THERMOSSOL STEAMBOILERS S.A.

GENERAL MECHANICAL CONSTRUCTIONS

94, TATOIOU Str. - 136.77, ACHARNES - ATHENS - GREECE
TEL: +30 210 8000036 / 6200630 / 6206634 – FAX: +30 210 6206636

STEAM BOILER PK-12000

(12 000 kg/h - 14 barg)

10. OPERATION &MAINTENANCE MANUAL

Version. 1.0 – 03/2017
 THERMOSSOL STEAMBOILERS S.A.
GENERAL MECHANICAL CONSTRUCTIONS
94, TATOIOU Str. - 136.77, ACHARNES - ATHENS - GREECE
TEL: +30210 8000036 / 6200630 / 6206634 – FAX: +30210 6206636

OPERATION
& MAINTENANCE
MANUAL OF STEAM
BOILER PK

ACHARNAI - 2017

Version. 1.0 – 03/2017

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CONTENTS

1. GENERAL

2. PK STEAM BOILER DESCRIPTION

3. INSTALLATION

4. FIRST-TIME START UP

5. REGULAR OPERATION

6. STORAGE

7. MAINTENANCE

ANNEX Α: OPERATION & MAINTENANCE

ANNEX Β: WATER QUALITY SPECIFICATIONS

Version. 1.0 – 03/17 3/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

1. GENERAL
PK type steam boilers are Holland type. They are horizontal, cylindrical, fire tube reverse
flame steam boilers.The PK type steam boilers are suitable for production of dry saturated
steam and they cover a steam production range from 400kg/h to 15000kg/h at operation
pressure range from 3 barg to 15 brag. The design and the construction of the PK type steam
boilers is according to EN 12953, which complies to directive 2014/68/EU (PED).

ATTENTION!
STEAM BOILERS AS PRESSURE VESSELS CAN BE EXTREMELY DANGEROUS
IN CASE OF DAMAGE OR INAPPROPRIATE HANDLING. READ CAREFULLY
O&M MANUAL BEFORE INSTALLATION, OPERATION & MAINTENANCE OF
STEAM BOILER. STORE MANUAL AT SAFE PLACE NEAR THE STEAM
BOILER FOR FUTURE REFERENCE

The steam boiler is delivered with all the necessary safety and operation control equipment, as
described in the Technical Specifications

ATTENTION!
NEVER ATTEMPT TO REPAIR OR REPLACE PART OR THE WHOLE OF THE
EQUIPMENT THAT ACCOMPANIES THE BOILER. ANY REPAIR OR
REPLACEMENT SHOULD BE DONE AFTER NOTIFYING AND BEING ADVISED
BY OUR COMPANY.

Each boiler bears a unique construction number (CN: ΧΧΧΧ), which is displayed with the
rest of the operation specifications on a metal plate, placed on the boiler (on the front door).
The boiler is delivered accompanied by full Technical Documentation. Our company keeps a
copy of the files for at least ten (10) years since its manufacturing. During the operation of the
boiler our company keeps a record of any possible problems may occur, as well as the repairs
and replacements, in order to have a full image of the boilers condition and follow up the
operation history of the boiler.

FOR A BETTER FUTURE SUPPORT FROM OUR COMPANY IT IS VERY

IMPORTANT THAT WE GET EARLY NOTIFICATION OF ANY CHANGES IN YOUR
INSTALLATION PLANT THAT COULD DIRECTLY OR INDIRECTLY AFFECT THE
OPERATION OF THE BOILER, AS WELL AS OF ANY PROBLEMS OR
MALFUNCTIONS MAY OCCUR

Version. 1.0 – 03/17 4/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

2. PK STEAM BOILER DESCRIPTION

The Steam boiler is consisted of the following parts:

1. Main boiler
2. Burner
3. Water feed pumps
4. Operation and safety equipment
5. Automation and control panel

2.1 Main Boiler

The main boiler is consisted of:

 Boiler Shell
Horizontal cylindrical shell constructed by metal steel plate P265GH according to EN
10028-2, with appropriate thickness for the operation pressure. The boiler shell has flat
flanged ends made of the same steel quality and of appropriate thickness. Every flat end is
constructed from one metal steel plate, so it is seamless. The metal steel plates of the boiler
shell and ends are delivered with their certification from their manufacturer.

 Firetube
It is constructed from metal steel plate P265GH according to EN 10028-2, with appropriate
thickness for the operation pressure. The firetube can be smooth or corrugated (FOX type)
with only one longitudinal weld. The firetube is delivered with its certificates from its
manufacturer.

 Smoke Tubes
The smoke tubes are seamless constructed by steel P235GH according to EN20216-2, of
appropriate thickness for the operation pressure. The smoke tubes are welded to the boiler
as one piece, which means that they don’t have any peripheral weld. The tubes are
delivered with their certification from their manufacturer.

 Tube Stays
The tube stays are seamless constructed by steel P235GH according to EN20216-2, of
higher than the required thickness for the operation pressure. The tube stays are placed
instead of the tubes in certain positions if necessary, for the support of the shell and the
area between the wet back reversal chamber and of the rear end. The tubes are delivered
with their certification from their manufacturer.

Version. 1.0 – 03/17 5/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 Gusset Stays
They are made of metal steel plates P265GH, with adequate thickness, formed for the
connection of the end plates to the cylindrical shell of the boiler. The gusset stays are
places symmetrically to the upper part of the boiler shell, where the end plates have the
most unsupported area (boiler room). The gusset stays are delivered with their certificates
provided by their manufacturer. The design and the placement of the gusset stays is
according to standard EN 12953-3.

 Wet Back Reversal Chamber

It is consisted of a horizontal cylindrical shell with flat ends. The ends are constructed by
one piece of metal steel plates of adequate thickness and the have flanged curvature. All the
metal steel plates are P265GH and they are delivered with their certificates from their
manufacturer. The reversal chamber is provided with an access opening with an
observation fire resistant glass at its rear. The access opening is sealed with a temperature
resistant sealing gasket, placed with bolts and nuts at its perimeter.

 Front reversal chamber

It is constructed from steel plates S235JR according to EN 10027-1. Front reversal

chamber is consisted of the shell and the two symmetrical access doors. The front reversal
chamber is located externally of the front end of the boiler and has the appropriate shape to
include the second and the third pass tubes allowing their communication. The front
reversal chamber doors are supported at their ends on a pin that allows their rotation. The
doors are insulated with asbestos free seal gaskets, made of glass fibers and high
temperature resistant. The front reversal chamber doors are supported with nuts and bolts
along its perimeter.

 Rear reversal chamber

It is constructed from steel plates S235JR according to EN 10027-1. Rear reversal chamber
is consisted of the shell and the two symmetrical access doors. The rear reversal chamber is
located externally of the rear end of the boiler and has the appropriate shape to include the
third pass tubes. The rear reversal chamber doors are supported parametrically with nuts
and bolts. The doors are insulated with asbestos free seal gaskets, made of glass fibers and
high temperature resistant. In the upper part of the rear reversal chamber a nozzle is placed
for the connection of the steam boiler to the chimney.

 Base
It is constructed from HPB beams and steel plates S235JR of adequate thickness to mount
the steam boiler. The boiler shell is seated on two semi cylindrical steel plates (pads) at
symmetrical longitudinal places. The boiler shell is not welded to the pads so it can freely
move because of expansion and contraction.

Version. 1.0 – 03/17 6/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 Manholes
Elliptical cross section (oval) manholes are placed to the boiler shell allowing access at the
inside of the steam boiler. Manholes are manufactured according to standard EN 12953-3
and they are sealed with special specification rubber gasket temperature resistant and with
two bolts.

 Nozzles & flanges

The steam boiler bears appropriate nozzles for ventilation, steam outlet and other functions.
The nozzles at placed at appropriate openings at the boiler shell and most of them are from
tube (P235GH, EN 10216-2) with welded neck flange (PN16 - DIN2633, PN40 -
DIN2635).

The steamboiler is equipped with nozzles of the appropriate size for the ventilation, steam
output and other functions. The nozzles are placed on the boiler shell and most of them
consist of one piece of tube (P235GH, ΕΝ 10216-2) with a welding neck flange (PN16 -
DIN2633, PN40 - DIN2635). Specifically, the following nozzles are placed:

Α/Α Nozzle Pc Flange Tube dimensions (DoxWxL)

1 Ventilation 1
2 Level Electrodes 2
3 Steam Outlet 1
4 Safety Valve 2
5 Blow down 1
6 Blow off 1
7 Level Gauges 2
8 Feed Water 1

 Other equipment
The boiler is also equipped with the following:

a) Steam seperator
It is an equipment that removes the moister and ensures the provision of dry steam. It is
places inside the boiler shell, below the steam outlet nozzle.

b) Blow off equipment

The equipment consists of tapered nozzle and tube that are connected to the blow off
nozzle at the center of the boiler shell for removing floating pollutants at the water surface
(eg salts, oils, etc.).

Version. 1.0 – 03/17 7/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

c) Lift Lugs
Consist of high thickness (18 mm) metal steel plates (quality P265GH), bearing hole for
the lifting wire. The lift lugs are placed at the top of the boiler shell near the ends and they
are calculated so that the steam boiler when empty (not containing water) can be safely
lifted from them.

ATTENTION!
THE LIFT LUGS ARE NOT CALCULATED TO LIFT THE STEAM BOILER WHEN
FILLED WITH WATER. ALWAYS DRAIN THE WATER FROM THE STEAM
BOILER BEFORE LIFTING IT BY ITS LIFT LUGS.

d) Fire-resistant compiling
The surfaces of the steam boiler that are subject to high temperature and are not sufficiently
cooled are protected with fire resistant compiling. Such surfaces are burner opening (flame
tube) , the rear inspection opening at the wet back reversal chamber and the two inspection
openings at the front reversal chamber. The compiling is either with refractory bricks and
concrete or with just refractory concrete.

e) External Insulation
The steam boiler is externally insulated by 100mm layer of high density (1400kg/m3)
mineral wool. The mineral wool is attached to the boiler shell with hooks and barbed wire.

CAUTION!
DURING INITIAL START-UP IT IS POSSIBLE TO SEE FUMES COMING OUT OF
THE INSULATION DUE TO THE HEATING OF THE INSULATING MAT. THESE
FUMES ARE NOT DANGEROUS, STILL IT IS ADVISED TO TAKE MEASURES
FOR THE PROPER VENTILATION OF THE AREA

Version. 1.0 – 03/17 8/39

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

11 15 16 17 18 11
10 1 14
5
5

1
1
3 19 20
7
4
8

12

12 2

10 13 21

No Subscription No Subscription No Subscription

1 Cylindrical Shell & Butts 8 Rear Flue Gas chamber 15 Level Electrodes nozzle
2 Furnace (corrugated, type FOX) 9 Base 16 Steam output nozzle
3 Firetubes (seamless) 10 Manhole 17 Safety Valve nozzle
4 Tube stays 11 Lift Lug 18 Ventilation nozzle
5 Gusset stay 12 Refractory coating 19 Water input nozzle
6 Reversal chamber (water cooled) 13 External thermal insulation 20 Surface Drain nozzle
7 Front reversal chamber 14 Flue Gas output nozzle 21 Blow Down nozzle

Version. 1.0 – 03/13 9/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

2.2 Burner
The steamboiler is equipped with an automatic dual-fuel burner suitable for diesel oil and
Natural Gas. The burner is a compact unit.

CAUTION!
THE STEAMBOILER’S EFFICIENCY AND SAFE OPERATION ARE
IMMEDIATELLY DEPENDED ON THE BURNERS OPERATION.
BEFORE INSTALLATION AND IGNITION OF THE STEAMBOILER PLEASE
READ THE BURNER’S MANUAL. KEEP IT ALONG WITH THIS MANUAL AND
THE REST OF THE STEAMBOILER’S DOCUMENTATION.
CONNECTING, REGULATING AND MAINTAINING OF THE BURNER MUST BE
DONE ONLY BY QUALIFIED TECHNICAL PERSONEL.
IN CASE OF MALFUNCTION OR NEED FOR REPLACEMENT PLEASE NOTIFY
OUR COMPANY.

2.3 Water Feed Pumps

The steamboiler is equipped with a pumping stage with two multistage rotatory pumps. The
pumps are the one as a backup to the other, using a by-pass. Each pump has been selected
having capacity 50% above the nominal steam production, and its boost power to surply at
least by 30% the nominal operating pressure. The pumping stage also includes three stop
valves and three non-return valves.

CAUTION!
TΗE PROPER FUNCTION OF THE PUMPS IS NECESSARY FOR THE SAFE
OPERATION OF THE STEAMBOILER. MAINTAIN THE PUMPS IN GOOD
SHAPE.
BEFORE INSTALLATION AND IGNITION OF THE STEAMBOILER PLEASE
READ CAREFULLY THE PUMPS MANUAL. KEEP IT ALONG WITH THIS
MANUAL AND THE REST OF THE STEAMBOILER’S DOCUMENTATION.
IN CASE OF MALFUNCTION OF ONE OF THE PUMPS, OPERATE THE
STEAMBOILER WITH THE AUXILLIARY PUMP AND HAVE THE DAMMAGED
PUMP REPAIRED IMMEDIATELY.
IN NO CASE SHOULD THE PUMPS BE REPLACED WITH DIFFERENT TYPE
PUMPS WITHOUT NOTIFYING AND CONSULTING OUR COMPANY.
OPERATING THE STEAMBOILER WITH ONE PUMP ONLY IS ILLEGAL AND
EXTREMELY DANGEROUS.

Εκδ. 1.0 –04/17 10/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

2.4 Safety Equipment & Operation Surveillance

The steamboiler is equipped with devices that allow its normal and safe operation as well as
monitoring its operation parameters such as pressure, temperature etc.

PRESSURE
 Safety Valves
The boiler has two safety valves against overpressure on the upper side of its shell. The safety
valves are spring loaded type.

CAUTION!
THE SAFETY VALVES PROVIDE DIRECT AND CERTAIN PROTECTION TO
THE STEAMBOILER AGAINST OVERPRESSURE.
BEFORE INSTALLATION AND IGNITION OF THE STEAMBOILER PLEASE
READ THE SAFETY VALVES MANUAL. KEEP IT ALONG WITH THIS MANUAL
AND THE REST OF THE STEAMBOILER’S DOCUMENTATION.
THE SAFETY VALVES ARE REGULATED AND ATTACHED TO THE
STEAMBOILER BY OUR COMPANY.
PLEASE CHECH REGULARLY THE SAFETY VALVES PROPER FUNCTION (SEE
MAINTENANCE INSTRUCTIONS).
IN NO CASE DO NOT ATTEMPT REGULATING, REPAIRING OR REPLACING
THE SAFETY VALVES.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

 Operation & Safety Pressure Switches or Pressure Sensor with Electronic Pressure Switch
These are pressure sensors that activate contacts. According to the pressure inside the
steamboiler they adjust the burner’s operation. A safety pressure switch turns off the burner in
case of malfunction of the high level pressure switch.

CAUTION!
PRESSURE SWITCHES ARE EXTREMELY IMPORTANT SINCE THEY ADJUST
THE BURNER’S OPERATION HENCE THE OPERATION OF THE
STEAMBOILER .
BEFORE INSTALLATION AND IGNITION OF THE STEAMBOILER PLEASE
READ THE PRESSURE SWITCHES MANUAL. KEEP IT ALONG WITH THIS
MANUAL AND THE REST OF THE STEAMBOILER’S DOCUMENTATION.
THE PRESSURE SWITCHES ARE REGULATED AND ATTACHED TO THE
STEAMBOILER BY OUR COMPANY.

Εκδ. 1.0 –04/17 11/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

PLEASE CHECH REGULARLY THE PRESSURE SWITCHES PROPER FUNCTION

(SEE MAINTENANCE INSTRUCTIONS).
IN NO CASE DO NOT ATTEMPT REPAIRING OR REPLACING THE PRESSURE
SWITCHES.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

 Analogue Manometers
Two manometers are placed on the steamboiler, the one on the front side and the other on the
water pumps pipeline. The front side manometer measures the pressure of the steam chamber
and allows constant and direct monitoring of the steamboiler’s pressure. It is connected on the
same pipeline with the three pressure switches.

WATER LEVEL
 Level Electrodes
The steamboiler is equipped with two independent level electrode setups. The first is a low
level safety setup. The second gives the orders to the pumps and controls the water level, and
inspects high and low water level.

CAUTON!
THE STEAMBOILER’S OPERATION WITH LOW WATER LEVEL IS
EXTREMELY HIGHLY DANGEROUS. THE LEVEL ELECTRODES PROTECT
THE STEAMBOILER FROM WATER LACK.

BEFORE IGNITION OF THE STEAMBOILER PLEASE READ THE PRESSURE

SWITCHES MANUAL. KEEP IT ALONG WITH THIS MANUAL AND THE REST
OF THE STEAMBOILER’S DOCUMENTATION.
THE LEVEL ELECTRODES ARE MOUNTED AND ADJUSTED ON THE
STEAMBOILER BY THERMOSSOL STEAMBOILERS.
CHECK THE LEVEL ELECTRODES PROPER FUNCTION REGULARLY.
IN NO CASE DO NOT ATTEMPT REPAIRING OR REPLACING THE LEVEL
ELECTRODES.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

 Level Gauges
The steamboiler is equipped with two level gauges for visual inspection of the water level
inside the steamboiler. The level gauges have heavy duty refractory sight glass. The glass is
marked with the operation water level and the lower allowable water level. The water content

Εκδ. 1.0 –04/17 12/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

between the lower level and the higher heated surface level is sufficient for nominal steam
production of at least 7 min, since the steamboiler’s water supply is interrupted, as indicated
in standard EN 12953-6:2002.

CAUTION!
THE STEAMBOILER’S OPERATION WITH LOW WATER LEVEL IS
EXTREMELY DANGEROUS. THE LEVEL GAUGES ALLOW DIRECT WATER
LEVEL INSPECTION. CHECK THE LEVEL GAUGES INDICATION REGULARLY
DURING THE BOILER’S OPERATION.
THE LEVEL GAUGES ARE MOUNTED AND ADJUSTED ON THE
STEAMBOILER BY THERMOSSOL STEAMBOILERS.
CHECK THE LEVEL GAUGES PROPER FUNCTION REGULARLY.

The level gauges valves are closed when the lever is looking downwards, parallel with the
flow, in contrast to the other valves.

WATER FEED
 Stop Valves
The pumping stage has three stop valves, one for each pump and a central mutual one.

CAUTION!
THE STOP VALVES AFFECT THE STEAMBOILER’S WATER SUPPLY. BEFORE
IGNITION THEY MUST BE COMPLETELY OPEN.
IN CASE OF A PUMP MALFUNCTION AND USE OF THE AUXILLIARY MAKE
SURE THAT THE DAMAGED PUMP’S STOP VALVE IS CLOSED AND THE
AUXILLIARY PUMP’S STOP VALVE IS OPEN
IN NO CASE DO NOT ATTEMPT TO OPERATE A PUMP WITH ITS STOP VALVE
OR THE CENTRAL VALVE CLOSED.
PLEASE CHECH REGULARLY THE STOP VALVES PROPER FUNCTION.

 Non-return Valves
The pumping stage has three non-return valves, each before every stop valve.

CAUTION!
THE NON-RETURN VALVES ENSURE THE STEAMBOILER’S WATER SUPPLY
AS THE PRESSURE BUILDS UP. THEIR MALFUNCTION CAUSES PROBLEMS
TO THE STEAMBOILER’S OPERATION AND MAY DAMAGE THE PUMPING
STAGE.
THE NON-RETURN VALVES ARE MOUNTED AND ADJUSTED ON THE
STEAMBOILER BY THERMOSSOL STEAMBOILERS.

Εκδ. 1.0 –04/17 13/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

AVOID OPERATING THE BOILER IF THERE ARE INDICATIONS THAT THE

NON-RETURN VALVES DO NOT SEAL.
CHECK THE NON-RETURN VALVES PROPER FUNCTION REGULARLY.
IN NO CASE DO NOT ATTEMPT REPAIRING OR REPLACING THE NON-
RETURN VALVES.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

STEAM OUTPUT
The steam output nozzle is in the middle of the boiler shell, on the top side. Inside the boiler
there is a steam separator, a specially designed device that separates steam from water droplets
accomplishing steam of extremely high dryness (~99%)..

STEAMBOILER CLEANING
 Blow Down - Drain
The Drain nozzle is on the back side of the steamboiler, on the lower part of the shell,
connected with the appropriate heavy duty Blow-Down Valve.

CAUTION!
THE BLOW-DOWN VALVE MUST BE CONNECTED TO AN APPROPRIATE
DRAIN FLASH TANK FOR THE DRAINAGE OF THE WASTE WATER.
THE BLOW-DOWN VALVE’S SEALING CAPACITY MUST BE CHECKED
REGULARLY DUE TO WATER’S HIGH CONTENT IN MINERALS, SEDIMENTS,
SLUG, ETC.
IN NO CASE DO NOT ATTEMPT REPAIRING OR REPLACING THE BLOW-
DOWN VALVE.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

 Surface Drain – Blow Off *

The surface drain nozzle is in the middle of the boiler shell, at the height of the operation
water level. It is connected with an automatic draining device equipped with a conductivity
sensor.

Εκδ. 1.0 –04/17 14/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CAUTION!
THE SURFACE DRAIN VALVE MUST BE CONNECTED TO AN APPROPRIATE
DRAIN FLASH TANK FOR THE DRAINAGE OF THE WASTE WATER.
THE SURFACE DRAIN VALVE’S SEALING CAPACITY MUST BE CHECKED
REGULARLY DUE TO WATER’S HIGH CONTENT IN MINERALS, SEDIMENTS,
SLUG, ETC.
IN NO CASE DO NOT ATTEMPT REPAIRING OR REPLACING THE SURFACE
DRAIN VALVE.
IN CASE OF MALFUNCTION PLEASE NOTIFY AND ADVISE OUR COMPANY
IMMEDIATELLY.

*Optional, after clients request

Εκδ. 1.0 –04/17 15/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

2.5 Automation & Operation Electric Panel

The steamboiler is equipped with an electric panel that allows automatically adjusting the
steamboiler’s operation. The electric panel comes with a PLC and a touch-screen that makes
inspection easy and the adjustments user friendly.

The electric panel is connected to:

 the fuel feed system

 the burner

 the water pumps

 the temperature sensors measuring steam and flue-gas temperatures

 the level electrodes of the steamboiler

 the level electrodes of the water tank (optional)

 the operation and safety pressure switches

During operation the electrical panel receives the signals from the inspection devices and
adjusts the burner’s and pumps’ operation, to ensure safe and efficient operation.
The electrical panel includes a safety circuit that immediately shuts down the steamboiler and
sets off the alarm siren in case of malfunction that is dangerous for the steamboiler or its
operators.

CAUTION!
THE ELECTRICAL PANEL COORDINATES THE STEAMBOILER’S
OPERATION. ANY MISUSE OR MALFUNCTION PUTS THE STEAMBOILER AND
ITS OPERATORS AT GREAT RISK!
THE ELECTRICAL PANEL MUST BE USED ONLY BY AUTHORIZED AND
PROPERLY TRAINED PERSONEL.
KEEP THE ELECTRICAL PANEL CLEAN AND IN GOOD CONDITION. CHECK
ON IT REGULARLY.
ΣIN CASE OF MALFUNCTION OF A PART OF THE ELECTRIC PANEL
(SWITCH, RELAY, ETC.) MAKE SURE OF ITS IMMEDIATE REPLACEMENT.
AVOID OPERATING THE STEAMBOILER UNTIL THE DAMAGE IS REPAIRED.
THE ELECTRIC PANEL IS DELIVERED BY THERMOSSOL STEAMBOILERS
TESTED AND READY FOR OPERATION. DO NOTATTEMPT ANY
INTERVENTION TO ITS CIRCUITS WITHOUT NOTIFYING AND CONSULTING
THERMOSSOL STEAMBOILERS.

Εκδ. 1.0 –04/17 16/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

3. INSTALLATION

CAUTION!
INSTALLATION WORKS OF PK STEAM BOILER TO BE ALWAYS PERFORMED
BY EXPERIENCED TECHNICIANS SUPERVISED BY ENGINEER

3.1 Installation Site

The site of installation should provide enough room for the vessel installation considering its
dimensions, according to the applying law context. The available installation space should
allow ease of access, of operation supervision and of maintenance works at all times.

The specifications of boiler house design, dimensions and construction materials as well as of
the position of the boiler inside the room should comply with the applying rules & regulations
at the installation site.

3.2 Installation Works

Installation works should be performed with respect to the following:

a) Site preparation
The installation site must fulfill the spatial and structural requirements for the safe and
ergonomic vessel operation. All necessary preparations and modifications, such as pipework
changes, obstacle removal and ground floor preparation, should be performed prior to
installation. Care should be taken to avoid damage to vessel parts while transferring it to its
final position.

b) Transportation and positioning of the boiler

The boiler in transported from our construction site to the installation site on a truck and is
positioned to its final place with lifting machinery. The boiler bears lift lugs for this purpose
and it should be lifted only by them.

CAUTION!
BEFORE LIFTING THE BOILER BY ITS LIFT LUGS, ALWAYS MAKE SURE
THAT IT IS COMPLETELY EMPTY OF WATER. FOR THAT PURPOSE BEFORE
ANY TRANSPORTATION, THE DRAIN VALVE SHOULD BE OPENED.

Εκδ. 1.0 –04/17 17/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CAUTION!
THE LIFTING MUST BE PERFORMED USING HEAVY TYPE WIRE, OF
SUITABLE GIRTH CAPABLE OF LIFTING THE BOILERS WEIGHT. THE WIRES
LENGTH MUST BE CALCULATED SO THAT THE ANGLE BETWEEN THE TWO
WIRES IS AS SMALL AS POSSIBLE (<120o).

CAUTION!
CHOOSING THE APPROPRIATE WIRES, LIFTING THE BOILER PROPERLY
AND USING THE SUITABLE LIFTING MACHINERY ARE EXTREMELY
IMPORTANT. MISJUDGMENT IN ONE OF THE ABOVE COULD CAUSE A VERY
DANGEROUS ACCIDENT.

c) Vessel support
The vessel should stand steadily on solid flat ground, capable to support its maximum weight
during operation. The base should be mounted on the ground with plugs or other means. The
whole area of the base feet should be attached to the ground, in order to achieve uniform
distribution of the pressure on the ground and avoid vibrations during the operation.

1) Pipe connections
Pipe connections to vessel nozzles should be made considering vessel nozzles as fixed points.
No stresses are allowed on any of vessel nozzles at any direction.
All connections should be made with flanges and sheet gaskets with operation specifications
above vessels maximum allowable operation pressure and temperature.
After accomplishing all connections a hydraulic leak test should be performed at room
temperature.

CAUTION!
PIPE CONNECTIONS TO BE MADE BY EXPERIENCED TECHNICΙANS
SUPERVISED BY ENGINEER.
LOOSE CONNECTIONS CAN LEAD TO LEAK OF STEAM AND CAUSE INJURIES
TO NEARBY WORKING PERSONNEL.

CAUTION!
LOOSE CONNECTIONS COULD LEAD TO LEAK OF FUEL AND CAUSE FIRE OR
EXPLOSION IN THE BOILERHOUSE.

Εκδ. 1.0 –04/17 18/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

2. Electric connections
The boiler is delivered with all the connections between the electrical & automation panel and
the boiler already made. It is only required to connect the boiler's electrical panel with the
main electrical supply of the boiler house. The supply on the panel should be 3phase,
230/400V, 50Hz. The supply line must have the appropriate width and be coated for high
temperatures. The line installation should be in a separate channel destined for that purpose.
The supply line must also connect the boiler with the earth grounding network of the
installation

CAUTION!
THE ELECTRICAL CONNECTIONS AS WELL AS THE MAINTENANCE OF THE
ELECTRICAL EQUIPMENT OF THE BOILER SHOULD BE PERFORMED ONLY
BY LICENCED ELECTRICAL INSTALLER ACCORDING TO THE ELECTRICAL
DRAWINGS OF THE MANUFACTURER. FAILED CONNECTIONS COULD LEAD
TO MALFUNCTIONING OF THE BOILER WITH SERIOUS DANGER OF FIRE OR
EXPLOSION IN THE BOILERHOUSE.

CAUTION!
SERIOUS DANGER OF ELECTRIC SHOCK!
BEFORE ANY WORK PERFORMED ON THE ELECTRICAL EQUIPMENT OF
THE BOILER BE SURE TO CUT THE POWER SUPPLY FROM THE MAIN PANEL
OF THE BOILERHOUSE AND HANG A WARNING SIGN ON IT INFORMING
THAT THERE IS WORK BEING DONE. AFTER THE COMPLETION OF THE
WORKS RECONNECT THE POWER SUPPLY AND REMOVE THE WARNING
SIGN.
THE BOILER'S ELECTRICAL PANEL SHOULD ALWAYS BE CLOSED DURING
OPERATION.
DO NOT ATTEMPT ANY REPAIR OR ADJUSTMENTS IN THE INTERIOR OF
THE ELECTRICAL PANEL WHILE THERE IS ELECTRICAL VOLTAGE.

3. Thermal insulation
It is recommended to use high quality, high temperature resistent, non-corrosive and
environmental friendly insulation materials, such as rockwool. The insulation material should
be covered with sheets of inox or galvanized metal. The water line, steam line and the exhaust
line must be carefully insulated. The thermal insulation reduces heat losses achieving on the
one hand less fuel consumption and on the other hand lower boiler house temperatures.
Care should be taken not to cover with insulating material telltale holes on base saddles and
nozzle reinforcing plates, if any.

Εκδ. 1.0 –04/17 19/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CAUTION!
SERIOUS DANGER OF BURNS!
NEVER LEAVE HIGH TEMPERATURE SURFACES WITHOUT INSULATION.
BESIDES THE HEAT LOSSES, THERE IS A GREAT DANGER OF SERIOUS
BURNS TO ANYONE WHO COMES IN CONTACT WITH THEM.
IN CASE THERE ARE HIGH TEMPERATURE SURFACES WITHOUT
INSULATION, THEY SHOULD BE BEARING PROPER WARNING SIGNS.

4. Fire extinguishing
Depending on the fuel being used, an appropriate fire extinguishing system should be installed
in the boiler house, as foreseen by legislation.

Εκδ. 1.0 –04/17 20/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

4. FIRST-TIME START UP
CAUTION!
FIRST-TIME START UP OF THE STEAM BOILER SHOULD BE PERFORMED
ONLY BY SPECIALISED AND EXPERIENCED TECHNICAL PERSONNEL.

4.1 General
The start up of a steam boiler in a new installation requires much attention, since the steam
boiler has not been adjusted yet, so the installation's behavior could be unpredictable.
Therefore preliminary inspections of the system should be performed.

4.2 Steamboiler internal cleaning

Before first-time start up the steamboiler’s internal heat transfer surfaces must be thoroughly
cleaned from debris, oil etc. The cleaning is made following the process below:

 Procedure No 1: Internal wash with sodium carbonate solution (Na2CO3 )

 Make sure that all the nozzles are closed, except the ventilation and the top manhole.
 Fill the steamboiler with water.
 Add crystal sodium carbonate (Na2CO3) in proportion approximately 5 kgsc / 100 kgwater
through the top manhole.
 Let the solution in the steamboiler for one (1) hour and then drain it through the blow-
down.
 Fill the steamboiler with water and drain again.
 All the internal surfaces have been cleaned and the steamboiler is ready for operation.

4.2 Preliminary Checks

Before first-time start up normal operation of the following must be ensured:

 Feed water tank level check

The water level must be in the normal operation height. Add water from the water softener
plant if necessary.

 Procedure 2: Feed water quality check

 Take a sample from the water of the water feed tank.
 Use the appropriate method to measure the values of the water's pH and hardness.
 In case the values outreach the limits defined in the prescriptions (Annex Β) the water
feed tank must be evacuated and refilled with water from the water softener plant.
 Check again the water quality and if the results are still off limits, check the water
softener plant.

Εκδ. 1.0 –04/17 21/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 Procedure 3: Water Pumps check (manual operation)

 On the electric panel set the main switch (ON), and adjust the following:
- Pumps (MANUAL/OFF/ΑUΤΟ): OFF
- Burner : OFF
- Burner switch (Light/Heavy Load): Light Load
- Pump switch: Ι or ΙΙ (depending on the pump that is feeding)
 Make sure that the valves before and after the feeding pump are open.
 Make sure that the manhole and the drains are sealed.
 The ventilation valve must be open.
 Set the pump switch to: MANUAL. The pump feeds the steamboiler with water. The low
level indication is on until the water level reaches the lower operation level.
 The steamboiler is filled with water until the water level reaches the normal operation level
(middle of the level gauges).
 Lower the water level by opening the blow down valve.
 Repeat the process using the second pump.

 Procedure 4: Water Pumps check (automatic operation)

 On the electric panel set the main switch (ON), and adjust the following:
- Pumps (MANUAL/OFF/ΑUΤΟ): OFF
- Burner : OFF
- Burner switch (Light/Heavy Load): Light Load
- Pump switch: Ι or ΙΙ (depending on the pump that is feeding)
 Make sure that the valves before and after the feeding pump are open.
 Make sure that the manhole and the drains are sealed.
 The ventilation valve must be open.
 If the water level is above the minimum, lower it by opening the blow down valve until the
low level alarm is on.
 Set the pump switch to: ΑUΤΟ. The pump feeds the steamboiler with water. The low level
indication is on until the water level reaches the lower operation level.
 The steamboiler is filled with water until the level reaches the maximum operation level,
when the pump stops automatically.
 When the pump stops lower the water level by opening the blow down valve until the
pump starts again automatically.
 Repeat the process at least three times to make sure that the system works properly.
 Repeat the process using the second pump.

 Procedure 5: Fuel supply check

Before the boiler's first-time start up it is necessary to check the proper and safe operation of
the fuel supply system. The check depends on the fuel type (solid, liquid or gas).

Εκδ. 1.0 –04/17 22/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

Procedure 5b: Liquid fuel supply check (diesel)

 Check that there is enough fuel stored in the daily tank.
 Check that the valves of the fuel supply circuit are open.
 Turn the fuel supply system on (fuel pump) without starting the burner.
 Check the pressure of the fuel circulation circuit (fuel supply and fuel return). The
pressure values vary depending on the size and type of the burner, during the plain fuel
circulation. Be sure that the indications on the manometers agree with the values shown in
the burner's manual.

Note: If the fuel used is heavy type oil (MAZOUT) preheating the fuel is required. In this case
before the fuel supply check switch on the resistant heaters until the oil reaches the
temperature of 80oC. Then follow the above procedure keeping the resistant heaters on.

Procedure 5c: Gas fuel supply check (LPG)

 Check that there is enough fuel stored for the daily operation (in case of Natural Gas
network feed, check the gas pressure after the gas meter).
 Check that the valves of the feed circuit are open.
 Check the manometers on the gas feed line. The pressure is indicative of gas existence and
changes depending on the burners size and type.

Εκδ. 1.0 –04/17 23/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 Procedure 6: Burner check (light load)

 On the electric panel set the main switch (ON), and adjust the following:
- Pumps (MANUAL/OFF/ΑUΤΟ): AUTO
- Burner : OFF
- Burner switch (Light/Heavy Load): Light Load
- Pump switch: Ι or ΙΙ (depending on the pump that is feeding)
 Since the pump switch is on AUTO the steamboiler is filled with water up to the normal
operation level.
 Check the water level on the level gauges. The water level indication of both level
gauges must be the same. If not, the reason must be investigated and dealt with before
any other action.
 All the stop valves must be closed, except from the pumps’ valves. There is no pressure in
the steamboiler.
 Check the pressure switches.
 Check the fuel supply and make sure that the burner is fed freely and safely (for Heavy Oil
MAZOUT the fuel must be preheated). Set the burner switch to: ΟΝ.
 Since there is no indication of malfunction the burner’s programmer starts the burner on
the light load program, spreading air in the flame chamber. The burner ignites and operates
constantly until the pressure inside the steamboiler rises to the value set on the pressure
switch for light load.
 During the burners operation make the required adjustments to maximize the burner’s
efficiency and ensure its normal operation (silent and stable flame, of the right color and
brightness depending on the fuel used, transparent flue-gas, etc.).
 When the burner stops lower the pressure by opening gradually the safety valve, the
ventilation valve or the blow-down valve. When the pressure undercomes the set value the
burner starts again.
 Repeat the procedure for at least five times to make sure that the system works properly.
 On the same time check the response of the selected pump to adjusting the water level.
 After the checks are completed set the burner switch to: OFF and lower the pressure
opening gradually the ventilation valve.

CAUTION!
OPENING AND CLOSING THE STEAM AND STOP VALVES MUST ALWAYS BE
SLOWLY AND GRADUALLY. ABRUPT MANIPULATION MAY STRESS THE
INSTALLATION AND MAY CAUSE UNPREDICTABLE DAMAGES SUCH AS
HYDRAULIC HAMMERS.

Εκδ. 1.0 –04/17 24/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 Procedure 7: Burner check (heavy load)

 On the electric panel set the main switch (ON), and adjust the following:
- Pumps (MANUAL/OFF/ΑUΤΟ): AUTO
- Burner : OFF
- Burner switch (Light/Heavy Load): Heavy Load
- Pump switch: Ι or ΙΙ (depending on the pump that is feeding)
 Perform steamboiler’s preparation as in the light load operation. There is no pressure in the
steamboiler. Set the burner switch to: ΟΝ.
 Since there is no indication of malfunction the burner’s programmer starts the burner on
the light load program, spreading air in the flame chamber. The burner ignites and operates
constantly until the pressure inside the steamboiler rises to the value set on the pressure
switch for heavy load. At that point the burner starts working on lighr load until the
desirable pressure is acquired.
 During the burners operation make the required adjustments to maximize the burner’s
efficiency and ensure its normal operation (silent and stable flame, of the right color and
brightness depending on the fuel used, transparent flue-gas, etc.).
 When the burner switches from heavy to light load lower the pressure by opening gradually
the safety valve, the ventilation valve or the blow-down valve.
 When the pressure undercomes the set value, the burner switches to heavy load.
 Repeat the procedure for at least five times to make sure that the system works properly.
 On the same time check the response of the selected pump to adjusting the water level.
 The burner’s switch from light to heavy load and reverse must be accomplished smoothly
and without interruption of the combustion.
 After the checks are completed set the burner switch to: OFF and lower the pressure
opening gradually the ventilation valve

 Procedure 3: Digital thermometers/thermostats check

Digital thermometers/thermostats are adjusted by our company to interrupt the operation
when the water and flue gas temperature outreach the normal operation limits. To check
their operation please follow the instructions below :
 Under normal operation conditions change the flue gas thermostat to a temperature
lower than the expected flue gas (or steam) temperature .
 The thermostat shows overheating and the burner and steam boiler operation
automatically shuts down.
 A warning light switches on (control panel) and a sonar alarm sounds. The safety
circuit is blocked.
 Pressing the siren (STOP) button , the sonar alarm stops.
 Pressing the boiler (START) button, the safety circuit does not reset as long as the
malfunction remains, i.e. until the boiler cools down and the temperature is reduced
under the limit.

Εκδ. 1.0 –04/17 25/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 In case the safety circuit does not block, the operation of the digital
thermometer/thermostat must be checked immediately.
 After finishing the check, please readjust the temperature limit to its initial value.

CAUTION!
IT IS IMPORTANT TO WRITE DOWN THE FLUE GAS TEMPERATURE AT
LEAST ONCE PER DAY. KEEPING TRACK OF THE TEMPERATURE VALUES
WILL GIVE AN INDICATION OF THE BOILER'S EFFICIENCY AND A WARNING
FOR MAINTENANCE AND CLEANING OF THE HEAT EXCHANGE SURFACES.
KEEP THE BOILER OPERATION LOG UPDATED ON A REGULAR BASES

CAUTION!
DO NOT CHANGE THE THERMOSTATS ADJUSTMENTS.
THE THERMOSTATS SHOULD ALWAYS BE ADJUSTED BY SPECIALISED
PERSONEL, ONLY AFTER NOTIFYING OUR COMPANY.

FALSE THERMOSTATS ADJUSTMENTS COULD LEAD TO A VERY

DANGEROUS OPERATION OF THE BOILER.

CAUTION: GREAT RISK OF IRREVERSIBLE BOILER DAMAGE (eg METAL

SHEET DISTORTION)

CAUTION: OVERPRESSURE EXPLOSION HAZARD

 Procedure 9: Pressure switch check

The operation and safety pressure switches are adjusted by the manufacturer according to
the steamboiler’s parameters. In order to confirm their proper operation please take under
consideration the value measured by the analogue manometer in the front of the
steamboiler as well as the steam temperature, if measured. Under normal operating
conditions adjusting the pressure switches set value leads to setting the steamboiler’s
maximum operating pressure.Their proper function check must be done following the steps
below:

 Start up the steamboiler having all the nozzles and valves closed.
 When the stemboiler’s operation stops check if the pressure switches set point is in
accordance with the manometer value.
 If the pressure switches set point dos not agree with the manometer value please check the
manometer’s accuracy and the pressure switches proper function.

Εκδ. 1.0 –04/17 26/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 The set point of the operation pressure switches is below the set point of the safety pressure
switch. The burner stops operating until the pressure value reaches the one of the safety
pressure switch.
 The siren starts buzzing and there is an indication on the control panel.
 Stop the siren by pressing the corresponding button.
 By pressing the start button the safety circuit does not reset as long as the malfunction
remains (until the pressure decreases).
 In case the safety circuit does not block the boiler’s operation please check immediately the
pressure switches operation.
 When all the checks are completed please readjust the pressure switches to their initial set
values.

CAUTION!
DO NOT CHANGE THE PRESSURE SWITCHES ADJUSTMENTS.
THE PRESSURE SWITCHES SHOULD ALWAYS BE ADJUSTED BY
SPECIALISED PERSONEL, ONLY AFTER NOTIFYING OUR COMPANY.

FALSE PRESSURE SWITCHES ADJUSTMENTS COULD LEAD TO A VERY

DANGEROUS OPERATION OF THE BOILER.

CAUTION: GREAT RISK OF IRREVERSIBLE BOILER DAMAGE (eg METAL

SHEET DISTORTION)

CAUTION: OVERPRESSURE EXPLOSION HAZARD

 Procedure 10: Safety valve check

The size of the safety valve against overpressure is chosen according to the boiler size and
heating capacity. The safety valve is adjusted by the manufacturer to a maximum pressure a
little higher (about 10%) than the boiler's maximum operation pressure. To check the safety
valve's function please follow the instructions below:

 Initially the safety pressure switch is adjusted to a pressure lower than the one of the safety
valves. Adjust the operation and safety pressure switches to a pressure higher than the
safety valve pressure.
 Start up the steamboiler having all the nozzles and valves closed.
 As the burner works normally, the pressure rises up to the set value of the safety valves..
The safety valve opens abruptly and relieves some steam to the environment until the
pressure becomes lower than the set value.

Εκδ. 1.0 –04/17 27/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

 If for whatever reason the safety valve does not open, the boiler operation must be stopped
immediately. The reason the safety valve did not open must be investigated and if
necessary replace the safety valve.
 Under no circumstances should the boiler operate if the safety valve does not function
properly.
 After finishing the check reset the pressure adjustment of the boiler to the initial value
 Regular check of the safety valve can be accomplished using their release handle, without
interfering in the pressure adjustments.

CAUTION!
SAFETY VALVES ARE THE LAST AND MOST DIRECT PROTECTION
MEASURE AGAINST BOILER OVERPRESSURE.
SAFETY VALVES SHOULD ALWAYS BE MAINTAINED IN GOOD CONDITION
AND THEIR PROPER FUNCTION SHOULD BE CHECKED FREQUENTLY AND
REGULARLY.
ANY INTERVENTION IN THE ADJUSTMENT OF THE SAFETY VALVES, THEIR
OPERATION OR THEIR REPAIR, IS INACCEPTABLE AND PUTS IN GREAT
DANGER THE OPERATION OF THE BOILER AND THE PERSONEL WORKING
NEXT TO IT.
IN CASE A MALFUNCTION IN THE SAFETY VALVES OCCURS, THE BOILER
OPERATION MUST BE IMMEDIATELY STOPPED.
ONLY AFTER REPAIRING THE MALFUNCTION OF THE SAFETY VALVES OR
REPLACING THEM SHOULD THE BOILER START AGAIN.

Regardless the equipment and the safety devices, it is strongly recommended to supervise the
operation of the boiler for at least 48hours since the final adjustments and the first-time start
up.

ATTENTION!
THE TECHNICAL PERSONEL RESPONSIBLE FOR THE OPERATION OF THE
BOILER MUST BE PROPERLY TRAINED FOR THAT PURPOSE AND MUST
HAVE READ THIS MANUAL.
THE OPERATION & MAINTENANCE MANUAL MUST BE KEPT IN GOOD
CONDITION CLOSE TO THE BOILER AND BE DIRECTLY ACCESSIBLE BY
THE TECHNICAL PERSONEL OF THE BOILER HOUSE AT ANY TIME.

Εκδ. 1.0 –04/17 28/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

5. REGULAR OPERATION OF THE STEAMBOILER

5.1 Start up
Before each start up please check the following:
 Feed water tank water level
 Feed water line (open valves, leak check, etc.)
 Fuel supply line (open valves, leak check, fuel preheating if necessary, daily tank check if
there is one, etc.)
 Steamboiler’s internal pressure (Front Manometer).
 Steamboiler’s water level (Level Gauges). If the water level is low please restore it to the
normal height, using the water pumps automatically or manually
 Steam output main shut-off valve must be closed
 Ventilation shut-off valve must be open
 Surface drain and Blow-down valves must be closed
 Manholes must be wide sealed

Additional check can be performed to ensure that the quality of the water in the water tank and
the steamboiler is right (e.g. pH value, hardness). If the measured values are above the
allowable limits (see Annex Β), than the tank and/or the steamboiler must be drained and
refilled with water of the right quality.

CAUTION!
TO STOP THE STEAMBOILER’S AND BURNER’S OPERATION IMMEDIATELY
IN CASE OF MALFUNCTION OR ANY OTHER EMERGENCY, PRESS THE BIG
RED BUTTON (MUSHROOM) ON THE CONTROL PANEL.
AS LONG AS THE RED BUTTON IS PRESSED DOWN THE STEAMBOILER DOES
NOT OPERATE.
THE BUTTON REMAINS PRESSED. TO RESET IT SIMPLY GIVE IT A TURN.
DO NOT PERFORM ANY CORRECTIVE MOVEMENTS OR REPAIRS WHEN THE
OPERATION OF THE STEAMBOILER HAS BEEN STOPPED ONLY BY THE RED
BUTTON. ALWAYS SWITCH OFF THE MAIN SWITCH OF THE CONTROL
PANEL BEFORE ANY OTHER ACTION.

Εκδ. 1.0 –04/17 29/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

5.2 Steamboiler operation

During the steamboiler’s operation you should always check:

 The water level inside the steamboiler. The water level must be on the height of normal
operation (the middle of the sightglass) or at least on the lower allowable point (50 mm
above the lower visible point of the sightglass).

CAUTION!
IF DURING THE STEAMBOILER OPERATION YOU CANNOT SEE THE WATER
LEVEL THROUGH THE SIGHTGLASSES, SHUT OFF THE STEAMBOILER
IMMEDIATELY AND LEAVE THE BOILERHOUSE UNTIL THE BOILER HAS
COOLED DOWN SUFFICIENTLY
CAUTION: GREAT RISK OF IRREVERSIBLE BOILER DAMAGE (eg METAL
SHEET DISTORTION)

CAUTION: GREAT RISK OF EXPLOSION DUE TO

OVERHEAT

 The pressure inside the steamboiler, on the front manometer. The pressure must in no
case overcome the maximum allowable pressure marked on the steamboiler’s plate.

CAUTION!
IF THE PRESSURE ON THE FRONT MANOMETER OVERCOMES BY 20% THE
MAXIMUM ALLOWABLE PRESSURE AND THE SAFETY MEASURES HAVE
NOT WORKED SHUT OFF THE STEAMBOILER IMMEDIATELY AND LEAVE
THE BOILERHOUSE UNTIL THE BOILER HAS COOLED DOWN SUFFICIENTLY
CAUTION: GREAT RISK OF IRREVERSIBLE BOILER DAMAGE (eg METAL
SHEET DISTORTION)

CAUTION: GREAT RISK OF EXPLOSION DUE TO

OVERPRESSURE

 The temperature of the flue gas. An indicative of the flue gas temperature is that it
should not be lower than the steam saturation temperature in the operating pressure
incremented by 25οC to 35οC (π.χ. for operating pressure: 10barg, we have: Τsat = 184οC,
and: Tf.g. = 184oC + 30 oC ±5oC = 214 oC±5oC). If the flue gas temperature is way above
the indicative value then the steamboiler is overheated and has a reduced efficiency.

Εκδ. 1.0 –04/17 30/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CAUTION!
PROLONGED STEAMBOILER OPERATION WITH HIGH FLUE-GAS
TEMPERATURE REDUCES THE LIFETIME OF THE FIRETUBES.
OPERATING THE STEAMBOILER WITH HIGH FLUE-GAS TEMPERATURES
RESULTS TO FUEL WASTE AS WELL AS TO ANTI-ECONOMICAL AND ANTI-
ENVIRONMENTAL OPERATION.

 Burner’s combustion quality. The flame must be silent, continuous, normal, shiny and
have the right color according to the fuel type. The flue-gas that comes out of the chimney
must not be visible (neither white nor black). The flame quality can be checked through
both sightglasses (on the burner an on the rear butt of the steamboiler.

CAUTION!
A WELL REGULATED BURNER RESULTS TO REDUCED FUEL CONSUMPTION,
NORMAL OPERATION, REDUCED WEAR AND MAINTENANCE DEMANDS FOR
BOTH THE BURNER AND THE STEAMBOILER.

 Possible leaks from the shell or the reverse chambers. In case of water leak through
the thermal insulation or the reverse chambers doors there is a strong possibility that there
is a hole in one of the firetubes or in some other part of the boiler shell. The steamboiler
must be shut down as soon as possible in order to examine the damage.

 The water level of the feed water tank. The feed water tank must contain water of the
appropriate quality enough to keep the steamboiler running for an hour (1h). The water
level can be easily read through the sightglass. If the level is lower than the minimum you
should stop the steamboiler.

 The normal fuel supply to the burner. The manometers on the fuel supply line should
indicate to right pressure value according to the burner specifications and the fuel type. In
case of deviations the boiler’s operation must stop.

 Procedure 12: Stopping the steamboiler

CAUTION!
TO STOP THE STEAMBOILER’S OPERATION FIRST YOU MUST SHUT DOWN
THE BURNER AND LAST THE WATER PUMP.
AS LONG AS THE STEAMBOILER IS STOPPED THE VENTILATION VALVE
MUST BE OPEN FOR SAFETY REASONS.

Εκδ. 1.0 –04/17 31/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

7. STEAM BOILER MAINTENANCE

7.1 General
The maintenance of the steam boiler takes place on a daily, weekly, monthly and annual basis.
Maintenance work must be performed with consistency and diligence. The use of a boiler
maintenance workbook is recommended, where noted:
a) maintenance works
b) modifications made to the steam boiler operation
c) occurrence of faults and their repair
d) fitting of spare parts due to wear

It is also recommended that the operating hours of the steam boiler until that moment should
be recorded before each entry at the boiler workbook. The boiler workbook should be kept in
good condition along with the operating instructions and maintenance of the boiler and to be
available to the qualified personnel operating the steam boiler as well as to qualified teams
that perform works in the boiler.
Our company has not any responsibility in case of operation with reduced performance,
generally malfunctioning, damage and losses that may arise from insufficient or improper
maintenance of steam boiler.

7.2 Required Maintenance Works

Under normal operating conditions without problems, typically required maintenance tasks are
presented in Appendix A. If any indicator of boiler (ie exhaust temperature) deviates from the
normal operating limits the cause of the discrepancy should be checked as soon as possible
and treated safely.

CAUTION!
IF THERE IS A DIFFERENCE BETWEEN THE OPERATING MEASUREMENT
AND THE NOMINAL PRICE OF ANY OF THE BOILER MEASUREMENTS DO
NOT MAKE ARBITRARY CORRECTION REGULATIONS TO SAFETY
EQUIPMENT.
IF THERE IS DOUBT ABOUT THE NORMAL OPERATION OF THE STEAM
BOILER ALWAYS CONSULT OUR COMPANY.
REGULATION AND INTERFIERCES AT THE EQUIPMENT OF THE STEAM
BOILER SHOULD ONLY BE MADE BY QUALIFIED TECHNICIANS AND AFTER
CONSULTING OUR COMPANY.

All the necessary tools and equipment required for maintenance works (spare parts, pliers,
screwdrivers etc.) should be kept inside the boilerhouse and be available to the authorized
personnel that operates the steamboiler.

Εκδ. 1.0 –04/17 32/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

7.3 Technical personnel εκτέλεσης εργασιών συντήρησης

All the maintenance works should be performed by authorized technical personnel only. The
authorized personnel must have read this manual and contact our company for any questions.
Maintenance works can also be performed by external crews and technicians, as long as they
are qualified and familiar with the specific type of steamboilers.

Εκδ. 1.0 –04/17 33/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

ANNEX Α
OPERATION & MAINTENANCE

Α.1. GENERAL
Under normal operating conditions, the maintenance of the boiler is on a daily,
monthly and annual basis. Additionally, it is recommended to keep a diary of
changes in operating conditions, damage and repairs to the boiler.

Α.2.DAILY
On a daily basis the following tasks should be performed:
Α.2.1 Check of the water level at the water level glass gauge. Before the
control the glass gauge should be cleaned thoroughly.
Α.2.2 Check of the water level at the feed water tank.
Α.2.3 Check of the automatic operation of the steam boiler water feed pump.
The check is carried out by empting the water from the steam boiler
through the blow down valve. The water feed pump should
automatically pump in water till the water level inside the steam boiler
reaches the operation level.
Α.2.4 Check of the shutdown of the burner in case of low water level. The
check is carried out by empting the water from the steam boiler through
the blow off valve while the feed water pumps are at OFF mode.
Α.2.5 Check of the combustion quality of the fuel with visual check of the flue
gas at the chimney (black smoke should not appear)
Α.2.6 Every five (5) hours of operation, a quantity of water should be removed
through the blow down valve so that the salt condensates are removed
too. The water removal should take place under steam pressure.
Α.2.7 Every eight (8) hours of operation a quantity of water should be
removed through the blow off valve, in case that automatic blow off
equipment is not installed to the steam boiler.

Α.3. WEEKLY
Α.3.1 Check for steam leaks from several connections, sealings, etc
Α.3.2 Check for fuel leaks (e.g. oil or diesel)

Εκδ. 1.0 –04/17 34/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

Α.3.3 Check and verification of the pressure gauge and the level gauge
measurements

Α.4. MONTHLY
Α.4.1 Check of the burner, cleaning of the injectors and of the diffuser
Α.4.2 Check of the safety valve. The check can be made at normal operation
conditions when the burner stops the operating pressure of the boiler, so
by slightly moving the safety valve lever steam should be relished.
Α.4.3 Cleaning of the smoke tubes from ash deposits

Α.5. ANNUALY
Α.5.1 Cleaning of the Level Electrodes
Α.5.2 Cleaning of the Level Gauge and of the float level controller
Α.5.3 Cleaning of the smoke tubes from ash deposits
Α.5.4 Check of the condition of the refractory bricks and cement and repair if
needed.
Α.5.5 Cleaning of the safety valve, of the pressure gauges piping and of the
pressure controller.
Α.5.6 Check and cleaning of the inside of the steam boiler from salt
condensates an chemical cleaning if necessary.

Εκδ. 1.0 –04/17 35/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

CAUTION!
 Extra care should be given to the water auto fill of the
b o i l e r . T h e n o mi n a l w a t e r l e v e l i s a l mo s t a t t h e h a l f o f
the glass level gauge.

IN CASE GLASS LEVEL GAUGE IS EMPTY OF WATER

DURING THE BOILER OPERATION, CUT OFF THE
POWER SUPPLY IMMEDIATELY AND NOTIFY A
QUALIFIED TECHNICIAN OR OUR COMPANY

 G e n e r a l l y , i n a n y c a s e o f ma l f u n c t i o n t u r n o f f t h e
p o w e r s u p p l y a n d n o t i f y o u r c o mp a n y o r o t h e r
qualified steam boiler technical.

 I f t h e b u r n e r i s b l o c ke d p r e s s t h e l i g h t e d b u t t o n o n i t s
c o n t r o l l e r . I f t h e b u r n e r i s s t i l l b l o c ke d a n d d o e s n o t
s t a r t o p e r a t i n g r e p r e s s t h e b u t t o n t w o o r mo r e t i me s . I n
c a s e t h a t t h e b u r n e r i s f r e q u e n t l y b l o c ke d a q u a l i f i e d
burner technician should check it.

Εκδ. 1.0 –04/17 36/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

ANEX B
WATER SPECIFICATIONS
Β.1. FEED WATER
Measurements at boiler input during its operation:
General Requirements Διαυγές & αχρωμάτιστο
PH value (at 25οC) >9
Total Hardness mval/kg <0.02
Oxygen Ο2 mg/kg <0.02
Iron (Fe) mg/kg <0.1
KΜnO4 Consumption mg/kg <10
Oily matter mg/kg <1
Cooper (Cu) mg/kg <0.01

Allowable chemical additives :

 Sodium Phosphate (Na3PO4)
 Ammonia (solution 24% NH3)

Β.2. WATER IN THE BOILER

During boiler operation:
Saturated Steam Superheated steam
PH value (at 25οC) >9.5 >9.5
Total Hardness mval/kg 1 – (max) 15 1 – (max) 10
Specific conductance at μS/cm <10000 <6000
25οC
Silica (as SiO2) mg/kg <150 <70
Posphate (as PO4) mg/kg 10 – 20 10 – 20

Εκδ. 1.0 –04/17 37/38

THERMOSSOL STEAMBOILERS SA PK Steam Boiler Manual

Β.3. WATER IN THE STEAMBOILER WITH DESALINATED WATER

FEED
If the steam boiler is supplied with desalinated water or condensates, then the
PH value should be ≥7, if the water feed pump is made of chromium alloy steel.
For the water inside the steam boiler in this case the following values should be
followed:

PH value at 25οC >9.5

Total Hardness mval/kg 0.1 – 1.0
Specific conductance at 25οC μS/cm <500
Silica (as SiO2) mg/kg <10
Posphate (as PO4) mg/kg 5 – 15

The use of sodium hydroxide (NaOH) or potassium hydroxide as chemical

additives for the increase of the PH Value is not allowed. As chemical additives
should be used the ones mentioned at Β.1.

CAUTION: Hydrazine (Ν2Η4) and its solutions are not allowed to be used at
any case as highly dangerous to human health.

Εκδ. 1.0 –04/17 38/38