Steam Boiler Operation

Key concepts:
Boiler preparation
Boiler startup
Boiler shutdown
 Routine Operator Duties

• Boiler operators are responsible for the safe and efficient operation of a
boiler plant. Boiler operators must undergo an effective training program
• Their duties will include normal routine operations, safety checks, starting
and stopping equipment, blowing down the water columns and gauge
glasses
• Boiler operators will follow established procedures as outlined in the
standard operating procedures ( SOP ) manual.
• Typical duties include take over the shift, blowdown of water columns and
gauge glasses, bottom blowdown, water testing and dosage adjustments,
inspecting and monitoring equipment, documenting details in the log book,
and checking auxiliaries for levels and operational status
 Routine Operator duties

• Operators report to work early enough to discuss the previous shifts operations
with that operator. They will review the log book, and follow the Chief Engineers
instructions.
• They confirm the boilers, deaerator, and treated water levels are at the NOWL/s ,
and blowdown the water column and gauge glass. This will test the LWFCO devices.
• They will inspect all pieces of operating equipment, for proper temperature, and
vibrations, lubrication, signs of leakage, for any unusual noises, vibrations, or
smells.
• Inspect the boilers flames, fuel pressure, temperature, etc.
• Run Sootblowers as required noting any unusual noises or operating conditions
• Generally, look for any unusual operating condition in all parts of the plant
 Common duties when taking over shift

• Read the log book noting any difficulties or problems.

• Check the boiler water levels, deaerator, treated water tank also.
• Blow down the water column and gauge glasses on the boilers testing the
LWFCO devices.
• Inspect all operating equipment and its auxiliaries for unusual noises,
vibrations, and temperatures.
• Check the fuel systems that they are at normal pressures and temperatures.
• Collect and test water samples for analysis and adjust pump rates, dosages,
continuous blowdown valve adjustments, etc.
 Blowdown valves
The valve located closest to the
boiler may be a quick opening, or
slow opening valve.
The second blowdown valve must be
a slow opening valve.
Blowdown water must be able to flash
off in a blowdown tank to lower the
temperature and pressure.
Never leave the blowdown valves
unattended when blowing down the
boiler. Blowdown valve procedure is:
Confirm boiler is at NOWL
Open first valve closest to the boiler
Open the second valve slowly
Close the second valve then the first
valve
 Routine checks
Inspect the feedwater pumps, motors
and/or turbines regularly checking for
proper lubrication, bearing noise,
vibrations, temperatures, and leaks.
Check the other pumps in the plant, both
running and not running and fans.
Inspect the fans motors and fans for
proper lubrication, unusual vibrations or
sounds. Check your air compressor and
refrigeration systems.
Routinely check the water level in your
boiler, deaerator, and storage tanks,
looking for any signs of leaks.
Check the boiler fire in the furnace for
proper flame size, flame condition, and
for any abnormal conditions
 Routine checks(2)
Always maintain proper water levels.
Maintain the proper steam pressures within
the min/max values.
Keep accurate records of the fuel levels,
water levels, and consumptions.
Always ensure that there is proper draft of
fresh air into the boiler room via openings,
windows, doors or mechanical fans.
Keep accurate documentation on all
aspects of the plant operation. Fill in the
logbook every shift.
Always wait for your relief operator to
meet with you to discuss the events of the
shift that you had. NEVER leave the plant
before the relief operator has met you.
 Routine Operation
Water tests must be done routinely as per
the plant SOP’s.
The water test results must be entered in
the water treatment log sheets.
Adjustments to the chemical dosages and
blowdowns will be necessary regularly
performed by the operators.
Any maintenance is to be performed by
skilled trades persons or operators.
Maintenance will typically be carried out
on routine down times depending on the
severity of the issue with the equipment.
Routine rounds must be done to inspect all
boiler room equipment, readings entered
onto a rounds log sheet.
 Flame Scanners
Flame scanners must be checked when
starting or stopping the boiler fires to
verify that the scanner recognizes a
flame failure condition.
This would be performed by removing the
scanner sensor during the pilot flame and
main flame conditions.
The flame scanner must recognize the
flame failure and cause the fuel valves to
close within a few seconds.
Some boilers may use a separate scanner
for the pilot flame and the main flame.
Some boilers have two or more burners
and each burner would have its own
scanner network
 Furnace fire
If the furnace has proper air flow for the
fuel being burned, the flame should be
active, not lazy. This indicates the fuel is
getting adequate air flow and mixing for
complete combustion. The Flame should
not extend to the rear furnace wall. The
flame should not be scrubbing the side
walls of the furnace.
The furnace casing should not be leaking
combustion gases into the boiler room.
When checking the furnace fires, make
sure adequate safety procedures are
followed to prevent possible face burns or
eye damage. Wear your PPE.
Colored glass must be used when viewing
fires other than natural gas to protect
your eyes.
 Burning Oil
When burning oil, the tip at the end of the
gun will become coated with carbon
deposits. On a routine basis, the oil gun
would be removed for cleaning. Steps
would be taken to maintain your steam
pressure while the boiler is not running.
The oil guns would be disassembled for
cleaning and inspection for wear. Cleaning
fluids such as kerosene would be used.
Proper hands and eye protection such as
mono goggles and rubber gloves is
necessary to avoid getting the cleaning
solution on your skin or in the eyes.
Care must be taken to avoid any spills and
the area must be well ventilated and not
have any open flames in the vicinity.
 Operator duties

• Conduct water testing and appropriate adjustments to the water

• Conduct the blowdowns of the boilers as per routine. Boilers with
sidewall headers must never be blown down while the boiler is
being fired
• Monitor all water sources for flow quantity and quality
• Inspect all pieces of plant equipment for any abnormal sounds,
vibrations, smells, or any other abnormality
 Attendance

• Jurisdictions will have regulations as to what the engineers

classification and how many will be needed for each individual
plant.
• Some plants do not require 24/7 operator attendance, while the
larger Btu input plants will require numerous operators, shift
engineers. All high pressure plants must have a Chief Engineer.
• These engineers will have varying duties, and scheduled time for
attendance.
• The Chief Engineer must attend weekdays at normal office hours.
• The Shift Engineer and operators will follow regular scheduled
shifts on rotation for days and night time work.
 Plant Startup

• Perform all safety checks of the boiler such as water levels, valving positions, all
necessary equipment is ready to go, not locked out, all covers are in place for
pumps and fans. Startup water levels should be slightly less than the NOWL
• The boiler vent, feedwater valves, and fuel valves open for lighting the boiler.
• Once all equipment has been put thru a pre-light sequence, begin the lighting off
procedure
• Start the combustion fans, purge the furnace, looking for smoothness of the damper
operation, fan and motor sounds. Once purge is done, move to lighting the flame.
• As ignition trials begin, watch the pilot ignition flame and then the main flame.
Check to ensure both flames are stable. IF there is a flame scanner voltmeter on the
panel, this will aid in proving that you have a stable flame.
 Plant Startup(2)

• If there is a flame failure during the lighting of the boiler, or if the flame
safeguard systems stop the ignition process, a thorough investigation must be
done.
• Once the main flame has been lit off, remove the flame scanner to prove that
the fuel valves will close stopping the fuel to the boiler.
• Make sure that the boiler vent and header drains are open. Do not open the non-
return valve until the boiler reaches 75% to 85% normal operating pressure. This
is done if there is more than one boiler in the plant and it is at normal pressure.
• Starting the boiler from cold requires the boiler be warmed up on a specific
time/heat up schedule. Boiler water warmup is generally around 100 degrees F
per hour, so in the initial starts, the burner may need to be cycled on and off
every 5-15 minutes.
 Plant Startup(3)

• Check the flame periodically. Maintain a low fire during the warm up stage.
• As the boiler heats up and the pressure increases, at 10-25 psi, the boiler vent may be
closed.
• Test the LWFCO by blowing down the water column and gauge glass to confirm proper
operation. This may be done during the on/off cycles of the burner.
• Slowly, open if any, the equalizing steam valves between the header valve and the boiler
steam header. This will start to warm up the header from the boiler to the steam header.
• It should take between 4-6 hours to warm up the boiler. This ensures all boiler parts heat up
and expand equally. At the startup, even minimum firing rate may cause the boiler to heat
up too quickly.
• While the boiler is warming up, the water level will raise, and the operator may have to
blow down the boiler to return the water level to NOWL.
 Plant Startup(4)

• AT 85 % of header pressure, slowly open the header stop valve and close the bypass valve.
Then open the non-return valve slowly. The boiler non return will stay closed until its
pressure reaches a few PSI above the header pressure. This is referred to cutting the boiler
on line with the other boilers.
• At 85% steam pressure, you will also test the safety valve(s) by lifting the lever for 2 short
blows and one long blow of 3-5 seconds. This makes sure that the safety valves are not
seized closed.
• As this boiler comes on line, the other boiler firing controls will sense the rise in plant steam
pressure and will reduce its firing rate to maintain steam pressure set point.
• Every plant will have within its SOP’s the procedure for cutting in one boiler to join another
boiler or boilers.
• This plant may have only 1 boiler and the startup SOP will have a different procedure.
 Plant Startup(5)

• As the boiler comes on line, there may be a momentary rise in the water level
because steam is now suddenly leaving the boiler; the swell effect.
• The operator will normally have the feedwater controls on manual for the
boiler during this startup time line and adjust accordingly.
• Once the boiler is cut in, the operator will switch the feedwater controls to
automatic to maintain NOWL in the boiler.
• The next thing to do is to set the fuel controls on this boiler to automatic or you
may want to leave it in manual.
• When there are two boilers on line, it is often preferred to set one of the
boilers in manual and permit the other boiler to run in automatic pressure
control. This prevent the boilers from having the firing rates both swinging at
the same time. In essence, each boiler is fighting the other boiler.
 Other conditions to consider

• If the boiler is equipped with a super heater, steam must flow

through the superheater tubes at all times to prevent the firing
rate from overheating the tube metal during warmup.
• You would open the superheater outlet drain as soon as the fire
has been lit.
• Each manufacturer will have specific warm up procedures and
they would be built into your start up SOP’s.
• The super heater drains would remain open until the boiler is
online and producing at least 25% steam load for the boiler.
• This will ensure the tube metal temperature is maintained within
the min/max temperature.
 Cold Plant Startup

• Starting a cold boiler plant where the temperatures and pressures are at ambient
requires different techniques. Plant steam drains around steam traps would be
open to assist in removing all condensate as the plant warms up to 40 psi.
• Flange and packing connections must be checked for tightness and no leaks.
• The fuel system must be prepared for cold starting. For boilers that burn heavy
oils, light oils are first used and circulated to the burner for readiness. Light oils
guns would be used instead of the heavy oil guns. Oil strainers would be cleaned.
• The boiler plant would be isolated from the outside plant steam systems.
• Running the boiler on light oil requires the same warm up checks.
• The boiler non return and header stop valves may be in the open position if there
is no steam pressure within the boiler plant.
 Cold Plant Startup(2)

• The boiler and plant steam pressure would come up together.

• As the boiler pressure rises, the steam vent may be pinched in until at 25-35 psi,
where the vent may be closed.
• As the plant warms up, start heating the heavy fuel oil and circulating it to the
boiler. This will be separate fuel oil lines.
• At 75 psi, and with the heavy fuel oil warmed up to operating temperature and
circulating to the boiler, the light oil burner would be shut down and the main
heavy oil burner would be started. Continue heating the boiler plant while
confirming the flame stability, and operational status of the plant.
• At 100 psi, warmup bypass valves may be opened around the header valves that
supply steam to the outside plant systems.
 Cold Plant Startup(3)

• This will slowly warm up the outside plant steam headers and allow their steam
traps to handle the condensate that is being formed in the relatively cold pipes.
• Once the outside plant header pressure is up to 40 -50 psi, most of the header
piping has been warmed up. At this point, the main header valve can be started
to slowly be opened up. Monitor your steam flow meters and the steam sound.
• Gas fired plants require little preparation for starting the boiler.
• Condensate drains throughout the plant would be left open during warmup
because this water will contain dissolved gases that you do not want returned to
the feedwater system.
• Chemical pumps, treated water pumps etc would be started during the warmup.
• Once the boiler is on line with stable flames, the controls may be put in auto.
 Plant startup things to note

• Non-return valves and stop valves would be opened slowly, while listening to
signs of water hammer. This occurs when a wall of fast moving water meets a
wall of steam. The sounds would be violent shaking of the steam header pipes
with loud banging noises. This is why operations are done slowly, condensate
and header drains are open at start up to stop an accumulation of water in the
headers.
• During the plant warmup, it is in its most critical stage.
• Very close observations must be done on all operating equipment.
• Condensate at startup make not have acceptable qualities so it may have to be
drained until the quality improves, and then sent to the treated water tank or
deaerator. The continuous blowdown would be started when the chemical
tests show the conductivity is at or above its maximum level.
 Boiler Shutdown

• Slowly reduce the firing rate on the boiler to be going off line. If the boiler
has a superheater, open its drain before the boiler drops to 25% steam load.
• Let the boiler sit at low fire for a few minutes for the plant to stabilize. This
is especially necessary when other boilers are online. They will pick up the
steam load as your boiler steam production reduces and ceases steaming.
• Shut down the fuel supply to the boiler and stop the oil pumps.
• The non-return steam valve will close by itself. There will be residual heat in
the furnace which may keep the boiler producing a small amount of steam.
• Maintain a close watch on the water level; some feedwater level controls may
not seal fully closed. Eventually the feedwater valves would be closed as well
as the non return valve and header stop valves. Stop the feedwater pump if it
only supplying this boiler.
 Boiler Shutdown(2)

• Stop the fans to allow the boiler to cool slowly.

• Continue to monitor the boiler water level and adjust as needed.
• At the boiler pressure drops to 15 psi, open the vent.
• If the boiler is equipped with superheaters, make sure they remain open.
• Venting the boiler will prevent a vacuum to be formed within the boiler .
• Go through the boiler shutdown checklist to ensure that you have correctly
shutdown and isolated all systems.
• Make the appropriate log book entries regarding the times the boiler was
stopped, and equipment, valving etc. where isolated.
 Boiler Safety Checks

• Each boiler plant will have specific SOP’s detailing procedures for the
starting, stopping, normal operation, and testing of the boiler and auxiliary
systems. Each jurisdiction has detailed requirements for each plants SOP,s.
• These SOP’s are generally set up to automatically remind plant personnel
that it is time to review the plants SOP’s.
• The review is generally conducted by a committee of management and
operating personnel.
• If any changes to plant equipment is done, these SOP’s would be adjusted
very soon after the changes were made to reflect those changes.
 Plant Safety Checks

• Boiler safety checks should initially be done while the boiler is

going to be put in service.
• While is service, preferably at minimum steam load, other checks
are done on the boiler.
• Loss of flame signal test by removing flame scanner eye
• Lifting safety valve lever manually
• Testing low and high pressure fuel cut out switches
• Primary and secondary LWFCO devices
• Oil gun limit switch is so equipped
• Evaporation test
• Operating controls
 Evaporative test
• This test is done to prove that the LWFCO
system will react to a slowly changing water
level. The boiler is put on low fire, and the
feedwater supply is closed to the boiler.
• As the water level slowly drops, one
operator will take record of the low-level
alarm and low water fuel cut off points at
the gauge glass and on the chart or DCS.
• The water level must be visible in the gauge
glass when the LWFCO activates.
• The feedwater is put back in service and
the water level is returned to NOWL.
• Entry will be made in the plant logbook that
the test was conducted, and what the levels
were.
 Operating Controls
Operating controls must be tested routinely.
The operation of the controls both in
manual and automatic must be verified.
The min/max pressure settings of the
pressure controller is to be verified
accurate.
The controller for the fuel and air must
operate smoothly.
Linkages if any must be secure and not
loose or falling apart.
All aspects of the plant operation must be
checked and recorded in the appropriate
checklists and logbooks. Adjusting the
pressure set point should vary the burner
firing rate.
 High Limit Controls

• The high limit pressure control must shut down the burner if the
steam pressure exceeds its setpoint. This point would be above
the normal operating pressure. IF the high limit control is
activated, the switch must be reset to allow the burner to be
started up.
• To test this control, while the boiler is on low fire, lower the high
limit pressure set point to a pressure below the boiler pressure.
The burner should shutdown.
• Reset the high limit pressure and then push the reset button to
allow the boiler to light up again.
• If it did not shut down the burner, observe the boiler and fix the
switch.
 LWFCO and Aux LWFCO

• Blowdown the water columns one at a time to ensure the burner

shuts down.
• An evaporative test could be done on the auxiliary LWFCO device.
• This would require qualified personnel to temporarily bypass the
main LWFCO device and then conduct the evaporation test again.
• Once both devices have been tested and proven operational, don’t
forget to have the main LWFCO device put back in service.
• If both cut out devices do not function shut the boiler down and
repair them
 Flame Scanners

• Without flame scanners, the fuel could be interrupted and then

resumed. With the high temperatures within the boiler, a furnace
explosion may occur.
• If the flame scanner does not sense a flame within the furnace, it
will close the fuel SSOV valves to the boiler.
• To test the scanner, remove the scanner eye from the furnace and
cover the sensor with your hand. The flame safeguard system
should see that as a flame failure and stop the burner in 3-4
seconds
• If that does not work, shut down the boiler and fix the scanner.
 Safety Valves

• Each boiler will have 1 or more safety valve. With more than 500 square feet
of heating surface, the boiler will have 2 or more safety valves.
• Each jurisdiction, and plant Chief Engineer will establish how often the
manual try lever will be pulled on the safety valves. Boiler pressure must be
at minimum 75% of normal operating pressure.
• Wear appropriate PPE including long sleeve shirts, and possible monogoggles.
• Quickly lift and release the lever 2 times allowing the valve to snap closed.
• Finally, lift the lever 1 more prolonged time for a few seconds and release.
• This will ensure there is no debris on the safety valves seat or huddling
chamber. If the safety valve leaks, notify the Chief Engineer.
• Return the boiler to normal operation
 Oil gun Safety Switch

• Boilers that burn oil, usually have a oil gun position switch.
• To prove that the oil gun is seated correctly, a limit switch circuit
will not be closed until the oil gun is correctly positioned.
• When the oil gun is inserted correctly into the furnace, the gasket
will seal against any leaks out of the gun assembly.
• To test this switch, ensure there is no fuel or atomizing steam/air
going to the furnace, turn the fuel mode switch to oil.
• Loosen the oil gun and pull the oil gun back so the switch contact
is not being made.
• Initate the oil start sequence; this should fail. If it doesn’t, have
the switch repaired or replaced.
 Energy
Consumption

• Periodically energy audits are

performed to verify that all the
combustion equipment is operating
at peak efficiency.
• The audit could identify possible
ways to improve the plant
efficiency.
• What are some ways to increase the
plant efficiency?
 Combustion Air Proving Pressure Switch

• The combustion air proving switch is used to prove that there is

sufficient forced draft air pressure to ensure proper air/fuel
combustion in the furnace.
• With sufficient air pressure, the switch contacts will be closed.
• Note the current pressure setting.
• Raise the setting to the highest point and try to start the burner.
• The sequence should fail; if not repair or replace it
• Make sure the air pressure switch setting is returned to its normal
position
 High Gas Pressure Switch

• Under normal operations, the high pressure gas pressure switch

contacts are closed. If the gas pressure exceeds this pressure, the
switch contacts will open.
• Note the current gas pressure switch setting.
• Reset the control to its lowest setting.
• Try to start the burner; it should not start.
• If it fails, shut off the burner and fix or replace the switch.
• Return the operating switch to its original setting
 Low Gas Pressure Switch

• The gas pressure switch verifies that the gas pressure is at or

above the minimum setting.
• Take note of the current pressure setting of the switch
• To test this switch, set the switch to the highest setting.
• Try to start the burner; if the burner starts, stop the burner,
isolate and fix or replace the low gas pressure switch.
• Reset the proper operating gas pressure switch to the proper
operating setting
 Low Oil Pressure Switch

• The low oil pressure switch is used to stop the burner if the oil
pressure drops below a predetermined low level.
• Take note of the current setting.
• Reset the switch to the maximum setting.
• Try to start the burner; if the burner starts, stop the burner, and
repair or replace the low oil pressure switch.
• Reset the functional low oil pressure switch to the proper setting.
 Low Oil Temperature Switch

• When burning heavy oil, it has to be heated so that the oil will
atomize properly. If the oil cools below its limit setting, the
burner will be shut down.
• Take note of the setting.
• Reset the switch to its highest setting and try to start the burner.
• If the burner starts, stop the burner, and replace or repair the
switch.
• Reset the proper operating switch temperature setting.
 High Oil Temperature Switch

• High oil temperature switches are used to stop the burner if the
oil temperature exceeds the maximum setting.
• Take note of the current setting.
• Reduce the setting to the lowest temperature.
• Try to start the burner.
• If it starts, stop the burner and replace or fix the switch.
• Reset the proper operating switch to the initial setting.
Atomizing steam/Air Pressure Switch

• For boilers burning heavy oil, they require steam or air to atomize
the oil into a mist for burning.
• Note the setting pressure for the pressure switch.
• Reset the control to its maximum setting.
• Begin the start up sequence; the ignition sequence should fail.
• If the sequence starts, shut down the sequence, and repair or
replace the faulty pressure switch.
• Reset the properly operating switch to the correct pressure.
 SSOV Gas Valve Leak Testing

• When you have an oil leak on the pipes, hoses, or at the gun, the
leak is easily located.
• Gas leaks are much more difficult to locate.
• Natural gas has an odorant added to it to help sense any leaks,
generally smelling like rotten eggs.
• SSOV Gas valves should be tested at least annually.
• Normal gas valve trains have a manual test valve installed.
• To do this test, the gas vent valve must be closed by bypassing or
by using a deadman switch that is installed in the solenoid wiring.
 Gas Valves Testing

• To test the gas valves for leaking,

• Turn off the power to the boiler controls to ensure there is no power to the
gas safety shut off valves.
• Ensure the manual test valve is closed, remove the leak test plug and connect
the test apparatus to the manual test petcock
• Close the downstream manual gas cock.
• Immerse the ¼” tubing vertically ½” into a clear container of water.
• Slowly open the test valve
• When the rate of bubbles coming through the water stabilizes, count the
number of bubbles in 10 seconds. The manufacturer stipulates how many
bubbles are permitted within this time.
 Gas Valve Testing

• Close the manual test petcock, remove the test apparatus and
replace the leak test plug.
• Open the downstream manual gas cock
• Restore the system to normal operation.
• If the leakage rate was beyond recommended leakage rate, the
valve would be repaired or replaced.
• Typically you would use a gas fitter person to conduct this test.
 Checkpoint Questions

• What are 6 common safety checks to be performed when a boiler

is on line.

• Why are off line safety checks done

• Why is a combustion air proving switch required