AKKAYA-BLOWTHERM SBK-YSB-HYB User manual

NAME : AKKAYA ISI MAKNALARI VE DOALGAZ SAN. TC. A..
TYPE : BOILE
R
MARK: AKKAYA - BLOWTHERM ADRESS: 1. ORGANZE SANAY BÖLGES YERLSU SK. NO:2 KONYA
MODEL: SBK - YSB - HYB
SUB-MODEL: STEAM BOILE
R
TELEPHONE: [phone]
FAX: [phone]
EMAIL: [email protected]
SBK-YSB-HYB MODEL STEAM BOILERS
USER MANUAL MANUFACTURING COMPANY
email: [email protected]
http://www.akkaya.com.tr
AKKAYA HEATING INSTRUMENTS
MANUFACTURING AND TRADE
INCORP.
Akkaya Is Mak. ve Doalgaz San. ve Tic. A..
Tel: [phone] Fax:[phone]

AKKAYA STEAM BOILERS
Valuable Customer,
The Akkaya steam boler whch you have bought are produced in Turksh Norm
(TS 497 And TS 377 are applied for designed pressure 0,6 - 2,5 Mpa) The boilers have
ten years life time that is determined by The Industry and Commercial Ministry . This
user guide is prepared for AKKAYA YSB-SBK AND HYB Type Boiler's.
The user guide has also technical specifications of the boilers.
Customer should employe a licensed or certificated boiler opretator for safe and
efficient use of the boiler. Its customer's responsibilty to avoid any kind of use of boiler
which will cause acciedents.
YSB MODEL FIREBOX TYPE STEAM BOILERS TECHNICAL SPECIFICATIONS
Type : Three pass wet back,low pressure,fre box type
Furnace - Reverse Chamber: It is produced from the steel materials Fig. 1. : Fire box type steam boiler
it is strengthen wth extra reinforcement. CAPACITY AND DIMENSIONS
Refrracter Materials: It is used for supplying completely burning
in the furnace and reverse chamber
Materials : Carbon steels as described in standards
Pipes : Carbon steel tubes as indicated in standards.
Welding Quality: It is done by certificated welder according to
EN 288 ,EN287-1
Fuel Type : Solid - Liquid - Gas
Table 1. : Fire Box Type Steam Boiler's
Dimensions AND Capacity
1 2

SBK MODEL - SCOTCH TYPE 3 PASS BOILERS TECHNICAL SPECIFICATIONS. CAPACITY AND DIMENSIONS - FOR OIL/GAS FIRED BOILERS
Type : Three pass wet back,low pressure, scotch type
Furnace - Reverse Chamber: It is produced from the steel materials
Refrracter Materials: It is used for supplying completely burning
in the furnace and reverse chamber
Materials : Carbon steels as described in standards
Pipes : Carbon steel tubes as indicated in standards.
Welding Quality: It is done by certificated welder according to
EN 288 ,EN287-1
Fuel Type : Solid - Liquid - Gas
Fig. 2. :Scoth Type Steam Boiler
3 4

HYB MODEL - HYBRID TYPE BOILERS TECHNICAL SPECIFICATIONS CAPACITY AND DIMENSIONS
Type : Water tube combustion chamber + 2 or 3 pass boiler
Furnace - Reverse Chamber: It is produced from the steel materials
Refrracter Materials: It is used for supplying completely burning
in the furnace and reverse chamber
Materials : Carbon steels as described in standards
Pipes : Carbon steel tubes as indicated in standards.
Welding Quality: It is done by certificated welder according to
EN 288 ,EN287-1
Fuel Type : Solid - Liquid - Gas
3 pass back boiler specifications are same with SBK models
Capacities for min. 5500 kcal/kg solid fuel and F&A 100 C (from and at 100 C)
A front chamber made of water tubes are attached in order to get sufficient
combustion chamber volume and tuyer area
5 6

PERCAUTIONS DURING CARRYING AND TRANSPORT ASSEMBLING AND CONNECTING
A.) SETTING BOILERS ON VEHICLE ASSEMBLING AND CONNECTING OF FIREBOX TYPE STEAM BOILERS
While boiler is setting on vehicle ,crane must be used .
The covers of the vehicle body must be opened before boiler is setted on it
You must use carrying circle during transporting boiler with crane.
You attached the hook of crane bom's to the boiler's carrying circle.
You must be sure safety of hook's pim .You discharge vacuum of bom by raising
up bom of crane slowly.You lift up the boiler slowly but the bottom of the boler
must be high 30 - 40 cm from surface of the vehicle.
You avaoid sudden acts wll cause shakng the boiler.You should carry
the boiler this by near to the vehicle.After taking away the boiler near to the vehicle,
raise up the boiler 30 - 40 cm higher than the vehicles 's body level and lower
the boiler on vehicle body.
Take of the hook of the crane from carryng circle of the boiler.
ATTENTION : The boiler must be carried usin
g
carr
y
in
g
circle in
p
er
p
endicuar
p
osition.When
y
ou lift u
p
the boiler b
y
crane ,there must be no one under the boiler
The boiler can be trans
p
orted wıth all of ıts accessories. Fig. 3 : Assembling of fıre box steam boiler with solid fuel
B.) TRANSPORTING BOILER ON VEHICLE Fitting up steam boiler ,lifting up the boiler on it is carrying legs and chimney
connectings are done by qualified service ,attaching safety and control instruments
When the boiler is being carried by vehicle it must be tied with barriers which to the boiler, connecting existing installations and building brick around carrying.
protect from slipping .The boiler shoul not be carried with fragile materials and Legs ,building similiar services cant be made by qualified service company.
living creature.After setting the boiler on the vehicle ,boiler must be covered wth The height of boiler room must be 2 m higher than the boiler 's height.
canvas. There must be 1 m space between the boilers .There must be distance in front of the
The driver of the vehicle must avoid sudden movements that wll cause any boiler at least as much as itself lenght .There must be at least two doors facing each
danger. other .One of them must have ventilation to let to the boiler room.
C.) SETTING DOWN THE BOILER TO BOILER HOUSE These doors must be 2 m height and 0.6 m width.These doors must be divided
from other places.The boiler room must be ventilated.Pressure decrase can be max.
Boiler shouln't be settled n dwelling and working areas .It must be settled to 0.5 mbar in the boiler room.
a special room ,again crane must be used .You must take into consideration topic A There must be wall opening to the air and this wall must be as much as %10
If it is impossible to bring crane to the boiler room ,you can land the boiler to floor area of the boiler room.
appropriate place than it be carried by instruments rollers on. The boiler must be jacked up from at least two points of the boiler.
The legs must be welded as seen in fig.3 and legs are raised up 30-40 cm from surface
Air inlet door and ash discharge door which are given with the boiler to the customer
are settled under the front of boiler as seen in figure ,they are built with bricks and
7 8

briquette without letting any air leakage.Side section and backside of the boiler Concrete step must be done in appropriate dimensions to the place where landing
are being built with brick and briquette as seen the figure to make ash space. boiler and the boiler must be placed there.
The place where the furnace and reverse chamber is attached (fig 1) ,must be built A hole which the barrel of the burner can enter in ,is drilling on the door of coal
by fire bricks.It is height must be as much as explotion doors height. Appropriate parts of assemblying are done on the connecting flange of the burner.
If the boiler will be used with solid fuel or gas fuel ,concrete step must be boiler and the boiler must be placed there.
spilled as we make scotch type boiler to the place where the boiler wll land and
the boiler must be setted on this concrete step.A hole which the barrel of burner Burner must be fitted up by these parts.
can enter in ,is drilling on the door of coal inlet.Appropriate parts of assemblying
are done on the connecting flange of the burner. CHMNEY CONNECTION
CONNECTION OF SCOTCH TYPE OF STEAM BOILER Boiler must be connected chimney by connecting parts which have the same
dimensions of stack connection of the boiler.
The distance between chimney and the boiler must be less than 3m.If it is possible
If you have to use elbow ,you cant use more than two elbows .
Becareful about sharp turning because tar can be formed n the chimney by
by chimney fumes pipe.Too long chimney connection pipes in horizantal section
cause poor draft of chimney because of quick cooling .Chimney draft is very
is important for the burning quality .The diameter of chimney must be in appropriate
dimensions for your boiler.
ASSEMBLNG ACCESSORIES OF STEAM BOLER
All accessories must have the specifications and quantities as inidicated in norms and standards
Fig 4 : Connection of scotch type steam boiler
Fitting up steam boiler and chimney connecting must be done by qualified service.
Attaching safety and control nstruments connectings existed nstallition.
Similiar services are made by recommended company by qualified service.
The height of the boiler 2m higher than the boiler height.
1 m distance must be between boilers and at least 1 m distance from side wall
of the boiler There must be at least two doors facing each other .one of them
must have ventilation to let to the boiler room.
These doors must be 2 m height and 0.6 m width.These doors must be divided The failures caused by the accessories provided by the customer is not at our responsibility and
from other places.The boiler room must be ventilated.Pressure decrase can be max. guarantee conditions do not apply.
0.5 mbar in the boiler room. Fig. 5 : Accessories Of Steam Boiler
9 10

Page 11 Fig. 6 (This is only for sample, Akkaya A. keeps the rigth to make any changes)

Page 12 Fig. 7 (This is only for sample, Akkaya A. keeps the rigth to make any changes)
SIDE VIEW

Pressure Switch : It must be two quantities on the Water Level Indicators :
boiler .One of them is for limit pressure switch .It stops There are two pieces water level indicator in the boiler.
burner n case of alarm. It has three kinds with steel body and magnetic type.
Other one s pressure adjusment switch.If you use two
stages systems ,you must use three pressure switchs.
The most important point of choosing pressure switch is
that adjustment pressure of ts must be in the mddle of
working range.
It is perferred that differation musnt be more than %
10 working pressure. Vacuum Breaker :
It is used for preventing vacuum in the boiler.
Manometers : Cheeking manometers also must be two
quantities .It is used for pressure of boiler.Working
pressure in manometers must be approximately as much Safet
y
Valves : It can be with spring or weight.t must
as 3/4 equipment design pressure value. be used two quantities on the boiler.One of them can
be with spring other one can be with weight .
Automatic Water Feed E
q
uı
p
ment Of Boiler : Both of safety valves can be attached on the safety
When adjusted water level reduce n the boiler this connecting mouth of the boiler.
eqipments provides feeding water in the boilerby using materials can be steel or special casting.They must
feed pumps and it provides the same level on water. be dimensioned in that way when safety valves opened
It is the most important safety and control instruments no pressure increas in the boiler must occur.
on the boiler.It is in two type ,one of them is with float mechanism,other one has Safety valve must be opened to any safe place and
contact is preferred. out of the boiler by a pipe with bigger diameter.
In the boiler ,even you choose feed equipment with float mechanism,your limit Certainly there musn't be any valve around safety valves exit and inlet.
level control equipment must be equiped with liquid contact. Safety valve must be chosen to discharge the steam when boiler is at its maximum
capacity without increasing % 6 of maaximum working pressure.Safety valve must
adjusted to valve %10 higher than working pressure. All valves should be CE certificated
E
q
ui
p
ment Of The Boiler:
Water Level Electrode Of The Boiler: Main steam discharge pipe dimension should thi same
It is used for controlling water level (shown in fig.3) with the exit valve dimension of the boiler. There must
It is assembled. be check valve and a closing valve inlet of feed water
boiler.Surface blowdown is used for regulationg salt
concentration of boiler.
Blowdown valve is used for throwing away mud,sediments,dirts from boiler.
Blow down process can be done manually.
13 14

Control board and alarm s
y
stem
there must be an electricalcontrol board equiped with
feed water syst em of boiler ,safety system and protection
Party on alarm system of boiler,
1) Maximum pressure system and alarm
2)Minumum water level and alarm
3)Boiler must include furnace over heat safety adn alarm
NO
T
E: 1.Pre
p
arin
g
of installion de
p
ends on usin
g
steam of boiler.And ad
g
ustment
assemblin
g
of instruments of boiler must be done b
yq
ualifed service com
p
an
y
.
2. Do not char
g
e the ad
j
usmtments of e
q
ui
p
ments and do not allow
p
eo
p
le
unauthorized o
p
erase the boiler.
BOILER OPERATION
Boiler operators are responsible of interfering in any urgnt situation.
The most important point, operators must know the principles of all equipments,property
of working, pressure, temperature and flowrates must be known by the operator.
They must know all control circuit,measurement equipments function and
working at electrical protect circuit very well.
BOILER OPERATOR MUST HAVE A VALID LICENCE OR CERTIFICATE
Operating boiler without licensed or certificated operator makes the guarantee invalid.
There must be an boiler operating note book and it must be filled daily.
There is a sample daily control table (Table 4).
This table must be filled daily if the controls are not done periodically and this notebook
is not filled regularly guarantee is not valid.
GETTING STARTED WITH BOILER AND FIRST START UP
* All equipments of chimney draft system and burning equipments must be working
correctly ,all dompersmust be fixed both opening and closing easily.
* If there are automatical burning system or any other automatical controls,all
of adjustments tests,caliberations of this systems must be controlled.
Tests,adjusments and functions controls of electrical protection and locking system
must be done and all equipments of system must be existed in working condition
* All blowdowns,discharging valves,level indicator discharcing volves,feed
water manuel vaves and control valves must be checked and must let no leakage.
15 16
Tablo 4. :Örnek Buhar kazan günlük kontrol çizelgesi
Bu tablo çoaltlarak bir iletme defteri oluturulmal ve düzenli doldurularak muhafaza edilmelidir.
Tablodaki kontrol süreleri ve skl iletme artlarna göre revize edilmelidir.

Coal food door must be closed after burning boiler and it must keept close.
*
If there is an automatical controling of water level,all of adjusments,tests, During the first burning air inlet door and secondary air inlet on the coal feed door
caliberations and inspections of function of this control system must be done must be open
and it must be proved to work correctly. Air inlet door,secondary air inlet and airdamper must be adjisted by keeping up first
* Be sure whether water level indicators are working or not, little flame
* If steam boiler is out of service for a long time,before starting ,all inspectetions You must not completely close air dampers and doors that getting air enter and air
must be done and all lomeness must be eliminated. exit.
*Water must be filled in boiler in appropriate checimal condition. EN12953-10 Not to let flying particules in coal go to air and not to cause or pollution ,new coal
The boiler feed water composition must be as indicated in Table 5-1 & 5-2. must not add on to the burning coal.
Otherwise guarantee is not valid. When you want to feed coal in the boiler ,you must pour ashes with pioner tool
* The water given to the boiler musn't be cold .The temperature difference of water to ash room you shoud feed coal to toiler by putting new coals on the
and boilers metal sufface must not exceed 10C°. side grill .After that new coals must be ….. In touch the burning coals.So that can
* Water feed must be stopped after filling the boiler, check whether there is any fired to support enough air for burning in your boiler,extremely ash massing
blockage or not in the pipes and valves and boiler must be discharged by must be prevented
discharcing valve.
* If the boiler is not connected to main steam pipe by only one valve ,steam * Water level must be kept stable by making blowdowm from time to time
discharge valve must be controlled by opening and closing. This valve must not be Water level rise because of heating of the boiler water.
tigthened very much while supplying steam, considering enlargement and explosion of it. * After obtaining homogenuos heat inside the boiler, flame can be enlarged and the pressure.
* Main steam pressure indicator must be inspected and calibrated. of the boiler can be increased, the time for increasing the boiler pressure must be according to
Fuel and Air adjusment must be done with on exhaust gas analyser and it boilers capacity. Quick pressure rises must be avoided.
must be done by experts.In practically ,flame colour and exhaust gas colour are * Safety valve must be controlled
used to make adjusment of mixture of air and fuel. * Water level indicators,mantoles and inspection door,must be controlled
If the flame colour is light yellow and the exhaust gas is colourless it means occasionally and if there is leakage ,it must be eliminated.
of air is high. When leakages occur at high pressures and temperatures do never attemp to eliminate,
If there is not burning or flame length is short and exhaust gas colour is dark,quantity wait for the boiler to cool down than take out those parts from system.
at air is little .
It is preferred to have an orange coloured flame.Flame and exhaust gas must be BOILING
controlled continuasly. Boiler must be boiled with chemical cleaner and alkali detergent for cleaning the dirt,rust
* First Flame when you ignite the boiler firstly must be little according to the filth on the water surface of newly sotted boiler or repaired boiler because of contacting
equipments capacity. high pressure.
The most little flame, at least one hour,must be kept up by not making it bigger. You must get out water level indicator during boiling and you must put on temporary
* Kazannz kat yaktl olarak kullanyorsanz,yakacanz kömür, portakal glass because of preventing water level indicator from dirt after finishing boiling,you
Coal must be spread on coal grill from coal inlet door. must put on water level indicator in its place.
Pieces of wood and fire wood must be spread over the coal. Quantity and Kinds of materials used for boiling must be like this;
Burning should be proved by locating paper,oaku,resinous wood among pieces For pertone of boiler water
of wood. 2 kg sodium carbonate
Boiler must be ignited from side up.If you ignite from bottom side,both coal flying 2 kg trisodium phosphate
particules are discharced and causes air pollution b burning the same ratio while 1 kg sodium hdyroxide
consuming %20-30 more coal.
17 18

Page 19
Feed water for steam boilers Feed water for
warm water boilers
Unit
Parameter
Working pressure Total interval
A
ppearance
Direct conductivity @ 25 C
Total Ph
@
25 C - a
Total hardness (Ca+Mg)
Iron (Fe) concentration
Copper
(
Cu
)
concentration
Silisiumdioxide (SiO2)
concentration
Not indicated check Table 5.2
Not indicated check Table 5.2
Must be clean and not involve suspended materials
Ox
yg
en
(
O2
)
concentration
oil /
g
rease concentration
Feed water for steam boilers and warm water boilers
Check EN12953-10 EN version for detailed information

Page 20
Water for steam boilers and warm water boilers. (Water in the boiler
Parameter Unit
Working pressure Total interval
Water for
warm water
boilers
Water for steam boilers
Feed water direc
t
conductivity
Feed water direct
conductivity
A
ppearance clean, no direct foam
Direct conductivity @ 25 C
Total Ph
@
25 C - a
composite alkaline
Silisiumdioxide (SiO2)
concentration
phosphat
(
PO4
)

Page 21
Direct conductivity
Working Pressure
A
cceptable direct conductivity of the boiler water versus operating pressur
e
Feed water direct conductivity > 30 mS/cm
A
cceptable SiO2 content of the boiler water versus operating pressur
e
Highest alowable SiO2 content
Working Pressure

Durin
g
usin
g
this checimal materials,
p
ersonnel must wear rubber
g
loves OPERATING THE RUNNING BOILER
,rubber shoes,
g
lasses and uniform.
Water must be taken to the boiler until normal level. A ) FLAME
Chemical materials must be added in the boiler water after words the chemical
materials melts.Synthetic detergent without no foam must be mixed at sufficient It is not important that what kind of fuel is used, flame must be rather smooth
quantity to the these chemical materials. and stable.
The doors must be closed and it must be ignited with the smallest flame and
must be boiled after words the chemical materials and the detergent is added to B ) WATER LEVEL
the boiler. The boiler pressure must be increased to the pressure of the system
and during boiling it must be stable at the same level.After that water must be Water level must be stayed required level during the boiler is working.
taken untill normal levelby making blowdown as much as half of the water level Water level can be controlled automatically.
indicators.The sample must be taken from the boiler water and must be analysed However ,water level must be controlled by boiler operator because
frequintly until water become clean.The boiler must be discharced and must be washed automatical equipments can be broken.
by pressurized waer,dirths,sediments must be cleaned. Water level equipments at least must be cleaned per month in order to work
efficiently.Also level electrodes must be kept clean.
STARTING THE BOILE
R
* After the boiler produces steam,you must do blowdown by opening
blowdown valf at the back of the boiler. C ) FOAM
* Surface blowdown must be done by using surface blowdown .
* Some water must be discharged by valves under the level indicators. Water level must be reduced to normal level by discharcing steam when the
* Steam must be discharged by raising a little the handle of safety valves. foam formation happens until foom finishes,you must feed the boiler with water
and you must make blowdown.
* This process must be done at least twice a day and must be recorded If you couldn't prevent foam,you must stop the boiler and you must search
The blowdown quantity may vary according to boiler capacity. for the reasons.
* If there is an another boiler that gives steam to the steam system,while the D) FEED WATER OF THE BOILER
Boiler is joining in the circuit by reaching pressure of system,the steam in the boiler Feed water of the boiler must be revized by chemically.Water of the boiler
must be prevented to contact the steam in the circuit and all condensated pipes must be analysed contiounus to prevent unexpected chemical condition.
of the boiler. The temperature of feed water and outlet pressure of pump must be supplied
* If there is no other boiler that gives steam to the steam system,the system at required level.
must be heated external system prossure must be raised with the boiler pressure The pipes of feed water of the boiler and feed pumps must be controlled
* If there is an steam exit valve on the boiler this valve must be open slowly with continiously.
highest attention E) BLOWDOWN
* IF THE WATER LEVEL IS LOW BOILER MUST NOT BE OPERATED. Bottom blowdown must be done at least once in 8 hours operation (may vary according to
* IF THE BOILER OR ANY EQUIPMENT IS FROZEN DO NEVER FIRE OR RESTART conditions) by openinn the vlave for 4 sec.Blowdown must be done when the steam consumption
THE BOILER BEFORE HAVING THE AUTHORIZED ASSOCIATION MAKE THE is low. Blown down system must be checked periodically for leakages. Blowdowns must be
NECESSARY CHECK. NEVER MELT THE BOILER BY FIRING IT. BOILER CAN recorded
EXPLODE. Surface blowdown (TDS control) can be done by opening the valve contiously or can be
* IF THERE IS NOT SUFFICIENT WATER IN THE BOILER NEVER FEED THE done by calculation. Level indicators and controllers must be blowdown at least once a day
22 HOT BOILER WITH WATER. IF YOU DO SO BOILER WILL EXPLODE 23

SHUTTING OFF THE BOILER PRECAUTIONS
While discharcing the steam is reduced feed water must be reduced and
flame must be lowered. * Do not fire th boiler when it has insufficient water.
After the flame is extinquished,closing valve must be closed tightly. * Do not put your hands or your head in during the the boileris burning and don't
If the water level is normal,feed water pump must be stopped and feed go in it during the boiler is burning.
water inlet valve must be closed . * Do not close chimney damper fully.
If the water level is too much higher than the normal level.Water must be * Bad chimney draft is harmful for human health and also bad chimney draft reduce
discharged by blowdown afterwords the boiler must be cooled. the boiler effenciency.
You should awoid fast cooling to prevent temperature differentiation in * Chimneys must be clean ad well-kept for good burning.Before burning the boiler you
the boiler. should control the draft of chimney.
* Be careful at chimney and connectings of chimney's leakage.
DISCHARCING * Cleaning door on the chimney connection mst be closed during burning.
The pressure reducing is observed while the boiler is cooling. * The doors of fume box and chimney cleaning door should not be opened certainly.
The boiler can be discharged after water temperature becomes under 90° * Certainly do not open the doors of the boilers while the burner is on firing.
temperature and pressure finishes. * Before firing the burner,be careful of existing burning materials in the boiler and be
However,it is very dangerous to discharge the boiler when the boiler isn't careful about cleaning of furnace.
cool enough. * You must control the boiler during burning frequently.
Blowdown valves mus be closed tightly afterthe boiler discharges fully. * Do not cook any food in the boiler.
And warning signs must be attached on the boiler.Indicating to open the * Explosion door behind the boiler should able to be easly.Do not put anything in
blowdown valves. front of the door .Don't play with explasion door.
OPERATING RULES FOR EXTRAORDINARY CONDITIONS * Do not use fuel with high sulfur content and don't use materials in the boiler that
* Whatever the reason is,If the water level reduces under the water level that threates peoples's health.
indicators,the boiler must be stopped(If it's working with solid fuel,fuels must * If you use the boiler with solid fuel,don't fire the boiler with gasoline,ethyl
be discharged)and steam discharging must be closed. alcohol,spirit petrol,kerosene.And Don't put these materials around the boiler.
After words,the reasons caused to reduce water level,must be investigated. * Don't put explosive materials in the boiler
It is dangerous to give water to the hot boiler.You can feed water gradually *Don't burn cake coal in the boiler.
after the boiler is getting cold. * Discharge the coalfrom its bag and you feed the boiler with shave
1) Valves of burners must be closed,after the burner gets cold ignition electrade must Bags of coal are petroelum products so when it is burned,same harmful
be taken out. churns and tors can exist in your chimney.
2) The flame must be abserved if the burner does not stop the fuel valve must be * When you feed your boiler be carfeul about coal prill and be careful about
closed immediately. spread of coals and quantity of coal because of efficintly burning .
3) The valve of fuel must be closed if the flame doesn't form in very short time at the * After feeding the boiler with fuel,you must close the doors of the boiler.
first ignition. * Fuel must burn with enough oxygen for good burning.
You must ignite again after burner is ventilated. Don't feed excessive coal in to the boiler not to cause to prevent taking
enough oxygen.
Excessive feeding make coal grill have very short life.
* Please contact the qualified service company when you met extraordinary
condition.
24 25

ANNUAL CLEANING AND MAINTENANCE
Discharge the boiler completely.Open all the man holes.Clean inside of the boiler.
CLEANING AND MAINTENANCE You can wash it with pressured water.clean the limes in the boiler.Afterwords you may
wash the boiler.
DAILY CLEANING AND MAINTENANCE You should revise monthly mainfaneonce.All bearings should be lubricated.
Feed water pump and fuel pumps and should be revised.Man hales should be cosed and
* You should discharge air (vacuum)of the water level indicator. you should put new gasket.The boiler should be filled with water.
* You should control and clean water level controller of the boiler. You should clean the chimney at least once in a year.
* You should mak blowdown a few times in a day.
* You should control the UV flame indicator.
* You should control the quantity of water in deaerator and feed water storage
tank.
* You should control inlet pressusre and exit pressure by gas pressure
regulator in gas ignition systems. CLEANING AND MAINTENANCE
* All leaking flanges and connections in the water steam and fuel lines and on
the boiler should be tightened and lekages must be premesed. The perfect reference for the boiler worker is a clear and well-kept boiler room.
* You should control safety valve whether is opening easly or not. To supply high efficiency and to supply continuity depends on the boiler operator.
* In the boilers with solid fuels,you should discharged the ashes everyday. Expenses of cleaning and maintenance do not bring high costs.
If you clean as it is told the boiler will have very longlife,fuel economy and it will
MONTHLY CLEANING AND MAINTENANCE payback itself in a very short time.
All equipments that does not belongs to the boiler room must be removed from the
* You should control safety valve boiler room by person in charge.
* Water levelindicator switch and minumum water level switch must be conrolled at It is very important to use the boiler room without non relevent things.
least in a month by reducing water level to minumum level slowly. There should be clean water connectings and dirth water connectings in the boiler
* The boiler and all systems of the boiler,pipe connectings,flanges,pot-holder,leakages room.
of valves and other failures must be controlled very carefully.If there is a problem,you There shouldn't be any diffuculity for cleaning the boiler room wih water.
must note it. The boiler room must be one of the most beatiful place in the company.
* You sould clean all the filters CLEANING OUT OF THE BOILER
* You shoud clean the burner. As all other technological equipments,3pass wet back scoth type boilers
* You should tighten all flanges and connection and prevent leakages,if it is necessary, have to give very clean and good effect to people.
you can chargewith new. If the control equipments,bushing,flanges have no leakage there won't be
* Power switch and switch system must be controlled by an electric technicion. any water and steam lekage anywhere at the boiler.So there won't be any salt and
* Open the door of front fume box and clean fume pipes by brush 3-4 times in a month dirth in the boiler.
* Clean front and back boxes and chimney connecting line from soots. It is very important to squeezed all man holes and all flanges after two months
If you don't squeeze all man holes and all flanges otherwise it will be impossible
to avoid leakages.
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PROTECTION THE BOILERS
A) PROTECTING WATER SIDE OF THE BOILERFOR LONG PERIOD OF TIME
CLEANING OF THE GAS SIDE If the boiler won't be used for along time,you should make the following processes
to protect it from rust and corrosion;
Opening fumes box's doors and connectings of burner is supplied to Turnace;fumes pipes and fume gas side of miror plates must be cleaned at the
determineand solve dirties that are became over the boiler. boiler temperature approx 40°.
If soots layeris less than 0,5mm,you don't need to clean it. All surfaces of gas side of the boiler are cleaned with oil to prevet it to get in ouch
Soot or dirt layer must be cleaned wit special boiler pipe brush. with air.
Thick soot layer cause to drop eficieny of the boiler. The air must be dried by putting air drier chemicals in the boiler.
Hard layers can be seen on the weited heat surface by companents of soot
and sulfur in the boiler that is worked very often in cold condition. B) PROTECTING WATER SIDE OF THE BOILER FOR SHORT PERIOD OF TIME
These layers are dangerous for the boiler's materials.
It must be cleaned in a very short time.It is not enough to clean with normal During the boiler is out of service,the boiler have more rust and corrosion than
fume pipes' brush during the boiler is in service.
A special cleaning equipments with electricity motor and special,playing If there is water with a little alkali and water with pas in the boiler,rust and
heads are used for cleaning. corrosion emiloccur in the boiler.
Before closing front doors again,MOLYKOTE must be applied on bolt If you don't take enough precautious for the boiler,even you discharge all water
and nuts. from the boiler,corrosion will be seen.
The boiler with no water can be prevented from corrosion.
külfetle korozyona kar korumak mümkündür.
CLEANING WATER SIDE
THE BOILER OUT OF SERVICE FOR ONE DAY
Man holes must be used to determine sediments on the water side.
The lime layer which is nearly 1mm on the water side of the boiler,not only You must clase all the steam and the water valves on the boiler.
drops the efficiency but also causes excess heatng of materials . Before stopping the boiler,
Practisally,If you feed right feed water,to the boiler,lime formation on the You must mix high quantity sodium carbonate and sodium sulp hide to the boiler
heating surface will not occur. water for oxygen compound.
In this case,the boiler must be cleaned with pressured water,If there is still lime
in the boiler .You must clean with chemical cleaner. THE BOILER OUT OF SERVICE FOR ONE WEEK
Conderated water must always be controlled whiter it incluedes oil or not.You have
to be careful about oil existing on the heating surface of the boiler. The quantity of phosphate of the boiler water is raised by mixing 600 gr trisodium
phosphate per m³.
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Safety precautions are taken by also mixing 700 gr hydrazine and 150 or 250 Gaskets of the doors are tightened equally and gradually.
gr sodium sulfide to the boiler water to prevent rust and corrasions in the boiler. Be careful about gaskets quality and please use gaskets with graphic rubber,as
Safety valve is adjusted as 0,2 kg/cm² to discharge out the rest of the oxygen. best as should not be used.
And water is filled to the boiler until water pass over the safety valve. Dimensions of gaskets should be choosen according to the dimensions of holes.
After the boiler is cool,water s filled and chemical materials are added and all
valves are closed very tightly. FEED WATER AND THE BOILER WATER
The temperature of the boiler room must not be dropped undertie +4°to It is essential to eliminate risks at the water,stea lines and the boiler by working
prevent freezing. about feed water and boiler water.
The water of the boiler have to be discharged portly with blowdown in order These risks are as follow;
to operate the boiler again. The heating surface of the boiler calcified be cause of hardness of water
After the qoiler must be filled again with normal rfeed water until water level. It cause difficulties inheat transfer,drop efficiency,heat depasition,even at the end
Be careful;during operating the boiler again,quantity of Bo musn't be very high of this process;the boiler can be come scrap.
Oil and organic materials cause to stone heat by making thin layers on the heat
MAINTENANCE OF THE EMPTY BOILER surface of the boiler.
If you don't use the boiler very longtimeiyou should keep it free of water. The most dangerous thing is miing oil in the boiler feed water.
All water in the boiler is discharged when the boiler is at the low pressure Free oxygen and free carbon dioxide in the feed water and the boilerwater are
and hot by blowdown valve. weaken the materials of the boiler and make corrosion.
After you discharge the boiler,you open safety valve in order to discharge Mostly quantity of the boiler water activate evaporation is dry and calm in normally.
steam. It causes to pollute pipe system,requipments,turbine and it causes to squeeze the
All man holes are opened and controlled wheather inside of the boiler is dry equipments and make norrow cross-sections.
or not. If there are high quantity of organic components in the water,water foams and
If it is wet,you should dry inside the boiler. evaporation is getting intormation.
The pots have dimished lime and clorcalciu are putted in the boiler.You have
to charge these pots every three months. TAKING SAMPLE OF THE BOILER WATER AND ANALYSIS
To eliminate the rest of oxygen in the boiler ,a burning pot with oil-lamp and
fire wood is setted in the boiler. There is no standart water feed system,
After words,allman holes andvalves have to be closed. Pure water is used for generating steam,its properties change from company to
All holes,flanges,all valves must be very tight to have no leakage.And all of company.
them have to be controlled. The date of taking sample and quantity of sample must be corned.
It is enough to take sample only one time from places where water components
MAN HOLES MAINTENANCE change very fast.
The sample must be taken just after blowdown and the sample must be analized
The doors of the man holes are placed with no cavity. under the pressure by cooling
Before you place the gaskets,the gasket's sockets must be cleaned and the The sample pot must be clean.The sample pot must be shaken with the same
gaskets must be pull in the sockets. sample before putting sample in.
The space between gaskets and their sockets must be equally placed. You must close the opening of the sample pot.
You have to draw up a daily report about analysis and have to keep it.
30 31

At least 2 litres water must be caried in the clean pot or plass bottle.
THE FOLLOWING ANALYSIS ARE USEFUL FOR THE BOILER WATER
SERVICE :
a) Colour and appearonce j) Sulphate Akkaya Is Mak. ve Doalgaz San. ve Tic. A..
b) Smell k) P alkalinate
c) Nitrit l) M alkalinate 1.Organize San. Bölgesi Yerlisu Sok. No: 2 KONYA
d) Ammonia m) Free chlorine TEL : [phone]
e) Hardness n) Magnesium FAX : [phone]
f) pH o) Chlorine WEB : www.akkaya.com.tr
g) Sediment p) Ferro E-MAL : [email protected]
h) Conductivity q) Silica
i) Organic materials r) Calsium
CONTACT POINT
Pure water must be clear and purified from mechanical dirts. Akkaya Is Mak. ve Doalgaz San. ve Tic. A..
The total quantity of manganese should'nt pass over 0,05 mg/kg in the water.
And the total quantity of ferro sholudn't pass over 0,2 mg/kg in the water.We Yal Mh. Fevzi Çakmak Cd. No:25 Marmaradeniz Sit. E Blk No:4 Maltepe stanbul
need them to determine the supplying capasity of the water softener. TEL : [phone]
IT IS CUSTOMERS RESPONSIBILITY SO PROVIDE SUITABLE WATER FAX :[phone]
CONDITIONS. OTHERWISE OUR GUARANTEE IS NO LONGER VALID.
You can use filter and manganese saving equipmenta and ferro saving equipments.
Check EN 12953-10 for detailed information of boiler water.
You can be sure that the your boiler will have long life If you use the boiler with
rules in the user guide.
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ADRESSES