TOPIC : STEAM BOILER ATOMIZATION & COMBUSTION

Combustion

Combustions - is the rapid oxidation of a substance accompanied by the release of

considerable amount of heat and by a large increase of the temperature of a substance
involved.
For such burning to take place, there are four prerequisites;
Fuel – the substance that will burn
Oxygen – to support combustion of the fuel
Mixing – the oxygen and the burning substance must be mixed to allow all of the fuel to
burn.
Ignition – the fuel must be ignited or brought up to a suitable temperature.

For Fuel Oil:

Specific gravity – is the ratio of unit weight of a substance to that of the same weight of
water. Specific gravity of oil varies with changes in temperature, it is necessary to calculate
the sp.gr. at standard temperature.
To calculate the sp. gr. of an oil at any temperature, if its sp.gr. is given (at 60F or
15°C):
Take the number of degrees above or below 15°C. Multiply by the constant 0.00034.(0.0034
is the coefficient of expansion of standard fuel oil.)The resultant figure is either added or
subtracted from the original sp.gr.

Example: The sp.gr. of 18 API fuel oil at 15°C is 0.9465. What will be the specific
gravity at (a)65°C (b) 0°C?

Difference in temp.; 65°C – 15°C = 50°C; 50 x 0.00034 = 0.017

Sp.gr. at 15°C = 0.9465; 0.9465 – 0.017 = 0.9295 sp.gr. @ 65°C.

Difference in temp. = 15 – 0 = 15°C; 15 x 0.00034 = 0.0051

Sp.gr at 15°C = 0.9465 ; 0.9465 + 0.0051 = 0.9516 sp. gr. @ 0°C

Note: Specific gravity of fuel decreases when temp. increases and increases when temp.
decreases from standard condition. Correspondingly, as temperature increases, the specific
volume increases.
Types of hydrometer used to measure the specific gravity of Oil:

1. Baume hydrometer – invented by French chemist, Baume, scales are graduated to

measure liquids lighter than water. °Baume = (140/ sp.gr. @
60/60°F) – 130

BAUME HYDROMETER

A.P.I. HYDROMETER

2. A.P. I.(American Petroleum Institute) hydrometer– is an American standard

of measurement used by petroleum industry.
°API = (141.5/ sp.gr.@60/60°F) -131
Calorific value – is the measure of the amount of heat contained in a fuel and is the
number of Btu’s contained in one pound of that fuel.
Bomb calorimeter – is a device used to measure the calorific value of any fuel

BOMB CALORIMETER
Throttling calorimeter – is a device used to measure the moisture content of
steam.
Pyrometer – is an instrument used to measure temperatures higher than those
that can be measured by mercurial thermometers.

Types of pyrometers;
1. Optical pyrometer - is a device which allows contactless temperature
measuring by using the incandescence color

OPTICAL PYROMETER

2. Radiation pyrometer - is a pyrometer for estimating the temperature of distant

sources of heat; radiation is focused on a thermo junction connected in circuit with
a galvanometer
3. Thermoelectric pyrometer - is a thermocouple consisting of two dissimilar
metals sealed at one end and open at the other end placed in a place to be
measured. The open end are connected to a sensitive millivoltmeter which
is mounted on a panel board. The difference in temperature detected
produces difference in electrical potential. This small voltage, produces a
current flow which actuates the millivoltmeter. Since millivoltmeter are
calibrated in degress, it serves as a very accurate temperature indicator.

DIGITAL THERMOELECTRIC PYROMETER

ANALOG THERMOELECTRIC PYROMETER

Advantages of Oil as fuel compared to Coal;
- Oil has higher calorific value
- Oil may be stored in double bottom tanks.
- Burning of oil requires fewer men
- Oil is cleaner, no ashes to be removed

Disadvantages of Oil as fuel;

- Requires heating equipments, pumps and piping
- Gives off flammable vapors w/c burn easily, so represent fire hazards.
- Higher cost than same weight of coal.

Desirable properties of Fuel Oil;

1. Flash point and fire point should be fairly high. The minimum flash pt. 150°F
2. Viscosity should be low to reduce the amount of heating necessary to insure
flow and proper atomization.
3. Heating value should be high. (18,500 Btu/lb – 19,500Btu/lb)
4. Ash content should be low.
5. Impurities should be at minimum.
6. Water content should be low.
7. Asphalt content should be low.
8. Sulfur content should be low.
9. No free acids(free acids refers to sulfur and the like which unites to oxygen and
water to form acids.)
10. Carbon and hydrogen content should be fairly high

Flash point – a temperature of fuel oil in which flammable vapor is given off.
Fire point – a temperature of fuel oil in which given off flammable vapor continuous
to burn even if igniter flame is removed.

Fuel Oil settling tanks;

Settling tank - where oil is transferred from storage tank to allow settling of
impurities and water.
Service tank - also known as circulating tank where purified fuel is stored ready
for consumption.
Pneumercator -is a device used to indicate the level of fuel oil in the settling
tanks. Fuel oil level pressure produces a corresponding level of
mercury in the gauge.
Fuel oil strainers - is a fuel oil system component that prevent foreign matters
from passing with the oil to the burners.

Fuel oil heaters – increased the fuel oil temperature until its viscosity is
sufficiently reduced to secure good atomization at the burner.
Combustion Air
Air is forced into the furnace by a forced draft blower. The forced draft blower is a large
volume fan that can be powered by an electric motor or a steam turbine. The forced draft
blower blows air into the outer casing of the boiler. The air then travels between the inner
casing and outer casing to the boiler front where it is forced into the furnace through the air
registers. The air registers are part of the fuel-oil burner assembly
that consists of four main parts: air doors, a diffuser, air foils, and the atomizer
assembly. Figure 1, shows a side view of a fuel-oil burner assembly.

Atomizer is a part of fuel burner where fuel is break up into fine particles and sprayed in
the combustion chamber to mix with air.

Principle of Atomization:
The primary function of atomizer is two- fold; first it must break up the oil into fine particles,
small enough to present a large contacting surface to the air for combustion, and secondly it
must project this oil spray in such direction that it will be intercepted by and mix with the air
stream supplied by the air-control register.
The air register is much more important device than the atomizer. The atomizer and air
register are developed together to secure optimum burner performance particularly where
range of operation are required. In general, the greater burner windbox pressures are
required for best burner performance as burner size increases.
It is important to correctly position the atomizer in the burner. If the atomizer is shoved in
too short, an eddy is formed in the entering air current. A fine fog of oil is drawn back
behind the face of the tip and is deposited back on the atomizer pipe and tip. If it is shoved
in too far (near the brickwork), oil sprays onto the brickwork before the oil has had an
opportunity to become atomized and mixed with air, and causes the formation of carbon on
the edges of furnace openings.

Methods of atomization:
1. Dynamic pulverization - is a method of atomization by pressure in w/c fuel pump
pressure is converted into velocity force projecting oil particles in
diverging path to mix with air.
2. Steam atomization - is a method of atomization where steam is used. Oil passes
through the annular passage of the atomizer and steam through the
inner tube to a sprayer plate where they mixed before discharging.
3. Mechanical atomization - is a method of atomization where it employ only the
pressure of the oil as it is delivered to the burner. Oil is sprayed into the
furnace in the form of fine mists, w/c assumes the shape of a cone with
its apex at the tip of the burner.
Boiler Fuel Oil Atomizers

Good combustion is essential for the efficient running of the boiler. It gives the best possible
heat release and minimum amount of deposits on the heating surfaces.

Types of fuel oil atomizers are:

1. Simple Pressure Jet Atomizer Different
- Figure below shows diagrammatically the principle of the simple pressure jet
atomizer. Oil fuel at a pressure of not less than 8 bar is supplied to the
tangentially arranged ports, wherein it falls in pressure, resulting in the oil
swirling around at high velocity inside the chamber. The greater the pressure
drop the greater would be the velocity, but generally supply oil pressure would
not be greater than 25 bar, high pressures create pumping and sealing problems.
At outlet from the short sharp edged orifice (care must be taken not to damage
the orifice during cleaning) a hollow expanding cone of fuel droplets is produced
whose initial film thickness reduces as oil supply pressure increases.
The following features of the simple pressure jet atomizer should be noted.
Simple, inexpensive and robust. No moving parts, hence no possibility of seizure.Large range
of droplet size for one pressure.

2. Spill type of pressure jet atomizer - With this type of atomizer throughput is varied
by adjusting the amount of spill, that is the return flow from the burner.

3. Constant differential type atomizer

- With the differential pressure between delivery and spill kept constant the
pressure drop across the tangential ports is kept constant and the rotational
velocity of the fuel in the swirl chamber will not alter. This will keep fuel
cone angle and atomization constant. The main disadvantage with these
types of burner is the large quantity of hot oil being returned, it may
prove difficult to keep control over oil temperature.

4. Plunger type of pressure jet atomizer

- Figure below shows the principle of operation of this type of burner, as the oil
supply pressure is increased the spring loaded plunger moves to uncover extra
tangential oil entry holes. The pressure drop and hence the rotational velocity
of the oil remains nearly constant.
5.Rotary or spinning cup jet atomizer - Figure below shows the arrangement in
principle. It consists of a motor driven fan, metering pump and fuel cup

The fuel cup which rotates at 70 to 100 rev/second is supplied with oil at low pressure (1.7
to 4.5 bar) from the metering pump which is used to control the throughput. Due to
centrifugal force and opposite swirl of air to fuel the oil film leaving the cup is rapidly broken
down into relatively even sized droplets.

Oil temperatures and pressures

- To obtain best result from the stand point of atomization, the fuel oil should
be heated to 100 - 130°C. Pressure at the burner varies with the capacity
required, but it should not be lower than 7 kg/cm².For higher capacities
pressures as high as 20 kg/cm² is used.
 TOPICS 3 & 4:
MARINE BOILER FUNDAMENTALS / CONSTRUCTION

Boiler - is one of the principal components of steam power plant. It is said to be the heart
of the steam power plant. It generates steam through the boiling of water.

Working Principle of Boiler

The basic working principle of boiler is very simple and easy to understand. The
boiler is essentially a closed vessel inside which water is stored. Fuel (generally coal) is
burnt in a furnace and hot gasses are produced. These hot gasses come in contact with
water vessel where the heat of these hot gases transfer to the water and consequently
steam is produced in the boiler. Then this steam is piped to the turbine of
thermal power plant. 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.

Parts of Steam Generating Unit or Boiler:

1. Combustion chamber or furnace – a component where fuel is burnt to release its energy
and transferred to the water.
2. Water wall tubes and floor tubes – are part of boiler tubes located on places as the
implied where water are circulated to maximize the usage of flue gas.
3. Downcomers – are tubes used to circulate feedwater between the steam and water
drums.
4. Steam drum – the upper side drum where steam is produced and the feed water enters.
5. Water drum – the lower drum connected to the steam drum by a bank of generating
tubes, sometimes called the mud drum.
6. Superheater – are bank of tubes where saturated steam from the steam drum are passed
to further heated and dried to increase its temperature and pressure.

7. Attemperator – a steam cooler fitted in the system to control the superheated steam
temperature.
8. Economizer – a component of steam generating unit where feedwater is heated before it
enters the steam drum.
9. Air heater – a component where the product of combustion passes to warm the air
before it enters the combustion chamber.

6 Basic Types of tube in a watertube boiler

1. DOWNCOMERS—These tubes have a large diameters of w/c main function is to circulate

water from the steam drum to mud drum or any collecting bottom
headers. The downcomers are normally placed outside the boiler casing
so that it cannot absorb heat. Fresh boiler feed water flows through
downcomers by gravitation and introducing heat to the dowcomers
will cause reversal flow and upset the boiler natural circulation.
2. GENERATING TUBES—These tubes from a large bank of heater exchangers and located at
the convective bank of the boiler. The heat occurs through convection.
The tubes from largest heating surface thus the highest proportion of
steam generated in the generating tubes.
3. RISERS—The return steam and water from the top waterwall headers to the steam drum.
4. WATERWALL Tubes—These tubes protect the boiler sidewall refractory from the direct
heat of combustion and generate a small amount of steam. There are
many types of waterwall tubes construction.
5. SUBERHEATER—Consists of small-diameter tubes (OD is in the range of 32 – 51 mm and
thickness in the range of 3 – 7mm), and receives saturated steam from
the boiler proper and superheat the steam.
6. SCREEN TUBES—Protect the convective superheaters from direct radiant heat from the
furnace. The screen tubes consist of two to three staggered rows of
tubes, which are usually connected from the steam drum to the water
drum.

Classification of Boilers
1. Smoke tube or Water tube
2. Internally or Externally fired
3. High or Low pressure
4. Natural or Forced circulation of water
5. Stationary, Marine or Locomotive
6. No. of drums – single or multi-drum
7. Gas flow
8. Natural or Forced draught
9. Heat source – solid/liquid/gas/nuclear/waste gas
10. Single or Dual evaporation

Services supplied by steam:

On board the ship, steam are used in;
1. Drives turbine or steam engine
2. Drives deck machineries like windlass, mooring winch and cranes
3. Distilling plant to produce fresh water
4. Space heating
5. Oil heating
6. Fuel heating
7. Water heating
8. Galley and laundry use

Types of water- boiler:

A. Natural circulation Water-tube boiler
- Water circulation in a “natural circulation water-tube boiler” uses the concept about
the density of water. When water is cold it is denser, so it sinks; hot water is lighter, so
it floats. The circulation of feed water inside the boiler from the steam drum flows
down passing through the large bore downcomer tube then to the mud drum. From
the mud drum, very hot boiling water rises up carrying steam bubbles then passes
through the generating tubes upward to the steam drum.
B. Forced circulation Water-tube boiler
- Feed water to boiler is forced to circulate by the use of circulating pump. It circulates
the water almost ten times the steam production rate thus giving good heat transfer.

“D type” water-tube boiler – the furnace is at the side of the two drums and is surrounded
on all sides by wall of tubes.
External superheater “D type” – used primary and secondary superheater located after the
main generating tube bank.
Radiant-type boiler – a type of water-tube boiler in which the radiant heat of combustion is
absorbed to raise steam, being transmitted by infra-red radiation.
Composite boiler – a type of water-tube boiler where arrangement permits steam
generation either by oil firing when necessary or by using the engine
exhaust gases when the ship is at sea.

Advantages of Water Tube Boiler

There are many advantages of water tube boiler due to which these types of boiler are
essentially used in large thermal power plant.
 1) Larger heating surface can be achieved by using more numbers of water tubes.
2) Due to convectional flow, movement of water is much faster than that of fire tube
boiler, hence rate of heat transfer is high which results into higher efficiency.
3) Very high pressure in order of 140 kg/cm2 can be obtained smoothly.

Disadvantages of water-tube boiler:

- Use pure water
- Must received constant supervision as regards both water level and steam pressure.
- Boiler must be heavily insulated to minimize radiation losses.
- First cost is higher
- To make repair on tubes, boiler must be emptied.
Fire-tube boiler - a type of boiler where the product of combustion passes through the
inside of the tube and water surrounds the tubes.

Three types of fire-tube boiler:

1. Scotch boiler – have horizontal tubes and commonly used in marine works.
2. Leg-type boiler – also has horizontal tubes.
3. Vertical boiler – tubes are installed in vertical position and the combustion gases, after
passing through the tubes, go directly to the smokestack.

Advantages of fire-tube boiler:

1. They contain large amount of water, and so do not require exacting supervision as
regards to water level. Steam pressure is steadier.
2. Use impure water without serious damage.
3. First cost relatively low
4. Easily accessible for maintenance
5. Radiation losses are lower

Disadvantages of fire-tube boiler:

1. Require long interval time to raise steam
2. More susceptible to explosion
3. High steam pressure would require thick boiler plate
4. Require large entrances into the fire room because they are generally riveted in boiler
shop and ship in large section.
5. Typically efficiency is less than that of water-tube boiler.

In a multiple boiler, cutting in must be done individually so that in the event of any
unforeseen trouble, only that one boiler would need to be secured.
 Common and general procedures for raising steam.
After the boiler has been filled with water and the fuel oil has been circulated until proper
pressure and temperature has been obtained, the boiler is now ready for lighting of fires to
raise steam. The following general procedure must be strictly observed:
1. Purged the furnace to clear out foul gases by operating the blower or draft fan
2. Light off with the use of torch the center burner first if it’s a multiple burner furnace.
3. Let the fire burn for ten minutes and then cut that burner out.
4. Light off the other burner on one side of the center burner and let it burn for say ten
minutes and then shut it off and light off a burner on the other side.
5. Continue this rotation until pressure of about 30 psig has been reached.
6. Close vents in the boiler drum but vents on the superheater should be left open until
the boiler is cut in on the line.
7. When boiler is ready to be cut in on the line, the by-pass around the main stop valve
should be first opened to warm up the line.
8. Drains from the main steam line should be opened to permit condensate to be drained
out.
9. Cracked open the main steam stop valve, and open wide gradually as pressure and
water level are monitored.

Causes of boiler explosions.

1. Excessive pressure
2. Localized weakness
3. Flareback
4. Low water level

Low water level - is caused by steam being generated at a faster rate than that at which
feed water is being supplied. When water level begins to drop, the caused
should be checked and remedied.
However if water drops completely out of sight;
1. Do not add water until the boiler is cooled enough to prevent any possible damage due
to rapid cooling of overheated plate.
2. Stop the burner immediately to prevent evaporation of water already contained within
the boiler
3. Closed the main stop valve to keep steam within the boiler.
4. Inform the bridge that engine will be running at reduced speed because one boiler is
removed from service.

Flareback - would likely occurs once lighting off burners with the presence of sufficient
flammable or foul gases inside the boiler furnace is done.

The following precautions must be observed to avoid flareback;

1. Always clear the furnace of flammable or foul gases by turning on the exhaust fan
2. Light off burners with a lighting torch (manual firing)
3. Never light off burner from hot brickworks.

Water hammer - is a violent reaction accompanied by a loud crackling noise causing the
tremendous vibrations of the steam line and a subsequent breaking on
the joining end of the piping if not corrected. This is caused by the rushing
steam inside the cold tube and cause the condensate to suddenly rise and
close the pipe line, then suddenly collapses keeping the steam rushing in
violent reaction.
Cascade tank or hot well - prevents the entering of oil or grease into the steam
generating tubes in an open feed water system. Oil and grease floats at
the surface of the feed water while the feed-water pump draws
water at the bottom.

Surface blow down:

- Whenever evidence of foaming or oil is noted in the gauge glass, conduct a surface
blow off to removed floating impurities. To conduct a surface blow, the boiler
water level should first be raised above from its normal level and then blow off to
a predetermined level but not more than half its water content in the drum. The
valve should be opened wide rapidly and should never be left unattended. ; closed
the valve when the predetermine level is reached.

Bottom blow down:

- A very low value of salinity in boiler water is desirable for it indicates that there is
less formation of salt, but high values of alkalinity are very undesirable because
of:
1. Unnecessary waste of chemicals
2. Danger of caustic embrittlement and subsequent grooving may develop on
the surface of boilerplates on the water side.

Boiler water should be accurately measured on the following:

1. Alkalinity –acidic condition (pH)
2. Salinity – salt content (ppm)
3. Oxygen dissolve – (ml per liter) pH of water is the logarithm of the reciprocal
of the hydrogen ion index. It is measured on the scale of 0 to 14.

Any value below 7 indicates an acid condition

- Values between 7 and 8.5 are said to be neutral
- Values above 8.5 are alkaline

Two types of Boiler Feed Water system

1. Open feed system –usually found in an boiler where condensate passes through an
 atmospheric hotwell and feed filter tank or simply in an observation tank and
suction by the feed pump going to the boiler.
2. Closed feed system – commonly used in a high pressure water tube boiler supplying
steam to a main propulsion turbine, the condensate passes in a series of devices
unexposed to the atmosphere. It has also an atmospheric drain tank and feed
water tank tap to the system for the purpose of storing surplus feedwater and
supply it when required.

Hotwell tank and feed water filter tank are arranged with internal baffles to bring
about preliminary oil separation from any contaminated feed or drains. The feed then is
passed through charcoal or cloth filters to complete the cleaning process.

Boiler Water Treatment

For water treatment to be anywhere near efficient, it is necessary to measure the
effectiveness of the various added chemicals. Whenever soda ash or trisodiumphosphate
are added, the salinity will decrease and the alkalinity will increase. A very low value of
salinity is desirable, but high values of alkalinity is undesirable because of:
1. Unnecessary waste of chemicals
2. The danger of caustic embrittlement and subsequent grooving.

Test for Alkalinity:

Water for this test is drawn from the salinometer cock. A specified amount of water, usually
50ml is poured into the porcelain casserole and five or six drops of phenolphthalein are then
added. If the water is acidic, no change in color will result, but if it is alkaline, the water will
turn red. A measured sulfuric or nitric acid is mix by the use of aspirator bulb, until the red
color disappear and the water return to its normal color. The volume of acid in ml mixed,
multiplied by a constant supplied by the manufacturer, gives the total alkalinity in grains per
gallon.

Test for Chlorine, Salinity, Density or Saturation:

To the same water that was used for alkalinity test, add two or three drops of potassium
chromate. This will turn the water color to yellow. Add silver nitrates a few drops at a time,
until the solution changes to a reddish-yellow color throughout. The volume of silver nitrate
added, multiplied by a constant furnished by manufacturer, gives the chlorine content of
boiler water in grains per gallon.
Titration - is a procedure of neutralizing an unknown solution with a reagent of known
quantity.

Hardness of boiler water is recognized by the excessive amount of soap required to produce a
lather with it. Calcium, magnesium, iron, and aluminum are the chief contributors to
hardness.
Test for boiler water Hardness:
The usual test consist of adding a measured amount of standard soap solution to a measured
sample of boiler water until a lather forms that persist, in a standard-sized bottle, for five
minutes on the surface of the sample of boiler water.

Purpose of boiler water treatment:

1. To prevent scale formation
2. To prevent corrosion on tubes and some metal needed for the structural strength of
boiler
3. To prevent trouble associated with excessive alkalinity of boiler water

Causes of scale formation: Scales formed due to impurities present on feed water that
remains dissolved in the water when it is cold, but settled out of solution
(precipitate) when temperature is raised above certain critical limits and form
the hard, adherent coating referred to as scale. Inadequate feed-water
treatment will results in a very thick coating of scale and attempts to remove it
with air cleaning tool might not be effective. In such case the scale can be
removed chemically by boiling out the tubes. For each 1000 lbs of water
contained in the boiler, three pounds each of soda ash and trisodium
phosphate are dissolved in warm water and poured into the boiler drum.

Effects of Scale:
1. Heat transfer is reduced thereby lowering boiler efficiency
2. Cross-sectional area of water space is reduced thereby lowers the boiler water capacity,
and create poor circulation through the water circuit.

Corrosion - is the deterioration or wearing away of the metal.

Forms of corrosion on boiler:

1. Pitting - is a decrease in a boiler-metal thickness in which this decrease appears as a small
holes eaten in the metal
2. Rusting or Wearing – is a fairly even wearing away of the boiler metal and is caused by
oxygen dissolved in boiler water.
3. Grooving – is a large cracks or grooves resulted from an efforts to prevent scale and
galvanic action.

Caustic embrittlement - is a failure in boiler metal which is caused by high alkalinity of

boiler water.

Boiler mounting materials with their temperature limitations:

Each plate of class “A” tested steel, is required to have the following:
1. Name of manufacturer or his trademark
2. The word marine followed by the letter indicating the grade of steel
3. The minimum tensile strength of the plate per square inch of cross-sectional area
expressed in thousands.
4. Official coast guard seal
5. Initial of coast guard inspector
6. The serial number

Steel used in boiler construction:

1. Chromium-molybdenum alloy steel, Spec. ASTM A335, Grade P-11 Max. temp. 1050°F
2. Alloy steel casting and forgings. Max. temp. 1000°F
3. Bronze casting, Grade B, 300 psig. Max. temp. 450°F
4. Cast iron, 30 psig maximum. Max. temp. 450°F

Both Firebox and Flange quality steel are Class “A” steel and are subject to test and stamping
by duly authorized coast guard inspector.

Firebox quality steel - are used for shell plates or any part of boiler that are subject to
pressure and are exposed to fire or product of combustion.
Flange quality steel or firebox quality steel - are used for any part of boiler subject to
pressure and not exposed to fire or product of combustion.

Terms used in Boiler testing:

Elastic limit – is the maximum stress that can be induced in a material without causing
permanent deformation.
Ductility – is that property of material which allows it to be drawn, by pulling on its ends, to
a smaller diameter.
Elongation – is the increasing of the length of a material by pulling its two ends away from
each other.
Reduction in area – results when a material is stretched to measure its elongation.
Factor of safety – is the ratio of ultimate strength of a material to its maximum working
stress.
Annealing – consist of allowing material to cool, after forging or rolling, to a temperature
below the critical range; reheating it to proper temperature to refine the grain;
then allowing it to cool in the furnace.
Normalizing – similar to annealing except that after reheating to refine the grain, the
material is allowed to cool in the air.

Term used in construction of boiler

Joints – is a connection between two shell plates made is such a way that the seam is in
perpendicular to the axis of the shell.
Lap joint – a connection made between two pieces of metal by lapping the two ends to be
joined, one over the other, and then securing the ends by bolting, riveting, or
welding.
Butt joint – is a connection made between two pieces of metal by butting the two pieces
together end-to-end, and securing the ends with one or two butt straps.
Longitudinal joints – is a connection between two shell plates made in such a way that the
seam is parallel to the axis of the shell.
Riveting – is a method of joining metal plates.
Girth or Circumferential – [Assign]
Chain riveting – which rivets are arranged in a square or rectangular pattern.
Staggered riveting – which rivets are arranged in a zigzag pattern.
Rivet pitch is the distance between adjacent rivets in any one row.
Single shears tress – rivets are said to be in single shear stress when rivets is sheared in only
one plane perpendicular to its axis.
Double shear stress – occurs when failure of the joint, the rivets sheared in two planes
perpendicular to its axis.
Stress in shell and joints; - It should be noted that the longitudinal pressure exerts a stress
on the circumference and the radial pressure exerts a stress
longitudinally. The strength of boilershells therefore depends on
the diameter and thickness and is independent of lengtSteam
Boiler Efficiency

Heat transfer and total heating surface is the key to boiler efficiency and in modern practice
5 sq. ft. of heating surface is considered to be the equivalent of one boiler horsepower.
The percentage of total heat exported by outlet steam in the total heat supplied by the
fuel(coal) is called steam boiler efficiency.

It includes with thermal efficiency, combustion efficiency & fuel to steam efficiency. Steam
boiler efficiency depends upon the size of boiler used. A typical efficiency of steam boiler is
80% to 88%. Actually there are some losses occur like incomplete combustion, radiating loss
occurs from steam boiler surrounding wall, defective combustion gas etc. Hence, efficiency of
steam boiler gives this result.
TOPIC: MARINE BOILER
MARINE BOILER OPERATION, MAINTENANCE, TROUBLESHOOTING AND REPAIR

FIRETUBE BOILER

Water-tube boiler
Boiler: A boiler is a closed vessel in which water is heated, steam is generated, superheated or any combination
thereof under pressure or vacuum by the direct application of heat from combustible fuels or electricity.
A boiler is one of those machineries that gets the ship going. A boiler is something, which though not required
continuously in operating a ship, cannot be done away with. Moreover, it’s a dangerous equipment which
generates steam at extremely high pressure, and it is for this reason that proper care should be taken while
operating it.

Working Principle of Boiler

The basic working principle of boiler is very very simple and easy to understand. The boiler is essentially a
closed vessel inside which water is stored. Fuel (generally coal) is bunt in a furnace and hot gasses are
produced. These hot gasses come in contact with water vessel where the heat of these hot gases transfer
to the water and consequently steam is produced in the boiler. Then this steam is piped to the turbine of
thermal power plant. 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.

Starting a Boiler
It is to note that the following steps may not apply to all types of boilers and each boiler requires some additional steps
to be followed as per its system design.
However, the basic steps remain the same:

1. Ensure that the vent valve on the boiler is open and check there is no pressure in the boiler.
2. Check that the steam stop valve is closed.
3. Check that all the valves for fuel are open, and let the fuel circulate through the system until it comes to the
temperature required by the manufacturer recommendation.
4. 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. This is done because it is not possible to start the boiler below the low water level due to safety
feature which prevent boiler from starting. Also, the level is not filled much because if filled too much, the water
inside the boiler might expand and over pressurize the boiler.
5. Start the boiler in automatic mode. The burner fan will start the purging cycle which will remove any gases
present in the furnace by forcing it out through the funnel.
6. After the pre-set purge time the pilot burner will ignite. The pilot burner consists of two electrodes, through
which a large current is passed, via the transformer, producing the spark between the electrodes. The pilot
burner is supplied with diesel oil and when the oil passes over, the former ignites.
7. The main burner which is supplied by heavy oil catches fire with the help of pilot burner.
8. Check the combustion chamber from the sight glass to ensure the burner has lit and the flame is satisfactory.
9. Keep a close eye on the water level as the pressure increases and open the feed water when the level of water
inside the gauge glass is stable.
10. Close the vent valve after the steam starts coming outside.
11. Open the steam stop valve.
12. Once the working steam pressure is reached, blow down the gauge glass and float chambers to check for the
alarms.

Stopping a boiler
1. If the boiler is needed to be stopped for longer duration for maintenance or opened up for survey, change the
fuel to distillate fuel.
2. If separate heating arrangement for heavy oil is present then there’s is no need to change over to distillate fuel
and the oil is kept on circulation mode.
3. Stop the boiler automatic cycle.
4. Close the steam stop valves.
5. Close the boiler feed water valves.
6. When the boiler pressure is just reduced to over atmospheric pressure the vent valve is kept open to prevent
vacuum formation inside the boiler.
Do’s and Don’ts for Efficient Boiler Operations On Ships
Accidents on board ships involving marine boiler has caused severe damage to the property and even claimed human
lives in the past. Mariners know the dangers of high temperature steam and therefore do not take any chances when it
comes to operation and maintenance of boilers.

According to an analysis, one of the main reasons behind accidents are improper operating procedures and overriding
safety precautions while operating boilers. The main concern of any ship engineer is to operate all engine room
machinery and systems to achieve maximum efficiency without hampering it’s operating life and safety measure.

When it comes to marine boilers, the steam demand is the main criteria of operating a boiler at a given load. It is
therefore important not to over-stress the boiler to achieve the desired output. Also it is necessary to ensure that the
boiler is operated within all safety limits.

Below are some of the important Do’s and Don’ts which a marine engineers must consider while operating a marine
boiler in a safe and efficient manner:

Do’s:
1. Operating Procedure: Follow the correct operating procedure when lighting up the boiler from the cold condition.
Ensure to pre and post purge every firing and also make sure that the air vent is kept open while initially firing
and shutting down the boiler.

2. Blow Down: A regular gauge glass blow down (once every watch) is a must. Boiler blow down is to be performed
once a day to keep the chloride level to minimum. If floating impurities are suspected (oil, foaming etc.) scum
blowdown is to be carried out.

Boiler blow down

Boiler blow down is done to remove carbon deposits and other impurities from the boiler.

Blow down of the boiler is done to remove two types of impurities – scum and bottom deposits. This means that blow
down is done either for scum or for bottom blow down.
Moreover, the reasons for boiler blow down are:
1. To remove the precipitates formed as a result of chemical addition to the boiler water.
2. To remove solid particles, dirt, foam or oil molecules from the boiler water. This is mainly done by scum valve
and the procedure is known as “scumming.”
3. To reduce the density of water by reducing the water level.
4. To remove excess water in case of emergency.

Procedure for Scumming and Bottom Blow Down

Below is the procedure for boiler blow down using the blow down valve located at the bottom of the boiler. In order to
do scumming, instead of bottom blow down, the scum valve is to be opened.
 Steps for blow down procedure are as follows:
Kindly refer the diagram to understand the blow down procedure properly.
1. Open the overboard or ship side valve(1) first.
2. Open the blow down valve (2), this valve is a non-return valve.
3. The blow down valve adjacent to the boiler (2) should be opened fully so as to prevent cutting of the
valve seat.
4. The rate of blow down is controlled by the valve (3).
5. After blow down close the valve in reverse order.
6. A hot drain pipe even when all valves are closed indicates a leaking blow down valve.

3. Soot Blow: Perform a soot blow for the boiler tube to continue the heat exchanging ability of the boiler tubes.
Do Soot Blowing to prevent fires.

4. Smoke: Check the smoke from the boiler trunk coming out of the ship’s funnel on every watch to gauge the
combustion quality.

5. Lubricate: All the boiler mechanical parts and links to be lubricated and greased at regular interval of time.

6. Emergency Shut Down: Ensure to check emergency shut down of the boiler, which is located in the ECR, is
working. This is to be tested as per the safety routine described in the company
(SMS).

7. Valves and Dampers: Ensure all the fuel line valves, steam valves and safety valves are working fine. Check the
quick closing valves and safety valves for their correct operation.

8. Attend Leakage: Steam system is prone to leakages because of their fluctuating steam pressure. Attend all the
leakages at the earliest to maintain the efficiency of the boiler at all times.

9. Check Furnace: Keep a check on the furnace for refractory deterioration and fuel dripping near the burner
assembly. Any defect to be attended at the earliest.

10. FFA for Boiler: Boiler is a high pressure machinery with its own set of prescribed fire fighting equipment. Check
the functioning of local fire extinguisher (foam type) and High pressure jet fog system. Drill to be
carried
out regularly to train the crew for fighting the boiler fire.
Don’ts:
1. Untrained Operator: Never leave a boiler operation at the hand of an assistant engineer or untrained operator,
especially when lighting up the boiler from the cold condition.

2. Blow Down: Never do excess blow down as the feed water system will add cold water in the boiler drum to
compensate which will lead to decrease in the thermal efficiency and stresses in the boiler.

3. Soot blow: Never Operate a soot blow system when the boiler is operating at high load.

4. Unusual Observation: Don’t avoid any unusual observation in the boiler whether it’s sound, smoke, flame quality or
other boiler parameters. Always rectify abnormalities related to boiler at the earliest.

5. Overload: Never operate the boiler at higher load as a regular practice. Boiler can be overloaded sometimes due to
load demand but regular overloading will lead to high stresses and tube failure.

6. Feed water: Never include sea water in any circumstances. If the hot well is filled with sea water (due to heavy
leakage in the condenser), shut down the plant and rectify the problem.

7. Leaking Tubes: Don’t Operate the boiler when any water tube is leaking. Rectify the leakage at the earliest.

8. Water Level: Don’t trust the water level indicator located at remote position i.e. in the control room. Keep a check
through local gauge glass to get the clear picture. Read Science behind boiler water circulation.

9. Furnace Door: Don’t keep the boiler furnace door open unnecessarily. If it is opened for burner cleaning or furnace
inspection, close the door if the equipment is unattended or once the job is over.

10. Periodic maintenance: Don’t skip the periodic maintenance of boiler and boiler auxiliaries as it will decrease the
efficiency of the boiler over a period of time.

The above mentioned Do’s and Don’ts provide a general overview to ensure that boiler efficiency is maintained while
the safety aspect is kept intact.

Boiler Maintenance
Maintenance Basics

What are the types of boiler by pressure ?

Low pressure boiler – up to 10Kg / Cm2
Medium pressure boiler – 10-25 Kg /Cm2
High pressure boiler – Over 25 Kg / Cm2

What is water hammering and how will you prevent it ?

- It is the impact of moving water in steam line when the steam is allowed to enter a line with condensed water.
- The steam will condenses and partial vacuum occurred and move back the water the along the pipe with very high
velocity, and the water will strike at the vent or valves.
To prevent the water hummer –
- Install steam trap in the line
- Open the drain first before allowing the steam into the line.
- Crack open of steam valve at first.

How to make boiler water test on your ship ?

The boiler test is carried out as follows:
1. Firstly take the boiler water sample from the salinometer cock or test cock and cool down.
2. The test is carried out by the using maker’s supply test kit, chemicals, instruments and instructions.
How do you take boiler water sample ?
- Slowly open the salinometer cock until clean hot water coming out.
- Then collect the boiler sample with copper jar.
How to know scum blow down valve open or not ?
- It can be check by opening of ship side blow down valve. Banging noise will appear, scum blow down valve is in open
position.
- It can also detect, over heating of scum blow down pipe.

Where is manhole doors fitted ?

They are fitted at one at steam side and other one for water side.
Effect of foaming and priming ?
- Can cause water hummer
- Can cause contamination and scaling.
- Can cause fluctuation of working water level.
What is boiler blow back ?
- It occurs when lighting up with explosive gas and oil droplet (Oil residue) inside the furnace without pre-purging
sufficiently.
- The ignition results in a large flue gas inside the furnace and these gases blow out with increase high pressure through
the furnace opening.
Procedure for hydraulic pressure test on marine boilers ?
Hydraulic pressure test is 1.25 times working pressure, ( 10 minutes maintain )
1. Close all openings.
2. Open air vent cock.
3. Fill up boiler water fully
4. Close the air vent cock
5. Place hydraulic jack to feed water line.
6. Fit standard pressure gauge.
7. Applied hydraulic pressure 1.25 times of working pressure and maintain 10minutes.

What is liquid coagulant in marine boilers ?

- It has more molecular weight, colorless solution, containing sodium aluminates, starch, terming, and resin.
- Once being dose into the boiler water floating solid particles and suspended solid are settled to the bottom of the
boiler and easily remove by blowing down.

Routine boiler maintenance carried out on ships ?

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

When boiler safety valve setting made ?

- Every boiler survey.
- After safety valve overhaul.

Why ship side blow down valve is open first and close last ?
- To prevent pressure build up in blow down line.
- In pipe burst, it may be injurious to watch keeper.
What if no test and treatments is done to boiler ?
- Reduction in boiler efficiency due to poor heat transfer
- Reduction in tensile strength
- Reduction in factor of safety
- Overheating of metal resulting distortion and eventual failure
- Increase in fuel consumption
- Excess concentration of NaOH (caustic soda) may cause caustic embrittlement on boiler metal and tend to failure of
boiler metal
- Corrosion
- Scale formation
- Foaming, Priming, carry over (due to increase T.D.S level, foaming is present and tend to carried over and priming)

How to control steam pressure in exhaust gas boilers ?

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

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

Why safety valve is fitted in two numbers ?

- To make sure that the positive discharging of higher steam pressure from boiler efficiency.
Why fitted in one valve chest ?
- To reduce stress by hole on pressure vessel (boiler)
- To minimize the numbers of cutting hole on boiler to save it’s strength.

The boiler operator is responsible for operating and maintaining the boiler in a safe and efficient manner through the
use of sound engineering practices and manufacturer’s specified maintenance procedures. Most boiler accidents are
caused by operator error and poor maintenance.

The Chief Engineer of a boiler plant holds the responsibility for directing boiler operations, procedures and maintenance.
The information used by the Chief Engineer comes from manufacturer’s recommendations.
Log sheets are a paper record of boiler operation and maintenance, and should be used in all boiler rooms to help
ensure safe operation. A log sheet will specify the task to be performed, such as blowing down the low water cut-out
(LWCO), and the operator can then mark the sheet to show that this operation was completed. General Boiler
Operations include:
Startup - Cold iron start up and new plant start up. Most furnace explosions occur during start up and when
switching fuels, so always follow the manufacturer’s guidelines.
Operation & General Maintenance – requires proper training, equipment familiarity and routine maintenance
procedures.
Shutdown – Whether for a short time or long time, different procedures exist. If the boiler is to be placed out of
service for an extended period of time, proper lay-up procedures are required and must be followed.

Troubleshooting

The technology behind the boiler control is well established and proven in service over many years. However, should a
problem or question arise regarding the operation of the system, the control can be very easily serviced.

Procedure for trouble shooting:

● Find the symptom of the problem and check the items listed on the table to find the solution.
Combustion problems
1.Not firing
2.Cooling down after ignition
3.Ignition slow
4.Black smoke emission
5.Combustion sound ceases
6.White smoke emission
7.Back fire
Draft Fan and Burner Fuel pump and fuel pressure
1.Noisy fuel pump, increased oil
1.Draft fan dose not stop
pressure
2.The oil pressure does not
2.Draft fan burning after running increase even when the oil pump is
working
3.Draft fan does not run 3.Excessive oil pressure
4. Fuel oil pump does not work

Combustion problems
Table: Combustion problems
Symptom Check Possible causes Remedy
1.Not firing 1.Fuel tank ●Empty or mixed with ●Blow down water, then
water fill fuel oi1.
2.Oil strainer, or fuel ●Strainer clog ●Clean the strainer
valve ●Valve closed ●Open the valve
3.0il pressure ●Incorrect pressure ●See symptom 3. (slow
ignition)
4.No electric arc between ●Clogged atomizer ●Lift out nozzle and
 electrodes
A. No oil flowing ●Oil pump broken
●The solenoid on the the
burner is broken
B. There is an electric are, ● The electrodes are out ● Move the electrodes
and the nozzle of position
produces nozzle
produces spray well
C. No electric are or 1. The gap between
unstable arc electrodes is too wide,
or too electrode has
twisted
2. The tip of electrode
has twisted
3. Fuel and carbon
deposits on the
electrode's circuit
4. The isolation of the
electrode is broken
5. The cable of the
electrode is not plugged correctly and tighten up
in correctly or the screw the screw
is loose
6. Ignition coil out of
order
5. Heavy oil heater ● Shift
temperature controller
(H type)
6.Atomizer ● Clogged
7.Electric eye ● Ash deposits on eye
● Disconnected
8.Items 1-7 are correct ● Electric eye out of order ●Replace electric eye 〔＊〕
2.Cooling down after 1.Fuel tank ● Empty
ignition ● Mixed with water
2.Oil strainer ●Blocked
3.Atomizer ●Blocked
4.Electric eye ●Ash deposits
● Disconnected
5.Items 1-4 are correct. ● Electric eye out of order
clean mesh strainer if
checks 1-3 are normal
●See reference to fuel oil
pump
●Check that power is
applied to the solenoid.
Replace solenoid if it
works s10w15r.
\back to the correct
position
● Same as above
● File the tip into 60℃
round shape
● Clean it are fully
● Replace
● Plug in the cable
● Replace
● Reset
● Clean it
● Clean with soft cloth
● Connect it well
● Fill with oil
● Drain water and fill oil
● Clean
● Clean
● Clean with a soft cloth
● Connect it well
● Replace electric eye 〔＊
〕
Table:Continued
Symptom Check Possible causes Remedy
3.Ignition slow 1. Check oil pressure. ●Oil pressure is high or ●Adjust oil pressure
low
2. Is mains power varied? ●Voltage has dropped ●Adjust voltage to correct
value
3. Is the position of the ●The position of the ●Move the electrodes
electrodes correct? electrodes is incorrect back to normal position

4.Black smoke emission 1. Check temperature in ●If the temperature in the ●Improve the air flow and
the furnace. furnace is above 40°C reduce the temperature
this is probably caused in the furnace.
by oxygen, and poor
combustion efficiency.
2.Oil pressure ●Oil pressure is too high ●Adjust the pressure to
normal
3.Position of fuel pump ●Incorrect position ●Move the position of the
fuel pump back to
normal.
4.Heavy oil heater ●Shift ●Reset〔＊〕Please
temperature controller consult an engineer if
(H type) needed.
5.Items 1-4 are correct ●Worn burner tips ●Replace the nozzle
●Poor quality fuel oil ●Drain and refill
5.Combustion sound 1.Mains voltage ●Voltage dropped ●Adjust the voltage
ceases
6.White smoke emission 1.Heavy load solenoid not ●The wires are not ●Connect it properly
powered connected
●The coil of the solenoid is ●Replace〔＊〕
broken
2.Heavy load solenoid ●Clogged solenoid ●Clean
powered
3.Oil pressure ●The oil pressure too low ●Inspect and adjust
4.Burner tips ●Blocked ●Clean
7.Back fire 1.Mains power voltage ●Voltage dropped ●Adjust the voltage
2.Electrodes settings ●Setting are not correct ●Adjust the electrodes

Draft fan and burner

Table: Draft Fan and Burner

Symptom Check Possible causes Remedy
1.Draft fan dose not stop ●Protection relay (PR) ●Broken ●Replace PR〔＊〕
2.Draft fan burning after ●Restarting immediately ●Starting again after 1
running minute
●The protection relay (PR) ●Replace〔＊〕see Other
is broken
3.Draft fan does not run 1.Fuses
A). Disconnected ●Shorted ●Check the isolation of
the control panel and
 replace fuses
B). Connected ●Connection of the ●Replace〔＊〕
solenoid is not correct
●Connection of wiring is ●Check wiring
not correct
2.Incorrect water level ●The caps of the water ●Plug in well
level electrodes are not
plugged
3.Pressure switch not ●Blocked pipeline ●Clean
powered ●The Pressure switch is ●Replace〔＊〕
malfunctioning
4.Heater connection ●Connection problems ●See Others
incorrect?
5.Heavy oil heater ●Shift ●Reset See section 4.2.6
temperature controller
(H type)
6.Temperature of heavy ●Temperature does not ●Check heavy oil heater.
oil increased ●Check heater
temperature controller.

Fuel pump and fuel pressure

Table: Fuel pump and fuel pressure

Symptom Check Possible causes Remedy
1.Noisy fuel pump, 1.Fuel pipeline ●Blocked pipeline and air ●Clean or vent the air.
increased oil pressure in the fuel pipeline Adjust the pipeline if
necessary
Table: Fuel pump and fuel pressure
Symptom Check Possible causes Remedy
2.Fuel pump strainer ●Blocked *Clean
3.Location of fuel tank ●Too low *After checking items 1-2,
contact engineer〔＊〕
4.Temperature ●Pipeline heater *Adjust pipeline heater
temperature setting too (temperature controller)
high to 60℃ and 80℃ for B
and C heavy oil
respectively
●Heavy oil heater *Set heavy oil heater to
temperature setting too 105℃ and 150℃ for B
high and C heavy oil
respectively
2.The oil pressure does 1.Oil strainer ●Blocked *Clean
not increase even when ●Leakage *Replace the shaft
the oil pump is working seal〔＊〕
●Faulty pipeline valve *See Section 4.2.7
switches
2.Idle running of fuel ●Air in the pump or *Vent air
pump pipeline
 3.Leaking fuel pump ●Worn shaft seal *Replace〔＊〕
4.None of items 1-3 ●Loosened oil pressure *Replace〔＊〕
adjustment screw
●Oil pressure gauge out of *Replace〔＊〕
order
●Worn oil pump gear *Replace〔＊〕
3.Excessive oil pressure 1.Pipeline ●Blacked *Clean
●Irregular oil pressure *Adjust see section
setting 4.2.5〔＊〕
●Oil pressure gauge out of *Replace
order
4. Fuel oil pump does not 1.Fuses ●Not installed ●See symptoms for draft
work fan not running
2.Is motor running idly? ●Broken coupling ●Replace
●Loosened coupling ●Tighten
3.Motor not running ●Gear blocked by foreign ●Adjust using pliers until
materials running, check oil
4.None of items 1-3 ●Thermal relay is not strainer as well 〔＊〕see
working section on
●Protection relay (PR) is thermal relay
out of order replacement〔＊〕

Repairs in Marine Boilers

Some of the common repair work carried out on the marine boiler while on board the ship is plugging of the tubes and
replacing the leaky manhole joints. Other major repairs like the renewal of the damaged tubes and furnace rebuilding
must be carried out in the dry dock. The plugging of the boiler leaky tube is a temporary repair which must be carried
out in order to fire the boiler. Whatever the situation, and in any condition the boiler must run to supply the working
steam.
When the gasket becomes damaged or gets old, smoke starts to come out of the boiler in the case of the water tube
boiler. In the smoke tube boiler, the water starts to leak outside the boiler. This must be repaired onboard by replacing
the leaky manhole joints.

Replacement of a Leaky Manhole Joint:

- Maintain proper spigot clearance- 1.5 mm to position the door centrally for evenly loading the gasket.
- Never use an old gasket.
- Do not over strain the door studs, which may stretch.
- Pull-up studs by re-tightening the nut after steam rising or warming up.
- Avoid causing damage to door by holding it by a rope and gently lowering it inside or taking it out.
- Mark the dogs and nuts to fit back correctly in the same door.
- Check for wear and tear on the studs and nuts.
- Carefully check the matting/ landing surface for corrosion and erosion on the door and boiler before reassembling.
Boiler Man Hole Door

Repairs In Smoke Tube Boilers:

1- Procedure for Plugging of a Damaged / Busted Smoke Tube:
2- Hydrostatic testing to mark the leaky tubes.
3- Cut the tubes on one end and clear of the tube plate. At the other end the tube is collapsed inside the tube
plate.
4- Pull out the tube from the collapsed end.
5- Insert a short tube into the tube plate and weld it in place.
6- Lap the spare tapered plugs on both stud ends in the tube plates.
7- Insert the tube plugs and tack weld it.
8- Alternatively, the plugs can be held in place by a long steel bar threaded and bolted at both ends.
9- Hydrostatic pressure test to confirm no leaks.
10- Flush up the boiler and re-inspect the plugs for leaks under full steam pressure.

Temporary Repairing Procedure to Rectify the Leakage in Smoke Tube:

1- Stop the burner, allow the boiler to cool and remove the soot.
2- Allow boiler to depressurize, and open the blow down valve to drain the boiler.
3- Enter the boiler flue box and cut a hole in the side of the relevant smoke tube.
4- Clean the rim of the smoke tube with a wire brush.
5- Cut a circular plate (15 mm thick) of the same diameter as the smoke tube and chamfer the top edge to 30 degrees by
grinding.
6- Fit the plate into the top of the smoke tube and weld it in position as shown.
7- Enter the boiler furnace and cut a similar hole in this end of the relevant smoke tube.
8- Repeat steps 4 to 6 for lower plate.
9- Refill boiler and check for leaks before start-up.
10- Start up boiler and check for leaks when pressurized.
Note: Any temporary repair to smoke tubes or boiler tubes should receive more permanent attention as soon as
conveniently possible.
Plugging of Boiler Tubes

Repairs In Water Tube Boiler:

1. Instruction for Plugging / Repair of Water Tube Boiler & Economizer:
2. In case of tube failure, steam pressure has to be removed and the oil burner dismantled.
3. If the leakage is readily visible from the burner hole, the boiler can be emptied and repairs commence.
4. Otherwise, the boiler is given pressure by means of the feed pump. The position of the leakage will be
indicated by the water flow.
5. This flow may not be visible from the burner hole. If it is not visible, remove the inspection door and enter
the furnace. If the tube failure is still not found, then enter the generating tube section. From here the
bottom of the membrane walls and generating tubes can be inspected for leakage.
6. If the leakage has resulted from the membrane walls or generating tube, the inspection door at the smoke
connection pipe must be removed, and the generating tube/ membrane tube in which the failure has
occurred is pointed out.
7. The leakage may also result from economizer.
8. By removing the inspection door at the bottom of the economizer, it can be determined which uptake has
caused the leakage.
9. If necessary other inspection doors should be removed to point out the damage register.
10. When a damaged tube or convection register has been removed, and the remaining tube studs have been
repaired/ plugged a new tube or register should be mounted as soon as possible.
11. Operation for longer periods with one or more registers missing involves the risk of further damage to the
boiler due to increasing heat leads on the parts next to the ones removed.

Boiler Inspection in Furnace

Boilers of all types are subjected to extremely hazardous conditions involving very high temperatures, abrasive, and
chemically aggressive fuel constituents. Vigilance is essential at all times and the prime consideration is cleanliness of
both the gas side and furnace.
The boiler furnace is the place where the combustion of fuel takes place and it is covered by refractory materials which
prevent the heat loss due to radiation. A high efficiency is obtained when heat losses are low. A major heat loss occurs if
the furnace refractory material is not maintained.
For any boiler inspection, the inspector must plan out a route for his movement starting from the furnace.
1. Almost always, the inspector must start at the furnace. The reason being that the furnace reveals the quality of
combustion and its effect s and any distortion at the crown or the tube walls signifying the problems originating
at the water side. In fact a good clean furnace with no signs of distortion could assure the inspector that the
 boiler is in good running condition.
2. The next in succession should be burner unit, the bottom headers, and the boiler bottom.
3. Mounting attachments on the upper shell will follow before entry is made through the manhole to inspect the
water side of the steam space.
4. Top mountings will be checked before entering the gas space through the inspection door for look at the boiler
tubes.
5. The inspector will end with a check on dismantled mounting parts arranged in order for the purpose.
6. If in doubt of gas side corrosion, checks on the gas uptake could be done as a final step in the inspection route.

Possible Defects in Boiler Furnace:

Sludge deposits continue to be the prime cause of non-operation of internal controls and overheating of a
furnace in a vertical boiler.

Overheating distortion on the furnace crown is mainly due to a deposit of oil, scale, or sludge on the heating surface
or due to water shortage. The lower section of the crown causes overheating distortion due to the sludge
deposits. The furnace connecting to the shell may have welding cracks due to rapid fluctuation of thermal and
mechanical stress, the results of improper starting up or shutting down procedures.
Direct flame impingement resulting in deformation of the crown or a local bulge in wall tubes opposite the burner
opening is also possible.
Dry cracks in the furnace mouth, crown, or the furnace tubes caused by flame impingement are possible due to
scale encrustation at the water side and forcing of the boiler. Areas suffering from poor circulation or relatively
uncooled area are also susceptible to the above failure.
Deep cracks in the furnace mouth, crown, or furnace tubes caused by flame impingement are possible due to scale
encrustation at the water side and forcing of boiler. Areas suffering from poor circulation or relatively uncooled
areas are also susceptible to the above failure.
Deep cracks on plating should be stopped by drilling a hole at each end, opening up, and then welding.

Indifferent feed water may cause pitting of the furnace crown. A careful examination through the bottom manhole
door would require detecting the above grooving.

Brickwork protecting the foundation, if damaged, may cause distortion of the bottom plating underneath the
furnace. Damaged brick wok need to be removed to inspect the bottom plating for distortion before repair s to
the brick work is carried out.
Corrosion: Any sign of corrosion on plating should be chipped clean and brushed clear. It is also possible to build up
the weakened areas by means of electric welding. Pitting arear are difficult to protect from further corrosion due
to the difficulty in maintaining the protective magnetic oxide layer.

Boiler Furnace Defects

Remedies for Common Defects:

Furnace crowns that have suffered a gradual deformation can be jacked back to their original shape with or without
heat. A shaper deformation may require the plating to be slotted so that the clean metal can extrude into the gap during
heating and jacking. The slot is butt welded on completion. A much neater repair is to burn out the affected area and
replace with a butt-welded insert section cut from a scavenged furnace. For a severely damaged furnace with a
pronounced large belly, replacement could be the only answer.

Furnace tubes must be inspected for correct alignment and the tubes together must form a circular tube wall; anywhere
the tubes are deformed, the furnace shape will show up as misaligned. Distortion to a very small extent could be
accepted, but beyond that renewal of tube will be mandatory.

Furnace tubes, if damaged (cracked, holed, or deformed) need to be renewed with new tubes. Only under emergency
conditions could one be allowed to operate a boiler at low load with plugged furnace tubes. (Plugging could be carried
out with tapered steel plugs on each tube ends.)

The bottom plug will have to be inserted through the bottom header. The difficulty in doing that may also compel
cutting windows on tubes from the furnace end and manipulating the tapered plug in position.

Furnace Inspection:
REFRACTORY MATERIALS:
1. The front wall with its quarls receives full radiant heat and also deteriorates more rapidly and may cause spalling
of brickwork, misshapen quarls, and badly burnt air registers.
2. Refractory to protect the front part of the water drum, particularly below the screen tubes, may fail and expose
the drum to the direct heat of the furnace resulting in circumferential thermal cracking.

WATER WALL TUBES:

1. There is a greater possibility of overheating due to restriction in circulation.
2. Roof tubes having horizontal portion show effect of overheating due to water shortage very quickly. Roof tubes
with roof fired boilers are also prone to distortion due to overheat.
3. Tubes around soot blower openings have greater chances of overheating due to turbulence at the bends
restricting circulation.

SCREENING TUBES:
1. Check for direction due to overheating maximum permissible deviation or sag may be 2 inch in 12 ft before renewal.
2. Leakage at top expansion usually shows by white stains down the outside of tubes- these may be re-expanded.
3. Check gas passage through superheated banks for cleanliness.
4. Examine furnace end of superheater supports visible through screen tubes.
5. Gas baffle conditions above and below the superheater attached to the rear screen tubes to verify which may cause
gas short circuit giving local overheating in superheater and loss of superheat.
6. Screen tubes exposed to excessive heat due to flame impingement, forcing, etc. possible high temperature creep
cracks or circumferential fatigue fracture due to rapid thermal cycling.

How to renew the boiler gauge glass ?

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