MANUAL FOR NSTALLATION,

OPERATION & Maintenance

Of
3 PASS VERTICAL COIL TYPE High and low
pressure BOILER

INSTALLATION ON :- MERCURY SHIPS REPAIRS PVT LTD

BOILER MAKER'S NO. : PTH/CT/43

STEAM GENERATION CAPACITY : 1000±10% KG./HR.

MAX. WORKING PRESSURE : 105 KG/CM2(G)

REF NO. : MSPL/PTHPL/07/20
20TH JULY, 2020

To,
MERCURY SHIPS REPAIRS PVT. LTD.
T-10/3rd Floor, Rayhilsort Residency
Dr Pickle Road Karwar – 581301, Karnataka

KIND ATTENTION. : - SHREE VIPUL MANIYAR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR
3 PASS VERTICAL COIL TYPE BOILER

Dear Sir,

We are enclosing herewith the captioned manual, for your CTB, in

original copy, one set comprehensive and complete the other extracted
write ups only for immediate reference.
We trust you shall find the above in order. In the event you need any
further information, please refer back to us and we shall be glad to oblige.

Thanking you therefore in the meantime and assuring you of our best
services at all time.

Faithfully Yours,
For
PAR TECHNO-HEAT PVT. LTD.
(HIREN BELADIYA)

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 INDEX
1. BASIC DATA..............................................................................................................................................4
2. DESIGN DATA...........................................................................................................................................5
3. BOUGHT OUT SPECIFICATIONS............................................................................................................6
3.1 BLOWER SPECIFICATION.....................................................................................................................6
3.2 BFW PUMP SPECIFICATION.................................................................................................................7
3.3 DIESEL PUMP SPECIFICATION............................................................................................................7
4. PREPARATION FOR COMMISSIONING OF COIL TYPE BOILER........................................................8
4.1 GENERAL INTRODUCTION............................................................................................................9
4.2 CHECK LIST BEFORE STARTING CTB UNIT................................................................................9
4.3 STARTING PROCESS (IN MANUAL MODE)...............................................................................10
4.4 STARTING PROCESS (IN AUTO MODE).....................................................................................11
4.5 PRE-COMMISSIONING PROCEDURE & CHECKS.......................................................................12
4.6 BRINGING CTB ON RANGE &WATER RAISING........................................................................12
4.7 RAISING TEMPERATURE.............................................................................................................13
4.8 SHUT DOWN PROCEDURE..........................................................................................................14
4.9 REASON FOR FLAME FAILURE...................................................................................................14
5. GENERAL OPERATING INSTRUCTION PERTINENT POINTS OF COMBUSTION ECONOMY AND
THERMAL EFFICIENCY..................................................................................................................................15
5.1 FURNACE MANAGEMENT............................................................................................................16
5.2 COMBUSTION................................................................................................................................16
5.3 FUEL BURNING EQUIPMENT AND COMBUSTION...................................................................16
6. MAINTANACE OF CTB...........................................................................................................................17
6.1 FOR DAILY MAINTENANCE CHECK............................................................................................18
6.2 FOR WEEKLY/MONTHLY MAINTENANCE WORK...................................................................18
6.3 FOR ANNUAL MAINTENANCE.....................................................................................................18
6.4 FOR ROUTINE MAINTENANCE...................................................................................................19
6.5 FOR PERIODICAL MAINTENANCE..............................................................................................19
7. PROCEDURE FOR LAYING UP CTB......................................................................................................21
7.1 DRY METHOD................................................................................................................................22
7.2 WET METHOD...............................................................................................................................22

3|Page
 1. BASIC DATA
NAME OF PARTY : MERCURY SHIPS REPAIRS PVT LTD.

LOCATION : T-10/3rd Floor, Rayhilsort Residency

Dr Pickle Road, Karwar – 581301,
Karnataka

BOILER TYPE : Diesel Fired, Coil Type Boiler

BURNER : DIESEL BURNER

BOILER NUMBER : CT-43

Faithfully Yours,
For
PAR TECHNO-HEAT PVT.LTD.
(HIREN BELADIYA)

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 2. DESIGN DATA

1. CODE AND TYPE OF OILER : IBR 1950 & ITS LATEST AMMENDMENT

2. MAX. WORKING PRESSURE OF BOILER : 105 KG/CM²G

3. MAX. WORKING STEAM TEMPERATURE : 305°C

4. EVAPORATION : 1000 KG/HR (FROM & AT 100°C)

5. FUEL : DIESEL

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 3. BOUGHT OUT SPECIFICATIONS
3.1 BLOWER SPECIFICATION

No
Detail FD FAN
.

1 MOTOR MAKE CROMPTON

2 CAPACITY (CMH) 1224

3 PRESSURE (MMWC) 250

4 OPERATING TEMPRATURE(°C) 30

5 FAN RPM 2900

6 MOTOR HP 3 HP

7 DRIVE DIRECT MOTOR

DRIVESIDE ANTICLOCKWISE
8 ORIENTATION
BOTTOM HORIZONTAL

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 3.2 BFW PUMP SPECIFICATION

SN DETAIL PUMP

1 PUMP MAKE HIRONISHA

2 QTY 2 Nos.

3 CAPACITY 17 LPM

4 DICHARGE PRESSURE 120 KG/CM^2

5 MOTOR HP 7.5 HP

6 DRIVE TRIPLEX PLUNGER

3.3 DIESEL PUMP SPECIFICATION

SN DETAIL PUMP

1 PUMP MAKE PRAKASH

2 QTY 1 Nos.

3 CAPACITY 300LPH

4 DICHARGE PRESSURE 10 KG/CM^2

5 MOTOR HP 1 HP

6 DRIVE DIRECT FLEXIBLE COUPLE

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 4. PREPARATION FOR
COMMISSIONING OF COIL TYPE
BOILER

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 1. PREPARATION FOR COMMISSIONING STARTING OF
CTB

4.1 GENERAL INTRODUCTION

Although this manual covers the general operating and maintenance
instruction for 3 Pass vertical coil type high and low pressure boiler and auxiliaries it
is not possible to include all cases of trouble and service condition within the scope of
this booklet. Therefore, it is emphasized that it will be the supervisor's and operator’s
responsibility to handle any unforeseen condition which may arise during operation.

The instruction contained in this manual should be considered as broad

guideline only. The operating person with proper training and experience should
however be able to exercises their judgment in following instruction to achieve letter
results, depending on the circumstances of the case. It is important that the operating
personal should have a comprehensive knowledge on the equipment as well as the
duties and functions of various part of the plant.

All auxiliary’s equipment must be in first class operating conditions and

suitable for operation at design condition and will be operated in accordance with the
manufacturer’s recommendations and instructions.

4.2 CHECK LIST BEFORE STARTING CTB UNIT

 In Feed water tank water level should be normal level.

 Diesel Level in fuel tank should be normal level.

 Boiler feed water pump suction valve should be opened.

 Boiler feed water pump discharge valve should be opened.

 All drain valves should be closed.

 Instrument isolation valve should be open.

 Fuel Pump suction line valve should be open.

 All strainers shall be clean properly.

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  Main outlet steam line to be connects with process.

 D.G. Set & control panel Earthing.

 Check blow down valve should be closed.

4.3 STARTING PROCESS (IN MANUAL MODE)

A) Start feed water pump and make continuous flow at CTB outlet.

B) Create minimum system pressure by operating MSSV valve.

C) Start air blower & maintain minimum air pressure required.

D) Start fuel pump & maintain minimum fuel pressure.

E) Start Ignition transformer & pilot solenoid valve(S.V.-1)

F) After receiving of flame (check by instrument & visual from burner glass).
Start secondary burner nozzle and open second level air damper.

G) Maintain pressure of steam by operating MSSV for Avoiding high pressure &
low feed water pressure tripping.

Note: If flame is not observed after starting pilot burner, do not try
continuously without making sufficient air purging to avoid back firing.

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4.4 STARTING PROCESS (IN AUTO MODE)

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4.5 PRE-COMMISSIONING PROCEDURE & CHECKS
A) Remove all foreign materials from the CTB such as scaffolding, unused bolts
and nuts, loose gaskets, planks rods etc... And close cover plates tightly.

B) Check the CTB header.

C) Check for dummies in the lines or at the valves, remove them if they are placed
for hydraulic test.

D) Pass the stop valve and drain /blow down valves etc... Make sure they open
and close without strains.

E) See the dampers are in working order and check their positions are correctly
marked.

F) Check the fan bearing and grease them. See the bearing sleeves are tight and
locked. Make sure the directions of rotation of the fans are correct.

G) See the alignment of the V-belt and their tension .The belt should not be too
tight.

H) Inspect the fuel burning equipment. See that the Air Nozzles are fitted
properly and air passages are clear...

I) Close the FD fan inlet damper and start the fan. Open the damper and see the
electric load. Check the leakages on the ducting. Keep that fan shut.

Keep the fan shut.

J) CTB Feed Water pump - Remove the belt from pump with motor start the
motor and confirm the direction of rotation .Put belt to pump with motor.
Prime the pump. Rotate the pump by hand and satisfy the pump is free.

K) Open the air vent valve on the CTB. Start BFW pump and take feed water in the
coil. Do not use very hot water.

L) Open the drain valves and be sure that no air locks. Close the drain valves.

4.6 BRINGING CTB ON RANGE &WATER RAISING

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 A) Raise Pressure gradually. Start FD fan and adjust the draft control the dampers
to get the required draft. Watch the fire conditions. Fire should be uniform
throughout the grate. When header pressure gauge indicates about 2.5

Kg/Cm2. close their vent. “Always maintain half gauge glass of water tank".

B) Raise water temperature slowly by 15% of working temperature.

C) Keep the main feed water pump always ON, even when the system is not
in firing mode.

D) After satisfying that all the dirt’s are cleared from the CTB, raise the
temperature to working temperature.

4.7 RAISING TEMPERATURE

In a newly installed CTB, temperature raising operation should be slow after post
boiling out

Firing:

A) The rate of firing should be adjusted to produce an increase in temperature

uniformly.

B) Though out the starting up period, the fire should be so regulated that temp of
the Coil tube metal should not exceed 400-degree C.

C) In arranging a starting up program, the test measurements should be carefully

translated in terms of available operating indications such as time version
water temperature, firing equipment speeds, gas temp., normally indicated air
pressures, draughts and valves opening, to serve as a schedule for the
operators.

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4.8 SHUT DOWN PROCEDURE
A) Stop Fuel Supply

B) Run Continuous Air Blower and Feed Water Pump Until Outlet Water Temp.
reach 50 to 60 0C

C) Then after close MSSV and Switch off all Blowers and Pumps.

4.9 REASON FOR FLAME FAILURE

A) During Starting

 Check Ignition (Sparking Between electrode)

- Set distance

- Electrode to spray Nozzle Position

 Air flow – Maintain proper flow for Sustain Flame

B) During Operation

 Air flow – Maintain proper flow for Sustain Flame

 Check solenoid valve.

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 5. GENERAL OPERATING
INSTRUCTION PERTINENT
POINTS OF COMBUSTION
ECONOMY AND THERMAL
EFFICIENCY

15 | P a g e
5.1 FURNACE MANAGEMENT
Take care of the combustion. See the ignition of the fuel and sufficient air is
received in the right zone for combustion. “Watch the Chimney". "No black smoke
comes over from the chimney".

5.2 COMBUSTION

The efficiency of the CTB depends on the complete combustion of the fuel without
much excess air. The CO2 and O2 must be monitored and recorded. The CO 2 must be
12.5 to 14 percentages and O2 should not be more than 7 to 6 percent for this firing.

5.3 FUEL BURNING EQUIPMENT AND COMBUSTION

The CTB is Equipment Diesel Burner. The fuel is required for proper combustion.

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 6. MAINTANACE OF CTB

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6.1 FOR DAILY MAINTENANCE CHECK
A) Gauge Glasses of Water and fuel tank

B) Drain Valves.

C) BFW pump Functioning.

D) Fuel pump Functioning.

E) Any leakage through glands of the valves etc.

6.2 FOR WEEKLY/MONTHLY MAINTENANCE WORK

A) The internal surfaces of tubes are to be cleaned once in every week.

B) The coil is to be flush cleaned once in a month and it is to be observed whether

there is sedimentation on the tube surface of the CTB. If sedimentation takes
place water is to be tested and suitable water treated to be store in the tank.

C) Greasing of bearing of Blowers/Fans should be taken up once in every months.

6.3 FOR ANNUAL MAINTENANCE

The CTB inspectorate will inspect the CTB once in a year. At the time of the inspection
the following maintenance work may be taken up.

A) Cleaning/Grinding of all the valve seats as may be required.

B) Renewal of all the packing & gaskets.

C) Re-setting of the safety valve.

D) Hydraulic Test of the CTB at 1.5 times of working Pressure after assembly of
the valves & mountings.

E) Greasing and over hauling of all the motor bearings, blowers, pumps etc.

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6.4 FOR ROUTINE MAINTENANCE
A) Tighten the gland bolts of the valves after water raised in the coil.

B) Lubricate all the bearings, feed the bearing temp. Check for any abnormal
sound. Check the holding down bolts.

C) See the valve spindles are free from dust and operated freely. Check the valves
are not closed too tight. If they are too tight ease it back by one round.

6.5 FOR PERIODICAL MAINTENANCE

3.5.1. Mandatory Annual Maintenance:

Thermic fluid heater should be over hauled once in a year and the certificate to
be renewed.

3.5.1.1. Cleaning Of CTB

 Stop the CTB and allow to cool isolate the CTB from the range. Put dummy
between the stop valve and Water line. Remove the mountings. Open the header
caps. Arrange for tube cleaning. Use flexible shaft and cutter for cleaning inside
the tubes.

 Make scaffolding inside the combustion chamber and clean the tubes externally.
Use flexible shaft and cutter for cleaning inside the tubes.

 Use rough emery papers clean the chamber wherever approach is there. The
faraway tube surface can be cleaned by chains.

 Over haul all the mountings. Lap the valve seats. Test all the valves hydraulically
once and half times of working pressure.

3.5.1.2. Presentation to CIB for annual inspection.

3.5.1.2.1. For Dry Test.

 After the cleaning is completed request the CIB Inspector for dry inspection.
When the dry inspection is done prepare the CTB for hydraulic test.

3.5.1.2.2. For Hydraulic Test.

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  Put blind on the mountings except air vent valve, feed check valve and blow down
valve. Fit back the feed line valve, feed check valve, air vent valve and blow down
valve. Keep air vent valve open. Take cold water through the coil. When water
rushes out from coil air vent, close the valve. Fill up the coil. Close air valve when
water comes out with force. Raise the pressure by hand pump to 1.5 times of the
working pressure. Check for leakages .Pressure should remain constant for ten
minutes. If the test is successful release the pressure slowly.

3.5.1.3. Preparation of before resuming normal operation again.

 Empty out the coil. Open the end cover plate. After drying out the inside of the
combustion chamber, apply "Appexior" of ferrotol paint. Fit back the end plate.
Remove all the foreign materials from the combustion chamber.

 Restart as mentioned earlier.

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 7. PROCEDURE FOR LAYING UP
CTB

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 There are two methods of protection the water side of idle water heaters, the
choice of method is governed by the length of time the water is to be out of service
and how quickly the CTB may be required for service.

7.1 DRY METHOD

The Dry method is preferable when a CTB is to be cut out of service for a
month or more and need not be ready for quick return to service. CTB must be
drained, thoroughly cleaned on Water side and fire side and carefully inspected and
repaired, if necessary, to ensure that everything is in good order. The inside of the coil
must then be thoroughly dried by means of hot air stove or a light wood fire. Quick
lime (approx.) 30 lbs for each 100 Sq.ft of heating surface should be spread on water
tight wood trays and placed in the CTB coil immediately after the drying out process.

7.2 WET METHOD

The wet method should be employed for CTB kept idle for a period longer than one
week and when CTB must be ready to return to service and short notice. The CTB
should be thoroughly cleaned and carefully inspected to ensure that everything is in
good order. After the water tank is filled to the normal water level, Water should be
boiled for a short period while the CTB is wanted to atmosphere. This procedure is
necessary to expel the dissolved gases released from the coil by boiling. water must
then be treated to raise its alkalinity to above 400 ppm by the use of caustic soda
( approx. 3 lbs of caustic soda per 1000 gallons of boiled water )Sufficient sodium
sulphite must be added to the CTB water to produce a minimum residual
concentration of 100 ppm (approx. 1.5 lbs of sodium sulphite per 1000 gallons of
water in the CTB).After the CTB water cools to about 200 F, but before a vacuum is
created, the CTB must be filled completely to the top of the highest pressure part and
all openings closed. It is recommended that the CTB water to be tested at weekly
intervals to check the alkalinity and sulphite concentrations. Add chemicals if
necessary to maintain the recommended concentrations. It is advisable to know keen
the temp of the water in the CTB as low as possible (but not below freezing) while the

22 | P a g e
CTB is idle. Luck warm water promotes corrosion. For this reasons feed valves and all
water connections should be tight at all times.

If it is necessary for such an idle CTB to be returned to service, the CTB should be
heavily blow down during warming up, and before it is placed on the line, to re-
establish correct working level in tank and to reduce CTB water alkalinity to prevent
carry over.

In addition to protecting the integral or water side, of these heating surface in the
above recommended manner. It is desirable that the external, or gas side, tubes be
cleaned of soot and foreign deposit and heat the gas passages be thoroughly cleaned
and air dried. Trays of quick lime should be placed in the combustion chamber and in
the various case passages to absorb moistures. The dampers should be closed to
prevent air circulation. The quick lime should be examined and renewed at regular
intervals as it deteriorates through absorption of moisture.

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