Boiler Manual

Cochrane Engineering (Pvt) Ltd
Stirling MK7 S4500-S20000 Range of Boilers

Boiler Manual Issue 3
Chapter 1
General Information
Contents
Introduction
Conversion to Gas or Oil Firing
Manufacturers Detail Plate
Serial number plates
Design and Performance Data
Design and construction
Clearance certificate
Turndown ratio
Smoke and grit emission
Dryness fraction
Physical data
General data
Services Required
Type of coal required
Feedwater
Electrical power requirements
Associated Equipment
Definition
Combustion equipment
Steam and furnace pressure control
Steam pressure gauge
Furnace pressure gauge
Control panel
Boiler feedwater pumps
Water level monitoring instruments
Water level controls
Ash removal trolley
Grit collector
Sootblowers
Inspections
Maintenance Tools and Consumable Spares
Optional Extras
Labour Requirements
Page 2
Annexure 1
Page 1
Page 2
Page 3
Table 101 - General Data

Boiler dimensions drawing single flue
Boiler dimensions drawing twin flue
Page 2
Page 3
Page 3
Page 3
Page 4
Page 4
Page 5
Page 5
Page 5
Page 5
__________________________________________________________________________________________
Chapter 1
Page 1 of 1

Chapter 1
General Information
Introduction
1.
The Stirling MK7 boiler is a high efficiency, wetback and fully packaged coal fired unit. The
boiler has been specifically designed for use with a Chaingrate Stoker. A cut-away view of a
single stoker Stirling MK7 boiler is given in Appendix A to this manual.
2.
The boiler is a horizontal three pass unit comprising :

a. A flue housing the stoker. Twin stoker packages have two separate flues and two separate
stokers.
b. A wetback return chamber.
c. Two convection tube passes.
Conversion to Gas or Oil Firing

3.
The Stirling MK7 boiler can be converted to fire gas or oil. Details will be supplied on request.
Manufacturers Name Plate
4.
A manufacturers detail plate is fitted to each boiler. The details stamped on this plate must be
quoted when ordering spares or making general enquiries concerning the boiler. (Ref. Appendix
A page 3.)
Serial Number Plates
5.
A serial number plate is fitted to the stoker hopper. The details stamped on this plate must be
quoted when ordering spares or making general enquiries concerning the stoker.
6.
A serial number plate is fitted to the forced draught (FD) fan casing. The details stamped on this
plate must be quoted when ordering spares or making general enquiries concerning the FD fan.
7.
A serial number plate is fitted to the induced draught (ID) fan casing. The details stamped on this
plate must be quoted when ordering spares or making general enquiries concerning the ID fan.
Design and Performance Data

Design and Construction
8.
The boiler has been designed and constructed in accordance with an approved code and
complies with the Factory and Works Regulations 1976, and the Mining (Management & Safety)
Regulations 1990.
9.
All pressure parts are manufactured under the supervision of a recognised Approved
Independent Inspection Authority (AIIA).
Clearance Certificate
10. On completion of manufacture, the Inspection Authority (see. Para. 9) issues a Release Note and
signs the Pressure Vessel Certificate confirming that the design and the materials used in
construction and manufacture comply with the relevant Code. The Quality Assurance file is
submitted to the relevant Regulating Authority with a copy to the Client, by Cochrane
Engineering (Pvt) Ltd.
__________________________________________________________________________________________
Chapter 1
Page 2 of 2

Turndown Ratio
11. Under normal operating conditions, the automatic combustion control has a turndown ratio of 3 :
1 without altering the fuel thickness. Under certain conditions a turndown ratio of 4 : 1 can be
achieved. If the boiler is to be operated on lower loads, it should be panel controlled or manually
controlled.
Smoke and Grit Emission
12. The design of the boiler is such that
smoke is eliminated provided that the boiler is operated correctly and that the correct fuel is used
(Ref. Appendix B to this manual). Grit emission is minimal as the fuel bed is quiescent at all
times.
Dryness Fraction
13. A large steam space ensures a dryness fraction of approximately 0.98 when the boiler is
operating at full load.
Physical Data
14. Dimensions and masses (operating and dry) of the boilers are shown in the drawing (Ref.
Annexure 1 to this chapter) and table (Ref. Annexure 1 to this chapter) attached.
General Data
15. Table 101 (Ref. Annexure 1 to this chapter) lists general data applicable to the Stirling MK7
boiler range.
Services Required
Type of Coal Required
16. The boiler is capable of burning a wide variety of coals. The main factors which affect the choice
of coals, are detailed in Appendix B to this manual.
Feedwater
17. Provision must be made for the supply of feedwater. The chemical content of the boiler water
and the feedwater must be maintained within close limits. Guidance on recommended qualities is
given in Appendix C to this manual.
18.
Because of the importance attached to the correct analysis and treatment of the boiler feedwater,
it is recommended that specialists carry out these functions.
Electrical Power Requirements

19. Standard electrical power connections to the control panel are as follows :
a. 380V, 3 phase, 4 wire line
b. Installed power (kW) required for the complete Stirling MK7 boiler range is given in Table 101
(Ref. Annexure 1 to this chapter).
Associated Equipment
Definition
20. For the purpose of this publication, associated equipment is defined as being standard items of
equipment normally supplied with a fully packaged boiler. Optional extras, which may be
obtained from Cochrane Engineering (Pvt) Ltd., are listed in para.42.
Combustion Equipment
__________________________________________________________________________________________
Chapter 2
Page 3 of 3

21.
In its standard form as a coal fired boiler, the Stirling MK7 boiler is equipped with the following
combustion equipment :
a. Chaingrate stoker.
b. Forced draught (FD) fan and damper.
c. An FD damper control unit.
d. An induced draught (ID) fan and damper.
e. An ID damper control unit.
22.
The combustion equipment is described in the Cochrane Chaingrate Stoker Manual.
Steam and Furnace Pressure Control

23. Control of the steam pressure and furnace pressure can be effected in three different ways as
follows :
a. Manually at the mechanical control units mounted on the boiler (manual).
b. Manually at the control panel (panel)
c. Automatically (auto).
24.
The automatic combustion controls used on the Stirling MK7 boiler ensure :
a. Maximum efficiency under fluctuating load conditions.
b. Correctly controlled air/fuel ratios to give smokeless combustion.
c. Boiler pressure is maintained within close limits.
d. Immediate response to changing load conditions.
e. A high turndown ratio to meet practically all conditions and demands.
f.
Minimal maintenance.
Steam Pressure Gauge

25. Steam pressure is measured by a standard Bourdon type pressure gauge fitted with an isolating
cock and an Inspectors test connection. The gauge is mounted on the boiler name plate.
Furnace Pressure Gauge
26. Furnace pressure is monitored by a draught gauge which is calibrated in Pascals. The gauge is
mounted on the fascia of the control panel and coupled to the furnace by a steel tube and rubber
pipe. The single stoker version employs one furnace pressure gauge, whereas the twin stoker
version employs two gauges.
Control Panel
27. The control panel provides a central point from which the boiler can be manually controlled
through the control regulators on the fascia (panel) or automatically controlled (auto). It also
serves as a connection point between the various circuits of the Stirling MK7 boiler. Housed
inside the control panel are the electric motor and start circuits, thermal overloads, fuses etc.
__________________________________________________________________________________________
Chapter 2
Page 4 of 4

Boiler Feedwater Pumps

28. Two electrically driven feedwater pumps are supplied with the boiler. Each pump is complete
with motor and coupling and has a capacity in excess of the boiler output at maximum
continuous rating (MCR). The pumps are designed to handle non-aggressive boiler feedwater.
One pump is used for standby purposes while the other is operating.
29.
On single stoker versions, the pumps are mounted on a bracket attached to the boiler. On
double stoker versions the pumps are supplied as separate units
which are mounted in the vicinity of the boiler.
30.
A central pump station is sometimes used for multi-boiler installations.
Water Level Monitoring Instruments

31. The boiler water level is monitored by two water gauges with top and bottom isolating cocks,
gauge glass protectors and tri-valves.
Water Level Controls
32. The water level in single stoker boilers is controlled by a float operated switch which starts and
stops the selected feedwater pump. Audible and visual alarms are incorporated to warn the
operator when the water level in the boiler is at an unsafe level.
33.
The water level in double stoker boilers is controlled by a modulating controller which actuates a
valve in the feedwater line. The feedpump operates continuously. Audible and visual alarms are
incorporated to warn the operator when the water level in the boiler is at an unsafe level.
34.
A second float operated switch is fitted to switch off the fan and stoker motors when the extra
low water level is reached. This level is never lower than the Lowest Legal Water Level
(LLWL) which is marked on the boiler. This is the same as the Lowest Working Water Level
(LWWL) in the boiler regulations.
Ash Removal Trolley

35. Mechanical ash extractors in the boiler flue have been eliminated by the incorporation of a
central ash discharge port in the boiler shell. Ash from the stoker drops through this port into the
ash sump. Emergency de-ashing can be effected by opening a door beneath the front of the
stoker and manually raking the ash out.
Grit Collector
36. To reduce grit emission a multicyclone
grit collector is supplied as standard equipment. A wet sump is supplied at the bottom of the
collector hopper. Grit collects in the sump and may be removed in a wheelbarrow.
Sootblowers
37. A set of sootblowers is supplied as standard equipment at the rear of the boiler to clean the
second pass tubes. A set of sootblowers can be supplied fitted in the front smokebox, to clean
the third gas pass.
Inspections (See Appendix F to this manual)
38.
To comply with relevant Regulating Authority regulations, the boiler must be inspected and/or
hydraulically tested whenever a Government Inspector decides. A boiler log book must also be
kept in which boiler maintenance work, inspections and tests must be recorded.
__________________________________________________________________________________________
Chapter 2
Page 5 of 5

Note - Inspection and testing must be carried out by a Government Inspector.

39.
It is general practice to have an internal inspection at regular yearly intervals and an external
inspection and hydraulic test at regular two yearly intervals. The boiler should also have an
external inspection and a hydraulic test when the following occur :
a. After positioning and before initial commissioning.
b. After the boiler has been moved from its original position.
c. After pressure part repairs.
40.
The hydraulic test pressure is given on the manufacturers name plate (Ref. Appendix A page 3).
Maintenance Tools and Consumable Spares

41.
A number of maintenance tools and consumable spares are provided with each installation.
(Ref. chapter 5 to this manual)
Optional Extras
42.
The following items are available as optional extras :

a.
b.
c.
d.
e.
f.
g.
43.
Swinging coal chute

Coal handling plant
Ash conveying equipment
Water sample cooler
Modulating water level controls on single stoker boilers.
Deaerator
Front sootblowers.
Details of these optional extras can be
obtained from Cochrane Engineering (Pvt) Ltd.
Labour Requirements
44.
Because of the boiler mass an experienced team consisting of one artisan and four labourers
with rigging tackle is required to off-load and position the boiler. It is strongly recommended that
only a company that has considerable experience in handling large boilers be engaged to offload and position the boiler. Cochrane Engineering (Pvt) Ltd. offers this service.
45.
When fully automatic facilities are provided, one man can operate the boiler. When coal and/or
ash has to be handled manually additional labour is required. One man can maintain the boiler
provided that heavy assemblies or sub-assemblies do not need to be removed.
__________________________________________________________________________________________
Chapter 2
Page 6 of 6

Chapter 2
Operating Information
Contents
Introduction
Page 3
CONTROLS
Component Location
Water Level Controls and Monitoring Instruments
Water level gauge glasses
Feedpump selection switches
Water level controls (single stoker boilers)
Water level controls (double stoker boilers)
Combustion Controls and Monitoring Instruments
Steam pressure controls
Steam pressure gauge
Firing rate control
Furnace pressure control
Furnace pressure gauge/switch
Stoker Controls
Coal cut-off gate
Guillotine door
Undergrate dampers
Ash and Grit Removal
Primary de-ashing port
Emergency de-ashing door
Grit collector
Sootblowers
Rear sootblowers
Front sootblowers
Valves and Mountings
Boiler blowdown valve
Safety valves
Main steam valve
Automatic sequencing blowdown valves
Main feedwater check valve
Air release valve
Inspectors test gauge connection
Page 3
Page 3
Page 4
Page 4
Page 5
Page 6
Page 6
Page 7
Page 7
Page 7
Page 7
Operating Procedures
Introduction
Page 8
__________________________________________________________________________________________
Chapter 2
Page 7 of 7

Sootblower Operation
Rear sootblowers
Front sootblowers
Blowdown Procedures
Blowdown of gauge glasses
Blowdown of float-operated switches
Boiler blowdown
Ash removal
Grit removal
Normal Water Level Control
Filling the boiler (on/off feedwater controls)
Lighting A Fire
Notes on Combustion
Low Load Firing Techniques
Shutting Down
Standby periods of up to 18 hours (banking)
Normal shutdown
Page 8
Page 9
Page 10
Page 11
Page 11
Page 11
Page 12
Page 14
Page 15
Page 16
Page 16
Page 19
Emergency shutdown (power failure or extra low

water level, ID fan, FD fan and stoker motors stopped)
Page 19
Emergency shutdown (extra low water level, ID fan,

FD fan and stoker motors stopped)
Page 20
__________________________________________________________________________________________
Chapter 2
Page 8 of 8

Chapter 2
Operating Information
Introduction
1.
For the convenience of the user, this chapter is divided into two parts :
CONTROLS
OPERATING PROCEDURES
2.
The first part describes the controls, gauges and valves fitted to the Stirling MK7 boiler. The
second part describes the actual procedures to be followed when operating the boiler.
3.
The heart of the Stirling MK7 boiler is the chaingrate stoker. Due to its wide appeal, to both
boiler and furnace users alike, the stoker is supplied with its own operating and maintenance
manual. To avoid unnecessary duplication, full descriptions of the stoker are not given in this
manual.
Meaning of Operating Terms

4.
Throughout the text, reference is made to the following :
a. Manual Control - This means that control is effected manually at the mechanical control units.
b. Panel Control - This means that control is effected manually through the control regulators on
the panel.
c. Auto Control - This means that control is effected automatically through the electro
mechanical control systems.
CONTROLS
Component Location
5.
The location of the various components fitted to a standard single stoker boiler is shown in
Appendix A to this manual
(Pages 4 and 5). Location of alternative water level controls sometimes fitted to single
stoker boilers as an optional extra, is also shown. The location of components on a standard twin
stoker boiler is as shown in Appendix A to this manual (Pages 6 and 7).
6.
Although component locations are the same for both single and double stoker boilers, several
controls are duplicated on the double stoker version. The standard feedwater control system
fitted to single stoker boilers employs a float operated switch, which switches the feedpump on
and off as the water level in the boiler varies with steam demand. The standard feedwater
control system fitted to double stoker boilers employs a modulating water level control to regulate
the flow of feedwater to the boiler in proportion to steam demand. This system can also be fitted
as an optional extra to single stoker boilers.
7.
Operators are advised to familiarise themselves with the controls and monitoring instruments as
fitted to their particular boiler, before any attempt at operating the boiler is made.
Water Level Controls and Monitoring Instruments

__________________________________________________________________________________________
Chapter 2
Page 9 of 9

Water Level Gauge Glasses

8.
Two gauge glasses are fitted to the boiler to enable the operator to visually monitor the water
level. One gauge faces to the front of the boiler and the other faces to the side of the boiler. A
common indicating plate indicates the water level in the boiler. It should be noted that extra low
water level has been reached when water is just visible in the glass. Each gauge is fitted with
test cocks and gauge glass protectors.
Feedpump Selection Switches
9.
A selection switch for the feedpumps is mounted on the control panel fascia. This two position
switch enables the selection of either feedpump No. 1 or No. 2. The selected feedpump is
controlled by a float-operated switch, which is described in para. 12. An indicating lamp
illuminates when either pump is operating.
10.
When modulating controls are fitted, the water level in the boiler is controlled by a modulating
valve which adjusts the flow of feedwater in proportion to steam demand. A two position switch
enables either pump No. 1 or pump No. 2 to be selected. The modulating valve cannot be bypassed for manual control except as described in para. 15.
Water Level Controls (Single Stoker Boilers)

11. The water level control system fitted to a single stoker Stirling MK7 boiler is known as on/off
feedpump control (two switch control). In this system two separate float operated control switch
units are used. One of these switch units contains two switch contacts actuated by a single float.
The function of the two switch units is as follows :
a. Control the water level in the boiler by switching the selected feedpump on and off.
b. Cause audible and visual alarms to be operated if the water level in the boiler falls to the low
water level mark.
12.
The second float operated switch has only one set of contacts, which open when the extra low
water level is reached. Since the combustion equipment control circuits are wired through this
switch, complete shutdown is initiated if the water level in the boiler falls to the extra low water
mark. It should be noted that this level corresponds to water just being visible in the gauge
glasses mentioned in para.8. The combustion equipment cannot be restarted until a safe water
level has been re-established.
Water Level Controls (Double Stoker Boilers)

13. In place of the two switch control a modulating controller is fitted which actuates a valve in the
feedwater line. This valve continuously controls the flow of water in proportion to steam demand.
Should the water drop to the low water level mark, the same audible and visual alarms
mentioned in para.11.b are operated.
14.
A float operated control switch identical to that described in para.12, is fitted to all boilers.
15.
Manual Control - Under certain circumstances, it will be necessary to over-ride the automatic
function of the modulating valve. To do this, it is necessary to open the by-pass valve and close
the globe valve feeding the modulating valve. The modulating valve is then fully open and the
water level in the boiler can be controlled by the main feedwater check valve. When the boiler is
filled to the required level, the globe valve feeding the modulating valve should be opened and
the by-pass valve closed.
16.
Pressure Relief Valve - Under low load conditions, the modulating valve is sometimes closed
for long periods and this could cause the feedpump to overheat since it is not designed to
operate against a fully closed discharge. To guard against this, when a modulating water level
controller is fitted to the Stirling MK7 boiler, a pressure relief valve is connected in the feedpump
__________________________________________________________________________________________
Chapter 3
Page 10 of 10

discharge pipe. The pressure relief valve allows feedwater to bypass the boiler and return to the
feedwater tank when the modulating valve is closed.
Combustion Controls and Monitoring Instruments
Steam Pressure Controls
17. Steam pressure is controlled through the ID damper control unit (Ref. Appendix A page 11). The
damper control linkage is brought down to the control unit at the rear of the boiler.
18. A pulling motor is fitted to enable auto control to be effected and a clutch lever is incorporated to
enable either auto and panel control (panel position) or manual control (manual position) to be
selected.
19. Manual Control - To enable the ID damper control unit and hence the steam pressure, to be
manually controlled, the clutch lever is set to the manual position. The ID damper control lever
can then be set in a selected position by turning the locking handle clockwise turning the
handle counter-clockwise releases the locking action.
20. Panel and Auto Control - To enable the ID damper control unit and hence the steam pressure,
to be panel controlled or auto controlled, the clutch lever is set to the panel position. The locking
handle is left loose with the control lever in the zero position.
21. When the ID damper manual/auto selection switch on the control panel is set to MANUAL the ID
damper control unit is controlled from the control panel through the panel mounted control
regulator. When the selection switch is set to AUTO, the ID damper control unit, and hence the
steam pressure, is automatically controlled. Automatic control is effected through a pressure
detector which, via a control relay and a pulling motor, converts pressure changes into
mechanical movement of the ID damper. The pressure detector, which is mounted on the side
of the control panel, incorporates a setting screw and scale indicator. A transmission range
slide screw and indicator is also incorporated and increases the sensitivity of the transducer if
the band width is decreased and decreases the sensitivity of the transducer if the band width is
increased.
Steam Pressure Gauge
22. Steam pressure is monitored on a standard Bourdon tube type pressure gauge, which is
calibrated in kilopascals (kPa) and mounted on the boiler nameplate. A red mark on the gauge
indicates the authorised working gauge pressure. For purposes of repair, replacement, etc., an
isolating valve is fitted to isolate the gauge from the steam pressure.
Firing Rate Control
23. Firing rate is controlled through the VSD (variable speed drive) and the Sauter motor..
24. The FD damper control unit relates the position of the FD damper to the grate speed. The
Sauter motor adjusts the position of the FD damper through a direct coupling and the
potentiometer in the Sauter motor provides the signal to the VSD to adjust the grate speed.
25. The maximum speed range is 0 to 15 metres per hour and the minimum speed range is 0 to 5.5
metres per hour.
26. Increasing the speed range of the grate decreases the air/fuel ratio (i.e. more fuel will be fed to
the boiler for a given amount of air) and the CO2 content of the exhaust gases will be increased.
Conversely, decreasing the speed range will increase the air/fuel ratio and the CO2 content of
the exhaust gases will be decreased.
__________________________________________________________________________________________
Chapter 3
Page 11 of 11

27. If the air/fuel ratio is too low (CO2 content greater than 14 percent) the coal will not be completely
burnt off before it reaches the end of the grate and it is possible then that black smoke will be
emitted. If the air/fuel ratio is too high (CO2 content less than 11,5 percent) the load carrying
capacity of the boiler will be impaired. Optimum results are obtained at a CO2 content of
approximately 12,5 percent.
28. A Sauter motor is fitted to enable auto control to be effected and a clutch lever is incorporated to
enable either auto and panel control or manual control to be selected.
29. Manual Control - To enable the FD damper control unit and hence the firing rate to be
manually controlled, the clutch lever is set to the manual position. The FD damper control lever
can then be locked in a selected position by turning it clockwise : turning the lever counterclockwise releases the locking action.
30. Panel and Auto Control - To enable the FD damper control unit, and hence the firing rate, to
be panel controlled or auto controlled, the clutch lever is set to the panel position.
31. When the FD damper manual/auto selection switch on the control panel is set to MANUAL, the
FD damper control unit is controlled from the control panel through the panel mounted control
regulator. When the manual/auto switch is set to AUTO, the FD damper control unit, and hence
the firing rate and furnace pressure, is automatically controlled. Automatic control is effected
through a transducer incorporated in the draught gauge. Two set-point adjusters and an
indicator are also incorporated on the draught gauge. The transducer through control relays
and a pulling motor, converts changes in the furnace pressure into mechanical movement of the
FD damper control unit and consequently varies the grate speed and FD damper opening.
Furnace Pressure Control
32. Adjusting the position of the FD damper through the FD damper control unit controls the air
supplied to the fuel bed. This will vary the firing rate and affect the furnace pressure. Opening
the damper increases the furnace pressure while closing the damper decreases the furnace
pressure.
33. Adjusting the position of the ID damper can also control furnace pressure. This is controlled
through the ID damper control unit. Normally, when increasing
the firing rate, the ID
damper should be opened first. When decreasing the firing rate, the FD damper should be
closed first.
Furnace Pressure Gauge/Switch
34. Furnace pressure is monitored by a photohelic draught gauge which is calibrated in Pascals
(Pa). The gauge is mounted on the side of the control panel. The instrument is connected to
the furnace by a copper or steel tube and a rubber pipe. Constricting the rubber pipe with a
clamp can dampen the signal to the instrument. When the needle is positioned to the right of
zero a negative pressure is indicated, whereas to the left of zero indicates a positive pressure.
Automatic control is effected through a transducer incorporated in the draught gauge. Two set
point adjustors are fitted. The right hand one should be set to minus 15Pa and the left hand one
to minus 3Pa.
Stoker Controls
C
Coal Cut-off Gate

35. A coal cut-off gate is incorporated in the stoker hopper. To isolate the coal supply to the gate,
the gate is lifted. A retaining pin holds the gate in the lifted position. When the gate is lowered,
it allows coal to flow onto the grate and simultaneously closes off the front of the stoker.
Guillotine Door
__________________________________________________________________________________________
Chapter 3
Page 12 of 12

36. The guillotine door enables the depth of the fuel bed to be adjusted. The door is raised and
lowered by the handwheel. The fuel bed depth is shown on the handwheel indicator.
Recommended fuel bed depths for various conditions are shown in Appendix B to this manual.
If the depth of the fuel bed is varied the air/fuel ratio will change and the fuel trim knob will have
to be adjusted accordingly. Increasing the fuel bed depth decreases the air/fuel ratio,
decreasing the fuel bed depth increases the air/fuel ratio.
Undergrate Dampers
37. Two adjustable undergrate dampers are provided and can be adjusted while the boiler is
operating. They enable the air distribution to be controlled along the length of the stoker. The
front undergrate damper is provided to control combustion under the ignition arch. The rear
undergrate damper is provided to adjust the length of the active fuel bed. If the damper is
opened, the active fuel bed will lengthen. If the damper is closed, the active fuel bed will
shorten. Both dampers should be closed when lighting a fire or when operating on low loads.
When operating at more than 30 percent load, the position of the dampers should be adjusted to
give optimum combustion conditions.
Primary De-ashing Port
38. Ash is discharged from the end of the stoker grate through the ashport located in the boiler shell.
The ash port should always be open and clear of ash.
Emergency De-ashing Door
39. An emergency de-ashing door is provided beneath the front of the stoker. This door should
always be kept closed and secured unless ash is actually being removed through it. A special
shovel is
provided for this purpose.
Grit Collector
40. The multicyclone is provided with a grit removal sump.
Sootblowers
41. Rear sootblowers are fitted as standard equipment. The layout of the front (if fitted) and rear
sootblowers is as illustrated in Appendix A to this manual (pages 13 and 14). Sootblowers must
only be operated when the boiler is on low loads and only for short periods. It is recommended
that the sootblowers are used once every 8 hours or once during a shift.
Rear Sootblowers
42. Steam is supplied to the sootblowers through a sootblower isolating valve. The left and right
hand blowers, when operated, allow steam to blow through the first pass fire tubes and remove
deposits. The drain cock is used to drain water out of the system.
Front Sootblowers
43. Steam is supplied to the sootblowers through a sootblower isolating valve. This valve has an
associated isolating cock and a drain cock : the latter is used to drain water out of the
sootblower pipe.
Valves and Mountings
Boiler Blowdown Valve
44. This valve serves two different purposes
a. It allows controlled blowdown of boiler water during operation. This procedure is necessary in
order to keep the chemical content of the water within the required limits.
__________________________________________________________________________________________
Chapter 3
Page 13 of 13

b. It allows the boiler contents to be discharged if the boiler is to come off range for service or
layup.
Safety Valves
45. These valves relieve excess steam pressure. Their settings are locked and must not be adjusted
during operation. It is recommended that the valves are tested once a week as detailed in
Chapter 4 paras.30 and 31
.
46. Steam relieved by the safety valves is blown through the take away pipes. These pipes must not
be blocked and must vent to atmosphere.
Main Steam Valve
47. This valve is used to isolate the boiler from the main steam range.
Automatic Sequencing Blowdown Valves
48. The float operated controls must be blown down regularly to ensure that they operate correctly.
These valves automatically provide sequenced blowdown of the controls.
Main Feedwater Check Valve
49. This valve is used to isolate the boiler from the feedwater supply and incorporates an accessible
check valve.
Air Release Valve
50. This valve is used to vent air during filling and steam raising and to prevent a vacuum forming
when taking the boiler off range or when emptying.
Inspectors Test Gauge Connection
51. The inspectors test gauge connection is positioned adjacent to the boiler pressure gauge to
enable both the test gauge and the boiler gauge to be viewed from one position. When the
gauge is not connected the gauge connection aperture is sealed off with a plug.
OPERATING PROCEDURES
Introduction
52. In this second part of Chapter 2 the operating procedures are given in the order usually carried
out (i.e. filling the boiler, lighting a fire from cold, etc.,). However, since sootblowing, blowdown
operations, ash and grit removal are carried out at various stages of operating the boiler, these
procedures are described first. Periods at which these operations should be implemented are
left to the discretion of the operator who must decide for himself when these are required.
53.
The operating procedures also assume that the operator has read the first part of this chapter
and is therefore, familiar with the controls as fitted to his particular boiler.
Sootblower Operation
54. Before carrying out sootblowing operations, the following conditions should be observed :
a. Sootblowers should only be used when the boiler is on low load and near its maximum working
pressure.
b. Panel control should be selected.
__________________________________________________________________________________________
Chapter 3
Page 14 of 14

c. Induced draught control dampers should be opened sufficiently to maintain balanced draught
conditions during operation.
d. If the steam pressure falls during sootblowing operations, allow sufficient time between
successive operations to enable the boiler to regain its normal working pressure.
Rear Sootblowers
55. These are operated as follows:
a. Open the drain cock.
b. Crank open sootblower isolating valve.
c. When all residual water and condensate has drained off, close the drain cock.
d. Fully open main sootblower isolating valve.
e. Over a period of approximately 15 seconds, turn the right hand blower handwheel to the fully
open position and then reverse slowly to the fully closed position.
f.
Repeat step e. three times and, finally leave the handwheel in the fully closed position.
g. Repeat steps e. and f. with the left hand blower handwheel.

h. Close the main sootblower isolating valve and open the drain cock.
i.
When all residual water has drained off, close the drain cock.
Front Sootblowers
56. These are operated as follows :
a. Open left hand drain cock.
b. Crank open left hand main sootblower isolating valve.
c. When all residual water and condensate has drained off, close drain cock.
d. Fully open left hand main sootblower isolating valve.
e. Over a period of 15 seconds, turn the left hand lever operated blower valve to the fully open
position and then reverse slowly to the fully closed position.
f.
Repeat step e. three times and, finally leave the valve in the fully closed position.
g. Close the left hand main sootblower isolating valve and open drain cock.
h. When all residual water has drained off, close the drain cock.
i.
Repeat steps a. to h. inclusive using the right hand front sootblower.
Blowdown Procedures
Blowdown of Gauge Glasses
57. To blow down the gauge glasses the following procedure should be adopted :
a. Close the water leg valve.
__________________________________________________________________________________________
Chapter 3
Page 15 of 15

b. Open the tailcock and allow steam to blow through the gauge.
c. Close the tailcock and open the water leg valve.
d. Close the steam leg valve. Open the tailcock and allow water to blow through.
e. Close the tailcock and open the steam leg valve.
Blowdown of Float-Operated Switches
58. Three different versions of float operated switches are used, depending on the boiler. When
these units are blown down, low water conditions are simulated.
59.
Two Switch Control - The two switch control is blown down as follows :
Note - This control should be blown down only when the feedpump is in the normal cut-out
condition. This enables the operation of the switch to be proven.
a. Turn the sequencing blowdown valve spindle clockwise until the valve is at the mid-travel
position as marked. Keep the valve in this position for 5 to 10 seconds to ensure full blowdown
of the water leg.
b. Continue turning clockwise to the full extent of travel. Keep the valve in this position for 5 to 10
seconds to ensure full blowdown of the float chamber and the steam leg.
c. Check that the low water level indicating lamp on the control panel is illuminated and that the
alarm bell is sounding. Check also that the pump has started.
d. Turn the sequencing valve counter-clockwise. Pause at the mid-travel position for a few
seconds and then turn counter-clockwise to the full extent of travel.
e. If the control unit is operating correctly and the boiler water level is correct, the low water level
indicating lamp should extinguish and the alarm bell cease sounding. The feedpump should
switch off.
60.
Single Switch Control - the single switch control is blown down as follows :
Caution - When this unit is being blown down, the fans and stoker(s) are automatically
shutdown. Therefore,
blowdown should only be carried out at low load to prevent the steam supply from being
seriously disrupted. After blowdown, it will be necessary to restart the fans and stoker(s)
from the control panel.
a. Turn the sequencing blowdown valve clockwise until the valve is in the mid-travel position as
marked. Keep the valve in this position for 5 to 10 seconds to ensure full blowdown of the
water leg.
c. Check that the ID fan, FD fan and stoker motors have stopped operating and that the
appropriate indicating lamps are extinguished.
d. Return the sequencing blowdown valve to its normal operating position by turning counterclockwise. Pause at the mid-travel position for a few seconds before continuing counterclockwise to the full extent of travel.
__________________________________________________________________________________________
Chapter 3
Page 16 of 16

e. Restart the fans and stoker drive motors as follows :

Note - If automatic combustion controls are fitted, set the manual/auto switches on the control
panel to MANUAL and the control regulators to the zero position.
1) Check that the ID damper is closed.
2) Check that the FD damper control unit is set at zero.
3) Start the ID fan and check that its indicating lamp illuminates.
4) Check that the FD fan has started and that its indicating lamp has illuminated.
5) Start the stoker and check that its indicating lamp illuminates.
6) Reset the ID damper to its normal operating position,
7) Reset the FD damper control unit lever to its normal operating position.
8) If the boiler pressure is now within 50kPa of normal operating pressure, all combustion
controls can be set to AUTO. If the boiler pressure is low, build up the pressure gradually
until the normal operating pressure is reached before setting the combustion controls to
AUTO.
61.
Modulating Control - This unit is blown down as follows :

Note - This check should be carried out on low load and only when the water level is just above
the average water level (i.e. when the control valve is approaching the closed position with the
spindle moving down).
a. Turn the sequencing blowdown valve spindle clockwise until the valve is in the mid-travel
position as marked. Keep the valve in this position for 5 to 10 seconds to ensure full blowdown
of the water leg.
c. Check that the low water level indicating lamp is illuminated and that the alarm bell is sounding.
Check that the control valve spindle has moved upwards.
d. Turn the sequencing blowdown valve counter-clockwise, pausing at the mid-travel position for a
few seconds, and then screw counter-clockwise to the full extent of travel.
e. If the control unit is operating correctly and the boiler water level is correct, the low water level
indicating lamp should extinguish and the alarm bell cease sounding. The control valve spindle
should move downward.
Boiler Blowdown
62. Under the following circumstances it will be necessary to blow down the boiler :
a. To control the quality of the boiler water.
b. To control the boiler water level under abnormal conditions.
c. To empty the boiler.
__________________________________________________________________________________________
Chapter 3
Page 17 of 17

d. To promote circulation during start up from cold.

63.
Boiler Water Quality - Feedwater entering the boiler contains dissolved solids. Steam leaving
the boiler will be virtually free of solids, thus solids entering the boiler will build-up in the boiler
water. To control the total solids concentration it is necessary to blowdown the boiler at regular
intervals.
64.
Abnormal Water Level - If the boiler water level rises well above the normal operating level it
may be necessary to drain off the surplus. Draining procedures are exactly the same as water
quality control procedures except that the blowdown valve is kept open until the control water
level is established.
65.
Procedure - To control the quality or the level of the water in the boiler, the following procedure
should be adopted :
Note - During routine blowdown procedures, always check that the valve is operating freely and
is not sticking.
a. Insert the blowdown valve key into the valve.
b. Check that the water level is at least above normal water level.
Caution - Under no circumstances should the boiler be blown down if the water level is
below normal.
c. Open the blowdown valve and allow the water level in the gauge glass to fall by approximately
25mm.
d. Close the blowdown valve.
Caution - If the blowdown valve key cannot be removed, then the valve is not properly
closed. Make sure that the valve is always fully closed.
e. If necessary, repeat the blowdown procedure. Before doing so ensure that the water level is at
least above the normal water level.
66.
Emptying the Boiler - To empty the contents of the boiler the following procedure should be
adopted :
Caution - Under no circumstances should the water be drained from the boiler unless the
fire has been completely run off.
a. Allow the boiler pressure to fall to approximately 50kPa.
b. Open the air release valve (do not close this valve until the boiler is cold).
c. Insert the blowdown key into the blowdown valve.
d. Open the blowdown valve and empty the boiler.
e. When the boiler has been fully drained, leave the valve in the open position with the blowdown
key inserted in the valve. This procedure indicates that the boiler is empty.
__________________________________________________________________________________________
Chapter 3
Page 18 of 18


Ash Removal
67. The frequency of emptying the ash sump is dependent on the size of the boiler and
the boiler load. The sump should not be allowed to overfill otherwise the ash port may become
blocked. It is therefore, important that the sump is cleared and the contents removed at regular
intervals as determined by the Engineer in charge of the boiler.
Grit Removal
68. The frequency of emptying the grit sump is dependent on the size of the boiler, the boiler load
and the type of coal being burnt. The intervals at which the grit sump should be removed are
determined by the Engineer in charge of the boiler.
Normal Water Level Control
Filling the Boiler (on/off feedwater controls)
69. To fill the boiler when standard on/off feedwater level controls are fitted, proceed as follows :
a. Ensure that the feedwater tank is full and water has been treated (Ref. Appendix C to this
manual). Check that a free running supply of make-up water is available.
b. Open all suction-line valves between the feedwater tank and the feedpump suction manifold.
c. Open the feedwater delivery valve on the discharge side of both feedpumps.
d. Crank open the main feed check valve.
Caution - If the valve is not opened sufficiently the pump will be damaged. Conversely, if it is
opened too much at this stage the motor will trip out on overload.
e. Open the air release valve.
f.
At the control panel :

1)
2)
3)
Set the main isolating switch to the ON position. Check that the mains on (red)
indicator lamp illuminates.
Check that the low water alarm lamp illuminates and that the alarm bell is sounding.
Set the pump selection switch to pump No. 1. Check that the feedpump ON lamp
(green) illuminates and that the pump is operating.
g. Monitor the water level in the gauge glasses until the extra low water level is reached (water
just appearing in the gauge glass). Set the pump selection switch to pump No. 2 check that the
feedpump ON lamp is illuminated and that the boiler continues to fill.
h. Note the level at which the low water alarm lamp extinguishes and the alarm bell stops
sounding, this level should be about 25mm above the low water level mark. Stop the pump.
Lighting a Fire
70. To light a fire, proceed as follows :
a.
Ensure that the boiler is filled with water as described in Para. 69. Start one of the feedpumps.
__________________________________________________________________________________________
Chapter 3
Page 19 of 19

b. Ensure that all dampers and firing controls are free to move.
c. Set the FD damper control unit and the ID damper control unit for manual operation.
d. Close the coal cut off gate to isolate the coal hopper. Check that the coal hopper is full and that
a plentiful supply of coal is available.
e. Ensure that the water feedline valves are set as described in Para. 69.
f.
Set the other valves on the boiler as follows :

Main steam valve
Pressure gauge
Isolating valve
Air release valve
Blowdown valve
Closed
Open
Open
Closed
Caution - The blowdown key must be kept in its storage rack position to indicate that
the blowdown valve is closed.
g. Check the draught gauge for correct operation as follows :
1) Remove the plastic pipe connection from the copper pipe at the rear of the control panel.
2) Blow the copper pipe through (see Caution below) preferably with compressed air.
Caution - Do not blow air into the plastic pipe connected to the draught gauge.
3) Check that the draught reads zero. Re-zero if necessary.
4) Re-connect the plastic pipe connection to the copper pipe.
h. Lower the guillotine door to grate level. Check that the fuel bed depth indicator reads zero.
Adjust the guillotine door until it is 80mm above the grate.
i.
Close the undergrate dampers, both front and rear.
j.
Set the FD damper to zero (closed).
k. At the control panel :

1) Switch on the main isolator switch.
2) Check that the mains ON indicator lamp illuminates.
3) Set the control regulators for panel operation.
4) Start the stoker. Check that it operates and that its indicating lamp illuminates.
5) Set the fuel feed timer knob to the 50% position.
l.
Fully open the FD fan damper.
__________________________________________________________________________________________
Chapter 3
Page 20 of 20

m. Crank open the coal cut-off gate and allow coal to run in until the length of the fuel bed is about
750mm from the guillotine door. Close the coal cut-off gate. Close the FD fan damper.
n. At the control panel, stop the stoker.
o. Open the guillotine door and spread live coals on the fuel bed. Alternatively, light a wood fire
on top of the coal. Lower the guillotine door to within 80mm of the grate and seal the gap with
coal.
p. Close the ID damper.
q. At the control panel :
1) Start the ID fan. Check that its indicating lamp illuminates.
2) Check that the FD fan has started and check that its indicating lamp has illuminated.
r. Open the FD fan damper approximately 40%.
s. Open the ID damper until a slight draught is evident above the fuel bed (this can be observed
through the spy hole in the ignition arch). The draught gauge should read approximately minus
3Pa.
t.
When the coal has ignited and the fire has burned back to the guillotine door, start the stoker
and run in 75mm of coal.
u. Stop the stoker.

v. Repeats steps t. and u. until there is a good fire over at least half the length of the grate, and
ignition occurs continuously.
w. Re-adjust the guillotine door to about 120mm above the grate and open the coal cut-off gate
fully.
x. At the control panel, start the stoker.
y. Check continuously that ignition is taking place not more than 50mm from the guillotine door. If
the ignition line tends to move away from the door, the stoker must be stopped.
z. Re-start the stoker when ignition has been re-established. Gradually increase the rate of
burning.
Note - Do not provide too much draught at this stage as this will retard burning.
Caution - It is normal for the grate to expand during operation and for a slight hump to
form where it passes over the front sprockets. If however, the humping effect becomes
pronounced, it will be necessary to re-tension the grate. Re-tensioning must only be
carried out when the grate is cold.
aa. When satisfactory combustion is achieved, set the guillotine door to give the required fuel bed
thickness. (Ref. Appendix B to this manual). Set the ID damper control lever to approximately
1/3 open and adjust the FD Fan damper lever to maintain balanced draught conditions, i.e. the
draught gauge should read approximately minus 3Pa.
bb. Allow the fire to stabilise for approximately twenty to thirty minutes.
__________________________________________________________________________________________
Chapter 3
Page 21 of 21

cc. As the boiler warms up, the water will expand, therefore, it will be necessary to keep a
continuous watch on the water level as indicated by the gauge glasses.
Note - If the water level is above the normal working level blowdown until the correct level is
reach (Ref. para.65).
dd. Close the air release valve when the boiler pressure is approximately 150kPa.
ee. Allow the pressure to build up to normal working pressure. If necessary, increase or decrease
the firing rate as required (Ref to para.71).
Note - Steam raising from cold should take at least five hours and should not exceed a rate of
250kPa per hour.
ff. During steam raising, it will be necessary to blowdown the boiler regularly to assist circulation.
Blowdown the boiler as described in Para. 65.
gg. At this stage the float operated switches should be blown down as described in Paras. 58 to 61
and as appropriate.
hh. When the boiler is at operating pressure, crank open the main steam valve in order to warm up
the steam range. Make sure that the steam range drains are functioning correctly.
ii. When the steam range is sufficiently warmed-up, fully open the main steam valve.
jj. Adjust firing conditions to meet load.
Notes on Combustion
71. The following notes should assist operators to obtain optimum combustion efficiency.
a. Combustion in the furnace takes place in
three stages :
1) Firstly, the volatiles or tarry fraction of the coal is distilled off and the coal ignited. Then
2) The coke formed during the first stage is burnt leaving a layer of ash on the grate and, finally
3)
The ash is transported to the ash port through a high temperature oxydising atmosphere to
burn off the remaining carbon.
b. For efficient combustion to take place, the air provided by the FD fan must be evenly distributed
across the fuel bed. There are two devices inside the stoker for controlling air distribution.
These are :
1) Fixed guide vanes fitted to the stoker to distribute air across its width. Whenever the grate
is opened it is advisable to check that these vanes are in their correct positions.
2) An undergrate damper to regulate the amount of air which is allowed to flow to the tail end
of the stoker. This damper should be closed during initial firing and when operating on low
loads. As the load increases above 30 percent, the fire will lengthen and it will be
necessary to open this damper in order to ensure complete burn-off of the coal.
c. Apart from the vanes mentioned above, air distribution is also affected by the depth and grading
of the fuel bed. Good distribution is obtained when the fuel bed provides a moderately high
resistance to air flow. A thick bed has a higher resistance than a thin one. Fine coal produces a
higher resistance than coarse coal. When burning pea coal, the fuel bed should, therefore, be
thicker than when burning mixed smalls.
__________________________________________________________________________________________
Chapter 3
Page 22 of 22

d. If the ignition line at high loads tends to move away from the guillotine door, the fuel bed
thickness should be increased. Changes in thickness should be made in increments of 10mm
until stable conditions are achieved. One hour should be allowed to elapse after a change has
been made for conditions to stabilise before making any further change.
e. When burning coal is discharged off the end of the grate a long fire condition exists. This
condition occurs either through over-loading or through operating with an air fuel ratio which is
too low.
f.
If a long fire is obtained with the stoker operating within its design capacity, too much fuel is
being fed onto the grate for the amount of air being supplied (i.e. the stoker is operating with an
air/fuel ratio which is too low). To correct this, the feed timer knob setting should be decreased.
This adjustment should be done in stages. Allow a minimum period of one hour to elapse
between adjustments.
g. A short fire occurs when the coal is burnt to ash well before the end of the grate. This
happens either because the load is too low or because too much air is being provided. If the
load is going to remain low for some considerable time, the undergrate damper must be closed.
If short fires are experienced at loads above 50 percent full load, the feed timer knob must be
turned clockwise to increase the amount of fuel being fed onto the grate for the amount of air
being supplied. The adjustments should be done in stages.
h. If the load on the boiler increases, the steam pressure will be decreased. Conversely, if the load
decreases, the steam pressure will increase. As a boiler should be operated at a steady steam
pressure, it is necessary to adjust the firing rate to follow changes in load. If the pressure falls,
the firing rate can be increased as follows :
1) Open the ID damper control lever. This unbalances the furnace draught.
2) Re-set the FD fan damper to balance the furnace draught and increase the fuel feed
timer setting.
3) If the pressure continues to fall after allowing firing conditions to stabilise for
approximately two minutes, steps 1) and 2) must be repeated until the pressure remains
steady.
i.
If the load on the boiler decreases and the pressure rises above the required limit, the firing rate
can be decreased as follows :
1) Re-set the FD fan damper to depress the furnace pressure and decrease the fuel feed timer
setting.
2) Close the ID damper control lever until the required balanced draught conditions are
obtained in the furnace.
3) If the pressure continues to rise after allowing combustion conditions to stabilise for two
minutes, steps 1) and 2) must be repeated until the pressure remains steady.
Notes - With reference to 71.h. and 71.i., adjustments must be made in small increments.
Never make a first adjustment of more than half a division on any of the indicator plates.
The combustion controls should be set up to meet the average load. Such a setting will
very frequently result in pressures fluctuating by plus/minus 50kPa without further
adjustments being required. When steaming on manual, this pressure fluctuation is quite
acceptable.
__________________________________________________________________________________________
Chapter 3
Page 23 of 23

j.
Combustion efficiency is determined by measuring the carbon dioxide (CO2) content of the
exhaust gases. This should normally be between 12 and 13,5 percent. Check the CO2 with a
Fyrite or equivalent CO2 analyser.
Low Load Firing Techniques

72. Under normal operating conditions the stoker has a turndown ratio of 3 : 1 without altering the
fuel bed thickness. Under test conditions a ratio of 4 : 1 can be achieved.
73.
If the boiler is to be operated at below 30 percent load for long periods, proceed as follows :
a. Lower the guillotine door to reduce the fuel bed thickness.
b. Adjust the ID damper control lever to maintain the required conditions.
c. Adjust the FD fan damper to maintain a balanced draught condition.
d. If necessary, adjust the air/fuel ratio using the fuel trim knob.
Note - If the load falls to zero, the stoker can be stopped for short periods, but care should be
taken to ensure that the fire does not burn back into the coal hopper. The grate should not be
allowed to overheat.
74.
If the load is to be increased from below 30 percent load to full load, proceed as follows :
a. Raise the guillotine door to increase the fuel bed thickness to the previous full load setting.
b. If necessary, re-adjust the fuel trim knob to the previous full load setting.
c. At the control panel, gradually increase the firing rate by increasing the ID damper control and
single knob combustion control unit control regulators. The over fire draught gauge reading
should be maintained at approximately minus 3Pa.
Note - The speed at which the firing rate can be increased is largely dependent on the
operators ability to hold the ignition line under the stoker arch.
d. Switch controls to auto when stable conditions have been achieved and when the steam
pressure is within 50kPa of the operating pressure.
Shutting Down
75. For very short standby periods, when the load on the boiler has been reduced to zero, the
following procedure should be adopted :
a. Set the FD damper control unit and the ID damper control unit for panel operation.
b. At the control panel :
1) Stop the ID and FD fans.
2) Set the ID damper control regulator to zero.
3) Close the FD fan damper and reduce the fuel feed percentage timer (in this position the
stoker should just be moving).
4) Adjust the ID damper control regulator to maintain a furnace pressure of at least minus 3Pa.
__________________________________________________________________________________________
Chapter 3
Page 24 of 24

Caution - Check frequently that the fire does not burn back into the hopper. If furnace
pressure is allowed to rise above minus 3Pa (i.e. more positive than minus 3Pa), the
grate will overheat.
76.
To re-start after a short standby period, proceed as follows :

a. At the control panel :
1) Set the ID damper control regulator to zero.
2) Start the ID and FD fans. Check that the fans operate and that their respective indicating
lamps illuminate.
3) Adjust the control regulators to re-establish the desired conditions.
Standby Period of up to 18 Hours (banking)

77. The boiler can be shut down for periods of 18 hours by banking the fire. Immediately prior to
coming off load, carry out the following preliminary steps :
a. Close the guillotine door gradually until it is 50mm above the grate.
b. Reduce the firing rate and allow the fire to burn to ash over the last half of the grate, leaving a
fire approximately 900mm to 1200mm long.
78.
When the load on the boiler has been reduced to zero, proceed as follows :
a. Close the main steam valve.
b. On/off feedpump control :
1) Check that the selected feedpump is operating.
2) Allow the water level in the boiler to rise until the gauge glass is 75 percent full, then stop
the feedpump at the MCB..
c. At the modulating control :
1) Open the by-pass valve and close the globe valve feeding the modulating valve.
2) Using the main feedwater check valve allow the water level in the boiler to rise until the
gauge glass is 75% full.
3) Open the globe valve feeding the modulating valve and close the by-pass valve.

d.
Stop the stoker, ID and FD fans
e. Open the FD damper fully.

f.
Adjust the ID damper control regulator until balanced draught conditions are obtained over the
fire (draught reading about minus 3Pa).
g. Shut the coal cut-off gate and allow the fire to die down.
h. Set the guillotine door to 100m above the grate.
__________________________________________________________________________________________
Chapter 3
Page 25 of 25

i.
At the control panel, start the stoker. Check that it is operating and that its lamp illuminates.
j.
Increase the fuel feed setting and run coal onto the grate.
k. When the coal bed is approximately 750mm long, stop the stoker at the control panel.
l.
Open the guillotine door fully (see Caution below) and rake the live coals back over the green
coal to form a bank.
Caution - Never open the guillotine door too soon. The sudden inrush of cold air will
adversely affect the grate, refractories, brickwork and tube sealing.
m. At the control panel start the stoker. Check that it is operating and that its indicating lamp
illuminates.
n. Run the stoker until the bank is about 300mm from the guillotine door. Stop the stoker.
o. Lower the guillotine door to within 25mm of the grate and seal the gap with green coal.
p. Leave the undergrate dampers open.
q. Adjust the ID damper until balanced draught conditions are obtained in the furnace.
r. At the panel, turn the main isolating switch off. Check that its indicating lamp goes out.
s. Close the feed check valve on the boiler.
79.
While banked, the boiler and bank should be examined at 3 hourly intervals when the following
should be checked :
a. Furnace pressure - this should be maintained at approximately minus 3Pa. If necessary, the
position of the ID damper should be adjusted to balance the furnace pressure.
b. Water level - if the water level falls, it will be necessary to fill the boiler as described in
para.70.
c. Bank conditions - the bank should not be allowed to burn up. This condition will normally
occur if the furnace pressure is lower than minus 3Pa.
d. Boiler pressure - an excessive drop in steam pressure must be avoided. Pressure can fall
due to one or more of the following reasons
1) Blowdown - the boiler should never be blown down during periods of banking.
2) Excessive stack losses - this is generally due to the ID damper being opened too far.
Keep the damper opening as small as necessary to maintain balanced conditions.
3) Leakage at valves, drains etc., - any leakage must be repaired as soon as possible.
4) Cold air circulating around the boiler - doors and windows should be kept closed. Make
sure, however, that there is sufficient ventilation in the boiler room to provide an adequate
supply of fresh air.
80.
The following guidance notes will assist the operators in making a bank and will help them
prevent damaging conditions occurring.
__________________________________________________________________________________________
Chapter 3
Page 26 of 26

a. Avoid rapid cooling of the arch.

b. When making a bank do not allow too much hot ash to accumulate at the rear of the stoker.
This can damage the grate.
c. When the fire is banked, make sure that a small quantity of air passes through the grate to
prevent it from overheating and being damaged.
81.
To re-start from bank, proceed as follows:

a. If necessary, use a slicing bar to remove clinker fused to the refractory arch and side seals.
Take care not to damage the refractories.
b. Open the feed check valve on the boiler.
c. At the control panel :
1) Turn the main isolating switch on. Check that its indicating lamp illuminates.
2) Switch on the selected feed pump. Set the feed pump manual/auto switch to AUTO.
d. Open the guillotine door fully.
e. Open the coal cut-off gate to allow coal to fall onto the grate surface.
f.
Close the coal cut-off gate and spread the green coal to a depth of about 150mm over the grate
surface just beyond the guillotine door.
g. Rake hot coals from the bank over the green coal.
h. Lower the guillotine door to about 120mm above the grate surface.
i.
Open the coal cut-off gate.
j.
Close the ID damper.
k. At the control panel, start the ID fan. Check that it is operating and that its lamp illuminates.
l.
Open the ID damper 20%.
m. Close the undergrate damper.

n. Close the FD damper fully. At the control panel, start the FD fan. Check that it is operating and
that its lamp illuminates.
o. Adjust the FD damper to balance the furnace pressure.
p. Turn the fuel feed timer clockwise to the end of its travel to give maximum stoker ON time.
q. When the fire has burned up and the arch is warm, start the stoker at the control panel. Check
that it is operating and that its lamp illuminates.
r. Check regularly that ignition is taking place at not more than 50mm from the guillotine door. If
the ignition line tends to move away from the door, stop the stoker. Re-start the stoker when
ignition has been established.
__________________________________________________________________________________________
Chapter 3
Page 27 of 27

Note - Do not provide too much draught at this stage as this will retard burning.
s. When satisfactory combustion is achieved, set the guillotine door to give the required fuel bed
thickness.
t.
Increase the rate of burning by opening the ID damper to 30% and adjusting the FD damper to
maintain balanced draught conditions.
u. Open the undergrate dampers.

v. Re-set the fuel feed timer to its normal position.
w. Adjust the burning rate and furnace pressure as required.
Normal Shutdown
82. If the boiler is to be shutdown for a period of more than 18 hours, the fire should be run off.
When the load on the boiler has been reduced to zero, proceed as follows:
a. Close the main steam valve.
b. On/off feedpump control :
1) Ensure that the selected pump is operating.
2) Allow the water level in the boiler to rise until the gauge glass is 75 percent full, then stop
the pump at the MCB.
c. At the modulating control :
1) Open the by-pass valve and close the globe valve feeding the modulating valve.
2)
Using the main feedwater check valve allow the water level in the boiler to rise until
the gauge glass is 75% full.
3) Open the globe valve feeding the

modulating valve and close the by-pass valve.
d. Close the feed check valve and the pump delivery valves.
e. Close the coal shut off gate.
f.
Lower the guillotine door gradually until it is 24mm above the grate.
g. Reduce the FD damper and fuel feed timer and set the ID damper to maintain balanced draught
conditions.
h. When the fire has burned out, stop the stoker, FD and ID fans at the control panel.
i.
At the control panel, turn the main isolating switch OFF . Check that the indicating lamp goes
out.
j.
Open the guillotine door fully.

Caution - Do not open the guillotine door too soon. The sudden inrush of cold air will
__________________________________________________________________________________________
Chapter 3
Page 28 of 28

k. If necessary use a slicing bar to remove clinker from the refractory arch and side seals.
l.
Remove all the ash and clean the boiler and its surroundings.
Emergency Shutdown (Power failure or extra low water level ID fan, FD fan and stoker
motor(s) stopped)
83. If either of these conditions occurs, shutdown the boiler as follows :
a. Close the main steam stop valve.
b. Set the ID damper 30% open.
c. Close the FD damper and set the fuel feed timer to 0.
d. Close the coal cut-off gate.
e. Turn the guillotine door operating handle until the indicator reads 25mm above the grate.
Note - The door must be lowered gradually while the grate is being rotated by hand. (Ref. g. 3
below).
f.
Open the undergrate dampers.
g. Run the live coals off the grate as follows :

1) Remove the grate movement indicator disc and cover.
2) Remove the shear pin.
3) Connect the crank handle to the squared end of the worm shaft and rotate the grate by
hand until all the live coals have been run off. Remove the live coals from the ash removal
system immediately.
h. Allow the stoker to cool for approximately 30 minutes, then open the guillotine door fully.
i.
If necessary, use a slicing bar to remove clinker from the refractory arch and side seals.
j.
Remove all the ash and clinker from the stoker and its surroundings.
k. Set the ID damper to the closed position.

l.
Close the feedwater check valve on the boiler when the water level has been restored to its
normal level.
m. At the control panel :

1) Turn the main isolator switch to the off position.
2) Set the FD damper control and ID damper control regulators to zero.
Emergency Shutdown (extra low water level, ID fan, FD fan(s) and stoker(s) operating)
84. This condition is extremely dangerous as it is a sign that the single switch float operated control
has not operated. To shut down the boiler, proceed as follows :
__________________________________________________________________________________________
Chapter 3
Page 29 of 29

a. Close the main steam top valve.

b. At the control panel, stop both the ID and FD fan(s).
c. Set the ID damper to 30% open.
d. Close the FD damper and set fuel feed timer to zero.
e. Close the coal cut-off gate.
f.
Turn the guillotine door operating handle until the indicator reads 25mm above the grate.
Note - The door must be lowered gradually while the grate is moving.
g. Open the undergrate damper.

h. Set the fuel feed timer to 100% and open the FD damper (to run the fire off the grate).
i.
Remove the ash and live coals from the de-ashing system at regular intervals.
j.
Allow the stoker to cool approximately 30 minutes after grate has been cleared, and then open
the guillotine door fully.
k. If necessary use a slicing bar to remove clinker from the refractory arch and side seals.
l.
Remove all the ash and clinker from the stoker and its surroundings.
m. Close the FD damper and set the fuel feed timer to 0%.
n. Close the ID damper.
o. Close the feedwater check valve on the boiler when the water has been restored to its normal
level.
p. At the control panel :
1) Stop the stoker.
2) Turn the main isolating switch off. Check that the panel ON light extinguishes.
Daily Log Sheet
85. A typical daily operating log sheet is shown in Appendix A page 15, to this manual.
__________________________________________________________________________________________
Chapter 3
Page 30 of 30

__________________________________________________________________________________________
Chapter 3
Page 31 of 31

Chapter 3
Technical Description
Contents
Introduction
Combustion
Combustion Controls
Automatic combustion control
Panel control
Mechanical Description
Boiler
ID Fan
ID Damper Control Unit
Instruments and Controls
Feedwater controls
Steam pressure
Furnace pressure
Control panel
Electrical Circuit Description
Interlocking
Protection circuits
Feedwater pump motors
Modulating feedwater level controller
Stoker, FD and ID fan circuits
Extra low water alarm
Automatic controls
Page 2
Page 2
Page 2
Page 2
Page 3
Page 3
Page 4
Page 4
Page 6
Page 6
Page 7
Page 8
Page 9
Page 9
__________________________________________________________________________________________
Chapter 3
Page 32 of 32

Chapter 3
Technical Description
Introduction
1.
The Stirling MK7 boiler is a high efficiency, wetback and fully packaged coal fired unit. The
boiler has been designed for use with a chaingrate stoker. The size of the stoker varies with
the size of the boiler. Two stokers are used in the larger twin flue boilers. The stoker and
associated equipment are fully described in the Cochrane Chaingrate Stoker Manual.
2.
The boiler is a horizontal three pass unit comprising the following :
a.
A flue which houses the stoker. A double stoker boiler has two flues and two stokers.
b.
A wetback return chamber.
c.
Two convection tube passes.
3.
A forced draught (FD) fan is fitted to the side of the stoker and an induced draught (ID) fan is
fitted to provide balanced draught conditions. Both the FD and ID fans rotate at a constant
speed. Each fan is fitted with contra rotating dampers which control the air flow from the fan.
4.
Two electrically driven feedwater pumps are supplied with the boiler.
5.
The water level in the boiler is controlled by either a float operated two switch control (on/off
feedwater control) or, alternatively a modulating feedwater level controller. Both systems
employ an audible alarm which warns the operator when the water in the boiler falls to a low
level. In addition to either water level control, a float operated single switch is used to stop
the fans and stoker if the water level in the boiler falls to a dangerously low level.
6.
A control panel, housing the motor switch gear, control switches and lights, etc., is mounted
on one side of the boiler.
7.
Throughout the text, reference is made to the following :
a. Manual Control - This means that control is effected manually at the mechanical control units.
b. Panel Control - This means that control is effected manually through the control regulators on
the panel.
c. Auto Control - This means that control is effected through the electro mechanical control
systems.
Combustion
8.
Combustion in the Stirling MK7 boiler takes place under balanced draught conditions in
three stages. Firstly, the volatile or tarry fraction is distilled off and the coal ignited. Then
the coke formed during the first stage is burnt, leaving a layer of ash on the grate. Finally,
the ash is transported to the ash port in a high temperature oxidising atmosphere, which
burns off most of the remaining carbon. As the volatiles released in the first stage pass
through the high temperature second stage zone, they are consumed thus eliminating black
smoke. Grit emission is minimal as the fuel bed is quiescent at all times.
9.
The products of combustion are cooled to at least 300C below the ash deformation
temperature before they enter the first tube pass. This design feature ensures that tube
__________________________________________________________________________________________
Chapter 3
Page 33 of 33

plate slag formation is minimal. The temperature of the flue gas, when leaving the boiler, is
only 75C above the boiling point of water and, therefore, as
much heat as is economically possible is transferred to generate steam.
Combustion Controls
10. An FD fan supplies the air required for combustion, to the fuel bed. An ID fan extracts the
combustion gases through the boiler. Since both fans run at a constant speed, air flow from
the FD fan and gas flow from the ID fan can only be controlled by the respective contra
rotating dampers. In principle, when the ID dampers are closed and the FD dampers are
open, the combustion chamber is pressurised (positive pressure). When the FD dampers
are closed and the ID dampers are open, the combustion chamber is under a vacuum
(negative pressure). Automatic combustion controls maintain balanced draught conditions in
the combustion chamber. Under ideal conditions the FD air flow and the ID gas flow are
balanced to achieve a zero pressure. In practice, a negative pressure of approximately
minus 3Pa is required to prevent intermittent pressurising of the combustion chamber.
11.
For efficient combustion, the amount of fuel fed to the furnace must be strictly controlled and
be related to the FD air- flow. On the Stirling MK7 boilers, the air/fuel ratio is controlled by
an FD damper control unit which automatically relates the amount of fuel fed to the furnace
to the amount of air necessary to complete combustion. A trimming assembly is
incorporated to vary this ratio by enabling the grate speed to be varied independently of the
air supply. Turning the trim knob counter-clockwise decreases the speed range and turning
the trim knob clockwise increases it. The maximum speed range is 0 to 9 metres per hour
and the minimum speed range is 0 to 4,5 metres per hour.
12.
Another important factor for efficient combustion is that the air provided by the FD fan must
be evenly distributed across the fuel bed. There are two devices inside the chaingrate
stoker for controlling air distribution. These are fixed guide vanes fitted to the stoker to
distribute the
air across its width, and two undergrate dampers to regulate the amount of air which is allowed to
flow to the tail end of the stoker. Air distribution is also affected by the depth and grading of the
fuel bed. Raising or lowering a guillotine door fitted between the coal hopper and the ignition
arch can regulate the depth of the fuel bed. Further details of these combustion controls can be
obtained from the Cochrane Chaingrate Stoker Manual.
Automatic Combustion Control

13. The automatic combustion control system is formed by a series of control loops, each
comprising a transducer, a control relay and a pulling motor.
14.
The primary control loop varies the position of the ID damper in relation to steam pressure.
As the steam pressure in the boiler falls, the ID damper is made to open. As the steam
pressure rises, the damper is made to close. By opening and closing the ID damper, the ID
fan draws more or less gas through the boiler. If more gas is drawn through the boiler, the
furnace pressure will be decreased, while if less gas is drawn through the boiler the furnace
pressure will increase.
15.
The secondary control loop varies the position of the FD damper to maintain constant
furnace pressure conditions. This ensures that ignition is controlled and that the correct
amount of air is supplied to the fuel bed to carry the load. As the secondary control loop
pulling motor positions the FD damper, via the single knob combustion control unit, it
simultaneously varies the grate speed and hence the amount of fuel entering the furnace.
Panel Control
__________________________________________________________________________________________
Chapter 4
Page 34 of 34

16.
The primary control loop transducer and the secondary control loop transducer can be
switched out of circuit and control regulators switched into the control loops.(Select MANUAL
at the ID Damper and FD Damper selection switches on the control panel) This facility
enables combustion to be controlled manually from the control panel.
Mechanical Description
Boiler
17.
The shell, furnace tubes and combustion chamber are all of welded construction. Tubes are
normally expanded into the tube plates. On high pressure versions of the boiler, the high
temperature end of the first pass tubes are seal welded after light expansion. All pressure
parts are manufactured in accordance with a recognised code of construction and under the
supervision of a recognised inspection authority.
18.
Thermal Insulation - The boiler shell is lagged with an adequate thickness of insulating
material which is covered with a mild or stainless steel sheet cladding.
The integral
pipework and ID fan are not lagged.
19.
Front and Rear Smokeboxes - The front and rear smokeboxes are fitted with easily
removable doors to facilitate tube cleaning. Seals between the doors and the smokeboxes
ensure a gastight fit. For ease of handling, both front smokebox doors are permanently
attached to lifting davits, which allow the doors to be swung clear of the tube access area.
The rear doors are small enough to be easily manhandled.
20.
Integral Pipework - terminal points for the pipework are as follows :
a. Feed check valve inlet connection (double stoker boilers only).

b. Feedpump suction connection (single stoker boilers only).
c. Main steam stop valve flange.
d. Boiler blowdown valve flange.
e. Safety valve discharge flanges.
f.
ID Fan
21.
Drain header outlet connection.

The centrifugal type ID fan maintains balanced draught conditions. The impeller is fitted with
radially tipped blades. With this design, fly ash build on the blades is eliminated thus
maintaining impellor balance. Low gas velocities through the fan considerably reduce blade
erosion. The fan shaft is mounted on roller bearings which are protected by a specially
designed heat flinger disc. The fan may be mounted on brackets welded to the boiler shell.
The fan housing has been designed to support a guyed chimney stack 23 metres high from
the firing floor level. Above this height, the stack should be mounted on the floor. A belt
drive enables the fan characteristics to be varied to suit different site altitudes without
changing the impeller.

22. The ID damper control unit is similar to but simpler than, the FD damper control unit. The
unit is fitted with a pulling motor and a clutch which enables manual or panel control to be
selected. In the manual position the ID damper can be opened and closed manually at the
unit itself by operating a lever. In the panel position, the damper can be manually controlled
__________________________________________________________________________________________
Chapter 4
Page 35 of 35

at the control panel by turning the control regulator for the ID damper, or alternatively, the
damper can be controlled via the automatic control system.
Instruments and Controls
Feedwater Controls
23. Two electrically driven feedwater pumps are supplied with the boiler. Each pump is
complete with motor and coupling, and has a capacity in excess of the boiler output at
maximum continuous rating. The pumps are designed to handle clear non-aggressive boiler
feedwater. When a modulating feedwater control valve is fitted, a pressure relief valve in the
pipework protects the feedpumps from being damaged.
24.
Either feedpump can be selected by setting a switch on the control panel to the desired
position. If on/off feedpump control (para.27) is fitted to the boiler, the feedpump can be
manually controlled at the control panel. If a modulating feedwater level controller (para.29)
is fitted manual control can only be effected at the modulating valve.
25.
Single Switch Control - This Mobrey float operated switch is fitted as standard equipment
on all Stirling MK7 boilers. The function of the single switch control is to switch the ID fan
(hence the FD fan and stoker motors) off when the water level in the boiler falls to a
dangerously low level, and activate an audible warning
(siren).
26.
Initial settings for the single switch control are as illustrated (Ref. Appendix A page 17). This
initial setting should then be proved by allowing the water level in the boiler to rise and fall
sufficiently to operate the switch and noting the water level in the gauge glasses. Should this
setting be incorrect, the necessary adjustments must be made immediately. The alarm and
feedpump should energise when this control is blown down.
Note Ten tonne boilers may have either one or two stokers and in either instance, may be
specified with either the On/Off Feedpump Control system or the Modulating Feedwater Level
Control system. Larger boilers will have two stokers and the Modulating Feedwater Level Control
system is specified as standard.
27.
28.
29.
On/Off Feedpump Control (Two switch control) (Single stoker boilers) - This feed pump
control system is fitted as standard equipment on the Stirling MK7 range of single stoker
boilers and incorporates two switches operated by a single float. The feedpumps are
controlled by one of these switches which starts the selected feedpump as water level in the
boiler falls below the average water level (AWL) and stops it when the water level rises
above the AWL. The AWL is shown on the common indicator plate for the gauge glasses as
illustrated (Ref. Appendix A page 16). A diamond shaped symbol is marked on the main
body of the float chamber. This symbol corresponds to the lowest operating level that this
control can be set to and is directly related to the bottom circlips in the control head. The
second switch is set to operate an audible alarm (bell) when the water level in the boiler falls
to a low (but not dangerous) level. Provided that immediate action is taken, the situation is
not critical when this alarm is activated.
Both switches should initially be set up as illustrated (Ref. Appendix A pages 17 and 18).
These initial settings should then be proved by allowing the water level in the boiler to rise
and fall sufficiently to operate both switches and noting the water level in the gauge glasses.
Should these settings be incorrect, all necessary adjustments must be made immediately.
The alarm and feedpump should energise when this control is blown down.
Modulating Feedwater Level Controller (Double stoker boilers) - The modulating
feedwater level controller is fitted as standard equipment on double stoker boilers and is
__________________________________________________________________________________________
Chapter 4
Page 36 of 36

used in place of the two switch control. Its function is to regulate the flow of feedwater to the
boiler in proportion to steam demand. It also energises the audible alarm (bell) when the
water level in the boiler falls to a low (but not dangerous) level.
30.
In this system, the selected feedpump runs continuously and the flow of feedwater to the
boiler is regulated by the modulating control valve. When the water demand in the boiler
reduces to the point where the pressure in the pipeline ahead of the modulating valve rises
above the relief valve set pressure, the pressure relief valve in the pipework opens and
allows the feedwater to return to the feedwater tank thus protecting the operating feedpump
from being over-loaded.
31.
Initial settings for the sensing coil (coil A) in the chamber head are preset in the factory as
illustrated (Ref. Appendix A page 10). The total operating range from
low water alarm setting to valve closed position may be raised or lowered as a group adjustment
by altering the height of the sensing coil. To individually adjust the low level alarm setting it is
necessary to remove the cover from the associated
control box and adjust the VR3 as follows :
a. To raise, turn VR3 counter-clockwise.

b. To lower, turn VR3 clockwise.
32.
It is essential that these settings are proved by allowing the water level in the boiler to fall
and rise sufficiently to energise the alarms and operate the modulating control valve, noting
the water level in the gauge glasses as each successive stage is reached. All final
adjustments for correct operation must be made immediately. The position of the
modulating control band can be adjusted as follows :
a. To raise, make a fractional turn of VR1 counter-clockwise.

b. To lower, make a fractional turn of VR1 clockwise.
Steam Pressure
33. Steam pressure in the boiler is indicated by a standard Bourdon type pressure gauge, which
is fitted with an isolating cock and inspectors test connection. A steam pressure detector is
mounted on the side of the control panel and is used to provide steam pressure related
signals for the ID damper automatic control system.
Furnace Pressure
34. Furnace pressure is indicated by a Photohelic furnace draught gauge which is mounted on
the control panel. Two gauges are fitted on double stoker boilers. Incorporated in the gauge
is a switch which provides control signals for the FD damper automatic control system.
Control Panel
35. The control panel is provided with a dust tight door (the larger control panels have two
doors) and several labels, various control switches, regulators, lights and gauges. The door
is hinged for easy access to the control circuits located inside the control panel.
Electrical Circuit Description
Interlocking
36. The electrical circuit of the Stirling MK7 boiler is arranged so that the ID fan, FD fan and
stoker motors are interlocked to meet the following requirements :
__________________________________________________________________________________________
Chapter 4
Page 37 of 37

a. If the boiler is operating under automatic control and the water in the boiler falls below a predetermined level, the ID fan, FD fan and stoker motors will automatically switch off.
b. The ID fan and FD fan motors cannot be restarted unless the MANUAL/AUTO switches for the
ID fan and FD fan are set for manual control. This series includes the both FD fans on double
stoker boilers.
Note The reason for the drop in water level should be investigated and rectified if necessary,
before restarting.
c. If the boiler is operating under automatic control and the ID fan motor trips out, the FD fan and
stoker motors will automatically switch off.
d. If the boiler is operating under automatic control and the ID fan stop button is pressed, the ID
fan motor and also the FD fan motor and the stoker motor(s) will automatically switch off .
e. The stoker motors can be started independently of the ID fan.
Protection Circuits
37. In addition to the above safety interlocking circuits, the electrical circuits of the Stirling MK7
boilers are adequately protected by main circuit breakers and/or thermal overloads. The
stoker, feedpump and fan motors are protected with both main circuit breakers and
resettable thermal overloads. The auxiliary switch contacts of the thermal overloads are
connected in the start circuit of each electrical motor.
Feedwater Pump Motors
38. There are two feedwater pumps fitted to the Stirling MK7 boiler, Pump No. 1 and Pump No.
2. Selection of either pump is made at the control panel by setting the pump selection switch
to the desired pump. Both feedpump motors are standard wired for star/delta operation.
39.
The 220Vac line to the feedpump motor control circuits is obtained from one phase of the
three phase input, whereas the feedpump motor windings are energised by the three phase
supply. The auxiliary switch contacts of the thermal overloads are shown (Ref. Wiring
diagram) in the closed-circuit condition, Normally, these switch contacts will be closed (reset)
unless an overload has occurred.
40.
Starting Sequence - When the mains isolator on the panel inside the control panel cabinet,
is switched ON the motor of the selected pump starts in star and after the set time, changes
to delta for normal operation.
41.
Shutdown Sequence (Manually Operated) - To stop the feedwater pump motor manually
the pump circuit breaker on the control panel must be tripped.
42.
Auto Control (Two switch) (para.27) - The 220Vac supply to the feedpump start circuit is
obtained, via Mobrey dual switch contacts B-B. These contacts are closed when the water
level in the boiler falls to approximately 12,5mm below the average water level. These
contacts are open when the water level in the boiler rises to approximately 12,5mm above
the average water level. It therefore follows that when the selector switch is in the AUTO
position and feedpump selection switch set to PUMP 1 or 2 and the water level in the boiler
is sufficiently low, the selected feedpump will start as previously described in para.27.
Conversely, the feedpump will stop when the water level in the boiler rises sufficiently high.
The feedpump switching on and off cycle continues while the AUTO position is selected.
The frequency of switching depends on load conditions.
__________________________________________________________________________________________
Chapter 4
Page 38 of 38

43.
First Low Water Alarm - The first low water alarm is initiated when the water level in the
boiler falls to approximately 75mm below the average water level. (AWL) This level is
indicated by the lowest mark on the gauge glass indicating plate. The alarm circuit
comprises the second half of the Mobrey two switch control and an alarm bell.
Modulating Level Controller
44. The Mobrey modulating feedwater level
controller (Ref.para 30) is used to control the
feedwater flow to the boiler in proportion to the steam demand. Any change in the water
level is detected and a feedwater control valve (VS1 or VS2) opens or closes to compensate
for the change in level.
45.
The application for the modulating feedwater level controller, as used with the Stirling MK7
boiler, is termed throttle control. A typical diagrammatic arrangement is shown in the
attached leaflet. The controller fitted to the Stirling MK7 boiler is shown in the overall circuit
diagram.
46. The controller comprises the following units :

a. Control unit
b. Modulating control valve
c. Control box
47.
The control unit (or head) consists of a float in a chamber, and a coil (coil A) with a variable
iron core. The iron core is attached to the float and moves up and down with it. The
inductance of the coil is thus related to the level of the water in the boiler.
48.
The modulating valve consists of a piston operated valve, a coil (coil B) with a variable iron
core and two solenoid valves. Movement of the piston is linked to the variable iron core of
the coil. Thus movement of the piston causes corresponding changes in the inductance of
coil B.
49.
The control box detects the inductive variations of coil A and coil B to carry out the following
functions.
a. De-energise a relay in the control box when the inductance coil A is minimum.
b. Control the opening and closing of the solenoid valves.
50.
Modulating Control Valve - With reference to the attached diagram (Ref. Appendix A page
9 ), the isolating needle valve is normally left open to allow feedwater pressure to act on the
surface of the piston of the modulating valve. The exhaust needle is normally closed to allow
pressure to be exerted on the piston. This valve can be used when manual control is required.
VS1 and VS2 are solenoid valves. If VS1 is open and VS2 closed, the force of the feedwater
pressure will be exerted on the piston and the modulating valve will be closed, stopping the
feedwater flow to the boiler. Conversely, if VS1 is closed and VS2 is open, the modulating valve
will be fully open and the flow of feedwater to the boiler will be maximum. When VS1 and VS2
are closed, the pressure acting on the piston will be constant until either VS1 or VS2 is open.
51.
If the water level in the boiler falls below normal, the inductance of Coil A will become less.
This change in inductance is sensed by the control box, which activates VS1 to close and
VS2 to open. Therefore, the feedwater pressure on the piston is reduced and the
modulating valve opens. The inductance of coil B starts to change, due to the movement of
the piston. When the inductance of coil B equals the inductance of coil A, VS2 also closes
thus maintaining the increased flow of feedwater to the boiler.
__________________________________________________________________________________________
Chapter 4
Page 39 of 39

52.
As the level of water in the boiler rises, the inductance of coil A increases. This change will
be sensed by the control box, which activates VS1 to open. The pressure of the piston
increases until the
inductance of coil B changes sufficiently to equal that of coil A, whereupon VS1 closes to
maintain the new flow rate to the boiler.
53.
During normal operating conditions, VS1 and VS2 open and close according to feedwater
demands. With a steady rate of evaporation, and a constant feedwater pressure, both VS1
and VS2 remain closed for long periods.
54.
First Low Water Alarm - As the water level in the boiler falls the inductance of coil A
reduces proportionately. When the value of inductance falls to a pre-determined level, the
relay in the control
box is de-energised. Relay contacts RL-1 change over to the normally open (NO) position thus
short circuiting terminals 8 and 11 on the control box. The audible low water alarm (bell) is
activated by the 220V connected to terminal 11. The alarm will remain on until either the water
level in the boiler rises to a safe level, or the main supply is switched off.
Stoker, FD and ID Fan Circuits

55. As shown in the overall circuit diagram, the 220Vac for the start circuits of the stoker, FD and ID
fan motors is derived from one phase of the main input supply, and the Mobrey single switch.
Provided that the water level in the boiler is above the extra low water level, contacts A-A of the
Mobrey single switch will be closed. It can also be seen from the circuit diagram that the
MANUAL/AUTO switches must be set to the MANUAL position before the motor start circuits
can be energised.
56.
Stoker Motor Start Circuit - In the wiring diagram, the circuit diagram of both the stoker and
the FD fan motors, is shown for a single stoker boiler. On a double stoker boiler, these circuits
are duplicated and operate in the same way.
57.
The stoker motor windings are connected via the variable speed drive (VSD) to the three phase
supply. The motors are protected against overloads by a circuit breaker connected into each
phase of the supply to the motor. In addition, an over-current sensor (thermal overload) is
connected in the motor winding supply circuit. The circuit breaker for the sensor is connected in
the control circuit.
58.
When 220Vac is available (control circuit) and the stoker selector switch is set to MANUAL, the
contactor coil is energised and the stoker ON lamp is illuminated. The stoker contactor close,
connecting the motor windings to the three phase supply and the motor runs at a fixed speed.
59.
If an overload occurs in the motor circuit, the over-current sensor break contact opens thus
removing the supply to the control circuit. The stoker motor will shut down and the indicator
lamp will extinguish. If the overload was transient and the thermal overload sensor operated,
the motor can be re-started by resetting the thermal overload and setting the stoker selector
switch to MANUAL.
60.
If the thermal overload fails to operate, the motor is further protected by the circuit breaker in the
three phase supply to the motor windings. If the circuit breaker trips, the motor will stop.
61.
When the stoker OFF position is selected the 220Vac path to the contactor coil is broken. The
contactors reset to open circuit the three phase supply to the motor windings. The latch for the
contactor coil is removed. The circuit will reset to the positions illustrated.
__________________________________________________________________________________________
Chapter 4
Page 40 of 40

62.
ID Fan Start Circuit - The ID fan motor is wired for standard star/delta operation. When the
ID fan ON/OFF switch is set to ON the ID fan motor starts in star, and after the set time, it
changes to delta for normal operation.
63.
When the ID fan ON/OFF switch is set to OFF the 220V supply to the ID and FD fans and stoker
motor control circuits will be removed. The fans and stokers will shutdown and the contactors
will reset to the position shown in the circuit diagram.
64.
FD Fan Start Circuit - The FD motor circuit is standard wired for star/delta operation.
65.
When the ID fan switch is selected to ON the ID fan will start and after a short delay, the FD fan
motor will start in star, and change to delta after the set time.
If an overload occurs the thermal overload will trip and isolate the start circuit from the 220Vac
supply. The FD fan will shut down and the green indicator lamp will go off and the red lamp will
illuminate. If the overload was transient and the thermal overload sensor operated, the motor
can be re-started by re-setting the thermal overload, if the ID fan is still running. If the overload
sensor fails to operate under overload conditions, the circuit breaker will trip.
66.
67.
To stop the FD fan use the circuit breaker or switch off the ID fan.
68.
Overloads - For protection of the electric motors, each motor is fitted with thermal overloads,
which are connected between the main contactors and the motor windings (these are the overcurrent sensors). The break contacts for the sensors are connected in the start circuits of the
respective motors. Should a motor be overloaded the excess current through the motor winding
will cause the auxiliary contacts to open, thus shutting down the appropriate motor. However, if
the ID fan motor thermal overload is actuated, a complete shutdown sequence of the stoker and
FD fan motors will be initiated.
Extra Low Water Alarm

69. When the water level in the boiler has fallen to a dangerously low level (water just visible in the
gauge glass or lower), and after the first low water alarm has been initiated, switch contacts A-A
open and disconnect the FD and ID fan start circuits from the 220V supply. Thus a complete
shutdown of these circuits is initiated. The fan circuits can only be restarted after the water level
in the boiler has risen to a safe level.
Automatic Controls
70. FD Damper Control Unit - Manual/Auto Control - When panel control is selected the
manual/auto switch is set to the manual position. In this position the panel potentiometer is in
circuit and manual control of the FD damper control unit can be made at the control panel. The
position of the single knob combustion control unit is adjusted by operating the potentiometer in
the required direction, which in turn sets the position of the pulling motor. The movement of the
pulling motor is coupled to a potentiometer which offsets the effect of the panel potentiometer
and brings the motor to rest in the new position. If the motor is driven too far in either direction,
the appropriate pulling motor limit switch will open and stop the motor from running any further in
that direction by disconnecting the supply to the appropriate winding. If the panel potentiometer
is turned in the opposite direction, the balance relay will become unbalanced and energise the
motor windings. The motor will turn to the new position and the limit switch will reset to the
normally closed position. Since the movement of the pulling motor is coupled to the FD damper
control unit, the position of the damper can be set to the required opening by turning the panel
potentiometer to the appropriate setting.
71.
When the auto/manual selector switch is in auto position, the furnace pressure gauge/switch is
in circuit and automatic control is allocated. The
pressure
__________________________________________________________________________________________
Chapter 4
Page 41 of 41

gauge/switch is controlled by a transducer which senses changes in furnace pressure. An

associated gauge indicates what these pressures are is as illustrated in the steam pressure
controller leaflet. A Hi set of relay contacts and a Lo set of relay contacts switch the 24Vac
supply to the balance relay. When the furnace pressure is zero, both sets of relay contacts will
be in
the positions shown in the steam pressure controller leaflet
72.
The gauge indicates zero pressure when the indicating needle is in the centre position. The
indicating needle moves to the left of the centre position when the furnace is operating under a
positive pressure. Conversely, the needle moves to the right of the centre position when the
furnace is operating under a negative pressure (vacuum). Since a slightly negative furnace
pressure is required, the left hand set point (Lo) is adjusted for 3Pa and the right hand set point
is adjusted for 15Pa.
73.
The Hi and Lo relays are de-energised when the indicating needle is to the left of the set points.
When the indicating needle is to the right of the set points, the relays will be energised. For
example, if the set points are adjusted for 3Pa and 15Pa (Ref. para.76) and the indicating
needle indicates 4Pa, the Lo relay will be energised and the Hi relay will be de-energised. Both
relays will be energised if the indicating needle indicates 16Pa.
74.
If the furnace pressure is zero, the controller causes the pulling motor to turn counter-clockwise.
The closes the FD fan damper(s) and will reduce the furnace pressure. When the furnace
pressure is below the lower set point of 15Pa, the controller causes the pulling motor to open
the FD fan damper(s).
75.
As previously described, provided that the furnace pressure is within the limits of 3Pa and
15Pa, the Lo relay is energised. Therefore, both coils of the
balance relay are de-energised and the pulling motor of the single knob combustion control unit
is stationary.
76.
ID Damper Control Unit Manual/Auto Control - In the manual position of the auto/manual
selector switch, both the ID damper control unit and the ID damper control unit circuits operate in
the same way. In the auto position automatic control of the ID damper control unit is allocated to
a steam pressure detector, whereas a furnace pressure gauge/switch controls the automatic
function of the single knob combustion control unit.
77.
The steam pressure detector is a variable resistor in which the resistance varies in proportion to
the steam pressure in the boiler. Its function in the circuit is the same as for RV3 panel control
potentiometer i.e. to form a Wheatstone bridge. The circuit is arranged so that the steam
pressure detector forms one arm of the bridge and the pulling motor potentiometer forms the
other arm of the bridge. The ID balance relay senses the difference between the two arms.
When steam pressure changes, one side of the bridge will become unbalanced and the
increased difference in current between the two sides will be sensed by the balance relay. One
of the relay contacts will make and thus apply 220V to one winding of the ID damper control unit
pulling motor. The motor will turn in the appropriate direction and change the setting of the ID
damper. As the motor turns the potentiometer adjusts to a new position and so balances the
bridge once more. The balance relay contact returns to a central position, thus disconnecting
the 220V supply to the pulling motor and the motor stops.
78.
Throughout the operation, the steam pressure detector follows the rise and fall of the steam
pressure in the boiler, and the position of the ID damper is adjusted accordingly.
79.
Under automatic conditions, the over-fire pressure will vary as the FD and ID damper settings
change. If the ID damper is fully closed and the FD damper is fully open, the over-fire pressure
__________________________________________________________________________________________
Chapter 4
Page 42 of 42

will be high. This will be sensed by the furnace pressure gauge/switch and cause the FD
damper to close. With both dampers closed, the steam pressure in the boiler will fall and the
steam pressure detector resistance will change. The resultant unbalance actuates the ID
balance relay and the ID pulling motor will be energised. The pulling motor will turn and open
the ID damper.
80.
If the over-fire pressure falls, it will cause the furnace pressure gauge/switch to change over
and energise the single knob combustion control unit pulling motor and open the FD damper.
Under varying load conditions the FD damper and ID damper settings will change in response to
the varying conditions. If the load demand is fairly constant, the FD and ID damper settings will
also remain fairly constant.
Chapter 4
Installation, Commissioning and Layup
Contents
Introduction
Installation
Pre-Commissioning Mechanical Checkout
Boiler shell (waterside)
Boiler shell (gas side) and ductwork
Grit collector
Induced draught (ID) fan
Outlet stack
Stoker and FD fan
Sootblowers
Pre-Commissioning Electrical Checkout
Control panel
Stoker and FD fan
ID fan
Feedpumps, monitoring and control devices
Page 2
Page 2
Page 2
Page 3
Page 4
Page 4
Page 5
Page 5
__________________________________________________________________________________________
Chapter 4
Page 43 of 43

Commissioning
Page 5
Filling the boiler (on/off feedwater controls)
Filling the boiler (modulating feedwater controls)
Setting up the FD damper control unit
Page 6
Setting up the ID damper control unit
Lighting a fire
Setting the combustion controls
Setting the steam pressure detector
Blowdown of gauge glasses
Page 7
Floating of safety valves (on/off feedwater controls)
Floating of safety valves (modulating feedwater control) Page 8
Putting the boiler on range
Page 9
Two switch control (on/off feedwater)
Single switch control
To re-start the boiler
Modulating control (modulating feedwater)
Acceptance certificate
Boiler Layup
Page 10
Wet preservation
Chemicals required
Procedure
Routine checks
Dry preservation
Routine checks
Annexure 1
Torque setting of bolts for chimney stack
Chapter 4
Installation, Commissioning and Layup
Introduction
1.
This Chapter describes the checks which must be carried out prior to commissioning and the
commissioning procedures themselves. A detailed description of the procedures to be
undertaken when taking the boiler out of service for a period of layup is also given. Engineers
in charge of these operations should familiarise themselves with the instructions given in
Chapter 2 of this manual.
Installation
2.
The boiler must be levelled on its foundation in accordance with the relevant layout drawings.
The cradles of the boiler are fixed during manufacture so that the rear of the boiler is 36mm
lower than the front (this set allows the boiler to be completely drained through the blowdown
valve). If necessary, packing pieces must be inserted under the cradles to ensure that the set
is accurate to within plus 0mm or minus 3mm. The boiler must be leveled in the transverse
plane to plus or minus 3mm.
Pre-Commissioning Mechanical Checkout
Boiler Shell (water side)
3.
After installation the boiler must be checked through both the water and gas sides. To check
out the waterside, proceed as follows :
__________________________________________________________________________________________
Chapter 4
Page 44 of 44

a. Disconnect the feed pipework on the suction side of the feedpumps in order to ensure that no
residue is washed into the pumps.
b. Clean the hotwell tank of all foreign material and brush down internally to remove all loose mill
scale, rust etc.
c. Hose out the hotwell tank and flush through the feed suction pipework. If a feedline strainer is
installed, clean thoroughly after the lines have been flushed.
d. Re-connect the suction pipework to the sump and disconnect the discharge pipework. Flush
the pump through. Re-connect the pipework.
e. Open the boiler manholes and handholes and thoroughly clean out the waterside of the boiler.
Take particular care to ensure that no foreign material is left inside the boiler.
f.
Remove the blowdown valve and hose down the waterside of the boiler. Removal of the valve
is necessary to ensure that the blowdown valve does not become clogged with any residue
washed out of the boiler.
g. When the boiler is thoroughly clean replace the blowdown valve. Note that the blowdown valve
key should always be removed from the blowdown valve to ensure that it is closed.
h. Inspect the inside of the boiler and note any signs of corrosion, damage, oil or any material
which will inhibit heat transfer. If any oil is present, follow the boil-out procedure described in
Appendix E. to this manual, checking that the internal feed pipe and sootblower take-off pipes
are fitted in accordance with the relevant drawings. Check that all pipework attachments have
been properly secured. Replace all handhole and manhole covers using new joint rings.
i.
The boiler is now ready for filling.
Boiler Shell (gas-side) and Ductwork

4.
To check out the gas-side, proceed as follows :
a. Remove all smokebox covers and access doors. Store all clamps removed in the process.
b. Clean out all dust, slag, ash, loose refractories etc.
c. Brush tube holes through to remove all foreign matter.
d. Check that refractories have been installed in accordance with the relevant drawings and that
they are in good condition. Where asbestos rope packings have been used, check that these
are sound and have been properly installed.
e. Check that the gas ducting expansion joints are free to move and that the seals are sound.
f.
Check that the control and isolating dampers are free to move. Ensure that they are firmly fixed
to their shafts and that their indicator plates are set correctly. The saw cuts visible on the shaft
ends must line up with the damper blades.
g. Check the grit collector, the ID fan, the stack and the stoker as detailed in paras.5 to 12
inclusive.
h. Replace and secure smokebox covers and access doors.
i.
The gas-side of the boiler is now ready for a fire to be lit.
__________________________________________________________________________________________
Chapter 5
Page 45 of 45

Grit Collector
5.
The efficiency of the grit collector drops off very rapidly if air is allowed to enter the collector
hopper through the grit discharge port or through any other opening in the hopper casing. The
hopper is provided with a wet sump as a primary seal. The sump must be filled with water to
ensure that the discharge is airtight. Check that the inspection port seals properly.
6.
Before being put into operation, the grit collector must be cleaned of all foreign material. If a
hydraulic grit removal system is installed, the system must be checked out in accordance with
the relevant drawings and instructions.
7.
With the sump provided it may be necessary to remove one of the lower leg ties of the grit
collector to allow for access.
Induced Draught (ID) Fan

8.
It is very important to ensure that the ID fan is properly installed before applying power to the
motor. Proceed as follows :
a. Take off the removable section of the fan casing. Check that the curvature of the impeller
blades is as illustrated (Ref. Appendix A page 20) (i.e. check that the handing is correct).
Remove all foreign material.
b. If the fan is fitted with an inlet remove the box inlet inspection cover. The box must incorporate
an anti-vortex vane as illustrated (Ref. Appendix A page 21). Remove all foreign material from
the box inlet and replace the inspection cover.
c. Check that the bearings have been correctly installed and have been lubricated with the correct
grease (Ref. Chapter 5). The bearing adjacent to the impeller is the fixed bearing.
d. Check that the inlet cone/impeller clearance is correct as illustrated (Ref. Appendix A page 21).
Adjust if necessary. Replace the fan casing.
e. Check that the heat flinger disc is in the correct position and is properly secured.
f.
Check that the drive motor is correctly aligned and that the belts are properly tensioned. Only
matched sets of belts must be used.
g. Carry out an electrical check of the installed fan, as detailed in para.20.

Caution - The ID fan must never be started or run cold unless the ID damper is closed,
otherwise the motor will be overloaded.
Outlet Stack
9.
The Stirling MK7 boiler can be fitted with two different types of stacks a free standing type
or a guyed type. To check that these units are installed correctly carry out the procedures
detailed in the following paragraphs.
10.
If a self-supporting stack is fitted the hold- down bolts must be checked to ensure that they
have been properly tightened as detailed in the attached table (Ref. Annexure 1 to this
chapter). The base of the stack must be cleared of foreign material and the access door must
be fitted with new jointing. The catladder and painters rail (if fitted) must be checked to
ensure that they are securely fixed.
__________________________________________________________________________________________
Chapter 5
Page 46 of 46

11.
Where a guyed stack is fitted, the securing points for the guy wires must be checked to ensure
that they are sound and the guy wires themselves must be checked to ensure that they are
properly tensioned. The base of the stack must be cleared of foreign material and the access
door (if fitted) must be re-fitted with new jointing. The catladder and painters rail (if fitted)
must be securely fixed.
Stoker and FD fan

12. The installation and commissioning of the stoker and its ancillary equipment is described in
the Cochrane Chaingrate Stoker Manual.
Sootblowers
13. Sootblowers should be checked out as in paras.14 and 15.
14. Rear Sootblowers
a. Lubricate in accordance with Chapter 5.
b. Turn the handwheel and check that the blower moves in and out.
c. Check the angle of rotation of the blower head.
d. Check that the correct orifice plate is fitted.
15. Front Sootblowers
Check that the operating valves are free to move.
Pre-Commissioning Electrical Checkout
16. All power supplies and connections to and from the power devices mounted on the boiler are
routed through the control panel. The control panel is factory wired and where possible, is
delivered to site connected to the relevant power and control devices. The following
paragraphs detail electrical checks which can be made whilst the boiler is empty. Details of
checks to be made when the boiler is full are given later in this chapter.
Caution - Before applying power to the control panel, the clutch levers on the FD damper
control unit and the ID damper control unit must be set to the manual position. The
controls must not be set to panel or auto positions until the pulling motor limit switches
have been set up.
Control Panel
17. Every installation is supplied with a control panel circuit diagram which must be kept with this
manual. During installation the control panel must be checked to ensure that it is wired in
accordance with the appropriate diagram.
18.
Before applying power to the control panel, the insulation of the motors controlled from the
unit must be checked using a Megger or similar, insulation testing instrument. If this test
shows any leakage however slight, the cause must be found and the defect rectified.
Moisture or dampness greatly affects the insulation properties of the motor windings. If a low
Megger reading is obtained, first dry out the windings by blowing hot air over them for
approximately 12 hours. If subsequent Megger checks still show leakage an expert should be
consulted.
Stoker and FD Fan

19. Full details of the electrical checks on the units of the stoker and its ancillaries are given in the
Cochrane Chaingrate Stoker Manual.
__________________________________________________________________________________________
Chapter 5
Page 47 of 47

ID Fan
20. To check the operation of the ID fan, proceed as follows :
a. Set the ID damper control unit clutch lever to the manual position.
b. Connect power to the control panel.
c. Close the ID damper.
Caution - The ID fan must never be started or run cold unless the damper is closed,
otherwise the motor will be overloaded.
d. On the control panel, press the ID fan START push button. Check that its indicating lamp
illuminates and that the fan rotates in the direction illustrated (Ref. Appendix A page 20).
e. Run the fan for several hours. Whilst running, check periodically for any sign of rubbing or
chafing. Keep a close check on the temperature of the bearings and ensure that they do not
overheat.
f.
During this test, the fan should be checked to ensure that there is no undue vibration. If the fan
shows any sign of being out of balance specialist advice must be sought in order to re-balance
the unit.
Feedpumps, Monitoring and Control Devices

21. These can only be checked when the boiler is being commissioned.
Commissioning
Filling the Boiler (On/Off feedwater controls)
22. To fill the boiler when on/off feedwater level controls are fitted, proceed as follows :
a. Ensure that the hotwell tank is full and that the correct chemicals (ref. Appendix C to this
manual) have been added. Check that a free running supply of make up water is available.
b. Open all suction line valves between the hotwell tank and the feed pump suction manifold.
c. Open the feedwater delivery valve on the discharge side of both feed pumps.
Caution - If the valve is not opened sufficiently the pump may be damaged. Conversely,
if it is opened too much at this stage the motor will trip out or overload.
f.

1)
Set the main isolating switch to the ON position and check that the mains on indicator
lamp (red) illuminates.
2)
Check that the low water alarm lamp is illuminated and that the alarm bell is
sounding.
__________________________________________________________________________________________
Chapter 5
Page 48 of 48

3)
Set the feedpump selection switch to pump No.1. Check that the feedpump on
indicating lamp (green) illuminates and that the pump is operating.
g. Monitor the water level in the gauge glasses until the extra low water level is reached (water
just appearing in the gauge glass). Set the pump selection switch to pump No.2, Check that
the indicating lamp is illuminated and that the boiler continues to fill.
h. Note the level at which the low water alarm lamp extinguishes and the alarm bell stops
sounding : this level should be about 25mm above the low water level mark.
Filling the Boiler (modulating feedwater controls)
23. For installations fitted with modulating level controllers, the boiler is filled as follows :
a. Ensure that the hotwell tank is full and that the correct chemicals (Ref. Appendix C to this
manual) have been added. Check that a free running supply of make up water is available.
b. Open all suction line valves between the hotwell tank and the feed pump suction manifold.
c. Open the feedwater delivery valve on the discharge side of both feed pumps.
Caution - If the valve is not opened sufficiently the pump may be damaged. Conversely,
if it is opened too much at this stage the motor will trip out on overload.
f.

1) Set the main isolating switch to the ON position and check that the mains on indicator lamp
is illuminated.
2) Check that the low water alarm lamp is illuminated and that the alarm bell is sounding.
g. At the modulating valve :

1) Close the isolating needle valve for the inlet solenoid.
2) Open the exhaust needle valve.
h. At the control panel, set the feedpump selection switch to pump No. 1.
indicating lamp illuminates to show that the pump is working.
i.
Check that the
Monitor the water level in the gauge glasses until the extra low water level is reached (water
just appearing in the gauge glass). Set the pump selection switch to pump No. 2, check that
the indicating lamp is illuminated and that the boiler continues to fill.
Setting up the FD Damper Control Unit

24. Setting up procedures for the single knob combustion control unit are fully described in the
Cochrane Chaingrate Stoker Manual, Chapter 2.
Setting up the ID Damper Control Unit
25. For these instructions, reference should be made to the Cochrane Chaingrate Stoker Manual,
Chapter 2.
__________________________________________________________________________________________
Chapter 5
Page 49 of 49

Lighting a Fire
26. These procedures are fully described in Chapter 2 of this manual. However, the following
points should be observed :
a. Ensure that the boiler is filled with water and that an adequate water supply is available.
b. Make sure that steam can be blown off through the steam range or to atmosphere.
Setting the Combustion Controls
27. To set the combustion controls, reference should be made to Chapter 2 of the Cochrane
Chaingrate Stoker Manual.
Setting the Steam Pressure Detector
28. To set the steam pressure detector, refer to the detector leaflet at the back of this manual and
proceed as follows :
a. Adjust the setting on the steam pressure detector to the required boiler operating pressure.
b. When the steam pressure is within 50kPa of the required operating pressure, switch the boiler
controls to auto.
c. Adjust the transmission range slide screw to eliminate any tendency for the controls to hunt
Caution - Never rely totally on automatic controls. Always make frequent visual checks
of operating conditions.
Blowdown of Gauge Glasses
29. The gauge glasses are as illustrated (ref Appendix A page 16).
To blowdown, proceed as follows :
a. Close the water leg valve.
b. Open the tailcock and allow steam to blow through the gauge.
c. Close the tailcock.
d. Open the water leg valve.
e. Close the steam leg valve.
f.
Open the tailcock and allow water to blow through.
g. Close the tailcock.

h. Open the steam leg valve.
Floating Safety Valves (On/Off feedwater control)
30. The following procedure should only be carried out in the presence of the engineer in charge
of the boiler :
a. At the control panel, set the FD damper control unit and the ID damper control unit regulators to
zero.
__________________________________________________________________________________________
Chapter 5
Page 50 of 50

b. Set the FD damper control unit clutch lever to panel.

c. Set the ID damper control unit clutch lever to panel.
d. Close the main steam stop valve.
e. Gag the safety valve not being floated.
Caution - Never exceed the boiler design pressure during this test.
f.

1) Adjust the control regulators to increase the steam pressure to 40kPa above the normal
working pressure.
2) If the safety valve being floated does not lift at this pressure, adjust the control regulators to
lower the steam pressure.
g. If the steam pressure does not fall open the blowdown valve until the water level falls
approximately 25mm in the gauge glasses.
h. Close the blowdown valve when the feedpump cuts in. When the feedpump cuts out at the
normal water level, the boiler pressure should be low enough for the procedure to continue.
i.
Reduce the spring compression by adjusting the lock nut as illustrated (Ref. Appendix A page
19).
j.
Repeat steps f., g. and h. until the safety valve lifts at the required pressure.
k. If the safety valve being floated lifts before the required pressure, adjust the control regulators
to lower the steam pressure.
l.
If the steam pressure does not fall, open the blowdown valve until the water level falls
approximately 25mm in the gauge glasses.
m. Close the blowdown valve when the feedpump cuts in. When the feedpump cuts out at the
normal water level, the boiler pressure should be low enough for the procedure to continue.
n. Increase the spring compression by adjusting the lock nut as illustrated.
o. Repeat steps k., l. and m. until the safety valve lifts at the required pressure.
p. Repeat the above procedures for the remaining safety valves.
q. Remove all gags.
See Note below
Note - Keep a careful check on the water level during these tests. Steam and water is lost through
the safety and blowdown valves respectively during the tests.
Caution - After the valves have been set correctly, at least one valve must be locked securely
and accessible only to the competent person responsible for the boiler.
__________________________________________________________________________________________
Chapter 5
Page 51 of 51

Floating Safety Valves (Modulating feedwater control)

31. The following procedure should only be carried out in the presence of the engineer in charge
of the boiler :
a. At the panel set the FD damper control unit and the ID damper control unit regulators to zero.
b. Set the FD damper control unit clutch lever to panel.
c. Set the ID damper control unit clutch lever to panel.
d. Close the main steam stop valve.
e. Gag the safety valve not being floated.
Caution - Never exceed the boiler design pressure during this test.
f.

1) Adjust the control regulators to increase the steam pressure to 40kPa above the normal
working pressure.
2) If the safety valve being floated does not lift at this pressure, adjust the control regulators to
lower the steam pressure.
g. If the steam pressure does not fall:

1) Ensure that the feedpump is operating.
2) Crank open the blowdown valve until the steam pressure falls approximately 40kPa.
3) Close the blowdown valve.
h. Reduce the spring compression by adjusting the lock as illustrated (Ref Appendix A page 19).
i.
Repeat steps f. and g. until the safety valve lifts at the required pressure.
j.
If the safety valve being floated lifts before the required pressure, adjust the control regulators
to lower the steam pressure.
k. If the steam pressure does not fall:

Ensure that the feedpump is operating.
Crank open the blowdown valve until the steam pressure falls approximately 40kPa.
Close the blowdown valve.
l.
Increase the spring compression by adjusting the lock as illustrated (Ref Appendix A page 19).
m. Repeat steps j. and k. until the safety valve lifts at the required pressure.
n. Repeat the above procedure for the remaining safety valves.
o. Remove all gags.
__________________________________________________________________________________________
Chapter 5
Page 52 of 52

Note - keep a careful check on the water level during these tests. Steam and water is lost through
the safety and blowdown valves respectively during the tests.
Caution - After the valves have been set correctly, at least one valve must be locked securely
and be accessible only to the competent person responsible for the boiler.
Putting the Boiler on Range
32. After floating the safety valves and setting the combustion controls, the boiler may be put on
range as follows:
a. Ensure that the steam from the boiler can be used safely and that the steam line is warm and
properly drained.
b. Slowly open the main steam stop valve.
c. Gradually increase the firing rate.
d. Set the combustion controls so that the boiler operates at about 50% of full load.
e. Open the undergrate dampers
f.
Allow conditions to stabilise for at least one hour. During this period, check that all mechanical
components are functioning satisfactorily and that the water level controls are responding
correctly.
33.
At this stage the low water level alarm and the extra low water level cut out should be checked
on the controls fitted.
34.
Two Switch Control (On/Off feedwater) The top switch of the two switch control has already
been checked. To check the bottom switch proceed as follows :
a. At the panel, set the pump control to manual.

b. Switch the operating pump off.
c. Allow the water level to fall to the low water level mark. Check that the alarm bell sounds and
the low water level lamp illuminates.
d. Switch the pump on.
e. As the water level increases, the alarm should stop sounding.
f.
At the control panel, switch the controls to auto.
35.
Single Switch Control - The single switch control should be checked as follows :
a. At the control panel, set the pump controls to manual (for on/off feedwater control only).
b. Switch the operating pump off.
c. Allow the water level to fall to extra low water level. The FD fan, stoker and ID fan motors
should now cut out.
__________________________________________________________________________________________
Chapter 5
Page 53 of 53

d. Switch the pump on.

e. When the low water alarm stops sounding, switch the feedpump to auto control (for on/off
feedwater control only). Lock the auto/manual selector switch in the AUTO position. The key
should be kept by a competent person.
36.
To Re-start the Boiler - Carry out the following procedure :
a. Set the FD damper control unit to zero.

b. Set the ID damper control unit to zero.
c. At the control panel :
1) Ensure that the controls are set to manual and zero.
2) Start the ID fan.
d. Reset the ID damper control unit to the position prior to checking the controls.
37.
Modulating Control (modulating feedwater) - The top switch of the modulating control has
already been checked. To check the bottom switch proceed as follows :
a. At the modulating control valve, shut the

valve
b. Allow the water level to fall to the low water level mark. The alarm bell should now sound and
the indicating lamp illuminate.
c. Switch the feed pump on. As the water level rises, the alarm should stop sounding.
38.
Acceptance Certificate - The boiler is now fully commissioned and ready for the customer
to sign the acceptance certificate and take over the boiler.
Boiler Layup
39. When it is necessary to layup the boiler for long periods, measures must be taken to avoid
damage due to corrosion. Two methods of preservation are possible :
a. Wet Preservation
solution.
- In this method the boiler is filled with a corrosion-resistant chemical
b. Dry Preservation - In this method the boiler is emptied completely.

40.
Wet preservation is suitable for layup periods of one or two months. Dry preservation is
suitable for longer periods and is the only method to be used if there is any danger of freezing.
Both methods depend on the boiler being completely airtight and for this reason it is
recommended that all manhole and access panels have their gaskets renewed before layup.
Wet Preservation
41. Chemicals required - The following chemicals will be required :
a. An alkali compound
__________________________________________________________________________________________
Chapter 5
Page 54 of 54

b. Sodium sulfite crystals

42.
Procedure - To layup the boiler, proceed as follows
:
a. Close all valves to and from the boiler with the exception of the feedwater delivery valves, the
main feed check valve and the air release valve.
b. Fill the boiler to above the high water level mark.
c. Introduce the chemicals into the boiler water so that the following concentrations are obtained :
1) Alkalinity : 300mg/l
2) Sodium sulphite : 80-120mg/l
d. Fill the boiler to capacity. Check that the aircock is open and the water is running freely from it.
e. Re-check the chemical concentration and add further chemicals if required.
43.
Routine Checks - During the period the boiler is laid-up regular checks must be made of the
water level and chemical concentration. If either decrease, it will be necessary to top-up as
follows :
a. Fill the boiler to the required level.

b. Introduce the necessary chemicals to bring the concentration to the required level.
Dry Preservation
44. The boiler must be emptied and the interior surfaces dried. These surfaces must be kept dry
and condensation must not be allowed to form. Proceed as follows :
a. Empty the boiler.
b. Open the manhole and thoroughly dry the boiler by ensuring good ventilation and, if necessary,
by lighting a slow wood fire on the grate.
c. To check whether the boiler is dry, hold a small piece of steel over the manhole the steel will
show no signs of condensation if the boiler is dry.
d. Close all valves tightly.
e. Place an open container, two thirds filled with quick lime, into the boiler.
f.
Close the manhole tightly.
45.
Routine Checks - The quick lime should be renewed at regular one-monthly intervals.
__________________________________________________________________________________________
Chapter 5
Page 55 of 55

Chapter 5
Maintenance Information
Contents
Introduction
Chaingrate stoker
Maintenance Tools and Equipment
Boiler Efficiency
Page 2
Page 2
Page 2
Page 2
Exhaust gas temperature

CO2 content
Feedwater Controls and Equipment

On/Off (Two switch) feedpump control
Modulating level controller
Single switch control
Feedwater Pumps
Strainer
Cleaning the feedwater tank
Cleaning the deaerator (optional extra)
Testing safety valves
Boiler Valves
Page 2
Page 3
Page 4
Page 5
Page 5
Boiler blowdown valve
Sootblowers
ID Fan
Check and renewal of ID fan belts
ID damper movement
Faulty damper movement
Page 5
Page 5
Page 6
__________________________________________________________________________________________
Chapter 5
Page 56 of 56

FD Damper Movement
Furnace Draught Gauge
Cleaning the Boiler
Page 6
Page 6
Page 7
Internal cleaning gas side

Replacement of firetubes
Internal cleaning water side
Exterior cleaning
Painting
Inspection
Page 7
Removal of slag
Brickwork and insulation
Seals in smokebox joints
Boiler foundations
Page 8
Lubrication
Page 8
ID fan bearings
FD fan bearings
Quantity of lubricant required
ID damper control unit
Sootblowers
Rear sootblowers
Front sootblowers
Annual Survey
Page 8
Mobrey air break water level control

Mobrey thermofeed regulator
Mobrey modulating level controller
Floating safety valves
Page 9
Chimney
Page 9
Annexure 1
Annexure 2
Maintenance Schedules
Table 501 - CO2 Indications
Chapter 5
Maintenance Information
Introduction
1.
This chapter sets out the maintenance procedures necessary to obtain the best results from the
Stirling MK7 boiler. The procedures are also set out in check list format, which allocates the
frequency of maintenance. (Ref. Annexure 1 to this chapter).
Chaingrate Stoker
2.
Maintenance of the stoker should be carried out in accordance with Chapter 5 of the Cochrane
Stoker Operating and Maintenance Manual.
Maintenance Tools and Equipment
3.
In addition to the items supplied with each stoker, the following items are supplied with each
boiler.
No.
1
1
1
1
1
1
2
2
Item
Manhole spanner
Handhole spanner
Tube cleaning rod
48mm brush for stay tubes
57mm brush for plain tubes
Manhole joint (single stoker boilers)
Manhole joints (double stoker boilers)
Handhole joints
__________________________________________________________________________________________
Chapter 5
Page 57 of 57

Boiler Efficiency
4.
A reliable check of boiler efficiency can be made by checking the temperature and the carbon
dioxide (CO2) content of the exhaust gases. Measuring points are provided at the rear of the
boiler and it is recommended that permanent or portable equipment be fitted to measure these
important parameters.
Exhaust Gas Temperature
5.
The exhaust gas temperature should be approximately 250C at 100% load. Some causes of
high exhaust gas temperatures are :
a. Fouling of boiler tubes
b. Low air/fuel ratio
c. Overloading the boiler
CO2 Content
6.
Combustion efficiency is determined by measuring the CO2 content of the exhaust gases. This
should normally be between 11% and 13,5%. Check the CO2 content with a Fyrite or
equivalent CO2 analyser. Causes of a high or low CO2 content are given in the attached tables
(Ref. Annexure 2 to this chapter).
Feedwater Controls and Equipment
On/Off Feedpump Control (Two Switch Control)
7.
During periods when the boiler is steaming on low loads, the action of the float operated controls
should be checked as follows :
a. Select feedpump No. 1.
b. Check that the feedpump cuts out at the correct water level in the gauge glasses.
c. Watch the water level fall and check that the feedpump cuts in at the correct water level in the
gauge glasses.
d. Allow the water level to rise to normal and the feedpump to cut out, then switch the pump off at
the MCB.
e. Watch the water level fall and check that the alarm sounds and the low water indicating lamp
illuminates at the correct water level in the gauge glasses.
f.
At the MCB switch pump No. 1 on and check that the feedpump operates. Check that the
alarm stops and that the low water indicating lamp extinguishes at the correct water level in the
gauge glasses.
g. Check that the water level returns to normal.

h. Repeat steps a. to g. using pump No. 2.
Modulating Level Controller
8.
If fitted, the modulating controls should be checked as follows :
a. Check that the water level in the gauge glasses is normal.
b. Shut boiler feedwater valve and switch off the pump at the MCB.
__________________________________________________________________________________________
Chapter 6
Page 58 of 58

c. As the water level in the gauge glasses falls, check that the spindle in the modulating control
valve moves upwards.
d. Open the boiler feedwater valve.
e. At the modulating control valve, shut the valve (Ref. Chapter 2 Para 15)
f.
Check that the alarm sounds and that the low water indicating lamp illuminates at the correct
water level in the gauge glasses.
g. At the MCB, switch on the pump and check that the feedpump operates. Check that the alarm
stops and that the low water indicating lamp extinguishes at the correct water level in the gauge
glasses.
h. As the water level rises above normal, check that the spindle in the modulating control valve
moves downwards.
i.
Check that the correct water level is maintained in the gauge glasses.
Single Switch Control

9.
The action of the single switch control should be checked as follows :
Caution - When this unit is being tested, the fan and stoker motors are automatically
shutdown. Therefore, testing should only be carried out at low load to prevent the steam
supply from being seriously disrupted. After testing it will be necessary to restart the fan
and stoker motors from the control panel.
a. Check that the water level in the gauge glasses is normal.

b. Switch the feedpump off at the MCB.
c. Watch the water level fall and check that the ID fan, FD fan and stoker motors stop at the
correct water level in the gauge glasses.
d. At the MCB switch the feedpump on and check that it operates.
e. Restart the fan and stoker drive motors as follows :
Note - If automatic combustion controls are fitted, set the manual/auto switches on the control
panel to manual and the control regulators to the zero position.
1) At this stage check that the water level is correct
2) Check that the ID damper is closed.
3) Start the ID fan and check that its indicating lamp illuminates.
4) Check that the FD damper control unit is set at zero.
5) Start the FD fan and check that its indicating lamp illuminates.
6) Start the stoker and check that its indicating lamp illuminates.
__________________________________________________________________________________________
Chapter 6
Page 59 of 59

7) Reset the ID damper to its normal operating position.

8) Reset the FD damper control unit to its normal operating position.
9) If the boiler is now within 50 kPa of normal operating pressure, all combustion controls can be
set to auto. If the boiler pressure is low, build up pressure gradually until the normal
operating pressure is reached before setting the combustion controls to auto.
Feedwater Pumps
10. The feedwater pumps should be inspected and checked as follows :
Note - To carry out the following instructions, it is not necessary to shut the boiler down. Faults
found during inspection should be remedied as soon as possible.
a. At the control panel, set the feedpump selection switch to pump No. 1
b. Check that pump No. 1 is operating correctly and that the pump indicating lamp on the control
panel is illuminated.
c. Check pump No. 1 for any leakage from:
1) Pump glands and fittings
2) Isolating valves, glands and fittings
3) Inlet and outlet pipework and fittings
d. If necessary, tighten the gland nuts to eliminate leakage. Renew gland packings and valve
flange gaskets as required.
Note - If it was necessary to tighten gland nuts etc., or renew gland packing, always check the
pump and/or valves for smooth operation without any signs of sticking or stiffness.
e. At the control panel, set the feedpump selection switch to pump No. 2.
f.
Check that pump No. 2 is operating correctly and that the pump indicating lamp on the control
panel is illuminated.
g. Check pump No. 2 for any leakage from:

1) Pump glands and fittings
2) Isolating valves, glands and fittings
3) Inlet and outlet pipework and fittings
h. If necessary, tighten the gland nuts to eliminate any leakage. Renew gland packings and valve
flange gaskets as required.
Note - If it was necessary to tighten gland nuts etc., or renew gland packing, always check the
pump and/or valves for smooth operation without any signs of sticking or stiffness.
Strainer
11. If a strainer is fitted in the feedpump suction pipework it should be removed for cleaning during a
boiler shutdown period.
__________________________________________________________________________________________
Chapter 6
Page 60 of 60

Cleaning the Feedwater Tank

12. At regular intervals the feedwater tank should be inspected inside and outside and be cleaned.
To carry out this task, it will be necessary to empty the tank.
Alternative feedwater
arrangements to the boiler will have to be made, or the boiler shut down.
Note - If the boiler is one of several drawing water from a common feedwater tank, cleaning can only
be carried out when the entire boiler installation is shut down.
13.
To clean the feedwater tank when the boiler has been shut down, the following procedure should
be adopted :
a. Close the fresh water isolating valve on the inlet side of the feedwater tank.
b. Close the feedwater isolating valve on the outlet side of the feedwater tank.
Note - Steps a. and b. isolate the feedwater tank from the fresh water supply and the boiler.
c. Check the feedwater tank and associated feedlines for any signs of leakage.
d. Drain the feedwater tank.
e. Remove all mud, sediment etc., from the interior and wash down with clean water.
f.
Carry out repairs as necessary to the tank and associated feedlines indicated in step c.
g. Open the isolating valve on the inlet side of the tank, allow the tank to fill to the recommended
level, and then add the correct amount of chemicals (Ref. Appendix C to this manual).
h. Have samples of the feedwater analysed to verify that the correct chemical content has been
obtained.
i.
Open the isolating valve on the outlet side of the feedwater tank and allow feedwater to
circulate to the boiler.
j. Start feedwater pump No. 1 at the MCB. .

k. Allow pump No. 1 to run for approximately 3 to 5 minutes.
l.
Switch off pump No.1 and switch on pump No. 2. Allow this pump to run for approximately 3 to
5 minutes. Switch pump No. 2 off.
m. Close the isolating valves on the inlet side of both feedwater pumps.
n. Remove the strainer/s on the suction side of both feedwater pumps.
o. Clean the strainer/s thoroughly in clean water.
p. Fit the strainer/s back in place on the suction side of both pumps and tighten in position.
q. Open the isolating valve on the inlet side of both pumps.
r. Check that the water level in the boiler is correct.
Cleaning the Deaerator (optional extra)
__________________________________________________________________________________________
Chapter 6
Page 61 of 61

14.
For deaerators supplied by Cochrane Engineering (Pvt) Ltd reference should be made to the
relevant instruction manual for the deaerator. For deaerators supplied by an alternative source,
reference should be made to the suppliers instructions.
Testing Safety Valves

15. It is recommended that safety valves are tested once a week. The procedures to be followed are
detailed in Chapter 4 paras.30 and 31.
Boiler Valves
16. All valves must be checked to ensure that they operate freely with no signs of sticking, and for
leakage. Leaks from the glands can be eliminated by tightening the gland nuts (do not overtighten). If necessary, the gland packing should be replaced when the boiler is shut down.
Boiler Blowdown Valve
17. The boiler blowdown valve must be checked to ensure that it is operating freely with no signs of
sticking, and for leakage. Leaks from the gland can be eliminated by tightening the gland nuts
(do not over-tighten). If necessary, the gland packing should be replaced when the boiler is
shutdown.
Sootblowers
18. Sootblowers must be checked for correct operation as follows :
a. Rear Sootblowers - Should be maintained in accordance with the manufacturers instruction
book, at the back of this manual.
b. Front Sootblowers (if fitted) Provided that these are operated regularly maintenance is not
required although the sootblower nozzles should be checked for blockages. To do this, the
front smokebox doors must be removed.
ID Fan
Check and Renewal of ID Fan Belts
19. At regular intervals, the ID fan belts should be checked for signs of wear. Worn fan belts must be
replaced with a matched set of Fenner SPB series belts.
ID Damper Movement
20. This is controlled through the ID damper control unit. During shutdown periods, the operation of
the ID damper and the control unit should be checked as follows:
a. Set the ID damper control unit for manual operation.
b. Move the ID damper control lever through its full range of travel and ensure that the damper
operates easily and with no signs of sticking.
c. If necessary lubricate the ID damper control unit by removing the central control shaft and
applying grease.
d. Set the ID damper control unit for panel operation.
e. At the control panel :
1) Set the main isolating switch to the ON position. Check that the panel òn lamp illuminates.
__________________________________________________________________________________________
Chapter 6
Page 62 of 62

2) Set the ID damper manual/auto selection switch to the MANUAL position.

3) Turn the ID damper control regulator through its full movement.
f.
Check that the ID damper opens and closes easily with no signs of sticking.
g. Reset the ID damper control unit as required.

h. At the control panel, set the main isolating switch to the OFF position and check that the panel
on lamp extinguishes.
Faulty Damper Movement
21. If the movement of the ID damper linkage is not smooth and shows signs of sticking, the linkage
must be removed and then cleaned. Lubricate the link pins with a suitable grease and reassemble the linkage. Re-check the movement of the ID damper as described in para.20.
FD Damper Movement
22. This is controlled through the FD damper control unit. During shutdown periods, the operation of
the FD damper and the control unit should be checked as follows :
a. Set the FD damper control unit for manual operation.
b. Move the FD damper control lever through its full range of travel and ensure that the FD
dampers operate easily and with no signs of sticking.
c. Set the FD damper control unit for panel operation.
d. At the control panel :
1) Set the main isolating switch to the ON position. Check that the panel òn lamp illuminates.
2) Set the FD damper and stoker manual/auto switches to the MANUAL position.
3) Turn the FD damper control regulator through its full movement.
e. Check that the FD damper opens and closes easily with no signs of sticking.
f.
Reset the FD damper control unit as required.
g. At the control panel, set the mains isolating switch to the OFF position and check that the panel
òn lamp extinguishes.
Furnace Draught Gauge
23. At regular intervals, the furnace draught gauge should be checked for correct operation as
follows :
a. Remove the rubber pipe connecting the gauge to the copper pipe, at the rear of the control
panel.
b. Blow the copper line through (see Caution below), preferably with compressed air.
Caution Do not blow air into the rubber pipe connected to the draught gauge.
c. Check that the draught gauge reads zero. Re-zero if necessary.
__________________________________________________________________________________________
Chapter 6
Page 63 of 63

d. Re-connect the rubber pipe to the copper pipe.

Cleaning the Boiler
Internal Cleaning Gas Side
24. The fire tubes should be cleaned at regular intervals to remove dirt and grit. The frequency of
tube cleaning operations depends largely upon the quality of fuel used and standard of operation
maintained. Tube cleaning is also recommended when sootblowers are installed, but under
normal circumstances, this will only be necessary at much longer intervals.
Note - The purpose of sootblowers is to keep the tubes free from soot and fine grit and so
maintain maximum efficiency during operation. The sootblowers will not remove hard rust or
scale.
25.
It is advisable to clean the tubes with hand or mechanically operated cleaners if they have not
been cleaned properly over a long period. It is also advisable to clean the flue, the combustion
chamber and the back tube plate with a wire brush and remove grit and soot deposits whenever
the boiler is shut down. Every three months, the brickwork of the boiler should be inspected and
repaired as required. Never allow uncooled mild steel parts to be exposed to the flame.
Replacement of Firetubes
26. The replacement of firetubes requires the services of a qualified artisan. It is, therefore,
recommended that the nearest office of Cochrane Engineering (Pvt) Ltd is contacted for this
service.
Internal Cleaning Water Side
27. Removal of Scale - Scale build up on the water side of the boiler must be prevented. Attention
is drawn to Appendix C to this manual where feedwater treatment is discussed.
28.
If however, a scale build up occurs, one of the following two methods can be used to remove the
deposits.
a. Chemical
b. Mechanical
29.
There are several de-scaling chemicals available and it is recommended that the services of a
qualified chemical cleaning firm be secured to advise on their use.
30.
Mechanical de-scaling using chipping hammers and chisels, is not recommended except for very
heavy scale deposits. Even if mechanical de-scaling is carried out it will still be necessary to use
chemicals to remove small deposits left behind
Exterior Cleaning
31. At regular intervals, the exterior of the boiler should be cleaned as follows :
a. Remove all coal dust from the boiler shell and controls.
b. Remove any traces of oil and grease from around and on the lubricating points on the boiler
and stoker.
Inspection
__________________________________________________________________________________________
Chapter 6
Page 64 of 64

Removal of Slag
32. When the fire has been run off open the guillotine door (see Caution) and inspect carefully for
any signs of slagging.
Caution - Never open the guillotine door too soon. The sudden inrush of cold air will
33.
Slag can be removed by using a slicing bar. Care must be taken to ensure that the refractory is
not damaged in the process.
Brickwork and Insulation

34. At regular intervals, the condition of the internal brickwork should be carefully inspected. This
can be carried out when the boiler is shut down by climbing through the rear access door and the
guillotine door openings.
35.
The insulation around the access door should be carefully checked. All defective insulation
should be replaced immediately. Ensure that the rear access door is tightly closed and the flap
door under the stoker is kept shut.
Seals in Smokebox Joints

36. Asbestos rope is placed in the front and rear smokebox door joints. This must be checked to
ensure that no gaps are present. When the furnace is pressurised, gas leaks can easily be seen.
Discoloured paint is another sign of leaking gas. If necessary, the asbestos rope should be
renewed to prevent leaks.
Boiler Foundations
37. If any cracks appear in the boiler foundations, the engineer in charge of the boiler must be
informed. If necessary, the boiler should be shut down until repairs can be carried out.
Lubrication
38. The following information is given for guidance only, and in general, applies to operating under
normal ambient temperature conditions. When other working conditions apply consult your oil
supplier. Lubrication of the stoker is covered in the Cochrane Chaingrate Stoker Manual and is
not repeated here.
ID Fan Bearings
39. Every three months (1100 hours at 12 hour rating) the grease should be changed. All signs of
old grease should be removed prior to applying fresh SKF LGMT3 grease or equivalent in
accordance with para.41.
FD Fan Bearings
40. Every three months (1100 hours at 12 hour rating) the grease should be changed on the FD fan
bearings fitted to the size 8 and 9 stokers. All signs of old grease should be removed prior to
applying SKF LGMT3 grease or equivalent in accordance with para.41.
Quantity of Lubricant Required
41. The quantity of lubricant that should be applied to the ID fan and FD fan bearing varies with the
size of bearing. To calculate the amount of grease required, the following formula should be
used :
M =
0,0051DB
__________________________________________________________________________________________
Chapter 6
Page 65 of 65

Where
M =
D =
B =
mass of grease in grammes

o/diameter of bearings in mm
width of bearing in mm

42. Every three months the ID damper control unit should be lubricated by removing the central
control shaft and applying grease.
Sootblowers
43. Rear Sootblowers - Refer to instruction booklet at the back of this manual for lubrication
procedures.
44.
Front Sootblowers - (if fitted) refer to the instruction manual at the back of this manual.
Annual Survey
45. Every boiler installation in Zimbabwe is subject to annual survey by a Government Inspector.
Information regarding this survey is given in Appendix F to this manual.
Mobrey Airbreak Water Level Controls
46. During the annual survey, the Mobrey water level controls both single switch and two switch,
should be removed and serviced. For details of this service, reference should be made to the
appropriate Mobrey instruction leaflet at the back of this manual.
Mobrey Modulating Level Controller
47. If a Mobrey modulating level controller is fitted it should be removed and serviced during the
annual survey. For details of this service, reference should be made to the appropriate Mobrey
instruction leaflet at the back of this manual.
Floating Safety Valves
48. At the completion of the annual survey, the Inspector will require the safety valves to be floated,
adjusted as necessary and then sealed. Details of this operation can be found in Chapter 4 of
this manual.
Chimney
49. The chimney should be inspected after the first twelve months in operation and thereafter, at a
maximum interval of three years. The inspection should include :
a. A check for corrosion by a thickness survey.
b. A check of flange bolts and alignment
c. .Surface coating integrity.
d. Connection of lightning conductor.
e. Check of guy tension (if guyed chimney)
f.
Check foundation for subsidence is chimney level?
__________________________________________________________________________________________
Chapter 6
Page 66 of 66

Chapter 6
Spare Parts and Related Information
Contents
Introduction
Parts Holding and Ordering
Manufacturers Detail Plates
Page 2
Page 2
Page 2
Annexure 1
Table 601 Recommended boiler spares
__________________________________________________________________________________________
Chapter 6
Page 67 of 67

Chapter 6
Spares Parts and Related Information
Introduction
1.
The component locations of a single stoker boiler as well as a double stoker boiler are as
illustrated (Ref. Appendix A page 4 and 6). For information regarding spare parts directly
associated with the stoker/s, reference should also be made to the Cochrane Chaingrate Stoker
Manual.
Parts Holding and Ordering
2.
It is not necessary for all boiler spare parts to be held in stock by the customer. Therefore, for
the convenience of the customer, parts holding and parts ordering are divided into the following
two categories :
a. Those parts which it is recommended that customers should hold are given in Table 601(Annexure
1 to this chapter).
b. Other parts which are required by customers can be ordered from Cochrane Engineering using the
appropriate description.
Manufacturers Detail Plates
3.
A manufacturers detail plate is fitted to each boiler. The details stamped on this plate must be
quoted when ordering spares or making general enquiries concerning the installation.
4.
A serial number plate is fitted to the stoker hopper. Details stamped on this plate must be quoted
when ordering spares or making general enquiries concerning the stoker.
5.
A serial number plate is fitted to the forced draught (FD) fan casing. Details stamped on this
plate must be quoted when ordering spares or making general enquiries concerning the FD fan.
6.
A serial number plate is fitted to the induced draught (ID) fan casing. Details stamped on this
plate must be quoted when ordering spares or making general enquiries concerning the ID fan.
__________________________________________________________________________________________
Chapter 6
Page 68 of 68

Stirling MK7 S4500-S20000 Range of Boiler
Appendix B
Fuel Recommendations
Contents
Introduction
Calorific Value and Ash Content
Volatile Content and Ignition
Coal Size and Segregation
Ash Fusion Temperature
Moisture Content
Fuel Bed Thickness
Trace Elements
Page 2
Page 2
Page 2
Page 3
Page 3
Page 3
Page 3
Page 4
Annexure 1
Table B01 - Classification of coal impurity ranges
__________________________________________________________________________________________
Appendix B to the Boiler Manual
Page 69 of 69

Appendix B
Fuel Recommendations
Introduction
1.
The Stirling MK7 boilers are capable of burning a wide variety of coals. They can also burn
sunflower seed husks and wood chips. By fitting alternative equipment they can be oil fired or
gas fired. When coal fired, the boiler output is dependent upon the type and quality of coal burnt.
The maximum output and efficiency is obtained by burning a high quality pea coal. The following
are important coal characteristics which affect stoker efficiency and boiler output.
a.
b.
c.
d.
e.
Calorific value and ash content

Volatile content and ignition
Coal size and segregation
Ash fusion temperature
Moisture content
Calorific Value and Ash Content

2.
The supplier on an air-dried basis, usually specifies the gross calorific value of a coal. Hwange
washed pea coal is rated normally at 29.5MJ/kg.
3.
The calorific value and ash content of a coal are closely related. As the ash content rises, so the
combustible content and hence the calorific value falls.
4.
As the calorific value falls so the useful heat available decreases. Although a greater amount of
lower calorific value coal can theoretically be burnt to meet the required thermal output,
combustion on a chaingrate stoker is essentially a mass controlled process. Hence, when
operating close to maximum combustion rates, the useful heat output increases with calorific
value.
__________________________________________________________________________________________
Appendix B to the Boiler Manual
Page 70 of 70

5.
As the ash content rises the unburned losses will increase in proportion provided that the
unburned carbon content of the discard remains unchanged. In practice, higher ash contents
reduce the combustion temperature and make it more difficult for the combustion air to reach any
unburned carbon. Both of these factors tend to increase the unburned carbon content of the
discards.
6.
This means that the unburned carbon losses on a mass basis tend to increase at a more rapid
rate that the ash content. The unburned carbon losses are often expressed as a percentage of
the calorific value. Since the losses tend to increase with increasing ash content while the
calorific value decreased, it can be seen that the unburned losses will increase very rapidly when
expressed as a percentage.
Volatile Content and Ignition

7.
Coal has an ignition temperature of approximately 400C. Release of the volatile constituents
commences at about 150C. After passing under the guillotine door the coal is heated by
radiation from the hot refractory ignition arch. The volatiles in this area are released and mix with
the combustion air to burn above the fuel bed. These burning volatiles heat the ignition arch and
radiate directly down onto the incoming fuel and supplement the effect of the arch. A step in the
arch increases gas turbulence in the ignition zone. This promotes mixing of the volatiles and air,
increasing the flame temperature and so improving the overall effect of the system.
8.
When the volatile content of the coal is low, insufficient heat is liberated beneath the arch and the
coal is difficult to ignite. There are two important properties to take into consideration when
evaluating the volatile content of the coal. These are the composition of the volatiles and the
ease with which they are released. These properties are dependent upon the vegetable matter
from which the coal was derived and the age or degree to which carbonisation has advanced.
Inert gases such as carbon dioxide and nitrogen obviously inhibit the ignition properties. In an
older coal where the volatiles are heavier and carbonisation further advanced, ignition will be
similarly effected.
9.
When firing a coal with a good quality easily released volatile content, the release of volatiles is
concentrated in a small area under the arch and stable ignition can be obtained even though the
volatile content is as low as 16%. On the other hand, for typical Transvaal coal the volatile
content should preferably be in the order of 23% to achieve stable ignition conditions.
Coal Size and Segregation

10. Coal size is probably the single most important factor affecting the performance of a chaingrate
stoker. By correlating established packed bed theory with the combustion pot tests, a uniformity
coefficient can be defined to describe the maximum permissible deviation from the effective
size for acceptable results to be obtained on a chaingrate stoker.
11.
The effective size is the sieve size through which 10% by mass of the coal particles will pass.
The effective size of the bed of mixed particle sizes is best described as that size which typifies
the flow characteristics through the bed for an incompressible fluid. In other words, using a bed
of effective size particles can reproduce the flow characteristics for a bed of mixed particle sizes.
12.
The uniformity coefficient is defined to be the ratio of the sieve size through which 60% by mass
of the coal will pass to the effective size. The uniformity coefficient is a measure of the range of
particle sizes present in a mixture of particle sizes. This coefficient gives a very good indication
of the likelihood of segregation becoming a problem.
13.
Consider a 100mm fuel bed which has been fed onto the stoker in badly segregated condition. If
the particles on the left hand side have an effective size of 1mm, the draught loss across the bed
at normal stoker rating would be 270Pa. If the effective size on the right hand side were 6mm,
__________________________________________________________________________________________
Appendix C to the Boiler Manual
Page 71 of 71

the draught loss would be 90Pa. Under these conditions 1.7 times more air would pass through
the right hand side of the stoker than the left.
14.
Fixed and adjustable baffles enable the air to be distributed along the length of the grate
according to fuel bed demand. Control across the width of the grate much more difficult to
obtain. Since it is desirable to achieve a uniform air distribution across the grate, it is vitally
important to ensure that a homogenous mixture of coal particles is fed onto the grate in the first
place.
15.
Two factors play a role in determining the ease with which this can be done. Firstly, the coal
particles should be as uniform in size as possible to minimise the risk of segregation occurring.
This consideration favours the use of a coal with lowest possible uniformity coefficient.
Secondly, coal-handling equipment should be designed to minimise the likelihood of segregation
occurring.
16.
A swinging coal chute installed above the stoker hopper will ensure that variations in coal particle
size are spread uniformly across the full width of the grate.
Ash Fusion Temperature

17. The ash fusion temperature should preferably be greater than 1400C. It should not be less than
1 280C.
Moisture Content
18. Moisture conditioning helps to limit segregation. It causes the fine coal particles to adhere to the
larger ones, so helping to hold them in the fuel bed until they are trapped by the release of tarry
volatile fractions. In this way, the amount of fine particles carried over in the flue gases is kept
to a minimum. A moisture content of approximately 8% is normally adequate for this purpose.
Fuel Bed Thickness
19. The optimum fuel bed thickness is dependent upon the coal type and size grading. As a fine
coal bed produces a higher resistance to air flow than a coarse coal bed, it follows that when
burning a smalls coal, the fuel bed should be thinner than when burning a pea coal. Normally
best results are obtained with a fuel bed thickness in the order of 4 to 5 times the maximum
particle size when firing an unwashed small and 7 to 8 times the maximum particle size for a pea
coal.
20.
Under normal operating conditions, the boiler automatic controls have a turndown ratio of 3 : 1.
Under test conditions a ratio of 4 : 1 can be achieved. Therefore, the fuel bed thickness need not
be reduced unless the boiler load falls below approximately 30 percent of the maximum
continuous rating.
Trace Elements
21. There are four trace elements in coal which have an effect on the utilisation of the stoker. These
are as follows :
a.
b.
c.
d.
Chlorine
Iron
Phosphorous
Sulphur
22.
High normal and low figures for these elements are given in Table B01 (refer to Annexure 1 to
this Appendix).
23.
The chlorine content in itself is not significant. It is used, however, as a measure of the alkali
metals such as sodium and potassium which are present in the coal. These metals have a low
__________________________________________________________________________________________
Page 72 of 72

melting point. They volatilise during the combustion process and condense out on high
temperature surfaces, in the heating system forming hard deposits which are very difficult to
remove by conventional on-load cleaning techniques.
24.
Iron in coal suppresses the ash fusion temperature. If the ash contains more than about 7
percent iron, slagging at grate level is likely to occur. Coals having a low ash fusion temperature
usually have a high iron content.
25.
The phosphate compounds which form in the fuel bed condense out on metal surfaces having a
temperature of about 300-350C. Fly ash is trapped, dissolved and bonded to the metal surfaces
by these condensates. The bonded deposits can only be removed by regular water washing
before they have solidified or by shotblasing once they have solidified.
26.
Sulphur oxidises in the fuel bed to sulphur dioxide and sulphur trioxide. The amount of sulphur
trioxide formed depends on a large number of factors, the two most important of which are the
amount of excess air present and the combustion reaction temperature. Sulphur trioxide
combines with water to form sulphuric acid. This condenses out in the low temperature sections
of the heat transfer device and it corrodes the surface with which it comes into contact. The
resultant sticky surfaces trap fly ash to form a bonded deposit which is best removed by frequent
water washing. To prevent corrosion, steel surfaces must be kept above the acid dew point.
__________________________________________________________________________________________
Page 73 of 73

Appendix C
Boiler Water and Feedwater Quality
__________________________________________________________________________________________
Page 74 of 74

Contents
Introduction
Untreated Feedwater Chemical Content
Boiler Water Chemical Content
Sample Taking
Page 2
Page 2
Page 2
Page 2
Annexure A
Limits of boiler water quality
Appendix C
Boiler Water and Feedwater Quality
Introduction
1.
The chemical dosing of boiler water and feedwater is a specialised procedure and it is
recommended that the services of a qualified treatment firm be retained.
__________________________________________________________________________________________
Page 75 of 75

2.
Boiler operators are referred to the following publication, produced by the Council for Scientific
and Industrial Research (CSIR) which contains general information on water treatment.
Technical Guide K15, Pretoria CSIR 1970
A Guide to Water Treatment in Low Pressure and Medium Pressure Boilers
Untreated Feedwater Chemical Content

3.
Untreated feedwater must have the following recommended characteristics :
Calcium hardness - less than 40mg/l of CaCO3
PH
- 7.5 - 9.5
Boiler Water Chemical Content

4.
In order to protect the internal surfaces of a boiler and prevent failure owing to corrosion and/or
overheating, the boiler water when analysed must be within the limits given in Table CO1.
Sample Taking
5.
Feedwater samples can be taken directly from the feedwater tank. For boiler water samples it is
recommended that a water sample cooler must be fitted to the boiler. This can be supplied as an
optional extra.
__________________________________________________________________________________________
Appendix D to the Boiler Manual
Page 76 of 76

Appendix D
Installation of a Stoker in a Boiler Flue
__________________________________________________________________________________________
Page 77 of 77

Contents
Introduction
Procedure
Page 2
Page 2
Appendix D
Installation of a Stoker in a Boiler Flue
1.
Appendix B sets out the basic procedures to be followed when installing a Chaingrate stoker into the
flue of a boiler. The procedures given herein are not detailed step-by-step instructions, but should be
sufficient to provide the Installation Engineer with enough information to carry out this important task.
__________________________________________________________________________________________
Page 78 of 78

Stirling MK7-S4500-S20000 Range of Boiler
Procedure
2.
To instal the stoker into the flue of a boiler, proceed as follows :
a. Slide the stoker into the flue using the
stoker trolleys.
b. Ensure that the frame is truly horizontal using a spirit level and levelling by means of the adjusting
bolts under the grate.
c. Apply two layers of 45mm diameter asbestos rope between the side seals and the flue.
d. Cast the side seal refractory between the ignition arch and the carbofrax blocks.
e. Fit the FD fan.
__________________________________________________________________________________________
Appendix E to the Boiler Manual
Page 79 of 79

Appendix E
Boil-out Procedure
Contents
__________________________________________________________________________________________
Page 80 of 80

Introduction
Boil-out
Page 2
Page 2
Annexure 1
Table E01 - Water volume required for a boil-out
Appendix E
Boil-out Procedure
Introduction
1.
In order to protect the boiler tubes from rust and corrosion before the boiler is fired, the tubes are
given a heavy oil coating before they are despatched from the tube manufacturing mill. This
__________________________________________________________________________________________
Page 81 of 81

coating should be removed before the boiler is used to produce steam. This procedure is known
as boil-out.
Boil-out
2.
To boil-out, proceed as follows :
1.
Fill the boiler with water to the average water level, as detailed in Chapter 2.
2.
Remove the manhole cover on top of the boiler.
3.
Add the appropriate chemicals in the quantities prescribed by a competent water treatment
company.
4.
Replace the manhole cover.
5.
Open the air release valve.
6.
Light a fire as detailed in Chapter 2.
7.
Do not raise any steam pressure, but maintain the boiler water temperature between 90 and
100C for at least 12 hours.
8.
Shutdown the boiler and run the fire off the grate, as detailed in Chapter 2.
9.
Empty the boiler through the blowdown valve.
10. Remove the top manhole cover and flush the boiler out using hot water and a hose pipe.
11. Replace all gaskets.
12. All traces of oil should now be removed. The boiler can now be refilled ready for operation.
13. When the boiler is steaming, take boiler water samples for analysis.
Table EO1 - Gives approximate volumes of water for the range of boilers for the purpose of
calculating the quantities of boil-out chemicals to use.
__________________________________________________________________________________________
Appendix F to the Boiler Manual
Page 82 of 82

Appendix F
Government Inspection
Contents
Introduction
Boiler Log Book, Tools and Assistance
Boiler log book
Tools and assistance
Internal and External Inspection
Hydraulic Test
Page 2
Page 2
Page 2
Page 2
__________________________________________________________________________________________
Page 83 of 83

Appendix F
Government Inspection
Introduction
1.
Once a year, a local Government
Inspector subjects all stationary boilers in
Zimbabwe to an inspection. Appendix F
is based on advice from the Chief
Inspector of Factories and Works,
Harare.
The Ministry of Mines Inspectors cover
boilers in the mining sector, and a
Factory Inspector from the National
Social Security Authority will inspect all
other boilers
Users are also advised to acquaint
themselves with the Factory and Works
(Boiler) (Amendment) Regulations, RGN

279.
2.
In order to assist you to prepare your

boiler
for
Government
Inspection,
Cochrane Engineering (Pvt) Ltd., offer
to carry out this service by their specialist
Service Department, at a nominal fee.
Boiler Log Book, Tools and Assistance

Boiler Log Book
3.
The boiler log book must be written
and be available together with
Government Boiler Register for
Inspector. An example of a typical
sheet is given in Appendix A. page 15.
__________________________________________________________________________________________
Page 84 of 84
up
the
the
log

Tools and Assistance

4.
Regulation 11 (6) of RGN 279 states that
The user of a boiler shall place at the
disposal of the Inspector, free of charge,
workmen, lights, tools or such other
apparatus or equipment as may be
required by an Inspector for the purpose
of examination or test .
Internal and External Inspection
5.
The following preparatory work should be
carried out prior to an internal and
external inspection :
b. Properly clean and expose all boiler

seams, stayheads and mountings.
c. Overhaul all boiler fittings to permit
satisfactory water test.
d. Open and clean blowdown and other
trenches. Renew defective blowdown
and other pipes.
e. Blank off stop and safety valves so
that the required test pressure can be
reached without difficulty.
Note - Removal of all lagging is not

required unless for examination of
external defects.
a. Clean hot and cold feedwater tanks
whenever practicable.
b. Open and clean all blowdown and
other trenches. Renew all defective
blowdown and other pipes.
Note - the screwing down of spring

loaded safety valves in lieu of
blanking off is not permitted for
obvious reasons.
f. Remove mechanical stokers and
clean thoroughly. Remove deposit
from the whole interior, including the
shell, tubes, flues and smokeboxes.
c. Overhaul all boiler fittings and renew

all defective studs.
g. Make sure that all water gauge cocks

are in the off position and that all
gauge glass protectors are in position.
d. Remove all handhole and manhole

covers.
h. The blowdown valve key should be in

position and ready for use.
e. Make all gas passes

accessible where possible.
i. Fill the boiler completely with water

until it overflows from the highest
opening at the top of the shell.
f.
freely
Examine and overhaul all automatic

boiler control appliances.
g. Internal parts must not be painted

prior to the inspection.
h. Clean and dry the boiler house.
j.
Before the arrival of the Inspector on

the premises, connect a suitable test
pump on the boiler and raise the
pressure to the maximum working
limit. Maintain the pressure at this
limit.
Hydraulic Test
6.
The following notes apply to preparing
the boiler for hydraulic testing :
a. Ensure that all control equipment is
isolated from the boiler.
Caution - When isolating the
control equipment, open the
appropriate drain cocks so that the
controls are not subjected to
excessive pressure.
__________________________________________________________________________________________
Page 85 of 85

__________________________________________________________________________________________
Page 86 of 86

Boiler Manual

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Boiler Manual

Diunggah oleh

Hak Cipta:

Format Tersedia

Cochrane Engineering (Pvt) Ltd

Stirling MK7 S4500-S20000 Range of Boilers

Table 101 - General Data

Cochrane Engineering (Pvt) Ltd

The boiler is a horizontal three pass unit comprising :

Conversion to Gas or Oil Firing

Design and Performance Data

Cochrane Engineering (Pvt) Ltd

Electrical Power Requirements

Cochrane Engineering (Pvt) Ltd

The combustion equipment is described in the Cochrane Chaingrate Stoker Manual.

Steam and Furnace Pressure Control

Steam Pressure Gauge

Cochrane Engineering (Pvt) Ltd

Boiler Feedwater Pumps

A central pump station is sometimes used for multi-boiler installations.

Water Level Monitoring Instruments

Ash Removal Trolley

Cochrane Engineering (Pvt) Ltd

Note - Inspection and testing must be carried out by a Government Inspector.

Maintenance Tools and Consumable Spares

The following items are available as optional extras :

Swinging coal chute

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

Emergency shutdown (power failure or extra low

Emergency shutdown (extra low water level, ID fan,

Cochrane Engineering (Pvt) Ltd

Meaning of Operating Terms

Water Level Controls and Monitoring Instruments

Cochrane Engineering (Pvt) Ltd

Water Level Gauge Glasses

Water Level Controls (Single Stoker Boilers)

Water Level Controls (Double Stoker Boilers)

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

Coal Cut-off Gate

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

g. Repeat steps e. and f. with the left hand blower handwheel.

Repeat steps a. to h. inclusive using the right hand front sootblower.

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

e. Restart the fans and stoker drive motors as follows :

Modulating Control - This unit is blown down as follows :

Cochrane Engineering (Pvt) Ltd

d. To promote circulation during start up from cold.

Cochrane Engineering (Pvt) Ltd

Ash and Grit Removal

At the control panel :

Cochrane Engineering (Pvt) Ltd

Set the other valves on the boiler as follows :

Close the undergrate dampers, both front and rear.

Set the FD damper to zero (closed).

k. At the control panel :

Fully open the FD fan damper.

Cochrane Engineering (Pvt) Ltd

u. Stop the stoker.

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

Cochrane Engineering (Pvt) Ltd

Low Load Firing Techniques

Cochrane Engineering (Pvt) Ltd