UNIVERSITY OF CAGAYAN VALLEY

COLLEGE OF ENGINEERING

CASE STUDY

ON BOILERS

PRESENTED TO:

ENGR. ROGER AGBISIT JR.

PRESENTED BY:

JAKE B. LOPEZ

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Table of Contents

Page:

I. INTRODUCTION

II. CLASSIFICATION

III. APPLICATION

IV. OPERATION

V. COMMON TROUBLES/PROBLEM

VI. CONCLUSON

VII. REFERENCES

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BOILER

I. INTRODUCTION

Boilers are also known as steam generators; they are a closed vessel in which water is

converted into steam through the application of heat. The steam is used for driving steam engines

or steam turbines for power generation. The steam is also used for producing process steam,

which is used for sizing and bleaching in the textile industry. The capacity of boilers used for

power generation is considerably compared with other boilers.

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The heating surface is any part of the boiler; hot gases of combustion are on one side and water

on the other. Any part of the boiler metal that actually contributes to making steam is heating

surface. The amount of heating surface of a boiler is expressed in square meters. The larger the

heating surface a boiler has, the more efficient it becomes.

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II. CLASSIFICATION

Boilers are classified into different types based on their working pressure and

temperature, fuel type, draft method, size and capacity, and whether they condense the

water vapor in the combustion gases. Boilers are also sometimes described by their key

components, such as heat ex-changer materials or tube design.

Two primary types of boilers include Fire- tube and Water- tube boilers. In a Fire-tube

boiler, hot gases of combustion flow through a series of tubes surrounded by water.

Alternatively, in a water – tube boiler, water flows in the inside of the tubes and the hot

gases from combustion flow around the outside of the tubes.

 Tube Contain

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In water-tube boilers the water flows through a large number of narrow tubes around the

fire. The tubes frequently have a large number of bends and sometimes fins to maximize the

surface area this boiler is generally preferred in high pressure applications since the high pressure

water /steam is container within narrow pipes which can contain the pressure with a thinner wall.

 Fire Tube

Boiler can be classified into fire-tube water tube boilers or cast iron sectional depending on

whether the heat source is inside or outside the tubes or in the case of the cast iron sectional the

design and manufacture of the boiler. The goal in all case is to maximize the heat transfer

between the water and the hot gasses heating it.

For example steam locomotion have five-tube boilers, water the fire is inside.

 Method of Firing

Externally fired and internally fired boiler according to the position of the furnace.

Externally fired boilers have a separate furnace at outside the boiler body. Example stirling

boiler, badcock and wilcox boiler. Internally fired boiler furnace integral to part of the structure

of boilers (Located inside)

 Circulation

In a natural circulation boiler the circulation is achieved by the difference in density when the

water in the boiler is heated. In natural circulation steam boiler the circulation of water is by

convection currents which are set up during the heating of water.

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A forced circulation boiler is a boiler water a pump is used to circulate water inside the boiler

this differs from a natural circulation boiler w/c relies on current density to circulate water.

 Pressure of Steam

High-pressure boiler will heat steam above 15psi and water at pressure that exceed 160psig.

Temperature in high pressure boiler will exceed 250 degrees F. Because of the elevated pressure

at which these boilers operate, they need to be monitored to ensure safety at all lines.

III. APPLICATION

While there are several types of steam boilers, their basic operating principle are nearly identical.

Water is heated to a gaseous state, generating pressure and steam. The steam is then transported

through pipes via that pressure, which is used to power radiators, turbines, steam rooms,

sterilization chamber, cooking equipment, etc.

Once water is converted into steam, minerals and other sediment that can’t be converted to a

gaseous state will be left behind and drop to the bottom of the boiler. This process, known as

blow down, is then used to help remove the sediment. If this process didn’t occur, the boiler

would not function properly.

 Operating steam engines.

A steam engine is a heat engine that performs mechanical work using steam as its

working fluid. The steam engine uses the force produced by steam pressure to push a

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piston back and forth inside a cylinder. This pushing force can be transformed, by a

connecting rod and crank, into rotational force for work

 Operating steam turbines.

In simple terms, a steam turbine works by using a heat source (gas, coal, nuclear, solar) to

heat water to extremely high temperatures until it is converted into steam. As that steam

flows past a turbine's spinning blades, the steam expands and cools.

 Operating reciprocating pumps.

The reciprocating pump operates on the positive displacement principle. The piston of a

reciprocating piston pump goes back and forth in a cylinder. With the help of a

connecting rod, the piston is connected to the crankshaft. The connecting rod moves as

the crankshaft rotates, causing this piston to move.

 Industrial process work in chemical engineering.

Chemical engineers (or process engineers) are responsible for developing new industrial

processes and designing new process plants and equipment or modifying existing ones.

The processes that they come up with are used to create products ranging from oil and

gas to food and drink

 In Power Plants

The process of using high-pressured steam to generate electrical power is known as the

Rankine cycle. The process was designed by William J.M Rankine, a Scottish engineer,
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in 1859. As we’ve mentioned earlier, power plants rely on steam to maximize the energy

coming from carbon-based fuel or nuclear reactors.

 In HVAC systems

The use of steam boilers in HVAC systems include water heating, sanitation, cooking,

waste energy utilization, and central heating. Fire-tube boilers are used to warm the air

which is transferred to the rooms of a house or warehouse. They are fixed with

ductworks.

IV. OPERATION

Understanding the working of the boilers is very simple. The boiler is closed vessel in which the

water is stored. Hot gases are produced by burning fuel in he furnace. These hot gases are made

to come in contact with the water vessel where the heat transfer take place between the water and

the steam. Therefore, the basic principle of the boiler is to convert water into steam by using heat

energy. There are different types of boilers used for different purposes.

It is to note that the following steps may not apply to all types of boilers and each boiler

requires some additional steps to be followed as per its system design. However, the basic

steps remain the same.

1. Ensure that the vent valve on the boiler is open and check there is no pressure in the

boiler.

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2. Check that the steam stop valve is closed.

3. Check that all the valves for fuel are open, and let the fuel circulate through the system

until it comes to the temperature required by the manufacturer recommendation.

4. Check and open the feed water valves to the boiler and fill the water inside the boiler

drum to just above the low water level. This is done because it is not possible to start

the boiler below the low water level due to safety features that prevent the boiler from

starting. Also, the level is not filled much because if filled too much, the water inside the

boiler might expand and over pressurize the boiler.

5. Start the boiler in automatic mode. The burner fan will start the purging cycle which will

remove any gases present in the furnace by forcing it out through the funnel.

6. After the pre-set purge time the pilot burner will ignite. The pilot burner consists of two

electrodes, through which a large current is passed, via the transformer, producing the

spark between the electrodes. The pilot burner is supplied with diesel oil and when the

oil passes over, the former ignites.

7. The main burner which is supplied by heavy oil catches fire with the help of the pilot

burner.

8. Check the combustion chamber from the sight glass to ensure the burner has lit and the

flame is satisfactory.

9. Keep a close eye on the water level as the pressure increases and open the feed water

when the level of water inside the gauge glass is stable.

10. Close the vent valve after the steam starts coming outside.

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11. Open the steam stop valve.

Stopping a boiler

1. If the boiler is needed to be stopped for a longer duration for maintenance or opened

up for the survey, change the fuel to distillate fuel.

2. If a separate heating arrangement for heavy oil is present then there’s is no need to

change over to distillate fuel and the oil is kept on circulation mode.

3. Stop the boiler automatic cycle.

4. Close the steam stop valves.

5. Close the boiler feed water valves.

6. When the boiler pressure is just reduced to over atmospheric pressure the vent valve is

kept open to prevent vacuum formation inside the boiler.

V. COMMON TROUBLES/PROBLEMS

Boiler problems can cause a significant headache, particularly during the winter months. From

leaks to cold radiators, boilers can suffer from a wide range of issues if not serviced regularly.

Fortunately, most of the most common issues are easy to identify and can easily be fixed by a

Gas Safe registered engineer.

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1. Hot Water But No Heating

A boiler should provide your home with central heating and domestic hot water. If you've

found that you're getting hot water from the taps but no central heating, there's a problem.

2. No Heat Or Hot Water

You should be able to rely on your boiler to provide your home with heating and hot

water. If you find that it isn't able to do either then you'll want to get it fixed as quickly as

possible.

3. Boiler Is Leaking

A leak coming from your boiler is never a good sign. And the cause of the leak will

depend where the water is coming from.

4. Boiler Is Kettling

When lime scale or sludge builds up on your boiler's heat exchanger (a coil that transfers

heat from the fuel to the water that will circulate around the heating system) you can get

something called kettling. If your boiler is kettling, it's advisable to call out a Gas Safe

registered engineer. The engineer will likely flush out your system to remove the build-up

of these deposits and ensure the system is working properly once more.

5. Noisy Boiler (e.g. banging, whistling, gurgling)

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From banging and clanging to whistles and gurgles, a heating system can make a number

of noises caused for a number of reasons. If you hear a noise coming from the boiler or

heating system, don't ignore it as there's probably a fault.

The potential fault will vary depending on the type of sound and where it's coming from.

We've listed some common boiler noises below to help you find the cause.

Whistling

We've already covered kettle-like sounds, caused by a build-up of sludge on the heat

exchanger.

Banging

Will commonly be caused by the pipework or an internal component coming loose but

could also be the result of debris building up on the heat exchanger.

Clanking

A sound not too far from banging is a clanging noise that could again be caused by loose

pipework.

Buzzing

A buzzing noise could indicate that electrical components within the boiler are

malfunctioning and likely need to be replaced.

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Gurgling

Too much air within the pipes can cause blockages that prevent the water from

circulating around the heating system. Should you be hearing this by a radiator then it's

likely that they need to be bled.

6. Low Boiler Pressure

Boiler pressure is a measurement of the pressure of the hot water passing through the

central heating system. Should the boiler pressure drop too low then the central heating

will fail to work.

All boilers will very gradually lose boiler pressure over time but a sudden sharp drop

could be the sign of a bigger issue. So if you've noticed a drop in boiler pressure check

for water leaks and cold patches on radiators (as they may need bleeding).

7. Frozen Condensate Pipe

Condensing boilers have a condensate pipe which leads acidic water, produced as the

boiler operates, away from the unit and down a drain. Many condensate pipes are external

to the property which, as they contain liquid, can make them prone to freezing.

8. Radiators Are Cold

In the case that some of your radiators aren't heating up then there could be a buildup of

sludge or air in the system.

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Bleeding a radiators

If only the bottom of your radiator is getting hot then you might need to bleed the

radiator. If certain radiators aren't getting hot then your radiators could need balancing.

The process involves adjusting the valves on all of the radiators in your property to

ensure each is getting enough hot water to work effectively. Our guide on How to

Balance Radiators can take you through the process.

9. Boiler Keeps Switching Itself Off

A boiler could be constantly switching itself off for a number of reasons. Some of the key

culprits are:

•Low boiler pressure

•Thermostat issues

•Lack of water flow due to a closed valve or the pump not circulating the water around

the system properly

•Too much air within the system

• A build up of sludge or other debris within the system

If the thermostat is working as it should and the boiler pressure is in line with the

manufacturer's instructions then it's time to call a Gas Safe

10. Boiler Is Not Responding To The Thermostat

Pairing your boiler with a thermostat -particularly a smart thermostat -is a great way to

increase the efficiency of your home.

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VI. CONCLUSION

Boilers are most important part of chemical industry.99 % boilers used in Pakistan

chemical industries are water tube boilers because of their high efficiency and safety.so we

should have cler understanding about the boilers.

 A steam boiler is a steam producing heating system; it produces energy by heating water

to create steam.

 A steam boiler burns fuel to heat water. The combination of heat and water produces

steam.

 Steam boilers are defined by their construction, portability, types of tubes, types of fuel,

and the pressure they produce.

 A steam boiler absorbs heat that is released from combustion. The three ways that the

heat is transferred are radiation, convection, and conduction.

 The designs and types of steam boilers widely vary depending on their construction and

purpose.

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BOILER DESIGN IN CONTROL PANEL

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SUMMARY

Boilers can suffer from many problems, most of which should be resolved by a qualified boiler

engineer.

Boiler leaks should be treated as a serious issue and resolved as soon as possible.

A lack of central heating could mean that the radiators need bleeding.

Low boiler pressure can be caused by leaks and can be solved by opening the filling loop.

Boiler kettling can make a lot of noise and sometimes requires the system to be cleansed or for a

part to be replaced.

Frozen condensate pipes can be thawed using warm water.

A boiler may not respond to a thermostat if the thermostat runs out of battery or is placed too far

away.

A lack of hot water and central heating is usually a larger issue that definitely needs the help of a

boiler engineer.

If a boiler keeps switching off, an engineer will be able to say whether a part needs replacing or

if the entire boiler needs to be replaced. Sometimes this is more cost effective.

Boilers can make lots of strange and distracting noises, such as gurgling and humming.

Never attempt to replace any parts yourself. An engineer is best to fix any issues safely.

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VII. REFERENCE

1. https://www.slideshare.net/MarineStudy/introduction-of-boiler

2. https://learnmechanical.com/boiler-overview

3. ^ Steingress, Frederick M.; Frost, Harold J.; Walker, Darryl R. (2003). High

Pressure Boilers (3rd ed.). American Technical Publishers. ISBN 0-8269-4300-4

4. BLAST 3.0 Users, Manual. 1999. Building Systems Laboratory. Urban a-

Champaign: Building Systems Laboratory, Department of Mechanical and

Industrial Engineering, University of Illinois.

5. TRNSYS 16 User Manual. 2004. A Transient System Simulation Program. Solar

Energy Laboratory, Madison. University of Wisconsin-Madison.

6. El-Wakil, M. M. 1984. Power Plant Technology, McGraw Hill, New York, pp. 30-72.

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