WHAT DO YOU MEAN BY MARINE BOILERS?

Boiler is a pressure vessel used on ships in which the water is heated to evaporate and generate
the steam and the unit is so arranged that the generated steam accumulated in it. The two main
types are water tube and fire tube.
 FIRE TUBE BOILER – Fire or smoke pass inside and water outside the tubes.
 WATER TUBE BOILER - Fire or smoke pass outside and water inside the tubes.

ADVANTAGES OF WATER TUBE BOILERS ARE:

 High efficiency (generally greater than 85 %) hence reduced fuel consumption.
 Flexibility of design – important space consideration.
 Capable of high output (i.e., high evaporation rate).
 High pressures and temperatures improve turbine plant efficiency.
 Flexible in operation to meet fluctuating demands of the plant – superheat control rapidly
responsive to changing demands.
 Generally, all surfaces are circular hence no supporting stays are required.
 Steam can be raised rapidly from cold if the occasion demands (3 to 4 hours compared to
24 hours for smoke tube or fire tube boilers) because of the positive circulation.
 Consider a fire tube or smoke tube boiler and a water tube boiler with similar evaporation
rates the water tube boiler would be compact and relatively light by comparison and its
water content would be about 7 tonnes or less compared with the smoke tube or fire tube
boiler’s 30 tonnes.
 With double casing radiation loss can be cut to 1 % or less.

BOILER MOUNTINGS
Various valves and other fittings attached directly to the pressure parts of the boiler which are
required for the proper working of the boiler are known as boiler mountings

SAFETY VALVES
 At least two safety valves must be fitted on the steam drum of each boiler.
 If the boiler is equipped with a superheater, then a 3 safety valve must be fitted on the
rd

superheater outlet header.

 The safety valve fitted on the superheater outlet header must be set to lift before the drum
safety valves to ensure a flow of steam through the superheater under blow off conditions.
MAIN STEAM STOP VALVE
 Mounted on the steam drum.
 It is a shut off valve.
 If two or more boilers are fitted supplying steam to a common line, the stop valve on each
boiler must be a screw down non-return type. This is to prevent steam from the other boiler
flowing into a damaged boiler in the event of a loss of pressure du e to a burst tube.
 When closed, it isolates the boiler from the main steam line.
BY-PASS VALVE
 It is a shut off valve.
 The purpose of the valve is to equalise the pressure between the boiler and the steam
system when the main steam valve is closed. Please note that the by-pass valve is only
supplied for larger boilers.
FEED WATER VALVES
 Two groups of feed water valves are provided in the boiler (main and auxiliary).
  Each group comprises of a shut-off valve and a non-return valve, in the event of a loss of
feed pressure, the boiler water cannot blow back into the feed line
WATER LEVEL GAUGES
 Two local water level gauges are connected to the boiler steam drum.
 Each local gauge being provided with two shut-off valves and a drain valve.
 The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-closing
mechanism to be used in case of broken glass.
 The pipes from the drain cocks on the water level gauge must lead to an open drain, visible
for inspection.
REMOTE WATER LEVEL INDICATOR CONNECTIONS
 One remote level indicator is fitted to show water level on the ECR.
BOTTOM BLOW-DOWN VALVES
 Two blow-down valves are mounted at the bottom of the water drum.
 When connected to a common drainage system two valves are provided in each group, one
shut-off valve and one shut-off/non-return valve.
 The shut-off function is for security and the non-return function prevents steam/water from
flowing into an empty boiler by mistake.
SCUM BLOW-DOWN VALVES
 The scum blow-down valves are mounted on the steam drum.
 When connected to a common drainage system two valves are provided, one shut-off valve
and one shut-off/non-return valve.
 The shut-off function is for security and the non-return function prevents steam/water from
flowing into an empty boiler by mistake.
AIR VENT VALVE
 The air vent valve is located on top of the boiler.
 It is a shut-off valve.
 It is normally closed except when the boiler is being filled or completely drained.
 The end of the drain pipe from the air valve must be visible in order to determine when
water or steam is coming out.
BOILER WATER SAMPLING VALVE
A sample valve is installed enabling connection to a sample cooler for taking test samples to
perform boiler water analyses.
MANHOLES
Two manholes placed at the boiler top and boiler bottom to allow inside inspection of the steam
and water drum.
HAND HOLES
Hand holes are provided circumferentially around the the boiler bottom for inspection and
cleaning purposes.
PEEP HOLE
 They are provided in the furnace wall to enable inspection of the burner flame.
 A proportion of the air supply is bled off from the burner fan to cool the window of the
inspection hole, and prevent soot deposits.
ACCESS DOORS
 Access to the furnace and smoke outlet box are possible through the access doors placed at
the bottom of the furnace and at the smoke outlet box respectively.
 Both access doors enable inspection of the generating tube bank.
FURNACE DRAIN
The furnace bottom is provided with a socket for drain of the washing water .
PRESSURE GUAGE CONNECTIONS
THERMOMETRE POCKETS

BOILER TUBES

SCREEN TUBES
These are placed adjacent to the furnace.
Receiving heat from the flame together with heat from the hot gases leaving the furnace.
Therefore, they need a relatively larger diameter to keep the ratio of steam to water low
enough to prevent overheating.
Function: To protect the super heater tubes from the direct radiant heat of the furnace flame.
GENERATING TUBES
These consists of numerous small diameter tubes placed in the main flow of hot gases, so forming
a large heat exchange surface; the generation of steam takes place mainly by convection.
In general, the number of generating tubes tends to be reduced in modern boilers, until indeed
in radiant heat boilers no generating tubes as such are fitted. Water walls receiving radiant heat
are used instead.
WATER WALL TUBES
These are used basically to contain the heat of the furnace, thus reducing the amount o f
refractory material required. In some types of boilers, water cooled refractory cells are used.
These consist of tubes with studs welded onto them, covered with refractory material, which can
now withstand the high temperatures without damage. In other designs part of the tube
surface is exposed to radiant heat which helps to generate steam. In some radiant heat boilers,
the tubes are welded together along their length by fins or strips, and refractory is required.
DOWNCOMER TUBES
These consist of large diameter, unheated tubes placed outside the gas stream which act as
feeders to the water drum and headers.
RISER OR RETURN TUBES
These return steam and water from the top water wall headers to the steam drum.
SUPERHEATER TUBES
These consist of small diameter tubes placed in the main gas stream, after the screen tubes.
Their duty is to superheat the saturated steam leaving the drum to a temperature suitable for
use in the main turbines. They must be protected from direct radiant heat as they are liable to
overheating due to the much smaller specific heat of steam compared to that of water.
SUPERHEATER SUPPORT TUBES
This relatively large diameter tubes act basically as water cooled supports for the superheater
tubes.

BOILER TUBE MATERIAL

 For steam temperatures below 455°C Solid-drawn mild steel tubes can be used.
 For steam temperatures above 455°C, in the case of superheater tubes, heat resisting
alloy steel, containing small amounts of chrome and molybdenum must be used.

HOW TO IDENTIFY A LEAKY TUBE IN A FIRE TUBE BOILER?

 Stop firing the boiler.
 Keep the boiler on pressurised condition.
 Open the access door on both sides of the boiler.
 Around the leaky tube edges sweating/steaming will be there.
 Or put a cotton on a long rod and push it inside each tube, leaky tube contains wet soot.

HOW TO PLUG A LEAKY TUBE IN A BOILER?

 Put holes on the tapered plugs supplied by the manufacturer.
 Plug the leaky tube on both sides using tapered plug.
 Insert a stud through both the tapered plug and tighten on both sides using washer and
nuts.
 If it is a curved tube put a chain instead of rod.

TAPPERED PLUG MATERIAL AND WHY SO?

 Same material as Boiler tubes- Mild steel.
 To prevent thermal expansion due to dissimilar metals
 To prevent galvanic corrosion.

PURPOSE OF AIR VENT COCK?

 To release air from the boiler either filling the boiler water or raising the steam.
 To allow air to enter in the event of boiler cooling down or blowing down. (To
prevent vacuum effect)

WHY MAN HOLE DOOR ARE ELLIPTICAL IN SHAPE?

 Any opening in a pressure vessel to be kept to a minimum. Thus, for a man entry an
elliptical hole is lesser in size than the corresponding circular hole.
 Moreover, it is prime concern to have a smoothed generous radius at the corners to
eliminate stress concentration
  To compensate for the loss of material in the shell due to opening, a doubler ring has to be
provided around the opening. The thickness of the ring depends on the axis length along
the direction in which the stresses are maximum and the thickness of the shell.

WHAT DO YOU MANT BY SPIGOTT CLEARANCE?

 It is the clearance provided between the compensating ring and the manhole door of the
boiler.
 Clearance is given for thermal expansion.
 Maximum clearance value is 1.5mm on both sides of the manhole door.

PURPOSE OF COMPENSATING RING ON BOILERS?

 If any holes cut in the boiler shell, with a diameter greater than 2·5 x plate thickness + 70
mm a compensating ring must be provided for the loss of strength due to the material cut
out.
 It can be fitted either internally or externally.
 Tell tale hole is provided between the inner and outer weld.

PURPOSE OF OGHEE RING ON BOILERS?

 Boiler crown is connected to the boiler shell via Oghee ring.
 Tell-tale holes drilled at equal circumferential intervals in the boiler shell enable leakage
between the ‘Ogee’ ring and the boiler shell to be detected.

PURPOSE OF GUSSET STAY ON BOILERS?

 It supports tube plate stack on top to the Boiler shell.

PURPOSE OF SLIDING FOOT ON BOILERS?

 Fitted only for bigger WT boilers.
 Provides room for expansion of the boiler when it is pressurised.

WHY SCUM BLOW DOWN OR SURFACE BLOW DOWN IS CARRIED OUT?

 To remove accumulated, suspended, and floating solids and impurities.
 It also removes dissolved solid concentration; they hinder the formation of steam.

WHY BOTTOM BLOW DOWN IS CARRIED OUT?

 To remove suspended solids and residual sludge that have settled at the bottom.
 If these contaminants are not removed regularly, they will build up until they hinder
the circulation patterns.
WHY GAUGE GLASS BLOW DOWN IS REQUIRED?
 To know the boiler and gauge glass connection is clear.
 To know the exact water level in the boiler.

BOILER GAUGE GLASS BLOW DOWN PROCEDURE?

 Shut steam and water cocks, then open the drain cock.
 After draining water from the sight glass, there is nothing come out, both steam and
water cocks are good in order.
 Keep the drain cock open and open the steam cock, steam blows out through the drain
cock. Close the steam cock, the steam connection is clear.
 Keep the drain cock open and open the water cock, water will blow out through the drain
cock. Close the water cock, the water connection is clear.
 Close the drain cock.
 Open the water cock, water should then gradually come and rise up to the top of the
gauge glass.
 Open the steam cock, the water in the glass should fall to the level of the water in the
boiler.

REFLEX/PLATE TYPE BOILER GAUGE GLASS

 The Reflex/Plate type gauge glass are suitable for medium pressure boilers.
 The gauge glass is normally fitted either directly or via a column to the boiler shell.
 The isolating cocks in the steam, water and drain are of the asbestos sleeve type. These
cocks can be operated by extended chains, to prevent injury in the event of the glass
shattering in the event of gauge glass blow down.
 However, the glass plates are made so strong, therefore failure does not occur often and
even it breaks the pieces of glass frequently remain in position; thus, the fitting of an extern
al guard is not necessary.
 The single-sided glass ingeniously makes use of the refraction of light so that, when
illuminated from the front, the series of ribs at the back of the glass plate cause the light
rays to be reflected from the steam space and absorbed in the wat er space. This gives a
bright silvery appearance to the former. while the latter shows dark. Th e strong contrast
between the two enables the operator to see immediately the position of the water level. It
also makes it possible to tell at a glance whether the glass shows completely empty or
completely full of water-a condition which causes some confusion with many other types of
gauge glass.
 A ball valve is normally fitted to the lower end of the gauge to shut off the water in the
event of glass plate shattering and blowing out. The ball valve thus pr events the escape of
water, with the resulting flash-off of large amounts of steam, making it difficult to shut off
the gauge, and possibly causing injury.
 To resist erosion a special borosilicate glass is used. But for higher pressures a sheet of mica
is used in between to prevent the water from coming into direct contact with the surface of
the glass.
FUNCTION OF SAFETY VALVE?
Safety valves are fitted to protect the boiler from the effects of overpressure.

HOW MANY SAFETY VALVES ARE FITTED?

 At least two safety valves must be fitted on the steam drum of each boiler.
 If the boiler is equipped with a superheater, then a 3 safety valve must be fitted on the
rd

superheater outlet header.

 The safety valve fitted on the superheater outlet header must be set to lift before the drum
safety valves to ensure a flow of steam through the superheater under blow off conditions.

SAFETY VALVE SETTING REQUIREMENT?

Lifting pressure: Should not exceed 3% of the maximum allowable working pressure.
Seating Pressure:

WHEN BOILER SAFETY VALVE SETTING MADE?

 During every boiler survey.
 After safety valve overhaul.

WHY SAFETY VALVE ARE FITTED INSTEAD OF A RELIEF VALVE?

Escape rate is more for a safety valve compared to that of a relief valve. The safety valves must be
supplied with waste steam pipes and either expansion devices, or bellows.

DIFFERENCE BETWEEN A SAFETY VALVE AND A RELIEF VALVE?

Safety valve
 Once the system pressure reaches the set pressure, safety valve lifts rapidly almost 60-70%
of full lift.
 Setting pressure is just above the working and not more than 3% above the
approved working pressure.
Relief valve
 Once the system pressure reaches the set pressure, relief valve starts to lift and the valve lift
is directly proportional to the system excess pressure.
 Setting pressure is 10% above working pressure.

WHY SAFETY VALVE IS FITTED IN TWO NUMBERS?

 To make sure that the positive discharging of higher steam pressure from the boiler.

WHY FITTED IN ONE VALVE CHEST?

To minimize the numbers of cutting holes on the boiler
 To save its strength.
 To reduce stress concentration

WHY SAFETY VALVES ARE FITTED AT DIFFERENT PRESSURE?

It is practically impossible to set both the safety valves at same pressure.

WHAT ARE THE MARKINGS ON SAFETY VALVE ?

 Manufacturer’s name
 Serial number
 Inlet diameter
 Operating pressure
 Discharge capacity
 Safe working pressure
 Blow off pressure
WHAT IS MEANT BY ACCUMULATION PRESSURE TEST IN BOILERS?
 As per Classification society requirement, with the steam stop valve shut and boiler under
maximum firing condition the accumulation of pressure should not exceed 10 percent of the
max design pressure within 15 minutes for a fire tube boiler or 7 minutes for a water-tube
boilers.
 During this test, no more feed water is to be supplied than is necessary to maintain a safe
working water level.

WHAT IS MEANT BY ACCUMULATION PRESSURE IN BOILERS?

Accumulation pressure is the rise in boiler pressure which takes place when the spring-loaded safety
valve lifts due to the increased loading caused by further compression of the spring.

WHAT IS THE PURPOSE OF ACCUMULATION PRESSURE TEST?

 To detect the safety valve is suitable for this boiler or not.
 To limit the rise in boiler pressure under full fire condition.

WHEN ACCUMULATION PRESSURE TEST CARRIED OUT?

 This test is carried out on a new boiler or new safety valve.
 If safety valve is replaced with a different type and make.

WHAT IS THE PROCEDURE OF ACCUMULATION PRESSURE TEST?

 Take required quantity of water, put the feed water pump in manual mode and isolate the
feed water system.
 Shut off the main steam stop valve.
 Increase the steam cut off pressure of the boiler.
 Bypass the high pressure cut off the boiler.
 Gag one safety valve.
 Start the boiler at maximum firing rate.
 Safety valve will lift during the test.
 Once the safety valve lifts, start the stop watch.
 Accumulation pressure should not exceed 10% of the maximum allowable working pressure
in the specified time (15 mins for a smoke tube boiler and 7 mins for a water tube boiler).

PROCEDURE OF SAFETY VALVE SETTING UNDER STEAM PRESSURE?

 Necessary tools required for the setting like spanner, gagging tool etc must be ready.
 Make sure that the steam blow off line and the drain after the safety valve is unclogged and
should have free passage.
 Make sure that safety valve has been assembled properly.
 Gag the other safety valve to prevent it from lifting.
 Take standard pressure gauge (approved by surveyor) for accuracy.
 Boiler is ready to be fired.
 Shut off the main steam stop valve.
 Increase the steam cut off pressure of the boiler.
  Bypass the high pressure cut off the boiler.
 Start firing the boiler manually and slowly raise the steam pressure.
 Screw down the compression nut little bit more than the previous distance.
 Now let’s say you have to set the safety valve at 9 bar. So, raise the pressure slowly. Just
before the 9 bars, like 8.8 or 8.9, you will start seeing little bit of steam coming out of the
safety valve. Slowly loosen the compression nut in such a way that the valve will lift at 9 bar
pressure.
Note: If your safety valve lifts at 10 bar instead of 9, then don’t try to set it down at the
same time. Lower the pressure to 7 bar or something and then adjust the compression nut
and then again raise the pressure to 9 bar.
 Once setting has completed, reduce the pressure and gradually increase to set pressure.
Ensure that safety valve lifts at 9 bar pressure.
 The distance between the bottom of the compression nut and the top of the safety valve
cover bushes are measured by a scale of vernier calliper.
 Then we must make split ring of the same size and put. This kind of locks the compression
nut.
 Again, fire the boiler and remove the gagging tool from the second safety valve and put it
on the first safety valve.
 Repeat the process with the second safety valve like the first one.
 When the surveyor satisfied the setting pressure, easing gear should be tested.
 All safety valves set to lift at not greater than 3% above the maximum allowable working
pressure.

PROCEDURE FOR HYDRAULIC PRESSURE TEST ON MARINE BOILERS?

Hydraulic pressure test is 1.25 times working pressure (10 minutes maintain)
 Close all openings.
 Open air vent cock.
 Fill up boiler water fully
 Close the air vent cock
 Place hydraulic jack to feed water line.
 Fit standard pressure gauge.
 Applied hydraulic pressure 1.25 times of working pressure and maintain 10minutes.
BOILER WATER TESTS ONBOARD SHIP
P-ALKALINITY
Recommended Limits: 150-300 ppm as CaCO3 The alkalinity is a more accurate indicator of the
boiler water condition than PH. The phenolphthalein (P) alkalinity is measured to determine
whether the correct conditions of alkalinity exist in the boiler.

CHLORIDE TEST
200 ppm maximum The chloride value will reveal any presence of dissolved salts in the boiler. An
increase, gradual or sudden, in the level of chloride is an indication of contamination by sea water
and the chloride level is often used as a reference point when controlling rate of blowdown.
PH TEST
Recommended limits of 9.5-11.0 To determine the pH of the boiler water can be carried out to
give a better overall understanding of the boiler water quality.

CONDUCTIVITY TEST
Recommended Limits: 1400-2000 ppm
1. Take a 50 ml sample of water to be tested in the plastic sample container provided.
2. Remove the protective cap of the conductivity meter.
3. Switch ON and put it in the sample container for 3 seconds.
4. Value will be displayed in the digital screen.

DEHA CHECKIT TEST KIT

Range 0 to 0.5mg/l

For this purpose, use a 60ml stoppered glass bottle. The sample point should be fitted with a
sample cooler, capable of cooling the sample to below 30oC.
Test Method
1. Carefully fill the 60ml bottle with sample direct from the water sample by immersing the outlet
tube to the bottom of the bottle. Let the sample flow and fill the bottle and allow to overflow for
one minute.
2. Gently remove the bottle from the sample outlet tube so that the sample continues to overflow.
3. Gently place the stopper in the bottle so that a small amount of sample is expelled and that no
air bubbles are trapped under the stopper
4. Cool the outside of the bottle with cold running water if the sample feels warm. Remove the
stopper.
5. Carefully pour the sample into a 10ml moulded cell, filling to the 10ml line.
6. Now transfer this10 ml into the amber glass bottle by pouring slowly down the side of the
bottle.
7. Add 6 drops of DEHA test solution by holding the plastic bottle vertically and squeezing gently.
Swirl to mix.
8. Now add one DEHA test tablet to the bottle. Crush and mix well to dissolve. Allow to stand for
exactly 10 minutes. 9. Whilst waiting, decant another 10 ml of original sample into the 10ml cell
and add one DEHA test tablet.
10. Crush and mix well to dissolve then place the cell in the left-hand compartment of the Check it
in comparator. Slide the Check it DEHA disc into the comparator.
11. After the 10-minute standing period is over, pour the test solution from the amber bottle into a
clean 10 ml cell and place this in the right-hand compartment of the Check it in comparator.
12. Immediately hold the compactor up to a good source of light and rotate the disc to match the
colour in the cell. 13. Record the reading from the disc as ppm DEHA.

BOILER WATER
1. P ALKALINITY
2. CHLORIDE TEST
3. CONDUCTIVITY TEST
4. PH TEST
HOTWELL OBSERVATION TANK
1. CHLORIDE
2. PH TEST
3. TEMPERATURE
CONDENSATE WATER
1. DEHA TEST
2. PH TEST

BOILER WATER TREATMENT

TEMPERORY HARDNESS
Caused due to Hydroxides, carbonates and bicarbonates of Ca and Mg salts. This hardness can be
decomposed by heating or boiling the water.

PERMANENT HARDNESS
Caused due to chlorides, sulphates, nitrates and silicates of Ca and Mg salts. This hardness can be
removed by chemical treatment.

WHY BOILER WATER TREATMENT IS REQUIRED?

1. To prevent corrosion
2. To prevent corrosion
3. For sludge conditioning
4. To prevent foaming, priming and carry over.

TO PREVENT CORROSION
To prevent corrosion Boiler water should be alkaline and contains little or no dissolved
oxygen in it.

 When iron is in contact with water containing H+ and OH- ions, corrosion will takes
place.
 When water is acidic, H+ ion concentration will be more compared to OH- ion
concentration.
  The excess H+ ions in contact with metal surfaces (Fe) will take electrons and
becomes Hydrogen atoms.
 The Fe losses electrons and becomes Fe2+ ions.
 This Fe2+ ions will react with OH- ions to form Fe (OH)3.
 They are soluble in water up to a PH value of 9.4. Hence metal is corroded.
To prevent this, reduce the H+ ion concentration, by making the boiler water alkaline.
Recommended PH value: 9.5- 11.5

 The Hydrogen atom formed on the metal surface will create a polarising layer above the
metal surfaces and prevent further corrosion.
 If dissolved oxygen is present in the boiler water, it will combine with Hydrogen to form
water, hence no polarisation will occur and corrosion continues.
To prevent this, reduce the dissolved oxygen content in the Boiler water

HOW TO MAKE BOILER WATER ALKALINE?

 Chemical Treatment
HOW TO ELIMINATE DISSOLVED OXYGEN FROM BOILER WATER?
 By maintaining Hot well temperature around 80–85-degree Celsius.
 By using mechanical De-aerators
 By chemical treatment.
o DEHA Di ethyl hydroxyl amine
o Hydrazine- excess dosage of hydrazine will lead to steam and condensate line
corrosion by forming Ammonia.
o Sodium sulphate- precipitation will takes place.

TO PREVENT SCALE FORMATION

A. PHOSPHATE TREATMENT
 For the precipitation of scale forming salts and to give alkalinity phosphates are used.
 Phosphates normally used are Disodium phosphate, Trisodium phosphate, Sodium
metaphosphate and Sodium hexametaphosphate.

B. LIME SODA TREATMENT

 Lime (Calcium hydroxide) and soda ash (Sodium carbonate) are used.

C. CAUSTIC SODA TREATMENT

 Sodium hydroxides are used.

FOR SLUDGE CONDITIONING

 Coagulants are used for sludge conditioning.

 Coagulants condition the sludge by rendering the precipitates in to non-adherent sludge,
which can be easily removed by blow down.
 Commonly used coagulants are Sodium Aluminate, starch, and tannin.
TO PREVENT PRIMING FOAMING AND CARRY OVER

 Frequent blow down

 By adding chemicals such as poly amide or poly oxide group.
FOAMING
Foaming is the formation of unbroken bubbles on the surface of the boiler water inside the boiler
drum. The bubbles may be in thin layer with few bubbles overlying each other or it may build up
throughout the steam space.
Reasons for foaming?
 High suspended solid concentration
 High dissolved solid concentrations in the boiler water
 High alkalinity concentration
 Oil and organic contaminants in the boiler water
 High impurities
 High dosage of chemicals
 High water level
How do you avoid foaming?
 Timely blow down & maintaining desired water quality
 Maintaining constant load on Boiler
 Avoiding high water level

PRIMING
Priming means carryover of water particle in the steam.
Reasons for Priming?
 Improper design of Boiler and steam drum
 Maintaining high drum level
 Boiler load fluctuation
 Sudden load raise due to steam demand
 Foaming in feed water
 Miss operation of Boiler
 Sudden lifting of Boiler safety valve or start up vent CV
 More impurities in Boiler water
Impacts of Priming
 Lower steam efficiency
 Water hammering
 Super heater coil failure due to thermal shock
 Turbine high vibration & blade failure
How do you avoid priming?
 Proper operation of boiler
 Maintaining drum level in between 45 to 55%
 Avoiding foaming
 Avoiding sudden load fluctuation
 Proper designing of Boiler

CARRYOVER
Carryover is the carryover of solid, liquid & gaseous contaminants with water and steam leaving
the drum due to incomplete separation of water and steam in steam drum.
Reasons for carryover
  Defects in steam and water separators
 Foaming
 Boiler load fluctuation
 Higher drum level
 Boiler steam drum construction defects
Effects of carryover on Boiler?
Contamination in steam leads to deposition of solid scale on Super heater coils & control and
regulating valves.

BOILER WATER TREATMENT SUMMARY

1. TO PREVENT SCALE FORMATION
 PHOSPHATE TREATMENT Phosphates normally used are Disodium phosphate,
Trisodium phosphate, Sodium metaphosphate and Sodium hexametaphosphate
 LIME SODA TREATMENT Lime (Calcium hydroxide) and soda ash (Sodium
carbonate) are used.
 CAUSTIC SODA TREATMENT Sodium hydroxides are used.

2. TO ADD ALKALINITY AND PREVENT CORROSION

 Sodium Hydroxide or sodium carbonate

3. TO CONDITION SLUDGE
 Commonly used coagulants are Sodium Aluminate, starch, and tannin.

4. TO REMOVE TRACES OF OXYGEN

 By maintaining Hot well temperature around 80–85-degree Celsius.
 By using mechanical De-aerators
 By chemical treatment.
o DEHA Di ethyl hydroxyl amine
o Hydrazine- excess dosage of hydrazine will lead to steam and condensate line
corrosion by forming Ammonia.
o Sodium sulphate- precipitation will takes place.

5. TO REDUCE CAUSTIC EMBRITTLEMENT

 Sodium Sulphite or Sodium Nitrate

6. TO REDUCE RISK OF CARRY OVER

 Frequent blow down
 By adding chemicals such as poly amide or poly oxide group.

7. TO PROTECT FEEDWATER AND CONDENSATE SYSTEM FROM CORROSION

 Filming amines or neutralising amines

BOILER WATER SAMPLEING

 Container name: Salinometer pot
 Material: Copper
  Function: Minimum flash off

HOW TO COLLECT BOILER WATER SAMPLE FOR TESTING ONBOARD SHIP?

 Slowly open the sampling test cock.
 Open the FW foe sample cooler if provided.
 Drain it until clean hot water coming out.
 Collect the sample in a salinometer pot.
 Close the sampling cock.
 Allow the collected sample cool down.
 The test must be carried out by the using maker’s supply test kit, chemicals, instruments
and instructions.

P ALKALINITY
Measures alkalinity due to Hydroxide and half of the carbonates.
Phenolphthalein is added in the test.
M ALKALINITY
Measures alkalinity due to Hydroxides, carbonates, and bicarbonates.
Methyl orange is added in the test.

CAUSTIC EMBRITTLEMENT
 Also known as Inter-crystalline fracture.
 It is a type of boiler corrosion caused by high concentration of sodium hydroxide and the
material under stress.
 Concentration of sodium hydroxide required for caustic embrittlement is roughly around
6000 grains/gallon at 300-degree Celsius.
 Normally such concentration can never be found in boilers. But leakages at rivet heads,
seams, and boiler mountings; the water gets flashed off to steam leaving behind the solids
locally, which can gradually result in higher concentration of NaOH.
 This phenomenon results in the breakage of protective magnetic oxide film of iron ( Fe3O4)
and the base metal is attacked by concentrated NaOH which may results in fatigue of
material.
 During high concentration of sodium hydroxide and sodium sulphate is present, the sodium
sulphate will precipitate out of the solution and forms a protective layer on the surface of
the plate.
 To keep this ratio at the safe level the sodium sulphate to sodium hydroxide should be
maintained above 2:5.
 Other inhibitors used are quebracho and sodium nitrate.
 BOILER WATER LEVEL CONTROLLER

THREE ELEMENT BOILER WATER LEVEL CONTROL

 The measured variables are steam flow, feed water flow and drum level.
 In a balanced situation, steam flow must be equal to the feed flow, these two signals are compared
in a differential relay.
 The differential relay output is fed to a P+I controller and comparator into which the measured
drum level signal and desired values are also fed.
 Any deviation between the desired and actual drum level and any deviation between feed and
steam flow will result in controller action to adjust the feed water control valve. The drum level will
then be returned to its correct position.
 A sudden increase in steam demand would result in a deviation signal from the differential relay
and an output signal to open the feed water control valve. The swell effect would therefore not
influence the correct operation of the control system. For a reduction in steam demand, an output
signal to close the feed water control valve would result, thus avoiding shrinkage effects. Any
change in feed water pressure would result in feed water control valve movement to correct the
change before the drum level was affected.

TYPES OF BOILER BURNERS

 Pressure jet type Burner
 Rotary Cup burner
 Steam blast jet type burner

WHAT ARE THE CAUSES OF BOILER FURNACE BLOW BACK ?

 Insufficient purging time
 Accumulation of oil in furnace from the leaky burners
 Boiler tubes and uptake have full of soot deposits.
 Air registers control not operating for the high flame mode.
  Too little air
 Insufficient oil temperature

AIR REGISTER

 This is typical arrangement of air resistor.

 The word air register is given to the Assembly of vanes, air swirl plates etc.
 Fitted with in the boiler casing in way of each burner position.
 Functions of air register are
 To keep the flame suspended in the centre of the furnace.
 Divides air into primary and secondary streams and to guide these streams to impart the correct airflow
pattern.
 To achieve proper mixing of air with hollow rotating corn of oil particles.
 The primary air flows and reaches the tip plate or stabilizer, its spins over to form a series of vortices which
reduces the forward velocity of the air, this retains the primary flame within the call.
 The outer secondary air passes over the swallow veins which causes the air to rotate thus assisting in proper
mixing of air and fuel in the secondary flame zone.

FORCED DRAFT FAN

It draws air from the atmosphere and pushes high pressure fresh air via blower flaps and air
register in to the combustion chamber to produce positive pressure where it mixes with the fuel.

TURN DOWN RATIO

Ratio between the boiler maximum and minimum output.
BOILER ALARMS AND TRIPS