BOILER

INTRODUCTION

A boiler is an enclosed vessel that provides a means for combustion heat to be transferred
in to water until it becomes heated water or a gas (steam). The steam or hot water under
pressure is then usable for transferring the heat to a process. Water is a useful and cheap
medium for transferring heat to a process. When water is boiled into steam its volume
increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This
causes the boiler to be an extremely dangerous item that must be treated with utmost respect.

Boilers were used in crude fashions for several centuries but development was slow because
construction techniques were crude and the operation was extremely dangerous. But by the
industrial revolution of the mid 1800s boilers had become the main source of energy to power
industrial operations and transportation. The use of water as a heat transfer medium has many
advantages. Water is relatively cheap, it can be easily controlled, the gas in invisible, odorless,
and extremely high purity

The process of heating a liquid until it reaches it's gaseous state is called evaporation. Heat is
transferred from one body to another by means of (1) radiation, which is the transfer of heat
from a hot body to a cold body through a conveying medium without physical contact, (2)
convection, the transfer of heat by a conveying medium, such as air or water and (3)
conduction, transfer of heat by actual physical contact, molecule to molecule. The heating
surface is any part of the boiler metal that has hot gases of combustion 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 a boiler has is expressed in square feet. The larger the
amount of heating surface a boiler has the more efficient it becomes. The measurement of the
steam produced is generally in pounds of water evaporated to steam per hour.
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. 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.

Fire tube boilers are more commonly available for low pressure steam or hot water
applications, and are available in sizes ranging from 500,000 to 75,000,000 BTU input. Water-
tube boilers are primarily used in higher pressure steam applications and are used extensively
for comfort heating applications. They typically range in size from 500,000 to more than
20,000,000 BTU input.

Cast iron sectional boilers are another type of boiler commonly used in commercial space
heating applications. These types of boilers don’t use tubes. Instead, they’re built up from cast
iron sections that have water and combustion gas passages. The iron castings are bolted
together, similar to an old steam radiator. The sections are sealed together by gaskets. They’re
available for producing steam or hot water, and are available in sizes ranging from 35,000 to
14,000,000 BTU input.

Cast iron sectional boilers are advantageous because they can be assembled on site, allowing
them to be transported through doors and smaller openings. Their main disadvantage is that
because the sections are sealed together with gaskets, they are prone to leakage as the gaskets
age and are attacked by boiler treatment chemicals.

Some of the well- known Boilers are:–

 Babcock & Wilcox boiler

 Cochran boiler – A vertical boiler with horizontal fire-tubes.

 Cornish boiler – A large horizontal stationary boiler with a single flue.

 La Mont boiler – A forced-water-circulation boiler. They are often used as marine heat-
recovery boilers. It was also used, unsuccessfully, for an experimental steam locomotive
in East Germany in the 1950s.

 Lancashire boiler – A development of the Cornish boiler, with two flues.

APPLICATION
Many big cities, including the Empire city, New York, run on steam. According to Frank Cuomo, the
G.M for steam distribution at Con Edison, 2.5 to 3 million New Yorkers are impacted by the steam
system. 

Whether you realize it or not, you’re benefiting from the steam boiler. Below are the various
industrial applications of steam boilers in our day to day life:
In Cement production
Like other established industries, the cement industry is a highly competitive one. Investors and
business owners are always seeking legal ways to increase profit without reducing the quality of
the end-product or putting the lives of the end-consumers in danger. 
One of the ways to reduce the cost of production is by utilizing every fuel used and reducing the
loss of energy. A waste heat recovery model is the solution and a waste heat boiler is the tool
needed to utilize the waste heat dissipated during cement production. 
The waste energy can be recycled, used to dry raw materials and compliment the power supply.
Waste heat boilers can help generate up to 20% to 30% electrical power needed in cement
manufacturing sites.
In Agriculture
One of the several uses of steam in agriculture is the disinfection of tools. However, that’s just a
tip of the ‘steamberg.’ Steam is used in soil sterilization. Soil steam sterilization is a farming
method that involves the sterilization of soil with steam. Steam sterilization can be carried out
in greenhouses or open fields.
The process is effective in the partial killing of weeds, bacteria, viruses and fungi. The product of
killing soil microbes is the release of cellular proteins, which increases the nutrients in the soil
considerably. The process is regarded as partial disinfection because spore-forming bacteria are
heat-resistant and can survive or reactivate once the soil is back to its cold state. 
Soil steaming is a perfect solution for soil fatigue. Revitalization, improved growth and
disinfection are the benefits of soil steaming. The 21st century method of disinfecting compost
and sick soil is soil steaming. It is preferred to the use of bromomethane. According to the
Montreal Protocol, “steam is effective in the elimination of soil pathogens that causes protein
coagulation or enzyme inactivation.”
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.
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, in 1859.
As we’ve mentioned earlier, power plants rely on steam to maximize the energy coming from
carbon-based fuel or nuclear reactors.
Final Thoughts on Steam Boilers
Though the steam boiler is crucial to civilization as we know it, its risks could be fatal, if
mismanaged.
Most big cities have steam pipes installed beneath the city. These pipes operate under high
pressure, but they are built to endure hot temperatures and high pressure. Steam pipe
explosion is not an event that occurs very often, however, it can be very devastating. A single
burst can result in the loss of lives and evacuation of an area. 
While most steam accidents are not caused by bad or faulty pipes, steam companies are
required to check the state of their pipes regularly and steam generation components through
advanced x-ray and ultrasonic tools.
Any steam company that fails to conduct regular inspections and take necessary precautions,
risks losing its license to operate within the nation. If the carelessness on the part of the
manufacturer results in societal damage, the company would most likely be sued and heavily
fined.
To avoid early damage of pipes, it’s better to purchase quality steam boilers, components and
pipes for your company, or home, including, pools and warehouses. Understanding the design
and function of your steam boiler is crucial to efficient and safe operation. When you have an
issue with a steam boiler, it's best to seek professional advice and follow proper protocols in
both its operation and maintenance schedules.
OPERATION
Starting a Boiler
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.
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.
11. Open the steam stop valve.
12. Once the working steam pressure is reached, blow down the gauge glass and float
chambers to check for the alarms.

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.

COMMON TROUBLES/PROBLEMS
Low boiler pressure
Low boiler pressure can lead to cold radiators and a lack of hot water. Low boiler pressure can
be identified on the boiler display panel, where either a digital or physical dial will show the
level of pressure in the system. The most typical pressure level should be around 1.5 bars, with
slight variance depending on the boiler manufacturer and model.
A boiler’s pressure can drop due to two main reasons:
 A leak in the system will result in not enough water being present in the system,
consequently causing the pressure to drop.
 A bleeding radiator can also reduce system pressure.
Low boiler pressure can be fixed by repressurising the boiler. This involves opening the boiler
filling loop to allow water to re-enter the system. Check out our guide on repressurising a
boiler to see the full list of steps to follow.
Boiler kettling
Another common boiler problem is kettling. Boiler kettling occurs when water is heated too
quickly and reaches boiling point, causing steam to be generated and air to become trapped.
The trapped air gives off a whistling sound, like a kettle.
Boiler kettling can be caused by limescale build-up, which slows down the flow of water in the
system and causes it to heat up excessively. A faulty component on the appliance could cause
the boiler to heat up water to higher temperatures than expected.
A boiler engineer will be able to inspect the system and identify the cause of the kettling. There
is a solution to this problem which depends on the severity. Sometimes the noisy component
can simply be cleaned using different methods, alternatively replacing the parts may be
required
CONCLUSION
 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.
REFERENCES
1.  Steingress, Frederick M. (2001). Low Pressure Boilers (4th ed.). American Technical
Publishers. ISBN 0-8269-4417-5.
2. ^ Steingress, Frederick M.; Frost, Harold J.; Walker, Darryl R. (2003). High Pressure
Boilers (3rd ed.). American Technical Publishers. ISBN 0-8269-4300-4.
3. ^ ASME Boiler and Pressure Vessel Code, Section I, PG-5.5. American Society of
Mechanical Engineers. 2010.
4. ^ BS EN 14222: "Stainless steel shell boilers"[full citation needed]
5. ^ "ASME Performance Test Codes".
6. ^ "EN 12952-15".