23/5099

Averon Engineering Limited

To access information click on relevant DOCUMENT section

INDEX
Introduction
Section A Description
General Arrangement
Section B Operation
Section C Maintenance
Section D Health & Safety
Section E Water Treatment Booklet
Section F Combustion Equipment and Drawings
1. Simplex Distillate Oil Burner
2. Schematic Wiring Diagrams
Section G Boiler Ancillary Equipment
1. Boiler Feed Pump
2. Water Level Controls
3. Safety Valve
4. Stop Valve
5. Pressure Gauge
6. Pressure Control Switch
7. Blowdown Vessel
BIB COCHRAN LIMITED
Newbie Works, Annan, Dumfries & Galloway, Scotland, UK, DG12 5QU
Tel: +44 (0) 1461 202111 Fax: +44 (0) 1461 205511
E-mail: [email protected]

OPERATION AND MAINTENANCE MANUAL

Averon Engineering
Milton of Thainstone
Inverurie
Aberdeenshire
AB51 5NS

BIB COCHRAN

Wee Chieftain
PACKAGE STEAM BOILER

Contract Number: 23/5099

The information in this document is the property of BIB Cochran Limited and may not be copied or
communicated to a further party or used for any purpose other than that for which it is supplied, without the
express written consent of BIB Cochran Limited.

Whilst this information is given in good faith, no warranty or representation is given concerning such
information which must not be taken as establishing any contractual or other commitment binding upon BIB
Cochran Limited, or any of its subsidiary or associated Companies.

© 2002 BIB Cochran Limited

All rights reserved

Weechief Intro/Rev.0-2002
INTRODUCTION
Page 2

INDEX
Introduction
Section A Description
General Arrangement
Section B Operation
Section C Maintenance
Section D Health & Safety
Section E Water Treatment Booklet
Section F Combustion Equipment and Drawings
1. Simplex Distillate Oil Burner
2. Schematic Wiring Diagrams
Section G Boiler Ancillary Equipment
1. Boiler Feed Pump
2. Water Level Controls
3. Safety Valve
4. Stop Valve
5. Pressure Gauge
6. Pressure Control Switch
7. Blowdown Vessel

Weechief Intro/Rev.0-2002
INTRODUCTION
Page 3

In accordance with Section 6 of the Health and Safety at Work Act 1974, we wish to
inform the user that every care, as far as is reasonably practicable, is taken to ensure
that your BIB Cochran boiler is safe and without risk to health when properly used.
You are requested to ensure that the information contained in this manual is brought to
the attention of all personnel involved with the operation and maintenance of the boiler
as required by the Act.

This manual has been prepared to assist personnel responsible for the daily operation
and maintenance of BIB Cochran. Every effort has been made to deal with variations in
equipment normally encountered; however, in complying with client preference in
ancillary equipment selection, some deviations may occur. Reference should, in such
cases, be made to contract documents or to your Regional Service Manager.

While daily routine maintenance should keep your boiler in good working order, expert
inspection and servicing will add considerably to its efficient working life. This service
is available to customers of BIB Cochran Ltd. under the Service Inspection Scheme, or
by contacting your Regional Service Manager. Further benefits can be obtained by
participation in our comprehensive range of Training Courses.

Finally, whilst we endeavour to give the user the fullest possible information in our
manual, our organisation remains at your full disposal should you have any doubts
whatsoever about any aspect relating to the proper use of the boiler.

SAFETY PRECAUTION
In the interests of personnel safety, the WARNING and CAUTION notes
contained in this manual are brought to the attention of the user.

Please note that whilst your BIB Cochran boiler is a packaged unit, the following items
are required for it to operate correctly:

• Boiler foundations
• Feedwater tank and pipework to boiler
• Oil tanks, outflow heaters and pumps (where applicable), fuel lines to
boiler, (oil and dual fuel units)
• Gas supply (gas and dual fuel units)
• Main electric supply to boiler control panel
• Chimney and ducting
• Steam line from boiler to process (not required for hot water boilers)
• Flow and return lines (not required for steam boilers)
• Drain and blowdown pipes
• Safety Valve exhaust pipe and drains
• Blowdown pit or blowdown vessel (not required for hot water boilers).

All these items can be supplied by or arranged through BIB Cochran.

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INTRODUCTION
Page 4

BOILER SPECIFICATIONS

Your Boiler Serial Number is: 23/5099

Maximum Continuous Rating: 2000 kg/hr
Design Saturation Temperature: 188ºc
Working Pressure: 10.34 bar g
Design Pressure: 11.00 bar g
Hydraulic Pressure: 16.50 bar g
Safety Valve Setting: 10.86 bar g
Electrical Supply: 440v 3ph 60hz
Control Circuit: 240v
Design Codes: BS 2790 Class 1
Year of Manufacture: 2010
Drawings Supplied: General Arrangement: V110089 Rev. A
Power & Symbols: VS106201 Sheet 1 Rev. D
Schematic Wiring Diagrams: VS106201 Sheet 2 Rev. E
Junction Box Wiring: VS105100 Rev. A
Boiler Control Panel GA: VSG40010 Rev. A

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INTRODUCTION
Page 5

PRODUCT PROFILE
BIB Cochran Limited are the UK market leader for shell package steam boilers and the
main UK exporter active throughout the World.

The BIB Cochran product line includes a full range of oil and gas fired boilers from
500 kg/hr up to 32,000 kg/hr at pressures up to 25 bar. This range is matched in both
steam boilers, hot water heaters and waste heat recovery boilers. A range of coal fired
boilers from 2,000 kg/hr to 16,000 kg/hr is also available.

To support the product range BIB Cochran have a project management capability for
Turnkey type projects which can involve the supply of Boilers; M & E Services, Civil
Work and After Sales Service.

In addition to the boiler and standard optional extra items, BIB Cochran can also offer a
complete range of boiler associated ancillary equipment including, but not limited to,
the following:

• Pipework Services
Including line fittings, supports and insulation.

• Pressure and Storage Vessels

Complete with fittings, mountings and support structures.

• Water Treatment Plant

Supplied as packaged skid mounted modules.

• Chimney and Flue Gas Ductwork Systems

Provided with lagging and/or cladding and support steelwork.

• Controls and Instrumentation

Total boilerhouse control and energy management systems.

• Electrical Services
Comprising power, lighting and small power cabling.

All ancillary equipment and services are supported by BIB Cochran Engineering,
Project Management and Site Supervision expertise including all planning, scheduling
and site management to meet contractual delivery, construction, commissioning, test
and handover programmes.

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INTRODUCTION
Page 6

BIB COCHRAN CUSTOMER SERVICE

BIB Cochran Limited
Newbie Works
ANNAN
Dumfries & Galloway
Scotland
DG12 5QU

Telephone: +44 (0) 1461 202111

Fax: +44 (0) 1461 205511
E-Mail: [email protected]

Our Spares Department can supply any spare parts which you may need to ensure the
continuity of operation and efficiency of the equipment supplied by BIB Cochran.

Other services are available. For example, we can provide quotations for the upgrading
of older equipment, as well as additional copies of drawings and of this manual.

SAFETY NOTICE

To ensure safe operation we strongly recommend that only genuine BIB

Cochran supplied spare parts are fitted to your plant.

The Boiler Serial Number must be quoted on all orders or enquiries for replacement
parts. The Boiler Serial Number is inscribed on the Boiler nameplate and also hard
stamped onto the boiler manhole door opening ring on top of the boiler. Where possible
the part names should be those used in this Manual. Where there is any doubt regarding
spares selection our Spares Department will be pleased to advise.

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INTRODUCTION
Page 7

SPARES ORGANISATION

To provide a service for our many customers worldwide the Spares Department within
BIB Cochran Ltd. is an important and significant element of our Customer Support
Organisation.

We have an extensive catalogue which lists circa 8000 parts against which adequate
volume of each item are held in stock in our main stores to meet client requirements.

This stock holding is augmented by additional stores facilities located throughout the
UK under the control of our Field Service operation.

We also hold parts in stock of boiler related equipment as supplied by other original
equipment manufacturers involved in the firetube package boiler business.

Where there are requirements for the more unusual type of part which may not be part
of our normal stockholding, we are always in a position to procure and provide items on
short notice with specialist/overnight delivery when required.

As an adjunct to spares sales, the Spares Department also handle other elements of our
business, by dealing with any requirements for conversion work to boilers including the
upgrading of equipment to meet current legislation. Additionally, they will deal with
specialist fabrications, retubing, repair work to boilers, refractory services, reburnering
and can assist clients with requirements for most boiler related equipment or services.

With respect to our export markets, we have an extensive network of agents worldwide,
strategically positioned to provide local assistance.

We regularly export to some 80 countries throughout the world where our products are
widely used and recognised for their compliance with the highest performance and
quality requirements.

For more information please contact Spares Department on:

Telephone: +44 (0) 1461 202111

Fax: +44 (0) 1461 205511
E-Mail: [email protected]

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INTRODUCTION
Page 8

BOILER EQUIPMENT SERVICING

We offer ongoing facilities, and in this regard with highly skilled staff, we are able to
carry out all aspects of maintenance, servicing and testing of coal, oil and gas fired
boilers, our comprehensive service includes:-

• 24 Hour Emergency Call Out • Refractory replacement

Cover

• All aspects of preventative • Recommended spares

maintenance

• Scheduled service contracts • Ex-stock availability of vital spares

(preferential breakdown service)

• Boiler repairs including tube • Performance testing of all combustion

renewal appliances

• Boiler/Burner conversions • Energy conservation systems

• Installations • Boiler cleaning

• Steam or hot water conversions • 5 year and 10 year tests

• Training Courses • Advice and measurement relating to

current legislation (NOx and SOx)

We aim to provide an efficient nationwide service and place our extensive knowledge
and skills at your disposal to ensure optimum operation of your boiler plant.

For more information please contact Customer Support on:

Telephone: +44 (0) 1461 202111

Fax: +44 (0) 1461 205511
E-Mail: [email protected]

Weechief Intro/Rev.0-2002
INTRODUCTION
Page 9

TRAINING COURSES
At BIB Cochran we understand the need for Organisations who have
reliable and efficient operation of your boiler benefited from our training
plant. A poorly operated and maintained include:-
boiler will increase your running costs
significantly. For example, for a medium Honeywell Controls
size boiler, a fall in efficiency of just 1% can
represent more than £1500 extra on your ICI
annual fuel bill.
Glaxo Operations
In addition, emission levels may be
increased, which are not only harmful to the National Power
environment, but may be outside the limits
permitted by legislation, leaving the operator London Underground
liable to prosecution.
BP Energy
Correct operation and regular routine
maintenance is the best way to ensure that United Distiller & Vintners
your boiler plant remains at peak efficiency,
keeping your running costs to a minimum Desmond Brothers

You can achieve this by developing the skills Castrol UK

and awareness of your boilerhouse and plant
maintenance staff through a BIB Cochran AEA Technology
Training Course regardless of make of boiler
and associated equipment. Ministry of Defence

BIB Cochran Limited is uniquely placed to AHS Emstar

offer you a range of Training Courses at
either our Annan Training Centre or at North Staffs Hospital Trust
locally based venues around the United
Kingdom and Ireland via our “roadshow” Babcock Rosyth Defence
programme. Courses provide highly
effective and practical training for boiler Whitbread Breweries
operators, plant maintenance personnel, or
indeed anyone associated with the operation, British Nuclear Fuels Ltd.
maintenance and use of boiler plant.
Aer Rianta - Dublin Airport

We will also be pleased to discuss any specialist training requirements you may
have through tailoring courses specifically for your needs.

For more information please telephone our Customer Training Department on:-

Telephone: +44 (0) 1461 202111

Fax: +44 (0) 1461 205511
E-Mail: [email protected]

Weechief Intro/Rev.0-2002
Product Support Services
Upgrades - Plant Enhancements

• Efficiency Upgrades • Load Control/Boiler Sequencing

• Replacement Burners/Burner Conversions • Emissions Monitoring
• Combustion & Control Upgrades • Economisers
• Remote Monitoring • Heat Recovery

Pressure Part Repair

• Rapid Response • Boiler Re-tube

• NDT Examination • Fully Coded Engineers
• Valve Refurbishment • Manufacturing Resource Support
• Refractory Repairs • Quality Assurance

Service

• Plant Operation • NDT Examination

• Structured Service Contract • Fully Accredited Engineers
• Annual Insurance Inspections • Manufacturing Resource Support
• Preventative Maintenance • Out of Hours Coverage

Spare Parts

• Dedicated Spares Interpreters • All Makes of Components Supplied

• Rapid Delivery Response • UK and Worldwide
• Manufacturers Approved Materials

Training

• CEA Approved Boiler Operative • Bespoke Courses Tailored to your

Accreditation Scheme Specific Site
• Operation & Safety Awareness Courses & • Meet your Health & Safety
Seminars Obligations
• Fully Qualified Trainers • Maintain Optimum Plant Performance

Water Treatment

• Water Softeners • Filters

• Chemical Dosing Pumps • Reverse Osmosis
• Chemicals • On Site Servicing

B I B C O C H R A N : A L I F E T I M E S O L U T I O N REF NO. COC / SUPPORT SERVICE/ 0706

Product Support Services
Upgrades Training

Boiler House Upgrades BIB Cochran can help train customers to operate plant
BIB Cochran can evaluate, recommend, supply and install efficiently, reliably and safely through a series of boiler,
boiler house upgrade packages aimed at prolonging the life combustion and ancillary plant operation and maintenance
of the boiler, improving reliability and ensuring compliance training courses based either in a classroom environment at
to the latest legislation. These can include replacement our Annan facility or at customer premises and hotel venues
burners, or burner conversions, level controls, pumps, worldwide.
valves, control panels, automatic blowdown systems, hot
well tanks and water treatment plants. BIB Cochran are one of a limited number of corporate bodies
accredited by the Combustion Engineering Association and
Energy Efficiency Upgrades can now offer a Boiler Operative Accreditation Scheme
BIB Cochran can evaluate, recommend, supply and install (BOAS) which gives your staff a formal qualification. Please
complete energy efficiency upgrade packages for existing contact our Training Department for details.
boilers and ancillary equipment. Energy efficiency packages
comply with the latest guidelines and legislation and are Repair
aimed at improving the overall efficiency of the plant, by
reducing the fuel and electrical consumption, whilst also BIB Cochran provide a comprehensive and rapid response
reducing emissions and maintenance costs. Typical upgrade pressure part repair service to extend the operational life of
packages can include combustion controls, replacement boilers and other pressure vessels, with full liaison directly
burners, economisers, variable speed motor drives and with insurance companies when required. Full
automatic monitoring systems. manufacturing facility support is available to help undertake
and complete all types of pressure part repair work, which
Service typically covers tubes, furnaces and other pressure parts.
Should an extended plant outage be necessary, hire boilers
BIB Cochran support boilers, combustion equipment and can be provided and installed as required.
boiler house ancillaries throughout their working lives to
help ensure efficient and reliable operation. The support Water Treatment
provided includes service contracts, insurance survey
preparation and breakdown response through to complete BIB Cochran provide a water treatment programme which
energy management contracts where BIB Cochran operate, should be incorporated to the daily operation and
monitor and maintain the plant in its entirety. All maintenance regime of the boiler to maintain performance
operational work is planned and co-ordinated via a central and integrity. The solution to water treatment is to select
Product Support Desk, providing UK customers with a single the appropriate combination of filters, water softeners,
point of contact. chemical dosing techniques and reverse osmosis.

Water softeners reduce the hardness of the water which

Spare Parts
combined with the correct technical dosing regime maintains
the optimum water conditions for safe and efficient
BIB Cochran provide a rapid spare part replacement service
operation. It is our experience that plants that utilise reverse
for a wide variety of boilers, combustion equipment and
osmosis can achieve payback in 12-18 months from
ancillary equipment. Stocks are kept at stores in our Annan
installation, even earlier for steam systems operating with
facility, in UK regional stores and throughout our global
low condensate return.
network of agents, providing in-country support for overseas
customers.

BIB Cochran Limited BIB Cochran Limited

Newbie Works, Annan, First Floor, 105 Sadler Road
Dumfries & Galloway, Doddington Road
Scotland, UK DG12 5QU Lincoln, UK LN6 3RS
A BIB Group Plc Company Tel: +44 (0) 1461 202111
Fax: +44(0) 1461 205511
Whilstthisinformationisgiveningoodfaithnowarrantyorrepresentationisgivenconcerningsuch
informationwhichmustnotbetakenasestablishinganycontractualorothercommitmentbindingupon Email: [email protected]
BIBCochranLimitedoranyofitssubsidiaryassociatedcompanies. www.bibcochran.com
Boiler House Training
Summary of Topics Covered:

• Boiler Construction and

Maintenance Boiler Controls

• Boiler Feed Water and Treatment

• Combustion Theory
• Burner Operation and
Maintenance
SAFED Guidelines for Safe Boiler Plant Operation
• Boiler and Burner Fault
“All personnel involved in the operation of a boiler house Identification and
should receive appropriate documented training to ensure they Recommendations
have sufficient knowledge to undertake their duties in a safe
manner.... Training should be viewed as an ongoing process.... • Boiler House Health & Safety
Generally personnel should receive re-training every 2 years (with reference to the
and after any significant modifications to the boiler or steam appropriate legislation)
system.... proof of training may be required to be viewed by
enforcing authorities”. • Action in Emergencies
BIB Cochran help to allow you to meet these guidelines in a cost effective way.
Safety, Efficiency and Security of Operations Organisations who have
At BIB Cochran we understand the need for safe, efficient and reliable operation of your benefited from our training:
boiler plant. A poorly operated and maintained boiler will increase your running costs
significantly. For example in a medium size boiler, a drop in efficiency of just 1% can add • GlaxoSmithKline
several thousand pounds to your annual fuel bill. • BP Energy
In addition, emission levels may be increased, which are not only harmful to the • Guinness
environment, but may be outside the limits permitted by legislation, leaving the boiler
owner liable to prosecution. • Castrol UK
Correct operation and regular routine maintenance is the best way to ensure that your • Diageo
boiler plant remains at peak efficiency, keeping your running costs to a minimum. • Ministry of Defence
You can achieve this by developing the skills and awareness of your boiler house and • Dalkia Utilities Services
plant operation and maintenance staff through a BIB Cochran Training Course regardless
of make of boiler and associated equipment. BIB Cochran is uniquely placed to offer • British Nuclear Fuels Limited
you a range of training courses at our Annan Training Centre or at locally based venues • Coca Cola
around the UK and Ireland via our ongoing seminar programme. Courses provide
efficient and practical training for boiler operators, plant maintenance personnel, or • Hilton Hotels
indeed anyone associated with the safe operation and maintenance of boiler plant. • Foster Wheeler
We will be pleased to discuss any specialist training requirements you may have and to • Unilever
tailor courses specifically for your needs.
• British Aerospace
• Shell
• Liverpool Royal Infirmary

B I B C O C H R A N : A L I F E T I M E S O L U T I O N REF NO. COC / PROD-SUP3 / 1008

Boiler House Training
Boiler Operation & Safety Awareness Course (BOSA)
A 1-day, on-site course designed to provide a basic understanding
of the everyday operation of boiler plant, covering essential daily
and weekly routines, boiler fittings, water treatment, combustion,
emergencies and Health & Safety issues.

Boiler Operation and Maintenance Course (BOM)

This course is designed primarily for Boiler Operators, Maintenance
Staff, Plant Technicians and Engineers. This is a 2-day intensive
course designed to provide a thorough grounding in the everyday
operation and maintenance of boilers, burners and boiler auxiliary
equipment. The course also covers all relevant Health and Safety
issues, fault identification and emergency situations. The ultimate
aim of the course is to make sure that the plant can be operated
safely, efficiently and economically.

Health & Safety in the Boiler House Course (HSB)

A 1-day, on-site course designed to cover all health & safety
regulations within your boiler house:- Noise at Work, Asbestos,
Manual Handling, Working at height, Lone Working, COSHH,
Safety Data Sheets and Confined Space Regulations. We also cover Course Notes and Certification
Electricity at Work, Risk Assessments and Method Statements as part A comprehensive pack of course notes are provided to each
of the course. student at the end of each course along with a certificate of
attendance.
Boiler Operation & Safety Awareness (BOSA) Seminar
This is a 1-day seminar designed to provide a basic understanding Specially Tailored Courses
of the everyday operation of boiler plant, covering essential daily If you have specific training requirements or want courses tailored
and weekly routines, boiler fittings, water treatment, combustion, to include specialist topics, please contact us - we can arrange
emergencies and Health & Safety Issues. Held at monthly venues this for you.
throughout the UK.

For further information on

any of our training courses,
please contact our Training Department.

BIB Cochran Limited

Newbie Works, Annan,
Dumfries & Galloway,
Scotland, UK DG12 5QU

A BIB Group Plc Company Tel: +44 (0) 1461 202111

Fax: +44 (0) 1461 205511
Whilst this information is given in good faith no warranty or representation is given concerning such
Email: [email protected]
information which must not be taken as establishing any contractual or other commitment binding upon BIB
Cochran Limited or any of its subsidiary associated companies. www.bibcochran.com
Boiler Operative Accreditation Scheme
In association with Combustion Engineering Association (CEA) GASTEC and Carbon Trust

Benefits:

• Increased safety of operatives

• Qualified personnel

• Increased operational efficiency

• Operate within current legislation

and best practice

Why Attend a BIB Cochran BOAS Course?:

• Reduce downtime

At BIB Cochran we understand the need for safe, efficient and reliable operation of your boiler
• Helps comply with current and
future government efficiency
plant. A poorly operated and maintained boiler will increase your running costs significantly. In
regulations
addition, emission levels may be increased which are not only harmful to the environment, but
may be outside the levels permitted by legislation, leaving the boiler owner liable for prosecution. • Can lower insurance premiums
A correct and regular routine is the best way to ensure that your boiler plant remains at peak
• Greater workforce morale
efficiency, keeping your costs at a minimum. You can help to achieve this by developing the skills
and awareness of your boiler house staff through a BIB Cochran Training Course regardless of
Objectives:
boiler and associated equipment.

BIB Cochran are one of a limited number of corporate bodies accredited by the Combustion • To provide delegates with a
Engineering Association to administer the BOAS course, which gives your staff a formal knowledge of current legislation
qualification (Cert IBO). and environmental requirements
Operating your boiler plant with qualified operatives also demonstrates an ongoing commitment • To understand the need for safe
to your obligations under Health and Safety Legislation. operational requirements and
how this influences personal
performance and plant output
Course Design:

The course is designed to allow delegates practical hands on experience and team exercises. Qualifications:
Each delegate is supplied with handouts, including technical publications to support the course,
giving additional reading beyond classroom lectures. • Delegates who pass will be
awarded the qualification of
There will be four days of classroom based lectures mixed with hands on experience and practical
case studies followed by a one day written and oral examination covering all aspects of the Certified Industrial Boiler Operative
preceding days topics. An independent assessor from CEA will assess the candidates at the end with the designated Cert IBO
of the week.
• The qualification is valid for five
Courses are scheduled to run on a monthly basis at our Annan Training Centre. years.

• Refresher courses are available

upon request for delegates
throughout the five year period

B I B C O C H R A N : A L I F E T I M E S O L U T I O N REF NO. COC / SUPPORT SERVICE/ 1008

Boiler Operative Accreditation Scheme
BOAS Schedule
Basic Heat & Transfer Concepts Draught & Combustion
Terms Elementary Principals of Combustion

LUNCH
Day 1 Conversion of Water into Steam/Units Air
Heat Transfer Combustion Products
Deposits Natural, Induced & Forced Draught Systems

Feed Water Control & Instrumentation

Feed Water for Different Boilers Boiler Instrumentation

LUNCH
Day 2 Simple Principles of Water Treatment Water Testing Instruments
Blowdown Systems Pressure & Level Switches
Carry-Over Controllers
Discharge of Effluent Works Tour

Energy Efficiency & Environment

Terms & Methods
Safety & Legal Requirements Portable Instruments & Installed Instruments
Basic Need for Continued Awareness Steam Tables & Energy Efficiency

LUNCH
Day 3 Principal Legislation
Legal Requirement ENVIRONMENT
Safety Rules & Practices Legislation
Good & Bad Practices Emissions to Air
Other Emissions

Boilers and Auxiliaries Operation & Fuel Concepts

Principal Types of Boilers Special Precautions
Construction Features Bringing on Load & On-load Operations
Feed Systems Abnormal Conditions
Day 4 Fittings & Mountings LUNCH Routine Checking
Methods & Pressurisation Preparation & use of Log Sheets

OPERATION FUEL CONCEPTS

Preparation Fuels, Terms
Raising Pressure Storage, Safety Features

Written Assessment
LUNCH

Day 5 Written Assessment

- All sections - All sections

The BIB Cochran Training Department will be pleased to discuss any HEALTH AND SAFETY IN THE BOILERHOUSE COURSE (HSB)
specialist training requirements you may have through tailoring courses A 1-day, on-site course designed to cover all health and safety
specifically for your needs. However the following courses are offered regulations within your Boilerhouse:- Noise at Work, Asbestos,
as standard:- Manual Handling, Working at Height, Lone Working, COSHH,
Safety Data Sheets and Confined Space Regulations. We also cover
BOILER OPERATION & SAFETY AWARENESS COURSE (BOSA)
Electricity at Work, Risk Assessments and Method Statements as part
A 1-day, on-site course designed to provide a basic understanding
of the course.
of the everyday operation of boiler plant, covering essential daily
and weekly routines, boiler fittings, water treatment, combustion,
BOILER OPERATION & SAFETY AWARENESS (BOSA) SEMINAR
emergencies and Health & Safety issues.
This is a 1-day seminar designed to provide a basic understanding
of the everyday operation of boiler plant, covering essential daily
BOILER OPERATION & MAINTENANCE COURSE (BOM)
and weekly routines, boiler fittings, water treatment, combustion,
This is a 2-day intensive course designed to provide boiler operators,
emergencies and Health and Safety Issues. Held at monthly venues
maintenance staff, plant technicians and engineers a thorough
throughout the UK.
grounding in the everyday operation and maintenance of boilers,
burners and boiler auxiliary equipment. The course also covers the
relevant Health and Safety issues, fault identification and emergency
situations. The ultimate aim of the course is to make sure that the
plant can be operated safely, efficiently and economically.

For further information on BIB Cochran Limited

any of our training courses, Newbie Works, Annan,
please contact our Training Department. Dumfries & Galloway,
Scotland, UK DG12 5QU
Tel: +44 (0) 1461 202111
Fax: +44 (0) 1461 205511
Whilst this information is given in good faith no warranty or representation is given concerning such
information which must not be taken as establishing any contractual or other commitment binding upon BIB Email: [email protected]
Cochran Limited or any of its subsidiary associated companies. www.bibcochran.com
SECTION A
DESCRIPTION
Page 1

1. BOILER......................................................................................................... 2
2. GENERAL OPERATION OF BOILER.................................................... 2
3. MOUNTINGS AND FITTINGS ................................................................. 4
BURNER ................................................................................................................................ 4
CONTROL PANEL ............................................................................................................... 4
CONTROL PANEL FASCIA ................................................................................................ 5
BOILER STOP VALVE ........................................................................................................ 6
BOILER SAFETY VALVE ................................................................................................... 7
COMBINED FEED CHECK AND SHUT-OFF VALVE ..................................................... 7
BOILER BLOWDOWN VALVE .......................................................................................... 7
PRESSURE CONTROLS ...................................................................................................... 7
PRESSURE LIMIT CONTROL ........................................................................................ 7
PRESSURE CONTROLLER ............................................................................................. 8
WATER LEVEL CONTROLS .............................................................................................. 8
FUNCTIONS OF OVER-RIDING CONTROL................................................................. 8
FUNCTIONS OF DUAL CONTROL................................................................................ 8
WATER FEED PUMP ........................................................................................................... 9
WATER GAUGE ASSEMBLIES.......................................................................................... 9
REFRACTORIES................................................................................................................... 9
ADDITIONAL FITTINGS..................................................................................................... 9
4. FIGURE A-1 : TYPICAL BOILER ARRANGEMENT ....................... 11
5. FIGURE A-2 : LAYOUT OF BOILER REFRACTORIES................. 12

weechiefA.doc
SECTION A
DESCRIPTION
Page 2

1. BOILER

The BIB COCHRAN Wee Chieftain Mark 6 is a package unit covering a range of
evaporations. The boiler is a 3-pass wet back design. The first pass is the furnace and
the second and third passes are two nests of small bore smoke tubes. All plain tubes are
expanded except for boilers with working pressure of 13.79 bar (200 lb/in2) and over,
when the second pass tubes are expanded and seal welded into the reversal chamber.

The required number of stay tubes and stay bars are fitted in all boilers. All stay tubes
are welded into the tube plates and reversal chamber. Stay bars are welded into the tube
plates. The flue gas outlet is normally positioned vertically on the rear casing.

Internal access is through an elliptical manhole with a removable door, which is

provided on top of the boiler. A muddoor is fitted to each tube plate. Access to the rear
chamber is achieved by removing the side doors of the rear casing, whilst access to the
front chamber is provided by opening a hinged door. All smoke tubes are then exposed
for cleaning. Access to the furnace is provided by a bolted, refractory lined rear door.

The boiler is of welded construction throughout and is designed to British Standard

Specification 2790 and AOTC Rules. It is X-rayed as required for Class 1 Fusion
Welded Pressure Vessels. The shell is insulated with high quality insulation and in turn
is completely encased with sheeting to provide a clean, easily maintained finish.

The boiler is suitable for either oil or gas firing and can be fitted with oil, gas or dual
fuel burners.

2. GENERAL OPERATION OF BOILER

NOTE
Numbers in parentheses in the text refer to items shown on Figure A-1.

The boiler is supplied with water by a feed pump (1).

Water enters the boiler through a feed check valve (2). When the water reaches normal
water level, which is approximately the middle of the water gauge glasses (4), the feed
pump is stopped by the dual control (5).

The burner (6) is bolted to the hinged front door (7). Air required for combustion is
provided by a forced draught fan which is integral with the burner unit.

The furnace receives radiant heat from the flame and the hot gases from the flame give
up heat to the tubes in the second pass as they travel to the front chamber. Gases turn in
the front chamber and give up more heat to the tubes in the third pass as they travel to
the rear chamber. The gases leave the boiler by the chimney (8) at the top of the rear
chamber.

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• Please refer to Diagram Figure A-1 : Typical Boiler Arrangement shown on Page
A-11.

As the steam pressure rises, the pressure in the boiler is shown by the pressure gauge
(9). When the pressure is sufficiently high, the main stop valve (10) can be opened to
allow steam to pass to the process or heating system.

When steam leaves the boiler, the water level will drop until it reaches a point
approximately 12.5 mm (½”) below the normal level. The dual control will start the
feed pump and more water will be fed into the boiler.

Two pressure switches are fitted to the boiler, one acts as a pressure limit control (11),
the other is a pressure controller (12). The pressure controller with be a high/low
pressurestat in the case of high/low burners and a modulating pressuretrol in the case of
modulating burners, which controls the firing rate of the burner.

When the boiler pressure reaches the maximum required, the limit pressurestat (11)
shuts down the burner. The burner will restart automatically when the pressure falls to
a preset point below the maximum.

Should the limit pressurestat fail to stop the burner, the safety valve (13) will lift the
excess pressure will escape to atmosphere, thus preventing any further rise in boiler
pressure.

CAUTION
The setting of the safety valve is checked by the valve supplier prior to despatch.
If necessary the valve should be adjusted during commissioning. The set pressure
should not be altered except by a suitably qualified person, who is also able to
fully assess the consequences of carrying out such an alteration.

The safety valve is provided with easing gear for test purposes and supplied with a
padlock to prevent unauthorised interference. The key should be retained in a secure
place under the supervision of a responsible person.

A steam accumulation test at the maximum evaporative capacity, with the stop valve
closed, should be performed in the presence of the inspecting authority before the boiler
is put into normal operation.

If for any reason water is not supplied to the boiler and the water level falls to a point
approximately 50 mm (2”) below the normal level, the dual control will stop the burner
and activate the low water alarm. Provided the water level is restored before reaching
the extra low (lowest) water level, the alarm will stop and the burner will restart
automatically.

If, however, the water level continues to fall unit it reaches a point approximately 75
mm (3”) below the normal level, the over-riding control (14) will activate the extra low
(lowest) water alarm, rendering the burner in a lock-out condition. The burner will not
start until the normal water level has been restored and the reset switch has been
operated to cancel the lock-out condition.

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If it is found necessary to let water out of the boiler, this can be done by opening the
blowdown valve at the rear of the boiler.

3. MOUNTINGS AND FITTINGS

BURNER

Your BIB COCHRAN Wee Chieftain Steam Boiler is normally fitted with either BIB
COCHRAN Simplex High/Low Pressure Jet Burner, a BIB COCHRAN Triplex
High/Mid/Low Pressure Jet Burner or the BIB COCHRAN Split Stream
Modulating Pressure Jet Burner. A description of the burner fitted to your BIB
COCHRAN boiler can be found in Section B of this manual.

CONTROL PANEL

The standard Wee Chieftain is supplied with all external electrical components pre-
wired to a control panel (15) which is normally mounted on the side of the boiler.
Reference should also be made to Section B of this manual.

Additional features may have been specified by the client, e.g. modulating or sealing
dampers and therefore the final electrical connections must be made at site. For details
of these, refer to the particular boiler wiring diagram.

The client is normally required to supply and fit a 3 phase 4 wire supply to the isolator
within the control panel, however the boiler may have been supplied suitable for other
electrical configurations. The panel also contains the following items:-

Sequence Timer
For regulation and flame supervision of the burner.

Starters
For forced draught fan/oil pump motor and feed pump motor.

Fuses, Relays and Switches

For control functions

Indicator Lights/Alarms
For normal and fault conditions

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CONTROL PANEL FASCIA

A typical control panel fascia (16) on the BIB COCHRAN Wee Chieftain Steam
Boiler will contain the following lights and switches, dependent on the rating of the
boiler and type of burner:

Normal firing light

This is illuminated when normal firing conditions exist.

Lock-out light
This is illuminated when flame failure or second low water conditions have occurred.
On some boiler ratings the lockout light also acts as a RESET pushbutton. The lamp
when pressed will reset the control panel after lockout.

Low water light

This is illuminated when the water level drops to the first low water level. An alarm
will sound and the burner will shut-down. The burner will restart automatically on
restoration of the correct water level.

Extra low water light

This is illuminated if the water level falls to the second low water level. Both low water
lights would be illuminated, an alarm is sounded and the burner proceeds to lockout.
The burner will require to be manually reset after the water level is restored.

Mute alarm/run switch

This is a two position switch. During normal operation this switch would remain in the
RUN position, only turning to MUTE ALARM to silence the alarm.

Fault switch
This is a spring loaded alarm switch which is fitted to some boilers as an alternative to
the Mute alarm/run switch and the press-to-reset lockout light. This switch performs
the same functions, i.e. stopping the alarm bell when rotated through 30° anti-
clockwise, or will reset the control panel after lockout when rotated through 30°C
clockwise. It will always return to the vertical position immediately after rotation.

Feed Pump Switch

The water feed pump switch has three positions, HAND/OFF/AUTO. When placed in
the HAND position, it will keep the pump running continuously. When placed in the
OFF position, it will stop the pump running. When placed in the AUTO position, it
allows the pump to start and stop under the control of the dual control.

Burner Switch (High/Low Burners only)

This has three positions, OFF/LOW/AUTO. When placed in the OFF position, the
burner motor will not run. When placed in the LOW position, the burner will only

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operate on low fire. When placed in the AUTO position, the firing rate of the burner
will be controlled by the steam load demand.

NOTE
In either the LOW or AUTO position, the burner will start and stop under the
control of the pressure limit stat.

Burner On/Off Switch (Modulating Burners only)

When this switch is placed in the OFF position, the burner will not fire. In the ON
position, the burner firing sequence will be initiated.

Modulation Hand/Auto Switch (Modulating Burners only)

When placed in the HAND position, any desired rate of firing can be obtained by
manual operation of the hand potentiometer. In the AUTO position, the burner will
modulate automatically to meet load demands.

Firing Rate Hand Potentiometer (Modulating Burners only)

This item is only operational when the hand/auto modulation switch is in the HAND
position. The dial is rotated to increase or decrease the firing rate as required.

BOILER STOP VALVE

The boiler stop valve (10) is fitted as an isolating valve between the boiler shell and the
pipework to the process or heating units. Screw lift stop valves should never be used to
control or throttle the steam flow as erosion of the disc and seat will result.

Valves are designed for specific duties and conditions of service. It is important that a
valve is not subjected to conditions outwith the design specification.

NOTE
Steam is compressible. A reduction of steam pressure results in an increase in
steam volume. Therefore a valve designed to pass a weight of steam at a pressure
of say 17 bar (246 psi) can only pass a small part of this weight at 5 bar (72 psi),
due to the increased volume of steam.

The valves used on steam boilers are designed for specific pressures and temperatures
and to meet the requirements of the Factories Act and British Standards.

When two or more boilers are connected to a common steam main, each boiler must be
fitted with a screw lift stop valve and a screw lift stop and check valve, capable of being
locked in the closed position. Alternatively, a screw lift stop valve capable of being
locked in the closed position and a separate check valve may be fitted. This
arrangement of valves is necessary to comply with the Factories Act, which requires all

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boiler valves, including the stop valve, to be checked periodically. Therefore it must be
possible to completely isolate the boiler and its stop valve from the rest of the plant.

It is recommended that the boiler stop valve be closed each time the boiler is shut down
at the end of each working day or at weekends. This will reduce the strains imposed by
the variations of pressure and temperature and increase the overall efficiency.

BOILER SAFETY VALVE

The boiler safety valve (13) ensures that the boiler cannot build up excessive steam
pressure, should the boiler limit control fail. The type of safety valve fitted to your BIB
COCHRAN Wee Chieftain Steam Boiler is defined by the British Standards as a high
lift type.

The safety valve settings have been adjusted prior to the boiler leaving our factory. A
plate on the safety valve specifies the operating conditions for which the valve was
supplied. Once set, the valve setting must not be tampered with. To prevent this, the
padlock keys should be kept in a safe place under the supervision of a responsible
person.

COMBINED FEED CHECK AND SHUT-OFF VALVE

The combined feed check and shut-off valve assembly is fitted between the water feed
pump (1) and the boiler shell. The assembly comprises of a right-angle stop valve (2)
and a spring-loaded non-return valve (3). When the feed pump is working, the non-
return valve is opened by the flow of feed water. When the water flow stops or a back
pressure is produced, the spring-loaded valve automatically closes. This valve will also
prevent flooding of the boiler, when the boiler is shut-down under pressure and allowed
to cool.

BOILER BLOWDOWN VALVE

The boiler blowdown valve (17) is fitted to the lowest part of the boiler shell. The valve
is used for blowing down the boiler while it is under steam pressure to remove
suspended solid matter from the boiler. Other uses are the draining of the cool boiler
and maintaining the correct water level when starting the boiler from cold.

Blowdown valves are fitted with an operating key which can only be removed when the valve is
in the closed position. This device is a safety lock which must not be interfered with.
PRESSURE CONTROLS

PRESSURE LIMIT CONTROL

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Your BIB COCHRAN Wee Chieftain Steam Boiler is fitted with a pressure limit
control (11). This control breaks and makes automatically as the pressure rises and
falls.

When the boiler pressure reaches the maximum pressure allowed the limit pressurestat
shuts down the burner. When the boiler pressure falls to a preset point below the
maximum pressure allowed, the limit pressurestat will cause the burner to restart
automatically.

NOTE
It is recommended that where possible the differential pressure between cut-in
and cut-out should be kept to less than 20% of the normal operating pressure.

In the unlikely event of the limit pressurestat failing to shut-down the burner, the boiler
safety valve will lift and the excess pressure will escape to atmosphere, thus preventing
any further rise in boiler pressure.

PRESSURE CONTROLLER

Boilers can be fitted with either a controlling high/low pressurestat or a modulating

pressuretrol (12). The controlling high/low pressurestat controls the firing rate of the
burner from high to low fire. The modulating pressuretrol measures variations in the
boiler pressure, which proportionately changes the position of the modulating motor
controlling the burner, to increase or decrease the quantity of fuel and air to meet load
demands.

WATER LEVEL CONTROLS

Your BIB COCHRAN Wee Chieftain Steam Boiler is fitted with boiler water level
controls which are mounted directly onto the boiler shell.

Two controls are fitted to the boiler. One (5) operates the water feed pump and locks
out the burner at the first low water level. The second (14) control operates as an
independent over-riding control, which activates the extra low (lowest) water alarm,
rendering the burner in a lock-out condition.

FUNCTIONS OF OVER-RIDING CONTROL

a) Activates the extra low (lowest) water level alarm.

b) Renders the burner in a lock-out condition.
c) Optional high water alarm can be fitted.

FUNCTIONS OF DUAL CONTROL

a) Operates feed pump on/off.
b) Activates the low water alarm.

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c) Shuts burner down on first low water.

WATER FEED PUMP

The water feed pump (1) supplies the boiler with water. When the feed pump is
operating normally under automatic control, it will be switched ON or OFF according to
the signal given by the dual control.

WATER GAUGE ASSEMBLIES

The water gauge assemblies (4) provide a visual indication of the level of the water
within the boiler.

CAUTION
At no time when the boiler is underpressure should the water gauge protection
glasses be removed.

The water gauge assemblies should be blown down daily or every shift. Regular checks
on the integrity of the assemblies is recommended.
REFRACTORIES

NOTE
The location of the refractories is shown on Figure A-2.

During the normal inspection period careful attention should be given to the condition
of these refractories and if any deterioration is apparent, repairs should be undertaken
immediately.

Should it eventually become necessary to renew these refractories, replacements can be

supplied. We would recommend the user to contact BIB COCHRAN LTD. for advice
and assistance, where arrangements can be made for any necessary repairs or renewal
work to be carried out by our own qualified tradesmen.

• Please refer to Diagram Figure A-2 : Layout of Boiler Refractories shown on

Page A-12.

ADDITIONAL FITTINGS

A vent cock (18) and point for the inspector’s test gauge is fitted in the copper piping to
the pressure gauge. The cock is provided to vent the air from the boiler when filling
and to relieve the vacuum created by condensation following a prolonged shut down.

A standpipe for a salinometer cock (19) is provided on the boiler.

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A low fire hold stat may be fitted for boilers operating on time clocks. The stat will
prevent the burner going to high fire until the boiler has reached a preset pressure,
normally approximately 2 bar (30 lb/in2).

A feed water inlet strainer should be fitted on the suction line to the water feed pump.

An anti-suction valve may be fitted to prevent over filling of the boiler, by gravity from
a high condensate tank or by suction following the creation of a vacuum in the boiler.
BIB COCHRAN LTD. should be consulted before this valve is fitted, because it will
increase the pressure which the feed pump must overcome and it may affect the
performance of the feed pump.

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4. FIGURE A-1 : TYPICAL BOILER ARRANGEMENT

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5. FIGURE A-2 : LAYOUT OF BOILER REFRACTORIES

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BOILER HEATING RATE

The following notes should be read before operating the boiler:
1) During a cold start operation, the burner should be held at low fire and fired
intermittently. This is intended to prevent excessive boiler stressing and reduce
stratification of the boiler water, which can lead to differential expansion of the boiler.
2) As the water temperature rises, its subsequent expansion will tend towards high water
condition. Water should be removed from the boiler by opening the blowdown valve.
This will help to promote internal circulation and prevent stratification.
When starting up from a prolonged shut down, the boiler should be brought up to temperature
under hand control. When warming up a cold boiler, two conflicting criteria arise:
1) The temperature rise should be slow, in order to reduce expansion stresses in the
boiler.
2) The temperature rise should be rapid in order to decrease the opportunity for acid
corrosion of the boiler and pipework.
The temperature rise should not exceed 30ºC per hour, or such lower figure as is specified by
the Commissioning Engineer as acceptable for the system. The burner should be fired
intermittently, preferably at the lowest firing rate, in order to maintain a steady increase in
temperature.
When the boiler pressure reaches 2 bar g the burner can be released to modulate automatically
according to load. For hot water boilers, the water temperature should reach the maximum
operating temperature or 120ºC, whichever is the lower, before the burner can be released to
modulate automatically according to load.
Acid corrosion is most frequently caused by the presence of dissolved oxygen in the water and
accelerated by the presence of carbon dioxide. The solubility's of both gases decreases as the
temperature rises, thus the opportunity for acid corrosion will decrease as the temperature is
raised. When the boiler water temperature reaches about 65ºC, the effects of acid corrosion
should be minimal.
As the boiler warms up, the water level will rise due to expansion. The level should be
restored to normal by opening the blowdown/drain valve. This will also remove colder water
from the bottom of the boiler and help to maintain an even distribution of heat.
CAUTION
The boiler blowdown/drain valve should be opened slowly to avoid shock loading on
the blowdown/drainage system.

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1. INTRODUCTION ........................................................................................ 2
2. GENERAL NOTES ON VALVE OPERATION ...................................... 2
CRACKING OPEN A VALVE.............................................................................................. 2
WATER HAMMER ............................................................................................................... 2
WIRE DRAWING.................................................................................................................. 2
3. PRELIMINARY PROCEDURE ................................................................ 3
4. FILLING THE BOILER WITH WATER ................................................ 3
5. PREPARING THE BURNER..................................................................... 5
6. GAS AND DUAL FUEL FIRED BOILERS.............................................. 5
7. STARTING-UP FROM COLD................................................................... 5
8. RAISING STEAM FROM A WARM BOILER ....................................... 8
9. PUTTING THE BOILER ON FACTORY LOAD ................................... 8
10. SHUTTING DOWN THE BOILER........................................................... 8
SHORT PERIOD SHUT DOWN........................................................................................... 8
EXTENDED PERIOD SHUT DOWN................................................................................... 9
11. EMERGENCY OPERATION .................................................................... 9
PRESSURE PART ............................................................................................................... 10
FUEL SYSTEMS ................................................................................................................. 10
FIRE...................................................................................................................................... 11
ELECTRICAL POWER SUPPLY ....................................................................................... 11

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1. INTRODUCTION
As far as is reasonably practicable, every care has been taken to ensure that the BIB
COCHRAN Wee Chieftain Steam Boiler is safe and without risk to health when
properly used. It is stressed that the boiler should only be operated by competent
personnel.

2. GENERAL NOTES ON VALVE OPERATION

Before operating a valve, check the valve position indicator and the direction of
operation of the handwheel. Always ensure that the pipework system is operational. If
repairs are being carried out, locks, danger notices and warnings should be posted to
prevent inadvertent operation of plant under repair.
Valves should be operated slowly and should never be forced to the limit in either
direction. Shutting a cold valve hard down may lead to its seizure when temperatures in
the adjacent pipework are later increased.
Never use excessive force to open or close a valve. The use of wheel spanners should
be discouraged as valves are provided with hand wheels large enough to give a turning
force sufficient to open or close the valve. If a valve is so tight that it cannot be fully
operated by the hand wheel alone, it is defective and the application of more force may
make matters worse.
On steam lines always open the drains and crack open the valves to rid the system and
valves of water prior to starting-up. On water lines, always vent any trapped air by
opening the air cocks or by cracking open bypass valves or main valves.

CRACKING OPEN A VALVE

This means opening the valve slowly but positively. Cracking open a valve allows the
pipework and valves to warm up before the system is subjected to full pressure and
temperature. Failure to drain and warm through the system in the correct manner can
produce water hammer.

WATER HAMMER
This is an alarming and damaging condition which sounds similar to a series of loud
reports like hammer blows within the pipeline. These blows are caused by wave motion
set up in the water lying in the line when steam or hot water is admitted too quickly. In
some cases, the hammering of the water waves can cause damage to valves, fittings and
pipework.

WIRE DRAWING
If a valve is not shut properly or is left cracked open for a long time, the valve seat may
become scored which is described as wire drawing.
Wire drawing takes place when steam, particularly wet steam, expands through a valve
which is partially open for prolonged periods. The scouring action of the rapidly

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moving expanding steam erodes the valve faces. The eroded grooves look as if they had
been produced by drawing a wire through the valve and over the valve faces.

3. PRELIMINARY PROCEDURE
The initial commissioning of the boiler is generally carried out by BIB COCHRAN
Engineers.
Commissioning must only be undertaken by competent personnel and the following
procedure is recommended if commissioning is carried out by personnel other than our
own qualified engineers.
WARNING
It is mandatory that gas and dual fuel boilers are only commissioned by
A.C.O.P.S. registered personnel.
Check that all mountings and front and rear access chambers are properly tightened and
have not worked loose in transit.
Check all electrical connections are tight and have not worked loose in transit.
Remove plug from inspector’s test point, which will allow air to be expelled. Open
cock to pressure gauge and pressure switches.
Close main stop valve.
Ensure the steam and water cocks on gauge glasses are open and the drain valves are
closed. Where boilers have been fitted with sequencing blowdown valves on the water
level controls, make sure these have been rotated fully anti-clockwise.
Check blowdown valve is closed.
Crack open feed check valve and open water supply from tank or softener but refer to
procedure for “Filling the Boiler with Water” (Page B-3).

CAUTION
No valve with a handwheel should be either fully opened or fully
closed, i.e. the handwheel should be turned backwards or forwards
half a turn as applicable to prevent seizure.

4. FILLING THE BOILER WITH WATER

CAUTION
The boiler feed pump must never be run against a closed valve.
It is permissible, when using the boiler feed pump to fill the boiler initially, to only
crack open the boiler feed check valve in order to create a head resistance for the pump
to operate against.
When boiler is filled to the normal water level the Control Switch should be returned to
the Off or Auto position. The Feed Check Valve must be fully opened prior to the
boiler being put to use.

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There are alternative methods of filling the boiler:

• Method A - Using the Feed Pump
• Method B - Using a Hose
Ensure that the system water is treated in accordance with your Water Treatment
supplier’s instructions.

If Method A is preferred, the following procedure should be adopted:

1) Remove pre-heater fuses from control panel. (Residual oils only).
2) Set burner switch Off.
3) Set pump switch Off. Ensure water supply is on.
CAUTION
If the pump is operated without water for even a few seconds, it will be damaged.

4) Prime water feed pump and check direction of rotation of feed pump.
5) When using the feed pump to fill the boiler, it is permissible initially to only crack
open the boiler feed check valve in order to create a head resistance for the pump to
operate against.
6) Set pump switch to Auto and pump will run. While the pump is running, the
lockout lamps and the first and second low water lamps will be illuminated and the
alarm will ring. The alarm can be muted by operating the spring loaded fault
switch to the mute position or the Mute/Run switch to mute, dependent on which
switch is fitted to the panel.
7) When the water level reaches a point above the second low water level, the alarm
will ring again if previously muted. It can be muted again if desired.
8) When the water feed pump stops, the lockout light will remain illuminated until
lockout is cancelled by operation of the spring loaded fault switch to the reset
position or by pressing the lockout lamp, which has a press-to-reset facility and is
fitted on some boilers as an alternative to the fault switch.
9) With boiler filled to the normal water level the feed check valve must be fully
opened prior to the boiler being put to use. When the boiler and feed pump are
operating all feed pump flow valves must be fully open.
If however, Method B is preferred the following procedure should be adopted:
1) Remove the manhole cover on top of the boiler.
2) Fill the boiler up to normal water level with a hose placed in the manhole.
3) Make sure the joint faces are thoroughly clean and replace the manhole door. It is
recommended that a new gasket is used each time.
4) Continue with steps 1) to 9) of Method A.

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5. PREPARING THE BURNER

Reference should be made to the Burner Manual located in the Combustion section of
this manual.

6. GAS AND DUAL FUEL FIRED BOILERS

WARNING
It is mandatory that gas and dual fuel boilers are only commissioned by
A.C.O.P.S. registered personnel.
It is recommended that a dual fuel burner is commissioned first on the primary fuel and
subsequently on the secondary fuel.
CAUTION
It is important that prior to the commissioning or in the operating procedure, the
fuel selector switch, mounted on the boiler control panel in dual fuel installations,
is selected to the appropriate fuel to be used, i.e. gas or oil.
It is also essential that the main gas manual isolating valve is in the closed position and
that the micro-switch contacts are closed when commissioning or operating on oil.
WARNING
During oil commissioning, under no circumstances open the main gas manual
isolating valve.

7. STARTING-UP FROM COLD

Reference should also be made to the Burner Manual located in the Combustion section
of this manual.
Ensure that the burner has been prepared in accordance with the procedure specified in
the combustion section.
Check that the plug has been removed from the Inspector’s test point and cock open to
pressure gauge and pressure switches.
Check the following valves:
• Steam stop valve shut
• Feed check valve open
• Boiler blowdown valve shut
• Water gauge assemblies open (all handles downwards)
• Sequencing blowdown valve (when fitted) in the normal position

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• Fuel supply open

• Water supply open
• Water feed pump on automatic
Ensure that the boiler contains water up to the normal water level.
Ensure that the burner switch is in the OFF position and check that all fuses are in place.
NOTE
When fuel oils below 15.5 centistokes at 38°C (70 seconds Redwood
No. 1 @ 100°F) are used, no oil heating is required. In this case,
heater circuit fuses MUST be removed and the heater thermostat
shorted out to simulate hot oil.
For dual fuel burners, move the fuel selection switch to the appropriate fuel to be used.
If selected to GAS ensure that all oil fuel isolating valves are closed and all gas isolating
valves are open. Similarly, if selected to OIL, ensure that the gas isolating valves are
closed.
NOTE
If the burner utilises a pilot gas for ignition ensure that the gas
isolating valves on the pilot ignition line to the burner are open.
On dual fuel burners, if the burner is fitted with an automatic gas valve proving system,
check that the proving pressure switch is set to approximately 50% of the nominal gas
pressure.
On closing the main isolator an alarm will sound. Operate the reset switch.
With the burner at the lowest firing rate switch the burner on. The flame can be viewed
through the observation port assembly at the rear of the boiler.
WARNING
Observation of the flame should NEVER be undertaken by the
naked eye, safety glasses preferably tinted should always be worn
when viewing the flame.
As a precautionary measure, operators should stand to one side
before opening the flap by moving the handle. From this position a
careful observation should be made, to ensure that the sight glass is
not cracked and that there is not hot gas emission.
It is important to remember that a cracked sight glass indicates a
dangerous condition, it can shatter outwards from the boiler and
should be renewed immediately. THE BOILER OF COURSE,
MUST BE SHUT DOWN BEFORE ANY REPLACEMENT IS
MADE.
If for any reason the flame is not established, the burner will go to lockout.

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WARNING
If the burner fails to start after two or three attempts, there is a
failure in the equipment that must be rectified before any further
attempt is made. A BIB COCHRAN Service Engineer should be
called in to investigate the fault. It is most important that no more
than three attempts are made to start the burner. Every time the
burner fails to light a small quantity of fuel is injected into the
furnace. This oil will build up and a potentially explosive situation
could arise.
The boiler should be warmed up slowly with the burner on the lowest firing rate. Steam
will blow through the open vent cock at the inspector’s test point. Allow the steam to
blow long enough to ensure that all air has been expelled from the boiler. Close the
three-way cock off to atmosphere and replace the vent cock plug, checking that the cock
remains open to pressure gauge and pressure switches.
NOTE
When the boiler pressure is being raised for the first time, the safety
valve should be opened by means of the easing lever to blow out any
foreign matter.
As the boiler pressure increases, the water level will rise due to expansion. The level
should be restored to normal by opening the blowdown valve. This will also remove
colder water from the bottom of the boiler and help to maintain an even distribution of
heat.
CAUTION
Care should be taken when opening the boiler blowdown valve. The
valve should be opened slowly to avoid shock loading on the
blowdown system.
When the boiler pressure reaches 2.0 bar (30 lb/in2). The firing rate of the burner can be
increased. The boiler pressure will continue to rise and the burner will stay on the
highest firing rate until the pressure reaches the setting of the pressure controller. The
burner will then go to the lowest firing rate until the pressure reaches the setting of the
limit pressure control when the flame will cease, the burner will continue to run on
post-purge to clear gases from the boiler.
When the boiler has been working for some hours at full pressure, tighten all doors and
mountings again. Inspect the drains at the rear of the boiler, when water and steam stop
issuing, replace the plugs.
Should the burner go to lockout, the flame will be extinguished, the lockout light will
be illuminated and an alarm will sound. When the fault is rectified and the fault switch
reset, the remainder of the cycle, i.e. the post-purge will be completed before the burner
can start again.

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8. RAISING STEAM FROM A WARM BOILER

When raising steam form a warm boiler, i.e. a boiler which has less than 2 bar (30
lb/in2) pressure being recorded on the pressure gauge, proceed as in “Starting Up from
Cold” (Page B-5) except of course steam can be raised much more rapidly and the
switching over of the burner to the higher firing rate can take place much sooner.

9. PUTTING THE BOILER ON FACTORY LOAD

Ensure that the burner and water feed pump are operating automatically.
Ease open the main steam stop valve. Wait for a few seconds, then carry on opening the
stop valve by quarter turns until fully open, then close one quarter turn.
NOTE
No extra leverage should be applied to the stop valve handwheel as
this could result in the spindle becoming twisted.
As the boiler pressure falls, the burner will respond under the command of the pressure
limit control (limit pressurestat) and the pressure controller (usually either a high/low
pressurestat or a modulating pressuretrol). These stats are adjustable to suit the load
requirements of the factory.

10. SHUTTING DOWN THE BOILER

It is recommended that the main steam stop valve on the boiler be closed each time the
boiler is shut down at the end of each working day or at weekends. This will reduce the
strains imposed by the variations of pressure and temperature and increase overall
efficiency.

SHORT PERIOD SHUT DOWN

For a short shut down such as overnight, there are two alternative methods of shutting
down the boiler.
Method A
Close the main steam stop valve.
Set water feed pump to HAND and raise the water level to 25 millimetres (1 inch) from
the top of the water gauge glasses. This allows for contraction as the boiler cools
overnight.
Allow the burner to cut-off on pressure.
CAUTION
If the boiler is to be shut down overnight, leave the main isolator ON,
burner OFF, water feed pump OFF and feed check valve SHUT. This
will prevent the boiler filling by gravity if the boiler pressure falls
overnight. BE SURE TO OPEN FEED CHECK VALVE BEFORE
SWITCHING PUMP ON at next start-up.

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Method B
Close the main steam stop valve and leave the boiler with the burner switch and water
feed pump on AUTO.
This will ensure that the boiler is kept up to pressure all night and will help to reduce
any strains imposed by variations of pressure and temperature.
NOTE
The BIB COCHRAN Wee Chieftain Steam Boiler is suitable for unattended
operation. However, this course of action MUST be discussed with your
Insurance Company to ensure that your policy covers this method of operation.
Upon completion of the shut-down procedure (either method) the following tasks
should be performed:-
• Blowdown water gauge assemblies
• Clean photocell
• Inspect burner head and clean if necessary
• Clean rear observation port assembly

EXTENDED PERIOD SHUT DOWN

If the boiler is to be shut-down for a longer period, shut-down the boiler as per the
instructions in “Short Period Shut Down” (Page B-8). Raise the water level and then
shut-off all valves. Put all switches to OFF and open the main isolator at the control
panel.
Upon completion of the shut-down procedure the following tasks should be performed:-
• Blowdown water gauge assemblies
• Clean photocell
• Inspect burner head and clean if necessary
• Clean rear observation port assembly
Any boiler that is laid off for an extended period should be protected against corrosion.
Details of recommended methods of laying up boilers for extended periods can be found
in “The Treatment of Water for Shell Boilers” published by the Association of Shell
Boilermakers.

11. EMERGENCY OPERATION

All members of staff should be aware of the procedures, as defined by Company Policy
Documents, to be adopted in the case of a major or minor accident or incident.
Emergency equipment must be readily available for use in emergency situations.

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WARNING
Car e should be taken when approaching the boiler during all emergency conditions.

PRESSURE PART
Low water is potentially the most dangerous situation which can occur in the
boilerhouse. The energy content in 100 gallons of water at 6.9 bar (100 lb/in2) would
have sufficient explosive force to demolish a small factory. During a low water
condition, the smoke tubes and furnace can become overheated and in the event of
furnace collapse, a major explosion may occur due to the sudden release of steam and
water at the moment of failure.
If no water is visible in the gauge glasses the following procedure will shut the boiler
down safely:-
WARNING
Under no circumstances should an attempt be made to fill the boiler
with water until it has been allowed to cool.
• Switch off the burner. Close fuel isolating valves.
• Close boiler stop valves.
• Check that all boiler drains are closed.
• Switch off water feed pump and close feed check valve.
• Isolate electrical supply at main isolator.
• Leave boiler plant to cool.
NOTE
Before attempting to re-activate the plant, a thorough investigation
must be carried out by competent personnel.

FUEL SYSTEMS
Any problems with the fuel systems should be attended to immediately.
Oil System
• Switch off the burner
• Close boiler stop valves
• Check that all boiler drains are closed
• Switch off water feed pump and close feed check valve
• Isolate electrical supply at main isolator
• Close fuel supplies from fuel tanks. If a particular area is affected, also
isolate the failed section of pipework.

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• Contain spillage using oil absorbent materials.

• Protect adjacent equipment from spillage.
• Care should be taken to ensure that oil does not enter the drainage system.
Gas System
WARNING
Under no circumstances must naked flame be used for checking gas leaks.
Any suspicion of a gas leak should be reported immediately to a responsible person and
an ‘authorised’ inspection carried out. DO NOT DELAY
• Isolate the main gas supply outside the affected area (if possible).
• Make no attempt to operate the plant whilst gas is escaping.
SAFETY NOTE
It is important to remember that some gaseous fuels are heavier than air.
These fuels tend to accumulate at ground level.

FIRE
• Switch off the burner
• Close boiler stop valves
• Check that all boiler drains are closed
• Switch off water feed pump and close feed check valve
• Disconnect all electric supplies
• Close all fuel supply lines
• Use fire appliances as applicable to the type of fire.

ELECTRICAL POWER SUPPLY

The main consideration in the formulation of actions required on the occurrence of
electrical failure is to retain steam pressure in the boiler to enable a speedy recovery
upon restoration.
Switch off the burner
Close boiler stop valves
Check that all boiler drains are closed.
Switch off water feed pump and close feed check valve.
Isolate electrical supply at main isolator.
A thorough investigation into the cause of the power supply failure should be made
before reactivating the boiler.

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Upon restoration of the power supply the plant can be reactivated by following the
pertinent procedures contained in Starting Up from Cold (Page B-5). Ensure that the
burner cycle has completed the post purge before attempting to restart the burner.

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Page 1

BOILER WATER LEVEL CONTROLS

1. WATER LEVEL CONTROLS

The importance of regular checks on the water level controls can not be overstressed since a
low water condition is potentially the most dangerous situation which can occur. The low
water level alarms are probably the most important safety equipment on a boiler, competent
inspection and checking is therefore essential. The boiler must not be left unattended
during the test.
NOTE
Some water level control switches are fitted with test buttons. Pressing the test button
simulates an alarm condition and the appropriate alarm should sound. This only
checks the electrical integrity of the circuits, it does not replace an evaporation tests.
The water level control tests should be carried out with the burner running and the boiler
under pressure. The burner should be held at low fire when checking the low and extra low
water level controls.
CAUTION
The boiler water level must always be visible in the water gauge glass.
Upon completion, the automatic control of the boiler should be monitored to ensure
satisfactory operation before leaving the boiler unattended.

1.1 Internally Mounted Controls

Daily testing is not required when high integrity, self-monitoring level controls are
fitted. However, the controls should still be checked on a daily basis. The operation of
internally mounted controls should be verified using the weekly evaporation test
procedure.

1.2 Externally Mounted Controls

Each of the externally mounted water level control chambers is fitted with a sequencing
blowdown valve. It is important that the water level controls should be checked at least
once per day, or once per shift.
Always check the chambers in the following order:
1) The chamber containing the pump or modulating valve controller and the
water alarm.
2) The chamber containing the extra low water level alarm.

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SECTION C
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1. HEALTH AND SAFETY MAINTENANCE REQUIREMENTS........... 2

2. ROUTINE PREVENTATIVE MAINTENANCE CHECK LIST ........... 2
3. GENERAL MAINTENANCE..................................................................... 3
CLEAN PHOTOCELL........................................................................................................... 3
CLEAN SIGHT GLASS ........................................................................................................ 3
WATER QUALITY TESTING.............................................................................................. 3
MONITOR FLUE GASES..................................................................................................... 4
BURNER ................................................................................................................................ 4
4. CLEANING OF BOILER TUBES ............................................................. 4
5. VALVES........................................................................................................ 5
6. BOILER SAFETY VALVE......................................................................... 5
7. ELECTRICAL FAULTS............................................................................. 6
8. SPARE PARTS............................................................................................. 7
9. TABLE C-1 : PREVENTATIVE MAINTENANCE CHECK LIST .... 8
10. GAUGE GLASS TEST PROCEDURE .................................................. 9

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1. HEALTH AND SAFETY MAINTENANCE REQUIREMENTS

The Factories Act 1961, now in part incorporated in the Health and Safety at Work Act
1974, with subsequent amendments, lays down specific rules to be observed by
manufacturers, the owners of the plant and the boiler operator.
Clients should obtain a copy of the Act and the part relating to boilers in particular, as well
as Guidance Note PM5 issued by the Health and Safety Executive entitled "Automatically
Controlled Steam and Hot Water Boilers". The appropriate section of Factories Act require
to be read in detail to ensure compliance.
Regular maintenance must be carried out in order to maintain plant performance at its
optimum. It is stressed that maintenance should only be carried out by competent
personnel.
WARNING
It is mandatory that maintenance or overhaul of any gas fired
equipment must only be carried out by ‘Gas Safe Register’. registered
personnel.
We wish to point out to the user when undertaking any work on the boiler, with regard to
maintenance, for example, laying up the boiler, tube removal and repair or when stripping
of the boiler is required for annual inspection, that adequate safeguards are taken to protect
personnel who are to undertake this work. Guards are fitted to various components on the
boiler, these should never be removed unless the control panel is first isolated.
Prior to undertaking any work of this nature on the boiler, if any doubt or question exists
related to safe procedures, the user is recommended to contact BIB COCHRAN
LIMITED for advice. In certain cases training of personnel may be considered
appropriate.
It is strongly recommended that a record should be kept of all tests and maintenance carried
out on the boiler.

2. ROUTINE PREVENTATIVE MAINTENANCE CHECK LIST

Reference should also be made to the burner manual located in the Combustion Section..
The check list is included for reference only. This list is not intended to be exhaustive but
presented as a general guide to the user, to encourage an awareness that at all times proper
attention to safe working practices must form an integral part of maintenance schedules.
Carry out preventative maintenance on the boiler as recommended in Table C-1 :
Preventative Maintenance Check List.

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3. GENERAL MAINTENANCE
Keep furnace, burner and associated equipment clean, repair any leaky joints without delay
and, if applicable, clean up any pools of oil.
Check all boiler mountings, gauges, etc. and deal with any leaks.
Check the electrical components for tightness, etc.
Keep all equipment clean.

CLEAN PHOTOCELL
Remove photocell head and carefully wipe clean.

CLEAN SIGHT GLASS

Clean sight glass and replace if necessary.
A cracked glass indicates a dangerous condition, it can shatter outwards from the boiler and
should be renewed immediately. The boiler must be shut down before any replacement
is made.
Ensure that any joints are maintained in good condition at all times. Failure to adhere to this
creates the possibility of an escape of hot gas round the sight glass causing overheating and
possible cracking of the glass.
• Please refer to table C-1 : Preventative Maintenance Check List on Page C-9.

WATER QUALITY TESTING

Regular daily checks should be made on the water quality, to ensure that the treatment is
being maintained. The advice of a competent water treatment specialist is recommended
with regard to testing procedures suitable for the boiler application and the initial feed water
quality.
Details of recommended water characteristics for shell boilers can be found in "The
Treatment of Water for Shell Boilers", published by the Association of Shell Boilermakers.
A copy of this publication is included in this manual for your information
SUMMARY OF RECOMMENDED BOILER WATER QUALITY
Hardness Nil
Oxygen Nil
pH 8.5 - 9.0
TDS (maximum) 3000 mg/litre (or ppm)
Total Alkalinity (maximum) Approximate 20% of TDS
(In terms of CaCO3)
Note: General guidance only. Specialist advice should be sought where appropriate.

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MONITOR FLUE GASES

Check flue gas emissions and gas exit temperatures to ensure that burner settings have not
altered.
NOTE
Any significant increase in the flue gas temperatures indicates
deteriorating combustion or that the appliance needs cleaning.

BURNER
For details of preventative maintenance refer to Combustion Section.
Fuel Conditions
Check that the operating conditions for the fuel(s) are as set by the BIB COCHRAN
Engineer or a competent person (see Combustion Section).

4. CLEANING OF BOILER TUBES

A definite ruling cannot be given on the frequency of cleaning as this depends on the boiler
loading and the type of fuel being fired. If necessary the boiler can be opened up after
several weeks of running to check if there is any build up of soot deposits in the tubes or
any other heating surface in the boiler. On the basis of the findings a definite programme of
cleaning should be formulated. Having regard for normal requirements for heat, we would
recommend that in any case, periods between cleaning should be between 3 months and 6
months but this can only be regarded as a guide.
It is important to arrange the cleaning of the boiler whilst it is 'warm', cleaning should never
be undertaken on a 'cold' boiler. Always bear in mind that the boiler will operate at a high
efficiency if the heating surfaces are cleaned regularly. If the boiler tubes are not cleaned
regularly the efficiency will fall and extra fuel must be burnt in order to meet heating
requirements. It is much cheaper to clean the boiler tubes at regular intervals than to burn
fuel at low efficiency.
METHOD OF CLEANING
All tubes are accessible from the front of the boiler, access to the tubes is achieved by
opening the doors of the smokebox at the front door of the boiler. As the tubes are cleaned,
all the soot will be deposited at the back of the boiler. The soot from the first pass of tubes
will be in the reversal (combustion) chamber and from the second pass of tubes, in the rear
smokebox. These soot deposits can be easily removed.

Entry to the reversal (combustion) chamber is gained by removing the circular reversal
(combustion) chamber access door. Entry to the rear casing is achieved by opening the rear
access doors.
On replacing the front door, particular attention should be paid to the sealing, both of the
outer seal and the extension to the reversal (combustion) chamber. The seals should be

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renewed each time the door is opened if there is any sign of deterioration. Bad seals will
cause low efficiency and high maintenance costs.
NOTE
If your boiler is fitted with retarders, these must be removed before the
tubes can be cleaned. Clean and replace the retarders after the tubes
have been thoroughly cleaned.

5. VALVES
Valves are designed for specific duties and conditions of service. It is important that a valve
is not subjected to conditions outwith the design specification.
CAUTION
It is important that the settings of safety valves should not be tampered with by
inexperienced personnel.
Before commencing work on a valve ensure that the valve has been isolated from the
system. Release any pressure in the system and drain carefully. Post WARNING
NOTICES on the isolating valves or blanking flanges.
The following information is a general guide to valve maintenance.
• Keep the valve stem and mechanism clean and lightly oiled.
• Tighten or repack the gland, as necessary, to prevent leakage. When the valve is not
being operated for long periods, occasionally ease open and shut when convenient.
• Gland packing and gasket joints should always be of the correct material and size.
Replacements can be obtained from the Spares Department at BIB COCHRAN
LTD.
• Any leakage between the valve faces should be attended to at the first convenient
opportunity.

6. BOILER SAFETY VALVE

The boiler safety valve is essential in ensuring that the boiler cannot build up excessive
pressure, should the boiler limit control fail. The type of safety valve fitted to your BIB
COCHRAN boiler is defined by the British Standards as a high lift type.
The safety valve should be mounted vertically and connected to escape pipes which are not
smaller than the connections on the valve. Any vent pipes from the safety valve should be
piped to safe places. None of these pipes should be plugged.
The safety valve has been adjusted to the required blow-off set pressure and the blowdown
ring positioned accordingly prior to the boiler leaving our factory. A plate on the safety
valve specifies the operating conditions for which the valve was supplied. The valve setting
must not be tampered with. To prevent this, the padlock keys should be kept in a safe place
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SECTION C
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safe place under the supervision of a responsible person.

Whilst the valve is adjustable any modifications to the safety valve must only be carried out
by a suitably qualified person who is cognisant of the effect of any alteration. Any
adjustment or change of setting can be carried out by BIB COCHRAN Service
Department but must be authorised by your Insurance Company.
A rise in the boiler pressure above the preset level will operate the valve automatically. The
discharge will cease on reaching the set level.
Failure to test these valves at regular intervals can result in over pressure, leading to serious
consequences. A common cause of safety valve failure is the build up of deposits which
can cause the valve to stick. This is usually caused by a slight leakage through the valve
over a period of time. To prevent such failures, a programme of regular testing and
maintenance should be set up.
It is difficult to specify a standard routine testing programme for all safety valves because
the time intervals will vary with the type of service, pressure, temperature and site
conditions. This should be discussed with your Insurance Company. The tests are
normally performed annually in the presence of an Insurance Company Surveyor.
Keep the safety valve and easing gear clean and free from obstruction. Lubricate the
easing gear periodically. Check the operation of the valve periodically. Any steam
leakage between the valve faces should be attended to at the first convenient opportunity.
As part of the regular maintenance programme, there should be a regular periodic manual
operation of the safety valve easing gear. With the boiler under pressure, the safety valve
can be eased or lifted by applying hand pressure to the easing gear lever.

7. ELECTRICAL FAULTS
Diagnosis of a fault should always be carried out with the aid of the schematic diagram of
the electrical controls. Electrical faults can usually be summarised under the following
headings, short circuits, open circuits, overloads, leakage and loose connections and/or bad
contacts.
Short Circuits
These occur when the circuit path is less than the designed path. A short circuit usually
becomes evident by the instantaneous failure of a fuse, a visible discharge and/or a loud
report.
Open Circuits
These occur when the designed circuit path is not completed. This usually results in
failure of the system to operate although fuses have not failed and the energising supply is
available.

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Overloads
An overload may be due to the electrical prime mover being undersized or due to partial
loss of supply voltage.
Leakage
This is generally due to the presence of moisture and/or damage to conductor insulation.
Loose Connections and/or Bad Contacts
These result in erratic and/or intermittent faults.

8. SPARE PARTS
Our Spares Department can supply any spare parts which you may need to ensure the
continuity of operation and efficiency of the equipment supplied by BIB COCHRAN.
SAFETY NOTE
To ensure safe operation, we strongly recommend that only genuine BIB
COCHRAN supplied spare parts are fitted to your plant.
In order to minimise the length of time that your boiler could be out of service, it is
recommended that you carry the following stock of replacement parts:-
NUMBER OFF DESCRIPTION
4 Joints for Mandoors
12 Joints for Muddoors
2 Rolls Fibre Glass Ladder Tape
6 Tube Brushes
2 Observation Port Sight Glasses
4 Joints for Observation Port Sight Glasses
1 Parallel Slide Blowdown Valve Disc (Male)
1 Parallel Slide Blowdown Valve Disc (Female)
2 Parallel Slide Blowdown Valve Seats
1 Parallel Slide Blowdown Valve Spring
Stocks of spare parts should also be carried for the burner and ancillary plant.

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WEE CHIEFTAIN STEAM BOILER Daily Weekly Monthly Quarterly Annually Oil Gas
PRESSURE JET BURNER
Clean Photocell ∗ 9 9
Check Photocell Operation ∗ 9 9
Clean Sight Glasses ∗ 9 9
Clean Atomiser Cup ∗ 9 9
Check Boiler Pressure ∗ 9 9
Check Oil Temperature ∗ 9
Check Oil Pressure ∗ 9
Monitor Flue Gases ∗ 9 9
Clean Ignitor Assembly ∗ 9 9
Clean Oil Filters ∗ 9
Service Burner Unit ∗ 9 9
Check Door and Furnace Seals ∗ 9 9
Visual Check of Refractories ∗ 9 9
Check Control Panel ∗ 9 9
Set-Up Combustion ∗ 9 9
Check Boiler Temperature Stats ∗ 9 9
Check Gas Pressures ∗ 9
Check Safety Interlocks ∗ 9 9
Check for Oil/Gas Leaks ∗ 9 9
Prepare for Annual Inspection ∗ 9 9
Clean Boiler ∗ 9 9
Internal Inspection ∗ 9 9
Overhaul Valves ∗ 9 9
Replace Joints and Seals ∗ 9 9
Internal Inspection of Refractories ∗ 9 9

9. TABLE C-1 : PREVENTATIVE MAINTENANCE CHECK LIST

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10. GAUGE GLASS TEST PROCEDURE

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HEALTH & SAFETY
Page 1

1. INTRODUCTION ........................................................................................ 2
2. UK HEALTH AND SAFETY REQUIREMENTS ................................... 3
3. TRAINING.................................................................................................... 3
4. HYGIENE ..................................................................................................... 4
5. PROTECTIVE EQUIPMENT.................................................................... 4
6. BOILER......................................................................................................... 5
7. CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH ............ 19
8. BOILER REFRACTORY CEMENT....................................................... 19
9. FIBRE BASED PRODUCTS .................................................................... 20
10. BOILER INSULATION – CERAMIC FIBRE ....................................... 22
11. BOILER INSULATION – MINERAL WOOL....................................... 27
12. GLASS FIBRE JOINTING MATERIAL................................................ 30
13. GLASS FIBRE GASKET MATERIAL ................................................... 31
14. GLASS FIBRE GLAND PACKING ........................................................ 31

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1. INTRODUCTION
As far as is reasonably practicable, every care has been taken to ensure that the
boiler and associated plant are safe and without risk to health when properly used
by competent personnel. Where hazardous or dangerous substances are
encountered, they must be dealt with to meet all applicable statutory regulations.
The information provided is given in good faith, but no liability will be accepted
by BIB Cochran Limited in relation to the same. We should also point out that the
hazard information reproduces data issued by our current suppliers. The
possibility exists that the chemical composition of some products is not generic,
that is, the information from alternative suppliers may indicate a different
chemical make-up for an apparently similar material.
No responsibility can be assumed by BIB Cochran Limited for any damage or
injury resulting from abnormal use, from any failure to adhere to recommended
practices, or from any hazards inherent in the nature of the equipment supplied.
Should you have any queries in regard to the information supplied, or related to
the Health and Safety of our products, please do not hesitate to BIB Cochran
Limited for further information.

1.1 GLOSSARY
AOTC Associated Offices Technical Committee
BSS British Standard Specification
COSHH Control of Substances Hazardous to Health Regulations 1988
ECFIA European Ceramic Fibre Industry Association
HSE Health and Safety Executive
IARC International Agency for Research on Cancer
LD/LC Lethal Dose/Lethal Concentration
LTEL Long Term Exposure Limit
MEL Maximum Exposure Limit
NDT Non-destructive testing
NPF Nominal Protection Factor
OEL Occupational Exposure Limits
PGCA Power Generation Contractors' Association
RCF Refractory Ceramic Fibre
RPE Respiratory Protective Equipment
STEL Short Term Exposure Limit
TDS Total Dissolved Solids
TWA Time-weighted average
WHO World Health Organisation

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2. UK HEALTH AND SAFETY REQUIREMENTS

New boiler plant must not be put into use unless a Certificate of Compliance has
been obtained from the manufacturer. The Certificate of Compliance specifies the
maximum permissible working pressure and states the nature of the tests to which
the boiler has been submitted. All certification must be kept available for
inspection. The boiler serial number is used to match individual boilers with their
unique certificates.
The Factories Act 1961, now in part incorporated in the Health and Safety at
Work Act 1974, with subsequent amendments, lays down specific rules to be
observed by the plant manufacturers, the plant owners and the plant operators.
The appropriate sections of the legislation should be read carefully to assure
compliance.
CAUTION
It is mandatory that maintenance or overhaul of any gas fired
equipment must only be carried out by suitably registered personnel.
Clients should also be aware of the following Health and Safety Executive
publications:
− Guidance Note PM5, “Automatically controlled steam and hot water
boilers”
− Guidance Note PM60, “Steam boiler blowdown systems”
− “Electricity At Work 1989”

3. TRAINING
It is expected that the boiler plant personnel are fully trained and
experienced with this type of plant. All personnel should be conversant with
the plant's operation and maintenance requirements.
The boiler plant should only be operated and maintained by competent
personnel. Competent personnel should have sufficient practical and theoretical
knowledge and actual experience of the equipment, so that they are able to detect
defects or weaknesses. A competent person should also be capable of assessing
the importance of any defect or weakness in relation to the strength and function
of the equipment. Details of various Training Courses are available from our
Training Department.

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4. HYGIENE
All personnel should be trained to observe a high standard of hygiene, but
experience has shown that different people, carrying out the same process, can
create different amounts of dust in doing so. Bad habits, such as throwing scrap
onto the floor instead of placing it into a waste bin, can substantially add to the
dust in the atmosphere.
Close observation of the procedures adopted by the operator will readily reveal
aspects, which can be improved by training. The operator must also be trained to
make proper use of any equipment provided.
Some substances can cause skin irritation in sensitive individuals. Some reactions
can be minimised by observing appropriate precautions. Operators should be
encouraged to wash exposed skin areas regularly. The skin should first be rinsed
with water and then washing carried out with soap (not detergent). Appropriate
washing facilities must be provided.
Usually individuals sensitive to some forms of skin irritation may acquire a
degree of tolerance after a few days of exposure. If this does not prove to be the
case and the condition persists, despite taking suitable precautions, consideration
must be given to transferring the individual to other work.

5. PROTECTIVE EQUIPMENT
It is good practice for personnel to be provided with protective equipment and
clothing for use in the work place.

5.1 PROTECTIVE CLOTHING

Protective clothing can take various forms. These include:

− light-weight overalls, to be worn over normal clothing.
− heavier weight working clothing, requiring a complete change of outer
clothing.
In general, work clothing should be comfortable and fit for purpose. Close-fitting,
but not tight, clothing is recommended. Excessively loose clothing should be
discouraged.
Protective clothing should be long-sleeved and loose at the neck and wrists, so
that any substances, which may be lodged in these areas, are not rubbed into the
skin. As a further precaution, safety footwear, gloves, hat and goggles can also be
worn.
Protective clothing should be removed when the operator leaves the workplace
and stored separately from normal clothing. An appropriate changing area may be
required.

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In all cases, working clothing should be laundered separately from personal

clothes. Where heavy contamination has occurred, care should be taken to ensure
that the equipment used for laundering is itself thoroughly cleaned after use.
Gloves, hats and goggles should be cleaned and replaced as necessary.

5.2 RESPIRATORY PROTECTIVE EQUIPMENT

Respiratory protective equipment should always be worn when the dust limit is
exceeded or when the atmospheric concentration of dust is not known. Different
types of Respiratory Protective Equipment are available. These range from simple
disposable dust masks to respirators supplied with clean air. The equipment is
broadly categorised by the Nominal Protection Factor (NPF). The NPF indicates
the ratio of “dust” concentration between the atmosphere and the inhaled air. The
respiratory protective equipment used must have an NPF greater than the value
given by dividing the measured atmospheric dust concentration by the applicable
dust limit.

6. BOILER
The boiler is capable of producing the required output of steam, or hot water, at
the design rating and working pressure. Reference should be made to specific
contract documents for the actual output and pressure. The steam, or hot water,
produced by the boiler is normally intended for process or plant usage.
Please note that while your BIB Cochran boiler is a packaged unit, the following
items may be required for it to operate correctly:
Boiler foundations
Feed water tank and pipework to boiler
Fuel handling plant, and fuel lines to boiler
Main electric supply to boiler control panel
Chimney and ducting
Steam line from boiler to process (not required for hot water boilers)
Flow and return lines from boiler to process (not required for steam boilers)
Drain and blowdown pipes
Safety valve exhaust pipe and drains Blowdown vessel (not required for hot
water boilers)
These items can be supplied by, or arranged through BIB Cochran Limited.

6.1 BOILER DESIGN & CONSTRUCTION

The boiler is normally designed and constructed to British Standard Specifications

and AOTC Rules. The boiler plant complies with Health and Safety Executive
Guidance Notes. The boiler plant can be designed, and constructed, to other
National Standards, or to the requirements of any other authority as specified by
the contract.

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6.2 BOILER MOUNTINGS & FITTINGS

The boiler is supplied with all necessary mountings and fittings in compliance
with statutory and insurance regulations for UK boiler plant. All mountings are
manufactured from suitable materials as required by the relevant Standards,
applicable under the contract. The required quality of workmanship and
construction is as specified in the relevant Standards, applicable under the
contract.
When the boiler is supplied incomplete, as specified by the contract, final
completion of the boiler is the responsibility of the buyer, or their agents. The
buyer must ensure that all components being fitted comply with the relevant codes
of practice and the appropriate safety standards.
NOTE
Steam is compressible. A reduction in the steam pressure results in an
increase in the steam volume. For example, a valve designed to pass a
weight of steam at a pressure of 10 bar, can only pass a small part of
this weight at 6 bar; this is due to the increased steam volume.
The mountings and fittings used on steam boiler plant are designed for specific
duties and conditions of service and to meet the requirements of the Factories Act,
British Standards, etc. It is important that equipment is not subjected to conditions
outwith the design specification.

6.2.1 Drains

Drain pipework from the water gauge drain cocks, safety valves, etc. should be
connected to the plant drainage system. Discharges from the boiler blowdown
equipment should be connected to the plant blowdown system.

6.2.2 Valves

6.2.2.1 VALVE OPERATION

Before operating a valve:

− Check the valve position indicator and the direction of operation.
− Check that the pipework system is operational.
Valves must be operated slowly, and must never be forced to the limit in either
direction. Shutting a cold valve hard down may lead to its seizure when
temperatures in the adjacent pipe work are later increased.
Never use excessive force to open, or close, a valve. The use of wheel spanners
should be discouraged as valves are provided with hand wheels large enough to
give a turning force sufficient to open, or close, the valve. If a valve is so tight
that it cannot be fully operated by the hand wheel alone, it is usually defective,
and the application of more force may make matters worse.

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On steam lines, always open the drains and crack open the valves to rid the
system and valves of water prior to starting up. On water lines, always vent any
trapped air by opening the air valves or by cracking open by-pass valves and/or
main valves.

6.2.2.2 VALVE MAINTENANCE

Before commencing work on a valve ensure that the valve has been isolated from
the system. Release any pressure in the system and drain carefully. Post
WARNING NOTICES on the isolating valves or blanking flanges.
The following information is a general guide to valve maintenance:
1) Keep the valve stem and mechanism clean and lightly oiled.
2) Tighten or repack the gland, as necessary, to prevent leakage.
3) When the valve is not being operated for long periods, occasionally ease open
and shut when convenient.
4) Gland packing and gasket joints should always be of the correct material and
size. Replacements can be obtained from BIB Cochran Limited Spares
Department.
5) Any leakage between the valve faces should be attended to at the first
convenient opportunity.
6) Where valves are lagged, it is important that the insulation should not extend
above the top facing of the valve cover. Glands should be left clear for
adjustment and inspection. When covers are fitted over the lagging, they
should be removable.

6.2.3 Safety Valve

The correct setting of the safety valve is of particular importance. The valve is
fitted with an internal spring and set to suit the contract's design conditions. The
set pressure should only be altered by a suitably qualified person, who is able to
fully assess the consequences of carrying out such an alteration. Once set, the
valve spring setting must not be tampered with. To prevent this, the valve should
be fitted with a padlock to prevent unauthorised interference. The padlock key
should be kept in a secure place, under the supervision of a responsible person.
The design of the safety valve escape pipe is critical. The internal diameter and
arrangement of the escape pipework must be verified with regard to the valve
manufacturers recommendations. The pipe should have a minimum amount of
bends and be taken straight to atmosphere clear of the boilerhouse roof.
Before the boiler is put into normal operation, a steam accumulation test should
be performed. The steam accumulation test, at the maximum rating of the steam
boiler, should be performed with the stop valve closed and in the presence of the
inspecting authority.

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6.2.4 Water Level Gauge Glass Assembly

The water level gauge assembly provides a visual indication of the level of the
water in the boiler. Frequent observation of the water level gauge glass assembly
is one of the most important functions of the boiler operator's duties. It is the
means by which failure of the water level control system can be detected. Gauge
glass observation is just as important when boiler plant is unattended.
The assembly usually comprises of a gauge pillar, gauge glass protectors, right
and left hand level gauges. Each level gauge is fitted with steam and water
isolating valves and a drain valve.
WARNING
At no time when the boiler is under pressure should the water gauge
glass protectors be removed without isolating the steam and water
valves.
Poor treatment of the boiler water can result in thinning of the gauge glasses. The
water gauge assembly should be blown down either daily or every shift. A
recognised programme of routine checks should be established by a designated
person, who is familiar with the boiler and the procedures required.

6.2.5 Blowdown Valve

Solid particles from the feed water can rapidly accumulate to form mud and scale
deposits inside the boiler. Deposits in the boiler's stand pipes can prevent
equipment from operating correctly and be potentially dangerous. The risk of
choked connections can be eliminated by a regular blowdown programme.
A manually operated blowdown valve is fitted to the lowest part of the boiler
shell. This valve is used to expel sludge and suspended solids from the steam
boiler, while it is under steam pressure. The blowdown valve can also be used for
draining the cool boiler and maintaining the correct water level when starting the
boiler from cold.
The blowdown valve is fitted with a removable operating key. A guard
incorporated on the gland ensures that the operating key can only be removed
when the valve is in the closed position. This device is a safety lock, which must
not be interfered with. The manual blowdown valve should be left in the closed
position while the boiler is operating.
WARNING
The key used to open the blowdown valve, MUST NEVER BE LEFT
ON THE VALVE WHEN THE VALVE IS CLOSED. The key
should be retained in a secure place under the supervision of a
responsible person.
When using the main boiler blowdown valve the operator must not, under any
circumstances, leave the valve unattended until the blowdown procedure has been
completed.

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If more than one boiler is connected to a common blowdown system, even if the
boilers are not in the same boilerhouse, UK Law stipulates that only one
blowdown key should be available on the premises. If there are two boilers with
different sizes of key, it is permissible to weld the keys end to end and make one
tool of them. The key must never be left on a closed valve.
When automatic blowdown equipment is fitted downstream of the manual
blowdown valve, it is usually necessary for the manual valve to be OPEN at all
times. Appropriate warning notices should be prominently displayed
adjacent to the blowdown system.

6.3 ASSOCIATED EQUIPMENT & SYSTEMS

The associated equipment fitted to the steam boiler has been designed to perform
a specific function at the conditions specified by the contract documentation.
Proposed changes to any part of this specification must be referred to the
manufacturer for approval, as must any other questions relating to the safe
operation of the equipment supplied.
All associated equipment is manufactured from suitable materials, as required by
the relevant Standards applicable under the contract entered into BIB Cochran
Limited. The required quality of workmanship and construction is as specified in
the relevant Standards applicable under the contract entered into BIB Cochran
Limited.
Reference must be made to the relevant British Standards and Codes of Practice
or the equivalent, in accordance with the Contract in the Country of application or
use. The end-user must also be familiar with local regulations and insurance
requirements, which will serve as a valuable guide for safe operation.
At all times the equipment should be operated in accordance with sound
engineering and safety principles and as outlined in the operating instructions.
Before operating or working on the associated equipment, it is essential that all
personnel involved in the activity have read and thoroughly understood the
operating instructions supplied.

6.3.1 Ventilation

Adequate ventilation within the boilerhouse is necessary:

− to provide combustion air.
− to prevent asphyxiation.
− to help prevent equipment from overheating.
Do not seal up established openings and do not aggravate these problems by
allowing the flue gas passages to foul up so that fumes enter the boilerhouse.

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6.3.2 Control Panel

WARNING
Before opening the control panel the incoming mains supply must
always be isolated.
When the boiler is supplied with external electrical components prewired to a
control panel, the panel will contain the required safety features such as starters,
fuses, relays and switches for control functions with indicator lights and alarms
for normal and fault conditions.

6.3.3 Water Treatment

All sources of water contain impurities, many of which can be detrimental to the
boiler. The water supply must therefore be treated so that the impurities can either
be removed or rendered harmless. Over a period of time, the concentration of
these solids in the boiler water will increase. Excessive concentrations of
dissolved or suspended solids can result in:
1) Formation of scale on the heat transfer surfaces, causing overheating,
possible tube failure and a reduction in boiler efficiency.
2) Foaming of the boiler water produces unstable water levels, which could
result in potentially dangerous levels of water in the boiler.
3) Foaming and carry-over of boiler water with the steam causing contamination
of the steam and condensate system. The impurities in the carry-over settle
out on heat transfer surfaces, leading to slower heat exchange rates. This can
also result in blockage of steam traps and pipework.
Regular checks should be made on the water quality to ensure that the treatment is
being maintained. The results of any water sample can be used to adjust the
chemical dosing rates and/or blowdown rates. The advice of a competent water
treatment specialist is recommended with regard to testing procedures suitable for
the boiler application and the initial feed water quality.
It is impracticable to deal with specific hazards associated with water treatment,
because of the varying water qualities encountered and the subsequent different
treatment required. Further details of the problems caused by poor water treatment
can be found in the booklet “The Treatment of Water for Shell Boilers”, published
by the Power Generation Contractors' Association Shell Boiler Group.
The chemicals used by the water treatment processes will form part of the client's
Health and Safety assessment. Dangerous or hazardous chemicals should be
stored in an enclosed, ventilated building. Provision for different bays should be
made to avoid mixing of chemicals. In the case of spillage, adequate washing
down facilities and effluent disposal facilities must be provided. Protective
clothing, gloves and eye protection must also be available.

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6.3.4 Feed Pump

An inlet strainer should be fitted to the pump suction line of each feed pump. The
feed pump and associated pipework must be primed/vented before start up. It is
essential that the feed pump is supplied with treated water, of the correct
temperature, at a positive pressure. Running the pump without water, even for just
a few minutes, can cause serious damage. Similarly, the feed pump should not be
operated against a closed valve.

6.3.5 Fuel Systems

Only the fuels specified by the manufacturer should be used in the combustion
equipment. Care must be taken to ensure that all fuels are stored, handled and
used in accordance with all applicable regulations and codes of practice. Details
of the correct handling procedure for a particular fuel should be obtained from
your fuel supplier.

6.3.6 Combustion Equipment

The combustion equipment, when supplied, is mounted at the front of the boiler.
The combustion equipment provides the boiler with heat, which is generated by
burning the fuel. At all times the combustion equipment should be operated in
accordance with sound engineering and safety principles and as outlined in the
operating instructions.
The automatic burner control system is designed for the efficient operation, safe
light up and shut down of the burners. The control system is divided into three
sections. These are:
Supervisory Control The supervisory controls coordinate the operations
of the programming control and the proportioning
control. This section of the control system uses
safety interlocks to continually monitor the burner
operating sequence to ensure hazard free control.
Programming Control When initiated by the supervisory control, the
programming control runs through the pre-purge,
safety checks and light up sequence.
Proportioning Control The proportioning control is initiated by the
supervisory control once the low fire main flame
has been established. Proportioning may be
controlled automatically by a boiler pressure
operated potentiometer or manually by a hand
potentiometer, selected using a hand/auto change-
over switch on the control panel.

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6.3.7 Water Level Controls

WARNING
The level controls and alarms are an important part of the safety
equipment of the boiler and should only be installed and serviced by
competent personnel. In particular they should be tested regularly
for correct operation. Any failure must be fully investigated, and the
fault rectified, before the boiler is allowed to operate automatically.
Low water is potentially the most dangerous situation which can occur. The
importance of regular checks on the water level controls can not be over-stressed.
The low water level alarms are probably the most important equipment on the
boiler for ensuring safety. Competent inspection and checking is therefore
essential.
The energy content in 500 litres of water at 6.9 bar would have sufficient
explosive force to demolish a small factory. During a low water condition, the
smoke tubes and furnace can become overheated. In the event of a collapse, a
major explosion may occur due to the sudden release of steam and water at the
moment of failure.

6.4 BOILER OPERATION

The steam boiler system is designed to operate automatically without the need for
constant supervision and attendance by the boiler operator. The boiler plant is
equipped with protection equipment to shut the plant down safely if abnormal
conditions occur.
The boiler is capable of continuous and intermittent operation at part or full load,
however, long term operation at minimum load conditions may damage associated
plant.
Personnel must always be available for checking the operating conditions. It is the
boiler operator's duty to ensure that the boiler plant is operated safely and
efficiently.

6.4.1 Safety Interlocks

The plant starting permissives, trips and alarms are important for the safe start up
and operation of the boiler plant. Safety interlocks are provided for your
protection. Alteration or adjustment of interlock settings must only be carried out
by suitably qualified personnel. Safety interlocks must be:
− in service at all times,
− set to specified values,
− tested at regular intervals to ensure correct operation and reliability.

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WARNING
Under no circumstances must any interlock be made inoperative or
prevented from establishing a fail safe condition.
In the event of a malfunction during start up or normal running the burner will
either:
− Shut Down, if a preset plant safety parameter has been reached.
− Lock-out, if a preset plant safety limit has been exceeded, or the
equipment has malfunctioned, tripping the lock-out system.
A shut down switches off the burner after completing the post purge sequence.
When the indicator returns to a normal safe level, the burner will automatically
initiate the start up procedure and normal running will be resumed.
A lock-out will cause the burner to switch off and an alarm to sound. It will be
necessary to correct the cause of the lock-out. The alarm can be muted while an
investigation is performed. The reset switch must be operated before the alarm
will cease to sound and the burner start-up procedure resumed.
If the cause persists after the reset and is not immediately obvious via the control
panel warning lights or related controls, then the equipment must be switched off.
The cause of the lock-out must be investigated and corrected before attempting to
restart the equipment.

6.4.2 Hot Surfaces

Ensure that hot pipes, such as those containing steam or oil, are lagged. Access to
any area where hot metalwork or gases may be encountered should be restricted..
All boilers lose heat by radiation and convection, but this loss is reduced
effectively by insulation of the boiler shell. Under normal operating conditions,
external boiler surfaces radiate a certain amount of heat, particularly at the rear of
the boiler. Boilerhouse personnel are advised to avoid touching these surfaces
unless they are properly protected.

6.4.3 Flame Observation

WARNING
Observation of the flame should NEVER be undertaken by the
naked eye. Safety glasses, preferably tinted, should always be worn
when viewing the flame.
Before viewing the flame, a careful observation should be made to ensure that the
sight glass is not cracked and that there is no hot gas emission.
WARNING
It is important to remember that a cracked sight glass indicates a
dangerous condition, it can shatter outwards from the boiler and

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should be renewed immediately. THE BOILER MUST BE SHUT

DOWN BEFORE ANY REPLACEMENT IS MADE.

6.4.4 Flue Gases

There are various methods of measuring flue gas characteristics. BIB Cochran
Limited can advise upon the most effective means for your boiler plant.

6.4.4.1 COMPOSITION

Combustion air should be adjusted to keep smoke emission within the local Clean
Air requirements, while maintaining the highest percentage of CO2 (carbon
dioxide) and the smallest percentage of O2 (oxygen).
It is important to note that CO (carbon monoxide) in the flue gas, not only
indicates a serious loss of efficiency but also the presence of a toxic gas. The
creation of CO in the flue gases must be avoided at all times.

6.4.4.2 TEMPERATURES

The hot flue gases leave the steam boiler by a flue connection at the rear of the
boiler. Gases are normally exhausted to atmosphere by a chimney. The products
of combustion must be adequately dispersed in order to comply with local
regulations. The temperature of the gases leaving the boiler may be of the order of
260°C.
It is recommended that instruments are mounted in the boilerhouse to constantly
display flue gas exit temperatures. If this is not possible, regular weekly checks
must be made with a thermometer through the rear instrument plug. A
temperature rise above the normal by approximately 10°C indicates a greater heat
loss and consequently a less efficient boiler. The boiler should be shut down and
cleaned. For optimum efficiency, periods of cleaning should not extend beyond
three months.

6.4.5 Emergency Procedures

All members of staff should be aware of the procedures, as defined by company

policy documents, to be adopted in the case of a major or minor accident or
incident.
WARNING
Care should be taken when approaching the boiler during all
emergency conditions.
Emergency equipment must be readily available for use in emergency situations.
Fire fighting equipment, including equipment particularly suitable for combating
the relevant fuel and electrical fires, must be available in the area. Staff should be
familiar with the correct use of the emergency equipment.

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6.5 BOILER MAINTENANCE

Regular maintenance must be carried out in order to maintain plant performance

at its optimum. It is stressed that maintenance should only be carried out by
competent personnel.
Before undertaking any maintenance work on the steam boiler and/or associated
plant, adequate safeguards must be taken to protect personnel who are to
undertake this work. Equipment must be properly isolated.
Guards are fitted to various components on the boiler. Guards should never be
removed without taking suitable precautions to protect the operator and the
equipment.
Automatic systems and equipment may operate without warning. Do not attempt
to work on any equipment, or any moving parts, which may become energised,
without switching off the control equipment and then isolating the energy
supply from all relevant items of plant.
If any doubt or question exists related to safe maintenance procedures, please
contact BIB Cochran Limited for advice.

6.5.1 General Recommendations

CAUTION
Should it be necessary for welding to be performed in the vicinity of
the boilers and associated plant, it is important that electronic
instrumentation is disconnected and isolated BEFORE welding
commences. This is particularly important when microprocessor-
based equipment is fitted to the boiler plant.
General recommendations for maintaining your boiler plant include:
1) Maintain accurate records of plant operation and maintenance.
2) Monitor all plant and be aware of changes in operation which could indicate
potential problems.
3) Keep all plant clean.
4) Repair any leaking joints without delay.
5) Check all electrical components for tightness, etc.
6) Repair or replace defective items of plant, components, etc. as soon as
practical.
7) Maintain a stock of spare parts in order to reduce down time.

6.5.2 Records

It is recommended that records should be kept of all tests, servicing and

maintenance performed on the boiler plant. It is also recommended that records of

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blowdown and daily water testing are kept. All tests should be carried out in the
presence of a competent person. The boiler logbook should be inspected and
countersigned by the plant management at least once per week.
Logbooks and records relating to the operation of boiler plant provide important
evidence that operational procedures have been followed. After an accident or
incident, these records may be essential if the operator is to prove that the plant
has been properly operated and maintained.

6.5.3 Plant Performance

Frequent observation of the operation of the boiler plant and associated equipment
will help the boiler operator to become familiar with all aspects of plant operation.
Familiarity with the plant can be used to detect potential faults before a serious
problem arises. Early detection can prevent costly breakdowns and serious
damage to the plant.
The boiler operator should be aware of changes and/or deterioration in plant
operation and/or performance, since they could indicate potential problems.
Changes in temperature or the levels of noise or vibration can indicate potential
problems, which if not rectified may seriously damage the boiler plant. Personnel
responsible for boiler plant operation and maintenance should investigate all
changes in plant operation as soon as practicable.

6.5.4 Cleanliness

It is generally easier to identify problems on clean plant. Dirt can often hide or
disguise minor problems so that faults can not be readily identified. For example,
dirty sensors or electrical contacts can produce erratic and/or intermittent faults in
control equipment, which prevent the plant from operating.
Debris in the boilerhouse can be a potential fire risk, especially if it comes into
contact with a fuel leak. Keep the area surrounding the combustion equipment and
its associated equipment clear of debris, dust and rubbish. If debris is sucked into
the air intake of a fan, the fan impeller could be seriously damaged.

6.5.5 Leaks

When the boiler and plant has been working for some time, it is good operator
practice to check for leaks. Regular checks for leakage of fuel, steam, water and
combustion gases should form part of a boilerhouse maintenance programme.
Contain any spillage using suitable absorbent materials.

6.5.5.1 STEAM AND HOT WATER

Live steam or hot water can escape from worn valve joints and connections. This
is not only wasteful and expensive, it also represents a danger to boilerhouse
personnel. Replacement joints should be readily available and all such leaks
should be repaired as soon as practical.

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6.5.5.2 LIQUID FUELS

Spilt fuel must not be allowed to accumulate since it presents a significant fire
hazard. It can cause serious accidents to personnel. Contain any spillage using oil
absorbent materials. Consult a responsible person or your Safety Officer, if
appointed, for appropriate precautions. Make no attempt to operate the boiler
plant while fuel is escaping.

6.5.5.3 GASEOUS FUELS

WARNING
It is important to remember that some gaseous fuels are heavier
than air. These fuels tend to accumulate at ground level.
With burners using gas, as either the main fuel or for ignition, any suspected
leakage of gas, must be treated as an immediate and dangerous explosion risk.
Any suspicion of a gas leak should be reported immediately to a responsible
person and an authorised inspection carried out.
Make no attempt to operate the plant while gas is escaping. The affected area
must be cleared immediately with full no smoking, no naked flames and no
source of ignition precautions taken as instructed by the responsible person or
Safety Officer, if appointed. Isolate the main gas supply outside the affected area
(if possible).
WARNING
Under no circumstances must a naked flame be used for checking
gas leaks.

6.5.6 Electrical Faults

WARNING
The boiler plant and associated equipment contain voltages that may
cause electrical shock, injury or death. Only suitably qualified, and
competent personnel should carry out work on the electrical
equipment of this boiler installation.
Before starting any electrical work on the equipment, ensure that the equipment is
isolated at the main boilerhouse switch board and cannot be reinstated without
adequate warning. Ensure that there is no possibility of a feed back from other
control systems. Warning notices must be posted and restricted access established.
Diagnosis of a fault should always be carried out by a competent person with the
aid of the schematic diagram of the electrical controls. Do not leave control panels
or junction boxes uncovered while the power is on. Should it become necessary to
do so, in the interest of rectifying faults, then only competent qualified personnel
must be involved. Covers must be replaced as soon as possible.

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6.5.7 Spare Parts

In order to minimise the length of time that your steam boiler is out of service, it
is recommended that you hold a stock of replacement parts. Stocks of spare parts
should also be held for associated equipment such as the burner, feed water pump,
etc.
To ensure safe operation, we strongly recommend that only genuine BIB
Cochran supplied spare parts are fitted to your plant. BIB Cochran Spares
Department can supply any spare parts which you may need to ensure the
continuity of operation and efficiency of the equipment supplied.

6.6 INTERNAL INSPECTION/MAINTENANCE

6.6.1 General Recommendations

General recommendations for working in a confined space include:

1) Do not allow unaccompanied personnel to work in confined spaces.
2) Warning notices, advising that personnel are working inside the boiler, must
be placed at clearly visible locations and all points of access and operation.
3) Ensure that the equipment has been properly isolated, or disconnected, from
other items of plant. Isolating valves should be locked with a padlock and
chain, or disconnected.
4) It must not be possible to operate any plant, without the permission of a
responsible person.
5) Do not enter a confined space without obtaining appropriate work
authorisation. A responsible person, acting on behalf of the boiler operator,
must be aware that people are inside the boiler.
6) Wear breathing apparatus, unless the area has been declared safe for working.
Precautions must be taken to ensure that personnel inspecting the boiler
internals are not exposed to dangerous fumes or inadequate ventilation.
7) Ensure that the area is devoid of personnel and equipment before closing up
access doors.
8) Do not attempt to operate any plant until all maintenance authorisations, work
permits, etc. have been cleared.

6.6.2 Internal Inspection of the Boiler

Internal inspection of the boiler and furnace must never be undertaken unless a
reasonable time has elapsed to allow the boiler and furnace to be fully vented.
Before an internal inspection, the boiler should be shut down and left to cool. The
boiler must be allowed to cool slowly to a safe condition for inspection and
maintenance. Rapid cooling hardens scale in the boiler and can cause joints to
open.

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WARNING
It is important to ensure that the boiler is vented before attempting
to remove pressure-side access doors. Due to the vacuum created
inside an idle boiler, failure to vent could result in an injury to the
operator when the access door securing nuts and bridges are
removed.
When atmospheric pressure shows on the gauge, vent valves can be opened and
the water run out. Manhole or access covers should not be removed or opened,
while there is the slightest possibility of any pressure or vacuum condition
existing in the boiler. Do not rely entirely upon the pressure gauge and sufficient
margin of time must be allowed after the pressure has fallen to atmospheric and
the vent valves have been opened.
Before entering a boiler, a check must be made to verify that all steam, water, fuel
and drain connections have been properly isolated or disconnected. With multiple
boiler installations, isolating valves should be locked with padlock and chain, or
be disconnected.

7. CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

This section contains Health and Safety information of equipment and materials
normally found on our boilers. This information, required by the Control of
Substances Hazardous to Health Regulations (COSHH) 1988, should be used
when making assessments of hazardous substances, or when removing or
renewing the materials mentioned. Outside the UK, reference should be made to
National and/or Regional legislation concerning the use and control of these
materials or their constituents.

8. BOILER REFRACTORY CEMENT

8.1 HEALTH AND SAFETY INFORMATION

Product Name NEI Castable 1550

Description Dry Mixed Castable Refractory
Constituents Corundum, Mullite, Mono-Calcium Aluminate,
Di-Calcium Silicate, Calcium Alumino Ferrites.

8.2 RECOMMENDED EXPOSURE

10 mg/m3 (8 hour time-weighted average (TWA) reference period)

8.3 STORAGE AND HANDLING

Storage Store material in a dry place. Shelf life 12 months.

Handling Use rubber gloves and suitable eye protection
during mixing. Where dust levels are likely to

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exceed the recommended exposure limit, suitable

dust masks or respirators should be used. (See
Special Handling Precautions).
Disposal No special precautions refer to Local Authority
disposal requirements.
Fire Hazard None

8.4 FIRST AID

Skin contact Wash with mild detergent and water.

Eye contact Use suitable eye protection to minimise risk. If
material comes into contact with eyes, wash with
plenty of water. Seek medical advice if necessary.
Inhalation Remove to fresh air. No known toxic effects.
Ingestion No known toxic effect: treat symptomatically and
seek medical advice if necessary.

8.5 SPECIAL HANDLING PRECAUTIONS

The above information relates to the material as supplied. Customers are advised
to evaluate any changes to the material which may occur due to operating
conditions before carrying out wrecking operations.

9. FIBRE BASED PRODUCTS

9.1 HEALTH AND SAFETY INFORMATION

Various animal and biological studies have been carried out on Man-Made
Mineral Fibres, involving both inhalation and injection experiments. The results
of both the animal injection and inhalation studies are conflicting.
Taking all available studies into account, along with other relevant health
information, the International Agency for Research on Cancer (IARC) has
categorised all Man-Made Mineral Fibres as “Possibly carcinogenic to Humans”.
As an on-going commitment to Health and Safety, the World Health Organisation
(WHO) has also classified all Mineral Wool, Rock Wool, Glass and other fibre
products and Ceramic Fibre products as “possibly carcinogenic to humans”. It
should be stressed that all man-made fibres are included in this category.

9.2 SAFETY PRECAUTIONS

Information regarding safe working practices with fibre-based products is given

below. These precautions should be observed when products containing these
materials are being manufactured, processed, converted or installed. Additional
precautions may be applicable when fibre-based products are being removed after

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service. More stringent precautions are required if

cristobalite or any other hazardous material is present, and in any circumstances
local regulations must be observed.
1) Design all operations to minimise dust. Assess the potential exposure to dust
(by measurement of atmospheric concentration if necessary).
2) Where necessary and reasonably practicable, provide dust extraction at
source. If the Exposure Limit is exceeded, or likely to be exceeded, suitable
Respiratory Protective Equipment should be provided.
3) Keep the Workplace clean, preferably by use of a vacuum cleaner fitted
with an exhaust filter.
4) Avoid contact with fumes from binding agents or lubricants, especially if
the material has been subjected to a high temperature.
5) Collect scrap near to its source into suitable containers or strong bags and
remove regularly.
6) Where appropriate, isolate working areas by partitions, screens or curtains.
7) Train operators in good and clean working habits.
8) Operators should wear long-sleeved clothing, loose at the neck and wrist,
together with a head covering, eye protection and gloves if desired. Try to
avoid skin contact.
9) Provide facilities for removal and storage of working clothes and
equipment.
10) Wash work clothes separately from ordinary clothing.
11) Instruct operators to wash all exposed skin areas after handling ceramic
fibre, first rinsing with water then washing gently with soap, not detergent.
12) Provide facilities for regular inspection and maintenance of all engineering
control and other protective equipment.

9.3 HANDLING

Caution is recommended when working with fibrous materials since they are a
potential source of fibrous dust. The dust may be harmful if inhaled and can cause
temporary irritation of the skin, eyes, throat and nose. Adequate precautions must
be taken (such as exhaust ventilation and, where necessary, suitable dust masks),
to ensure that individual exposure to fibre dust is minimised.
Working with fibrous materials may involve other substances, used either as
bonds or lubricants, as additions to the fibre composition or as contaminants
arising from processes or fuels. In these circumstances the precautions should be
reviewed against any which may be required for the other substances and the most
stringent applied.

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9.4 EXPOSURE

Any applicable exposure limit must be observed. In most countries a limit of 5

mg/m3 of total dust measured as a time-weighted average over eight hours is
applicable although some authorities prefer a fibre count limit.
Accidental exposure resulting in inhalation of a high concentration of fibres can
produce temporary coughing and throat irritation but this condition should subside
shortly after removal from exposure.
Skin contact with fibrous materials can cause mild transitory mechanical irritation
in some sensitive individuals. It is recommended that, as a precaution, gloves and
long-sleeved garments be worn by operators handling the material and that
clothing should be loose around the neck and wrists.

10. BOILER INSULATION – CERAMIC FIBRE

10.1 HEALTH & SAFETY INFORMATION

Product Name Fiberfrax Durablanket 1400 (AZS)

Description Refractory ceramic fibre composed of alumina,
silica and zironia.
Composition Glass, Oxide, Chemicals
EINECS Number 266 –046 –0
CAS Number 65997 –17 –3
Symbol Xn (harmful)
Risk Phrases R20: Harmful by inhalation.
R36/37/38: May be irritating to skin, eyes and
respiratory system.
R40: Possible risks of irreversible effects
Safety Advice Phrases S24/24: Avoid contact with skin and eyes.
S36/37/39: Wear suitable loose fitting, long-
sleeved clothing, gloves and eye protection
S38: Wear suitable respiratory equipment

10.2 HAZARDS

Pre-Existing Conditions As with any dust, pre-existing upper respiratory

and lung diseases may be aggravated.
Acute Health Effects Product is a mechanical irritant to skin, eyes and
upper respiratory system.
Chronic Health Effects Based on animal studies, excessive exposure to
refractory ceramic fibres (RCF) dust before and

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after service may cause lung damage (fibrosis) and

tumours. IARC has classified RCF as “Possibly
carcinogenic to human” (2B) and crystalline silica
as “Probably carcinogenic to humans” (2A).
This material contains small amounts of uranium and thorium, which are naturally
occurring radioactive elements. The material can only present a significant
radiological hazard if inhaled during dusty operations. As long as airborne dust is
controlled in such a way that the limit for fibre concentration 4 mg/m3 is not
exceeded the radiation exposure will not be significant. If this limit is exceeded,
the requirements of the Ionising Radiations Regulations 1985 will have to be met.
Continuous use of RCF products at temperatures above 900°C, may, as with many
other refractories, leads to the formation of cristobalite (a type of crystalline
silica). Prolonged/repeated inhalation of respirable crystalline silica dust may
cause delayed lung injury (silicosis). Although research on after-service RCF have
shown that it poses no greater health hazard than unused ceramic fibre, the
appropriate hygiene standards for cristobalite must be followed. Cristobalite has a
maximum exposure limit of 0.4 mg/m3 which should not be exceeded.

10.3 FIRST AID

Inhalation Irritation or soreness in throat and nose. In

extreme exposure some congestion may occur.
Remove to fresh air, drink water to clear throat
and blow nose to evacuate fibres.
Skin Contact Temporary irritation or rash.
Rinse affected areas with water and wash gently
with soap. Do not use detergent.
Eyes Temporary irritation or inflammation.
Flush eyes with large quantities of water. Have
eye bath readily available where eye contact may
occur.
Ingestion May cause temporary irritation and disturbance to
the gastro-intestinal system.
Drink plenty of water
Other Information Acute irritation and/or inflammation are due to
mechanical action. Seek medical attention if
symptoms persist.

10.4 FIRE-FIGHTING

These materials are non-combustibles. Use extinguishing agent suitable for type
of surrounding combustible materials.

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10.5 ACCIDENTAL RELEASE

Personal Precautions If spillage causes unnaturally high dust levels, use

RPE as recommended in Section 5.
Environmental Precautions Do not flush spillage to drain and prevent from
entering natural water courses. Do not allow to be
wind blown.
Methods for Cleaning Up Good housekeeping practices, such as planned
cleaning, will reduce underfoot debris. Pick up
large pieces and use a vacuum cleaner with a
high-efficiency filter fitted to the exhaust for
smaller pieces or dust; otherwise ensure the area is
wetted down prior to brushing.

10.6 TRANSPORTATION, HANDLING AND STORAGE

Transportation Ensure that dust is not wind blown during

transportation.
Handling Keep dust levels to a minimum and below OEL or
ECFIA exposure guideline of 1fibre/ml. (See
Section 9).
Storage Store dry and cool
Recommended packaging Recyclable cardboard and/or plastic films.
material

10.7 EXPOSURE CONTROL/PERSONAL PROTECTION

10.7.1 Engineering Control

Use engineering controls, such as dust extraction at point of work, to keep dust
level to a minimum. A vacuum cleaner, fitted with HEPA filters, should be used
to collect debris.

10.7.2 Specific Control Parameters

Health and Safety Executive publication EH40 recommends the following

maximum exposure limits, based on an eight hour time weighted average:
Phase Control Optical Microscope ................................................. MEL 2 fibres/ml
Gravimetric ......................................................................................... MEL 5 mg/m3
ECFIA recommended a maximum refractory ceramic fibre exposure limit value of
1 fibre/ml and a maximum recommended respirable cristobalite exposure limit
value of 0.5 mg/m3

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10.7.3 Personal Protective Equipments

General Recommendations Maintain high standards of personal hygiene.

Keep work areas regularly cleaned.
Respiratory Protection
0 to 1 fibres/ml Optional approved respiratory protection type
FFP2
1 to 5 fibres/ml Approved respiratory protection type FFP2
5 to 25 fibres/ml Full-face air purifying respirator with high-
efficiency particulate air filter cartridges or a
powered air-purifying respirator equipped with
similar cartridge filters (FFP3).
Over 25 F/ml Please contact the manufacturer for assistance.
Hand Protection Use of gloves is recommended
Eyes Protection Wear goggles or safety glasses with sideshields.
Do not wear contact lenses
Skin Protection Wear overalls which are loose fitting at the neck
and wrists

10.8 PHYSICAL AND CHEMICAL PROPERTIES

Appearance White fibre

Odour None
Boiler Point N/A
Melting Point 1560 °C
Flash Point N/A
Flammability N/A
Autoflammability N/A
Explosives Properties N/A
Oxidising Properties N/A
Vapour Pressure N/A
Bulk Density 96 –192 kg/mM3
Solubility Slight
Partition Coefficient N/A

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10.9 STABILITY AND REACTIVITY

Conditions To Avoid N/A

Materials To Avoid N/A

10.10 TOXICOLOGICAL INFORMATION

10.10.1 Acute Toxicity

Lethal dose 50% (LD50)/Lethal concentration 50% (LC50) : N/A

Irritation tests: Not a skin irritant according to method B4 of the directive
84/449/EEC

10.10.2 Epidemiology

Industry epidemiologic investigations of RCF production works are continuing.

The preliminary evidence, obtained from employees in RCF manufacturing
facilities is as follows:
1) There is no evidence of any fibrotic lung disease (interstitial fibrosis)
whatsoever on x-ray.
2) There is no evidence of any lung disease among those employees exposed to
RCF that have never smoked. Among smokers and ex-smokers some
symptoms of dry cough and breathlessness were found.
3) A statistical trend was observed in the exposed population between the
duration of exposure to RCF and a decrease in some measures of pulmonary
function. These observations are clinically insignificant. In other words, if
these observations were made on an individual employee, the results would
be interpreted as being within the normal range.
4) In a US study, pleural plaques (thickening along the chest wall) have been
observed in a small number of employees who had a long duration of
employment. There are several occupational and non-occupational causes
for pleural plaques. It should be noted that plaques are not pre-cancer, nor
are they associated with any measurable effect on lung function.

10.10.3 Toxicology

A number of studies on the health effects of inhalation exposure of rats and

hamsters have been completed. The results of the studies show conflicting results.
IARC reviewed the carcinogenicity data on man-made vitreous fibres (including
ceramic fibre, glasswool, rockwool and slagwool) in 1987. IRAC classified
ceramics fibre, fibrous glasswool and mineral wool (rockwool and slagwool) as
possible human carcinogens (Group 2B). This classification of ceramic fibre was
based on sufficient evidence of carcinogenicity in experimental animals in the
absence of data on the carcinogenicity of ceramic fibres to humans.

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10.11 ECOLOGICAL INFORMATION

These products are inert materials which remain stable over a considerable time.

10.12 DISPOSAL CONSIDERATIONS

Waste from these materials (even after use above 900°C) is not classified as
hazardous waste and may generally be disposed of at a normal tipping site which
has been licensed for the disposal of industrial waste. Where such a waste has
been contaminated by products which may be classified as hazardous, expert
guidance should be sought.
Such a waste is normally dusty (unless wetted) and so should be properly bagged
or contained for disposal. At some tip sites dusty wastes may be treated
differently in order to ensure they are dealt with promptly and to avoid them being
wind blown.

10.13 REGULATORY INFORMATION

RCF classification and labelling following Directive 67/548/EEC is presently

under review by the EEC Commission. EEC regulations are implemented in all
EEC States through their own existing legislative system, for example in the
United Kingdom:
1) Chemicals (Hazard Information and Packaging) Regulations 1993 (CHIP)
2) Control of Substances Hazardous to Health Regulations 1998 (COSHH)
3) Ionising Radiation regulations 1985
4) HSE EH 40 – Occupational Exposure Limits – latest issue
5) HSE EH 46 – Man Made Mineral Fibre guidance note
6) HSE EH 59 – Crystalline silica guidance note
7) MDHS 14 – General methods for the gravimetric determination of
respirable and total inhalable dust
8) MDHS 59 – Man Made Mineral Fibre. Airborne number concentration by
phase contrast light microscopy

11. BOILER INSULATION – MINERAL WOOL

The information in this section is intended to ensure the safe handling and use of
the Ecomax range of mineral wool insulation products. The products are all based
on rock wool, which is classified as a man-made mineral fibre.

11.1 COMPOSITION

Rock wool is manufactured from the volcanic rock, diabase. The molten rock is
spun into fibres which are bound with a small amount of resin (generally less than
3%), composed of heat cured urea/phenol formaldehyde. The fibres are treated

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with a small quantity of sunflower oil (generally less than 0.5%), which acts as a
dust suppressant. The composition of the rock wool is such as to render it inert in
normal applications.

11.2 FIRE PROPERTIES

Many of the Ecomax products are non-combustible or faced with a Class 1

surface material. The products will not add to the risk of fire and some products
are used for fire protection purposes. Ecomax products do not melt at
temperatures below 1200°C.

11.3 HEALTH RISKS

The health risk from working with Ecomax products is believed to be very low.
The subject of health risks associated with man-made mineral fibres has been
intensely studied. There is no evidence that the material presents any risk to
production workers either today or in the past 20 to 30 years. Reports of slight
cancer excess in workers in some plants with 30 or more years exposure to the
manufacturing environment should be considered against the considerable
scientific information on human and animal studies, where no increased risk of
disease is suggested.
The World Health Organisation classifies man-made mineral fibre as a “possible
carcinogenic”. It would be prudent to act on the basis that sufficient exposure to
man-made mineral fibres in industry may increase the risk of lung cancer among
the workforce.

11.4 HANDLING AND USE

The products are generally supplied in cartons, polythene bags or shrink-wrapped

on pallets.
In the normal handling and use of Ecomax products no special precautions are
required. The products do not give rise to significant levels of airborne dust.
Where products are being processed (such as sanding, cutting on a band saw, etc.)
it is recommended that any dust generated is removed by an air extraction system
at the cutting point, and that the extraction air is filtered.

11.5 RESPIRATORY PROTECTION

Where significant levels of airborne dust may be unavoidable, e.g. working with
materials in a confined unventilated space, then a suitable disposable face mask
complying with BS 6016, or equivalent, should be worn in order to minimise
inhalation of dust and fibres.
The maximum exposure limit of man-made mineral fibre is 5 mg/m3 of air (for an
exposure of 8 hours on a time weighted average period). In practice airborne dust
levels are usually only a small fraction of this level.

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11.6 SKIN IRRITATION

Ecomax products are normally comfortable to work with, but skin irritation may
be experienced by some people. If this occurs then gloves should be worn when
handling this product. Always rinse hands and wrists in cold running water before
washing with soap. Barrier creams can be used.

11.7 EYE PROTECTION

Eye protection may be required when working with materials directly overhead.
Should material get into the eye, wash the eye with plenty of clean cold water.

11.8 CLOTHING

Work clothing that has been soiled with fibres should be washed separately from
other clothing. Avoid clothing that fits tightly at neck or wrists. Change work
clothing regularly.

11.9 HOUSEKEEPING

When working with Ecomax products, keep the work area clean and tidy. No
special precautions need be taken regarding storage or transport. Waste products
are not hazardous and should be disposed of in accordance with local regulations.

11.10 REGULATIONS

Under the Control of Substances Hazardous to Health Regulations, employers and

employees have a number of responsibilities and duties to minimise any risks to
health caused by various materials including man-made mineral fibres. The
Approved Codes of Practice to enable them to comply with the regulations is
published by the Health and Safety Commission. Additional information is also
available from Health & Safety Executive Guidance Notes EH46 and EH40.

11.11 FURTHER INFORMATION

1) Mineral Wool & Health – A Summary leaflet issued by the Eurisol UK

Mineral Wool Association dated 29 June 1967.
2) Annals of Occupational Hygiene Col 31 No 4B WHO Symposium on Man-
Made Mineral fibres in the Working Environment held in Copenhagen 28 –
29 October 1986.
3) Health & Safety Executive Guidance Note EH40/88 Occupational Exposure
Limits 1988 Appendix 2.
4) ACGIH Booklet. “Threshold Limit Values and Biological Exposure Indices
for 1987/88".

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12. GLASS FIBRE JOINTING MATERIAL

12.1 PRODUCTS

Glass fibre textiles, such as yarns, cloths, tapes, ropes, tubings and braided and
knitted packings including plain woven glass carded fibre fabric wire reinforced
with natural rubber proofing (but not glass wool produced from blown glass fibre
such as lagging).
The products covered by this data sheet are manufactured from glass fibres having
a diameter of at least 6 micrometres. The fibres may be continuous, sometimes
with broken ends, for example, air-texturised, or discontinuous.

12.2 COMPOSITION

Glass fibre textiles are most commonly made from continuous filament
borasilicate type “E” glass. Some speciality products may be made from chemical
resistant type “C” glass.
Typical Composition “E” Glass “C” Glass
Silicone Dioxide 55.0 62.0
Aluminium Oxide 14.5 5.0
Calcium Oxide 22.0 7.0
Magnesium Oxide 0.3 4.0
Sodium Oxide 0.4 15.0
Boron Oxide 7.5 6.0
Potassium Oxide 0.3 1.0

12.3 APPLICATION

Glass textiles are used for fire and heat protection and as reinforcement in
composite materials. Typical applications include insulation, protective clothing,
and manway, head and mud hole seals and fire barriers.

12.4 HAZARDS

When first exposed to high temperatures, some fumes may be given off due to
small concentrations of textile processing additives.
Contact with glass fibre products may cause temporary irritation. Wear long
sleeved, loose fitting clothing, preferably made out of cotton, when handling the
material. Gloves and eye protection may be appropriate in certain operations,
wash with soap and warm water after handling.
If high levels of dust are encountered, the use of a disposable mask suitable for
nuisance dusts is advisable.
Despite exhaustive investigations there is no evidence to link exposure to glass
fibres of 6 micrometre diameter and above, which are non-respirable, with cancer.

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12.4 DISPOSAL

The disposal of waste material should be carried out in accordance with national
& regional directives.

13. GLASS FIBRE GASKET MATERIAL

13.1 PRODUCTS & APPLICATION

Sheet sealing materials, used for sealing flanged steam and water connections.

13.2 COMPOSITION

Materials covered contain fibres made from Borosilicate-E-Glass (CAS 65997-

17-3) and para-aramind (CAS 24938-60-1) organic fibre of which some fibres are
respirable size. Other constituents include inert filler, rubber binder, curing agent,
processing aids, pigments and surface finish.

13.3 HAZARDS

Occupational exposure to para-aramid fibre dust should be kept to the minimum

and not exceed Occupational Exposure Limit of 0.5 f/ml 8Hrs TWA (1). Only
when the material is being is subject to harsh abrasion or damaged by fire are dust
levels likely to raise above the given exposure limits.
If high levels of dust are encountered the use of a disposable mask, suitable for
irritant dust is advisable.
Contact with glass fibre products may cause temporary irritation. Wear long
sleeved, loose fitting clothing, preferably made out of cotton, when handling the
material. Gloves and eye protection may be appropriate in certain operations,
wash with soap and warm water after handling.
Despite exhaustive investigations there is no evidence to link exposure to glass
fibres of 6 micrometers diameter and above, which are non-respirable, with
cancer.

13.4 DISPOSAL

The disposal of waste material should be carried out in accordance with national
& regional directives.
(1) Health and Safety executive Guidance Note EH40.99

14. GLASS FIBRE GLAND PACKING

14.1 PRODUCT & APPLICATION

High quality braided packing manufactured from high purity exfoliated graphite.
Packing is used as a sealing medium in valve glands.

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14.2 COMPOSITION

A soft naturally lubricious braided packing made from 98.5% exfoliated graphite.
The material is suitable for sealing high pressure, high temperature applications
(steam) 650°C.

14.3 HAZARDS

The material is believed to present no health and safety hazards and, under normal
handling and use, it is unlikely that the product will give rise to significant levels
of exposure to constituent materials.
Under harsh mechanical treatment (e.g. abrasion) the constituents may give rise to
irritant dust which, in extreme cases of exposure, could lead to more serious
respiratory problems. Occupational exposure to such dust should therefore be
minimised. If high levels of dust are encountered the use of a disposable mask,
suitable for irritant dust is advisable.
Good standards of hygiene should be applied during cutting, installation and
removal, the use of barrier creams is advisable when handling the material.

14.4 DISPOSAL

The disposal of waste material should be carried out in accordance with national
& regional directives.

HS0-1299.doc
 ASSOCIATION OF

ASB SHELL BOILERMAKERS

AND ALLIED EQUIPMENT
MANUFACTURERS

The Treatment of Water

for Shell Boilers

A short guide compiled by

the Association’s Technical Committee

SIXTH EDITION
1997

Published by the
Association of Shell Boilermakers and Allied Equipment Manufacturers

4 Bankfield Lane, Norden

Rochdale Ol11 5RJ

Copyright Price £5.00 post free

 CONTENTS
INTRODUCTION ……………………………………………………… 2

SCALE Overheating boiler failure, water impurities,

Blowdown, conditioning …………………………….2

CORROSION Dissolved oxygen, chemical deaeration,

Physical deaeration …………………………………. 3

FOAM Steam wetness, water level controls,

Thermal conductivity ………………………………..3

Chapter 1: SCALE FORMATION

Impurities, temporary and permanent hardness,
Control of silica, overheating effect, thermal
Conductivity, external treatment, base exchange,
Dealkalisation, demineralisation, reverse
Osmosis, blow-down ……………………………….. 4

Chapter 2: CORROSION
Preboiler system, deaeration, boiler, condensate
System, oxygen, carbon dioxide, amines ………….. 11

Chapter 3: FOAMING IN BOILERS

Stability of water level, anti-foams, boiler pressure,
Level sensors ……………………………………….14

Chapter 4: CONDITIONING TREATMENT …………………19

Chapter 5: HOT WATER BOILERS …………………………. 21

Chapter 6: IDLE BOILER PLANT ……………………………23

1
INTRODUCTION
Boiler failures can, and do, occur. Common reasons for failures are: non-operation of
controls due to sludge accumulation, perforation of smoke tubes due to corrosion and,
less frequently but even more serious, overheating, distortion and even collapse of
furnace caused by scale or other deposits.

All these can be avoided by correct water treatment.

All sources of water contain impurities which are harmful to steam and hot water
boilers. All waters, therefore, need to be chemically treated, either to remove these
impurities or to render them innocuous.

In what follows the injurious substances and their effects are described and advice is
given on what to do about them. The chapters enlarge on the details of these subjects.

Note 1. Regulation 11 of the Pressure Systems and Transportable Gas Containers Regulations, 1989
came into effect on 1 July 1994 and require boiler users to provide operators with adequate and
suitable instructions for the safe operation of the boiler, and to ensure that the boiler is not
operated, except in accordance with these instructions. Guidance given in the Health and
Safety Executive’s Approved Code of Practice Safety of Pressure Systems requires that
instructions should cover, if appropriate, the feed water treatment.

Note 2. The Control of Substances Hazardous to Health (COSHH) Regulations 1994 require an
assessment of the risk of exposure to substances hazardous to health and implication of the
control measures needed to prevent, or if that is not reasonably practicable, adequate control
such exposure. All sources of exposure in the workplace are covered including releases resulting
from explosion or venting. For further information users are advised to consult the Approved
Code of Practice covering Control of Substances Hazardous to Health and Control of
Carcinogenic Substances (Reference ISBN 0-7176-0819-0).

SCALE
Many waters when heated cause scale to form on the heated surfaces. Scaling of the
domestic kettle in hard water areas is an example. If heat transferred from the burner
through the furnace tube to the water in a steam boiler were to be impeded by scale the
result could be serious; the temperature of the metal of the furnace tube would rise and
could reach softening point. At this stage it would become unable to bear the stress
upon it and it would fail by distortion or fatigue. Such failures occur even today as a
result of using water of unsuitable composition.

Waters containing salts of calcium and magnesium are described as hard. Hard waters
are potentially scale forming especially when heated, thus to avoid these salts are
removed and the waters then described as soft. Perfectly soft waters do not deposit
scale. However, the best techniques available are less than perfect and even softened
waters require further conditioning to avoid scale and corrosion. Corrosion is described
in Chapter 2.

Chapter 1 briefly describes and reviews the main methods of softening.

Whatever system of water treatment is used it is essential to blowdown sufficient of the

water in a working boiler to maintain the total dissolved solids at the level
recommended by the boiler manufacturers or water treatment consultants. This is
particularly the case with steam boilers. This is also discussed in chapter 1 and a
formula given for determining the percentage blowdown needed.

2
CORROSION
Corrosion is electro-chemical in nature, and any or all of four basic reactions may
proceed according to prevailing conditions. For all practical purposes in boiler water
treatment, oxygen must be present for corrosion to proceed and by eliminating this
substance, corrosion in the boiler will be controlled and the metal life extended
indefinitely. For example, there are now many, packaged boilers which have been in
daily use for 15 years or more which have not been re-tubed; others, due to corrosion,
fail within a year. Deaeration can be chemical, physical or a combination of the two.

Deaeration is described in Chapter 2.

FOAM
Unavoidably there is always a small degree of carry-over of water with the steam
generated from a boiler. However, under certain conditions when contaminants are
present the boiler water may foam badly and this can cause a number of difficulties:

(a) Gross carry-over of boiler water into the steam main can occur. Traps may
be overloaded and pipes flooded leading to dangerous water hammer. Slugs
of water travelling at speeds approaching one hundred and fifty kilometres
an hour can cause serious damage.

(b) Water level controls are designed to operate in water, not in foam and
lockout of the boiler may result.

(c) Foam in contact with heated surfaces does not conduct heat away from
them as effectively as water. The boiler metal may overheat, perhaps
dangerously.

Substances which cause foam include detergents, oils, fats and solids suspended in the
boiler water. General guides to the "foaminess" of the boiler water are the Total
Dissolved Solids content and the Suspended Solids content, both increasing the
tendency to foam as their concentrations rise . This tendency to foam may also be
enhanced by the presence of high caustic alkalinity levels.

The subject is discussed in more detail in Chapter 3. "

3
 Scale Formation
A simplified explanation of scale formation is given.
Calcium, magnesium and silicon are the main offenders. Since calcium and magnesium
behave similarly, only the classic explanation of scale formation for calcium is
described. Dissolved compounds of silicon are briefly discussed separately.
In nature, rain falling through the atmosphere dissolves carbon dioxide among other
impurities to form carbonic acid.
H20 + C02 Æ H2CO3

rain carbon carbonic

dioxide acid
This acid dissolves, amongst other impurities and at atmospheric temperature, calcium
carbonate (chalk) from the rocks over which it passes to form calcium bicarbonate.

H2CO3 + CaC03 Æ CA(HCO3) 2

carbonic calcium calcium

acid carbonate bicarbonate
Subjected to high temperatures such as occur in boilers the bicarbonate breaks down
with liberation of the original carbon dioxide to deposit chalk scale.

CA(HCO3) 2 + CaC03 Æ CaC03 + CaC03 + C02

calcium chalk water carbon

bicarbonate scale dioxide

In a steam boiler the scale deposits on the heat transfer surfaces and the released carbon
dioxide mixes with the steam.
The older term "temporary" hardness derives from this process. Modern nomenclature
uses the term "alkaline" hardness.
In a similar manner rain dissolves sulphur gases from the atmosphere to form an acid
which reacts with rocks, etc., to produce calcium and magnesium sulphates. Other
calcium and magnesium salts are commonly found in water these being: calcium and
magnesium chloride and nitrate. These sulphur, chloride and nitrate salts do not break
down under the conditions found in shell boilers. Because of this, this process was
described as "permanent" hardness, nowadays referred to as "non-alkaline" hardness.
"Permanent" or "non-alkaline" hardness salts precipitate when concentrated beyond
their solubilities. The solubility of calcium sulphate decreases with increasing
temperature thus scale is likely to form if water containing calcium sulphate (gypsum) is
heated.
The compounds of silicon met with in boiler practice are generally described as silica
and these can form particularly difficult scales of very low thermal conductivity.
Defence against these very objectionable scales is by keeping the silica in solution and
at a safe level. To do this the recommended caustic alkalinity to silica ratio must be
maintained in the boiling water and/or a maximum level of silica, consistent with the
boiler operating pressure, must be maintained. Control is by regular and frequent
chemical testing.
Silica can combine with traces of metals to Form complex silicates which are extremely
troublesome.

4
5
If, in spite of adhering to all the recommendations given in Table 2 it is suspected that
silica-bearing scales are present, advice must at once be sought in the first instance from
the boiler maker and the insurance company. Failure to control silica scaling can lead to
severe overheating and to very expensive repairs.

Figure l illustrates how the metal temperature in a boiler furnace plate increases, under
the conditions indicated, as a result of the thermal impedance of a layer of average
boiler scale on the waterside surface. For a given heat flux the metal temperature will
increase as the thickness of the scale increases. If the temperature of the steel exceeds
that at which creep begins to dominate elasticity, deformation may occur. This can
result in leaking tube-plate joints, cracked tube and furnace ends, cracked ligaments and
in extreme cases, furnace collapse. Table 1 shows the thermal conductivities of various
scales.

Table 1

Typical Boiler Scales and their Thermal Conductivities

Scale Substances Conductivity

Btu in/ft2 h degF W/mK

Calcium Carbonate 6.0 - 18.0 0.864 - 2.59

Calcium Sulphate 6.0 - 18.0 1.73 - 3.45
Complex Silicates 1.5 -5.0 0.216 – 0.72
Average Boiler Scales 15.6 2.24

The very low thermal conductivities of silicate scales should be noted.

Different types of scale have different thermal conductivities and therefore thickness is
not a true measure of potential danger.

To avoid scale, one of the several softening methods described below is normally used.
Even after softening, the water needs further conditioning to guard against traces of
hardness passing the softener, against transient maloperation and to prevent corrosion.
For shell boilers such conditioning typically takes the form of calculated additions to the
softened feedwater, sodium phosphate to precipitate remaining traces of hardness salts,
sufficient alkali to ensure feed of pH 8.5 to 9.5 to avoid corrosion in the preboiler
system and in the boiler itself, and sodium sulphite to scavenge final traces of oxygen
after some form of physical deaeration.

EXTERNAL SOFTENING
The main types of external softening processes are:

a) Those based on exchange of ions, principally simple base exchange but

sometimes dealkalisation and occasionally demineralisation.

b) Those based on reverse osmosis.

6
BASE EXCHANGE SOFTENING
Ion exchange is widely used in many kinds of industrial processes. For water softening
for boiler feed base exchange is the cheapest to buy and simplest to run.

Basically the plant consists of a cylinder containing a specially prepared resin through
which water is pumped. In this vessel, calcium and magnesium ions are exchanged for
sodium ions, the product being sodium bicarbonate from the alkaline hardness salts and
sodium nitrate, chloride and sulphate from the non-alkaline hardness salts. These
sodium salts are very soluble and do not form scales when the boiler water T.D.S. (total
dissolved solids) is maintained at or below the recommended level. When the ion
exchange capacity of the resin is exhausted it is regenerated with common salt, the
calcium and magnesium ions being flushed to drain and replaced by sodium.

Figure 2 shows the cycle of events in an automatic base exchange plant. Regenerated
with common salt and given simple maintenance, such plant will produce soft water
cheaply and reliably for years. It can be used successfully even in high alkaline hardness
districts such as London, provided there is a fairly high percentage, at least 40%,
condensate return. However, in cases where there is little or no condensate return,
dealkalisation/base exchange may be necessary.

DEALKALISATION
The disadvantage of the base exchange process is that there is no reduction in TDS and
alkalinity. This may be overcome by prior removal of the alkalinity. This may be
achieved by preceding the base exchange softener by lime treatment or by a dealkalising
ion exchange process. The latter is preferred because the size of the plant is much
smaller, it can easily be made automatic and the process is more easily controlled. This
ion exchange process differs from base exchange in that the resin exchanges hydrogen
for calcium and magnesium by removing the calcium and magnesium, leaving a
solution of carbon dioxide in water. The water, after the dealkalising ion exchange
treatment, is passed through a degassing tower where the carbon dioxide is removed.
After this stage caustic soda solution is added to raise the pH value to at least 8.5.

The water, now containing little alkaline hardness, is passed through a normal base
exchanger where the non-alkaline hardness is removed. The dealkalising stage is
regenerated with acid and the base exchange stage with salt brine in the normal manner.
The total dissolved solids content and the alkalinity of the treated water are reduced by
an amount below the alkaline hardness content of the raw water. The process is
illustrated in fig. 3.

DEMINERALISATION
For very high pressure boilers such as those in power stations, this is essential.

For packaged steam raising shell boilers it can seldom be justified since both capital and
running costs are many times higher than simple base exchange. For hot water boilers
using only a small amount of make up, demineralisation is often economic and is to be
recommended. Basically it consists of removing the cations of dissolved salts in one
part of the process and the anions in another thus producing water of a very high quality
containing virtually zero dissolved solids.

7
CYCLE
1. Water passes downward through resin in regenerated condition until resin
becomes exhausted as shown by hardness breakthrough.

2. Unit is taken out of service.

3. Resin bed is backwashed to remove debris and loosen bed.

4. Saturated brine is run through resin bed to regenerate it. Calcium and
magnesium chlorides, and excess sodium chloride runs to drain followed by
rinse water. (Brine feeding arrangement not shown.)

5. Unit is returned to service.

FIG 2
TYPICAL AUTOMATIC BASE EXCHANGE UNIT

8
CYCLE
1. Water passes downward through resin in regenerated condition until resin
becomes exhausted as shown by rising pH.

2. Unit is taken out of service.

3. Resin bed is backwashed to remove debris and loosen resin.

4. Diluted (1-5%) mineral acid, e.g. H2SO4, or HC1, is run through resin bed to
regenerate it. Waste product runs to drain followed by rinse water. (Acid
feeding arrangement not shown.)

5. Unit is returned to service.

FIG 3
TYPICAL DE-ALKALISATION UNIT
(For boiler feed this is normally followed
by automatic base exchange unit)

9
REVERSE OSMOSIS
RO as it is now called is a process finding increased application for boiler feed make up
and in some cases may compare favourably with others.

If salt water and pure water are separated by a semi-permeable membrane, osmotic
pressure causes pure water to pass through it to dilute the salt water. By applying
sufficient pressure to the salt water the direction of flow is reversed and pure water
moves through the membrane leaving behind it a more concentrated salt water.

Plant to supply boiler feedwater consists essentially of a pump feeding into a bank of
tubes containing the membranes, the whole being compactly mounted in a framework
together with control panel and interconnecting pipework.

Although simple in concept RO is not yet a panacea and competent specialist advice
should be sought before adopting it. Pretreatment plant may well be necessary to
prevent membrane fouling, power costs may be high because of the high pressures
required to reverse the osmotic pressure and replacement membranes may be costly and
short lived.

BLOWDOWN
Steam raising inevitably results in the concentration of dissolved and suspended solids
in the boiler water. These promote foaming and overheating. It is therefore necessary to
control their level in the boiler by blowing down. The minimum amount of blowdown
required is calculated as a percentage of the evaporation rate by use of the following
formula.

F x 100%
Blowdown Rate =
B F
F = The total dissolved solids content of
the feed in parts per million
F = The maximum recommended solids
content for boiler water in parts per
million

Blowdown may be carried out intermittently (either manually or automatically) or

continuously, or both. The former is preferred for boilers operating with internal
treatment, this method being most effective in removing sludge particularly when
applied in short, sharp bursts.

The latter is preferred where external treatment is used, i. e., where sludge removal is
less important. In this case it is often economic to recover the heat in the blowdown
water by heat exchange.

10
 CHAPTER 2
Corrosion
Corrosion may occur in all parts of boiler plant-in the feed system, in the boiler itself, and
in the steam and condensate pipework.
PREBOILER SYSTEM
Oxygen is the main cause of corrosion in hotwells, feedlines, and feed pumps, but if
carbon dioxide is present then the pH will be low (i.e. the water will tend to be acidic) and
the rate of corrosion will be increased.
Typically, the corrosion is of the pitting type where, although the loss of metal may not be
great, deep penetration and perforation of tubes can occur within a few months:
The essential requirements for prevention of corrosion are to keep the pH of the feedwater
between 8.5 to 9.5, the lowest level at which carbon dioxide is absent, and to eliminate
oxygen. Higher levels of pH should be avoided as they lead to bumpy boiling, carry-over,
and to attack on the gauge glasses.
DEAERATION
Elimination of oxygen can be by chemical or physical methods or by a combination of
both. Water exposed to air is always saturated with oxygen, according to the water
temperature. At 0°C the oxygen content is 14ppm and this gradually reduces to zero at
100°C. The addition of sufficient oxygen scavenger sodium sulphite, hydrazine or tannin
will chemically fix it and remove its corrosive effect. The amount of sodium sulphite, the
most frequently used scavenger, required is about 10 ppm for each ppm of oxygen. To add
over 100 ppm sulphite to cold water would be expensive in chemicals, blowdown, and
loss of heat caused by the latter. Physical deaeration by preheating the feed water followed
by chemical fixation of residual oxygen is strongly recommended, as this substantially
reduces the amount of oxygen scavenger needed.
An economic case can be often made for a packaged deaerator working at or slightly
above atmospheric pressure. Since it will heat the water to or above atmospheric
saturation temperature it must be sited with sufficient head to overcome any tendency for
the boiler feedpump to cavitate. Several designs are available from water treatment
companies. It should be noted that apart from radiation losses which are negligible from
well lagged installations there is no running cost as the heat input is quickly returned to the
boiler. On the contrary there is a bonus as hot feed reduces thermal shock to the boiler.
Final traces of oxygen must always be scavenged by appropriate conditioning treatment,
details of which are given in Chapter 4.
BOILER
The process of boiling causes any carbon dioxide and oxygen present to flash off into the
steam lines. Even so, corrosion within the boiler itself may take place unless the water is
conditioned to avoid this. Corrosion may be particularly severe in idle boilers. The
precautions necessary are described in Chapter 6.
CONDENSATE RETURN SYSTEM
In condensate lines some carbon dioxide is always present even when the feed has been
dealkalised. Where simple base exchange is used for water of high alkaline hardness and
with little condensate return the carbon dioxide in steam may be as high as 150 ppm; after
dealkalisation of the same feed it may only be a few ppm. Nevertheless, condensate line
corrosion problems can occur in both cases.
The concentration of carbon dioxide in water varies with temperature and pressure; at
steam-condensing temperatures above atmospheric pressure it is virtually nil, even though
the atmosphere above it is rich in the gas. Thus the temperature of the condensate, not the
concentration of carbon dioxide in the steam, determines the corrosion potential.

11
The severity of corrosion in condensate lines increases as the temperature falls; it will
generally be found to be most severe at the end of the condensate line where it is
coolest. Where use of boiler plant is intermittent it should be remembered that copious
amounts of oxygen and carbon dioxide are available from the atmosphere and wherever
these have access to pockets of undrained cold condensate, corrosion of the containing
vessel, usually pipelines, will be very severe.

Where condensate lines are too small, a corrosion/erosion mechanism may be found
where any protective oxide film formed under favourable conditions is subsequently
destroyed by water droplets carried by steam at high velocity, say 45 m/s (150ft/s).
Carry over from the boiler will aggravate the conditions by varying the pH. Incorrect
sizing of condensate lines is prevalent, and advice on this subject is available from
technical literature. Condensate line corrosion can also be reduced to acceptable levels
by using either neutralising or filming amines; neutralising amines when the carbon
dioxide content of the steam is only a few PPM and filming amines when it is high, e.g.,
after simple base exchange in high alkalinity water areas. The materials are toxic and
may not be acceptable in the food industries.

Recommended conditions for both feed and boiler waters are given in Table 2. It is
emphasised that these are of a general nature only and special conditions may apply to
unusual waters. Specialist water treatment companies can advise in these circumstances.

Table 2. Recommended water characteristics for shell boilers up to 30 bar

Feed Water
Parameter Units Values
Appearance Clear, produces no stable foam
pH value at 25ºC 8.5 to 9.5 (note 1)
Total hardness mg/kg CaCO3 2 max. (note 1)
Dissolved oxygen mg/kg 02 (notes 3 and 4)
Total alkalinity to pH 4.5 mg/kg CaCO3 (note 5)
(M-alkalinity)
Oil and grease mg/kg (note 6)
Boiler Water
pH value at 25ºC -
Total alkalinity mg/kg CaCO3 10.5 to 12.0
(M-alkalinity) (note 7)
Caustic alkalinity mg/kg CaCO3 1000 max.
(O or P2 alkalinity)
Oxygen scavenger
(note 15)
Sodium sulphite mg/kg 30 to 70
or Hydrazine mg/kg 0.1 to 1.0
or Tannin mg/kg 120 to 160
or o ascorbic acid mg/kg 15 to 30
or Diethyl Hydroxylamine mg/kg 0.1 to 1.0 in feed water
Phosphate mg/kg PO4 30 to 60
(notes 9 and 10)
Silica mg/kg SiO2 150 max.
(note 11)
Suspended solids mg/kg 200 max.
Dissolved solids mg/kg 3500 max.
(note 12) (notes 13 and 14)

12
NOTES ON TABLE 2
1. When copper alloys are present in the feed system this value should not exceed pH 9.2 if
corrosion of these materials is to be avoided. Also, if feed pumps made from cast iron are
used, the pH may have to be increased.

2. This value can be achieved only by the use of suitable external pre-treatment plant. It is
essential that such plant should be properly maintained. It is also recommended that a
suitable polymer dispersant be used to ensure clean heat transfer surfaces.

3. Dissolved oxygen should be reduced to the lowest practicable level which will be achieved
by the use of a properly designed feed tank or a deaerator.

4. An oxygen scavenger should be used and should be added at the outlet of the feed tank or
the deaerator in sufficient quantity to reduce the dissolved oxygen level to zero before the
feed water enters the boiler or the economizer (where fitted).

5. It is recommended that feed water alkalinity be maintained below 25 mg/kg. Alkalinity of

25 mg/kg and above will result in 10 mg/kg carbon dioxide in the steam. This level of
carbon dioxide can be economically controlled by the use of a neutralizing amine. If this
feed water alkalinity level cannot be achieved, it is recommended that dealkalization of the
make-up water be carried out.

6. If the possibility exists for these substances to enter the feed system, then suitable detection
equipment should be installed to activate an alarm if they are detected.

7. Corrosion of boiler internals can occur if the pH value is outside these limits.

8. It is recommended that the caustic alkalinity be maintained at 10% to 15% of the total
dissolved solids concentration if phosphate conditioning is practised. If carbonate
conditioning is used, see note 9.

9. Maintenance of a phosphate reserve is not essential provided either that a minimum

carbonate alkalinity of 250 mg/kg can be maintained, depending on the alkalinity of the
feed water and the working pressure of the boiler, or that an appropriate programme of
transporting polymers is employed. It is important to ensure that magnesium phosphate is
not precipitated in the boiler water as it can cause sludges to adhere and form hard scales on
heat transfer surfaces. Experience has shown that this is unlikely if the phosphate does not
exceed 10% of the minimum caustic alkalinity specified in the tables. As an additional
safeguard it is common practice to use an appropriate polymeric sludge conditioner which
will maintain precipitates in suspension for removal with the blowdown.

10. The use of solubilizing treatments using chelants (EDTA, NTA etc) is permissible provided
that a maximum of 10 mg/kg is not exceeded at any time. Complete removal of oxygen
should have been achieved prior to injection of the chelant.

11. Silicate scales can be formed readily in all boilers. Maintenance of a ratio of silica content
to caustic alkalinity of less than 0.4:1 can prevent this.

12. Of these two parameters, conductivity and TDS, only one needs to be measured.

13. These values are for guidance only. It might be found from experience that lower values are
necessary to avoid priming or carryover.

14. These values are recommended for fully softened feed water in accordance with the
table. If, for whatever reason, feed water with a significant hardness has to be used then
TDS/conductivity level should be reduced to achieve the suspended solids limit. At 20
mg/kg feed water hardness the upper limit should be reduced to 6000 µS/cm* and at 40
mg /kg hardness it should be reduced to 4000 µS/cm*.

* Conductivity measured on un-neutralized sample.

15. Other oxygen scavengers are available. Control levels of these should be as recommended
by the supplier of the treatment chemical.

13
 CHAPTER 3
Foaming in Boilers
It is well known that the water level in a boiler can become unstable, the evidence being
that the water in the gauge glasses surges and copious liquid trickles downwards from the
steam connection. With automatic boilers the level controls may cause the burner to lock-
out. Wet steam can also be produced, sometimes to an alarming extent. These
phenomena are due to foaming of the boiler water.
The trend in shell boilers has been towards smaller shells for a given evaporation, thus
leaving less space to accommodate any foam formed so that modern boilers are likely to
be more sensitive than older types, such as the Lancashire. Having said that, foaming is a
function of the nature of the boiler water and can only be treated by correcting the water
conditions, which in turn will need to be examined to find out what substances are likely
to be the cause.
Foam, whether it be on a glass of beer in the kitchen sink or in a sewage works, is a
familiar sight and certain facts emerging from everyday experience are:
1. Pure water does not foam.
2. ‘Hard’ water, though it contains impurities such as the bicarbonates of calcium and
magnesium, and calcium sulphate, will not foam.
3. The addition of common soda, caustic soda, soap, or domestic detergents can all
cause foam to be formed. Some of these substances are used to soften water. Boiler
water is softened to prevent scale formation and is therefore predisposed to foaming.
4. Violent agitation of a foamy liquid increases foam formation.
5. A powder introduced into an ebullient solution causes violent foaming e.g. pure
ground ginger sprinkled onto a glass of sweet mineral water.
6. Boiling of a colloidal suspension, e.g. milk, causes violent foaming. (Note: colloidal
particles are less than 0.0001mm diameter and can pass through a normal filter.
They remain in suspension in the liquid and never settle).
Foam in a glass of beer sits on the top of the liquid; what is not generally realises is that
when foam is formed in a boiling liquid, the liquid surface disappears and the whole
content of the containing vessel becomes a graduation of foam bubbles, small and
relatively few at the bottom, large in size and number near the top. This can be studied by
gently boiling milk in a glass boiling tube.
The last simulates foaming in a boiler, and the level sensors may, under some
circumstances, give false signals. A boiler may be severely foaming and in fact be short
of water so that the heating surface may become overheated and collapse. Moreover,
foam may occur in the locality of heated surfaces and this foam cannot conduct the heat
away as quickly as water so that the heated surfaces are at risk. The ‘foaminess’ of a
boiler water can be roughly tested by withdrawing a sample from the boiler and shaking it
in a bottle.
All level sensors, electrodes and floats must be protected against a foaming condition.
This can be achieved either by enclosing the sensor in a suitably designed tube, or, as is
mostly the case, install the sensor in an external chamber where, because no heat is
generated therein, there are no bubbles or foam.
The main substances which cause or assist foam formation are:
1. Alkaline Salts
2. Suspended Solids
3. Detergents

14
In boiler waters, the amounts of the first two of these substances should be measured,
preferably daily, and if found to be increasing beyond the normal satisfactory figure,
blowdown should be increased. Excessive alkalinity can cause gauge glass failure.
The total dissolved solids content should not exceed 3,500 p.p.m. but this is a very rough
guide, as much depends on the nature of the dissolved solids. The same applies to
suspended solids which should normally not exceed 200 p.p.m. but also depends on their
nature. Solids which are distributed throughout the water stabilise foam; but if the
particles are heavy they sink out of harm’s way to the bottom of the boiler. It all depends
on what impurities are present in the feed water.
Detergents are another matter. They may be of natural origin, colloids resulting from
decaying vegetable matter, or they may be of domestic or industrial origin. The
occurrence of the latter substances is tending to increase markedly in boiler water
supplies, particularly when these are derived from streams or rivers into which the outflow
from sewage works is directed.; sewage purification processes do not break down many of
the substances. The estimation of detergent concentration will require rather special
techniques and should only be undertaken by an expert if and when their presence is
suspected. A detergent content of only 1 p.p.m. in the boiler feed can cause severe
foaming as it concentrates in the boiler; in such cases a change to town or county source
could be tried, inconvenient and expensive though it may be. The use of anion resins or
activated carbon filters may be considered as an alternative to a change of supply as they
remove many types of organic materials. Even though capital expenditure is incurred in
providing the plant, it could prove cheaper in the long run than to use an expensive water
supply.
Antifoams can be supplied by water treatment contractors. These are substances which
are added to the boiler water and break down the foam bubbles. Sometimes they can be
extremely effective, but in other cases do not have any beneficial effects. Such is the case
when foams are caused by suspended solids which absorb the antifoams and render them
useless. Hey are however, always worth a trial.
Figure 4 shows how the volume of steam increases with decreasing pressure. It follows
that the volume of foam will increase in like manner and it will be noted that the volume
increase is particularly sharp at pressures below 7.0 bar (100 lb/in2). Anything which
tends to reduce the boiler pressure, such as a sudden increase in steam demand will
therefore make a foaming condition worse. It also follows that boilers operating above7.0
bar are less sensitive than those working below. Figure 5 shows diagrammatically,
various stages of boiler foaming related to load.
It is recommended that, where boilers are known to be subject to foaming, they should be
worked right up to the maximum pressure for which they are intended and if low pressure
steam is required, this should be obtained through a reducing valve. Care should be taken
to ensure that the various steam users are phased in rather than all coming on together,
which can create steam and fuel demands beyond the capacity of the burner, and the boiler
pressure can then only fall, and this will result in carry-over.
Figure 6 is a photograph of foaming taking place in a horizontal packaged boiler
delivering 1,500kW (4,500 lb/h) and working at 7.0 bar (100 lb/in2). The view is taken
from a quartz window in the rear tube plate of the boiler and the foam has been formed by
excessive suspended solids. The foam can be seen rising in a column to the steam off
take. Needless to say, this is most undesirable and would be detectable by unstable gauge
glass levels and by high electrical conductivity of the condensate from steam users.

15
THE VOLUME AND PRESSURE OF STEAM

16
17
 Figure 6

Foaming takes place in a horizontal packaged boiler, photographed through a quartz

window in the rear tube plate. Foam is being drawn up towards the steam off-take which
is behind the structure in the foreground. The stepped tube is a depth gauge and the boiler
delivery is 1,500 kW at 7.0 bar (4,500 lb/h at 100 lb/in2). This photograph is a still from a
research film ‘Boiling Phenomena in Boilers’, prepared by Cochran Boilers Limited.

18
 CHAPTER 4
Conditioning Treatment
No matter how efficient the prior treatment of feedwater has been to remove scale forming
minerals by softening, and corrosive oxygen and carbon dioxide by elevation of pH and
deaeration. sufficient of these impurities remain to cause scaling and corrosion in the long
term. Additional chemical treatment must therefore be applied to the feedwater to ensure
that these problems do not arise. Such treatment is known as conditioning and may either
precipitate the scale forming impurities in a non-adherent and thus nonscaling condition,
or it may keep them in solution. Dissolved oxygen is removed by the addition of an
oxygen scavenger. These processes are discussed in more detail below.
Table 2 gives guidance on the qualities of both feedwater and boiler water to be
maintained to avoid scale and corrosion in the preboiler and boiler systems. To ensure
that the parameters are met it is essential to carry out the simple control tests described
in BS 2690 periodically, at least daily.
It may also be found necessary to add to the feed one or more of the following:
1. Sufficient alkali - typically a one per cent solution of caustic soda fed continually
to the hot well - to maintain pH 8.5 to 9.5 in the softened feed.
2. Sufficient sodium phosphate to precipitate the residual hardness in the feed and to
provide a reserve in the boiler to accommodate any transient mal-operation of the
softener; extra hardness coming forward would be signalled by reduction or even
disappearance of the reserve. Although calcium and magnesium phosphates
precipitated in the boiler are highly insoluble and intended to be rejected with the
blowdown an additional precaution is to add a few parts per million of a
conditioner to prevent their adherence to heating surfaces.
4. Sufficient sodium sulphite to scavenge remaining traces of oxygen and to provide
a reserve of sulphite in the boiler to accommodate any transient malfunction of the
deaerator or preheating system; if extra oxygen were to come forward this would
be signalled by a reduction or even disappearance of the reserve.
If hydrazine is being used then the limits shown in Table 2 on page 12 apply
4. Sufficient caustic soda extra to that supplied under 1 above may be necessary to
provide the desired minimum level of caustic alkalinity in the boiler water.
Addition of conditioning chemicals will of course increase the TDS and in turn the
blowdown, therefore overdosing is to be discouraged. To avoid excessive blowdown
losses, the TDS should be kept as high as possible up to the limit suggested in Table 2
consistent with avoidance of foaming.
It may occasionally be found necessary, e.g., in areas of high alkalinity, to blow down
to keep below the recommended maximum Total Alkalinity given in Table 2 instead of
the TDS. In such a case investigation of dealkalisation might be found to prove cost
effective.
Although not fundamentally difficult, the practical application of boiler water
conditioning can be rather complicated. For example, several boilers working at
different loads may be fed from a single feed pump. To provide accurate dosing
proportional to the needs of each would call for a multiplicity of chemical dosing
pumps. An experienced qualified field chemist such as can be engaged under a service
contract from several competent and reliable water treatment companies can often
provide an acceptable compromise in such a case. These companies provide chemicals
and prescribe conditioning programmes including periodic visits where laboratory
resources and water treatment knowledge are not readily available on site.

19
Conditioning chemicals other than those mentioned above can, in certain circumstances
where additional problems exist, be effective in maintaining clean metal surfaces. These
can be chelating or complexing agents such as E.D.T.A. or N.T.A. compounds;
polyelectrolyte dispersants and crystal growth distorters; polyamine based products
which form a film on metal surfaces, etc.
These products are supplied by the various water treatment companies and boiler
operators will have to assess the advantages and disadvantages of using these alternative
conditioning schemes by consultation with the water treatment specialist companies.
Although water treatment specialist companies usually provide their chemicals under
trade names or numbers this is not necessarily done to confuse or evade - names such as
" the sodium salt of ethylene diamine tetra acetic acid-(E.D.T. A.)", a commonly used
chelant - are even more confusing to the layman. Normally such companies will
willingly divulge the names of the chemicals used in their formulations on request.

20
 CHAPTER 5
Hot Water Boilers
The need for water treatment applies to all boilers whether they be for steam or hot
water. It has been commonly assumed that, because hot water boilers operate in an
apparently closed circuit, no water treatment is necessary. This is far from the truth.
Sometimes hot water, as such, is drawn-off from hot water systems. This should never
be done; a calorifier should always be used. Any accidental loss must be made up with
properly treated water.
Hot water boilers and their systems need to be initially charged with water, which will
normally contain the usual hardness salts and corrosive substances which, unless
treated, will do their share of damage. All hot water systems need to have arrangements
made for expansion of system water content and in most cases the expanded water will
at some time be in contact with the atmosphere and so be able to absorb oxygen and
carbon dioxide. Any arrangements which can be made to reduce or avoid such contact
should be made, e .g., nitrogen blanketing of expansion tanks, or the floating of an
impermeable blanket on the water surface, and for very small installations, the use of
diaphragm chambers. Even when such measures are taken, it is wise to maintain a
reserve of an active oxygen scavenger, such as sodium sulphite or hydrazine in the
system.
A hot water system is rarely perfectly sealed. There will be losses from leakage, and
evaporation from the expansion tank which may jointly need a monthly make up of
10% of the system capacity, more or less according to circumstances. The make-up
water will therefore need to be treated both for hardness and corrosion, otherwise scale
deposition and corrosion in the boiler can occur.
It is important that, particularly in hard water areas, the initial charge, and all
subsequent charges should be softened, even demineralised water, and should contain a
sufficient amount of oxygen scavenger. As stated above all make-up water needs to be
so treated.
Small inexpensive demineralising plant of sufficient capacity to handle the make-up
should be installed. Charging an empty system with such plant could take several days
or more, and this inconvenience has to be accepted. Alternatively it is possible to charge
from a tanker, loaded from a source of demineralised water, e.g. a power station.
When a heating system is commissioned after installation or modification, it is pressure
tested. This should be done with water treated for cleansing. No system should he left
drained, otherwise rapid corrosion will take place from dampness and air.
The water conditions in a hot water system should correspond to the boiler water in
Table 2, and should be kept under observation. Because there is no evaporation, and
therefore comparatively little make-up, the water analyses should remain stable over
much longer periods than with steam boilers, but this does not mean that the subject can
be neglected. Measurement and control of pH is a simple matter.
In the special case of steam-pressurised high pressure hot water systems, from which
any steam is taken as such, the water treatment should he as for steam boilers, with
much more frequent checking of the water analysis than with hot water only.

21
The following recommendations are therefore made:

1. COMMISSIONING
Before charging flush the system with water treated for cleaning. Use water
treatment specialists for this purpose, and empty the whole system immediately
afterwards. Flush with water, and immediately charge as below

2. INITIAL CHARGING
Fill the system with treated water only, if need be taking several days to fill via
the make-up treatment plant. Alternatively use a tanker to deliver treated
water.

3. MAKE-UP
Use a small amount of external water treatment plant, base exchange at
simplest and with relatively good water, whilst at the other extreme a
demineralisation plant should be used in very hard water areas.

4. CONTROL
Have the water analysed at monthly intervals at least ensuring that the
conditions in Table 2, especially the sulphate or hydrazine reserve, are
maintained. This will avoid system as well as boiler corrosion.

5. STEAM PRESSURISED HOT WATER SYSTEMS

Treat as for steam boilers if any steam is taken off.

22
 CHAPTER 6
Idle Boilers
Sometimes boilers are in full-time operation throughout the year, whilst in other cases
they are laid off for extended periods, e.g. space heating boilers during the summer
months. The former case, where the boilers are in constant demand, is the best and easiest
condition, whereas the latter can cause severe difficulties with both water-side and gas-
side corrosion unless precautions are planned.

1. WATER-SIDE CORROSION
With hot water systems, the system and boiler should be left full of properly
treated water, as described in Chapter 5 and Table 2. With steam boilers the
method is more complex, and depends on the period of lay off. If this is only a
few days it is sufficient merely to valve off, but ensuring that the sulphate or
hydrazine reserve is adequate according to Table 2. For periods of up to three
months the boiler should be fully flooded and the water checked to give a pH of
10-11.5 and a sulphite reserve of at least 150 p.p.m. The water analysis should
be checked at, say fortnightly intervals and corrected if necessary. All air should
remain excluded from the steam and water space of the boiler. If the lay off
period is over three months the boiler should be drained, the man and mud holes
should be knocked-in, and the inside completely dried out. A source of hot air,
such as that from a small convection heater, is then ducted to a mud hole and the
boiler inspected from time to time to ensure that it is kept dry. These various
methods are summarised in Table 3.

2. GAS-SIDE CORROSION
More corrosion can take place on the gas-side of an idle boiler than when the
boiler is in operation.
Gas-side corrosion results from attack on the metal of the boiler by sulphur
compounds. These accumulate in soot deposits, which may contain up to 30%
sulphuric acid, which is hygroscopic, i.e. absorbs moisture from the atmosphere.
The soot becomes wet and allows the acid, otherwise absorbed on the particles,
to migrate to and attack the boiler metal.
When boilers are laid off it is important that the gas-side is thoroughly cleaned
and all soot removed. This is much more easily done with the boiler hot. The
soot is then much drier and more readily removed than if he boiler is left, even
for a few hours.
Where the boilers are connected to separate chimneys it is best to leave the gas-
side fully ventilated, i.e. open up the burner, or remove it, and leave the exit
damper, if any, fully open.
Where the boiler outlets are connected to a common chimney this cannot be
done, otherwise flue gases may discharge back into the boiler house through idle
boiler. In these cases the exit damper must be shut.

23
24
INDEX
Activated carbon filters ………………………………………………………15
Amines Use of, to protect condensate lines ………………….12
Antifoams ………………………………………………………15
Base Exchange ……………………………………………………6,7,8
Blowdown Calculations of ………………………………….… 10
Methods of …………………………………………10
Boiler failure …………………………………………………….. 2,6
Calcium salts ……………………………………………………2,4,6
Carbon Liberation of……………………………….. 4,7,11,12
Removal of ……………………………………..…. 7
Carbonic Acid ……………………………………………………….4
Caustic Soda Use in water treatment ……………………………..6,7
Carryover Of water from boiler ……………………3,11,12,14,15
Chelants ………………………………………………. 13,20,21
Conditioning Against corrosion ……………………………12,13,19
As an adjunct to external treatment …………………19
Against foaming ……………………………………15
Corrosion Control ………………………………………….12,13
Gas side …………………………………………….23
In boilers ………………………………. 3,11,12,13,21
In condensate system ……………………………11,12
In heating system ………………………………….. 21
In idle boiler ………………………………………..23
In pre-boiler system ………………………………...11
Deaeration Need for …………………………………………….. 3
Chemical ………………………………………..11,12
Physical …………………….………………………11
Dealkalisation Principles of …………………………………………7
Degassing Removal of CO2 ……………………………………. 7
Demineralisation ……………………………………………………7,21
Detergents Effect of foaming …………………………………..15
External Treatment …………………………………………………….. 6,7
Foaming …………………………………………………...14,15
Hardness ………………………………………………2,4,6,7,21
Heat flow …………………………………………………….. 2,6
Hot-water boilers ………………………………………………….. 21,22
Hydrazine …………………………………………….11,12,13,23
Idle Boilers ………………………………………………………23
Impurities ……………………………………………………….2
Ion exchange ……………………………………………………….7
Magnesium salts …………………………………………………….. 2,4
Organic matter ………………………………………………….. 12,13
Overheating ……………………………………………………….6
Oxygen corrosion …………………………………………11,12,13,19,21
Oxygen scavenging ……………………………………………………11,12
PH …………………………………………11,12,19,21,23
Phosphate conditioning ………………………………………………. 12,13,19
Regeneration Of ion exchange systems …………………………… 7

25
Reverse osmosis ………………………………………………………10
Scale Effect on heat flow ………………………………...2,6
Occurrence of ……………………………………...2.4
Thermal conductivity of ……………………………..6
Silica ……………………………………………………4,12
Silicon ……………………………………………………….4
Sludge ……………………………………………………6,13
Sodium Sulphite …………………………………………11,12,13,23,24
Tannin ………………………………………………………11
Thermal Conductivity ……………………………………………………….6

Whilst every care has been taken in the preparation of this booklet by the Association of
Shell Boilermakers and Allied equipment manufacturers, no liability can be accepted for
the consequences of any inaccuracies or mis-statements

26
SIMPLEX DISTILLATE OIL BURNER
Page 1

CONTENTS
1. INTRODUCTION...................................................................................................................................... 2

2. GENERAL DESCRIPTION ..................................................................................................................... 2

2.1 AIR INTAKE SILENCER ...................................................................................................................... 3
2.2 OIL PUMP .............................................................................................................................................. 3
2.3 DAMPER MOTOR DRIVE UNIT ......................................................................................................... 4
2.4 BURNER SEQUENCE TIMER ............................................................................................................. 4
2.4.1 SEQUENCE LOGIC ...................................................................................................................... 4
2.4.2 Pre-Purge Sequence ...................................................................................................................... 4
2.4.3 Light-Up Sequence ........................................................................................................................ 5
2.4.4 Normal Firing................................................................................................................................ 5
2.4.5 Post-Purge Sequence..................................................................................................................... 5
2.5 BURNER OIL SYSTEM ........................................................................................................................ 5
2.6 IGNITION ASSEMBLY......................................................................................................................... 5
2.7 CONTROL PANEL ................................................................................................................................ 6
2.7.1 Sequence Timer.............................................................................................................................. 6
2.7.2 Starters........................................................................................................................................... 6
2.7.3 Fuses, Relays and Switches ........................................................................................................... 6
2.7.4 Indicator Lights/Alarms................................................................................................................. 6
2.7.5 Normal Firing Light ...................................................................................................................... 6
2.7.6 Lock-Out Light............................................................................................................................... 6
2.7.7 Mute Alarm/Run Switch ................................................................................................................. 6
2.7.8 Burner Switch ................................................................................................................................ 6
3. OPERATION ............................................................................................................................................. 7
3.1 PRELIMINARY PROCEDURE ............................................................................................................. 7
3.2 STARTING UP THE BURNER ............................................................................................................. 7
3.3 TYPICAL OPERATING PARAMETERS ............................................................................................. 8
3.4 SHUTTING DOWN THE BURNER...................................................................................................... 8
4. MAINTENANCE ....................................................................................................................................... 9

5. FAULT FINDING HINTS......................................................................................................................... 9

5.1 BURNER WILL NOT START......................................................................................................................... 9
5.2 BURNER STARTS WILL NOT LIGHT ............................................................................................................. 9
5.3 BURNER LIGHTS BUT LOCKS OUT .............................................................................................................. 9
5.4 BURNER CUTS ON AND OFF CONTINUOUSLY ........................................................................................... 10
5.5 IMPROPER COMBUSTION ........................................................................................................................ 10
6. SPARE PARTS ........................................................................................................................................ 10

7. DAMPER MOTOR DRIVE UNIT INSTRUCTIONS.......................................................................... 11

7.1 DAMPER ASSEMBLY OPERATION................................................................................................. 11
7.2 POSITIONING DRIVE MOTOR ......................................................................................................... 11
7.2.1 Cam Function Identification........................................................................................................ 11
7.3 DAMPER ADJUSTMENT ................................................................................................................... 11
7.4 ADJUSTMENT TO HIGH FIRE AIR .................................................................................................. 12

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1. INTRODUCTION
The BIB COCHRAN Mark III Simplex Distillate Oil Burner is an automatic pressure jet
type burner capable of high/low operation.

The burner has been designed to operate with distillate oils as defined by British Standards
Specification BS2869 as Class ‘D’. That is gas oil with a viscosity in the range of 1.5 to 5.5
centistokes at 40°C or equivalent. Consideration must be given to regulations applicable to
the storage and handling of fuels.

If the burner is not fitted to an appliance of BIB COCHRAN manufacture, due regard must
be given to the operating instructions of that appliance.

2. GENERAL DESCRIPTION
The Burner is an automatic pressure jet type burner capable of high/low operation. The
burner is a composite unit comprising of a combustion head assembly, electrically operated
air damper, forced draught fan, electric ignition and flame monitoring equipment pre-wired
to a junction box. The sequence of operation of the burner is controlled by a sequence timer,
which is located in the separate control panel. The burner is arranged in the gun type
configuration.

Please refer to diagram figure 1 : Side View of Burner

as shown on page number 14
A fan casing which is bolted on to the windbox, forms the carcass of the burner. The burner
motor is flange mounted on a ported carrier ring, which is bolted to the right hand side of the
fan casing. The motor is surrounded by a two pass air casing which acts as a silencer. A
forced draught fan is mounted directly on the motor shaft.

The oil pump is flange mounted on the left hand side of the fan casing and is driven through
a coaxial coupling from the motor shaft. The combustion air is controlled by a positioning
drive motor which operates a blade type damper inside the casing. The position of the
damper is adjustable.

Please refer to diagram figure 2 : End View of Burner

as shown on page number 15
The combustion head assembly is located within the windbox, which is mounted on the front
of the boiler. The air sleeve or blast tube, which surrounds the burner lance assembly,
protrudes into the furnace.

A flame detector is fitted to the backplate of the burner to monitor the flame.

The burner has two atomisers, for low and high fire, each of which is controlled by a
solenoid valve. A third solenoid valve acting as a back-up is also fitted to the oil system.

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The burner lights up on low fire. The low fire oil flame is ignited by a spark produced across
the two electrodes by a high voltage transformer.

The oil is pumped at a pressure of approximately 200 lb/in2 (13.8 bar), through the burner
atomisers. This results in the oil breaking up into very small droplets which mix intimately
with the combustion air.

Care should be taken when replacing atomisers since the oil spray pattern determines the
flame shape. For this reason all atomisers should be purchased from BIB COCHRAN
LIMITED.

If the flame is extinguished for any reason other than a controlled shut down, the burner will
lock-out and an alarm will sound. Once the fault has been rectified, the burner will require
manual resetting at the control panel before recommencing start-up. Repeated lockouts
should be investigated by a BIB COCHRAN Service Engineer.

2.1 AIR INTAKE SILENCER

The burner air intake is designed to provide a two pass air flow through the unit and is also
acoustically lined to provide effective sound attenuation.

The inlet silencer is basically formed by an inner and outer shell. Acoustic material lines the
periphery of the inner shell and also on the end surface of the larger outer shell. An annular space
is formed between the shells, which establishes the first air passage. Air is drawn into this duct
and around the inner shell over the motor, towards and finally into the burner fan casing. The air
reversing back over the motor, towards the eye of the fan, forms the second pass.

Please refer to diagram figure 3 : Fan and Motor Assembly

as shown on page number 16

2.2 OIL PUMP

The oil pump on the burner is fitted with an internal filter and an internal pressure regulating
and cut-off valve.

Please refer to diagram figure 4 : Oil Pump

as shown on page number 17

Fuel oil from storage which must not exceed 30 lb/in2 (2 bar) in pressure, is delivered to the
burner head at a pressure of 200 lb/in2 (13.8 bar).

CAUTION
Exercise care in a single pipe system not to run the oil pump too long without the
burner firing, as the oil pump heats up appreciably. If this occurs the burner should
be stopped and the pump left to cool.

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2.3 DAMPER MOTOR DRIVE UNIT

The air inlet damper is adjusted to suit the rate of firing by a positioning drive motor.

2.4 BURNER SEQUENCE TIMER

The sequence timer controls the pre-purge and ignition sequence necessary to ignite the fuel
and bring the burner to its normal running condition. When this occurs automatic control of
the burner is assumed until such time as the burner is switched off, or a fault causes a lockout
condition requiring a manual resetting. The timer then controls the necessary post-purge
sequence shutting the burner down safely.

2.4.1 SEQUENCE LOGIC

Before the timer can start a firing cycle, the following conditions must be observed:

a) Electricity supply must be on.

b) A “dark” signal must be received from the flame detector. Any fault in the flame
detector circuit (e.g. simulated flame) results in lockout at the beginning of the
starting sequence.

c) The sequence timer must be in the standby position.

d) The burner control switch must be on.

e) The boiler limit stat must be calling for heat.

f) The burner or boiler must not be in a state of lockout.

g) All safety switches and interlocks must be in the safe position.

When the preceding conditions are satisfied, the sequence timer cycle commences with the
pre-purge period.

2.4.2 Pre-Purge Sequence

The pre-purge sequence begins with the operation of the forced draught fan/oil pump motor.

Shortly after the fan/oil pump motor starts, the air pressure switch on the fan casing (when
fitted) must register an increase in air pressure. If an increase in air pressure is not detected,
then the system locks out.

The safe operation of the flame sensing procedures are tested.

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2.4.3 Light-Up Sequence

The ignition transformer switched on, producing the ignition spark.

The low fire oil solenoid and back-up oil solenoid valve opens.

If no flame is detected by the flame detector, the system locks out.

2.4.4 Normal Firing

The firing rate of the burner is controlled by the high/low stat. The sequence timer cycle is
only interrupted when a lockout condition occurs or the burner control is switched off.

2.4.5 Post-Purge Sequence

The post-purge takes place after a controlled shutdown.

The fan/oil pump motor continues to run for a short time to purge the furnace and flue
systems. This prevents the risk of build-up of explosive gases.

End of cycle. Cycle can be restarted if the system is reset and all the safety interlocks are
proved.

2.5 BURNER OIL SYSTEM

Fuel oil from storage, which must not exceed 20 lb/in2 (1.4 bar) in pressure, is delivered to
the burner head at a pressure of 200 lb/in2 (13.8 bar) via the oil pump.

With the burner switched OFF, all the solenoid valves are closed.

With the burner on low fire, the low fire and back-up solenoid valves are opened allowing oil
to pass through to the low fire atomiser.

After a flame has been established on low fire and provided that the boiler controls require an
increase in heat input, the burner is able to operate on high fire as demand requires. The
burner is now under the control of the boiler pressure/temperature stats.

Please refer to diagram figure 5 : Oil System

as shown on page number 18

2.6 IGNITION ASSEMBLY

The oil flame is ignited by a spark produced by the two electrodes and a high voltage
transformer. It is necessary to clean the electrodes at regular intervals.

Unless the transformer fails, which is very unusual, the electrodes will only fail to work if
they are incorrectly set or dirty. Under these conditions the current may be able to find an

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alternative route to earth instead of jumping between the electrode tips. Cracked or damaged
insulators must of course be changed at once. (See Figure A-6).

Please refer to diagram figure 6 : Sleeve ring and Electrode Arrangement

as shown on page number 19

2.7 CONTROL PANEL

The client is normally required to supply and fit a 3 phase 4 wire supply to the isolator within
the control panel, which also contains the following items:-

2.7.1 Sequence Timer

For regulation and flame supervision of the burner.

2.7.2 Starters
For forced draught fan/oil pump motor.

2.7.3 Fuses, Relays and Switches

For control functions

2.7.4 Indicator Lights/Alarms

For normal and fault conditions
A typical control panel fascia will contain the following lights and switches for the burner:-

2.7.5 Normal Firing Light

This is illuminated when normal firing conditions exist.

2.7.6 Lock-Out Light

This is illuminated when a flame failure condition exists. The lockout light also acts as a
RESET pushbutton. The lamp when pressed will reset the control panel after lockout.

2.7.7 Mute Alarm/Run Switch

This is a two position switch. During normal operation this switch would remain in the RUN
position, only turning to MUTE ALARM to silence the alarm.

2.7.8 Burner Switch

This has three positions, OFF/LOW/AUTO. When placed in the OFF position, the burner
motor will not run. When placed in the LOW position, the burner will only operate on low
fire. When placed in the AUTO position, the firing rate of the burner will be controlled by
the boiler controlling pressure/temperature stat.

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NOTE
In either the LOW or AUTO position, the burner will start and stop under the control of
the boiler pressure/temperature limit stat.

3. OPERATION
It is stressed that the burner must be operated by competent personnel. A range of Training
Courses is available from BIB COCHRAN LIMITED.

If the burner is not fitted to an appliance of BIB COCHRAN manufacture, due regard must
be given to the operating instructions of that appliance.

3.1 PRELIMINARY PROCEDURE

It is recommended that the initial commissioning of the burner should be carried out by
COCHRAN Engineers as commissioning must only be undertaken by competent personnel.

The following notes are not exhaustive and are included as a guide only.

a) Ensure that the permanent ventilation of the boilerhouse (excluding doors and windows) is
capable of supplying sufficient air for combustion and to keep the boilerhouse cool.

b) Ensure that the burner is correctly mounted on the boiler.

c) Check all mechanical connections are properly tightened and have not worked loose in
transit.

d) Check all electrical connections are tight and have not worked loose in transit.

e) Check direction of rotation of burner fan motor.

f) Ensure that boiler contains water and is ready for operation.

g) Check that the fuel to be burnt is of the same class as that for which the burner has been built
and set.

h) Ensure that there is an adequate supply of oil available at the correct supply conditions.

3.2 STARTING UP THE BURNER

CAUTION
Never run or attempt to run the oil pump without oil.
To ensure that oil is present, prime the oil system under gravity.

Ensure that the burner switch on the control panel is in the OFF position.

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On closing the main isolator an alarm will sound. Operate the reset switch. Move the burner
switch to LOW. The sequence timer will now activate the sequence of operation of the
burner with constant flame monitoring, as described in the sequence logic (Page A-4).

WARNING
If the burner fails to start after two or three attempts, there is probably a fault in the
equipment that must be rectified before any further attempt is made. A COCHRAN
Service Engineer should be called in to investigate the problem.
It is most important that no more than three attempts are made to start the burner.
Every time the burner fails to light a small quantity of fuel is injected into the furnace.
This fuel will build up and a potentially explosive situation could arise.

The boiler should be warmed up slowly. When the boiler has warmed through the burner
switch can be moved to the AUTO position. This allows the burner to operate at high fire.

When the boiler controls call for no heat input or if the burner is switched OFF at the control
panel, the sequence timer closes all the oil solenoid valves. This results in the flame being
extinguished as part of a controlled shutdown.

Unless the burner is switched OFF at the control panel, the burner will remain in a state of
readiness until the boiler calls for a heat input. The burner will then automatically light-up
under the supervision of the sequence timer.

If the flame is extinguished for any reason other than a controlled shut down, the sequence
timer will activate the lockout indicator on the control panel and an alarm will sound. Once
the fault has been rectified, the burner will require manual resetting at the control panel
before the burner can start again.

3.3 TYPICAL OPERATING PARAMETERS

Once the combustion settings have been set, they should not be tampered with.

The burner will normally operate with a turndown in the region of 2 - 2½ to 1.

CO2
High Fire 13.5%
Low Fire 11.5 - 12.5%
These figures are included as a guide only.
3.4 SHUTTING DOWN THE BURNER
Switching the burner switch to OFF extinguishes the flame. Once the sequence timer has
completed the post-purge, the main isolator on the control panel can be opened.

WARNING
Do not open the main isolator until the post purge has been completed.

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4. MAINTENANCE
Before carrying out any maintenance on the burner, ensure that the incoming electricity
supply to the burner has been isolated. As part of any ongoing maintenance procedure any
faults or leaks should be rectified immediately.

The following tasks should be performed daily or once per shift:-

• Clean Photocell

The following tasks should be performed weekly:-

• Monitor Flue Gases

• Clean Ignitor Assembly

• Clean Burner Lance

• Clean Oil Filters

• Check Photocell Operation

Every three months the burner should be serviced by a competent engineer and the
combustion reset.

5. FAULT FINDING HINTS

5.1 Burner will not start
• No electrical supply
• Start-up interlocks not satisfied
• Boiler at lockout
• Photocell not proved
• Loose connections
5.2 Burner starts will not light
• No ignition
• Insufficient fuel
• Excess air
5.3 Burner lights but locks out
• Faulty photocell
• Insufficient fuel

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• Incorrect air/fuel setting

5.4 Burner cuts on and off continuously
• Faulty pressure switch
• Insufficient load
5.5 Improper Combustion
• Incorrect air/fuel setting
• Dirty boiler tubes
• Defective brickwork
• Carbon built-up

6. SPARE PARTS
To ensure safe operation, we strongly recommend that only genuine BIB COCHRAN
supplied spare parts are fitted to your burner.

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OIL BURNERS
7. DAMPER MOTOR DRIVE UNIT INSTRUCTIONS
Combustion air is controlled by a positioning drive motor, which operates a damper inside
the burner fan casing. The position of the damper and the position of the switching cams
within the drive motor assembly, are adjustable.

7.1 DAMPER ASSEMBLY OPERATION

The damper gear wheels and lever assembly is driven by the positioning drive motor. When
the panel isolating switch is closed and the panel becomes live, the positioning drive motor
drives the lever arms clockwise to the low fire position. This low fire position is adjustable
to suit the low fire combustion conditions, by adjustment of the switching cams within the
drive motor.

On receiving a signal from the boiler pressure control stats calling for steam, the motor is
driven anti-clockwise to the high fire position, as determined by the setting of the motor
switching cam, which is adjustable to suit the required conditions.

When the steam requirement is satisfied, the pressure stats will return the driving motor to
the low fire position.

7.2 POSITIONING DRIVE MOTOR

7.2.1 Cam Function Identification

The five cams within the body of the drive motor (cams 4 and 5 are not used on oil firing) are
identified as follows:

Cam 1 High Fire Drive Limit

Cam 2 High Fire Fuel Valve Interlock
Cam 3 Low Fire Drive Limit
* Cam 4 Low Fire Proving
* Cam 5 High Fire Proving

• These cams not used on oil firing.

7.3 DAMPER ADJUSTMENT

Initial setting of the cams to achieve optimum air to combustion settings, should have been
established at the commissioning stage. Should it be found necessary to trim the air, the
following procedure can be adopted.

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1. Place burner control switch to LOW.

2. Having previously determined by flue gas analysis, the air adjustment requirements for
optimum combustion at low fire. Observing the low fire flame, trim the air
requirements to increase or decrease as necessary to improve flame condition:

a) To decrease air for low fire - insert screwdriver into Cam 3 adjuster and rotate
clockwise. A slight movement of the cam should only be necessary, therefore
check flame condition after first adjustment and continue a further equal
adjustment should it be necessary, until flame condition appears satisfactory.
Note the number of turns or fractions of a turn required to achieve that condition.

b) To increase air for low fire - insert screwdriver into Cam 3 adjuster and rotate
anti-clockwise a fraction of a turn. Switch burner control momentarily to AUTO
an immediately return to LOW. Check flame condition and repeat above
procedure as necessary. Noting the number of turns or fractions of a turn required
to achieve a satisfactory condition.

7.4 ADJUSTMENT TO HIGH FIRE AIR

Switch burner to high fire and, using a flue gas analysis, determine the air adjustment
requirement for optimum combustion, proceeding as follows:-

a) To increase air for high fire - insert screwdriver into Cam 1 adjuster and rotate
anti-clockwise. Note the number of turns or fractions of a turn required to
establish optimum combustion.

b) To decrease air for high fire, insert screwdriver into Cam 1 adjuster and rotate
clockwise in fraction of a turn stages. At each stage, switch burner momentarily
to low fire and restore to high fire. Note the number of turns or fractions of a turn
required to establish optimum combustion.

If necessary, adjust Cam 2 in small increments, to give a smooth transition from low to high
flame and vice-versa.

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POSITIONING DRIVE MOTOR CONNECTIONS AND

CAM FUNCTION IDENTIFICATION

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FIGURE 1 : SIDE VIEW OF BURNER

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FIGURE 2 : END VIEW OF BURNER

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FIGURE 3 : FAN AND MOTOR ASSEMBLY

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FIGURE 4 : OIL PUMP

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FIGURE 5 : OIL SYSTEM

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FIGURE 6
SLEEVE RING AND ELECTRODE ARRANGEMENT

OPERATION & MAINTENANCE MANUAL -SIMPLEX BURNER