EXPERIMENT NO.

HOW TO RUN A BOILER

ME LAB 2

ALMORADO, RONALD Q.
CARDANO, SEDRICK RYAN V.
DASAL, CARLO MIGUEL C.
DELA CRUZ, KYLE ERJO E.
I. OBJECTIVES
1. To be familiar with the operation of a fire tube boiler.
2. To be able to determine the importance of the boiler safety procedures.
3. To formulate a boiler maintenance schedule.

II. THEORY

A boiler is a closed vessel intended for use in heating water or for application of heat
to generate steam or other vapour to be used externally to itself as defined in the PSME
Code.

Boiler operation is one of the important roles of a practicing mechanical engineer.

Knowledge of the following must be obtained and every engineer must be equipped:

Boiler parts and auxiliary equipment identification

Boiler start-up parameters

Boiler safety and operating procedure

Boiler maintenance and troubleshooting

III. LIST OF APPARATUS / EQUIPMENT

Fire tube Boiler

IV. PROCEDURE:
1. Check the fuel oil and feed water system.
2. Switch on the main switch located at the side of the main control panel.
3. Unit will start and continue to operate until desired steam pressure is reached. When
maximum pressure is reached, unit will stop. As the pressure lowers to predetermine
setting on the pressure unit will again fire and repeat the cycle. A pressure controller
which is mounted in the panel box stops and starts their boiler to meet steam
requirement.
4. Open main steam valve slowly.
5. To stop unit, flick main switch to stop position.
6. Close main steam valve, fuel supply valve and water supply valve.
V. SET-UP OF APPARATUS
VI. QUESTIONS AND ANSWERS
1. From the set-up, define and discuss the importance of the parts of the boiler.
a. Steam Dome: This is a chamber located at the top of the boiler where the
steam collects before being released through the steam outlet.
b. Safety Valve: A crucial safety component, the safety valve is designed to
release excess steam if the pressure inside the boiler exceeds the safe limit,
preventing explosions due to pressure buildup.
c. Large Flues and Small Flues: Flues are the passages or channels through
which the hot gases produced by combustion travel before they reach the
chimney. Large flues are the main channels where gases pass through, while
small flues are secondary passages that help improve heat transfer
efficiency.
d. Fire Grate: It's a platform within the boiler where the fuel, such as coal or
wood, is burned. The fire grate allows air to pass through the fuel bed for
combustion and ash removal.
e. Saturated Steam Outlet: This is the point where the saturated steam,
generated by heating water in the boiler tubes, exits the boiler. Saturated
steam is steam at its saturation temperature corresponding to the pressure of
the steam.
f. Exhaust Gases: These are the waste gases produced during the combustion
process. They contain heat energy that is transferred to the water
surrounding the boiler tubes, increasing the temperature and producing
steam.
g. Superheater Header: A superheater is a component that further heats the
saturated steam to increase its temperature and energy content. The
superheater header is the part of the boiler where superheater tubes are
connected to receive saturated steam.
h. Superheater Elements: These are the tubes or coils within the superheater
section where the saturated steam passes through. They are exposed to
high-temperature gases to increase the steam temperature beyond its
saturation point.
2. Enumerate the do’s and don’ts in operating a boiler.

Dos:

a. Follow Manufacturer's Instructions: Adhere strictly to the manufacturer's

guidelines and operating manual for the specific boiler model. This includes
startup, shutdown, and maintenance procedures.
b. Regular Inspections: Conduct regular inspections to check for leaks,
corrosion, and any other issues that may affect the boiler's operation.
Address any problems promptly.
c. Water Level Monitoring: Maintain proper water levels in the boiler. Low water
levels can expose heating surfaces and cause damage, while high levels can
lead to inefficiency or even a hazardous situation.
d. Water Quality: Ensure the water used in the boiler is of suitable quality, as
poor water quality can cause scale buildup or corrosion, affecting efficiency
and longevity.
e. Safety Devices Check: Test and maintain safety devices regularly, such as
safety valves, pressure gauges, and alarms, to ensure they are functioning
correctly.
f. Proper Ventilation: Ensure proper ventilation around the boiler area to prevent
the accumulation of flammable gases or carbon monoxide.
g. Training and Certification: Ensure that operators are adequately trained and
certified to operate the boiler. Proper training helps in understanding the
equipment and handling emergency situations.
h. Regular Maintenance: Follow a scheduled maintenance plan for cleaning,
lubrication, and inspection to keep the boiler in optimal condition.

Don'ts:

a. Neglecting Safety Procedures: Avoid bypassing safety devices or operating

the boiler without following proper safety protocols.
b. Overpressure: Do not allow the boiler to operate at pressures higher than the
manufacturer's specified limits. This can lead to equipment failure or even
explosions.
c. Improper Water Treatment: Don't neglect water treatment processes. Poor
water quality can lead to scale buildup, corrosion, and decreased efficiency.
d. Ignoring Warning Signs: Don't ignore warning signs such as unusual noises,
leaks, or fluctuations in pressure or temperature. Address these issues
promptly.
e. Unauthorized Modifications: Avoid making unauthorized modifications to the
boiler system. Any alterations should be carried out by qualified professionals
following safety guidelines.
f. Skipping Regular Inspections: Neglecting routine inspections and
maintenance can lead to undetected issues that may worsen over time,
impacting boiler performance and safety.
3. What are the classifications/types of boilers? Differentiate

Fire Tube Boilers:

 Water surrounds the tubes containing hot gases.

 Generally used for low to medium pressure applications.
 Suitable for small steam capacities and low to medium steam pressures.
 Easy to operate and maintain due to simple construction.
 Typically have a compact design and respond quickly to load changes.

Water Tube Boilers:

 Tubes containing water are surrounded by hot gases.

 Ideal for high-pressure applications and large steam capacities.
 Efficient heat transfer due to large surface area for heat exchange.
 More complex construction but allows for higher steam generation rates.
 Require more careful water treatment and maintenance due to complex
design.
4. When entering a boiler room, what must be an engineer do first? Why?

Upon entering a boiler room, the foremost priority for an engineer is ensuring
safety. This involves conducting a thorough visual inspection to identify any potential
hazards. Checking for proper ventilation, verifying the status of safety protocols, and
wearing appropriate personal protective equipment (PPE) are crucial steps. Assessing
the condition of the boiler, whether it's operational, shut down, or undergoing
maintenance, is imperative. Reviewing operational records and logs helps in
understanding recent activities and any reported issues. Additionally, familiarizing
oneself with emergency procedures and the location of safety equipment like shutdown
switches, fire extinguishers, and emergency showers is essential. Taking these
precautionary measures ensures a safe environment for further operations or
maintenance tasks within the boiler room.

5. Where should a boiler be located? Why?

A boiler should be situated in a dedicated boiler room or a specially designated

area designed to meet specific requirements. The location of the boiler is critical for
several reasons. Firstly, it needs proper ventilation to facilitate the intake of air required
for combustion and the expulsion of combustion by-products. This ventilation helps
prevent the buildup of potentially harmful gases. Secondly, the chosen location should
comply with safety regulations and building codes, ensuring easy accessibility for routine
maintenance and inspections while minimizing risks in case of emergencies. Sufficient
space around the boiler is necessary to allow for installation, servicing, and repairs,
along with accessibility to essential resources like water, fuel sources, electrical
connections, and drainage systems. Shielding the boiler from environmental factors such
as extreme weather conditions, direct sunlight, and freezing temperatures is also
important to maintain optimal operation. Additionally, placing the boiler in an area that
minimizes noise and vibration disturbances to occupants or neighboring spaces is
crucial for comfort and safety. Ultimately, the chosen location must adhere to local
regulations, zoning laws, and safety standards regarding clearances, fire safety, and
environmental considerations. Consulting with professionals during the installation
process ensures that all these factors are taken into account to determine the most
suitable location for the boiler.

6. Make a boiler maintenance schedule and checklist. In a frequency of daily, weekly,

monthly
Maintenance Task Description Status

Daily

Check Water Level Ensure water level is within []

specified range
Monitor Pressure Check boiler pressure gauge for []
recommended range
Inspect for Leaks Look for leaks, unusual noises, []
or irregularities
 Check Safety Test safety valves, pressure []
Devices switches, etc.
Weekly
Perform Bottom Remove sludge and sediment []
Blowdown buildup
Check Flame Inspect burner flame for color []
Appearance and stability
Inspect Fuel Levels Ensure adequate fuel supply []
Clean Boiler Remove debris, ensure proper []
Surroundings ventilation
Monthly
Inspect and Clean Inspect burner components, []
Burners clean fuel nozzles
Test Alarms and Verify proper functioning of []
Controls alarms and controls
Check Electrical Inspect wiring and connections []
Connections for damage
Inspect Water Check water treatment []
Treatment System equipment and chemicals
Annually
Shutdown Comprehensive examination of []
Inspection internals and insulation
Safety Valve Testing Testing and inspection of safety []
valves
Inspect and Clean Check and clean flue passages []
Flue Gas Path and soot blowers
Efficiency Testing Conduct efficiency test to []
assess performance
Review Maintenance Update records, note repairs, []
Records replacements, etc.

VII. CONCLUSION

In conclusion, fire tube boilers serve as essential components in various industrial and
residential settings, utilizing a straightforward design where hot gases pass through tubes
surrounded by water to generate steam. These boilers are recognized for their simplicity,
ease of operation, and quick response to load changes. They are suitable for low to medium
pressure applications, offering reliability and efficiency in powering machinery, generating
heat, and producing steam for different purposes. While fire tube boilers have their
advantages, such as ease of maintenance and compact design, they may not be as suitable
for high-pressure applications compared to water tube boilers. Understanding their design,
maintenance requirements, and safety considerations is crucial for ensuring their safe and
efficient operation in diverse industrial and heating applications.
 VIII. REFERENCES

Apex Team. (2023, November). Fire Tube Boilers. Retrieved from

https://www.apexengineeringproducts.com/fire-tube-boilers/

Pearson. (n.d.). Boilers. Retrieved December 13, 2023, from

https://www.pearsonhighered.com/assets/samplechapter/0/1/3/4/0134891260.pdf

Wikipedia contributors. (2006, February 10). File:Locomotive fire tube boiler schematic.png -
Wikipedia. Retrieved from
https://en.m.wikipedia.org/wiki/File:Locomotive_fire_tube_boiler_schematic.png