Boilers

Package Boiler

Class 2 Boilers

Low Level x 2, High Level and Feed Control

Steam Space Stay Bars

Safety Valves

Vacuum Breaker

Pressure Alarms / Automation

Main Stop Pressure Gauge Gauge Glass

Manhole

Scum Valve

Furnace Door Refractory Burner Unit

Inspection Door

Heating Coil

Sample Cock

Main and Auxiliary Feed

Blowdown Valve
Class 2 Boilers

Boiler Fittings
The minimum fittings required are: Safety valves. Water Level indicators. Low water alarm and shut down. Main Stop valve Feed Cheek valves Pressure Gauge Salinometer Valve Blow Down Valve Manhole
Class 2 Boilers

HSE Rules
9 Water level controls and the first low water alarm which also extinguishes the burner may be housed in the same external chamber or internal protection tube. Additionally a separate chamber or internal protection tube with an independent electrical control circuit is required for an overriding second low water alarm and fuel cut out; this should be a lock out type requiring manual reset (para 17(c)).
Class 2 Boilers

c Automatic firing controls so arranged that they effectively control the supply of fuel to the burners on oil or gas fired boilers, or air to solid fuel fired boilers, and effectively shut off the supply in the event of any one or more of the following circumstances: (iv) when the water level falls to a predetermined point below the normal operating level. When the water level is restored the burner may be automatically refired; Note: In the case of (i) (ii) and (v), these controls should be of the lock out type requiring manual resetting. In the case of (iv) this control should cut off the fuel/air supply and cause an audible alarm to sound.
Class 2 Boilers

Exhaust Gas Boiler

Low Level x 2, High Level and Feed Control
Steam Space Stay Bars

Safety Valves

Vacuum Breaker

Pressure Alarms / Automation

Main Stop Pressure Gauge Gauge Glass

Manhole

Scum Valve Exhaust Trunking

Inspection Door

Heating Coil

Sample Cock

Main and Auxiliary Feed

Blowdown Valve Class 2 Boilers

Manhole Door

Class 2 Boilers

Fuel Shut Off

Electric Heater
P PC P L

Pressure Control

Fuel Oil Service Tank

Control

Alarm and ShutDown

Q.C. Valve

Steam Heater

Feed Control

Class 2 Boilers

Class 2 Boilers

Boiler Tubes

Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

Increased Area for Steam Pressure to Act Steam Guided to Act Under Valve

Class 2 Boilers

Exhaust Steam Acts On Lower Spring Carrier Giving Extra Lift

Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

SALTS IN FEED WATER

NONE HARDNESS, SOLUBLE SALTS SODIUM SALTS

HARDNESS OR SCALE FORMING SALTS CALCIUM AND MAGNESIUM SALTS

SOLUBLE UNLESS VERY HIGH CONCENTRATIONS

ALKALINE OR TEMPORARY HARDNESS SALTS BI-CARBONATES

NON ALKALINE OR PERMANENT HARDNESS SALTS CHLORIDES, CARBONATES, SULPHATES

DECOMPOSE TO FORM CO2 AND SCALE

FORM SCALE OR ACID SOLUTION

Class 2 Boilers

Class 2 Boilers

Boiler Pressure Low Y Boiler Level OK Y Start Burner Control

N Stop Fan Lockout, Manual reset Y Purge Time Complete N

Fuel Temp and Pressure OK Y Start Fan, move damper to max

N Reduce Fuel Pressure, Stop Pump, Switch Off Heater Y Boiler Pressure High N

Air Pressure OK

N Control Fuel and Air supply to Requirements

Y Purge Time Complete Y Start Igniters N N

Y Flame Detected

Damper to min, Fuel Control to min

Class 2 Boilers

Uptake Fires
Prevention. Regular soot-blowing to prevent build up of carbon ash Ensure circulation of boiler Early detection of soot fires. If boiler/economiser is leaking and has to be run dry
Increase frequency of sootblowing Remove cover to prevent build up of pressure Fully drain boiler

Soot Fires. Stop engine as soon as possible Continue circulation of boiler/economiser, unless water is being lost, if so drain completely. Do NOT use soot-blowers Stop air circulation through engine Use water washing to fight fire (if fitted) otherwise wait and prepare boundary cooling.
Class 2 Boilers

Uptake Fires
Hydrogen Fires. Stop the main engine as soon as possible Stop circulation of boiler/economiser and close valves Drain the boiler/economiser Stop air circulation through the engine Boundary cool Fire may be extinguished by large amounts of water directed to the heart of the fire (DnV).
Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

Class 2 Boilers

Initial Boiler Entry

Permit to Work. Isolate all fires by shutting off the burner fuel inlets. Close feed inlets Let the boiler cool down until about 3 4 bar steam pressure remains Open the blowdown line to empty the boiler drum. When about 2 bar pressure remains in the boiler drum open the air vent and leave open Prepare to open the manhole doors by loosening nuts and breaking seal when the steam drum pressure has reduced to atmospheric (22.5.1) Remove top doors first, and then bottom after ensuring contents drained. Thoroughly ventilate. Personnel should not enter boiler, furnace or flue until the unit has cooled sufficiently. (22.5.2) Ensure all connections to drum are either blanked off, removed or valves locked in closed position with posted notices. (22.5.3) All personnel working on boiler require PPE. (22.5.4) Treat the boiler as an enclosed space, so ventilate and test atmosphere for oxygen content (22.5.5)
Class 2 Boilers

Oil Contamination Of Boiler

Change feed to an uncontaminated supply. Do not blow down the boiler from the bottom; just surface blow (scum) several times. If you bottom blow the boiler, it will become totally covered in oil. The boiler should be shut down and released from pressure and the venting valve opened. Drain the boiler slowly until water stops flowing from the loosened, upper manhole door before opening up the manhole for inspection. The oil will now only cover the boiler in the normal water level range and can be manually removed. Hot or cold water high-pressure jet equipment together with oil dispersive additives would be efficient for removal of the oil. In case the boiler is completely oily inside, the cleaning work should be turned over to a cleaning company specialised in such work. A full alkaline wash of the inside and complete structural inspection would be required.
Class 2 Boilers

Boiler Inspection
FIRESIDE
Loss or refractory Condition of the refractory around the burner and the back wall, as these areas suffer from high temperature cracking. Distortion to any metal surfaces including the furnace and the tube plates Condition of the furnace floor looking for signs of oil contamination Signs of overheating at the burner assembly. Tube ends for signs of leakage, creep cracking.
Class 2 Boilers

Boiler Inspection
WATERSIDE
Integrity of the bottom blow down pipe and other internal fittings. Boiler bottom plate (furnace top fire tube boiler), furnace wall for steam bubble pitting Mechanical grooving of boilerplates at internal supports Oxygen pitting of shell at the water line Thinning or necking of the tubes Pitting of the boiler tubes Feed and scum pipe integrity Oxygen pitting in the steam space Condition of manhole opening, joint faces, welds, corrosion Steam space stay condition. Scale deposits Condition of welds Class 2 Boilers Blockages in pipes for mountings

Boiler Inspection
SHELL

Condition of lagging Signs of leakage Fit of manhole door and condition of securing device Overhaul all valve and fittings;
Check for corrosion. All parts should be made from non-corrodable material Check valve seat faces free from defects and face width not excessive Check valve bodies for corrosion and cracks Hang all components and check free from cracks by NDT inspection Check spring length, and carry out NDT inspection Check valve spindle straight Cheek valve body drain clear Check easing gear operation and condition

For safety valves

Class 2 Boilers

Refilling And Raising Steam

Replace all mountings, ensuring correct fitting and direction of flow. Replace inspection covers, ensuring securing devices not overightened. Refill boiler water, adding correct chemical dosage. Level should be just above Low Level alarm. Check operation of level alarms, feed controls, automation pressure switches. Ensure all valves are in their working positions, test gauge glasses. Check burner controls and cut outs. With the vent open, start to warm the boiler. Firing should initially be for short periods (5 mins) with a break (15 mins) to allow the boiler to warm through evenly. When steam is coming out of the vent, (2 bar pressure), close vent and bring boiler to working pressure. Set safety valves. Test all alarms and shutdowns. Check tightness of glands and bolts. Check tightness of manhole and inspection covers.
Class 2 Boilers

Adjustment Of Safety Valves.

Calibrate pressure gauge and check pipes clear Raise steam Steam outlet closed Gag one valve Raise pressure and adjust valve to open at required pressure Check blowdown Change over gag Repeat 5 & 6 Remove gag Lock valve adjusters / make and fit spacers Recheck opening pressure Check easing gear and seal covers Check alarms and burner operation
Class 2 Boilers

Soot Fires
Action Stop engine as soon as possible Continue circulation of boiler/economiser, unless water is being lost, if so drain completely. Do NOT use soot-blowers Stop air circulation through engine Use water washing to fight fire (if fitted) otherwise wait and prepare boundary cooling. Prevention Regular soot-blowing to prevent build up of carbon ash Ensure circulation of boiler Early detection of soot fires. If boiler/economiser is leaking and has to be run dry
Increase frequency of soot-blowing Remove cover to prevent build up of pressure Fully drain boiler

Class 2 Boilers

Hydrogen Fires
Conditions Required Tube metal temperatures of over 705C Tubes with some steam content (poor circulation) The presence of a catalyst in the form of a carbon ash. Prevention. Regular sootblowing to prevent build up of carbon ash Ensure circulation of boiler If boiler to be run dry, drain and vent to eliminate possibility of steam presence Fighting. Shut of air by gagging turbo blowers wet canvass over intakes, ensure exhaust valves closed Boundary cool
Class 2 Boilers

Typical Analysis of Sea Water. Calcium Bicarbonate 200ppm Ca(HCO3)2 Calcium Sulphate 1200ppm CaSO4 Magnesium Sulphate 2000ppm MgSO4 Magnesium Chloride 3300ppm MgCl2 Sodium Chloride 25300ppm NaCl

Typical Analysis of Fresh Water. Sodium Chloride 50ppm Magnesium Sulphate 30ppm Calcium Sulphate 90ppm Calcium Carbonate 200ppm

Class 2 Boilers

Scale Forming Salts.

Magnesium Chloride Decomposes to form hydroxide and hydrochloric acids. The former will produce hard scale and the later lowers the pH. MgCl2 + 2H2O 2HCl + Mg(OH)2 Magnesium Sulphate Forms a hard scale on the heating surfaces Calcium Sulphate Forms a hard scale on the heating surfaces Calcium Bi-carbonate Decomposes at a low temperature when CO2 is liberated. Remaining Calcium carbonate deposits on the heating surface as a soft scale. Ca(HCO3)2 CaCO3 + CO2 + H2O
Class 2 Boilers

Boiler Treatment
ALKALIS Sodium Carbonate (soda ash). Reacts with nonalkaline hardness salts by either precipitating them, or converting into sodium salts, which stay in solution. Excess Sodium carbonate remains in solution to provide an alkalinity to reduce corrosion. Na2CO3 + CaSO4 CaCO3 + Na2SO4 Sodium Hydroxide. (caustic soda) Reacts with magnesium chloride producing a harmless precipitant and sodium chloride, which remains in solution. It is not suitable for premixing with other chemicals. But can be used in conjunction with other chemical treatments. 2NaOH + MgCl2 2NaCl + Mg(OH)2
Class 2 Boilers

Boiler Treatment
PHOSPHATES Disodium Phosphate Dissolves in water and forms a neutral solution. Reacts with magnesium and calcium sulphates and precipitates them as phosphates, or converts them to sodium salts, which will remain in solution. Na2HPO4 + MgSO4 MgHPO4 + Na2SO4 Trisodium Phosphate Dissolves in water to produce disodium phosphate and

sodium hydroxide, an alkaline solution.

Na3PO4 + H2O

Na2HPO4 +

NaOH

The function of both these chemicals is to prevent scale formation by precipitating the salts of magnesium and calcium as a soft sludge.
Class 2 Boilers

Boiler Treatment
Coagulants (Starch, Tannin, Sodium aluminate) These chemicals attract the sludges which float in the boiler water. They keep the sludge in suspension and so avoid any build up of sludge on the heating surfaces. Can also help in the reduction of foaming and also keep any oil present in an emulsified form.

Class 2 Boilers

Boiler Treatment
OXYGEN SCAVENGERS Presence of oxygen in the boiler water will result in serious corrosion. To reduce the amount of oxygen present in the boiler water oxygen scavengers are used. These are Hydrazine or Sodium Sulphite Hydrazine N2H4 + O2 2H2O + N2 Sodium Sulphite 2NaSO3 + O2 2NaSO4

Class 2 Boilers