Manual de La Caldera

MACKENZIE
INDUSTRIES
SDN. BHD.
MACKENZIE
OPERATION &
MAINTENANCE MANUAL
27TONS/HR
31 BARG
PROJECT: WATER TUBE BOILER

27 TONS / 31 BARG
Manufactured by:
MACKENZIE INDUSTRIES SDN. BHD.
Lot 1930, Batu 7, Jalan Bukit Kemuning,
Seksyen 32, 40460 Shah Alarn,
Selangor Darul Ehsao, Malaysia.
END USER: EXTRACTORA CATATUMBO
MANUFACTURERNO: MB 12001
Tel: + 603-5123 0018

Fax: + 603-5123 0028
Website: www.mackenzieind.com
BOILER SERIAL NO: 212084
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MACKENZIE INDUSTRIES SDN. BHD.
(649756-K)
Lo1 1930. Batu 7. Jalan Bukit Kemuning, Seksyen 32. 40460 Shah AJam, Selangor O.E., Malaysia
Tel. : +603-5123 0018 Fax : +603-5123 0028 Email : oeneral@mackenzieind.com
Websire: www.mackenzieind.com
Ref. No.:
Date:
MISAOOl-27/12
I" December 2015
TECHNICAL SPECIFlCATION
1) BOILER PROPER
The boiler provded is a Mackenzie BD2700 series site erected bi-drum water tube type. le
consists of upper steam drum and lower mud drum. The drums are connected by boiler rubes
attached by propulsive expansin into the drums. Elliptical manway is provided ar the dished
end for access nro the drum intemal.
The integral combustion furnace is enclosed by closely ptched boiler tubes which serve as the
radiant heatng surface of the boiler. The boiler rubes consst of furnace roof rubes, furnace side
wall rubes and rear wall tubes. The roof and side wall tubes are joned by propulsive expansion
into rhe header pipes which are joined to the drums by riser rubes and clown comer pipes.
Sufcient hancl holes are provided on the header pipe for access to header intemal for
maintenance and cleanng.
The complete boiler is carried on a structural sreel frame. The whole boiler is provided wth
adequate nsularion and fully enclosed by mild steel skin casing.
The rube and riles constructon make ir easy for site nstallarion work and for furure tube
replacemenc if required. Mnimum site welding work on pressure part is requred ar site.
2) BOILER OPERA TION SYSTEM
The boiler operares on a balance draught desgn. Primary air or force draught suppled by the FD
fan is introduced to the sub-grate ancl blow through che fuel on top of the fue grate. At the same
time, over fred secondary ar by the SA fan is introduced into the fumace ro complete the
combuston process. The produce of combuston or flue gas is then drawn out from the boler by
the induced draught fan (ID fan).
Fuel feeding is ar the ftont of the boler. Specially desgned air swept feeder chutes where the fuel
drops nto it and blown nto che furnace by the air from the fuel feeder fan. The fuel spreading is
controlled by electric driven modulating damper which modulare the air acton to provide a front
ro rear spread of the chargng fuel. Where necessary, a pendulum type fuel distributor is utilized
to provide equal fuel drop into rhe feeder chutes.
Ash from the combuston process will drop clown and collect in the ash pit below the grate. The
ash can be disposed off from che ash doors located in front of the boler durng boler shut clown.
The supply of air and fuel nto the furnace is automatic conrrolled, It is mportanc to maintain a
close air-fuel ratio over che boler steaming range in arder to get a good combustin and avoid
black smoke ernsson. This is acheved by utlzng a pneumatic operated controller to operare
the dampers and modulare the amount of air and fuel supply simulraneously in response to steam
demand. Ir works as below.
A Memberof
Wah Seong Corporation Bhd
Ref. No.:
Dale:
MISA00!-27/12
1 ::>ece mber 2015
On falling boUer steam gressure

Falling stearn pressure signaled an increased sream load or steam surge. Tbe controller responds
to chis change in pressure by providng a signa! ro the air damper and fuel conc:rol damper to open
more. Ths wll let in more air and more fuel into che furnace, The air damper openng is in sceps
correspond to magnitude of the steam pressure change. In chis way, combustin rate is increased
to supply more heac to che boiler and hence increase che steamng load.
On rising boiler sream pressure
The reverse of che above occurs. The air damper and fuel control gate will auromatically modulare
clown and reduce che arnounr of ar and fuel far combusrion. In chis wav, the combustion rate is
auromatcally runed downed.
'
In order far che above automatic air and fuel control to functon properly, it is mportant that fuel
muse be made available ar all time and when needed, A recyc.ling fue! conveyor is necessary to
ensure fuel is available on demand ar all time. The fuel recycling conveyor is excluded in che offer.
3) FIRING EQUIPMENT
Reciprocacing Grate Stoker

The frng equipmenr conssrs of ar-cooled recprocarng grate sroker operated by a hydraulic
power pack le is an nclined step grate consists of alternare statonary and moving rows of grate
bar. The grate bar on the Front and middle secton is made of high crome stanless steel material.
The rear section will be of alloy case iron material.
Due ro che reciprccatng action of the grate bars, che fuel is agtated ar the same time migrare
clown che fuel bed from che Iront ro che rear of the fumace. Ash is contnuously discharged ar the
end of che bed va a scainless sreel water submerged ash conveyor. There is no requrement for
manual racking of che fuel bed and ash removaL
The recprocarng acton and che sectonal control of che burning process guarantees a good burn
out of che fuel even of che relanvely hgh rnosrure concenr materals. Envronrnentally harmful
ernssions from the srack are further reduced as che slag is burned out.
4) FABRICATION AND INSPECTION
The boiler is fabricated in accordance to boiler design and fabricaron code British Standard
BSlll3:1999 Edition. Drurns and headers are fusion welded. The main seams on che drums are fully
radiographed. Other destructve and non destructive teses are also carred out and in ful!
cornpliance to che requirernent of the boiler fabrication Code.
During fabricacion in the shop, the pressure pare fabrication process is inspected and cerrfed by
a 3"' Parry mspecrion cercification cornpany Uoyds which will also appraise the boiler design.
This is in addition ro che boiler desgn approval by the Deparrmenr of Occuparonal, Safecy and
Health of Malaysia.
A Member of '\t' Wah Seong Corporation Bhd
Ref. No.:
Date:
MISA001-27/l2
1 December 2015
5) BOILER PRESSURE PARTS MATERIAL

Boiler place for che drums, header pipes and boiler rubes are of high qualiry low carbon
manganese steel, Superheater rubes are of low alloy carbon steel Ali header pipes and boiler
tubes are of seamless type.
6) INSPECTION OPENING AND CASTING WORK

A complete set of baffle support castngs would be supplied together wirh access inspection and
clean out doors.
Three (3) sets - Furnace access and firing <loor.
Three (3) sets - Fumace sub-grate ash <loor.
Two (2) sets - Convecton chamber access door.
Three (3) sets - Fuel feeder chutes.
7) MOUNTir\GS
Ali necessary valves, fittings and controls necessary for the safe operation of che boler are
provided. The tems supplied shaJJ meet the requirement of che specifcaron as required by the
fabrcaron Code, DOSH and conform to bese engneerng practce.
Main steam stop check valve
Feed valve stop &: check valve
Safety relie valves
Make
YONEKI or equvalent
YONEKI or equivalent
ARI/LESER (GERMANY)
WIKA
Steam pressure gauges

Water Ievel gauges
Feed water regulator valve
Extra/low water level alarm
Hgh/low water level alarm
Boiler blowdown valve
Drain valves
BONT (ITAlY)
NHESJAMESBURY (FINL\ND)
MOBREY (UK)
CHINO CONTROUER (JAPAN)
GESTRA (GER\11A.NY)
V ARIMEX (KOREA)
8) BOILER FEED WATER REGULATOR

The feed water regulator comprises of a Neles Jamesbury control unt rogether wth rransmitter
and controller. The unir wll maintan a constant drum water level by regulating the amounc of
boiler feed water feed into che boiler in response to rsng or falling water Ievel in the steam drurn.
The controller makes use of che water level changes in the stearn drum to provde the signal to
the conrroller which in rurn operare the control valve,
A Member of 11)' Wah Seong Corporation Bhd
Ref. No.:
Date:
MISAOOI-27112
l December 2015
A by-pass isolating valve is provided n che pipng manifold to the control valve, This is for
ernergency feeding of water into the boiler when the control valve is out of action,
9) SOOT BLOWER SYSTEiYi
Five (5) sets of rotary rype soot blowing equpmenr are suppled. Ths equprnenc would ensure
adequate seor removal from the boiler tube heating surface to gve satisfactory boiler availabilry.
The soot blowers are of manual opera red type.
One (1) - Economiser &: airpreheater
Three (3) - boler Ban.k
10) FAN SYSTEM

The boler fans complete wth elecrric motor driver are as below. Ali fan shall be Phoenix , motor
shall be ELEKTRIY! I equvalent
Induced Draught
Force Draught
Secondary Ar
Fuel Feeding
(One unit)
(One unt)
(One unit)
(One unt)
Type
Cenrrfugal
Cenrrfugal
Cenrri.fugal
Cemri.fugal
Motor Type
Squirrel Caged
Squirrel caged
Squirrel caged
Squrrel caged
Capacity
CFM
64,000 X -13"@
200C
24,000 - 5.6"
@30C
6,900-16"
@30C
Fan Speed
RPM
889
1755
2392
2900
Motor Power
160kW
37kW
30kW
18.5 kW
MotorRPM
1,800
1,800
3,500
3,500
Fan
2,800-18"
@30C
11) ACCESS GALLERIES

Adequate access galleres and ladders are provided for easy access to controls, inspection and
mainrenance of the equipment installed. Access to each level is designed accordance with the
requiremems of sound practce.
A Member 0(1/ Wah Seong Corporation Bhd
MISAOO 1-27 /12

1December2015
Ref. No.:
Date:
12) FLUE GAS DUCT &: AIR DUCT

A complete set of mild steel boiler flue gas duct and air duct wrh necessary dampers are
provded, The dampers are either auto pneumatc operated for conrrols or manual damper for
isolaton. The flue gas duce is supplied with necessary thermal expansin jonrs.
13) STACK
One sel-supporting, stack is provided to disperse the combustin produces from the boiler
when burning che specfied fuel. Platform and test point complete with caged monkey ladder
and a lghmng arrestar sysrern are provided. An access openng is located ar rhe lower section
of rhe stack for clearing of accumulated ash.
Heghr
22.0m
Diameter at top
1.60 m
14) FEEDWATERPUMPS
The boiler is equipped wirh rwo nos. elecrrical operared boiler feed water pump. The pping
manifold is arranged in such a manner rhat it is possible to select any pump.
BOILER FEED WATER PU:V!P
STEA1\ll OPERA TED
ELECTRlC
OPER..\TED
Make
r:\IA
SlHI
Numoer off
Nil
Two
Type
NI .\
Horizontal rnulrsraze centrifuga}
Inler Water Ternperarure, max
't\/ ..\
105C
Purnp Inlet Size
N/A
80m.m
Pump Outlet Sze
N/A
50 mm !\13
Driver
N/A
Power
N/A
Elekrrim/Equivalent
brand motor
90kW
NB
15) THERMAL INSULA TION

All pipe works and vessels from whch che heat loss would affect the plant efficiency would be
supplied wth sufficient insulation material. The insulation material consists of mineral
rockwool sectons for pipes and slabs for other areas.
A Member o 17 Wah Seong Corporation Bhd
Ref. No.:
Date:
MISAOOl-27112
l December 2015
16) DUST ARRESTOR

A mulr-cyclone dust arrestar is provided to reduce particulate emission level in the flue gas. The
cenrrfuge effecr inside the collector eones causes the ash to drop clown into the hopper below,
The ash is then continuously discharged va an air rght rotary valve which also serves to
mantan a vacuum insde the hopper,
MULTl-CYLONE DUST ARRESTOR
Model
Qty
Material
Pressure Drop
Collectng Efficiency
: MC12
: 50 nos. x 300 mm 0
: White Cast lron Cene
: 50 mm W. G. ar 350 deg. C across arrestor

: The cyclone unit shall be capable of meeting the dust partcle
emssion level of 0.4gm/Nm3.
17) ELECTRICALPANEL
An elecrrical panel whch incorporares all the motor starters necessary for the operaron of the
rnorors supplied wth che boiler.

18) AIR COMPRESSOR
One (1) unit single stage air compressor, oil rype complete with motor drve, power 2.2 kW.
19) lNSPECTlON
An independenr agency Uoyds will carry out fabrcaron inspecron and provide certficaron
report on the manufacture and testing of the boiler. Uoyds wll also carry out the drawng
apprasal and is one of the 3'd Party inspection agencies recognzed by the Deparrrnenr of
Occupational, Safery and Health (DOSH) of Malaysia.
20) NON DESTRUCTIVETEST (NDT)
All .'-IDT are carried out in fu.ll compliance to che requrements of boiler fabricaon Code British
Standard lll3. Main weld seams on che drums are fully radiographed
21) SPECIAL TOOLS
One (1) set rube cleaner dw motor and flexible shat
One (1) set erecron rube expander
One (1) set manhole &: handhole Spanners
A Membcr of Y/' Wah Seong Coqxxation Bhd
MISAOOI-27/12
1 December 2015
Ref. No.:
Date:
22) INSTRUMENTATION
a)
Pressure Gauge I Transmirter ( WlKA - USA/ YOKOGA WA- JAPA. )

l.) - l x sream drum pressure gauge
2.) - l x boiler feed water dscharge pipe manifold pressure gauge
3.) -1 x steam pressure transrnitter
b)
Ternperarure Gauge ( 'vVIKA- USA)

l.) l x boiler outler Ilue gas tempera cure gauge
e)
Water LevelGauge /Transmrter ( BONT - rTALY I \10BREY - UK/ YOKOGAWA)

l.) l x water level gauge, reflex glass rype
2.) 1 x water leve! gauge, illurnnated rype
3.) l x water level rransrntrer for hgh/low water level alarm
4.) 1 x water leve! rransmitter for extra Iow leve! switch to cut off fan sysrem
5.) 1 x water leve! rransmrter to provide sgnal ro leve! controller
d)
Flow Transmirter / Flow meter (YOKOGAWA- JAPAN)

l.) l x steam flow rransmtter
e)
Flow control valve (, ELES ]A.\i1ESBURY - Fl. L\1'\iTI)

1.) l x boiler feed water .flow control val ve
f)
Combustion control ( YOKOGA WA - JAPAN)

l.) l x steam pressure ccnrroller for ar and fuel damper control
2.) 1 x fue! gate openng position concrols
23) AIR- PREHEATER

One (1) unit of cross .flow tubular air preheater, The unir will be located between mult cyclone &:
ID fan. Flue gas ducrng from multi cyclone to air pre-heater and from air pre-heater is ncluded
with 3mm mld steel ductng,
Tube Material: BS 1387 Class Medium

24) ECONOMISER
One (I) unir of economzer to increase feedwater temperarure and boiler efficiency. The unit
consst of horizontal bare rube arrangement dw inlet and outler header. One unir sream soot
blower unir will be provided,
Constructon
Material
: Hori::ontal multi-Ioop, self draining type.

: BS3059 Part l. G.320
A Member of ~
Wah Seong Ccepoearon Bbd
Ref. No.:
Date:
MISA00\-27112
1 December 2015
25) THERMAL DEARA TOR SYSTEM
1) Deaerator Booster Pumpset

Quanriry
: Two (2) nos
Make
Type
Capacry
Pressure
: Nowa or equvalenr
: Centrifugal end sucton
: 31 m3/hour each
: 3.5 bar
Motor
: 11kW/3500rpm,440V/3<p/60Hz.
C/w
: lsolation valve, strainer, pressure gauge and MS baseplate
2) Thermal Deaerator
: One (1) no
Model
: MTD-2700
Type
: Tray spray type
Capacity
: 27mi/h.r
Operatng condition
: 105C @ 0.35barg
Quantry
SPECIFTCA TIOK:
Deaerated water quantity
Mnmum water inlet temp
Outlet water ternperarure
Design pressure of vessel
Deaerator operatng pressure
Water quality
Steam consumpton
: 27mJ/hr
:60oC
: 105"C
: 3.5 kg/cm2
:0.35kg/cm2
: less than 0.05 mg/lit
: 2,500kg/hr
EQUIPMEI'l'T SUPPLY:
2.a)
Storage
a) 1 no.
b) l set
e) l set
d) l ser
e) l lot
f) l ser
2.b)
compamnent
- Vacuum breaker
- T ernperacure gauge
- Steam safery valve with lever
- Gauge glass tube and fitting to cover full water level
- Water and srearn pressure relief val ve
- CS Pressure Vessel (l,940mrn da x 3048mmSL)
Spraying compamnent
- SS pressure vessel
- SS Spring loaded spray nozzle
- SS tray
1 set
- Actuator pressure reducing station for steam at 3.5~0.35kg/crn2
(Incoming steam by clent)
1 set
- Inlet water modulating control by bali valve c/w pneumatic acruator
controller and positioner with DP transmitter
1 set
- Water safecy valve wch end cap
l ser
- High &: low range pressure gauges c/w isolation cork
1 ser
- H/Low level switch c/w audio alarm panel
g) 1 no.
h) l lot
i) l lot
j)
k)
l)
rn)
n)
A Member of
lt/' Wah Seong Corporarion
Bhd
Ref. No.:
Date:
MISAOOl-27112
l December 2015
3) Supporting Structure C/w Platform for the Thermal Deaerator

Quanrity
: One (1) set
Material
: Mild steel
Ht.
: 8,000mm
C/w
: Handrail, safery ring, platform and walkway
Loading
: Sta tic loading equally share by 4columns
4) Insulation Material For Thermal Deaerator
Quantry
: One (I) lot
Material
: 50 mm Rockwool c/w 0.7mm thk. alumnum cladding
5) Boiler Chemical Pump c/w motorized stirrer
Quantry
: Two (2) secs
Make
: LMI MILTON ROY
Model
: P 065 , 738 NI
Flowerate
: 7.61/hr
Head
Clw
: 3.8 bar
: LMI Mlton Roy Agrator, P/T\': 25290, 34~ SS316 Shaft &: Impeller, 230V
Tank
: PE tank, 200 liter
: Injeccion valve, foot valve, 5m long PE tubing
6) Inte:--connecting piping within the deaerator

Quanrry
: One (1) loe
Material
: GI (Water) and black pipe (Steam) inclusive of PRV downstream to vessel
7) Electrical control panel

Quantity
: One (1) set
26) To supply and commission a PLC-Syscem for a Biornass Boiler Control with che followng
item.l)PLC
Omron/Gf CSl PLC Hardware wth Hgh Resoluton T ouch Screen
Engneerng.Commisonng &: Training
Please refer to the Bill Of Material for detals
Field Control Svsrem
PLC Hardware Configuration
Descripton
PLC Power Supply Unit (DC24V, 50W)
CPU (lOK-steps Prograrn, 64K-words DM, 2 Rack Max) 10-Slots CPU Rack
Inner Board LCU Unit
Digital Input Module 32-poims
Digital Ourput Module l-ponts
A Member of ~
Wah Seong Corporanon Bhd
Ref. No.:
MISAOOl-27/12
1 December 2015
Dac.e:
Analogue Input Module 8-poims

Analogue Ourput Module 8-points
I/O Connecting Cable
Terminal Block Far 32-Points Digital Input Unit
Omron 10' High Resolution Touch Screen
Required and supplied I/O ponts wch above PlC confguraron are as Iollows:
Requrernent
+ 10%
Su I
DI
50
55
64
DO
31
34
64
Al
18
20
24
AO
6
7
8
2) f:IM[ Station
1
j)
Operator Server
HP MU10G6 SER VER
Intel X34 30 (2.4GHz SMB) PROCESSOR
2x500GBSATAHDD
4GB UDIMM AP SVR
HP PS/2 MOUSE &: KEYBOARD
MS WS08 FOUNDATION SRV R2 ROK ENG SW
GV-R5570C-1GD PCI-E-GRAPHIC CARD
SAMSUNG 2T LED MONITOR
HP COLOR L<\SERJET CP1025. l6PPM Black, 4PPM Color, SMB R.ANI 2MB Flash,
600 x 600 DPI wth imageret 2400: 150 Sheet input Tray connectviry l H-Speed CSB
2.0
APC SMART-UPS TOWER 1500VA USB &: SERLA.L 230V
Omron/GE Ethernet Module with lOOMbos
3
a)
SCADA Software
CIMPUCITY with 1500 Tags full Server License Software
4
a)
b)
SCADA Sofrware Developmenc

SCADA Program Development as per inicial requesr/desgn
SCADA software confguraron and graphic screen design as per initial request
5
a)
Trainings
SCADA Operaron Training To Enduser
a)
b)
e)
d)
e)
f)
g)
h)
i)
A Member of 17' Wah Seong Corporation Bhd
10
Ref. No.:
MISAOOl-27112
Dale:
1 December 2015
27) Elecrrostatic Precipitaror

Technical Specilication of Electrostatic Precipitator
Ar Control Engineerng Pvt.
Name of Vendor
Ltd.
1.1 Date Techncal Data Requirements Compleced

2 Item Identfcaton
ll
2.1.l
2.1.2
2.1.3
2.lA
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.1.10
2.111
2.112
2.1.13
2.1.14
2.1.15
2.1.16
2.1
2.2.l
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
Dc:sign Paramaas
64000
5
200
rmi./NM1
e
e
T ernperarure
Srrucrural Desgn Temperarure
Pressure Drop
Casing Design Pressure
Migraron Velociry
Face Velociry
Aspect Ratio
Specilic Colleccing Area
Retenrion Time
Efficency
Hopper Valley Angle ( approx)
HopperType
Hopper Design Dust Depth
T ype of Rapper
H- 3-13-45-80-400
cfrn
Gas Flow Race at 199c

In ler dust concentraton
(-) 20
mmWg
mmWg
cnvs
4.95
0.73
M/s
1.29
92.97
18.49
N61vl'/s
99.0%
Deg
60
Pyramidal
100
%
Tumbling Hammer
~uanriries
One set
' fidd
No of fields.
Nos.
T/R Lnits
Sets
Hopper Outlets
Inlet Baffles/Nozzle
400 mm x 400 mm
Collecting Places
2.2.8
Dscharge Elecrrodes
3
3
Provided
Outlet Baffles/Nozzle
Rappers
2.2.7
2.2.9
2.2.10
2.2.11
2.2.12
27-05-2011
Provided
Provided
Cold rolled mild steel as per
IS: 513
Cold rolled mild steel as per
IS: 513 on whch SS barbs
made of AISI-304 are welded.
Perforated Places
Fields Height
Elect:ical Sections Wide
Inlet Perforated Places

\i[
M
Nos.
Insulator Compartments
A Member of ~
8.0
3 X 4.5
3X3
Wah Seong Corporalioo Bhd
11
Ref. No.:
Date:
23
2.3.l
2.3.2
2.3.3
2.3.4
MISAOOl-27/12
1 December 2015
Maurials of Construction
Casing
Collecting Places
Dscharge Electrodes
Siding Bearing
2.3.5 Recommended Casing Insulaton

2..J Material Thicunessc:
2.4.1 Inlet Nozzles
2.4.2 Outlet Nozzles
2.4.3 Casing Walls
2.4.4 Hoppers
2.4.5 Collectng Plates
2.4.6 Casing Roof
2.4.7
r
_.J
2.6
mm
mm
mm
mm
mm
Discharge Elecrrodes
mm
T/R Units (Each) 110 KV (P)I Output Current

Conrrols
mA
2.8.l
2.8.2
2.8.3
2.8.4
2.8.5
2.8.6
2.8.7
2.8.8
2.8.9
Type of Voltage Control

Manual and Auto Control Provided (Yes/No)
Variation Lmits on Voltage and Frequency
Control Panel Enclosure Rating
Rapper Controls
Outla Dusr Concentration (Dry)
Dimensions
Overall Arrangement Drawing
Access Doors
Hopper Discharge
Collecting Plate Heght
Collecting Plate Width
Plate to Piare Spacing
Nurnber of Gas Passages
Tora: Collecting elecrrode Area
Dscharge Electrode Length ( each)
2.8.10
Recomrnended Insulation Type
2.7
2.8
50 mm thk. LRB (120 Kg/M3)

&: 24 SWG Al Cladcling
mm
2.6.1 Type ofT/R Unts

2.6.2
2.6.3
2.6.4
2.6..3
2.6.6
IS: 2062 Gr. A

IS: 513 Gr. DD
AISI- 304 &: IS: 513
Mono &: Bi-axial Bearing
5
5
5
5
1.25
5
l.6 chk body
with O. 7 Barb
600
Double wound ol immersed

rransformer with silicon
rectifier ( full wave )
Yes
440 V 10% 60 Hz 6%
IP - 52
Microprocessor based
mg!Nm3
50
Attached
800 mm x 620 mm
400 mm x 400 mm
mm
8000
mm
4500
mm
400
3X18
M2
2808
mm
8655
50 mm thk. LRB (100 Kg/M3)
& 24 SWG Al Claddng
A Member of W Wah Seong Corporation Bhd
12
Ref. No.:
Date:
MISAOOL-27/12
l )ecember 2015
DESCRRIPTION OF ESP ITEMS:

ESPCASING
Casing is of Iabricared panels made of Smm Mild. Steel plate, angle, channel and jost (as per IS 226/IS - 2062). Casing is made of welded consrructon consisting of wall, roof. Etc. lnspection
doors on casing are provded for mainrenance and access. Bottom pan of casing is desgned wrh
pyramidal hopper made of5mm Mld Sreel (as per IS 226/IS-1026) and of welded consrrucron.
Hoppers are provided with langed oudet connecrion of 300mmx300 mm size. In arder to avod
distortion due to thermal expansion in casing, bearings are provided berween casing and
supportng srructure.
SUPPORTTNGSTRUCTURE,PLATFORM, WALKWAYS&STAJRS
SET OF STEEL SUPPORT!t G STRUCTCRE IS PROVIDED FOR PRECIPITATOR, Steel work
includes column, base plate, bearns, grder, bearing, foundation boles, etc. The equpment is
provided with requisite platform, walkways, stairs and hand rails to provide access for operation
and maintenance of Elecrrostarc Precpitator and its pares. The gap between hopper outlet flange
and the grcund leve! considered as 2.0m.
INLET AND OUTLET FUNNEL
Complete inlet and outlet funnels of precptacor are provded with rransition boxes made of 4
mm Mild Steel places and of welded construction supported from casing and to be connected
with gas duce as requred.
GAS DISTRIBUTIONARRANGE.MENT
Gas dstrburon arrangement consists of one number screen at ESP inlet to ensure ideal
distribution of gas over cross-secton of ESP. Necessary rapping arrangement of flail harnmer type
is provided to clean rhe screen,
COLLECTTNGELECTRODE{STRIP PLA TE TYPE)
Collectng elecrrode places are of specal design, suitably srffened, Iabrcared from cold rolled
Mild Steel sheet complete wth mounrng position to rake hammer rapping anvils. Collecting
electrodes are of strip rype configuration. Plates are suspended by their top comers from roof
bcams fitted with the main srructure ar roof level, rraversng full width of casing.
E\1lTTING ELECTRODE
Emitting elecrrodes are fabrcated from Mild Steel to provde a rigid vertical member and on
which staicless sreel shaped barbs are welded, The resultanr elecrrodes provde robust, rgd
assembly whch is virrually unbreakable, resistant to erosion and corrosion and has high emission
characterstcs under all concenrraton of dust in gases. Emttng electrodes are suspended
berween Mild Steel angle and channel grids to ensure a high degree of algnrnent wth collectng
A Member of ~
Wah Seoog Corporatioo Bhd
13
Ref. No.:
Date:
MISAOOl-27/12
l December 2015
electrodes. Top grids are, in turn, suspended from high voltage insulators mounted outsde gas
srream on roof of precpirator.
RAPPING
Collecting Elecrrode rappng conssts of rumbling hammer desgned to rap each place in che
plane. Rappng is done ar bottom to achieve the rnost efficient dust removal. Hammers are fitted
to sha.fts which extend che full wdth of casting, adjacent to the places, as the shafts rotare,
hammers are untl they over balance and swing downward to strike a rappng pad ftred to che
edge of che places. This rapping system is very flexible as the frequency between rappng cycles
would be regulated by a mcroprocessor based sequenrial tmer capable of adjusrrnent to give any
normal time nrerval to suit each stage of precptator, Intensiry of rappng would be regulared by
controlling che number of time of a place is struck by a hammer during each rapping cycle with
chis rype of rappng. Collected dusrs are effectvely sheared from che place surface and chus
remain close to the places while falling toward the dust storage hoppers. This fearure limits reenrertanmenc ensurng high collecting efcency is mantained.
Emttng Elecrrode rappng gear conssts generally of cam operated lft &: drop hammers, located
on shafrs carried by electrode support grids. These shafts are rotated by a cam mechansm /
Electrode and then suddenly released. Hammerheads are chus lfted and chen allowed to fall to
strike rapping joists bolted to the electrode grds. The mechansm would be driven from a geared
motor unir and controlled by rmer providing the same facilities as those for che collectng
electrode rappng in addition to the force of harruner blow may be varied by adjusting lft of the
hammers.
ROTARYAIR LOCK WITH DRIVE

At the Out let of each Hopper Rotary Air Lock wll be provided whch will be drven by Geared
Motor.
HIGH VOLTA GEINSULATOR

Hgh Voltage Insulators made of porcelain are used to support Emtting electrodes and grids,
situated on roof of precptacor casing and are placed in housings.
BUSDUCT
HV Bus duce connecton from T/R sets to Erntting system.
INSULATOR HEATER
To prevem moisrure condensation on nsulators, l K'vV 440 V, 2 wred nsulator heaters are used
for heatng each hgh voltage support insulator. Heaters will encrcle perphery of insulator ar che
bottom, Heaters will be co9ncrolled indvidually by thermostat of suitable range.
A Member of "f1 Wah Seong Ccrporation Bhd
14
Ref. No.:
Date:
MISAOOl-27112
1 December 2015
HOPPERHEATERS
Therrnosracically controlled Hopper heaters are provided at a level of lOOOmm from bottom of
each ESP hopper ro elirnnate stickness of dust insde hopper sides enabling free fl.ow of dust
through clischarge point. For each hopper, heaters are provded rated at llOV AC., 2K\N single
phase.
RAPPINGGEARED MOTOR
Horizontal foot rnounred rype geared motors are provded for rapping system of collecting
electrode, dscharge elecrrode and gas disrributon arrangement at ESP inlet, The offered rnorors
will be suitable for 415 V, 50 Hz, 3 Phase AC supply and are designed for arnbient ternperature of
50''C.
EARTHING
/DISCONNECT!NG
SWITCH
Manually operared earth swtch/dsconnectng switch will be provided w facilitare feld
earthlng. The pertinent system is properly desgned for ensurng complete discharge of che feld
which is also equipped wth sutable nsulators for human proteccion.
SAFETYINTERLOCK
Snce electroscatc precpraror (ESP) works on high voltage electrical feld, necessary safery
precaurons are to be provided during operarion of the equiprnent. For this purpose, whole of the
electrcal equpment and precptator will be nterlocked both rnechancally and electrcally
making it possible to enter nto any charged porron of SP unit whch pare has been shut clown
and safery earthed. Inspection doors are fitted wth safery nterlockng arrangernent. The locks
are of special rype, i.e. when che door is open, key will be trapped in the lock and after closing che
<loor and locking it, key will be released.
T/R SET WITH CONTROL PANEL

Each rranslormer recrer set is a robust weatherproof unir consrructed from sheet steel. Ol
filled and natural convecton ONAN cooled. It is designed to comply with IP-55 protecton. The
T/R set control panel is constructed from sheer metal, Iloor rnounted, vertical and freestanding
with IP -52 class of prorecron. The microprocessor based autornatic voltage controller is used in
che TR control panel whch will also coordinare che rapping system as well as rappng
sequencing. Each T/R control panel shall equpped with primary AC Voltmeter/Ammeter,
Precipitator DC Volrmerer/Arnmerer, Mains / HT on lndication etc. The Transformer Recnher
shall equpped with silica gel breather, Marshalling box, Conservator, Ol leve! gauge, HV
bushng, Thermomerer, HV OC voltage / Current feedback assembly etc.
LEVEL INDICATOR
High leve! switch for each Hopper will provded.
A Mernber of 'fj
15
Ref. No.:
Date:
MISAOOl-27112
1 :::)ecember 2015
ESPAUXILIARY CONTROL PANEL

LT DB Curn Auxiliary Control panel shall be non-draw out, vertical free standing,
compartmentalzed pattern havng feeders for rapping geared moors, insulator heater, hopper
heaters, T / R sets. The feeder shall be equipped with SFU, contacrors, therrnal overload relays
etc. for control of motors. The heater feeders shall have SFU units. The control panel will be
rnade of 2mm thck CRCA steel sheet
NOTE:
The specification artached with ths sales agreernent are centarve only. 'Ne reserve the rghr to
vary che desgn or consrructon, provided it <loes nor impair the efficiency and ourpur of the unit.
A Member of
l!J
16
Ref. No.:
Date:
MISAOOI-27/12
1 December 2015
BOILER TECHNICAL DATA
TYPE
DR.AUGHT SYSTE\il
Balance draught
WORKING PRESSURE
31 bar(G)
DESIGN PRESSURE
34.5 bar(G)
STEAM TEMPERA TURE
320 +/- lOoC Superheared Steam
STEAMING CAPACITY
27,000 kg/h.r MCR from feed water at l05C
STEAM DRUlv[ DIAMETER
l370mm
MUD DRUM DIAMETER
915mm
405 mm x 305 mm ellptical man way on both ends of
DRUM ACCESS OPEJ'\ING

DRUM CENTER DlSTANCE
drum
-
TUBE SIZE & 'vtA TERIAL:

- Benteler / Germany
6500mm
50.8
Convection secton
- Sumitorno / Japan
Radiant sectior.
Bl-Drum waterrube bottorn supporred. Natural
crcularon type.
mm O.D. x 3.25 mm thck
BS 3059 Pare l Gr.320, Seamless cype carbon steel

-
76.2 mm O.O. x 3.6 mm thick

BS 3059 Part 2 Gr. 360, Seamless type carbon steel
HEADER SIZHst NlATERL'li:
200 mm NB x sch 140, 300 mm NB x sch 120

AST\i[ A106 Grade B / SA 106 B carbon sreel
HEATING SURFACE
Total
- 907 m2
Convecton - 694 m2
Radiant
- 213 m2
Expected Boiler Efficency
82% Net CV base on 30% shell & 70% fber
A Mernber ofl!/
17
Ref. No.:
Date:
MISAOOl-27/12
1 December 2015
RECOMMENDED
BOILER WATER CONDITION AT BOILER DRUM
pH Value (ar 25 degree C)
10-11
Caustc Alkalinity (Ca Co3)
150 - 350 ppm
Total Dissolved Solids
1500 - 2000 ppm
Chloride ( NaCl)
Below 250 ppm
Sulphte ( Ka2 So3)
50-150ppm
Silica (Si 02)
Below 75 -120 pprn (or 0.4 x caustic alkalniry)
Phosphate ( P04)
30-?0ppm
Hardness as Ca Co3
Nil
A Member of W Wah Seong Corporation Bhd
18
Ref. No.:
Date:
MISAOOl-27/12
l December 2015
EXHIBIT A
SCOPE OFTHE INSPECTION THAT HAS TO BE DONE ON BEHALF OF PMT
April 2012
The following are che specifications about the scope of the inspection that must be done by SOS on the Boiler,
ESP that are going ro be purchased from MACKENZIE in Malaysia and India.
a.
Jointly with MACKENZIE staffs and also the Indian manufacturer of the ESP:
./ Revisin of the planning documents for che production of ali che equipment .
./ Check ali che acrivities of the manufacturing process.
MI reply: We will serve one ( !) week advance notice to SOS for any pre-agreed inspection. Should there
is delay by SOS. we will proceed with the activiries with our interna! QC or/and 3r<1 party inspector: where
applicable as per our lTP; withour waiting for SOS. Refer attached pressure pares ITP, the only hold point
is hydrostatic test. Other activiry customer is welcome to review but is nota hold point pending customer
approval.
./ Identification of the jobs that make pare of the critica! path of the production.
MI reply : We will generare a project schedule similar to the attached cypical progress mouitoring .
./ Identification of production milestones that will be useful for following up the manufacturing process.
MI reply : Same as Point 3 above .
../ These documents will be checked and approved by SGS. MACKENZIE. PMT - SHINKO and
ACEITES Y GRASAS DEL CATATUMBO.
MI reply : Production schedule will be checked and approved by SGS and the buyer.
b.
SGS inspection schedule will be as follows:

1.
2.
Boiler
ESP
1 st inspection will be carried out on the 2d month of production

2nd inspection will be carried out on the 4th month of production
3'd,4th and 51h inspection will be carried out every month until completion of
production.
Monthly inspection will be carried out every month until completion of production,
estimated will be tour (4) months.
c.
Verification and certification of the shipment date and the accomplishment of the certification process
offered by MACKENZIE, as well as delivery of ali the documents that confirm che correct application of
the offered manufacturing standards cedes.
d.
Periodical information to ACEITES Y GRASAS DEL CATATUMBO about the progress

of purchase, production and assembly of the machinery,
MI reply :Same as tem B.
A Member of
W'
Wah Seong Corporauon Bhd
19
Ref. No.:
Dale:
MISAOO 1-2711 2
l December 2015
e.
Informat:on in advance to ACEITES Y GRASAS DEL CATATUMBO about che shpment date in
order to prepare everything ro avoid delays.
MI reply : Mackenzie will provide nformaton one(l) month in advance to PMT about rhe
shpment date in order to prepare everythng to avod delays.
f.
ITP is applicable for pressure pan only. Other items; i.e. non pressure part, strucrure, etc. will be
done in accordance to our in-house manufacturing standard practce.
g.
SGS: inspecrions will be conrracted, coordnated and pad by Buyer.
A Member of V Wah Seong Corporation Bhd
20
Ref. No.:
Date:
MISAOOl-27/12
l December 20 15
EXHIBITB
Warrantes with Respect to the Boler
Mackenze warrants !he integrity of the boiler parts against detective material and workmanship
in manufacture and construction
tor a period of twelve {12) month alter the Date of
Commissioning.
In case that commissioning
cannot be achieved on !he expected date due to causes not
attributable to Seller then warranties will be expired eighteen (18) months after Ex-Works
delivery.
The
the
and
any
warranty shall be subject to proper Boiler operation and maintaining a proper water quality in
Boiler in accordance to recommended operating procedures as mentioned in the operation
maintenance manual referred to in Annex l. lt does not cover any normal wear and tear of
of the Equiprnent nor does it cover any malfunction due to misuse of the Equipment.
Should the Equipment

established by SGS.
or material be found detective
or fail prematurely,
the cause shall be
PMT shall notify Mackenzie the failure of the Equipment by written notce. Withn 30 calendar
days following the receipt of PMT's written notice, Mackenzie shall supply the required
replacement materials and parts to make good and functioning the Facility.
Mackenze's oblgaron is lmted only to che supply of replacement material and necessary labor
to replace or make good and functonng rhe defectve parrs. lf Mackenzie <loes not supply the
Equpment and material requred to repar the Faciliry in rime, Mackenze will pay PMT 0.25%
of che arder value for every entire week of delay to a maxmum of 2.3% of the arder value.
l.
Operaton Warranties
Mackenze guaranrees che Iollowng with respect to che Boiler, provded (i) the inlec utilites
(feed water, electriciry, biomass fuel) are supplied accordng to the specfcaron, in suffcent
quanrtes and qualtes: () the erecton has been done according tO Mackenze's
recornrnendaron, and (iii) the unir is operated and mantaned by skilled scaff followng
Mackenze's instrucrions: instruct:ions as mentoned in che operarion and maintenance manual
attached hereto as Annex I:
a.
b.
c.
Steam boiler evaporarion capacty:

Sream boiler working pressure:
Steam remperacure:
27,000 kg/h considerng feed water l05C
31 bar (g)
Superheared ar 320C /- IOC
The figures wll be subject to a test run, under Mackenze's supervson, whch must be
performed wthn less than one (1) month after the Iirst srarrup. The test run will last 24 hours
consecurively.
If che performance test is consdered to have been successfully carried out, che acceptance
certificare wi.ll be immed:iarely ssued. The operation warrantes shall be deemed fully d:ischarged
followng che issuance of che acceptance certfcate,
A Member of 'l/' Wah Seong Corporarion Bhd
21
Ref. No.:
Dace:
MISAOOl-27/12
l December 2015
lf che test cannot be achieved wthn one (1) month from the first starrup date for reasons not
atrributable to Mackenze, che unir will be deemed to have been accepted and the acceptance
certificare will be mmedately issued and signed by both parties.
In case of unsuccessful test run, Mackenze may ask, wthn two (2) weeks, for a second test run
to be performed wthin one (1) month after che frsc test run,
In case of unsuccessful results from chis second test run, che penalties will apply, as follows:
a.
Penalty of 0.3% per every 200 kgs per hour drop in stearn capacity wth maximum of
2.3% of che order prce;
b.
Penalty of 0.3% per every bar pressure drop in steam capacity with rnaxmum of 2.3%
of che order prce;
,.,........,_.
c.
d.
2.
Penalry of 0.5% per every 2oc sream remperature drop wth rnaximurn of 2.5% of the
order prce;
The maxmum accumulated penalty for che three cases mentoned above will nor
exceed 2.3% of the order price.
Mechanical Warrantes
Mackenzie warrants che ntegriry of the Boiler pares against defectve material and
workmanship in manufacture and construction for a period of rwelve (12) months after
comrnissioning of the Boler,
In case that comrnissioning cannot be acheved on che expected date due to causes nor
attributable to Seller rhen warranries will be expired eghteen (18) months after Ex-Works
delvery.
Mackenze wll replace the damaged part wrhin warranty time period
wear and tear or any rnalfuncron due ro misuse of che equipment.
if failure is not due ro
The warranty shall be subject to proper Boiler operation and maintaining a proper water quality
in the Boiler in accordance to recommended operating procedures as mentioned in the
operation and maintenance manual referred to in Annex l. Should the Equipment or material be
found detective or fail prematurely, the cause shall be established by SGS.
PMT shall notify Mackenzie the failure
ot the Equipment by written notice. Within 30 calendar
days foll::>wing the receipt of PMT's written notice, Mackenzie shall supply the required
replacement materials and parts to make good and functioning the Facility.
Mackenze's obligation is lmted only to the supply of replacernent material and necessary
labor to replace or rnake good and functianing the defecnve parts. lf Mackenzie does not
supply the Equipment and material required to repair che Faciliry in time, Mackenzie will pay
PMT 0.25% of the arder value for every encite week of delay to a maxmum of 2.3% of che arder
value.
A Member of
1i/
Wah Seong Corporaticn Bhd
22
Ref. No.:
Date:
3.
MISAOOl-27112
1 December 2015
Delay in Delivery
Based on a delivery time of Seven (7) months ex-work, Mackenzie will pay 0.1% of the order
value as .quidated damages, for every entire week of delay after the contractual delivery date
far srartup. The frsr rwo weeks of delay \Ni..1.1 nor be subject to lqudated damages, as this wi..1.1
be considered grace period. Liquidated damages for delay will be Irnited to a maximum of 2.5%
of the arder value.
The overall lqudated damages and penalty of the operation warrantes shall not be exceedng
2.5% of the order value.
4.
ESP PERFORMANCE
Mackenzie guarantees che correct performance of ESP. Therefore, should the performance of
ESP be defecrve, PMT shall have che rghr to assert a clam Iollowng rhe process set forth in
secton 7.01 of this agreement. In this case, the followng '" bnn bng penalties will be
applcable to Mackenzie:
Penalty of 0.15% of the contract price for every 10mg/Nm3 increased in excess of
guaranteed value of 50 mg/Nm3 in the ernission of dry ash from the boiler systern and
subject to a maximum penalty of 2.50% of the contraer price. Base on Palm fiber and
Shell fue! condtion in boiler technical data.
Accumulatve penalty Ior above warranty Item.I to Item.4 is lrnted to total of 2.5% only.
A Member of
'lf
Wah Seong Corporauon Bhd
Ref. No.:
Dace:
MlSAOOl-27112
l December 2015
EXHIBlTC
TYPICAL PRESSURE PART ITP AND PROJECT SCHEDULE.
TYPICAL PRESSURE PART ITP
wasco
JtTAS..UU. SI>~.
mm.
n. !AHYU liHIHGlflAMA
rroject:
INSPECTION & TEST PLAN
40 TOH.$/HdJ4 SAi'Gal-0"'1~ IOIU

MACK.EHllE rHOO$TIJES.SCH..!HO
#..-,. cJ
Equipment:
Cfient:
OOC-ument
81-0RUM 801lER
--
ae.: M8J 101-4-0COOJ
Cfieftl
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A Mernber of
\7
24
Ref. No.:
Date:
M!SA00!-27/12
l December 2015
nojecf:
~:
Ci&nl:
DocotlMntHO.;
INSPECTION & TEST PlAN
wasc:o
81.0RUM !OllER
~-
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Wah Seong Corporaton Bhd
28
Ref. No.:
MISAOOl-27/12
l December 2015
Date:
EXHIBITD
MISCELLANEOUS
7.01 Method of Asserting Claims

In case PMT intends to seek the effectiveness of any of the warranties, penalties and
ndernnifcarons offered by Mackenzie under ths agreement, PMT shall subrnit to Mackenze a
written notice specfyng the reasons of such demand and the warranties sought, together with
copies of the relevant documents wthn 30 days following the occurance of the event in which
the warranty request is based on ("Notice"). Mackenzie shall answer the Notice within the 5
days following its receipt. If Mackenzie has tmely dsputed its lablty wth respect to such
clam, PMT and Mackenzie will proceed in good fath to negotiate a resoluton of such dispute,
and f not resolved through negorations within twenty (20) days, such dispute shall be
resolved by arbtraton in accordance wth provison 7.08 hereunder.
7.02 Warranries
Any warranry set forth in this agreemenr pursuant rn any section hereof s deemed set forth for all
purposes of this agreernent, as applicable. Therefore, each starement shall guarantee any oblgaton
established in this agreernent and shall be deemed to be set Iorth and incorporared by reference in any
other secron of rhs agreement as though fully set forth in such other secton for which the
applicabiliryo such warranry is reasonably apparenr.
7.03 Narices.
Ali narices, recuests, consents, demands and other communications under ths agreemenr shall be in
wrrng,
and shall be deerned ro have been given or made when delivered (i) by hand, () by courier
service, when provided to an internarionally recognzed overnght delvery servce for overnight
delvery, or (ii) when transmitted to a receiving facsmile machne, addressed as follows, orto such
other address or facsmile number, as may be hereafrer designated by wrtten notice to the other
Party:
A Member of
't/'
29
MlSA00!-27/12
l December 2015
Ref. No.:
Date:
if to che Buyer, to:
P\llT Industries SDN BHD

Loe 1929,Jalan Bukc Kemuning, Seksyen 32
Selangor Darul Ehsan, Malaysia
Tel.: 60351225522
Fax: +60351225533
Emal: pmtenqury'pmr-grp.com
Artenron: Chia Kim
if to the Seller to:
Mackenzie Incusrres Sdn Bhd
Lor 1930, Batu 7, Jalan Bukr Kemuning
Seksyen 32, 40460 Shah Alam
Selangor Malaysia
Tel: 603-51230018 Fax : ..-603-51230028
Contact Person : T ee Kian Lim
Email: kianlirr .. tee@mackenzieind.com
Ali such notices, requests and other communications shall be deemed receved on the date of receipt
by the recpient thereof f received prior to 5:00 P.M. in the place of recept and such <lay is a business
<lay in the place of recept. Otherwse, any such notice, request or communication shall be deemed
not to have been received until the next succeedng business <lay in the place of receipt.
7.04 Amendments; Waivers.
(a)
Any provson of ths agreement may be amended or waived f, but only if, such
amendment or waiver is in writing and is signed, in che case of an amendrnent, by each Party to
chis agreement or, in the case of a waiver, by each Party against whom che waver is to be
effective.
(b)
No falure or delay by any Party in exercising any rght, power or privilege hereunder
shall operare as a waiver thereof nor shall any single or parcial exercse thereof preclude any
other or further exercse thereof or che exercse of any other right, power or privilege.
A Mernber of
'fV
30
Ref. No.:
Date:
MISAOOI -27112
1 December 2015
7.05 Costs
Each
party will pay the coses and expenses incurred by ir in connecton wth che negotaton,
enrering into and completon of rhis agreernent, ncludng, without Imiraron, expenses of legal
counsel, accountants and other advsors.
7.06 Confdenraliry
Each of che Parcies hereto agree to protect any propretary non-publc informaton of the other Parry
which has been or will be ctisclosed for purposes of chis agreement (the "Confidencial Informarion").
None of che Partes will disclose the Confidencial Information to third parries ( other than its
advisors) without rhe other Parry's permission. The Confidencial Informaton does not include any
information which becomes avalable to the public other than through disclosure by a Parcy in breach
of chis agreemenr, or is requred to be disclosed by law, regulation or by a tribunal or government
agency.
7.07 Governing law
This agreement is governed by and wll be construed in accordance with rhe laws of Malaysia
7.08 Arbitration
(a)
Ali disputes arsing out of chis agreement shall be settled as far as possble by
negotatons
between the Patries or their designated representatves, If the Partes cannot agree
on an amicable settlernent withn twenty (20) days from written submsson of the matter by
one Party to che other Party, the matter shall be submtted for decision and final resoluton to
arbitration.
(b)
The Parties hereto irrevocably agree that all disputes arising in connection wth the
present agreement shall be fnally settled by arbtraton in New York Cty, New York under the
Rules of Conciliation
and Arbitration (the "ICC Rules") of che Internacional
Chamber of
Commerce (the "ICC") by rhree arbitrators that shall be attorneys at law and apponted in
accordance wirh the followng procedure: () the Party invoking arbrraton shall notfy che
other Party statng the substance
of ts claim and the name, address and other contact
information of the arbitrator t has chosen, who may be a citizen of any country; and (ti) within
A Member of'W Wah Seong Corporaticn Bhd
31
MISAOOI-27/12
Ref. No.:
Date:
l December 2015
twenty (20) days recept of such notfcarion, the other Party shall notfy the frst Party of its
answer
to
the clam made, any counterclam that
wshes to assert in the arbitrarion and the
name, address and other contact information of its elected arbtrator, who may be a citizen of
any country. If chis is not done wthn the twenty (20)-day-period, appontment of the second
arbtracor shall be rnade by the Court of Arbitraton of the Internatonal Chamber of Commerce
upon request of che initiatng Party.
(e)
The arbicrarors shall choose a third arbrraror, who shall serve as presdent of the
arbitral tribunal/panel thus composed. lf the arbtrators elected by the Parties fail to agree upon
the choice of the thrd arbitrator within twenty (20) days following the appointment of the
second arbitrator, the third arbtrator will be apponted by che Court of Arbtraton of the
Internacional Chamber of Commerce upon the request of the arbitrators or of ether of che
Pa.rties.
( d)
The Partes herero agree rhat each arbcrator apponted in connecton herewth shall be
fluent in English and Spansh. Unless the partes to arbcraton orherwse agree, all submissions
and awards in relation to arbitration under ths agreement shall be made in Englsh and all
arbitraton proceedngs and all pleadings shall be in English. Original documents in English or
Spansh may be submitted as evdence in ther original language; witnesses not fluent in English
may give evidence in ther native tengue (wth appropriate translation). Original documents in
a language other than Englsh or Spanish shall be submitted as evdence in English translation
accompanied by the original or true copy thereof.
(e)
The ICC procedural rules shall govern all arbitrations hereunder; provided that () each
Party may call upon che other to supply the arbirrator with docurnents in such other Party's
control relevant to the dispute; (ii) each Party shall be entcled
to
present the oral testirnony of
wtnesses as to fact and expen wtnesses; () each Party shall be entitled to question directly
any witnesses who present testimony to the arbitral panel; and (iv) ar the request of either
Party, a written transcrpt shall be made of each hearing before the arbitral panel at whch
testmony is presented and shall be furnshed to the Parties.
(f)
The arbtrators shall decide the dispute by rnajority decson and in accordance with the
governng law as set forth in the Governing Law provson of ths agreernent. The arbitral
decson/award shall be rendered in wrtng, it shall state the reasons on whch it is based and
shall bear the signatures of at least two arbitrators. It shall also dentfy the members of the
A Mernber of
32
Ref. No.:
MISAOOl-27/12
Date:
1 December 2015
arbitration tribunal/panel, and the date and place of the award granted. The award shall be
final, bndng and not subject to appeal, and any judgrnent upon such award may be entered and
enforced in any court of competent jursdcton.
7.09 Language
Ir is understood that, fer all purposes, the primary and prevalng language of chis agreement is
Englsh and therefore, che English version controls its nterpreraron, and ali notces and other
communcanons and documents prepared under or in connection wirh this agreemenr shall occur in
che English language.
7.10 Counterparrsand Exhibits
This agreement may be sgned in multiple counterparts, each of which shall construte an original bur
whch should collectivelyconstitute a single instrument.
By sgnng and rerurning a counterpart of chis agreemenr, che Parties agree that chey are bound by the
provisions of chis agreement.
7.11 Entre Agreement,
This agreemenr (and all documents annexed hereto) construtes the enrre agreement between che
Parties with respect to rhe subject matter of chis agreement and supersedes all prior agreements and
understandings.borh oral and written, berween the Parties wrh respect to the subject matter of ths
agreement.
7.12 Severabilry.
If any term, provsion, covenant or restriction of this agreement is held by a court of competent
jurisdction or orher aurhorry to be invald, void or unenforceable, the remainder of the terrns,
provisons, covenants and restrictions of rhs agreement shall remain in full force and effect and shall
in no way be affected, irnpaired or nvalidated so long as che economc or legal substance of che
ttansactions contemplated hereby is not affected in any manner materally adverse to any Party.
Upon such a determnaton,the Parties shall negorate in good faith to modify chis agreement so as to
A Mernber of
33
Ref. No.:
Dace:
MISAOOl-27112
1December2015
effect the original nrent of the Partes as closely as possible in an acceptablemanner in order that the
transactons ccnrernplated hereby be consummated as originally contemplated to the fullest extent
possible.
A Member of 1ij Wah Seong Corporalion Bhd
34
.\'IACKENZIE INDuSTRIES SDN. BHD. (649756-K)
~~
MACKENZIE
1111
OPERATING MANUAL
INDEX
Title
l. Technical Svnopsis for Mackenzie Water Tube Steam Boiler
2. Operation and Maintenance Instruction for the Mackenzie
Industries: Boiler Waste Fuel - Water Tube
Pre-Operatve Requirernents
3. Operation and Maintenance lnstruction for the Mackenzie
Industries: Boiler Waste Fuel- Water Tube
Operating requirements
4. Mackenzie Industries Product lnformation
Water Treatment Of Mackenzie Boilers
Page
2
3-4
5 - 25
26-46
-...~
MACKENZIE INDUSTRIES SDN. BHD. (649756-K)
MACKENZIE
TECHNICAL SYNOPSIS FOR MACKENZIE WATER TUBE

STEAM BOILER
The boiler is of the site assembled design being the MACKENZIE Watertube boiler
specially adopted for palm waste and similar high moisture fuels. To this end it has been
equipped with a drop grate oven with air swept spouts and secondary air nozzles. The
secondary air will maintain combustion in the volatile zone of the fumace with the result
of a mnima! amount of salid material on the grate.
The units possess ali the flexibility of the watertube design, are conservatively rated in
terms of heat flux, are a free and steady steamer and possess good tolerance to adverse
water conditions.
Automatic control on firing rate/boiler pressure is applicable to this type of firing
equipment and a degree of control could be achieved by pressure modulation of the feed
conveyor and F.D. fan.
The principie of operation with the equipment offered is that the fuel bed thickness is
minimal. The load level and the combustion rate are then controlled by air flow alone.
Fuel flow is varied by means of adjustment of the conveyor which is supplied by others.
This concept of firing is supported by a controlled fue! feed system to give available fuel
flow into the fumace and also to ensure that there is no tendency to blow-back from the
combustion chamber. It will be noted that such a firing system in common with all salid
fuel firing does not lend itself to the inclusion of autornatic emergency cut-off equipment
as there is the inherent problem of the fumace loaded with incandescent fuel. Only two
altematives are available : firstly to isolate the air supply to preclude further combustion
and allow the fire to die down, relying on emergency feed equipment to maintain water
level and relying on safety valve capacity to get rid of steam in the absence of any
alternative steam load; secondly to manually pull the fire out of the unit.
Both of these procedures are standard practice with installations of this type.
With this design, initially in a cold setting, rate of combustion is slow, but increase as
warmth gathers in the setting and produces further increase in the combustion rate. The
process is self accelerating in accordance with the heat leve! in the setting so that the
heating of the setting is not forced with resultant spalling and other expansion damage.
~~
MACKENZIE
11111
MACKENZIE INDUSTRIES PRODUCT INFORMATION
OPERATION AND MAINTENANCE INSTRUCTIONS FOR THE
MACKENZIE INDUSTRIES
BOILER WASTE FUEL- WATER TUBE
PRE-OPERA TIVE REQUIREMENTS
Before steaming your MACKENZIE boiler there are severa! factors that will require
attention :
a.
b.
c.
a.
Chernical Feed Water Dosing.

Cleaning.
Drying Refractories.
Chemical Feed Water Dosing :
All feed water equipment should be available to run prior to filling the boiler.
This ensures that the boiler water has the correct chemical feed water treatment.
Alternatively, other dosage arrangements for initial filling can be made. (Notes
on feed water treatment are included in this manual.)
b.
Cleaning :
The boiler interior shall be thoroughly cleaned. During construction (though the
boiler openings are sealed prior to shipment), the interior inevitably becomes
contaminated with foreign matter which rnay include rust, scale, oil, welding
deposits, silicon and other foreign matter. If these are not removed, trouble such
as corrosion and priming will arise during operation of the boiler. (Notes are
included with these instructions to help you decide the correct cleaning
procedures. It should be noted however that any reputable water treatrnent
service company can give you advice on this matter). It is rnost important that
the boiler is thoroughly cleaned and treated before cornrnencing firing.
c. Drying Refractories :
Before firing the boiler, fil! the drum with treated water and start a slow fire for
at least one or preferably two weeks to complete the drying of the brickwork.
This should be done with a low fire, usually fired with wood on the ash pit floor
with the grate removed. If the bricks are not dried out slowly, cracking of the
brickwork will occur, due to stearn formation in the mortar joints between the
bricks and in the fire brick themselves. Only when the brickwork is dried out,
should the boiler be fired at full rate to bring up pressure.
A general guide to adequate drying is that the outer bricks will feel warm to
touch, indicating the brickwork is sufficiently heated. While initially heating the
boiler, the rnain stop valve should be open to allow air to vent.
MACKENZIE
lliDUSTRIES SDN. BHD. (649756-K)

OPERATION AND MAINTENANCEINSTRUCTIONS FOR THE
MACKENZIE INDUSTRIES
BOILERWASTE FUEL - WATER TUBE
OPERATINGREQUIREMENTS
The following notes will cover the most important points to be observed while operating
your boiler. These instructions are not intended to be exclusory but rather should be taken
as a guide to sound boiler operation. Experience in the operation of your own Plant wll,
in the long term, is your best guide to correct running procedure. The following points
wll be covered:
a.
Firing.
Clinker Formation.
c. Air Swept Spout Firing.
d. Water Leve l.
e. Water Treatment.
f. Superheater.
Cleaning.
o
h. Blow Down.
l.
Boiler Feed Water Systern.
J. Brickwork.
k. Fans.
l. Dust Collectors.
b.
(7
a. FIRING:
The firemen operating your boiler should be trained to appreciate the various
facets of combustion chamber control and to appreciate the results or effects on
boiler demand by varying plant operation. When changes occur in stearn demand,
the firemen should be capable of dealing with such conditions. They should be
warned to anticipate heavy steam demand and prepare for it in advance of process
or other work by studying the general operation of the plant. It should be that the
routine is in a general way similar from <lay to <lay. Correct firing of the boiler
involves the supply of fuel in the correct quantity, in order to maintain adequate
steam supply, to anticpate steam needs at a later time and to provide correct
combustion conditions in the cornbustion charnber, consistent with good operating
practice to prevent premarure failure of the fire bars and the refractoriness.
Moderately thin fires are best with an even surface and no bare or very thin parts,
Thick fuel beds tend to the formation of clinker and smoke, and fuel is thereby
wasted. Under low draft or low fire conditions, thin fires are a necessity. Where
both fibre and shell fuel are used together, a thorough intermixing of these fuels,
rather than stoking of each separately in large quantities, should aid in the
reduction of the formation of clinker and give an even fuel bed.
It is possible to bum the fuel so that the entire grate area will eventually become
blanketed over to the complete exclusion of air for combustion. This is of course
the extreme case, but it indicates that to obtain the utmost out of your boiler and
hence the optimum conditions in your combustion in chamber, the correct method
of fue] feeding must be employed. The correct firing of fuel giving the greatest
utilization of the fuel bed is very closely connected with correct draft control and
clinker forrnation control. Aspects of these are covered in the sections below. A
feature of the MACKENZIE furnace is that at normal operating capacity, the
flame will tend to lift off the grate leaving only a thin layer of fue! on the grate.
Where manual stoking is used, the firing doors should only be opened while fuel
is being fed. This will reduce the amount of air leakage over the top of the fire and
force most of the cornbustion air to reach the flame from the underside of the
grate, so helping to keep the fire bars cool and the bed at an even temperature.
Excessive air leakage over the fire can cause chilling of the flame and will result
in a smoke fire.
The boiler is fitted with a pneumatic fuel feeder to spread the fuel within the
furnace. When the supply of fuel is regular and the opening on the fuel conveyor
is properly adjusted, manual feeding is not necessary. During times of fuel
interruption, manual feeding can be achieved either by cutting an opening on the
chute from the conveyor to the feeder or by feeding through the firing <loor.
b.
CLINKERFORMA TION AND ASH DISPOSAL :

Clinker is formed in the furnace through the ash becorning fused owing to the
high temperature and the quantity that may be formed is more or less dependent
upon the ash type and content of the fuel. This does not necessarily mean that the
fuel, when the ash content is high or low, cannot be burnt without forrning clinker.
It certainly does mean that whether there is much or little clinker formed, depends
to a large extend upon how the fuel is treated and bumt in the fumace. It has been
noted that there is evidence in the Palm Oil Industry that shell fuel is more
responsible for the formation of clinker than fibre fuel. As stated before, where
MACKENZIE ll'IDlJSTRIES SDN. BHD. (649756-K)
both fuels are used, a through interrnixing of these fuels, rather than the stoking of
each separately should aid in the reduction of large clinkers.
Clinker, being formed of ash which has been separated from the carbon, is
produced a little at a time. Each particle, as its temperature is raised, melts and
becomes sticky, and so adheres to ns neighbour until large pieces are formed
which in tum adhere to the hot bars or fumace walls. Stirring of the fire with a
rake or slice moves the small pieces of ash and so brings them into contact with
each other, as they tend to drop to the fire bars, thus making still larger masses of
clinker. As the fue! below each formation is consumed, the clinker mass falls onto
the fire bars and, if the bars are hot, adhere and gradually become cooled by the
air rising form the ash pit. If the bars are very hot when the molten ash contacts
them, fusion takes place resulting in bar trouble and air stoppage, causing
increased work for the operator. With brick lined fumaces, excessive clinker will
cause severe damage to the brickwork such as the failure of the surface of the
brick.
With thin fires, the ash release from the fue! as it bums and drops into cooler
zones in the region of the fire bar tops and so finds its way through the air spaces
in the bars to the ash pit with the result that little orno clinker is formed.
Thick fires are the most prolific source of clinker formation and as the resistance
to air flow is greater - less air thus passes through the fuel from the ash pit. This
results in hotter lower regions and bars so creating appropriate conditions for
prolific clinker formation. Further, the ashes which are left in the higher region of
the fuel bed on account of greater top combustion cannot find their way to the ash
pit and so remain lost in the fuel bed and form clinkers.
A further source of clinker is too much disrurbance of the fire. A careless fireman
using the slice may lift ashes in large quantities with grave results. To eliminate or
considerably reduce clinker troubles the following general rules should be
followed:
1. Shell and fibre fuel should be well mixed.
2. The fire should be thin.
3. Small charges of fuel should be fired at short intervals.
4. The slice, poker or rake should be used sparingly.
The MACKENZIE boiler has a dump grate incorporated which is operated by
cylinders mounted on the front of the boiler.
This should be operated periodically so that the ash can be dumped onto the ash
pit which prevents the accumulation of clinker. However, after large clinker has
~~
MACKENZIE
1111
been formed, the grate should not be operated as the large clin.ker may lodge
between two rows of grate and prevent the grate from closing. Large clin.kers
should be removed from the fire <loor before operating the dump grate.
The suspended firing design of the MACKENZIE fumace at rated capacity will
reduce the tendency of clinker to form.
c.
AIR SWEPT SPOUT FIRING

A. General.
B. Combustin Principies.
C. Combustion Equipment.
D. Firing Practice.
(i)
Protection of Superheater.
(ii)
Starting & Load Raising.
(iii)
Low Load Operation.
(iv)
Normal Operation.
(v)
Ashing.
Notes on the operation of vegetable waste fired W.T. boilers

General:
The major feature of the air swept spout fired water tube boiler is its flexibility in
responding to variation in load demands. This results from the semi fluidized
firing system whereby much of the fuel is burned in suspension coupled with the
responsive nature of the water tube boiler due to its low thermal inertia. Thus,
there is almost instantaneous reaction to changes in demand and the firing system
has the capacity to rapidly adjust the rate of heat input to meet this change.
This is in very strong contrast to most other forms of steam raising, particularly a
combustion systern consisting of keeping the furnace flushed with fuel and
controlling its rate of burning by regulating the arnount of air admitted.
The air swept spout boiler demands that the fuel and air be continuously fed into
the boiler in correct ratio to one another and at the correct rate ro meet the boiler
loading; as ir swings around to meet process and power generation demands.
Failure to meet either of these control demands, i.e. correct fuel/air ratio and
correct firing rate, would cause inefficient operation and may jeopardize the
whole operation. If the furnace is over fed with fuel or under fed with air the
furnace becomes quenched and the combustion rate collapses. If the rate of heat
input does not balance with the boiler load, being of low thermal inertia, the boiler
MACKENZIE INDL"STRIES SDN. BHD. (649756-K)
either rapidly loses pressure or conversely becomes over pressured and blows its
safety valves.
Properly equipped and operated, the air swept spout fired W.T. boiler provides the
most flexible cornbination available with the ability to follow load almost asan oil
fired unit world, to the very great benefit of the generation plant, both in
efficency and maintenance requirements. The boiler itself, because of the stable
and low intensity conditions sustained in the combustion charnber, has low
maintenance requirements.
However, to achieve these benefits it is stressed that the unit must be properly
operated. Not only rnust the fuel/air ratio and the firing rate be correct, but also
the fumace conditions be allowed to develop with minimum interference such as
unnecessarily opening the firing doors, rak.ing or barring the fire. Minor unevenness in the fuel spread, can be expected, but must be left alone and accepted
as a characteristic of the fuel and fi.ring systern because eventually the spread will
stabilize.
~~
MACKENZIE
1111
Combustion Principies:
The combustion of high moisture vegetable waste fuels, such as palm-nut refuse, bagasse
or wood-waste; is a staged process comprising drying, pyrolysis and the distillation of
volatiles and carbon bum out. Each stage must be completed before the ensuing one takes
place. This is most easily appreciated on an inclined step grate where it can be readily
observed as the fuel migrares down the grate. Firstly the drying action on the dead plate
and top section, then as the fuel moved down it begins to char with the release of
volatiles, which, supports long flame combustion above the fue! bed. As it progress
further, the fuel bed develops incandescence when the carbon burns out with short but
more intense and brighter flame.
When firing with the air swept spout onto a stationary grate the stages of the combustion
process rernains the same but their progression accelerates as the load increases. The heat
release on the grate gradually reaches a stage of intensity that initiates, and then increases
to the point ar which buming take place in suspension; in the form of a flame mass above
the fuel bed.
Thus, at low load, all combustin takes place on the grate, with degree of combustion
advancing through the fue! bed. The buming out of carbon in the lower regions
supporting distillation and drying in the over-layers of "green" fuel, with only a nominal
degree of drying taking place as the fue! falls through the furnace atmosphere onto the
grate.
As the load increases to an intermediare stage the fuel bed becomes more active with the
increase of heat release, and the turbulence above the grate increases considerably with
the greater gas flow so that drying becomes active above the grate and the release of
volatiles is initiated, with the support of a considerable flame body above the grate.
With further increase in load, fumace heat release is intensified to the point where the
high pressure secondary air, or over-fire air, can be gainfully employed. This increases
the furnace turbulence greatly and accelerates the degree to which cornbustion takes place
in suspension, by increasing the suspension time so that fue! fall out onto the grate
becomes dirninished and the furnace immediately above the grate becomes a buming
mass, with the grate tending to become barely covered by the time maximum load is
reached.
These stages are not strictly defined but overlap one another because of the natural
grading of the fuel. Obviously fine particles will advance to suspended buming much
more rapidly than courser particles, and with high density fuels such as palrn-nut, shells
bumed on their own, it is high improbable that an advanced stage of suspension buming
would ever be achieved. So load carry capacity on shell alone should be limited. It is
stressed that if high capacities are forced by burning shell alone on the grate, heat release
in excess of design intensions would be reached in the confines of the grate and the
setting would be impaired. It is also emphasized that if the high pressure overfire air is
introduced too soon it would have a chilling effect on the combustion process and not
only retard load pick-up but also cause the carry-over of fuel particles into the boiler gas
passes where they could constitute a defined hazard, leading to fire in the setting or gas
side explosions.
It is particularly stressed that the fluidized combustion condition airned at for the higher
portian of che boilers load range is both highly reactive and sensitive. Collapse of the
combustion process would be brought about by too sudden an increase in the firing rate
or the "green" fuel feed rate, or by over "airing" the combustion chamber, any of which
would bring about a flame chilling effect and, with loss of temperature, loss of the
necessary supportive conditions for suspended firing. However, if appropriate adjustrnent
can be made continuously as the load on the boiler vares, and this is readily reflected by
the faster reacting, low inertia characteristic of the water tube boiler, then the combustion
process is most flexible and controllable, and easily has the potencial to keep the boiler
pressure within a 2-3% range of set-point.
If high fire range conditions are lose the condition must be recognized immediately,
otherwise the furnace could become flooded with "green" fuel with would not only
depress conditions still further but would also inhibir the recovery process; and load
raising would have to be recommenced from whatever level can be supported. In this
context it is registered that fuel feed rate can only be increased at a rate which conditions
existing in the combustion chamber will support. Exceeding this rate of increase causes
further chilling to take place with an overall retarding of the recovery rate. The process
can be linked to towing a vehicle with a light tow rope. If acceleration is applied
gradually it is quite satisfactory and could go on for ever, but if acceleration is applied too
suddenly then the rope would break immediately.
Combustion Eguipment:
The firing equipment consists of the following principle components:
l.
2.
3.
4.
Air swept spout fuel feeder.

Dumping pin-hole grate.
Combustion draught system.
Over-fire air system.
Differentiation is made between the last two because of the very distinctive role played
by each.
M.ACKENZIE INDUSTRIES SDN. BHD. (649756-K)
The air swept spout is the means by which the fuel is projected into che furnace in such a
way as to result in an acceptable degree of distribution over che grate. The spoots are of a
fixed design and not subject to any manipulation or adjustment in operation of the boiler.
There are three critica! aspect of spout feeder performance. Firstly, the feeder air fan
(H.P. Secondary Air Fan) muse always be running when fuel is being delivered into the
fuel chutes otherwise the chutes will block and become jammed with fuel even to the
extent of necessitating a shut-down to clear them. Secondly, the rotary air pulsating
damper should always be actuated when feeding fuel to the boiler. This damper has a
split blade design which alternately blocks off one side of the spout air slot and then the
other thereby biasing the fuel/air flow from the spout first to one side and then the other
so that appropriate distribution is achieved. Thirdly, as already commented on, to be
effective the fue! delivery to the spout must be metered to match the load rate on the
boiler unit.
The dumping pin-hole grate is a stationary grate (that is it remains in a fixed position and
<loes not move the fuel through the furnace) with pin-hole finger bars or links specifically
designed for high volatile and waste vegetable rnatter fuels. These boles are designed to
provide the correct air flow area and distribution and have a reverse taper on them to
inhibir blockage by particles passing into the hole - it should not jam there but fall
straight through to the ash-pit. The dumping facility is to clear the grate of ash as the
situation demands and is effected by tilting the grate sections with one simultaneous
movement to an angle of approx 80 to the horizontal so that ali material drops off into
the ash pit. This movement is carried out with the aid of steam powered cylinders so that
both the opening and closing action is vigorous, ensuring a full drop of ash material on
the one hand and a satisfactory closure on the other. If finger bars do not close properly
the projecting portion soon becomes burned and distorted so that closure is further
inhibited and rapid deterioration progressively follows. To aid satisfactory closure,
particularly in the presence of hard shell particles the finger bars are designed to have
narrow leading edges, one link to the next, so that not only is there a srnall area to retain a
shell particle bue also on closure maximum force can be brought to bear.
The cornbustion draught systern provides the mass of air for buming che fuel (the overfire air merely stirs it around) and is of the balanced draught design. That is, it comprises
a forced draught fan pushing combustion air under the grate and an induced draught fan
sucking the produces of combustion away from the combustion chamber, through the
boiler ductwork and grit arrester and delivering them to che chimney.
The point of balance between the pressure of the F.D. fan and the suction of the I.D. fan
should be at the grate so that the fumace always operares ar a nominal suction of around
10.0 mm W.G. This ensures that any gas/air leakage is always by way of air infiltration
to the boiler which merely supplements the combustion air (provided ir is in moderation)
rather than by way of hot gases issuing from the boiler causing over-heating of fire doors,
ash doors, peep-holes and the like with associated distortion and generally detrirnental
effects to the boiler fabric as well as making conditions in the boiler house unpleasant.
The I.D. fan has powerful drive and should never be started with the dampers open
because this will overload rhe motor.
Over-fire air system is a duplex systern comprising low pressure over fire air generally
applied to the lower regions of the setting, and a higher pressure system, in this instance
combined with the fuel feeder air, applied at a more elevated level in the boiler setting.
Special angles of disposition are built inro these air nozzles, which are also carefully
sized for their particular duty and location. The supply pressure to these is set up at the
time of commissioning to achieve optimum result. These adjustments of dampers are then
tightened into their fixed positions and should not require further attention unless the
nature of the fuel changes and necessitates re-adjustment. The purpose of the over-fire air
systems is to induce the right level of turbulence in zones appropriate to the loading on
the boiler and the intensity of the combustion process needed to meet that load.
Firing Practice :
Protection of the superheater.

The superheater elernents are positioned in a high temperature zone of the boiler flue
gas strearn from which they have no protection against over heating until stearn is
actually passing through them.
For this reason, whenever the boiler is being started up, the vent/drain is always
opened so that as soon as any steam what-so-ever is generated it is blown to
atrnosphere through the superheater thereby keeping it cool and enabling the firing
rate to be increased without danger of the superheater becoming over heated, leading
to earl y failure.
At first sight it might appear that blowing stearn to atmosphere in this way defeats the
object of the exercise, which is to raise pressure, however, the rate of energy loss
through the superheater vent/drain soon becomes very marginal compared to the rate
of energy input through the steadily increasing firing rate, and it will be found that the
pressure increase ata satisfactory rate.
Nominal the rate of heat input should be such as to result in boiler water temperature
increase of about 100 F per hour. This is rnost critica! in a stone cold setting when no
steam is available for maintaining the superheater but may be increased in a boiler
that has been ban.ked over night and probably has steam available.
This rate of temperature/steam raising is shown on the attached diagram, and it can be
further gauged by the advancement in the flue gas temperature.
Temperature & Pressure Raising Rates From Cold

I
I
I
I
I
Boiler Steam
Pressure
P.S.I.G.
I
I
i " - .,
400
I
I
1 , ,
1 ,,
300-+-~~~~~~~~~~i.-.~i.-.~~,'
I
Boiler Water
Temperature F
I
I
200
1
1
1
1
1
1
1
I
I
I
100
1
1
:-------~--------1
.;
.;
.;
.;
1 /
1 /
Pressure
I
1 /
1 1
---~--------L--J'
1
Arnbient
80F
I
I
.;
Time In Hour From Start-up
It is stressed that the superheater vent/drain is never closed until the boiler has
been put on range and flow through the steam main is established.
Likewise, when taking the boiler out of service, before the main stop on the boiler
is operated to isolate the boiler from the range the superheater vent/drain is always
opened so that as the stearn flow to the main ceases it is replaced by flow to waste
and the superheater remains protected while heat remains in the boiler setting.
Similariy, if in the course of general operation in conjunction with another boiler
on a common steam range, pressure in the boiler is lost for any reason such that
the other boiler by virtue of its higher pressure assumes all the load, the steam
tlow from the boiler is thereby interrupted while it continues to the fired. The
superheater vent/drain is immediately opened and kept open until such time as
pressure has been regained and the boiler takes over its share of the load once
more.
A constant awareness of the superheater condition is essential if it is to achieve
satisfactory long life in operation, and any condition which may lead to its
becoming over heated circumvented by appropriate venting. It is far better to
over-use the vent facility and waste a very marginal amount of energy than
neglect to vent for 5 or 10 minutes and take years off the useful life of the
superheater by over heating it.
The superheater must receive similar care and attention during initial firing.
Under this circumstance, when the boiler is relatively cold, a tire is being put on
the grate without stearn available to pass through the superheater. Under this
condition the fire is to be kept at a strictly controlled small size. Steam is raised at
this condition until a steady tlow of stearn is flowing from the superheater
vent/drain, upon which the firing rate can be increased within the limits discussed
below.
Once more, it is emphasized that there must be a constant awareness of the safety
of the superheater heating surfaces under all circumstances of operation.
Boiler with superheater. it is critica! that boiler capaciry should maintain above
70% boiler load condition. This is to prevent uneven steam tlow during Iow load
that may result in superheater tubes overheated. Please consult manufacture if the
operation is below limit of 70% MCR.
Starting and load-raising.

Normal checks on the
equiprnent having been
boiler feed-water plant,
boiler can be considered
satisfactory functioning of all ancillary and auxiliary

performed and the conditions of the boiler water level,
fue! supply, and the like all being confirmed before the
ready for start-up.
Quite apart from consideration of the superheater commented on above, because

of the mass of brickwork contained in the boiler setting, temperature must be
raised at a strictly controlled rate or otherwise differential expansion in the
brickwork will weaken it structurally and can cause collapse not only m the
structure but also in the refractory themselves by the process of spalling.
Thus, moderately sized tires must be set and must be kept to a size that, in a stone
cold boiler, would require at least 2 hours to bring about steam blowing (at
atmosphere pressure) at the superheater vent.
This is achieved through natural draught in the boiler setting by manually opening
the I.D. damper and adjusting the F.D. damper to the appropriate leve!. As the fire
catches on and is further fed by hand firing wood Iogs (or similar fuel), the
setting, the ducts and the chimney will warm up and create more draught then can
be tolerated so that attention must be exercised in easing in the F.D. damper until
a lirnited amount of heat input is achieved.
The process of soaking the brickwork with heat to bring it up to ultimate working
temperature cannot be forced without inducing undesirable temperature stressing
and it is recommended that on bringing a boiler up from cold the load is limited to
about 30% MCR for the first 24 hours to enable this end to be achieved.
Once steam is issuing freely from the superheater vent/drain a higher rate of heat
input can be accepted to achieve which the forced draught fan can be run, firstly
with the damper closed as leakage air will be found sufficient for temperature
raising in the inicial stages, Should the rate of heat pick-up becomes too fast it is
essential that this fan be switched off at intervals to maintain the temperature
raising rate under control. Initially, this temperature raising will probably use shell
fired by hand, but if fibre is available it may be used intermittently by feeding
through swept spouts for which purpose the H.P. fan is run. To run this fan
without exceeding the natural draught capacity of the chimney it will probably
first prove necessary to stop the F.D. fan for the duration so that excessive
quantities of airare not forced into the setting thus pressurising it.
When pressure is raised such that the boiler pressure is a few pounds in excess of
the range pressure and the mains have been purged of any condensate, then the
boiler can be put on line; and once steam flow is established the superheater
vent/drain may be isolated.
Low Load Operation :

For the lower end of the load range the firing technique is quite standard with fuel
being burned on the grate in the conventional manner.
a...~
MACKENZIE
As soon as the boiler has been put onto the stearn range the induced fan can be
started. As this fan has a large capacity drive circurnstances of power generation
should first be checked. Starting the I.D. fan must take place with the damper
closed.
Load can then be raised feeding the fuel onto the grate via the air swept spouts,
and as the fuel flow is increased, increasing the F.D. fan opening so that the
burning rate is equivalent to the feeding rate and a heavy mass of fuel is not
permitted to accumulate on the grate. Every effort should be rnade to keep the fuel
bed thickness down to 4 or 5 inches in depth,
It is stressed that whenever the fuel is being fed through the air swept spouts, the
high pressure air fan must be running to sweep the fuel from the spout. Otherwise
the chutes will soon become blocked with fuel. For low load operation fuel may
be fed on an on/off basis if found necessary, the high pressure air fan being turned
off when not in use. Also, for low load operation the H.P. wall nozzle should
prove unnecessary, unless there is difficulty achieving reasonably even fuel feed
in which case the front wall nozzles only may be brought into use.
As the load increases to around 8,000 - 10,000 pph stearn flow the use of the low
pressure air nozzles and the grit refiring should prove beneficia! in achieving good
fuel utilization as established by high C02 figures in the boiler flue gases and as
confinned by low carbon-in-ash present in the grit arrestor discharge.
Normal Operation
Under normal operation the objective is to fire the boiler with fuel and just the
right amount of air to bum it, and that this fuel/air mixture is supplied to the boiler
at just the correct rate to meet the load on the boiler.
If too much air is supplied with the fuel it unnecessarily chills the setting and
takes heat away with it when it leaves the boiler with the flue gases. Thus, it
retards the combustion process and waste fuel through inefficiency.
If too little air is supplied the combustin process is starved and excess fue!
accumulates on the grates, leading to a poorly conditioned fire.
The correct fuel/air ratio for palm-nut refuse should result in a C02 in flue gas in
the arder of 13.0% and is equivalent to an excess air arnount of 50%. A very
rough guide to the air quantities can be obtained from the appearance of the
chimney stack. Too much air, chilling the gas and condensing the moisture in it
gives it the while appearance of stearn while too little air causes volatiles from the
fuel to be only partly burned and the carbon molecules in the volatiles appear as
carbon particles and to gives the chirnney a darkened or black plume. When the
fuel is receiving the correct amount of air the chimney is clear with a slight brown
haze to it.
When the boiler is receiving too little fuel/air mixture it cannot meet the load and
pressure falls. Conversely, when too much the pressure climbs and could reach a
point where the safety valves are lifted. In either case the boiler is no longer under
control.
With the systern installed fuel is admitted to the fuel chutes through sliding gates
in the cross-feed conveyor. When feeding through the chutes the sliding gate will
require adjustment so that the fuel feed is evenly balanced between the two
chutes. This can be roughly assessed by looking down the chutes but rnust be
confirmed on the fuel bed from time to time. Uneven firing, particularly if bare
patches develop, can lead to rapid deterioration of the grate castings.
Variation in boiler pressure (reflecting an increase or decrease in boiler load) is
adjusted for by increasing or decreasing the fuel flow rate and on such changes
the evenness of fuel distribution needs to be rechecked.
With fuel the correct amount of combustion air must be admitted and it is
regulated by adjustment to the forced draught damper. This damper remete
control device is mounted at the top firing floor in the form of an air regulator set.
By varying the air pressure signal, the damper position is changed. This is so
arranged that a pressure read-out on the gauge of 2.0 psi corresponds to the
damper shut position and a read-out of 12 psi corresponds to damper fully open
position. The appropriate amount of F.D. opening for a given fuel feed rate must
be assessed from the condition of the fire and the appearance of the chirnney.
This assessment must be ternpered by any gradual change in the fuel bed. An
accumulation of fuel in an increasing depth of fuel bed would indicare under
supply of air (or over supply of fuel) and the bed buming out in patches could
indicate excessive air - although pressure would probably be lost, calling for other
corrective action, before this condition set in.
As the F.D. damper controlled air is increased or decreased the induced draught
equipment supplied is designed to automatically adjust itself to follow the amount
of air/flue gas being generated in such a way as to rnaintain a constant pre-set
suction in the combustion chamber. This suction is in the order of 10 mm W.G.
but will be exceeded at low load as the I.D. damper shut-off is approached and
control is lost.
Superimposed on this fuel/air supply is the overfire air system. The prime
intention of this system is not so much the supply of air of combustion but rather
the stirring, or creation of turbulence, in the air supplied by the F.D./I.D. system.
This rurbulence serves severa! purposes including adequate admixture of fuel and
air so that maximum oxygen utilization is achieved in the combustion process,
assistance in achieving even fuel distribution from the air swept spout fuel feeder
equiprnent, and in the case of the high pressure over fire air system, increased
buoyancy of fuel particles through high velocity turbulence. The application of
these systems may be summarized as follows :
l.
Fuel Feeder Air : Tapped off the H.P. secondary air system and must always
be running at all time when fuel is being fed to the air swept spouts to ensure
the chutes do not block.
Under 'feed only' conditions the air ducts to the front wall and to the rear wall
of the combustion chamber are closed by means of dampers.
2. Low Pressure Over-Fire Air : Once the unit has been put onto the stearn
range and fuel feed is continuous the low pressure systern is initiated. This
system assists in fuel distribution with air jets under each feeder spout,
provides the necessary low-level turbulence for on-grate buming and keeps
the rear grit hoppers under the convection bank clear through its secondary
grit-refiring function.
3. High Pressure Over-Fire Air : This systern is used in stages as higher loads
are reached, with a view to achieving the maximum degree of suspension
burning but with sufficient retention time that carbon-in-ash content of the
particles being carried through to the grit arrestor is acceptable low.
The front wall system, particularly the sharply angled nozzles above each
feeder spout are intended to assist in fue! distribution at heavy fuel feed rates
where greater energy is required to cope with the increased mass rate.
The rear wall nozzle is purely for irnparting high turbulence swirling to
achieve maximum buming rates.
Experience will dictate at what levels of load the L.P. and H.P. over-fire air
systems are brought into use. Each system is operated by a damper on an
oo/off basis and is a static control feature, not subject to manipulation in
following the load, which is the prime objective of boiler operation. However,
in-so-far as they play an important part in maintaining the ability of the boiler
to so perform in the long term by preserving acceptable fumace conditions,
their correct functioning rnust be kept under constant surveillance.
It is stressed once more that, in principie, the aim is to bum the fuel at the
same rate as ir is being fed; at the precise rate that the boiler requires; to meet
the load imposed on it at any given time. To depart from this principie
automatically means that boiler control is lost and/or combustion conditions
deteriorare (most likely, from the accumulation of excessive fuel on the grate).
Ashing:
Ashing the fire is carried out by using the dumping grate mechanism.
At full load fuel is consumed ata rate approaching
4114
tons per hour.
Of this, if a mixed fuel of fibre and shell is being consumed, 4.0 percent will be
ash and this ash will also contain something in the order of 30.0 percent carbonin-ash. This will result in an ash residue of approximately 540 Ibs per hour ar
which level fue! build-up will be at the rate of 2" distributed over the grate area
per hour.
Ashing should take place when the depth of ash on the grate reaches 6" and thus,
when operating continuously, full load could only be sustained for 2-3 hours
without ashing. As che average load decreases, the interval between ashing
decreases, it being carried out as this same depth of asb accumulates on che ash
bed.
During the ashing operation the boiler continues firing on only half its grate.
Whilst the boiler may be capable of significant load, load must obviously be shed
during the time chis operation is being performed. Therefore, it should be timed to
take advantage of any cycle of rnill operation which offers a period of reduced
load.
In carrying out the ashing operation firstly che fuel feed to the side of the fumace
in question is isolated, being cornpensated in part by increasing fue! to the other
half together with increased F.D. This increased F.D. rapidly bums out tbe
residual combustibles and as the fire loses intensity, air to that half of the fumace
is isolated. In the meantime the steam/air line to the power dumps is bled and the
cylinders made ready to operare. As che heat is lost from the now isolated grate,
the power dump is then operated depositing the ash in the ash pit.
The dump is operated a couple of times to ensure that ash material is slackened
and cleared from between the links. The grate is rerumed to its operating position
and, whilst the F.D. is still isolated, the ash is drawn from the ash-pit as rapidly as
possible and the ash door re-sealed.
-~~
MACKENZIE INDGSTRIES SDN. BHD. (649756-K)
MACKENZJE
This completes part of the ashing cycle and fuel irnmediately is fed lightly back to
the grate followed by the air, which should cause immediate ignition, so that the
fue! can then be adjusted slowly up to its full recovery rate.
Once the ashed part of the grate has recovered, the same procedure is repeated for
the other half of the grate and then the total mass of ash debris is cleared away.
It is most important that the ash is cleared as soon as it is dumped as, when air is
returned to that part of the ash-pit, the carbon-in-ash residue will ignite and cause
destructive over heating to the underside of the grate.
Likewise, in an emergency, the dumping gear is used to draw the fires, the
draught plant must be stopped immediately and the material withdrawn from the
ash-pit using water quenching if necessary.
Remember, this should be used in an emergency only as water quenching causes

rapid deterioration of the concrete through spalling.
d. THE WATER LEVEL :
Though the water level should be maintained at about the centre of the glass when
the boiler is steaming at full rating, the gauge will show more or less a false water
reading. This is particularly so when the stop valve is opened or when the safety
valve blows, due to the tendency of the water to rise, but with a little experience
the boiler operator will gain full knowledge of just how his water level stands.
The water level of the MACKENZIE boiler is automatically control by a level
control val ve. Manual control, if needed to anticpate high steam flow, is possible
by using the bypass and isolating the control val ve.
The operator can arrange to do this by allowing the water level to drop to near the
bottom of the glass prior to the time when the fire is increased. The boiler
pressure can then be controlled to a certain degree by increasing the water feed to
the boiler to keep the pressure within the required limits as firing is increased. In
this way, it can be arranged so that the boiler is available to stearn at full output
with the maximum leve! showing on the gauge glass when the heavy demand
occurs. This will help ease out peaks in boiler operation.
e.
WATER TREATMENT :
All boilers should preferably be fed with pure water but as this is mpossble to
obtain, sorne form of water treatment must be used. Comprehensive notes on the
way in which you can obtain a sound water treatment scheme are included in this
manual.
f.
SUPERHEA TER :
The superheater when installed is connected directly to the boiler and cannot be
isolated from it. To protect operating equipment, the superheated steam should be
thoroughly vented to ensure that all condensare are removed before being used.
With correct water treatment there should be no build up of scale on the interior
surfaces of the superheater, but if this does occur you water treatment specialist
should be consulted to obtain information on the correct cleaning procedure.
g.
CLEANING SCHEDULES :
l. Boiler Interior :
If full control can be maintained over boiler feed water and its treatment, it
should never be necessary to open the boiler for cleaning. However, it is rare
that the ideal is achieved and regular inspection serves to give supervisory
staff an opportunity to assess the performance of those who attend to the
routine treatment of water and the handling of the boiler. As cleaning the
boiler often becomes necessary, the time allowed to lapse between cleaning
must be determined by the amount of impurities deposited by the water. It is
extremely important that no sizable deposit be allowed to rest on the boiler
shell or tubes. This will cause an insulating layer which <loes not allow the
heat from the fire to be conducted through to the water inside. In this casa,
overheating will result and may bring about failure, causing loss of life.
Therefore, it cannot be too highly stressed that attention to these details must
be performed thoroughly.
2.
Sootblowers :
Depending on the quality of the fuel, there will be sorne sooting of the tubes
and deposits of ash and soot in the convection bank. Sootblowers are
permanently installed in the fumace to enable cleaning of the gas side of the
convection tubes on stream. Operation of the sootblower is by opening the
steam valve on each blower and rotating the chain wheel on the blower
between the two stops.
The ash thus cleaned falls onto the hopper which is than blown automatically
into the fumace through the grit refiring nozzles installed on the hopper.
3. Motors:
It is particularly important that the driving motors be kept clean, as areas
around the boilers tend to accurnulate dirt over a period.
As their exterior surfaces are important for the cooling of the motor,
overheating and later failure of the windings of the motor rnay result if not
kept clean. Your motors should be regularly inspected and sorne cleaning
schedule, consistent with your Plant requirements, adhered to. No motor will
operate satisfactorily under conditions where its cooling capacity is severely
reduced.
h. BLOW DOWN :
The essence of implementing sound water treatment is to understand the
chemical properties of the impurities in the water. With most kinds of treatrnent,
the actual arnount of impurities in the water does not change, but rather their
action within the boiler is altered. With correct water treatment, solids (dissolved
or undissolved) in the boiler water will be precipitated immediately on entry to
the boiler, and will be of a t1occulent nature, remaining suspended in the water.
The aim of this treatrnent is to prevent dissolved solids from precipitating by
adhering to the hot boiler surfaces, thus forming scale. With correct treatment and
the correct addition of chemicals, your boiler water will consists of a fine
suspension of solids within the boiler. These will eventually settle out on the
bottom of the boiler and certain other chemicals are normally added so that when
these do settle out they form a mobile sludge, rather than an adhering cake. Blow
down is the normal method used to remove the accurnulation of these solids from
the boiler proper. lf the proportion of solids (dissolved or suspended) within the
boiler is allowed to accumulate over the recommended limits, excessive scaling
of the interior surfaces and priming of the solids with steam can occur. Priming
of solids with steam can be disastrous to mechanical stearn power equipment and
other heat transfer surfaces.
The aim of blow down therefore is to keep the proportion of the dissolved and
undissolved solids in the boiler within the limits recommended by sound water
treatment.
Blow down control can be obtained in three manners - these are :
l. Continuous blow down.
2. Automatic intermittent blow down usually with a timer and
solenoid valves.
3. Interrnittent manual blow down, usually on a 4 or 8 hour

basis.
The concentration of solids within the boiler should be regularly monitored as
instructed under the water treatment section of this manual. Regular checks
should be made by the operator to arri ve at a workable blow down schedule.
Advice in the water treatment notes will give an indication of how to calculate
blow down quantities to control the total dissolved and undissolved solids within
your boiler.
Never blow the boiler right down to the ernpty condition when the brickwork is
hot or the fire is buming.
i.
BOILERFEED WATER SYSTEM :

The notes on boiler feed water treatment that have been included will affect the
design of the feed water plant. For the complete removal of oxygen, the feed
water should be heated as much as possible, consistent with your feed pump
requirernents. As dissolved gases coming out of the solution due to heating must
be vented, an open or vented feed tank is recommended, rather than an enclosed
heat exchanger for feed heating. Sorne sketches of recommended installations are
enclosed. As an alternative, a complete de-aerator can be supplied, but this will be
dictated by the economics of your installation and the advice of a reputable water
treatment specialist should be obtained. Feed tanks should have at least a capacity
equal to 90 minutes rated boiler evaporation. In addition, hot feed water forros a
very convenient thennal storage which will assist the boiler in maintaining steam
pressure during periods of heavy steam demand and hot feed water can be
pumped in the boiler with less thermal shock than that which would apply if cold
water is used. Normally a feed tank should be erected as far above the feed water
pump as can be obtained. This will enable the feed water to be heated to as high a
temperature as possible. The feed water pump manufacturer will give the suction
heads required consistent with the inlet feed water ternperarure. It is
recommended that the feed water be heated to at least 80 Centigrade. Sorne
sketches are enclosed with this manual showing various recommended layouts of
feed water tanks. All tanks should be fitted with a clean-out opening for periodical
interna! cleaning and with a ball valve large enough to pass the equivalent
quantity of steam evaporated per hour at 150% o boiler rating. The suction pipe
should be fitted with a strainer.
A light dust-proof cover should be fitted in the interest of cleanliness, but not tight
enough to cause a partial vacuum in the tank when the water leve! sinks quickly or
-...~
MACKENZIE
the feed purnp will be adversely affected. Of course this is not a worry where a
vent pipe is fitted.
It is bad practice to heat feed water by the injection of exhaust steam which may
contain ol as the oil will be passed inro the boiler and serious damage may result.
If exhaust steam containing oil is used to conserve heat, it should be passed
through a coil placed at the bottom of the tank and then to the drain, as its heat
rnust be given up to the feed water without contaminating the feed water.
Where H.P. steam is used for heating the feed water, it may be used by leading a
pipe direct to the tank near the bottom, but not low enough to disturb any
sediment. Considerable noise and vibration results as steam passes into water, but
silencers and distributors are available which can be fitted to make the operation
practically noiseless, elirninate vibration and avoid the flashing of the steam off
the top of the tank. This fixture also ensures a faster rise in temperature with cold
water then if a heating coil was used.
j.
BRICKWORK :
Regular repair of any deteriorated refractory surfaces or brickwork will result in
greatly extended life of the overall setting and is normally the economical method
of repair rather than waiting until major repairs are required.
k. FANS:
As stated under the section of motors, all fan motors should be regularly in
inspected to see that their outside surfaces are clean. Though other aspects of the
fan will not require much attention, regular inspection of the belt drives and
bearings is recommended. Bearings should be adequately packed as per the
manufacturer' s.
l.
DUST COLLECTORS
Dust collectors, where provided, remove dust from the flue gas and is mounted on
the boiler outlet. Dust is collected in a hopper and is removed by a motor operated
air vaJve/reinjected into the furnace.
It is essential that the valve be operated continuously to prevent cake-up of the
dust in the hopper.
Also the valve must be inspected regularly to ensure that it does not leak as a
leaky valve will affect the draft available in the system and would affect the
performance of the boiler.
~~
MACKENZIE
1111
WATER TREATMENT OF MACKNZIE BOILERS
The major of problems which beset the average Steam Raising Plant can be traced
directly to the treatrnent of the water being used in that boiler.
It is therefore extremely important that the operators are completely familiar with the
various problerns associated with poor water treatrnent, their method of control, and the
benefits obtained from water treatment.
The following notes should serve as a guide to the method of obtaining a sound water
treatment scheme for your boilers.
As a minimum standard of satisfactory water treatment, British Standard B.S. 2486, 1954
- "Treatment for Water for Land Boilers" serves as a useful guide.
We draw your attention as this code. "Care should therefore be exercised in making use
of this standard, the advice of a technical specialist being usually desirable before
deciding to adopt any particular form of water treatment."
A full water treatment programmed should take account of certain aspects of boiler
operation and the operator should obtain assurances that all those factors have received
adequate consideration.
Por the information of operators, the following is considered the basis of establishing a
sound water treatment scheme for your boiler :
(i)
An appreciation of general water treatment principies.
(ii)
Initial testing to establish a satisfactory programmed.
(iii)
Water treatment equipment.
(iv)
Routine control and testing.
(v)
Dosage planning control.
(vi)
Testing appararus.
a) AN APPRECIATION OF GENERAL WATER TREATMENT PRINCIPLES:
All natural waters contain impurities in the form of dissolved gases and dissolved
salts derived from the atmosphere or from mineral salts in the earth through which
they have passed. Water used as a dornestic supply is usually clarified and sterilized
to remove color, suspended matter and bacteria bur the dissolved gases and mineral
salts remain in the solution in the water entering the public mains. Waters from
springs, streams or rivers, will also contain mineral salts and gases, together with
suspended material.
A water treatrnent programmed should take into consideration the following boiler
operating problerns.
l.
Scale and sludge prevention.
2. Corrosion :
1. Feed Water.
2. Boiler.
3. Condensate.
3. Caustic cracking.
4.
Carry over.
1) Scale Prevention :
The irnpurities, dissolved and undissolved, can give rise to heavy scale and sludge
deposits within the boiler unless adequate steps are taken to prevent them forming.
The suspended matter (undissolved) is not normally a major problem with domestic
supplies, but if the water contains appreciable quantities, removal of this matter is
necessary prior to its use in the boiler. This will normally require the use of
coagulation and/or filtration equipment designed to suit your particular requirements.
The dissolved solids give rise to the familiar scale fonnation on the interna! surfaces
of the boiler and the treatment to prevent this occurring in your boiler will depend on
the quality of the water you have available.
Your water may contain a solution of salts of Calcium(Ca), Magnesium(Mg), and
Sodium (Na), cornbined with Chlorides (Cl), Sulphates (S04), Carbonates (C03), and
Bicarbonates (HC03). You may also have your water containing either dissolved or
colloidal Silica. The calcium and magnesium salt content is termed the hardness of
the water and will give rise to scale formation on the interna! surfaces. Scale can also
be formed by excessive arnounts of silica. Abnormal amounts of sodium salts will not
normally form deposits, although further problems may arise.
For high hardness waters, sorne form of externa! treatment will probably be
recommended and the economics of the use of various types of equipment will be
dependen: again on the quality and the through put of your Plant. The normal form of
pre-treatment will either be Lime Soda Softening or Ion Exchange.
For low hardness feed waters, internal treatment may be sufficient.
Chemical addition will be required for adequate water treatment irrespective of the
use of pre-treatment. These chemicals will ensure that any scale forming salts do not
precipitare themselves onto the heating surfaces and are removed by the correct blow
down procedure. Notes on Externa! Softening, Ion Exchange and Interna! Treatment,
published by Imperial Chemical Industries a reputable water treatment company, are
enclosed.
2) Corrosion :
Corrosion of equipment can be caused by :
a) Acidic properties of your water (i.e. low pH and excessive C0:2).
b) Dissolved oxygen.
Corrosion can be associated with :
a) The Feed Water Systern.
b) The Boiler.
e) The Condensare System.
Effective control of corrosion will require the addition of chemicals to counteract
acidic properties of your feed water and condensare, and the complete removal of
dissolved oxygen. Removal of oxygen can be accomplished partially or completely
by heating and de-aeration of feed water, (solubility of oxygen decreases markedly
with temperatures above 65 Centigrade). The degree of de-aeration by externa!
means which can be econornically accomplished is dependent upon the size and
characteristics of your boiler installation.
The residual oxygen is removed by the addition of chemicals to the feed water.
The complete removal of dissolved oxygen is imperative to prevent corrosion in your
boiler. Incomplete removal of oxygen will result in pitting of boiler tubes and the
other waterside surfaces, eventually causing failure. It is most important that the
operator satisfies himself that the proposed treatment will effectively control the
dissolved oxygen and hence corrosion.
~~
MACKENZIE
1111
Various chernicals are available to correct low feed line pH conditions from pretreatment equipment, such as demineralization units, and these are nonnally in the
form of neutralizing Amines, which raise the pH to a safe level of approximately 8 to
8.5. This will elirninate any possibility of copper pick-up and plating within the
boiler.
Condensare corrosion can be affected by the use of either neutralizing Amines, which
raise the low pH of the condensare caused by dissolved carbon dioxide. As these
chemical normally return with the condensate to the feed water tank, the make-up of
the chernical is minirnal. Where extensive heat transfer equipment is installed, filming
Amines are normally recomrnended. These Amines have the ability to film the metal
surface, protecting the steel from corrosion due to the carbon dioxide and oxygen and
have additional benefits of maintaining the metal surface clean and are quoted as
increasing heat transfer rates by drop wise condensation. For the applicability of
various Amines to your particular system, a Water Treatment Consultant should be
contacted.
3) Caustic Cracking :
Caustic cracking or embitterment is not normally a problem with modem all welded
designs, but the probability <loes exist that failure can occur, especially with poor
water treatment control.
Instances of failure due to caustic cracking have been very dramatic and in sorne
cases failure have resulted in loss of life. Adequate protection must be ensured.
The decision on the applicability of the problem to your installation should be
referred to a qualified Water Treatment Specialist. An enclosure, published by
Imperial Chernical Industries of the effects and control of caustic cracking has been
enclosed.
4) Carry Over:
Carry over will not normally be a problem with your boiler, as we have taken steps tp
eliminare the possibility in our design.
Excessive dissolved solids, suspended solids and organic contaminants negate the
effect of these design features. Advice could be sought to obtain the maximum
concentration that is acceptable with your source of water, and your installation
should be designed to eliminare the possibility of contamination due to oil and fats
entering the boiler or condensate system.
Chernicals are available to counteract carry over problems, but application and use of
them should be referred to a Specialist.
b) INITIAL TESTING TO ESTABLISH A SATISFACTORY PROGRAMME

FOR YOUR INSTALLATION:
While planning your installation, consideration should be given to your water
treatment requirements. The information which will be required is :
l. Full laboratory analysis of the water supply.
2. Infonnation on the variability of your water.
3. Expected steam consumption and retum of condensare.
4. Degree of sophistication of equipment required.
Armed with this information, a detailed programmed can be established which takes
into account the previous factors that require attention.
Normally, a reputable Water Treatment Specialist will carry out the analysis for you
and, in fact, it is in your own interest for the Specialist to do so. However, it is
recommended that you also have an independent analysis carried out on your water
supply for you own protection. This will also ensure that there can be no
disagreement later on the samples supplied. It should be noted that Water Treatment
Specialists can only recommend treatrnent on the basis of the water sample
forwarded to them an their report will always include the analysis of the sample that
they obtained. As a result, regular checks of the water, especially where it is highly
variable, should be taken to ensure that the water treatment programmed that you are
using continues to be satisfactory for the supply.
This would be particularly irnportant in the case of suspended solids where water is
not taken from the normal domestic scheme. Such factors as flooding, low water
leve! in srnall dams and the performance of bores may effect the water quality.
Any major discrepancy between the water supply and that which was originally used
as a basis for treatment should be referred to the Water Treatment Specialist so that
modifications can be proposed.
e)
WATER TREATMENT EQUIPMENT :

The amount of equipment required for water treatment, will once again depend on:
1.
2.
3.
4.
The quality of the water.

The size of installation.
The degree of sophistication required.
Economics.
Specifications for any of the equiprnent considered can norrnally be obtained frorn a
reputable water treatrnent equipment manufacturer. Irrespective of the forms of
treatrnent applicable to your installation, chernicals will be required and though
should be given to ensure a satisfactory arrangement for addition of these chemicals
to your feed system. As a guide, the normaJJy accepted methods are summarized
below:
Chemicals for the prevention of scale in the feed water are normally injected
continuously. Those for scale prevention within the boiler, such as phosphates and
alkalis are normally slug fed periodically to prevent feed line deposition, but advice
should be obtained from a reputable supplier. Oxygen scavenging chernicals should
be, by their very nature, fed continuously, imrnediately downstrearn on the feeding or
pre-treatment equipment. Sophistication of the dosing equipment will of course
depend on the economics invoJved.
Amines are normally injected at a convenient point, depending upan the function
they are expected to perform. Neutralising Amines are normally fed into the feed
water after any pre-treatrnent equipment far pH control but filming Amines are
ideally injected into the steam header, so that evaporation takes place immediately
and an effective film is built up.
Notes published by ICI on the feeding requirements for their chernicals are included
with these notes.
d) ROUTINE CONTROL AND TESTING :

Effective water treatment is entirely dependent on adequate control. These controls
involve regular monitoring of the pre-treatment systems and chemical reserves and
concentrations within the boiler.
The chemical control tests have normally been simplified so that they can be undertaken efficiently by plant personnel.
Because the regular monitoring is so important to ensure the maximum effective life,
efficiency by your installation, and safe accident free operation, personnel must be
effectively trained in the operation of these tests and their supervisors should be
encouraged to take an active interest to ensure that they are conducted efficiently and
correctly. The degree of testing required depends upon the treatment preferred, but
the following instruction sheets have been included as a preliminary guide for your
information. The tests that could possible be recornmended include :
1. Total Dissolved Solids.

2. Phosphate.
3. Alkalinity.
4. Chloride.
5.
6.
7.
8.
9.
Organics.
pH.
Hardness.
Sulphite.
Positive Amine.
It is unlikely that all these tests will be required and the advice should be sought again on
which of these are applicable.
CONTROLTEST
Total dissolved
solids.
SIGNIFICAN CE
PURPOSE
Concentration of
Prevention of carry
salts in Boiler water. over and blow down
control.
METHOD
Gravo metric
Conductivity
Density.
Phosphate
Reserve of softening
chemicals.
Prevention of scale
formation.
Chemical color
comparison.
Alkalinity
Reserve of softening
chemicals.
Prevention of scale
formation.
Titration.
Chloride
Concentration salts
in Boiler
Blow down control.
Titration.
Organic
Reserve of sludge
mobilizing agents.
Sludge conditioning
control.
Chernical color
comparison.
pH
Degree of alkalinity
or acidity.
Prevention of
corrosion.
Indicator.
Hardness
Amount of Calcium
and Magnesium
Salts.
Effectiveness of pre- Titration.

treatment and/or
intemal softening.
Sulphite
Reserve of oxygen
scavenger.
Prevention of
oxygen corrosion.
Titration.
Positive Amine
Reserve of Amine
Effectiveness of
dosing
Chemical color
development.
Test required by boiler water, feed water and condensare, as well as the frequency of the
testing, should be specified by the specialist.
MACKENZIE
INDUSTRIES SDN. BHD. (649756-K)
e) DOSAGE PLANNING CONTROL :

Once a test has been completed, it is imperative that steps are taken to ensure the
results are within the limits specified. The following notes are a guide to efficient
control :
Control of the dissolved solids of course is very important and a guide to the
concentration of these within a boiler is usually obtained by a chloride test or total
dissolved solids test. If the figures obtained from the test result are above that
specified by the Specialist, more blow down is required. If the result is too low, less
blow down is required. It is important that a set and regular blow down pattem is
maintained so that variations to this pattem, as required by test results, are easily
made.
Chemical reserves such as phosphate, organics, sulphite and alkalinity are indications
of the effectiveness of treatrnent within the boiler. If che results indicare that the
reserve is lower than specified, more chernical is required. If the test indicates that the
reserves are too high, less chemical than that normally added is required. Once again
it is suggested that a set procedure of adding chemicals is adopted. Set amounts are
added in accordance with the recommendations of the treatment programmed and
simple adjustments made to this routine prograrnme when required.
The effectiveness of any pre-treatrnent such as softening, ion exchange and fi!ters can
be gauged by the test recommended by the equipment suppliers. These tests should be
conducted in accordance with their recomrnendations to ensure efficient treatment.
All water treatment programmes will include suggested control limits - for example,
the programrne may suggest that the phosphate reserve be between 30 and 70 parts
per million. The optimum condition may well be somewhere in between these, but
though no control can be as accurate as would be scientifically advisable, the control
range, specified as maximum and minimurn, should nor be exceeded for efficient
treatment.
TETING APPARA TUS :

The mode of testing required will depend upon your installation under programme
adopted.
The test equipment should be capable of conducting all those routine tests necessarily,
and should be either conducted in the laboratory or by the Plant operator. If the Plant
operator has been specified to conduct the test, then suitable test equipment should be
purchased.
This test equipment should include all the necessary apparatus and be properly
constructed of unbreakable material.
BOIL OUT TREA TMENT OF BOILERS

CHEMICALS/1000 GAL FIRE-TUBE BOILERS WATER-TUBE BOILERS
A 724 (Detergent)
A 214 ( Alkalinity)
A 310 (01 Scavenger)
(Na2S03)
A 304 (Sludge conditioner
/antifoam)
10 lb
10 lb
10 lb
20 lb
6 lb
12 lb
20lb
20lb
To assist circulations blow off stearn for 5 sec every 5-1 O min during 1 st hour under
pressure or blow-down once (open/close) every 20 minutes during 2"d and 3rd hour.
Test water every 3 hours for chemicals. Bol out for 24 hours @ 100 p.s.i.
Rernaining water to have
Phosphate Reserve
300 - 600 ppm
Phenolphthalein Alkali vities
200- 400 ppm
Sulphite Reserve
100 - 200 ppm
ALKALINITY lL"lBOILER WATERS

Using Phenolphthalein Indicator
The sample of boiler water must be filtered before testing, using a Whatman No.1 paper
or equivalent. (See NALFLOC Test Methods No. 1).
PHENOLPHTHALEIN ALKALINITY P
1. Measure 20 ml of filtered boiler water from a graduated cylinder into a casserole. Add
10 drops of Phenolphthalein Alkalinity is present.
2. Add 0.02N Sulphuric Acid solution (Ref. ASOO l) from a 1 O ml autornatic burette,
stirring continuously, until the pink color just disappears. Note the burette reading.
3. If more than 20 ml of acid has been used, repeat the test using a smaller sample.
Conversely, if less than 5 ml of acid has been used, repeat the test using a larger
sample.
4. Calculate the resultas follows :p 1000
ml of 0.02 N Sulphuric Acid used

Volume of sample in ml.
(expressed in p.p.m. in terms of CaCOJ)

5. Record the result under Pon your log sheet.
6. If chlorides CI are to be determined also retain the sample and proceed as described in
NALFLOC Test Methods No. 10.
CAUSTIC ALKALINITY O
1. Measure 20 ml of filtered boiler water from a graduated cylinder into a casserole. Add
about 1 gramme of salid Barium Chloride reagent (Ref. A5039) or 10 mi of 10 % w/v
Barium Chloride solution (Ref, A5008). Add 10 drops of Phenolphthalein lndicator
solution. The sample will turn pink if Caustic Alkalinity is present.
2. Add 0.021\ Sulphuric Acid solution, stirring continuously, until the pink color just
color just disappears. Note the burette reading. Ignore any return of the pink color on
standing.
3. If more than 20 ml of acid has been used, repeat the test using a smaller sample.
Conversely, if less than 5 ml of acid has been used, repeat the test using a larger
sample.
4. Calculare the resultas follows :-
1000
ml of 0.02 N Sulphuric Acid used

Volume of sample in ml.
(expressed in p.p.m. in terms of CaC03)

5. Record the result under O on your log sheet.
6. Wash the casserole thoroughly immediately after completing the test.
~~
MACKENZIE
1111
SULPHITE IN BOILER WATERS
Using Potassium lodate-lodide Solution
To avoid the effects of oxygen in the atmosphere upon the sulphite in the boiler water, it
is important that a separate sample be taken via a sample cooler or through a cooling coil,
to which a supply of cooling water is provided.
SILPHITE Na2S03
l. Measure 4 ml of 6.5% v/v Sulphuric Acid reagent (Ref. A5035) into a casserole.
2. Place a graduated cylinder (50 or 100 ml) under the outlet end of the sample cooler or
cooling coi! so that the end dips to the bottom of the cylinder.
3. Let the boiler water to be sampled run through the cooler and graduated cylinder to
waste for 2 minutes.
4. Withdraw the filled measuring cylinder from the outlet of the cooler.
5. Take the filled measuring cylinder, and decant to waste the excess boiler water above
the top graduation mark. Pour the remaining sample (50 or 100 ml) at once on to the
acid in the casserole.
6. Add about 0.5 gramme lodine Indicator (Ref. A5037).
7. Add Potassium lodate-lodide solution (Ref. A5034) from a 10 ml burette, stirring
continuously, until a permanent faint blue color is obtained. Note the burette reading.
8. Calculate the resultas follows :Na2SQ3
1250 3
ml of Potassium lodate/lodide solution used

Volume of sample in ml
(expressed in p.p.m. in terms of Na2S03)

9. Record the result under Na2SQ3 on the log sheet.
For details of a suitable Test Kit and Reagents for the above Test, consult the NALFLOC
Test Kit Schedules, NALFLOC can also supply a suitable cooling coil assembly.
MACKENZIE IND{;STRIES SDN. BHD. (649756-K)
PHOSPHATE IN BOILER WATER

Bv the Comparator Method
The sample of boiler water must be filtered befare testing, using a Whatman No. 6 paper
or equivalent. Check that the fil trate is clear and bright. If filtration through a folded filter
paper does not give a clear filtrate, filter the sample through a hard pad of paper pulp in a
Hirsch filter funnel (see NALFLOC Test Methods No. 1).
PHOSPHATE P04
l. Check that the temperature of the sample and reagents lies between 208 to 308C (708
to 858F).
2. Arrange four 10 ml test tubes, which must be clean and dry, in two rows of two.
3. Measure 5 ml of clear and bright boiler water filtrate into each of the two front test
tu bes.
4. Add 2 ml of 6.5% v/v Sulphuric Acid solution (Ref. A5035) into the front left test
tube. Mix well.
5. Add 2 ml of Acid-Molybdate solution (Ref. A5030) into the front right test tube. Mx
well.
6. Add 1 ml of Hydroquinone solution (see below) to each of the two front test tubes.
Mix well and allow standing for five minutes.
7. Meanwhile, measure 2 ml of carbonate-Sulphite solution (Ref. A5032) into each of
the two back test tubes.
8. At the end of the 5 minutes carefully pour the contents of the front test tubes into the
corresponding tubes in the back row, i.e. left to left and right to right. Then carefully
pour the mixtures into their respective tubes in a Lovibond comparator.
If phosphate is present in the water the contents of the right-hand comparator tube
will be colored blue whilst the contents of the Ieft-hand comparator tube will remain a
pale yellow and serve as a blank to compensate for any initial color of the boiler
water and chernicals.
9. Rotate the phosphate color disc 3/12 until a color match is obtained, when the number
appearing will indicate the phosphate present in the original boiler water in parts per
rnillion in terms of P04.
10. If the phosphate content of the sample is 70 ppm or greater, then the boiler water
should be diluted with distilled water and the test repeated. The amount of dilution
(which should start at equal parts, e.g. 20 ml. of boiler water plus 20 ml of distilled
water) should be sufficient to produce a color which is within the range of the disc.
The disc reading should then be multiplied by the factor appropriate to the dilution,
e.g. in the case mentioned above the factor would be 2.
11. Record the result under P04 on the log sheet.
12. Rinse all tubes with water and dry with a clean cloth.
11...~
MACKENZIE INDUSTRIES SDN. BHD. (649756K)
MACKENZIE
Preparing the Hydroguinone Solution

l. Add one Hydroquinone tablet (Ref. A5033) to the reagent bottle
marked
'Hydroquinone Solution'.
2. Measure SO ml of 0.02N Sulphuric Acid solution (Ref. A5001), using a graduated
cylinder, and pour ir into the bottle. Crush the tablet with a glass rod and stir well to
dissolve.
NOTE: If, on storage, the solution turns brown, discard it.
For details oi a suitable Test Kit and Reagents to carry out the above test, consult the
NALFLOC Test Kit Schedules.
g) EXTERNAL TREA TMENT

Externa! treatment is the reduction or removal of impurities from water outside the
boiler. In general, extemal treatment is used when the amount of one or more of the
feed water impurities is too high to be tolerated by the boiler system. In most palm oil
milis the system will incorporate ion-exchange process - to remove che total hardness
and deacration - for removing dissolved gases before entering the boiler.
The goal of externa! treatment is to produce quality water acceptable for the boiler.
This means that the ion-exchange and deaerating equipments must function as the
manufactures intended. And, if it is to function properly, the equipments must be
controlled and understood by ali involved personnel. Remember, whatever is done or
not done in the external treatrnent system directly affects the operation of the boiler.
A system that is not controlled properly results in :1. Scale or corrosion in the boiler.
2. Upset of the interna! treatment programme.
3. Excessive downtime and maintenance and loss of production.
These upsets resulting in excessive leakage of hardness salts and oxygen to the boiler
feed water, causing scale to forro in the boiler or pitting and the tube failure due to
oxygen corrosion. Scale and corrosion occur because the interna! chemical
programme in the use is designed to control these contaminants at their normal
controlled levels. The interna! chernicals programme can be adjusted for minor
fluctuation in the boiler make-up feed water, but, because of these fluctuations, it
cannot be expected to keep the boiler system free from deposits and corrosion. Finally
the deposits formed in the boiler cause overheating, loss of efficiency and, eventually,
tube failures. These tube failures lead to a very serious situation - excessive
mechanical repairs and loss of production. So, to prevent the ultimare loss of plant
production and for proper functioning of the interna! chemical treatment programme,
the externa! treatment equipments must be controlled and maintained in proper
working order.
h. ION-EXCHANGE PROCESS
In most oil milis ion exchange process is mainly the sodium caution type and will
remove most of the calcium and magnesium hardness salts in the treated raw water.
Ion exchange in water treatment is the transfer of unwanted ions from the raw water
to a solid, which accepts these and exchanges them for a desirable species of ion.
This process is reversible: after the solid ion exchanger becomes saturated with the
unwanted ions, it is relieved of them by washing with a regenerating solution
containing the desirable ions, which then occupy the exchange sites.
Regardless of their chemical structure the sodium cycle ion exchanger consists of
sodium (Na) attached to a complete molecule of resin usually indicated by Z. The
following equation therefore represents reactions which take place. This method is
often called the 'Base Exchange Process'.
s~
Ca
Mg
Ch
(HCQ3)2
(NQ3)2
+ Na2Z-----CaZ + MgZ + Naz
s~
Ch
(HCQ3)2
(N03)2
It should be noted that all calcium and magnesium salts have been converted to their
correspondng sodium salts which result in a slight increase of the dissolved solids
content of the softened water. In addilion there is no reduction in total alkalinity.
When ali replaceable sodium ions have been removed the material is regenerated
with sodium chloride (NaCI). The point at which regeneration of resins is necessary
being indicated by a sharp rise in the hardness of the so softened water.
CaZ + MgZ + 4NaCI -----2Na2Z + CaCl2 + MgCl2
The volume of resins in a softener is often measured in terms of cubic foot. The
exchange capacity is the weight of ions exchanged between the resins and the water
during a service run, expressed in kilograms (1000 grams) of ions transferred, as
CaC03, by each cubic foot of resin (kgr/cu.ft.). 1 gram per gallon
17 .1 ppm. Most
base exchange softening resins in palm oil mills have exchange capacity of 20
kilograrnf cu.ft.
Problems To Look Out On Softner

a.
b.
c.
Temperatures: - Temperature rise in the water supply may lead to gas release
which disrupts the resin bed. Susceptibility to chemical attack increases with
temperature rise. In the absence of oxidizing agents, the resins are stable well up
to 2008F.
Organic matter and turbidity: - Both materials have detrimental effects on resins.
Besides they fouled on the resins preventing and restricting the flow of water and
could lead to pressure build-up. NALFLOC N344 Liquid an anonc dispersant
can effectively clear up the fouling on the resins and at the same time disperse
them into very fine particles that during backwash all these will be removed.
Iron, aluminium and copper: - All these elements are potential foulants and will
not be removed by normal regeneration. By coating on the resins the exchange
capacity of the resins is greatly reduced thus necessitating more frequent
regeneration. Poisoned resins can be cleaned by NALFLOC CZ Powder which is
a powerful reducing agent.

~~
MACKENZIE
1111
d.
e.
f.
i.
Sodium: - As base exchange is an equilibrium process which is reserved by the

presence of sodium salts, an abnormal quantity of the sodium salt in the raw
water will increase the amount of hardness which will rernain after softening.
500 ppm of sodium salts will have a detrimental effect, even 100 ppm may cause
a noticeable increase in hardness if the raw water hardness is high.
De-Crosslinking: - Certain oxidizing chernicals in water especially free chlorine,
attack the resin skeleton at the cross-links, thus weakening the gell structure. Decrosslinking can be detected by an actual increase in bed volume. For maximum
resin life, chlorine can be removed by catalysed sodium sulphite (NALFLOC
A310 Powder or NALFLOC N780A Liquid) prior to ion exchange.
Oxygen: - Although oxygen attack of caution exchangers is not severe below
1008F, attack in hot water systems is rapid at higher temperatures. Above 2008F
02 should be completely removed before ion-exchange.
Por maximum
protection, NALFLOC A310 Powder or NALFLOC N780A Liquid may be
added as far upstream as is practical, preventing corrosion while protecting the
res in.
SCALE PREVENTION
For scale prevention in boilers Nalfloc has been adopting three approaches to curing
the following potential scale problems in palm oil mill boilers: a. Precipitation
b. Supersaturation and crystallization
c. Accumulation of deposits of iron and copper
d. Analcite and Acmite scales.
The three Nalfloc concepts of internal boiler water treatment scale control are: a. Alkali Dispersancy and Coagulation Programme.
b. Phosphate Organics Programme.
c. Scale Control Agent (SCA) Programme.
A. Alkali Dispersancy and Coagulation Programme

The principies and mechanisms of coagulation programme have been well defined
and tested over the years. This programme is mainly for feedwater having total
hardness more than 60 ppm and high turbidity, iron and copper contents. The
programme consists of using: -
l. NALFLOC A51 l Liquid-A blend of alkaline, corrosion inhibitors and

dispersants in liquid form.
2. NALFLOC N780A Liquid - A blend of stabilized catalysed sulphite in liquid form.
3. NALFLOC N73 l l Liquid -A blend of antiscalant, dispersant and crystal
modifiers.
MACKENZIE
INDUSTRIES SDN. BHD. (649756-K)
Essentially the programme preferentially precipitates feedwater calcium hardness

as calcium carbonate, while the magnesium hardness is precipitated as magnesium
hydroxide or magnesium silicate.
a)
Ca(HC03)2
CaC03
C02
Calcium
Hardness
Calcium
Carbonate
Precipitate
Carbon
Dioxide
b) Ca(HC03)2
NaOH
CaC03
Sodium
Hydroxide
Calcium
Carbonate
Precipitate
Calcium
Hardness
e) CaS04
Na2C03
H20
Water
Na2C03
Sodium
Carbonate
CaC03
4Na0H
Mg(OH)2
Sodium
Hydroxide
Magnesium
Hydroxide
Precipitate
Magnesium
Hardness
e) MgCh
Magnesium
Hardness
f) MgCh + Si02 +
Sodium
Hydroxide
Magnesium
Hydroxide
Magnesium
Silicate
Precipitate
Sodium
Carbonate
Mg(OHh
MgSi03
Soluble
Sodium
Sulphate
2Na2C03
2Na0H
NaOH
Water
Na2C04
Calcium
Carbonate
Precipitate
d) Mg(HC03)2
2H20
Water
2NaCI
2H20
Sodium
Chloride
NaCI
Sodium
Chloride
H20
Water
The crystal growth is controlled by NALFLOC N7311 which wil1 permit the formation of
large, flocculant suspended solids that can be easily removed by blowdown. Dispersants
in NALFLOC A5 l l and N73 l l will ensure that iron, copper and suspended matters will
~~
MACKENZIE
1111
not deposit on the hot metal surfaces by dispersing and keeping the suspended matters
from baking on tubes.
If the hardness salts do precipitate directly on the hot metal surfaces the crystal modifier
in NALFLOC N73 l l will distort the crystal structure of the scale forming compounds so
that the crystals will not deposit and built up to form hard scale.
Analcite and acmite scales are inhibited from forming in the boilers by maintaining the
caustic alkalinity: silica ratio to be greater than 2.0. By maintaining this ratio the
troublesorne silica is kept in the soluble sodiurn silicate form.
Given below are the control limits on Nalfloc Alkali Dispersancy and Coagulation
Programme in palrn oil rnill boilers working up to 300 psi.
CONTROL LIMITS
Total Dissolved Solids

Caustic Alkalinity as CaC03
Silica as Si02
Below 3000 ppm

350 to 650 ppm
Less than Yz caustic
Alkalinity
50 to 150 ppm
2ppm
Below 25 ppm
Sulphite Reserve as S03

To tal Iron as Fe
Total Hardness as CaC03
Initial Filling Charge
Whenever a boiler is initially filled the following 'NALFLOC' chemical dosages should
be added if the boiler is using 'NALFLOC' Alkaline Dispersancy Coagulation
Programme: NALFLOC A5 l l Liquid
NALFLOC N780A Liquid
2 litres
-
NALFLOC N7311 Liquid
0.4 litres
0.25 litre
)
)
)
)
per ton of water used to

fill the boiler
Control and Adjustment of Boiler Water Results

j.
BOILER BLOWDOWN
Blow down to a boiler rnust be considered an important practice of good boiler
house-keeping. Blow down controls the arnount of suspended and dissolved
impurities in boiler water. Too little blow down allows suspended solids (sludge) and
MA.CKENZIE INDUSTRIES SDN. BHD. (649756-K)
dissolved solids to accurnulate leading to sludge deposition and carryover. Too much
blow down waste fue!, chemicals and feed water.
In general, blow down quantity depends on both the level of solids in the feed water
and the level of solids that can be tolerated in the boiler.
Control limits for boiler water solids are usually based on one or more of the
following factors: l. Sludge - This is a direct measurement of feedwater hardness (calcium and
magnesium) since virtually all hardness comes out of solution in a boiler.
Sludge can contribute to both deposits and carryover.
2. Total Dissolved Solids - These consist of sodium salts naturally present in the
feedwater, soluble silica and any chemical treatment added. Total dissolved
solids do not normally contribute to scale formation but excessive amount can
cause foaming and carryover.
3. Silica - High silica level in boiler water necessitates blow down to control
selective silica carry over and silicate scale.
4. Iron - High iron in the boiler water can lead to deposit problems and blow
down should be regulated to limit the leve! of iron in the boiler water.
In most palm oil mill boilers operating up to 250 psi the maximum allowable total
dissolved solids to be maintained in the boiler water is 3000 ppm. However in sorne
cases we limit the level up to a maximum of 2000 ppm if feedwater total iron and
copper contents contribute up to a total 0.2 ppm.
Blow down is often expressed in terms of percent of total evaporation. It can be
calculated as follows: % Blowdown
Where
A
B
A
B-A
100%
Feedwater solids
Maximum perrnissible boiler water solids.
Blowdown in palm oil mill boilers are mainly carried out manually at regular interval
or automatically carried out at more frequent and short interval. Very rarely has a
palm oil mill boiler is practicing a system of continuous blowdown.
MACKENZIE u-lDUSTRIES SDN. BHD. (649756-K)
Most manual blowdown is carried out about once every 2 to 3 hours and the method
conssts of a few short bursts of few seconds duration with one minute or more
intervals between successive bursts.
However if automatic blowdown val ve is installed then the manual blowdown needs
to be carried out once per shift to lower the dissolved solids concentration and
removal of sludge that tends to accumulate in these low areas.
1000 PPM
1500 PPM
i-=-:"'"-=-="'-~"-"--''-=-"'--'--""l'-~~--.G-.-~~-1-~~~4-~~--i-~,....,._~--+-~~----1HO'W
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SO LID
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20
40
60
80
100
120
TOTAL SOLIDS IN FEED'W ATER (PPM)
140
160
4000
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MACKENZIE

PROJECT: WATER TUBE BOILER

END USER: EXTRACTORA CATATUMBO

Tel: + 603-5123 0018

&.l.l.L llicolo,;r 1,,1wl G.fl.ilt lody fa< 99

Air U.-. touiome"'u

s.fetv Valw Tvoe "22.4&JS

MaMal llowowll v-..

Otff~~ ... tTr*''"'"""-r!JAllOE

'ed Water Une

8oltr fttd Watts Pu.mos

l~tr~I Cace Motor

Fe.O Water Une

!O. fO SA, Ff Fan

Modulatinc Gor Motot

Comprtss A.Ir tree

MACKENZIE INDUSTRIES SDN. BHD.

Wah Seong Corporation Bhd

On falling boUer steam gressure

Reciprocacing Grate Stoker

A Member of '\t' Wah Seong Corporation Bhd

5) BOILER PRESSURE PARTS MATERIAL

6) INSPECTION OPENING AND CASTING WORK

Steam pressure gauges

8) BOILER FEED WATER REGULATOR

10) FAN SYSTEM

11) ACCESS GALLERIES

A Member 0(1/ Wah Seong Corporation Bhd

MISAOO 1-27 /12

12) FLUE GAS DUCT &: AIR DUCT

BOILER FEED WATER PU:V!P

STEA1\ll OPERA TED

Horizontal rnulrsraze centrifuga}

Inler Water Ternperarure, max

Purnp Inlet Size

Pump Outlet Sze

15) THERMAL INSULA TION

A Member o 17 Wah Seong Corporation Bhd

16) DUST ARRESTOR

: 50 mm W. G. ar 350 deg. C across arrestor

rnorors supplied wth che boiler.

A Membcr of Y/' Wah Seong Coqxxation Bhd

Pressure Gauge I Transmirter ( WlKA - USA/ YOKOGA WA- JAPA. )

Ternperarure Gauge ( 'vVIKA- USA)

Water LevelGauge /Transmrter ( BONT - rTALY I \10BREY - UK/ YOKOGAWA)

Flow Transmirter / Flow meter (YOKOGAWA- JAPAN)

Flow control valve (, ELES ]A.\i1ESBURY - Fl. L\1'\iTI)

Combustion control ( YOKOGA WA - JAPAN)

23) AIR- PREHEATER

with 3mm mld steel ductng,

Tube Material: BS 1387 Class Medium

: Hori::ontal multi-Ioop, self draining type.

Wah Seong Ccepoearon Bbd

25) THERMAL DEARA TOR SYSTEM

1) Deaerator Booster Pumpset

: lsolation valve, strainer, pressure gauge and MS baseplate

lt/' Wah Seong Corporarion

3) Supporting Structure C/w Platform for the Thermal Deaerator

: PE tank, 200 liter

: Injeccion valve, foot valve, 5m long PE tubing

6) Inte:--connecting piping within the deaerator

: One (1) loe

: GI (Water) and black pipe (Steam) inclusive of PRV downstream to vessel

7) Electrical control panel