CHAPTER 1

INTRODUCTION

1.1 Project Overview

A steam boiler is a closed container in which fire is used to heat water or other
liquids. The hot steam or steam coming out of this boiler will be used in various processes
or heating uses. There are various uses of the boiler including, used in supplying heat, hot
water, or steam for dosing use, or use for energy generators. it can also be used in vehicles
such as supplying steam to trains, ships or boats. boilers are used as a means of transferring
stored energy from fuel sources to water in boilers and finally to the end user. the use of
boilers is very important in various industrial sectors such as in the timber industry, oil &
gas, palm oil, rubber, plastics, food, energy generators and many other industries. because
boilers are an alternative that can save costs in the industry.

Oil & gas industry

FIGURE 1.1
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Palm oil industry

FIGURE 1.2

Power generation industry

FIGURE 1.3

Plastic industry

FIGURE 1.4
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Types of boilers

1. Boiler water tube

Water tube boiler is a type of boiler where the water circulating in the tube is heated
externally by fire. The fuel burned in the furnace creates hot gas that will heat the
water in the generator steam tube. In smaller boilers, the tube a separate auxiliary
generator in the furnace, while a larger utility boiler relies on a tube filled with water
that forms the wall of the furnace to produce steam. In smaller boilers, the auxiliary
generator tubes are separate in the furnace, while larger utility boilers rely on water -
filled tubes that form the walls of the furnace to produce steam.

The heated water will then rise to the steam drum. Here, compressed steam is drawn
from the top of the drum. In some parts, the steam will return back into the furnace through
an over heater that becomes overheated. Superheated steam is defined as steam that is heated
above the boiling point at a given pressure. Superheated steam is a type of dry gas used to
drive a turbine.

FIGURE 1.5
2. Fire tube boiler

A fire tube boiler is a type of boiler in which hot gas from a fire passes through one or
more tubes that pass through a container covered with water around the tube. The heat
of the gas is transferred through the walls of the tube by heat conduction, heating the
water and eventually creating steam or steam.
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FIGURE 1.6

1.2 Problem Statement

A Problem Statement is a brief, three-part overview of a difficulty or lack and the way
we propose to address that difficulty or lack. The ultimate goal of a problem statement is
to transform a generalized problem into a targeted, well-defined problem - one that can be
resolved through focused research and careful decision-making. In that case, this project
had problem statement for to solve. That the problems are:

1.2.1 Essential 13 Fitting Not Working Properly

In the operation of the boiler there are 13 essential fittings that must be complied
with which are subject to the factories and machinery act 1967 which must be known by
employers and employees. If employers and employees fail to comply will be subject to
legal action.
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1.2.2 Workers Do Not Follow Safe Working Methods During Boiler Start Up

. Boiler start up is done to ensure that the boiler is in a safe condition before fully
operating. The purpose of the start up is to ensure that the boiler works properly and safely.
Boiler start up can also extend the life of the boiler in operation.

1.2.3 Corrosion, Carry Over, And Caustic Attack/Caustic Cracking On The Boiler

Water quality is not treated properly and will cause corrosion, carry over, and
coustic attack/coustic cracking on the boiler. The content of chemicals in untreated water
will also cause damage to the boiler and shorten the operating life of the boiler.

1.3 Project Objective

The objective is once main component in the project to realize that successfully to
achieve. In this project has to objective for achieved and solve that the problem. That the
objectives to achieve are

1.3.1 To Ensure The Boiler Operates Properly And Safely.

Under the factories and machinery act 1967, Section 14 is Boilers must be
constructed and designed safely. This is to ensure that the boiler operates in accordance
with the prescribed act.
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1.3.2 To Start Up The Boiler According To The Safe Working Method.

To operation of the boiler must be tested and must obtain approval/commissioning

from the state DOSH officer. Steam boilers are sensitive machinery. Boilers need to be
well maintained and operated by a competent person with high training and experience

1.3.3 Water Treatment Operation.

The main purpose of water treatment operation is to ensure the quality of water
treated properly will affect the efficiency of operation and maintain the lifespan of the boiler
as well as get quality and clean steam. Water treatment is an important part of boiler
operation. Water treatment operation aims to remove insoluble solutes (TDS)/compounds of
gases contained in water.
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1.4 Scope Of Project.

Each a project has should be a scope for find a goal until completion of project. The
scopes of this project are:

1.4.1 To Ensure Water Gauge Glass Valve Working Properly.

Each boiler must be equipped with 2 gauge glass. to find out the water level in the
boiler. It needs to be opened and serviced to ensure it is not clogged or leaking. It is
important because we must ensure that the water in the boiler is not under the tube.

1.4.2 To Make Annual Inspection.

After 15 months or 18 months the boiler in operation must make an annual

inspection after the operating permit certificate expires. online application to DOSH is
made 3 months before the expiration date.

1.4.3 To Install Economizer.

Economizers are heat exchangers that transfer the heat in the flue gas to another
medium‚ generally the boiler feed-water‚ although other streams are sometimes used such
as make-up water. There are 2 types of economizers non-condensing and condensing.
Usually installed between ducting and chimney. The purpose of the economizer is installed
on the boiler it can also save fuel costs.
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1.5 Project Schedule. (Gantt Chart)

The following information lists several dates for the project. Company will develop
a detailed schedule outlining all of the various design, construction, and closeout tasks
associated with the project and that interfaces with other construction work not under this
proposal

2/2/2021 3/2/2021 4/2/2021 5/2/2021 6/2/2021

Boiler Shutdown
Check Water Gauge Glass Valve
Install Economizer
Annual Inspection
Commissioning & Closeout

1.6 Summary

Boilers have many uses. It can be used in permanent uses such as supplying heat,
hot water, or steam for domestic use, or for generators. It can also be used in mobile uses
such as supplying steam to locomotives in trains, ships, and boats. Boilers are used to
transfer stored energy that comes from the fuel source to the water in the boiler, and
ultimately to the end user.
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