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,OPERATING&MAINTENANCE
INSTRUCTIONS

MARINE AUXILIARY BOILER .

GK SERIES

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QS90-040S-03
 MARINE AUXILIARY BOILER

GK SERIES

MANU AL

Introduction

Thank you very much for selecting the Z-Boiler.

This manual gives you instructions on how to use the Z-Boiler. In using the boiler, make sure you
choose a person in charge of handling the boiler (Engineer) and use the boiler after perusing the
manual and understanding the contents. In addition, we recommend that you always have this
manual at hand when you work.
The main contents of this manual are: Outline of GK series Z-Boiler, main functions, descriptions of
the control system, operating procedure and maintenance. Precautions relating to operating
method and safety indicated in this manual from damages to measures only relate to usage for
specified purposes.
Do not use the boiler by methods that are not mentioned in this manual. Please be aware that we
cannot be held responsible if the boiler is used by methods not mentioned in this manual.
As a result of tireless research for improvement involving the design of the Z-Boiler, there are
details that do not correspond to the product you have purchased. Please note that the contents of
the manual may change without notice.
If you have any inquiries concerning the product you have purchased or about the contents on this
manual, please do not hesitate to contact us.
 Z BUILcH

CONTENTS

it 1. Terms ..........................................................,................... .............................. "'5

~ 2. Warning Label ........, .. , ................................, ........... , .. , ... ................................. "'6

~ 3. Basic Precautions .,...••.•.••••...• '" ................................. .. ..................................... '''7

4. Boiler External View'" ................................, ... ...... .. ........................................ ... "'8

5. Internal Structure .............. ~ ............................" .......................................... ~ ..... "'9

6. Structure, Part Name, Inspection and Adjustment of each Device ........................ .. .... '''10

6-1 Fuel Oil Piping .............. ....................... ....... .... ........... ........................................ " '10

6-2 Burner Assembly .......... ............................... .......... ........... "' .... ··· .. ·· .. •· .. ··· .. ·· .... ·· .. ···11

6-3 Damper (Fully Open - Fully Close) .... · .... · .. · .... · .. .. .... ·· ...... ·· .................... _.. · .. .. · .... · ........ 12

6-4 Combustion Control Damper ........... ................ .......... ................ ........ ·· .. · .. ·· .. · .. .. ····· .. ·12

6-5 Timing Switch for the Damper (High-Low Type) ·.. · .. ·...... ·· ·· .. · .... · .. ·...... ·.... ·· ............ .... · .. 13

6-6 Blower·· .. ····· .. ·· ····· .... ··· .... ·················· ·.. ··· .. ·· ··· .. ······· .. ·· .. ·· .. ···· .. · .. ·· .. ····· .. ···· .. .. ·.. · .. '13

6-7 Burner Nozzle ...... ... .... .. .................... ...... . ..................................... ... ..... · .... ··.. .. .. .. 14

6-8 Nozzle Tip ..... ....... ............... ....................... ......................................................... '15

6-9 Solenoid Valve ........................................... .. ....... ..................................... ... .... ..... ·16

(1) Solenoid Valve for Pilot Burner .......... · .... ·................ · .. ·· .... · .... ·.......... · .. ··· .. .... · .... ·16

(2) Solenoid Valve for Main Burner ............................................................. · .. · .. · .. .. ···17

(3) Solenoid Valve Unit ... ...... .................................... ................................... ....... ' '' 18

6-10 Fuel Oil Pump ...... .......................................................................................... · .. · .. 19

6-11 Flow Control Valve .... .. .... .. · .... .. .... .. ...... ·............ ·.................... ................ ..... .... .... "22

6-12 Ignition Transformer ...... .. ............................................................•.. ···· .. ···· .... · .. · .. ··23

6-13 Flame Eye .... .. ... ......... .. ................................................................................... "24

6-14 Fuel Oil Heater .. ....................................... .. ....................................................... '25

6-15 Fuel Oil Temperature Controller " ....................... ............. ·.. · .... · ............ ·..........; .... · .. 26

6-16 Thermostat (For fuel oil) ..................................................;.......,.................. .. ....... ·27

6-17 Temprature for Heating Heavy Oil ........................................................................ ·· .. 29

2
 6, 18 Feed Water Pump (Miura Water Pump) · ............ · .. · ...... ·.............. ·· .... . .·, .... · ...... · .. · .... · .. 30

6-19 Water level gauge and Water level control cylinder ...... ·...... ·· ...... , .... ·........ · .. , · .. ·, ······ .... 31

6-20 Exhaust gas thermostat .. ·........ · .. · .. · .. ·.. · .. · .. · .. · .. · .. ·.......... ·· .............. · .... ·· .. · .. · .. · ...... ·"33

'7
6-21 Pressure Switch (For Steam and Fuel Oil) ............................................................ · .... ·34

'8
6-22 Pressure Switch Adjustment ................................................................................... ,35

"9
(1) SNS Type ...................................................................................................."35

10
(2) RT Type .................................................................. ~ ...................... · .. · .. · .... · .... 36

10
6-23 Safety Valve ........................... .......... ................................................................ ,37

11
6-24 Fuel Oil Strainer (Fuel System) .. ..... .... ....... .. ........................................................· .. 40

'12
6-25 Y Shaped Strainer ....................... .... ..............................., .................................... ,42

'12
6-26 Feed Water Check Valve .................. .... ................................................................'42

' 13
6-27 Sequencer (Programmable Controller) ... .. ........................... ...... ............................ '''43

,13
(1) Outline of The Sequencer .... ........... .................... .. ....... ......... ........................... '43

' 14
(2) CQM1 H Unit Explanation .. .. ......... ....................... .. .......................................... '43

" 15
(3) Display Function ................. ...... ..................................................................... '47

.. 16
(4) Errors and Their Measures ........ · .. · .... · .. · .......... ·.............. ·............ · .. · .... ·.......... · .. ·48

" 16
6-28 Flame Detector (FS-100) ....................................... .. ............................................. '49

" 17
6-29 Water Level Detector (L'M1-200) .. · .. ·· .......... ·........ · .. · .. · .. ·........ · .. · .. •.. · .... · ...... · .... ·· .. · .. ·50

''' 18
6-30 High Pressure Air Soot Blower .. ·...... · .. ·.............. .. ........ · .... · .... · ...... · .... · .... ·.......... · .... ·51

" 19
6-31 Soot Cleaning in the Exhaust Gas Side while the ship is in Port .......... ~ .........................53

·..22
6-32 Washing whi,le in Dock ....................................................................... .. .............. '''54

", 23
6-33 Excess Steam Dump Valve ........ · .. ·.. · ...... ·...... · .. ·· .......... · .. ·· .. · .. ·........ · .. · .. · .... · ...... · .. ·55

" '24

' '' 25
'111 7. Automatic Operation of the Boiler by the Sequencer ............................................. "'56

7-1 Summary .................. ...................... .................. · .. ······· ············· .. ···· .. ···················56

.... 26
7-2 Basic Time Chart ............................................................................................·.. ·.. ·56

.... 27
7-3 Flowcharts ................................ .......... ................ ...... . ················ .. ············ .. · ...... ·· ..58

.... 29

3
 Z BOILER

8. Safety Devices .. · .. · .. · ....................................................................................... "'61

9. Inspection Before Operation and Operation ...................... .............. .. ................. ·....62

9-1 Inspection of Every Check Points Before Operation ·· .. ··· ...... · .......... · .. ···· .......... ·........ .. ··62

9-2 Operation (In Case of Automatic Burner Operation) ... ........ ·· .. · ........................ · ...... ...... ·63

9-3 Manual Combustion by CAM Switch· ·· .. ·········· .. · .............................. .......................... '65

10. Regular Maintenance ............................................. ......... .. .... ... ......... .. . ... ......... "'66

10-1 Regular Maintenance ..................... ........... ............. ........................ ...... .. .......... ..... '66

10-2 Inspection and Precautions Before Starting Operation ...... .. ..................................... .. '68

10-3 Inspection and Precautions During Operation · .. .. ·· ~ ...... ··· ...... .. ...... ·.. ·...... •·· .... ·· .. ·····• .. 68

10-4 Inspection After Operation ........ .. ..... ............. ... ............ .. .. ....... .... .... ...... ...... ........ "68

10-5 Handling Water in Storage Water Heating ..... ........................................................ "68

10-6 Long-term Shut-down .... ..... .. ......... .............. ............... ...................... .... ............ .. '68

11. Trouble Shooting .................. ..... . ... ..................... ......... ...... ... ~ ....................... '''69

11-1 Feed Water System ...... .. ................ ~ ..... ...... .. .................. ...... ........... ····· .... · .. ···· .... 69

11-2 Fuel System············· ·· .. ···· .. · .. · .. ·· ····· ··· .. ·· ···· .. .. ······ .. ··· .. ···· .. · .. · .. ··········· .. · .... · .. ·· .. ·· ··70

11-3 Combustion ................... ....... · .... ···· · .. ...... ·· .. · .... ···· .... · .. ·· .. ·.......... · .. ·· .......... · .. ··· .. · .. 71,

11-4 Safety Control and Alarm Circuit .... ..... ................. .. .... .................... · .. · .. · .... ·· ...... .. .. · .. 72

11-5 Exhaust Control and Lines (Main Engine, Burner) ·· .. ·· .. · ...... .. .... ,·, .. ·· ........ •.. · .. .. .... ···· .. 72

12. Remedy against Water Tube trouble ... ......... ...................................................... "'73

12-1 Water Tube Leakage ....... ...... ... ........ ...... .. ........ ...... .......... ..... ··········· .. ···· .. ·········· .. ·73

12-2 Repair for Water Tube Trouble· ·· .. .. ·...... ·...... .. · .. · .. ·· .... .. · .. ·· .. ·...... · .... ·.......... ·· ............ 74

 1. Terms

The following terms are used in this manual for your safe and effective operation.

'61

'62

'62 ~ Warning
'63 1. Indicates a condition or practice which may cause death
or serious injury to the operator.
'65

'66

'66

~
'68

'68
Caution I.
2. Indicates a condition or practice which may result in
'68
damage or destruction of property and/or minor personal
'68 injury.

'68

" 69

" 69 Note
" 70
3. Indicates cautions for preventive the failure of the devices,
'71 and points for effective operation.

" 72

" 72

" 73

..73

" 74
cr

4. Number in the pointing hand sign indicates the page for

related items .
 L. U\JIL-L..I I

2. Warning Label

& Warning
The body of the Z-Boiler GK series and its ancillary equipment have parts with the fo llowing warning
label attached.

2-1. Scald Warning Label

Attached near parts with hazard of scalding or hot parts (Parts with suriace temperature of over 60°C).

2-2. Entrainment Warning Label

Attached on rotating parts with gaps in the structure that could catch fi ngers (Fingers might get
trapped).

2-3. Electrocution Warning Label

Attached on electric parts or around the parts that cannot be disconnected (Or covered) completely.

2-4. Trap Warning Label

Synonymous with the entrainment label, it is attached on moving parts.

2-5. Damage Warning Label

Attached on the water gage as there is a possibility of damage by aged deterioration when it is used
for long periods.

6
 3. Basic Precautions

& Warning
When operating the GK series Z-Boiler, please comply strictly with all precautions relating with safety

'9
indicated in this manual. There is a danger of serious physical injury if the precautions are not observed.

3-1. Carry Out a Check Before Using The Device

Check the pipe system diagram of the completion drawing and the system of the vessel. Do not operate the

device with the wrong system as this could lead to serious accidents.

Moreover, refer to the completion drawing for specifications.

When handling the device, be sure to choose a person in charge of handling. The person in charge should

not operate or carry out maintenance of the device until they have perused the precautions relating to safety

indicated in the manual and have a sufficient understanding of the precautions.

get 3-2. Wear Proper Outfit and Protection Gears

The device should not be operated or serviced wearing baggy clothes and accessories as they could catch

on the valve or machinery parts. Do not wear oil stained clothes as they could catch fire.

Do not forget to wear a helmet, protection eyewear, safety shoes and gloves when working on the device.

Protection gears must be wom as there is a particular danger of scalding near hot parts. Moreover, protection

eyewear and gloves must be worn as chemicals could splatter on hands and eyes while injecting chemicals.

3-3. Do not Remodel The Device, Use The Genuine Products for The Parts.
Do not remodel the device without our approval. We may not be able to permit such remodeling by regulations.
Moreover, such remodeling could compromise safety. Use the manufacturer's genuine products for parts.
3-4. Use The Designated Fuel
Do not use fuels other than those designated. There would be a danger of the device exploding if other fuels are used.
Jsed
3-5. Do not Keep Flammable Goods Near The Boiler
Do not keep flammable goods near the boiler. There would be danger of fire.

It is highly dangerous as there would be a danger of fire if flame were brought near the boiler fuel.

Store flammable goods in a safe place away from flames, check where the fire extinguisher is kept, and learn

how to use it in case of emergency.

Dispose of cloths stained with fuel or oil. Such cloths could ignite spontaneously if kept in a wrong way.

Wipe up spilt fuel and oil immediately.

3-6. Keeping a Fire Extinguisher and First-aid Kit

Keep a fire extinguisher in preparation for fire and learn how to use it.

Establish where to keep the first-aid kit.

Establish the contact numbers in case of fire or accident and how to handle such emergencies.

3-7. Advice on Moving The BoHer or Selling The Vessel

A correct installation and incidental work are required in operating the boiler. Please be sure to contact our

company when moving the boiler or selling the vessel.

Do not carry out incorrect installation or incidental work as there is a danger of such work leading to physical injury.

& Warning
Always disconnect all electrical power at the main circuit breaker, close the main and pilot manual shut off
valves before performing adjustments and/or maintenance. Failure to do so could cause electrical shock
explosion, fires and/or burners which will result in serious personal injury and/or death . All adjustments and/or
maintenance must be performed by qualified and experienced personnel only.

7
 L- LJ~'L..'-' I

4. Boiler External View

12) 1)

h>

13)

7)

4)

5)

I
1 Hand Rail 8 Rolling Stay 1

2 Steam Pressure Switch 9 Water Level Controller Cylinder

3 Steam Pressure Gauge 10 Water Level Gauge
4 Soot Blower Inlet 11 Bottom Blow Off Valve
5 Hand Hole 12 Fuel Oil Heater
6 Funnel Base of M/E Inlet 13 Boiler Water Sampling Valve
7 Funnel Base of M/E Outlet 14 Burner Exhaust Gas Outlet
- - -

_8
· 5. Internal Structure

~ Wa rning
Before inspecting the interior of the unit, tum it off, purge with the bottom blow-off valve and ventilator, and cool both
the inside of the drum and the combustion chamber. Then make sure that the pressure inside the drum is 0 MPa.
Also, when conducting the inspection, make sure ventilation is provided by the air duct and/or the ventilator fan.

9) The boiler consists of the doughnut shaped steam

drum 1) and water drum 2) which are connected by
multip'le water tubes 4). Water tubes with swagged
ends are arranged as shown.
Fuel oil pressurized by the fuel pump is heated to
the specified temperature by the oil heater and is
atomized from the burner 9). It is mixed with air
from the forced draft fan and ignited by the ignition
transformer to form a suitable flame in the furnace.
The flame transfers heat to water in inside water tubes
by radiation. It becomes the combustion gas and is
branched into two rows of water lubes and meets at
the exit and is discharged from the funnel 6). Contact
heat transfer is made when water passes in water
tubes and heat is transferred to water efficiently.
Particulary.
The main engine exhaust gas side is provided with a
group of water tubes reasonably arranged circumfer­
entially on upper and lower drums to transfer heat
efficiently.
The exhaust gas inflowed through the flue is separat­
ed in two directions of left-hand and right-hand to
effect heat exchange and discharged through the
outlet funnel as low temperature exhaust gas.lnner
and outer casings are arailable. Heat insulating mate­
rial 7) is placed between inner and outer casings to
restrict radiation of heat.
The lower part of the furnace and the swaged part of
the water tube are insulated by refractory and short
6) pass of gas is also prevented.
12) At the upper and lower drums, there are manholes
which allow you to check the interior. Check the state
• 1 Steam Drum 7 Insulation of deposits (scaling), corrosion, pitching, and reflect the
2 Water Drum 8 Soot Blower results in processing boiler water. (For more details,
I-­
3 Manhole 9 Burner please refer to the separate manual for water treat­

4 Water Tube 10 Fixed Plate ment). When you check the inside of the fumace, look
for deposits of soot, peeling of refractory, fuel leakage
l5 Refractory 11 Manhole
on the fumace bottom, traces of water leakage, accu­
I 6 Funnel (Burner) 12 Handhole
mulations of unburnable materials, and so on.

9
 Z BOILER

6. Structure, Part Name, Inspection and Adjustment of each Device

6-1 Fuel Oil Piping (Please Refer to The Final Drawing, If The Device is Specially 'Made_)

M-1 Auto-strainer for main line

M-2 Fuel 011 pump for main line
M-3 Fuel pump motor for main line
M-4 V-shaped Strainer
M-5 Auto-strainer for pilot line
M-6 Fuel oil pump for pilot line ,
M-7 Fuel pump motor for pilot line
FCV Fuel 011 control valve
TC-1 Thermocouple for adjustment
c - -­
T8-1 "'1I'lITTlOS1at for low oil temperature
T5-2 ~'TTlOStat for high oil temperature
T5-3 Thermostat for protecting heater
ElLRNER F_ 0, !-EATER
5'1-1 I Scle-OOld valve for low combustion
SV-2 '1 SryIenoid valve for high combustion
OIL PLA1E
8',·3 SolenOId shut-off valve I

l S'y -~ r Sotenoid valve for pilot line

1 T VALVE

LiNE

M-3

FUEL OIL PUMP UNIT

~

I>() Glove valve hy1 Y -shaped strainer

[0J Ball valve Kl)i Strainer
t:*:J Needle valve ~ Thermostat
----()~-
Cock ~ Pressure switch
I Flange joint (£) Pressure gauge
~ Screw-down slop check valve qp Thermocouple

U Pump ----l: I---­ Orifice

!1 Safety valve --JUl- Copper pipe (tl>10)

~ Solenoid valve t*J Relief valve

-JV'­ Flexible tube
-­
--cFt:P- Teflon lined flexible tube

10
<How to Operate>
1. All of the solenoid valves (SV-1 to SV-4) should be closed when operation is stopped. The shut-off valve (SV-3)
will open when operation starts and the main fuel pump motor is running. Pressurized fuel will enter the burner
nozzle pipe from the heater, SV-3, flow control valve (FCV) and circulator opening and will be heated to the end
of the pipe, then it will return to the air separator to begin the cycle again.

2. When the main fuel oil is heated and pre-purge is undertaken, the pilot fuel pump and the ignition transformer
will engage, the shut-off valve for the pilot (SV-4) will open and the pilot flame will ignite.

3. When the fl'ame eye sense the pilot flame, the solenoid valve of the main bumer will open and a flame will be
ignited, then the pilot valve will close and the pilot flame will go out to keep combustion by the main burner. (In
three-step control, the valve for HIGH combustion will open and start high combustion .

4. Even during combustion, the pressurized fuel will continue circulation through the flow control valve (FCV) to
maintain steady temperature and pressure of the fuel oil.

6-2 Burner Assembly

~ Warning
Before opening the burner and making the inspection, you must first use the fan to make a purge, and
be sure the furnace chamber is sufficiently cooled and ventilated . Turn off the F.O. pump, F.O. booster
pumps, and close the main F.O. valve and pilot F.O. valve. If fuel oil is leaking from the flexible tube,
burner, or elsewhere, wipe it up immediately and dispose it properly.

5) 2) 1)
6)

10)

9)
/ -r+Y
8) 7) 4) 3)
11 k / I I I 12)
1 Fan 9 Flow Control Valve

13) " / 14)

2 Fan Motor 10 Wind Box
IlillV
15)
3 Damper Unit High-Low 11 Nozzle Pipe
4 Damper Unit Fully Open-Close 12 Ignition Rod
16)

5 Iginition Transformer 13 Air Register

6 Flame Eye 14 Burner Insulation Plate
7 Peep Hole 15 Shroud
8 Solenoid Valve Unit 16 Baffle Plate

11
 L J:jUILcH

6-3 Damper (Fully Open - Fully Close)

Series GK units come with a completely open-- fully

close damper on the outlet side of the FD fan. When
the FD fan is running, it will be completely open; at all
other times, it will be completely closed .
The damper is opened and closed by the motor forward
or backward. Electricity usually flows through the
damper motor, which is held to the damper plate by a
strong torque. The damper motor is connected to the
damper shaft by a coupling and a lever.
Make periodic inspections to check for looseness in the
coupling set screw, etc., and to make sure there is no
rattling. The coupling rubber and the damper packing
can become worn and deteriorate, so please replace
them whenever necessary.

6-4 Combustion Control Damper

Normal air flow adjustment bolt The unit comes equipped with a combustion control
(High combustion) damper to adjust the air volume for proper combustion.
If there is ON-OFF control, there will be a fixed-in-place

j damper at the forced draft fan inlet.

If there is 3-step control, it will be at the inleVoutlet of
the burner, and the aperture will automatically be
changed at the damper motor.
As with the fully open-- fully close damper, make periodic
inspections of the set screw and coupling, and replace
when necessary.
Ignition/air flow adjustment bolt

(Pilot, low combustion)

.Adjusting the damper position

You can adjust the air flow using the damper motor-type control chamber (see photo above) installed on the

outlet side of the FD fan . The position during ignition and low combustion win be the same.

These apertures are set by the ignition/air flow adjustment bolt shown in the photo above. The high combustion

position is set using the normal air flow adjustment bolt in the photo.

Tum the adjustment bolt toward the OPEN arrow to open the damper; tu rn it toward CLOSE to close the

damper. After you have made the adjustments, tighten the lock nut securely so that it will not become loose.

*With ON-OFF control, the damper is set up so that it slides toward the FD fan inlet. Please adjust the air flow
while the main bumer is burning fuel.
*If you cannot change combustion conditions no matter how rnany times you adjust the damper, the problem
probably lies with some other cause and not with the damper.lf this is the case , you will need to check for other
problems, like improper burner adjustment, change in oil pressure, too much soot in the combustion chamber,
and clogging of the FD fan intake.

12

 6-5 Timingl Switch for The Damper (High-Low Type)

The Timing Switch for the Damper corrects the disparity
Iy of the operation timing of the Damper and the fuel
en 2) ~I• i i '~
I
1 Solenoid Valve during the switch over of the low fire and
all high fire .
3) In other words, the momentaneous lack of air flow by the
4) delay of the Damper function during the transition from low
fire to high fire, and the excessive air flow by the same
o 1)
o
o delay of the Damper function during the transition from high
fire to low fire are resolved by adjusting the operation timing
of the Fuel Solenoid Valve using the timi'ng switch.

< Adjustment>
Rotate the damper to mid-degree between low and high
combustion, after its opening range is decided.

o o o
T hen, adjust it by sliding the cam, after loosening the
locking screw for the cam, so that the switch roller is turned
to the cam to switch ON. (the high fire solenoid valve is
open at this point). Make sure it clicks when the roller is on
the cam; sometimes the switch cannot be turned on, due to
1 Timing Switch
the lack of stroke.
2 Cam
If it does not click, loosen the screw on the switch
3 Cam Adjusting Shaft
attachment and re-fix it after moving the whole the
4 Lock Bolt switch unit toward the cam.

6-6 Blower

Note
Check the blower regularly.

The Blower that forced air into the burner ensures velocity, pressure and airflow by rotating the impeller by a

motor. In addition, as the GK series allows for greater flue gas velocity to improve the heat exchange wiht the flue

gas, a high speed blower with high static pressure is used.

Attention and care are required to prevent foreign particles clogging the wire mesh of the suction opening.

~ Regular Maintenance

If there is major vibration even after the impeller has been cleaned, you will need to either replace the bearings or
balance the impeller.
• Inspections
Check for vibrations, strange noises, and abnormal bearing temperature during operation. When not in
operation,turn off the power, then move the impeller by hand to check for abnormalities.
• Insulation test
You should conduct an insulation test either once every three months, after the unit is being restarted after a
long period of being idle, or when otherwise necessary. If the value does not exceed 3M Q, you should either
replace the motor, or fix it once the ship has docked in port.
• Replacement of bearings

The bearings for the fan motor have shield type bearings. Replace the bearings once every two years.

13
 ILt::.H

6-7 Burner Nozzle

~
9) I..J
I F .~ High- Law Type 1 Upper Plate
co 2 L ead Rod

~~t
3 Ignition Rod
4 Nozzle Pipe
6)
I~ /?
High-Low Type 5 Baffle Plate
6 Nozzle Tip (Pilot)
3)

l
2)
7 Nozzle Tip (Low)
1(' L

i·:
8 Nozzle Tip (High)

~
IH 9 Shroud

~+
P Plio! '­
L : Low Fire
- ~ co
H
CI
CO
:
:
:
High Fire
Circulation In
Circulation Out
,p
ON-OFF Type -­Ii 2

Type of Evaporation Measure of Burner Nozzle I Type of Evaporation Measure of Burner Nozzle
Boiler of Burner L F .
I
I,
Boiler of Burner L F
400kg/h 803 25 GK-20XX 1000kg/h 997 60
GK-22XX
500kg/h 823 45 I

GK-14XX GK-24XX
600kg/h 819 70 GK-27XX 1200kg/h 997 70 'i
I

700kg/h 824 75 GK-22XX 1300kg/h 972 45

GK-24XX
400kg/h 811 25 GK-27XX 1500kg/h 982 55

, 500kg/h 831 45
I

GK-16XX 600kg/h 827 70

700kg/h 832 75
800kg/h 813 56

The burner nozzle part is a device that burns fuel while igniting and keeping the flame effectively by
atomizing the supplied fuel, and is an important part that determines the combustion.
The fuel sent in by the fuel pump is sprayed from the nozzle tip via the Fue'l Heater, Solenoid Valve and Burner
Nozzle Pipe, atomizes and expands the contact area with air, ignites and makes flame by the spark from the tip of
the Spark Rod. •
The spark disappears a few seconds after igniti,on and the flame is kept by pulling back the flame in front of
the nozzle tip by the reverse-flow region of air that is produced at the back of the Baffle Plate.
When the butterfly bolts for fixating the burner on the top part of the window box are removed and the plug caps on the
Spark Rod, fuel joint pipes are removed, the burner nozzle part can be pulled out as shown in the diagram above.
The pulled out burner nozzle can be disassembled further into Nozzle Pipe, Nozzle Tip, Spark Rod and Baffle
Plate. The parts should be washed with light oil and cleaned with air for assembly. It is advisable to adjust the
relative distance of the Nozzle Tip, Baffie Plate and Spark Rod based on the value in the paragraph.
The fuel, air and respective conditions may differ depending on the boiler. As such, if the best fired condition
cannot be obtained, make adjustments so that a good fired condition can be obtained by adjusting the
measurement of each part.

14
Take care as although hexagon head bolts are fixed tightly in assembly, fixing the bolt too tightly on the
Spark Rod coul d split or crack the insulator, causing the ignition to fail.

Note
Do not screw too tightly when assembling the Spark Rod and Lead Rod.

& Warning
The combustion chamber should be cooled off and purged by the blower before remove and inspection the
burner. Wipe away the spilt fuel oil from burner nozzle and flexible tubes immediately and handle it properly.

6-8 Nozzle Tip

(for pilot)

(for main)

Cut Off Valve

Body Screw Pin Filter

The oil coming into the nozzle passes through the cut off valve for prevention of oil leakage and enters the
Spinning Chamber via a thin channel of the Distributor. This Spinning Chamber is conical and the tip has
an orifice. The oil increases its ve locity while it swirls inside the Spinning Chamber, passes through the ori­
fice and sprayed to the Combustion Chamber. As the machine work of the nozzle is very precisely, care
must be exercised in handling the nozzle. In addition, a hard material is used for the nozzle as oil always
frictions the orifice and other parts at a very high pressure and speed, it should be exchanged every year.
The size by the model differs slightly. Please check the notes on the final drawing .

• There is a cut-oft valve attached to the nozzle tip. When replacing the nozzle tip, please remove the filter
and attach the cut-off valve .
• When removing and fitting the nozzle tip use the special box wrench which is provided as special tool.

& Warning
Improper spray volume, spray angle, and/or spray pattern can lead to poor combustion, which may some­
times cause backfiring that can damage the unit. Please use only genuine parts.

& Caution
The cut off valves with the nets cannot be used for C. F. Oil. Replace the valves after checking the nozzle
standards.

15
6-9 Solenoid Valve

The Solenoid Valve opens and closes by the electric activation and no ral t he supply of
fuel oil to the burner nozzle.
Take care in handing the Solenoid Valve as its style and valve opening aCli!J g on the model.

& Warnin g
To prevent the possibility of personal injury or property damage c....e proper operation
before returning to service. Also perform internal seat and extern allea~.acE 0_

Note
Clean and inspect the Solenoid Valve regularly. When replacin g the valVe cne e IIOW direction.

In either of the Solenoid Valves, ignition may fail when there is foreign oa~:ces on the seat as the oil
pressure will not rise due to oil leakage. Moreover, as obstruction may cause all leakage inside the
combustion chamber, which could develop into ignition failure and other prob(ems related to combustion,
please carry out a regular inspection. Take care in disassembling the de .. :ee. as internal parts, valve seat
and springs can easily be lost.

1. Solenoid Valve for Pilot Burner

This solenoid valve is used iln the pHot system and its capacity is relatively sma ll.l! opens when activated
and two valves are used for the pilot burner. During pre-purg e, the solenoid valve is closed, and fuel
circulates in the fuel pump. And oil pressure keep rises. When pre-purge is completed, the solenoid valves
is activated and opens, and combustion is started.

1) 2) 3) 4) 1 External Cabinet Stop Bolt

I
2 Attractor
6) 3 Top Plate
4 Coil
5) 7)
5 Label
8) 6 Plunger Spring
7 External Cabinet
9)
8 Plunger Tube
9 Pl1unger
~10)
10 Bottom Plate
17) ~~i~
____ I ,
11 )
11 Coil Packing
16) 12 Cover Plate
13 o Ring
14 Stopper
. 14) 15 Body

~ \
Direction 01 the I~ 15)
16
17
Spacer
Valve

16

 2. Solenoid Valve for Main Burner

The main burner of Series GK uses a valve that opens when an electrical current passes through it.

10)
1 Valve Case
2 Spring
3 Valve Fitting
4 Piston Rod
5 Body
6 Case Set Nut
7 Spring
8 Plunger .
:e oil 5) 9 Suction Body
the 1) 10 Coil
,tion,
---2)
seat

Ives

17
 L f:jUILI::H

3. Solenoid Valve Unit

(p)

i
ON-OFF Control

To Burner Nozzle Port Pilot F.O. O utlet

(H )
!r.
To Burner Nozzle Port
(en
1)

Pressure Gauge 3/8X75X3.5MPa

~I lu II u--JO

6)
Pilot F.O. Inlet

Main F.O. Inlet 2)

Three Position Step Control I 1)

Pilot F.O. Inlet ­ -­ - -- ­. Pilot F.O. Outlet (p )

Main F.O. Inlet ­ - - (H)

--~,- To Burner Nozzle Port (L)

1 Pilot Solenoid Valve

4) Fuel Oil Flow Control Valve
2
3 Pressure Gauge
From Burner 4 Low Combustion Solenoid Valve
Nozzle Port (CO)
5 High Combustion Solenoid Valve
6 Solenoid Valve Shut Off

18

6-10 Fuel Oil Pump

Note
Please try not to disassemble major components such as the rotor when making repairs. The manufacturer
will not be liable for problems arising from a disassembled pump.

Three types of the fuel pump are used in models of GK type boiler. The pump is connected to the motor by
coupling and is operated at about 3500 r.p.m to send fuel to the nozzle though the solenoid valve.

~~-

) o
The fuel pump is of the trochoid system as shown above and generates high pressure by revolution of
inner and outer rotors . The rotor has the prof.ile shown above and inner and outer rotor~ rotate in light
contact with each other and tooth surface slippage is quite limited . Noises and wear are hardly caused
because no oil containment.

1. GFS Type (Used for the Pilot)

< Adjustment> Discharge Opening PT1/8

Pressure is adjusted by the "Pressure
Regulating Screw". Loosen the lock nut and
turned clockwise with a hexagon wrench, the
pressure rises and the pressure drops when it
. - ­ Return
is turned counterclockwise, allowing for easy Opening
adjustment of pressure within a 0.6-1.2MPa PT1/4
range.
Standard, set pressure 0.8MPa.

< Inspections and Maintenance>

Please check every day to make sure that
there are no leaks from the cover, oil seals,
and other parts. There is a strainer inside,
which should be cleaned once a month. Pressure
Regulating
Screw

19
 L J:jUILI=H

2. GFH Type (Used for The Main Burner)

--­
ucllOn port
PT1 4

Use the pressure adjusting screw to adjust pressure. Put 5 mm All wrench in the pressure adjusting screw and turn it to

adjust pressure in the range from 10 to 25 kglcm2. Tum it clockwise to increase pressure and counterclockwise to

decrease pressure. Do not turn it excessively to prevent a trouble. Do not tum it beyond the limit

< Inspections and Maintenance>

Check every day to make sure that there are no leaks from the cover, oil seals. and other parts. There is no

strainer inside. In case of breakdown , do not disassemble the unit, but have it repaired when you reach port.

3. GO Type (Used for The Main Burner)

/ Return Opening

/ Pressure Regulating Valve

Suction Opening .....1 - - - ... Vent

< How to Adjust>

Use the pressure adjustment valve to adjust the pressure. Turning it to the right will increase pressure,

turning it to the left will decrease pressure. Make periodic adjustments of the pressure following the

instructions given in 6-7-(4) .

< Inspections and Maintenance>

Check every day to make sure that there are no leaks from the cover, oil seals, and other parts. There is no

strainer inside . In case of breakdown , do not disassemble the unit, but have it repaired when you reach port.

20

 -.-J

4. Setting The Pressure Range of The Fuel Pump

& Warning
Periodically (once a month), set the pressure of the fuel pump. If you don't set this pressure, then you will not be able to
accurately adjust the rate of combustion of the CS burner. Adjustments can be made with heavy oil A, but if you switch over to
heavy oil C, then you will have to redo your adjustments. Set the safety valve pressure of the FO heater to less than 2.3 MPa.

FUEL OIL PUMP UNIT

~FOP
2)

Return--~

to 3)
Oil Air Separator

FO IN " WiPlTI I f ,I,

\ I

1. Operate the fuel oil pump running (manual combustion). Stop the combustion.
2. Close fuel pipe return valve 1). The pressure rises in Pressure gauge 2).
3. Turn the pressure adjust screw of F.O. pump and adjust the pressure in Pressure gauge 2) to 2.1 ~2.2MPa.
(Refer to the boiler instruction manual "Fuel Pump" section in adjusting the pressure of F.O. Pump.) ,
4. Open fuel pipe return valve 1). The pressure falls down in Pressure gauge 2) and this is normal.
5. Check if the fuel oil is circulating. (Close fuel pipe return valve 1) and Open drain valve 2) and check the
fuel oil go out.)
6. Carry out combustion rate adjustment of CS burner following the instruction for CS burner.

& Caution
You should make this adjustment when you replace the oil pump. Make adjustments with the flow control
valve after you have yompleted adjusting the pressure of the fuel pump. Over tirne, the oil pump will
deteriorate and its performance will gradually decline.

21
 Z BOILER

6-11 Flow Control Valve

The fuel oil is pressurized by the fuel pump and heated by the heater. The flow control valve in the solenoid valve

unit keeps the fuel oil at a constant pressure. Some of the fuel oil is cycled through during combustion. The burner

nozzle and the retum pipe are heated and kept at a constant temperature. The flow control valve is plays an

important role in combustion and maintaining the temperature of the combustion equipment, so it should be

periodically inspected and the pressure adjusted when necessary.

< How to Inspect The Flow Control Valve>

During its test run at the factory, the flow control valve was set at 1.8MPa (specification for heavy oil A is 1.5MPa) .

. _.-.-:'
Please make sure that the fuel oil pressure gauge in the fuel pump unit shows a reading of at least 1.8MPa, and that the

fuel pressure gauge next to the flow control valve shows 1.8MPa (1.5MPa is the specification for heavy oil A).

< How to Adjust The Flow Control Valve >

Before starting this procedure, please adjust the pressure, follOwing the instructions in 6-10-Ai4). Please switch over to

heavy oil A, and lower the temperature of the fuel oil.

Remove the adjustment screw cover and loosen the lock nut. While manually operating the fuel pump, make your

adjustments as you check the fuel pressure gauge on the side of the flow control valve.

1. Remove the adjust screw cover at the top of the

Burner Specification Pressure
flow control valve when the specified pressure is
Diesel Oil Only 1.5MPa (15kgf/cm 2 )
different from the standard et pressure.
2. Unscrew lock nut Heavy Oil 1: 8MPa (18kgf/cm2)
3. Adjust the pressure to the standard set pressure
by turning adjust screw. t To pump suction side
Turn clockwise the screw to increase pressure r-----,

and combustion flow.

Turn counterclockwise the screw to decrease
pressure and combustion flow.
4. Make sure again that pressure is the standard
set pressure, and tighten the lock nut. Pressurized fuel oil from
the fuel oil pump Lock nut
5. Put the cover screw.

~ Warning
Wear safety equipment during operation to avoid durn when fuel oil temperature is high. The defective of
combustion and explosion may occur by malfunction of combustion adjustment. If you decide that combustion
adjustment is necessary, contact maintenance staff of our company first, and follow the directions.

~ Caution
When replacing the flow control valve, adjust the pressure for heavy oil A, then switch over to heavy oil C.
Make sure that oil pressure is steady.

22
 6-12 Ignition Transformer

.alve
-mer
E
an
be
Primary side

AC100V

The Ignition Transformer is an important device

for creating sparks from the Ceramic 'nsulator for
the Ignitor by changing the 100V voltage on the
primary side to high voltage.(1 Okv)
The primary voltage of the transformer has dual
vOltages; 100V and 200V. When the control circuit
voltage is 100V, install the wire on the primary
side as shown in the right diagra.m. E

Primary side

& Warning
Beware of electrocution as the Ignition AC200V
Transformer conducts high voltage.

Avoid using it with rubber disconnected from the

boiler as it cannot be earthed, which would cause
the transformer to burn out.

23

6-13 Flame Eye

2)

1)

3) ..l1L--J

4) - 5)

1 Flame Eye
2 Fitting Box
3 Fitting Stand
4 Flame Eye Glass
5 Packing

The Flame Eye is a device that gives an indication to the combustion circuit by detecting the flame during
combustion and monitors the flame using its photosensitive characteristic (Normally, when a resistance of
100kQ catches flame , it drops under 5000) of CdS (Cadmium sulfide cell).
The Flame Eye will not be able to catch the brightness of the flame inside the furnace when it is damaged
or the protection glass is blackened with soot. Such soiling could stop the burner as it produces the same
condition to failed ignition or mis-fire. The failure of the Flame Eye may be caused by soiled protection
glass if the flame dies out in about 3-4 seconds after combustion as the burner is ignited by turning the
burner switch to combustion while looking inside the furnace from the sight glass . Do not neglect cleaning
the protection glass at all times.

Note
Clean the protection glass regularly.

24

 6·14 Fuel Oil Heater

f.O. Outlet

Safety Valve

F.O. Inlet -­

Drain

/!\ Caution
Open the fuel oil heater then inspect and clean once a year.

during The electric heater as shown in the figure is used as standard to heat fuel oil to a proper temperature. The
ce of heater is installed in the outlet side of the oil pump and oil temperature is regulated by the temperature
controller.
The element in the heater has a nichrome wire coil in the center of the pipe. The pipe is filled with special
same power which has high conductivity and good high-temperature electric insulation. Both of them are
ection solidified under high pressure.
g the After use for a long period, oil sludge is accumulated in the heater and this may cause lower heating
aning temperature. Therefore, the heater must be overhauled and cleaned during drydocking or as necessary.

25

 Len

6-15 Fuel Oil Temperature Controller

The appropriate heating temperature of fuel oil differs by the viscosity of the oil. Determine the temperature
following the Heavy Oil Heating Temperature Chart.
U
Heavy Oil Heating Temperature Chart

Control Output Indicator Lamp

C. Green
~ ·c
Lights up when the control
output is ON. CO HO LO
o
PV [ ,n n n 1
Reading Indicator Lamp
~ • U U U
PV . Red
The value is decreases
Lights up when a reading is by 1 when pressed once.
indicated. The value decreases
when continuously
pressed.
Set Value Indicator Lamp

SV. Green

Lights up when a set value is

indicated. The value increases by 1
when pressed once.
Select Key The value increases
Used in chan ging th e set when continuously
value. pressed.

Note
• Set up the data by pressing the key steadily with the fingertip.
• The data is automatically registered 3 seconds after it is set up.
• The indicator automatically reverts to indicate reading in approximately 30 seconds after set up.
• Don't press SEL key for one second or more.
• Don't change the parameter and inside data .

...
< How to Set Up The Set Value (SV) >

Example: Changing the set value (SV) from 120'C to 130°C.

Key Operation Explanation Indication

SEL Reading indicated (PV)

C=> The SV indicator lamp 'Iights up when SEL is pressed once to indicate the
PV'o' 1/1210 1
current set value. SV'O' 1/1210 1
/"­

C=>
Keep pressing until the changed value reaches 130. SV 'O' 1/13 101
(The value is automatically registered 3 seconds after set up)

SEL Reading is indicated (PV) when pressed once .

C=> (The reading is also indicated automatically in approximately 30 seconds
PV'o' 1/12101
after set up without this operation)

26

 6-16 Thermostat (For fuel oil)

1. Dial Type

art Thermostat specifications For Heater Protection

For High Temp Alarm

For Low Temp Alarm

The Fuel Oil Thermostat switches the electrical switch on and off by sensing the temperature, and uses a

fluid with high expansion co-efficiency in its thermos sensor. When it senses temperature, the expanded

fluid and pressure inflates the diaphragm inside the body, releases the lever to open the electrical contact

and when the diaphragm deflates, the electrical contact closes.

The following thermostats are used for the GK type boiler.

< How to adjust>

As shown in the above diagram, the thermostat is a dial type. After loosening the dial set hardware,

arrange the dial scale to align with the set points so that the designated temperatures will be reached.

Then tighten the set hardware.

G) Low temperature alarm thermostat : Set the temperature to be about 20-30'C lower than the
heating temperature.

CV High temperature alarm thermostat : Set the temperature to be about 30-40'C higher than
the heating temperature.

® Heater protecting thermostat : Set it to 180'C.

Once every three months, turn the dials to change the settings and perform a check of the electrical system.

27

 2. RTType

Use the RT model shown at the left based on your specifications.

1) Setting Knob
2) Setting scale plate
3) Differential Setting Disk

< Adjusting Range>

Rotate the Setting Knob to adjust to the specific figure on the Graduated Dial.

< Differential Control >

Adjust differential pressures by using the Differential Setting Disk. The specified value should be decided using

the chart. Connect the main preset value (A) with preset differential value (B) by straight ,line, and locate where

it crosses with the differential value (C). This value should be identified as preset value of the disk.

Note
Since the thermostat has been adjusted. Do not try to adjust frequently.

Chart to set differentials.

'C 'C
'C 'C 1.8
1.8 120
70

80
130
E

I
140

I
90 150 10
1<
100 A 10 160 A .1.
B 170 16
110
!O? B 18
~ 15 100
120 2Q
100 <I A. =; Main preset value
130 . 24
20 100
<6 B. =; Preset differential value
140
210 <S
150 RT107 25
215 RT120 30 C. = Differential value

28

 6-17 Temperature for heating heavy oil

For optimum combustion conditions, keep the viscosity of the fuel oil in the nozzle section at 12 cSt or less.
For the proper temperature for heating, different viscosities of fuel oil, please refer to the following chart.

Redwood No.1 Sec'/1 00 ' F 1500sec. 2500sec. 3500sec.

Kinematic Viscosity (cSt) at 50'C IF-180 IF-380
(IF) Residual Fuels, cStl50'C 180cSt (290cSt) 380cSt

Kinematic Viscosity (cSt) at 100'C 25cSt 35cSt

-
CIMAC and ISO Fuels, cStl100'C CIMAC/RM-25 CIMAC/RM-35

Fuel heating temperatures

(Setting the temperature of the temperature adjuster)
-­ - - ­ -
~1 25'C 130'C 135-140'C
-

using
where

lue

29
 L OUILen

6-18 Feed Water Pump (Miura water pump)

MSY User's Manual

Please refer to the user's manual for
the MSY feed water pump (separate
fro m th is manual)

Air Vent Valve , Plug

IN
¢=:::J

OUT
-I *-..--++ ~

Air Vent Valve, Plug

,I

30

 6-19 Water Level Gauge and Water Level Control Cylinder

& Warning
As the water level gauge glass may be damaged due to aged deterioration, replace it on regular basis
(once a year)
I for
ate

The water level gauge is built in with the water level control cylinder as an integral-type as shown below.

~
9)

1)W
2)~8)
~i:
3)
6) -5)
4)

7)

/ I "I-­ 10)
I

1 Water Level Gauge Box 6 Hexagon Bolt

2 Gauge Glass Seat 7 Hexagon Nut
3 Gauge Glass Cover 8 Connecting Pipe
4 Gauge Glass 9 Water Level Control Cylinder Cover
5 Gauge Glass Packing 10 Drain Valve

Water level control cylinder is installed in the top and the bottom (on the steam side and water side) of the
steam drum via the valve and combines the water level gauge and water level. control cylinder with the
gauge glass attached on the body.
The water level gauge is an important device for safety to check if the prescribed water level is kept in the
boiler. As the glass of the water level gauge always needs to be kept clean , clean it by blowing the water
level gauge at least once a day.
The water level gauge glass uses the reflective type and the size varies among boiler models.

31
 L tiUILCn

In addition to the water level gauge to check water level by eyesight, the level control cylinder has four (or

five) water level detecting rods 3) with different lengths inside the cylinder to electrically detect water level

and put out a signal to automatically start/stop the feed pump and stop the burner when the level is low.

The stainless detecting rod is screwed in the electrode holder and further tightened with set screws.

As the water level detecting rod may get dirty with concentrated boiler water and cause malfunction , pull

the water level detecting rods out and clean them at least once a three months .

1) if @ ~ ~
S@ 6:Qe
1) 3) L I
2)~ 1 Wh' WR
-~F:~;~
@ t
®
(9)
3) II .11

1 Electrode Holder s
2 Water Level Gauge Box
M
3 Water Level Detecting Rod
L
4 L-_D~~nValv~Flange _____
LL ----

4) ~I I~I

Continuity and Insulation Check of The Electrode Holder

Check continuity and insulation of the electrode holder every three months.
Continuity check W~ @ 0 Q
Insulation check W ~ ® 0.1 M Q or more
Replace the electrode holder periodically (once/2 years) as it causes insulation and continuity failure due
aged deterioration.

< How to Blow The Water Level Gauge>

1. Close the steam valve of the water level gauge and open the drain valve to discharge water in the gauge.
2. Close the drain valve and open the steam valve .
.-........
3. Close the water valve, open the drain valve, discharge steam and clean the water level gauge.
4. Open the water valve and close the drain valve.

32

 6-20 Exhaust Gas Thermostat

The exhaust duct comes with a thermostat to

measure the temperature of the exhaust gas.

If there is an abnormal temperature, an alarm will

sound and operation will be stopped electrically.

At the time the thermostat leaves the factory, it is set

at 450°C.

If it appears that the thermostat is working but the boiler is stopped when the boiler is supposed to be
running, take a reading of the gas temperature with a thermometer, then decide whether the problem is
due to a defect in the thermostat, or whether the temperature is actually increasing.
If the temperature of the exhaust gas exceeds 450°C, there is a high possibility that there is some sort of
malfunction in the combustion chamber. Open the furnace, and check whether some sort of unburnable
material has fallen Into the furnace, or there is some other sort of cause. If there is a malfunction,
immediately take corrective action.
~ If incomplete combustion continues for a long time, there is a chance that soot has accumulatec! gn the
waterPipes in the furna~e and the temperature of the exhaust gas is higher1fianit should be.
Jre due to Paycon~ant att~~ti~n to the furna"Ceto keep completecom b-ustiGn:" - --- - ­

< Inspection>

About once every three months, lower the set temperature and make a test run of the equipment.

uge.

33
 Z BUlL e

6-21 Pressure Switch (For Steam and Fuel Oil)

Steam pressure switch

ON-OFF control

< Inspection>
Make sure that steam is not leaking at the connections or Into
• Once every three months, lower the setting of the pressure SVo'itch 0" ''''e ntgh pressure alarm system a
conduct a test run of the equipment.
• Once every three months, heighten the setting of the pressure switch of the low pressure alarm syst
and conduct a test run of the equipment.
After a test run , reverse the pressure switch setting .

On GK series models, there are two types of pressure switches: one for oil , and one for vapor.
(a) Vapor pressure switch
ON-OFF control: One standard switch
3-level control: Two standard switches

In ON-OFF control, there is one switch that controls the vapor pressure.

In 3-level control , there are two switches: low vapor pressure , and high vapor pressure.

* In some cases, there are more switches, as some are used for alarms.

(b) Oil pressure switch

This mainly uses a low oil pressure alarm system .
If the oil pressure falls below the level set at the pressure switch, an alarm will sound.

< Inspections>
• Make sure that fuel oil is not leaking at the connections or into the cover.
• Conduct a test run of the equipment once every 3 months.
• During combustion, make sure that the oil pressure is 1.8 MPa (1 .5 MPa for heavy oil A).
automatic combustion, gradually close the fuel pump outlet valve to decrease the oil pressure, and
sure it can run at 1.4 MPa (1.1 MPa for heavy oil A).

34
• r

6-22 Pressure Switch Adjustment

1. SNS Type

Spring regulator Spring regulator

for pressure difference 1.1f I I~ I tI for pressure

Pressure pointer_
Differential pressure pointer --.........
Scale plate -----.In

/ stem a

m syste

1) Control Range
Contact pressure goes up by rotating the spring regulator for pressure counter-clockwise, as it is shown
on the gauge. When contact pressure goes up , disconnection pressure goes up, too . As you see , the
spring regulator for pressure cannot adjust differential pressure of gating.

2) Differential Pressure Control

The differential pressure can be widened between contact pressure and disconnection pressure, by
rotating the spring regulator for pressure difference clockwise (by tugging). Comprehensively, the
spring regulator for pressure adjusts contact pressure and the spring regulator for pressure difference
adjusts disconnection pressure. The contact pressure is shown in the pressure pointer, and differential
pressure of gating is shown on the differential pressure pointer on the calibrated dial.
Therefore, disconnection pressure = contact pressure - differential pressure of gating .
For your reference, the above-mentioned description about how to read thes scale plate is based on
(contact A) pOint of view; (contact B) should, then , be just the opposite.

A). Du
_, and m

35

 Z BUILt:H

2. RT Type

1)
2)
3)

1) Setting knob
2) Setting scale plate
3) Differential setting disk

1) Control Range
Rotate the setting knob to adjust to specific figures on the setting scale plate .

2) Differential Pressure Control

Adjust differential pressures by using setting disk. Refer to the left table to see the appropriate value.

Relation between differential disk scale and differential pressure

2 3 4
5 6 7 8 9 10
I , r ,
, ,_.1 J I I
1. 2 1. 6 2. 0 2. 4 2. 8 3.2 3. 6 4.0
RT 5 ~ __ I .' ',I, . I, I bar
I' I ' (-( L ~:=J_T 1
, \, I I I , 1 I
O. 3 O. 5 O. 7 O. 9 1. 1 1. 3
RT 116 I II
T­ -,
I
'I1- I
1
I I
, '
I I
, - , - ­ -," -,I
I ! I
~T
bar

1.01.52.02. 53.03 . 54.0

RT 117 I . I , I. I I I. I J bar
j·-l'..1-I--j'r--, !' I I
MIN. MAX.
1 2 3 4 5 6 7 8 9 10
•• 1 ••••••••••••••••

36
 L. LJV/L,-n

6-23 Safety Valve

& Warning
It is not allowed to change the outlet pressure of the safety valve.

The safety valve is a safety device implemented to prevent the boiler steam pressure from rising to the
maximum allowable working pressure and the full-bore safety valve is used for GK type. Normally, the
safety valve won't operate as the steam pressure switch work. In case the pressure switch does not work
for some reason, combustion continues and the steam pressure abnormally or abruptly rises due to rapid
load change, it protects the boiler by blowing steam off and lowering the steam pressure. Two or more
safety valve are installed and an adequate margin of safety is provided to the total relieving capacity with
more than the maximum amount of evaporation of the boiler.
The boiler's safety valve is set at the presence of
(Type 1627)
an sureyor, so as to blow off at the strictly limited
press u.re ; nobody should be allowed to make an

1~:~ ~
attempt of further adjustment on board . However,
only in case of emergency, such as when the
8) safety valve leaks, or some kind of appropriate
countermeasure can be taken on the judgment of
chief engineer discretion. In that case, the
following procedure should be followed to adjust
blowout pressure of the safety valve.

1 Valve Casing
e.
@=
2
3
4

Valve Seat
Valve Body
Adjusting Ring
5
Valve Body Cylinder
6 Lift Stopper
7 Spring I

8
Valve Stem
9
Adjusting Bolt & Nut
10 Cap
11 Lift Valve Lever
< How to Adjust>
1. Unlock the key on the 11) lift valve lever arm then, pull off the shaft and take off the lever.
2. Take off the cap by loosening its setting screw.
3. Activate safety valve, while 9) adjusting nut is loose. (Check blowout pressure when the boiler gets
shifted to manual operation and steam goes up)
4. Rotate the 9) adjusting bolt to the left, if blowout pressure is higher than limited pressure, to the right, if
it is lower, so that it blows off at the limited pressure.
5. After the adjustment, fasten the 9) adjusting nut tightly to fix it securely.
6. Put back the cap, restoring 11) lift valve lever, lock it and fix it.

37
 Z BOILER

(Type SP-B1 M 40A)

7)

2)
1 Cap
3 )~
2 Lock Nut
5)
3 Lever
8)
4 Adjusting Needle

9)
5 Lock Bolt
4) 6 Body
10)
7 Pin
11 )
8 Adjusting Screw
12) 9 Spring
13) 10 Spindle
11 Guide
12 Valve Disk i
13
,~-~-
Valve Seat
-- - -­

Adjustment of set pressure

Turn the adjusting screw to adjust the set pressure. Be careful to ensure that the valve stem is not turned .

To increase the opening pressure Turn the adjusting screw clockwise as viewed from top .

To decrease the opening pressure Turn the adjusting screw counterclockwise as viewed from top .

38

 Adjustment of closing pressure

The closing pressure is adjusted with the adjusting guide and backpressure needle. Remove the valve
cage fixing bolt, insert a screwdriver or fine stick through the tg.pped hole, and turn the gear type teeth on
the peripheral of the adjusting guide to adjust the closing pressure. Change the backpressure adjusting
needle throttling condition to adjust the closing pressure easily.

To increase the closing pressure. *Adjusting the needle clockwise with a screwdriver
(1/2 to 114 turns each at a time).
*To increase the closing pressure more, turn the adjusting guide I
(5 teeth each at a time) Clockwise, peeping through the tapped I
hole.

To decrease the closing pressure. *Turn the backpressure adjusting needle counterclockwise (loosen)
with a screwdriver (1/2 to 114 turns each at a time).
*To decrease the closing pressure more, turn the adjusting guide
(5 teeth each at a time) counterclockwise, peeping through the
tapped hole.

When the lift is not perfect. *Turn the backpressure 10 to 20 teeth counterclockwise with the
adjusting stick.
* If stabilized operation is still not achived, turn it a further 5 teeth
each at a time, counterclockwise.

t turned.

top.

rom top.

39

 L t1UILt:;H

6-24 Fuel Oil Strainer (Fuel System)

The oil strainer removes dust and impurities from the fuel entering the bo il er and prevents them from

entering into and damaging the fuel pump, solenoid valve, or burner nozzle.

It is installed on the suction side of the fuel pump . Since it is an oil strainer, its element can be cleaned

during operation . Turn the handle once a day to prevent it from clogging .

Open the plug then drain all water and sludge out once a month.

23)

6)

7)

14)
13)
16)
15)

~:;= II ~ ~~13)
21 )
22)

ill = ~~~
1 Cleaner Cover 9 Air Plug 17 Square Rod
2 Oil Tank 10 Packing 18 Round Rod
3 Handle 11 Upper End 19 Plug
4 Main Shaft 12 Lower End 20 Packing
5 Gland 13 Fixing Plate 21 Washer
6 O-ring 14 Packing 22 Nut
7 Ring 15 Filter Plate 23 Cap Nut
8 -
P~cking ---­ -
16
"--- ~- -
Scrape r Plate

40

 Z BOILER

Oil strainer for pilot burner

from 1) Draining
Close the supply valve of the oil tank, then
eaned loosen the drain release bolt at the bottom of ~ .1Ai Air vent screw
the strainer and flush out any water or
contaminants that have collected on the
- - - Strainer
bottom.

2) Disassembly and cleaning

After making sure that the valve of the oil tank
is closed, remove the bolt at the top of the oil Drain cock plug
strainer, then remove the cup section and flush
out any gunk on the filter plate with cleaning oil.

3) Air release
Open the valve of the oil tank and slightly
tighten the air release screw at the top of the oil Note
burner. Clean the protection glass regularly.
If, after releasing the air, oil starts to come out
from the place where the screw was loosened,
then tighten the screw.

41

--*'
--
 L OUILCM

6-25 V Shaped Strainer (Miura Feed Water Pump) (Fuel Oil)

1. V-Shaped strainer for feed water line.

The strainer removes impurWes such as dust and sand in feed water supplied to the boiler and prevents
them from entering the feed water pump and the feed water check valve and damaging them. When the
strainer is choked, the inlet side will be in negative pressure and cause cavitation in the pump. Periodically
clean the element to avoid the situation. The element has an internal net of 50-mesh with an external net.
Replace it with a new one if the net is broken or damaged.

2. V-Shaped strainer for fuel oil line

There is a V-shaped strainer at the fuel heater outlet and burner inlet. This is for removing contaminants in the
fuel oil that could prevent damages of solenoid valves and other parts. Depending on the condition of the fuel oil,
approximately once every three months, you should open the strainer, clean it, and check to make sure there Is
no deformation or other damage to the element. If the element is damaged or deformed, replace it.

6-26 Feed Water Check Valve

Feed water check

A check valve is provided in front of the feed
water inlet valve to prevent boiler water from
flowing back.
If the check valve leaks, the steam pressure lowers.
Furthermore, when the feed water pump is activated,
~
high temperature in the pump generates air bubbles
II I I II (l)
111 III cr; due to cavitation, disables pump operation and feed
3: water to the boiler and finally causes abnormal low
-0
(l)
(l) water level.
lJ..
It is important to periodically check the valve seat
and valve disc of the check valve and exercise
care to reduce wear and tear.

42

 6-27 Sequencer (Programmable Controller)

1. Outl'ine of the sequencer

The conventional sequencer is the one called hard wired logic (for short, hard logic) to compose a logic
(logical circuit) by wiring among devices composed of relays and timers.
A computer does nothing with the hardware alone and takes advantage of its function with software called
net. programs. It can also have various functions depending on how software is created. Namely, logic can
change by software even on the same hardware and the computer logic is subject to software logic.
Applying the same idea to the sequence control , we can replace "wiring" assembly of relay circuit logic with
software called programs. As software plays a role of wiring , it is called soft wired logic (for short, soft logic).
To realize the sequence control with soft logic, we install a storage device (memory) on the hardware to be
able to load various programs on it exactly like a computer. Such devices designed for sequence control is
called a programmable controller or simply a sequencer.

2. CQM1 H unit explanation

CQM1 H

feed

Input unit
Output unit

--­ /~
43
 L LJV'L...'-' I

1) Names and explanation of parts of CPU unit

CQM1 H-CPU11

Battery storage cover I Sli der

If you open the cover, you will find Fix adjacent units.
a battery and a front dip switch.
Install the memory cassette inside
the cover. .LED display

Peripheral port Connector

This is for connection with mainly Mate connectors of adjacent units
peripheral tools (eX-Programmer, to connect them.
programming console). Upward
link and NPP communication are
CPU unit built-in
alsO available.
16-point input
If you open the cover, you will
find a 16-point input terminal
block.

How to open the battery storage cover

Insert your finger tip or a small slotted screwdriver into th e gap Status of the dip switch
on the bottom of the battery storage CD and open the cover
upward ~. OFF

2 ON

3 OFF

4 OFF
(Z) Q
5 OFF

6 OFF

7 ON
Battery
Dip switch 8 OFF

D Memory cassette (option)

You will find a slot to install a
memory cassette on the back.

D
44
 Z BOILER

Installing the memory cassette

CPU unit

Memory cassette

nits

will
'TJi nal
l~ ....
Ii I
~, ~
Insert a memory cassette along the slot and tuck it in until the connector is engaged.
Turn off the boiler power to replace the memory cassette.

45

 ~UILt=H

2) Replacement procedure of the built-in battery

Replace the built-in battery according to the following steps.

1.Turn off the boiler power.

If the power is on, turn on the power once and leave it at least for 5 minutes.
2.Pull off the connector of the battery in the cover of CQM1 H and replace the battery with a new one.

Once you have removed the old battery, install a

new batterv with in fjye mjgutes. If the power is not
supplied to the CPU for five minutes or more, the

-
stored data may be lost.

3) Battery
A battery is built in the CPU unit.

The following- data will be backed up by the battery.

• EIIO memory (including PC system configuration)

• User programs
• Clock data (when the memory cassette with clock function is installed)
The battery lasts for 5 years in 25'C ambient temperature. When the battery runs out, the front
ERR/ALM LED flashes. You need to replace it with a new one within a week. Contact to our maritime
application maintenance section . Prepare a spare battery in advance .

4) Input unit
An operation switch, a pressure switch on the detector and the thermostat will be connected to
work as a joint.

5) Output unit
An electromagnetic relay, an electromagnetic valve and indication lights are connected. Relay contact
output is adopted. You can check the operation status of output points with LED on the unit surface.
(The light is on when the output relay is on)

46

 L OUILt::H

3. Display Function

The light is on when the

operation is normal.

CPU unit built-in input relay (O~15) I (Yellow)

This indicates the ON/OFF status of the input relay OCH
built in the CPU unit (lights up when the relay is on).

Load rejection (lNH)

L-~~~_ __ _~_ _~~~~~
I(Yellow)
The light is on. The light is on when the load rejection relay (25215) is on.
Operation stops. All outputs of the output unit will be shut off.
RUN LED lights out.
Peripheral port (PRPHL) I(Yellow)

Alarm (ERRIALM) I (Red) Unavailable

The light flashes.

Operation continues. --I Built-in RS·232C port (COMM) I(Yellow)
Unavailable .

LED Color Status Condition

CPU unit is running a program in " Monitor"

RUN Green D and "Run" mode.

nt
• Under operation stop and irregular stop

CPU stops operating when an operation stop

e D error is detected by self-diagnosis.

All outputs will be shut off.
I
I

ERR/ALM Red CPU continues operating when an operation

~ continuation error is detected by self-diagnosis.

to

• CPU is operating normally.

However, this LED lights out when WDT error occurs.

When the auxiliary relay for load rejection is on,

INH Yellow D all outputs of the output unit will be shut off.
ct

D :Light on
•
~ :Flashing •
When the auxiliary relay for load rejection is off

Light out

47
 UILI=.H

4. Errors and Their Measures

Abnormal phenomenon Probable cause Measures

rpOWERJ LED does not Loose connection of the power Terminal block:
1
light up. terminal block connector Correctly insert the connector. ,

Power line failure Replace CPU unit.

2 rRUNJ LED does not light up.
Program mistake Correct the program.

Loose connection of the unit Correctly insert the unit.

All output (input) units won't
3 Loose connection of the terminal Correctly insert the terminal
turn on.
block connector block connector.

All output (input) units won't

4 Input circuit failure Replace the output (input) unit.
turn off.

External voltage is low. Use rated external voltage.

Output (input) units turn on Loose terminal screw Fasten the screw.
5
and off. Loose connection of the terminal Correctly insert the terminal
block connector block and lock it.

Output (input) operation indicator LED

6 LED failure Replace output (input) units.
does not light up. (normal operation)
- ._-­

48

 BOILER

6-28 Flame Detector (FS-100)

The flame detector is the relay to detect burner flame and take it out as an electric signal and includes
built-in operational amplifier, electrolytic capacitor, transistors, diodes, auxiliary relay and many other
electronic parts.

. ~

tt!t~
~
~
:::;:=

5·riitin~ Terminal

Terminal block

Rating
1. Rated voltage :AC100/110V 50/60Hz Output
...---'T----II ON
2. Permissible ambient temperature :-5°C -+55°C

3. Action
'"
_ _ _ _ _ _ _ _L ­_ _L ­_ _~I OFF
15 10.5
4. Output : 1 a relay contact Flame eye resistance (k 0 )
*Flame eye (Flame detecting sensor) .... ··
5. Basic connection Cadmium sulfide cell (CdS) P621-03 type

u
Power r=~~IOII Flame detecting circuit

FR
4
I I
I I
b!
Output ~
Flame eye

49
 L /:jUIL/::;H

6-29 Water Level Detector (LM1-200)

1. Outline
1) Summary
LM1.-200 is a water level detector which is an integral type of the conventional level detector consisting
of two switches and sequencer output without changing the sequencer program and major connections.

2) Characteristics
LM1-200 is characterized as fo'ilows.
• 100V/200V voltage available
• No relay is used and open collector is used for output.
• IC (TC4584) for detection can be replaced.

2. Rating
1) Rated Voltage : 1 1> AC1 00V/200V SO/60Hz
Voltage variation : +10%--15%

2) Permissible ambient temperature : -10°C -+60°C

3) Basic connection

-
.
I,

OFF
-
Water level detector LM1-200

-u
0
~
CD
Logic circuit - ~

(")
Level detecting c ircuit ~.
c

I 1 I
fI I
Semiconductor contact
I

~ AA I
NPN·type

oaa aal oaJ aae A. A. B c· C. D. D. ft t ov , ,

It IO~

TelOH

r h
,-.-. ,"""lhp ~ oaa aal au aa. •,
:~OOYIDC:.'f1

Sequencer input terminal

Note) Irrelevant terminals
I - A.
A.­
are omitted. So
I L I-- B.
c­ c.
n. o.
BOILER WATER LEVEL
7

50
6-30 High Pressure Air Soot Blower

Series GK units come with high pressure air soot blower.

1) Make sure that the pressure in the air tank reaches the preset pressure (2.5MPa).
2) Make sure that all of the soot blower main valve on the boiler side are closed.
3) Open the main valve on the air tank side.
4) Carry out soot blower according to the following procedure.

1. Soot Blower (1) (2) of Upper Tube Plate

CD Open the soot blower main valve No.(1) of the upper tube plate and carry out soot blower for about 20
seconds. (The valve is open, soot blows and then the valve is close in about 20 seconds.)
(2) Carry out soot blow at NO.(2) of the upper tube plate same as mentioned item CD.
(Operation: about 20 seconds X 2 sets (Soot blower of the upper tube plate} = about 40 seconds.)

& Caution
When the pressure in the air tank is sufficient (over about 2.2 MPa), the next operation will be able to be
followed. If the pressure is below about 2.2 MPa, make sure that it will charge up into the preset pressure.
Start the next operation after makin9 sure that the pressure will return to the preset pressure.

& Caution
When the pressure in the air tank decreases (into about 1.8 MPa), stop the operation even in the middle of the
operation and make sure that the pressure in the air tank will charge up into the preset pressure.
Continue the operation after making sure that the pressure in the air tank will return to the preset pressure.

2. In case GK 14XX, 16XX, 18XX operate the soot blower as same way as soot blower (1) (2).
Soot Blower (3) (4) on the Middle
CD Open the rotary soot blower main valve No.(3) on the middle and then carry out soot blow for about
30 seconds. (The valve is open, soot blows and then the valve is close in about 30 seconds.)
(2) Carry out rotary soot blow at No. (4) on the middle same as mentioned CD.
(Operation: about 30 seconds X 2 sets {Rotary soot blower on the middle} = about 60 seconds.)

3. Soot Blower (5) (6) of l ower Tube Plate

CD Open the soot blower main valve No.(5) of the lower tube plate and carry out soot blow for about 20
seconds. (The valve is open, soot blows, and then the valve is close in about 20 seconds.)
(2) Carry out soot blow at No. (6) of the lower tube plate same as mentioned item CD.
(Operation: about 20 seconds X 2 sets {Soot blower of the lower tube plate} = about 40 seconds.)

51
 L f:jUILJ:::H

4. Finish
CD When all of the above mentioned process is completed, the soot blower has been finished.
Adjust the time for operation while referring to the range of the air pressure gauge installed on the
equipment because it is standard time.
If there are no capacity of the air tank to spare, the operation time is possible to be cut down, please
refer to the minimum time required in the attached sheet.
® During voyage , carry out soot blow at least once a day and decide the appropriate number and time
of the operation according to your experience while checking the effect caused by soot remove.

HIGH PRESS AIR SOOT BLOWER

(1) (2) Soot Blower of

Upper Tube Plate

(3) (4) Soot Blower

on the Middle

(5) (6) Soot Blower of

Under Tube Plate

52

6-31 Soot Cleaning in the Exhaust Gas Side while the ship is in Port

Series GK units come equipped with high pressure air soot blower. Soot that cannot be removed by the
soot blower while the ship is at sea must be periodically removed. At that time, the soot should be removed
with a vacuum cleaner and a compressed air blower.

The following is the procedure for removing the soot from the water pipes on the exhaust gas side:
1) Leaving the manhole on the inlet side of the exhaust open , collect the soot that has built up on the
bottom cover. If you have a vacuum cleaner, suck up all the soot that is within reach of the nozzle.
2) Use a compressed air blower to blow away remaining soot in the same direction as the exhaust gas flow.
3) Open the cleaning opening in the middl'e portion and collect the soot that has accumulated.
4) Use a compressed air blower to blow the soot away from the middle cleaning opening toward the exhaust outlet.
5) Open the manhole on the outlet side of the exhaust and collect the soot that has accumulated. As soon
as possible after cleaning , close the manhole and the cleaning opening and start the boiler.

j- - ' Cleaning opening

Inlet side manhole Outlet side manhole

.. ~.
4 )

'~"" '\.

080 0 0
0000
0000
/­ 03
b~oV ,~ u 0
I / ; - hL--...l..-----"
o (',--_
2)" 0 ~,o
0 ( 3 ! 0 ,-....(
/
~ 0 ' ._( ' 0 ( 4 )
o 0 I
',- '
g 1\ g
.~i
- - Cleaning opening
 UILcH

6-32 Washing while in Dock

1. Using a high pressure cleaning pump, blow the soot away from the exhaust gas inlet and toward the
middle area and the exhaust gas outlet, as described previously in (1).
2. Blow the soot adhering to the water pipes from the top toward the bottom.
3. Remove the soot remaining on the top cover and the cleaning water, then use a fan on the manhole on
the inlet side to dry the water pipes.
4. When the water pipes have dried, sometimes some of the remaining soot will have fallen onto the bottom
cover. In such a case, remover the soot using either compressed air or high pressure cleaning water.
5. Immediately after cleaning with water, dry the water pipes and start the boiler.

~ Warning
II Frequent washing with water can cause sulphur-induced corrosion of the water pipes, drum, and casing.
Therefore, you should use water as little as possibLe.

54

 L DUILCn

6-33 Excess Steam Dump Valve

The pressure of the steam that is generated in this boiler is affected by the loaded condition of the ship. When the
steam pressure is low, the auxiliary boiler can supply additional steam from additional fire (concurrent operation),
but when the steam pressure rises rapidly, it is sometimes impossible to adjust the exhaust gas volume.
Therefore, some of the generated steam is released through the drain cooler to adjust the steam pressure. In
other words, there is an excess steam release valve between the main steam line and the drain cooler; when the
set pressure is exceeded, the excess steam is released through the drain cooler.

From Load

By-Pass Valve Cooling se:wate

q Drain Cooler
D
-
III III
.. I I II
Observation Tank

~
Cascade
PS Feed Water Pump I Tank

1:~~JI IW"
1) Body There are basically two types of excess steam release
2) Bottom Cover
3) Top Cover
valves: a direct driven type, and a pneumatic type.
4) Spring Chamber The type installed depends on the ship's specifications.
5) Cylinder
6) Piston The release valve ~or the direct-driven type has the
7) Main Valve same structure as the pressure reducing valve.
8) Main Valve Seat
@ (Referring to the figure below.) You can adjust the set
9) Pilot Valve Seat
@ 10) Pilot Valve pressure by removing the cap (11) from the upper part
11) Cap
12) Cap Pilot Valve Screw of the release valve, then loosening the lock nut (17)
13) Washer Of Spring
and adjusting the regulating screw. Please monitor the
®- D~~\(Q---~ 14) Washer Of Spring

15) Washer Of Spring pressure gauge as you make your adjustments.

16) Adjusting Screw

@)' 17) Lock Nut The pneumatic release valve monitors senses the
@ 18) Plug actual steam pressure and convents the difference
19) Diaphragm
@ with set pressure o~ the release valve into an air
20) Strainer
@
21) Main Valve Spring signal that moves the diaphragm adjustment valve
@ 22) Adjusting Screw Spring
® 23) Pilot Valve Spring which in turn regulates the steam pressure.
® / / 24) Strainer Spring

~~ * For more
25) Bolt & Nut
26) Bolt & Nut in~ormation
about the direct-driven and
Q) 27) Bolt & Nut
pneumatic release valves, please consult the
® 28) Valve Guide

29) Thrust Bearing operating manual.

55

 OILE-H

7. Automatic Operation of the Boiler by the Sequencer

7-1 Summary
Sequence control is an automatic control to sequentially perform a series of different operations different
from the set-point control that allows the feedback control to maintain controlled variable during operation
and the proportional control that maintains the ratio of two controlled variables at a constant level.
Speaking of this boiler, it activates the timer and relay to sequentially and automaticaUy performs a series
of actions such as starting the feed water pimp and the fan motor, activating the ignition device after full
pre-purge, opening the fuel valve to ignite the burner, shutting off the ignition device and gradually
steaming up to terminate startup with a press of button .

7-2 Basic Time Chart

The following shows basic patterns for the normal operation, flame failure during operation, ignition failure
in operating the boiler.

1. Normal operation
Combustion SW-----.l.-- - - - - - - - - - - -- -- !

~~ CJ - - - - - - - - - - - - ­
gnition transformer -------'---'--
5S ~j I.. 12S .1
Pilot solenoid valve 1
~: 1~7S
Combustion solenoid valve _ _ _ _-!-_-.L_ _ _ _ _ _ _ _ _ _ _---'

Flame eye _ __ _ ..L.-_ _ __ __ _ _ _ _ __ ------!

~
. operation ;
2. Flame
failure dUring .
Combustion sWitch I ,358 I

Burner motor f :~
:I

Flame failure fire

Alarm bell--- - - - - - -- - --L- - - --.J

56

3. Ignition failure

Combustion SW ---,---~+l-------------
1

~
Fan Motor r== .! I
I.. 358 • I II'" 3.5S
1

Pilot Solenoid Valve - ------'-q -l--- - - - - - - - -- - ­

I
1
1
1

Flame Eye Flame Failure i

1
1
I

Alarm Bell c-
Turn off the combustion switch once or press the alarm reset button to reset operation when you
experienced the situation stated (2) and (3).

Note .
Time charts varies depending on specifications. See the final drawing for details.

..

57
 L t1UILt::.H

7-3 Flowcharts

NFBON Power Lamp ON

Low level lamp On 11. YES

Feed Water
Pump Run

NO '

~ Normal Water
Level

ES
Combustion Oil pump, Fan on

start button Boiler running 11.

+
- -- - - - - ---,
3-4B ON (COM MODE)

Lamp ON

(B)

Oil Heater SW
11 A" Position is at. ..
""0
ro,
""0
c:
cO "NC"I "C"
ro
w
(J1
NO
rn
ro
(')
Oil Heater operation ~ Normal Temp

YES

(A)

58

 Z BOILER

(A) (8)

Is there any
other interlock
cause

NO lJ
lJ
....
CD
o
~
-0 I
"D
c
.... C
....
CO co
CD High steam CD
Pressure SW Stand by
is

CLOSE

Mis fire lamp ON

NO Ignition Trans OFF 1 - 1_ _- - '

Pilot Solenoid Post-purge

Valve OFF

Low Oil Pressure Post-purge

Does Oil NO I lamp ON
Pilot Solenoid
Valve OFF

Combuslion Solenoid
Valve OFF
Low Comb Solenoid Valve ON
(3 Position Conlrol)

(C )

59
 Z I:3UILI=.H

-------·..·· ··---.... -----1Three Level Control 1··..___ ....··..___ ..__ ·..·: :..···--··..···.. ·....·..1 ON-OFF control 1··..·.. ·······.....--..
® Ii @
!
Low steam pressure,,) OPEN
Switch contact is

Lowsteam pressure";,CLOSE
Switch contact is

CLOSE
@
CLOSE High steam pressure

Switch contact is

I Post purge
35 Sec.

CLOSE_
f LOSE
Steampressure
Switch contact is

,
- - ___ . _ - - - - - __ - - - - - - - - - - _ __ - - - - - - - - _ _ - - __ __ _ _ __ __ .. - - - - _..1 __ ___ _ _ __ ____ _ .. _ ___ __ _ __ _ _ _ _ _ _ .. . . __ _ __ .. __ • _ ........ _ _ ... ..... _ _ __ _ ...... . .-.. _ _ _ _ _ _ ....... _ _ ___ .. .. _ .... .... .. ___ _ .. _ .. _ _ •• _ .. __ .. .. __ .. .. ..

Combustion stop switch

3-438 ON

NFB OFF

& Caution
If the warning lamp for the burner interlock lights up, the bu rn er will not automatically return to its
previous setting-it will have to be reset.

60

 Z BOILER

8. Safety Devices
~ Caution
The main boiler system is always alert for the
The specifications of your warning apparatuses
following malfunctions may vary.

Status Response by system How to reset

Ignition failure to burner Shut off burning appliances Reset button On

Burner flame out (ignition transformer, solenoid valve) in 3.5
1
False flame detected during burner seconds Mis-fire, flame failure lamp lights

stand-by (pre-purge)
on,Activate alarm bell. Post purge start

Lower water level Shut off burning appliances, Reset button On

(burner cut the water level) lower water levell'amp lights on, (Reset after the water
2
Activate alarm bell, Post purge start level recovered)
J
I

Fuel 0il temperature drop Shut off burning appliances , Reset button On
(lower than specified oil temperature F.O temp drop lamp lights on
3
set by thermostat) Activate alarm bell , Post purge start

F.O pressure drop (lower than specified Shut off burning appliances in 2seconds, Reset button On
pressure set by F.O presswe switch, Indicator light up for lower
4
during burner ignition.) F.O press drop lamp lights on, Activate
alarm bell, Post purge start

Abnormal rise of exhaust gas temperature Shut off burning appliances , Reset button On
(higher than specified temperature set Exhaust high temp lamp lights on,
5 by exhaust gas thermostat) Activate alarm bell,
Post purge start

Fan stop Shut off burning appliances , Operate thermal relay

(when thermal trips due to overload Fan abnormal stop lamp lights on, reset button,
6
upon draft fun) Activate alarm bell Reset button On

Flame detected during post purge Shut off burning appliances, Reset button On
operation Abnormal fire lamp lights on ,
7 Activate alarm bell,

Extend post purge operation

Abnormal rise of fuel oil temperature Shut off fuel heater, Automatic restoration
(h igher than specified temperature set F.O temp high lamp lihjts on F.O temp high lamp
8 by high temperature thermal alarm) Activate alarm bell lights on
F.O high temperature thermostat

Low water level (Alarm level) Low water level lamp lights on Automatic restoration
Activate alarm bell
9

Abnormal CPU , Other abnormality of Shut off every sequencer output such Power restoration
the seq uencer as the feeding water pump,burning
10 appliances

61
 Z BOILER

9. Inspection Before Operation and Operation

9-1 Inspection of Every Check Points Before Operation

& Warning
6. Are there any clogging or loosened parts at
The following points should be examined to the connections throughout the fuel piping?
prevent accidents.
7. Are there any air in the fuel line?
8. Isn't the fuel strainer clogged?
1. Around The boiler 9. Is oil properly running from every tank
1. Area around the boiler cleaned thoroughly? through the fuel pump?
2. Any obstacles on the way? 10. Check thoroughly for any leaks from the fuel
3. Any flammable around the boiler? plumbing above the boiler.
4. Is there air inlet, or proper ventilator? 11. Is every needle of the pressure gauge and
5. Is air pressure in engine room appropriate? thermometer o.k.?
If it is negative, make it positive by adding 5. Burner
another ventilator. 1. Is installment of every equipment around the
6. Is fire distinguishing system equipped? b.urner o.k.?
2. The boiler and its Accessories 2. Is the glass or flame eye not contaminated?
1. Is equipment installation such as inspection 3. Is the ignition rod dirty, or is the size of each
holes, covers, valves o.k.? part o.k.?
2. Is valve opening/closing, or switching of 4. Is the lead wire from the ignition transformer
every drain valves all right? through the rod, and each attachment o.k.?
3. Is draining direction out of safety valve o.k.? 5. Is the nozzle tip not clogged?
4. Is glass stained or broken on the water level 6. Is a solenoid valve running properly? Are
gauge? there any oil leaks, or is the installment of the
5. Are needles of each pressure gauge o.k.? exiting open/close type o.k.?
3. Feed water system 7. Are there any deviance in the damper
1. Is the Cascade Tank filled with water? caused by loose screws or levers, etc.?
2. Is it dirty, or is there any oil in it? . 8. Does the damper motor run properly?
3. Is automatic feed water valve (ball tap) 6. Electricity
function normally? 1. Does every motor of the draft fun, the water
4. Is switchi,ng of every valve for feed water line feeding pump, fueling pump, etc. run properly?
o.k.? And/Or, does it turn to the right direction?
5. Does the switch No. on the control panel 2. Is every value for the thermostat (exhaust gas,
match with feed water pump for actual use? fuel heater, etc.) , fuel oil temperature adjuster
6. Is there any clogging , air, leaking , or loose and pressure switch specified correctly?
part in pipes? 3. Is ignition transformer running normally?
7. Isn't strainer for sucking clogged? Does it generate any sparks?
8. Isn't there any leaking from mechanical seal 4. Is the control panel not broken, or is every
of the feed water pump? attachment tool o.k.?
9. Are needles of pressu re gauge and 5. Are there any disconnected lead wires, loose
compound gauge o.k.? screws, broken lumps or switches?
4. Fuel oil system 6. Is voltage 440V (220V) provided for regular
1. Is there oil in the service tank for the boiler operation, and 1OOV for operating the circuits?
(0.0 tank and F.O tank)? 7. Are there not any disconnections throughout
2. Is the F.O tank heated properly? the external wiring of all equipment?
3. Is the F.O purified by the purifier. 8. Is every relay on the control panel running
4. Is the tank drained properly? properly? O r flame detector, every timer
5. Is every valve switching through the fuel running o.k.?
piping from the tank to the boiler o.k.? 9. Is the sequencer running?

62

7. Steam 4. Has the valve for excess steam dump valve

1. Is every valve line opening/closing of the boiler o.k.? been installed? Or, is it set at the specified
2. Is overboard discharge valve closed? pressure properly?
3. Is coding sea water flowing through the drain 5. Thorougl1ly examine other valve switching
cooler? for steam pipes , loosened parts around
flange, before operation .

9-2 Operation (in case of automatic burner operation)

1. Confirm operating switches for the boiler o Any vibration?
Make sure all the switches (incl. N.F.B) are set 6. Stop combustion, if there is any. Check oill
at the OFF position; if not, set it OFF. pressure , oil temperature, the damper
2. Feeding water to the boiler opening burner nozzle etc .
Always before starting burner operation, feed water 7. If steam pressure rises, check for any
to the boiler, following the procedures below: leaking from any parts.
1. Open all valves throughout systems from the 8. When steam pressure rises up to specified level
cascade tank through the boiler. set by pressure switch, examine combustion
2. let out air from the feeding water pump and control if it works by following the order, from low
systems. combustion middle combustion high combustion
3. The boiler power on. (NFB) middle combustion low combustion - stop.
4. Set the feeding water pump at automatic (auto 9. Stop combustion ...... confirm.
vs. manual shifting) and set No. 1 and No.2 Is pressure gauge running o.k.?
shifting switch at arbitrary; to activate the 10. Suspend fan motor after 60 seconds post­
feeding water pump, light up operation indicator purge .... Confirm.
lump, low and lower water level lamp, and bell 11. Open main steam va'ive little by little , not to
for low water level .. .. ..press on stop bell button . cause water hammer, to supply through systems.
5. Alert for noise of feed water pump/motor, and 12. Examine if there is any leakage in pipes of
overheat. steam system.
6. Are compound gauge and pressure gauge 4. Termination with 0.0 (Heavy oil A)
run ning properly? 1. Raise steam pressure close to the maximum
7. Is it easy to view the water level gauge? Did pressure for general.
he water feeding stop at the proper level? 2. Close main steam valve .
8. DOU ble check against any leaking water 3. Press down combustion stop button .
around boiler body. 4. Blow off the water surface, bottom of the
9. Lowe r water level lump turns off by pressing water, and water level control cylinder.
reset the switch . 5.. Close va lve in the feed water system and
3. Combustion; Start from 0.0 (A heavy oj(,) 0.0 valve .
1. Close the air vent valve of the air separator, open 6. Close the valve, checking the amount of the
booster pump retum line valve to the D.O.tank cascade tank/oil service tank.
and close the return line valve to the F.O.tank. 7. Turn off the boiler (NFB) .
2. ODen the supply valve of the D.O. tank, close 5. Switching fuel
tl'le su pply valve of the F.O. tank, open the • Switching from 0.0 (Heavy oil A) to F.O
inetloutlet valve of the booster pump and run (Heavy oil C)
e booster pump. 1. Operate with 0 .0 properly.
3 . T,...n the heater switchover switch to the A side. 2 . Raise F.O service tank to 80 - 90 'C
4 . Press combustion button. 3. Open steam trace valve in the boiler fuel oil pipe.
Be ca reful for F.O pump motor, noise of draft

~ Warning
and temperature .
Pre-pu rge ... confirm
an rombustion...combustion indicator lump lights on
Alarm bell for low temperature of fuel oil is can­
5. Pay attention to the following points during
celed , the moment heater switch shifted into
bustion :
"AlC". Stop the combustion , when inappropriate
Color of flame, expansion, stability
fuel oil temperature causes faulty combustion.
Color of smoke, any gas leak from its path

63

 L f:jUILl=H
~

4. Temporarily turn off the boiler and booster

pump. Close the D.O. return valve of the aler heater body cools
booster pump , and open the F.O . return =test drive and using new
valve. should be paid.
5. Open slightly the air vent valve of the oil air rastically, when the entire
separator. it should take enough
6. Close the supply valve of the D.O . tank, re is raised to 0.1 MPa.
open the supply valve of the F.O. tank, and gradually up to 0.1 MPa
run the booster pump. combustion and 4 minute
7. Set the boiler to automatic operation, then when tes at steam pressure
the oil in the pipe between the booster pump a 1 M Pa and 0.2MPa
outlet and the boiler F.O. pump unit switches ·at 2 minute combustion
over to fuel oil (F.O.), tum the heater switchover raise pressure.
switch to AlC. '::lJnd 0.2MPa (2kgf/cm 2 ) ,
B. Confirm that F.O temperature is raised up to ... rellghten the screws and
the proper level and that pressLire is stable. ~nec' l ng pints of each valves
9. Open slightly drain valve of oil air separator, e r body, man haul packing,
to check outgoing of F.O. etc.
10. When F.O temperature reaches close to the evel gauge to give the
specified temperature, shift heater switch to "C".
11. Confirm that there is no smoke in normal
operation .
• Shifting from F.O (Heavy oil C) to 0.0 ~ process is all done , turn on
(Heavy oil A) " Itch to combustion again .
1. Operate normally with F.O. sure reaches the maximUm
2. Open 0 .0 supply valve, and then close F.O raJ use, check if any steam
supply valve quickly.
3. Close steam trace valve in the boiler fuel oil valve, to start automatic
piping.
4. Shift the heater switch to "A", exactly when 0.0
fills pipes from 0.0 valve through F.O pump unit. • gnition failure
5. Open the D.O. return valve of the booster ustion switch, take off lead
pump, then close the F.O. return valve. ransformer at upper bumer, by
6. Confirm that temperature at heater outlet t3umer flame out oocurs due to
drops and pressure is stable. rod. When it happens, check
7. Close fully the air vent valve of the oil air p lights up, switching off on
separator. aarm bell rings after post purge.
B. Confirm outgoing 0.0 by opening slightly 2. Bumer C~: 'or ·O'.. er water level
drain valve of oil' air separator. Drain the Neuer ''1sce, by opening drain valve
9. Confirm that there is no smoke in normal and clOSing upper and lower detective piping
combustion . valve on ore. do the water I'evel control cylinder
the combusoon Make sure alarm bell goes off
in 10 se conds and burner is cut. After
~ Warning restoration of each valve, examine other side for
proper operation. Then restore each valve.
Stop combustion right away, when alarm bell
rings or faulty combustion occurs at shifting fuels.
If any appropriate fuel oil temperature and pres­
sure is not given, manual operation should be
& Caution
activated to operate heater, oil pump to reach the Switch fuel to 0.0 (Heavy oil A) when the boiler is
proper temperature and pressure. No manual suspended for a long time. Low temperature F.O
combustion should be attempted at switching (Heavy oil C) should lead to damaging oil pump,
fuels; it causes accidents such as backfire. its mechanical seal, solenoid valve, heater, etc.
9·3 Manual Combustion by CAM Switch

& Warning
In the manual combustion, ignition error may cause dangers such as backfire, or over heat; do not use
unless otherwise emergency. In case of using, the following rules should be followed.

Start Combustion Stop operation

1) Tum Cam Switch to off position, to stop automatic a) Return combustion change over switch to (Low
combustion. Comb.) to reverse the above-mentioned operation ,
2) Shift fuel heater switch to A. Confirm that and turn Cam Switch counter-clockwise.
combustion shifting switch is set at (Low Comb). Keep running more than 60 seconds at FAN
3) Turn Cam Switch to (FO.Pump/heater) position . position.
At this point, check that fuel is properly circulating.
(by pressure gauge) In manual operation as well, combustion is restricted
4) Shift fuel heater switch to C, in case of C heavy by interlocking of safety system as follows:
oil, and make sure the temperature goes up to the a) in case of flame-out, or ignition failure
specified level properly. If not, stand·by until it b) when steam pressure rises
reaches the proper level. c) when the water level of the boiler goes down to
(A heavy oil should not require this step) . lower water level
5) Turn Cam Switch to (Fan Running,) position . d) when the temperature of exhaust gas rises
Make sure that draft fun is running properly. e) when the fan motor stops
6) Sufficient pre-purge lamp should be confirmed on.
7) Turn Cam Switch to (Ignition) position. In manual operation where there is not enough inter­

Pilot burner combustion should be confirmed locking system for safety, pay extra attention to the

through sight glass, and combustion lamp. boiler status.

If there is no combustion, immediately set the a) Take sufficient time for pre-purge before manual

switch to FAN RUNNING. operation and post-purge after operation. (more

8) Turn Cam Switch to (Pre. Comb) position. than 70 seconds)
After confirming combustion through sight glass, b) Run/or stop the feed water pump, while checking
turn Cam Switch to (Comb) position. the water level of the boiler.
If it is not burning, return Cam Switch to (Fan
Running) right away.
9) Turn combustion change over switch to (High
CAM Switch Combustion
Comb), after confirming the right status of Changeover Switch
combustion. IGNITION
FAN
~
F.O.PUMP

'~~~
COMB.
~

& Warning
OFF
AUTO
COMB. }"

Sufficient purge should be conducted before

ignition; lack of pre-purge can cause accidents
such as backfire.

65

10. Regular Maintenance

6 Caution
Carry out conduct the following maintenance regularly.
10-1 Regular Maintenance

1. Cleaning of inside of the cascade tank When docked

2. Cleaning of filter within the cascade tank Every 6 months

Feeding Water 3. Cleaning of strainer/suction side of feeding water Every 2 months

System 4. Over hauling and inspection of the feed water check valve Every 6 months

5. checking of feed water pressure compound gauge On demand

6. Cleaning of water level detecting' rod , electrode holder Every 3 month

I~
1. Examination/cleaning of the inside of the fuel service tank When docked

2. Drainage of the fuel service tank Every day

3. Cleaning of the fuel strainer Every 1 week

4. Cleaning of the strainer inside fuel oil pump (Pilbt pump) Every 1 month

5. Inspection/cleaning of fuel oil heater element On demand

Fuel System
6. Fuel oil pump (contact manufacturer) On demand

7. Major cleaning/exam of the fuel heater Every 1 year

8. Inspection/adjustment of the fuel oil thermostat and Temperature indicator/adjuster I Every 3 months I,

9. Inspection/adjustment of the coupling for fuel pressurized pump Every 2 months

10. Cleaning of V-type oil strainer for fuel line Every 3 months

1. Inspection of the fuel oil solenoid valve Every 3 months

2. Check for any leakage of the burner nozzle Every 3 months

3. Maintenance of the burner body (baffle, rectifier grid, etc) Every 1 week

4. Inspection/adjustment for ignition rod Every 1 week

5. Inspection of the nozzle tip Every 1 week

Burner system
6. Inspection of the air register Every 3 months I ,'

7. Inspection/adjustment of the motor related parts of the damper Every 1 month

8. Inspection of the dirt on flame eye/glass. Every 1 month

9. Inspection of the draft fan, ball bearing, etc. On demand

10. Window box insulation On demand

1. Inspection within the boiler (manhole) Every 1 year

2. Inspection within combustion chamber When burner Every 6rnonth

Storage Water 3. Inspection within exhaust line Extracted

Heater Body 4. Every type of valve attachment Every 1 year

5. Blow of the water level gauge and control cylinder Every 1 year

6. Blow of the surface/bottom of the boiler Every day

66

 1. Check insulating resistance of the relative motors Every 3 months

Electricity 2. Inspection of the ball bearing of the relative motors Every 1 month

3. Check resistance of the water level detector and holder Every 3 months

4. Operative test for burner interlocking Every 3 months

Burner Control Panel

Cut Alarm Bell Display
Ignition failure and/or mis-fire 0 0 0
Draft fan suspended 0 0 0
Heavy oil pressure goes down 0 0 0
Heavy oil temperature goes down 0 0 0
Water level drops specified low water level X 0 0
Exhaust gas temperature abnormally goes up 0 0 0
The feeding water pump delivery pressure abnormal~ rises 0 0 0
I, Water level'drops specified very lower water level 0 0 0
Heavy oil temperature abnormally rises X 0 0
Sequencer malfunction 0 X 0
Power shut off 0 X X
Refer to completed archive of each boiler for details

5. Various automatic control test Every 3 months

I *Automatic start/stop of the feed water pump Every 3 months

* Check On-Off/3-position control of the boiler Every 3 months

* Oil temperature control of the F.O. heater Every 3 months

~~I:; :
;....­

67

 L DLlIL.En

10-2 Inspection and Precautions Before Starting Operation

1. Be aware of the oil level, heating temperature and drainage in the fuel tank.
2. Check the cascade tank level and cleanliness.
3. Gating of the valves for water feeding and fueling.
4. Check the water level of the storage water tank.
5. Check steam pressure.
6. Make sure every switch on the control panel is OFF.

10-3 Inspection and Precautions During Operation

1. Be aware of overheat, motor sound, vibration of accessories.
2. Be aware of pipes/tubes leaks.
3. Be aware of flame color, sound of burning, vibration.
4. Ensure if pressure gauge, pressure switch, and thermostat are working properly.
5. Examine if the water level gaug'e is visible, and be aware of the water level change.
6. Check against earth in the motor system.
7. Check against any vi!Jration of the control panel.
8. Ensure that the water feed pump stops/starts normally.
9. Check if there is any overheat around the boiler body or other parts.
10. Check condensed water temperature and see if there is any condenser overheat.
11. Ensure that the ampere meter gauges correctly.

10-4 Inspection After Operation

1. Check for any water or oil reservoir.
2. Check water level gauge instruction and steam pressure .
3. Check fuel tank level.
4. Check gating of every system valve.
5. Check the power switch.

10-5 Handling Water in Storage Water Heating

The details are shown in the accompanied boiler water log book.

Be aware that most of the water tube accidents come from faulty water treatment. Through understanding of

the instruction book it should contribute to good management. The instruction book refers to how to

preserve the water tank, in case of a long-term shut-down, as well.

U Refer to the "Manual for Water Treatment".

10-6 Long-term Shut-down

& Warning
Be aware that non-compliance of the proper procedures may damage the boiler rapidly or cause corrosion.
Details should be consulted with our Marine maintenance service.

68

11. Trouble Shooting

it Caution
Details should be consulted with marine maintenance service.

11-1 Feed Water System

1. Suction failure of feed water pump
a Mixing of air from suction side. Or insufficient venting.

a No water in feed water tank.

a Clogging of feed water line, strainer, etc., or excessive suction resistance .

o Feed water tank is installed at a position much lower than feed water pump. (i.e. lack of NPSH)
o Cavitation due to back flow of boiler water or abnormally-high feed water temperature.
o Insufficient capacity due to abnormal wear of impeller or guide plate of feed water pump .
a When priming occurs due to high concentration of boiler water, feed water supply is not enough and
low water level alarm may sound.
2. Excessive rise of feed water pump discharge pressure
o Clogging of discharge side valve system or piping .
o Defective pressure gauge.
o Flooding of boiler due to improper feed water control.
3. Water leakage from feed water pump
o Defective mechanical seal.
o Defective cover O-rings.

a Defective air vent cock or improper htting of pressure gauge piping joint.

4. Feed water pump does not start or stop properly or at the specified water level
o Wrong connection of water level detecting rod with lead wire or disconnection.
a Poor conductivity due to green rust in joint of water level detecting rod and lead wire. (In some cases no
change is seen on the surface and conductivity is normal when measured with a tester because of its small
current used.)
o Loose fitting parts on term inal board.
o Detecting rod is stained or in contact with main body cylinder.
o Water level detecting rod drops from the holder due to vibration.

a Defective feed water pump switch (88W1 or W2).

a Clogging of valve for water level control cylinder.

a Clogging of water level control stand pipe.

o Improper water level indication due to stained water level gauge glass.
o When priming or foaming occurs due to high concentration of boiler water, normal feed water control
may not be made.

a Defective water level detector LM 1-200.

5. Water level in water level gauge is not known.

o Water level gauge glass is stained.
o Water level gauge is filled completely with boiler water.
o Water level gauge valve is blocked or not opened.
6. Water leakage from water level gauge
a Defective glass packing.
o Improper fitting or uneven tightening of water level gauge.

69
 L. LJ\JIL...L...I I

11-2 Fuel System

1. Fuel oil pump does not run.

o Fuel oil pump magnet contactor 880 is defective.
o Fuel oil pump switch thermal relay 490 is actuated.
o Push the start button 3-4B is defective or not turned ON.
o Rotor is seized or foreign matter is present.
o Bearing is seized or shaft is locked.
o Defective coupling.
o Motor main body burned, single-phase operation or disconnection of external wiring.
2. Fuel oil pump sounds loud or is overheated.
o Pump cavitation or excessively-high discharge pressure.
o Clogging of discharge piping , valve, or so on .
o Air mixing from suction side.
o Shaft locking or rotary section seizure.
o Vapor locking due to excessively-high fuel oil temperature .
o Excessive draining of fuel oil.
o Misalignment of pump and motor center lines.
o Damage of shock absQrbing rubber coupling.
3. Fuel booster pump does not run .
o Defective pressure gauge .
o Improper pressure adjustment.
o Clogging of discharge side piping or valve.
o Defective solenoid valve.
o Cloggin9' of nozzle pipe.
o High fuel viscosity. Excessively-low heating temperature .
4. Fuel oil temperature does not rise.
o Mixing of air.
o Temperature setting of thermostat 23T is too low.
o Defective thermostat 23T.
o Disconnection of heater heating coil.
o Defective steam heater solenoid valve.
o Fuel heater switch 43H is defective .
o Defective combustion start button 3-4B or not being pushed ON.
o Decrease in capacity of heater due to its stained inside .
5. Fuel does not spray.
o Defective fuel solenoid valve (for circulation or combustion).
o Clogging of nozzle tip (Filter, screw pin, etc)
o Leakage from fuel pipin 9' or joint or clogging of pipe.
o Improper discharge pressure of fuel booster pump.
o Excessively-high fuel viscosity... lock of heating .
o Defective fan switch 88F or defective contact.
6. Will not go on high fire.
o Defective steam pressure switch 63SL (Defective contact).
o Defective fan switch 88F or defective contact.
o Defective high combustion solenoid valve 20VH.
o Defective damper limit switch and improper adjustment.

Note
Regarding trouble shooting of fuel pump and fuel booster pump refer to separated instructions.

70

11-3 Combustion

1. Fan does not run.

o Defective fan switch 88F.
o Thermal relay 49F of fan switch 88F is actuated.
o Steam pressure rises above steam pressure switch set pressure.
o Defective combustion start button 3-4B or not being pushed ON.
o Motor burned out, disconnection, or defective bearing.

2. Ignition failure
1) Fire goes out after burning far 2 or 3 seconds.
o Defective flame eye or stained lens.
o Improper air flow adjustment (Improper damper adjustment).
o Clogging of chimney.
o Defective fuel solenoid valve.
o Improper position between nozzle tip and baffle plate.
2) Fire goes out after burning for about 10 seconds.
o Improper position relative to the nozzle tip, baffle plate, and flame funnel.
o Oil pressure drop in about 10 seconds due to defective solenoid varve, etc.
o Wrong flame detecting position of flame eye.
o Flame blowout due to excessive airflow.
3. Vibration combustion.
o Air is included in fuel.
o Burner ignition position is not proper. (Ignition delay is caused .)
o Oil heating temperature is too high or too low.
o Nozzle tip size does not fi t air flow.
o Oil collects in the combustion chamber and burns.
o Air register is bu rned .
o High combustion solenoid valve leaks during low combustion.
o Low and high combustion pipes leak in the nozzle pipe.
o Oil pressure rises slowly. (ignition delay is caused.)
o Leak from cut-off valve.
o Insufficient air flow.
o When fuel property changes extremely, combustion condition may be affected delicately.
o Funnel is clogged.

71
# ~
 Z BOILER

11-4 Safety Control and Alarm Circuit

1. NFB is ON, but the boiler does not start.

o Power is not turned ON.
o Damaged NFB.
2. Combustion start button is pushed, but the combustion does not start.
o Low-low watef level (Low-low water level alarm lamp illuminates.)
o Manual combustion switch is set at Manual. Or manual operation switch is not tumed OFF.
o Steam pressure rises to set pressure of high set pressure switch 63S.
o Refer to Item 11-3 Combustion.
3. Water is Low-low level, but no indicator lamp illuminates. Alarm bell does not sound either.
o Defective lamp or socket.
o Defective bell stop pushbutton switch 3-28B.
o Defective bell.
4. When ship rolls, water level becomes lower one and burner stops immediately.
o Defective water level detector LM 1-200.
o Wrong connection of lead wire with water level detecting rod terminal or disconnection.
5. Ignition tails, but ignition failure lamp does not illuminate. Alarm does not sound either.
o Defective flame detector FS-1 00.
o Defective lamp or socket. Defective bell.
o Defective bell stop switch 3-28B.

11-5 Exhaust Gas Lines (Main Engine, Burner)

1. Exhaust gas temperature of burner side is high.

o Too much fuel consumption.
o Adhesion of soot to water tubes and smoke tubes.
2. Exhaust sparks from a funnel and condition of main engine become out or order.
o Adhesion of soot to water tubes.
3. Leakage of gases from burner at main engine running (burner stop)
o Refractory are broken off.
o Bend of innermost tubes due to over-heat.

Simple causes of problems are described above During boiler operation, unexpected troubles may occur
including troubles with the sequencer itself which is in charge of control. Therefore, pay special attention to
a meter value, pressure gauge indication , heating and abnormality of components, etc., so that abnormal
symptoms can be discovered in the early stages.
With regard to electric items, check terminal screws for looseness, damage of lead wire, etc. regularly to
prevent any possible troubles .

72

 BOIL

12. Remedyagainst Water Tube trouble

12-1 Water Tube leakage

No leakage from the water tube of the GK type boiler occurs if water quality control is carried out properly.
External water treatment with the water softner and boiler internal water treatment with boiler compound
are absolutely essential. If leakage is found from the boiler water tube due to improper boiler water
treatment, check it as follows:

1) Remove the burner and wind box from the upper section of the boiler. (Open the chimney manhole on
the exhaust gas side.)

2) Enter the boiler combustion chamber and check the water tube wall. (Enter the chimney on the exhaust
gas side.) (It can be checked In this stage, if a leak location is discovered.)

3) Set the feed water pump switch to Manual and perform a hydraulic test. .

4) If water is leaking from the connection of a water tube and tube plate, remove castabe filled around the
connection and check it.
When water is leaking from the back side of the first row of tubes toward the second row of tubes, we
may easily consider that water is leaking from the second row of tubes. Therefore, check it carefully in
full consideration of the above.

5) When the leaking water tube is found, drive a stopper, replace it or so on in accordance with "Damaged
water tUbe".

6) Investigate the cause of water tube leakage and use it as reference for future operation. If the use it as
reference for future operation . If the water treatment is the problem, it may continue to occur until it is
properly looked after.
When water is leaking on the exhaust economizer side, open manhole on the exhaust gas inlet and
outlet and hand hole on middle portion and check it.

73
 Z BUlLER

12-2 Repair for Water Tube Trouble

The GK type boiler is a verticail natural-circulation boiler. Since, Deposits of impurities in feed water
(calcium, magnesium, and silica) may form on the heating surface which could hinder the heat exchange
process, damage the water tubes , and cause leakage, if boiler water is not controlled as shown in the
attached "Manual for water treatment. To operate this boiler most economically and efficiently, it is essential'
to control boiler water by blowing down boiler water and using proper boiler compounds and a water
softener, etc." This chapter describes ways to fix damaged water tubes and leakage which are caused by
unsatisfactory boiler water control.

& Warning
Before inspecting the interior of the unit, tum it off, purge with the bottom blow-off valve and ventilator, and cool both
the inside of the drum and the combustion chamber. Then make sure that the pressure inside the drum is 0 MPa.
•
Also, when conducting the inspection, make sure ventilation is provided by the air duct and/or the ventilator fan .

1. Stopper treatment applied from inside the water drum

Stopper This method uses the 12 steel stoppers that are

~ included as boiler spare parts to plug up from the
~ inside of the water drum, and upper and lower steam
drums. Before inserting the stoppers, you will have to
determine which water tube(s) is/are leaking.
First of all , remove the ventilator, bu rn er assembly
and window box at the top of the boiler, then enter
the combustion chamber.
Sometimes, you can determine by sight where the
Combustion
Chamber leak is coming from. However, in all other cases
you will have to conduct a wate r pressure test to
determine the orig'in . Operate the water supply
pump manually. Loosen the pressure gauge and
the ground part of the pressure switch valve to
release the air. (For boilers with an air release
cock, use the cock to let the air out).
Once you have identif ied the leaking water
tube(s), enter the drum through the manhole and
insert the stoppers from inside as shown in the
diagram .
In this case, you should clean the area so that
junk or foreign substances will not accumulate
where the stopper touches the water tube; this is
t especially important if there is some sort of
Stopper damage. It is also effective the po lish the parts
with carborundum or similar substance .

74
2. Repair by stopper welding from inside the combustion chamber. (Tubes in the first line)

4)

Combustion

Chamber

1 Steam Drum
I

Cut by Gas
2 Water Drum I

3 Water Tube
4 Castable

,I I I. "

2)
/'
3)

This method is exactly like the previous method up to the point where the water pressure test is conducted inside the
combustion chamber to determine which tube(s) is/are leaking. However, the stopper treatment method is completely
different; in this case, the stoppers are welded from inside the combustion chamber, as shown in the diagram.
Therefore, the number one prerequisite for using this method is to have a certified welder on board the ship.

Anchor
Welding

ICastai;e
Combustion Combustion
Chamber Chamber
I

If you undertake the stopper treatment from just the top and bottom without welding the stoppers, keep in mind
that the water tube (which doesn't contain water) will become damaged and water will leak from the exhaust gas
outlet. Therefore, the previous type of work should be done only in case of emergency; it is highly recommended
that the stoppers be welded once the ship reaches port. However, if there is some technical issue, such as with
welders, and application of castable refractories is neglected after the stopper treatment as shown in the figure,
this may other problems to develop. Therefore, you must follow the manufacturer's instructions precisely.

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