A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated

water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. When water is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous equipment that must be treated with utmost care. The process of heating a liquid until it reaches its gaseous state is called evaporation. Heat is transferred from one body to another by means of (1) radiation, which is the transfer of heat from a hot body to a cold body without a conveying medium, (2) convection, the transfer of heat by a conveying medium, such as air or water and (3) conduction, transfer of heat by actual physical contact, molecule to molecule.

Boiler Systems
The boiler system comprises of: feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system.

The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returned from the processes and (2) Makeup water (treated raw water) which must come from outside the boiler room and plant processes.

Boiler Types and Classifications:

The boilers may be classified as follows: 1.Horizontal, vertical or inclined If the axis of the boiler is horizontal, the boiler is called as horizontal, if the axis is vertical, it is called vertical boiler and if the axis is inclined it is called inclined boiler. The parts of a horizontal boiler can be inspected easily but it occupies large area. The vertical boiler occupies less area. 2. Externally fired and internally fired The boiler is externally fired if the fire is outside the shell. Example : Babcock and Wilcox, stirling boiler etc. In case of internally fired boiler, the furnace is located inside the shell. Example: Cochran, Lancashire boiler etc. 3. Forced circulation and natural circulation In forced circulation type of boilers, the circulation of water is done by a forced pump. Example: Velox, Lamont, Benson boiler etc. In natural circulation type of boilers, circulation of water in the boiler takes place due to natural convention currents produced by the application of heat. Examples : Lancashire, Babcock and Wilcox boiler etc. 4. High presuure and low pressure boilers The boilers which produce steam at pressure of 80 bar and above are called high pressure boilers. Examples: Babcock and Wilcox boiler, Velox, Lamont, Benson boiler etc. The boilers which produce steam at pressure below 80 bar are called low pressure boilers. Example: Cochran, Lancashire boiler etc. 5. Fire tube & Water tube boilers Fire tube or fire in tube boilers; contain long steel tubes through which the hot gasses from a furnace pass and around which the water to be converted to steam circulates. Fire tube boilers, typically have a lower initial cost, are more fuel efficient and easier to operate, but they are limited generally to capacities of 25 tons/hr and pressures of17.5 kg/cm2.

Water tube or water in tube boilers in whichthe conditions are reversed with the water passing through the tubes and the hot gasses passing outside the tubes. These boilers can be of single- or multiple-drum type. These boilers can be built to any steam capacities and pressures, and have higher efficiencies than fire tube boilers.

BOILER SAFETY STANDARDS Before entering any boiler : 1) Lock out and tag all equipment items with movable parts connected to the boiler and fuel system and place a sign at the operating controls indicating that a workman is in the boiler. 2) Make sure it is properly isolated at ALL fuel, flue gas, steam and water sources; make sure it is properly vented and obtain an air sample tocheck for breathing quality. Use low voltage lights or explosion proofflashlights inside the boiler. 3) Notify the person in charge at the site when beginning and upon completion of the inspection. 4) Always be aware of the nearest escape routes. 5) Before closing drum manholes and furnace doors, it is essential to ensure that all personnel are out of the boiler. Before Closing The Boiler 1) Thoroughly inspect all available parts of the boilers interior, both the waterside and the fireside. Ensure no tools, rags or other debris are left lying around inside the boiler that could cause problems. 2) Tubes and other areas that are not easily visible should be checked using other suitable methods i.e. push rods, mirrors, etc. All loose tubes and debris should be swept into a dustpan being careful not to sweep into tubes, drains, or blow-down connections. 3) Check all internal piping, hangers, brackets, etc. to be sure they not been damaged during maintenance work. 4) Replaceall gaskets on the waterside and steam connections. The cost is minor compared with the headaches from leakages later on. Use a graphite paste or other suitable paste to prevent sticking.

5) Gas side gasket joints are not as critical, but require close inspection and cleaning and replacement if necessary. Testing The Gas Side For Leakage

1) For a forced draught unit, the draft fan may be used to place the furnace under high enough pressure by closing off the outlet damper. Passing a lighted candle along all the joints to be tested, tests the furnace attachments, furnace seals and smoke-box seals. The effects upon the flame will detect any leaks of air from the positive pressure furnace to the atmosphere. Another method is to use a soap test, which must be thoroughly dried after the test.
Water And Steam Systems 1) Visual survey all the areas of the plant to check for damage and ensure no unauthorized persons tampered with the plant. 2) Do NOT refill a boiler while it is hot. Treated warm water should be used. The boiler should be vented to permit air to escape. 3) Check the water level in the gauge glass (mid point) and all the gauge glass valves are open. 4) Open all the feed water supply valves. 5) If water level was low, use the manual bypass valve to raise the water level to slightly below the midpoint of the gauge glass )i.e. head pressure from the hot well). 6) Check the make-up water supply system to the hot well and whether it shall function automatically i.e. check float condition and operation. 7) Start the feed water pump. 8) Check the water treatment plant is in full operating condition. 9) Boiler vent valve and any steam line vents should be opened to bleed air out as steam is raised. 10) Open the main steam valve bypass. When distribution manifold is up to temperature and pressure, bypass valve is closed and main steam valve is opened. 11) Open all steam drains, including steam trap bypasses, when the bypass valve was opened.

Fuel Systems Covers fuel oil and fuel gas supply to a boiler. 1) Check furnace internals for obvious signs of fuel leaks due to failure of the fuel valves to shut off (oil). 2) Check the gas supply pressure is greater than the minimum permissible. 3) Check the fuel oil temperatures (for heavy fuel oil). 4) Check all the fuel valves are in final position for light-up sequence.The vent valves between the gas shut-off valve should be closed. 5) Check all burner control panel lights are ready.

Air Systems Covers the combustion air system and the instrument air system and/or

plant air for oil atomizer: 1) Check the intake air dampers are open and clear of any debris or obstructions. 2) Check both the primary and secondary air dampers are set and ready for automatic operation. 3) Check the damper control system is ready to operate. 4) Check the flue dampers for readiness to operate. 5) Check the draft fans are clear, run free and ready to operate. 6) Check the instrument air supply lines are clear of water and pressure is correct. 7) If atomizing air is being used for the fuel oil, clear the line of all condensed water by draining and check its pressure. Manufacturer's Instructions - Equipment manufacturer's instructions should be followed. Training - Employees must be trained in safety prior to operation of the equipment. The training in safety should be a continuous process for the purpose of educating employees to recognize and to keep safety in their minds throughout their careers. A training program should be established and maintained. Housekeeping - Good housekeeping is essential for safety and good plant operation. Poor housekeeping results in increased safety hazards. A clean and orderly environment will foster safety. Clothing and Protective Equipment - Proper clothing should be worn at all times. Avoid loose clothing and jewelry. Protective equipment must be worn when necessary (i.e.: hard hats, respirators, ear plugs, goggles, gloves, safety shoes, etc.). Never operate rotating equipment, mechanically automated devices, or electrically and pneumatically operated control components unless guides, shields, or covers are in place. Hot Surfaces - Many hot surfaces exist in a boiler area and even non-heated surfaces can become uncomfortably warm, therefore, employees, especially new employees, must be made aware of these conditions. Refractory and insulation are typically provided to encounter elevated surface temperatures in some installations. Care must be exercised to prevent burns and other thermal hazards when near the boiler. Never enter the boiler until an adequate cool-off period has been observed and the Owner's entry procedures have been completed. Lockout and Tagout Procedures - Every plant should have a formalized lockout and tagout procedure that is strictly enforced. Remote Starting of Equipment - Much of the equipment in plants are started remotely and/or automatically without warning; therefore, employees must be alert to avoiding that equipment which can be started remotely. If work is to be done on any equipment, lockout and tagout procedures must be followed. Attach signs to equipment such as "DO NOT START - MEN AT WORK". Attach a similar sign on the equipment control panel. Unexpected Noise - A sudden and/or unexpected noise may cause employees to move involuntary. Such reaction may result in injury. Precautions against this are hard to take out but experience probably is the best teacher to prevent such inadvertent responses.

Unconventional Fuels - Sometimes unconventional fuels need to be burned in boilers. When this is done, particular attention should be paid to the hazards that can result. Theses may from characteristics in the fuels, toxic chemicals in the fuel, and toxic chemicals produced through combustion. Persons knowledgeable in the use of such unconventional fuels should be consulted concerning the problems that may be encountered. Because of the wide variety and limited use, such fuels are not addressed in this manual. Fire and Explosion Hazards - A fired boiler utilizes fuels which are flammable and potentially explosive. Extreme care should be exercised when making fuel-piping connections. Use the correct gasket, bolts, thread lubricants, and tightening torque to prevent leaks. It is recommended that drain valve and/or vent piping be channeled to safe locations. Valve packing should be periodically tightened and a rigorous leak check program be implemented as part of the Owners preventative maintenance program. Electrical Hazards - Potentially hazardous voltages exist in control cabinets and electrically actuated control components. These components should only be serviced when system power is removed and only by qualified electrical or instrumentation servicemen.