INDEX [khinzawshwecom.files.wordpress.com]...May 01, 2018 · boiler tube damaged. power source for...

A 4 x 3 7 T o t a 1 3 7 SHEET (S) W l T H COVER

MARINE BOILER DESIGNING SEC.

MlTSUBlSHl HEAVY INDUSTRIES. LTD. I\ NAGASAKI SHIPVARD MACHINERV WORKS

DRAWL Mar 12, 2003 1 SSi [,I1

7%

4

@A

7fl;

F i % G

Zi- E G

S ~ G

TURBO & MARINE MCHIN. DESIG DEPT.

APPROVED 7. .S&%?O~A

5. UZO

CHECKED -

DRAWN ?. 3 CONFERRED

N A M U R A S. z-a-/ 2 3 4

Aux. Boiler ( MAC 25Bx2 )

BOILER TROUBLE

/

SHOOTING LIST

DRAWING NO. REV NO

N 5 7 - 9 9 K - N 5 1 0 /

N SCALE

ORDER

K I ~ / ~ I l TEM

61 500

N57-99K-N510 BOILER TROUBLE SHOOTING LIST

I N D E X

1. BOILER TROUBLE SHOOTING

INDEX

A- 1 DRUM LEVEL HIGH

A-2 DRUM LEVEL LOW

A-3 DRUM LEVEL LOW-LOW

FUEL OIL PRESSURE LOW

FUEL OIL PRESSURE LOW-LOW

ATOMIZING PRESSURE LOW

ATOMIZING PRESSURE LOW-LOW

DRUM STEAM PRESSURE HlGH

DRUM STEAM PRESSURE LOW

FUEL OIL TEMPERATURE HlGH

FUEL OIL TEMPERATURE LOW

FUEL OIL TEMPERATURE LOW-LOW

SMOKE HlGH

IGNITION FAILURE

IGNITION VALIDITY TERM OVER

FLAME FAILURE

FLAME EYE ABNORMAL

F.D. FAN TRlP

PILOT PUMP TRlP

VALVE ABNORMAL

ITEM

ABCIBMS CONTROLLER FAILURE

MAIN SOURCE FAILURE

DC24V SUPPLY UNIT ABNORMAL

BOILER TRlP

CONTROL AIR PRESSURE LOW

WIND BOX TEMPERATURE HlGH

FEED WATER PRESS LOW

FEED WATER PUMP TRlP

BURNER START SEQUENCE REMAINS INACTIVE

CHECK OF INSTRUMENTS (TRANSMITTER, CONTROL VALVE & CONTROL DRIVE)

2. LIST OF EMS INPUT / OUTPUT ! I/O ) AND SET POINT OF ALARM / TRlP CONDITION

SHIP NO. 226 /BOILER TYPE MAC-25B

Ol<IGlN!\IL I



ORIGINAL 2

INTERLOCK

ALARM

INDEX

A- 1 !TEA

DRUM LEVEL HIGH

Set Point for Abnormal Condition

" SEE I10 LIST " SEC. HAS ELAPSED AFTER STEAM DRUM LEVEL EXCEEDED "NOR "SEE 110 LIST" mm".

ACTION TO BE TAKEN

OPEN & ADJUST

CONTROL VALVE

SUPPLY CONTROL AIR OF

6 kg/cm" OR MORE.

SEE INDEX Z

CHECK & ADJUST

SEE INDEX Z

SEE INDEX Z

ESTIMATED CAUSE

MALFUNCTION

OF

CONTROL VALVE

FOREIGN MATERIAL CAUGHT BY VALVE

SEAT.

SLIDING PART OF VALVE HAS STICKED.

CONTROL VALVE HAS BEEN LOCKED

DUE TO L S S THAN 4 kglcm" OF

CONTROL AIR PRESSURE FOR ITS DRIVING.

MALFUNCTION OF VALVE POSlTlONER

MALFUNCTION OF MONITOR SWITCH, DISCONNECTION OF SIGNAL

LINE.

MALFUNCTION

OF

WATER LEVEL

TRANSMlnER

MALFUNCTION OF FWR DRUM WATER

LEVEL TRANSMITER (ELECTRONICS)

MALFUNCTION OF RWL DRUM WATER

LEVEL TRANSMITTER (ELECTRONICS)



ORIGINAL 3

INTERLOCK

ALARM

INDEX

A-2 lTEM

DRUM LEVEL LOW


"SEE I10 LIST" SEC. HAS ELAPSED AFTER STEAM DRUM LEVEL LOWERED "NOR "SEE I10 LIST" mm".

ACTION TO BE TAKEN

OPEN & ADJUST

CONTROL VALVE


6 kg/cm" OR MORE.

SEE INDEX Z

CHECK & ADJUST

SEE INDEX Z

SEE INDEX Z

CHECK & ADJUST

PLUG OR REPLACE

BOILER TUBE.

ESTIMATED CAUSE

MALFUNCTION

OF

CONTROL VALVE


SEAT.



DUE TO LESS THAN 4 kg/cm2g OF



MALFUNCTION OF MONITOR SWITCH, DISCONNECTION OF SIGNAL

LINE.

MALFUNCTION

0 F

WATER LEVEL

TRANSMITTER

ABNORMAL CONDITION

OF

FEED WATER LlNE

ABNORMAL CONDITION

OF

BOILER PRESSURE PARTS

MALFUNCTION OF CONTROL WATER

LEVEL TRANSMllTER (ELECTRONICS)



FEED WATER PUMP STOPPED.

BOILER TUBE DAMAGED.



k

INDEX

A-3 lTEM

DRUM LEVEL LOW-LOW

INTERLOCK

ALARM a BOILER TRIP


STEAM DRUM LEVEL HAS REACHED "NOR - "SEE I/O LIST" mm".

ACTION TO BE TAKEN

OPEN & ADJUST

CONTROL VALVE


6 kg/cm2g OR MORE.

SEE INDEX Z

CHECK & ADJUST

SEE INDEX Z

SEE INDEX Z

CHECK & ADJUST

PLUG OR REPLACE

BOILER TUBE.

SEE INDEX 0

REMARKS

ESTIMATED CAUSE

MALFUNCTION

OF

CONTROL VALVE


SEAT.



DUE TO LESS THAN 4 kg/cm2g OF



MALFUNCTION OF MONITOR SWITCH, DISCONNECTION OF SIGNAL LINE

MALFUNCTION

0 F

WATER LEVEL

TRANSMITTER

ABNORMAL CONDITION

OF

FEED WATER LlNE

ABNORMAL CONDITION

OF BOILER PRESSURE PARTS

MALFUNCTION OF

FWC CONTROLLER



MALFUNCTION OF RWL 8, DLSS DRUM

WATER LEVEL TRANSMITTER

(ELECTRONICS)

FEED WATER PUMP STOPPED.

BOILER TUBE DAMAGED.

POWER SOURCE FOR ABC CONTROLLER

HAS FAILUREED.

OPERATION OF PROTECTIVE SYSTEM

STOP BOILER BY EMERGENCY TRIP.

CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION, AND THEN,

RE-START BOILER AFTER FEEDING WATER TO NOR. LEVEL.


SHIP NO. 226 /BOILER TYPE MAC-258

k

INDEX

A-4 lTEM

DRUM LEVEL HIGH-HIGH

INTERLOCK

ALARM a BOILER TRIP


STEAM DRUM LEVEL HAS REACHED "NOR - "SEE I10 LIST" mm".

ACTION TO BE TAKEN

OPEN & ADJUST

CONTROL VALVE


6 kglcm" OR MORE.

SEE INDEX Z

CHECK & ADJUST

SEE INDEX Z

SEE INDEX Z

CHECK AND BLOW THE

DETECTING PIPE OF STEM

FLOW

SEE INDEX O

REMARKS

ESTIMATED CAUSE

MALFUNCTION

OF

CONTROL VALVE


SEAT.



DUE TO LESS THAN 4 kglcm" OF



MALFUNCTION OF MONITOR SWITCH, DISCONNECTION OF SIGNAL LINE

MALFUNCTION

OF

WATER LEVEL

TRANSMlTiER

MALFUNCTION OF STEAM

FLOW TRANSMITER

MALFUNCTION OF

FWC CONTROLLER


LEVEL TRANSMITER (ELECTRONICS)


LEVEL TRANSMITTER

(ELECTRONICS)

STEAM FLOW TRANMSllTER DETECTS WRONG

STEAM FLOW SIGNAL.

POWER SOURCE FOR ABC CONTROLLER

HAS FAILUREED.




RE-START BOILER AFTER FEEDING WATER TO NOR. LEVEL.


--


.INDEX

B- 1

ORIGINAL ti

lTEM FUEL OIL PRESSURE LOW

INTERLOCK

ALARM


"SEE IIO LIST'' SEC. HAS ELAPSED AFTER F.O. BURNING PRESSURE LOWERED BELOW "SEE IIO LIST'.

ACTION TO BE TAKEN

OPEN & CHECK

CONTROL VALVE


6 kglcm" OR MORE.

SEE INDEX Z

CHECK & ADJUST

CHANGE, CHECK

&ADJUST PUMP

& STRAINER

CHECK & ADJUST

SEAL ETHYL GLYCOL

INTO SEAL POT

CHECK & ADJUST

CHECK & ADJUST

A

MALFUNCTION

0 F

CONTROL VALVE

REDUCED

DISCHARGE PRESSURE

FROM F.O. PUMP

DETECTING FAULT

OF

ECC. CRT.

ESTIMATED CAUSE

FOREIGN MATERIAL CAUGHT BY VALVE SEAT.


CONTROL AIR PRESSURE FOR DRIVING HAS

LOWERED BELOW 4 kglcm",

CAUSING VALVE TO BE CLOSED.


CONTROL SIGNAL LINE DISCONNECTED.

MALFUNCTION OF F.O. PUMP (F.O. PUMP TO

BE STOPPED BY MANUAL), STRAINER

CLOGGED, OR MALFUNCTION OF

DlSCH ARGE PRESSURE CONTROL SYSTEM

MALFUNCTION OF PRESSURE SWITCH

DISCONNECTION OF SIGNAL LINE

F.O. PRESSURE DETECTING LINE CLOGGED

WITH HEAVY OIL.

F.O. LEAK FROM BURNER PIPING

MALFUNCTION OF PRESSURESWITCH



INDEX

8-2

ORIGINAL '7

lTEM FUEL OIL PRESSURE LOW-LOW

INTERLOCK

ALARM 8,

BOILER TRIP


F.O. BURNING PRESSURE HAS LOWERED BELOWUSEE I/O LIST".

ACTION TO BE TAKEN

OPEN & CHECK

CONTROL VALVE


6 kglcm" OR MORE.

SEE INDEX Z

CHECK & ADJUST

CHANGE, CHECK

& ADJUST PUMP

& STRAINER

CHECK & ADJUST

SEAL ETHYL GLYCOL INTO

SEAL POT

CHECK 8, ADJUST

CHECK & ADJUST

CHECK & ADJUST

REMARKS

MALFUNCTION

OF

CONTROL VALVE

REDUCED

DISCHARGE PRESSURE

FROM F.O. PUMP

DETECTING FAULT

OF

PRESSURE SWITCH

ESTIMATED CAUSE


SEAT.


CONTROL AIR PRESSURE FOR DRIVING HAS

LOWERED BELOW 4 kg/cm2g,

CAUSING VALVE TO BE CLOSED.


CONTROL SIGNAL LINE DISCONNECTED.

MALFUNCTION OF F.O. PUMP (F.O. PUMP

TO BE STOPPED BY MANUAL), STRAINER

CLOGGED, OR MALFUNCTION OF

DISCHARGE PRESSURE CONTROL SYSTEM.

MALFUNCTION OF PRESSURE SWITCH WIRE

DISCONNECTED.

F.O. PRESSURE DETECTING LINE CLOGGED

WITH HEAVY OIL.

F.O.PUMP DOES NOT RUN

F.O. LEAK FROM BURNER PIPING




CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION

AND THEN RESET BOILER TRIP, AND RESTART BOILER.



INDEX

c- 1

ORIGINAL 8

lTEM ATOMIZING PRESSURE LOW

INTERLOCK

ALARM


"SEE I10 LIST" SEC. HAS ELAPSED AFTER ATOMIZING PRESSURE LOWERED BELOWMSEE I10 LIST".

ESTIMATED CAUSE

ATMIZING SUPPLY STEAM PRESSURE HAS LOWERED (DUE TO LOW DRUM

STEAM PRESSURE)

DISORDER OF SIGNAL FROM PRESSURE SWITCH DUE TO ITS LINE

DISCONNECTED.


ACTION TO BE TAKEN

CHECK & ADJUST

CHECK & ADJUST

CHECK & ADJUST


SI-IIP NO. 226 /BOILER TYPE MAC-25B

INDEX

c-2

ORIGINAL 9

lTEM ATOMIZING PRESSURE LOW-LOW

INTERLOCK

ALARM &

BOILER TRIP


ATOMIZING PRESSURE HAS LOWERED BEL0W"SEE I10 LIST".

ESTIMATED CAUSE

ATMlZlNG SUPPLY STEAM PRESSURE HAS LOWERED (DUE TO LOW DRUM

STEAM PRESSURE)

DISORDER OF SIGNAL FROM PRESSURE SWITCH DUE TO ITS LINE

DISCONNECTED.


ACTION TO BE TAKEN

CHECK & ADJUST

CHECK & ADJUST

CHECK & ADJUST



IF ATMlZlNG SUPPLY STEAM PRESSURE REMAINS LOW (LOW STEAM

DRUM PRESSURE), RE-START BOILER AFTER CHAINGING-OVER TO

COMPRESSED AIR.

REMARKS



INDEX

D- 1

ORIGINAL 10

lTEM DRUM STEAM PRESSURE. HIGH

INTERLOCK

ALARM & BNR

START-INTERLOCK


"SEE I10 LIST" SEC. HAS ELAPSED AFTER DRUM STEAM PRESSURE HIGHERED ABOVEUSEE I10 LIST"

ESTIMATED CAUSE

BURNER STARTED BY MANUAL OPERATION.

BURNER STOPPED BY AUTO OPEARTION

1) MALFUNCTION OF ACC MASTER TRANSMlllER

2) DISORDER OF MASTER CONTROLLER OR SIGNAL FROM ABC TO

BMS (DUE TO ITS LINE DISCONNECTED)

DISORDER OF E.C.C. CRT, SIGNAL LINE DISCONNECTED.

ACTION TO BE TAKEN

STOP BURNER.

CHECK & ADJUST OR

SEE INDEX 0

ADJUST

OPERATION OF PROTECTIVE SYSTEM REMARKS

P


SI-IIP NO. 226 /BOILER TYPE MAC-25B

ORIGINAL 11

INTERLOCK

ALARM & BNR

START-INTERLOCK

INDEX

D-2 lTEM

DRUM STEAM PRESSURE LOW


"SEE I10 LIST" SEC. HAS ELAPSED AFTER DRUM STEAM PRESSURE LOWERED BELOW "SEE I/O LIST"

AT 'TANKER SERVICE MODE" OR BELOW "SEE I/O LIST" AT "ECO BACK UP MODE'.

ESTIMATED CAUSE

BURNER STOPPED BY MANUAL OPERATION.

BURNER STOPPED BY AUTO OPEARTION

1 ) MALFUNCTION OF ACC MASTER TRANSMITER

2) DISORDER OF MASTER CONTROLLER OR SIGNAL FROM ABC TO

BMS (DUE TO ITS LINE DISCONNECTED)

DISORDER OF SIGNAL FROM ECC CRT DUE TO ITS LINE

DISCHARGED

ACTION TO BE TAKEN

RE-START BURNER OR

CHANGE TO AUTO

CHECK & ADJUST OR

SEE INDEX 0

ADJUST


WITH DRUM STEAM PRESSURE BELOW 5.0 kg/cmzg, BURNER CAN NOT

BE RE-STARTED, USING A.C.C. AUTO.

SET A.C.C. TO MAN. AND RE-START BURNER, THEN, SET A.C.C.

TO AUTO.

REMARKS

I



INDEX

F- 1 FUEL OIL TEMPERATURE HIGH

INTERLOCK

ALARM


"SEE I10 LIST" SECONDS AFTER THE F.O. TEMPERATURE LOWERED BELOW THE LEVEL CORRESPONDING TO

THE VISCOSITY OF "SEE I10 LIST" SEC. R.W. N0.1.

ACTION TO BE TAKEN

CHECK F 0.HEATER OR

HEATING STEAM LINE

CHECK & ADJUST

pp

SEE INDEX Z

ESTIMATED CAUSE

7

TROUBLE

0 F

F.O. HEATER

TOO MUCH HEATING STEAM

DISORDER OF TEMPERATURE CONTROL

SYSTEM

DISORDER OF SIGNAL FROM E.C.C. CRT DUE TO ITS LINE

DISCONNECTED.

6



OKIGINAL 13

i

INDEX

F-2 lTEM

FUEL OIL TEMPERATURE LOW

INTERLOCK

ALARM


"SEE I10 LIST" SECONDS AFTER THE F.O. TEMPERATURE LOWERED BELOW THE LEVEL CORRESPOND1 NG

TO THE VISCOSITY OF "SEE I10 LIST" SEC. R.W. NO.l.

ACTION TO BE TAKEN

CHANGE TO A OIL

CHECK & ADJUST

CHECK & ADJUST

CHECK & ADJUST OR

SEE ADJUSTMENT DATA

SEE INDEX Z

ESTIMATED CAUSE

TROUBLE

OF

F.O. HEATER

FAULTY AUTO.

WARMING OF

F.O. LlNE DURING

BURNER STOP

HEATING STEAM INSUFFICIENT


SYSTEM

F.O. RECIRC. MODE HAS NOT BEEN

SELECTED

F.O. PUMP TO BE STOPPED BY MANUAL

DISORDER OF F.O.TEMP CONTROLLER OR INADEQUATE SET POINT

OF F.O.TEMP CONTROLLER

DISORDER OF SIGNAL FROM E.C.C. CRT DUE TO ITS LINE

DISCONNECTED.

P



ORIGINAL 14

INDEX

F-3 lTEM

FUEL OIL TEMPERATURE LOW-LOW

INTERLOCK

ALARM 8,

BOILER TRlP


THE F.O. TEMPERATURE LOWERED BELOW THE LEVEL CORRESPONDING TO THE VISCOSITY

OF "SEE 110 LIST" SEC. R.W. NO.l.

ACTIObI TO BE TAKEN

CHANGE TO A OIL

CHECK & ADJUST

CHECK & ADJUST

CHECK

CHECK & ADJUST

SEE INDEX Z

ESTIMATED CAUSE

TROUBLE OF

F.O. HEATER

FAULTY AUTO.

WARMING OF

F.O. LINE DURING

BURNER STOP

HEATING STEAM INSUFFICIENT


SYSTEM

F.O. RECIRC. MODE HAS NOT BEEN

SELECTED.

F.O. PUMP STARTER HAS NOT BEEN

TO BE STOPPED BY MANUAL.


1 ) IN CASES WHERE THE F.O. TEMPERATURE IS BELOW THE LEVEL

CORRESPONDING TO THE VISCOSITY OF "SEE 110 LISTSEC.,

BURNER START SEQUENCE IS HELD UNDER STAND-BY UNTIL LOW

ALARM IS RESET AFTER COMPLETION OF FURNACE PURGE.

CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION, AND THEN

CHANGE TO "D.O. MODE" AND IGNITE BURNER.

2) IN CASES WHERE THE F.O. VALVE HAS ALREADY OPENED,

CARRY OUT THE EMERGENCY BOILER TRlP INTENTIONALY

BY INDUCING THE "F.O. TEMPERATURE LOW-LOW,

CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION,

THEN, SELECT "D.O. MODE" AND RESTART THE BOILER

TO ADJUST THE F.O. TEMPERATURE.

DISORDER OF F.O.TEMP CONTROLLER

INADEQUATE SET POINT OF F.O.TEMP CONTROLLER

DISORDER OF SIGNAL FROM F.O. TEMPERATURE INDICATOR DUE TO ITS

LlNE DISCONNECTED.

REMARKS



INDEX

G lTEM

SMOKE HIGH

INTERLO

ALARM


"SEE 110 LIST" SEC. HAS ELAPSED AFTER SMOKE CONCENTRATION OF EXHAUST GAS EXCEEDED

ACTION TO BE TAKEN

CHECK & ADJUST

ADJUST F.O. TEMPERATURE

TO

REQUIRED VISCOSITY

SEE INDEX Z

SEE INDEX 0

SEE INDEX Z

CHANGE-OVER TO PROPER

ATOMIZING SOURCE.

SEE INDEX Z

SEE INDEX Z

CHECK & ADJUST

CHECK & ADJUST

CHECK & ADJUST

RINGEL MANN CONCENTRATION OF " "SEE I/O LIST"

BURNER FIRING

IS FAULTY

MALFUNCTION OF F.D. FAN

FAULTY DETECTION OF AIR FLOW TRASMITTER

MALFUNCTION OF SMOKE INDICATOR (SENSOR FOULED) OR

SIGNAL LINE DISCONNECTED. (BMS IN "SEE I10 LIST")

F.D. FAN IS NOT RUNNING.

MALFUNCTION OF CONTROL DRIVE UNIT

ESTIMATED CAUSE

BURNER ATOMIZER FOULED OR DAMAGED.

BURNER SWIRLER FOULED OR DAMAGED.

BURNER THROAT DAMAGED.

F.O. VISCOSITY INADEQUATE

REQ'D VISCOSITY : 60-85 SEC.

AT RW; N0.1

DISORDER

OF

ATOMIZING

PRESSURE

MALFUNCTION OF ATOMIZING

STM CONTROL VALVE

DISORDER OF ATOMIZING

PRESSURE CONTROL. (ABC

CONTROLLER)

FAULTY DETECTION OF

ATOMIZING TRANSMITTER.

ATOMIZING SOURCE SUITABLE TO

USED FUEL IS DISREGARDED.

C-OILISTEAM

A-OIL/AIR

INLET VANE CONTROL DRIVE UNIT

r N57-99K-N510 BOILER TROUBLE SHOOTING LIST


1

INDEX

H- 1 lTEM

IGNITION FAILURE INTERLOCK

ALARM &

BOILER TRlP Set Point for Abnormal Condition

1) DURING BURNER IGNITION PROCESS, FLAME EYE DID NOT CATCH FLAME WITHIN SPARK TIME "SEE I10 LIST" OF PILOT BURNER.

2) F.O. VALVE DID NOT OPEN WITHIN "SEE H-2" MINUTES AFTER BURNER "ON" PUSH BUTTON

ACTION TO BE TAKEN

CHECK & ADJUST

SEE ADJUSTMENT DATA

SEE INDEX M SEE INDEX Y

SEE INDEX I

REMARKS

WAS PRESSED.

PILOT BURNER DOES NOT IGNITE

PILOT BURNER IGNITE, BUT

ESTIMATED CAUSE SPARK PLUG OF PlLOT BURNER HAS BEEN

CONSUMED. MALFUNCTION OF IGNITION SOURCE PlLOT BURNER ATOMIZER FOULED OR

DAMAGED.

INADEQUATE INSTALLED POSITION OF BODY, SPARK PLUG AND ATOMIZER BURNER SWIRLER FOULED.

INADEQUATE PlLOT PUMP OUTLET PRESSURE (REQ'D PRESSURE:] 2-1 6 kglcm2g)

INADEQUATE DRAFT LOSS (REQ'D DRAFT LOSS 20 to 35 mmAq) PlLOT PUMP DOES NOT RUN DISORDER OF FLAME EYE SIGNAL DUE TO ITS

LINE DISCONNECTEDHSEE I10 LIST"

FAULTY DETECTION OF FLAME EYE BY DIRT OF FLAME EYE LENS DAMAGE OF CDS CELL FLAME EYE DOES NOT LOOK AT PlLOT BURNER

FLAME DUE TO INADEQUATE ANGLE OF FLAME EYE OR INADEQUATE IGNITION AIR RATE (20 to 35 mmAq)

F.O. BURNER DOES NOT CATCH FLAME. BURNER IGNITION SEQUENCE REMAINS INACTIVE. (IGNITION FAILURES 5 MINUTES AFTER BURNER START.)

A.C.C. DISORDER I SEE INDEX M


STOP BOILER BY EMERGENCY TRIP. CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION, AND THE RESET BOILER TRlP AND RE-START BOILER

!


SHIP NO. 226 /BOILER TYPE MAC-25B b

INDEX

H-2

ORIGINAL 17

lTEM IGNITION VALIDITY TERM OVER

INTERLOCK

ALARM 8,

BOILER TRlP


F.O. VALVE DID NOT OPEN WITHIN "SEE I10 LIST" MINUTES AFTER BURNER "ON" PUSH BUTTON WAS

PRESSED.

BURNER IGNITION SEQUENCE REMAINS INACTIVE.

(IGNITION FAILURES 5 MINUTES AFTER BURNER START.)

SEE INDEX Y



CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION

AND THEN, RESET BOILER TRlP AND RE-START BOILER.

REMARKS



ORIGINAL 18

INTERLOCK

ALARM &

BOILER TRIP

INDE

I lTEM

FLAME FAILURE


AFTER F.O. VALVE OPENED (BURNER IGNITED), FLAME EYE FAILUREED TO CATCH FLAMES

ACTION TO BE TAKEN

CHECK & ADJUST

ADJUST F.O. TEMPERATURE TO

REQUIRED VISCOSITY

SEE INDEX Z

CHECK & ADJUST

CHECK & ADJUST

CHANGE-OVER TO PROPER

ATOMIZING SOURCE.

SEE INDEX Z

SEE INDEX Z

CHECK & ADJUST

CHECK DRAIN TRAP

CHECK & ADJUST

REMARKS

BURNER FIRING

IS FAULTY

A.C.C.

DISORDER

F.O.LINE IS CROGGED.

ATOMIZING STEAM HAS BEEN CONTAMINATED WITH DRAIN.

FAULTY DETECTION OF FLAME EYE. SIGNAL LINE DISCONNECTED.

"SEE I/O LIST"


STOP BOILER BY EMERGENCY TRIP, CLARIFY THE CAUSE(S), AND

TAKE CORRECTIVE ACTION. WHEN EXCESSIVE SMOKING IS

OBSERVED, INSPECT BOILER BY BOILER SIDE. THEN RE-START BOILER

AFTER TRlP RESET.

ESTIMATED CAUSE

BURNER ATOMIZER FOULED OR DAMAGED.

BURNER SWIRLER FOULED OR DAMAGED.

BURNER THROAT DAMAGED.

F.O. VISCOSITY INADEQUATE REQ'D

VISCOSITY : 60-85 SEC. AT RW. NO.l

DISORDER

OF

ATOMIZING

PRESSURE

MALFUNCTION OF ATOMIZING

STM CONTROL VALVE

DISORDER OF ATOMIZING

PRESSURE CONTROL.

FAULTY DETECTION OF

ATOMIZING TRANSMlllER

ATOMIZING SOURCE SUITABLE TO

USED FUEL IS DISREGARDED.

C-OILISTEAM

A-OILIAIR

MALFUNCTION OF F.D. FAN INLET VANE

CONTROL DRIVE UNIT

FAULTY DETECTION OF AIR FLOW

TRASMlllER

-- - - - - - - - -



INDEX

J

ORIGINAL 19

FLAME EYE ABNORMAL

INTERLOCK

ALARM &

BOILER TRIP


1) DURING STOP OF F.O. BURNER OR PILOT BURNER, FLAME EYE KEPT ON DETECTING FLAMES

FOR LONGER THAN "SEE I10 LIST" SEC.

2) FLAME FAILURE (INDEX H, I) OCCURRED.

ESTIMATED CAUSE

ERRONEOUS ACTION OF FLAME EYE "SEE 1/0 LIST"

( FLAME EYE TURNED ON WITH NO FLAME IN FURNACE )

FUEL IS LEAKING INTO FURNACE AND FIRING.

FLAME FALL IN "INDEX H, I" OCCURRED.

ACTION TO BE TAKEN

CHECK & ADJUST

CHECK FUEL LINE &

PURGE FURNACE

SEE INDEX H, I



CLARIFY THE CAUSE(S), TAKE CORRECTIVE ACTION, AND THEN

RESET BOILER TRIP.

REMARKS

IN THE CASE OF FLAME EYE

ABNORMAL DURING

BURNER STOP CONDITION,

ALARM LAMP & BZ ARE

INDICATED.

DURING BOILER STARTING

(BURNER IS STARTING),

THE ALARM ARE INDICATED

AND THE BOILER IS TRIPPED.



No.

ITEM (%€I&)

M I C N (rn

PIIRPCGE (Elm)

ORIGINAL 20

FLAME EYE ABNORMAL 7 P--474 77'1 -?/b BDILER TRIP OR ALARM

Flame eye abnormal is to give an alarm to warn the operator if incorrect flame detector signal (flame eye signal) against the boiler condition came back, and to stop the boiler in emergency mode by immediately shutting down the fuel oil supply to the boiler if such abnormality shoul(l

be too serious to continue running any longer.

7 k-474 7?/ -?lbG;t, 33%69$-r' 7WKEizN LTiE L < f~L\k%&&%tl5%d:3 2, ~ M W ~ Z H L % ~ H E T - P ~ T Z M I ~ , 5 DT;&, 9. w, 5 L ~ E ~ ~ S ~ T ~ ~ E ~ G E R C L ~ J L T ~ ~ E %GZ%?$D@$e@BEL, $4 7 %l$=k';f6,

REMKs (W)

F M EYE CLOSE

FU V/T OPE3 OR BURNER STOP

PILOT

NORMAL POSITION

GN

NORMAL WSITION

OFF

BNR STAKT OITION

ABNORMAL PCGITION FUN(JT1ON (TIMER)

OFF

TRIP *FLAME FAILURE *IGNITION FAILURE

(2sec)

NOTE This timer is hardware timer

to prevent flame failure due

to flame flickering.

CmDITION

ABNORMAL PCGITION RhCTION (TIMEII)

ON

AIAIiM m Before completion of re) furnace purge.

(15sec)

. . . . . , , . . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON

TRIP h'mE After completion of

(pre-) furnace purge.

(Osec)

N57-99K-N5 10 BOILER TROUBLE SHOOTING LIST


INDEX

K

ORIGINAL 21

lTEM F.D. FAN TRIP

INTERLOCK

ALARM &

BOILER TRIP


1. DURING BOILER OPERATION, F.D. FAN STOPPED.

2. MOTOR OVERLOAD OCCURED.

ESTIMATED CAUSE

F.D. FAN STOPPED DUE TO OVERLOAD

"SEE I10 LIST"

MALFUNCTION OF F.D. FAN STARTER

F.D. FAN RUN SIGNAL WIRE DISCONNECTED.

"SEE I10 LIST"

ACTION TO BE TAKEN

CHECK & ADJUST

CHECK & ADJUST

CHECK & ADJUST



AFTER CHECKING F.D. FAN FOR BEING RUNNING, RESET

BOILER TRIP, AND THEN, RE-START BOILER.

REMARKS



ORIGINAL 22

INTERLOCK

ALARM

INDEX

L lTEM

PILOT PUMP TRIP


1. DURING PILOT PUMP OPERATION, PILOT PUMP STOPPED.

2. MOTOR OVERLOAD OCCURED.

ESTIMATED CAUSE

OVERLOAD CAUSED PILOT PUMP TO STOP.

"SEE I10 LIST"

ACTION TO BE TAKEN

CHECK & ADJUST


P


ORIGINAL 23

INDEX

M lTEM

VALVE ABNORMAL

INTERLOCK

AL ALARM OR

BOILER TRlP


"SEE I/O LIST" SECONDS HAVE ELAPSED A DIFFERENCE BETWEEN THE COMMAND SIGNAL

TO VALVE AND THE ACTUAL SIGNAL.

ESTIMATED CAUSE

VALVE COMPRESSED AIR PRESSURE LOWERED

(REQ'D PRESSURE : 5 kg/cmZg OR MORE)


VALVE SEAT HAS CAUGHT FOREIGN MATERIAL.

FAULT OF VALVE & DAMPER LIMIT SWITCH

ACTION TO BE TAKEN

CHECK AIR SUPPLY BOARD.

CHECK &ADJUST

BURNER PISTON VALVE

BMS INPUT

F.O. PISTON V/V "SEE I10 LIST" ( ON AT CLOSED )

ATOMIZING PISTON V/V "SEE I10 LIST" ( ON AT OPEN )

BNR PURGE PISTON V/V "SEE I/O LIST" ( ON AT CLOSED )

F.O. RECIRC V/V "SEE I/O LIST" ( ON AT CLOSED )

IN THE FOLLOWING VALVE ABNORMAL CONDITION, LET THE BOILERUNDERGO THE TRIP.

1 . "SEE I10 LIST" SECONDS HAVE ELAPSED WlTH ANY ONE OF F.O. VALVES OPENED IN

RESPONSE TO F.O. VALVE "CLOSE' COMMAND FROM THE SEQUENCER.

2. "SEE I10 LIST" SECONDS HAVE ELAPSED WlTH BOTH F.O. FAlLURElNG TO OPEN IN RESPONSE

TO F.O. VALVE "OPEN" COMMAND FROM THE SEQUENCER.

3. "SEE I10 LIST" SECONDS HAVE ELAPSED WlTH ATOMIZING VALVE FAlLURElNG TO OPEN IN

RESPONSE TO ATM VALVE "OPEN" COMMAND FROM THE SEQUENCER.


LOOK FOR AND DETERMINE THE CAUSES OF THE BURNER PISTON

VALVE ABNORMAL STATES, AND THEN RESTART THE BOILER.

RESETTING THE TRlP INTERLOCK.

REMARKS


No.

ITEM (%@%I

tvLTICN (#.a

PURPosE (Ern)

VALVE AND DAMPER ABNORMAL 1x/k7 '77 F57-71<77+] - ~ / b

BOILER TRIP OR AIARM

Valve and damper abnormal is to give an alarm to warn the operator if incorrect feed back signal (limit switch signal) against the order signal from PLC came back, and to stop the boiler i l i

emergency mode by immediately shutting down the fuel oil supply to the boiler l f sucl, abnormality should be too serious to continue running any longer.

/ < r b 7 ' 7 7 F P ' 2 / < 7 7 1 - ~ r ~ G 3 , P L c ~ ~ ~ ~ ; I . Q ~ ~ + { ~ + + [ z ~ L T I E L ( 7'2~ \ y < bz-1' .)/fa l ) f = ~ d a 5 S$fcW, R~WC~~L%O~&%~-~-~~"ZM,I~) 5 0 ~ h 5. &k, 5 L ~ $ ~ & ? ; ~ ~ ~ T T J ~ ~ E ~ L

%G:%? LTC~E%~Z%~EBD%$$~&% L, $4 5 %f$k-J-63

FO V / V #1

FU V / V #2

REC. V / V

Am V / v

BMl PURGE V / V


FJmRKs (W)

m m V N

ORIGINAL 24

L. S. WSITION

cZCGE

CLOSE

CLOSE

OPEY

CLOSE

L. S. PCGITION

m E

N O W POSITION

OFF

OFF

ON

ON

ON

BUIWER RUN

ABNORMAL POSITION FUNCTION (TIMER)

ON ALm i

i In case of both (3sec) i IV/V close,

ON iboiler trip. i i TRIP (3sec) j

OFF ALARM (3sec)

OFF TRIP (5sec)

OFF TRIP (10sec)

NORMN. POSITION

ON

ON

OFF

OFF

ON

BURN3 PURGE SEQllENCE

BURNER STOP

tlkmWL POSITION FUNCTION (TIMER)

OFF r n P (IOsec)

OFF TRIP (1Osec)

ON ALARM (1Osec)

OFF AIARM (10sec)

OFF ALRRM (10sec)

N O W POSITION

OFF

NOT BNR PURGE SEQ.

A B N O W PCGITION FUNCTION (T m ON AIARM (3sec)

N O M PCGITION

ON

ABNOM POSITION FLWION (TIMER)

OFF NARM (1Osec)



NDfX lTEM INTERLOCK

0 ABCIBMS CONTROL LER ABNORMAL Alarm &

Boiler Trip


AN ABNORMAL CONDITION "OPERATION STOPPED OR "OPERATION STILL CONTINUES" HAS

OCCURRED IN THE ABCIBMS CONTROLLER, AND THE LAMP "ABCIBMS CONTROLLER ABNORMAL"

ON THE BOILER CONTROL PANEL STARTS TO BE ON.

ABNORMAL CONDITION PRESUMABLE CAUSE(S)

STEPS TO BE TAKEN

FOR RESTORATION

ACTUATION OFTHE PROTECTION SYSTEM

(EXECUTION BY THE PROTECTION SYSTEM)

THE CAUSE IS TO BE INVESTIGATED ACCORDING TO THE

"OPERATION AND MAINTENANCE INSTRUCTION",

FOR THE RESTORATION OF THE ORIGINAL CONDITION.

REMARKS

N57-99K-N510 BOILER TROUBLE SHOOTING L I S T

--

S H I P NO. 226 /BOILER TYPE MAC-25B

INDEX

Q

ORIGINAL 26

!TEiAJ

MAIN SOURCE FAILURE

INTERLOCK

ALARM &

BOILER TRIP


POWER SUPPLY SOURCE A.C. OF BCP HAS FAILUREED.

ESTIMATED CAUSE

BREAKER(MCB-1) OF CONTROL SWITCH BOARD TURNED OFF.

DISORDER OF RELAY.

(BOILER CONTROL PANEL RAC)

NO-FUSE HAS DAMAGED.

(BOILER CONTROL PANEL NF)

DISCONNECTION OF A.C. SOURCE LINE.

ACTION TO BE TAKEN

CHECK & CORRECT

CHECK & ADJUST

(ONLY ALARM)

CHECK & ADJUST

CHECK &ADJUST



RESET BOILER TRIP, AND THEN, RE-START BOILER.

fl

INTERLOCK

R DC24V SUPPLY UNIT ABNORMAL ALARM &

BOILER TRIP


POWER SUPPLY UNlT DC24V OF BOILER CONTROL PANEL HAS FAILUREED.

ESTIMATED CAUSE

BREAKER(MCB2) OF BOILER CONTROL PANEL TURNED OFF.

MALFUNCTION OF TRANSFORMER (SR 1 ,SR2)

DISCONNECTION OF A.C. SOURCE LINE.

CTlON TO BE TAKEN

CHECK & CORRECT

CHECK 8, ADJUST

CHECK & ADJUST

NOTES

WHEN ONLY ONE POWER SUPPLY UNlT FAILURES, ALARM LAMP & BUZZER ARE INDICATED.

AND WHEN BOTH TWO UNITS FAILURE, THE ALARM IS INDICATED AND THE BOILERS ARE TRIPPED.




RESET BOILER TRIP, AND THEN, RE-START BOILER.

= lTEM INTERLOCK

s BOILER TRIP ALARM &

BOILER TRlP


BOILER TRlP FACTOR HAS WORKED.

ESTIMATED CAUSE AND RESET OPERATION REQ'D ACTION

PRIMARY FACTOR OF BOILER TRlP

1. BOILER TRIP AS WELL AS BOILER TRIP INDICATION

FACTOR HAS IS BEING ILLUMINATED. CHECK & CORRECT

WORKED. CHECK LAMP INDICATIONS AND TAKE

NECESSARY ACTION ACCORDING TO

INDICATIONS.

(1) CARRY OUT BZ-STOP.

(2) CHECK PRIMARY TRlP FACTOR

AND ELIMINATE THE CAUSE.

2. RESET OPERATION (3) RESET BURNER TRIP BY PRESSING

BURNER "OFF' PB.

(4) CARRY OUT LAMP RESET.

(5) RE-START BURNER BY PRESSING

BURNER "ON" PB. SWITCH.

= lTEM INTERLOCK

T- 1 CONTROL AIR PRESSURE LOW ALARM


"SEE I10 LIST" HAS ELAPSED AFTER THE CONTROL AIR PRESSURE LOWERED "SEE I10 LIST

ESTIMATED CAUSE ACTION TO BE TAKEN


FAULTY DETECTION SIGNAL LINE DIISCONNECTED .

OF BMS IN "SEE I10 LIST" CHECK & ADJUST

PRESSURE SWITCH I CLOGGING IN PIPING LEADING TO THE I DETECTION TERMINAL.

DECREASE IN CONTROL CONTROL AIR LEAKAGE

AIR PRESSURE DECREASE IN CONTROL AIR SIURCE PRESSURE CHECK & ADJUST

OPERATION OF PROTECTIVE SYSTEM REMARKS

ORIGINAL 28

ORIGINAL 30

lTEM [NTERLOCK

u WIND BOX TEMP. HIGH ALARM


"SEE 110 LIST" HAS ELAPSED AFTER THE WlND BOX TEMPERATURE EXCEEDED THAN "SEE I10 LIST".

ACTION TO BE TAKEN

CHECK & ADJUST

REMARKS

ESTIMATED CAUSE

FAULTY DETECTION

MALFUNCTION OF TEMPERATURE SWITCH SIGNAL

LINE DIISCONNECTED .

OF

TEMP. SWITCH


i N57-99K-N510 BOILER TROUBLE SHOOTING LIST i


INTERLOCK

ALARM

INDD(

v lTEM

FEED WATER PRESS LOW


4 SEC HAS ELAPSED AFTER FEED WATER SUPPLY PRESS. LOWERED BELOW SET POINT AT NOR .MODE

OR ECO MODE.

ESTIMATED CAUSE

OVERLOAD CAUSED FEED WATER PUMP TO STOP.

ACTION TO BE TAKEN

CHECK & ADJUST

START STAND-BY

FEED WATER PUMP DISCHARGE PRESS HAS LOWERED. FEED WATER PUMP



INDEX

w lTEM

FEED WATER PUMP TRIP

INTERLOCK

ALARM


I . OVERLOAD CAUSED BOTH MAlN FEED WATERT PUMPS AT TANKER SERVICE OR IGS MODE.

(BOILER TRIP)

2. OVERLOAD CAUSED BOTH AUX. FEED WATER PUMPS AT ECO MODE.(BOILER TRIP)

ESTIMATED CAUSE

OVERLOAD CAUSED MAIN OR AUX. FEED WATER PUMP TO STOP.

ACTION TO BE TAKEN

CHECK 8, ADJUST

I 1 1 N57-99K-N510 BOILER TROUBLE SHOOTING LIST

SHIP NO. 226 /BOILER TYPE MC-25B

= y-(1/2)

lTEM BURNER START SEQUENCE INACTIVE

INTERLOCK

IGNITION

ALARM & TRlP


BURNER SEQUENCE FAILURES TO PROCEED. BOILER TRlP TAKES PLACE FIVE MINUTES AFTER STARTING THE BURNER.

START SEQUENCE

SEQUENCE WlLL NOT START WITH BURNER "ON PB. PRESSED. (WILL NOT STOP)

FURNACE PURGE CAN NOT BE ESTABLISHED.

(FURNACE PURGE LAMP FLICKERS)

IGNITION WlLL NOT START.

"-2 (IGN. LAMP FLICKERS)

ESTIMATED CAUSE 1 ) BOILER TRIP FACTOR IS WORKING. 2) DRUM STEAM PRESSURE IS BELOW 5K

AND F.O. CONTROL IS SET TO AUTO. 3) MALFUNCTION OF STARTISTOP

INPUT CIRCUITS. "SEE I10 LIST"

1 ) BURNER DRAFT LOSS "SEE I/O LIST"

2) AIR CONTROL SET TO MANU. 3) FURNACE PURGE ORD. HAS NOT

BEEN INPUT INTO ABC CONTROLLER. ("SEE I10 LIST" BEEN INPUT ABC CONTROLLER.)

4) AIR FLOW CONTROL IS FAULTY. (ABC CONTROLLER, CONTROL DRIVE UNIT AND AIR FLOW TRANSMITTER)

5) F.D. FAN IS NOT RUNNING. "SEE I/O LIST"

1) F.O. CONTROL VALVE IS NOT SET AT THE OPEN POSITION FOR IGNITION.

2) F.O. CONTROL AND AIR CONTROL ARE IN THE MANUAL MODE.

3) BURNER DRAFT LOSS IS NOT SET AT "SEE I10 LIST"

4) F.O. TEMPERATURE IS AT THE LOW LEVEL. "SEE I10 LIST"

5) BOTH F.O. PUMP IS NOT RUNNING. "SEE I10 LIST"

ACTION TO BE TAKEN 1 ) CANCEL TRIP FACTOR. 2) BELOW 5K, START SEQUENCE

WITH F.O. CONT. TO MAN. 3) CHECK & ADJUST.

1 ) OPEN F.D. FAN INLET VANE.

2) SET AIR CONT. TO AUTO. 3) CHECK WIRING.

4) CHECK & ADJUST. (SEE INDEX Z)

BURNER DRAFT LOSS (AIR FLOW)

=(WIND BOX)-(FURNACE DRAFT) 1) SET F.O. CONT. V/V TO

OPENING OF "SEE I/O LIST"

2) SET TO AUTO.

3) ADJUST F.D. FAN INLET VANE. "SEE I/O LIST"

4) EITHER ADJUSTTHE F.O. TEMPERATURE OR TURN ON

THE F.O. TEMPERATURE BY PASS. 5) START F.O. PUMP


INDEX

y- (2/2)

2)F.O.TEMP BY-PASS OR F.E. BY-PASS

HAS BEEN SELECTED.

ESTIMATED CAUSE

3)IGS MODE HAS BEEN SELECTED.

4)MALFUNCTlON OF AUTO SIGNAL,

CIRCUIT,

lTEM BURNER START SEQUENCE INACTIVE

BURNER REFUSES TO

SWITCH TO AUTO 4 KgIcm2 ,CHECK & ADJUST

2)CHECK & ADJUST

INTERLOCK

IGNITION FAILUF

ALARM & TRIP

1)STEAM PRESSURE IS BELLOW 3 Kglcm2

& BURNER IS NOT START

3)CHECK & ADJUST

4)CHECK & ADJUST

BURNER DOES NOT START

(STOP)

AUTOMATICALLY

I


"SEE 110 LIST"

1)BURNER IS IN THE MANUAL MODE

2)MALFUNCTION OF STM PRESSURE TRANS.

3)MALFUNCTlON OF START(ST0P) INPUT

SIGNAL CIRCUIT.

"SEE I10 LIST"

I SEE INSTRUCTION MANUAL

:TOP SEQUENCE

NACTIVE

1)SWITCH THE BURNER

CONTROL TO AUTO.

2)SEE INDEX Z

3)CHECK & ADJUST

1 )MALFUNCTION OF STOP SIGNAL

CIRCUIT.

"SEE I10 LIST"

2)BURNERDRAFTLOSSBELOW lSOmmAq

AT AFTER FURNACE PURGE.

BMS IN. "SEE I10 LIST"

1)CHECK & ADJUST

2)OPENF.D.FANlNLETVANE

N57-99K-N510 BOILER TROIJBLE SHOOTING LIST

REQUIRED

SHIP N0.226 /BOILER TYPE MAC-25B

INDEX

z lTEM CHECK OF INSTRUMENTS

INTERLOCK


INTSPECTION OF TRANSMITTER, CONTROL VALVE AND CONTROL DRIVE.

ACTION TO BE TAKEN

SET TO SPECIFIED SOURCES.

CHECK AND ADJUST AS

INSPECTION PROCEDURE

CHECK OF ELECTRIC SOURCE AND CONTROL AIR SOURCE

REFER TO DWG. N57-99K-N551 ADJUSTING DATA SHEETS.

CHECK INPUTIOUTPUT CHECK PRESSURE DETECTING LINE

(CLOSURE 8, LEAK OF PIPING)

OF ON-LINED

INSTRUMENT IN

ACCORDANCE WITH

ADJUSTMENT DATA

SHEETS.

CHECK SIGNAL WIRING

(WIRE DISCONNECTION, LOOSE SET

SCREWS)

CHECK LINK UNIT

(STICKING OR RICKm MOVING PARTS

AND LOOSE SETSCREWS)

REMOVE INSTRUMENT FROM PROCESS LINE, AND CALIBRATE

SEPARATED INSTRUMENT INDIVIDUALLY.

':5:-9!4K-LHIO R O l l lilt TilOl,Rl ii Sl lOOTI \C I I S ' i

2. LIST O F BMS INPUTIOUTPUT

- - -- -- - ~ -

FO COIITPO! ; / I , / OPEISI POS~TO1.1

~ J P ? I E ? D ~ P ~ T IGS~ -- --

. - - ~ - ~ - . . ~ ~ - i'lo 1 FO PUlvlP RUbI

~.. - - ~ - - --

INDEX [khinzawshwecom.files.wordpress.com]...May 01, 2018 · boiler tube damaged. power source for...

Documents

Transcript of INDEX [khinzawshwecom.files.wordpress.com]...May 01, 2018 · boiler tube damaged. power source for...