Composite Boiler

TABLE OF CONTENTS
Table of contents
System Concept
Recommended system layout........................................................................................1
Technical data.............................................................................................................2
Steam Water System....................................................................................................3
Pressure atomizing burner.............................................................................................4
Fuel oil supply Pressure atomizing burner.......................................................................5
Control System Aalborg OC-TCi...................................................................................6
Drawings....................................................................................................................7
Spare Parts..................................................................................................................8
Aalborg OC-TCi Boiler

Descriptions................................................................................................................9
Installation................................................................................................................10
Feed and boiler water.................................................................................................11
Safety valves.............................................................................................................12
Feed water system......................................................................................................13
Feed water pump unit.................................................................................................14
Salinity alarm equipment............................................................................................15
Oil detection equipment..............................................................................................16
Steam dump equipment...............................................................................................17
Pressure atomizing burner

Descriptions..............................................................................................................18
Installation................................................................................................................19
Cooler unit................................................................................................................20
Aalborg OC-TCi Control system (touch)

Aalborg control system...............................................................................................21
Language UK i
TABLE OF CONTENTS
Table of contents
Recommended system layout

.
Description Document ID Page
Recommended system layout...................................... SD9010_33.................. 1-2
Language UK 1-1 / 10
SD9010_33#P.1
RECOMMENDED SYSTEM LAYOUT
Recommended system layout
1 Description
The layout of the steam/water system as well as the oil system is essential for the boiler
plant operation and operation philosophy. The design and construction of the system
components should therefore be considered carefully during layout of the plant. Alfa
Laval gives some general requirements and recommendations regarding the layout of
the system. These recommendations should be followed strictly in order to have the
best working conditions for the boiler plant and to extend the working life of the plant.
Please note that operation data, process data, etc. are listed elsewhere in this manual,
e.g. like in the “Technical data for boiler unit” section. The requirements/recommen-
dations for some of the most essential components are listed below.
Attention: If the following sections describe system components, which are al-
ready included in the delivery from Alfa Laval, the specific instruc-
tions for these parts should also be consulted. If system components
are not a part of the actual plant these recommendations should be
ignored.
2 Recommendations
2.1 Hydraulic pressure test
If a hydraulic pressure test of the boiler with valves mounted is required, it shall be
performed by sealing the open valve ends with blind flanges or in case of connecting
piping system already connected, with flat "Spade type" flange inserts.
2.2 Feed water pumps
- Min./max. inlet pressure: according to the recommendations of the manufacturer.

- Max. permissible operating pressure: according to the recommendations of the
manufacturer.
- Min. flow rates: according to the recommendations of the manufacturer.
- Feed water operation temperature:85-95˚C.
- Pump flow layout: 1.25 times max. steam output of the boiler(s).
- Pump pressure layout: max. allowable working pressure of the boiler (s) + 4 bar.
1-2 / 10 Language UK
SD9010_33#P.1
2.3 Feed water line layout
- In case of a double boiler plant with common feed water pumps the layout of the
feed water lines for each boiler must be arranged symmetrically. It can be arranged
by e.g. installing a T-connection piece when dividing the common feed water line
after the pumps.
- According to classification requirements a double line is required from feed water
pump to feed water valves for each boiler. For installation of chemical dosing unit
a short piece of common line can be used, the maximum length of this common
line should be 1 m.
- The suction line must have a continuous fall from the hot-well tank to the pumps
(min. 15˚).
- Velocity in suction lines should not be higher than 2 m/s.
- Bendings, T-connections, etc. should not be located closer than 5 times the size of
the pump inlet diameter, or pipe diameter, whichever are the largest, in order to
reduce cavitations occurring from these item.
2.4 Chemical dosing
- Chemical dosing: see the specific instruction (OM9210#99).
2.5 Feed water control valve
- The inlet and outlet stretches of the piping should be of straight piping length. Min.
two times the pipe diameter by inlet and six times by outlet.
- Valve plug type: parabolic plug installed with the feed water flow direction against
the valve closing direction.
- The valve should be designed for a pressure drop of 2.7 bar at max. steam output.
- Regulation type: single loop PID-controller.
2.6 Safety valve waste pipe
- Safety valve: see the specific instruction (IN6040#01).
2.7 Boiler drain
- Drain pipes from the scum valve and blow down valves must lead to an overboard
line. If the blow down valves do not include a non-return function the drain lines
from these must lead to separate overboard lines.
2.8 Sample cooler
- Sample cooler: should be able to cool the collected boiler water down to approx.
25˚C.
- Sample line from boiler to be as short as possible, and with a small volume (di-
ameter)
- Preferred material of sampling pipe: Stainless Steel, which does not have influence
on common analyse of the boiler water
SD9010_33#P.1
2.9 Circulation pumps
- Min. two circulation pumps should be included. One pump must be kept in con-
tinuous operation (also in port) and the other pump in automatic stand-by operation
mode.
- As a guideline for the circulation at design load the flow should be min. six times
the load for water tube exhaust gas boilers and three to four times the load for
smoke tube exhaust gas boilers. The combined pressure drop across the orifice and
reducing valve should not be less than 0.5 – 1.0 bar.
- Observe the temperature of the water to be pumped.
2.10 Circulation water line layout
- The suction and pressure pipes must be designed in accordance with the recom-
mendations of the manufacturer. The water velocity should not exceed approx. 0.5
m/s in the suction line and approx. 1.5 m/s in the pressure line.
- The circulation pumps must be located at least 10 m below the outlet circulation
socket on the oil fired boiler.
- The suction line must have a continuous fall from the oil fired boiler to the pumps
(min. 15˚).
2.11 Circulation flow measurement
- The circulation flow measurement system for exhaust gas boilers without separate
steam space must ensure a continuous water circulation.
- It can e.g. consist of a reducing valve, orifice, and differential pressure indicator
switch. The reducing valve is used to ensure a considerable higher pressure drop
over the valve than the exhaust gas boiler and circulation return pipe. The orifice
and differential pressure indicator switch are used for alarm and start of the stand-
by pump.
- A valve size which is two times smaller than the inlet pipe should normally be
chosen. Furthermore, the reducing valve should have a locking function.
- The orifice must be installed in a straight pipe with a length of at least 25 and 10
times the nominal pipe size before and after the orifice, respectively.
- The pipe connection for the differential pressure indicator switch should not be
located closer to the orifice than 2 and 5 times the nominal pipe size before and
after the orifice, respectively.
- In case two or more boilers are sharing the same pump, an orifice must be installed
at each boiler water inlet to secure a uniform water distribution according to the
requiremnet in technical data for each boiler.
The orifice size must be calculated to fit the specific installation.
SD9010_33#P.1
2.12 Main steam line layout
- The steam piping up to the main steam valve must be flexible in order to minimise
external loads on the main steam valve and associated branch. The flexibility can
be achieved with loops build into the main steam line to take up heat expansion
from the boiler and steam piping or with an expansion joint next to or close to the
main steam valve. Alfa Laval recommend to provide the system with loops as
expansion joints should only be used on very short steam lines and are dangerous
if not installed correct.
- In case of a double boiler plant the layout of the main steam pipe for each boiler
must be arranged symmetrically. It can be arranged by e.g. installing a Y-connec-
tion piece at the common steam line.
- Even steam lines are insulated condensate may appear in long lines and/or where
the steam flow not are present. It is recommended to make condensate traps/pock-
ets with manual or automatic drains at suitable locations in order to avoid that
condensate can accumulate making corrosion and/or water hammering/chocks in
the system.
2.13 Soot blower supply lines
- Irrespective whether the soot blower are supplied with steam or air, it must be
ensured that the supply line to the blower are free from condensate/water. Soot
bower pipe lines should be made with so much inclination that condensate/water
can not accumulate irrespectively the vessels trim, and manual or automatic drains
installed.
2.14 Steam dump equipment
- The dump valve must be able to blow off the exhaust gas boiler steam capacity at
100% boiler design load (ISO condition). The smallest possible valve size should
be chosen.
- The pipe size before the valve must be min. two pipe sizes larger than the dump
valve size.
- The pipe size after the valve must be min. four pipe sizes larger than the dump
valve size.
- The dump valve should be placed as near the dump condenser as possible.
- The inlet and outlet stretches of the piping from the dump valve should be of
straight piping length. Min. two times the pipe diameter by inlet and six times by
outlet. The stretches should, however, be as short as possible.
- If there are valves placed in the system before and/or after the dump valve these
should be of the straightway type and of the same size as the pipes.
- Regulation type: single loop PID-controller.
2.15 Steam dump condenser
- The steam dump condenser must be able to condensate the full amount of steam
generated in the exhaust gas boiler(s). Or if a composite boiler is installed, the full
amount of steam generated by the exhaust gas part of the composite boiler(s).
2.16 Hot-well
- The hot-well tank should be of the pressure less type.

- The hot-well tank capacity should be designed to at least contain 1.25 times the
water volume between the high and low water level marks on the boiler(s).
SD9010_33#P.1
2.17 Steam injection system
- The steam injection system must be able to increase the hot-well water temperature
by min. 30˚C. The recommended service steam pressure is 6-7 barg.
2.18 Oil detection equipment
- Oil detection equipment: should be able to measure accumulated oil content in the
hot-well tank.
2.19 Salinity alarm equipment
- Salinity alarm equipment: should be able to measure the feed water conductivity
in the units [μS/cm] or [ppm] and include temperature compensation.
2.20 Smoke funnel
- The smoke funnel should have a sufficiently stiffness to avoid pulsation during
operation of the boiler.
- Smoke funnel: see the specific instruction for installation of the boiler.
- In case of exhaust gas boilers or combined boilers the exhaust gas inlet piping
should be designed so that the exhaust gas flow is evenly distributed over the entire
inlet cross-section area. The inlet piping should furthermore be constructed so that
no washing water can enter the turbo chargers of the main engine.
- The design of the smoke funnel shall be made in a way securing that rain water
not will make damage corrosion to the boiler. (Standard boiler outlet arrangements
is not designed as rain collectors)
2.21 Smoke density equipment
- Smoke density equipment: should be of the obscuration measuring type.
2.22 O2-measurement
- O2-measurement equipment: according to the recommendations of the manufac-

turer.
2.23 Fuel Compatibility
As fuel oil systems normally are build in a way where light and heavy fuels from time
to time will be mixed in periods, as well as fuel lines commonly are flushed to the
heavy fuel oil tanks, it is essential that it is ensured that the fuels used are able to be
mixed together in order to avoid operation problems.
2.24 Three-way valve unit (MDO/MGO/HFO )
- As flushing of the fuel oil system requires knowledge of position of the 3 way
valves in both supply and return lines, the valves must be equipped with position
indicators for both positions. As the selection of fuel normally is done by the 3
way valves in the supply line, they can be manual operated valves. As the desti-
nation of the return oil is shifted during flushing the 3 way valves in the return line
should be fitted with an actuator. Please see recommended fuel oil supply system
layout, for the actual plant.
SD9010_33#P.1
2.25 Fuel oil pumps
- Fuel Oil Pumps are not to be used for pipe flushing purpose, unless special means
are taken to prevent the pump to be exposed to foreign matter in the oil, do note
that the normal operation filter is not designed for flushing purpose.
- Min./max. inlet pressure: according to the recommendations of the manufacturer.
It is important to observe the min. NPSH value in all possible operating conditions
also with regard to the oil level in the tanks.
- Max. permissible operating pressure: according to the recommendations of the
manufacturer.
- Heavy fuel oil must be pre-heated to a temperature which secures the oil pumps
suitable operation conditions. For most pump types the viscosity should not exceed
380 cSt.
- The viscosity of marine gas oil and marine diesel oil at the pump should not be
lower than minimum stated in Pump Technical Data in any operation condition to
ensure suitable lubricating conditions for the oil pumps .
- Min./max. operational temperature: according to the recommendations of the
manufacturer.
- Pump capacity layout: 2.0 - 2.5 times max. oil amount for the burner(s) in case of
a boiler plant with pressure atomizing burner(s).
- Pump capacity layout: minimum 1.1 times max oil amount for the burner(s) in case
of a boiler plant with steam atomizing burner(s) or rotary cup burner(s).
- In case of pump aggregates which do not have filters attached, it is recommended
to mount a filter in the suction line to protect the pumps against solid contamina-
tion. Filter should always be installed during commissioning. The filter mesh width
should be 0.1 – 0.3 mm.
- As an overload protection, a pressure-relief valve must be installed in each pump,
which is serially set to a response pressure approx. 10% above the operating pres-
sure.
2.26 Fuel pressure control valve
- Fuel pressure control valve: according to the recommendations of the manufac-

turer.
- Regulation type for steam atomizing burner: Single loop PID -controller or self
acting valve depending of fuel type .
2.27 Oil pre-heaters for steam atomizing burner(s)
- Each oil pre-heater must be able to heat the full amount of heavy fuel oil for the
oil burner(s) to obtain the correct viscosity of the oil.
- The oil pre-heaters must be installed in such a way that the tube insert easily can
be dismantled for inspection and cleaning.
- Temperature transmitters and indicators should not be installed more than 0.5 m
after the oil pre-heater(s) connection point.
2.28 Oil pre-heaters for rotary cup burner(s) (if mounted in ring-
line)
- Each installed oil pre-heater must be able to heat the full amount of heavy fuel oil
for the oil burner(s) to obtain the correct viscosity of the oil.
- Temperature probes/sensors and indicators should not be installed more than 0.5
m after the oil pre-heater(s) connection point.
SD9010_33#P.1
2.29 Steam traps for steam atomizing pipeline
- Steam traps for steam atomizing pipelines must be of the ball float type. Other
types of steam traps can cause instability in the atomizing pressure which affects
the burner when it operates on low load.
2.30 Ignition oil pump for rotary cup burner(s) and steam atomiz-
ing burner(s)
- Pump pressure range: 7 – 14 barg

- Pump capacity at 10 bar, 4 cSt.: approx. 50 l/h
- Viscosity range of ignition fuel oil: 1.1 -12 cSt.
- One-pipe system should be used when the pump is placed lower than tank level
(positive suction head).
- Two-pipe system should be used when the pump is placed higher than tank level
(negative suction head).
- It is recommended to install a pressure relief valve with an opening pressure of 20
barg. The relief valve protects the pressure pipes against leaks which can occur
due to heating of the ignition oil when the pump is stopped.
2.31 Mixing tube
- Mixing tube for steam atomizing burners:

HFO tank mounting see IN5580#01
MGO tank mounting see IN5580#04
- Mixing tube for rotary cup and pressure atomizing burners:
HFO tank mounting see IN5590#02 and IN5590#05
MGO tank mounting see IN5580#04
Caution: Actual pump flow should be based on pump flow for operating on a
HFO oil with a viscosity of 380 cSt.
2.32 Gas/air separator unit for pressure atomizing burner(s)
- For pressure atomizing burners with high pressure oil pumps mounted at the burner
unit.
- The gas/air separator and filter unit must be placed next to the burner (if installed).
- The ring line pressure should be dimensioned according to the technical specifi-
cation for the burner.
- For pressure atomizing burners with high pressure pump at the tank, a mixing tube
is installed see instruction (IN5590#02).
SD9010_33#P.1
2.33 Oil pipeline layout
- The oil flow velocity should not exceed approx. 0.5 m/s in the suction line and
approx. 1.0 m/s in the pressure line.
- Observe the NPSH (net positive suction head) values of the pumps when the oil
pipelines are designed and installed.
- The suction and pressure pipes must be designed in accordance with the recom-
mendations of the manufacturer. The nominal diameter of the suction and pressure
pipelines must at least be of the same size as the nominal pump diameter or larger.
- Sudden changes of cross-sections and directions, as well as hairpin bends, must
be avoided.
- The oil pumps must be protected during pressure test of the pipelines. It is not
recommended to carry out the test using water as this immediately destroys the
pumps. Furthermore, water residues, still in the pipelines create rust formations.
- The suction line must have a continuous fall from the oil tanks to the oil pumps in
the system (min. 15˚).
- Be aware that varying pressure loss’s in the pipe lines due to variance in flow and
viscosity may have a negative effect on mechanical regulation valves, whereas
such pressure loss’s should be kept insignificant.
2.34 Tracing
- Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
fuel oil must be insulated and traced in order to keep a sufficiently low viscosity
of the oil. The tracing can be done either by means of steam heating or by means
of electric heating cables. The tracing must be controlled.
- Components carrying heavy fuel oil, such as oil pumps, valves, etc., should also
be traced, and insulated, if not equipped with other heating sources.
2.35 Engine room pressure
- It is expected that the control of the engine room ventilation keeps an equal or
positive engine room pressure compared to the atmospheric pressure.
2.36 Combustion air fan for steam atomizing burner(s)
- Construction of the air duct system: see the specific instruction (IN5550#01).
- The maximum allowable air duct pressure loss stated in the technical data for
combustion air fan (SD9010#14) must be observed. If the actual pressure loss is
higher than stated, Alfa Laval must be informed for review of the fan design data.
2.37 Control air supply
- Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 µm and a pressure dew point 20 K below the lowest ambient tem-
perature must be supplied. (OM5510_05)
SD9010_33#P.1
2.38 General pipeline notes and recommendations
- Please note that all pipelines are expanding with increased temperatures and must
be arranged in such a way that the thermal expansion of the piping systems as well
as the connected components (boiler, pumps, etc.) do not transform any significant
forces to the sockets on the various components.
- Galvanised piping should not be used in steam boiler plants, as the galvanisation
layer by experience is pealing off, as well as form part of a galvanic process, and
cause corrosion problems in the systems.
- In connection with the boiler plant installation all piping systems must be thor-
oughly cleaned in order to remove all welding beads, grease, dirt, etc.
- System components, such as e.g. pumps, must be protected during pressure test of
pipelines. This can be done by disconnecting the components, inserting blind
flanges, or taking special care of the components afterwards.
- Before start up it must be ensured that all pipelines are ready for operation and that
possible blind flanges used during pressure tests have been removed. Alfa Laval
recommends to use blind flanges of the “spade” type, having a long handle indi-
cating that it is mounted and hereby indicating this to the personnel.
2.39 Exemption of liability
The above mentioned recommendations has not solely been given as recommenda-
tions, but included as well good practice and common engineering, and is intended to
cause the design and installation staff to consider how the successful installation can
be made in the individual installations.
Further, in case of trouble which can be related to that the above not has been considered
and incorporated as intended, the liability of Alfa Laval becomes void.
TABLE OF CONTENTS
Table of contents
Technical data
.
Technical data for boiler plant..................................... 106988........................ 2-2
Technical data for Aalborg OC-TCi............................. 106988........................ 2-3
Technical data for feed water pumps............................ 106988........................ 2-6
Technical data for Cooler........................................... 106988........................ 2-7
Technical data for fuel oil pump G147......................... 106988........................ 2-8
Technical data for fuel oil pump G450......................... 106988........................ 2-9
Language UK 2-1 / 9
TECHNICAL DATA FOR BOILER PLANT
Technical data for boiler plant
1 General data
• Request No./Order No.:..........................................................................106988-1

• Hull No./Nos.:..............................................................................DY152, DY153
2 General plant data
• Classification society:......................................................................................BV
• Sub-notification (Unattended operation):.............................................AUT-UMS
• Service level:...........................................................................................Essential
• Flange standard:...............................................................................................EN
• Plant supply voltage:..............................................................................3 x 440 V
• Plant control voltage:...................................................................................230 V
• Pilot voltage:..................................................................................................24 V
• Frequency:...................................................................................................60 Hz
• Pressure gauge calibration:...................................................................Mpa/Multi
• Thermometer calibration:...................................................................................ºC
• Language on signs:....................................................................................English
• Ambient air temperature:..............................................................................45 ºC
3 Documentation data
• Language for manuals:..............................................................................English

• Set of approval manuals:.....................................................................8 sets+1CD
• Set of working manuals:......................................................................6 sets+1CD
• Set of instruction manuals:...........................................................6 sets+1CD/ship
2-2 / 9 Language UK
TECHNICAL DATA FOR AALBORG OC-TCI
Technical data for Aalborg OC-TCi
1 General data

• Hull No./Nos.:..............................................................................DY152, DY153
2 Dimensions for boiler unit
• Height to top of smoke outlet box:.........................................................5,061 mm

• Diameter incl. insulation:.......................................................................2,570 mm
• Weight of boiler unit excl. water:..............................................................16.0 ton
• Weight of boiler unit incl. water:..............................................................24.3 ton
3 Water/steam process data
• Steam output, simultaneous operation:..................................................2,300 kg/h

• Steam output, oil fired section:..............................................................1,600 kg/h
• Steam output, exhaust section:.................................................................700 kg/h
• Working pressure:................................................................................0.6 Mpa(g)
• Working temperature:.................................................................................165 ºC
• Max. allowable working pressure:........................................................0.8 Mpa(g)
• Feed water operation:..................................................................................OnOff
• Feed water temperature, layout:....................................................................80 ºC
4 Data for pressure part
• Boiler type:.......................................Vertical, composite smoke/water tube boiler

• Boiler model:..............................................................................Aalborg OC-TCi
• Test pressure:............................................................1.5 x Design pressure bar(g)
• Protection of boiler body:.................................................................HeatResistant
• Insulation thickness:...................................................................................75 mm
• Cladding type:............................................................................................Trapez
• Colour of insulation plates:..........................................................Blue(RAL5002)
Language UK 2-3 / 9
5 Combustion process data (oil-fired section)
• Min. calorific value of Marine Gas Oil:.............................................42,200 kJ/kg

• Min. viscosity of Marine Gas Oil:....................................................2 cSt. at 40ºC
• Max. viscosity of Marine Gas Oil:....................................................6 cSt. at 40ºC
• Max. density of Marine Gas Oil:...............................................890 kg/m³ at 15ºC
• Min. calorific value of diesel oil:.......................................................42,200 kJ/kg
• Min. viscosity of diesel oil:..............................................................2 cSt. at 40ºC
• Max. viscosity of diesel oil:............................................................11 cSt. at 40ºC
• Max. density of diesel oil:.........................................................900 kg/m³ at 15ºC
• Min. calorific value of fuel oil:..........................................................40,200 kJ/kg
• Max. viscosity of fuel oil:.............................................................700 cSt. at 50ºC
• Max. density of fuel oil:............................................................991 kg/m³ at 15ºC
• Turn down ratio on fuel oil:..............................................................................3:1
• Fuel oil temperature before pre-heater:.........................................................60 ºC
• Fuel oil viscosity at burner inlet:..............................................................8-10 cSt.
• Fuel oil temperature at burner inlet:............................................................145 ºC
• Air excess No. at 100% load:............................................................................1.2
• Flue gas temperature (clean boiler):............................................................355 ºC
• Air consumption at 100% load:..............................................................2209 kg/h
• Flue gas flow (approx.):.........................................................................2323 kg/h
6 Combustion process data (exhaust gas sec-

tion)
• Main engine:.............................................................................5S60ME-C8.1 TII

• Engine load, design:..............................................................................80 %MCR
• Design condition:............................................................................................ISO
• Exhaust gas flow:................................................................................62,900 kg/h
• Inlet temperature of exhaust gas:.................................................................214 ºC
• Outlet temperature of exhaust gas:..............................................................188 ºC
7 Data for pressure loss layout
• Pressure loss across flue gas system, max.:...........................................10 mmWC

• Pressure loss across boiler (oil-fired section):.....................................267 mmWC
• Pressure loss across boiler (exhaust gas section):................................107 mmWC
2-4 / 9 Language UK
8 Data for burner
• Burner type:.............................................................................Pressure atomizing

• Burner regulation:...............................................................................Modulating
• Model:...................................................................................................KBM 125
• Primary fuel:...................................................................................Heavy fuel oil
• Secondary fuel:...............................................................Marine gas oil/Diesel oil
• Burner capacity on diesel oil/marine gas oil, min.:.....................................40 kg/h
• Burner capacity on diesel oil/marine gas oil, max.:..................................114 kg/h
• Burner capacity on fuel oil, min./max.:...............................................52/119 kg/h
• Nozzle:................................................................................................W1-100-50
• Flame tube:...................................................................................Maker standard
• Diffuser disc:.................................................................................Maker standard
• Colour of burner unit:...........................................................................RAL 5002
9 Data for control system
• Power consumption for boiler plant, approx.:...............................................32kW

• Insulation class:...................................................................................................F
• Degree of protection:......................................................................................IP54
• Colour of boiler control panel:................................................Munsell(7.5BG7/2)
• HMI unit:........................................................................................................Yes
• Ethernet:...........................................................................................................No
• MODBUS interface:........................................................................................Yes
10 Operational data for boiler plant
• Operation:......................................................................................24h unattended
• Automatic mode:.............................................................................................Yes
• Manual mode:..................................................................................................Yes
• Emergency mode:............................................................................................Yes
Language UK 2-5 / 9
TECHNICAL DATA FOR FEED WATER PUMPS
Technical data for feed water pumps
1 General data

• Hull No./Nos.:..............................................................................DY152, DY153
2 Data for pump
• Pump operation type:...........................................................................Centrifugal

• Pump type:................................................................................................CR3-17
• Number of pumps:...............................................................................................2
• F.W pump designed for simultaneous operation:.............................................Yes
• Delivery head:......................................................................................12.0 bar(g)
• Pump capacity:.....................................................................................2,875 kg/h
• NPSH:........................................................................................................1.75 m
• Max. media temperature:............................................................................120 ºC
• Weight of unit:...........................................................................................44.5 kg
• Colour of unit:.............................................................................Makers standard
3 Data for pump motor
• Motor type:..................................................................................Makers standard

• Rated current:..................................................................................................4 A
• Starting method:...............................................................................Direct on line
• Starting current:.............................................................................................39 A
• Rated output for motor:..............................................................................2.2 kW
• Revolutions:.......................................................................................3,500 r.p.m.
• Standby heating:...............................................................................................No
2-6 / 9 Language UK
TECHNICAL DATA FOR COOLER
Technical data for Cooler
1 General data
• Project No.:......................................................................................106988-01/02
• Hull No.:........................................................................................DY152,DY153
• Colour of cooler unit:...................................................................Silver RAL9006
2 Data for Cooler
• Cooler type:................................................................................MX10 T16 L600

• Number of coolers:..............................................................................................1
• Marine gas oil capacity:.........................................................................3000 kg/h
• Design pressure (oil side):...........................................................................16 bar
• Design pressure (water side):.......................................................................16 bar
• Marine gas oil inlet temperature:...........................................................max 60 C
• Marine gas oil outlet temperature:................................................................54 C
• Cooling media:........................................................Technical treated fresh water.
• Cooling water amount:.......................................................................... 3900 kg/h
• Cooling water inlet temperature:...................................................................36 C
• Cooling water outlet temperature:.................................................................38 C
• Weight of heat-exchanger:.............................................................................50kg
• Pressure drop (oil side)...................................................................... 0.04476 bar
• Pressure drop (water side).................................................................. 0.13528 bar
Language UK 2-7 / 9
TECHNICAL DATA FOR FUEL OIL PUMP G147
Technical data for fuel oil pump G147
1 General data
• Request No./Order No.:...................................................................106988-01/02

• Hull No./Nos.:...............................................................................DY152,DY153
2 Data for pump
• Pump operation type:...........................................................................Screw type

• Pump type:................................................................................DLC-900-1,4 cSt.
• Number of pumps:...........................................................................................two
• Delivery head:.........................................................................................33 bar(g)
• Pump capacity at 1.4 cSt.:...........................................................................558 l/h
• Pump capacity at 380 cSt.:........................................................................1056 l/h
• NPSH at 1.4 cSt. (including filter):...............................................................5,0 m
• NPSH at 380 cSt. (including filter):..............................................................2,8 m
• Max. inlet pressure:.......................................................................................6 bar
• Relief valve set point (factory set):..............................................................36 bar
• Weight of unit:............................................................................................175 kg
• Colour of unit:..........................................................................Muncell 7,5BG7/2
• Motor type:.........................................................................................FCA-90 S-2

• Operating current (full load):......................................................................3,26 A
• Starting current:........................................................................................22,82 A
• Rated output for motor:..............................................................................1,8 kW
• Power consumption at 1.4 cSt.:..................................................................1,2 kW
• Power consumption at 380 cSt.:.................................................................1,4 kW
• Revolutions:........................................................................................3408 r.p.m.
• Heating element (standstill): optional............................................................25 W
• Thermostat protection:................................................................................NONE
• Numbers of cable entries with reliever:........................................2 pcs. M25X1,5
2-8 / 9 Language UK
TECHNICAL DATA FOR FUEL OIL PUMP G450
Technical data for fuel oil pump G450
1 General data
• Request No./Order No.:...................................................................106988-01/02

• Hull No./Nos.:...............................................................................DY152,DY153
2 Data for pump
• Pump operation type:...........................................................................Screw type

• Pump type:................................................................................DLC-900-1,1 cSt.
• Number of pumps:...........................................................................................two
• Delivery head:.........................................................................................33 bar(g)
• Pump capacity at 1.1 cSt.:...........................................................................504 l/h
• Pump capacity at 380 cSt.:........................................................................1056 l/h
• NPSH at 1.1 cSt. (including filter):...............................................................5,0 m
• NPSH at 380 cSt. (including filter):..............................................................2,8 m
• Max. inlet pressure:.......................................................................................6 bar
• Relief valve set point (factory set):..............................................................36 bar
• Weight of unit:............................................................................................175 kg
• Colour of unit:..........................................................................Muncell 7,5BG7/2
• Motor type:.........................................................................................FCA-90 S-2

• Operating current (full load):......................................................................3,26 A
• Starting current:........................................................................................22,82 A
• Rated output for motor:..............................................................................1,8 kW
• Power consumption at 1.1 cSt.:..................................................................1,2 kW
• Power consumption at 380 cSt.:.................................................................1,4 kW
• Revolutions:........................................................................................3408 r.p.m.
• Heating element (standstill): optional............................................................25 W
• Thermostat protection:................................................................................NONE
• Numbers of cable entries with reliever:........................................2 pcs. M25X1,5
Language UK 2-9 / 9
TABLE OF CONTENTS
Table of contents
Steam Water System

Tag Number
.
................................... P&I diagram-Steam water diagram.............................. X01_910074................ 3-3
................................... List of parts - steam/water........................................... X01_910074................ 3-5
3C1, 3C301.................. Safety valve, DN 32/50, PN 40/16............................... 2611171...................... 3-9
3C184, 3C484.............. Expansion joint, DN 50.............................................. 85Y_013421................ 3-11
3C186, 3C486.............. Remote pull for safety valve....................................... K03_032121................ 3-13
3C2............................. Stop valve, angle, DN 100, PN 25................................ 2511094...................... 3-15
3C3,3C303,3C6,3C7,
3C307, 3C27, 3C327,
3C28, 3C328................ Stop valve, straight, DN 25, PN 25.............................. 2501088...................... 3-16
3C4,3C304.................. Stop valve, straight, non return, DN 25, PN 25.............. 2641088...................... 3-17
3C9, 3C10, 3C11.......... Stop valve, straight, DN 8, PN 160.............................. 6220000002................. 3-18
3C16........................... Gate valve, straight, 1 1/2".......................................... 2931116...................... 3-19
3C17........................... Water level gauge, left, 2 x 6, DN 25, PN 25................. 7010000431................. 3-20
3C18........................... Water level gauge, right, 2 x 6, DN 25, PN 25............... 7010000430................. 3-22
3C187, 3C487.............. Remote pull for water level gauge................................ K03_032122................ 3-25
3C198......................... Stop valve, gate straight, DN 50, PN 10........................ 2531005...................... 3-27
3W14.......................... Level float switch RBA 24, DN 25, PN 40.................... 8100000008................. 3-28
3W16.......................... Water level control unit (dp), DN 25............................ 70Z_036686................ 3-29
3K5............................. Temperature switch AHTs-20/a................................... 6320110...................... 3-31
3M169,3M170............. Feed water pump, type CR3-17................................... 5541002002................. 3-32
3M130........................ Remote start/stop box................................................. 8001000003................. 3-35
3M23.......................... Chemical dosing unit................................................. 9296006003................. 3-36
3H2, 3W32.................. LED indicator / limit switch........................................ 8001000002................. 3-38
3M25.......................... Sample cooler........................................................... 8750005...................... 3-40
Pneumatic control valve, DN 50, PN 25, with DP actuator
3N5............................. and I/P positioner....................................................... 6050000423................. 3-42
3N6............................. Filter regulator with automatic drain............................ 2915101...................... 3-44
................................... Steam injection system............................................... 64Z_064071................ 3-45
M82............................ Stop valve, straight, DN 15, PN 25.............................. 2501086...................... 3-47
M83............................ Filter, DN 15, PN 25.................................................. 7040000041................. 3-48
M84............................ Control valve, DN 15, PN 25...................................... 6050000458................. 3-49
M85............................ Temperature switch.................................................... 8070000023................. 3-50
M85.1......................... Pocket for temperature sensor..................................... 8500001104................. 3-51
M86............................ Check valve, DN 15, PN 40........................................ 6020000101................. 3-52
M87............................ Vacuum breaker, 1/2", PN 40...................................... 6000000121................. 3-53
M89............................ Steam injector, 1/2", PN 25......................................... 7000000085................. 3-54
M145.1........................ Ultrasonic sensor for oil detection equipment................ 8310000005................. 3-55
M145.2........................ Control unit for oil detection equipment....................... 8210000025................. 3-56
M146.1........................ Conductive electrode.................................................. 8620000104................. 3-57
M146.2........................ Control device, salinometer......................................... 8210000032................. 3-58
M146.3........................ T-piece for salinity alarm equipment............................ 8500000115................. 3-59
M77............................ Water test equipment, AGK 100 with armerzine test...... 8800050...................... 3-60
C191........................... Water washing hose with nozzle.................................. 2941001...................... 3-61
(c.fl.)........................... Counter flange........................................................... K16_004096................ 3-63
X01_910074#A.2
P&I DIAGRAM-STEAM WATER DIAGRAM
P&I diagram-Steam water diagram
LIST OF PARTS - STEAM/WATER
List of parts - steam/water

Boiler plant:...................................................................................................................1 x Aalborg OC-TCi
Request number:................................................................................................................................106988
Configuration number:.................................................................................................................................1
Hull number(s):.....................................................................................................................DY152, DY153
Project number(s):....................................................................................................................106988-01/02
P&I diagram drawing number:...................................................................................................X01_910074
P&I diagram revision:..................................................................................................................................a
Date:...........................................................................................................................................9. July 2013
Reading guide:
List of Parts reflects parts delivered by Alfa Laval.
Tag Numbers are given without the index used on the P&I diagram. E.g. “C2" is found on the P&I Diagram
as "1C2" and "2C2" for boiler 1 and 2 respectively.
1 Aalborg OC-TCi boiler
Tag no. Qty. Dim (DN) Application Type Datasheet or draw-

ing
Composite boiler (Qty. gives the number of parts per boiler)
C 1 N/A Aalborg OC-TCi - 15Y_910075
C1 1 32/50 Safety valve Safety 2611171
C301 1 32/50 Safety valve Safety 2611171
C184 1 50 Expansion joint for safety valve - 85Y_013421
C484 1 50 Expansion joint for safety valve - 85Y_013421
C186 1 N/A Remote pull for safety valve - K03_032121
C486 1 N/A Remote pull for safety valve - K03_032121
C2 1 100 Main steam valve Stop 2511094
C3 1 25 Feed water valve Stop 2501088
C303 1 25 Feed water valve Stop 2501088
C4 1 25 Feed water valve Stop SDNR 2641088
C304 1 25 Feed water valve Stop SDNR 2641088
C6 1 25 Scum valve Stop 2501088
C7 1 25 Blow down valve Stop 2501088
C307 1 25 Blow down valve Stop 2501088
C9 1 1/2" Sample valve Stop 6220000002
C10 1 1/2" Air escape valve Stop 6220000002
C11 1 1/2" Gauge board valve Stop 6220000002
C16 1 1 1/2" Furnace drain valve Gate 2931116
C17 1 25 / length Water level gauge left Reflective 7010000431
700
C18 1 25 / length Water level gauge right Reflective 7010000430

700
C187 1 N/A Remote pull for water level gauge - K03_032122
C487 1 N/A Remote pull for water level gauge - K03_032122
C198 1 50 Drain valve for exhaust gas part Gate 2531005
C27 1 25 Stop valve, DP Unit Stop 2501088
C327 1 25 Stop valve, DP Unit Stop 2501088
C28 1 25 Stop valve, Level Switch Stop 2501088
C328 1 25 Stop valve, Level Switch Stop 2501088
W14 1 25 Low level alarm Float switch 8100000008
W16 1 25 Water level control DP control 70Z_036686
unit
Smoke outlet - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
C179 1 - Smoke outlet - -
K5 1 1/2" Temperature switch, smoke outlet ATHs-20/a 6320110
Feed water pump - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
M169 1 32 Feed water pump CR3-17 5541002002
M170 1 32 Feed water pump CR3-17 5541002002
M130 1 - Remote start/stop box Double 8001000003
Chemical Dosing - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
M23 1 - Chemical dosing - 9296006003
Remote indication - Steam pressure and Water level - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
H2 1 N/A Remote indication of Steam pressure Digital 8001000002
W32 1 N/A Remote indication of Water level Digital 8001000002
Sample coolers - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
M25 1 N/A Sample cooler SCS20 8750005
Steam dump valve
N5 1 50 Steam dump control valve with pneumatic ac- Control 6050000423
tuator
N6 1 1/4" Filter regulator with auto. drain - 2915101
Gauge Board - Aalborg OC-TCi (Qty. gives the number of parts per boiler)
C30 1 N/A Gauge board (Specified on the fuel oil diagram - -
or connection"M"/"T" on the burner diagram -
therefore not shown on water/steam P&I-dia-
gram).
Control system - Aalborg OC-TCi
L1 1 - Local control panel - -
Tag no. Qty. Dim (DN) Application Type Datasheet or draw-

ing
Hot well - steam injection ---64Z_064071
M82 1 15 Stop valve Stop 2501086
M83 1 15 Strainer Strainer 7040000041
M84 1 15 Control valve Control 6050000458
M85 1 Temperature controller with probe 8070000023
M86 1 15 Check valve Check 6020000101
M87 1 1/2" Vacuum breaker - 6000000121
M89 2 1/2" Steam injector - 7000000085
Hot well - oil detection
M145 1 - Oil detection equipment - -
M145.1 1 Sensor- 6 m cable - 8310000005

M145.2 1 Control unit - 8210000025
Salinity control
M146 1 - Salinity control - -
M146.1 1 N/A Salinity Electrode including wire SL 78 8620000104
M146.2 1 N/A Control device SL 700 8210000032
M146.3 1 25 T-piece - 8500000115
Boiler water test kit
M77 1 N/A Boiler water test kit (not shown on the diagram) - 8800050
Water hose and spray gun
C191 1 - Water hose and spray gun (not shown on the di- - 2941001
agram)
Counter flanges
(c.fl.) 1 - Set of counter flanges (not shown on the P&I di- - K16:004096
agram)
DATA SHEET
Tag No(s): 3C1, 3C301
Type:
• Safety valve, full lift
Min. 200
• 25.912
Size:
• Nominal diameter: DN 32/50
Application:
• To blow off saturated steam, air or water
Material:
• Body: GGG 40.3
DIN-Material No.: 0.7043
• Seat: X6 Cr Ni Mo Ti 17122
330
DIN-Material No.: 1.4571
• Disc: X35 Cr Mo 17
DIN-Material No.: 1.4122.05
Technical data:
• Nominal pressure: PN 40/16
• Weight: 14 kg
• Flanges according to DIN
• Inlet: DN 32, PN40
• Outlet: DN 50, PN16
ø125/ 4 x ø18
ø 165
ø 50
Disc
ø 29
115
Seat
Body
ø 32
ø 100 / 4 x ø 18
ø 140
110
Type No.: 6040

Version: A.2 Safety valve, DN 32/50, PN 40/16 2611171
85Y_013421#B.1
EXPANSION JOINT, DN 50
Expansion joint, DN 50
1 --- NO TITLE ---
85Y_013421#B.1
EXPANSION JOINT, DN 50
K03_032121#C.1
REMOTE PULL FOR SAFETY VALVE
Remote pull for safety valve
DATA SHEET
Tag No(s): 3C2
Type: Material:
• Stop globe valve, angle • Body: GP240GH+N
Size: DIN-materiale No: 1.0619+N
• Seat: G19 9 Nb Si
• Nominal diameter: DN 100 DIN-materiale No: 1.4551
Application: • Disc: X20Cr13+QT
• For steam and/or water flow DIN-materiale No: 1.4021+QT
Technical data:
• Nominal pressure: PN25
• Weight: 34 kg
• Valve seat tightness according to DIN
EN 12266-1, leak rate A, standard
225
36
300
Disc
Seat
Body
175
ø 100
ø 190 / 8 x ø22
ø 235
175
Type No.: 6010

Version: C.1 Stop valve, angle, DN 100, PN 25 2511094
DATA SHEET
Tag No(s): 3C3,3C303,3C6,3C7, 3C307, 3C27,

3C327, 3C28, 3C328
Type: Material:
• Stop globe valve, straight • Body: EN-GJS-400-18U-LT
Size: DIN-materiale No: EN-JS1049
• Seat: X20Cr13+QT
• Nominal diameter: DN 25 DIN-materiale No: 1.4021+QT
Technical data:
• Nominal pressure: PN 25
• Weight: 5.4 kg
ø 140
13
190
Disc
ø 85 / 4 x ø14
Seat
ø 25
ø 115
Body
160
Type No.: 6010

Version: C.1 Stop valve, straight, DN 25, PN 25 2501088
DATA SHEET
Tag No(s): 3C4,3C304
Type: Material:
• Stop check globe valve, screw down non • Body: EN-GJS-400-18U-LT
return, straight DIN-materiale No: EN-JS1049
Size: • Seat: X20Cr13+QT
DIN-materiale No: 1.4021+QT
• Nominal diameter: DN 25 • Disc: X20Cr13+QT
Application: DIN-materiale No: 1.4021+QT
• For steam and/or water flow Technical data:
• Weight: 5.4 kg
ø 140
13
190
ø 85 / 4 x ø 14
Disc
ø 115
Seat
ø 25
Body
160
Type No.: 6030

Version: C.1 Stop valve, straight, non return, DN 25, PN 25 2641088
DATA SHEET
Tag No(s): 3C9, 3C10, 3C11
Type: Material:
• Instrument stop cone valve, straight, with • Body: C 22.8
security plate DIN- Material No. 1.0460
Size:
• G ½" x ø 12 • Seat: X20 Cr13
• Nominal diameter: DN 8 DIN- Material No. 1.4021
Application:
• For steam, water and/or air • Needle tip: X35 CrMo17
DIN- Material No. 1.4122
Technical data:
• Inlet: G ½" male DIN
19207, form R
• Outlet: For steel tube ø 12

• Weight: 0.8 kg
Ø 75
115
1/2” BSP
Security plate
12
22
90
Type No.: 6220

Version: A.2 Stop valve, straight, DN 8, PN 160 6220000002
DATA SHEET
Tag No(s): 3C16
Type:
• Gate valve, straight
Size:
• Nominal diameter: 1 1/2"
Application:
• Water, steam and diesel oil
Material:
• Red brass
Technical data:
• Max. working pressure: 16 bar
• Max. temperature: 150°C
• Weight: 0.85 kg
Ø 70
Max. 126
53
1 ½"
23
57
Type No.: 6010

Version: A.2 Gate valve, straight, 1 1/2" 2931116
DATA SHEET
Tag No(s): 3C17
Type: Material:
• Reflective water level gauge • Body: Carbon steel 45#
• Orientation: left • Connection valve body: WCB
• Model size: 26 • Drain valve body: WCB
• 9020 Technical data
Size: • Connection valves type: PX
• Connection, nominal: DN 25 • Weight:16.3 kg
• Connection, drain: ø 10 Dimension:
Pressure rating: • H: 700
• Pressure of unit, nominal: PN 25 • H1: 530
• Pressure of connection valves, nominal: • H2:493
PN 40 • H3: 250
• Pressure of drain valve, nominal:PN 40 • H4:160
Connection type: • H5:115
• Connection type: Flanges according to • L: 84.5
DIN • W:125
Application: • W1:150
• For boiler water level indicator • D: ø 10
Type No.: 7010

Version: B.1 Water level gauge, left, 2 x 6, DN 25, PN 25 7010000431
DATA SHEET
Tag No(s): 3C17
W1
L
W
Visible length H2
H1
H
H3
H5
H4
Drain connection ø D
Type No.: 7010

Version: B.1 Water level gauge, left, 2 x 6, DN 25, PN 25 7010000431
DATA SHEET
Tag No(s): 3C18
Type: Material:
• Reflective water level gauge • Body: Carbon steel 45#
• Orientation: right • Connection valve body: WCB
• Model size: 26 • Drain valve body: WCB
• 9020 Technical data
Size: • Connection valves type: PX
• Connection, nominal: DN 25 • Weight:16.3 kg
• Connection, drain: ø 10 Dimension:
Pressure rating: • H: 700
• Pressure of unit, nominal: PN 25 • H1: 530
• Pressure of connection valves, nominal: • H2:493
PN 40 • H3: 250
• Pressure of drain valve, nominal:PN 40 • H4:160
Connection type: • H5:115
• Connection type: Flanges according to • L: 84.5
DIN • W:125
Application: • W1:150
• For boiler water level indicator • D: ø 10
Type No.: 7010

Version: B.1 Water level gauge, right, 2 x 6, DN 25, PN 25 7010000430
DATA SHEET
Tag No(s): 3C18
W1
L
W
Visible length H2
H1
H
H3
H5
H4
Drain connection ø D
Type No.: 7010

Version: B.1 Water level gauge, right, 2 x 6, DN 25, PN 25 7010000430
K03_032122#C.2
REMOTE PULL FOR WATER LEVEL GAUGE
Remote pull for water level gauge
DATA SHEET
Tag No(s): 3C198
Type:
• Stop valve, gate straight
Size:
• Nominal diameter: DN 50
Application:
• Sea water, fresh water, oil, steam etc.
Material:
• Body: GG 25
Technical data:
• Max. temperature: 150 °C
• Weight: 11.5 kg
Type No.: 6010

Version: A.2 Stop valve, gate straight, DN 50, PN 10 2531005
DATA SHEET
Tag No(s): 3W14
Type:
• Level float switch
• RBA 24
Size:
175
• DN 25
251
Application:
• Low water level switch
Material:
• St. 35.9
• C 22.8
110
Technical data:
• Drain connection: ø 12 mm
• Cable connection: PG 11
• Max. working pressure: 32 bar
• Max. working temperature: 239°C
• Flanges according to DIN 2635-C
• Magnetic switch: 2 x M130
525
1190
• Switching voltage: 6-250V

• Switch current max: 1A ac; 0.5A dc
• Protection of switch housing: IP 54
130
174
ø 12
140
284
Type No.: 8100

Version: A.2 Level float switch RBA 24, DN 25, PN 40 8100000008
70Z_036686#D.1
WATER LEVEL CONTROL UNIT (DP), DN 25
Water level control unit (dp), DN 25
1 --- NO TITLE ---
DATA SHEET
Tag No(s): 3K5
Type:
• Temperature switch
• ATHs-20/a
Application:
66
• For exhaust gas
Material:
• Steel
Technical data:
• Measuring range: + 20 - +500 °C
• Protection: IP54
• Cable entry: PG 13.5
85
G 1/2”
300
8
94 67
Type No.: 8070

Version: A.2 Temperature switch AHTs-20/a 6320110
Technical data
5541002002#A.2
CR 3
FEED WATER PUMP, TYPE CR3-17
Dimensional sketches Dimensions and weights

Net weight
D2 Dimensions [mm]
Pump [kg]
Feed water pump, type CR3-17

D1
type Oval flange DIN flange
Oval
DIN
B2 D1 D2
B1 B1 + B2 B1 B1 + B2
CR 3-2 256 447 281 472 191 141 109 18.4 22.5
B2
CR 3-3 256 447 281 472 191 141 109 18.9 23.0
CR 3-4 274 465 299 490 191 141 109 19.2 23.3
CR 3-5 296 527 321 552 231 141 109 21.1 25.2
G 1/2 G 1/2 CR 3-6 314 545 339 570 231 141 109 22.8 26.9
CR 3-7 332 563 357 588 231 141 109 23.4 27.5
CR 3-8 350 581 375 606 231 141 109 24.2 28.3
CR 3-9 384 665 409 690 281 178 110 30.5 34.6
B1
CR 3-10 402 683 427 708 281 178 110 31.0 35.1
G 1/2 19 x 24.5 DIN CR 3-11 420 701 445 726 281 178 110 31.5 35.6
CR 3-12 438 719 463 744 281 178 110 34.0 38.1
ø100
ø140
ø89
CR 3-13 456 737 481 762 281 178 110 34.2 38.3
75
CR 3-15 492 773 517 798 281 178 110 34.8 38.9
20
100 ø35 4 x ø13.5

141 180 CR 3-17 528 809 553 834 281 178 110 35.3 39.4
250 220 CR 3-19 593 928 335 178 110 45.6
Oval CR 3-21 629 964 335 178 110 46.4
G 1/2 Rp 1
22 M10 x 40 CR 3-23 665 1000 335 178 110 47.2
CR 3-25 701 1073 372 220 134 57.1
TM02 0193 2501
50
20
100 75 4 x ø13.5
145 180
160 220
Electrical data 3 x 220-255/380-440 V, 60 Hz

Motor Full load current Power factor Motor efficiency I
Pump type start
Cos Ê1/1 ----------------
P2 [kW] I1/1 [A] Ë [%] I 1/1
CR 3-2 0.37 1.58-1.46/0.91-0.84 0.88-0.82 78.0-79.0 4.80-6.00

CR 3-3 0.55 2.40-2.18/1.38-1.26 0.88-0.82 80.5-82.0 4.80-6.00
CR 3-4 0.55 2.40-2.18/1.38-1.26 0.88-0.82 80.5-82.0 4.80-6.00
CR 3-5 0.75 3.15-2.85/1.82-1.64 0.89-0.84 82.0-84.0 5.10-6.50
CR 3-6 1.1 4.50-4.00/2.60-2.32 0.89-0.84 82.0-85.0 5.10-6.50
CR 3-7 1.1 4.50-4.00/2.60-2.32 0.89-0.84 82.0-85.0 5.10-6.50
CR 3-8 1.1 4.50-4.00/2.60-2.32 0.89-0.84 82.0-85.0 5.10-6.50
Electrical data 3 x 220-277/380-480 V, 60 Hz

Motor Full load current Power factor Motor efficiency I start
Pump type Cos Ê1/1 ----------------
P2 [kW] I1/1 [A] Ë [%] I 1/1
CR 3-9 1.5 5.70-5.00/3.30-2.90 0.89-0.78 80.5-82.0 5.90-8.40

CR 3-10 1.5 5.70-5.00/3.30-2.90 0.89-0.78 80.5-82.0 5.90-8.40
CR 3-11 1.5 5.70-5.00/3.30-2.90 0.89-0.78 80.5-82.0 5.90-8.40
CR 3-12 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50
CR 3-13 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50
CR 3-15 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50
CR 3-17 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50
CR 3-19 3.0 10.6-9.00/6.10-5.20 0.90-0.83 85.0-86.0 7.40-11.0
CR 3-21 3.0 10.6-9.00/6.10-5.20 0.90-0.83 85.0-86.0 7.40-11.0
CR 3-23 3.0 10.6-9.00/6.10-5.20 0.90-0.83 85.0-86.0 7.40-11.0
CR 3-25 4.0 13.6-11.4/7.85-6.60 0.92-0.85 86.0-87.0 8.00-12.0
3-32 / 63 Industries
Aalborg Data sheet No. 5541 002002 Language UK 1/3
General data
5541002002#A.2
Vertical multistage centrifugal pumps
CR 3
10
4 6
7 TM02 1194 0601Materials: CR, CRI, CRN 1, 3 and 5
Materials: CR
Pos. Description Materials DIN W.-Nr. AISI/ASTM
Cast iron
1 Pump head EN-JL1030 ASTM 25B
EN-GJL-200
3 Shaft Stainless steel 1.4401 AISI 316
4 Impeller Stainless steel 1.4301 AISI 304
5 Chamber Stainless steel 1.4301 AISI 304
6 Outer sleeve Stainless steel 1.4301 AISI 304
O-ring for outer
7 EPDM or FKM
sleeve
Cast iron
8 Base EN-JL1030 ASTM 25B
EN-GJL-200
9 Neck ring PTFE
10 Shaft seal Type cartridge
Rubber parts EPDM or FKM
Language
Aalborg UK
Industries Data sheet No. 5541 002002 3-33 / 63
2/3
Performance curves
5541002002#A.2
CR 3
p H
[Mpa] [m]
CR 3
240 -25
60 Hz
ISO 9906 Annex A
220 -23
2.0 -21
200
180 -19
1.6 160 -17
140 -15
1.2 -13
120
-12
-11
100
-10
-9
0.8 80
-8
-7
60
-6
-5
0.4 40 -4
-3
20 -2
0.0 0
0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 Q [m³/h]
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 Q [l/s]

P2 P2 Eta
[hp] [kW] [%]
0.16 0.12 P2 60
0.12 Eta
0.08 40
0.08
0.04 20
0.04
0.00 0.00 0
0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 Q [m³/h]
p H NPSH
[kPa] [m] [m]
QH 3500 rpm
9 6
80
60 6 4
40
3 NPSH 2
20
0 0 0
TM02 1507 1301
0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 Q [m³/h]
3-34 / 63 Industries
Aalborg Data sheet No. 5541 002002 Language UK 3/3
DATA SHEET
Tag No(s): 3M130
Type: Technical data:

• Remote start/stop box • Nominal operating condition:
Application: U = 600 V and I = 1.2 A or
U = 240 V and I = 3 A or
• For start/operation and stop of feed water U = 120 V and I = 6 A
pumps • Protection: IP 65
Material: • Temperature: -25°C to +70°C
• House: Polycarbonate
• Colour: Grey
120
83 85
Feed water pumps

1 2
Start/operation
incl. lamp function
123
105
145
177
Stop
Cable glands M 32 (PG 29)
105
Ø 5.8
70
Ø 5.8
Type No.: 8001

Version: D.1 Remote start/stop box 8001000003
DATA SHEET
Tag No(s): 3M23

• Dosing pump CNPA -1601 PPE2 with • Max. outlet pressure: 16 bar
chemical tank. • Max. inlet pressure: 8 bar
Application: • Capacity at 16 bar: 1.0 l/h
• For chemical dosing, on/off feed water • Stroke at 16 bar: 0.10 ml
regulation. • Capacity at 8 bar: 1.4 l/h
• For boiler with max. design pressure: 12 • Stroke at 8 bar: 0.13 ml
bar • Max. frequency: 180 stroke/min
Material: • Suction lift: 6 m WC
• Pump • Max. ambient temperature at max. coun-
ter pressure: 45°C
Liquid end: Polypropylene
Valves: Polypropylene • Wattage: 10 W
Seals: EPDM • Peak current: 0.5 A
Balls: Ceramic • Fuse (placed behind the control pan-
• Chemical tank: Polyethylene el): 0.16 AT
• Enclosure rating: IP 65
Feed line to boiler • Insulation class: F
Cooling neck 200 - 300 mm
Yard supply
• Motor: 1 phase AC
Dosing valve, spring loaded • Control supply: 230 V 50/60 Hz
ø 6/ø 4 x 5000 mm PE Hose • Weight: 8 kg
Air escape valve

159
Dosing pump, 5540 000313

incl. air escape valve,
hoses, dosing valve and
non return valve
Manual stirrer, item 8500 000716
60 l chemical tank, item 8500 000715

590
Pover connection
Non return valve
ø 410 Dosing valve

96
35
18
ø 30
Customer connection 1/2”
Type No.: 9296

Version: C.1 Chemical dosing unit 9296006003
DATA SHEET
Tag No(s): 3M23
CNPa 1601 at medium back pressure

1,6
1,4
180 strokes/min
135 strokes/min
90 strokes/min
1,2 45 strokes/min
1
I/h
0,8
0,6
0,4
0,2
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Stroke length
Correction factor
2
1,5
1
0,5
0
1 2 3 4 8 11 13 16
Back pressure
Type No.: 9296

Version: C.1 Chemical dosing unit 9296006003
DATA SHEET
Tag No(s): 3H2, 3W32
Type • Auxiliary voltages:

2-wire supply: 25…16 VDC / 0…20 mA
• LED indicator/limit switch • EMC immunity influence: < ± 0.5% of
• 5714B reading
Application: • Max. wire size: 1 x 2.5 mm²
• Relative air humidity:< 95% RH (non
condensing)
• Tightness (mounted in a panel): IP65
Voltage input:
• Measurement range: -20mV...12 VDC
• Program measurement range :
5714 OK
0…1/0,2…1/0…10/2…10VDC
• Input resistance: nominal 10 M
48
0
12
1 2
Current input:
• Measurement range: -1...25 mA
96
• Program, measurement range:
0…20 and 4…20mA
• Input resistance:
Nominal20  + PTC 25
• The 5714 with 2 relay outputs is designed • Sensor error detection: loop break
for digital readout of current / voltage or 4…20mA…..Yes
temperature signals.
Display:
Relay outputs:
• Display readout: -199…9999 (4 digits)
• Are selected as either a make or a break • Decimal point: programmable
function. The relays can be used as a trip
amplifier. • Digit height: 13.8 mm
• Two yellow front LEDs indicate the re- • Display updating: 2.2 times/s
lay status. The relays can be set up with • Input outside input range is indicated by:
either delayed on or off. Active relay can Explanatory text
be selected for either an increasing or de- Relay outputs:
creasing signal. The arrow keys can be
used for fast change of the set point. • Relay function: setpoint
Technical data: • Hysteresis, in % display counts:
0.1…25%/1…2999
• Panel cut out: 44.5 x 91.5 mm • On and Off delay: 0…3600s
• Weight: 230 g • Max. voltage: 250 VRMS
Electrical specifications: • Max. current: 2 A / AC
Common specifications: • Max. AC power: 500 VA
• Supply voltage: • Max. current at 24 VDC: 1A
Max. voltage: 24…230 VA C, ±10%50… • Sensor error action: Make / break/hold
60Hz
24…250 VDC ± 20%
• Internal consumption: 2.7W
Max. consumption: 3.0 W
Type No.: 8001

Version: E.1 LED indicator / limit switch 8001000002
DATA SHEET
Tag No(s): 3H2, 3W32
Supply
Connections
Input:
RTD, 2-wir e RTD, 3-wire RTD, 4-wire
2-wire transmitter Current
Voltage Potentiometer
Output:
Relays
R1 R2
Block Diagram
Type No.: 8001

Version: E.1 LED indicator / limit switch 8001000002
DATA SHEET
Tag No(s): 3M25
Type: Material:
• Sample cooler • Sample cooler: austenitic stainless steel
Size: grade 316L
• Cooling water inlet valve: stainless steel
• SCS 20 • Sample inlet valve: stainless steel.
Application: • Compression fitting: carbon steel
• The sample cooler is designed for taking Technical data:
manual samples of boiler water for anal-
ysis. The cooling water is turned on and • Coil design pressure: 32 bar g
the sample inlet valve is adjusted until a • Coil design temperature: 300°C
sample of boiler water is obtained at a • Body design pressure: 10 bar g
suitable temperature. For manual sam- • Body design temperature: 100°C
pling it is not normally necessary to
measure sample or cooling water flow • Weight: 4 kg
rates.
ø 90
Sample in ø 6 mm O/D
Customer supply
2. Sample inlet valve

1/4” BSP (each ends)
ø 13
3. Compression fittings
for sample in 1/4” BSP
Cooling water out 1/2” BSP

Customer supply
1. Sample cooler
4. Cooling water Sample out

inlet valve 1/2” BSP
Cooling water in1/2” BSP
Customer supply
Type No.: 7050

Version: D.1 Sample cooler 8750005
DATA SHEET
Tag No(s): 3M25
Installation: • Allow the sample to run for a while be-

fore collection. This will ensure that a
• Fit the SCS 20 so that the bottom of the true sample is collected for analysis.
unit is accessible for the collection of the
cooled sample. • When enough liquid has been collected
close the sample inlet valve first and then
• Connect the cooling water inlet in ½” the cooling water inlet valve.
nominal bore pipe via an inlet valve.
• After closing the sample inlet valve the
• The cooling water outlet should be piped sample out connection may drip for a few
to an open drain or tundish. minutes while the coil drains.
• The sample inlet pipe should be in 6 mm Performance:
O/D tubes.
• The sample inlet to the cooler can be tak- • When it is required to predict the per-
en direct from a boiler or steam line iso- formance of the sample cooler system,
lating valve. the table below gives the sample outlet
temperature to be expected for two boiler
Operation: pressures an for two cooling water flow
• Sample pipe work will become very hot rates.
under normal working conditions, and Example
will cause burns if touched.
• Open the cooling water inlet valve first • A sample flow rate of 30 l/h is required
and ensure that a flow can be seen at the from a boiler operating at 10 barg. For a
cooling water outlet. cooling water flow rate of 0.4 l/s, from
the table the sample outlet temperature
• It is essential that cooling water is flow- would be 4K (4°C) above the cooling
ing before opening the sample inlet water inlet temperature. If the cooling
valve. water is 15°C, the sample temperatures
• Gradually open the samples inlet valve would be 19°C.
and regulate the flow to achieve a cooled
sample at about 25°C.
Sample flow rate Cooling water flow rate Cooling water flow rate
0.25 l/s (900 l/h) 0.4 l/s (1440 l/h)
Boiler pressure
10 barg 20 barg 10 barg 20 barg
l/h l/min Sample outlet temperature above cooling water inlet temperature K (°C)
10 0.17 3 3 1 1
20 0.33 5 5 2 3
30 0.50 7 9 4 5
40 0.67 8 10 5 7
50 0.83 10 12 6 8
60 1.00 11 13 7 10
80 1.33 12 16 8 12
100 1.67 15 19 9 14
120 2.00 17 22 10 16
Table 1
Type No.: 7050

Version: D.1 Sample cooler 8750005
DATA SHEET
Tag No(s): 3N5
Type: Technical data unit:

• Control globe valve, straight with pneu- • Weight: 42 kg
matic actuator and I/P positioner
• 23.470, DP 32
Size:
Application:
• For cooling, water, steam, brine and/or
gas flow
Material valve:
• Body: EN-GSJ-400-18U-LT
Material No.: EN-JS1049
• Seat: X20 Cr13 + QT
Material No.: 1.4021 + QT
• Plug: X20 Cr13 + QT
Material No. 1.4021 + QT
• Stuffing box: PTFE V-ring unit(-10°C to
+ 220°C)
Technical data, valve:
• Positioning ratio: 30:1
• Flow characteristic: Equal percentage
• Kvs value: 16 m³/h
• Travel: 30 mm
• Plug type: Perforated plug with post and
port guiding
Technical data, actuator:
• Spring range: 0.8 – 2.4 bar
• Closing pressure: 11.3 bar
• Diaphragm area: 250 cm²
• Filling volume: 1.4 l
• Max air supply pressure: 6 bar
• Action: Spring closes valve on air failure
Technical data, I/P positioner:
• Air connection: G ¼”
• Inlet air supply: 1.4 to 6 bar, instrument
air
• Air inlet consumption in stable state:
0.036 Nm³/h
• Cable inlet: M20 x 1.5
• Input signal: 4-20 mA
• Ambient temperature: -30°C to +80°C
• Protection: IP65
Type No.: 6050 Pneumatic control valve, DN 50, PN 25, with DP

Version: A.1 6050000423
actuator and I/P positioner
DATA SHEET
Tag No(s): 3N5
Installation: Dimension:
• Only as shown in the picture • L = 230
• H = 504
O.D.2 • H1 = 270
• I.D. = 50
O.D.1
• n x I.D.1 = 4 x 18
Hand wheel • P.D.C. = 125
• O.D. = 165
Stroke indicator
• O.D.1 = 225
• O.D.2 = 250
H1
Actuator
I/P Positioner
H
Stuffing box
Body
P.D.C. n x I.D.1
Plug
O.D.
I.D.
Seat
Flow direction for gas and steam to reduce the sound level
Flow direction for liquids to reduce the cavitation
Type No.: 6050 Pneumatic control valve, DN 50, PN 25, with DP

Version: A.1 6050000423
actuator and I/P positioner
DATA SHEET
Tag No(s): 3N6
Type:
• Filter regulator with automatic drain 30
Size: H andle
Body
• Connections ports 1/4” BSP
Max. 6
• Gauge ports 1/8” BSP
Application:
66
• Instrument air for regulating pressure Fitting
28
Technical data:
• Medium: instrument air only
Gauge por ts
18
Di smantel length 138

• Max. inlet pressure: 17 bar
• Operating temp.: –20 °C to + 65 °C
99
23
• Filter element: 5 m
• Recommend pressure regulating range: 6
8
7.5
0.14-7.0 bar
2.5
• Pressure gauge: 0 – 10 bar
Bin
14
• Weight: 0.4 kg 7
Material:
44
Connections ports
• Body: Steel
• Bin: Steel R1
• Handle: Acetal 9
38
SW19 31
Flow characteristics
41
8
Inlet pressure 7 bar
7
Outlet pressure [bar]
5
4
3
2
1 2 3 4 5 6 7 8 9 10
3
Air flow [dm /s]
Type No.: 8000

Version: B.1 Filter regulator with automatic drain 2915101
64Z_064071#D.1
STEAM INJECTION SYSTEM
Steam injection system
DATA SHEET
Tag No(s): M82
Type: Material:
Technical data:
• Weight: 3.9 kg
ø 120
9
180
Disc
ø 65 / 4 x ø14
Seat
ø 15
ø 95
Body
130
Type No.: 6010

Version: C.1 Stop valve, straight, DN 15, PN 25 2501086
DATA SHEET
Tag No(s): M83
Type Technical data:

• Filter • Nominal pressure: PN 25
Size: • Filtration: 1.0
• Nominal diameter: DN 15 • Flange according to DIN
• Weight: 3.5 kg
Application
Installation:
• For mechanical cleaning of different me-
dias in tube systems before control • The filter can be mounted in optional po-
valves, reduction valves, pumps, steam sitions with the flow following the direc-
traps and flow meters tion of the arrow.
For steam installations the filter basket
Material: should be installed horizontally with the
• Body: EN-GJS-400-18U-LT flow following the direction of the arrow.
Din-Material No. EN-JS1049 Dimension:
• Cover: EN-GJS-400-18U-LT • H: 90
Din-Material No. EN-JS1049
• Screen: X 5 CrNi 18-10 • H1: 135
Din-Material No. 1.4301 • L: 130
• L1: 10
• O.D: 95
• P.D.C: 65
• I.D: 15
• I.D.1: 14
• n: 4
L L1
Body
Screen
P.D.C / n x I.D.1
O.D
I.D
H1
Cover
Type No.: 7040

Version: B.1 Filter, DN 15, PN 25 7040000041
DATA SHEET
Tag No(s): M84
Type
• Thermal-closing valve, straight through L
with flanges and cooling spacer
P.D.C. / n x I.D.1
Size: Seat
• Connection nominal: DN 15
O.D.
I.D.
Body
Pressure rating:
• Pressure nominal: PN 25 Spindel unit
Connection type:
• Connection type: flanges according to
DIN en 1092-2
Application:
• For regulating temperature of fluids, air Cooling spacer
and steam
Material:
• Body: EN-GJS-400-18U-LT
DIN material No. EN-JS1049
• Seat:X6CrNIiTi8-10 M 38 x 1.5
DIN material No: 1.7218
• Spindle unit: X6CrNiTi18-10
DIN material No: 1.4541
Technical data:
• Kvs-value: 4.0 m3/h
• Closing pressure: 16 bar
• Weight: 4.3 kg
Dimension:
• L = 130
• H = 305
• I.D. = 15
• O.D = 95
• P.D.C. = 65
• I.D.1: = 14
• n=4
Installation:
• Spindle and cooling spacer vertical
downwards
Type No.: 6050

Version: B.1 Control valve, DN 15, PN 25 6050000458
DATA SHEET
Tag No(s): M85
Type: Dimension:
• Temperature switch with 8 m capillary • H = 339
tube • H1 = 269
Temperature range: • H2 = 275
• Temperature range: 60°C to 130°C • L1 = 8000
Material: • O.D. = 23
• R min. = 50
• Actuator: CuZn37, CW614N
(nickel plated)
Technical data:
• Weight 1.8 kg
Indicator unit
Pipe
H1
L1
M38 x 1.5
Thermal sensor
Actuator
H2
O.D.
.
in
m
R
Type No.: 8070

Version: F.1 Temperature switch 8070000023
DATA SHEET
Tag No(s): M85.1
Type:
• Pocket for temperature sensor M38 x 1.5
Size:
• Connection instrument: M38 x 1.5
• Connection pocket: G 1"A according to
ISO 228-1
Material:
• Stainless steel G1"
Technical data:
• Pressure max: 40 bar
• Temperature max.: 250ºC
• Weight: 0.7 kg
L
Dimension:
• L = 344
Ø 27
Type No.: 8500

Version: D.1 Pocket for temperature sensor 8500001104
DATA SHEET
Tag No(s): M86
Type:
• Check valve
• Disc-spring
Size:
Pressure rating:
• Pressure nominal: PN 40
Application:
• The check valves are designed to be
sandwiched between flanges. They are
suitable for use on a wide range of fluids Technical data:
for applications in process lines, hot wa-
ter systems, steam and condensate sys- • Weight: 0.14 kg
tems etc. • Kvs-value: 4.4 m³/h
Material:
• Set pressure: 0.02 bar(g)
Installation:
• Body: GX5CrNiMo19-11-2
DIN material No. 1.4408 • The Check valves must be fitted in ac-
• Spring: X10CrNi18-8 cordance with the direction of flow arrow
DIN material No. 1.4310 indicating correct fluid flow direction.
• Valve plate: X6CrNiMoTi17-12-2 • The Check valves can be installed in any
DIN material No. 1.4571 position, except upside down.
• Spring plate: X6CrNiMoTi17-12-2 • The ”cam” design of the body allows the
DIN material No. 1.4571 various flange types to be accommoda-
ted. The body is rotated to touch the
• Retaining ring: X39CrMo17-1+QT flange joint bolts ensuring that the valve
DIN material No. 1.4122+QT is centred in the pipeline.
• Disc check valves are not suitable for use
Retaining ring where heavily pulsating flow exists, such
Valve plate Spring plate as close to a compressor.
Dimension:
• I.D. = 13
• O.D. = 45
• O.D.1 = 95
• W = 16
O.D.
I.D.
Spring
Preparation for
eart connection
Type No.: 6020

Version: A.3 Check valve, DN 15, PN 40 6020000101
DATA SHEET
Tag No(s): M87
Type:
• Vacuum breaker
Size:
• Connection: G 1/2" BSPP
Pressure rating:
• Pressure, nominal: PN 40
Application:
• Ventilation valve for pipelines, condens-
ing vapour (steam) or liquid systems,
where the system pressure should not fall
below the atmospheric pressure.
Material:
• Body: X5CrNi18-10
DIN material No. 1.4301
Cap
• Ball: X20Cr13+QT
DIN material No. 1.4021+QT
• Cap: X17CrNi16-2
Technical data:
• Operating temperature: 220°C
• Operating pressure: 21 bar(g)
• Set pressure: 7 mbar
• Kvs-value: 0.55 m³/h
• Weight: 0.38 kg
Installation:
• The Vacuum Breaker must be installed
in a vertical position, cap on top. System
connection downwards.
Dimension:
• H = 57
• H1 = 10
• W = 42
• HEX = 36
• HEX1 = 32
Type No.: 6000

Version: A.5 Vacuum breaker, 1/2", PN 40 6000000121
DATA SHEET
Tag No(s): M89

• Steam injector • Operating pressure: 17 bar(g)
Size: • Operating temperature: 207 °C
• Connection, internal: G 1/2" BSPP • Weight: 0.4 kg
• Connection, external: G 1" BSPT Installation:
Pressure rating: • The steam injectors must be installed
horizontally.
• Pressure, nominal: PN 25 • The steam injectors are designed to op-
Application: erate with the minimum noise provided
• Steam injectors are designed to inject the installation is correct.
steam into water or process liquor to en- Dimension:
sure quiet and efficient heating of the liq-
uid. The injector draws in cold liquid, • HEX = 36 mm
mixes it with steam within the injector • O.D. = 29 mm
nozzle and distributes the hot liquid. In • L =200 mm
many applications the circulation in-
duced by the injector is an advantage en-
suring thorough mixing and avoiding
temperature stratification.
Material:
• Head: X5CrNi18-10
• Pipe: X5CrNi18-10
L
G 1/2" BSPP
O.D.
G 1" BSPT
Head Pipe
Type No.: 7000

Version: A.4 Steam injector, 1/2", PN 25 7000000085
DATA SHEET
Tag No(s): M145.1
Type: Material:
• Ultrasonic sensor for oil detection equip- • Sensor: Stainless steel
ment Technical data:
Application: • Temperature: -70ºC to 150ºC
• The ultrasonic sensor is operated togeth- • Design of duty: Chemical interface
er with a control unit. • Liquid type: Clean, viscous with solids
• The equipment provides for oil detection • Cable: 6 metre
in feed/make-up water.
258
10 20 25 152 26
11
¾" ø 22
Type No.: 8310

Version: B.4 Ultrasonic sensor for oil detection equipment 8310000005
DATA SHEET
Tag No(s): M145.2

• Control unit for oil detection equipment • Power supply (selector switch):
Application: 110/120V or 220/240V AC
• Relay output: DPCO
• The control unit is operated together with • Enclosure: IP 65
an ultrasonic sensor.
• The equipment provides for oil detection • Holes for glands 3 of ø 16
in feed/make-up water.
Material:
• Control device cabinet: Polycarbonate
Normal
Alarm
Fault
120
88
188 Holes for mounting

75
60
40
Holes for glands

40
130
160
200
Type No.: 8210

Version: B.1 Control unit for oil detection equipment 8210000025
DATA SHEET
Tag No(s): M146.1
Type: Electrical:
• Conductive electrode • Connection to control device via junction
Application: box:
Sensor pin 1 to pin 11 (brown)
• The conductive electrode is used in com- Sensor pin 2 to pin 12 (blue)
bination with a control device to measure Sensor pin 3 to pin 13 (grey)
and supervise the salinity of feed water. Sensor pin 4 to pin 14 (shield)
Technical data: Sensor pin 5 to pin 15 (black)
Instrument: Installation:
• Salinity range: 0 to 100 ppm (sea salt) • The conductive electrode must be instal-
led in the supplied T-piece (item 8500
• Pressure range: 0 to 1 bar(g) 000115). The cable must be connected to
• Temperature range: 0 to 100°C the control device via a junction box (not
• Accuracy: +/- 10% Alfa Laval supply).
• Weight: 0.3 kg • Maximum pressure in line: 1 bar(g)
Note:
• The electrode is totally sealed and must
not be opened. The guarantee is void if
opening of the electrode is attempted.
Cable lenght: 2.5 metre
Blue top cap
Gasket
Gold-plated
electrodes
Type No.: 8620

Version: A.1 Conductive electrode 8620000104
DATA SHEET
Tag No(s): M146.2
Type: Electrical:
• Control device for salinometer • Mains supply: 98 – 122 VAC or
Application: 196 – 244 VAC, 50 – 60 Hz
• Mains current: mains supply must be se-
• The control device is used in combina- cured against over current externally by
tion with a conductive electrode to meas- using a fuse (max. 100 mA)
ure and supervise the salinity of feed wa-
ter. • Power: max. 3.5 W
• Cable connections:
Technical data: Terminal 1-4: mains supply
Instrument: Terminal 5-10: relay contacts for alarm
and solenoid
• Salinity range: 0 – 100 ppm (sea salt) Terminal 11-16: electrode unit
• Accuracy: +/- 10% of displayed value Terminal 17-18: 4-20 mA current loop
• Adjustable alarm range:1 – 100 ppm mA =(0.16 x ppm) + 4 mA)
• Display: LED indication bar • Relay contacts: 8 A / 24 VDC
86
105
Type No.: 8210

Version: D.1 Control device, salinometer 8210000032
DATA SHEET
Tag No(s): M146.3

• T-piece for salinity alarm equipment • Pressure range: 0 to 1 bar(g)
Size: • Flanges according to DIN 2501
• DN 25 • Weight: 2.65 kg
Application:
• Housing for salinity electrode
Material:
• Housing: RG 5
• Nut for electrode: RG5
110
115
10
PCD 85
4 x ø 12
Type No.: 8500

Version: C.1 T-piece for salinity alarm equipment 8500000115
DATA SHEET
Tag No(s): M77

• Test kits Drew AGK100 supplemented • AGK100 test kit.
with Amerzine test. Consisting of:
Size: 1 Comparator, phosphate, 0 - 20 ppm.
1 Snapping cup.
• Dimension of box for AGK 100 test kit: 1 Plastic vial.
Height 105 mm, length 270 mm, 1 Glass tube vial.
width 185 mm 1 Dropper.
• Dimension of box for amerzine test kit: 30 Phosphate test tubes.
Height 45 mm, length 195 mm, 2 Hydrate alkalinity, rgt. A.
width 155 mm 1 Hydrate alkalinity, rgt. B.
• Dimensions of box for hardness test kit: 1 Phenolphthalein
Height 145 mm, Length 250 mm, • Amerzine Test Kit.
Width 165 mm Consisting of:
• Dimensions of conductivity meter: 1 Cylindrical comperator, Amerzine
Height 230 mm, length 140 mm, 1 Sample cup
width 130 mm 30 Ampoules.
Application: • Hardness test kit.
Consisting of:
• Test kits for boiler water treatment. 1 Snapping cup
• Test kit AGK100 should only be used 2 Boxes ampoules, 30 each
with Amerzine test kit • Conductivity kit, loose supply.
Consisting of:
1 Conductivity meter
4 x AAA alkaline batteries
4 x AAA alkaline batteries -spares
1 Low range cell, white band, range
1-500
1 High range cell, range 20-10.000
1 Conductivity cylinder, 100 ml
1 Thermometer
1 Gallic acid
1 Brass spoon
• Weight: 4 kg
Type No.: 8500 Water test equipment, AGK 100 with armerzine
Version: B.1 8800050
test
DATA SHEET
Tag No(s): C191
Type:
• Water washing hose with nozzle Nozzle,
item No. 294 1101
Couplings (2” Storz) Hose,
item No. 294 1001
Size:
• V-nozzle: 12 mm
• Length: 15 metre (hose)
• Inner diameter: 52 mm (hose)
Application:
• For spraying of water
Material:
• Hose: full-synthetic material (polyester)
woven in 1/1 binding, with inner rubber
lining
Technical data: 2” BSP connection Couplings (2” Storz),
(male) item No. 294 1201
• Max allowable working pressure: 20 bar
• Water temperature area: -30ºC-+60ºC
• Weight: 5.5 kg
Water flow
I/min
210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
1 2 3 4 5 6 7 8 9 10 Bar
Type No.: 8615

Version: A.2 Water washing hose with nozzle 2941001
K16_004096#D.1
COUNTER FLANGE
Counter flange
1 --- NO TITLE ---
TABLE OF CONTENTS
Table of contents
Pressure atomizing burner

Tag Number
.
................................... KBM burner flow diagram.......................................... 96X02_065366............. 4-3
................................... List of parts –Aalborg KBM125 burner........................ 96X02_065366............. 4-5
C31, C331, C431.......... Needle valve, straight, ½" x ½", PN 400....................... 2541002...................... 4-7
C33............................. Pressure gauge, ø 100................................................. 6632972...................... 4-8
C35............................. Pressure switch RT30AW 1-10 Bar............................. 6310310...................... 4-9
C48............................. Pressure transmitter 0 - 10 bar(g)................................. 8010000022................. 4-11
C50............................. Instrument stop valve, straight, DN 10, PN 100............. 2573307...................... 4-12
................................... Performance Curve DO.............................................. 106988........................ 4-13
................................... Performance Curve HFO............................................ 106988........................ 4-17
96X02_065366#A.2
KBM BURNER FLOW DIAGRAM
KBM burner flow diagram
LIST OF PARTS –AALBORG KBM125 BURNER
List of parts –Aalborg KBM125 burner

Request No.:.......................................................................................................................................106988
Configuration No.:.......................................................................................................................................1
Hull No./Nos.:........................................................................................................................DY152,DY153
Project No./Nos.:..................................................................................................106988-01-2,106988-01-2
P&I Diagram drawing No.:.....................................................................................................96X02:065366
P&I Diagram revision :................................................................................................................................e
Reading guide:
List of Parts reflects parts included in the burner unit. The parts are related to the P&I diagram for functionality
and no separate data sheet for each part is prepared.
Tag No. Qty. Dim. Application Material Part no.

F1 1 125 Pressure AtomizingBurner - 5561000052
F32 1 N/A Flame scanner RAR 9 (1) - 8630000005
F32.1 1 N/A Cover for flame scanner - 8500001086
F33 1 N/A Flame scanner RAR 9 (1) - 8630000005
F33.1 1 N/A Cover for flame scanner - 8500001086
1F133 1 12 Flex hose DN12 L=1250mm connecting pipe ø15 - 8615000135
2F133 1 10 Flex hose DN10 L=1100mm connecting pipe ø10 - 8615000133
F134 1 10 Flex hose DN10 L=1100mm connecting pipe ø12 - 8615000134
F36 1 ½" Temperature transmitter - 8060000043
F166 1 N/A Ignition transformer - 1 x 230V - 8500001146
F182 1 Ø8 Straight connector BSP ¼"-m Galv. steel 2000000317
F183 1 N/A Junction box - Part of 1F
F187 1 Ø6x40 Heating element for Lance - 8660000046
F201 1 3/8" Solenoid valve, N.O. - 1 x 230V, 60Hz Brass 6240000027
F202 1 1/2" Solenoid valve, N.C. - 1 x 230V, 60Hz Brass 6240000030
F203 1 1/4" Solenoid valve, N.O. - 1 x 230V, 60Hz Brass 6240000027
F206 1 N/A Burner lance - L=350 mm - 4800000282
F206.1 1 N/A Nozzle for burner W1-100-50° - 8610000154
F207 1 N/A El. heater 1 x 8,3 Kw 50/60 Hz - 8689000030
F208 1 N/A Servo motor for oil regulating – 1 x 230V, 50/60 Hz Aluminium 5530000137
F211 1 3/8" Filter ASTM A351 7040000029
F212 1 1/4" Temp. transmitter, 4-20 Ma , 0-200°C - 8060000037
F212.1 1 1/2" Pocket for temperature transmitter - 8500000870
F214 1 1/4" High oil pressure switch -0.2- +10 bar(g) - 8030000010
F217 1 3/8" Oil reg. valve 24-VK2-1.6 PN40 Steel 1.0161 6050000471
F218 1 1/2" Pressure gauge 0-40 bar(g), ø63 - 6633122
F219 1 1/2" Pressure gauge 0-40 bar(g), ø63 - 6633122
F220 1 1/2" Quick closing valve, unit with limit switch - 6000000127
LIST OF PARTS –AALBORG KBM125 BURNER
F220.1 1 M12 Inductive sensor - 8310000018

F222 1 N/A Temperature sensor –fuel oil heater - 8060000049
F223 1 N/A Thermostat 100-200 degrees STB switch - 60T3010
F224 1 M12 Inductive sensor – burner in position - 8310000018
F225 1 1/2" Pressure transmitter, 4-20 mAp , 0-40 bar(g) - 8010000025
F235 1 Ø12 Non return valve Galv. steel 6020000113
F248 1 1/4" Ball valve Brass 6666006
F249 1 1/4" Ball valve Brass 6666006
F255 1 Ø8 Non return valve Galv. steel 6020000112
R1 1 N/A Fan - Complete - 5551000043
R3 1 N/A Low combustion air pressure – 0.5-50 mbar(g) - 8030000020
R7 1 N/A Air damper - 4800000278
R15 1 N/A Fan motor – included in R1 - Part of Fan
R16 1 N/A Servo motor for oil regulating – 1 x 230V, 50/60 Hz - 625 Aluminium 5530000137
R25 1 1/4" Ball valve T bore Steel 6000000104
C31 1 1/2'' Instrument valve C22.8 2541002
C33 1 1/2" Pressure gauge, 0-16 bar, ø100 - 6632972
C35 1 1/2" Pressure switch RT30AW – 0-10 bar - 6310310
C48 1 1/2" Pressure transmitter, 4-20 Ma, 0-10 bar(g) - 8010000022
C50 1 3/8" Instrument valve Brass 2573307
DATA SHEET
Tag No(s): C31, C331, C431
Type:
• Pressure gauge valve needle straight.
Size:
• 1/2” x 1/2”
Application:
• For instrument connections
Material:
• Body: C22.8
• DIN-material No. 1.0460
Technical data:
• Test connection: M20 x 1.5 mm threaded
male
• Weight: 0.4 kg
Type No.: 6210

Version: C.1 Needle valve, straight, ½" x ½", PN 400 2541002
DATA SHEET
Tag No(s): C33

• Pressure gauge • Measuring unit: bar – Mpa - kg/cm²
Size: • Measuring range: 0 – 16 / 1.6 /16 with
mechanical stop
• ø 100 • Connection: BSP1/2”-m
Application: • Operating temperature:
• For all gaseous and liquid media Ambient: 0 to + 60°C
Medium: 0 to + 70°C
Material: The mean value of the maximum ambi-
• Case: Black enamelled steel ent temperature and the medium temper-
• Socket: Brass ature must not exceed the maximum am-
• Liquid filling:Glycerine bient temperature.
45
ø 108
0 bar 16
MPa=bar x 0.1
0 kg/cm² 16
83
16
BSP 1/2" -m
Type No.: 8050

Version: A.2 Pressure gauge, ø 100 6632972
DATA SHEET
Tag No(s): C35
Version: B.2 Pressure switch RT30AW 1-10 Bar 6310310
DATA SHEET
Tag No(s): C35
Version: B.2 Pressure switch RT30AW 1-10 Bar 6310310
DATA SHEET
Tag No(s): C48
Type:
• Pressure transmitter 52
Range: 36
• 0 - 10 bar(g)
Application:
• The pressure transmitter converts pres-
sure to an electric signal. The units are
supplied as passive two wire transmit-
ters. The output current is linearly pro-
portional to the input pressure.
PG 11
Material:
• Housing: Stainless steel with piezoresis-
tive measuring cell and electronics mod-
ule. 106
• Process connection: Stainless steel
Technical data:
ø24
Electrical specification:
• Current output signal: 4 to 20 mA SW 24
• Power supply terminal voltage for cur-
55
rent output: 7 to 33VDC

Accuracy:
• Response time T99: < 5 ms
25
• Influence of ambient temperature at start

of scale: 0.25%/10K of full scale value
• Influence of ambient temperature at full
scale value: 0.25%/10K of full scale val-
ue G 1/2” -m
Mechanical:
• Process temperature: -30°C to +120°C Connection diagram:
• Max pressure: 25 bar(g)
• Min pressure: -1 bar(g)
• Degree of protection to EN 60529: IP65
• Cable gland: PG11
(cable size ø5 to 10 mm)
• Weight: 0.09 kg
Type No.: 8010

Version: B.2 Pressure transmitter 0 - 10 bar(g) 8010000022
DATA SHEET
Tag No(s): C50
Type: Material:
• Instrument stop needle valve, straight • Body: brass
Size: • Spindle: brass
• 3/8" BSP • Packing: PTFE
• Nominal diameter: DN 10 • Hand wheel: steel
Application: Technical data:
• For steam, water and/or air • Nominal pressure: PN 100
• Working pressure: 25 bar
• Weight: 0.32 kg
•
55
95
3 / 8”
56
Type No.: 6220

Version: A.2 Instrument stop valve, straight, DN 10, PN 100 2573307

106988#A.2
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TABLE OF CONTENTS
Table of contents
Fuel oil supply Pressure atomizing burner

Tag Number
.
................................... P&I diagram-Fuel oil supply system............................ 96X02_910073............. 5-3
................................... List of parts-Fuel oil supply........................................ 96X02_910073............. 5-5
G115, G441................. Three-way valve Ball DN32 BW................................. 6070000013................. 5-7
1G340,2G340............... Flow meter unit DN20, ring line.................................. 71Z20_065695............. 5-11
Parts of G340,3G448..... Stop valve, ball, straight, DN 32.................................. 87D3066..................... 5-13
Parts of G340............... Stop valve, ball, straight, DN 20.................................. 87D3064..................... 5-14
Parts of G340............... Differential pressure switch........................................ 8040000010................. 5-15
Parts of G340............... Flow meter, VZO 20.................................................. 7060000015................. 5-17
Parts of G340............... Filter; DN 20, PN 25.................................................. 7040000071................. 5-18
3G147......................... Fuel oil supply unit, with filter, size 900, 33 bar............ 9294002642................. 5-19
3G450......................... Fuel oil supply unit, with filter, size 900, 33 bar............ 9294002602................. 5-22
3G224,3G424............... Remote start/stop box................................................. 8001000005................. 5-25
3G432......................... Heat Exchanger MX10 T16 L=600.............................. 15K7603..................... 5-27
3G433,3G470............... Safety valve, DN 15, PN 100...................................... 87S0032...................... 5-29
3G434......................... Stop valve, ball straight, DN 15, PN 40........................ 6666106...................... 5-30
3G435......................... Needle valve 1/2" x 1/2"............................................. 87N6004..................... 5-31
3G468,3G469............... Stop valve, straight, DN 20, PN 25.............................. 2501087...................... 5-32
3G436......................... Three-way valve, ball, DN 32..................................... 87D3073..................... 5-33
Three-way valve, ball DN 25 build together with actuator,
3G460,3G461............... solenoid valve and switch box..................................... 6070000017................. 5-34
Three-way valve, ball DN 25 build together with actuator
3G437......................... and solenoid valve..................................................... 6070000047................. 5-36
1G114,2G114............... Filter regulator with automatic drain............................ 2915101...................... 5-38
1G466,2G466............... Sample Unit.............................................................. 6000000119................. 5-39
3G471, 3G481.............. Pressure control valve, 1/2"......................................... 6050000542................. 5-41
G274........................... Temperature transmitter in ring line............................. 71Z20_056461............. 5-43
Parts of 3G274............. Temperature sensor.................................................... 8060000046................. 5-45
Parts of 3G274............. Pocket for temperature transmitter............................... 8500000870................. 5-46
3G99........................... Pressure transmitter 0 - 40 bar(g)................................. 8010000025................. 5-47
3G105......................... Needle valve, straight, ½" x ½", PN 400....................... 2541002...................... 5-48
(c.fl.)........................... Counter flange........................................................... K16_004096................ 5-49
96X02_910073#A.2
P&I DIAGRAM-FUEL OIL SUPPLY SYSTEM
P&I diagram-Fuel oil supply system
LIST OF PARTS-FUEL OIL SUPPLY
List of parts - fuel oil supply for
KBM
List ofparts
List of parts-Fuel
- fuel oil oil supply
supply for KBM
Boiler plant: ...................................................................................................... 1 x Aalborg OC-TCi
Request number: ................................................................................................................. 106988
Configuration number: .................................................................................................................. 1
Hull number(s): ........................................................................................................ DY152, DY153
Project number(s): ............................................................................................................... 106988
P&I diagram drawing number: .................................................................................96X02_910073
P&I diagram revision: ................................................................................................................... a
Date: .......................................................................................................................... 26 July 2013
Reading guide:
List of Parts reflects parts delivered by Alfa Laval.
Tag Numbers are given without the index used on the P&I diagram. E.g. “C2” is found on the P&I
Diagram as "1C2" and "2C2" for boiler 1 and 2 respectively.
Pressure Atomizing Burner

Tag no. Qty. Dim (DN) Application Type Datasheet or
drawing
Pressure Jet Burner
F1 1 125 Burner unit KBM 5561000052
Change over valve(s)
G115 1 32 Three-way valve (incl. micro switches) - 6070000013
Oil flowmeter
1G340 1 32 Oil flow meter incl. filter & bypass - 71Z20_065695
2G340 1 32 Oil flow meter incl. filter & bypass - 71Z20_065695
Fuel oil supply pump
G147 1 Fuel oil supply pump unit Double 9294002642
G224 1 N/A Remote start/stop box - 8001000005
Control system
L1 1 - Local control panel - -
Counter flanges
(c.fl.) 1 - Set of counter flanges (not shown on - K16:004096
the P&I diagram) (9492006030)
Fuel oil supply pump
G450 1 - Fuel oil supply pump unit - 9294002602
G424 1 - Remote start/stop box - 8001000005
Cooling unit G429 consisting of
G432 1 - Cooler 15K7603 8670000010
G433 1 - Safety valve - Part of cooler
G434 1 - Drain valve - Part of cooler
LIST OF PARTS-FUEL OIL SUPPLY
page 2/2
Tag no. Qty. Dim (DN) Application Type Datasheet or

drawing
G435 1 - Air escape valve - Part of cooler
Cooling unit line
G468 1 20 Stop valve – cooling water inlet - 2501087
G469 1 20 Stop valve – cooling water outlet - 2501087
G470 1 1/2" Safety valve – cooling water - 87S0032
MGO/HFO select at cooler
G436 1 32 Three-way valve - manual - 87D3073
Stop valve at cooling unit
G448 1 32 Stop valve - 87D3066
At mixing tube
G437 1 DN25 Three-way valve incl. actuator and - 6070000047
solenoid
MGO/HFO select at burner (pressure line)
G460 1 25 Three-way valve incl. actuator, - 6070000017
solenoid and switch box
MGO/HFO select at burner (return line)
G461 1 25 Three-way valve incl. actuator, - 6070000017
solenoid and switch box
Air filter regulator

G114 2 ¼” Air filter/reduction - 2915101
Pressure control valve
G471 1 1/2" Pressure control valve SPV-10 6050000542
G481 1 1/2" Pressure control valve SPV-10 6050000542
Sample stop valve unit
1G466 1 1/4" Sample stop valve unit - 6000000119
2G466 1 1/4" Sample stop valve unit - 6000000119
Temperature transmitter
G274 1 ¼” Temperature transmitter - 71Z20:056461
Pressure transmitter
G99 1 1/2" Pressure transmitter - 8010000025
Stop valve for pressure transmitter
G105 1 1/2" Stop valve - 2541002
DATA SHEET
DATA SHEET
Tag No(s): G115, G441
1 --- NO TITLE ---

Type: Installation:
• Three-way valve, ball
Information and caution before installation
• LB 283 BW, reduced bore
of the valve:
Size: • Pipe must be free of tension.
• DN 32 • Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
Application: which would damage the ball and seat.
• For air, steam, or oil flow • The valve must be kept in open position
during installation. Protective plastic
Material covers must not be removed before the
• Body: ASTM A105 installation work commences.
• End connections: ASTM A105 • At the moment of the shipment the ball is
Technical data: lubricated with a pure vaseline oil,
which can be easily removed with a
• Min./max. temperature at 30 bar:
solvent, if required.
- 29°C to + 230°C
• Ball valves normally have a space
• End connections: Butt weld according to
between ball and inside cavity of the
ASME/ANSI B16.25 - XS-80
body, which could trap the product, care
• Pipe size: DN 32
should be taken to drain the cavity.
• Weight: 7 kg
Instruction for welding the valve on the pipe
line:
Detail A
• Tack weld in four points on both end-
connections.
• Lift out the centre part to protect the
ø 42.2
gaskets against damage and complete

ø 32.7
4.9
1.6
the welding.
• Insert the centre part and ensure easy
37.5°
operation.
225
Centre part
Bolt
L-Bore
Detail A
98
Port 1 Port 2
Port 3
End connections
Port 1 Port 2
158 121.5
Port 3
60
Type No.: 6070

Version: B.1
Version: A
Three-way
Three-wayvalve Ball
valve, DN32
ball BW
DN 32 6070000013
6070 000013
87D3073
B
Language UK
Language UK 5-7 / 1/1
Page 49
1/3
DATA SHEET
EGO SWITCHBOX
TYPE M
Tag No(s): G115, G441
Description:
EGO switchbox with integrated mikroswitches to be used

for remote as well as visual indication of valve position
The switchbox include bracket for mounting on a
pneumatic actuator. With use of a special bracket the box
can be mounted on a gearbox or directly on a valve.
SSpecifications
pecifikations
Box B us Polycarbonat
ShaftAksel POM
Kaplate
Cam mskive Nylon
Bundpplate
Ground lade Pertimax
Kamhoved
Cam Messing
Brass
Tætningsgrad
Protection IP 65
Indikaindicator
Position tor POM
Version: B.1 Three-way valve Ball DN32 O

BW
-rings tætning
O-ring 6070000013
Viton
Aalborg Industries Data sheet No. 6070 000013 2/3
DATA SHEET
EGO SWITCHBOX
TYPE M
Tag No(s): G115, G441
Teknisk ddata
Technical ata:
EGO BOX M EGO BOX I EGO BOX N
Kontakt antal
No. of switches 1+1 1+1 1+1
Type of Kontakttype
switch Mikroswitch PNP induktiv Namur
Fabrikat
Manufacture Honeywell Honeywell Pepperl + Fuchs
ManufactureTy pe No.
item V5C010TB1C 992FS2-A9PV3-L NJ2-V3-N-V5
Voltage Spænding max. 250 VAC 9,6 - 50 VDC 8 VDC
Forbrug
Consumption - ≤ 10 mA -
Max. belastning
Max. load 10 (3) A 200 mA -
Max. frekvens
Max. frequency - 2 KHz 1 KHz
Ambitemperature
Ambient ent temperatur ÷ 55oC til +85oC ÷ 25oC til +75oC ÷ 25oC til +100oC
Dimensioner LxBxH
Dimensions 82x80x67 82x80x67 82x80x67
Cable size: PG 11 (o.d. 5mm to 10 mm)
Version: B.1 Three-way valve Ball DN32 BW 6070000013
Aalborg Industries Data sheet No. 6070 000013 2/3
71Z20_065695#A.1
FLOW METER UNIT DN20, RING LINE
Flow meter unit DN20, ring line
DATA SHEET
Tag No(s): Parts of G340,3G448
Type: Installation:
• Stop ball valve, straight Information and caution before installation
• 133 BW, full bore of the valve:
Material during installation. Protective plastic
covers must not be removed before the
• Body: ASTM A105 installation work commences.
• End connections: ASTM A105 • At the moment of the shipment the ball
Technical data: is lubricated with a pure vaseline oil,
which can be easily removed with a sol-
• Min./max. temperature at 30 bar: vent, if required.
- 29°C to + 230°C
• End connections: Butt weld according to • Ball valves normally have a space be-
ASME/ANSI B16.25 - XS-80 tween ball and inside cavity of the body,
which could trap the product, care should
• Pipe size: DN 32 be taken to drain the cavity.
• Weight: 4.3 kg Instruction for welding the valve on the pipe
line:
Detail A
connections.
• Lift out the centre part to protect the gas-
kets against damage and complete the
ø 42.2
ø 32.7
4.9
1.6
welding.
• Insert the centre part and ensure easy op-
eration.
37.5°
225
Bolt
Detail A
108
End connection
Center part
120 85
Type No.: 6010

Version: B.1 Stop valve, ball, straight, DN 32 87D3066
DATA SHEET
Tag No(s): Parts of G340
Type: Installation:
• Stop ball valve, straight Information and caution before installation
• 133 BW, full bore of the valve:
Material during installation. Protective plastic
covers must be removed before the in-
• Body: ASTM A105 stallation work commences.
• End connections: A105 • At the moment of the shipment the ball
Technical data: is lubricated with a pure vaseline oil,
• Min./max. temperature at 30 bar: vent, if required.
- 29°C to + 230°C
• End connections: Butt weld according to • Ball valves normally have a space be-
ASME/ANSI B16.25 – XS-80 tween ball and inside cavity of the body,
• Pipe size: DN 20 be taken to drain the cavity.
• Weight: 2.3 kg Instruction for welding the valve on the pipe
line:
Detail A
connections.
welding.
ø 26.7
ø 18.9
1.6
3.9

eration.
37.5°
193
Bolt
Detail A
80
End connection
Center part
100 66
Type No.: 6010

Version: B.1 Stop valve, ball, straight, DN 20 87D3064
DATA SHEET
Type:
• Differential pressure switch 116
90
Ø7
Application: 68
11 6
• The units are pressure-controlled
switches.
• The pressure controls are suitable for use Ø3
in alarm and regulation system.
120
103
79
Enclosure:
• IP 67 to IEC 529 and DIN 40050.
• The pressure control housing is enamel-
55
led pressure die cast aluminium (GD-AI-
Si 12). The cover is fastened by four G ¼" (Lp) 29
screws which are anchored to prevent G ¼" (Hp)

35
44
loss. 41
68
The enclosure can be sealed with fuse 81
wire.
Adjustment:
• When the pressure control cover is re- 3
moved, and the locking screw (3) is loos-
ened, the range can be set with the spin- 1
dle (1) while at the same time the scale
(2) is being read. 2
Technical data:
• Operating pressure: 0 – 8 bar
• Differential: 0.2 bar
• Test pressure: Max 22 bar 1 Range spindle
• Pressure connection: G 1/4 -f 2 Range scale
• Medie temperature: Max 80°C 3 Locking screw
• Cable entry: Pg 13.5 for cable diameters
5 to 14 mm.
• Weight: 1.5 kg
Type No.: 8040

Version: A.5 Differential pressure switch 8040000010
DATA SHEET
Type No.: 8040

Version: A.5 Differential pressure switch 8040000010
DATA SHEET

• Flow meter with flanges • Nominal pressure: 25 bar
• VZO 20 • Installation length: 165 mm
Application: • Max. temperature: 130°C
• Measuring of oil consumption • Ambient temperature: -10 to +70°C
• Flow rate:
Maximum: 1500 l/h
Nominal: 1000 l/h
Minimum: 30 l/h
Approx. starting: 12 l/h
• Flanges: according to DIN 2501 / SN
21843
• Weight: 4.5 kg
115
Ø 105
54
165
Type No.:7060
Version: A.2 Flow meter, VZO 20 7060000015
DATA SHEET
Type Technical data:

• Filter • Nominal pressure: PN 25
Size: • Filtration: 0.25
• Nominal diameter: DN 20 • Flange according to DIN
• Weight: 4 kg
Application
Installation:
• For mechanical cleaning of different me-
dias in tube systems before control • The filter can be mounted in optional po-
valves, reduction valves, pumps, steam sitions with the flow following the direc-
traps and flow meters tion of the arrow.
For steam installations the filter basket
Material: should be installed horizontally with the
• Body: EN-GJS-400-18U-LT flow following the direction of the arrow.
Din-Material No. EN-JS1049 Dimension:
• Cover: EN-GJS-400-18U-LT • H: 100
Din-Material No. EN-JS1049
• Screen: X 5 CrNi 18-10 • H1: 150
Din-Material No. 1.4301 • L: 150
• L1: 10
• O.D: 105
• P.D.C: 75
• I.D: 20
• I.D.1: 14
• n: 4
L L1
Body
Screen
P.D.C / n x I.D.1
O.D
I.D
H1
Cover
Type No.: 7040

Version: C.1 Filter; DN 20, PN 25 7040000071
DATA SHEET
Tag No(s): 3G147
Type: Electrical specification:

• Fuel oil supply pump unit, with filter • Rated output for motor: 1.8 kW
Connection type: • Starting metod: Direct
• Connection inlet and outlet, pipe size in- • Starting current: 22.82 A
side / outside diameter: 38 / 48.6 • Operating current (full load): 3.26 A
• Connection type: Flange according to • Revolutions: 3408 r.p.m.
SAE, hole pattern 3.000PSI • Heating element motor: Not fitted
• Cable connection: 2 x M 25 x 1.5 • Power supply: 3 x 440V
Application: • Frequency: 60 Hz
• For handling fuel oils - DMA, DMB, • Insulation class: F
DMZ and RMx according to ISO 8217 • Degree of protection: IP55
Material:
• Station block, casing: EN-GJS-400-15
• Station block, filter cover: S235JR
• Pump, casing: EN-GJS-400-15
• Pump, screw set: 16MnCrS5
• Pump, flange cover: EN-GJS-400-15
• Pump, end cover: EN-GJS-400-15
Technical data:
• Ambient air temperature: 50°C
• Pressure, max. supply: 5.0 bar(g)
• Pressure, relief design: 36 bar(g)
• Pressure, discharge outlet: 33 bar(g)
• Temperature max. fuel oil: 150°C
• Foundation bolts: M16
• Oil viscosity min.: 1.4 cSt
• Oil viscosity max.: 380 cSt
• Oil viscosity: 1.4 cSt
Oil capacity: 558 l/h
NPSH: 5.0 mWC
• Oil viscosity: 3 cSt
NPSH: 2.0 mWC
• Viscosity: 380 cSt
NPSH: 2.8 mWC
• Filtration: 250 µ
• Weight, motor: 11.8 kg
• Weight, unit: 175 kg
Type No.: 9294

Version: A.1 Fuel oil supply unit, with filter, size 900, 33 bar 9294002642
DATA SHEET
Tag No(s): 3G147
L8
Lifting eye
Lifting eye
H3
H2
H4
H1
G 1/2" SAE 1 1/2" L4 L4

3000 PSI
L5 L6 L7 L9
L3
I.D.
W1
W
W2
L2
L1
L
Type No.: 9294

DATA SHEET
Tag No(s): 3G147
Dimension: Installation:
• L: 700 • The pump/motor assemblies are of a ver-
• L1: 650 tical design and are delivered with
• L2: 580 mounting feet and oil sump. For safety
purposes, the arrangement with “motor
• L3:374 downwards” is not admissible
• L4: 110
Connections / flanges:
• L5: 90
• L6: 270 • Counter flanges according to SAE. Bolts
and gaskets will be included in the sup-
• L7:190 ply.
• L8: 655
• L9: 18 Connection diagram:
• W: 568
• W1: 550
• W2: 64
• H: 791
• H1: 80
• H2: 217
• H3: 297
• H4: 20
• I.D.: 19
1 Pump
2 Pressure-side pressure gauge
3 Reversing valve
4 Filter
5 Suction-side pressure gauge
6 Pressure relief valve
7 Non return valve
Type No.: 9294

DATA SHEET
Tag No(s): 3G450
Type: Electrical specification:

• Fuel oil supply pump unit, with filter • Rated output for motor: 1.8 kW
Connection type: • Starting metod: Direct
• Connection inlet and outlet, pipe size in- • Starting current: 22.82 A
side / outside diameter: 38 / 48.6 • Operating current (full load): 3.26 A
• Connection type: Flange according to • Revolutions: 3408 r.p.m.
SAE, hole pattern 3.000PSI • Heating element motor: Not fitted
• Cable connection: 2 x M 25 x 1.5 • Power supply: 3 x 440V
Application: • Frequency: 60 Hz
• For handling fuel oils - DMA, DMB, • Insulation class: F
DMZ and RMx according to ISO 8217 • Degree of protection: IP55
Material:
• Station block, casing: EN-GJS-400-15
• Station block, filter cover: S235JR
• Pump, casing: EN-GJS-400-15
• Pump, screw set: 16MnCrS5
• Pump, flange cover: EN-GJS-400-15
• Pump, end cover: EN-GJS-400-15
Technical data:
• Ambient air temperature: 50°C
• Pressure, max. supply: 5.0 bar(g)
• Pressure, relief design: 36 bar(g)
• Pressure, discharge outlet: 33 bar(g)
• Temperature max. fuel oil: 150°C
• Foundation bolts: M16
• Oil viscosity min.: 1.1 cSt
• Oil viscosity max.: 380 cSt
• Oil viscosity: 1.1 cSt
NPSH: 5.0 mWC
• Oil viscosity: 3 cSt
NPSH: 2.0 mWC
• Viscosity: 380 cSt
NPSH: 2.8 mWC
• Filtration: 250 µ
• Weight, motor: 11.8 kg
• Weight, unit: 175 kg
Type No.: 9294

DATA SHEET
Tag No(s): 3G450
L8
Lifting eye
Lifting eye
H3
H2
H4
H1
G 1/2" SAE 1 1/2" L4 L4

3000 PSI
L5 L6 L7 L9
L3
I.D.
W1
W
W2
L2
L1
L
Type No.: 9294

DATA SHEET
Tag No(s): 3G450
Dimension: Installation:
• L: 700 • The pump/motor assemblies are of a ver-
• L1: 650 tical design and are delivered with
• L2: 580 mounting feet and oil sump. For safety
purposes, the arrangement with “motor
• L3:374 downwards” is not admissible
• L4: 110
Connections / flanges:
• L5: 90
• L6: 270 • Counter flanges according to SAE. Bolts
and gaskets will be included in the sup-
• L7:190 ply.
• L8: 655
• L9: 18 Connection diagram:
• W: 568
• W1: 550
• W2: 64
• H: 791
• H1: 80
• H2: 217
• H3: 297
• H4: 20
• I.D.: 19
1 Pump
2 Pressure-side pressure gauge
3 Reversing valve
4 Filter
5 Suction-side pressure gauge
6 Pressure relief valve
7 Non return valve
Type No.: 9294

DATA SHEET
Tag No(s): 3G224,3G424

• Remote start/stop box • Nominal operating condition:
Application: U = 600 V and I = 1.2 A or
U = 240 V and I = 3 A or
• For start/operation and stop of fuel oil U = 120 V and I = 6 A
pumps • Protection: IP 65
Material: • Temperature: -25°C to +70°C
• House: Polycarbonate
• Colour: Grey
120
83 85
Fuel oil pumps

1 2
Start/operation
incl. lamp function
123
105
145
177
Stop
Cable glands M 32 (PG 29)
105
Ø 5.8
70
Ø 5.8
Type No.: 8001

Version: B.1 Remote start/stop box 8001000005
15K7603#D.1
HEAT EXCHANGER MX10 T16 L=600
Heat Exchanger MX10 T16 L=600
DATA SHEET
Tag No(s): 3G433,3G470
Type:
• Safety valve
100
Size:
Application:
• To blow off steam, neutral gases, va-
pours and liquids
Material:
• Body: GGG 40.3
• DIN-material No.: 1.4581
Technical data:
187
• Thread: DIN ISO 228 part 1
• Set point:10 bar
• Weight: 1.2 kg
1/2”
34
15
ø 12
1/2”
42
Type No.: 6040

Version: C.1 Safety valve, DN 15, PN 100 87S0032
DATA SHEET
Tag No(s): 3G434

• Stop valve, ball straight • Max. workingpressure at 80°C: 32 bar
Size: • Max. working pressure at 150°C: 10 bar
• DN 15 • Weight: 0.18 kg
Application:
• For water, compressed air and oil
Material:
• Body: Nickel-plated brass (MS 58)
• Ball: Hard chromium plating brass
(MS 58)
• Stem: Brass (MS 58)
• Stem nut: Galvanized steel
• Seat rings: Teflon (PTFE)
• Stem gasket: Teflon (PTFE)
85
44
½”BSP
31
60
Type No.: 6010

Version: A.2 Stop valve, ball straight, DN 15, PN 40 6666106
DATA SHEET
Tag No(s): 3G435
Type:
• Needle valve
Size:
• 1/2" x 1/2"
Application:
• For air and oil flow
Material:
• Body: Brass CuZn39Pb3
• Gasket: Teflon
• Handle: Nylon 6.6
Technical data:
• Working pressure: 250 bar(g)
• Working temperature max.: 200ºC
Dimension:
• A: 1/2" BSPP
• B: 1/2" BSPP
• H max.: 53
• L: 46
Type No.: 6000

Version: A.2 Needle valve 1/2" x 1/2" 87N6004
DATA SHEET
Tag No(s): 3G468,3G469
Type: Material:
Technical data:
• Weight: 4.3 kg
ø 120
9
180
Disc
ø 75 / 4 x ø14
Seat
ø 105
ø 20
Body
150
Type No.: 6010

Version: D.1 Stop valve, straight, DN 20, PN 25 2501087
DATA SHEET
Tag No(s): 3G436
Type:
• Three-way valve, ball Detail A
• LB 283 BW, reduced bore
Size:
• DN 32
ø 42.2
ø 32.7
4.9
1.6
Application:
• For air, steam, or oil flow 37.5°
Material
• Body: ASTM A105
• End connections: ASTM A105 L-Bore
Technical data:
Port 1 Port 2
• Min./max. temperature at 30 bar:
- 29°C to + 230°C
• End connections: Butt weld according to Port 3
ASME/ANSI B16.25 - XS-80
• Pipe size: DN 32 Port 1 Port 2
• Weight: 7 kg
Installation:
Information and caution before installation Port 3
of the valve:
• Pipe must be free of tension.
• Pipe must be flushed to clean the dirt, 225

Centre part
Bolt
which would damage the ball and seat. Detail A

98
• The valve must be kept in open position

during installation. Protective plastic End connections
covers must not be removed before the 158 121.5

installation work commences.
• At the moment of the shipment the ball
is lubricated with a pure vaseline oil,
vent, if required.
• Ball valves normally have a space be-
tween ball and inside cavity of the body,
be taken to drain the cavity.
line:
connections.
welding.
eration.
Type No.: 6070

Version: A.2 Three-way valve, ball, DN 32 87D3073
DATA SHEET
Tag No(s): 3G460,3G461
Type:
• Three-way ball valve (reduced L-bore) L W
Switchbox
with actuator and solenoid valve
Size: Actuator
• Connection nominal: DN 25 Solenoid valve
• Cable connection, switch box: PG 11

• Cable connection, solenoid valve: PG 9
H
H1
• Pipe connection, solenoid valve: 1/4" Detail A Three-way valve
Connection type:
• Connection type: Butt welded ends ac- W2
cording to ASME/ANSI B16.25 - XS-80 L1
W1
Application:
• For air, steam, or oil flow
Material, three-way valve:
• Body: ASTM LF2 (A105)
• End connections: ASTM LF2 (A105)
Material, actuator:
Detail A
• Body: Alodur (special hard anodized)
Material, solenoid valve:
• Body: Aluminium, black anodized
O.D.
I.D.
T1
T

• Temperature at 30 bar min.: - 29°C r
• Temperature at 30 bar max.: + 230°C

Dimension:
• Actuator: Spring return (SR)
• Air supply pressure min.: 5 bar • L: 268.5
• Air supply pressure max.: 8 bar • L1: 150
• Temperature, min. operating: -20°C • H: 221
• Temperature, max. operating: +80°C • H1: 393
Technical data, solenoid valve:
• W: 163
• W1: 114
• Orifice size: 6 mm • W2: 75
• Flow coefficient: 0.6 m³/h • T: 1.6
Technical data switch box: • T1: 4.6
• Temperature min., ambient: - 55°C • r: 37.5º
• Temperature max., ambient: + 80°C • I.D.: ø 24.3
Technical data, unit: • O.D.: 33.4
• Weight: 15 kg
Three-way valve, ball DN 25 build together with

Version: D.1 6070000017
actuator, solenoid valve and switch box
DATA SHEET
Tag No(s): 3G460,3G461
Electrical data: Micro switch connection:

• Power supply: 230 V
• Frequency: 50 / 60Hz
Installation:
of the valve:
• Pipe must be flushed to clean the dirt,
which would damage the ball and seat. 2 3 4
vent, if required.
line:
connections.
welding.
eration.
L-Bore
Port 1 Port 2
Port 3
Port 1 Port 2
Port 3
Three-way valve, ball DN 25 build together with

Version: D.1 6070000017
actuator, solenoid valve and switch box
DATA SHEET
Tag No(s): 3G437
Type:
• Three-way ball valve (reduced L-bore) L
W
with actuator and solenoid valve Actuator
Size: Solenoid valve
• Cable connection, solenoid valve: PG9
H
H1
Connection type: Detail A Three-way valve
• Connection type: Butt welded ends ac-

cording to ASME/ANSI B16.25 - XS-80 W2
L1
Application: W1
• For air, steam, or oil flow

Material, three-way valve:
• Body: ASTM A105
• End connections: ASTM A105
Material, actuator:
• Body: Alodur (special hard anodized) Detail A
Material, solenoid valve:
• Body: Aluminium, black anodized
O.D.
I.D.
T1
T
• Temperature at 30 bar min.: - 29°C

• Temperature at 30 bar max.: + 230°C r

• Actuator: Spring return (SR) Dimension:
• Air supply pressure min.: 5 bar
• Air supply pressure max.: 8 bar • L: 268.5
• Temperature, min. operating: -20°C • L1: 150
• Temperature, max. operating: +80°C • H: 221
• H1: 263
Technical data, solenoid valve: • W: 163
• Pipe connection: 1/4" • W1: 114
• Orifice size: 6 mm • W2: 75
• Flow coefficient: 0.6 m³/h • T: 1.6
Technical data, unit: • T1: 4.6
• Weight: 13 kg • r: 37.5º
Electrical data: • I.D.: ø 24.3
• O.D.: 33.4
• Power supply: 230 V
• Frequency: 50 / 60Hz
Type No.: 6070 Three-way valve, ball DN 25 build together with

Version: F.1 6070000047
actuator and solenoid valve
DATA SHEET
Tag No(s): 3G437
Installation:
of the valve:
• Pipe must be flushed to clean the dirt,
which would damage the ball and seat.
vent, if required.
line:
connections.
welding.
eration.
L-Bore
Port 1 Port 2
Port 3
Port 1 Port 2
Port 3
Type No.: 6070 Three-way valve, ball DN 25 build together with

Version: F.1 6070000047
actuator and solenoid valve
DATA SHEET
Tag No(s): 1G114,2G114
Type:
• Filter regulator with automatic drain 30
Size: H andle
Body
• Connections ports 1/4” BSP
Max. 6
• Gauge ports 1/8” BSP
Application:
66
• Instrument air for regulating pressure Fitting
28
Technical data:
• Medium: instrument air only
Gauge por ts
18
Di smantel length 138

• Max. inlet pressure: 17 bar
• Operating temp.: –20 °C to + 65 °C
99
23
• Filter element: 5 m
• Recommend pressure regulating range: 6
8
7.5
0.14-7.0 bar
2.5
• Pressure gauge: 0 – 10 bar
Bin
14
• Weight: 0.4 kg 7
Material:
44
Connections ports
• Body: Steel
• Bin: Steel R1
• Handle: Acetal 9
38
SW19 31
Flow characteristics
41
8
Inlet pressure 7 bar
7
Outlet pressure [bar]
5
4
3
2
1 2 3 4 5 6 7 8 9 10
3
Air flow [dm /s]
Type No.: 8000

Version: B.1 Filter regulator with automatic drain 2915101
DATA SHEET
Tag No(s): 1G466,2G466

• Sample Unit • Weight: 1.5 kg Approx.
Size: Dimension:
• DN 8 • L: 100 Approx.
Connection type: • L1: 113.5
• Connection type: Butt welded end • H: 57
• O.D.: 13.5
Application:
• I.D.: 8
• For oil flow
Material:
• 1. Body: ASTM A216-WCB
• 2. Body: Carbon Steel
L1
Item. 6010000372
H
Item. 6000000109
ø I.D.
ø O.D.
1 2
1. Stop valve - ball type.

2. Spring loaded stop valve (normally closed)
push to open.
Type No.: 6000

Version: C.1 Sample Unit 6000000119
DATA SHEET
Tag No(s): 1G466,2G466
Installation, welded end :

• With the valve in the open position, re-
move body connector bolts (or screws).
• Separate pipe ends from body and re-
move seat rings, and body seals, taking
care not to damage plastic parts. Place
ball in part-open position to assist re-
moval of seat.
• Support ball to prevent it from falling out
of body and turn valve to closed position
for removal.
• Place all components removed in clean
secure position, clear of welding splatter.
• Replacing two bolts reassemble body
connectors with body.
• Align valve to pipe line, ensuring proper
fit to minimize pipe load. Tack weld on-
ly.
• Undo body bolts and remove body to
clean secure area.
• Protect body connector faces from weld-
ing splatter and complete welding. Allow
enough time for cooling.
• Replace the ball carefully in the body and
turn to fully open position. Replace body
seals (from attached package).
• Assemble seats in the body.
• Ease body assembly between body con-
nectors, taking care not to score faces or
damage seals.
• Replace body bolts and nuts (or screws)
and tighten firmly.
Type No.: 6000

Version: C.1 Sample Unit 6000000119
DATA SHEET
Tag No(s): 3G471, 3G481
Type: Diagram:
• Pressure control valve
To burner From pump
Connection type:
• Connection type: 1/2" BSP
Pressure rating: Return line
• Pressure design: 30 bar
Applilction:
• For handling fuel oils - DMA, DMB,
DMZ and RMx according to ISO 8217
40
Material:
Ø35
• Housing: GJS-400
Technical data:
40
• Flow range: 2400 l/h
• Setting range: 10 to 30 bar
G 1/2
• Fluid temperature min.: -20°C Ø35
• Fluid temperature max.: 220°C

• Temperature min., ambient: - 20ºC
• Temperature max., ambient: 60°C
182
• Weight: 1.3 kg
Installation:
142
• In pipe line
• Recomended pipe size up steam and
down steam of pressure control valve -
DN25
• Pipe line pressure loss is to be kept at
minimum
• Set screw down (preferred)
To burner From pump
Return to
Mixing tube/tank
Type No.: 6050

Version: K.1 Pressure control valve, 1/2" 6050000542
71Z20_056461#E.1
TEMPERATURE TRANSMITTER IN RING LINE
Temperature transmitter in ring line
DATA SHEET
Tag No(s): Parts of 3G274
Type: Mechanical:
• Temperature sensor • Connection: G ¼”A, according to ISO
Range: 228-1
• Weight: 0.15 kg
• 0°C to +150°C
Dimension:
Application:
• W = 37
Designed for use in harsh maritime
• L = 50
• L1 = 33
Environments where reliable, robust and ac- • L3 = 148
curate equipment is required • W = 37
• O.D. = 8
Material: • G = 1/4" A, according to ISO 228-1
• Housing: Stainless steel • G1 = PG 11
• Enclosure ( AISI 316L )
Technical data: W
Performance:
• Accuracy:<± 0.5 % FS (typ.), <± 1 % FS
(max.)
• Response time: Water 0.2m/s : t05= 10
sec / t09= 30 sec G1
• Response time: Air 1m/s:t05= 95 sec
• / t09= 310 sec
• Max. load protection tube : 100 bar
Electrical specifications:
• Output signals: 4-20 mA
• Electrical connection 43650-A. ( 2 wire )
L1
L3
PG 11
• Supply voltage: 10 to 32 VDC
• Current limitation: 30mA
• Output impedance: < 225 ohm G
• Degree of Protection: IP65
Electrical connection:
L
• Pin1: + supply
• Pin 2: - supply
• Pin 3: Not used
• Earth: Not connected to housing O.D.
Type No.: 8060

Version: B.1 Temperature sensor 8060000046
DATA SHEET
Tag No(s): Parts of 3G274
Type:
• Pocket for temperature transmitter Connection
instrument
Size:
• Connection instrument: G 1/4” tolerance
class A
• Connection pocket: G 1/2” tolerance
class A
Application:
• Pocket for temperature transmitter
Material:
• Material: Stainless steel
Technical data:
L
• Media temperature: -50°C to 200°C
Dimension:
• O.D. = 11
• L = 50
O.D
Type No.: 8500

Version: A.3 Pocket for temperature transmitter 8500000870
DATA SHEET
Tag No(s): 3G99
Type:
• Pressure transmitter 52
Range: 36
• 0 – 40 bar(g)
Application:
• The pressure transmitter converts pres-
sure to an electric signal. The units are
supplied as passive two wire transmit-
ters. The output current is linearly pro-
portional to the input pressure.
PG 11
Material:
• Housing: Stainless steel with piezoresis-
tive measuring cell and electronics mod-
ule. 106
• Process connection: Stainless steel
Technical data:
ø24
Electrical specification:
• Current output signal: 4 to 20 mA SW 24
• Power supply terminal voltage for cur-
55
rent output: 7 to 33VDC

Accuracy:
• Response time T99: < 5 ms
25
• Influence of ambient temperature at start

of scale: 0.25%/10K of full scale value
• Influence of ambient temperature at full
scale value: 0.25%/10K of full scale val-
ue G 1/2” -m
Mechanical:
• Process temperature: -30°C to +120°C Connection diagram:
• Max pressure: 100 bar(g)
• Min pressure: -1 bar(g)
• Degree of protection to EN 60529: IP65
• Cable gland: PG11
(cable size ø5 to 10 mm)
• Weight: 0.09 kg
Type No.: 8010

Version: B.2 Pressure transmitter 0 - 40 bar(g) 8010000025
DATA SHEET
Tag No(s): 3G105
Type:
• Pressure gauge valve needle straight.
Size:
• 1/2” x 1/2”
Application:
• For instrument connections
Material:
• Body: C22.8
• DIN-material No. 1.0460
Technical data:
• Test connection: M20 x 1.5 mm threaded
male
• Weight: 0.4 kg
Type No.: 6210

Version: C.1 Needle valve, straight, ½" x ½", PN 400 2541002
K16_004096#D.1
COUNTER FLANGE
Counter flange
1 --- NO TITLE ---
TABLE OF CONTENTS
Table of contents
Control System Aalborg OC-TCi

.
Electric drawing for boiler control panel....................... 104X3_1045................ 6-2
Set point list.............................................................. 106988........................ 6-87
Modbus list............................................................... 106988........................ 6-89
104X3_1045#A.2
ELECTRIC DRAWING FOR BOILER CONTROL PANEL
Electric drawing for boiler control panel
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
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104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
104X3_1045#A.2
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104X3_1045#A.2
104X3_1045#A.2
106988#A.3
SET POINT LIST List of Indicators and Set Points for ON 106988
Item Units Range Default Type ITEM NO IN DRAWING Element Bnr Physical Remarks
Set point 1) Steam/water P/I diagram X01:910074a Terminal Trip Location
2) Oil flow diagram 96X02:910073a No. in
Set point list 3) Burner drawing:

4) Wiring diagram:
96X02:065366e
104X03:1045
wiring
diagram
1 2 3 4
Oil fired boiler / Burner
Safety Valve BAR 8.0 25.912 C1 Mechanical
High Steam Pressure Switch BAR 1-10 7,8 RT30 C35 102S33 X3: 109-110 X Boiler
Steam Pressure Transmitter Boiler BAR 0-10 7MF1567 C48 100U23 X3: 101-102 Boiler
High steam pressure BAR 0-10 7,5 - - - - X
Low steam pressure BAR 0-10 4 - - - -
Start/Stop Pressure BAR 0-10 6.2-7.0 - - - -
Steam pressure set point BAR 0-10 6 - - -
Water Level Transmitter (4-20mA) DP mA 4-20 7MF433 - 2.5-250 mBar W16 110U37 X3: 133-134 Boiler
Too high water level mm WG +180 - - X
High Water Level mm WG +150 - - Boiler
Normal Water Level mm WG 0 - -
Stand by feed water pump mm WG - -
Low Water Level mm WG -135 - -
Too Low Water Level (float switch) mm WG -180 Igema RBA24 W14 33S6 X3: 54-55 X X Panel
Oil Pressure Transmitter Burner (4-20mA) BAR 0-40 7MF1567 F225 100U24 X3: 103-104 Boiler
High oil pressure BAR 0-40 2.3 - - - - X
Low oil pressure BAR 0-40 0.8 - - - - X
Oil pressure set point BAR 0-40 1.8 - - - -
Stand by oil pump start BAR 0-40 1.2 - - - -
Oil Pressure Transmitter Ringline (4-20mA) BAR 0-40 7MF1567 G99 100U71 X3: 105-106
High oil pressure BAR 0-40 2.3 - - - - X
Low oil pressure BAR 0-40 0.8 - - - - X
o
Oil temperature Transmitter Burner (4-20mA) C 0-200 MBT 5560 F212 105U30 X3: 119-120 Boiler
o
High oil temperature C 0-200 130 - -
o
Low oil temperature C 0-200 65 - -
Low Com. Air Pressure Switch mBAR -0,5-50 5 GW 50 A4 R3 32S5 X3: 52-53 X Burner
Burner Swing Out / Burner Open Limit Sw. F224 34B6 X3: 56-38 X Panel
Flame Failure 1 RAR9/LAE10 F32 36F32 X3: 61-62 X Bnr. + Panel Cut Off Oil Supply
Flame Failure 2 RAR9/LAE10 F33 36F33 X3: 63-64 Bnr. + Panel Cut Off Oil Supply
o
High temperature in preheater C 0-160 125 F223 09S25.1 X3: 34-35 X
o
Temperature transmitter in preheater (for reg.) C PT100 F222 106U32 X3: 123-125
o
Oil temperature Transmitter Ringline (4-20mA) C 0-150 MBT 5560 G274 105U30 X3: 121-122
o
High oil temperature C 0-150 65 - -
o
Low oil temperature C 0-150 0 - -
High oil pressure in return line BAR -0.2 - 10bar 3,0 Danfoss MBC 5100 F214 102S34 X3: 111-112
106988#A.3
SET POINT LIST List of Indicators and Set Points for ON 106988
Item Units Range Default Type ITEM NO IN DRAWING Element Bnr Physical Remarks
Set point 1) Steam/water P/I diagram X01:910074a Terminal Trip Location
2) Oil flow diagram 96X02:910073a No. in
3) Burner drawing: 96X02:065366e wiring
4) Wiring diagram: 104X03:1045 diagram
1 2 3 4
Oil
OilServo
firedMotor Limit Switches:
boiler / Burner F208 37U50 X3: 65-71 See sheet 35 in wiring
Max. Position Degr. 0-90 90 To be set during commisioning - Burner diagram and burner
Min. Position Degr. 0-90 0 To be set during commisioning - Burner instruction manual
Air Servo Motor Limit Switches: R16 38U50 X3: 72-78 See sheet 36 in wiring
Max. Position Degr. 0-90 90 To be set during commisioning - Burner diagram and burner
Min. Position Degr. 0-90 0 To be set during commisioning - Burner instruction manual
Remote Indicator:
Steam pressure remote indicator PR-5714 H2 44U56 X3:89-92 component ECR
Water level Remote indicator PR-5714 W32 44U58 X3:95-98 component ECR
o
Windbox temperature transmitter C -50-200 110 Danfoss MBT-5250 F36 106U33 X3: 126-128
o
Smoke Temperature switch uptake. C 20-500 300 Jumo AHTs-20 K5 108S37 X3: 129-130
General signals
Thermal Overload Relays:
Burner Motor A 9,0-14 10,7 GV2-P16 08Q5 X Panel
Fuel Oil pump 1 A 2,5-4,0 3,26 GV2-P08 02Q3 Panel
Fuel Oil pump 2 A 2,5-4,0 3,26 GV2-P08 02Q4 Panel
Preheater A 9,0-14 10,9 GV2-P16 09Q6 Panel
Marine Gas Oil Pump 1 A 2,5-4,0 3,26 GV2-P08 05Q26 Panel
Marine Gas Oil Pump 2 A 2,5-4,0 3,26 GV2-P08 05Q27 Panel
Feed Water Pump 1 A 4,0-6,3 4,0 GV2-P10 10Q7 Panel
Feed Water Pump 2 A 4,0-6,3 4,0 GV2-P10 10Q8 Panel
X Panel
High oil content Mobrey MCU 200 M145 40B1 X3: 81-84
High Salinity ppm 0-1000 8 Uni-Safe SL700 M146 42B7 X3: 85-88
106988#A.2
7.15 Rev 4615 (Released 2013-06-10)
MODBUS LIST
Burner Type: KBM
Please Reserve Address 40000 - 41999 to AI Modbus
Boiler Type: EGB

Boiler Type: None Format: Decimal, Protocol: Master RTU
Oil System: 12 Start Adress: 0
Modbus Addr. Word no. Type Remarks

40522.12 AI Unit of measurement (pressure values only) 0 = 1/10 bar; 1 = 1/10 kg/cm; 2 = 1/100 Mpa
Burner state 0 = STOPPED; 1 = SHUTDOWN; 2 = READY; 3 = PMS REQUEST;
4 = STARTING; 5 = PRE PURGE POSITION; 6 = PRE PURGE;
7 = IGNITION POSITION; 8 = IGNITION; 9 = SAFETY TIME;
10 = FLAME STBLE; 11 = MAN LOAD; 12 = LOW FIRING POSITION;
Modbus list
40890 13 = LOW FIRING; 14 = RISING; 15 = MODULATION FREE;
Analog I/O
16 = NORMAL STOP; 17 = STEAM PURGE POSITION;

18 = STEAM PURGE 1; 19 = STEAM PURGE 2 ;
20 = POST PURGE POSITION; 21 = POST PURGE; 22 = X-TRACKING; 23 = WHR BLOCK; 24 =
AI SAFETYPURGE
40020 AI Burner Load %
40010 AI Steam pressure (boiler) Unit of measurement - See word 11
40022 AI Water level boiler mmWC
40077 AI Fuel Oil pressure Unit of measurement - See word 11
40063 AI Fuel Oil temperature 1/10 °C
AI Steam pressure common line Unit of measurement - See word 11 Option (Double plant)
40508.02 DO Fuel oil pump 1, start/stop 0 = Stopped; 1 = Running
Digital I/O
40508.03 DO Fuel oil pump 2, start/stop 0 = Stopped; 1 = Running

40509.01 DO Chemical dosing station 1 0 = Stopped; 1 = Running Option
40508.05 DO Feed water pump 1 start/stop 0 = Stopped; 1 = Running Option
40508.06 DO Feed water pump 2 start/stop 0 = Stopped; 1 = Running Option
41005.08 OIL CONTENT HIGH
41005.09 SALINITY HIGH
41005.15 BILER PRESSSURE LOW
41006.01 WATER LEVEL HIGH
Alarms
41006.02 WATER LEVEL LOW

41006.04 HEAVY FUEL OIL TEMPERATURE LOW
41006.10 WATER PUMP 1 OVERLOAD
41006.11 WATER PUMP 2 OVERLOAD
41007.01 ST.BY WATER PUMP STARTED
41008.10 HOTWELL LOW (FEED PUMPS STOPPED)
41007.06 BOILER PRESS. HIGH
41008.02 HEAVY FUEL OIL TEMPATURE HIGH IN PREHEATER
41008.03 FUEL OIL TEMPATURE LOW IN PREHEATER
41009.07 GAS OIL PUMP 1 OVERLOAD
41009.08 GAS OIL PUMP 2 OVERLOAD
41009.09 GAS OIL TEMPATURE HIGH
41009.14 HEAVEY FUEL OIL PRESSSURE HIGH
41009.15 GAS OIL PRESSURE HIGH
0.00 Shutdowns
41000.01 HIGH STEAM PRESSURE SWITCH
41000.02 TOO LOW WATER LEVEL SWITCH
41000.05 FLAME OUT
41001.00 QUICK CLOSING VALVE NOT OPEN
41001.05 BURNER SWING OUT
41001.06 OIL TEMPERATURE LOW SWITCH
41001.08 HIGH OIL PRESSURE RETURN LINE
41001.09 HEAVY FUEL OIL TEMPERATURE HIGH
41001.10 HEAVY FUEL OIL TEMPERATURE LOW
Shutdowns
41001.11 HEAVEY FUEL OIL PRESSURE LOW

41001.12 WATER LEVEL HIGH
41001.13 WATER LEVEL LOW
41001.14 BOILER PRESSURE HIGH
41002.03 BURNER MOTOR OVERLOAD
41002.02 LOW COMB AIR PRESS SWITCH
41003.13 HIGH OIL TEMP SW IN PREHEATER
41003.14 HEAVY FUEL OIL PRESSURE HIGH
41003.15 FUEL OIL TEMPATURE LOW IN BURNER
41004.03 OIL TYPE CHANGED WHILE FLUSHING
41004.09 GAS OIL PRESSURE HIGH
41004.10 GAS OIL PRESSURE LOW
41004.08 GAS OIL TEMPERATURE HIGH
Default Config Telegram example

Connection: LAN
Modbus addres Modbus telegram

Steam Pressure 40010 01 03 00 0A 00 01 A4 08
Water level 40022 01 03 00 16 00 01 65 CE
FO Press. 40077 01 03 00 4D 00 01 14 1D
Start Adress: 0 CMD operation mode 40525 01 03 02 0D 00 01 14 71
Format: Decimal FO Temp 40924 01 03 03 9C 00 01 44 60
Protocol: TCP/IP
TABLE OF CONTENTS
Table of contents
Drawings
.
General Arrangement drawing for Aalborg OC-Tci....... 15Y_910075................ 7-3
Aalborg OC-TCi, Thermal expansion........................... 15K00_054126............. 7-5
Lifting eye................................................................ K17_014283................ 7-7
Lifting eye................................................................ K17_014307................ 7-9
Round flange............................................................. K16_030052................ 7-11
Burner unit complete - KBM 125................................ 96Y_616754................ 7-13
15Y_910075#A.2
GENERAL ARRANGEMENT DRAWING FOR AALBORG OC-TCI
General Arrangement drawing for Aalborg OC-Tci
15K00_054126#C.2
AALBORG OC-TCI, THERMAL EXPANSION
Aalborg OC-TCi, Thermal expansion
AALBORG OC-TCI, THERMAL EXPANSION
K17_014283#G.1
LIFTING EYE
Lifting eye
LIFTING EYE
K17_014307#H.1
LIFTING EYE
Lifting eye
DATA SHEET
Tag No(s):
Version: A.2 Round flange K16_030052
96Y_616754#A.3
BURNER UNIT COMPLETE - KBM 125
Burner unit complete - KBM 125
TABLE OF CONTENTS
Table of contents
Spare Parts
.
Spare parts for AalborgOC-TCi................................... 106988........................ 8-2
Spare parts for Pressure atomizing burner - KBM.......... 106988........................ 8-3
Language UK 8-1 / 3
106988#A.2
SPARE PARTS FOR AALBORGOC-TCI
Spare parts for AalborgOC-TCi

Request No.:...................................................................................................................................... 106988
Hull No./Nos.:.......................................................................................................................DY152, DY153
Project No./Nos:.................................................................................................................................106988
Date:..........................................................................................................................................29 July 2013
The spare parts supplied in the scope of delivery for includedAalborgOC-TCi boilers are listed in the table
below.
1 Spare parts
Tag No. Qty. Application Spare part N o.

Spare parts for the b oiler
S-C1-3 1 Spring for safety valve, OD32 8580000001
S-C17-1/S-C18-1 2 Water level glass, Size 16, Dim. 250x30x17 mm 8590000019
S-C17-2/S-C18-2 6 Gasket for water gauge stud 2163719
S-C-1 4 Gasket for manhole 2158320
S-C-2 16 Gasket for handhole 2153140
S-C-3 12 Plug for helix tubes 2000000140
S-C-7 12 Plug for smoke tube, OD42/OD48 6494104
S-C-8 1 Moulding Powder 2118236
S-C-13 1 Test gag for safety valve OD 32 7000000053
S-C-17 1 Inspection mirror 8500000362
S-C17+C18-6 1 Inst., maintenance and operation manual 8500001056
Spare part s for commissioning
S-C-5 2 Gasket for manhole 2158320
S-C-6 8 Gasket for handhole 2153140
8-2 / 3 Language UK
106988#A.2
SPARE PARTS FOR PRESSURE ATOMIZING BURNER -
KBM
Spare parts for Pressure atomizing burner

- KBM
Request No.:...................................................................................................................................... 106988
Hull No./Nos.:.......................................................................................................................DY152, DY153
Project No./Nos.:................................................................................................................................106988
Date:..........................................................................................................................................08 July 2013
The spare parts included in the scope of delivery of a standard Modulating pressure atomizing burner are
listed in the table below.
1 Spare parts
Tag No. Qty. Application Spare part N o.

Spare parts for the burner
S-F1-1 1 Pressure gauge 6633122
S-F1-3 1 Nozzle for burner 8610000154
S-F1-8 1 Photo cell 8630000005
S-F1-8.1 1 Rubber cover for photo cell 8500001086
S-F1-62 1 Set of ignition electrodes (left and right) 8620000084
S-F1-113 1 Burner lance repair kit - O-rings 3520000128
S-C33-1 1 Pressure gauge 6632972
Spare parts for the oil pumps
S-G147-1 2 O-ring for Filter cover 3520000089
CS-G147-9 2 O-ring for mechanical seal – inner 8500000486
CS-G147-10 2 O-ring for mechanical seal – outer 8500000608
Spare parts for the oil pumps
S-G450-1 2 O-ring for Filter cover 3520000089
CS-G450-9 2 O-ring for mechanical seal – inner 3520000195
CS-G450-10 2 O-ring for mechanical seal – outer 3520000198
Language UK 8-3 / 3
TABLE OF CONTENTS
Table of contents
Descriptions
.
Aalborg OC-TCi boiler............................................... SD9210_17.................. 9-2
Boiler mountings....................................................... SD9220_17.................. 9-5
Water level control.................................................... SD9230_46.................. 9-7
Gauge board............................................................. SD9240_14.................. 9-8
Language UK 9-1 / 8
SD9210_17#D.1
AALBORG OC-TCI BOILER
Aalborg OC-TCi boiler
1 Description
The Aalborg OC-TCi boiler is a combined oil and exhaust gas fired vertical marine
boiler, insulated and assembled as a unit with the boiler mountings mounted on the
boiler body.
The boiler mountings are mainly mounted on top of the boiler body in order to allow
a simple connection to the piping systems on board the ship.
The burner is ready for mounting in the furnace and connection of pre-marked electric
wiring.
The control system supplied with the Aalborg OC-TCi boiler unit provides fully au-
tomatic operation of the boiler and burner.
1.1 Boiler pressure part
The pressure part of the Aalborg OC-TCi boiler is shown in Figure 1. The combined
oil fired and exhaust gas fired boiler is designed as a vertical boiler with a cylindrical
shell surrounding the oil fired and the exhaust gas fired sections. The oil fired section
comprises the cylindrical furnace, the steam space, and the convection section con-
sisting of helix tubes. The exhaust gas fired section comprises the stay tubes and smoke
tubes.
The pressure part is made of mild carbon steel with elevated temperature properties.
This means that stress concentrations in corner welding are minimised by the design
of the cylindrical shell with the flat endplates of equal thickness.
The cylindrical shell with the two flat endplates welded on is supported by the stay
tubes, the helix tubes, and the furnace. Also the steam drum is a cylindrical vessel
welded on the top plate and upper tube plate. The drum acts as a dividing plate to the
exhaust gas fired section. This unique design ensures that no supports are required.
The helix tubes are seamless steel tube (formed by rolling process) and are installed
between the furnace top plate and the boiler top plate.
The tubes in the exhaust gas fired section consist of a small number of stay tubes and
a large number of smoke tubes. The stay tubes with an increased diameter act as support
for the boiler. Both types are welded onto the endplates.
9-2 / 8 Language UK
SD9210_17#D.1
The furnace is cylindrical with two flat plates. The bottom steel plate is protected from
radiation of heat by refractory. Furthermore, the furnace bottom is provided with a
socket for drain of washing water.
For inside inspection, the Aalborg OC-TCi boiler is arranged with both hand holes and
manholes. Two manholes are arranged on the boiler shell for convenient access both
into the oil fired section and into the exhaust gas fired section. For visual check of the
smoke tubes, a number of hand holes are arranged in a suitable distance at the bottom
of the boiler drum. For inspection of the flue gas side, inspection doors are arranged
on the flue gas inlet and outlet chamber.
The boiler mountings such as safety valves, steam outlet valve, etc. are mainly mounted
on top of the boiler body in order to allow simple connection to the piping system on
board the ship. Furthermore, inlet and outlet boxes are included in the delivery.
Boilers with a diameter up to 3,000 mm are prepared for tack welding along the boiler
shell. For boilers with a diameter above 3,000 mm, the boiler foundation is arranged
as a flanged type which reduces the thermal mechanical stresses to a minimum during
operation. The counter flange is included and ready for welding to the deck. In both
cases, vent holes in suitable numbers are arranged to ensure the circulation of air below
the boiler.
The boiler is prepared for mounting of a compact silencer to suit any type of engine.
The optimal silencer dimensions suitable for each installation should be calculated on
basis of the data for the engine, exhaust gas system, and level of sound absorption.
Principle drawing of the Aalborg OC-TCi boiler (vertical exhaust inlet)

Smoke tubes
Stay tubes
Smoke/stay tubes Helix-tube
Inspection door
End plate
(top plate)
Helix-tube
Boiler drum
Furnace
Fire hole
Refractory
End plate
Inspection door
Foundation
Figure 1 octci1cx1192650en.wmf
Language UK 9-3 / 8
SD9210_17#D.1
Principle drawing of the Aalborg OC-TCi boiler (horizontal exhaust inlet)

Smoke tubes Smoke/stay tubes
Helix-tube
Stay tubes
Inspection door
End plate
(top plate)
Helix-tube
Boiler drum
Furnace
Fire hole
End plate Refractory
Inspection door
Foundation
Figure 2 octci3x1192140en.wmf
1.2 Heat transfer and water circulation
Oil ignition and combustion take place in the furnace. The produced heat is transferred
mainly by radiation from the flame to the furnace shell. Leaving the furnace, the flue
gases enter the vertical uptakes where heat is transferred to the helix tubes mainly by
convection.
In the exhaust gas fired section, heat from the engine exhaust gas is transferred to the
water side by convection.
On the water side, the heat is transferred by evaporation of the saturated water adjacent
to the furnace shell or tube wall (smoke- and helix) where steam bubbles are formed.
As the steam bubbles have a much lower specific density than the water, they will rise
rapidly to the steam space where water and steam are separated.
The oil fired section of the boiler is designed so that approximately half of the steam
is generated in the helix elements and the rest by radiation in the furnace.
1.3 Steam space
The steam space in the oil fired boiler is designed to absorb the shrink and swell vol-
umes. It is advisable, however, to avoid sudden and large load variations as this might
create instability in the steam system, and cause level alarms.
9-4 / 8 Language UK
SD9220_17#C.1
BOILER MOUNTINGS
Boiler mountings
1 Mountings
The following is a brief description of the most important items of the boiler mountings.
The components mentioned in this section are referring to the general arrangement
drawing of the boiler.
Safety valves
Two safety valves are fitted to the pressure vessel of the boiler. They are installed for
security reasons, and designed to prevent the boiler pressure from rising above the
design value.
The safety valves must be supplied with waste steam pipes and either expansion de-
vices, or bellows.
Main steam valve

The main steam valve is a shut off/non-return valve. When closed, it isolates the boiler
from the main steam line. When open, it prevents steam from flowing backwards into
the boiler.
Feed water valve / feed water valve (sdnr)

Two feed water lines are provided in the boiler. Each line is fitted with a shut-off valve
and a non-return valve.
The shut-off valve in the primary line must be open when the boiler is in operation.
This also applies if only the exhaust gas fired section is in operation.
The shut-off valves should be closed when the boiler is not in use.
Water level gauges

Two local water level gauges are connected to the front of the boiler, each gauge being
provided with two shut-off valves and a drain valve.
The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-self
closing mechanism to be used in case of broken glass.
The pipes from the drain cocks on the water level gauge must lead to an open drain,
visible for inspection.
Language UK 9-5 / 8
SD9220_17#C.1
BOILER MOUNTINGS
Blow-down valve / blow-down valve (sdnr)

Two blow-down valves are mounted at the bottom of the boiler body. If connected to
a separate drainage system the valves are of the ball type. When connected to a common
drainage system two valves are provided in each group, one shut-off valve and one
shut-off/non-return valve. The shut-off function is for security and the non-return
function prevents steam/water from flowing into an empty boiler by mistake.
Air valve
The air/ventilation valve located on top of the boiler is a shut-off valve. It is normally
closed except when the boiler is being filled or completely drained. The end of the
drain pipe from the air valve must be visible in order to determine when air or steam
is coming out.
Scum valve
The scum valve is mounted at the top of the boiler body. In the event of scum in the
boiler, this scum can be blown off from the water surface by opening this valve. If
connected to a separate drainage system the valve is of the ball type. When connected
to a common drainage system two valves are provided, one shut-off valve and one
shut-off/non-return valve.
Sample valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Manhole
Two manholes are arranged on the boiler shell which allow inside inspection of the oil
fired section and the exhaust gas fired section.
Hand hole
A number of hand holes are distributed regularly around the circumference of the boiler
and at the bottom of the boiler drum for visual check and cleaning of the smoke tubes.
Inspection hole
A small inspection hole is provided in the furnace wall to enable inspection of the
burner flame. A proportion of the air supply is bled off from the burner fan to cool the
window of the inspection hole, and prevent soot deposits.
Inspection door
The boiler is provided with two inspection doors to enable inspection of the flue gas
inlet and outlet chambers.
Access to the furnace is gained by swinging out the burner unit.
Drain for furnace

The furnace bottom is provided with a socket for drain of the washing water.
9-6 / 8 Language UK
SD9230_46#C.1
WATER LEVEL CONTROL
Water level control
1 Description
The water level control is an on/off regulating system at this type of boiler. The system
is illustrated in Figure 1. The safety device system for too low water level shut down
and burner stop consists of a level float switch mounted as an external unit. For meas-
uring and control of the water level, the boiler is equipped with a dp water level trans-
mitter unit, which includes external reference and variable legs, and a dp-transmitter.
The continuous 4-20 mA output signal from the dp-transmitter is processed in the
control system, which provides level alarms/shut downs and start/stop of the feed water
pumps.
Water level control system
Feed water
valves
Reference leg
Too low
level switch
Variable leg
Boiler
Valve Control
manifold system
(panel)
dp-transmitter
Feed water pumps
Figure 1 sd9230_46_dp_1_ox0064290en.wmf
Language UK 9-7 / 8
SD9240_14#B.1
GAUGE BOARD
Gauge board
1 Description
The function of the gauge board is to control the burner and to give alarm and shut
down for low and high steam pressure.
• A pressure gauge is fitted for analogous reading of the actual steam pressure in the
boiler.
• A pressure switch "high steam pressure" gives shut down and burner cut-off when
the steam pressure rises above the pre-adjusted set point. The pressure switch locks
the burner in stop mode. Operation of the burner is only possible when the steam
pressure falls below the differential set point of the pressure switch and the shut
down function is reset.
• A pressure transmitter connected directly on the boiler converts the actual steam
pressure of the boiler into corresponding electric signals. The signals are used to
give alarms for low/high steam pressure and shut down/burner cut-off for high
steam pressure. The signals also control start/stop and modulation set point of the
burner. Furthermore, the pressure transmitter can be used for remote steam pres-
sure indication.
9-8 / 8 Language UK
TABLE OF CONTENTS
Table of contents
Installation
.
Installation of Aalborg OC-TCi boiler.......................... IN9210_52................. 10-2
Support of Aalborg OC-TCi boiler............................... IN9210_53................. 10-9
IN9210_52#H.1
INSTALLATION OF AALBORG OC-TCI BOILER
Installation of Aalborg OC-TCi boiler
1 General
This chapter describes the work procedures which should be followed during instal-
lation of the Aalborg OC-TCi boiler.
1.1 Corrosion preventive initiatives
When the boiler leaves the factory corrosion preventive initiatives are taken to ensure
the state of the boiler during transportation and intermediate storage. In the following
section the corrosion preventive initiatives are briefly described.
Cleaning of internal and external surfaces

- Internal and external surfaces are free from corrosion, grease, iron scale, and other
impurities. This ensures that the surface treatment work is carried out without the
risk of subsequent scaling.
External surfaces
- External surfaces are painted with a thin layer of primer.
Furnace and smoke uptake
- The furnace of the boiler plate is painted with a thin layer of primer.
- Furnace tubes, tubes in the convection part, and smoke outlets are painted on visible
surfaces.
- Tubes inside cleaning doors are spray-painted.
- Visible surfaces in the smoke uptake are spray-painted.
Water and steam side
- Internal surfaces on the water/steam side are treated, by adding an inhibitor to the
water during pressure test.
- After pressure test of the boiler the water is drained and a powdered inhibitor is
added.
Note: The powdered inhibitor provides sufficiently preservation during six

months. At storage beyond this period contact Alfa Laval or preserve the
boiler again with VCI-609 powder inhibitor.
Boiler bottom and top

- Raw/non-treated surfaces, plates, profiles, and tubes, that are visible from the out-
side, are spray-painted. Insulated boilers are painted with black painting.
IN9210_52#H.1
Closing of boilers
- Manholes and hand holes are closed with cover plates and gaskets.
- Flanged sockets are closed with plastic tube closing plugs.
- Smoke outlets and inlets, if provided, are closed with galvanised plates.
- If no burner is mounted, the fire hole in boiler front plate is closed with a galvanised
plate.
- Bolts, blot supports, tap holes, hinges, etc., are greased with a protective agent.
2 Handling and lifting the boiler

When the boiler is delivered, the exhaust gas inlet tube is not fixed to the connection
ring, and the tube is pushed up against the bottom of the furnace. By doing so, the
boiler can be placed into an up-right position without risk of damaging the tube. During
installation of the boiler, the exhaust gas inlet tube must be placed in the correct position
and fixed to the connection ring.
Furthermore, the boiler is delivered with the transportation supports mounted.
Note: If the boiler unit is stored for a period of time before it is mounted in the
ship, it must be stored inside to protect against corrosion caused by rain,
pollution, etc. When the boiler unit has been installed in a ship still under
construction, it may also be exposed to rain, pollution, etc. Therefore it
must be covered with a waterproof tarpaulin.
Step A: Whether the boiler is placed on the quay or directly in the ship, the trans-
portation supports should not be removed before the boiler is turned into an
up-right position. The boiler should always be placed on a plane foundation.
This secures the boiler foundation from deformation.
Step B: The boiler must be turned into an up-right position by the use of two cranes
as shown in Figure 1.
Step C: The transportation supports must be cut inside the insulation. Insulation
plates for covering this area are supplied with the boiler.
Step D: Finally the boiler can be installed in the ship by lifting it as shown in Fig-
ure 2.
Note: The lifting wires should at least be dimensioned to a force equal to the
weight of the boiler. The weight appears from the technical data.
IN9210_52#H.1
Turn the boiler into an up-right position
Figure 1 octci_instal09ax2916640en.wmf
Lift the boiler into the ship
Figure 2 octci_instal10x1229710en.wmf
IN9210_52#H.1
3 Installation of the boiler

Welding to the deck/ship structure
Exhaust gas
outlet
For boilers with counter flange,

diameter above 3,000 mm
For boilers with shell,

diameter up to 3,000 mm
a6
a6
Deck or tank top
Ventilation holes not to

Exhaust gas
be covered
inlet
Figure 3 octci_instal04cx3589000en.wmf
3.1 Welding to the deck/ship structure
Prior to installation of the boiler, it must be ensured that the deck or ship structure,
onto which the boiler should be welded, is sufficiently plane and has the adequate
strength to support the boiler. Furthermore, the boiler foundation in the ship must have
the sufficient stiffness to avoid that vibrations from the ship are transformed to the
boiler. The vibration levels generated by other sources than the boiler itself and meas-
ured on the boiler body during normal operation loads of the ship should not exceed
an overall velocity of 30 mm/s (peak) in the frequency range 5 – 50 Hz measured in
any direction.
After lining-up, the boiler must be welded to deck/ship structure as shown in Fig-
ure 3. The boiler shell is welded from outside only. The cut-outs in the foundation of
the boiler may under no circumstances be covered or sealed. This is due to the fact that
there should always be an air circulation below the boiler.
IN9210_52#H.1
In some cases, due to class requirements to form a water tight spill tray around the
boiler, the cut-outs aren't made. If this is the case, approximate 50% of the area (ex-
cluding the exh. gas pipe area) underneath the boiler have to be cut away to insure
sufficient ventilation.
Note: If the boiler is installed on a tank top, the distance between the bottom of
the furnace and the tank top must be at least 760 mm or according to the
rule of the classification society.
3.2 Connection of the exhaust gas inlet/outlet and smoke outlet
The inlet and outlet sections can be delivered with both flange and counter flange.
To absorb the thermal expansions when the boiler is heated, expansion bellows must
be installed. The bellows must be installed right before and after the exhaust gas inlet/
outlet and right after the smoke outlet box. The thermal expansion can be estimated to
2.15 mm/m both in horizontal and vertical direction.
Attention: The boiler may under no circumstance carry the weight of the flue
gas funnel or the exhaust gas funnel. Fix-points should be arranged
for the funnels right below and above the boiler.
The exhaust gas inlet piping should be designed so that the exhaust gas flow is evenly
distributed over the entire inlet cross-section area. An uneven distribution may result
in a reduced steam output as well as an increased exhaust gas pressure drop across the
boiler. The exhaust gas inlet piping should furthermore be constructed so that no
washing water can enter the turbo chargers of the main engine.
Recommended dimension of the flue gas funnel

The following table shows the recommended dimension of the smoke funnel. The
stated dimensions imply a smoke velocity of 25 m/s and a draft loss of maximum 5-10
mm WC. If these conditions cannot be fulfilled, the diameter should be increased.
Recommended dimension of the smoke funnel

Boiler type (oil fired section) Dimension (mm)
Aalborg OC-TCi 1200 DN 200
Aalborg OC-TCi5500 DN 400
Aalborg OC-TCi6500 DN 450
Table 1
IN9210_52#H.1
Welding of the exhaust gas inlet tube

The exhaust gas inlet tube must be placed in the correct position and fixed to the
connection ring as shown in Figure 4.
Welding of exhaust gas inlet tube

Transport and storage position of the exhaust gas inlet tube
Bottom plate Exhaust gas inlet tube
Connection ring
Boiler foundation
Installation position of the exhaust gas inlet tube
Detail A
Site weld
A
Max. 45 mm
Site weld
Figure 4 octci_instal05bx1996160en.wmf
Note: Min. 30mm gab between deck and inlet tube.
3.3 Connection of pipes and boiler mountings
Note: The connection pipes to the boiler mountings must be arranged in such a
way that the thermal expansion of the boiler and the piping system do not
transform any significant forces to the sockets on the boiler or the boiler
mountings. The thermal expansion can be estimated to 2.15 mm/m both in
horizontal and vertical direction.
3.3.1 Connection of pipes

The connection of pipes to the boiler mountings should be performed by means of
welding neck flanges or slip-on flanges. Figure 5 illustrates the piping connections for
the boiler.
IN9210_52#H.1
3.3.2 Connection of boiler mountings

The boiler mountings are pre-mounted on the boiler body. Counter flanges can be
supplied (option) for the connection pipes. The counter flanges must be dismantled
from the boiler mountings and welded to the system pipe.
The open ends of the mounting connections are closed with plastic plugs. These plugs
must be removed before the mountings are connected to the system with gaskets, sup-
ports, and bolts.
Connection of pipes
Slip-on flanges Welded neck flanges
Figure 5 in9210_52_flangex0224492en.wmf
Flange and tube sizes

According to EN standard According to JIS standard
Inside diame- Outside di- Inside diame- Outside di-
DN size ter of flange ameter of DN size ter of flange ameter of
(mm) tube (mm) (mm) tube (mm)
DN15 22.0 21.3 DN15 22.0 21.7
DN20 27.5 26.9 DN20 27.5 27.2
DN25 34.5 33.7 DN25 34.5 34.0
DN32 43.5 42.4 DN32 43.5 42.7
DN40 49.5 48.3 DN40 49.5 48.6
DN50 61.5 60.3 DN50 61.5 60.5
DN65 77.5 76.1 DN65 77.5 76.3
DN80 90.5 88.9 DN80 90.5 89.1
DN100 116.0 114.3 DN100 116.0 114.3
DN125 141.5 139.7 DN125 141.5 139.8
DN150 170.5 168.3 DN150 166.0 165.2
DN200 221.5 219.1 DN200 217.0 216.3
DN250 276.5 273.0 DN250 268.5 267.4
DN300 327.5 323.9 DN300 319.5 318.5
Table 2
IN9210_53#G.1
SUPPORT OF AALBORG OC-TCI BOILER
Support of Aalborg OC-TCi boiler
1 Description
Due to the height and weight of the boiler and the proportionally high location of the
centre of gravity, the boiler top must be supported. This will contribute to relieve the
boiler foundation from stresses. The supports must be arranged both in longitudinal
and transversal direction.
The top end of the boiler is, as a standard, provided with two fixing eyes and two
combined lifting/fixing eyes. Additional fixing eyes can be provided.
When the boiler is fixed, beams provided with links in each end should be used. The
boiler should be arranged with at least one beam in the longitudinal direction and at
least one beam in the transverse direction.
When the beams are arranged, the distance from the boiler to the nearest fix bulkhead
should be as short as possible. This also means that the shortest possible distance is
decisive for whether the longitudinal support should be arranged on the fore or after
side of the boiler and whether the transversal support should be arranged in starboard
or port side of the boiler (see Figure 1).
If the transverse support cannot be arranged in a directly transversal position, it might

be advantageous to support the boiler with two transverse beams to secure the boiler.
Note: In double boiler installations, the boilers must not be linked together.
In order to reduce the influence of the thermal expansion between the boiler, beam,
and bulkhead, the optimal installation angle of a beam is -15° with a length of at least
500 mm. However, angles between ±20° from the optimal angle position can be ac-
cepted. Furthermore, it must be ensured that the thermal expansion does not create any
tension on the beam arrangement by having a sufficient clearance between the link
holes and bolts.
IN9210_53#G.1
SUPPORT OF AALBORG OC-TCI BOILER
Support of Aalborg OC-TCi boiler
Optimal beam
position: -15º
+5º
The nut shall be

Counter nut finger tightened only
-35º
m
5 00 m
Min.
* Max. distance according to

dimension in drawing of
lifting eye.
See seperate drawings in
drawing chapter.
Figure 1 octci_instal01c3x2916920en.wmf
TABLE OF CONTENTS
Table of contents
Feed and boiler water

.
Feed and boiler water................................................. OM9210_99............... 11-2
OM9210_99#D.1
FEED AND BOILER WATER
Feed and boiler water
1 General
Note: The recommended feed and boiler water characteristics are only valid for
boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants. Methods
such as e.g. reverse osmosis plants or ion exchange plants produce good quality dis-
tillate. Also evaporators generally produce good distillate. The important thing is that
the distillate used should be clean and without foreign salt contamination.
In practice most distillates used contain minor parts of various salt combinations which
can and must be chemically treated away. Furthermore, the distillate may contain dis-
solved gases like for example oxygen (O2) and carbon dioxide (CO2) which may lead
to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically treated in order to avoid
corrosion and scaling in the boiler.
2 Layout of the treatment system

The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system should
therefore be considered carefully during layout of the plant. Alfa Laval gives some
general requirements and recommendations regarding the conditions of the feed and
boiler water. However, there is several ways to obtain this results, or similar, by using
different treatment systems. The following should therefore be considered already at
the layout stage:
- Choose the treatment system that should be used.

- Present the condensate and feed water system to the supplier of the treatment sys-
tem and inform about the operation philosophy of the plant.
- Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
- Let the supplier inform about which test facilities is needed.
- Purchase the recommended equipment and install it in the correct way.
- Use the treatment system as soon as the boiler is taken into operation.
OM9210_99#D.1
3 Feed and boiler water characteristics

The following text regarding feed and boiler water treatment is the normal recom-
mendations given by Alfa Laval. These recommendations should be followed strictly
in order to have the best working conditions for the boiler plant and to extend the
working life of the plant. The requirements/recommendations of the various values for
feed and boiler water are listed in Table 1 below.
Requirements for feed and boiler water

Unit Feed water Boiler water
Appearance - Clear and free of mud Clear and free of mud
Hardness ppm CaCO3 0-5 -
Chloride content ppm Cl- 15 100
"P" alkalinity ppm CaCO3 - 100 - 150
Total (T) alkalinity ppm CaCO3 - 2 x "P" - Alkalinity
PH-value at 25C - 8.5 - 9.5 10.5 - 11.5
Hydrazine excess ppm N2H4 - 0.1 - 0.2
Phosphate excess ppm PO4 - 20 - 50
Specific density at 20C Kg/m3 - 1.003
Conductivity at 25C S/cm - 2000
Oil content - NIL NIL
Copper content ppm <0.02 <0.3
Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2SO3) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended that
an excess of oxygen binding agents can be measured and indicates that no oxygen has
been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is recommended

to keep the value  0.02 ppm.
In addition to the above values, the various water treatment companies will add further
demands, depending on the method used for treatment of feed and boiler water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.
3.1 Units of measurement
Concentrations are usually expressed in "ppm" i.e. parts solute per million. Concen-
trations for parts solution by weight are the same as "mg/litre".
OM9210_99#D.1
3.1.1 Specific gravity

As guidance the following conversion can be used:
• 1 Be = 10.000 mg/l total dissolved solids (TDS)

• 1 mg/l total dissolved solids = 2 S/cm
• 1 S/cm = 1 mho
4 Feed and boiler water maintenance

The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together with the supplier of
chemicals for water treatment.
4.1 Recommended water maintenance
4.1.1 Daily
Step A: Analyses of feed and boiler water.
4.1.2 Weekly
Step A: Skimming (surface blow down) according to analyses, but at least once per
week (2 minutes with fully open valve).
Step B: Blow down (bottom blow down) according to analyses, but at least once per
week (each blow down valve 1 minute in low load condition).
If the copper content is on a stable level below the value in table 1, the analyse frequence
can be reduced to once per week.
4.1.3 Monthly
Step A: Check the functions for salinity and oil detection systems.
4.1.4 Every six months
Step A: The boiler water side (interior) must be carefully inspected at least twice a
year.
4.1.5 Yearly
Step A: Check of the water side of the boiler and hotwell/deaerator for corrosion and
scaling.
Step B: Check the chemical pump unit.
5 Treatment systems / injection points

In the following tables and illustrations a number of different feed and boiler water
treatment systems are shown together with the recommended location for the injection
point of the individual chemicals as stated by the manufacturer. The general informa-
tion regarding the injection point principle can be used as guidelines for the most
common systems. But should there be any doubt for a specific system the manufacturer/
supplier should be consulted in order to obtain the correct result.
OM9210_99#D.1
Notes for tables/illustrations:

• Note No. 1: the preferred injection point of chemicals stated by the manufacturer/
supplier.
• Note No. 2: the alternate injection point of chemicals stated by the manufacturer/
supplier.
• Note No. 3: Valid for modulating feed water systems.
• Note No. 4: valid for on/off operating feed water systems. The chemical pump
starts/stops together with the feed water pump.
• Note No. 5: valid for two boiler installation. Control of the chemicals in question
work properly at an equal load condition (feed water flow) on the two boilers.
How to use the tables:
The tables can be used in different ways but the main idea is to do following:
Step A: Discover which manufacturer and type of chemicals that should be used for
the actual boiler plant.
Step B: Use the name of the manufacturer and type of chemicals to select which
tables that can be used.
Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram
that matches the actual boiler plant.
Step D: Find in the selected tables the table which includes the matching diagram.
Step E: If more than one table is found to match the actual boiler plant in question
it is recommended to use the method/table which includes note No. 1.
Step F: If no table is found to match the actual boiler plant in question it is recom-
mended to seek assistance by the chemical manufacturer/supplier.
OM9210_99#D.1
Chemical injection points

Table No. 1
Manufacturer / supplier: Ashland Chemical / Drew Marine Division
Product name / method: Standard with Drewplex OX
Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No.
Adjunct B 3, 3a, 3b X 1
GC 3, 3a, 3b X 1
1, 2, 3
SLCC-A 3, 3a, 3b X 1
Drewplex OX 2, 2a, 2b X 1, 3, 4
Chemical injection points (continued)

Table No. 2
Product name / method: Standard with Amerzine
Adjunct B 3, 3a, 3b X 1
GC 3, 3a, 3b X 1
1, 2, 3
SLCC-A 3, 3a, 3b X 1
Amerzine 2, 2a, 2b X 1, 3, 4

Table No. 3
Adjunct B 3 X
GC 3 X
1
SLCC-A 3 X
Amerzine 1 X 2, 3, 4

Table No. 4
Adjunct B 3a, 3b X
GC 3a, 3b X
2, 3
SLCC-A 3a, 3b X
Amerzine 1 X 2, 3, 4, 5

Table No. 5
Product name / method: Drewplex AT / OX
Drewplex AT 3, 3a, 3b X 1
Drewplex OX 2, 2a, 2b X 1, 3, 4
1, 2, 3
OM9210_99#D.1

Table No. 6
Product name / method: Drewplex AT / OX
Drewplex AT 2, 2a, 2b X 2, 3, 4
Drewplex OX 2, 2a, 2b X 3, 4
1, 2, 3

Table No. 7
Product name / method: Drewplex AT with Amerzine
Amerzine 2, 2a, 2b X 1, 3, 4
1, 2, 3

Table No. 8
Amerzine 2, 2a, 2b X 3, 4
1, 2, 3

Table No. 9
Amerzine 1 X 2, 3, 4, 5
1, 2, 3

Table No. 10
Product name / method: AGK-100 with Amerzine
AGK-100 2, 2a, 2b X 1, 3, 4
Amerzine 2, 2a, 2b X 1, 3, 4
1, 2, 3
OM9210_99#D.1

Table No. 11
AGK-100 2, 2a, 2b X 3, 4
Amerzine 1 X 2, 3, 4, 5
1, 2, 3

Table No. 12
AGK-100 1 X 2, 3, 4, 5
Amerzine 1 X 2, 3, 4, 5
1, 2, 3

Table No. 13
Manufacturer / supplier: Marichem
Product name / method: Standard
Alkalinity control 3, 3a, 3b X 1, 3, 4
Phosphate 3, 3a, 3b X 1, 3, 4
1, 2, 3
Oxycontrol 2, 2a, 2b X 1, 3, 4
Marichem CCI 2, 2a, 2b X 1, 3, 4

Table No. 14
Product name / method: Standard
Alkalinity control 1 X 2, 3, 4
Phosphate 1 X 2, 3, 4
1
Oxycontrol 2 X 3, 4
Marichem CCI 2 X 3, 4

Table No. 15
Product name / method: BWT new formula
BWT new formula 2, 2a, 2b X 1, 3, 4
1, 2, 3
OM9210_99#D.1

Table No. 16
Product name / method: BWT new formula
BWT new formula 1 X 2, 3, 4, 5
Marichem CCI 2, 2a, 2b X 3, 4
1, 2, 3

Table No. 17
Product name / method: BWT
BWT powder 2, 2a, 2b X 1, 3, 4
1, 2, 3

Table No. 18
Product name / method: BWT
BWT powder 1 X 2, 3, 4, 5
Marichem CCI 2, 2a, 2b X 3, 4
1, 2, 3

Table No. 19
Product name / method: I
Hardness control 3, 3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1
1, 2, 3
Oxygen control 2, 2a, 2b X 1, 3, 4
Condensate control 2, 2a, 2b X 1, 3, 4

Table No. 20
Manufacturer / supplier: Unitor Chemicals
Hardness control 1 X 2
Alkalinity control 1 X 2
1
Oxygen control 2 X 3, 4
Condensate control 2 X 3, 4
OM9210_99#D.1

Table No. 21
Product name / method: II
1, 2, 3
Cat sulphite L (CSL) 2, 2a, 2b X 1, 3, 4

Table No. 22
1
Cat sulphite L (CSL) 2 X 3, 4

Table No. 23
Product name / method: Liquitreat
Liquitreat 3, 3a, 3b X 1
1, 2, 3
(Oxygen control) 2, 2a, 2b X 1, 3, 4

Table No. 24
Product name / method: Liquitreat
Liquitreat 1 X 2
Condensate control 2, 2a, 2b X 3, 4
1
(Oxygen control) 2, 2a, 2b X 3, 4

Table No. 25
Product name / method: Combitreat
Combitreat 3, 3a, 3b X 1
1, 2, 3
OM9210_99#D.1

Table No. 26
Product name / method: Combitreat
Combitreat 1 X 2
1

Table No. 27
1, 2, 3
Hydrazine 2, 2a, 2b X 1, 3, 4

Table No. 28
Manufacturer / supplier: Uniservice Group
1
Hydrazine 2 X 3, 4

Table No. 29
1, 2, 3

Table No. 30
1
OM9210_99#D.1

Table No. 31
Product name / method: One Shot
BWT One Shot 3, 3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1, 3, 4
1, 2, 3
(Hydrazine) 2, 2a, 2b X 1, 3, 4

Table No. 32
Product name / method: One Shot
BWT One Shot 1 X 2
Alkalinity control 2, 2a, 2b X 3, 4
1
(Hydrazine) 2, 2a, 2b X 3, 4

Table No. 33
Product name / method: Organic Treatment
OBWT 3 3, 3a, 3b X 1
OBWT 4 2, 2a, 2b X 1, 3, 4
1, 2, 3
Table 2
OM9210_99#D.1
Flow diagram No.: 1

Service
steam
3 PT
Steam
dump
valve
Cooling
Condenser
water
Condensate
Make-up
Boiler
Overflow
Hot well
Drain
2
PI PI
PS
Feed water
pumps
Single boiler operation with or without PI PI
forced circulation exhaust gas boiler
Figure 1 om9210_99_flowdix0060010en.wmf
OM9210_99#D.1
Flow diagram No.: 2

Service
steam
3b 3a PT
Steam
dump
valve
Cooling
Condenser
water
Condensate
Make-up
Boiler Boiler
Overflow
Hot well
Drain
1
2a
PI PI
PS
Feed water
2b PI PI PI PI
pumps
PS
Feed water
pumps
Double boiler operation with separate feed water pumps PI PI
with or without forced circulation exhaust gas boiler
OM9210_99#D.1
Flow diagram No.: 3

Service
steam
3b 3a PT
Steam
dump
valve
Cooling
Condenser
water
Condensate
Make-up
Boiler Boiler
Overflow
Hot well
Drain
1
2a
PS PI PI
Feed water
pumps
2b PS PI PI
PS PI PI
Double boiler operation with common feed water pumps

with or without forced circulation exhaust gas boiler
TABLE OF CONTENTS
Table of contents
Safety valves
.
Safety valves............................................................. IN6040_01................. 12-2
IN6040_01#D.1
SAFETY VALVES
Safety valves
1 Installation
In the following the measures required to achieve a safe and reliable installation of the
safety valves will be described. If the installation is subject to approbation from special
authorities, their requirements must be observed.
1.1 Mounting of safety valves
Figure 1 shows an installation example of the safety valves.
Note: Safety valves should be handled carefully. Any rough treatment can cause
damage to the seating surfaces.
Mounting of safety valves, example
Waste steam pipe

Support
Drain
Expansion joint
with sealing ring
Drain
Drain
If safety valve ≤ DN50/80

drain connection is G1/4" BSP
If safety valve ≥ DN65/100
drain connection is G3/8" BSP
Figure 1 safe_01ex0518880en.wmf
IN6040_01#D.1
SAFETY VALVES
It is recommended to provide each safety valve with a separate waste steam pipe, which
must have a sufficient inside diameter determined by the full exhaust quantity of the
valve as well as the resistance of the pipe (pressure loss) and must be at least one
dimension larger than the outlet flange. The pressure loss in the escape pipe including
the exhaust loss should not be higher than 10% of the set pressure for the valve, (or
30% if the safety valve is special back pressure type).
The vertical pipe must run as straight as possible and be thoroughly anchored and
supported to the structure of the vessel to withstand the reaction during blow out. A
long escape pipe with more bends may necessitate that a pipe with a larger inside
diameter is chosen in order to secure that the back pressure will not be too high.
It is necessary to install a horizontal expansion device between the valve outlet and the
escape pipe or in other ways. This is to secure that forces from the latter are not trans-
ferred to the safety valve body with subsequent tensions and dislocation of the body
resulting in leakage or, at the worst, destruction of the valve. Alfa Laval recommends
an expansion device as shown in Figure 1.The escape pipe will normally expand about
2.5 mm per metre of pipe from the valve to the fixed point.
The distance between the centre lines of the safety valve and expansion joint must be
as short as possible. A large horizontal length increases the risk of tensions in the valve
body during blow out, and in such cases a support is required to avoid forces/tensions
are transferred to the safety valve and boiler.
Note: It is very important that the gaskets used have the correct dimensions
compared to the inlet and outlet flanges, and that the hole is big enough to
allow free passage. The bolts must be tightened equally all the way round
the flange to avoid unequal tensions.
1.2 Drain
The drain from the drip tray must be led separately to an open outlet to prevent pene-
tration of steam from other sources involving a risk of blocking the valve.
The outlet may be covered by a ‘splash-cover’ to avoid splashing to the surroundings

when a safety valve is blowing.
1.3 Lifting device
The safety valve can be equipped with a lifting device. Any extensions from the lifting
lever of a safety valve to the operating stand must be arranged in such a way as not to
transmit any force to the lever when at rest, see Figure 2.
By securing a steel wire to the lifting device, it is possible to operate the safety valve
in a safe distance. The safety valve can be operated by means of the lifting lever at
85% of the set pressure.
IN6040_01#D.1
SAFETY VALVES
Warning: It is very important to make sure that no restrictions obstacle the op-
eration of the lifting device and steel wire.
Arrangement of lifting device for safety valve, example
Figure 2 in6040_01_safe_0x0052170en.wmf
TABLE OF CONTENTS
Table of contents
Feed water system

.
Water level control.................................................... SD9230_46................ 13-2
Level float switch...................................................... OM8210_15............... 13-3
dp water level transmitter unit..................................... OM8210_18............... 13-7
SD9230_46#C.1
WATER LEVEL CONTROL
Water level control
1 Description
The water level control is an on/off regulating system at this type of boiler. The system
is illustrated in Figure 1. The safety device system for too low water level shut down
and burner stop consists of a level float switch mounted as an external unit. For meas-
uring and control of the water level, the boiler is equipped with a dp water level trans-
mitter unit, which includes external reference and variable legs, and a dp-transmitter.
The continuous 4-20 mA output signal from the dp-transmitter is processed in the
control system, which provides level alarms/shut downs and start/stop of the feed water
pumps.
Water level control system
Feed water
valves
Reference leg
Too low
level switch
Variable leg
Boiler
Valve Control
manifold system
(panel)
dp-transmitter
Feed water pumps
Figure 1 sd9230_46_dp_1_ox0064290en.wmf
OM8210_15#A.2
LEVEL FLOAT SWITCH
Level float switch
1 General
The level float switch of type RBA 24 supervises the water level in the boiler. It is
installed in a vertical position and connected to the boiler sockets, provided for this
purpose, by means of shut-off valves.
A float and float rod carry a transmitting magnet which runs in a stainless steel trans-
mitting tube. The transmitting magnet operates the externally installed magnet
switches. When the magnet switches have been triggered, they remain in that position
until trigged again. Figure 1 illustrates the level float switch.
Illustration of the level float switch
Shut-off valves
Terminal
row
Transmitting
tube
1 2 4
Float rod 2
Boiler
1 3
3
4
Steam drum 5
6
N
S
Transmitting
7 magnet
8
9
Level float 10
2 4
1 3
Magnet
switches
Drain valve
Figure 1 om8210_15_rba24x0058460en.wmf
2 Commissioning
2.1 Electrical connection
When installing the level float switch use acetic acid-free silicon cable in the internal
part of the switch housing.
Step A: Unscrew the switch housing and check for correct assembly and wiring.
OM8210_15#A.2
LEVEL FLOAT SWITCH
2.2 Adjusting the switch point
The switch point of the level float switch should be pre-adjusted before the boiler is
pressurised and started for the first time.
Step A: Open both shut-off valves and close the drain valve.
Step B: Open the feed water valves and the air valve. Fill the boiler with evaporated
water until the "Too low water level" mark has been reached and adjust the
magnet switch to the switch point. It should be moved in upwards direction
until the switch is trigged and secured in this position. The magnet switch
must rest against the transmitting tube.
Note: If the temperature difference between the boiler and feed water exceeds
approximately 50°C, the boiler must be filled very slowly. When filling a
pressure less boiler, the shut-off valve after the feed water pump must be
throttled. Otherwise the pump motor will be overloaded.
2.3 Function test
During commissioning a live test of the level float switch must be carried out before
the boiler is put into normal operation. The purpose of the live test is to check that the
shut down for too low water level and cut out function of the burner is operational.
When the boiler is pressurised and the burner is in operation carry out the following
work steps:
Step A: Slowly decrease the water level in the boiler by means of the blow down
valves until the water level has fallen to the "Too low water level" mark.
Ensure that the boiler is not refilled with water by closing the feed water
valves.
Step B: Note that both the shut down and cut out function is delayed via a timer in
the control panel.
Step C: Adjust the switch point, if necessary.
Step D: After completion of the function test open the feed water valves fully and
raise the water level to the normal level.
3 Operation and maintenance
Attention: Both shut-off valves must always be fully open during normal oper-
ation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the level float switch
whenever an opportunity occurs by comparing the magnetic switch function with the
level indicated in the water level gauges.
A great difference in the water levels may indicate either blocked connections to the
float chamber or a water filled level float. Therefore it is recommended to blow-through
the level float switch and connection pipes frequently (see below). The blow-through
procedures can be performed, e.g. in connection with stopping the boiler plant, in order
OM8210_15#A.2
LEVEL FLOAT SWITCH
to get rid of dissolved particles that could settle during the stop periods. In case of
prolonged standstill the level float switch should be checked for the correct function
before the boiler plant is restarted.
3.1 Blow-through procedure
The blow-through procedure with cleaning of the float chamber should be performed
as describe below when the boiler plant is in operation. The procedure should be carried
out at least once each week.
Step A: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step B: Close the drain valve again.
In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through proce-
dure of the level float switch must be done more often.
3.2 Blow-through and test procedure
The blow-through procedure with test of the shut down and burner cut out function
should be performed as describe below when the boiler plant is in operation. The pro-
cedure should be carried out at least once each month.
Step A: Fully close the upper shut-off valve.

Step B: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step C: Then close the drain valve and open the upper shut-off valve again.
Step D: Fully close the lower shut-off valve.
Step E: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds. As the water level falls inside the float
chamber check that the shut down function is activated and the burner cuts
out. Please note that both the shut down and cut out function is delayed via
a timer in the control panel.
Step F: After performing the blow-through and test procedure close the drain valve
and open the lower shut-off valve again.
dure of the level float switch must be done more often.
3.3 Cleaning
The float chamber, transmitting tube, and transmitting magnet must be opened,
checked, and cleaned from dirt at least once a year. Carry out the following work
procedures:
OM8210_15#A.2
LEVEL FLOAT SWITCH
Step A: Perform a blowing-through procedure as described above.

Step B: Close the two shut-off valves and slowly open the drain valve.
Step C: Remove the top flange of the chamber.
Step D: Loosen the float and float rod with transmitting magnet from the top flange.
Step E: Clean the transmitter tube and transmitting magnet.
Step F: Clean the float chamber for any fossilised mud.
Step G: Check the condition of the float and that it is not water filled.
Step H: Check the condition of the electrical wiring. Exchange damaged wires if
necessary.
When the cleaning procedure is completed the level float switch must be assembled
as follows:
Step I: Assemble the transmitting magnet in the top flange.
Step J: Assemble the top flange on the float chamber.
Step K: Perform a function test as described previously when the boiler is pressur-
ised.
OM8210_18#A.2
DP WATER LEVEL TRANSMITTER UNIT
dp water level transmitter unit
1 General
The dp water level transmitter unit controls and supervises the water level in the boiler.
The complete unit is installed in a vertical position and connected to the boiler sockets,
provided for this purpose, by means of shut-off valves (see Figure 1).
The dp water level transmitter unit includes reference leg, variable leg, transmitter
connection valves mounted on a manifold, and a differential pressure transmitter. The
differential pressure transmitter converts the detected water level into an analogue
signal (4-20 mA) which is transmitted to the control system. The signal can also be
used for remote level indication in the engine control room.
Illustration of the dp water level transmitter unit

Shut-off valves
Filling plug
Reference leg
Drain valve
Boiler
Filling plug
Variable leg
Drain valve
Valve manifold
Connection
valves
Equalising valve
dp-transmitter
Figure 1 om8210_18_dpunitx0058500en.wmf
The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°) from
the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low pres-
sure connection (-).
OM8210_18#A.2
Note: The dp water level transmitter unit or any part of it must not be insulated
to ensure the correct function.
2 Commissioning
2.1 Initial commissioning
Before the boiler is pressurised and started for the first time some initial commissioning
procedures can be performed with regard to the valves of the dp water level transmitter
unit. The shut-off valves, transmitter connection valves, and equalising valve should
be operated in the following sequence during the initial commissioning:
Step A: Initial setting; all valves of the dp water level transmitter unit closed (see
Figure 1).
Step B: Open the equalising valve located on the valve manifold.
Step C: Unscrew the filling plugs for the reference leg and variable leg. Fill the legs
with feed water.
Step D: Open the transmitter connection valve and venting facility on the reference
leg side of the transmitter.
Step E: Close the venting facility on the reference leg side of the transmitter when
no more air escapes.
Step F: Open the venting facility on the variable leg side of the transmitter.
Step G: Close the transmitter connection valve on the reference leg side of the trans-
mitter when no more air escapes.
Step H: Open the transmitter connection valve on the variable leg side of the trans-
mitter.
Step I: Close the venting facility on the variable leg side of the transmitter when no
more air escapes.
Step J: Close the transmitter connection valve on the variable leg side of the trans-
mitter.
Step K: Close the equalising valve.
Step L: Refill the legs with feed water and screw on the filling plugs for the reference
leg and variable leg.
Step M: Open both transmitter connection valves fully.
2.2 Commissioning of the differential pressure transmitter
The differential pressure transmitter can be commissioned either through "blind cali-
bration" or "live calibration". In the following sections both methods are described.
2.2.1 Blind calibration

Blind calibration of the differential pressure transmitter can be performed if no pressure
source is available. This means when the boiler cannot be operated at normal working
pressure and the water level cannot be increased/decreased. The "start of scale" and
"full scale" differential pressures are calibrated on the basis of calculated values. The
start of scale value should be calibrated to obtain a 4 mA output signal from the trans-
mitter when the water level is at the lower connection point and the full scale value to
OM8210_18#A.2
obtain a 20 mA output signal when the water level is at the upper connection point. To
ensure an accurate calibration it is necessary to take the density difference between the
water in the reference leg and in the boiler into consideration when calculating the
differential pressure values.
4 mA output signal from the differential pressure transmitter:

- When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection points
(column of water) corrected with the density of the water in the reference leg. The
value must be specified and entered in engineering unit, e.g. in mm H2O.
20 mA output signal from the differential pressure transmitter:
- When the water level in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection points
corrected with the density difference between the water in the reference leg and in
the boiler. The value must be specified and entered in engineering unit, e.g. in mm
H2O.
Figure 2 indicates the calculation procedures of the differential pressures. As standard
it is assumed that the temperature in the reference leg (condensate receiver) is 40C.
Table 1 shows the calculated values for some standard heights between the connection
points. If the actual boiler plant does not fit any of the standard calculations the speci-
fied calculated values can be entered in the table for calibration record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure mode)
the differential pressure transmitter must be calibrated so that the minimum indicated
"Too low water level" on the control system not is lower than the actual "Too low water
level" mark. Because of the density difference in the boiler water at different working
pressures/temperatures the indicated water levels will not be identical. This means that
the differential pressures for start of scale and full scale should be calculated using the
parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of scale" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential pressure
transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys  and  are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H2O" as engineering units.
Step D: Select mode 5 using the "M" key.
Step E: Use the  or  key to set the start of scale in the selected engineering unit.
If mm H2O is selected as engineering units, then set the start of scale to the
calculated value in mm H2O (differential pressure at 4 mA).
Step F: Press both the  and  keys simultaneously for about 2 seconds, and the start
of scale is set to zero (in the selected engineering unit).
Step G: Select mode 6 using the "M" key.
OM8210_18#A.2
Step H: Use the  or  key to set the full scale in the selected engineering unit. If
mm H2O is selected as engineering units, then set the full scale to the cal-
culated value in mm H2O (differential pressure at 20 mA).
Step I: Press both the  and  keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).
Step J: Mount the protective cover of the differential pressure transmitter again.
Calibration of differential pressure transmitter

Height between con- Working pressure Transmitter output, Differential pressure
Connection point
nection [mm] [barg - kg/²]cm [mA] calibration [mm H2O]
Calculations for standard heights, working pressures, and ambient temperature (40C)
Lower connection 4 521
7.0
Upper connection 20 50
525
16.0
7.0
700
16.0
7.0
800
16.0
Calculation records for other heights, working pressures, and/or ambient temperatures
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Table 1
OM8210_18#A.2
Calculation of the differential pressures

o 3
t2 = 40 C, density: 992.2 kg/m
t1 = not existing
Differential pressure
between connections:
Height between
525 x 0.9922 =
connections, e.g.:
525 mm
521 mm H2O (at 4 mA)
Water level
o
t3 = 170 C at 7 barg,
204oC at 16 barg
o 3
t2 = 40 C, density: 992.2 kg/m t1 = not existing
Water level
between connections
(at 7 barg):
525 x (0.9922 - 0.8970) =
Height between
50.0 mm H2O (at 20 mA) connections, e.g.:
525 mm
between connections
(at 16 barg):
525 x (0.9922 - 0.8596) =
69.6 mm H2O (at 20 mA)
o
t3 = 170 C at 7 barg,
3
density 897.0 kg/m
o
204 C at 16 barg,
3
density 859.6 kg/m
Figure 2 om8210_18_dpunitx0058510en.wmf
2.2.2 Live calibration

Live calibration of the differential pressure transmitter can be performed when a pres-
sure source is available. This means when the boiler can be operated at normal working
pressure and the water level can be increased/decreased. The "start of scale" and "full
scale" output signals of the differential pressure transmitter are set during actual op-
erating conditions. It is therefore not necessary to take the density difference between
the water in the reference leg and in the boiler into consideration.
OM8210_18#A.2
However, if the boiler plant is intended to operate at different set points (high/low
pressure mode) the differential pressure transmitter must be calibrated so that the min-
imum indicated "Too low water level" on the control system not is lower than the actual
"Too low water level" mark. Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels will not be iden-
tical. This means that the differential pressure transmitter should be calibrated when
the boiler plant operates in high pressure mode.
When the boiler operates at normal working pressure carry out the following work
steps (please also see the specific instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential pressure
transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys  and  are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select "mA" as engineering units.
Step D: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step E: Slowly decrease the water level in the boiler until the lower connection point
is reached (socket centre line of the variable leg). The water level can be
decreased by means of the blow down valves.
Step F: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step G: Select mode 2 using the "M" key.
Step H: Set the output current corresponding to the start of scale using the  and 
keys. Or set the output current to 4 mA by pressing the  and  keys simul-
taneously for about 2 seconds.
Step I: Slowly increase the water level in the boiler until the upper connection point
is reached (socket centre line of the reference leg). The water level can be
increased by means of the feed water pumps.
Step J: When the water level is increased operate the burner so that the boiler pres-
sure is kept at normal working pressure.
Step K: Select mode 3 using the "M" key.
Step L: Set the output current corresponding to the full scale using the  and  keys.
Or set the output current to 20 mA by pressing the  and  keys simultane-
ously for about 2 seconds.
Step M: Mount the protective cover of the differential pressure transmitter again.
2.3 Final commissioning
During final commissioning a function test of the dp water level transmitter unit must
be performed before the boiler plant is put into normal operation. The purpose of the
function test is to check that the output signals from the differential pressure transmitter
are correct. Furthermore, it should be checked that the connected alarms/shut downs
OM8210_18#A.2
and control functions are operational. The boiler should be operated at normal working
pressure during the test to provide for correct indications. When the boiler is at normal
water level and the burner is in operation, carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. The burner should stop, and a shut down should be indicated on
the control system, (if provided).
Step C: Increase the water level somewhat until the upper connection point is
reached (socket centre line of the reference leg). Check that the output signal
from the differential pressure transmitter is at 20 mA or the full scale value
in the selected engineering units.
Step D: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step E: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the "Start of feed water pump" level. Check
that the operating feed water pump starts.
Step F: Check that the operating feed water pump stops when the water level is at
the "Stop of feed water pump" level.
Step G: Ensure that the operating feed water pump cannot be started. Decrease the
water level in the boiler until the "Start of stand-by feed water pump" level
is reached (if provided). Check that the stand-by feed water pump starts.
Step H: Ensure that the boiler cannot be filled with feed water by closing the feed
Step I: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.
Step J: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step K: Decrease the water level somewhat until the lower connection point is
reached (socket centre line of the variable leg). Check that the output signal
from the differential pressure transmitter is at 4 mA or the start of scale value
in the selected engineering units.
Step L: After completion of the function test open the feed water valves or start the
feed water pumps.
OM8210_18#A.2
3 Operation and maintenance
Attention: Both shut-off valves between the boiler and impulse legs must always
be fully open and the reference leg must be totally filled with water
during normal operation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the dp water level
transmitter unit whenever an opportunity occurs by comparing the water level indicated
by the control system with the level indicated in the water level gauges.
A great difference in the water levels may indicate blocked connections to the differ-
ential pressure transmitter. Therefore it is recommended to blow-through the impulse
legs and connection pipes frequently. The blow-through procedures can be performed,
e.g. in connection with stopping the boiler plant, in order to get rid of dissolved particles
that could settle during the stop periods. In case of prolonged standstill the dp water
level transmitter unit should be checked for the correct function before the boiler plant
is restarted.
3.1 Blow-through procedure of the impulse legs
3.1.1 Blow-through procedure of the impulse legs

The blow-through procedure should be performed as describe below when the boiler
plant is in operation and in steady load condition. The procedure should be carried out
at least once each month. When the blow-through procedure is carried out, it is very
important that the water level in the boiler is carefully and continuously supervised by
the ship engineering personnel. The feed water pumps must be operated manually, if
necessary.
Step A: Isolate the differential pressure transmitter by closing the two transmitter
connection valves in the manifold. The equalising valve must remain closed
during the blow-through procedure and normal operation.
Step B: Slowly open the drain valves of the impulse legs, and allow the legs to blow-
through for a few seconds.
Step C: Close the shut-off valve for the reference leg.
Step D: Close the drain valves again when the reference leg is completely depres-
surised.
Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step F: Screw on the filling plug and slowly open the shut-off valve for the reference
leg.
Step G: Open the two transmitter connection valves in the manifold.
Step H: After performing the blow-through check that the dp water level transmitter
unit and feed water pumps are fully operational.
dure of the impulse legs must be done more often.
OM8210_18#A.2
3.1.2 Blow-through procedure of the connection pipes

The blow-through procedure should be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least once
each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transmitter connection valves must remain open and the equalising
valve closed during the blow-through procedure.
Step B: Close the venting facilities on the valve manifold when only clean water
escapes.
Step C: Close the shut-off valve for the reference leg.
Step D: Slowly open the drain valve of the reference leg.
Step E: Close the drain valve again when the reference leg is completely depressur-
ised.
Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step G: Screw on the filling plug and slowly open the shut-off valve for the reference
leg.
dure of the connection pipes must be done more often.
3.1.3 Function test of the dp water level transmitter unit

During normal operation of the boiler plant a function test of dp water level transmitter
unit should be carried out at least once each month. The purpose of the function test is
to check that the connected alarms/shut downs and control functions are operational.
The boiler should be operated at normal working pressure during the test to provide
for correct indications. When the boiler is at normal water level and the burner is in
operation, carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
the control system, (if provided).
Step C: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the "Start of feed water pump" level. Check
that the operating feed water pump starts.
Step D: Check that the operating feed water pump stops when the water level is at
the "Stop of feed water pump" level.
Step E: Ensure that the operating feed water pump cannot be started. Decrease the
water level in the boiler until the "Start of stand-by feed water pump" level
is reached (if provided). Check that the stand-by feed water pump starts.
Step F: Ensure that the boiler cannot be filled with feed water by closing the feed
OM8210_18#A.2
Step G: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.
Step H: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step I: After completion of the function test open the feed water valves or start the
feed water pumps.
TABLE OF CONTENTS
Table of contents
Feed water pump unit

.
Pumps, type CR, CRN................................................ IN5540_20................. 14-2
IN5540_20#C.1
PUMPS, TYPE CR, CRN
Pumps, type CR, CRN
1 General
The multistage in-line centrifugal pumps are used as condensate, make-up, and feed
water pumps in boiler plants. To have a proper functioning of the centrifugal pumps it
is essential that the pumped liquid does not contain any steam, air, solid particles or
fibres. Furthermore the liquid must not attack the pump material chemically.
1.1 Technical data
• Electrical data: see motor nameplate.

• Ambient temperature: Max. 45°C.
• Minimum inlet pressure: see section 2.
• Maximum inlet pressure: see Table 1. However, the actual inlet pressure + pressure
when the pump is running against a closed valve must always be lower than the
“maximum permissible operating pressure".
IN5540_20#C.1
PUMPS, TYPE CR, CRN
Maximum inlet pressure

50 Hz 60 Hz
CR, CRN 1
CR, CRN 1s-2 → CR, CRN 1s-36 10 bar CR, CRN 1s-2 → CR, CRN 1s-27 10 bar
CR, CRN 1-2 → CR, CRN 1-36 10 bar CR, CRN 1-2 → CR, CRN 1-25 10 bar
CR, CRN 1-27 15 bar
CR, CRN 3
CR, CRN 5
CR, CRN 10
CR, CRN 15
CR, CRN 20
CR, CRN 20-1 → CR, CRN 20-3 8 bar CR, CRN 20-1 8 bar
CR, CRN 32
CR, CRN 32-1-1 → CR, CRN 32-4 4 bar CR, CRN 32-1-1 → CR, CRN 32-2 4 bar
CR, CRN 32-11-2 → CR, CRN 32-14 15 bar CR,CRN 32-7-2 → CR,CRN 15 bar
32-10-2
CR, CRN 45
CR,CRN 45-6-2 → CR,CRN 45-13-2 15 bar CR, CRN 45-4-2 → CR, CRN 45-7 15 bar
CR, CRN 64
CR, CRN 64-1-1 → CR, CRN 64-2-2 4 bar CR, CRN 64-1-1 4 bar
CR, CRN 64-2-1 → CR, CRN 64-4-2 10 bar CR, CRN 64-1 → CR, CRN 64-2-1 10 bar
CR, CRN 64-4-1 → CR, CRN 64-8-1 15 bar CR, CRN 64-2 → CR, CRN 64-5-2 15 bar
CR, CRN 90
CR, CRN 90-1-1 → CR, CRN 90-1 4 bar CR, CRN 90-1-1 → CR, CRN 90-2-1 10 bar
CR, CRN 90-2-2 → CR, CRN 90-3-2 10 bar CR, CRN 90-2-2 → CR, CRN 90-4-2 15 bar
CR, CRN 90-3 → CR, CRN 90-6 15 bar
Table 1
IN5540_20#C.1
PUMPS, TYPE CR, CRN
• Maximum permissible operating pressure: see Table 2.
Maximum permissible operating pressure

Frequency Pump type Temperature range Operating pressure
CR, CRN 1s, 1 25 bar
CR, CRN 3 25 bar
CR, CRN 5 25 bar
CR, CRN 10-1 → CR, CRN 10-22 25 bar
CR, CRN 15-1 → CR, CRN 15-17 25 bar
CR, CRN 20-1 → CR, CRN 20-17 25 bar
CR, CRN 32-1-1 → CR, CRN 32-7 16 bar
CR, CRN 32-8-2 → CR, CRN 32-12 25 bar
50 Hz -20°C to +120°C
CR, CRN 32-13-2 → CR, CRN 32-14 30 bar
CR, CRN 45-1-1 → CR, CRN 45-5 16 bar
CR, CRN 45-6-2 → CR, CRN 45-9 25 bar
CR, CRN 45-10-2 → CR, CRN 45-10 33 bar
CR, CRN 64-1-1 → CR, CRN 64-5 16 bar
CR, CRN 64-6-2 → CR, CRN 64-7-1 25 bar
CR, CRN 90-1-1 → CR, CRN 90-4 16 bar
CR, CRN 90-5-2 → CR, CRN 90-6 25 bar
CR, CRN 1s, 1 25 bar
CR, CRN 3 25 bar
CR, CRN 5 25 bar
CR, CRN 10-1 → CR, CRN 10-17 25 bar
CR, CRN 15-1 → CR, CRN 15-12 25 bar
CR, CRN 20-8 → CR, CRN 20-10 25 bar
CR, CRN 32-1-1 → CR, CRN 32-5 16 bar
60 Hz CR, CRN 32-6-2 → CR, CRN 32-8 -20°C to +120°C 25 bar
CR, CRN 32-9-2 → CR, CRN 32-10-2 40 bar
CR, CRN 45-1-1 → CR, CRN 45-4 16 bar
CR, CRN 45-5-2 → CR, CRN 45-6 25 bar
CR, CRN 64-1-1 → CR, CRN 64-3 16 bar
CR, CRN 64-4-2 → CR, CRN 64-4-1 25 bar
CR, CRN 90-1-1 → CR, CRN 90-3 16 bar
CR, CRN 90-4-2 25 bar
Table 2
IN5540_20#C.1
PUMPS, TYPE CR, CRN
• Minimum flow rates: See Table 3.
Minimum flow rates

Liquid temperature
Pump type
Up to + 80ºC + 80ºC to + 120ºC
CR, CRN 1s 0.1 m3/h 0.2 m3/h
CR, CRN 1 0.1 m3/h 0.3 m3/h
CR, CRN 3 0.4 m3/h 0.8 m3/h
CR, CRN 5 0.6 m3/h 1.3 m3/h
CR, CRN 10 1.2 m3/h 2.6 m3/h
CR, CRN 15 1.8 m3/h 3.8 m3/h
CR, CRN 20
2.4 m3/h 5.0 m3/h
CR, CRN 32 3.8 m3/h 7.6 m3/h
CR, CRN 45 5.4 m3/h 11.0 m3/h
CR, CRN 64 7.7 m3/h 16.0 m3/h
CR, CRN 90 11.0 m3/h 24.0 m3/h
Table 3
• Liquid temperature: -20°C to 120°C. See also Table 2 which indicates the rela-
tionship between liquid temperature and maximum permissible operating pressure.
Note: In condensate and feed water systems where an open hot-well is used it is
recommended to keep a temperature in the hot-well of 85-95ºC.
• Further technical data can be found on the data sheet related to the pumps.
2 Calculation of minimum inlet pressure

The minimum inlet pressure "H" in metres head required to avoid cavitation in the
pump is calculated as follows:
H = pb x 10.2 - NPSH - Hf - Hv - Hs
• pb = barometric pressure in bar (barometric pressure can be set to 1.0 bar). In closed
systems pb indicates the system pressure in bar.
• NPSH = net positive suction head in metres head (to be read from the NPSH curves
in Figure 2 and Figure 3 at the highest flow the pump will be delivering).
• Hf = friction loss in suction pipe in metres head at the highest flow.
• Hv = vapour pressure in metres head, see Figure 1. Tm = liquid temperature
• Hs = safety margin = 0.5 metres head.
If the calculated “H” is positive, the pump can operate at a suction lift of maximum
“H” metres head. If the calculated “H” is negative, an inlet pressure of minimum “H”
metres head is required. There must be a pressure equal to the calculated “H” during
operation.
Example:
Pump type = CR 20 - 60 Hz, flow rate = 24 m3/h, pb = 1.0 bar.
IN5540_20#C.1
PUMPS, TYPE CR, CRN
Hf = 3.0 metres head, liquid temperature = + 90ºC.
Hv (from Figure 1) = 7.5 metres head.
NPSH (from Figure 2) = 2.5 metres head.
H = pb x 10.2 - NPSH - Hf - Hv - Hs
H = 1 x 10.2 - 2.5 - 3.0 - 7.5 - 0.5 = -3.3 metres head.
This means that an inlet pressure of minimum 3.3 metres head is required.
Relationship between Hv and Tm
Figure 1 in5540_20_cr02ax0051251en.wmf
IN5540_20#C.1
PUMPS, TYPE CR, CRN
NPSH curves
Figure 2 in5540_20_2x3619790en.wmf
IN5540_20#C.1
PUMPS, TYPE CR, CRN
NPSH curves, continued
3 Installation
The pump should be installed with the motor shaft vertical. Ensure that an adequate
supply of cool air reaches the motor cooling fan.
Arrows on the pump base show the direction of flow through the pump see Figure 4.
Illustration of flow direction
Flow direction
To minimise possible noise from the pump, it is advisable to fit anti-vibration mount-
ings on either side of the pump and between foundation and pump.
Isolating valves should be fitted on either side of the pump to prevent the system from
being drained if it is necessary to clean, repair or replace the pump.
Install the pipes so that air locks are avoided, especially on the suction side of the pump.
Correct pipe work is shown in Figure 6.
Note: The pipes should be fitted so that any tension caused by variations in tem-
perature does not affect the pump.
IN5540_20#C.1
PUMPS, TYPE CR, CRN
If the pumps are installed in long pipes, these should be adequately supported before
and after the pump.
For pumps size at CR64 and above top support is required see Figure 5.
Top support
For tall pumps use bolt in

motor bracket for attachment
to support...
Figure 5 in5540_20_4ax3623140en.wmf
Correct pipe work.
Figure 6 in5540_20_cr04ax0051271en.wmf
Note: The pump is not allowed to run against a closed discharge valve as this will
cause an increase in temperature/formation of steam in the pump which
may cause damage to the pump.
If there is any danger of the pump running against a closed discharge valve, a minimum
liquid flow through the pump should be ensured by connecting a by-pass/ drain to the
discharge pipe. The drain can for instance be connected to a hot-well / tank.
IN5540_20#C.1
PUMPS, TYPE CR, CRN
3.1 Installation example
Figure 7 shows an example of a typical high-pressure wash down system. The illus-
trated installation is recommended in cases where the “minimum flow" through the
pumps cannot be ensured.
Installation example
Pump
1 - Flow Switc h
2 - Filte r
3 - Dia phra gm Ta nk
2 1 3
Figure 7 in5540_20_cr05x0051282en.wmf
The flow switch (1) will protect the pumps against damage caused by overheating by
stopping the pumps in the event of too small a flow of liquid. The filter (2) is fitted to
protect the flow switch in installations used for the pumping of slightly polluted water.
In installations where the flow conditions are stable and where the minimum flow rate
required can be ensured, the above measures are unnecessary.
In installations where there is a risk of water hammering, a non-return valve should

always be fitted on the discharge side of the pumps. Do not use rapid-closing valves,
e.g. rapid-closing spray guns, as these may cause water hammering.
3.2 Electrical connections
Caution: Before removing the terminal box cover and before any removal/dis-
mantling of the pump, make sure that the electricity supply has been
switched off.
The electrical connections should be carried out by an authorised electrician in ac-

cordance with local regulations.
The pump must be connected to an external switch.
The operating voltage and frequency are marked on the nameplate. Make sure that the
motor is suitable for the electricity supply on which it will be used.
Three-phase motors must be connected to a motor starter.
The terminal box can be turned to four positions, in 90° steps. If necessary, remove
the coupling guards by means of a screwdriver. Do not remove the coupling. Remove
IN5540_20#C.1
PUMPS, TYPE CR, CRN
the bolts securing the motor to the pump. Turn the motor to the required position.
Replace and tighten the bolts. Replace the coupling guards so that they are centred
vertically in the recesses in the pump head.
The electrical connection should be carried out as shown in the diagram inside the
terminal box cover.
4 Start-up
Warning: Do not start the pump until it is filled with liquid and has been primed
and vented.
4.1 Priming
Note: The following does only apply to systems where the liquid level is above
the pump inlet
Step A: Close the discharge isolating valve and loosen the vent screw in the pump
head, see Figure 8.
Illustration of the centrifugal pumps
Figure 8 in5540_20_cr06x0051292en.wmf
Note: Pay attention to the direction of the vent hole and take care to ensure that
the escaping water does not cause injury to persons or damage to the motor
or other components. In hot water installations, special attention should
be paid to the risk of injury caused by scalding hot water.
Step B: Slowly open the isolating valve in the suction pipe until a steady stream of
liquid runs out the vent hole.
Step C: Tighten the vent screw and completely open the isolating valve(s).
IN5540_20#C.1
PUMPS, TYPE CR, CRN
4.2 Checking direction of rotation
Do not start the pump to check direction of rotation until it has been filled with liquid.
Note: The direction of rotation should not be checked with the motor alone, as
an adjustment of the shaft position is required when the coupling has been
removed.
The correct direction of rotation is shown by arrows on the pump head and/or on the
motor fan cover. When seen from the fan, the pump should rotate counter-clockwise.
4.3 Starting
Before starting the pump:
Step A: Open the isolating valve completely on the suction side of the pump and
leave the discharge isolating valve almost closed.
Step B: Start the pump.
Step C: Vent the pump during starting by loosening the vent screw in the pump head
until a steady stream of liquid runs out the vent hole, see Figure 8.
Warning: Pay attention to the direction of the vent hole and take care to ensure
that the escaping water does not cause injury to persons or damage to
the motor or other components. In hot water installations, special at-
tention should be paid to the risk of injury caused by scalding hot
water.
When the piping system has been filled with liquid:
Step D: Slowly open the discharge isolating valve until it is completely open.
When pumping liquids containing air, it is advisable to vent the pump regularly. To
vent the pump:
Step E: Loosen the vent screw in the pump head during operation.
4.4 Frequency of starts and stops
Motors smaller than 4 kW should not start more than 100 times per hour.
Other motors should not start more than 20 times per hour.
5 Frost protection
Pumps which are not used during periods of frost should be drained to avoid damage.
Step A: Drain the pump by loosening the vent screw in the pump head and by re-
moving the drain plug from the base.
IN5540_20#C.1
PUMPS, TYPE CR, CRN
Warning: Care must be taken to ensure that the escaping water does not cause
injury to persons or damage to the motor or other components. In hot
water installations, special attention should be paid to the risk of injury
caused by scalding hot water.
Do not tighten the vent screw and replace the drain plug until the pump is to be used
again.
Step B: Before replacing the drain plug in the base, screw the by-pass valve out
against the stop, see Figure 8.
Step C: Fit the drain plug by tightening the large union nut followed by the bypass
valve.
6 Fault finding chart

Before removing the terminal box cover and before any removal/dismantling of the
pump, make sure that the electricity supply has been switched off.
Fault finding chart

Fault Cause Remedy
1. Motor does not run when a) Supply failure. Connect the electrical supply.
started. b) Fuses blown. Replace fuse.
c) Motor starter overload has tripped out. Reactivate the motor protection.
d) Main contacts in motor starter are not making contact Replace contacts or magnetic coil.
or the coil is faulty. Repair the control circuit.
e) Control circuit fuses are defective. Replace the motor.
f) Motor is defective.
2. Motor starter overload trips a) One fuse is blown/automatic circuit breaker is blown. Cut the fuse.
out immediately when supply is b) Contacts in motor starter overload are faulty. Replace motor starter contacts.
switched on. c) Cable connection is loose or faulty. Fasten/replace the cable connection.
d) Motor winding is defective. Replace the motor.
e) Pump mechanically blocked. Remove blocking of the pump.
f) Overload setting too low. Set the motor starter correctly.
3. Motor starter overload trips a) Overload setting too low. Set the motor starter correctly.
out occasionally. b) Low voltage at peak times. Check the electrical supply.
4. Motor starter has not tripped
a) Check 1 a), b), d) and e). -
out but the pump does not run.
5. Pump capacity not constant. a) Pump inlet pressure is too low (cavitation). Check the suction conditions.
b) Suction pipe/pump partly blocked by impurities. Clean the pump or suction side.
c) Pump draws in air. Check the suction conditions.
6. Pump runs but gives no wa- a) Suction pipe/pump blocked by impurities. Clean the pump or suction side.
ter. b) Foot or non-return valve blocked in closed position. Repair the foot or non-return valve.
c) Leakage in suction pipe. Repair the suction pipe.
d) Air in suction pipe or pump. Check the suction conditions.
e) Motor rotates in the wrong direction. Change the direction of rotation of
the motor.
7. Pump runs backwards when a) Leakage in suction pipe. Repair the suction pipe.
switched off. b) Foot or non-return valve defective. Repair the foot or non-return valve.
IN5540_20#C.1
PUMPS, TYPE CR, CRN
Fault finding chart

8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal.
9. Noise. a) Cavitation occurs in the pump. Check the suction conditions.
b) Pump does not rotate freely (frictional resistance) be- Adjust the pump shaft.
cause of incorrect pump shaft position.
Table 4
TABLE OF CONTENTS
Table of contents
Salinity alarm equipment

.
Salinometer............................................................... OM8210_41............... 15-2
OM8210_41#G.1
SALINOMETER
Salinometer
1 Description
The salinometer is used in combination with a conductive electrode to measure and
supervise the salinity of feed water. Figure 1 illustrates the control device and electrode.
The control device is provided with indication LED’s for monitoring the salinity level
and two LED’s for alarm purpose. The measuring range as well as the adjustable alarm
range is 0 – 100 ppm (sea salt). The alarm limit can be adjusted by means of the set
screw located on the front panel. The alarm limit is indicated by a flashing LED in the
indication LED row. If the salinity level exceeds the alarm limit the alarm LED’s start
flashing.
During commissioning it is not necessary to carry out any adjustments of the equipment
except setting the alarm limit. When the power is turned on, the salinometer will per-
form a self test. This calibration will take approximately 5 sec.
Illustration of the control device

Control
device
Indication
PG 13.5
LEDs
Gasket
Gold-plated
electrodes
Terminals
Figure 1 sl700g_bx3194020en.wmf
Note: The electrode is totally sealed and must not be opened. The guarantee is
void if opening of the electrode is attempted.
OM8210_41#G.1
SALINOMETER
2 Installation
The conductive electrode may be installed vertically, horizontally, or radial inclined.
However, the electrodes must be constantly submerged in feed water. Figure 2 illus-
trates the salinity system.
Illustration of the salinity system

Make-up
Condensate
Hot well
T-piece
Electrode
Cable lenght 2.5 m
Junction box
(not Alfa Laval supply)
Cable lenght max. 200 m
PI PI
Salinometer
PS (mounted in
power panel)
To boiler Feed water
PI PI
pumps
Figure 2 sl700d_bx3198720en.wmf
OM8210_41#G.1
SALINOMETER
2.1 Wiring
The wiring should be carried out in accordance with the diagram shown in Figure 3.
Wiring diagram
Brown
Shield
Black
Grey
Blue
Junction box
Brown
Shield
Black
Grey
Blue
Figure 3 sl700i_ax3115920en.wmf
The mains supply of the control device is 98-122 VAC or 196-244 VAC, 50-60 Hz.En-
sure that the mains supply is secured against over current by a fuse (max.100mA).
The recommended cable for the conductive electrode is a multi-screened twin twisted,
where the screen is connected to connector 14, one pair is used for connector 11+12,
and the other pair is used for connector 13+15. The length of the cable must not exceed
200 m.
Important: The cable may not be placed together with power cables, as this will
cause damage to the gold plating on the electrodes.
3 Maintenance
The accuracy of the salinometer equipment is very dependent on the electrodes are
kept clean. The electrodes should be taken out and cleaned at least once a week. Use
only a clean and soft cloth. When cleaning the electrodes it is important that oil or other
chemicals do not pollute the electrodes. Any pollution will immediately result in an
inaccurate measurement of the salinometer.
Note: Avoid damaging the gold plating.If the gold plating is damaged, the con-
ductive electrode must be replaced.
The expected longevity of the conductive electrode is approximately 1.2 – 2.2 years.
OM8210_41#G.1
SALINOMETER
4 Troubleshooting
Step Problem Description Posible causes

1 No lights in Check external fuse. Salinometer has no power.
Salinometer Check AC power on Salinometer terminal’s .Check the cable
(1) connections to the Salinometer.
2 No lights in Check voltage between pin 12 and 14. Electrode unit is defective or cable
Salinometer Voltage from electrode shall be approx. 2 VDC. failure (reference voltage from
(2) If the voltage is low (near 0 Vdc), disconnect the electrode unit electrode unit is missing).
and check that the light in the salinometer is on again.
3 Wrong reading Disconnect the connector to the electrode unit. Salinity level If no reaction: The salinometer is
of salinity. shall increase to approx. 100 PPM and the alarm will be flash- defective.
ing.
4 Wrong reading Remove Electrode unit and inspect/clean the electrodes. Use a Electrodes dirty or damaged.
of salinity. clean and dry rag. Avoid touching the electrodes with the fin- We recommend replacement of the
gers. Check that the gold plating not is damaged. This should electrode unit every 18 months de-
be done at least once a week. pending on the condition of the
gold plating.
5 Wrong reading This test has to be done with electrode in open air (not in water). Cable failure: Check connections.
of salinity. a) Check voltage between pin 11 and 14
(Voltage from electrode: 0 VDC).
b) Check voltage between pin 12 and 14
(Voltage from electrode: 2 VDC).
c) Check voltage between pin 13 and 14
(Voltage from salinometer: +12 to 15 VDC).
d) Check voltage between pin 15 and 14
(Voltage from salinometer: -12 to 15 VDC).
e) Disconnect electrode unit and check voltage between pin 11
and 14
(Voltage from electrode more than: 2 VDC).
6 Corrosion of Check that the sensor cable is mounted at far as possible from The cable to the Salinometer sen-
electrodes. high power cables. sor is mounted near some high
power cables. The induction from
the high power cables gives a high
voltage on the sensor cable and the
sensor. A high voltage on the sen-
sor will cause corrosion faster than
normal.
Table 1
OM8210_41#G.1
SALINOMETER
No. Picture Description What to do

1 Electrode unit in good condi- The unit is ready for installation.
tion. No visible damages.
2 Electrode unit with damaged The unit is ready for exchange. We recommend replacement of
gold platin the electrode unit every 18 months depending on the condition of
the gold plating.
Send a request for a new sparepart.
3 Electrode unit with serious The cable to the Salinometer sensor is mounted near some high
corrosion/erosion. power cables. The induction from the high power cables gives a
One of the sensors has almost high voltage on the sensor cable and the sensor. A high voltage
disappeared. on the sensor will cause corrosion faster than normal.
Relocate the cables and send a request for a new sparepart.
4 Electrode unit with crack in Under normal circumstances the electrode unit is covered by war-
the white moulding. ranty (as long as the electrode unit is not tampered with). When
The gold platin is in good discovering an electrode units with this fault please send following
condition. information to your supplier:
1. Serial number of the salinometer
2. Photos of the electrode unit, showing the crack and the golden
plated electrodes
3. Name of the vessel
4. Your reference no.
5 Warning: Send a request for a new sparepart.

Do not try to open the elec-
trode unit. Warranty will be
void if the electrode unit is
open or damaged.
Table 2
TABLE OF CONTENTS
Table of contents
Oil detection equipment

.
Oil detection equipment.............................................. OM9410_01............... 16-2
OM9410_01#C.1
OIL DETECTION EQUIPMENT
Oil detection equipment
1 General
This chapter contains installation, operation, and maintenance instructions for the ul-
trasonic interface detection system, Mobrey type 402 SD, using control unit type
MCU200.
Each Mobrey ultrasonic control system requires a sensor to suit the specific application,
plus a control unit. These instructions cover the control units in the MCU200 series.
2 Sensor installation
2.1 General description
The ultrasonic sensor contains two piezoelectric crystals. A high frequency signal (3.7
MHz) generated by the control unit is transmitted to one piezoelectric crystal by coaxial
cable. This crystal converts the electrical signal into an ultrasonic oscillation.The sen-
sor design allows the ultrasonic oscillation to pass from the transmitter crystal to the
receiver piezoelectric crystal. The sensors of type 402 are “gap” type sensors, where
the two piezoelectric crystals are separated by a gap. When the gap is in liquid the
signal reaches the receiver, because of the low ultrasonic attenuation of the liquid.
When the gap is filled with air, no ultrasonic signal can pass from transmitter to re-
ceiver. See Figure 1.
Working principle of the oil detection equipment
Figure 1 om9410_01_mobreyx0063070en.wmf
OM9410_01#C.1
When the gap is filled with liquid, the piezoelectric receiver crystal converts the ul-
trasonic wave into an electrical signal, which is transmitted back to the control unit
using a second coaxial cable. Usually the two coaxial cables to the sensor are in one
overall sheath. The control unit circuitry is a feedback amplifier, which oscillates when
the sensor is wet, and is quiescent for the sensor dry. The “oscillating” or “non-oscil-
lating” sensor states dictate the output relay states of the MCU200.
For interface detection the sensor “oscillates” in a clear liquid, and is “non-oscillating”
at the interface.
2.2 Switching levels and orientation
The gap sensors should normally be mounted with the gap vertical, to avoid build up
of solids on the sensor faces on either side of the gap. In this condition the switching
level will be half way up the face: if the sensor is mounted from the side of the tank
this is normally on the centreline of the cylindrical body.
Occasionally such sensors are mounted with the sensor faces horizontal, either to avoid
air bubbles passing through the gap or for convenience of installation. In this case the
switching level will be at the sensor face at the top of the gap.
2.3 Installation of sensor
The sensor must be handled with care - it is a measuring instrument. Before installation,
check that sensor, cable and control unit have not been damaged in transit. Drill and
tap a hole with a suitable thread. It is advisable to use a boss or similar on thin walls.
The sensor has a tapered thread. Use Ptfe tape or similar to seal the thread. Mark the
sensor hexagon to identify the gap orientation of the sensor, if appropriate. Take care
not to damage the sensor cable during tightening.
The cable should be laid on cable trays and separated from any high voltage or mains
cables. The normal cable termination is a plastic gland (to fit the MCU200 control box
drilled hole) and crimped terminal pins to suit the MCU200 terminals.
2.4 Extensions cables
Extension cables up to 50 metres long can be fitted to most Mobrey ultrasonic sensors
in the factory to special order but a better site arrangement is to have a separate ex-
tension cable. Table 1 shows a list of suitable extension cables.
Suitable extension cables

50 m 50 - 100 m Above 100 m
RG174 URM76
Consult Alfa Laval
RG178 RG58
Table 1
OM9410_01#C.1
When double coaxial cable needs to be extended, two sets of coaxial plugs and sockets
will be needed, one set for transmit and one receive. Care must be taken that the con-
nectors are not connected to earth or shorted together in any way, to prevent cross-talk
or pick-up. The coaxial connections must be made in a waterproof junction box. Ter-
minal blocks should not be used.
The extension cable needs to be of 50 Ohm characteristic impedance. Suitable dual

coaxial extension cables can be purchased from Alfa Laval. For extensions over 50
metres it is recommended two runs of single coaxial low loss cable is used, with the
transmit and return cable runs separated by 0.15 metres to minimise cross-talk.
If several sensor cables are being run together then all the transmit cables (those con-
nected to E2) should be grouped together and all receive cables (those connected to
1E) grouped together maintaining the separation specified above.
Two cables are required per sensor. The RG178 should be used where the cable itself
is subject to temperatures exceeding 74°C.
3 Control unit installation
3.1 Mechanical
The control unit is supplied with three holes drilled in the bottom (longer) side of the
box. Two glands are supplied for the power input cable and relay output cable. The
sensor is normally supplied fitted with a suitable gland on the cable. Two further holes
can be drilled in the bottom side of the box should these be needed: it is recommended
that the circuit board is removed whilst drilling extra gland holes.
Figure 2 shows the dimensions of the MCU200 housing box.
OM9410_01#C.1
MCU200 Housing dimensions
All cable connections are made to the terminal blocks along the bottom edge of the
pcb, see Figure 3. Release the terminal screw before inserting the wire.
MCU201 PC board
OM9410_01#C.1
3.2 External connections
3.2.1 AC mains
AC mains is connected between the “N” terminal for neutral and one of the “115V”
or “230V” terminals depending on the voltage supply available - BEWARE - the ter-
minal not connected externally will be “live” once the transformer is powered via the
other terminals.
3.2.2 Mains earth

Mains earth should be connected to the terminal marked “E”. This provides an earth
contact for the pcb mounting pints.
3.2.3 The relay

The relay output connections are labelled:
• NC - Normally closed (relay de-energised)

• C - Common
• NO - Normally open (relay de-energised)
There are also two sets of contacts for DPCO relay, labelled 1 & 2.
3.2.4 The sensor

The sensor connections are labelled "1", "E" for the receiver crystal and "2", "E" for
the coax cable to the transmitter crystal. The screens of these coax cables are connected
to the terminals marked "E".
3.2.5 The auxiliary input

The auxiliary input is a terminal which can be connected to a "push to reset" button to
achieve a latching alarm, or to another Mobrey Control unit, to give a pump control
from the MCU200 unit relay output. If a short circuit is connected between terminals
3 & 4, the MCU200 relay, once de-energised, is held de-energised. Even if the sensor
attached to the MCU200 changes state, to that which should energise the output relay,
this relay will not energise until the link between terminals 3 & 4 is broken in the circuit
external to the MCU200.
3.3 Switch settings in MCU200 series
3.3.1 Gain switch and potentiometer

See section 4.
3.3.2 Frequency selection

This slide switch is labelled "FREQ" and is located between the sensor terminal block
E2, and the Aux. input terminals. This selects the operating frequency of the MCU200
oscillator, which for the present installation must be set to 3.7 MHz (switch in the “up”
position). The setting required is dictated by the sensor type connected to the control
unit.
OM9410_01#C.1
3.3.3 Cable check option selection

This slide switch is located directly above the sensor terminal block E2. It is labelled
"Cable Check" and the ex factory setting is "OUT" with the slide switch to the right.
By sliding this switch to the left, the cable check circuitry is brought into action. This
circuitry monitors the continuity of the screens of the two coaxial cables attached to
the sensors: normally these are linked at the sensor to the metal body of the fitting (or
to each other in the case of non metallic sensors). If this continuity is broken, the
"FAULT” LED" will illuminate giving an indication that the sensor cable is damaged,
and the MCU200 will give the "ALARM" output relay state (see Figure 4).
3.3.4 Relay output and LED logic selection

The bank of six slide switches towards the top of the pcb sets the relay output state
logic relative to the sensor state, associated time delays and the LEDs. These are slide
switches, best adjusted with a pencil, and the ex factory wetting is with all switches to
the right.
Each switch is colour coded as shown in Figure 4, and the PC board labels give brief
function information.
Relay output and LED logic switch
Note: At Figure 4 OSC means sensor oscillating. E means relay energised, NE

means de-energised.
Set the switches in the following order, starting at the bottom and working upwards:
BLUE:
If the MCU200 relay is to be energised (E) when the sensor is oscillating (OSC) then
set the No 6 blue switch to the right (OSC=E). This is the preferred setting, to give a
de-energised relay in the ALARM state for a gap sensor as a low level alarm.
OM9410_01#C.1
GREEN:
This selects the relay change which is subject to the time delay selected on the top
switches. When the No.5 green switch is set to the right, the delay occurs between the
sensor changing state and the relay de-energising or becoming “not energised” (NE).
This time delay is a minimum of 0.l5 seconds, (achieved by switching the top BROWN
switch to the right) and is used to prevent relay chatter at the changeover point. Longer
time delays are selected on the top three slide switches as shown in Figure 5.
The relay change in the opposite direction is immediate (within 50 milliseconds).
The top three slide switches
YELLOW:
Only one of the GREEN or RED LEDs will be illuminated at any one time. These
LEDs show the state of the MCU200 output relay. The RED LED is labelled "ALARM"
and the GREEN LED is labelled "NORMAL". The yellow slide switch (Number 4)
determines which LED will be illuminated when the relay is energised (E). It is usual
to have the GREEN/NORMAL condition occur with the relay energised, i.e. with
switch Number 4 to the right (E=GREEN).
4 Applications
4.1 Gain adjustment
Correct adjustment of the gain (HI/LO switch and potentiometer) is essential for proper
operation of any ultrasonic sensor system. This adjusts the gain of the feedback am-
plifier in the control unit, which produces oscillation of the sensor when the coupling
between the ultrasonic crystals is sufficient. Therefore the higher the gain setting, the
lower the coupling needed to produce an oscillating sensor.
The universal control unit of the MCU200 operates with many sensors, so the correct
setting for the particular sensor and application should be found on site by experiment,
if possible. This will take account of particular site conditions like RF coupling between
extension cables, which can affect the maximum allowed gain. Other liquid charac-
teristics, such as presence of suspended solids, or air bubbles, can mean that for reliable
operation the MCU200 gain must be set as high as possible, to overcome future solids
OM9410_01#C.1
build up, but at least one potentiometer division below the maximum allowed level, to
ensure temperature and component ageing stability.
The particular procedures outlined below for gain adjustments give the mid point gain
settings, which may need to be adjusted to meet specific site/sensor future requirements
as indicated above.
4.2 Interface detection
4.2.1 Interface detection between two dissimilar liquids

Viscous liquids, emulsions and liquids containing solid particles have a greater ultra-
sonic attenuation than clear liquids. This technique is used to detect which liquid is
present at the sensor, for example for the separation of oil and water. For this duty
Mobrey 402 sensors are used, operating at 3.7 MHz to produce the maximum ultrasonic
difference between two liquids monitored.
The gain is adjusted so that the sensor oscillates only in the liquid with the lower
ultrasonic attenuation: this is usually the clearer liquid (water in the example of Fig-
ure 6). Note that the signal when oil is present in the sensor gap will be the same as
that for air in the gasp, and that emulsion layers give a very high attenuation.
Mobrey 402 Sensor as oil/water interface
Step A: Reduce the gain potentiometer with the sensor immersed in one of the liquids
until a "false dry" indication is obtained. Note the position of the pot.
Step B: Repeat for the sensor immersed in the other liquid.
OM9410_01#C.1
Step C: Set the potentiometer half way between these two values. Correct perform-
ance requires a total difference between the two set points of at least 3 di-
visions.
Interface detection between two immiscible similar liquidsWhen liquids are

ultrasonically very similar - as happens for example with paraffin or oil and
water - the procedure in section 4.2.1. produces very little difference between
the two "false dry" points. In this case the "reflection" method of interface
detection is used. An illustration of this method is shown in Figure 7.
Note: The Mobrey 402 sensor in the hot well tank is installed as shown in Fig-
ure 7.
If an ultrasonic beam is transmitted from one liquid to another at a suitable angle (10%)
it is split at the interface into a reflected and a refracted beam, so that it does not reach
the receiver crystal. If there is no interference in the gap, but only one liquid, the beam
is received and the sensor oscillates.
Interface detector by reflection method
The gain adjustment is made so that the gain is 3 divisions higher than the highest false
dry position obtained, as in section 4.2.1. Performance at the interface should then be
checked.
Note: That the non oscillating state of the sensor, at the interface, also occurs
throughout any emulsion layer at the interface, and also when the sensor
is in air.
OM9410_01#C.1
5 Spares and fault finding
5.1 Spares
The following parts are suitable for replacements on the MCU201:
• Main pcb complete: K2641

• LED indicator pcb: K2643
• LED pcb spacers: K2623
• LED pcb connector: K2624/50
• Box assembly: K2662
• Gland Assembly: K746/K747/K748
There are no consumable items such as fuses.
5.2 Fault finding
Step A: At least one LED should be illuminated. If not check the power supply to
the unit.
Step B: If the "Fault" LED is on, check the coax cable to the sensor for incorrect
wiring or damage. Particularly check continuity of extension cables, con-
nection of crimped connectors on cable ends. The pcb board can be checked
by linking the two terminals labelled E on the sensor terminals - this should
cancel the fault indication LED.
Step C: If the sensor is giving incorrect indications check the gain adjustment (see
section 4.0).
Check for correct sensor operation whenever the gain is adjusted away from the normal
set point. Assume an overlap of 2 divisions between the "LO" and "HI" gain ranges.
Step D: Check that the incorrect operation has not been produced by incorrect setting
of the frequency selection switch, or an external short circuit on the Auxiliary
input terminals.
Step E: The circuit board can be checked by linking the sensor terminals 1 and 2
with a wire, to simulate an oscillating sensor.
TABLE OF CONTENTS
Table of contents
Steam dump equipment

.
Steam dump equipment.............................................. OM6050_03............... 17-2
OM6050_03#C.1
STEAM DUMP EQUIPMENT
Steam dump equipment
1 General description
The steam dump equipment is designed for dumping excess steam generated by the
exhaust gas boiler from the steam system to an atmospheric dump condenser.
This chapter contains some general instructions, which should be taken into consid-
eration before installing and during operation of the steam dump equipment. More
detailed instructions related to the components of the equipment can be found in other
sections.
Note: It is essential that the condenser is dimensioned to be able to absorb the

amount of steam generated in the exhaust gas boiler(s). Or if a composite
boiler is installed the amount of steam generated by the exhaust gas part
of the composite boiler(s).
Schematic illustration of the steam dump system for exhaust gas operation
Service steam line
1 - Steam dump valve
2 - I/P positioner 6
4 - 20 mA
3 - Pneumatic actuator
4 - Air reducing set
5 - Process controller/local panel
6 - Pressure transmitter Boiler/
7 - Steam trap steam drum
Control panel
1
2 5
3
I
P
7 4
AIR inlet
(max. 17 bar)
Steam/condensate line
Control air (instrument air)
To atmospheric dump condenser Electrical signal
Figure 1 om6050_03_1ax0756600en.wmf
Figure 1 shows a schematically illustration of the system, which consists of the fol-
lowing components:
OM6050_03#C.1
• Control valve with pneumatic actuator.

• I/P positioner.
• Air reduction set.
• Process controller or local panel.
• Pressure transmitter.
• Steam trap.
The equipment is working by measuring the steam pressure (e.g. in the boiler, the steam
drum or the main steam pipe) with a pressure transmitter (6). The transmitter sends an
electrical signal (4-20 mA DC) to the process controller/local panel (5). In the control
system the signal is compared with a pre-set adjustable value.
The steam pressure is then regulated when the control system sends an electrical signal
to the I/P positioner (2). It converts the signal and via the pneumatic actuator (3) con-
trols the position of the steam dump valve (1), through which the excess steam is lead
to the atmospheric dump condenser.
The control valve will automatically close in case of air or power failure. A hand wheel
enables manual operation of the valve. Figure 2 shows a complete control valve ar-
rangement consisting of valve, I/P positioner and actuator.
Arrangement of control valve, positioner and actuator
Figure 2 om6050_03_k7462_x0056760en.wmf
Under normal circumstances the control valve, actuator and I/P positioner is delivered
as a complete unit already assembled.
OM6050_03#C.1
The air supply to the actuator is controlled by the air reduction set (4). The compressed
air at the inlet of the air filter must have a max. pressure of 17 bar and a temperature
laying in the interval from -20 to +65°C. Furthermore, the supplied air must be instru-
ment air.
Any adjustment of the system must be carried out on the process controller/local panel
(5).
Note: All pipes must be thoroughly cleaned before commissioning
2 Steam dump valve

The system is designed to be able to dump the amount for the control valve type 23.470
DP.
The construction of the valve can be seen on Figure 3.

The steam dump valve together with actuator and positioner are suitable for installation
in dry or damp locations, and in order to avoid damage to the drives it is recommended
to install the components in an right position.
Ambient temperatures on the valve drive should not fall below -15°C or rise above
50°C. Precautions should however be taken when using the equipment where the am-
bient temperature are likely to drop below 0°C to prevent condensation of water in the
instrument air.
Drawing of of control valves

23.470 DP
1 - Body
2 - Seatring
3 - Mounting bonnet
4 - Guiding bush
5 - Plug
6 - Spindle
7 - Gland flange
8 - Spindle guiding
10 - Stuffing box
14 - Gasket
15 - Studs
17 - Hexagon nut
19 - Spring-type straight pin
Figure 3 om6050_03_3ax0756610en.wmf
OM6050_03#C.1
2.1 Fitting instructions
The installation point should allow sufficient space to ensure correct maintenance of
the valve and actuator. The valve should be inserted so that the spindle has a vertical
position and the actuator being up above. The valve can also be tilted to a maximum
horizontal position if the installation point does not allow any better condition. If
painting is necessary, ensure that valve and actuator spindle as well as mechanical links
are free from paint. The flow direction is signalled through an arrow on the valve body.
The valves should be insulated against high temperatures to guard the actuator. Suffi-
cient space must be left to undertake maintenance on the spindle-sealing.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length min. 2 times pipe diameter
by inlet and 6 times by outlet. The piping must be aligned to prevent any strain on the
valve. Precautions to restrict strain on the piping should be regarded. In no case sup-
porting must be fitted to the valve to hold the piping system.
The piping should be rinsed to clear out any pollution, welding beads, rust etc. before
inserting the control valves. A strainer should be fitted in front of the control valve to
catch remaining particles. Bolts should be re-tightened after taking into operation.
When the piping system is filled and set under pressure, the spindle sealing should be
checked for leakage, and if necessary be carefully tightened until the leakage is stopped.
The PTFE-V-ring unit does not require any re-tightening, the spring tension maintains
the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs but not tighter
than it is necessary for sealing.
Flange connections bolts should never be loosened or tightened when the valve is under
temperature or pressure, even if a leakage may arise.
3 Actuator
Select the site of installation so that the actuator is readily accessible and that there is
adequate room for later maintenance work.
The mounting position is preferably with the actuator and valve spindle in the vertical
position. For assembly onto the valve please see the separate instructions described in
the sections for valve and actuator (see also Figure 4).
The instrument air supply should be dry for low temperature service. A heat-guard
should be installed for high temperature service.
Note: Please observe the maintenance instructions for valves.
OM6050_03#C.1
3.1 Pneumatic connection
The pneumatic supply tube must be connected to the diaphragm housing.
The thread connection for the actuators DP 32 and DP 33 is R 1/4" and for the actuator
DP 34 is R 3/8".
Warning: The actuator diaphragm may only be pressure loaded on the side op-
posite of the springs. The vent hole in the other connection must stay
free.
Assembling of the actuator on valve
Figure 4 om6050_03_acu_06x0056730en.wmf
4 I/P positioner
The positioner must be installed and commissioned in exactly the same sequence as
described in the section for the positioner. It is essential that the warnings in the relevant
sections are heeded during this process.
Warning: This instrument must only be installed and commissioned by qualified

personnel. The degree of electrical safety is determined solely by the
devices supplying the power.
OM6050_03#C.1
Warning: Pneumatic drives generate considerable positioning forces. Safety pre-

cautions must therefore be scrupulously observed during installation
and commissioning in order to prevent injuries. Your attention is
drawn, if applicable, to the relevant regulations regarding operation
in hazardous areas.
5 Steam pipe connections to dump valve

Referring to the diagram in Figure 1, some remarks have to be made on the piping
system before and after the dump valve. This is due to the fact that a proper functioning
of the steam dump equipment (i.e. the equipment is able to blow off the required amount
of steam) requires as low a resistance in the piping system as possible.
In order to obtain this low resistance the following topics should be considered:
• The dump valve should be placed as near the dump condenser as possible.
• According to the amount of steam that the system is dimensioned to dump the
diameter of the pipe before and after the dump valve must be of a certain size,
which can be deduced from Table 1.
• It is essential the transitions from pipes to the dump valve both before and after
the valve are smooth and without any sudden contractions or expansions.
• Furthermore should the pipe section be as short as possible and preferably without
bends.
• If there are valves placed in the system before and/or after the dump valve these
should be of the straightway type and of the same size as the pipes.
Amount of dumped steam related to min. pipe diameter

Operating pressure 6 bar(g) / Dump pressure: 7.3bar(g)
Size of dump valve, DN 25 32 40 50 65 80 100 125
Max. steam amount, kg/h 380 598 949 1519 2373 3797 5980 9492
Pipe size before valve, DN 40 50 65 80 100 125 150 200
Pipe size after valve, DN 50 65 80 100 125 200 200 250
Operating pressure 7 bar(g) / Dump pressure: 8.3 bar(g)
Operating pressure 8 bar(g) / Dump pressure: 9.3 bar(g)
Table 1
OM6050_03#C.1
6 Process controller/local panel

The process controller or local panel are installed in the boiler control panel. For in-
structions regarding one or the other please see the specified instructions in the control
system sections.
Warning: This is an electrically-operated device. Certain parts in electrical de-

vices carry dangerous voltages during operation. Severe injury or
damage to property could therefore occur if the warnings are not ob-
served. Staff working with this device should be suitably qualified.
Reliable and safe operation of these devices depend on correct trans-
port, storage, assembly and operation.
7 Pressure transmitter
The pressure transmitter converts the steam pressure to an electrical signal proportional
with the pressure. The unit is supplied as two-wire transmitters with an output signal
of 4-20 mA.
7.1 Installation conditions
The zero point is factory-set with the pressure connector pointing downwards. If the
unit is installed in another position the zero point will be displaced approx. 1% as far
as the lowest pressure range is concerned, decreasing in the higher pressure ranges.
The displacement can be eliminated by using a zero-point potentiometer.
To protect the pressure element against temperatures higher than the maximum per-
missible temperature of the element (100°C), it is recommended to insert a water-filled
loop. An example of such an installation is shown on Figure 5, which also shows an
example of insulation against radiant heat.
OM6050_03#C.1
Example of installation/connection of transmitter
Thin (= Low heat co nductivity) uninsulated tube Max. 70 °C
Steam
e.g. 170 °C
Insulation
against radiant heat
Condensed liquid
reliable, good convection
Figure 5 om6050_03_emp2_2x0056750en.wmf
There are facilities for adjusting zero point and span. Zero point adjustment is necessary
to equalise pressure arising from any differences in level between the pressure trans-
mitter and the medium being measured. Zero point adjustment results in a parallel
adjustment of span.
8 Air reducing set
8.1 Installation
Before installation the operating conditions of temperature and pressure must be

checked.The unit should be mounted securely in an accessible and visible location
upstream from lubricators and near components being served. Strain on pipe work and
fittings should be avoided and directional flow arrows observed.
With cyclic demand systems the filter-regulator should be installed upstream of di-
rectional control valves. Airline piping should be the same size as unit ports with air-
flow in the direction of the arrow.A pressure gauge may be connected to the appropriate
1/8 port after removing the plug and should have a range exceeding the maximum
proposed outlet setting.Figure 6 shows an illustration of the filter-regulator.
OM6050_03#C.1
Filter-regulator
Figure 6 om6050_03_b07_fx0056740en.wmf
8.2 Adjustment
With the regulator adjustment completely backed-off the air supply can be turned on.
The adjusting knob can be rotated clockwise to increase the spring load and the pressure
increase observed on the gauge.
Minor adjustment after setting changes can be avoided by always approaching the
desired setting from the lower level. When a lower setting is required, firstly reduce
to a lower level and then increase to the desired setting.
Decreasing the pressure setting on a relieving type regulator will cause air to exhaust
through the bonnet vent hole.
The non rising adjusting knob includes a locking feature;
• Push knob in after setting to lock and prevent adjustment.

• To release pull knob out.
If the adjustment knob is fitted with the tamper resistant screw option, the screw must
be removed to enable the knob to be unlocked.
Auto drain units should have a 1/4" (6 mm) bore flexible tube pushed over the bottom
protrusion to pipe away expelled liquid. Avoid restricting the drain pipe.
Manual drain units must be drained before the contaminant level reaches the element.
Should this occur then liquid contaminant will be carried downstream.
TABLE OF CONTENTS
Table of contents
Descriptions
.
Pressure atomizing burner KBM.................................. SD5560_22................ 18-2
Fuel oil supply system................................................ OM5560_155............. 18-4
SD5560_22#B.1
PRESSURE ATOMIZING BURNER KBM
Pressure atomizing burner KBM
1 Burner description
The KBM burner is a modular built burner designed for modulating operation. The
KBM designation is followed by a 3 digit number. This number indicates the design
consumption heavy fuel oil expressed in kg/h. The burner, in this configuration, is
designed to operate on MGO, marine gas oil, MDO, marine diesel oil and HFO heavy
fuel oil. The specific oil type according to ISO 8217 can be seen on the burner data
sheet.
Burner unit F1
Figure 1 065366x3252550en.wmf
Figure 1 Shows in schematic form the functional components in the burner system.
1.1 The complete burner unit F1 consists of four modules.
The FD fan module:

The FD fan module includes blower R1/R15 and air damper R7/R16
The burner module:

The burner module includes the essential burner parts such as; windbox, burner tube,
swirler, flex connections 1F133/2F133/F134, oil lance F206, heating element F187,
oil nozzle F206, flame scannersF32/F33, ignition electrodes, ignition transformer
F166, air pressure switch R3, scavenge air valve R25, switch for closed burner F224
and air temperature transmitter F36
SD5560_22#B.1
PRESSURE ATOMIZING BURNER KBM
The oil cabinet module:

The oil cabinet module includes a heater unit F207, a heater unit thermo sensor F222
and heater safety temperature limiter F223 all oil valves F201/F202/F203/F204/F205/
F220, non return valves F235 and F255 and an oil strainer F211, flow control valve
F217/F208, pressure reduction orifice F182, oil gauges F218/F219, pressure switch
F214 and transmitters F212/F225, the electric junction box with solid state relays F183
and the steam gauge board components C31 until C50.
The frame module:

The frame module includes the frame that mounts on the boiler flange complete with
hinges for the burner front plate and the foundation for the blower.
1.2 To complete the burner unit
The modules comes as a unit which shall be mounted on the boiler flange and connected
to the frame supports on the boiler body.
The burner front plate can be mounted either before at the same time or after the frame
module. Once the frame and front plate are mounted then the oil cabinet can be mounted
in place. When this is done, the burner module can be mounted as follows:
First the windbox is mounted and connected to the FD fan and the burner front plate.
Then the burner tube and end cap assembly is mounted in the windbox. But if the
machine room space allows it the aim should always be to mount it as a unit.
Finally all the electric connections to the burner module are established. All these
connections are made with a connector.
The required oil pressure at the nozzle varies according to maximum burner power.
To accommodate this and to save space in the oil cabinet module, the oil pressure
regulating valve is included in the fuel oil supply system.
There is no oil pump in the burner oil system; it is also included in the fuel oil supply
system.
As the supply pressure to the burner unit is constant the compound regulator F217, can
control the oil flow through the nozzle F206 by increasing or decreasing the flow
resistance in the return line.
The air damper R7 on the inlet to the blower, courses more or less air flow as it is more
or less open. 10 different pair of settings for the air damper and the compound regulator
that ensures a proper combustion, are stored in the control system. Interpolating be-
tween these points gives the settings of F217 and R7 for various load operations.
Presence of a flame is checked by the two photo cells F32 and F33
The start up sequence, the operation and the shut down sequence is controlled by an
electric system. All feed back signals are handled by this system. Start and stop signals
as well as load regulation signals are set by the control system in accordance with the
actual requirements. In the event of a fault, safety valves F202, F204 and F205 will be
shut down and F203 will be opened immediately. Depending on the fault, signal set-
tings can be given to shut down the oil pumps in the fuel oil supply system as well.
OM5560_155#F.3
FUEL OIL SUPPLY SYSTEM
Fuel oil supply system
This section describes the double string fuel oil supply system for a KBM/KBP mod-
ulating oil burner. The system is described in general terms, together with some of the
requirement needed to have a safe and reliable burner operation.
The burner is designed for both marine diesel oil MDO, marine gas oil MGO and heavy
fuel oil HFO, operation.
The applicable fuels depends upon the "Fuel oil supply system" layout.
The diagram of the fuel oil system for 2 fuels are shown in Figure 1.
The diagram of the fuel oil system for 3 fuels are shown in Figure 2.
The systems are double line fuel oil supply system.
The diaphragms are for plants with only one burner.
This instruction refers both to; marine diesel oil MDO, marine gas oil MGO and heavy
fuel oil HFO.
The fuel oil supply system shown in Figure 1 consists of the following main compo-
nent:
Oil tanks for; marine gas oil MGO and heavy fuel oil HFO.
Quick closing valves for each tank G431 and G96 .
Mixing tubes for HFO G110, for MGO G473.
Outlet valve for each mixing tube G49 and G474.
Non return valve G477.
Fuel selection valve on HFO string G115 .
Cooler unit on MGO string, with flow direction valve G432 and G436.
Safety valve, vent valve and drain valve, cooler oil side, G433, G434 and G435.
Safety valve, inlet and outlet shut off valves, cooler water side G470, G468 and G469.
Cooler outlet valve G448.
Oil flow meters for MGO and HFO 1G340 and 2G340.
Temperature transmitter for MGO fuel oil temperature control G274.
Twin type fuel oil supply pump units for high pressure MGO, G450.
Twin type fuel oil supply pump units ringline low pressure HFO, G147.
HFO supply pressure transmitter G99.
Separate oil pressure control valve for each string MGO, HFO; G471, G481.
Sampling valve unit 1G466.
3 way MGO / HFO supply selection valve G460.
Burner connections.
3 way MGO / HFO return selection valve G461.
Fuel return flow direction valve on HFO string G437.
OM5560_155#F.3
The fuel oil supply system shown in Figure 2 consists of the following main compo-
nent:
Oil tanks for; marine diesel oil MDO, marine gas oil MGO and heavy fuel oil HFO.
Quick closing valves for each tank G94, G431 and G96 .
Mixing tubes for MDO and HFO G110, for MGO G473.
Outlet valve for each mixing tube G49 and G 474.
Fuel selection valve on MDO/HFO string G115 .
Cooler unit on MGO string, with flow direction valve G432 and G436.
Safety valve, vent valve and drain valve, cooler oil side, G433, G434 and G435.
Safety valve, inlet and outlet shut off valves, cooler water side G470, G468 and G469.
Cooler outlet valve G448.
Oil flow meters for MGO and MDO/HFO 1G340 and 2G340.
Temperature transmitter for MGO fuel oil temperature control G274.
Twin type fuel oil supply pump units for high pressure MGO, G450.
Twin type fuel oil supply pump units ringline low pressure MDO/HFO, G147.
HFO/MDO supply pressure transmitter G99.
Separate oil pressure control valve for each string MGO, MDO/HFO; G471, G481.
3 way MGO / MDO/HFO supply selection valve G460.
3 way MGO / MDO/HFO return selection valve G461.
Fuel return flow direction valve on MDO/HFO string G437.
OM5560_155#F.3
Double string system
Pressure atomizing
burner F1
Figure 1 f_oilsyskbp2cx3258300en.wmf
OM5560_155#F.3
Double string system
Pressure atomizing
burner F1
Figure 2 f_oilsyskbp3bx3258310en.wmf
OM5560_155#F.3
1.1 Oil tanks
The oil in the tanks shall be kept within the viscosity limits mentioned on the drawings
and in the specifications. Concerning fuels that requires heating for the combustion:
The viscosity shall not be reduced below the limit, were it no longer is the burner heater
unit, that determines the condition of the oil, at the burner. For viscosity vs. temperature
relations please see instruction OM9280#01.
Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
heavy fuel oil must be insulated and traced in order to keep a sufficiently low viscosity
of the oil. The tracing can be done either by means of steam heating or by means of
electric heating cables. Tracing heat input must be controlled.
Quick closing valves. Like the tanks these valves are not an Alfa Laval supply. The
valves shall meet the requirements from the classification society.
1.2 Mixing tube
During operation on MGO the MGO is returned to G473.

During operation on HFO the HFO is returned to G110.
Only applicable to Figure 2:
During operation on MDO the MDO is returned to G110.
The outlet valves for each tank shall only be in the closed position during maintenance
and repair work.
If they are placed in a easy accessible area the valve should be opened and the handle
should be demounted and only mounted for maintenance and repair work.
1.3 Fuel selection valves
Figure 1:
G115 is only used in case flushing of the HFO system with MGO is required.
Figure 2:
G115 shifts between MDO and HFO in the HFO ringline.
1.4 Cooler unit
The cooler G432 is supplied complete with isolating valves and safety valve for the
water system, G468, G469 and G470 as well as safety, drain, and relief valves for the
oil side G433, G434 and G435.
The 3 way valve is normally in position "oil to cooler", for maintenance and repair of
the cooler it should be in position "by-pass" and G448 should be closed.
By cooling the oil the viscosity can be raised to a level above the limit for the pumps.
The source for the cooler is LT water. The temperature of the water should be kept
below 36°C.
1.5 Oil flow meter
The oil flow meters are only used to show accumulated flow. Since they are mounted
on the outlet of the tanks, they only measures the oil consumed in the burner plus the
amount of oil used for flushing.
The meters can be isolated and by-passed for maintenance under operation.
OM5560_155#F.3
The meters are optional.
1.6 Fuel oil temperature control
The MGO system is equipped with a thermometer and a temperature transmitter

mounted at the inlet to the pump unit. The output from the temperature transmitter is
used in the control system to check if the temperature is within the limits applicable
for MGO operation.
1.7 Fuel oil supply pumps
The oil system is fitted with 2 set of supply oil pumps:

The high pressure MDO/HFO pump unit G147 is intended to operate on fuels with a
minimum viscosity of 4 cSt at 60°C.
The high pressure MGO pump unit G450 is intended to operate on fuels with a mini-
mum viscosity of 1,1 cSt at 60°C.
The pump unit G147 and the pump unit G450, are twin type package units, with two
screw pumps connected to separate driving motors.
Each run of the pumps are fitted with; an inlet shut off valve, a filter, a manometer
gauge, a pressure safety valve, the pump with motor and a non return valve on the
outlet.
The pumping capacity for the pump units are selected for full load condition oil flow
to the burner.
1.8 Ring line pressure transmitter and pressure regulator
The HFO high pressure line is equipped with a pressure transmitter G99. The output
from the pressure transmitter is used by the BMS system to check if the pressure is
with in acceptable limits for the actual operation.
As the MGO ring line is only pressurerized during burner operation, the pressure
transmitter F225 on the burner, can be used by the BMS system to check if the pressure
is with in acceptable limits for MGO operation.
1.9 Heat tracing
All piping carrying HFO must be heat traced. Heat tracing can be either electric or
stream tracing. Heat tracing must be controllable. From the control panel we offer a
potential free switch to turn it on and off. Heat tracing is not part of the supply from
Alfa Laval.
1.10 Oil deaerating
All oil deaerating takes place in the mixing tubes.
1.11 Burner line pressure
The BMS system measures the pressure from transmitter F225 on the burner unit.
Depending on the selection of fuel different high and low values are used in the BMS.
The HFO/MDO burner pressure is adjusted with pressure controller G481. The MGO
OM5560_155#F.3
burner pressure is adjusted with pressure controller G471. Normally the setting of the
light fuel oil is higher than the setting of the heavy fuel oil.
Note: The calorific value of fuel changes, so after each bunker please check the
combustion quality. If necessary re-adjust the relevant regulator.
1.12 Burner connections
The fuel oil connections to the burner are rigid pipework. The burner is designed for
easy access to the interiors without external flexible hoses. During any kind of work
on the burner, the quick closing valves shall be fully closed.
1.13 Piping
The piping is sized to a maximum flow velocity of 0,5 m/s in the suction pipes and 1.0
m/s in the pressure pipes.
1.14 Fuel selection
Note: Before any fuel selection is changed, the burner must be stopped. After the
selection is done, an oil flushing will be performed.
For Figure 1 and Figure 2.

MGO is selected on the control Panel, the position of G115 is not considered. HFO is
selected on the control Panel, the position of G115 is set to HFO.
Only for Figure 2.

MDO is selected on the control Panel, the position of G115 is set to MDO.
1.15 Return flow
HFO operation.
When the burner is in stand by mode pump G147 is still running. The full flow capacity
of pump G147 less burner consumption is returned to the mixing tube via G437.
MDO operation.
Only applicable for 3 fuel systems according to Figure 2.
When the burner is in stand by mode, pump G147 is stopped. Only when the burner is
in operation the pump run. Full pump G147 flow capacity, less burner consumption is
returned to the mixing tube via G437.
MGO operation.
When the burner is in stand by mode, pump G450 is stopped. When the burner is in
operation the pump run. Full pump G450 flow capacity less burner consumption is
returned to the MGO mixing tube G473. Eventual gas in the oil is degassed in the
mixing tube. The return flow to G450, which equals the full pump G450 capacity less
burner consumption, is led through the cooler unit G432.
OM5560_155#F.3
1.16 Return flow. Fuel change sequence
MGO to HFO.
As the systems in both Figure 1 and Figure 2 are double string systems, flushing the
oil system is only a matter of flushing the burner.
Flushing is done to avoid heating on MGO.
Flushing is done at the time the fuel is selected.
Pump G147 is started. Burner inlet valve G460 is set to "HFO". Burner outlet valve
G461 is set to direction G437.
G437 is set to HFO tank.
The flushing time is determined at commissioning.
At the end of the flushing period the valves are set for normal HFO operation.
HFO to MGO.
Flushing is done to avoid contamination of the cooler and also to avoid firering with
HFO were this is not allowed.
Pump G450 is started. Burner inlet valve G460 is set to "MGO". Burner outlet valve
At the end of the flushing period the valves are set for normal MGO operation.
Only applicable to Figure 2 .

MGO to MDO.
As MGO and MDO are very much alike. And since you are always allowed to burn
MGO were you are allowed to burn MDO. No flushing is required.
Note: Check the setting of G481, if it is set to HFO operation it should be changed
to MDO operation.
MDO to MGO
Flushing is done to avoid firering with MDO were this is not allowed.
Pump G450 is started. Burner inlet valve G460 is set to "MGO". Burner outlet valve
At the end of the flushing period the valves are set for normal MGO operation.
HFO to MDO
Flushing is done to avoid cold HFO.
Pump G147 is started. Burner inlet valve G460 is set to "HFO". Burner outlet valve
OM5560_155#F.3
At the end of the flushing period the valves are set for normal MDO operation.
Note: Check the setting of G481, if it is set to HFO operation it should be changed
to MDO operation
MDO to HFO
Flushing is done to avoid heating on MDO.
Pump G147 is are started. Burner inlet valve G460 is set to "HFO". Burner outlet valve
At the end of the flushing period the valves are set for normal HFO operation.
Note: Check the setting of G481, if it is set to MDO operation it should be changed
to HFO operation.
Note: Heat tracing must be de activated for MGO/MDO operation and re acti-
vated for HFO operation.
TABLE OF CONTENTS
Table of contents
Installation
.
Mounting and connection of the burner........................ IN5560_05................. 19-2
Installation of mixing tube.......................................... IN5590_05................. 19-8
IN5560_05#B.1
MOUNTING AND CONNECTION OF THE BURNER
Mounting and connection of the burner
1 Description.
The following instructions, describes the standard installation of the Aalborg KBM
pressure atomizing burner and the connection of the modules for oil, air and electric.
Final assembly
Figure 1 kbmins02x3281820en.wmf
1.1 Mechanical mounting of the burner
When the boiler plant is delivered, the burner unit is supplied loose. After the pressure
part is installed, the following work procedures must be carried out in order to mount
the complete burner unit.
Note: The burner is too heavy to lift by hands. Therefore it is necessary to install
a beam with a lifting trolley.
The lifting wires should at least be dimensioned to a force equal to the
weight of the burner unit.
IN5560_05#B.1
On delivery the burner unit has mounted four transport feet and a lifting yoke as shown
below. During transport the unit is standing on the feet. And with a pallet truck it can
be lifted out of the transport box.
Note: Make sure the lifting forks does not touch and destroy the front plate
brickwork.
To lift the burner unit: lift in the hole on top of the lifting yoke. Lift slowly and just
before the unit slips the ground lift extra slow to avoid fluctuations.
The burner unit can now be lifted in position on the boiler burner flange. Make sure
mounting bolts are ready to fix the burner on the flange. And also demount the transport
feet before it is mounted.
Lifting
Figure 2 kbmins054ax3417050en.wmf
IN5560_05#B.1
Note: If the burner unit is stored for a period of time before it is mounted on the
boiler, it must be stored inside to protect against corrosion caused by rain,
pollution, etc.
Step A: Ensure that transportation supports, if any, are removed from the boiler.
Step B: Make sure the threaded burner mounting plates as shown on Figure 3 below
are available and welded to the boiler burner flange..
Boiler Burner Flange with threaded mounting plates:
Step C: Remove the galvanised plate which is used to protect and close the fire hole
on the pressure part.
Step D: Take the burner unit out of the transport box. Lift it to a position just in front
of the boiler
Step E: Demount the transport feet from the burner frame.
Step F: Mounting of ceramic felt. Apply gasket material to position 2, according to
Figure 4 “Front plate insulation”.
IN5560_05#B.1
Front plate insulation
Figure 4 burn_op5x2453500en.wmf
Step G: Position the burner unit with the hole of the frame surrounding the "Boiler
Burner Flange". See Figure 5 below.
Note: The Burner is shown with the "Front Plate" in the open position. This only
to show how the burner frame is mounted on the "Boiler Burner Flange".
During mounting the Front plate is supposed to be in the normal position.
Illustration of the boiler burner flange
Step H: Mount the burner unit to the boiler with the mounting bolts in the frame plate
Step I: Demount the 4 transport bolts in the hinges and mount the 2 pin bolts instead.
See Figure 6 below.
IN5560_05#B.1
Transport and adjustment screw.
Step J: If required adjust the front plate adjusting screws to have the front plate
aligned with the boiler burner flange.
Step K: Mount the front plate on the boiler burner flange
Step L: Connect the piping for scavenging air to the connection on the windbox.
Step M: Connect the oil in and outlet to the respective bite type mechanical joints
inlet equals 22 mm outlet 18 mm pipe outer diameter.
Step N: Establish the electric connections between junction box and control system
also connect the fan motor.
1.2 Pipe connections
The pipe dimensions between the oil pump(s) and the burner unit must have a dimen-
sion that ensures a the velocity inside the suction pipe below 0.5 m/s and a velocity
inside the pressure pipe below 1.0 m/s. The oil pressure in the ring-line must as a
minimum be 30.0 bar, and as a maximum 33.0 bar.
Attention: Pressure testing with water is not allowed.
The burner is delivered with 22 mm pipe to the inlet and 18 mm pipe on the outlet
placed according to the general arrangement drawing on the data sheet.
Note: All pipelines are expanding with increased temperatures and must be ar-
ranged in such a way that the thermal expansion of the piping systems as
well as the boiler do not transform any significant forces to the connection
points of the burner unit.
IN5560_05#B.1
Note: During installation all piping systems must be thoroughly cleaned in order
to remove all welding beads, grease, dirt, etc. Furthermore, system com-
ponents must be protected during pressure test of pipelines.
1.3 Electrical connections
The internal electric cables are pre-mounted in the oil cabinet. When the boiler unit is
delivered the electrical cables between the control system and burner unit must be
connected as described below.
Cable connection
Figure 7 kbmins06bx3289670en.wmf
Step A: Remove the covers on the oil cabinet.

Step B: The prewired cables are mounted on the left side, the yard cables should
therefore be mounted on the right side in the cabinet. See Figure 7.
Step C: The terminal rows are marked with numbers
Step D: Connect the cables from the control system to the marked/numbered termi-
nal rows according to the electrical drawings
IN5590_05#C.1
INSTALLATION OF MIXING TUBE
Installation of mixing tube
To obtain a well functioning oil system for this boiler plant, it must be provided with
a mixing tube. The purpose of the mixing tube is to degas the fuel oil return flow from
the oil pressure control valve and burner. By this action the risk of pump cavitation is
minimised.
Figure 1 shows a drawing of the mixing tube, and in Figure 2 and Figure 3 installation
sketch of are shown.
1.1 Mixing tube
The mixing tube must be designed for a velocity inside the tube of 0.02 - 0.03 m/s.
Table 1 shows the dimensions of the mixing tube in relation to the oil flow.
Mixing tube
Nominal size
1.25 x C
C
A
250
A A
Min. 2000
Depending of tank height
C
View A-A
A
B1
B2
Figure 1 mixingkb1ax1313490en.wmf
IN5590_05#C.1
Actual pump A [DN] B1 [DN] B2 [DN] C [DN]

flow at 380
cSt. [m³/h]
0-0.75 100 40 32 32
0.75-1.1 150 40 32 32
1.1-2 200 50 40 40
2-4 250 65 50 50
4-6 300 80 65 65
6-8 350 100 80 80
8-10 400 100 80 80
10-12 450 125 100 80
Table 1
1.1.1 Installation of the mixing tube

When the mixing tube is installed, the top of the tube must be at least 500 mm above
the highest oil level of the heavy fuel oil tank. The vertical distance between the top
of the tube to the highest point of the vent pipe for gasses to the oil tanks must be at
least 250 mm. Furthermore, the distance between the highest oil level of the marine
diesel oil tank or marine gas oil tank and the vent pipe must be at least 750 mm in
vertical direction.
Further we refer to "Recommended system layout - SD9010_33"
Installation sketch of the mixing tube, common fuel oil pump
Min. 250 mm
Min. 750 mm
Min. 750 mm
High oil level High oil level

Mixing tube

LFSO / MGO Diesel oil tank
Min. 500 mm
Min. 500 mm
tank
Heavy fuel oil Heavy fuel oil
Settling tank Service tank
A
Low oil level Low oil level
Tank
Low oil level Low oil level low level
B1
Min. 100 mm
B2
XS
XS
Pump unit
Pipe length to be less 1 m
Fuel oil return from oil pressure control valve / burner
Figure 2 mixingkb3cx1322540en.wmf
IN5590_05#C.1
Installation sketch of the the mixing tube, with separete pump set
Min. 250 mm
Min. 750 mm
Min. 750 mm
Mixing tube
LFSO / MGO Diesel oil tank
Min. 500 mm
Min. 500 mm
tank
Heavy fuel oil Heavy fuel oil
Settling tank Service tank
A
Low oil level Low oil level
Tank
Low oil level Low oil level low level
B1
Min. 100 mm
B2
Pump unit
XS
Pump unit
Pipe length to be less 1 m
Fuel oil return from oil pressure control valve / burner
Figure 3 mixingkbe2x1925550en.wmf
Separete MGO pump set and separate MDO & HFO pump set.
TABLE OF CONTENTS
Table of contents
Cooler unit
.
Installation of the cooler............................................. IN8640_06................. 20-2
IN8640_06#B.1
INSTALLATION OF THE COOLER
Installation of the cooler
This chapter describes the installation and mounting of the cooler. Figure 1 shows an
illustration of the cooler.
The cooler is of the shell and tube type with u-bent tubes.
The cooler has been hydrostatically tested before delivery. The cooler is type approved
by all major classification societies.
Illustration of the cooler
L + shell diameter L
Oil inlet Oil outlet

Air vent valve
Water inlet
Safety valve
Drain valve
Mounting holes
Water outlet
Figure 1 cooler3ax1462790en.wmf
1.1 Placement of the cooler
The cooler must be placed on a level and stable surface.
The distance between the cooler and the wall must be sufficiently large. As shown in
the illustration, the minimum distance between the wall and the inlet/outlet water pipes
must be at least equal to the distance between the pipes for oil inlet and oil outlet in
order to clean, inspect or replace the tube insert.
IN8640_06#B.1
INSTALLATION OF THE COOLER
1.2 Storage
If the cooler must be stored prior to the installation, it should be in a dry storage room .
If the storage room is damp, the cooler must be wrapped together with bags of silica
gel. To avoid damages it is recommend that the cooler is stored in the original packing.
The cooler has been hydrostatically tested before delivery. The used test medium con-
tains a certain amount of corrosion protection (CASTROL SYNTIOL R HIGH
SPEED). Any further steps should not be necessary regarding storage before installa-
tion.
When the cooler is kept in storage for an extended period of time, it is recommend to
use CASTROL SYNTIOL R HIGH SPEED as protection against corrosion.
2 Mounting and installation

The cooler can be mounted in a horizontal position or in a vertical position.
If the cooler is placed in a horizontal position, the water inlet and the oil outlet must
face upwards.
If the heat-exchanger is placed in a vertical position, the inlet water and the outlet water
tubes as well as the oil inlet must face downwards.
Step A: Place the cooler on a level and stable surface.

Step B: Drill holes for the bolts.
Step C: Place the bolts into the holes and tighten them.
2.1 Connection
Step A: Remove all plugs and cover flanges before the cooler is connected.
Step B: Remove sand and other impurities form the connections.
Step C: Set up the pipe connections. Make sure that no forces are transferred to the
cooler.
TABLE OF CONTENTS
Table of contents
Aalborg control system

.
Touch control system................................................. SD9306_20................ 21-2
SD9306_20#D.1
TOUCH CONTROL SYSTEM
Touch control system
1 General
The Aalborg control panel is designed to provide safe and functional operation of the
boiler plant both at the boiler and from a remote location such as the engine control
room. The general design is a common panel solution. The panel is capable of con-
trolling one oilfired boiler and one exhaust gas boiler. The panel is locally controlled
by means of a touch screen in the front of the panel.
Figure 1 illustrates a typical configuration for a boiler system. The example shown is
for a Aalborg OS boiler plant with a Aalborg XS exhaust gas boiler. The control system
is constructed in a similar way for other boiler installations.
The communication between the common panel and touch screen is achieved through
a LAN network. The cable type is a Cat 5E cable and should not exceed 1000 metres
in total length.
Illustration of the control system
LAN, network
Figure 1 control_sd9306_2x3671630en.wmf
Common panel
The common panel holds one PC, communication interface, relays, flame monitoring
equipment, water level control equipment, switches for emergency operation but also
power supply systems, motor starters, input/output modules and optional components
like smoke density monitoring system, salinity alarm equipment, oil detection equip-
ment, etc.
SD9306_20#D.1
The cabinet gives an IP 55 insulation class and can be located in ambient temperatures
between 0-50ºC with a relative humidity up to 90%. The maximum vibration level is
100 Gal at 10-30 Hz. And the power supply is 115 or 230 V AC, 45-65 Hz. The
maximum power consumption for the control panel is approximately 1000 VA.
The complete boiler system can be operated from the HMI panel on the front, the burner
can be operated both in auto and in manual mode, and shut downs/alarms can be ac-
knowledged.
It is also through the HMI panel that the basic configuration of the system is done
during commissioning. Access to a number of different parameters, settings, etc. is
limited by password entering. This secures the operation from unintentional entering
and modification, which might cause damage to the boiler plant. The password routine
is divided into two steps. The entering of the common user password provides access
to the most common menu items. The super user password, which is only known by
Alfa Laval and chief eng. provides unlimited access.
Monitoring and control from the remote screen

The control system is provided with a HMI panel which contains a graphic user inter-
face for a quick user-friendly overview of the boiler operation. This remote screen can
be installed anywhere, as long as the length of the cables does not exceed 1000 metres.
The boiler plant can be monitored and operated from the screen as well as from the
HMI in the front of the control panel. Furthermore, trend curves for the plant can be
viewed and alarms can be acknowledged.
In Figure 2 the main screen of the touch screen is shown. By use of the touch screen,
shutdowns/alarms can be acknowledged from the [ALARM] button in the upper right
corner. The buttons on the right side of the display give access to detailed information
on the steam system, feed water system, fuel system, and burner operation. From the
buttons on the left side of the touch screen, key lock, trend curves and the set-up menu
can be accessed. The button [BOILER] gives access to an overview of the operation
of the boiler system.
SD9306_20#D.1
Illustration of the main page of the touch screen
Figure 2 controlabc_4x3439370en.wmf
A password system provides the logged-on user with permissions/restrictions and en-
sures that no parameters can be changed by unauthorised personnel.
An optional communication interface via Modbus protocol (RS485) or (TCP) to other

systems on board the ship can be provided from the PC in the common panel
The Modbus interface feature offers external control and monitoring of a limited num-
ber of parameters in the boiler control system from an external operating place such
as e.g. the cargo control room. It is possible to control and/or monitor parameters such
as boiler operation mode, state (stopped, starting, purge, etc.), manual start/stop and
load, selection of master/slave boiler, inert gas mode (if provided), boiler/system pres-
sure, and water level.
If Modbus is selected, Alfa Laval supplies a complete address list.

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TABLE OF CONTENTS

Aalborg OC-TCi Boiler

Pressure atomizing burner

Aalborg OC-TCi Control system (touch)

Recommended system layout

Recommended system layout

2.1 Hydraulic pressure test

2.2 Feed water pumps

- Min./max. inlet pressure: according to the recommendations of the manufacturer.

2.3 Feed water line layout

2.4 Chemical dosing

- Chemical dosing: see the specific instruction (OM9210#99).

2.5 Feed water control valve

2.6 Safety valve waste pipe

- Safety valve: see the specific instruction (IN6040#01).

2.7 Boiler drain

2.8 Sample cooler

2.9 Circulation pumps

2.10 Circulation water line layout

2.11 Circulation flow measurement

2.12 Main steam line layout

2.13 Soot blower supply lines

2.14 Steam dump equipment

2.15 Steam dump condenser

- The hot-well tank should be of the pressure less type.

2.17 Steam injection system

2.18 Oil detection equipment

2.19 Salinity alarm equipment

2.20 Smoke funnel

2.21 Smoke density equipment

- Smoke density equipment: should be of the obscuration measuring type.

- O2-measurement equipment: according to the recommendations of the manufac-

2.23 Fuel Compatibility

2.24 Three-way valve unit (MDO/MGO/HFO )

2.25 Fuel oil pumps

2.26 Fuel pressure control valve

- Fuel pressure control valve: according to the recommendations of the manufac-

2.27 Oil pre-heaters for steam atomizing burner(s)

2.29 Steam traps for steam atomizing pipeline

- Pump pressure range: 7 – 14 barg

2.31 Mixing tube

- Mixing tube for steam atomizing burners:

2.32 Gas/air separator unit for pressure atomizing burner(s)

2.33 Oil pipeline layout

2.35 Engine room pressure

2.36 Combustion air fan for steam atomizing burner(s)

2.37 Control air supply

2.38 General pipeline notes and recommendations

2.39 Exemption of liability

Technical data for boiler plant

• Request No./Order No.:..........................................................................106988-1

2 General plant data

• Language for manuals:..............................................................................English

Technical data for Aalborg OC-TCi

• Request No./Order No.:..........................................................................106988-1

2 Dimensions for boiler unit

• Height to top of smoke outlet box:.........................................................5,061 mm

3 Water/steam process data

• Steam output, simultaneous operation:..................................................2,300 kg/h

4 Data for pressure part

• Boiler type:.......................................Vertical, composite smoke/water tube boiler

5 Combustion process data (oil-fired section)

• Min. calorific value of Marine Gas Oil:.............................................42,200 kJ/kg