AKKAYA-BLOWTHERM ELKBJ User Manual

Steam boilers

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USER MANUAL

ELKBJ MODEL

STEAM BOILERS

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Page 1 USER MANUAL ELKBJ MODEL STEAM BOILERS...
Page 2: Table Of Contents
APPENDIX 1 -Sample Daily Control Chart ..................................24 APPENDIX 2 -WATER QUALITY REQUIREMENTS ..............................25 APPENDIX 3 - Dimension Table of ELKBJ Model Boilers ............................. 27 APPENDIX 4 - system Accessories and Auxiliary Equipment Explanations ..................28 APPENDIX 4.1 Heaters ..........................................28 APPENDIX 4.2 Steam Exit Valve ......................................
Page 3 Low Temperature Alarm ........................................42 High Temperature Alarm ........................................42 High Pressure Alarm ..........................................42 Feed Water Pump & Solenoid Operation .................................42 Hooter/ Siren Shutdown ........................................42 Manual Restart Button ..........................................42 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 4: Introduction
Akkaya steam boiler you have purchased is produced according to EN & TURKISH norms. This user guide is prepared for Akkaya ELKBJ electric powered steam boilers. This user guide includes technical information about the boiler and operating and safety instructions as well.
Page 6: General Desıgn And Construction Features
2.GENERAL DESIGN AND CONSTRUCTION FEATURES 2.1 Design ➢ ELKBJ model boilers are designed and manufactured according to the system which transfers the heat via submerged electrical resistance heaters to the water. ➢ ELKBJ boilers are cylindrical vessels with proper resistance connection flanged nozzles.
Page 7: Working Principle
2.3 Construction ELKBJ boiler body consists of cylindrical shell, heater connection flanges and control nozzles. The selection of the materials is made according to the boiler’s operating pressure. EN12953 is taken as reference for design calculations where applicable. In most cases the electrical steam boilers are constructed as fully packaged and skid mounted type.
Page 8: Quality
(specifications of which can be changed according to customer request) is applied. Rock wool isolation on body ~100 mm isolation on front & back door panels Figure 2.4.4.1 Isolation 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 9: Product Coding
ELKBJAAA – P – M Material Type (SS- in case stainless steel) Maximum Operating Pressure Steam Production Capacity (kg/h – F&A 100 2.6. Boiler Name Plate (sample) 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 11: Transportation Instructions
Safety tools like helmets, gloves, eye protectors… etc. must be provided. The boiler room must be free from dust, flammable materials, dangerous or corrosive gases. The fire protection & extinguishing system must be installed. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 13: Installation Of Boiler And Auxiliaries
The safety valve outlets must be taken out of boiler room with proper separate piping for each of them. Do not connect the exits of the safety valves to a common pipe. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 14 The configuration and the equipment descriptions given in this manual are for a standard package ELKBJ boiler system. The specifications and quantities of the accessories may vary due to customer’s requests. For safety accessories EN12953 has been taken as reference where applicable.
Page 16: Start-Up , Operating, Cleaning And Maintanence
Please refer to wiring diagram of the control board for detailed information. If the operation of the heaters is not stable Akkaya technical service must be informed. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 17 26- Blow down of level indicators and mechanical level controllers must be done at least daily. (see Appendix 27- Boiler operator must record all the operations done on the boiler regularly. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 18: Shutdown And Discharging The Boiler
Be sure the heaters and pumps are not working. Turn of the power supply switches of the heaters and shut off the water inlet valve of the boiler. Never restart the boiler without inspection of an authorized body after an emergency stop. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 19: Precautions
If proper water is fed to the boiler, lime formation on the heating surfaces will not occur. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 20: Protecting The Non-Operating Boiler
Corrosion can only be prevented if there is NO water in the boiler and the oxygen attack to the metal surfaces are prevented when it is NOT operating. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 21: Feed Water And Boiler Water Quality
Daily report of the analysis carried out must be written and archived. Below specifications must be measured and recorded in the analysis report Color ➢ Smell ➢ Nitrite ratio ➢ 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 22 (EN 12953-10 must be studied for detailed information) MANUFACTURER’S GUARANTEE SHALL BE VALID IF ONLY CUSTOMER CARRIES OUT THE RESPONSIBILITY TO PROVIDE PROPER FEED WATER CONDITIONS. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 24: Appendix 1 -Sample Daily Control Chart
A daily control chart must be recorded and kept by the operator of the boiler. If the daily controls are not done and recorded properly manufacturer’s guarantee will be invalid. A safe and efficient operation of the boiler can be sustained by making these controls. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 26 This level of alkalinity is not permissible ≥ 20 bar a) Alkalinity in mmol / 1 Chart 1.2 Maximum acceptable silica content (SiO2) of the boiler water dependent on the pressure 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 27: Appendix 3 - Dimension Table Of Elkbj Model Boilers
APPENDIX 3 - DIMENSION TABLE OF ELKBJ MODEL BOILERS Maximum Maximum Weight Model Installed Length (mm) Width (mm) Height (mm) Steam (kg) Power (kW) Capacity (kg/h) ELKBJ06 ELKBJ30 1060 1060 1440 ELKBJ50 1100 1100 1900 ELKBJ75 1100 1100 1900 ELKBJ100...
Page 28: Appendix 4 - System Accessories And Auxiliary Equipment Explanations
Figure Ap. 4.1 Boiler Heater Connection Flanges and A Sample Heater Photo According to the power of the ELKBJ model boilers, they must be equipped with proper capacity heaters. The specifications are indicated in each models’ item list. The heaters can easily be affected by the water quality and power supply fluctuations.
Page 29: Appendix 4.3 Bottom Blowdown & Drain Valve Group
Overheating may result with metal annealing and pipe explosion. Automatic blowdown system is used to purge these substances from the boiler automatically at certain intervals without human interaction. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 30: Appendix 4.4 Surface Blowdown Valve And System
The sample cooler is a small heat exchanger that uses cold water to cool the hot water sample taken from the boiler. Please refer to the P&ID and sample coolers user manual for installation and operation instructions. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 31: Appendix 4.6 Boiler Water Inlet Valve & Check Valve
Although one piece is accepted by the norms it is also possible to use two safety valves in ELKBJ configurations. Safety valve must be opened to any safe place out of the boiler room by a pipe with same or bigger diameter with the valve’s exit dimension.
Page 32: Appendix 4.8 Automatic Boiler Water Level Controllers
According to the selected configuration a secondary low water level controller, a high-water level controller and a modulating water level controller can be installed in the system additionally. Minimum one piece of level controller must be installed for ELKBJ systems. Figure Ap.4.8.12Automatic Water Level Controller sensor positions Low water level sensor is appr.
Page 33: Appendix 4.9 Reflex Glass Boiler Water Level Indicator
Figure Ap. 4.9 Reflex Glass Boiler Water Level Indicator There is at least one piece of reflex glass type, level indicator in ELKBJ boiler configuration. The most frequently used models are Reflex Glass types with the dimension 310 mm & 400 mm (these are the distances between connection flanges).
Page 34: Appendix 4.11 Pressure Transmitter
The manometers must be connected onto a siphon (or omega) type tube. This prevents the manometer from getting harmed by high temperature and sudden pressure hit. Some water is added into the siphon before connecting the manometer. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 35: Appendix 4.13 Boiler Temperature Control And Alarm System (Thermocouple)
Figure Ap. 4.13 Boiler Temperature Sensor ELKBJ model boilers’ control panel is equipped with a digital heat indicator and alarm system, receiving the heat value by the help of a thermocouple placed on the boiler top. This heat controller is a safety device. It saves the boiler from getting damaged by low or high temperature.
Page 36: Appendix 4.15 Electrical Control Board
APPENDIX 4.15 Electrical Control Board Figure Ap. 4.15 Electrical Control Board A PLC board is provided in the standard package of ELKBJ model boilers. The control board contains the boiler operation system, and the safety system controls. There is an emergency stop button (can be increased in serial connections) to stop the whole operation in case of emergency or unexpected situations.
Page 37: Appendix 4.18 Condensate Tank Without Heater
Water level controller is used for controlling the level of the condensate tank. Condensate tank drain valve is used for draining the water inside the condensate tank. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 38: Appendix 4.19 Pre-Heated Condensate Tank (Atmospheric Deaerator)
The steam increases the temperature of the water and so feed water free of dissolved gases at a temperature of 90-95 ° C is obtained. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 39: Appendix 4.20 Condensate Tank With Spray Scrubber Type Compact Deaerator
Undissolved gases are thrown into the atmosphere through the vent valve on the tank. There is also a steam trap group in the tank to eliminate the overflows that may occur at the water level. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 40 Probe sizes are shown in detail in the figure above. (Dimensions are from flange to rod end.) 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 41: Appendix 4.21 Feed Water Pump Group
Inlet and outlet connections must be made by considering suction and compression side dimensions of pump. Internal sealing of pumps and gaskets between group elements need to be controlled periodically since their working temperature is generally 90 C -120 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 42: Appendix 5 -Boiler Control System Standard Alarms Explanations
The main source for reference shall be the special ‘’electrical control board diagram’’ that is provided to the customer during the system installation. 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)
Page 43 US AND THE EXPLANATION OF THIS USER MANUAL HAS BEEN DONE BY AKKAYA TECHNICAL SERVICE. WE AGREE TO OPERATE THE BOILER UNDER THE CONDITIONS EXPLAINED IN THIS USER MANUAL. CUSTOMER NAME: ADRESS: DATE: SIGNED BY (NAME-SURNAME-SIGNATURE): 2024 Akkaya Isı Makinaları A.Ş., All rights reserved. ELKBJ USER MANUAL - 2024-rev00 (NA-01.01.2024)

AKKAYA-BLOWTHERM ELKBJ User Manual

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