PLC Guideline 2004-01

PLC Guidelines
Title Boiler Pressure Vessel Basics Page 1 of 11
January 22, 2004
Topic Risk Management Guidelines for Boiler Fundamentals Supersedes: New

Author Marc Brodt, Corporate Risk Management

ABSTRACT
This document describes the design and operation of boilers, as well as introduces terminology
common to most boilers. A boiler transfers energy from the combustion of fuel to an operating
fluid. Usually water and steam are the most common operating fluids, but organic liquids,
molten metals, or molten salts may be used.

Different boiler types and configurations will be discussed, as well as safe boiler operation for
each type and configuration. Various design features will be discussed along with boiler water
chemistry and treatment.

TABLE OF CONTENTS

1. PURPOSE ....................................................................................................................................2

2. SCOPE .........................................................................................................................................2

3. GENERAL DISCUSSION ..........................................................................................................2

3.1. Boiler Classification............................................................................................................2
3.2. Boiler Configurations..........................................................................................................3
4. GENERAL BOILER REQUIREMENTS....................................................................................3
4.1. Boiler Water Return............................................................................................................3
4.2. Pressure Control..................................................................................................................5
4.3. Temperature Control...........................................................................................................5
4.4. Water Level.........................................................................................................................6
4.5. Conditions Affecting Heat Transfer....................................................................................7
4.6. Water Sources .....................................................................................................................8
4.7. Inspections ..........................................................................................................................9
5. TRAINING ..................................................................................................................................9

6. CONTACTS AND REFERENCES.............................................................................................9

7. DEFINITIONS...........................................................................................................................10

Published by: Contact:

Corporate Risk Management - 300 Park Ave., NY Marc Brodt
PLC Guideline Boiler PV Basics.doc
 PLC Guideline 2004-01

PLC Guidelines Page 2 of 11

Boiler Pressure Vessel Basics January 22, 2004

1. PURPOSE

The intent of this document is to provide a basic understanding of the various types and designs of boilers
that may be located at Colgate facilities, as well as applications for each style of boiler. Basic descriptions
of the operations and terminology of boilers will be discussed. Reference the Guideline on Firetube
Scotch Marine Boilers for more information of specific type and configuration of boilers and the
Guideline entitled Boiler Pressure Vessel Log for information on inspection, testing, maintenance, and
repair of Firetube Scotch Marine Boiler vessels.

2. SCOPE

This guideline applies to all Colgate-Palmolive and subsidiary locations.

3. GENERAL DISCUSSION

3.1. Boiler Classification

3.1.1. Low Pressure (also known as Heating Boilers)

Are defined by one of the following characteristics:

• Steam operated boilers with an allowable pressure of 15 pounds per square inch (1 bar) or
less.
• Hot water operated boilers having an allowable pressure of 160 pounds per square inch (11
bar) or less and an allowable temperature of 250 degrees or less.

3.1.2. High Pressure (also know as Power Boilers)

Are defined as follows:

• Any steam boiler with 15 pounds per square inch (1 bar) or greater allowable pressure.
• Hot water operated boilers having an allowable pressure of 160 pounds per square inch (11
bar) or more and an allowable temperature of 250 degrees or more.
 PLC Guideline 2004-01

PLC Guidelines Page 3 of 11

Boiler Pressure Vessel Basics January 22, 2004

3.2. Boiler Configurations

3.2.1. Water tube

Boilers designed to have water or steam inside tubes and the products
of combustion or other heat source outside the tubes. These tubes are
joined to drums or headers which are located inside a combustion
chamber, furnace, flue space or product stream.
• Water tube type systems are found in most large industrial
applications and all large utility boilers.

3.2.2. Fire Tube

In contrast to the water tube, the fire tube has the combustion products
or heat source inside the tubes. These tubes are located inside a shell or
tank which contains the water or steam. The tubes are connected to a
tubesheet. The furnace, firetubes, tubesheet and the cylindrical shell or
tank form the water/steam pressure boundary.
• Fire tube boiler systems are utilized in both smaller industrial
applications as well as large heating boiler applications.

3.2.3. Cast Iron

Boilers constructed from a number of hollow cast iron sections which

contain the water and steam and are heated by a burner. They should never
be used where 100% of the water or condensate is not returned, because of
corrosion concerns and the difficulty of removing mud and scale deposits.
• Cast iron boilers are typically utilized for smaller heating
applications.

4. GENERAL BOILER REQUIREMENTS

4.1. Boiler Water Return

4.1.1. Steam traps

A self-acting device that will discharge water that has accumulated in a pipe or vessel containing
steam without permitting steam to escape.
 PLC Guideline 2004-01

PLC Guidelines Page 4 of 11

Boiler Pressure Vessel Basics January 22, 2004

Boilers that provide heat usually have a steam trap installed at its outlet, which must be located at
the lowest point. The purpose of this trap or valve is to provide for the removal of any condensate
with a minimal release of steam. An efficient heating system will return almost all the condensed
steam to the boiler as condensate.

4.1.2. Condensate Collection

There are 4 basic flows of formed condensation back to the boiler determined by the boiler
classification as shown below:
• Small low pressure heating systems – condensation returns to the boiler by gravity flow.
• Medium and large low pressure heating systems – condensation is collected in a
condensate tank. From this tank it is then pumped back to the boiler.
• Medium and large high pressure heating systems – condensation is collected in a
condensate tank which is then pumped to a deaerating feed tank. In the deaerating tank,
oxygen is removed from the condensation before it is returned to the boiler as feedwater.
This removal of oxygen helps minimize boiler corrosion.
Condensate Tank Deaerating Tank

• All power systems – condensation is collected for reuse in one of two ways:
1. Exhausted to a condenser, then pumped to a deaerating tank, and finally returned as
feedwater.
2. Exhausted to a low pressure heating system to produce heat.

4.1.3. Boiler Water Replacement

There are several reasons why water is lost in boiler systems. It may be caused by a leak, or by
applying steam directly to a process, or where condensate return is not possible in heating systems
because of contamination or physical location. Makeup water must be added where water is lost.
The place to add makeup water is indicated below:

Heating Systems
• to the condensate tank
• directly to the boiler
 PLC Guideline 2004-01

PLC Guidelines Page 5 of 11

Boiler Pressure Vessel Basics January 22, 2004

Power Generating Systems

• to the condenser
• to the deaerating tank
Further definition of both makeup water and feed water will be given in section 5.6 Water Sources.

4.1.4. Expansion Tank

A tank or chamber limited to provide for the expansion of water.

As water is pumped through the heating system, it will expand and

contract based on the temperature of the system. An expansion tank is
needed to avoid excessive pressure on the boiler system. This tank
contains an air or inert gas that provides a cushion which modifies
pressure changes.

Typical Expansion Tank

4.1.5. Thermal Shock

A stress producing phenomenon resulting from a sudden temperature drop.

If the air cushion in the expansion tank is lost, the normal pressure rise within the system will
increase the pressure and cause the pressure relief valve(s) to lift. These constantly fluctuating
temperature and pressure changes can cause thermal shock. Damage to the boiler is possible from
stress and also from scale buildup caused by the increased feedwater required.

4.2. Pressure Control

Steam boilers require at least two (2) pressure control devices:

• One controls normal operating pressure and the other functions as a high limit backup control
device.
• A safety valve is also required.
Both steam and hot water boilers require at least one pressure gauge.
• It must have a range of approximately twice the intended working pressure of the system, but
at least 150% of the boiler maximum allowable working pressure.
4.3. Temperature Control
Hot water boilers require at least two (2) temperature control devices and a temperature & pressure
gauge:
• One controls normal operating temperature and the other functions as a high limit backup
control device.
• A relief valve is also required.
 PLC Guideline 2004-01

PLC Guidelines Page 6 of 11

Boiler Pressure Vessel Basics January 22, 2004

• The temperature gauge indicates the water temperature at the boiler outlet.
4.4. Water Level
4.4.1. High Water Conditions

When the water level within the boiler is too high, the ability to remove water from the steam is
not possible. When this happens, water will leave the boiler along with the steam and may cause
damage to the piping, valves, and other system equipment. This condition is known as water
carryover.
4.4.2. Low Water Conditions

When the water level within the boiler is too low, the top ends of the tubes will become exposed
and overheat. The overheating could crack the tubes and cause them to leak. Devices used to
monitor the water level and protect against high or low water conditions are described below:

4.4.3. Monitoring and Testing Devices

• Sight Glass or Gauge Glass – are designed to provide a way to visually
determine the actual water level in the boiler. A usable sight glass must be
installed on all high pressure boilers during operation.

Tubular Glass
• Tri-Cock Assembly – an alternative device used to determine
the actual boiler water level. The device has three valves
located at the high, mid-point, and lowest water level expected
under normal operating conditions.

• Low Water Fuel Cutout Device (LWFCO or LWCO) – a device designed to shut off the
fuel supply when the water level in the boiler falls to an unsafe level. Its function is to
eliminate damage to the boiler caused by a low water condition. Two independent devices
should be installed (primary and secondary) each with an audible alarm.

Float Type LWFCO

o Primary (Operational) LWCO – It is set to operate

before the secondary LWCO. Its purpose is
twofold: 1) to start and stop the flow of boiler
feedwater for normal operations; 2) to shut off the
fuel supply to the burner if the water level drops
too low.
 PLC Guideline 2004-01

PLC Guidelines Page 7 of 11

Boiler Pressure Vessel Basics January 22, 2004

o Secondary (Low) LWCO – Its purpose is to cause a safety shutdown and lockout before
a low water condition occurs. A manual reset would be required to put the boiler back
into service.
• Testing – The following tests must be performed periodically:

o Fast Drain Test – perform this test to properly remove accumulations in the float
chamber and the connecting lines. This test should be performed and recorded
daily. Documentation in the log is required if a leakage problem exists.

o Slow Drain Test – perform this test to determine that the LWCO will operate properly
under normal operating conditions. This test is necessary to pick up subtle problems
with the LWCO that were not detected during the Fast Drain Test. This test should be
conducted and recorded annually.

4.5. Conditions Affecting Heat Transfer

4.5.1. Scale

Dissolved mineral salts and other contaminants may concentrate in the boiler. These salts will
deposit as a scale on the water side of the tubes within the boiler. The scale then insulates the
metal which reduces the heat transfer process from the metal to the water or steam. This causes
high metal temperatures which eventually may cause failure to the tubes, tubesheet, or the joints
between the two.

4.5.2. Sediment

Differs from scale in that it does not stick to the furnace or the tubes, it settles to the bottom of the
boiler. It can damage boiler systems in the same manner by insulating the metal surface and
causing possible metal failures.

4.5.3. Corrosion

Corrosion deposits may occur on both the water and fireside of the tubes.
• On the water side, high iron and oxygen content in the boiler water will lead to possible
corrosion.
• On the fire side, low stack temperatures will cause condensation which leads to corrosion.
Also, oil fired systems may have concentrations of ash that promote corrosion on exposed
metal surfaces.
 PLC Guideline 2004-01

PLC Guidelines Page 8 of 11

Boiler Pressure Vessel Basics January 22, 2004

4.5.4. Water Chemistry

Systems where makeup water must be added require the addition of feedwater
chemicals to control water chemistry problems. Maintenance of the boiler
feedwater requires the removal of dissolved and suspended solids and
sediments from the boiler water. Below are several methods of treating or
removing these solids from the water:
• Internal Water Treatment – adding chemicals to the water in the boiler.
• External Water Treatment – purifying the water before it is pumped
into the system.
Blowdown Tank
• Bottom Blowdowns – this is done using a connection located on the bottom of the boiler
called a blowdown line. The process will remove sediment from the bottom of the boiler
and reduce the amount of dissolved solids contained in the boiler water.
• Surface Blowdowns – this is done using a surface blowdown line, located in the steam
drum just below the level of the water. This process is used to control floating and
suspended solids and oils.
o All water removed during the blowdown operation must be stored in a blowdown tank,
which is sized to handle the expected volume.

4.6. Water Sources

Steam boiler operation requires water of reliable quality and of sufficient quantity that can be
delivered at a pressure higher than the boiler operating pressure.

4.6.1. Feed Water

Treated condensate collected within the system and returned to the boiler is called feedwater. All
boilers need at least two feed water sources.
• Power Boilers – the two feed water sources must be independent, preferably one motor
should be steam driven and the other motor electric.
4.6.2. Makeup Water

Water used to compensate for lost boiler water is referred to as makeup water.
• Heating Boilers – connecting to the local water supply through a pressure-reducing valve is
sufficient. The infeed system should be designed to allow a tempering of the water by
mixing it with the warm condensate returning to the boiler.
• Cast Iron Boilers – connect to the local water supply in the return or feed line just upstream
of the boiler to allow for easier removal of accumulated scale.
 PLC Guideline 2004-01

PLC Guidelines Page 9 of 11

Boiler Pressure Vessel Basics January 22, 2004

4.7. Inspections

A complete preventative maintenance and inspection program should be developed and implemented.
Internal and external inspections should be conducted periodically. Regular equipment inspections
will help to prevent failure and save lost time and production.

Colgate-Palmolive has developed a comprehensive Guideline document to assist in the proper

operation, maintenance, testing and inspection of all boiler equipment. Refer to the Guideline entitled
“Boiler Pressure Vessel Log” published by the Risk Management department.

5. TRAINING

All employees responsible for the operation of power or heat generating boiler systems must be properly
trained to provide adequate service. The following points detail the level of training required for all such
employees:

5.1 Where required by the jurisdiction having authority, boiler operators should be properly
licensed or certified

5.2 Initial training must be provided to familiarize boiler operators with the design, construction,
operation, and maintenance of boiler systems.

5.3 Boiler operations employees should be trained to recognize early signs and symptoms of
possible boiler problems to minimize possibilities of catastrophic loss or personal injury
resulting from boiler failure.

5.4 Emphasis should be placed on periodic maintenance and inspection schedules.

5.5 Periodic refresher training should be provided when necessary to keep all boiler maintenance
employees knowledgeable of their responsibilities, as well as update them on new
developments and/or procedures recently introduced.

6. CONTACTS AND REFERENCES

For assistance in applying this Guideline, contact Marc Brodt, Corporate Risk Management, New York,
(Phone: 212-310-3268, Fax: 212-310-3782), or the local property risk control service provider.

For additional supporting information, refer to the following:

• Colgate Risk Management PLC Guidelines 2004-12 “Causes of Firetube Scotch Marine Boiler
Failures”
Also, the Industrial Risk Insurers (IRI) group has published informational reference documents as listed
below:
• IRInformation IM.7.0.5.0 Overpressure Protection
 PLC Guideline 2004-01

PLC Guidelines Page 10 of 11

Boiler Pressure Vessel Basics January 22, 2004

• IRInformation IM.7.1.0.3 Boiler Fundamentals

• IRInformation IM.7.1.0.6 Low Water Protection for Boilers
• IRInformation IM.7.2.0.5 Sight Glasses and Gauge Glasses
Additional supporting information can also be found by referring to the following data sheets published by
the Factory Mutual Insurance Company (FM Global):
• FM Global Property Loss Prevention Data Sheet 12-0 “Applicable Pressure Equipment Codes and
Standards”
• FM Global Property Loss Prevention Data Sheet 12-16 “Firetube Boilers”
• FM Global Property Loss Prevention Data Sheet 12-17 “Watertube Boilers”
• FM Global Property Loss Prevention Data Sheet 12-37 “Low Water Protection”

7. DEFINITIONS

7.1 Authority Having Jurisdiction (AHJ): This phrase is used in this document in a broad
manner, since jurisdictions and approval agencies vary, as do their responsibilities. The
authority having jurisdiction may be a federal, state, local, or other regional department or
individual, such as building code officials, public health officials, environmental departments
or others having statutory authority. In many circumstances, due to lack of statutory
requirements, Colgate may assume the role of the authority having jurisdiction. In any event,
all designs, layouts, storage arrangements, construction, etc. must also be acceptable to
Colgate's Loss Control Service Providers. This approval helps provide a uniform level of
quality on a global scale.

7.2 Blowdown: removal of a portion of boiler water for the purpose of reducing solids or to
discharge sediment. It can be from the bottom of the boiler, called bottom blowdown, or from
the just below the water/steam surface, called surface blowdown.

7.3 Condensate: to make a substance more dense or compact, e.g. steam converting to water.

7.4 Convection: the transfer of heat by the automatic circulation of a fluid.

7.5 Corrosion: the wasting away of boiler metal due to chemical action between the metal and
hydrogen, oxygen, carbon dioxide, or strong acids and bases.

7.6 High Pressure Boiler: a boiler furnishing steam at a pressure in excess of 15 pounds per
square inch or hot water at temperatures in excess of 250 degrees F and/or at a pressure in
excess of 160 psi.

7.7 Low Water Fuel Cutoff (LWFCO or LWCO): a device that stops the burner if unsafe low
water conditions exist in the boiler.
 PLC Guideline 2004-01

PLC Guidelines Page 11 of 11

Boiler Pressure Vessel Basics January 22, 2004

7.8 Makeup Feed Water: water introduced to a boiler to compensate for loss from design or
leakage.

7.9 Pressure Relief Valve: A spring loaded valve designed to relieve gas, vapor or steam pressure.
They are pressure-relieving devices actuated by inlet static pressure. It opens in proportion to
the increase in pressure over the opening pressure.

7.10 Relief Valve: relief valves are designed to relieve water or liquid pressure. They are pressure-
relieving devices actuated by inlet static pressure. It opens in proportion to the increase in
pressure over the opening pressure.

7.11 Scale: a hard coating on the waterside of boiler pressure retaining surfaces.

7.12 Sediments: naturally occurring solid material in water, which may be combined with
chemicals that are not soluble and fall to the bottom of the boiler. Also called sludge.

7.13 Stack Temperature: Temperature of the flue gas exiting the boiler through the stack. The
higher the temperature the greater the energy content.

7.14 Tubesheet: a flat steel sheet to which the ends of the furnace and firetubes are attached. The
furnace, firetubes, tubesheet, and the cylindrical shell form the water/steam pressure boundary.

7.15 Tri-cock Assemblies: externally mounted devices on the water column used to provide an
alternative means of determining the actual water level in the boiler.

7.16 Water Level Indicator (Sight Glass): a device designed to visually indicate the water level in
the boiler at all times. The device can be installed directly to the boiler shell or remotely
monitored in a control room.