UNIVERSIDAD DE SAN MARTIN DE PORRES

FACULTY OF ENGINEERING AND ARCHITECTURE

PROFESSIONAL SCHOOL OF INDUSTRIAL ENGINEERING

Subject:

Instrumentation and Industrial Control

FINAL WORK

INDUSTRIAL BOILER

Teacher: MG. ING. JORGE LUIS CALDERON CACERES

Members
Zevallos Degregori Piero Jesús

Santa Maria Ruiz Jherson

Camila Lizeth García Asca

Group: 7

2022 I

LIMA -PERU

Date of presentation: 08/06/2022

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INDEX

I. INTRODUCTION.................................................................................................4

II. OBJECTIVES:...................................................................................................6

2.1 General Purpose:............................................................................................6

2.2 Specific Goal:..................................................................................................6

III. THEORETICAL FRAMEWORK...................................................................7

3.1 Conceptual Definitions.......................................................................................7

3 .2 Operation of the boilers....................................................................................9

3 .3 Classification of boilers.....................................................................................9

3.4 Classification of boilers according to their technology.................................16

3.5 Boiler Behavior.................................................................................................19

3.6 Main Parts That Make Up a Boiler................................................................20

3.7 Description of Boiler Accessories....................................................................24

3.8 Boiler Applications...........................................................................................28

IV. MAINTENANCE OF BOILERS.......................................................................29

4.1 Cleaning Accessories........................................................................................30

4.2 Main problems of steam boilers:....................................................................32

V. BOILER IN ARZOBISPO LOAYZA NATIONAL HOSPITAL.....................35

5.1 Boiler.................................................................................................................35

5.2 Operation and parts of the boiler...................................................................36

5.3 Applications of condensed steam....................................................................47

CONCLUSIONS........................................................................................................49
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RECOMMENDATIONS...........................................................................................50

Photographic evidence of the visit to the Boiler Industrial.........................................51

References....................................................................................................................52

List of figures

Figure 1 Horizontal boilers............................................................................................8

Figure 2 Smoke box.....................................................................................................11

Figure 3 multiple water tubes.......................................................................................13

Figure 4 Principle of operation of a single water tube boiler.......................................14

Figure 5 Hot water boilers............................................................................................17

Figure 6 Superheated water boilers..........................................................................17

Figure 7 Thermal fluid boilers.....................................................................................18

Figure 8 Steam boilers.................................................................................................18

Figure 9 Boiler characteristics using input tables........................................................20

Figure 10 Water supply chamber.................................................................................24

Figure 11 Head Fluses..................................................................................................24

Figure 12 Corrosion of material by oxygen.................................................................33

Figure 13 Condensate carryover..................................................................................34

Figure 14 Firetube Boiler.............................................................................................35

Figure 15 Firetube boiler..............................................................................................36

Figure 16 CNG line......................................................................................................37

Figure 17 Caliche or tartar...........................................................................................37

Figure 18 Programmer.................................................................................................38

Figure 19 Pressure gauge and soft water inlet.............................................................39

Figure 20 Pressure switches.........................................................................................39

Figure 21 Safety valves................................................................................................40

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Figure 22 Softener Tank...............................................................................................41

Figure 23 Brine Tank...................................................................................................42

Figure 24 Daily tank.....................................................................................................43

Figure 25 High-pressure electric pump........................................................................43

Figure 26 Dispenser.....................................................................................................44

Figure 27 McDonnell valve.........................................................................................45

Figure 28 Headboard System.......................................................................................46

Figure 29 Fluses...........................................................................................................46

Figure 30 Fireplace......................................................................................................47

Figure 31 Kettles, steam pressure cooker....................................................................48

Figure 32 Steam iron....................................................................................................48

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I. INTRODUCTION

Heat energy, "heat" is a way of manifesting energy, it is very important in the

life of our planet. Heat produces work if you go from a higher temperature to a lower

one (Carnot's principle).Steam boilers, also called steam generators, are machines

whose purpose is the production of steam from a heat transfer to a fluid. Said energy

transfer is carried out in a medium at constant pressure in which the fluid, initially in a

liquid state, is heated until its phase changes. The pressure at which the boiler works

marks the temperature at which the steam will be obtained. In the diagram below, you

can see the behavior of water in a constant volume.

The multiple applications that industrial boilers have, the varied working

conditions and the innumerable technical and practical requirements that they must meet

in order to offer the maximum guarantees in terms of solidity, safety in handling,

durability and economy in operation, It has forced the manufacturers of these equipment

to constantly refine in order to address the problems. The search for solutions has led to

various existing types grouped according to their most important characteristics. The

importance of this work is justified by the preponderance of the use of boilers to save

energy, generate the necessary steam and distribute it to different areas. Given the

importance of this process, the study of its control loop, identifying the instrumentation

it has, is substantial.
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SUMMARY

In this work we talk about steam boilers, especially fire tube ones. And it seeks

to understand the operation and use of these instruments.

The boilers steam are devices in which it is boiled Water to produce steam. He

hot necessary for heating and steaming Water could be supplied by a household, by

gases recovered at the outlet of another industrial device (furnace, for example), by the

cooling fluid of a nuclear reactor, by irradiation solar or by an electric current. The

synonym steam generator is used preferably when talking about boilers of a certain

importance. If the boiler itself is connected to others, some of which heat the water

(water reheaters, economizers) or theair of combustion (air preheater), and others reheat

the steam (reheaters), is often called the set group evaporator. During operation, the

boiler itself is internally subjected to the Pressure of Balancefrom the water and its

steam to the temperature reached. The other elements of the group run by the water or

steam, starting from the feeding (economizer, reheater), are subjected to almost the

same pressure, but the fluid temperature can be lower or higher than boiling.
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II. OBJECTIVES:

II.1 General Purpose:

 Describe the boiler or steam generator system, thus consolidating the

knowledge acquired in the Industrial Instrumentation and Control course.

II.2 Specific Goal:

 Identify the main characteristics of the boiler.

 Identify the different types of boilers.

 Understand the principle of operation of a boiler.

 Explain the two main types of boilers: water-tube and fire-tube.

 Identify the applications of boilers in industry and in daily life.

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III. THEORETICAL FRAMEWORK

This document shows the study carried out on the horizontal fire-tubular boiler

system for energy saving. This work consists of the recognition of the instrumentation

that the control loop under study has, as well as the explanation of its operation. In this

way, we students have the opportunity to consolidate the knowledge acquired in the

Industrial Instrumentation and Control course during this cycle. In addition to acquiring

new knowledge related to industrial processes in different areas.

This document will give a brief explanation of the concepts necessary to enter

into context with the process under study, to later enter the description of the work

carried out.

3.1 Conceptual Definitions

a) Boiler

According (Martínez, 2010)A boiler is a device that is designed to generate

saturated steam. This saturated vapor is generated through an energy transfer (in the

form of heat) in which the fluid, originally in a liquid state, heats up and changes state.

The heat transfer is carried out by means of a combustion process that occurs inside the

boiler, progressively raising its pressure and temperature. The pressure, as indicated at

the beginning, cannot increase excessively, since it must remain constant, which is why

it is controlled by the exhaust of combustion gases, and the exit of the steam formed.

Because the pressure of the steam generated inside the boilers is very high, they

are built with metals highly resistant to high pressures, such as rolled steel.

Boilers are classified by their design as fire-tube or water-tube. However, they

can be classified from other aspects, which include, by the type of materials they are
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made of, by their application, by the form of air intake, by the type of fuel they use, by

the pressure with which they operate or by the heat transfer fluid they use.

From the above it is understood that a boiler is a closed metal container in which

steam is generated or water is heated, through the action of heat at a temperature higher

than that of the environment and at a pressure higher than atmospheric.

b) Steam Generator

This is the name of the set or system formed by a boiler and its accessories. In

practice we speak of "Boilers" referring to the entire system or "steam generator". For

this reason, both terms will be used interchangeably.

Figure 1 Horizontal boilers

c) Purpose of the boilers

Boilers are devices whose objective is:

a) Generate hot water for heating and general use.

b) Generate steam for power plants, industrial processes or heating.

3 .2 Operation of the boilers

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They work through the transfer of heat, generally produced by burning a fuel,

which is delivered to the water contained or circulated in a metal container.

In every boiler, there are two important areas:

a) Heat release zone or hearth or combustion chamber: It is the place where

fuel is burned. It can be inside or outside with respect to the metal container.

 Inside: The hearth is inside the metal container or surrounded by water-

cooled walls.

 Exterior: Home built out of the metal container. It is partially

surrounded or without water-cooled walls. The heat transfer in this area

is carried out mainly by radiation (flame - water).

b) Tube area: It is the area where the combustion products (gases or fumes)

transfer heat to the water mainly by convector (gases - water). It is made up of tubes

with in which fumes or water can circulate

3 .3 Classification of boilers

There are different ways to classify boilers according to their position,

installation, location of the hearth or stove, gas circulation, heating method, steam

pressure, type of fuel, among others.

All boilers can be classified according to the characteristics mentioned in the

previous point. Each manufacturer has taken or selected some of these aspects, creating

types of boilers that have become popular in the industrial environment. However, the

most widely accepted classification is based on the circulation of water and hot gases in

the boiler tube area or the arrangement of their fluids. According to this, there are two

general types of boilers:

a) Firetube or Multiple Smoke Tube

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In these boilers, the fumes pass inside the tubes, giving up their heat to the water

that surrounds them. These fire tube boilers can be vertical or horizontal. Among the

vertical boilers, two types can be found with respect to the tubes: semi-submerged

tubes, and totally submerged tubes.

In the first case, the water does not completely cover the tubes; in the second,

they are fully covered. Horizontal boilers with multiple flue pipes, an internal hearth

and a single or double return return are the so-called Scottish boilers and are the most

frequent in our country. These boilers, like any other type, can be used with a fireplace

to burn coal, firewood or with oil burners.

a.1) Parts of Firetube Boiler

Locomotives and locomotives are found in this group of boilers that are mainly

characterized by being medium-volume water, forced draft and have three well-defined

parts:

 A firebox where the hearth is mounted. This box can be rectangular or

cylindrical in section; it is double-walled, so the home is surrounded by a

body of water. Due to this double wall, the plates have to be reinforced

with tie rods or stays (bolts or reinforcements with a central hole to

detect leaks when they are cut due to corrosion or excess stress).

 A cylindrical body pierced, longitudinally, through small diameter

tubes, through which hot gases circulate.

 A smoke box, which is the extension of the cylindrical body, to which

the gases arrive after passing through the tube bundle, to exit towards the

chimney. These boilers almost always work with forced draft, which is
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achieved by means of a jet of steam from the same boiler (live steam) or

by using exhaust steam from the machine.

Advantage

 Lower initial cost, due to the simplicity of design compared to water

tubes of the same capacity.

 Greater operating flexibility, as the large volume of water allows

fluctuations in steam demand to be easily absorbed.

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 Lower purity requirements in the feed water, because the incrustations

formed on the outside of the tubes are easier to attack and are eliminated

by the purges.

 Ease of inspection, repair and cleaning.

Disadvantages

 Larger size and weight than water tubes of the same capacity.

 Longer time to build pressure and go into operation.

 Great danger in case of explosion or rupture, due to the large volume of

stored water.

 They are not used for high pressures.

b) Water tubes or multiple water tubes

The water circulates inside the tubes, capturing heat from the hot gases that pass

through the outside. In these boilers, water or steam passes through the interior of the

tubes and the hot gases are in contact with the outer faces of them. They are of small

volume of water. Water-tube boilers are used almost exclusively when it is important to

obtain high pressures and performance, because the stresses developed in the tubes by

the high pressures translate into tensile stresses in their entirety. Cleaning of these

boilers is easily accomplished because scale is removed using air or mechanically

actuated tube cleaning devices. The water circulation, in this type of boiler, it reaches

considerable speeds with which an efficient heat transfer is achieved; consequently, the

steam production capacity is raised.

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Figure 3 multiple water tubes

b.1) Principle of Operation

Suppose that figure No. 1 represents a boiler with a single water pipe. Only one

branch of the tube is heated, since the other is protected by an insulating screen. In the

left branch, the heat heats the water, generating steam and causing both (water and

steam) to move upward. This mixture enters the collector and the cold water takes its

place in the heated tube. Cold water is in the unheated tube and at the bottom of the

manifold. In this way, there is a continuous movement of water-steam in the direction

indicated by the arrows, in which the mixture of hot water and steam always rises to the

collector, while the cold water at the bottom of the collector goes down and takes its

place. mixture.
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Figure 4 Principle of operation of a single water tube boiler

Advantage

 Less weight per unit of power generated.

 Because it has a small volume of water in relation to its evaporation

capacity, it can be started up quickly.

 Greater safety for high pressures.

 Greater efficiency.

 They are unexplosive.

Disadvantages

 Its cost is higher.

 They must be fed with high purity water, since the incrustations inside

the tubes are sometimes inaccessible and can cause them to break.

 Due to the small volume of water, it is more difficult to adjust to the

large variations in steam consumption, being necessary to work them at

higher pressure than is necessary in the industries.

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Water tube boiler components

Dome or Calderín

It is cylindrical in shape and inside it contains the two fluids (water / steam).

Being small in size, it must be equipped with droplet separators to raise the steam title.

As in the outer shell of water-tube boilers, the control, supervision and service nozzles

are located in the dome.

Combustion chamber or combustion hearth

Generally in the form of a prism with a rectangular base, it is the area designed

for combustion to take place. It is delimited on all six sides by membrane walls that,

except for one of them, the rest are completely sealed to the passage of combustion

gases to the outside. The membrane wall, which is not completely airtight, is designed

so that the gases leave the furnace and start their way through the different

components of the boiler's gas circuit, in addition to producing a change in the

direction of the gases.

Membrane walls

They are formed entirely of tubes cooled by the water that circulates inside

them. These pipes are joined together by sealing welding on the gas side and, in turn,

by larger distributor collectors on the water side.

Up and down tubes

The riser pipes are responsible for bringing the hottest fluid (by temperature

difference) from all the boiler zones to the dome.

The downcomers are responsible for returning the fluid that has cooled from

the dome to the heating zones.

Evaporators or flag tubes

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They are bundles of tubes generally arranged in the countercurrent of the

gases, especially where the exchange takes place by convection.

Economizers

They are those elements that are installed in the gas outlet of the boilers to

increase their performance. Formed by smooth or finned tubes, the feed water to the

boiler circulates through the interior of said tubes and the combustion gases circulate

countercurrently outside the tubes. These gases transfer their energy to the water,

increasing its temperature and requiring less energy consumption to produce a

kilogram of steam or to produce a kilowatt.

Reheaters or over heaters

They are equipment made up of tube coils installed in the highest temperature

areas of the boiler. Except for their installation in the combustion chamber, they are

generally arranged just behind the membrane wall and after the combustion chamber.

They are intended to raise the steam title to “1”, as well as the temperature of the

saturated steam that passes through its interior, producing superheated steam or

superheated steam at a temperature higher than the saturation temperature.

3.4 Classification of boilers according to their technology

Hot water boilers

Hot water boilers are those in which the heat transfer fluid is water and have a

maximum service temperature of less than 100 ºC. This type of boiler can be water

tube or fire tube.

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Figure 5 Hot water boilers

Superheated water boilers

Superheated water boilers are those in which the heat transfer fluid is water

and have a maximum service temperature of over 110ºC. This type of boiler can be

water tube or fire tube.

Figure 6 Superheated water boilers

Thermal fluid boilers

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Thermal fluid boilers are those in which the heat transfer fluid is different from

water. This type of boiler can only be water tube.

Figure 7 Thermal fluid boilers

Steam boilers

Steam boilers are those in which the heat transfer fluid is water vapour. This

type of boiler can be water tube or fire tube.

Figure 8 Steam boilers

3.5 Boiler Behavior

How is your production measured?

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According (Bahamondes, 2008)the behavior of a boiler can be expressed as a

function of the kilograms of steam produced per square meter of heating surface and per

hour (evaporation coefficient). This steam production has been rising in modern times.

The intensification of steam production is mainly based on the circulation of

water inside the tubes, with such a speed that the steam that is formed by heating them,

leaves with the same current of the water that is evaporates, because otherwise, the

vapor bubbles formed would create hollow spaces in the liquid that could not absorb the

transmitted heat, burning the material in the tubes.

Heating surface (SC) is understood to be the total surface of the plates and tubes

of the boiler that on the one hand are in contact with the gases and on the other with the

water to be heated. The heating surface is measured on the gas side. Some of these

characteristics are seen in the attached table

Figure 9 Boiler characteristics using input tables

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3.6 Main Parts That Make Up a Boiler

Because each boiler has, depending on the type, characteristic parts, it is very

difficult to attribute a certain component to all of them. Due to the above, the main parts

of the boilers will be analyzed in general, specifying in each case the type of boiler that

has said element.

Home Or Stove

 It is the space where combustion occurs. It is also known as the

Combustion Chamber.

b) Home Door

It is a metal piece, hinged, generally lined inside with refractory or double-

walled brick, through which solid fuel is poured into the hearth and fire control

operations are carried out. In boilers burning liquid or gaseous fuels, this door is

replaced by the burner

c) Grilling

They are metal pieces in the form of bars, generally rectangular or trapezoidal,

that go inside the stove and that serve as a support for the solid fuel. Due to the shape of

a grate they have, they allow the passage of the Primary Air that serves to produce

combustion. a) The grills must be adapted to the fuel and must mainly meet the

following requirements: - They must allow the air to pass properly. - They must allow

the ashes to fall. - They must allow them to be cleaned easily and quickly. - They must

prevent slag from collecting. - The bars of the grill must be of good quality so that they

do not burn or deform. - They must be durable. Some grill designs allow water to pass

through to cool it down and prevent overheating.

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d) Ashtray

It is the space that is under the grill and that serves to receive the ashes that fall

from it. The accumulated residues must be removed periodically so as not to obstruct

the passage of air necessary for combustion. In some boilers, the ashtray is a water tank.

e) Ashtray Door

Accessory used to perform the cleaning functions of the ashtray. By means of

this adjustable door it is also possible to control the intake of primary air to the home.

When cleaning fires or charging the hearth, it is recommended that said door remain

closed in order to avoid the flashback of the flame ("Bull's tongue").

f) Altar

It is a small brick wall, refractory, located in the hearth, at the opposite end of

the stove door and at the end of the grill, which must exceed it by approximately 30 cm.

The objectives of the altar are: - To prevent debris or fuel particles from falling

from the grill. - Offer resistance to flames and gases so that they are distributed evenly

across the width of the grill and thus achieve complete combustion. - Resist hot gases on

their way to the chimney. With this it is achieved that they deliver all their heat and

come out at the right temperature.

g) Smoke Ducts

They are the spaces through which the fumes and hot combustion gases

circulate. In this way, the heat delivered by these is used to heat the water and / or

produce steam.

h) Smoke Box
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It corresponds to the space of the boiler in which the fumes and gases gather,

after having delivered their heat and before leaving through the chimney.

i) Chimney

It is the set of gases and fumes from combustion for the atmosphere. In addition,

its function is to produce the necessary draft to obtain adequate combustion.

j) Explosion Doors

They are metal doors with a counterweight or spring, generally located in the

smoke box and that open in the event of excess pressure in the combustion chamber,

allowing the gases to escape and eliminating pressure. They are only usable in boilers

that work with liquid or gaseous fuel.

k) Water Chamber

It is the volume of the boiler that is occupied by the water it contains and has as

an upper limit a certain minimum level from which the water must never drop during

operation. It is comprised of the minimum level visible in the level tube downwards.

l) Steam Chamber

It is the space or volume that remains above the maximum upper level of water

and in which the steam generated by the boiler is stored. The more variable the steam

consumption, the greater the volume of this chamber must be. In this space or chamber,

the vapor must be separated from the water particles that it carries in suspension. For

this reason, some boilers have a small cylinder in the upper part of this chamber, called

a “dome”, which helps to improve the quality of the steam (make it drier).

m) Water Feed Chamber

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It is the space between the maximum and minimum water levels. During the

operation of the chamber, it is occupied by water and / or steam, depending on where

the water level is.

Figure 10 Water supply chamber

n) Fluses

The flutes are attached to the header by means of expansion (either by rolling or

expanding them under pressure). The fluses can be arranged in lime rows or alternately

in a zigzag fashion. Flushes are typically 2 "to 4" (51mm to 102mm) in diameter, and

your selection depends on draft loss and the type of fuel to be used. The diameter is

often increased by 25mm (1 ") for every 1.22m (4 ') increase in the length of the flutes.

Figure 11 Head Fluses

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3.7 Description of Boiler Accessories

A) Observation accessories

a.1) Water level indicators

According (Dunn., 2015) every boiler must be equipped with at least two water

level indicators, independent of each other. One of them must be for direct observation

of the water level, of the glass tube type, the other format being a series of three taps or

test taps.

a.2) Pressure indicators

Every boiler must be provided with one or more pressure gauges that will be

connected to the steam chamber of the boiler by means of a tube that forms a water seal.

a.3) Gas analyzers

They are devices that serve to control the quality of combustion inside the home,

through the analysis of the gases that come out of the chimney

a.4) Temperature indicators

They are instruments designed to measure the temperature, whether of the feed

water, steam, oil combustion gases, etc.

B) Safety accessories

b.1) Safety valves

Its purpose is to vent the steam from the boiler when it exceeds the maximum

working pressure

b.2) Fusible plug

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The fusible plug is an element that allows steam and water to pass into the home

when the water level in the boiler drops below the minimum allowed.

b.3) Alarms

Every boiler will have an acoustic or visual alarm system that works when the

water level reaches the minimum or maximum, while stopping the operation of the

combustion system when the minimum water level is reached.

C) Water supply accessories

c.1) Pumps

This accessory, like the injector, allows us to replenish the water that has

vaporized inside the boiler. Among these, we have Centrifugal Pumps and Plunger

Pumps.

c.2) Injectors

The injectors are devices that work with the same steam produced by the boiler

and are capable of discharging water at a pressure greater than the internal pressure of

the boiler.

D) Control accessories

Many steam generating equipment have automatic controls in order to regulate

the operation of the boilers and contribute to the operator's work. In no case do

automatic control accessories replace the Boiler Operator.

d.1) Pressure Control or Pressure Switches

They are accessories that work based on the maximum and minimum pressure of

jobs team from the boiler. They act on the burner, turning it off when it reaches the
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maximum pressure for which it was set and turning it on when it reaches the minimum

desired steam pressure.

d.2) Temperature Control or Thermostats

They are accessories that work according to the temperature of the water, steam

or combustion gases. They turn off the burner when the desired maximum temperature

is obtained and turn it on when the minimum temperature for which it was set has been

reached.

d.3) Low Water Level Control

The water level controls work by means of a float, which when the water

reaches the maximum level, cuts the current of the water feed pump. When lowering the

water to its minimum working level, reconnect the pump. If in the latter case, the pump

does not respond to start-up and the level continues to drop, this control is generally

provided with a third position, in which it cuts off the current to the burner.

d.4) Air Control

This control consists of as witch of mercury It acts through air pressure and is

connected to the burner head, preventing the operation of the burner without auxiliary

air.

d.5) Flame Control

By means of a photoelectric cell, the flame (its length) is controlled, preventing

the supply of fuel if it does not exist in the home.

d.6) Ignition Control (Spark)

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By means of this control, fuel is prevented from escaping without the spark to

ignite it.

d.7) Inspection Doors

They are openings that allow the boiler to be inspected, cleaned and repaired.

There are two types depending on their size:

 Men's doors: As the name implies, these doors are large enough to allow

a man to pass inside to inspect the boiler and clean it.

 Manhole Covers: All boilers have conveniently distributed a certain

number of covers that are intended to visually inspect the interior of the

boilers or wash them, if it is necessary to remove mechanically or

manually, the sludge that has accumulated and that has not come out

through the purges.

3.8 Boiler Applications

The water vapor generated by a boiler has multiple applications, depending on

its pressure, temperature and flow, they are:

 Heating of machinery and process equipment.

 Generation of strength driving mechanics, by steam engines.

 Driving force generation mechanics by turbines.

 Generation of electric power by turbines.

 Other minor uses. (Household uses, kitchen, laundry, heating, among

others).
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IV. MAINTENANCE OF BOILERS

According (Lahoz, 2012) "Make a boiler room in optimal operating conditions

available to the processes, based on trying to achieve a lack of errors, failures and

performance below the set values".

The maintenance of the boiler must be preventive and continuous mainly aimed

at optimizing production processes, reducing direct and indirect costs caused by failures

or shutdowns, achieving the maximum useful life of the boiler and the equipment

associated with it.

Javier Lahoz explains that the operations, activities and maintenance tasks vary

according to the facility but that in general they can be grouped into Daily, weekly,

monthly, semi-annual, and annual operations.

Daily Operations:

 Monitoring of the water treatment equipment, dosage of additives to

have adequate autonomy, temperature of the gases in the chimney.

 Check the correct operation of the level indicators.

 Bleed the level indicators.

Weekly Operations:

 Take and analyze samples of the water contained inside the boiler.

 Check the correct operation of the steam generator, thermometers,

thermostats, pressure gauges, pressure switches and tightness in the

boiler.
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 Clean filters, photocell and burner ignition electrodes if using liquid fuel.

Monthly Operations:

 Functional tests of: burner equipment and accessories stop with the

emergency switch and water feed pumps.

 Check the proper functioning of the electrical box elements.

 Semi-Annual Operations:

 If using liquid fuel, clean the smoke pipes, removing soot.

 Check the state of the parts.

Annual Operations:

 Cold inspection, boiler stopped, proceeding to open all the registers on

the water and gas side.

 Inspect the state of the boiler for the appearance of corrosion

 In the case of gases, an exhaustive cleaning is also carried out, removing

soot.

 Perform thickness measurement by ultrasound on the parts of the boiler

body.

4.1 Cleaning Accessories

They serve to clean the inside of the boiler, both on the side of the gasesas on the

waterside.
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a) Inspection Doors

According to their dimensions, they are called manor caps of registry. The latter

only allow the passage of one arm. Both doors are used for cleaning or inspection inside

the main manifolds or tubes depending on their location.

b) Purge Cocks

b.1) Bottom extraction valves.

They are located in the lowest parts of the boiler and serve to extract the sludge

or mud from the vaporization of hard water and action the use of descalers. They are

also used to empty boilers. These taps must be fully open and the entire section of the

discharge pipe free.

b.2) Surface extraction valves.

Some boilers also have at the level of the water, inside the feeding chamber, a

so-called surface extraction tap to dispose of some light impurities.

c) Soot Blowers - Clean Mechanical Pipes

Soot accumulates on the parts exposed to the gases of the combustion. As the

soot has a high power insulating the hot, it is necessary to prevent it from sticking to the

boiler tubes. This is achieved by cleaning them with soot blowers, mechanical tube

cleaners or, tools manuals like brushess teel.

Soot blowers are permanently installed in the boiler and allow those parts of

sufficient heating subject to accumulation of soot to be cleaned with jets of steam, air or
 32

an air-steam mixture. The mechanical tube cleaners can be of the vibratory type, which

remove the incrustation by means of rapid blows and which are applicable to water-tube

and fire-tube boilers.

They can also be of the rotary or rotary cutter type; these start the incrustation by

means of a cutting tool. This type of tube cleaner is only used in water tube boilers.

Pokers, rakes, reamers, bars, and tube cleaning brush complete the cleaning accessories.

4.2 Main problems of steam boilers:

a) Inlays

Hard, crystalline scale forms directly on the heating surface by crystallization of

saturated solution salts present in the boiler water. They are made up of elements whose

solubility decreases with increasing water temperature. These incrustations affect the

thermal performance of the boilers and cause significant overheating when exposed to

the flame.

The action of dispersants, chemical washes or the expansion and contraction of a

boiler can loosen the scale, so it must be removed to prevent its accumulation in the

bottom of the body.

b) Corrosions

This process occurs rapidly in heat transfer equipment, such as steam boilers,

since in the presence of high temperatures, corrosive gases and dissolved solids in

water, corrosion processes are stimulated.

b.1) General corrosion

A unique case of this corrosion is due to the acidity of the water depending on

the reaction. Iron and other metals dissolve more rapidly in water the lower the pH
 33

value or the more acidic the water. Hence the need to maintain a strongly alkaline or

high pH inside the boilers.

b.2) Corrosion by oxygen

When metal is unevenly coated by bars and encrustations, in the presence of

dissolved oxygen, the covered areas are preferably attacked and are the center of

localized and deep corrosion.

Figure 12 Corrosion of material by oxygen

b.3) Caustic corrosion

This type of corrosion manifests itself in the form of deep cavities filled with

black oxides, present only in the areas of high thermal release (stove, plate and rear

chamber) of a boiler.

c) Dragging:

Condensate carry-over in a boiler is related to the supply of wet steam (with

drops of water). The supply of wet steam can be related to mechanical and chemical

deficiencies. Mechanical deficiencies are related to operation with high water levels,

drop separators deficiencies, thermal overloads, sudden variations in consumption, etc.

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On the other hand, chemical deficiencies are related to the boiler water

treatment, specifically with excessive alkalinity contents. Total solids (dissolved and

suspended and silica, which favors the formation of foam

Figure 13 Condensate carryover

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V. BOILER AT THE HONORIO DELGADO HOSPITAL

5.1 Boiler

According (Cerderia, 2012)the boilers provide the steam required for the dry

cleaning, ironing and sterilization of materials, also feeding areas with steam for food

preparation. This type of boiler is known as firetube and works with both oil and NGV

gas.

Figure 14 Firetube Boiler

5.2 Operation and parts of the boiler.

The dual fire tube boiler works with oil and CNG. Three steps away. First step:

Home, burn the fuel at 1500 ° C. Second Step: Fire Pipes, through which the hot gas

passes. Third Step: Fire tubes, where the hot gas returns. Finally, it ends up through the

chimney at 200 ° C approx.

 36

Initially these boilers worked with oil and the liquefied gas lines were only for

ignition. Since the end of 2017, the two boilers that are operational are already

completely working with Natural Gas. The boiler works at a minimum gas pressure less

than a pressure bar (0.3 bar). Currently the boiler is dual, in the event of a gas

emergency they can still operate with oil since they have an oil reserve.

Figure 16 CNG line

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Figure 17 Caliche or tartar

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Figure 18 Programmer

This Boiler works at a pressure of 100 PSI. We have boiler pressure gauges; if

the pressure drops, it is regulated in the header (thick black tube).

 39

Figure 19 Pressure gauge and soft water inlet

Once the boiler reaches 100 PSI you have safety devices. There are three

pressure switches, the first is used to turn off the boiler. The second to avoid overload or

short circuit. The third pressure switch measures or controls the water pressure. If for

some reason the pressure switch does not cut off or close the flow of the fluid, at 100

PSI there are two safety valves that are in the upper part. If the pressure reaches 100 PSI

the safety valves open. There is also an alarm that goes off when the pressure drops.

Three pressure switches, control the safety valves, avoid the lack of water. The safety

valves work at 110psi and 120psi, respectively.

Figure 20 Pressure switches

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Figure 21 Safety valves.

In the boiler, fuel gases can accumulate internally, and “Fogonazos” can exist or

occur, which are cushioned by the shock absorbers, so that they do not damage the

covers or doors.

For optimal steam production, treated water must be supplied to the boiler.

There are two softening tanks, in these equipments the water is softened; in other words,

calcium and magnesium are removed from the water, to prevent the boiler from liming.

Likewise, that caliche in the sterilization area can damage the sterilization equipment, as

it is more delicate equipment. On the other hand, in the area of washing machines there

is not so much rigor. But if steam is generated with hard water, that is to say with tap

water, they cause the pipes to become covered with caliche inside and lower the power

of the boiler.
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Figure 22 Softener Tank

The softener consists of coarse quartz sand, thin sand (finer) and on top of the

thin sand is resin or cellulite (70% of tank capacity), which has the property of trapping

calcium and magnesium ions. The hardness test is carried out daily to inspect the water

and if it is hard (It means that the resin has already been saturated) the softener is

regenerated through the salted water contained in the brine tank (The salted water enters

the softener tanks by the black tubes). In these tanks, 125 kilograms of industrial salt is

prepared and the softener tank is washed, for this reason there are two softener tanks,

while one regenerates the other operates and thus they rotate. The water reaches the

softener through the green pipe (SEDAPAR network) it enters through the upper part

and the soft water exits through the light blue pipes (thanks to the resin that has trapped

the calcium and magnesium ions)

 42

Figure 23 Brine Tank

At present, there are two boilers in operation and they rotate every 15 days one

works and 15 days rest. This in order to do fortnightly preventive maintenance. The

third red boiler is already out of power due to its time of use (30 years) and the lack of

maintenance.

From the softeners the water goes to the underground tank. And through an

electric pump, the soft water is directed or pumped to the daily tank or recovery of the

condensate, which is the blue-colored one in the upper part. The daily tank allows, as its
 43

name implies, to recover the condensed steam from other processes such as ironing or

drying. In the event of a water cut, terminate the process (allows the boiler to operate for

up to 2 hours). It also allows the water to be preheated so that its subsequent entry into

the boiler through the blue tubes. The preheated water through the second high pressure

electric pump supplies water to the boiler.

Figure 24 Daily tank

Figure 25 High-pressure electric pump

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Chemical products are also added to the boiler through a dispenser, the sulfite

and phosphate are added with this, the liming of the fire tubes of the boiler is avoided.

These products pass throughout the entire day or operation of the boiler. Sulfite has the

property of trapping oxygen molecules and precipitating them to the bottom of the

boiler to eliminate these molecules through the purge. In the same way, phosphate

causes all the particles that are in suspension to precipitate and thus they are eliminated

through the purge. This dosing process allows the output of a quality steam, clean and

free of impurities.

Figure 26 Dispenser
 45

Every two hours through the purge valves and the dispenser, the boiler is purged

to guarantee the quality of the water and the caliche or scale and all the sludge are

removed to avoid damage to the equipment. There are a surface, bottom and column

purge valve. In the water column there is a McDonnell valve, this McDonnell has a float

that opens and closes the water flow. This column purge prevents the formation of

caliche crystals. There are also water level sensors with a viewer to see if the level is too

low or high.

Figure 27 McDonnell valve

The maintenance of the boilers is carried out on a fortnightly basis: generally

preventive ventilation filters are cleaned. An evaluation is made quarterly to determine

the internal state of the boiler. There are two forms for this evaluation: the hand

entrance and the male door. For this quarterly evaluation, the water is first discharged

and the boiler is cooled. Then the hand is inserted into the boiler and by touching the

condition of the tubes in the boiler shell is determined. If the status cannot be

determined with the manual input, proceed with the man input located at the top of the

boiler. If it is determined that it is for maintenance, a chemical wash is scheduled that is

carried out by an outsourced company. Chemistry checks and cleaning of the internal

chambers are also carried out annually,

 46

All the steam produced by the boiler is directed to a headboard, which is a

system that distributes steam uniformly and continuously to all the areas it can use,

which are the sterilization area, kitchens (kettles), laundries and drying.

Figure 28 Headboard System

Figure 29 Fluses
 47

Figure 30 Fireplace
 48

5.3 Applications of condensed steam

This steam obtained in the boiler is used for different areas such as: laundry,

kitchen and sterilization for its different uses.

Figure 31 Kettles, steam pressure cooker

Figure 32 Steam iron

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CONCLUSIONS

 The boilers are the main part of the factory whose purpose is to produce

vapors that are widely used to obtain any product, it can also be a means

of heating for large places and work with various types of fuels, both

liquid and solid.

 Boilers are one of the highest consumption points in an industrial

establishment, so it is considered of utmost importance to take measures

to increase energy savings and, consequently, improve the productivity

of the industry in question.

 Steam is widely used in the industrial, commercial and health sectors,

especially for process heating, in power generation, energy generation, in

space heating and for the sterilization of surgical instruments.

 Boilers are mainly classified into two classes: fire tube, when hot fumes

circulate through tubes and water is around them, and water tubes, when

water circulates through tubes and hot fumes are around them.

 If a problem occurs, the relief valves actuate the pressure to drop. For

boilers to last longer, they have to undergo good maintenance and add

special liquids when they are working. Mishandling a boiler can cause

damage to victims and material, especially if you don't know how to

handle the machinery.

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RECOMMENDATIONS

 The industrial boiler is the main part of a factory that we have to take

into account how to operate and carry out the respective safety and

maintenance protocols.

 Check the steam pressure from time to time.

 We must treat the water that we are going to use for the boiler since

corrosion could occur inside it or solids could settle inside it.

 It is recommended to carry out corrective and preventive maintenance to

the boilers in order to avoid human and economic losses.

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Photographic evidence of the visit to the Boiler Industrial

Photo taken at the Arzobispo Loayza Hospital (06/05/2023)

Referencias
 52

Bahamondes, P. A. (2008). DESCRIPCION DE CALDERAS Y GENERADOS DE

VAPOR. Obtenido de Archivo PDF:

https://www.achs.cl/portal/trabajadores/Capacitacion/CentrodeFichas/

Documents/descripcion-de-caldera-y-generadores-de-vapor.pdf

Cerderia, J. D. (2012). FUNDACION DE LA ENERGIA DE LA COMUNIDAD DE

MADRID. Obtenido de Archivo PDF:

http://recursosbiblio.url.edu.gt/publicjlg/biblio_sin_paredes/fac_ing/Quimica/

cald_efi_indus.pdf

Dunn., W. C. (2015). Fundamentals of Industrial Instrumentation and Process Control.

Obtenido de Archivo PDF: https://doc.lagout.org/electronics/Fundamentals

%20of%20Industrial%20Instrumentation%20and%20Process%20Control

%20%5Bby%20William%20Dunn%5D.pdf

Lahoz, J. (2012). CALDERAS INDUSTRIALES EFICIENTES. Obtenido de Archivo

PDF: http://recursosbiblio.url.edu.gt/publicjlg/biblio_sin_paredes/fac_ing/

Quimica/cald_efi_indus.pdf

Martínez, J. U. (2010). calderas industriales eficientes. Obtenido de Archivo PDF:

http://recursosbiblio.url.edu.gt/publicjlg/biblio_sin_paredes/fac_ing/Quimica/

cald_efi_indus.pdf