erensan° erensan°

“The Heating Engineer” “The Heating Engineer”

liquid/gas fuelled
boiler (HDR)
operating and
maintenance instruction
manual
 erensan° erensan°
“The Heating Engineer” “The Heating Engineer”

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 erensan° erensan°
“The Heating Engineer” “The Heating Engineer”

İÇİNDEKİLER :
FEATURES OF e r e n s a n° BRAND BOILERS .............. 8
THE APPLIED DIRECTIVES AND STANDARDS ............... 8
INTRODUCTION .............................................................................. 9
BOILER DIMENSIONS FOR DIFFERENT BOILER TYPES .. 12
BOILER OPERATING PERSONNEL ....................................... 13
TRANSPORTATION AND TEMPORARY STORAGE ....... 13
Automatic lockout and protection hardware ................. 14
BURNER SELECTION AND INSTALLATION .................... 15
FUEL SELECTION AND STORAGE ......................................... 15
ENSURE THAT THE BOILER PERSONNEL READ FUEL HARDWARE ......................................................................... 16
THESE OPERATING-MAINTENANCE Liquid fuel hardware ..................................................... 16
INSTRUCTIONS Gas fuel hardware ........................................................ 17
SAFETY RULES................................................................................ 18
PREPARATION OF THE BOILER FOR OPERATION
AND FIRST FIRING...................................................................... 20
Initial preparations ....................................................... 20
ADJUSTMENTS AND CONTROLS TO BE PERFORMED23
Control of safety valves ................................................ 24
Water level control ....................................................... 25
Foam control................................................................. 27
Boiler feedwater control ............................................... 27
Blowdown ..................................................................... 27
THINGS TO BE DONE IN EMERGENCY CONDITIONS28
Abnormally low water level .......................................... 28
BOILER HARDWARE OPERATING, INSPECTION AND
MAINTENANCE RULES ............................................................... 29
Safety valves ................................................................ 29
Feedwater pumps ......................................................... 30
BOILER INSPECTION AND MAINTENANCE RULES .... 30

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General ......................................................................... 30
Taking the boiler out of operation ................................. 30 FEATURES OF e r e n s a n° BRAND BOILERS
Discharging ................................................................... 31 “thermal engineer”
Inspection and maintenance preparation ..................... 31
Inspection and maintenance of internal surfaces ......... 33 • By virtue of pressurized combustion the flame is cycled
Inspection of the outer surfaces and other parts .......... 33 back in the same cell.
Cleaning of internal surfaces ........................................ 34
Deposits ........................................................................ 35 • The gases that meet the flame a second time, ignite
Deposits in the form of scales ....................................... 35 and convert to heat the half burned fuel particles and
Mud ............................................................................... 35 harmful waste is annihilated totally.
Corrosion ...................................................................... 35
Prevention of gas side corrosion ................................... 36 • The heat of the bright flame that is formed in the
Cracks and brittleness formed in steel parts ................. 36 combustion chamber with the double pass concentrated
combustion, is passed from the combustion chamber to
CHEMICAL SPECIFICATIONS OF BOILER
the water through heat exchange.
FEEDWATER AND BOILER WATER .................................... 37
Deterioration of steam purity........................................ 37 • Gas delaying turbulators, increase the speed of the
Effects of water dragging .............................................. 38 smoke and gases in the flame pipes and enable
Checking of steam purity .............................................. 38 convection maintenance of heat transfer at optimal
Measures to prevent water dragging ............................ 38 level.
Sampling boiler feedwater, boiler water and stream .... 38
Boiler water chemical specifications .......... Hata! Yer işareti • erensan° brand liquid and gas fuelled steam boilers
tanımlanmamış. that provide high efficiency with these features, lower
Maximum acceptable boiler water conductivity operational costs entering normal operation very fast.
depending on the pressure ........................................... 42
Maximum silicate (SiO2) quantity acceptable in boiler
water depending on the pressure ................................. 43 THE APPLIED DIRECTIVES AND STANDARDS
INSTALLATION CIRCUIT DIAGRAM .................................. 44
• 97/23/AT (PRESSURIZED EQUIPMENT PROCEDURE
BOILER LIFE SPAN ...................................................................... 45 GUIDE)
AUTHORIZED SERVICES ......... Hata! Yer işareti tanımlanmamış. • EN 12953-1.....8:2002
• pr EN 12953-9:1999
• pr EN 12953-10:1998
• pr EN 12953-11:2001

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“The Heating Engineer” “The Heating Engineer”
INTRODUCTION

1 Flame Inspection System

2 Door Lever
3 Door
4 Eyebolt
5 Safety Valve Nozzle
6 Manhole

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7 Steam Outlet Nozzle
16
8 Air pipe
9 Rupture Door
10 Chimney Outlet

15
11 Water Level Bottle
12 Foot Group
11

13 Smoke Chest
14 Cleaning Door

14
15 Bottom Blowdown Nozzle
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16 Burner Connection Flange

13
17 Bottom Mud Blowdown Nozzle
18 Water Level Upper Connection Nozzle
8

21

19 Water Level Lower Connection Nozzle

20 Surface Blowdown Nozzle
21 Water Feed Inlet Nozzle
20
7

6
18

19
6
5

12
4
3

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 erensan° erensan°
“The Heating Engineer” “The Heating Engineer”

c BOILER DIMENSIONS FOR DIFFERENT BOILER TYPES

n
h
m

Øk

i 100
f

Øb
d
g
a
e

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“The Heating Engineer” “The Heating Engineer”
BOILER OPERATING PERSONNEL The mechanical connections of the boiler should comply with
The personnel to be charged with boiler operation are Installation Circuit Diagram.
responsible for intervention in case of any emergency. For this Purchase of the boiler as a package including armature is
purpose they must be fully informed about the functions, recommended. In case the steam boiler is purchased without
operating characteristics, operating pressure and temperature armature the armature choice should comply with boiler
and flow quantities; they should know the functions and operating pressure and related standards and procedures; and
operation of all control circuits and measuring devices and the installation should be done by qualified technical personnel.
electrical safety hardware well.
The following control devices should exist on the boiler:
• At least 2 manometers (min. Ø100mm)
MAKE SURE BOILER PERSONNEL HAVE • 1 pressurestat (Number of burner stages + 1)
BOILER CERTIFICATES ! • Thermometer (for chimney gas and feed water
temperature)
• At least 2 level gages
TRANSPORTATION AND TEMPORARY STORAGE • Automatic feed device
• At least 2 safety valves
The boiler should be transported using the lifting and
Alarm element that is recommended to exist in a boiler;
transportation points and utilizing appropriate equipment.
• Low and high water level alarm.
For horizontal movement, horizontal displacement is possible
through controlled sliding on pipes, when it is not possible to
Automatic lockout and protection hardware
utilize a winch.
The boiler should be protected against mechanical blows and For their safe operation, boilers should be equipped with safety
collisions during loading, transportation and unloading. lockout systems and alarm circuits depending on their type,
During temporary storage before transportation and capacity and features. At least the following lockout elements
installation, the boiler must be protected against damages that are recommended to exist in a boiler:
may result due to moisture and external mechanical agents.
• A main flame prevention system that will continuously
monitor initial ignition flame and stop the ignition circuit
USE THE BOILER IN COMPLIANCE WITH
if the flame goes out.
WARNINGS AND RECOMMENDATIONS IN
• A photo-electric monitor that checks main burner flame
THIS INSTRUCTION GUIDE !
and shuts off fuel and puts the flame out if the flame
INSTALLATION goes out or combustion is excessively smoky.
Boiler installation site should comply with the related standards • An adjustable pressure safety switch (pressurestat) that
and procedures. Boiler room door should open outside and stops the burner when steam pressure is too high.
fresh air inlet at floor level and polluted air outlet at ceiling • A level control device that stops the burner when water
level should exist. More than one boiler should not be level is excessively low.
connected to the same chimney. • In kerosene burning boilers, an adjustable pressure
switch that cuts fuel if fuel pump outlet pressure drops.
The boiler should be installed on a foundation elevated from the • In fuel oil burning boilers, an adjustable thermostat that
floor at the installation site. The back feet have been cuts fuel if fuel temperature drops.
manufactured as a slider system to meet thermal expansion. • A pressure switch that shuts the burner in case boiler
The slider system bolts should be loosened to enable system combustion air pressure drops.
functioning.

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• If atomization is being applied during liquid fuel burning,
hardware to cut fuel if atomization (steam or pressurized Fuel transfer lines should comply with technical specifications,
air) environment pressure drops. procedure guides and standards in effect. The fuel tank-burner
• In gas burning boilers, an adjustable pressure switch axis levels should not exceed figures specified in the burner
that cuts fuel if gas pressure drops. user manual.
• Gage glasses, discharge valves, control valves, pressure
and temperature gages, safety valves, measuring and Fuel tanks should conform to standards. A wall must exist
control devices, locking and protecting hardware, air between the fuel tank and the boiler.
heaters, boiler feed pumps, blower should be inspected,
maintenance, control and adjustment operations should If the fuel is oil, the necessary arrangements and heating
be done. system should be installed for fuel flow to burner from tank.
• Electric panel, burner panel and fan, boiler feed pump
propellers should be cleaned with dry pressurized air.
Should be protected from dust and water. BEFORE OPENİNG FRONT DOOR SHUT THE
BURNER AND DISCONNECT BURNER
Required protective elements, apart from these: POWER!
BURNER SELECTION AND INSTALLATION
To achieve efficient combustion, the burner to be attached to FUEL HARDWARE
the boiler should be selected in compliance with the combustion In a boiler operation, fuel hardware is quite important. Different
chamber defined in the boiler technical specifications section. burner hardware exists for various fuels. Automatic systems are
also used for fuel burning. Because the system may
During the installation of the burner, care should be shown to malfunction at any time for any reason during automatic fuel
match burner nozzle axis with combustion chamber axis. burning, the operating personnel for automatic burning
controlled boilers should be trained to operate the boiler
To prevent entry of excess air into the combustion chamber manually when necessary and automatic operation should be
from outside, the burner installation should performed carefully continuously monitored by the boiler men and the system
to prevent leakage. should be transferred to manual mode immediately in
emergencies.
The fuel used for operating should comply with burner
manufacturer recommendations. The fuel hardware should be controlled before firing, whatever
the fuel type it runs with.
A suitable burner should be selected, that conforms to nominal
power of the boiler and whose combustion chamber pressure When the boiler is first fired or a burner, which was shut off for
(at nominal capacity) meets the counter pressure of the boiler. any reason, is restarted the boiler should be ventilated for at
When ordering a boiler, the related sales personnel should be least 2 minutes to enable purging of flammable gas mixtures
informed about the burner selected, to enable the design of the that may have collected in the furnace and chimney gas
boiler door and connection flange to suit the burner. channels.

FUEL SELECTION AND STORAGE Liquid fuel hardware

Fuel complying with the characteristics indicated in the burner In liquid fuel burning boilers, before first firing, all the tank,
user manual or burner vendor catalogues should be obtained. heater, pump, valve and pipe system related to the fuel circuit

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should be reviewed and ensured that they are in good status hardware such as burners, control valves should be controlled,
and function normally. the leaks found should be urgently removed.

If the liquid fuel tank is at a lower level than the fuel pump, The burners should be fired after adjusting the gas and air
parts such as valves, flanges, filters should be inspected and quantities to first firing values. A burner to be fired should
full leakage prevention should be provided in suction pipe; the never be ignited from the flame of another burner in operation.
pump should thus be prevented from drawing air. When fuel-
oil is used as liquid fuel, all heaters operating with electricity or In both the liquid and gas fuel burning hardware, the fuel valve
steam should be checked to be in good working order. In steam or valves, coming after the last manometer in front of the
heaters, fuel oil leakage to steam side should be checked. To burner or burner group, should always be kept fully open
understand this, the oil pump should be run and using the during combustion. Otherwise, the real conditions in the
pump safety valve or the first valve after the heater outlet on burner (such as the real value of the fuel feed pressure) cannot
fuel oil pipe, the highest pressure in the system should be be monitored.
applied for five minutes while the steam is closed on the heater
fuel oil side. After this, the steam inlet should be fully opened The first firing flame to be used in the first firing hardware in
and the condenser water should be checked for fuel oil HDR type boilers should be great enough to overcome the
existence. counter pressure of the boiler.
In liquid fuel burning boilers, the most important reason for bad
combustion is fuel not being fully atomized. To ensure full SAFETY RULES
atomization, the type of atomization that will be recommended • The boiler should only be used for steam production
by the manufacturer should be applied. purposes.
• The boiler should be used complying with warnings and
The water collected at the bottom of the fuel tank should be recommendations in this procedure.
discharged. • Steam installation should be commissioned to authorized
personnel.
Fuel circulation should be provided running the pump after • Electrical connections of the boiler should be
ensuring the fluidity of the fuel-oil in the pipes. All air in the commissioned to authorized personnel.
fuel-oil hardware should have been bled. • The boiler should not be operated if boiler water level is
below minimum.
The fuel residues collected in the burner, boiler front and • When opening the front door, the burner should be shut
especially at furnace bottom should be cleaned before firing. off and burner power should be disconnected.
• It should be ensured that the personnel to operate the
When load needs to be reduced while the boiler is operating, boiler have boiler certification.
the burners in operation should be shut off one by one and the • The boiler chimney should be built in compliance with
required minimum fuel quantity should never be dropped chimney building rules. Airbrick and briquette should not
under, thus the continuity of the flame should never be be used in boiler chimneys.
jeopardized. • 2 times a year, chimney cleaning should be procured, it
should be ensured that the chimney has no any cracks,
Gas fuel hardware holes, the chimney cleaning door is closed and insulated
Before firing, all jointed points such as valves, flanges in the properly.
gas pipe should be checked for gas leaks; all burning hardware, • During first operation and subsequent firings, it should
be checked that the boiler and condenser tank is filled

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with water and that the suction and discharge valves of stopped immediately. The steam should be let off from
the boiler feed pump, which is expected to run, are the discharge and the authorities should be notified.
open, the pump air has been bled and pump rotation • If the burner does not run, do not press the computer’s
direction is correct. reset button more than twice and call authorized burner
• If abnormal noises are heard in the boiler or the service.
installation when the boiler is operated, the burner • If leaks and drains are observed on burner fuel
should be immediately shut off and pressure should be connections and transfer lines, the burner should be
relieved by the discharge lines. Then, the fault should be immediately stopped and line valves should be closed.
determined and removed. In the case of natural gas or LPG usage, utilize a
• In cold climate regions, required measures should be leakage detector device in the boiler room and an
taken to prevent boiler and condenser tank water automatic fuel cut-off system on the main inlet.
temperature dropping to freezing temperature. • In the case of LPG usage, when you observe icing and
• Except before firing, the boiler should not be fed cold dew on fuel pipes due to liquidizing of residual gas in
water. Feedwater temperature should be 80oC for a fuel pipes from previous night, especially on cold days,
pressure of 10 bars. It is recommended not to drop do not absolutely operate the burner. The LPG should be
below 70oC, in any case. To be used in processes where safely discharged from the drain tap. (Liquidizing may
condenser return is low or nil and at times when also form at normal times due to gasification level
condenser water temperature is low; heating of the control or line regulator problem.)
condenser tank should be ensured by connecting the • The boiler door should absolutely not be opened before
condenser tank to steam heater line. the burner is stopped and electric power is cut.
• The boiler water level should be checked continuously. If
the water level cannot be seen properly or the gage is
defective, the burner should immediately be stopped Have the vapor system installed by
and the gage glass should be cleaned or the gage error authorized personnel!
should be investigated and corrected. It should be
frequently checked that the gage valve and connection
pipes are not blocked internally. PREPARATION OF THE BOILER FOR OPERATION AND
• Boiler feed devices should always be in working FIRST FIRING
condition and at least once in each shift the device
discharge valve should be opened to discharge possible Initial preparations
deposits and pipe clearance should be inspected. Once a Before a boiler that is to be newly put in operation or on which
month, the feeding device body should be opened, maintenance-repair work has been performed is fired both the
checked, any existing deposits should be cleaned, the water side and the gas side (such as furnace inside, chamber,
connection pipes and valves should be checked with a chimney gas channels, air channels, air heater, burner
wire for blockage. Measures should be taken to prevent combustion chamber) should be inspected thoroughly; should be
use of hard water that causes deposits or for more cleaned of tools sets, pieces of cloth, iron pieces, oakum, etc.
regular utilization of the Water Softener Device. Residues such as dust, soot, slag should be removed by washing
• In abnormal situations, for example when water level is or sweeping.
rapidly dropping, steam pressure is rapidly rising, when
redness/bending at some parts of the boiler is observed Any existing loose places in boiler internal parts and all other
or any leakage or drain is seen, the burner should be loose places such as holders, clamps and similar, should be

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tightened. After this, all inlets should be closed and manholes Operating and first start
should be tightened using appropriate gaskets. • Check system and boiler connections.
• Fill boiler with chemically suitable water up to the
It should be ensured that all hardware in the fuel equipment and required level. The air discharge valve of boiler should
chimney draught system function correctly, any existing flaps be kept open to enable air discharge during water filling.
should be control for ease of opening and closing. If automatic (The air discharge valve should be kept open until steam
combustion controls or other automatic controls exist, all is seen to come out.) When the water level is
adjustments, tests and all calibrations related to these should satisfactory, the boiler feed device will automatically
have been made and faultless operation status of the system stop the feeding pump. The bottom and surface
should have been provided. discharge valves and boiler feeding device and level
gage valves should be opened to check any blockage.
After making sure all discharge and release valves, level indicator • During the first run of the boiler or during initial ignition
relief valves and control valves are in working condition and leak- of a cold boiler, the burner should be fired so that it will
proof these should be closed. run 10 for minutes and wait for 10 minutes at 1st level
small flame for at least 1 hour to let pressure and
Water with required chemical specifications (see: Boiler temperature rise gradually and to prevent thermal stress
feedwater specifications, page 36) should be filled into the boiler forming on boiler.
up to the normal water level seen on page 22. During this • When the boiler starts to build up pressure, the steam
operation, while water fills the boiler, air valves should be outlet valve should be opened a little to let steam into
opened to prevent trapping of air at any part. the system for gradual warm up. When steam pressure
reaches ¼ operating pressure the burner should be
When the boiler is filled up to the desired level, water feeding stopped and waited for 5-10 minutes for balanced heat
should be stopped. Water level column and level indicator distribution to system. Then, firing should be resumed
discharge valves should be opened fully and some discharge by restarting the burner and the operating pressure
should be allowed and to determine whether blockages exist in should be reached as slowly as possible. When the
valves and pipes. Controls should be made, by performing steam pressure reaches the adjusted pressurestat level,
blowdowns from others discharge valves related to the boiler. It the burner will stop and further rising of pressure will be
should be ensured that the main steam pressure gage shows the prevented.
correct value (furthermore, the connections of the pressure gage • After the boiler operating pressure is reached, the
with the boiler should be checked). surface discharge should be opened for 10 seconds and
the lower discharge for 5 seconds to flush undesired
If the boiler is not attached to the main steam pipe with only one substances from the boiler. In order to prevent human
valve, the steam outlet valve should be checked by opening and errors and negligence in the operation of your boiler,
closing it and ensured to function well. This valve should not be usage of automatic discharge systems is recommended.
tightened too much to prevent to prevent getting stuck from heat • For boilers without automatic discharge systems, boiler
expansion when steam is produced. When the boiler is heated water should be analyzed and surface discharging
and steam starts to come from the discharge pipe, the air in the should be done more frequently when the conductivity
boiler should be allowed to bleed off with steam waiting for some coefficient is found to be high and bottom discharging
time and the discharge valve should be tightened fully. Because should be done more frequently when hardness value is
water level will rise as boiler water is heated, the water level high.
should be kept constant by discharging from the bottom. • Boiler and feed water analyses should be repeated
The nuts on boiler feet should be loosened to free the bolts. periodically. If any negative analysis results are

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obtained, improvement procedures should be performed with standards should be used and support may be requested
under control of expert water chemists. Our company from our company on armature selection.
should be consulted on these topics. Burner capacity adjustment should be made by the relevant
• When water analyses cannot be done, bottom and burner firm and not exceed boiler nominal value.
surface discharging should be performed at least 3 times Pressurestat adjustments should be made not to exceed boiler
a day. Bottom discharging should be performed several operating pressure and in line with process requirements.
times with bottom discharge valve fully opened for at Boiler feedwater pump should turn in the direction indicated by
most 3 seconds; surface discharge should be done arrow, if it is in reverse, phase connections should be reversed.
opening the surface discharge valve very little and The boiler water level should be checked from the level gage
keeping it open for long times. and pressure from manometer and the boiler feed device
• The operation of the boiler gages and control devices operation should be controlled continuously. Boiler safety valve
should be checked continuously every day and in case a opening pressure (see safety valve adjustment table, page 25)
condition out of normal operational behavior is should be tested once a month and if weighted safety valve is
observed, the boiler firing should be stopped under utilized, the weight positions should be constantly checked to
control and the necessary inspections and evaluations stay at marked positions.
should be done. If needed defective devices should be
replaced. Control of safety valves
• Condenser tank temperature should be continuously The nominal values of safety values should be recorded at start
controlled and not let rise over 80o C. High water and these records should be kept. In boilers that have more
temperature may cause cavitation in boiler feed pumps, than one safety valve, the valve that opens at the greatest
may result in pump failure in a short time and pressure should be controlled first. For this purpose valves that
intermittent water pumping into boiler may disrupt rate higher opening pressures should be locked with special
normal operation. For this reason the condenser stops in mechanisms and the safety valve spring to be controlled should
condenser lines should be checked and cleaned one by be released. When the boiler reaches operating pressure the
one and should be replaced if steam leakage is still safety valve should be opened and closed manually several
observed. times. This way the safety valve should be ensured to work
• During the firing of boiler and pressure build up, the properly and valve body should be allowed to warm up.
boiler armatures and connections, manhole door gasket
edges should be controlled and any leakages should be After this, the boiler pressure should be raised to valve
removed. The leakages detected after boiler operating- discharge value and it should be checked whether the safety
pressure is reached, should not be handled immediately, valve opens automatically at required pressure. As soon as the
the required intervention should be performed after safety valve opens combustion should be stopped and the
combustion is stopped, boiler depressurized and pressure should be dropped discharging steam to a level
material temperature drops to enable handling. enabling safe operation on valve.
• Steam valves should be opened and closed slowly. Otherwise,
steam impacts may form. Safety valves not rating desired nominal value are adjusted as
recommended by manufacturer. While adjusting safety valves
ADJUSTMENTS AND CONTROLS TO BE PERFORMED (especially high pressure and capacity boiler valves) the boiler
Purchase of boiler as a package with all armatures included, is pressure should have been lowered to 20% under operating
recommended. For steam boilers not purchased as a package, pressure. The same inspection should be repeated after valve is
armatures that suit the nominal values of boiler and comply adjusted.

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Water level control
During boiler operation, water level should be kept at desired In boilers with automatic water level control, if water level
value for as constantly as possible. For boilers of high capacity drops or rises excessively, the system should be taken out of
and with constant changes in steam draught, automatic control automatic control and water level should be put in manual
of water level should be provided. However, probability of mode. After this, the system should not be connected to
malfunction in device should be kept under consideration and automatic control before understanding and correcting the fault
water level continuously be monitored by operators. reason.

There must exist at least 2 level measuring tools in each boiler

to inspect water level, one being the level gage glass. If
differences are observed between gages, the reason should be
found out and corrected. Tagdiye Cihazi Min.
Su Seviyesi Referans
At least once every shift, level control device should be Çizgisi
discharged by opening its discharge valve and closed to see 1

120mm
2

70mm
that the control device is filled with water again. 3

Minimum and maximum water levels should be marked off on

the level gage glass. Level gage glass and surroundings should Seviye Sisesi

be lighted well and steam leaks should not be allowed. Level

gage glasses should be kept clean. If water level is not seen in
level gage glasses, discharging should be performed to make
water level visible.
Obtain opinion from producer/vendor firms in case level
electrode is being used.

1
120mm

2
70mm

1 Normal water level UYGUN

2 Lowest allowable water level
APPROPRIATE
3 Highest point of heating level
Automatic boiler feed device installation

Boiler water level

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Foam control During high volume blowdowns, the shutting valve should be
When foam formation occurs manifesting itself with fluctuations opened slowly to its end and then blowdown should be started
in water level and unexplained drops in steam temperature, turning the valve slowly ½ turn. In this case, blowdown should
steam draught should be reduced to restore constant water be done until the water level in level gage drops 1.5-2 cm. If
level. To remove foam, water level should be returned to more blowdown is required, blow down should be completed
normal level and steam should be discharge at foam level opening the blowdown valve fully after this stage and first the
continuously. The boiler should be fed with fresh water and blowdown valve then the shutting valve should be closed.
foam discharge should be continued until foaming is prevented
and if foaming cannot be prevented the boiler should be taken THINGS TO BE DONE IN EMERGENCY CONDITIONS
out of operation and the reasons of the problem investigated.
Abnormally low water level
Boiler feedwater control For whatever reason, if the water level in the level gage drops
Boiler feedwater should be sent to the boiler after passing below minimum, the burner should be stopped immediately and
through a water softener device and undesired conditions steam outlet should be closed. Then the reasons for water level
should be removed making constant analyses of the boiler drop should be investigated.
water.
It is very dangerous to feed water immediately, to restore a
Boiler feedwater pumps should be kept under observation closed boiler’s water level to its previous state. Water should
during operation and in case a fault arises, the spare pump be fed under control after the boiler is cooled for some time.
should be operated immediately to prevent feedwater cut.
When the water level dropping reason is understood and the
Blowdown fault is removed, the water should be brought to normal level
and then the boiler should be re-fired. In boilers that have
Maintaining the concentration of solids dispersed in the boiler
electrical alarm and locking systems, which notify low water
water (TDS- Total Dissolved Solids) at an acceptable-level, can
level, these systems should be always kept in good working
be provided by constantly analyzing the boiler feedwater and
order, providing safety against sudden level drops.
blowing down continuously from the blowdown pipe installed for
this purpose. If water analyses that can determine the
continuous blowdown quantity and duration are not being
made, the boiler should be blown down by opening fully the
lower blowdown valve once every shift. Blowdowns should be
done when steam draught is at minimum. PERFORM THE INSPECTION AND
MAINTENANCE OF THE BOILER AND
While blowing down boiler in cases where there are double BOILER ACCESSORIES FULLY
valves on the blowdown line, the valve first opened should be
closed last. Blowdown valves must be opened carefully and
slowly.

The blowdown system should be inspected frequently and

leaking valves should be repaired or replaced. Leaks under high
pressure or temperature, should be removed after burner is
shut and pressure drops.

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BOILER HARDWARE OPERATING, INSPECTION AND
MAINTENANCE RULES
Feedwater pumps
Inspection, maintenance and controls of boiler hardware should Before boiler feed pumps are put in operation, the protective
be done in compliance with hardware manufacturer’s substances applied to shiny external surfaces by manufacturers
instructions. for protection purposes should be cleaned off. Pump suction is
checked and water feed provided.
Safety valves
Generally there should be two safety valves on boilers. Boiler feed pumps should be utilized in alternation to balance
their operating lives. Bearing grease heads should be checked
Safety valves should always be in good working order. and depleted grease should be completed. Water drop leaks on
their gaskets are normal for cooling the shaft. Over squeezing
Safety valves should be passed through hot test at least once a of gasket retainer to prevent water droplets may cause erosion
year and compliance of opening and closing values with of shaft and gasket due to overheating. In case of too much
nominal values should be checked. water leak gasket retainer must be tightened, if it fails to
prevent leak the gasket should be reinforced. In case out of
For new safety valves, nominal values should absolutely be normal mechanical sounds are heard from pump bearings or
controlled without regard to their having been adjusted by the pump internals or frequent thermal cuts happen, authorized
manufacturer. pump service should be contacted.

If a leak is seen in the safety valve during operation, the safety BOILER INSPECTION AND MAINTENANCE RULES
valve is manually opened to remove this leak and steam is
General
blown down for a short time to enable discharge extraneous
substances that may exist on valve seat. If the leak is still not Boiler periodical maintenance should be planned according to
removed, the safety valve is removed and repaired after the boiler operating conditions and how fast it gets dirty. In normal
boiler is cooled. Spring pressure should not be increased in operating conditions smoke side maintenance (turbulator and
leaking safety valves to remove the leak. smoke pipe cleanup) should be performed at least once in a
week for liquid fuels, at least once in 2 months for gas fuels
and waterside maintenance at least once in 6 months. If the
During safety valve opening control the following formula boiler gets dirty faster due to operating conditions,
should be taken into consideration: maintenance period should be shortened.

Popening = 1.05 x Poperating. Furthermore, for the purpose of removing malfunctions seen in
steam boilers the boiler should be stopped at least once a year
EXAMPLE: Safety valve adjustment pressure for 6 bar and the boiler and hardware should be passed from a general
operating pressure: inspection and maintenance.
is found to be: Popening = 1.05 x 6 = 6.3 bars Taking the boiler out of operation
While steam output is reduced, feedwater should also be cut
down and the flame lowered. When the flame size goes down to
desired level, the fuel is cut and flame put out. Airflow should
be continued for some more time and flammable gases

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collected in the furnace and chimney channels should be purged
out. • Before entering the boiler for inspection, the main steam
outlet valve or valves should be closed. The blowdown
Whether a check-valve exists or not in the boiler outlet, the valve between the two valves is opened. Warning plates
shutting valve at the steam outlet should be tightly closed after are tied on the valves. Boiler feedwater inlet valve,
the flame is put out. If there are two shutting valves at the blowdown valves are closed and warning plates are tied
outlet, the steam in the pipe between them should be blown on them. If the blowdown valve of the boiler is
down after both are closed. connected to blowdown valves of other boilers, stricter
safety measures should be provided (for example,
After the fuel is cut, if an atomizing medium such as steam or taking out fly wheels after blowdown valves are closed).
pressurized air exists, the atomizing medium inlet should be
closed. • All fuel inlet valves are closed and warning plates are
tied on them. To provide for the safety of the
If the boiler water level is normal, feedwater pump should be maintenance personnel, the burner ignition pipes are
stopped. Feedwater inlet valve should be closed and if the taken out and in gas fuel burning boilers the gas line is
water level is too high blowdown should be performed to bring plugged off or part of the gas pipe is removed.
it to normal.
• Before entering the boiler, the combustion chamber and
The cooling period of the boiler differs according to boiler type, chimney channels are aired and gases inside are purged.
capacity and features. To prevent formation of differential heat,
fast cooling should be avoided. In very big boilers, additional
• When personnel enter the boiler for inspection, etc.
(short time) firings may have to be performed in the boiler
labels or warning plates are placed at visible places to
during cooling to provide equalized heat distribution.
indicate that people are working inside. Hinged doors
are fully opened and tied back before entering.
Discharging
When the boiler is left to cool down, pressure drop is
• Before stopping the boiler for inspection and
monitored. When pressure goes down to 2-2.5 bars (2-2.5
maintenance purposes soot blowing is performed to
kgf/cm2) the air bleed pipe should be opened to prevent parts
clean the heating surfaces. For inspection purposes, first
working under pressure. When boiler pressure becomes “0” and
the soot on the heat transfer surfaces of the boiler such
water temperature drops under 90oC the boiler may be
as pipes, etc are swept and cleaned thoroughly.
discharged.

If the boiler to be discharged operates in parallel with other • The mobile lamps and lining to be used for lighting in
boilers, care should be shown for the discharge valve to belong the boiler should not be over 42 volts and the extension
to that boiler only. After the boiler is fully discharged, cables should be faultless and thickly isolated. The
cables should be protected from crushes, cuts from
blowdown valves should be tightly closed and warning label
should be hung on them stating that they should not be possible damaging locations (such as sharp edges, door
opened. openings), all electrical devices to be used should be
properly grounded and devices that work with the lowest
Inspection and maintenance preparation voltages should be preferred and electricity connection
work should be done outside the boiler.
• The boiler is stopped, cooled and discharged for inspection
and maintenance.

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Inspection and maintenance of internal surfaces should be controlled to see if dislocations and bends
exist.
• Internal surfaces of the pressurized boiler parts are
• Water level glass and position should be inspected to
inspected to control the suitability of the chemical
see if dislocations exist and the pipes connecting the
specifications of the feedwater and the boiler water
water level bottle to the boiler should be checked for
being used. Before entering the boiler for this purpose,
the door must have been opened and the boiler should being slightly tilted towards the boiler.
have been aired thoroughly. • During maintenance and inspection, the boiler and its
surroundings, air channels, chimney bottom, burners,
• In boilers with flame pipes, pipes should be controlled, boiler front, fuel hardware and control devices should
lighting their insides to ensure they are clean and free of always be kept clean. The tools and kits to be used
blockage. during maintenance should not be scattered around in
disorderly manner.
• Pipes should not be damaged any way during
mechanical washing and cleaning. Cleaning of internal surfaces
• Before making an installed boiler operational, rust,
Inspection of the outer surfaces and other parts corrosive substances, grease leftovers, organic
• The boiler should be inspected from outside to ensure substance leftovers, protective paint, welding electrodes,
that there are no breaks, welding tears at any part due and other extraneous materials leftover from installation
to heating. should be cleaned as thoroughly as possible.
• The turbulators should be taken out and all pipes should • Surfaces that are in contact with water and steam
be cleaned with a suitable mop. Turbulators should be during boiler operation should be cleaned of substances
reinstalled in place after cleaning. For full boiler such as oil, grease, oil acids, rust, paint.
efficiency, turbulators should be installed in full. • Help must be obtained from expert institutions for
chemical cleaning of the boiler.
• All detected leaks and drains should be removed.
• If the boiler will be kept out of operation for a period of
Excessive force should not be applied while tightening
for this purpose and if the leak does stop in spite of time, it should be fully cleaned as in weekly cleaning and
the surfaces should be cleaned with soda solution to
tightening, the leaky places should be opened and new
remove acidity. If deposits have formed a layer, soda
gaskets should be placed after cleaning. While removing
solution cleaning should be repeated as many times as
gaskets on shiny parts, care should be shown not to
scratch these surfaces. required. Sufficient cleaning of sulphur may be tested
with pH paper (pH value should be 7-9). Acid removal
• The valves, pipes, pipe connection fittings and outer
operation should be performed when the boiler is at a
pipes on the boiler and boiler hardware should be
inspected for leaking. temperature of 50-60oC. When this process is
completed, surfaces are left to dry and then linseed oil,
• Manholes known to leak should be passed from
turpentine and graphite are sprayed to prevent oxidation
maintenance and existing leaks should be removed.
of metallic surfaces. The boiler doors should be closed to
• If the chimney is directly above the boiler or boiler
construction, measures taken to prevent rainwater from isolate it from air. In addition a container of half active
lime is placed in the boiler to keep the air inside boiler
the chimney entering and corroding the boiler should be
dry.
controlled.
• The steel construction, the steel platforms and stairs,
boiler wall pipes, carrier supports, pipe suspension bars

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Deposits in water of neutral character, although more slowly. As a result
The solid deposits in the boiler are in the form of scales or mud of this type of corrosion, iron oxide and hydrogen gas formed.
in pipes and other surfaces. Sometimes, due to high metal temperatures that arise because
of bad heat transfer on surfaces covered with excessive
Deposits in the form of scales deposits, the deposited materials enter reaction with the metal
leading to corrosion.
The reason for scaling is lack of a chemical medium that will
turn deposits that form in many boilers into mud and such
Therefore, the necessary hardware should be used to purge
deposits, normally forming mud, hardening and sticking to
boiler feedwater from all kinds of gases, especially from
surfaces under specific conditions.
oxygen. (For this purpose a gas remover called degasser should
be utilized.) Furthermore, various gas removing chemicals
Scaling leads to excessive heating in heating surfaces and
should be added to the boiler water.
thereby to pipe perforations. To ensure prevention of scaling,
the boiler feedwater should be passed from processing to
The CO2 concentration in the steam condenser should be kept
provide the desired chemical conditions before being given to
at minimum value.
the boiler. The water in the boiler should also be kept in
suitable chemical conditions. The correctness of the chemical
Prevention of gas side corrosion
process to be applied should be checked with periodical boiler
water and boiler feedwater analyses. When liquid fuel and especially heavy fuel oil is used sulphur
content reaches 3%. During combustion sulphur collects on fire
Mud and smoke surfaces, especially in far corners. During start stop
operations of the boiler, the water vapor in the chimney gas
Formation of mud on boiler surfaces should be prevented as it
condenses and sulphur mixes with water to form sulphuric acid.
will reduce heat transfer and lead to overheating of surfaces.
To prevent this:
• Liquid fuel with low sulphur content should be used.
When the boiler is put out of operation, the water inside should
• Soot and smut gathering on boiler heating surfaces
not be discharged until it has cooled down thoroughly and the
(combustion chamber, smoke pipes, smoke chest)
mud thus formed should be prevented from baking solid on hot
should not be allowed, cleaning process should be
surfaces.
performed as frequently as possible.
• Panorin should be applied to heating surfaces. (The soot
Corrosion
on surfaces will disappear and boiler smoke side
Corrosion may happen when the boiler is in operational or when cleaning will become easier).
it is taken out of operation. If crusty deposits do not exist in the • The burner should not be stopped very frequently.
boiler, the life of the metal parts and pipes of the boiler • Burner combustion settings should be good. Burnet
depends on local blowholes or erosion of pipes or body due to adjustment should be performed by authorized burner
corrosion. services with Chimney Gas Analyzer.

If red or black iron oxide stains exist in locations with

blowholes, these have formed due to neutral or alkaline Cracks and brittleness formed in steel parts
character of the boiler water.
Cracks in the boiler and smoke pipes should be removed
immediately, as they will lead to dangerous consequences.
If there is excessive heat in regions the boiler water is in
contact with metal parts and water circulation is not sufficient,
they develop blowholes or pitting. Corrosion may similarly form
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CHEMICAL SPECIFICATIONS OF BOILER FEEDWATER Silicate (SiO2)- Solid substances suspended in boiler water
AND BOILER WATER collect in the film layer around steam bubbles and increase
Water to be used in boilers must have been conditioned. The resistance of the bubble against breaking and cause foaming.
chemical specifications that the feedwater and the water in the
boiler must meets are shown in the tables and graphics below. Effects of water dragging
To operate the boiler efficiently and economically, the boiler • Dropping of boiler operating efficiency
feedwater and boiler water should be continuously checked to • Erosion of devices that work with steam
ensure provision of the necessary chemical conditions for the • Deposits forming in steam and condenser circuits
water.
Checking of steam purity
The degree of pureness of the steam and the degree of being Foaming and water dragging in boiler are dangerous conditions
polluted should be determined with samples taken from the that require taking measures and removing immediately.
steam condenser.

Deterioration of steam purity Measures to prevent water dragging

All solid and liquid extraneous substances carried away with • Performing controlled blowdowns continuously to keep
steam produced in the boiler, are polluters that impair steam the condensation in the boiler water at values foreseen
purity. Liquid substances consist of water droplets that are by the application,
dragged along without evaporating and solids consist of • Ensuring lack of foaming substances in the boiler water,
suspended or dissolved solid substances that are dragged along • Preventing sudden changes in steam draught,
together with these water droplets or steam. • Keeping water level at limits shown on page 22.
• Reducing chemical substances input to the boiler.
Water dragging is dragging along of large volumes of water • Establishing the feedwater conditioning system so as to
together with steam, due to increase in boiler level or a sudden provide the conditions in table-1,
increase in steam draught in a short time, for any reason. • Adding special foam removing substances to boiler
Water dragging leads to water impacts in steam pipes. water,
• Check the suitability of the boiler capacity selection,
Foaming, is collection of boiler water around steam bubbles in • Checking the conformance of the selected burner and
membrane form due to pollutant solid or liquid substances burner nozzle with boiler capacity,
existing in the boiler water. The foam forming as a result of this • During initial operation in the morning, giving way to
may rise and be dragged along with steam. steam after all pipe lines reach operating pressure,
• Using steam water separator (especially after the main
Fog - little water droplets existing on boiler water surface in steam valve, before any existing pressure reliever, at
the form of spray or fog are thrown into the steam due to steam using device inlets),
explosion of steam bubbles rising on the surfaces where steam • Designing steam pipelines so as to prevent steam
is freed. cooling and condensing.

Priming is the event of water being moved along with steam Sampling boiler feedwater, boiler water and stream
with a sudden displacement of boiler water. (It can be
İ The sampling dates and sample quantity of the samples taken
compared to the event observed when an open cola or soda
for use in experiments to be performed for checking desired
bottle is shaken.)
water conditions.

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In conditions where boiler water composition changes slowly or
generally stays constant, it is sufficient to take samples once in
each shift or once a day. At places where water composition
changes fast, more samples should be taken.

In a system where various boilers exist, a separate sample

should be taken from each boiler. Samples should be taken just
before blowdowns or during blowdowns and should be
immediately analyzed after cooling under pressure.

The container for taking sample should be clean and the

container should be rinsed with the water to be sampled before
the last sample is taken in the container. Sample containers
should be closed and contact with dust or carbon dioxide in the
air should be prevented. The results of the experiments made
should be recorded daily with a record and kept.

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Maximum acceptable boiler water conductivity
depending on the pressure

Boiler feedwater conductivity should be>30 µS/cm.

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Maximum silicate (SiO2) quantity acceptable in boiler INSTALLATION CIRCUIT DIAGRAM

A boiler installation diagram is given as an example. An
water depending on the pressure installation according to the needs of the operation and the
characteristics of the process where the steam is utilized,
should be setup.

K
TI

P
M

M
PI
3
2

4
1
SV
SV

5
LS LS
PI

LI
• If operating pressure is >20 bars it is not appropriate to

PI

5
work in region (a).

LI
PS PS
•

6
max. acid quantity in (b) region should be pH= 8.2

BRULÖR
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Installation circuit diagram
Note:
PS Pressurestat
_____________________________________________
PI Manometer
_____________________________________________
SV Safety valve
_____________________________________________
LI Water Level Gage
_____________________________________________
LS Water Feed Device
_____________________________________________
LE Level Electrode
_____________________________________________
K Water coming from the condenser tank
_____________________________________________
TI Thermometer
_____________________________________________
M Motor
_____________________________________________
P Pump
_____________________________________________
1 Steam Outlet
_____________________________________________
2 Air pipe
_____________________________________________
3 Feedwater Inlet
_____________________________________________
4 Surface Blowdown
_____________________________________________
5 Level Bottle Discharge Valves
_____________________________________________
6 Bottom Blowdown
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
BOILER LIFE SPAN
_____________________________________________
Hot water boilers’ economic life span has been set by the _____________________________________________
Ministry of Industry to be 10 years. If erensan° brand boilers _____________________________________________
are utilized in compliance with operating and maintenance _____________________________________________
instructions, it is possible to go well over the ministry stated life _____________________________________________
span. Therefore, make sure that this operating and _____________________________________________
maintenance procedure is read and fully applied by _____________________________________________
operating personnel. _____________________________________________
When the boiler has reached unusable state, remove the junk _____________________________________________
from usage area in compliance with environmental procedures. _____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
WISHING HAPPY USE OF YOU’RE YOUR BOILER… … …
_____________________________________________

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Note:
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_____________________________________________
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_____________________________________________
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_____________________________________________
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_____________________________________________
_____________________________________________
_____________________________________________
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_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________

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ısı sanayi a.ş.

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Tel: +90 212 551 05 00 Fax: +90 212 551 34 84
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e-mail: info@erensan.com.tr

İB52003-1
This document is subject to change without notice by Erensan