Clayton EO-100-1M Instruction Manual

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Clayton Steam Generator model EO-100-1M PAGE 1 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Order ref nr :
INSTRUCTION MANUAL
STEAM GENERATOR
EO-100-1M
EUROPE, AFRICA & MIDDLE EAST HEADQUARTERS
CLAYTON OF BELGIUM NV Rijksweg 30 B-2880 Bornem Belgium
Tel.: +32-(0)3-8905700 Fax: +32-(0)3-8905701 E-mail: sales@clayton.be www.clayton.be
CLAYTON DE FRANCE s.a.r.l. CLAYTON DEUTSCHLAND Gmbh 160, rue du Tuboeuf Lindemannstraβe 75 F-77170 Brie Comte Robert D-40237 Düsseldorf France Germany Tel.: +33-(0)1-64053824 Tel.: +49-(0)211-2339790 Fax: +33-(0)1-64052437 Fax: +49-(0)211-23397922 E-mail: lavapeur@clayton.fr E-mail: info@clayton-deutschland.de
www.clayton.fr www.clayton-deutschland.de
CLAYTON NEDERLAND B.V. p/a CLAYTON THERMAL PRODUCTS Ltd. Rijksweg 30 5, Boleyn Court B-2880 Bornem Manor Park Industrial Estate Belgium Runcorn, Cheshire WA7 1SR, U.K.
Tel.: +31-(0)78-6139311 Tel.: +44-(0)1928-579009 Fax: +31-(0)78-6139347 Fax: +44-(0)1928-571155 E-mail: clayton@clayton.nl E-mail: sales@claytonindustries.co.uk
www.clayton.nl www.claytonindustries.co.uk
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Clayton Steam Generator model EO-100-1M PAGE 2 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC
TABLE OF CONTENTS.
TABLE OF CONTENTS. ................................................................................................................................... 2
TECHNICAL SPECIFICATIONS. ..................................................................................................................... 4
CHAPTER 1 : INTRODUCTION ...................................................................................................................... 5
CHAPTER 2 : SAFETY INFORMATION .......................................................................................................... 6
2.1 GENERAL, IMPORTANT INFORMATION ............................................................................................ 6
2.2 INSTALLATION ...................................................................................................................................... 6
2.3 OPERATION ........................................................................................................................................... 7
2.4 REST RISKS............................................................................................................................................. 7
CHAPTER 3 : DESCRIPTION. ....................................................................................................................... 11
3.1 GENERAL.............................................................................................................................................. 12
3.2 WATER AND STEAM SYSTEM ............................................................................................................. 12
3.3 FUEL SYSTEM OIL FIRED UNITS ( DRAWING HE-2673 ) ............................................................. 15
3.4 AUTOMATIC BURNER MODULATION .............................................................................................. 15
3.5 BURNER MANIFOLD ........................................................................................................................... 15
CHAPTER 4 : ELECTRICAL SYSTEM & MAIN COMPONENTS ................................................................. 16
4.1 DESCRIPTION OF MAIN COMPONENTS .......................................................................................... 16
4.2 OPERATION ......................................................................................................................................... 16
CHAPTER 5 : INITIAL FIRING. ..................................................................................................................... 18
5.1 BEFORE FIRING .................................................................................................................................. 18
5.2 CONDITIONING OF NEW INSTALLATIONS OR INSTALLATIONS WITH A NEW COIL ................ 18
CHAPTER 6 : OPERATION.& SHUTTING DOWN ....................................................................................... 20
6.1 GENERAL.............................................................................................................................................. 20
6.2 BEFORE STARTING ............................................................................................................................. 20
6.3 STARTING PLANT ................................................................................................................................ 20
6.4 STARTING THE BURNER .................................................................................................................... 21
6.5 AUTOMATIC OPERATION .................................................................................................................. 21
6.6 SHUTTING DOWN THE GENERATOR ............................................................................................... 21
CHAPTER 7 : TROUBLE SHOOTING ........................................................................................................... 25
7.1 WATER SYSTEM ................................................................................................................................... 25
7.2 FUEL SYSTEM OIL FIRED UNITS ...................................................................................................... 26
7.3 ELECTRICAL SYSTEM ......................................................................................................................... 29
7.4 BURNER FAILURE ............................................................................................................................... 29
CHAPTER 8 : PERIODIC MAINTENANCE. .................................................................................................. 34
8.1 GENERAL.............................................................................................................................................. 34
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8.2 FEEDWATER TREATMENT ................................................................................................................. 34
8.3 DAILY SERVICE ................................................................................................................................... 34
8.4 WEEKLY MAINTENANCE.................................................................................................................... 35
8.5 MONTHLY MAINTENANCE ................................................................................................................ 36
8.6 SERVICE ANNUAL (OR SEMI-ANNUAL FOR SEVERE SERVICE) ................................................... 37
8.7 PERIODIC INSPECTION OF SAFETY, CONTROL AND MONITORING DEVICES. ....................... 38
CHAPTER 9 : COMPONENT MAINTENANCE. ............................................................................................ 42
9.1 FEEDWATER PUMP.J-2 ...................................................................................................................... 42
9.2 HEATING COIL .................................................................................................................................... 49
9.3 BURNER OIL FIRED UNITS & FUEL PRESSURE REGULATOR ..................................................... 55
9.4 AIR DAMPER ADJUSTMENT E-100 ................................................................................................... 60
CONTROLLER ............................................................................................................................................ 61
9.5 START GENERATOR. ........................................................................................................................... 61
9.6 START BURNER. .................................................................................................................................. 61
9.7 CONFIGURATION OF TEMPERATURE INDICATOR JUMO ( 0202485 ) ...................................... 62
9.8 STEAM PRESSURE SWITCH (F20) ..................................................................................................... 63
9.9 MODULATION PRESSURE SWITCH [F22] ..................................................................................... 63
9.10 LIMIT PRESSURE SWITCH [F21] ................................................................................................... 64
9.11 AIR PRESSURE SWITCH [ F81,-FIG 8.22 ] ..................................................................................... 64
9.12 AIR PRESSURE SWITCH HIGH FIRE [F82 - FIG 8.22 ] ............................................................... 64
CHAPTER 10 : RECOMMENDED OILS FOR CLAYTON WATERPUMPS .................................................. 65
10.1 PURPOSE AND SCOPE. .................................................................................................................... 65
10.2 OIL SPECIFICATIONS ....................................................................................................................... 65
10.3 OILS FOR FOOD INDUSTRIES ......................................................................................................... 65
CHAPTER 11 : INSTRUCTION AND OPERATION FOR PRESSURE VESSELS ........................................ 66
11.1 DESCRIPTION OF PRESSURE VESSEL ........................................................................................... 66
11.2 TRANSPORT, HANDLING AND STORAGE. ..................................................................................... 66
11.3 ASSEMBLING AND ERECTION. ....................................................................................................... 67
11.4 TAKING INTO OPERATION. ............................................................................................................. 68
11.5 SUPERVISION AND MAINTENANCE. .............................................................................................. 69
11.6 SUPERVISION AND INSPECTION. ................................................................................................... 69
11.7 MAINTENANCE. ................................................................................................................................. 69
PSC 04-02-2014 .......................................................................................................................................... 70
End Table of Contents
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TECHNICAL SPECIFICATIONS.
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CHAPTER 1 : INTRODUCTION
This manual is intended to be used as instruction to operate the Clayton Steam Generator, providing maximum safety, efficiency, and to guaranty reliable operation over an extended lifetime.
Read this manual carefully before commissioning the Steam Generator, so that the equipment is safely and correctly installed, operated and serviced from the beginning.
Keep this manual available at all times for the operating and servicing personnel. Record all important information such as operating conditions, including feedwater treatment analyses, alarms, service interventions, in a logbook.
All activities (mounting, installation, operation and service work, etc.) must be performed by qualified and authorized staff only.
Notify the serial number of the steam generator, which is indicated on the certification label / plate, on all correspondence.
End Chapter - 1
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CHAPTER 2 : SAFETY INFORMATION
2.1 GENERAL, IMPORTANT INFORMATION
Read this instructions carefully, and look at the equipment to become familiar with the steam generator before trying to install, operate, or service it.
Never install or start-up damaged products. Make a complaint about the damage to shipping company immediately.
Installation, start-up, operation and maintenance may only be performed by qualified and authorized personnel with the relevant training in accident prevention, in compliance with the valid regulations.
Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked. Any modification on the steam generator shall only be performed in agreement with Clayton Industries, and under supervision of authorized, competent personnel.
The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.
Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every pressure vessel or auxiliary installed outside the unit to contain gases or liquid above atmospheric pressure shall be protected by a pressure-relieving device or devices as required.
The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.
DANGER Indicates an imminently hazardous situation, which, if not avoided, could result
in death, serious injury, or equipment or environment dammage.
WARNING Indicates a potentially hazardous situation, which, if not avoided, could result in
death, serious injury, or equipment or environment dammage.
CAUTION Indicates a potentially hazardous situation, which, if not avoided, could result in
serious injury or equipment or environment dammage.
2.2 INSTALLATION
Apart from general engineering practice in conformity with the local safety regulations, the following directives are specially stressed:
A steam generator or its auxiliary equipment shall be lifted only with adequate equipment in conformity with local safety rules. Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes. Distribution pipes and connections shall be of correct size and suitable for the working pressure.
Pipework or other parts with a temperature in excess of 80 degrees celsius and which may be accidentally touched by personnel in normal operation shall be guarded or insulated. Other high-temperature pipework shall be clearly marked.
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2.3 OPERATION
If remote control is installed, the unit shall bear an obvious sign reading:
DANGER: This machine is remotely controlled and may start without warning.
As a further safeguard, persons switching on remotely controlled units shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment.
On units with automatic start-stop system, a sign indicating "This machine may start without warning" shall be attached near the instrument panel.
Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked.
2.4 REST RISKS
2.4.1 GENERAL
A steam generator and its parts is based on physical processes, each with typical characteristics and possible hazards. All necessary safety precautions were taken during the design and construction of the generator. However, during certain manipulations or maintenance, there are still remaining risk factors. These are described below :
Hot components : Fire injury Let hot components cool down to ambient temperature. Use insulating or heat
repellent protective clothing, especially gloves. Do not wear short sleeves.
Badly ventilated boiler rooms : Ambient temperature rise, lack of oxygen, dehydration, fainting, combustion
gasses accumulate in boiler room : suffocation, poisoning. Foresee permanent or temporary ventilation through openings in the wall or ventilators with sufficient capacity. The generator must be able to function normally during ventilation. Insufficient oxygen can lead to poisonous CO gas.
Frost : supercooling, exhaustion. Wear warm clothing. Contact with cold metals can lead to stiff and hence
less sensitive hands, creating a bigger chance for hand injury.
Rotating or moving parts : injury to body or clothing. All rotating parts are screened off. If screens are
removed for maintenance or repair, make sure to cut the electrical power on this particular part. Use a lock or remove the key from the switch. If you need to work on parts without protective screens, make sure not to wear loose clothing such as ties, open coats etc.. Only authorized personnel should be present near the generator.
Parts sticking out : body/head injury. Wear a helmet to prevent head injuries.
Wire-edges or sharp parts : Cuts. Bramble-edges from mechanical wear or dismantling of parts. Wear
gloves and use the right tools.
Welding and grinding : hot metal sparks. Hot metal sparks are inherent for these operations. Wear protective
clothing, no short sleeves. Wear a face mask with side shields and make sure it has the appropriate color filter when welding. Glowing metal parts can cause fire. Make sure a 2nd person is present with extinguishing media and communication material so they can call for assistance in case of fire.
Difference in heights/obstacles : injury from falling down or tripping over. Check out the situation before
taking actions and inform other workers accordingly. Make sure to have the proper equipment available if you need to work on heights.
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Liquid/gas under pressure : skin penetration resulting in injuries, poisoning, eye damage. Fluids or gasses
under pressure can cause severe skin or eye damage due to their impact when flowing through fine openings. They can even enter the body, resulting in poisoning. Before taking any action, check out the situation. Eventually put pieces of cloth around the parts that need to be opened so that possible fluids or gasses get diffused. Close off isolated areas, so the fluids can be drained away and the pressure removed.
Heavy or loose parts : injuries by mechanical impact from twisting or carrying heavy weights. Use pulleys
and gloves when assembling heavy parts. Save your strength. Use tools such as crowbars and hydraulic pumps as lever or power intensifier. Appoint a coordinator when several persons are working on the same job. Watch out for injuries from crushing during assembly work.
Vacuum created by steam and/or hot water cooling down : injuries by under pressure. A vacuum can be
created in machine parts that are closed off from the atmosphere and are cooling down, after they were filled with steam and/or hot water. By opening these areas, severe suction can be created by under pressure. Make sure not to expose body parts to these openings, since this could cause skin injury.
Water-hammer . A mixture of 2 media such as water and steam in 1 pipe can create a water-hammer. This
is a ball of water blocking an entire section of the pipe. It moves forward via the steam against the steam speed. At seams or curves in the pipes, this ball of water can create an impact or become a water-hammer. Seams can be torn so that the steam escapes and/or the fixing of the piping gets damaged.
Pre-stressed springs : injuries by mechanical impact. Loosening parts with pre-stressed springs can cause
injuries by a sudden position change of the parts. Check out how these parts are interlinked first. Use accessories such as pins to disassemble parts with pre-stressed springs.
Parts not strong enough to support heavy weights : Some parts can bend or break with overloads. Parts can
never be used as a platform, support or connector. Use ladders or platforms.
Electrical parts : electrocution. Always cut the electrical power when working on electrical components.
This can be done by locking the main switch or by removing its key, when there is one available. Should repair or maintenance be needed when the equipment is under current, use rubber gloves, isolated tools and isolation between the body and the earth.
Chemicals : burns and/or poisoning. Wear face mask, chemical gloves and protective clothing when
manipulating chemicals. Keep the technical data on all chemicals used available for persons working with them. Make sure to note down the phone number of the poison control centre and local aid services.
Noise hindrance : deafness, communication problems. Wear ear protection. If you work with 2 or more
persons in a noisy environment, make sure to communicate clearly. Eventually leave the noisy area to make sure communication is not misinterpreted.
Human error : bad maintenance or wrong interpretation of circumstances. Provide training to operators and
maintenance workers.
Automation : unexpected circumstances f.i. automatic start of installation. A steam generator and its parts
can cause all of the safety hazards explained above, during maintenance or inspection. Although the equipment is well protected, caution is needed at all times. Only trained personnel can operate or maintain the generator, its devices or parts.
Please find below an explanation of the specific safety hazards, per part :
2.4.2 PUMP
Hot surface : The pump (1 or 2 depending on the model) is fed with hot water from the hotwell.
Frost : Do maintenance if a generator is not used during cold periods, ice can be formed in the parts
containing water
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Fluid/gas under pressure : Steam/water can escape when dismantling various parts.
Manipulation of heavy and/or loose parts : When changing diaphragms, heavy pump sides and pipes need to
be disassembled. Make sure to have pulleys and assistance available.
Pre-stressed springs : Between the diaphragms and sides of each cylinder, a pre-stressed spring is mounted.
Electrical parts : Make sure to cut the power of the frequency controller and motor(s) of the pump(s)
Human error : A Clayton pump is fairly complex. Make sure to foresee operator and maintenance training.
Automation : the generator and pumps can be operated via a remote control
2.4.3 COIL AND STEAM / WATER SEPARATOR
CAUTION ! Testing of Safety valves
Open bonnet or spindle guides( Danger from leaking media): Make sure that no danger can arise from
leaking media. Keep a SAFE distance. Wear suitable protective equipment.
Hot medium(Burns or scalding): Wear suitable protective equipment. Hot surfaces: Burns.
Hot surfaces : Hot feed water from the pump is pumped into the coil under pressure. As mentioned in the
“general” instructions, caution should be taken during repair or maintenance due to the temperature of the piping and equipment. During dismantling or opening of parts steam and/or water could escape. This especially goes true for the inspection calibration flange of the steam collector. A calibration pressure gauge can be installed on this flange to monitor the calibration of the different measuring devices.
Frost : Do maintenance if a generator is not used during cold periods. Be aware of the fact that in cold
periods, the water in the coil/separator can be icy.
Parts sticking out : are present.
Difference in height and obstacles : The coil is mounted vertically. Use ladders or platforms during
maintenance on upper parts.
Fluid/gas under pressure : Be aware of the fact that steam and/or water can escape when opening or
dismantling various parts.
Water hammer : During manual operation of the valves, the steam/water mixtures cause water hammer.
Vacuum : created by the cooling down of steam/hot water. In generator parts closed off from the air and
filled with steam and/or hot water, a vacuum can be created after cooling. When opening these areas, a strong suction can be created.
Electrical parts : make sure to cut off the electricity from motors and pumps.
Automation : the generator and pumps can be operated from a distance, as well as the steam generator itself.
2.4.4 FUEL AND AIR PIPING
Badly ventilated boiler rooms : The heating coil is surrounded by an air cover under a predefined over pressure. As a result combustion gasses cannot leave the generator but only escape via the chimney. However, if this system fails, combustion gasses can get into the boiler room. This problem could occur when the air supply to the ventilator is blocked and hence no overpressure can be build up. Also poisonous CO gas can be formed due to lack of oxygen. Therefore always make sure to close the gas street manually and secure it via a lock, if maintenance or repair is needed.
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Frost : Do maintenance if a generator is not used during cold periods.
Rotating or moving parts : These are : motor, ventilator, belts and pulleys, oil fuel pump installed on blower
axe, oil fuel pump (motor + pump assembly). Always disconnect electrical power of the generator during maintenance.
Height difference and hindrance : Be careful when taking samples of exhaust gasses at the coil outlet, in the
chimney or when inspecting the inlet of the blower.
Parts not strong enough to support body weight : the protective screen at the air blower entry
Electrical parts : Make sure to cut the power from all the motors, ventilators and oil pumps
Automation : Generator ,fuel and air hook-up can be started via remote control.
2.4.5 CERTIFICATION
The Clayton steam generator is designed and manufactured in compliance with:
Pressure Equipment Directive (PED) 97/23 EC Machine Directive 98/37 EC Low Voltage Directive 2006/95 EC Electro Magnetic Compatibility (EMC) 2004/108/EC Electrical safety EN 60204-1 Reviced Machine Directive 2006/42/EC
End Chapter - 2
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CHAPTER 3 : DESCRIPTION.
Flow diagram WATER / STEAM Drawing : HE-2528-C
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3.1 GENERAL
The Clayton steam generator will deliver its rated output of 99% quality steam (containing less than one
percent moisture). The generator will develop its full rated pressure within five minutes from a cold start.
Standard equipment includes safety devices for protection against water failure, burner failure, excessive pressure, and electrical overload. Automatic controls regulate the flow of the feedwater and modulate the burner in accordance with steam load demand. An attendant in charge, however, must give the equipment the attention prescribed in this manual.
3.2 WATER AND STEAM SYSTEM
3.2.1 FLOW
Supply water and return condensate blend in the hotwell. Water is pumped directly from the hotwell into the heating coil, flowing through the spiral single passage section of the coil in a direction opposite to that of the combustion gases, where it is rapidly heated to steam temperature. As the fluid leaves the generator section, it passes through the ring thermostat tube and helically wound water wall section, into the separator nozzle in the steam separator. The centrifugal force in the nozzle separates dry steam from excess water, which returns to the lower section in the separator. Steam is delivered through the steam discharge outlet located at the top of the steam separator. The excess water is returned to the hotwell through the steamtrap.
3.2.2 WATERPUMP
The diaphragm type waterpump is designed to deliver sufficient water to maintain a wet coil at all operating conditions. The pump is driven by a electric motor and contains no stuffing boxes. The diaphragms are operated through hydraulic oil which is displaced by reprocicating pistons. Corrosion-resistant springs, discs and seats are used in the check valve housings. Tubular columns separate the check valve housings from the pump heads to keep excessive temperature from the diaphragms. Snubbers absorb pressure pulsations to ensure stabilized pump delivery. A relief valve protects the pump against excessive pressure. A pump oil level switch, float operated, is mounted to the waterpump with a sensing tube plumbed to the pump crankcase. This pump oil level switch will secure the plant if there is improper oil level in the waterpump, either too low or too high. Heating coil and separator Fluid is circulated through a single-pass, continuous steel tube (heating coil) where it is progressively heated to the steam temperature. It is then discharged into the steam separator where steam and liquid are separated.
The heating coil is mounted to allow free expansion. It is arranged to provide maximum heat absorption by a series of coils with fluid counterflowing the combustion gasses at controlled velocities. A tightly wound helical section tube forms the fluid wall around the combustion chamber. A feedwater pressure gauge is mounted on the pump. A higher pressure indication than normal and/or a leaking relief valve on the waterpump indicates a formation of scale or even partial restriction of the heating coil.
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3.2.3 STEAM SEPARATOR
Steam and fluid entering the separator from the heating coil are discharged through a separating nozzle where steam is released and excess water is centrifugally separated. The excess water passes to the lower section of the separator where it is trapped back to the hotwell. This positive control of separation prevents carry-over of liquid into the steam lines.
3.2.4 STEAM TRAP
The steam trap returns excess water from the separator.
A pressure gauge has been mounted on the steam trap discharge line. It has been provided to indicate when the steam trap is either open or closed. A rising pressure on the gauge indicates that the steam trap is discharging condensate. When the pressure begins to drop, the trap is closed. If the steam trap is not opening and closing in a normal matter, this would indicate malfunctioning of the trap or some other component in the steam generator. Also the waterpump may not be discharging its normal capacity or the blowdown valve may be partially open.
On initial start of the plant, after the correct air-fuel and water rates have been established, a record of the steam temperature and trap opening time should be recorded. Periodically, these figures can be checked to assure the operator that the generator is operating properly.
If the steam generator is connected to an open system where the feedwater temperature is 90 to 95°C, the steam trap should be open approximately 10 to 15 minutes (accumulated) of each hour at high-fire operation. At steady half-fire, the accumulated time should be half this amount.
By checking and recording the operation time of the steam trap under normal conditions, malfunctioning of the generator can be noted. If a component such as the waterpump (which has a fixed pumping rate) does not work properly, the opening time of the steam trap will differ from above values. An increase in the firing rate or decrease in the pump rate will likewise decrease the trapping time. Trap open time should not fall below 3 minutes per hour at high-fire and 2 minutes per hour at low fire (accumulated) under any condition.
When starting the generator, or during periods of abrupt load changes, excess heating coil liquid may enter the separator, where it is carried off by the steam trap.
3.2.5 TEMPERATURE SENSOR
The temperature sensor protects the heating unit against overheating. Temperature sensor B29 is mounted in the wall of the heating unit In case of overheating of the tube wall, at a temperature approx. 50°C above saturation temperature , the generator will shut down. When the alarm condition is corrected the generator must be manually restarted.
Temperature sensor mounted in the wall of the heating unit
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Flow diagram FUEL OIL ( HE-2673-C )
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3.3 FUEL SYSTEM OIL FIRED UNITS ( DRAWING HE-2673 )
Fuel is delivered to the forced draft burner under pressure. Fuel pressure is governed by an adjustable fuel pressure regulator [11]. Burner modulation is achieved by the electrically operated low fire [Y42] and high fire [Y43] solenoïd valves. After manual start, oil will enter through the burner nozzle after a prepurge period and be ignited by an electric spark. Burner operation is fully automatic and all controls are arranged to fail safe. Flame failure will cause automatic shut-off within one second. A switch [F81]+[F82] operated by combustion air pressure is provided to shut down the generator if the motor or blower fails. Control of the air is accomplished by electrically operated [M83] motor air damper.
3.4 AUTOMATIC BURNER MODULATION
Automatic burner modulation prevents frequent on/off cycling of the burner and provides stable operation during periods of low load. This is accomplished by controlling the burner by means of the electrically operated three position (off, low-fire and high-fire) main gas valve with an adjustable low fire position. When steam pressure rises to the adjusted modulation point [F22] the gas valve will close to the low fire position. When the burner modulates, the solenoid operated automatic damper restricts the burner air supply to maintain oil-fuel ratio. The unit will automatically return to high fire operation if low fire operation will not carry the steam demand. A manually operated switch [S1] on the electrical control box prevents high fire operation when desired or when making certain burner adjustments. Control of the air is accomplished by electrically operated [M83] motor air damper.
3.5 BURNER MANIFOLD
Air entering the burner volute from the blower, is centrifugally directed at high velocity to the burner manifold, where it blends with the fuel. Fuel is automatically ignited by an electric spark. A flame detector is incorporated to detect the flame and maintain safe burner operation.
Steam pressure (bar)
Steam temp. (°C)
Steam pressure
(bar)
Steam temp. (°C)
1 120 11
188
1,4 126 13
195
1,8 131 15
201
2 134 17
207
2,4 138 19
212
2,8 142 21
217
3 144 23
222
3,5 148 25
226
4 152 27
230
5 159 29
234
6 165 31
237
7 170 33
241
8 175 35
244
9 180
Steam pressure - steam temperature
End Chapter - 3
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CHAPTER 4 : ELECTRICAL SYSTEM & MAIN COMPONENTS
4.1 DESCRIPTION OF MAIN COMPONENTS
For the description of the main components, we refer to the electrical drawing(s). in the Clayton Binder The last pages of these electrical drawings contain the function of the components.
4.2 OPERATION
4.2.1 GENERATOR ON
S10 = POWER ON S1 = 1-STOP -2- PUMP -3- BURNER -4- High FIRE S02 = RESET
All the alarms are wired in series. In case one of the alarms opens, it interrupts the power supply to burner control and motor. Also the specific alarm relay is energized causing a second interruption of the circuit to burner and motor. Exact cause of failure can be determined from alarm indication light on the control box.
From the [LAL2] combustion controller, via the normally closed contacts of the alarm relais, power is transmitted via the "no air" contact of [F81] to the motor contactor. (in case a boosterpump is connected, it
now starts). The motor contactor or support relay asures +-30" pre-purge at initial generator start. From this
contact power is transmitted to the burner switch [S01 position burner ]
4.2.2 BURNER ON
- S01 = Burner position
When the switch [S01] is placed in the burner position, power is transmitted through steampressure switch
[F20] to combustion controller, initiating the start-up of the burner..
Now the ignition transformer is energized.. Burner should ignite within 2" and the flame detected by the
[UV-B3 ]flame scanner. Now the burner operates at low fire. Combustion air rate and waterpump rate are at
50%. Waterpump runs at low speed and MOTOR AIR DAMPER [M83]. is energized
4.2.3 BURNER MODULATION
S01 = Position high fire
When [S01] and steampressure switch [F22] are closed and after the high fire delay of +-25 seconds, the air damper is opened, switching on the high fire oil valve [Y43] . At same time the waterpump operates at full capacity.( motor at high speed)
When steampressure reaches set point of the modulating steampressure switch [F22], this switch opens and the high fire oil solenoid valve is de-energized. Simultaneously the waterpump operate at half capacity, low
speed , also the air damper [M83] is energized restricting the air flow to the burner to half rate. This pressure
switch is normally set to operate +/- 1 bar below the steam operating pressure switch [F20.]
4.2.4 BURNER STOP AT MAXIMUM STEAM OPERATING PRESSURE
At maximum steam operating pressure, pressure switch [F20] opens the circuit to the combustion controller, causing the oil valves [Y42 & Y43] to close and the combustion controller to cycle to its start position. Simultaneously the waterpump stops.. When steam pressure has fallen +/- 1 bar [F20] restarts the burner and waterpump according the program described previously.
For this manual the electrical drawing is SW-3192
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4.2.5 ALARM STOP
All alarms interrupt the circuit to the combustion controller and the motor, and consequently stop the steamgenerator. In all these cases the accompanying alarm failure lamp is lit up. After the failure is corrected the unit can be reset with button [S02].
The unit is equipped with the following alarms :
H-10 : stops the unit in case of generator motor overload or wrong oil level in waterpump
crankcase. H-21 : stops the unit in case of excessive steam pressure. H29 stops the unit in case of coil temperature H-31 : stops the unit in case of high steam temperature. H-81 : stops the unit in case of insufficient combustion air pressure. or flame failure. H-200 : stops the unit in case of external conditions. H-47 : stops the unit in case of minimum fuel pressure / burner failure
End Chapter - 4
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CHAPTER 5 : INITIAL FIRING.
5.1 BEFORE FIRING
Every steam generator is thoroughly tested and all adjustments are correctly made under actual operating conditions before shipment from the factory. Rough handling in shipment may cause loosening of plumbing connections or change some of the adjustments. It is recommended that the following procedure be carried out before initial starting to ensure satisfactory operation.
Visually inspect and tighten any loose plumbing connections and make sure plant has been installed in accordance with installation manual (ref 191.076), regarding fuel system, exhaust systems, etc...
Check rotation direction of the blower. This can be checked by removing the inspection cover on the air inlet duct.
Verify that all fuel lines are open and fuel circulation through the burner circuit is present. If operated without fuel, the fuel pump will quickly score and be damaged. When initially starting, disconnect return line to check flow and thus be sure that fuel is circulating.
Suitable watertreatment equipment should be installed before steam generator is placed in service. Adequate water treatment MUST be used from the time the generator is first operated.
It is IMPORTANT that the coil overheating protection be tested after the generator has been initially started and brought up to operating steam pressure. The sensor ( thermocouple or PT-100 ) should be tested periodically to ensure continuous protection.
After proper firing rate has been established, check coil feed pressure at high fire. Record steam pressure and coil feed pressure for future reference.
5.2 CONDITIONING OF NEW INSTALLATIONS OR INSTALLATIONS WITH A NEW COIL
5.2.1 PURPOSE
To remove residual mill scale, metal shavings, oils and other contamination captured within the heating coil & feedwater system during installation of the steam generator, its ancillary equipment, and the feedwater system. It is essential to “boiled out” the plant prior to full commissioning of the generator to prevent deposits from attaching themselves to the coil tube wall.
5.2.2 STEP 1
Flush out the hotwell and steam generator system, using soft water.
Thoroughly dissolve 5 kg (10 lbs) of commercial tri-sodium phosphate (Na3PO4.10H2O) or 2,5 kg (5
lbs) pure (anhydrous) tri-sodium phosphate (Na3PO4) in softened water in a separate container per m³ (250 gallons) water. Ratio amounts listed above based on the volume required to fill the applicable
coil, separator, and receiver tank being installed.
In order to ease the dissolving of the product, it is strongly recommended to use hot softened water at or above 60°C (140°F)
Add the tri-sodium phosphate mixture to the receiver.
Operate the steam generator & feedwater system (plant) for at least one hour.
Blowdown the plant.
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With plant operating at normal steam pressure, open separator drain valve After 30 seconds, shut off burner and close steam discharge valve Open coil drain valve and close separator drain valve When steam pressure drops to zero, close coil drain valve
5.2.3 STEP 2
Mix another solution of tri-sodium phosphate, this time using 2,5 kg (5 lbs) of commercial tri-sodium phosphate or 1,25 kg (2½ lbs) pure (anhydrous) tri-sodium phosphate per m³ (250 gallons) water. Again, ratio the volume to fill the applicable coil, separator, & receiver.
Add this solution to the receiver and allow the plant to operate normally for 10 to 12 hours.
Blowdown the plant again as instructed
This should completely clean the system of all construction and installation residues.
End Chapter - 5
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CHAPTER 6 : OPERATION.& SHUTTING DOWN
6.1 GENERAL
The guidelines in this section are intended in the first instance to make the service personnel confident with each phase of the operation of the steam generator. Remarks and notes are inserted to underline the importance of specific points. Reference numbers in the text refer to the electrical components described in the electrical plan or to appendices described in the generator’s P&ID diagrams.
Please read the instructions and remarks in the instruction handbook fully before starting up the generator. Faults arising as a result of failure to observe these instructions relating to maintenance, tests and inspection of the generator parts will render the guarantee for the installation null and void.
6.2 BEFORE STARTING
- Close : - Soot blower valve [28], only for oil and oil/gas fired units
- Steam discharge valve [47]
- Coil drain valve [25]
- Drain cock at base water pump
- Open : - Water supply to the hotwell
- Coil feed valve [26]
- Valve steam Trap (35)
6.3 STARTING PLANT
Place all switches in "off" position.
Start motor by switching [S01]. The generator motor starts now. If motor does not start and the yellow alarm lamp is lit up, then push [S02],
Prime feedwaterpump housing [40] by opening bleeder cock, until air is expelled. If pump fails to prime, loosen intake valve cap two turns (wrench furnished) to eliminate air, then retighten. When plant is started initially, or if it has been idle for a long time, remove intake and discharge valves from feedwaterpump housings and wipe the discs and seats with a clean cloth to ensure proper seating. Be sure check valves are installed into the same port from which they were removed.
If pump fails to prime after inital start or at any time when the unit is started completely dry, stop plant and close feedwater intake valve [20]. Remove check valves from feedwater pump. Then open feedwater intake valve [20] just anough to allow pump columns to fill completely. When pump is full, replace check valves. Reopen feedwater intake valve and restart plant.
Check waterpump prime by throttling coil feed valve until pressure rises to XX bar. If feed pressure does not rise to XX bar, prime waterpump in similar manner as explained. Reopen coil feed valve
[26] after check.(XX See QC-1039 test sheet)
If plant is completely dry or if plant is restarted (not completely filled with water), allow 20 minutes for the pump to fill heating coil. Rising pressure registered on the steam pressure gauge indicates that water has reached the steam separator.
If plant is wet shut-down, burner can be started immediately
CAUTION : Be sure all fuel lines are open and fuel circulation through burner circuit is present. If operated without fuel, the fuel pump will be quickly score and be damaged. When initially starting, disconnect return line to supply tank to check flow and thus be sure that fuel is circulating
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6.4 STARTING THE BURNER
Start burner. Switch [S01] in position burner. After a 10 seconds prepurge time the burner should ignite. If no flame is detected, the generator will be stopped and a manual reset by switch [S2] will be necessary.
After burner is ignited, allow steam generator to come up to operating steam pressure. With the coil and separator full of water, open separator drain valve [32] until first pressure drop shows on steamtrap pressure gauge [41].
When steam pressure has reached maximum, put control switch [S01] in position "HIGH FIRE" and gradually open steam discharge valve.
Check stack for burner smoke. If smoke is noticed regulate the air supply to the burner to eliminate the smoke and prevent sooting.
When the plant has reached full pressure and temperature after initial start, record feed pressure for use in determining degree of coil restriction.
6.5 AUTOMATIC OPERATION
When steam pressure rises to approximately XX bar), the modulating pressure switch [F22] will cut burner capacity to low-fire operation.
On light steam demands or when no steam is required, the steam pressure switch [F20] will cut out and stop the burner when steam pressure rises to working pressure .It will automatically restart the burner when pressure drops about 1 bar below maximum. The burner will thus cycle between on and off during light steam demands.
. If the steam demand increases, high-fire operation of the burner will be re-established by means of the modulating pressure switch [F22] when steam pressure drops to +-1 bar below maximum. With moderate to heave steam demands, the burner will cycle between high and low-fire operation, or operate on high fire continuously, depending on the steam demand
During on/off or low-fire/high-fire operation of the pump will operate by means of the 2 speed motor.
6.6 SHUTTING DOWN THE GENERATOR
PURPOSE AND SCOPE
The purpose of conserving generators, exhaust gas boilers or any other installation is to protect the installation against in- and outside corrosion and/or freezing during periods of shutdown. Protection of generators, exhaust gas boilers or others parts during fabrication and/or storage, (that is before
they are incorporated in an installation) is described in a Clayton procedure
BASE AND REFERENCE DOCUMENTS
-- Clayton installation manual
-- Clayton instruction manual
WARNING : Start the burner only when the water pump has been properly deaerated and
when the generator is completely filled with water
NOTE : Pressures given in the following text are typical for a unit adjusted for a maximum
operating pressure of 10 bar. The pressure ranges given in parenthesis are the values that have to be substracted from the maximum operation pressure if the unit is adjusted for other pressures.
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CONSERVATION OF GENERATORS
Generally two conservation methods can be distinguished. The first one is the dry shutdown method, the second one is the wet shutdown.
6.6.1 DRY SHUT DOWN PROCEDURE
With plant operating at normal steam pressure, close feedwater intake valve [26], open separator drain valve [32] and coil drain [25] valve and start timing.
Progressively close steam discharge valve in such a manner as steam pressure will remain just below the modulation pressure. This will permit continuous burner operation. If coil thermocouple protection does not shut down the boiler in 60 seconds, shut down plant manually after 60 seconds
Close valve in steam trap line and valve in automatic blowdown line.
When steam pressure drops to zero, close coil drain valve and steam discharge valve.
Leave separator drain open but make sure that the drain line contains a vacuum break, so that no drain water can be returned to boiler. If block and bleeder valves are installed in separator drain line, leave bleeder valve open to aerate boiler.
To protect the whole installation from freezing, drain all water containing pipes and vessels. Drain pumps, separators, hotwells and/or pressure vessels. Remove all tubes and equipment from water and steam system in which a low sump may contain water. Remove snubbers from pumps and pig-tails from pressure gauges. Drain blowdown tanks. See to it that no water can enter the system from drains. If necessary create vacuum breaks on drain lines.
When restarting the installation and the boiler after long dry shutdown, adapt watertreatment in order to rebuild protecting magnetite layer.
To restart, fill-up pressure vessels, hotwells, accumulators and/or separators with water. Circulate water over boiler for two hours and purge all piping before applying heat to the boiler.
6.6.2 WET SHUT DOWN PROCEDURE
6.6.2.1 If feedwater tank is installed at top level of installation
Bring system under steam pressure
If the content of feedwater tank is not sufficient to fill up the system, raise water level before starting this procedure or contact Clayton.
For longer shut down periods, bring oxygen scavenger level in feedwater tank up to 4 times normal working level.
Shut down burners.
Close drain valves and automatic blowdown valves
Close off supply water to feedwater tank.
Gradually close steam outlet valves (do not create overpressure)
Fill system with water using feedpumps and/or circulation pumps.
Stop pumps.
Check oxygen scavenger level weekly. If oxygen scavenger level drops below normal working level, add oxygen scavenger to feedwater and run feedpumps and/or circulation pumps for two hours.Check water level in feedtank weekly. If level drops below minimum level add water and oxygen scavenger to tank until normal scavenger level is established.
Whenever feedtank is refilled, check alkalinity . If needed bring alkalinity up to normal level while running feedpumps.
Close off supply water to feedwater tank and check for leakages in system.
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To restart system, open steam outlet valves, water supply valve and automatic blow down valves and start generator. If low-level alarm occurred during the shut down period, run feedpumps and/or circulation pumps for two hours to fill up the system.
Fired Clayton generators and exhaust gas boilers can be equipped for fully automatic wet shut down procedure in this context.
6.6.2.2 If feedwater tank is not installed at top level of installation
For shut downs of maximum two weeks
Follow above described procedure.
For shut downs of more then two weeks: if feedtank remains pressurized
Follow procedure below.
Bring system under steam pressure
If content of feedwater tank is not sufficient to fill up the system, raise water level before starting this procedure or contact Clayton.
For longer shut down periods, bring oxygen scavenger level in feedwater tank up to 4 times normal working level.
Shut down burners.
Close drain valves and automatic blowdown valves.
Close off supply water to feedwater tank.
Gradually close steam outlet valves (do not create overpressure)
Fill up system with water using feedpumps.
Check oxygen scavenger level in system on a weekly basis. If oxygen scavenger level drops below normal working level, add oxygen scavenger to feedwater and run feedpumps for two hours.
Whenever feedtank is refilled, check alkalinity . If needed bring alkalinity up to normal level while running feedpumps and/or circulation pumps.
To restart system, run feedpumps and/or circulation pumps for two hours to fill up the system.
Then open steam outlet valves, water supply valve and automatic blow down valves and start generator.
For shut downs of more then two weeks: if feedtank does not remain pressurized
Follow procedure below.
Prepare nitrogen connection to system
Bring system under steam pressure
If content of feedwater tank is not sufficient to fill up the system, raise water level before starting this procedure or contact Clayton.
For longer shut down periods, bring oxygen scavenger level in feedwater tank up to 4 times normal working level.
CAUTION : In this case, do not start burners nor apply hot exhaust gasses to system before
filling up the system, this could cause serious damage to the boiler.
CAUTION : Never start burners nor apply hot exhaust gasses to system before filling up the
system, this could cause serious damage to the boiler.
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Shut down burners.
Close drain valves and automatic blowdown valves
Close off supply water to feedwater tank.
Gradually close steam outlet valves (do not create overpressure)
Fill up system with water using feedpumps and/or circulation pumps.
Stop pumps and close all valves connecting the system to the feedwater tank.
When system pressure drops below one bar, open nitrogen and set nitrogen pressure regulator at two bars
Check oxygen scavenger level in system on a weekly basis. If oxygen scavenger level drops below normal working level, add oxygen scavenger to feedwater and run feedpumps and/or circulation pumps for two hours.
Whenever feedtank is refilled, check alkalinity . If needed bring alkalinity up to normal level while running feedpumps.
Do release nitrogen pressure before running pumps and re-establish nitrogen pressure at 2 bars after pumps are stopped.
Check nitrogen pressure weekly. If nitrogen pressure drops below one bar, check nitrogen supply. Check for leakages in system. Reestablish nitrogen pressure at two bars.
To restart system, close off nitrogen supply, open all connection valves to the feedwater tank and run feedpumps and/or circulation pumps for two hours to fill up the system and to purge all nitrogen.
Then open steam outlet valves, water supply valve and automatic blow down valves and start generator and/or exhaust gas boiler.
End Chapter - 6
CAUTION : . Never start burners nor apply hot exhaust gasses to system before filling up the
system and purging all nitrogen, this could cause serious damage to the boiler
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CHAPTER 7 : TROUBLE SHOOTING
7.1 WATER SYSTEM
TROUBLE POSSIBLE CAUSE SOLUTION
Pump failing to maintain proper feed
volume to heating coil causing
thermostat interruption
- Pump check valves not operating properly
- Surging because of insufficient level difference hotwell - waterpump
- Pump not primed
- Leaking drain valve
- Low oil level in waterpump causing reduced pump capacity
- Abrupt steam demand causing low pressure in the separator
- No water at waterpump inlet
- Feedwater strainer plugged
- Wateroutlet hotwell plugged
- Waterpump solenoid sticking
- Clean and inspect valves
- See installation manual
- Prime pump
- Close or replace drain valve
- Be sure oil is maintained at proper level
- On installations where there are sudden heavy steam demands, a back pressure regulator should be installed to retain a normal pressure in the separator during these periods
-
Check water level in hotwell.
Check if water intake valve is open
- Remove screen from strainer and clean thoroughly. Clean hotwell more frequently
- Clean hotwell
- Check waterpump solenoid, disassemble and clean
Steam trap discharge pressure registers
fixed pressure reading
- Steam trap open - Ensure waterpump is dischar­ging at normal capacity
- Check for possible malfunc­tioning of steam trap
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TROUBLE POSSIBLE CAUSE SOLUTION
Noisy water pump operation
- Waterpump discharge snubber not working properly
- Flexible coupling loose between motor and pump
- Hotwell not mounted at proper height
- Worn bearings or lack of oil in crankcase
- Restricted heating coil causing excessive back pressure
- Check and clean intake surge chamber. Replace rubber mould if necessary
- Tighten setscrews in flexible coupling
- Install boosterpump
- Replace bearings if necessary. Add oil to proper level
- Check for scale formation in heating coil (comparison of feed press. with normal value)
Steam pressure discharge gauge reaches
zero pressure
- Steam trap closed
- Pressure gauge defect
- Ensure waterpump is discharging at normal capacity
- Blowdown valve partially open. Close blowdown valve
- Check for possible malfunc­tioning of steam trap
- Replace pressure gauge
7.2 FUEL SYSTEM OIL FIRED UNITS
TROUBLE POSSIBLE CAUSE REMEDY
Fuel pressure to low
(stop generator immediately to avoid
dammage to oil pump)
- Fuel tank empty or supply lines plugged
- Fuel pressure not adjusted properly
- Air leak in supply line causing loss of pressure
- Fuel pump failure
- Check level in fuel storage tank.
- Check if all valves in supply lines are opened.
- Adjust fuel pressure regulator
- Suction line must be air tight and air pockets eliminated
- Replace fuel pump
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TROUBLE POSSIBLE CAUSE REMEDY
Burner fails to ignite
- Faulty ignition
- Fuel pressure switch failure
- Burner nozzle not replaced in burner
- Low fire solenoid valve does not open
- Check and adjust ignition electrodes
- Check ignition transformer and ignition cables
- Check for intermittent low voltage condition which may cause weak spark from trans­former. Install heavier feeder line to unit if necessary
- Check and adjust fuel pressure switch
- Be sure nozzles are replaced after cleaning manifold
- Check for burned out solenoid coil. Replace solenoid
Smoke from flue outlet
(to prevent sooting of heating coil and
burner, this condition must be corrected
immediately)
- Improper air supply to burner
- Fuel pressure not adjusted properly
- Carboned, loose or worn burner nozzle
- Heating coil sooted
- Dirt or sludge in fuel oil or wrong grade of fuel used
- Check air adjustment
- Clean cupped sides of blower rotor blades
- Adjust fuel pressure
- Clean and tighten burner nozzle. Replace if worn.
- If soot can not be satisfactorily removed with soot blower.
- Be sure fuel is clean. See installation manual or specifi­cation table for details
Burning or fluttering flame after burner
stop during automatic operation
- Oil solenoid valve does not close completely
- Check and clean oil solenoid valve
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TROUBLE POSSIBLE CAUSE REMEDY
Oil drip from burner
- Oil solenoid valve not seating properly
- Loose burner nozzle
- Carbon on burner nozzle causing deflection of oil spray
- Poor setting of ignition electrodes
- Check and clean oil solenoid valve
- Tighten burner nozzle
- Remove and clean burner nozzle
- Disassemble burner and readjust electrodes
Dead or fluttering flame
- Restricted or sooted flue pipe causing back pressure in combustion chamber
- Heating coil sooted
- Insufficient air to boiler room
- Air supply to burner not adjusted properly
- Burner nozzle carboned
- Remove soot or restrict
ion.
Be sure flue pipe is installed correctly.
- Remove soot with sootblower.
- Install duct from outside air to blower
- Check adjustment
- Remove and clean nozzle
Generator shuts off before maximum
pressure is reached
- One of the safety devices interrupts safety circuit
- Check which safety device has stopped generator
- Correct cause
Partial or improper operation causing
low steam pressure at normal load
- Fuel pressure too low
- High fire solenoid valve does not open or is plugged
- See "Fuel pressure too low"
- Check high fire solenoid valve
- Replace solenoid valve if necessary
Safety circuit interrupts burner operation
after normal automatic burner stop
- Fuel solenoid valve not seating properly (cause stray light lockout)
- Check and clean solenoid valve
Burner ignites but safety shutdown
occurs about 2 seconds after initial start
(inadequate flame signal)
- Dirt on UV-cell
- UV-cell defect
- Clean glass UV-cell
- Replace UV-cell
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7.3 ELECTRICAL SYSTEM
TROUBLE POSSIBLE CAUSE REMEDY
Motor fails to start or stops during
operation
- Power failure or thermic motor
- Shutdown caused by one of the safety devices
- Wait 2 to 3 minutes to cool down safety device. Reset
manually and start generator.
look for cause. Check if motor is not overheated.
- Check which light is burning and correct cause
Magnetic contactor fails to contact
- Operating coil failure
- Contact failure caused by poor contact pressure, dirt, arcing or low voltage
- Replace coil
- Replace contactor
Magnetic contact fails to disconnect
- Welded contacts due to arc or mechanical binding
- Replace contactor
Motor noisy or running hot
- Motor running single phase
- Insufficient lubrification of bearing failure
- Check for blown fuse in feeder lines
- Lubricate bearings and check for worn bearings
Magnetic contactor noisy
- Poor alignment mechanical binding
- Disassemble and clean magnetic contactor
7.4 BURNER FAILURE
NOTE : Before reset and attempting to restart, check position of coded disc, as referred to the
Burner Controller A1 (LAL2 inside electrical panel). This information will help to diagnose the exact cause of burner failure
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POSSIBLE CAUSE SOLUTION
- low combustion air pressure
- stray-light during air-purge
- check air intake of fan for obstruction or dirt
- check operation of fan
- check operation of air combustion air Pressure switch [F81] and
BELIMO MOTOR [M83]
- check if UV-cell [B3] is properly seated in its socket
- no pilot flame
- low combustion air pressure
- too high combustion air pressure, blowing out pilot-flame
- check (oil) supply to pilot burner (pilot
solenoid valves, pilot /oil pressure regulator)
- check air supply to pilot burner
- check ignition electrode, cable and transformer
- check air damper (air/ oil ratio)
- no main flame
- too high combustion air pressure, blowing out main-flame
- check (oil) supply to main burner
(solenoid valves, control valve, oil pressure regulator)
- check air damper (air/ oil ratio)
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End Chapter - 7
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CHAPTER 8 : PERIODIC MAINTENANCE.
8.1 GENERAL
Like any other piece of mechanical equipment, the CLAYTON steam generator must receive periodic inspection and attention to maintain the efficiency and service it is designed to perform. The following service recommendations require a few minutes each day and will maintain the efficiency of the unit and minimize repairs and replacements. A pad of monthly maintenance log sheets is included with each steam generator. Proper use of these sheets provides an accurate record and serves as a daily reminder of routine maintenance. Extra pads are available at request.
8.2 FEEDWATER TREATMENT
The importance of feed water treatment is discussed in detail in the "FEED WATER TREATMENT
MANUAL". To prevent internal corrosion and to eliminate scale formation, proper control of feed water
must be given serious consideration before start – up, during operation and wet shut down. For automated plants that operate without permanent supervision, supplemental feedwater control monitoring devices with lock-out function shall be provided on installation level.
8.3 DAILY SERVICE
8.3.1 FEEDWATER CONTROL
Test feed water according to the specifications of the "Feed water Treatment Manual".
8.3.2 STEAM PRESSURE AND TEMPERATURE
Record feed water pressure and steam temperature. By comparing the measured values with those recorded at initial start-up, coil restrictions can be noted.
8.3.3 STEAM TRAP TIMING
Check the operation time of the steam trap ( via manometer [41] ) under normal conditions , malfunctioning of the generator can be noted. If a component such as the water pump (which has a fixed pumping rate) does not work properly, the opening time of the steam trap will differ from above values.
8.3.4 MANUAL BLOWDOWN
Manual blow down is used to control dissolved solids and to remove suspended solids and sludge.
The manual blow down operation should be performed every 10 to 12 hours of operation. By daily chemical test, the blow down frequency can be determined more accurately. At shutdown the blow down may be performed any time during the day but at least one hour before the final shutdown.
Blow down sequence (see also instruction plate) :
With plant operating at normal steam pressure, close feed water intake valve [20] and open coil drain valve [25] and separator drain valve [32].
Progressively close steam discharge valve [47] in such a manner that steam pressure will remain just below the modulation pressure. This will permit continuous burner operation.
Shut off plant after 60 s. Put switch [S1] in position "stop".
NOTE
:
If the steam generator is equipped with an automatic blow down system, the manual blow down may be eliminated from daily operation as long as the feed water is tested daily for total dissolved solids (TDS)
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When steam pressure drops to zero, close coil drain valve [25], and separator drain valve [32] and steam discharge valve [47].
To resume operation, allow plant to fill with water and start burner in normal manner.
8.3.5 SOOTBLOW
Soot blow is only applicable for oil fired units. Each 8 working hrs or as required. To remove soot from heating coil, the following steps are to be followed :
Operate plant at normal pressure.
Close drain cock [28] located in the soot blower line to the heating coil. Open soot blower valves [28] and close the steam discharge valve [47]. This will direct the maximum available output into the soot blower.
Soot blow for 30 seconds.
Allow plant to recover for 2 minutes and soot blow for another 30 seconds period.
Then close soot blower valves [28] and open drain cock [28] and steam discharge valve [47]. This operation must be repeated at more frequent intervals if a bad soothing condition persists. If excessive soot has been allowed to gather on coil, refer to “Removal of excessive soot from heating coil”
8.3.6 WALK AROUND INSPECTION
Check for leaks, unusual noise, stack smoke, etc... Hot lines on manual blow down discharge is an indication of valve leakage.
8.3.7 TEST OF BURNER SAFETY CONTROLS
Press S2 for activation the operator presence.
With burner in operation either
8.4 WEEKLY MAINTENANCE
Partially drain hotwell. Open drain valve for 1 minute (this can be done during normal operation,
water level should be kept in sight in the gauge glass). In this way, sludge on the bottom of the
hotwell is removed.
This may be omitted if total dissolved solids' (TDS) readings are stable and within desired range. A properly adjusted blow down rate should maintain the total dissolved solids (TDS) level in the feed water to the pump at 3000 - 6000 ppm. If this level is exceeded, perform a manually blow down to re­establish the correct TDS level and re-adjust the automatic blow down valve.
NOTE : It may be necessary to reprime the pump after the blowdown operation
NOTE
:
If the steam discharge equipped with back pressure regulator and the soot blow valve is installed upstream of this backpressure regulator, the soot blow operation can be conducted without closing the steam discharge valve. In multiple steam generator installations, where sootblow steam is taken from main steam collector, the soot blow operation can be conducted without closing the steam discharge valve.
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8.5 MONTHLY MAINTENANCE
8.5.1 FEEDWATER PRESSURE AT HIGH LOAD
Check coil feed pressure at high fire rate. Record and compare with original reading for indication of internal scaling (normal feed pressure may vary slightly with each installation and it is advisable to carefully note the pressure immediately after the steam generator is installed so that an accurate check of coil restriction can be made for the particular unit).
Always note feed pressure after the steam generator has operated for a while and is thoroughly heated, and always at the same operating steam pressure, feed water temperature and at full load. Steam pressure must be maintained at least 1 or 2 bar below the maximum, under-steady load condition, to prevent burner modulation.
Coil restriction is indicated if feed pressure is 2 bar or more above the normal feed pressure noted immediately after installation or when the coil was completely clean. For example, if it is noted that feed pressure was 10 bar at a given steam pressure when the unit was in new condition, remove scale from heating coil when this pressure rises to 12bar.
If rising feed pressure is noted within 10 to 30 days after initial installation, take steps immediately to correct the cause and prevent future trouble. Carefully consider the following :
Carefully check to be sure feed water treatment is adequate and is being used properly and consistently. Feed water treatment must be consistent and continuous.
Blow down the plant more frequently. It is sometimes necessary to blow down more often than specified in this manual to remove solids which are precipitated in the form of sludge. The blow down operation is not a cure of all but it will remove scale and thereby delay coil restriction.
8.5.2 CHECK VOLUTE PRESSURE
A 6 mm diameter tube stub (or 3 mm diameter hole) is located on the left hand side of the burner volute. This is a convenient hose connection to operate a manometer for periodic or continuous monitoring of the volute pressure. A 30 cm range water column instrument can be used for this purpose. An economical model may be constructed from plastic tubing. A 10 % decrease in reading would indicate a need for cleaning of the blower rotor.
8.5.3 FLUSHING WATER PUMPHEAD AND COLUMN
Flush water pump head and column. Open drain cock at base of water pump until clear water appears. If heavy accumulations of sludge are indicated, repeat this operation more frequently. If drain cock is plugged, remove cock and us a stiff wire to dislodge sediment. Water pump may be operated and coil feed valve throttled to provide pressure to purge cock if not severely plugged.
8.5.4 CHECK BURNER SAFETY CONTROL
Simulate by removing photocell from burner volute momentarily. Generator should go out in two seconds. After check, replace cell and reset plant.
8.5.5 DRAINING AND CLEANING OF THE HOTWELL
To remove sludge, accumulated at the bottom of the hotwell.
CAUTION : Stop plant before attempting to remove drain cock
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8.5.6 CLEAN BLOWER ROTOR
If dirt or lint is allowed to accumulate on the cupped side of the blower rotor blades, shortage of air to the burner will cause reduced burner efficiency. The frequency of cleaning will depend on the amount of dirt or lint in the air at the particular installation. To clean, remove nut and remove blower inspection cover. Insert the curved end of the cleaning tool under rotor blade (fig 7.1) and move the tool back and forth until the entire under surface of the blade is cleaned
Repeat on all blades. The volute pressure, at high fire, is a good indicator of blower condition (if no change
in damper adjustment has been made).
Fig 7.1 : Clean blower rotor
8.5.7 CLEAN AND ADJUST BURNER
Wipe electrode insulator with clean soft cloth. Check electrode gap. Clean photocell. Remove nozzle only when smoke from flue outlet can not be avoided by other means.
8.6 SERVICE ANNUAL (OR SEMI-ANNUAL FOR SEVERE SERVICE)
These inspections are preferably executed by an authorized Clayton technician
Replace burner nozzle
Replace oil in crankcase. Drain and refill water pump crankcase with new hydraulic oil (chapter10 )
Inspect water pump check valves. Replace seats and discs if worn.
Inspect pump diaphragms. Replace at about 7000 hours operation.
Inspect all air, fuel and water control linkages (where applicable) for wear, screws tight, free movement, etc...
Test steam safety valve(s) [30]. Set steam pressure parameter and limit pressure switch [F21] to exceed steam relief valve pressure setting. Allow pressure to increase (by throttling discharge valve) until steam safety actuates.
WARNING
:
If valve does not actuate, after exceeding pressure setting, open steam
discharge valve immediately
The operation and setting of all alarm and operating switches, as well as setting and operation of safety and relief valves should be checked by a qualified Clayton technician
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After test is accomplished, regulate limit pressure switch and reset steam parameter to desired working pressure.
Open steam discharge valve completely. Service or replace steam safety if test fails.
8.7 PERIODIC INSPECTION OF SAFETY, CONTROL AND MONITORING DEVICES.
8.7.1 SAFETY AND CONTROL DEVICES ON THE STEAM GENERATOR ASSEMBLY.
Each steam generator assembly is as a minimum to be provided with the instrumentation, monitoring, control and safety devices as required by the harmonized standard EN 12952-7 and EN 12952-10 for the water steam system and EN 12952-8 (which refers to EN 12953-7 for coil type boilers) for the firing system. The type and quantity of monitoring, control and safety devices depends on the mode of operation and the options the user included in his order, and of the degree of automation. The P& ID diagrams give a schematic presentation of these devices and the options.
EN 12952 distinguishes plants with permanent supervision (attended operation) or plants without permanent supervision (unattended operation). For a generator operated under permanent supervision, the qualified generator/plant operator has to observe the good functioning of the generator and its appurtenances on a permanent basis, either in the boiler room, either in a control room adjacent to the boiler room and from which this operator has immediate and direct access to the safety lock-out controls.
For plants operated without permanent supervision, supplemental monitoring, control and safety devices as defined in EN 12952-7/8 are required for both the steam generator assembly and for the steam installation, essentially to monitor and lock-out the generator when the limits are exceeded. See paragraphs 8.7.2
Clayton of Belgium offers 3 different options of steam generator equipment for the different modes of operation :
1) EN-AT : Attended operation: this generator assembly is equipped for permanent supervision
2) EN-24 : Unattended 24h: this generator is supplemental equipped for maximum 24 hours continuous operation without interruption and without permanent supervision. The only difference with EN-1W is that the flame detector (UV-cel) and combustion controller are approved for maximum 24 hours continuous operation though not of the self-checking type. The burner shall be stopped at least once every 24 hours to allow the combustion controller to do its test cycle.
3) EN-1W : Unattended 1 week: this generator assembly is supplemental equipped with a self­checking flame detector and fail-safe, special design type approved and/or redundant safety lock-out devices for continuous operation without interruption and without permanent supervision during maximum 1 week.
Because of the very low, almost un-existing risks to create a steam explosion with a Clayton type steam generator (with all safety devices removed, Clayton did practical firing tests which resulted in a complete
coil burn down but no explosion), and because of use of special limiting devices, the periodicity of the
periodic inspection and testing or checking of the functioning of these devices is specified in Table 8.7-1. For a generator operated under permanent supervision, the interval of periodic testing and inspection shall be as a minimum the same as for EN-24.
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8.7.2 SUPPLEMENTAL SAFETY, CONTROL AND MONITORING DEVICES FOR STEAM INSTALLATIONS WITHOUT PERMANENT SUPERVISION .
Following precautions shall be taken and supplemental monitoring, control and safety devices are to be provided for as required in EN 12952-7/8 for steam plants operated without permanent supervision: It shall be ensured that no harmful matter (e.g. oil, grease, seawater) can enter the feedwater or generator system
The hardness of the feedwater shall be monitored automatically and
In case of totally demineralized feedwater the conductivity shall be monitored automatically
The conductivity shall be monitored permanently for non-demineralized feedwater.
If the feedwater limit values for hardness and conductivity prescribed in the feedwater manual are exceeded, the heat supply shall be cut off and locked by a device. This cut off and lock-out function is integrated into the electrical safety circuit of the steam generator through a ‘break contact from external conditions’.
The periodic inspection and testing or checking of the functioning of these devices is specified in Table
8.7-2: Installation devices for different modes of operation and their periodic testing.
IMPORTANT NOTES - WARNINGS:
The operation and setting of all alarm and operating switches, as well as setting and operation of safety and relief valves should be checked by a qualified Clayton technician
a) Any periodic testing should be carefully planned, preferably simultaneously with the official
periodic testing and inspection as required by the national legislation on steam plants supervision
b) All periodic inspections and tests of safety devices shall be recorded on the maintenance log
sheets, or in the generator log book or other appropriate reports that are to be kept available for the Authorities for the lifetime of the generator
c) Periodic testing of safety and control devices shall only be done by qualified technicians of
Clayton, preferably without changing original set points. When this is not possible, set-points may only be changed in presence of the AIA and/or a qualified technician of Clayton and the broken seal(s) shall be replaced after testing and readjusting to the original settings
d) Restarting the generator after a shut down by a safety device is only allowed and possible after the
anomaly is solved and the reset button is activated. The normal starting sequence for taking a generator into operation shall be followed
e) When during the inspection and testing any mal functioning devices are found, they shall
immediately be replaced. Only original genuine parts may be used for replacement of any of the safety devices. Any alternatives shall be approved for the same application, range and qualifications and shall have the required certificates and/or declarations. All such replacements shall be reported in the logbook or other recordings
f) For residual risks see chapter 3: Safety instructions – section rest risks.
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Table 8.7-1: Generator devices for different modes of operation and their periodic testing.
Col 7: Actions of the provided devices:
A = pressure accessory; C = operation control device; M = monitoring or indicating device; P = Overpressure protection device
;
S = Safety cut off and locking (or shut off) device
.
Col 8->10 :
Operation modes to EN12952
-7/8
: EN-AT=attended; EN
-
24=max.24h continuous unattended ; EN
-
1W= max.1 week unattended
Devices for specific mode: X=standard installed; XC=supplemental installed by Clayton; XM=generator model dependant; XS=special device; O=optional device (sold as an option); OM=optional device generator model dependant.
Col 11->14 : Testing
: V=visual check; F=functional check or compare with calibrated device.
Max. Interval
(=max. inspection interval for periodic checks unattended mode): D=daily; 1W=weekly; 4W=every 4
weeks; 1M=monthly; 6M/12M=every 6/12 months.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
System Ge nerator model
PID or
E.diagr.
Ref.(s)
Device type
Type EN 12952-7/8
Protection and/or Operational
requirement or function
Action EN- AT
EN-24
(O)
EN-1W
(O)
Testing
Max.
Interval
EN-24
Max.
Interval EN-1W
Test instruction Notes
Air/atomising Modulating - Oil F83 Pressure switch PSZ-A- Min. press ure limiter – Min. atomising air pressure
S XM XS XS V+F 6M 6M
Type approved device. Close atomising air supply slowly ti
ll
generator shuts down.
Air/combustion Modulating F08 End switch ZSL-A- Min. position detection of air damper
C (S) XM XM XM V 1W 1W
Check activation and switching at intended position. Integrated in modulating motor or as a separate switch
Air/combustion Modulating F09 End switch ZSH+A+ Max. position detection of air damper
C (S) XM XM XM V 1W 1W
Check activation and switching at intended position. Integrated in modulating motor or as a separate switch
Air/combustion All F81 Pressure switch PSZ-A-
Min
. pressure limiter
– combustion air pressure
blower
S XS XS XS V+F 6M 6M
Type approved device. Cover air inlet or disconnect pressure
sensing hose.
Air/combustion Step fired F82 Pressure switch PSZ+A-
Min. pressure limiter
– combustion air pressure
blower
C XM XM XM V+F 6M 6M
Type approved device. Cover air inlet or disconnect pressure
sensing hose.
On some models with end switch F89
Combustion
Control
All B03 UV cell B Flame detection (& combustion controller A1 in panel)
S X X XS V+F D/M 6M
Type appro
ved device. With flame on or generator ready to
start, remove cell from holder and cover it from light.
Self checking type approved device if > 24 hr continuous
operation, else any burner shall be stopped every 24 hours.
Exhaust All B95 Temperature element TSZ+A+ Max. temperature limiter – Max. exhaust temperature
M (S) O O O V+F D 1W
Check and record temperature readings at full load and
compare with previous readings.
With controller in panel. Can be used as an alternative F32
TAH in combination with a special controller!
Exhaust All TI 7.2 Temperature indicator TI
Temperature indicator
- Exhaust gas temperature
gauge
M O O O V+F D* 1W*
*Daily/weekly readings should be recorded on the log
sheets.
Compare with previous readings and take appropriate action.
Fuel - Gas All-Gas>1200kW A60 Gas leak detector A Tightness of gas valve
S XM XM XM V 6M 6M
Type approved device. Self
-
checking device
– Check
functioning of indication led(s)
Optional if burner capacity <= 1200kW (EN676).
Fuel - Gas All F60 Pressure switch PSZ-A- Min. pressure limiter – Min. gas pressure at inlet
S XM XM XM V+F 6M 6M
Type approved device. Slowly close main gas valve at
maximum firing rate till gas pressure at in let drops below set point.
Fuel - Gas Step fired F61 Press ure switch PSZ-A- Min. pressure limiter HF - Inlet generator gas valves
S XM XM XM V+F 6M 6M
Type approved device. Slowly close main gas valve at
maximum firing rate till gas pressure at in let drops below set point.
Fuel - Gas All F62 Pressure switch PSZ+A+ Max . pressure limiter – Max. gas pressure at inlet
S XM XM XM V+F 6M 6M
Type approved device. At low firing rate, a qualified
technician decreases the set point till the switch shuts down the generator.
For detection of membrane failure or wrong adjustment of
the pressure regulator.
Reset to original setting after functional testing!
Fuel - Oil All – Oil fired F47 Pressure switch PSZ-A-
Min. pressure limiter
– Inlet generator oil valves/
burner
S XM XM XM V 6M 6M
Type approved
fail safe device. Check combust
ion &
emission measurements.
F47 is not installed on units with built
-
in low pressure
protection in the fuel pump.
Steam All 30.(1/2/3) Safety valve(s) PSV Safety valve – Max. steam pressure
P X X X V+ F 4W/6M 4W/6M
Type approved device.
Pull lever to lif
t the valve from its
seat. Periodicity may be extended to 6M if salt free demi­water is used!
Min.1 safety valve installed for capacity to be evacuated to a
safe area, normally set at design pressure of the generator assembly
Steam All B29 Temperature element TSZ+A+
Max. temperature limiter – Max. coil pipe metal temperature
M (S) XC XC XC V+F 6M 6M
At low firing rate, a qualified technician decreases the set
point till the switch shuts down the generator. Reset to original setting after functional testing!
XM : Either connected to PLC either to a temperature
controller
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Steam All F21 Pressure switch PSZ+A+ Max. pressure limiter - Max. steam pressure
S O XS XS V+F 12M 12M
Type approved
fail safe device. Qualified technician
bypasses or increases steam modulating pressure switch to a set point higher than limit switch in presence of AIA.
Reset to original setting after functional testing!
Steam All F31 Temperature switch TSZ+A+ Max. temperature limiter – Max. steam temperature
S XS XS XS V+F 6M 6M
Type a
pproved device. A qualified technician decreases the
set point till the switch shuts down the generator.
For high pressure units, TE with special approved controller!
Reset to original setting after functional testing!
Steam All F32 Temperature switch TSZ+A+ Max. temperature limiter – Max. steam temperature
S O XS XS V+F 6M 6M
Type approved device. A qualified technician decreases the
set point till the switch shuts down the generator.
For high pressure units, TE with special approved controller!
Reset to original setting after functional testing!
Steam All F38 Pressure switch PSZ+A+ Max. pressure limiter - Max. steam pressure
S O O O V +F 6M 6M
Type approved device. A qualified technician bypasses or
increases steam modulating pressure switch to a set point higher than limit switch in presence of AIA.
Reset to original setting after functional testing!
Steam All PI 38 Pressure indicator PI Pres sure indicator - Steam pressure gauge
M X X X V+F D* 1W*
Device to EN 837
-
1. *Daily/weekly readings should be
recorded and minimum once every 12 months this reading shall be compared with a calibrated gauge.
Compare with previous readings and take appropriate action.
Steam Superheaters TI Temperature indicator TI
Temperature indicators
– Superheated steam
temperature gauge
M X X X V D 1W
Check and record readings at the same load any time
recordings are made and compare to previous readings
On inlet and outlet of superheater. Compare with previous
readings and take appropriate action.
Steam All TI 7 Temperature indicator TI Temperature indicator - Steam temperature gauge
M XM XM XM V D 1W
Check and record readings at the same load any time
recordings are made and compare to previous readings
Not on models with display & B29. Compare with previous
readings and take appropriate action.
Water All F18/F19 Level switch LSZ+-A+-
Oil level detection/membrane failure pumps with oil
carter
S OM XM XM V+F 6M 6M
Check horizontal position of float switch. Force it to go in
upward or downward direction till generator shuts down.
Protection against ingress of pump oil in system or water in
oil carter (works in 2 directions!) for pumps with oil carter.
Table 8.7-2: Installation devices for different modes of operation and their periodic testing.
Col 7: Actions of the provided devices:
A = pressure accessory; C = operation control device; M = monitoring or indicating device; P = Overpressure protection device
;
S = Safety cut off and locking (or shut off) device
.
Col 8->10 :
Ope
ration modes to EN12952
-
7/8
: EN-AT=attended; EN
-
24=max.24h continuous unattended ; EN
-
1W= max.1 week unattended
Devices for specific mode: X=standard installed; XC=supplemental installed by Clayton; XM=generator model dependant; XS=special device; O=optional device (sold as an option); OM=optional device generator model dependant.
Col 11->14 : Testing
: V=visual check; S=sample analysis.
Max. Interval
(=max. inspection interval for periodic checks unattended mode): D=daily; 1W=weekly; 4W=every 4 weeks; 1M
=monthly; 6M/12M=every 6/12 months.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
System Ge nerator model
PID or
E.diagr.
Ref.(s)
Device type
Type EN 12952-7/8
Protection and/or Operational
requirement or function
Action EN- AT
EN-24
(O)
EN-1W
(O)
Testing
Max.
Interval
EN-24
Max.
Interval EN-1W
Test instruction Notes
Feedwater All HAH
Hardness sensor with controller
HAH+
Monitor feedwater hardness and shut down the heat supply when prescribed limits are exceeded.
C,M (S) O O, XS O, XS V+S D 1W
Take daily (weekly)
samples of the feedwater and analyse.
The hardness of the feedwater should be below the requirements defined in the feedwater manual.
Compare results with monitoring device and previous readings and take appropriate action.
Feedwater All CAH
Conductivity sensor with controller
CAH+
Monitor feedwater conductivity permanently and shut
down the heat supply when prescribed limits are exceeded.
C, M (S) O O, XS O, XS V+S D 1W
Take daily (weekly) samples of the feedwater and analyse.
The conductivity of the feedwater should be below the requirements defined in the feedwater manual.
Compare results with monitoring device and previous readings and take appropriate action.
Feedwater/Conden
sates
All OP Oil sensor
Monitor feedwater purity/opacity and shut down the heat supply when prescribed limits are exceeded.
C, M (S O O, X O, X V+S D 1W
Take daily (weekly) samples of the feedwater and analyse.
The conductivity of the feedwater should be below the requirements defined in the feedwater manual.
Compare results with monitoring device and previous readings and take appropriate action.
End Chapter - 8
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CHAPTER 9 : COMPONENT MAINTENANCE.
9.1 FEEDWATER PUMP.J-2
Fig.8.1 : Waterpump assembly. (2 pistons : models J2 VSD )
1 Plug 1/4"npt 16 Elbow pipe street 31 Plug mech 2 Screw drive 17 Plug plastic 32 Nut 3 Name plate 18 Seat valve check 33 Washer lock spring 4 Standpipe 19 Disc valve check 34 Stud 5 Housing valve check 20 Spring intake 35 Cap bearing 6 Plug 1/4 npt 21 gasket cap - vlv ck hi-pres 36 Seal oil 7 Crankcase pump 22 Cap valve check 37 Piston & link assy-pump 8 Stud 3/8 - 16 x 23 Spring discharge 38 Crankshaft wp belt drive
9 Cock drain 24 Gskt cap brg, 0.015" thick 39 Bearing roller Timken 10 Nut,hex 25 Gskt cap brg, 0.010" thick 11 Stud pump 26 Gskt cap brg, 0.005" thick 12 Diaphragm 27 Cap bearing 13 Washer diaphragm 28 Screw cap 14 Spring return diaphragm 29 Washer lock spring 15 Head pump 30 Plate assy cover
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9.1.1 PUMP CHECK VALVE MAINTENANCE ( FIG 8.1 )
Unscrew check valve caps from check valve housings and disassemble springs and discs from caps. Remove scale and pits from discs by rubbing them in a "figure 8" motion on a piece of fine sandpaper
(wet-or- dry Nr 400 or finer) placed on plate glass. Discs must be perfectly smooth and flat for proper
water pump operation.
Inspect springs for distortion and free length. Free length of discharge springs should be 25 mm, free length of intake springs should be 19 mm. If not within 1mm, replace spring. Also replace broken or distorted springs.
Inspect seats for scored or damaged condition. Replace damaged seats
Scale may be removed from inside of check valve housings by filling the housings and pump columns with a solution of two parts water and one part Clayton Manufacturing Company KLEENKOIL or other properly inhibited scale removing acid. Scale on springs and discs may be removed by immersing in the same solution. After scale has been dissolved, thoroughly flush parts with water. Open drain cock and flush pump columns.
9.1.2 REPLACING WATER PUMP VALVE SEATS ( FIG 8.2 )
To replace the valve seats, it will be necessary to use a special seat puller (part nr. UH-25257 and a special
seat driving tool part nr UH-18389).
Adjust puller stem counterclockwise until jaws can be retracted into the body. Unscrew body nut sufficiently to allow retracted jaws to extend below valve seat when puller is inserted into check valve housing (fig 8.2 A)
Insert puller into check valve housing and turn stem clockwise in body, until jaws are fully extended below bottom of valve seat (fig 8.2 B).
Hold body with wrench and turn body nut clockwise until valve seat is free of check valve housing
(fig 8.2 C).
Drive in new seat assembly using seat driving tool (fig 8.2
D) using care to avoid
damaging seat face.
After seats have been properly installed, assemble springs to check valve discs. Install correct springs and caps in proper ports of check valve housing.
Fig 8.2 : Use of special seat puller and seat driver
NOTE :
Remove and process check valves one at a time to avoid interchanging parts.
When reassembling, assemble the spring to the disc and attach spring to valve cap. This will
prevent unneces
sary di
stortion and possible deformation of the springs.
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9.1.3 WATERPUMP DIAPHRAGM REPLACEMENT
9.1.3.1 Removal ( fig 8.1 )
Remove drain cock and drain water from pump.
Drain oil from cranckcase
Disconnect piping from pump. Unscrew hex nuts which secure pump heads to crankcase and remove check valve housings, pump heads and stand pipes as a unit, from each side of crankcase.
Remove diaphragm return springs, diaphragm washers and diaphragms.
Replace worn or deteriorated diaphragms. Replace broken or distorted springs. Free length of springs should be 132 mm. If not within 1 mm replace spring.
9.1.3.2 Reassembly ( fig 8.1 )
Position diaphragms, washers and springs to pump case and install pump heads. Tighten stud nuts as described below. Be sure springs and diaphragm washers remain in correct position during assembly.
fig 8.3 : Torqueing sequence pump
* = starting position. Apply torque as indicated in the table, through 6cycles, using the above
sequence for tightening.
Fill pump crankcase with hydraulic oil to proper level
1 3
2 4
1 2 3 4
ft.lbs N.m ft.lbs N.m ft.lbs N.m ft.lbs N.m
20 28 20 28 20 28 20 28
40 55 40 55 40 55 40 55
60 83 60 83 60 83 60 83
100 138 100 138 100 138 100 138
150 207 150 207 150 207 150 207
200 277 200 277 200 277 200 277
- IMPORTANT :
After installation, operate plant normally for at least 24 hours. Then shut down plant and allow to completely cool. Retighten all pump head nuts while pump is cold to take up set in diaphragms and prevent leakage.
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9.1.4 WATERPUMP DISASSEMBLY AND REPAIR ( FIG 8.1 )
9.1.4.1 Disassembly
Disconnect piping and tubing from pump at unions. Unscrew attaching screws and remove pump from frame.
Remove waterpump heads, check valve housings, and diaphragms from pump. Remove oil level switch from pump case.
Unscrew capscrews and remove top plate and gasket from pump crankcase.
Unscrew nuts which attach bearing caps to front and rear of the crankcase. Insert 3/8-16 screws into tapped holes in the bearing caps and carefully jack the caps away from the pump case.
With the bearing caps removed, the crankshaft and attached parts can be removed through the top of the case.
Pull bearings from each end of crankshaft.
Slide pump pistons and links from the crankshaft. Note location of each piston and link to be sure they are installed into the same location when reassembling.
Remove retaining rings from pump pistons. Disassemble spring retainers, springs and discs from pistons.
Remove bearing retainer and slide pinion shaft and gear from crankcase.
9.1.4.2 Inspection
Inspect all bearings and bearing surfaces for worn or scored condition. Inspect pistons and cylinder walls for worn or scored condition.
Inspect valve discs and seats for scores or pits. Inspect springs for distortion or damage. Free length of discharge springs should be 25 mm, free length of intake springs should be 19 mm. If not within 1mm, replace spring. Also replace broken or distorted springs.
Inspect oil seals and packing’s for worn or deteriorated sealing members.
9.1.4.3 Repair
Replace piston and link assemblies if links or pistons are worn or damaged. Replace worn or scored crankshaft.
Scored discs may be resurfaced by rubbing them in a "figure 8" motion on a piece of fine sandpaper
(wet-or- dry Nr 400 or finer) placed on plate glass.
Replace all other worn, scored, or damaged bearings and parts.
9.1.4.4 Reassembly
Install pinion shaft and gear with bearings assembled into pump case and secure with bearing retainer. Check end play of pinion shaft. Endplay must be 0,2mm minimum to 0,4mm maximum. Add or remove shims to maintain this tolerance.
Assemble disc, spring and spring retainer into pump piston and secure with retaining ring.
Slide pump piston and link on the end of the crankshaft. Piston and link must be installed with the machined side of the link facing the gear end of the pump.
Assemble and secure main gear to crankshaft. Screws must be tightened securely. Press cone sections of bearings on ends of crankshaft.
CAUTION : Use a shield to protect the oil seal
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Press cup sections of bearings into bearing caps. Place one 0.38 mm aluminum gasket on front bearing cap. Place one or more gaskets on rear bearing cap. These gaskets are used for clearance purposes and are available in three thick nesses - 0.13 mm, 0.25 mm , and 0.38 mm. As a trial, the first stackup should total at least 0.38 mm in thickness.
Carefully lower the crankshaft and attached parts into the crankcase while guiding the pistons into the cylinders.
Position the bearing caps to crankcase and align crankshaft with bearing caps; then tap caps into place and secure caps to crankcase.
Crankshaft end-play should be checked with a dial indicator as follows, place pressure on front end of crankshaft to seat cone of rear bearings in its cup. Set indicator on high spot of crankshaft and adjust indicator to zero. Remove pressure from front end of crankshaft and reverse the procedure by placing pressure on rear end of shaft to seat cone of front bearing in its cup, then read indicator. End play should not be less than 0,08 mm not more than 0,15 mm. If end play does not fall within these limits, remove one of the bearing caps and add or remove gaskets to compensate and bring end play within the accepted tolerance.
Install gasket, top plate and oil level switch to pump.
Install diaphragms and add oil as instructed
Reconnect pump. After starting plant, inspect for leaks and tighten if necessary. Watch plant carefully for the first few hours of operation to be sure pump is maintaining a fully charged system.
9.1.5 WATERPUMP OIL LEVEL SWITCH ( FIG 8.4 )
a) Operation
The switch actuating points should be set approximately 20 mm above and below normal oil level to secure the pump. In normal operating conditions, the switch level arm should be in horizontal position.
b) Adjustment
Disconnect main electrical power
Remove the housing cover
Manually move lever arm up and down and check actuation by listening for switch "clicking" sounds.
Adjust switch actuating points by loosing both mounting screws and move bottom of switch to the right to increase actuating limits, or to the left to decrease actuating limits.
After adjustment, tighten mounting screws and recheck switch actuation.
Fig.8.4 : Waterpump oil level switch.
1 Housing cover 7 Cover waterpump 2 Oil level switch 8 Bottom mounting screw 3 Top mounting screw 9 Calibration mark
4 Switch extension arm 10
Arm position with correct oil
level
5 Lever arm 11 Calibration mark 6 Housing 12 Float
CAUTION
:
Do not adjust switch by bending
the extension arm
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9.1.6 WATERPUMP RELIEF VALVE ( FIG 8.5 )
1 Adjusting screw 2 Locknut 3 Housing 4 Spring washer 5 Spring 6 Stem 7 Guide 8 Disc 9 Seat 10 Body
Fig 8.5 : Waterpump relief valve
9.1.6.1 Adjustment
The relief valve should be adjusted to open at 35 bar feed pressure but remain drip tight during operation. Leakage from this valve will result in insufficient water to the heating unit and cause overheating
Start plant without burner operation and slowly close coil feed valve until relief valve just begins to di­scharge and check pressure on feed pressure gauge at that point.
To raise pressure adjustment, turn adjusting screw clockwise; to lower pressure adjustment, turn screw counterclockwise. Secure adjustment screw with locknut after adjustment.
Fully open coil feed valve. Inspect relief valve for leakage during normal operation.
9.1.6.2 Repair
Loosen adjusting screw (1) and unscrew housing (3) form body (10). Inspect disc (8) and seat (9) for scored or damaged condition. Replace damaged seat.
If disc is scored, it may be resurfaced by rubbing it on a "figure 8" motion on a piece of fine sandpaper
(wet-or- dry Nr 400 or finer) placed on plate glassrubbing it on a piece of fine sandpaper placed on a
perfectly flat surface
When reassembling, make sure that the spring washers are not cocked in the housing.
NOTE
:
Under certain conditions, when starting the units, feed pressure may temporarily rise sufficiently to cause the relief valve to release a small amount of water. Feed pressure will return to normal, however, after the unit heats and the system becomes stabilized.
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9.1.7 WATERPUMP INTAKE SNUBBER
The waterpump intake surge chamber absorbs pulsations at the waterpump intake, reducing the possibility of vapor-lock with high temperature feedwater. This type of intake surge chamber is non-adjustable. If replacement of the rubber insert is necessary, the old insert must be cut away from the retainer [3]. To facilitate assembly, lubricate the new insert with glycerin (do not use oil) to allow it to be pushed into the retainer and bottom housing.
1 Housing 2 Rubber insert 3 Insert retainer
Fig 8.6 : Waterpump intake snubber
9.1.8 WATERPUMP DISCHARGE SNUBBER
Rubber insert type
This type is non-adjustable. If replacement of the rubber insert is necessary, the old insert must be cut away from the retainer [2]. To facilitate assembly, lubricate the new insert with glycerin (do not use oil) to allow it to be pushed into the retainer and bottom housing.
1 Top housing 2 Insert retainer 3 Rubber insert 4 Bottom housing
Fig 8.7 : Waterpump discharge snubber
END Section waterpump
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9.2 HEATING COIL
Fig.8.8 : Heating coil.
1 Heater outer cover 2 Heater inner cover 3 Upper clamp band 4 Soot blower deflector 5 Outer shell 6 Lower clamp band 7 Burner base 8 Burner manifold 9 Volute(in burner base) 10 Bolt Anchor 11 Burner base insulations 12 Water wall 13 Air passage 14 Heating coil 15 Coil insulation cloth 16 Coil insulation blok 17 Lifting eye 18 Sensor coil temp
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THE CLAYTON COIL
The coil of a Clayton Steam Generator is of a unique design which has been developed for optimum heat transfer at all steam output levels.
The coil is a single water tube which is stacked in spirally wound layers in the upper section of the
Clayton Steam Generator and forms a ‘water wall’ around the combustion chamber of
the lower section. The configuration of the coil as well as the variation in the tube
diameter, spacing between layers and spacing between tube turns in different
temperature zones of the coil are all carefully designed to maximise efficiency and
thereby minimising fuel consumption.
The spiral construction of the coil is extremely robust and counteracts the effects of expansion during rapid heating and cooling cycles. The coil also undergoes in-house heat treatment to eliminate stresses and each coil is tested at high pressure.
An added advantage of the single coil design is that the internal condition can be monitored by observing the pressure of the feedwater at the coil inlet. In the case of oil fired units, sootblowing facilities are provided to remove deposits from the outside of the coil.
It is recommended to open the soot blower valve once every 8 hours of operation, for a period as described in
( 9.2.2. ). Soot is removed by blowing full capacity of the steam generator into the combustion chamber through
connection (4-fig.8.8).
9.2.1 REMOVAL OF SCALE FROM RESTRICTED HEATING COIL ( FIG 8.8 )
-An authorized Clayton technician should supervise this operation
Obtain a 200 l container (heat resistant, not galvanized) and place it near the feedwaterpump. If possible provide a pipe outlet DN 50 at 50 mm above the bottom of the container for acid suction. Elevate the container to provide about 30cm gravity feed to the feedwaterpump.
Close steam discharge valve [47]
Start unit without burner operation and circulate cold water until entire system is cooled. Then stop plant and drain hotwell.
Remove intake pipe and attach a suction hose (heat and acid resistant). Attach other end of suction hose to outlet at bottom of container. If an outlet is not provided in the bottom of the container, fasten a fine mesh screen over end of hose and place the end of the hose in the tank. Place about 20 cm of water into the tank. Be sure suction hose or suction outlet is below the water level.
Attach hose to separator drain valve [32], long enough to reach the 200 l container. Securely tie or fasten the end of the hose to the container so that it will not be dislodged during the cleaning operation. Considerable pressure is sometimes developed in the hose due to acid reaction with scale.
Close steam trap valve [35].
Start plant without burner operation. Add or remove water from the container until a steady circulation can be maintained trough unit and back to container with about 13 cm of water above suction outlet remaining in container. Be sure feedwater pump housing is primed.
Mix a can KLEENKOIL with 4 litres of hydrochlorid acid and slowly add this solution to the water in the container. If necessary prepare more solution
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Continue circulation 4 to 6 hours. A longer circulation will be required if bubbling still occurs in the discharge solution.
Test acid at regular intervals by dropping in a pinch of ordinary baking soda. If no foaming reaction takes place, the acid has been neutralized and it will be necessary to add more acid to the solution. If baking soda is not available use pH indicator paper. PH reading should be 6.5 to 6.8
Shut down plant. Carefully remove suction and discharge hose from acid container and direct them into a drain. Open separator drain valve [32]. Allow as much of the solution to drain to waste as possible; then remove suction hose and install water pump intake hose.
Fill hotwell. With discharge hose still directed to drain, start plant without burner operation and allow to run for about 30 minutes to purge system of acid solution. Be sure feedwater pump remains primed. Flush pump column by opening drain cock at base of pump until clear water appears.
Stop plant and remove discharge hose. Inspect and clean waterpump check valves, close seperator drain valve [32].
9.2.2 REMOVAL OF EXCESSIVE SOOT FROM HEATING COIL
-An authorized Clayton technician should supervise this operation
Where the steam generator has been operated with improper air adjustment for any period of time of where uniform periodical soot blowing has not been followed, it may be necessary to wash the coil with water to remove the excessive soot accumulation.
Set [S01] in position 2 ( pump ) and let the generator running for about 15 minutes to cool the unit before the washing is started.
Disconnect and remove stack section immediately above the heater cover.
Remove the burner manifold.
Provide a trough under the burner volute opening to drain off the water used for washing the coil.
CAUTION
:
Wear protective clothing !!! At first, add the acid at a very slow rate until
circulation can be maintained without excessive bubbling from the discharge hose. For
example, add about 200 cm3 and wait for reaction to subside; then add another 200 cm3 etc....
As the cleaning operation progresses, acid can be added in gradually increasing amounts. In extreme cases, it is possible to completely block the passage through the coil with loosened scale if acid is added too rapidly. Adding the acid too rapidly will also cause bubbling in the waterpump check valve housings and result in loss of pump prime
WARNING
:
Some countries (or local rules) do not allow that the water is drained to the sewer. Please verify if special rules are applicable for your country or region. If so, consult a specialized company for neutralisation and removal of the water
IMPORTANT
:
Start plant and blowdown the unit thoroughly 4 or 5 times before
resuming normal operation
NOTE :
During this period, frequently check to be sure feedwater pump is primed. The only way to make sure that the pump is primed is to slowly throttle coil feed valve [26] until pressure rises on feed pressure gauge. If pressure fails to rise, the pump must be primed. Reopen coil feed valve [26] after check
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Use preferably a 20 mm hose (large garden hose which can supply water at a minimum of 20 l per
minute) and insert the discharge of the hose (no nozzle) through the stack opening and under the inner
heater cover. Move the hose discharge to direct the water evenly over the entire top surface of the heating coil.
Soot removal will be obvious by the dark color of the water draining into the trough from the burner opening. When water runs clear, it will indicate that the soot has been removed.
When the heating unit has drained, operate the blower for a few minutes to remove water which may have collected in the volute and air damper.
After washing, it is preferred that the unit stand overnight to drain thoroughly before the burner is replaced. If it is necessary to start the unit as soon as possible after washing, the burner should be operated with short interval firing several times before it is put back into service under full operation. It is suggested that four firing periods of 1/2 minute each (spaced at three minute intervals) be used to gradually dry out the combustion chamber and thus avoid any refractory deterioration.
9.2.3 HEATING COIL REMOVAL
-An authorized Clayton technician should supervise this operation
Removal of the heating coil from the burner base is done as follows :
Remove inspection covers and remove thermocouple.
Disconnect piping from heating coil inlet and outlet connections. Remove pipe fittings from outlet connection located at bottom of coil. On oil fired units, remove soot blower pipe fittings. Remove capscrews which attach separator to bracket on coil.
Disassemble removable section of exhaust stack above heater cover [1]. Remove upper and lower clamb band [3 and 6]. Remove outer and inner heater cover [1 and 2]. Unscrew sheet metal screws from outer shell and remove both halves.
Remove hold-down bolts [17] located at the bottom of the shell at each support channel and lift coil and shell assembly complete from burner base.
9.2.4 HEATING COIL REPAIR AND INSTALLATION
-An authorized Clayton technician should supervise this operation
Hydrostatically test coil for leaks. If suitable welding cannot be made, coil must be replaced.
To replace a coil, proceed as follows :
Seal vent opening around top of burner base with masking tape. This will prevent insulation material from entering the base through this opening.
Mix castable insulation with water to a consistency equal to an ordinary concrete mixture. Fill coil recess to 90 mm (fig 8.9) in height. The coil discharge line is to be used as a locating device in the burner base, in combination with the coil spacers to center the coil. Lift and position coil on the burner base and allow coil to settle into the insulation. Secure coil to burner base with the hold-down bolts. Remove masking tape seal from vent opening when insulation dries sufficiently.
Install outer heater shells, front and back and inner and outer heater covers. Remound upper and lower clamp bands. Remound removable section of the exhaust stack.
Replace capscrews which attach separator to bracket on coil. If oil-fired unit, connect sootblower pipe fittings. Connect all in- and outlet connections
WARNING
:
Some countries (or local rules) do not allow that the washing water is drained to the sewer. Please verify if special rules are applicable for your country or region. If so, consult a specialized company for neutralisation and removal of the washing water
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9.2.5 HEATING COIL INSULATION
-An authorized Clayton technician should supervise this operation
Cracks or breaks in the coil insulation can be repaired by plastering with a coating of insulation cement. If complete insulation is necessary, proceed as follows :
Remove all insulation from coil, salvaging as much of the block insulation as possible.
Cut and arrange coil insulation [15] vertically around coil shell. Use elastic bands around the coil to provide ease in arranging and holding blocks in place. By a few of these bands, stretched around the coil as necessary, insulation blocks can be slipped under the bands and held in place.
After coil shell is completely covered with blocks, secure blocks with strands of ordinary baling wire.
Position innner heater cover and insulation on the coil. Carefully fill all cracks between the insulation blocks and the seam between the heater cover insulation and the coil insulation with a mortar of insulating cement. Smooth cement with a trowel.
Securely cement a layer of glass cloth to the outside of the coil insulation. Allow glass cloth to extend 100 to 150 mm above the coil insulation and fold and cement the extended portion over the edge of the inner heater cover. The seam between the inner heater cover and the coil must be completely sealed to prevent escape of the hot combustion gasses to the periphery.
9.2.6 BURNER BASE INSULATION REPLACEMENT
-An authorized Clayton technician should supervise this operation
Remove burner
Remove the heating coil .Repair small breaks in the insulation with a mortar of high temperature refractory cement and water. If complete replacement is necessary, proceed as follows :
Break up and remove refractory from burner base. Vermiculite insulation may be reused if kept clean.
Mix castable insulation with enough water to make a damp (not wet) pliable mixture. Fill burner base bottom with this mixture and tamp firmly to about the dimensions in fig 8.9 item 6
Use [ ** kg ] vermiculite insulation ( Clayton order nr.: M018506 ) < max.temperature : 1000°C ;
density : 450 kg/m³ >
Do not finish the surface too slippery to secure a good adhering with te castable insulation ( item 7 )
Use [ ** kg ] castable insulation ( Clayton order nr.: M011297 ) < refractory cement max.temperature
: 1350°C ; density : 1770 kg/m³ >
Mix refractory cement with water to a consistency equal to an ordinary concrete mixture and pour this on top of the insulation. Carefully trowel the cement, sloping the surface from about (15 mm) above the insulation ring (5) at the outside of the choke ring (8) in the center. Do not finish the surface too slippery to secure a good porosity og the cement.
Allow just enough time for the cement to set firmly. Then, using a knife or piece of sheet metal, cut six grooves 5 to 6 mm deep in surface of refractory, equally spaced, running radially from the opening in the center of the base to the outside edge. Drill or punch 1/16" holes through the cement approximately 100 mm apart to allow escape of moisture from the insulation.
Allow to dry for 48 hours before reinstalling the heating coil.
CAUTION
:
When initially starting the generator after replacement of the burner base insulation, use a very low intermittent fire until insulation is cured. Insulation will crack due to moisture content if heated to rapidly
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MODEL E-60 E-80/100/125/185
Insulation cement (Clayton part number - M018506 ) 2 kg 4 kg Refractory cement (Clayton part number - M011297 ) 15 kg 65 kg
Fig.8.9 : Burner base.
1 Heating coil 5 Insulation retaining ring 9 Burner base 2 Coil insulation 6 Plastic vermiculite insulation 10 Coil spacer 3 Coil shell 7 Refractory insulation 4 Plastic vermiculite insulation 8 Choke ring
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six grooves 5 to 6 mm deep
Fig.8.9 : Burner base.
9.3 BURNER OIL FIRED UNITS & FUEL PRESSURE REGULATOR
9.3.1 FUEL PRESSURE REGULATOR
Excessive fuel pressure will cause the burner to smoke and result in sooting of the heating coil. If fuel pressure is too low, the plant will be slow in coming up to pressure and will not maintain adequate steam pressure during periods of maximum steam demand. For maximum steam output, the pressure regulator setting may range from *** bar fuel pressure.
*** See QC-1039 test sheet
1 Cap 2 Locknut 3 Adjusting screw
fig.8.12 : Fuel pressure regulator.
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Adjust fuel pressure regulator as follows.
Remove cap [1] and loosen locknut [2]
Turn adjusting screw [3] clockwise to raise pressure, counterclockwise to lower pressure. Avoid raising pressure to a point which will cause overfiring and thermostat interruption.
After adjustment, fasten locknut and replace cap
WARNING
:
The maximum burner capacity should not be exceeded. It is very important to maintain an balance between fuel, water and air is maintained under all load conditions. The burner capacity depends also on the combustion air pressure. Check this pressure first before
regulation of the fuel pressure
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Fig 8.13 a : Oil burner (Sectional view ) Drawing 0160555
1 Cone assy.burner manifold 10 Plate assy.manifold 2 Stem assy. burner manifold 11 Spacer manifold burner 5 Electrode ignition E-100 Nozzle 9.5GPH -- 90° qty 1 6 Nut lock electrode E-100 Nozzle 4.5 GPH -- 80° qty 2
FOR THIS ORDER
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Fig 8.13 a : Oil burner ( ignition electrodes) Drawing 0160555
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9.3.2 CLEANING AND ADJUSTING THE OIL BURNER MANIFOLD
-An authorized Clayton technician should supervise this operation
Disconnect ignition wires (attached to item 16) from burner manifold. Disconnect fuel lines. Unscrew nuts which attach manifold to burner volute and remove manifold
For disassembly of the burner nozzle see fig. 8.14. Unscrew burner nozzle from stem [8]. Unscrew strainer from nozzle and remove distributor. Blow parts out with compressed air jet if available. Be sure all dirt and grit are removed.
When reassembling nozzles do not force screw tight enough to cause galling; merely tighten snugly.
Scrape all carbon from manifold cone and electrodes.
If electrode has to be replaced, adjust ignition electrodes to conform to dimensions given in ( Burner
drawing in binder ). The gap must be positioned as accurately as possible so that it is at the immediate
edge of the nozzle spray. Electrodes may be raised lowered or rotated by loosening the lock nuts attaching them to the mounting plate.
Install burner manifold to burner volute and tighten nuts
Make sure the label reading FRONT is placed facing the operator
Connect fuel and ignition wires.
Fig.8.14 : Burner nozzle
NOTE
:
The nozzle can be removed without disturbing the setting of the manifold by
unscrewing setscrew [15] and sliding the stem [8] out of the plate [1].
CAUTION
:
Do not use a sharp instrument for cleaning which can scratch or
the tip orifice or slots in the distributor.
CAUTION
:
Use care when adjusting electrode to avoid cracking the insulator.
The insulator may develop a short due to such a fracture, resulting in ignition
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9.4 AIR DAMPER ADJUSTMENT E-100
9.4.1 SECONDARY AIR DAMPER
1- 2+ 3 Y 4= SPARE
Part nr: 0204920 FIG 001
1 See parts catalog 2 Bearing 3 0-90% / 90-0 %DO NOT RETURN SCREW “leave on Nr ( 0) 4 Mounting plate motor E-100 MOUTING PLATE “UB70330 “ 5 Belimo motor 24v “0204920”
2
3
4
5
1
**
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CONTROLLER
1 Contoller 2 Low fire adjustment. screw 3 High fire adjustment screw 4 Input power 24VAC 5 Output to motor “Belimo” 1-& 2+ 6 Output Voltages
Output A=(Low Fire) Output B=(High fire)
Part nr: 0204934
FIG 002
9.5 START GENERATOR.
Place (S1) on low fire .Verify combustion Attach a U-tube manometer to the upper part of the burner volute to obtain a readout of the secondary air pressure. Turn low fire adjustment screw (2) until the pressure on the manometer corresponds to the value noted on the testsheet (burner volute upper, low fire). Turning the screw clockwise increases
pressure, counterclockwise decreases.
9.6 START BURNER.
Flue gas sampling should be taken from the centre and just below the cone in the stack adapter on the heater cover of the generator. Drill a hole in the stack to allow the sampling tube to be inserted at this position. Adjust the low fire adjustment screw until the measured CO, O2 and NOx (and soot factor for
oil fired units) values reach the values on the testsheet.
Put burner in high fire position. Adjust the high fire adjustment screw (3) until the measured CO,O2 and NOx (and soot factor for oil fired units) values reach the values on the testsheet. Turning the screw
clockwise increases pressure, counterclockwise decreases.
After regulating LF & HF note the tension of the potentiometers for further Reference.
1
2 3 4 6 5
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9.7 CONFIGURATION OF TEMPERATURE INDICATOR JUMO ( 0202485 )
STEP
ACTION Press key
DISPLAY REMARKS
Measured Temp.
1 P (2 sec.) +xxx AL Access to Parameter level
2 P (2 sec.)
+003 C111 +024 C111 +040 C111
For coil or stack, sensor =
1 x PT100
For separator, sensors = 2 x PT100 For coil or stack ,sensor = 1 x TC/J
3 P +0 C113 No decimal point
4 P
+2 C114
+1 C114
Temperature monitor (auto reset) Temperature
limiter (manual reset for models E10 -> E-50 only) 5 P +0 C115 Inverse switching action 6 P +1 C116 Display = measurement 7 P +0 C117 Logic input not used 8 P +0 C118 Display remains on 9 P +0 C119 Pre-alarm not used
10 P +100 AL LO 11 P +300 AL HI 12 P +0 OFFS 13 P +2.0 HYST1 14 P +xxx AL Temp. Alarm 15 P +10 ALD Diff. temp. alarm – only for separator 16 P +0.6 DF Digital filter
NOTE 1: adjust parameters with or keys to desired value.
Confirm by either waiting 1 second (display blinks once), or by pressing the P key.
NOTE 2: The parameters AL, ALD and DF (step 14, 15, 16) are also accessible in the parameter
level, by pressing the P key once during 2 seconds. Adjust temperature alarm value (AL) as follows:
xxx = saturation temperature + 50 C for coil [A29]; xxx = nominal stack temperature at max. firing-rate + 15 C for stack [A95]; xxx = saturation temperatuur + 15 C for separator [A31].
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9.8 STEAM PRESSURE SWITCH (F20)
1 Range spindle 2 Range scale 3 Differential spindle 4 Differential scale 5 Lock srew
Valve Ball 3-way –T SS ( option)
The steam pressure switch can be adjusted to start and stop the burner at any desired maximum steam pressure between 4,5 and 28 bar (depending on execution). The switch will close and restart the burner when steam pressure drops about 1 bar (adjustable by means of the differential spindle) below that point. To adjust the setpoint of the switch, turn the range spindle on the switch housing until the dial points the desired pressure. See fig 8.21
9.9 MODULATION PRESSURE SWITCH [F22]
The modulating pressure switch is normally adjusted to modulate burner to "low-fire" operation when steam pressure reaches 1 bar below maximum and return the burner to high fire operation when steam pressure drops about 0.8 bar below that point. This adjustment can be raised or lowered in relation to maximum steam pressure, but should never be set lower than 0.3 bar below the steam pressure switch cut-out point. If it is set to close to the maximum steam pressure, operation will be unstable and there will be a tendency to "override" during abrupt drop in steam load. If set to low, steam pressure will not be maintained at high level during heavy loads. The way of adjustment of the switch is identical to the one for the steam pressure switch.
Fig.8.21 Land Installation
Fig.8.21 Marine application
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9.10 LIMIT PRESSURE SWITCH [F21]
The limit pressure switch is normally set 0.5 to 1 bar above the normal operating pressure. If this pressure switch closes, manual reset of the boiler is necessary. The way of adjustment for this switch is identical to the one for the steam pressure switch.
9.11 AIR PRESSURE SWITCH [ F81,-FIG 8.22 ]
Actuated by blower air pressure, the air pressure switch will open and stop generator if insufficient air is supplied to the burner. It is set at 80 % of the blower pressure at 100% load (which can be found on the test
sheet). To adjust the pressure switch :
Remove cover of pressure switch. Turn external ring with scale to the value which corresponds to 80% of normal blower pressure. An indication arrow is provided on the internal ring.
With plant operating at high fire, put a piece of carton over blower inlet until pressure decreases 20%. Normally generator operation should be stopped. If not, adjust switch.
1 External ring 2 Internal ring with indication arrow
Fig 8.22 Air pressure switch
9.12 AIR PRESSURE SWITCH HIGH FIRE [F82 - FIG 8.22 ]
Actuated by volute air pressure (for value see test sheet), the air pressure switch will stay open in case of insufficient air pressure for high fire operation. Burner operation will remain in low fire operation. It is set at 80 % of the normal volute pressure at high fire operation.
Remove cover of pressure switch. Turn external ring with scale to the value which corresponds to 80% of normal volute pressure. An indication arrow is provided on the internal ring.
End Chapter - 9
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CHAPTER 10 : RECOMMENDED OILS FOR CLAYTON WATERPUMPS
10.1 PURPOSE AND SCOPE.
Depending from pump construction and application it is necessary to use different oil types for Clayton waterpumps. This procedure has to be followed to make the right choise for any Clayton waterpump application.
For other then Clayton pumps, please follow the specific instructions from the relevant pump manufacturer.
10.2 OIL SPECIFICATIONS
DESCRIPTION CLAYTON PART NUMBER
SHELL TELLUS S3M
Clayton PN : 0205812 ( partnumber
for 20 liter barrel. )
To fill up crankcase, please follow instructions on pump.
10.3 OILS FOR FOOD INDUSTRIES
Clayton recommends BEL RAY NO TOX GEAR OILS or MOLYKOTE OILS as replacement as per table below:
Part
number
Clayton standard oils Replacement oils for food industries
BEL RAY MOLYKOTE
0205812 SHELL TELLUS S3M
NO TOX GEAR OIL 80 or
L-0510FG
Clayton PN : 0202955 ( partnumber
for 18,9 liter barrel. )
ANTI-WEAR LUBRICANT 30
drain pump thoroughly
when drained oil is heavily polluted, fill up pump with replacement oil, operate pump at low capacity and low pressure for one hour and drain oil
fill up pump with replacement oil and operate pump at normal condition for one week
drain pump thoroughly
fill up pump with replacement oil
have your oil quality assessed by your supplier after one month of operation
When replacing standard Clayton oils by oils for food industries that are not mentioned in above table, please contact your local supplier for the correct replacement procedure.
End Chapter - 10
For applications were incidental food contact is possible the above mentioned oils are not
allowed to be used. It is recommended to substitute these oils by oils that received an H-1
certification from the USDA or an equivalent assesment
IMPORTANT:
When replacing standard Clayton oils by oils of above mentioned brands following procedure
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CHAPTER 11 : INSTRUCTION AND OPERATION FOR PRESSURE VESSELS
11.1 DESCRIPTION OF PRESSURE VESSEL
The wording “pressure equipment” in this document is used for steam vessels and collectors, pressurized water and/or steam accumulators, return receivers and pressurized hot water drums where the water can flash into steam when released directly to the atmosphere, any of them operated at a pressure exceeding 0,5 barg, with no limitations on size when their volume is over 1 liter.
11.1.1 SCOPE - APPLICATION.
The instructions of this manual are only applicable for the pressure equipment supplied or manufactured by Clayton of Belgium. The vessel serves as a recipient that collects pressurized water, steam or a mixture of both, in which the separation of steam and water occurs or in which the pressurized condensates return. The operating conditions must fall within the specified limits defined in the specifications and/or drawings. The instructions contained in this document should be read and used together with the specific operation, maintenance and safety instructions applicable to steam and/or hot water and/or high pressure units. Consequently, these instructions can also be applied to pipe connections and tubes to the users of the pressure equipment.
11.1.2 SPECIFICATIONS. AND DESIGN DATA
Please refer to final QC documents :
11.2 TRANSPORT, HANDLING AND STORAGE.
The pressure equipment shall not be transported under pressure or any loading. The lifting capacity of the hoist should be checked before lifting.
For handling, transport and assembly suitable lifting tools and devices shall be used to avoid any deformation or any damage to any of the connection points, joints, flanges or installed equipment and devices. The equipment shall never be lifted from the casing or the connecting flanges or piping.
The pressure equipment shall be supported by its specific designed supporting legs and/or by a wooden structure designed for that purpose. Point loads on the body can lead to serious deformation.
Transport and storage below the freezing point (0°C) are not allowed. (Freezing risk of un-drainable
remaining water in the pressure equipment).
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11.3 ASSEMBLING AND ERECTION.
11.3.1 ERECTION CONDITIONS.
The pressure equipment shall be so installed that employees, operators or third person will not be endangered. Minimum safety distances as prescribed by local or national legislations shall be respected.
The pressure equipment shall be installed in such a way that:
Inspection openings will be accessible.
The nameplate is conspicuous wherever practicable.
Access to and operation of controls is possible.
All hot parts that can be touched or approached by the operator are properly shielded or insulated.
Outlet openings of safety accessories (e.g. safety valves, pressure relieve valves) or drains are directed to a safe area.
Suitable foundation for the specific pressure equipment shall be provided to avoid deformation or sagging due to its own load, its content or any other external loads e.g. resulting from traffic or other machinery, wind, etc…. The pressure equipment installation shall be protected from access by unauthorised persons. Protective measures shall be provided when in case of a fire the safety of the pressure equipment or its controls and/or safety equipment may be endangered.
11.3.2 CONNECTING AND PREPARING THE PRESSURE EQUIPMENT.
The external connections shall be made to the connection points provided on the equipment, avoiding any supplemental or fatigue loads or bending moments. Any welded connection directly to the pressure equipment shall be made by qualified welders according to qualified procedures and those welds shall be inspected and tested per local Regulations or Codes. Bolted connections shall be diametrically and gradually tightened with a calibrated torque wrench and torque load shall be appropriate for the bolt size and type.
Pre-start-up cleaning of the pressure equipment may be required prior to assembling some instrumentation or safety and pressure accessories. Consult specialized companies when internal cleaning will be done with chemicals or other aggressive products that may attack the materials, gaskets, instruments etc…
11.3.3 SAFETY AND PRESSURE ACCESSORIES.
To avoid that the allowable relevant operating condition such as pressure and/or temperature, level and/or volume, etc.. can be exceeded, suitable measuring, control and limiting devices shall be provided and installed.
Control devices :Suitable manual or automatic regulating devices to maintain all operating parameters within the normal operating conditions shall be installed. E.g. pressure switches or transmitters, temperature switches or transmitters, level switches or transmitters etc… Monitoring and limiting devices :Relevant operation and parameter specific monitoring instruments and alarm devices shall be provided. Limiters shall prevent that the maximum allowable operating parameters are exceeded and require a manual reset intervention of the operator after solving the problem and before again taking in operation the equipment. Safety accessories :Suitable safety devices shall be installed to prevent that the maximum allowable operating parameters are exceeded in case of failing limiting devices.
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11.4 TAKING INTO OPERATION.
11.4.1 GENERAL INSTRUCTIONS.
The pressure equipment may only be taken into operation when: All internals of the equipment are sufficiently flushed and cleaned where needed with suitable products. All instrumentations, controls and safety devices are provided, properly installed and adjusted. Tested for leaks with potable water or treated feedwater and checked on its safe functioning.
Prior to taking into operation, the equipment may need to be inspected and tested by the Authorities. Local Regulations shall be respected before taking the equipment into operation.
The owner shall only employ well-trained and qualified operators to operate the pressure equipment. Unauthorised employees or third persons are not allowed to operate or to approach the equipment. Safety areas and distances are to be maintained and respected. Do not operate the equipment with safety guards, shields, covers, and other protective devices disconnected, removed, or out of place. If a guard, shield, or cover, or other protection (i.e. electrical interlock or alarm) is removed for maintenance or repairs, re-install it properly before connecting the power supply to the equipment.
Operating instruction shall be made available for the operators. This equipment should be operated only by qualified personal, instructed in safety and all equipment functions. Every person operating this equipment and every person working the area of this equipment must be trained to understand and use your facility's Energy Control (Lockout/Tagout) Procedures. Refresher training should be done periodically. Local Regulations for operation of pressure equipment shall be observed.
11.4.2 INITIAL START-UP.
To minimise stresses (thermal or other) and to minimise or avoid water hammer, initial cold start-up shall be done at minimum load. Any manual valves that are to be operated at start-up shall be opened and/or closed very slowly. During this period up till the moment of reaching the normal operating conditions, the operator shall be present and observe the equipment (amongst others all monitoring devices).
11.4.3 NORMAL OPERATING CONDITIONS.
The pressure equipment may only be operated when all of its control and safety devices are functioning and they cannot be taken out of operation or changed during operation of the pressure equipment. The normal operating parameters are given in the design and operating specification section.
11.4.4 PUTTING OUT OF OPERATION.
As for initial start-up, temperature and/or pressure drops shall be under control to minimise extra stresses and fatigue loads. The maximum wall temperature drops should not exceed 50 °C/hr. For a wet shut down, the pressure equipment shall be filled with treated feedwater as required for the generator shutdown. Consult your generator or installation manual. A dry shut down is normally only used for maintenance or for longer period of standstill. In the latter case, precautions shall be made to prevent internal corrosion e.g. by putting and maintaining the pressure system under inert gas pressure of 0,5 to 1 barg.
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11.4.5 INCORRECT OR UNEXPECTED USE.
When due to any external or internal process condition the safe operation of the pressure equipment is endangered, suitable measures will be taken and the equipment may need to be put out of operation. When in such cases the maximum allowable pressure is exceeded by more than 10 % or the maximum allowable temperature has been exceeded considerably, the equipment and its control and safety devices shall be subjected to a special examination before any further operation.
11.5 SUPERVISION AND MAINTENANCE.
11.5.1 GENERAL INSTRUCTIONS.
All local national stipulations regarding supervision and periodic inspection and testing shall be observed.
11.5.2 CLOSING AND OPENING THE PRESSURE EQUIPMENT.
All openings shall be suitably closed. Threads and flange faces shall be clean and free of defects. Only new and suitable gaskets may be used and the appropriate bolting shall be diametrically and gradually tightened with a calibrated torque wrench.
11.6 SUPERVISION AND INSPECTION.
11.6.1 INSPECTION BY AUTHORISED OWNER-USERS.
When allowed by local national Regulations, inspections can be done by specialized companies or by the supplier of the equipment. The Owner-User inspector shall not perform inspections on equipment for which he has operation or maintenance responsibilities.
11.6.2 IN SERVICE INSPECTION PROGRAM.
The Owner-User Quality Control System shall include provisions to ensure that inspections are carried out in accordance with written procedures. These procedures must delineate all sources and references of pertinent information to be furnished by the Inspector. These procedures shall highlight the degree of inspection required for the types of vessels involved. As a minimum these procedures shall include provisions for reporting the following:
Internal or external inspection.
Location and thickness of sample areas.
Location and extent of corrosion, bulging, blistering or cracks in shells, heads, welding seams, and/or weld heat affected zones.
Type and extent of non-destructive examination employed.
Setting and condition of safety valve or safety relief valve.
11.6.3 PERIODIC INSPECTION OF THE PRESSURE EQUIPMENT.
The type and frequency of periodic inspection is prescribed by local national Regulations.
11.7 MAINTENANCE.
11.7.1 MAINTENANCE
DANGER !
Dismantling or working on any component of a system under pressure can cause serious injury. Before opening or dismantling any part of the pressure equipment, disconnect electric power and lock out at main panel, then completely vent internal pressure to atmosphere and drain where needed (e.g. where there are no block valves installed or allowed). Check surface temperatures
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Periodic maintenance shall be done according to the scheme of the steam generator (exhaust gas boiler).
Drain and flush the pressure equipment, open all handholes and manholes, clean and remove deposits and scale from the inside. Examine the pressure equipment for damage and corrosion.
Have the pressure equipment inspected by an authorized inspector, as required.
Install new gaskets, replace all handhole and manhole covers, refill the pressure equipment (section or
part), and perform a hydrostatic test, if required.
Verify operation of all operating and limit controls, interlocks, and gauges.
Have the technician disassemble the waterlevel control devices to clean, recondition, and reassemble them.
Have the technician test and check all limiters, controllers and monitoring devices.
Check all pressure equipment and piping for leaks and missing insulation and repair where needed
Make sure provision is made for establishing and keeping a maintenance logbook.
After performing maintenance,
Re-install all guards, shields, covers, and other safety devices. Install all fasteners provided for attaching these devices to prevent accidental or unauthorized removal. Make sure all guards, shields, covers, and other protective devices (i.e. electrical interlock or alarm) have been installed before removing lockout protection. Be sure all safety devices are in place when the equipment is operating again.
11.7.2 PRESSURE EQUIPMENT REPAIRS AND PART REPLACEMENTS.
WARNING !
Completely vent the internal pressure to the atmosphere and drain completely before disassembling any piping, fittings, valves or other components and before doing any repair work on pressure equipment.
All pressure equipment put on the EU market are manufactured, inspected and certified according to the PED 97/23/EC.
Repairs to such equipment are subjected to local National Regulations. The authorized inspector and local jurisdiction must grant approval before the repair is made.
The firm making the repair must have qualified procedures, use qualified welders and Code-approved materials. The repair must be inspected as required by the authorized inspector and local jurisdiction. Only original parts may be used.
End Chapter - 11
END MANUAL
PSC 04-02-2014
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