B Tech: Monthly test on boilers.

Out of all yellow marked questions (IMU) prepare to answer 10

questions.

What are the types of boiler by pressure?

1. Low pressure boiler – up to 10Kg / Cm2

2. Medium pressure boiler – 10-25 Kg /Cm2
3. High pressure boiler – Over 25 Kg / Cm2

What is water hammering and how will you prevent it?

 It is the impact of moving water in steam line when the steam is allowed to
enter a line with condensed water.
 The steam will condenses and partial vacuum occurred and move back the
water the along the pipe with very high velocity, and the water will strike at the
vent or valves.
To prevent the water hummer –

1. Install steam trap in the line

2. Open the drain first before allowing the steam into the line.
3. Crack open of steam valve at first.

How to make boiler water test on your ship?

The boiler test is carried out as follows.

1. Firstly take the boiler water sample from the salinometer cock or test cock and
cool down.
2. The test is carried out by the using maker’s supply test kit, chemicals,
instruments and instructions.
3.
How do you take boiler water sample?

 Slowly open the salinometer cock until clean hot water coming out.
 Then collect the boiler sample with copper jar.
Where is manhole doors fitted?

They are fitted at one at steam side and other one for water side.

Effect of foaming and priming?

1. Can cause water hummer
2. Can cause contamination and scaling.
3. Can cause fluctuation of working water level.
4.
What is boiler blow back?
 It occurs when lighting up with explosive gas and oil droplet (Oil residue)
inside the furnace without pre-purging sufficiently.
 The ignition results in a large flue gas inside the furnace and these gases blow
out with increase high pressure through the furnace opening.

Procedure for hydraulic pressure test on marine boilers?

Hydraulic pressure test is 1.25 times working pressure, (10 minutes maintain)
1. Close all openings.
2. Open air vent cock.
3. Fill up boiler water fully
4. Close the air vent cock
5. Place hydraulic jack to feed water line.
6. Fit standard pressure gauge.
7. Applied hydraulic pressure 1.25 times of working pressure and maintain
10minutes.

What is liquid coagulant in marine boilers?

 It has more molecular weight, colourless solution, containing sodium

aluminates, starch, terming, and resin.
 Once being dose into the boiler water floating solid particles and suspended
solid are settled to the bottom of the boiler and easily remove by blowing down.

How to renew the boiler gauge glass?

1. Shut steam and water cocks and open drain cock.

2. Check any leakage from the respective cock.
3. Slacken the gland nuts.
4. Open the cap and remove gauge glass.
5. Fit new gauge glass, correct size and length into its space.
6. Give the expansion allowance 1/8 in vertical clearance.
7. Use new packing.
8. Close the cap.
9. After fitting, warm the glass by steam.
10. Tighten the gland nut.
11. Then steam and water pressure should be tested whether they are fair and
clear.
12. Close the drain and open the water and steam side cocks.
13. Check the leakage; all are satisfactory put back into operation.

Routine boiler maintenance carried out on ships?

1. Clean the rotating cup.

2. Check and adjust the belt tension between motor and rotating shaft.
3. Clear the pilot burner nozzle and fitter.
4. Clean carbon deposit on electrodes (igniter) and adjust the gap.
5. Check the fuel valve and air register linkages and joints.
6. Check and clean the flame eye cover glass.
7. Check and clean inspection peep hole glass cover.
8. Clean fuel oil fitter.
9. Check the fuel oil pressure.

When boiler safety valve setting made?

 Every boiler survey.

 After safety valve overhaul.
Why ship side blow down valve is open first and close last?
 To prevent pressure build up in blow down line.
 In pipe burst, it may be injurious to watch keeper.
What if no test and treatments is done to boiler?

 Reduction in boiler efficiency due to poor heat transfer

 Reduction in tensile strength
 Reduction in factor of safety
 Overheating of metal resulting distortion and eventual failure
 Increase in fuel consumption
 Excess concentration of NaOH (caustic soda) may cause caustic
embrittlement on boiler metal and tend to failure of boiler metal
 Corrosion
 Scale formation
 Foaming, Priming, carry over (due to increase T.D.S level, foaming is present
and tend to carried over and priming)
How to control steam pressure in exhaust gas boilers?

1. By regulating the amount of gas flowing over the extended surface, i.e. by
damper regulation.
2. By dividing the unit into sections so that each section is controlled by an inlet
valve.
3. By passing steam through an automatic pressure controlled surplus valve to a
dump condenser.
4. By a system designed for a higher pressure than that it is to operate.

Boiler safety valve examination and attention during overhauling?

 Checked its valve and valve seat for wear, cavity corrosion and any fault.
 They should be grounded properly but maker’s limit must be maintained such
as width of seating, clearance between valve lip and seat.
 Valve chest must be cleaned condition and drain line clear.
 The spring should be hammer tested for any fracture and check for corrosion.
Free length is limited to 0.5 % of original free length.
 The spindle should be hammer tested for any crack and its straightness.
 The guide plates and bushes are checked for uneven wear and have sufficient
clearance to allow free movement of spindle.
 The compression nut and cover bush’s threads are carefully checked it for any
sign of wear and tear.
 The easing gear should be checked in good order including bearings, cable
pulley, and connecting links.
 Connecting pin should be a free fit in the lid and pin should not bent or
pinhole gone out of shape.
 All safety valves are to be set to operate under steam a little above working
pressure not greater than 3% above the approve working pressure of the boiler.
Why safety valve is fitted in two numbers?

 To make sure that the positive discharging of higher steam pressure from
boiler efficiency.

1. Explain the function of Compensating Ring in a boiler.

When a hole is cut or machined in pressure vessel, higher stresses will subject to the
material around the hole, and to reduce this compensation rings are fitted.

2. Explain the Functions of Screen tubes in a water tube boiler.

The purpose of screen tubes in a water tube boiler is to shield the super heater tubes
from excessive heating.

3. Discuss the need for control over superheat temperature in water

tube boilers.
Regulating the degree of super heat imparted to steam by super heater so as to meet
change condition of working which would alter the super heat temperature.
4. State the requirement of Soot blowers in water tube boiler.
5. Explain the function of Labyrinth Seal.
6. State the desired purpose and properties of refractory material in boilers.
The main purpose of refractory materials that is used in marine boiler is to contain the
heat generator by burning of the fuel in the furnace and to minimise the heat loss from
the furnace. Refractory materials are: Oxides of Alumina, Clay, quartz, silicon,
Gamister, Sand stone, Plumbago and plibrico.
7. What is the requirement of sliding feet?
Thermal expansion
8. State few important uses of steam onboard ship.
9. State advantages of water tube boiler over smoke tube boiler.
10. Explain the term Economizer.
11. Explain the function of easing gear.
12. How to check the correctness of flame inside the furnace of the boiler.
13. What is the material of refractory in the furnace? Mention the reason for the failure of
Refractory material.
14. Mention few safety alarms and trips of the Boiler automation.
15. What is the necessary of drain cocks in the steam system?
16. Procedure for blowing thru gauge glass.
17. Blow down of boiler.
18. With a neat sketch explain the working principle of an Improved High Lift Safety Valve.
19. Explain pressure accumulation test for a boiler safety valve setting.
20. Explain Pre purging and post purging requirements of a boiler furnace.
21. Necessity of fitting ogee ring.
22. Reason of feed water heating.
23. Effect of Very High Fuel temperature before the burner.
24. 5. Explain
a. Pre purging and post purging requirements of a boiler furnace.
b. Functions of cascade tank or hot well of the boiler feed system.
c. Requirement of Dump steam condenser.
Brgds
SDR