Boiler Operation Engineers Questions and Answers

Q: How would you define boiler? 1

A: A boiler is a closed pressure vessel in which a fluid is heated for use external to itself by the direct
application of heat resulting from the combustion of fuel (solid, liquid, or gaseous) or by the use of
electricity or nuclear energy.
Q: What is the steam boiler?
A: A steam boiler is the closed vessel in which the steam or other vapor is generated for use external to
itself by the application of heat resulting from the combustion of fuel
Q: What is difference between a steam boiler and a steam generator?
A: Technically speaking a steam boiler consists of the containing vessel and convection heating surface
only, where as a steam generated consists the whole unit encompassing water wall tube, super heaters, air
heaters and economizers
Q: Define a hot water heating boiler?
A: A hot water heating boiler is a boiler used for space hot water heating with the water returned to the
boiler. It is further classified as low pressure it does not exceed 160 psi or 250 f. but it exceeds any of these,
it becomes a high pressure boiler
Q: What is a hot water supply boiler?
A: A hot water supply boiler is a boiler furnishing hot water to be used externally to itself for washing,
cleaning, etc. If it exceeds 160psi or temp 250f, it becomes a high-pressure power boiler.
Q: What is supercritical pressure boiler?
A: Steam and water have a critical pressure at 3206.2psi absolute(psia).At this pressure steam & water are
at same density, which means that the steam is compressed as tightly as water. When this mixture is heated
above corresponding saturation temperature of 705.4F for this pressure, dry, superheated steam is produced
to do useful high-pressure work. This dry steam is especially well suited for driving turbine-generators. A
super-critical boiler is thus one that operates above the supercritical pressure of 3206.4psia & 705.4f
saturation temperature.
Q: What is a once through boiler?
A: This refers to a boiler or steam generator, which receives, feed water at one end of continuous tubes &
discharges steam at other end.
Q: What is meant heating surface in a boiler? 2
A: This is the (fireside) area in a boiler exposed to the products of combustion. This area is usually
calculated on the basis of areas on the following boiler element surfaces: tubes, fireboxes, shells, tube
sheets and projected area of headers.
Q: What is conduction?
A: Conduction is the transfer of heat from one part of a material to another or to a material with which it is
in contact. Heat is visualized as molecular activity-crudely speaking, as the vibration of the molecules of a
material. When one part of a material is heated, the molecular vibration increases. This activity in adjacent
molecules, and heat flow is set up from the hot parts. In boilers, considerable surface conduction between a
fluid and a sold takes place, for example, b/w water and a tube and gas and a tube, in addition to
conductance through the metal of a tube, shell, or furnace.
While surface conductance can also lead to metal failures when heating surfaces become over-
heated, as may occur when surfaces became insulated with scale.

Q: How would you define convection?
A: Convection is the transfer of heat to or from a fluid (liquid or gas) flowing over the surfaces of a body. It
is further refined into free and forced convection. Free convection is natural convection causing circulation
of the transfer fluid due to a difference in density resulting from temperature changes.
Forced convection results when circulation of the fluid is made positive by some mechanical means, such
as a pump for water or a fan for hot gases. The heat transfer by convection is thus aided mechanically.
Q: Define radiation?
A: Radiation is a continuous form of interchange of energy by means of electromagnetic waves without a
change in the temperature of the medium b/w the two bodies involved. Radiation is present in all three
means of heat transfer: cond, convec, & radiation.

Q: How the term ligament defined, and how does this term affect WT boiler design?
A: A ligament is the section of solid plate b/w tube holes. But the drilling of these holes in a pattern
weakens the solid plate. Thus in designing or calculating the strength of a boiler drum, the ligament
efficiency must be considered in determining the safe working pressure, and the ligament efficiency will
always be in reference to tube hole arrangement
Whether the steam drums or mud drum. The term tube sheet may be used, even through a tube sheet such
as on ft tube boiler does not exist. In WT boiler drum design, the weld or rivet & the ligament tube
efficiency of the drum are very crucial in establishing plate thickness required for a given pressure with a
given material.
Q: Why are tubes flared in a WT boiler? 3
A: To add to the holding power of the tubes after rolling, and also to prevent the tubes from pulling out of
the tube holes if the holes should become enlarged from overheating caused by low water other reasons.
Q: What is Box header?
A: A box header is constructed of flat plates, referred to as a tube sheet and tube cap sheet. But these
surfaces must be to prevent deformation. The sides, top, bottom are flanged and riveted to the tube sheets
cap sheet. The staying of sheets limits pressure for a box header to about 600psi.
Q: Why are baffles used in the passage of WT boiler?
A: Baffles deflect the hot gases back and forth b/w the tubes a number of times to enables greater heat
absorption by the boiler tube. They also permit designing for better temperature differences b/w tubes and
gases throughout the boiler. Baffles help maintain gas velocity, eliminate dead pockets, deposit fly ash and
soot for proper removal, and prevent high draft losses.
Q: What happens when furnace baffle breaks?
A: The gases short-circuit one or more passes, causing excessive flue-gas temperature and a loss in
efficiency & also capacity. Over heating and damage might result in those parts of the boiler designed for
low gas temperature. Thus on any outage inspection, the baffle should always be carefully checked for
erosion, breaks, leakage (around tubes), or dislocation, as tube failure may result.

Q: What are some causes of tube failure in WT boiler?
A:
1. Solid deposits
2. Low water conditions
3. Corrosion
4. Slagging of gas passages which restrict normal heat transfer
5. High concentration of heat in some tube areas
6. Stress corrosion
7. Flame impingement
8. Poor circulation
9. Steam cutting and external erosion and corrosion by soot blowers that are improperly located or in
poor condition
Q: What are the economizers, and how they classified? 4
A: Economizers serve as traps for removing heat from the flue gases at moderately low temperature, after
they have left the steam-generating and superheating sections of the boiler. The general classifications is:
1: Horizontal or counter flows, according to the direction of gas flow with respect to the tubes in the bank.
2. Parallel flow or counter flow, with regard to the relative direction of gas with respect to the tubes in the
bank.
3. Steaming or non-steaming, according to thermal performances.
4. Return-bend or continuous-tube type.
5.Plain-tube or extended-surface type, according to the details of design and the form of the heating
surface.
Q: Where and why are self-locking door latches required on the firing floor? Or
What type of firing door is required on water tube boiler?
A: The inward opening type, or type provided with self-locking door latches which on its spring or friction
contact. Because so the door cannot be blown open from pressure inside the furnace in case of the tube
rupture or furnace explosion, and thus possibly burn or scald personnel standing near by
The explosion doors, it used, and it located in the setting walls with in feet of the firing
floor or operating platform must have deflectors to divert any blast

Q: What is down comer?
A: A large vertical tube or pipe for circulating from the water space of the steam drum to water wall
headers.
Q: How does gauge and absolute pressure differ?
A: Gauge pressure, as the name implies, is the pressure noted on a pressure gauge when it is installed at any
opening into the pressure part of the pressure vessel. It indicates the pressure inside the vessel. But on the
out side the vessel, the atmosphere is also exerting a pressure on outer surface of the shell. Absolute
pressure is thus total pressure of gauge pressure plus atmospheric pressure. Absolute pressure is influenced
by the elevation above sea level.
Q: Is there a difference b/w force and pressure?]
A: Yes, pressure is always expressed in kilograms per unit area. It is the force exerted on a unit area. Force
is expressed simply by the weight term. Pounds. But there is a relationship between force and pressure.
F =P * A
F is force, P is pressure, and A is area.
Q: What is modulus of elasticity, and how is this determined? 5
A: This also known as Hookes law, which states that the unit stress in a material is proportional to the
accompanying unit strain, provided that the unit stress does not exceed the proportional limit. In different
words, it states that the ratio of stress to strain for a certain material is always a constant, called E, the
modulus of elasticity, or in equation form
E =stress/strain =constant
For steel M of E is 30,00,000
Q: What is meant by safety factor?
A: In a boiler usage the factor of safety is the ultimate strength divided by the allowable loading, or the
ultimate stress (Su) divided by the allowable stress (Sa). In equation form
Su
Safety factor =------
Sa
Another method of expressing safety factor is by dividing the bursting pressure by the allowable pressure.
This method is used on state inspection reports and on ASME data reports. In equation form, it is
bursting pressure
Safety factor = -------------------
Allowable pressure
Q: What three requirements are needed for the proper chemical reaction to take place in combustion?
A:
1. Proper proportional of fuel and oxygen (or air) with fuel element as shown by chemical equations.
2. Thorough mixing of fuel & oxygen so a uniform mixture is present in the combustion zone & so every
fuel particle has air around it to support the combustion. Solid fuels will generally be converted to the
gas first the heat & pressure of air. Liquid fuels will vaporize into gases and then burn. Atomization of
liquid increases the mixing with air and increases the vaporization into a gas. Pulverization of coal
will have the same effect.
3. The ignition temperature must be established & monitored so that the fuel will continue to ignite itself
without external heat when combustion starts.
Q: What are the chief heat-producing elements in solid, liquid, or gaseous fuels?
A: the chief heat-producing elements in fuels are carbon, hydrogen, and their compounds. Sulfur, when
rapidly oxidized, is also a source of some heat energy, but its presence in fuel has bad effects. The burning
of coal, oil, or gas is a chemical reaction involving the fuel &oxygen from the air. Air is 23% oxygen by
weight & 21% by volume. The remainder of air is mostly nitrogen, which takes no actual chemical parts in
combustion but does it affect the volume of air required.
Note: it is always the carbon, hydrogen, or sulfur that produces the chemical reaction for heat by
combining with oxygen.





Q: How does nitrogen affect the combustion process? 6
A: Because nitrogen does not burn although occupying 79% by volume of air used in fuels, it increases the
amount of air required to support combustion. Oxygen occupies only 21% of the airs volume. Although
nitrogen will not burn, it will absorb the released heat. Thus nitrogen affects combustion as to the
temperature and time needed to complete the burning of the fuel. With pure oxygen, combustion is more
spontaneous and rapid.

Q: What function does draft plays in the combustion of fuel?
A: Draft provides the differential pressure in a furnace to ensure the flow of gases. Without draft,
stagnation in the burning process would result, and the fire or process of combustion would die from lack
of air. Draft pushes or pulls air and the resultant flue gas through a boiler up into the stack. The draft over
comes the rsistance to flow of the tubes, furnace walls, baffles, dampers, and the chimney lining (Also
slag).
Natural draft is produces by chimney into which the boiler exhausts. The cool air admitted to a furnace
(by the mean of dampers opening) rushes in to displace the lighter hot gases in the furnace. Thus the hot
gases rise (chimney effect), causing a natural draft.
Mechanical draft is produces artificially by the means of forced or induced draft fans. The chimney is
still necessary on mechanical draft installations for venting the products combustion high enough not to be
offensive to the surrounding. Most modern boilers, including the domestic type, use some from mechanical
draft. Domestic burners may have a fan built into the burner unit.

Q: How does a forced draft fan differ from induced draft fan?
A: A forced draft fan pushes, or forces, air into the furnace, usually at a pressure higher than the
atmospheric pressure, where as induced draft fan draws the air out of the furnace by creating the partial
vacuum on the suction side of the fan. The blades of induced draft fans are prone to the rapid wear because
they have handle hot, corrosive gases, possibly hot unburned cinder or fly ash. Thus they required periodic
cleaning and dynamic balancing to prevent excessive vibration.
Q: What is meant by the balanced draft?
A: A boiler using both forced draft fans and induced draft fans can be regulated and balanced in the amount
of air and the flue gas handled so that furnace pressure is almost atmospheric. This results in better control
of air leakage from the furnace and thus control of the fuel/air ratio in the furnace.

Q: How is draft measured? 7
A: Air and gas under the flow conditions are measured in inches of water column (balanced by air and
pressure) usually with a U tube (manometer). One side of the tube is connected to the chimney or furnace.
The other side is open to the atmosphere. Thus the difference in the water level in the two columns
indicates the inches of water. Which is measured of the difference in the pressure. If the furnace pressure is
greater than ATM, the water in the column connected to the furnace will be pushed down, and the column
connected to the ATM, the water will rise the same amount. If the pressure is less than ATMP, the reverse
will take place.
Q: Explain the term heating value?
A: The heat liberated by the complete and rapid burning of a fuel per unit weight or volume of the fuel is
the heating, or calorific, value of the fuel. For solid and liquid fuels, this is usually expressed in Btu per
pound. For gaseous fuels, it is expressed in Btu per cubic foot at a standard temperature and pressure,
usually atmospheric pressure at 68F

Q: What controls are needed to prevent furnace explosion on large boilers firing in suspension?
A: These four basic controls:
1. An automatic burner control system properly programmed and composed of reliable hardware and
sensitive discriminating flame detectors.
2. A fully integrated combustion control system to maintain the correct fuel and air ratios under all
operating conditions.
3. A complete safety interlock system including furnace purge, fan failure, fuel supply failure, and
furnace over pressure interlocks.
4. Communication equipment, such as furnace television, for viewing operating conditions, and
combustible analyzer and inter locks to trip the fuel when approaching hazardous conditions.

Q: What is the primary function of flame safeguard system?
A: Boilers are always prone to two possible types of explosion.
1. Boiler explosion: These are caused by the release of accumulated energy in the form of pressure.
Then, because of structural weakness or malfunctioning of pressure and temperature controls, the
vessel (or part of it) can explode from forces that are normally contained by the boiler structural
element. This type of explosion referred to as a steam type explosion.
2. Furnace explosion: combustion explosion: These are caused by the sudden ignition of accumulated
fuel and air in the fireside of the boiler. This can also lead to devastating property damage and loss
of life. The flame safeguard system used on the different boilers firing different types of fuel is
designed to sense, and some time anticipate, this accumulation of unburned fuel and air in the
fireside of the boiler. It safely shuts off the firing equipment, with the purging of the furnace usually
following in a time sequence so as drive the unburned fuel air mixture out of the furnace.
Q: Name some safety controls on a boiler? 8
A: safety controls generally are those that limit energy input and thus shut down the equipment when
unsafe condition develops, they are.
1. Pressure limit or temperature limit switches.
2. Low water fuel cutoffs
3. Flame failure safe guard systems
4. Automatic ignition controls
5. Oil & gas fuel shut off valve controls.
6. Air & fuel pressure interlock controls.
7. Feed water regulating controls.

Q: What are the minimum appliances or appurtenances necessary for safe boiler operation?
A: The pressure gauge and test connection, safety v/v, blow down v/v, gauge glass, gauge cocks, stop v/v in
the steam line, and the stop and check v/v in the feed water line.



Q: What conditions are necessary to cause a furnace explosion?
A: Usually three
1. Accumulation of un burned fuel,
2. Air and fuel in an explosive mixture, and
3. A source of ignition, such as hot furnace walls, improper ignition timing, faulty torch, and
dangerous light off procedures on manually started boiler combustion systems.
Q: Explain enthalpy
A: At one time, the expression heat in the water, and heat in the vapor were used for the modern term
enthalpy means the heat content of the fluid. In dealing with water and steam enthalpy are noted as follows.
1. Enthalpy of saturated liquid, which is the heat content of the water at a certain pressure and
temperature under consideration.
2. Enthalpy of evaporation, which is the heat, required evaporating 1 pound of water to steam at that
pressure and temperature.
3. Enthalpy of saturated vapor, which the heat content of the saturated steam at the pressure and
temperature being considered.
The enthalpy of saturated steam is thus sum of the enthalpy of saturated liquid plus the enthalpy of
evaporation or the total heat content of the saturated steam in Btu/lb









Q: What is the trend in feed water control in modern boilers? 9
A: Most boilers today use two element (drum level and steam flow) or three element controls in which
steam flow and water flow form the primary measured variables, with water level acting as a third input.
But the single element (drum level) regulator is still popular. This is a thermo hydraulic device based on the
principle that the volume of a given weight of low-pressure steam is far greater than of the water from
which it is generated.
The regulator forms a closed hydraulic system, including the annular space b/w inner & outer tubes of
steam generators, the connecting tubing, & the metal bellows of the regulating v/v. Heat from steam in the
upper portion of the inner tube causes the surrounding water (in the space b/w the two tubes) to flash into
steam. The remaining water is thus forced out of this space until the water levels in the two tubes are equal.
The displaced water passes into the actuator bellows, thus partially opening the regulating v/v.
As steam demand increases, the water level in the drum and generator will fall: more water in the
annular space b/w the tubes flashes into the steam, and the regulating v/v opens still further. Thus if the
drum level rises, the water in the generator rises also; cooled by the radiating fins, this water condenses part
of the steam in the annular space and in turn permits the regulating v/v to partially close. Since this is a
proportional device, it is suitable only for small boilers with relatively stable steaming rates.
In larger units, drum level measurement forms a trimming signal, with steam and water flow as the
primary variables. Displacer-type units are also replacing the self-acting, thermo hydraulic device. In these,
a cylindrical floats or displacer is suspended in the measuring chamber; as the water level rises, the
displacer is lightened by weight of the liquid it displaces. This change in weight is detected by either a
torque-tube or a force-balance system and converted into a pneumatics or electric output signals to a
controller.

Q: Explain the difference between a relief v/v and a safety v/v. what is safety relief v/v?

A: A relief v/v is used primarily for liquid services and is an automatic relieving devices actuated by the
static pressure upstream of the v/v, which opens farther with an increase in the pressure over the opening
pressure (no pop action).
An SV is used for gas. Or vapor services and is an automatic pressure-relieving device, actuated by the
static pressure upstream of the v/v, and which opens with the full pop action once the upstream pressure
activates the v/v.
An SRV is an automatic pressure-relieving device actuated by the pressure upstream of the v/v, and
which opens by pop action with further increase in the lift of the v/v when pressure increases over the
popping pressure. It thus combines the feature of pop action and lift with pressure increases.


Q: what is the code rule for determining SV relieving capacity? 10

A: The following rules on HP boilers must be followed:

1: The SV capacity on boiler must such that SV will discharge all the steam that can be generated by
the boiler (this assumed to be the maximum firing rate) without allowing the pressure to rise more than 6%
above the highest pressure at which any v/v is set, and no case more than 6% above the maximum
allowable pressure.
2: The minimum SV relieving capacity, for other than electric boiler, must be determined on the basis
of pounds of steam generated per hour per square foot of boiler heating surface and water well heating
surface, For the electric boilers, the relieving capacity is determined by the multiplying the kilowatt input
3to obtain the pounds per hour of steam-relieving capacity.
3: For HTHW boilers, the required steam-relieving capacity in pounds per hour is determined by
dividing the max Btu output (for the fuel being fired) of the boiler by 1000.

Q: What area of the boiler shall be computed as the heating surface?
A: That side of the boiler surface exposed to the products of combustion, exclusive of super heating
surface. The areas to be considered for this purpose are tubes, fireboxes, shells, tube sheets, and the
projected area of the headers. For vertical FT boilers, compute only the portion of the tube surfaces up to
the middle gage cock.

Q: Why are the instruments important for properly operating a steam generator or boiler?
A: Use of instruments and a knowledge of such factors as normal operating pressure, temperature, flows,
draft, CO2 content, Btu input, and permissible variation in the reading observed are the most important
responsibilities of any operator or owner of a boiler. Instruments indicate condition the boiler. Thus any
variation from design or stipulated conditions in the boiler. Thus any variations from design or stipulated
conditions serve as warning of impending danger or inefficient operation.

Q: Give the Code rules for range of pressure setting for two or more SVS on an HP steam boiler?
A: 1. One or more SVS must be set at or below the maximum allowable pressure.
2. The highest-pressure setting of any SV cannot exceed the maximum allowable working pressure
by more than 3%.
3. The range of pressure setting of all the saturated steam SVS on the boiler cannot exceed 10% of
the highest pressure setting to which any v/v is set.

Q: What causes a safety v/v to stick to its rest? 11

A: Mostly corrosion and deposits on v/v and v/v seat due to the safety v/v not having lifted for a long
period. To avoid this most dangerous condition on automatic fired boilers, the SV should be periodically
raised by the hand lever, or preferably by raising the steam pressure to the popping point. The latter
practice should be done only with the constant attendance at the boiler, and then only under the supervision
of trained personnel who will carefully watch the boiler pressure and immediately shut the boiler down if
the pressure starts exceeding the maximum allowable. The lever testing of SVS should be done with at least
75% boiler pressure on the SV.

Q: Is there any desirable location for the gauge glass?
A: Yes, The gauge glass should be easily seen from the operating floor, with its lowest visible point at least
2in. above the lowest safe water level in the boiler.

Q: Explain the why blow downs are necessary on boilers?

A: Blowing down does three jobs:
1. Rapidly lowers the boiler-water level in case it accidentally rises too high. This action reduces the
possibility of slugs of water passing on with the steam to wreck machinery.
2. Permits removal of precipitated sediment or sludge while the boiler is in service. Other wise it might
be necessary to take the boilers off the line frequently to wash out sludge accumulations.
3. Controls the concentration of the suspended solids in the boiler. The solids would settle on metal
parts, reducing heat transfer and causing metal overheating where the scale is located. Rupturing of
the tubes, shells, and tube sheets may then occur.



Q: What is an evaporator, and why it is used for boiler operation?
A: Evaporators are used to distill makeup water required in boilers as a result of leakage, process, or other
unavoidable losses. The use of distilled water almost eliminates the formation of scale and feed water
difficulties associated with raw water being pumped into boiler. Evaporators are classified by the method
of vaporization used as:
1. Flash type. Hot water pumped or injected into a chamber under vacuum, where the water flashes into
steam.
2. Film type. Water in a thin film is passed over steam-filled tubes.
3. Submerged type. Steam-filled tubes are submerged in the water to be evaporated.
Deaerators are also used. Air, oxygen, CO2, or other such entrained gases are carried by water into a
boiler. These may come from raw water, from leakages within the system. Or by the chemical reaction of
water and metals in the boiler loop system. The deaerators main function is to remove these gases from the
boiler water so as to prevent corrosion of metals parts in the boiler loop.

Q: What is an operators first duty when taking over a watch? 12
A: First observe the water level in the gauge glasses of all boilers. Blow-down the water column and gauge
glass on each boiler and observe the return of water back into the glass. Then check the water level with
gauge cocks, if installed. Check the operating pressure and note if it is within the pressure of the boiler.

Q: When should boilers be blow down?
A: Only during minimum steaming periods. The reason is that circulation in some boilers is very sensitive.
Thus blowing down during maximum steaming condition could upset the circulation so badly that some
parts, especially tubes, might be seriously damaged.
Caution: Blow down v/v on water wall serve primarily as drain v/v. never blow down the water walls
when the boiler is in operation. If difficulties arises that the require blowing down water walls, do this with
your boiler manufactures instruction.

Q: List the operating precautions needed to prevent furnace explosion?

A: 1. Check the operation of boiler periodically
2. If a burner goes out accidentally shut off the igniter and fuel supply and thoroughly scavenge the
furnaces and gas passes before again attempting ignition. Always determine and remedy the cause of the
stoppage.
3. Keep the burner and allied equipment clean.
4. On a boiler using both forced and induced draft fans test the inter lock periodically.
5. Do not attempt to secure excessively high C02 by using too rich a fuel and air ratio or by on
inadequate secondary air supply.





Q: Explain the wet-storage method?
A: This method best when freezing is not a problem and if the unit will not be needed for at least a month.
After it is prepared for storage, fill the boiler to water level with the deaerator water. If no deaerator water
is used, open a top vent. Then build a light fire to boil the water for 8 hrs so dissolved gases are driven to
the atmosphere. Use 1 lb of sodium sulfite for each 1000 gal of water stored in a boiler to protect against
oxygen. The concentration should be about 75 ppm. Use caustic soda to obtain alkalinity of 375 ppm. Keep
the water temperature as low as possible and test the water weekly.

Q: How and why hydrostatic test made on a boiler?
A: fill the boiler with 70F or warm h2o until the water comes out of highest vent. Remove the safety v/v
and blank their connections. Do not apply gags to the spindle because this will blend them and blind the
v/v. apply the gag only to the disk of v/v. if the boiler is in battery, close both stop v/v. and open the drip
v/v b/w the stop v/v. leakage at the drip v/v indicates that the first stop v/v near the boiler leaking. Stop the
test and insert the blank in the line. Raise the pressure slowly to 1 times the SV setting and hold this
pressure until the areas to be checked can be examined. Then apply the hammer test for weaknesses.
13
The purpose of the hydrostatic test is to see that all the welds, joints, and tube
conditions are tight. It is not a proof test. This hydraulic test is also used on new construction, when repairs
are made to a boiler or to determine the exact source of leakage or defect suspected in some part of the
boiler.

Q: List the impurities that produce hard and soft scale and corrosion in boilers?
A: Hard scale is caused by calcium sulfate, calcium silicate, and silica. Soft scale is caused by calcium
bicarbonate, calcium carbonate, calcium hydroxide, magnesium bicarbonate, iron carbonate, and iron
oxide. Oxygen, carbon dioxide, magnesium chloride, hydrogen sulfate, magnesium sulfate, calcium
chloride, Mg nitrate, Ca nitrate, Na Cl2, and certain oils and organic matter cause corrosion.


Q: What are major treatment problems with heating boilers?
A: Corrosion and fitting. Scale is not a problem because the same feed water is used continuously, and
initial treatment usually lasts throughout the heating season.

Q: What is the meaning of pH in water chemistry?
A: It is number b/w 0 and 14 indicating the degree of acidity or alkalinity. The pH scale resembles a
thermometer scale, but the pH scale indicates intensity of acidity or alkalinity. The mid point of the pH
scale is 7,and solution with the pH is neutral. Numbers below 7 denotes acidity; those above, alkalinity.
Since pH is a logarithmic function, solutions having a pH of 6.0, 5.0, or 4.0, are 10. 100 or 1000 times more
acid than one with a pH 7.

Q: What is carry over, and how it is caused?
A: Carry over is entrained moisture and associated solids passing from a boiler with the steam. These slugs
of moisture cause erratic super heat and mechanical troubles with the engines and turbines. Carry-over also
deposits solids in super heaters and on turbine blades. And it may even spoil materials in process. But the
main cause of the carry over are priming. Foaming or both.
Q: Explain priming of boiler water?
A: Priming is the spouting or surging of water into the steam outlet. It is caused by too high a water level,
uneven fire distribution, load swings, too high a steaming rate, or even faulty boiler design. Remedies range
for redesigning the boiler or steam drum to installing steam purifiers, lowering the h20 level, improving
firing distribution, or reducing the boiler load. Chemicals anti foams also helps.
Q: What cause foaming? 14
A: Foaming is the formation of small stable, noncoalescing bubbles through the boiler water. Water film
around each steam bubble generated at the heating surface is stabilized by an increase in dissolved and
suspended solids in the boiler. Thus the bubble skin becomes tough and doesnt permit coalescence or
break readily when the bubble emerges, the resulting expansion of the boiler water permits carry-over and
priming. the main cause of the carry-over are excessive dissolved and suspended solids, high alkalinity, and
the presence of oil and various organics that react with alkalinity. Steam washers and mechanical separators
in the boiler drum effectively control carry-over within reasonable and tolerable limits. The right amount of
blow down the key to maintaining these limits.

Q: How does deaerator reduce the oxygen content of feed water?
A: Oxygen can be dissolved gas in the water that does not react chemically with the water and becomes less
and less soluble as the water temperature increases. Thus it is easily removed by bringing the water to the
boiling point corresponding to its operating pressure. Pressure and vacuum designs are used. Deaerators are
used to heat water for boiler feed. But if water is used for cooling or other purposes where heating is not
needed, vacuum units are used. Steam deaerators breakup water into a spray or film and then sweep the
steam across and through it to force out dissolved gases like oxygen or carbon dioxide. The oxygen content
can be reduced by below 0.005 cc per liter, almost the limit of sample testing by the chemical means. As
the carbon dioxide removed, the increase in the pH also gives an indication of deaeration efficiency.

Q: What is meant by ion exchange in water treatment?
A: Impurities that dissolve in water dissociates to form positively and negatively charged particles known
as ions. These impurities, or compounds, are called electrolytes. The positive ions are named cat ions
because they migrate to the negative electrode (cathode) in an electrolytic cell. Negative particles are then
anions since they are attracted to the anode. These ions exists throughout the solutions and act almost
independently.