Booster NBO User manual

OPERATION MANUAL
BOILER FOR FUEL OIL
( NBO -TYPE )
BOOSTER Boiler Co., Ltd.

1
Thank you very much for purchasing Booster boiler.
The Booster boiler is a once through type steam boiler with highest thermal efficiency. Equipping various safety
devices, the BOO TER boiler is being used the most safely. This operation manual describes the operation method
and brief maintenance method. Before you start the operation, please read this manual carefully and always main
tain in the best operation condition.
Contents
C apter 1 General
1-1 Part Name and Function for the Boiler ------------------------- 4
(1) Part Name and Function for the Boiler Main Body ----------------- 4
(2) Part Name and Function for the Control Panel -------------------- 5
(3) Part Name and Function for the Burner ------------------------- 6
(4) Part Name and Function for the Concentration Blowing-off Assembly
and the Oil Pump ------------------------------------------ 7
1-2 Steam Generation System------------------------------------ 8
(1) From Water feeding to Steam Generation------------------------- 8
(2) Flow sheet - ---------------------------------------------- 9
C apter 2 Boiler Operation
2-1 Check Item before Operation--------------------------------- 10
2-2 Operation Start--------------------------------------------10
2-3 Operation Stop--------------------------------------------10
2-4 Cautions during Operation -----------------------------------10
2-5 Checking the Combustion Condition during Operation---------------11
2-6 Instruction for the Boiler When It is not Operated for a Long Time-----11

2
C apter 3 Manipulation of t e Auxiliary Equipment
3-1 Manipulation Method ---------------------------------------------------------------------------12
(1) etting Method for the Thermal Relay of the Magnetic witch(OCR) ------------ ------- 12
(2) Adjusting Method for the Pressure witch -------------------------------------------------- 13
(3) Air Extraction for the Feed Water Pump ---------------------------------------------------- 13
(4) Air Extraction Method for the Oil Heater --------------------------------------------------- 13
(5) Pressure Adjusting Method for the Oil Pump ----------------------------------------------- 13
(6) Wiring Method for the Feed Water Pump and the Oil Pump ------------------------------ - 14
(7) Capacity Adjusting Method (Damper Blade) -------------------------------------------------- 14
(8) Adjusting Method for the Water Level Control Equipment ------------------------------- 16
(9) Concentration Blowing-off Device ------------------------------------------------------------17
(10) Operation status for Combustion Control(Protect Relay) --------------------------------18
3-2 Brief Maintenance Check and Cleaning Method --------------------------------------------- 19
(1) Check for the oft Water ---------------------------------------------------------------------- 19
(2) Check for the Concentration Blowing-off Device ------------------------------- -----------20
(3) Check and Cleaning for the Oil trainer ----------------------------------------------------- 20
(4) Check and Cleaning for the Oil Heater trainer -------------------------------------------- 20
(5) Check and Cleaning for the Feed Water trainer and the Concentration
Blowing-off trainer ---------------------------------------------------------------------------- 21
(6) Check and Cleaning for the Water Level Electrode Bar ----------------------------------- 21
(7) Check and Cleaning for the Oil Pump -------------------------------------------------------- 21
(8) Check for the afety Valve --------------------------------------------------------------------- 22
(9) Check and Cleaning for the Burner ----------------------------------------------------------- 22
(10) Cleaning for the Returning Water Tank and Check for the Ball Tap --------------------- 24
(11) Cleaning for the Oil Tank ----------------------------------------------------------------------- 24
C apter 4 Safety Device
4
-1 uperheating Prevention for the Boiler Main Body ------------------------------------- 24
(1) Burner Operation uspension at the Low Level -------------------------------------------- 24
(2) uperheating Prevention witch -------------------------------------------------------------- 25
4-2 Freezing Prevention ------------------------------------------------------------------------------- 25

3
C apter 5 Boiler Water Treatment
5-1 Boiler Water Treatment ---------------------------------------------------------------------- 26
(1) Harm for the Boiler by Water ------------------------------------------------------------ --- 26
(2) cale Protection ----------------------------------------------------------------------------- -- 26
(3) Corrosion Protection -------------------------------------------------------------------------- 27
5-2 Instruction for Blowing-off of Water ------------------------------------------------------- 27
C apter 6 Maintenance for Boiler
6-1 Cause and Countermeasure for Trouble --------------------------------------------------- 29
6-2 Maintenance Checksheet --------------------------------------------------------------------- 30
6-2 After ervice ----------------------------------------------------------------------------------- 31
C apter 7 Reference Document
7-1 Piping Instruction for the Feed Water Pump ----------------------------------------------32
7-2 Piping Diagram for the Feed Water Pump ------------------------------------------------ 33
7-3 Piping Drawing for oftener -----------------------------------------------------------------34

4
C apter 1 General
1-1 Part Name and Function for Boiler
(1) Part Name and Function for t e Boiler Main Body
No.
Nomenclature Function
1 Automatic control panel Operates boiler, start and stop.
2 afety valve afety device which exhausts steam if the boiler main body
pressure is above 10Kg/cm2.
3 Burner Combustion equipment which sprays the fuel mechanically.
4 Main steam valve A valve used for steam supply.
5 team separator A equipment generating high dryness steam through
separating the steam and the moisture.
6 Pressure gauge A gauge which indicates the steam pressure in the boiler
7 Air Extraction Valve A valve extracting air and draining water when blowing-off.
8 Water level gauge A gauge which indicates water level in the boiler.
9 Motor for oil gear pump A motor which supplies fuel to the burner by pressurizing
fuel.
10
Ladder A structure to climb up to the top of the boiler.
11
Concentration blowing-
off solenoid
valve
A device which controls concentration of water by blowing
off automatically.
12
Blower A equipment which generates air for combustion and
forwards it to wind box.
13
Wind box A equipment which supplies air for combustion in the
furnace.

5
(2) Part Name and Function for t e Control Panel
No.
Nomenclature Function
1 Warning Buzz A alarm which buzzes when abnormal tube water condition.
2 Protect relay Controls combustion, and stops operation when emergency.
3 Initial chemical injection device A device which injects chemicals for corrosion protection
when initial operation.
4 Fuse Protects control system by cut-off when over current.
5 Magnetic switch for burner motor Controls the burner motor operation.
6 Terminal board for power Connects between wire on the control panel and the external
power.
7 Magnetic switch for feed water pump Controls operation of the feed water pump
8 Magnetic switch for oil pump Controls operation of the oil pump.
9 Circuit breaker hut off when over current and electrical leakage.
10
Terminal board Connects wiring in the control panel and external wire.
11
Water level controller Controls water level and integrates combustion time.
12
Flame detection transducer Transduce the signal of flame eye to electrical signal for
control

6
(3) Part Name and Function for t e Burner
No.
Nomenclature Function
1 Burner A equipment which sprays and burns fuel.
2 afety valve A safety device which open and exhausts steam automatically
at above 10 Kg/cm2 of the boiler main body pressure.
3 Ignition transformer A device which makes spark for ignition.
4 Blower motor Rotates the blower for supplying combustion air.
5 Blower body Impeller is included in it.
6 Damper motor A device which controls capacity automatically for complete
combustion.
7 Flame eye(flame detector) A device which detects ignition or flame failure, and have
stop operation.
8 Wind box A box which supplies air for combustion in the furnace.
9 olenoid valve A device which controls fuel supply depending on low fire
and high fire.
10
Upper terminal box A terminal board for power supply on upper side.

7
(4) Part Name and Function for t e Concentration Blowing-off and t e
Oil Pump
No.
Nomenclature Function
1 Concentration blowing-off valve It is used for replacing the solenoid valve for continuous blow
or cleaning the strainer.
2 Concentration blowing-off strainer
It is used for filtering the blowing-off water and sludge.
3 Oil heater strainer It is used for filtering the sludge in the heater.
4 Oil heater It is used for heating the fuel(for heavy oil).
5 Concentration blowing-off
solenoid valve
A solenoid valve which drains and shut off the blowing-off
water automatically.
6 Oil pump motor A motor which rotates the oil pump.
7 Oil pump coupling It connects the oil pump to the oil pump motor.
8 Oil pump A equipment which pressurizes and supplies fuel to the burner.
9 Oil strainer It is used for filtering foreign substance in the oil.
10
Oil pressure gauge It Indicates pressure of fuel coming out from the oil pump.
11
Oil air cock It is used for extracting air in the oil pump.

8
1-2 Steam Generation System
(1) From Water Feeding to Steam Generation
1) Water Feeding
Raw water at the pressure of 1.5 - 5 kg/cm2 is flowing to softener[2] for making soft water. The soft water is flowing
to the feed water tank[3]. The water level of the feed water tank is maintained constantly by the ball tap. When the
power switch “ON”, the feed water pump[6] is operated(the chemical injection pump[10] is also operated for
injecting the tube cleaning detergent) and the feeding water from the feed water tank is pressurized and forwarded to
the evaporating tube by the feed water pump[6] through the feed water strainer for filtration of foreign substance,
check valves[7], [8] in feed water line and lower header.
2) Oil Feeding
The oil which is removed the foreign substance through the oil strainer[29], [30], [53] is pressurized up to the
specified pressure(15 Kg/cm2 for light oil, 20 Kg/cm2) by the oil pump[32] ,and is sprayed through nozzle. When
using the “B” heavy oil or “C” heavy oil, the oil is sprayed after heating by the oil heater[31] due to its high viscosity
at the ambient temperature.
3) Ignition
The lighting bar makes spark by the raised voltage(from 220V to 10,000 - 13,000V: 10,000V for light oil, 13,000 for
heavy oil) from ignition transformer and ignites the flame on the sprayed oil from nozzle.
4) Steam Generation
The water in the tube is heated by the combustion of burner and evaporated on the evaporation surface. The saturated
steam including moisture is forwarded to the steam separator through upper header. This steam including moisture is
separated into steam and moisture by the steam separator[12] ,and the dry steam only is supplying for load through
the valve[14].

9
(2) Flow S eet
Light oil specification
NO NAME NO NAME
1 Boiler 35 2
nd
oil solenoid valve
2 oftner 36 1
st
oil solenoid valve
3 Feed water tank 37 Return solenoid valve
4 Feed water valve 38 Float switch
5 Feed water strainer 39 Oil temperature gauge
6 Feed water pump 40 Plug heater
7 wing check 41 Control box
8 Lift check 42 Feed oil valve
9 Feed chemical check 43 Feed oil valve
10 Feed chemical pump 44 Akastart(Burner temp. sensor)
11 Feed chemical tank 45 Circulation pump
12 team separator 46 Feed oil valve
13 Water level gauge 47 Feed oil valve
14 Main steam valve 48 By-pass valve
15 Air extraction valve 49 Oil water separator
16 Low pressure gauge 50 Blowing-off valve
17 High pressure gauge 51 Pressure gauge
18 team pressure gauge 52 Air extraction valve
19 afety valve 53 Oil strainer
20 Concentration blowing-off
valve 54 Oil nozzle
21 Concentration blowing-off
strainer 55 team control valve
22 Concentration blowing-off
valve 56 team strainer
23 Concentration blowing-off
solenoid valve 57 team solenoid valve
24 Blowing-off valve 58 team valve
25 ampling valve of the tube
water 59 team By-pass valve
26 Oil tank 60 team blowing-off valve
27 Feed oil valve 61 team trap
28 Oil tank blowing-off valve 62 Blower motor
29 Oil strainer 63 Feed oil valve
30 Oil strainer 64 Feed oil valve
31 Oil heater 65 Oil heater sensor
32 Oil pump 66 Diesel tank
33 Pressure gauge 67 Return pressure control valve
34 Oil temperature gauge 68 Pressurizing pump
Heavy oil specification