Maintenance and Operation LEADER: MIRANDA, ROCKY

MEMBERS: ABUCAYON, JEROME

CAMPO, MICO
of Boilers GERCAN, RONNEL JAY
LERIO, REY GUILLER
BOILER
Boiler, also called Steam Generator,
apparatus designed to convert a liquid
to vapour. In a conventional steam
power plant, a boiler consists of a
furnace in which fuel is burned,
surfaces to transmit heat from the
combustion products to the water, and a space where
steam can form and collect.
History and Theory
The steam-generating boiler’s roots go
back to the late 1700s and early 1800s with
the development of the kettle-type boiler,
which simply boiled water into steam. The
water was placed above a fire box and then
boiled into steam. It wasn’t until around
1867, with the development of the
convection boiler, that the steam-generating
industry began.
 It may be debated who
developed the first steam-
generating boiler; however, most
will agree that George Babcock and
Steven Wilcox were two of the
founding fathers of the steam-
generating boiler. They were the
design, which used
first to patent their tubes
boiler inside a firebrick-
walled structure to generate steam, in 1867, and
they formed Babcock & Wilcox Company in New
York City in 1891.
 Their first boilers were quite small,
used lump coal, fired by hand, and
operated at a very low rate of heat
input. The solid firebrick walls that
formed the enclosure for the unit
were necessary because they helped
the combustion process by reradiating
heat back into the furnace area.
Late 1700s – early 1800s: The development of the kettle-type boiler; a simple design that
featured water placed above a fire box that was boiled into steam

1867: The invention of the convection boiler, which ushered in the steam-generating industry.

1867: George Babcock and Steven Wilcox were the first people to patent a boiler design. Their
version consisted of tubes inside a firebrick-walled structure to create steam.

1891: The Babcock and Wilcox Company was founded in New York City. It manufactured
small boilers that used lump coal and were fired by

1891:C. Barber opens the Stirling Boiler Company in Barberton, Ohio. The boilers
manufactured at Stirling were much larger than the Babcock and Wilcox designs. They used
three drums to circulate the water and steam flow.
1907: Babcock and Wilcox merged their company with Stirling. Their new boiler design,
named the H-Type Stirling and able to produce 50,000 pounds of steam an hour, became one of
the best-selling boilers of the time.

1912: Other companies had been manufacturing boilers in the late 1800s, but on a smaller
scale. Two of them, the Grieve Grate Company and the American Stoker Company, combined
to form the Combustion Engineering Company.

Early 1920s: The “tube and tile” boiler design was created. Unlike the original boiler designs,
which had firebrick walls requiring no insulation, the tube and tile version added insulation
over the fire box for better efficiency.

Late 20s – early 30s: The invention of the flat studded tube and the loose wall constructed
boilers led to the development of higher-capacity boilers – including the radiant boiler.
Late 50s – early 60s: The development of the membrane tube wall eliminated the need for
refractory (using the fire inside the fire box). This reduced construction costs and speeded up
manufacturing. The radiant boiler designs could now produce up to 4,000,000 pounds of steam
an hour.

Late 70s – early 80s: Major developments in alternative-burning boilers. The installation of
residential units expands, allowing more homeowners an opportunity to use the time-tested
technology.
Design or Drawing/Setup:

 
Technical Specifications:
Model & TypeModel TT BOILERS
Type DT(HP) & DTM(HP)- with burners
Type DH(HP) & DH2(HP) - electrical
 Steam Capacities70 - 2,000 kg/hour
 Working Pressures20 - 190 bar gauge
Energy Source
Burner for natural gas, LPG, bio-gas, light and heavy
fuel oil, and combinations hereof.
 -Electrical Heated
The Basic Models DT & DTM : oil- and gas-fired
units
DH & DH2: electrically heated units
Main parts of a Boiler
Steam drum
Steam drum is a collection vessel for
steam & water. Here water & steam is
separated. It has steam separators. Steam
goes from top side to superheater &
water goes from the bottom through
down comer Mud drum, then to furnace
bottom ring headers (bottom of furnace
water wall).
Mud or Water Drum
Mud or water drum the lower drum is
directly attached to upper steam drum with
large no of straight tubes bundles called boiler
bank tubes. Solids and mud can settle in this
mud drum for removal through periodic
blowdown. Some times desuperheater coil
also installed in this drum to recover heat
from superheated steam.
Water walls
Tubing arrangement around the furnace
to extract heat from fuel to generate steam
is called water wall circuit. These water
walls can be arranged in line arrangement
or stagger arrangement. Water walls get the
heat from radiation and approximately
absorb the 50% of the total heat produced
in the furnace.
Super heater
If the temperature of the steam is above its
saturation temperature then it is called superheated
steam. The super heater (heat exchanger) is used
to increase the temperature of the steam. These are
bundles of high strength tube which can bear
temperature 600C Depending upon the material of
tubes Mostly SA-213 is used.
Economizer
Economizer (heat exchanger) is the
boiler accessory used to recover the heat
of flue gas that leaving the boiler by
heating feed water. The efficiency of a
boiler can be increased with an
economizer.
Typically economizer is used before the air heater in flue
gas path of athe boiler to increase the boiler efficiency.
Burner – The burner is the component of boiler
that provides the heat that heats the water of
system. The fuels used can be natural gas or oil.
How Boilers Work
The burner mixes the fuel and
oxygen together and, with the
assistance of an ignition device,
provides a platform for
combustion.  This combustion
takes place in the combustion
chamber, and the heat that it
generates is transferred to the
water through the heat
exchanger.
Controls regulate the ignition, burner firing rate, fuel supply, air
supply, exhaust draft, water temperature, steam pressure, and
boiler pressure.
 Hot water produced by a boiler is pumped through pipes
and delivered to equipment throughout the building, which
can include hot water coils in air handling units, service hot
water heating equipment, and terminal units.  Steam boilers
produce steam that flows through pipes from areas of high
pressure to areas of low pressure, unaided by an external
energy source such as a pump. Steam utilized for heating
can be directly utilized by steam using equipment or can
provide heat through a heat exchanger that supplies hot
water to the equipment.
Boiler Testing procedures and
Maintenance
What is the need to maintain
a boiler?

• To ensure 100% safe to operate the boiler.

• To ensure 100% availability for the Production
Requirement.
• To ensure the boiler runs at its Best efficiency.
• To ensure the operation to be cost effective.
How often should you need
to service the Boiler?
How often should you need
to service the Boiler?
To ensure that it's running safely and efficiently, your
boiler should be serviced as often as once a year. Not
having your boiler serviced could lead to faults, higher
energy bills and your warranty ending early.
The Hydraulic test of the boiler is
carried out at the following conditions / situations:

•On completion of the boiler erection activities.

•On completion of repair work on boiler pressure parts.
•On completion of annual overhaul.
•At the request of statutory authority to fulfill the
statutory requirements.
•New Boiler ready for hydro-static test.
Hydrostatic testing Procedure:
Hydrostatic testing in the boiler is carried out to check the following:
•Leakages in the boiler pressure parts (Tubes, headers and
Pipes).
•To test the soundness of welded joints and associated pressure
parts of the boiler in order to comply the code requirements.
•To prove the strength of the boiler pressure parts at a pressure
greater than the working pressure of the boiler at ambient
temperature.
Preparation for Boiler Hydrostatic test:
The following activities have to be completed before carrying out the
boiler hydraulic test.
• Ensure that the complete boiler pressure part erection is
completed.
• Ensure that all welding/NDt and heat treatment activities
are completed.
• Ensure that necessary pressure parts welding are completed as
per the drawing.
• Ensure that pressure parts welding joints are free from paint
& rust
 Preparation for Boiler Hydrostatic test:
• Ensure that, all the buck stays, its guides and anchors are
nstalled as per the drawings. (Check and confirm the
learance provided in the guides and anchors are strictly as
per the drawing).
• Ensure that all the boiler permanent supports, structural
bracings are provided as per the drawings.
• Ensure that all temporary supports provided for erection
upports are removed.
• Ensure that, all tools; equipment and loose items have
been removed from the drums and manifolds.
Preparation for Boiler Hydrostatic test:
• Ensure that, steam drum, man holes and manifolds inspection
caps are properly joined and tightly sealed.
• Ensure that, the constant load hangers are locked in position
with locking pin and the spring loaded hangers are locked.
• Ensure that the Boiler filling arrangements are ready.
• Ensure that Hydrostatic testing pump is available.
• Ensure that Power supply to the pressure raising pump should
be available.
• Ensure the DM water quality & availability as per requirement.
(Minimum three (3) times of the boiler water holding capacity
shall be readily available).
 Preparation for Boiler Hydrostatic test:
• Ensure that, minimum two set of spare gaskets for the drum and
oiler important gaskets must be available ready.
• Ensure that proper lighting, approach platforms and communication
ystems, are ready.
• Ensure that, the following temporary arrangements are completed
or conducting a hydraulic test.
• Temporary piping connection from pressure pump discharge to hydro
est connection point in the Boiler.
• Boiler filling line to be made ready from existing DM fill pump
tation for Boiler filling.
• Ensure that, all the temporary piping’s are adequately supported.
 Preparation for Boiler Hydrostatic test:
• Ensure that minimum three (3) numbers of calibrated pressure gauges
fitted at the identified locations (One in the steam drum, one in the
am outlet header and the other at the outlet of the hydraulic pump).
• Ensure that, the dial pressure gauge used in the testing shall have
ls graduated over the entire range of the hydro test pressure.
• It is preferable to have calibrated pressure gauge size greater than
0mm.
• Ensure proper and adequate man power is available during the test.
• Ensure that, the drum internals are not fitted inside the steam drum
 Boiler Filling Operation for
Hydrostatic testing:
• Ensure that the following valves are closed.
• Root valves of all instruments.
• Chemical dosing line valves
• CBD and IBD Valves
• All header and pipe drain valves
• Soot blowing system and sample cooler system isolation
alves.
Hazard and Risk Management:
 Common Boiler Hazards:
• The most common boiler hazards that lead to accidents are low
water levels, excessive pressure and a failure to purge combustible
gases from the firebox before ignition. These hazards can cause
serious boiler accidents like explosions or fire.
•Low water levels in a boiler are caused by improperly functioning
low water cut- offs. Water levels that are too low can cause the boiler
to buckle or deform, melt down or even explode—all of which can
generate severe damage to the boiler and/or to the building.
 Common Boiler Hazards:
•Excessive pressure in a boiler can also lead to explosions.
This occurs when pressure is allowed to build in the boiler.
Boiler explosions are very dangerous and can completely
destroy buildings.
•Fuel-related accidents, like fires and explosions, are also
common and occur when combustible gases are not purged
rom the firebox. Leaking fuel valves can also cause this kind
of accident.
Some of the most common
risks in boiler operations include:
•Burns - High-temperature oil, steam, or
water can escape from high-pressure
chambers or the pipework of an
interconnecting system that has been
improperly locked out. Depending on the
percentage of the body that is affected,
burns can range from manageable to
highly serious and even lethal.
Some of the most common
risks in boiler operations include:
• Explosions and Noxious Vapors
-Explosions may occur from the unwanted
accumulation of hydrogen gas during acid
cleaning processes. Other flammable
and/or combustible cleaning solvents can
be just as dangerous, as the vapors given
off by all of these substances are highly
toxic.
Some of the most common
risks in boiler operations include:
•Asbestos -Due to its insulation properties,
asbestos was frequently used in the make-up of
certain boiler systems, the rooms that contain
them, as well as marine-related piping systems.
Asbestos dust is highly toxic when inhaled, which
means anybody who comes in contact with it
while unprotected will likely face serious adverse
reactions. Although the substance is rarely used in
newly built ships, workers who must operate
boilers on older vessels continue to be at risk.
Some of the most common
risks in boiler operations include:
•Maintenance Accidents -A great
number of accidents take place during
maintenance times when the ship is
docked. Isolating chambers and ensuring
that the entire valve system is shut-off is
not an easy operation, which is why any
inadvertence can ultimately mean that
employees are exposed to high-
temperature steam, oil, or water.