BOILER – STEAM GENERATOR

Know your Boiler

1. Do not operate boiler unless you have
been trained and qualified. Operate
boiler in accordance with the
manufacturer’s recommendation.
2. Comply with environmental regulations:
a. Air pollution from heavy smoke
b. Disposal of used oil in drainage
c. Blow down containing chemicals in
drainage.
3. Should have installation and operating
permits from the DOLE/DENR.
 Rules to Remember when
Operating a Boiler
Do not operate new boiler until it has first been boiled out
with caustic solution to remove oil or grease.
When starting up for the first time, fire at low rate to dry
refractory lining.
Avoid sudden heating or cooling.
Check water level daily or upon taking up a shift.
Blow water level controls frequently
Keep boiler clean on inside (soot and scale).
Inspect regularly both fire- and water-sides surfaces for
corrosion or pitting
Give boiler immediate attention when taken out of
service to prevent deterioration.
Consult boiler water specialist for correct treatment to
prevent scale and corrosion.
Horizontal boiler
Vertical boiler
Code Requirements for Boiler Trim
Boiler Trim – minimum accessories that are required to monitor the
boiler properly and to operate it safely.
1. Steam Pressure Gage –registers the actual steam pressure;
should be calibrated at least once a year; dial shall be graduated
approximately double the pressure at which the safety valve is set,
but in no case less than 1-1/2 times the safety valve setting; a valve
or cock shall be placed in the gage line adjacent to the gauge; shall
contain a siphon which will develop and maintain a water seal that
will prevent the steam from entering the gauge.

2. Water Column – for observing water level in the boiler. The

standard water column consists of an enlarged water chamber with
tappings on top and bottom for vertical installation, provisions for a
water level gauge glass, and three tappings on the side for test
cocks. These three (3) cocks are of the manual style, and are the
only approved guarantee of water level indication. The glass gauge
is not considered 100% reliable, since is it subject to plugging and
dirt and may be unreliable, and the gauge valves may jamb closed.

3. Safety Valves – most important valve on the boiler. It can mean

between life and death. Each boiler shall have at least one safety
valve, and if the boiler has more than 46.5 sq. m. water heating
surface or the generating capacity exceeds 910 kg/hr, it shall have
two (2) or more safety valves.
 Boiler Controls for Safety
Burner Management Systems
1. Low Water Cutoff – interlocked to cause a
non-recycling safety shutdown when a low
water level exists.
2. Excess Pressure Cut-off Switch – safety
shutdown in case of abnormally high steam
pressures.
3. Excess Temperature Cut-off Switch – safety
shutdown in case of abnormally high
temperatures.
4. Suitable Limit Switches – to insure that the
fuel-air proportioning dampers and burner
controls are on the low-fire start position before
burner can be fired.
5. Combustion Flame Safeguard – for the
igniter and main burner flames
6. Automatic Restart, Alarm, Safety Shut-off
Valve, Flame Detectors, Flame Rods,
Infrared Detectors.
7. Steam Pressure Control
8. Boiler Alarm System

Water Level Control

1. On-and-Off Feed Water Pump
Controls – to meet the water level
requirements of the boiler.
2. Fusible Plug – melt out and allow any
remaining water in the boiler to spray down the
flame.
 Boiler Plant Safety
A. Boiler Testing and Inspection
1. All boilers are inspected once a year by the Bureau of Labor
Standards and insurance agencies.
2. All boilers must be given a hydrostatic test if any repairs are made
on the pressure portions of the boiler, and also whenever the
inspector determines that a test should be made for any reason.
3. Hydrostatic will be made at one and one half times the maximum
allowable working pressure of the boiler.
4. To prepare boiler for inspection –
a. The water must be drawn off and boiler thoroughly washed.
b. All hand hole covers and wash-out plugs in the boiler, feed
lines, and water column connections that are necessary for
adequate inspection must be removed.
c. The furnace and combustion chambers shall be thoroughly
cooled and cleaned.
d. Enough of the brickwork, refractory, or insulating material shall
be removed to permit the inspector to determine the condition of
the boiler, furnace and other part of the boiler.
c. When opening up the boiler in preparation for testing, we
suggest that a water treatment specialist be present to obtain
sample of the sludge, scale or soot deposit from the boiler for
analysis.
Remember! The boiler inspector is looking after your
safety, as well as the safety of other, so it makes good
sense to cooperate with him. They are an excellent
source of help and information on how to get the best
from your boiler.

Compliance with Codes

The PSME Boiler Construction Code Committee was
set up in 1992 to formulate standard rules of safety
governing the design, fabrication, and the inspection
during the construction of the boilers and unfired
pressure vessels.

Certificate of Boiler Inspection and Permit to Operate

 Boiler Efficiency
Factors that Affect Boiler Efficiency:
1. Combustion Efficiency – relate to burner performance
and stack losses only, quality of fuel oil, proper air to
fuel ratio, pre-treating of the fuel that affect combustion
and influences efficiency.
2. Scale and soot deposits.
3. Blow down – high blow down rates contribute to huge
heat losses and low blow down promote scale
formation
4. Mode of operation – Low-medium-high-fire

Boiler Efficiency Tester – (flue gas analyzer) to

determine if a burner needs adjustments or the boiler
needs to be cleaned.
 NORMAL OPERATION REMINDERS
1. Exit flue gas temperature (boiler pressure of
150 psig)– not over 550 °F/ 285 °C
2. Heavy fuel oil temperature -- 90°C - 110°C
3. Feed water hardness – 0-10 ppm
4. Excess air – 15% no.6 bunker, 10% diesel
5. Feed water pH – 7.5-11.5
6. Safety valve setting – 6 % above operating
pressure (factory set)
7. Blow off frequency – once per shift do not blow
off at high pressure or during maximum steam
demand.
 MAINTENANCE
- Systematic Inspection
- Systematic repair

Annual boiler inspection and boiler

permit to operate
Things to Do During Shutdown
Maintenance
Remove soot from fireside.
Remove scale from waterside.
Drain water from boiler.
Remove handhole and manhole covers.
Remove oil from waterside.
Check boiler accessories.
Remove grates and check setting.
 Daily check list/recorded
Check fuel oil temperature
Check exit flue gas temperature
Check air/fuel ratio (visual at smoke stack)
Check feed water hardness, pH
Check fuel oil atomizing pressure
Check feed water pump amperage
Check water column blow down
 Monthly Check List/Recorded
Check/ clean fuel oil filters
Check/ clean atomizing cups/ nozzles
Check/ clean/ adjust controls

Annual Shutdown for Boiler Inspection

Clean fire- and water-side
Check and calibrate all boiler fittings
Hydro-testing
 Primary Causes of Boiler Damage
1. Overheating due to low water level and of scale
formation.
2. Corrosion due to inadequate feed water treatment.
3. Gross operator error.

Boiler availability program should include at least

these objectives:
Have competent technicians frequently maintain and
test water level monitoring devices and low water
alarm.
Use state-of-the-art waste chemistry to reduce scale
formation and eliminate corrosion, foaming, priming
(carryovers).
Provide on on-going training program for both new and
veteran boiler operators and maintenance.
Complacency among your experienced employees is
almost as destructive as the lack of knowledge among
new hires.
 Boiler feed water treatment
Zeolite softener – mixed bed resins consisting of
anions and cations. The most common method
of boiler feed water treatment.

Demineralization process – consist of from three

to as many as six separate steps in the process,
before water is reduced to almost chemically
pure water.

Dealkalizer – reduces alkalinity and sometimes

will reduce silica in the water
 Energy Savings in the Boiler
Room
1. Improving combustion efficiency.
2. Reducing energy cost in boiler blow down
3. Improving efficiency through good water
quality.
4. Use of economizers and air pre-heater.
5. Boiler maintenance and operating
considerations (flue gas temperature and
analysis, etc.)
6. Prevent leakages (water, fuel, air, heat, etc.)
7. Recycle condensate
8. Steam traps