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INSTRUCTION MANUAL for BOILER PLANT
Boiler Type MISSION^" OS 3300
Boiler No. 9689 Project No 34012
Customer Kvaerner Warnow Werft Newb. No.
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Pi&O
Fleet Management Division (DTR) P&O Nedllovfd Genoa

Pi&O Nedlloyd Ltd. Voy: 003
40 Boompjes Port: Jeddah
30011 XB Rotterdam Date: 30thApril99
The Netherlands Your Ref: DTR 17/99
Dear Sirs,
Please find the following spares catalogue as sent by KWW to enable you to update^
component AMOSD 751.000.20. -s
Yours sincerely
C. Mellor
Chief Engineer
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INSTRUCTION MANUAL
FOR
MISSION™ OS 3300 BOILER
Customer Kvaerner Warnow Werft

Newb. No. 012
Project No. 97-34014
Date OCT 1997
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AALBORG SUNROD
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• 99*
A l G r o u p - A d d r e s s List AALBORGINDUSTRIES
EUROPE
AALBORG INDUSTRIES A/S (Al) AALBORG HEATERS A/S (AH)

P.O. Box 661, Gasvaerksvej 24 P.O. Box 548, Gasvaerksvej 7
9100 Aalborg, Denmark 9100 Aalborg, Denmark
Phone: +45 99 304000 Phone: +45 98 114000
Fax:+45 98 163022 Fax:+45 98 103001
Telex: 61730 vestadk
Telex: 69705 albordk
E-mail: aalborg-heaters.dk
E-mail: info@.aalborg-industries.dk
/V\LBORG SUNROD AB (ASAB)

AALBORG INDUSTRIES Oy (Al-Oy)
P. O. Box 9 P.O. Box 907,Riddarpiatsen 36,
FIN-26101 Rauma S-175 29 Järfälia, Sweden
Finland Phone: +46 8 580 243 00
Phone: +358 2 838 3100 Fax:+46 8 580 278 01
Telefax:+358 2 823 1133 Telex: 19268sunrods
E-mail: pipemasters@unex.inet.fi
AALBORG BOILER PRODUCTION AB (ABPAB)
AALBORG SUNROD (AS) Södra Stilierydsvägen 127
P.O. Box 844, Gasvaerksvej 24 S-374 93 Karlshamn
9100 Aalborg, Denmark Sweden
Phone: +45 99 304400 Phone: +46 454 858 00
Fax:+46 454 121 38
Fax:+45 98 168316
Telex: 69705 albor dk
E-mail: info@.aalborg-sunrod.dk
CISERV AB (CAB)
AALBORG KEYSTONE (AK-DK) Box 8988
P.O. Box 845, Gasvaerksvej 24 Anders Carlssons Gata 11,
9100 Aalborg, Denmark Lundbystrand
Phone: +45 99 304500 S-402 74 Gothenburg
Sweden
Fax:+45 98 101330
Telex: 69705 aibordk Phone: +46 31 657400
Fax: +46 31 515033 (administration)
E-mail: info@.aalborg-boilers.dk
Fax: +46 31 227225 (service/repair)
Telex: 20937 CISERV S
AALBORG KEYSTONE AB (AK-S)
Box 907, Riddarplatsen 36
175 29 Järfälia, Sweden AALBORG SUNROD Rotterdam B.V. (ASR)
Phone: +46 8 580 243 01 Glasblazerstraat 19
Fax:+46 8 580 358 79 2984 BL Ridderkerk
The Netherlands
/\ALBORG BOILER PRODUCTION (ABP) Phone: +31 180 461 462
P.O. Box 843, Gasvaerksvej 40 Fax: +31 180 461 602
9100 Aalborg, Denmark E-mail:.aalborg@worldaccess.nl
Phone: +45 99 304300
Fax:+45 98 123606
Telex: 69705 albor dk
E-mail: info@.aalborg-boiler-production.dk
DS/ISO 9001 P.O. Box 661 • Gasvaerksvej 2 4 Tel. +45 9 9 3 0 4 0 0 0 Bankers:

9100 Aalborg Fax+45 9 8 16 3 0 22 Den Danske Bank A/S Aalborg
Denmark Telex 6 9 7 0 5 albordk Account No. 3201-14162-1
DS/EN 29001
Reg.No.A/S 158349 Giro No. 196-8645 Unibank A/S, Copenhagen
PBS No. 0 0 8 9 3 2 8 5 Account No. 2 1 4 9 - 0 3 5 0 - 3 1 9 - 0 9 3
MIDDLE EAST AALBORG QINGDAO BOILER CO. LTD.
AALBORG SUNROD Dubai (ASD) No 32 Lanzhou Road West
P.O. Box 53073, AI Jadaf Jiaozhou/Qingdao City
Dubai Shandong Prov.
United Arab Emirates Peoples's Republic of China
Phone: +971 4 341061 Phone: +86 532 722 2833
Phone: +971 50522854 (24 Hour) Fax: +86 532 721 8074 (AQBC)
Fax: +9714 341790
E-nriail: aalborg ©emirates.net.ae
AALBORG SUNROD Korea (ASK)
P.O. Box 596
ASIA PACIFIC 9th Floor, Nulwon BIdg.
825-3, Bumil-dong
Dong-ku, Pusan, Korea
AALBORG SUNROD (S) Pte. Ltd. (ASS) Phone: +82 51 636 5800
24 Mandai Estate Fax: + 82 51 636 5887
Singapore 729915
Republic of Singapore ALBORG SUNROD K.K. (ASKK)
Phone: +65 2619898 Sannomiya Intes
Fax: +65 266 1111 1-8, 7-chome, Isogami-dori
Telex: rs 26720 alborg Chuo-Ku, Kobe 651
E-mail: @.aalborg-sunrod.com.sg Japan
Phone: +81 78 271 5720
Fax: +81 78 271 5741
PT AALBORG SUNROD Indonesia (ASI) Telex: 720 5622 056 gmarin j
Jl. Rawa Sumur II, Block III
Kav. CC. 7, Kawasan Industri Pulogadung
Jakarta 13470
Republic of Indonesia SOUTH AMERICA
Phone: +62 21 461 0569
Fax:+62 21 461 0568 AALBORG BRASIL IND. E COM. LTDA
E-mail: aalborg@.rad.net.id. Av. Vereador Isaias Prieto, 46
Rancho Grande - ItCi - SP
AALBORG SUNROD Hong Kong Ltd. (ASHK) 13.304-780
Room 2010, 20/F, CC. Wu Building Brazil
302-308 Hennessy Road, Wanchai Phone: +55 11 7824 0631
Hong Kong (SAR) Fax:+55 11 7824 0706 (ABr-Itu)
People's Republic of China
Phone: +852 2836 3826
Fax:+852 2834 8905 AALBORG BRASIL IND. E. COM. LTDA.
Telex: 69998 cserv hx Rua Monte Alegre, 212-conj.132 -13 andar
Perdizes - Sao Paulo - SP
AALBORG SUNROD Hong Kong Ltd. 05.014-000
Shanghai Liaison Office Brazil
Room 602, Jiu He & Xin Yi Building Phone: +55 11 871 1373
528 Tian Tong Road Fax:+55 11 65 0187 (ABr-SP)
Shanghai 200085
People's Republic of China
Phone: +86 21 6357 6781 AMERICA
Fax:+86 21 6357 6783 (ASSh) AALBORG KEYSTONE, INC. (AK-US)
1422 East Avenue
AALBORG SUNROD Hong Kong Ltd. Erie, PA, 16503-1592
Dalian Liaison Office U.S.A.
Room 7, 7/F, 6 Minshou Street Phone:+1 814 452-6421
Zhongshan District, Dalian 116001 Fax:+1 814 455 9932
People's Republic of China E-mail: zedeamil@zurnenergy.com
Phone: +86 411 280 0979
C:\TEMPV^DRLIS2.DOaaug97
Fax:+86 411 2825103 (ASDa)
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AALBORG SUNROD
Table Of Contents
MISSION™ OS Boiler
Technical Data of MISSION™ OS Boiler (97-34012) 1
MISSIONTM OS Boiler 2
Operation and Maintenance of Boiler (OM0540.0) 3
Boiler Control System 4
Water Level Gauge (K.7461.1) 5
Safety Valves (OM4000.0) 6
Feed and Boiler Water (K.7464.0) 7
Feed Water Pumps (OM3010.0) 8
Modulating Oil Burner 9
Fuel Oil Supply Pump (OM3505.0) 10
Drawings 11
Data Sheets 12
Electrical Diagrams 13
Alarm and Control Functions (340121) 14
Spare Parts (34012_3.0) 15
AALBORG SUNROD
^
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AALBORG SUNROD
Table Of Contents
Technical Data of M I S S I O N ^ M OS Boiler

General 1
Boiler Design Data 2
Boiler Dimensions ., 3
Technical Data of Burner 4
Electrical Data 5
AALBORG SUNROD
ENG Technical Data of MISSION™ OS 3300 Boiler 97-34012
Technical Data of MISSION™ OS 3300 Boiler
General
» Boiler type: Small Oilfired Boiler

* Model: (330Ö)
* Classification Society: GL + NSI
* Project No.: 97-34014
« Newb. No.: 012
« Boiler No.: (969V> ^^J^KOS) ^ ,
« Language: English
Boiler Design Data
» Steam output: 3,200 kg/h

* Normal working pressure: 7.0 barg
« Max. allowable working pressure: 9.0 barg
* Test pressure: 13.5 barg
* Feed water temperature: 80°C
* Max. allowable shrink: 0.45 m
» Max. allowable swell: 0.45 m
* Flue gas temperature (clean boiler): 339°C
* Draft loss across pin-tube elements: 58 mmWC
« Flue gas flow: 3,912 kg/h
Boiler Dimensions
» Diameter incl. insulation: 2,150 mm

« Height to smoke outlet: 4,355 mm
* Weight excl. water: 8,900 kg
® Operation weight: 14,400 kg
« Number of pin-tube element: 9
AALBORG SUNROD Page 1/2

Technical Data of MISSION™ OS 3300 Boiler 97-34012
Technical Data of Burner
• Burner type: ^.M."> .^ Pressure Atomizing Burner

• Operation principle: Modulating
• Burner capacity, min./max.: 76/228 kg/h
• Min. calorific value of fuel oil: 9,600 kcal/kg
• Max. fuel oil viscosity: 700 cSt at 50°C
• Nozzle: W250
• Flame tube: M9/la
• Diffuser disc: 165 x 50
• Oil pump pressure: 26 barg
• Oil temperature before burner: 75°C
Electrical Data
• Electrical power source: 3 x 440 V, 60 Hz

• Electrical control source: 1 x 220 V, 60 Hz
• Pilot voltage: 24 V
• Power consumption at full load: 20 kW
• Min burner motor insulation class: "B"
• Enclosure type: IP 44
AALBORG SUNROD itfjiilj, Page 2/2

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AALBORG SUNROD
Table Of Contents
MISSION™ OS Boiler
Description of Boiler Plant SD01Z00#01.0
Boiler Accessories SD01Z03#01.0
Modulating Oil Burner SD691#02.0
Boiler Control Panel and System 34012
Water Level Control SDZ01#03.0
Gauge Board SD01Z02#03.0
Gas/Air Separator and Filter Unit SD81Z#03.0
AALBORG SUNROD
ENG. MISSIONTM OS Boiler SD01Z00#01.0
MISSIONTM OS Boiler
Description of Boiler Plant
The MSSION^'^ OS boiler is a vertical oil-fired auxiliary marine boiler, insulated

and assembled as a unit with boiler accessories mounted on the boiler body.
The boiler is equipped with a pressure jet burner, which is delivered separately ready
for hinge mounting in the fiimace firehole and connection of premarked electric
wiring.
The boiler plant is supplied with a filter and air separator unit for filtering of the
fuel oil and separation of air.
The following subsections give some brief descriptions of the components included
in the scope of supply of the MISSIONTM OS boiler.
1.1 Boiler Pressure Part
The general arrangement of the MISSION'"'^ OS boiler is shown in Figure 1.

Basically, the boiler is designed as a vertical cylindrical boiler with a shell
surrounding a cylindrical fiimace, and a convective section consisting of pin tube
elements.
The pin tube elements consist of an outer tube enclosing the pin tube. The pin tube
is a plain seamless steel tube provided with an inlet pipe at the bottom and an outlet
pipe at the top. A large number of pins are welded around the outside of the tube
creating an extended heating surface. This extended heating surface transfers heat
from the flue gas to the steam/water mixture in the pin tube.
The fiamace floor consists of a steel plate protected from radiation of heat by
refractory.
The flimace bottom is provided with a socket for drain of washing water.
As shown in Figure 1, the boiler accessories such as safety valves, steam outlet
valve and water level elecfrode are mainly mounted on top of the boiler body in
order to allow a simple connection to the piping system on board the ship.
1.2 Heat Transfer and Water Circulation
Oil ignition and combustion take place in the fiimace. The produced heat is
transferred mainly by radiation from the flame to the fiimace shell. Leaving the
fiimace thefluegasesflowthrough the vertical uptakes where heat is transferred to
the pin-tube elements mainly by convection.
On the water side the heat is transferred by evaporation of the saturated water
adjacent to the fiimace shell or tube wall 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 natural circulation in the pin-tube element occurs because the density of water
is higher than the density of steam. The density of the water outside the pin-tube
element is higher than the steam/water mixture inside the pin tube element. The
AALBORG SUNROD Jjjj^ Page 1/2

MISSIONTM OS Boiler SD01Z00#01.0
difference in the static pressure at the lowêr connection to the pin tube creates the
driving force for the circulation. The steam/water mixture is discharged into the
steam space where the heavier water particles separate from the steam and flow
back into the water.
The boiler is designed so that approximately half of the steam is generated in the
pin-tube elements and the rest by radiation in the fiimace.
Principle Drawing of MISSIONT^* OS Boiler
Figure 1 OS 001a.cdr
1.3 Steam System
The steam space in the oilfired boiler is designed to absorb the shrink and swell
volumes. However, it is advisable to avoid sudden and large load variations as this
might create instability in the steam system, and cause level alarms.
It is very important to note that a boiler plant consisting of one or more exhaust gas
boiler(s) using the steam space in the MISSION^" OS boiler is not designed for
simultaneous operation in its basic design. In some cases the volume of the steam
space should be enlarged.
AALBORG SU^fROD iiiUiii) Page 2/2

ENG. Boiler Accessories SD01Z03#01.0
Boiler Accessories
1 Accessories
The following is a brief description of the most important items of the boiler
accessories. The components mentioned in this section are referring to the General
Arrangement Drawing of the boiler.
Safety Valves
Two safety valves arefittedto the pressure vessel of the boiler. They are installed
for security reasons, and designed to prevent the boiler pressurefi-omrisingabove
the design value.
Main Steam Valve
The main steam valve is a shut ofCnon-retum valve. When closed, it isolates the
boiler fi-om the main steam line. When open, it prevents steam fi-om flowing
backwards into the boiler.
Feed Water Valve / Feed Water Valve (sdnr)
Two groups of feed water valves are provided in the boiler. Each group comprises
a shut-off valve and a non-return valve.
The shut-off valve in the ordinary group must be open when the boiler is in
operation, or if the boiler is used as a steam drum.
The shut-off valves should be closed when the boiler is not in use.
WaterLevel 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-closing mechanism to be used in case of broken glass.
Blow-Down Valve
One blow-down valve of the shut-offnon-retum type is mounted at the bottom of
the boiler body.
The shut-off fimction is for security and the non-return fiinction prevents
steam/waterfromflowinginto an empty boiler by mistake.
Air Valve
The air/ventilation valve located on top ofthe boiler is a shut-off valve. It is normally
closed except when the boiler is being filled or completely drained.
Scum Valve
The scum valve is a combined shut-offnon-retum valve. In the event of scum in
the boiler, this scum can be blown offfromthe water surface by opening this valve.
Blind Flanges for WHR Inlet and Outlet
The boiler is provided with two sockets and blind flanges for inlet and outlet
connections to possible exhaust gas boiler(s).
In case that the boiler is connected to one or more exhaust gas boiler(s), the
connection valves should be shut-off valves, and depending on deviations in the
system, these valves can also have a non-retum fiinction.
AALBORG SUNROD JÜ^ Page 1/2

ENG. Boiler Accessories SD01Z03#01.0
Sample Valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Inspection Hole
A small inspection hole is provided in thefiimacewall 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.
Manhole
A manhole at the boiler top allows inside inspection of the pressure vessel.
Access to the furnace is gained by swinging out the bumer unit.
Handholes
Four handholes are distributed regularly around the circumference of the boiler and
at the bottom of the shell. These handholes enable inspection of the bottom part of
the boiler between furnace and boiler shell.
AALBORG SUNROD iÜüttb Page 2/2

ENG. Modulating Oil Burner SD691#02.Ö
Modulating Oil Burner
1 Burner Description
Illustration of Modulating Pressure Jet Bumer
FIcmetubeind. diffuser,
igiition éectrodes end nozzle
Oil pump
Fen heiuse
ind. mota
Savemnoteir f a
oil / d r recplciion
Oil prehecêr
Air demper intd<e
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The bumer is a pressure jet atomizing bumer with one nozzle for modulating
operation. It is capable of burning both diesel oil (DO) and heavy fuel oil (HFO).
The design of the bumer makes installation, adjustment and servicing easy. The
bumer housing is mounted on the boilerfi-ontwith side hinges, enabling the bumer
to be swung out. In this case a switch immediately stops the bumer.
The electric fan motor isfittedon the side of the housing and is directly connected
to the fan wheel. Via coupling the same motor is connected to the oil pump which
is a gear-wheel pump providing an operating pressure up to 30 bar.

ENG. Modulating Oil Burner SD691#02.0
The oil pipes leading the oil from the gas/air separator and filter unit to and from
the burner oil pump are made offlexiblehoses.
An oil regulator regulats the oilflowthrough the nozzle by increasing or decreasing
the flow resistance. This causes that more or less oil is pressed through the nozzle
as the supply pressurefromthe oil pump is constant. The pressure in the retum line
is checked by a pressure switch. If the pressure is too high, the burner shuts down
because it has reached the minimum load for operation.
To ignite the oil, two ignition electrodes are mounted just above the nozzles. In case
of flame failure in the starting and running mode, a photo cell immediately stops
the burner.
Electric signals corresponding to the pressure gauge board signals operate a servo
motor which drives a compound mechanism in a continous movementfrompartial
load to fiill load, regulating the air quantity in proportion to the oil quantity fired.
The cam has an adjustable spring band on the side which is moved by means of
adjustable socket screws.
The setting of the spring band is determined of various load positions by flue gas
measurements.
A diffuser and a combustion head are placed infrontof the nozzles with the purpose
of mixing air and oil mist to a suitable mixture.
The burner is equipped with a control and supervision unit. The unit controls all
start/stop sequences, and in the event of fault conditions the oil supply is always
interrupted immediately.
The burner unit is equipped with afiielheating system consisting of an oil preheater
and heating cartridges. One of the heating cartridges is placed in the nozzle head in
order to keep a sufficiently high temperature close to the nozzle. The nozzle head
is of the recirculating type which means that fuel oil is circulated in the nozzle head
from the time where the bumer is released for start until it begins operation.
AALBORG SUNROD ifttî Page 2/2

ENG. Boiler Control Panel and System 34012
Boiler Control Panel and System
Description
The control system supplied with the MISSIONT"^ OS boiler provides fully
automatic operation of the boiler and the pressure jet burner. The control panel is
normally pre-mounted on the boiler. A sketch ofthe control panel is shown in Figure
1.
Sketch of Control Panel
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QPERflTlNC INSTRUCTION
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Figure 1 34012b.cdr
The front of the control panel consists of switches for operation of the boiler and
light indicators for indication of alarms and operations. The control panel includes
the following:
• Load controller for increasing/decreasing the burner load
• Safety device, alarm indication and operation indication panels for water,
steam, oil, burner and pumps
• Water level control system for ON/OFF regulating
• Reset button and emergency stop
• Switches for fuel oil pumps for start, stop or stand-by mode
• Burner operation mode selector for automatic operation, emergency opera-
tion and burner off
• Burner modulation mode selector for automatic operation and emergency
operation
AALBORG SUNROD idiUlii Page 1/1

ENG. Water Level Control SDZ01#03.0
Water Level Control
1 Description
The water level control is an on/off regulating system on this type of boiler. The
system consits of two independent safety devices with the purpose of stopping the
burner and giving alarm if the water level is to low. For measuring the water level
a level probe is used. A sketch of the water level control system is shown in Figure
1. The electrodes are used for the following alarm and control functions:
• Too high water level
• High water level
• Feed water pump stop
• Feed water pump start
• Stand-by feed water pump start
• Low water level
• Low low water level (2 pes.)
Sketch of The Water Level Control System
Level probe
Low level electrodes
A. A OiJ
P?-^
I Oil fired boiler

1 MISSiON'"OS
ill i
1. High/low water level,

Level switch NRS 1-b
LU LU 14J
2. Start stand-by pump /
Boiler control panel too high water level,
3. Start/stop feed water pun:ip,

4. Too low water level,

Level switch NRS 1-7b
5. Too low water level,

Level switch NRS 1-7b
Figure 1 w level8.cdr
AALBORG SUNROD ,mtf{ii Page 1/1

ENG. Gauge board SD01Z02#03.0
Gauge board
1 Description
The function of the gauge board is to control the bumer and to give alarm for max.
and min. steam pressure. A sketch of the gauge board is shown in Figure 1.
• The pressure gauge is for analogous reading of the actual steam pressure.
• The pressure switch max. steam gives alarm when the steam pressure rises
above the preadjusted set point. Furthermore, the pressure switch locks the
bumer in stop mode. Operation of the bumer is only possible when the
steam pressure falls below the differential set point of the pressure switch
and the reset button in the control panel is activated.
• The pressure transmitter converts the actuel steam pressure into corre-
sponding electric signals. The signals are used to give alarm for min. steam
pressure and start/stop of the bumer. Within the limits for start and stop the
bumer is operating in modulation mode thereby maintaining the steam
pressure.
Sketch of Gauge Board.
41 Pressure switch valve

42 Pressure Gauge
43 Pressure switch max. steam
44 Pressure transmitter
Figure 1 manot04.cdr

ENG. Gas/Air Separator and Filter Unit SD81Z#03.0
Gas/Air Separator and Filter Unit
1 Description
The gas/air separator and filter unit is mounted on the boiler foundation next to the
burner. The unit is placed in the fuel oil ring line to remove gas or air from the oil
and to avoid abrasive materials to enter the oil pump and bumer nozzles. A sketch
of the unit is shown in Figure 1.
Sketch of Gas/Air Separator and Filter Unit
02 Pressure regulating valve

03 Quick closing vaive
04 Thernnometer
05 Pressure gauge
06 Pressure switch auto stand-by
FROM BURNER 07 Pressure switch low oil pressure
08 Heating cartridge
11 Flowmeter
TO BURNER^*
Air escape-4
Draln-^
Figure 1 asfti 02.cdr
The pressure regulating valve (02) is to be used when adjusting the pressure set
point of the fuel oil system. The pressure switches (07) and (06) are for safety shut
down in case of low oil pressure and start of stand-by pump respectively.
The quick closing valve is equipped with an interlock microswitch used for stopping
of the bumer, thereby preventing the bumer oil pump from sucking oil when the
valve is closed, which will cause cavitation damages in the oil pump. Further the
valve serves as an emergency quick closing valve.
The temperature and pressure of the fuel oil main ring line can be read on the unit
via the mounted instruments.
AALBORG SUNROD itHHJi, Page 1/1

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AALBORG SUNROD
TABLE OF CONTENTS
Operation and Maintenance of Boiler

General 1
Start-up 2
Boiler Maintenance 3
Boiling Out 4
Stopping of Boiler 5
Cleaning Pin-tube Elements 6
Preservation of Boiler 7
Boiler Repair 8
AALBORG SUNROD
ENG. Operation and Maintenance of Boiler OM0540.0
Operation and Maintenance of Boiler
General
This chapter of the instruction manual describes the operation and maintenance of
the pressure part of the MISSION^'^ OS boiler. As this is only a part of the hole
boiler plant it is important to notice that all the rest of the chapters in this manual
should be studied thoroughly. It is specially important that the operator of the boiler
plant has become familiar with the operation instructions of the burner and the
control panel.
Important! In order to have a safe and reliable operation of the boiler plant it is important
that all operation and/or maintenance of the boiler is carried out only by skill
personnel.
Start-up
2.1 Before Start-up
Before starting-up the boiler plant there are some work and check procedures that
has to be considered.
Q Fill the boiler with evaporated water to normal water level.
When filling a pressureless boiler, the shut-off valve after the pump shall be
throttled, otherwise the pump motor will be overloaded.
Check that the water level control is connected and in function.
Check the burner and the safety functions according to the separate
instuction.
Start the fuel oil circulation pump and preheat the fuel oil to the cor-
rect temperature.
This is valid if there is an electrical heater, otherwise the boiler shall be started with
diesel oil.
2.2 Start and pressure raising
The following work procedures has to followed during start-up of the boiler.
Open the venting valve.
Start the burner on manual control and low load.
Check that the water level does not rise too high during the pressure raising period.
Drain via the blowdown valves If the water level is to high.
AALBORG SUNROD iiiUÜb Page 1/14

Shut the venting valve when the steam blows out.

Tighten the manhole cover and hand hole covers during the pressure
raising period, if required.
Check all flange joints at the plant.
Q Change to automatic control when the boiler pressure is 0.5 bar lower
than the working pressure of the boiler.
Open the main steam valve slowly
Q Open the valves to the steam consumers carefully, in order to avoid
waterchocks.
Note: After 3-4 weeks in operation, mud and deposits in the piping system may have
accumulated in the boiler water. This can cause level variations which disturbs
the steam generation, and it is therefore recommended to blow-down the
boiler. It should then be inspected, cleaned and refilled with new boiler water.
Boiler Maintenance
The boiler maintenance should always be executed with skill and in accordance
with valid mles and regulations from the authorities, and below are given some
recommendations for periodical inspections and maintenance.
3.1 Daily Operation
During normal operation of the boiler some work and check procedures has to be
considered every day.
The boiler has to be blown-down by opening the blow-down valves quickly
for a few seconds, and then closed and opened again for about 5-10 seconds.
Repeat this operation when required according to the boiler water tests.
Check the boiler water condition and make necessary countermeasures with
regard to the feed and boiler water treatment.
Check the function of the fuel oil burner at different capacities through the
inspection tube on the boiler.
Check the flue gas temperature and/or draft loss after the boiler. If either the
temperature or the draft loss is too high, the pin-mbe element shall be cleaned
(see section 5).
Check the boiler steam pressure and the water level.
Check the feed water control according to separate instructions.
3.2 Weekly Routine Checks
Drain each level glass for about 10-15 seconds.

In case of contaminated boiler water or insufficient water treatment, the draining of
the water level glasses must be done more often.
Check the safety level device.
AALBORG SUNROD Jijj. Page 2/14

3.3 Monthly Routine Checks
Test the stand-by pumps.

Check: the function of the high steam pressure switch by lowering the set-
point or by raising the steam pressure, e.g. by closing the main steam valve
slowly.
The burner shall stop automatically.
3.4 Inspection of the Boiler
3.4.1 Inspection of Furnace

The furnace should be inspected at least twice a year. During this inspection the
following issues should be taken into consideration:
• Check for cracks at the refractory lining and that the furnace walls are
free from excessive soot deposits.
• Examine carefully the area opposite the burner. Too much soot deposits
indicate that the burner has to be adjusted.
• Check that the pin-tube elements are intact and that soot deposits are
within normal limits. The pin-tubes elements can be inspected both from
the furnace and from the man door in the flue-gas box on top of the
boiler.
3.4.2 Inspection of Boiler Water Side

The boiler water side (interior) has to be carefully inspected at least twice a year.
This inspection of great importance and no doubt the most important of all the
maintenance measures, since it has direct influence on the boiler lifetime and on
the security.
At these inspections, hard deposits, corrosion and circulation disturbances can be
found at an early stage, and preventive measures should be taken to avoid unex-
pected material damage and boiler breakdown.
Presence of hard deposits at the furnace wall and the pin-tubes reduces their heat
transfer properties and decrease the capacity of the boiler. Appropriate inspection
point is the inlet of the pin-tubes.
Further, it can be found out if the feed water treatment has been satisfactorily and
if the blow-down has been carried out sufficiently.
Incorrect feed water treatment is commonly causing hard deposits or corrosion.
Insufficient blow-down will cause sludge deposits in the tubes and accumulation
of sludge in the bottom of boiler.
If hard deposits are not removed, it may lead to overheating in the boiler plate
material exposed to flame and in the furnace wall area, which may cause material
damages.
Incorrect feed water treatment does not always lead to hard deposits. For example,
a too low or too high a pH-value may give an electrolytic reaction, causing corrosion
in the boiler.
AALBORG SUNROD «tiliMb Page 3/14

.NG. Operation and Maintenance of Boiler OM0540.0
When the boiler interior is inspected, examine all parts carefully and be attentive to
deposits, corrosion and cracks. It is advisable to spend a long time for this inspection.
If any unusual signs are found, contact Aalborg Sunrod at once for advice.
3.4.3 Procedure and remarks for inspection

O Shut off the boiler and allow it to cool (below 100 °C).
Note: The boiler should NOT be depressurized by lifting the safety valves and then
filled with cold water since the stress induced by too rapid cooling may cause
damage.
Empty the boiler and close all valves.

If the boiler is connected to a second boiler, check that the valves between them are
closed.
Unscrew and remove the manhole hatch and mud hole covers on the
boiler and enter the boiler when it is sufficient cold.
Check the weldings in the boiler. A careful examination should be carried out with
respect to any possible corrosion or crack formation.
Special care should be taken to the water line area in the pressure vessel, where
oxygen pittings may occur.
If deposits are found to be forming in the boiler tubes, the boiler should be
chemically cleaned.
It is advisable to consult a company of cleaning specialists who will examine the
boiler deposits and treat the boiler accordingly.
Note. After chemical treatment should be blown-down at least twice a day for
approximately one week. This will ensure that excessive sludge deposits due
to chemical treatment does not collect in the bottom of pressure vessel.
3.5 Contamination
If the boiler is contaminated with foreign substances like oil, chemicals, corrosion
products etc., it is very important to act immediately to avoid damages to the boiler.
Layers of thin oilfilms,mud, etc. exposed to the heating surfaces causes a bad heat
transfer in the boiler, leading to overheating followed by burned out pressure parts.
In order to remove such contamination, a boiling out or acid cleaning have to be
performed immediately.
Note: Corrosion products from the pipe system or insufficient boiler water treatment
may result in corrosion in the boiler itself. It is therefore important to observe
that such circumstances do not occur in the system.
AALBORG SUNROD iiiattb Page 4/14

ENG. Operation and Maintenance Of Boiler OM0540.0
Boiling Out
Before putting the boiler into operation for thefirsttime, it should be boiled out to
remove all protecting remedies and impurities in tubes and drums.
The boiling out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling the chemicals. The person
handling the chemicals/solution should be properly dressed/protected.
Fill the boiler with a solution consisting of 4-5 kg trinatriumphosphate

Na3P04 per 1000 kg water. The chemicals can be added through the
manhole.
Add feed water until the solution is visible in the water gauges above
"lower water level".
Close the feed water valve (pump stopped).
Caution: Do never fill feed water into the boiler if the temperature difference between
boiler and feed water exceeds 50° C.
Raise steam pressure slowly to working pressure, and keep the pres-
sure for approx. 3-4 hours with closed main steam valve.
Scum until water level is between "Normal water level" and "High
water level".
By this procedure grease and other impurities are removed from the internal surfaces
of the boiler.
K l Start skimming by opening the scum valve, and lower the water level
to lower edge of "Normal water level" mark.
^ ] Close the scum valve.
^ J ReHll the boiler with feed water and start skimming again in intervals
of 30 minutes for a period of two hours.
Stop the boiling out procedure by switching off the burner.
Q ] Let the boiler water rest for about Ave minutes.
Carry out a final skimming.
Blow off the boiler water by opening the two blowdown valves.
Remember to open the air escape valve, to avoid a vacuum in the
boiler when the boiler pressure falls back to approx. unpressurized/at-
mospheric pressure.
Open the manhole and let the boiler cool down to approx. 100°C.
The boiler is to be flushed with clean water in upper and intermedi-
ate drum, when the temperature has decreased. The flushing removes
remaining impurities.
AALBORG SUNROD läm. Page 5/14

ENG. Operation and Maintenance of Boiler OM0540.()
3 Take the two bottom blowdown valves, to pieces for cleaning and in-
spection because deposits/foreign substances will usually be accumu-
lated in these valves and cause leakings if not cleaned.
Inspect the boiler and remove any remaining deposits and foreign sub-
stances.
IE] Finally, new gaskets to be fitted in all hand- and manholes before
refilling the boiler with water to upper edge of "Low water level".
The boiler is now ready to be taken into service.
Advice: During thefirsttwo weeks in operation we recommend to carry out frequently

skimming and bottom blowdown to remove impurities entering the boiler
from the pipe system.
Stopping of Boiler
The following decribes the measures to be taken when the boiler is shut down.
m Clean the boiler from soot with water immediately before shutdown.
Start the burner and keep it in operation for at least 15 min. after the
soot removal to dry out the remaining water.
Check the furnace and the pin tubes with regard to cleanliness.
Empty the boiler from water and clean it.
Check if lime stone has appeared.
Check and clean the outer fittings.
Change gaskets where required.
Clean feed water tank and feed water pipes.
Clean and grease the bearings of motor, pump and fan.
Q Check and align the burner.
If the boiler is to be shut down for a longer period, the pin tubes must be thoroughly
cleaned.
Check that necessary spare parts are available. Order complementary parts in time.
WARNING! Do not operate the boiler without water!
Do not operate the boiler with oil in the feed water!
AALBORG SUNROD «iiäJiit Page 6/14

Cleaning Pin-tube Elements

In order to keep the heat transfer area sufficiently clean, the boiler has been designed
with a high flue-gas velocity through the pin-tube elements. And therefore fouling
will be minimized, under normal circumstances, with a correct combustion.
After a certain time in operation, soot deposits are however accumulated inside the
boiler. The quantity of soot and the time of forming it, depends on factors such as
oil quality, boiler load and how the burner is adjusted. Therefore it is impossible to
specify exact time intervals between which the boiler should be soot cleaned.
However, some general guidelines are given below.
There are three methods to check if soot cleaning is necessary:
• Inside inspection.
• Checking of the flue gas temperature. The boiler should be cleaned if
the flue gas temperature lies approx. 20 °C above the temperature in
clean boiler.
• Checking the draft loss, the boiler should be cleaned if the draft loss lies
approx. 20 mmWC above the pressure loss in a clean boiler.
It is recommended to keep a consecutive record of the flue gas temperature or the
draft pressure loss related to different boilers load in a clean boiler. These original
data should be used for comparison, and it is therefore a good idea to plot the
measurements in a chart like the one shown on Figure 1 (an empty chart is enclosed
at the back of the paper manual). In this way it is possible to monitor the fouling
condition of the pin-tubes and determine when they need to be cleaned.
Check scheme for flue gas measurements
V
u
O
3
O <4M
0 10 20 30 40 50 60 70 80 90 100
Load %
Figure 1 dp_lubk.cdr
AALBORG SUNROD •uiUib Page 7/14

6.1 Cleaning Procedure
As most of the deposits consist mainly of non-soluble particles held together by a

water soluble bonding material, water washing will have the following benefits:
• Dissolves the bonding material.
• Washes the loosened insoluble deposits away.
The most effective way of soot cleaning is water washing, carried out when the
boiler is as hot as possible. The procedure for soot removal is as follows.
Shut off burner.
Wait a minimum of time (10-20 min.) allowing the boiler to cool.
Unlock burner unit and swing it out of the furnace.
Open soot water drain valve and check piping not choked.
Unlock and remove the flue box inspection hatches located on top of
boiler.
Q Using a hand water lance, direct a jet of fresh water directly at each
of the vertical uptakes. Flush carefully over each tube for 20-30 seconds
with a flow of approx. 501/min. Water pressure should be between 4 and
6 bar.
Warning! When washing the pin-tube elements while they are hot a lot of steam will be
generated. It is therefore very important that all of your body are outside flue
gas uptake box in order not to get your skin burnt by the steam.
Q Completing flushing the pin-tube elements, they should be washed

thoroughly with a lot of fresh water.
Note: Care should be taken not to let water get in contact with burner throat
refractory.
Allow time for water to drain and check that soot water is draining
from the furnace floor and that drain outlet has not become choked.
If necessary repeat step 7 and 8.
By looking into the furnace from the burner opening, ensure that all washing water
is drained away
3 Close soot water drain valve.
Put back inspection hatches on flue gas box and secure.
Swing burner back into position and dry out the boiler by restarting
the burner.
AALBORG SUNROD uiiUii. Page 8/14

It is essential that the boiler is dried out in this manner since soot formations
produced by an oil burner contains sulphur compounds. Any residual soot and water
will therefore react chemically to form highly corrosive sulphuric acid.
Q The burner should now be run for approx. 15 min. and then
stopped
While running the bumer check that the exhaust gas temperature is now within the
correct limits.
Check that all inspection hatches are clamped as tightly as possible and that no gas
leaks have occurred. If a hatch is suspected of leaking, replace the gasket.
Preservation of Boiler
If the boiler is to be shut-down for a period of 1-30 days, it should be topfilledto
prevent corrosion. Before topfilling,it should be cleaned from soot deposits.
If the boiler is to be shut down for more than one month, different methods to prevent
corrosion can be applied:
• Dry preservation.
• Wet preservation.
• Nitrogen preservation.
The work procedures related to each of these preservation methods are described
in the following:
7.1 Dry Preservation
When applying this method the boiler is totally emptied of water and dried out.
Emptying the boüer of water is done by bottom blowing the boiler at 3-5 bar
pressure, opening the boiler and draining it of remaining water.
Manhole doors and handhole covers to be opened as long as the boiler is hot,
and if there is water left in the bottom it has to be removed, e.g. by using a
vacuum cleaner.
ff the boiler is cold, drying of the boiler is done by either circulating dried air
from a fan or by placing bags of silicagel in the boiler.
Before closing manhole doors, place a tray with burning charcoal to remove
oxygen. As soon as you have placed the charcoal, close manhole doors with
new gaskets.
Alternatively, a small steam phase inhibitor is to be added to the boiler after
cooling and careful draining, and the boiler can afterwards be closed com-
pletely.
7.2 Wet Preservation
While dry preservation is a question of draining off water to avoid corrosion, the
principle of wet preservation is to prevent oxygen from entering the boiler.
This method can be used for a short period of 'lay-up' (1-3 months).
AALBORG SUNROD iiiüäit Page 9/14

The boiler is filled with treated boiler water and hydrazine is added until an
excess of 100-200 ppm is obtained.
The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen, and it is necessary to check
the hydrazine concentration and add the necessary amount to have an excess
of 100-200 ppm. Other oxygen binding agents can be used, too.
The pH-value should be 9.5-10.5.
Note: K there is any risk of temperature falling back below 0°C, this method should
not be used to avoid frost damages.
As this preservation method involves applying hydrazine to the water inside the
boiler, the boiler must be completely drained and refilled with a fresh water before
taken into service again.
7.3 Nitrogen Preservation
The boiler has to be drained, dried and sealed in the same way as mentioned above
under Dry Preservation above.
Makeaconnectiontothebottomof the boiler and open air escape valve in
the top of the boiler.
Connect cylinders with nitrogen to the bottom via a reduction valve and
purge the boiler until you are sure that no oxygen is left.
Close air escape valve (8).
Leave a cylinder with nitrogen connected to the boiler via reduction valve
and keep an overpressure of approx. 0.2 bar in the boiler.
8 Boiler Repair ^^t,
8.1 Repairing a Pin-tube Element
In the unlikely event of a leaking pin-tube element, the burner and feed water pump
must be stopped and the boiler unpressurized.
Q Now empty the boiler and removed the manhole cover.
Q The boiler is now to be inspected in order to locate the damaged pin-
tube element.
In case of a damaged inner tube.

The pin-tube must be plugged with conical tube plugs at the inlet and outlet
connections.
Before the tube plug is mounted clean the inside of the tube ends with
a steel brush, so that no deposits are present in the tube.
Cut a hole in the damaged pin-tube, when it has been plugged.
AALBORG SUNROD aÉi. Page 10/14

ENG. Operation and Maintenance of Boiler OM0540Ö
In case of a damaged outer tube.
Note: Before repairing a damaged outer tube the pm-tube element should be clean
as described in section 5.
The pin-tube element must be blocked by welding a circular plate, with the same
diameter as the outer tube, at the in- and outlet of the outer tube.
This circular plate must be made of boiler plate and should be approx. 15 mm thick.
The weldings must be performed by skilled personnel with knowledge and quali-
fications to perform certified weldings.
Before mounting the plates, two holes should be cut in the outer tube, as shown on
Figure 2.
niustration of how to block the outer tube
Repair plate (ø259)
Holes to be cut before

welding of repair plates (ø35)
Repair plate (ø259)
Figure 2 pin_rep.cdr
Before starting up, refill the boiler and check for leaks.
Start the boiler and check for leaks when pressurized.
Note: When a pin-tube element has been plugged as described above, a new pin-tube
element should be mounted as soon as possible. The boiler should NOT be
operated with more than one blocked pin-tube element, without approval from
the supplier.
AALBORG SUNROD •iüiüi« Page 11/14

ENG. Operation and Maintenance of Boiler OM0540.(
Note: Temporary repairs require more attention than a normal working boiler.
Temporary repair of pin-tube elements has naturally an influence on the efficiency

since the heating surface is reduced. It can therefore be expected that the flue gas
temperature will rise. In this view it must be noted that the flue gas temperature
never must exceed 450 °C. If the temperature exceeds 450 °C the burner must be
stopped or fired on a low firing rate.
8.2 Refractory Repair
The furnace floor is lined with an insulating material (Verilite R6), close to the
casing covered with a layer of castable refractory (Plicast 31).
The refractory is made with expansion joints, which should under no circumstances
be blocked or filled on purpose.
Even though the refractory has been made with expansion joints, it will tend to
make additional natural expansion joints, which will be seen as fissures. However,
thefissureswill generally close when the boiler is put into service. The following
rule-of-thumb is a guideline when examining the fissures:
• white/light fissures, which are getting darker over the time, are closing
when the boiler is in service and opening in cold condition, and they do
not need further attention.
• dark/black fissures suddenly occured, seen in cold condition, are not
closing when boiler is in service and need to be repaired/filled up with
refractory (Plicast 31).
All refractory subjected to wear will, as time goes by, need to be repaired. This can
be done as a temporary repair or on a permanent basis.
8.2.1 Temporary Repair

Smaller areas can be temporarily repaired making use of the repairmix Plistix 14,
supplied separately with the boiler equipment.
The durability of such a repair depends on the location, but the more exposed to
heat, the shorter lifetime. Generally spoken it is recommended to let a temporary
repair be replaced by a repair on a permanent basis within one year.
Temporary repairs in vertical places ought to be made "swallow tailed", see Figure
3, if possible, which secures a better attachment to the existing refractory.
AALBORG SUNROD tiiiiiUi Page 12/14

Sketch indicating a "swallow tail" repair
<^ ... . • ." ... \
Refractory / N
7m:
Swallowtail (filled in with Plistix 14)
Figure 3 swaltail.cdr
The surface to which the temporary repair is going to be performed, shall always
be clean, dry and rugged.
Mixing instructions for the castable refractory appears from the instruction on the
plastic bucket.
Note: Plistix 14 must be applied to site immediately when mixed.
The boiler can be lightended-up approx. 1 hour after the refractory has been applied.
The refractory needs no further time for hardening.
If the boiler is pressurized, the lighting-up should be started with the burner in "on"
position for one (1) minute and then in "off' for two (2) minutes, during the first
half (Vi) hour. Then it can be started up according to the ordinary lighting-up
procedure.
Warning: Failed Y-anchors must only be replaced by Y-anchors made from heat
resistant steel. Y-anchors made from incorrect materials will cause damage to
the refractory.
Note: Observe the safety rules regarding the refractory which can be seen on the
plastic bucket
8.2.2 Permanent Repair

Major repairs and renewal of temporary repairs shall always be carried out and
supervised by maker's specialists, among other things securing that correct drying-
out time and lighting-up is observed.
AALBORG SUNROD aüiiii» Page 13/14

8.3 Maintenance of Refractory
Note: The refractory should be inspected once a year for shape and wear. It is
recommended to carry out an inspection in due time prior to long repair
periods such as drydockings, etc.. Should a repair be required castable
refractories and bricklayers can then be ordered on short notice.
If the refractory has been exposed to water, the refractory should be dried out as
soon as possible. The drying out can be done by hot air (approx. 50°C) or by
operating the oil burner.
Warning: However, if the burner is being used, the burner should be operated with great
care.
Generated steam evaporated from water absorbed into the refractory might
cause fissures and cracks when expanding, if the heat input from the oil burner
is too heavy.
8.3.1 Typical Refractory Data

Below in Table 1 is a list of typical refractory data shown.
• ; Refractory Data :
- VeriüteR6 Plicast31 Plistix 14
AI2O3 32% 44% 48%
SiOa 24% 46% 43%
|Fe202 12% 1% 1%
'T1O2 1.6% 1% 1.9%
CaO 23.3 % 6.5% 4.8%
MgO 6.1% 0.5% 0.2%
Alkanes 1% 1%
NaiO 0.1%
K2O 0.2%
Operating Range 100-1000 °C 20-1450°C 100-1420°C
Table 1
AALBORG SUNROD iiiiiiiu Page 14/14

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AALBORG SUNROD
Table Of Contents
Boiler Control System

Boiler Control Panel and System 34012
Safety Device OMZ04#21.0
Water Level Control System OMZ04#31.0
Burner Load Controller OMZ04#50.0
Operating, Configuring and Parameterization of the Process Controller OMZ04#60.0
Burner Sequence Control OMZ04#71.0
Flame Safeguard OMZ04#72.0
Alarm and Operation Indication Panels OM01Z04#80.0
AALBORG SUNROD
ENG. Boiler Control Panel and System 34012
Boiler Control Panel and System
Description
The control system supplied with the MISSION^'** OS boiler provides fully
automatic operation of the boiler and the pressure jet burner. The control panel is
normally pre-mounted on the boiler. A sketch ofthe control panel is shown in Figure
1.
Sketch of Control Panel
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Figure 1 34012b.cdr
The front of the control panel consists of switches for operation of the boiler and
light indicators for indication of alarms and operations. The control panel includes
the following:
• Load controller for increasing/decreasing the burner load
• Safety device, alarm indication and operation indication panels for water,
steam, oil, burner and pumps
• Water level control system for ON/OFF regulating
• Reset button and emergency stop
• Switches for fuel oil pumps for start, stop or stand-by mode
• Burner operation mode selector for automatic operation, emergency opera-
tion and burner off
• Burner modulation mode selector for automatic operation and emergency
operation
AALBORG SUNROD iitiHtt,

Page 1/1
ENG. Control System OMZ04#21.0
Control System
Safety Device
The system consists of two independent safety devices with the purpose of stopping
the burner and giving alarm if the water level is too low. Each safety device consists
of a self-monitoring level electrode (type NRG 16-1 IS) and a two charmel level
switch (type NRS 1 -7b). The self-monitoring design ensures that the bumer circuit
is interrupted in case of a failure of the electrode, the supply cables, Ihe level switch
or in the power supply.
The safety device system is connected to a timer which is set to a time-delay of
approximately 15 seconds to eliminate interference from splash, level fluctuations,
etc.
1.1 Level Electrode
The level electrode operates on the conductive measuring principle using the
electrical conductivity of the water for level signaling.
In normal operation the electrode tip is submerged in the water, and the imbalance
of the bridge circuit is positive. If the water level is below the electrode tip or in
case of a fault, the electrode produces a negative imbalance of the bridge circuit and
the safety device system cuts out the bumer.
The lengths of the electrodes are adjusted by the factory.
1.2 Level Switch
In normal operation two green LEDs indicate that the water level is above the
electrode tip. Too low water level, or malfunction of the system are indicated by
two red LEDs. The safety device is automatically reset when the electrode tip is
wet again. Only one red LED indicates a fault in one of the channels.
As the circuit of the relay contacts is normally closed, an alarm is also signalled in
the event of a power fault.
The level switch can be tested manually:
Test 1: By pushing the the button "Test 1" to simulate a defect in the
electrode.
Test 2: The test switch "Test 2/Inspection" is provided for checking the
function of the checking circuitry.
An illustration of the level switch can be seen in Figure 1.

< tiU- COU.o i.OlO

Level Switch Type NRS l-7b
GesTRn m
Test 11/ I
Inspection*
2min
I
Alarm
{ I
MIN
• Test!
¥
NRS 1-7 O
(§1
Figure 1 nrsl7.cdr

Control System
1 Water Level Control System

The system is provided with a level probe and two level switches. The purpose of
the system is to control the water level in the boiler and to give alarm for abnormal
water levels. An illustration of the system is shown in Figure 1.
The fiinctions are:
• High water level alarm
• Feed water pump stop
• Feed water pump start
• Feed water stand-by pump start and alarm
• Low water level alarm
Furthermore, it is possible to connect a level indicator and a too high water level
alarm.
The water level control system is connected to timers which are set to a time-delay
of approximately 15 seconds to eliminate interference from splash, level fluctua-
tions, etc.
Illustration of the Water Level Control System
Level Indicator
Too Hig^ m t e r Level Alaim
L e v e l ^ "^ •
switch , ^
type NRS 2 Start of Staad-By Feed Water Pump
Level probe - ^ H i g h s t e r Level Alarm

type ER 96 Level switah
type NRS;l
—«r»- - • Low Water Level Alann
r^~^ Feed Water Pump Stait/Stop
Feed pump
Figure 1 gwl.cd
AALBORG SUNROD îlllHi- Page 1/4

1.1 Level Probe (Type ER 96-2)
The capasitive level probe with protection tube is mounted on top of the boiler. The
level probe is used for on/off feed water control.
A high-frequency oscillator provided in the terminal box of the probe produces a
current flow between measuring tip and boiler wall. The current varies, i.e.
proportional to the level, and is rectified for transmission to the level switches. The
oscillator is fed from the level sv^tches.
1.2 Level Switch (Type NRS 2-b)
The level switch is mounted inside the control panel. The purpose ofthe level switch
is adjustment of the zero point and measuring range for the level probe. The switch
point "NW" is used for start of the stand-by feed water pump.
The switch point "HW" has differentfimctionsdepending on classification society.
Theftmctionsare:
• Too high water level alarm
• Too high water level alarm and stop of feed water pumps
• The switch point is disconnected
It is possible to connect a level indicator to the terminals for adjustment of the zero
point and the measuring range. The level switch type NRS 2-b is shown in Figure
2.
Level Switch Type NRS 2-b o u c,. coc, .0 ^ c 20
LED for Too High Water Level Alarm
Adjuster for Switch Point Too High

Water Level Alarm
. Adjuster for Measuring Range
(100%)
Adjuster for Zero Point
(0%)
Adjuster for Start Stand-By Pump
Stop screw
LED for Start Stand-By Pump
Figure 2 nrs2b.cdr

1.3 Level Switch (Type NRS 1-b)
The level switch is mounted inside the control panel. The purpose ofthe level switch
is to start and stop the feed water pump. The level switch is also used for high level
alarm and low level alarm. The level switch type NRS 1-b is shown in Figure 3.
Level Switch Type NRS 1-b ûu.

h'Go<~( • of.o-^
Figure 3 nrslb.cd
1.4 Commissioning
The best way to adjust the switch points is with the aid of the water level gauge
glasses and the boiler at service temperature. An ammeter can also be connected to
the terminals for the level indicator.
Loosen the stop screws of the adjusters before turning and tighten afterwards.
1.4.1 Adjustment of the Zero Point (Level Switch Type NRS 2-b)
The lowest possible zero point is pre-determined by the length of the level probe.
However, it is possible to adjust the zero point at a higher level with the aid of the
adjuster for 0%.
Fill the boiler to the level required as zero point. Set the adjuster "NW" to zero.
Turn the adjuster "0%" until the red LED 'TSIW" just Ughts up. The current output
is 0 mA.

1.4.2 Adjustment of the Measuring Range (Level Switch Type NRS 2-b)
Fill the boiler until the required max. water level is reached. Set the adjuster "HW"
to max. Tum the adjuster measuring range "100%" until the red LED "HW" just
lights up. The current output is 20 mA.
1.4.3 Adjustments of the Switch Points

The switch points can be adjusted by filling or lowering the water level until the
required level is reached. The actual adjuster is turned until the corresponding LED
Hghts up. The water level can be checked on the water level gauge glasses or
indicated on an ammeter.
The switch points for too high water level alarm and start stand-by pump can be
pre-adjusted as the graduations on the switch points are calibrated in %.
Low Level Alarm "NW" (Level Switch Type NRS 1-b)
Lower the water level until the required level is reached. Turn the adjuster NW
(NRS 1-b) until the red LED " N W just lights up.
Start Stand-By Pump "NW" (Level Switch Type NRS 2-b)
Fill the boiler until the required level is reached. Turn the adjuster NW (NRS 2-b)
until the red LED " N W just lights up.
Start Feed Water Pump "PUMPE" (Level Switch Type NRS 1-b)
Fill the boiler until the required level is reached. Set the adjuster HUB (NRS 1-b)
to max. and turn the adjuster PUMPE (NRS 1-b) until the red LED "PUMPE" just
hghts up.
Stop Feed Water Pump "HUB" (Level Switch Type NRS 1-b)
Fill the boiler until the required level is reached. Tum the adjuster HUB (NRS 1-b)
until the green LED "HUB" just hghts up.
ffigh Level Alarm "HW" (Level Switch Type NRS l b )
Fill the boiler until the required level is reached. Tum the adjuster HW (NRS 1-b)
untiltiiered LED "H W just lights up.
Too High Water Level Alarm "HW" (Level Switch Type NRS 2-b)
Fill the boiler until the required level is reached. Turn the adjuster HW (NRS 2-b)
until the red LED " H W just lights up.
1.5 Fault Finding
1.5.1 Level Probe

The correct operation of the level probe can be checked as follows:
Connect a voltmeter by means of the probe tip to terminal 1 and A. of the level probe
or to the corresponding terminals ofthe level switch type NRS 2-b. It should indicate
a voltage between 0.5 and 8.0 V.
The supply voltage ofthe level probe is 12 V and can be measured between terminals
3 and ± of the probe or between the corresponding terminals of the NRS 2-b.
1.5.2 Level Switches

If there are no switching functions and the current is zero, check the fuses located
on the side of the level switch boxes.
AALBORG SUNROD ^ Page 4/4

Control System
Burner Load Controller

The purpose of the burner load control system is to maintain normal working
pressure in the boiler regardless of the steam output. The system consists of a steam
pressure transmitter connected to a process controller. The output signal from the
steam pressure transmitter is sent to a process confroUer which controls the burner
load.
Furthermore, the steam pressure transmitter signals are used for low steam pressure
alarm and start/stop of the bumer.
1.1 Steam Pressure Transmitter
The steam pressure transmitter converts the actual steam pressure into a continuous
4-20 mA current output to be used in the process confroller.
Note: It is the operating range of the steam pressure transmitter which covers the 4
- 20 mA output signal.
1.2 Process Controller
The analog 4 - 2 0 mA output signal from the steam pressure transmitter is fed to
the process controller. The signal is compared to the setpoint in the process
controller. After processing the data signal is fed to the servo motor which drives
the compound mechanism of the bumer. This means that whenever the steam
pressure in the boiler changes, signals are sent to the servo motor which regulates
the oil/air flow.
If the signalfromthe steam pressure transmitter is above or below the setpoints for
operating the bumer, the process confroller starts or stops the bumer via the bumer
sequence confrol box.
If the steam pressure drops below the setpoint for low steam pressure alarm, the
process confroller activates an alarm in the alarm indication panel.
The chapter "Operating, configuring and parameterization ofthe process confroller"
describes the adjustment.

ENG. Control System OMZ04#60.Ö
Control System
1 Operating, Configuring and Parameterization

of the Process Controller
This chapter contains information about operating, monitoring, configuring, para-
meterization and electric connection of a process controller.
The process controller is a programmable controller with digital data processing.
An analog output signal from a transmitter is fed into the process controller and
compared to the adjustable setpoint in the process controller. After the data are
processed an electric signal is fed to an adjustable unit which controls a media
(water, air, fuel, etc.).
A number offiinctionsarefiledin the programme memory of the controller. These
functions are activated from the memory by structuring and parameterization.
The structuring or configuration of the process controller define the instrument
function and are factory set. The parameterization adjusted during cormnissioning
defines how the process runs, displays elements, limit values, etc.
A list of settings for the specific process controller can be found in a later chapter.
1.1 Operation and Monitoring
Illustration of a Process Controller
SIPART DR 19
17
16
15
14
13
12
11
10
- 9
SIEMENS SIPART DR19
Figure 1 sipartl9.cdr
AALBORG SUNROD iÜiüiit Page 1/12

The following numbers refer to the illustration shown in Figure 1:

1. Digital indicator "PV-X" for actual value x (pv)
2. Digital indicator "SP-W" for setpoint w (sp) or manipulated variable y (out),
other values are possible
3. Analog indicator for e (xd) or -e (xw). Other values can be displayed
3.1. Null indicator for w-x=0
4. "x" signal lamp - indicates the displayed values, see configuring switch S88
5. "w" signal lamp - lights up when w is displayed on the digital indicator SP-W
(2)
6. Switch-over button for digital indicator "SP-W" (2) and adjustment buttons (7)
and (8). Push button to acknowledgeflashingafter power restored or for accessing
selection level
7. Button to modify manipulated value - decrease (increase) or button "decrease
setpoint"
8. Button to modify manipulated value - increase (decrease) or button "decrease
setpoint"
9. Switch-over button for "Hand / Auto" or "enter" button for accessing the
selection level in the configuration level
10. Signal lamp for "y-extemal operation"
11. Signal lamp for "hand operation"
12. Signal lamps for the -y-digital outputs with S contioUer
13. Switch-over button for "intemal/extemal setpoint" or "Exit" button to return
from configuration and selection levels to the process contiol level
14. Signal lamp for "computer (with wext.) switched off"
15. Signal lamp for "intemal setpoint"
16. Signal lamp for "adaptation in progress"
17. Signal lamp for "limit value violated". Other signals are possible
1.1.1 Accessing the Levels

Configuration and parameterization are performed from the front panel of the
process confroUer. The function of thefrontpanel is first changedfromthe process
control level to the selection level. From this level the configuration level can be
selected. An illustration of the levels is shown in Figure 2.
AALBORG SUNROD if^î Page 2/12

Illustration of Process Controller Levels
Proces* eentroJ l«v«l

Display and input of:
• setpoint w
• manipulated variable y
• actual value x • etc.
(6)5sH <Ü H BMS)

Selection level
JfPSl "
JSJffi
onPA ] 1. h-!
tf i j- (7) (8)
w _J
«P 1
tn
(9) @D Configuring tevel

1> 1(13)
parametsr valua/ • K l S K l — .
conftguting switcri m H « g l | ^ ^
paiameter nam« /
configuring fiwtch (6) (7) (8)
adjustabt« panat
flashing
Figure 2 tabel3.cdr
1.2 On-line Parameters (onPA)
Parameters that determine how the process runs and can be modified during
unrestricted controller operation (on-line). See Table 1.
1.2.1 Accessing the onPA List

• Press button (6) for about 5 sec. until "PS" flashes. Release the button
and "onPA" (selection level) is displayed. It is blocked if digital signal
BLPS=1.
• Press button (9) once, the digital indicator SP-W (2) flashes (configura-
tion level).
1.2.2 Selecting and Modifying Parameters

• Use buttons (7) or (8) to select parameter names from SP-W (2) digital
indicator.
• Press button (6) once, the indicator PV-X (1) flashes and the input field
is switched over.
• Use buttons (7) or (8) to modify the parameter value in the PV-X (1) in-
dicator.
• Press button (6) once, the indicator SP-W (2) flashes and the input field
is switched back.
• Repeat these steps until all desired parameters are set.
1.2.3 Exit to Process Control Level

• Press button (13) twice (selection level and process control level).

onPA - on-line Parameters

Parameter Parameter Factory
Min. Max. Eng. Unit
Name Setting
Filter time constant for xdfilter(adaptive) tF off/1.000 1000 1.000 s
Derivative action gain Vv uu 0.100 10.00 5.000 1
Proportional gain Kp cP 0.100 100.0 0.100 1
Integral action time Tn m 1.000 9984 9984 s
Derivative action time Tv tu ofB'1.000 2992 off s
Response threshold AH 0.0 10.0 0.0 %
Working point YO Auto/0.0 100.0 Auto %
Safety setpoint 1 SHI -10.0 110.0 0.0 %
Safety setpoint 2 SH2 -10.0 110.0 0.0 %
Start of manip. variable scale (YA<YE) YA -10.0 110.0 -5.0 %
Full scale of manip. variable YE -10.0 110.0 105.0 %
Heating period / y positioning time open tp offO.lOO 1000 1.000 s
Cooling period / y positioning time closed tM off/0.100 1000 1.000 s
Actuating pulse interval tA 20 600 (9980 if 200 ms
S2=0orl)
Length of actuating pulse tE 20 600 (9980 if 200 ms
S2=0orl)
Filter time AEl tl offi'O.lOO 1000 1.000 s
Filter time AE 2 t2 off/0.100 1000 1.000 s
Filter time AE 3 t3 ofCO.lOO 1000 1.000 s
Constant c 1 cl -1.999 9.999 0.000
Constant c2 c2 -1.999 9.999 0.000
Constant c3 c3 -1.999 9.999 0.000
Constant c4 c4 -1.999 9.999 1.000
Constant c5 c5 -1.999 9.999 0.000
Constant c6 c6 -9.99 9.99 0.00
Constant c7 c7 +1.000 9.999 1.000
Display refresh rate dr 0.100 9.900 1.000 s
Table 1
1.3 Off-line Parameters (oFPA)
Parameters determining basic functions such as display elements, limit values,

safety values, etc. See Table 2.
1.3.1 Accessing the oFFA List

• Press button (6) for about 5 sec. until "PS" flashes. Release the button,
and "onP A" (selection level) is displayed. It is blocked if digital signal
BLPS=1.
• Press button (8) several times until "oFPA" is displayed (selection
level). It is blocked if digital signal BLS=1.

• Press button (9) for about 3 sec. until digital indicator SP-W (2) flashes
(configuring level). The controller is now blocked, and the last value of
y is retained.
1.3.2 Selection and Modification of Parameters

indicator.
• Press button (6) once, the indicator PV-X (1) flashes and adjustment but-
tons (7) and (8) operate on PV-X (1).
dicator.
• Press button (6) once, the indicator SP-W (2) flashes, and the input field
is switched back.

oFP A - nft-lmc Parameters

Parameter Min. Max.
Parameter Name Factory Setting Eng Unit
Decimal point, x- and w- indicator dP .- -
Scale start value dA -1999 9999 0.0
Full scale value dE -1999 9999 100.0
Alarm 1 Al 5.0
Alarm2(A2<Al) A2 -110% to 110% of dA, dE with -5.0
Alarms A3 S76/S77-0/2/3/4/5 5.0
Alarm 4 (A3<A4) A4 -5.0
Alarm hysteresis HA 0.1 10.0 1.0 %
Setpoint start of scale SA -10%tollO%ofdA,dE -5.0
Setpoint full scale SE 105.0
Setpoint ramp time tS oFF/0.100 9984 OFF min
Ratio factor-start vA 0.000 9.999 0.000 1
Ratio factor - end vE 0.000 9.999 1.000 1
Safety manipulated value YS -10.0 110.0 0.0 %
Split range left (Y1<Y2) Yl 0.0 100.0 50.0 %
Split range right Y2 0.0 100.0 50.0 %
L-1 -10.0 110.0 -10.0 %
LO -10.0 110.0 0.0 %
Linearizar output value L-1 (-10%) to L11 LI -10.0 110.0 10.0 %
(110%) are equidistant input vertices. If L2 -10.0 110.0 20.0 %
S21 =4, the values are standardized on dA
L3 -10.0 110.0 30.0 %
todE fi
etc. (( etc. "
up to (( )» up to "
Lll -10.0 110.0 110.0 %
Table 2

1.4 Configuring Switches (StrS)
Switches that define how the instrument is configured. See the tables in Figure 3 ,
Figure 4 , Figure 5 , Figure 6 and Figure 7.
1.4.1 Accessing the StrS List

• Press button (6) for about 5 sec. until "PS" flashes. Release the button,
and "onPA" (selection level) is displayed. It is blocked if digital signal
BLPS-1.
• Press button (8) several times until "StrS" is displayed (selection level).
It is blocked if digital signal BLS=1.
• Press button (9) for about 3 sec. until digital indicator SP-W (2) flashes
(configuring level). The controller is now blocked, and the last value of
y is retained.
1.4.2 Select and Modify Configuring Switches

indicator.
• Press button (6) once, the indicator PV-X (1) flashes and adjustments
buttons (7) and (8) operate on PV-X (1).
dicator.
• Press button (6) once, the indicator SP-W (2) flashes, and the input field
is switched back.

Table of StrS - Configuring Switches
Contlg. Sett-
swttcn ing Function
SI Controlier type
Fixed selpoint/three-component controller/
controller with 2 internal setpoints
1 Fixed setpointrthree-component controller witti 5 internal
setpoints
2 Slave / synchro / SPC controller
3 Ratio controller
vt 4 Control station / process variable indicator
c 5
Program controller (only types 6OR1902-, 6DR1905-)
S2 Output structure
(01 K output
1 S output: Two-step controller with 2 outputs
m heating / cooling
2 S output Three-step controller (or motorized drives,
internal feedback
3 S output: Three-step controller for motorized drives,
external feedback
S3 IMalns frequency supprsssion
(0, SO Hz
60 Hz
Figure 3 TableCSLcdr

Table of StrS - Configuring Switches (Continued)
Conflg. Sett- Sett-

switches ing
S4
Function
SUndard Input A E I (1, mV, R, P, T) -
Transmitter fault signal
a S11
ing Function
Thermocouple type AE3 (slot 2) with UNI module
(only effective if S10=l/2)
(0, UNI input AEI min.on sensor breakage, without MUF fOl TypeL
UNI input AEI min. on sensor breakage, with 1 Type J
2 UNI input .AE1 sensor breakage, without
mF
MUF 2 TypeK
3 UNI input AEI max.on sensor breakage, with 3 Types
MUF
4 TypeB
S5 Input signal AEI
101 mV (linear), wHh range plug 1 [mA] or U [V] 5 TypeR
Thermocouple with intemalrelerence junctkin 6 TypeE
2 Thermocouple with external reference junction 7 TypeN
8 TypeT
3 PT100 4-wire connection 9 TypeU
4 PT100 3-wire connection 10 Any lype (without linearization)
5
6
PT100 2-wire connection
Resistance transmitter with
Resistance transmitter with 500 Q ^
R < 600O
R <: 2,8kn
1
.2
Take square root of A E I to AE3
no yes
7
S12 AEI (01 1
S6 Thermocouple type A E I (only effective wlien SS=1/2) St3 AE2 (01 1
foi TypeL
i^ S14 AE3 (01 1
Type J Allocation of x 1 , x2, x3, yN, yR, z to AEI A to AE3A
2 TypeK
3 Types 0% AE1A AE2A AE3A
4 TypeB S15 Xl 0 (11 2 3
St 6 x2 0 1 (21 3
5 TypeR SI 7 x3/we 0 1 2 (31
6 TypeE
7 TypeN Sie yN [°i 1 2 , 3
8 TypeT S19 yH |u| 11 2 3
9 TypeU . S20 z (01 2 3
10 Any type (without linearization)
» S21 Allocation of linearizer (see oFPA) to
3 S7 Temperature unit AEI and AE3 with UNI-module none
a (only effective wtten S5 or S10=1/2/3/4/S)
(01
c
O) [01 Degrees Celsius AEI
o 1 Degrees Fahrenheit 2
n 2 Degrees Kelvin AE2
c 3
< S8 Input signal AE2 (slot 2) and AE3
transmitter fault signal . 4
[0] 1 [0...20 mA) or U,R,P,T without MUF xl
1 1 (0...20 mA] or U,R,P,T with MUF
MUF
522 Configuration ot slot 3
2 1 i4...20 mA) or U without
3 1 i4...20 mA) or U with MUF cry [0] nothing installed
Ö 1 4 B A / Z B E (BA3 - BA6 / BE3, BE4 )
S9 Input signal AE3 (slot 1) and S 4 BA / 1 BE (BA3 - BA6 / BE3, BE4=0)
transmitter fault signal 2 5 BE (BE3 - BE7 )
[01 1 (0...20 mA] or U,R,P,T without MUF 3 2 relays (BA3, BA4)
1 1 [0...20 mA) or U,R.P,T with MUF
Allocation ol control signals to digital inputs
2 1 (4...20 mA] Of U without MUF
3 1 (4...20 mA] Of U with MUF Basic unit Slots
Low BEI BE2 BE3 BE4 BES BE6 BE7 High
4 UNI module min.on sensor breakage, without MUF
MUF
323 CB 0 2 3 4 5 6 7 (8)
5 UNI module max.on sensor breakage, without
6 UNI module min.on sensor breakage, with MUF S24 He (01 2 3 4 5 6 7 .
UNI module max.on sensor breakage, with MUF 0
7 ^ S25 N (11 2 3 4 5 E 7 .
S10 Input signal AE3 (slot 1) with UNt module ^ 326 Si 0 [2] 3 4 5 6 7 -
(only ettective when 89=4/5/6/7) 15 S27 P (01 2 3 4 5 6 7 8
[0] U [mV] Oinear), with range plug 1 (mA] or U [V] % 328 ts [01 2 3 4 5 6 7
1 Thermocouple with internal reference junction 5 S29 + yBL (01 2 3 4 5 6 7
2 Thermocouple with external reference junction 330 • yBL 10] 2 3 4 5 6 7
3 FT too 4-wire connection S31 BLB (01 2 3 4 5 6 7 -
4 PT100 3-wire connection 332 BLS (01 2 3 4 5 6 7
5 PT100 2-wife connection 333 BLPS 101 2 3 4 5 6 7 -
S34 PU 10) 2 3 4 5 6 7 -
6 Resistance transmitter with R < 600O
7 Resistance transmitter with 500 n < R < 2,8kfi
Figure 4 TableCS2.cdr

Conflg. Sett- Sett-

switch ing
Control Signal logic
Function
24V = Hiqli OV = Hiqh

a S53
ing
(01
Function
ly shutdown In tracking mode (K controller only)
without
ii
S35 CB 10] with
S36 He (0) S54 Uniiting ol manipulated variable YA / YE
S37 N [Ol
10] only eitecUve in automatic mode
S38 Si 101 1 effective in all modes
S39 P 101
S40 ts S55 Manipulated variable disptay
10]
S41 +/-yBl. 10] 10) contraller output y
i? 1 posUnn feedback yR
S42 Control Signal CB 2 spin range y 1 ^ , with two-point conln)ller heating/cooling
sialic, no acknowledgement
& 3 no display
5
static witti acknowleêmenl
dynamic as pulse (fllp-llop effect) > 856 Direction of action ot manipulated variable display yAn
fO] nonnal; yAn = y
S43 Blocking of Internal / external setpoint swltctiover 1 reversed: yAn = 100%-y
internal only
external only S57 Allocation of controller variables to analog output
no blocking |0) y Olo20mA
n 1 y 4 to 20 mA
S44 x-tracking with H or N or SI
2 w 0 to20 mA
9-
no 3 w 4to20mA
yes g 4 X 0 to 20 mA
01
S4S Selpoint following CB-failure ^ 5 X 4 to 20 mA
6 xl 0to20niA
lastwi = 7 xl 4to20mA '
safety setpoint SH1
8 xd + 5fl% Oto20mA
S46 Tracking of wi or SH1/SH2/SH3/SH4 to actual setpoint w 9 xd + 50% 4lo20mA
SHItoSH4 S58 Allocation -fZ-Ay
yes no BA1 BA2 BA7 (relay) BA8 (relay)
no no +Ay -Ay
yes yes (no H SI=1) (01
1 +Äy
- -Ay
S47 Direction ol action in relatkm to xd (w - x) 2 -Ay +Ay
3 +4y -Ay
normal (Kp > 0)
reversed (Kp<0) Nole:
• 858 has priority over S59 to 875;
S48 Connection of 0 elemenl
xd Allocation of signals to binary outputs
X Basic unit Skits Basic unit
Xl none BA1 BA? BA3 BA4 BA5 BA6 BA7 BAe
z direction of action against X (conn, to manip. var. y) (relay) (relay)
z directkin ol action with x (conn, to manip. var. y)
» S59 RB [0] 2 3 4 5 6 7 8
S49 Choice of adaption
no adaptation
Å S60 RC (01 2 3 4 5 6 7 8
6 7
control response without overshoot = set
S62
H
1^
|01 2
2
3
3
4
4
5
5 6 7
8
8
10)
ConlfSol response with overshoot based on absolute value m
optimization 0 J1] 7
S50 Priority N or H i
n
S63
SB4
S65
At
A2
A3
0
(01
2
(21
2
3
3
3
4
4
4
5
5
5
6
e
6
7
7
8
8
8
N S66 A4 (01 2 3 4 5 6 7 8
H
867 MUF (01 2 3 4 5 6 7 8
S51 Manual mode In case ot transmitter fault S68 t4w (0] 2 3 4 5 6 7 8
no switchover (display only) 369 •ÄW (01 2 3 4 5 6 7 8
manual mode beginning wrth most recent y
manual mode beginning with ys Notes:
• l( BA1/2 or BA7/8 have been allocated +/-Äy by 857.
S52 Blocking of manual / auto switchover duplicated alkxalion is not possible.
nobkicking • Alkication of vahous control signals to a digital output
automatic mode only effects an OR lunction!
manual mode internal only
AALBORG SUNROD iiiiiiiii Page 8/12

Conflg. Sett- Cenflg. Sett-

swHc
lehr ing Function switch ing Function
Time bus / status signals Sequence on Indicators PV-X (1) and SP-W (2)
Allocation of digital signals of thr program controller t o 388 « SlaO/Kflxed value! or S1=2 (slave controller)
digital outputs mil Sequence on indicator SP-W Indicator P V X
Basic unü Slot 3 Basic unit st=o
(relay) (relay)
keine BAI BA2 BA3 BA4 BA5 BA6 BA7 BA8 1 1 II 111 IV
S70 CLbl 0 1 2 3 4 5 6 7 2 fO) w y . . X
S71 CLb2 0 1 2 3 4 5 6 7 1 v»/wi '1 y we/wi" X
S72 2 w y - XI X
S73
CLb3
CLb4
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7 3 w/wi '1 y w e / v-i f i « x1 X
S74 0 0 0 0.5 Signal lamp x
S75 CLb5 0 1 2 3 4 5 6 7
CLbS 0 1 2 3 4 5 6 7 1 0 0.5 0 Signal lamp w
Note: 1 = continuous, 0.5 = flashing, 0 = off
n BA1/2 or BMm have been allocated W-Äy by S58. Notes:
duplicated aBocaHon is not possible i| effective wi
Logic of BA on allocated control signals ^1 ineffective wl for fixed value controller with two or five
24V = High OV = High setpoints
• By using S87, the display sequence can be extended by A l
S76 RB (01 to A4.
S77 RC 01
S78 588 Sequence on indicators PV-X (1) and SP-W (2)
H 0| lfS1=3
S79 Nw
S80 A1/A2
o|
0|
mil Sequence on indjcator
S81 Sl=3 SP-W IndkatorPV-X
A3/A4 01
582 1 II III IV 1 II III IV
MUF (0) > t
(01 wv Y - XV XV
- -
Allocation of A1/A2 and A3/A4 to process variables 1 wv Y w'l XV" XV X II
xd x1 X w XV Y»v y y1 y21AEI*E|AElAElAE|AE in 2 wv V -
wve XV XV - XV
' 1 2 f 3 |1A|2A|3A X
3 wv y wve w ' l XV XV XV - X ' )
S83 A1/A2 (01 I 2 3 4 S l 6 | 7 1 8 9 10 11 12 13 14 n n 0 1 0 0 0 1 LEDx
S84 A3/A4 [0] 1 .2 3 4 5 fi 7 8 9 1 0 | l l | l 2 | l 3 14 1 0 0.5 1 1 0 0.5 1 LEDw
1 = continuous, 0,5 = (lashing, 0 = 0«
S85 Function of limit monitor A1/A2
Notes:
A I max / A2 min li Display in xxx.x %
A I min / A2 min • By using 887, the display sequence can be extended by A1
A I max / A2 max
to A4.
SB6 Function of limit monitor A3/A4 SS8 Sequence on indicators PV-X (1) and SP-W (2)
A3 max / A4 min if S I =4
A3 min / A4 min mil Sequence on Indicator
A3 max / A4 max St=4 indicator SP-W PV-X
S87 and setting of limit values A I toA4 In the process 1 II III 1 bis III Identilicalion ot clisplaysd value
control level 101 w V Xl Setpoint Qtrwator + control MB.
1 w y we X l Setpotnt øanaralor 4. cootrat sta.
lr>d)cator on Parameteil Signallina of violated limit values 2<hann«l pracass indicaur (r^tysical)
2 w» xl
SP-W(21 'I adjustable via L1 to L4 'I
3 V" - xl 2<tiannet pracass mdcator (x1 „ ^ v y 'n %}
no A1/A2/A3/A4 4 - - 31 -
-3) xl Process rduplsy with alarm iraenl.
no no A3/A4 (for S I « 5)
no (for SI = 1 or 5) 0 0 0 Signal lamp X
no 1 0 0.5 signal larnp w
A3/A4 no A3/A4(forS1=5)
A1/A2/A3/A4 1 = continuous, 0.5 = flashing, 0 = off
A1/A2/A3/A4 yes A3/A4 (lor S1 = 5)
A3'A4 Notes:
yes A1/A2/Aä'A4
A1/A2/A3/A4 ') i n XXX.X %
^) Signal lamp w off
• In switch positions 1,2,3 and 5 the lamps L I and 12 are n Signal lamp w oil:
Iree lor signalling of program 1 or 2 running Inifcatar SP-W blank (Iree for limit value display)
1) In this case the parameier names are Indicated with the
• By using S87, the display sequence can be extended by A l
frequency 0.5 l)y the lamps L I to L4. to A4.
By pointed and adressed limit value the deflned signal LED
Mashes vnlh the frequency 0,9.

Sett- Conflg. Sett-
a SB8
mit
ing Function
Seauence on indicators PV-X (11 and SP-W (2) if S I =5
Sequence on
switch ing
S92 Serial interface (slot 4)
101 without
Function
S(=5 fldicator SP-W Indicator PV X Analog indicator '> 1 with

1 II III IV 1 II III IV 1 1 II 1 III IV
S93 Data transmission
(0) w y - - X X X
- Precess value. -
1 w y xl ' X X X
" satv)ithS89
. [0] nothing
2 w y X X X Cufrent interval
3 w y xl X X X
- -
1 4
5
6
7
w
w
w
w
y
y
wpz
xl wpz
X
X
X
X
X
X
Time lefl in interval
Process value.
set wit) 389
Current Interva
parameters, conligurations
CB = CB(ES)orC8(BE>
5 - - wpz
x-LED 0 0 0.5 0.5 |0.5 10.5
w-LEC 1 0 0 0.5 |0.5 parameters, configurations, process values '
lo.s status register
• 1 = continuous, 0.5 = Hashing, 0 = o((
• wpz: target setpoini of current interval CB = CB (ES) und CB (BE)
• By using S87, the display sequence can be extended by AI
to A4. parameters, configurations, process values '
status register
S89 Analog Indicator (3) - allocation ot controlled variable
101 e (xd) +/• 5% bar graph Sending the controller values is possible in all
3 1 e xd) +/-10% conligurations
2 e(xd) +/-20% S94 Data transmission rate
, 3 -e(xw)+/- 5% 9600Bit/s
•o 4 -e(xw)+/-10% 4800 BIt/s
5 -e (xw) +/- 20% 2400 Bit/s
6 xl 0 to 100% Illuminated moving mark 1200Btt/s
7 x2 ' • 600 Bit/s
e
9
X
we "
300Bil/s
10 w S95 Vertical parity
11 y even
S90 Restart following return of power odd
10) last mode ot operation, last w, last y, program controller: S96 Longitudinal parity position
time is stored none
Program continues seamlessly with the stored values, if after ETX
operating conditions permit. before ETX
n
^n
1 Manual and internal mode, last w. program controller: start
position (reset state) S97 Longitudirtal parity
-. VS with K controller, last y with S controller normal
inverted
S91 Optical signalling following return of power
(Ol without PV-X- and SP-W indicators flashing 898 Station numtier
. J 1 with PV-X- and SP-W indicators flashing 0
to
31
S99 Time monitoring CB (ES)
[01 OFF
Ito Is to
25 25 s

1.5 Operating and Error Messages
The following operating and error messages can be displayed on the PV-X (1)
digital indicator as shown in Figure 8.
List of Error Messages
i.iolFlL: Value too large/small for

indicator.
! .I.JMJ Analog signal monitoring, e.g.
input 3 (character in 3rd digit
position) tripped.
CPU monitoring following power
ifcrEisffci up
lOPruls! CPU defective.

inlElnrsi EEPROM defective.
UNI signal conditioning module
joipjrj (optional) in slot 1 not installed.
brRTJi Signal conditioning module
(optional) in slot 3 not installed.
Figure 8 Tabel2.cdr
AALBORG SÜNROD iaii% Page 11/12

1.6 Electric Connections
The diagram Figure 9 shows the electric connections of the basic process controller.
Block Diagram
TCim»ma( 6OR1901 SScontrofléf
60ft2K05-aA
Basic (M)-N
setbngs
U, L-\ -^r Analog inputs

S4I0S21
Configuration o(
3lo(3 S22
SJ 34l-f Digitll inputs
i-i 21 — S23toS41
S«1poin( tnckirtg
U'r, æ ^rOH •
5t S42IOS46
Comrol algcxithin
3 4 7 1 0 349
YswÄcftOver
SS0toSS4
Yindic«tor
UNI _^^*ati ssstoSse

Anaicg output
10... sr
U S ^ S57
SMrtKfMig outputs
sss
24y OiQital output»
S59k>S82
IjRKt monitors
ai\ S^ 5 — 563(0 307
Ht* indicator
s-VTvh SS8toS89
Æ r\
Restart
cor^tior>s
S90toS31
Sønal tniBriac«
S33IOS99
1—s:i L ! — r ^ - * 24 V
UH'— . • 5V
•Uittt
f^
Æ
Figure 9 Blokdial.cdr

Control System
1 Burner Sequence Control

The burner sequence controller L0K16 is placed inside the control panel. The
function of the LOK 16 is to control the start of the burner in a pre-fixed start-up
sequence in automatic operation. A motor driven cam shafl activates electric
switches which control servo motor, bumer motor, ignition and solenoid valves.
In normal operation LOK 16 controls the flame supervision circuit. The system is
self-checking. However, the LOK 16 has no function when running the bumer in
manual mode.
In the event of fault, the supply of fuel is instantaneously interrupted and the
sequence controller switch stops. The lock-out indication shows where the fault has
occurred in the sequence.
•^ : No start
A : Abortion of start-up sequence
• : Abortion of start-up sequence
• : Lock-out (fault in the flame supervision circuit)
1 : Lock-out (no flame)
2 : Lock-out (no flame)
P : Lock-out (no air pressure)
The bumer sequence controller can be reset by pushing the lock-out indication
window.

Control System
Flame Safeguard
Theflamesafeguard LAEIO is placed inside the control panel. The function of the
LAEIO is supervision of the oilflamewhen the bumer is running in manual mode.
However, the LAE10 has no function when running the bumer in automatic mode.
In the event of fault, the supply of fuel is instantaneously interrupted. The unit can
be reset by pushing the reset button on the flame safeguard.
AALBORG SUNROD tfljpi Page 1/1

ENG. Control System OM01Z04#80.0
Control System
1 Alarm and Operation Indication Panels

The alarm and operation indication panels with individual light indicators are
installed on thefrontpanel. Each channel is equipped with its own LED for alarm
or indication with individual pre-set time delay. Any alarm will effect a group alarm
that is connected to the engine room control system. The unit can be tested by
pushing the alarm test, and the LED by pushing lamp test.
AALBORG SUNROD iiUütii Page 1/1

01
AALBORG SUNROD
Table Of Contents
Water Level Gauge

Mounting on Boiler 1
Maintenance and Service Instructions 2
AALBORG SUNROD
ENG. Water Level Gauge K.7461.1
Water Level Gauge
Mounting on Boiler
This section describes how to mount the water level gauge on the boiler side.
Water level gauge on boiler side
1 -Nut
2 - Box heads
3 - Joint rings
4 - Box heads
5 - Tubes
6 - Screws
7 - Screws
8 - Cock plug
D - Drain cocks
G - Gauge body
S - Cocks
W - Cocks
Figure 1 kli Ole.cdr
Remove nuts (1) and lift off stuffing box head (2) from cock.
Insert gaskets between cock flanges and boiler flanges and bolt up
the cocks S and W on to the boiler flanges.
Place the stuffing box heads (4) on the end tubes (5) - insert joint rings
(3) in the recess of each cock.
AALBORG SUNRÖD duuiii Page 1/5

Press the stuffing box heads (4) together with the gauge body (G) on
the gauge cocks S and W.
Tighten units (1) to form a pressure tight seal.
B l Turn the gauge body (G) to the required position and tighten the union
nuts (4).
WjM Open the cocks.
Maintenance and Service Instructions

2.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure
I.
When out of service with the gauge body in cool and unpressurized condition the
hexagon screws (6) can be retightened.
Start at the centre, working to opposite sides altematety. Max torque: 60 Nm
in cold and under working conditions.
2.1.1 Maintenance During Service Check-up

n Tighten the nuts (1).
Bolts on boiler flanges.
Union nuts (4).
Boltform screws (7) with cocks in open positions.
If a leak cannot be stopped by tightening the bottom screws (7), the sealing surface
of the cock plug (8) may be damaged or corroded. It can also be necessary to change
the packing (3).
2.2 Blowing Down.
The item nos. mentioned in this following blowing down procedures refer to Figure
1.
The gauge should be blown down before lighting up the boiler and just be-
fore closing down the boiler.
2.2.1 Cleaning the Water Side:

• J Shut the cock S and open the cock W.
N Open the drain cock D for a short time. This sucks the water out of
the glass without, however, totally unpressurizing the gauge body.
K | Shut the cock D and then water is forced upwards into the glass again.
m Repeat this procedure several times, opening and shutting the cock
D. The water level in glass rises and falls.
AALBORG SUNROD Jjjj. Page 2/5

2.2.2 Cleaning the Steam Side.

g Shut the cock W.
Open the cock S.
Blow through the steam side and gauge body by opening the drain
cock D for 1-2 seconds.
A steam blowing of longer duration is not advisable considering the
service life of glass.
Turn the cocks to operating position.
2.3 Dismantling.
The following dismantling instructions refer to Figure 1 and Figure 2.
6 - Screws
9 - Wedge piece
10 - Centre piece
11 - Reflex
12 - Sealing gasket
13 - Cushion gasket
14 - Cover plate
Figure 2 kli 05e.cdr
Sectional view of the water level gauge
Shut the cocks S and W.

The drain cock D to be opened until the glass is completely emptied.
Remove nuts (1) and lift off stuffing box heads (2) together with the
gauge body from the cocks S and W.
Slacken the union nuts (4) and pull off the stuffing box head (2).
Place the gauge body (G) horizontally with the screws (6) turning up-
wards and loosen the screws.
Move the wedge piece (9) lengthwise and lift upwards.
Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
AALBORG SUNROD oiUlii» Page 3/5

^ Clean sealing surface of cover plate (14) and centre piece (10) and
examine for through going scars.
2.4 Assembling
The following assembling instructions refer to Figure 2.

Insert following items into the centre piece (10): sealing gasket (12)
reflex glass (11) cushion gasket (13).
Place cover plate (14) on top.
Insert wedge piece (9) and move lengthwise forcorrect position.
Tighten screws (6) evenly starting at the centre, working to opposite
alternately. Max torque: 60 Nm in cold and under working conditions.
2.5 Maintenance of the Straight-through Cock.
2.5.1 Operation Principle and Maintenance.

The following assembling instructions refer to Figure 3.
15 - Screw
16 - Split ring
17 - Packing sleeve
18-Plug
19 - Bottom screw
Figure 3 kli 06e.cdr
Detail drawing of the straight - through cock
The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be fiuther compressed
by tightening the bottom screw (19) until the leakage is stopped. This must only be
done with the cock in open position.
2.5.2 Dismantling.
Remove bottom screw (19).
A A L B O R G SUNROD iÜüiÜt Page 4/5

Remove screw (15), washer and handle. ^

Knock the plug (18) together with split ring (16) and packing sleeve
(3) out of the cock body by means of a soft mandrel.
Remove split ring and knock plug out of the packing sleeve.
Clean all sealing surfaces carefully and lubricate threads with a high
temperature grease before installation.
2.5.3 Assembly.
n Place the split ring (16) in the recess of the plug (18).
Push new packing sleeve onto plug.
Press the complete unit into cock body.
Note: Turn the packing sleeve until the ridge fits with the groove in the cock body.
The eyelets of the packing sleeve must neither protrude nor be tilted.
Screw in bottom screw (19).

Place the handle and washer on the plug and fit screw (15).
Tighten the bottom screw(19) and check if the plug is turnable.
AALBORG SUNROD «iiiJIib Page 5/5

O)
éJHItiii
AALBORG SUNROD
Table Of Contents
Safety Valves
General 1
Maintenance and Start-up of Boiler 2
Adjustment and Dismantling 3
AALBORG SUNROD
ENG. Safety Valves OM4000.0i
Safety Valves
General
In the following the measures required to achieve a safe and reUable maintenance
of the safety valves will be described, together with adjustment and dismantling
instructions.
An example of an installation of the safety valve is shown on Figure 1.
Mounting of safety valves, example
Drip pan
Drain
Figure 1 safe Olaxdr
Maintenance and Start-up of Boiler

A regular inspection of the safety valve is recomended at least once a year. Some
media and appliances require a more frequent inspection, this is according to the
experience of the appher.
Warning! Before handling and dismantling of the safety valve ensure that the system is
NOT pressurized!
Before lighting-up the boiler the pipe connections must be thoroughly cleaned for
dirt and foreign bodies.
AALBORG SUNROD <üiüii> Page 1/4

ENG. Safety Valves OM4000.0
If the valve is not completely tight, which often happens after starting up the plant,
this is usually caused by impurities between the seat and the cone. In order to remove
these impurities the valve must be heavily blown out by means of the lifting device.
If the valve is not tight after several blowings, it may be due to the fact that a hard
foreign body has got stuck between the cone and the seat, and it will then be
necessary to dismount the valve for overhaul.
Warning: In case of a leaking safety valve the valve must be inspected and over-hauled
at earUest possible opportunity. It must be ensured that the boiler is totally
unpressurized before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facihtate the adjust-
ment later when the valve is to be adjusted when in service.
If the facings between the cone and the seat have been damaged, they must be
grinded.
MM The cone can be grinded against a cast iron plate, using a fme
grained carborundom stirred in kerosene.
The seat in the valve body can be grinded in the same way by using a
cast iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against turning as the
seat and the cone may thus be damaged.
M Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
When the valve has been mounted the boiler is commissioned, and the valve is then
checked for leakages and adjusted to the set pressure.
E l The adjustment screw is secured by means of its lock nut, and the
valve is sealed.
2.1 Routine Check
The following should be regarded as recommendations of routine checks on the

safety valves, in order to keep a proper fiinctioning.
2.1.1 Yearly
The safety valve should be tested in operation by raising the boiler pressure.
AALBORG SUNROD iiäUiit Page 2/4

ENG. Safety Valves OM4000.0|
Expansion and exhaust pipe should be examined at the same time.
2.1.2 Monthly
Examine the safety valves for any leaking, such as:

• Is water seeping from the drain plug at the valve body?
• Is the escape pipe hot due to seeping steam from the valve seat?
Examine the drain and expansion device at the escape pipe.
Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Adjustment and Dismantling

Safety valves are delivered with the required spring setting and sealed against
unautherized adjustment.
Adjustments are only allowed in the spring margins. Outside the margin a new
spring is required. The pressure in a system should not exceed 90% of the set
pressure.
All item nos. mentioned in the following sections refer to Figure 2.
3.1 Dismantling of Lifting Device
Safety valve with open cap

Q Remove bolt(39)
Remove lift lever (41)
3.2 Set Pressure Change without Spring Change
Note: Pay attention to spring range
Spindle (14) must be held fast by all alterations

Loosen lock nut (21)
Turn the adjusting screw (17) clockwise for higher and anticlockwise
for low set pressures
Secure the new setting with the lock nut (21)
Reassemble lifting device
3.3 Spring Change
• • Spindle (14) must be held fast by all alterations

Remove pin (16) from spindle cap (39)
AALBORG SUNROD Jjjii. Page 3/4

ENG. Safety Valves OM4000.0
Loosen lock nut (21) and turn adjusting screw (17) anticlockwise,
then the spring (37) is not under tension
Loosen the nuts (8) and remove the bonnet (42)
Remove the upper spring plate (26) and spring (37)
Remove the spindle (14) with disc (12), guide plate (4) and lower
spring plate (26)
Clean the seat (2) and disc (12)
Remount the spindle unit with the new spring and upper spring plate
Assemble bonnet (42) and adjust to the spring range
Secure the spring setting through the lock nut (21)
ny Remount lifting device
HI
Assembling drawing of safety valve
47 Ball 39,40
42 Bonnet
41 Lifting lever
40 Split pin
39 Bolt
38 Screw
37 Spring
29 Cap
27 Gasket
26 Springplate
23 Lead seal
22 Drain screw
21 Lock nut
18 Ball
17 Adjusting screw
16 Slotted pin
15 Gasket
14 Spindle
13 Lift aid
12 Disc
10/25 Split cotters
9 Lift limitation ring
8 Hex. nut
7 Gasket
4 Spindle guide
3 Stud
2 Seat
1 Bodv
Figure 2 safe 03axdr
AALBORG SUNROD iiUüÜt Page 4/4

o @ ® • • 9 o
AALBORG SUNROD
Table Of Contents
Feed and Boiler Water
General 1
Feed and Boiler Water Characteristics 2
Feed and Boiler Water Maintenance 3
AALBORG SUNROD
ENG. Feed and Boiler Water
1. Feed and Boiler Water
1.1 General
Important: These recommended feed and boiler water characteristics are only valid for
boilers with a working pressure below 20 barg.
The following text regarding feed and boiler water treatment is the normal recom-
mendations provided by Aalborg Sunrod. 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.
Boiler and feed water should be chemically treated in order to avoid corrosion and
scaling m the boiler.
In most vessels make-up / feed water is distilled by an evaporator, and the distillate
is generally very good make-up water. Other methods to produce make-up water,
e.g. reverse osmosis plants or ion exchange plants, are also possible good distillate
producers. The important thing is that the distillate used should be clean and without
foreign salt contaminations.
In practice most distillate used contains minor parts of various salt combinations,
which can be chemically treated away.
Further, the distillate may contain dissolved gases like for example oxygen (O2)
and carbondioxid (CO2), which may lead to corrosion in the boiler, steam and
condensate system.
Note: It is of great importance that the feed and boiler water are chemically treated
in order to avoid corrosion from the above mentioned things.
It is recommended that the operator contacts an established water treatment

company and gets assistance to have a suitable water treatment system put into
operation from the very beginning of the service of the boiler.
Aalborg Sunrod <üiüii> Page 1/3

ENG. Feed and Boiler Water K.7464.0
1.2 Feed and Boiler Water Characteristics
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 andfiêeof mud Clear and free of mud
Hardness ppm CaC03 0-0.5
Cloride content ppm er <15 <100
"P" Alkalinity ppm CaCOs 100-150
Total (T) Alkalinity ppm CaCOs <2x"P"-Alkalinity
pH-valueat25°C - 8.5-9.5 10.5-11.5
Hydrazine excess ppm N2H4 0.1-0.2
Phosphate excess ppm PO4 20-50
1 Specific density at 20°C kg/m^ < 1.003
'conductivity at 25°C nS/cm <2000
* Oil content - NIL NIL
Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2S04) 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 ofoxygen binding agents can be measured and indicate that no oxygen
has been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is recom-
mended 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 (see
next section).
Aalborg Sunrod iiliiiiit Page 2/3

Feed and Boiler Water
1.3 Feed and Boiler Water Maintenance
The following are recommended water maintenance instructions. More exact

details concerning analyses and blowdowns should be set up together with the
supplier of chemicals for water treatment.
1.3.1 Daily
Analyses of feed and boiler water.
1.3.2 Weekly
Skimming (surface blowdown) according to analyses, but at least once per

week (2 minutes with fully open valve).
Blowdown (bottom blowdown) according to analyses, but at least once per
week (each blowdown valve 1 minute in low load condition).
1.3.3 Monthly
Check of functions for salinity and oil detection systems.
1.3.4 Yearly
Check of the water side of the boiler and hotwell/deaerator for corrosion and
scaling.
n Check the injection pump unit.
Aalborg Sunrod iiiUliit Page 3/3

00
i:::il.
iHiittii
AALBORG SUNROD
Table Of Contents
Feed Water Pumps

General 1
Start-up 2
Maintenance 3
Frost Protection 4
Fault Finding Chart 5
Service 6
AALBORG SUNROD
ENG. Feed Water Pumps OM3010.0
Feed Water Pumps
General
The multistage in-line centrifugal pumps are usable for pumping feed and boiler
water in the boiler plant.
To have a proper functioning of the centrifugal pumps it is essential that the pumped
liquid does not contain any solid particles or fibres. Further the Hquid must not attack
the pump material chemically.
1.1 Technical Data
• Ambient temperature: Max. 40°C.

• Liquid temperature: -15°Cto 120°C.
• • 3
• Mmimum flowrate (independent of liquid temperature): 0.4 m /h.
• Maximum inlet pressure: 15 bar, 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".
• Electrical data: See motor nameplate.
• Noise level: 71 dB(A).
Further technical data can be found on the Data Sheet related to the pumps.
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 liquidflowthrough the pump should be ensured by connecting a bypass/a
drain to the discharge pipe. The drain can for instance be connected to a tank.
Start-Up
Warning: Do not start the pump until it has been filled with liquid.
Do not start the pump until it has been primed and vented.
AALBORG SUNROD iiUUfe Page 1/5

2.1 Priming
Note: The following does only apply to systems where the liquid level is above the pump
inlet
n Close the discharge isolating valve and loosen the vent screw in the
pump head, see Figure 1.
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.
Slowly open the isolating valve in the suction pipe until a steady stream
of liquid runs out the vent hole.
Tighten the vent screw and completely open the isolating valve(s).
Illustration of the centrifugal pump
Vent Screw/
Priming Plug
Drain Plug/
Bypass Valve
Flow direction
Figure 1 CR.tif
2.2 Checking Direction of Rotation
Do not start the pump to check direction of rotation until it has been filled with
Uquid.
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.
AALBORG SUNROD iÜiiiÜ> Page 2/5

The correct direction of rotation is shown by arrows on the pump head and/or on
the motor fan cover. When seenfromthe fan, the pump should rotate counter-clock-
wise.
2.3 Starting
Before starting the pump,

• • completely open the isolating valve on the suction side of the pump
and leave the discharge isolating valve almost closed.
H Start the pump.
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 1.
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 attention should be paid
to the risk of injury caused by scalding hot water.
When the piping system has been filled with liquid,

E l 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,
loosen the vent screw in the pump head during operation.
2.3.1 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.
Maintenance
Caution: Before starting work on the pump, make sure that no power is supplied to the
pump and that it cannot be accidentally switched on.
Caution: Before removing the cover of the electrical terminal box and before any
removal/dismantling of the pump, make sure that the electricity supply has
been switched off.
Pump bearings and shaft seal are maintenance-free.

If the pump is to be drained for a long period of mactivity then.

D Remove one of the coupling guards to inject a few drops of silicone oil
on the shaft between the pimip head and the coupling.
This will prevent the shaft seal faces from sticking.
Whenfittingthe coupling guards, make sure that they are centred vertically in the
recesses in the pump head.
3.1 Motor Bearings
Motors which are notfittedwith grease nipples are maintenance-free.

Motors fitted with grease nipples should be lubricated with a high-temperature
lithium-based grease.
In the case of seasonal operation (motor is idle for more than 6 months of the year),
it is recommended to grease the motor when the pump is taken out of operation.
Frost Protection
Pumps which are not being used during periods offrostshould be drained to avoid
damage.
n Drain the pump by loosening the vent screw in the pump head and by
removing the drain plug from the base.
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 installa-
tions, 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.
Before replacing the drain plug in the base, screw the bypass valve out
against the stop, see Figure 1.
Fit the drain plug by tightening the large union nut followed by the
bypass valve.
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.
AALBORG SUNROD lÜiUÜa Page 4/5

^f.> 'HA - V i '•'':; >; J-> f ;k^" ---Fäult^Finding Chart

Fault Cause
1. Motor does not run when started a) Supply failure
b) Fuses blown.
c) Motor starter overload has tripped out.
d) Main contacts in motor starter are not makingcontact or the coil is faulty.
e) Control circuit fuses are defective.
f) Motor is defective.
2. Motor starter overload trips out a) One fuse is blown.
immediately when supply is b) Contacts in motor starteroverload are faulty.
switched on. c) Cable connection is loose or faulty.
d) Motor winding is defective.
e) Pump mechanically blocked.
f) Overload setting too low.
3. Motor starter overload trips out a) Overload setting too low.
occasionally. b) Low voltage at peak times.
4. Motor starter has not tripped a)Checkla),b),d)ande).
out but the pump does not r\m.
5. Pump capacity not constant. a) Pump inlet pressure is too low.
b) Suction pipe/pump partly blocked by impurities.
c) Pump draws in air.
6. Pump runs but gives no water. a) Suction pipe/pump blocked byimpurities.
b) Foot or non-return valve blocked in closedposition.
c) Leakage in suction pipe.
d) Air in suction pipe or pump.
e) Motor rotates in the wrong direction.
7. Pump runs backwards when a) Leakage in suction pipe.
switched off. b) Foot or non-retum valve defective.
c) Foot valve blocked in open or partly openposition.
d) Non-retum valve leaks or is blocked in partly open position.
8. Leakage in shaft seal. a) Pump shaft position is incorrect
b) Shaft seal is defective.
9. Noise a) Cavitation occurs in the pump.
b) Pump does not rotatefreely(frictional resistance) because of incorrect pump shaft position.
c) Frequency converter operation: Resonance in the installation.
Table 1
Service
Note: If a pump has been used for a Uquid which is injurious to health or toxic, the
pump will be classified as contaminated.
Any application for service (no matter to whom it may be made) must include details
about the pumped liquid if the pump has been used for Uquids which are injurious
to health or toxic.

CO
• o o o •
o o o o o
o o o oo
o o o o o o o
AALBORG SUNROD
Table Of Contents
Modulating Oil Burner OM691#03.0
Burner Fuel Oil Pump OM691#11.0
Electric Oil Preheater OM691#14.0
Heating Cartridges OM691#17.0
Oil/Air Regulation OM691#20.0
Ignition Electrodes OM691#23.0
Combustion Head OM691#25.0
Photo Cell OM691#27.0
Burner Housing OM691#28.0
Nozzle Head OM691#31.0
Nozzles OM691#35.0
Nozzles OM691#37.0
Viscosity-Temperature Chart OM69_#01.0
Oil System OM691#41.0
Pre-Service OM691#51.0
Start of the Burner OM691#56.0
Start on Diesel Oil OM691#62.0
Change to Heavy Fuel Oil OM691#65.0
Manual Operation OM691#71.0
Faults and Rectifying Faults OM691#90.0
AALBORG SUNROD
ENG. Modulating Oil Burner OM691#03.0
General
The modulating oil bumer is a pressure jet atomizing bumer capable of burning
both diesel oil (DO) and heavy fuel oil (HFO).
As the bumer is a very vital component ofthe boiler plant, the operating staff should
be thoroughly instmcted with regard to the operation ofthe equipment and the safety
regulations. This is due to the fact that bumer problems are often caused by incorrect
bumer operation. Withfrequentlyoccuring bumer faults, the nearest service centre
should be consulted.
To ensure a safe and reliablefiinctionof the bumer it must be inspected at least once
a year by a representative of the supplier or by another competent and qualified
person.
1.1 Safety Regulations
Caution: To ensure safe bumer operation, the bumer has to be installed and commis-
sioned by qualified personnel, and all guidelines in these instructions have to
be followed.
All safety equipment such as flame sensoring equipment and correcting elements
may only be replaced by qualified personnel, which can be ordered by contacting
Aalborg Sunrod.
Warning Repair of any of the safety components is NOT permitted. Failure to comply
may result in serious injury or death and may cause considerable damages to
the boiler plant.
1.2 Qualified Personnel
Qualified personnel according to these operating instmctions are persons, who are
confident in installing, regulating and commissioning the bumer, and who have
qualifications to carry out this work i.e.:
• Persons who are trained to operate electric circuits and units according
to the safety standards.
• Persons who are qualified in the use of dangerous fuel according to the
relevant laws and regulations.

ENG. Burner Fuel Oil Pump OM691#11.0
Burner Fuel Oil Pump
Fuel Oil Pump

The fuel oil pump is a gear-wheel pump which provides an operating pressure up
to 30 bar. The fuel oil pump is equipped with a built-in pressure regulator with a
fast working valve to keep a constant pressure. In order to protect the pump against
impurities in the oil a filter is built-in. An illustration of the burner fuel oil pump is
shown in Figure 1.
Attention: The fuel oil pump and oil lines must be filled with oil and properly vented
before the burner motor is started. Failure to comply may causes cavitation
damage to the fuel oil pump.
Illustration of a Burner Fuel Oil Pump
Figure 1 10 OOlOxdr
1. Suction connection
2. Return connection
2a. Bumer spill back connection
3. Nozzle supply line
4. Locking screw

5. Pressure gauge connection

6. Suction gauge connection
7. Pressure adjusting screw
1.1 Adjustment of the Fuel Oil Pump
The oil line on the suction side of the pump must be primed and the pump vented
before commissioning, otherwise the pump will be damaged due to cavitation.
The supply pressure on the suction side of the fuel oil pump must be between 1.0
and 5.0 bar. The oil temperature should not exceed 90 °C.
1.1.1 Testing the Suction Pressure

• Insert a pressure gauge into the suction gauge connection (6) to measure
the supply pressure.
1.1.2 Adjust the Fuel Oil Pump Pressure

• A pressure gauge must be connected into the pressure gauge connection
(5) to measure the fiiel oil pump pressure. Do not use hemp or oakum as
sealing material.
• In order to make the final adjustment of the oil pressure the burner must
be running in normal operation
• Remove the locking screw (4) and set the required oil pressure on the
pressure adjusting screw (7)
• Clockwise rotation increases the pressure
• Anti clockwise rotation decreases the pressure
The recommended pressure settings are as follows:
• Diesel oil: 20 - 25 bar
• Heavy fuel oil: 25 - 30 bar
1.1.3 Boiler Shut Down

If the boiler plant has been shut down and the plant is started from cold conditions
the following procedures must be taken into consideration:
n The fuel oil transfer pump should be started in order to circulate oil
in the system
Remove the pressure gauge connection (6) and add some oil to pro-
tect the fuel oil pump from cavitating
Start the burner and wait until bubblefree oil appears. Remount the
pressure gauge cormection (6) again
1.1.4 Filter
The pump filter requires cleaning at intervals, depending on the condition of the
oil. In the event of thefilterbecoming blocked, excessive vacuum will be the result.
To remove the filter for cleaning extract the eight screws (7) on the
fuel oil pump cover
AALBORG SUNROD JÜi. Page 2/3

Note: After replacing the filter ensure that the pump cover is tightly sealed.
1.1.5 Pump Coupling

Aflexiblecoupling is fitted between the fan rotor and the oil pump.
When adjusting the coupling ensure that there is no axial tension on the pump drive
shaft.
The coupling element on the pump should have an axial movement of 1.5 mm.
1.1.6 Exchange of the Fuel Oil Pump.

If the fuel oil pump breaks down, it should be exchanged with a new fuel oil pump
alternatively with an overhauled spare pump (repaired pumps at full guarantee).
Aalborg Sunrod cannot recommend that the user repairs it. The defective pump
should be sent for repair.
Exchanging the Fuel Oil Pump:
• • Close the quick closing valves
j n Disconnect the oil hoses and the other oil pipes on the fuel oil pump
^ 9 Remove the plastic cover of the observation hole which is found
above the air intake over the fuel oil pump
E l Unscrew the two bolts in the fuel oil pump flange
Note: The coupling centre piece, between the fuel oil pump and the fan wheel is loose
and may be taken out through the air intake for inspection.
Place the coupling crosses into the coupling centre piece and draw
out the fuel oil pump. The flexible coupling crosses must be renewed if
necessary
Remount the coupling part from the fuel oil pump shaft, and the place
coupling part on the new fuel oil pump shaft
Remount the pressure gauge with the cock and mount it on the new
fuel oil pump
Replace the new fuel oil pump together with the coupling centre piece.
Ensure that the engagement of the two coupling crosses is done correctly
Screw in the two bolts in the fuel oil pump flange
Adjust the tolerance (gab) between the coupling parts to 1.5 mm
Remount pipe and hose connections and open the quick closing
valves. Fill the system with oil and vent it before starting up
AALBORG SUNROD ii^mi, Page 3/3

ENG. Electric Oil Preheater OM691#14.0
Electric Oil Preheater
1 Electric Oil Preheater
The electric oil preheater, illustrated in Figure 1, is placed on the burner housing
and is used for preheating the fuel oil.
The fuel oil supply pipe coils are cast integral in an aluminium alloy plate. The heat
energy is transferred by the electric heating element via the aluminium casting and
the pipe coils to the fuel oil for heating. This ensures an even and rapid transfer of
heat thus preventing local overheating of the heating element and the exchanger
surface to the oil. No liquid medium is used for the heat transfer.
Fluctuations in oil temperature are minimized by a<!ftl0|)) resistance temperature
sensor placed directly on the heating plate.
The preheater is suited for handling HFO with viscosities up to 700 cSt. at 50°C for
modulating burners and HFO with viscosities up to 570 cSt. at 50°C for two stage
burners. The oil throughput should be minimum 100 kg/h for the two stage burner.
The max. obtainable oil temperature is approx. 180°C. Please note that this
temperature depends on the throughput and the supply temperature of the fuel oil.
Illustration of the Electric Oil Preheater
2 3
1 Ft 100 resistance temperature sensor

2 Temperature limit thermostat
3 Reset for temperature limit thermostat
Figure 1 wev2.cdr

ENG. Electric Oil Preheater OM691#14.0
1.1 Setting the Preheater Set Point
The desired fiiel oil temperature is set at the CROw regulator fitted in the control
panel. The setting range isfi'om40°C to 180°C.
The fiiel oil temperature in the preheater is registered by the Pt 100 resistance
temperature sensor and supplied to the CROw regulator which is an electronic two
point controller with PID control behavior.
Please note that the CROw regulator has to be set 10 -15 °C higher than the desired
preheating temperature on account of the heat loss between the oil preheater and
the nozzle head.
1.2 Release Contact
The CROw regulator has a built-in oil release contact which has a fixed setting of
5 °C below fiiel oil set point. The oil release contact allows the burner to start when
the temperature is higher than the fixed setting. The pre-purge then commences.
When startingfi-omcold condition, the oil release contact will operate several times
before the temperature in the preheater has reached the set point.
A signal lamp on the control panel "Low oil temperature" indicates that the oil
temperature is not yet above the fixed setting.
If the oil temperature becomes too low during operation, e.g. if the CROw regulator
fails to respond or if the heater elements are faulty, the oil release contact shuts down
the bumer and actuates an alarm.
1.3 Temperature Limit Thermostat
The preheater is equipped with a temperature limit thermostat with afiixedtempera-

ture limit which is higher than the max. temperature of the CROw regulator. If the
oil temperature becomes too high, the temperature limit thermostat shuts down the
bumer and actuates an alarm, e.g. if the CROw regulator has failed.
A signal lamp on the control panel "High oil temperature" indicates this situation.
In case of failure the fault has to be repaired. Before the preheater can be taken into
service again, the reset button on the temperature limit thermostat must be activated.
1.4 Test of the Functions
Thefiinctionof the temperature limit thermostat can be tested by dismantling one

of the wires at the terminals to the temperature limit thermostat. The bumer stops
immediately.
Thefiinctionof the oil release contact can be tested by removing thefiisesfor the
preheater. When the oil temperature drops below the limit of the oil release contact,
the bumer shuts down.
AALBORG SUNROD ^ Page 2/2

ENG. Heating Cartridges OM691#17.0
Heating Cartridges
Heating Units
The bumer is provided with a number of heating cartridges used to ensure a
sufficientiy low viscosity.
The heating cartridges are placed in the fuel oil pump, on the supply and return
solenoid valves, on the solenoid valve block, on the oil quantity regulator and in
the nozzle head.
1.1 Nozzle Head Heating
The nozzle head heating system consists of a heating cartridge placed in the nozzle
head, a thermostat also placed m the nozzle head and an electronic P type controller.
The controller is a ROB regulator which can be set between 65°C and 130°C. The
ROB regulator is placed behind the terminal box inside the bumer housing.
The release thermal switch in the regulating control is coimected in series vsdth the
electric oil preheater release thermostat. The system only allows a bumer start after
the selected nozzle head temperature and the minimum oil preheater temperature
have been reached.
AALBORG SUNROD ^^^1^ Page 1/1

ENG. Oil/Air Regulation OM691#20.0
Oil/Air Regulation
Oil/Air Compound Regulator

The oil/air compound mechanism is driven by the servomotor in a continuous
movement from partial load to Ml load regulating the air quantity in proportion to
the oil quantityfired.An illustration of the oil/air compound mechanism is shown
in Figure 1.
The cam has an adjustable spring band on the side which is adjusted by means of
adjustable socket screws. The spring band is mechanically linked to the air damper.
The cam segment is driven clockwise and as the movement progresses, the air
damper is opened, and the oil control valve is closed. This reduces the oil return
quantity and increases the nozzle throughput.
Through flue gas measurements the air quantity is compared to the oil throughput
at various load positions, and the oil/air ratio is adjusted on the spring band.
The outer scale on the cam shaft serves as a position indicator.
With a leverfittedon the gear box the cam shaft can be disengaged from the drive.
This makes it possible to manually turn the cam to any position required. When the
lever is in the vertical position, the drive is engaged.
Illustration of the Oil/Air Regulation
Full load (100%)
Partial load (from 30 - 70%)

Ignition load (from 20 - 30%)
Basic position
Air damper
with linkage Nozzle return line
Metering slot
Oil regulating valve
Cam disc
Adjustable spring band
Figure 1 coinpoun5.cdr
AALBORG SUNROD iäÜÜfa Page 1/2

ENG. Oil/Air Regulation OM691#20.0
Servomotor
The limit switches and auxiUary switches are set manually on the adjustable cams.
The cams have a small pointer which indicates the appropriate switching point on
a scale between the cam discs. The cam switches and the connection diagram are
shown in Figure 2.
The servomotors are supplied with standard switch settings which must be reset,
during commissioning to the requirements of the installation. The outer scale on
the cam shaft serves as a position indicator.
Cam Switches and Connection Diagram
QN
Cam switch no. I = opened

Cam switch no. n = closed
Cam switch no. ni = ignition load down
Cam switch no. rv = ignition load iq)
Cam switch no. V = not used
Cam switch no. VI = partial load up
Cam switch no. Vn = partial load down
Figure 2 compoun6.cdr
AALBORG SUNROD iH}HB^ Page 2/2

ENG. Ignition Electrodes OM691#23.0
Ignition Electrodes
1 Ignition Electrode Settings

The ignition electrodes are shown in Figure 1 together with the adjustment
dimensions. As the conditions may vary from boiler to boiler, the indicated
dimensions should only be considered as guidelines. If ignition problems emerge,
a more favourable adjustment of the electrodes, suitable for the present conditions,
must be found by experiments.
Illustration of the Ignition Electrode Settings
Ignition electrodes
Figure 1 10_0005b.cdr
When the ignition electrodes are adjusted, the following must be observed:
• The distance of the ignition electrodes to the nozzle and diffuser should
be checked.
• The ignition electrodes must not be touched by the atomizing oil spray.
• The distance of the ignition electrodes to the diffuser and the nozzle
must always be lager than the distance of the spark gap.
If a nozzle with a larger spray angle is fitted, the electrodes must be adjusted
backwards, or perhaps be bend slightly upwards.
AALBORG SUNROD aiilMi» Page 1/1

ENG. Combustion Head OM691#25.0
Combustion Head
1 Adjustment of the Combustion Head and the

Diffuser
The combustion head and the diffuser are marked with their type designation. The
identification of the flame tube is stamped on the neck, and the extemal diameter
of the diffuser is stamped on the side towards the burner.
The oil bumer is delivered with a combustion head and an air diffuser disc that suit
the specified boiler type and oil quantity in the best way.
Iffiirtheradjustment is needed to obtain the best possible combustion performance,
this is done by moving the combustion head and/or the air diffuser disc. Doing this,
make sure not to change the position of the ignition electiodes and thereby
disturbing a proper spark formation. It should also be noted that it is important that
the air diffuser disc is placed in a small distance in jfront of the nozzle(s) in order to
keep a sufficient cooling on the nozzle(s).
Figure 1 and Table 1 shows the different combustion heads, types, dimensions and
measurements.
Illustration of the Combustion Heads
Fig. 1 Fig. 2 Fig. 3 Fig. 4
^
i_i ayiS
0-10 0-10 0-10 0-10
1 Diffuser
2 Oil nozzle
3 Combustion head
Figure 1 comhead.cdr
AALBORG SUNROD iiüUiii Page 1/2

ENG. Combustion Head OM691#25.0
Combustion Hea^ls
Combustion Head Type Diffuser Disc L D
M5/2a 125x40 50 160
M5/la 125x40 65 180
M5/la 145x40 65 180
M6/la 155x50 90 200
M6/la 165x50 90 200
M6/la 175x50 90 200
M7/la 155x50 100 220
M7/la 165x50 100 220
M7/la 175x50 100 220
M8/la 155x50 110 240
M8/la 165x50 110 240
M8/la 175x50 110 240
—=-> M9/la -165x50 -90 -^240
M9/la 185x50 90 240
Ml 0/2 185x50 140 265
Ml 0/2 200x50 140 265
Ml 0/2 220x50 140 265
Mll/1 245x70 170 325
Mll/1 260x70 170 325
G7/2a 165x50 120 265
• G7/2a 175x50 120 265
U2/1 145x50 85 220
U2/1 155x50 85 220
U2/1 165x50 85 220
Table 1
AALBORG SUNROD iÜüiÜ« Page 2/2

ENG. Photo Cell OM691#27.0
Photo Cell
1 Description
The burner is equipped with photo cells placed intiieair duct close to the difiliser.
The number of photo cells for automatic operation and emergency operation
respectively depend on the classification society.
The photo cell is used for supervision of oil flames in connection with a burner
sequence controller type(^^ÔKl^>nd/or a flame safeguard typeC^£KD If
the photo cell detects a missing flame, the bumer stops instantaneously. It is not
possible to start the bumer before the bumer control panel has been reset.
The radiation of the oil flame generates a flame signal in the visible band of the
Hght spectrum. The light-sensitive element is a selenium photo cell. When illumi-
nated, it generates D. C. voltage causing a current toflowto the input of the flame
signal ampfilter. Hence, the selenium photo cell is an active detector.
The cell is insensitive to infrared radiation. Ifthe bumer is started with an illuminated
combustion chamber, e.g. due to glowingfirebrick,the bumer motor will start but
the ignition sequence and the oil release will not take place.
AALBORG SUNROD liHjtfi, Page 1/1

ENG. Burner Housing OM691#28.0
Burner Housing
1 Burner Swing Out
The burner swing out switch breaks the interlock circuit to the burner if the burner
is opened at the hingedflange.Before the burner can be started, the burner control
system must be reset.
Inspection of the Burner Housing
A cover for inspection and cleaning of the air duct is fitted on the top of the burner
housing. The electric terminals and the ignition transformer are located on the left
side behind the cover
Inspection of the Oil Flame
The boiler is provided with an inspection hole for manual supervision of the oil
flame. The sight glass is air-cooled. The fan motor on the burner supplies the sight
glass with the necessary cooling air through a tapping in the air duct.

ENG. Nozzle Head OM691#31.0
Nozzle Head
1 Recirculating Nozzle Head
A basic piping diagram of the fuel oil system at the nozzle head is shown in Figure
1. The system is constructed with a return line and a recirculating nozzle head.
When the fuel oil has been heated to the minimum oil temperature, the bumer start
is released and the oil system at the nozzle head isfilledwith oil. The shut-off device
in the nozzle head remains closed preventing the fuel oil from flowing through the
nozzle.
Basic Piping Diagram of the Oil System at the Nozzle Head
///////////.
10
Nozzle
1 - Oil pump
2 - Oil preheater
3 - Filter EM52S$
4 - Safety solenoid valve (normal closed)
4a - Safety solenoid valve (normal closed)
5 - Solenoid valve (nomnal open)
/////////////
6 - Solenoid valve (normal closed)
7 - Pressure switch
10 - Nozzle head with shut-off device
12-Oil regulator
. 5 =BM2
\Ä
\M:^^
Ii
A f
Inlet Outlet
Figure 1 noz_sys2.cdr
During shut-down of the bumer and during the pre-purge period, the shut-off
devices (4), (4a) and 6 are closed, and the solenoid valve (5) is open.
After pre-purge the solenoid valves (4), (4a) and (6) will open, and the solenoid
valve (5) in the retum line from the nozzle is closed. The pressure in the nozzle
shut-off device is hereby raised, and at a pressure of approx. 12 bar the shut-off
device opens to commence bumer operation.
AALBORG SUNROD täUiiii Page 1/2

ENG. Nozzle Head OM691#31.0
The oil regulator (12) regulates the oil flow through the nozzle by increasing or
decreasing the flow resistance. This causes that more or less oil is pressed through
the nozzle as the supply pressure from the oil pump is constant.
The pressure in the return line is checked by the pressure switch (7). If the pressure
is too high, the burner shuts down. Shut-off devices (4), (4a) and (6) will close, and
at the same time the solenoid valve (5) will open.
The closure around the nozzle shut-off device prevents oil from dripping from the
nozzle.

ENG. Nozzle OM691#35.0
Nozzle
1 Nozzle Selection
The selection of a nozzle to a modulating oil bumer can be done on the basis of the
chart shown in Figure 1. The chart shows the throughput of the spill type nozzle in
relation to the supply pressure. The supply pressure should be between 25 - 30 bar
when running on both DO and HFO. If the burner only operates on DO, the supply
pressure should be between 20-30 bar.
Note: Ensure that the supply pressure does not faU below the above mentioned
settings. The bumer can only operate if the pressure is sufficiently high in
order to withdraw the spring inside the nozzle head.
The nozzle is a spill type nozzle W with a spray angle of 50°. The regulating range
for this type of nozzle is between 30 -100% of the total oil throughput. The nozzle
return pressure must be measured during commissioning. The pressure should not
be set below 10 bar for partial load.
1.1 Selecting a Nozzle Size
When a nozzle is selected the required oil throughput must be known. The selection
should be made with regard to the above mentioned supply pressure settings.
If the gap between two nozzle sizes results in a lower supply pressure than required,
the pressure must be increased to minimum 25 bar for HFO and 20 bar for DO. The
higher oil throughput caused by an increase of the supply pressure can be reduced
by limiting the oil regulator movement. This is done by adjusting the full load limit
switch in the servomotor to an appropriate lower postion. The range of regulation
is reduced by this action.
1.2 Example
Known:
Required oil throughput: 230 kg/h HFO
Required:
The nozzle size and the supply pressure
Procedure to be followed:
Follow the 20 bar reference pressure line vertically up to the intersection with the
230 kg/h oil throughput line. From this point move horizontally to the intersection
with a nozzle size line and read the nozzle size. When this is done, move vertically
down to the pressure line and read the required supply pressure. If the appearing
supply pressure iscbelow 25 bar>a larger nozzle size must be chosen. In this case a
nozzle size of W 250 must be chosen.
f
K/i,
AALBORG SUNROD litiiiii, Page 1/2
ENG. Nozzle OM691#35.0
Nozzle Selection Chart
440.
420. W420
^ i /
400. J/
y r
r
W390
380. y A /
>/ / y
r
360. > ^ y W360
/ ^ A/ > y
340. / / r
r
y y
t / >y W330
320. > / y y y y
r ^/ 4 y
^
300. / y ^ y W300
/ Ay > \y
280. /* y ^ y <•"
-/ y y y y W275
260.
^ y y ^ y ^-
^ y .^ y ^ 25S~^É
240. \^ ^ y
r^
^ y
w^
220. ^ ^ W225
200. W200
180. W 180
160. W160
140. W140
W125
120.
W 110 w
eg
100. W 100'^
o
W90 "
O
£ 80 . W80 «
Ok >
W 7 0 -^
4^
3 60 . W60 £
a, W55 o
W50 N
W45 «
o 40 . W40 e
JZ 73
N
O
Ö 20
20 25
z
30
Figure 1 nozchart.cdr

ENG. Nozzles OM691#37.0
Nozzles
Fitting and Removal of Nozzles

A nozzle can be replaced without affecting the function of the hydraulic nozzle
shut-off valves.
Inspection and change of the nozzles are easily done as the burner is constructed
with a swing flange.
Exchanging of an Oil Nozzle:
• Unscrew the locknut, and the casing can be swung out
• For mounting/dismounting use a spanner and keep the nozzle head fixed
by means of another spanner
• After replacing the nozzle ensure that it is tight
To prevent entry of air into the oil system it is advisable to close the stop valves in
the suction intake and return line during exchange of the nozzle.
As a general rule a nozzle should always be exchanged if it is dirty or worn out. A
good burner performance can only be guaranteed with a new and/or a clean nozzle.
The nozzles should only be cleaned due to a shortage of nozzles.
The nozzles should be dismantled into individual parts and washed in a suitable
fluid such as benzine or petrol. If available, compressed air is the most suitable
cleaning medium.
Note: Solid objects such as steel needles are completely unusable, and they are under
NO circumstances to be used as cleaning tools.
Note: Nozzles cannot be returned for credit or exchange.
When extra oil nozzles are ordered please state the through-put in US Gal/h and the
spray angle.

ENG. Viscosity - Temperature Chart OM69 #01.0
Viscosity - Temperature Chart
Description
The preheating temperature can be determined by means of the viscosity - tempera-

ture chart shown in Figure 1. In order to use the chart, the viscosity of the fuel oil
must be known at a reference temperature.
It should be noted that the preheating temperature should be set somewhat higher
than the temperature shown in the ch

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Customer Kvaerner Warnow Werft

AALBORG INDUSTRIES A/S (Al) AALBORG HEATERS A/S (AH)

/V\LBORG SUNROD AB (ASAB)

DS/ISO 9001 P.O. Box 661 • Gasvaerksvej 2 4 Tel. +45 9 9 3 0 4 0 0 0 Bankers:

Technical Data of M I S S I O N ^ M OS Boiler

Technical Data of MISSION™ OS 3300 Boiler

» Boiler type: Small Oilfired Boiler

Boiler Design Data

» Steam output: 3,200 kg/h

» Diameter incl. insulation: 2,150 mm

AALBORG SUNROD Page 1/2

Technical Data of Burner

• Burner type: ^.M."> .^ Pressure Atomizing Burner

• Electrical power source: 3 x 440 V, 60 Hz

AALBORG SUNROD itfjiilj, Page 2/2

Description of Boiler Plant

The MSSION^'^ OS boiler is a vertical oil-fired auxiliary marine boiler, insulated

1.1 Boiler Pressure Part

The general arrangement of the MISSION'"'^ OS boiler is shown in Figure 1.

1.2 Heat Transfer and Water Circulation

AALBORG SUNROD Jjjj^ Page 1/2

Principle Drawing of MISSIONT^* OS Boiler

1.3 Steam System

AALBORG SU^fROD iiiUiii) Page 2/2

AALBORG SUNROD JÜ^ Page 1/2

AALBORG SUNROD iÜüttb Page 2/2

Modulating Oil Burner

Air demper intd<e

AALBORG SUNROD Page 1/2

AALBORG SUNROD iftt^i Page 2/2

Boiler Control Panel and System

Sketch of Control Panel

AALBORG SUNROD idiUlii Page 1/1

Water Level Control

Sketch of The Water Level Control System

I Oil fired boiler

1. High/low water level,

3. Start/stop feed water pun:ip,

4. Too low water level,

5. Too low water level,

AALBORG SUNROD ,mtf{ii Page 1/1

Sketch of Gauge Board.

41 Pressure switch valve

43 Pressure switch max. steam

AALBORG SUNROD Page 1/1

Gas/Air Separator and Filter Unit

Sketch of Gas/Air Separator and Filter Unit

02 Pressure regulating valve

Figure 1 asfti 02.cdr

AALBORG SUNROD itHHJi, Page 1/1

Operation and Maintenance of Boiler

Operation and Maintenance of Boiler

2.2 Start and pressure raising

AALBORG SUNROD iiiUÜb Page 1/14

Shut the venting valve when the steam blows out.

3.1 Daily Operation

3.2 Weekly Routine Checks

Drain each level glass for about 10-15 seconds.

AALBORG SUNROD Jijj. Page 2/14