HB-T E990-1112-03

OPERATION
MANUAL
MARINE AUXILIARY BOILER
HB-T
Operation Manual No.
E990-1112-03
Important Safety Information

In handling marine auxiliary boiler HB-T type (hereinafter called this boiler), read and fully understand
this manual and follow instruction that is contained in this manual.
This boiler contains hot parts that may cause burn, high-pressure parts that may cause injury due to
pressure break, moving parts in which a part of body may get caught, and high-voltage parts that may
cause electrical shock. Improper handling of these parts may cause accident involving death, fire, or
other disasters.
This boiler can be operated in automatic operation mode (normal mode) and manual operation
mode for emergency. In manual operation mode, fire or burn due to backfire (*) may be caused
unless boiler is handled properly. Use manual operation mode only in emergency.
To ensure safety of operation and maintenance of this boiler, it is essential to know possible causes of
disasters in advance. We cannot predict all potential dangers, but present dangers involved in
handling of boiler in this manual to the best of our knowledge. Following warnings or instructions that
are contained in this manual better ensures safety of work.
In this manual, harm and damage are categorized into following three levels. These are attached on
this boiler as warning labels (*) and also described in this manual.
DANGER
WARNING
CAUTION
Indicates any condition or practice that, if not observed,

causes imminent danger of death or serious injury to user.
Indicates any condition or practice that, if not observed, may

cause death or serious injury to user.
Indicates any condition or practice that, if not observed, may

cause minor injury to user or property damage.
If failed components are found, contact MIURA offices and replace them with genuine parts. Using
different model part may reduce safety of boiler.
Remodeling this boiler without consultation with MIURA or repairing it in way that is not specified in this
manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.
Introduction
This manual describes procedures for handling this boiler for proper operation. Precautions relating to
operating method and safety indicated in this manual from damages to measures only relate to usage
for specified purposes. Do not use boiler by methods that are not mentioned in this manual. Be aware
that MIURA cannot be held responsible if boiler is used by methods that are not mentioned in this
manual.
Before using this boiler, those who use it for the first time as well as those familiar with handling of it
must read this manual thoroughly and understand proper method of handling it.
Keep this manual in place so that it can be consulted whenever there is any uncertainty about this
boiler.
In addition to this manual, following booklets are provided as information that is needed to use this
boiler. Before using boiler, thoroughly read these booklets in addition to this manual.
[1] Final Drawing: Final drawing is documents containing all specifications for customer. Look
over and understand final drawing before use. Refer to this document for
information that depends on capacity or options.
[2] Procedure: Manual for Installation: Procedure manual for installation contains information
on installation of this boiler and incidental parts. Install this boiler according to
this procedure manual (This procedure manual is contained in final drawings).
[3] Instruction manuals for incidental equipment:
Handle incidental equipment according to respective instruction manuals.
[4] Manual for Water Treatment: Manual for water treatment describes procedure of water treatment
that is needed to use this boiler. Understand content of manual, and handle
chemicals and carry out water treatment work according to instructions that
are contained in this manual.
ii
[Graphical symbols]
Graphical symbols used in this manual have following meanings:
Indicates certain behavior is prohibited.
Prohibition
Indicates touching certain area may cause personal injury.

Do Not Touch
Indicates handling with wet hands may cause electrical shock.
Do Not Touch
with Wet Hands
Provides instruction to be followed (action to be taken).

Instruction
Indicates ground wires must be connected.
Connect
Ground Wire
Indicates a precaution to be remembered.

Caution
Indicates potential danger of injury from heat under certain

conditions.
Caution: Hot
Note
Provides precaution to prevent boiler failure, point to be

remembered for effective operation, or other useful information.
Indicates related page(s).
iii
Term Definitions
Terms that are used in this manual are defined as follows.
These terms are marked with asterisk (*) in manual.
Term
H.F.O.
Description
Abbreviation of fuel oil. Fuel used with main burner. When this boiler is used
in Japan, term refers to heavy oil C.
M.D.O.
Abbreviation of marine diesel oil. When this boiler is used in Japan, term
refers to heavy oil A. Fuel used with pilot burner.
Flammable
Substance with low ignition temperature that is fire hazard (A handling place
Dangerous
for flammable dangerous substance refers to place where such a substance
Substance
is stored).
Wind Box
Wind box in which burner is installed. It controls air flow from fan.
Oil Air Separator
Container that is designed to separate components evaporated from fuel oil

or air retaining in fuel oil circulation line or other gas phases from liquid
phases. Oil air separator is installed on inlet side of fuel oil pump.
Air Supply Fan
Air supply system designed to bring air into furnace.
Warning Label
Label to call attention to operating precaution.
Ventilation (draft)
Phenomenon that exhaust gas with higher temperature and smaller specific
gravity than surrounding air rises toward outlet of funnel.
Differential
Differential means control width that is set with controller. It is control width
between when contact of controller is turned off (on) and when it is turned on
(off) again.
Ignition Transformer
High voltage supply system designed to generate sparks for igniting pilot
burner or main burner.
F.O. Heater
Heater that is designed to heat fuel to suitable temperature to be atomized by

burner. This heater is included as standard when H.F.O. is used as main fuel.
Pilot Flame
Fire source for igniting main burner when H.F.O. is used as main fuel. Pilot
flame is formed by igniting pilot burner.
Backfire
Phenomenon that fire source is generated in furnace under poorly ventilated

conditions before combustion is started or when combustion is stopped, and
combustible gas mixture in furnace is ignited to cause explosion.
Flame eye
Sensor that is designed to detect flame in furnace.
iv
Term
Pre purge
Post purge
Main fuel
Description
Pre-purge is ventilating combustion chamber of boiler before combustion.
Post-purge is ventilating combustion chamber of boiler when combustion is
stopped.
Fuel used with main burner.
CONTENTS
Important Safety Information .............................................................. i

Introduction........................................................................................ ii
Term Definitions................................................................................ iv
CHAPTER 1: SAFETY.........................................................................1
1. Safety Regulations ........................................................................1
2. Knowledge and Skill Required for Safe Handling .........................1
3. Protective Equipment ....................................................................1
4. Prohibition of Remodeling without Permission..............................1
5. Use of Specified Fuels ..................................................................2
6. Warning Labels (*) on Products......................................................2
7. Precautions for Safe Handling ......................................................3
7.1 Safety Precautions in Installation ................................................................................3
7.2 Safety Precautions in Pre-operation Inspection and Preparation ................................4
7.3 Safety Precautions in Operating Boiler........................................................................5
7.4 Safety Precautions in Bringing Boiler to Emergency Stop...........................................7
7.5 Safety Precautions in Inspections and Maintenance ...................................................7
7.6 Safety Precautions in Replacing Parts ........................................................................9
7.7 Safety Precautions in Working on Failures..................................................................9
7.8 Safety Precautions in Storage Work..........................................................................10
vi
CHAPTER 2: OVERVIEW ................................................................. 11

1. Features of Product..................................................................... 11
1.1 Functions and Operating Principle ............................................................................ 11
1.1.1 Functions .................................................................................................. 11
1.1.2 Operating Principle ................................................................................... 11
1.2 Product Components ................................................................................................ 11
2. Water and Steam Supply Flow.................................................... 12

2.1 Water and Steam Pipe System ................................................................................. 12
3. Fuel Supply Flow......................................................................... 13

3.1 Fuel Pipe System ...................................................................................................... 13
4. Basic Specifications .................................................................... 14

5. Part Names and Functions.......................................................... 15
5.1 Boiler Body................................................................................................................ 15
5.2 Burner and Burner Piping Structure .......................................................................... 16
5.3 Internal Structure of Boiler Body ............................................................................... 17
6. Boiler Automatic Operation by Sequencer .................................. 19

6.1 Overview ................................................................................................................... 19
6.2 Flowchart .................................................................................................................. 19
6.3 Operation Explanation of Steam Pressure Control.................................................... 21
6.3.1 Proportional Control.................................................................................. 21
CHAPTER 3: BASIC OPERATION.................................................... 22

1. Details of Control Panel and Display .......................................... 22
1.1 Details of Control Panel and Display......................................................................... 22
1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch) ................. 23
1.3 Details of Alarm Display ............................................................................................ 23
vii
CHAPTER 4: OPERATION................................................................24
1. Inspection and Preparation before Operation .............................24
1.1 Inspection and Preparation of Boiler and Peripheral Equipment ...............................24
1.2 Inspection of Boiler Body and Accessories................................................................25
1.3 Inspection and Preparation of Feed Water System ...................................................26
1.3.1 Inspection Items........................................................................................26
1.3.2 Flushing of Pipes ......................................................................................27
1.3.3 Air Vent .....................................................................................................27
1.4 Inspection and Preparation of Fuel System...............................................................28
1.4.1 Preliminary Inspection...............................................................................28
1.4.2 Air Vent .....................................................................................................29
1.5 Inspection and Preparation of Burner........................................................................29
1.6 Inspection and Preparation of Electrical System .......................................................30
1.7 Inspection and Preparation of Steam System ...........................................................30
2. Automatic Operation (Normal Operation) ....................................31

2.1 Checking of Control Panel Switches .........................................................................31
2.2 Feeding Water to Boiler.............................................................................................31
2.3 Feeding Water to Boiler by Differential Transmitter ...................................................32
2.3.1 Feeding Water to Differential Transmitter..................................................32
2.4 Starting Combustion with M.D.O.(*)............................................................................34
2.4.1 Combustion with Air Atomization...............................................................34
2.4.2 Control and Checking during Operation (Combustion with Air
Atomization)..............................................................................................35
2.4.3 Combustion with Steam Atomization ........................................................35
2.4.4 Control and Checking during Operation (Combustion with Steam
Atomization) .............................................................................................35
2.5 Combustion Stop.......................................................................................................36
2.6 Shift from M.D.O. to H.F.O. .......................................................................................36
2.7 Shift from H.F.O. to M.D.O. .......................................................................................37
3. Emergency Operation .................................................................38

3.1 Emergency Combustion Operation ...........................................................................38
3.2 Control and Checking during Operation ....................................................................38
3.3 Restoration to Normal Combustion and Checking of Combustion ...........................38
viii
4. Manual Operation (Use Only in Emergency) .............................. 40

4.1 Starting/Stopping Manual Feed Water Pump Operation ........................................... 41
4.1.1 Starting Manual Operation........................................................................ 41
4.1.2 Stopping Manual Operation ...................................................................... 41
4.2 Manual Combustion .................................................................................................. 42
4.3 Manual Combustion Stop.......................................................................................... 43
5. Emergency Stop.......................................................................... 44
5.1 Emergency Stop of Combustion System................................................................... 44
5.1.1Cases in which Emegency Stop is Required ........................................... 44
5.1.2 Stop Procedure......................................................................................... 44
5.2 Emergency Stop of Entire Boiler ............................................................................... 44
5.2.1 Cases in which Emegency Stop of Entire Boiler is Required .................... 44
5.2.2 Stop Procedure......................................................................................... 44
6. Cold Start .................................................................................... 45
CHAPTER 5: INSPECTION AND MAINTENANCE ........................... 46

1. List of Inspection Items and Inspection Frequencies .................. 46
1.1 Regular Inspection and Maintenance........................................................................ 47
1.2 Safety Valve .............................................................................................................. 49
1.2.1Internal Structure of Safety Valve .............................................................. 49
1.2.2 Adjustment of Safety Valve....................................................................... 50
1.3 Other Important Inspection Items .............................................................................. 50
2. Daily Inspection and Maintenance .............................................. 51

3. Weekly Inspection and Maintenance .......................................... 52
3.1 Main Burner .............................................................................................................. 52
3.1.1 Overview................................................................................................... 52
3.1.2 Disassembly and Adjustment.................................................................... 52
3.2 Nozzle Tip ................................................................................................................. 53
3.3 Pilot Burner ............................................................................................................... 54
3.3.1 Overview................................................................................................... 54
3.3.2 Disassembly and Adjustment.................................................................... 55
ix
4. Monthly Inspection and Maintenance..........................................55

4.1 Fan ............................................................................................................................55
4.1.1 Overview...................................................................................................55
4.1.2 Regular Maintenance................................................................................56
4.2 Suction Damper (Attachment of Blower) ...................................................................57
4.2.1 Overview...................................................................................................57
4.2.2 Inspection .................................................................................................57
4.2.3 Measures on Failures (Fixing Fully Open State).......................................58
4.3 Fuel Flexible Tube .....................................................................................................59
4.4 Oil Flow Control Valve, Air Flow Controller, and Damper ..........................................59
4.4.1 Overview ...................................................................................................59
4.4.2 Inspection..................................................................................................60
4.5 Control Motor ............................................................................................................61
4.5.1 Overview...................................................................................................61
4.5.2 Inspection .................................................................................................61
4.6 Flame Eye (*)..............................................................................................................62
4.6.1 Overview...................................................................................................62
4.6.2 Inspection and Cleaning ...........................................................................62
4.7 Strainer for Fuel.........................................................................................................63
4.7.1 T-type Auto-cleaner...................................................................................63
4.7.2 Y-type Strainer ..........................................................................................64
4.7.3 Double Strainer.........................................................................................64
4.8 Fuel Oil Pump............................................................................................................66
4.8.1 GFS Type (for Pilot Burner) ......................................................................66
4.8.2 Main Fuel Oil Pump ..................................................................................67
4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting .........................67
4.8.4 Circulation Relief Valve .............................................................................69
5. Quarterly Inspection and Maintenance .......................................70

5.1 Inspection and Blow of Boiler Water..........................................................................70
5.2 Equipment around Burner .........................................................................................70
5.2.1 Solenoid Valve ..........................................................................................70
5.2.1-1 Solenoid Valve for Pilot Burner...........................................................71
5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve ..............................71
5.2.1-3 Solenoid Valve for Atomized Air .........................................................72
5.2.1-4 Solenoid Valve for Atomized Steam ...................................................73
5.2.2 Other Equipment ...................................................................................... 74

5.2.2-1 Pneumatic Fuel Shutoff Valve ............................................................ 74
5.2.2-2 Filter Regulator .................................................................................. 75
5.2.2-3 Pressure Reducing Valve................................................................... 76
5.2.2-4 Seal Pot ............................................................................................. 77
5.2.2-5 Equalizing Valve................................................................................. 78
5.3 Fuel Oil Thermostat (for Fuel Oil Heater) .................................................................. 79
5.3.1 Dial Type................................................................................................... 79
5.3.2 RT Type .................................................................................................... 80
5.3.3 Heavy Oil Heating Temperature................................................................ 81
5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil)....................................... 82
5.4.1 Steam Pressure Switch ............................................................................ 82
5.4.2 Atomized Fluid Pressure Switch ............................................................... 83
5.4.3 Fuel Oil Pressure Switch .......................................................................... 83
5.4.4 Pressure Switch Adjustment Procedure.................................................... 84
5.5 Differential Transmitter .............................................................................................. 85
5.6 Flow Control Valve .................................................................................................... 86
5.7 Operation Check of Each Safety System .................................................................. 87
5.7.1 Ignition Failure Alarm ................................................................................ 87
5.7.2 Fan Abnormal Stop Alarm......................................................................... 87
5.7.3 Flame-out Alarm ....................................................................................... 88
5.7.4 Abnormal Fire Alarm ................................................................................. 88
5.7.5 Low Oil Pressure Alarm ............................................................................ 88
5.7.6 Low Oil Temperature Alarm ...................................................................... 89
5.7.7 High Oil Temperature Alarm...................................................................... 89
5.7.8 Exhaust Gas High Temperature Alarm...................................................... 90
5.7.9 High Steam Pressure Alarm ..................................................................... 90
5.7.10 Low Steam Pressure Alarm .................................................................... 91
5.7.11 Low Water Level Alarm ........................................................................... 91
5.7.12 Low Low Water Level Alarm ................................................................... 91
5.7.13 Power-off Alarm ...................................................................................... 91
5.7.14 Sequencer Error Alarm ........................................................................... 91
5.7.15 Low Atomized Steam Pressure Alarm..................................................... 92
5.7.16 Low Atomized Air Pressure Alarm........................................................... 92
5.7.17 Damper Control Alarm ............................................................................ 92
5.7.18 Operation Check by differential transmitterLow Water Level, Low Low
Water Level, High Water Level .......................................................... 92
5.7.19 Suction Damper Error Alarm................................................................... 94
xi
6. Yearly Inspection and Maintenance ............................................95

6.1 Fuel Oil Heater ..........................................................................................................95
6.1.1 Combined Use of Electricity and Steam....................................................95
6.1.2 Solenoid Valve for Steam Heater..............................................................96
6.2 Water Level Gauge and Water Level Detecting Rod .................................................97
6.3 Flame Detector (FS-901)...........................................................................................98
7. Inspection and Maintenance on Vessel Docking.......................100

7.1 Soot Cleaning of Furnace........................................................................................100
8. Parts Information about Replacement.......................................101

8.1 Ignition Transformer (*) .............................................................................................101
8.2 Sequencer (Programmable Controller)....................................................................102
8.2.1 Description of Component Unit of CJ2M.................................................102
8.2.2 Function of Display .................................................................................105
8.2.3 Errors and Countermeasures..................................................................106
8.3 Steam Pressure Regulator ......................................................................................107
8.4 Fuel Oil Temperature Controller ..............................................................................108
8.4.1 Name and Function ................................................................................108
8.4.2 Setting Procedure ...................................................................................108
8.5 Water Level Detector (LM1-200) .............................................................................109
8.6 Water Level Indicator...............................................................................................110
CHAPTER 6: TROUBLE SHOOTING.............................................. 111

1. Feed Water System................................................................................................... 111
2. Fuel System .............................................................................................................. 114
3. Combustion System .................................................................................................. 116
4. Control System..........................................................................................................122
5. Trouble Shooting for Boiler Body...............................................................................123
6. Repairing Damaged Water Tubes .............................................................................124
6.1 Insertion of Stoppers from Inside of Water Drum.................................................124
6.2 Stopper Welding from Combustion Chamber ......................................................125
xii
CHAPTER 7: STORAGE ................................................................. 126

1. Maintenance When Boiler is Shut Down for a Long Time......... 126
2. Movement or Resale ................................................................. 126
3. Export........................................................................................ 126
CHAPTER 8: DISPOSAL ................................................................ 127

1. Disposal Procedure................................................................... 127
CHAPTER 9: GUARANTEE ............................................................ 128

1. Description of Guarantee .......................................................... 128
2. Contact Information for Inquiries about Products and Instruction
Manual....................................................................................... 128
3. Sale of Instruction Manual......................................................... 128
4. Sale of Parts.............................................................................. 128
xiii
CHAPTER 1: SAFETY
1. Safety Regulations
In sailing in the high seas, observe the Rules and Regulations for the Classification of Ships, the
SOLAS Convention, the MARPOL Convention, and other international conventions. Also observe
regulations in way ports or the country in which vessel is registered and other applicable regulations.
2. Knowledge and Skill Required for Safe Handling

Handling of this boiler includes operating boiler, operating controller for controlling operation of boiler,
and maintaining them. Before carrying out work, fully understand this manual.
People who satisfy all of following requirements are qualified to handle this boiler. They are called
operators.
[Requirements to be satisfied by operators]

Those who have received explanation of handling from our service staff during trial operation or
those who have received explanation of handling directly from them
Those who have thoroughly read instruction manual for this boiler and have full understanding of
content
Those who have been permitted to handle this boiler by chief engineer
Appoint chief operator from among operators.
3. Protective Equipment
Do not forget to wear helmet, protection eyewear, safety shoes, safety belts, leather gloves, protective
masks, or other appropriate protective equipment when working on device.
4. Prohibition of Remodeling without Permission

Remodeling this boiler without consultation with MIURA or repairing it in a way not specified in this
manual may seriously affect safety of boiler. Do not remodel or repair boiler on your own.
5. Use of Specified Fuels

Do not use fuel that is not specified with this boiler. Failure to observe this instruction may seriously
affect safety of boiler.
6. Warning Labels (*) on Products

For safe use of boiler, warning labels are attached on locations where attention to operating precaution
is called for.
If warning label comes off or tears, replace it with new warning label.
For more details about warning labels, contact MIURA offices.
Scald Warning Label: Attached near parts with hazard of scalding or hot parts
(Parts with surface temperature of over 60C).
Do not touch surface around this warning label.
Catch Warning Label: Attached on rotating parts with gaps in structure that
could catch fingers (Fingers might get trapped).
Do not get close to area near warning label before parts
are operated or when they are in operation.
Electric Shock Warning Label: Attached on or around electric equipment that cannot be
insulated (or covered) completely.
To prevent electrical shock or electric leakage, prevent
objects or body from coming in contact with such
Damage Warning Label: Attached on water gauge glass as there is possibility of

damage by aged deterioration when it is used for long
periods. When deterioration, cracks, or other problems are
found, promptly replace part.
7. Precautions for Safe Handling

7.1 Safety Precautions in Installation
In carrying out installation work, observe following safety precautions:
WARNING
Secure ventilation (draft) (*) in funnel (exhaust stack) and ensure that exhaust from outlet
does not have harmful influence on surrounding environment.
(Refer to 1. Safety Regulations.)
In engine room, secure adequate area for air inlet, exhaust outlet, and air supply fan (*). If
these are not installed and managed properly, carbon monoxide poisoning due to exhaust
gas may be caused.
Ensure that ventilation fan, air inlet, and exhaust outlet are installed in engine room.
Insufficient air supply or exhaust ventilation may cause carbon monoxide poisoning due to
exhaust gas or explosion.
Ensure that boiler is not installed in handling place for flammable dangerous substance
Instruction
(*)
.Install it on floor made of noncombustible material. Ensure that boiler is more than 45 cm
away from flammable materials. They may ignite due to hot part of boiler to cause fire,
resulting in accident involving death.
Ignition due to hot part may cause fire.
If exhaust stack or steam piping is passed through wall that is made of flammable material,
use noncombustible material for fire protection.
Water discharged from boiler is extremely hot and may cause burn.
Ensure that drainage piping is fixed to prevent it from being forced to move by discharged
water and that the end of piping is released into safe place.
Connect power supply using cables with specified diameters.
Use special wiring breaker.
Failure to observe this instruction may cause electrical shock, burn, or other serious
accidents.
Wiring breaker
Breaker
capacity
Connect
Ground Wire
Wiring
Wiring breaker
7.2 Safety Precautions in Pre-operation Inspection and Preparation (Excerpt from

page 24-)
In pre-operation inspection and preparation, observe following safety precautions:
WARNING
Keep flammable materials away from boiler.
They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.
Prohibition
Do not put flammable materials in control box.

They may ignite to cause fire, resulting in accident involving death.
If you touch coupling of pump that is spinning rapidly, you may get caught in it. Do not touch
Do Not Touch
coupling of pump during pump operation.

Do not operate breaker of main power supply and equipment in control panel with wet
hands.
Do Not Touch
with Wet Hands
Failure to observe this instruction may cause electrical shock due to high voltage, resulting
in injury or death.
Check that funnel (exhaust stack) is properly constructed.
Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around boiler related equipment.
Switching on or off wet equipment may cause electrical shock or fire from short circuit.
Run ventilation (air supply and exhaust equipment) in engine room and check that air vent
is not blocked off.
Instruction
If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may
be caused.
If you touch hot piping of feed water system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving
death. Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage
and waste cloth used to wipe off oil immediately in an appropriate manner.
If you touch hot piping of cascade tank, you may suffer burn. Do not touch tank. Wear
protective equipment while working around tank.
Caution: Hot
If you touch hot fuel piping, you may suffer burn. Do not touch fuel piping directly.
CAUTION
If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures
Instruction
to prevent fuel oil spill and establish method for coping with spillage in advance.
4
7.3 Safety Precautions in Operating Boiler (Excerpt from page 31-)

In operating boiler, observe following safety precautions:
WARNING
If automatic operation is hindered by parts damage or another reason, remove cause of
problem and start automatic operation again.
This boiler has manual operation circuit for emergency operation when automatic operation
is hindered. Operating error in manual operation mode, in which some safety systems are
disabled, may cause accident involving death. Do not use manual operation mode except in
emergency. If manual operation circuit must be used for unavoidable reason, follow
instructions in this manual.
Cases in which automatic operation cannot be continued are as follow:
<Feed water pump circuit>
Failure of instrumentation
Prohibition
<Combustion circuit>
Sequencer trouble
Sensor trouble, interlock by abnormality detection
In manual operation mode, backfire (*) or other accidents involving death by ignition error or
fire by empty heating may be caused. Do not use manual operation mode except in
During manual combustion operation, do not shift fuel (M.D.O. (*) H.F.O. (*)).Failure to
observe this instruction may cause backfire or other accidents involving death.
hands.
Do Not Touch
with Wet Hands
in injury or death.
If water or steam leaks out of system, burn, blindness, or accidents involving death may be
caused. During operation and after operation stop, check connections of piping and air vent
valve for leaks.
If you touch hot piping of water and steam systems, you may suffer burn. Wear protective
If fuel oil leaks out of system, it may ignite to cause fire, resulting in accident involving death.
Instruction
Check connections of piping and air vent valve for leaks. Dispose of fuel oil leakage and
waste cloth used to wipe off oil immediately in an appropriate manner.
Surface temperature of upper part of boiler exceeds 60C and may cause burn if surface is
touched. When working with upper part of boiler, wear gloves and other protective
equipment to prevent direct contact.
5
WARNING
Perform purge operation sufficiently before ignition and when combustion is stopped.
Insufficient purge operation may cause backfire(*) or other accidents involving death.
Pre-purge (*) (before ignition): 20 seconds or longer *
Post-purge (*) (when combustion is stopped): 60 seconds or longer *
Instruction
*In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit
after 20-second or longer pre-purge.
Switch fuel when boiler is in automatic operation mode. Operating error in manual operation
mode may cause backfire or other accidents involving death.
In manual operation mode, following interlock functions of safety system are disabled.
Improper operation may cause accidents involving death. Be careful with operating boiler in
manual operation mode.
Interlock functions disabled when manual combustion circuit is used:

Fuel oil pressure low (fuel)
Fuel oil temperature high (fuel)
Fuel oil temperature low (fuel)
Steam pressure high
Caution
Steam pressure low

Abnormal fire
These interlock functions work only when all functions are working properly. When there are
problems with sensors or other parts, interlock functions may not work properly.
In feed water control by differential transmitter, feed water pump control does not operate
properly when feeding water and adjustment of differential transmitter is not completed.
Boiler becomes fill with water and high water level, it may cause hot water blow out from
safety valve during boiler combustion.
Caution: Hot
7.4 Safety Precautions in Bringing Boiler to Emergency Stop (Excerpt from page 44-)
In bringing boiler to emergency stop, observe following safety precautions:
DANGER
Emergency stop is operation that gives top priority to stopping boiler immediately in
emergency. If breakers are turned off inadvertently, feed water and circulation pumps may
be stopped to cause soot fire, explosions in furnace, or other accidents. Do not use this
function except in emergency.
emergency. Emergency stop skips safety checks for ongoing operation and may cause
Caution
unexpected accident or failure. Use this function only when there is unavoidable reason for
bringing boiler to emergency stop. Users must judge when and how boiler should be
brought to emergency stop because it depends on situation.
When resuming operation after emergency stop, ensure that switches are turned on or off to
stop all ancillary equipment before turning power on.
Otherwise, equipment may start to
work unexpectedly to cause accidents.
7.5 Safety Precautions in Inspections and Maintenance (Excerpt from page 46-)
In inspections and maintenance, observe following safety precautions:
DANGER
Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to
Instruction
deterioration of impeller or external force, resulting in injury or death.
WARNING
Improper adjustment of blow off pressure of safety valve may damage boiler body.
As a rule, do not adjust blow off pressure of safety valve.
Prohibition
Remodeling of safety valve may damage boiler body.

As a rule, do not remodel safety valve.
If steam leak from safety valve is found, replace part and repair it immediately.
When steam leak is left, function of safety valve is decreased and there is possibility of
leading to serious accident
Instruction
Complete purge by fan before burner opening and inspection to make combustion chamber
cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.
Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it
properly.
7
WARNING
Before moving impeller by hand, turn off main power supply. If impeller is rotated
accidentally during maintenance, physical injury may be caused.
Inspect suction damper once a month. Failure to inspect suction damper may cause
damage of part and malfunction due to looseness of part, resulting in injury or death.
Do not give impact to boiler fuel pipe or bend any part of it.
Failure to observe this instruction may cause fuel oil leak, resulting in fire.
Equipment has been brought into optimum state in trial operation. Do not make changes to
state after trial operation. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA
Instruction
offices and ask for instructions.

In order to prevent serious accident, check solenoid valves and valve seats for oil leaks after
cleaning, inspecting, or replacing.
Before inspection or adjustment, check that there is no internal pressure present.
Compressed air or steam may blow out, causing burn or laceration.
Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to
change setting as a rule. Failure to observe this instruction may cause poor combustion,
backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for
instructions.
Surface temperature of the top of boiler exceeds 60C and may cause burn if surface is
touched. Take extra care in daily inspection work.
Blow valve and sample water (blow water) are hot. When carrying out inspection and
maintenance work, wear protective equipment to prevent burn.
During inspection work, hot steam may blow out to cause burn. Be careful when operating
Caution
valves.
Before wiring work, be sure to turn control panel power off. Failure to observe this instruction
may cause electrical shock due to high voltage, resulting in injury or death.
Do not pull out lead wire with wet hands. Failure to observe this instruction may cause
electrical shock due to high voltage, resulting in injury or death.
CAUTION
When cleaning strainer or performing other work using oil, wear protective equipment to
protect eyes and body from splashes of oil.
This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating
Instruction
valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil
pump is deteriorated over time and its performance is gradually declined.
CAUTION
Improper spray volume, spray angle, and spray form cause poor combustion and sometimes
Caution
cause backfire. Use only genuine parts.
7.6 Safety Precautions in Replacing Parts (Excerpt from page 101-)

In replacing parts, observe following safety precautions:
WARNING
Ignition transformer (*) conducts high voltage. Touching live wiring may cause electrical
shock. Turn power off before working with ignition transformer.
Instruction
Do not make changes to state after trial operation. Failure to observe this instruction may
cause poor combustion, backfire (*), or other accidents.
CAUTION
Improper setting of water level may damage boiler body.
Do not change setting from trial operation.
Instruction
Do not change internal parameters.

7.7 Safety Precautions in Working on Failures (Excerpt from page 111-)

In working on failures, observe following safety precautions:
WARNING
Stopper treatment and furnace building with refractory is temporary treatment. Do not
operate for a long time; otherwise, there is possibility of serious accident. Contact each
classification in advance and replace water tubes (or body) immediately at periodical
inspection. Contact with MIURA offices about replacement of water tubes (or body).
Instruction
Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool
both the inside of drum and combustion chamber. Then make sure that pressure inside the
drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan
during inspection.
CAUTION
Before working on water tube leaks, check water tubes and burner funnel that may be
touched are fully cooled. Otherwise, you may suffer from burn. For more information,
Caution: Hot
contact with MIURA offices.
7.8 Safety Precautions in Storage Work (Excerpt from page 126-)

In storage work, observe following safety precautions:
WARNING
Do not perform installation work and connection of incidental equipment unless it is
specified.
Prohibition
Failure to observe this instruction may cause physical injury.
10
CHAPTER 2: OVERVIEW
1. Features of Product
1.1 Functions and Operating Principle
1.1.1 Functions
This boiler burns fuel oil and collects resultant heat to provide high-temperature, high-pressure
steam.
1.1.2 Operating Principle

<Feed water>
Feed water is pressurized by feed water pump and supplied to upper drum.
Water that is fed to upper drum is loaded into boiler body (upper drum, water tubes, and lower
drum).
<Combustion>
Heat to generate steam comes from combustion heat by burner. Fuel oil heated and pressurized
by fuel oil pump unit to right temperature and pressure, respectively, is supplied to burner. Boiler
employs two-fluid burner that uses atomized fluid (steam or compressed air) to atomize fuel oil
and combines atomized particles with air supplied by fan to cause combustion.
<Generation of steam>
Water in water tubes is heated by combustion heat from burner into gas-liquid phase, which rises
to upper drum. Liquid phase in water tubes without thermal load drops down to lower drum. This
series of actions causes natural circulation inside boiler body and allows heat recovery. Steam
generated in drum is subjected to steam separation to obtain saturated steam, which is supplied
to load side through main steam valve.
1.2 Product Components

This boiler consists of boiler body and following units:
Boiler body
Feed water pump (including feed water strainer and valves)
Fuel oil pump unit
Control panel
Fan
*This is standard configuration. For details about configuration of product that is delivered, refer to
final drawing.
11
2. Water and Steam Supply Flow

Typical flow for this boiler is described here. Actual flow may be different from flow described here,
depending on specifications. Check pipe system diagram in final drawing before use.
2.1 Water and Steam Pipe System

Water in system is supplied to boiler body by feed water pump. Water sent to boiler is heated by
combustion heat into high-temperature, high-pressure steam. Generated steam is supplied to load
side and used as a heat source.
Figure 2-1 Water and Steam Pipe System Diagram (Example)
12
3. Fuel Supply Flow

Typical flow for fuel pipe system of this boiler is described here. Actual flow may be different from flow
described here, depending on specification. For details about flow for product that is delivered, refer to
pipe system diagram in final drawing.
3.1 Fuel Pipe System
F.O. TANK
F.O. TANK
D.O. TANK
D.O. TANK
Figure 2-2 Fuel Pipe System Diagram

<Description of operation> (H.F.O.(*))
a) All solenoid valves (SV-1 to SV-4) are closed when operation is stopped. When operation is started
and main fuel (*) oil pump (M-2) is brought into operation, fuel oil is circulated throughout fuel pipe
system leading back to oil air separator (*) via circulation relief valve (RV) and is heated by heater.
b) When H.F.O. is heated and pre-purge (*) is performed, solenoid valve for atomized fluid (SV-2) is
opened. When pre-purge is completed, pilot fuel oil pump (M-4), ignition transformer(*), and solenoid
valve for pilot burner (SV-1) are started to form pilot flame(*).
c) When flame eye (*) detects pilot flame, solenoid valve for air-driven valve (SV-3) is started to open
air-driven valve (AC-1), allowing main burner and pilot burner to form mixed flame. After mixed
flame is formed, solenoid valve for pilot burner (SV-1) is shut off to put out pilot flame, and flame
from main burner is formed.
d) While combustion is continued, pressurized fuel oil is still circulated throughout fuel pipe system via
circulation relief valve (RV) to keep fuel oil temperature and oil pressure stable.
13
4. Basic Specifications
Table 2-1 lists specifications of different types of boilers and different capacities. Specifications may be
different from those listed here, depending on special order requirements. For detailed specifications of
product that is delivered, refer to list of principle items on final drawing.
Table 2-1 Basic Specifications of HB-T Type Boiler
HB-08T
Model
Max. Design Press.
Heating Surface Area
Actual Evaporation
Water 60C
Steam 0.69 MPa
Net Heat Output
HB-12T
MPa
HB-15T
HB-18T
HB-20T
1.0
m2
104
115.5
131.6
kg/h
8,000
10,000
12,000
15,000
18,000
20,000
kW
5,580
6,980
8,380
10,470
12,570
13,970
kcal/
h
4,806,800
6,008,500
7,210,200
9,012,750
10,815,300
12,017,000
Fuel Oil
HB-10T
184.2
224.6
Heavy Fuel Oil: Up To 380 cSt (at 50 C)
kg/h
578
722
866
1,082
1,299
1,444
Installed Electric Capacity
kW
62.5
65.5
77.5
96
121
124.5
Type
Steam Atomizing Type
High Voltage Spark System
Flame Eye Type
Ignition
System
Flame
Detector
Capacity
m3/h
Pressure
MPa
Motor
1.41
2.4
1.5
kW
2.2
3.7
m3/min
160
200
240
300
Motor
kW
30
37
45
55
Type
kW
17
Capacity
m3/h
12
Pressure
MPa
0.98
Electric Power
Motor
Control System
360
395
75
Electric Heater With Steam
F.O.
Heater
Capacity
Feed Water
Pump
Fan
F.O. Pump
Burner
Fuel Consumption
kW
13
17
14
20
25
18
22
23
1.08
11
15
18.5
Proportional Control
Boiler Weight(Dry)
kg
14,200
17,300
18,000
21,600
23,500
Normal Weight of Boiler

Water
kg
5,020
6,650
6,890
8,200
9,170
Note 1: Power supply is 60Hz, 3 AC 220V or 440V.

Note 2: H.F.O.(*) with low calorific value of 41,000 kJ/kg (9,800 kcal/kg) is used.
14
5. Part Names and Functions

Part names and functions are described here. Appearance and layout depend on type and capacity.
For details of product that is delivered, refer to final drawing.
(1) Main steam valve
Valve to supply steam to load side
(2) Burner
Equipment to burn fuel and to generate heat
source
(3) Water level gauge
Equipment that indicates water level of boiler
(4) Boiler water sampling valve
Valve to sample boiler water
(5) Manhole (upper)
This manhole is used to inspect and clean
boiler and water tubes.
(6) Surface blow valve
Valve to discharge concentrated boiler water
around evaporation surface
(7) Funnel flange
Outlet of exhaust gas generated by
combustion of heavy oil (leading to funnel)
(8) Fan * 1
Equipment to send burner air for combustion
(9) Control panel * 1
Equipment to operate boiler
(10) Fuel oil pump unit * 1
Equipment to pressurize and heat fuel and
send it to burner
(11) Manhole (lower)
Same as (5)
(12) Bottom blow valve
Valve to discharge concentrated boiler water
(including sludge)
(13) Steam pressure gauge unit *2
Unit of boiler pressure gauge and pressure
switches for combustion control
5.1 Boiler Body
Figure 2-3 External View of Boiler
No
Part name
No
Main steam valve
Fan
Burner
Control panel
Water level gauge
10
Fuel oil pump unit
11
Manhole (lower)
12
Bottom blow valve
4
5
6
7
Boiler water
sampling valve
Manhole (upper)
Surface blow
valve
13
Part name
*1: Equipment installed separately from boiler.

Installed into a unit here just for simplicity of
illustration.
*2: Equipment installed separately from boiler for
standard specifications. Depending on
specifications, it can be provided as part of
boiler.
Steam pressure gauge

unit
Funnel flange
15
5.2 Burner and Burner Piping Structure
Figure 2-5 Structural Diagram of Burner Piping
Figure 2-4 Structural Diagram of Burner
Oil flow control valve
11
Atomized steam valve
Pneumatic fuel shutoff valve
12
Pressure reducing valve
Circulation relief valve
13
Solenoid valve for atomized steam
Emergency fuel switch valve (main)
14
Seal pot
Emergency fuel switch valve (pilot)
15
Equalizing valve
Solenoid valve for pilot burner
16
Cock for equalizing valve oil detection
Filter regulator
17
Main burner ASSY
Solenoid valve for fuel shutoff valve
18
Main baffle plate
Atomized air valve
19
Pilot burner ASSY
10
Solenoid valve for atomized air
20
Inner cylinder
16
5.3 Internal Structure of Boiler Body

Burner
Wind box
Stay
Upper drum
Heat insulator
Expansion ring
Inner casing
Water tube
Castable
Outer casing
Funnel flange
Lower drum
Figure 2-6 Internal Structure of Boiler Body
Combustion chamber
Funnel
Figure 2-7 Water Tube Arrangement
17
Boiler consists of doughnut shaped upper drum and lower drum that are connected through water
tubes. Water tubes with narrow ends are arranged as shown Figure 2-7. Combustion gas flows in
two directions as shown by arrows and meets again at exit to be discharged from funnel. While water
in innermost water tubes is subjected to flame, other water tubes are subjected to combustion gas
that passes through them. This allows efficient transfer of heat to water.
Casing consists of welded inner casing and outer casing. Heat insulating material is placed between
water tubes and inner and outer casing to restrict radiation of heat.
Inner lower part of furnace and narrow end part of water tubes are insulated with castable to prevent
short path of combustion gas.
Upper and lower drums have manhole to check inside. Check condition of scaling, corrosion,
pitching on tubes, and reflect results in boiler water treatment (For more details, refer to Manual for
Water Treatment). At furnace inspection, check for soot adherence, peeling of castable, fuel leakage
on furnace bottom, traces of water leakage and accumulations of unburnable materials.
18
6. Boiler Automatic Operation by Sequencer

6.1 Overview
Sequence control is automatic control that completes each control step following procedure that is
provided in advance.
This boiler starts fuel oil pump and fan operation, and after pre purge is completed sufficiently, ignition
device is started; after fuel valve is opened to ignite burner, start-stop of burner is controlled by steam
pressure switch. These steps are carried out automatically.
6.2 Flowchart
Figure 2-8 shows flowchart of basic operation of boiler; actual flow may be different depending on
specifications.
Fuel
oil SWONON
SW
Boiler
operation
(Combustion
mode)
Indicator
lump on
NO
When alarm is started, reset after combustion intercepted.
Combustion
is requested.
YES
Fan
operation
Ignition
transformer on
20
Pre-purge
(20 sec.)
Reset
Pilot solenoid valve
open
Flame
censor
Flame
Detector
NO
Misfire alarm
Ignition
transformer off
Pilot
solenoid valve close
Boiler operation lamp off
YES
Combustion
lamp
on
(A)
(B)
Figure 2-8 Flowchart of Basic Operation
19
(A)
(B)
When alarm is started, reset after combustion intercepted.
Combustion solenoid
valve open
Ignition
transformer
stopped.
Pilot solenoid valve close.
Proportional control
combustion
(Low combustion
is continued for 30
30
seconds after combustion is
entered.)
YES
Combustion
is
requested.
NO
Solenoid
valve close.
Combustion
lamp off
Post-purge
35S
35
Fan
stopped
Figure 2-8 Flowchart of Basic Operation (Continued)
Note
When alarm lamp related to burner interlock lights up, automatic recovery does not take place. Be
sure to perform reset operation.
20
6.3 Operation Explanation of Steam Pressure Control

6.3.1 Proportional Control
Steam pressure regulator installed on control panel controls boiler burner and adjusts steam
pressure.
Sample settings of steam pressure regulator
Boiler steam pressure

Higher pressure limit
Normal working pressure

Lower pressure limit
Time
a) For 30 seconds after ignition, low combustion (20% load) is kept not to put boiler under heavy load.
30 seconds later, boiler is held under proportional control so that normal working pressure can be
kept in response to changes in steam pressure.
b)
When steam consumption is lowered and boiler steam pressure is increased to reach higher
pressure limit, burner is stopped and post-purge(*) is performed.
c)
When boiler steam pressure is decreased to lower pressure limit, combustion is started again
under proportional control so that normal working pressure is kept.
*1:
At start of operation, atomized air is used (with M.D.O.(*)) to increase boiler steam pressure to 0.7
MPa.
Refer to page 34 2.4 Starting Combustion with M.D.O in Chapter 4.
Note
When air is used as atomized fluid, only M.D.O. can be used as fuel, and proportional control
cannot be used. (Forced low fire)
21
CHAPTER 3: BASIC OPERATION

1.Details of Control Panel and Display
Layout and functions of control panel and display are described here. Actual layout and functions may
be different from those described here, depending on specifications. For details about layout of control
panel and display, refer to external view of control panel in final drawings.
1.1 Details of Control Panel and Display

Water level indicator
Control equipment for opens and closes flow control

valve depending on signal from differential transmitter.
Alarm display
Ammeter (fan)
Alarm lamps blink or

light up to warn of failures.
Ammeter (fan)
It indicates current value of fan.

Steam pressure regulator
Control equipment for proportional combustion
control based on boiler steam pressure.
It indicates current value of fan.
Boiler operation (COM MODE) lamp
Atomized fluid selection switch
Lamp is on when combustion

switch is on.
Combustion lamp
This switch can be used to switch atomized fluid

between air and steam.
Buzzer stop switch
Lamp is on when
combustion is continued.
When alarm is started, this switch can be pressed

to stop buzzer.
Combustion switch
Alarm reset switch

This switch can be pressed to reset alarm.
Pressing this switch

allows boiler to start combustion.
Combustion stop switch
Fuel heater switch
Pressing this switch allows

boiler to stop combustion.
This switch can be used to switch by fuel oil type.When it is

switched to A, fuel heater is stopped.When it is switched to C,
low oil temperature alarm function is enabled.When it is
switched to A, fuel heater is stopped.
Booster pump operation lamp
Lamp test switch
This lamp lights up when booster

pump is in operation.
Booster pump operation switch
This switch can be used to check lamps on display.

When switch is pressed, all the indicator lamps are lit.
Turning this switch on starts booster

pump.
Fuel oil pump selection switch

This switch can be used to switch main fuel oil
pump between No. 1 and No. 2.
Manual combustion
control part
Combustion changeover switch
Manual combustion switch
This switch can be used during manual combustion to

switch between low combustion and proportional
combustion control.
Auxiliary equipment is started

operation by cam switch turning.The
ignition transformer is not started until
pre-purge time elapses.
For automatic combustion, set cam at
AUTO.
Pre-purge completion lamp

This lamp lights up when operation time of fan
exceeds set time in manual operation.
When sufficient pre-purge lamp lights up, ignition
transformer for manual operation is started.
Indicator lamp (G: green, O: orange, W: white)

Selection switch
Push-button switch
Figure 3-1 Layout and Functions of Control Panel and Display
22
1.2 Details of Manual Combustion Switch (Automatic / Manual Shift Switch)

Ignition transformer (pilot burner) is started.
It is not started until operation time of fan exceeds pre-purge time.
If switch is shifted to IGNITION position before pre-purge time elapses,
ignition transformer (pilot burner) remains stopped.
Fuel solenoid valve is opened.

Fan is started.
Ignition transformer (pilot burner) remains running.
Fuel oil pump and fuel oil heater are started.
Ignition transformer (pilot burner) is stopped.

Combustion with main burner alone is continued.
When combustion lamp is off, close combustion solenoid
valve.
When combustion lamp is turned off, immediately shift
switch back to FAN RUNNING position and perform purge
for 60 seconds or longer.
Starting combustion without sufficient purge may cause fire
or an explosion.
All equipment is stopped.

Some self-diagnosis
functions are also stopped.
Shifting switch to this position enables with ON.
Fuel oil pump and fuel oil heater are started.
(When selecting C. A/C)
Some self-diagnosis functions are enabled.
Figure 3-2 Manual Combustion Switch
Note
Do not use manual combustion switch except emergency.
1.3 Details of Alarm Display
Circles (O) in the figure represent (red) indicator lamps.
Figure 3-3 Details of Alarm Display
23
CHAPTER 4: OPERATION
1. Inspection and Preparation before Operation

1.1 Inspection and Preparation of Boiler and Peripheral Equipment
Before starting operation, check followings:
WARNING
Keep flammable materials away from boiler.
They may ignite due to hot part of boiler to cause fire, resulting in accident involving death.
Prohibition
Do not put flammable materials in control box.

They may ignite to cause fire, resulting in accident involving death.
Check that funnel (exhaust stack) is properly constructed.
Gaps, faulty construction, blocked outlet of funnel (exhaust stack), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around boiler related equipment.
Switching on or off wet equipment may cause electrical shock or fire from a short circuit.
Instruction
Run ventilation (air supply and exhaust equipment) in engine room and check that air vent is
not blocked off.
If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may be
caused.
a) Check that funnel (exhaust stack) has been properly constructed.

If problem is found with funnel, do not operate boiler.
Restore funnel (exhaust stack) to normal state.
b) Check for water or oil leaks around boiler.
If leak is found, do not operate boiler. Turn off breaker of main power supply.
Remove cause of leak and dry the area completely.
c) Check where air inlet of engine room is and check that ventilation (air supply and exhaust
equipment) is working.
If engine room does not have air inlet, provide air inlet.
If air supply and exhaust equipment is stopped, bring it into operation.
24
d) Check that there are no flammable materials around boiler.

If flammable materials are found, remove them to safe place where flame is not used.
Improper storage of cloth stained with fuel or oil may cause it to ignite spontaneously. Handle
such materials carefully and dispose of them properly.
Wipe up spilt oil immediately.
e) Check where fire extinguishing system and first-aid kit are placed.
If these are not available, put them in place.
f) Check that contact numbers in case of fire or accident and how to handle such emergencies have
been established.
g) Check that there are no obstacles around boiler and in walkways.
If obstacles are found, put them back in place.
h) Check that air pressure in engine room is positive.
If air pressure in engine room is negative, install additional ventilator.
1.2 Inspection of Boiler Body and Accessories

a) Check equipment, inspection holes, covers, valves, and connections for water leaks.
If leak is found, fasten part or install it again to make it watertight.
b) Check that valves are opened and closed properly.
Check that outlet and inlet valves are opened.
Check that air vent valve is closed.
c) Check that drain pipe of safety valve is installed in safe place.
Check that wiring for operation of safety valves lever is operated normally.
d) Check that water level gauge glass is not stained and not damaged.
e) Check that needles of pressure gauges work properly.

When pumps are stopped, they are under head pressure only.
For details about inspection items, refer to page 47 1.1 Regular Inspection and
Maintenance in Chapter 5.
25
1.3 Inspection and Preparation of Feed Water System
WARNING
If you touch coupling of pump, which is spinning rapidly, you may get caught in it. Do not
Do Not Touch
touch coupling of pump during pump operation.

If you touch hot piping of feed water system, you may suffer burn. Wear protective
Instruction
Caution: Hot
1.3.1 Inspection Items

a) Check that cascade tank contains sufficient amount of water.
b) Check that feed water is clean.
c) Check that oil has not gotten into feed water (Use observation measure to check that oil has not
gotten into feed water).
d) Check that automatic feed water valve (ball tap) works properly.
e) Check that valves on feed water line are opened and closed properly.
Check that all valves on feed water line of feed water pump in use are opened.
(Check that opening instruction of flow control valve is proper.)
Check that feed water pump in use matches switch number in control panel.
f) Check pipes for clogging, air inclusion, leaks, or loose connections.
g) Check that strainer on suction side is not clogged.
h) Check that seal of feed water pump has no leaks.
i) Check that needles of pressure gauge and compound gauge work properly.
j) Check chloride ion concentration of water in cascade tank (once a week).
For more details, refer to Manual for Water Treatment.
26
1.3.2 Flushing of Pipes

Note Following preparation procedure is needed when boiler is used for the first time or when pipe
system is repaired.
There may remain in pipes welding chips, rust or other foreign matters that may have bad
influence on feed water. Before feeding water, flush pipes with treated water or pressurized gas as
needed.
Whether flushing is needed or not depends on how pipes have been constructed. Before flushing
pipes, consult with constructor about procedure and safety precautions.
1.3.3 Air Vent

Note Following preparation procedure is needed when boiler is used for the first time or when pipe
system is repaired.
Let out air of pipes on suction side. Air remaining in pipes may cause cavitation, resulting in
damage of pump.
Prepare for operation of feed water pump according to instruction manual for feed water
pump.
27
1.4 Inspection and Preparation of Fuel System
WARNING
Instruction
Caution: Hot
CAUTION
If fuel oil spill occurs, it may have adverse influence on marine ecosystem. Take measures
Instruction
to prevent fuel oil spill and establish method for coping with spillage in advance.
1.4.1 Preliminary Inspection

a) Check that F.O. service tank contains specified fuel.
b) Check that F.O. service tank is heated moderately.
When H.F.O. (*) is used, heat it so that temperature reaches over 65C at main fuel pump inlet.
c) Discharge drainage from F.O. service tank.
d) Check valves open-close condition on fuel piping between F.O. service tank and boiler.
Open all valves on supply line.
Close all air vent valves.
e) Check that there are no pipes clogging, loose connections, or fuel leaks.
Especially, check the top of boiler carefully because burner is often removed for inspections.
f) Check that pipe system has no place where air tends to build up.
g) Check fuel strainer has no clogging.
h) Check that fuel is supplied properly from service tanks to fuel oil pump.
If problems are found or fuel is not supplied properly, check whether or not booster pump is
working properly.
i) Check that needles of pressure gauges and thermometers are working properly.
28
1.4.2 Air Vent

a) Open valves of fuel system.
b) Open strainer air vent valve to remove air.
c) Close air vent valve after removing air.
Remove air for both main and pilot.
To F.O. Tank or D.O.

Tank
d) Close valve V-1 in Figure 4-1.Check that drain valve V-2

is closed.
e) Shift manual combustion switch to AUTO COMB.
Oil air separator
From burner
position.
Main fuel oil pump starts running.
Check that main fuel oil pump motor is running in
right direction with no abnormal noise.
f) Open drain valve V-2 and remove air sufficiently.
g) Check fuel system for leaks.
If leak is found, immediately stop fuel oil pump to stop
Figure 4-1 Valves around Oil Air

Separator (*)
leak.
h) Check in fuel oil temperature controller that fuel is heated to right temperature.
Refer to page 108 8.4 Fuel Oil Temperature Controller in Chapter 5.
1.5 Inspection and Preparation of Burner

a) Check that ignition rod is clean and parts size is normal.
b) Check that pilot nozzle tip and main burner nozzle are not clogged.
c) Check that flame eye (*) and glass are clean.
d) Check that lead wire is installed properly between ignition transformer (*) and ignition rod.
e) Check that screws, levers, lock nuts, and other parts of damper are not loosened.
f) Check that equipment around burner is installed properly.
g) Check that there is no fallen object (insulation materials, castable, etc.) in furnace.
h) Check furnace for boiler water or traces of fuel oil leaks.
i) Check that inner cylinder is not damaged.
j)) Check generating tubes for heavy soil, wastage, or pinholes.
k) Check that atomized air pressure is between 0.6 MPa and 0.9 MPa.
29
1.6 Inspection and Preparation of Electrical System
WARNING
hands.
Do Not Touch
with Wet Hands
Failure to observe this instruction may cause electrical shock due to high voltage, resulting in
injury or death.
a) Check that motors of fun, feed water pump, fuel oil pump, and other equipment run properly in
right direction.
b) Check that thermostats (exhaust gas, fuel oil heater (*), etc.), fuel oil temperature controller, and
pressure switch are set properly (Check setting values in list of principle items in final drawings).
c) Check that control panel is not damaged and that each equipment is installed properly.
d) Check for broken wires, loose screws, or damaged lamps or switches.
e) Check that power supply is as specified in list of principle items in final drawings.
f) Check external wiring of each equipment for broken wires or other problems.
1.7 Inspection and Preparation of Steam System

a) Check that valves on boiler and on steam piping are opened and closed properly.
b) Check that valves on boiler and on piping are installed properly.
If loose connections or other problems are found, retighten that part or install it again to bring
it back to normal condition.
c) Check that outboard valve for boiler water blow is closed.
d) Check that cooling water is circulating throughout drain cooler.
e) Check that excess steam dump valve is installed and set to specified pressure.
30
2. Automatic Operation (Normal Operation)
WARNING
hands.
Do Not Touch
with Wet Hands
in injury or death.
If water or steam leaks out of system, burn, blindness, or accidents involving death may be
caused. During operation and after stop, check connections of piping and air vent valve for
leaks.
If you touch hot piping of water and steam system, you may suffer burn. Wear protective
Instruction
Surface temperature of upper part of boiler exceeds 60C and may cause burn if surface is
touched. When working with upper part of boiler, wear gloves and other protective
equipment to prevent direct contact.
Switch fuel when boiler is in automatic operation mode. Operating error in manual
operation mode may cause backfire(*) or other accidents involving death.
Caution: Hot
2.1 Checking of Control Panel Switches

Check that all switches on control panel are set at OFF position.
If switch is not set at OFF, shift it to OFF position.
2.2 Feeding Water to Boiler

Before starting burner, feed water to boiler according to following procedure:
a) Open all valves from cascade tank to boiler.
b) Turn on boiler power supply.
c) Set feed water shift switch to AUTO and select pump to operate by feed water pump shift switch.
d) Turn on feed water pump start switch.
Operation indicator lamp of feed water pump lights up.
Buzzer of low low water level sounds. Press buzzer stop switch.
Check feed water pump and motor for abnormal noise or abnormal heating.
31
e) Check compound and pressure gauges on inlet and outlet of feed water pump.
f) Check in water level gauge that water supply is stopped at right level.
Check that water level gauge is cleaned and easy to read.
If it is dirty and difficult to read, clean it.
g) Check pipe system for water leaks.
h) Press alarm reset switch and check that low low water level lamp is turned off.
2.3 Feeding Water to Boiler by Differential Transmitter
CAUTION
In feed water control by differential transmitter, feed water pump control does not operate
properly when feeding water and adjustment of differential transmitter is not completed.
Caution
Boiler becomes fill with water and high water level, it may cause hot water blow out from
safety valve during boiler combustion.
Note
Supply water to differential transmitter when pressure of boiler body is atmospheric pressure
and temperature of water is normal. Feeding water to differential transmitter under high
temperature and high pressure may cause damage of differential transmitter.
Set feed water shift switch to AUTO after feeding water to piping of differential transmitter and
close bypass valve of manifold valve.
In case that feed water pump is operated before adjustment, feed water pump is not stopped
until high water level. Stop feed water pump manually.
2.3.1 Feeding Water to Differential Transmitter

Before feeding water to differential transmitter, flush pipes. Recommend procedure is described
below. Start operation when close all valve and plug.
aCheck that all manifold valve of differential transmitter is closed.

Feed water to boiler manually to upper level of root valve for low pressure side (position
above middle of water level gauge)
Open root valve for low pressure and drain valve of low pressure side piping when water is
accumulated.
Blow low pressure side piping until drain water is not dirty.
bWhen drain water is not dirty, open all manifold valves, and close drain valve of low pressure side.
Open drain valve of high pressure side piping.
Take off plug of air vent valve of seal pot, and open air vent valve. Blow high pressure side
piping.
32
cWhen drain water is not dirty, close manifold valve (bypass valve).
Supply water from air vent valve of seal pot. Or feed water to seal pot after raising water level
of boiler and opening root valve for high pressure side.
Continue to blow high pressure side piping.
Note
Select feed water from air vent valve of seal pot in case it cant blow from high water level to return
to normal water level.
dWhen drain water is not dirty, close drain valve of high pressure side pipng.
eAccumulate water to air vent valve of seal pot.
Open root valve for high pressure side in case of feed water to boiler from air vent valve. Stop
supplying water and close air vent valve and install plug.
Close air vent valve and install plug in case that feed water from boiler. And blow to boiler
normal water level.
fFeeding water of differential transmitter is completed in above procedure.
Figure 4-2 Reference piping layout of differential transmitter(Remote level gauge
33
2.4 Starting Combustion with M.D.O. (*)

Note
When H.F.O (*) is used as main fuel (*), switch main fuel to M.D.O. in advance for cold start. If H.F.O
is used in cold start, poor combustion or failure of fuel oil pump may be caused. Similarly, before
stop operation, switch to M.D.O. in advance if it is expected that fuel oil pump will not be used for a
long period of time.
2.4.1 Combustion with Air Atomization

a) Close air vent valve of oil air separator (*).
b) Open and close return lines of booster pump leading to D.O. tank and to F.O. tank, respectively.
c) Open D.O. tank valve and close F.O. tank valve.
d) Open outlet and inlet valves of booster pump and start booster pump.
As for use of booster pump with M.D.O. combustion, follow rules of vessel.
e) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.
f) Shift fuel oil heater (*) switch to A position.
g) Shift atomized fluid selection switch to AIR position.
h) Close main steam valve and atomized steam valve and open atomized air valve.
i) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot
side.
j) Check that filter regulator pressure is set at 0.4 MPa.
k) Select pump to be used by fuel oil pump selection switch.
Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.
l) Shift manual combustion switch on AUTO COMB. position.
m) Press combustion switch.
After fan starts running and pre-purge (*) is completed, combustion operation is started.
Several seconds later, combustion is started and combustion lamp lights up.
Check fuel oil pump and fan for abnormal noise.
34
2.4.2 Control and Checking during Operation (Combustion with Air Atomization)
After combustion is started, check that boiler is in normal operation.
Check that fuel flow amount, fuel oil pump discharge pressure, damper opening, and current
are not different substantially from those recorded on trial operation report.
Check that color, expansion, and stability of flame are the same as usual.
Check color of smoke (black) and check for any gas leakage from its path.
Check for vibration or abnormal noise.
If any problem is found, stop combustion and remove cause of problem.
Check fuel pipe system for fuel leaks.
Check that needles of pressure gauges do not jump.
2.4.3 Combustion with Steam Atomization
a) Check that boiler steam pressure is 0.7 MPa or above.If it is below 0.7 MPa, increase steam
pressure by combustion with air atomization.
b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized
steam.
c) Shift atomized fluid selection switch to STEAM position.
d) Check that main steam valve is closed.
e) Check that emergency fuel switch valve on main side is opened and emergency fuel switch valve
on pilot side is closed.
f) Check that filter regulator pressure is set at 0.4 MPa.
g) Select pump to be used by fuel oil pump selection switch.
Check that outlet and inlet valves of fuel oil pump to be used are opened and closed properly.
h) Check that manual combustion switch is set at AUTO.COMB.
i) Press combustion switch.
Check that after about 30-second low combustion, proportional control combustion based on
steam pressure is started.
2.4.4 Control and Checking during Operation (Combustion with Steam Atomization)
a) Check that boiler is in normal operation.
Refer to 2.4.2 Control and Checking during Operation (Combustion with Air Atomization)
in Chapter 4.
b) Check that when steam pressure increases and reaches max. design pressure, combustion is
automatically stopped.
Main fuel oil pump is stopped.
After about 35-second post-purge (*), fun stops running.
35
c) Open main steam valve gradually to send air to steam system.

Check steam system for leaks.
2.5 Combustion Stop

Press combustion stop switch.
Main fuel oil pump is stopped.
(When H.F.O.(*) is used, it continues to operate.)
<Perform following operations as needed :>
Blow of boiler through surface, bottom and of water level gauge
Closing valves of feed water system and fuel system
Note
When switching fuel from M.D.O.(*) to H.F.O., check that boiler steam pressure is 0.7 MPa or
above, and then close mail steam valve and stop combustion.
2.6 Shift from M.D.O. to H.F.O.

a) Operate boiler with M.D.O. properly.
b) Heat F.O. service tank to proper temperature (between 80C and 90C).
Heat tank so that temperature reaches over 65C at main fuel oil pump inlet.
c) According to procedure in 2.4, stop boiler and F.O. booster pump.
d) Open and close return lines of booster pump leading to F.O. tank and to D.O. tank, respectively.
e) Open F.O. tank valve and close D.O. tank valve.
f) Run booster pump.
Check that heated H.F.O. is flowing through return lines of booster pump.
g) Shift manual combustion switch to AUTO.COMB position.
h) Press combustion switch.
Main fuel oil pump is started.
i) Shift fuel oil heater (*) switch to A/C position.
Note
When fuel oil heater switch is shifted to A/C position, fuel oil heater is turned on with low oil
temperature alarm function disabled.
36
j) Adjust opening of air vent valve of oil air separator (*).

Adjust opening according to combustion state.
k) Open steam trace valve of boiler fuel oil pipe.
l) When indication of fuel oil heater (*) temperature controller reaches setting value (refer to page 78
5.3.3 Heavy Oil Heating Temperature in Chapter 5.), and pressure is settled, slightly open drain
valve on fuel return line of oil air separator and visually check that oil has been fully replaced.
m) Shift fuel oil heater switch from A/C position to C position.
Low oil temperature alarm function is enabled.
n) Check that boiler is in normal operation.
Refer to page 35 2.4.2 Control and Checking during Operation (Combustion with Air
Atomization) in Chapter 4.
Note
If fuel is heated before M.D.O.(*) is fully replaced with H.F.O.(*), fuel is vaporized to cause cavitation
in fuel oil pump. If abnormal noise or rapid change of pressure gauge value is observed,
immediately shift fuel oil heater switch to A position (turn off fuel oil heater) and check again that
M.D.O. has been fully replaced with H.F.O.
2.7 Shift from H.F.O. to M.D.O.

a) Operate boiler with H.F.O. properly.
b) Open M.D.O supply valve, and close H.F.O. supply valve quickly.
c) Close steam trace valve on boiler fuel oil pipe.
d) Shift fuel oil heater switch to A position.
e) Check that fuel oil heater outlet temperature is decreased and pressure is stable.
f) Fully close air vent valve of oil air separator.
g) Slightly open drain valve on fuel return line of oil air separator and visually check that oil has been
fully replaced.
h) Open and close return lines of relief valve of F.O. booster pump leading to D.O. tank and to F.O.
tank, respectively.
i) Check that boiler is in normal operation.
Note
Switch fuel to M.D.O. when boiler is shut down for a long period. Low temperature F.O. may
damage fuel oil pump, mechanical seal, solenoid valves and fuel oil heater.
37
3. Emergency Operation
Emergency operation is function that restarts boiler quickly when low atomized steam pressure alarm is
issued or when boiler steam pressure is temporarily decreased during combustion with H.F.O.(*).
This function switches atomized fluid to air, circulates H.F.O. in fuel piping, and temporarily causes main
burner to burn M.D.O.(*) in pilot burner line.
This is emergency operation, and cannot be used in other situations.
3.1 Emergency Combustion Operation

a) Press combustion stop button and check that combustion is stopped.
Main fuel oil pump continues to operate.
b) Close main steam valve, atomized steam valve, and valve on boiler body for atomized steam and
open atomized air valve.
c) Open compressed air valve and check that pressure is between 0.6 MPa and 0.9 MPa.
d) Check that filter regulator pressure is set at 0.4 MPa.
e) Shift atomized fluid selection switch to AIR position.
f) Close emergency fuel switch valve on main side and open emergency fuel switch valve on pilot
side.
g) Check that manual combustion switch is set at AUTO.COMB.
h) Press combustion switch.
3.2 Control and Checking during Operation

Check that boiler is in normal operation.
3.3 Restoration to Normal Combustion and Checking of Combustion

a) Check that boiler steam pressure is 0.7 MPa or above.
If it is below 0.7 MPa, increase steam pressure by emergency combustion.
b) Close atomized air valve and open atomized steam valve and valve on boiler body for atomized
steam
c) Shift atomized fluid selection switch to STEAM position.
38
d) Check that main steam valve is closed.

e) Open emergency fuel switch valve on main side and close emergency fuel switch valve on pilot
side.
f) Press combustion switch.
After fan starts running and pre-purge is completed, combustion operation is started.
g) Check that boiler is in normal operation.
39
4. Manual Operation (Use Only in Emergency)
WARNING
If automatic operation is hindered by parts damage or another reason, remove cause of
problem and start automatic operation again.
This boiler has manual operation circuit for emergency operation when automatic operation
is hindered. Operating error in manual operation mode, in which some safety systems are
disabled, may cause accident involving death. Do not use manual operation mode except in
Cases in which automatic operation cannot be continued are as follow:
<Feed water pump circuit>
Failure of instrumentation
Prohibition
<Combustion circuit>
Sequencer trouble
Sensor trouble, interlock by abnormality detection
In manual operation mode, backfire (*) or other accidents involving death by ignition error or
fire by empty heating may be caused. Do not use manual operation mode except in
During manual combustion operation, do not shift fuel (M.D.O.(*) H.F.O.(*)).Failure to
observe this instruction may cause backfire or other accidents involving death.
Perform purge operation sufficiently before ignition and when combustion is stopped.
Insufficient purge operation may cause backfire or other accidents involving death.
Pre-purge (*) (before ignition): 20 seconds or longer *
Instruction
Post-purge (*) (when combustion is stopped): 60 seconds or longer.

* In manual operation mode, ignition is not started until sufficient pre-purge lamp is lit after
20-second or longer pre-purge.
40
WARNING
In manual operation mode, following interlock functions of safety system are disabled.
Improper operation may cause accidents involving death. Be careful with operating boiler in
manual operation mode.
Interlock functions disabled when manual combustion circuit is used:

Fuel oil pressure low (fuel)
Fuel oil temperature high (fuel)
Caution
Fuel oil temperature low (fuel)

Steam pressure high
Steam pressure low
Abnormal fire
These interlock functions work only when all functions are working properly. When there are
problems with sensors or other parts, interlock functions may not work properly.
There are two circuits for manual operation: one for manual feed water pump operation and another for
manual combustion operation.
4.1 Starting/Stopping Manual Feed Water Pump Operation

Note
When feeding water manually, do not leave boiler.
Proportional control from differential pressure is operated, but high level alarm is disabled.
4.1.1 Starting Manual Operation

a) Turn on breaker of main power supply.
Power lamp lights up.
b) Select pump to be operated by feed water pump shift switch.
Check that outlet and inlet valves of feed water pump to be used are opened and closed
properly.
c) Set feed water shift switch to MANU.
Feed water pump is started.
4.1.2 Stopping Manual Operation
Set feed water shift switch to OFF.
Feed water pump is stopped.
41
4.2 Manual Combustion

Note
When manual combustion is performed, do not leave boiler. If there is any problem, it is not
controlled automatically.
Enter manual operation by shifting manual combustion switch in order. Manual combustion switch
can be set to the following positions: [OFF], [F.O. PUMP/HEATER], [FAN RUNNING], [IGNITION]
(ignition (pilot burner)),[ PRI.COMB.] (preliminary combustion (double combustion with pilot burner
and main burner), [COMB.] (combustion (single combustion with main burner). These positions are
arranged in this order. Boiler also has combustion changeover switch that can be used to switch
between low combustion and proportional control combustion. Because individual operation of each
equipment is not allowed for safety reasons, turn cam switch in order to check operation.
Procedure for starting combustion with air atomization using M.D.O. (*) as main fuel (*) is described
below:
a) Check that manual combustion switch is set at [OFF].
b) Check that combustion changeover switch is set at [LOW] (low
combustion).
c) Follow steps a) to k) in 2.4.1.
Refer to page 34 2.4.1 Combustion with Air
Atomization in Chapter 4.
d) Shift manual combustion switch to [F.O. PUMP/HEATER].
Main fuel oil pump is started.
Check that fuel is circulating properly (Check oil pressure gauge).
e) Shift manual combustion switch to [FAN RUNNING].
Fan is started.
Check for abnormal noise.
f) Check that pre-purge (*) completion lamp lights up.
Combustion can be started when pre-purge completion lamp
lights up.
g) Shift manual combustion switch to [IGNITION].
Ignition rod sparks and pilot burner ignites.
Check through sight glass that pilot burner is burning.
Note
If pilot burner is not burning, immediately shift manual combustion switch back to [FAN RUNNING]
and repeat f) and subsequent steps in 4.2.
42
h) Shift manual combustion switch to [PRI.COMB.].

Double combustion with pilot burner and main burner is started.
Check through sight glass that it is burning.
Note
If main burner is not burning, immediately shift manual combustion switch back to [FAN
RUNNING] and repeat f) and subsequent steps in 4.2.
i) Shift manual combustion switch to [COMB.] position.

Pilot burner is put out, and combustion is continued with main burner alone.
Check through sight glass that it is burning.
Note
If main burner is not burning, immediately shift manual combustion switch back to [FAN
RUNNING] and repeat f) and subsequent steps in 4.2.
j) When combustion changeover switch is shifted to [AUTO.] (proportional control combustion)

during combustion with steam atomization, proportional control combustion is started.
4.3 Manual Combustion Stop

a) Shift manual combustion switch from [COMB.] to [FAN RUNNING].
Combustion is stopped. Only fan continues to operate.
Keep switch at [FAN RUNNING] for 60 seconds or longer for post-purge (*).
b) Shift manual combustion switch to [OFF].
Fan and main fuel oil pump are stopped.
43
5. Emergency Stop
DANGER
emergency. If breakers are turned off inadvertently, feed water and circulating water pumps
may be stopped to cause soot fire or furnace explosion. Do not use this function except in
emergency.
emergency. Emergency stop skips safety checks for ongoing operation and may cause
Caution
unexpected accident or failure. Use this function only when there is unavoidable reason for
bringing boiler to emergency stop. Users must judge when and how boiler should be
brought to emergency stop because it depends on situation.
When resuming operation after emergency stop, ensure that switches are turned on or off to
stop all ancillary equipment before turning power on. Otherwise, equipment may start to
work unexpectedly to cause accidents.
Procedure of boiler emergency stop because of accident or other necessity to stop boiler urgently is
described here.
5.1 Emergency Stop of Combustion System

5.1.1 Cases in which Emergency Stop is Required
Fuel oil leaks
Considerably poor combustion
Abnormal noise from fan or fuel oil pump
Exhaust gas leaks
When part of body or object gets caught in rotating parts of fan or fuel oil pump, etc.
5.1.2 Stop Procedure
a) Shift manual combustion switch to OFF position.
Fuel oil pump and fan are stopped, and combustion is stopped.
b) Close main fuel valve.
5.2 Emergency Stop of Entire Boiler

5.2.1 Cases in which Emergency Stop of Entire Boiler is Required
Fire
When all running equipment should be stopped immediately, etc.
5.2.2 Stop Procedure
Stop power supply to boiler or turn off power supply breaker in control panel.
All equipment is stopped.
44
6. Cold Start
When boiler water becomes completely cold and especially when trial operation is started or new boiler
is brought into operation, start boiler with followings in mind:
For cold start, it needs to take enough time until steam pressure is raised to 0.1 MPa because each
part of boiler is completely cold.
Note
Do not raise steam pressure rapidly.
a)
Raise steam pressure gradually to 0.1 MPa by repeating 1 minute combustion and 4 minute
purge.
Keep steam pressure at 0.1 MPa for 10 minutes.
While steam pressure is between 0.1 MPa and 0.2 MPa, repeat 2 minute combustion and
3 minute purge to raise pressure.
b)
When steam pressure reaches around 0.2 MPa, stop boiler.

Retighten bolts and nuts around fastening parts and connections of valves on body, manhole
packing and water level gauge.
c)
Blow water level gauge to make it easy to check.
d)
Blow boiler water and purify water.

Make boiler water purify.
e)
After steps a) to d) are finished, turn on combustion switch to start combustion again.
f)
When steam pressure is increased to maximum pressure for general use, check for steam
leaks.
g)
Open main steam valve and start automatic operation.
45
CHAPTER 5: INSPECTION AND MAINTENANCE

1.
List of Inspection Items and Inspection Frequencies
WARNING
Surface temperature of the top of boiler exceeds 60C and may cause burn if surface is
Caution
touched. Take extra care in daily inspection work.
CAUTION
When cleaning strainer or performing other work using oil, wear protective equipment to
Instruction
protect eyes and body from splashes of oil.
In order to prevent accidents, carry out inspection and cleaning listed below regularly.
(Some items should be inspected depends on system.)
List shows standard inspection frequencies. More frequent inspections may be required, depending on
use conditions or environments.
Carry out inspections with appropriate frequency on your own responsibility.
Note
When carrying out inspections, put sign on boiler stating that it is under inspection.
46
1.1 Regular Inspection and Maintenance

Every
day
Inspection/maintenance item
Check of ventilation
Check of surroundings for flammable materials
Check of funnel (exhaust pipe)
Check of feed water pump for leaks or abnormal noise
and check of pressure gauge
Retightening of valves, gland, and flanges (only when
signs of leaks are found)
Drainage of fuel service tank
Blow of water level gauge
Inspection and adjustment of drive part of dampers
P 97
Every
year
P 59
Hardness check of water softener

Cleaning of fuel strainer
P 63 - 65
()
()
()
Maintenance of burner body (Baffle plate, rectifier grid, etc.)
P 52 - 55
Inspection of burner nozzle

Inspection of ignition rod for cracks and adjustment
(*)
Inspection of wind box
Inspection of fan
P 52 - 55
P 55
Inspection of link of blower suction damper
P 57
Measurement of insulation resistance of each motor
P 56
Inspection of flexible tube

Inspection of oil flow control valve, air flow controller
and damper
Inspection of control motor
(*)
Inspection of dirt on flame eye /glass.
Inspection and adjustment of discharge pressure of
fuel oil pump
Inspection and adjustment of circulation relief valve
Visual inspection of wiring
Inspection of motor ball bearings
Inspection and cleaning of dirt on feed water strainer
Drainage of cascade tank
Inspection of drive valve for burner control
Inspection and adjustment of fuel oil thermostat
Inspection and adjustment of pressure switch
Operation check of each safety system
Operation test of exhaust gas thermostat
Check of main burner assembly for fuel oil leaks
Inspection and adjustment of coupling for fuel oil pump
Inspection of inner cylinder of burner
P 59
P59,60
P 61
P 62
P 66-68
P 69
P 56
P 70~
P79,80
P 82 - 84
P 87~
P 90
P 57
P 97 - 98
P 85
Greasing of bearing of blower suction damper

Cleaning of water level detecting rods and holder and
check of continuity and insulation
Inspection of differential transmitter
Inspection of flow control valve
Cleaning and inspection of fuel oil heater
Inspection of feed water check valve
Voltage check of flame detector
Every 3
months
()
Blow of boiler through surface and bottom
Every
month
Manual for
WaterTreatment
Manual for
WaterTreatment
Manual for
WaterTreatment
Sampling of boiler water
Every
week
P 86
P 95
P 99
47
When
docked
Every
day
Inspection/maintenance item
Inspection of inside of boiler
Inspection of combustion chamber and cleaning of
furnace with water to remove soot
Inspection and cleaning of inside of fuel service tank
Every
week
Every
month
Every 3
months
Every
year
When
docked
P 100
Inspection of inside of chimney
Inspection of valve on boiler
Cleaning of inside of cascade tank
Inner inspection and maintenance of differential transmitter
48
1.2 Safety Valve
WARNING
Improper adjustment of blow off pressure of safety valve may damage boiler body.
As a rule, do not adjust blow off pressure of safety valve.
Prohibition
Remodeling of safety valve may damage boiler body.

As a rule, do not remodel safety valve.
If steam leak from safety valve is found, replace part and repair it immediately.
When steam leak is left, function of safety valve is decreased and there is possibility of
Instruction
leading to serious accident
Safety valve is safety device that is installed to prevent boiler steam pressure from exceeding
maximum allowable working pressure; full-bore safety valve is used for this boiler. Normally, safety
valve does not operate because steam pressure switch works. When pressure switch does not work
for some reason and combustion is continued to cause abnormal steam pressure increase or rapid
pressure increase is caused by rapid load change, safety valve protects boiler by blowing steam off
and lowering steam pressure. As a rule, two or more safety valves are installed and they are
selected so that total blow off level exceeds the maximum evaporation level of boiler for safety.
Boiler safety valve is set at presence of inspector, so as to blow off at strictly limited pressure;
nobody is allowed to make attempt of further adjustment on board. However, only in case of
emergency, such as when safety valve leaks, some countermeasures, such as opening or adjusting
valve, can be taken at discretion of chief engineer. In that case, adjust blow off pressure of safety
valve according to procedure that is described in next page.
1.2.1 Internal Structure of Safety Valve
<50A or less>
No.
1
Valve casing
Valve seat
Valve body
Adjustment ring
Valve cylinder
Lift control bush
Spring
Valve stem
Adjusting bolt and nut
10
Cap
11
Valve lift lever
Figure 5-1 Internal Structure of Safety Valve : 50A or less

49
Part name
65A or more
No.
Nut
Stud bolt
Part name
Valve casing
Valve seat
Lower ring
Set bolt
Valve body
Upper ring
Guide
Valve stem
Adjusting bolt and nut
10
Cap
11
Valve lift lever
12
Spring
Figure 5-1 Internal Structure of Safety Valve : 65A or more

1.2.2 Adjustment Procedure of Safety Valve
a) Unlock key on shaft of valve lift lever (11), pull out shaft, and remove lift lever.
b) Remove cap (10) by loosening setting bolt.
c) Loosen nut (9) of adjusting bolt and activate safety valve.
Switch to manual operation of boiler and check that steam goes up and blow off pressure of
safety valve.
d) Turn adjusting bolt (9) to left if blow off pressure is higher than pressure limit and to right if it is
lower than that, so that it blows off at limited pressure.
e) After adjustment, fasten adjusting nut (9) tightly to fix it securely.
f) Put cap back in place, set valve lift lever, and lock and fix key.
1.3 Other Important Inspection Items

<Boiler Water Treatment>
The procedure for water treatment is described in Manual for Water Treatment. Most of boiler
accidents come from faulty water treatment; read and understand instruction manual thoroughly for
water treatment.
Manual also describes procedure of long-term boiler shutdown. Refer to "Manual for Water
Treatment".
Note
If boiler that is designed 60 Hz power supply inside of vessel is docked and operated in 50 Hz land
power supply, each motor capacity for 60 Hz is decreased and cases lack of combustible air,
insufficient fuel flow rate. Be sure to use power supply on vessel. If boiler that is designed 50 Hz
power supply is operated in 60 Hz land power supply, motor is burned and magnetic contactor is
tripped.
50
2. Daily Inspection and Maintenance

Peripheral equipment depends on system. Use equipment properly according to instruction manual.
Put instruction manuals together with this manual in place so that they can be read whenever they are
needed.
For details about inspections of equipment around boiler before operation and monitoring for problems
during operation, refer to 1. Inspections and Preparation Before Operation, "2.4.2 Control and
Checking during Operation (Combustion with Air Atomization), and "2.4.4 Control and Checking during
Operation (Combustion with Steam Atomization" in Chapter 4.
Refer to page 24 1. Inspections and Preparation Before Operation in Chapter 4.
Refer to page 35 2.4.4 Control and Checking during Operation (Combustion with Steam
51
3. Weekly Inspection and Maintenance

3.1 Main Burner
WARNING
Instruction
Complete purge by fan before burner opening and inspection to make combustion chamber
cold and ventilate. Stop fuel oil pump and close main fuel valve of main and pilot burners.
Wipe away fuel oil from burner nozzle and flexible tubes immediately and dispose of it
properly.
3.1.1 Overview
Main burner consists of main burner body with burner nozzle and guide pipe with baffle plate. In
burner nozzle, fuel oil sent by fuel oil pump is mixed with fluid for atomization (air or steam). The
mixture is squirted out of cap end and atomized.
Burner nozzle consists of cap, mixer, nozzle, check valve, and ferrule. Fuel oil sent from center of
burner nozzle and fluid for atomization supplied from circumference are squirted out of nozzle, mixed
in mixer, and then atomized through opening in cap. Check valve is installed before nozzle to prevent
oil dripping when combustion is stopped.
Clean main burner on a weekly basis.
3.1.2 Disassembly and Adjustment

< Main burner>
a) Loosen 2 hexagon socket set bolts on top of guide pipe and pull out burner gun.
b) Remove burner nozzle from main burner in ferrule position.
c) Disassemble burner nozzle into cap, mixer, nozzle, check valve, and ferrule.
When disassembling it, pull out lock screws completely. Failure to pull out lock screws may
damage burner nozzle.
d) Wash these components with light oil, clean them with air, and assemble them by following
disassembly steps in reverse.
52
<Guide pipe>
a) Remove nut on upper plate and pull out guide pipe.
b) Remove baffle plate, wash these components with light oil, clean them with air, and assemble
them by following disassembly steps in reverse.
Fuel oil inlet

x3
Atomized fluid inlet
x3
x3
D.O. inlet
Atomized fluid
Fluid oil
Enlarged View of Section A
No.
Figure 5-3 Structure of Burner
Part name
Guide pipe
Main burner
Pilot burner
Cap
Mixer
Nozzle
Check valve
Ferrule
Lock screw
10
Upper plate
3.2 Nozzle Tip
CAUTION
Improper spray volume, spray angle, and spray form cause poor combustion and sometimes
Caution
cause backfire (*). Use only genuine parts.
53
3.3 Pilot Burner

3.3.1 Overview
This burner comes with pilot burner designed for use with M.D.O.(*). Pilot burner consists of baffle
plate, nozzle tip, nozzle holder, check valve, ignition rod, and nozzle pipe.
Oil entering nozzle tip of pilot burner goes through strainer and trench of distributor and enters
evolution room. Conical evolution room has orifice in its end. Oil increases its speed while swirling in
evolution room, passes through orifice, and then is sprayed to combustion chamber.
Nozzle tip is made of hard material as high-pressure, high-speed oil wears away orifice and other
parts. Replace it on a yearly basis.
No.
Part name
Baffle plate
Nozzle tip
Nozzle holder
Check valve
Ignition rod
Nozzle pipe
Figure 5-4 Structure of Pilot Burner
Body
Distributor
Figure 5-5 Nozzle Tip of Pilot Burner
54
Strainer
3.3.2 Disassembly and Adjustment

a) Remove bolt on pilot burner and pull out pilot burner.
b) Remove nozzle tip, baffle plate, and ignition rod from pilot burner.
c) Disassemble nozzle tip into strainer, distributor, and strainer, wash these parts and baffle plate
with light oil, and clean them with air.
d) Remove soot out of ignition rod with brush.
e) After cleaning these parts, adjust their dimensions with reference to pilot burner dimensions
shown in Figure 5-3 and burner dimensions measured in trial operation, and assemble them.
4. Monthly Inspection and Maintenance

4.1 Fan
DANGER
Inspect fan once a month. Failure to inspect fan may cause it to break or fly apart due to
Instruction
deterioration of impeller or external force, resulting in injury or death.
WARNING
Before moving impeller by hand, turn off main power supply. If impeller is rotated accidentally
Instruction
during maintenance, physical injury may be caused.
4.1.1 Overview
Fan, which forces air into boiler, secures wind pressure and wind flow by rotating impeller by motor.
This boiler has fan with high wind pressure and high revolution speed because combustion gas
speed is high for efficient heat exchange with combustion gas.
Attention and care are required to prevent foreign particles from clogging wire mesh of suction.
When there is significant vibration even after impeller is cleaned, bearing replacement or impeller
adjustment is required.
55
4.1.2 Regular Maintenance

a) Inspect fan once a month.
b) Check for vibration, strange noises, and abnormal bearing temperature increase during
operation. When fan is not in operation, turn off power supply, and move impeller by hand to
check for problems.
Conduct insulation test once a month, after long-term shutdown, and when it is necessary. If
insulation resistance is below 1 M, replace motor or unship and repair it.
Motor bearing requires grease injection.
Grease motor bearing regularly according to notes on greasing on motor. Greasing is not
needed for HB-08T type because grease is sealed in bearing.
HB-10T, 12T
HB-15T, 18T, 20T

Figure 5-6 Bearing Grease Inlet
Table 5-1 List of Bearing Greases

Greasing
Model
Amount
to inject
(g)
Interval
(hrs)
Recommended grease
Exxon Mobil
12T
10T
20T
18T
15T
08T
20
35
1200
800
Nippon Oil Corporation
JOMO
Shell
Esso
Mobil
Shell
SKF
Klumber
FAG
:Beacon 325
:multinoc SDX
:LT Grease
:Albania Grease HVQ
:UnirexN2,N3 or S2(lithium complex base)
:Mobilith SHC 100(lithium complex base)
:Albida EMS2(lithium complex base)
:LGHQ3(lithium complex base)
:Kluberplex BEM 41-132(spectial lithium base)
:Arcanol TEMP110(lithium complex base)
Greasing is not needed because grease is sealed in bearing.
56
4.2 Suction Damper (Attachment of Blower)
WARNING
Inspect suction damper once a month. Failure to inspect suction damper may cause damage
Instruction
of part and malfunction due to looseness of part, resulting in injury or death.
4.2.1 Overview
Suction damper opens fully when combustion is started and it closes fully after post purge(*) of
combustion stop for restraining heat loss due to blowing of continuous-running fan motor.
3 damper plates are connected to motor with damper arm. They open and close in interlock with
rotation of motor. Limit switch is installed on damper arm part to check that damper opens fully during
combustion.
Oscillation and external force apply to damper continually, so pay attention to looseness of part etc.
Motor wiring hole
Motor
Damper body
Wiring fixing base3
Motor arm
Limit Switch
Wiring hole
Link block
Damper arm
Figure 5-7 Suction Damper
4.2.2 Inspection
a) Confirm that there is no looseness of fastening part once a month.
(Link block, damper arm and damper plate)
b) Grease bearing of damper shaft once every three months.
Required grease is alvania grease S3 (SHOWA SHELL SEKIYU K. K.). Greasing amount is 1.4g.
c) Confirm that there is no looseness of fixed screw and wiring once a month.
This boiler doesnt shift to automatic combustion if motor is damaged.
57
4.2.3 Measures on Failures (Fixing Fully Open State)

In case that damper doesnt fully open automatically due to malfunction of motor, this boiler doesnt
shift to automatic combustion, so damper needs to be fixed in open state forcibly.
Follow the following instructions for fixing damper.
a) Remove link block of tip part of motor arm A.
b) Pull up connecting rod until damper opens fully.
Confirm that damper arm touches limit switch in that position.
c) Let removed link block through connecting rod and fix motor arm B and connecting rod firmly.
d) Confirm that damper is fixed in open state.
Motor arm B
Motor arm A
Link block
Connecting rod
ucture of Safety
Figure 5-8 Diagram of fixed position of open state (Left: Fully closed, Right: Fully open)
58
4.3 Fuel Flexible Tube
WARNING
Do not give impact to boiler fuel pipe or bend any part of it.
Instruction
Failure to observe this instruction may cause fuel oil leak, resulting in fire.
Flexible tube on burner is used at high temperature and high pressure.

Generally, it needs to be replaced once every 1 or 2 years.
4.4 Oil Flow Control Valve, Air Flow Controller, and Damper
WARNING
Equipment has been brought into optimum state in trial operation. Do not make changes to
state after trial operation. Failure to observe this instruction may cause poor combustion,
Instruction
backfire (*), or other accidents. If changes are made for unavoidable reasons, contact MIURA
offices and ask for instructions.
4.4.1 Overview
Fuel oil flow rate and air flow rate are adjusted by oil flow control valve, air flow controller, and
damper.
Oil flow control valve changes its opening to adjust fuel oil flow rate. By rotating control motor on oil
flow control valve shaft, slot in shaft is rotated to change inner opening.
Air flow controller attunes throttling characteristics of oil flow control valve to air flow throttling
characteristics of damper. It has leaf spring bent into a fan-like shape, along which damper drive arm
moves. This leaf spring has 8 adjustment bolts, with which spring's shape can be changed to adjust
air flow throttling characteristics of damper. This mechanism adjusts air flow to optimum rate for
combustion levels at different combustion loads.
Damper is subject to continuous vibration and external force and must be checked for loose parts.
59
4.4.2 Inspection
Loose parts of damper cause changes in damper opening. Check damper drive arm and leaf spring
for loose lock screws on a monthly basis. If loose parts are found, retighten them or apply grease.
Coupling is connects motor and air flow controller shaft by tightening lock screw. Inspect looseness
of lock screw once a month because it can not control combustion normally when lock screw is
loosened. If loose parts are found, retighten them additionally and check that control motor opening
and air flow control valve opening have not deviated from position in trial operation.
Air flow controller
Leaf spring
adjusting bolt
Air flow controller
Leaf spring
Coupling
Lock screw
Control valve
Control motor
opening instruction
plate
Damper drive arm
Oil flow control
Lock nut
valve
Damper drive arm
Air flow controller

Leaf spring
adjusting bolt
Damper
5-6
Damper drive arm
Lock nut
Coupling
Control motor opening
Lock screw
Coupling
Figure 5-9 Oil Flow Control Valve and Air Flow Controller
60
4.5 Control Motor

4.5.1 Overview
Control motor controls oil flow control valve and damper to realize proper combustion conditions for
different pressure conditions according to signals from steam pressure regulator. It also has cam
switches in it, which notify control panel of damper position.
Because it repeats opening and closing constantly during combustion control, parts of control motor
inside are consumed gradually. Generally, it needs to be replaced at every docking.
Figure 5-10 Control Motor
4.5.2 Inspection
If control motor is failed, it cannot be burned normally.
Inspect fixed screw and wiring for looseness every month.
61
4.6 Flame Eye (*)
Flame eye
Flame eye fitting box
Flame eye fitting stand
Protection glass
Packing (2 pcs.)
Figure 5-11 Flame Eye
4.6.1 Overview
Flame eye is a device that detects flame during combustion and gives instruction to combustion
circuit. It monitors flame by using photosensitive characteristic of CdS (cadmium sulfide cell)
(Normally, when resistance of 100 k catches flame, it drops under 500 ).
If flame eye is damaged or protection glass is blackened with soot, it cannot detect flame and
stops burner and brings it to the same state as when ignition failure or flame-out occurs.
4.6.2 Inspection and Cleaning

Ignite burner with burner switch and look in furnace through sight window. If flame dies out about 3
or 4 seconds after burner is ignited, flame eye or flame detector may be out of order or protection
glass soiled. Inspect and clean protection glass on a monthly basis.
Refer to page 99 6.3 Flame Detector (FS-901) in Chapter 5.
62
4.7 Strainer for Fuel

4.7.1 T-type Auto-cleaner
T-type auto cleaner removes dust and other impurities from fuel to prevent them from entering and
damaging fuel oil pump, solenoid valves, or burner nozzle. It is installed on suction side of fuel oil
pump.
<Cleaning>
Element of auto cleaner can be cleaned during operation. To prevent it from being clogged, turn
handle and clean it at least once a day.
Drain all water and sludge from strainer once a month.
1
2
3
4
5
6
7
8
Cleaner cover
Oil tank
Handle
Main shaft
Gland
O ring
Ring
Packing
9
10
11
12
13
14
15
16
Air vent plug

Packing
Upper end
Lower end
Fixing plate
Packing
Filter plate
Scrapper plate
Figure 5-12 Oil Strainer

63
17
18
19
20
21
22
23
Square rod
Round rod
Drain plug
Packing
Washer
Nut
Cap nut
a) Draining strainer
Close main valve of fuel service tank, loosen drain plug (19) in lower part of strainer, and drain
water and impurities from strainer.
b) Disassembling and cleaning
Check main valve of oil tank is closed.
After draining of strainer, remove bolt on the upper part of oil strainer to remove cup.
Clean dust off plate filter with oil.
Assemble strainer in reverse order.
c) Air vent
Open main valve of oil tank and slightly loosen air vent plug (9) on the upper part of auto cleaner.
When air is removed and oil starts to come out of loosened screw, fasten screw.
4.7.2 Y-type Strainer
Y-type strainers are installed on outlet of fuel oil heater (*) and inlet of burner. Remove foreign
materials that are contained in fuel oil to prevent solenoid valves and other parts from being
damaged.
Cleaning
Open and clean Y-type strainer and inspect element for deformation or damage about once
every 3 months; frequency depends on property of fuel oil.
Replace a deformed element with new one.
1
Body
2
Cover
4.7.3 Double Strainer
3
Upper cock cover
4
Lower cock cover
5
Cock plug
6
Cock switch handle
7
Cock lift handle
8
Spindle
9
Cover retainer
10 Fastening bolt
11 Ring
12 Packing retainer
13 Filter tube handle
14 Filter tube
15 Filter rope
16 Drain plug
17 Air vent plug
18 O ring
19 O ring
20 O ring
21 O ring
22 Gasket
Figure 5-13 Double Strainer
23 Gasket
Double strainer removes dust, sand, and other impurities from fuel that is used with boiler to prevent
them from entering and damaging fuel oil pump, solenoid valves, or burner nozzle. Double strainer is
installed on suction side of fuel oil pump.
64
<Procedure of screen switching>

a) Close line valve first.
b) Pull up cock lift handle (7), give it two turns
counterclockwise when viewed in Figure 5-13, and pull
up cock plug (5).
c) Turn cock plug (5) in desired direction by using cock
switch handle (6).
Figur
Figure (a)
If cock switch handle (6) is turned rightward (refer to

Figure (a)), strainer B is used.
If cock switch handle (6) is turned leftward (refer to
Figure (b)), strainer A is used.
d) Pull up cock lever (7) and turn it clockwise to allow cock
plug (5) to adhere closely to body (1).
e) Fully open line valve gradually.
f) When oil passes through strainer A or B, air is
Figure
Figure
(b)
accumulated in upper part of body (1). Loosen air vent

plug (17), and close it after checking that oil comes out
Figure 5-14 Double Strainer
slightly.
Screen Switching
<Procedure of disassembling and cleaning of strainer>

Disassemble and clean strainer that is not used according to following procedure:
a) Check that screen that is disassembled is not used.
b) Loosen drain plug (16) and air vent plug (17) to drain oil.
c) Loosen fastening bolt (10) and remove cover retainer (9) and cover (2) after oil is completely
discharged.
d) Take out screen (14) by using screen handle (13).
e) Clean screen filter (15).
f) Assemble strainer in reverse order. Set screen (14) in strainer body.
g) Close drain plug (16) and air vent plug (17).
h) Fully open line valve gradually, and close air vent plug when oil comes out from air vent plug (17)
that fills stop side with oil.
65
4.8 Fuel Oil Pump

4.8.1 GD Type (for Pilot Burner)
This boiler uses GD type pilot pump. This pump is connected to motor through a coupling and runs
at a speed of about 3500 rpm to send fuel to pilot burner nozzle though solenoid valve.
Figure 5-15 Rotors of Fuel Oil Pump (Trochoid System)

Fuel oil pump employs trochoid system as shown above and it generates high pressure by rotation of
inner and outer rotors. Rotor has profile as shown above and inner and outer rotors rotate in light
contact with each other and tooth surface slippage is quite limited. Almost no noise is generated
because oil is not contained.
However, inspect fuel oil pumps and adjust discharge pressure once a month.
Refer to page 67 4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting in Chapter 5.
Return opening
Pressure regulating valve
Note: Do not disassemble rotors and other major parts
for repair. It cannot be repaired disassembled
pump that is not covered by guarantee.
Discharge opening
Suction
opening
Figure 5-16 GD Type

< Adjustment>
Adjust pressure by using pressure regulating valve.
Turning it to right increases pressure, and turning it to left decreases pressure.
Note Pump rotates clockwise when viewed from the end of pump shaft.
< Inspection and maintenance>

Check cover and oil seals for leaks on a daily basis.
It does not contain strainer. In case of trouble, do not disassemble unit, and unship and have it
repaired.
66
4.8.2 Main Fuel Oil Pump

This pump is connected to motor through a coupling and sends fuel to burner nozzle though fuel oil
heater (*), oil flow control valve, and fuel shutoff valve.
Prepare for operation of main fuel oil pump according to instruction manual for screw pump.
4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting
CAUTION
This adjustment is also needed when fuel oil pump is replaced. Adjust pressure regulating
valve in burner piping unit after discharge pressure of fuel oil pump is adjusted. Fuel oil
Instruction
pump is deteriorated over time and its performance is gradually declined.
If fuel oil pump is used for many years without adjustment, it deteriorates and becomes worn and
causes decreases in oil pressure.
In order to maintain proper oil temperature and circulation level, check and adjust discharge
pressure of fuel oil pump once a month according to following procedure. If oil pressure is adjusted
with M.D.O. (*), adjust it again when fuel oil is switched to H.F.O. (*).
Note Ensure that safety valve pressure setting of fuel oil heater is not exceeded.
a) Stop combustion and run fuel oil pump.
b) Slowly close fuel return pipe valve (1) shown in Figure 5-17.
Pressure indicated in fuel oil pump discharge pressure gauge (2) is increased slowly.
c) Adjust pressure indicated in fuel oil pump discharge pressure gauge (2) to value set in trial
operation by using pressure regulating valve (3) of fuel oil pump unit.
d) Slowly open fuel return pipe valve (1). Pressure indicated in fuel oil pump discharge pressure
gauge (2) is decreased slowly.
e) Open discharge valve (4), check that fuel oil is circulating, and close it.
F.O. return
F.O. inlet
Figure 5-17 Fuel Oil Pump Discharge Pressure Setting

67
<Adjustment of Pressure Regulating Valve>

(1) Remove adjustment screw cover of fuel pressure regulating valve and loosen lock nut.
(2) Turn adjustment screw of fuel pressure regulating valve to adjust pressure.
Turn screw clockwise to increase pressure.
Turn screw counterclockwise to decrease pressure.
(3) Check indicated pressure and tighten lock nut.
(4) Install adjustment screw cover.
68
4.8.4 Circulation Relief Valve

Fuel oil is pressurized by fuel oil pump and heated by fuel oil heater, and its pressure is adjusted
properly by circulation relief valve on top of boiler. Part of fuel oil circulates throughout system and
heats fuel return pipes during combustion, keeping fuel at constant temperature. Circulation relief
valve is important part that controls combustion level and temperature of combustion system. Inspect
this valve and adjust pressure once a month.
<Inspection>
Circulation relief valve is adjusted to optimum pressure in trial operation.
a) Check that inlet pressure of adjusting flow valve when H.F.O. (*) is circulating is pressure set in
trial operation.
b) Check that lock nut is not loosened.
If lock nut is loosened, retighten it.
<Adjustment>
If pressure gauge indicates pressure set in trial operation, combustion level does not need to be
adjusted. If pressure gauge does not indicate pressure set in trial operation, adjust combustion level.
a) Adjust fuel oil pump discharge pressure according to procedure in 4.8.3.
b) Adjust circulation relief valve according to 3) <Adjustment of pressure regulating valve> in
4.8.3.
Refer to page 67 4.8.3 Procedure of Fuel Oil Pump Discharge Pressure Setting in
Chapter 5.
List of standard pressure settings (reference)

HB-08T
HB-10T
HB-12T
HB-15T
HB-18T
HB-20T
M.D.O.MPa
0.8
0.8
0.9
1.1
1.2
1.2
MPa
1.0
1.0
1.1
1.3
1.4
1.4
H.F.O.
Figure 5-18 Circulation Relief Valve
69
No.
1
2
3
4
5
6
7
8
9
10
13
14
15
16
17
Part name
Relief valve body
Relief valve plunger
Spring retaining nut
Spring strike plate
Relief spring
Relief valve cap
Pressure adjusting bolt
Hexagon nut
O ring
O ring
Relief valve packing
Relief valve stand
Packing
Hexagon bolt
Spring washer
5. Quarterly Inspection and Maintenance

5.1 Inspection and Blow of Boiler Water
WARNING
Blow valve and sample water (blow water) are hot. Wear protective equipment while working
Caution
with them to prevent burn.
Treat and blow boiler water regularly according to Manual for Water Treatment.
5.2 Equipment around Burner

5.2.1 Solenoid Valve
WARNING
Instruction
Solenoid valve opens and closes by electric activation and non-activation to control supply of fuel
oil to burner nozzle and other control equipment.
If seat of any of solenoid valves is clogged due to foreign particles on seat, oil leak into combustion
chamber, ignition failure, or other combustion related problems may be caused. Visually check
flow meter when combustion is stopped or check for oil leaks in bottom of furnace on quarterly
basis. In disassembling device, be careful not to lose internal parts. When replacing valve, check
flow direction.
70
5.2.1-1 Solenoid Valve for Pilot Burner

This solenoid valve is used to control fuel used with pilot burner.
It is opened when activated and two valves are used for combustion.
When pre-purge (*) is completed, this solenoid valve is activated and opened.
No.
A1
A2
A3
A4
A5
A6
A7
A8
A13
N
1
2
3
Part name
Tube & base ASSY
O ring
Top plate
Spring washer
Coil
O ring
Base nut
O ring
Terminal box
Neon lamp
Plunger ASSY
O ring
Spring
Figure 5-19 YS301 Type
5.2.1-2 Solenoid Valve for Pneumatic Fuel Shutoff Valve

This solenoid valve controls air that drives pneumatic fuel shutoff valve. It uses compressed air in
line for atomized air to drive main fuel shutoff valve. When it detects flame of pilot burner, it is
opened to start air supply to pneumatic fuel shutoff valve. This solenoid valve is installed in each of
air supply lines leading to 2 main fuel shutoff valves.
Lead wire
Solenoid
Spring
Movable element
Poppet set screw

V seal
Poppet shaft
Body
Figure 5-20 062E1 Type

71
5.2.1-3 Solenoid Valve for Atomized Air

This solenoid valve is used to control atomized air. A single solenoid valve for atomized air is
installed in atomized air line and is opened when activated. When "AIR" is selected as atomized
fluid, it is opened following detection of flame of pilot burner to supply atomized air to main burner
and atomize fuel.
O-ring
Coil
Bracket
(Option)
Nut
Washer A
Bolt
Washer B
Bonnet
Diaphragm ASSY
Lock washer
Name plate
Housing
Base nut
O-ring
Spring
washer
Tube ASSY
Spring
O-ring
Plunger ASSY
Body
Figure 5-21 YS211 Type
72
5.2.1-4 Solenoid Valve for Atomized Steam

This solenoid valve is used to control atomized steam. A single solenoid valve for atomized steam
is installed in atomized steam line and is opened when activated. When "STEAM" is selected as
atomized fluid, it is opened following detection of flame of pilot burner to supply atomized steam to
main burner and atomize fuel.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19
20
21
29
Figure 5-22 DP Type
73
Part name
Valve casing
Cover
Spring pin
Pipe
Valve body
Valve disk
Valve body washer
Connecting spring
Piston ring
Pilot ring
Pilot disk
Spring retainer
Plunger
Pin
Valve body spring
Gasket
O ring
Coil
O ring
Pilot spring
5.2.2 Other Equipment
WARNING
Instruction
Before inspection or adjustment, check that there is no internal pressure present.

Compressed air or steam may blow out, causing burn or laceration.
If seat of any equipment is clogged due to foreign particles on seat, oil leak into combustion
chamber, ignition failure, or other combustion related problems may be caused. Visually check
flow meter when combustion is stopped or check for oil leaks in bottom of furnace on a quarterly
basis, along with carrying out inspection specified in each section.
5.2.2-1 Pneumatic Fuel Shutoff Valve
This is pneumatic actuator used to control fuel oil supplied to main burner. Two pneumatic fuel
shutoff valves are installed in main fuel oil (*) line and actuated by compressed air. This valve is
closed under no pressure and opened to start fuel oil supply to main burner when it detects
compressed air from filter regulator or solenoid valve for fuel shutoff valve.
<Inspection>
Carry out following inspections while boiler is in operation:
Check positions of valve when it is fully opened and fully
closed.
Check valve and pneumatic pipe connections for leaks.
Check valve and pneumatic pipe for abnormal noise.
Check for vibration when it is actuated.
Check for loose bolts or nuts.
Nominal diameter:
50 or below
Nominal diameter:
25 or below
Figure 5-23
FAS-2 Type
74
No.
1
2
3
4
7A
7B
8
19
20
30
33
34A
34B
35
36
47
67
92
93
94
96
99
124A
124B
145
155
Part name
Valve casing
Cover
Valve stem
Ball
Packing retainer
Packing retainer ring
Packing
Gasket
Packing washer
Ball seat
Nut for cover bolt
Nut for packing retainer
Nut
Cover bolt
Packing retainer bolt
Thrust washer
Stem bearing
Connector
Bracket
Bolt
Pneumatic actuator
Set bolt
Spring & pin
Spring
Spring washer
Spacer
5.2.2-2 Filter Regulator

Filter regulator is used to reduce pressure of compressed air supplied to solenoid valve for fuel
shutoff valve and to remove sludge. Installed in inlet of atomized air line, filter regulator reduces
pressure of air supplied to fuel shutoff valve to 0.4 MPa as well as removes dust in air with inner
filter to prevent solenoid valve for fuel shutoff valve from including dust.
<Inspection>
a) Check that pressure is set at 0.4 MPa.
b) Drain filter regulator.
If drain level exceeds upper limit, drain filter regulator in shorter intervals than inspection.
c) Check plastic bowl in filter regulator for cracks, scratches,
or deterioration.
Pressure
adjusting knob
<Adjustment>
Pull pressure adjusting knob a notch to unlock it.
Turning pressure adjusting knob in "H" direction shown in upper
surface increases secondary pressure, and turning it in "L"
direction decreases secondary pressure.
After adjusting secondary pressure, push pressure adjusting
Figure 5-24 Detailed View

of Pressure Adjusting Knob
knob a notch to lock it.
<Draining Procedure>
Turn cock in "O" direction to drain filter regulator and in "S"
direction to stop draining it
Figure 5-25 Detailed View of

Drain Outlet
<Inspection of Plastic Bowl>
Stop compressed air flow, check that there is no pressure present in product, and then remove bowl.
a) Turn bowl and bowl guard by about 45 until they are stopped while pushing them up (Figures
[1] and [2]).
By pulling bowl and bowl guard out downward, they can be removed (Figures [2] and [3]).
b) Assemble them in reverse order (Turn them until they are stopped).
c) Before letting compressed air in, check that marks of bowl guard and body meet each other in
point A (Figure [1]).
[1]
[2]
[3]
Body
Bowl guard
75
Figure 5-26
Procedure for
Removing Bowl Guard
5.2.2-3 Pressure Reducing Valve

This valve reduces pressure of steam for atomization supplied by boiler. It adjusts secondary
steam pressure to 0.5 MPa.
<Inspection>
a) Check that lock nut of adjusting screw (9) is not loosened.
b) Check secondary pressure.
Check secondary pressure when primary pressure is 0.6 MPa or above.
c) Check for abnormal noise.
d) Check for steam leaks.
<Adjustment>
If secondary pressure cannot be adjusted to 0.5 MPa, adjust it by steps below:
a) Check that atomized steam can be supplied and run fan in manual operation mode. After a while,
solenoid valve for atomized steam is opened.
Refer to page 40 4. Manual Operation in Chapter 4.
b) Loosen lock nut of adjusting screw (9).
Turn adjusting screw to adjust pressure to 0.5 MPa while checking atomized steam pressure
gauge.
c) After adjusting pressure, tighten lock nut.
No.
1
Body
Diaphragm
Adjusting spring
Adjusting screw
11
Main valve
12
Valve seat
13
Main valve spring
14
Piston
15
Cylinder
19
Pilot valve body
20
Pilot valve seat
28
Strainer
42
43
44
Figure 5-27 GP Type
76
Part name
Primary
communicating port
Secondary pressure
detection port
Diaphragm chamber
5.2.2-4 Seal Pot

This is a pot filled with ethylene glycol. Ethylene glycol is a liquid used to transmit fuel atomizing
pressure to equalizing valve. If seal pot does not contain a sufficient amount of ethylene glycol,
atomized steam pressure is not set properly to cause poor combustion.
<Inspection>
Follow steps below to check ethylene glycol level and fill seal pot with this liquid.
Use ethylene glycol that meets following specifications:
Purity: 99.5% or above
Density (20C): 1.12 to 1.15 g/ml
Water content: 0.2% or above
<Procedure>
a) Close cock for equalizing valve oil detection connected to fuel piping.
b) Remove air vent plug on top of seal pot and open cock.
c) Loosen air vent plug of equalizing valve body, check that ethylene glycol comes out, and then
tighten it.
d) Pour ethylene glycol until it comes out of air vent cock on top of seal pot.
Ethylene glycol comes out soon if there is no vent.
e) Close air vent cock.

f) Open cock for equalizing valve oil detection connected to fuel piping.
g) Put air vent plug back in place.
Air vent cock and plug
Seal pot
Cock for equalizing

valve oil detection
Air vent plug on
equalizing valve body
77
5.2.2-5 Equalizing Valve
WARNING
Equalizing valve has been set at optimum pressure in trial operation, and it is prohibited to
change setting as a rule. Failure to observe this instruction may cause poor combustion,
Instruction
backfire (*), or other accidents. If changes are made, contact MIURA offices and ask for
instructions.
Equalizing valve adjusts atomized steam flow rate appropriately for different combustion levels. It
also detects fuel oil pressure and keeps difference from steam pressure constant. Reference
differential pressure settings for different models at combustion load of 20% (low combustion) are
(Reference value)
shown below:
Model
HB-08T HB-10T HB-12T HB-15T HB-18T HB-20T
Differential pressure
setting of atomized
MPa
0.05
0.08
steam equalizing valve
Differential pressure setting of atomized steam equalizing valve = (steam) pressure at exit of
equalizing valve - (fuel) pressure at exit of shutoff valve (MPa)
<Inspection>
a) Check secondary pressure of equalizing valve at
combustion load of 20%.
Confirm that primary steam pressure of equalizing valve
is around 0.5 MPa.
b) Check for abnormal noise.
c) Check for steam leaks.
<Adjustment>
If difference between secondary pressure and fuel
Figure 5-28 Inter structure of

equalizing valve RCV Type
pressure at combustion load of 20% has deviated from

1
Body
16
Spring
Lower cover
17
Gasket
Valve Sheet (upper)
18
Bellows unit
Valve Sheet(lower)
19
Packing
Spring Sheet(upper)
20
Plug
b) Remove cap (13) .
Stud bolt
21
Air vent plug
c) Turn adjusting screw (11) to adjust secondary pressure.
Lower cover gasket
22
Hexagon bolt
Adjusting screw guide
23
Spring washer
Valve Stem
24
Hexagon nut
10
Lower cover
25
Hard lock
value set in trial operation, adjust it by following steps

below:
a) Ensure that combustion is taking place at load of 20%.
d) After adjusting pressure, put cap (13) back in place.
78
11
Adjusting screw
26
Plate spring washer
12
Packing retainer
27
Gland packing
13
Cap
28
Spring Sheetlower
14
Upper cover gasket
15
Setting spring
5.3 Fuel Oil Thermostat (for Fuel Oil Heater)

Carry out operation test of each alarm once every three months. Check that temperature at which
alarm is activated is almost the same as dial setting.
Temperature setting of thermostat for low and high temperature alarm depends on viscosity of fuel.
Refer to temperature chart.
Refer to page 81 5.3.3 Heavy Oil Heating Temperature in Chapter 5.
5.3.1 Dial Type

Thermostat for fuel oil senses temperature and turns electrical switch on or off. It uses fluid with
high expansion coefficient in thermo sensor. When it senses temperature, fluid is expanded and
pressure inflates diaphragm of body inside to activate lever for opening electrical contact. When
diaphragm is deflated, electrical contact is closed.
< Adjustment>
As shown in below figure, thermostat is dial type. After loosening dial set fittings, set dial to given
temperature and fasten it with set fittings.
Set thermostat for heater protection at 180C (Unchangeable).
EGO thermostat specification
Thermostat for heater protection
Thermostat for high

temperature alarm
Thermostat for low

temperature alarm
Figure 5-29 Fuel Oil Thermostat (Dial Type)
79
5.3.2 RT Type
Note
Some boiler use thermostat of RT type depending on specification.
< Adjusting operation temperature>
Adjust temperature by setting knob with reference to value on setting scale plate.
Set differential (*) to the minimum.
1. Setting knob
2. Setting scale plate
3. Differential setting disk
Figure 5-30 Fuel Oil Thermostat (RT Type)
80
5.3.3 Heavy Oil Heating Temperature

For effective combustion ability, keep viscosity of fuel oil in nozzle section at 12 cSt or less.
For proper fuel oil heating temperature for different viscosity standards of fuel oil, refer to following
chart.
Table 5-2 Temperature Setting for Viscosity (Example)
Redwood No.1Sec./100F
1500sec.
Kinematic ViscositycStat 50
IF-180
IFResidual Fuels, cSt/50
180cSt
Kinematic ViscositycStat 100
25cSt
CIMAC and ISO Fuels, cSt/100
2500sec.
280cSt
CIMAC/RM-25
3500sec.
IF-380
380cSt
35cSt
CIMAC/RM-35
Fuel oil heating temperature

(Setting temperature of temperature
125C
130C
135140C
controller)
Table 5-3 Heavy Oil Heating Temperature Chart
When 300cSt (at 50C)
81
5.4 Pressure Switch (for Steam, Atomized Fluid, and Fuel Oil)
WARNING
During inspection work, hot steam may blow out to cause burn. Be careful with operating
valves.
Caution
Before wiring work, be sure to turn control panel power off. Failure to observe this instruction
may cause electrical shock due to high voltage, resulting in injury or death.
Note
Inspect pressure switches and check their operation once every 3 months according to steps
below:
5.4.1 Steam Pressure Switch
Steam pressure switch is used to issue alarms. Contact of pressure switch for low pressure alarm
is opened to issue alarm when steam pressure falls below set pressure. Contact of pressure
switch for high pressure alarm is opened to issue alarm and stop combustion when steam
pressure exceeds set pressure.
<Inspection>
Check connections for steam leaks.
Carry out inspections with reference to Sections 5.7.9 and 5.7.10 in "5.7 Operation Check of
Each Safety System" in Chapter 5.
Refer to page 90 5.7.9 High Steam Pressure Alarm and page 91 "5.7.10 Low Steam
Pressure Alarm" in Chapter 5.
Figure 5-31 Steam Pressure Switch and Pressure Gauge
82
5.4.2 Atomized Fluid Pressure Switch

Atomized fluid pressure switch is used to issue low atomized fluid pressure alarm. When atomized
fluid pressure falls below set pressure, contact is opened to issue alarm and stop combustion.
<Inspection>
Carry out inspections with reference to Sections 5.7.15 and 5.7.16 in "5.7 Operation Check of
Each Safety System" in Chapter 5.
Refer to page 92 5.7.15 Low Atomized Steam Pressure Alarm and "5.7.16 Low
Atomized Air Pressure Alarm" in Chapter 5.
Figure 5-32 Atomized Fluid (Air / Steam)

Pressure Switch and Pressure Gauge
5.4.3 Fuel Oil Pressure Switch

This pressure switch is used to issue alarm when fuel oil pressure drops for some reason during
combustion.
Note Some boilers use fuel oil pressure switch of RT type, depending on specifications (Standard
boilers use SNS-P type).
<Inspection>
Carry out inspections with reference to Sections 5.7.5 in "5.7 Operation Check of Each Safety
System" in Chapter 5.
Refer to page 88 5.7.5 Low Oil Pressure Alarm in Chapter 5.
Figure 5-33 Fuel Oil Pressure Switch

83
5.4.4 Pressure Switch Adjustment Procedure

Note
Do not adjust working position adjustment screw. Adjusting screw may cause trouble.
<Adjusting working pressure>
a) Turn pressure regulating screw counterclockwise. (pressure regulating spring is compressed)
Contact pressure goes up as shown on gauge.
b) When contact pressure goes up, disconnection pressure goes up, logically.
< Adjusting differential (*)>
Set differential for pressure switch that is used for alarm to the minimum by turning differential
pressure regulating screw counterclockwise.
Pressure differential
regulating screw
Pressure
regulating screw
Pressure pointer
Differential pressure pointer
Scale plate
Working position
adjustment screw
1. Setting knob
2. Setting scale plate
3. Differential setting disk
b) RT type
a) SNS Type
Figure 5-34 Pressure Switch
84
5.5 Differential Transmitter

Differential transmitter detects differential pressure occurred by boiler water level and sends
electric signal accordingly differential pressure to water level indicator inside of boiler control
panel .
<Inspection>
aConfirm that there is no difference between water level indicator display and water level gauge
display.
In case difference is big, perform zero adjustment by normal water level at zero adjustment
trimmer of side of differential transmitter.
bCheck for water leakage.
<Zero adjustment>
aAdjust water level to normal water level while checking water level of water level gauge.
bAdjust zero while pushing adjustment trimmer and turn trimmer.
cConfirm water level indicator displays 0mm, for normal water level of water level gauge.
Note
Adjust normal water level during combustion at pressure for general use. Display of water level
gauge and water level indicator occur error due to steam pressure and operation condition. And,
display of water level gauge and water level meter occur error during combustion stop, because
water level ware adjusted to normal level during combustion at pressure for general use at the
time boiler is delivered.
Manifold valve
Zero adjustment trimmer
Figure 5-35
Differential transmitter
85
5.6 Flow Control Valve

Flow control valve opens and closes by electric signal from water level indicator, and controls
amount of feed water with target of normal water level.Feed water pump is always in operation.
<Inspection>
aCheck for water leaks.
bConfirm opening indication and operation time is in normal range.
cCheck for abnormal noise.
dCheck there is no water or dew condensation inside of controller.
No
Part name
Material
Body
Cap
Ball
Temper
Sheet
Temper
Stellite
Stem
Packing
Bracket
Connector
Electric operate machine
Direction of flow
Figure 5-36 Flow control valve
86
Temper
Quantity
5.7 Operation Check of Each Safety System
WARNING
Do not pull out lead wire with wet hands. Failure to observe this instruction may cause
Caution
electrical shock due to high voltage, resulting in injury or death.
5.7.1 Ignition Failure Alarm

a) Before igniting burner, remove flame eye (*) on the top surface of wind box (*) and put your hand
over tip.
b) Press combustion switch.
Ignition is attempted after pre-purge (*); however, flame eye does not detect flame and
determines that there is something wrong.
c) Check that audio and visual alarms are issued.
Check that combustion is stopped.
d) Press buzzer stop switch.
Audio alarm is stopped.
Alarm lamp does not turn off and comes to remain on.
e) Put flame eye back in place.
Alarm lamp does not turn off but remains on.
f) Press alarm reset switch.
Alarm lamp turns off and alarm is reset.
5.7.2 Fan Abnormal Stop Alarm
a) Trip fan thermal relay during combustion.
b) Check that audio and visual alarms are issued.
c) Press buzzer stop switch.
d) Reset fan thermal relay.
e) Press alarm reset switch.
87
5.7.3 Flame-out Alarm

a) Remove flame eye (*) during combustion, and put your hand over tip.
d) Put flame eye back in place.
5.7.4 Abnormal Flame Alarm

a) Remove flame eye during post-purge (*), and illuminate flame eye.
Check that post-purge is continued.
d) Put flame eye back in place.
Check that post-purge is stopped 35 seconds after flame eye is put back in place.
5.7.5 Low Oil Pressure Alarm

a) Press combustion switch.
b) Lower flow rate of fuel oil by adjusting fuel oil pump outlet valve or pump oil pressure.
c) Check that audio and visual alarms are issued. There should be 2-second delay before they are
issued.
d) Press buzzer stop switch.
f) Adjust flow rate of fuel oil.
88
5.7.6 Low Oil Temperature Alarm

a) Switch fuel to M.D.O. (*).Shift fuel oil heater (*) switch to A.
Check that fuel oil heater is stopped, and fuel oil is no longer heated.
b) Shift manual combustion switch to AUTO position, and press combustion switch.
c) Shift fuel oil heater switch to C position.
d) Check that audio and visual alarms are issued.
e) Press buzzer stop switch.
f) Shift fuel oil heater switch to A position.
Check that fuel oil pump is stopped.
g) Press alarm reset switch.
h) Switch fuel to H.F.O. (*). Shift fuel oil heater switch to C position.
5.7.7 High Oil Temperature Alarm
a) Lower setting of thermostat for high oil temperature during combustion.
b) Check that audio and visual alarms are issued. When fuel oil heater is not working, there should
be 10-second delay before they are issued. There is no such delay if fuel oil heater is in
operation.
Check that combustion is continued.
d) Reset thermostat for high oil temperature to value in list of principle items.
Alarm lamp turns off.
89
5.7.8 Exhaust Gas High Temperature Alarm

Boiler flue has thermostat to measure temperature of
exhaust gas. If there is abnormal temperature, alarm is
started and operation is stopped electrically.
At the time thermostat is delivered from factory, it is set at
450C (Unchangeable).
If thermostat is activated to stop boiler during operation,
measure gas temperature with thermometer, and
determine whether problem is due to failure of thermostat
or temperature is actually increasing.
If temperature of exhaust gas exceeds 450C, there is high
possibility that there is some sort of malfunction in
combustion chamber. Open furnace, and check for fallen
refractory materials, or other causes. If there is
malfunction, immediately take corrective action.
Figure 5-37 Exhaust Gas Thermostat
If incomplete combustion continues for a long time, soot

may be accumulated on heating pipes to increase
temperature of exhaust gas.
Pay constant attention to furnace to keep complete
combustion.
<Operation check>
a) Lower setting of thermostat by turning dial during combustion.
5.7.9 High Steam Pressure Alarm
a) Turn off main power supply of control panel.
b) Disconnect wiring from back surface of pressure regulator (see right figure).
c) Turn on main power supply of control panel and start combustion.
Boiler continues combustion at pressure above set pressure.
Check that pressure switch (for high steam pressure) is activated

when set pressure is reached and combustion is stopped following
issuance of alarm.
d) Turn off main power supply of control panel and connect wiring
disconnected above.
e) Open main steam valve to make boiler pressure fall within normal
working pressure range.
Disconnect wiring of
Y434 or Y515.
Figure 5-38 Back Surface
90
of Pressure Regulator
5.7.10 Low Steam Pressure Alarm

a) Increase boiler pressure to normal working pressure.
b) Close steam pressure gauge valve.
c) Check that test cock is closed and remove plug.
d) Open test cock gradually.
Note
Hot, high-temperature steam blows out. Be careful not to get burned.
Check that pressure gauge reading decreases and that pressure switch is activated when set
value of pressure switch is reached. Combustion is not stopped.
e) Close test cock, put plug back in place, and open steam pressure gauge valve.
5.7.11 Low Water Level Alarm
a) Close upper and lower water level gauge valves.
b) Open water level gauge drain valve slightly.
Check that boiler water is discharged from inside water level gauge and that low water level
alarm is issued.
Combustion is not stopped.
c) Close water level gauge drain valve and open upper and lower water level gauge valves.
5.7.12 Low Low Water Level Alarm
a) Perform steps a) and b) in 5.7.11.
Check that boiler water is discharged from inside water level gauge and that combustion is
stopped following issuance of low low water level alarm.
b) Close water level gauge drain valve and open upper and lower water level gauge valves.
5.7.13 Power-off Alarm
a) Turn power off during combustion.
Check that burner is stopped.
b) Turn power on.

5.7.14 Sequencer Error Alarm
When malfunction of sequencer is detected, lamp lights up as visual alarm.
Note
To allow sequencer operating normally to malfunction intentionally, special equipment must be
used.
For more details, contact MIURA offices.
91
5.7.15 Low Atomized Steam Pressure Alarm

a) Switch atomized fuel to "STEAM" and bring boiler into automatic combustion.
b) Close atomized steam valve.
Check that pressure gauge reading decreases and that pressure switch is activated to stop
combustion when set value of pressure switch is reached.
c) Open atomized steam valve.

5.7.16 Low Atomized Air Pressure Alarm
a) Switch atomized fuel to "AIR" and bring boiler into automatic combustion.
b) Close atomized air valve.
Check that pressure gauge reading decreases and that pressure switch is activated to stop
combustion when set value of pressure switch is reached.
c) Open atomized air valve.

5.7.17 Damper Control Alarm
aTurn off main power supply of control panel.
bDisconnect wiring of external wiring terminal 23 on control panel.
cTurn on main power supply of control panel and start combustion.
dCheck that audio and visual alarm are issued within 90 seconds after combustion is started.
ePress stop buzzer switch.
Blinking alarm lamp does not turn off and comes to remain on.
fPress combustion stop switch.
Alarm is reset.
gTurn off main power supply of control panel and connect wiring disconnected above.
5.7.18 Operation Check by differential transmitterLow Water Level, Low Low Water Level,
High Water Level
Adjust water level of water level gauge to proper level and close upper and lower water level
gauge valves on water level gauges of water level electrode to check differential transmitter.
Check water level by water level indicator. Check water level control and adjust water level to
proper, before check open upper and lower water level gauge valves on water level gauges.
Note
Perform operations after ensure that boiler combustion is stopped.
Water level alarm detects at each water level electrode and differential transmitter. Checking
water level control by differential transmitter is described here. For details about checking
water level control by water level electrode, refer to 5.7.11 Low Water Level Alarm and
5.7.12 Low Low Water Level Alarm in Chapter 5.
Refer to page 91 5.7.11 Low Water Level Alarm in Chapter 5.
Refer to page 91 5.7.12 Low Low Water Level Alarm in Chapter 5.
92
Low Water Level Alarm

aSet feed water pump shift switch to OFF, open bottom blow valve slowly.
Check that water level is lowered to low water level.
When water level is lowered to low water level, close bottom blow valve.
bCheck that audio and visual alarms are issued. There should be 10-second delay before they are
issued.
cPress stop buzzer switch.

dSelect pump for operation by feed water pump shift switch.

Operation indicator lamp of feed water pump is lightened. Feed water to boiler uppered to low
water level, set feed water pump shift switch to OFF. Alarm lamp turns off.
Low Low Water Level Alarm
aSet feed water pump shift switch to OFF, open bottom blow valve slowly.
Check that water level is lowered to low low water level limit.
When water level is lowered to low low water level limit, close bottom blow valve.
bCheck that audio and visual alarms are issued.
cPress stop buzzer switch
dSelect pump for operation by feed water pump shift switch.
Operation indicator lamp of feed water pump is lightened. Alarm lamp does not turn off but
remains on when water level rises over low low water level.
ePress alarm reset switch.
High Water Level Alarm

aSet feed water shift pump to MANU and select pump for operation by feed water pump shift
switch.
Operation indicator lamp of feed water pump is lightened.
Ensure that water level does not reach upper limit.
bWhen water level is uppered to high water level, set feed water pump shift switch to OFF.
cCheck that audio and visual alarms are issued. There should be 30-second delay before they are
issued.
dPress stop buzzer switch
eOpen bottom blow valve slowly.
When water level is lowered to high water level, alarm lamp turns off.
93
5.7.19 Suction Damper Error Alarm

aTurn off main power supply of control panel.
bDisconnect wiring of external wiring terminal 49 on control panel.
cTurn on main power supply of control panel and start combustion.
dCheck that audio and visual alarm are issued in 50 seconds after combustion is started.
ePress stop buzzer switch.
fPress alarm reset switch.
gTurn off main power supply of control panel and connect wiring disconnected above.
94
6. Yearly Inspection and Maintenance

6.1 Fuel Oil Heater (*)
6.1.1 Combined Use of Electricity and Steam
Heater that uses both electricity and steam as shown in figure below is used to heat heavy oil to
proper temperature.
F.O. outlet
Steam inlet
Safety valve
Drain
Steam outlet
F.O. inlet
Drain
Figure 5-39 Fuel Oil Heater (Electricity/Steam)
Electric heater contains nichrome wire coil with high thermal conductivity as heating element in the
center of pipe, and is filled with special fused powder with excellent electric insulation at high
temperature.
To save electric capacity, heater body is heated by steam from outside. Thus, electric heater is
combined with steam.
Both steam and electric heater are controlled by opening or closing steam solenoid valve with fuel
oil temperature controller.
If sludge adheres to heater, poor combustion or abnormal heating may be caused due to unstable
control. Clean inside of heater on a yearly basis.
<Overview>
Electric heater as shown in figure is used as standard to heat heavy oil used as fuel to proper
temperature. Heater is installed on outlet side of oil pump and oil temperature is regulated by
temperature controller.
Fuel oil heater contains nichrome wire coil as heating element in the center of pipe for high
conductivity, and is filled with special powder that has excellent electric insulation at high
temperature; these materials are solidified under high pressure.
<Inspection and maintenance>
Long-term use of fuel oil heater causes accumulation of oily sludge in heater, which may lower
heating temperature or damage element due to insulation failure.
Open and clean fuel oil heater on a yearly basis.
In addition, raise discharge pressure of fuel oil pump and check operation of safety valve.
Note
Sludge remaining after cleaning may cause leaks from solenoid valves.
Remove it completely by flushing or by another method.
95
6.1.2 Solenoid Valve for Steam Heater
Core assembly (fixed iron core)
Coil
Plunger spring
Plunger
Tension spring
Stuffing
Main valve assembly
Body
Figure 5-40 Solenoid Valve for Steam Heater
< Inspection and maintenance>

Check valve and seat for scratches, check for coil burnout, and clean them regularly.
In disassembling device, be careful not to lose internal parts. When replacing valve, check flow
direction.
96
6.2 Water Level Gauge and Water Level Detecting Rod

Note
Replace water level gauge glass once a year. If it is not replaced, it may be deteriorated with time
and damaged to cause hot water or steam to blow out from damaged part and cause a burn.
Water level gauge is integrated with water level detecting rod as shown below:
Boiler body
Upper water level

gauge valve
Upper water level

detecting rod
connecting pipe
Lower water level

gauge valve
Lower water level
detecting rod
connecting pipe
Section view
along line A-A
Water level gauge column
Hexagon nut
Water level gauge glass seat
Spring washer
Water level gauge glass holder
Plain washer
Water level gauge glass
10
Connecting pipe
Water level gauge glass packing
11
Water level gauge cover
Hexagon bolt
12
Water level gauge drain valve
Figure 5-41 Water Level Gauge and Water Level Detecting Rod
Water level detecting rod is installed on the top and bottom of steam drum (on steam side and water
side) with valves. Rod contains water level gauge glass to serve as both water level gauge and water
level detecting rod.
Water level gauge is important device for safety to check if prescribed water level is kept in boiler. As
glass of water level gauge must be kept clean, clean it by blowing water level gauge at least once a
day.
Reflective gauge glass is used for water level gauge, and size depends on rules of vessel
classification.
97
Aside from water level gauge, which is designed to visually check water level, water gauge column
has four (or five) water level detecting rods (3) with different lengths, which electrically detect water
level and put out signal to automatically start/stop feed water pump or to automatically stop burner
when low low level is detected. Stainless detecting rod is screwed in electrode holder and further
tightened with set screws. As water level detecting rod may get dirty with concentrated boiler water
and cause malfunction, pull water level detecting rods out and clean them at least once every three
months.
Electrode holder
Water gauge column
Water level detecting rod
Drain valve flange
Figure 5-42 Water Level Detecting Rods

<Inspection and Maintenance>
a) Continuity and insulation check of electrode holder.
Check continuity and insulation of electrode holder every three months.
Replace electrode holder periodically (once every 2 years) as aged deterioration causes
insulation and continuity failure.
a to
Continuity check
c : 0
Insulation check
a to
b : 0.1 M or above
b) If continuity or insulation failure is found, replace electrode holder.
<How to blow water level gauge>

Blow water level gauge once a day.
a) Close upper water level gauge valve and open water level gauge drain valve.
Boiler water is discharged from inside water level gauge, and lower water gauge column
connecting pipe is cleaned.
b) Close water level gauge drain valve and lower water level gauge valve, and open upper water
level gauge valve.
c) Open water level gauge drain valve.
Steam is discharged, and upper water gauge column connecting pipe and inside of water
gauge column are cleaned.
d) Close water level gauge drain valve and open lower water level gauge valve.
98
6.3 Flame Detector (FS-901)

Flame detector is auxiliary relay that is installed to detect burner flame and output electric signal.
Figure 5-43 Flame Detector

<Inspection>
Check on a yearly basis that voltage between terminals [3] and [4] of flame detector during
combustion does not exceed 2.5 V. If voltage exceeds 2.5 V, check whether or not flame eye (*)
glass and light sensitive surface of flame eye are dirty. If they are dirty, clean them.
Refer to page 62 4.5 Flame Eye in Chapter 5.
If voltage exceeds 2.5 V even after cleaning, there is possibility of failure of flame eye or flame
detector. In that case, replace flame eye with a spare one. If voltage exceeds 2.5 V again, there is
high possibility of failure of flame detector. In that case, replace flame detector.
99
7. Inspection and Maintenance on Vessel Docking

7.1 Soot Cleaning of Furnace
a) Remove burner from boiler.
b) Open inspection opening of funnel.
c) Visually inspect inside of combustion chamber and check conditions of castable and whether or
not inside is blackened by soot.
d) Clean combustion chamber with high-pressure water cleaner. Also clean boiler body from
inspection opening of funnel.
Refer to page 15 5.1 Boiler Body in Chapter 2.
e) Suck out cleaning solution in bottom of furnace with pump.
Note
Dispose of wastewater after cleaning, which has a low pH of around 1, properly.
MIURA cleans furnace to remove soot. For more details, contact MIURA offices.
100
8. Parts Information about Replacement

8.1 Ignition Transformer (*)
WARNING
Ignition transformer conducts high voltage. Touching live wiring may cause electrical shock.
Instruction
Turn power off before working with ignition transformer.
Figure 5-44 Ignition Transformer

Ignition transformer is important device for creating sparks from ignition rod by converting voltage of
100 V on primary side to a high voltage of 10 KV. Primary voltage of transformer can be 100 V or 200
Wiring is different depending on primary voltage.
Control voltage 100V
Control voltage 200V
Figure 5-45 Ignition Transformer Wiring Diagram

Note
Avoid insulating ignition transformer from boiler by rubber or other materials. Otherwise, it cannot
be earthed and may be burned.
101
8.2 Sequencer (Programmable Controller)

8.2.1 Description of Component Unit of CJ2M
Input unit
Output unit
CPU
Figure 5-46 External View of the Sequencer Unit
<Name and explanation of each part of CPU unit>

Slider
Fix adjacent units
Battery storage cover
When cover is opened, there are battery and
front dip switch.
Memory cassette is also installed inside of
cover.
LED display
Connector
Connect between adjacent units.
Memory card cover

There is memory card in cover.
Figure 5-47 Name of Part of CPU Unit
102
Dip Switch
Shows standard condition of dip switch
Condition of dip switch
1
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
Figure 5-48 Dip switch
How to install memory card
Pull the top of memory card to remove.
Insert memory card back with label is on left side.

Label
Figure 5-49
Installing/Removing of Memory Card
103
<Battery>
Battery is built in CPU unit.
Following data is backed up by battery.
I/O memory (including PC system configuration)
Clock data (when memory cassette with clock function is installed)
Battery lasts for 5 years in 25C ambient temperature. When battery runs out, front ERR/ALM
LED flashes.
It must be replaced with new battery. Contact with MIURA offices.
<Procedure of battery replacement>

Replace battery according to following steps.
a)
Turn off boiler power.

If power is off, turn on power once and leave it at least for 5 minutes.
b)
Pull out connector of battery in battery storage cover and replace battery with new one.
Once old battery is removed, install new battery within

5 minutes. If power is not supplied to CPU for 5
minutes or more, stored data may be lost.
Figure 5-50 Replacement of Battery
<Input unit>
Operation switch, pressure switch on detector and thermostat are connected to work as joint.
<Output unit>
Electromagnetic relay, solenoid valve and indication lights are connected. Relay contact output
is adopted.
It can be checked operation status of output points with LED on unit surface.
(Light is on when output relay is ON)
104
8.2.2 Function of Display
CPU unit front

LED display
Light up
LED NAME
Color
Green
Status
Turn off
Flash
Condition
CJ2 CPU unit is running normally withOperationorMonitormode.
Dip switch setting abnormal.
Operation is stopped withProgrammode or operation is stopped because of operation stop abnormal
Red
Operation stop abnormal (including FALSE command action) or hardware abnormal (WDT
abnormal) are occurred based on self diagnosis.
CJ2 CPU unit operation is stopped and all outputs are intercepted (OFF)
Operation stop abnormal (including FALSE command action) is occurred base on self diagnosis
CJ2 CPU unit operation is continued

CJ2 CPU unit is running normally.
Yellow
Specific auxiliary relay for load interception (A50015) is ON

All outputs of output unit are intercepted (OFF)
Specific auxiliary relay for load interception (A50015) is OFF
Yellow
CJ2 CPU unit peripheral (USB) port is communicating (either send or receive)
CJ2 CPU unit peripheral (USB) port is not communicating
Yellow
CJ2 CPU unit serial port (RS-232C) is communicating (either send or receive)
CJ2 CPU unit serial port (RS-232C) is not communicating
Yellow
It is lightened during insert into built in flash memory (back up memory)

It is also lightened during restoration of user program when PLC power supply is set from
OFF to ON (*).
It is not lightened during un insert into built in flash memory (back up memory)
Figure 5-51 Description of Sequencer Display
105
8.2.3 Errors and Countermeasures

Table 5-4 Sequencer Trouble Shooting
Abnormal phenomenon
1
Probable cause
POWER LED does not light
Loose connection of power
Terminal block: Correctly insert
up.
terminal block connector
connector.
Power line failure
Replace CPU unit.
Program mistake
Correct programs.
Loose connection of unit
Correctly insert unit.
Loose connection of terminal
Correctly insert terminal block
block connector
connector.
Input circuit failure
Replace output (input) unit.
RUN LED does not light up.
All of output (input) units are

not turned on.
All of output (input) units are
not turned off.
Low external voltage

5
Countermeasure
Outputs (inputs) irregularly
Loose terminal screw
turn on and off.
Loose connection of terminal

block connector
Use rated external voltage.

Correctly insert and lock
terminal block.
Output (input) operation

6
indicator LED does not light

up (although operation is
LED failure
Replace output (input) unit.
normal).
106
8.3 Steam Pressure Regulator
WARNING
Do not make changes to state after trial operation. Failure to observe this instruction may
Instruction
cause poor combustion, backfire (*), or other accidents.
Steam pressure regulator controls steam pressure by sending signals from pressure transmitter to
control motor under proportional control.
This steam pressure regulator controls combustion level under proportional control as well as sends
combustion stop and start signals. It can also be used to change combustion level setting.
Figure 5-52 Pressure Transmitter
Figure 5-53 Steam Pressure Regulator
Manual (MAN) mode lamp (green)
Remote (REM) mode lamp (green)

Auto tuning (AT) lamp (green)
Present value (PV) indicator

Shows boiler steam pressure in MPa.
Manipulated value (MV) lamp (green)
Set value (SV) indicator
Memory area indicator
Output (OUT1 and OUT2) lamps (green)

Digital output (D01 to D04) lamps (green)
Alarm (ALM) lamp (red)
Bar graph
Direct key
Set key
Up key
Shift key
Down key
Figure 5-54 Display of Steam Pressure Regulator
107
8.4 Fuel Oil Temperature Controller

8.4.1 Name and Function
No.
Name
Measurement indicator
Function
Measurement is indicated.
(PV)
2
Set value indicator(SV)
Up Key
Down Key
Set value is indicated.

Value is increased by 1 when
pressed once. Value is
increased by keeping on press.
Value is decreased by 1 when
pressed once. Value is
decreased by keeping on press.
Figure 5-55 Temperature controller (For temperature of fuel oil control)
Note
Appropriate heating temperature of fuel oil depends on viscosity of oil. Determine temperature
following Heavy Oil Heating Temperature Chart.
Refer to page 81 5.3.3 Heavy Oil Heating Temperature in Chapter 5.
Set data by pressing key firmly with fingertip.
Data is automatically registered 3 seconds after it is set.
Do not press SEL key.
8.4.2 Setting Procedure

Example: Changing set value (SV) from 120C to 130C
Press Up key until changed value reaches 130. Value is automatically registered 3 seconds
after set up.
108
8.5 Water Level Detector (LM1-200)

Water level detector (LM1-200) has following features:
It can be used at voltage of 100 V or 200 V.

No relay is used and open collector is used for output.
Logic circuit
Level detecting
circuit
Power
circuit
Water level detector

LM1-200
Figure 5-56 Sequence Diagram (Water Level Detector (LM1-200))
109
8.6 Water Level Indicator
CAUTION
Do not change setting from trial operation.
Instruction

Water level indicator opens and closes flow control valve depending on signal from differential
transmitter.
Water level displayunitmm
Normal water level display

(unitmm
Normal water level was set to 0mm.
Alarm lamp
1Low Low water level
2Low water level
3High water level
Figure 5-57 Water level indicator
Note
In case of trouble or wiring disconnection of differential transmitter, water level indicator

displays B.OUT that means out range of display.
Adjust normal water level (0mm) during combustion at pressure for general use. Display of
water level gauge and water level meter of control panel occur error due to steam pressure
and operation condition. Display of water level gauge and water level meter occur error during
combustion stop, because water level ware adjusted to normal level during combustion at
pressure for general use at the time boiler is delivered. Refer to manual for External zero
adjustment of differential transmitter when adjust normal water level.
110
CHAPTER 6: TROUBLE SHOOTING
Trouble shooting for each system is described in this chapter. If problem is not resolved by taking
measures in this chapter, there may be another cause. In that case, stop operation, and contact MIURA
offices.
1. Feed Water System

Table 6-1 Trouble Shooting (Feed Water System)
Phenomenon
Item to be checked
Feed water pump
Confirm that power is
does not run.
turned on.
Cause
Countermeasure
Power is not turned on.
Turn power on.
Confirm that terminal is
Wiring disconnection or
Check wire connection.
inserted properly.
contact failure.
Confirm that thermal relay
(1) Thermal relay failure
is not run.
(2) Overload of motor
(1) Manually restore

thermal relay and
check set value.
(2) Check whether motor is
overloaded or not.
Confirm that water level
Water level not detected.
detecting rod is not dirty.

Confirm that motor is not
Clean water level

detecting rods.
Motor failure and other.
Contact MIURA offices.
Insulation failure.
Disconnection.
Replace wiring.
Contact failure.
Fasten connection screws
burned or coil is not

broken.
Confirm that bearing,
mechanical seal, and
impeller are not burned.
Confirm that breaker for
feed water pump is not
tripped.
Feed water pump
Confirm that there is no
is running, but
disconnection of wiring on
indicator lamp
control panel.
does not light up.

contact failure of wiring on
tightly.
control panel.
Abnormal noise or
Confirm that bearing and
heat is generated.
gland packing are not
burned.
111
Phenomenon
Item to be checked
Cause
Countermeasure
Abnormal noise or
Confirm that foreign
Inclusion of foreign
Remove cause of inclusion
heat is generated.
materials have not gotten
materials in pump.
of foreign materials.
Confirm that impeller is not
Partial contact between
in contact with guide plate.
impeller and guide plate
Feed water pump
Confirm that air does not
Defective piping.
is running, but it
come into pump from
does not feed
suction side.
water.
Confirm that air is not built
into pump.
Install feed water pipes

properly.
Insufficient air vent.
Vent air sufficiently.
No water in cascade tank
Feed water into cascade
up.
Confirm that there is water
in cascade tank.
tank.
Confirm that feed water
Clogging of feed water
pipes and valves are not
pipes.
Clean inside of pipes.
clogged.
Confirm that strainer is not
Clogging of strainer.
Clean strainer.
Cavitation.
Clean, adjust, or replace
clogged.
leakage from feed water
check valve.
check valve.
Confirm that temperature
Cavitation.
of feed water is kept within
Lower temperature of feed

water.
specifications of pump.
Confirm that shaft center
Misalignment of shaft.
of feed water pump is
Align shaft center of feed

water pump with motor.
aligned with motor.

Confirm that impeller and
Decline of performance of
guide plate are not worn
feed water pump.
abnormally.
Confirm that remote level
Differential pressure
Open remote level gauge
gauge valves are opened.
detection failure.
valves.
Confirm that flow control
(1) It is controlled to be
(1) Valve is closed when
valve is working properly.
closed.Normal
feed water is not required
(2) Wiring disconnection or
(water level is over normal
Contact failure
water level) because of
(3) Failure
proportional control.
(2) Check wire connection.
(3) Contact MIURA offices.
(1) Wiring disconnection or
(1) Check wire connection.
indicator is displayed
Contact failure
(2) Contact MIURA offices.
B.OUT.
(2) Failure of indicator.
112
Phenomenon
Item to be checked
Cause
Pump is feeding
Confirm that performance
Decline of performance of
Switch to another pump
water, but water
of feed water pump is not
feed water pump.
and inspect pump.
level is lowered to
declined.
low water level
Confirm that zero
Zero adjustment position is Readjust position during
easily.
adjustment position of
low.
differential transmitter is
Countermeasure
combustion at pressure for

general use.
proper.
Confirm that pressure
Failure of pressure gauge.
Replace pressure gauge.
Clogging of discharge line.
Remove clogging of
gauge is working properly.

Discharge
Confirm that pipes and
pressure of feed
valves on discharge side
water pump is
are not clogged.
increased too
Confirm that pressure
much.
gauge is working properly.
discharge line.
Clogging of orifice.
Clean orifice.
Deterioration of seal parts.
Replace seal parts.
Failure of cocks or
Install problematic parts
leakage from cocks and
instrumentation pipes and
correctly.
instrumentation parts.
defective installation.
Water level that is
Dirt on water level gauge
Clean water level gauge
indicated by water
gauge glass is not dirty.
glass.
glass.
level gauge cannot
Failure of water level
be read.
gauge is not filled with
control system.
Confirm that orifice of feed

water pump outlet is not
clogged.
Water leakage
Confirm that seal parts,
from feed water
such as gland packing and
pump.
O rings, are not

deteriorated.
boiler water.
Water level remains
Open water level gauge
gauge valves are opened.
unchanged.
valves.
Water level remains
Clean water level control
control cylinder connecting
unchanged.
cylinder connecting pipes.
Deterioration of seal parts.
Replace water level gauge
pipe is not clogged.

Water leakage
from water level
gauge glass packing is not
gauge.
deteriorated.
glass.
Defective installation of
Install water level gauge
gauge glass is fastened on
water level gauge glass.
glass properly.
the both sides.

Note For details about problems of feed water pumps, refer to instruction manual for feed water pump.
113
2. Fuel System
Table 6-2 Trouble Shooting (Fuel System)
Phenomenon
Item to be checked
Fuel oil pump does
Confirm that power is
not run.
turned on.
Cause
Countermeasure
Turn power on.
Rotor burning.
materials are not
materials in pump.
of foreign materials and
Confirm that rotor is not

burned.
entangled in rotor.
Confirm that bearing or
replace pump.
Bearing burning.
Defective coupling.
Replace coupling.
Burnout of motor.
inserted properly.
contact failure.
Confirm that thermal relay
is not run.
mechanical seal is not

burned.
Confirm that shock
absorbing rubber of
coupling is not damaged.
burned or coil is not
broken.

thermal relay and check
set value.
overloaded or not.
Confirm that breaker for
Insulation failure.
Idling of pump.
Feed pump with fuel.
Pressure is too high.
Adjust pressure to
auxiliary equipment is not

tripped.
Running fuel oil
Confirm that fuel oil pump
pump sounds loud.
is filled with fuel.

Confirm that discharge
Fuel oil pump is
pressure of fuel oil pump is
heated.
normal.
specified pressure.
Clogging of flow path.
pipes and valves are not
Clean pipes and open and

close valves properly.
clogged.
Confirm that air does not
Inclusion of air.
come into pump from

of air, and let out air.
suction side.
Confirm that bearing or
Bearing burning.
mechanical seal is not

burned.
114
Phenomenon
Item to be checked
Running fuel oil
Confirm that rotor is not
pump sounds loud.
burned.
Cause
Countermeasure
Rotor burning.
Fuel oil pump is
materials are not
materials in pump.
of foreign materials and
heated.
entangled in rotor.
replace pump.
Confirm that fuel
Inclusion of air due to
temperature is not too
evaporation of volatile
high.
components in fuel.
Confirm that sludge is not
Inclusion of dust, air, or
contained in fuel oil.
other foreign materials.
Confirm that shaft center
Misalignment of shaft.
Lower fuel temperature.
Drain fuel service tank.

Align shaft center of fuel oil
of feed water pump is
pump with motor.
aligned with motor.

Confirm that shock
Defective coupling.
Replace coupling.
Confirm that pressure is
Maladjustment of pressure
Adjust pressure.
adjusted.
gauge.
Confirm that pipes and
Clogging of pipes and
Clean pipes and open and
valves on outlet side of
valves.
close valves properly.
Failure of solenoid valves.
Replace solenoid valves.
Clogging of flow path.
Clean burner ASSY.
Viscosity of fuel is high.
Replace fuel.
absorbing rubber of
coupling is not damaged.
Discharge
Confirm that there is not
pressure of fuel oil
anything wrong with
pump is too high.
pressure gauge.
pump are not clogged.

Confirm that solenoid
clogging in burner ASSY.
Confirm that viscosity of
fuel is appropriate.
(*)
Confirm that heating
Failure of fuel oil heater
Check heating
temperature of heater is
(wrong setting).
temperature.
Vent air sufficiently.
normal.
Fuel oil
Heating failure due to
temperature does
inclusion of air.
inclusion of air.
not rise.
Confirm that temperature
Set value is low.
Change set value.
Failure of fuel oil heater
Replace coil for heating
broken wire in fuel oil
coil.
heater.
Contact failure.
controller is set properly.
heater coil.
Confirm that wiring of fuel
oil heater is connected.
tightly.
115
Phenomenon
Item to be checked
Cause
Countermeasure
Fuel oil
Confirm that solenoid
Failure of solenoid valve
Disassemble and clean
temperature does
valve for steam and steam
and steam trap.
solenoid valve and steam
not rise.
trap are working properly.
trap.
Confirm that inside of
Performance decline due
heater is not dirty.
to dirt.
Failure of thermocouple.
Clean inside of heater.

Failure of thermocouple.
error indication in fuel oil

3. Combustion System
Table 6-3 Trouble Shooting (Combustion System)
Phenomenon
Item to be checked
Fan does not run.
Confirm that power is turned
Cause
Countermeasure
Turn power on.
Steam pressure is high.
Open main steam valve to
on.
Confirm that steam pressure
is not higher than setting of
lower steam pressure.
steam pressure switch.

inserted properly.
contact failure.
Confirm that thermal relay is
not run.
burned or coil is not broken.

thermal relay and check
set value.
overloaded or not.
Confirm that motor is
Insulation failure.
Bearing burning.
insulated.
Confirm that bearing is not
burned.
Fan is running, but
ignition is not
inserted properly.
contact failure.
Misfire / ignition
Failure of flame eye
failure
anything wrong with flame
dirt on glass.
clean glass.
Confirm that damper is
Improper adjustment of
opened properly.
damper.
started.
(*)
or
Replace flame eye or
(*)
eye .
116
Phenomenon
Item to be checked
Cause
Countermeasure
Misfire / ignition
(1) Clogging of pipes
(1) Remove cause of
failure
pressure of fuel oil pump is
(2) Pump failure
high enough.
(3) Decline of
(2) Replace fuel oil pump.
(including pilot pump)
performance of pump
(3) Readjust pressure. If
clogging.
this does not work,

replace parts.
Confirm that burner nozzle
Flame blowout.
Adjust their positions with
and baffle plate are correctly
reference to burner
positioned relative to each
dimensions in final
other.
drawing.
Confirm that pilot nozzle tip
Flame blowout.
Adjust their positions with
and baffle plate are correctly
reference to Figure 5-3 in
Chapter 5.
other.
Confirm that flame eye is
Flame eye does not
Install and fix flame eye
installed and fixed correctly.
catch flame.
correctly.
Confirm that moisture is not
Pressure drop due to
Drain fuel service tank to
included in fuel.
evaporation of moisture
remove moisture.
in fuel (cavitation).
Confirm that air flow
Looseness of coupling.
Tank is out of fuel.
Supply fuel to fuel service
controller is working with

running of control motor.
Confirm that fuel remains in
fuel service tank.
tank.
Confirm that burner nozzle is
Burner nozzle is clogged Clean burner nozzle.
not dirty or is not clogged.
with dust.
Confirm that pilot nozzle tip is
Pilot nozzle tip is
not dirty or is not clogged.
clogged with dust.
Leakage from joint of
Fasten joint of burner
leakage from burner nozzle.
burner nozzle.
nozzle tightly.
Leakage from joint of
Fasten joint of pilot nozzle
leakage from pilot nozzle tip.
pilot nozzle tip.
tip tightly.
Confirm that fuel system is
Clogging of fuel system.
Remove cause of
not clogged.
Clean pilot nozzle tip.
clogging.
Confirm that oil pressure
Failure of oil pressure
Check and adjust setting
switch is working properly.
switch.
of pressure switch. If this

does not work, replace it.
Confirm that ignition spark
(1) Failure of ignition
flies.
transformer .
(*)
(1) Replace parts.

(2) Connect wire properly.
(2) Defective wiring.

Confirm that opening in the
Dimension failure of
Check final drawing and
tip of ignition rod is the same
ignition rod.
adjust dimensions.
Confirm that the tip of ignition Miss spark.
Clean ignition rod.
as specified in final drawing.

rod is not dirty.
117
Phenomenon
Item to be checked
Cause
Misfire / ignition
failure
anything wrong with fuel
properly by fuel oil
temperature.
Confirm that equalizing valve
seal pot is filled with ethylene
glycol.
(1) Fill seal pot with
ethylene glycol.
(2) Fill seal pot with
ethylene glycol and
clean strainer.
(1) Adjust pressure setting
of pressure reducing
valve.
(2) Adjust pressure setting
of pressure reducing
valve and clean strainer.
Fuel temperature is low.
(1) Excessive amount of

atomized steam.
(2) Insufficient amount
of atomized steam.
Countermeasure
Adjust fuel temperature
Confirm that pressure setting

of pressure reducing valve is
proper.
(1) Excessive amount of

atomized steam.
(2) Insufficient amount
of atomized steam.
Confirm that air-driven valve
(1) Insufficient operating
is working properly.
air.
compressed air and
(2) Clogging of
pressure setting of filter
operating air system.
regulator.
(1) Adjust pressure of
(2) Clean operating air

system.
Confirm that solenoid valve
(1) Inclusion of dust in
(1) Disassemble and clean
for air-driven valve is working
solenoid valve for
solenoid valve for
properly.
air-driven valve.
air-driven valve.
(2) Failure
(2) Replace parts.
(3) Compressed air
(3) Open compressed air
valve is closed.
(4) Clogging or setting
error of filter regulator.
valve.
(4) Clean filter regulator
and adjust pressure
setting.
Confirm that atomized air
(1) Atomized air
pressure is 0.4 MPa or
pressure drop
supply pressure
above.
(2) Clogging of atomized
between 0.6 MPa and
air line.
0.9 MPa.
(3) Atomized air valve is

closed.
(1) Adjust atomized air
(2) Remove cause of

clogging.
(3) Open atomized air
valve.
Atomized air pressure
Adjust atomized air supply
increase.
pressure between 0.6 MPa
below.
and 0.9 MPa.
Confirm that fuel oil is
Flame blowout due to
Clean fuel strainer and
circulating at proper
fuel shortage.
adjust pressure of relief
pressure.
Confirm that hydraulic line
valve.
Lack of atomized steam.
valve of seal pot is opened.
118
Open valve.
Phenomenon
Item to be checked
Misfire / ignition
failure
and steam valves are
Cause
Countermeasure
Lack of atomized fluid.
Open valve.
opened and closed properly.

Confirm that solenoid valves
for atomized air and steam
solenoid valves for
solenoid valves for
are working properly.
atomized air and
atomized air and steam.
steam
(2) Replace parts.
(2) Failure
Combustion can
be observed, but
disconnection of wiring on
combustion lamp
control panel.
does not light up.
Disconnection.
Replace wiring.
Contact failure.
contact failure of wiring on
tightly.
control panel.
Combustion is not
Confirm that steam pressure
Failure of steam
stopped even after
regulator and pressure
pressure regulator or
steam pressure
transmitter are working
pressure transmitter.
rises up to
properly.
specified pressure.
Failure of pressure
anything wrong with pressure gauge.

Or, combustion is
gauge.
stopped
Confirm that pressure shown
independently of
in steam pressure gauge is
specified pressure.
not decreasing.
(1) Clogging of steam

pressure gauge line.
(2) Steam pressure
gauge valve is closed.
Confirm that drive valve is
working properly.
drive valve
(1) Clean steam pressure

gauge line.
(2) Open steam pressure
gauge valve.
drive valve.
(2) Failure
(2) Replace parts.
Flame is not
stabilized
(Unbalanced
temperature.
flame).
Excessive air flow.
Adjust position of damper
opened properly.
(Improper adjustment of
based on results of trial
damper opening)
operation.
not clogged with dust.
with dust.
Confirm that pilot burner,
Eccentric installation of
Adjust their positions
burner nozzle, baffle plate,
burner.
and other parts are correctly
operation.

other.
Confirm that fuel oil pressure
Fuel oil pressure is low
Readjust pressure. If this
is proper.
or oscillating.
does not work, replace

parts.
119
Phenomenon
Item to be checked
Cause
Countermeasure
Exhaust gas is
Insufficient air flow.
black.
opened properly.
damper opening)
operation.
Confirm that lock nut on link
Insufficient air flow.
arm is not loosened.
damper opening)
Fuel oil pressure is high.
is proper.

parts.
temperature.
Confirm that inner cylinder
Burnout of parts.
Replace parts.
Confirm that burner nozzle,
baffle plate, and other parts
burner.
and baffle plate are not

burned.
are correctly positioned
operation.
relative to each other.

Confirm that fan is running in
Defective wiring.
right direction.
Exhaust gas is
Excessive air flow.
white.
opened properly.
damper opening)
operation.
Confirm that lock nut on link
Excessive air flow.
arm is not loosened.
damper opening)
Fuel oil pressure is low.
is proper.

parts.
Confirm that fuel pipes are
Clogging of fuel pipes
Clean fuel pipes.
not clogged.
not clogged with dust.
with dust.
Confirm that burner nozzle,
baffle plate, and other parts
burner.
are correctly positioned
operation.
relative to each other.

Failure of drive valve.
is not too high.
Decline of performance
of pump
parts.
Inclusion of air.
Remove air from fuel line
Vibration
Confirm that air is not
combustion
included.
occurs.
Confirm that atomized steam
Excessive amount of
Adjust pressure setting of
pressure is not too high.
atomized steam.
pressure reducing valve.
sufficiently.
120
Phenomenon
Item to be checked
Cause
Countermeasure
Vibration
Fuel oil temperature is
combustion
too high or too low.
occurs.
temperature.
Excessive or insufficient
opened properly.
air flow.
operation.
damper opening)
Confirm that oil accumulated
Failure of burner nozzle.
Stop operation and contact
in the bottom of furnace is
Failure of drive valve.
MIURA offices.
Burnout of parts.
Replace parts.
(1) Insufficient operating
(1)
not burning.
Confirm that inner cylinder
and baffle plate are not
burned.
Confirm that main air-driven
air.
Adjust pressure of
compressed air and
(2) Clogging of
pressure setting of filter
operating air system.
regulator.
(2) Clean operating air
system.
Confirm that solenoid valve
(1)
Inclusion of dust in
(1)
Disassemble and
for air-driven valve is working
solenoid valve for
clean solenoid valve for
properly.
air-driven valve
air-driven valve.
(2) Failure
(2) Replace parts.
(3) Compressed air
(3) Open compressed air
valve is closed.
(4) Clogging or setting
valve.
(4) Clean filter regulator
error of filter
and adjust pressure
regulator.
setting.
Low atomized
Confirm that atomized fluid
Operation error of
Check atomized fluid
steam/air pressure
selection switch on control
atomized fluid selection
selection switch.
alarm is issued.
panel is set properly.
switch.
Open valve.
Clean strainer.
Confirm that atomized fluid
Failure of pressure
Check and adjust setting
pressure switch is working
switch.
of pressure switch. If this
and steam valves are

opened and closed properly.
strainer is not clogged.
properly.
does not work, replace it.

(1) Atomized air

above.
pressure drop
(2) Clogging of atomized
air line.
(1) Adjust atomized air

supply pressure
between 0.6 MPa and
0.9 MPa.
(2) Remove cause of
clogging.
121
Phenomenon
Item to be checked
Cause
Low atomized
steam/air pressure
alarm is issued
above.
(1) Atomized steam

pressure drop
Countermeasure
(1) Close main steam
valve, etc.
(2) Clogging of atomized (2) Remove cause of

steam line.
clogging.
4. Control System
Table 6-4 Trouble Shooting (Control System)
Phenomenon
Item to be checked
Cause
Countermeasure
Pressing
Confirm that manual
Manual combustion switch
Shift burner selection
combustion switch
combustion switch is not
is set at OFF position.
switch to automatic
does not start
set at OFF position.
combustion.
Confirm that safety
position.
Safety system activated.
systems are not activated.
Remove cause of alarm

issuance and press reset
button.
Ignition failure
lamp does not light
anything wrong with flame
up and alarm does
detector.
not sound following

ignition failure.
Failure of flame detector.
Replace parts.
Failure of lamp, socket, or
Replace parts.
anything wrong with lamp,
buzzer.
Refer to P99
"6.3 Flame Detector
(FS-901)" in Chapter5
socket, or buzzer.
Failure of buzzer stop
anything wrong with
switch.
Replace parts.
buzzer stop switch.

Damper control
Confirm that control motor
error alarm is
is working properly.
issued.
Failure of control motor.
Confirm that steam
Failure of steam pressure
pressure controller, parts
controller parts in control
in control panel is proper.
panel
disconnection or contact
contact failure.
failure of wiring.
122
Check wiring.
5. Trouble Shooting for Boiler Body
CAUTION
Before working on water tube leaks, check water tubes and burner funnel that may be
touched are fully cooled. Otherwise, you may suffer from burn. For more information,
Caution: Hot
contact MIURA offices.
Checking Leaked Water Tubes

No leakage from water tube of GK type boiler occurs if water quality control is carried out properly.
Boiler external treatment and boiler internal treatment with boiler compound are absolutely essential.
If leakage is found from boiler water tube due to improper boiler water treatment, check it as follows:
a) Remove burner and wind box (*) from the upper part of boiler. Open manhole of funnel on
exhaust gas side.
b) Enter boiler combustion chamber and funnel inside on exhaust gas side to check water tube wall
(Obvious leakage may be detected at glance in this stage).
c) Switch feed water pump to manual operation and perform a hydraulic test.
d) If water is leaking from joint of water tube and tube plate, remove refractory castable around
water tube swaged area and inspect whole area.
When water is leaking from back side of the first row of tubes toward the second row of tubes, it is
easily considered that water is leaking from the second row of tubes. Therefore, check it carefully
in full consideration of above.
e) When leaking water tubes are found, insert stoppers or replace tubes with new ones.
Refer to page 124 6. Repairing Damaged Water Tubes in Chapter 6.
f) Investigate cause of water tube leakage for future reference. If leakage came from improper
water treatment, take secure measures to prevent recurrence.
If leakage is found on exhaust gas economizer side, open manhole on exhaust gas
inlet and outlet and hand holes in the middle part and find where leakage is occurring.
123
6. Repairing Damaged Water Tubes
WARNING
Stopper treatment and furnace building with refractory is temporary treatment. Do not
operate for a long time; otherwise, there is possibility of serious accident. Contact each
classification in advance and replace water tubes (or body) immediately at periodical
inspection. Contact MIURA offices about replacement of water tubes (or body).
Instruction
Before inspecting interior, stop main engine. Purge with the bottom blow and fan, and cool
both the inside of drum and combustion chamber. Then make sure that pressure inside the
drum is 0 MPa. Also, make sure ventilation is provided by air duct and/or the ventilator fan
during inspection.
This boiler is vertical natural-circulation boiler.

If boiler water is not controlled according to "Manual for Water Treatment, that is provided separately,
impurities in feed water (calcium, magnesium, and silica) may be accumulated and turned into scale
on heating surface, that could hinder heat exchange process, damage water tubes, or cause
leakage.
To operate this boiler most economically and efficiently, it is essential to control boiler water by
blowing down boiler and using proper boiler compounds and water softener. This chapter describes
ways to fix damaged water tubes and leakage that are caused by unsatisfactory boiler water
treatment.
6.1 Insertion of Stoppers from Inside of Water Drum

Stopper
This method uses iron stoppers that are included as spare

parts to plug tubes from inside the upper and lower steam
drums and water drum. Before inserting the stoppers,
determine which water tube(s) is/are leaking.
Refer to page 123. 5. Trouble Shooting for Boiler
Body in Chapter 6
Combustion
Chamber
Once it is identified leaking water tube(s), enter drum

through manhole and insert stoppers from inside as it is
shown in the figure.
In this case, clean thoroughly contact surface between
stopper and water tube so that dust or other foreign materials
do not get caught in surface; this is especially important if
there is some sort of damage. It is also effective to polish
Stopper
parts with carborundum or a similar material.
Figure 6-1 Insertion of Stoppers from Inside of Water Tube

124
Combustion
Chamber
Cut off this portion

with gas (Cut off the second
and subsequent water
tubes).
6.2 Stopper Welding from Combustion Chamber
Steam drum
Water drum
Water tube
Castable
Figure 6-2 Stopper Welding from Combustion Chamber

This method is the same as the previous method up to the point that water pressure test is conducted inside
combustion chamber to determine which pipe(s) is/are leaking. However, stoppers are used in completely
different way. In this method, stoppers are welded from inside of combustion chamber as it is shown in
Combustion Anchor
Chamber
Apply castable (only to
the innermost row).
Combustion
Chamber
Seal the opening by welding.
figure. Therefore, the first prerequisite for using this method is to have certified welder on board.
Figure 6-3 Stopper Welding from Inside of Combustion Chamber

If it is undertaken stopper treatment from just the top and bottom without welding stoppers, there is
possibility that water tube (that does not contain water) is damaged and water is leaked to exhaust gas side.
Therefore, the previous type of work should be completed only in case of emergency; it is strongly
recommended that stoppers are welded once ship reaches port. However, if there is some technical issue,
such as with welders, or application of refractory castable is omitted (refer to above figure), other problems
may be caused. Therefore, it is necessary to follow instructions of MIURA offices.
125
CHAPTER 7: STORAGE
1. Maintenance When Boiler is Shut Down for a Long Time

When boiler is shut down for a long time, it is important to store it properly. Before boiler is shut down,
wash soot off boiler and clean and fully dry inside of furnace. In addition, pour silica gel to protect
against rust.
Conduct procedure for shutdown according to Manual for Water Treatment.
2. Movement or Resale
WARNING
Do not perform installation work and connection of incidental equipment unless it is
specified.
Prohibition
Failure to observe this instruction may cause physical injury.
In reselling or reusing boiler, procedure that is based on rules of vessel classification must be taken.
Contact MIURA offices since it must be checked that vessel equipment does not affect normal
operation of boiler. Installation work or connection of incidental equipment that is not specified may
cause physical injury. If our products are resold, deliver instruction manuals and related materials along
with product to new owner, and inform us of resale (We need to transfer maintenance records that kept
since it was placed in service).
3Export
When exporting products whose export is regulated under the Foreign Exchange and Foreign Trade
Act, approval of the Japanese government for export must be obtained. When MIURA products are
exported, products and their use are subjected to many laws and regulations in the destination country.
If there is plan to export MIURA products, contact MIURA offices.
126
CHAPTER 8: DISPOSAL
1. Disposal Procedure
This boiler must be disposed of as industrial waste.
Dispose of boiler properly according to the laws in the country where it is to be disposed of. For details
about recycling of materials that are used in this boiler, contact MIURA offices.
127
CHAPTER 9: GUARANTEE
1. Description of Guarantee
Guarantee period is either of following, whichever comes first:
12 months after vessel is delivered.
18 months after equipment is shipped
If boiler has trouble within this guarantee period, trouble is repaired or parts are replaced for free so
that boiler functions as required in agreement as long as it has been installed and used properly
according to instruction manual, warning labels, and other instructions.
Trouble with equipment other than MIURA products that is installed on vessel is not covered by this
guarantee. Deterioration of consumable parts is not covered by this guarantee unless it is abnormal
deterioration.
In any of following cases, repair work is charged even within guarantee period:
[1] Failure or damage that is caused by wrong use, poor maintenance, or improper repair or
remodeling
[2] Failure or burnout due to natural disasters such as fires, typhoons, or tsunamis, or other external
factors
[3] Replacement of consumable parts
[4] Other matters that are specified in the agreement
If repair work is required outside Japan, travel expenses including accommodation and transportation
fees are charged. Repair service outside Japan cannot be provided if travel to that country is banned.
If there is any question about repair service within or after guarantee period, contact MIURA offices.
2. Contact Information for Inquiries about Products and Instruction

Manual
If you have any question about products that you purchased or about this instruction manual, contact
MIURA offices.
(Contact information can be found on back cover.)
3. Sale of Instruction Manual

If you need instruction manual for this boiler, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, boiler number, and manual
number on cover of instruction manual.
4. Sale of Parts
If you need parts that are used with this boiler, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, and boiler number.
128
DOMESTIC SERVICE STATION

*HEAD OFFICE:
7, Horie, Matsuyama, Ehime, Japan,

799-2696
TEL: (+81)89 979 7066

FAX: (+81)89 979 7067
2-15-35 Takanawa, Minato-Ku, Tokyo,

Japan, 108-0074
3-20-9 Matsunaga-Cho, Fukuyama,
Hiroshima, Japan, 729-0104
3-19-20, Hakataekiminami Hakata-ku
Fukuoka,Japan, 812-0016
TEL: (+81)3 5793 1047

FAX: (+81)3 5793 1045
TEL: (+81)84 930 0740
FAX: (+81)84 930 0741
TEL: (+81)92 432 3277
FAX: (+81)92 432 3278
1-3-10, Shibaura, Minato-Ku, Tokyo,

Japan, 105-0023
4-28-2, Abraya-Cho, Minato-Ku,
Nagoya, Aichi, Japan, 455-0824
TEL: (+81)3 6809 4540

FAX: (+81)3 6809 4541
TEL: (+81)52 383 3166
FAX: (+81)52 383 3607
MIURA SOUTH EAST ASIA PTE. LTD.
No.3 Soon Lee Street #03-36-37-38,

Pioneer Junction Singapore 627606
MIURA Co., Ltd ROTTERDAM OFFICE
Rotterdam Business Centre. Westblaak 140,
TEL: (+65)6465 1147

FAX: (+65)6465 1148
TEL: (+31)10 412 2015
FAX: (+31)10 412 4109
MIURA Co.,Ltd.
SHIP MACHINERY DEPT.
*BRANCH:
TOKYO MAINTENANCE DIV.
SHIMANAMI MAINTENANCE DIV.
KYUSHU MAINTENANCE DIV.
*AUTHORIZED DISTRIBUTORS:
N.Y.CO.,LTD.
CHUOKIKI CO.,LTD.
OVERSEAS SERVICE STATION
3012KM Rotterdam The Netherlands
OVERSEAS NETWORK
1.CHINA
IHI MARINE (SHANGHAI) CO., LTD.
Room No.706-707, Information Tower No.1403
Minsheng Rd, Pudong New Area, Shanghai, 200135,
P.R.China
Tel : (+86)21 6351 8029
Fax: (+86)21 6351 8028
SHANGHAI WEN CHIUAN MARINE
SERVICE&ENGINEERING CO., LTD.
No.951 Kesheng Rd. Beiguan, Malutown, Jiading district
Shanghai, 201801, P.R.China
Tel : (+86)21 6915 2475
Fax: (+86)21 6915 2476
2.GERMANY
TAKNAS MARINE ENGINEERING GMBH
"Fruchthof" Oberhafenstr.1 20097 Hamburg, Germany
Tel : (+49)40 32 1305
Fax: (+49)40 33 0608
3.KOREA
DONG YANG ENGINEERING
#10-11,2Ka Myeong-Ryun-Dong Dongrae-Ku Busan,
607-802, Korea
Tel : (+82)51 552 6503
Fax: (+82)51 557 4830
SEIN BESTECH
302, 64 Keumo-5Gil, Dong-Myeon, Yangsan,
626-821, Korea
Tel : (+82)51 961 7771
Fax: (+82)51 961 7772
4.PHILIPPINES
PHIL-NIPPON KYOEI CORP.
S-705 Royal Plaza Twin Towers 684 Romedios St.,
Malate Manila, Philippines
Tel : (+63)2 400 5778
Fax: (+63)2 400 9130
5.SINGAPORE
TAKNAS ENGINEERING PTE.LTD.
102, Pandan Loop, Singapore 128310
Tel : (+65)6777 5856
Fax: (+65)6779 6711
6.TAIWAN
AL SEA-LAND ENGINEERING CO.,LTD.
1F,No.51, Lane 164, Chung He Rd, Chung Shan Dist.,,
Keelung, Taiwan
Tel : (+886) 2 24367812
Fax: (+886) 2 24373219
MING YUNG MACHINERY.,LTD.
27.Shin Shing St., Yan Cherng District Kaohsiung,
Taiwan
Tel : (+886)7 521 6266
Fax: (+886)7 521 9368
7.THE NETHERLANDS
NICOVERKEN HOLLAND B.V.
Algerastraat 20 3125 BS Schiedam, The Netherlands
Tel : (+31)10 2380999
Fax: (+31)10 2380990
FUJI TRADING (MARINE) B.V.
Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
Tel : (+31)10 429 8833
Fax: (+31)10 429 5227
8.USA
CISCO BOILER SERVICE CO., INC.
5935 Griggs Road, Houston, TX 77023, U.S.A.
Tel : (+1)713 928 5700
Fax: (+1)713 928 5795
INDUSTRIAL BOILER SERVICE, INC.
23132 East Echo Lake Rd., Snohomish, WA 98296,U.S.A.
Tel : (+1)206 624 1171
Fax: (+1)206 483 9112
9.VIETNAM
SHM-VLK CO.,LTD
64 D2 Street, Van Thanh Bac Precinct, Ward 25,
Binh Thanh District, Ho Chi Minh, S.R. Vietnam
Tel : (+84)8 3512 8379
OPERATION MANUAL
MARINE AUXILIARY BOILER
HB-T
Published by MIURA Co.,Ltd. Ship machinery Dept. Dec. 2011.

3rd edition Aug. 2014 No. E990-1112-03
All rights reserved, Copyright 2014 MIURA Co.,Ltd.
No part of this publication may not be reproduced, transmitted, distributed or
modified, in any form or by any means, without the written permission of the
publisher MIURA Co.,Ltd.
Visit us at www.miuraz.co.jp and get the latest information and Service News!
Printed in Japan

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OPERATION

Operation Manual No.

Important Safety Information

Indicates any condition or practice that, if not observed,

Indicates any condition or practice that, if not observed, may

Indicates any condition or practice that, if not observed, may

Indicates touching certain area may cause personal injury.

Indicates handling with wet hands may cause electrical shock.

Provides instruction to be followed (action to be taken).

Indicates ground wires must be connected.

Indicates a precaution to be remembered.

Indicates potential danger of injury from heat under certain

Provides precaution to prevent boiler failure, point to be

for flammable dangerous substance refers to place where such a substance

Oil Air Separator

Container that is designed to separate components evaporated from fuel oil

Air Supply Fan

Air supply system designed to bring air into furnace.

Label to call attention to operating precaution.

Heater that is designed to heat fuel to suitable temperature to be atomized by

Phenomenon that fire source is generated in furnace under poorly ventilated

Sensor that is designed to detect flame in furnace.

Important Safety Information .............................................................. i

CHAPTER 2: OVERVIEW ................................................................. 11

2. Water and Steam Supply Flow.................................................... 12

3. Fuel Supply Flow......................................................................... 13

4. Basic Specifications .................................................................... 14

6. Boiler Automatic Operation by Sequencer .................................. 19

CHAPTER 3: BASIC OPERATION.................................................... 22

2. Automatic Operation (Normal Operation) ....................................31

3. Emergency Operation .................................................................38

4. Manual Operation (Use Only in Emergency) .............................. 40

6. Cold Start .................................................................................... 45

CHAPTER 5: INSPECTION AND MAINTENANCE ........................... 46

2. Daily Inspection and Maintenance .............................................. 51

4. Monthly Inspection and Maintenance..........................................55

5. Quarterly Inspection and Maintenance .......................................70

5.2.2 Other Equipment ...................................................................................... 74

6. Yearly Inspection and Maintenance ............................................95

7. Inspection and Maintenance on Vessel Docking.......................100

8. Parts Information about Replacement.......................................101

CHAPTER 6: TROUBLE SHOOTING.............................................. 111

CHAPTER 7: STORAGE ................................................................. 126

CHAPTER 8: DISPOSAL ................................................................ 127

CHAPTER 9: GUARANTEE ............................................................ 128

2. Knowledge and Skill Required for Safe Handling

[Requirements to be satisfied by operators]

4. Prohibition of Remodeling without Permission

5. Use of Specified Fuels

6. Warning Labels (*) on Products

Damage Warning Label: Attached on water gauge glass as there is possibility of

7. Precautions for Safe Handling

7.2 Safety Precautions in Pre-operation Inspection and Preparation (Excerpt from

Do not put flammable materials in control box.

coupling of pump during pump operation.

7.3 Safety Precautions in Operating Boiler (Excerpt from page 31-)

Interlock functions disabled when manual combustion circuit is used:

Steam pressure low

Otherwise, equipment may start to

work unexpectedly to cause accidents.

deterioration of impeller or external force, resulting in injury or death.

Remodeling of safety valve may damage boiler body.

offices and ask for instructions.

cause backfire. Use only genuine parts.