B-4 AUX BOILER SYSTEM

4.1 AUX BOILER

4.1.1 GENERAL LAYOUT OF CONTROL PANEL

Steam pressure controller

Water level controller

Circulation Pump Controls

Feed Pump Controls

Manual Combustion Switch

4.1.2 OPERATION OF AUX BOILER

4.1.2.1 WATER LEVEL CONTROL

Boiler equipped with 2 sets of Feed Water Pumps. One pump continuously running
and other rest at ST-BY. Start one pump from boiler control panel and set other pump
to ST-BY

Water level in boiler detected by differential pressure

transmitter.

Equalization Valve
Never close any inlet valve for DPT on DPT itself or
on the boiler without first opening equalization
valve. High pressure differential at DPT diaphragm
may cause permanent damage or loss of precision
Inlet Valves

Water level controller controls automatic feed valve to

keep boiler level at “0” (Reference Point)

One feed water pump runs continuously and water level

controlled by automatic feed valve, when valve fully
closed, water circulates through cascade tank.

Water level alarms controlled by water level controller

and electrodes inside level gauge glass tube. Low Low,
Low and High level alarms monitored individually by
both systems, failure in one system will not effect the
activation of alarm
4.1.2.2 FUEL SYSTEM & BURNER

Booster Pump

Relief Valve

Flow meter

Booster Pump

Booster pump can be operated manually from boiler control panel and keeps constant
pressure at circulation pump inlet line. Excessive fuel returns back to Service tank
system through Relief Valve, After relief valve HFO or MGO service tanks can be
selected via manual valves.
FAILING TO CHANGE MANUAL RETURN VALVE DURING
FUEL CHANGEOVER WILL LEAD TO CONTAMINATION / LOSS
OF FUEL

Fuel Circulation Pump Module

Fuel Circulation pumps and fuel heater located in this module. Fuel circulation pumps
can be operated from boiler control panel.
Fuel heater equipped with steam and electrical heating coils. Temperature can be
adjusted via control module.

Fuel Type “A” or “C” can be selected from boiler control panel. Selection of “A”
automatically disables heater and low temperature alarm.

Burner Assembly

Double block fuel valves

Relief Valve

Heavy Fuel continuously circulates through Relief valve via fuel circulation pumps

Atomizing medium can be selected from boiler control panel as “AIR” or “STEAM”.
Automatically controlled by solenoid valves. Manual valves must be opened before
selection

Manual Air Valve

 Use air at initial starting of boiler

Manual Steam Valve

Use steam when boiler steam pressure is over

2.5 bar

4.1.2.3 MANUAL OPERATION

- While Manual Combustion switch at “OFF” , change switch to “FO

PUMP/HEATER”, wait till pressure and temperature of fuel become correct
value for selected fuel.
- Set Switch to “FAN RUNNING” and wait till “SUFFICIENT PREPURGE”
indication lit
- Set Switch to “IGNITION”, confirm pilot burner ignited
- Upon ignition of pilot burner wait 10 seconds and set switch to “PRE COMB”.
Confirm main burner ignited and have steady flame. At pre-combustion pilot
and main burners running together.
- Set switch to “COMB” confirm for steady flame
- Adjust capacity via “COMBUSTION CHANGEOVER” switch.
- Monitor steam pressure as there will not be an AUTO STOP.
- In order to stop, set switch back to “FAN RUNNING” , confirm flame out,
carry out post purge for 5 minutes and set switch to “OFF”

4.1.2.4 AUTO OPERATION

 - While switch at “OFF” set it to “AUTO COMB”
- Press “COMBUSTION” button located on control panel to activate auto mode
- In order to stop auto mode, press “COMBUSTION STOP” button.

In auto mode burner capacity controlled by steam pressure controller depending on

steam consumption.
NOTE: When atomizing medium selected as “AIR” boiler only runs at
MINIMUM LOAD in auto mode. “STEAM” must be selected for higher outputs

4.2 ECONOMIZER

4.2.1 CIRCULATION PUMPS

Economizer equipped with two sets of Water Circulation Pumps, which can be
operated from boiler control panel.
Run circulation pump at least one hour before M/E test.
Two stopping options available
Emergency Stop : Stops the pump immediately
Delayed Stop: Runs pump 6hrs more then automatically stops
Always use delayed stop for normal operation

Glands of Circulation pumps cooled by LT CFW System, check cooling valves

before starting pumps

4.2.2 EXCESS STEAM CONTROL

Excessive steam produced by Economizer dumped through relief valve back to

Condenser
 Relief Valve

4.2.3 SOOT BLOWING

Economizer equipped with four sets of nozzles

Handles are marked for directions of nozzles

-Inform bridge, altering course may be necessary

-Set Aux Boiler to Auto Mode
-Slowly open steam supply valves for lower and upper nozzle group
-Carry out soot blowing for 15 minutes each and twice a day
-Change position of nozzles at every two minutes, scan a total angle of 120o
-Close Steam supply valves
-Inform bridge

4.3 ALARM AND SAFETY TESTS AND PROCEDURES

CONTROL PANEL - ALARM INDICATOR

SYSTEM ALARMS LIST :

1. Miss fire & Flame failure
2. Fan abnormal STOP
3. FO press. LOW
4. Exh. Gas temp. HIGH
5. FO temp. HIGH
6. FO temp. LOW
7. Atomize air press. LOW
8. Atomize steam press. LOW
9. Cas. Tank LOW level
10. Steam press. Abnormal
11. Sequencer Abnormal
12. Fire Abnormal
13. Water level LOW LOW
14. Water level LOW
15. Water level HIGH
16. Steam press HIGH
17. Steam press LOW
18. Air control motor – Control Abnormal
19. F.O. control motor – Control Abnormal

NOTE :
* In E.C.R. - A.M.S. display, there are also indicated Alarms related to
Circulating Pumps, Feed Water Pumps, and only the bolded Alarms listed above.
* In A.M.S. display, the non-bolded Alarms are included all-in-one > BOILER
ABNORMAL.
* In Extended Alarm system – 1 Alarm for all system = Aux. Boiler
ABNORMAL.
ALARMS TESTING :

1. MISS FIRE & FLAME FAILURE :

 - Remove flame eye from its position while FO valves are open (boiler
top).
- The alarm will be activated in Alarm systems previously mentioned.
- Combustion shall Stop
- Confirm that Automatic FO valves are SHUT and FO pressure gauge
indicates 0 (press gauge=same location).
- Reset alarm signal
- Install the Flame Eye at initial position
- System ready for normal operation.
* Location - Boiler TOP

2. FAN ABNORMAL STOP :

- Select Boiler AUTO mode and Press COMBUSTION STOP button.
- Pull the RED pin to Trip Fan Contactor ( Inside Control Panel) and
Alarm will be activated
- Confirm that FO supply is SHUT OFF
- Reset thermal relay by Pressing the BLUE button
- Reset Alarm on Front Panel and from E.C.C.
- Press COMBUSTION START
- System ready for normal operation - AUTO.
3. F.O. PRESSURE LOW :
- At Booster Unit : - CLOSE manual valve No.1
- OPEN manual valve No.2 to drain Press, Connect pressure
calibrator to Valve No2. Increase pressure to 2 bars. Confirm no alarm and start to
release slowly.

- Alarm signal will be activated, record activation point

- Confirm that FO supply is SHUT OFF
- Now, CLOSE valve 2 and OPEN valve 1, to restore pressure on line.
- Reset Alarm.
- System normal operation.

4. EXHAUST GAS TEMPERATURE HIGH :

* Location – E/R Upper DK, right near exhaust gas of boiler.
 - At the moment Alarm activation Confirm that FO supply is
SHUT OFF.

5. F.O TEMPERATURE HIGH :

* Location – E/R 2nd DK Stbd side

6. F.O TEMPERATURE LOW :

* Location – E/R 2nd DK Stbd side

 - At the moment Alarm activation Confirm that FO supply is
SHUT OFF.

7. ATOMIZE AIR PRESSURE LOW :

-Set boiler to AUTO

-Confirm AIR selected as atomizing medium on control panel
-Run boiler
-While main burner is ON, slowly close atomizing air valve and drop pressure
below 4 bar.

When Alarm is activated Confirm that FO supply is SHUT OFF.

8. ATOMIZE STEAM PRESSURE LOW :

-Set boiler to AUTO

-Confirm STEAM selected as atomizing medium on control panel
-Run boiler
 -While main burner is ON, slowly close atomizing steam valve and drop
pressure below 2.5 bar.
-Confirm ALARM

When Alarm is activated Confirm that FO supply is SHUT OFF.

9. CASCADE TANK LOW LEVEL :

- Press down the floater from the tank ( Right Side)

- Keep pressed for 15 seconds
- Alarm will be activated
- Release Floater and RESET the Alarm.
- System - normal operation.

10. STEAM PRESSURE HIGH & LOW :

VALVE POSITIONING ON NORMAL OPERATION

Test – during system normal operation :

- Close the ROOT valve.

- Unscrew and remove the cap of the TEST valve and the adapter of
calibrating pump can be fitted.
- Open slowly the TEST valve to release the pressure from the pipe of
the switches and transmitter. If ROOT valve is completely CLOSED,
the pipe pressure should be quickly released and LOW PRESSURE
Alarm will be activated by low pressure Switch.

- Next, connect the Calibrating Pump to Test Valve end and start
raising the pressure in the pressure SW line until HIGH Press. Alarm
is activated. Sistem HI PRESS.
- When Alarm is activated Confirm that FO supply is SHUT OFF.

- The HI Press. Alarm SW is calibrated at 0.88 MPa – same value

should be indicated on Calibrator gauge at the moment of Alarm
activation. (see picture below)
 - After testing, release calibrator pressure, (Low press Alarm will
activate again – which is normal for the case) and disconnect the
press. Calibrator.
- Close TEST valve and install back the valve cap.
- Now, the ROOT valve can OPEN as it was initially and the boiler real
pressure will be read by the Press. Transmitter and Switches
- System – normal operation.

11. SEQUENCER ABNORMAL :

This Alarm signal is activated when Sequencer unit failure occurs.

Also the Alarm can be activated due to external Power Failure, (e.g.) the
circuit breaker marked with red colour.

Note : If NO errors or alarms related to this unit occur, cutting OFF and ON
of the unit power is to be avoided. DON’T TEST THIS ALARM

- When Alarm is activated Confirm that FO supply is SHUT OFF.

 12. ABNORMAL FIRE :

* Location - Boiler TOP

- As can be seen in picture, the HFO feed is manually selected (valve

Open).
- While boiler Combustion is ON, start Closing the HFO manual fuel
valve slowly.
- The burner flame will become smaller and Alarm signal should be
active.
- Confirm that F.O. Pump Stopped
- After test, put the valve back on OPEN position
- Reset alarm
- System - normal operation.
- Same steps are to be followed for D.O fuel Run.
13. WATER LEVEL HIGH, LOW , LOW LOW :

Alarms through water level controller and level electrodes must be tested
separately.

Water Level Controller

Close upper and lower valves for level gauge glass while boiler water at normal
level. This will inhibit electrodes to sense actual level change in boiler.

High Level Alarm

While feed water pump is running OPEN by-pass valve of Automatic feed water
valve and fill boiler manually.
Monitor Water level controller, when indication reaches +190, HL alarm
shall be activated and feed water pump will be stopped.
Close by-pass valve

Low Level Alarm

Stop feed water pumps and drain boiler water
Monitor Water level controller, when indication reaches -150, Low Level
alarm shall be activated.

Low Low Level Shut Down

Continue draining
Monitor Water level controller, when indication reaches -190, Low Low
Level shut down shall be activated.

Fill boiler to normal running level. Reset all alarms

Level Monitoring Electrodes

3 electrodes located inside tube

SS (black cable) - High Water level
L (red cable) - Low Water Level
LL (yellow cable) - Low Low Water Level
Ground (green cable)
Low and Low Low level alarms active when electrode circuit is open (not
touching water)
High level alarm activated when electrode grounded (touches water)

IMPORTANT: Periodical cleaning of electrodes must be carried out as in

time they will covered with scale and effect proper operation on electrode.
Remove electrodes and remove all scale or dirt on the electrodes. DO NOT
MIX POSITION OF THE ELECTRODES OR CABLES. MEASURE
VOLTAGE ON THE ELECTRODE CABLES BEFORE REMOVING

While boiler water level is normal, close upper and lower valves of tube.

Low Level Alarm

Open drain valve and start to drain water in tube very slowly. Low Level alarm
shall be activated.

Low Low Level Shut Down

Continue draining till low low water level alarm received.

High Level Alarm

Remove one free electrode (2 pcs available) and access water chamber.
Externally fill the chamber, confirm high water level alarm activated and feed
pump stopped. Install removed electrode back.

Restore valves and system

14. AIR CONTROL MOTOR – CONTROL ABNORMAL :

- Confirm that Boiler is on AUTO mode

 - While Combustion is OFF, disconnect wire ‘’65’’ from position ‘’SS’’ which are
located in air control motor connection box.- see picture above
- At Combustion start/ignition sequence, the Alarm for Air Control Motor –
Control Abnormal will activate on Control Panel and Aux Boiler Abnormal will
be displayed in AMS
- Combustion will not start.
- Reset alarm and reconnect 65.
- System – Normal operation.

15. FUEL CONTROL MOTOR - CONTROL ABNORMAL :

- Confirm that Boiler is on AUTO mode

- While Combustion is OFF, disconnect wire ‘’61’’ from position ‘’SS’’ which are
located in fuel control motor connection box.- see picture below
- At Combustion start/ignition sequence, the Alarm for Fuel Control Motor –
Control Abnormal will activate on Control Panel and Aux Boiler Abnormal will
be displayed in AMS
- Combustion will not start.
- Reset alarm and reconnect 61.
- System – Normal operation.

Air control and fuel control abnormal alarms activated when any of the
controllers fails to come ignition position.
16. STEAM PRESSURE ABNORMAL

There is an additional pressure switch located on boiler casing, receiving pressure

directly from boiler steam drum. Setpoint 13 bar, stops combustion and initiate
shutdown of burner if both high steam pressure switch and transmitter fails as well as
Safety valves not able to release pressure, as a final measure of safety.

While boiler pressure is below 6.5 bar, set pressure switch to 7.5 bar and run boiler.
Confirm alarm when setpoint reached. Set back to 13 bar. Reset alarm