Heating Boiler Operator's Manual: Maintenance, Operation, and Repair

Home >
Browse >
Heating Boiler Operator's Manual: Maintenance, Operation, and Repair

Heating Boiler Operator's Manual: Maintenance, Operation, and Repair

Authors: Mohammad A. Malek

Published: 2007

ISBN: 9780071709668 0071475222

Contents

Preface

Chapter 1. Heating Boiler Basics

1.1 Hot Water and Steam

1.1.1 Properties of hot water

1.1.2 Properties of saturated steam

1.2 History of Heating Boilers

1.3 Types of Heating Boilers

1.3.1 Classification based on use

1.3.2 Classification based on material

1.3.3 Classification based on fuel

1.3.4 Classification based on tube type

1.3.5 Miscellaneous boilers

1.4 Heating Boiler Code

1.5 Adoption of Boiler Code

Chapter 2. Steam Heating Boilers

2.1 Steam Boilers

2.2 Types of Steam Heating Boilers

2.2.1 Space heating steam boilers

2.2.2 Steam cooker

2.2.3 Steam sterilizers

2.3 Steam Heating System

2.3.1 Piping arrangements

2.4 Steam Heating System Components

2.5 ASME Code Requirements

2.5.1 Materials requirements

2.5.2 Welding requirements

2.5.3 Design of weldments

2.5.4 Attachment welding

2.5.5 Inspection

2.6 Specifying a Steam Heating Boiler (Combination Gas/No. 2 Oil-Fired, 200 HP, MAWP 15 psi)

Chapter 3. Hot Water Heating Boilers

3.1 Hot Water Heating Boilers

3.2 Types of Hot Water Heating Boilers

3.2.1 Hot water heating boilers for space heating

3.2.2 Boosters for commercial dishwashers

3.3 Hot Water Heating System

3.3.1 Gravity system

3.3.2 Forced circulation heating system

3.3.3 Zone-controlled system

3.3.4 Solar system application

3.4 Hydronic Heating Systems

3.4.1 Components of hydronic heating system

3.5 Specifying a Hot Water Heating Boiler (Gas-Fired, Capacity 500 MBtu/hr, MAWP 150 psi)

Chapter 4. Hot Water Supply Boilers

4.1 Hot Water Supply Boilers

4.2 Types of Hot Water Supply Boilers

4.2.1 Hot water supply boilers without tanks

4.2.2 Hot water supply boilers with tanks

4.2.3 Pool heaters

4.3 Hot Water Supply System

4.3.1 Hot water supply system with gravity tank

4.3.2 Hot water supply with a pressurized tank

4.4 Specifying a Hot Water Supply Boiler (Gas-Fired, Capacity 2,450,000 Btu/hr, MAWP 160 psi)

Chapter 5. Hot Water Heaters

5.1 Working Principle

5.2 Types of Hot Water Heaters

5.2.1 Use type

5.2.2 Tank type

5.2.3 Water heaters based on fuels

5.2.4 Miscellaneous water heaters

5.3 Combination Space and Water Heaters

5.3.1 Working principle

5.3.2 Application

5.4 Hot Water Heater System

5.5 ASME Requirements

5.5.1 General outline

5.5.2 Material requirements

5.5.3 Design

5.5.4 Inspection and stamping

5.5.5 Controls

5.6 Installation

5.6.1 Safety relief valve requirements

5.6.2 Water supply

5.6.3 Storage tanks

5.6.4 Expansion tank

5.6.5 Piping expansion

5.6.6 Bottom drain valve

5.6.7 Thermometer

5.7 Maintenance and Repairs

5.8 Inspection

5.9 Specifying a Hot Water Heater (Gas-Fired, 125 Gallons, MAWP 160 psi)

Chapter 6. Cast Iron Boilers

6.1 General Features

6.1.1 Construction

6.1.2 Major components

6.2 Classification of Cast Iron Boilers

6.2.1 Horizontal-sectional cast iron boiler

6.2.2 Vertical-sectional cast iron boiler

6.2.3 One-piece cast iron boiler

6.3 ASME Code Requirements

6.3.1 Material requirement

6.3.2 Design requirements

6.3.3 Assembly method

6.3.4 Hydrostatic test

6.3.5 Stamping requirements

6.3.6 Manufacturer’s data reports

6.4 Prevention of Thermal Shock

6.5 Maintenance

6.6 Inspection

6.7 Specifying a Cast Iron Boiler (Natural Gas-Fired Steam Boiler 100 HP, MAWP 15 psi)

Chapter 7. Modular Boilers

7.1 Modular Systems

7.1.1 Modular steam heating boilers

7.1.2 Modular hot water boilers

7.1.3 Modular hot water heaters

7.1.4 Combination modular system

7.2 Installation of Modular Boilers

7.2.1 Individual modules

7.2.2 Assembled modular boilers

Chapter 8. Boiler Design

8.1 Cylindrical Parts under Internal Pressure

8.1.1 Tubes

8.1.2 Heads

8.1.3 Flat Heads

8.2 Cylindrical Parts under External Pressure

8.3 Openings in Boilers

8.4 Reinforcement Requirements for Openings

8.5 Inspection and Access Openings

8.6 Stayed Surfaces

8.7 Staybolts

8.8 Staying of Heads

8.9 Tube Sheets

8.10 Ligaments

8.11 Tube Holes and Tube Attachments

8.12 External Piping

Chapter 9. Pressure Relief Valves

9.1 Types of Pressure Relief Valves

9.1.1 Safety valves

9.1.2 Relief valves

9.1.3 Safety relief valves

9.2 ASME Code Requirements

9.2.1 Safety valve requirements for steam boilers

9.2.2 Safety relief valve requirements for hot water boilers

9.2.3 Safety and safety relief valves for tanks and heat exchangers

9.2.4 T&P safety relief valves for hot water heater

9.2.5 Minimum requirements for safety and safety relief valves

9.2.6 Discharge capacities of safety and safety relief valves

9.2.7 Calculation of capacity to be stamped on valves

9.3 Specifying Presure Relief Valves

9.3.1 Specifying a safety valve

9.3.2 Specifying a safety relief valve

Chapter 10. Boiler Construction

10.1 Material Requirement

10.1.1 Stress values

10.1.2 Minimum thickness

10.2 Fabrication

10.2.1 Specific welding requirements

10.3 Inspection and Testing

10.4 Stamping of Boilers

10.4.1 Code symbol stamp

10.4.2 Stamping of boilers

10.5 Manufacturer’s Data Reports

Chapter 11. Combustion Systems

11.1Fuels

11.1.1Gas

11.1.2 Liquefied petroleum gas (LPG)

11.1.3 Fuel oils

11.1.4 Coal

11.1.5 Electricity

11.2 Fuel Burning Equipment

11.2.1 Gas burning equipment

11.2.2 Oil burning equipment

11.2.3 Coal burning equipment

11.3 NOx Control

11.3.1 NOx control technologies

Chapter 12. Boiler Appurtenances

12.1 Safety Valves and Safety Relief Valves

12.2 Low-Water Fuel Cutoffs and Water Feeders

12.2.1 Float-type low-water fuel cutoffs

12.2.2 Electric probe-type low-water fuel cutoffs

12.3 Steam Traps

12.3.1 Thermostatic steam trap with a bellows element

12.3.2 Thermostatic steam trap with a bimetallic element

12.3.3 Inverted bucket steam trap

12.3.4 Float and thermostatic (F&T) traps

12.3.5 Thermodynamic disc steam traps

12.4 Air Eliminators

12.5 Condensate Return Pumps and Return Loop

12.5.1 Hartford Loop

12.6 Vacuum Return Pumps

12.7 Circulating Pumps

12.8 Expansion Tanks

12.9 Oil Preheaters

12.10 Fuel Oil Storage and Supply Systems

12.10.1 Storage tanks

12.10.2 Fuel strainers

12.11 Pressure Gage

12.11.1 Gage range

12.11.2 Accuracy

12.11.3 Calibration

12.11.4 Siphon tubes

12.12 Pressure or Altitude Gages

12.13 Water Gage Glasses

12.14 Pressure Controls

12.15 Thermometers

12.16 Temperature Controls

12.17 Stop Valves

12.18 Bottom Blow-off Valves

Chapter 13. Instruments and Controls

13.1 Controls for Steam Heating Boilers

13.1.1 Steam gages

13.1.2 Water gage glasses

13.1.3 Water column

13.1.4 Pressure control

13.1.5 Automatic low-water fuel cutoff

13.2 Controls for Hot Water Heating or Hot Water Supply Boilers

13.2.1 Pressure or altitude gage

13.2.2 Thermometer

13.2.3 Temperature control

13.2.4 Low-water fuel cutoff

13.3 Controls for All Boilers

13.3.1 Instruments and control-mounted inside jackets

13.3.2 Electrical

13.3.3 Control circuits

13.3.4 Limit controls

13.3.5 Shutdown switches and circuit breakers

13.3.6 Controls and heat-generating apparatus

13.4 Controls and Safety Devices

13.4.1 Operating controls

13.4.2 Limit controls

13.4.3 Safety controls

13.4.4 Programming controls

13.4.5 Testing of controls and safety devices

Chapter 14. Installation

14.1 Boiler Room

14.1.1 Safety

14.1.2 Lighting

14.1.3 Water and drain connections

14.1.4 Fire protection

14.1.5 Housekeeping

14.1.6 Posting of certificates

14.1.7 Recordkeeping

14.2 Combustion Air

14.3 Venting

14.4 Boiler Placement

14.4.1 Mounting pressure relief valves

14.4.2 Feedwater and makeup water connections

14.4.3 Oil heaters

14.4.4 Storage tanks

14.4.5 Expansion tanks

14.4.6 Stop valves

14.4.7 Bottom blow-off and drain valves

14.4.8 Methods of support

14.4.9 Piping

14.5 Operation Tests

14.6 Documentation

Chapter 15. Operation

15.1 Boiler Operators and Engineers

15.2 Steam Boiler Operation

15.2.1 Cleaning and filling a new boiler

15.2.2 Boiling out method

15.2.3 Starting a boiler (single boiler installation)

15.2.4 Condensation

15.2.5 Cutting in an additional boiler

15.2.6 Operation

15.2.7 Removal of boiler from service

15.3 Heating Boiler and Hot Water Supply Boiler Operation

15.3.1 Cleaning and filling a new boiler

15.3.2 Starting a new boiler (single boiler installation)

15.3.3 Condensation

15.3.4 Cutting in an additional boiler

15.3.5 Operation

15.3.6 Removal of boiler from service

15.4 Periodic Tests

15.5 Boiler Room Emergency

15.6 Operation Log Sheet

Chapter 16. Inspection

16.1 Authorized Inspectors

16.1.1 Qualification

16.1.2 Authorized inspector’s responsibilities

16.1.3 Inspection tools

16.2 Boiler and Machinery Insurance

16.3 Boiler Inspection

16.3.1 First inspection

16.3.2 Routine inspection

16.4 Inspection of Steam Heating Boilers

16.5 Inspection of Heating Boilers and Hot Water Supply Boilers

Chapter 17. Maintenance and Repairs

17.1 Maintenance Tools

17.2 Tube Cleaning

17.2.1 Mechanical cleaning

17.2.2 Chemical cleaning

17.3 Tube Expansion

17.4 Refractory Maintenance

17.5 Preparing for Inspection

17.6 Maintenance of Steam Heating Boilers

17.7 Maintenance of Hot Water Heating and Hot Water Supply Boilers

17.8 Boiler Repairs

Chapter 18. Water Treatment

18.1 Boiler Water Troubles

18.2 Water Treatment Chemicals

18.3 Functions of Chemicals

18.4 Treatment Alternatives

18.5 Blowdown

18.6 Feeders

18.7 Procedures

18.8 Treatment of Laid-Up Boilers

Chapter 19. Glossary of Terms

19.1 Boilers and General Terms

19.2 Fuels, Fire Burning Equipment, and Combustion

19.3 Terms Relating to Water Treatment

Appendix A. Extraction from Rules for the Construction of Low-Pressure Heating Boilers (1923)

Appendix B. Maximum Allowable Stress Values for Ferrous Materials

Appendix C. Maximum Allowable Stress Values for Nonferrous Materials

Appendix D. Maximum Allowable Stress Values in Tension for Lined Materials

Appendix E. Maximum Allowable Stress Values for Materials in Tension for Unlined Water Heaters

Appendix F. First Inspection Report on Boilers

Appendix G. Charts for Components under External Pressure

Appendix H. Manufacturer’s Data Report for All Types of Boilers Except Watertube and Those Made of Cast Iron

Appendix I. Manufacturer’s Data Report for Watertube Boilers

Appendix J. Manufacturer’s Master Data Report for Boilers Constructed from Cast Iron

Appendix K. Manufacturer’s Data Report for Water Heaters of Storage Tanks

Appendix L. Manufacturer’s/Installing Contractor’s Report for ASME CSD-1

Appendix M. Properties of Water

Appendix N. Properties of Saturated Steam

Appendix O. Unit Conversions

Bibliography

Index