Experiment No.

3
How to run a boiler
I. OBJECTIVE:
1. To be familiar with the operation of a fire tube boiler
2. To be able to determine the importance of boiler safety procedures
3. To formulate a boiler maintenance schedule

II. Theory:

A boiler is a closed vessel intended for use in heating water or for

application of heat to generate steam or other vapor to be used externally to itself
as defined in the PSME Code.
Boiler operation is one of the important roles of a practicing mechanical
engineer. Knowledge of the following must be obtained and every engineer must
be equipped:
Boiler parts and auxiliary equipment identification
Boiler start-up parameters
Boiler safety and operating procedure
Boiler maintenance and troubleshooting

III. LIST OF APPARATUS / EQUIPMENT:

Fire tube Boiler

IV. PROCEDURE
1. Check fuel oil and feed water system
2. Switch on main switch located at the side of the main control panel
3. Unit will start and continue to operate until desired steam pressure is
reached. When maximum pressure is reached, unit will stop. As the
pressure lowers to predetermine setting on the pressure unit will again fire
and repeat the cycle. A pressure controller which is mounted in the panel
box stops and starts the boiler to meet steam requirement.
4. Open main steam valve slowly
5. To stop unit, flick main switch to stop position
6. Close main steam valve, fuel supply valve, and water supply valve
V. SET-UP OF APPARATUS
Draw the front, rear, and side views of the boiler. Identify and label its
parts.
(PALAGAY NALANG PICTURES ACCORDING SA INSTRUCTION)
 VI. QUESTION AND ANSWERS:
1. From the set-up, Define and discuss the importance of the parts of the boiler.
A boiler consists of several vital components, each playing a critical role in ensuring
its efficient and safe operation:
a) Water Level Indicator: This component is used to observe the water level inside
the boiler. Maintaining an appropriate water level is crucial because low levels
can cause overheating, while high levels may reduce efficiency.
b) Pressure Gauge: The pressure gauge measures the internal pressure of the
boiler. It is essential to monitor this to ensure the boiler operates within safe
limits, preventing dangerous conditions from developing.
c) Safety Valve: One of the most important safety mechanisms, the safety valve
automatically releases steam if the pressure inside the boiler exceeds a set limit,
preventing explosions. Typically, two valves are used to ensure redundancy.
d) Stop Valve: This valve controls the steam flow from the boiler to the steam pipe,
allowing users to regulate the distribution of steam as needed, which helps in
efficient energy management.
e) Blow Off Cock: Located at the bottom of the boiler drum, this valve is used to
remove excess water and sludge that accumulates during operation, which helps
maintain the system's efficiency.
f) Feed Check Valve: This valve, a non-return type, manages the supply of water
to the boiler, ensuring a constant flow of water to replace the steam being
produced, which is critical for continuous operation.
g) Grate: Positioned within the furnace, the grate holds and burns the fuel used for
heating the boiler. It ensures that the combustion process is consistent, allowing
for proper heat generation.
h) Feed Pump: This pump ensures a continuous supply of water into the boiler,
keeping the water level stable and the system running smoothly. It is powered
either by electricity or a steam turbine.
i) Superheater: The superheater increases the temperature of the steam before it
enters the turbine. By reducing the presence of water droplets in the steam, it
helps protect the turbine from corrosion and improves overall efficiency.
j) Economizer: This component boosts the boiler’s efficiency by using the heat
from exhaust gases to preheat the incoming water, reducing the energy required
to heat it to the desired temperature.
k) Air Preheater: Another efficiency enhancer, the air preheater uses heat from the
flue gases to warm the air entering the furnace. Preheating the air ensures better
fuel combustion and reduces energy consumption.

2. Enumerate the do’s and don’ts in operating a boiler

 Do’s for Boiler Operation:
1. Exercise caution and respect the boiler's potential hazards. Mishandling it
can lead to serious accidents, so always be vigilant and follow safety protocols.
2. Ensure proper venting and setup before operation. Open the air vent during
both start-up and shutdown phases, and make sure the dampers and valves of
fans and pumps are properly closed before starting.
3. Conduct regular purging and maintenance. Before ignition, use the ID fan to
purge the boiler, and make sure you perform thorough inspections every three
months to keep the system in good working order.
4. Monitor equipment condition regularly. Keep an eye on the bearings of
motors, pumps, and fans, and check the water level and gauge glass during
every shift to ensure safe operation.
5. Keep detailed records. Maintain a logbook and history card for tracking the
boiler's performance and identifying any recurring issues.
Don’ts for Boiler Operation:
1. Avoid long ash accumulation times. Do not allow hot ash to sit in the ash
chamber for more than two hours, as it can impact the boiler’s efficiency and lead
to operational problems.
2. Don’t frequently adjust the boiler’s parameters. Constant changes to
operational settings can create instability and reduce efficiency, so it’s best to
maintain a steady configuration.
3. Do not frequently open the inspection door. Opening it too often can disrupt
the boiler’s performance and safety, potentially leading to hazardous conditions.
4. Never let the water level go outside safe limits. Ensure that the water level
stays between 25% and 75% in the gauge glass to avoid damage to the boiler
and reduce the risk of accidents.
5. Do not stop the ID fan during manual operation. Turning off the ID fan while
the boiler is being operated manually can lead to improper combustion and
unsafe pressure buildup.

3. What are the classifications/types of boiler? Differentiate.

Types of Boilers
1. Shell and Tube (Fire Tube) Boilers
o Hot gases pass through steel tubes, heating the surrounding water to
produce steam. Compact and simple, they are typically used for low- to
medium-pressure applications.
o Examples:

 Cornish Boiler: Features a single large flue for heat transfer, used
primarily for low-pressure applications.
 Lancashire Boiler: Similar to the Cornish but with two flues for
enhanced efficiency, suitable for medium pressure.
 Locomotive Boiler: Portable design used in steam engines, with
multiple small flue tubes for high mobility.
2. Water Tube Boilers
o Water flows inside the tubes while hot gases pass over them, designed for
high-pressure and high-capacity applications like power plants. They are
more efficient and produce steam faster than fire tube boilers.
o Examples:

 Longitudinal Drum Boiler: Features a drum above the heat

source for efficient steam collection, ideal for medium applications.
 Cross Drum Boiler: Drum is placed perpendicular to the heat
source, allowing uniform temperature but may struggle with heavy
loads.
 Stirling Boiler: Complex arrangement for large-scale industries,
featuring near-vertical tubes for efficient heating.
Classification of Boilers
1. Fire Tube Boilers
o Combustion gases heat the water surrounding the tubes. They are
suitable for low- to medium-pressure operations, such as smaller
industries or building heating.
o Advantages:

 Lower cost, easy to operate, and maintain.

 o Disadvantages:

 Limited pressure capacity and not ideal for large, continuous

operations.
2. Water Tube Boilers
o Water circulates in the tubes, heated from outside. They are ideal for high-
pressure, high-capacity applications like power generation and chemical
processing.
o Advantages:

 Higher pressure capabilities, more efficient steam generation, and

faster production.
o Disadvantages:

 Higher initial costs and more complex maintenance requirements.

4. When entering a boiler room, what must be an engineer do first? Why?

When entering a boiler room, an engineer must first ensure that all safety
protocols are followed, such as verifying that the equipment is installed securely and
checking for any potential hazards. This is important because the boiler room contains
high-pressure systems and machinery that can pose significant risks, including burns,
explosions, or exposure to hazardous materials. By conducting inspections and
following safety standards, the engineer ensures the safety of everyone in the area and
prevents accidents or injuries.

5. Where should a boiler be located? Why?

The optimal location for a boiler in a steam power plant is crucial for ensuring efficiency,
safety, and operational effectiveness. Here are key considerations for determining the
ideal boiler placement:
1. Proximity to Fuel Source:
o Efficiency: The boiler should be located close to its fuel source (such as
natural gas, coal, or biomass) to minimize transportation costs and losses.
This ensures a steady and reliable supply of fuel, which is essential for
maintaining consistent steam generation.
o Environmental Impact: Reducing the distance fuel must travel can also
decrease transportation emissions and minimize environmental impact.
 2. Access to Water Supply:
o Steam Generation: A boiler requires a substantial amount of water for
steam production. Locating it near a reliable water source can enhance
efficiency and reduce the costs associated with water transport and
treatment.
o Cooling Needs: Proximity to cooling water sources is also important for
maintaining optimal operating temperatures and managing heat
dissipation.
3. Space and Layout Considerations:
o Plant Layout: The boiler should be integrated into the overall layout of the
power plant to optimize workflow and facilitate maintenance. This includes
considering the space needed for auxiliary systems, such as fuel handling,
water treatment, and emissions control.
o Accessibility: Easy access for maintenance and repairs is crucial for
minimizing downtime and ensuring safe operations.
4. Safety Regulations and Environmental Compliance:
o Regulatory Compliance: The boiler's location must adhere to local
regulations regarding emissions, noise, and safety. This includes ensuring
adequate distance from residential areas and sensitive ecosystems to
mitigate the impact of operations.
o Emergency Response: The placement should facilitate quick access for
emergency services in case of incidents such as leaks or explosions.
5. Structural Considerations:
o Support and Stability: The chosen location must be structurally sound to
support the weight of the boiler and associated equipment. This includes
evaluating the foundation and surrounding structures to ensure they can
withstand vibrations and thermal expansion.

6. Make a boiler maintenance schedule and checklist. In a frequency of daily, weekly,

monthly, and annually.
Daily Maintenance
 Check Water Level:
o Ensure that the water level in the sight glass is within the safe operating
range.
 Inspect Pressure Gauge:
o Verify that the pressure readings are within the normal operating range.

 Examine Fuel Supply:

o Check fuel supply levels and ensure there are no leaks in the supply lines.

 Monitor Blowdown:
o Perform a blowdown of the boiler to remove sludge and sediments.

 Check for Leaks:

o Inspect boiler, piping, and fittings for any signs of leaks.

 Record Operating Conditions:

o Log boiler operating parameters such as temperature, pressure, and water
levels.
Weekly Maintenance
 Clean Water Gauge Glass:
o Clean the water gauge glass to ensure accurate readings.

 Inspect Safety Valves:

o Test safety valves to ensure they are functioning correctly.

 Check Burner Operation:

o Inspect the burner for proper operation and adjust if necessary.

 Examine Flue Gas System:

o Inspect flue gas ducts for blockages and clean if necessary.

 Lubricate Moving Parts:

o Lubricate any moving parts of the boiler system as per manufacturer
specifications.
Monthly Maintenance
  Inspect Insulation:
o Check insulation for damage or wear and repair as necessary.

 Check Electrical Connections:

o Inspect electrical connections and tighten loose wires.

 Calibrate Instruments:
o Calibrate pressure and temperature gauges for accuracy.

 Test Emergency Shutoff:

o Conduct a test of the emergency shutoff system to ensure proper function.

 Check Water Treatment Levels:

o Test water treatment levels and adjust chemicals as necessary.

Annual Maintenance
 Conduct a Comprehensive Inspection:
o Perform a thorough inspection of the entire boiler system, including internal
components.
 Boiler Cleaning:
o Schedule a complete cleaning of the boiler, including the firebox, tubes, and flue
passages.
 Inspect and Test Controls:
o Inspect and test all control systems, including automatic controls and safety
systems.
 Pressure Testing:
o Conduct a hydrostatic pressure test to check for leaks and ensure integrity.

 Review Maintenance Logs:

o Review all maintenance logs and operating records for compliance and performance
trends.

VII. CONCLUSION / RECOMMENDATION

Conclusion
In summary, this experiment highlights the critical role of boiler operation,
maintenance, and safety within the field of mechanical engineering.
 Understanding the workings of a fire tube boiler, its components, and the
essential safety procedures is fundamental for engineers tasked with managing
such systems. The hands-on experience gained from operating the boiler not
only reinforces theoretical knowledge but also emphasizes the importance of
adherence to safety protocols to mitigate risks. Through the formulation of a
maintenance schedule, we recognize that systematic upkeep is vital to ensuring
the boiler's efficiency and longevity.

Recommendations
a) Regular Training: Conduct ongoing training for engineers and operators
on boiler operation and safety protocols.
b) Enhanced Safety Measures: Enforce strict safety protocols and conduct
regular safety drills to prepare for emergencies.
c) Advanced Monitoring Technologies: Implement real-time monitoring
systems for boiler performance to enable early issue detection.
d) Regular Maintenance Audits: Schedule periodic audits of the
maintenance schedule for compliance and optimization.
e) Environmental Compliance: Ensure boiler operations meet
environmental regulations and sustainability goals.
f) Documentation: Maintain comprehensive records of maintenance and
operational parameters for accountability and trend analysis.

VIII. REFERENCE:

Boilers : Types and classification. Forbes Marshall - Trusted Partners in Steam

Engineering & Control Instrumentation. (n.d.).
https://www.forbesmarshall.com/Knowledge/SteamPedia/Boilers/Types-of-Boilers-and-
Boiler-Classification

BYJU’S. (2022, August 5). Working of boiler- parts, efficiency, classification and
Application. BYJUS. https://byjus.com/physics/working-of-boiler/

Do’s & don’ts. Chahal Boilers. (n.d.). https://www.chahalboilers.com/dos-donts/

Medium. (2023, January 18). The role of Mechanical Engineers in boiler room
design. Medium. https://medium.com/@yecengineering1/the-role-of-mechanical-
engineers-in-boiler-room-design-a6bf73301165

Steam Power Plant :Exploring the working principle, components, and diagram.
Boiler Used in Steam Power Plant. (2023, November 20).
https://www.thermodyneboilers.com/steam-power-station/