UT KATILAI UT-100, UT-150, UT-320, UT-200, UT-250 User Instructions

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WATER HEATING BOILERS

UT-100; UT-150; UT-200; UT-250; UT-320

USER INSTRUCTIONS

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Table of Contents

1. SCOPE OF USE ................................................................................................................................................. 3

2. GENERAL PROVISIONS .................................................................................................................................... 3

3. TECHNICAL DATA ............................................................................................................................................ 4

4. SCOPE OF SUPPLY ........................................................................................................................................... 5

5. DESIGN ........................................................................................................................................................... 6

6. INSTALLATION ................................................................................................................................................ 9

7. USE OF BOILER .............................................................................................................................................. 19

8. REQUIREMENTS FOR SAFE OPERATION ....................................................................................................... 21

9. MAINTENANCE AND INSPECTIONS .............................................................................................................. 23

10. STORAGE AND TRANSPORTATION ............................................................................................................. 24

11. WARRANTY STATEMENT ............................................................................................................................ 25

DECLARATION OF CONFORMITY ...................................................................................................................... 26

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1. SCOPE OF USE

The user instructions are intended to acquaint with design and operation principles of water
heating boilers UT - 100; UT - 150; UT-200; UT-250; and UT-320.
Choosing premises for a boiler, installation and operation thereof require a compliance with
guidelines of the user instructions.

2. GENERAL PROVISIONS

2.1. Water heating boilers UT - 100; UT - 150; UT-200; UT-250; UT-320 are used for household,
industrial, and other facilities, which are equipped with central heating systems for the purposes
of heating, for domestic or other process hot water treatment through intermediate water
preheaters.

2.2. Heating and hot water treatment systems, connected to the boilers, must apply only softened
water according to LST EN 12953-10 requirements.

2.3. The boilers are intended to burn lump solid fuel: firewood, wood waste (non-bulky), wood
waste briquettes, peat briquettes, coal.

2.4. These boilers can be connected to combustion chambers, which burn fine wood waste
(sawdust, chips). Boiler adjustment to a combustion chamber and boiler selection must be carried
out by a manufacturer.

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3. TECHNICAL DATA

Key technical data of water heating boilers UT - 100; UT - 150; UT-200; UT-250; UT-320 are
provided in Table 3.1.

3.1 Table

Technical Data

Type of Boiler

UT -

100 UT -

150 UT -

200 UT -

250 UT -

320

Thermal capacity

, KW ± 7%

- when burning coal (calorific value of
at least 29,880 MJ/kg)

- when burning firewood of maximum
20% humidity

100 150 200 250 320

87 131 175 220 310

Efficiency rate

, % 74...82

Temperature of b

oiler water

, oC

- return, at least

- effluent, maximum

65
95

Boiler w

ater pressure, maximum, bar

4,0

Boiler

water capacity,

maximum

, l 342 469 616 683 1065

Boiler heating surface

, m2

7,6 11,4 14,7 17,7 25,8

Safety device pressure

, bar 4,0

Pressure outside boiler

, Pa 28 34 40 46 58

Temperature of combustion gas

, oC 250

Boiler

water circulation

forced

Type of fuel

Lump solid

,

with add

-

on combustion chamber

-

bulky

wood waste

(sawdust, chips)

Furnace depth / max. firewood length

,

mm

948/800

1148/1100

1348/1300

1546/1400

1536/1400

Boiler weight: empty / full

, kg 810/1152

1070/1539

1330/1946

1650/2333

1950/3015

Boiler service life

,

years

10

Ele

ctrical data

230/50

- power voltage

, V

/Hz

- usable capacity

, kW 0,08 0,18 0,47

Dimensions

; mm

1950 1950

1950

1950

2150

- height

- width

700 800 950 1000

1220

- length

1390

1620

1850

2050

2150

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4. SCOPE OF SUPPLY

Table 4.1 provides a list of products supplied with boilers UT-100; UT-150; UT-200; UT-250; UT-320.

No. Name of product supplied Quantity per boiler, pcs.

UT-100 UT-150 UT-200 UT-250 UT-320

1. Boiler 1 1 1 1 1

2. Safety valve DN25; PN 4 bar 1 1 1 1 -

3. Safety valve DN32; PN 4 bar - - - - 1

4. Ball valve DN25 2 2 2 2 2

5. Contact pressure gauge 0 ÷ 6 bar; Ø - 160 mm 1 1 1 1 1

6. Three-way valve for pressure gauge Dn 15 1 1 1 1 1

7. Thermal pressure gauge 0 - 120 oC 1 1 1 1 1

8. Fan CMP 512 - 2M 1 1 - - -

9. Fan CMP 514 - 2M - - 1 1 -

10. Fan CMP 616 - 2M - - - - 1

11. Control console, temperature sensors (comp.) 1 1 1 1 1

12. Fire-grates..........x...........

13. Cleaning toolkit 1 1 1 1 1

14. Tech. documentation set 1 1 1 1 1

Boiler No. is supplied with UT - a set of water heating boiler according to the list of the Table 4.1.

L.S. ______________________________________________________
(manufacturer’s responsible person – signature, full name, position)

th 201

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5. DESIGN

5.1. A boiler heat exchanger is made of carbon steel sheet and pipes, with fittings welded
together and fixed by reinforced ties - pos. 11.
Other boiler components and units are connected to the heat exchanger with standard or
special fasteners.
Pipelines are connected to the boiler by means of thread joints - pos. 15, 16, 17, 18 19.

5.2. The front part of the boiler has two doors: an upper door - pos. 21, for closing a combustion
gas circulation chamber - pos. 4, and for funnel cleaning, pos. - 3, 5; and a lower door - pos. 22, for
closing a combustion chamber hole - pos. 2, and for fuel loading. Both doors’ opening direction
can be easily changed during operation, by reversing positions of hinges - pos. 26 and a clamping
unit - pos. 27.
The lower door has an inspection hole to monitor the combustion process, which is closed
by a rotating cover - pos. 23.
For safe opening, both doors are provided with handles, pos. 28, with the mounting location
subject to the door opening direction.

5.3. The bottom part of the boiler is equipped with a fan - pos. 32, which delivers air through the
air channel - pos. 12 under boiler fire-grates - pos. 13. The delivered air flow is adjusted with
valves - pos. 31.

5.4. For a better heat removal, funnels of the boiler convective part, pos. 3; 5 are equipped with
smoke spins - pos. 7.
Beside boiler flue pipes, the boiler is connected with a position lock - pos. 9, through a flue
pipe - pos. 6, which is provided with a traction control valve - pos. 8. For cleaning a soot or ash
deposit, this interim flue pipe is provided with a manhole closed with a lid - pos. 10th

5.5. The entire outer surface of the boiler is insulated with 50 mm heat insulation layer - pos. 29,
from the outside sealed with decorative coating - pos. 30.

5.6. For boiler incoming flow temperature and pressure control, the boiler surface is equipped
with: thermometer - pos. 34 and a contact pressure gauge - pos. 35 with a threaded tap - pos. 36.

5.7. For air supply fan control and boiler emergency mode alarms, the boiler is equipped with a
control console - pos. 33, which, by means of wires and cables, is connected to the fan - pos. 32,
the contact pressure gauge - pos. 35, a temperature sensor, inserted in a slot - pos. 20, and power
line 220V, 50Hz.

5.8. For boiler transfer from one place to another or for loading, the boiler is fitted with two lifting
loops - pos. 38.

5.10. Junction pipes:

- pos. 15 - return water to boiler

- pos. 16 – feed water from boiler

- pos. 17 - draining valve (tap)

- pos. 18 - safety valve

- pos. 37 - bypass line for non-return valve

- pos. 39 - draining valve (not indicated in the Picture, behind the fan)

Note: upon continuous boiler upgrading, there may be slight deviations from the boiler
design, provided in these instructions, without impairing any technical or operational features.

5.11. High-wear components
The list of the components is provided in Table 5.1. Their durability depends mainly on the type
and quality of fuel used, as well as on proficiency of service staff.

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Picture 5.1 Design of water heating boilers UT-100; UT-150; UT-200; UT-250; UT-320

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Table 5.1

Type of

boiler

Combustion chamber

fire-grates

,

pcs. Combustion chamber

door screen shields

,

pcs.

Door seal TC-SPx2

(20x20), mm

Control

console
fuse 5A,

pcs.

200x400 200x500 200x600 200x700 250x900 565x430 565x530 565x630 565x730 565x930

UT -

100 5 - - - - 1 - - - - 2 x 2580

1

UT -

150 - 6 - - - - 1 - - - 2 x 2780

1

UT -

200 - - 7 - - - - 1 - - 2 x 2980

1

UT -

250 - - - 7 - - - - 1 - 2 x 3180

1

UT -

320 - - - - 7 - - - - 1 2 x 3580

1

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6. INSTALLATION

6.1. General Instructions

6.1.1. A boiler (boilers) must be installed in accordance with design, developed by an engineering
company.

6.1.2. Designers of boiler-house and boilers UT-100, UT-150, UT-200, UT-250, UT-320, as well as
installers thereof must be acquainted with these user instructions.

6.2. Premises

6.2.1. Boilers may be installed:

- in separate rooms;

- in premises that are immediately adjacent to residential, public, and industrial buildings,

separated from them by firewalls;

- inside production facilities if the total boiler water capacity does not exceed 2,000 l,

provided that the boilers are isolated from other parts of the premises by fire-resistant
partitions at full height of the boiler, but not lower than 2 m in height;

- on lower floors and basements of residential, public (except for premises specified in cl.

6.2.2), and industrial buildings where the total boiler capacity does not exceed 1,000 l.

6.2.2. Boilers are prohibited from installing:

- immediately under the room where a lot of people may gather: under theatre lobbies or

audience halls, sauna’s dressing rooms and washing facilities, shops, medical offices,
classrooms and lecture halls of schools and educational institutions, children institution
rooms, nurseries and group rooms, and under other similar facilities;

- in premises located under a flammable materials warehouse, except for a fuel storage of the

boiler-house;

- in areas adjacent to a flammable materials warehouse, except for a fuel storage of the

boiler-house;

- inside production facilities, where the manufacturing process emits flammable gases,

vapours, or dust.

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6.3. Boiler installation and Connection Dimensions

Picture 6.3.1. Boiler Layout Plan

Layout

Dimensions, mm

Amin Bmin Cmin

Fmin.N/F

min.S

Gmin

UT-100 UT-150 UT-200 UT-250 UT-320
a) installation of 1
boiler

800 1500 -

3000/

2500

800 900 1000 1200 1400

1500 800 ­b) installation of
multiple boilers

800 800 1500

3000/

2500

800 1500 800
c) installation of
multiple boilers
each against other

800 800 1500

4000

800 1500 800

*N - a newly installed boiler-house; S – a boiler-house installed in old premises.
If the distance Fmin from the boilers’ front line to the wall is 3,000 mm, the wall is permitted to be
equipped with other boiler-house equipment (pumps, water preheaters, manifolds, etc.), provided
that the distance between the boiler and installations will stay at least L

1

+ 500 mm (see Picture

6.6.3).

Boiler front line

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Picture 6.3.2 Vertical Cross-section of Boiler Layout

Boilers are recommended to install on a low-profile foundation with dimensions provided in Table

6.3.2 and Picture 6.3.2, where * denotes a recommended height of foundation.

Table 6.3.2
Type of boiler UT-100 UT-150 UT-200 UT-250 UT-320
Length, mm 1100 1300 1500 1500 1700
Width, mm 600 700 800 900 1100

Boilers can be installed only on a non-combustible floor!

6.3.1 Connection Dimensions

Layout of all boiler junction pipes, their purpose and connection dimensions are provided in

Picture 6.3.3 and Picture 5.1.

Ceiling

Boiler

Floor

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Picture 6.3.3 Main dimensions of water heating boilers UT-100; UT-150; UT-200; UT-250; UT-320, mm

Type of

boiler

Dimensions

, mm

B B1 B2 b H H1 H2 h L L1 I I1 I2 I3 D G g

UT-100 730 590 160 200 1950 1770 1363 321 1600 1090 330 150 100 300 DN50 11/2" 1"

UT-150 830 690 180 240 1950 1770 1363 321 1830 1290 457 180 100 330 DN80 11/2" 1"

UT-200 930 790 200 280 1950 1770 1363 321 2060 1490 650 180 100 330 DN80 11/2" 1"

UT-250 1030 890 220 3200 1950 1770 1363 321 2060 1490 650 190 100 340

DN100

11/2" 1"

UT-320 1250 1110 240 400 2160 1980 1563 321 2360 1700 650 210 150 420 DN100

2"

11/4"

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6.4. Boiler Piping and Valve Connection

6.4.1. A boiler must be connected the heating water replenishment and smoke exhaust system in

such a way as to ensure its longevity and safe operation.

The key factors ensuring the longevity of the boiler are the following:

- the use of softened water, as stated in clause 2.2 of Section 2 of the Instructions;

- a temperature of the return water to the boiler, not lower than specified in Section 3 of the

Instructions.

Technical measures for safe operation of the boiler are provided in Section 8.

6.4.2. Valve and pipe connection is required to use only high-quality and proven sealing and

connection devices and components, capable of reliably maintaining the system pressure.

6.4.3. In the heating or hot water treatment system on the boiler piping, it is required to provide

and install vent assemblies located in areas of potential air accumulation and jams that block

water circulation. We recommend a vent assembly diagram shown in Picture 6.4.1.

Picture 6.4.1 Vent Assembly Diagram

1 - automatic air vent device; 2 - valve, tap

Automatic air vent is used to remove air accumulating during the operation. A valve or tap is used

to remove air pockets by filling a pipeline with water.

6.4.4. Pictures 6.4.3 and 6.4.2 present two possible boiler connection diagrams. For a variety of

needs, the engineering process may involve other boiler connection diagrams. In any case, the

following conditions must be satisfied:

- sound system replenishment with softened water;

- redundancy of pressure safety devices;

- compensation of changes in volume and service of compensatory device without draining

the system;

- safe draining and dewatering of the boiler;

- sound preservation of boiler certificate’s parameter values during operation: water

temperature (feed and return), water pressure in the boiler.

6.5. System Filling and Leakage Check.

Main pipe (air outlet)

Air escape pipe

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6.5.1. A boiler (boilers), boiler pipes are filled with softened water through a fill line (see Picture

6.4.2 and 6.4.3) as follows:

- boilers;

- boiler-house piping and manifolds;

- heating system.

When filling boilers, boiler piping, and a heating system, air must be extracted respectively

from these components.

If pressure of supply water is lower than required one, operational filling must be done

through the fill line by means of a pump.

In any case, there must be provided a pressure regulating device which, during

replenishment or filling, prevents an increase in the boiler pressure, higher than an operating one,

specified in the boiler certificate.

6.5.2. When necessary (see Section 9), a boiler pressure test must be carried out by using a

hydraulic press, in accordance with requirements set out in Table 5.6.

Table 6.5
Boilers or piping Test pressure, bar Operating

pressure, bar

Lifting time, min Preservation

time, min
UT-100; UT-150;
UT-200; UT-250;
UT-320

6 4,0 10 10

6.6. Flue Pipe Connection

6.6.1. A cross-section of flue pipes, connected to the boiler, cannot be smaller than a cross-section
of the outgoing boiler flue pipe (see Table 6.6.1).

Table 6.6.1
Type of boiler UT - 100 UT - 150 UT - 200 UT - 250 UT - 320
Cross-section, cm

2

600 726 850 980 1227

6.6.2. A flue pipe must be fitted with elevation (at least 10%) from the boiler to the chimney. If

turnings are impossible to avoid, they must be as milder as they can. For a flue pipe cleaning, there

must provided manholes, sealed with air-tight lids, at least every 2.5 m on straight components

and at each turn.

6.6.3. Long flue pipes must be fitted with a compensator to prevent a transfer of the expansion

force to the boiler or other boiler-house equipment.

6.6.4. Flue pipes in cooler areas or outside a building must be insulated.

6.6.5. Flue pipe installation requires to prevent a condensate, resulting for any unforeseen reason,

from entering the boiler. It’s prohibited to fit a condensate drain into a rain water or soil system.

6.6.6. Flue pipe connection and sealing requires the use of only standard proven means.

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Picture 6.4.2 Connection of one or more water heating boilers to the overall heating system with hot water treatment, when temperature of
return water in the heating system and boilers is controlled by means of a four-way mixing valve.

Hot water

treatment

To the heating system

Hot water

boiler

Hot water

boiler

System

replenishment

To the drain

networks

To the drain networks

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Picture 6.4.3 Connection of one or more water heating boilers to the overall heating system with hot water treatment, when temperature of
return water in the heating system and boilers is controlled by means of a three-way mixing valve.

Hot water

treatment

To the heating system

Hot water

boiler

Hot water

boiler

To the drain

networks

To the drain networks

System

replenishment

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Table 6.4.1

Pos. Name Purpose

1 Valve, tap Closing, opening of feed water flow from boiler
2 Valve, tap Closing, opening of return water flow to boiler
3 Valve, tap Draining, venting
4 Valve, tap Water draining from boiler
5 Safety valve Over-pressure relief
6 Non-return valve Feed water flow release at a closed feed water valve

(tap), pos. 1
7 Contact pressure gauge Feed water pressure control, emergency alarm
8 Pressure gauge Return water pressure control
9 Thermometer Feed water temperature control

10 Thermometer Return water temperature control
11 Safety valves Redundancy of valve functions, pos. 5.
12 Valve, tap Closing of water flow through recycle loop
13 Non-return valve Preventing a backward flow through recycle loop
14 Pump Water flow maintenance in boiler circuit
15 Filter Solids collection
16 Three-way (four-way) valve Flow separation or mixing
17 Tap, valve Compensatory loop closing with a device against a

reckless closure.

18 Compensatory vessel Compensation of changes in water volume
19 Valve, tap Hot water treatment pump service
20 Filer Solids collection
21 Pump Water flow maintenance in hot water treatment circuit
22 Non-return valve Preventing a backward flow in hot water treatment

circuit

23 Valve, tap Water flow closing in hot water treatment circuit
24 Valve, tap Pump service in heating system network
25 Non-return valve Preventing a backward flow through another pump

branch of non-operating network

26 Pump Water flow maintenance in heating system
27 Filter Solids collection
28 Pressure gauge Water pressure control in a return water pipe
29 Non-return valve Water flow retention from getting into a fill line
30 Valve, tap Replenishment water flow closing

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6. 7. Electrical Part Installation
Boilers are supplied with a fan, control console, contact pressure gauge, a set of
temperature sensors and connecting wires (cables) kit. During assembly, they must be combined
into a single scheme according to instructions provided in the boiler control console description.
Equipment adjustment and preparation of it for operation are as well provided in the control
console description.

6.8. Ventilation
Upon fuel loading to boilers, boiler funnel or other heating surface cleaning, smoke, soot,
ash, or dust may release into the environment, therefore, it is necessary to provide and install an
exhaust ventilation with a capture hood (see Picture 6.8) by the boiler, above the boiler cleaning
and fuel loading doors.

1 - boiler; 2 - fan; 3 – air duct; 4 – capture hood; 5 - valve.

Picture 6.8 Local Boiler Ventilation Equipment Layout

Combination of several boilers’ local exhaust ventilation devices into a single system requires
installation of stopcocks for each capture hood in order to close an exhaust opening of the fume
capture hood at inactive boiler.
The ventilation assembly is not included in the boiler set.

From a boiler-house

Smoke,

dust,

ash

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7. USE OF BOILER

7.1. Boiler or boilers are allowed to put into service only in boiler-houses recognised suitable for
use (see “Power Station and Power Grid Operating Rules” as of 12/21/2001).

7.2. The operation of one or more boilers must comply with these Instructions and the Power
Station and Power Grid Operating Rules.

7.3. Prior to firing up a boiler (boilers) at the beginning of operation, after repairs or a long-term
keeping in reserve (3 days), it is necessary to check whether an auxiliary equipment, controls and
gauges, fixtures and machine remote controls, automatic controllers, protectors, interlocks,
alarms are in good working order and ready to turn on. It is prohibited to fire up any boiler if it
shutdown safety device is in bad repair.

7.4. In addition to equipment and devices listed in clause 7.3, please check the following prior to
firing up a boiler (boilers):

- the amount of water in boilers and heating system;

- the amount of water in reserve fill tank; if necessary, to fill up;

- water pressure in the boiler and the fill line;

- water pressure in front of and behind network pumps, as they run;

- thrust in a flue pipe next to the boiler;

- air supply to boiler or boilers.

7.5. The boiler firing and heating

7.5.1. A smoke valve in the flue pipe must be completely open (see Picture 5.1, pos.8), and in
boiler reserve – closed.
For firing the main fuel, it is recommended to use finer, dry, easy combusted fuel, i.e., wood
or paper waste. After burning up of a finer fuel layer, please, put bigger fuel on the fire-grates,
close a combustion chamber door (see Picture 5.1, pos. 22), and turn on a fan (see Picture 5.1,
pos. 32). When the fuel layer fan properly burns up, turn the fan off, open a combustion chamber
door, and load the main fuel throughout the grate area (coarse wood, peat or sawdust briquettes,
coal). You can monitor the combustion process through a hole in the combustion chamber door
(see Picture 5.1, pos.23).
This type of boiler is not a durable capacity boiler, thus, fuel must be loaded into the
chamber at regular intervals in the manner described.
The amount of air, entering the grate and needed to maintain the combustion process, must
be controlled by means of a valve (Picture 5.1, pos.31), by screwing in or out the adjustment screw
(reduce by screwing in; increase by screwing out).
Upon burning up the main fuel layer, is necessary to adjust the thrust behind the boiler so as
to maintain the temperature of exhaust combustion (flue) gases as low as possible.

7.5.2. Water pressure emergency values are set by auxiliary arrows (contacts) of a contact
pressure gauge with a special tool supplied together with the contact pressure gauge. The
pressure values may differ in each boiler-house , yet, they must not exceed a max. operating
value.

7.5.3. Boiler feed water’s operating and emergency temperature settings, emergency mode
alarming, a fan’s manual and automatic modes are described in the boiler control console user
instructions enclosed to the entire documentation set.

7.5.4. Both upon firing a boiler and during its operation (work), it is very important to maintain the
temperature of water returning to the boiler at least at a value specified in the boiler certificate.
Diagrams in Pictures 6.4.2 and 6.4.3 present four-way and tree-way mixing valves. The best results
are obtained if these valves are operated automatically. Manual operation provides for a constant

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monitoring of changes in return water temperature and respective reduction or increase of water
flow, supplied by a network pump through a boiler or multiple boilers.
Always note that an acidic condensate emerges on the boiler heating surface at a too low return
water temperature, that results in a much shorter boiler’s service life; besides, a caked resin
reduces the boiler’s efficiency rate and boosts the amount of fuel used.

7.5.5. When connecting boilers with a combustion chamber for burning a wood waste (shavings,
sawdust) and upon using them, apart from these instructions, it is necessary to comply with
guidelines and requirements, set out in the combustion chamber’s technical specification.

7.6. Stopping a Boiler
A boiler may be stopped in the following cases:

- stopping by transferring the boiler to reserve, at the end of the heating season, or for

repairs and technical maintenance inspection;

- emergency boiler shutdown (boiler is shut down as soon as service staff is forced to

immediately turn the boiler off without coordinating their actions with department
management) is carried out in the following cases:

- upon increase in pressure in the boiler above the maximum operating pressure by 10% for

longer than 10 s;

- upon decrease in pressure in the boiler below an operating pressure for longer than 10 s;

- upon shutdown of more than 50% of safety valves (including operating through collars,

non-return valves, mounted on the feed flow line);

- upon failure of network pumps (unacceptably low water flow through the boiler);

- upon drop in a water level in the heating system;

- upon break of water route pipes, upon detection of bursts, cracks, bloats in major boiler

components (a furnace, funnels, reverse chamber) or at the outside of the boiler, water
leaks through the welded seams;

- upon loss of flue pipe thrust behind the boiler or upon failure of exhauster;

- upon explosion in the furnace, upon explosion or ignition of combustible debris in flue

pipes or in gas cleaning facilities, as well as other cases where employees or equipment are
at risk;

- upon loss of voltage in remote and automatic control or measurement devices.

7.6.1. When stopping a boiler in order to transfer it to reserve, first, burn the fuel layer, next,
switch a fan off, tightly close s door for a boiler modification with an air intake system, and allow
the boiler to cool. The boiler is disconnected from an overall heating system (see Picture 6.4.2 or

6.4.3, pos. 2 and 3) by means of valves only when no coal is left in the fuel level! Monitoring of
exhaust gas from the water heating boiler can be stopped at least 24 hours after boiler shutdown.

7.6.2 Upon emergency boiler shutdown, a burning fuel layer must be extinguished (i.e., by pouring
a sand) or removed from the furnace. In any case, before it, please, turn the fan off (if it is not
turned off automatically), thus, interrupting the air supply into the combustion chamber, and keep
the control console turned on, with an emergency situation causes and settings displayed on it.
After having removed the fuel from the combustion chamber or having extinguished it, both boiler
doors must be left open to let the boiler cool down. Further steps are as described in clause 7.6.1
above. In both cases of stopping the boiler, do not allow the boiler valve to close and do not turn
the smoke exhauster off, except for an emergency when the soot ignites in flue pipes.

7.6.3 During the operation, boiler heating surfaces must be cleaned regularly. Cleaning frequency
depends on the type and quality of fuel, as well as on the properly selected boiler operating mode.
Furnace heating surfaces are cleaned and ash is removed from the boiler through the lower door

21

of the boiler (Picture 5.1, pos. 22). Boiler fume pipes must be cleaned by opening the upper boiler
door and removing smoke spins. The boiler heating surfaces are recommended to clean as often
as possible, since clean heating surfaces increase boiler efficiency. Deposits or soot layer on the
surface cannot be thicker than 3 mm.
When cleaning the 2nd stage fume pipes, soot deposits from a boiler flue pipe must be removed
every time upon cleaning the boiler funnels. Ash and soot must be removed through a special
opening, closed with a lid on the side of the flue pipe (Picture 5.1, pos.10).

8. REQUIREMENTS FOR SAFE OPERATION

8.1. The following safety requirements must be applied to water heating boilers UT - 100, UT - 150,
UT-200, UT-250, UT-320 UAB UT boilers, manufactured by CJSC “UT KATILAI“. For the purpose, it is
required to use the below listed organizational and technical measures.

8.2. Organizational Measures
After installation works, an owner of a boiler (boilers) must ensure that:

- a boiler (boilers) is (are) included to the company's list of potentially dangerous equipment

and specify its number in the boiler certificate;

- a responsible person for boilers (boilers) maintenance has been assigned, by recording

his/her data in the boiler certificate;

- the first inspection after the installation has to be performed at the presence of an expert of

any republic (having a relevant permission) public authority. the inspection results must be
recorded in the boiler certificate;

- the boiler certificate must be completely filled in;

- boiler servicing must be administered by persons not younger than 18 years old, having

passed the compulsory operational safety briefings, and their knowledge on fire safety,
operational and safety at work has been checked.

- during operation, an owner of a boiler (boilers) must ensure boiler technical maintenance

inspections in due time (see section 9 of these instructions) to follow technical safety
measures, controls, and timely instrumentation verification listed in clause 3.8;

- a boiler-station, as a power facility, must be recognised by the State Energy Inspectorate as

suitable for use.
Boilers' operating personnel must ensure an order in boiler-station rooms and around the
outside facilities, that is, not to block passages, not to store unnecessary items in the boiler­station, not to overload flue pipes with flammable items, not to store combustible or explosive
materials in the boiler-station, to clean the boiler-station and its installations on a regular basis.
By controlling and by using instrumentation, by paying attention to certain external signs
(water leakage outside the piping or fittings; smoking through collars from the boiler or flue pipes;
the emergence of unusual sounds: water bubbling, rattle, squeak of rolling bearings, etc.),
evidencing an abnormal functioning of heating systems, boiler (boilers) operating personnel must
constantly control a boiler’s (boilers’) parameters and sizes and technical condition of the overall
boiler-station equipment. All boiler equipment malfunctions, occurred during a shift, must be
recorded in a logbook. Apart from these malfunctions, the logbook must be used to record
equipment shutdowns, boiler cleansing, performed during the shift, details of the operating
personnel, and if required, work schedules and assignments.

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The boiler-station wiring and electrical equipment must be connected to the mains and repaired
only by electrical personnel with appropriate qualifications.

8.3. Technical Measures
On the top of a boiler (boilers), there must be fitted:

- control and measuring devices to control boiler (boilers) parameters during operation,

automatic devices to control combustion process, emergency mode alarms. The list of
devices is provided in Table 1.8.

Table 8.1

No.

Purpose Technical Data Name of device

No.

in

schemes

6.4.2

1. Outgoing water

temperature control

(0 - 120) oC Thermometer pos. 9

2. Pressure in

outgoing water

junction pipe, emergency
mode alarm upon
unacceptable increase or
decrease in pressure

0 - 6 bar, Ø160, 2.5 accuracy class

Contact pressure

gauge

pos. 7

3. Return water

temperature

control

(0 - 120)oC Thermometer pos. 10

4. Pressure in

return water

junction pipe

0 - 6 bar, Ø100, 2.5 accuracy class Pressure gauge pos. 8

5. Combustion process

control basing on outgoing
water temperature,
emergency mode alarms,
the air supply block

Fan control

0 -

95 oC

alarm:

- high temperature > 95 oC

- high pressure > 4 bar

- low pressure < regular operating

Boiler control

console,

temperature

sensor

-

- closing or adjusting valves, pressure safety devices, only provided in the boiler design or

supplied with the boiler, with the parameter values no lower or no higher than operating

ones, specified the boiler certificate.
During operation, a short-term increase in pressure above the specified one in the boiler
certificate by maximum 10% is allowed.
A casing of the boiler used must be connected to a boiler grounding device by means of the
protective earthing conductor "PE".
A smoke capture hood and an exhaust ventilation system are recommended to install above
the front of the boiler, beside the funnel cleaning door.
When carrying out boiler cleaning or repair, it is required to use only tools, supplied by the
manufacturer or other standard tools. When cleaning boilers, please, use goggles and respirators.
Any repair works inside the boiler are allowed only after cooling down of it to below 50°C.
The lighting in controls and instrumentation sites must be at least 300 lx. During repairs, only a
12V movable lamp is allowed to use as auxiliary lighting.

8.4 The boiler operation is prohibited when:

- leaking and clogged heating system;

-

leaking flue pipes or boiler door, cleaning vents caps;

- control and instrumentation devices in bad order, safety automation is out of order;

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- pressure limiting devices are out of order or concealed, or the parameters do not meet

the ones in the boiler certificate;

- faulty fittings;

- loss of water circulation through the boiler;

- a boiler operating personnel untrained;

- technical maintenance not carried out on time (see Section 9 of these Instructions);

- failure to follow the measures listed in clause 8.2 hereof.

9. MAINTENANCE AND INSPECTIONS

9.1. Boiler technical maintenance inspections must be carried out by the person responsible for
their maintenance.

9.2. Technical maintenance inspections are carried out in the following cases within the below
specified scope:

9.2.1. Internal and external inspection and hydrostatic test pressure of 6 bar – for a newly installed
boiler, a boiler manufactured more than 2 years ago, or a boiler has been damaged during
transportation or installation.

9.2.2. Internal and external inspection and hydrostatic test pressure of 6 bar – for relocated
boilers, as well as after the repair with welding.

9.2.3. Internal and external inspection and hydrostatic test pressure of 6 bar – for boilers in
service, at least once every 5 years.

9.2.4. Internal and external inspection and hydrostatic test pressure of 6 bar – for boilers being in
service over 10 years, at least once per year.

9.2.5. Internal inspection after each cleaning and repair.

9.3. Before the internal inspection and hydrostatic testing, a boiler must be cooled down and
disconnected with valves from the heating surfaces; dirt, soot and ash must be thoroughly
removed.
When carrying out an internal and external inspection, please, pay attention to the state of
boiler walls both inside and outside, funnels and welded joints, as well as to the state of fume
pipes, cleaning vent lids, door sealing, thermal insulation, controls instrumentation, and safety
devices.

9.4. Before carrying out a hydrostatic test, please, thoroughly clean all the boiler fittings, check
their tightness, and conceal safety valves.

9.5. A boiler is hydrostatically tested along with its fittings equipped. The boiler hydrostatic test
must be carried out for 10 minutes; then the pressure is reduced to the operating one and
maintained all the time required for the boiler inspection.

9.6. A boiler is considered to have passed the hydrostatic test if:

9.6.1. no crack signs found;

9.6.2. no leakage found, when the water leaks through threaded, flange fitting connections as fine
dust or droplets;

9.6.3. no permanent deformation identified;

9.6.4. Upon identifying a water leakage a fine dust or droplets in welded joints, on the pressurised
surface or in the above-mentioned joints, upon emergence of crack in seams or permanent
deformation, the boiler shall be considered to have failed the hydrostatic test;

24

9.6.5. Evaluation of the external inspection is considered positive, if no leak fume pipes, doors,
cleaning vents lids, irregular and unverified controls and instrumentation, or bad pressure limiting
devices are found during the inspection.

9.7. In case of a negative evaluation of the technical maintenance inspection, boiler operation is
prohibited. The evaluation must be recorded in the boiler certificate.

9.8. After having eliminated the defects, prohibiting the use of the boiler, it shall be allowed to
continue working only after the repeat technical maintenance inspection at the maximum period
provided for in clause 2.3 of the Section.

9.9. Results of technical maintenance inspections on the boiler status, permits to its operation,
and due dates of next inspections must be recorded by an inspection executor to the boiler
certificate. The certificate must also include information about every boiler repairs implemented.

10. STORAGE AND TRANSPORTATION

10.1. Before boiler installation, it must be stored in dry premises. All boiler outlet connections
must be covered, the doors – closed and tightened. Control instrumentation, fittings, pressure
limiting devices (safety valves), a fan, supplied with the boiler, must be stored in a room at a
temperature of at least +5°C.

10.2. Do not load boilers on top of each other during their storage and transportation.

10.3. The upper part of the boiler is fitted with two lifting loops for boiler loading or unloading.
Boiler can be unloaded or loaded with an automatic or electric loader. In this case, the boiler must
rest upon the loader’s lifted part with its supports, located at the bottom of the boiler, but not
with the bottom structure.

10.4. If necessary, a boiler can be transported being placed on its side. In this case, remove a
decorative insulating sheath from the side on which the boiler is placed; as well, remove fire­grates from the boiler furnace.

10.5. In any case of boiler transportation, it must be protected against atmospheric precipitation;
a fuel loading door, fume cleaning doors, and a boiler outgoing flue pipe must be well fixed and
tightened.

10.6. During boiler transportation, it is recommended to fix it to the vehicle body, in places,
uncovered by the decorative sheath, with special adjusting strips.

10.7. Control and instrumentation, electrical equipment, and other components are transported
being packaged, as provided by the manufacturer.

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11. WARRANTY STATEMENT

11.1. The manufacturer undertakes to perform a free boiler repairs upon its failure due to the
manufacturer's fault within 12 months following commissioning of the boiler, but not later than
within 18 months following the boiler sale, provide that a supplier, designer, installer, and owner
(operator) have followed the Instructions.

11.2. This warranty statement is not applicable to high-wear components, supplied with the boiler,
the list of which is provided in Table 5.1 (see Section 5).

11.3. A boiler buyer (owner) must demand of timely making the records, above said in this Section,
on the boiler type and number, dates of sale and installation, since otherwise the manufacturer's
warranty statement under clause 11.1 shall not be applicable to the boiler.

Date of sale: th 201__

L.S. ______________________________________________________
(manufacturer’s responsible person – signature, full name, position)

Date of installation: th 201__

L.S. ______________________________________________________
(manufacturer’s responsible person – signature, full name, position)

Note: The boiler commissioning is considered to be the date of completing installation and start­up.

26

CJSC “UT KATILAI”

Code 302618728

VAT payer’s code: LT100006099318

Alytaus str. 10, LT-20175 Ukmerge

E-mail [e-mail]

www.utkatilai.lt

DECLARATION OF CONFORMITY

No..................

Product characteristics: hot water boiler.

Type: UT - ........

Purpose: hot water treatment, building central heating.
Medium: water, Group 2
Operating pressure up to: 0.4 Mpa
Operating temperature up to: 95oC
Fuels: solid fuel

We hereby declare that a hot water boiler UT-........, serial No............ year of manufacture 201....,

meets the requirements of installation project No........ technical documentation and the European

Community Council’s Pressure Equipment Directive 97/23/EC.

The declaration shall be invalid if the product design is modified without the consent of the
manufacturer or upon non-compliance with requirements of the User Instructions of the product
during its installation and operation.

....-.....- 201....

Representative of CJSC “UT KATILAI”:

.............................................................................................................

L.S.