AUXILIARY BOILERS

OPERATION AND MAINTENANCE

Functions of Auxiliary Boiler

Steam Supply System and System Devices
Operation and Maintenance of Auxiliary Boiler
Nejat ÖZTEZCAN
2018
 Marine Steam Boilers

Historical development of the marine boiler :

• the first practical steam engine Symington, 1803

(a small paddle-wheeled vessel)

• the first passenger steamship Clermont, 1807

• Merchant Ship Great Easter 1858

(213 m in length and 24.5 m in breadth)
Definition of Boiler

Steam boiler or a boiler is basically a closed vessel

into which water is heated until the water is
converted into steam at required pressure.

This is most basic definition of boiler.

There are many different types of boiler utilized for

different purposes like running a production unit,
sanitizing some area, sterilizing equipment, to
warm up the surroundings etc.
The boiling point of water will be raised with an increase in pressure.
Basic diagram of a boiler
 LATENT HEAT: Latent heat is the heat which supplies the energy
necessary to overcome some of the binding forces of attraction
between the molecules of a substance and is responsible for it
changing its physical state from a solid into liquid or from liquid
into a vapor, the change taking place without any change in temp.

SENSIBLE HEAT :Sensible heat is the name given to heat when its
transferred to or from a substance with changes in temp only, and
no physical change of state.
Normally, the steam for an engine takes in sensible heat between
the feed temperature and saturation temperature, latent heat at
saturation temperature, and sensible heat between the saturation
temperature and final steam temperature.
HEAT TRANSFER METHODS

There are three ways that heat is transferred,

• conduction,
• radiation,
• convection

and all three means occur in a boiler.

CONDUCTION: Conduction is the flow of heat energy through a
body or from one body to another in contact with each other, due
to difference in temp.

The natural flow of heat takes place from high temp to a lower
temperature.

Example: in boilers heat is conducted through the heating surface

to the water.
RADIATION: Radiation is the transfer of heat energy from one
body to another through space by rays of electro-magnetic waves.

The rays of heat travel in straight lines in all directions at approx.

the same velocity as light.

Example: in a boiler the heat from the burning fuel passes off in
rays in all directions striking the furnace walls, tubes, and other
heating surfaces raising their temps.
CONVENTION: Convention is the method of transferring heat
through a fluid by the movement of heated particles of the fluid.

Example: In the water tube boiler the tubes are arranged to assist
the convection current and the boiler designed to take full
advantage of the law of heat transmission.
 Classification of Boilers

Boilers can be classified as follows:

1. According to geometric orientation of boiler:

2. According to location of furnace:
3. According to method of water circulation:
4. According to working pressure:
5. According to number of tubes in the boiler:
6. According to relative position of water and hot gases:
Types of Boilers

Boilers are generally divided into two types: ''firetube'' and ''water-
tube''.

Fire-tube Boilers

In fire-tube boilers, combustion gases pass through the inside of the

tubes with water surrounding the outside of the tubes.

The advantages of a fire-tube boiler are its simple construction and

less rigid water treatment requirements.

The disadvantages are the excessive weight-per-pound of steam

generated, excessive time required to raise steam pressure because of
the relatively large volume of water, and inability to respond quickly to
load changes, again, due to the large water volume.
Fire-tube boilers are:

• Relatively inexpensive
• Easy to clean
• Compact in size
• Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
• Easy to replace tubes
• Well suited for space heating and industrial process applications
• Minimal refractory

Disadvantages of fire-tube boilers include:

•Not suitable for high pressure applications 250 psig ( 18 Bar) and
above.
•Limitation for high capacity steam generation.
scotch marine firetube boiler
Water-tube Boilers

In a water-tube boiler, the water is inside the tubes and

combustion gases pass around the outside of the tubes.

The advantages of a water-tube boiler are a lower unit weight-per-

pound of steam generated, less time required to raise steam
pressure, a greater flexibility for responding to load changes, and
a greater ability to operate at high rates of steam generation.

• Saving in weight.
• The possibility of using high pressures and temperatures.
• Greater mechanical flexibility.
• Rapid steam raising.
• Saving in space.
• Wider safety margin in event of explosion.

A water-tube design is the exact opposite of a fire-tube.

Various Uses Of Steam On Ships

•For Main Engine Propulsion/Turbines (in case of steam ships)

•For Power Generation (to run steam turbo generators)
•For Running Auxiliary Machinery (in case of steam ships)
•For Soot Blowing and for the steam atomized burners.
•For Fresh water generation (Evaporators)
•For Fire Fighting (Steam drenching)
•For heating duties (Main Engine Fuel Oil Heater, Galley Supply,
Purifier, Calorifier , Galley, Accommodation heating, Sea
chests tracer lines for pipeline heating)
•For cargo heating
•For fuel tank heating
•For deck machinery
•For running Cargo pump turbines
•For tank washing in tanker ships and general cleaning
Advantages of Steam

Steam are clean, pure and naturally safe.

Steam is water, which is plenty of available and cheap.
Due to the high heat content of steam, relatively small bore, pipe
work is required to distribute the steam at high pressure. The
pressure is then reduced at the point of use, if necessary.
Steam provides excellent heat transfer.
Relationship between the pressure and temperature of saturated
steam, easiest way to control the amount of energy input to the
process simply by controlling the saturated steam pressure.
Because of very high heat transfer properties of steam, the
required heat transfer area is relatively small.
Not only is steam an excellent carrier of heat, it is also sterile, and
thus popular for process use in the food, pharmaceutical and health
industries.
Boiler types : According to usage

• Hot water boiler

• Thermal oil boiler

• Steam boiler

• Steam generator

• Exhaust gas boiler

Hot water boiler: Hot water boilers are normally used in room
and building heating. These kinds of systems are suitable for
discharge temperatures of up to 140°C. The advantage of hot
water over steam is that the energy loss is much lower than with
steam boilers.

Thermal oil boiler : In hot oil boilers, oil is used instead of

steam or water. The advantage of oil is that the system does not
have to be pressurised above 100°C as with water and steam.
Thermal oil is still liquid in atmospheric pressures of up to 300°C.
In contrast, water requires a pressure of 85 bar to avoid
evaporating at that temperature.

If the unique features of steam are not required, thermal oil can
be a good alternative.
Steam generator:

In the steam generator, the feed water and steam are in principle
passing through one long tube - designed as winded-up tube coils
serially connected.

The advantages using a steam generator compared to conventional

steam boilers:

• Easy to operate - normally no requirement for boiler authorisation

• Rapid start-up and establishing full steam pressure
• Compact and easy to adapt in the existing machinery arrangement
• Price attractive - especially at low steam rates.
Exhaust gas boiler: Steam can be produced not only by oil or gas-
fired burners, but also by utilising the substantial amount of waste
heat in hot flue gasses or exhaust air. Waste heat boilers use heat
that would otherwise be wasted by exhausting into the
atmosphere to heat water and make steam.

Standart Engine Fuel Consumption % 100 (167

gr/kW)
Exhaust gas
25%

Heat radiation Shaft power

1% Output
Air cooler 49%
17%

Jacket water Lubricating

cooler oil cooler
5% 3%
With more expensive bunker oil prices and much tougher
environmental requirements, it is of major importance for shipping
companies to reduce their consumption of fuel oil today than it ever
has been before.

One of the ways to reduce emissions is to utilize the energy in the

exhaust gas with waste heat boilers.

Typically, an Exhaust Gas Economizer is able to generate approximately

500 kg/h steam from the exhaust gas of a single 1000 kW auxiliary
engine.

Recovery of waste heat from the exhaust gases has a direct effect on
the efficiency of the process.
New environmental regulations

In 1973, IMO adopted the International Convention for the Prevention of

Pollution from Ships, today known universally as MARPOL, which has
been amended by the Protocols of 1978 and 1997 and kept updated
with relevant amendment.

MARPOL Annex VI, first adopted in 1997, limits the main air pollutants
contained in ships exhaust gas, including sulphur oxides (SOx) and
nitrous oxides (NOx), and prohibits deliberate emissions of ozone
depleting substances (ODS).
Under the revised MARPOL Annex VI, the global sulphur cap
will be reduced from current 3.50 % to 0.50 %, effective from
1 January 2020, subject to a feasibility review to be
completed no later than 2018.

The limits applicable in ECAs for SOx and particulate matter

were reduced to 0.10 %, from 1 January 2015 (IMO, 2015).

As of 1st of January 2015 regulation 14 of the IMO MARPOL

Annex VI states that all vessels sailing within the
environmental controlled areas ((North American Emission
Control Area, Baltic Sea and the U.S. Caribbean Sea
Emission Control Area) must reduce their SOx emissions to a
maximum of 0.10 %.
 Why MARPOL Annex VI?
Emission Gases from Ships

Oxides of Nitrogen (NOx) – create Ozone and smog

Sulphur Oxides (SOx) – create acidification
Carbon Dioxide (CO2) – is a GHG
Carbon Monoxide (CO)- is s very toxic gas
Hydrocarbons (HC) – gas, soot and some particulates
The concentration of the differing exhaust gases is variable
according to the
engine type,
engine settings and
fuel type.
Historical Crude Oil Prices and Price Chart
Composite boilers

A composite boiler arrangement permits steam generation either

by oil firing when necessary or by using the engine exhaust gases
when the ship is at sea.

Composite boilers are based on fire tube boiler designs.

The Cochran boiler, for example, would have a section of the tube
bank separately arranged for the engine exhaust gases to pass
through and exit via their own exhaust duct.
Steam Boiler Efficiency
The percentage of total heat exported by outlet steam
in the total heat supplied by the fuel is called steam
boiler efficiency.

Steam boiler efficiency depends upon the size of

boiler used. A typical efficiency of steam boiler is 80%
to 88%.
There are 6 important points that must be considered in order to improve
boiler efficiency.

1. Feed Water Temperature

To improve any system’s efficiency, it is important to maintain the

standard of all the inputs of that system. In boiler system, it is the feed
water which plays an important role in deciding the overall efficiency. For
this, the feed water temperature must be maintained at approx. 80- 85 deg C
to ensure boiler is operated at high efficiency.
The hot well needs to be monitored for correct temperature and level. Any
sudden fall in the level of hot well means more addition of cold water to
maintain the level, which leads to reduction in the feed water temperature.

•Maintain Feed Water temp- 80 to 85 deg. C

•Ensure hot well level controller is operating properly
•Monitor feed water temperature through hot well
2. Supply of Air to Burner

Air is required to ensure adequate fire is generated inside the

furnace through good combustion. It is therefore important to
know the percentage of air for efficient combustion. For fuel oil
fired marine boiler with register type burner, 15-20 % by weight
of air is required for efficient combustion.
Controlling excess air within the required range will lead to
decrease in the flue gas losses

•Excess Air to be reduced or avoided

•Know the air fuel ratio for your boiler under its current rating
•Keep a check on the content of combustion gases using flue gas
analyzer to adjust the air fuel ratio accordingly
3. Structural Importance
The outer shell or structure is an important part which not only
contains the pressure but keeps the temperature of the flue gas
intact inside the boiler for better heat exchanging ability.

Things to Check:
•Leakage from the boiler shell must also be checked. This
occurs mainly due to deformation or bulging of shell leading to
cracks and leakage.
•The insulation of the boiler must be checked for any damage or
leakage.
•The refractory should be checked at least once in a month for
their condition. Any damage in the refractory will lead to
localized heating of the shell and damage to the same.
4. Blow Down Control

It is normally observed that boiler blow down is not performed

regularly by operators.

Blow down is only performed when the water test results are high
in chloride or when high conductivity alarm occurs. This leads to
uncontrolled continuous blowdown which is actually waste of
boiler heat and efficiency.

•Avoid continuous long blowdown

•Regular short blowdown are recommended
•Keep a regular check on boiler water chloride content
5. Boiler Loading
Ships provided with more that one boiler or steam generators
must ensure that the load of the boiler is neither too low nor too
high. The best operating range to get the maximum boiler
efficiency is 2/3rd of the boiler full load. If the boiler is operated
below 50% load, more air is required to burn the fuel which
increases the sensible heat loss. It is always better to run less
number of boiler at high load than more number at low load.

Pro Tips:
•Highest efficiency of boiler can be achieved at 2/3rd of the full
load
•Avoid running the boiler at below 25% load as the efficiency
reduces significantly below this load
6. Soot deposits

The oil fired boilers are prone to soot deposits in the tube and
internal boiler surface which reduces the heat transfer rate.

A regular cleaning of boiler and economiser tubes must

therefore be performed. Record and observe the stack
temperature for indication of soot deposits.

An accumulation of soot on the fire side of boiler tubes

decreases boiler efficiency.

•Recommended to install a dial type thermometer at the base of

the stack to monitor the exhaust flue gas temperature
o
•When the flue gas temperature rises to about 20 C above
the temperature for a newly cleaned boiler, it is time to
remove the soot deposits
Choosing A Marine Boiler While Designing A Ship
Marine boilers used in ships today are mostly for auxiliary purposes in
vessels that run on marine diesel engines or diesel electric propulsion.

In case of ships using steam turbines (mostly found in high speed vessels
used by navies), boilers are a part of the main propulsion system.

A ship designer’s should be able to choose the right kind of boiler for a
particular ship depending on the requirement for that particular project.

To rate a boiler, one first needs to correctly estimate the steam output
required from a boiler for the ship being designed. For this, the three
main requirements are:

Requirement 1 – Steam consumption required to compensate heat

losses in tanks.
Requirement 2 – Steam consumption required to raise the temperature
of fuel oil in tanks.
Requirement 3 – Steam consumption required for other services.
Requirement 1- Steam consumption required to compensate heat
losses in tanks:

Most ships run by diesel engines have fuel oil tanks that are used to
store Heavy Fuel Oil (HFO).

Since the viscosity of HFO is very high, and its high viscosity makes it
unable to flow. But in order to transfer the stored HFO to the settling
tanks and then the HFO service tank, the viscosity needs to be
maintained at a level corresponding to which easy flow is possible.

For this, HFO storage tanks are equipped with heating coils to maintain
the fuel at a certain temperature. The heating fluid in the heating coils is
steam that is produced in the auxiliary boiler.
Requirement 2- Steam consumption required to raise the temperature
of fuel oil in tanks:

Not only is steam required to compensate the heat losses from fuel oil
tanks, but steam is also used to heat the fuel oil to required
temperature before being used in the engine.

For this, the time (t) in hours, required to heat up the oil in each type of
tank is generally considered as follows:

For Storage Tank – 0.2 DEG C/HR RISE IN TEMP.

Service and Settling tank – 4 DEG C/HR RISE IN TEMP.
All other Tanks – 1 DEG C/HR RISE IN TEMP.
Requirement 3- Steam consumption required for other services:
Steam is also used in ships to supply to other heating requirements,
some of which are listed below:

Used as a heat exchange medium in Heavy Fuel Oil purifiers, Light Diesel
Oil purifiers, and Lube Oil purifiers.

Steam used as a heating medium in booster modules.

To pre-heat main engine jacket cooling water.

Used as a heating medium in calorifiers (calorifiers are high pressure

storage units of heated water, which is used in gantry and toilet
utilities).
The type of boiler to be used in the ship is also to be chosen by the
designer based on the following criteria:

•Functionality of the boiler.

•Space Constraints.

For most auxiliary boilers, shell and tube boilers are used,.

However, for exhaust gas economisers or exhaust gas boilers (These are
boilers that do not have a furnace. They are also fire tube boilers, where
exhaust gases from the engine are passed through the fire tubes to heat
the water in the boiler drum.) vertical configurations are preferable, as it
provides less back pressure on the exhaust gas system.

Exhaust gas boilers are used when the vessel is on voyage, and when in
port, the auxiliary boiler is used.
The Basic Steam Cycle
The basic steam cycle

The basic steam cycle is a four phased closed, heated cycle. This
means that the fluid in the system is reused and heat must be
added to the cycle.

The heat is added in the boiler firebox or furnace where the

chemical energy of fuel is converted to the thermal energy of
combustion gases and water is boiled to generate steam.

This steam is expanded in the turbines, converting the thermal

energy of the steam into mechanical energy of the engines and
other turbine driven machinery such as turbine generators and
main feed pumps.
This steam is exhausted to a condenser which cools the steam
and turns it to a fluid which can be pumped through the system
again.

This condensed steam, or condensate, is deaerated and pre-

heated to remove oxygen and stored till needed.

When needed, the water, now called feedwater, is raised to the

proper pressure so that it can be fed into the cycle again.
1. Generation Phase ( Boiler)

To generate steam, it is necessary to heat water to its boiling point

by adding a sufficient amount of heat to change the boiling water
into steam.

2. Expansion Phase ( Work to be done)

The expansion phase of the basic steam cycle is where steam is

expanded in turbines to convert the thermal energy of steam to
the mechanical energy of rotation in the turbines.
3. Condensation Phase ( Condencer or Hotwell)

When steam changes phase from vapor to water in the main and
auxiliary condensers, that water is called condensate.

4. Feed Phase ( Pressure )

The condensate that is collected in the storage section of the

Hotwell or DFT is now called feedwater and becomes a supply for
the steam cycle. It also provides a positive suction head for the
main feed booster pumps (MFBPs) or the main feed pumps
(MFPs), as applicable.
Boiler Feed Systems

Types of Feed Systems

There are basically two main types of feed systems :

1. Open feed System

2. Closed feed system

The main difference between an open feed system and a closed feed
system is that in a closed feed system none of the parts of the
system are exposed to the environment.

Closed feed system is generally used in a high pressurized system such

as a high pressure water tube boiler supplying steam to the main
propulsion steam türbine, turbo generators or cargo pumps in
tankers.
The main parts of a closed feed system are:

1. A regenerative type condenser

2. Air ejector
3. Extraction pump
4. Deaerator
5. Feed tank.
 Open feed system for an auxiliary boiler

An open feed system for an auxiliary boiler ; the exhaust steam

from the various services is condensed in the condenser.

The condenser is circulated by cooling water and may operate at

atmospheric pressure or under a small amount of vacuum.

The condensate then drains under the action of gravity to the

hotwell .

The hotwell will also receive drains from possibly contaminated

systems, e.g. fuel oil heating system, oil tank heating, etc.
•The feed filter and hot well tank is arranged with internal baffles
to bring about preliminary oil separation from any contaminated
feed or drains.

•The hotwell provides feed water to the main and auxiliary feed
pump suctions.

•De-aeration is the removal of oxygen in feed water which can

cause corrosion problems in the boiler.
 HOTWELL

• Hot well is a tank or reservoir in which condensed hot water

is collected from different steam lines.
• It’s also called as Cascade tank.
• It’s an integral part of Boiler feed water system.
Purposes:
•Collects condensed water
•Supply feed water
Steam-dumping equipment

The steam dump equipment is designed for dumping excess

steam generated by the boiler plant from the steam system to
an atmospheric dump condenser.

It is essential that the condenser is dimensioned to be able to

absorb the amount of steamgenerated in the exhaust gas boiler or
exhaust gas part of the combined boiler.
BOILER MOUNTINGS
BOILER External attachments. ( Mountings on Boiler )

All marine boilers are required to be fitted with certain essential

mountings.

The minimum requirements are as follows:

• 2 safety valves
• 1 steam stop valve
• 2 independent feed check valves
• 2 water gauges (or equivalent)
• 1 pressure gauge
• 1 salinometer cock or valve
• 1 blow-down valve
• 1 low water level fuel shut-off device and alarm
Boiler equipment for safety :

1. Water level gauges and indicators

2. Safety valves. ( 2 pcs.)

3. Combined high steam and low water safety valve.

4. Fusible plug.
 Safety Valve

The safety valve, which prevents over pressure is one of the

most important fittings. The spring-loaded pop-off safety
valve pops open when steam pressure exceeds the MAWP.
There is no routine maintenance on a safety valve.

Safety valves are routinely tested to ensure proper operation..

With the boiler pressure at a minimum of 75% of the safety valve

set pressure, the safety valve try lever is lifted to wide open
position.

Steam is discharged for 5 sec to 10 sec.

The try lever is released, and the disk should snap to the closed
position against the valve seat.
Malfunctioning safety valves must be replaced as soon as
possible.

Replacement safety valves must comply with the Class

Boiler and Pressure Vessel Code and all design
specifications of the boiler.

Any adjustments or repairs to a safety valve must be

performed by the manufacturer or an authorized
manufacturer representative.
•The full rated discharge capacity of the safety valve(s) must be
achieved within 110% of the boiler design pressure.

•There must be an adequate margin between the normal

operating pressure of the boiler and the set pressure of the safety
valve.

•As per the requirements, at least two safety valves should be

fitted to the boiler and both are mounted on a common manifold
with a single connection to the boiler. Boiler with super heater,
normally three safety valves are fitted; two to the boiler drum and
one to the superheater.

•The superheater must be set to lift first to ensure a flow of steam

through the superheater.
Close examination and attention during overhauling

•Check valve and seat for wear, cavity corrosion , pitting and any
fault.
•Valve chest must be cleaned condition and drain line clear
•Hammer test to spindle for any crack and check its straightness
•Hammer test to compression spring for any fracture and check
for corrosion. Free length is limited to 0.5 % of original free
length.
•Check the guide plates and bushes for uneven wear and have
sufficient clearance to allow free movement of
•Check compression nut and cover bush’s threads and any sign
of wear and tear.
•Connecting pin should be a free fit in the lid and no bending.
Pinhole to be regular shape.
Routine check

The following should be regarded as recommendations of routine

checks on the safety valves, in order to secure a correct function:

Monthly
Examine the safety valves for any leaking, such as:
Is water seeping from the drain plug at the valve body?
Is the escape pipe hot due to seeping steam from the valve seat?
Examine the drain and expansion device at the escape pipe.
Examine the lifting gear device, i.e. clean up and grease all sliding
parts.
Yearly
The safety valve should be tested in operation by raising the boiler
pressure.
Expansion and exhaust pipe should be examined at the same time.
47 Ball
42 Bonnet 39, 40
41 Lifting lever
40 Split pin 41
39 Bolt 17
38 Screw 21
37 Spring
29 Cap
27 Gasket 29
26 Springplate
23 Lead seal 23 38, 47
22 Drain screw
21 Lock nut 26
18 Ball
17 Adjusting screw 27
16 Slotted pin
15 Gasket
14 Spindle 37
13 Lift aid
12 Disc 42
10/25 Split cotters 14
9 Lift limitation ring
8 Hex. nut 10, 25
7 Gasket
4 Spindle guide 8
3 Stud
2 Seat
1 Body

16
18
12
13
15, 22
2
1
STEAM STOP VALVE

This valve, typically installed directly on the steam output fitting on

the boiler, has several functions.

• It is primarily used to close the steam boiler from the downstream

system when needed.

• it can also be used to slowly preheat the system following

stoppages.

• It is also used to ensure a minimum boiler pressure in the event of

excess steam demand.
 Cast steel self-closing main stop valve for
water tube boilers

main stop valve for fire tube boilers

FEED CHECK VALVES

The feed check valve as fitted to the boiler is normally a non-return

globe valve, the chest being spigotted into the boiler end-plate.

Some boiler makers fit a combined shut-off and feed valve, two valves in
one chest, on both the main and auxiliary feed lines. The shut-off valve,
a screw-lift valve, is between the feed valve and the boiler, and the
boiler pressure is under this valve

Feed water regulation :

The feed water control valve
supplies the boiler with at
least the same amount of water
discharged in form of steam.
WATER LEVEL GAUGES

Water gauges play an important part in the safety of boiler operation.

The water level gauge provides a visible indication of the water level in
a boiler in the region of the correct working level.

You should blow down a gauge glass periodically to remove any

sediment from the glass.

Types of water gauge:

For boiler pressures up to about 20 bar it is normal practice to use

round glass tubes suitably connected to the boiler by means of cocks
and pipes, for indicating the working level of the water.

Above 20 bar the glass tube is replaced by what is in effect a built-up

rectangular-section box having a thick plate glass front and back.
The Normal Water level indicators and gauges
Operating Water
Level (NOWL)
should be
approximately in
the middle of the
gauge glass.
The water column is
blown down first and
then the gauge glass
to remove any
sediment. Water
should enter the
gauge glass quickly If the apparent obstruction cannot
when the gauge glass be removed by blowing down,
blowdown valve is then the boiler should be shut
closed. down and allowed to cool.
 For pressures above 20 bar the round water
gauge glass has been replaced by rectangular-
section box having a thick glass front and back.
To test a gauge glass, the following procedure should be followed:
1. Close the water cock and open the drain cock for approximately 5 seconds.
2. Close the drain cock and open the water cock
Water should return to its normal working level relatively quickly. If this does not
happen, then a blockage in the water cock could be the reason, and remedial action
should be taken as soon as possible.
3. Close the steam cock and open the drain cock for approximately 5 seconds.
4. Close the drain cock and open the steam cock.
If the water does not return to its normal working level relatively quickly, a blockage
may exist in the steam cock. Remedial action should be taken as soon as possible.
The authorised attendant should systematically test the water gauges at least once
each day.
Overhaul of water gauge mountings :

Water gauge mountings should be overhauled at least at every boiler

survey and, at this time, particular care should be taken to see that
all passages through the cocks and also those through pipes and
columns (if fitted) are clear.

Water-level indicators:

For emergency conditions, remote water-level indicators are fitted in

water tube and fire tube boiler installations.

These are always additional to the normal classification society

requirements for water-level indication.
Water level controls
The maintenance of the correct water level in a steam boiler is
essential to its safe and efficient operation..
Water level transmitter in all steam boilers is most importance
to have a constant water level in order to have a safe boiler
operation and to maintain a good steam quality.

The steam boiler is normally equipped with the following

transmitters:

SAFETY • Low low level, burner shut down. • Low level alarm.
• High level alarm.

CONTROL • Low level, pump start. • High level, pump stop.

The control level transmitter can also be a modulating type

which can work according to the following principles:

• Conductivity probes. • Float control. • Differential pressure

cells.
PRESSURE GAUGES

All pressure gauges on marine boilers operate on the Bourdon principle.

The main component is a phosphor bronze or stainless steel tube of oval

cross section which is bent in the form of an arc being fixed at one end
and free at the other.

By applying pressure internally, the tube tends to straighten and the

amount of movement at the free end is proportional to the pressure
applied.

Through a link attached to the free end of the tube motion is

transmitted by means of a quadrant to a small pinion on the pointer
which, in turn, pivots about the central axis of the gauge.
 They should always be
mounted in an upright
position and should be
regularly checked for
accuracy.

When the gauge is not under pressure, the pointer rests on a pin. It is
important to ensure that this pin is fitted and remains in position. There
have been cases where a missing pin has allowed a pointer to
commence a second circuit of the gauge dial thus falsely indicating a low
pressure when in fact a dangerous overpressure situation has endured.
SOOTBLOWERS

The heating surfaces of any boiler, both fire and watertube types, may
be kept clean, and the boiler thus be constantly available for service
in an efficient condition.

Soot blowers are fitted in suitable positions so that all the heating
surfaces, tubes, superheaters, economisers and air-heaters can be
maintained in a clean condition, provided, of course, that the
equipment is properly maintained and regularly operated (usually
every twelve hours).

The cleaning operation is performed by jets of high-pressure steam or

air.
BOILER DRUM INTERNALS

It is obviously an essential requirement for any boiler that steam

supplied to the range or to the superheater should be free of water
particles.
 MANHOLE

This is provided at suitable position on the boiler shell so that the man
can enter into boiler shell for inspection, maintenance and repairs.

This hole is usually made in elliptical shape of the size convenient for a
man to enter through this hole. The opening is closed by steam tight
cover.
 Handhole Covers
Manhole and handhole covers are
removed to provide access to boiler
parts during a boiler inspection.

Before removing any covers, make sure

all the proper permits and lockout
tagout procedures have been followed.
Make sure the boiler is not in a vacuum
by opening the boiler vent valve.
As soon as the boiler has been dumped, open the handholes, remove
the manhole cover, and thoroughly flush and wash out the water side.

Do not dump a boiler unless it can be flushed immediately. If a boiler

is dumped and not flushed right away, the sludge and sediment air-
dry on the heating surfaces, making it extremely difficult to clean.
Boiler Accessories for efficient operation:

1. Feed water pumps

2. Superheater
3. Economizer
4. Air preheater
5. Steam Trap
6. Condenser
 Function:

Its is a pump which is used to deliver

feed water to the boiler.

 The appliances in common use for

delivering the feed-water into the
steam boilers are:

a) Reciprocating pump

b) Rotary pump
 SUPERHEATER
A Superheater is a device used to convert saturated steam or wet
steam into dry steam used in steam engines .
 Economiser
• An economiser is a device in which the waste heat of the flue gases
is utilised for heating the feed water.
• The economizer on a boiler is used to add heat to feedwater

Advantages of Economiser

• The Temperature range between various parts of the boiler is

reduced which results in reduction of stresses due to unequal
expansion.
• Evaporation capacity of boiler is increased.
• Overall efficiency of boiler is increased.
 Air Preheater
• The function of the air pre-
heater is to increase the
temperature of air before it
enters the furnace. It is generally
placed after the economizer; so
the flue gases pass through the
economizer and then to the air
preheater.

Combustion efficiency can be

increased when air is preheated.
 STEAM TRAP
(Condenstop)

Steam trap is used to collect and automatically drain away the

water resulted from partial condensation of steam without
steam to escape with this condensate through a valve.

The valve after draining the condensate is closed. Is presses the

leakage of steam from the trap.

A Steam trap allows condensate to pass through, but stops

steam.
Why Steam Traps?

• The duty of a steam trap is to discharge

condensate, air and other incondensable
gases from a steam system while not
permitting the escape of live steam.
Reliability
• Experience has shown that 'good steam trapping'
is synonymous with reliability, i.e. optimum
performance with the minimum of attention.

Causes of unreliability are often associated with

the following:

• Corrosion, due to the condition of the

condensate.
• Waterhammer.
• Dirt
Types of steam trap:

• Thermostatic (operated by changes in fluid

temperature

• Mechanical (operated by changes in fluid

density) - This range of steam traps operates by
sensing the difference in density between
steam and condensate.

• Thermodynamic (operated by changes in fluid

dynamics)
 Mechanical Steam Traps

Bimetallic steam trap

Thermostatic Steam Traps

Liquid expansion steam trap

Balanced pressure steam trap
Thermodynamic steam trap
 Considerations for Selecting Steam Traps

• Waterhammer

Waterhammer is a symptom of a problem in the steam system.

This could be due to poor design of the steam and condensate
pipework, the use of the wrong type of trap or traps or a leaking
steam trap, or a combination of these factors.

• Dirt

Dirt is another major factor which must be considered when

selecting traps.
 Testing and Maintenance of Steam Traps

Routine maintenance

Routine maintenance depends on the type of trap and its application.

Routine maintenance which involves cleaning and re-using existing

internals uses just as much labour but leaves an untrustworthy steam
trap.

It will have to be checked from time to time and will be prone to fatigue.

Any routine maintenance should include the renewal of any suspect

parts, if it is to be cost effective.
Replacement of internals

The renewal of internal parts of a steam trap makes good sense.

The body will generally have as long a life as the plant to which it
is fitted and it is only the internal parts which wear, depending on
system conditions. There are obvious advantages in replacing
these internals from time to time.

Replacement of traps

On occasions, it will be easier and cheaper to replace traps rather

than repair them. In these cases it is essential that the traps
themselves can be changed easily.
 CONDENSER

The condenser is a heat exchanger which removes the latent heat from
exhaust steam so that it condenses and can be pumped back into the
boiler.. A condenser is also arranged so that gases and vapours from the
condensing steam are removed.

It is also required to reduce the back pressure and so allowing a greater

amount of work to be done by the engine, improving efficiency.
The two principle types of condenser are:

• Surface : in the surface type, there is a temperature drop of about

8°C from inlet to outlet and the condensate and air leave from the
bottom

• Regenerate : in this type, steam flowing along the regenerative

passage and up into the tube nest heats the condensed droplets
from the tubes so there is practically no temperature drop in the
condenser. Air trapped by the exhaust baffles is extracted
separately by an ejector.
• Strainers

Pipe scale and dirt can affect control valves and steam traps, and
reduce heat transfer rates. It is extremely easy and inexpensive to
fit a strainer in a pipe, and the low cost of doing so will pay
dividends throughout the life of the installation.

Scale and dirt are arrested, and maintenance is usually reduced

as a result.
Pressure Reducing Valves

Where there is a possibility that the pipework downstream of

reducing valves could be shut off during normal operation, a
trapping point should be provided to drain any condensate formed
during this period.

This keeps the downstream pipework free of water and protects

the reducing valve from filling with water and 'locking-up'.

Float traps discharge condensate continuously and do not disturb

the pressure in the pipe when discharging.
 Ejector
For most water-cooled condensers, the shell is under vacuum
during normal operating conditions.

Diagram of a typical modern injector or ejector

This diagram shows the basic components of an Ejector used in the Oil and Gas industry. This
Ejector was designed for use with gas. It has similarities with the “basic” Ejector shown in the
above diagrams.
These are:
1) There are three connections. One for the high pressure (HP) motive, one for the low
pressure (LP) suction entrained and one for the medium pressure discharge.
2) The suction (in this case gas) comes in at the side.
3) There is a nozzle for converting the pressure energy of the high pressure motive into
kinetic energy.

The Diffuser

The Diffuser is designed to firstly mix the two incoming streams. Then, when mixing is
complete, the diverging section slows the mixture down, thereby increasing it’s pressure. This
is the reverse of the process occurring in the nozzle.
BOILER SAFETY DEVICES
Function Audible and visual Action
Low water level Alarm
Low Low water level * Alarm Burner stop
High water level Alarm
Feedwater pump
High High water level Alarm
stop
Low steam pressure Alarm
High steam pressure Alarm Burner stop
Low feedwater pressure Alarm Stand-by pump start
Low fuel oil pressure Alarm Stand-by pump start
Low fuel oil temperature Alarm
High fuel oil temperature Alarm
Low combustion air pressure Alarm Burner stop
Flame failure ** Alarm Burner stop
Burner not in firing position Alarm Burner stop
Boiler Safety Devices as for UMS status:
1. Flame failure: (Photocell shut down combustion system and gives alarm.)
2. Low and high water level: (Level is maintained by feed pump, controlled by float
operated on/off switch.)
3. Low and high Steam pressure: (If steam demand drops, high steam pressure will
shut down burner and/or ME speed reduced. Low steam pressure
alarm, will be given if there is fault in combustion condition)
4. Fuel temperature: (Deviation from set temperature range, cause burner to be shut
off and alarms given for both low and high temperature.)
5. Fuel pressure: (Low fuel pressure cause automatic controller to shut down
burner and alarms given.)
6. Smoke density: (Emitted smoke through uptake, being monitored and if deviate
from normal limit, shut down the system and alarm given.)
7. Air / fuel ratio: (Air register damper controller keeps correct ratio, and shut down
the system and alarm given on deviation.)
8. Draught fan failure: (Air supply fan failure operate audible and visual alarms.)
9. Very low water level: (Burner stopped and alarms given.)
10. Very high water level: (Burner stopped or ME slow down and alarms given to
avoid foaming and carry over.)
11. High flue gas temperature: (Burner stopped and alarms given.)
Safety Devices on Boiler:

1. Flame failure alarm

2. Low water level alarm.
3. Very low water level alarm and cut-off.
4. High water level alarm
5. Low steam pressure alarm
6. Low oil temperature alarm and cut-off
7. High oil temperature alarm and cut-off
8. Low oil pressure alarm and cut-off.
9. Force Draught Fan failure alarm and cut-off.
10. Power failure alarm.
11. Safety Valves.
 BURNER

At ship, for burning low grade residual fuel, burner is essential for
atomization.
Burner is a mechanical device which supplies the required amount
of fuel and air to create a condition of rapid mixing and for
producing flame.
This mixing rate is very important as it decides the stability and
emission of flame.
Types

Pressure Jet Burner: This uses the pressure of the fuel oil to create
atomization and a rotating spray. The fuel, at the correct viscosity,
passes the centre passage of the burner, so the swirl plate where
the pressure energy is converted into tangential velocity energy.

Rotating Cup Burner: It uses the principle of centrifugal force to

increase the velocity of the fuel and thus achieve atomization. The
burner unit comprises a heat resistant steel cup, which is fixed to
the end of a shaft that is rotated at high speed by an electric
motor.
Y-Type Burner: It atomizes the oil by spraying it into the path of a
high velocity jet of steam or air. Although either medium can be
used, steam is usually more readily available and economical at sea.

Steam Assisted Burner: In this burner, when running at full power,

the burner operated as a pressure jet burner and steam and hence
water consumption was kept to minimum.

A good burner should have:

• Stable and Proper operation

• Less pollution
• Less noise
• Increased safety
• More operational life
Dual fuel burners:

These are burners designed with gas as main fuel and have
additional facility for burning fuel oil. The changeover of the fuel
from gas to oil should be rapid as there should not be any
interruption in the supply.

While changing the supply from gas to oil, the gas lines should be
first isolated, and oil supply should be switched on. The boiler
should then be re-fired. Fuel oil is a stand by and used for short
periods. Oil firing capacity may be basic.
Ultrasonic Burner

Manufactured by Kawasaki is said to offer the following

advantages;

• Wider turn down ratio with lower excess air (15 :1)
• Low O2 levels
• Simplified operation
• Reduced acid corrosion problems

Atomisation is achieved primarily by the energy of ultrasonic

waves imparted onto the fuel by the resonator tip which vibrates
at a frequency of 5 MHz to 20 MHz under the influence of high
speed steam or air impinging on it.

Extremely small droplet sizes result which allow for a very stable
flame.
Burner And Controls

Before making any attempt to start a burner-boiler unit, the

manufacturer’s instruction manual should be read thoroughly in
order to get a good understanding of how the burner operates.

The operator should be familiar with the various parts of the burner
and understand their function and operation.
The burner should be checked over thoroughly to ascertain all parts
are in proper operating condition. Some of the points to check are:

1. Fuel lines: All of the fuel connections, valves, etc., should be

inspected thoroughly. Make sure all the joints are tight, pressure
gauges and thermometers are in place and tight, and valves are
operative. Fuel lines should be checked for leakage.

2. Check all of the burner linkage for tightness and wear at

connecting points.

3. The electrical wiring should be checked very carefully. Make sure

all connections are tight. Check all the terminal strip connections.
Sometimes the vibration from shipping or operation will loosen
them
Boiler Automatic Burning System:

1. With correct water level, steam pressure transmitter initiates

cut-in at about 1.0 bar below working pressure.

2. Steam pressure transmitter initiates Master Relay to allow ‘Air

On’ signal to force draught fan.

3. Air feedback signal confirms ‘Air On’ and allows 30-sec. delay
for purge period.

4. Then Master Relay allows Electrode to strike ‘Arc’.

5. Arc striking feedback signal confirms through electrode relay

and allows 3-sec. delay.
6. Then Master Relay allows burner solenoid valve for ‘Fuel
On’ operation.

7. Fuel On feedback signal allows 5-sec. delay to proceed.

8. As soon as receiving Fuel On feedback signal, Master

Relay checks ‘Photocell’, which is electrically balanced when
light scatter continuously on it.

9. Result is OK and cycle is completed.

10. If not, fuel is shut-off, Alarm rings and cycle is repeated.

11. Steam pressure transmitter initiates cut out automatically

at about 0,06 bar above W.P.
Examples of ship boiler systems
Typical marine oil-fired auxiliary boiler for cargo ships – vertical water-tube type.
Legend:
1. Steam boiler 2. Water drum
3. Steam drum 4. Row of water tubes
5. Furnace 6. Exhaust gases chamber
7. Water level gauge 8. Float switches chamber
9. Feed valve 10. Scum funnel
11. Bottom blow-off funnel 12. Safety valve
13. Main steam valve 14. Air escape valve
15. Manometer and press. controls cut-off valve 16. Fuel nozzle pressure controls
17. Float switches chamber blow-off valve 18. Float switches chamber
upper valve
19. Float switches chamber lower valve 20. Hot well
21. Condensate observation tank 22. Hot well refilling pump
23. Boiler water tank 24. Burner
25. Fuel supply valve 26. Drain ( dewatering ) valve
27. Scum valve 28. Blow down valve
All personnel charged with the operation of an auxiliary boiler should be
thoroughly familiar with the boiler, its controls, and all safety precautions.

Operating instructions can be found in the appropriate manufacturer’s technical

manual.

All boiler operators must be concerned with two hazardous conditions that
could occur in a boiler when the automatic control system malfunctions:

(1) low water level

(2) excess fuel in the combustion space (which tends to turn the boiler into a
bomb).

Operator and maintenance personnel must NEVER bypass or defeat any

of the safety controls and devices used on auxiliary boilers.

Maintenance requirements for auxiliary boilers are contained in your ship’s

PMS Manual.
FIRING UP

Firing the burner should follow the procedure(s) outlined in the

specific burner operating instruction manual for the equipment being
started.
Check the condition of all auxiliary equipment that serves in firing or
feeding the boiler, interlocks, limits, feedwater supply pumps, etc. By
this time all of the auxiliary equipment should have been checked out
for proper size and pressure to ensure proper operation of the unit.

1. When the boiler is closed, check and close the blow off valves, water
column and gauge glass drains, and gauge cocks.

2. Open the vent valves, gauge glass shutoff valves and steam pressure
gauge valves.

3. Fill the boiler with water at ambient temperature, but not less than
20°C. Fill to a level about 3 cm. above the bottom of the gauge glass.
4. Blow down the water column(s) and the gauge glass(es),
making sure that water returns to proper level promptly.

5. Fuel piping should have been pretested for leaks. The oil pump
sets should be started so oil can be circulating, and oil pressures
adjusted to the burner requirements.

İf fuel lines are new or repaired precautions should be taken to

make sure these lines are clean.

The strainers should be checked frequently.

6. Start the burner on low fire in accordance with instructions
listed in the specific burner operating instruction manual.

7. The boiler should be warmed up slowly to permit

temperatures to reach saturation temperatures, and metal and
refractory temperatures to equalize.

As the boiler begins to warm up, it should be watched closely for

leaks and also signs of expansion.

8. When pressure in the boiler has reached 10 to 15 psi, close

the drum vent.
COMBINED OIL FIRED AND EXHAUST GAS BOILER FOR CARGO SHIPS
BOILER SYSTEM FOR TANKERS
A circulation flow measurement
control system must be installed to
ensure a continuous water
circulation. M33

The system should in general consist

of an orifice, differential pressure
indicator switch, and reducing valve.

The reducing valve and the orifice will

protect the system by reducing the
pump discharge flow variations
resulting from different working
conditions.

The differential pressure indicator

switch provides low circulating flow
alarm and start of the stand-by pump.
Sample valve
A sample valve is installed enabling connection to a sample cooler for
taking test samples to perform boiler water analyses.
 Boiler operation
Boiler operation mode

The exhaust gas boiler is operated in connection with one or more

oil fired boilers.

The combination between an exhaust gas boiler and oil fired

boiler(s) makes it possible to operate the boiler plant in different
modes.

The different modes are:

1. Operation only on the oil fired boiler(s)

2. Operation only on the exhaust gas boiler
3. Operation on both the oil fired boiler(s) and exhaust gas boiler.
Oil fired boiler operation mode

When the main engine is stopped, the only heat source is the
burner(s) of the oil fired boiler(s).

The burner is operated by means of signals from the boiler gauge

board and the steam pressure is kept within the set point limits.

As the circulation pumps are operational, hot boiler water is

pumped through the circulating system and the exhaust gas boiler
is kept heated and pressurised.
Exhaust gas boiler operation mode

When the exhaust gas flow through the boiler, produced by the
main engine, is sufficient to maintain the steam pressure, the
burner(s) of the oil fired boiler(s) will not be in operation.

If the exhaust gas flow is above the required flow to maintain the
steam pressure at a given steam output, the pressure increases.

At a pre-selected set point the steam dump equipment, located

elsewhere in the steam system, opens the dump valve and regulates
the steam line pressure.

If, however, the circulation outlet valve has been closed the boiler
pressure may rise above the maximum allowable working pressure.

At this point, the safety valves open and ensure any further increase
of the steam pressure.
Normal operation
When an exhaust gas boiler has been put into service it requires
only little attendance. However, the following items must be
ensured:
The circulation valves on both the exhaust gas boiler and oil fired
boiler(s) must be opened.
One of the circulation pumps must be operating continuously
(also in port) while the other pump is in automatic stand-by start
mode.
The flow measurement system must be operational.
Open the air escape valve once in a while to remove air pockets in
the boiler.
All alarms, especially circulation failure/start of stand-by pump,
must be attended to immediately and the cause must be
established and rectified as soon as possible.
The routine maintenance must be followed according to the
recommendations.
Dry running
Continuous water circulation must always be maintained through the
exhaust gas boiler while the main engine is running.

However, the design of the boiler allows operation without water

with the full exhaust gas flow through the smoke tubes, provided the
boiler is operated depressurised.

Although the boiler materials are selected to accept unlimited dry

running, there is always the risk of a soot fire and every effort to re-
establish the water circulation should be made in order to reduce
the dry running period to a minimum.

Furthermore, operation of the boiler without water eventually dries

out the gaskets, and a replacement of the gaskets is necessary.
Dry running must be limited as far as possible and only allowed in
case of emergency if no other operation alternatives are present.

Before start of the boiler it must be drained and the manhole

cover should be dismounted to ensure that it is operated
completely depressurised.

Please note that the temperature inside the boiler must not
exceed 400ºC.

When the boiler operates without water, it will gradually be heated

to the same temperature as the exhaust gas. It is therefore
important to allow the boiler to cool before restarting the boiler
water circulation, thereby avoiding excessive thermal shock
stresses which, if repeated, would result in damage.
Combined operation mode

The steam production is controlled by the amount of exhaust gas

from the main engine and the gauge board of the oil fired boiler(s)
which controls the burner(s).

If the main engine produces an insufficient amount of exhaust gas

to maintain the steam pressure, the boiler gauge board initiates
start of the burner.

The burner operates as long as the steam pressure does not

exceed the set point for stop.

If the steam pressure increases above this set point, the boiler
gauge board initiates stop of the burner.
Stop to normal stand-by condition

The main engine can be stopped at any time without special

preparations regarding the boiler plant.

The circulation of water through the exhaust gas boiler must be

maintained after stop of the main engine for the following reasons:

The boiler is kept heated by the oil fired boiler(s) and therefore
ready for start of the main engine.
A soot fire may develop even after stop of the main engine, and if
the tubes are not properly cooled, this may result in severe damage
to the boiler.
External corrosion of the boiler tubes due to sulphuric acid is
reduced.
Stop to cold condition

Stop to cold condition is generally the same procedure as stop to

normal stand-by condition.

If required, the circulation pumps can be stopped during prolonged

stays in port.

However, not earlier than 12 hours after the main engine has been
stopped and provided that no abnormal conditions have occurred
during the cooling period, e.g. small soot fires.

The boiler water circulation must be re-established prior to the next

start of the main engine.
Emergency stop

The boiler must be taken out of service immediately if:

A substantial loss of water is noted.

The safety valve cannot function.

Oil in the boiler water is detected.

Too high salinity level is detected.

 BOILER REPAIR
Plugging of tubes

In case of a leakage tube, the boiler must be stopped and the pressure
lowered to atmospheric pressure.

If the leaking tube cannot be located immediately via the inspection

doors, the boiler should be set on pressure by means of the circulation
pumps so that the leakage indicates the damaged tube.
The main engine must be stopped during the repair work.

Open and, if necessary, remove the inspection doors in the exhaust gas
inlet box and outlet box.

When the damaged tube has been located, clean the inside of the tube
ends with a steel brush so that no deposits are present in the tube.

Plug and seal weld both tube ends with a conical plug.

Tube plugging results in reduced efficient heating surface, and

accordingly the boiler efficiency will decrease.
Exchange of tubes

From an operational point of view up to 10% to 15% of all tubes

can be plugged with a conical plug, but if more tubes are
damaged, an exchange of tubes is necessary.

It is possible to replace the tubes from the outside of the boiler.

After location of the damaged tubes, they must be replaced
according to the following procedure:

The main engine must be stopped during the repair work.

Ensure that the boiler pressure is lowered to atmospheric

pressure and that it is completely drained of water.

Open and remove the inspection doors in the exhaust gas inlet
box and outlet box. If necessary remove the inlet box and/or
outlet box.
The damaged tubes must be cut right below and above the tube
plates.

Remove the damaged tubes.

Scraps of metal and welding material in the tube holes as well as the
tube plates must be grinded off.

The new tubes should be placed in the tube holes one by one and
seal welded onto the tube plates .

Only skilled personnel with knowledge and qualifications to perform

certified welding should perform repair work.
The tubes should be rolled after the welding work has been
completed.

After completion of the repair work, clean the working area.

Refill the boiler with water and check for leaks through the
inspection doors before starting up.

Mount and close the inspection doors again.

MAINTENANCE
Daily Maintenance
Check water level.
Upon entering the boiler room, check to ensure there is water in the gauge
class.
Blow down boiler.
Blow down boiler in accordance with the recommendation of your feed
water consultant.
Blow down water level controls to purge float bowl of possible sediment
accumulation.
Check combustion visually.
Look at the flame to see if something has changed. Changes may be an
indication that a problem is developing.
Treat water according to the established program.
Add chemicals and take tests as outlined by consultant.
Record boiler operating pressure or temperature.
Excessive steam or water temperature drop will alert you to excessive loading
on the boiler.
Record feedwater pressure and temperature.
Change in pressure or temperature may indicate a problem is developing
with feed system.
Record stack temperature.
Changes in stack temperatures could indicate a boiler heat transfer
problem.
Record oil pressure and temperature.
Changes in pressure and/or temperature could have an effect on
combustion in the boiler.
Record oil atomizing pressure.
Changes in pressure could have an effect on combustion in the boiler.
Record boiler water supply and return temperatures.
Check temperatures to detect system changes.
Record makeup water usage.
Excessive makeup water could be an indication of system problems in
both steam and hot water systems.
Weekly Maintenance
Check for tight closing of fuel valves.
Check to ensure fuel does not flow through the fuel valve(s) when
the burner is shut off.
Check fuel and air linkages.
Check to ensure all set screws on linkages are tight and securely
holding the linkage in place.
Check indicating lights and alarms.
Check for burned out or loose light bulbs. Also check to ensure the
alarm bell or horn sound on the appropriate shut down condition.
Check operating and limit controls.
Check to ensure the controls shut the burner down at their
predetermined set point. Settings should be verified with actual
pressures and temperatures on the boiler gauges.
Check safety and interlock controls.
Check to ensure the controls shut the burner down at their
predetermined set point. Settings should be verified with actual
pressures and temperatures on the boiler gauges.
Check for leaks, noise, vibration, unusual conditions, etc.
Check operation of all motors.
By developing a routine, any change in operation or bearing temperature will
usually be caught in time to avoid a failure.
Check lubricating levels.
Check levels of any oil bath filters, oil level in air/oil tank, oilers on pumps,
etc. Add oil in accordance with the manufacturer’s recommendations.
Check flame scanner assembly.
Using the appropriate meter, check the flame signal strength at the program
relay flame amplifier. Ensure the scanner assembly is clean and dry.
Check packing glands on all pumps and metering devices.
Proper tension on packing glands will extend life of equipment.
Check gauge glass.
Ensure there are no cracks or etching in the glass or leakage around the
packing.
Check operation of water level controls.
Stop the boiler feed pump and allow control to stop the boiler under normal
low fire conditions. See your operating and maintenance manual for a more
detailed procedure.
Monthly Maintenance
Inspect burner operation.

Analyze combustion.
Take the flue gas analysis over the entire firing range, comparing these
and stack temperature readings with previous month.
Inspect for hot spots.
Inspect the boiler to ensure no hot spots are developing on the outside
of the boiler. Hot spots can indicate a refractory failure or baffle failure,
thus causing improper gas flow through the boiler.
Inspect burner operation.
Visually inspect the pilot flame, main burner flame throughout the firing
range, free movement of linkages and general burner operation.
Check for flue gas leaks.
Ensure something hasn’t changed in the breeching, stack or overall
system that allows flue gas to be drawn into the boiler room.
Semi-Annual Maintenance
Clean low water cutoff (s).
Remove head assembly or probes, inspect and clean out any sediment
or contamination in the column or piping. If the condition exists,
determine why.
Check oil preheaters.
Remove the heating element an inspect for sludge or scale.
Clean oil pump strainer and filter.
Ensure they are not plugged, thus reducing the flow of the required oil
to the burner.
Clean air cleaner and air/oil tank.
Inspect and clean out any sediment or contamination. Add oil in
accordance with the manufacturer’s recommendations.
Check pump coupling alignment.
Check alignment of all couplings to ensure the tolerances are within the
manufacturer’s recommendations.
Annual Maintenance

Annual maintenance should be coordinated with the annual

pressure vessel inspection performed by insurance or government
groups.

Establish a firm procedure with all outside inspection groups so that

your equipment will be in a proper state of readiness.

Disconnect all power supplies and lock switches in the off position.
Whenever there is more than one boiler connected to a common
header establish a routine procedure of locking the header valve on
any unit that is down for cleaning or inspection, close any flue gas
outlet dampers, and all pieces of equipment required to isolate the
boiler.
1. Clean fireside surfaces by brush or use a powerful vacuum cleaner to
remove soot. After the cleaning process and if boiler is to be left open,
it is advisable to spray all fireside surfaces with some type of corrosion
preventative.

2. Clean breeching. Inspect breeching and stack and remove any soot
build up.

3. Clean waterside surfaces. Remove all handhole and manhole plates,

inspection plugs from water column tees and float.
Thoroughly wash all waterside surfaces.

4. Check oil storage tanks. Oil storage tanks should be inspected for
sludge and water accumulation.
5. Check fluid levels on all hydraulic valves. If any leakage is apparent,
take positive corrective action immediately.

6. Check gauge glass for possible replacement. If internal erosion at

water level is noted, replace with new glass and gaskets. On all
unattended boilers, the gauge glass mounting should be of the safety
style with stopchecks in case of glass breakage.

7. Remove and recondition safety valves. Have them reconditioned by

an authorized safety valve facility.

8. Check on the condition of the fuel pump. Fuel pumps wear out and
the annual inspection time is the opportune time to rebuild or replace
them.
9. Boiler feed pumps. Strainers should be reconditioned. Feed pump
elements wear and must be replaced.

10. Condensate receivers should be emptied and washed out. Make

an internal inspection, if possible. If the receiver has a make-up
valve mounted, it should be overhauled and checked for proper
operation.

11. Chemical feed systems should be completely emptied, flushed

and reconditioned. Metering valves or pumps should be
reconditioned at this time.

12. Tighten all electrical terminals. All terminals should be checked

for tightness, particularly on starters and movable relays.
 Inspection of the boiler

Inspection of boiler exhaust gas side

The exhaust gas section should be inspected at least once a year.

During this inspection, the following issues should be taken into
consideration:

Check the welding in the exhaust gas section. A careful examination

should be carried out with respect to any possible corrosion or crack
formation.
Check that the smoke tubes and stay tubes are intact and that soot
deposits are within normal limits.
Check that the inlet box and outlet box are intact and that soot
deposits are within normal limits.
Inspection of boiler steam/water side

The boiler water side (interior) must be carefully inspected at least once
a year.

At these inspections, hard deposits, corrosion, and circulation

disturbances can be found at an early stage and preventive measures
must be taken to avoid unexpected material damage and boiler
breakdown.

The presence of hard deposits at the boiler tubes reduce their heat
transfer properties and decrease the capacity of the boiler. Further, it
can be established whether the feed water treatment is satisfactory, and
whether the blow-down is carried out sufficiently.
Insufficient blow-down will cause accumulation of sludge in the
bottom of the boiler.

Incorrect feed water treatment is commonly causing hard deposits

or corrosion. If hard deposits are not removed, it may lead to
overheating.

Incorrect feed water treatment does, however, not always lead to

hard deposits. For example, a too low or too high pH-value may give
an electrolytic reaction, causing corrosion in the boiler.

When the boiler interior is inspected, examine all parts carefully and
be attentive to deposits, corrosion, and cracks. It is advisable to pay
special attention to this inspection.
 Procedure and remarks for inspection

Stop the boiler and allow it to cool.

Ensure that the boiler is depressurised and that all valves are
closed.
Access for inspection is achieved through the manholes, hand
holes and inspection doors. The boiler can be entered when it is
sufficiently cold.
Check the welding in the boiler. A careful examination should be
carried out with respect to any possible corrosion or crack
formation.
If deposits are forming at the boiler tubes, the boiler should be
chemically cleaned.
After chemical treatment the boiler should be blown-down at
least twice a day for approximately one week. This will ensure
that excessive sludge deposits due to chemical treatment do not
collect in the bottom of the pressure vessel.
Contamination

If the steam/water side of the boiler is contaminated with foreign

substances like oil, chemicals, corrosion products etc., it is very
important to act immediately to avoid damage of the boiler.

Layers of thin oil films, mud, etc. exposed to the heating surfaces
cause poor heat transfer in the boiler, leading to overheating
followed by burned out pressure parts. In order to remove such
contamination, a boiling out or acid cleaning should be performed
immediately.

Corrosion products from the pipe system or insufficient boiler

water treatment may result in corrosion in the boiler itself. It is
therefore important to observe that such circumstances do not
occur in the system.
 Cleaning smoke tubes

The main engine exhaust gas contains carbon particles and unburnt
residues (soot, etc.) and the amount is strongly dependent on the state
of the engine and the supply of scavenging air.

These soot/un-burnt residues will accumulate on the boiler heating

surface if not removed by cleaning.

Furthermore, the combustion quality of the engine is changing together

with the load, where the best combustion is in the high load range and
the lower range is giving a more “contaminated” (black/coloured)
exhaust gas.

And the more contaminated the exhaust gas is, the more fouling will
appear in the exhaust gas boiler. Therefore, it is impossible to specify
exact time intervals in which the smoke tubes should be soot cleaned.
Some general guidelines are given below:

Inside inspection.

Check of the exhaust gas temperature on the outlet side of the

boiler. The boiler should be cleaned if the outlet exhaust gas
temperature lies approx. 20°C above the temperature in a clean
boiler at a specified engine load.

Check of the pressure loss. The boiler should be cleaned if the

pressure loss lies approx. 20 mm WC above the pressure loss in a
clean boiler.(At the specified MCR - Maximum Continuous Rating -of the engine, the total back
pressure in the exhaust gas system after the turbocharger (as indicated by the static pressure measured
in the piping after the turbocharger) must not exceed 350 mm WC (0.035 bar).)

It is recommended to keep a consecutive record of the exhaust gas

temperature and pressure loss related to different engine loads in a
clean boiler.
Water washing procedure

The most effective way of soot cleaning is water washing, as most of

the deposits consist mainly of non-soluble particles held together by a
water soluble bonding material. Water washing will have the following
benefits:
Dissolves the bonding material.
Washes the loosened insoluble deposits away.

Water washing must be carried out when the main engine is stopped
and the boiler has been cooled down. However, the boiler should be
warm enough for the water to evaporate so that the tubes will not
remain moist after washing.
Both fresh and sea water can be used. However if sea water is used,
the boiler must be thoroughly washed afterwards with fresh water in
order to remove all salt deposits. Where deposits are highly corrosive
or bonded, a soaking spray with a 10% soda ash solution is advisable
before washing.
 Hydraulic Testing of Boiler:

Necessary condition:

1. Boiler internal inspection is not satisfactory.

2. Surveyor demanded.

3. After structural repairs of boiler.

Requirement:

1. Surveyor must be present.

2. Gag the Safety Valves.

3. Close all opening.

4. Blanks inserted at Main Steam Stop Valve and Gauge

Glass.

5. Measuring tape placed around boiler to check bulging.

6. Deflection gauge placed in the furnace.

7. Remove lagging to check leak points.

Procedure:

1. Open vent cock, fill boiler with warm water completely,

until water overflows from vent cock, and close the vent
cock.

2. Attach force pump and test pressure gauge.

3. Apply water pressure, 1.25 times of approved working

pressure, for not more than 10 minutes.

4. If satisfied, Surveyor will stamp on bottom front plate near

the furnace.
Important Points for Boiler Cleaning on a Ship

Boiler cleaning is one of the most important processes that are to be

performed routinely on marine boilers on a ship.

•If the boiler water is treated properly with chemicals and the
concentration of chemicals is within the acceptable range then the
deposits on the walls of water and steam side of the boiler will be
minimal.
•If boiler is operating on distille water rather than drinking water, the
deposits inside the tubes will also be minimal and can be removed by
boiling out. The hard deposits inside the tubes are removed with the
help of scrubber and brush from the upper drum.
•If the boiler oil burner is functioning properly and proper maintenance
is being carried out from time to time then the soot deposits inside the
oil fired boiler will be minimal.
The soot deposits can be removed with the help of water washing with
10 percent soda solution through the inlet door in the uptake with the
help of water hose.

Necessary precautions are to be taken during water washing. It is to be

noted that the refractory present inside the boiler does not get wet.

During water washing the refractory should be covered with the plastic
sheet and water should be drained off continuously through the drain
provided at the bottom.

In case the refractory gets wet, the lighting of boiler should be done
very slowly, otherwise the refractory will crack and drop down and
finally cause overheating and deformation inside.
Feedwater Pump maintanence:

During periods of operation, there is very little that can be done except
to check it periodically to make sure everything is functioning normally.

Bearing temperatures should be checked and the vibration can also be

observed. Packing gland adjustment can be done and, depending on
types of lubrication methods employed, lubrication of the bearing can
be done.

At that time the bearings should be checked carefully, lubricant replaced

or added.

Flexible couplings should be opened up, checked for wear and

alignment, washed out thoroughly and reassembled with new lubricant.

During the same inspection, the pump seals can be inspected and, if
necessary, replaced.
 FEED WATER TREATMENT

The treatment and conditioning of boiler feed water must satisfy

three main objectives:

• Continuous heat exchange

• Corrosion protection
• Production of high quality steam
Feed and boiler water

Boiler and feed water should be chemically treated in order to avoid

corrosion and scaling in the boiler.

In most vessels make-up / feed water is distilled by an evaporator, and

the distillate is generally very good make-up water.

In practice most distillate used contains minor parts of various salt

combinations, which can be chemically treated away. Further, the
distillate may contain dissolved gases like for example oxygen (O2) and
carbondioxide (CO2), which may lead to corrosion in the boiler, steam
and condensate system.

Note : It is of great importance that the feed and boiler water are
chemically treated in order to avoid corrosion resulting from the above
mentioned factors.
SCALE
Scale formation in boilers leads to lower efficiency because of reduction
in heat transfer rates.
Overheating and tube failures may result, and often the high cost of
chemical cleaning may be entailed.
Typical constituents of scales and deposits in boilers are:
• Calcium carbonate
• Calcium sulphate
• calcium and Calcium phosphate
• Complex silicates of magnesium
• İron and copper oxides.
• sodium
• aluminium
• Magnesium hydroxide
• Magnesium phosphate
Boiler Corrosion

Electro-chemical Corrosion:

•Hydrogen ions (H⁺) are generated by acid concentration under hard

dense deposits and can penetrate grain boundaries of tube metal,

•Hydrogen attack can occur very rapidly, causing the tubes cracked,
failed and ruptured.

•General wastage occurs when pH value is < 6.5.

•Pitting (Air Bubble pitting and Scab pitting) occur when pH value is
between 6–10 in the presence of dissolved Oxygen.
CORROSION

The presence of oxygen in the feed water can cause serious effects
on the metals of the system.

It can give rise to feed line corrosion with the formation of corrosion
products of iron and copper and a simultaneous reduction in the
effective thickness of the metals used to construct the feed system.

The most serious aspect of corrosion in the feed line is that the iron
and copper oxides thus formed are carried further through and will
tend to accumulate in the boiler, even if adequate blowdown has
been regularly carried out.
Localised pitting can lead to tube failure
Caustic Cracking corrosion:

•Inter-crystalline cracking occurs when excess concentration of

Caustic Soda (NaOH) in boiler water, comes in contact with steel,
under stresses and high temperature.

•Metal becomes brittle and weak.

•Damage occurs to riveted seams, tube ends and bolted flanges.

•Prevented by dosing Sodium Sulphate (Na₂SO₄) to give

protective layer.

•Ratio of Na₂SO₄ to NaOH should be maintained 2 : 5.

Corrosion by Oil:

•Animal or vegetable oil decomposed to fatty acid and causes

corrosion.

•Causes are over lubrication of machinery, leakage of heating

coils & inefficient filtering of feed water.

•Prevented by Liquid Coagulant Treatment, which coagulates oil

droplets & suspended solids and settle them at low points, and
they can be blown-down.
Corrosion by Galvanic Action:

With dissimilar metals in a saline solution, galvanic action results

and more anodic metal corrodes.

Corrosion occurs when feed water is contaminated with salt-water.

Prevented by carrying out Chloride Test daily.

Chloride Level should be 0 – 300 ppm, and blow-down if > 300

ppm.
CO₂:

Reacts with H₂O to form Carbonic Acid (H₂CO₃) which

reduces pH value (Alkalinity) of feed water and accelerates
general type of corrosion.

Groovings along the pipe’s bottom, bends & threaded

section.
 FEED AND BOİLER WATER ANALYSİS

Marine Engineers must make following analysis of the feed and

boiler water in order to have a good treatment.

•pH
•Conductivity
•Total Alkalinity
•Chloride
•Hardness
•Chlorine
•Iron
•Phosphate
•Hydrazin
The water required for boiler feed purposes i.e for steam
generation should be of very high quality and thus requires a lot of
treatment.

Untreated water, containing impurities may lead to the following

problems in boilers:

•Scale and sludge formation

•Boiler Corrosion
•Caustic embrittlement
•Priming and foaming
Proper treatment of boiler feed water is an important part of
operating and maintaining a boiler system. As steam is
produced, dissolved solids become concentrated and form
deposits inside the boiler. This leads to poor heat transfer
and reduces the efficiency of the boiler.

Dissolved gasses such as oxygen and carbon dioxide will

react with the metals in the boiler system and lead to boiler
corrosion.

In order to protect the boiler from these contaminants, they

should be controlled or removed, trough external or internal
treatment.
Foaming and priming in boilers

Boiler water carry-over is the contamination of the steam with boiler-

water solids. This is called foaming and it is caused by high
concentration of any solids in the boiler water.

Priming is the carryover of varying amounts of droplets of water

in the steam (foam and mist), which lowers the energy efficiency
of the steam and leads to the deposit of salt crystals on the super
heaters and in the turbines.
Foaming:
Formation of thick layer of steam bubbles, on top of water surface
inside boiler.
Priming:
Rapid carry-over of large amount of water, in steam as it leaves the
boiler.

Causes:
1. Higher water level than normal
2. High amount of TDS, total dissolved solids
3. High amount of suspended solids
4. Contamination by oil and other organic substances
5. Forcing the boiler
Effects:
1. Water hammer
2. Contamination and scaling
3. Fluctuation of working water level
When taking a sample for water testing, please observe the
following:

Use a clean, rubber-stoppered, resistant glass bottle or a new

plastic bottle

Either thoroughly wash and rinse used bottles or use new bottles
for samples

Before taking samples through metal lines and valves, allow water
to run for several minutes to wash out the system. This is necessary
to make certain the sample taken is representative and not
contaminated with a disproportionate amount of any one impurity.

Rinse the container throughly with the water that is to be analyzed

before taking a sample.
•Salinity Indicating System

A Salinity indicating system is installed to detect the presence

and source of salt in the feedwater system and thus guard
against its discharge to the boiler. There is a salinity indicator
panel mounted on the main operating platform near the main
switchboard. This panel indicates the salinity readings
measured by cells located at;

•Main condensate pump suction

•Auxiliary condensate pump suction
•Feed pump suction
•Atmospheric Drain Tank
 Chemical Feed System

Provision is made in the feed piping for injecting boiler compound

into either boiler while in operation. The system consists of a
chemical compound feed tank and all the necessary piping,
valves and fittings, and is arranged to discharge chemical
compounds from the compound feed tank to each of the boilers,
using feed pump discharge pressure.

The compound tank has a capacity of approximately five gallons.

The purpose of chemically treating feedwater is to turn scale forming

salts to a nonadhering sludge
 Chemical Safety

Containers
that contain
hazardous
materials
must be
labeled,
tagged, or
marked.
Boiler Blowdown

Many difficulties in boiler operation occur because of excessive

concentrations of sludge, silica, alkalinity, chlorides, or total dissolved
solids.
To prevent an excessive accumulation of dissolved and undissolved
solids which will interfere with proper boiler operation, a blowdown
program should be established.

The amount of blowdown or number of times the boiler is blown each

day depends upon the concentration of solids in the boiler water.
When necessary to blow down the boiler through the blowoff
valves they should be opened slowly and carefully.

The boiler should be blown down at lower firing rates.

Blowoff valves should be closed tightly after blowdown is

completed.

The boiler should be equipped with either two slow-opening

valves or one quick-opening valve and one slow-opening valve
piped in series.
Sootblowers

Boiler tubes and heating surfaces get dirty because of an

accumulation of soot, slag deposits, and fly ash. These substances are
excellent insulators and reduce the effectiveness of the heating
surface.

Therefore, they must be removed to ensure the continuation of

optimal boiler performance.

Removal can be accomplished by using a hand lance or a sootblower.

Steam and compressed air are usually used for blowing, although
water and shot are sometimes used to remove certain types of
deposits that become baked hard and are difficult to remove with the
conventional sootblower.
The operation of soot blowers is called "blowing tubes." Tubes are
blown on the following minimum occasions:

•After leaving port

•Before entering port

•After making heavy smoke

•Once each week when steaming

SOOT BLOWERS are normally used water tube boilers.

Before using soot blowers on a boiler, drain soot blower lines.

•Bridge must be informed before blowing.

 BOILER ACCIDENTS

Chart Title
LOW WATER LEVER POOR OPERATION AND MAINTENANCE OTHERS

28%
33%

39%

1586 BOILERS (739 STEAM BOILER- 847 HOT WATER BOILER) / 11 injuries
FURNACE EXPLOSIONS

During this past year a number of boiler furnace explosions have

occurred and have resulted in several deaths and many injuries. A
furnace explosion is usually a result of instantaneous
combustion of flammable gas, vapour or dust that has been
allowed to accumulate in the boiler. Precautions against
furnace explosions may include:

•Ensure that fuel valves on non-operating burners do not leak.

•Ensure that fan(s), dampers and burners are in good condition.

Purge the furnace each time before igniting the first burner.

•Ensure that fuel controls and flame safeguards operate as

required. Ensure the air intake is open and the stack is not
obstructed.
•Ensure that fuel system is free of contaminants.

•Ensure proper fuel/air ratio.

•Clean and service the guns before reuse.

•Do not use soot blowers to blow soot in a cold boiler.

•Ensure that limit and operating controls are in good

working order and are not by-passed or jumpered-out.
Seawater in the boiler
If the boiler had to be operated with seawater the salinity will rise
rapidly since the salt remains in the boiler while the water boils off.

Salt will son precipitate and accumulate on the bottom and also on
the heating surface where it, just as boiler-scales, inhibit the heat
transmission to the water and causes the metal to overheat and in
worst case burst.

You may also get foam in the boiler that will cause difficulties to
maintain the water level and water droplets might follow with the
steam, causing problems with turbines and engines.
It is very dangerous to operate a boiler with salt in it, and
you have to control the salt concentration by frequently
blowing off from the bottom of the boiler and form the
water surface to keep the salinity below 9.5%
(boilermakers and classification societies may
recommend other values).

It would also be a good measure to reduce the capacity of the

boiler.

After this emergency operation it would be wise to open up

the boiler for inspection since seawater promotes formation of
scale.
 Oil showing in the water level gauge glass

Stop the burner immediately.

Oil present, even small quantities, in boiler water will cause

foaming and moisture carry-over.

It also forms a heat insulating film, sometimes a carbonized layer,

over tubes or shell surfaces. Even a very thin layer may result in
tube or plate material failure due to overheating.

The oil manifests itself by forming an oily ring inside the water
gauge glasses, at the water level.
QUESTIONS AND ANSWERS
FOR BOILERS
What is Steam Hammering in Ship’s Steam System?

While working on ship or in steam system, one must have heard an

abnormal banging and rattling sound from the steam pipe. This is known
as Steam hammering.

Steam Hammering in Steam System

In a steam piping, when steam flow is suddenly stopped or condensed,
then it results in gaseous shock wave, which are thermal shock wave
resulting in to steam hammering.

Causes
Normally, if the steam piping system is not properly drained then the
steam travelling in the pipe will come in contact with cold water and
implode causing shock wave, developing thermal stress.
Boiler Gas side is cleaned during operation;

i. By means of steam, soot blowing

ii. By injecting soot remover powder (chemical) to the system.

To test a gauge glass, the following procedure should be followed:

•Close steam and water cock, open drain cock, nothing should come out
the cocks are not leaking.
•Open and close steam cock to check cock is clear.
•Open and close water cock to check cock is clear.
•Close the drain
•Now open water cock, water should gradually rise up the top of gage
glass.
•Open the steam cock, the water should fall to the level of the water in
the boiler.
What is the consequence of low water level? What is your immediate
action?

Boiler running without water will cause overheating the tubes, tube
plates and shell, that will lead the boiler to face thermal over stress
damage, crack or rupture to the tube, tube plates, shell plates.

However, low water level alarm should be activated and boiler firing
will shutdown.

If the boiler water level found minimum at the water cock level it is safe
to put feed water in the boiler.
What is the consequence of high water level? What is your action?

Ans: This will cause priming of the boiler, loss of heat from the
heaters, possibly loss of steam pressure.

As per as possible steam heating to be minimized temporarily, carry out

partial blow down to normal level. Then introduce normal heating again.
What is the purpose of treating boiler water?

Ans:
a) Prevent scale formation
b) Prevent corrosion
c) Control of sludge formation and prevent carry over to the system
d) Prevent entry of foreign matters to the boiler.

What is the problem if boiler water contaminated with oil?

Ans:
i) Create layer on the boiler plates, tubes etc and reduces heat transfer
and thermal stresses are induced.
ii) initiates corrosion
Question:
What will be the probable reasons, when the boiler load can not be
increased to peak conditions?
Answer:
Soot on the heating surfaces. Even a thin layer of soot will reduce the
boiler efficiency.
Not the right fuel for the burner.
Too low feed water temperature.

Question: Boiler manholes

Why are boiler manholes elliptical in shape?
Answer:
The boiler manhole-lids are mounted from the inside of the boiler so
that the boiler pressure will help to keep them tight. Hence the
manholes have to be elliptical in shape to make it possible to take the lid
out from the boiler.
Question:
Is it possible to overheat heavy fuel oil thus causing any water in it to
turn to steam and cause problems at the pump and burner?
Answer:

Yes it is. The temperature of the heavy fuel oil is very often 130°C to
150°C and water introduced to that temperature would immediately
evaporate into steam; well it depends on the pressure too.

Question:
How to operate auxiliary boiler onboard ship for at least 10 days period
when all boiler chemicals are finished.

Answer:
Pay attention to the measured values of the boiler water quality,
when/if the salt concentration increases then blow off from the bottom
of the boiler more frequently.
What is the proper maintenance of boiler:

Water Side:
Daily boiler water test.
Boiler water treatment.

Gas Side:
Regular cleaning.

Combustion System:
Fuel pressure, temperature and viscosity correct values maintained.
Burner maintenance.
Air register, Air damper and forced draught fan.
Effect of foaming and priming ?

1.Can cause water hummer

2.Can cause contamination and scaling.
3.Can cause fluctuation of working water level.

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.
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 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
What is meant by soot blow ?

•Purpose is to remove soot, to prevent EGE fire or soot fire.

•To get steam generating efficiency good
•To increase heat transfer efficiency
•Time – Day time at sea 2 -3 times/day

What is the procedure to soot blow ?

1.Inform to bridge
2.Check wind direction, good if transverse direction
3.Raise boiler pressure
4.Open drain cock until soot blow pipe drain clear
5.Open soot blower valve
6.Increase the air to boiler to more than 50 %
7.Open steam valve & carried out by turning wheel 20 -30 sec
8.Then close steam valve, soot blower valve
9.Open drain valve
Boiler safety valve examination and attention during
overhauling ?
•Checked its valve and valve seat for wear, cavity corrosion .
•They should be grounded properly but maker’s limit must be
maintained such as width of seating, clearance between valve
ex.
•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 .
•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.
•Connecting pin should be a free fit in the lid and pin should not
bent or pinhole gone out of shape.
What are the indication of tube leaking :

• White smoke
• Boiler Water Low Level Alarm
• Hot Well tank low water level
• Feed Pump running continuously
• Chane flame shape
• Noise
If the boiler water level low, what are the reasons?

1. Consumption rate is higher than the feed rate

2. Hot Well tank empty
3. Safety valve blowing
4. Blowdown valve leaking
5. Boiler tubes leaking
6. Feed water pump is not working properly
7. Heating coil is leaking
8. Faulty gauge glass
9. Faulty working water level transmitter
If the boiler water is low, what to do ?
1. Stop firing
2. Check the water level gauge
If water level is low then;
1. Inform the C.E
2. Stop feed pump
3. Shut main steam stop valve
4. Stop purifier if running
5. Go for a check

At sea;
1. If water level is below the gauge glass, it is unsafe to put water.
2. Inform the C/E
3. Stop feed pump
4. Inform bridge and reduce engine RPM
5. Shut main steam stop valve
6. Stop purifier if running
7. Go for a check
With the respect to contamination of boiler water by fuel oil
explain why the presence of oil is hazardous?

Oil will effect to the heating surface and causes;

1. Over heating
2. Poor heat transmission
3. Efficiency loss
4. Oil may cause acid corrosion
5. It may cause priming
What actions will you take in case of foaming and priming?

• Scum blow down

• Reduce boiler fire rate
• Check whether boiler chemicals added are excess
• In case of bad priming the boiler may have to be taken out of
service, shut down
• For contamination due to oil have to be chemically cleaned
What check should be carried out on a boiler during watch?

1. Steam pressure and temperature

2. F.O pressure and temperatures
3. Drain the water level gauge glass
4. Check the flow gas temperatures
5. Check the flame shape
6. Feed water pump pressure and temperatures
7. Feed water transmitter
8. Check safety valves
9. Hot well tank temperatuer and level
10.Hot well check for oil
11.Condenser cooling water temperatures
12.Check any leaking of pumps and valves
13.Blow down the boiler
14.Soot blow
Describe starting a boiler?

• Ensure that the vent valve on the boiler is open

• Check that the steam stop valve is closed.
• Check that all the valves for fuel are open, and let the fuel
circulate through the system Ÿ
• Check and open the feed water valves to the boiler and fill the
water inside the boiler drum to just above the low water level.
• Ÿ
Start the boiler in automatic mode.
• Check the combustion chamber from the sight glass to ensure
the burner has lit and the flame is satisfactory.
• Keep a close eye on the water level as the pressure increases
• Close the vent valve after the steam starts coming outside.
• Once the working steam pressure is reached, blow down the
gauge glass and float chambers to check for the alarms.
• Open the steam stop valve.
NEJAT ÖZTEZCAN CHIEF ENGINEER 248