What is the meaning of marine boilers ?

Boiler is a pressure vessel used on ships in which the water is heated to evaporate and
generate the steam and the unit is so arranged that the generated steam accumulated in it.
The two main types are water tube and fire tube.

Types of Boilers :

1. Coal/Wood (Solid Fuel) fired boilers.

2. Liquid Fuel Fired Boilers.
3. Gas fired boilers.
4. Economisers.
5. Water Tube Type.
6. Smoke Tube Type.
7. Horizontally mounted Boiler.
8. Vertically mounted Boiler.

What is boiler mounting ?

It is directly fitted to the boiler shell. They are:
1. Safety valve
2. Main steam stop valve
3. Air vent cock
4. Two gauge glass level indicators
5. Feed check valve
6. Scum blow down valve
7. Bottom blow down valve
8. Salinity cock or test cock
9. Man hole doors.
10. DP Transmitter
11. Refractory bottom drain

Where are air vent cock located and its purpose ?

The air vent cock is fitted at the top of the steam space of the boiler.

Its purpose are-

1. To release air from the boiler either filling the boiler water or raising the steam.
2. To allow air to enter in the event of boiler cooling down or blowing down. ( to
prevent vacuum effect)

What are the safety arrangements in marine boiler ?

1. Safety valve
2. Low / high water level alarm
3. High / Low water level alarms
4. Water level indicators
5. Pressure gauge
6. Low fuel oil pressure alarm
7. Low / high fuel oil temperature alarm
8. Flame failure alarm
9. Smoke density alarm
10. Easing gear arrangement
11. Air vent
12. Force draught fan stop alarm
13. Low / high steam pressure alarm
14. High Pressure cutout
15. High High / Low Low water level cutout

Why need to blow down the gauge glass ?

Gauge glass blow down is made to know the boiler and gauge glass connection is clear or
not and to give the exact water level in the boiler.
Boiler gauge glass blow through procedure ?
1. Shut steam and water cocks than open the drain cock.
2. After draining water from the sight glass, there is nothing come out, both steam and
water cocks are good in order.
3. Open the steam cock side, blow out the steam.
4. Close the steam cock side, the steam connection is clear.
5. Open the water cock side, blow out the water.
6. Close the water cock side, the water connection is clear.
7. Close the drain cock.
8. Open the water cock, water should then gradually come rise up to the top of the
gauge glass.
9. Open the steam cock, the water in the glass should fall to the level of the water in the
boiler.

Why need to blow down the boiler water ?

Boiler blow down is made to reduce the density of salt and to remove the dissolved
and suspended solids, also the floating solid impurities in the boiler system.
If there are not removed from the boiler water system, foaming, priming, corrosion
will occur in the boiler steam space and feed water system.

Why scum blow down or surface blow down is carried out ?

To remove accumulated, suspended and floating solids, impurities and also remove
dissolved solid concentration, they hinder the formation of steam.

Why bottom blow down is carried out ?

To remove suspended solids and residual sludge that have settled at the bottom.
If these contaminants are not removed regularly they will build up until they hinder
the circulation patterns.
What is the purpose of boiler water test ?
To ensure that proper chemical treatment are maintained at all time.
To detect the present of contaminants in the water that may be injurious to boiler and
system.
Enumerate the boiler water test ?

1. Alkalinity test [Phenolphthalein ( p) alkalinity test, Total ( T ) alkalinity test (2 x P)]

2. Chloride test
3. Condensate PH test
4. Amerzine test ( Hydrazine test )
5. Excess phosphate test
6. Conductivity test (Total dissolve solids test)
7. Hardness test

Alkalinity test

This is to ensure that the boiler water prevent corrosion by neutralization of acidic
gases.

(a) Phenolphthalein or p alkalinity

This test is carried out to prevent acidic corrosion
To test for presence of all of the hydroxide, one half of the carbonate and one third of
phosphate present in a water sample.
(b) Total ( T ) alkalinity test
To determine the amount all of hydroxide, all of the carbonate, and two thirds of the
phosphates

Chloride test
 To know the amount of salt in boiler water.
To minimize chloride level and to adjust the blow down.

Condensate PH test

To control condensate PH value within a limit.

To minimize corrosion in steam and condensate system.

Amerzine test ( Hydrazine test )

To test for dissolved Oxygen content

To know reserve hydrazine (N2H4 ) ppm and to prevent corrosion and aeration.
To minimize oxygen pitting and corrosion in boiler, steam and condensate system.

Phosphate test

To control the scale formation due to hardness (presence of Phosphate in sample

means no hardness salts)
A reserve of phosphate should be maintained in the boiler water ready to neutralize
any hardness salts which may enter.

Conductivity test

Measure of the total amount of dissolved solids (T.D.S) including the

treatment chemicals. (Excessive density leads to priming and or deposits)
To remove dissolved and suspended solid by blowing down.

Hardness test

To check for salt causing hardness

Note: Hardness test of boiler water are not necessary when the phosphate is above the lower
limit of the control range.

What are the advantages of boiler water treatment ?

1. To prevent the scale formation in the boiler and feed system
2. To prevent corrosion in boiler and feed system.
3. To control the sludge formation and prevention of carry over with the steam.
4. To maintain the boiler water in alkaline condition and free from dissolved gases such
as Oxygen, thereby minimizing corrosion.
5. To prevent of entry into the boiler of foreign matter such as oil, waste, mill scale, FeO,
Cu, Sand, etc.
6. To reduce risk of Caustic Cracking.

What is meant by erosion in boilers ?

It is a mechanical attack on the metal surface which may be due to a disturbance in the
flow of the fluid over the metal surfaces, resulting in a loss of metal. Suspended
abrasive matters in the fluid can increase the rate of metal losses.

What is meant by corrosion in boilers ?

It is the deterioration of metals due to oxidation. The present of water in an acidic

condition provides the electrolyte required for corrosion action.

Two forms of corrosion

Direct chemical attack

It occurs when metal at high temperature comes into contact with air or other gases,
resulting in oxidation or sulphidation of the metal.
Electro-chemical action
Galvanic action, this being set up when two dissimilar metals are placed in an
electrolyte. The noble of the two metals form a cathode to the base metal which,
forming the anode, is wasted away.

What is meant by caustic embrittlement in boilers?

Caustic Embrittlement is the phenomenon in which the mterial of a boiler becomes brittle
(breakable) due to accumulation of caustic substances.
it is caused by formation of NaOH by reaction of Na2CO3 and water. NaOH produced reacts
with the surrounding material and dissolves iron as iron ferrate. this causes embrittlement.
it can be prevented by using sodium triphosphate as softening agent instead of sodium
carbonate.

What is pH value for boiler water ?

It is the logarithm of reciprocal of hydrogen iron concentration.

What do you do for preventing of oxygen in boilers?

The oxygen-scavenging chemical which is used for deaerating the water are usually
sodium sulphate or hydrazine.
2Na2SO3 + O2 = 2Na2SO4
N2H4 + O2 = 2H2O +N2
Excessive dosage of hydrazine could lead to steam and condensate line corrosion due
to ammonia being produced as the excess hydrazine decomposed.
In high pressure boiler, by using the sodium sulphite, the sulphite can break down to
give hydrogen sulphide which can attack steel brass and copper.

If chloride is found too much in your boiler water what will you do ?
Blow down frequently
Reduce the boiler load to minimum.
If highly contaminant shut down completely and wash out.
Trace and find out the fault and remedies.

What do you understand by composite boiler ?

If exhaust gas and oil fired can be used the same time, it is termed the composite boiler.
In this type a separate tube nest of tube for exhaust gas is provided, situated above the
return tubes from the fire furnace.
Uptake from the tube nest are separated.

What do you understand by alternative boiler ?

If the exhaust gas and the oil fire are arranged to be used only at a time, the exhaust
gas boiler term as the alternative boiler.
This unit can be oil fire heated by the exhaust gases alternatively.
It required only one uptake.
What do you understand by economizer boiler ?
In this system a separate exhaust gas economizer is connected to an oil fired auxiliary
boiler or an accumulator by means of piping and a set of circulation pump.
Exhaust gas is used as heating medium and it has no steam space.

What is meant of accumulation pressure in marine boilers?

Accumulation pressure is the rise in boiler pressure which take place when the spring
loaded safety valve lift due to the increase loading caused by further compression of
the spring.

What is the purpose of accumulation pressure test ?

To detect the safety valve is suitable for this boiler or not.
To limit the rise in boiler pressure under full fire condition.

What is the procedure of accumulation pressure test ?

This test is carried out a new boiler or new safety valve.
1. Shut off feed water
2. Closed main steam stop valve.
3. Increase cut off pressure of boiler.
4. Bypass high pressure cut off of the boiler.
5. Arrange the boiler fire rate to a maximum.
6. Safety valve will be lift during the test.
7. The test is carried out as long as the water permits in the boiler.
8. Accumulation pressure should not exceed 10% of working pressure in the specified
time.
9. Specified time is 15 mins for a smoke tube boiler and 7 mins for water tube boiler.

Procedure of safety valve setting under steam pressure ?

Setting of safety valves:
1. Take standard pressure gauge (approved by surveyor) for accuracy.
2. Fill up water up to of gauge glass level, and shut main steam stop valve, feed check
valve.
3. Without compression rings, hoods and easing gears, reassembled the safety valves
with spring compression less than previous setting.
4. Raise the boiler pressure to desired blow off pressure.
5. Screw-down spring compression nuts of any lifting valves, until all are quite.
6. Arrange to have the desired steam pressure
7. Adjust each valve in turn: Slacken compression nut until the valve lifts. Screw-
down compression nut sufficiently enough, so that when the valve spindle is lightly
tapped, valve return to its seat and remain seated. Measure gap between compression
nut and spring casing. Make a compression ring equal to this gap, and insert under
compression nut. Gag the spindle of this safety valve, to prevent opening, while
remaining valve is being set.
8. Remaining valve is again set and insert compression ring.
9. Remove gag and retest both valve to lift and close together.
10. Cap, cotter and easing gear to be refitted
11. Caps and cotter pins padlocked to prevent accidentally altering the setting.
12. When the surveyor satisfied the setting pressure, easing gear should be tested.
13. All safety valves set to lift at not greater than 3% above approved working pressure
(design pressure).

How do you take action if one of the passages of gauge glass is

chocked ?
Steam and water cocks and passages in the gauge can be cleared while the boiler is
still steaming.
To do this, shut the steam and water cocks and open the drain cock.
Remove the check plug opposite the obstruction.
Insert the cleaning plug. Screw in the plug with small hole about 5 mm diameter,
drilled through it in place of the cleaning plug.
Insert into this hole a rod of such a size that held by a gloved hand, it can be easily
moved without being stuck.
Then open the chocked and push the rod through to clear the blockage.
When clear, open drain to prevent a build up of pressure and only a small amount of
steam will blow past the rod, the glove protecting the operator from injury.
Then close the cock and replace the normal cleaning plug. The gauge glass can be
tested now and if satisfactory return to service.
Do not carry out this operation on a plate type glass on a high pressure boiler.

What are the causes of boiler furnace blow back ?

1. Insufficient purging time
2. Accumulation of oil in furnace from the leaky burners
3. Boiler tubes and uptake have full of soot deposits.
4. Air registers control not operating for the high flame mode.
5. Too little air
6. Insufficient oil temperature

How to keep boiler not in service ?

For fire tube boiler out of service for short period
The boiler must be completely filled with alkaline water.
The boiler must be topped up periodically and any air in the system must be got rid off.
Regularly test the boiler water and keep the alkalinity in the range of recommended
value.
If the boiler is to be taken out of service for long period
It should be drained completely and open up.
Dried out by means of heater units.
Then the trays of quick lime (moisture absorbent material) should be place internally
in suitable positions.
Blanks should be fitted to the pipe connections in the event of steam being maintained
in other boiler and blow down line.
The quick lime should be renewed at least once every two months.

What is the difference between safety valve and relief valve ?

Safety valve
1. Directly open the design lift at set pressure.
2. Can open manually by easing gear.
3. Setting pressure is just above the working and not more than 3% above the
approved working pressure.
Relief valve
1. Setting pressure is 10% above working pressure .
2. Opening is proportion to the increase in pressure.
3. Can not be open manually.

What are the markings on safety valve ?

1. Manufacturers name
2. Serial number
3. Inlet diameter
4. Operating pressure
5. Discharge capacity
6. Safe working pressure
7. Blow off pressure