Basic Boiler operations

Presented by
Bapu Rane
Devanshu Kumar
Loganathan
Thao

TOPICS TO BE COVERED

BOILER SAFETY V/V SETTING

BOILER GAUGE GLASS
BLOW DOWN OF BOILER
FILLING BOILER WITH WATER
AUTOMATIC START UP & SHUT DOWN OF OIL
FIRED BOILER
AUTOMATIC START UP & SHUT DOWN OF EXAUST
BOILER

SAFETY VALVES

At least two safety valves have to be fitted to the boiler.

BLOWDOWN
The pressure drop below the lifting pressure for a safety v/v is set at 5%
by regulation although it is more normal to set v/v's at 3% to prevent
excessive loss of stm. For boilers with a superheater it is important that
the superheater v/v not only lifts first but closes last.

Safety v/v setting

SETTING
Must be set with the surveyor present except when on the waste heat unit. A chief
engineer with three years experience may then set the safety valve but must submit
information to surveyor for issue of certificate.
Superheated steam safety valves should be set as close to operating temperature as
possible as expansion can alter the relationships between valve trim and
guide/nozzle rings which can effect the correct operation of the valve.

Two safety valves- each set independently

Each safety valve must release entire steam flow in pressure accumulation test
Surveyor uses specially checked gauge
One valve gagged
valve initially set to approximately the correct position then steam pressure increased to
set pressure
adjust valve to lift
raise and lower pressure to check
fit locks to both valves on completion

Easing gear to be checked free before setting valves. Steam should not be released
as this can damage seat.

Setting of v/v

Adjustment by compression nut on top spring

plate
Compression spring over nut-no movement
Cap with cotter prevent unauthorized person
Easing gear for manual operation

BOILER GUAGE GLASS

blow the water gauge glass with A and E open.
(1) Close steam (B) and water cocks (C) then open the drain
(D). Nothing should blow out of the gauge if the steam and
water cocks are not leaking.
(2) Open and close water cock (C) to check that the water
cock connection to the boiler is clear.
(3) Open and close steam cock (B) to check that the steam
cock connection to the boiler is clear.
(4) Close the drain (D).
(5) Open the water cock (C). Water should then gradually
rise up to the top of the gauge glass.
(6) Open the steam cock (B) and the water in the glass
should fall to the level of the water in the boiler.

BOILER GUAGE GLASS

If when (5) is reached the water cock is opened and water
does not flow up the gauge glass, the water level in the boiler
is below the water cock connection to the boiler and it is unsafe
to put feed water into the boiler.

- If when the water cock has been opened the water flows to
the top of the gauge glass and then when the steam cock is
opened the water flows down and out of the glass, the water
level is between the water cock connection to the boiler and
the bottom of the gauge glass. In this case it is safe to put
feed water into the boiler.
- If after (5) when the glass is full of water, the steam cock is
opened and the water in the glass does not descend in the
glass, the water level is above the steam cock connection to
the boiler and there is a danger of priming the boiler if any
additional feed is put into it.

FILLING THE BOILER WITH

WATER

LINE UP THE VALVES TO FILL WATER FROM CASCADE TANK.

DO NOT FORGET TO OPEN VENT VALVE ON THE BOILER AND AT SAME TIME CLOSE
THE MAIN STEAM STOP VALVE.
START THE BOILER FEED WATER PUMP.
FILL THE BOILER WITH WATER UPTO SUCH LEVEL SO THAT WE CAN JUST SEE THE
WATER IN GAUGE GLASS.
SIMALTANEOUSLY LINE UP THE VALVES IN THE FUEL OIL LINE.(IN COLD STARTING
WE WILL BE STARING ON DIESEL OIL)
START THE FORCED DRAUGHT FAN FOR PRE-PURGING FOR ATLEAST 2-4 MINUTES
START THE PILOT BURNER FUEL PUMPAND IGNITOR SIMALTANEOUSLY.
IF THE FLAME IS ESTABLISHED SWITCH OFF THE IGNITOR.
START THE MAIN BURNER FUEL PUMP SO THAT FUEL IS INJECTED THROUGH MAIN
BURNER.
FLAME IS ESTABLISHED BY THE MAIN BURNER THEN SWITCH OFF THE PILOT
BURNER FUEL PUMP.
NOW START HEATING UP THE BOILER THIS IS DONE BY INTERMETTENT FIRING .
RAISE THE STEAM PRESSURE UPTO WORKING PRESSURE
ONCE THE STEAM COMES OUT OF THE VENT VALVE ,CLOSE THE VENT AND OPEN THE
MAIN STEAM STOP VALVE
DIRECT THE STEAM TO F.O HEATER

Boiler starting procedure

Preparations for firing a boiler

Before putting a boiler into operation, certain checks have to be made.
Ensure that the openings to the boiler mountings are clear and that all the
tubes of the boiler are not faulty. Replace any fittings that have been
removed and making a physical check of the boiler to ensure that they are
correctly positioned and secured.
Close all access holes such as handhold plugs and manhole covers are put
back. Check all boiler mountings and ensure that they can be operated
freely such as feed valves and steam stop valves.
Check all dampers and ensure that they are moving freely and can be
opened or closed fully. Boiler doors can now be closed up.
Check the burner to ensure that it is in good working condition. Also check
to make sure that there are no leaks and the lines are holding.
Once all checks are done and the boiler is found to be satisfactory, filling
can now begin. Start filling the boiler slowly with feed water and begin
dosing of the boiler water.

Boiler starting procedure

putting into operation
Fill water up to the lowest part of the gauge glass as this will give allowance for the water
to expand when heated.
Ensure all air check valves are opened fully.
Start the forced draught fan and commence purging of the boiler.
Carry out final checks and see whether the gauge glass cocks are properly opened and
giving a proper water level reading.
Leave the steam vent slightly opened.
Stop all air supply except to the burner and commence firing at a very low rate.
Start intermittent firing and monitor the steam pressure. Firing should be carried out
every 10 minutes for 5 minutes each time to prevent thermal shock to the boiler.

Boiler starting procedure

Slow firing should be carried out until light steam can be seen coming from
the vents.

Once the there is very high steam coming from the vents, shut the vents
and increase the firing rate.
When the steam pressure comes up to about 2 bars, slightly crack open the
main steam stop valve. This is done to heat up the line to prevent
hammering and sudden loss of pressure in the steam drum.
Once the steam pressure increases and firing is steady, the main steam stop
valve can be opened fully.
Start the feed pumps and allow the steam pressure to build up to
operational level.
Start the circulating pumps for the economiser.

when blowing down a boiler.

A modern boiler should never be blown down while the boiler is steaming at high
rates.
To blow down...
Cut the fires and close the steam and feeds stops. Allow the boiler to cool off. At
25psi, blow down to sea, the shipside valve should be open first, then the blow
down valve. This will maintain control to the operator should a pipe burst.
Care must be taken that no cold sea water enters the boiler due to residual steam
cooling to create a vacuum. A non return valve would prevent this from happening
but prudence would dictate shutting off blow down valve when getting close to no
pressure.
Open boiler vent to allow as much natural cooling as possible at atmospheric
pressure. Remove belly plug to drain the remainder contents in the bilge.
One door can then be open, top or bottom, but not both and with care. Loosening
dogs, but not undoing then to determine condition on other side steam, hot water.
Once determine door can be open being careful of remaining hot water.

Automatic Start-up of Oil Fired Boiler

Before the boiler can be started up automatically, the control unit must be preset,
sequence switch be put to start position, air damper must be closed, all thermostat
and pressurestat contacts are closed and the air pressure monitor contact must be
closed.
Once all this prerequisites are in order, the boiler can be fired automatically,
following a start-up sequence
By turning the start switch on, the burner motor receives a voltage signal to start
Exhaust gas ventilator receives a signal to open
Electric air dampers open.
Pre-purging begins and removes all gasses in the boiler and fills it with fresh air.
Air pressure monitor senses the air volume and automatically cuts off the F.D. fan.
The air dampers now go to half open position. A short pre-ignition of the burner
starts and fuel valves are opened to begin firing.
A flame eye detects the flame and sends an amplified electrical signal to the burner
which continues ignition until the desired pressure is reached

Automatic Start-up of Oil Fired Boiler

If the flame eye detects a fault i.e. the boiler does not
fire up, it will close the fuel and air valves which stop
the firing sequence immediately.
Once successfully fired up, the sequence switch
switches off immediately and the burner is allowed to
continue firing.
Pressure controllers maintain the steam pressure by
cutting the burner in and out automatically.

Automatic Shut Down of Oil Fired

Boiler

When automatic shut down switch is pressed, the fuel valves

are closed immediately.
The F.D. fan continues to supply air and post-purge begins.
The post-purging time is controlled by a timer in the switch
and usually lasts for a minimum of 3 minutes.
Once post-purging is finished, the air damper closes.
During this time, there may still be flames in the boiler known
as after burning.
The flame eye will detect the after burning period to ensure
that it dies out within a set-time.
If there is still flame present after the time delay period of the
flame eye. It will detect this and an alarm will go off.

Automatic Start-up of Exhaust Gas

Boiler

The exhaust gas boiler is a water tube exhaust gas boiler with forced water
circulation. The feed water is first supplied to the oil-fired boiler and then supplied
to the exhaust gas boiler by means of a circulating pump. The steam produced in
the exhaust gas boiler is then returned to the oil-fired boilers steam drum where it
can be put into use. The procedure for starting up the exhaust gas boiler is as
followed;

All the valves on the exhaust gas boiler except for the circulating pump discharge
valve to be opened.
The oil-fired boiler is to be started up and set under pressure before the circulating
pumps are started. This is to ensure that the feed water to the exhaust gas boiler is
hot and will reduce the heat needed to generate steam by the flue gas.
Once the oil-fired boiler is started up, the circulating pump discharge valves are to
be opened and the pump to be put on auto.
The water level in the exhaust gas boiler is kept constant by a level indicator.
The boiler circulating pump will start and stop automatically depending on the
water level in the exhaust gas boiler.

Automatic Shut down of Exhaust Gas

Boiler

The exhaust gas boiler will automatically stop

producing steam when the engine has stopped due to
the lack of heat from the flue gas.
When the engine has stopped, the circulating pump
must be put on manual so as to keep the tube coils full
of water. This is to prevent uneven heating of the
tubes due to the void space left by the loss of steam.
The valves connecting the exhaust gas boiler and the
oil fired boiler, are normally kept open after stopping
to keep the system warm and reduces the time taken
to start up the boiler from cold.