BOILER

1) What is auxiliary boiler and exhaust boiler?

A steam generator, in the sense of an auxiliary boiler on a ship, is a form of boiler. It uses highpressure superheated steam from the main steam supply used for propulsion, and uses this to
generate low pressure saturated steam. This is then used to power auxiliary steam engines
around the ship such as winches or pumps, or to supply any steam requirement on the ship that
does not require high superheating, such as boiler feed water and freshwater evaporators.
An exhaust boiler is one in which the exhaust gases from diesel main propulsion engines is used
to generate steam.
2) What is the use of safety valve?
Boilers have safety valves can relieve the entire generating capacity of the boiler if the pressure
goes above a limit and are provided in the drum, superheater, and reheater.
3) What is the lifting pressure of the safety valve?
The safety valves are designed to go full open within an overpressure level of 3%. The safety
valve will close once the system pressure reduces to what is called the "reseat pressure."
4) What is meant by accumulation test and how it is done?
An accumulation test determines if there is enough safety valve capacity. With the
steam stop valve closed, the boiler is brought up to high fire. Under these conditions
the safety valves are naturally going to lift. The boiler inspector watches the boilers
pressure gauge to make sure that there is enough safety valve capacity. This test is
not done on boilers equipped with superheaters as the superheaters would be
damaged with no cooling steam flowing through them.
5) What is meant by hydraulic test and how it is done?
Hydrostatic test in steam boiler is one of non-destructive examinations which should be
performed for new steam boiler or steam boiler which has been repaired such as replace water
wall, superheater, reheater, economizer and so on to. Hydrostatic test must be done to make
sure that steam boiler is free from leakage before start up is performed. Before hydrostatic
test is executed, inspection for all welds and installation of pressure parts should be done.
Moreover inside and outside of steam boiler and pressure part shall be free from all dirt, scale,
paint, debris, dirt, weld slag, rust, oil, spatter and all other foreign matter.
Before perform hydrostatic test (hydrotest) in steam boiler, the following matter should be prepared as
follow:
1.
Non-destructive examination shall be verified to confirm acceptance as per Code and
specification.
2.

Dimensional inspection.

3.

Full visual inspection for all welds.

4.

Boiler pressure part installation is completed.

5.

No painting work on pressure part before hydrostatic test.

6.
Inside and outside of boiler and pressure part shall be free from all dirt, debris, weld
slag and spatter, oil, rust, scale, paint and all other foreign matter.
7.

Prepare and check valve line-up.

8.

All gags shall be installed on safety valve.

9.

Vent and drain are to be provided for the system before commence of hydrostatic test.

10.
All temporary fitting, blind flange shall be suitable for the test procedure and should
not have defect that may cause failure during hydrostatic test.

11.
Fill boiler with treated water and free from mineral or other suspended matter
(Demineralized water).
Requirement of gauge and record during hydrostatic test in steam boiler (hydro test):
1.
A minimum of 2 (two) pressure gauge shall be used for pressure tests. One shall be a
pressure temperature recorder with a range suitable for recording of the test pressure. The full
scale of the other pressure gauge shall preferably 1 to 4 times of test pressure.
2.
The test pump and the line to be tested shall be provided with the separate indicating
test gauges. In case of testing between a high and low point of the module, gauges shall be
placed one at the top and one at the bottom to measure the pressured drop.
3.
The pressure gauge shall be calibrated and still valid before used. Any gauges showing
incorrect zero error more than + 1% of full-scale range shall not be used without repair and
recalibrate.
Hydrostatic test must follow the determined procedure which is generally as follows:
1.
Install suitable temporary fitting such as blind flange or end plate to close opening and
ensure all of openings are closed except venting valve.
2.
Fill the steam boiler with treated water, free from mineral or other suspended matter
at temperature not under 70 F or ambient temperature.
3.
Inspect leakage when steam boiler is being filled, remove air through venting valve,
close it if there is not leakage and air is totally removed.
4.
Increase pressure gradually with maximum pressure rate 5 kg/cm2 until 1.5 times of
maximum allowable working pressure for new boiler and 1.2 times for repaired boiler.
5.
Record pressure, time and temperature during test and inspect all of pressure parts of
steam boiler at holding time of hydrostatic test approximately 10 minutes. 6. After hydrostatic
test, the pressure should be release in a manner and at rate so as not to endanger personnel or
damage equipment.

6) What is meant by blow down and how it is done?

Blow down of the boiler is done to remove scum and bottom deposits. This means
that blow down is done either for scum or for bottom blow down.
There are two types of boiler blowdowns - continuous and manual. A continuous blowdown utilizes a
calibrated valve and a blowdown tap near the boiler water surface. As the name implies, it continuously
takes water from the top of the boiler at a predetermined rate
A continuous blowdown is an optional feature and may not be included on your steam boiler. However,
all steam boilers should include a means for manual blowdown as standard equipment.
Manual blowdowns are accomplished through tapings at the bottom of the boiler. These openings allow
for the removal of solids that settle at the bottom of the boiler. Manual blowdown is also used to keep
water level control devices and cutoffs clean of any solids that would interfere with their operation. All
steam boilers require manual blowdown whether or not they are supplied with continuous blowdowns.

Proper blowdown is performed as follows:

Blowdown should be done with the boiler under a light load. Open the blowdown valve nearest the boiler
first. This should be a quick opening valve. Crack open the downstream valve until the line is warm. Then
open the valve at a steady rate to drop the water level in the sight glass inch. Then close it quickly
being sure that the hand wheel is backed off slightly from full close to relieve strain on the valve packing.
Close the valve nearest the boiler.
Repeat the above steps if the boiler has a second blowdown tapping. Water columns should be blown
down at least once a shift to keep the bowls clean. Care should be taken to prevent low water shutdown if
this will affect process load.
Please keep in mind that all blowdown piping should be checked once a year for obstructions.

7) What are the chemicals used for water test?

1. HARDNESS TEST - Hardness is a word used to describe dissolved calcium and magnesium
salts in water. We can determine the amount of these salts in water by simple titration; that is,
adding chemical Hardness indicators to a sample of water.
Hardness is expressed in ppm, which stands for parts per million.
Hardness must be precipitated out of water so that scale does not form. When high alkalinity is present in
the water, the Hardness is precipitated as soft sludge that is held in suspension by either the boilertreat
1000 series of chemicals until blowdown. When low alkalinity is present in the raw water, the alkaline
builders in these products provide the alkalinity necessary to precipitate the Hardness as soft sludge. A
smaller dosage will be used if the makeup water is highly alkaline. The amount of alkalinity in the raw
water is determined by the "M" Alkalinity test.
2. "M" ALKALINITY TEST - This is used to determine the Total Alkalinity of the raw water in ppm. The
result of the "M" Alkalinity test is used to determine how much Boilertreat 1000 to use. Subtract the "M"
Alkalinity in ppm from the Hardness in ppm and divide by 20 to get the dosage of Boilertreat 1000.
3. SULFITE TEST - This test indicates the amount of Sulfite in the water. Sulfite and oxygen cannot
coexist; therefore, by keeping an excess of sulfite in the boiler water, we can be sure there is no oxygen is
present. If no oxygen is present, no acid can be formed and there will be no corrosion.
4. CONTROL TEST FOR ISOMINE - Phenolphthalein is an indicator which is colorless below and pink
above a pH of 8.2. When the pH of the condensate is higher than 8.2, pink indicates that corrosion is
being prevented effectively. A red color indicates excess chemical is being used; therefore, the feed rate
should be reduced.
5. CHLORIDE TEST - When water is converted to steam, the dissolved solids do not travel with the
steam, but are left behind in the boiler water. Water enters the boiler to replace the amount lost through
steam evaporation. When this new water is converted to steam, more solids are left behind. As steam is
continually produced, evaporated, and replaced with new water, the amount of solids in the boiler
continues to increase.
8) What action you will take if the chloride value is high?
In case the chloride value is high boiler blow down is done.

INCINERATOR
1) What are things that can be burnt in incinerator?
Sludge oil consisting of:
75% sludge oil from heavy fuel oil
5% waste lubricating oil
20% emulsified water
Solid waste (class 2)
50% Food Waste consisting of:
50% rubbish Containing
Approx.
30% paper,
40% Cardboard,
10% Rags,
20% Plastic (only if the incinerator is approved to burn plastics)
2) What are the safety interlocks provided in the incinerator?Where charging is not effected
through a charging lock, an interlock should be installed to prevent the charging door from opening while
the incinerator is in operation with burning of garbage in progress or while the furnace temperature is above
220C.
Interlocks should be installed to prevent ash removal doors from opening while burning is in progress or
while the furnace temperature is above 220C.
3) Why plastics are not burnt in incinerator unless approved?
If the incinerator ash from plastic products contain toxic or heavy metal residues, then no. if it
does not, then it is legal, but the vessel must be more than 12 miles from land and the disposal
event recorded in the Garbage Record Book.
Also the release of hydrogen chloride and dioxins from PVC incineration can be very toxic to
animal species. The corrosive fumes released into the atmosphere from plastic combustion can
also increase acidity levels of the environment. A potential effect from such emissions is the
generation of acid rain.