Operation and Maintenance 1 PDF

PLAN RECORD REVISIONS AP- CHECK-
N57-30M-M500(1) PROVED ED
ISO METRIC SCREW THREADS NO. DESCRIPTION (DATE)
DRAWING NO.

MAC TYPE AUX. BOILER
7 5
RP0

OPERATION AND MAINTENANCE
INSTRUCTIONS(1)

SZ
7 5
A34
A4447 total 451 SHEET(S) WITH COVER
MARINE BOILER DESIGNING SEC.

TURBO&MARINE MACHIN.DESIG.DEPT
SAMSUNG H.NO.1451/2/3/4/75/1506/7
APPROVED T.Yuki AUX. BOILER (MAC-30B)
Y.Ono
CHECKED OPERATION AND
DRAWN S.Sueno MAINTENANCE INSTRUCTIONS(1)
CONFERRED SCALE
ORDER ITEM D R A WI N G N O . REV.NO.
F1562/3/4/5
/K1A25/6/7
- N57-30M-M500(1) 0
MITSUBISHI HEAVY INDUSTRIES, LTD.

NAGASAKI SHIPYARD & MACHINERY WORKS
DRAWN Oct. 2, 2003. ISSUED
FOREWORD
This instruction manual treats of affairs requiring attentions of workers in

charge of this boiler with a view to giving them a guidance for proper
operation to make the most of the boiler, to prevent injuries of damages that
may be caused by improper handling and to ensure high-efficiency service and
perfect safety for a long time.
However, this instruction manual refers to only fundamental rules necessary

for operating handling the boiler.
Consequently, those who are in charge of handling the boiler are expected to
learn completely the subjects included in this manual and get well versed in all
related appliances including pippins and fittings as well as the boiler itself so
that they can handle the equipment perfectly.
Warning
Please strictly refrain from copying the contents of this manual or making an
extract from them and revealing them to others.
A-0
(1)
TABLE CONTENT
SECTION
A. INTRODUCTION
1. PRINCIPAL PART A-1
2. DESIGN DATA A-2
3. PERFORMANCE DATA A-3
4. BOILER ACCESSORIES A-4
5. CONSTRUCTION A-5
6. OPERATING PROCEDURE A-6
7. MAINTENANCE A-7
8. CHECK LIST A-8
B. OPERATING PROCEDURES
1. INTRODUCTION B-1
2. OPERATING OF AUXILIARY BOILER B-2
3. BOILER HEATER OPEATION PROCEDURE B-3
C. GENERAL MAINTENANCE
1. FEED WATER AND BOILER WATER TREATMENT C-1
2. CARE OF BOILER OUT OF SERVICE C-2
3. HYDROSTATIC TESTS C-3
4. BOILER OUT C-4
5. WATER WASHING FIRESIDES C-5
6. ACID CLEANING C-6
A-0
(2)
D. MAINTENANCE AND REPAIR

1. MAINTENANCE OF REFRACTORY D-1
2. BOILER PRESSURE PART D-2
3. HEADER END PLATE D-3
4. FLANGED JOINT D-4
5. SLIDING SADDLE D-5
6. TUBE PLUGS D-6
7. REFERENCE DRAWINGS D-7
E. BOILER ACCESSORIES
1. AUTOMATIC BOILER CONTROL SYSTEM E-1
2. OIL BURNER E-2
3. SOOT BLOWER E-3
4. WATER GAUGES E-4
5. SAFETY VALVE E-5
8. CHEMICAL DOSING EQUIPMENT E-8
10. F.D. FAN E-10
18. PISTON VALVE E-18
A
A. INTRODUCTION
PRINCIPAL PART A-1

DESIGN DATA A-2
PERFORMANCE CURVE A-3
BOILER ACCESSORIES A-4
CONSTRUCTION A-5
OPERATING PROCEDURE A-6
MAINTENANCE A-7
CHECK LIST A-8
A-1
1. PRINCIPAL PART
MITSUBISHI MAC-B AUX. BOILER
A-2
(1)
2. DESIGN DATA FOR 1 BOILER
PRESSURE Kg/cm2g
Design 18.0
Operation 16.0
Hydrostatic test 27.0
Safety valve setting 18.0
TEMPERATURE
Steam (at drum) 203.4 (Saturated)
Feed water 80.0
Air to Burner 45
EVAPORATION Kg/h
Boiler Max 16 k MODE 26,000
2
HEATING SURFACE m 328
FURNACE VOLUME m3 20
BOILER WATER WEIGHT kg
Total cold water fill the unit completely 12,500
Cold water to fill boiler to normal water level 9,500
Water at operation 8,200
BOILER WEIGHT kg
Boiler dry (with burner & soot blower) 31,400
Total operation 39,600
A-2
(2)
THE DATE
Location No. Tubes O.D.(mm) Thickness(mm)
Rear Bank Tubes 372 45.0 2.9
Front Water Wall Tubes 24 76.2 4.0
Rear Water Wall Tubes 24 76.2 4.0
Front Bank Tubes 23 76.2 4.5
Floor, Side, Roof, Wall Tubes 23 76.2 4.5
Rear Bank Front Wall Tubes 15 76.2 4.0
Rear Bank Rear Wall Tubes 15 76.2 4.0
Gas Outlet Water Wall Tubes 15 76.2 4.5
A-2
(3)
AUX. BOILER MAC TYPE
LEVEL - ALARM AND FUEL OIL CUT

A-3
(1)
26T/H
BOILER EXPECTED PEFORMANCE DATA (16.0K
LOAD 25% 50% 75% 100%
EVAPORATION kg/h 6,500 13,000 19,500 26,000
2
DRUM PRESSURE kg/cm 16.0 16.0 16.0 16.0
FEED WATER TEMP. deg.C 85.0 85.0 85.0 85.0
SATURATED STEAM TEMP. deg.C 203.4 203.4 203.4 203.4
BOILER EFFICIENCY (LHV BASE) 82.1 82.8 81.9 80.5
CALORIFIC HHV kcal/kg 10,280 10,280 10,280 10,280
VALUE LHV kcal/kg 9,713 9,713 9,713 9,713
FUEL OIL CONSUMPTION kg/h 475 941 1,427 1,935
EXCESS AIR RATE 31 16 15 15
O2 RATE 5.0 3.0 2.9 2.9
COMBUSTION AIR FLOW kg/h 8,720 15,290 22,980 31,160
FLUE GAS FLOW kg/h 9,190 16,230 24,410 33,090
AMBIENT AIR TEMP. deg.C 45 45 45 45

A-3
(2)
MAC-30B BOILER EXPECTED PERFORMANCE CURVE
EFFICIENCY CURVE (L.H.V. BASE)

83
82
EFFICIENCY (%)
81
80
79
0 10 20 30 40 50 60 70 80 90 100
F.O.C. CURVE ( * 1,000 kg/h)

2.2
2
1.8
1.6
1.4
F.O.C.
1.2
1
0.8
0.6
0.4
0.2
0
0 10 20 30 40 50 60 70 80 90 100
O2 RATE CURVE (% BY VOLUME)

10
9
8
7
6
O2 RATE
5
4
3
2
1
0
0 10 20 30 40 50 60 70 80 90 100
BOILER LOAD %
A-4
4. BOILER ACCESSORIES
EQUIPMENT MANUFACTURER
(1) COMBUSTION CONTROL MITSUBISHI HEAVY IND.
Electronic operated
(2) FEED WATER REGULATOR MITSUBISHI HEAVY IND.
Electronic/air operated
(3) DRUM LEVEL SAFETY SYSTEM YAMATAKE CO., LTD.
Electronic operated
(4) OIL BURNER VOLCANO CO., LTD.
Steam atomizing venture type
(5) SOOT BLOWER KIKAN BUHIN CO., LTD.
Rotary type
(6) WATER LEVEL GAUGE SAWADA SEISAKUSHO CO., LTD.
Transparent type
(7) SAFETY VALVE FUKUI SEISAKUSHO CO., LTD.
(8) F.D. FAN TONG YANG MAGIC CO., LTD.
(9) CHEMICAL DOSING EQUIPMENT I.T.I CO., LTD.
(10) PISTON VALVE KONAN VALVE CO., LTD.
A-5
(1)
5. CONSTRUCTION
The boiler is named MITSUBISHI MARINE WATER TUBE BOILER. The description
given below is an outline of its construction. For its further details, you are referred to the
reference drawings for the ship equipment.
1. General construction
The boiler is of two-drum construction with one steam drum and one water drum, and
mainly consists of boiler proper, boiler casing, fuel firing equipment, mountings,
fittings and other accessories.
The boiler structure is supported with a water drum water wall lower headers as
supporting bases. The whole boiler constructions is so designed as to be able to
withstand the rolling, pitching and the shock of the ship. Careful consideration is also
given to the movement by thermal expansion of the boiler.
Combustion gas flows through the boiler in a return flow path where necessary,
manholes, peep hole are provided for easy access and inspection.
2. Furnace
Closely spaced water wall tubes of 76.2 mm outside diameter are provided to the
furnace side, rear, roof except burner opening and front wall in order to increase the
heat absorption in the furnace and form it strong enough to withstand vibration, etc.
A-5
(2)
At the top and bottom of the front and rear walls are provided water wall headers
respectively. The water that entered the bottom headers rises through the wall tubes to
the top headers. As it rises, it is heated to saturation temperature and begins
evaporating and from the top headers this water-steam mixture is led to the steam
drum.
One end of each top header is directly connected to the steam drum and one end of
each bottom header is directly connected to the water drum.
The roof, side and bottom water walls of the furnace are formed with welded water
wall tubes connecting the water drum to the steam drum. No headers are provided for
them.
3. Boiler casing
The furnace of the boiler is made completely gas-tight by the adoption of welded water
wall construction. The welded water wall construction is also adopted to the front and
rear walls of the rear evaporating tube section where tubes are exposed to the
combustion gas.
On the outer surface of the furnace water walls, insulation are provided.
Insulations are applied to the outer surface of the water walls and the outermost
surface of the furnace is covered with galvanized steel casing except furnace roof and
floor.
A-5
(3)
4. Steam Drum
The steam drum and water drum are to be fabricated using boiler steel plate approved
by applicable ship classification society. They are to be of all-welded construction, and
welded joints are to be produced in accordance with the procedures approved by
applicable ship classification society and then given the post-weld stress relieving.
In the steam drum, a multi-perforated baffle plate covering the entire steam evaporation
surface is provided to prevent the generation of water-saturated steam. Also, in the
steam compartment the steam separator is provided to completely remove the moisture.
The water compartment is provided with the feed water internal pipe, surface blow-off
internal pipe, chemical feed internal pipe, and sampling pipe.
The baffle plate and steam separator in the steam compartment are of built-up type,
permitting to be disassembled for bringing in and out of the drum by way of the
manhole.
A-6
(1)
6. OPERATING PROCEDURE
1.Preparation
Prior to beginning operation, check and prepare for the following.
(1) Boiler proper
Refractoriness, manhole covers, Header end plate covers and oil residue in the burner
wind box
(2) Valve settings
Water level gauge root valves, drum vent valves, safety valves, pressure gauge root
valves, blow-off valves, and pressure detecting root valves for ACC.
(3) Burners and accessories
Heavy oil lines and atomizing steam lines and valves.
Opening and closing of F.D. FAN inlet vane.
Kind of fuel oil (Diesel oil or heavy oil C).
(4) Ancillary equipment
Proper functioning of automatic combustion control equipment, automatic feed water
regulator, soot blowers and remote water level indicator.
(5) Filling the boiler
Fill the boiler up to the normal water level with distilled water or demineralized water.
Check feed water system.
(6) Starting the forced draft fan
Start the forced draft fan with inlet vane fully closed.
(7) Starting the fuel oil burning pump
Start the pump. In case of hot start, clean the oil line of cold heavy oil and warm-up the
line with oil flow through the recirculation line. In case of cold start, discharge oil
remaining in the line and fill it with diesel oil.
A-6
(2)
2. Lighting off and pressure raising

Proceed in the following order.
(1) Confirmation of response of water level gauges.
(2) Purging the furnace
Operate the fan with inlet vanes opened 100 % for more than 1.0 minute.
(3) Lighting off the burner
Use a nor tip for the burner, and light off it with a pilot burner. After lighting off,
observe combustion condition.
(4) Pressure raising
Note drain discharge, air venting and water level fluctuation.
(5) Inspection after completion of pressure raising
Confirm response of water level gauges. Check indication of pressure gauges and
functioning of safety valves.
3. Operation notes during normal service operation

(1) Change load as slowly as possible when load is high.
(2) Lower the steam pressure set point to prevent popping off of safety valves when the
load fluctuation is severe.
(3) Check various parts referring to the check list.
(4) Check combustion condition and make a necessary adjustment to obtain good
combustion. Reduce excess air as much as possible.
(5) Analyze boiler water and feed water, and maintain proper condition of them.
(6) Blow soot blowers to maintain heating surfaces clean.
Caution
Operate the fan with inlet vanes opened 100 % for
more than 1.0 minute.
A-6
(3)
4. Boiler shut-down
Shut down the boiler in the following order.
(1) Blow soot blowers.
It should be made while the boiler is carrying not less than 50 % load.
(2) Shut-down burner, one at a time.
(3) Purge the furnace.
(4) stop the fan.
(5) In case of boiler stand-by
Burn a burner at times and maintain the boiler at about normal pressure with boiler
water at normal level.
(6) In case of complete shut down;
Close the feed water valve and the steam stop valve.
Open the drum vent to release steam to lower the pressure.
After that, laid-up the boiler dry or wet.(Refer to C-2.)
A-6
(4)
5. Operation of ancillary equipment

(1) Burner
Pay attention to excess air ratio, oil pressure and temperature atomizing steam pressure,
and cleanness of burner tips to maintain good combustion. Never fail to purge the
furnace before lighting off and after shutting down burner.
(2) Automatic combustion control equipment
Operators are requested to be well versed in change-over operation of the boiler control
mode AUTO to and from MANUAL so as to be able to change control mode smoothly.
Pay attention to indications of various controls and see whether they are all functioning
properly or not.
Blow off drain from supply air lines every 4 hours.
(3) Automatic feed water regulator
Pay attention to water level fluctuation and see whether the feed water regulator is
functioning properly or not.
(4) Soot blowers
Soot blower shall be operated by the MANUAL and must not be operated in IGS mode.
A-7
(1)
7. MAINTENANCE
1. Feed water and boiler water treatment (refer to C-1)

Feed water and boiler water shall be analyzed at least once a day. Amount of chemicals
to be added and amount of boiler water to be blow down shall be controlled referring to
the results of the analysis so as to maintain each chemical content of the water within
the prescribed limit. Operators are requested to have correct understanding about the
action and effect of each chemical and calculation method of required quantity of it.
Recommended chemicals are as follows.
For raising pH value AMEROID/GC

For raising PO43- ADJUNCT "B"
2. Maintenance during shutdown

There are two ways of laying up the boiler, dry and wet. Either way may be adopted as
the case may be. When the boiler is laid-up wet, care should be taken to the
concentration of chemicals in the boiler water, and when the boiler is laid-up dry, care
should be taken to the effectiveness of the drying agent.
A-7
(2)
3. Hydrostatic test
There are two kinds of hydrostatic test one for checking water tightness of pressure
parts and the other for checking strength of the same.
Test pressure should be determined to suit the case.
4. Boiling out
Boiling out is intended to cleanse the boiler internal surface of oil and grease. The
boiler is filled with high alkaline solution and is heated for a predetermined duration by
means of steam or by burning oil whichever the occasion demands.
Boiling out burning oil is often made to serve as burning and drying out refractory used
in the boiler setting, too.
Recommended duration of boiling out for a new boiler is 2 to 3 days.
5. Hot water washing

Hot water washing is intended to remove sludges sticking to the gas side of the boiler
that can not be blown off by soot blowing. There are two ways for hot water washing,
one by use of soot blowers and the other by use of a temporary hand nozzle, Both ways
have their own merits, either way may be adopted as the case may be.
Recommended hot water temperature is about 80 .

A-7
(3)
6. Acid cleaning
Acid cleaning is intended to remove scales on the water side of the boiler. Inhibited
hydrochloric acid solution is generally used for this purpose. But it is important to
consult with the professional expert as to the details of cleaning job so as to take most
suitable measures to the actual case and to prevent damage that may result otherwise.
7. Refractory
Two kinds of refractory used are for this boiler, one is plastic refractory and the other is
castable refractory. Both refractory are often used for repairing work, too. As the plastic
refractory needs to be burned after placed, it is not used on the boiler pressure parts,
where the castable refractory should be used instead.
When the castable refractory is to be used on the pressure parts, it should be given
necessary clearances for thermal expansion.
After repairing refractory work. never fail to dry it out by firing.
8. Boiler proper and water walls

Inspect both gas and water sides of the boiler whenever the opportunity is afforded and
see whether it is necessary or not to clean the gas side, to acid-wash the water side or to
replace tubes. Results of these inspections should be referred to in the subsequent
burner operation, feed water control, etc.
9. Boiler drum support legs

The water drum support legs on the boiler rear side are the only fixed legs, and all the
other legs are of sliding type requiring the injection of grease once a year (Grease:
SHELL ALVANIA EP NO.2, MOBILUX 2 or equivalent).
10. Boiler repair

The boiler repair work includes the tube plugging, header end plate renewal, removal
of manhole cover, tube renewal, expander renewal, packing renewal, etc. It is required
that the boiler operator be familiar with the working procedures there in involved.
A-7
(4)
11. Maintenance of accessories

(1) Burner
The burner tip is to be cleaned periodically and examined for disorder. The swirler is to
be maintained as clean as practicable, and also the burner throat area is to be always
kept in good working order.
(2) Soot blower

The soot blower steam line drain discharge, smoothness of rotary motion, and adequacy
of lubrication are to be monitored. In the process of boiler open-up inspection, the
element nozzle is to be examined for disorder and also the element for bend.
(3) Automatic Combustion Control System and Automatic Feed water Regulator.
By taking the control unit indicator reading, the control performance of each system is
to be monitored.
The air supply line drain is to be blown out once every four hours.
The moving parts of every equipment are to kept always clean.
(4) Water level gauge

The transparent gauge glass is to be blown clear at least once a day to ascertain its
responsiveness.
The remote-reading level gauge reading is to be compared with the transparent gauge
glass reading (once a day) to ascertain its reliability.
A-8
(1)
8. CHECK LIST
For the safety of the boiler operation, at least the following items should be checked
periodically.
Item Checking method Frequency

Water level Open and close the drain valve and see Once a day
gauge the response of the water level in the
gauge.
Boiler water Measure concentration of chemicals in Once a day
boiler water and check water quality.
Remote water Lower the drum water level down to Once per
level indicator -100 mm by operating the feed water two weeks
regulator by hand and compare the
indication of the remote water level
indicator with that of the transparent
water level gauge.
Burner When the burner only is in service, Once per

flame-eye shut it down and see that the indicator six months
lamp for loss of fire goes on.
Water level When the boiler is running under low Once per
alarm load, change the drum water level. two weeks
F.O. cut-off When the boiler is stopping, change the Once Per
condition drum level (low-low), stop the F.D. FAN, three months
and stop the F.O. PUMP.
Steam leakage Check the boiler press, parts, flanges, Once a day
water leakage and valves.
B
B. OPERATING PROCEDURES
INTRODUCTION B-1
OPERATION OF AUXILIARY BOILER B-2
BOILER HEATER OPERATION PROCEDURE B-3

B-1
(1)
INTRODUCTION
The auxiliary boiler generates steam required for tanker service.
When the main engine is out of service, the steam necessary for tanker service is supplied by the
auxiliary boiler only.
As the engine load increases, the exhaust gas economizer evaporated more steam and the
auxiliary boiler is placed out of service.
When inert gas is necessary at normal sea going, boiler should be operated in order that O2
content in boiler exhaust gas is less than allowable limited value (abt. 5%).
At the above operation, the burner mode becomes manual mode and boiler minimum load is
limited in order that exhaust gas O2 content is less than allowable limited value.
Therefore, there are three kinds of boiler operation modes as shown below.
1) Auxiliary boiler to be operated : TANKER SERVICE MODE
2) Auxiliary boiler to be operated : IGS TOP UP MODE

when inert gas is necessary.
3) Exhaust gas economizer alone to be operated : REPOSE MODE

B-2
(1)
OPERATION OF AUXILIARY BOILER
1. General notes on boiler operation

(1) Introduction
The following notes on boiler operation are of general nature to be observed by the boiler
operators.
Although some basic rules must be strictly followed in operation and maintenance of the
boiler and ancillary equipment, it is up to the operators familiarize themselves with
characteristics of individual equipment.
This can only be accomplished by diligently observing, recording, checking and comparing
data and details.
Such attentions and proper measures promptly taken by the operators often prevent boiler
outages and repairs.
(2) Performance
a) The boiler is designed to deliver steam at required pressure and temperature when
supplied with feed water at the specified temperature. Operating conditions exceeding
the design limitations will shorten the life of the boiler and component parts.
b) The concentration of solids entrained in the steam leaving the steam drum depends to a
great extend upon the quality of the feed water.
Suitable feed water treatment and adequate blow down should be used to maintain the
boiler water alkalinity and concentration of total solids below a predetermined point.
B-2
(2)
c) If each heating surface of the unit is kept clean, the temperature of the gas leaving the
boiler and the draft loss through the boiler will normally be constant for a given load and
excess air ratio.
This illustrates the desirability of keeping records of boiler performance from the start of
operation. If a standard is set up when the boiler is new, the deviation from it will serve
as an indicator that shows the operating condition of the boiler as well as its own
condition.
Then, steps may be taken to determine and correct the cause for the discrepancy and
often avoid the development of difficulties.
It is desirable to keep records of operating data in a form that facilitates comparison of
similar operating conditions.
d) The amount of fuel oil consumed should be measured.

Fuel oil should also be periodically sampled and analyzed to check calorific value,
chemical composition, etc.
e) The temperature and analysis of gases leaving the boiler are invaluable as an index of
complete and economical combustion.
The best percentage of excess air to use depends upon the nature of the fuel, the
design of the fuel burning equipment and other factors. The most desirable conditions
for different rates of evaporation should be established through the diligent study of the
performance of the boiler.
B-2
(3)
(3) Operation
a) When hot water is used to fill the boiler, care should be exercised to feed slowly to avoid
severe temperature strains on drums, headers, etc. Always see that each part of the unit
is properly vented, and fill it till water level appears in the level gauge.
The vent valve of the steam drum should be kept open during the filling operation and
should not be closed till all the air is vented from the unit.
The unit will have been completely vented by the time when the drum pressure reaches
approximately 2 kg/cm2g.
b) The time required to bring the boiler up to pressure and temperature depends upon the
pressure and temperature at which it is to operate. During initial start-up of a new boiler,
the longer time then the standard must be used for heating up and pressure raising so as
to allow careful inspection of expansion movements and clearances of various parts.
Increase of firing rate should not exceed a saturation temperature rise of 67C (120F)
per hour for a natural circulation boiler.
Ordinary start-up can be done at faster rate than the above. But, the operating
procedure for starting up the boiler safety should be established through measurements
of metal temperatures of important parts of the boiler, and the boiler should be started
accordingly.
B-2
(4)
(4) Water level

a) When the boiler is to be filled for operation, slowly feed water till the water appears 25
to 50 mm high in the level gauge. This is a precaution against the swell that occurs when
the boiler water is heated and begins evaporating and also against the sudden fall of the
boiler pressure when feeding comparatively cold water.
b) Before lighting a fire, the operator should check the water level in the boiler by blowing
down the water level gauge. Usually, slowly cracking the drain valve on the level gauge
will suffice. A liberal blow down will serve to clear the drain valve seat of any foreign
matter that may be present.
When the new boiler is in operation, routine check of the water level gauge should be
made at least once a day. If the action of the water in the gauge is sluggish when the
drain valve is opened or closed, investigation should be made of the cause and the
condition should be corrected immediately.
c) Even though the boiler is equipped with the reliable automatic feed water regulator and
the remote water level indicator, the water level in the level gauge should be observed
periodically during normal operation.
Never shut off the feed water supply completely to the steaming boiler even for only a
short period.
B-2
(5)
d) Unless otherwise instructed, the water level should be carried near the center of the
gauge glass. Any adjustment of the water level should be gradual. If the water level is
too high, priming may occur, especially when the steam demand is large or rapidly
fluctuating.
If priming occurs, blow down the boiler water and changing over the feed control to
manual operation, reduce the water level.
But, the water level should be maintained as such that is just sufficient to take care of a
drop in level that may occur in the subsequent change in steam demand. Reduce the
steaming rate if necessary. Investigate the condition of the boiler water with regard to
concentration of alkalinity and total solids, and examine the condition of the drum
internals when the opportunity is afforded.
e) While the boiler is being brought up to pressure, gradually heat and properly drain all
cold steam piping.
f) During the pressure raising operation, the drum water level often rises higher than the
normal level due to the expansion of water. If it is desired to keep the water level visible
in the level gauge at this time, boiler water should be blow down.
g) Observe the drum water level at times to confirm the proper functioning of the automatic
feed water regulator.
B-2
(6)
(5) Others
a) When re-igniting the burner to bring the boiler back into service from the standby state,
the furnace still remains hot, filled with unburned fuel particles and unburned gas, and
thus requires internal purging by means of forced draft fan (this is an exceptional
instance in which the furnace, still hot, may be air-purged).
b) In case of relighting the burner, an igniter must be used. Never attempt to light the burner
with hot refractory in the furnace.
c) Check chemical contents of the boiler water at least once a day. Add chemicals or blow
down the boiler water as required to maintain proper concentration of chemicals in the
boiler water.
d) Frequently check the smoke indicator to maintaining efficient combustion.
e) Keep burner tips clean as they are adopt to be fouled with dirt and soot.
Note : Be absolutely sure to use the steam drum surface blow off valve when blowing
boiler water during boiler operation and to blow boiler water using the water
drum bottom blow off valve only during boiler outage.
B-2
(7)
2. Preparations
Prior to starting the boiler, attention should be paid to the following items and thorough
checking should be made on them.
Boiler
(1) All foreign materials have been remove from pressure parts.
(2) All gas side heating surface are clean and all refractory are in good condition.
(3) The furnace bottom and the burner wind box have been cleaned of oil and others.
(4) All personnel are clear.
(5) All manhole covers are securely tightened.
(6) Inspect safety valves and see that gags have been removed and easing levers are in
good condition.
(7) Open root valves for all instruments and controls connected to the boiler.
(8) Open the vent valve of the steam drum.
(9) Open all pressure gauge valves and check and see all valves on the pressure gauge
piping are open.
(10) Check and close all blow-off valves and drain valves.
(11) Fill the boiler till water level appears 25 to 50 mm high in the gauge glass.
B-2
(8)
The boiler shall be filled in the following procedure and the feed water line shall be inspected
simultaneously.
(a) When the boiler was laid up wet (Refer to "Protection of the boiler during shutdown".),
drain the boiler till the water level falls down to the bottom of the gauge glass, and bring
the water level up again to about 25 mm high in the gauge glass feeding through the
auxiliary feed water line.
Then, bring the water level up further by about 25 mm feeding through the main feed
water line.
(b) When the boiler was laid up dry, first fill the boiler feeding through the auxiliary feed water
line till the water level just appears at the bottom of the gauge glass. Then, raise the water
level feeding through the main feed water line up to about 25 to 50 mm higher then the
normal water level. This practice serves to check that both the auxiliary and the main
feed water lines are ready for service. Use distilled water for feed water whenever
possible. Boiler compound shall be added as instructed by the expert of boiler water
treatment.
Fuel burning equipment

(1) Make sure that all fuel oil lines including oil filters, etc. are in good condition.
(2) Make sure that no oil residue is in the burner wind box.
(3) Make sure that F.D.FAN inlet vane is clean and moves smoothly.
B-2
(9)
3. Lighting off and pressure raising
(1) Make sure of the drum water level by the water level gauge.
That is, the water level should fall when the drain valve of the water level gauge is
opened, and it should return to the previous level when the valve is closed.
Attention must be paid not to take the empty level gauge for full of water or stains on the
gauge glass for water level.
(2) Start the forced draft fan

Prior to lighting off, place the forced draft fan with inlet damper fully opened and purge
the furnace for at least one minute.
(3) Start the fuel oil burning pump and begin the use of the fuel oil heater, using heavy fuel oil
with normal tip which condition is operated by H.F.O. mode, MADIC auto mode.
Start the fuel oil firing pump and open the oil recirculation valve to recirculate oil through
the oil heater and burner manifold discharging cold heavy oil in the line.
(4) When the oil in the burner manifold has reached a proper temperature, burner ignition
sequence start.
(5) Reduce air pressure at WIND BOX to 20 to 40 mmAq. And securely close the oil
recirculation valve. Check the fuel oil control valve opening by the output signal of
MADIC to ensure it is ready for service.
B-2
(10)
(6) Light on the burner and immediately make a necessary adjustment of oil pressure and air
pressure to ensure a stabilized combustion of the fuel.
At this time, care should be taken to obtain such a burning condition that the fuel oil
burns completely without scattering unburned practices or producing heavy smoke.
Frequently check the indication of the smoke indicator and the flame through the
observation holes, especially after making any change in firing rate or burner inlet air
pressure.
(7) When raising the pressure, keep the burner firing five minutes and out of service 15
minutes repeatedly at the lowest oil pressure (2.5 kg/cm2g) for one hour and then again
repeatedly light off and shut down the burner to raise the steam pressure at the rate
indicated in Fig. 2-1 or less.
(8) When the drum pressure has risen to about 2 kg/cm2g, close the drum vent valve.
(9) Close the valve of the pressure gauge and remove the gauge. Then, open the valve a crack
and release steam to make sure the tubing for the gauge is clear.
Reinstall the pressure gauge and see that it works as soon as the valve is opened. In this
case, care should be taken to allow several minutes to cool the line before opening the
valve.
B-2
(11)
(10) Check the water level gauge to see nothing is the matter with it by opening and closing its
drain valve, and make sure of the drum water level again.
(11) Drain and warm all steam supply lines to the ancillary equipment and devices. It is very
important to discharge drain water from these lines and warm them up to near the
operating temperature before loading the boiler.
(12) When the drum pressure is raised to about 3 to 4 kg/cm2g below the normal operating
pressure, check the safety valves with the easing gear. Care must be taken to open and
close the valve quickly so as to prevent damaging the disc and the seat of the valve.
16
14
12
Drum Press (kg/cm g)
2
10
0
0 0.5 1 1.5 2 2.5
Time (hr)
Fig..2-1 RECOMMENDED PRESSURE RISE

B-2
(12)
4. Cold Start-up
(1) When the boiler is to be started from the cold state in which no steam is available from the
land , use the starting diesel oil for fuel till the steam necessary for the oil heater becomes
available.
(2) Fill the boiler with the best water available. For this, purpose, feed water tank as much as
necessary to start the boiler before shutting down the boiler.
It is advisable to fill the boiler up to 50 to 80 mm above the normal water level so that no
additional feed water is required till the feed water pump is placed in service.
(3) Start the diesel generator and light off the burner using diesel oil with the nor tip which
condition is operated by AIR ATOMIZING with F.O.TEMP. BY-PASS MODE and
burner manual mode.
Before lighting off, never fail to purge the furnace adequately.
(4) Take necessary measures as described in "PREPARATION".
(5) Close valves of the heavy oil lines from the fuel oil tank to the burner manifold and open
valves of the diesel oil line from the diesel oil tank.
(6) Start the FUEL oil pump and open the oil recirculation valve to discharge heavy oil
remaining in the line, burner manifold and oil inlet pipes to burners thoroughly.
B-2
(13)
(7) Set the atomizing air pressure at 5 K and fuel oil pressure at 3 K.
(8) Run the forced draft fan and ignite the burner using the pilot burner.
(9) When the steam pressure has risen to about 2 kg/cm2g, start warming the steam pipe lines
and the feed water pump pipe lines, ant turn on steam to the settling tank.
(10) When the heavy oil in the settling tank has been heated enough to be pumped by the F.O.
pump, turn on steam supply to the oil heater in preparation for changeover from diesel
oil firing to heavy oil firing.
(11) Circulate oil through the oil heater and the oil recirculation line till the oil of the proper
temperature is available in the burner manifold. Then, switch diesel oil firing to heavy oil
C firing and continue pressure raising.
(12) Start the feed water pump as early as possible so that it can feed water to the boiler
immediately when the drum water level should fall.
B-2
(14)
5. Shutting down
(1) Blow all soot blowers before shutting down the boiler whenever possible.
(2) Shut down one burner at a time.
(3) Continue operation of the forced draft fan for a while after shutting down, keeping air
pressure of about 150 mmAq at burner inlet and then stop the forced draft fan and close
the inlet damper
(4) Maintain the drum water level visible about 50 mm in the gauge glass.
(5)When it is necessary to stop the boiler temporarily and keep it in the standby state, ignite
the burner from time to time for sporadic firing to maintain the steam pressure at 5 to 7
kg/cm2g which is lower than the normal working pressure.
(6) In order to maintain drum water level visible about 50 mm in the gauge glass even when
the boiler in cold, raise the water level 70 to 120 mm above the normal water level
before closing the feed water valve.
(7) When the boiler is to be shut down completely, close the steam stop valve immediately
after the boiler stops steaming.
(8) When the boiler pressure has fallen to the atmospheric pressure, open the drum vent
valve.
(9) If it is 4 hours after shut down, the boiler may be cooled with the forced draft fan
operation as the case may require.
But, if possible, such a forced air cooling should be avoided not damage refractory in the
furnace. Do not attempt to cool the boiler by blowing down the hot boiler water or by
refilling the boiler with cold water after blowing down.
B-2
(15)
6. Emergency operation
Water level low

If the water level falls down to 200 mm or more below the normal water level due to failure of
the feed water supply or neglect of the operator, the alarm lamp on the boiler control panel
goes on and simultaneously the alarm buzzer sounds. If the level falls further down to 240 mm
or more below the normal water level, the fuel oil emergency trip valve fully closes cutting of
the fuel supply to the boiler automatically. Then, fully close the feed water valve and the steam
stop valve and shut down a burner completely and stop the forced draft fan.
In this case, never attempt to feed water to the boiler till the boiler has cooled sufficiently,
since, otherwise, there may be a danger of quenching the hot pressure parts with
comparatively cold feed water.
Flame out
In the event of a flame out, immediately close the oil inlet valves and reduce air pressure at
burner inlet so as to present overcooling the furnace.
Prior to relighting burner, purge the furnace adequately following the procedure mentioned in
"Lighting off and pressure raising".
A pilot burner must be used for relighting a burner. Never attempt to light a burner by the heat
from the hot refractory in the furnace.
B-2
(16)
Failure of evaporating tube

A. In case of a tube failure which results in a loss of water so great that the water level can not
be maintained, use the method outlined below.
(1) Shut off oil supply to burner to extinguish the fire. When the tube failure is resulted from
low water, shut off feed water to the boiler closing the feed water valve and the steam
stop valve. This is to avoid the damage that may be caused by quenching hot pressure
parts other than the failed tube with comparatively cold feed water. Refer to "Water
level low".
(2) When the failure of the evaporating tube is resulted from the cause other than low water,
maintain the water level, if possible, at the normal level till the boiler has cooled
enough and then close the steam stop valve and open the drum vent valve.
(3) In either case of the above, keep the forced draft fan in operation to maintain sufficient
air flow to carry the escaping steam out through the stack, adjusting the F.D.FAN
INLET VALVE to such an opening so as to avoid damaging refractory by quick
cooling.
(4) Do not blow down the boiler to lower the pressure rapidly unless the failure is so severe
as to endanger the personnel near the boiler.
(5) Dump the boiler water overboard through the bottom blow valve after cooled enough.
(6) When the furnace has cooled enough to permit a man to enter it, make a thorough
inspection of all pressure parts for any indication of damage. After necessary repairs
have made, apply a hydrostatic test to see whether the unit may be put back in service
or not.
B-2
(17)
B. In case of a leak which does not involve a serious difficulty, the water level should be
maintained and the boiler taken out of service in the normal manner.
(1) Blow soot blowers if circumstances permit.
(2) Switch the combustion control equipment to manual control and reduce combustion rate
following the normal procedure.
(3) Continue air flow through the unit at reduced rate till all combustible gases, vapors, etc.
have been removed.
(4) Feed water to the boiler manually ,maintaining a high level in the water gauge. When the
boiler stops steaming ,open the drum outlet drain valve to drain enough to reduce the
saturation temperature by approximately 65 per hour. When the drum pressure
has fallen to 2 kg/cm2g,open the drum vent valve and when the boiler water has
cooled to about 65, drain the boiler.
Fire inside the casing

Shut off oil supply to the burners immediately and close the forced draft fan inlet vane.
Failure of forced draft fan

In case of a failure of the forced draft fan, oil supply to the burners is stopped automatically
with the fuel oil emergency trip valve.
Close oil inlet valves to the burner.
B-2
(18)
7. Emergency case and measures to be taken

Case Measures to be taken Causes
Drum water level (1) Close F.O. emergency trip Too low feed water pressure
valve. Improper functioning of feed
Shut down burner. water control valve
(2) Stop feeding water. Improper functioning of feed
water regulator
Faulty water level indication
Boiler tube failure
Flame out (1) Close F.O. emergency trip Too low oil pressure valve
valve. Too high excess air
Shut down burner. Faulty flame eye
(2) Purge furnace and relight off. Fouled burner tip
Improper atomizing steam
pressure
Drain in atomizing steam
Tube failure (1) Close F.O. emergency trip Too low water level
valve. Tube corrosion
Shut down burner. (Improper water treatment)
(2) In case of low water Tube overheat
-Stop feeding water. (Scale deposit, poor boiler
In case of not low water water circulation)
- Maintain normal water level. Too high combustion rate
(3) Keep forced draft fan in
operation and reduce pressure
gradually.
(4) Start blowing down at 10
kg/cm2g or less.
(5) Plug off or replace tube.
B-2
(19)
Case Measures to be taken Causes

Fire inside the casing (1) Close F.O. emergency trip Oil leak from burner
valve. Unburned oil in furnace
Shut down burner. Incomplete combustion on
(2) Stop forced draft fan and fully burner
close inlet vane.
Fire inside the casing (1) Close F.O. emergency trip Oil leak from burner
valve. Unburned oil in furnace
Shut down burner. Incomplete combustion on
(2) Stop forced draft fan and fully burner
close inlet vane.
Failure of forced draft (1) Close F.O. emergency trip Failure in electric circuit
fan valve. Failure of electric motor
Shut down burner.
(2) Restart forced draft fan.
(3) Purge furnace and relight off.
Sea water leakage (1) Reduce boiler load. Leakage in condenser
into feed water line (2) Raise pH value and PO43- to Faulty water-making equipment
upper limit of allowable range.
(3) Analyze feed water and boiler
water every two hours.
(4) Blown down boiler so as to
maintain chlorine content within
limitation.
(5) Inspect inside of boiler, etc. at
earliest opportunity.
Apply acid cleaning if
necessary.
B-3
(1)
BOILER HEATER OPERATION PROCEDURE
The subject ship is equipped with 2 auxiliary boilers. When only one boiler is in service, be sure
that the internal pressure of the other boiler in the stand-by mode will not go down below
atmospheric pressure. If the boiler should be brought into the cold state while still at pressure
and with the steam valve kept closing. The steam drum would turn vacuum and draw in air to
probably suffer the internal corrosion. For the stand-by boiler. use the boiler heater to keep the
boiler internal pressure higher than atmospheric pressure.
1.When Using Exhaust Gas Economizer

Operate the valve so that heating steam flows into the boiler heater for the stand-by boiler.
See following Table 1.
Keep the pressure at 0.5kg/cm2g and above.
Table 1
Valve name Stand-by Stand-by
boiler boiler
Boiler heater inlet valve 41B open open
Boiler heater outlet valve 42B open open
Boiler heater leak test valve 43B close close
B-7
(2)
2.When Using Boiler Alone

Be sure that the stand-by boiler pressure is maintained at 2 kg/cm2g and above by
switching on and off the burner. The stand-by boiler will be starting and stopping
automatically. However, keep the boiler pressure at 0.5kg/cm2g and above. Do not use the
boiler heater. See following Table 1 for valve operation.
Table 2
Valve name Boiler in Stand-by
service boiler
Boiler heater inlet valve 41B close close
Boiler heater outlet valve 42B close close
Boiler heater leak test valve 43B open open
C
C. GENERAL MAINTENANCE
FEED WATER AND BOILER WATER TREATMENT C-1

CARE OF BOILER OUT OF SERVICE C-2
HYDROSTATIC TESTS C-3
BOILING OUT
C-4
WATER WASHING FIRESIDES
C-5
ACID CLEANING C-6
C-1
(1)
1. TREATMENT OF FEEDWATER AND BOILER WATER
Mitsubishi Heavy Industries Nagasaki Shipyard & Machinery Works has a wealth of experience
and excellent industrial research laboratory facilities to bank on as regards the treatment of feed
water and boiler water. It therefore is recommended that any questions or difficulties
experienced as regards the treatment of feed water and boiler water be referred to the Company
for advice.
Control of Feed water and Boiler-water Impurities

With boilers in service, it is recommended that at least once everyday feed water and boiler
water be sampled for analysis and appropriate measures taken for qualitative control. When
sampling boiler water, care is to be exercised so as to take the sample that truly represents boiler
water, by for example cleaning the sampling vessel twice to three times with boiler water
beforehand.
Feed water and boiler water sampled are to be thoroughly and carefully analyzed using an
appropriate analysis equipment, it accordance with instruction given on the use of the equipment.
Every effort is to be made to control oxygen, pH, salt, dissolved solids, phosphoric acid, etc. in
feed water and boiler water to within the specified limits.
Requirements specified for the ships boiler as regards the control of feed water and boiler-
water impurities follow.
C-1
(2)
Feedwater
(1) Oxygen : The oxygen content of feedwater is to be controlled to below 0.5 ppm.
(2) pH : The recommended pH value is 7.0 to 9.0. For the pH control purpose,
however, it is recommended that the target be set at 8.5 to 9.0.
Boiler Water
(1) pH : pH of boiler water requires to be controlled to 10.8 to 11.3.
(2) Salt : The salt content of boiler water (as C1-) requires to be controlled
to 300 ppm as far below as possible, preferably below 150 ppm.
(3) Dissolved solids : Dissolved solids in boiler water require to be controlled to 2000
ppm and as far below as possible.
(4) Phosphoric acid : Phosphoric acid of boiler water (as PO43-) requires to be
controlled to 20 to 40 ppm.
C-1
(3)
1. FEED WATER AND BOILER WATER TREATMENT
Limits of Chemical Concentration
Item Unit Boiler Water Feed Water to Boiler

pH (at 25) - 10.8 - 11.3 7.0 - 9.0
Phenolphthalein ppm Max.500 -
Alkalinity (CaCO3)
Total ppm Max.600 -
Alkalinity (CaCO3)
Chloride (C1-) ppm Max.300 -
Total Solid ppm Max.2000 -
Excess ppm 20 - 40 -
Phosphate (PO43-)
Hardness (CaCO3) ppm - Max.1.0
Oxygen mg/l - Max.0.5
Hydrazine mg/l -
(Note) :
(1) Feed water in this table means the mixture of condensate and distilled water to supply
into the boiler.
(2) When only the exhaust-gas economizer is in operation, perform the boiler-water
treatment based on the results of circulating-water analysis.
C-1
(4)
(3) Estimate the pH value from alkalinity tends to give pH readings varying with silica, Ca,
Mg, and other salt contents of boiler water and hence is not necessarily deemed
appropriate : resort to this method only as a means to obtain a rough guide (alkalinity
serves merely as an auxiliary means in determining the pH level).
Also, be sure to control pH to the target value while, on the other hand, keeping
alkalinity at the minimum necessary level.
Limiting the P alkalinity to within a certain range would make it possible to inhibit the
alkali corrosion even if boiler water concentration should take place on the heating
surface, etc.
C-1
(5)
BOILER ANTISCALES AND THEIR INJECTION QUANTITIES (EX.)
1. Boiler Antiscale
The following chemicals of Ameroid Co., ltd. manufacture are to be used.
pH enchanting agent (GC) or KALGEN 459
PO4 enchanting agent (ADJUNCT B) or ALCON 401
(1) GC
Containing sodium hydroxide as its principal ingredient, this chemical is used for controlling
pH of boiler water.
(2) ADJUNCT B
This chemical, the alkaline anti scale with tri-sodium phosphate as its principal ingredient, is
used for controlling PO4 content of boiler water. It serves to prevent the accumulation of
scale deposits as well as to inhibit the boiler steel corrosion.
2. Injection Quantity
(1) Initial injection
Antiscale Initial injection quantity (g/ton) pH & PO4 values
ADJUNCT B Approx.80 PO4 : 20ppm
GC Approx.25 pH : 10.8
(Notes)
1) The injection quantities indicated are calculated with feedwater hardness at zero.
2) In the initial phase of operation, reaction with iron content of boiler steel produces
iron phosphate film on the steel surfaces causing phosphoric acid to remain below
the specified limit. In such an instance, inject additional doses of ADJUNCT B.
C-1
(6)
(2) Makeup injection

According to the results of boiler-water analysis, makeup dose of antiscales are to be
injected with the values indicated in the following table as reference targets.
Antiscale Qty required to raise Qty required to raise
P alkalinity Phosphoric acid radical
(as CaCO3 ppm) by (as PO43- ppm) by
10ppm, g/ton 10ppm, g/ton
ADJUNCT B - Approx.40
GC Approx.8 -
(Notes)
1) The injection quantities indicated are calculated assuming distilled water to be used
as boiler feedwater.
2) The values given are mere theoretical targets and hence require to be controlled as
appropriate for actual boiler load and feedwater quality so that the desired boiler
water quality can be ensured in each particular application.
3. Deoxidizing Agent
For removal and deactivation of residual oxygen in the feed water system, hydrazine (N2H4) is
to be injected into the cascade tank outlet (or feed pump suction inlet) by means of drip-
injection device.
Injection Quantity
In case of 10% concentration of hydrazine solution.
Initial injection : Approx.70 g/ton (at 30deg.C and atm. press.)
Makeup injection : Approx.45 g/ton (at 60deg.C and atm. press.)
C-1
(7)
Boiler Blow down

Blowing down boiler water by operating the blow down valve and replenishing the amount of
water blown down with fresh water is of vital importance of reducing the concentration of
boiler water to satisfactory level for operation. Also, the boiler blow down is just as
important to discharging sludge, oily substance, and other impurities accumulated in the boiler.
The amount of boiler water to blow down and how often to blow down are to be decided
based of factual data, such as the results of boiler-water analysis, turgidity of sampled boiler
water, etc., so that the aforementioned requirements on boiler-water chemistry can be
satisfied.
Makeup-water and Boiler-water Treatment

The boiler disorders caused by inadequate control of boiler water and feed water may be
broadly defined as follows.
(1) Overheating of heat-transfer surfaces due to accumulation of scale and oil/grease
deposits
(2) Corrosion (and caustic embattlement)
(3) Turbine and other associated equipment disorders due to carryover.
Some restrictions, therefore, require to be imposed as follows in order to prevent the above
disorders.
* To cope with (1) above, the hardness and oil/grease content of feedwater require to be
controlled to within allowable limits, as does silicic acid contained in boiler water.
* To deal with (2) above, feedwater pH and boiler-water pH require to be controlled to
allowable levels.
* Salts defy the generalization, some serving to inhibit the corrosion and some promoting the
corrosion. Chlorine (chloride), however, generally promotes the corrosion when present in
a large amount and hence requires to be controlled to as low a level as is practicable.
* To prevent the problem (3), dissolved solids and oil/grease contained in boiler water
require to be controlled to within allowable limits.
C-1
(8)
Restriction of Individual Impurities

(1) Hardness
The formation of scale deposits on the boiler drum and evaporating tube internal surfaces
and the accumulation of sludge within the boiler are attributable, principally, to hardness-
constituting elements carried into the boiler by feedwater.
Leaving the feedwater supply as it is while obviously high in hardness and treating it in the
boiler has potential of having the impurities adhere to heat-absorbing surfaces and also can
cause the rise in antiscale consumption and quantity of dissolved solids.
The best practice dictates, therefore, that the hardness of feedwater be restricted to within
an allowable limit and what is left of the hardness removed through boiler-water treatment
in the boiler.
Specifically, the hardness of feedwater for a 16.0 kg/cm2g boiler is to be controlled to 1
ppm. With makeup water produced by distilling seawater in a desalination plant, assuming
impurities carried over through evaporation to be same as those in raw seawater (of total
salts, Cl=55%,Ca=1.2%,and Mg=3.7%),the hardness brought in per 1 ppm of chlorine
(C) is 0.34 ppm. Then, even with the allowable limit of chlorine at 5 ppm, the hardness
upon evaporation is 1.7 ppm, which suggests that judging from the rate of makeup feed,
restricting the feedwater hardness to within the above mentioned limit is not difficult.
In cases where the distilled-water tank is coated with water cement (definitely not
encouraged) or where there is leakage in the condenser, however, large amounts of calcium
and magnesium can eventually enter the boiler, warranting due precaution.
In some instances the required hardness is specified for boiler water. The hardness values
suggested for boiler water are prone to error and often turn out to be unrealistic. For this
reason and also since the boiler-water hardness should remain about 1 ppm as long as
excess phosphoric acid and pH of boiler water are controlled to the values given in Table 1,
MHI does not make it its practice to specify the hardness requirements.
C-1
(9)
(2) pH Value (Alkalinity)

The boilers are made almost entirely of steel, and iron, beside being susceptible to heavy
corrosion in acidic environments, dissolves in neutral pure water to produce iron
hydroxide as follows.
Fe + 2H2O = Fe(OH)2 + H2
Iron Water Iron-hydroxide Hydrogen
When iron has dissolved in pure water, pH with Fe(OH)2 at the saturation point is 0.9.
The larger the pH value, I.e., the higher the alkalinity, the more sharply the amount of
iron dissolution goes down. It therefore is necessary for the pH value to be maintained
constantly at a high level in order for iron being prevented from becoming corroded. A
word of caution is deemed in order because pH at too high a level can backfire in the
from of caustic corrosion or caustic embattlement or carryover.
Also, it is known that boiler water is not uniform in concentration throughout its body.
So, everything considered, the reasonable proposition is that pH of boiler water should
be maintained at 10.8 to 11.3.
Alkalinity may be deviled into total alkalinity and active alkalinity. Included in the total
alkalinity reading are caustic soda, potassium carbonate, and potassium bicarbonate, all
these being put together. The active alkalinity, on the other hand, called phenolphthalein
alkalinity (or P alkali, in short), represents the amount of alkali high enough in strength to
turn phenolphthalein indicator in color.
It is the active alkalinity that serves as a rough guide to the pH level.
With all the foregoing in consideration, therefore, the phenolphthalein alkalinity as
CaCO3 is to be controlled to about 50 to 300 ppm when boiler water is in excess of
1000 ppm in concentration and to about 30 to 100 ppm when boiler water
concentration is below 1000 ppm.
C-1
(10)
(3) Dissolved Oxygen

The dissolved oxygen constitutes a single greatest factor in causing corrosion, being
responsible for boiler steel corrosion in well more than 50% of the time.
In reaction between water and iron, which is defined as Fe + 2H2O = Fe(OH) 2 + H2,
hydrogen thereby produced is absorbed in metal surface to serve as a negative factor in the
reaction. When oxygen is present, however, it causes hydrogen to disappear by oxidation,
so the reaction progresses toward the right term of the formula with the dissolution of iron
taking place continuously. In addition, iron hydroxide turns into ferric hydroxide by being
oxidized by oxygen, ferric hydroxide settling down to produce rust, thereby causing the
corrosion of iron to progress intermittently.
2Fe(OH)2 + 1/2 O2 + H2O = 2Fe(OH)2

Iron Ferric
hydroxide hydroxide
The pitting corrosion, found concentrated under the drum waterline, is attributable to the
dissolved oxygen. Iron transported from the feedwater piping into the drum, plus iron oxide
produced within the drum, accumulates as deposits or settles down to cause the pitting.
The presence of carbon dioxide gas together with dissolved oxygen in saturated-steam
piping or condensate piping can cause a total corrosion. Carbon dioxide gas is produced
by dissolution of bicarbonate in makeup feed as well as by dissolution of sodium carbonate
within the boiler.
2NaHCO2 Na2CO3 + H2O + CO2

Sodium Sodium Carbon
bicarbonate carbonate dioxide gas
Na2CO3 + H2O 2NaOH + CO2
Sodium Caustic Carbon
carbonate soda dioxide gas
C-1
(11)
The use of sodium carbonate as boiler antiscale, therefore, is not recommendable.

Carbon dioxide gas dissolves in water and acts as carbonic acid but does not cause by
itself so heavy corrosion. If there is oxygen together, however, the effect of the dissolved
carbon dioxide gas becomes pronounced, as it to play a role of some oxidizing medium as
indicated by the following reaction formulas.
Fe + 2H2CO3 = Fe(HCO3) + H2 (1)

Carbonic Ferrous
acid bicarbonate
2Fe(HCO3)2 + 1/2 O2 + 5H2O = 2Fe(HCO3) + 4H2CO3 (2)

Ferric
hydroxide
The dissolved oxygen in feedwater, therefore, requires to be strictly controlled, preferably

to below 0.25 ppm for 16.0 kg/cm2g boiler even though it is specified to be 0.5 ppm.
For removal of dissolved oxygen, it is recommended that volatile hydrazine be continuously
added to feedwater. Hydrazine reacts as follows
N2H4 + O2 N2 + 2H2O
C-1
(12)
(4) Chlorine (Chloride)

Salts, when present in large quantity, raise the electric conductivity of liquid to promote the
corrosion and hence require to be controlled to as low a level in quantity as is practicable.
Feedwater containing too large an amount of magnesium salt can produce the sediment of
magnesium hydroxide upon entering the boiler, and this is said to raise the corrosiveness of
boiler water by bringing down the boiler water pH value.
All the same pH and oxygen remain the greatest factors in causing the corrosion. and the
measurement of chloride is performed more or less to obtain a rough idea as to the amount
of dissolved solids contained.
The relation between the dissolved solids and chlorine ion, though subject to some
variations depending on the water quality or performance of the water-making device, can
be established by measuring these elements in boiler water of each individual boiler
beforehand. Then, it is possible, as well as does no harm for practical purposes, to estimate
the amount of dissolved solids. It is assumed that the concentration of boiler water, as long
as it is controlled using the amount of dissolved solids as a yardstick, can not rise to such a
level as to greatly promote the corrosion except in special instances. The feedwater
Committee, therefore, sets forth no requirements in particular as to the allowable limit of
chlorine.
C-1
(13)
(5) Oil/Grease
Oil/grease coming out of auxiliary machinery, especially those started in reciprocating
motions, enters feedwater and then adheres to the boiler heat-absorbing surfaces to cause
the overheating trouble there upon oxidation.
Also, since boiler water is alkaline, both animal and vegetable oils are liable to be emulsified
in it. The results are foaming of boiler water and degradation in steam purity.
Although the allowable limit is specified for the amount of oil/grease in boiler water in some
instances, it seems highly likely that such an oil/grease will be several-hundreds fold greater
in concentration at the boiler-water surface than the mean oil/grease content. As
specifying such a limit is deemed to make not so much of sense, it is only requested that
feedwater and boiler water should be controlled so that the amount of oil/grease can be
kept to zero as far as is practicable.
(6) Silica (Silicic Acid)

The scale that contains silica is the poorest in heat transfer and thus the most harmful to
boiler operation.
Also, what is called the silica carryover takes place, in which silica carried in steam enters
the turbine and deposits itself on the turbine blades as hard scale encrustation. This is the
single most nettlesome phenomenon, which warrants a serious consideration in connection
with the care of high-pressure boilers.
For a 16.0 kg/cm2g boiler, it is recommended that the silica content of boiler water be
controlled to below 50 ppm to cope with both the scale formation and silica carryover.
Silica acid should be no cause of concern so long as distilled water produced from
seawater is used as makeup feed in nearly all the instances. When water is obtained from
land, however, necessary precautions are to be taken in this respect.
C-1
(14)
(7) Dissolved solids

The larger the amount of dissolved solids in boiler water, the more dampened the steam
becomes, to the point where a large amount of solids are carried in steam as carryover to
the turbine.
The tendency of such a carryover varies with the steam evaporation rate, boiler type, and
performance of the steam separator in the steam drum, as well as with constituents of solids
even if the solids are same in quantity.
Although the relation between these factors still defies quantitative definition, at least a
rough standard can be given for safe and practical operational purposes from the past
experience. In normal operation, the amount of dissolved solids is to be kept to below
2000 ppm.
C-2
(1)
2. CARE OF BOILER OUT OF SERVICE
For the out-of-service boiler, exercise adequate care to minimize the corrosion of its pressure
part and also inspect it closely.
In cases where the boiler is put out of service for 24 hours or more, either fill the boiler
completely with water (wet storage) or drain the boiler of water and thoroughly dry it (dry
storage). Whether it is the wet storage or the dry storage, the purpose is to eliminate air and
dissolved gas from within the boiler for prevention of boiler internal surface corrosion.
Also, when placing the boiler in storage, be sure to keep the gas side completely clean. Any
residual soot deposits on evaporating tube surfaces could absorb moisture from air and cause
the surface corrosion.
Wet Lay-up Method

The wet lay-up is preferable as it requires less preparation, the boiler can quickly be returned to
service, and protection of the waterside is adequate. This method can be safely used for a lay-
up of any length of time, if the fire room temperature is not below freezing.
C-2
(2)
(1) When the boiler is being cooled down after shutting off firing ,boiler compound
(Na/PO4=2.8 mole ration) of trisodium phosphate (Na3PO4) and dosodium phosphate
(Na2HPO4) ,and hydrazine shall be added to the boiler water by the chemical injection
system in such a manner as to make the boiler water of phosphoric acid (PO43-) of about
50 ppm and hydrazine (N2H4) of 100 - 200 ppm (pH is about 10.510.6). The
boiler water should be kept in high alkalinity to protect the boiler from corrosion. Since
the boiler water density during the wet laid-up period is very high compare with that of
ordinary operating condition.
The boiler should be carefully blown down when starting operating to bring the boiler
water concentration down to the normal value (with the boiler water treating limits).
For this ,some amount of make-up water is necessary and the distilled water should be
prepared beforehand accordingly.
(2) When the pressure has gone down to nearly zero, open the steam drum air-vent valve.
(3) When the pressure is almost off the boiler, fill the boiler with distilled water until it issues
from the air vent valves, then close the valve.
(4) Put a hydrostatic pressure of 3.5 to 5 kg/cm2g on the boiler. Hold this pressure until
the boiler has cooled to fire room temperature, then bleed the boiler, using the air vent
valve, to be sure all air is out. Hold a hydrostatic pressure of about 2 to 3.5 kg/cm2g
on the boiler.
C-2
(3)
(5) Maintaining the alkalinity at a uniform level throughout respective boiler parts is an
important consideration, so periodically sample boiler water for analysis during the
storage and replenish what have been spent of alkalinity and sodium sulfite.
(6) In case the atmospheric temperature threatens to fall below the freezing point, take care
to maintain the boiler room temperature at higher than 5 so as to prevent the boiler
water from freezing.
(7) When interrupting the wet storage to put the boiler back into service, bring down the
steam drum water level.
Dry Lay-up Method

In case the wet lay-up method cannot be performed, resort to the dry lay-up method.
(1) While the boiler still remains warm, drain out boiler water and open up the boiler for
ventilation until completely dried internally.
(2) Remove the end plate of the water wall lower header, to check and make sure that no
residual water remains collected inside the header.
(3) If necessary, burn coke or charcoal in a container within the furnace to promote the
internal surface drying.
C-2
(4)
(4) When completely dried, put quick line or calcium chloride in a shallow dish for
placement in the drum and header and then close the end plate and manhole cover.
Use 2 to 5 kg of moisture absorbent for 1000 kg of boiler water when quick line is
employed and 1.8 kg of silica gel for 1000 kg of boiler water, as a matter of standard
practice.
(5) Be sure to close securely all the air-inlet openings into the furnace and provide the cover
on the stack.
(6) Check the moisture absorbent every one to two weeks at the beginning and every one to
three months thereafter at the circumstances call for and renew deteriorated absorbent.
Other Cares for Protection

Do not forget the protection for the gas side, as well as for the boiler-water side. Have the
gas side cleaned of soot or dust while in preparation for the storage.
Soot or slug becoming moistened by moisture of air can cause the corrosion the gas side.
Be absolutely sure to close the furnace and F.D.F. inlet vane and cover up the stack to
prevent the ingress of air or moisture.
Periodically open and close the F.D.F. inlet vane to make sure that it can operate successfully.
Maintain the boiler gas side and casing in the dry state as far as is practicable.
C-3
(1)
3. HYDROSTATIC TESTS
Hydrostatic test pressure should not be higher than necessary to prove the intended test. The
maximum allowable hydrostatic test pressure should be carried out only for design pressure.
See the hydrostatic test planning particulars included in this Manual for the maximum test
pressure to employ. The specified pressure is to be applied to ensure the boiler structural
integrity, only for inspection by applicable ship classification society surveyor.
(1) To check the boiler and fittings for leaks, a test pressure of about 85 percent of the safety
valve popping pressure is sufficient. Caution should be used to avoid accidentally raising
the pressure enough to open a safety valve.
(2) Hydrostatic tests up to normal feed line pressure may be applied with the feed pump if
handled carefully to avoid sudden changes in pressure, producing shock or impact stresses
in the boiler. For maximum test pressure use the test pump.
(3) A commonly used chemical injector has a pressure connection from the feed line to the
boiler compound vessel and a discharge line from the vessel to the boiler. This type of
chemical injector can be used to apply hydrostatic pressure from the feed line. Ordinarily
the lines are O.D. 12 to 20 mm lines. It is easier to control the pressure with the small
valves than with the larger feed valves.
C-3
(2)
(4) Before applying a hydrostatic pressure, it is advisable to cool the boiler to approximately
fire room temperature. The water used for filling should be warmer than the boiler metal, to
avoid moisture condensation on the fireside. Hydrostatic pressure should not be applied if
the temperature of the boiler and filling water is less than 20 deg. C.
(5) Place test clamps (gags) on all safety valves, if the test pressure is to be higher than 85
percent of the safety valve popping pressure. Safety valves should never be opened by
hydrostatic pressure.
(6) The pressure gauge to be used should be checked, before applying the maximum test
pressure.
(7) When filling the boiler open the vent valves on the boiler drum, to bleed off all air, close the
valves when water runs out.
(8) Before lowering the pressure, take up the slack on the nuts of the inspection hole and
manhole fittings, were new gaskets have been fitted. The nuts should be pulled just snug
with the wrenches supplied for the purpose. Do not use a pipe or other extension on the
wrench handle.
(9) When inspection is completed, open the vent valves and lower the pressure slowly by
cracking a drain valve.
(10) Remove the safety valve gags, replace the lifting lever and easing gear.
C-4
(1)
4. BOILING OUT
If the presence of oil is found on the waterside of the boiler, it must be removed by boiling out.
This is necessary after assembly of a new boiler, after completion of repairs requiring extensive
replacement of tubes, or if oil has entered the feed water from some other source.
Boiling out is also a quick and efficient method of removing various types of scale. The
chemicals to be used and the strength of solution required, depends on the character of the scale.
Consult the boiler water chemist.
Boiling out to remove oil requires the use of a fairly strong caustic solution. One such solution
is 1 kg of caustic soda and 1 kg of tri-sodium phosphate, for each 1000 kg of cold water
required to fill the boiler. This chemical solution is sufficient to remove ordinarily compounded
lubricating oils or the usual protective oil coating applied to tubes before shipment.
Straight mineral lubricating oils used for high temperature engines requires stronger solutions. If
such oil is present in the boiler used 4 kg tri-sodium phosphate and 4 to 5 kg caustic soda per
1000 kg of water. In addition it is advisable to add detergent (wetting agent) amounting to
about 0.5 percent of the boiler water. There are other chemical solutions which can be used.
There are many satisfactory compounds for boiling out, they are sold under various trade names
by reputable firms. When such compounds are used, follow the manufactures instructions.
C-4
(2)
Steaming Method
This is a method in which steam is injected by way of a temporary piping externally connected to
the air-vent valve, for soda boiling. Water is to be discharged by way of the bottom blow-
down valve and through a temporary discharge piping. The discharge piping is to be connected
to the boiler water sampling tank, which is requires for inspection or analysis of boiler water.
(1) Inject chemicals into the water wall tubing as required, using the chemical injection device.
Dissolve the chemicals in clean water, in proportion to the weight of water required to
completely fill respective boiler parts, for injection. See the planning particulars included
in this Manual for the weight of water required to fill each of the boiler parts.
(2) Upon finishing the injection of chemical solution, gradually blow in steam in such a manner
as to permit condensed water to collect until the boiler is completely filled with water to the
point where water begins to overflow by way of the air-vent valve.
(3) Maintain the boiler pressure at about 3.5 kg/cm2g and adjust each air-vent valve so that the
quantity of overflowing water from each individual air-vent valve and bottom blow-down
valve will be approximately in proportion to the quantity of water in each corresponding
boiler part.
(4) Determine the progress in removal of oil through test of sample water taken from the
discharge piping. Analyze the sample water for alkalinity and then add chemicals required
to maintain the chemical concentration at the specified level : by so doing, continue the soda
boiling until no trance of oil can be seen in the sampled water. The oil content can be
detected by examining the surface of cooled sample water for sign of oil. If possible
however, analysis by ether method, etc. should be in order.
C-4
(3)
Firing Method
If steam and electric power are available and the auxiliaries are ready for service a boiler can be
boiled out using a light fire. When the firing method can be used, it is much simpler and does
not require temporary piping.
The quantity of solution to use should be figures for the weight of cold water required to fill the
boiler to normal steaming level.
(See Design Data.)
(1) Dissolve the chemicals in water and inject into the boiler with the compound ejector.
(2) Close the boiler and fill to the normal starting level.
(3) In cases where the boiler is of new construction with new refractory in it, avoid the sharp
thermal expansion of the refractory by preheating the furnace internals by burning firewood
inside the furnace for 3 to 4 hours or by firing the burner intermittently.
(4) Ignite and shut down one burner using the smallest-capacity burner tip, repeatedly until the
pressure is gradually raised to the level corresponding to 85 to 88% of normal operating
pressure. Maintain the pressure at that level, for soda boiling. If necessary to maintain
the pressure, intermittently fire the burner.
(5) If the refractory is new, alternate the burner at fifteen minute intervals.
C-4
(4)
(6) When the boiler is thoroughly heated, raise the water level slowly to about 75 to 100 mm
above normal operating level, then give a surface blow followed by several short bottom
blows to bring the water level 30 to 50 mm below normal.
(7) Refill the boiler slowly, until the water level is reached to about 75 to 100 mm above
normal, and additional chemical based on the approximate amount of water blown down.
(8) Perform the soda boiling continuously for 24 to 48 hours, blowing down boiler water every
6 to 8 hours through the blow-down valve by 100 to 150 mm on the level gauge each time.
3.2 Wash and Inspect

(1) After boiling out is completed by the firing method, blow down the boiler through the
water drum bottom blow off valve while the boiler is fairly warm. Discharge the water
overboard, to avoid damaging paint in the bilge by the strong caustic solution.
(2) Open up the boiler and wash it down with a high pressure water hose, playing the hose
into all tubes.
(3) Carefully inspect the boiler, and if any trace of oil remains, repeat the boiling out process.
C-5
(1)
5. WATER WASHING FIRESIDES
Slag is a mixture composed of sodium sulfate or a mixture of sodium sulfate and vanadium oxide,
and lesser amounts of the oxides of other impurities.
When burner is kept in proper adjustment, the burner tip kept clean and in good condition, and
the soot blowers operated at correct intervals, slag formation may be slowed down. However
slag formation will eventually accumulate on the tubes and should be removed before it has
bridged over between tubes.
A water washing schedule should be set to coincide with normal fireside cleaning. Operating
practice will indicate at what intervals of fireside cleanings water washing is necessary.
Since slag is soluble in hot fresh water, hot fresh water is sprayed on the slag encrusted tubes
with a lace, using sufficient force to soften the slag and knock it off the tubes.
There are two methods in water washing. One is to use a hand nozzle and the other is to utilize
the soot blower in spraying hot water.
The former permits concentrated washing of important points so that effective washing can be
done with relatively small quantity of water resulting in less moisture of the boiler ; but much time
and labor is required. With the latter, washing can be done easily in a short space of time but it
requires relatively much water resulting in larger moisture of the boiler.
Water washing is usually carried out at a dock. A member of the crew can do it quite easily.
C-5
(2)
If preparation has been made in advance while the boiler is cooling, water washing will be done
in 6 - 8 hours although it depends on the extent of dirtiness.
The following is the order of process of water washing the fireside with a hand nozzle.
(1) Prepare an apparatus to supply adequate quantity of hot water and a hose and nozzle for
spouting hot water.
(2) Remove casing access doors and dusting panels to facilitate the work.
(3) Provide a means for immediate and constant draining of the waters and the removal of the
sludge, resulting from washing down.
(4) Water under 5 kg/cm2g and at a temperature of 80 deg. C should be sprayed on to the
tubes, using an armored hose. Work from the top of the boiler down, in cases where slag
removal is extremely difficult, secure from washing, and allow the water to soak into the
slag for a period of 30 minutes to one hour. Then continue washing down the tubes.
(5) Attention should be paid not to let washing water penetrate behind the refractory. It will
be effective to lay a sheet of canvas on the furnace floor. If small quantity of water is
absorbed by refractory and heat-insulating materials, the bad effect will be removed by
slowly drying soon after finish of washing.
(6) Preferably complete the washing with warm water in short time : it is not desirable to
continue the washing over 8 hours.
(7) As soon as possible after washing is completed, light off the boiler at minimum F.O. press.
The drying out operation should be done very slowly and should be continued until the
boiler is thoroughly dried out. When the boiler has entirely been washed, the drying
should be made at least for 12 hours.
C-6
(1)
6. ACID CLEANING
Thanks to development of good inhibitors, it has become possible to effectively remove scale on
the waterside of the boiler by acid cleaning.
However, acid cleaning requires a suitable treatment according to actual conditions of the boiler,
otherwise it will not only damage the boiler but also be attended by dangers. So this work
should be done by specialized constructors having experienced and competent personal with
proper equipment. It is desirable for the work to be done under the leadership of Mitsubishi,
Nagasaki Shipyard, if possible.
Boiler operators should have a knowledge of the following general items.
6.1 Equipment
The following devices should be prepared for the acid cleaning.
(1) An acid filling tank of sufficient capacity to hold the prescribed amount of acid and
inhibitor.
(2) One centrifugal acid filling and circulating pump with bronze impeller designed to deliver
a minimum of from 0.2 to 0.4 m3/min at 35 mth. or of such capacity as so fill the unit in
not more than 2 hours.
(3) Suitable temporary piping and fittings to connect both the pump and tank to the boiler.
(4) A typical cleaning solution would contain 28 percent to 34 percent hydrochloric
(muriatio) acid, an inhibitor and water. The amount of acid used would be roughly 10
to 20 percent by volume of the volume of water necessary to fill the component to be
cleaned. See Design Data.
Selection of the concentration of acid used (one to six percent by weight for any one
unit) depends upon the type and amount of scale or rust and other impurities to be
removed.
C-6
(2)
Special attention must be given to ensure that the acid solution is not enriched by ferric or
cupric ion, which can be caused from the removed scale or deposits containing a large
portion of ferric or cupric oxide.
This will impair the effect of the inhibitor. In such a condition, keep the acid solution
below the maximum allowable concentration of ferric or cupric ion, by adding renewing
the reducing agent.
Procedure
(1) If a trace of oil is found in the boiler, it must first be boiled out with an alkaline solution.
A boiling out period of from 6 to 10 hours is adequate when followed by acid cleaning.
(2) Remove all tools, rags and other foreign material from the waterside of the boiler.
Secure all header end plates, the manhole plates and valves, that will make the boiler
watertight and isolated from all boiler accessories except the water gauges.
(3) In order to ensure safe removal of hydrogen gas generated during the acid cleaning,
connect a pipe line to the highest vent of the part to undergo acid cleaning. Never do
welding while acid cleaning is being performed.
(4) Temporary piping for pumping the acid liquid into the boiler should be connected from
the tank to the pump suction, and from the pump discharge to the nozzle of the bottom
blow pipe. Piping should also be connected.
From the other steam pipe nozzle of the boiler steam drum to the tank.
(5) Start filling the boiler with water 75 degree C to 90 degree C. While the feed water is
being injected into boiler through the main or auxiliary feed system, start pumping the
acid and inhibitor into the boiler through the chemical feed pipe. If all the acid has not
been pumped into the boiler by the time the water shows in the gauge glass, secure
feeding the boiler, until all the acid has been injected into the boiler.
C-6
(3)
(6) When all of the acid liquid has been injected into the boiler, continue to fill the boiler with
water until the level in the steam drum is high enough to cover all the tubes to undergo
acid cleaning. This is necessary for the circulation of the cleaning solution and for
cleaning all the tubes of the unit.
(7) When acid-cleaning the entire steam drum, fill the boiler with water containing the same
proportion of acid.
(8) Run the circulating pumps 3 to 5 minutes each hour. If it is found that a wide
temperature spread exists between various parts of the boiler or if the scale deposit is
excessive, use a half hour cycle.
(9) Check test samples of the cleaning solution with a standard sodium hydroxide solution
and methyl orange indicator. The value of this depends upon being able to get a true
representative sample. The acid concentration should be tested at the end of each
circulation period. When the concentration has leveled off, and remains constant over
two successive tests the dissolution can be considered complete.
(10) Empty the boiler through the skin valve using compressed air.
(11) Average acid contact time should be from 6 to 8 hours. If the scale has not been
removed during this period, the probable cause is :
(a) Weak solution ; repeat process.
(b) Misidentified scale and wrong solution used, high in silicates, sulfates or oil.
C-6
(4)
General Precaution
(1) Before injecting the acid solution into the boiler it is good practice to check the
effectiveness of the inhibitor. A weak inhibitor will permit excessive corrosion of the
boiler metal.
(2) A quick check of inhibition consists of diluting the concentrated acid to approximately 5
percent, then drop in a piece of cold rolled steel in the solution and heat to 65 degree C.
Well mixed inhibited acid produces very few hydrogen bubbles which should be small
and difficult to see. For comparison run a test with inhibited acid.
(3) Check the metal temperatures particularly the steam drum before injecting acid, before
and during each pumping operation. This can be down by using thermocouples located
at critical points or by contact pyrometer.
It should be noted that THE TEMPERATURE IS A MOST CRITICAL FACTOR in
the procedure. Too low a temperature, under 50 degree C, will result in poor
dissolution of most deposits. Too high a temperature, more than 80 degree C for most
inhibitors, will increase the corrosion rate appreciably, if not to a damaging degree.
Stay within the temperature limits prescribed by the manufacturer of the inhibitor. If
there is any doubt, stay under a temperature of 65 degree C.
(4) After draining out the acid, wash down the boiler with fresh water, using the same
washing process as described after boiling out.
(5) The boiler should be boiled out with an alkaline solution (see Boiling Out). This is to
both clean the boiler of suspended particles and to return all surfaces to an alkaline base.
(6) After boiling out, wash the boiler with a strong stream of hot fresh water with a hose.
(7) After acid cleaning DO NOT ENTER OR WORK in the boiler until it has been filled at
least once with water, and preferably after the boiling out process.
D. MAINTENANCE AND REPAIR
MAINTENANCE OF REFRACTORY D-1
BOILER PRESSURE PART D-2
HEADER END PLATE D-3
FLANGED JOINT D-4
SLIDING SADDLE D-5
TUBE PLUGS D-6
REFERENCE DRAWINGS D-7

D-1
(1)
1. MAINTENANCE OF REFRACTORY
1. Drying Out
A new refractory furnace lining or one that has been extensively repaired should be
carefully warmed up and dried out to avoid damage.
1.1 Drying out in Lighting up and Pressure Raising

If the boiler is clean and ready for service, as after boiling out by the Steaming Method,
prepare the boiler for service
(1) Light off burner at min. firing rate. Secure the burner after five minutes and light off
again after fifteen minutes.
(2) Continue in this manner, for a period of six hours.
(3) Allow an off period between securing burner and lighting off the next if necessary to
prevent the steam pressure from going above 3.5 to 5.0 kg/cm2g.
(4) At the end of the first six hour period raise the steam pressure slowly during a second
six hour period, cutting the boiler in on load at the end of the period.
(5) During a third six hour period increase the firing rate slowly until at the end of the
period the boiler is being fired at the maximum rate (up to normal power) under the
load conditions existing at the time. Continue firing at the maximum rate (up to
normal) possible for a fourth six hour period.
1.2 Drying out in alkali-boiling

(1) If the boiler is to be boiled out by the Firing Method the burner in service for the
first six hour period. Maintain the firing rate as required for the boiling out process.
(2) After the boiling out is completed, and the boiler washed out, refilled and ready for
service, light off and raise slowly to operating pressure in from four to six hours.
(3) Cut the boiler in on the load and continue with the third and fourth periods as
described above.
D-1
(2)
2. Burner Throat
(1) Inspect the refractory burner throat. The surface of the flared opening should be
smooth. Repair if roughened by spilling or burning.
(2) The burner throat opening must be a true conical shape with the center exactly on a
centerline through the center of the jacket tube.
(3) The sweep used with plastic refractory throat molding tool can be used to check throats
for accuracy. If these tools are not available use a length of spare pipe or tube in the
jacket tube as a reference center.
D-1
(3)
3. Castable Refractory
(1) Castable refractory should not be in close contact with metal, either pressure parts or
hanger bolts. Always coat metal with a heavy coat of bituminous paint, wrap tubes
with tar paper, which will burn out to allow some expansion clearance otherwise the
refractory will crack and eventually fail.
(2) Castable refractory is used principally in locations requiring a refractory shield over
pressure parts of the boiler or water wall headers to protect them from furnace heat.
(3) The refractory should be one that will set and develop strength without the application of
heat. This characteristic is necessary because the close contact with the boiler or water
wall surfaces prevents it from reaching the temperature required to vitrify.
(4) This material is mixed with water and poured like concrete. The quantity of water used
is important and should not vary from the amount recommended by the manufacturer.
The usual time required for this material to set is from 6 to 8 hours, after which a fire can
be started.
(5) To patch small portions of the header protection refractory, remove the old material to
its full depth.
(6) Replace the anchor bolts as necessary. Coat all anchor bolts or reinforcing with a
heavy coat of Bituminous paint. Forms can be made of wood or sheet metal, if
needed.
(7) Where the refractory is to placed around tubes, wrap the tube with tar paper or coat
heavily with Bituminous paint. This material burns out and will allow an expansion
space and avoids cracking the refractory. Before it sets, slit the face of the refractory
to a depth of 75 mm with a trowel to make expansion joints on approximately 350 mm
centers.
D-2
(1)
2. BOILER PRESSURE PARTS
In repairing and checking the pressure parts of the boiler, confirm non-existence of pressure by
the pressure gauge. If the boiler is under pressure, open the air vent valve to lower the
pressure sufficiently. If the gauge shows no pressure, open the air vent valve to confirm non-
existence of pressure.
1. Inspection of Fireside
(1) Inspect the fireside at every shut-down. Be sure the tube bank is clean and free of any
accumulation of soot or slag. Pay particular attention to the water drum and be sure
there is no heavy accumulation of soot on it. Use a steam lance to clean the bank if
necessary.
(2) Accumulated soot is to be removed through the cleaning hole on the side of the water
drum if necessary.
(3) Ordinarily the boiler front bank tubes can be cleaned as much as is necessary by rattling
or bumping the tubes with a fairly heavy hammer handle. Cleaning these tubes or the
water wall tubes with a scraper or wire brush is considered unnecessary except when
making a careful surface inspection of the tubes.
(4) Inspect the water wall tubes and front bank tubes for any indication of cracking,
blistering or over-heating. Replace any faulty tubes which may be found.
D-2
(2)
2. Inspection of Waterside
(1) Make an inspection of the waterside at least once every six months until certain that
method of analysis and treatment of the feed water and boiler are satisfactory and will
permit longer steaming periods between inspections.
(2) Open both drums and check the appearance of the drums and tubes carefully. Open
end water wall header end plate. See that the water wall tubes and water wall headers
are free of sludge or other foreign material which may restrict the circulation. Boiler
and water wall tubes must be kept free of scale deposits, oil and corrosion.
(3) Scale deposits in the boiler and water wall tubes can be prevented by maintaining the
correct chemical conditions in the boiler water. This requires strict adherence to the
boiler water chemists instructions.
(4) Water wall tubes and the front bank tubes which are exposed to the radiant heat of the
furnace will overheat with a very thin layer of scale deposit.
(5) Corrosion in the boiler is usually due to oxygen in the feed water, low alkalinity in the
boiler water, failure to vent the boiler when starting to raise pressure or improper care of
the boiler when not in service.
(6) Oxygen pitting is the most common form of corrosion found in boilers. It usually occurs
above the water level in the steam drum but it is often found also in tubes and water
drums. The pits are usually covered with a dull red, scabby oxide under which is a pit
with a shiny black surface.
(7) After completing inspections or any repair work in the boiler, be sure that all tools, bolts,
etc., have been removed. Brush out all dirt, welding spatter and similar material.
Wipe up any oil and wash the drums with a high pressure water hose.
D-2
(3)
3. Replacement of Boiler Tubes

(1) Working in the inside of the drum, slot and crimp the faulty tube ends until the tube can
be driven from the tube hole. Tubes which are easily accessible can be cut of the 30
50 mm from the drum. The remaining nipples can be removed, working either from the
outside or the inside of the drum.
(2) Clean the tube holes carefully, removing all scale and rust. Clean the replacement tube
ends to bright metal with emery cloth. Clean the inside of the tube to remove the
protective coating. This may be done by pulling a kerosene soaked swab through with
a wire, then blowing out thoroughly with a steam hose.
(3) Round the edges of the tube end before welding to avoid developing cracks.
(4) Enter the tube in the tube holes and clamp in position. The tube ends must project into
the drum to allow for bellying.
D-3
3. HEADER END PLATE
(1) Use High Temperature Lubricant (Molykote, Elesco No.100, etc.) on the header end
plate volts and nuts.
(2) To install fittings with Flexitallic gaskets, clean the gasket seats of the fitting and header
end plate carefully. Do not use graphite or other compounds on the gaskets.
(3) Center the fitting in the header end plate making sure the shoulder does not bind on the
edges of the header end plate. Then slip on the bridge yoke and start the stud nuts.
(4) Run the nuts on the stud hand tight plus a three-quarter turn with a wrench. It is
important that the gasket is not mashed by excessive tightening of the stud nuts.
(5) If a new gasket leaks while filling the boiler, slack off the stud nuts enough to loosen the
bridge, then shake the header end plate to get it squarely on its seat and set up the stud
nuts again. This will usually stop leakage through a new gasket. Sweat or slow drips
ordinarily will take up under hydrostatic or steam pressure.
(6) Before closing the cover panels put a hydrostatic pressure of about working pressure on
the boiler and then go over the fittings and tighten the stud nuts hand tight plus one-
quarter turn with a wrench.
(7) Manhole gasket are handled in the same manner. The nuts may be pulled tight with the
wrench furnished. Use no pipe or other handle extension.
D-4
4. FLANGED JOINT
All flanged connections to the boiler nozzles are made up with Flexitallic type, gaskets.
(1) Clean the faces of the companion flanges perfectly. Apply gasket paste to the gasket
or the gasket sheet thinly and evenly. Use no graphite or other compound on the
gasket or the gasket seats.
(2) See that the flanges match accurately with no strain. Pull up the flange bolt evenly.
(3) When making up a flange joint pull up the nuts uniformly. Never pull the nuts more than
one flat at a time. Never tighten the nuts in consecutive order around the flange, always
cross over to a nut on the opposite side of the flange.
D-5
5. SLIDING SADDLE
Check the sliding saddle provided to permit expansion of the boiler. Grease occasionally and
see that the bearing surface and the slotted bolt holes are not fouled with dirt. The holding
down bolts should be either shouldered or provided with sleeves to prevent pulling the bolts too
tight and pinching the sliding saddle is the front saddle.
D-6
6. TUBE PLUGS
(1) Tube plugs are included with the shipboard tools to permit plugging a faulty tube until
replacement can be made. A boiler can be safely operated with several tubes plugged.
(2) Be sure the tube end and the plug are perfectly clean to assure a metal-to-metal contact
when the plug is driven into the tube end.
(3) Boiler tube that has been plugged should be replaced at the earliest opportunity.

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PLAN RECORD REVISIONS AP- CHECK-

MARINE BOILER DESIGNING SEC.

MITSUBISHI HEAVY INDUSTRIES, LTD.

This instruction manual treats of affairs requiring attentions of workers in

However, this instruction manual refers to only fundamental rules necessary

D. MAINTENANCE AND REPAIR

PRINCIPAL PART A-1

2. DESIGN DATA FOR 1 BOILER

AUX. BOILER MAC TYPE

LEVEL - ALARM AND FUEL OIL CUT

LOAD 25% 50% 75% 100%

EVAPORATION kg/h 6,500 13,000 19,500 26,000

FEED WATER TEMP. deg.C 85.0 85.0 85.0 85.0

SATURATED STEAM TEMP. deg.C 203.4 203.4 203.4 203.4

BOILER EFFICIENCY (LHV BASE) 82.1 82.8 81.9 80.5

CALORIFIC HHV kcal/kg 10,280 10,280 10,280 10,280

VALUE LHV kcal/kg 9,713 9,713 9,713 9,713

FUEL OIL CONSUMPTION kg/h 475 941 1,427 1,935

EXCESS AIR RATE 31 16 15 15

O2 RATE 5.0 3.0 2.9 2.9

COMBUSTION AIR FLOW kg/h 8,720 15,290 22,980 31,160

FLUE GAS FLOW kg/h 9,190 16,230 24,410 33,090

AMBIENT AIR TEMP. deg.C 45 45 45 45

MAC-30B BOILER EXPECTED PERFORMANCE CURVE

EFFICIENCY CURVE (L.H.V. BASE)

F.O.C. CURVE ( * 1,000 kg/h)

O2 RATE CURVE (% BY VOLUME)

2. Lighting off and pressure raising

3. Operation notes during normal service operation

5. Operation of ancillary equipment

1. Feed water and boiler water treatment (refer to C-1)

Recommended chemicals are as follows.

For raising pH value AMEROID/GC

2. Maintenance during shutdown

Test pressure should be determined to suit the case.

Recommended duration of boiling out for a new boiler is 2 to 3 days.

5. Hot water washing

Recommended hot water temperature is about 80 .

8. Boiler proper and water walls

9. Boiler drum support legs

10. Boiler repair

11. Maintenance of accessories

(2) Soot blower

(4) Water level gauge

Item Checking method Frequency

Burner When the burner only is in service, Once per

OPERATION OF AUXILIARY BOILER B-2

BOILER HEATER OPERATION PROCEDURE B-3

The auxiliary boiler generates steam required for tanker service.

1) Auxiliary boiler to be operated : TANKER SERVICE MODE

2) Auxiliary boiler to be operated : IGS TOP UP MODE

3) Exhaust gas economizer alone to be operated : REPOSE MODE

OPERATION OF AUXILIARY BOILER

1. General notes on boiler operation

d) The amount of fuel oil consumed should be measured.

(4) Water level

d) Frequently check the smoke indicator to maintaining efficient combustion.

Fuel burning equipment

3. Lighting off and pressure raising

(2) Start the forced draft fan

Fig..2-1 RECOMMENDED PRESSURE RISE

(4) Take necessary measures as described in "PREPARATION".

(2) Shut down one burner at a time.