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:

1. Table content

2. Introduction

3. Classification

4. Classification source

5. Application

6. Application

7. Operation

8. Common troubles

9. Conclusion

10. Boiler design in Control Panel

11. References

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BOILER

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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CLASSIFICATION

 Tube Contain
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

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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.
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.
APPLICATION
 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
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

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 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.

 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.

OPERATION
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.

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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
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.

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.

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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.

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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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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COLLEGE OF ENGINEERING

BOILER DESIGN IN CONTROL PANEL

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COLLEGE OF ENGINEERING

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

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