OPERATION MANUAL

BOILER FOR FUEL OIL

( NBO -TYPE )

BOOSTER Boiler Co., Ltd.

Thank you very much for purchasing Booster boiler.
The Booster boiler is a once through type steam boiler with highest thermal efficiency. Equipping various safety
devices, the BOOSTER boiler is being used the most safely. This operation manual describes the operation method
and brief maintenance method. Before you start the operation, please read this manual carefully and always main
tain in the best operation condition.

Contents
Chapter 1 General

1-1 Part Name and Function for the Boiler ------------------------- 4

(1) Part Name and Function for the Boiler Main Body ----------------- 4
(2) Part Name and Function for the Control Panel -------------------- 5
(3) Part Name and Function for the Burner ------------------------- 6
(4) Part Name and Function for the Concentration Blowing-off Assembly
and the Oil Pump ------------------------------------------ 7

1-2 Steam Generation System------------------------------------ 8

(1) From Water feeding to Steam Generation------------------------- 8
(2) Flow sheet - ---------------------------------------------- 9

Chapter 2 Boiler Operation

2-1 Check Item before Operation--------------------------------- 10

2-2 Operation Start--------------------------------------------10
2-3 Operation Stop--------------------------------------------10
2-4 Cautions during Operation -----------------------------------10
2-5 Checking the Combustion Condition during Operation---------------11
2-6 Instruction for the Boiler When It is not Operated for a Long Time-----11

1
Chapter 3 Manipulation of the Auxiliary Equipment

3-1 Manipulation Method ---------------------------------------------------------------------------12

(1) Setting Method for the Thermal Relay of the Magnetic Switch(OCR) ------------ ------- 12
(2) Adjusting Method for the Pressure Switch -------------------------------------------------- 13
(3) Air Extraction for the Feed Water Pump ---------------------------------------------------- 13
(4) Air Extraction Method for the Oil Heater --------------------------------------------------- 13
(5) Pressure Adjusting Method for the Oil Pump ----------------------------------------------- 13
(6) Wiring Method for the Feed Water Pump and the Oil Pump ------------------------------ - 14
(7) Capacity Adjusting Method (Damper Blade) -------------------------------------------------- 14
(8) Adjusting Method for the Water Level Control Equipment ------------------------------- 16
(9) Concentration Blowing-off Device ------------------------------------------------------------17
(10) Operation status for Combustion Control(Protect Relay) --------------------------------18

3-2 Brief Maintenance Check and Cleaning Method --------------------------------------------- 19

(1) Check for the Soft Water ---------------------------------------------------------------------- 19
(2) Check for the Concentration Blowing-off Device ------------------------------- -----------20
(3) Check and Cleaning for the Oil Strainer ----------------------------------------------------- 20
(4) Check and Cleaning for the Oil Heater Strainer -------------------------------------------- 20
(5) Check and Cleaning for the Feed Water Strainer and the Concentration
Blowing-off Strainer ---------------------------------------------------------------------------- 21
(6) Check and Cleaning for the Water Level Electrode Bar ----------------------------------- 21
(7) Check and Cleaning for the Oil Pump -------------------------------------------------------- 21
(8) Check for the Safety Valve --------------------------------------------------------------------- 22
(9) Check and Cleaning for the Burner ----------------------------------------------------------- 22
(10) Cleaning for the Returning Water Tank and Check for the Ball Tap --------------------- 24
(11) Cleaning for the Oil Tank ----------------------------------------------------------------------- 24

Chapter 4 Safety Device

4-1 Superheating Prevention for the Boiler Main Body ------------------------------------- 24

(1) Burner Operation Suspension at the Low Level -------------------------------------------- 24
(2) Superheating Prevention Switch -------------------------------------------------------------- 25

4-2 Freezing Prevention ------------------------------------------------------------------------------- 25

2
Chapter 5 Boiler Water Treatment

5-1 Boiler Water Treatment ---------------------------------------------------------------------- 26

(1) Harm for the Boiler by Water ------------------------------------------------------------ --- 26
(2) Scale Protection ----------------------------------------------------------------------------- -- 26
(3) Corrosion Protection -------------------------------------------------------------------------- 27

5-2 Instruction for Blowing-off of Water ------------------------------------------------------- 27

Chapter 6 Maintenance for Boiler

6-1 Cause and Countermeasure for Trouble --------------------------------------------------- 29

6-2 Maintenance Checksheet --------------------------------------------------------------------- 30
6-2 After Service ----------------------------------------------------------------------------------- 31

Chapter 7 Reference Document

7-1 Piping Instruction for the Feed Water Pump ----------------------------------------------32

7-2 Piping Diagram for the Feed Water Pump ------------------------------------------------ 33
7-3 Piping Drawing for Softener -----------------------------------------------------------------34

3
Chapter 1 General
1-1 Part Name and Function for Boiler
(1) Part Name and Function for the Boiler Main Body

No. Nomenclature Function

1 Automatic control panel Operates boiler, start and stop.
2 Safety valve Safety device which exhausts steam if the boiler main body
pressure is above 10Kg/cm2.
3 Burner Combustion equipment which sprays the fuel mechanically.
4 Main steam valve A valve used for steam supply.
5 Steam separator A equipment generating high dryness steam through
separating the steam and the moisture.
6 Pressure gauge A gauge which indicates the steam pressure in the boiler
7 Air Extraction Valve A valve extracting air and draining water when blowing-off.
8 Water level gauge A gauge which indicates water level in the boiler.
9 Motor for oil gear pump A motor which supplies fuel to the burner by pressurizing
fuel.
10 Ladder A structure to climb up to the top of the boiler.
11 Concentration blowing-off solenoid A device which controls concentration of water by blowing
valve off automatically.
12 Blower A equipment which generates air for combustion and
forwards it to wind box.
13 Wind box A equipment which supplies air for combustion in the
furnace.

4
(2) Part Name and Function for the Control Panel

No. Nomenclature Function

1 Warning Buzz A alarm which buzzes when abnormal tube water condition.
2 Protect relay Controls combustion, and stops operation when emergency.
3 Initial chemical injection device A device which injects chemicals for corrosion protection
when initial operation.
4 Fuse Protects control system by cut-off when over current.
5 Magnetic switch for burner motor Controls the burner motor operation.
6 Terminal board for power Connects between wire on the control panel and the external
power.
7 Magnetic switch for feed water pump Controls operation of the feed water pump
8 Magnetic switch for oil pump Controls operation of the oil pump.
9 Circuit breaker Shut off when over current and electrical leakage.
10 Terminal board Connects wiring in the control panel and external wire.
11 Water level controller Controls water level and integrates combustion time.
12 Flame detection transducer Transduce the signal of flame eye to electrical signal for
control

5
(3) Part Name and Function for the Burner

No. Nomenclature Function

1 Burner A equipment which sprays and burns fuel.
2 Safety valve A safety device which open and exhausts steam automatically
at above 10 Kg/cm2 of the boiler main body pressure.
3 Ignition transformer A device which makes spark for ignition.
4 Blower motor Rotates the blower for supplying combustion air.
5 Blower body Impeller is included in it.
6 Damper motor A device which controls capacity automatically for complete
combustion.
7 Flame eye(flame detector) A device which detects ignition or flame failure, and have
stop operation.
8 Wind box A box which supplies air for combustion in the furnace.
9 Solenoid valve A device which controls fuel supply depending on low fire
and high fire.
10 Upper terminal box A terminal board for power supply on upper side.

6
(4) Part Name and Function for the Concentration Blowing-off and the
Oil Pump

No. Nomenclature Function

1 Concentration blowing-off valve It is used for replacing the solenoid valve for continuous blow
or cleaning the strainer.
2 Concentration blowing-off strainer It is used for filtering the blowing-off water and sludge.
3 Oil heater strainer It is used for filtering the sludge in the heater.
4 Oil heater It is used for heating the fuel(for heavy oil).
5 Concentration blowing-off A solenoid valve which drains and shut off the blowing-off
solenoid valve water automatically.
6 Oil pump motor A motor which rotates the oil pump.
7 Oil pump coupling It connects the oil pump to the oil pump motor.
8 Oil pump A equipment which pressurizes and supplies fuel to the burner.
9 Oil strainer It is used for filtering foreign substance in the oil.
10 Oil pressure gauge It Indicates pressure of fuel coming out from the oil pump.
11 Oil air cock It is used for extracting air in the oil pump.

7
1-2 Steam Generation System
(1) From Water Feeding to Steam Generation
1) Water Feeding
Raw water at the pressure of 1.5 - 5 kg/cm2 is flowing to softener[2] for making soft water. The soft water is flowing
to the feed water tank[3]. The water level of the feed water tank is maintained constantly by the ball tap. When the
power switch “ON”, the feed water pump[6] is operated(the chemical injection pump[10] is also operated for
injecting the tube cleaning detergent) and the feeding water from the feed water tank is pressurized and forwarded to
the evaporating tube by the feed water pump[6] through the feed water strainer for filtration of foreign substance,
check valves[7], [8] in feed water line and lower header.

2) Oil Feeding
The oil which is removed the foreign substance through the oil strainer[29], [30], [53] is pressurized up to the
specified pressure(15 Kg/cm2 for light oil, 20 Kg/cm2) by the oil pump[32] ,and is sprayed through nozzle. When
using the “B” heavy oil or “C” heavy oil, the oil is sprayed after heating by the oil heater[31] due to its high viscosity
at the ambient temperature.

3) Ignition
The lighting bar makes spark by the raised voltage(from 220V to 10,000 - 13,000V: 10,000V for light oil, 13,000 for
heavy oil) from ignition transformer and ignites the flame on the sprayed oil from nozzle.

4) Steam Generation
The water in the tube is heated by the combustion of burner and evaporated on the evaporation surface. The saturated
steam including moisture is forwarded to the steam separator through upper header. This steam including moisture is
separated into steam and moisture by the steam separator[12] ,and the dry steam only is supplying for load through
the valve[14].

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

Heavy oil specification

9
Chapter 2 Boiler Operation
2-1 Check Item before Operation
* Before start the operation, check the following items:
(1) The gauges(whether the pressure gauges, oil pressure gauges and water level gauges are working in
the normal condition).
(2) Water level in the feed water tank before opening the feed water valve;
(3) Oil level in the oil tank before opening the valve;
(4) Cleaning detergent in the chemical injection tank;
(5) Quality of soft water.

2-2 Operation Start

(1) Main switch for boiler “ON”.
(2) The power switch “ON” on the control panel equipped with the
front side of the boiler.
(3) Check that the water level on the water level gauge is normal, and
water is feeding automatically.
(4) Operation switch “ON” on the control panel.
(5) Push the manipulation switch(push button) for boiler operation.
(6) Check ignition condition in the low and high fire through the
reflection mirror after normal operation.
(7) Open the main steam valve slowly when the steam pressure is
reached up to 3 Kg/cm2.
(Control panel)
2-3 Operation Stop
(1) Operation switch “OFF”.
(2) Power switch “OFF” after post purge.
(3) In case of using bunker C oil, it is to be ignited by the light oil for 10 minutes before operation
suspension.
(4) Close the fuel valve and the main feed water valve.

2-4 Cautions during operation

(1) Open the main steam valve slowly.
(if open the valve rapidly, the water level in the tube could be the low level temporarily).
(2) In the event that the operation is stopped through sensing of the thermistor due to superheating of
the boiler main body, the operation switch and the power switch is to positioned to “stop” and close
the main fuel valve slowly.

10
(3) In case of suspension of water supply or power interruption, wait until the power or water is supplied
again in the condition of power “OFF”.
(4) In case of abnormal noise due to ignition failure or flame failure, the power switch “OFF” and the
gas in the firebox and the flue is to be purged by the blower, and try to re-ignite. If ignition failure
again, stop the operation and check the fuel in the oil storage tank, pressure of the oil pump, oil
temperature, flame eye(flame detector), ignition device and nozzle, etc.
(5) In case that the operation of boiler is to suspended for a moment and try to restart the operation for
the boiler using bunker-C oil, oil preheating is necessary up to appropriate temperature.
Preheating temperature:
A-heavy oil : 50 - 60°C, B-heavy oil : 90 - 110°C, C-heavy oil : 130 - 150°C.

2-5 Checking the Combustion Condition during Operation

For complete combustion, the balance of fuel and air volume( excess of air ratio) is to be appropriate. BOOSTER
boiler have so manufactured as to do complete combustion utilizing the automatic damper control of the three
position control method. The burning gas is also to be able to verified visually and checked as follows:
(1) When the flame color is red and black smoke in the stack
1) Lack of combustion air(damper closed).
2) Oil spray is not performed smoothly due to dust in the nozzle.
3) Oil temperature is too low.
4) Interval between flame panel and diffuser is in appropriate.
5) Oil quality is no good.
(2) When the flame color is bright and white smoke( the flame is short and split)
1) Combustion air is too much.
(3) The flame color is brown and white smoke but combustion condition is good
1) The moisture of exhaust gas has formed dew due to radiating in the flue and gas temperature drop.
(4) Flame failure during combustion
1) 1st. and 2nd. solenoid valve is shut off and oil supply is shut off through the flame detector’s
sensing.
2) Warning lamp of the protect relay is lit up and the alarm is buzzing informing abnormal
combustion.
3) Investigate and take a corrective action for the cause of warning lamp operation of protect relay,
and push the reset button for reoperation.
* Note
Trying for reoperation should be done minimum 1 minute after warning lamp operated. If the boiler
is not operated in spite of trying reoperation in several times, please contact to BOOSTER A/S team.

11
2-6 Instruction for the Boiler When It is not used for a Long Time
Most people cares a lot for corrosion protection of the boiler during operation, but cares nothing for the boilers which
is not used for a long time. In case that the boiler is not used for a week, the boiler could be corroded unexpectedly
due to wrong preservation.
The boiler preservation methods are as follows:
Boiler banking method by fulfilling water: injects the chemical to the boiler water to remove the
dissolved oxygen for maintaining the PH of the water as. PH 11.0 - 11.8.
Boiler banking method by drying : stores the boiler in the dry condition for freezing prevention in winter time.

Chapter 3 Manipulation of Auxiliary Equipment

3-1 Manipulation Method

(1) Setting Method for the Thermal Relay(OCR) of the Magnetic Switch
If the motor for blower, feed water pump or oil pump is
overloaded due to any reason, the thermal relay(overload
protection device) is working and then shut off the
magnetic switch to stop the motor for protection of it.
When the thermal relay is working, the lamp indicating
overcurrent is lit up, warning alarm is buzzing and reset
lever of the thermal relay is raised up about 2mm.
Pushing the reset lever after checking and corrective action (Thermal relay of the magnetic switch)
for motor, it will be reoperated

(2) Adjusting Method for the Pressure Switch

It is able to adjust the pressure range of 4 -9 Kg/cm2
(below maximum pressure). The pressure of the pressure
switch is adjusted by using the pressure adjusting bolt
and the pressure variation adjusting bolt to control
“ON - OFF” for combustion.
* Example of Pressure Adjusting :
In order to perform combustion as the figure
in the right side:
1) Set the pressure adjusting bolt of the high pressure switch to 8 Kg/cm2.
2) Set the pressure variation adjusting bolt of the high pressure switch to 3Kg/cm2.
3) Set the pressure adjusting bolt of the low pressure switch to 6 Kg/cm2.
4) Set the pressure variation adjusting bolt of the low pressure switch to 1 Kg/cm2.

12
 Note :
The copper pipe connected to the pressure switch has antifreezing solution for freezing prevention,
So, refilling the antifreezing solution in the winter time is required.

(Pressure and Pressure Variation Adjusting Bolt) (Low and High Pressure Switch)

(3) Air Extraction Method for the Feed Water Pump

Open the air cock on the outlet of the feed water pump and extract the air until the
water is coming out strongly. Including air in the pipe, water feeding is not performed
smoothly and shorten the pump life due to impeller abrasion.
So, periodic air extraction must be performed.

* Note:
In the winter time, open the upper and lower air cock for exhausting the water in the
pump in the no load condition for about 5 seconds to remove the residue attached on
the impeller. When operation the pump manually, push the magnetic switch
of P.5 (7) using the screwdriver, and then operate it for 5 to 10 seconds.
(Feed water pump)
(4) Air Extraction Method for the Oil Heater(For Heavy Oil)
Operate the oil pump and open the air cock valve for air extraction until fuel oil is coming out strongly. Including the
air in the oil heater causes not to raise the oil pressure. So, periodic air extraction must be performed.

(5) Setting Method for the Oil Pump Pressure

The following values are the standards of the oil pump pressure:
Kerosene, light oil --------------------------15 Kg/cm2
Bunker-A oil, B oil, C oil --------------------20 Kg/cm2
The pressure adjusting of oil pump to one other than the standard pressure is to be used by a L-wrench and
screwdriver(-).

13
(6) Wiring Method for the Feed Water Pump and the Oil Pump
(Feed Water Pump) (Oil Pump)
R S T R S T R S T R S T
| | | | | | | | | | | |
① ② ③ ① ② ③ Blue White Red Blue White Red
| | | | | |
⑥- ④ -⑤ ⑥ ④ ⑤ Yellow - Black - Green Yellow Black Green
(380V) (220V) (380V) (220V)

Note:
Rotating direction is to be checked after completion of wiring for the feed water pump and the oil pump.

(7) Adjusting Method for the capacity(Damper Blade)

* TYPE : DM-320-3
1) Cam Adjusting Method for Control Position
① BLUE (L1) : Adjusting cam for “low over run” prevention.
② BROWN(L2) : Complete close position adjusting cam
③ GREEN (L3) : Position adjusting cam for 1st. solenoid valve
open and opening angle(Low fire angle position adjusting).
④ BLACK (L4) : Position adjusting cam for 1st. return(Returning
position adjusting from high fire to low fire).
⑤ YELLOW (L5) : Adjusting cam for 2nd. solenoid open position
(Position adjusting for 2nd solenoid valve opening movement).
⑥ RED (L6) : Position adjusting cam for 2nd. opening angle
(High fire opening angle position adjusting).

2) The Wire Colors of the Damper Motor

① Blue(S0), ②Green(R0), ③Black(OV1 In), ④Red(OV2 In)
⑤ White(OV2 Out), ⑩ Yellow(OV1 Out)

3) Adjusting Method and Example of the Damper Blade Angle

1. Cam Adjusting Method for Control Position
The cam is adjusted in the angle of L1<L2<L3<L4<L5<L6 and the damper is opened wider rotated
it clockwise.
2. Adjusting Example:
If you want to adjust at the damper angle of (3.0) when 1st. combustion and (6.5) when 2nd.
combustion, adjust as follows:

14
 1) BLUE (L1) : Set the cam position to “0” which is indicated on the cam shaft by manual.
2) BROWN (L2) : Set the cam position to “1.0” which is indicated on the cam shaft by manual.
3) GREEN (L3) : Set the cam position to “3.0” which is indicated on the cam shaft by manual
(1st low fire opening angle position adjusting).
4) BLACK (L4) : Set the cam position to “3.2” which is indicated on the cam shaft by manual
( Position adjusting when returning from high fire to low fire).
5) YELLOW (L5) : Set the cam position to “5.0”which is indicated on the cam shaft by manual
(Position adjusting for 2nd. solenoid valve opening movement).
6) RED (L6) : Set the cam position to “6.5” which is indicated on the cam shaft by manual
(2nd high fire opening angle position adjusting cam).

* TYPE : DM-320-4
1) Cam Adjusting Method for Control Position
① BLUE (L1) : Position adjusting cam for 2nd. Return.
(Returning position adjusting from high fire to middle fire).
② BROWN (L2) : Position adjusting cam for 2nd. opening angle.
(Middle fire opening angle position adjusting).
③ GREEN (L3) : Adjusting cam for 2nd. solenoid open position.
(Position adjusting for 2nd. solenoid valve opening movement).
④ BLACK (L4) : Position adjusting cam for 1st. opening angle.
(Low fire opening angle position adjusting).
⑤ YELLOW (L5) : Adjusting cam for 3rd. solenoid open position.
(Position adjusting for 3rd. solenoid valve opening movement).
⑥ RED (L6) : Position adjusting cam for 3rd. opening angle.
(High fire opening angle position adjusting).
2) The Wire number of the Damper Motor
(1) So, (6) Ro(open), GV1 In, (7) GV3 Out, (8) GV3 In, (13) GV2 Out, (14) GV2 In, (17) Ro(close)
3) Adjusting Method and Example of the Damper Blade Angle
1. Cam Adjusting Method for Control Position
The cam is adjusted in the angle of L4<L3<L2<L1<L5<L6 and the damper is opened wider rotated
it clockwise.
2. Adjusting Example:
If you want to adjust at the damper angle
1) BLACK (L4): Set the cam position to “0.5~2.0” which is indicated on the cam shaft by manual.
(1st. low fire opening angle position adjusting).
2) GREEN (L3): Set the cam position to “4.0” which is indicated on the cam shaft by manual.
(Position adjusting for 2nd. solenoid valve opening movement).

15
 3) BROWN (L2) : Set the cam position to “5.0” which is indicated on the cam shaft by manual
(2nd. middle fire opening angle position adjusting).
4) BLUE (L1): Set the cam position to “5.3” which is indicated on the cam shaft by manual
( Position adjusting when returning from 3rd. high fire to 2nd. middle fire).
5) YELLOW (L5) : Set the cam position to “6.0”which is indicated on the cam shaft by manual
(Position adjusting for 3rd. solenoid valve opening movement).
6) RED (L6) : Set the cam position to “8.0” which is indicated on the cam shaft by manual
(3rd. high fire opening angle position adjusting cam).
Note:
Angle adjusting of the damper blade affects to the combustion condition and efficiency significantly and causes for
smoke. Do not adjust it at his discretion. Wrong direction is caused for smoke.

(8) Adjusting Method for the Water Level Device (BWC-3000L)

1) Direction for use Water Level Control Conversion Switch
This is a control device which has functions of water control,
concentration blowing-off and accumulation of combustion time.
[1] Combustion Time Check Conversion Mode
When pushing the conversion switch on the left side of the
water level unit, the LED lamp of the high fire, medium fire
and low fire are changed in sequence and the accumulated
combustion time is indicated on the monitor.
Ex) In case that the following indication are shown on the
monitor when pushing the conversion switch:
a) When the high fire[PH] lamp is lit up and [1][3] indication
is shown up on the monitor, total high fire operation time is
13 hours.
b) When the medium fire[PM] and the low fire[PL], the
indication is shown in the same method as the above.
[2] Water Level Control Conversion Switch (BWC – 3000L)
This is a switch which has functions of 3 position water level control and 5 position water level
control located on the upper position of the left side, and the function is being able to converted each other.
[3] Three position control(0.5 - 1.5 T/H) - E1, E2, E3 water level detection
(E1 : High water level, E2 : Medium water level, E3 : Low water level).
[4] Five position control(2.0 - 3.0 T/H) - E1, E2, E3, E4, E5 water level detection
(E1 : High water level, E2 : Medium water level, E3 : Low water level, E4 : Forced water level,
E5 : Safe water level).
When each water level detection lamp is lit up, current water level is indicated.

16
 [5] PL, PM, PH
Indicates present combustion detection status of the water level unit.
* Low fire : PL lamp is lit up.
* Medium fire : PM lamp is lit up(2.0 - 3.0 T/H).
* High fire : PH lamp is lit up
[6] Concentration Blowing-off Adjusting Method
This equipment is used to keep the electric conductivity of water in boiler uniformly and protect water pipe
from accuring of carry over, scale and corrosion.
By using this equipment, boiler can supply more stabilized steam for a long time.
The setting value is 3.7 at the normal condition on the dial indication which is setting the concentrated water
density. (Electrical conduction setting value is 4500µs/cm2).
If resistance is over 4500µs/cm2 electric conductivity of water, solenoid valve opened automatically and
concentrated water in pipe is drained if resistance will be downed under 2500~3300µs/cm2, then solenoid
valve will be closed automatically

* Note:
1) The time indicated on the combustion time accumulation device is operated even in the power interruption by
the battery.
2) The battery is charged automatically when power on and can be used about 10,000 hours per one charge.
3) For time initiation(0000 hours, 00 minutes, 00 seconds), the reset switch inside is used.

(9) Concentration Blowing-off Device

This is a device for supplying high quality of
steam for prolonging the life of the boiler which
protects scales and carry over through blowing
off the boiler water automatically. When the
boiler water concentration is exceeded the
allowable range, the concentration blowing-off
sensor monitors it and its electrical signal is
flowed to the solenoid valve for blowing-off
following by open the valve and blow off the
concentrated water. When concentrated water
density is dropped down, the solenoid valve for
concentration water blowing-off is shut off and
stopped the exhausting the boiler water.
(Concentration Blowing-off Device)

17
(10) Operation status for combustion Control(Protect Relay

◀ Ⅱ ▲ Ⅱ P ⅡⅡ ■ ⅡⅡⅡ ▼ ⅡⅡ ▤1 Ⅲ ▤2 Ⅲ …… ⅢⅢ ◀
Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ Ⅰ
① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ①

( Combustion Control Sequence)

1) Ignition Program Indication Chart

① Manipulation start
② Damper open(Residual combustion gas exhaust)
③ Circuit check of the flame detector in the control
④ Damper close
⑤ Ignition transformer operation
⑥ 1st. combustion ignition
⑦ Ignition transformer operation stop
⑧ 2nd. combustion ignition
⑨ Normal operation (Protect Relay: Combustion Controller)

[a] - [b] Ignition time

[b] - [b’] Normal combustion
[b’] - [a] Post purge
←•→ Safe time in case of intermittent
pilot
←••→ Safe time in case of interrupted
pilot

18
2) Indication Method
Symbol Indication Power failure or Cause for operation stop
Operation No operation Damper limit switch shut off
without power
Leakage detection failure
failure
Fuse cut-off, not reached up to the high water level
◀ Protect relay operation error due to moisture( Remove
moisture by dry air)
Manipulation switch failure
Power failure
Suspected flame signal
Damper open(to 2nd. Combustion is Limit switch open(short)
▲ Combustion not performed
position) continuously
P
Circuit check for Power failure Suspected flame signal
flame detector in the
■
control Control system failure

Damper close(1st. No operation Damper limit switch close(shut off)

▼ combustion continuously
preparation)
1st. safety time Power failure Check the polarity of the flame detector

Ignition transformer failure

1 Fuel valve failure
Lack of flame stability
Flame detector failure
2nd. safety time Power failure Ignition failure of the burner(1st. solenoid valve shut off or
2
too much air volume)
― (2nd combustion) Power failure Weak flame current
· Operation Fuel supply suspension
·
Abnormal operation of the flame detector(QRA-2), Clean
·
dust on the glass surface or flame-eye(P-930 -5)
―
3-2 Brief Maintenance and Cleaning Method
(1) Check for Soft Water
The followings are to be checked for the boiler durability:
1) Feed water must be soft water.
2) Soft water quality must be checked by the hardness indicator at least
once a day. (About 30 -50cc water in the container taken from the softener
outlet is examined by dropping the hardness indicator).

(Soft Water Check)

19
 * Acceptance standard

Blue Soft water : Accept for use

Red Hard water : Reject for use ( To be returned to the softener manually)
* Note:
1) If the water includes foreign substance or washes hands in it, inspection could be resulted hard
water even being taken from the softener. Therefore, careful handling of water sample taken is
required.
2) When the regeneration of softener is needed during continuous operation, 2 units of softener have to
be installed for alternative operation.

(2) Check for the Concentration Blowing-off Device

Check whether the specified blowing-off is performed everyday and the concentrated water sensing device is
operated in the normal condition. If any problem on the blowing-off performance, it causes the scale attachment.
Therefore, careful checking is required.

(3) Check and Cleaning for the Oil Strainer

(For heavy oil)
1) Close the main valve of the oil tank and unscrew the
lower drain plug for draining the foreign substance
deposited in the strainer.
2) Unscrew the bolts(6) for taking off the cap.
3) Take off the filter and clean it by using light oil, etc. (Oil Strainer for Heavy Oil)
(For light oil)
1) Take off the cap by unscrewing the cap nut.
2) Clean the filter.
* Note:
Careful attention is required for the packing damage
when disassembling. (Oil Strainer for Light Oil)
(4) Check and Cleaning for the Oil Heater Strainer(For Heavy Oil)
Disassemble the heater strainer and remove the sludge
attached to the strainer(at least once a month).
* Note:
The clogging of the heater strainer could cause the
combustion failure and ignition failure.
(The frequency of cleaning depends upon the oil quality). (Oil Heater)

20
(5) Check and Cleaning for the Feed Water Strainer and the Concentration Blowing-off
Strainer
Check the inside of the feed water strainer and concentrated blow
strainer and remove the foreign substance(dust, scale, rust, etc.)
at least once a month.

* Note:
After disassembling and cleaning the feed water strainer,
air extraction must be performed through operating the feed water pump. (Feed Water Strainer)

(6) Check and Cleaning for the Water Level Electrode Bar
The water level electrode bar is installed on the
water level gauge.
Disassemble the electrode bar from the water level
gauge body and remove the scale and dirt on it using
the soft cloth. When reassembling the electrode bar,
careful attention is required not so as to be changed
the wire connection. In order for prevention of wire
connection error, sequential disassembling and cleaning
is recommended(once per 3 months).
(After checking and cleaning, the water level gauge
must be checked whether it is being operated in the
normal condition).
(Electrode Bar Holder) (Water Level Gauge)

(7) Check and Cleaning for the Oil Pump

Shut off the oil tank main valve and unscrew the eight of cap bolt
by using the open wrench for disassembling of the strainer of the
oil pump, and clean it to remove the foreign substance using the
light oil or others.
* Note:
Do not disassemble the pump main body for prevention of packing
damage.
(OIL PUMP)

21
(8) Check for the Safety Valve
Extract the steam 2 or 3 times by using the safety valve lever at the
8 - 9 kg/cm2 of steam pressure at least once a month from trial operation.

(Safety Valve)
(9) Burner
1) Disassembling Method of the Burner
Pull out the ignition plug and the flame detector from the
burner, disassemble the inlet and the outlet pipe for oil
feeding.
Unscrew the butterfly nut, and take off the wind box from
the burner assembly.
When reassembling, reverse sequence is applied.
(Burner for Heavy oil fuel)
2) Cleaning for the Lighting Bar and the Diffuser
Clean the carbon attached to the lighting bar and the diffuser
which is caused for ignition failure or back fire at least once a month.
( Refer to the burner drawings).
When assembling it after cleaning, careful cautions to keep the correct
distance between the edge of the light bar and the diffuser is required.
Tight fastening of bolts and nuts is recommended. Inappropriate
distance causes the diffuser damage and ignition failure.
(At least once a month).

(Burner for Light oil fuel)

22
3) Check for the Nozzle
Disassemble the nozzle from the burner ,and remove the foreign
substance in it by the light oil or others.

* Note:
When reassembling the nozzle, sequential disassembling and
reassembling is recommended not so as to be changed the position
of the low fire nozzle and the high fire nozzle. Careful caution (Nozzle)
is required not so as to be changed the assembling sequence of
and  as the figure in the right side.

4) Cleaning for the Flame Detector

Clean the sight glass of the flame detector using the soft cloth.
The scale and carbon on the sight glass of the flame detector have causes to be difficult to do flame monitoring and
normal operation. If flame monitoring failure of the flame detector, the flame is failed 4 -5 seconds after ignition.

( Flame Detector)
5) Check and Cleaning for the Solenoid Valve
Clean the solenoid valve by the light oil or others.
The foreign substance on the solenoid valve seat(heavy oil ,
light oil ) causes the gas explosion, the smoke and the
hydraulic oil pressure drop(B-C oil; 1st solenoid valve)
due to leakage.
    
* Note: (Solenoid valve for heavy oil fuel)
Disassembling sequence is referred to the right side figure.
Do not unscrew the  for heavy oil and  for light oil by the
plier or other tools(the seat damage causes the valve operation
failure and the gas explosion).
* When taking off the complete burner assembly, careful
attention for the solenoid valve connection(to  in the
   
above figure) is required. (Solenoid valve for light oil fuel)

23
(10) Cleaning for the Returning Water Tank and Check for the Ball Tap
Remove and clean the deposit at the bottom of the tank to
prevent that the foreign substance flows to the boiler.
Clean and remove the foreign substance attached on the seat
of the ball tap frequently.
(Ball tap)
(11) Cleaning for the Oil Tank
Open the valve for cleaning and remove the foreign substance and water deposited at the bottom of the tank.
Mixing the foreign substance and water in the oil hampers normal pump operation and shorten the life of the oil
pump.( At least once per 3 months).

Chapter 4 Safety Device

4-1 Superheating Prevention for the Boiler Main Body

(1) Burner Operation Suspension at the Low Level
1) 0.5 – 1.5 T/H
A device which controls the feed water pump and burner
automatically for superheating prevention by the electrical
signal from the computer by sensing the water level.
When the water level dropped down to the low water level limit,
the combustion circuit of burner is shut off automatically (when the
water level is not reached to the high water level limit in the initial
operation stage, the blower is not operated and the burner is not ignited).
Once the water level reached up to the high water level (Water Level Control for Superheating Prevention)
limit, the feed water pump operation is repeated in between the high water level and the medium water level. If the
wire of the lighting bar holder is disconnected, correct water level control is impossible and make a abnormal noise.
The foreign substance on the lighting bar have it be difficult to detect the water level and causes the superheating.
Therefore periodic cleaning is required.

24
2) 2.0 T/H – 3.0 T/H
There are 5 electric bar for water level.
Signal condition method : When electric bar is under water for 1 sec, there is water.
When electric bar is out of water for 1 sec, there is no water.

(Water Level Control for Superheating Prevention)

* Note:
Careful attention is required not so as to be incorrect length and position of the lighting bar when connected 3
terminal after cleaning.

(2) Superheating Prevention Switch

If the boiler main body temperature is raised up abnormally,
the superheating prevention switch is operated and shut off the
burner combustion circuit for protecting the boiler main body
and the risk of fire.
( If the boiler main body temperature is raised up to 200°C,
the power is cut off). (Superheating Prevention Switch)

4-2 Freezing Prevention

For the place where is possible to freeze in the winter time, the blowing-off after operation finished should be
performed and preserve the boiler with the blow valve and main steam valve closed. And also open the upper and
lower cock of the feed water pump and drain the water in the water feeding pipe(refer to figure of feed water pump
on P.11). and also open the plug of the feed water tank blowing-off and the feed water strainer, and then drain the
water in them completely.
* Note:
The water in the softener is impossible to be drained and have high risk of freezing in the winter time. Therefore,
external insulation is required. The pressure gauge and the pressure switch have antifreezing solution in the pipe line.
Therefore after using for period before coming to winter, the antifreezing solution must be refilled.

25
 Chapter 5 Boiler Water Treatment

5-1 Boiler Water Treatment

For a longer boiler life and for maintaining continuous good operation condition, appropriate water treatment is
required like a food control for our health. The hard water such as tap water and underground water includes various
foreign substance. Therefore the softener or chemicals(tube cleaning detergent) which changes the hard water to soft
water shall be used. Especially, boiler damage due to bad quality of water is not able to be identified immediately.
Therefore, daily water check and control is very important
* When using underground water, the feed water filter must be used.
(1) Boiler Harm by the water
The boiler water including the hardening elements(Ca, Mg) and silica causes high water concentration and scale
attachment to the tube wall. Since thermal conductivity of the scale is extremely low, the boiler efficiency is reduced
which is caused of boiler superheating. Corrosion of steel is caused by acid and alkali water. If the boiler tube is
corroded, the thickness of tube is to be thinned by damaging of surface and come to rupture. Conclusively, the boiler
harm by the water is the scale and corrosion.
(2) Scale Protection
1) Softener Use
The boiler water is to be the soft water which is removed the hardening elements of Ca and Mg dissolved in the water
which become to the scale by the softener.
2) Chemical Use(BOOSTER Cleaning Detergent: Direct Heating - 182 ppm for general use, Indirect Heating - 98
ppm for industrial use)
The chemical is injected for protection that the small amount of hardening elements and silica in the water leaked
from the softener become to scale, and of corrosion of tube by removing the dissolved oxygen in the water to
maintain the water in the alkalinity(PH:11.0 - 11.8) which is the most difficult condition for corrosion).
* Chemical Injection Method
The chemical should be injected continuously during operation by the chemical injection device balanced with the
amount of feed water from the feed water pump.
* Relation between Scale and Tube Wall Temperature *Boiler Efficiency Reducing by Scale

Thickness of Scale Tube Wall Temp.

0 mm about 180°C
0.5 mm about 280°C
1 mm about 360°C

* Exceeding the tube temperature 350°C, the allowable stress is dropped down rapidly.

26
(3) Corrosion Protection
1) Maintaining the Appropriate PH
Chemicals to the boiler changes the tube water to alkali property from acid property which is the most bad condition
for corrosion. Appropriate PH is PH 11.0 - 11.8.
2) Removing the Dissolved Oxygen
The boiler is corroded when using the water including dissolved oxygen. This dissolved oxygen could be removed by
chemical injection.
3) Blowing -Off
The blowing-off should be performed so that chloride concentration in the water is not exceeded
400mg Cl/l. When using the underground water near the seaside, special attention is required. If tube water is not
maintained in appropriate condition during operation suspension, small corrosion occurred during operation could be
increased or new corrosion could be appeared.
The quality of the boiler feed water and the tube water shall be in compliance with the following standard values:
(Feed Water Quality) (Tube Water Quality)

Inspection Item Std. Value Inspection Item Std. Value

PH (25°C) 6-9 PH (25°C) 11.0 - 11.8
Hardness (mgCaCO3/l) 1 and below M Alkalinity (mgCaCO3/l) 250 - 800
Oil(s) and Fat(s) (mg/l) nearly 0 P Alkalinity (mgCaCO3/l) 150 - 600
Dissolved Oxygen (mgC/l) nearly 0 Total Evaporation Residue (mg/l) 2800 and below
Total Iron (mgFe/l) 0.3 and below Electrical Conductivity (µs/cm) 4000 and below
Electrical Conductivity (µs/cm) 350 and below Chloride Ion (mgC l/l) 400 and below
M Alkalinity (mgCaCo3/l) 80 and below Phosphate Ion (mgPO4/l) 20 - 40
Chloride Ion (mgC l/l) 50 and below Hydrazine (mgN2O4/l) 0.1 - 05
Silica (mgSiO2/l) 50 and below Silica (mgSiO2/l) 350 and below
Sulfite Ion (mgSO3/l) 10 - 20

* Sampling Method of theTube Water for Quality Test

The water sample is taken through the drain valve when the steam pressure is reduced and water has been drained a
half of the tube water after finished operation. The water sample must be taken 3 hours after operation finished. The
amount of water sample is about 500cc.

5-2 Instruction for Blowing-off of Water

The tap water or underground water used for boiler water is transparent and is seen as not included any foreign
substance, but it has a lot of organic and inorganic matter such as calcium, magnesium, silica, etc. The softener
cannot remove the other foreign substance but calcium and magnesium which is caused for scale. Therefore, for
adjusting the concentration of the boiler water to a standard value, the blowing-off should be performed through
exhausting the concentrated tube water. Blowing-off should be performed at least once a day(8 hour basis a day) for
prevention of superheating which is caused by scale and sludge deposit.

27
♦ Blowing-off should be performed as follows before starting the normal boiler operation at least once a day(one day
is 8 hour basis):
1) Check whether the water level in the tube is normal.
2) Close the main steam valve(ignite according to instruction for operation start on P.9).
3) Operate the boiler ,and if steam pressure is reached up to 1.5 - 2 kg/cm2, the operation switch “OFF”.
4) After post purge, the power switch “OFF”.
5) Open the blowing-off valve and perform blowing-off.
6) If steam pressure is 0 kg/cm2, open the air extraction valve and perform blowing-off continuously. After finished
the blowing-off, close the blowing-off valve.
7) Power switch “ON”. Close the air extraction valve when the water is feeded by the feed water pump and the air has
been exhausted completely. Check whether the water level is normal.
* Blowing-off is not necessary everyday when operation load is not much.

28
Chapter 6 Maintenance of Boiler
6-1 Cause and Countermeasure for Trouble
When founded the trouble for boiler operation, check the following items before contact for A/S:
Trouble Condition Causes Countermeasure
No operation of the feed water 1) Power shut off 1) Check main power switch, the magnetic switch
pump connection, and if the power lamp is on.
2) Tube water is full. 2) Open the boiler main body blowing-off

3) Thermal relay(OCR1) of the

valve(check
magnetic switch for the feed water through water level gauge).
pump is operating normally. 3) Investigate the trouble cause and take corrective
4) Contamination of the water level action ,and then reset.
electrode bar. 4) Check and clean it one by one.
5) Wire connection is loosed. 5) Fasten tightly the electrode bar holder and the terminal
in the control box.
No water feeding but the feed 1) No water in the feed water tank, or 1) Check the water in the tank ,and clean the ball tap and
water pump is operated. slow speed of flowing in . The strainer.
2) Closed the main valve of the feed 2) Open the main valve.
water tank.
3) Clogged the feed water strainer. 3) Clean the strainer.
4) Opened the boiler main body 4) Close the valve.
blowing- off valve.
5) Air included in the feed water pump. 5) Extract the air by opening the air extraction valve.
Low water indication buzz is 1) Contamination or cut-off of the low 1) Check and clean the low water level electrode bar.
alarming but indicated normal water level electrode bar.
water level on the water level 2) Earthing conductor cut-off or incomplete contact.
gauge
Feed water pump is not 1) Contamination or cut-off of the high 1) Check and clean the high water level electrode bar.
stopped. water level electrode bar
(keep operating) 2) Earthing conductor cut-off or incomplete contact.
Frequent ON-OFF of feed 1) Low water pressure 1) Adjust the main steam valve raise the pressure.
water 2) High concentration of tube water 2) Perform the blowing off.
3) High variation of load. 3) Open and close the main steam valve slowly.
4) Contamination or incomplete contact 4) Check and clean it one per one time.
of the water level electrode.
No operation of the Blower 1) Power shut off. 1) Power “ON”.
2) Water level is not reached up to 2) Wait until low water lamp is turned off and the feed
setting level. water pump is stopped.
3) Terminal relay(OCR2) is operating. 3) Investigate the cause and reset.
4) The boiler pressure is not reach up to 4) Drop down the steam pressure.
setting pressure.
Alarm indicating abnormal 1) Attached the carbon and smoke on 1) Clean the glass surface of the flame detector.
burner operation is buzzing the glass of the flame detector.
2) Contaminated the spark electrode. 2) Clean the spark electrode.
3) Inappropriate distance of the spark 3) Adjust the distance of the spark electrode.
electrode.
4) Opened too wide the blower damper. 4) Close the damper appropriately.

29
6-2 Maintenance Checksheet
Every- Every Every 3
Check Item Maintenance Method
day Month Months

Softer O Check by hardness indicator(Blue is acceptable), Salt check

Chemical volume check O Check whether the chemical is in the tank ,and check injection status.

Blowing- Blowing off of O Perform blowing off before operation everyday

off water in boiler

Continuous O Check whether the blowing -off is performing by monitoring of

blowing-off concentration blowing-off sensor.

Water Level gauge O Check whether it is operating normally(High water level shut-off and low
water level shut-off).

Pressure gauge O Check whether it is operation normally(No variation?).

Combus- Ignition O Check whether the ignition is performing normally.

tion Smoke O Check if smoke out.

Automatic Abnormal Low O Check the low level status indication lamp and buzz operation status.
control water level
device Pressure shut-off O Check for automatic ON-OFF at the setting pressure.

Oil strainer O Disassemble and clean the filter every month.

Oil heater Strainer O “

Blowing-off O Blow off the sludge and foreign substance.

Tube water quality O Take a tube water sample and analysis.

Strainer Feed water O Clean the filter

Blowing-off O “

Burner Lighting bar O Remove carbon attached.

Diffuser O “

Nozzle O Cleaning by the light oil after disassembling.

Flame-eye O Clean the surface of glass.

Safety valve O Check the test lever operation.

Ball tap O Operation test

Water level electrode bar O Clean after disassembling.

Feed water tank blowing-off O Remove and clean the dust, foreign substance and deposits.

Oil tank blowing-off O

30
6-3 After Service
When requesting the after service, please contact BOOSTER After Service Team with the following information:
(1) Boiler Type(indicated on the Name Plate).
(2) Manufacturing Number and Date(indicated on the Name Plate).
(3) Trouble situation(as detail as possible).
(4) Fuel type
Occasionally, the BOOSTER engineer could request the recheck for the trouble item. In this case, your corporation
would be highly appreciated.

31
Chapter 7 Reference Document

7-1 Piping Instruction for the Feed Water Pump

* Note
No. Part Name Specification
1. When using the returning water tank, the circulation
1 Nipple 40A
pump is to be installed in front side of the feed water
2 Strainer 40A
pump.
3 Reducer 40A*25A
2. The length of each pipe is to be as built.
4 Tee 25A*15A
3. When the feed water pump is BFME, the diameter of
5 Bushing 15A*10A
the pump outlet is 25A, therefore 25*20 socket is to
Compound
be used. 6 φ 75
Pressure gauge
7 Nipple 25A
8 Nipple 20A
9 Flexible 20A

32
7-2 Piping Diagram for Feed Water Pump and Feed Water Tank
1) When the feed water tank is installed under the ground (the circulation pump is
positioned under the ground) :

2)When the feed water tank and the feed water pump
are installed under the ground:

3)When the feed water tank is installed above the

ground(the feed water pump position is above the
ground):

Note
1. The elevation of the feed water tank outlet is to be above the one of the feed water pump outlet.
2. The pump may be positioned in the side of the boiler and the feed water tank side.
3. Prior to start the operation, fill the water fully in the pipe between the feed water tank and the water
level gauge through the water filling hole.
4. For site using condensate , the pressurizing pump is to be installed in front side of the feed water tank.

33
7-3 Piping Diagram for Feed Water Pump and Feed Water Tank

Note
1. The length of each pipe is to be as built.
2. Piping connection of softener is to be TK -12, 20, 30, 40.
3. If softener inlet pressure(water head) is 1.5 Kg/cm2 and below, the pressurizing pump is to be installed.

34
 BOOSTER BOILER CO., LTD
● HEAD OFFCE & FACTORY
1142,NOWEON-RI, IWEOL-MYEON,CHINCHON-GUN,
CHUNGBUK-DO, KOREA
TEL:(82 43)536-9107 FAX:(82 43)536-9109
● SEOUL OFFICE:
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SEOUL KOREA .
Postal code : 420-130
TEL: (82 2)2062-0760-8 FAX:(82 2)0262 -1078
● Beijing Office
RM.952,JINGXIN BUILDING,NO.2(JIA),DONGSANHUAN BEILU,
CHAOYANG DISTRICT,BEIJING CHINA
TEL:010-6663-4691 FAX:010-6463-4692

● Booster Boiler . Service Reservation

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35