5560_98#F.2
BURNER OPERATION
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
Figure 2
Language UK
Flushing period
Atomizing period
Stop period
oilburn_m100x3684080en.wmf
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OM5560_98#F.2
BURNER OPERATION
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
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.
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OM5560_234#B.1
EMERGENCY OPERATION
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OM5560_234#B.1
EMERGENCY OPERATION
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OM5560_234#B.1
EMERGENCY OPERATION
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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.
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OM5560_118#D.2
COMMISSIONING
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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.
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Language UK
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.
Language UK
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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.
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Language UK
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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COMMISSIONING
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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.
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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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MAINTENANCE
Maintenance
1
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.
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MAINTENANCE
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FAULTS AND RECTIFYING FAULTS
Trouble shooting
In the event of fault conditions the basic requirements for correct operation must be
examined first:
Possible cause
Remedy
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.
Caution
Possible cause
Remedy
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FAULTS AND RECTIFYING FAULTS
Burner motor starts, ignition is in order, nozzle supplies no oil or nozzle valve does not
function. After a short time lockout occurs.
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.
Tighten joints.
Clean filter, check and adjust pressure.
Adjust.
Clean.
Replace.
Repair or replace.
Check and adjust temperature of incoming oil.
Language UK
Adjust.
Clean.
Check burner adjustment.
Replace.
Replace.
Replace.
Replace.
Find cause and remedy.
Replace.
Replace.
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FAULTS AND RECTIFYING FAULTS
Combustion head
Diffuser disc burned out.
Worn out.
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...............
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OM8640_06#C.1
COOLER FOR MARINE GAS OIL
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
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
A:
B:
C:
D:
E:
Step F:
Step G:
Step H:
Step I:
Step J:
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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.................................................
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OM9294_10...............
OM9294_11...............
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Table of contents
Aalborg control system
Description
Touch control system.................................................
Language UK
Document ID
SD9306_14................
Page
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SD9306_14#F.1
TOUCH CONTROL SYSTEM
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
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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
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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.
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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
Language UK
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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)
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
[VALUE 1]
[VALUE 2]
[VALUE 3]
[LOAD%]
BOILER PRES
WATER LEVEL
HFO PRES
[
STOPPED
Figure 1
0.0 BAR
0 mm
0.0 BAR
0%
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
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
Figure 2
Language UK
KEY POSITION
REQUEST KEY
PP1
NO
STOPPED
0%
Press once
unisab701ax2411370en.wmf
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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
25-6 / 37
0.0 BAR
0 mm
0.0 BAR
0%
unisab702ax2411380en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
Figure 4
Language UK
unisab301cx2411300en.wmf
25-7 / 37
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
CTRL MODE
TIMERS
SETTINGS
DIAGNOSES
LOGGINGS
CALIBRATE
CONFIG
LANGUAGE
Press once
Press once
Figure 5
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om9306_58_unisabx0062920en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
Press once
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)
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 %
Figure 7
25-10 / 37
unisab401dx2412000en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
HI.SHT.DWN.
HIGH ALARM
LOW ALARM
REG OUTPUT
18.0 BAR
17.5 BAR
4.0 BAR
0.0 %
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
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)
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
25-12 / 37
16.5 BAR
12 mm
22.0 BAR
0%
unisab403dx2411330en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
Figure 10
Language UK
unisab501cx2411340en.wmf
25-13 / 37
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
Figure 11
25-14 / 37
om9306_58_unisabx0062980en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
SHT.DWN.
990530-1230
SHT.DWN.
990530-1230
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)
BOILER PRES
WATER LEVEL
HFO PRES
READY
7.5 BAR
12 mm
22.0 BAR
0%
BOILER PRES
WATER LEVEL
HFO PRES
READY
7.5 BAR
12 mm
22.0 BAR
0%
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%
unisab601cx2411360en.wmf
Language UK
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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
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25-17 / 37
OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
BOILER PRES
WATER LEVEL
HFO PRES
READY
7.0 Bar
12 mm
22.0 Bar
0%
Figure 15
unisab901ax2411390en.wmf
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
BOILER PRES
WATER LEVEL
HFO PRES
WAIT TIMER
Figure 18
7.0 Bar
12 mm
22 Bar
0%
unisab904ax2411420en.wmf
25-18 / 37
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OM9306_63#H.3
OPERATION OF THE PANELS (ACT)
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25-19 / 37
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
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.
Language UK
25-21 / 37
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
Language UK
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
PP1
Request key:
Figure 2
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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 3
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contouch_116x0200480en.wmf
Language UK
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 4
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contouch_121ax1762780en.wmf
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OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 5
25-26 / 37
contouch_117bx1610420en.wmf
Language UK
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 6
Language UK
contouch_122ax1762790en.wmf
25-27 / 37
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 7
25-28 / 37
contouch_112x0200440en.wmf
Language UK
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 8
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contouch_113x0200450en.wmf
25-29 / 37
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 9
25-30 / 37
contouch_123ax1762800en.wmf
Language UK
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 10
Language UK
contouch_120bx1610430en.wmf
25-31 / 37
OM9306_70#B.1
OPERATION OF THE TOUCH SCREEN
Figure 11
contouch_126x1761570en.wmf
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
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
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OM9306_67#D.2
KEY OPERATION LOCK
Language UK
25-35 / 37
OM9306_67#D.2
KEY OPERATION LOCK
Figure 1
25-36 / 37
contouch_106x0197660en.wmf
Language UK
OM9306_67#D.2
KEY OPERATION LOCK
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
26-19
26-1 / 99
OM9306_62#F.1
COMMISSIONING AND SERVICE
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
Figure 1
26-2 / 99
[VALUE 1]
[VALUE 2]
[VALUE 3]
[LOAD%]
om9306_59_unisabx0063040en.wmf
Language UK
OM9306_62#F.1
COMMISSIONING AND SERVICE
Figure 2
unisab19x1478340en.bmp
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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.
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.
Language UK
26-5 / 99
OM9306_62#F.1
COMMISSIONING AND SERVICE
26-6 / 99
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OM9306_62#F.1
COMMISSIONING AND SERVICE
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OM9306_62#F.1
COMMISSIONING AND SERVICE
26-8 / 99
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OM9306_62#F.1
COMMISSIONING AND SERVICE
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.
Language UK
26-9 / 99
OM9306_62#F.1
COMMISSIONING AND SERVICE
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.
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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.
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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.
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COMMISSIONING AND SERVICE
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.
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2.
3.
4.
Panel cabinet
5.
Figure 3
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MONITORING AND CONTROL VIA TOUCH SCREEN
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.
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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 1
contouch_140x2046900en.bmp
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.
Figure 2
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Figure 3
contouch_16x0197880en.wmf
From the picture containing contact information access is given to the main menu by
clicking the arrow in the lower left corner (Figure 3).
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Alarm button
Figure 4
contouch_142x2046920en.wmf
The [ALARM] button gives access to the alarm / shutdown list as illustrated Figure 5.
Alarm / Shutdown list
Figure 5
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MONITORING AND CONTROL VIA TOUCH SCREEN
The alarm / shutdown list functions are operated by use of six operation buttons as
illustrated in Figure 6.
Operation buttons
Figure 6
contouch132x1986420en.png
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
contouch133x1986480en.wmf
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
contouch135x1986440en.png
Figure 10
contouch136x1986450en.png
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 11
contouch137x1986460en.png
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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Figure 13
contouch_144x2046930en.bmp
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 15
contouch_261x2361610en.bmp
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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Figure 16
contouch_262x2361620en.wmf
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
contouch148x2047200en.png
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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Figure 18
contouch_252x2353570en.png
Figure 19
contouch_150x2047300en.wmf
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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MONITORING AND CONTROL VIA TOUCH SCREEN
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
contouch151x2047220en.png
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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Figure 21
contouch_263x2361630en.wmf
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
contouch154x2047240en.png
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 24
contouch155x2047250en.png
Figure 25
contouch_223x2333010en.wmf
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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Figure 26
contouch_224x2333020en.png
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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MONITORING AND CONTROL VIA TOUCH SCREEN
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 28
contouch_253x2353580en.png
Figure 29
contouch_191x2176920en.bmp
The water menu is entered from the main menu (Figure 30) or from any of the other
overview pictures.
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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 30
contouch_163x2047360en.wmf
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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MONITORING AND CONTROL VIA TOUCH SCREEN
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
contouch_161bx2356370en.wmf
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 33
contouch_229x2333070en.png
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 34
contouch_230x2333080en.wmf
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
contouch_166x2095420en.bmp
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
contouch192x2194980en.png
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Figure 38
contouch193ax2195000en.wmf
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
contouch_218x2328920en.bmp
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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MONITORING AND CONTROL VIA TOUCH SCREEN
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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MONITORING AND CONTROL VIA TOUCH SCREEN
Fuel overview
Figure 42
contouch_171x2047390en.bmp
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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MONITORING AND CONTROL VIA TOUCH SCREEN
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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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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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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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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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 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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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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Figure 56
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Flush Timers
Figure 57
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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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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.
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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Figure 61
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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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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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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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Figure 66
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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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Figure 69
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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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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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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
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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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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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Figure 76
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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
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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
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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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Figure 80
contouch_217x2328910en.bmp
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
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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Figure 84
contouch_82x0198540en.wmf
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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Figure 85
contouch_232x2333100en.bmp
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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Figure 88
contouch_235x2333130en.bmp
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Figure 89
contouch_236x2333140en.bmp
Figure 90
contouch_237x2333150en.bmp
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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
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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Figure 94
contouch_241x2333190en.bmp
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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Figure 97
contouch_244x2333220en.bmp
Figure 98
contouch_245x2333230en.bmp
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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Figure 99
contouch_246x2333240en.bmp
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
contouch_247x2333250en.bmp
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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27-1 / 7
OM5560_131#H.2
BURNER SEQUENCE DIAGRAM - OIL FUEL
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
Power ON
Initial
Power ON?
Not initial
Valid for oil fuel and gas
fuel firing modes in case
of dual fuel burner
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
STEP No.
Sequence
Figure 2
Language UK
STEP No.
Sequence
(continued)
Normal stop
of the burner
om5560_94_seqguix0055840en.wmf
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BURNER SEQUENCE DIAGRAM - OIL FUEL
Sequence diagram
Burner firing sequence
Power on
STEP
Shut-down
Safety interlocks OK. When all shut downs can be and are
reset change to step 0 (ready)
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
Shut-down
STEP 1
Starting
STEP 1
Starting
(continued)
Figure 3
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BURNER SEQUENCE DIAGRAM - OIL FUEL
STEP 2
Purge
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)
STEP 3
Ignition
position
STEP 4
Ignition
STEP 5
Safety time
Figure 4
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BURNER SEQUENCE DIAGRAM - OIL FUEL
STEP 5
Safety time
(continued)
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
Change step when timer period for flame stable has expired
STEP 8
Rising/
mod. free
(continued)
STEP 11
Steam
purge 1
Shut-down
STEP 13
Postpurge
Figure 5
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BURNER SEQUENCE DIAGRAM - OIL FUEL
STEP 13
Postpurge
(continued)
STEP 0
Ready
Figure 6
om5560_94_seqrmsx0055880en.wmf
Figure 7
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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
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.
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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
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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
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OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM
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
initiated
Change logic
Step 1
Starting
Flushing sequence
initiated
Burner sequence
Figure 3
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FUEL FLUSH SEQUENCE DIAGRAM
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
initiated
Change logic
Step 1
Starting
Flushing sequence
initiated
Burner sequence
Figure 4
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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
initiated
Change logic
Step 1
Starting
Flushing sequence
initiated
Burner sequence
Figure 5
seq115x1754690en.wmf
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FUEL FLUSH SEQUENCE DIAGRAM
Change logic
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
Run
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
Step 104
MGO
Wait
Valves
F Timer 3
F Timer 2
Step 105
MGO
Wait Timer
Cooler Bypass = NO
F Timer 3
Time expired
F Timer 3
G437
G436
Reset
Tank
Cooler
F Timer 3
G437
G436
Reset
Tank
Bypass
Step 106
MGO
Wait
Valves
F Timer 6
Start
F Timer 6
Time expired
F Timer 6
G147
Reset
Stop
Step 107
MGO
Wait Timer
Step 108
MGO
Wait
Pump
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.
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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
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
Start
F Timer 2
Time expired
F Timer 2
G437
F202
F205
F201
Reset
Mix tube
Close
Close
Open
Step 110
MGO
Wait Timer
Start
Step 111
MGO
Wait
Valves
F Timer 3
Step 112
MGO
Wait Timer
Cooler bypass = NO
F Timer 3
Time expired
F Timer 3
G437
G436
Reset
Tank
Cooler
Step 113
MGO
Wait
Valves
F Timer 3
G437
G436
Reset
Tank
Bypass
Step 114
MGO
Wait
Valves
F Timer 6
Start
F Timer 6
Time expired
F Timer 6
G147
Reset
Stop
Step 115
MGO
Wait Timer
Step 116
MGO
Wait
Pump
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.
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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
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
F Timer 2
Start
F Timer 2
Time expired
F Timer 2
G437
F202
F205
F201
Reset
Mix tube
Close
Close
Open
Step 118
HFO
Wait Timer
Start
F Timer 3
Time expired
F Timer 3
G437
F207
Reset
Tank
ON
Step 119
HFO
Wait
Valves
F Timer 3
Step 120
HFO
Wait Timer
Step 121
HFO
Wait Valve
2F207
Feedback from fuel oil return valve is a
condition for proceeding.
2F222
F Timer 6
Start
F Timer 6
Time expired
F Timer 6
G437
Reset
Mix Tube
Step 122
HFO
Wait Timer
Figure 8
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
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
Step 124
DO
Wait
Valves
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
Step 125
DO
Wait Timer
Step 126
DO
Wait
Valves
F Timer 3
Cooler bypass = NO
F Timer 3
Time expired
F Timer 3
G436
Reset
Cooler
Step 127
DO
Wait Timer
Start
Step 128
DO
Wait Valve
F Timer 3
G436
Reset
Bypass
Step 129
DO
Wait Valve
G437
Tank
Step 130
DO
Wait Valve
F Timer 6
Start
F Timer 6
Time expired
F Timer 6
G437
Reset
Mix tube
Step 131
DO
Wait Timer
Step 132
DO
Wait Valve
G147
Stop
Step 133
DO
Wait
Pump
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
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 134
DO
Wait
Valves
F Timer 2
Start
F Timer 2
Time expired
F Timer 2
G437
F202
F205
F201
Reset
Mix tube
Close
Close
Open
Step 135
DO
Wait Timer
Step 136
DO
Wait
Valves
F Timer 3
Cooler bypass = NO
F Timer 3
Time expired
F Timer 3
G436
Reset
Cooler
Step 137
DO
Wait Timer
Start
Step 138
DO
Wait Valve
F Timer 3
G436
Reset
Bypass
G437
Tank
Step 140
DO
Wait Valve
F Timer 6
Start
F Timer 6
Time expired
F Timer 6
G437
Reset
Mix tube
Step 141
DO
Wait Timer
Step 142
DO
Wait Valve
G147
Stop
Step 143
DO
Wait
Pump
Change logic
Figure 10
Language UK
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
Flush stop
2
AL/SD Reset
Flush stop
3
Figure 11
seq121x1754750en.wmf
Language UK
28-15 / 17
OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM
28-16 / 17
Language UK
OM5560_162#E.1
FUEL FLUSH SEQUENCE DIAGRAM
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
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
evAn_event
[Conditions]/
GEN(evAn_event)
Figure 1
pumpc16x2036240en.wmf
Figure 2
pumpc8x2031850en.png
Figure 3
Language UK
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
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
Language UK
29-7 / 11
OM9294_07#C.2
OIL PUMP CONTROL
A high oil pressure alarm will occur if following conditions are met:
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
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.
Language UK
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.
29-10 / 11
Language UK
OM9294_07#C.2
OIL PUMP CONTROL
Operation
Burner stopped
(STEP SHUTDOWN,
STOPPED, READY)
evBurner_Stop
evShutdown_acknowledgded
evBurner_Start
Burner shutdown
NO FUEL/GAS OIL
PUMPS AVAILABLE
Burner running
(STEP 1-13)
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
pumpc19x2036270en.wmf
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
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
Steam space
Internal cone
NW
Scum tube
Feed tube
Smoke tubes
Shell plate
Water drum
Manhole
Stay
tubes
Blow down
tube
Smoke
tubes
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.
Language UK
31-5 / 6
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..............................................................
Language UK
Document ID
OM9210_05...............
OM9210_11...............
OM9010_39...............
OM9210_16...............
OM9210_38...............
OM9210_13...............
OM9210_17...............
Page
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32-1 / 21
OM9210_05#B.1
START/STOP OF THE BOILER
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:
32-2 / 21
Language UK
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.
Language UK
32-3 / 21
OM9210_05#B.1
START/STOP OF THE BOILER
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.
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.
Language UK
32-5 / 21
OM9210_05#B.1
START/STOP OF THE BOILER
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.
32-6 / 21
Language UK
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.
Language UK
32-7 / 21
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.
32-8 / 21
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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.
Language UK
32-9 / 21
OM9010_39#D.1
GASKETS FOR BOILER BODY
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.
1.2 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
1.4 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.
Language UK
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.
32-12 / 21
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OM9210_16#B.1
BOILER MAINTENANCE
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.
Language UK
32-13 / 21
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
Language UK
OM9210_38#B.1
CLEANING SMOKE TUBES
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
90 100
Load %
Figure 1
Language UK
om9210_38_dp_tubx0059900en.wmf
32-15 / 21
OM9210_38#B.1
CLEANING SMOKE TUBES
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
Language UK
OM9210_38#B.1
CLEANING SMOKE TUBES
Inspection door
Water washing hose
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.
Language UK
32-17 / 21
OM9210_13#C.1
PRESERVATION
Preservation
1
Dry preservation.
Wet preservation.
Nitrogen preservation.
VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:
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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.
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
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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
Figure 1
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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
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.
33-2 / 15
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
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.
Language UK
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OM9210_99#D.1
FEED AND BOILER WATER
33-4 / 15
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OM9210_99#D.1
FEED AND BOILER WATER
Language UK
33-5 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Note No.
1
1
1
1, 3, 4
Table No. 1
Note No.
1
1
1
1, 3, 4
Table No. 2
Note No.
Table No. 3
2, 3, 4
Note No.
Table No. 4
2, 3, 4, 5
Drewplex AT / OX
Continuous
X
X
33-6 / 15
Batch
Note No.
1
1, 3, 4
Table No. 5
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Drewplex AT / OX
Continuous
X
X
Batch
Note No.
2, 3, 4
3, 4
Table No. 6
Note No.
1, 3, 4
1, 3, 4
Table No. 7
Note No.
2, 3, 4
3, 4
Table No. 8
Note No.
2, 3, 4
2, 3, 4, 5
Table No. 9
Language UK
Note No.
1, 3, 4
1, 3, 4
Table No. 10
33-7 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Note No.
3, 4
2, 3, 4, 5
Table No. 11
Note No.
2, 3, 4, 5
2, 3, 4, 5
Table No. 12
Marichem
Standard
Continuous
Table No. 13
Batch
X
X
X
X
Note No.
1, 3, 4
1, 3, 4
1, 3, 4
1, 3, 4
Marichem
Standard
Continuous
Table No. 14
Batch
X
X
X
X
Note No.
2, 3, 4
2, 3, 4
3, 4
3, 4
Marichem
33-8 / 15
Table No. 15
Batch
Note No.
1, 3, 4
1, 3, 4
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Marichem
Table No. 16
Batch
X
Note No.
2, 3, 4, 5
3, 4
Marichem
BWT
Continuous
X
X
Table No. 17
Batch
Note No.
1, 3, 4
1, 3, 4
Marichem
BWT
Continuous
Table No. 18
Batch
X
Note No.
2, 3, 4, 5
3, 4
I
Continuous
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Table No. 19
Unitor Chemicals
Language UK
Continuous
X
X
Table No. 20
Batch
X
X
Note No.
2
2
3, 4
3, 4
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OM9210_99#D.1
FEED AND BOILER WATER
Unitor Chemicals
II
Continuous
Table No. 21
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Unitor Chemicals
II
Continuous
Table No. 22
Batch
X
X
X
X
Note No.
2
2
3, 4
3, 4
Unitor Chemicals
Liquitreat
Continuous
Table No. 23
Batch
X
X
X
Note No.
1
1, 3, 4
1, 3, 4
Unitor Chemicals
Liquitreat
Continuous
Table No. 24
Batch
X
X
X
Note No.
2
3, 4
3, 4
Unitor Chemicals
Combitreat
Continuous
33-10 / 15
X
X
Table No. 25
Batch
X
Note No.
1
1, 3, 4
1, 3, 4
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
Unitor Chemicals
Combitreat
Continuous
Table No. 26
Batch
X
X
X
Note No.
2
3, 4
3, 4
Unitor Chemicals
I
Continuous
Table No. 27
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Uniservice Group
I
Continuous
Table No. 28
Batch
X
X
X
X
Note No.
2
2
3, 4
3, 4
Uniservice Group
II
Continuous
Table No. 29
Batch
X
X
X
X
Note No.
1
1
1, 3, 4
1, 3, 4
Uniservice Group
II
Continuous
Language UK
X
X
Table No. 30
Batch
X
X
Note No.
2
2
3, 4
3, 4
33-11 / 15
OM9210_99#D.1
FEED AND BOILER WATER
Uniservice Group
One Shot
Continuous
Table No. 31
Batch
X
X
X
Note No.
1
1, 3, 4
1, 3, 4
Uniservice Group
One Shot
Continuous
Table No. 32
Batch
X
X
X
Note No.
2
3, 4
3, 4
Uniservice Group
Organic Treatment
Continuous
Batch
X
X
Table No. 33
Note No.
1
1, 3, 4
Table 2
33-12 / 15
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
PT
Steam
dump
valve
Condenser
Cooling
water
Condensate
Make-up
Boiler
Overflow
Hot well
Drain
1
2
PI
PI
PI
PI
PS
Figure 1
Language UK
Feed water
pumps
om9210_99_flowdix0060010en.wmf
33-13 / 15
OM9210_99#D.1
FEED AND BOILER WATER
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
Figure 2
33-14 / 15
Feed water
pumps
om9210_99_flowdix0060020en.wmf
Language UK
OM9210_99#D.1
FEED AND BOILER WATER
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
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
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:
Language UK
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
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.
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
34-5 / 6
OM7010_03#A.2
WATER LEVEL GAUGE
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
Figure 1
om6040_01_safe_0x0056591en.wmf
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.
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.
Language UK
OM6040_01#A.2
SAFETY VALVES
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
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.
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.
35-6 / 7
A:
B:
C:
D:
Language UK
OM6040_02#A.2
TEMPORARY LOCKING OF A SAFETY VALVE
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
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
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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.
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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.
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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
t1 = not existing
Differential pressure
between connections:
525 x 0.9922 =
Height between
connections, e.g.:
525 mm
Water level
t3 = 170 C at 7 barg,
204oC at 16 barg
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
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.
Language UK
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.
36-8 / 10
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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.
Language UK
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OM8210_35#A.2
DP WATER LEVEL TRANSMITTER UNIT
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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
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.
37-2 / 12
Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
60 Hz
10 bar
10 bar
10 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
10 bar
15 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
8 bar
10 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
4 bar
10 bar
15 bar
10 bar
15 bar
Table 1
Language UK
37-3 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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
37-4 / 12
Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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.
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.
Language UK
37-5 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Figure 1
37-6 / 12
om5540_20_cr02ax0054100en.wmf
Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
NPSH curves
Figure 2
Language UK
om5540_20_cr03bx0054110en.wmf
37-7 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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).
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Language UK
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Figure 4
om5540_20_cr06x0054120en.wmf
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:
Language UK
37-9 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Step E: Loosen the vent screw in the pump head during operation.
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.
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
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.
Language UK
37-11 / 12
OM5540_20#C.1
PUMPS, TYPE CR, CRN
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.
Table 4
37-12 / 12
Language UK
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
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
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
Language UK
OM6050_03#C.1
STEAM DUMP EQUIPMENT
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.
Language UK
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
Figure 3
38-4 / 38
om6050_03_3ax0756610en.wmf
Language UK
OM6050_03#C.1
STEAM DUMP EQUIPMENT
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.
Language UK
38-5 / 38
OM6050_03#C.1
STEAM DUMP EQUIPMENT
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.
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.
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
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.
38-8 / 38
Language UK
OM6050_03#C.1
STEAM DUMP EQUIPMENT
Steam
e.g. 170 C
Insulation
against radiant heat
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.
Language UK
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;
38-10 / 38
Language UK
OM6010_02#B.1
CONTROL VALVES, TYPE 470/471
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
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.
38-12 / 38
Language UK
OM6010_02#B.1
CONTROL VALVES, TYPE 470/471
Maintenance
Before any maintenance of the control valve is carried out, the piping system must be
shut off and pressure free.
Language UK
38-13 / 38
OM6010_02#B.1
CONTROL VALVES, TYPE 470/471
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.
38-14 / 38
Language UK
OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP
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
38-15 / 38
OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP
Figure 1
om5520_01_dpactux0053610en.wmf
Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.
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
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.
Language UK
38-17 / 38
OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP
Figure 2
om5520_01_dpactsx0053600en.wmf
38-18 / 38
Language UK
OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP
Language UK
38-19 / 38
OM5520_01#B.1
PNEUMATIC ACTUATOR, TYPE DP
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
Language UK
38-21 / 38
OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000
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.
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
Figure 1
om5510_05_sips2_x0053470en.wmf
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
Figure 2
om5510_05_sips2_x0053480en.wmf
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.
38-26 / 38
Language UK
OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000
Figure 3
Language UK
om5510_05_sips2_x0053490en.wmf
38-27 / 38
OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000
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.
38-28 / 38
Language UK
OM5510_05#B.1
POSITIONER, SIPART PS2 6DR5000
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:
Figure 5
om5510_05_sips2_x0053510en.wmf
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.
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
ERR OR
Strt
Me asures
Acknowled ge message
using the hand symbol key
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
88.4
d u IU
Down tolerance
band violated
6.4
d 0 IU
Then only
Continue us ing the down key
S Et
Determina tion of minimum incre ment length
MID DL
98.3
UP
>
Up tolerance b and
violated
92.8
90_9 5
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
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)
3.YWAY2)
4.INITA
5.INITM
Initialisation (automatically)
Initialisation (manually)
6.SCUR
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
11.TSDO
7.SDIR
13.SL03)
14.SL1
to
32.SL19
33.SL20
34.DEBA
12.SFCT
35.YA
36.YE
37.YNRM
38.YDIR
38-34 / 38
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
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
Function
Parameter values
Unit
40.YCDO
41.YCUP
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
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
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
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
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
Language UK
Page 1/1
SP 9011000006#C.2
BOILER
UNIT AALBORG
XS-2V
SP 9011000006
B
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
Language UK
UK
Language
39-3
26
Page/ 1/1
SP 2501086#C.1
STOP
SPVALVE
2501086 A
SPARE PARTS FOR 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
1
1
1
1
2
Notes/Recommended
No item on drawing
39-4 Language
/ 26
UK
Language UK
Page 1/1
SP 2501088#C.1
STOP VALVE
SP 2501088 A
SPARE PARTS FOR 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
1
1
1
1
2
Notes/Recommended
No item on drawing
LanguageUK
UK
Language
39-5
26
Page/ 1/1
SP 2511088#C.1
STOP VALVE
SP 2511088 A
SPARE PARTS FOR VALVE
Stop
valve
Size: DN25
PN25
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
39-6 Language
/ 26
UK
Language UK
Page 1/1
SP 2511093#C.1
STOP VALVE
SP 2511093 A
SPARE PARTS FOR 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
LanguageUK
UK
Language
39-7
26
Page/ 1/1
SP 2611171#C.1
SAFETY VALVE
SP 2611171 A
SPARE PARTS FOR VALVE
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
39-8 Language
/ 26
UK
Language UK
Page 1/1
SP 2641088#C.1
STOP VALVE
SP 2641088 A
SPARE PARTS FOR 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
LanguageUK
UK
Language
39-9
26
Page/ 1/1
SP 2641090#C.1
STOP VALVE
SP 2641090 A
SPARE PARTS FOR VALVE
Size: DN40
PN25
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
39-10Language
/ 26
UK
Language UK
Page 1/1
SP 5541002014#C.1
FEED
WATER PUMP
SP 5541002014
A
Language UK
UK
Language
39-11
26
Page/ 1/2
SP 5541002014#C.1
FEED
PUMPA
SPWATER
5541002014
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
39-12Language
/ 26
UK
Language UK
Page 2/2
SP 61Z_050525#F.2
GAUGE
BOARDC
SP 61Z:050525
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
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
39-14Language
/ 26
UK
Language UK
Page 2/2
SP 6020000101#A.1
CHECK
VALVE A
SP 6020000101
Check
valve
Size: DN15 PN40
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
Language UK
UK
Language
39-15
26
Page/ 1/1
SP 6050000240#B.1
SP 6050000240 B
CONTROL VALVE
SPARE PARTS FOR CONTROL VALVE
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
39-17
26
Page/ 2/2
SP 6050000458#A.1
CONTROL
VALVE A
SP 6050000458
Control
valve
Size: DN15 PN25
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
Language UK
Page 1/1
SP 70Z_036686#B.1
WATER
LEVEL CONTROL
UNIT
SP 70Z:036686
B
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
39-19
26
Page/ 1/1
SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A
39-20Language
/ 26
UK
Language UK
Page 1/3
SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A
Language UK
UK
Language
39-21
26
Page/ 2/3
SP 7010000430#A.1
WATER
LEVEL GAUGE
SP 7010000430
A
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
39-22Language
/ 26
UK
Language UK
Page 3/3
SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A
Language UK
UK
Language
39-23
26
Page/ 1/3
SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A
39-24Language
/ 26
UK
Language UK
Page 2/3
SP 7010000431#A.1
WATER
LEVEL GAUGE
SP 7010000431
A
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
Language UK
UK
Language
39-25
26
Page/ 3/3
SP 7040000041#B.1
SP 7040000041 A
FILTER
SPARE PARTS FOR 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
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
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
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
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
1
1
1
1
1
1
1
1
1
Application
Qty
1
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
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
64
-
8615000111
8500000780
Application
Oil, inlet
and outlet
Oil, inlet
and outlet
Qty
2
2
1
1
1
1
Notes/Recommended
2
1
Approved by BV
No item on drawing
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
Language UK
40-7 / 10
SP 2501087#C.1
STOP VALVE
SP 2501087 A
SPARE PARTS FOR VALVE
Size: DN20
PN25
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
1
1
1
1
2
Notes/Recommended
No item on drawing
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
Size: DN32
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
LanguageUK
UK
Language
40-9
10
Page/ 1/1
SP 6070000047#B.1
THREE WAY BALL VALVE
SP 6070000047 A
SPARE PARTS FOR 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
40-10Language
/ 10
UK
Language UK
Page 1/1