Front

Back view

VI.1

Accessories[edit]
Boiler fittings and accessories[edit]

Pressuretrols to control the steam pressure in the boiler. Boilers generally have 2 or 3
pressuretrols: a manual-reset pressuretrol, which functions as a safety by setting the upper limit
of steam pressure, the operating pressuretrol, which controls when the boiler fires to maintain
pressure, and for boilers equipped with a modulating burner, a modulating pressuretrol which
controls the amount of fire.

Safety valve: It is used to relieve pressure and prevent possible explosion of a boiler.

Water level indicators: They show the operator the level of fluid in the boiler, also known as
a sight glass, water gaugeor water column.

Bottom blowdown valves: They provide a means for removing solid particulates
that condense and lie on the bottom of a boiler. As the name implies, this valve is usually located
directly on the bottom of the boiler, and is occasionally opened to use the pressure in the boiler
to push these particulates out.

Continuous blowdown valve: This allows a small quantity of water to escape continuously.
Its purpose is to prevent the water in the boiler becoming saturated with dissolved salts.
Saturation would lead to foaming and cause water droplets to be carried over with the steam a
condition known as priming. Blowdown is also often used to monitor the chemistry of the boiler
water.

Trycock: a type of valve that is often use to manually check a liquid level in a tank. Most
commonly found on a water boiler.

Flash tank: High-pressure blowdown enters this vessel where the steam can 'flash' safely
and be used in a low-pressure system or be vented to atmosphere while the ambient pressure
blowdown flows to drain.

Automatic blowdown/continuous heat recovery system: This system allows the boiler to
blowdown only when makeup water is flowing to the boiler, thereby transferring the maximum
amount of heat possible from the blowdown to the makeup water. No flash tank is generally
needed as the blowdown discharged is close to the temperature of the makeup water.

Hand holes: They are steel plates installed in openings in "header" to allow for inspections &
installation of tubes and inspection of internal surfaces.

Steam drum internals, a series of screen, scrubber & cans (cyclone separators).

Low-water cutoff: It is a mechanical means (usually a float switch) that is used to turn off
the burner or shut off fuel to the boiler to prevent it from running once the water goes below a
certain point. If a boiler is "dry-fired" (burned without water in it) it can cause rupture or
catastrophic failure.

Surface blowdown line: It provides a means for removing foam or other lightweight noncondensible substances that tend to float on top of the water inside the boiler.

Circulating pump: It is designed to circulate water back to the boiler after it has expelled
some of its heat.

Feedwater check valve or clack valve: A non-return stop valve in the feedwater line. This
may be fitted to the side of the boiler, just below the water level, or to the top of the boiler.[10]

Top feed: In this design for feedwater injection, the water is fed to the top of the boiler. This
can reduce boiler fatigue caused by thermal stress. By spraying the feedwater over a series of
trays the water is quickly heated and this can reduce limescale.

Desuperheater tubes or bundles: A series of tubes or bundles of tubes in the water drum
or the steam drum designed to cool superheated steam, in order to supply auxiliary equipment
that does not need, or may be damaged by, dry steam.

Chemical injection line: A connection to add chemicals for controlling feedwater pH.

Steam accessories[edit]

Main steam stop valve:

Steam traps:

Main steam stop/check valve: It is used on multiple boiler installations.

Combustion accessories[edit]

Fuel oil system:fuel oil heaters

Gas system:

Coal system:

Soot blower

Other essential items[edit]

Pressure gauges:

Feed pumps:

Fusible plug:

Inspectors test pressure gauge attachment:

Name plate:

Registration plate:

2.) Dos:

1. Operating Procedure: Follow the correct operating procedure when

lighting up the boiler from the cold condition. Ensure to pre and post purge
every firing and also make sure that the air vent is kept open while initially
firing and shutting down the boiler.
2. Blow Down: A regular gauge glass blow down (once every watch) is a
must. Boiler blow down is to be performed once a day to keep the chloride
level to minimum. If floating impurities are suspected (oil, foaming etc.) scum
blow down is to be carried out.
3. Soot Blow: Perform a soot blow for the boiler tube to continue the heat
exchanging ability of the boiler tubes.
4. Smoke: Check the smoke from the boiler trunk coming out of the ships
funnel on every watch to gauge the combustion quality.

5. Lubricate: All the boiler mechanical parts and links to be lubricated and
greased at regular interval of time.
6. Emergency Shut Down: Ensure to check emergency shut down of the
boiler, which is located in the ECR, is working. This is to be tested as per the
safety routine described in the company Safety management System (SMS).
7. Valves and Dampers: Ensure all the fuel line valves, steam valves and
safety valves are working fine. Check the quick closing valves and safety valves
for their correct operation.
8. Attend Leakage: Steam system is prone to leakages because of their
fluctuating steam pressure. Attend all the leakages at the earliest to maintain
the efficiency of the boiler at all times.
9. Check Furnace: Keep a check on the furnace for refractory
deterioration and fuel dripping near the burner assembly. Any defect to be
attended at the earliest.
10. FFA for Boiler: Boiler is a high pressure machinery with its own
set of prescribed fire fighting equipment. Check the functioning of
local fire extinguisher (foam type) and High pressure jet fog system.
Drill to be carried out regularly to train the crew for fighting the
boiler fire.
Donts:
1. Untrained Operator: Never leave a boiler operation at the hand of an
assistant engineer or untrained operator, especially when lighting up the

boiler from the cold condition.

2. Blow Down: Never do excess blow down as the feed water system will
add cold water in the boiler drum to compensate which will lead to decrease in
the thermal efficiency and stresses in the boiler.
3. Soot blow: Never Operate a soot blow system when the boiler is
operating at high load.
4. Unusual Observation: Dont avoid any unusual observation in the
boiler whether its sound, smoke, flame quality or other boiler parameters.
Always rectify abnormalities related to boiler at the earliest.
5. Overload: Never operate the boiler at higher load as a regular practice.
Boiler can be overloaded sometimes due to load demand but regular
overloading will lead to high stresses and tube failure.
6. Feed water: Never include sea water in any circumstances. If the hot
well is filled with sea water (due to heavy leakage in the condenser), shut down
the plant and rectify the problem.
7. Leaking Tubes: Dont Operate the boiler when any water tube is
leaking. Rectify the leakage at the earliest.
8. Water Level: Dont trust the water level indicator located at remote
position i.e. in the control room. Keep a check through local gauge glass to get
the clear picture.

9. Furnace Door: Dont keep the boiler furnace door open unnecessarily. If
it is opened for burner cleaning or furnace inspection, close the door if the
equipment is unattended or once the job is over.
10. Periodic maintenance: Dont skip the periodic maintenance of
boiler and boiler auxiliaries as it will decrease the efficiency of the boiler over a
period of time.
3.)

Types of Boilers
Different types of boilers are available in the market, which are manufactured by different
manufacturers. The different types of boilers find their use in different applications. As the time has
passed, more efficient types of boilers have replaced the old and inefficient ones. This article
elaborates on different types of boilers and the boiler classification. Boilers can be broadly classified
as shell tube and water tube boilers.

Shell and tube boilers

Shell and tube boilers are also referred to as fire tube or smoke tube boilers. Fire tube boilers; contain
long steel tubes through which the hot gasses from a furnace pass and around which the water to be
converted to steam circulates. Fire tube boilers, typically have a lower initial cost, are more fuel
efficient and easier to operate. Their capacities are up to 25tons/hr and 17.5 kg/ cm2.

Different types of fire tube boilers:

Cornish boiler
These are the earliest form of high pressure fire tube boiler. These consist of long horizontal cylinder
with single large flue containing fire. Fuel is added in the grate area where it burn to produce hot
gases. The hot gases transfer the heat to the water.
Water takes heat and after some time it starts boiling to produce steam. Hot gases upon reaching at
the end of the fire tube, divided into two section and each move into the one of two side flue which
take them once again at the front section of the boiler where they are move into the bottom flue and
bottom flue take them toward the chimney.
Chimney throws these gases out of the boiler into the atmosphere. Maximum heat transfer is taken
place at fire tube and shell section then taken place at side flue and at last at bottom flue.
For efficiency, the boiler was commonly encased beneath by a brick-built chamber.

Lancashire boiler:
The Lancashire boiler is similar to the Cornish, but has two large flues containing the fires. Pressure
range of the boiler is about 0.7 MPa to 2 MPa and efficiency is 65 to 70%. Fuel in these boilers is
added into the grate which heats the gases.
Hot gases enter the front section of the boiler and leave the boiler from back and then enter the
bottom flue and start moving to front section of boiler. At front section hot gases leave the bottom flue
and enter in side flue and move again towards the back of the boiler and enter the main outlet. 85% of
heat is transferred when hot gases are in fire tube while 15% is transferred when they are in bottom
and side flue.

Locomotive boiler
A locomotive boiler has three main components:
1. Double-walled firebox;
2. Horizontal, cylindrical "boiler barrel" containing a large number of small flue-tubes; and
3. Smokebox with chimney, for the exhaust gases.
Fuel is burned to produce the hot gases. Fuel is feed through fire hole. Hot gases are diverted to fire
tube with the help of fire brick arch. Steam is collected in the steam drum which is placed at the top of
the shell.
The wet steam goes through inlet headers of super heater and after passing through tubes, it returns
to the outlet header of super heater and is taken out for steam engine.
Locomotive-type boilers are also used in traction engines, steam rollers, portable engines etc.
On the basis of construction these can be classified wet back boilers and dry back boilers.
Reversal Chamber:
This is the posterior portion of the combustion chamber through which the flue gases travel from the
first pass (furnace) to the second-pass tubes

Wet Back Boilers:

In wet back boilers as the name suggests the reversal chamber is completely surrounded by water.
The combustion reversal chamber is surrounded by water and therefore the heat in the flue gases is
optimally utilized. Radiation losses are reduced as none of the parts of the combustion chamber are
open to atmosphere instead they are surrounded by water. That means fewer losses, and lesser fuel
bills. Most efficient modern boilers supplied are wetback type.

Dry Back Boilers:

The reversal chamber in dry back boilers is not completely surrounded by water. The posterior part is
exposed to the atmosphere. This leads to the increased radiation losses, as the radiant heat is lost to
the atmosphere instead of going to the water as in wet back boilers. Earlier generation boilers used to
be dry back.
Thus wet back boilers ensure lesser radiation losses and hence save fuel.
The layout of the tubes involves the number of passes the tube will make to pass the heat from the
boiler furnace before being discharged. These can be two- pass and three pass boiler.
Depending upon the layout of tubes boilers can be two pass or three pass boilers.

Two pass boilers:

In two pass the combustion gases travels two times in the boiler.
Combustion gases should be cooled before entering the reversal chamber. Excess temperature
causes overheating and cracking of the tube. The heat transfer rate is maximum at the first pass, this
rate decreases with the increasing passes.

Three pass boilers:

A three pass design provides three opportunities for heat transfer. The stack temperature of 3 pass will
be lower than that of 2 pass boiler, of the same design and operating pressure. Efficiency is more than
two pass boiler.
Each pass in boiler should be designed with cross sectional area to achieve optimal flue gas velocity,
which in turn maximizes heat transfer while also minimizing performance robbing sooth build up within
the tubes.

No. Of pass Area of tube m2

1st 11 1600 65%
2nd 43 400 25%
3rd 46 350 10%

Temperature 0C

Heat transfer

Water tube boilers:

In water tube boilers, water and steam flow inside the tubes and the hot gases flow over the outside
surface. Modern high capacity boilers are of water tube type. The boiler circulation system is
constructed of tubes, headers, and drums joined in arrangement that provide water flow to generate
steam.
Water tubes have high pressures and capacity than shell tube boilers. These boilers can be of singleor multiple-drum type. These have higher efficiencies than fire tube boilers.
Depending on layout boilers can also be classified as:

1.

Longitudinal drum boiler.

The feedwater is feed in drum. The drum is placed above the heat source. The cooler water goes to
the inclined tubes and the water is heating eventually in the hot tubes. As the water boils its density
decreases and there is circulation of hot water and steam. Steam is separated from water in steam
drum and taken out. Longitudinal drum boilers range from 2250 kg/h to 3600 kg/h.

2.

Cross drum boiler.

The drum in this type is placed in cross to the heat source. The temperature obtained in this type of
arrangement is more uniform. When the steam loads are high the upper tubes can become dry which
cause them to fail. The layout of tubes is made in such a way that large numbers of tubes are made
available. The capacity of cross drum range from 700kh/h to 240000 kg/h

3.

Stirling boiler:

A Stirling boiler has near vertical, almost straight water tubes that zig-zag between a number of steam
and water drum. Usually there are three banks of tubes in a four drum layout.
The feedwater enters the left upper drum, from where it falls to lower water drum. Water in pipes and
two drums is heated, the steam produced rise in upper drum from where steam is separated and
taken off.

Package Boiler:
These boilers come as complete package. It requires only the steam, water pipe work, fuel supply and
electrical connections to be made for it to become operational. Package boilers are generally shell
type with fire tube design so as to achieve high heat transfer rates
The packaged boiler is so called because it comes as a complete package. Once delivered to site, it
requires only the steam, water pipe work, fuel supply and electrical connections to be made for it to
become operational. Package boilers are generally of shell type with fire tube design so as to achieve
high heat transfer rates by both radiation and convection
The features of package boilers are:
1. Small combustion space and high heat release rate resulting in faster evaporation.
2. Large number of small diameter tubes leading to good convective heat transfer.
3. Forced or induced draft systems resulting in good combustion efficiency.
4. Number of passes resulting in better overall heat transfer.
5. Higher thermal efficiency levels compared with other boilers.

4.)
To Check on Your Boilers
Again, these might be every 20 minutes, hour, shift, or day. Use the operating
procedures for your plant to determine what needs to be checked and tested, and
how often. Every plant is different and the procedures for each should reflect the
differences as well.

The list below are things a boiler operator, stationary engineer, or building engineer
should be checking, especially on the first set of your rounds, readings, or logs.

Boiler Water Level

checking boiler water level
See the boiler water level at the arrow?
This should be the first thing you do when taking over control of the boilers check
the water level inside. Boiler water level should be somewhere within the
acceptable range in the gauge glass and water column if operating.

If the boiler is shut down or secured, there might not be a water level visible. See?
This is one of those things you can take note of and ask the off going engineer
about. Hey, why is there no water level in #3 boiler? Because we have it drained
for maintenance.

Check, listen, or feel which boilers are operating and then glance at the gauge glass
and make sure the boiler water level is within the proper range.

Flame Condition
Checking the condition of the flame is important as well.

The color and shape can sort of tell you what is going on, it gives you a decent
indicator from the outside of the combustion conditions going on inside the boiler.

Your plant will have its own criteria for what it considers to be a good flame, its
impossible to come up with one awesome flame condition that covers all boilers.

In a gas combustion flame, this document says a blue, slightly streaked or invisible
flame is desired. In an oil fired boiler, you want to see a short, bright, crisp, and
turbulent flame. This is the condition we typically see on the Cleaver-Brooks boilers
here. A bright, crisp, swirling and turbulent orange.

You also want to sort of check the stability of the flame. Is it nice and strong or does
it kind of peter out for a second, re-ignite, and repeat?

Sometimes you might look in the peephole and see a perfect looking flame. Be
careful though, this may be simply because combustion is occurring in an oxygen
rich environment. Ideally, youd want the perfect flame using the minimum amount
of oxygen necessary to achieve perfect combustion. You dont want a perfect flame
as a result of adding and adding excess oxygen.

Steam Header Pressure

This one is straightforward.

As you walk through the boiler room, take a look at your steam header pressures.
Check your main steam header pressure as well as any branch lines like one going
to your low pressure steam header.

Looking at this pressure will also give you an idea of steam demand from the
building or facility.

Steam Demand or Load

cleaver brook boiler flame scanner
Looking down the peephole at the flame. Wish I could get a better pic.
Check the fire rate of your boilers.

By looking at the boiler fire rates, you can determine how much demand is being
placed on the boilers. Are they all at 100% load? Does one boiler handle the load?
Are your other boilers running at 0.1%?

Checking steam demand along with header pressure can give you an indication of
what is going within the plant as well as what may be coming up.

Conductivity
Check conductivity of the boilers.

Maybe you have a water treatment controller that gives a simple read out of what
current boiler conductivity is. If youre like the majority of us, youll have to draw a
sample, let it cool, and then use a meter to measure conductivity.

By measuring this youll get an indication of if you need to blow down or not. Use
this in conjunction with your plant procedures to determine if you will perform a
bottom.

For instance, despite being classically (lol) trained in boiler operations (taught to
conduct at least 1 bottom blow down per day,) currently we have been instructed to
not conduct them until further notice because our conductivity is too low.

These are things we should be checking, looking, at inspecting. Next we are going
to go over some things you should be doing on your first set (or sometime during
your shift.)

To Test/Do on Your Boilers

If youve gotten your boiler operator or steam engineer license, you know there are
some things that are supposed to be done at least every day, and sometimes each
shift. Personally, I like to do all of the boiler related tasks below during my first walk
through of the shift. It kind of puts me in tune with them. Plus you get the required
stuff over with right away. Not much worse than getting slammed at work and not
being able to conduct your mandatory checks or tests.

Bottom Blowdown
Just above here, we talked about measuring conductivity. That reading helps
determine if we perform bottom blowdowns every shift, every day, or never.

Coming up through the ranks, it was an accepted practice to bottom blow at least
once per day regardless of conductivity in order to remove sludge and solids from
the mud drum.

Water Column & Gauge Glass Blowdown

These two pieces of equipment, the column and gauge or sight glass, are blown
down at least once per shift to ensure we are getting an accurate indication of boiler
water level.

The water column is what signals the feed pump to come on or shut off, it also can
signal the boiler to shut down if water level is too low. For this reason, just like a
bottom blow on a boiler, we want to blow down the water column and sight glass to
get rid of any garbage or sediment that may impact its operation.

Low Water Cutoff

boiler low water cutoff check
A low water (LWCO) on a boiler. Works like a float in a toilet tank.
This is probably the most important safety feature on a boiler. It is crucial that you
test this. Often. This is the safety feature that completely shuts down the boiler if it
senses a low water condition inside. It secures all fuel to the boiler almost instantly.

Currently the low water cutoff (LWCO) is tested once per shift.

A low water condition means that not enough water is inside the boiler to support
full combustion or boiler operations.

You might have combustion taking place with no water. What happens when all of a
sudden you throw water onto a scorching hot surface?

Boom.

Alternate Low Water Cutoff

This is the almost the same as above. It is essentially a back-up to the primary
LWCO. This should also be tested once per shift.

By testing them, you are also in essence, almost blowing these down as well,
getting rid of sediment and sludge.

Flame Scanner
how often should you test boiler flame scanner
A flame scanner removed.
The flame scanner is scary ha ha. Testing it is anyways.

This device should be tested at least once per day to ensure proper operation. It too
shuts down the boiler but not on a low water condition. It shouts down the boiler
when it doesnt see a flame present. Within a few seconds of not seeing it, it will
secure the boiler and shut off the fuel.

Its important that this device functions properly so if something goes wrong, the
boiler combustion chamber just doesnt fill up and up with un-burned fuel, like a
barbeque grill you know?

It scans the area inside the combustion chamber looking for particulate and/or light.
If it doesnt sense it, shut down.

You test it by removing it WHILE the boiler is firing and cover the lens with
something. It should secure the boiler.

6.)