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York-Shipley 5 Series Installation, Operation And Maintenance Manual

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5 Series
Firetube Boilers
Installation, Operation and
Maintenance Manual
40-1000 Horse Power
Dry Back Horizontal Fire Tube Design
York-Shipley Global
Division of Power Mechanical, Inc.
All Rights Reserved
500CRev0 

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  • Page 1 5 Series Firetube Boilers Installation, Operation and Maintenance Manual 40-1000 Horse Power Dry Back Horizontal Fire Tube Design York-Shipley Global Division of Power Mechanical, Inc. All Rights Reserved 500CRev0 ...
  • Page 3 Owners, Operators and Maintenance Personnel This operation and maintenance manual presents information to properly install, operate, and care for the York-Shipley Global Series 500C Boiler. Study its contents in its entirety. The York-Shipley Global Boiler will provide efficient, continued reliability, if properly operated and maintained.
  • Page 4 York-Shipley Global's Standard Limited Warranty, or any other warranty or guarantee. Waterside surfaces must be frequently inspected for the presence of mud, sludge, scale and corrosion.
  • Page 5 5 Series IOM side of boiler 36” - the flue pipe shall not pass through any floor or ceiling or any combustible wall or partition unless suitably guarded. In every case, installations must comply with all applicable insurance requirements, codes and regulations of Jurisdiction Having Authority.
  • Page 6  Make sure footing and body position will not cause a loss of balance in the event of an unexpected occurrence;  Never work near energized electrical “live” circuits.  Consult the Installation, Operation and Maintenance Manual or York-Shipley Global on any questions relating to proper maintenance, installation or operation of this equipment.  ...
  • Page 7 5 Series IOM CAUTION POTENTIAL HEALTH RISKS ASSOCIATED WITH FAILURE TO UTILIZE SPECIAL PROTECTION AND SPECIAL PRECAUTIONS ASSOCIATED WITH HAZARDOUS MATERIALS The manufactures of the refractory and gaskets, as well as other materials commonly used in boilers have issued Materials Safety Data Sheets (MSDS's) for each of their products. Many of these products contain free or crystalline silica and other products which are considered hazardous and pose a health or safety risk if handled improperly.
  • Page 8  ...

  • Page 9: Table Of Contents

    500 Series IO&M Manual TABLE OF CONTENTS Preface..........................i Table of Contents ......................... I Section I General Description 1-1. Purpose ........................1-1 1-2. Arrangement ......................1-1 1-3. General Description ....................1-2 1-4. The Boiler ......................... 1-2 1-5. Description of Boiler Components ................1-3 1-6.
  • Page 10 500 Series IO&M Manual 4-6. Flame Safety Control ....................4-17 4-7. Combustion Program Control ................. 4-20 4-8. Boiler Operation ..................... 4-24 4-9. Boiler Prerequisites ....................4-24 4-10. Start-up ......................... 4-24 4-11. Normal Operation ....................4-25 4-12. Shutdown ......................4-26 4-13. Safety ........................4-26 Section V Startup, Adjustment and Operating Procedures 5-1.
  • Page 11 500 Series IO&M Manual 6-8. Pre-Startup Inspection ....................6-6 6-9. Instructions for Installing New Chamber Tile in Furnace Tube ......6-11 6-10. Instructions for Installing Plastic Refractory in Rear Arch ........6-12 6-11. Removal and Replacement of Front Cover and Gaskets ........6-14 6-12.
  • Page 12 500 Series IO&M Manual Fransil Wet Set Mortar ....................C-53 Franco Super Plastic, Air Set ...................C-55 Hydrecon 56-2750 Light Weight & Gun Mix ............C-57 V-44 Surface Seal ....................C-59 Fiberglass Insulation ....................C-61 Carbomastic 801 Part A ...................C-65 Carbomastic 801 Part B ...................C-73 D.

  • Page 13: General Description

    1-1. Purpose This technical manual provides the necessary information to install, start-up, operate, service, store and maintain the York-Shipley Global Series 500C Packaged Firetube Boilers manufactured by Power Mechanical, Inc. Throughout this manual the York-Shipley Global Series 500L Boiler will be referred to as the Series 500C Boiler, the packaged boiler, or more simply the boiler.

  • Page 14: General Description

    Boiler. 1-4. The Boiler The York-Shipley Global packaged boiler is a steam generating unit that can use a variety of fuels for generating heat to produce steam or hot water for industrial use. The boilers are self- contained units that range in size from 20 HP to 1000 HP. The boiler produces saturated steam which can be delivered at a variety of pressures as required by the end-user.

  • Page 15: Description Of Boiler Components

    Efficient control of the boiler is only possible when the operator understands the function and operation of each of the major components of the boiler systems. Many of these components are purchased by York-Shipley Global from manufactures specializing in boiler controls and boiler related components. The individual manufacturer's operation and maintenance manuals have been furnished with your equipment.
  • Page 16 SECTION I - GENERAL DESCRIPTION Air Compressor The Air Compressor Oil Reservoir ensures the Oil Reservoir delivery of clean lubricating oil to the air compressor. It is normally located at the top of the intake side of the air compressor. The Auxiliary Switch (Low Fire End Switch) is Auxiliary Switch actuated by the modulating motor.
  • Page 17 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Basic Firetube Boiler Components No. COMPONENT DESCRIPTION The Gas Flow Control Valve regulates the flow rate of natural gas to the burner. The power output of the Gas Flow boiler is controlled in this fashion. The Gas Flow Control Valve Control Valve position is controlled by a Modulating Motor and operates in conjunction with the forced...
  • Page 18 SECTION I - GENERAL DESCRIPTION The Forced Draft Fan or Blower provides the combustion air to the burner assembly. The Forced 13 Forced Draft Fan Draft Fan or Blower operates continuously during or Blower boiler operation supplying combustion air. The Forced Draft Fan or Blower starts before the burner begins operation to prepare the boiler and firetube for combustion.
  • Page 19 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Basic Firetube Boiler Components No. COMPONENT DESCRIPTION The Ignition System Transformer steps up the 16 Ignition System voltage to supply the high voltage necessary for Transformer spark ignition. Should the gas main pressure change dramatically the operator may need to adjust the gas pressure regulator.
  • Page 20 SECTION I - GENERAL DESCRIPTION The Pilot Solenoid Valve is the normally closed 23 Pilot Solenoid valve in the line supplying fuel to the pilot. This Valve valve is opened only during the period of ignition by the flame safeguard system. 24 Air Compressor The Air Compressor Pump furnishes filtered air Pump...
  • Page 21 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Firetube Boiler Basic Components No. COMPONENT DESCRIPTION The Pump Control and Low Water Cutoff responds to the level of boiler water. Typically, this control is float operated. It performs two 26 Pump Control distinct functions: The first is to stop the firing of the boiler when the boiler water is below the safe Low Water Cutoff...
  • Page 22 SECTION I - GENERAL DESCRIPTION 29 Steam Pressure or These gauges indicates internal boiler pressure or Pressure Temperature pressure-temperature conditions. and Altitude Gauge The Test Tee is located on the piping immediately below the boiler pressure gauge. On steam boilers it is supplied for the 30 Test Tee convenience of the boiler inspector in making routine checks of the calibration of the steam...

  • Page 23: Warning And Caution Label Identification

    SECTION I - GENERAL DESCRIPTION 1-6. Warning and Caution Label Identification Read and understand each label placed on the boiler and boiler room equipment. 1-7. DEFINITION OF DANGER, WARNING AND CAUTION DANGER used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.
  • Page 24 SECTION I - GENERAL DESCRIPTION Label 2. 1 ‐ 16  ...

  • Page 25: Electrical Data

    SECTION I - GENERAL DESCRIPTION Label 3. Typical Fuel Burning Equipment Electrical Data Tag Fuse Component Data Volts Amps Phase Freq Ampacity Amps 1. Blower Motor 2. Fuel Pump Mtr 3. Com'pr Motor 4. Elec Htr #1 5. Elec Htr #2 6.
  • Page 26 SECTION I - GENERAL DESCRIPTION Label 4. 1 ‐ 18  ...
  • Page 27 SECTION I - GENERAL DESCRIPTION Label 5. Typical Fuel Burning Equipment Rating Tag Label 6. NOTICE A GAS PRESSURE REGULATOR CAPABLE OF BEING ADJUSTED TO WC MANIFOLD PRESSURE SHALL BE INSTALLED AT THE TIME OF INSTALLATION OF THE UNIT THIS BURNER WAS TESTED ON BTU/CU.
  • Page 28 Make sure footing and body position will not cause a loss of balance in the event of an unexpected occurrence. Consult the Installation, Operation and Maintenance Manual on any questions relating to proper Maintenance, Installation or Operation of this equipment. YORK-SHIPLEY GLOBAL 144712 1 ‐ 20  ...
  • Page 29 SECTION I - GENERAL DESCRIPTION Label 9. PROBE L.W.C.O. RELAY RELAY MUST BE RESET AFTER LOW WATER CONDITION OR POWER FAILURE. RESET BUTTON UNDER COVER. N-149014-A Label 10. CAUTION REPLACE OIL EVERY 3 MONTHS. USE COMPRESSOR LUBRICATING OIL IN FILTER. FILL TO BEAD BELOW 87342 Label 11.
  • Page 30 SECTION I - GENERAL DESCRIPTION Label 12. WARNING When Lifting, Use a Spreader Bar to Prevent Damage to the Boiler SPREADER BAR Label 13. IMPORTANT Be sure to flush your boiler water level control DAILY while boiler is in operation. Failure to follow this procedure can cause the control to malfunction resulting in serious boiler damage.
  • Page 31 SECTION I - GENERAL DESCRIPTION Label 14. Remove this Block and Install Pipe Plug before Starting this Unit PART NO. 710651 Label 15. REMOVE COVER AND REMOVE PAPER BLOCKING AROUND MERCURY SWITCHES. PART NO. 710652 Label 16. WARNING This pump should be used with two pipe system only. It is specifically designed and built to eliminate air from nozzle pipe and minimize after drip.
  • Page 32 SECTION I - GENERAL DESCRIPTION Label 17. Hot Water Boiler Thermal Shock Warning WARNING AVOID THERMAL SHOCK Rapid replacement of your boiler's hot water with return water at a temperature below the boiler manufacture's recommendations can cause serious damage to your boiler. DO NOT ALLOW THIS TO HAPPEN.

  • Page 33: Storage Information

    Upon receipt, check the boiler and all accompanying packages. Immediately make claims to the carrier for all items and/or parts either damaged or missing. In addition, notify York-Shipley Global of all items and/or parts either damaged or missing. Failure to immediately advise and make shortage, or damage, claim to carrier may preclude ability to recover compensation.

  • Page 34: Dry Storage

    SECTION II - INSPECTION AND STORAGE   Employ the services of a competent and qualified water quality service provider to ensure proper lay-up procedures and safely administer any program to accommodate same Whenever a package boiler is taken out of service for any purpose, it should be internally cleaned when put back into service or placed in wet or dry storage.
  • Page 35 SECTION II - INSPECTION AND STORAGE   company for the specific requirements at your site. Water pressure greater than that of the atmosphere should be maintained within the boiler during the storage period. NOTE The percentage of soda and sulfite noted above is greater than recommended for operation of the unit.
  • Page 36  ...

  • Page 37: Description And Boiler Room Items

    York-Shipley Global strongly recommends that a qualified engineer review the design of the pad(s) used to support all boiler room equipment to meet all federal, state and local codes and site conditions relative to ground conditions and related factors such as seismic conditions, etc.
  • Page 38 Care should be taken to ensure the test tee is not obstructed. The test tee is provided for the convenience of inspectors when calibrating the steam pressure gauge on all York-Shipley Global steam boilers. It also serves to relieve the vacuum created by steam condensing upon shut down of the boiler.
  • Page 39 SECTION III PART 1 - INSTALLATION WARNING Do not sling the boiler. Rear Covers and Manway Water backed boilers are generally provided with a two piece rear access doors which can be removed for inspection, cleaning, and/or the tube removal of the third pass tubes. Access to the second pass tubes is through a manway which permits access to the reversing chamber, furnace and second pass tubes for inspection, cleaning and maintenance, but not tube removal.
  • Page 40 SECTION III PART 1 - INSTALLATION Standard boilers have a flanged vertical connection. 3‐4 ...
  • Page 41 SECTION III PART 1 - INSTALLATION 13). Front Access Doors The front Access Doorsr are attached with studs and nuts. Removal provides for inspection, cleaning and tube removal. The front cover is also available with optional hinges. Always provide adequate clearance for maintenance, cleanout and front door swing or removal. 14).
  • Page 42 SECTION III PART 1 - INSTALLATION All low pressure units are equipped with side outlet safety valves. Low points in all safety exhaust lines should be dripped to remove all water. On low pressure units the exhaust piping size is the same as the safety valve size. Safety Valve with Drain &...
  • Page 43 SECTION III PART 1 - INSTALLATION When a boiler is equipped with a firing rate motor, either a modulating or a two position high/low and additional control are furnished to regulate the position of the firing rate motor. This control is normally adjusted at a pressure setting lower than both limit controls. 21).
  • Page 44 SECTION III PART 1 - INSTALLATION 22). Auxiliary Low Water Cut-Off The second manual reset low water cut-off can be piped in the same manner and the blow-down valve connected to blow-down piping. Probe type manual reset LWCO controls are typically mounted at top centerline of boiler shell.
  • Page 45 SECTION III PART 1 - INSTALLATION For 200°F water level in the tank should be 7’ from C/L of the pump. For 190°F water level in the tank should be 5’ from C/L of the pump. For 180°F water level in the tank should be 4’ from C/L of the pump. The tank is equipped with a gauge glass (item 37) make up valve (item 41), thermometer (item 42) and an opening in the tank to accommodate the installation of other components which might be necessary.
  • Page 46 SECTION III PART 1 - INSTALLATION The vent should be sized in accordance with the Table 3-1 below. The vent piping should run full size with as few fittings as possible and with no reduction in size or restrictions. The vent piping should pitch upward so water cannot be trapped inside.
  • Page 47 SECTION III PART 1 - INSTALLATION 27). Steam Piping Main Bleed Trap During certain periods of operation steam will condense in the header and remain there unless drained. In pressure piping, water caught in the rapid flow of live steam causing hammering condition has been known to cause severe damage and destruction in steam lines and fittings.
  • Page 48 SECTION III PART 1 - INSTALLATION magnesium. A desirable covering such as canvas should be used over the insulation to prevent deterioration. 31). Blowdown Tank A blowdown tank is recommended to allow proper blowdown of all units without affecting the drain or sewer connections.
  • Page 49 SECTION III PART 1 - INSTALLATION 33). Surface Blowdown Valve Each York-Shipley Global high pressure boiler is provided with a surface blowdown connection. It is located on the standard water line of the unit. Surface blowdown connections can be ordered as optional tapping on low pressure boilers.
  • Page 50 SECTION III PART 1 - INSTALLATION angle to prevent flue gas back-up to "down' units on a multiple installation. Vents or breathings for other appliances should not be connected to boiler breaching, since other appliances usually depend on natural draft for optimal operations. IMPORTANT Steel breaching vent connection must be round and not square.
  • Page 51 SECTION III PART 1 - INSTALLATION Figure 3-1. Connection of Breaching to Stack. 36). Stack Cleanout Cover and Deflector The stack should include a cleanout provision near the bottom and a deflector to the joint where the breaching enters the stack. See Figure 3-1 (page 3-12). 37).
  • Page 52 SECTION III PART 1 - INSTALLATION DANGER Fresh air inlet must not be blocked or obstructed at any time the boiler is operating. NOTE In all cases, fresh air inlet area must meet the minimum requirement of the local (city or state) jurisdictional code.

  • Page 53: Principles Of Operation, Startup And Safety

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Section IV Principles of Operation, Startup and Safety 4-1. Combustion The three basic elements needed to burn a fuel are: fuel, • oxygen and • heat. • The relationship of the three combustion requirements are illustrated by the combustion triangle in Figure 4-1 below.
  • Page 54 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Figure 4-1. Combustion Triangle 4‐18 ...
  • Page 55 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The combustion process produces a fire. The fire burns the fuel and changes chemical energy into heat energy. Fuel plus heat plus air make hot gas. Hot gas contains the fuel's heat energy. Figure 4-2 illustrates the combustion process.

  • Page 56: Boiler Fluid Flow Paths

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   gas. Portable instruments may be used to check the amount of oxygen in the flue gas. Also boilers may be equipped with oxygen recorders to continuously monitor the amount of excess air available.
  • Page 57 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The cold dense feedwater is directed down the outside of the boiler shell to the bottom of the shell. The incoming feedwater acts as an insulator cooling the shell and becoming preheated as it sinks to the bottom of the shell.
  • Page 58 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The temperature increases in the boiler water occur in steps. There are three steps that occur in the process. The first is the preheating that occurs in the third pass firetubes where the incoming feedwater mixes with the recycled boiler water and passes over the firetubes.
  • Page 59 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Figure 4-4. Typical Natural Gas Flow Path Figure 4-5. Typical Fuel Oil Supply 4‐23 ...

  • Page 60: Thermodynamics

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Combustion Air The Combustion Air System supplies the oxygen to the burner for burning the fuel. The system also removes the spent gases from the boiler. The air in the system is controlled by a series of dampers and fans.
  • Page 61 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Table 4-1. Temperature Pressure Relationships Pressure Boiling Point 92  F .7365 psia 1.5 "Hg 161  F 4.91 psia 10 " Hg 0 psig (atmospheric) 212  F 14.7 psia 327 ...
  • Page 62 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Figure 4-7. Thermodynamic Properties of Water At the moment all steam has condensed, but the water temperature is still 212  F, the water temperature in the pan will have increased from 80  F to 177  F. This 97 degree temperature rise for 10 pound of water represents a 970 BTU energy transfer: 10 pounds (97 degrees) = 970 BTU of heat energy.
  • Page 63 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The amount of energy needed to convert saturated water into saturated steam is called the latent heat of vaporization. The amount of energy released when saturated steam condenses to saturated water is called the latent heat of fusion. The latent heat values equal one another as long as the system pressure remains constant.
  • Page 64 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Heat Transfer Heat transfer is continuous throughout the boiler during operation. The majority of heat transfer within the package boiler occurs in one or more of the following processes: conduction, •...
  • Page 65 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Convection is classified as either "natural" (hot air or liquid rising because it is lighter than the surrounding air or liquid), or "forced" (a pump moving liquid, a fan moving hot gases, or steam moving through a pipe).

  • Page 66: Instrumentation

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   4-4. Instrumentation The instrumentation that the operator encounters on a daily basis is the only means of communicating with the package boiler. Proper operation of the boiler requires the operator to fully understand the condition of the boiler and its auxiliaries.

  • Page 67: Controls

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Flow The package boiler can be equipped with an air flow safety switch for monitoring the forced draft fan condition. The switch is a differential pressure switch. It provides inputs to the Flame Control circuit for indication of blower failure.

  • Page 68: Burner Controls

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Burner Controls Terminology • High (Safety) Limit Control is a pressure (steam) or temperature (water) control used as a safety feature to prevent the boiler from developing excessive pressure or temperature. This is often called only a limit control (no reference to “safety”...

  • Page 69: Flame Safety Control

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The burner control system uses boiler steam pressure to determine the amount of energy being used by the system. As the system uses more steam or heat (energy) than the boiler is producing, the pressure or hot water temperature in the boiler will start to drop.
  • Page 70 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   A furnace explosion is the ignition and almost instantaneous combustion of highly inflammable gas or vapors in the boiler. It can cause a greater expansive force on the boiler than the boiler is designed to withstand.
  • Page 71 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Self-checking control de-energizes flame relay if 1. any electronic component fails 2. flame signal is absent or continuous for any other reason. Figure 4-11. UV Detector The pulses from the detector tube are passed to a transistor type pulse amplifier and are integrated in a capacitor.
  • Page 72 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Whereas the system does not “detect" hot refractory, excessive steady radiation reduces flame signal. The same effect results from excessive scanner temperature. To avoid nuisance shutdowns, it is important to avoid sighting hot refractory and to keep scanner temperature low (never over 125 ...

  • Page 73: Combustion Program Control

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   4-7. Combustion Program Controller The microprocessor based flame safety and burner management system is designed to provide the proper burner sequencing, ignition and flame monitoring. In conjunction with limit and operating controls, it programs the burner/blower motor, ignition and fuel valves to provide for safe and proper burner operation.
  • Page 74 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The main fuel valve is in the closed position. This indication is provided by a position indicating switch on the valve stem. a. If the valve is not closed, the program will lockout the controller and the startup sequence will stop.
  • Page 75 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The presence of main flame is continually checked during normal firing. a. If main flame fails at any time during normal firing, all fuel valves will be closed within 4 seconds and the program will lockout. b.
  • Page 76 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   close, the program will hold in this position for ten minutes waiting for it to close. If it does not, the control will lockout. 6. When the prepurge is completed, the firing rate motor is driven toward the low purge damper position.

  • Page 77: Boiler Operation

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   4-8. Boiler Operation The following section discusses good operating procedures and practices. These practices will be presented in the condition of the boiler operation that the operator will most likely experience them.

  • Page 78: Normal Operation

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   3) Align the boiler control systems and commence a startup. Take a complete set of operating data logs to record the initial starting conditions. Energize the control systems and start the boiler into the operating mode. During the automatic boiler startup operation continuously monitor the boiler and support systems for proper behavior.

  • Page 79: Shutdown

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   4-12. Shutdown When the plant conditions dictate that the package boiler is no longer needed for supplying process steam the unit may be shutdown. The initial actions required to shutdown the boiler are the same until the point is reached when the shutdown is for a long term or short term duration.

  • Page 80: Safety Rules

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The ASME Boiler Code and the National Board of Boiler and Pressure Vessel Inspectors Inspection Codes are important source documents for legal requirements in the various states and municipalities that have adopted boiler safety laws. In addition to maintaining active boiler and pressure vessel committees in order to keep the published codes up to date with developing technology, the ASME issue to qualified manufacturers, assemblers, material suppliers and nuclear power plant owners Code symbol stamps indicating that the manufacturer has received...

  • Page 81: Safety

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Table 4-4. Safety Rules (continued) NEVER give verbal orders for important operations or ALWAYS accompany orders for important operations report such operations verbally with a written memorandum. Use a log book to with no record.
  • Page 82 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Table 4-4. Safety Rules (continued) NEVER attempt to light a burner without venting ALWAYS allow draft to clear furnace of gas and dust The furnace until clear. for prescribed purge period. Change draft conditions slowly.

  • Page 83: Startup, Adjustment And Operating Procedures

    5-1. Introduction York-Shipley Global Boilers are all fire tested before shipment. The purpose of the fire test is to check all components for proper operation, etc., and to aid in field startup. Because job site conditions are different than factory test conditions, fire test readings can only be used as a guide.
  • Page 84 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   (Suggested Procedure) The internal surfaces of a newly installed boiler will have oil, grease or other protective coating used in manufacturing. Such coatings must be removed since they lower the heat transfer rate and could lead to overheating of a tube and reduce unit operating efficiency.

  • Page 85: Initial Startup Check List

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Gauge glasses must be protected from contact with the boil out chemicals during procedure. 7) Fill pressure vessel with clean water until top of the tubes in the boiler are covered. Add cleaning solution and then fill to the top of pressure vessel.

  • Page 86: Gas Startup

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   NOTE Low fire hold equipped boilers will remain in low fire until set release point. 5) Light burner on oil and hold on low fire until steam comes out of steam pressure gauge test cock.
  • Page 87 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Open manual shutoff valve closest to modulating butterfly valve. Reset flame safeguard control and high gas pressure switch. Cycle burner and establish main flame. (Hold burner on low fire if not equipped with a low fire hold switch).

  • Page 88: Normal Operation

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   5-6. Normal Operation The role of the operator is primarily one of surveillance during normal boiler operations. The following items should be checked during the rounds: Fuel pressures Piping integrity feedwater and fuel Proper air seals on all boiler doors General cleanliness Unobstructed intake dampers...

  • Page 89: Smoke Testing

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The primary enemy of the oil fired boiler is smoking and sooting. Smoke color and opacity and CO 2 are the primary method of determining the combustion efficiency of the boiler. Smoke Testing Smoke testing is commonly performed by drawing a known volume of boiler flue gas through a filter paper and examining the particulates that remain.
  • Page 90 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Figure 5-1. Soot Buildup vs. Efficiency There are many factors that affect the flue gas smoke levels. The following is a list of typical items. Insufficient Overdraft The ration of fuel-to-air is a critical parameter in the operation of a boiler. Too low of an air flow will result in unburnt fuel atoms in the flue gas.
  • Page 91 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Firing Periods A boiler that is constantly cycled  will have a higher probability of  soot buildup compared to one  which is left at a steady firing rate.   The cycling boiler will not be  allowed to reach and maintain an  even combustion temperature.  The  cooler regions in the boiler will  exhibit excessive soot buildup and  tend to further promote incomplete  combustion.  Figure 5‐2 shows the  effects of firing period changes on  the boiler efficiency.  Figure 5-2. Burner Operation vs. Efficiency Startup and Shutdown The starting and shutdown periods when the boiler is in transition will result in some smoking as a result of excess fuel that is being sent to the boiler when ignition is not complete.

  • Page 92: Stack Temperature

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Carbon Dioxide (CO 2 ) Testing The testing of CO in the flue gas is a direct indication of the combustion quality occurring in the boiler. The physical laws of nature dictate the by-products of combustion and the initial contents of the combustion air.

  • Page 93: Gas-Fired Testing

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   brought to the combustion chamber to support combustion. This value is based on the fuel type and the burner capacity. The flue draft is a measure of the volume of gases passing through the boiler to ensure that the combustion pressure remains under slightly negative pressure conditions.

  • Page 94: Boiler Startup

    SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Operator duties typically consist of routine, periodic inspections and minor preventive maintenance functions while the boiler is in operation. Some of these functions are performed daily others are inspections and boiler up-keep items performed weekly, monthly, semi-annually and even annually.
  • Page 95 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Water Supply Systems Many package boiler installations use a connection to a municipal water system as a makeup supply. Others use well water pumped directly into boiler supply piping or into a storage tank. When a storage tank is used, it usually contains condensed steam from steam distribution system return piping and city or well water as a makeup source.
  • Page 96 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Deaerator Feedwater flow must be established through the deaerator before admitting steam. Otherwise, overheating will take place. With this in mind, and the fact that in some installations no steam source is available until the boiler is on-line, we can see that it may not be possible to deaerate the initial boiler fill water.
  • Page 97 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Boiler Feedwater Chemical Injection Systems Some boiler feedwater systems include chemical injection equipment. This equipment is usually a one shot feeder or a mixing tank-pump assembly. Regardless of the type of feed system, boiler feedwater chemical injection is important during initial boiler filling.
  • Page 98 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The strength of the solution in the mixing tank is determined by the amount of chemical (wet or dry) that is dissolved in a specific amount of water. Water treatment contractors (or plant chemists) are usually responsible for specifying the strength of the mixture.
  • Page 99 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Boiler fuel oil supply systems are much more sophisticated than gas systems. A boiler fuel oil supply system is shown in Figure 5-6. The system shown is typical for fairly large boiler installations.
  • Page 100 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   The fuel oil pumps are usually positive displacement type pumps (previously discussed). Positive displacement pumps will build enough pressure to damage downstream components, as well as their own components if the discharge flow path becomes blocked (closed discharge valve, etc.).
  • Page 101 Place the oil heater in service (if so equipped). Compressed Air System Startup The York-Shipley Global boiler systems that used compressed air are supplied prior to startup by the boilers own dedicated compressor. If the compressed air system is completely shutdown, the steps for startup include: Drain all moisture from the compressed air piping, then close drain valves.

  • Page 102: Boiler Startup Steps

    5-15. Boiler Startup Steps Once the boiler support systems are in operation, the boiler itself can be started. The following startup steps provide a general method of starting the York-Shipley Global Model SPH and SPL 4‐66 ...
  • Page 103 Section 1 of this text describes the various control systems commonly used on York-Shipley Global boilers. 14. If the boiler is being started as a cold startup operation (cold water in the boiler), the burner should remain in the Low Fire mode of operation to allow the boiler to warm up slowly.
  • Page 104 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Once the boiler is started, it will be necessary to adjust the modulating control (mounted on the low water piping) for the desired pressure at which the control system switches back to the low fire mode. 4‐68 ...

  • Page 105: Boiler Failure To Start

    York-Shipley Global distributor for assistance. 5-17. Boiler Shutdown The shutdown of the York-Shipley Global Series 500L consists basically of shutting down the burner. The burner is stopped by opening the blower and control operating (emergency) switch.
  • Page 106 SECTION IV - PRINCIPLES OF OPERATION, STARTUP AND SAFETY   Ensure that a normal boiler water level is maintained until the boiler is cool. The boiler metals store a lot of heat and remain hot enough to cause extensive damage if not cooled by the proper water level.

  • Page 107: Service And Maintenance

    To be performed once a year in addition to the semi-annual, monthly, weekly, and daily duties. NOTE The exact duties listed in this section are specified to York-Shipley Global Series 500c. However, they are typical of the types of duties performed for many other package boiler models.

  • Page 108: Weekly Procedures

    SECTION VI - SERVICE AND MAINTENANCE 5) Monitor stack temperature. If high, check fire side of boiler for dirt, over-firing, or improper combustion. 6) Check temperature of water supplied to unit and if below 160 degrees, preheat return to not more than 200 degrees. 7) Check oil pump suction conditions.

  • Page 109: Semi-Annual Procedures

    5) Check the rear head refractory and patch any cracks or sprawls with refractory cement. If refractory requires replacement a sectional assembly may be obtained from the factory through the nearest York-Shipley Global distributor. 6) Always replace the 1-1/4" ceramic fiber rope around the edge of the rear refractory with a new rope and clean off any old cement.

  • Page 110: Operation Test

    Fill the boiler by means of the feed water pump and reset the low water cut-off. 3) At the time of this yearly inspection and cleaning, it is recommended that the local York-Shipley Global distributor, or agent, be called in to check the condition of the equipment. 6-7.
  • Page 111 SECTION VI - SERVICE AND MAINTENANCE Figure 6-1. Operation Test 6‐5   ...
  • Page 112 SECTION VI - SERVICE AND MAINTENANCE 6-8. Pre Start-Up Inspection A Start-Up form shown in Figures 6a-2 through Figure 6b-2 pages 6-7 through 6-10 is supplied to each respective representative for his/her Pre Start-Up Inspection as required by terms of existing contracts. The representative will forward the form to the service agency, who in turn starts the equipment and completes this form.

  • Page 113: Pre-Startup Inspection

    SECTION VI - SERVICE AND MAINTENANCE PRE START-UP INSPECTION Packaged Firetube Boilers Name of Independent Representative: Date: Start-Up Agency: Address: City: ________________ State: Zip: Customer Name: Address: City: ________________ State: Zip: Location of Installation: H-Number: Unit Model Number: Serial Number: Type Fuel: Voltage/Frequency/Phase : The equipment described above has been inspected by me and the following points checked for...
  • Page 114 SECTION VI - SERVICE AND MAINTENANCE York – Shipley Global Pre Start-Up Inspection Packaged Firetube Boilers H-Number:________________ Is fuel burning equipment now operable and fuel oil and/or main gas and   pilot gas piping complete? Has fuel oil suction line been tested by installer? ...
  • Page 115 SECTION VI - SERVICE AND MAINTENANCE York – Shipley Global Pre Start-Up Inspection H-Number________________ Packaged Firetube Boilers Are there any items supplied by us that are obviously damaged, missing   or defective? Have you informed York – Shipley Global of such damage? ...
  • Page 116 SECTION VI - SERVICE AND MAINTENANCE York – Shipley Global Pre Start-Up Inspection Packaged Firetube Boilers H-Number________________ 23. List below the name, address, and telephone and fax numbers of the person located at the installation who is responsible for completion of the above work so that we can communicate with him, if necessary.

  • Page 117: Instructions For Installing New Chamber Tile In Furnace Tube

    SECTION VI - SERVICE AND MAINTENANCE Figure 6-2d. Pre Start-Up Inspection page 4 of 4 6-9. Instructions for Installing New Chamber Tile in Furnace Tube 1) Before attempting to cement the chamber tile in position, lay the bricks up dry at the end of the firing tube.
  • Page 118 SECTION VI - SERVICE AND MAINTENANCE 6-10. Warning for Installing Plastic Refractory WARNING POTENTIAL HEALTH RISKS ASSOCIATED WITH FAILURE TO UTILIZE SPECIAL PROTECTION AND SPECIAL PRECAUTIONS ASSOCIATED WITH HAZARDOUS MATERIALS The manufactures of the refractory and gaskets, as well as other materials commonly used in boilers have issued Materials Safety Data Sheets (MSDS ' s) for each of their products.
  • Page 119 SECTION VI - SERVICE AND MAINTENANCE IMPORTANT Before removing the old refractory, make a note of the thickness at different positions on the boiler. If you have the thickness greater than it should be, the rear head will not enter properly. Check the refractory at the tube sheet so that refractory is approximately three-eighth inch (3/8") lower than the tubes.

  • Page 120: Removal And Replacement Of Front Cover And Gaskets

    SECTION VI - SERVICE AND MAINTENANCE 6-11. Removal and Replacement of Front Cover and Gaskets 1) Remove the nuts which fasten the front cover to the boiler, and remove the cover. 2) On boilers with optional front cover hinges, unscrew the two (2) special hinge bolts evenly until the head clears the studs on the boiler.

  • Page 121: Feed Water Treatment

    Check the rear head and baffle refractory and patch any cracks or spawls with high temperature cement. If refractory requires replacement, a sectional assembly may be obtained from the factory through the York-Shipley Global representative in your area, baffle can be replaced with Plastic Refractory or similar material.
  • Page 122 SECTION VI - SERVICE AND MAINTENANCE 2. C : The chemical method of cleaning the insides of packaged boilers HEMICAL involves the selection of a chemical (acid) which will react with the type of scale present. WARNING Muriatic acid is dangerous to use and it is strongly recommended that the greatest precautions be exercised in its use.

  • Page 123: Cause Of Tube Leaks

    SECTION VI - SERVICE AND MAINTENANCE Secure a sample of the remaining solution in the boiler and test to see if the soda ash has neutralized the acid content. If not, add more soda ash and bring unit to boil as per the above.

  • Page 124: Condensation

    SECTION VI - SERVICE AND MAINTENANCE York-Shipley Global manufactures a safety control which affords complete and positive protection against thermal shock of water boilers. This control is adaptable to any boiler, regardless of its make. 3. H Hot firing a cold boiler is another method whereby...

  • Page 125: Installation Of New Tubes

    York-Shipley Global has a water temperature control that can be readily applied to any unit to provide for this type of control.

  • Page 126: Repair Or Replacement Of Tubes

    SECTION VI - SERVICE AND MAINTENANCE On straight expanding, it is advisable to use two expanders, letting one of them cool while the other is in use. The tubes in the bottom of a firetube boiler should be expanded first. 4.

  • Page 127: Corrosion

    SECTION VI - SERVICE AND MAINTENANCE IMPORTANT It is never recommended that the repairs be made to tubes and tube sheets through welding. Repair or replacement of boiler tubes is sometimes necessary due to scale, shock, corrosion, or pitting. 1. "T "...
  • Page 128 SECTION VI - SERVICE AND MAINTENANCE 2. F Corrosion on the fire side of boiler tubes is caused by ORROSION moisture condensing from the atmosphere during periods of shut-down or from flue gases during operation. This type of corrosion is especially troublesome in boiler installations near bodies of water or where the atmosphere is humid and is accelerated by the use of high-sulfur fuels.

  • Page 129: General Rules For Avoiding Corrosion

    SECTION VI - SERVICE AND MAINTENANCE demonstrated by filling a clear bottle with cold tap water and allowing it to stand for a few days. The bubbles may then be seen on the sides of the bottle. In some cases, the pits occur in a straight line. Straight line pitting is almost always located along the top of the boiler tube.

  • Page 130: Scale Formation

    SECTION VI - SERVICE AND MAINTENANCE There are eight general rules to help boiler operators avoid serious tube corrosion problems and obtain longer tube life with fewer unscheduled shutdowns and more economical maintenance. 1. Keep all boiler fittings and piping tight to keep air out as much as possible. 2.
  • Page 131 SECTION VI - SERVICE AND MAINTENANCE 1. Scale is a very efficient "non-conductor" of heat. The degree of non-conduction varies with its density. Its presence in appreciable thickness means less heat absorption by the boiler water, with consequent loss of boiler efficiency. 2.

  • Page 132: Bagging

    No representative of York-Shipley Global is permitted to administer, recommend, or in any way become involved with treatment of boiler water for any York-Shipley Global product. IMPORTANT No materials for the prevention of scale, priming corrosion, etc., should be employed unless the...

  • Page 133: Foaming

    SECTION VI - SERVICE AND MAINTENANCE If precautions are taken to make frequent examinations of the boiler heating surfaces, it is possible to eliminate scale by one of the methods outlined. Many modern plants are operating continuously at very high ratings without any difficulty in this respect. By combining a careful plan of pre-treatment in addition to internal treatment, boring of the tubes can be eliminated.

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