English

USER MANUAL SU-14

Important information
1. Never start before this procedure is read and understood.

2. See data sheet for technical information.

3. All operations to be performed by trained personnel.

4. The area around the unit and elsewhere where there is work are to be blocked off
with barrier tape and warning signs.

5. Procedures for the job should be read and understood before work is started.

6. Return Status shall be written before return of unit.

7. All repairs / procedures should be clarified with the maintenance foreman at IKM
Base.

8. Negligence or improper use can cause serious injuries to personnel and property.

NB!
Personell that shall operate a steam boiler must have a boiler Certificate
(This is required by law)

Startup and operation

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USER MANUAL SU-14

Preparing unit.

1. The steam unit is prepared to the appropriate voltage / Hz at IKM Testing's

maintenance yard if nothing else is agreed.
(Test and maintenance form is written and put in documentation booklet which
follows unit, and in the maintenance journal in workshop.)
Check the label on the key switch voltage selector / supply cable for the info on
this, and connect to the correct voltage.
Connect cable 230VAC "light / heat"
Connect cable 400-690V Mount stuffing boxes around cables
Connect cable with signals to the CCR
Connect cable to PA
2. Make sure the container has a clear airway at air shutter.
3. Container must be level (maximum of 5  slope)
4. Mount spark arrestor on the roof.

- Connect the water hose to the 1” Chicago claw coupling on the spark arrestor
with a ball valve for regulation.
- Connect a 2" camlock hose to the drain in the bottom of the spark arrester

NOTE: Make sure the drain-hose does not have:

- Damages
- Sharp bend
- Is too long
- That the drainage water at any time can run freely

This is very important as it may result in the drainage water flows into the
combustion chamber and damages burner!

5. Close the drain valve on the feed water tank, water filter and drainage point at
the water solenoid valve.

6. Connect to fresh water (not desalinated seawater) on the claw coupling marked
"Fresh Water in" with a maximum pressure of 7 bar.
See also the operating manual for the boiler for water quality.
Water tank has an overflow, which is carried out through the deck.

7. Diesel with a max pressure of 10 bar is to be connected to the claw coupling

marked "Diesel in". Fuel tank has an overflow, which is labeled "airing DIESEL".

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USER MANUAL SU-14

8. Connect the steam hoses.

9. Check that the emergency stop switches is not activated (2ea)

FIRE & GAS Shutdown panel

Press the reset button to reset any alarms.

TRAFO AND CONTROL UNITS

Check that the voltmeter shows the connected voltage and the voltage selector is in
the right position.

Set "master switch", "Water Solenoid Valve" and "Kjem.Dos.Pump" in ON. (Time
Delayed)
Now, the feed water tank is being filled.
Make sure the chemical pump is running and that there is flow in the hose.
Chemical Pump setting about 50/50, adjusted for the water samples during
operation.
After the red signal lamp "Low-level water" goes off, the air damper in the
containerwall begins to open.

Before startup
The following valves shall be closed:
 Soot blower valve (28)
 Steam valve (47)
 Drain valve condensate trap(32)
 Drain valve coil (25)

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USER MANUAL SU-14

 Drain Valves at Clayton feed water pump, drain plug ½ "on the feed pump,
drain valve on the condensate trap and valve manifold pressure switches (29)

The following valves shall be opened:

 Feed water valve (20) 2ea
 Feed water valve, coil (26)
 Valve between the separator and condensate trap (35)
 Fuel supply from the fuel tank, turn and return.
 Valve heating watertank (50)
 Valve return condensate to the water tank (30)
 Valves on the pressure switches (F20, F21, F22)
 Valve (40) Fremo control valve is normally about 50% open.
Whose function is to regulate the volume of water that should go into the
boiler. Pressure gauge after the feed pump should be about 2-3 bar. If the
valve is too much opened, it can cause the boiler to stop due to overheating.
Opening time total (10-15 min / hour) on the condensate trap pressure gauge
indicates whether the boiler is supplied with the right amount of water.

Start Clayton Control Cabinet

When the feed water tank level is above min. level and the air damper is fully
open (90sec) the H1 signal lamp turns green Power On

1. Turn the switch S10 on the right side of the cabinet "on" and set all switches to
position 0 (left)

2. Turn the switch S1 to "start". Check direction of rotation on the Booster

Pump / feed pump. Clayton motor unit will always go clockwise due to the
frequency converter. (Now the fan, water pump and diesel pump will be

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USER MANUAL SU-14

running)

3. Check that there is enough water in the coil. (Takes ca.5-10 min) Is to be
controlled by opening the valve 32 until the water runs out of the forklift
channels. Then close the valve 32

4. Turn switch S4 to "1" (Now the boiler start "low burn/lavfyr") If burner does not
light at the first attempt, set switch S4 and S1 to 0 and press the reset button.
Then start up again, set switch S1 and S4 to the ON position.

5. After the burner has ignited, the pressure will rise to pre-set pressure on work
pressure controller F20, and the burner stops.

6. Open valve for steampressure gradually until the pressure is stabilize at about
7 bar. (Valve no.47)

7. Now you can choose whether the boiler will be operated on "highburn/høyfyr"
or "lowburn/lavfyr" (This is selected by turning the switch S7)

User tips:
 The boiler should run at a constant pressure on either lowburn or highburn.
Is the need for steam low, some steam must be dumped so that the burner will
go most continuously on low fire. This will prevent the coil from sooting.

 Temperature in feed water tank shall be about 90˚C.

Stop:
1. Close the valve for steam outlet (valve no.47)

2. Turn the switch S7 to "low" and switch S4 to "0" (let the pump run
approximately 1-2 min)

3. Turn the switch S1 to "Stop"

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USER MANUAL SU-14

Emergency stop:
When the emergency stop on the "FIRE & GAS" panel or the emergency stop button
outside the door is activated, the power to the boiler is cut and the boiler stops.
The gas and fire alarm will also cut the power to the boiler.
Pressure relief valve for steam Y45 will open and blow off steam pressure.
At startup after "SHUTDOWN", let pump (S1) go for 2-3 minutes before burning (S4) is
started. This is to fill the system with water again.

Storage and return.

Dry shutdown

1. Let the boiler run on highburn, with consumption during modulation pressure
about 7 bar. (Valve 47 open).

2. Shut off water supply to the feed water pump (20) and open the valve (25) and
(32), start clocking the time.

3. Let the burner run for about 30 seconds continuously on high burn and set switch
S7, S4 and S1 to "stop".

4. Close the steam valve (47) and valve (30) and (50)

5. Close the valve (32) and (25) before the pressure has dropped to 2 bar.

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USER MANUAL SU-14

6. Open the drain valve on the tank, stop the chemical pump and turn off the water
supply.

7. When the water tank is empty, open valve (30), (50) and drain valve on the trap.

8. Open all valves to drain out water and steam.

9. Put all in ball valves half open position, unscrew the ½ "drain plug on the feed
pump and drain the 2" strainer for feed water.

10. Shut off fuel supply and all other valves on the fuel tank.

Maintenance
The purpose of regular maintenance and inspection is to ensure uninterrupted and safe
operation.

Daily maintenance when the steam unit is in use:

 Check the oil, diesel, chemicals, etc.

 Inspect for visible damage / defects
 Check all valves, pipes, hoses and connections for leaks.
 Be alert for abnormal noise or vibration.
 Keep the container clean and tidy.
 Check that the pressure switches for steam is functional.
 Take water samples and adjust the chemical pump.
 Soot blow the boiler every 8 hours for about 10 minutes:
Run the boiler on highburn with normal operating pressure not less than 5 bar, and
open the soot blowing valve (28) at the same time as the main steam valve (47) is
closed. After about 10 min close the soot burning valve (28) and open the drain
valve (27). Boiler is then put back in normal operation.
 Bottom blow the boiler every 8 hours for about 5 min

IKM Testing AS, Ljosheimvegen 14, 4050 Sola, Norway ● +47 51 64 90 00 ● +47 51 64 90 01 ●  [email protected] ● www.IKM.no
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USER MANUAL SU-14

 Drain water tank every 8 hours for about 2 min

 Drain sludge out of the drain valves in the bottom of the Clayton Water Pump 10
seconds every 8. Hours.
 Clean the 2 "strainer on the feed water.

Weekly maintenance:

 Functional test of safety valves for steam

Yearly maintenance:

1 year

 Control of electrical equipment with insulation test.

 Inspection of Lifting Equipment
 Calibration of safety valve
 Inspection of fire extinguishers

2 years

 Pump service.
 Replace oil (Holst 100)

5 years

 Overhaul electric motors.

 Boiler control

IKM Testing AS, Ljosheimvegen 14, 4050 Sola, Norway ● +47 51 64 90 00 ● +47 51 64 90 01 ●  [email protected] ● www.IKM.no