MEPC 103 ME Laboratory 3

EXPERIMENT NUMBER 03

STARTING UP AND SHUTTING DOWN OF BOILER

I. Objective:
1. To be able to know how to start and shut down the boiler.
2. To determine the different boiler pre-starting inspections.
3. To test the fuel consumption of the boiler.

II. Theory:
Discuss the theory of CIMECH BOILER SET, MODEL CB7.5-2PDB.
The Cimech Boiler Set, a product of Cimech Systems Construction INC. and
manufactured in 2009, serves as a vital apparatus for heating and steam generation within
laboratory environments. This analysis aims to delve into the theoretical principles governing
its operation and to emphasize the significance of its specific design parameters.
Boiler Fundamentals:
A boiler, at its core, is a specialized vessel designed to heat water and generate steam.
Within laboratory settings, boilers play a crucial role in various applications, including
sterilization, autoclaving, and experimental setups.
Boiler Specifications:
The Cimech Boiler Set, designated as CB7.5-2PDB, bears a 7.5 HP rating, indicating
its capacity to generate heat and steam. This rating is instrumental in determining its suitability
for laboratory tasks. Furthermore, it boasts a rated steaming capacity of 258.7 lbs/hr, signifying
its ability to produce steam efficiently under specified conditions.
An essential feature contributing to its operational efficiency is its substantial heating
surface area, measuring 75.20 sq. ft. A larger heating surface ensures better heat transfer,
facilitating consistent and reliable steam production. The boiler is designed to operate safely at
a design pressure of 150 psi, providing a safety margin to accommodate fluctuations during
operation. Its maximum allowable working pressure is set at 145 psi, defining the safe
operational limit and serving as a critical parameter to prevent damage and ensure the boiler's
longevity.
Operational Considerations:
To guarantee that the Cimech Boiler Set operates safely and effectively, it is essential
to conduct meticulous maintenance. This encompasses regular inspections, cleaning, and
servicing of safety equipment to ensure they are in their best working condition. Furthermore,
effective management of fuel and precise control of combustion is vital to maintain steady
steam production while minimizing emissions.
Safety measures, including the presence of pressure relief valves and pressure gauges,
are imperative to prevent situations where excessive pressure might jeopardize both the safety
and the integrity of the equipment. Additionally, the implementation of routine water treatment
is another crucial element, as it helps prevent the accumulation of scale and corrosion, which
can hinder efficiency and potentially harm the boiler.

In conclusion, the Cimech Boiler Set stands as a cornerstone of laboratory

infrastructure, providing reliable and controlled heating and steam generation capabilities. Its
specific design and parameters are tailored to meet the demands of laboratory applications,
with safety and efficiency at the forefront. Diligent maintenance and adherence to safety
protocols are paramount to ensuring its safe and effective operation within laboratory settings,
supporting various scientific and practical processes.
III. Equipment, Instruments and Apparatuses:
CIMECH BOILER SET, MODEL CB7.5-2PDB.
Infra Red Thermometer

IV. Drawing/Set up:

Draw the single line diagram of the boiler set in the laboratory using symbols specified
in the PSME code.

V. Methods and Procedures:

A. Sequence of operation of Burner with modulator
1. Pre-Purging - The process of clearing the combustion chamber of any residual
gases or air before igniting the burner to ensure a safe and clean start-up.
2. Ignition - The act of sparking or igniting the fuel-air mixture within the burner to
initiate the combustion process and generate heat.
3. Move to low fire - Transitioning the burner to a lower firing rate or reduced heat
output to match the current demand for steam or heating, optimizing fuel
efficiency.
4. High fire - Increasing the burner's firing rate to its maximum capacity to meet
higher demand for steam or heat output, maximizing boiler performance.
5. Modulation - Adjusting the burner's firing rate dynamically to maintain a
consistent steam pressure or temperature, optimizing fuel consumption and
operational efficiency.
6. Stop/purging and stop position- Shutting down the burner and purging any
remaining fuel or gases from the combustion chamber to ensure safe shutdown
and prevent potential hazards.

B. Boiler Controls
1. Burner and its Components
a) Burner Controller - A device responsible for regulating the operation of the
burner, controlling aspects such as fuel flow rate, air-to-fuel ratio, and
ignition timing to maintain optimal combustion conditions.
b) Ignition Transformer- An electrical component that generates a high-voltage
spark to ignite the fuel-air mixture in the burner, initiating the combustion
process.
c) Ignition Rod- A conductive rod positioned near the burner nozzle, which,
when electrified, creates a spark to ignite the fuel, facilitating the startup of
the burner.
d) Flame Eye - A sensor or optical device that detects the presence and stability
of the flame within the burner. It ensures continuous combustion by
monitoring flame conditions and initiating safety measures if necessary.
e) Fuel Pump- A mechanical or electrical device responsible for delivering fuel
from the storage tank to the burner at the required pressure and flow rate for
combustion.
f) Burner Motor- An electric motor that drives the components of the burner
assembly, such as the fuel pump and air blower, facilitating the combustion
process by supplying the necessary mechanical energy.

2. Vessel Control
a) Pressure Controllers- Devices that monitor and regulate the pressure within
the boiler vessel, ensuring it remains within safe operating limits by activating
safety mechanisms or adjusting burner output as needed.
b) FWP cut-in/cut-off controller (Mc donnel & miller)- A control device that
manages the operation of the feed water pump, automatically starting or
stopping it based on preset water level parameters to maintain optimal boiler
water levels.
c) Warrick Relay Control- A relay control system used to manage various
functions within the boiler, such as activating alarms or safety shutdown
procedures in response to specific conditions detected by sensors or
switches.
d) Feed Water Pump- A pump responsible for delivering water from the feed
water tank to the boiler vessel, maintaining the required water level and
ensuring continuous steam generation by replenishing water lost through
evaporation or blowdown.
C. Starting up the Boiler
1. Check water level of feed water tank. Be sure that water is sufficient in the
entire system.
2. Check fuel system of burner. Mark the fuel level indicated in the Fuel tank
sight glass.
3. Check valves of the entire system. Position them according to their specified
positions. Valves are labelled according to their operational use.
4. After checking all the parameters above, power on the boiler Main Control
Panel (MCP).
5. Position the feed water pump switch to auto mode.
6. Position the buzzer selector switch to on position. The buzzer sounds if the
water level controller detects low water level in the boiler.
7. Be sure that the air vent valve is open. This is to expel all air from the steam
shell. Note: Before starting the burner always check the normal water level of
boiler. The quality of steam produced is low if the water level is higher
than normal. Since the water day tank is installed at a higher elevation than the
boiler vessel, if the boiler is at zero pressure, water can enter into the
boiler from the day tank through gravity. Therefore, always check water
level of boiler before starting up the burner. If the water level is higher
than normal, open the blow-down valve to discharge excess water. The
feed water pump starts automatically at low water level to fill the boiler
with water then automatically shuts off when normal water level is
achieved. Close the blow-down valve as soon as the feed water pump
starts.
8. Switch on the burner. The burner starts running following the sequence
specified in item III.
9. Record the burner starting time.
10. Verify boiler pressure setting. For example:
Boiler maximum pressure setting- 45
Psi Initial differential setting - 15
Psi Boiler cut-in pressure setting - 30 Psi
11. When steady flow of steam from the air vent is observed, close the air vent
valve. Take note that pressure starts to build up in the steam shell as indicates in
the steam pressure gauge.
12. The burner automatically shuts off upon reaching the maximum setting pressure
and automatically starts at minimum or cut-in setting pressure.
13. Record the pressure reading, stack gas temperature reading and the time as the
burner shuts off.
14. Mark the fuel level as indicated in the sight glass of the fuel tank.
15. The whole system operates continuously as specified above unless the burner
switch is manually turned off.
 D. Shutting down the boiler
1. Power off the burner selector switch.
2. Let the power supply of the main control panel on until no more pressure can
be read from the boiler pressure gauge. This may take more than 24 hours. This
is to let the feed water pump feed the condensate of the boiler even it is no
longer running. It will also safeguard the boiler tubes.
3. If the boiler will not be used for a longer period, fill completely the boiler shell
with water so that no air space is inside the boiler. Oxygen in air causes serious
corrosion on both the shell and the tubes.

E. Trouble Shooting
1. Burner does not start
Solution: - Check limit controller
- Reset pressure controller
- Check water level controller
- Check warrick contact
- Push burner reset button.
2. Burner runs but not firing
Solution: - Check fuel supply, bleed the fuel pump
- Check ignition rod spacing. Adjust if necessary
- Check ignition transformer
- Wipe flame eye with dry cloth
- Check burner controller
3. Burner runs but not stable
Solution: - Check and adjust air:fuel ratio of burner
4. High stack temperature
Solution: - Check and adjust air:fuel ratio of burner
- Reduce boiler pressure
- Reduce air opening of blower
NOTE: In adjusting air:fuel ratio, Adjust the fuel inlet and air opening one at
a time.
5. Feed water pump is not pumping
Solution: - Check overload relay of FWP. Reset.
- Bleed the pump if pressure is unstable to release unnecessary
air inside the pump.

VI. Data and Results:

A. Tabulate the following:
1. Start time of burner
2. Initial Steam shell pressure
3. Initial stack gas temperature
4. Burner shut off time
5. Final steam pressure
6. Final stack gas temperature
7. Steam temperature measured at the steam exhaust.
8. Voslume of fuel consumed.
 B. Compute for the actual fuel consumption and compare it with that indicated in
the specifications by computing the percent error.
C. Determine the condition of exhaust steam.

VII. Discussion and Conclusion:

The laboratory activity focusing on the starting up and shutting down of boilers
provides us with essential experience vital for our future careers in the industry. By engaging
in this activity, we not only gain practical knowledge of boiler operations but also develop
crucial skills in maintenance, troubleshooting, and safety protocols.
Starting up the boiler involves a series of meticulous steps, including pre-starting
inspections, checking fuel systems, and verifying valve positions. Through these procedures,
we learn the importance of ensuring proper water levels, fuel supply, and valve
configurations to initiate safe and efficient boiler operation. Additionally, we familiarized
ourselves with the sequence of operations for burner ignition and modulation, contributing
to our understanding of combustion processes and steam generation.
During the shutdown process, we learn the significance of gradual cooling and proper
maintenance to safeguard equipment integrity and prolong the lifespan of boiler
components. By following prescribed shutdown procedures, we can develop a keen
awareness of safety protocols and preventive measures, which are essential for mitigating
risks and ensuring operational efficiency.
Through the activity, we are also exposed to troubleshooting scenarios, such as
burner malfunctions and fuel supply issues, which sharpen our problem-solving abilities and
critical thinking skills. By addressing these challenges, we gain valuable insights into
diagnosing and rectifying common boiler problems, preparing us for real-world engineering
scenarios where quick and effective solutions are imperative.
In summary, the laboratory activity involving the startup and shutdown of boilers
forms the basis of our mechanical engineering education, furnishing us with real-world
experience and information that can be used in a wide range of sectors. Through a thorough
understanding of boiler operations, maintenance, and troubleshooting, we graduate with the
knowledge and self-assurance necessary to take on challenging engineering problems in their
professional careers. We maintain the highest levels of engineering excellence by practicing
diligently and adhering to safety procedures, guaranteeing the safe and effective functioning
of boiler systems in various industrial settings.

VIII. References:
Book title, Author, Publisher, Edition, page/pages.
Internet websites.

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