Boiler Safety Operation
Boiler systems are designed for safety and efficiency. The boiler operator is the
key to safe boiler operations. Having knowledge about boiler systems and maintenance
can ensure years of safe, reliable operation.
Marine boiler is one of the most important systems on board which is used to
produce steam to drive the main engines or auxiliary machinery. Steam demand is the
main criteria of operating a boiler at a given load for marine boilers. It is of importance
that boilers cannot be overloaded to achieve excessive output and ensure all the
parameters are within the safety limits. Therefore, some important do’s and don’ts must
be followed which marine engineers must know on operating a marine boiler in a safe
and efficient manner.
It must be ensured that engineers should follow correct operating procedures when
igniting the boiler from the cold condition. In addition, pre and post purging is very
critical for every ignition and the air vent must be kept open when initially firing and
shutting down the boiler.
Safety Operation of Steam Boiler Onboard
To ensure the boiler can function well, a variety of important parts and systems
need to be checked, otherwise, accidents may occur and cause damage to the boilers.
Engineers should check the smoke from the funnel on every watch to gauge the
combustion quality of the boiler. Actions should be taken in the event of abnormal color
of smoke. Make sure that various valves and dampers, e.g. fuel line valves, steam
valves and safety valves, are in good order. Quick-closing valves and safety valves
should be correctly operational as well. In addition, one of most important part needs to
be examined is the furnace. Check the furnace for refractory deterioration and fuel
dripping near the burner assembly. If any defect is found, it should be rectified as soon
as possible.
In order to make the boiler have a good performance, cleaning and maintaining work is
necessary. Measures mentioned below are some common ones to improve boiler
efficiency.
Scum valve should be opened to discharge floating impurities and scum regularly
and blow down should be performed once a day to keep the chloride level
minimum.
Soot blowers should be used to perform blowing soot since it can assist to
continue the heat exchanging ability of the boiler tubes.
On the other side, soot blowing is a precaution against fire.
Lubricating is a good and effective measure in maintaining the boiler so that all
the required parts and connections should be lubricated and greased at regular
intervals.
Besides, steam system in boiler is prone to leakages because of fluctuating
steam pressure.
It is necessary to attend all the leakages as soon as possible to maintain the
efficiency at all times.
Safety Precautions in handling Steam Boiler
For the safety reason, it is essential for the engineers to know the safety
measures which mostly described in the company Safety Management System. For
example, emergency shut down of the boiler, which is located in the ECR, should be
checked whether it is functional or not. Marine boiler is oil-fired, high-pressure device
with its own firefighting apparatus. The crew on board should be aware of application
method of local fire extinguisher (foam type). In addition, fire drill needs to be carried out
periodically to prevent accidents. Apart from measures and operations mentioned
above, there are other points that need to be paid attention in boiler operation.
Periodic Maintenance
Watch out the water level at regular intervals instead of relying on the water level
indicator which is located in the ECR. Keep a close watch to get the real and clear level
by the local glass gauge. Keep the furnace door of the boiler closed in normal condition.
The door can be opened to do cleaning and inspection work for the burner or furnace.
Once the work is done, the furnace door will be closed. In addition, periodic
maintenance work is critical for the boiler and boiler auxiliaries and fittings as the boiler
efficiency will be much reduced if the maintenance work is not carried out over a period
of time.
Starting Failure
Never let the inexperienced engineer and untrained operator light up the boiler,
especially from the cold condition. If the boiler is started but failed 3 times, trouble
should be traced prior to another starting. Important points, e.g. pre and post surging,
correct starting operating, should be observed. In addition, abnormal conditions in the
boiler should be observed carefully in terms of sound, smoke, flame quality, drum level
and other parameters. Any abnormalities are found; correct them as soon as possible.
Avoiding Actions
Never operate a soot blower when the boiler is at a high load. Never do the blow
down excessively since the feed water system will add cool water to the boiler drum
which will reduce the thermal efficiency and stress in the boiler. Never operate the boiler
at a higher load as a regular practice. Occasionally, boiler can be overloaded because
of excess demand; however, frequent overload will lead to high stress and tube failure.
Never operate the boiler when there is leakage in any water tube and rectify the failure
at the earliest. Never supply sea water in any condition. If the cascade is filled with sea
water because of heavy leakage in the condenser, secure the equipment and correct
the problem.
Suggestions on Improving Boiler Efficiency on Board
One of the important tasks for marine engineers on board ships is to ensure that
all the machinery and systems are running efficiently, especially the critical equipment.
The good running conditions depend on a variety of factors which can affect the overall
performance and efficiency of these applications. Special attention must be paid to
these important parameters for the marine boilers as well. Several important points
mention below must be taken into account in order to improve boiler efficiency and
performance.
Feed Water Temperature and Level
It is essential to maintain the standard of all the inputs of the boiler system in
order to improve the system’s efficiency. Feed water system in the boiler system plays
an important role in enhancing the boiler operation efficiency. First of all, desired
temperature of feed water is required. The optimum temperature is maintained at
approx. 80-85℃ which can ensure the boiler can be worked at a high efficiency. Any
decrease in feed water temperature can result in more time for heating up the water to
produce steam, more fuel consumption and less overall efficiency. Besides, water level
and temperature in the cascade should be monitored carefully as well. Any drop of the
level in the cascade should be arouse attention, it indicates more cold water will be
added to maintain the correct level, which cause reduction in the feed water
temperature. In summary, feed water temperature is a key factor to improve boiler
efficiency. Therefore, feed water temperature should be maintained. Hot well level
controller should be operated properly. Feed water temperature in hot well should be
monitored
Observation of Critical Parameters and Parts
Marine boiler is a device which maintains high pressure to produce high
temperature steam for driving or other purposes. The outer shell or frame of the boiler is
a key part since it not only has a lot to do with the pressure but also maintains the flue
gas temperature intact inside the boiler to have a good heat exchanging ability. It is
therefore necessary to check whether there is leakage from the boiler shell which may
be caused by deformation or bulging of shell resulting in cracks. If there are black spots
in the outer plates of the boiler, it indicates the boiler shell has cracks and leakages may
be occurred. Check the refractory of the boiler to avoid overheating of the shell and
damage to it. If there is failure, replace the damage refractory as soon as possible.
Check the insulation of the shell to minimize the heat loss and maintain the boiler
efficiency
Necessary Cleaning Work
Soot deposits will form in the tube and internal surface of the oil-fired boilers
which can decrease the heat exchanging effect. It is indicated by the elevated tube
stack temperature whether there are soot deposits or not. Every 22℃ increase in the
stack temperature will cause approx.1% loss in efficiency and 3mm soot formation will
cause about 2.5% fuel consumption increase. Therefore, regular cleaning work and
observation of parameters must be carried out to avoid loss of efficiency as much as
possible. Blow down is a very important cleaning work as well to maintain the efficiency
and it should be performed at regular intervals. It indicates that such work should be
done only when the chloride level is high in the test or high conductivity alarm occurs.
However, long period of blow down is avoided since correct chloride and thermal stress
should be kept. Regular short blow down and check on chloride in the feed water are
recommended.
Boiler Loading
Boiler loading should be maintained within a correct range, neither too high nor
too low. The optimum range to obtain the highest efficiency is 2/3 of the full load. If it
falls below half of the full load, more air is required to burn the fuel which can increase
of the heat loss. Therefore, avoid operate the boiler below 25% load because the
efficiency will be much reduced. Keep the load at the 2/3 of the full load.
Conclusion for Safe Operation of Steam Boiler
Marine boiler is a device that requires a lot of attention to achieve the maximum
efficiency. There are a number of measures to achieve the efficiency. In the previous
passages, some do’s and don’ts and suggestions about boiler efficiency have been
discussed. Apart from suggestions above mentioned, it is certain that there are other
measures need to be taken. In conclusion, correct operation is the essential step to run
the boiler. The operator is required to have the professional knowledge to operate the
boiler. Keep a check on the various important parts and systems and do the cleaning
and maintaining work play a crucial role in obtaining the boiler efficiency. Feed water
temperature and level control, supply air/steam to burner, important parameters and
parts and systems, boiler loading, etc. are common factors need to be controlled strictly
and carefully. It is therefore necessary for the engineers to do the check and cleaning
work according to the instruction manual. During boiler operation, safety precautions
need to be taken to avoid potential accidents and hazards.
Safety Guideline for Boiler Operations
Boiler water is to be kept within the upper and lower limits at all times. If the
water level disappears from either the top or the bottom of the glass and does not return
immediately, then all burners are to be shut off until the water level has been restored in
the gauge glass. Any such loss of water must be recorded in the Engine Log Book and
reported to the Chief Engineer.
Whenever the water level indicated is suspect it is essential that the remote
water level indications are not used in place of the readings from the water level gauge
glass. Low pressure water level gauge glasses are to be "blown down" by an approved
method for the type of gauge glass at least once per watch or whenever the water level
indication is suspect. High pressure water level gauge glasses are to be blown through
only when necessary.
Testing of Boiler Water Controls, Regulators, Alarms and Trips.
All boiler controls, regulators, alarms and trips must be tested regularly in
accordance with the applicable Planned Maintenance System and maker’s
recommendations. Each test is to be recorded with the signature of the Engineer Officer
who conducted the test.
Boiler level alarms or trip defects are to be rectified immediately. The boiler
should not normally be operated with any such safeguards inoperative unless under the
supervision of the Chief Engineer. In this circumstance the boiler must be continuously
monitored.
The appropriate Management office is to be advised of details of any defects,
remedial measures taken, and confirmation of satisfactory re-tests which are also to be
recorded in the Engine Room Log Book.
Boiler Scale
Hard deposit on the interior of a boiler plate or tube. The scale generally contains
magnesium and calcium carbonates as well as calcium sulphate derived from the water
used.
Boiler Water Tests and Treatment
To reduce corrosion and scale formation in boilers, boiler water must be
maintained in slightly alkaline conditions by carefully controlled addition of chemicals.
Water in the boilers, steam/steam generators together with samples from their feed
water systems is to be tested daily. Testing is to be carried out in accordance with
procedures laid down by the suppliers of the water treatment systems. Completion of
tests is to be recorded in Engine Room logbook and the full results entered on the
appropriate forms and sent to the laboratory for evaluation. Test results indicating
contamination or loss of chemical reserve are to be investigated immediately.
Departures from normal operating conditions are to be recorded, and the relevant
Management Office immediately advised.
Storage and Handling of Boiler Chemicals
Attention is drawn to the spontaneous combustion properties of certain oxygen
scavenging materials such as hydrazine. Any material (e.g., cleaning material, rags,
cotton waste, sawdust etc.) contaminated with chemicals of this type, must be washed
or destroyed immediately, to avoid the risk of self-ignition.
Blowing Down Boilers
Boilers are to be blown down at least once per week dependent upon the
frequency required to control the level of dissolved solids contained in the boiler water.
Ideally blowdown should be carried out under light load conditions with at least one
tonne being blown down from each boiler, the actual quantity being recorded in the ER
log book and the boiler water report forms. Blowing down is to be carried out
irrespective of the salinity or chemical reserve readings. Use is also to be made of the
surface blow down valve to remove scum from the boiler.
Boiler Maintenance at Sea
Should it become necessary to shut a boiler down for repairs or routine
maintenance, and if this results in a reduction in speed or adversely affects operational
requirements, the appropriate Management Office must be informed. Details concerning
the reason for the shutdown and the likely delay should be advised. For main propulsion
boilers, wherever possible, routine maintenance should be carried out during ballast
rather than loaded passages.
Cleaning of Gas Side Surfaces
During cargo operations, in the interests of safety, and in particular to avoid the possible
emission of sparks, the use of soot blowers or other devices for cleaning the gas side
surfaces is prohibited.
Safety Precautions during Boiler Operation, Maintenance and Cleaning
During the operation, cleaning and maintenance of boilers safe working practices
are of paramount importance. Qualified personnel are to be familiar with correct
operational procedures and manufacturers recommendations.
Where these operations involve personnel entering the gas or water spaces, the
full safety precautions outlined in the Company Safety and Environmental Manual are to
be adhered to. In particular, respirators, protective clothing, and low voltage lamps are
to be used.
Spark and Smoke Emission
You should be aware that under various regulations applicable to the area your
vessel is in, it may be an offence to emit dark smoke. The Master should therefore
request appropriate detailed information from the local agent concerning the area
emission regulations and pass the information to the Chief Engineer. Careful
consideration should be given to the location and operational circumstance of the vessel
before soot blowing. Permission should be sought from the bridge before soot blowing.
Soot blowing or cleaning of turbochargers should not be carried out when gas
freeing cargo tanks, when bunkering or transferring fuel or when working cargo
alongside a terminal or during ship-to-ship transfer. In order to ensure that sparks are
not generated from the funnel flame arrestors and screens they must be regularly
checked and replaced when required. High back pressures can be generated if these
devices become blocked. Flame screens must not be painted.
Emissions of smoke, soot and exhaust gases such as COx, NOx and SOx
(Carbon, nitrogen and sulphur) is minimised by controlled running, systematic
maintenance and inspection routines of machinery, boilers and funnel. The emissions of
exhaust gases contribute to pollution and environmental problems such as acidification
and global warming. We aim to focus on control and reduction of the emission of these
harmful gases. Reference is made to MARPOL Annex VI and of the Company’s Safety
and Environmental Procedures.
Some of the ships are equipped with funnel filters to prevent large emissions
from occurring. Special care shall be exercised during port stays and when starting
main and auxiliary engines and lighting boilers.
General Precautions
A notice should be displayed at each boiler setting out operating instructions.
Information provided by the manufacturers of the oil-burning equipment should be
displayed in the boiler room. To avoid the danger of a blowback when lighting boilers,
the correct flashing up procedure should always be followed:
1) there should be no loose oil on the furnace floor;
2) the oil should be at the correct temperature for the grade of oil being used; if not,
the temperature of the oil must be regulated before lighting is attempted;
3) the furnace should be blown through with air to clear any oil vapour; (iv) the
torch, specially provided for the purpose, should always be used for lighting a
burner unless an adjacent burner in the same furnace is already lit; other means
of ignition, such as introducing loose burning material into the furnace, should not
be used. An explosion may result from attempts to relight a burner from the hot
brickwork of the furnace;
4) if all is in order, the operator should stand to one side, and the lighted torch
inserted and fuel turned on. Care should be taken that there is not too much oil
on the torch which could drip and possibly cause a fire;
5) if the oil does not light immediately, the fuel supply should be turned off and the
furnace ventilated by allowing air to blow through for two or three minutes to clear
any oil vapour before a second attempt to light is made. During this interval the
burner should be removed and the atomizer and tip inspected to verify that they
are in good order;
6) if there is a total flame failure while the burner is a light, the fuel supply should be
turned off.
The avenues of escape from the boiler fronts and firing spaces should be kept clear.
Where required to be fitted, the gauge glass cover should always be in place when the
glass is under pressure. If a gauge glass or cover needs to be replaced or repaired, the
gauge should be shut off and drained before the cover is removed.
