OPERATION MANUAL

NNB(NBO) - 2000G, 2500G, 3000G

BOOSTER Boiler Co., Ltd.

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

Contents

1. Part Name and Function for the Boiler ---------------------------2

2. Part Name and Function for the Control Panel ---------------------3
3. Steam Generation System------------------------------------------4
4. Concentration Blowing-off Device---------------------------------4
5. Specification----------------------------------------------------5
5. Check Item before Operation--------------------------------------6
6. Operation Start -------------------------------------------------6
7. Operation Stop---------------------------------------------------6
8. Cautions during Operation----------------------------------------7
9. Instruction for the Boiler not Using for a Long Time-------------7
10. Manipulation Method for Auxiliary Equipment----------------------7
11. Water Level Control Device(BWC - 3000A)-------------------------11
12. Operation Status for Combustion Control(Protect Relay)----------12
13. Brief Maintenance Check and Cleaning Method --------------------13
14. Superheating Prevention Device ---------------------------------16
15. Safety Device for Abnormal Combustion --------------------------16
16. Freezing Prevention --------------------------------------------16
17. Instruction for Blowing-off of Water ---------------------------17
18. Boiler Water Treatment------------------------------------------17
19. Troubleshooting-------------------------------------------------20
20. Maintenance Checksheet -----------------------------------------22
21. After Service --------------------------------------------------23
22. Reference Document----------------------------------------------24

1
※1 Part Name and Function for Boiler
1. Part Name and Function for Boiler

No Nomenclature Functions

1 Flame Detector A safety device which detects ignition or flame failure

Adjusting pressure operate of the boiler

2 Pressure Switch

3 Pressure Gauge A gauge which indicates steam pressure in the boiler

4 Automatic Control Panel Operates boiler to start and to stop

5 Water Level Gauge A gauge which indicates water level in the boiler

7 Drain valve Blow off inside the boiler water per a day

Concentration Blow-off A device which controls concentration of water by blowing off

8
Solenoid Valve automatically.
A equipment generating high dried steam through separating the
9 Steam separator
steam and the moisture.

10 Main Steam Valve A valve used for steam supply.

11 Burner Combustion equipment which sprays the fuel mechanically.

2
 2. Part Name and Function for the Control Panel

No Nomenclature Functions
A control device which have functions of water level control,
1 Water Level Controller feed water control, concentration blowing-off and integration of
combustion time

2 Protect Relay Controls combustion, and stops operation when emergency.

A device which injects chemicals for corrosion protection when

3 Initial Chemical Injection Device
initial operation.
Connects between wire on the control panel and the external
4 Terminal Board for Power
power.

5 Magnetic Switch for Burner Motor Controls the burner motor operation.

Magnetic Switch for Feed Water

6 Controls operation of the feed water pump
Pumper
7 Fuse Protects control system by cut-off when over current.

8 Circuit Breaker Shut off when over current and electrical leakage

9 Gas Detector Detects the gas leakage on the main gas cut-off valve

10 Transformer Transforms the voltage from 220V to 110V(to Softner)

11 Terminal Board Connects wiring in the control panel and external wire.

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

2. Gas Combustion
The gas which is removed the foreign substance through the gas strainer is pressurized up to
the specified pressure by the main governor, and is combusted after through the 1st. and the
2nd. main shut-off valve.

3. Ignition
Ignition is performed by the raised voltage(from 220V to 7,000V) on the pilot burner, and then
on the main burner in the 15 seconds.

4. Steam Generation
The water in the tube is heated by the combustion of burner and evaporated on the evaporation
surface. The saturated steam including moisture is forwarded to the steam separator through
upper header. This steam including moisture is separated into steam and moisture by the steam
separator, and the dried steam only is supplying for loaded side through the main steam valve.

※3 Concentration Blowing-Off Device

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

Concentration Blowing-off Device

4
※4. Specification
Item Type Unit NBO-2000G NBO-2500G NBO-3000G

Rated evaporation kg/h 2,000 2,500 3,000

Max.allowable working press. kg/㎠ 10

Total Heating Value kcal/h 1,287,400 1,609,250 1,931,100

Boiler Efficiency % 90
Heating Surface ㎡ 28.7 33.4 40.1
Contained water ℓ 380 420 480
Weight kg 3,510 3,800 4,600
Power Source V 220V/380V Χ 3Φ
Total Electric Power Capacity kw 11.2 14.7 14.7
Blower Motor Capacity kw 7.5 11 11
Feed water Pump motor Capacity kw 3.7) 3.7 3.7
Oil pump motor Capacity kw

Dimension Width(W) mm 2,135 2,170 2,400

Length(L) mm 3,330 3,375 3,645
Height(H) mm 3,030 3,240 3,260

Burner type - Forced draft , first mixing blast

Control System - HIGH-LOW-OFF
Spark method - High voltage electric spark

City Gas(13A) N㎥/h 103.6 129.5 155.5

Burner Natural Gas(13A) N㎥/h 144.4 180.6 216.7
Fuel N㎥/h 63.9 79.8 95.9
Consumptio LPG
(Propane) kg/h 129.1 161.3 193.7
n(Gas)
N㎥/h 50.3 62.9 75.6
LPG
(Butane) kg/h 130.8 163.5 196.3
13A L. P. G 13A L. P. G 13A L. P. G
Gas Inlet A
50 50 50 50 50 50

Steam outlet A 80 80 100

Connect Feed pumpWater outlet A 25 <inlet 32A>
size Seafty valve A 32 <전> 40 <전>

Drain valve A 40

Flue Size Φmm 400 450 500

Flue Size(Diameter) Φmm 500 550 600

The values ( ) are for GD type

* Above specifications are based on the followings:
- Heating Value
13A(Town Gas) : High/Low Heating Value 15,000/13,000 Kcal/Nm3
13A(Natural Gas) : High/Low Heating Value 11,000/9,900 Kcal/Nm3
Propane : 24,300/22,380 Kcal/Nm3 12,030/11,080 Kcal/kg
Butane : 30,740/28,400 Kcal/Nm3 11,830/10,930 Kcal/kg
Low Heating Value for Fuel : 10,300 Kcal/kg(Light Oil)

5
※5. Check Item before Operation
* Before start the operation, check the following items:
(1) The gauges are working properly;
(2) Water level in the feed water tank before opening
the feed water valve;
(3) Any gas leakage on the gas piping lines;
(4) That cleaning detergent are enough in the chemical
injection tank;
(5) Quality of soft water.

※6. Operation Start

Before operation the boiler, the blowing-off of water shall be performed to prevent tube
clogging or rupture due to priming and scale caused by foreign substances ( see page 16,
Instruction for blowing-off of water).

The boiler is operated normally in the following sequence:

1. Main switch of boiler "ON".
2. Open the main gas valve.
3. The power switch “ON”. The water feeding is performed
automatically.
4. When feeding the water automatically, the water level
reached to Low level, the gas detector is operating,
and detects any gas leakage on the 1st. and the 2nd.
main gas valves for 20 seconds.
5. During 20 seconds, the time when the gas detector
operates, the boiler is not able to be operated even
the Operation switch is "ON".
Therefore Push the Operation switch "ON" after
reaching up to the normal water level on the
water level gauge.
6. Push the manipulation switch for combustion control
when the water level is reached up to the High.
In the 40 seconds, the pilot burner will be ignited and
the Indication lamp for operation will be lit up.
7. Open the main steam valve slowly when the steam
pressure is reached up to 3 Kg/cm2.

※7. Operation Stop

1. Operation switch OFF.

2. Power switch OFF after post purge.
3. Close the main gas valve and the main feed water valve.
4. Boiler Main switch "OFF".

6
※8. Cautions during the operation

1. Open the main steam valve slowly.

(If open the valve rapidly, the water level in the tube could be the low level temporarily).
2. In the event that the operation is stopped through sensing of the thermistor due to
superheating of the boiler main body, the operation switch and the power switch is to
be positioned to "stop", and close the main fuel valve slowly.
3. In case of suspension of water supply or power interruption, wait until the power or
water is supplied again in the condition of power OFF.
4. In case of closing the gas valve by wrong handling during operation or be suspected
gas leakage, the Operation switch "OFF" immediately, and push the Reset button on
the protect relay after assuring normal conditions.

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

Note : In case that the boiler is not used for a long time, please contact BOOSTER BOILER.

※10. Manipulation of Auxiliary Equipment

1. Setting Method for the Thermal Relay of the Magnetic Switch

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

Thermal relay of the magnetic switch

7
 2. Adjusting Method for the Pressure Switch

The steam pressure is able to adjust the pressure range of 4 -9 Kg/㎠ (below maximum
pressure).
The pressure of the pressure switch is adjusted by using the pressure adjusting bolt and the
pressure variation adjusting bolt to control ON - OFF for combustion.
* Example of Pressure Adjusting :
In order to perform combustion as the figure in the right side:
1) Set the pressure adjusting bolt of the high pressure switch to 8 Kg/㎠.
2) Set the pressure variation adjusting bolt of the high pressure switch to 3Kg/㎠.
3) Set the pressure adjusting bolt of the middle pressure switch to 7 Kg/㎠..
4) Set the pressure variation adjusting bolt of the middle pressure switch to 1.5Kg/㎠.
5) Set the pressure adjusting bolt of the low pressure switch to 6 Kg/㎠..
6) Set the pressure variation adjusting bolt of the low pressure switch to 1Kg/㎠.

Pressure and Pressure Variation Adjusting Bolt Low and middle, High Pressure Switch
Note :
The copper pipe connected to the pressure switch has anti-freezing solution for freezing prevention.
Refilling the anti-freezing solution in the winter time is required.

3.Air Extraction Method for the Feed Water Pump

Open the air cock on the outlet of the feed water

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

Feed water pump

* Note:
In the winter time, open the upper and lower air cock for exhausting the water in the pump in the no
load condition for about 5 seconds to remove the residue attached on the impeller.

8
4. Adjusting Method for the capacity(Damper Blade)
1) Cam Adjusting Method for Control Position

① BLUE (L1) : Position adjusting cam for return from 3rd

to 2nd (Returning position adjusting
from high fire to low fire).
② BROWN(L2) : Position adjusting cam for 2nd . opening
angle. (middle fire opening angle position
adjusting).
③ GREEN (L3) : Position adjusting cam for 2nd .
solenoid valve open and opening angle.
④ BLACK (L4) : Position adjusting cam for pilot and
1st solenoid valve opening angle.
(Pilot and low fire opening angle position TYPE : DM-320-4
adjusting).
⑤ YELLOW (L5) : : Position adjusting cam for 3rd solenoid valve open and opening angle.
⑥ RED (L6) : Position adjusting cam for 3rd . solenoid valve open and opening angle
High fire opening angle position adjusting

2) The Wire Colors of the Damper Motor

{① Blue(1), ② Green(2), ③ Black(3), ④ Red(4) ⑤ White(5),
⑥ Yellow(6)} ⇒ 6p cable, { ⑦ White(7) ⑧ Black(8) } ⇒ 0.75*2c wire

3) Adjusting Method and Example of the Damper Blade Angle

1. Cam Adjusting Method for Control Position
The cam is adjusted in the angle of L4<L3<L2<L1<L5<L6 and the damper is opened wider
rotated it clockwise.
2. Adjusting Example:
If you want to adjust at the damper angle of (3.0) when 1st and pilot combustion
and (4.5) when 2nd combustion, and (6.5) when 3rd combustion adjust as follows:
1) BLUE (L1) : Set the cam position to “5.0” which is indicated on the cam shaft by manual
2) BROWN (L2) : Set the cam position to “4.5” which is indicated on the cam shaft by manual
3) GREEN (L3) : Set the cam position to “3.5”which is indicated on the cam shaft by manual
4) BLACK (L4) : Set the cam position to “3.0” which is indicated on the cam shaft by manual
(pilot and 1st low fire opening angle position adjusting).
5) YELLOW (L5) : Set the cam position to “5.5” which is indicated on the cam shaft by manual.
6) RED (L6) : Set the cam position to “6.5” which is indicated on the cam shaft by manual

9
※11.Adjusting Method for the Water Level Control Device
(BWC-3000R)
This is a control device which has functions of water control concentration blowing-off
and accumulation of combustion time.
1) Direction for use
① Combustion Time Check Conversion Mode
When pushing the conversion switch on the right above of the water level unit, the
lamp of the High fire and Middle fire, Low fire are changed in sequence and the
accumulated combustion time is indicated on the monitor.
Ex) In case that the following indication are shown on the monitor when pushing
the conversion switch:
a) When the high fire lamp is lit up and ⑤ indication is shown up on the
monitor, the total high fire operation time is 13 hours.
b) When the middle fire, the indication is shown in the same method as the above.
c) When the low fire, the indication is shown in the same method as the above.
② Water Level Control Conversion Switch
This is a switch which has functions of 3 position water level control and
5position water level control located on the upper position of the left side, and
the function is being able to converted each other

Note :
Prior to start boiler operation, make sure that the Water level control switch is on the
Three-position control. If the Water level control switch is on the Five-position control,
the boiler is not been able to combusted but feeding water.
(Refer to right figure for Five-position and Three-position conversion switch).
However, 2000-3000G Boilers are able to be operated in the five-position control.

③ E1, E2, E3,E4,E5 water level detection lamp

When each water level detection lamp is
lit up, current water level is indicated.
water density.
(Electrical conduction setting value I
④ PL, PH Lamp
Indicates present combustion detection
status of the water level unit.
* Low fire : PL lamp is lit up.
Middle fire : PM lamp is lit up
* High fire : PH lamp is lit up
⑤ Concentration Blowing-off Adjusting Method
The setting value is 3.7 at the normal condition
on the dial indication which is Water Level Control Device
setting the concentrated s 4500s/cm2).

10
※12. Combustion Control Status(Protect Relay)

1. Ignition Program Indication Chart

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

2. Indication

Symbol Indication Power Failure or Cause for Operation Stop

Damper limit switch shut off
Leakage detection failure
Fuse cut-off, no reached up to the high level
No operation without Protect relay operation error due to
◀ Operation power failure moisture(remove moisture by dry air)
Manipulation switch failure
Air pressure switch connected to pressurizing
side(trouble for contact)
Power failure Suspected flame signal
Combustion is not
Damper open(to 2nd.
▲ performed Limit switch open(short)
combustion position)
continuously
P Check air pressure Power failure Check air pressure or Air pressure switch
Circuit check for flame Suspected flame failure
■ Power failure
detector in the control Control system failure
Damper close(1st. No operation Damper limit switch close(shut off)
▼
combustion preparation) continuously Trouble of Controls
Check the polarity of the flame detector
Ignition transformer failure
1st. safety time
1 Power failure Fuel valve failure
(Pilot combustion)
Lack of flame stability
Flame detector failure
2nd. safety time Ignition failure of the burner(1st. solenoid valve
2 Power failure
(1st. combustion) shut off or too much air volume)
Weak flame current or weak air pressure
. Fuel supply suspension
. Operation Abnormal operation of the flame detector
Power failure
. (2nd. 3th combustion) QRA-2 :Clean out dust on the glass
surface
― Flame rod type :check corrosion on the rod

11
※13. Brief Maintenance and Cleaning Method

1. Check for Soft Water

The following are to be checked for the boiler durability:
1) Feed water must be soft water.
2) Soft water quality must be checked by the
hardness indicator at least once a day.
(About 30-50cc water in the container
taken from the softener outlet after draining
away 3-5ℓ of water is examined by dropping
a few drop of hardness indicator).
Inspection Indicator for
hard water and soft water
* Acceptance standard

Blue Soft water : Accept for use

Red Hard water : Reject for use(To be returned to the softener manually

* Note:
1) If the water includes foreign substance or you wash the container by hands,
the inspection could be resulted as a hard water even being taken from the
softener. Therefore, careful handling of water sample taken is required.

2) When the regeneration of softener is needed during continuous operation,

two unit of softener have to be installed for alternative operation.

2. Check for the Concentration Blowing-off Device

Checking whether the specified blowing-off is performed everyday and whether the
concentrated water sensing device is operated in the normal condition is required.
If any problem on the blowing-off performance, it causes the scale attachment.
In that case, contact the BOOSTER BOILER. (See Page 4 Concentration Blowing-off Device).

3. Check and Cleaning for the Feed Water Strainer and the Concentration
Blowing-off Strainer

Check the inside of the feed water strainer

and concentration blow-off strainer and
remove the foreign substance(dust, scale,
rust, etc.) at least once a month.
Note :
After disassembling and cleaning the feed
water strainer, air extraction must be
performed through operating feed water pump. (Feed Water Strainer)

12
 4. Performance Test for Safety Valve

Extract the steam 2 or 3 times by using the safety

valve lever at the 8-9kg/cm²of steam pressure at
least once a month from trial operation.
(The Pressure adjusting bolt of the pressure switch
is to be set on 8.5kg/cm²)

Safety Valve

5. Check and Cleaning for Electrode Type Water Level Detector

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

Electrode Bar Holder Water Level Gauge

13
 6. Check and Cleaning for Flame Detector
* QRA Type
The scale or carbon on the sight glass makes difficult to do flame monitoring caused for
ignition failure and flame failure. Periodic cleaning the sight glass of the flame detector using
the soft cloth is required (once a month).
* Flame Rod Type
Check and clean corrosion on the flame detector rod.
QRA Type Flame Detector Flame Lot Type Flame Detector

QRA Type Flame Detector Flame Lot Type Flame Detector

※14. Superheating Prevention for the Boiler Main Body

1 Burner Operation Suspension at the Low Level
A device which controls the feed water pump
And Burner automatically for superheating
prevention by the electrical signal from the
computer by sensing the water level.
When the water level dropped down to the
low water level limit, the level reached up
to the high water level limit, the feed water
pump operation is repeated in between the
high water level and the medium water level.
If the wire of the lighting bar holder is disconnected,
correct water level control is impossible and make a
abnormal noise. (Water Level Control for
Superheating Prevention)
The foreign substance on the lighting bar have it be
difficult to detect the water level and causes to combustion circuit of burner is shut off
automatically (when the water level is not reached to the high water level limit in the initial
operation stage, the blower isnot operated and the burner is not ignited).
Once the water he superheating. Therefore periodic cleaning is required.
* Note:
Careful attention is required not so as to be incorrect length and position of the lighting
bar when connected 3 terminal after cleaning.

14
 2 Superheating Prevention Switch

If the boiler main body temperature is raised up

abnormally, the superheating prevention switch
is operated and the burner combustion circuit
is shut off or protecting the boiler main body
and the risk of fire.

Superheating Prevention Switch

※15. Safety Device at the Abnormal Combustion

In the event of flame failure during operation,
the gas supply is shut off through
the shut-off of main solenoid valve,
shut-off valve and pilot solenoid valve by
a flame detector's sensing.
Warning lamp of the protect relay is lit up
and the alarm is buzzing informing
abnormal combustion.
After correction for cause of warning lamp
operation of protect relay, push the
reset button for re-operation.
Protect Relay

※16 Freezing Prevention

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

15
※17. Instruction for Blowing-off of Water
The tap water or underground water used for boiler water is transparent and is seen as not
included any foreign substance, but it has a lot of organic and inorganic matter such as calcium,
magnesium, silica, etc. The softener cannot remove the other foreign substance but calcium and
magnesium which is caused for scale. Therefore, for adjusting the concentration of the boiler
water to a standard value, the blowing-off should be performed through exhausting the
concentrated tube water. Blowing-off should be performed at least once a day(8 hour basis a day)
for prevention of superheating which is caused by scale and sludge deposit.
♦ Blowing-off should be performed as follows before starting the normal boiler operation at least
once a day(one day is 8 hour basis):
1) Check whether the water level in the tube is normal.
2) Close the main steam valve(ignite according to instruction for operation start on P.9).
3) Operate the boiler ,and if steam pressure is reached up to 1.5 - 2 kg/cm2, the operation
switch “OFF”.
4) After post purge, the power switch “OFF”.
5) Open the blowing-off valve and perform blowing-off.
6) If steam pressure is 0 kg/cm2, open the air extraction valve and perform blowing-off
continuously. After finished the blowing-off, close the blowing-off valve.
7) Power switch “ON”. Close the air extraction valve when the water is feeded by the feed water
pump and the air has been exhausted completely. Check whether the water level is normal.

Blowing-off is not necessary everyday when operation load is not much, in this case
contact to BOOSTER BOILER.

※18 Boiler Water Treatment

For a longer boiler life and for maintaining continuous good operation condition, appropriate water
treatment is required like a food control for our health. The hard water such as tap water and
underground water includes various foreign substance. Therefore the softener or chemicals(tube
cleaning detergent) which changes the hard water to soft water shall be used. Especially, boiler
damage due to bad quality of water is not able to be identified immediately. Therefore, daily water
check and control is very important
* When using underground water, the feed water filter must be used.

1. Boiler Harm by the water

The boiler water including the hardening elements(Ca, Mg) and silica causes high water
concentration and scale attachment to the tube wall. Since thermal conductivity of the scale is
extremely low, the boiler efficiency is reduced which is caused of boiler superheating. Corrosion
of steel is caused by acid and alkali water. If the boiler tube is corroded, the thickness of tube is to
be thinned by damaging of surface and come to rupture. Conclusively, the boiler harm by the water
is the scale and corrosion.

16
 2. Scale Protection
1) Softener Use
The boiler water is to be the soft water which is removed the hardening elements of Ca and
Mg dissolved in the water which become to the scale by the softener.
2) Chemical Use(BOOSTER Cleaning Detergent: Direct Heating - 182 ppm for general use,
Indirect Heating - 98 ppm for industrial use)
The chemical is injected for protection that the small amount of hardening elements and silica
in the water leaked from the softener become to scale, and of corrosion of tube by removing
the dissolved oxygen in the water to maintain the water in the alkalinity(PH:11.0 - 11.8) which
is the most difficult condition for corrosion).
* Chemical Injection Method
The chemical should be injected continuously during operation by the chemical injection
device balanced with the amount of feed water from the feed water pump.
* Relation between Scale and Tube Wall Temperature *Boiler Efficiency Reducing by Scale

Thickness of Scale Tube Wall Temp.

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

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

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

17
 (Feed Water Quality) (Tube Water Quality)

Inspection Item Std. Value Inspection Item Std. Value

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

* Sampling Method of theTube Water for Quality Test

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

18
※19. Trouble sooting
When founded the trouble for boiler operation, check the following items before contact to BOOSTER BOILER for A/S:
Trouble Condition
No operation of the feed
water pump
No water feeding but the
feed water pump is operated.
Low water indication buzz
is alarming but indicated
normal water level on the
water level gauge
Feed water pump is not
stopped.(keep operating)
Frequent ON-OFF of feed water 1) Low water pressure
No operation of the Blower
Alarm indicating Abnormal
burner operation is buzzing
Causes Countermeasure
1) Power shut off 1) Check main power switch, the magnetic switch
connection, and if the power lamp is on.
2) Tube water is full. 2) Open the boiler main body blowing-off valve(check
through water level gauge).
3) Thermal relay(OCR1) of the 3) Investigate the trouble cause and take corrective
magnetic switch for the feed water action ,and then reset.
pump is operating normally.
4) Contamination of the water level 4) Check and clean it one by one.
electrode bar.
5) Wire connection is loosed. 5) Fasten tightly the electrode bar holder and the
terminal in the control box.
1) No water in the feed water tank, or 1) Check the water in the tank ,and clean the ball tap and
The strainer.
slow speed of flowing in .
2) Open the main valve.
2) Closed the main valve of the feed
water tank.
3) Clean the strainer.
3) Clogged the feed water strainer. 4) Close the valve.
4) Opened the boiler main body
blowing- off valve. 5) Extract the air by opening the air extraction valve.
5) Air included in the feed water
1) Contamination or cut-off of the low 1) Check and clean the low water level electrode bar.
water level electrode bar.
2) Earthing conductor cut-off or incomplete contact.
1) Contamination or cut-off of the 1) Check and clean the high water level electrode bar.
high water level electrode bar ( Earthing conductor cut-off or incomplete contact).
1) Adjust the main steam valve raise the pressure.
2) High concentration of tube water 2) Perform the blowing off.
3) High variation of load. 3) Open and close the main steam valve slowly.
4) Contamination or incomplete 4) Check and clean it one per one time.
contact of the water level electrode.
1) Power shut off. 1) Power ON.
2) Water level is not reached up to 2) Wait until low water lamp is turned off and the feed
setting level. water pump is stopped.
3) Terminal relay(OCR2) is operating. 3) Investigate the cause and reset.
4) The boiler pressure is not reach up 4) Drop down the steam pressure.
to setting pressure.
1) Attached the carbon and smoke on 1) Clean the glass surface of the flame detector.
the glass of the flame detector.
2) Contaminated the spark electrode. 2) Clean the spark electrode.
3)Inappropriate distance of the spark 3) Adjust the distance of the spark electrode.
electrode.
4) Opened too wide the blower damper. 4) Close the damper.
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※20. Maintenance Check sheet
Every- Every Every 3
Check Item Maintenance Method
day Month Months
Softer O Check by hardness indicator(Blue is acceptable), Salt
check
Chemical volume O Check whether the chemical is in the tank ,and check
check injection status.
Blowing Blowing off O Perform blowing off before operation everyday
-off of water in
boiler
Concentra-t O Check whether the blowing -off is performing by
ion monitoring of concentration blowing-off sensor.
blowing-off
Water Level gauge O Check whether it is operating normally(High water
level shut-off and low water level shut-off).

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

Combus Ignition O Check whether the ignition is performing normally.

-tion
Smoke O Check if smoke out.

Automa Abnormal O Check the low level status indication lamp and buzz
tic Low water operation status.
control level
O Check for automatic ON-OFF at the setting pressure.
device Pressure
shut-off
Tube water quality O Take a tube water sample and analysis.

Strainer Feed water O Clean the filter

Blowing-off O Clean the filter

Gas leakage check O Check on the gas pipe connection by a soap bubble
test
Safety valve O Check the test lever operation.

Ball tap O Operation test

Water level electrode O Clean after disassembling.

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

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※21. After Service

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

21
※22. Reference Document
1. Piping Instruction for the Feed Water Pump

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

22
 2. Piping Diagram for Feed Water Pump and Feed Water Tank
1) When the feed water tank is installed under the ground (the circulation pump is positioned under
the ground) :

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

3) When the feed water tank is installed above the

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

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

23
 3 .Piping Diagram for Feed Water Pump and Feed Water Tank

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

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 BOOSTER BOILER CO., LTD
● HEAD OFFCE & FACTORY
4/5SHINAN B/D ,1029-12 SHINJEONG-1DONG YANGCHUN-GU
SEOUL KOREA .
Postal code : 420-130
TEL: (82 2)2062-0760-8 FAX-(82 2)0262 -1078
● Beijing Office
RM.952,JINGXIN BUILDING,NO.2(JIA),DONGSANHUAN BEILU,
CHAOYANG DISTRICT,BEIJING CHINA
TEL:010-6663-4691 FAX:010-6463-4692

● Booster Boiler . Service Reservation

Cheju (064)743-1290 Chonan (041) 575-9769

Chongju (043)215-0273 Chonju (065) 253-1286

Chunchon (033) 243-0628 Euijongbu (031) 846-7191

Inchon (032) 874-8258 Kangbuk (02) 359-1459

Kangdong (02) 438-0385 Kangnam ( 02)579-8870

Kwagju 062)371-8112 Masan (055)296-3565

Pohang (054)275-2871 Puchon (032)675-2005

Pusan (East) (051)803-7775 Pusan(North) 051) 972-0364

Sunchon (061)722-0213 Suwon (031)298-0361

Taegu (053)744-8925 Taejon (042)541-7676

Ulsan (052)236-8596

2001-07-05 제작

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