4.

MAINTENANCE Manual STEAM-MATIC FT

Manual STEAM-MATIC FT

Chapter 4 - MAINTENANCE
4.1. MAINTENANCE SCHEDULE
The STEAM-MATIC generator, like any machine, requires careful maintenance.
BONO ENERGIA recommends the following maintenance schedule :

4.1.1. DAILY MAINTENANCE

Daily perform the following operations and checks:

 Drain at least once a day the boiler in order to eliminate the excessive alkalinity and
any sludge. The drains should be greater for plants that have less recovery of
condensate: follow the instructions provided by the cleaner. It is recommended that the
purge pressure is not high.

 Drain the levels and monitor their efficiency.

 Drain the barrel and check its efficiency.

 Check the efficiency of the probe.

 Check the characteristics of the supply water and the boiler water.

 If the burner is powered by fuel oil or diesel fuel:

- before starting, check that the unit switches on regularly
- check the vacuum nozzle pressure (0.5 ate)
- check the min. and max. pressure of the fuel control valve
- turn the top handwheel of the self-cleaning filter
- after about a week of operation, replace the air compressor oil

Always with reference to the burner, perform these operations monthly:

- nozzle cleaning (if necessary)
- remove the fuel suction filter and rinse it thoroughly with petrol (clean it more frequently
if the operating conditions require it)
- remove (if necessary) the pilot burner and clean the ignition electrode
- check that the distance between the electrode tip and cap is about 2-2.5 mm
- lubricate the bearing of the fuel adjusting valve and the screws for the adjustment of
the cams with a few drops of oil
- clean the protective glass of the photoelectric cell

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4.1.2. HALF-YEAR MAINTENANCE

Every six months you should check the cleanliness of the smoke side and, if required,
clean as follows:

 Open the front covers of the boiler.

 Remove the internal parts of the fire tubes and clean them.

 Clean pushing the soot toward the rear of the boiler and remove the soot.

 Refit the internal elements of the fire tubes in the same position and precisely with their
back close to the front tube sheet.

 Close the covers after making sure that the seals are in good condition and in their
seat.

 Burner:
- Clean the safety net and the fan impeller
- Clean the air intake filter of the air compressor
- Clean the filter trap of the preheater (in the case of fuel oil)
- Check the operation of the controller (in the case of fuel oil)

 Before tightening the bolts, sprinkle them with graphite to facilitate their subsequent
removal.

 If necessary, replace the seals.


 Air pre-heater: for cleaning the tube bundle, dismantle the upper doors of the preheater
and clean the pipes with a metal brush or with a jet of compressed air, and then open
the front covers and remove the soot.

 When cleaning, protect engines and equipment from dust.

4.1.3. YEARLY MAINTENANCE

Annually perform the following operations and checks:

 Open the manhole and inspection doors after emptying the boiler completely.

Cleaning the smokes side

 Check the inside of the boiler. The presence of fouling indicates the need for better
purification.

 Replace the manhole and access doors after replacing the gaskets with new ones.

 Examine the valves (including the check and safety valves) and, if necessary, replace
the gland packing and grind its seats.

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Manual STEAM-MATIC FT 4.MAINTENANCE

 Fill the boiler with water to the normal level with purified water (when restarting the
boiler, check that, while the pressure rises, the seals do not leak, and if required,
tighten the inspection doors and the manhole).

 Check the alignment of the water pump and the air compressor.

 Check and, if necessary, replace the rubber parts of the couplings of the water pump
and compressor.

 Check the securing bolts of the engine on the crankcase.

 Remove the level controller by disconnecting the electrical connections, remove the
electrode-holder flange and clean the electrodes and barrel. Replace carefully, paying
attention to the electrical connections and their mounting (this operation has to be
performed by trained personnel).

 Drain the tank of condensate and check the operation of the float valve. Remove any
deposits in the tank with a jet of water under pressure.

 Review the status of the refractory materials: if they are damaged, repair them with
refractory cement that is resistant to high temperatures.

Cleaning the water side

Check the status of cleaning on the water side and, if necessary, proceed to clean as
follows:

 Completely empty the boiler after it cools

 Open one or more cleaning doors and inspect the internal surfaces of the boiler by
checking that they are clean.

 Replace the seals of the removed doors and close them.

If it’s detected the presence of fouling, this stresses is a malfunction of the purification
plant. Inspect system and check its operation.

Miscellaneous

In addition, perform the operations below:

 Remove and clean the water check valves

 Check the gland packing of the water pump
 Clean the water filter on the suction pipe of the pump.

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