Safety Operating Procedure of a Fire Tube Boiler

Joshua Nepomuceno1

Abstract: Boilers are pressure vessels designed to heat water or produce steam, which can then
be used to provide space heating and/or service water heating to a building. In most commercial
building heating applications, the heating source in the boiler is a natural gas fired burner. Oil
fired burners and electric resistance heaters can be used as well. Steam is preferred over hot
water in some applications, including absorption cooling, kitchens, laundries, sterilizers, and
steam driven equipment. Boilers have several strengths that have made them a common feature
of buildings. They have a long life, can achieve efficiencies up to 95% or greater, provide an
effective method of heating a building, and in the case of steam systems, require little or no
pumping energy. However, fuel costs can be considerable, regular maintenance is required, and
if maintenance is delayed, repair can be costly. Boilers are often one of the largest energy users
in a building. For every year a boiler system goes unattended, boiler costs can increase
approximately 10%. Boiler operation and maintenance is therefore a good place to start when
looking for ways to reduce energy use and save money. The objective of the experiment is to
learn the procedure of starting a boiler and to put into operation stream in generating sufficient
steam for power utilization purposes and the stopping of boiler for inspection, maintenance,
standby, and other purposes at the University of San Carlos Technological Center, Machine
Shop Boiler Room.

Author Keywords: Fire tube boiler, Fuel day tank, Pressure pump, Water softener

Student, Department of Mechanical Engineering, University of San Carlos, Cebu City, Philippines, Email:
nepomuceno.joshy@gmail.com

Introduction

depends on the type of fuel used in the

A boiler is an enclosed vessel that provides a

system.

means for combustion heat to be transferred

The water supplied to the boiler that

to water until it becomes heated water or

is converted into steam is called feed water.

steam. The hot water or steam under

The two sources of feed water are:

pressure is then usable for transferring the

Condensate or condensed steam returned

heat to a process. Water is a useful and

from the processes and Makeup water

inexpensive medium for transferring heat to

(treated raw water) which must come from

a process. When water at atmospheric

outside the boiler room and plant processes.

pressure is boiled into steam its volume

For higher boiler efficiencies, an economizer

increases about 1,600 times, producing a

preheats the feed water using the waste heat

force that is almost as explosive as

in the flue gas.

gunpowder. This causes the boiler to be the

Both gas and oil fired boilers use

equipment that must be treated with utmost

controlled combustion of the fuel to heat

care.

water. The key boiler components involved

The boiler system comprises of: a

in this process are the burner, combustion

feed water system, steam system and fuel

chamber, heat exchanger, and controls.

system. The feed water system provides

water to the boiler and regulates it
automatically to meet the steam demand.
Various

valves

provide

access

for

maintenance and repair. The steam system

collects and controls the steam produced in
the boiler. Steam is directed through a
piping

system

to

the

point

of

use.
Figure 1: Fire Tube Boiler

Throughout the system, steam pressure is

The burner mixes the fuel and

regulated using valves and checked with

oxygen together and, with the assistance of

steam pressure gauges. The fuel system

an ignition device, provides a platform for

includes all equipment used to provide fuel

to

generate

the

necessary

heat.

combustion. This combustion takes place in

The

the combustion chamber, and the heat that it

equipment required in the fuel system

generates is transferred to the water through

2

the heat exchanger. Controls regulate the

through a series of tubes surrounded by

ignition, burner firing rate, fuel supply, air

water. Alternatively, in a water tube boiler,

supply, exhaust draft, water temperature,

water flows in the inside of the tubes and the

steam pressure, and boiler pressure.

hot gases from combustion flow around the

Hot water produced by a boiler is

outside of the tubes.

pumped through pipes and delivered to

Fire tube boilers are more commonly

equipment throughout the building, which

available for low pressure steam or hot

can include hot water coils in air handling

water applications, and are available in sizes

units, service hot water heating equipment,

ranging from 500,000 to 75,000,000 BTU

and terminal units. Steam boilers produce

inputs. Water tube boilers are primarily used

steam that flows through pipes from areas of

in higher pressure steam applications and are

high pressure to areas of low pressure,

used

unaided by an external energy source such

applications. They typically range in size

as a pump. Steam utilized for heating can be

from 500,000 to more than 20,000,000 BTU

directly utilized by steam using equipment

inputs.

or can provide heat through a heat

exchanger that supplies hot water to the
equipment.
Boilers are classified into different
types based on their working pressure and
temperature, fuel type, draft method, size
and capacity, and whether they condense the
water vapor in the combustion gases. Boilers
are also sometimes described by their key
components,

such

as

heat

exchanger

materials or tube design. These other

characteristics are discussed in the following
section on Key Components of Boilers.
Two primary types of boilers include
Fire Tube and Water Tube boilers. In a fire
tube boiler, hot gases of combustion flow
3

extensively

for

comfort

heating

Boiler Room Floor Plan

Dimensions in inches (in.) and feet (ft.)

University of San Carlos Technological Center

Boiler Room, Floor Plan

Boiler Specifications of Parts

Blowdown

Fire Tube Boiler

Eliminating the water that was left inside the

boiler must be done before running an

Name: Kriekenbeek Boiler Works

operation of any kind of boiler especially to

Model: KBW 119-H

the case in which the boiler were stagnant

Serial #: KB -0430-119

for a very long time. Blowdown was done

Boiler Rating: 20 HP

by opening first the swing valve then

Heating surface: 100 ft^2

followed by the butterfly valve at the drain

Evaporation Rate: 690 lbs steam per

pipe beneath the boiler.

hour
Design Pressure: 150 psi

Softening of Feedwater

Max working pressure: 100 psi

The water from the water main tank

Year built: 1998

was delivered to the pressure tank of the

Booster Pump

water softener by the use of booster pump.

The brine tank was filled with salt then the

Type: Y90L-2

brine solution was added to the zeolites tank.

Three Phase Induction Motor

To activate the zeolites inside the zeolites

Power: 2.2 kW, 3 hp

tank, upwash and downwash procedure was

Speed: 3470 rpm

performed. To correlate downwash, all the

Centrifugal Pump

valves were closed and valves 4 and 6 were

opened. Then valves 4 and 6 were closed

Model #: 5KC39HN2701CX

and valves 5 and 7 now were opened to

Power: 1 1/2 HP

associate with upwash process. These

Speed: 3450 rpm

processes were done alternately over and

Water Day Tank

over again until the calcium and magnesium

Diameter: 2ft and 4in

content of the water were washed out. When

Length: 4ft and 4in

the water that washed out from the upwash

Fuel Day Tank

and downwash processes were already clear,

Diameter: 2ft

washing was brought to an end and the

Length: 3ft

valves to the water day tank were then

Boiler Operation
5

opened to fill it with soft water which will

immediately. At High Fire, whitish that

be supplied to the boiler on the operation.

gradually turns colorless came out the

chimney stack. The pressure gage of the fuel
pump and burner during the purging period

Starting the Boiler

The water level of the water day tank

registers more or less 100 psi.

was checked whether it was filled to the top

or not in order to be sure that there was a

Stopping the Boiler

sufficient supply of water for the boiler. The

The stop button was pressed down.

valve from the softener was opened to admit

The characteristic behavior of the burner-

water into the feedwater day tank during the

fuel pump was observed. The pressure

lowering of the water level. The fuel day

reading of the burner and the feedwater

tank was checked and the level gage was

pump was monitored. The operator may

inspected if it was full or empty. For low

now leave the steam generating unit to

level, the valve of the pipe connecting the

standby when all safety precautions were

fuel storage tank was opened. Situated

observed.

behind the Control Panel at the side of the

boiler, the water level at the float level gage

Data Gathering

was checked. The main switch was switched

The time during the start of the

on at the circuit breaker. The Control Panel

experiment was recorded. The time the 100

Board was opened and the three magnetic

psi reading was obtained and the duration of

switches were switched on which were all

firing in the steam generating unit was again

situated inside the Control Panel Box. The

recorded. The volume of water added to the

Main Control Switch on Control Panel

boiler and the number of minutes the

Board was switched on by turning the

feedwater pump was operating was then

switch on then the red lamp lit up. The start

recorded. The consumption of the fuel was

button was pressed and the fuel burner starts

recorded by taking readings at the fuel day

purging. After waiting for 15 seconds, the

tank.
The thermal efficiency, th of the

Low Fire ignites and after waiting for

another 15 seconds, the High Fire ignites.

boiler was calculated using the equation:

During the Low Fire, the smoke coming out

of the chimney stack was then observed
6

= 3140 + 2991 + 12207

()
=
( )

= 18339.16 3

The tank was filled with diesel fuel.

The tank was filled with soft water.

The initial fuel level was 14, and dropped

The initial water level was 15.8678, and

to13 2/16for the whole duration of the

reached 25.9 after 335 seconds.

experiment which lasted 37 minutes and

= 2 196 2

45.7 seconds.

= 52" 2

25.914

196 2

= 2 196 2

15.867814

= 12207.123
=

12207.12
355

13.12514

196 2

= 36 2

1514

= 1888.5683

3
= 34.39
=

= 1888.568 2.543

0.885/1000

The booster pump was turned on

= 27.389

again when the water level was at 6.5338

while the feedwater pump was pumping
water to the boiler. After 87 seconds, the
water level dropped to 3.7336 and both

Boiler Code Standard

pumps were switched off.

Section 1.0 General Requirement for Boiler

= = 34.39
= 2991.60

87

and Pressure Vessel Installation

1.2 Locations

a.

Steam

boilers

should

preferably be located in detached buildings

= 52"

of fire resistant construction used for no

3.733614

196 2

other purpose and situated not less than 3 m

6.533814

distance from building not forming part of

= 3140.443

factory, or in structures of fire resistant

materials, preferably stone or concrete walls
7

connected to or in close proximity to other

factory buildings.

1.3 Steam Boiler Rooms

a. Although not to be used for

The criterion states that steam boilers

passage, boiler rooms should be provided

should preferably be located in detached

with two doors preferably on opposite ends

building and this was not followed by

or sides which if locked may be opened

the university because the boiler room

without key from the inside.

was on the same roof next to the

university machine shop. This criterion

Though the first part of this criterion is

according to the PSME Code must be

followed, the last part contradicts also.

followed in order to refrain from any

Which if locked may be opened without

injury or casualty if any fire or explosion

key from the inside. The door facing

that may happen inside the boiler room.

the registrars office need to open from

the outside due to only a padlock was
used for locking the room. And this must

b. No part of the steam boiler

not be made in order for the safety of the

should be closer than one meter from any

boiler operator inside the boiler room

wall.

that he/she may exit the room at all

This criterion was not followed by the

university

registered

his/her cost if any complexity such as

mechanical

explosion, fire and etc. that may happen

engineer and professional mechanical

inside the boiler room.

engineer because as seen on the boiler

room floor plan, almost all of the parts

1.7 Ceiling Clearance

of the boiler if not being close to the

a. When boilers are replaced

wall, would be close to any sub-part of

or new boilers are installed in either existing

the operation like the brine tank, zeolites

or new buildings, a minimum height of at

tank and etc. The criterion is important

least 2130 mm shall be provided between

to be followed for the mechanical

the top of the boiler proper and the ceiling

engineer that is assigned to check for

except in single installation of self-contained

any maintenance to never have a hard

boilers where a minimum height of at least

time in going through all its parts and

915 mm shall be provided between the

sub-parts.
8

highest point of any valve steam or fitting

h. Ladders and Catwalks. A

and the ceiling.

steel catwalk or platform at least 455 mm

wide and provided with standard handrails

The ceiling clearance of the university

and toe-board on either side shall be

boiler room didnt reach the standard of

installed across the tops of adjacent boilers

the PSME Code. The clearance of the

or at some other convenient level for the

highest point of any valve steam or

purpose of affording safe access to the

fitting and ceiling must be at least 915

boilers. All catwalks shall have at least two

mm.

means of exit, each exit to be remotely

located from the other, and connected to a

1.8 Other Requirements

permanent stairway or inclined ladder

a. All boilers and unfired

leading to the floor level.

pressure vessels shall be so located that

The standard didnt meet with the design

adequate space shall be provided for the

and output of the boiler room in the

proper operation of the boiler and its

university because no

appurtenances, for the inspection of all

ladders and

catwalk was found inside the boiler

surfaces, tubes, water walls, economizers,

room. The ladders and catwalks must be

piping, valves and other equipment and for

installed in order for the purpose of

their necessary maintenance and repair.

affording safe access to the boilers.

The space requirement inside the boiler

room is of great significance for in

Section 6.0 Boiler Inspection

viewing the inspection of all surfaces,

6.6 Care and Maintenance

tubes, water walls, economizers, piping,

6.6.1 Housekeeping

valves and other equipment and for their

Generally,

necessary maintenance and repair may

neat

boiler room indicates a well-run plant. The

be without difficulty. With correct

boiler room should be kept free of all

positioning, it can shorten the time of the

material and equipment not necessary to

inspector in verifying all equipment of

operate

the boiler.

the

power

boiler.

Good

housekeeping should be encouraged, and

procedures should include routine inspection

that their boiler room must be closed for the

to maintain a desired level of cleanliness.

safety of not just by the mechanical

engineering students, teachers and faculty

As observed inside the boiler room, the

but also to the people passing by and offices

boiler and all its equipment even the

erected near the boiler room.

chairs were covered with dust particles.

No forms of any housekeeping were
maintained in the boiler room. The 5S
(seire/sort,

Notation

seiton/systematize,

seiso/sweep, seiketsu/ standardize, and

shitsuke/self-discipline) system is a good
method of solving and manufacturing
housekeeping not only at the workplace
but in everyday life.

= thermal efficiency, %

= mass of water or steam, kg

= change in enthalpy, KJ/kg

= mass of fuel consumed, kg

= heating value of diesel fuel, KJ/kg

= volume added, in3

Conclusion

References

From the PSME codes and standards, it can

Philippine Society of Mechanical Engineers

be clearly seen that many standards were not

Code, 2003 Edition

followed on the design and output of the

Gunn, D., and Horton, R. Industrial Boilers,

boiler of the University of San Carlos

Longman Scientific & Technical, New York

Technological Center such as the General

Requirement for Boiler and Pressure Vessel

Shields, Carl D. Boilers, McGraw Hill Book

Installation

Company, U.S, 1961.

Location,

Boiler

Room,

Clearances, Boiler Inspection, Care and

Jackson, J. James, Steam Boiler Operation.

Maintenance and etc. If I would be the

Prentice-Hall Inc., New Jersey. 1980.

Professional Mechanical Engineer that will

be inspecting the boiler of the University of

Considine, Douglas M. Energy Technology

San Carlos, I would strongly recommend it

Handbook. McGraw Hill Inc, New York.

to revise all the design on their blueprint and

1977.

if it is difficult to modify then I will suggest

10