Your guide to safer boiler operation

Your guide to safer boiler operation

Your guide to safer boiler operation BOILER CHEMICAL INFORMATION
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4 1

8 C
5 Supply main D
2 E
ASME
B Relief valve
Check
valve
City water
supply
8
6 Fill valve
normally
used

3 7
Hot water boiler

Pump

Return main

Steam boiler Hot-water boiler

1. Safety valve Steam boiler A. Expansion tank
Hot-water boiler
2. Safety
1. Low-water valvecutoffSteam boiler B.A.Low-water
Expansion cutoff
Hot-water
tank boiler
3.Safety
1.2. Water column
valve
Low-water cutoff blow-down valve C.A.
B. Combination
Expansion
Low-water temperature/pressure
tank
cutoff
4.Low-water
2.3. Pressuretrols
Water column (one
cutoff is high-limit
blow-down valvesafety) gauge
C. or altitude/temperature
B. Combination
Low-water cutoff gauge
temperature/pressure
5. Steam
3.4.Water pressure-gauge
column(one
Pressuretrols blow-down valvesafety)
is high-limit D. Operating
C. Combination
gauge aquastattemperature/pressure
or altitude/temperature gauge
6.Pressuretrols
4.5. Water column
Steam clean-out
pressure-gauge
(one (cross tee)
is high-limit safety) E.D.High-limit
Operating
gauge safety
aquastataquastat
or altitude/temperature gauge
7.
6. Bottom
Water blow-off
column
5. Steam pressure-gauge and
clean-out drain valve
(cross tee) E. High-limit
D. Operating aquastatsafety aquastat
8.Water
6.7. Low-water
Bottom column cutoff/blow-off
blow-off and drain
clean-out valve
(crossvalve
tee) E. High-limit safety aquastat
Note:
7.8. Second
Low-water
Bottom low-water-cutoff
cutoff/blow-off
blow-off and drain valve not shown in diagram
valve
8.Note:
Low-waterSecondcutoff/blow-off
low-water-cutoff not shown in diagram
valve
Boiler water-level – The first duty when taking over a boiler-room shift is to make certain the pipe, fittings and valves
betweenNote: the water Second
glasslow-water-cutoff
and boiler are free notandshownopeninbydiagram
blowing down the water column and water glass and noting the
Boiler water-level – The first duty when taking over a boiler-room shift is to make certain the pipe, fittings and valves
promptness of the return of water to the glass.
betweenwater-level
Boiler the water glass and first
– The boiler are when
duty free and takingopen by ablowing
over downshift
boiler-room the water column
is to make and water
certain glass
the pipe, and noting
fittings the
and valves
promptness
between of the return of water toare
thefreeglass.
The most important rule – The most important rule for the safe operation of boilers is to maintain the proper water- the
the water glass and boiler and open by blowing down the water column and water glass and noting
promptness
level at all of the return
times, and as of water to
constant the glass.
a level as conditions will permit. If water is not visible in the water glass, shut the boiler
The most important rule – The most important rule for the safe operation of boilers is to maintain the proper water-
off immediately until a safe water-level has been determined.
levelmost
The at all times,
important and as constant
rule – The a level
most as important
conditionsrule willforpermit. If water
the safe is notof
operation visible
boilers in is
thetowater glass,the
maintain shut the boiler
proper water-
off
level immediately
at all times, until
and a
as safe water-level
constant a level has
as been determined.
conditions will permit. If water
Low-water and feedwater controls – The low-water cutoff is the most important electrical/mechanical device on is not visible in the water glass, shut the boiler
offyour
immediately until a safeawater-level
boiler for maintaining safe water-level. has been determined.
If a low-water condition develops, it could very well result in an overheating and
Low-water
explosion of your and feedwater
boiler. The low-water controls – The low-water
cutoff should be tested atcutoff is the most important electrical/mechanical device on
least weekly.
your boiler for maintaining a safe water-level.
Low-water and feedwater controls – The low-water cutoff is the most If a low-water condition develops, it could very well
important result in an overheating
electrical/mechanical andon
device
explosion
your of your
boiler for maintaining
Low-water boiler. The low-water
a safe water-level.
cutoff, evaporation cutoff should
test If(steam be
a low-water tested at least
– While
condition
boiler) weekly.
the boiler
develops, is invery
it could operation, shut in
well result offanthe feedwater and
overheating
pump and
explosion ofmonitor
your boiler.the boiler water-level.
The low-water Theshould
cutoff low-water cutoffatshould
be tested shut down the burner before the water level goes
least weekly.
Low-water
out of sight low; cutoff, evaporation
if the burner does not shut testoff,(steam
restart theboiler)
feedwater – While the boiler
pump before is in operation,
the water level goes shut
out ofoffsight
the low
feedwater
and
pump and
immediately monitor the
troubleshoot boiler
the water-level.
low-water The
cutoff to low-water
determine cutoff
the causeshould
of shut
failure.
Low-water cutoff, evaporation test (steam boiler) – While the boiler is in operation, shut off the feedwater
down
The the
boiler burner
must be before
under the water
constant level
attendancegoes
out
by ofproperly
a sight low; if the burner
licensed engineer doesat nottimes
all shutduring
off, restart
this the feedwater pump before the water level goes out of sight low and
test.
pump and monitor the boiler water-level. The low-water cutoff should shut down the burner before the water level goes
immediately troubleshoot the low-water cutoff to determine the cause of failure. The boiler must be under constant attendance
out of sight low; if the burner does not shut off, restart the feedwater pump before the water level goes out of sight low and
by a properly licensed
Low-water cutoff,engineer
slow drain at alltest
times(steam
during this test. – While the boiler is in operation, shut off the feedwater pump
boiler)
immediately troubleshoot the low-water cutoff to determine the cause of failure. The boiler must be under constant attendance
byand slowly open the bottom blow valve to drain the water from the boiler. The low-water cutoff should shut down the burner
a properly licensed engineer at all times during this test.
Low-water
before the water cutoff,
level goesslow outdrain
of sighttestlow;(steam
if the burner boiler)
does not– While the restart
shut off, boiler the
is infeedwater
operation,pump shut before
off thethefeedwater pump
water level
and
goesslowly
out ofopensightthelowbottom blow valvetroubleshoot
and immediately to drain the water from thecutoff
the low-water boiler.toThe low-water
determine the cutoff
cause should shutThe
of failure. down themust
boiler burner
Low-water cutoff, slow drain test (steam boiler) – While the boiler is in operation, shut off the feedwater pump
before
be under theconstant
water level goes outbyofasight
attendance low;licensed
properly if the burner doesatnot
engineer allshut
timesoff, restart
during thetest.
this feedwater pump before the water level
and slowly open the bottom blow valve to drain the water from the boiler. The low-water cutoff should shut down the burner
goes out of sight low and immediately troubleshoot the low-water cutoff to determine the cause of failure. The boiler must
before the water level goes out of sight low; if the burner does not shut off, restart the feedwater pump before the water level
be under constant attendance by a properly licensed engineer at all times during this test.
goes out of sight low and immediately troubleshoot the low-water cutoff to determine the cause of failure. The boiler must
be under constant attendance by a properly licensed engineer at all times during this test.
 Firing – Aside from the standpoint of economy, maintain the fire as uniformly as possible to avoid an excessive rate of
combustion, undesirable variations in temperature and possible explosions. The destructive force in a boiler explosion is
caused by the instant release of energy stored in the water as heat.

Water gauges – Keep all connections and valves clear. Test by blowing down the water glass and water column regularly.
Gauge cocks or tri-cocks should also be blown regularly.

Safety valves – The safety valve is the most important valve on the boiler. Safety valves prevent dangerous over
pressurization of the boiler. Safety valves are installed in case there is failure of pressure controls or other devices designed
to control the firing rate. All safety valves should be kept free of debris by testing the safety valve regularly. This should be
done when the steam pressure is at approximately 75 percent of the safety-valve set pressure. Safety and safety-relief valves
on low-pressure boilers should be tested at least quarterly, this is in accordance with the National Board Inspection Code.

Blow-down valves – The concentration of solids in the boiler should be measured and the boiler blown-down at such
intervals as necessary to maintain established limits. Blow-down valves are placed at the lowest point of the boiler for the
purpose of blowing sediment or scale from the boiler. They should be maintained in good working order and are to be opened
and closed carefully when used.

Starting fires in a boiler – Before starting fires in a cold boiler or restarting a fire that may have been accidentally
extinguished, the entire fireside of the boiler must be thoroughly ventilated (purged) with the dampers open to remove
unburned gases before attempting to relight the fire. Attempting to start a fire in a boiler with unburned gases is the most
common cause of boiler furnace explosions.

Boiler-room requirement – A current proper engineer’s license and log shall be posted in the boiler room. It is the
responsibility of the owner and the engineer to make sure the boiler is inspected annually.

Hot-water systems – These systems are equipped with expansion tanks for the expansion and contraction of the water
as the temperature varies.

Firing cycle, power burners – The burner will start when the aquastat or pressuretrol calls for heat. The breeching
damper will open and the draft fan will purge the combustion chamber. The main gas or oil valve will be energized when
the pilot or ignition is proved.

Repairs – Any excessive overheating or burning, and any major repairs, must be reported to your boiler inspector.

Classification of boilers – High-pressure boilers are boilers operating at a steam or other vapor pressure in excess of 15
psig, or a water or other liquid boiler in which the pressure exceeds 160 psig, or has a temperature greater than 250 degrees
Fahrenheit. Others are low-pressure boilers.

License requirement – Minnesota Statutes §183.501 states "No person shall be entrusted with the operation of or
operate any boiler, steam engine or turbine who has not received a license of proper grade covering that boiler, steam engine
or turbine.

Study material – The Division of Boiler Inspection has no study material available and suggests you contact your nearest
technical college for classes or resource materials, or contact a library or bookstore for the appropriate book.

The following books may prove useful to boiler operators:

• Special Engineer: Safe Boiler Operation Fundamentals by ATP and Low Pressure Boilers by Frederick
M. Steingress
• Grade "C" licenses: Low Pressure Boilers by Frederick M. Steingress
• Grade "B" licenses: High Pressure Boilers by Frederick M. Steingress and H.J. Frost
• Grade "A" licenses: Steam Plant Operation by Woodruff and Lammers
• Grade "B" and "A" licenses: Stationary Engineering by Steingress, Frost and Walker
This document can be made available in alternative formats, such as large print,
Braille or audio, by calling (651) 284-5031; TTY call 1-800-627-3529.
Revised July 2013
ORIGINAL Source: Minnesota Department of Labor & Industry, https://www.dli.mn.gov/ccld/PDF/guide2saferboiler.pdf