Presented by Moises Rodriguez Cleaver Brooks Sales & Service, Inc.

Have you ever asked yourself what is your job as a boiler plant engineer? Do you know what is the purpose of the equipment and how it works? How would you rate your knowledge about the equipment and how it works? Do you know how to maintain the equipment? What is the objective of a good operation and maintenance program?

To answer these questions lets take a look at what is the system and how it operates. Once we have a good understanding of the system it becomes easier to maintain. A good operation & maintenance program will provide many benefits.

Proper Operation & Maintenance Objectives Safe operation = Prevent accidents Efficient operation = Save money Extend the useful life of the equipment Reduce the unscheduled downtime

Safe Operation o o o When not operated and maintained properly, any boiler room equipment can fail with devastating consequences including personal injuries and/or death The energy available in a typical heating boiler is more than enough to remove the boiler from it s original location The energy available in the fuel and steam in a boiler is sufficient to destroy a building and/or damage other equipment in the boiler room

Boiler Explosion

Efficient Operation o o o Properly maintained equipment reduces operating cost and increase overall efficiency 1 % increase in efficiency can reduce fuel cost by 1% With a good preventive maintenance program the number of unscheduled shut down is reduced

Extend Useful Equipment Life o o o Properly maintained equipment will last longer Properly operated equipment will breakdown less Higher return on investment when the equipment last longer (no major capital investment for longer time)

Equipment Longevity/Decreased Downtime Follow Manufacturers recommendations for; 1) Minimum temperatures 2) Minimum & maximum flow rates 3) Maximum capacity Be aware of boiler overloading and prevent it

Decrease / Reduce Down Time o o Properly maintained and properly operated equipment will breakdown less and last longer. A good preventive maintenance program will help reduce the down time and extend equipment useful life A ounce of prevention is worth a pound of correction

Two Exemplary Boiler Rooms

Today We Will Discuss Steam & Hot Water System Equipment Common Types Of Boilers Burner Controls and Safety Interlocks Feed System Maintenance Water Softener and Water Treatment The Maintenance Program

To obtain maximum benefit from the discussion Please ask questions Address your questions to the facilitator or to the group Take notes Keep a copy of the presentation for future reference Please refrain from conversation Any Questions? Are we ready to begin?

Lets begin our discussion with the following simple questions. 1. What is a steam or hot water system? 2. What is the purpose of the system? 3. What is the steam or hot water used for? 4. How much steam or hot water is needed 5. How much steam or hot water is generated 6. How efficient is my system? 7. Is the system being maintained properly? 8. Can the system be improved for better efficiency?

Steam System Steam System Care & Preventive Maintenance

Steam System Equipment o o o o o Water Pretreatment System Boiler Feed Water System Fuel Supply System Boiler Blow Down System

Water inlet

o Water Pretreatment Filters Softener Chemical Feed Other

Filters Remove impurities from the water by passing the water through the filter media. There are several filtering media (material) available among them, sand, carbon, paper, membranes, manganese, etc.

Filter

Water inlet

What is hard water? When water is referred to as 'hard' this simply means, that it contains more minerals than ordinary water. These are, primary, the minerals calcium and magnesium. The degree of hardness of the water increases when more calcium and magnesium dissolves. Magnesium and calcium are positively charged ions. Because of their presence, other positively charged ions will dissolve less in hard water than in water that does not contain calcium and magnesium. Hardness is the cause why soap doesn't really dissolve in hard water. You can experience this effect when taking a bath with hard water that the skin feels dry. On the contrary when the water is soft you will feel the skin softer and feels like if you had applied skin lotion.

Softener Remove the hardness producing minerals (Ca & Mg) from the water by passing the water through a synthetic resin in a process know as ion exchange. Ca & Mg produce scale in the boiler, pipes, etc.

Water softeners are specific ion exchangers that are designed to remove ions, which are positively charged. Softeners mainly remove calcium (Ca 2+ ) and magnesium (Mg 2+ ) ions. Calcium and magnesium are often referred to as 'hardness minerals. Softeners are sometimes capable to remove some iron. Softeners can operate automatic, semi-automatic, or manual. Each unit is rated or has a capacity based on the amount of hardness it can remove before regeneration is necessary.

Water Softener

Water inlet

Chemical Feed System Use to inject chemicals in the boiler water to control certain parameters in the water. More than one chemical feed systems might be necessary to accomplish the desired results.

Chemical Feed System

Recommended Boiler Water Control Limits

o Boiler Feed Water System Atmospheric Feed System Deaerator Surge Tank Condensate Receiver System Heat Recovery System

Boiler Feed Water System Make up water from the pre-treatment system (softener) and condensate return are receive and store in the tank (10 minutes reserve is recommended) where the water is heated and chemicals added prior to entering the boiler.

Boiler Feed Water System - The system is comprised of a water storage tank, a supporting stand, one or more boiler feed water pump (s) and steam (or high temperature condensate) return diffuser along with safety controls, alarms and indicators. The two most common type of boiler feed water systems in use are; Atmospheric Feed System Deaerator

Atmospheric Feed Water System Non pressurized boiler feed water system that receive make up water from the water pretreatment system (softener and other) and condensate return, preheats the water and feeds the water to the boiler via the boiler feed pump (s). The system can operate to a maximum water temperature of 99 deg C or 210 deg F (Recommended minimum 85 deg C or 180 deg F). The system can be equipped with a steam diffuser, water level and pump controls, gauge glass, thermometer, etc.

Atmospheric Boiler Feed System

Deaerator Boiler Feed System The principle on which a deaerator works is Henry's Law, expressed graphically on the next slide. At the chosen pressure the amount of dissolved gases goes to zero when the water is at the boiling temperature for that particular pressure. Since it takes time for a bubble of oxygen to form and rise, boiling the water hard shortens this time. It is therefore possible to have a deaerator work at vacuum, atmospheric pressure, or a higher pressure. Atmospheric and low pressure (5 PSI) deaerators are the most common and often used.

Good deaerator performance depends on hard boiling, therefore the generated steam must be highly condensed before the gases are vented to atmosphere to avoid loss of steam. A properly operated deaerator require drastically fewer oxygen scavenging boiler treatment chemicals. In summary deaeration achieves the following: Removes air (oxygen and carbon dioxide) Raises feed water temperature (reduces boiler shock, less fuel to heat up the water in the boiler) Improves heat Saves money (limits chemicals, limits boiler re-tubing, saves return lines, heat exchangers & process equipment)

Deaerator Packed Column Type Deaerator Spray Type Deaerator

Water inlet

Other Water Pretreatment Equipment Demineralizer Dealkalizer Reverse Osmosis Ultra Violet Deionizer Heat Recovery System Sampler Cooler Sampler Cooler Heat Recovery System Demineralizer

Water inlet

o Fuel Supply System Fuel Oil Gas Solid Fuel

Gas Supply System The gas supply system delivers fuel to the boiler from the fuel storage tank or city supply at a specific pressure. The system is comprised of Pressure Reducing Valve Fuel Shut Off Valves Vent Valve Metering Valve (Fuel Flow Control) Controls Alarms Pressure Indicator

Typical Multiple Boiler Gas System

o Boiler

Boiler A boiler is used to heat water or other media (including thermal fluid/oil) in order to produce steam, hot water or high temperature heating oil. The energy released by burning fuel in the boiler furnace (or by electric heating elements) is stored in the steam, water or heated oil produced. A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications.

Fire Tube Boiler

o Blow Down System The blow down system is used to safely discharge the boiler blow down water.

To drain To drain Water inlet

What are the different types of Boilers available?? 50

There are --- Watertube Sectional or Cast Iron 51

They can be --- 52

ASME Code Section I or Power boilers High pressure - Steam boilers above 15 psi. Hot water boilers above 160 psi and/or 250 0 F. Section IV or Heating Boilers Low pressure - Steam boilers less than 15 psi. Hot water boilers less than 160 psi and/or 250 0 F. 53

ASME Code Section VIII Unfired pressure vessels Deaerators or pressurized tanks 54

Field Repair Pressure vessel National board State boiler inspectors Insurance company inspectors Repair forms Repair procedures R Stamp companies 55

Common Types Of Boilers o Fire Tube o Water Tube o Fire Box o Tube Less

Fire Tube Boiler A fire tube boiler is a boiler where the combustion gases travel inside the boiler tubes while the water is outside of the boiler tube.

Fire Tube Boilers Dry Back Design 3 pass Dry Back Design 4 pass Wet Back Design

Commercial Boilers Steam, Hot Water & HW Condensing Boilers

Water Tube Boiler A water tube boiler is a boiler where the water is inside the boiler tubes while the combustion gases travel outside of the boiler tube.

Water Tube Boiler Commecial Water Tube Industrial Water Tube Flex Tube Water Tube

Fire Box Boiler A boiler where the furnace is below the boiler pressure vessel and not integral to the boiler as is found on fire tube boilers. The combustion gases travel inside of the boiler tubes.

Tubeless A boiler where the combustion gases travel outside the pressure vessel. Does not has flux tubes.

HMS Titanic Boiler Steam System Care & Preventive Maintenance

HMS Titanic Boilers Steam System Care & Preventive Maintenance

Steam System Care & Preventive Maintenance

Any Questions?

Hot Water Boiler Design 74

Air Removal & Make-up 75

Air Removal - Remote Expansion Tank Auto Air Vent System Circulating Pump 76

Interlock Of Pump With Boiler System Circulating Pump 77

Proper Over-Pressure System Circulating Pump 78

Minimum Operating Temperature of 170 o F Return Temp - 150 Outlet Temp - 170 System Circulating Pump 79

Two Good HW Operating Practices Periodic water analysis to see when treatment is needed. A planned preventative maintenance program. 80

Three-Way Valve in System 81

Circulation through Boiler 82

By-Passing Boiler 83

Boiler Circulating Pump 84

Balance Flow Through Boilers 85

Summary Provide continuous circulation through the boiler Prevent hot or cold shock Prevent frequent cycling Balance the flow through boilers Provide proper over-pressure Provide water treatment 86

Any Questions?

Boiler Description

Boiler Exterior

Boiler Exterior Combustion Air Inlet Steam Outlet Manhole Safety Valves Chimney Blower Motor Surface Blow Off Low Water Level Cut Off Rear Door Davit Air Pump Front Head (Door) Electrical Entrance HIGH VOLTAGE Fuel Oil Connections (Supply / Return) LWCO Blow Off Valve Handhole Base Rail Casing And Insulation

Rear Head (Door) Rear sight port Union connection Sight port cooling line

Boiler Interior

Boiler Interior (Fire Side & Water Side) Water Side Fire Side

Fire Side Front View Tube Sheet Stay Braces (Water Side) Head Gasket (Door) Front Tube Sheet Front Baffle Gasket Flux Tubes (Water Side) Front Baffle (Tap Pole Gasket) Burner Housing (Dry Oven)

Fire Side Rear View Rear Tube Sheet Flux Tubes Furnace (Also Know as Morrison Tube)

Fire Side Refractory Mineral Wool Rear Door Baffle Flame Sight Port Hi Temp Castable Refractory Head Gasket (Door)

Fire Side Furnace Refractory Throat Tile Furnace Liner

Water Side Stay Braces Rear Tube Sheet Flux Tubes Furnace

Controls and Safety Interlocks

Controls & Safety Interlocks ALWCO Safety Valves Stack Thermometer Blower Motor OLC HLC MFC Surface Blow Off Low Water Level Cut Off Low Oil Press Switch Electrical Entrance HIGH VOLTAGE LWCO Blow Off Valve Fuel Filter

Flame Safeguard Controls Sequence the operation of the burner Receives inputs from safety controls Generates outputs to turn on combustion air fan, fuel valves, etc.

Flame Safeguard Controls Electro mechanical type Mechanical timer motor Limited diagnostics Limited replacement availability

Steam Boiler Pressure Controls OLC HLC MFC

Hot Water Boiler Temperature Controls Temperature Indicator OLC HLC MFC Temperature Sensors

Water Level Controls Auxiliary Low Water Cut Off Low Water Cut Off Head Water Level Gauge Glass Low Water Cut Off Body

Low Water Cut Off (McDonnell & Miller) Gauge Glass Connection Head Assembly With Switches Tricocks Gauge Glass Connection Float

Safety Relief Devices Ensure proper piping of safety valves Test operation on a regular basis Remove and recondition safety valves as required by boiler inspector

Air Intake Blower Motor CAPS Control Panel Atomizing Air Pump AAPS Burner Drawer Fuel Oil Controller Electrical Entrance Panel High Voltage Ignition Transformer

Atomizing Air Pump Oil Reservoir Burner Switch Alarm Bell Manual / Auto Switch Fuel Shut Off Valves LOPS Fuel Flow Meter Fuel Oil Controller Ignition Transformer Fuel Pump

Flame Detector Flame Detector Ignition Electrode Pilot Gas Manual Shut Off Valve

Burner

Burner Gas Burner Drawer Fuel Oil Nozzle Burner Housing Burner Gun Ignition Electrode Gas In

Burner Drawer Air Damper Linkage Atomizing Air Pressure Gauge (12 psi @ LF 22 psi @ HF) Burner Gun Assembly Oil Drawer Swtch Modulating Motor Fuel Oil In Atomizing Air In

Burner Drawer Gas Metering Cam Fuel Oil Metering Cam Burner Fuel Supply Pressure Indicator Flame Sight Port Fuel Oil Shut Off Valves (solenoid or motorized) Air Register (Damper) Fuel Oil Line Atomizing Air Line

Any Questions?

The Maintenance Program

Boiler Explosion

Safe Operation Maintain proper amount of combustion air supply Keep flue gas breechings and stacks clean and sealed Maintain and check operation of any flue gas dampers Atmospheric Motorized

Boiler Care & Treatment Efficient operation A 300 HP boiler is capable of burning over $300,000 worth of natural gas in one year Every 1% improvement in efficiency drops directly to the bottom line Does not include savings in chemicals, maintenance, etc.

Burner Efficiency A 40 o F change in boiler room air temperature will result in a 15% excess air change in the burner Too low excess air - sooting Too high excess air - inefficient operation

Burner Performance Also relates to safe operation Maintain burner linkages Check fuel and air pressures Have burners tuned semi-annually

Safety Interlock Controls Test all safety controls on a regular basis Don t allow the normal reliability to lull you into a false sense of security Increases maintenance awareness

System Efficiency Steam/Hot water leaks Bad steam traps Insulating piping Operating at proper temperatures/pressures Be aware of consequences of changing

Equipment Longevity Maintain water treatment!!! Poor water treatment can destroy a boiler in less than one year Be sure auxiliary equipment is operational Softeners, chemical feed systems, etc. Costs of boiler repairs related to poor water treatment can get close to the cost of a new boiler

Equipment Longevity/ Decreased Downtime Be aware of proper warm up and shut down procedures Limit the amount of cold startups a piece of equipment is exposed to Set up controls or sequence boilers to reduce excessive on/off cycling

Water Treatment & Boiler Blowdown Proper mechanical treatment Water softeners Deaerators, feedsytems Blowdown systems Proper chemical treatment Chemical feed systems More is not necessarily better Proper boiler blowdown

Heat Transfer Surfaces Prevent soot buildup 1/8 of soot increases fuel consumption 40% Prevent scale buildup 1/8 of scale increases fuel consumption 20% Stack temperature is main indicator 40 o F rise is 1% efficiency loss Hot Gasses Water Hot Gasses

Soot vs. Heat Transfer Scale vs. Heat Transfer Heat Transfer Loss Due To Scale & Soot Soot Thickness Scale Thickness 0.14 0.25 0.12 0.1 0.08 0.2 0.15 0.06 0.04 0.02 0.1 0.05 0 1 0.98 0.96 0.94 0.92 0.9 0.88 0.85 0.82 0.76 0.6 0.55 0.5 Heat Transfer Multiplier 0

General Maintenance Boiler room equipment biography Keep written operating procedures Good housekeeping a must Keep electrical equipment clean Keep fresh air supply adequate Keep accurate fuel records

General Maintenance Establish a regular schedule Use a log sheet SAFETY - SAFETY - SAFETY

Maintenance Daily Weekly Monthly Annual/Semi-annual

Daily Maintenance Check water level No water in glass? Shut off burner Secure water supply to the boiler - DO NOT LET ANY WATER GET INTO THE BOILER Cool down boiler, open it up and inspect for damage

Daily Maintenance Check boiler pressure or temperature Higher or lower than normal

Boiler Blowdown Surface blowdown / TDS control Bottom blowdown Primarily sludge removal Review monthly with water treatment company Quick opening valves Slow opening valve

Daily Maintenance Bottom Blowdown Procedure 1. Open valve A 2. Open valve C (10-15 seconds or as directed) 3. Close valve C 4. Close valve A 5. Check Water level, allow to return to normal level 6. Open valve B 7. Open valve C (10-15 seconds) 8. Close valve C 9. Close Valve B 10. Check water level returns to normal Slow opening valve C Quick opening valves A & B

Daily Maintenance Water Column Blowdown Low Water Cutoff, gauge glass and Auxiliary Low Water Cutoff on a regular schedule Place burner in manual low fire Open valve slowly Burner should shut off *** *** Blowdown IS NOT the proper method to test the operation of the Low Water Cutoff ***

Daily Maintenance Record makeup water usage Check general burner operation and flame pattern Check operation of auxiliary equipment Treat water

Daily Maintenance Record gas pressure Inlet to regulator Outlet from regulator Manifold (elbow) pressure

Daily Maintenance Record oil pressure and temperature Base-rail pressure Supply pressure Return pressure Heavy oil - temperature

Daily Maintenance Record boiler water supply and return temperatures Watch for widely varying return temperatures Return Supply

Daily Maintenance Record oil atomizing pressure Varies with burner firing rate Approx. 7 psi with no fuel flow to 25 psi at high fire (CB Boiler only) Low pressure Problem with gun or air pump

Daily Maintenance Check stack temperature 50 O - 100 O F above steam or water temperature Reference firing rate

Daily Maintenance Record feedwater pressure / temp. DA - pressure and temperature in tank should correspond 5psi - 227 O F Feedsystem - vented tank, variable temp Minimum recommended water temp is 180 deg. F

Weekly Maintenance Water level controls evaporation Test Boiler steams off naturally

Weekly Maintenance Water level controls Evaporation Test Under Constant Attendance and burner at low fire monitor water level in the gauge glass 1. Stop feedwater flow to the boiler 2. Shut off pump 3. Burner must shut off when water level reaches the marking on the LWCO 4. Close a valve, return pump to automatic operation and check water level returns to normal 1. Do this once a week

Test the Low Water Cutoff Burner must shut off when water level reaches the marking on the casting of the Low Water Cutoff If burner does not shut off at the low water cutoff point: 1. Turn the burner switch off 2. Cool down the boiler 3. Open and inspect the Low Water Cutoff assembly 4. Replace if defective, do not attempt to repair

Weekly Maintenance Check gauge glass Tubular & Prismatic Check for etching on waterside - thinning of glass

Weekly Maintenance Check flame scanner assembly Remove and check flame failure response (burner should stop in < 4 sec) Record signal strength (on FSG) Clean lens Clean sight tube

Weekly Maintenance Check operating and limit controls Are they level Free movement of mercury switches/snap switches Turn on & off at settings

Weekly Maintenance Check fuel and air linkage Smooth movement Tight connections Check set screws Spray with light lubricant 156

Weekly Maintenance Check fuel valves Open & Close visual check Vent valve leaks Manual plug cock operation 157

Weekly Maintenance Do the things we ve already covered Test low water cutoffs Blowdown boiler Keep heat transfer surfaces clean Check flame safeguard and safety interlock controls

Weekly Maintenance Check for hot spots Wherever hot gases are being contained Usually a sign of a more serious problem Investigate and repair quickly Rear sight port Sight port cooling line Union connectio n

Weekly Maintenance Check indicating lights and alarms Check operation of all motors Check safety and interlock controls Check for leaks, noise, vibration, unusual conditions, etc.

Monthly Maintenance Review boiler blowdown Inspect burner operation Perform flue gas analysis Inspect for flue gas leaks

Monthly Maintenance Check cams, linkage and swivels connecting linkage for free movement Insure tightness of setscrews Wear of cam spring Spray with light lubricant

Monthly Maintenance Check Burner Drawer Diffuser position & condition Pilot tube condition Electrode condition and position Damper movement

Monthly Maintenance Check combustion air supply Pay special attention to the boiler air intake, look for blockage like plastic bags, debris build up, etc. Check filter elements Check fuel system Check belt drives Check lubrication requirements

Annual/Semi-annual Maintenance Check all safety and interlock controls Have burners readjusted to optimum efficiency Don t forget about auxiliary equipment

Semi-Annual Maintenance Clean low water cutoff (s) Clean cross connecting piping Should not be heavy accumulation Check water treatment

Semi-Annual Maintenance Repair refractory Throat & Liner No loose bricks Seal between housing and throat Rear door No loose sections Baffle to lower half joint Wash-coat lightly, if any minor cracks or porosity

Semi-Annual Maintenance Inspect switches operation Mercury should be shiny Dull surface indicates contamination Check wires going to switches Look for burned wires

Semi-Annual Maintenance Check pump coupling alignment Reset combustion

Annual Maintenance Coordinate with inspector Establish procedures SAFETY - SAFETY - SAFETY

Annual/Semi-annual Maintenance Usually coordinated with boiler inspector Completely open fireside and waterside of boiler Use proper lockout/tagout procedures Be aware of any confined space requirements Use low voltage lights when entering boilers

Annual Maintenance Clean fireside surfaces Brush & vacuum tubes Clean tube sheets & refractory Amount of soot indicates how well burner is performing

Annual/Semi-annual Maintenance Clean fireside and waterside surfaces Dirty surfaces are an indication of a problem Waterside - water treatment Fireside - burner/combustion air Repair and maintain refractory surfaces

Annual/Semi-annual Maintenance Replace gaskets Inspect and maintain any special seals Burner housings to burner refractory Baffle seals Check tubes for signs of leakage, cracking or overheating

Annual Maintenance Repair refractory Cracks 1/8 and under will close up when heated Look for loose sections

Annual Maintenance Check hydraulic valves Bubble test for valve seat tightness check Actuators open & close properly

Annual Maintenance Check gauge glass Leaks Thinning of glass Alignment of valves Tubular Replace - with new grommets

Annual Maintenance Clean breeching Clean waterside surfaces Check oil storage tanks Check oil pumps

Annual Maintenance Remove and Recondition safety valves Inspect piping for loose hangers putting weight on valves

Annual Maintenance Recondition Boiler feed pumps Wear rings Seals Packing Bearings Recondition shaft and/or impellers

Annual Maintenance Check condensate receivers Flush out Check any lining for failure Clean pump strainers

Annual Maintenance Check chemical feed system Clean out tank Recondition pump Inspect & clean out piping to injection points

Annual Maintenance Tighten electrical terminals!! Power off!! All panels, all controls & components

Annual Maintenance Check deaerator or boiler feed system Water sprayhead Collector cone assembly & steam atomizing valve of spray types Check any possible lining Clean out pump strainers

Annual Maintenance Check linkages Lubricate Tighten Replace worn parts

Boiler Room Log Water level Steam pressure / water temperature Feed pump pressure Feed water temperature Condensate temperature

Boiler Room Log Flue gas temperature Gas pressure Oil pressure Oil temperature Deaerator water level

Steam Cleaver-Brooks Boiler Room Log Date Time Boiler # Operator Water visible in gauge glass Combustion check (visual) Steam pressure Feedwater pressure Feedwater temperature Flue gas temperature Burner Gas pressure Gas meter reading Oil pressure (regulated) Oil temperature Oil meter reading Atomizing air pressure Ambient air temperature Barometric pressure Blowdown water column Blowdown boiler Comments/Observations Note: Record water analysis and treatment on separate log.

Any Questions?

A quick look at the Cleaver Brooks Web Site Steam System Care & Preventive Maintenance

Any Questions?

Thank you for your participation. Should you have additional questions please contact us

Cleaver Brooks Sales & Service, Inc. 210.798.1808 Moises Rodriguez 210.557.0472 mrodriguez@cbservice.com Javier Tovar 210.563.9839 jtovar@cbservice.com