Operation & Maintenance Manual
Foreword
This documentation serves as a pertinent reference to the Frontier Dryback Firetube Boiler, an engineered solution provided by Victory Energy Operations (“VEO”). The boiler operates in unison with the burner and a variety of ancillary components, encompassing controls, switches, and valves among others. Distinct from auxiliary manuals such as the burner manual, this document provides information integral to the boiler itself.
These components are assembled and tailored for the unique requirements of each client. Incorporated within this documentation is a list of these components, supplemented by their corresponding technical specifications. Together, these ensure that the boiler operates safely and efficiently.
Engagement of a VEO Service Engineer is not inherently included unless explicitly defined within the contractual terms with VEO. If a client wishes to use a VEO service engineer, these services can be procured via submission of a purchase order.
In circumstances where the professional services of a VEO engineer are enlisted, the intention is to function as a supplementary resource, and not to supplant or assume the responsibilities of the plant workforce. The sole responsibility and liability for the operational performance remain vested with the licensed operators.
VEO disclaims any accountability for any inadequacies in the operators’ aptitude to fulfill their duties effectively. Furthermore, the physical presence of a VEO engineer at the client’s location does not absolve the plant’s licensed operating personnel of their incumbent responsibilities.
Documents
This manual references and is used in conjunction with other documents:
- Burner manual and supplemental documents related to the burner
- Manuals relating to major components employed by the Frontier® product line
*Documents are located in Appendices 2–7 of this manual.*
To uphold the integrity of your warranty, it is imperative that you complete all validation reports pertaining to the initial boiler start-up. You have four (4) weeks after initial burner light-off to return these completed reports to VEO. This is crucial for the maintenance of your warranty.
Buyer / Owner Responsibility
Operational Responsibility
The Buyer/Owner is charged with maintaining comprehensive logs and records as evidence of proper equipment operation. Parameters of appropriate operation include, but are not limited to:
- Correct erection and proper initiation of operation
- Suitable equipment maintenance and service practices
- Preventing damage from abrasion, corrosion, or undue temperature, and ensuring servicing of equipment exclusively by VEO-authorized personnel
The warranty extended by VEO does not encompass wear and tear or the following:
- Water treatment and boiler water condition. Damage due to oil, grease, scale, or deposits; damage from foaming driven by water chemistry; or damage from corrosion or caustic embrittlement. The Buyer is responsible for validating water analysis, using chemical additives when necessary, and ensuring proper operation of water treatment equipment.
- Corrosion, erosion, and fouling. This includes damage related to SCR or CO systems, fuel constituents, combustibles, residues, ash, or other corrosive agents. The Buyer must validate fuel analysis, use fuel additives when required, and ensure proper operation of soot-blowing equipment.
- Improper utilization or handling. Including overloading, excessive temperature, improper operation, inadequate maintenance, neglect, or the use of inappropriate cleaning materials.
- Operation outside specified parameters. Including voltage, frequency, or power-supply issues; severe environmental conditions; and exposure to harsh chemicals.
- Limitation of liability. Company liability for personal injury and property damage is limited as defined in the Terms and Conditions; all other liabilities are limited to the order value.
The Buyer must thoroughly understand and comply with the complete Terms and Conditions document, as it delineates the full spectrum of buyer responsibilities and stipulations pertaining to the use, maintenance, and servicing of the products.
Safety Introduction
Failure to properly install, operate, and maintain your firetube boiler can result in severe personal injury, damage to property, serious injury, or fatality. Always refer to this manual for proper guidelines.
When initial operation of the boiler is to be delayed for more than three months, procedures must be taken to dry out any unfired or green castable refractories to prevent corrosion of pressure parts in contact with them. Consult the refractory contractor for an appropriate dry-out and firing-in schedule.
Installation and Operation
Proper installation and operation of the Firetube Boiler are crucial to ensure safety and prevent accidents. All procedures must be performed by qualified personnel in accordance with Buyer, local, State, and Federal requirements.
Storage
When the boiler is not in use, it should be stored in a clean, dry environment to prevent corrosion, degradation, and other damage due to weather or contaminants.
Long-term Storage
Carefully seal the boiler water side and gas side for long-term storage. Remove vulnerable items such as valves, motors, burner parts, and electrical equipment, and store them indoors. Even during storage, rotating equipment such as fan, pump, and motor shafts should be attended to routinely.
Air and Gas Side Preparation
- Cap or plug all pipe connections to the windbox or furnace and inspect regularly.
- Cover flue gas outlet and burner windbox/forced draft fan inlet with steel plates.
- Protect burner moving parts, fuel injectors, and similar components with suitable preservatives.
- Keep all gas- and water-side openings sealed when not under inspection.
- Remove and store removable burner system parts and instruments in a weather-protected area.
Avoid flammable substances. Keep the area free from gasoline and other flammables.
Use approved fuels only. Use only fuels specified by VEO.
Startup and maintenance. Adhere strictly to startup and maintenance procedures. VEO authorized personnel should be used for initial startup and commissioning to maintain performance guarantees.
Operator Skill
Operation of the Firetube Boiler should only be carried out by individuals familiar with the equipment and who have thoroughly read and understood the content of this manual. Operators should have relevant experience in boiler operations, including maintenance and startup procedures.
Actions to Take in the Event of a Natural Gas Odor
| Action | Details |
|---|---|
| Do not ignite anything | Avoid any action that could cause a spark or fire. |
| Do not use electrical switches | Switching can create small sparks that may ignite gas. |
| Notify authorities | Contact your local gas company or emergency services. Provide clear details of the situation and follow their instructions. |
| Arrange professional inspection | Ensure that the Firetube Boiler and surrounding equipment are inspected by qualified personnel before operation resumes. |
Approvals & Recordkeeping
All Dryback boiler units manufactured by VEO are subject to certification procedures in strict compliance with the ASME Boiler and Pressure Vessel Code (ASME BPVC).
VEO Dryback boilers require installation in strict accordance with local regulations and codes, which may vary by jurisdiction. It is critical to verify that your installation aligns with the standards and regulations specific to your location and industry sector.
Installations in the United States
| Regulatory Reference | Details |
|---|---|
| NFPA 31 | Installation of Oil-Burning Equipment |
| NFPA 54 | National Fuel Gas Code |
| NFPA 85 | Boiler and Combustion Systems Hazards Code |
| NFPA 70 | National Electrical Code |
| IFGC | International Fuel Gas Code |
| ASME CSD-1 | Boiler Codes and Safety Systems on Boiler Burners |
Note: Installations in Canada must follow the appropriate CSA standards and Provincial Regulations.
Recordkeeping
It is essential to securely preserve all pertinent materials, including schematics, wiring diagrams, literature, spare parts lists, and written operating directives. Store these resources in a readily accessible location, such as the boiler room. Diagrams and schematics should be enclosed and displayed near the relevant equipment, with remaining materials compiled and stored in a binder.
Any modifications or additions to the boiler system must be promptly reflected in these records to maintain accuracy and support efficient operation and maintenance.
Certain jurisdictions may require licensing or certification for personnel operating or maintaining heating equipment, as well as the display of inspection certificates in the boiler room. The individual responsible for the installation must ensure full compliance with these mandates.
Boiler Receiving & Unloading
Boiler Receipt Protocol
Upon delivery of your VEO Dryback boiler unit, the recipient must perform a thorough visual examination to identify any potential transit-related damage. In the presence of such damage, initiate a claim with the freight service provider immediately.
Any issues concerning damage unrelated to shipping should be addressed in accordance with the signed contractual agreement. Recipients must confirm receipt of all components as specified in the freight documentation.
The boiler unit is dispatched in an assembled state for transit purposes but is not intended for long-term storage. Sensitive components may be delivered separately to ensure their integrity.
Unloading the Dryback Boiler
Use the provided lifting lugs for unloading and placement of the boiler unit. A crane or dollies under the unit’s legs are the recommended equipment. Do not pass lifting cables around the unit and do not operate a forklift beneath the boiler shell, as these practices can cause damage.
Unloading Guidelines
- Engage a transportation firm capable of safely unloading the boiler.
- Ensure the crane has sufficient capacity for the boiler weight.
- Report any delivery damage to VEO immediately.
- Use only the lifting lugs provided and remove all transport tie-downs before lifting.
- Secure all doors, access panels, and connected piping prior to lifting.
- After placement on the foundation, verify clearances, including safe distance from combustibles and access for future retubing.
If crane repositioning is not possible, trucks with winches and appropriate cables attached to non-load-bearing points on the boiler legs may be used to reposition the unit. Once in final position, remove rollers by lifting on the lugs or using jacking pads.
Boiler Signage & Model Identification
Each boiler is furnished with a nameplate and signage indicating maximum capacity, steam production, heating surface, VEO job number, and year of manufacture. Refer to the supplied drawings and figures for the exact location and layout of this signage on your boiler.
Model numbering conventions and identification details are provided in the manual to assist in technical support, spare parts ordering, and reference to performance data.
1. Component Identification
This section illustrates major boiler components including feedwater connections, low-fire hold, chemical feed, stack connector, burner, blowdown, access points, and pass arrangements (2-pass, 3-pass, and 4-pass technologies).
1.1 Water Columns
Water columns and associated instrumentation provide indication and control of boiler water level. Refer to the figures for arrangement and connection details.
1.2 Pressure Manifolds
Pressure manifolds distribute steam and connect to pressure sensing instruments as shown in Figure 11.
1.3 Smokebox
The smokebox section includes stack flange details and front and rear assembly views, including gasketing and bolting arrangements.
1.4 Cleanout Plug
Cleanout plugs provide access for inspection and removal of deposits. Refer to the drawing for dimensions and threaded connections.
1.5 Burner Mounting
Boiler and burner integration details (for example, with the Vision ProSelect burner) are provided to ensure correct alignment and sealing.
1.6 Feedwater Piping
Feedwater piping, valving, and connection points are illustrated in the manual drawings. Layout must be installed per design to ensure proper circulation and control.
1.7 Manway Assembly, Low-Fire Hold & Chemical Feed
This section shows the manway assembly and the location of low-fire hold and chemical feed connections (see Figure 20).
1.8 Safety Valve
Safety valve sizing, setting, and mounting details are provided in the manual. Safety valves must not be altered except by authorized and certified personnel.
1.9 Blowdown Valves
Intermittent and continuous blowdown valves, their locations, and recommended configurations are shown in this section.
1.10 Miscellaneous
Additional components and penetrations not covered in prior subsections are detailed here, including inspection doors and instrument connections.
1.11 Access Doors
When opening an access door, observe all ca
utions. Do not enter a confined space where the
temperature inside is 120°F or higher. Use combustion air fans or other means to cool and ventilate
the equipment before entry.
Implement lockout/tagout on electrical supplies and isolate all fuel, steam, and gas paths before opening or entering.
Refer to the detailed procedures in the manual for cooling, ventilating, isolating, and safely accessing the interior of the boiler through access doors.
1.12 Manway Gasket (Below 600 PSI)
This subsection provides step-by-step guidance for cleaning, inspecting, installing, tightening, and leak-checking manway gaskets. Follow the specified procedures and manufacturer recommendations for gasket types such as Topog-E Series 180 and 2000.