Any closed vessel exceeding 22.

75 litres in capacity which is used for generating

steam under pressure and includes any mountings or other fittings attached to such
vessel which is wholly or partly under pressure when steam is shut off.
Acts Governing Boilers

Indian Boiler Act 1923

Indian Boiler Regulation 1950
Tamilnadu Boiler Rules 1924
Tamilnadu Boiler Attendants Rules 1964
Tamilnadu Boiler Operation Engineers Rules 1965

BOILER LEGISLATIONS

To protect the life of operating personnel and the public

To protect the damage to the property.
Boiler cannot be fired unless it is registered
CIB issue a registry number for each boiler
Authorize the use of the boiler for a period of 12 months.

BOILER RULES
To secure uniformity throughout India in technical matters in
Construction
Manufacturing testing
Inspection
Boiler Rules
To insist on the registration and regular inspection of all boilers throughout India.
Applicable to all boilers, Steam pipes, feed pipes and to all Economisers
Act authorizes state Government to appoint Inspector and Chief inspector for
carrying out the provisions of this act.
Only IBR Qualified welders to be used for welding in Boilers
Welders should produce their certificate whenever required.

An owner of a boiler shall not use it or permit to be used

Unless it has been registered in accordance with the provision of this act
Transport of boilers from one state to another to be reported in prescribed format
Unless a certificate authorizing the use of the boiler is obtained for the time
being in force under this act
At a pressure higher than the max pressure recommended in such certificates or
provisional order
Unless the boiler is in charge of a person holding the certificates of competence.
Certificate to be renewed

On expiry of period of which it was granted. (1 year)

When any accident occurs to the boiler
When it has been removed to another state
When the steam pipe or piece of the boiler found to be in dangerous conditions.
When any structural alterations, addition or removal is made into any steam pipe
attached to the boiler.

LOSSES IN BOILER
Sensible heat in flue gas

Main loss
less excess air

Radiation losses

Poor insulation
Irrespective of load

Unburnt in fuel -

C+02------->CO2+8084 K cal/Kg of C
2C+O2------->2CO+2430 Kcal/Kg of C
For every C 8084 Kcal loss
For partial 5654 Kcal loss

Blow down loss

give exact quantity

Gas side deposit

Regular soot blowing

38o above normal running needs cleaning
3mm thick deposit -2-5% fuel loss

Water side deposit

1 mm thick scale-5-8 % fuel loss

Tube failure
WET PRESERVATION

Done if the Boiler is not in service for longer duration

Hydrazine is used
Maintain 200 ppm
Avoids oxygen ingression

HYDRO TEST

Done to ensure pressure tightness

Hydrotest and start up time to be less
Pressure raise 10Ksc/Minute
1.5 times of working pressure
Not to be held more than 10 minutes
Check for pressure drop
Depressurise at 5 Ksc/minute

SAFETY VALVE FLOATING

Done if the safety valve is renewed

Gag the lower setting safety valves
start from higher setting safety valve
Release gagging one by one and float the other safety valves

PROBLEMS

Corrosion
Erosion
Swelling
Sagging
Safety valve
Formation of soot
Water cut off
Leak in welding joints .

Burner failure in operation

Low oil pressure

water in oil
Oil temperature very low
Atomizing steam failure
Gun choke
Interlock

Burner light up difficulties

No oil supply/ Check isolation valve

Too low air flow/oil pressure less
Too high air flow
Improper atomization/At steam pressure low
Water in fuel
Gun tip choked
Interlock

Fire puff/Explosion

Unsteady oil pressure

Poor atomisation
Very low draft
Excessive oil temperature
Burner lighted up without pilot flame
Inter lock failure/FD Trip

Flame away from tip

Burner tip loose on gun
Poor atomisation
Improper draft
Flame impingement
Too low oil pressure
Flame away from tip
Choked gun tip

 Low secondary air

Clinker formation in gun tip

Stack smoking

Improper burner alignment

Insufficient air
Too much oil flow
Unclean burner
Low oil temperature
Poor atomisation
Fluctuating draft

Cannot carry maximum load

Oil pressure low

Check FCV/Oil pump
Draught limitation
Gun tip choke
Choked strainer

QUALITIES OF BOILER

Quick start up
Less maintenance
Less floor space
Able to meet load fluctuation
Less fuel
Maximum efficiency
Easy for maintanance

Boiler efficiency depends on

Calorific value of the Fuel

Atomisation of the fuel
Boiler Feed Water (BFW)
Internals (construction, water tubes, accessories)
Efficient Utilization
Saturation temperature
Losses

PROBLEMS

Corrosion
Erosion
Swelling
Sagging
Safety valve
Formation of soot
Water cut off
Leak in welding joints.

Causes of furnace explosion

Flame failure due to entering of liquid in the fuel system.

Insufficient purging before lighting the first burner.
Human error
Faulty automatic fuel regulation system.
Fuel shut off valve leakage.
Unbalanced fuel air ratio.
Faulty fuel supply system.
Loss of furnace draught.
Faulty burner igniter.

Tips on boilers
If 22C reduced at Stack emission 1% of fuel will be saved and overall
efficiency of boiler will increase 3~5%
Electrically operated boilers are costlier by 3 times compared to oil
fired boilers.
Steam is also like electricity which means cannot be stored. Hence
effectively produced and used.
Thermodynamic Laws connected to Boilers
Zeroth Law:

 If A & B are in thermal equilibrium as A & C, then B & C also in

equilibrium.
First Law:
Energy can neither be created nor be destroyed but can be transformed
from one form to another
W=Q
W=Work done
Q=Heat transfer
Boiler Thermal Efficiency
This is given by the ratio of the energy received by the steam to the
energy supplied by the fuel to produce the steam.
Energy to steam
Boiler thermal efficiency
=
--------------------Energy from fuel
Actual evaporation x (H-h)
Equivalent Evaporation
=
-------------------------------540
(Saturated steam at 100C is 540 Kcal/kg)
H Total heat in generated steam in Kcal/Kg
h Heat content in feed water in Kcal/kg

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Boiler
OSB
Aux. Boiler
ASGU
RGB
Waste heat boiler
Waste heat boiler

Test / Design pr
67.5 /54
150 / 120
155 / 123
153 / 122
24 / 19
27/21