Operation and Maintenance Manual

OPERATION AND MAINTENANCE
MANUAL
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START-UP BURNER AND FIRING SYSTEM
Vol. C Maintenance Instructions
C 1 Maintenance at the Firing System .................................................................2

C 1.1 Safety Warning Notes ..................................................................................... 2
C 1.2 Analysis and Instructions for Maintenance Checks ......................................... 4
C 1.3 Maintenance Checks during Operation ........................................................... 4
C 1.4 Maintenance Checks after Longer Stops ........................................................ 5
C 1.5 Maintenance Checks after Revision ................................................................ 5
C 2 Maintenance at the Burners ...........................................................................7

C 2.1 Flame Monitor ................................................................................................. 7
C 2.2 Ignitor .............................................................................................................. 9
C 2.3 Oil Lance ....................................................................................................... 11
C 2.4 Further Burner Parts ...................................................................................... 14
C 2.5 Instruments, Valves, Measuring and Control Equipment .............................. 15
C 3 Storage / Preservation ..................................................................................16

C 3.1 Delayed Commissioning ................................................................................ 16
C 3.2 Decommissioning .......................................................................................... 16
C 4 Lists and Drawings .......................................................................................18

C 4.1 Instrument List ............................................................................................... 19
C 4.2 Equipment List............................................................................................... 21
C 4.3 Material Specifications .................................................................................. 23
C 4.4 Spare Parts List ............................................................................................. 25
C 4.5 Drawings ....................................................................................................... 27
C 5 Documentation of Instruments and Measuring Equipment ......................31
C 6 Documentation of Valves, Aggregates and Control Equipment...............33
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C1 Maintenance at the Firing System
This chapter provides information to be observed carefully when mainte-

nancing and repairing of the firing system together with its associated equip-
ment. Beside this information, there is further information provided for each
individual component of equipment.
Please refer to the relevant manufacturer's technical documentation given in
Vol. C 5 “Documentation of Instruments and Measuring Equipment” or
Vol. C 6 “Documentation of Valves, Aggregates and Control Equipment”.
C 1.1 Safety Warning Notes
• The equipment may be in fully automatic operation and may start-up

or shut down unexpected. Any motors, linkages, actuators, etc. may
move without warning.
• Do not attempt to work on the equipment or any moving parts of it or

any items, such as safety shut-off valves, regulator valves or any other
items which may become energized by their associated control or
monitoring equipment. In any case, first switch off the equipment,
allowing it to complete its shut down sequence and then isolate the
energy supply from all of the relevant equipment to be worked upon.
• Prior to carry out any electrical work on the equipment, ensure it is

isolated from the control room and cannot be reinstalled without prior
warning. Ensure that signal feedback from other control systems is
impossible.
• Safety interlocks in the burner management system (BMS) are pro-

vided for your protection. Their correct operation and settings must be
checked at regular intervals.

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Qualified personnel only must carry out alteration or adjustments of

these settings. Under no circumstances, any interlock must be made
inoperative or prevented from establishing a fail-safe condition.
• Do not uncover control panels or junction boxes whilst power is on.
Should it become necessary to do so, in the interest of rectifying
faults, qualified personnel only must be involved.
• Check for any hazardous conditions and follow the local and / or na-
tional safety standards. Warning notices must be posted and any
covers must be replaced as soon as possible.
• Gaseous fuel systems shall be purged with nitrogen prior to mainte-

nance or repair work on these gas lines. For (pressure) testing of the
gaseous fuel system, nitrogen is also recommended. The use of water
shall be avoided.
• Isolate electrical supplies and fuel lines as required before starting to

work on this equipment. Post warning notices as necessary and en-
sure that the firing system is sufficiently cooled down and ventilated.
• Do not open any access door to the combustion chamber or furnace

until it is sufficiently cooled down; ventilated and dangerous toxic
gases are dispersed. Check area for dioxygen (O2) amount.
• In case of carbon monoxide gas (CO) will be present, be very careful

and follow strictly the plant operator’s instructions. People cannot
smell CO-gas and can be killed, if inhaled.
• Do not make attempts to disconnect the ignitor or the ignition

electrode of the ignitor when the power is on.
• Keep the surrounding area of the firing system and its associated
equipment clear of debris, dust and rubbish.

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• Do not make repeated attempts to light a fuel. If a flame cannot be

established, carry out an investigation into the cause. A succession of
abortive attempts may result in the build-up of an explosive mixture at
some point in the system.
• During installation and maintenance activities, proper lifting equipment

shall be used in accordance with local regulations.
• Due to the nature of the product, local high temperatures (hot spots) in
the direct vicinity of the burner unit are unavoidable. Plant operators
shall be aware of this and ensure protective measures for operation.
C 1.2 Analysis and Instructions for Maintenance Checks

Continuously sampling for determination of fuel properties is not required,
however operating conditions and fuel properties, listed in Vol. A 1
“Technical Data” must be observed.
Piping systems for fuels and auxiliary media together with their associated
valves and flange connections have to be checked daily for tightness by
suitable methods.
Any identified defects have to be corrected as soon as possible.
C 1.3 Maintenance Checks during Operation

During operation, check the following components:
- Check intensity of flame detectors. If intensity has decreased, the

optical lens has to be cleaned.
- Check flame through inspection hole.
- Check local measuring equipment for anomaly.

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- Check valves and piping system of gaseous fuels for tightness (visual
check and test with soap sud).
- Check valves and piping systems of fuels, purging media and auxiliary
media for tightness.
C 1.4 Maintenance Checks after Longer Stops

Before commissioning after longer stops, check the readiness for use of
the firing system, by:
- Driving all fuel control valves;
- Checking flame detection system (remove unit and check flame with a
flame of a lighter for example). There must result a signal at the flame
detector;
- Checking function of all pneum. valves for the different fuels;
- Checking function of any pneum. actuators of oil lance or ignition lance

extend and retract mechanisms and of control dampers.
C 1.5 Maintenance Checks after Revision

Before commissioning after revision, check the readiness for use of the firing
system, by:
Prepare the system as described in Vol. B 1 „ Preparations for

Commissioning and Operation”.
Start combustion chamber / furnace purging program.
Check if signal „Ready for Operation” is existent.

Simulate all relevant tripping criteria according BMS.
- Driving all fuel control valves;

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- Checking flame detection system. There must result a signal at the

flame detector;
- Checking function of all pneum. valves for the different fuels;
- Checking function of any pneum. actuators of oil lance or ignition lance

extend and retract mechanisms and of control dampers.

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C2 Maintenance at the Burners
This chapter provides information to be observed carefully when mainte-

nancing and repairing of the burner together with its associated equipment.
Beside this information, there is further information provided for each individ-
ual component of equipment.
Please refer to the relevant manufacturer's technical documentation given in
Vol. C 5 “Documentation of Instruments and Measuring Equipment” or
Vol. C 6 “Documentation of Valves, Aggregates and Control Equipment”.
C 2.1 Flame Monitor

Each burner is equipped with 1 self-monitoring and fail-safe compact
flame monitor with integrated IR flame scanner.
The device is mounted on a sighting tube via an adjustable swivel mount,
thus enabling a correct alignment to the flame to be monitored.
For maintenance purposes, the flame monitor can completely be removed

from the sighting tube as a complete unit, after the firing system has been
put out of operation.
Directly upstream the swivel mount the sighting tube can be manually
isolated by a ball valve. The flame monitor is also equipped with connec-
tions for cooling air (which also acts as purge air) to avoid rough contami-
nation and excessive heat from the furnace.
- The optics (lens) of the flame monitor should be regularly checked (e.g.
every 4 weeks) for dust and debris and cleaned when necessary. If the
outside of the lens regularly accumulate deposits, the purge air flow
should be adjusted to alleviate this problem.
- Remove deposits with oil-free compressed air or a soft lint free cloth
(optical cleaning cloth or microfibre cloth) and if necessary with water
and alcohol.

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Danger!
The firing system must have been put out of operation prior
to start any maintenance work at the flame monitor!
Danger!
High voltage. Danger of fatalities due to electrical current!
Coming into contact with live parts poses a direct risk of fatalities.
- Before removing the casing or guard, check that the devices are
deenergised.
Caution!
Danger of burns due to hot surfaces or hot gases!
- Take care when touching the flame monitor. It might be warm. If
necessary, use heat protection gloves.
- Pay attention of hot gases, coming out of the sighting tube.
The flame monitor may only be removed, after:

• the firing system has been put out of operation;
• the electric power supply has been switched off and secured against
being switched back on.
Action steps for removing of the flame monitor:
1. Leave the ball valve for cooling air shut-off open.

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2. Completely disconnect the flame monitor from the energy supply.

3. Close the ball valve for sighting tube isolation.
4. Loosen the safety screw at the connecting nut.
5. Detach the complete blue device part (housing) from the black
front part (sighting tube / purge air connection thread).
6. Carry out intended maintenance work.
After performing intended maintenance work at the flame monitor, carry

out listed action steps 2 to 5 in reverse order
For details of maintenance of the flame monitor with scanner refer to the
manufacturer’s instructions in the DURAG manual “D-LX 100 All-In-One
Flame Scanner”, assorted in Vol. C 5, Reg. 03-2_item no. 0111.
C 2.2 Ignitor
Each burner is equipped with 1 fully electric ignitior, consisting of a high
energy ignition device with separate lance.
For protection of the lance against excessive thermal stress after igniting
the diesel / air mixture, it will be retracted from the combustion zone by a
pneumatic cylinder.
The lance is furthermore mounted into a guide tube which can be manually
isolated by a ball valve. This enables removing of the lance for mainte-
nance work even under diesel oil firing conditions.
The ignitor should be inspected at regular intervals, e. g. every 3 months,
or more frequently depending on local operating conditions.
- Check cables for correct fit, ageing and wear. The same applies to any
plug connections. Have porous cables, defective insulation or plug con-
nectors replaced immediately by original spare parts.

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- Check for deformation and damage to the housing and reliable fitting of
the devices on the assembly panel or flange.
- Check the device for dirt. If there is contamination due to high relative
humidity or sticky dust, the device is to be cleaned from outside with a
(damp) cloth or with compressed air. Cleaning is then to be repeated at
regular intervals.
The ignition tip is subject to natural wear. Under operating conditions, this
can result in a service life from several months to several years.
- Check tip regularly and replace it when required.
Danger!
Fatal danger due to high voltage!
The high energy ignition device contains capacitors whose dis-
charge time is a minimum of 60 seconds. Only then can work be
carried out safely on the device and ignition tip (in the Ex zone wait
at least 5 minutes due to possible spark generation). Check the
device has been de-energised.
Caution!
- Take care when touching the ignition lance. It might be warm. If
necessary, use heat protection gloves.
- Pay attention of hot air, coming out of the guide tube.

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The igniton lance may only be removed, after:

• the high energy ignition device has been put out of operation and the
pneumatic cylinder at the lance is in retracted position,
• the electric power supply has been switched off and secured against
being switched back on.
Action steps for dismantling of the ignition lance:
1. Leave the ball valve for cooling air shut-off open.

2. Detach lance from cylinder guide block.
3. Loosen and remove clamping bush from adapter.
4. Pull out lance from its guide tube.
5. Close ball valve for guide tube isolation.
After performing intended maintenance work at the lance:
1. Open ball valve for guide tube isolation.

2. Remount lance correspondingly in reverse order.
For details of ignitor maintenance refer to the manufacturer’s instructions

in the DURAG manual “D-HG 400 High Energy Ignition Device”, assorted
in Vol. C 6, Reg. 05-4_item no. 2.01.
C 2.3 Oil Lance

Each burner is equipped with 1 oil lance for firing diesel oil as fuel. The
lance can be retracted from the combustion zone by a pneumatic cylinder.
This will be done for protection of essential lance assemblies against exces-
sive thermal stress after heating up the furnace to operation temperature.
The lance is furthermore mounted into a diffuser tube which can be manu-
ally isolated by a ball valve.

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For maintenance purposes, e. g. cleaning or replacement of nozzle insert or

tip, the lance can be completely pulled out of the diffuser tube, after the
firing system has been put out of operation.
- The lance should be inspected at regular intervals, e. g. every 3

months, or more frequently, depending on local operating conditions. In
any case, it is advised to perform a check on the degree of wear or
contamination of nozzle insert and tip after a longer burner stop.
Danger!
The firing system must have been put out of operation prior
to removing of the oil lance!
Caution!
- Take care when touching the oil lance. It might be warm.
If necessary, use heat protection gloves.
- Pay attention of hot gases, coming out of the diffuser tube.
Note: Prior to maintenance, stop burner operation and apply purging program
sequence in accordance with the instructions of the control system supplier.
The oil lance may only be removed, after:

• it has been put out of operation and purged;
• any valves for the supply with liquid fuel or atomising / purging me-
dium have been closed and secured against reopening;

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• the start program in the higher-level control system has been blocked.
Action steps for dismantling of the oil lance and lance inserts:
(For assignment of components refer to M&S draw. no. 1646 14-D-1-50

using the item numbers in brackets).
1. Stop operation of oil lance and purge it.
2. Close any shut-off valves for liquid fuel supply.
3. Close any shut-off valves for atomising / purging medium supply.
4. Leave the ball valves for cooling air shut-offs open.
5. Detach hose connections for liquid fuel and atomising / purging
medium supplies from coupling (1).
6. Remove folding spring bolt at fork head (7).
7. Loosen headless screw (15) at cap nut (14), unscrew cap nut.
8. Pull out lance of diffuser tube.
9. Close ball valve for diffuser tube isolation.
10. Unscrew tip cap nut (18).
11. Remove tip (16) and nozzle insert (17) from inner tube (11).
Note: Do not use sharp or hard tools for cleaning of nozzle insert and tip of
oil lance.
Before remounting of the lance check all sealings and renew, if necessary.
Clean sliding surface of the diffuser tube.
After performing intended maintenance work at the lance:
1. Open ball valve for diffuser tube isolation.

2. Remount lance correspondingly in reverse order

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C 2.4 Further Burner Parts

Most burner components are maintenance free, such as windbox, air
register or swirler. However, the swirler is subject to high thermal load and
needs to be exchanged from time to time, when signs of wear appear.
Note: Some maintenance works including the replacement of the swirler

can possibly only be carried out from inside the furnace.
Danger!
- The firing system must have been put out of operation prior
to working on the burner!
- For maintenance works carried out from inside the furnace: Do
not enter the furnace until it has been cooled down and venti-
lated sufficiently!
Burner components may only be removed, after:

• the firing system has been put out of operation and the electric power
supply has been switched off;
• any manual fuel shut-off valves have been closed and secured
against reopening;
• (with gaseous fuels) the burner has been made inert with nitrogen.
The swirler can be exchanged from the furnace inside wall. Therefore, the
fixing screws at the front side of the diffuser tube have to be loosened.
Then the swirler can be removed from the diffuser tube.
In particular case, the swirler cannot be reached from the furnace inside
wall, e.g. due to special furnace geometry, the centre plate of the burner
has to be disassembled. Therefore, all relevant connections have to be
removed.

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C 2.5 Instruments, Valves, Measuring and Control Equipment

Detailed information is provided for each individual component of equip-
ment. Please refer to the relevant manufacturer's technical documentation
given in Vol. C 5 “Documentation of Instruments and Measuring Equip-
ment” or Vol. C 6 “Documentation of Valves, Aggregates and Control
Equipment”.
Warning!
Prior to maintenancing and repairing of instruments, valves
and equipment it is necessary to check that the components
are free of pressure and voltage!
In general, qualified personnel only must carry out maintenance and repair
work!

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C3 Storage / Preservation
Preservation is required in the following cases:
- System sections are not installed or commissioned for an extended

period;
- System sections are decommissioned.
C 3.1 Delayed Commissioning

If it is known in advance that certain system sections have to be preserved,
pressure tests must also be carried out for system sections for liquid fuel and
atomising steam if possible with air or nitrogen.
All system sections, e.g. valves, apparatus and pipes must be rendered pres-
sureless and drained completely.
All system sections must be dried and filled with nitrogen under a pressure of
0.5 to 1 bar in order to prevent corrosion.
The manufacturer’s instructions for specific valves and apparatus in Vol. C 5

and Vol. C 6 must be observed.
C 3.2 Decommissioning
All system sections, e.g. valves, apparatus and pipes must be rendered pres-
sureless and drained completely or dried.
System sections filled with gaseous fuels or air must be filled with nitrogen
under a pressure of 0.5 to 1 bar.
System sections filled with atomising steam must be blown out with air or
nitrogen until they are absolutely dry and subsequently filled with nitrogen
under a pressure of 0.5 to 1 bar.

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System sections filled with liquid fuel must be filled either with fuel oil under a
low pressure or treated analogous to atomising steam pipes. Filling with nitro-
gen is also to be given preference.
The manufacturer’s instructions for specific valves and apparatus in Vol. C 5

and Vol. C 6 must be observed.

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C4 Lists and Drawings

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C 4.1 Instrument List
Designation M&S Doc. No.
Instrument list 1612 13-4-03

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C 4.2 Equipment List
List of equipment 1612 13-4-02

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C 4.3 Material Specifications
Material specification 1612 13-4-04

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C 4.4 Spare Parts List
List of spare parts 1612 13-4-02-1

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C 4.5 Drawings
Designation M&S Draw. No.
Boiler 1
P&I Firing Diagram (Burner A) 1612 13-1-01-SH 1/8

(assorted in Vol. A 2)
P&I Firing Diagram (Burner B) 1612 13-1-01-SH 2/8

P&I Firing Diagram (Burner C) 1612 13-1-01-SH 3/8

P&I Firing Diagram (Burner D) 1612 13-1-01-SH 4/8

Oil Burner Type NAB 37-O 1612 13-0-05
Assembly Burner Gun M3 1612 13-D-1-50
Burner Valve Set Diesel Oil / Plant Air (Burner A) 1612 13-1-14-SH 1/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner B) 1612 13-1-14-SH 2/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner C) 1612 13-1-14-SH 3/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner D) 1612 13-1-14-SH 4/8
M&S item No. 10.14

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Designation M&S Draw. No.
Boiler 2
P&I Firing Diagram (Burner A) 1612 13-1-01-SH 5/8

(Assorted in Vol. A 2)
P&I Firing Diagram (Burner B) 1612 13-1-01-SH 6/8

P&I Firing Diagram (Burner C) 1612 13-1-01-SH 7/8

P&I Firing Diagram (Burner D) 1612 13-1-01-SH 8/8

Oil Burner Type NAB 37-O 1612 13-0-05
Assembly Burner Gun M3 1612 13-D-1-50
Burner Valve Set Diesel Oil / Plant Air (Burner A) 1612 13-1-14-SH 5/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner B) 1612 13-1-14-SH 6/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner C) 1612 13-1-14-SH 7/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner D) 1612 13-1-14-SH 8/8
M&S item No. 10.14

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MANUAL

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Order Scope /
Auftrag:

25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
MANUAL

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C5 Documentation of Instruments and Measuring Equipment
The associated technical documentations for each component of equipment

are kept separately, located in attached folders (for electronic files) or ring
binders (in case of paper copies). Please refer to the relevant volume C 5.
Ident. No. Item Designation, Type, Manufacturer, Register

No. Specifications Supplier
PG FA1043-A/B/C/D 0101 pressure gauge Wiegand 02
PG FA2043-A/B/C/D 433.50.100
BT DO1043-A/B/C/D 0111 compact flame detector Durag 03
BT DO2043-A/B/C/D D-LX 100 IG-P
0111.1 15 meter cable for flame scanner Durag 03
D-LX 100 CBL-V1C-PP2-15
PG DO1043-A/B/C/D 0313 pressure gauge Wiegand 01
PG DO2043-A/B/C/D 232.50.100
PT DO1043-A2/B2/C2/D2 0314 pressure transmitter ABB 04
PT DO2043-A2/B2/C2/D2 266GST
PSH DO1043-A1/B1/C1/D1 0315 pressure switch FEMA 05
PSH DO2043-A1/B1/C1/D1 DWR 625-363-S
PG DO1043-A2/B2/C2/D2 0316 pressure gauge Wiegand 01
PG DO2043-A2/B2/C2/D3 232.50.100
FE-DO1043-A/B/C/D 0321 flow meter Endress+ 06
FE-DO2043-A/B/C/D Coriolis Promass 80F25 Hauser
FT DO1043-A/B/C/D
FT DO2043-A/B/C/D
PSL PA1043-A1/B1/C1/D1 0412 pressure switch FEMA 05
PSL PA2043-A1/B1/C1/D1 DWR 625-363-S
PG PA1043-A1/B1/C1/D1 0413 pressure gauge Wiegand 01
PG PA2043-A1/B1/C1/D1 232.50.100
PG PA1043-A2/B2/C2/D2 0416 pressure gauge Wiegand 01
PG PA2043-A2/B2/C2/D2 232.50.100

25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
MANUAL

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Auftrag:

25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
MANUAL

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INDUSTRIES CORP.
AG-Auftrags-Nr.:
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Order Scope /
Auftrag:
C6 Documentation of Valves, Aggregates and Control Equipment
The associated technical documentations for each component of equipment

are kept separately, located in separate folders (for electronic files) or ring
binders (in case of paper copies). Please refer to the relevant volume C 6.
Ident. No. Item Designation, Type, Manufacturer, Register

No. Specifications Supplier
L-1043A/B/C/D 1.01 oil burner NAB 37 - 0 M&S 01
L-2043A/B/C/D
1.11 windbox M&S 01
incl. accessories
ZSE DO1043-A5 1.12 limit switch for oil gun retraction Omron 01
ZSE DO1043-B5 mechanism
ZSE DO1043-C5 D4A-5101N
ZSE DO1043-D5
ZSR DO1043-A5
ZSR DO1043-B5
ZSR DO1043-C5
ZSR DO1043-D5
ZSE DO2043-A5
ZSE DO2043-B5
ZSE DO2043-C5
ZSE DO2043-D5
ZSR DO2043-A5
ZSR DO2043-B5
ZSR DO2043-C5
ZSR DO2043-D5
ZS1 FA1043-A/B/C/D 1.16 air damper 850x1600 R/M HMT 02
ZS1 FA2043-A/B/C/D incl. accessories (Omron)
ZS2 FA1043-A/B/C/D (Omron)
ZS2 FA2043-A/B/C/D
ZT FA1043-A/B/C/D 1.16.1 electric actuator HMT 02
ZT FA2043-A/B/C/D SAR07.6-GS80.3 (AUMA)
MV FA1043-A/B/C/D
MV FA2043-A/B/C/D
V-FA1401/1402/1403/1404 1.21 block & bleed valve Schneider 03
V-FA2401/2402/2403/2404 N354.60.409.05
1.22 pulsation absorber Schneider 04
S005.10.210
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2.01 ignitor lance with tip type Durag 05

D-ZL 421
2.02 ignition box Durag 05
D-HG400-65
ZSE DO1043-A4 2.06 limit switch for ignitor retraction Omron 05
ZSE DO1043-B4 mechanism
ZSE DO1043-C4 D4A-5101N
ZSE DO1043-D4
ZSR DO1043-A4
ZSR DO1043-B4
ZSR DO1043-C4
ZSR DO1043-D4
ZSE DO2043-A4
ZSE DO2043-B4
ZSE DO2043-C4
ZSE DO2043-D4
ZSR DO2043-A4
ZSR DO2043-B4
ZSR DO2043-C4
ZSR DO2043-D4
ZV-DO1043A/B/C/D 3.27 safety relief valve Leser 06
ZV-DO2043A/B/C/D 4623.2914
V-DO1301/1306/1311/1316 3.31 ball valve Alms 07
V-DO2301/2306/2311/2316 FIG.KV-062S (Kingdom)
STR-DO1043A/B/C/D 3.32 y-strainer Alms 08
STR-DO2043A/B/C/D FIG. F3YH400 (BFE)
3.33 valve combination Albrecht 09
ASV/N-ASV/B
consisting of:
XV-DO1043-A1/B1/C1/D1 3.33.1 pneum. valve Albrecht 09
XV-DO2043-A1/B1/C1/D1 ASV/N-ASV/B
ZSC DO1043-A1/B1/C1/D1 incl. attachment parts (Omron)
ZSC DO2043-A1/B1/C1/D1
ZSO DO1043-A1/B1/C1/D1 (Omron)
ZSO DO2043-A1/B1/C1/D1
XV-DO1043-A2/B2/C2/D2 3.33.2 pneum. valve Albrecht 09
XV-DO2043-A2/B2/C2/D2 ASV/N-ASV/B
ZSC DO1043-A2/B2/C2/D2 incl. attachment parts (Omron)
ZSC DO2043-A2/B2/C2/D2
ZSO DO1043-A2/B2/C2/D2 (Omron)
ZSO DO2043-A2/B2/C2/D2
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3.40 stainless steel hose Induflex 10

ICP-N1
V-DO1303/1304/1305/1325 3.43 block & bleed valve Schneider 03
V-DO1308/1309/1310/1326 N354.60.409.05
V-DO1313/1314/1315/1327
V-DO1318/1319/1320/1328
V-DO2303/2304/2305/2325
V-DO2308/2309/2310/2326
V-DO2313/2314/2315/2327
V-DO2318/2319/2320/2328
V-DO1321/1322/1323/1324 3.44 ball valve Alms 07
V-DO2321/2322/2323/2324 FIG. KV-L30S (Kingdom)
V-DO1302/1307/1312/1317 3.45 check valve Gestra 11
V-DO2302/2307/2312/2317 RK 86
FCV DO1043-A3 3.51 fuel oil control valve ARI 12
FCV DO1043-B3 ARI-STEVI 470 ANSI
FCV DO1043-C3 incl. attachment parts (Riegler)
FCV DO1043-D3 (Siemens)
FCV DO2043-A3 (Omron)
FCV DO2043-B3
FCV DO2043-C3
FCV DO2043-D3
V-PA1631/1641/1651/1661 4.31 ball valve Alms 07
V-PA2631/2641/2651/2661 FIG. KV-L61S (Kingdom)
STR-PA1043A/B/C/D 4.32 Strainer Alms 08
STR-PA2043A/B/C/D FIG. F3YH400 (B.F.E)
XV-PA1043-A2/B2/C2/D2 4.33 pneum. valve Albrecht 13
XV-PA2043-A2/B2/C2/D2 ASV/N
ZSC-PA1043-A2/B2/C2/D2 incl. attachment parts (Omron)
ZSC-PA2043-A2/B2/C2/D2
ZSO-PA1043-A2/B2/C2/D2 (Omron)
ZSO-PA2043-A2/B2/C2/D2
V-PA1635/1645/1655/1665 4.34 check valve Gestra 11
V-PA2635/2645/2655/2665 RK 86
V-PA1632/1633/1637 4.36 block & bleed valve Schneider 03
V-PA1642/1643/1647 N354.60.409.05
V-PA1652/1653/1657
V-PA1662/1663/1667
V-PA2632/2633/2637
V-PA2642/2643/2647

25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
MANUAL

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Auftrag:
V-PA2652/2653/2657
V-PA2662/2663/2667
4.37 stainless steel hose Induflex 10
ICP-N1
PRV PA1043-A1/B1/C1/D1 4.51 air control valve Hochdruck-Re- 14
PRV PA2043-A1/B1/C1/D1 K32-P8-L-N duziertechnik
V-PA1671/1672/1673/1674 4.64 check valve Gestra 11
V-PA2671/2672/2673/2674 RK 86
V-PA1636/1646/1656/1666 4.65 globe valve with throttle cone Alms 15
V-PA2636/2646/2656/2666 and position indication (SWI)
FIG. ABB-11AB-RA1A
XV-PA1043-A3/B3/C3/D3 4.66 pneum. valve Albrecht 13
XV-PA2043-A3/B3/C3/D3 ASV/N
ZSC-PA1043-A3/B3/C3/D3 incl. attachment parts (Omron)
ZSC-PA2043-A3/B3/C3/D3
ZSO-PA1043-A3/B3/C3/D3 (Omron)
ZSO-PA2043-A3/B3/C3/D3
V-PA1638/1648/1658/1668 8.12 ball valve Alms
V-PA2638/2648/2658/2668
V-PA1639/1649/1659/1669 8.13 ball valve Alms
V-PA1636/1656/1676/1696
V-PA1640/1650/1660/1670
V-PA2639/2649/2659/2669
V-PA2636/2656/2676/2696
V-PA2640/2650/2660/2670
FC-PA1043A1/B1/C1/D1 8.22 hose Induflex 16
FC-PA2043A1/B1/C1/D1 GP-N1 - 3/4" NPT
FC-PA1043A2/B2/C2/D2 8.23 hose Induflex 16
FC-IA1043A5/B5/C5/D5 GP-N1 - 1/2" NPT
FC-PA1043/A3/B3/C3/D3
FC-PA2043A2/B2/C2/D2
FC-IA2043A5/B5/C5/D5
FC-PA2043/A3/B3/C3/D3
V-IA1627-1630 9.05 ball valve air distributor Albrecht 17
V-IA1632-1635 4 outlets
V-IA1622-1625
V-IA1647-1650
V-IA1652-1655
V-IA1642-1645
V-IA1667-1670
25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
MANUAL

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Auftrag:
V-IA1672-1675
V-IA1662-1665
V-IA1687-1690
V-IA1692-1695
V-IA1682-1685
V-IA2627-2630
V-IA2632-2635
V-IA2622-2625
V-IA2647-2650
V-IA2652-2655
V-IA1621/1626/1641/1646/ 9.12 filter regulator Norgren 18
1661/1666/1681/1686 B74G-4AK-AD3-RMN
V-IA2621/2626/2641/2646/
2661/2666/2681/2686
FC-IA1043A1/B1/C1/D1 9.25 rubber hose Induflex 16
FC-IA1043A2/B2/C2/D2 GP-N1
SV-DO1043-A1/B1/C1/D1 9.31 3/2-way solenoid valve Norgren 20
SV-DO2043-A1/B1/C1/D1 2401138.0827
SV-DO1043-A2/B2/C2/D2
SV-DO2043-A2/B2/C2/D2
SV-PA1043-A2/B2/C2/D2 9.42 3/2-way solenoid valve Norgren 19
SV-PA2043-A2/B2/C2/D2 9713042.3034
SV-PA1043-A3/B3/C3/D3
SV-PA2043-A3/B3/C3/D3
SVE-DO1043-A4/B4/C4/D4 9.51 5/2-way solenoid valve Norgren 19
SVE-DO2043-A4/B4/C4/D4 9710042.3034
SVE/SVR-DO1043- 9.52 5/2-way solenoid valve Norgren 19
A5/B5/C5/D5 9711042.3034
SVE/SVR-DO2043- impulse type - 2 coils
A5/B5/C5/D5

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Operation and Maintenance Manual

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OPERATION AND MAINTENANCE

Client / FORMOSA HEAVY Project /

Vol. C Maintenance Instructions

C 1 Maintenance at the Firing System .................................................................2

C 2 Maintenance at the Burners ...........................................................................7

C 3 Storage / Preservation ..................................................................................16

C 4 Lists and Drawings .......................................................................................18

C 5 Documentation of Instruments and Measuring Equipment ......................31

C 6 Documentation of Valves, Aggregates and Control Equipment...............33

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

C1 Maintenance at the Firing System

This chapter provides information to be observed carefully when mainte-

C 1.1 Safety Warning Notes

• The equipment may be in fully automatic operation and may start-up

• Do not attempt to work on the equipment or any moving parts of it or

• Prior to carry out any electrical work on the equipment, ensure it is

• Safety interlocks in the burner management system (BMS) are pro-

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

Qualified personnel only must carry out alteration or adjustments of

• Gaseous fuel systems shall be purged with nitrogen prior to mainte-

• Isolate electrical supplies and fuel lines as required before starting to

• Do not open any access door to the combustion chamber or furnace

• In case of carbon monoxide gas (CO) will be present, be very careful

• Do not make attempts to disconnect the ignitor or the ignition

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

• Do not make repeated attempts to light a fuel. If a flame cannot be

• During installation and maintenance activities, proper lifting equipment

C 1.2 Analysis and Instructions for Maintenance Checks

C 1.3 Maintenance Checks during Operation

- Check intensity of flame detectors. If intensity has decreased, the

- Check flame through inspection hole.

- Check local measuring equipment for anomaly.

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

C 1.4 Maintenance Checks after Longer Stops

- Checking function of all pneum. valves for the different fuels;

- Checking function of any pneum. actuators of oil lance or ignition lance

C 1.5 Maintenance Checks after Revision

Prepare the system as described in Vol. B 1 „ Preparations for

Check if signal „Ready for Operation” is existent.

- Driving all fuel control valves;

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

- Checking flame detection system. There must result a signal at the

- Checking function of all pneum. valves for the different fuels;

- Checking function of any pneum. actuators of oil lance or ignition lance

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

C2 Maintenance at the Burners

This chapter provides information to be observed carefully when mainte-

C 2.1 Flame Monitor

For maintenance purposes, the flame monitor can completely be removed

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

The flame monitor may only be removed, after:

Action steps for removing of the flame monitor:

1. Leave the ball valve for cooling air shut-off open.

Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:

Client / FORMOSA HEAVY Project /

2. Completely disconnect the flame monitor from the energy supply.