Boilers & Steam

A boiler is used to boil water to produce steam. In most boilers, the

heat to boil the water is supplied by burning fuel oil and/or using main
engine exhaust gas. There are two types of steam used on vessels.
They are:

 Saturated Steam
When water is boiled, it gives saturated steam, (in this case, the steam
is in contact with water). This is of low to medium pressure (5 - 50
bar), and is usually used for heating purposes.

 Superheated Steam
The saturated steam is further heated to give superheated steam. This
type of steam is of high pressure (50 - 300 bar), and is used for driving
turbines on vessels with steam propulsion plants.

Boiler Construction
 Fire Tube
The hot gasses from the burning fuel pass through the tubes, while the
water surrounds the tubes. They are usually low to medium pressure
boilers, producing saturated steam. They are used as auxiliary boilers
on vessels for heating purposes.

 Water Tube
The water flows through the tubes, while the hot gasses pass around
the outsides. Although these boilers are mainly used for high pressure
steam to drive steam turbines, they are also used on medium pressure
systems.

Low Pressure Boilers

There are numerous designs of low pressure boilers and virtually all can
be classified as being of the Fire-Tube type. This means that the
furnace is contained within the pressure shell of the boiler and the hot
gases from the furnace leave through tubes which are surrounded by
the boiler.

MEC3 Boiler & Steam system Page 1 of 25

(courtesy: Reed‟s General Engineering Knowledge - L Jackson & T Morton)

The consequences of this type of construction are:

 The pressure vessel is large and heavy in relation to the steam

generating capacity of the boiler.

 Circulation in the boiler is primarily due only to differences in water

density, creating convection currents.

 The boiler tends to be mechanically very rigid and thus must be

warmed through slowly during steam raising operations.

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 The boiler has a relatively large steam storage capacity and thus
relatively simple fuel burning systems can be employed, (ie. the
pressure does not change rapidly during load changes).

 The water surface area in the boiler is relatively large and thus very
simple feed water control systems can be used.

 Since the furnace is exposed to the highest temperatures, it is the

part most likely to fail. The furnace is part of the pressure shell of the
boiler and is large in size, any failure (collapse due to overheating) can
be catastrophic.

Medium Pressure Boilers

Water Tube boilers are characterised by having unheated steam and
water drums connected by small bore pipes. The pipes are arranged in
banks and bent to form the combustion space (furnace). All of the
steam is generated inside the tubes and because the water/steam
mixture has a low density, circulation is rapid and positive.

Because of the rapid circulation within the steam generating tubes, high
rates of heat transfer can be achieved without overheating the tubes.
Thus, water tube boilers have high rates of steam generation relative to
their size and weight.

Most water tube boilers suitable for medium pressures will have one
water drum, one steam drum, and one or more small headers to which
the ends of some of the tubes are attached.

Below is a typical water tube boilers that could produce pressures up to

about 18 bar and suitable for auxiliary duties on vessels. Note that
these boilers are designed to produce only saturated steam, although
similar designs might include superheaters.

MEC3 Boiler & Steam system Page 3 of 25

Simple Water Tube Boiler

Pictorial View of a Water Tube Boiler

MEC3 Boiler & Steam Systems Page 4 of 24

The consequences of this type of construction are:
 The pressure vessels (steam and water drums), are small in diameter
in relation to the steam generating capacity of the boiler and are
unheated.
 Circulation in the boiler is primarily due to the differences in density
between tubes containing only water and those tubes containing a
steam/water mixture. The differences are large and therefore
circulation is rapid.
 The boiler tends to be mechanically very flexible, as the tubes can
expand freely, and thus steam can be raised more quickly than in a
typical fire tube boiler.
 The boiler has a relatively small steam storage capacity and thus
more complex fuel burning systems must be employed,.
 The water surface area in the boiler is small and thus more complex
feed water control systems must be used, (ie. the water level changes
rapidly when changes to the load or to feed water supply occur).
 Since only the small bore steam generating tubes are exposed to the
furnace gases, failure due to overheating will result in tube rupture.
The tubes are of relatively small diameter, thus failure is not likely to
endanger life.
 Since the construction of the furnaces tends to be large and relatively
weak, a furnace explosion can be catastrophic.

Boiler Fittings
Safety Valves

Function: To prevent the pressure in the boiler exceeding the design

pressure.

There are many different types of safety valve varying from the very
simple as used on small auxiliary boilers to the very complex as used on
high performance water-tube boilers.

Safety valves are fitted in pairs to minimise the danger of a valve failing
to lift when required. Easing gear is provided to enable the valves to be
manually operated to ease the pressure and check the valve operation.
The discharges from the valves are led into a pipe that is diverted out of
the engineroom.
These valves are set and approved by a surveyor. Thus, the setting
mechanism is locked to prevent tampering.

MEC3 Boiler & Steam system Page 5 of 25

(courtesy: Reed‟s General Engineering Knowledge - L Jackson & T Morton)
Boiler Fittings

Virtually all marine safety valves are of the spring loaded type and thus
suffer from Accumulation of Pressure. This “accumulation” occurs
because as the valve opens to allow the escape of surplus steam, the
spring becomes further compressed and thus requires an increasing
pressure to continue opening the valve until it is fully open.

The boiler safety valves must have sufficient capacity (rate of steam
discharge) such that all of the steam that is produced by the boiler at
maximum firing rate can be discharged.

Water Level Gauges [Gauge Glasses]

Function: To indicate the water level in the boiler.

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All boilers must be fitted with at least two independent means of
indicating the water level.

Gauge Glass

In its simplest form the water level gauge consists of a glass tube
mounted between valves or cocks. It is connected to the pressure shell
of the boiler, such that when the water level in the boiler is correct, the
level in the glass tube is at about 2/3 height.

It is necessary for the gauge to be “blown down” regularly to ensure it

is not blocked.

Low Water Level Shut Down and Alarm

Function: To shut down the oil fuel burners in the event of a low water
level in the boiler.

All boilers are fitted with low water level alarms and "trips" to shut the
boiler down in the event of a dangerously low water level. It usually
consists of a float that activates magnetic switches. Fire-tube boilers
may have only one such device, but water-tube boilers will have two.

Extra Low Water Level Shut Down and Alarm

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Function: To shut down the oil fuel burners and put the boiler in
lockout mode in the event of a dangerously low water level if the low
level has not activated.

Steam Stop Valve(S)

Function: To provide a connection so that steam can be drawn from the

boiler and to enable the boiler to be isolated by closing the valve(s).

The valves are mounted directly on the boiler shell in the steam space.
Usually some form of internal perforated pipe or other device acts as a
“steam strainer” to minimise the number of water droplets carried over
with the steam.

Feed Water Valves [Feed Check Valves]

Function: To allow feed water to be admitted to the boiler.

The feed water valves are directly mounted on to the shell of the boiler
and fitted with a perforated internal pipe to distribute the relatively cold
feed water throughout the boiler. The valves usually consist of two
valves, a screw down non-return valve and a screw lift valve. The non-
return valve is required to prevent the boiler contents from discharging
through any damage to the feed water pipe.

(courtesy: Reed‟s General Engineering Knowledge - L Jackson & T Morton)

Blowdown Valve

Function: To allow the sludge which collects in the bottom of the boiler
(resulting from chemical treatment) to be periodically discharged, to
lower the water level, and to allow the boiler to be completely emptied
for maintenance.

MEC3 Boiler & Steam Systems Page 8 of 24

This usually consists of two valves in series. When blowing down the
boiler, the shipside valve is first opened, and the boiler valve is used to
control the flow. This will ensure that the blowdown line is not
pressurised and causes possible rupture if damaged. It also enables the
operator to shut the steam flow in case of a leakage. The shipside
valve is led to below the waterline of the vessel, so that the hot water
does not scald anyone who may be tied up alongside the vessel.

Scum Valve [Surface Blowdown Valve]

Function: To allow the surface water in the boiler to be discharged

through the blowdown line, thus removing any "scum" from the surface.

The scum valve is attached directly to the pressure shell of the boiler
and is fitted with an internal pipe terminating in a flat dish shaped tray.
This tray is arranged just below the normal working water level, thus
collecting any froth or scum floating on the water surface.

The pipework from to the scum valve is usually connected to the

blowdown line.
The scum valve may be used periodically if surface scum is suspected.
It is always used prior to emptying a boiler to avoid any scum being
deposited on the internal surfaces of the boiler.

Salinometer Cock/Valve [Sampling Connection]

Function: To enable samples of boiler water to be taken for chemical

testing.

When taking samples, the water will require to be cooled to prevent

“flash off” into steam.

Air Vent Cock [or Valve]

Function: To allow air to be removed from the boiler during the early
stages of steam raising and to prevent a vacuum being created within
the boiler when shutting it down.

A small cock or valve fitted to the shell of the boiler at the highest part
of the steam space. It allows air in the boiler to be removed while
steam is being raised, and is closed a few minutes after steam has
started to issue from the vent. Air in an operating boiler can cause
pitting and thus its removal is important.

MEC3 Boiler & Steam system Page 9 of 25

They also need to be opened when shutting down the boiler to allow air
into the steam space during cooling. This will avoid a vacuum from
developing inside the boiler as it cools.

Pressure Gauge Connection

Function: To enable a pressure gauge to be fitted to the boiler.

This consists of a small cock or valve fitted to the shell of the boiler
somewhere near the upper part of the steam space.

Manholes

Function: To allow internal inspection of the boiler and to permit

internal fittings to be inserted or removed.

All manhole doors are oval in shape, enabling them to be inserted and
removed through the hole. They are fitted on the inside of the shell so
that the pressure in the boiler will force the door against the joint and
thus provide a good seal. These doors will be heavy. Therefore, when
opening a boiler manhole:
 ensure there is no steam inside the boiler; and
 secure the weight of the manhole door by a block and tackle.

Burners

Usually low to medium pressure boilers are fitted with one burner.
The burner consists of a nozzle, which supplies fuel as a finely divided
spray into the furnace.
 Air is also supplied by a blower to the furnace.
 The fuel and air is mixed in the furnace.
 Ignition of the fuel/air mixture is achieved by the use of an electrical
igniter

Soot Blowers

Operated by steam or compressed air, they act to blow away any soot
that deposit on the tube surfaces. The collection of soot can cause fires
in the exhaust uptake. The type, size and number of soot blowers will
depend on the size and type of boiler.

MEC3 Boiler & Steam Systems Page 10 of 24

Waste Steam Generation
Diesel engine vessels are fitted with waste heat boilers, in order to
reduce the fuel burnt in the boiler. The hot exhaust gasses from the
main diesel engine is used to heat the water in the boiler to produce
steam. This exhaust gas heating can be achieved through two
configurations.

MEC3 Boiler & Steam system Page 11 of 25

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(a) Waste Heat Composite Boiler

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P um p
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(b) Waste Heat Economiser

Composite Boiler
The exhaust gas from the diesel engine passes directly through the
boiler, thus heating the water to produce steam. When the engine is
not running or is at low loads, a burner is used to produce steam.

Economiser
This is a heat exchanger located in the diesel exhaust line. Water from
the boiler is pumped to the economiser, where it is heated by the

MEC3 Boiler & Steam Systems Page 12 of 24

exhaust gas. The steam thus produced, is returned back to the boiler.
Again a burner is used to produce steam, when the engine is not
running.

Basic Steam System

Since the system is open to the atmosphere at the hot well, it is
referred to as an open system.

The steam is fed from the boiler to the services such as the heating of
various fluids (eg. heavy oil, fresh water etc). Each of these services
has valves fitted to the inlet and outlet to isolate the system if
necessary.

MEC3 Boiler & Steam system Page 13 of 25

Steam Trap

A steam trap fitted to the return line from each service. This is an
automatic valve, that allows only water to pass and prevents steam
from passing. This ensures that the steam is completely used before
leaving the service.

Condenser
The condenser is a heat exchanger, which is used to cool the returning
steam/water (called condensate) from the services. This usually
consists of a shell and tube type heat exchanger. The steam or
condensate passes around the tubes of the condenser, whilst sea water
is pumped through the tubes.

Hot Well
The water from the condenser is drained into a tank called the hot well
(or observation tank). Any oil that may have leaked into the steam
system through the heating coils in oil tanks, will float on the surface in
the observation tank. This oil will be visible floating on the water.

Feed Pumps

MEC3 Boiler & Steam Systems Page 14 of 24

There are two pumps and two feed lines from the hot well to the boiler.
The second system is a backup in the event of the main feed line
breaking down.

Steam Distribution System

Steam services on a diesel vessel include:

Tank Heating
Various tanks including fuel oil and lubricating oil tanks will require
heating. The fuel oil tanks will be continually heated to maintain a low
viscosity, thus enable the oil to be pumped easily. Lubricating oil tanks
may only require heating during warming through of the main engine.

Evaporators
Evaporating/distilling plant provides the fresh water supplies for the
vessel.

Steam Smothering
Steam smothering was used as a common fixed fire fighting installation.

Purifiers
Steam heating is commonly used to heat the fuel and lubricating oil prior to centrifuging. Heating
the oil creates increases the difference in density between the water and oil, as well as assisting in
the separation of solid particles.

Testing and Treatment

Reasons for Boiler Water Treatment
Due to the high temperatures encountered and the salts in the boiler
water, the following effects may occur in a boiler.

Scales
This is the depositing of salts that are dissolved in the water on the
heating surfaces. This will result in the reduction in heat transfer,
overheating of the surfaces, and a loss of efficiency.

Corrosion
Due to salts, electrolysis, and acidity of the water, corrosion may occur
on the surfaces of the boiler. This can cause failure of boiler
components, collection of corrosion products in the boiler, and scales.

The presence of oxygen in the water can lead to localised “oxygen cell
pitting”, that can result in tube failure. Oxygen can also cause corrosion

MEC3 Boiler & Steam system Page 15 of 25

in the feed line that can reduce strength in the system and carry over
iron and copper oxides to accumulate in the boiler.

Priming (Carry Over)

This is the carry-over of water with the steam that will result in salts
and solids being carried over to the steam distribution system, causing
corrosion, scaling, erosion, and damage. Carry over can occur due to a
high concentration of salts, solids, impurities, and corrosion products in
the boiler water. However, they may also occur due to mechanical
reasons such as high water level and sudden increase in steam demand.

Foaming is due to small stable bubbles on the water surface, which will
promote priming. Foaming occurs due to an increase in dissolved
salts/solids and the mixing of oil/organic matter with the water.

Hardness Salts
The term „hardness‟ is used to denote salts that can be precipitated
from the water when heated. These salts may form scales on the
heating surfaces. The various salts that occur in water can be grouped
as follows:

Temporary Hardness Salts

 Calcium Bicarbonate [Ca(HCO3)2]

 Magnesium Bicarbonate [Mg(HCO3)2]

These salts tend to decompose on boiling (at relatively low

temperatures). In isolation, they tend to deposit as sludge of Chalk and
Magnesium Hydroxide. However, in the presence of other salts they
may form a soft scale.

Permanent Hardness Salts

 Calcium Sulphate [CaSO4]

 Calcium Chloride [CaCl2]
 Magnesium Sulphate [MgSO4]
 Magnesium Chloride [MgCl2]
 Magnesium Nitrate [Mg(NO3)2]
 Calcium Nitrate [Ca(NO3)2]

These salts tend to retain their solubility to somewhat higher

temperatures than the temporary hardness salts.

MEC3 Boiler & Steam Systems Page 16 of 24

Calcium Sulphate is the first to come out of solution and can form a
hard, dense, and adherent scale. Magnesium Chloride tends to
decompose at certain temperatures to form Hydrochloric Acid (HCl)
which is corrosive, and Magnesium Hydroxide [Mg(OH)2] that can
deposit as scales. There are both neutralised by adding chemicals.

Non-Hardness Salts

 Sodium Bicarbonate [NaHCO3]

 Sodium Chloride [NaCl], (ie. common salt)
 Sodium Sulphate [NaSO4]
 Sodium Nitrate [NaNO3]

These salts remain very soluble in water and thus do not normally
produce scale. They are, however, „electrolytes‟, thus promoting
electrolytic corrosion. In addition, they will raise the density of the
boiler water, thus promoting „priming‟ (ie. carry-over of water with the
steam).

Objectives of Treatment
The objectives of boiler water treatment include:

 To prevent scale, by modifying or precipitating the scale forming salts

in the form of a non-adherent sludge. The sludge can then be removed
by periodically „blowing down‟ the boiler.
 To minimise acidic corrosion by maintaining a suitable level of
alkalinity in the boiler.
 To prevent „oxygen cell‟ pitting by minimising free oxygen in the
boiler water.
 To minimise the possibility of priming by maintaining a suitable
density of the water in the boiler.

Boiler Water Treatment

Scale Prevention
For high pressure boilers a „Phosphate‟ based treatment is invariably
adopted. For medium pressure boilers it is also common to use a
phosphate treatment, the most widely used being Disodium Phosphate
[Na 2 HPO 4 ]. This has the effect of converting the Calcium and
Magnesium salts to a non-scale forming phosphate precipitate. Adding
Disodium Phosphate does not increase the alkalinity of the boiler water;
this is usually considered an advantage, particularly in higher pressure
boilers, as it allows more precise control over the alkalinity.

MEC3 Boiler & Steam system Page 17 of 25

Trisodium Phosphate [Na 3 PO 4 ], is sometimes used in lower pressure
boilers where precise control over alkalinity is less important. This has
the side effect of increasing the alkalinity.

For low pressure boilers, particularly when „raw water‟ (fresh water
obtained from town mains or other fresh water sources) is used, it may
be impractical to use a phosphate based treatment due to the amounts
of chemicals required. Thus, one of the proprietary organic compounds
based on polymers, tannins, may be used. These compounds tend to
prevent scale formation by interfering with the way the precipitated salt
crystals lock together rather than by modifying the calcium and
magnesium salts themselves.

Sludge Conditioners
All proprietary phosphates supplied for boiler water treatment also
include ingredients, which cause the precipitated salts to collect in the
form of a soft non-adherent sludge. This tends to collect in the lower
part of the boiler and can be easily removed by blowing-down the
boiler.

Anti-Foam Agents
Most propriety chemicals supplied for boiler water treatment also
include agents which can have a large effect on minimising the
tendency for „priming‟ or carry-over of boiler water with the steam.
These chemicals can be very useful if operating problems are making
the task of maintaining a suitable water density difficult. They are also
widely used in the chemical treatment of evaporators, as they can have
a significant effect on the quality of the water produced.

Alkalinity
The two chemicals used to create alkalinity in the boiler water are
Sodium Hydroxide [NaOH] and Sodium Carbonate [Na 2 CO 3 ].

Sodium Hydroxide: is a strong alkali which should be stored in a cool

dry place in tightly sealed containers.
Sodium Hydroxide also has the effect of harmlessly precipitating some
of the scale forming salts.

Sodium Carbonate: is normally supplied in the anhydrous (dry) form

as a white powder. This is easy to handle and store but should be
stored in a dry place, as it tends to absorb moisture and convert to its
hydrated form (ordinary washing soda) having a crystalline appearance.

Under the influence of heat in the boiler, the Sodium Carbonate tends to
break down and form Sodium Hydroxide and Carbon Dioxide. Thus, it

MEC3 Boiler & Steam Systems Page 18 of 24

has a similar effect to Sodium Hydroxide but the carbon dioxide forms
carbonic acid, which can be corrosive.

Oxygen Cell Pitting

Oxygen in the boiler water tends to form local corrosion in the form of
„pits‟. In high pressure boilers every effort is made to minimise oxygen
(air) in the feed water by employing deaerators in the feed system and
the small amounts of remaining oxygen are then dealt with by adding
chemicals to the boiler water.

In low pressure boilers with “open” feed systems, (ie. the condensate is
exposed to the atmosphere in the hot well), it is not practicable to
employ chemical treatment in the boiler. Since the amount of oxygen
dissolved in water is reduced as the temperature of the water rises, the
temperature of the hot-well should be maintained at as high as
possible. This will be limited, as too high a temperature will cause
cavitation in the feed pump.

Boiler Water Density

As the density of the boiler water increases (due to dissolved salts)
there is an increased tendency for the boiler to prime. Priming causes
deposits in steam lines, heaters, etc. and can damage steam driven
equipment.

The tendency for a boiler to prime depends largely on the rate of steam
production and the water surface area in the steam space. Thus, the
maximum allowable density in a boiler depends on the type of boiler as
well as its operating pressure.

For low pressure boilers which can tolerate a significant density, a

hydrometer can be used to measure the density. However, for higher
pressure boilers where the density must be kept very low, some sort of
conductivity meter calibrated in Parts per Million (ppm) must be used.
For all boilers it is customary to quote the recommended maximum
density for that boiler in parts per million.

Instead of using the term “Density” it is common practice to refer to the

“Total Dissolved Solids” (TDS) of the boiler water, particularly when
expressed in ppm.

Boiler Water Tests

The boiler water is periodically tested to ensure that the dissolved salts
are within specified levels, corrosion control is maintained, and the
chemical treatment is adequate.

MEC3 Boiler & Steam system Page 19 of 25

Chemical suppliers provide test kits that enable shipboard staff to carry
out simple test to ascertain the condition of the boiler water. The
sample taken from the boiler is cooled, filtered, and then subjected to a
number of tests. These usually consist of the addition of indicators that
change colour depending on the condition of the water.

For low pressure boilers only the following tests are normally carried
out.
 alkalinity;
 chloride;
 hardness; and
 density TDS.

When taking samples, the following should be observed:

 take care to avoid contact with steam;

 flush the line before taking a sample;
 rinse the container with the boiler water;
 use condenser coils if provided; and
 do not delay testing after taking sample.

Recommended Values for Boiler Water

The recommended values to be maintained for a given boiler depend

upon its construction, rate of steam production and operating pressure.
Typical values for a Vertical Boiler operating at up to 17·5 bar (1.75
Mpa) are:

alkalinity (phenolphthalien) 300 - 500 ppm

chlorides (maximum) 1,200 ppm
hardness (maximum) 5 ppm
density (maximum) 2,750 ppm [or 4,500 µS at 25
0
C]

MEC3 Boiler & Steam Systems Page 20 of 24

Hazards and Safety Devices
Furnace Explosions and Purging
Furnace Explosions

Furnace explosions are the result of the ignition of accumulated

combustible vapours in the confined spaces of the furnace or boiler
uptakes. The explosions may range from a small "puff" or "blow-back"
to a violent explosion which can wreck the boiler and lead to loss of life,
(larger the furnace the more damaging any explosion is likely to be).

The events which can lead to a furnace explosion include:

 Temporary loss of flame, which allows unburnt fuel to enter the

furnace (in the period before fuel is automatically shut off by the flame
monitoring system). The unburnt fuel may form an explosive mixture
which can be ignited by hot brickwork etc..
 Fuel leaking into an idle furnace via leaky valves. This may form an
explosive mixture which can be ignited by sparks or by a burner being
lit etc.
 Attempting to light-off burners from hot brickwork or adjacent
burners. A proper lighting-up torch or igniter should be used for every
burner lit.
 Faulty igniter, which may not produce sufficient energy to light-up
the burner as quickly as it should. This will allow unburnt fuel to
accumulate and may lead to an explosion.
 Repeated unsuccessful attempts to establish a flame in the furnace
without adequate purging between each attempt.

Purging
Purging consists of blowing air through the furnace and uptakes for a
sufficient length of time to ensure that no pockets of flammable vapours
exist. The actual period of purging will depend on the furnace size and
design. For large boilers the purge period is approximately three
minutes.

Post-Purge Period
Immediately after purging the furnace can be assumed to be free of
flammable vapours and it is safe to make an attempt to ignite a burner.
However, if ignition is delayed, there is always the possibility of
flammable vapours accumulating, and thus a danger of an explosion
occurring when ignition is attempted.

MEC3 Boiler & Steam system Page 21 of 25

The “Post-Purge” period is defined as that period after purging, during
which an attempt to light up a burner can safely be made. It is not
easy to quantify this period as the condition of the boiler and its
equipment must be considered. However, it should never be more than
a few minutes and is often set at one minute.

After the elapse of the post purge period, the boiler must again be
purged prior to attempting to light the first burner in the furnace of the
boiler.

Lighting up on Diesel Fuel

Particular care should be taken when raising steam in a cold boiler using
diesel fuel. Since a small flame is used, it is easy for droplets of fuel to
cool before combustion is complete, (particularly if large amount of
excess air is supplied). These droplets of unburnt fuel may accumulate
as vapour in the uptakes of the boiler and cause an explosion, even if
flame failure does not occur.

The procedure of manually starting a burner includes:

1. Circulate fuel in the lines and heat up if required, (do not allow fuel
to enter the furnace).
2. Purge the furnace by blowing through air for a specified period.
3. Start the igniter.
4. Open the fuel to the burner.
5. Ensure flame has commenced.
6. Stop igniter.

Most burners will have a photocell that will sense the flame. If flame failure occurs, an alarm will
sound and the fuel will be shut off.

Boiler Water Level

Maintaining the correct water level in a boiler at all times is vital for the
safety of a boiler. In most boilers the lowest safe level occurs when the
water level is just visible in the bottom of the gauge glass. Thus, if the
water level is not visible in the gauge a dangerous condition has arisen
and the boiler must be immediately shut down. If the boiler
continues to operate with a low water level, the heating surfaces will
overheat, resulting in their failure.

Therefore, maintaining the water level gauges in an efficient working

order and testing them at regular intervals is thus an important part of
a boiler operators function. In low pressure boilers the water level

MEC3 Boiler & Steam Systems Page 22 of 24

gauges should be tested at least every watch. Any difference in the
levels between the two gauges should be immediately investigated.

The procedure to “blow down” a gauge glass is:

1. shut steam cock, shut water cock, and open drain
2. open steam cock and check clear then shut
3. open water cock and allow water to fill glass then shut
4. shut drain cock open water cock then steam cock

Operation and Maintenance

Raising Steam
Before attempting to light up a burner in the boiler, every effort should
be made to confirm that the water level indicated by the gauge glass is
correct, (Note: it is not possible to blow through the gauge glasses until
steam is available). As soon as sufficient steam pressure is available
the gauge glasses should be blown through.

For low pressure boilers of the Fire-Tube type, it is customary to raise

steam slowly using intermittent firing of the burner, say 10-15 minutes
firing with a small burner tip and then 10-15 minutes off. This allows
the heat to conduct through the boiler. Depending on the type and size
of boiler, the time taken to raise a full head of steam will vary. The first
few hours are usually the most critical and is the time when excessive
stresses can be created due to unequal expansion of the boiler.

For Water-Tube boilers, particularly those with a great deal of furnace

brickwork, it is not advisable to use intermittent firing. Thus, the
smallest burner tip should be used and with a minimum fuel pressure to
give a stable flame. The boiler should be constantly fired until steam is
raised, which usually takes 3 - 4 hours.

For all boilers, the air-cock on top of the boiler should be left open until
there is a good blow of steam to ensure all of the air has been expelled.

When the steam pressure has reached about half of the normal working
pressure, the handhole and manhole securing arrangements should be
slightly tightened. Do not over tighten, as the threads can be over-
stressed the next time the boiler is shut down.

When steam has been raised all of the alarms and other safety devices
should be tested.

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Combustion
Although the amount of excess air necessary to achieve complete
combustion in the boiler furnace varies depending on the design of the
equipment, there will always be some excess air required. Since the
excess air simply passes through the boiler and carries away heat to the
atmosphere, it results in a loss of the efficiency. However, it is
important to optimise the amount of excess air since too little excess air
may lead to incomplete combustion or very long flames, which may
cause local overheating at the point of flame impingement.

Shutting Down
When shutting down boilers, the following should be followed:

1. Shut steam stop valve(s).

2. Shut down feed pump.
3. Stop burner, shut fuel, and purge furnace.
4. Allow boiler to cool down, opening air vents before reaching
atmospheric pressure, (to prevent vacuum being created when cooling).
5. Blow down boiler, stopping before pressure is too low, (to prevent
vacuum being created when cooling).
6. Allow boiler to completely cool down.

Survey Requirements
Depending on the type and the age of the boiler, it may require to be
surveyed every year or every two years. The surveyor will require
access to all parts of the boiler and its mountings, and thus the boiler
has to be shut down, drained and opened up. The procedure in
preparing a boiler for survey includes the following.

 Make sure that boiler is completely isolated. If there is more than

one boiler and the other boilers are under steam, it will require great
care to ensure there is no possibility of steam entering the idle boiler
from stop valves, blow-down valves, etc. Ensure that the feed pump
cannot start. Deal similarly with the force draft fan and fuel pump.
 Post warning notices on pumps, fans, etc. and on the boiler itself.
 Remove manhole and handhole doors and arrange for surveyors
inspection.
 Ventilate the boiler shell to ensure that its atmosphere is safe.
 Open up, ventilate, and clean access arrangements to combustion
spaces to facilitate inspection.
 Dismantle boiler mountings (safety valves, stop valves, etc.) for
inspection.

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 The surveyor will want to examine the external parts of the boiler
close to the manholes, attachment points of boiler mountings, holding
down arrangements, and any parts of the shell where wastage may
have occurred due to leakage. This may require some lagging to be
removed.

In general, remember that the surveyor is expected to examine all of

the important parts of the boiler. Therefore, it is your job to ensure
that all parts are accessible, cleaned, and neatly presented so that no
time is wasted. Most importantly these tasks should be carried out in a
safe manner

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