eBook ; BOILER OPERATOR'S HANDBOOK

Chapter 1 - OPERATING WISELY
Why wisely? .......................................................................... 1
Prioritizing ............................................................................. 1
Safety ....................................................................................... 5
Measurements ....................................................................... 7
Flow ...................................................................................... 13
What happens naturally ................................................... 14
Water, steam and energy .................................................. 15
Combustion.......................................................................... 18
The central boiler plant ..................................................... 25
Electricity .............................................................................. 26
Documentation .................................................................... 31
Standard Operating Procedures ...................................... 33
Disaster Plans ...................................................................... 36
Logs ....................................................................................... 37
Chapter 2 - OPERATIONS
Operating Modes ................................................................ 45
Valve manipulation ............................................................ 45
New startup ......................................................................... 49
Dead plant startup ............................................................. 62
Normal boiler startup ........................................................ 63
Emergency boiler startup .................................................. 65
Normal operation ............................................................... 67
Idle equipment .................................................................... 69
Superheating ........................................................................ 72
Switching fuels .................................................................... 73
Standby operation .............................................................. 75
Rotating (alternating) boilers ........................................... 76
Bottom blowoff ................................................................... 77
Annual inspection .............................................................. 78
Operating during maintenance and repairs .................. 80
Pressure testing ................................................................... 81
Lay-up................................................................................... 83
Tune-ups ............................................................................... 84
Auxiliary turbines .............................................................. 88
Chapter 3 - WHAT THE WISE OPERATOR KNOWS
Know your load ................................................................. 93
Know your plant ................................................................ 97
Matching equipment to the load .................................... 98
Efficiency ............................................................................ 100
Performance monitoring ................................................. 105
Modernizing and upgrading .......................................... 106
Chapter 4 - SPECIAL SYSTEMS .............................................. 109
Vacuum systems ............................................................... 109
Hydronic heating .............................................................. 110
High temperature hot water (HTHW) ......................... 114
Organic fluid heaters and vaporizers .......................... 116
Service water heating ...................................................... 118
Waste heat service ............................................................ 123
Chapter 5 - MAINTENANCE
Maintenance....................................................................... 125
Cleaning ............................................................................. 126
Instructions and specifications ....................................... 127
Lock-out, tag-out .............................................................. 128
Lubrication ......................................................................... 129
Insulation ........................................................................... 132
Refractory ........................................................................... 134
Packing ............................................................................... 136
Controls and instrumentation ........................................ 138
Lighting and electrical equipment ................................ 140
Miscellaneous .................................................................... 143
Replacements ..................................................................... 144
Maintaining efficiency ..................................................... 148
Records ............................................................................... 149
Chapter 6 - CONSUMABLES
Fuels .................................................................................... 151
Fuel gases ........................................................................... 152
Oils ...................................................................................... 154
Coal ..................................................................................... 159
Other solid fuels ............................................................... 160
Water ................................................................................... 162
Treatment chemicals ......................................................... 164
Miscellaneous .................................................................... 165
Chapter 7 - WATER TREATMENT
Water treatment ................................................................ 167
Water testing ...................................................................... 168
Pretreatment ...................................................................... 172
Feedwater tanks and deaerators ................................... 175
Blowdown .......................................................................... 179
Chemical treatment .......................................................... 180
Preventing corrosion ........................................................ 182
Preventing scale formation ............................................. 184
Chapter 8 - STRENGTH OF MATERIALS
Strength of materials ....................................................... 187
Stress ................................................................................... 187
Cylinders under internal pressure ................................ 189
Cylinders under external pressure................................ 191
Piping Flexibility .............................................................. 192
Chapter 9 - PLANTS AND EQUIPMENT
Types of Boiler Plants ...................................................... 195
Boilers ................................................................................. 196
Heat transfer in boilers ................................................... 197
Circulation .......................................................................... 199
Construction ...................................................................... 202
Boiler, cast iron and tubeless ......................................... 203


Firetube boilers ................................................................. 203
Watertube boilers .............................................................. 208
Trim ..................................................................................... 219
Heat traps .......................................................................... 231
Burners ............................................................................... 234
Pumps ................................................................................. 249
Fans and blowers ............................................................. 268
Cogeneration ..................................................................... 280
Chapter 10 - CONTROLS
The basics ........................................................................... 289
Self contained controls .................................................... 305
Linearity ............................................................................. 307
Steam pressure maintenance .......................................... 308
Fluid temperature maintenance ..................................... 312
Fluid level maintenance .................................................. 314
Burner management......................................................... 318
Firing rate control ............................................................ 321
Low fire start ..................................................................... 322
High-Low ........................................................................... 322
Burner cutout .................................................................... 323
Jackshaft control ............................................................... 323
Establishing linearity ....................................................... 326
Startup control .................................................................. 327
Parallel positioning .......................................................... 328
Inferential metering .......................................................... 330
Steam flow / air flow ..................................................... 330
Full metering cross limited ............................................ 331
Dual fuel firing ................................................................. 333
Choice fuel firing .............................................................. 334
Oxygen trim ...................................................................... 334
Combustibles trim ............................................................ 336
Draft control ...................................................................... 336
Feedwater pressure control ............................................ 338
Instrumentation ................................................................. 340
Chapter 11 - WHY THEY FAIL
A little bit of history ........................................................ 347
Low water .......................................................................... 347
Thermal Shock .................................................................. 349
Corrosion and wear ......................................................... 350
Operator error and poor maintenance ......................... 350
APPENDICES
Properties of water and steam ...................................... 353
Water pressure per foot head ........................................ 357
Nominal capacities of pipe ............................................. 358
Properties of pipe ............................................................. 360
Secondary ratings of joints,
flanges, valves, and fittings ................................. 368
Pressure ratings for various pipe materials ................ 371
Square root curve ............................................................. 372
Square root graph paper ................................................. 373
Viscosity conversions ....................................................... 374
Thermal expansion of materials .................................... 376
Value conversions ............................................................. 377
Combustion calculation sheets ...................................... 378
Excess air/O2 curve ......................................................... 384
Properties of Dowtherm A ............................................. 385
Properties of Dowtherm J ............................................... 386
Chemical Tank Mixing Table ......................................... 387
Suggested mnemonic abbreviations for
device identification .............................................. 389
Specific heats of common substances .......................... 391
Design temperatures for selected cities ....................... 392
Code Symbol Stamps....................................................... 395
Bibliography ................................................................................. 396
Index ............................................................................................. 397

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