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08.KS, KF E992-1103-02

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0% found this document useful (0 votes)
71 views37 pages

08.KS, KF E992-1103-02

Uploaded by

juho5305
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 37

OPERATION

MANUAL
EXHAUST GAS ECONOMIZER

KS, KF SERIES

Operation Manual No. E992-1103-02


Important Safety Information

In handling marine exhaust gas economizer KS, KF type, read and fully understand this manual and
follow instruction that is contained in this manual.

Exhaust gas economizer contains hot parts that may cause burn, high-pressure parts that may cause
injury due to pressure break, moving parts that a part of body may get caught, and high-voltage parts
that may cause electrical shock. Improper handling of these parts may cause accident involving death,
fire, or other disasters.

To ensure safety of operation and maintenance of exhaust gas economizer, it is essential to know
possible causes of disasters in advance. We cannot predict all potential dangers, but present dangers
involved in handling of boiler in this manual to the best of our knowledge. Following warnings or
instructions that are contained in this manual better ensures safety of work.
In this manual, harm and damage are categorized into following three levels. These are attached on
exhaust gas economizer as warning labels (*) and also described in this manual.

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


DANGER causes imminent danger of death or serious injury to user.

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


WARNING may cause death or serious injury to user.

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


CAUTION may cause minor injury to user or property damage.

If failed components are found, contact MIURA offices and replace them with genuine parts. Using
different model part may reduce safety of exhaust gas economizer.
Remodeling exhaust gas economizer without consultation MIURA or repairing it in way that is not
specified in this manual may seriously affect safety of exhaust gas economizer. Do not remodel or
repair exhaust gas economizer on your own.

i
Introduction

This manual describes procedures for handling exhaust gas economizer for proper operation.
Precautions relating to operating method and safety indicated in this manual from damages to
measures only relate to usage for specified purposes. Do not use exhaust gas economizer by methods
that are not mentioned in this manual. Be aware that MIURA cannot be held responsible if exhaust gas
economizer is used by methods that are not mentioned in this manual.

Before using exhaust gas economizer, those who use it for the first time as well as those familiar with
handling of it must read this manual thoroughly and understand proper method of handling it.
Keep this manual in place so that it can be consulted whenever there is any uncertainty about exhaust
gas economizer.

In addition to this manual, following booklets are provided as information that is needed to use exhaust
gas economizer. Before using exhaust gas economizer, thoroughly read these booklets in addition to
this manual.
(1) Final Drawing:
Final drawing is documents containing all specifications for customer. Look over and understand
final drawing before use. Refer to this document for information that depends on capacity or
options.
(2) Procedure Manual for Installation:
Procedure manual for installation contains information on installation of exhaust gas economizer
and incidental parts. Install exhaust gas economizer according to this procedure manual (This
procedure manual is contained in final drawings).
(3) Instruction manuals for incidental equipment:
Handle incidental equipment according to respective instruction manuals.

ii
[Graphical symbols]
Graphical symbols used in this manual have following meanings.
Indicates certain behavior is prohibited.

Prohibition
Indicates touching certain area may cause personal injury.

Do Not Touch
Indicates handling with wet hands may cause electrical shock.

Do Not Touch
with Wet Hands

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

Instruction

Indicates a precaution to be remembered.

Caution
Indicates potential danger of injury from heat under certain
conditions.
Caution: Hot
Provides precaution to prevent exhaust gas economizer failure,
Note point to be remembered for effective operation, or other useful
information.
Indicates related page(s).

iii
Term Definitions

Terms that are used in this manual are defined as follows.


These terms are marked with asterisk (*) in manual.

Term Description

Substance with low ignition temperature that is fire hazard (A handling place
Flammable Dangerous
for flammable dangerous substance refers to place where such a substance
Substance
is stored).

Air Supply Fan Air supply system designed to bring air into engine room.

Warning Label Label to call attention to operating precaution.

Phenomenon that soot (minute particle ingredient that is exhausted from


diesel system, and adhered and gathered on generating tube of exhaust
Soot Fire
gas economizer) causes spontaneous combustion and fire by spark, and
generating tube gets damaged hole and disadvantage.

To remove soot that is adhered on generating tube with soot blower to


Soot Blow
prevent soot fire.

Phenomenon that exhaust gas with higher temperature and smaller specific
Ventilation (draft power)
gravity than surrounding air rises toward outlet of funnel.

Circulating water amount of circulating water pump is changed widely by


load change of main engine normally. Flow control valve is installed to
Flow Control Valve
restrain circulating water amount change and control water circulating
system movement including boiler.

iv
CONTENTS
Important Safety Information ......................................................................... ⅰ

Introduction ................................................................................................... ⅱ

Term Definitions ............................................................................................ ⅳ

CHAPTER 1: SAFETY......................................................................... 1
1. Safety Regulations ...................................................................................... 1
2. Knowledge and Skill Required for Safe Handling ........................................ 1
3. Protective Equipment .................................................................................. 1
4. Prohibition of Remodeling without Permission ............................................ 1
5. Warning Labels on Products ....................................................................... 2
6. Precautions for Safe Handling .................................................................... 3
6.1 Safety Precautions in Installation .............................................................................. 3

6.2 Safety Precautions in Basic Operation ...................................................................... 4

6.3 Safety Precautions in Pre-operation Inspection and Preparation .............................. 4

6.4 Safety Precautions in Operating Economizer ............................................................ 5

6.5 Safety Precautions in Bringing Economizer to Emergency Stop ............................... 5

6.6 Safety Precautions in Inspections and Maintenance ................................................. 5

6.7 Safety Precautions in Storage Work .......................................................................... 6

v
CHAPTER 2: OVERVIEW ........................................................................... 7
1. Features of Product .................................................................................... 7
1.1 Functions ................................................................................................................. 7

1.2 Product Components ............................................................................................... 7

2. Part Names and Functions ....................................................................... 8


2.1 Economizer Body..................................................................................................... 8

2.2 Internal Structure of Economizer Body .................................................................... 9

CHAPTER 3: BASIC OPERATION .......................................................... 10


1. Basic Operation ........................................................................................ 10
1.1. Outline and Basic Operation of Each Equipment.. ................................................ 10

1.1.1 Soot Blower ..................................................................................................... 10

1.1.2 Excess Steam Dump Valve. ............................................................................ 12

1.1.3 Safety Valve. ................................................................................................... 13

CHAPTER 4: OPERATION ....................................................................... 15


1. Inspection and Preparation Before Operation ........................................... 15
1.1. Inspection and Preparation of Economizer and Peripheral Equipment.. ............... 15

1.1.1 Flushing of Pipes............................................................................................. 16

2. Exhaust Gas Economizer Operation......................................................... 17


2.1 Procedure of Circulating Water Pump Operation..................................................... 17

2.1.1 Before Main Engine Start ............................................................................... 17

2.1.2 After Main Engine Stop .................................................................................. 18

2.2 Emergency Stop of Circulating Water Pump............................................................ 18

2.3 Adjustment of Steam Pressure ................................................................................ 18


vi
2.4 Treatment of Boiler Water........................................................................................ 19

CHAPTER 5: INSPECTION AND MAINTENANCE .............................. 20


1.Maintenance of Exhaust Gas Economizer ................................................. 20
1.1 Soot Blow ................................................................................................................ 20

1.2 Water Cleaning of Economizer ................................................................................ 21

1.3 Acid Cleaning of Economizer .................................................................................. 22

1.4 Replacement of Generating Tube ........................................................................... 22

CHAPTER 6: STORAGE ........................................................................... 23


1. Maintenance When Economizer is Shut Down for a Long Time ................ 23
2. Movement or Resale ................................................................................. 23
3. Export ....................................................................................................... 23

CHAPTER 7: DISPOSAL .......................................................................... 24


1. Disposal Procedure................................................................................... 24

CHAPTER 8: GUARANTEE ..................................................................... 25


1. Description of Guarantee .......................................................................... 25
2. Contact Information for Inquiries about Products and Instruction Manual.. 25
3. Sale of Instruction Manual......................................................................... 25
4. Sale of Parts ............................................................................................. 25

vii
CHAPTER 1: SAFETY

1. Safety Regulations
In sailing in the high seas, observe the Rules and Regulations for the Classification of Ships, the
SOLAS Convention, the MARPOL Convention, and other international conventions. Also observe
regulations in way ports or the country that vessel is registered and other applicable regulations.

2. Knowledge and Skill Required for Safe Handling


Handling of this exhaust gas economizer includes operating economizer, operating controller for
controlling operation of economizer, and maintaining them. Before carrying out work, fully understand
this manual.
People satisfy all of following requirements are qualified to handle this economizer. They are called
operators.

[Requirements to be satisfied by operators]


 Those who have received explanation of handling from our service staff during trial operation or
those who have received explanation of handling directly from them
 Those who have thoroughly read instruction manual for this boiler and have full understanding of
content
 Those who have been permitted to handle this boiler by chief engineer

Appoint chief operator from among operators.

3. Protective Equipment
Do not forget to wear helmet, protection eyewear, safety shoes safety belts, leather gloves, protective
masks, or other appropriate protective equipment when working on device.

4. Prohibition of Remodeling without Permission


Remodeling this economizer without consultation MIURA or repairing it in a way not specified in this
manual may seriously affect safety of economizer. Do not remodel or repair economizer on your own.

1
5. Warning Labels (*) on Products
For safe use of exhaust gas economizer, warning labels are attached on locations where attention to
operating precaution is called for.
If warning label comes off or tears, replace it with new warning label.
For more details about warning labels, contact MIURA offices.

Burn warning label・・・・・・・・・・・・・・・・ Attached near parts with hazard of scalding or hot parts
(Parts with surface temperature of over 60°C).
Do not touch surface around this warning label.

Catch warning label・・・・・・・・・・・・・・・ Attached on rotating parts with gaps in structure that could
catch fingers (Fingers might get trapped).
Do not get close to area near warning label before parts are
operated or when they are in operation.

Electric-shock warning label・・・・・ Attached on electric equipment or around it that


cannot be insulated (or covered) completely.
To prevent electrical shock or electric leakage,
prevent objects or body from coming in contact with
such equipment or water from getting though it.

2
6. Precautions for Safe Handling
6.1 Safety Precautions in Installation
In carrying out installation work, observe following safety precautions:

WARNING
Secure ventilation (draft) (*) in funnel (exhaust stack) and ensure that exhaust from outlet
does not have harmful influence on surrounding environment.
(Refer to “1. Safety Regulations.”)
In engine room, secure adequate area for air inlet, exhaust outlet, and air supply fan (*). If
these are not installed and managed properly, carbon monoxide poisoning due to
exhaust gas may be caused.

Instruction Ensure that ventilation fan, air inlet, and exhaust outlet are installed in engine room.
Insufficient air supply or exhaust ventilation may cause carbon monoxide poisoning due
to exhaust gas or explosion.
Ensure that boiler is not installed in handling place for flammable dangerous substance
(*). Install it on floor made of noncombustible material. Ensure that boiler is more than 45
cm away from flammable materials. They may ignite due to hot part of boiler to cause
fire, resulting in accident involving death.
Connect power supply using cables with specified diameters.
Use special wiring breaker.
Failure to observe this instruction may cause electrical shock, burn, or other serious
accidents.
Connect with indicated electric wire size for power supply construction.
Use no fuse breaker as special power supply.
There is possibility of electric shock, burn and serious accident.

Wiring breaker Wiring breaker


Connect
Ground Wire
Breaker
capacity

Wiring

3
6.2 Safety Precautions in Basic Operation (Excerpt from P10~)
In basic operation, observe following safety precautions:

WARNING
Close steam valve and steam supply valve and open drain valve.
If drain flows into soot blower, there is possibility of corrosion of soot blower and casing .
When steam is come out from drain valve, replace or maintain steam valve because
there is possibility of over valve leakage of steam stop valve.
Instruction
Improper adjustment of blow off pressure of safety valve may damage body.
As a rule, do not adjust blow off pressure of safety valve.

If you touch soot blower handle, you may suffer burn because soot blower handle is high

Caution: Hot
temperature. Wear protective equipment while working with it.

6.3 Safety Precautions in Pre-operation Inspection and Preparation


(Excerpt from P15~)
In pre-operation in inspection and preparation, observe following safety precautions;

WARNING
Keep flammable materials away from exhaust gas economizer.
They may ignite due to hot part of economizer to cause fire, resulting in accident involving
death.
Prohibition Do not put flammable materials in control box.
They may ignite to cause fire, resulting in accident involving death.
Check that funnel (exhaust pipe) is properly constructed.
Gaps, faulty construction, blocked outlet of funnel (exhaust pipe), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around exhaust gas economizer.
Switching on or off wet equipment may cause electrical shock or fire from a short circuit.
Run ventilation (air supply and exhaust equipment) in engine room and check that air
vent is not blocked off.
Instruction If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may
be caused.
If you vent air, you may suffer burn because of hot water spout. Install proper cover to
prevent spread to surrounding.

If you touch hot piping of circulating water system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.
4
WARNING
If you touch economizer body and soot blower handle, you may suffer burn because of
high temperature. Be careful not to touch economizer and soot blower handle and wear
Caution: Hot
protective equipment while working around economizer.

6.4 Safety Precautions in Operating Economizer (Excerpt from P17~)


In operating economizer, observe following safety precautions;

WARNING
Open circulating return valve to boiler surely during economizer operation. There is
possibility of fatal accident by pressure damage.
Start circulating water pump and circulate water in economizer before main engine
Instruction
operation start. To prevent soot fire(*) accident, follow procedure at operation of circulating
pump operation.

6.5 Safety Precautions in Bringing Economizer to Emergency Stop


(Excerpt from P18~)
In bringing economizer to emergency stop, observe following safety precautions;

WARNING
If circulating water pump is stopped for a long time during main engine operation, fire may
be caused by soot fire.
Caution

6.6 Safety Precautions in Inspection and Maintenance (Excerpt from P20~)


In inspections and maintenance, observe following safety precautions;

CAUTION
Be careful with drain flush and drain inflow to supercharger.
In some case, soot adherence is increased during operation on early stage by main
engine lubricant at new shipbuilding and docking; confirm soot adherence condition and
try soot blow immediately.
When manhole is opened, ignition of soot gathered inside may be caused by fresh air
Instruction
inflow. Do not stop circulating water pump right after main engine is stopped.
On chemical treatment and acid cleaning, contact MIURA offices and ask for instructions
because proper maintenance is required depending on scale adherence condition of
generating tube inside and dangerous maintenance is prevented.

5
6.7 Safety Precautions in Storage Work (Excerpt from P23~)
In storage work, observe following safety precautions;

WARNING
Do not perform installation work and connection of incidental equipment unless it is
specified.
Prohibition Failure to observe this instruction may cause physical injury.

6
CHAPTER 2: OVERVIEW

1. Features of Product
1.1 Functions
Exhaust gas economizer circulates auxiliary boiler water in generating tubes compulsively by
circulating pump drive, and returns steam that is occurred by heat exchange with exhaust gas of
main engine to boiler. After steam and water is separated in boiler steam room, steam is taken out
from steam outlet of boiler.

1.2 Product components


Exhaust gas economizer consists of economizer body and following units;
・Exhaust gas economizer
・Flow control valve (*)
・Circulating water pump (including strainer, valves) (option)
・Flushing cooler (option)
・Pump starter (option)
・Excess steam dump valve (option))

※This is standard configuration. For details about configuration of product that is delivered, refer to
final drawing.

7
2.Part Names and Functions
Part names and functions are described here. Appearance and layout depends on type and
capacity. For details of product that is delivered, refer to final drawing.

2.1 Economizer body

(a) type KS

(b) type KF
Figure 2-1 External Drawing
No. Name No. Name
1 Thermometer Board 7 Manhole
2 Safety Valve 8 Air Vent Valve
3 Upper Header (Outlet side) 9 Rolling Stay
4 Drain Valve 10 Body Cover
5 Lower Header (Inlet side) 11 Inspection Hole
6 Soot Blower

8
2.2 Internal Structure of Economizer Body

Upper Header (outlet side) Upper Header (Outlet side)

Lower Header (Inlet side)


(Ou tlet

side)

Generating
Tube

Generating
Tube
Lower Header (Inlet side) Lower Header (Inlet side)

type KS type KF
Figure 2-2 Inside Structure

Generating
Tube

Fin

Figure 2-3 type KF Generating Tube

Inside of economizer is as above; meandered generating tube is welded installed between upper
header (outlet side) and lower header (inlet side to absorb exhaust gas energy of main engine
efficiently. Generating tube of type KS has small bended radius; it is the best structure to install on
narrow space because shape (especially height) can be small with the same electric area.
Generating tube of type KF has special fin to absorb heat sufficiently. Diameter of generating tube is
round wider compared with type KS and special formed fin is welded installed on generating tube
and it is effective for heat absorption.

9
CHAPTER 3: BASIC OPERATION

1. Basic Operation
1.1 Outline and basic operation of each equipment

1.1.1 Soot Blower


Soot is adhered on generating tube of exhaust gas economizer by exhaust gas from main engine.
Soot adherence decreases heating efficiency; it causes evaporating amount increase and duct
loss is decreased and corrosion of generating tube is caused at the same time. If oil that is used
for main engine is low ability oil, it can be caused of soot fire(*) .
Soot blower is installed on exhaust gas economizer to remove soot and prevent heating efficiency
decrease (to recover). Soot blower is installed on the bottom area of generating tube; it can be jet
out with turning handle to adjust inside jet nozzle.
Because soot adherence condition depends on each vessel and operation condition, it is
necessary to decide operation frequency and jet time according experience. Soot blow (*) needs to
be completed at least over twice a day during sailing to prevent soot adherence on generating
tube of exhaust gas economizer.

1) Soot blow procedure

WARNING
Close steam valve and steam supply valve and open drain valve. If drain flows into soot
blower, there is possibility of corrosion of soot blower and casing. When steam is come

Instruction
out from drain valve, replace or maintain steam valve because there is possibility of over
valve leakage of steam stop valve.

If you touch soot blower handle, you may suffer burn because soot blower handle is high

Caution: Hot
temperature. Wear protective equipment while working with it.

a) Close drain valve before steam supply valve and steam valve is opened.
b) Keep steam pressure as much as high. (Stop other steam using during soot blow temporarily and
try to keep steam pressure. When steam pressure is low, soot blow effect is decreased.)
c) Open steam stop valve and steam valve slowly. Do not open them rapidly.
d) Turn soot blower handle about 45° right and left, and change angle of jet nozzle gradually to turn
whole of generating tube.
e) Confirm wind power and direction during soot blow so that much soot is not fallen down on
vessel.
f) Close steam stop valve and steam valve and open drain valve after soot blow is completed.

10
Exhaust
Gas Out

Steam Circ. Water


Outlet
Exhaust Gas
Steam Supply Valve Economizer

Circ. Water
Inlet Soot Blower
Jet Nozzle

Drain Valve Steam Valve

Exhaust
Gas In

Figure 3-1 Soot Blow (*) Drawing

1 Body 11 Packing Stay


2 Inlet Tube 12 Packing Support (2)
3 Bolt 13 Socket
4 Name Plate 14 Set Bolt
5 Handle Stay 15 Lock Nut
6 Handle 16 Bolt
7 Cover 17 Bolt
8 Packing Support (1) 18 Packing
9 Washer 19 Gland Bush
10 Gland Packing

Figure 3-2 “A” Details


Note
・Parts⑩,⑬,⑭,⑮ need regular check during docking and precede replacement is recommended.
・Check gas leakage from ⑩ gland packing regularly and fasten ⑯evenly and hold it with ⑲.
Confirm that handle can be turned.
・Replace ⑩ gland packing as set.

11
1.1.2 Excess Steam Dump Valve
Pressure of steam that is generated by economizer is changed depending on load on vessel.
When steam pressure is low, pressure can be increased by running auxiliary boiler (concurrent
operation). However, when steam pressure rises rapidly, pressure cannot be lowered by adjusting
exhaust gas volume; therefore, some of generated steam is released though drain cooler to adjust
steam pressure. In other words, there is steam dump valve between main steam line and drain
cooler; when set pressure is exceeded, excess steam is released through drain cooler.
Excess Steam To Load
Dump Valve From Exhaust
Main Steam
From Load Gas Economizer
Valve
Cooling Sea
Water Bypass valve
Drain Cooler

Observation tank

Cascade
Tank
Feed Water Pump
To Exhaust Gas
Figure 3-3 Piping Diagram
Economizer

There are basically two types of excess steam dump


valves; direct driven type and pneumatic type; which
type is installed depends on specification of vessel.
Direct driven type valve has the same structure as
pressure reducing valve. (Refer to left figure).Set
pressure can be adjusted by removing cap 11 on upper
part of valve, loosening lock nut 22 and adjusting
screw 21 . Make adjustment monitoring pressure
gauge.
Pneumatic type valve detects actual steam pressure
and converts difference from set pressure of damp
valve into air signal. It can regulate steam pressure by
moving diaphragm adjustment valve.

1 Valve Body 13 Pilot Valve Stem


2 Pilot Valve Body 14 Pilot Valve Seat
3 Protection Cylinder 15 Pilot Valve Spring
4 Upper Diaphragm Case 16 Seal Bellows
5 Lower Diaphragm Case 17 Pilot Valve Diaphragm
6 Main Valve 18 Adjusting Spring
7 Valve Seat 19 Upper Spring Support
8 Valve Stem 20 Lower Spring Support
9 Retainer 21 Adjusting Screw
10 Main Diaphragm 22 Lock Nut
Figure 3-4 Direct Driven Type Dump Valve
11 Main Diaphragm Spring 23 Detection Tube
12 Screen
Note Install not to be affected by drain.

12
1.1.3 Safety Valve

WARNING
Improper adjustment of blow off pressure of safety valve may damage economizer body.

Instruction As a rule, do not adjust blow off pressure of safety valve.

Safety valve is safety device that is installed to prevent steam pressure from exceeding maximum
allowable working pressure; full-bore safety valve is used. Normally, safety valve does not operate
because excess steam dump valve works usually. When excess steam dump valve does not work
for some reason and abnormal pressure is increased or when rapid pressure increase is caused by
rapid load change, safety valve protects economizer by blowing steam off and lowering steam
pressure.
Safety valve is set at presence of inspector, so as to blow off at strictly limited pressure; nobody is
allowed to make attempt of further adjustment on board. However, only in case of emergency, such
as when safety valve leaks, some countermeasures, such as opening or adjusting valve, can be
taken at discretion of chief engineer. In that case, adjust blow off pressure of safety valve according
to procedure that is described in following.

1 Valve Casing
2 Valve Seat
3 Valve Body
4 Adjustment Ring
5 Valve Cylinder
6 Lift Control Bush
7 Spring
8 Valve Stem
9 Adjusting Bolt and Nut
10 Cap
11 Valve Lift Lever

Figure 3-5 Safety Valve Inside Structure

Adjusting Procedure
1) Unlock key on shaft of valve lift lever 11, pull out shaft, and remove lever.
2) Remove cap 10 by loosening setting bolt.
3) Loosen adjusting nut 9 and activate safety valve.
(Increase pressure by closing circulating return valve and check blow off pressure of safety
valve).
13
4) Turn adjusting bolt 9 to left if blow off pressure is higher than pressure limit and to right if it is
lower than that, so that it blows off at limited pressure.
5) After adjustment, fasten adjusting nut 9 tightly to fix it securely.
6) Put cap back in place, set valve lift lever, and lock and fix key.

14
CHAPTER 4: OPERATION

1.Inspection and Preparation before Operation


1.1 Inspection and Preparation of Economizer and Peripheral Equipment
Before starting operation, check followings;

WARNING
Keep flammable materials away from economizer.
They may ignite due to hot part of economizer to cause fire, resulting in accident involving
death.
Prohibition Do not put flammable materials in control box.
They may ignite to cause fire, resulting in accident involving death.

Check that funnel (exhaust pipe) is properly constructed.


Gaps, faulty construction, blocked outlet of funnel (exhaust pipe), or other problems may
cause carbon monoxide poisoning due to exhaust gas or fire.
Check for water or oil leaks around economizer.
Switching on or off wet equipment may cause electrical shock or fire from short circuit.
Run ventilation (air supply and exhaust equipment) in engine room and check that air
vent is not blocked off.
Instruction If air vent is blocked off, carbon monoxide poisoning due to exhaust gas or explosion may
be caused.

If you vent air, you may suffer burn is vent because of hot water spout.
Install proper cover to prevent spread to surrounding.

If you touch hot piping of circulating water system, you may suffer burn. Wear protective
equipment while working with it. If insulation of piping deteriorates or falls off, repair it.

If you touch economizer body and soot blower handle, you may suffer burn because of
high temperature. Be careful not to touch exhaust gas economizer and soot blower
Caution: Hot
handle and wear protective equipment while working around economizer.

a) Confirm that funnel (exhaust pipe) is installed correctly.


・If funnel has problem, do not start economizer operation.
・Recover funnel (exhaust pipe) to normal condition.
b) Confirm that there is no water leakage and oil leakage around economizer.
・If there is leakage, do not start economizer operation and shut off breaker of power supply.
・Remove cause of leakage and dry economizer completely.
15
c) Confirm air inlet place in engine room and that ventilation (facilities for air supply and exhaust) is
on operation condition.
・When there is no air inlet, install it.
・When facilities for air supply and exhaust is stopped, start operation.

d) Confirm that there is no inflammables on economizer surrounding


・If there is flammable materials, move them to safety place with no fire.
・When fuel and oiled cloth is miss kept, there is possibility of spontaneous combustion. Be careful
with dealing with them and treat them correctly.
・Wipe dropped oil immediately.

e) Confirm place and procedure of extinction facilities and first aid kit.
・If there is no facilities, install them.

f) Confirm that contact place and emergency procedure is ruled in case of fire and accident.

g) Confirm that there is no obstacle on economizer surrounding and passage.


・If there is obstacle, move it to safety place.

h) Confirm that there is no water leakage from connection of each equipment, inspection hole,
cover and valves.
・If there is leakage, recover it to no leakage condition by additional fasten or maintenance again.

i) Confirm that open-close condition of valve is correct.


・Confirm that outlet and inlet valve is opened.
・Confirm that air vent valve and drain valve are closed.

j) Confirm that Indicator of each pressure gauge is normal.

1.1.1 Flushing of Pipes


Note Following preparation procedure is needed when boiler is used for the first time or when
pipe system is repaired.

There may remain in pipes welding chips, rust or other foreign matters that may have bad
influence on feed water. Before starting operation, flush pipes with treated water or pressurized
gas as it is needed.
Whether flushing is needed or not depends on how pipes have been constructed. Before
flushing pipes, consult with constructor about procedure and safety precautions.

16
2.Exhaust Gas Economizer Operation

WARNING
Open circulating return valve to boiler surely during economizer operation. There is
possibility of fatal accident by pressure damage.
Start circulating water pump and circulate water in economizer before main engine
Instruction
operation start. To prevent soot fire( * ) accident, follow procedure at operation of
circulating pump.

2.1 Procedure of Circulating Water Pump Operation


Start circulating water pump operation after read carefully and understand “Circulating Water Pump
Instruction Manual”.
Refer to「Circulating Water Pump Instruction Manual」

2.1.1 Before Main Engine Start


a)Valve operation of circulating water line
open each valve of ○
A 、○
B 、○
E 、○
F 、○
G

on drawing 4-1gradually. After slightly


opening air vent valve of circulating
water pump to vent air, full close it.
Open pump outlet valve ○
C being
Economizer
carefully with boiler water level moving.
Flow cintrol valve (*) on circulating water
pump second side is standard installed.
Always full open ○
H ○
J and full close ○
K .

b)Check the condition of cooling water flow


Flow
to flushing cooler before circulating water
Control
pump operation and confirm that there is Valve

no problem.
Boiler Circulating
Water
c)Start circulating water pump Pump
Be careful with suction outlet pressure in
this case. When boiler water level is
Flashing
decreased seriously, adjust outlet valve ○
C Cooler

to control water level decrease.


d)Be careful with inlet and outlet pressure,
cooling water temperature, abnormal
sound and abnormal heating for circulating
water pump operation condition. Figure 4-1 Circulating Water System

17
2.1.2 After Main Engine Stop
1)Continue circulating water pump operation over 6 hours after main engine is stopped to prevent
soot fire (*) . Do not shut off breaker because 6 hours operation is continued by timer after
circulating pump switch is OFF; during this process, make jacket water of flushing cooler for
circulating water pump on flow condition. After circulating water pump is confirmed be stopped,
close pump outlet and inlet valve ○
B○C and boiler outlet and inlet valve ○
E ○
A.

2.2 Emergency Stop of Circulating Water Pump

WARNING
If circulating water pump is stopped for a long time during main engine operation, fire may
be caused by soot fire.
Caution

When there is involving to circulating water pump and damage apparently, stop motor with pressing
circulating water pump emergency stop switch of pump starter. Shift to another pump installed
parallel during main engine operation.

2.3 Adjustment of Steam Pressure


As description of excess steam dump valve mentions,
occurred steam pressure is increased depending
on main engine start. Open outlet and inlet valve

A○C and confirm that steam pressure is controlled To Load
From
as setting pressure of dump valve ○
B. Exhaust Gas
Economizer
When load is heavy and steam pressure is not
increased to setting pressure, confirm that dump
valve movement is normal with reducing necessary
load or decreasing setting pressure of dump valve,
including operation confirmation at the same time.
When heavy beginning drain is gathered on
Circulating
excess steam dump valve inlet on steam and drain Water Pump
piping installation, open bypass valve gradually
and exhaust drain for adjustment. Figure 4-2 Adjustment of Steam Pressure

Refer to page 12 “1.1.2 Excess steam dump valve” in Chapter 3.

18
2.4 Treatment of Boiler Water
Inspect boiler water regularly to keep proper boiler water condition because it has big effect on
economizer efficiency and lifespan (for example, corrosion). “Manual for Water Treatment” shows
details of boiler water treatment.
Refer to「Manual for Water Treatment」

19
CHAPTER 5: INSPECTION AND MAINTENANCE

1.Maintenance of Exhaust Gas Economizer


1.1 Soot Blow (*)

CAUTION
Be careful with drain flush and drain inflow to supercharger.
In some case, soot adherence is increased during operation on early stage by main engine
lubricant at new shipbuilding and docking; confirm soot adherence condition and try soot

Instruction blow immediately.


When manhole is opened, fresh air inflow ignition of soot gathered inside may be caused
fresh air inflow. Do not stop circulating water pump right after main engine is stopped.

As description of soot blow mentions detail, soot adherence by exhaust gas from main engine can
not be avoided perfectly because of structure during economizer operation. Soot adherence disturb
heat transmission of exhaust gas and it causes trouble such as corrosion of generating tube and
soot fire (*).
Try soot blow and prevent soot adherence on generating tube.
Refer to Page 10 “1.1.1 Soot Blower” in Chapter 3.

20
1.2 Water Cleaning of Exhaust Gas Economizer
It is difficult to remove soot adherence completely on exhaust gas economizer entirely even soot is
prevented to be adhered with soot blow (*) over twice a day during a voyage (during exhaust gas
economizer operation). Therefore, check soot adherence condition every month to prevent soot
fire(*) in prevent, and try water cleaning when soot adherence is serious. When pressure loss
between outlet and inlet of exhaust gas economizer becomes 1.5 times of beginning, try water
cleaning in reference to exhaust gas standard value of main engine. (Cleaning cycle depends on
main engine operation condition.). Water cleaning is effective when economizer body is cooled
enough after main engine stop and circulating water pump automatic stop.
Note
If you open manhole with high temperature of exhaust gas economizer body, gathered soot may fire.
(Soot fire)

Fresh Water Upper Upper


Valve Manhole Manhole
Water Water
cleaning by cleaning by
hose hose
directly. directly.
Insert shut plate Temporary
Cover Lower Lower between exh. Drain Valve
gas economizer
Manhole Manhole and expansion
joint to prevent
drain overflow.
Drain Valve

Figure 5-1 Exhaust gas economizer water cleaning


Note
When drain discharge hole is installed for water cleaning as drawing ○
A , open bottom drain valve

and it can be easy to water clean by opening fresh water valve for water cleaning. In case of
drawing ○
B , there is no drain valve on bottom of exhaust gas economizer; it is difficult to water

clean on vessel because drain is flowed into main engine and super charger directly. Try water
cleaning on docking after drain valve is installed temporary as drawing ○
C .

<Water Cleaning>
Water cleaning procedure when drain discharge valve is installed, is following;
a) Open upper manhole on economizer and confirm soot adherence condition.
b) Open drain valve (temporary drain valve) on economizer bottom.
Because drain valve and pipe are choked with soot in many cases, confirm that drain can be
discharged not to inflow to main engine and super charger.

21
c) Open lower manhole on economizer and cover penetrated are of main engine exhaust pipe with
canvas to prevent drain inflow to exhaust pipe.
d) Water clean from manhole with high pressure washer. When jet facility for water cleaning is used,
open fresh water valve and cleaning. Check jet condition and confirm that jet nozzle is not choked
from manhole in this case.
e) Decide water cleaning time confirming soot removal condition.

Note
Continue water cleaning until soot is removed completely. If water cleaning is not enough, non
flam soot is exposed and it can be easy to get fire, and sulfuric acid corrosion may occur because
sulfur of remained soot and water is reacted.

1.3 Acid Cleaning of Economizer

CAUTION
On chemical treatment and acid cleaning, contact with MIURA offices and ask for
instructions because proper maintenance is required depending on scale adherence
Instruction
condition of generating tube inside and it involves dangerous maintenance is prevented.

If scale is adhered on generating tube inside surface of exhaust gas economizer, heat transmission
efficiency is decreased and it can cause trouble such as corrosion and over heat.
Try water treatment completely to prevent scale adherence. Scale removal is impossible physically
because of structure of exhaust gas economizer, acid cleaning is general procedure. Try acid
cleaning when additional running frequency of auxiliary boiler during operation is abnormally
increased.

1.4 Replacement of Generating Tube


Concerning replacement of generating tube and stopper repair, contact MIURA offices and ask for
instructions because special welding technique is required. Use genuine generating tube approved
by societies of classification approved.

22
CHAPTER 6: STORAGE

1.Maintenance When Economizer is Shut Down for a Long Time


When exhaust gas economizer is shut down for a long time (over 48 hours), it is recommended that
boiler water with boiler compound is filled and keep pressure over 0.1MPa to prevent corrosion of
generating tube and header inside. Corrosion by oxygen in air and feed water proceeds rapidly once
it is occurred and leakage of generating tube is started unexpectedly; if trouble is happened during a
voyage, main engine needs to be stopped for emergency maintenance.
Try proper maintenance to keep ability of exhaust gas economizer.

2.Movement or Resale

WARNING
Do not perform installation work and connection of incidental equipment unless it is
specified.
Prohibition Failure to observe this instruction may cause physical injury.

In reselling or reusing economizer, procedure that is based on rules of each classification must be
taken. Contact MIURA offices since it must be checked that vessel equipment does not affect normal
operation of economizer. Installation work or connection of incidental equipment that is not specified
may cause physical injury. If our products are resold, deliver instruction manuals and related
materials along with product to new owner, and inform us of resale (We need to transfer
maintenance records that is kept since it was placed in service).

3. Export
When exporting products whose export is regulated under the Foreign Exchange and Foreign Trade
Act, approval of the Japanese government for export must be obtained. When MIURA products are
exported, products and their use are subjected to many laws and regulations in the destination country.
If there is plan to export MIURA products, contact MIURA offices.

23
CHAPTER 7: DISPOSAL

1.Disposal Procedure
Exhaust gas economizer must be disposed as industrial waste.

Dispose exhaust gas economizer properly according to the laws in the country where it is to be
disposed. For details about recycling of materials that is used in this eoconomizer, contact MIURA
offices.

24
CHAPTER 8: GUARANTEE

1. Description of Guarantee
Guarantee period is either of following, whichever comes first:
 12 months after vessel is delivered
 18 months after equipment is shipped
If economizer has trouble within this guarantee period, trouble is repaired or parts are replaced for free
so that boiler functions as required in agreement as long as it has been installed and used properly
according to instruction manual, warning labels, and other instructions.
Trouble with equipment other than MIURA products that is installed on vessel is not covered by this
guarantee. Deterioration of consumable parts is not covered by this guarantee unless it is abnormal
deterioration.
In any of following cases, repair work is charged even within guarantee period:
(1) Failure or damage that is caused by wrong use, poor maintenance, or improper repair or
remodeling
(2) Failure or burnout due to natural disasters such as fires, typhoons, or tsunamis, or other external
factors
(3) Replacement of consumable parts
(4) Other matters that is specified in the agreement
If repair work is required outside Japan, travel expenses including accommodation and transportation
fees is be charged. It cannot be provided repair service in countries where it is banned traveling.
If there is any question about repair service within or after guarantee period, contact MIURA offices.

2. Contact Information for Inquiries about Products and Instruction


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

3. Sale of Instruction Manual


If you need instruction manual for this economizer, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, boiler number, and manual
number on cover of instruction manual.

4. Sale of Parts
If you need parts that are used with this economizer, contact MIURA offices.
In that case, let us know vessel name, nationality of vessel, vessel number, and economizer number.

25
<NETWORK>
JAPAN SERVICE OFFICES
MIURA Co.,Ltd.
SHIP MACHINERY DEPT. 7, Horie, Matsuyama, Ehime, Japan, TEL: (+81)89 979 7066
799-2696 FAX: (+81)89 979 7067
TOKYO MAINTENANCE DIV. 2-15-35 Takanawa, Minato-Ku, Tokyo, TEL: (+81)3 5793 1047
Japan, 108-0074 FAX: (+81)3 5793 1045
SHIMANAMI MAINTENANCE DIV. 3-20-9 Matsunaga-Cho, Fukuyama, TEL: (+81)84 930 0740
Hiroshima, Japan, 729-0104 FAX: (+81)84 930 0741

HIROSHIMA MAINTENANCE DIV. 1-6-30 Nishihara, Asaminami-ku, TEL: (+81)82-850-3577


Hitoshima, Hiroshima, Japan, 731-0113 FAX: (+81)82-850-3566
KYUSHU MAINTENANCE DIV. 3-19-20, Hakataekiminami Hakata-ku TEL: (+81)92 432 3277
Fukuoka, Japan, 812-0016 FAX: (+81)92 432 3278
1.CHINA 6.SINGAPORE
MIURA INDUSTRIES (SUZHOU) CO., LTD. MIURA SOUTH EAST ASIA PTE. LTD.
SHANGHAI BRANCH, SHIP MACHINERY DIVISION No.3 Soon Lee Street #03-36-37-38, Pioneer Junction
Floor 5, Building 3, No.658 Jinzhong Rd., Changning Singapore 627606
Dist., Shanghai China TEL: (+65)6465 1147
TEL: (+86)21 6447 9246 FAX: (+65)6465 1148
FAX: (+86)21 6447 9502
TAKNAS ENGINEERING PTE.LTD.
MIURA INDUSTRIES (SUZHOU) Co., Ltd. 102, Pandan Loop, Singapore 128310
ZHOUSHAN BRANCH, SHIP MACHINERY DIVISION Tel : (+65)6777 5856
Room 2102, Building C Jian She Dasha, No.195, Qiandao Fax: (+65)6779 6711
Rd., Dinghai Dist., Zhoushan, Zhejiang, 316021, China FUJI HORIGUCHI ENGINEERING PTE.LTD.
TEL: (+86)580 2268 268 12H Enterprise Road, Singapore 619976
FAX: (+86)580 2268 268 Tel : (+65)6863 6368
Fax: (+65)6863 8310
SHANGHAI WEN CHIUAN MARINE
SERVICE&ENGINEERING CO., LTD.
No.951 Kesheng Rd. Beiguan, Malutown, Jiading district
7.TAIWAN
Shanghai, 201801, P.R.China MIURA CO., LTD TAIWAN BRANCH
Tel : (+86)21 6915 2475 17F-9., No.189, Sec. 2, Keelung Rd., Xinyi Dist., Taipei
Fax: (+86)21 6915 2476 11053, Taiwan
TEL: (+886)2 2732 1250
FAX: (+886)2 2732 9030
2.DENMARK
SCANDINAVIAN BOILER SERVICE A/S MING YUNG MACHINERY.,LTD.
Industrivej 12 9490 Pandrup Denmark 27.Shin Shing St., Yan Cherng District Kaohsiung,
Tel : (+45)7027 1000 Taiwan
Fax: (+45)7027 1001 Tel : (+886)7 521 6266
Fax: (+886)7 521 9368
3.GERMANY
TAKNAS MARINE ENGINEERING GMBH 8.THE NETHERLANDS
"Fruchthof" Oberhafenstr.1 20097 Hamburg, Germany MIURA NETHERLANDS B.V.
Tel : (+49)40 32 1305 Buitenveldertselaan 106, 1081AB Amsterdam, the
Fax: (+49)40 33 0608 Netherlands
TEL: (+31)20 661 6372
FAX: (+31)20 661 6373
4.KOREA miuranetherlands@miuraz.com
DONG YANG ENGINEERING
30-10,Sisil-ro, Dongrae-gu, Busan, 607-802 Korea
FUJI TRADING (MARINE) B.V.
Tel : (+82)51 552 6503
Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
Fax: (+82)51 557 4830
Tel : (+31)10 429 8833
Fax: (+31)10 429 5227
SEIN BESTECH
302, 64 Keumo-5Gil, Dong-Myeon, Yangsan,
626-821, Korea
Tel : (+82)51 961 7771
Fax: (+82)51 961 7772

5.PHILIPPINES
PHIL-NIPPON KYOEI CORP.
S-705 Royal Plaza Twin Towers 684 Romedios St.,
Malate Manila, Philippines
Tel : (+63)2 400 5778
Fax: (+63)2 400 9130
OPERATION MANUAL
EXHAUST GAS ECONOMIZER KS, KF SERIES
Published by MIURA Co.,Ltd. Ship machinery Dept. Mar. 2011.
2nd edition May.2013 No. E992-1103-02

All rights reserved, Copyright © 2013 MIURA Co.,Ltd.


No part of this publication may not be reproduced, transmitted, distributed or
modified, in any form or by any means, without the written permission of the
publisher MIURA Co.,Ltd.

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