BOILER WATER TREATMENT

Objectives of the Boiler Water Treatment:

The principal objects of boiler feed water treatment should be:
1. Prevention of scale formation in the boiler and feed system by using distilled
water or precipitating all scale forming salts into the form of a non-adherent
sludge.
2. Prevention of corrosion in the boiler and feed system by maintaining the
boiler water in the alkaline condition and free from Oxygen and other
dissolved gases.
3. Control of the sludge formation and prevention of carry over with the steam.
4. Prevention of entry into the boiler of foreign matter such as oil, waste, mill-
scale, iron oxides, copper particles, sand etc. By carefully use of oil heating
arrangements, effective pre-commission cleaning and maintaining the steam &
condensate systems in a non corrosive condition.
5. To maintain the boiler in healthy state, around any possible seawater
contamination. The first stage in the boiler water testing is to collect feed water
sample from the boiler concerned. The water sample collected from the boiler
through connection would be relatively clean and does not represent the true
through connection would be relatively clean and does not represent the true
condition of the boiler water it considered as good sample. This is because hot
sample particles is flushed off into a steam making that dissolved solid in the
sample higher and lots of volatile such as hydrazine will reduce the
concentration measure in the test program.

Sampling for external analysis:

When taking a sample of boiler water it is important to ensure that it is
representative. It is not recommended that the sample be taken from level gauge
glasses or external control chambers; the water here is relatively pure condensate
formed by the continual condensation of steam in the external glass / chamber.
Similarly, samples from close to the boiler feedwater inlet connection are likely to
give a false reading.

Nowadays, most boilermakers install a connection for TDS blowdown, and it is

generally possible to obtain a representative sample from this location.

If water is simply drawn from the boiler, a proportion will violently flash to steam
as its pressure is reduced. Not only is this potentially very dangerous to the
operator, but any subsequent analysis will also be quite wrong, due to the loss of
the flash steam concentrating the sample.

Since a cool sample is required for analysis, a sample cooler will also save
considerable time and encourage more frequent testing.

A sample cooler is a small heat exchanger that uses cold mains water to cool the
blowdown water sample.

General Boiler Water Tests:

1. Alkalinity test
2. PH test
3. Chlorides test
4. Phosphates test
5. Total Hardness test
6. Conductivity test

Details of the Common Boiler Water Tests:

Test for Alkalinity
The Alkalinity Test is carried out in two stages:
1)Phenolphthalein Alkalinity Test
2)M-Alkalinity
P- Alkalinity Test (CaCO3)
Purpose:
1.It gives the alkalinity of the sample due to Hydroxides and Carbonates.
2.It gives warning against high concentration of sodium hydroxides and subsequent
damage to the boiler from caustic embitterment.
Procedures:
1.Take a 200 ml water sample in the stopped bottle.
2.Add one P- Alkalinity tablet and shake or crush to disintegrate.
3.If P-Alkalinity is present the sample will turn blue.
4.Repeat the tablet addition, one at a time (giving time for the tablet to dissolve),
until the blue colors turns to permanently yellow.
5.Count the number of tablets used and carry out the following calculation:
P-Alkalinity, ppm CaCO3 = (Number of tablets x 20) – 10
e.g. 12 Tablets = (12 x 20) – 10 = 230 CaCO3
6.Record the result obtained on the log sheet provided, against the date on which
the test was taken.
7.Retain the sampler for the M-Alkalinity.
M-Alkalinity Test
Purpose:
1.It gives alkalinity due to bicarbonates, includes the bicarbonates formed during
the P-alkalinity test.
2.The result warns us against possible formation of carbonic acid inside the boiler
as well as in the steam condensate lines, due to high concentration of bicarbonates.
Procedures:
1.To the P-Alkalinity sample add one M. Alkalinity tablet and shake or crush to
disintegrate.
2.Repeat tablet addition, one at a time (giving time for the tablet to dissolve), until
the sample turns to permanent red/pink.
3.Count the number of tablets used and carried out the following calculation: M-
Alkalinity, ppm CaCO3= (Number of P. & M. Tablets x 20) – 10 e.g. If 12 P. 5 M.
Alkalinity tablets is used.
4.Record the result obtained on the log sheet provided, against the date on which
the test was taken.
PH Test
Solutions of which water forms a part, contain hydrogen ions and hydroxyl ions,
when this are present in equal amounts the solution is said to neutral. When there is
an excess of hydrogen ions it is acid, and when an excess of hydroxyl ions it is
alkaline. Keeping the water in slightly alkaline condition reduces corrosion. The
level of acidity or alkalinity is usually express in terms of pH Value. This is
basically a measure of the hydrogen ion concentration in the solution; for
convenience the very small values involved are express in terms of the logarithms
of their reciprocals.
PH = Logarithm of the reciprocal of the Hydrogen Ion in the solution
It should be noted that as the reciprocal is being use, the pH value increases as the
actual hydrogen ion concentration decreases.

PH Value (Reciprocal or Hydrogen Ion) Test

7.5 – 14.0 for Boiler Water
6.5 – 10.0 for Condensate Water
Purpose:
1. To give warning on acidity or alkalinity of boiler water sample.
2. Result help to establish the dosage of boiler compound to fight against
corrosion.
Procedures:
1.Take a 50 ml sample of the water to be tested in the plastic sample container
provided.
2.Using the white 0.6 gram. Scoop provided, add one measure of the pH reagent to
the water sample, allow dissolving – stirring if required.
3.Select the correct range of pH test strip and dip it into the water sample for one
minute.
4.Withdraw the strip from the sample and compare the color obtained with the
color scale on the pH indicator strips container.
5.Record the pH value obtained on the log sheet provided, against the date on
which the test was taken.
Chloride ppm CI Test
Purpose:
1. Gives warning against any seawater contamination of the Boiler Feed System.
2. Help to establish an effective blow down control of the boiler.
Procedures:
The range of chloride to be tested determines the size of water sample used. The
higher the chloride level, the smaller the size of water sample used – this saves
tablets. E.g. for Low Chloride Levels use 100 ml. water sample. For Higher
Chloride Levels 50 ml water samples.
1.Take the water sample in the stopper bottle provided.
2.Add one Chloride tablet and shake to disintegrate. Sample should turn yellow if
chlorides are present.
3.Repeat tablet addition, one at a time (giving time for the tablet to dissolve), until
the yellow color changes to permanent red/brown.
4.Count the number of tablets used and perform the following calculation:
For 100 ml Water Sample: Chloride ppm = (Number of tablets x 10) – 10 e.g 4
tablets = (4 x 10) – 10 = 30 ppm chloride
For 50 ml Water Sample: Chloride ppm = (Number of tablets x 20) – 20 e.g 4
tablets = (4 x 20) – 20 = 60 ppm chloride
For small steps of ppm chloride use a larger sample.
For larger steps of ppm chloride use a smaller sample.
5.Record the pH value obtained on the log sheet provided, against the date on
which the test was taken.
Phosphate ppm Test (PO4)
Purpose:
1.It helps to maintain a phosphate reserve in the boiler to counter any possible
contamination of the boiler water by corrosive and scale forming salts. However,
too much phosphate in the boiler may also contribute to foaming and priming.
Procedures:
1.Take the comparator with the 10 ml cells provided.
2.Slide the phosphate disc into the comparator.
3.Filter the water sample into both cells up to the 10 ml mark.
4.Place one cell in the left hand compartment.
5.To the other cell add one Phosphate tablet, crush and mix until completely
dissolved.
6.After 10 minutes place this cell into the right hand compartment of the
comparator.
7.Hold the comparator towards a light.
8.Rotate the disc until a color match is obtained.
9.Record the result obtained on the log sheet provided, against the date on which
the test was taken

Some common boiler problems are described below:

Fires
Cleanliness of the heat recovery surfaces after the boiler can often be judged by
observing the gas pressure differential above and below. Any significant rise in this
value should be attended to. Whilst good combustion conditions will minimise the
risk, deposits allowed to accumulate in this area are a fire risk and, should fire take
hold undetected, it can prove impossible to control and can wreck the heat
exchanger, or even the whole boiler. There is plenty of evidence of soot fires
leading on to hydrogen fires.
Soot Fires
The ignition of an accumulation of soot, rich in carbon, caused by poor combustion
either in port or when operating at low power for prolonged periods, can when
supplied with the necessary oxygen be the source of a fire sufficiently intense to
melt and burn steel. Air heaters, with their thin steel plates or air tubes and an
abundance of oxygen, can, unless kept clean, be very susceptible to this kind of
damage.
Hydrogen Fires
Instances have occurred in which the tubes of watertube boilers, superheaters,
economisers and exhaust gas heat exchangers have, as a result of an intense fire,
literally melted and run away in streams. Sometimes in the case of vertical tubes,
they have melted and flowed back into their headers to solidify. According to the
engineers who investigated these cases, the fires were subsequent to the
overheating of tubes which were short of water or steam.
Reasons of ‘hydrogen’ fire in a watertube boiler or exhaust gas heat exchanger:
In the watertube boiler the importance of always ensuring an adequate steam
circulation through superheaters has already been mentioned, and cannot be
overstressed. Additionally, the firing rate, actual location of the superheater in the
boiler, the inner and outer surface cleanliness and condition of the superheater
tubes, and possible maladjustment of the burner equipment causing ‘flaming
through’ screen tubes, can all influence the likelihood of severe overheating of
these tubes.

When overheating of a superheater due to insufficient steam circulation is very

severe, the tube material may ignite at about 700°C and, burning in the steam,
produce free hydrogen. The iron will continue burning independently of any
supply of oxygen from the air, and the hydrogen produced by the reaction will burn
on coming into contact with air. This means that once such a fire has started there
are likely to be two fires burning simultaneously, one, iron burning in steam and
the other, hydrogen burning in air, the combined fire being self supporting and
probably lasting until the supply of steam is exhausted.

The conditions necessary for the initiation of a hydrogen fire fortunately rare
are generally accepted to be as follows:
1. Tube metal temperatures of over 705°C.
2. Tubes with some steam content (usually quiescent or of poor circulation).
3. The presence of a catalyst in the form of a carbon ash.

The extreme importance of adequate steam circulation was vividly demonstrated in

one case where one of the two D type main boilers of a VLCC burnt out. In this
incident, subsequent to a tube burst and reduction of steam pressure in one boiler,
the NR stop valve shut and, before low water level shut off the fuel, a hydrogen
fire started in its steam starved superheater. This white hot fire spread throughout
the boiler melting and burning most of the tubes, and also initiated soot fire in the
air heater. Water wall and screen tube headers were subsequently found to be
blocked solid with plugs of steel which had formed when the molten boiler tubes
and run back into their holes.
In the foregoing incidents with water tube boilers the source of heat responsible for
the overheating has been the boiler burners. Such fires do, however, occur in
finned tube exhaust gas heat exchangers and boiler economisers, where the source
of heat is flue gas with a temperature much too perchance during a soot fire; the
unit concerned is not being circulated, the intense heat of the soot fire, rich in
carbon, may initiate a hydrogen fire and that this, as in the case of boiler
superheater fires, once started, is self-supporting until al steam is exhausted.

It is important, therefore, that boiler economisers and exhaust gas heat exchangers
are kept clean on the gas side to prevent soot fires, and that if defective are either
bypassed on the gas side, or if not bypassed have their defective sections properly
blanked off, drained and vented.

Sometimes, due to tube failure in an economiser if the individual tube cannot be

isolated, or if the failures are of a multiple nature, it becomes necessary to make an
emergency bypass of the economiser on the water side. Ordinarily, the gas
temperature in this zone will not be sufficiently high to cause any distress to the
metal parts, but there will be a fire risk due to the overheating of any deposits on
the tubes. Sootblowers should therefore be operated prior to operation with the
economiser bypassed, a suitable reduced firing rate should be established and the
gas temperature into and out of the bypassed unit monitored, the plant being shut
down at the first sign of untoward readings. Such events are also known to have
occurred in diesel exhaust gas boilers and, apart from keeping them clean, a
sensible precaution with this equipment is to leave the circulating pump running,
after the engine is shut down, to cool down the unit and to ensure that air is not
admitted until cooler conditions prevail. The only cure is prevention.

Furnace Explosions
Furnace explosions or on a lesser scale ‘blow backs’ generally occur when
volumes of oily vapour and air, present in a furnace in explosive proportions, are
ignited, although sudden admission of air to a fuel-rich burner flame may well
produce the same result. These explosions should not occur in boilers fitted with
automatic sequential controls, as these, apart from controlling the fuel to air ratio
also ensure adequate purging before ignition.
Even in the best designed system, however, automatic light-up failures do occur,
and it is then, when going over to manual control, often in a hurry that the wrong
action is sometimes taken, resulting in an explosion. Failure to obtain ignition at
the first attempt must be followed by adequate purging.

Explosions in watertube boilers with their large capacity furnaces can, be a serious
occurrence, often involving the loss of lives. These explosions usually occur when
steaming conditions are not stabilised, as for instance during a vessel’s fitting-out
period when steam is intermittently required for testing auxiliaries. At such times
the operation of the boiler is sometimes a divided responsibility, and may well be
under manual control without all its safety devices completely installed.

Boiler operation should always be the responsibility of one qualified engineer who
full appreciates, from the furnace explosion aspect, the vital necessity of adequate
pre-ignition purging, and who is aware of the possibility; especially with
membrane walled boilers, of a serious furnace explosion pulling tubes out of drums
and disgorging the boiler contents into the engine room.

Laying-up Boilers
During idle periods precautions have to be taken to protect boiler internal surfaces
against corrosion. Two methods are in common use dependant on the length of lay-
up.
For short periods up to say a maximum of one month, the boiler, superheater
desuperheater and economiser, with all valves and cocks shut, are completely filled
with hot distilled de-aerated alkaline water – daily checks subsequently being made
to ensure that fullness and alkalinity are maintained.

In the second methods, used when longer lay-ups are envisaged, the boiler,
superheater, desuperheater and economiser are completely dried out using heating
stoves in the drums and hot air through the tubes. When dry valves and cocks are
shut tight, all doors replaced (using new joints) and the boiler hermetically sealed –
trays of a drying agent such as ‘silica gel’; usually being inserted before sealing up.
In the case of auxiliary boilers which operate under intermittent steaming condition
corrosive conditions are likely to occur both internally and externally unless
precautions are taken during their off periods.

A method frequently used, always assuming steam is available from another source
is to embody simmering coils in their water drums. The use of such coils enables a
slight pressure to be maintained in the off duty auxiliary boiler, thus eliminating
the risk of air ingress, and the gas side is kept warm and dry.

Tube Failures:
Tube failures can occur at very inopportune moments, renewals are costly and a
ship may be delayed; it is of the utmost importance, therefore, when active pitting
at present, that its cause is established and obviated. In most cases, having
established the cause and satisfied oneself regarding the internal condition of the
tubes, it is an advantage to chemically clean the boiler so that any oxide scabs
covering pits are removed, prior to re-steaming the boiler under corrected water
treatment conditions.

While examining steam drums internally attention should be paid to the condition
and fastenings of any fittings not removed for access purposes – internal pipes to
desuperheaters, internal feed pipes, low-water pipes, low-water alarms and in
particular steam driers.

The problems associated with furnace refractory materials, particularly on vertical

walls, have resulted in two water-wall arrangements without exposed refractory.
These are known as ‘tangent tube’ and ‘monowall’ or ‘membrane wall’.

Fig 2.
Tangential and monowall arrangement

In the tangent tube arrangement closely pitched tubes are backed by refractory,
insulation and the boiler casing. In the monowall or membrane wall arrangement
the tubes have a steel strip welded between them to form a completely gas-tight
enclosure. Only a layer of insulation and cladding is required on the outside of this
construction.

The monowall construction eliminates the problems of refractory and expanded

joints. However, in the event of tube failure, a welded repair must be carried out.
Alternatively the tube can be plugged at either end, but refractory materials must
be placed over the failed tube to protect the insulation behind it. With tangent tube
construction a failed tube can be plugged and the boiler operated normally without
further attention.

Sometimes it is difficult to find the failed tube, in an exhaust gas boiler with
closely fitted finned tubes for example, a method, which has found success, is
ultrasonic detection.
Equipment required is a microphone pickup, connected to an oscilloscope.
• Pressurise the tube stack and headers with air.
• Enter the gas space with the microphone pick up.
• Go round the tube stack with the microphone.
• The maximum air hiss will give the maximum deflection on the oscilloscope.
• The leaking tube will be in that area.
Temporary Repairs To Membrane Or Monowalls At Sea (Ships’ Personnel)
The method of tube repair used in an emergency at sea would depend principally
on whether a competent welder and machine are available. If not, the suitable plugs
or expandable blind nipples for each of the failed tubes, should be available and
also a supply of protective refractory to prevent subsequent burning through of the
casing in way of the blanked-off tube.

(a) Welded repairs:

Welded repairs are usually of a patch nature and have the advantage that as the
tube remains in use it is not necessary to protect it with refractory. A butt welded
patch is preferable, but as this, and also any internally fitted patch, are liable, in the
hands of an inexperienced welder, to result in weld splatter entering the tube bore,
it is safer for a quick temporary repair to rely on an external fillet welded patch.
For repairs of this nature the defective part of the failed tube is cut back to sound
material and then a patch piece, preferably cut from a tube having bore equal to the
outside diameter of the failed tube, is filet welded over the removed section of the
failed tube – the overlap being kept small to prevent subsequent overheating when
in service. Subject to a satisfactory hydraulic test on completion such a repair
should allow the vessel to reach a port where permanent repairs can be effected
(see below).
Fig 3.
Permanent welded repair

(b) Mechanical repairs:

If a welded repair is impracticable the tube may be plugged at both ends providing
the tube is subsequently protected by refractory to prevent local burning of tubes
and possible the boiler casing.

Various mechanical plugging methods have been devised by the boiler designers,
but lack of internal access and the high temperatures appertaining at shut down can
make this an extremely unpleasant and/or lengthy operation. Two methods are
described below:

Fig 4.
Permanent Mechanical repair
(Source: Seamanship International PC CD-ROM Engineering Knowledge)

Method 1. Windows are cut in the tube about 62mm from its extremities through
which wires with taper plugs attached can be pulled the taper plugs having been
inserted into the headers via the inspection doors. The plugs are pulled into
position through pieces inserted across the windows, and are then pulled up solids
by nuts.

After both ends of the tube have been plugged in this manner the whole length of
the defective tube and the boiler casing behind it are shielded from the furnace heat
during subsequent steaming by a thick shield of plastic refractory.

Method 2. Again windows are cut at each end of the tube through which blind
nipples are inserted and subsequently expanded.

It will be appreciated that in this method boiler pressure tends to blow the plugs out
whereas in Method 1 boiler pressure tightens the plugs in the hole. It is important
to ensure therefore that with this method the expander rollers project down the bore
of the nipple beyond the header or drum thickness so that an internal anti blow-out
‘collar’ is formed on the nipple during expanding; as a double precaution special
‘stepped’ roller can be used to form this collar.

As in Method 1, the whole length of the failed tube has subsequently to be shielded
from the furnace heat.

Repairs To Membrane Or Monowalls In Port

The type of repair whether accepted as permanent or semi-permanent will depend
largely on the availability of welders skilled in this type of work.
Inserting a new section
The obvious and most straightforward permanent repair consists of cutting out the
defective length of tube along with part of its adjoining membranes and butt
welding in a new section. This repair entails the services of skilled welders, the
removal of casing and refractory in way of the repair, and accurate weld
preparation.
Fig 5.
Insert repair
(Source: Seamanship International PC CD-ROM Engineering Knowledge)

It is important to note that unless welders skilled in the type of repair are available,
the surveyor should insist that the welders being employed do a preliminary
procedure test to his satisfaction.

Fish mouth tube replacement method

Fig 6.
Fish mount tube replacement method
(Source: Seamanship International PC CD-ROM Engineering Knowledge)

This method, when carefully executed, is also acceptable as a permanent repair and
has the advantage that as all welding is done from the furnace it is not necessary to
disturb the boiler casing and refractory.

The defective part of the tube along with part of its adjoining membranes are burnt
out, as in the previous method. The replacement piece of tube is prepared with its
top and bottom ends cut off at 45° to give access when the replacement is in
position for welding, from the furnace, the rear part of the two circumferential butt
welds.

When these rear parts of the circumferential welds have been satisfactory
completed, wedge-shaped pieces of tube are welded into the two windows, and the
circumferential butt weld then complete working from the outside. The membranes
are subsequently closed by welding as in the previous method.

The configuration of the wedge pieces can be varied to suit tube diameter and
access required and, if necessary, backing rings may be used.

The loose ring method

Fig 7.
Loose ring method
(Source: Seamanship International PC CD-ROM Engineering Knowledge)
In ports where it is doubtful whether the experience of the welders justifies their
employment on the previous two methods of repair, it is possible by this ‘loose
ring’ method, to make an acceptable repair of a semi-permanent nature using down
hand welding.

In this method access has to be made all around the tube and loose rings with
cupped upper surfaces are slid into position in way of the butts to be welded, so
that an inexperienced welder has a better chance of making a butt cum fillet joint.
In all other aspects the repair is as in the previous two cases.

In view of the extra metal thickness in way of the rings and possible build up of
weld metal this repair could subsequently be the subject of overheating in service,
and on that account the repair should only be regarded as semi-permanent.
Testing
On completion of any of the foregoing repairs whether temporary or permanent,
the boiler should be subjected to a working pressure hydraulic test. In the case of
the repairs effected in port the welds should be crack detected and, if possible, X-
ray detection equipment should be used.

Exhaust Gas Boilers:

o About 30% – 34% of Fuel Energy input to engine are discharged to Exhaust
Gas, as Thermal Energy.
o This thermal energy is converted into useful work in Exhaust Gas Boiler.
Cochran Exhaust Gas Boiler:
1. A double-pass, vertical type, in which Exhaust gases from ME pass through 2
banks of tube.
2. Served as an efficient silencer, when the boiler is in use.
3. A separate Silencer, always fitted along with exhaust gas boiler, to be used when
the boiler is generating more steam than required.
4. All or part of exhaust gases can be directed to the Silencer and atmosphere,
without going through the boiler.
5. Working Pressure is around 7 bars.
Composite Boiler (Composite type Cochran boiler):
1. If Exhaust Gases and Oil fire can be used at the same time, it is termed
Composite Boiler.
2. In double-pass, composite type Cochran Boiler, it provides a separate tube nest
for exhaust gas passage, situated immediately above the return tube nest from Oil-
fired Furnace.
3. Exhaust gases from Oil-fired Furnace and ME; pass through the tubes, which are
surrounded by boiler water.
4. Separate Uptakes provided for Exhaust Gases and Oil-fired Smoke.
5. Heavy Changeover Valves are fitted, to divert the gases straight to the funnel,
when desired.

Alternative Boiler: (Alternative type Cochran boiler)

1. If Exhaust Gases and Oil fire can be used only one at a time, it is termed
Alternative Boiler.
2. Double-pass, Alternative Cochran Boiler, can be oil fired and heated by exhaust
gases alternatively.
3. Since both systems use the same Combustion Chamber, one system required
being blank, while the other is in operation.
4. Only one Uptake required.
Economiser as Exhaust Gas Boiler:
1. In this system, a separate Exhaust Gas Economiser EGE is connected to an Oil-
fired Auxiliary Boiler (or an Accumulator) by means of piping and a set of
Circulating Pumps.
2. Heat absorbed from exhaust gas in EGE is transmitted by working fluid, to
Auxiliary Boiler or Accumulator, from which steam is drawn for use.
3. Economiser unit cannot deliver steam, directly to steam range.
4. Straight gas lead from ME Exhaust Manifold, pass through EGE under the
Funnel, and this arrangement permits the Auxiliary Boiler or Accumulator, to be
placed in any convenient position in ER.
5. Inlets and outlets of piping coils are connected to External Headers [Distributing
and Collecting], that are simply inserted in Exhaust Trunk way.
6. Water from Auxiliary Boiler or Accumulator is fed by Circulating Pump through
a Non-Return Valve into Distributing Chest or header and from it, water passes
into Coils.
7. Water and steam from outlets of these Coils pass into Collecting Header, and
then to the steam space of Auxiliary Boiler or Accumulator.
8. EGE Safety Valve is adjusted at slightly higher pressure than Safety Valves of
Auxiliary Boiler; in order to ensure that Economiser operates in flooded condition
at all times.
EGE out of order:
1. Isolate the EGE.
2. Wash down the economiser tubes and completely dried.
3. Drain all water content.
4. Start the auxiliary boiler.
5. Maintain low steam consumption.
6. Proceed to next port with suitable speed.
7. Write down damage report.
Exhaust Gas Boiler Safety Valve setting:
1. EGE safety valves to be set under full load steaming condition, if Surveyor
delegates the responsibility to CE.
2. Setting pressure ≯ 3% above max: working pressure.
3. In doing so, EGE steam pressure control is done as follows:
EGE steam pressure controls:
1) Steam control: By providing Dumping Valve in by-pass system, to Condenser.
Excess steam can be discharged into Condenser.
2) Water control: By shutting the inlet valve to boiler coils.
3) Exhaust gas control: By controlling the Exhaust Gas Damper.
Boiler Safety Devices as for UMS status:
1. Flame failure: (Photocell shut down combustion system and gives alarm.)
2. Low and high water level: (Level is maintained by feed pump, controlled by
float
operated on/off switch.)
3. Low and high Steam pressure: (If steam demand drops, high steam pressure
will
shut down burner and/or ME speed reduced. Low steam pressure
alarm, will be given if there is fault in combustion condition)
4. Fuel temperature: (Deviation from set temperature range, cause burner to be
shut
off and alarms given for both low and high temperature.)
5. Fuel pressure: (Low fuel pressure cause automatic controller to shut down
burner and alarms given.)
6. Smoke density: (Emitted smoke through uptake, being monitored and if deviate
from normal limit, shut down the system and alarm given.)
7. Air / fuel ratio: (Air register damper controller keeps correct ratio, and shut
down
the system and alarm given on deviation.)
8. Draught fan failure: (Air supply fan failure operate audible and visual alarms.)
9. Very low water level: (Burner stopped and alarms given.)
10. Very high water level: (Burner stopped or ME slow down and alarms given to
avoid foaming and carry over.)
11. High flue gas temperature: (Burner stopped and alarms given.)
Safety Devices on Boiler:
1. Flame failure alarm
2. Low water level alarm.
3. Very low water level alarm and cut-off.
4. High water level alarm
5. Low steam pressure alarm
6. Low oil temperature alarm and cut-off
7. High oil temperature alarm and cut-off
8. Low oil pressure alarm and cut-off.
9. Force Draught Fan failure alarm and cut-off.
10. Power failure alarm.
11. Safety Valves.
12. Gauge Glass.
13. Easing Gear.
Mountings on Boiler:
1. Safety Valves
2. Easing Gear.
3. Gauge Glass.
4. Pressure Gauge.
5. Feed Check Valve.
6. Flame Eye.
Open-up Procedure:
1. Stop firing and cool down.
2. All steam valves tight shut.
3. Blow down until empty. [ Ship-side Cock opened first, then gradually open
Blow-down Valve. When loud noise dies down and blow-down pipe becomes cold,
boiler is about empty. Blow-down Valve shut and then shut Ship-side Cock.]
4. Easing Gear lifted.
5. Open Air Vent Cock, Salinometer Cock and Drain Cock of water Gauge Glass,
to let air enter. Ensure no vacuum and only atmospheric pressure inside, before
knocking in the manholes.
6. Slacken dog-holding nut of Top Manhole door, break the joint, from the place
safe from blast as a safeguard against scalding, and then nut removed and door
taken out.
7. When knocking in the Bottom Manhole door, use crowbar and stand back when
breaking the joint, as there may be hot water left.
8. Mud holes and all other doors open-up for cleaning, both smoke side and
waterside.
9. Allow the boiler to be ventilated before entry.
Boiler Internal Inspection: [For Survey]
1. After normal open-up procedure, allow the boiler to ventilate.
2. Initial internal inspection is done before cleaning, for general condition and
any special deposited area.
3. Plugged Blow-down hole to prevent choking.
4. Cover Manhole door’s landing surface to prevent damage.
5. Final internal inspection done after thorough cleaning:
a) Check level gauge connections for blockage.
b) Check securing system of internal pipes and fitting.
c) Hammer-test furnace, fire and stay tubes.
d) Check firebrick, casing, baffles and welding seams.
e) Tubes checked for leak, crack, distortion and bulging
f) Check fireside is clean, without soot.
g) Cleaning and inspection of Manhole doors, joint landing surfaces.
h) Use new joints.
Refitting Procedure:
After Internal Survey:
1. Remove plug at blow-down pipe.
2. Box back all manholes and mud doors with new joints, and refit all mountings.
3. Open Air Vent Cock, and boiler filled-up with water up to ¼ of Gauge Glass
level. ( If hydraulic test is required, fill-up completely.)
4. Normal flash-up procedure follows.
5. Pressure setting of Safety Valves, under steaming condition, with Surveyor’s
presence.
Safety Valves:
Function:
1. Must open fully at definite pressure, without preliminary simmering.
2. Must be still opening until pressure in boiler has dropped to a certain definite
value, not more than 4% under set value.
3. Must close tight without chattering.
4. Must close tightly without leaking.
Setting of Safety Valves:
1. Take Standard Pressure Gauge for accuracy.
2. Fill up water up to ¼ of Gauge Glass level, and shut Main Stop Valve, Feed
Check Valve.
3. Without Compression Rings, Hoods and Easing Gears, reassembled the Safety
Valves with spring compression less than previous setting.
4. Raise boiler pressure to desired blow-off pressure.
5. Screw-down Spring Compression Nuts of any lifting valves, until all are quiet.
6. Adjust each valve in turn:
a) Slacken Compression Nut until valve lifts.
b) Screw-down Compression Nut sufficiently enough, so that when valve spindle
is lightly tapped, valve returns to its seat and remain seated.
c) Measure gap between Compression Nut and spring casing.
d) Make a Compression Ring equal to this gap, and insert under Compression Nut.
e) Gag the Spindle of this Safety Valve, to prevent opening, while remaining valve
is being set.
7. Remaining valve is again set and insert Compression Ring.
8. Remove gag and retest both valves to lift and close together.
9. Caps and Cotter Pins padlocked.
10. When the Surveyor satisfied the setting pressure, Easing Gear should be tested.
11. All Safety Valves set to lift at ≯ 3% above approved working pressure (design
pressure).
Accumulation of Pressure:
1. Pressure is liable to rise after Safety Valves have lifted, caused by increased
spring load due to increased compression.
2. This rise in pressure is known as “Accumulation of Pressure”. {OR}
3. Pressure rise in excess of Working Pressure is termed, “Accumulation of
Pressure”.
4. Accumulation of pressure test is carried out to see whether this safety valve is
suitable or not for this boiler. Pressure rise after safety valves have lifted, must not
exceed 10% of working pressure.
5. Tested when safety valves are new or boiler is new or safety valves and boiler
are new ones.
Safety Valve on EGE and Economiser:
1. Slightly higher set pressure than drum Safety Valves.
2. It is to ensure operation under flooded condition at all times.
Hydraulic Testing of Boiler:
Necessary condition:
1. Boiler internal inspection is not satisfactory.
2. Surveyor demanded.
3. After structural repairs of boiler.
Requirement:
1. Surveyor must be present.
2. Gag the Safety Valves.
3. Close all opening.
4. Blanks inserted at Main Steam Stop Valve and Gauge Glass.
5. Measuring tape placed around boiler to check bulging.
6. Deflection gauge placed in the furnace.
7. Remove lagging to check leak points.
Procedure:
1. Open vent cock, fill boiler with warm water completely, until water overflows
from vent cock, and close the vent cock.
2. Attach force pump and test pressure gauge.
3. Apply water pressure, 1.25 times of approved working pressure, for not more
than 10 minutes.
4. If satisfied, Surveyor will stamp on bottom front plate near the furnace.
Chemical Treatment:
Two ways of treating the water for boiler use:
1. External Feed Water treatments.
2. Internal Boiler Water treatment.
External Feed Water Treatment:
Purpose:
1. To reduce TDS in feed water.
2. To arrest Suspended Solid Particles.
3. To reduce Dissolved Gases.
4. To prevent feed water system corrosion, by maintaining correct pH value of feed
water.
Treatments:
1. To reduce TDS, the best way is to use evaporated feed water.
2. To arrest Suspended Solids, use feed line filters.
3. To reduce Dissolved Gases, inject Hydrazine and maintain Hot Well
temperature between 60~70°C to promote O₂ deaeration through hot well vent.
4. To prevent feed water system corrosion, use Salinometers on feed line or
Evaporator outlet. Maintain pH value by dosing Hydrazine or Amine.
Internal Boiler Water Treatment:
Advantages:
1. Precipitate Calcium and Magnesium salts, into non-adherent, harmless sludge.
2. Prevent these salts, from baking on boiler heating surfaces.
3. Sludge is blown-down from boiler.
4. Treatments also remove Dissolved Oxygen, Dissolved Gases, and CO₂, to avoid
their corrosive actions.
Treatments for Moderately Rated Auxiliary Boiler:
[Medium and Low Pressure Boilers]
(1) Phosphate Treatment:
1. AGK 100 or Adjunct B is used.
2. Combat scale-forming salts to form non-adherent sludge.
3. Give Alkalinity to reduce corrosion.
4. Form Iron Phosphate Film on internal surfaces, as protection against corrosion.
(2) Caustic Soda Treatment: [NaOH]
1. Maintain correct pH value and required Alkalinity.
2. Precipitate scale-forming Permanent Hardness Salts. [Chlorides and Sulphates of
Calcium and Magnesium: They are in Acid nature. ]
3. Remove Temporary Hardness Salts. [Bicarbonates of Calcium and Magnesium:
They are slightly in Alkaline nature.]
4. Excess concentration of NaOH may cause Caustic Cracking of metal.
(3) Soda Ash Treatment: [Na₂CO₃]
1. Precipitate scale-forming Permanent Hardness Salts, (Non-Alkaline Hardness
Salts) as Calcium Carbonate, CaCO₃.
2. Produce NaOH, to give required Alkalinity.
(4) Dissolved Oxygen Treatment:
1. Two chemicals, Hydrazine N₂H₄, and Sodium Sulphite Na₂SO₃ are used to
remove dissolve O₂.
(5) Liquid Coagulant Treatment:
1. High molecular weight, colourless solution, likes Sodium Aluminate or Starch is
used.
2. Coagulate oil droplets and Suspended Solids, and settle them at low points.
3. They can be Blown-down.
(6) Blow-Down Treatment:
1. Integral part of water treatment program, as it removes solids, which are results
of chemical conversion of salts and impurities in water.
2. Surface Blow-down or Scumming is quick removal of solids, without wasting
feed water.
3. Bottom Blow-down is vital, when solids become dense, heavy and remain at
boiler bottom, despite circulation.
4. Daily short blows of top and bottom are necessary.
Boiler Laying up Procedure:
(Boiler may be laid up wet or dry.)
Wet Method:
1. When laid up in warm climate, boiler is filled with water until it comes out from
air vent.
2. Then the boiler is sealed off.
Dry Method:
1. Boiler is emptied and cleaned thoroughly on both fire and waterside.
2. Corroded parts, wire brushed and coated with anti-corrosive paint.
3. Shallow metal trays filled with quicklime should be placed in both water and fire
space.
4. Then boiler is closed up airtight.
Proper Maintenance of Boiler:
Water Side:
o Daily boiler water test.
o Boiler water treatment.
Gas Side:
o Regular cleaning.
Combustion System:
o Fuel pressure, temperature and viscosity correct values maintained.
o Burner maintenance.
o Air register, Air damper and forced draught fan.
Caustic Cracking or Embrittlement of metal:
1. Caused by excess concentration of Sodium Hydroxide, NaOH [Caustic Soda] in
boiler water, and the material under stresses.
2. Ratio of Na₂SO₄ to NaOH should be maintained 2 : 5.
3. Caustic Soda is used for boiler water treatment, to maintain correct pH value and
required alkalinity, so excess concentration should be avoided.
4. Excess concentration of NaOH may be from Overdosed Chemical and Leakage.
5. Damage occurs to riveted seams, tube ends and bolted flanges.
To prevent Caustic Embrittlement:
1. Sodium Sulphate, Na₂SO₄ should be dosed, to give protective layer.
2. Ratio of Na₂SO₄ : NaOH should be maintained at 2 : 5
Turn Down Ratio of Burner:
1. The ratio of maximum to minimum oil throughput of the burner.
2. In case of pressure jet burner, this can be stated in terms of square root of the
ratio of maximum to minimum oil supply pressure.
3. Large Turn Down Ratio of up to (20: 1) is available with blast jet burner,
without having resort to unduly high pressure.
Foaming:
Formation of thick layer of steam bubbles, on top of water surface inside boiler.
Priming: Rapid carry-over of large amount of water, in steam as it leaves the
boiler.
Carry-over: Carry-over of small amount of water, in steam as it leaves the boiler.
Causes:
1. Higher water level than normal
2. High amount of TDS, total dissolved solids
3. High amount of suspended solids
4. Contamination by oil and other organic substances
5. Forcing the boiler
Effects:
1. Water hammer
2. Contamination and scaling
3. Fluctuation of working water level
Boiler :
Boiler Automatic Burning System:

1. With correct water level, steam pressure transmitter initiates cut-in at about 1.0
bar below working pressure.
2. Steam pressure transmitter initiates Master Relay to allow ‘Air On’ signal to
force draught fan.
3. Air feedback signal confirms ‘Air On’ and allows 30-sec. delay for purge
period.
4. Then Master Relay allows Electrode to strike ‘Arc’.
5. Arc striking feedback signal confirms through electrode relay and allows 3-sec.
delay.
6. Then Master Relay allows burner solenoid valve for ‘Fuel On’ operation.
7. Fuel On feedback signal allows 5-sec. delay to proceed.
8. As soon as receiving Fuel On feedback signal, Master Relay checks ‘Photocell’,
which is electrically balanced when light scatter continuously on it.
9. Result is OK and cycle is completed.
10. If not, fuel is shut-off, Alarm rings and cycle is repeated.
11. Steam pressure transmitter initiates cut out automatically at about 1/15 bar
above W.P.

Accumulation Pressure Test:

1. Required for new boiler or new safety valve.

2. Tested under full firing condition.
3. Feed Check valve and Main Stop valve shut.
4. Test is to be continued as long as water in the boiler permits, but 7 minutes for
Water tube Boiler and 15 minutes for Cylindrical Boiler.
5. With Safety Valve opening, Boiler pressure must not accumulate to exceed 10%
of Working Pressure.

Difference Between Safety Valve and Relief Valve:

1. Safety valve fully open at set pressure. Start open at set pressure. But relief
valve fully open at 15 – 20% above set pressure.
2. Safety valve close at set pressure. But the relief valve close below set pressure.
3. Safety valve relieve excess mass. But the relief valve relieve excess pressure.
4. Safety valve can open manually but relief valve cannot open manually.
5. Safety valve set to open 3 % above WP but the relief valve set to open 10 %
above WP.

Waste Heat Recovery System

oThe use of exhaust gas from main engine to generate steam is means of heat
energy recovery and improved plant efficiency.
o In ME ≯ 40 % of fuel consumed is converted into useful work, and 30 – 34
% of remaining energy contain in Exhaust Gas.
Waste Heat Recovery System is employed as:

1. Composite boiler system.

2. Two separate boiler system ( One oil fire and one ordinary coil type exhaust gas
boiler)
3. Tubular type heat exchanger system ( One oil fire and one tubular economizer)
4. Separate steam receiver system ( Two duel pressure boiler and one economizer)
5. Advanced waste heat system (Exhaust gas economizer with 3 separate sections).

Why boiler water test carried out?

1. To know boiler water condition.

2. To control chemical treatment and blow down.
3. To prevent scale formation, corrosion and impurities.
4. To prevent damage to steam operated equipment and condensate line.
5. To maintain alkaline condition.
6. To improve boiler efficiency.
Boiler Water Test:

1. Chloride Test.
2. Excess Phosphate Test.
3. Total Dissolved Solid Test (Conductivity Test).
4. pH value Test.
5. Hydrazine Test.
6. Alkalinity Test: ‘P’ Alkalinity (Phenolphthalein) and ‘M’ Alkalinity (Methyl-
orange) and Total Alkalinity

Proper Sample:

1. Sample line is usually located in steam drum, just above the tubes and as far as
possible from chemical feed line.
2. Sample water is taken at water surface, since highest concentration is at this
point.
3. Sample water is cooled down to about 25°C.
4. Flush out sample stream for 5 minutes before taking.
5. Test apparatus should be cleaned with sample water.
6. Sample water is tested as soon as possible after drawing.

Alkalinity Tests:

1. ‘P’ Alkalinity finds presence of Hydroxyl, Phosphate and half of Carbonates,

excluding Bicarbonates.
2. ‘T’ Alkalinity gives total quantity of all Alkaline Dissolved Salts in boiler water.
3. ‘M’ Alkalinity finds presence of remaining Carbonates and Bicarbonates.
4. Total Alkalinity is < 2 x ‘P’ Alkalinity. 5. Desired value is 150 – 300 ppm for
‘P’ Alkalinity. Increase of Alkalinity Level: Causes: 1. Alkalinity treatment has
been done recently. 2. Using of Alkaline rich makeup feed water. 3. Incorrect
strength of reagent used. Effect: Caustic Embrittlement. Decrease of Alkaline
Level: Causes: 1. Feed water is contaminated with acid. 2. Direct water loss from
boiler. 3. Incorrect strength of reagent used. Effect: Corrosion. Chloride Test: 1.
Gives quickest indication of any salt-water leakage into boiler. 2. Must be carried
out daily. 3. Chlorides of Calcium, Magnesium and Sodium are extremely soluble.
4. Chloride level is proportional to TDS level in boiler water. 5. Rate of blow-
down is governed by chloride level. 6. Chloride Level should be 0 – 300 ppm, and
blow-down if > 300 ppm.

Increase of Chloride Level:

Causes:
1. SW leaking into system.
2. Incorrect strength of reagent used. (Silver Nitrite and Potassium Chromate).
3. Due to treatment chemical and hardness salt reaction.

Effects:
1. Increase in TDS level causes Foaming/Priming.
2. Drop in Alkalinity causes Corrosion.

Phosphate Test:

1. Presence of Phosphate in sample means no hardness salts.

2. Na₃PO₄ added to boiler water, precipitate all scale forming hardness salts of
Calcium and Magnesium.
3. With Phosphate Test done, no need to do Hardness Test.
4. Phosphate ppm of 20 – 40 is satisfactory, and blow-down if > 40 ppm.

pH value Test:

1. Once Alkalinity Test is done, no need to check pH value, since Alkalinity and
pH value are proportional.
2. Litmus Strip is used for quick reference however.
3. pH value maintained at 10.5 – 11.5.

Condensate pH:

1. Condensate pH is measured at Condenser outlet.

2. By theory, it should not be acidic, i.e. (9.5 – 11.5) but practically it is always
less than 9.5.
3. (8.3 – 8.6) is satisfactory.
4. If < 8.3, increase dosage by 25% Condensate Corrosion Inhibitor. 5. If > 8.6,
decrease dosage by 25% Condensate Corrosion Inhibitor.

Hydrazine Test: (for Dissolved Oxygen)

1. Hydrazine ppm maintained at 0.1 – 0.2 ppm.

2. If < 0.1 ppm, increase dosage by 25% hydrazine. 3. If > 0.2 ppm, decrease
dosage by 25% hydrazine.

Types of Boiler Gauge Glass:

1. Fitted directly.
2. Fitted to a large bored bent pipe.
3. Mounted on a hollow column.
4. Fitted to a column with its centre part solid.

Boiler Corrosion:
(1) Electro-chemical Corrosion:

1. Hydrogen ions (H⁺) are generated by acid concentration under hard dense
deposits and can penetrate grain boundaries of tube metal,
2. Hydrogen attack can occur very rapidly, causing the tubes cracked, failed
and ruptured.
3. General wastage occurs when pH value is < 6.5.
4. Pitting (Air Bubble pitting and Scab pitting) occur when pH value is
between 6–10 in the presence of dissolved Oxygen.
(2) Caustic Cracking corrosion:

1. Inter-crystalline cracking occurs when excess concentration of Caustic Soda

(NaOH) in boiler water, comes in contact with steel, under stresses and high
temperature.
2. Metal becomes brittle and weak.
3. Damage occurs to riveted seams, tube ends and bolted flanges.
4. 4. Prevented by dosing Sodium Sulphate (Na₂SO₄) to give protective layer.
5. Ratio of Na₂SO₄ to NaOH should be maintained 2 : 5.

(3) Corrosion by Oil:

1. Animal or vegetable oil decomposed to fatty acid and causes corrosion. 2.

Causes are over lubrication of machinery, leakage of heating coils & inefficient
filtering of feed water. 3. Prevented by Liquid Coagulant Treatment, which
coagulates oil droplets & suspended solids and settle them at low points, and they
can be blown-down.

(4) Corrosion by Galvanic Action:

1. With dissimilar metals in a saline solution, galvanic action results and more
anodic metal corrodes. 2. Corrosion occurs when feed water is contaminated with
salt-water. 3. Prevented by carrying out Chloride Test daily. 4. Chloride Level
should be 0 – 300 ppm, and blow-down if > 300 ppm.

CO₂:
1. Reacts with H₂O to form Carbonic Acid (H₂CO₃) which reduces pH value
(Alkalinity) of feed water and accelerates general type of corrosion.
2. Groovings along the pipe’s bottom, bends & threaded section.

NH₃:
1. Attacks Copper based Alloy, in the presence of O₂