Bestech Industrial & Technical Training Center, Inc .

BOILER DESIGN
CONCEPT,OPERATION
MAITENACE, and INSPECTION
 PRESENTER

V EJ IEH J IM , SU M A G A YSA Y
PROFESSIONAL MECHANICAL ENGINEER
License Welding Engineer – Japan Welding Engineering Society
Certified Welding Inspector – Philippine Welding Society
 Understand the Design Principle and
Design Consideration of Steam Boiler
Technical Familiarize the different types of

Training Boiler
Familiarize with different Boiler Parts, Boiler
Outcomes Assembly and Associated System

Identify Boiler Mounting and Accessories

Understand the boiler Operation and Routine

Activities

Familiarize with common problem encountered

during operation
Understand the HSE impact of Boiler
Operation
Boiler Definition
Steam Boiler or Steam Generator is an Boiler Horsepower Definition
Equivalent to evaporating of 34.5 pounds of steam from and at 212 0F per hour
enclosed pressure vessel into which heat
Enthalpy
energy is applied to water until water is Total energy of a substance , H = U + PV
converted into steam. Specific Enthalpy of Water @ 212 0F (100 0C) at Saturation Pressure P
BTU/lb KJ/kg
Saturated Liquid, hf =
Transition Phase, hfg =
Saturated Vapor hg =

Liquid into Steam Transition

When water is heated and converted into steam
Its volume increases by 1600 times! It can
produce a force as explosive as gun powder
A B Thus Boiler must be treated with out must
care
Thermodynamic Properties of Water
Saturated Steam Tables (SI Units) Saturated Steam Tables (English Units)
Boiler Design Principle
Boilers are Design and Maintained in Compliance with
Safety
ASME CODE SEC I – Power Boiler
Installed Cost SME CODE Sec VIII – Division 1/Division 2 – Pressure
Vessel
Availability ASME B31.1 – Power Piping
PME CODE Chapter 7 2018 Edition
Efficiency
Boiler Over Pressure Regulation and Testing Requirement
Certificate to Operate in Compliance with DOLE Regulation
Serviceability
 Boiler Design By Code
BOILER AND PRESSURE VESSEL DESIGN SCOPE
▪ POWER BOILER ASME Sec I
▪ Pressure Parts Directly Connected to the
Boiler
▪ POWER PIPING ASME B31.1
▪ Boiler External Piping
▪ Terminates at first Circumferential
Welding of First Flange
▪ PRESSURE VESSELS
▪ ASME SEC VII
▪ Division I - Design By Rules (F.S.=4)
▪ Division II – Design By Analysis (F.S.=3)
Boiler Design By Code
Boiler Drum Design Formula
Where:
Theoretical Formula
t = thickness, mm
P = Design Internal Pressure, MPag
ASME Code Sec I Do = Outside Diameter, mm
S = Allowable Stress at Design Temp, MPag
E = Joint Efficiency (%)
y = Temperature Coefficient
Proposed PME Code
C = Threading and Structural Allowances
Boiler Design By Code
DESIGN PARAMETERS
Design Pressure 8.0 MPa
Maximum Allowable Temperature, 350 0C
Tube Outside Diameter, Do 127 mm
Material SA 106 -C R/t > 10
Maximum Allowable Stress, S Refer to ASME Code Sec I PG – 27.4.2 Table
1A
Temperature Coefficient, y Refer to ASME Code Sec I PG- 27.4.6
Joint Efficiency, E Refer to ASME Code Sec 1 PG 24.7-1

Minimum Allowance for Threading and Refer to ASME Code Sec 1 PG 24.7.3
Structural integrity, C
 Boiler Design By Code
Mechanical Properties of Material by ASME Code
 Boiler Design By Code
Table Temperature Coefficient and Joint Efficiency
Boiler Design By Code
DESIGN PARAMETERS
Design Pressure 8.0 MPa
Maximum Allowable Temperature, 350 0C
Tube Outside Diameter, Do 127 mm
Material SA 106 -C
Maximum Allowable Stress, S 135 MPa
Temperature Coefficient, y 0.04
Joint Efficiency, E 1 Seamless Pipe/Tube
Minimum Allowance for Threading and 0
Structural integrity, C
DESIGN CALCULATIONS RESULTS
Theoretical Formula 3.763 mm

ASME CODE Sec 1 3.675 mm

R/t > 10
FINAL DESIGN RESULT
Standard Boiler Tube Thickness 10 mm
Boiler Design Calculation
Boiler Design Parameters Boiler Drum Design Calculation
Design Pressure P = 8 MPa Theoretical –Thin Walled Cylinder
Design Temperature , T = 350 0C
Outside Diam = 127 mm = 3.76 mm
Material = SA 106 –C ( Carbon Steel -
Seamless Pipe)
ASME CODE SEC 1
t
Material Properties and constants as per
ASME Sec II –Material
S = 135 MPa = 3.68 mm
E = 1 (Seamless)
C=0
Standard Boiler Pipe Thickness , t = 10 mm
y = 0.4
Boiler Design Consideration
Fuel Characteristics
Fuel Characteristics
Heating Value
Ash fusion characteristics
Erosive and Corrosive Nature of Ash

Design Parameters Design Parameters

Furnace Design (Residence time, fouling, slagging)
Entry velocity design in convective pass and HRU (Erosion)
Flue gas exit temperature and skin temperature (Corrosion)
Boiler Design Concept
Steam Boiler or Steam Generator are
design to dispose the total heat
absorbing surface in a manner that
will obtain maximum available heat
from the fuel and product of
combustion
Boiler Design Principle
Primary Input
➢ Boiler Output
➢ Process Load Profile
➢ Nature of Load (Constant or Fluctuating)
➢ Fuel
➢ Efficiency
Boiler Design Principle
Boiler Working Principle
Steam Boiler or Steam Generator is an Boiler Horsepower Definition
enclosed pressure vessel into which heat Equivalent to evaporating of 34.5 pounds
of steam from and at 212 0F per hour
energy is applied to water until water is Enthalpy
converted into steam. Total energy of a substance , H = U + PV
Specific Enthalpy of Water @ 212 0F (100 0C) at Saturation Pressure P
BTU/lb KJ/kg
Saturated Liquid, hf =
Transition Phase, hfg =
Saturated Vapor hg =

Water into Steam @ 100 0C

When water is heated and converted into steam Its volume increases by about
1600 times! It can produce a force as explosive as gun powder . Thus Boiler must
be treated with out must care
Boiler Working Principle
Steam Boiler or Steam Generator is an Boiler Horsepower Definition
Equivalent to evaporating of 34.5 pounds of steam from and at 212 0F per hour
enclosed pressure vessel into which heat
Enthalpy
energy is applied to water until water is Total energy of a substance , H = U + PV
converted into steam. Specific Enthalpy of Water @ 212 0F (100 0C) at Saturation Pressure P
BTU/lb KJ/kg
Saturated Liquid, hf =
Transition Phase, hfg =
Saturated Vapor hg =

Water to Steam Conversion

When water is heated and converted into steam
Its volume increases by 1600 times! It can
produce a force as explosive as gun powder
Thus Boiler must be treated with out must
care
Boiler Classification

Hybrid
Boilers

Fire Tube Boilers Water Tube Boilers

Boiler Classification
Fire Tube Boiler

Fire Tube Boiler Characteristics

▪ Consists of number of tubes in which hot gases are passed
▪ Tubes are immersed /surrounded with water to absorb the heat
▪ Fire tube boilers are used for low pressure and low temperature process application

Advantages
▪ Relatively inexpensive compare to Water Tube Boilers
▪ Compact in size
▪ Easy to maintain
▪ Suitable for fluctuating load applications such as in space heat industrial process
plant
Disadvantages
▪ Not suitable for high pressure and high temperature application above 250 PSIg
Types of Boiler System
Closed System
Closed System
▪ 100 % of the steam produced including
condensate are returned to be used.
▪ Examples: Close Steam Heating, Hot Water
Heating, and One Pipe Systems

Open System Open System or Ounce Through

▪ System does not return the condensate
▪ Example: Locomotive Engines
Boiler Classification
Water Tube Boiler

Water Tube Boiler Characteristics

▪ Consists of number of tubes in which contain
water
▪ Tubes are surrounded with hot gases which
transfer the heat to water
▪ Water tube could be single or multiple drum type
▪ Can be built in higher steam capacity and high
pressure, high temperature applications
▪ Higher efficiencies than fire tube boilers
Boiler Classification
Water Tube Boiler
Water Tube Boiler

Advantages
▪ Higher Capacity (several million pounds/hour of steam) compare to fire tube boiler
▪ Design to operate at higher pressure up to 5000 PSIg ( 345 Bar)
▪ Recover faster than fire tube boilers
▪ Ability to reach higher temperatures

Disadvantages
▪ High initial cost
▪ Massive structure
▪ Higher maintenance cost
▪ Difficult to maintain/clean compare to fire tube boilers
Boiler Design WATER TUBE BOILER

2 Drum D-Type Boiler

Boiler Classification
Hybrid Boilers
Defined as Hydronic Heating
Plant
Combining condensing and non
condensing boilers.
Boiler Classification
Waste Heat Recovery Boilers

Waste Heat Recovery Boiler

▪ Generally water tube boilers in which the hot
exhaust gases from diesel engines, gas turbines,
incinerators, etc., pass over a number of parallel
tubes containing water. . The water is vaporized in
the tubes and collected in a steam drum from
which it is drawn off for use as heating or
processing steam.
▪ Usually produces MP and LP Steam for industrial
process application
▪ Improves overall steam generation efficiency
Boiler Classification
Waste Heat Recovery Boilers

Waste Heat Recovery Boiler

▪ Used when waste heat available in medium/high temperature
▪ Auxiliary fuel burners used if steam demand is more than the waste
heat can generate
▪ Used in heat recovery from exhaust gases from gas turbines and diesel
engines
Boiler Classification By Application
Heating Boilers
HEATING BOILERS Provide steam and hot water for building heat such as in
Hotels, Medical Facilities, Housing Facilities, Schools etc.

Process Boilers
PROCESS BOILERS
Referred to as Power or Industrial Boilers provide steam or
high temperature hot water for uses in process ,
manufacturing, power generation
Boiler Pressure Classification By ASME
LOW PRESSURE
LOW PRESSURE ▪ Steam Boiler : 15 PSI Maximum Operating Pressure
▪ Hot Water Boiler : 160 PSI Maximum Operating Pressure
: 250 0F Max Operating Temperature
HIGH PRESSURE
HIGH PRESSURE
▪ Steam Boiler : Above 15 PSI Operating Pressure
▪ Hot Water Boiler : Above 160 PSI Operating Pressure
: Above 250 0F Operating Temperature
General Boiler Pressure Classification
LOW PRESSURE
LOW PRESSURE ▪ Pressure : 500 KPa to 1500 KPa
▪ Temperature : 150 0 C to 200 0 C
Applications
Steam jackets for reaction vessels, Steam Tracing/Heating Coils
HIGH PRESSURE ,Steam Chest of Evaporator
HIGH PRESSURE
▪ Pressure 1500 KPa to 20 000 KPa
▪ Temperature : 500 0 C
Applications
Steam Turbines, Reciprocating Engines, Steam Ejectors
Boiler Steam Pressure Classification
Steam Pressure Classification in Relative Application
P (Barg) T (0C)
▪ Superheated High Pressure Steam 105 510
LOW PRESSURE
▪ High Pressure Steam 45 385
MEDIUM PRESSURE
▪ Medium Pressure Steam 14 245
HIGH PRESSURE ▪ Low Pressure Steam 3 210
 Boiler System Assembly
A. Boiler and all pressure parts - from feed water
BOILER SYSTEM inlet valve and hot water outlet valve
ASSEMBY ➢ All Superheaters, Reheaters, Economizers and
associated safety accessories /devices
A. Pressure Parts ➢Isolatable superheaters, reheaters, economizers
B. Feedwater System and related interconnecting tubing
C. Fuel System B. Means of providing the boiler with feedwater
including the control system
D. Draft System
C. Heat Supply and Firing System
E. Steam System
D. Combustion Air and Control System
E. The pressure expansion vessels and tanks of hot
water generating plant
Boiler Feed Water System
Deaerator Function ▪ Deaerator is a device that removes
oxygen and other dissolved gases from
feed water from steam boilers.

▪ Dissolve oxygen in water can cause

serious corrosion problem in the boiler by
attaching to the walls of metal piping and
other parts forming an oxide
Boiler Feed Water System
Deaerator Working Principle
Boiler Feed Water System
Feedwater Pump Function ▪ Supplies feed water at high pressure
maintaining water inventory at various
operating load

▪ Common type of pump used is Multistage

Centrifugal Pump to ensure the supply of
water at high pressure head

▪ Most common drive is Steam Turbine with

two or more standby Electric Motor
Boiler Feed Water System
Boiler Feedwater Pump

Pump Classification
Motor Driven BFP Steam Turbine Driven BFP
Centrifugal Pump
Impeller Between Bearings
Multistage
 Boiler Pressure Parts
BOILER PRESSURE PARTS GROUP ▪ Economizer
▪ Steam Drum
▪ Water Drum/Mud Drum
▪ Down Comer
▪ Convection Bank
▪ Furnace Walls
▪ Riser
▪ Distribution Headers
▪ Superheaters
▪ De-Superheaters
▪ Air Preheaters
 Boiler Pressure Parts
ECONOMIZER ▪ HRU used to increase the temperature of feedwater
supply using the heat from flue gas leaving the steam
generator through exhaust duct or stack
▪ Economizer improves cycle efficiency by pre heating
feedwater supply to the boiler
▪ For every 6 degree raise in boiler feed water
temperature , the estimated of fuel cost that can be
saved is 1%
Boiler Pressure Parts
HP BOILER ECONOMIZER
FLUE GAS TEMP IN = 360 0C

Water Out Temp = 210 0C

SPECIFICATIONS
➢ 56 Tubes / Diam 38.1 mm
➢ 28 Passes/ Tube
➢ Wind Velocity 200 Km/hr

Water In Temp = 150 0C

FLUE GAS TEMP OUT = 100 0C

 Boiler Pressure Parts
AIR PREHEATER ▪ HRU used to increase the temperature of air
before it enters the furnace
▪ Generally placed after the economizer
▪ An increase in 200C in air temperature
increases the boiler efficiency by 1%
▪ Hot air supply is necessary to remove
moisture in the fuel to improve combustion
process
3 types of Air Preheater
▪ Tubular
▪ Plate
▪ Regenerative
 Boiler Pressure Parts
AIR PREHEATER
BENEFITS OF PREHEATING

▪ Improve combustion
▪ Successful burning of low grade fuel
▪ Increased thermal efficiency
▪ Saving in fuel consumption
▪ Increased steam generator capacity
 Boiler Pressure Parts
AIR PREHEATER
DRAW BACK

▪ There are formation of clinkers , on the gate due

to higher combustion temperature

▪ Natural draft is not possible with air preheater

because of temperature of flue gas is reduced,
also pressure drop take place in the flow of the
flue gases, therefor forced draft is required
 Boiler Pressure Parts
BOILER STEAM DRUM
Function of Steam Drum
1. To store water and steam sufficiently to
meet varying load demands.
2. To provide a head and thereby aiding the
natural circulation of water through water
tubes.
3. To separate vapour or steam from water-
steam mixture, discharged by the risers.
4. To aid in chemical treatments to remove
dissolved O2 and to maintain required pH.
 Boiler Pressure Parts
BOILER STEAM DRUM
Function of Steam Drum
1. To store water and steam sufficiently to
meet varying load demands.
2. To provide a head and thereby aiding the
natural circulation of water through water
tubes.
3. To separate vapour or steam from water-
steam mixture, discharged by the risers.
4. To aid in chemical treatments to remove
dissolved O2 and to maintain required pH.
 Boiler Pressure Parts
BOILER STEAM DRUM
Function of Steam Drum
1. To store water and steam sufficiently to
meet varying load demands.
2. To provide a head and thereby aiding the
natural circulation of water through water
tubes.
3. To separate vapour or steam from water-
steam mixture, discharged by the risers.
4. To aid in chemical treatments to remove
dissolved O2 and to maintain required pH.
 Boiler Pressure Parts
BOILER STEAM DRUM
 Boiler Pressure Parts
MUD OR WATER DRUM
Function of Water drum
1. Distributes feed water from the
downcomer to the headers and
generating tubes.
2. Provide a space for accumulating the
precipitates and allows them to be blow
down
3. Allows colder, denser water flows the mud
drum through small number of down
comer , and rises to the steam drum
through a much larger number of riser
tubes
 Boiler Pressure Parts
MUD OR WATER DRUM

Inside Water/ Mud Drum

 Boiler Pressure Parts
CONVECTION BANK Function
1. Part of the furnace between the radiant
section and stack. The area is filled with
tubes or pies which carry process steam
and which absorb heat via convection
heat transfer from hot gases passing
through the are on their way out of the
stack.
2. The convection section forms an obstacle
to the combustion gas flow and can
greatly affect furnace draft in the radiant
section of the furnace.
 Boiler Pressure Parts
FURNACE
An enclosed combustion
chamber where the air and
fuel mix and burn or place
where combustion takes place
 Boiler Pressure Parts
FURNACE WALL
FURNACE WALLS
1. FRONT WALL
2. FURNACE REAR WALL
3. FURNACE SIDE WALL
4. BOILER SIDE WALL
 Boiler Pressure Parts
WATER WALL TUBES
WATER WALL TUBES
Is a wall inside a boiler enclosure that is
composed of closely set water tubes
▪ 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
absorb the heat produce in the furnace
 Boiler Pressure Parts
WATER WALL TUBES DESIGNS
 Boiler Pressure Parts
DISTRIBUTION HEADER
Description
Are big pipe headers that transfer water from
the downcomers to the risers, through a
combustion zone where water gets partially
heated to steam from the heat of fuel
combustion
 Boiler Pressure Parts
SUPER HEATERS Description
▪ Superheater supplies dry and saturated
steam at rated temperature to downstream
process
▪ Saturated steam from the steam drum flows
to superheater assembly to increase the
steam temperature
▪ Saturated steam from steam drum internals
flows through the supply pipes to the
superheater inlet header from , where it s
distributed to other superheater tubes
▪ Bundles of high strength tubes able to
handle temperature up to 600 0C.
 Boiler Pressure Parts
SUPER HEATERS
 Boiler Pressure Parts
DESUPER HEATERS
Description
▪ Known as Attemperator
▪ Function to control and reduce steam
temperature of superheated steam
▪ If superheated steam is over heated,
desuperheater will spray amount of water
(from feedwater pump) into steam flow to
reduce its temperature
 Boiler Pressure Parts
DESUPER HEATERS WORKING PRINCIPLE
 Boiler Blowdown System
General Purpose
▪ The quality of water included in the steam drum may be poor
▪ In order to avoid poor quality water being transformed into steam, this poor
quality of water is bled from the drum and led to blowdown system.
Blowdown
Certain amount of water is blown off through blowdown valve and is
automatically replaced by feedwater to maintain the water to maintain to
desired level of TDS in boiler water
TYPE OF BLOWDOWN
▪ Intermittent Blowdown
▪ Continuous Blowdown
Boiler Blowdown System
Typical CBD and IBD Valves
Combustion Air Systems
AIR FLOW IN BOILER FURNACE
 Boiler Draft System
Boiler Draft
The pressure difference between the pressure of ambient air
and the flue gases pressure within the boiler furnace or chimney
which causes the flow of hot flue gas to take place in the boiler
Types of Draft
▪ Natural Draft – Gas flow due to density difference between outside air
and hot gases
▪ Forced Draft – Mechanically forcing air into the furnace
▪ Induced Draft – Mechanically drawing hot gases from the furnace
▪ Balance Draft – Combination of Forced and Induced draft
 Boiler Draft System
Fans
▪ The pressure ratio (P2/P1) up to 1.11 and
▪ Pressure Rise (DP) = 11 KPa
▪ Pressure Discharge, P2 = 112 KPa
Blowers
▪ The pressure ratio (P2/P1) range from 1.11 t o
1.2
▪ Pressure Rise (DP) Range = 11 KPa to 20 KPa
▪ Discharge Pressure, P2 Range = 112 KPa to
121 KPa
Fans and Blowers
 Boiler Fuel Systems
FUEL BURNER
The primary purpose of the burner is to
accomplish the complete combustion of
specific fuels such fuel oil and fuel gas
▪ A burner is a mechanical device that
supplies required amount of fuel and air for
combustion
▪ Creates condition for rapid mixing of fuel
and air
▪ Produce a flame which transfers thermal
energy to the furnace tubes
 Boiler Fuel Systems
FUEL BURNER
 Boiler Fuel Systems
FUEL OIL BURNER
 Boiler Fuel Systems
BURNER GUN
 Boiler Fuel Systems
SOOT BLOWING SYSTEMS
Why Soot Blowing is Necessary?
▪ The fuel used in thermal plants causes soot and is
deposited on the boiler tubes, superheater,
economizers, air preheaters etc.
▪ Soot deposits drastically reduces the amount of heat
transfer
▪ Soot blowers control the formation of soot to reduce
its corrosive effect.
▪ Pressure drop in the gas side remain in acceptable
limits
Boiler Fuel Systems
SOOT BLOWING SYSTEM
 Boiler Fuel Systems
SOOT BLOWING SYSTEM

Manually Operated Rotary Soot Blower Short Retractable Wall Soot Blower

Fully Retractable Soot Blower Long Retractable Soot Blower

 Flue Gas Stack
Stack or Chimney

A vertical channel or similar structure through

which combustion product gases called flue
gases are exhausted to the atmosphere
▪ Used for releasing the flue gases after they have
delivered their heat for warming the inlet water
▪ Flue gases are discharged to the atmosphere
through the main stack
▪ Flue gases are corrosive, thus flue stack must be
insulated to prevent moisture condensation
 Chemical Dosing System
Purpose of Chemical Dosing System

▪ Prevent scale deposit on boiler’s heat exchange

surfaces
▪ Prevents Corrosion
▪ Modulate pH value of feedwater
▪ Eliminate the presence of oxygen in water/steam
cycle
 Emissions Control Unit
Purpose of Emission Control Unit
▪ Emissions Standard are legal requirements
governing air pollutants release to atmosphere
▪ Emission standards set quantitative limits on the Refer to the following:
permissible amount of specific air pollutants that ➢R.A. 8749
may be released from specific sources over ➢RULE of DOLE and DAO 2000-81
specific timeframes
▪ Generally designed to achieve air quality
standards and protect human health
BOILER
EMMISSION
CONTROL
EQUIPMENT

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
 Emissions Control Unit
DUST COLLECTING EQUIPMENT
▪ ESP – Electrostatic
Precipitators or Electronic
Filters
▪ MDC – Mechanical Dust
Collector
▪ FFS – Fabric Filters or Bag
Type Dust Collectors
▪ Wet or Dry Scrubbers
 Emissions Control Unit
ELECTROSTATIC PRECIPATATOR

▪ Control is relatively complex,

▪ High-voltage equipment,
▪ High security requirements.
▪ Boiler operation requirements are not
high
▪ Strict equipment management
requirements.
Emissions Control Unit
ELECTROSTATIC PRECIPATATOR
 Emissions Control Unit
ELECTROSTATIC PRECIPATATOR
ADVANTAGES
▪ Can work with large air flow
▪ Collects both dry and wet pollutants
▪ Removes tiny dust particle
▪ Effective for high dust loaded gas
▪ Dust is collected in dry form and can be disposed dry or in
wet form
▪ Easy maintenance
▪ Controls Air Pollution and Save Environment
 Emissions Control Unit
ELECTROSTATIC PRECIPATATOR

PROBLEMS
▪ Dust accumulation
▪ Wire breakage
▪ Insulation cracking
▪ Air ingression
 Emissions Control Unit
MECHANICAL DUST COLLECTOR

Operation of Dust Collector

Cyclone Dust Collector Multi-Cyclone Dust Collector
 Emissions Control Unit
BAG FILTER DUST COLLECTOR

▪ Stable operation
▪ No high-voltage equipment,
▪ Good security requirements.
▪ Boiler operation with close , strict
equipment management requirements.
 Emissions Control Unit
BAG FILTER DUST COLLECTOR

Bag Filter Dust Collector Set Up Bag Dust Collector Operation

 Emissions Control Unit
BAG FILTER DUST COLLECTOR

Parts/Components Bag House Filter Bags

Emissions Control Unit
BAG FILTER DUST COLLECTOR
 Emissions Control Unit
SCRUBBERS
Scrubbers are absorption equipment used as pollution control devices.
➢Used to remove harmful materials from the boiler exhaust gases before they
are released into the environment.
Major Categories
▪ Dry Scrubbers – Mainly used for removal of acid gases from product of
combustion by introducing series of dry reactants at very high speed.
▪ Wet Scrubbers – Devices which use scrubbing liquid for the removal of
source emissions from effluent gas streams. Removes both particulate matter
and gaseous pollutants
 Emissions Control Unit
DRY AND WET SCRUBBERS

Venturi – Cyclone Scrubber Wet Venturi Scrubber

 Emissions Control Unit
DRY SCRUBBERS
Advantages
▪ Prevents large number of pollutants from escaping into the air
▪ Comparatively produce little waste material
▪ Low maintenance cost
Disadvantages
▪ Disposal of residual waste power/hazardous material to comply with
Environment Standards
▪ Scrubbing process is expensive
▪ Can not remove all contaminants from the gas
 Emissions Control Unit
WET SCRUBBERS
Advantages
▪ Prevents wide range of pollutants from escaping into the air
▪ Equipment are fairly sturdy and can tolerate wide range of
temperature
▪ Able to remove pollutants such as sulfur and acidic gases
Disadvantages
▪ Require frequent maintenance/High maintenance cost
▪ Device is susceptible to severe corrosion
BOILER
MOUNTINGS

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
 Boiler Mountings
Boiler Mountings , Valves and Fittings
▪ Main Steam Stop Valve Boiler Relief System
▪ NRV on Steam Line ▪ Boiler Relief System are
▪ Safety Valves installed to boilers to comply
▪ Blowdown Valves with regulation requirement to
▪ High-Low Water Level Alarms on Steam Drum prevent boiler over pressure
and to compromise the
▪ Water Level Indicator on Steam Drum
integrity of the boiler and its
▪ Pressure gauges on steam drum and SH associated equipment.
 Boiler Mountings
Boiler Drum Safety Valves

▪ Fail safe device that prevents failure under overpressure condition

Boiler Mountings
Superheater Safety Valves

▪ Installed at main steam line piping

between SH outlet and first main
stop valve
Boiler Mountings
Water Level Indicator
▪ Purpose
▪ To indicate the level of water in the
boiler and to enable the operator to
regulate the supply of feed water in
the boiler to maintain the correct
level.
Boiler Mountings
PRESSURE GAUGE
▪ Purpose
▪ Pressure measuring device installed in the
front of the boiler
▪ Connected with the boiler steam zone by a
tubular siphon connector and efficient
checks the steam pressure of the boiler.
FUSIBLE PLUG
▪ Purpose
▪ Typically installed in Firetube Boilers that acts
like a safety fuse to prevent the adverse effect of
over heating
BOILER
OPERATION
AND
MAINTENANCE

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
Boiler Operation
Sequence of Event
1. Feed water is pump to the boiler
(passing through economizer)
ensuring that the boiler is filled up to
the required amount.
2. Required amount air enters the
furnace by means of blower (passing
through the Air Pre-Heater)
3. Main fuel is supplied to the boiler
burner (passing through the fuel pre-
heater device to attain the fuel
combustion set temperature to sustain
combustion process )
Boiler Operation
Sequence of Event Continuation
4. Fire Eye/Fire Monitor to check presence of fire inside
the furnace
5. Pilot fire is ignited electronically
6. Atomized fuel is fired through the burner /nozzle to
start combustion process
7. Hot gases produced by combustion transfer heat the
water to produce the desired amount of steam.
8. Flue gas is exhausted to the stack by means of
mechanical draft
9. The process will continue until the desired pressure,
temperature and steam flowrate is achieve.
 Safety in Boiler Operation
1. Maintain the Normal Operating Water Level
2. Never attempt to add water to a hot boiler when water level cannot be
determined
3. Test PSV/PRV regularly in compliance with DOLE Technical Safety Rule
4. Follow SOP and approved WIP
5. Maintain proper steam pressure and or water temperature
6. Routinely test the low water fuel cut – offs and feed water pump controls
7. Routinely blow down the water column, water gauge (sight glass, and try
cocks.
8. Maintain the burner according to manufacturers recommendation.
 Safety in Boiler Operation
9. Maintain proper fuel oil temperature and or gas pressure
10. Record fuel consumption regularly
11. Maintain optimum feedwater temperature
12. Record make up water consumption regularly
13. Monitor and record stack temperature
14. Maintain control of the boiler at all times. Observe operation of the boiler
auxiliary equipment
15. Maintain Boiler Log Record all appropriate data and document any unusual
conditions.
 Boiler Preventive Maintenance
1. Safety First Always - Follow approved Safe Working Practices
2. Refer to Boiler OEM for Technical Specifications and
Maintenance Procedure
3. Establish a Boiler Maintenance Standard Operating Procedure
(SOP) or Work Instruction Procedure (WIP) as a reference guide
for any Boiler Maintenance activities
4. Maintain a Boiler Log Book to record routine operation and
maintenance activities are performed as planned.
➢ Maintenance routine/periodic include daily, weekly, monthly,
quarterly and annually.
➢ All PM activities must be recorded in the Boiler Daily Log Sheet
with notes in any abnormalities observed. Use PICO as PM
reporting guideline
 Boiler Preventive Maintenance
5. Maintain accurate and complete records of service, repairs and
boiler system replacement. Maintain record in database
6. Monitor boiler water consumption in regular basis
7. Monitor fuel consumption on regular basis
8. Ensure boiler room has adequate supply of air for combustion and
ventilation
➢ Insufficient air leads to incomplete combustion, high unburnt
carbon emission that leads to air pollution/environmental issues
9. Maintain Boiler Electrical and Instrument and Control System
10. Observe 5S - good housekeeping in the Boiler Room and the
surrounding area.
BOILER
PERFORMANCE
EVALUATION

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
 Boiler Efficiency and Emissions

1. Combustion
Efficiency
2. Heat Exchanger
Losses
3. Flue Gas Analysis
4. Emissions
 COMBUSTION EFFICIENCY
Facts about Burning of Fossil Fuel

1. Heat is lost into the surroundings during energy

conversion ( Chemical to Thermal Energy)

2. Combustion Process Analysis is intended to

improve Steam Generator fuel economy and the
safety of the fuel burning equipment
 HEAT EXCHANGER LOSSES
Heat Losses in Heat Exchangers During Water to
Steam Conversion

1. Convection Heat Loss : from steam and hot water

leaks

2. Radiation Heat Loss : Radiating heat from the

boiler shell to surrounding atmosphere

Above are part of Energy Management System

 FLUE GAS ANALYSIS

1. The analysis of the flue gas allows the engineer/operator to

determine boiler burner efficiency

2. The reaction of air and the fuel to the combustion process

3. Stoichiometric Combustion produces only the following gases

CO2, N2 and Water Vapor
 COMBUSTION EFFICIENCY
CALCAULTION
Required Data:
1. Fuel Analysis
2. Fuel Heating Value
3. Fuel Rate
4. Average Flue Gas Temperature
5. Ambient Temperature
6. Flue Gas Analysis: % CO, % H2O , % Ash
7. Boiler Heating Surface Area
 COMBUSTION EFFICIENCY
CALCAULTION
CALCULATION STEPS
1. Determine the Theoretical Air Fuel Ratio
2. Determine the Theoretical % CO2
3. Determine the Actual Excess Air Supplied based on amount of CO2 in the Flue Gas
4. Determine the Actual Amount of Air Supplied
5. Determine the Actual Mass of Dry Flue Gas
6. Determine All the Losses (L1, L2, L3, L4, L5 , L6, L7 and L8)
7. Determine the Combustion Efficiency = Heat Input – Summation of Heat Losses
 COMBUSTION EFFICIENCY
SUMMATION OF HEAT LOSSES
Heat Losses due to
1. L1 = Dry Flue Gas
2. L2 = Presence Hydrogen in Fuel
3. L3 = Moisture in Fuel
4. L4 = Moisture in Air
5. L5 = Partial Combustion of Carbon to CO
6. L6 = Surface Heat Losses
7. L7 = Unburnt HC in Fly Ash
8. L8 = Unburnt HC in Bottom Ash
 BOILER PERFORMANCE
FACTORS AFFECTING BOILER PERFORMANCE
▪ Periodic cleaning of boilers
▪ Periodic soot blowing
▪ Proper water treatment program and blowdown control
▪ Draft control
▪ Excess air control
▪ Percentage loading of boiler
▪ Steam generation pressure and temperature
▪ Boiler insulation
▪ Fuel grade and quality
BOILER
OPERATION
LAWS AND
REGULATION

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
 RULES AND REGULATION
FOR SAFE BOILER OPERATION

➢ OSH Standards Rule 1160 : Boiler

➢ Clean Air Act and Other Applicable

Laws : RA 8749

➢ Monitoring and Compliance to

Government Regulatory Standards :
DOLE and DENR Administrative Order
(DAO)
 OSHS RULE 1160
General Provision

➢ NO Boiler PTO Certificate , NO Installation/Operation

➢ Portable Boilers with PTO will be honored within the

validity of the permit

➢ Minimum personnel requirement in the operation of

Boilers as per R.A. 8495 Mechanical Engineering Law
 OSHS RULE 1160
BOILER INSPECTION
➢ Newly Constructed Boilers must be Hydrostatically Tested at 1.5
X the Designed Operating Pressure ( As per PME and ASME
Code Sec VIII)
➢ Re-constructed/Repaired Boiler must be Hydrostatically Tested
at 1.5 X the Designed Operating Pressure ( As per ASME
Section VIII Division I adopted by PME Code )
➢ Boiler in Service ; Hydrostatically Tested at 1.3 X the Designed
Operating Pressure ( As per PME and ASME Code Section VIII)
➢ Annual Inspection in compliance with DOLE Technical Safety
Rule
 OSHS RULE 1160
BOILER RECORD

➢ New Boiler : Name Plate/ Technical Specifications

➢ Used Boiler : Detailed Drawing and Inspection
Certificate Signed and Sealed by Professional
Mechanical Engineer
➢ Boiler Maintenance Record
 Boiler Technical Specification
1. Boiler ID Code and Make
2. Year of Make
3. Boiler Capacity and Rating
4. Type of Boiler
5. Type of Fuel used
6. Maximum Fuel Flow rate
7. Efficiency by HHV or LHV
8. Steam Generation pressure and superheat temperature
9. Heat transfer area
10. HRU installed
11. Type of Draft
12. Chimney Height
 OSHS RULE 1230
PIPING COLOR CODING AND IDENTIFICATION
CLEAN AIR ACT R.A. 8749
SECTION 12 : National Ambient Air Quality
Guidelines – Necessary to Protect Public Health
and Safety and General Welfare
DAO 2000-81 IRR of RA 8749
National Emissions Standards
DAO 2000-81 IRR of RA 8749
National Emissions Standards
DAO 2000-81 IRR of RA 8749
National Emissions Standards
 Compliance to Regulatory
Requirements of Boiler Operation
➢ Establish and Monitor List of Compliance
Obligations applicable to Boiler Operation
➢ Regular Monitoring (Monthly/Quarterly)
➢ Regular checking and updating of Regulatory
Issuances applicable to Boiler Operation
➢ Compliance to Permit Conditions
➢ Secure ISO Certification - ISO 14001: 2015/ ISO
45001: 2018
 THANK YOU!

Bestech Industrial & Technical Training Center, Inc.

PHONE NUMBER
0949 889 4118
BOILER DESIGN CONCEPT,
OPERATION, MAINTENACE
AND INSPECTION
QUESTION
AND
ANSWER