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Normal Operating Procedures
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Normal Operating Procedures

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  • 1. Normal Operating Procedures Boiler Room Services, Inc. 724-695-8110
  • 2. ContentsStart-up Checks 2Nexus Touchscreen Start-up 3Sequence 6Common Faults 10Blowdown Procedures
  • 3.  Ensure that no lock-out/tag-outs are present. Check that all ventilation & combustion air openings and louvers are clean and free of Start-up Checks debris. Verify normal boiler water level. Check that all stack dampers are open. Examine the boiler furnace for foreign material and loose/displaced refractory. Ensure that fuel lines are not leaking gas (distinctive smell) or oil (liquid accumulation). Ensure the manual fuel valves are open.Based on National Board of Boiler & Pressure VesselInspection
  • 4.  Complete start-up checks first. The Start-up sequence should be closely Nexus Touchscreen monitored to ensure proper mechanical Start-up Overview function. Remain present until the boiler successfully switches to modulation mode. Note: You may experience a slight lag/delay when pressing the touchscreen. Use slow deliberate touches with the tip of your finger. Review the start-up sequence on the following pages:
  • 5. The burner is held Burner Off/Standbyin this state untilall faults areremoved. To mutean alarm, pressand release"Mute." To reset afault aftertroubleshooting,press and HOLD"Reset” for 3seconds. Press"Start" to initiateautomatic start-upSequence.Nexus 6000 Start-up Screen Shots
  • 6. The fuel and air Proving Closedservos are drivenclosed and must bewithin +/- 5° to theclosed positionsstored in memory.Variable FrequencyDrives (VFD) mustread zero.Nexus 6000 Start-up Screen Shots
  • 7. The burner control Proving Purgerecognizes a callfor heat. Thecontrol verifies afuel/profileselection.Nexus 6000 Start-up Screen Shots
  • 8. The controller Pre-Purgeconfirms allrequired drives areat their purgepositions and givesa "purge proved"signal. Thecontroller remainsat this state untilthe burnercontroller signalsthe end of pre-purge, indicatingthat all combustiblegases are safelyremoved.Nexus 6000 Start-up Screen Shots
  • 9. The selected Moving to Ignitionmotors are movedto their ignitionpositions. The"purge proved"signal is switchedoff. When thedrives have allstopped moving,the controladvances toignition.Nexus 6000 Start-up Screen Shots
  • 10. The controller Pilot Trial for Ignition (PTFI)confirms that apilot flame existsfor 10 secondsbefore switching tomain ignition.Nexus 6000 Start-up Screen Shots
  • 11. The controller Main Trial for Ignition (MTFI)confirms allrequired drives areat their ignitionpositions, andgives an "ignitionproved" signal. Thecontroller will holdthe drives at theirrespective ignitionpositions until thesignal to modulateis received fromthe burnercontroller.Nexus 6000 Start-up Screen Shots
  • 12. Once the AUTO Moving to Low Firesignal is received,the fuel and airmotors are movedfrom their ignitionpositions to theirlow fire positions.These positionsmay or may not bethe same as theignition positions.Nexus 6000 Start-up Screen Shots
  • 13. Once the fuel and Modulating (Online Operation)air motors reachtheir low firepositions, they aremodulatedaccording to thedemand placed onthe burner.Nexus 6000 Start-up Screen Shots
  • 14. All servo motors Move to Post-Purgeare moved to lowfire position(caused by a faultor manualshutdown). The airdamper is held inposition or movedto low fire.Nexus 6000 Start-up Screen Shots
  • 15. The controller Post Purgeconfirms allrequired drives areat their purgepositions andgives a "purgeproved" signal. Inthe event of ashutdown orlockout, the burnerwill shutoff andremain in standby.Nexus 6000 Start-up Screen Shots
  • 16.  Familiarize yourself with the following faults. Understand the cause of the fault before restarting the boiler. Common Faults Review the start-up sequence to bring the boiler back online. Remain present until the boiler successfully switches to modulation mode. Follow proper reporting procedures.Nexus 6000 Common Fault Screen Shots
  • 17. This fault is the Low Water Cut Out (LWCO)first low waterindicator(McDonald-Miller).Since it is not alock-out, the boilerwill reignite oncethe water level isresolved. Followproper reportingprocedures.Nexus 6000 Start-up Screen Shots
  • 18. This fault is the Low Water Probesecond low waterindicator (extra lowwater). Since it is alock-out, you mustpress and hold“Reset” for 3seconds to clearthe alarm AFTERthe water level isresolved.Nexus 6000 Start-up Screen Shots
  • 19. The Variable Fan Fault (VFD)Frequency Drive(VFD) did notproperly start thefan. Ensure the fanhas power and isfree fromobstructions.Nexus 6000 Start-up Screen Shots
  • 20. This fault indicates Air Flowimpropercombustion air.Ensure the motoris running and thedamper is properlypositioned andfree fromobstruction.Nexus 6000 Start-up Screen Shots
  • 21. Pilot gas pressure Low Pilot Gasdoes not meetminimalrequirements.Check that manualgas valves areopen. Note: pilotgas valves areupstream fromsolenoid valves.Nexus 6000 Start-up Screen Shots
  • 22. This fault indicates Main High Gasthat the gaspressure exceedsset-points on theregulator valves.Verify that the set-points are properlycalibrated.Nexus 6000 Start-up Screen Shots
  • 23.  Ensure the boiler is in low-fire operation before blowing down. Open the quick-opening Bottom Blowdown valve closest to the boiler first. Procedures Steadily open the slow- opening valve until you see a ½” to 1” drop in the sight glass. Quickly close the slow- opening valve, backing off slightly from fully closed to relieve pressure. Close the valve nearest the boiler.Illustration from CleanBoiler.org
  • 24.  Ensure the boiler is in low-fire operation before Water Column Blowdown blowing down water columns. Slowly open ONE hand valve, taking care not to Procedures trip the boiler on low water. Close the valve after a healthy flush occurs. Repeat process for remaining columns. Blow down columns once a shift to keep bowls clean.Illustration from Johnston Boiler Company