EFFICIENT PRODUCTION
OF STEAM VIA PROPER
BOILER OPERATION
oilers are industrial
equipment used for the
production of steam. There
are various types of boilers
in industrial use, from the
small scale process user to the large scale
combined heating and electric power
producer. They are classified as plain double
shell, fire tube, and water tube boilers in
terms of their construction and as low
pressure, medium pressure, high pressure
and very high pressure boilers in terms of
the pressure. The water tube boiler is large
scale. Most large scale industries use water
tube boilers. Boilers being high-pressure
vessel have to be designed and fabricated
to a high standard of safety. They are made
up of bank of tubes, inside which water
circulates, connected to one or more
headers and drums.
B
The variety of types in the steam generation
field has led to the classification in terms or
their characteristics. A possible classification
criterion is the pressure and temperature,
however the distinction is not very precise
but can be adapted for convenience. Boiler
can be defined as a process equipment
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PECM Issue 31
that is used to generate steam by heating
de-mineralized water until it is converted to
steam of varying pressures.
B oiler O perations
• How to prepare the boiler for
commissioning
• How to operate the boiler
• About boiler servicing and maintenance
T o prepare B oiler for
C ommissioning
Process operators need to ensure that;
1. The water tubes are leak free.
2. The water chamber is leak free and
pressure tight.
3. The steam tubes are leak free.
4. The steam chamber is leak free and
pressure tight.
5. The combustion chambers is lined with
correct refractory materials.
6. The flue gas chamber is lined with correct
refractory material.
7. The combustion chamber, gas path down
to the stack is unblock and Ok.
8. The flue gas chamber and its path to the
stack is also clear.
9. The force draught fans is functioning well
10. The feed water (well treated and de-
ionized) pump is functioning alright and its
pressure slightly above the pressure of its
surge drum.
11. The economizer and exchanger are
ready, and in good condition.
12. The down-comers and riser are leak free
and pressure tight.
13. The safety valves, vents and drains are in
good working condition.
14. All instruments (level, pressure gauge,
controllers and valves etc) are all ok.
15. The cyclones in the steam drum is
functional.
16. The scrubbers are in good condition.
T o O perate a B oiler
1. Start water circulation.
2. Check for leakages.
3. Pressure test.
4. Start heating up.
5. Monitor pressure rise.
6. Check for leaking tubes as temperature
and pressure rise.
7. Continue heating up.
8. Stabilize the operating condition.