08.KS, KF E992-1103-02
08.KS, KF E992-1103-02
MANUAL
EXHAUST GAS ECONOMIZER
KS, KF SERIES
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.
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.
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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.
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[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
Instruction
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).
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Term Definitions
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.
Phenomenon that exhaust gas with higher temperature and smaller specific
Ventilation (draft power)
gravity than surrounding air rises toward outlet of funnel.
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CONTENTS
Important Safety Information ......................................................................... ⅰ
Introduction ................................................................................................... ⅱ
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
v
CHAPTER 2: OVERVIEW ........................................................................... 7
1. Features of Product .................................................................................... 7
1.1 Functions ................................................................................................................. 7
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.
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.
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.
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
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.
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.
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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.
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.
WARNING
If circulating water pump is stopped for a long time during main engine operation, fire may
be caused by soot fire.
Caution
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.
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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.
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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.
※This is standard configuration. For details about configuration of product that is delivered, refer to
final drawing.
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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.
(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
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2.2 Internal Structure of Economizer Body
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
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.
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CHAPTER 3: BASIC OPERATION
1. Basic Operation
1.1 Outline and basic operation of each equipment
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.
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Exhaust
Gas Out
Circ. Water
Inlet Soot Blower
Jet Nozzle
Exhaust
Gas In
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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
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1.1.3 Safety Valve
WARNING
Improper adjustment of blow off pressure of safety valve may damage economizer body.
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
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).
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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.
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CHAPTER 4: OPERATION
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.
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.
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.
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.
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.
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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.
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
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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.
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.
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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」
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CHAPTER 5: INSPECTION AND MAINTENANCE
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
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.
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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)
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.
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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.
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.
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CHAPTER 6: STORAGE
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.
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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.
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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.
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.
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<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
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
Visit us at www.miuraz.co.jp and get the latest information and Service News !
Printed in Japan