Table of Contents
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Table of Contents
Summary of Contents for Booster NBO
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Page 1: Operation Manual
OPERATION MANUAL BOILER FOR FUEL OIL ( NBO -TYPE ) BOOSTER Boiler Co., Ltd. -
Page 2: Table Of Contents
Thank you very much for purchasing Booster boiler. The Booster boiler is a once through type steam boiler with highest thermal efficiency. Equipping various safety devices, the BOOSTER boiler is being used the most safely. This operation manual describes the operation method and brief maintenance method. - Page 3 Chapter 3 Manipulation of the Auxiliary Equipment 3-1 Manipulation Method ---------------------------------------------------------------------------12 (1) Setting Method for the Thermal Relay of the Magnetic Switch(OCR) ------------ ------- 12 (2) Adjusting Method for the Pressure Switch -------------------------------------------------- 13 (3) Air Extraction for the Feed Water Pump ---------------------------------------------------- 13 (4) Air Extraction Method for the Oil Heater --------------------------------------------------- 13 (5) Pressure Adjusting Method for the Oil Pump ----------------------------------------------- 13 (6) Wiring Method for the Feed Water Pump and the Oil Pump ------------------------------ - 14...
- Page 4 Chapter 5 Boiler Water Treatment 5-1 Boiler Water Treatment ---------------------------------------------------------------------- 26 (1) Harm for the Boiler by Water ------------------------------------------------------------ --- 26 (2) Scale Protection ----------------------------------------------------------------------------- -- 26 (3) Corrosion Protection -------------------------------------------------------------------------- 27 5-2 Instruction for Blowing-off of Water ------------------------------------------------------- 27 Chapter 6 Maintenance for Boiler 6-1 Cause and Countermeasure for Trouble --------------------------------------------------- 29 6-2 Maintenance Checksheet --------------------------------------------------------------------- 30...
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Page 5: Chapter 1 General
Chapter 1 General 1-1 Part Name and Function for Boiler (1) Part Name and Function for the Boiler Main Body Nomenclature Function Automatic control panel Operates boiler, start and stop. Safety valve Safety device which exhausts steam if the boiler main body pressure is above 10Kg/cm2. -
Page 6: Part Name And Function For The Control Panel
(2) Part Name and Function for the Control Panel Nomenclature Function Warning Buzz A alarm which buzzes when abnormal tube water condition. Protect relay Controls combustion, and stops operation when emergency. Initial chemical injection device A device which injects chemicals for corrosion protection when initial operation. -
Page 7: Part Name And Function For The Burner
(3) Part Name and Function for the Burner Nomenclature Function Burner A equipment which sprays and burns fuel. Safety valve A safety device which open and exhausts steam automatically at above 10 Kg/cm2 of the boiler main body pressure. Ignition transformer A device which makes spark for ignition. -
Page 8: Part Name And Function For The Concentration Blowing-Off Assembly And The Oil Pump
(4) Part Name and Function for the Concentration Blowing-off and the Oil Pump Nomenclature Function Concentration blowing-off valve It is used for replacing the solenoid valve for continuous blow or cleaning the strainer. Concentration blowing-off strainer It is used for filtering the blowing-off water and sludge. Oil heater strainer It is used for filtering the sludge in the heater. -
Page 9: Steam Generation System
1-2 Steam Generation System (1) From Water Feeding to Steam Generation 1) Water Feeding Raw water at the pressure of 1.5 - 5 kg/cm2 is flowing to softener[2] for making soft water. The soft water is flowing to the feed water tank[3]. The water level of the feed water tank is maintained constantly by the ball tap. When the power switch “ON”, the feed water pump[6] is operated(the chemical injection pump[10] is also operated for injecting the tube cleaning detergent) and the feeding water from the feed water tank is pressurized and forwarded to the evaporating tube by the feed water pump[6] through the feed water strainer for filtration of foreign substance,... -
Page 10: Flow Sheet
(2) Flow Sheet Light oil specification NAME NAME Boiler oil solenoid valve Softner oil solenoid valve Feed water tank Return solenoid valve Feed water valve Float switch Feed water strainer Oil temperature gauge Feed water pump Plug heater Swing check Control box Lift check Feed oil valve... -
Page 11: Chapter 2 Boiler Operation
Chapter 2 Boiler Operation 2-1 Check Item before Operation * Before start the operation, check the following items: (1) The gauges(whether the pressure gauges, oil pressure gauges and water level gauges are working in the normal condition). (2) Water level in the feed water tank before opening the feed water valve; (3) Oil level in the oil tank before opening the valve;... -
Page 12: Checking The Combustion Condition During Operation
2-5 Checking the Combustion Condition during Operation For complete combustion, the balance of fuel and air volume( excess of air ratio) is to be appropriate. BOOSTER boiler have so manufactured as to do complete combustion utilizing the automatic damper control of the three position control method. -
Page 13: Chapter 3 Manipulation Of The Auxiliary Equipment
2-6 Instruction for the Boiler When It is not used for a Long Time Most people cares a lot for corrosion protection of the boiler during operation, but cares nothing for the boilers which is not used for a long time. In case that the boiler is not used for a week, the boiler could be corroded unexpectedly due to wrong preservation. -
Page 14: Adjusting Method For The Pressure Switch
Note : The copper pipe connected to the pressure switch has antifreezing solution for freezing prevention, So, refilling the antifreezing solution in the winter time is required. (Pressure and Pressure Variation Adjusting Bolt) (Low and High Pressure Switch) (3) Air Extraction Method for the Feed Water Pump Open the air cock on the outlet of the feed water pump and extract the air until the water is coming out strongly. -
Page 15: Wiring Method For The Feed Water Pump And The Oil Pump
(6) Wiring Method for the Feed Water Pump and the Oil Pump (Feed Water Pump) (Oil Pump) ① ② ③ ① ② ③ Blue White Red Blue White Red ⑥- ④ -⑤ ⑥ ④ ⑤ Yellow - Black - Green Yellow Black Green (380V) (220V) (380V) - Page 16 1) BLUE (L1) : Set the cam position to “0” which is indicated on the cam shaft by manual. 2) BROWN (L2) : Set the cam position to “1.0” which is indicated on the cam shaft by manual. 3) GREEN (L3) : Set the cam position to “3.0” which is indicated on the cam shaft by manual (1st low fire opening angle position adjusting).
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Page 17: Adjusting Method For The Water Level Control Equipment
3) BROWN (L2) : Set the cam position to “5.0” which is indicated on the cam shaft by manual (2nd. middle fire opening angle position adjusting). 4) BLUE (L1): Set the cam position to “5.3” which is indicated on the cam shaft by manual ( Position adjusting when returning from 3rd. -
Page 18: Concentration Blowing-Off Device
[5] PL, PM, PH Indicates present combustion detection status of the water level unit. * Low fire : PL lamp is lit up. * Medium fire : PM lamp is lit up(2.0 - 3.0 T/H). * High fire : PH lamp is lit up [6] Concentration Blowing-off Adjusting Method This equipment is used to keep the electric conductivity of water in boiler uniformly and protect water pipe from accuring of carry over, scale and corrosion. -
Page 19: Operation Status For Combustion Control(Protect Relay)
(10) Operation status for combustion Control(Protect Relay ◀ Ⅱ ▲ Ⅱ P ⅡⅡ ■ ⅡⅡⅡ ▼ ⅡⅡ ▤1 Ⅲ ▤2 Ⅲ …… ⅢⅢ ◀ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ ① ② ③ ④ ⑤ ⑥... -
Page 20: Brief Maintenance Check And Cleaning Method
2) Indication Method Symbol Indication Power failure or Cause for operation stop Operation No operation Damper limit switch shut off without power Leakage detection failure failure Fuse cut-off, not reached up to the high water level ◀ Protect relay operation error due to moisture( Remove moisture by dry air) Manipulation switch failure Power failure... -
Page 21: Check For The Concentration Blowing-Off Device
* Acceptance standard Blue Soft water : Accept for use Hard water : Reject for use ( To be returned to the softener manually) * Note: 1) If the water includes foreign substance or washes hands in it, inspection could be resulted hard water even being taken from the softener. -
Page 22: Blowing-Off Strainer
(5) Check and Cleaning for the Feed Water Strainer and the Concentration Blowing-off Strainer Check the inside of the feed water strainer and concentrated blow strainer and remove the foreign substance(dust, scale, rust, etc.) at least once a month. * Note: After disassembling and cleaning the feed water strainer, (Feed Water Strainer) air extraction must be performed through operating the feed water pump. -
Page 23: Check For The Safety Valve
(8) Check for the Safety Valve Extract the steam 2 or 3 times by using the safety valve lever at the 8 - 9 kg/cm2 of steam pressure at least once a month from trial operation. (Safety Valve) (9) Burner 1) Disassembling Method of the Burner Pull out the ignition plug and the flame detector from the burner, disassemble the inlet and the outlet pipe for oil... - Page 24 3) Check for the Nozzle Disassemble the nozzle from the burner ,and remove the foreign substance in it by the light oil or others. * Note: When reassembling the nozzle, sequential disassembling and reassembling is recommended not so as to be changed the position (Nozzle) of the low fire nozzle and the high fire nozzle.
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Page 25: Cleaning For The Returning Water Tank And Check For The Ball Tap
(10) Cleaning for the Returning Water Tank and Check for the Ball Tap Remove and clean the deposit at the bottom of the tank to prevent that the foreign substance flows to the boiler. Clean and remove the foreign substance attached on the seat of the ball tap frequently. -
Page 26: Superheating Prevention Switch
2) 2.0 T/H – 3.0 T/H There are 5 electric bar for water level. Signal condition method : When electric bar is under water for 1 sec, there is water. When electric bar is out of water for 1 sec, there is no water. (Water Level Control for Superheating Prevention) * Note: Careful attention is required not so as to be incorrect length and position of the lighting bar when connected 3... -
Page 27: Chapter 5 Boiler Water Treatment
The boiler water is to be the soft water which is removed the hardening elements of Ca and Mg dissolved in the water which become to the scale by the softener. 2) Chemical Use(BOOSTER Cleaning Detergent: Direct Heating - 182 ppm for general use, Indirect Heating - 98 ppm for industrial use) -
Page 28: Corrosion Protection
(3) Corrosion Protection 1) Maintaining the Appropriate PH Chemicals to the boiler changes the tube water to alkali property from acid property which is the most bad condition for corrosion. Appropriate PH is PH 11.0 - 11.8. 2) Removing the Dissolved Oxygen The boiler is corroded when using the water including dissolved oxygen. - Page 29 ♦ Blowing-off should be performed as follows before starting the normal boiler operation at least once a day(one day is 8 hour basis): 1) Check whether the water level in the tube is normal. 2) Close the main steam valve(ignite according to instruction for operation start on P.9). 3) Operate the boiler ,and if steam pressure is reached up to 1.5 - 2 kg/cm2, the operation switch “OFF”.
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Page 30: Chapter 6 Maintenance For Boiler
Chapter 6 Maintenance of Boiler 6-1 Cause and Countermeasure for Trouble When founded the trouble for boiler operation, check the following items before contact for A/S: Trouble Condition Causes Countermeasure No operation of the feed water 1) Power shut off 1) Check main power switch, the magnetic switch pump connection, and if the power lamp is on. -
Page 31: Maintenance Checksheet
6-2 Maintenance Checksheet Every- Every Every 3 Check Item Maintenance Method Month Months Softer Check by hardness indicator(Blue is acceptable), Salt check Chemical volume check Check whether the chemical is in the tank ,and check injection status. Blowing- Blowing off of Perform blowing off before operation everyday water in boiler Continuous... -
Page 32: After Service
(1) Boiler Type(indicated on the Name Plate). (2) Manufacturing Number and Date(indicated on the Name Plate). (3) Trouble situation(as detail as possible). (4) Fuel type Occasionally, the BOOSTER engineer could request the recheck for the trouble item. In this case, your corporation would be highly appreciated. -
Page 33: Chapter 7 Reference Document
Chapter 7 Reference Document 7-1 Piping Instruction for the Feed Water Pump * Note Part Name Specification 1. When using the returning water tank, the circulation 1 Nipple pump is to be installed in front side of the feed water 2 Strainer pump. -
Page 34: Piping Diagram For The Feed Water Pump
7-2 Piping Diagram for Feed Water Pump and Feed Water Tank 1) When the feed water tank is installed under the ground (the circulation pump is positioned under the ground) : 2)When the feed water tank and the feed water pump are installed under the ground: 3)When the feed water tank is installed above the ground(the feed water pump position is above the... -
Page 35: Piping Drawing For Softener
7-3 Piping Diagram for Feed Water Pump and Feed Water Tank Note 1. The length of each pipe is to be as built. 2. Piping connection of softener is to be TK -12, 20, 30, 40. 3. If softener inlet pressure(water head) is 1.5 Kg/cm2 and below, the pressurizing pump is to be installed. - Page 36 Postal code : 420-130 TEL: (82 2)2062-0760-8 FAX:(82 2)0262 -1078 ● Beijing Office RM.952,JINGXIN BUILDING,NO.2(JIA),DONGSANHUAN BEILU, CHAOYANG DISTRICT,BEIJING CHINA CHINA CHINA CHINA TEL:010-6663-4691 FAX:010-6463-4692 ● Booster Boiler . Service Reservation Cheju (064)743-1290 Chonan (041) 575-9769 Chongju (043)215-0273 Chonju (065) 253-1286 Chunchon...
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