MARINE AUXILIARY

BOILERS
1.Smoke tube Tank type
Combustion gas pass through inside of
tubes,
water is outside of tubes.
2. Water tube Drum type
Water is in tubes, smoke pass outside of
tubes.
 Smoke tube single pass composite Boiler

5/11/17 3
 WATER TUBE BOILER

(1) Steam drum One largest cylinder at top.

() Collect & separate steam & water, come up from generating
tubes.
() Steam leave from top.
() Distribute water to down comer tubes.
() Receives feed water.
2) Water drum Cylindrical shape, half size of
steam drum at bottom.
Distribute water to screen& generating tubes.
Provides a space for accumulating suspended
solids precipitated from boiler water.
Blow down v/v is fitted. 1 manhole is at front end.

(3) Headers Cylindrical or rectangular shape, half

size of water drum,
At bottom opposite side of water drum.
Perform as water drum.
Only hand hole at front end for cleaning.
(4) Generating tubes
Large quantity small diameter (32mm) tubes
placed in main flow of hot gases between steam
drum& water drum, large heat exchange surfaces.
Steam generated at mid portion of generating tubes
and raise up together with hot water to steam drum.

(5) Screen tubes Place in front of generating tubes

to protect from direct heat of flame.
Large diameter (50mm) to keep ratio of steam to
water, to prevent over heating

(6) Down comer tubes Water from steam drum down

to header(50mm)
 AUXILIARY BOILER MOUNTINGS
Mounting mean v/vs & fittings direct attached to pressure sides.

(1) SAFETY VALVE

Protect overpressure.
2 valves on same chest with single pipe at top of steam
space.
Drain pipe without v/v fitted at chest, draining condensate.

(2) STEAM STOP VALVE

SLSD v/v on top of steam space.

.
 MAIN & AUXILIARY FEED V/VS( 3)
Fitted to steam space,
1 feed check v/v (NR) and 1 feed stop v/v
between shell and feed check v/v.
2 inlet lines are fitted on same feed line.
Extended spindles fitted to operate from
convenient position---
Always ensure v/v can be operated easily &
quickly
have open/ close position indicator
feed p/ps are positive pumps.
(4) WATER LEVEL INDICATOR (GAUGE
GLASS)
At least 2 for each boiler, at water level.
Place on each side of boiler at direct visible
positions.

(5) LOW AND HIGH WATER LEVEL ALARM

Float and Electrically operated.
To prevent loss of water in boiler
Due to burst tube or fail to feed.
 (6) BOTTOM BLOW DOWN V/VS
Fitted to lower water space
to blow out water and sediments,
internal pipe reach to bottom.
Consist 2 v/vs in series,
connected by a pipe to ship side discharge v/v.

(7)SCUM BLOW DOWN V/V

Fitted in upper water space
to discharge oil or floating particles on surface
of water
in way of a pan just below normal water level.
Pipe from this v/v connected between 2 bottom
blow down v/vs.
 DRAIN VALVE(8)
At lowest water space. To drain water
. completely
AIR VENT(9)
, At top of steam drum
To release air at filling water or raising
.steam

SALINOMETER V/V(10)
Fitted at mid of water space to get water
. sample

PRESSURE GAUGE(11)
,At top of steam space
, Direct and remote reading
Cycle of steam and water
 SAFETY DEVICES ON BOILER
.Low and high water level alarm.1
.Very low water level cut out burner.2
. Low and high pressure alarm.3
.Very high steam pressure cut out burner .4
Safety valve & easing gear prevent over .5
.pressure
 Boiler gauge glass or water level indicator

SINGLE SIDED GLASS PLATE TYPE (Used. 1

in LP 17 bar and MP17~ 30 bar)
Forged steel body in which is reflex glass
.plate

DOUBLE SIDED GLASS PLATE TYPE (HP. 2

.above 30bar)
 METHODS OF FITTING ON BOILER
Direct on shell 2. On bore pipe. 1
On hollow column 4. On solid column. 3

GAUGE GLASS CROSS BLOWDOWN

COCK POSITIONS
Steam & water cocks are vertical downward at
. open& horizontal at close
Drain is vertical downward at close &
horizontal at open, to prevent change of
.position due to vibration
-BOILER F.O BURNING SYSTEM
. F.O about 60C come from F.O tank
. Pass coarse filter& pump
Then heated in heater about 100C controlled
. by viscorator
If temp. high cracking occur, form gas in fuel
. line
. If low, poor combustion and back fire
Then pass through auto-clean fine filter,
rotated by motor or hand
Then oil pass an control v/v, which regulate
oil pressure to burner relative steam pressure
. in boiler, then enter burner

Air controller maintain correct ratio of fuel & air
.to furnace
emergency v/vs are fitted, one quick shut off 2
v/v or safety cock, shut by hand rapidly in
emergency, and another one shut of v/v with a
steam actuator, to shut off fuel when boiler
.water loss
To maintain oil temp. at desired value, a v/v is
fitted to circulate oil back to p/p suction and
. closed when burner is in operation
.D.O line also fitted for flash up boiler from cold

. Burner is ignited by 2 electrodes
. Pressure gauges & thermometers are fitted
Quick closing v/v on fuel tank outlet pipe &
Emergency stop of fuel p/p operated from out
. side of E/R is fitted
Whole system should be above floor plate, well
lighted to see leakage
Can easily change to manual, bypassing
automatic control v/v and oil supply pressure by
. hand wheel on spring loaded relief v/v
 SAFETY DEVICES ON FUEL BURNING SYSTEM (UMS)

Flame failure alarm & cut out burner (by

photo cell)
Low & high fuel temp. alarm & cut out burner.
(by temp. sensor)
Low fuel pressure alarm & cut out burner (by
pressure switch)
Force draught fan failure alarm & cut out
burner (by electric relay)
Power failure alarm.(relay)
High flue gas temperature alarm & cut out
(temp. sensor)
Smoke density alarm & cut out burner (by
photo cell)
Air fuel ratio alarm & cut out controlled by air
. damper
BOILER RAISING STEAM FROM COLD
open air vent , pressure gauge, gauge glass .1
.v/vs steam & water. Other v/vs kept shut
.Fill up water about of sight glass .2
. Run force draught fan to purge out furnace .3
First 3,4 times flash up 5min./ 45 min., then .4
. 5min./ 30 min
When boiler get warm more firing times till air .5
.come out from vent
When steam come out from vent, close vent .6
.v/v, raise steam to working pressure
ACTION TO BE TAKEN WHEN WATER
LEVEL DISAPPEAR IN GAUGE GLASS
. Stop fire
.Close non essential steam consumers
Close main steam stop v/v
.Make sure lower or higher than glass
If higher- blow down, If lower-reduce boiler load
. and fill water

When water level come into glass. Restart

.burning and put in service
If water level still disappearing, inform to C/E to
stop engine, and inform to duty officer if involve
.with inert gas generator on tanker
Boiler operation
CHECK POINTS ON BOILER AT BIGINING AND
KEEPING WATCH

1. Gauge glass water level about glass.

2. Cross blow gauge glass.
3. Boiler pressure always in limit 4 to 7 bar.
4. FO temp.& press. in limit.
5. No leakage in steam and fuel v/vs or pipes.
6. Flame color must be clean, clear and bright
yellow, not white or black smoke.
7. Drain oil from feed tank water surface, wipe out
with paper, fill water. ( feed tank sketch)
8. Safety v/v easing gear to be made ease.
 BOILER BACK FIRE
Unburnt fuel due to improper combustion (by
low fuel temp., nozzle defect, improper
air/fuel ratio, oil leak fr. burner, collect on
. floor
Then get firing temp. by radiation of burning
flame, suddenly explode during firing (or)
Flammable gases in furnace from previous
time explode when supply air and ignition for
. next start
Fire blow back to boiler front through
.inspection door and air passage

To prevent, well ventilate furnace before

ignite fuel, maintain correct fuel temperature,
air/fuel ratio and burner in good condition,
.clean burner tip. Keep good combustion
 BOILER MAINTENANCE
. Boiler water test and treat daily( 1)
. Clean gas side and water side regularly (2)

Combustion system( 3)
. Maintain correct fuel pressure, temperature
. Clean and overhaul burner
.Check and clean air regulator system
 BOILER BLOW DOWN
Open ship side discharge cock and v/v first, to prevent high
. pressure in pipe between boiler & ship side
.Handle on cock can be removed when only close position
Fully open blow down v/v (scum or bottom), crack and
.gradually open intermediate v/v to control discharge rate
Never control discharge rate by boiler v/v, to prevent
. seating of v/v from damage and leakage when closed
noising at high press discharging, when press. low, noise
.level fall
While blowing down, watch gauge glass water level and
. pressure gauge all the time

When fall to , close blow down v/v first, then close ship
.side cock
Ship side v/vs are usually non-return or one more n-r v/v
.fitted before ship side cock
BOILER PROBLEMS
SCALES 2.CORROSION 3. SLUDGE 4.PRIMING 5. FOAMING . 1
. CARRY OVER. 6

SCALES. 1
Dissolved alkaline ( temporary hardness) decompose by
heat and become (permanent hardness). Then stick on
. heating surfaces and become scale
SCALE reduce heat transfer & boiler efficiency. Tubes
. over heat& damage
CORROSION. 2
Oxidation / Reduction Reaction
. If a metal meet acid or alkaline, become oxidized
. Iron is more ready to dissolve in acid

Iron can corrode even in pure water(condensate)

. High chloride show s.w leak to boiler and get corrosion

SLUDGE --Combination of suspended. 3
materials in water (loose corrosion products,
insoluble mineral precipitates & oil), baked
on heat surfaces and become insulation. To
prevent Make sludge down to bottom by
. (Liquid Coagulant) and blow down

PRIMING Surface suddenly rise by. 4

. expansion large amount of water

FOAMING Thick bubbles form on water. 5

surface, due to oil, organic substances and
high amount of total dissolved solids (TDS)
.in water
CARRY OVER Water carry with steam, by. 6
BOILER WATER TESTS

.Excess phosphate test or hardness test.1

Phenolphthalein alkalinity test.2
Total alkalinity test or pH test.3
Chloride test.4
Hydrazine test.5
 WHY BOILER WATER TEST AND TREAT
. By Test--- Know condition in boiler, dose, blow down
By treat---(1) Remove scale forming particles (2)
Maintain alkaline condition to prevent corrosion (3)
Improve boiler efficiency.(4) Remove suspended solids
.& dissolved oxygen

SAMPLING # Taken while boiler is in operation

Before taking blow off salinometer valve to clear#
. scales

. If test Alkalinity, no need pH test

.pH is tested with litmus, maintain pH11
. If test excess phosphate, no need hardness test
. Hardness is tested with soap solution
One shot water treatment (DREW AKG 100) is
.enough for LP boiler
 FEED WATER TREATMENT
To reduce TDS, use evaporated water
To arrest suspended solids (use feed line
filter)
to prevent feed system corrosion (maintain
correct pH of feed water by GC)
To reduce dissolved O2 (dose Amerzine and
maintain hot well temp. 60~70C to promote
de aeration of hot well)
 MAINTAIN BOILER OIL FUEL BURNER

Regularly or when flame condition become

bad, burner to be removed, dismantled and
.clean the tip

Clean burner tip. Take care not to scratch

surfaces of swirl& orifice plate during
. cleaning

Renew if orifice wear beyond limit, check by

. gauge

. Assemble all parts correctly

Immediately rectified any oil leakage, they