2.

Instruction Manual
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OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

1. General

2. Preparation for service

3. Lighting-up and service

4. Taking out of service

5. Cleaning

6. Boiling out

7. Plugging of tubes and Replacing with new tube

8. Feed and boiler water

KANGRIM INDUSTRIES CO., LTD.

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OPERATION AND MAINTENANCE

VERTICAL WATER TUBE BOILER

TYPE MC

KANGRIM INDUSTRIES CO., LTD.

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OPERATION AND MAINTENANCE

1. General

1.1 It rests with the boiler attendant to see to service and supervision of the
boiler plant. He is to see to it that all parts of the plant are properly
maintained, if the task has not been assigned to other persons.
On sea - going vessels the tasks and responsibility of the boiler attendant
rest with the ship's officer from the machine section on duty.

1.2 The boiler attendant is to follow the below working and operation
instructions. If there are interruptions of service and damages and other
irregularities this must be reported to the nearest superior after, of course,
the operational measures, which are necessary in order to obviate a
situation of danger, have been carried out.

2. Preparation for service

2.1 Before filling of water it must be checked that all strange objects have
been removed from the interior of the boilers, that all drain mountings are
closed, that all loose parts have been fastened, and that built - in blind
flanges, if any, have been removed.
If the boiler has been out of service fore quite a long time the walls are
to be examined for possible damages arisen during the standstill period.
The temperature of the water which is to be led into the boiler is to be
fairly corresponding to the temperature of the walls.
If there is a bigger difference than abt. 50 the boiler is to be filled
quite slowly.

2.2 Before heating is begun it must be checked if the gas openings are open
( danger of explosion ), that all safety devices are OK, accurately adjusted
and ready for service, and that the water in the boiler is between the
lowest and normal water level.

2.3 Valves and shut - off devices ought to be served slowly, connection pipes
must, if necessary, be emptied of water and ventilated ( water chock,
cooling, at sudden differences in temperature ).

2.4 Before the boiler is used for the first time it must be boiled out in order
to remove all protecting materials and dirt in pipes and drums.
See paragraph about boiling out.

2.5 During the first filling with boiler water the water level indicators to be
controlled by opening the blow - off valve and upper and lower water level
valve to open by turns. A weak air flow should then be heard.

KANGRIM INDUSTRIES CO., LTD.

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3. Lighting - up and service

3.1 This boiler is provided to work :

A) As a separate oil fired boiler.

B) As a combined oil fired / exhaust fired boiler.

C) As a separate exhaust fired boiler

The mode of operation of A) and B) will required constant water level

of the boiler because of danger of burning down in operation.
Constant water level is not required at C).
However, this is recommended, as the most favorable water circulation
and most be stable operating conditions will be obtained.
As to the construction and the strength it is fully proper at C) to lover
the water level of the exhaust tube section and even empty the boiler
from water, while the whole gas volume flows through the tube section.
The boiler will in such case, gradually, get the same temperature as that
of the exhaust gas. The boiler should be cooled before refilling it with
feed water. Where this could not be done the feed water is to be
preheated, and the feeding should commence very carefully ( slowly ).

3.2 When the boiler has been ignited the lighting - up rate must not be
speeded up too much in order not unnecessarily to overstrain the boiler
material by quick, uneven temperature rises.
The lighting - up time ought to be abt. 1 1/2 hours.

3.3 The air escape valve at the boiler is to be kept open until a heavy
steam jet is flowing out, this occurs at a steam pressure of abt.1, 5 bar.

3.4 The pressure gauge and its connecting pipe line are regularly to be tested
carefully as regards free passage. By this must be stated if the indicator
can reach the O - point without obstructions at slow relief of the pressure
gauge, and if it can reach its former position at slow load.
Further, it must be stated if the pressure gauge shows the indicated
allowable working pressure.
At and after every blow - through of the connecting pipe line the pressure
gauge may not be connected until sufficient steam is condensed in the
pipe loop.

KANGRIM INDUSTRIES CO., LTD.

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3.5 During service the water level may not fall below the mark for lowest
water level. If the water level cannot with certainty be said to be
sufficient the firing must be stopped at once ( see also paragraph 4.1 )
and the nearest superior informed immediately.
If the water level goes beyond the top visible water level without
Perceptible reason the firing must be stopped at once if you cannot with
Other measures again reduce the water level.

3.6 All the water level indication
therefore, to be kept clean.
regulator and limiter. Cocks
be closed in the same way.
removed at once.
instruments are currently used and have,
The same thing applies for water level
and valves are to be opened slowly and to
Lacks, especially obstructions, are to be

3.7 Before the boiler is connected it is necessary that the safety valves are
adjusted so that they can begin to function at the prescribed pressure.
Alteration of the adjustment is to be carried out only by an expert
from the local classification society. If the steam pressure rises above
the allowable working pressure, which is marked by a red line, the firing
I reduced and the feeding intensified.
If the safety valves do not blow they are to be checked at once.
If the cause is not stated the firing must be stopped and the superior
informed.

3.8 Once a day mud is blown from the boiler through the bottom blow - off
valve until clear water is coming.

3.9 If priming takes place as a consequence of pollution of oil or the like

in the boiler water ( is normally seen as a brown layer in the water
gauge glasses ), the impurities are blown out through the scum valve
( see paragraph about boiling out ).

3.10 Should the firing fail, for some reason, during a heavy steam demand
period, then the steam outlet valve is to be closed immediately, and
the feed pump is to kept in service until a normal water level is reached.

3.11 If priming takes place because of a sudden pressure drop in the pipe,
the firing to be reduced, the feeding increased and if necessary the steam
outlet to be reduce, too.

KANGRIM INDUSTRIES CO., LTD.

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4. Taking out of service

4.1 The boiler must be taken out of service immediately and the superior
informed as soon as possible if you have a suspicion that something
dangerous is arising. The applies especially when :

1) Heating or deformation of the boiler walls are found somewhere

2) A big loss of water is noted.

3) The feed water system is unable to provide the necessary feed

water amount due to failure of parts.

4) The safety valve cannot function

5) Sudden cracks or big damages are noted in the refractory on the

furnace side, or steam or moisture is coming out of the refractory.

This can also be the case when pipe damages, plate crack or the like
( I. e. at steam outlet ) are stated.

4.2 If the boiler is to be taken out of service in a emergency the fuel supply
is stopped. The steam valve is to be closed gradually and the boiler
must stand until it is cooled. The safety valves may not be touched.
Parallel working boilers are to be disconnected at once.

4.3 If part of the heating surface has been glowing or the boiler shows
recognizable deformations the supervising authorities must be informed,
and the boiler is not to be used until approval from these authorities is
available.

4.4 When stopping the service, so much feed water to be filled on that a
suitable water level is present at next firing ( between lower and normal
water level ).

5. Cleaning of fired section

5.1 If the feed water is properly treated the possibility of impurities at the
water and steam side of the boiler should be minimal.

KANGRIM INDUSTRIES CO., LTD.

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5.2 Deposits in the tubes are notoriously extremely small owing to the heavy
water circulation. If impurities which cannot be boiled out should come
inside the tubes, the tubes can be cleaned by scraper and brush.

5.3 Once a day mud is blown from the boiler through the bottom blow - off
valve until clear water is coming.

5.4 If the oil burner is functioning correctly and the combustion is complete
the soot deposit on the tubes will be minimal, but in practice it can
hardly be avoided that soot will deposit in the course of time, I. e. due to
the starting periods of the oil burner.
Attached soot deposits can be removed by water washing with a 10 per
cent soda solution through the inlet door in the uptake, drain pipe at
the bottom of the fire box is available.

5.5 Cleaning of exhaust gas fired section.

Outside the tubes are to be cleaned by boiling out, possible by using
scraper and brush.

5.6 Inside the tubes can be cleaned for attached soot deposits by washing
with water with a 10 per cent soda solution through the inlet door of
the uptake, drain pipe at the bottom of the boiler is available.
The cleaning can possibly be mode by brushes mounted in chains.

6. Boiling out

The boiling out is made in the following way :

6.1 In the boiler is to be filled a solution consisting of 4 - 5 kg.

tri - sodiumphosphate ( Na3 Po4 ) per 1000 kg water.
It is preferable to add the chemicals through the manhole.
Then water is filled in, until the solution is just visible in the water gauge.
Untreated water can be use.

6.2 The boiler is slowly brought on working pressure and kept on this pressure
in abt. 6 - 8 hours with closed main stop valve, after which fat and
other impurities should be boiled out of the interior surfaces of the boiler.

KANGRIM INDUSTRIES CO., LTD.

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6.3 Then to be skimmed of ( through the scum valve ), however, it must be

seen that before the water level is 20 - 30 mm above the scum funnel.
If the boiler is equipped with automatic water level control it may be
necessary to close for this unit during the skimming.

6.4 After the boiling out the burner is switched off, and after abt.1 quarter
the bottom blow - off valve and the air valve at the boiler top is to be
opened, and all the water is to be blown out of the boiler.
Then the boiler is washed and brushed inside, and the bottom blow - off
valve is examined in such a way that possible oxide scales and welding
pearls, which have been collected there, can be removed ( if necessary
the bottom blow - off valve is to be dismounted ). The handholes in the
bottom of the boiler is to be opened and the boiler carefully cleaned.

6.5 Treated, softened water to be added to a little below normal water level
when the bottom valve and handholes have been closed.

6.6 If the boiler shows a tendency to priming it is recommended to carry

out an extra boiling out. Besides, it is recommended to carry out another
boiling out after a time of operation of 2 to 3 months with a subsequent
inside cleaning and inspection.

7. Plugging of tubes and replacing with new tubes

7.1 Plugging of tubes

(1) In case of leakage on a water tube the pressure is to be removed from

the boiler, and the oil burner is to be dismantled.

(2) If the tube in question cannot be pointed out immediately from the
furnace, the boiler is to be put on pressure by means of the feed pump
so that the leakage will indicate which tube has been damaged.

(3) The boiler is emptied of water, and the manhole cover in the bottom
receiver is dismantled.

(4) When a furnace tube has been plugged, the damaged tube is to be
removed.

KANGRIM INDUSTRIES CO., LTD.

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(5) When the damaged tube has been removed, you can by means of a
torch see from the bottom receiver through the remaining piece of tube
which tube is to be plugged.

(6) Plugging of a furnace tube can be carried out from the furnace and the
bottom receiver. It is not necessary to remove insulation and casing on
the outside of the furnace.

(7) When a furnace tube has been plugged, a new tube should be mounted
as soon as possible. As operation for a longer period involves the risk
that the casing plate is damaged by the increased heat affection.

7.2 Replacing with new tube

(1) The boiler is emptied of water, and the manhole cover in the bottom
receiver is dismantled.

(2) After taken off, the damaged tube is replaced with new tube.

KANGRIM INDUSTRIES CO., LTD.

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8. For feed and boiler water

The below values are, unless special conditions are to be taken into
Consideration, to be kept for KANGRIM boiler type MA and MC

Feed water Boiler water

Appearance Clear and free of mud -
Hardness < 0, 2 dH -
Chloride content C1 Max. 100 PPM Max. 300 PPM
Alkalinity P - 100 150
pH-valve at 25 7-9 10.5 - 11.0
Hydrazine excess - 0.2 - 0.5 PPM
Phosphate excess (P2O5) - 20 - 40 PPM
Specific gravity at 20 - Max. 0.5
Oil content 0 0

The tabulation indicates in general terms the desired water conditions.

It is suggested that in any particular case the recommendations of a
Recognized boiler water chemist should be sought, and there are a number
of reputable firms offering this service.
Some of these will offer refinements additional to the requirements of the
Above table, and may recommend slightly different methods of achieving
the desired water conditions.
The important point is that these conditions should be obtained and
Maintained by regular testing applying corrective measures where
Indicated.

KANGRIM INDUSTRIES CO., LTD.

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SOOT CLEANING PROCEDURE

SOOT CLEANING PROCEDURE

1. Cleaning of Oil firing setion

2. Cleaning of Exh. Gas section

3. Procedure for Soot cleaning

KANGRIM INDUSTRIES CO., LTD.

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SOOT CLEANING PROCEDURE

1. Cleaning of Oil firing section

If the feed water is properly treated, the possibility of impurities

at the water and steam side of the boiler should be minimal.

Deposits in the tubes are notoriously extremely small owing to

the heavy water circulation.
If impurities which cant be boiled out should come inside the tubes,
the tubes can be cleaned by scraper and brush.

Once a day mud is blown from the boiler through the bottom blowoff valve
until clear water is coming.

If the oil burner is functioning correctly and the combustion is complete

the soot deposit on the tubes will be minimal, but in practice it can hardly
be avoided that soot will deposit in the course of time,
i. e. due to the starting periods of the oil burner.
Attached soot deposits can be removed by water washing
with a 10 percent soda solution through the inlet door in the uptake,
drain pipe at the bottom of the fire box is available.

2. Cleaning of Exh. gas section

The main engine exhaust gas contains a certain amount of carbon particles
and unburnt residues (soot etc.). The amount is strongly dependent on the
condition of the engine. These soot/unburnt residues will accumulate on the
boiler heating surface if not removed by cleaning.

It is important that the general maintenance standard of the combustion

equipment, i.e. fuel injectors, injection pumps, turbo charges, air coolers,
cleanliness of scavenge parts, etc., is satisfactory so that the soot/residue
production is reduced to a minimum.

A regular exhaust gas testing procedure should be applied in order to

reveal an abnormal increase of the soot content.

Every endeavor must be made to eliminate accumulation of soot deposits

in the boiler so that the risk of soot fire is diminished, and a high thermal
efficiency is achieved.

KANGRIM INDUSTRIES CO., LTD.

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SOOT CLEANING PROCEDURE

2-1. Soot blowing

The boiler is equipped with inspection doors in both ends. This enables
access to clean the boiler manually by means of a suitable hand-carried
cleaning tool.

The cleaning medium might be fresh water or alternatively compressed air.

If the boiler is water washed, the drain on the exhaust gas inlet side
should be closely monitored to avoid overflow conditions in case the drain
should block, and it is important that the washing is continued, until the
boiler is completely clean. Large soot accumulations which might be present
after unfinished cleaning will not only result in reduced boiler efficiency, but
also increase the risk of a soot fire.

KANGRIM INDUSTRIES CO., LTD.

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3. Procedure for Soot cleaning

Removal of Soot by Use of Hand Lance

Water is used for soot removal with a hand lance. This soot removing method is
very simple and quite effective. When the main engine is stopped, check the soot
accumulation condition and remove soot in accordance with the below instructions :

(1) Make sure that the main engine has been completely stopped.
(2) Open the inspection doors of the exhaust gas boiler body and the inlet/outlet
ducts and check the condition of soot accumulation.
(3) Take care never to make cleaning water flow into the main engine
through the gas inlet duct.
(4) Open the change-over flange or valve at the cleaning water outlet.
(5) Adjust washing water pressure to 4 7 /G
(6) Note that 5 10liter water will be needed for cleaning per 1 heating surface.
(7) Direct washing nozzle as perpendicularly with the element surface as
possible so that cleaning will be most effective.
(8) When soot is clogged between studs, prick soot with a flat bar or the like.
(9) Check the drain tube to see whether exhaust water is being discharged .
(10) When one cycle of cleaning has been done, check each part for any soot and,
if necessary, repeat cleaning.
(11) Close tightly the inspection doors.
(12) Close the change-over flange or valve at the cleaning water outlet.

KANGRIM INDUSTRIES CO., LTD.